748H Skidder

Repair
(Serial No. 630436 ­ )

TECHNICAL MANUAL
748H Skidder
Repair
(S.N. 630436— )
TM11813 13OCT10 (ENGLISH)

For complete service information also see:

748H Skidder Operation and Test (S.N.

630436— )............................................................. TM11797
H­Series Skidder Operator’s Manual
(S.N. 630436— ).................................................... OMT255825
PowerTech™ 4.5L & 6.8L Diesel Engines ­
Base Engine ......................................................... CTM104
PowerTech™ Plus 4.5L & 6.8L Diesel
Engines—Level 14 Electronic Fuel System
With Denso HPCR................................................ CTM320
TeamMate™ IV Axles 1200 ­ 1400 Series
Inboard Planetary Axles...................................... CTM442
40 and 4000 Winches .......................................... CTM25
60 and 6000 Winches .......................................... CTM41
DF180 Series Powershift Transmission Repair
Manual .................................................................. CTM308
120 Series Cylinders ........................................... CTM114319
125 Series Cylinders ........................................... CTM109319
JDLink™ / ZXLink™ Machine Monitoring
System.................................................................. CTM10006
Specifications Manual......................................... SP458

Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
 Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for beginning of each group are summary listings of all
use. applicable essential tools, service equipment and tools,
Live with safety: Read the safety messages in the other materials needed to do the job, service parts kits,
introduction of this manual and the cautions presented specifications, wear tolerances, and torque values.
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on­the­job guides containing only the
This is the safety­alert symbol. When you see this vital information needed for diagnosis, analysis, testing,
symbol on the machine or in this manual, be alert to the and repair.
potential for personal injury.
Fundamental service information is available from other
Technical manuals are divided in two parts: repair and sources covering basic theory of operation, fundamentals
operation and tests. Repair sections tell how to repair of troubleshooting, general maintenance, and basic type
the components. Operation and tests sections help you of failures and their causes.
identify the majority of routine failures quickly.
,0004E4A ­19­08SEP08­1/1

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 Introduction

Technical Information Feedback Form

We need your help to continually improve our technical
publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO: John Deere Dubuque Works
18600 South John Deere Road
Attn: Publications, Dept. 324
Dubuque, IA 52004­0538
USA

FAX NUMBER: 1­563­589­5800 (USA)

Publication Number:

Page Number:

Ideas, Comments:

Name:

Phone:

Email Address:

THANK YOU!
TX,TM,FAX ­19­03JUL01­1/1

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 Introduction

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 Contents
Section 00—General Information Group 1746—Frame Bottom Guards
Group 0001—Safety
Group 0003—Torque Values Section 18—Operator’s Station
Group 1800—Removal and Installation
Section 01—Wheels Group 1810—Operator Enclosure
Group 0110—Powered Wheels and Fasteners Group 1821—Seat and Seat Belt
Group 1830—Heating and Air Conditioning
Section 02—Axles
Group 0200—Remove and Install Section 19—Sheet Metal and Styling
Group 0225—Input Drive Shaft and U­Joints Group 1910—Hood or Engine Enclosure
Group 0260—Hydraulic System
Section 20—Safety, Convenience, and
Section 03—Transmission Miscellaneous
Group 0300—Remove and Install Group 2003—Pressurized Water System
Group 0315—Controls Group 2004—Horn and Warning Devises
Group 0325—Input Drive Shafts and U­Joints
Group 0350—Gears, Shafts, and Power Shift Clutches Section 21—Main Hydraulic System
Group 0360—Hydraulic System Group 2160—Hydraulic System

Section 04—Engine Section 30—Winch

Group 0400—Removal and Installation Group 3000—Removal and Installation
Group 3015—Control Linkage
Section 05—Engine Auxiliary Systems Group 3025—Input Drive Shafts and U­Joints
Group 0505—Cold Weather Starting Aids Group 3050—Drive and Clutch
Group 0510—Cooling System
Group 0520—Intake System Section 32—Stacking Blades
Group 0530—Exhaust System Group 3201—Blades
Group 0560—External Fuel Supply System Group 3215—Controls Linkage
Group 3260—Hydraulic System
Section 07—Dampener Drive
Group 0752—Elements Section 38—Grapple
Group 3803—Grapple Mechanism
Section 09—Steering System Group 3840—Frames
Group 0930—Secondary Steering Group 3860—Hydraulic System
Group 0960—Hydraulic System
Group 0962—Dual Mode Steering Section 99—Dealer Fabricated Tools
Group 9900—Dealer Fabricated Tools
Section 10—Service Brakes
Group 1015—Controls Linkage
Group 1060—Hydraulic System

Section 11—Park Brake

Group 1111—Active Elements
Group 1160—Hydraulic System

Section 17—Frame, Chassis, or Supporting

Structures
Group 1740—Frame Installation

Original Instructions. All information, illustrations and specifications in this

manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2010
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ® Manual

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 Contents

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 Section 00
General Information
Contents

Page

Group 0001—Safety ................................00­0001­1

Group 0003—Torque Values

Hardware Torque Specifications................ 00­0003­1
Keeping ROPS Installed Properly.............. 00­0003­1
Torque Value
Metric Bolt and Cap Screw....................00­0003­2
Additional Metric Cap Screw
Torque Values ........................................ 00­0003­3
Unified Inch Bolt and Cap Screw ..........00­0003­4
Check Oil Lines And Fittings ..................... 00­0003­5
Service Recommendations for
37° Flare and 30° Cone Seat
Connectors ............................................ 00­0003­5
Service Recommendations for
O­Ring Boss Fittings.............................. 00­0003­6
Service Recommendations For
Flat Face O­Ring Seal Fittings .............. 00­0003­7
Service Recommendations for
Metric Series Four Bolt Flange
Fitting..................................................... 00­0003­8
Service Recommendations For
Inch Series Four Bolt Flange
Fittings ................................................... 00­0003­9

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 Contents

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 Group 0001
Safety

Recognize Safety Information

This is the safety alert symbol. When you see this

T133555 —UN—28AUG00
symbol on your machine or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION —
is used with the safety alert symbol. DANGER identifies
the most serious hazards.
On your machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are

T133588 —19—28AUG00
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.

TX03679,00016CC ­19­03NOV08­1/1

Follow Safety Instructions

Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are

TS201 —UN—23AUG88
available from your John Deere dealer.
There can be additional safety information contained on
parts and components sourced from suppliers that is not
reproduced in this operator’s manual.
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition.
If you do not understand any part of this manual and need
Unauthorized modifications to the machine may impair the
assistance, contact your John Deere dealer.
function and/or safety and affect machine life.
DX,READ ­19­16JUN09­1/1

Operate Only If Qualified

Do not operate this machine unless you have read the Know and observe all safety rules that may apply to your
operator’s manual carefully and you have been qualified work situation and your work site.
by supervised training and instruction.
Familiarize yourself with the job site and your surroundings
before operating. Try all controls and machine functions
with the machine in an open area before starting to work.
TX03679,00016FA ­19­03NOV08­1/1

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 Safety

Wear Protective Equipment

Guard against injury from flying pieces or metal or debris;
wear goggles or safety glasses.
Wear close fitting clothing and safety equipment
appropriate to the job.

TS206 —UN—23AUG88
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises. Radio or music headphones
are not suitable to use for hearing protection.
OUT4001,0000570 ­19­12FEB10­1/1

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deere reliability, and may create a hazard for the operator or
replacement parts to ensure machine performance. others near the machine. The installer of any modification
Never substitute genuine John Deere parts with alternate which may affect the electronic controls of this machine is
parts not intended for the application as these can responsible for establishing that the modification does not
create hazardous situations or hazardous performance. adversely affect the machine or its performance.
Non­John Deere parts, or any damage or failures resulting
from their use are not covered by any John Deere Always contact an authorized dealer before making
warranty. machine modifications that change the intended use,
weight or balance of the machine, or that alter machine
Modifications of this machine, or addition of unapproved controls, performance or reliability.
products or attachments, may affect machine stability or
AM40430,00000A9 ­19­20AUG09­1/1

Inspect Machine
Inspect machine carefully each day by walking around it
before starting.
Keep all guards and shields in good condition and properly
installed. Fix damage and replace worn or broken parts

T6607AQ —UN—18OCT88
immediately. Pay special attention to hydraulic hoses and
electrical wiring.

TX03679,0001734 ­19­03NOV08­1/1

Stay Clear of Moving Parts

T133592 —UN—12SEP01

Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard
or shield that has been removed for access as soon as
service or repair is complete.
TX03679,00016D2 ­19­03NOV08­1/1

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 Safety

Avoid High­Pressure Fluids

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

X9811 —UN—23AUG88
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

Avoid High­Pressure Oils

This machine uses a high­pressure hydraulic system.
Escaping oil under pressure can penetrate the skin
causing serious injury.
Never search for leaks with your hands. Protect hands.

T133509 —UN—17MAR06
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.

T133840 —UN—20SEP00
TX03679,00016D3 ­19­03NOV08­1/1

Do Not Use Starting Fluid

IMPORTANT: Avoid an explosion or fire. Machine
is equipped with electrical cold start assist
system. Do not use starting fluid of any
type on the machine.
T145705 —UN—18SEP01

This machine is equipped with a Tier III engine. Fire,

explosion or engine damage will result from using starting
fluids of any type on this machine.

OUO1065,00001B7 ­19­09JUN08­1/1

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 Safety

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.

TS220 —UN—23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.

DX,AIR ­19­17FEB99­1/1

Prevent Fires

T133552 —UN—14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
T133553 —UN—07SEP00
materials inside a machine compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly. T133554 —UN—07SEP00

TX03679,00016F5 ­19­03NOV08­1/1

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 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
across the posts. Use a volt­meter or hydrometer.

TS204 —UN—23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).

DX,SPARKS ­19­03MAR93­1/1

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.

TS1132 —UN—26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical
products used with John Deere equipment.)
DX,MSDS,NA ­19­03MAR93­1/1

Dispose of Waste Properly

Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.

TS1133 —UN—26NOV90
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 Earth’s 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

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 Safety

Prepare for Emergencies

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

TS291 —UN—23AUG88
DX,FIRE2 ­19­03MAR93­1/1

Clean Debris from Machine

Keep engine compartment, radiator, batteries, hydraulic
lines, exhaust components, fuel tank, and operator’s
station clean and free of debris.
Clean any oil spills or fuel spills on machine surfaces.

T6669AG —UN—18OCT88
Temperature in engine compartment may go up
immediately after engine is stopped. BE ON GUARD
FOR FIRES DURING THIS PERIOD.
Open access door(s) to cool the engine faster, and clean
engine compartment.

OUT4001,00000E3 ­19­20AUG09­1/1

Use Steps and Handholds Correctly

Prevent falls by facing the machine when you get on and

T133468 —UN—30AUG00
off. Maintain 3­point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.

TX03679,00016F2 ­19­03OCT07­1/1

Start Only From Operator’s Seat

T133715 —UN—07SEP00

Avoid unexpected machine movement. Start engine only

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

TX03679,0001799 ­19­03OCT07­1/1

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 Safety

Use and Maintain Seat Belt

Use seat belt when operating machine. Remember to

T133716 —19—14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not
cut or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every three years, regardless of appearance.
TX03679,00016DD ­19­03OCT07­1/1

Prevent Unintended Machine Movement

Be careful not to accidentally actuate controls. Move
transmission out of gear and lower all equipment to the
ground during work interruptions. Follow these steps
before allowing coworkers to approach the machine, 2
before standing up, leaving the operator’s seat, or exiting 1
the machine:
• Lower equipment to the ground
• Move transmission gear selector to neutral position

TX1076184 —UN—16APR10
• Engage park brake by pressing park brake switch.
Verify park brake indicator light on the standard display
monitor comes on.
• Stop the engine

1— Gear Selector 3— Park Brake Switch

2— Gear Enable/Differential
Lock Switch
Gear Enable/Differential Lock Switch

TX1076187A —UN—16APR10

Park Brake Switch

OU90V02,000042C ­19­25MAY10­1/1

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 Safety

Avoid Work Site Hazards

Plan your operation before starting work. Check skidding
trails and landings for stumps, large rocks, drop­offs,
muddy areas and standing water. Carefully examine
overhead for trees and branches that might fall or strike

T146611 —UN—22OCT01
the operator’s station. Take precautions to avoid these
hazards.
Be sure co­workers and bystanders are clear of
machine before operating. Keep bystanders away
from attachments and unsupported loads over or near
personnel. Keep co­workers a safe distance away when
skidding, because logs may kick­out unexpectedly.
Use extra care if you must drive over logs or saplings
that may be dislodged or spring­up against the machine Do not operate under low­hanging electrical wires.
or bystanders. Contact may cause serious injury or death by
electrocution.
Keep bystanders clear at all times. Keep bystanders
away from raised booms, attachments, and unsupported Reduce machine speed when operating equipment with
loads. Avoid swinging or raising booms, attachments, or tool on or near ground when obstacles may be hidden
loads over or near personnel. Use barricades or a signal (e.g., during snow removal or clearing mud, dirt, etc). At
person to keep vehicles and pedestrians away. Use a high speeds, hitting obstacles (rocks, uneven concrete or
signal person if moving machine in congested areas or manholes) can cause a sudden stop. Always wear your
where visibility is restricted. Always keep signal person in seat belt. On units equipped with shoulder belts, always
view. Coordinate hand signals before starting machine. wear both the seat and shoulder belts and do not lean
forward while operating.
OU90V02,000042D ­19­12APR10­1/1

Operate Machine Safely

Wear the seat belt when operating this machine. Do
not operate the machine if all elements of the operator
protective structure (OPS) are not in place and in good
repair.

T146610 —UN—22OCT01
Use extra care around landings where bystanders are
more likely to be present. Do not skid logs past people
that are not a safe distance away from logs that may
swing or kick­out.
Use extra care when backing­up with logs attached. Make
sure the de­limbing grate is in good repair and bystanders
are a safe distance away.
Be careful when operating in muddy or frozen conditions side slopes when possible. Drive straight up or down
because the machine may slide or tip more easily. Avoid slopes to reduce the possibility of tipping.
TX03679,000180A ­19­03OCT07­1/1

Keep Riders Off Machine

Only allow operator on machine.
T145263 —UN—06SEP01

Riders are subject to injury. They may fall from machine,

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

TX03679,0001800 ­19­03OCT07­1/1

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 Safety

Avoid Backover Accidents

Before moving machine, be sure all persons are clear
of machine path. Turn around and look directly for best

T145264 —UN—06SEP01
visibility. Use mirror to assist in checking around machine.
Keep windows and mirror clean, adjusted, and in good
repair.
Be certain reverse warning alarm is working properly.
Use a signal person when backing if view is
obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
TX03679,0001801 ­19­03OCT07­1/1

Avoid Machine Tip Over

Use seat belt at all times.

T133716 —19—14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
Be careful on slopes. Avoid sharp turns. Avoid stumps,
rocks and drop­offs when possible. Use extra care on
soft, uneven or frozen ground.

T145266 —UN—06SEP01
Do not overload. Know the capacity of the machine.
Be careful with heavy loads which may affect machine
stability.
Ensure solid footing. Use extra care in soft ground
conditions that may not uniformly support the wheels. Do
not operate close to banks that may cave in and cause
machine to tip or fall.

T146612 —UN—06NOV01

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 Safety

Operating on Slopes
Avoid side slope travel whenever possible. When working
on steep slopes, travel as straight up and down as

T145730 —UN—20SEP01
possible to prevent machine tip over.
Select low gear before starting down slope. The slope on
which you can operate safely will be limited by ground
condition and the load being handled. Use service brakes
to control speed.

TX03679,0001803 ­19­03OCT07­1/1

Operating or Traveling On Public Roads

Machines that work near vehicle traffic or travel slower
than normal highway speeds must have proper lighting

T141891 —UN—22MAY01
and markings to assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle
(SMV) emblems, or other devices and use as required
to make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.
TX03679,00017C8 ­19­03OCT07­1/1

Inspect and Maintain ROPS

A damaged roll­over protective structure (ROPS) should To maintain the ROPS:
be replaced, not reused.
The protection offered by ROPS will be impaired if ROPS
• Replace missing hardware using correct grade
hardware.
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
• Check hardware torque.
bending, drilling, or cutting.
• Check isolation mounts for damage, looseness or wear;
replace them if necessary.
If ROPS was loosened or removed for any reason, inspect • Check ROPS for cracks or physical damage.
it carefully before operating the machine again.
TX03679,000179F ­19­03OCT07­1/1

Keep the Operator Protective Structure (OPS) in Place

It is important to keep the operator protective structure The protection offered by OPS will be impaired if OPS is
(OPS) in place (doors, screens, windows, windshield, subjected to structural damage, is involved in an overturn
etc.) to minimize hazards from whipping or intruding incident, or is altered by welding, bending, drilling, or
objects. To maintain OPS protection, replace damaged cutting. Damaged OPS components should be replaced,
parts immediately. not reused.
The polycarbonate windows are part of the operator Keep all bolts and attaching hardware tight.
protection system. Replace if damaged, cloudy, or has
visible micro­cracking or crazing.
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 Safety

Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting is required or recommended. Verify that all connections
your authorized dealer. Adding unapproved attachments are secure and attachment responds properly to controls.
may affect machine stability or reliability, and may create
a hazard for others near the machine. Carefully read attachment manual and follow all
instructions and warnings. In an area free of bystanders
Ensure that a qualified person is involved in attachment and obstructions, carefully operate attachment to learn its
installation. Add guards to machine if operator protection characteristics and range of motion.
TX03679,00016F0 ­19­03OCT07­1/1

Park and Prepare for Service Safely

Warn others of service work. Always park and prepare
your machine for service or repair properly.
• Park machine on a level surface and lower equipment
to the ground.

T133332 —19—14DEC01
• Engage park brake.
• Stop engine and remove key.
• Install articulation locking bar.
• Attach a “Do Not Operate” tag in an obvious place in
the operator’s station.
IMPORTANT: Engine side panels may be warm
immediately after machine shut down and
gloves may need to be worn.

Support machine or attachment before working under it.

• Do not support machine with any hydraulically actuated
tools or attachments.
• Do not support machine with cinder blocks or wooden

TS229 —UN—23AUG88
pieces that may crumble or crush.
• Do not support machine with a single jack or other
devices that may slip out of place.
Understand service procedures before beginning repairs.
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
OUTJ003,00007AB ­19­17AUG06­1/1

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 Safety

Service Tires Safely

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

TS211 —UN—23AUG88
DX,RIM ­19­24AUG90­1/1

Service Cooling System Safely

Explosive release of fluids from pressurized cooling
system can cause serious burns.
Do not service radiator through the radiator cap. Only fill
through the surge tank filler cap. Shut off engine. Only

TS281 —UN—23AUG88
remove surge tank filler cap when cool enough to touch
with bare hands. Slowly loosen cap to relieve pressure
before removing completely.

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 Safety

Service Accumulator Systems Safely

Escaping fluid or gas from pressurized hydraulic
accumulator systems can cause serious injury. Extreme
heat can cause the accumulator to burst, and pressurized
lines can be accidentally cut. Do not weld or use a torch
near a pressurized accumulator or pressurized line.

TS281 —UN—23AUG88
Relieve pressure from the hydraulic system before
removing accumulator. Never attempt to relieve hydraulic
system or accumulator pressure by loosening a fitting.
Accumulators cannot be repaired.

DX,WW,ACCLA ­19­15APR03­1/1

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:

TS220 —UN—23AUG88
• 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

Make Welding Repairs Safely

IMPORTANT: Disable electrical power before

T133547 —UN—31AUG00
welding. Turn off main battery switch
or disconnect positive battery cable.
Separate harness connectors to engine
and vehicle microprocessors.

Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Make sure there is good ventilation. Wear eye protection
Remove paint properly. Do not inhale paint dust or fumes. and protective equipment when welding.
Use a qualified welding technician for structural repairs.
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 Safety

Drive Metal Pins Safely

T133738 —UN—14SEP00
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened
parts. Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.

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 Group 0003
Torque Values

Hardware Torque Specifications

Check cap screws and nuts to be sure they are tight.
If hardware is loose, tighten to torque shown on the
following charts unless a special torque is specified.
04T,90,K271 ­19­08AUG91­1/1

Keeping ROPS Installed Properly

CAUTION: Make certain all parts are reinstalled

correctly if the roll­over protective structure
(ROPS) is loosened or removed for any reason.

T129546C —UN—31MAR00
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.

IMPORTANT: Do not over­tighten cap screws

as clevis will be deformed.

Install lock nuts (A) onto cap screws (B) until full thread
engagement is achieved so nut, washers (C), and head of
cap screw are flush against each clevis.

T129547D —UN—03APR00
Tighten pin locking cap screws (D) to specification.
Keeping ROPS Installed Properly—Specification
Pin Locking Cap
Screw—Torque.............................................................. 130 Nm (95 lb­ft)

A—Lock Nut (2 used) C—Washer (As required)

B—Cap Screw (2 used) D—Pin Locking Cap Screw (2
used)

CED,OUO1079,98 ­19­26MAY00­1/1

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 Torque Values

Metric Bolt and Cap Screw Torque Values

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

TORQ2 —UN—07SEP99
Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Thread Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.

Fasteners should be replaced with the same or higher property class. If

CAUTION: Use only metric tools on metric hardware. Other higher property class fasteners are used, these should only be tightened
tools may not fit properly. Tool may slip and cause injury. to the strength of the original.

Make sure fastener threads are clean and that you properly start thread
DO NOT use these values if a different torque value or tightening engagement. This will prevent them from failing when tightening.
procedure is given for a specific application. Torque values listed are for
general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel­type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut, not
Shear bolts are designed to fail under predetermined loads. Always to the bolt head. Tighten toothed or serrated­type lock nuts to the full
replace shear bolts with identical property class. torque value.

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 Torque Values

Additional Metric Cap Screw Torque Values

T6873AA —UN—18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly.
They may slip and cause injury.

Check tightness of cap screws periodically. Torque values

listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
Shear bolts are designed to fail under predetermined

T6873AB —UN—18OCT88
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 —UN—18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
a
METRIC CAP SCREW TORQUE VALUES
T­Bolt H­Bolt M­Bolt
Nomi­
nal Dia N∙m lb­ft N∙m lb­ft N∙m 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%.
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 Torque Values

Unified Inch Bolt and Cap Screw Torque

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

TORQ1A —UN—27SEP99
Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
b c
Thread Lubricated Dry Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Size N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft) N∙m (lb­ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
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)
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, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start thread
procedure is given for a specific application. Torque values listed are for engagement. This will prevent them from failing when tightening.
general use only. Check tightness of fasteners periodically.
Tighten plastic insert or crimped steel­type lock nuts to approximately
Shear bolts are designed to fail under predetermined loads. Always 50 percent of the dry torque shown in the chart, applied to the nut, not
replace shear bolts with identical grade. to the bolt head. Tighten toothed or serrated­type lock nuts to the full
torque value.
Fasteners should be replaced with the same or higher grade. If higher
grade fasteners are used, these should only be tightened to the strength
of the original.

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 Torque Values

Check Oil Lines And Fittings

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

X9811 —UN—23AUG88
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.
TX,90,DH1559 ­19­01AUG94­1/1

Service Recommendations for 37° Flare and

30° Cone Seat Connectors
1. Inspect flare and flare seat. They must be free of dirt
or obvious defects.
2. Defects in tube flare cannot be repaired.

T6234AC —UN—18OCT88
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 N∙m 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

NOTE: Torque tolerance is ± 10%.

T82,BHMA,EL ­19­29SEP99­1/1

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 Torque Values

Service Recommendations for O­Ring Boss

Fittings
Straight Fitting
1. Inspect O­ring boss seat for dirt or defects.

T6243AE —UN—18OCT88
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 —UN—18OCT88
3. Turn fitting head­end counterclockwise to proper index
(maximum of one turn).
NOTE: Do not allow hoses to twist when tightening fittings.

4. Hold fitting head­end with a wrench and tighten locknut

and back­up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size N∙m lb­ft
3/8­24 UNF 8 6
7/16­20 UNF 12 9
1/2­20 UNF 16 12
9/16­18 UNF 24 18
3/4­16 UNF 46 34
7/8­14 UNF 62 46
1­1/16­12 UN 102 75
1­3/16­12 UN 122 90
1­5/16­12 UN 142 105
1­5/8­12 UN 190 140
1­7/8­12 UN 217 160

NOTE: Torque tolerance is ± 10%.

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 Torque Values

Service Recommendations For Flat Face O­Ring Seal Fittings

1. Inspect the fitting sealing surfaces and O­ring. They IMPORTANT: Tighten fittings to 150% of listed torque
must be free of dirt or defects. value if indexing is necessary or if fitting is
2. Lubricate O­rings and install into grove using attached to an actuating devise.
petroleum jelly to hold in place. Tighten fittings to 50% of listed torque value
3. Index angle fittings and tighten by hand pressing joint if used in aluminum housing.
together to insure O­ring remains in place.
4. Tighten fitting or nut to torque value shown on the
chart. Do not allow hoses to twist when tightening
fittings, use backup wrench on straight hose couplings.
FLAT FACE O­RING SEAL FITTING TORQUE*
Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. N∙m lb­ft N∙m lb­ft
6.35 0.250 9/16­18 16 12 12 9
9.52 0.375 11/16­16 24 18 24 18
12.70 0.500 13/16­16 50 37 46 34
15.88 0.625 1­14 69 51 62 46
19.05 0.750 1 3/16­12 102 75 102 75
22.22 0.875 1 3/16­12 102 75 102 75
25.40 1.000 1 7/16­12 142 105 142 105
31.75 1.250 1 11/16­12 190 140 190 140
38.10 1.500 2­12 217 160 217 160
*Torque tolerance is +15 ­20% unless otherwise specified.
Stud End O­ring Seal Torque for Straight and Adjustable Fittings*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch N∙m lb­ft
3/8­24 5/8 9/16 12 9
7/16­20 5/8 5/8 21 15
1/2­20 3/4 11/16 26 19
9/16­18 3/4 3/4 34 25
3/4­16 7/8 15/16 73 55
7/8­14 1 1/16 1 1/16 104 76
1 1/16­12 1 1/4 1 3/8 176 130
1 3/16­12 1 3/8 1 1/2 230 170
1 5/16­12 1 1/2 1 5/8 285 210
*Torque tolerance is +15 ­20% unless otherwise specified.

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 Torque Values

Service Recommendations for Metric Series Four Bolt Flange Fitting

T6890BB —UN—01MAR90
A—Sealing Surface B—Split Flange C—Pinched O­Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause

DO NOT use air wrenches. DO NOT tighten one cap
leaks. Roughness causes seal wear. Out­of­flat
screw fully before tightening the others. DO NOT over
causes seal extrusion. If defects cannot be polished
tighten.
out, replace component.
a
TORQUE CHART
2. Install the correct O­ring (and backup washer if
required) into groove using petroleum jelly to hold it
b
Thread N∙m lb­ft
in place. M6 12 9
M8 30 22
3. Split flange: Loosely assemble split flange (B) halves.
M10 57 42
Make sure split is centrally located and perpendicular
to the port. Hand tighten cap screws to hold parts in M12 95 70
place. Do not pinch O­ring (C). M14 157 116
M16 217 160
4. Single piece flange (D): Place hydraulic line in center
M18 334 246
of flange and install four cap screws. Flange must be
centrally located on port. Hand tighten cap screws to M20 421 318
a
hold flange in place. Do not pinch O­ring. Tolerance ± 10%. The torques given are enough for the given size
connection with the recommended working pressure. Increasing
5. After components are properly positioned and cap cap screw torque beyond these amounts will result in flange and
screws are hand tightened, tighten one cap screw, cap screw bending and connection failures.
b
Metric standard thread.
then tighten the diagonally opposite cap screw.
Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.
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 Torque Values

Service Recommendations For Inch Series Four Bolt Flange Fittings

T6890BB —UN—01MAR90
A—Sealing Surface B—Split Flange C—Pinched O­Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause TORQUE CHART

leaks. Roughness causes seal wear. Out­of­flat N∙m lb­ft
causes seal extrusion. If defects cannot be polished Nominal Cap Screw
out, replace component. Flange Size
Size Min Max Min Max
2. Install O­ring (and backup washer if required) into 1/2 5/16­18 UNC 20 31 15 23
groove using petroleum jelly to hold it in place.
3/4 3/8­16 UNC 28 54 21 40
3. Split flange: Loosely assemble split flange (B) halves. 1 3/8­16 UNC 37 54 27 40
Make sure split is centrally located and perpendicular 1­1/4 7/16­14 UNC 47 85 35 63
to port. Hand tighten cap screws to hold parts in place. 1­1/2 1/2­13 UNC 62 131 46 97
Do not pinch O­ring (C).
2 1/2­13 UNC 73 131 54 97
4. Single piece flange (D): Place hydraulic line in center 2­1/2 1/2­13 UNC 107 131 79 97
of flange and install cap screws. Flange must be 3 5/8­11 UNC 158 264 117 195
centrally located on port. Hand tighten cap screws to 3­1/2 5/8­11 UNC 158 264 117 195
hold flange in place. Do not pinch O­ring.
4 5/8­11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 5 5/8­11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.
DO NOT use air wrenches. DO NOT tighten one cap
screw fully before tightening the others. DO NOT over
tighten.
04T,90,K174 ­19­01AUG94­1/1

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 Torque Values

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 Section 01
Wheels
Contents

Page

Group 0110—Powered Wheels and Fasteners

Wheel Remove and Install......................... 01­0110­1
Tire Remove and Install............................. 01­0110­2
Dual Wheel Installation.............................. 01­0110­3

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 Contents

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 Group 0110
Powered Wheels and Fasteners

Wheel Remove and Install

1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)

T7382AN —UN—27SEP90
CAUTION: Avoid possible injury from unexpected
machine movement. Install wheel chocks under
one or more wheels not being removed.

3. Install wheel chocks under one or more wheels not

being removed. Wheel

CAUTION: Prevent possible crushing injury from surfaces. Paint, rust, and dirt prevent good
heavy component. Use appropriate lifting device. contact between the surfaces and can result
in the wheels coming loose.
4. Raise machine. Place an 18­t (20­ton) floor stand
under axle. 8. Clean the threads of cap screws and axle flange; and
Specification the mating surfaces on washers, rim, and axle flange.
Machine—Weight Apply a drop of oil to cap screw threads after cleaning
(approximate)........................................................................... 17 030 kg with solvent.
37 540 lb.
9. Install three studs, equally spaced, into the axle flange.
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device. CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.
5. Place wheel lift under wheel. Fasten safety chain
around upper part of tire. 10. Install wheel.
Specification Specification
Wheel—Weight Wheel—Weight
(approximate)................................................................................ 545 kg (approximate)................................................................................ 545 kg
1200 lb. 1200 lb.

IMPORTANT: The rim dropping onto the cap screws 11. Install cap screws and washers.
when loosened can damage the threads. Tighten the cap screws just enough to hold wheel
Install studs before loosening all the cap in position. Remove the studs. Install the three
screws to keep wheel centered on axle flange remaining cap screws.
to prevent thread damage.
Tighten cap screws to specification in a circular pattern
6. Remove three cap screws equally spaced around bolt continuing past the starting point by four cap screws.
circle. Install T45672 Studs.
Specification
7. Remove cap screws and washers to remove wheel. Rim­to­Axle Flange Cap
Screw—Torque............................................................................868 N∙m
IMPORTANT: Paint, rust, and dirt must be removed 640 lb­ft
from the cap screws and axle flange threads,
washers, and mating surfaces of axle flange For machines with dual wheels, see Dual Wheel
and rim to ensure good contact between all Installation. (Group 0110.)
SW03989,0000B30 ­19­17SEP10­1/1

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 Powered Wheels and Fasteners

Tire Remove and Install

CAUTION: Tire repair should only be performed
by a qualified tire repair service. Do not attempt
to mount or demount a tire unless you have the
proper equipment and experience to perform the
job safely. Failure to follow proper procedures

TS952 —UN—12APR90
when mounting or demounting a tire from a wheel
or rim can result in explosive separation of a tire
and rim parts, causing serious injury or death

Always maintain the correct tire pressure. Do not inflate

the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly, as heating can increase Explosive Single Piece Rim and Tire
air pressure and result in tire explosion. Welding can also
structurally weaken or deform the wheel.
For initial inflation, always use a clip­on chuck and
extension hose long enough to allow you to stand to one
side and NOT in front of, or over, the tire assembly. Inflate
in a safety cage if available. Use safety chains, cables, or
equivalent restraining devices during inflation.

CAUTION: Stand clear when using a cable or

chain sling. These devices can snap and lash
out, causing serious injury or death.

Check tire and wheel assemblies for low pressure, cuts,

bubbles, damaged rim components, or missing lug bolts
and nuts.
Check that the tire size exactly matches the rim size.
Improperly­sized tires may not perform as intended.
Wheels may contain multi­piece rim components. Inspect
all rim components and replace those that are cracked,
worn, damaged, or severely rusted. Use only rim

TS211 —UN—23AUG88
components designed to work with one another. Do not
combine rim components from different rim types or rim
manufacturers. Incorrectly assembled or mismatched rim
components can fly apart with explosive force.
NOTE: See supplied Off­The­Road Tire Maintenance
Manual to remove tire from wheel.
Explosive Multi­Piece Rim and Tire
VD76477,000049C ­19­12NOV08­1/1

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 Powered Wheels and Fasteners

Dual Wheel Installation 4. Insert each cap screw outward through inner washer,
inner flange and outer washer. Install nut.
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device. 5. Seat wheels to rim by tightening nuts in a criss­cross
pattern to specification.
1. Position outer dual wheel flange­to­flange with inner Specification
wheel. Dual Wheel Nuts—Initial
Specification Torque.........................................................................................407 N∙m
Dual Wheel—Weight 300 lb­ft
(approximate)................................................................................ 545 kg
1200 lb
6. Tighten nuts to final specification.
Specification
2. Align cap screw holes in flanges using punches if Dual Wheel Nuts—Final
necessary. Torque.........................................................................................712 N∙m
3. Lubricate cap screw threads with grease. 525 lb­ft
AC12469,0000462 ­19­06AUG07­1/1

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 Powered Wheels and Fasteners

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 Section 02
Axles
Contents

Page

Group 0200—Remove and Install

TeamMate™ IV Axles ................................ 02­0200­1
Front Axle, Differential, and
Oscillation Supports Remove
and Install .............................................. 02­0200­1
Rear Axle and Differential Remove
and Install .............................................. 02­0200­5
Front Axle Guards Remove and
Install ..................................................... 02­0200­8
Oscillation Supports Repair ....................... 02­0200­8

Group 0225—Input Drive Shaft and U­Joints

Front Axle Drive Shaft Remove and
Install ..................................................... 02­0225­1
Rear Axle and Transmission Drive
Shaft Remove and Install ...................... 02­0225­2

Group 0260—Hydraulic System

Differential Lock Solenoid Valve
Repair .................................................... 02­0260­1

TM11813 (13OCT10) 02­1 748H Repair (S.N. 630436— )

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 Contents

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 Group 0200
Remove and Install

TeamMate™ IV Axles
For additional information on TeamMate ™ IV axles and
components, see TeamMate™ IV 1200 ­ 1400 Series
Inboard Planetary Axles. (CTM442.)
TeamMate is a trademark of Deere & Company
AC12469,0000382 ­19­01JUN07­1/1

Front Axle, Differential, and Oscillation

Supports Remove and Install
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate all hydraulic functions, including brake, to

release pressure in the hydraulic system. Depress

TX1024537A —UN—06JUN07
brake pedal at 1­second intervals 20 times to remove
pressure from service brake accumulator.
3. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
4. Identify axle fitted to machine. See Axle Identification.
(CTM442.)
Front Axle­to­Drive Shaft Disconnect
5. Remove engine frame rear bottom guard.

CAUTION: Prevent possible crushing injury from 1— Rear Oscillation Support 3— Drive Shaft
Lubrication Hose 4— Front Axle Yoke
heavy component. Use appropriate lifting device. 2— Cap Screw (4 used)

6. Raise front of machine and support with stands.

Specification
Machine—Weight
(approximate)........................................................................... 17 030 kg
37 540 lb.

7. Remove front wheels. See Wheel Remove and Install.

(Group 0110.)
8. Drain differential oil into an appropriate container for
storage or disposal. See Change Front Axle Oil.
(Operator’s Manual.)
9. Remove engine frame side guards.
10. Remove cap screws (2). Disconnect universal joint
from front axle.
11. Disconnect rear oscillation support lubrication hose
(1). Close all openings using caps and plugs.
Continued on next page MH66088,0000D71 ­19­10SEP10­1/5

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 Remove and Install

12. Disconnect service brake hose (5) and differential lock

hose (6) from axle. Close all openings using caps and
plugs.

5— Service Brake Hose 6— Differential Lock Hose

TX1024546A —UN—06JUN07
Service Brake and Differential Lock Hoses
MH66088,0000D71 ­19­10SEP10­2/5

13. Disconnect front axle vent hose (7). Close all openings
using caps and plugs.
14. Remove front engine frame bottom guard.

7— Front Axle Vent Hose

TX1081761A —UN—10SEP10
Front Axle Vent Hose
Continued on next page MH66088,0000D71 ­19­10SEP10­3/5

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 Remove and Install

15. Disconnect lubrication hose (8) from front axle

oscillation support (9). Close all openings using caps
and plugs.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

16. Remove cap screws from front and rear oscillation

supports. Lower axle and remove from under machine.
Specification
1400 Series
Axle—Weight
(approximate)................................................................................ 862 kg

TX1081763A —UN—10SEP10
1900 lb.
1400 Series Super
Wide Extreme Duty
Axle (SWEDA)—Weight
(approximate).............................................................................. 1450 kg
3200 lb.

17. Repair or replace axle. See TeamMate™ IV Axles.

(Group 0200.) Front Oscillation Support Lubrication Hose
18. For oscillation supports repair procedure, see
Oscillation Supports Repair. (Group 0200.) 8— Lubrication Hose 9— Front Axle Oscillation
Support
19. Clean mounting surfaces on oscillation supports,
dowels, and engine frame. Mounting surfaces should
be free from dirt, paint, and corrosion.
Specification
20. Install dowels in oscillation supports if they were 1400 Series
removed during removal or repair. Axle—Weight
(approximate)................................................................................ 862 kg
CAUTION: Prevent possible crushing injury from 1900 lb.
heavy component. Use appropriate lifting device. 1400 Series Super
Wide Extreme Duty
21. Support and raise axle into position. Axle (SWEDA)—Weight
(approximate).............................................................................. 1450 kg
3200 lb.
Continued on next page MH66088,0000D71 ­19­10SEP10­4/5

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 Remove and Install

22. Position oscillation supports. Install front and rear

oscillation support­to­engine frame cap screws (10
and 11 and tighten to specification..
Specification
Oscillation Support­
to­Engine Frame Cap
Screw—Torque.................................................................. 488—596 N∙m
360—440 lb­ft

NOTE: It may be necessary to loosen the front

cover­to­oscillation support cap screws (12) in
order to align support cap screws with holes
in engine frame. Hold thrust washer (13) in
place using a hex key wrench.

23. Adjust axle end play to specification. See Adjust Axle

Assembly End Play ­ In Vehicle. (CTM442.)
24. Connect front oscillation support lubrication line.
25. Install front engine frame bottom guard and tighten
cap screws to specification.

TX1024597A —UN—06JUN07
Specification
Bottom Guard­to­Engine
Frame Cap
Screw—Torque............................................................................620 N∙m
457 lb­ft

26. Connect axle vent tube.

27. Connect service brake and differential lock hoses. Oscillation Support Cap Screws

28. Connect rear oscillation support lubrication hose.

10— Front Oscillation 11— Rear Oscillation
29. Install front differential drive shaft and tighten cap Support­to­Engine Frame Support­to­Engine Frame
Cap Screw (6 used) Cap Screw (6 used)
screws to specification.
Specification
3/8 in. Cross and Bearing
Assembly­to­Yoke Cap
Screw—Torque...................................................................... 51—57 N∙m
38—42 lb­ft

TX1024596A —UN—06JUN07
1/2 in. Cross and Bearing
Assembly­to­Yoke Cap
Screw—Torque.................................................................. 127—142 N∙m
94—105 lb­ft

30. Install engine frame side guards.

31. Fill axle with oil. See Change Front Axle Oil.
(Operator’s Manual.)
Front Oscillation Support Cap Screws
32. Install front wheels. See Wheel Remove and Install.
(Group 0110.)
12— Front Cover­to­Oscillation 13— Thrust Washer
33. Lower front of machine to the ground. Support Cap Screw (6
used)
34. Install rear engine frame bottom guard.
Specification
Bottom Guard­to­Engine 35. Bleed service brakes. See Service Brake Bleeding
Frame Cap Procedure. (Group 9025­20.)
Screw—Torque............................................................................620 N∙m
457 lb­ft
36. Turn battery disconnect switch to the ON position.
MH66088,0000D71 ­19­10SEP10­5/5

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 Remove and Install

Rear Axle and Differential Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate all hydraulic functions, including brake, to

release pressure in the hydraulic system. Depress
brake pedal at 1­second intervals 20 times to remove

TX1024608A —UN—06JUN07
pressure from service brake accumulator.
3. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
4. Identify axle fitted to machine. See TeamMate™
IV 1200 ­ 1400 Series Inboard Planetary Axles.
(CTM442.)
Rear Drive Shaft
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.
1— Transmission­to­Rear Axle 2— Cap Screw (4 used)
Drive Shaft
5. Raise rear of machine and support with stands.
Specification
Machine—Weight
(approximate)........................................................................... 17 030 kg
37 540 lb

6. Remove rear wheels. See Wheel Remove and Install.

(Group 0110.)
7. Drain differential oil into an appropriate container for
storage or disposal. See Change Front Axle Oil.
(Operator’s Manual.)

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.
Bottom guard weight increases due to trash
buildup in equipment frame.

8. Remove equipment frame rear bottom guard.

Specification
Equipment Frame Rear
Bottom Guard—Weight
(approximate).................................................................................. 34 kg
75 lb.

9. Disconnect transmission­to­rear axle drive shaft (1) by

removing cap screws (2).
Continued on next page MH66088,0000D72 ­19­10SEP10­1/4

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 Remove and Install

10. Disconnect service brake hose (3) and differential lock

hose (4) from axle. Close all openings using caps and
plugs.

3— Service Brake Hose 4— Differential Lock Hose

TX1081760A —UN—10SEP10
Service Brake and Differential Lock Hoses
Continued on next page MH66088,0000D72 ­19­10SEP10­2/4

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 Remove and Install

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

11. Support rear axle. Remove nuts, washers, and

cap screws. Lower axle and differential slightly and
disconnect breather hose.
Specification
1400 Series
Axle—Weight
(approximate)................................................................................ 862 kg
1900 lb.
1400 Series Super
Wide Extreme Duty
Axle (SWEDA)—Weight
(approximate).............................................................................. 1450 kg
3200 lb.

12. Lower axle and differential and remove from under

machine.
13. Repair or replace axle. See TeamMate™ IV Axles.

TX1024615A —UN—06JUN07
(Group 0200.)
14. Clean mounting surface on axle housing and
equipment frame. Mounting surface should be free
of dirt and corrosion.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.
Rear Axle Cap Screws
15. Position axle underneath equipment frame.
Specification 5— Rear Axle Cap Screws
1400 Series
Axle—Weight
(approximate)................................................................................ 862 kg Specification
1900 lb. Rear Axle and
1400 Series Super Differential­to­Equipment
Wide Extreme Duty Frame Cap
Axle (SWEDA)—Weight Screws—Torque..........................................................................660 N∙m
(approximate).............................................................................. 1450 kg 487 lb­ft
3200 lb.
19. Install rear differential drive shaft and tighten cap
16. Connect breather hose. screws to specification.
IMPORTANT: The tightening sequence for cap screws Specification
and nuts must be followed to prevent binding 3/8 in. Cross and Bearing
which would result in inadequate clamping Assembly­to­Yoke Cap
force applied to the axle and frame joint. Screw—Torque...................................................................... 51—57 N∙m
38—42 lb­ft
NOTE: Apply oil to threads of rear axle and 1/2 in. Cross and Bearing
differential­to­equipment frame cap screws Assembly­to­Yoke Cap
before installation. Screw—Torque.................................................................. 127—142 N∙m
94—105 lb­ft
17. Apply oil to threads of cap screws. Hold the cap
20. Connect service brake and differential lock hoses.
screws and tighten the nuts from the inside to the
outside, alternating sides. Tighten nuts until they are 21. Bleed service brakes. See Service Brake Bleeding
snug. Procedure. (Group 9025­20.)
18. Tighten cap screws to specification, from inside to
outside, alternating sides.

Continued on next page MH66088,0000D72 ­19­10SEP10­3/4

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 Remove and Install

22. Install rear equipment frame bottom guard. Tighten 23. Fill axle with oil. See Change Rear Axle Oil.
cap screws to specification. (Operator’s Manual.)
Specification
24. Install rear wheels. See Wheel Remove and Install.
Bottom Guard­to­
(Group 0110.)
Equipment Frame Cap
Screw—Torque............................................................................620 N∙m 25. Lower rear of machine to ground.
460 lb­ft
26. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.)
MH66088,0000D72 ­19­10SEP10­4/4

Front Axle Guards Remove and Install

1 3
2

TX1024347 —UN—06JUN07
TX1024347
1— Cap Screw (2 used per guard) 2— Washer (8 used per guard) 3— Guard (2 used per axle)

Remove and install parts as shown.

Item Measurement Specification

Axle Guard­to­Transmission Torque 346 N∙m

Case Cap Screw 255 lb­ft
AC12469,000033E ­19­29MAY07­1/1

Oscillation Supports Repair To repair oscillation supports, front axle must be removed
See TeamMate™ IV 1200­1400 Axles (CTM442) from machine. See Front Axle, Differential, and Oscillation
for disassembly, assembly, adjustment, and repair Supports Remove and Install. (Group 0200.)
information for front and rear oscillation supports.
To adjust oscillation supports, front axle must be installed
in machine. See Front Axle, Differential, and Oscillation
Supports Remove and Install. (Group 0200.)
PM10405,0000576 ­19­07OCT10­1/1

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 Group 0225
Input Drive Shaft and U­Joints

Front Axle Drive Shaft Remove and Install

3
2

3
2 5

TX1024375 —UN—07JUN07
1

TX1024375
1— Front Differential Yoke 3— Cross and Bearing Assembly 5— Double Universal Joint
2— Cap Screw (12 used) (2 used) 6— Transmission Yoke
4— Cap Screw (4 used)

1. Park and prepare machine for service. See Park and 5. Assemble universal joint so lubrication fittings are
Prepare for Service Safely. (Group 0001.) aligned. Bearing cup keys must engage the keyway
and bearing cups the yoke pilot.
2. Remove bottom guards on engine frame to gain
access to drive shaft. See Engine Frame Bottom Tighten cap screws in even steps to specification.
Guard Remove and Install. (Group 1746.)
Specification
3. Remove cap screws (2 and 4) to remove double 3/8 in. Cross and Bearing
universal joint (5). Assembly­to­Yoke Cap
Screw—Torque...................................................................... 51—57 N∙m
IMPORTANT: Yoke faces, pilots, keyways, bearing 38—42 lb­ft
cup mounting face, and key must be free of 1/2 in. Cross and Bearing
foreign material, burrs, and nicks which will Assembly­to­Yoke Cap
prevent the cross and bearing assembly and Screw—Torque.................................................................. 127—142 N∙m
yoke from becoming properly seated. 94—105 lb­ft

4. Inspect parts for wear or damage. Repair or replace 6. Install lubrication fittings and tighten to specification.
as necessary. Specification
IMPORTANT: Universal joints are precision Lubrication
components. The fit is intended to be tight and Fitting—Torque........................................................................ 5—16 N∙m
some compression of seals and thrust washers 48—144 lb­in.
is required to seat the bearing cups in the yoke. 7. Lubricate universal joints. See Grease Front Axle
Hand pressure, a tap with a soft­faced hammer Drive Shaft U­Joints and Transmission Output Shaft
or a “C” clamp can be used to seat a bearing Seal. (Operator’s Manual.)
cup in the yoke. DO NOT use the cap screws
to pull bearing cups into the yokes.
SW03989,0000B3A ­19­24SEP10­1/1

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 Input Drive Shaft and U­Joints

Rear Axle and Transmission Drive Shaft

Remove and Install

TX1024417 —UN—07JUN07

Continued on next page SW03989,0000B3B ­19­24SEP10­1/3

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 Input Drive Shaft and U­Joints

1— Transmission Yoke 6— Universal Joint 11— Drive Shaft Yoke 16— Set Screw
2— Snap Ring 7— Lubrication Fitting 12— Snap Ring 17— Support Bearing
3— Slotted Nut 8— Telescoping Drive Shaft 13— Nut 18— Drive Shaft
4— Cotter Pin 9— Lock Nut 14— Washer 19— Cap Screw (2 used)
5— Cap Screw (8 per universal 10— Washer 15— Nut 20— Alignment Marks
joint)

CAUTION: Avoid possible injury from unexpected 9. Install universal joint so drive shaft yoke is to the rear
machine movement. Install articulation locking of machine.
bar before working in frame hinge area.
10. Apply PM37566 Anti­Seize Lubricant to support
bearing­to­coupling shaft contact surface of support
1. Park and prepare machine for service. See Park and
bearing (17).
Prepare for Service Safely. (Group 0001.)
11. Install support bearing on drive shaft so set screw is
2. Remove shields at the articulation joint as needed for
towards the threaded end of shaft.
access. Remove the equipment frame bottom guard
for access at rear axle and differential. See Equipment 12. Install set screw to contact bottom of slot in shaft and
Frame Bottom Guard Remove and Install. (Group then loosen one turn. Install nut over set screw and
1746.) tighten.
IMPORTANT: Yoke faces, pilots, keyways, bearing Specification
cup mounting face, and key must be free of Support Bearing­to­
foreign material, burrs, and nicks which will Coupling Shaft Slot Set
prevent the cross and bearing assembly and Screw—Clearance....................................................... One turn out from
yoke from becoming properly seated. bottom of slot in coupling shaft.

3. Disassemble parts as shown. Inspect parts for wear 13. Install snap ring (12) into groove of drive shaft.
or damage and replace as necessary. Position snap ring opening opposite the slot in the
drive shaft.
4. Loosen the nut (15) and then the set screw (16) to
remove support bearing (17) from drive shaft (18). 14. Install yoke (11) on drive shaft so alignment marks
(20) are aligned.
5. Install snap ring (2) into groove of transmission yoke
(1). 15. Install washer (10) and lock nut (9). Tighten lock nut
to specification.
6. Install transmission yoke on transmission output shaft. Specification
Install slotted nut (3) and tighten to specification. Lock Nut (Machines
Specification with 1200 Series
Yoke­to­Transmission Axle)—Torque.................................................................... 542—610 N∙m
Output Shaft Slotted 400—450 lb­ft
Nut—Torque...................................................................... 271—339 N∙m Lock Nut (Machines
200—250 lb­ft with 1400 Series
Axle)—Torque.................................................................... 720—800 N∙m
NOTE: Slotted nut can be tightened up to an additional 531—590 lb­ft
1/24 turn to align slot with hole.
16. Install drive shaft so support bearing is on the front
7. Install cotter pin (4). Bend legs of cotter pin against side of mounting plate.
sides of nut.
17. Install washers (14) under the head of the cap screws
IMPORTANT: Both universal joints (6) on telescoping (19) and nuts (13). Tighten nuts to specification.
drive shaft must be assembled with alignment Specification
mark and yokes aligned. Yokes not aligned Nut—Torque................................................................................325 N∙m
will cause excessive vibration during turns 240 lb­ft
resulting in failure of bearings.

8. Assemble telescoping drive shaft (8) so alignment

mark (20) on drive shaft yoke (11) and transmission
yoke are aligned.
Continued on next page SW03989,0000B3B ­19­24SEP10­2/3

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 Input Drive Shaft and U­Joints

IMPORTANT: Universal joints are precision

components. The fit is intended to be tight and
some compression of seals and thrust washers
is required to seat the bearing cups in the yoke.
Hand pressure, a tap with a soft­faced hammer,
or a “C” clamp can be used to seat a bearing
cup in the yoke. DO NOT use the cap screws
to pull bearing cups into the yokes.

18. Assemble universal joint so lubrication fittings are

aligned. Bearing cup keys (21) must engage the
keyways and bearing cups engage the yoke pilot (22).
19. Install and tighten cap screws to specification.

TX1024439A —UN—06JUN07
Specification
3/8 in. Cross and Bearing
Assembly­to­Yoke Cap
Screw—Torque...................................................................... 51—57 N∙m
38—42 lb­ft
1/2 in. Cross and Bearing
Assembly­to­Yoke Cap
Screw—Torque.................................................................. 127—142 N∙m
94—105 lb­ft

20. Install and tighten lubrication fittings (7) to specification. 21— Bearing Cup Key 22— Yoke Pilot

Specification
Lubrication
Fitting—Torque........................................................................ 5—16 N∙m 22. Install shields at the articulation joint and install the
48—144 lb­in. equipment frame bottom guard. See Equipment
Air Relief Valve—Torque.......................................................... 5—16 N∙m Frame Bottom Guard Remove and Install. (Group
48—144 lb­in. 1746.)

21. Grease drive shaft. See Grease Rear Axle Drive Shaft
U­Joints, Telescoping Splines, Support Bearing, and
Transmission Output Shaft Seal. (Operator’s Manual.)
SW03989,0000B3B ­19­24SEP10­3/3

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 Group 0260
Hydraulic System

Differential Lock Solenoid Valve Repair

1. Prepare machine for service. See Park and Prepare
For Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)

CAUTION: To avoid injury from escaping fluid

TX1079259A —UN—29JUN10
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

3. Operate all hydraulic control valves to release pressure

in hydraulic system. Depress brake pedal at 1 second
intervals 20 times to drain oil from accumulator.
Left Access Panel
4. Remove cap screws (1 and 2) to remove access panel
(3). 1— Cap Screw 3— Access Panel
2— Cap Screw

NM00125,0000583 ­19­04OCT10­1/2

5. Disconnect wire connector from differential lock

solenoid valve (5).
6. Remove cap screws (4) and remove solenoid from
valve body (6). Close all openings using caps and
plugs.
7. Repair or replace parts as necessary.
8. Install new O­rings and backup rings on solenoid valve
using petroleum jelly for installation.
4
9. Connect electrical connector to solenoid valve.
10. Install access panel.
11. Turn battery disconnect switch to the ON position. See

TX1024458 —UN—06JUN07
Battery Disconnect. (Operator’s Manual.)
12. Before returning machine to service, check operation
of differential lock solenoid valve. See Differential
Lock Switch. (Operator’s Manual.)

4— Cap Screw (2 used) 6— Valve Body 6 5

5— Differential Lock Solenoid
Valve

NM00125,0000583 ­19­04OCT10­2/2

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 Hydraulic System

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 Section 03
Transmission
Contents

Page

Group 0300—Remove and Install

Transmission Remove and Install.............. 03­0300­1
Transmission Mount Remove and
Install ..................................................... 03­0300­6

Group 0315—Controls
Transmission Bump Shifter
Remove and Install................................ 03­0315­1

Group 0325—Input Drive Shafts and U­Joints

Engine­to­Transmission Drive
Shaft Remove and Install ...................... 03­0325­1

Group 0350—Gears, Shafts, and Power Shift Clutches

Transmission Repair Procedures .............. 03­0350­1
Winch Drive Repair.................................... 03­0350­2
Input Yoke Remove and Install.................. 03­0350­7

Group 0360—Hydraulic System

Transmission Charge Pump
Remove and Install................................ 03­0360­1
Transmission Charge Pump Drive
Repair .................................................... 03­0360­4
Transmission Suction Tube
Repair .................................................... 03­0360­8
Transmission Control Valve
Repair .................................................... 03­0360­9

TM11813 (13OCT10) 03­1 748H Repair (S.N. 630436— )

101310

PN=1
 Contents

TM11813 (13OCT10) 03­2 748H Repair (S.N. 630436— )

101310

PN=2
 Group 0300
Remove and Install

Transmission Remove and Install

1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)

TX1080860A —UN—16AUG10
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate all hydraulic controls to relieve pressure

in the hydraulic system. Depress brake pedal at
1­second intervals 20 times to discharge pressure Transmission
from accumulator.
3. Turn the battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s

TX1025638A —UN—29JUN07
Manual.)
5. Remove engine frame side access covers. See
Opening Engine Side Shields. (Operator’s Manual.)
6. Apply vacuum or drain hydraulic reservoir. If draining
hydraulic reservoir, see Change Hydraulic Oil.
(Operator’s Manual.)
7. Remove priority valve. See Priority Valve Remove and Spline Coupler
Install. (Group 2160.)
8. Remove hydraulic attenuator, (if equipped). See
Hydraulic Attenuator Remove and Install. (Group
2160.)

TX1025630A —UN—29JUN07
9. Remove hydraulic pump (1). See Hydraulic Pump
Remove and Install. (Group 2160.)
10. Remove hydraulic fan and cooling loop pump (3) from
transmission case. See Hydraulic Fan and Cooling
Loop Pump Remove and Install. (Group 2160.)
11. Remove spline coupler (6).
12. Drain transmission oil. See Change Transmission Oil, Transmission Harness
Replace Filter, and Clean Suction Screen. (Operator’s
Manual.) 1— Main Hydraulic Pump 6— Spline Coupler
2— Transmission Charge 7— Clamp and Cap Screw
13. Remove engine­to­transmission drive shaft. See Pump­to­Filter Hose 8— Transmission Wiring
Engine­to­Transmission Drive Shaft Remove and 3— Hydraulic Fan and Cooling Harness
Install. (Group 0325.) Loop Pump 9— Transmission Wiring
4— Transmission Harness­ Harness Plug
14. Disconnect transmission charge pump­to­filter hose to­Fuel Sender Harness
(2). Close all openings using caps and plugs. Connector
5— Transmission Charge Pump
15. Disconnect transmission wiring harness plug (9) from
cab.
differential lock solenoid connector, and park brake
16. Disconnect transmission harness­to­fuel sender
pressure switch connector.
harness connector (4), park brake solenoid connector,
Continued on next page SW03989,0000B37 ­19­07OCT10­1/7

TM11813 (13OCT10) 03­0300­1 748H Repair (S.N. 630436— )

101310

PN=57
 Remove and Install

17. Remove dipstick (10) from transmission.

18. Disconnect transmission fill hose (11) and transmission
vent hose (12). Close all openings using caps and
plugs.

TX1025640A —UN—29JUN07
19. Disconnect winch drive shaft (if equipped) from winch
output yoke. See Winch Drive Shaft Remove and
Install. (Group 3025.)
20. Disconnect rear axle drive shaft from transmission.
See Rear Axle and Transmission Drive Shaft Remove
and Install. (Group 0225.)

10— Dipstick 12— Transmission Vent Hose Transmission Dipstick

11— Transmission Fill Hose

TX1025641A —UN—29JUN07
Transmission Vent Hose and Fill Hose
SW03989,0000B37 ­19­07OCT10­2/7

21. Identify and disconnect park brake and differential lock

valve return hose (13), winch return hose (17), and
park brake valve hose (18). Close all openings using 14
caps and plugs.
22. Remove cap screw (15), washer (16), and winch
output yoke (14). 13 15

13— Park Brake and 16— Washer

Differential Lock Return 17— Winch Return Hose 16
Hose 18— Park Brake Valve Hose 17
14— Winch Output Yoke
15— Cap Screw
TX1081025 —UN—24AUG10

18

TX1081025
Winch Drive
Continued on next page SW03989,0000B37 ­19­07OCT10­3/7

TM11813 (13OCT10) 03­0300­2 748H Repair (S.N. 630436— )

101310

PN=58
 Remove and Install

23. Identify and disconnect hoses (19—23) at transmission

control valve. Close all openings using caps and
plugs.
24. Remove front axle drive shaft. See Front Axle Drive
Shaft Remove and Install. (Group 0225.)

19— Transmission­to­Oil 22— Oil Cooler Return Hose

Cooler Hose 23— Winch Control Valve

TX1081023A —UN—27AUG10
20— Charge Pump Pressure Pressure Hose
Hose
21— Park Brake and
Differential Valve Supply
Hose

Transmission Control Valve

Continued on next page SW03989,0000B37 ­19­07OCT10­4/7

TM11813 (13OCT10) 03­0300­3 748H Repair (S.N. 630436— )

101310

PN=59
 Remove and Install

25. Remove cap screws (24) and washers (25) securing

lower transmission mount to machine frame.
26. Remove upper transmission mounting cap screws
(26), washers (27 and 28), nut (31) and upper isolators
(29).

24— Cap Screw (2 used) 28— Washer (4 used)

25— Washer (2 used) 29— Upper Isolator (2 used)
26— Cap Screw (2 used) 30— Lower Isolator (2 used)
27— Washer (4 used) 31— Nut (2 used)

TX1081027A —UN—27AUG10
Lower Transmission Mount

26

27

28

29

30

TX1081024 —UN—01SEP10
28

27
31
TX1081024
Upper Right Transmission Mount
Continued on next page SW03989,0000B37 ­19­07OCT10­5/7

TM11813 (13OCT10) 03­0300­4 748H Repair (S.N. 630436— )

101310

PN=60
 Remove and Install

27. Remove cap screw (32) from upper left transmission

mount. Install JT01748 Lifting Bracket (33) using a
cap screw 12.7 mm (1/2 in.) longer than cap screw
removed.

TX1081026A —UN—27AUG10
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.

28. Attach D01043AA Load Positioning Sling (34) to

appropriate lifting device.
29. Attach one hook from load positioning sling to lifting
bracket (33).
30. Attach remaining hook to lifting location at rear slot in Lifting Bracket
upper right transmission mount.
31. Adjust load positioning sling to raise right side of
transmission first. Carefully remove transmission from
machine and support on an appropriate stand.
Specification
Transmission—Weight
(approximate)................................................................................ 590 kg
1300 lb.

32. Repair or replace parts as necessary.

33. Inspect and replace transmission mounts as needed.
See Transmission Mount Remove and Install. (Group
0300.)
NOTE: Make sure lower isolators are installed
in transmission upper mount before setting
transmission into place.

TX1081028A —UN—27AUG10
34. Install transmission into engine frame.
Specification
Transmission—Weight
(approximate)................................................................................ 590 kg
1300 lb.

35. Install cap screws and washers. Tighten to

specification.
Load Positioning Sling
Specification
Lower Transmission
Mount Plate­to­Frame 32— Cap Screw 34— Load Positioning Sling
Cap Screw—Torque.......................................................... 230—312 N∙m 33— Lifting Bracket
170—230 lb­ft

36. Install upper transmission mounting hardware and

38. Connect hoses to transmission control valve.
tighten to specification.
Specification 39. Install engine­to­transmission drive shaft. See
Upper Transmission Engine­to­Transmission Drive Shaft Remove and
Mount Cap Screw and Install. (Group 0325.)
Nut—Torque...................................................................... 607—743 N∙m 40. Connect park brake and differential lock valve return
450—550 lb­ft hose, winch return hose, and park brake valve hose.
37. Install front axle drive shaft. See Front Axle Drive
Shaft Remove and Install. (Group 0225.)

Continued on next page SW03989,0000B37 ­19­07OCT10­6/7

TM11813 (13OCT10) 03­0300­5 748H Repair (S.N. 630436— )

101310

PN=61
 Remove and Install

41. Install winch output yoke on shaft. Apply Thread Lock 49. Connect transmission charge pump­to­filter hose.
and Sealer (medium strength) to cap screw and install
with washer. Tighten cap screw to specification. 50. Install hydraulic attenuator, if equipped. See Hydraulic
Attenuator Remove and Install. (Group 2160.)
Specification
Winch Output Shaft Yoke 51. Install priority valve. See Priority Valve Remove and
Cap Screw—Torque....................................................................215 N∙m Install. (Group 2160.)
159 lb­ft
52. Remove vacuum if hydraulic reservoir was not drained
42. Install remaining drive shafts. See Winch Drive Shaft or fill hydraulic reservoir. See Change Hydraulic Oil.
Remove and Install (Group 3025.) and see Rear Axle (Operator’s Manual.)
and Transmission Drive Shaft Remove and Install. 53. Install engine frame side access covers. See Opening
(Group 0225.) Engine Side Shields. (Operator’s Manual.)
43. Install transmission vent hose and transmission fill 54. Lower cab. See Hydraulic Cab Tilt Procedure.
hose. (Operator’s Manual.)
44. Connect transmission wiring harness to cab. 55. Fill transmission with proper oil. See Change
45. Connect transmission harness­to­fuel sender harness Transmission Oil, Replace Filter, and Clean Suction
connector, park brake solenoid connector, differential Screen. (Operator’s Manual.)
lock solenoid connector, and park brake pressure 56. Check hydraulic fluid level. See Check Hydraulic
switch connector. Install all harness clamps in original System Oil Level. (Operator’s Manual.)
locations.
57. Turn battery disconnect switch to the ON position. See
46. Install spline coupler. Battery Disconnect. (Operator’s Manual.)
47. Install hydraulic fan and cooling loop pump. See 58. Calibrate transmission. See Transmission Control Unit
Hydraulic Fan and Cooling Loop Pump Remove and (TCU) Calibration. (Group 9015­20.)
Install. (Group 2160.)
48. Install hydraulic pump. See Hydraulic Pump Remove
and Install. (Group 2160.)
SW03989,0000B37 ­19­07OCT10­7/7

Transmission Mount Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn the battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
3. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

4. Install JT05552 20­mm Ringbolt (1) to rear half of

TX1081406A —UN—01SEP10

transmission case and support with appropriate

device.
Specification
Transmission—Weight
(approximate)................................................................................ 590 kg
1300 lb.

5. Remove dipstick support (2) from upper right Transmission Support

transmission mount.
6. Remove harness clamp (3) from upper left 1— JT05552 20­mm Ringbolt 3— Harness Clamp
transmission mount. 2— Dipstick Support 4— Cap Screw (2 used)

Continued on next page NM00125,000057C ­19­30SEP10­1/3

TM11813 (13OCT10) 03­0300­6 748H Repair (S.N. 630436— )

101310

PN=62
 Remove and Install

CAUTION: Prevent possible crushing injury

or death, and damage to machine from 5
transmission shifting. Service only one
transmission mount at a time
6
7. Remove cap screw (5), washers (6 and 7), nut (12),
and upper isolator (8). 7
NOTE: For upper right transmission mount, it may be
necessary to disconnect transmission harness at 8
cab for removal of mount bracket cap screws.

8. Remove cap screws (10) and transmission mount

bracket (9). 9

9. Separate lower isolator (11) from mount bracket

10. Inspect and replace parts as necessary. 10
11. Install lower isolator to mount bracket before
installation. 11
12. Position mount bracket and install cap screws. Tighten

TX1081404 —UN—03SEP10
to specification.
Specification
Upper Transmission
Mount Bracket­to­
12
Transmission Housing
Cap Screw—Torque....................................................................319 N∙m
235 lb­ft Upper Right Transmission Mount
13. Install upper isolator with washers. Tighten cap screw
and nut to specification. 5— Cap Screw (2 used) 9— Mount Bracket (2 used)
6— Washer (4 used) 10— Cap Screw (8 used)
Specification 7— Washer (4 used) 11— Lower Isolator (2 used)
Upper Transmission 8— Upper Isolator (2 used) 12— Nut (2 used)
Mount Cap Screw and
Nut—Torque...................................................................... 607—743 N∙m
450—550 lb­ft 15. Connect transmission harness to cab.
14. Install harness clamp and dipstick support.
Continued on next page NM00125,000057C ­19­30SEP10­2/3

TM11813 (13OCT10) 03­0300­7 748H Repair (S.N. 630436— )

101310

PN=63
 Remove and Install

16. Remove lower transmission mount cap screws (19)

and remove mount block (17).
17. Remove cap screw (13) and lower mount hardware
(14—16 and 18).
18. Inspect and replace parts as necessary.
19. Install lower transmission mount hardware. Tighten 17
cap screws to specification.
Specification
Lower Transmission 15
Mount Block­to­Frame 16 18
Cap Screw—Torque.......................................................... 230—312 N∙m 15
170—230 lb­ft

TX1081405 —UN—03SEP10
19
Lower Transmission
Mount Cap
Screw—Torque.................................................................. 607—743 N∙m
450—550 lb­ft

20. Remove JT05552 20­mm Ringbolt. 14

13
21. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operator’s Manual.) Lower Transmission Mount

22. Turn battery disconnect switch to the ON position. See

13— Cap Screw 17— Mount Block
Battery Disconnect. (Operator’s Manual.) 14— Washer 18— Rear Isolator
15— Washer (2 used) 19— Cap Screw With Washer
16— Front Isolator (2 used)

NM00125,000057C ­19­30SEP10­3/3

TM11813 (13OCT10) 03­0300­8 748H Repair (S.N. 630436— )

101310

PN=64
 Group 0315
Controls

Transmission Bump Shifter Remove and Install

T210585 —UN—23MAR06
Transmission Bump Shifter
A—Transmission Bump Shifter B—Screws (4 used) C—Wiring Harness Connector

1. Remove four screws (B) securing bump shifter (A). 5. Connect wiring harness connector (C) to bump shifter.
2. Lift out bump shifter. 6. Position bump shifter.
3. Disconnect wiring harness connector (C) from bump 7. Install four screws (B) securing bump shifter (A).
shifter.
4. Inspect and replace parts as necessary.
OUO1065,0000312 ­19­10MAR09­1/1

TM11813 (13OCT10) 03­0315­1 748H Repair (S.N. 630436— )

101310

PN=65
 Controls

TM11813 (13OCT10) 03­0315­2 748H Repair (S.N. 630436— )

101310

PN=66
 Group 0325
Input Drive Shafts and U­Joints

Engine­to­Transmission Drive Shaft Remove 2. Remove engine side shields. See Opening Engine
and Install Side Shields. (Operator’s Manual.)
Machines Without Cold Weather Disconnect 3. Turn battery disconnect switch to the OFF position.
1. Prepare machine for service. See Park and Prepare See Battery Disconnect. (Operator’s Manual.)
for Service Safely. (Group 0001.) 4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)

6
5

4
3

TX1024482 —UN—06JUN07
1

TX1024482 7
Drive Shaft—Without Cold Weather Disconnect
1— Cap Screw (8 used per joint) 3— Cap 5— Cap Screw (12 used) 7— Lubrication Fitting
2— Universal Joint 4— Drive Shaft 6— Washer (12 used)

5. Remove and inspect drive shaft. Repair or replace Specification

parts as necessary. Cross and Bearing
6. Install lubrication fittings and tighten to specification. Assembly­to­Yoke Cap
Screw—Torque...................................................................... 51—57 N∙m
Specification 38—42 lb­ft
Lubrication
Fitting—Torque........................................................................ 5—16 N∙m 8. Install drive shaft and tighten cap screws to
48—144 lb­in. specification.
IMPORTANT: Universal joints are precision Specification
components. The fit is intended to be tight and Cross and Bearing
some compression of seals and thrust washers Assembly­to­
is required to seat the bearing cups in the yoke. Transmission Input Yoke
Hand pressure, a tap with a soft­faced hammer Cap Screw—Torque.............................................................. 51—57 N∙m
or a “C” clamp can be used to seat a bearing 38—42 lb­ft
cup in the yoke. DO NOT use the cap screws Drive Shaft­to­Damper
to pull bearing cups into the yokes. Cap Screws—Torque..................................................................150 N∙m
110 lb­ft
7. Align lubrication fittings and fasten universal joint (2) to 9. Lower cab. See Hydraulic Cab Tilt Procedure.
drive shaft (4.) Tighten cap screws (1) to specification. (Operator’s Manual.)
10. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.)
Continued on next page SW03989,0000B3D ­19­06OCT10­1/3

TM11813 (13OCT10) 03­0325­1 748H Repair (S.N. 630436— )

101310

PN=67
 Input Drive Shafts and U­Joints

11. Install engine side shields. See Opening Engine Side 3. Turn battery disconnect switch to the OFF position.
Shields. (Operator’s Manual.) See Battery Disconnect. (Operator’s Manual.)
Machines With Cold Weather Disconnect 4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.) 5. Remove bottom guard on cold weather disconnect.
See Transmission Cold Weather Disconnect
2. Remove engine side shields. See Opening Engine Repair—If Equipped. (Group 0752.)
Side Shields. (Operator’s Manual.)
Continued on next page SW03989,0000B3D ­19­06OCT10­2/3

TM11813 (13OCT10) 03­0325­2 748H Repair (S.N. 630436— )

101310

PN=68
 Input Drive Shafts and U­Joints

7
6
5

TX1024664 —UN—06JUN07
2
TX1024664 1
Drive Shaft—With Cold Weather Disconnect
1— Cap Screw (8 used per 3— Lubrication Fitting 5— Cap Screw (12 used) 7— Cold Weather Disconnect
universal joint) 4— Drive Shaft 6— Washer (12 used)
2— Universal Joint

NOTE: Engine must be rotated to remove all cap Specification

screws on cold weather disconnect. Cross and Bearing
Assembly­to­Yoke Cap
6. Remove and inspect drive shaft. Repair or replace Screw—Torque...................................................................... 51—57 N∙m
parts as necessary. 38—42 lb­ft
For cold weather disconnect repair, see Transmission 9. Install drive shaft and tighten cap screws to
Cold Weather Disconnect Repair—If Equipped. specification.
(Group 0752).
Specification
7. Install lubrication fittings and tighten to specification. Cross and Bearing
Specification Assembly­to­
Lubrication Transmission Input Yoke
Fitting—Torque........................................................................ 5—16 N∙m Cap Screw—Torque.............................................................. 51—57 N∙m
48—144 lb­in. 38—42 lb­ft
Drive Shaft­to­Damper
IMPORTANT: Universal joints are precision Cap Screws—Torque..................................................................150 N∙m
components. The fit is intended to be tight and 110 lb­ft
some compression of seals and thrust washers
is required to seat the bearing cups in the yoke. 10. Lower cab. See Hydraulic Cab Tilt Procedure.
Hand pressure, a tap with a soft­faced hammer (Operator’s Manual.)
or a “C” clamp can be used to seat a bearing 11. Install cold weather disconnect bottom guard.
cup in the yoke. DO NOT use the cap screws
to pull bearing cups into the yokes. 12. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.)
8. Align lubrication fittings and fasten universal joint (2) to
drive shaft (4.) Tighten cap screws (1) to specification. 13. Install engine side shields. See Opening Engine Side
Shields. (Operator’s Manual.)
SW03989,0000B3D ­19­06OCT10­3/3

TM11813 (13OCT10) 03­0325­3 748H Repair (S.N. 630436— )

101310

PN=69
 Input Drive Shafts and U­Joints

TM11813 (13OCT10) 03­0325­4 748H Repair (S.N. 630436— )

101310

PN=70
 Group 0350
Gears, Shafts, and Power Shift Clutches

Transmission Repair Procedures • Inspect bushings, remove burrs and sharp edges.
Replace bushings if out­of­round, scored or excessively
For repair procedures not covered in this book such worn.
as clutch replacement and gear replacement, see
DF180 Series Powershift Transmission Repair Manual.
• Inspect control valve bores for contamination.
(CTM308.)
• Inspect clutch and brake plates for facing material
condition wear to teeth and flatness of the plate.
Before beginning repair: • Inspect clutch and brake separator plates for
discoloration, teeth wear, scoring and flatness.
• Drain transmission oil. • Inspect all thrust surfaces for scoring.
• Thoroughly clean the outside of the transmission before • Inspect all gear and spline teeth.
disassembly to reduce the possibility of contamination. • Inspect all gasket and sealing surfaces for damage.
Disassembly: IMPORTANT: If the transmission has had a major
failure, replace all bearings, springs, oil seals,
• Clean all parts and flush any debris from oil passages. O­rings, ring seals, and gaskets.
• Use moisture­free air to dry parts (except bearings) and
to clean out oil passages. Assembly:
IMPORTANT: DO NOT use solvent to clean the
clutch and brake disks; use a lint­free cloth. • Lightly oil all bearings.
• Use new O­rings, seal rings, oil seals and gaskets.
• Lightly oil all bearings after cleaning. • Lubricate oil seals and O­rings.
• Wet clutch and brake plates with clean hydraulic oil
IMPORTANT: Spinning a bearing without lubrication before assembly.
can damage the bearing. • Clean and prepare all gasket and sealing surfaces.
• Inspect bearings for discoloration, roughness of
rotation, and excessive wear of rollers or balls.
PM10405,0000575 ­19­07OCT10­1/1

TM11813 (13OCT10) 03­0350­1 748H Repair (S.N. 630436— )

101310

PN=71
 Gears, Shafts, and Power Shift Clutches

Winch Drive Repair

TX1081448 —UN—01SEP10

Winch Drive and Cap Screw Tightening Sequence

1— Winch Drive Cover 6— Yoke Washer 11— Output Shaft 16— Snap Ring
2— Cap Screw (11 used) 7— Yoke 12— Bearing 17— Cover Assembly (if winch
3— Oil Seal 8— Dowel Pin 13— Bearing (2 used) option not present)
4— V­Ring Seal 9— Dowel Pin 14— Idler Gear 18— O­Ring
5— Cap Screw 10— Bearing 15— Drive Gear 19— Cover

1. Prepare machine for service. See Park and Prepare 2. Turn battery disconnect switch to the OFF position.
for Service Safely. (Group 0001.)
Continued on next page NM00125,000057F ­19­27SEP10­1/6

TM11813 (13OCT10) 03­0350­2 748H Repair (S.N. 630436— )

101310

PN=72
 Gears, Shafts, and Power Shift Clutches

3. Remove cap screw (5), yoke washer (6), and yoke (7).
4. Remove V­ring seal (4) and oil seal (3).
5. Remove cap screws (2) securing winch cover to
transmission housing.

TX1081441A —UN—01SEP10
2— Cap Screw (11 used) 5— Cap Screw
3— Oil Seal 6— Yoke Washer
4— V­Ring Seal 7— Yoke

Winch Output Yoke

TX1081442A —UN—01SEP10
Output Shaft Seals

TX1081444A —UN—01SEP10
Winch Cover Cap Screw Removal

Continued on next page NM00125,000057F ­19­27SEP10­2/6

TM11813 (13OCT10) 03­0350­3 748H Repair (S.N. 630436— )

101310

PN=73
 Gears, Shafts, and Power Shift Clutches

6. Remove winch cover (1) and output shaft (11).

7. Remove idler gear (14).
8. Remove snap ring (16) and drive gear (15).
9. Repair or replace parts as necessary.

TX1081443A —UN—01SEP10
1— Winch Cover 15— Drive Gear
11— Output Shaft 16— Snap Ring
14— Idler Gear

Winch Cover Removal

TX1081445A —UN—01SEP10
Idler Gear

TX1081447A —UN—01SEP10
Snap Ring Removal

NM00125,000057F ­19­27SEP10­3/6

10. Install winch output shaft.

11. Install idler gear.
12. Install drive gear and snap ring.
TX1081446A —UN—01SEP10

11— Output Shaft 15— Drive Gear

14— Idler Gear 16— Snap Ring

Winch Drive Gears

Continued on next page NM00125,000057F ­19­27SEP10­4/6

TM11813 (13OCT10) 03­0350­4 748H Repair (S.N. 630436— )

101310

PN=74
 Gears, Shafts, and Power Shift Clutches

13. Clean mating surfaces of housings with isopropyl

alcohol or equivalent.
IMPORTANT: Excessive amounts of gasket adhesive
may cause incorrect bearing end play, extend
cure time, and cause runoff of material.

TX1081439A —UN—01SEP10
Using a small roller will help to apply a
thin, even layer of adhesive.

14. Apply PM38655 Flexible Form­In­Place Gasket to rear

housing mating surface, using care to apply a thin
layer over the entire surface.Excess gasket material
should be wiped from joint. Installation should occur
within three minutes of application. Allow a minimum Winch Cover Installation
of 30 minutes of cure time before adding oil.
15. Ensure dowel pins (8 and 9) are installed in rear
housing.
16. Install winch drive cover.
17. Install and tighten cap screws to specification in
sequence shown. Repeat sequence again to check
cap screw torques.

YZ4114 —UN—20MAR01
Specification
Winch Cover­to­Rear
Housing Cap
Screw—Torque...................................................................... 20—30 N∙m
14—22 lb­ft

18. Apply PM37418 Thread Lock and Sealer (medium

strength) to outside diameter of oil seal. Apply Winch Drive Cover Torque Sequence
petroleum jelly to inside diameter of oil seal between
seal lips. 1— Winch Drive Cover 2— Cap Screw (11 used)

Continued on next page NM00125,000057F ­19­27SEP10­5/6

TM11813 (13OCT10) 03­0350­5 748H Repair (S.N. 630436— )

101310

PN=75
 Gears, Shafts, and Power Shift Clutches

19. Install new oil seal using JDG1110 Input Shaft Seal
Installation Tool (20) and JDG1108 Clutch Bearing
Driver (21).
20. Lubricate and install V­ring seal.
NOTE: OPTIMOLY PASTE WHITE T® reduces
spline wear.

TX1081440A —UN—01SEP10
21. Apply OPTIMOLY PASTE WHITE T® on output shaft
spline before installing yoke.
22. Install yoke.
23. Apply PM37421 Thread Lock and Sealer (high
strength) to cap screw.
24. Install yoke washer and cap screw. Tighten cap screw
to specification. Installing New Output Oil Seal
Specification
Cap Screw—Torque....................................................................215 N∙m
159 lb­ft

25. Turn battery disconnect switch to the ON position.

TX1081442A —UN—01SEP10
3— Oil Seal 20— JDG1110 Input Shaft Seal
4— V­Ring Seal Installation Tool
21— JDG1108 Clutch Bearing
Driver

Output Shaft Seals

OPTIMOLY PASTE WHITE T is a trademark of Optimal Lubricants, Inc.

NM00125,000057F ­19­27SEP10­6/6

TM11813 (13OCT10) 03­0350­6 748H Repair (S.N. 630436— )

101310

PN=76
 Gears, Shafts, and Power Shift Clutches

Input Yoke Remove and Install

1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.

TX1081449A —UN—01SEP10
3. Remove cap screw (1).
4. Remove washer (2).
5. Remove O­ring (3).
6. Remove yoke (4).
7. Remove oil seal (5). Transmission Input Yoke
8. Apply PM37418 Thread Lock and Sealer (medium
strength) to outside diameter of oil seal. Apply
petroleum jelly to inside diameter of new oil seal .
Install using a disk driver.
NOTE: OPTIMOLY PASTE WHITE T® reduces

TX1081451A —UN—01SEP10
spline wear.

9. Apply OPTIMOLY PASTE WHITE T® on input shaft

spline before installing yoke.
IMPORTANT: The yoke may need to be moved up
and down until the seal lip is over the full
circumference of yoke. Seal lip of oil seal must
not be rolled when yoke is installed. Transmission Input Yoke Removal

10. Install yoke.

11. Install O­ring.
12. Install washer.

TX1081450A —UN—01SEP10
13. Apply PM37421 Thread Lock and Sealer (high
strength) to cap screw.
14. Install and tighten cap screw to specification.
Specification
Input Yoke Cap
Screw—Torque............................................................................215 N∙m
159 lb­ft Torque Wrench

15. Turn battery disconnect to the ON position.

1— Cap Screw 4— Yoke
2— Washer 5— Oil Seal
3— O­Ring 6— Torque Wrench

OPTIMOLY PASTE WHITE T is a trademark of Optimal Lubricants, Inc.

NM00125,0000580 ­19­27SEP10­1/1

TM11813 (13OCT10) 03­0350­7 748H Repair (S.N. 630436— )

101310

PN=77
 Gears, Shafts, and Power Shift Clutches

TM11813 (13OCT10) 03­0350­8 748H Repair (S.N. 630436— )

101310

PN=78
 Group 0360
Hydraulic System

Transmission Charge Pump Remove and

Install
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

1. Operate all hydraulic functions, including brake, to

release pressure in the hydraulic system. Depress
brake pedal at 1­second intervals 20 times to remove
pressure from service brake accumulator.

TX1025182A —UN—21JUN07
2. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)
3. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)
5. Drain transmission oil. See Change Transmission Oil, Cooling Loop Pump
Replace Filter, and Clean Suction Screen. (Operator’s
Manual.)
IMPORTANT: Cooling loop pump must be removed
prior to charge pump removal. This eliminates
the potential of dropping cooling loop

TX1025193A —UN—21JUN07
drive coupler into transmission during
charge pump removal.

6. Remove cap screws (1) and lay cooling loop pump

(2) aside.
7. Remove drive coupler (3).
8. Remove hydraulic pump. See Hydraulic Pump Drive Coupler
Remove and Install. (Group 2160.)
1— Cap Screw (2 used) 3— Drive Coupler
2— Cooling Loop Pump

Continued on next page NM00125,0000591 ­19­30SEP10­1/4

TM11813 (13OCT10) 03­0360­1 748H Repair (S.N. 630436— )

101310

PN=79
 Hydraulic System

9. Remove transmission charge pump suction tube (6).

See Transmission Suction Tube Repair. (Group 0360.)
10. Remove charge pump­to­transmission filter hose (4).
11. Remove cap screws (5) and remove transmission
charge pump.

4— Charge Pump­to­ 6— Transmission Charge Pump

Transmission Filter Hose Suction Tube
5— Cap Screw (4 used)

TX1081234A —UN—30AUG10
Transmission Charge Pump

NM00125,0000591 ­19­30SEP10­2/4

12. Inspect spline coupler and drive gear assembly (8).

Repair or replace parts as necessary.
IMPORTANT: Always replace charge pump flange
O­ring. Old or damaged O­rings may leak.

TX1081233A —UN—30AUG10
13. Apply petroleum jelly to new O­ring (7) and install on
charge pump flange.
14. Apply OPTIMOLY PASTE WHITE T® to pump splines.
IMPORTANT: Install gear assembly with seal side of
bearing facing transmission charge pump.

15. Install drive gear assembly to charge pump splines. Charge Pump Flange

7— O­Ring 8— Drive Gear Assembly

TX1081232A —UN—30AUG10

Transmission Charge Pump Drive Coupler

OPTIMOLY PASTE WHITE T is a trademark of Optimal Lubricants, Inc.

Continued on next page NM00125,0000591 ­19­30SEP10­3/4

TM11813 (13OCT10) 03­0360­2 748H Repair (S.N. 630436— )

101310

PN=80
 Hydraulic System

16. Position charge pump to transmission housing. Install

and tighten cap screws in the sequence shown to
specification.
Specification
Cap Screw—Torque......................................................................73 N∙m
55 lb­ft

T114002 —UN—16MAR98
17. Install transmission charge pump suction tube. See
Transmission Suction Tube Repair. (Group 0360.)
IMPORTANT: Transmission charge pump must
be filled with oil prior to start­up to
prevent pump damage.
Cap Screw Torque Sequence
18. Remove 90­degree fitting from top of transmission
charge pump and fill pump with proper oil. See
Transmission, Park Brake, Differential, Cab Tilt 24. Fill transmission with proper oil. See Change
Hydraulic Pump and Winch Oil. (Operator’s Manual.) Transmission Oil, Replace Filter, and Clean Suction
Screen. (Operator’s Manual.)
19. Install 90­degree fitting and transmission charge
pump­to­transmission filter hose. 25. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.)
20. Install hydraulic pump. See Hydraulic Pump Remove
and Install. (Group 2160.) 26. Calibrate transmission control unit. See Transmission
Control Unit (TCU) Calibration. (Group 9025.)
21. Install spline coupler.
22. Install cooling loop pump.
23. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operator’s Manual.)
NM00125,0000591 ­19­30SEP10­4/4

TM11813 (13OCT10) 03­0360­3 748H Repair (S.N. 630436— )

101310

PN=81
 Hydraulic System

Transmission Charge Pump Drive Repair

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

1. Operate all hydraulic functions, including brake, to

release pressure in the hydraulic system. Depress
brake pedal at 1­second intervals 20 times to remove
pressure from service brake accumulator.
2. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)
3. Turn battery disconnect switch to the OFF position.
4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)
5. Remove transmission charge pump. See Transmission

TX1081407A —UN—01SEP10
Charge Pump Remove and Install. (Group 0360.)
6. Remove drive gear (1).
7. Remove cap screw (2).

1— Drive Gear 2— Cap Screw

Drive Gear

TX1081408A —UN—01SEP10
Cap Screw

Continued on next page NM00125,0000592 ­19­06OCT10­1/5

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 Hydraulic System

8. Install M8 x 35 mm cap screw (3) in tapped hole.

9. Use cap screw to remove idler shaft (4).
IMPORTANT: There are 2 O­rings (5), one at each end
of shaft. The O­ring located on the bottom of the

TX1081409A —UN—01SEP10
idler shaft may slip off at removal of shaft.

10. Remove and discard O­rings (5).

11. Remove idler gear (6).
12. Replace bearings in idler gear if worn or damaged.

3— M8 x 35 mm Cap Screw 5— O­Ring (2 used)

M8 x 35 mm Cap Screw
4— Idler Shaft 6— Idler Gear

TX1081410A —UN—01SEP10
Idler Shaft, O­Rings, and Idler Gear

Continued on next page NM00125,0000592 ­19­06OCT10­2/5

TM11813 (13OCT10) 03­0360­5 748H Repair (S.N. 630436— )

101310

PN=83
 Hydraulic System

13. Install idler gear (6) into front housing.

NOTE: Lubricate O­rings to avoid damage
during assembly.

14. Install new O­rings (5) on idler shaft.

TX1081411A —UN—01SEP10
15. Install M8 x 35 mm cap screw (3) in tapped hole.
16. Install idler shaft through idler shaft port and idler gear
assembly.
NOTE: Using cap screw (3) turn idler shaft to align
holes in shaft and housing.
Idler Gear and O­Rings
17. Use cap screw, align idler shaft with rear housing hole.
18. Remove M8 x 35 mm cap screw.

3— M8 x 35 mm Cap Screw 6— Idler Gear

5— O­Ring (2 used)

TX1081409A —UN—01SEP10
M8 x 35 mm Cap Screw

Continued on next page NM00125,0000592 ­19­06OCT10­3/5

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101310

PN=84
 Hydraulic System

19. Install and tighten cap screw in idler shaft to

specification.
Specification
Idler Gear Shaft­to­Front
Housing Cap

TX1081408A —UN—01SEP10
Screw—Torque..............................................................................87 N∙m
64 lb­ft

2— Cap Screw

Cap Screw

YZ1148 —UN—23DEC97
Tighten Idler Shaft Cap Screw

NM00125,0000592 ­19­06OCT10­4/5

IMPORTANT: Seal on bearing must face

transmission charge pump.

20. Install bearing (7), drive gear (8), and bearing (9).
21. Install charge pump. See Transmission Charge Pump

TX1081412A —UN—01SEP10
Remove and Install. (Group 0360.)
22. Turn battery disconnect switch to the ON position.

7— Bearing 9— Bearing
8— Drive Gear

Drive Gear and Bearings

NM00125,0000592 ­19­06OCT10­5/5

TM11813 (13OCT10) 03­0360­7 748H Repair (S.N. 630436— )

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PN=85
 Hydraulic System

Transmission Suction Tube Repair

1. Remove cap screws (3). 1

2. Disconnect suction tube (2) from charge pump (1).

3. Remove suction screen (5).
4. Remove and discard O­ring (5).
5. Inspect suction screen for signs of collapse or
plugging. Clean or replace suction screen as
necessary.
6. Inspect and replace suction tube as necessary.
7. Install suction screen (5) and new O­ring (4).

TX1024819 —UN—13JUN07
8. Install suction tube (2).
9. Install cap screws and tighten to specification.
Specification 2
3
Suction Tube­to­Front
Housing Cap
Screws—Torque............................................................................25 N∙m
18 lb­ft

1— Transmission Charge Pump 4— O­Ring

2— Transmission Suction Tube 5— Suction Screen
3— Cap Screw (2 used)

TX1024821A —UN—13JUN07
AC12469,0000388 ­19­09JUL07­1/1

TM11813 (13OCT10) 03­0360­8 748H Repair (S.N. 630436— )

101310

PN=86
 Hydraulic System

Transmission Control Valve Repair

YZ104543A —UN—11SEP03
Transmission Control Valve
A—Valve Housing C—Cooler Pressure Relief Valve E—Plug (12 used) G—O­Ring
B—Proportional Solenoid ( 8 D—Main Pressure Valve F— Plug (2 used) H—Temperature Sensor
used)
AC12469,0000389 ­19­13JUL07­1/22

1. Remove cap screws from control valve.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

2. Remove valve (A).

YZ1077 —UN—17DEC97

Specification
Control Valve—Weight
(approximate)............................................................................... 27.5 kg
61 lb

A—Control Valve

Continued on next page AC12469,0000389 ­19­13JUL07­2/22

TM11813 (13OCT10) 03­0360­9 748H Repair (S.N. 630436— )

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 Hydraulic System

3. Remove gasket (A), plate (B) and gasket (C) from

front housing and discard gaskets.

A—Gasket C—Gasket
B—Plate

YZ1078 —UN—17DEC97
AC12469,0000389 ­19­13JUL07­3/22

4. Remove nut (A), washer (B) and coil (C) from

proportional solenoid valve. Flange nut also used in
place of nut and washer.

A—Nut or Flanged Nut C—Coil

B—Washer (Not used with
Flanged Nut)

YZ1079 —UN—17DEC97
AC12469,0000389 ­19­13JUL07­4/22

IMPORTANT: When any proportional solenoid valves

are removed or replaced, Transmission Control
Unit (TCU) must be calibrated.

5. Remove proportional valve (D).

6. Inspect for contamination.

D—Proportional Valve YZ1080 —UN—17DEC97

Continued on next page AC12469,0000389 ­19­13JUL07­5/22

TM11813 (13OCT10) 03­0360­10 748H Repair (S.N. 630436— )

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PN=88
 Hydraulic System

7. Remove relief valve (A).

8. Inspect for wear or contamination.
NOTE: Check backup rings for damage.

A—Cooler Pressure Relief

YZ1081 —UN—17DEC97
Valve

AC12469,0000389 ­19­13JUL07­6/22

9. Remove main pressure regulator (A).

10. Inspect for wear or contamination.

A—Main Pressure Regulator

YZ1082 —UN—17DEC97
AC12469,0000389 ­19­13JUL07­7/22

11. Remove temperature sensor (A).

12. Remove O­ring (B).
13. Inspect for contamination.

A—Temperature Sensor B—O­Ring

YZ1083 —UN—17DEC97

Temperature Sensor and O­Ring

Continued on next page AC12469,0000389 ­19­13JUL07­8/22

TM11813 (13OCT10) 03­0360­11 748H Repair (S.N. 630436— )

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PN=89
 Hydraulic System

14. Remove twelve plugs (A).

15. Inspect for contamination in control valve passages.
NOTE: Apply lubricant to all O­rings prior to
installing into valve housing.

YZ1084 —UN—17DEC97
16. Install new O­ring.
17. Install plugs (A) and fitting into valve housing.
18. Tighten plugs (A) to specification.
Specification
Plug­to­Valve
Housing—Torque...........................................................................12 N∙m
106 lb­in.
A—Plugs (12 used)

AC12469,0000389 ­19­13JUL07­9/22

19. Install new O­ring (B).

20. Install temperature sensor (A).
21. Tighten temperature sensor to specification.
Specification
Temperature

YZ1083 —UN—17DEC97
Sensor­to­Valve
Housing—Torque...........................................................................16 N∙m
142 lb­in.

A—Temperature Sensor B—O­Ring

AC12469,0000389 ­19­13JUL07­10/22

22. Install new O­rings on main pressure regulator.

23. Install and tighten main pressure regulator (A) to
specification.
Specification
Main Regulator
Assembly­to­Valve
YZ1082 —UN—17DEC97

Housing—Torque................................................................... 34—47 N∙m

25—35 lb­ft

A—Main Pressure Regulator

Continued on next page AC12469,0000389 ­19­13JUL07­11/22

TM11813 (13OCT10) 03­0360­12 748H Repair (S.N. 630436— )

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PN=90
 Hydraulic System

24. Install new O­rings (A) on relief valve.

NOTE: Install new backup rings as needed.

25. Install and tighten relief valve to specifcation.

Specification
Cooler Relief

YZ1081 —UN—17DEC97
Valve­to­Valve
Housing—Torque................................................................... 34—47 N∙m
25—35 lb­ft

A—O­Rings

AC12469,0000389 ­19­13JUL07­12/22

IMPORTANT: When any proportional solenoid valves

are removed or replaced, Transmission Control
Unit (TCU) must be calibrated.

26. Lubricate and install new O­rings (A—C) on

proportional valve.

YZ327 —UN—24SEP96
A—O­Ring C—O­Ring
B—O­Ring

AC12469,0000389 ­19­13JUL07­13/22

27. Install proportional valve (D) into valve housing.

28. Tighten proportional valve.
Specification
Proportional Valve­to­
Valve Housing—Torque......................................................... 16—20 N∙m
142—177 lb­ft

YZ1080 —UN—17DEC97
D—Proportional Valve

Continued on next page AC12469,0000389 ­19­13JUL07­14/22

TM11813 (13OCT10) 03­0360­13 748H Repair (S.N. 630436— )

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PN=91
 Hydraulic System

29. Install coil (E) and washer (F) on proportional valve.

NOTE: Make sure nut threads and valve are
free of oil before applying sealer to ensure
sealer will set up properly.

30. Clean threads on proportional valve and nut. Apply

YZ1079D —UN—12JAN98
cure primer.
31. Apply high strength thread lock and sealer to nut (G)
and install on proportional valve.

E—Coil G—Nut or Flange Nut

F— Washer (Not used with
Flange Nut)

AC12469,0000389 ­19­13JUL07­15/22

32. Tighten solenoid coil nut.

Specification
Proportional Valve
Nut­to­Proportional
Solenoid—Torque................................................................ 4.5—6.8 N∙m
40—60 lb­in.

YZ4136 —UN—22MAR01
33. Repeat steps to install remaining proportional solenoid
and valve assemblies.

AC12469,0000389 ­19­13JUL07­16/22

34. Install two guide pins (A) in the front housing.

NOTE: The guide pins help align the gaskets by holding
them in place and ease valve assembly installation.

A—Guide Pins

YZ1088 —UN—23DEC97

Continued on next page AC12469,0000389 ­19­13JUL07­17/22

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 Hydraulic System

35. Gasket, Plate and Gasket Alignment

IMPORTANT: Gaskets and plate must be in correct
order and correct side up. Printed side of gasket
must be towards the control valve.

B—Gasket D—Gasket
C—Plate

YZ5087 —UN—18SEP03
AC12469,0000389 ­19­13JUL07­18/22

36. Put gasket (B), plate (C) and gasket (D) on front
housing using guide bolts as alignment guide.

B—Gasket D—Gasket
C—Plate

YZ1078A —UN—23DEC97
Continued on next page AC12469,0000389 ­19­13JUL07­19/22

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 Hydraulic System

37. Install control valve (A) on front housing.

38. Remove guide pins.
39. Install and tighten cap screws (B) per numerical
sequence drawing.

A—Control Valve B—Cap Screws

YZ1087 —UN—23DEC97
Continued on next page AC12469,0000389 ­19­13JUL07­20/22

TM11813 (13OCT10) 03­0360­16 748H Repair (S.N. 630436— )

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 Hydraulic System

T163650 —UN—14JAN03

Cap Screw Tightening Sequence

A—Cap Screw, 45 mm long and B—Cap Screw, 90 mm long and C—Cap Screw, 75 mm long and
Flat Washer (5 used) Flat Washer (9 used) Flat Washer (13 used)

Continued on next page AC12469,0000389 ­19­13JUL07­21/22

TM11813 (13OCT10) 03­0360­17 748H Repair (S.N. 630436— )

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 Hydraulic System

40. Tighten cap screws (A—C) again in sequence shown. Specification

Control Valve­to­Front
Housing Cap
Screws—Torque............................................................................39 N∙m
29 lb­ft
AC12469,0000389 ­19­13JUL07­22/22

TM11813 (13OCT10) 03­0360­18 748H Repair (S.N. 630436— )

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 Section 04
Engine
Contents

Page

Group 0400—Removal and Installation

PowerTech Plus™ 6.8L (6068)
John Deere Engine—6.8L Tier
3/Stage IIIA............................................ 04­0400­1
PowerTech Plus™ 6.8L (6068)
John Deere Engine—6.8L Stage
II............................................................. 04­0400­1
Engine Remove and Install........................ 04­0400­2

TM11813 (13OCT10) 04­1 748H Repair (S.N. 630436— )

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PN=1
 Contents

TM11813 (13OCT10) 04­2 748H Repair (S.N. 630436— )

101310

PN=2
 Group 0400
Removal and Installation

PowerTech Plus™ 6.8L (6068) John Deere

Engine—6.8L Tier 3/Stage IIIA
For additional information on John Deere PowerTech™
and PowerTech Plus™ engines and components, see
the following component technical manuals:
• PowerTech™ 4.5 L and 6.8 L Diesel Engines—Base

M44215 —UN—07SEP88
Engine. (CTM104.)
• PowerTech Plus™ 4.5 L and 6.8 L Diesel Engines—
Level 14 Electronic Fuel System with Denso HPCR.
(CTM320.)

PowerTech is a trademark of Deere & Company

PowerTech Plus is a trademark of Deere & Company
PM10405,0000573 ­19­07OCT10­1/1

PowerTech Plus™ 6.8L (6068) John Deere

Engine—6.8L Stage II
For additional information on John Deere PowerTech™
and PowerTech Plus™ engines and components, see
the following component technical manuals:
• PowerTech™ 4.5 L and 6.8 L Diesel Engines—Base

M44215 —UN—07SEP88
Engine. (CTM104.)
• PowerTech Plus™ 4.5 L and 6.8 L Diesel Engines—
Level 14 Electronic Fuel System with Denso HPCR.
(CTM320.)

PowerTech is a trademark of Deere & Company

PowerTech Plus is a trademark of Deere & Company
PM10405,0000574 ­19­07OCT10­1/1

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PN=99
 Removal and Installation

Engine Remove and Install

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or

TX1080866A —UN—16AUG10
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

1. Operate all hydraulic functions, including brake, to

release pressure in the hydraulic system. Depress
brake pedal at 1­second intervals 20 times to
discharge pressure from brake accumulator.
2. Park and prepare machine for service. See Park and Hydraulic Oil Return Filter Assembly
Prepare for Service Safely. (Group 0001.)
3. Turn battery disconnect switch to the OFF position. 1— Hydraulic Oil Return Hose 3— Hydraulic Return Filter
2— Hydraulic Reservoir Assembly
See Battery Disconnect. (Operator’s Manual.)
4. Remove engine side shields. See Opening Engine
Side Shields. (Operator’s Manual.)
5. Drain cooling system. See Draining the Cooling
System. (Operator’s Manual.)
6. Remove hood. See Hood Remove and Install. (Group
1910.)
7. Remove hydraulic fan motor. See Hydraulic Fan Motor
Remove and Install. (Group 2160.)
8. Remove fan shroud. See Fan Shroud Remove and
Install. (Group 0510.)
9. Disconnect hydraulic oil return hose (1) at hydraulic
reservoir (2). Close all openings using caps and plugs.
Secure hydraulic filter assembly (3) to the side.
10. Remove air cleaner assembly. See Air Cleaner
Remove and Install. (Group 0520.)
Continued on next page MH66088,0000DAC ­19­07OCT10­1/9

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 Removal and Installation

11. Remove engine deaeration hose (4) from thermostat

housing. Disconnect coolant fill hose (5) at engine
block and remove surge tank. Close all openings
using caps and plugs. 4
12. Disconnect heater hoses from engine. Remove any
hose clamps or wire ties. Close all openings using
caps and plugs.

4— Engine Deaeration Hose 5— Coolant Fill Hose

5

TX1080867 —UN—13AUG10
Surge Tank Removal
MH66088,0000DAC ­19­07OCT10­2/9

13. Disconnect fuel supply hose (6) at final fuel filter (7) on
right side of engine. Disconnect fuel return hose (8)
on left side of engine at high pressure fuel pump (9).
Close all openings using caps and plugs.
14. Remove serpentine belt. See Serpentine Belt Remove

TX1080911A —UN—16AUG10
and Install. (Group 0510.)

6— Fuel Supply Hose 8— Fuel Return Hose

7— Final Fuel Filter 9— High Pressure Fuel Pump

Fuel Supply Hose

TX1080908A —UN—16AUG10

Fuel Return Hose

Continued on next page MH66088,0000DAC ­19­07OCT10­3/9

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 Removal and Installation

NOTE: It is not necessary to disconnect air conditioner

lines when removing the compressor for engine
removal and installation.

15. Disconnect wire harness connector (10) and ground

TX1080909A —UN—16AUG10
wire (11) at air conditioner compressor (13). Remove
cap screws (12) and secure compressor to the side.

10— Wire Harness Connector 12— Cap Screw

11— Ground Wire 13— Air Conditioner
Compressor

Air Conditioner Compressor

MH66088,0000DAC ­19­07OCT10­4/9

16. Remove cap screw (14) and clamp (15). Tag and
disconnect wiring harness connectors (16) from
engine control unit (19).
17. Remove cap screws (17) and remove ECU (19) and
ECU mouting bracket (18).
18. Remove wiring harness clamps along right side frame.
19. Tag and disconnect all electrical connections at starter.
20. Tag and disconnect all electrical connections at
alternator.
21. Remove ground wire from battery disconnect switch.

TX1080907A —UN—16AUG10
22. Remove batteries from machine. See Remove and
Install Batteries. (Operator’s Manual.)
23. Remove two engine wiring harness clamps on back
side of engine and on left rear engine mount.
24. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)
25. Remove ground strap from engine, located near right Engine Control Unit (ECU)
rear engine mount.
26. Disconnect cold weather disconnect linkage, 14— Cap Screw 17— Cap Screw (3 used)
if equipped. See Transmission Cold Weather 15— Clamp 18— Engine Control Unit (ECU)
16— Wiring Harness Connector Mounting Bracket
Disconnect Linkage Remove and Install—If Equipped. (3 used) 19— Engine Control Unit (ECU)
(Group 0752.)
27. Remove engine­to­transmission drive shaft. See
Engine­to­Transmission Drive Shaft Remove and
Install. (Group 0325.)
Continued on next page MH66088,0000DAC ­19­07OCT10­5/9

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 Removal and Installation

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

NOTE: If engine does not have lifting lugs, they can

be procured through service parts.

TX1081034 —UN—23AUG10
Use of an engine lifting sling (as shown) is the
ONLY APPROVED method for lifting engine.

28. Install engine lifting lugs (20) to engine. Attach JDG23

Engine Lifting Sling (21) and appropriate lifting device
to engine lifting lugs. Support engine.
Specification Engine Removal
Engine—Weight
(approximate)................................................................................ 771 kg
20— Engine Lifting Lug (2 21— JDG23 Engine Lifting
1700 lb.
used) Sling

MH66088,0000DAC ­19­07OCT10­6/9

29. Remove cap screws (22), nuts (28), and washers (23,
24, and 27) securing engine mounts to frame.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

30. Remove engine from machine.

Specification
Engine—Weight
(approximate)................................................................................ 771 kg
1700 lb.

31. Repair or replace engine as necessary.

TX1081035 —UN—23AUG10
32. Inspect engine mount rubber isolators (25 and 26) for
damage or excessive wear. Replace as necessary.
33. Install engine mount brackets to engine block, if
removed, and tighten to specification.
Specification
Engine Mount Bracket
Cap Screw—Torque....................................................................320 N∙m Engine Mounts
236 lb­ft

34. Install engine isolators to engine mounts. 22— Cap Screw (4 used) 26— Lower Isolator
23— Washer (4 used) 27— Washer (4 used)
35. Install engine to machine. 24— Washer (4 used) 28— Nut (4 used)
25— Upper Isolator
Specification
Engine—Weight
(approximate)................................................................................ 771 kg
Rear Engine
1700 lb.
Mount­to­Frame Cap
36. Tighten engine mount­to­frame cap screws to Screw—Torque............................................................................712 N∙m
specification. 525 lb­ft

Specification 37. Install engine­to­transmission drive shaft. See

Front Engine Engine­to­Transmission Drive Shaft Remove and
Mount­to­Frame Cap Install. (Group 0325.)
Screw—Torque............................................................................620 N∙m
457 lb­ft
Continued on next page MH66088,0000DAC ­19­07OCT10­7/9

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 Removal and Installation

TX1081054 —UN—23AUG10
Engine­to­Transmission Drive Shaft Alignment
29— Torsional Dampener 30— Top Measurement 31— Bottom Measurement 32— 6­inch Steel Scale

38. Using a 6­inch steel scale (32) or depth gauge,

measure distance at top and bottom (30 and 31) of 46. Connect electrical connections at starter.
torsional dampener (29). Measurements should be 47. Install ECU mounting bracket and ECU. Connect
less than a 2 mm (0.08 in.) difference. Loosen engine electrical connectors to ECU.
mount­to­engine cap screws and raise or lower rear
of engine to change measurement. 48. Install air conditioner compressor and connect wiring
harness connector and ground wire.
39. Once correct measurement is achieved, tighten engine
mount­to­engine cap screws to specified torque. 49. Connect fuel supply and fuel return hoses.
Specification 50. Connect heater hoses.
Engine Mount­to­Engine
Cap Screw—Torque....................................................................320 N∙m 51. Connect coolant fill hose at engine block. Connect
236 lb­ft deaeration hose to thermostat housing.

40. Remove lifting sling and lifting lugs from engine. 52. Install air cleaner assembly. See Air Cleaner Remove
and Install. (Group 0520.)
41. Connect cold weather disconnect linkage, if equipped.
See Transmission Cold Weather Disconnect Linkage 53. Connect hydraulic return line at hydraulic reservoir.
Remove and Install—If Equipped. (Group 0752.) 54. Install fan shroud. See Fan Shroud Remove and
42. Install ground strap to engine. Install. (Group 0510.)

43. Install batteries. See Remove and Install Batteries. 55. Install hydraulic fan motor. See Hydraulic Fan Motor
(Operator’s Manual.) Remove and Install. (Group 2160.)

44. Install ground wire to battery disconnect switch. 56. Install hood. See Hood Remove and Install. (Group
1910.)
45. Connect electrical connections at alternator.
Continued on next page MH66088,0000DAC ­19­07OCT10­8/9

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 Removal and Installation

57. Fill cooling system. See Filling the Cooling System. 61. Bleed fuel system. See Bleed Fuel System.
(Operator’s Manual.) (Operator’s Manual.)
58. Install engine side shields. See Opening Engine Side 62. Check Engine Oil Level. See Check Engine Oil Level.
Shields. (Operator’s Manual.) (Operator’s Manual.)
59. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.)
60. Check hydraulic oil level. Add hydraulic oil, if
necessary. See Check Hydraulic System Oil Level.
(Operator’s Manual.)
MH66088,0000DAC ­19­07OCT10­9/9

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 Removal and Installation

TM11813 (13OCT10) 04­0400­8 748H Repair (S.N. 630436— )

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 Section 05
Engine Auxiliary Systems
Contents

Page

Group 0505—Cold Weather Starting Aids

Do Not Use Ether Start Aid........................ 05­0505­1

Group 0510—Cooling System

Air Baffle Enclosure Remove and
Install ..................................................... 05­0510­1
Serpentine Belt Remove and
Install ..................................................... 05­0510­2
Serpentine Belt Tensioner—Spring
Tension Check ....................................... 05­0510­3
Serpentine Belt Tensioner Remove
and Install .............................................. 05­0510­4
Aftercooler Remove and Install ................. 05­0510­5
Radiator Remove and Install ..................... 05­0510­8
Transmission Oil Cooler Remove
and Install ............................................ 05­0510­10
Hydraulic Oil Cooler Remove and
Install ................................................... 05­0510­13
Fan Blade Remove and Install ................ 05­0510­16
Fan Shroud Remove and Install .............. 05­0510­16

Group 0520—Intake System

Air Cleaner Remove and Install................. 05­0520­1

Group 0530—Exhaust System

Muffler Remove and Install........................ 05­0530­1

Group 0560—External Fuel Supply System

Fuel Tank Remove and Install ................... 05­0560­1

TM11813 (13OCT10) 05­1 748H Repair (S.N. 630436— )

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 Contents

TM11813 (13OCT10) 05­2 748H Repair (S.N. 630436— )

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 Group 0505
Cold Weather Starting Aids

Do Not Use Ether Start Aid

IMPORTANT: Avoid an explosion or fire. Machine
is equipped with electrical cold start assist
system. Do not use ether start aid or any type
of starting fluids on this machine.

T145705 —UN—18SEP01
This machine is equipped with a Tier III engine. Fire,
explosion or engine damage will result from using starting
fluids of any type on this machine.

SW03989,0000B39 ­19­24SEP10­1/1

TM11813 (13OCT10) 05­0505­1 748H Repair (S.N. 630436— )

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 Cold Weather Starting Aids

TM11813 (13OCT10) 05­0505­2 748H Repair (S.N. 630436— )

101310

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 Group 0510
Cooling System

Air Baffle Enclosure Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
3. Drain cooling system. See Draining the Cooling
System. (Operator’s Manual.)
4. Remove grille housing side panels (1) and grille

TX1080338A —UN—29JUL10
housing top left panel (2).

1— Grille Housing Side Panel 2— Grille Housing Top Left

(2 used) Panel

Grille Housing Access Panels

MH66088,0000D7D ­19­10SEP10­1/3

NOTE: Access to hose bracket cap screws (3) and

hose bracket (4) is obtained after grille housing
top left panel (2) is removed.
3
5. Remove caps screws (3) and hose bracket (4) from
grille housing.
6. Remove left side engine side shields. See Opening
Engine Side Shields. (Operator’s Manual.)
7. Remove upper charge air tube. Close all openings 4
using caps and plugs.
8. Disconnect upper radiator hose from radiator and
remove hose from air baffle. Close all openings using

TX1080210 —UN—29JUL10
caps and plugs.

3— Cap Screw (2 used) 4— Hose Bracket

Access for Hose Bracket Removal

Continued on next page MH66088,0000D7D ­19­10SEP10­2/3

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 Cooling System

9. Remove caps screws (5), washers (6), nuts (7), and 9

washers (8) securing air baffle panels (9—12) to grille
housing.
10. Remove upper right air baffle panel (9).
11. Remove lower left air baffle panel (10).
6 11
12. Remove upper left air baffle panel (11). 5
13. Remove lower right air baffle panel (12).
14. Inspect and replace parts as necessary.
NOTE: Air baffle panels must be installed in
reverse order of removal.

15. Install air baffle panels in reverse order of removal. 12

Install cap screws, nuts, and washers securing air
baffle panels to grille housing.
16. Install upper radiator hose.
17. Install upper charge air tube.

TX1080209 —UN—18AUG10
18. Install left side engine side shields. See Opening
Engine Side Shields. (Operator’s Manual.) 10
7
19. Install hose bracket to grille housing.
8
20. Install grille housing top left panel.
21. Install grille housing side panels.
Air Baffle Panel Removal (view from front of machine)
22. Fill cooling system. See Filling the Cooling System.
(Operator’s Manual.) 5— Cap Screw (20 used) 9— Upper Right Air Baffle
6— Washer (20 used) Panel
23. Turn battery disconnect switch to the ON position. See 7— Nut (2 used) 10— Lower Left Air Baffle Panel
Battery Disconnect. (Operator’s Manual.) 8— Washer (2 used) 11— Upper Left Air Baffle Panel
12— Lower Right Air Baffle
Panel

MH66088,0000D7D ­19­10SEP10­3/3

Serpentine Belt Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
3. Remove right side grille housing vent panel (1).
TX1080357A —UN—30JUL10

4. Remove top right air baffle panel. See Air Baffle

Enclosure Remove and Install. (Group 0510.)

1— Right Side Grille Housing

Vent Panel

Right Side Grille Housing Vent Panel

Continued on next page MH66088,0000D7E ­19­10SEP10­1/2

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 Cooling System

5. Install a 1/2­in. drive wrench into belt tensioner (4) 5

arm and pull wrench and arm downward to loosen
serpentine belt.
6. Remove serpentine belt. 6
4 7
7. Check serpentine belt for wear or damage. Replace if
necessary. See Inspect Serpentine Belt. (Operator’s
Manual.)

TX1080369 —UN—30JUL10
8. Install serpentine belt as shown. 3
9. Install air baffle panel. See Air Baffle Enclosure
Remove and Install. (Group 0510).
10. Install right side grille housing vent panel. 2

11. Turn battery disconnect switch to the ON position. See

Battery Disconnect. (Operator’s Manual.) Serpentine Belt Routing

2— Crankshaft Pully 5— Alternator Pully

3— Water Pump Pully 6— Idler Pully
4— Tensioner 7— Air Conditioner
Compressor Pully

MH66088,0000D7E ­19­10SEP10­2/2

Serpentine Belt Tensioner—Spring Tension

Check
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
3. Remove right side grille housing vent panel (1).

TX1080357A —UN—30JUL10
4. Remove top right air baffle panel. See Air Baffle
Enclosure Remove and Install. (Group 0510).
5. Remove serpentine belt. See Serpentine Belt Remove
and Install. (Group 0510.)

1— Right Side Grille Housing

Vent Panel Right Side Grille Housing Vent Panel

Continued on next page MH66088,0000D7F ­19­18AUG10­1/2

TM11813 (13OCT10) 05­0510­3 748H Repair (S.N. 630436— )

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 Cooling System

6. Put an alignment mark (2) on swing arm of tensioner

as shown.
7. Measure 21 mm (0.83 in.) down from swing arm mark
and put a mark (3) on tensioner mounting base.
Specification
Belt Tensioner
Spring—Distance.......................................................................... 21 mm
0.83 in.

TX1080385A —UN—30JUL10
8. Rotate the swing arm tensioner using a torque wrench
until marks (2 and 3) are aligned.
9. Record torque wrench measurement and compare
with specification. Replace tensioner as required.
Specification
Spring Tension—Torque........................................................ 18—22 N∙m
Alignment Marks
159—195 lb­in.

10. Install serpentine belt. See Serpentine Belt Remove 2— Swing Arm Mark 3— Tensioner Mark
and Install. (Group 0510.)
11. Install top right air baffle panel. See Air Baffle
Enclosure Remove and Install. (Group 0510.) 13. Turn battery disconnect switch to the ON position.
12. Install right side grille housing vent panel.
MH66088,0000D7F ­19­18AUG10­2/2

Serpentine Belt Tensioner Remove and

Install
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
3. Remove right side grille housing vent panel (1).

TX1080357A —UN—30JUL10
4. Remove top right air baffle panel. See Air Baffle
Enclosure Remove and Install. (Group 0510.)
5. Remove serpentine belt from tensioner pulley. See
Serpentine Belt Remove and Install. (Group 0510.)

1— Right Side Grille Housing

Vent Panel Right Side Grille Housing Vent Panel

Continued on next page MH66088,0000D80 ­19­10SEP10­1/2

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 Cooling System

6. Remove cap screw (2) and belt tensioner (3).

7. Inspect and replace tensioner as needed.
8. Install belt tensioner (3). Install and tighten cap screw
(2) to specification.

TX1080391A —UN—30JUL10
Specification
Belt Tensioner Cap
Screw—Torque..............................................................................50 N∙m
37 lb­ft

9. Install serpentine belt, making sure that belt is correctly

seated in all pulley grooves. See Serpentine Belt
Remove and Install. (Group 0510.)
Serpentine Belt Tensioner
10. Install top right air baffle panel. See Air Baffle
Enclosure Remove and Install. (Group 0510.) 2— Cap Screw 3— Belt Tensioner
11. Install right side grille housing vent panel.
12. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.)
MH66088,0000D80 ­19­10SEP10­2/2

Aftercooler Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.

TX1080521A —UN—05AUG10
See Battery Disconnect. (Operator’s Manual.)
3. Open grille. See Opening the Grille. (Operator’s
Manual.)
NOTE: Air conditioner condenser is hinged on the
left side of the grill housing.

4. Remove cap screws (1) and swing air conditioner Air Conditioner Condenser
condenser (2) open.
1— Cap Screw (2 used) 2— Air Conditioner Condenser

Continued on next page MH66088,0000D9A ­19­23SEP10­1/6

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 Cooling System

5. Support air conditioner condenser. Remove cap

screws (3) and move assembly to the side.

3— Cap Screw (4 used)

TX1080526A —UN—05AUG10
Air Conditioner Condenser Hinge Mounting Cap Screws

MH66088,0000D9A ­19­23SEP10­2/6

6. Remove cap screws (4) and washers (5). Remove

lower air baffle insert (6).

4— Cap Screw (3 used) 6— Lower Air Baffle Insert

5— Washer (3 used)

TX1080537A —UN—05AUG10
Lower Air Baffle Insert

MH66088,0000D9A ­19­23SEP10­3/6

7. Remove cap screws (7), washers (8), and lower cooler

support (9).
8. Remove cap screws (10) and aftercooler­to­radiator
bracket (11).
TX1080539A —UN—05AUG10

7— Cap Screw (3 used) 10— Cap Screw (2 used)

8— Washer (3 used) 11— Aftercooler­to­Radiator
9— Lower Cooler Support Bracket

Lower Cooler Support

Continued on next page MH66088,0000D9A ­19­23SEP10­4/6

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 Cooling System

9. Remove grille housing access panels (12 and 13).

12
10. Disconnect upper and lower aftercooler air piping from
aftercooler. Close all openings using caps and plugs.

12— Top Panel (2 used) 13— Side Panel (2 used)

TX1080450 —UN—03AUG10
TX1080450 13

Grille Housing Access Panels

MH66088,0000D9A ­19­23SEP10­5/6

11. Remove cap screws (14) securing upper support (16)

to top of coolers. 17 16 14
12. Remove nuts (15) and remove upper support and
foam insert (17).

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

13. Remove aftercooler.

Specification
15
Aftercooler—Weight
(approximate).................................................................................. 29 kg
64 lb.

TX1080515 —UN—04AUG10
14. Inspect and replace as necessary.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

15. Install aftercooler. TX1080515

Upper Support
Specification
Aftercooler—Weight
(approximate).................................................................................. 29 kg 14— Cap Screw (8 used) 16— Upper Support
64 lb. 15— Nut (4 used) 17— Foam Insert

16. Install upper support.

17. Connect upper and lower aftercooler air piping to 21. Install lower air baffle insert.
aftercooler.
22. Install air conditioner condenser.
18. Install grille housing access panels
23. Close grille.
19. Install aftercooler­to­radiator bracket.
24. Turn battery disconnect switch to the ON position. See
20. Install lower support. Battery Disconnect. (Operator’s Manual.)
MH66088,0000D9A ­19­23SEP10­6/6

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 Cooling System

Radiator Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.

TX1080521A —UN—05AUG10
See Battery Disconnect. (Operator’s Manual.)
3. Open grille. See Opening the Grille. (Operator’s
Manual.)
NOTE: Air conditioner condenser is hinged on the
left side of the grill housing.

4. Remove cap screws (1) and swing air conditioner Air Conditioner Condenser
condenser (2) open.
1— Cap Screw (2 used) 2— Air Conditioner Condenser

MH66088,0000D9C ­19­15SEP10­1/6

5. Support air conditioner condenser. Remove cap

screws (3) and move assembly to the side.
6. Perform Draining the Cooling System. (Operator’s
Manual.)

3— Cap Screw (4 used)

TX1080526A —UN—05AUG10
Air Conditioner Condenser Hinge Mounting Cap Screws

MH66088,0000D9C ­19­15SEP10­2/6

7. Remove cap screws (4) and washers (5). Remove

lower air baffle insert (6).

4— Cap Screw (3 used) 6— Lower Air Baffle Insert

5— Washer (3 used)
TX1080537A —UN—05AUG10

Lower Air Baffle Insert

Continued on next page MH66088,0000D9C ­19­15SEP10­3/6

TM11813 (13OCT10) 05­0510­8 748H Repair (S.N. 630436— )

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 Cooling System

8. Remove cap screws (7), washers (8), and lower cooler

support (9).
9. Remove cap screws (10), aftercooler­to­radiator
bracket (11), and transmission­to­radiator bracket (12).

TX1080594A —UN—05AUG10
7— Cap Screw (3 used) 10— Cap Screw (2 used)
8— Washer (3 used) 11— Aftercooler­to­Radiator
9— Lower Cooler Support Bracket
12— Transmission­to­Radiator
Bracket

Lower Cooler Support

MH66088,0000D9C ­19­15SEP10­4/6

10. Remove grille housing access panels (13 and 14).

14
11. Disconnect upper radiator hose and deaeration hose
from radiator. Close all openings using caps and
plugs.

TX1080595 —UN—05AUG10
12. Disconnect lower radiator hose from radiator. Close
all openings using caps and plugs.

13— Grille Housing Side 14— Grille Housing Top Access

Access Panel (2 used) Panel (2 used)
TX1080595 13

Grille Housing Access Panels

Continued on next page MH66088,0000D9C ­19­15SEP10­5/6

TM11813 (13OCT10) 05­0510­9 748H Repair (S.N. 630436— )

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 Cooling System

13. Remove cap screws (14) securing upper cooler

support (16) to top of coolers. 17 16 14
14. Remove nuts (15) and remove upper support and
foam insert (17).

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

15. Remove radiator.

Specification
15
Radiator—Weight
(approximate).................................................................................. 50 kg
110 lb.

TX1080515 —UN—04AUG10
16. Inspect and replace as necessary.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

17. Install radiator. TX1080515

Upper Cooler Support
Specification
Radiator—Weight
(approximate).................................................................................. 50 kg 14— Cap Screw (8 used) 16— Upper Cooler Support
110 lb. 15— Nut (4 used) 17— Foam Insert

18. Install upper cooler support.

19. Install upper radiator hose and deaeration hose to 24. Install lower air baffle insert.
radiator.
25. Install air conditioner condenser assembly.
20. Install lower radiator hose to radiator.
26. Perform Filling the Cooling System. (Operator’s
21. Install top and side grille housing access panels. Manual.)
22. Install aftercooler­to­radiator bracket and 27. Close grille.
transmission­to­radiator bracket.
28. Turn battery disconnect switch to the ON position.
23. Install lower cooler support.
MH66088,0000D9C ­19­15SEP10­6/6

Transmission Oil Cooler Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
TX1080521A —UN—05AUG10

See Battery Disconnect. (Operator’s Manual.)

3. Open grille. See Opening the Grille. (Operator’s
Manual.)
NOTE: Air conditioner condenser is hinged on the
left side of the grille housing.

4. Remove cap screws (1) and swing air conditioner Air Conditioner Condenser
condenser (2) open.
1— Cap Screw (2 used) 2— Air Conditioner Condenser

Continued on next page MH66088,0000DA8 ­19­30AUG10­1/6

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 Cooling System

5. Support air conditioner condenser. Remove cap

screws (3) and move assembly to the side.

3— Cap Screw (4 used)

TX1080526A —UN—05AUG10
Air Conditioner Condenser Hinge Mounting Cap Screws

MH66088,0000DA8 ­19­30AUG10­2/6

6. Remove cap screws (4) and washers (5). Remove

lower air baffle insert (6).

4— Cap Screw (3 used) 6— Lower Air Baffle Insert

5— Washer (3 used)

TX1080537A —UN—05AUG10
Lower Air Baffle Insert

MH66088,0000DA8 ­19­30AUG10­3/6

7. Remove cap screws (7), washers (8), and lower cooler

support (9).
8. Remove cap screws (10) and hydraulic oil
cooler­to­transmission oil cooler bracket (11).
TX1080655A —UN—26AUG10

7— Cap Screw (3 used) 10— Cap Screw (2 used)

8— Washer (3 used) 11— Hydraulic Oil
9— Lower Cooler Support Cooler­to­Transmission
Oil Cooler Bracket

Lower Cooler Support

Continued on next page MH66088,0000DA8 ­19­30AUG10­4/6

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 Cooling System

9. Remove grille housing access panels (12 and 13).

12
NOTE: Some loss of transmission fluid will occur during
removal of transmission oil cooler lines from cooler.
Use an appropriate container to capture fluid.

TX1080450 —UN—03AUG10
10. Disconnect transmission oil cooler lines at cooler.
Close all openings using caps and plugs.

12— Grille Housing Upper 13— Grille Housing Side

Access Panel (2 used) Access Panel (2 used)
TX1080450 13

Grille Housing Access Panels

MH66088,0000DA8 ­19­30AUG10­5/6

11. Remove cap screws (14) securing upper cooler

support (16) to top of coolers. 17 16 14
12. Remove nuts (15) and remove upper cooler support
and foam insert (17).

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

13. Remove transmission oil cooler.

Specification
15
Transmission Oil
Cooler—Weight
(approximate).................................................................................. 28 kg

TX1080515 —UN—04AUG10
62 lb.

14. Inspect and replace as necessary.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.
TX1080515
15. Install transmission oil cooler. Upper Cooler Support
Specification
Transmission Oil 14— Cap Screw (8 used) 16— Upper Cooler Support
Cooler—Weight 15— Nut (4 used) 17— Foam Insert
(approximate).................................................................................. 28 kg
62 lb.

16. Install upper cooler support. 21. Install air conditioner condenser assembly.

17. Connect transmission oil cooler lines at cooler. 22. Close grille.

18. Install hydraulic oil cooler­to­transmission oil cooler 23. Turn battery disconnect switch to the ON position. See
bracket. Battery Disconnect. (Operator’s Manual.)

19. Install lower cooler support. 24. Check transmission oil level. See Check Transmission
Oil Level. (Operator’s Manual.)
20. Install lower air baffle insert.
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 Cooling System

Hydraulic Oil Cooler Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)

TX1080521A —UN—05AUG10
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate all hydraulic functions, including brake, to

release pressure in the hydraulic system. Depress
brake pedal at 1­second intervals 20 times to relieve Air Conditioner Condenser
pressure from service brake accumulator.
3. Turn battery disconnect switch to the OFF position. 1— Cap Screw (2 used) 2— Air Conditioner Condenser
See Battery Disconnect. (Operator’s Manual.)
4. Open grille. See Opening the Grille. (Operator’s
Manual.)
NOTE: Air conditioner condenser is hinged on the
left side of the grill housing.

5. Remove cap screws (1) and swing air conditioner

condenser (2) open.
MH66088,0000DA2 ­19­23SEP10­1/6

6. Support air conditioner condenser. Remove cap

screws (3) and move assembly to the side.

3— Cap Screw (3 used)

TX1080526A —UN—05AUG10

Air Conditioner Condenser Hinge Mounting Cap Screws

Continued on next page MH66088,0000DA2 ­19­23SEP10­2/6

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 Cooling System

7. Remove cap screws (4), washers (5), and lower air

baffle insert (6).

4— Cap Screw (3 used) 6— Lower Air Baffle Insert

5— Washer (3 used)

TX1080762A —UN—10AUG10
Lower Air Baffle Insert

MH66088,0000DA2 ­19­23SEP10­3/6

8. Remove cap screws (7), washers (8), and lower cooler

support (9).
9. Remove cap screws (10) and remove hydraulic oil
cooler­to­transmission oil cooler and hydraulic oil
cooler­to­radiator brackets (11 and 12).

TX1080763A —UN—10AUG10
7— Cap Screw (3 used) 11— Hydraulic Oil
8— Washer (3 used) Cooler­to­Transmission
9— Lower Cooler Support Oil Cooler Bracket
10— Cap Screw (4 used) 12— Hydraulic Oil
Cooler­to­Radiator
Bracket
13— Hydraulic Oil Cooler
Lower Cooler Support

MH66088,0000DA2 ­19­23SEP10­4/6

10. Remove upper and side grille housing access panels 14

(14 and 15).

14— Grille Housing Upper 15— Grille Housing Side

Access Panel (2 used) Access Panel (2 used)

TX1080766A —UN—10AUG10

15
Grille Housing Access Panels

Continued on next page MH66088,0000DA2 ­19­23SEP10­5/6

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 Cooling System

11. Remove cap screws (16) securing upper cooler

support (18) to top of coolers. 19 18 16
12. Remove nuts (17) and remove upper support and
foam insert (19).
13. Apply vacuum to hydraulic oil reservoir to minimize
oil loss.
14. Disconnect hydraulic oil hoses at hydraulic oil cooler.
Close all openings using caps and plugs.
15. Remove hydraulic oil cooler. 17
16. Inspect and replace as necessary.

TX1081462 —UN—30AUG10
17. Install hydraulic oil cooler.
18. Connect hoses to hydraulic oil cooler.
19. Remove vacuum from hydraulic oil reservoir.
20. Install hydraulic oil cooler­to­radiator bracket and
hydraulic oil cooler­to­transmission oil cooler bracket. TX1080836
21. Install lower cooler support. Upper Cooler Support

22. Install upper cooler support.

16— Cap Screw (8 used) 18— Upper Cooler Support
23. Install lower air baffle insert. 17— Nut (4 used) 19— Foam Insert

24. Install air conditioner condenser assembly.

25. Remove vacuum pump. 28. Check hydraulic oil level. See Check Hydraulic
System Oil Level. (Operator’s Manual.)
26. Close grille.
27. Turn battery disconnect switch to ON position.
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 Cooling System

Fan Blade Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
3. Remove engine side shields. See Opening Engine
Side Shields. (Operator’s Manual.)
4. Remove radiator. See Radiator Remove and Install.
(Group 0510.)
5. Remove fan blade retaining lock nut (1). Remove fan
1
blade.
6. Inspect and replace fan blade as necessary.
7. Install fan blade. Install fan blade retaining lock nut
and tighten to specification.
Specification
Fan Blade Retaining Lock

TX1080211 —UN—03AUG10
Nut—Torque..........................................................................81 ± 16 N∙m
60 ± 12 lb­ft

8. Install radiator. See Radiator Remove and Install.

(Group 0510.)
9. Install engine side shields. See Opening Engine Side
Shields. (Operator’s Manual.)
Fan Blade Retaining Lock Nut
10. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.)
1— Fan Blade Retaining Lock
Nut

SW03989,0000B3E ­19­27SEP10­1/1

Fan Shroud Remove and Install

CAUTION: Prevent possible crushing injury from
1. Remove grille housing. See Grille Housing Remove
heavy component. Use appropriate lifting device.
and Install. (Group 1910.)
4. Install fan shroud.
CAUTION: Prevent possible crushing injury from
Specification
heavy component. Use appropriate lifting device.
Fan Shroud—Weight
(approximate).................................................................................. 25 kg
2. Remove fan shroud.
55 lb.
Specification
Fan Shroud—Weight 5. Install grille housing. See Grille Housing Remove and
(approximate).................................................................................. 25 kg Install. (Group 1910.)
55 lb.

3. Inspect and replace as necessary.

MH66088,0000D84 ­19­30AUG10­1/1

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 Group 0520
Intake System

Air Cleaner Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Operator’s Manual.)
2. Turn battery disconnect switch to the OFF position.

TX1024247A —UN—29MAY07
See Battery disconnect. (Operator’s Manual.)
3. Remove air cleaner cap (1).
4. Remove left and right engine side shields. See
Opening Engine Side Shields. (Operator’s Manual.)

1— Air Cleaner Cap 2— Air Cleaner

Air Cleaner Cap

MH66088,0000DA5 ­19­30AUG10­1/3

5. Loosen clamp (4) and disconnect turbocharger inlet

pipe (5). Close all openings using caps and plugs.
6. Disconnect electrical connector.

2— Air Cleaner 5— Turbocharger Inlet Pipe

TX1024248A —UN—29MAY07
4— Clamp

Turbocharger Inlet Pipe

MH66088,0000DA5 ­19­30AUG10­2/3

7. Remove cap screws (3) and air cleaner (2).

8. Inspect and replace as necessary.
9. Install air cleaner.
10. Connect electrical connector.

TX1024246A —UN—29MAY07
11. Connect turbocharger inlet pipe.
12. Install left and right engine side shields.
13. Install air cleaner cap.
14. Turn battery disconnect switch to the ON position.
Air Cleaner
2— Air Cleaner 3— Cap Screw (4 used)

MH66088,0000DA5 ­19­30AUG10­3/3

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 Intake System

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 Group 0530
Exhaust System

Muffler Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.

TX1024238A —UN—29MAY07
See Battery Disconnect. (Operator’s Manual.)

CAUTION: Prevent possible burn injury. Hot

equipment can cause burns to unprotected
skin. Allow equipment to cool before servicing.
Wear gloves and protective clothing when
working with hot equipment.
Muffler
3. Loosen upper muffler clamp (3).
4. Remove cap screws (2) and muffler outlet tube (1). 1— Muffler Outlet Tube 4— Muffler
2— Cap Screw (2 used) 5— Lower Muffler Clamp
5. Loosen lower muffler clamp (5). 3— Upper Muffler Clamp 6— Muffler Inlet Tube

6. Remove upper muffler clamp and muffler (4).

Specification
9. Install muffler outlet tube. Tighten upper muffler clamp.
Muffler—Weight
(approximate).................................................................................... 7 kg 10. Turn battery disconnect switch to the ON position. See
17 lb. Battery Disconnect. (Operator’s Manual.)
7. Inspect and replace as necessary.
8. Install muffler and tighten lower muffler clamp. Leave
upper muffler clamp loose.
MH66088,0000DA6 ­19­30AUG10­1/1

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 Exhaust System

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 Group 0560
External Fuel Supply System

Fuel Tank Remove and Install

NOTE: Model 648H with 4000 Series winch is shown.
Other configurations are similar.

TX1081659 —UN—07SEP10

Standard Fuel Tank

1— Fuel Tank 4— Cap Screw (4 used) 7— Cap Screw (2 used) 10— Nut (2 used)
2— Lift Mounting Hole (2 used) 5— Washer (6 used) 8— Washer (2 used) 11— Fuel Level Sending Unit
3— Wire Guard 6— Drain Plug 9— Bushing (2 used)

1. Park and prepare machine for service. See Park and

CAUTION: Avoid possible injury from unexpected Prepare for Service Safely. (Group 0001.)
machine movement. Install articulation locking
bar before working in frame hinge area. 2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)

Continued on next page SW03989,0000AF1 ­19­04OCT10­1/6

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 External Fuel Supply System

3. Drain fuel tank (1). For fuel tank capacity, See Fuel 4. Remove arch. See Dual Function Grapple Arch
Tank. (Operator’s Manual.) Remove and Install. (Group 3740.)
SW03989,0000AF1 ­19­04OCT10­2/6

5. Remove two cap screws (13) and guard (12).

6. Remove winch, if equipped. See Winch 4000 Series
Remove and Install or see Winch 6000 Series Remove
and Install. (Group 3000.)

TX1081656A —UN—07SEP10
7. Remove reverse warning alarm. See Reverse
Warning Alarm Remove and Install. (Group 2004.)
8. Disconnect fuel suction hose (14) and fuel return hose
(15). Close all openings using caps and plugs.

12— Guard 14— Fuel Suction Hose

13— Cap Screw (2 used) 15— Fuel Return Hose
Fuel Hose Guard

TX1081655A —UN—07SEP10
Fuel Hose Connections

Continued on next page SW03989,0000AF1 ­19­04OCT10­3/6

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 External Fuel Supply System

9. Remove cover (17).

10. Disconnect wire leads from wire lead connections
(18). Pull wire leads free from wire guard (3).

1— Fuel Tank 17— Cover

TX1081653A —UN—07SEP10
3— Wire Guard 18— Wire Lead Connection (2
16— Cap Screw (2 used) used)

Fuel Level Sending Unit—Cover

TX1081654A —UN—07SEP10
Fuel Level Sending Unit

Continued on next page SW03989,0000AF1 ­19­04OCT10­4/6

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 External Fuel Supply System

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

11. Attach JT01748 Lifting Brackets (19) to fuel tank.

Specification
Fuel Tank—Stan­
dard—Weight (approxi­
mate)............................................................................................. 165 kg
364 lb.
Fuel Tank—Dual
Function—Weight
(approximate)................................................................................ 205 kg
452 lb.
Fuel Tank—Dual
Function Without
Winch—Weight.............................................................................. 325 kg
718 lb.

12. Remove cap screws (4 and 7), washers (5 and 8),

TX1081375A —UN—07SEP10
bushings (9), and nuts (10).

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

13. Remove fuel tank.

Specification
Fuel Tank—Stan­ JT01748 Lifting Brackets (shown on grapple machine)
dard—Weight (approxi­
mate)............................................................................................. 165 kg 19— JT01748 Lifting Bracket (2
364 lb. used)
Fuel Tank—Dual
Function—Weight
(approximate)................................................................................ 205 kg Fuel Tank—Dual
452 lb. Function Without
Fuel Tank—Dual Winch—Weight.............................................................................. 325 kg
Function Without 718 lb.
Winch—Weight.............................................................................. 325 kg
718 lb.
16. Install cap screws, washers, bushings, and nuts.

14. Inspect fuel tank and components. Repair or replace 17. Pull unit wire leads through wire guard.
parts as necessary. 18. Connect wire leads to wire lead connections. Install
cover.
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device. 19. Connect fuel tank return line and fuel tank suction line.
20. Install guard.
15. Install fuel tank.
21. Install reverse warning alarm. See Reverse Warning
Specification
Alarm Remove and Install. (Group 2004.)
Fuel Tank—Stan­
dard—Weight (approxi­ 22. Install winch, if equipped. See Winch 4000 Series
mate)............................................................................................. 165 kg Remove and Install or see Winch 6000 Series Remove
364 lb. and Install. (Group 3000.)
Fuel Tank—Dual
Function—Weight 23. Install arch. See Dual Function Grapple Arch Remove
(approximate)................................................................................ 205 kg and Install. (Group 3740.)
452 lb. 24. Fill tank with fuel. See Diesel Fuel. (Operator’s
Manual.)

Continued on next page SW03989,0000AF1 ­19­04OCT10­5/6

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 External Fuel Supply System

25. Turn battery disconnect switch to the ON position. See 26. Remove articulation locking bar.
Battery Disconnect. (Operator’s Manual.)
SW03989,0000AF1 ­19­04OCT10­6/6

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 External Fuel Supply System

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 Section 07
Dampener Drive
Contents

Page

Group 0752—Elements
Dampener Remove and Install .................. 07­0752­1
Transmission Cold Weather
Disconnect Linkage Remove
and Install—If Equipped ........................ 07­0752­2
Transmission Cold Weather
Disconnect Repair—If
Equipped ............................................... 07­0752­4

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 Contents

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 Group 0752
Elements

Dampener Remove and Install

1. Set battery disconnect switch to OFF position.
2. Remove engine side shields.
3. Remove drive shaft. See Engine­to­Transmission
Drive Shaft Remove and Install. (Group 0325.)
4. Remove cap screws (A) to remove cover (B).
For machines equipped with transmission disconnect,
see Transmission Cold Weather Disconnect Linkage
Remove and Install—If Equipped. (Group 0752.)
5. Remove cap screws (C) and remove damper (D).

T114951B —UN—23APR98
A—Cap Screw (6 used) D—Torsional Damper
B—Cover E—Dowel Pin (2 used)
C—Cap Screw (6 used)

PM10405,0000572 ­19­07OCT10­1/2

6. Position damper (D) on dowel pins (E).

7. Install and tighten cap screws (C) to specification.
Specification
Flywheel­to­Flywheel
Housing Cap
Screw—Torque..............................................................................68 N∙m
50 lb­ft

8. Install cover (B). Tighten cap screws (A).

On machines equipped with transmission disconnect,
see Transmission Cold Weather Disconnect Linkage
Remove and Install—If Equipped. (Group 0752.)
9. Install drive shaft. See Engine­to­Transmission Drive

T114951B —UN—23APR98
Shaft Remove and Install. (Group 0325.)
10. Turn battery disconnect switch to ON.
11. Install engine side shields.

A—Cap Screw (6 used) D—Torsional Damper

B—Cover E—Dowel Pin (2 used)
C—Cap Screw (6 used)

PM10405,0000572 ­19­07OCT10­2/2

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 Elements

Transmission Cold Weather Disconnect Linkage Remove and Install—If Equipped

NOTE: Before repairing cold weather disconnect, ensure it 3. Turn battery disconnect switch to the OFF position.
is properly adjusted. See Cold Weather Disconnect See Battery Disconnect. (Operator’s Manual.)
Linkage Adjustment—If Equipped. (Group 9020­20.)
4. Remove transmission drive shaft. See
1. Prepare machine for service. See Park and Prepare Engine­to­Transmission Drive Shaft Remove
For Service Safely. (Group 0001.) and Install. (Group 0325.)
2. Remove engine side shields. See Opening Engine
Side Shields. (Operator’s Manual.)
4
6
3 7
8

5 9
11
1
2 10

14

12 13
15

TX1081470 —UN—30AUG10
15

15
16
TX1081470
Transmission Cold Weather Disconnect
1— Cap Screw (6 used) 5— Pin 9— Cap Screw (2 used) 13— Cap Screw (2 used)
2— Washer (6 used) 6— Yoke 10— Flange Nut (2 used) 14— Cover
3— Lever 7— Nut 11— Actuator Rod 15— Cap Screw (9 used)
4— Cotter Pin 8— Bracket 12— Housing 16— Cover

5. Remove cap screws (15) securing cover (16). Weather Disconnect Repair—If Equipped. (Group
0752.)
6. Remove cotter pin (4) and pin (5).
7. Remove cap screws (9) and flange nuts (10). CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.
8. Remove actuator rod and bracket.
9. Remove cap screws (13) and cover (14). 12. Install housing. Tighten cap screws to specification.
Specification
CAUTION: Prevent possible crushing injury from Transmission Disconnect
heavy component. Use appropriate lifting device. Housing­to­Flywheel
Housing Cap
10. Remove cap screws (1) and washers (2) and remove Screw—Torque............................................................................217 N∙m
housing (12). 160 lb­ft

11. Inspect housing for cracks or damage. Inspect linkage 13. Install cover (14).
for damage or excessive wear. See Transmission Cold
Continued on next page NM00125,0000581 ­19­29SEP10­1/2

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 Elements

14. Install actuator rod and bracket. 18. Install engine side shields. See Opening Engine Side
Shields. (Operator’s Manual.)
15. Install cover (16).
19. Turn battery disconnect switch ON position. See
16. Install transmission drive shaft. See Battery Disconnect. (Operator’s Manual.)
Engine­to­Transmission Drive Shaft Remove
and Install. (Group 0325.)
17. Adjust cold weather disconnect. See Cold Weather
Disconnect Linkage Adjustment—If Equipped. (Group
9020­20.)
NM00125,0000581 ­19­29SEP10­2/2

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 Elements

Transmission Cold Weather Disconnect

Repair—If Equipped

T8483AD —UN—15MAY95

Continued on next page NM00125,0000582 ­19­27SEP10­1/5

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 Elements

1— Cap Screw (4 used) 9— Inner Collar 17— Thrust Bearing Race (2 25— Snap Ring
2— Universal Joint Cross 10— Bushing used) 26— Cap
3— Stub Shaft 11— Oil Seal 18— Needle Thrust Bearing 27— Bearing Kit
4— Seal 12— Needle Bearing 19— Compression Spring 28— Disconnect Spline Kit
5— Cap Screw (6 used) 13— Cap Screw (12 used) 20— Sliding Shaft 29— Washer (6 used)
6— Collar 14— Washer (12 used) 21— Bearing 30— Transmission Disconnect
7— O­Ring 15— Cover 22— O­Ring 31— Transmission Disconnect
8— Snap Ring 16— Pipe Plug (2 used) 23— Splined Hub Kit
24— Cap Screw (2 used)

1. Remove cap screws (1) from stub shaft (3). 4. Remove cap (26).
2. Remove cap screws (13) and washers (14) to remove 5. Remove snap ring (25) to pull out stub shaft.
disconnect cover (15) from damper.
6. Remove seal (4) and collar from stub shaft.
3. Remove cap screws (5) and washers (29) to remove
collar (6).
NM00125,0000582 ­19­27SEP10­2/5

CAUTION: Splined hub is spring loaded. Follow

proper procedure to remove splined hub and
collar to prevent personal injury. If splined
hub is removed improperly the spring will
pull hub up against collar.

TX1081486A —UN—01SEP10
7. Press inner collar (9) down to release pressure on
snap ring (8).
8. Remove snap ring.

8— Snap Ring 23— Splined Hub

9— Inner Collar
Splined Hub With Collar

TX1081485A —UN—01SEP10
Snap Ring Removal
Continued on next page NM00125,0000582 ­19­27SEP10­3/5

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 Elements

NOTE: Hydraulic press is shown for removal. If

press is not available, a lead hammer and
appropriate drivers can be used.

9. Remove collar from sliding shaft using a 35­mm disk.

Collar is a light press fit.

T7502HP —UN—11JUL91
10. Remove sliding shaft from splined hub.

Continued on next page NM00125,0000582 ­19­27SEP10­4/5

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 Elements

CAUTION: Splined hub is spring loaded.

Follow proper removal procedure to
avoid personal injury.

11. Loosen cap screws (24) until heads are exposed.

TX1081487A —UN—01SEP10
12. Install cap screws (32) in lifting holes of splined hub.
Tighten puller cap screws until hub releases.
13. Disassemble parts from cover.
14. Press seal into collar counterbore. Install on stub shaft
with lip on ground diameter of shaft.
15. Install O­ring (7) on stub shaft. Cap Screws

16. Install all bushings and bearings that were removed.

24— Cap Screw (2 used) 32— Cap Screw (2 used)
17. Install sliding shaft bushing (10) to specified depth in
sliding shaft (20).
Specification Specification
Sliding Shaft Collar­to­Collar Cap
Bushing—Depth...............................................................1.97—2.23 mm Screw—Torque..............................................................................14 N∙m
0.075—0.085 in. 124 lb­in.

18. Install needle bearing (12) flush with bottom of 81­mm 28. Apply plastic gasket into bore of cap and drive into
(3.2­in.) diameter cavity in cover. splined hub.
19. Install cover bearing to specified depth below end 29. Install and tighten cap screws (13) to specification.
surface of cover. Specification
Specification Cap Screw—Torque.................................................................... 113 N∙m
Cover Bearing—Depth........................................................17—17.5 mm 83 lb­ft
0.67—0.69 in.
30. Remove pipe plug (16) and add specified amount of
20. Install parts (17—21) in cover as shown. hydraulic fluid.
21. Apply grease between lips of seal. Install oil seal (11) Specification
into cover after installing sliding shaft. Cold Weather
Disconnect—Capacity.................................................................. 118 mL
22. Install O­ring (22) into groove of splined hub (23). 4 oz

23. Press collar onto sliding shaft past snap ring groove. 31. Install universal joint cross and tighten cap screws to
Install snap ring (8). Pull collar back against snap ring. specification.
24. Install splined hub on cover. Tighten cap screws (24) Specification
to specification. Cap Screw—Torque......................................................................60 N∙m
45 lb­ft
Specification
Cap Screw—Torque......................................................................14 N∙m 32. Install transmission cold weather disconnect. See
124 lb­in. Transmission Cold Weather Disconnect Linkage
Remove and Install—If Equipped. (Group 0752.)
25. Apply grease to splines of stub shaft. Install cover with
splined hub assembly onto stub shaft. 33. Turn battery disconnect switch to the ON position.
26. Install snap ring (25) in stub shaft groove. 34. Before returning machine to service, check operation
of transmission cold weather disconnect. See
27. Install washers (29) into collar counterbores. Apply
Transmission Cold Weather Disconnect Clutch Check.
Thread Lock and Sealer (medium strength) on cap
(Group 9005­10.)
screws. Install and tighten to specification. Recheck
torque after all cap screws are tightened.
NM00125,0000582 ­19­27SEP10­5/5

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 Elements

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 Section 09
Steering System
Contents

Page

Group 0930—Secondary Steering

Secondary Steering Pump Remove
and Install .............................................. 09­0930­1

Group 0960—Hydraulic System

Steering Valve Remove and
Install ..................................................... 09­0960­1
Steering Valve Disassemble and
Assemble............................................... 09­0960­5
Steering Cylinder Remove and
Install ..................................................... 09­0960­9

Group 0962—Dual Mode Steering

Dual Mode Steering Solenoid Valve
Remove and Install................................ 09­0962­1

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 Contents

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 Group 0930
Secondary Steering

Secondary Steering Pump Remove and

Install

TX1080206 —UN—18AUG10
TX1080206
Secondary Steering Pump Location

CAUTION: To avoid injury from escaping fluid 4. Turn battery disconnect to the OFF position.
under pressure, stop engine and relieve the
NOTE: Secondary steering pump is located inside right
pressure in the system before disconnecting or
engine frame, forward of front axle.
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
5. Disconnect all electrical connections at secondary
steering pump and pump relay. See Secondary
1. Park and prepare machine for service. See Park and
Steering Harness (W19) Wiring Diagram—If Equipped.
Prepare for Service Safely. (Group 0001.)
(Group 9015­10.)
2. Operate all hydraulic controls to release pressure in
the hydraulic system.
3. Remove right side engine shields. See Opening
Engine Side Shields. (Operator’s Manual.)
Continued on next page NM00125,0000598 ­19­07OCT10­1/2

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 Secondary Steering

2
1

TX1080205 —UN—27JUL10
8
7
6
TX1080205
Secondary Steering Pump Exploded View
1— Secondary Steering Pump 3— Supply Hose­to­Secondary 5— Secondary Steering Relay 7— Washer (3 used)
2— Bracket Steering Valve 6— Cap Screw (3 used) 8— Rubber Bushing (3 used)
4— Pressure Hose­to­Secondary
Steering Valve

6. Disconnect supply hose­to­secondary steering valve 12. Connect all electrical connections at secondary
(3) and pressure hose­to­secondary steering valve (4) steering pump and pump relay. See Secondary
at secondary steering pump. Close all openings using Steering Harness (W19) Wiring Diagram—If Equipped.
caps and plugs. (Group 9015­10.)
7. Support pump (1). Remove cap screws (6) and 13. Install right side engine shields.
washers (7) securing bracket (2) to frame.
14. Turn battery disconnect switch to the ON position.
8. Remove secondary steering pump and bracket from
frame. 15. Check hydraulic oil level in the hydraulic reservoir
before starting engine. See Check Hydraulic System
9. Repair or replace components as required. Oil Level. (Operator’s Manual.)
10. Install secondary steering pump and bracket assembly 16. Before returning machine to service, check operation
to frame using washers and cap screws. of secondary steering system. See Secondary
11. Connect pressure hose and supply hose to secondary Steering System Check. (Group 9005­10.)
steering valve.
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 Group 0960
Hydraulic System

Steering Valve Remove and Install

CAUTION: Avoid possible injury from unexpected

machine movement. Install articulation locking
bar before working in frame hinge area.

T131633B —UN—15JUN00
1. Install articulation locking bar.
2. Operate hydraulic control valves to relive pressure in
the hydraulic system.
3. Remove cap screws (1) to remove lower console
(2). As necessary, remove the fire extinguisher and
windshield washer tank.
4. Remove the cap screw from lower end of universal
joint (4).
5. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)

T131635B —UN—15JUN00
1— Cap Screw (4 used) 3— Lower Steering Column
2— Lower Console 4— Universal Joint

Continued on next page AC12469,0000396 ­19­23JUL07­1/4

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 Hydraulic System

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.

X9811 —UN—23AUG88
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.

NOTE: Attach labels to all lines before disconnection.

6. Disconnect lines 8—14. Close all openings using

caps and plugs.

5— Cap Screw (4 used) 11— Port R­to­Steering

6— Nut and Washer (3 used) Cylinders Line
7— Cap Screw (3 used) 12— Priority Valve Port
8— Dual Mode Steering CF­to­Port P Line
Solenoid Valve­to­Steering 13— Port L­to­Steering

TX1024858A —UN—15JUN07
Valve Pressure Hose Cylinders Line
10— Dual Mode Steering 14— Port T­to­Return Oil Filter
Solenoid Valve­to­ Line
Steering Valve Return
Hose

Steering Valve—Dual Mode Steering

Continued on next page AC12469,0000396 ­19­23JUL07­2/4

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 Hydraulic System

NOTE: Make note of rubber isolator position between

mounting support and cab for installation.

7. Remove nuts and washers (6) and remove steering

valve (17) lower steering column, mounting plate (15),

TX1024871A —UN—13JUN07
and adapter plate (16) (Dual Mode Steering machines
only). Seal may come with the valve or remain stuck
to the platform.
8. For machines equipped with standard steering,
remove cap screws (5) and separate steering valve
from mounting plate (18) and lower steering column.
For machine equipped with dual mode steering,
Steering Valve Mounting—Standard Steering
remove cap screws (7) and separate adapter plate
(16) from mounting plate (15). Remove cap screws (5)
and separate adapter plate (16) and lower steering
column from steering valve.
9. For machines equipped with standard steering, inspect
and repair parts as necessary. See Steering Valve
Disassemble and Assemble. (Group 0960.)
For machines equipped with dual mode steering,
inspect and replace parts as necessary.

6— Nut and Washer (3 used) 16— Adapter Plate

7— Cap Screw (3 used) 17— Steering Valve
8— Dual Mode Steering 18— Mounting Plate (Standard
Solenoid Valve­to­Steering Steering)

TX1024860A —UN—13JUN07
Valve Pressure Hose 19— Lower Steering Column
9— Port LS­to­Priority Valve 20— Rubber Isolators (3 Used)
Port LS Line
15— Mounting Plate (Dual
Mode Steering)

Steering Valve Mounting—Dual Mode Steering

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 Hydraulic System

10. Install lower steering column (19).

11. For machines with standard steering, install mounting
plate (18) so the side with the single rubber isolator is
toward the Port T and Port P corner of the steering
valve.

TX1024871A —UN—13JUN07
For machines with dual mode steering, install the
adapter plate so the side with two holes faces the inlet
and outlet ports.
12. Install cap screws (5) and tighten to specification.
Specification
Mounting Plate and
Lower Steering Column Installation (standard steering shown)
Lower Steering
Column­to­Steering Valve
Cap Screw—Torque......................................................................26 N∙m 5— Cap Screw (4 used) 19— Lower Steering Column
234 lb­in. 17— Steering Valve 20— Rubber Isolators (3 Used)
18— Mounting Plate (Standard
13. For dual mode steering machines, attach adapter Steering)
plate to mounting plate.
14. Install seal between mounting plate and cab.
19. Connect hydraulic lines.
15. Install one washer on each stud.
IMPORTANT: Check for pinched lines when cab is
lowered. Adjust line position if necessary.
CAUTION: Cab door is heavy. Use caution when
opening cab door while cab is tilted. 20. Lower the cab. See Hydraulic Cab Tilt Procedure.
(Operator’s Manual.)
16. With the help of an assistant working through the right
cab door, install steering valve (17) so the splines of 21. Install lower console cover.
the lower steering column engage splines in the lower
universal joint. 22. Turn battery disconnect to ON position.

17. Install nuts and washers. 23. Check hydraulic oil level in the hydraulic reservoir
before starting engine. See Check Hydraulic System
18. Install cap screw in lower universal joint. Check that Oil Level. (Operator’s Manual.)
splines are engaged to specification.
24. Remove articulation lock bar.
Specification
Lower Steering
Column­to­Lower
Universal Joint Spline
Engagement—Distance................................................................ 19 mm
0.75 in.
AC12469,0000396 ­19­23JUL07­4/4

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 Hydraulic System

Steering Valve Disassemble and Assemble

T162227B —UN—04DEC02
Steering Valve Components

IMPORTANT: Perform all service on steering valve in

a clean isolated work area. Use proper tools,
cleaning material, and lubricants.
Use wooden blocks or similar material to protect
steering valve. Tighten vise just enough to hold

T162221 —UN—12DEC02
valve. Overtightening can damage the valve.

1. Put steering valve in a vise with the gerotor end up.

Tighten just enough to hold valve.
2. Remove the two cap screws (1) to remove pins (2)
and anti­cavitation steel balls (3). 1 1
3. Remove the remaining cap screws to remove end Cap Screws
cap (4), gerotor star (8), gerotor housing (9) and plate
spacer (10). 1— Cap Screw (7 used) 9— Gerotor Housing
2— Pins (2 used) 10— Plate Spacer
4. Hold spool (7) and reposition valve with lower steering 3— Anti­Cavitation Steel Balls 11— Lower Steering Column
column (11) end up. (2 used) 12— Mounting Plate
4— End Cap 13— Housing
5. Remove mounting plate (12) and lower steering 7— Spool
column. 8— Gerotor Star

Continued on next page AC12469,000039A ­19­13JUN07­1/5

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 Hydraulic System

6. Assemble tool using a M10 x 120 mm cap screw (22)

and two nuts (28).
7. Install cap screw into housing so head engages into
input spline.
8. Hold drive spline head (20) with 20 mm socket (21).
IMPORTANT: Spring tension must be compressed
before spool is removed.

9. Rotate cap screw using a wrench to compress spring

T162215B —UN—04DEC02
tension.
10. Push spool (7) down out of housing (13) while spring
tension is compressed.
Be careful not to remove pin (14) from spool (7) and
drive spline (19).
11. Inspect all parts for contamination, nicks and burrs. Spring Compression Tools
Spool is not serviceable. Do not disassemble spool.
12. Replace O­rings (18), dust seal (24), backup washer
(25) and seals (26, 27).

7— Spool 21— 20 mm Socket

T162222B —UN—04DEC02
13— Housing 22— M10 x 120 mm Cap Screw
20— Spline Head 28— Nuts

Spool Removed From Housing

Continued on next page AC12469,000039A ­19­13JUN07­2/5

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 Hydraulic System

18

27
26
25

T162216 —UN—20DEC02
24

T162216
Seal Placement
18— O­Ring (3 used) 25— Backup Washer 27— O­Ring
24— Dust Seal 26— Seal

13. Lubricate O­rings (18 and 27) and seals (24 and 26)
15. Install spool (7) by compressing spring tension.
with TY24416 Multi­Purpose HD Lithium Complex
Grease. If petroleum jelly is used for O­ring lubrication, 16. Hold drive spline head (20) with 20 mm socket (21).
use small enough amount to avoid spreading on
surfaces of other parts. 17. Rotate cap screw (22) using wrench on nuts (28) to
compress spring tension.
14. Lubricate spool with clean hydraulic oil to ease
assembly.
IMPORTANT: Make sure drive pin does not slip
out of spool and drive spline.
Continued on next page AC12469,000039A ­19­13JUN07­3/5

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 Hydraulic System

IMPORTANT: Timing of drive with respect to

gerotor star is critical. 8

18. Drive pin (14) must be aligned with valley (minor

diameter) of gerotor star. 9
19. Align pin (14), drive spline (19) and gerotor star (8) 17
as shown. 18
20. Install plate spacer (10).
21. Install gerotor star (8) and gerotor housing (9). 10
22. Install end cap (4).
18
23. Apply pipe sealant to bottom side of cap screw (1)
heads.
19
24. Install the cap screws except in the holes (1) for
anti­cavitation steel balls (3) and pins (2).
25. Install anti­cavitation steel balls and pins.
26. Install remainder cap screws. 16

T160389 —UN—02DEC02
8— Gerotor Star 16— Alignment Line 14
9— Gerotor Housing 17— Alignment Line
10— Plate Spacer 18— O­Ring (3 used)
14— Drive Pin 19— Drive Spline
15— Alignment Line
15
Component Alignment

AC12469,000039A ­19­13JUN07­4/5

IMPORTANT: Any cap screw can be tightened first,

but the sequence shown must be followed.
7
27. Tighten cap screws to the initial specification in the
tightening sequence (1—7). Then tighten in sequence 2 5
to final specification.

T160436 —UN—17OCT02
Specification
End Cap­To­Housing Cap 4 3
Screw—Torque (Initial)..................................................................17 N∙m
150 lb­in.
End Cap­To­Housing Cap
Screw—Torque (Final)...................................................................34 N∙m 6 1
300 lb­in. Tightening Sequence

1—7— Tightening Sequence

AC12469,000039A ­19­13JUN07­5/5

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 Hydraulic System

Steering Cylinder Remove and Install

1. Engage park brake.

CAUTION: Avoid possible injury from unexpected

machine movement. Install articulation locking

X9811 —UN—23AUG88
bar before working in frame hinge area.

2. Install articulation locking bar.

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 of injury should reference a knowledgeable
all connections before applying pressure. medical source. Such information is available
Search for leaks with a piece of cardboard. from Deere & Company Medical Department
Protect hands and body from high pressure fluids. in Moline, Illinois, U.S.A.

If an accident occurs, see a doctor immediately. 3. Operate all controls to release hydraulic pressure.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene 4. Remove engine frame shields.
may result. Doctors unfamiliar with this type
AC12469,0000397 ­19­25JUL07­1/2

5. Disconnect lines (6 and 7) at rod and head end of 1

steering cylinder (5). Close openings with caps and 3
plugs. 5
3
6. Remove lock nuts (2) and cap screws (1) to remove
pins (3) and thrust washer (4).

T162743 —UN—18DEC02
2 7
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device. 4

7. Remove the cylinder. 4

6
Specification
T162743 1
Steering Cylin­
der—Weight (approxi­
mate)............................................................................................... 45 kg 1— Cap Screw (2 used) 5— Steering Cylinder
100 lb 2— Lock Nut (2 used) 6— Rod End­to­Steering Valve
3— Pin (2 used) Line
8. Repair or replace cylinder. 4— Thrust Washer (as required) 7— Head End­to­Steering Valve
Line
9. Install cylinder so work ports are on the bottom, and
cap screw hole in rod end clevis is on top.
10. Install thrust washers (4) to center cylinder clevises on Specification
the mounting plates. Cylinder­to­Pin Cap
Screw and Lock
11. Install the pins (3). Nut—Torque..................................................................................27 N∙m
12. Install cap screws and lock nuts. Tighten to 20 lb­ft
specifications. 13. Connect hydraulic lines and check for leaks.
14. Remove articulation locking bar.
AC12469,0000397 ­19­25JUL07­2/2

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 Hydraulic System

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 Group 0962
Dual Mode Steering

Dual Mode Steering Solenoid Valve Remove

and Install
1. Turn battery disconnect switch to OFF.

CAUTION: Avoid possible injury from unexpected

X9811 —UN—23AUG88
machine movement. Install articulation locking
bar before working in frame hinge area.

2. Install articulation locking bar.

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before of injury should reference a knowledgeable
disconnecting hydraulic or other lines. Tighten medical source. Such information is available
all connections before applying pressure. from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure fluids.
3. Operate hydraulic control valves to relive pressure in
If an accident occurs, see a doctor immediately. the hydraulic system.
Any fluid injected into the skin must be surgically
4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
removed within a few hours or gangrene
Manual.)
may result. Doctors unfamiliar with this type
AC12469,0000398 ­19­10MAR09­1/2

NOTE: Attach labels to hoses before disconnection.

If hoses are reversed, dual mode steering
switch operation will be reversed.

5. Disconnect wire connectors from solenoid (6).

6. Disconnect all hydraulic lines. Close all openings
using caps and plugs.
7. Remove cap screws (2) and remove valve.
8. Inspect valve and repair or replace parts as necessary.
9. Install valve on underside of cab.
10. Connect hydraulic hoses.

TX1024857A —UN—13JUN07
11. Connect wiring to solenoid.
12. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
13. Check hydraulic oil level in the hydraulic reservoir
before starting engine. See Check Hydraulic System
Oil Level. (Operator’s Manual.)
Dual Mode Steering Solenoid Valve
14. Remove articulation locking bar.
15. Turn battery disconnect switch to ON. 1— Return Hose 4— Steering Valve­to­Solenoid
2— Cap Screw (2 used) Valve Return Hose
3— System Pressure Hose 5— Solenoid Valve­to­Steering
Valve Pressure Hose
6— Solenoid

AC12469,0000398 ­19­10MAR09­2/2

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 Dual Mode Steering

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 Section 10
Service Brakes
Contents

Page

Group 1015—Controls Linkage

Service Brake Pedal Remove and
Install ..................................................... 10­1015­1

Group 1060—Hydraulic System

Service Brake Valve Remove and
Install ..................................................... 10­1060­1
Service Brake Valve Disassemble
and Assemble........................................ 10­1060­3
Service Brake Accumulator
Remove and Install................................ 10­1060­4

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 Contents

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 Group 1015
Controls Linkage

Service Brake Pedal Remove and Install

TX1056808 —UN—06MAR09
TX1056808
Service Brake Pedal
1— Pedal 4— Bushing (2 used) 7— Flange Nut
2— Shaft 5— Bracket 8— Cap Screw
3— Spring 6— Spring Pin 9— Cap Screw (3 used)

1. Remove spring pin (6). 4. Assemble parts as shown. Adjust brake pedal to
2. Slide out shaft (2). specifications. See Service Brake Pedal Adjustment.
(Group 9025­20.)
3. Inspect parts for wear or damage. Replace parts as
necessary.
AC12469,000039C ­19­06MAR09­1/1

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 Controls Linkage

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 Group 1060
Hydraulic System

Service Brake Valve Remove and Install

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

X9811 —UN—23AUG88
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 Actuate the brake pedal 20 times at one­second
of injury should reference a knowledgeable intervals to relieve oil pressure from brake accumulator.
medical source. Such information is available
from Deere & Company Medical Department 2. Tilt cab for access to service brake valve. See
in Moline, Illinois, U.S.A. Hydraulic Cab Tilt Procedure. (Operator’s Manual.)

1. Operate all hydraulic functions, including service

brakes, to relieve pressure in the hydraulic system.
AC12469,000039D ­19­13JUN07­1/3

NOTE: Observe position of lines before disconnection

to aid in assembly.

3. Disconnect hoses (2—5). Close openings using caps

and plugs.
4. Disconnect wiring connectors for the service brake
pressure switch (7).

1— Service Brake Valve 4— Brake Accumulator­to­Port

2— Port BS­to­Front Axle P Hose
Service Brake Pistons Hose 5— Port T­to­Hydraulic
3— Port BR­to­Rear Axle Reservoir Hose
Service Brake Pistons Hose 7— Service Brake Pressure
Switch

TX1024889A —UN—20JUN07

Continued on next page AC12469,000039D ­19­13JUN07­2/3

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 Hydraulic System

CAUTION: Cab door is heavy. Use caution when

opening cab door while cab is tilted.

5. While holding valve in place, have an assistant,

working through right cab door, remove cap screws
(F) to remove valve.
6. Repair or replace service brake valve as necessary.
See Service Brake Valve Disassemble and Assemble.
(Group 1060.)
7. Install fittings and pressure switch.
Specification
Fitting to

T114341B —UN—10APR98
Housing—Torque................................................................... 27—39 N∙m
20—29 lb­ft
Service Brake
Pressure Switch to
Housing—Torque...........................................................................12 N∙m
106 lb­in.

8. Install valve. Install and tighten cap screws.

Specification
Cab Platform­to­Valve F— Cap Screw (2 used)
Cap Screw—Torque........................................................... 23—32.5 N∙m
17—24 lb­ft

9. Connect hoses and wiring connectors. CAUTION: Before operating machine, the brake
10. Lower the cab. Check that hoses do not become bleed procedure must be done to remove air
pinched as cab is lowered. Adjust angle of elbows from service brake hydraulic system.
and hoses as necessary.
12. Bleed service brakes. See Service Brake Bleeding
11. To adjust clearance between pedal and brake valve Procedure. (Group 9025­20.)
plunger, see Service Brake Pedal Adjustment. (Group
9025­20.)
AC12469,000039D ­19­13JUN07­3/3

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 Hydraulic System

Service Brake Valve Disassemble and

Assemble
IMPORTANT: Perform all service on brake valve in
a clean isolated work area. Use proper tools,
cleaning material and lubricants.

T7516AO —UN—23APR91
Disassemble valve for cleaning and inspection only. Only
a seal repair kit is available for service.
If any parts, except seals, are damaged, replace the valve
as a complete assembly.

A—Boot I— Spring
B—Plug J— Spring Retainer
C—O­Ring K—Spring
D—Spring L— Plunger
E—Spool M—O­Ring
F— Valve Housing N—Plug
G—Seal O—Plug
H—Spring Retainer P—O­Ring

T7516AP —UN—23APR91
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 Hydraulic System

Service Brake Accumulator Remove and

Install
IMPORTANT: Clean all dirt and debris from service
brake accumulator before disconnecting hoses.
Contamination introduced into the hydraulic
system can lead to premature equipment failure.

X9811 —UN—23AUG88
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
1. Operate all hydraulic functions including brakes to
Search for leaks with a piece of cardboard. relieve pressure in the hydraulic system. Depress
Protect hands and body from high pressure fluids. brake pedal at one­second intervals approximately 20
If an accident occurs, see a doctor immediately. times to relieve pressure from brake accumulator.
Any fluid injected into the skin must be surgically 2. Remove right rear engine side shield for access to
removed within a few hours or gangrene brake accumulator.
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable 3. Tag and disconnect hoses at accumulator. Close all
medical source. Such information is available openings using caps and plugs.
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
AC12469,000039E ­19­23JUL07­1/3

4. Remove two cap screws, spacers, bands and nuts

securing service brake accumulator to reservoir leg.
5. Remove fittings from accumulator. Save fittings for
use on new accumulator.
NOTE: The inlet check valve fitting is serviced
with the brake accumulator.

6. Install accumulator so the inlet check valve fitting is

towards the center of machine.
7. Install two cap screws, spacers, bands and nuts
securing service brake accumulator to reservoir leg.
Note that upper cap screw and spacer are shorter
than lower cap screw and spacer.

A—Service Brake Accumulator D—Band (2 used)

B—Cap Screw (2 used) E—Spacer (2 used)
C—Nut (2 used)
WC1005587 —UN—12APR06

Service Brake Accumulator Mounting

Continued on next page AC12469,000039E ­19­23JUL07­2/3

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 Hydraulic System

IMPORTANT: Always use new O­rings and seals.

Damaged or used O­rings and seals will leak.

8. Install fittings on new accumulator.

9. Connect hoses at accumulator as tagged.
10. Install new decal on accumulator.
11. Install right rear engine side shield.

CAUTION: Before operating machine, the brake

bleed procedure must be done to remove
air from hydraulic system.

12. Before operating machine, see Service Brake Bleeding

Procedure. (Group 9025­20.)

A—Service Brake Accumulator F— Hose to Brake Pedal Valve

WC1006701 —UN—19APR06
B—Check Valve port P
C—Swivel Tee Fitting G—Hose from Priority
D—Swivel Tee Fitting Valve/Hydraulic Pump
E—Adapter H—Hose to Main Control Valve
I— Hose to Grapple Rotate
Solenoid Valve port P

Service Brake Accumulator Hoses and Fittings

AC12469,000039E ­19­23JUL07­3/3

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 Hydraulic System

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 Section 11
Park Brake
Contents

Page

Group 1111—Active Elements

Park Brake Remove and Install .................. 11­1111­1

Group 1160—Hydraulic System

Park Brake Solenoid Valve Repair...............11­1160­1

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 Contents

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 Group 1111
Active Elements

Park Brake Remove and Install

4 5 6

2 8

20
9

10
19
11

T162978 —UN—02JAN03
1
12
13

T162978
18 17 16 15 14
Park Brake Cross Section
1— Transmission Housing 6— Disk Spring 11— Separator Plate (9 used) 16— Inner Seal Ring
2— Transmission Output Shaft 7— Oil Seal 12— M12 x 140 mm Cap Screw 17— Housing
3— Disk (8 used) 8— Grease Seal (2 used) (10 used) 18— Gasket
4— O­Ring 9— Transmission Yoke, Nut, and 13— M12 x 110 mm Cap Screw (4 19— Hub
5— Piston Cotter Pin used) (recessed in cover) 20— Snap Ring
10— Lubrication Fitting 14— Cover
15— Outer Seal Ring

1. Prepare machine for service. See Park and Prepare 4. Drain transmission oil. See Change Transmission Oil,
for Service Safely. (Group 0001.) Replace Filter, and Clean Suction Screen. (Operator’s
2. Turn battery disconnect switch to the OFF position. Manual.)

3. Install wheel chocks under one or more wheels before 5. Remove engine frame shields as needed to access
disconnecting drive shaft. park brake assembly.
Continued on next page NM00125,0000585 ­19­06OCT10­1/2

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 Active Elements

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

TX1024926A —UN—20JUN07
6. Disconnect park brake release hose (22). Close all
openings using caps and plugs.
7. Disconnect rear axle drive shaft and remove
transmission output yoke. See Rear Axle and
Transmission Drive Shaft Remove and Install. (Group
0225.)
Park Brake Hose
CAUTION: Park brake contains a disk spring (6)
under load. Four M12 x 110 mm cap screws
(13) are shorter and recessed into park brake
cover. These four recessed cap screws hold
cover (14) and housing (17) together.
Prevent possible crushing injury from heavy
component. Use appropriate lifting device.

8. Remove 2 of 10 M12 x 140 mm cap screws (12) from

opposite sides of cover. Install guide pins.

TX1024924A —UN—20JUN07
9. Only remove remaining 10 M12 x 140 mm cap screws
(12), leaving M12 x 110 mm cap screws (13) installed
securing park brake housing (17) and cover (14)
together. Remove park brake as an assembly.
Specification
Park Brake
Assembly—Weight Park Brake Housing
(approximate).................................................................................. 43 kg
95 lb.
9— Transmission Yoke, Nut, 17— Housing
10. Repair or replace parts as necessary. See Remove and Cotter Pin 21— Double Universal Joint
Park Brake and see Install Park Brake. (CTM308.) 12— M12 x 140 mm Cap Screw (Telescoping Drive Shaft)
(10 used) 22— Park Brake Release Hose
11. Install drive shaft and yoke. See Rear Axle and 13— M12 x 110 mm Cap Screw
(4 used) (recessed in
Transmission Drive Shaft Remove and Install. (Group cover)
0225.) 14— Cover

12. Connect park brake release hose.

13. Install shields at articulation point. 16. Before returning machine to service, check park
brake operation. See Operational Checkout. (Group
14. Turn battery disconnect switch to the ON position. 9005­10.)
15. Fill transmission with oil and check transmission oil
level. See Change Transmission Oil, Replace Filter,
and Clean Suction Screen. (Operator’s Manual.)
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 Group 1160
Hydraulic System

Park Brake Solenoid Valve Repair

1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)
2. Remove cap screws (1 and 2) and remove access
panel (3).

1— Cap Screw 3— Access Panel

TX1079259A —UN—29JUN10
2— Cap Screw

Left Access Panel

NM00125,0000584 ­19­06OCT10­1/2

3. Disconnect wire connector from park brake solenoid

valve (5).

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

4. Remove cap screws (4) and pull park brake solenoid

from valve body (6). Close all openings using caps
and plugs.
5. Repair or replace parts as necessary.

TX1024459 —UN—06JUN07
6. Install new O­Rings and backup rings on solenoid
valve using petroleum jelly for installation. 4
7. Connect electrical connector to solenoid valve.
8. Install access panel and cap screws. 5
6
9. Before returning machine to service check park
brake operation. See Operational Checkout. (Group
9005­10.)
4— Cap Screw (2 used) 6— Valve Body
5— Park Brake Solenoid Valve

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 Section 17
Frame, Chassis, or Supporting Structures
Contents

Page

Group 1740—Frame Installation

Welding Repair of Major Structure.............. 17­1740­1
Engine and Equipment
Frames—Separate ................................ 17­1740­2
Lower Pivot Pin Repair .............................. 17­1740­6
Upper Pivot Pin Repair ............................ 17­1740­12

Group 1746—Frame Bottom Guards

Bottom Guard
Engine Frame........................................17­1746­1
Equipment Frame..................................17­1746­2

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 Group 1740
Frame Installation

Welding Repair of Major Structure • AWS­E70T­1 or E71T­1 wire electrode with flux core
arc welding (FCAW) process.
CAUTION: Avoid potentially toxic fumes and dust. Welding Repair of Major Structure—Specification
Hazardous fumes can be generated when paint is Weld Metal—Tensile
heated by welding, soldering, or using a torch. Strength...................................................................................482.6 mPa
Do all work outside or in a well ventilated area. 70 000 psi
Dispose of paint and solvent properly. Yield Strength .........................................................................413.7 mPa
60 000 psi
If you sand or grind paint, avoid breathing the
Elongation......................................................................................... 22%
dust. Wear an approved respirator. If you use
solvent or paint stripper, remove stripper with IMPORTANT: Area to be repaired must be preheated
soap and water before welding. Remove solvent to allow better weld penetration.
or paint stripper containers and other flammable
material from area. Allow fumes to disperse at 3. To repair weld metal failure, remove failed weld metal
least 15 minutes before welding or heating. using arc or grinding equipment. Thoroughly clean
area to be welded. Preheat structural assemblies to a
1. Remove paint before welding or heating. minimum of 38°C (100°F). Preheat ground engaging
tools (cutting edges, skid shoes, and teeth shanks) to
IMPORTANT: Electrical current traveling from the
177°C (350°F).
welder through the machine electrical system
may damage the machine electrical system, To repair base metal failure remove enough material to
including battery, machine information center, allow weld to penetrate to the bottom of crack. Preheat
and pump and valve controller. Disconnect structural assemblies to a minimum of 38°C (100°F).
battery ground cable, machine information Preheat ground engaging tools (cutting edges, skid
center, and pump and valve controller electrical shoes, and teeth shanks) to 177°C (350°F).
connectors before welding on the machine.
Welding Repair of Major Structure—Specification
Have only a qualified welder do this job. Connect Structural
welder ground clamp close to each weld area Assemblies—Preheat
so electrical current does not pass through any Temperature..................................................................................... 38°C
bearings. Remove or protect all parts that can 100°F
be damaged by heat or weld splatter. Ground Engaging
Tools—Preheat
2. Use one of the following weld processes: Temperature................................................................................... 177°C
350°F
• AWS­E­7018 covered electrode with shielded metal
arc welding (SMAW) process.
• AWS­ER­70S­3 wire electrode with gas metal arc
welding (GMAW) process.
JW40272,0000028 ­19­18APR08­1/1

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 Frame Installation

Engine and Equipment Frames—Separate

1. Park machine on smooth, level surface and align
frames straight ahead.
2. With engine running, lower blade. Close grapple tong
and lower boom to rest grapple tong on lift table (if

T8465AE —UN—09MAY95
grapple equipped).
3. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
Grapple Tong on Lift Table
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
CAUTION: Prevent possible crushing injury from
4. Operate all hydraulic functions including brake to heavy component. Use proper lifting device.
release pressure in the hydraulic system. Depress
brake pedal at 1­second intervals 20 times to 6. Install floor stands under grille housing.
discharge oil from accumulator.
5. Turn battery disconnect switch to OFF position. See
Battery Disconnect. (Operator’s Manual.)
SW03989,0000A9F ­19­07OCT10­1/5

7. Support grapple arch as shown.

8. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)
IMPORTANT: Clean all dirt and debris from
hydraulic reservoir before removing fill cap
or disconnecting hoses. Contamination
introduced into the hydraulic system can lead
to premature equipment failure.

9. Drain hydraulic reservoir. See Change Hydraulic Oil.

(Operator’s Manual.)

T114406B —UN—29APR98

Grapple Arch Support

Continued on next page SW03989,0000A9F ­19­07OCT10­2/5

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 Frame Installation

10. Remove right equipment frame shield (1) and bottom

engine frame shield (2).
11. Remove hose brackets (3).
12. Remove left frame shields (4—6).
13. Remove drive shafts. See Rear Axle and Transmission
Drive Shaft Remove and Install. (Group 0225.) Also
see Winch Drive Shaft Remove and Install. (Group

TX1080646A —UN—09AUG10
3025.)

1— Right Equipment Frame 4— Top Engine Frame Shield

Shield 5— Left Equipment Frame
2— Bottom Engine Frame Shield
Shield 6— Left Engine Frame Shield
3— Hose Bracket (2 used)

Right Frame Shields

TX1080647A —UN—09AUG10
Hose Brackets

TX1080648A —UN—09AUG10

Left Frame Shields

Continued on next page SW03989,0000A9F ­19­07OCT10­3/5

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 Frame Installation

14. Disconnect winch control cable (8). See Winch Control

Cable Remove and Install. (Group 3015.)
15. Identify and disconnect winch supply hose (7) and
winch return hose (9). Close all openings using caps
and plugs.
16. Disconnect rear axle differential lock hose (11). Close
all openings using caps and plugs. 7
8

TX1080654 —UN—06AUG10
17. Disconnect reverse alarm and fuel sender electrical
connector (10).
18. Identify and disconnect hydraulic and fuel hoses at
hose junction bracket (12). Close all openings using
9
caps and plugs.

7— Winch Supply Hose 10— Reverse Alarm and

8— Winch Control Cable Fuel Sender Electrical Winch
9— Winch Return Hose Connector
11— Rear Axle Differential
Lock Hose
12— Hose Junction Bracket

TX1080649A —UN—09AUG10
Differential Lock Valve

TX1080651A —UN—09AUG10

Hose Junction Bracket

Continued on next page SW03989,0000A9F ­19­07OCT10­4/5

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 Frame Installation

IMPORTANT: Identify hoses and fittings at bulkhead

before removal. Hoses can be interchanged,
causing machine damage.

19. Identify and disconnect hydraulic hoses (13—18).

TX1080652A —UN—09AUG10
Close all openings using caps and plugs (grapple
machines only).
20. Disconnect steering cylinder from equipment frame.
See Steering Cylinder Remove and Install. (Group
0960.)

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device. Bulkhead

21. Remove pivot pins. See Upper Pivot Pin Repair and
13— Arch Retract Hose 16— Boom Retract Hose
see Lower Pivot Pin Repair. (Group 1740.) 14— Arch Extend Hose 17— Boom Extend Hose
15— Grapple Rotate Hose 18— Grapple Rotate Hose
22. With the aid of an assistant, slowly roll equipment
frame and service jack away from front engine frame.
23. Repair or replace parts as necessary. 34. Install left engine frame shield and left equipment
24. With the aid of an assistant, slowly roll equipment frame shield and hose brackets.
frame and service jack to engine frame and align 35. Install right equipment frame shield and bottom engine
upper and lower pivot pin sleeves. frame shield.
25. Install pivot pins. See Lower Pivot Pin Repair and see 36. Lower cab. See Hydraulic Cab Tilt Procedure.
Upper Pivot Pin Repair. (Group 1740.) (Operator’s Manual.)
26. Connect steering cylinder to equipment frame. See 37. Fill hydraulic reservoir. See Change Hydraulic Oil.
Steering Cylinder Remove and Install. (Group 0960.) (Operator’s Manual.)
27. Connect all hydraulic hoses to bulkhead (if grapple 38. Remove floor stands under grille housing.
equipped).
39. Turn battery disconnect switch to ON position. See
28. Install drive shafts. See Rear Axle and Transmission Battery Disconnect. (Operator’s Manual.)
Drive Shaft Remove and Install. (Group 0225.) Also
see Winch Drive Shaft Remove and Install. (Group 40. Start engine and follow hydraulic oil warmup
3025.) procedure. Operate all hydraulic functions to remove
any air trapped in system. See Hydraulic Oil Warmup
29. Connect reverse alarm and fuel sender electrical Procedure. (Group 9025.)
connector.
41. Stop engine. Check for leaks and check hydraulic
30. Connect rear axle differential lock hose. reservoir oil level. See Check Hydraulic System Oil
31. Connect hydraulic hoses to junction bracket. Level. (Operator’s Manual.)

32. Connect winch cable. See Winch Control Cable 42. Bleed service brakes. See Service Brake Bleeding
Remove and Install. (Group 3015.) Procedure. (Group 9025.)

33. Connect winch hoses. 43. Remove articulation locking bar.

SW03989,0000A9F ­19­07OCT10­5/5

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 Frame Installation

Lower Pivot Pin Repair

TX1056815 —UN—06MAR09

TX1056815
Lower Pivot Pin

Continued on next page SW03989,0000B40 ­19­27SEP10­1/9

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 Frame Installation

2— Cap Screw (6 used) 9— Pin Retainer Guard 14— Ring (2 used) 23— Bushing (2 used)
4— Cap Screw (3 used) 11— Snap Ring (2 used) 20— Seal (2 used) 24— Upper Quill
5— Cap Screw (6 used) 12— Lubrication Fitting (2 used) 21— Lower Pivot Pin 25— Special Washer
8— Seal (2 used) 13— O­Ring (2 used) 22— Pin Sleeve 31— Spherical Bushing

CAUTION: Avoid possible injury from 2. Lower blade and grapple equipment to ground.
unexpected machine movement. Install
Operate all hydraulic functions including brake, to
articulation locking bar.
release pressure in the hydraulic system. Depress
brake pedal at one second intervals 20 times to
1. Park machine on a level surface with frames aligned.
discharge oil from accumulator.
Install articulation locking bar.
SW03989,0000B40 ­19­27SEP10­2/9

3. Remove shields and retainers (32—38).

4. Remove drive shafts.
See Winch Drive Shaft Remove and Install. (Group
3025.)

TX1026578A —UN—17JUL07
See Rear Axle and Transmission Drive Shaft Remove
and Install. (Group 0225.)

32— Left Engine Frame Shield 36— Top Engine Frame Shield
33— Left Equipment Frame 37— Bottom Engine Frame
Shield Shield
34— Hose Retainer 38— Right Equipment Frame
35— Hose Retainer Shield
Left Shields

TX1025712A —UN—13JUL07
Right Shields
Continued on next page SW03989,0000B40 ­19­27SEP10­3/9

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 Frame Installation

5. Remove bottom cover (9).

9— Bottom Cover 5— Cap Screw (6 used)

TX1025042A —UN—20JUN07
Bottom Cover
SW03989,0000B40 ­19­27SEP10­4/9

6. Remove upper quill (24).

7. Place 10­ton service jacks under engine and
equipment frames at hinge area for support.

2— Cap Screw (6 used) 24— Upper Quill

TX1026420A —UN—27JUL07
Upper Quill
SW03989,0000B40 ­19­27SEP10­5/9

8. Remove cap screws (4) to remove special washer

(25).

4— Cap Screw (3 used) 25— Special Washer

22— Pin Sleeve
TX1026419A —UN—13JUL07

Special Washer
Continued on next page SW03989,0000B40 ­19­27SEP10­6/9

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 Frame Installation

21 23

31 3
20

TX1026427 —UN—16JUL07
23
22

TX1026427
Lower Pivot Pin
3— Engine Frame 20— Seal (2 used) 22— Pin Sleeve 31— Spherical Bushing
7— Equipment Frame 21— Lower Pivot Pin 23— Bushing (2 used)

NOTE: Lower pivot pin is a press fit in the pin sleeve. 14. Apply several shots of grease to three articulation
joint grease fittings to purge the old grease and to
9. Press lower pivot pin (21) out of pin sleeve (22). ensure that the grease is getting through upper and
10. Remove pin sleeve (22). lower bushings in engine frame and through spherical
bushings in equipment frame.
11. Remove seals from lower pivot pin (21) and from pin
sleeve. 15. Clean all articulation joint components.

12. Clean and inspect seals.

13. Remove seals (20) from lower articulation joint
bushings (23). Discard seals.
Continued on next page SW03989,0000B40 ­19­27SEP10­7/9

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 Frame Installation

11

20

3
7 20

TX1026459 —UN—13JUL07
11

TX1026459
Bushing
3— Engine Frame 7— Equipment Frame 11— Snap Ring (2 used) 20— Seal (2 used)

16. Remove snap rings (11).

The lip on the lower seal should point up.
17. Remove bushings (23) using a driver. For bushings
with a groove machined into the end surface, apply 23. Install new seals into bushings. Install seals with the
force to that end of bushing to remove. slotted side of the seal towards the short side of the
bushing.
18. Remove spherical bushing (31) from equipment frame
(7) using a driver that applies force to the outer race. 24. Install new seal into pin sleeve. Install pin sleeve into
bushing.
19. Inspect and replace as necessary.
25. Support pin sleeve in bushing.
IMPORTANT: Force must only be applied to
the outer race of spherical bushing to 26. Install new seal in lower pivot pin.
avoid damaging bushing.
27. Apply grease to lower pivot pin and bushings.
20. Install spherical bushing into equipment frame using NOTE: Lower pivot pin is a press fit in the pin sleeve.
a driver that applies force to the outer race. Install
bushing so it is centered in equipment frame. 28. Install pivot pin in pin sleeve.
IMPORTANT: Bushings with a groove machined 29. Install special washer and cap screws. Evenly tighten
into the end surface must be installed cap screws to draw pivot pin into pin sleeve.
applying force to that end of the bushing.
The bushing shoulders only have a lead­in 30. Tighten cap screws to specification.
machined on one side. Specification
Lower Pivot Pin Cap
21. Install bushings into engine frame. For bushings with Screw—Torque............................................................................319 N∙m
the groove machined into the end surface, apply force 235 lb­ft
to that end of bushing to install.
22. Install snap rings.
31. Grease pivot pins.
NOTE: The lip on the upper seal should point down.
Continued on next page SW03989,0000B40 ­19­27SEP10­8/9

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 Frame Installation

32. Clean upper quill, clean and inspect O­ring and

packing. 36. Install drive shafts.
33. Install upper quill with cap screws. See Winch Drive Shaft Remove and Install. (Group
34. Clean bottom cover, clean and inspect O­ring and 3025.)
packing. See Rear Axle and Transmission Drive Shaft Remove
35. Install bottom cover with cap screws and tighten to and Install. (Group 0225.)
specification. 37. Install shields.
Specification
Bottom Cover­to­Engine
Frame Cap
Screw—Torque............................................................................624 N∙m
460 lb­ft
SW03989,0000B40 ­19­27SEP10­9/9

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 Frame Installation

Upper Pivot Pin Repair

TX1056816 —UN—06MAR09

TX1056816
Upper Pivot Pin

Continued on next page GD61784,0000067 ­19­06MAR09­1/9

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 Frame Installation

1— Cap Screw (6 used) 12— Lubrication Fitting 17— Lock Collar 27— Shim
6— Cap Screw (3 used) 15— Upper Pivot Pin 18— Special Washer 28— Shim
10— Spherical Bushing 16— Quill 26— Seal 29— Shim

release pressure in hydraulic system. Depress brake

CAUTION: Avoid possible injury from pedal at one second intervals 20 times to discharge
unexpected machine movement. Install oil from accumulator.
articulation locking bar.
3. Install floor stands under grille housing and ahead of
1. Park machine on a level surface and install articulation lower pivot pin of engine frame. Support equipment
locking bar. frame behind lower pin with 10­ton jack.
2. Lower blade and grapple equipment to ground and
operate all hydraulic functions, including brake, to
GD61784,0000067 ­19­06MAR09­2/9

4. Remove cap screws (6) and special washer (18).

6— Cap Screw (3 used) 18— Special Washer

TX1024978A —UN—20JUN07
Special Washer
GD61784,0000067 ­19­06MAR09­3/9

5. Use the 17­1/2 ton hydraulic push­puller from

D01047AA 17­1/2 and 30­Ton Puller Set, to press on
bottom of upper pivot pin (1).
6. Push pin through spherical bushing (2) in engine
frame (3) and out the top of equipment frame (4).

3— Engine Frame 10— Spherical Bushing 10

7— Equipment Frame 15— Upper Pivot Pin

3 7

TX1024982 —UN—22JUN07

15

Upper Pivot Pin

Continued on next page GD61784,0000067 ­19­06MAR09­4/9

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PN=193
 Frame Installation

7. Remove cap screws (1) and quill (16).

8. Using a bushing driver, drive out bushing (10) from
the bottom of engine frame through the top of engine
frame.
9. Install new spherical bushing until it bottom in bore
of engine frame.
10. Install quill without shims. Contact with spherical

TX1024980A —UN—20JUN07
bushing must be made.

1— Cap Screw (6 used) 16— Quill

10— Spherical Bushing

Cap Screw and Quill

GD61784,0000067 ­19­06MAR09­5/9

11. Measure gap from quill to frame with a feeler gauge.

Add shims to attain 0.03—0.13 mm (0.001—0.005 in.)
preload on spherical bushing.
Specification
Shim Pack Less Than
Gap—Preload...................................................................0.03—0.13 mm

T128532 —UN—17FEB00
0.001—0.005 in.

GD61784,0000067 ­19­06MAR09­6/9

12. Install seal in quill with sealing lip toward the quill.

T128533 —UN—17FEB00

Continued on next page GD61784,0000067 ­19­06MAR09­7/9

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 Frame Installation

13. Install required shims, quill (16) and cap screws (1).
Tighten cap screws to specification. Bushing (10)
must oscillate.
Specification
Quill Cap
Screw—Torque............................................................................140 N∙m
103 lb­ft

TX1024980A —UN—20JUN07
1— Cap Screw (6 used) 16— Quill
10— Spherical Bushing

Install Shims
Continued on next page GD61784,0000067 ­19­06MAR09­8/9

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 Frame Installation

15 1

26

16
7
10

3 26

17

TX1024991 —UN—22JUN07
30

18
TX1024991 6
Lower Seal
1— Cap Screw (6 used) 7— Equipment Frame 16— Quill 26— Seal
3— Engine Frame 10— Spherical Bushing 17— Lock Collar 30— Gap
6— Cap Screw (3 used) 15— Upper Pivot Pin 18— Special Washer

14. Install lower seal (26) into engine frame (3) with
sealing lip facing away from spherical bushing (10).
19. Grease pivot pin.
15. Install lock collar (17) into seal.
IMPORTANT: There must be a 1.0 mm (0.039 in.)
16. Apply grease to pivot pin and install into bushing (10). gap between special washer (7) and upper
pivot pin (1) after cap screws have been
17. Install special washer (18) and cap screws (6). tightened to specification.
18. Evenly tighten cap screws to draw pin through
bushing. Tighten cap screws to specification. 20. Measure gap between special washer and upper pivot
pin. Gap must be to specification.
Specification
Retaining Cap Specification
Screws—Initial—Torque...........................................................230.5 N∙m Special Washer and
170 lb­ft Upper Pivot Pin—Gap.................................................................. 1.0 mm
Retaining Cap 0.039 in.
Screws—Final—Torque
Turn.....................................................................................................90°
GD61784,0000067 ­19­06MAR09­9/9

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 Group 1746
Frame Bottom Guards

Engine Frame Bottom Guard Remove and

Install

T114595 —UN—29APR98
A—Rear Bottom Guard D—Cap Screw (2 used) G—Washer (2 used)
B—Washer (2 used) E—Front Bottom Guard H—Washer (4 used)
C—Cap Screw (4 used) F— Cotter Pin (2 used) I— Cap Screw (2 used)

1. Use a service jack to hold the bottom guards (A and

CAUTION: Heavy component; use a hoist. E) in place while removing the cap screws (C and I).
Weights may increase due to the buildup The front bottom guard is hinged and will swing down
of mud and debris. to the front of machine.
Specification
Front Bottom
2. Tighten cap screws (C, D, and I) to specifications.
Guard—Weight Specification
(approximate).................................................................................. 36 kg Front and Rear Bottom
80 lb Guard­to­Engine Frame
Rear Bottom Cap Screw—Torque....................................................................620 N∙m
Guard—Weight 460 lb­ft
(approximate).................................................................................. 25 kg
55 lb
GD61784,0000068 ­19­02JUL07­1/1

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 Frame Bottom Guards

Equipment Frame Bottom Guard Remove

and Install

T114596 —UN—29APR98
A—Washer (8 used) D—Plate (2 used) G—Cap Screw (4 used) J— Cap Screw (4 used)
B—Cap Screw (4 used) E—Bottom Door H—Washer (4 used)
C—Cover F— Cap Screw (2 used) I— Rear Bottom Guard

CAUTION: Heavy component; use a hoist. 2. Tighten cap screws to specifications.

Weights may increase due to the buildup Specification
of mud and debris. Bottom Guard­to­
Equipment Frame Cap
Specification Screw—Torque............................................................................620 N∙m
Bottom Guard—Weight 460 lb­ft
(approximate).................................................................................. 27 kg Bottom Door­to­
60 lb Equipment Frame Cap
Screws—Torque..........................................................................130 N∙m
1. Use a service jack to hold the bottom guard (I) in place 95 lb­ft
while removing the cap screws (G).
GD61784,0000069 ­19­15JUN07­1/1

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 Section 18
Operator’s Station
Contents

Page Page

Group 1800—Removal and Installation Air Conditioner Compressor

Cab Remove and Install ............................ 18­1800­1 Manifold Remove and Install ............... 18­1830­11
Cab Isolators Remove and Install.............. 18­1800­8 Air Conditioner Condenser Remove
Steering Column and Steering and Install ............................................ 18­1830­11
Wheel Remove and Install..................... 18­1800­9 Blower Motor Remove and Install............ 18­1830­13
Steering Column and Steering Precleaner Blower Assembly
Wheel Disassemble and Remove and Install.............................. 18­1830­14
Assemble............................................. 18­1800­11 Refrigerant High/Low Pressure
Cab Tilt Hand Pump Remove and Switch Remove and Install .................. 18­1830­15
Install ................................................... 18­1800­13 Coolant Valve Remove and Install............ 18­1830­16
Cab Tilt Hand Pump Disassemble Freeze Control Switch Remove
and Assemble...................................... 18­1800­14 and Install ............................................ 18­1830­17
Cab Tilt Hand Pump Bleeding Expansion Valve Remove and
Procedure ............................................ 18­1800­15 Install ................................................... 18­1830­18
Cab Tilt Cylinder Remove and Heater Core Remove and Install ............. 18­1830­19
Install ................................................... 18­1800­17 Evaporator Remove and Install ............... 18­1830­20
Receiver­Dryer Remove and
Group 1810—Operator Enclosure Install ................................................... 18­1830­21
Window Remove and Install ...................... 18­1810­1
Window Cleaning Procedure ..................... 18­1810­4
Cab Door Remove and Install ................... 18­1810­4
Cab Door and Door Latch
Disassemble and Assemble .................. 18­1810­5
Front Windshield Wiper Remove
and Install .............................................. 18­1810­6
Rear Windshield Wiper Remove
and Install .............................................. 18­1810­7
Windshield Wiper Adjustment.................... 18­1810­9

Group 1821—Seat and Seat Belt

Seat Remove and Install ........................... 18­1821­1
Seat Disassemble and Assemble.............. 18­1821­2
Seat Belt Remove and Install .................... 18­1821­7

Group 1830—Heating and Air Conditioning

R134a Refrigerant Cautions and
Proper Handling..................................... 18­1830­1
Air Conditioning System Flush and
Purge ..................................................... 18­1830­2
R134a Refrigerant Oil Information.............. 18­1830­4
R134a Refrigerant
Recovery/Recycling and
Charging Station Installation
Procedure .............................................. 18­1830­5
R134a Refrigerant Recovery ..................... 18­1830­6
R134a System Evacuate ........................... 18­1830­6
R134a System Charge .............................. 18­1830­7
Compressor Relief Valve Remove
and Install .............................................. 18­1830­7
Air Conditioner Compressor
Remove and Install................................ 18­1830­8
Air Conditioner Compressor Clutch
Remove and Install................................ 18­1830­9

TM11813 (13OCT10) 18­1 748H Repair (S.N. 630436— )

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 Contents

TM11813 (13OCT10) 18­2 748H Repair (S.N. 630436— )

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 Group 1800
Removal and Installation

Cab Remove and Install

1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate all hydraulic controls to relieve pressure

in the hydraulic system. Depress brake pedal at
1­second intervals 20 times to discharge pressure
from accumulator.
3. Remove engine side shields. See Opening Engine
Side Shields. (Operator’s Manual.)
4. Turn battery disconnect switch to the OFF position.

TX1082472 —UN—05OCT10
See Battery Disconnect. (Operator’s Manual.)

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

5. Remove right limb riser (1).

Specification
Right Limb Limb Riser Remove and Install
Riser—Weight
(approximate).................................................................................. 39 kg 1— Right Limb Riser 2— Left Limb Riser with Muffler
85 lb.

CAUTION: Muffler and left limb riser may be hot

from exhaust. Allow riser to cool before removal. CAUTION: Coolant may be hot. Wait until radiator
is cool to the touch before draining radiator.
6. Disconnect muffler flex pipe from turbocharger outlet
elbow. Close opening using cap or plug. 8. Drain cooling system. See Draining the Cooling
System. (Operator’s Manual.)
CAUTION: Prevent possible crushing injury from
9. Remove lower cab shields.
heavy component. Use appropriate lifting device.
10. Disconnect steering column from steering valve. See
7. Remove left limb riser with muffler (2). Steering Valve Remove and Install. (Group 0960.)
Specification 11. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Left Limb Riser Manual.)
with Muffler—Weight
(approximate).................................................................................. 50 kg 12. Recover air conditioning refrigerant. See R134a
110 lb. Refrigerant Recovery. (Group 1830.)
Continued on next page SW03989,0000B47 ­19­05OCT10­1/13

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 Removal and Installation

13. Disconnect air conditioner suction hose (3) at air

conditioner compressor.
14. Remove clamp (4) and slide protective sleeve (5)
up on hose. Disconnect pressure hose at fitting (6).
Close all openings using caps and plugs.
15. Remove hoses from hangers routed to cab. Attach
hose temporarily to bottom of cab. Hoses will be

TX1082473A —UN—05OCT10
removed with cab.
16. Apply vacuum or drain hydraulic reservoir. If draining
hydraulic reservoir, see Change Hydraulic Oil.
(Operator’s Manual.)

3— Air Conditioner Suction 5— Protective Sleeve

Hose 6— Air Conditioner Pressure
4— Clamp Hose Fitting
Air Conditioner Suction Hose

TX1082474A —UN—05OCT10
Air Conditioner Pressure Hose
SW03989,0000B47 ­19­05OCT10­2/13

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

17. Identify and disconnect hydraulic lines from service TX1082475A —UN—05OCT10
brake valve (7). Close all openings using caps and
plugs.
18. Remove hydraulic hoses through hanger and set
aside.
19. Disconnect service brake pressure switch connector Service Brake Valve and Engine Speed Control
(8) and engine speed control harness connector (9).
20. Disconnect dual mode steering solenoid valve. See 7— Service Brake Valve 9— Engine Speed Control
Dual Mode Steering Solenoid Valve Remove and 8— Service Brake Pressure Harness Connector
Install. (Group 0962.) Switch Connector

Continued on next page SW03989,0000B47 ­19­05OCT10­3/13

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 Removal and Installation

21. Disconnect heater hoses (9). Close all openings using

caps and plugs.
NOTE: Do not disconnect hoses from steering valve.

22. Remove steering valve from bottom of cab. See

Steering Valve Remove and Install. (Group 0960.)

10— Heater Hose (2 used)

TX1082476A —UN—05OCT10
Heater Hoses
SW03989,0000B47 ­19­05OCT10­4/13

23. Disconnect wire harness connections (11 and 12)

and transmission wire harness connection (13) from
bottom of cab. Remove cap screws and clamps
securing wire harnesses to cab.

TX1082477A —UN—05OCT10
11— Wire Harness Connection 13— Transmission Wire
12— Wire Harness Connection Harness Connection

Wire Harness Connections

TX1082478A —UN—05OCT10

Transmission Wire Harness Connection

Continued on next page SW03989,0000B47 ­19­05OCT10­5/13

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 Removal and Installation

24. Disconnect ground strap (14) from cab mount.

14— Ground Strap 15— Cap Screw

TX1025516A —UN—28JUN07
Cab Ground Strap
SW03989,0000B47 ­19­05OCT10­6/13

NOTE: Leave nut (19) finger tight, so it can be removed

later without the use of a wrench.

25. Loosen nut (19) but DO NOT remove from cap screw
(16).

TX1082480A —UN—05OCT10
16— Cap Screw 18— Washer (2 used)
17— Shim (as needed) 19— Nut

Cab Tilt Cylinder Cap Screw and Nut

SW03989,0000B47 ­19­05OCT10­7/13

IMPORTANT: All components, hydraulic lines, and

electrical harnesses disconnected from machine
and cab must be placed in areas that will be
clear when lowering cab. Lowering cab on
top of such items will cause damage.
TX1082481A —UN—05OCT10

26. Lower cab. See Hydraulic Cab Tilt Procedure.

(Operator’s Manual.)
Remove cap screw (20) to disconnect tether cable
(21) from cab.

20— Cap Screw 21— Tether Cable

Cab Tether Cable
Continued on next page SW03989,0000B47 ­19­05OCT10­8/13

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 Removal and Installation

NOTE: Mark quantity and location of shims to

aid in assembly.

27. Remove nut (19), shims (17), washer (18), and cap
screw (16). Move cab tilt cylinder (22) away from

TX1082479A —UN—05OCT10
clevis.

16— Cap Screw 19— Nut

17— Shim (as needed) 22— Cab Tilt Cylinder
18— Washer (2 used)

Cab Tilt Cylinder

SW03989,0000B47 ­19­05OCT10­9/13

28. Disconnect winch control cable (23), if equipped.

29. Disconnect transmission vent hose (25).
30. Tag and disconnect hydraulic hoses (24, 27—31).
Close all openings using caps and plugs.
31. Remove all clamps and ties securing hydraulic hoses
to cab.

23— Winch Control Cable (if 28— Boom Hose (if equipped,
equipped) 2 used)
24— Pilot Pressure Hose 29— Blade Hose (2 used)
25— Transmission Vent Hose 30— Valve Return Hose
26— Grapple Tong Hose (2 31— Valve Supply Hose
used)

TX1082482A —UN—05OCT10
27— Arch Hoses (2 used)

Dual Function Pilot Control Valve Shown

Continued on next page SW03989,0000B47 ­19­05OCT10­10/13

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 Removal and Installation

32. Attach lifting chains to rear lift points (32) on right and
left sides of cab.
33. Install JDG909 Lifting Brackets (33) in both limb
riser eyelets. Attach lifting chains to JDG909 Lifting

TX1082483A —UN—05OCT10
Brackets.

32— Rear Lift Point 33— JDG909 Lifting Bracket (2

used)

Cab Rear Lift Point

TX1082484A —UN—05OCT10
JDG909 Lifting Brackets
Continued on next page SW03989,0000B47 ­19­05OCT10­11/13

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 Removal and Installation

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

NOTE: Mark quantity and location of washers and

shims to aid in assembly.

TX1082485A —UN—05OCT10
34. Remove nuts (34). Raise cab slightly to remove cap
screws (37), washers (35), and shims (36) from both
cab pivots.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.
Cab Pivots
IMPORTANT: Carefully remove cab, making sure
all hydraulic lines, harnesses, and valves
34— Nut (2 used) 36— Shim (as needed)
are clear as cab is lifted. 35— Washer (4 used) 37— Cap Screw (2 used)

35. Remove cab.

Specification 45. Position tilt cylinder into cab clevis and install cap
Cab—Weight screw, washers, shims, and nut as were marked
(approximate).............................................................................. 1281 kg during removal. Do not tighten nut at this time.
2825 lb.
46. Install tether cable and cap screw.
36. Inspect, repair, or replace cab components as
necessary. 47. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)
37. Inspect and replace cab isolators if necessary. See
Cab Isolators Remove and Install. (Group 1800.) IMPORTANT: DO NOT overtighten tilt cylinder
nut. Overtightening of nut can cause
cab clevis to deform.
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device. 48. Tighten tilt cylinder nut until washers are snug.
IMPORTANT: Hydraulic lines, hoses, and electric 49. Install cab ground strap.
harnesses must be clear of cab while
lowering, or damage may occur. 50. Connect all electrical harnesses to cab and install all
clamps in original positions.
38. Install cab onto frame mounts, guiding hydraulic lines, 51. Attach steering valve to bottom of cab. See Steering
valves, and electrical harnesses into position for Valve Remove and Install. (Group 0960.)
hookup.
52. Install dual mode steering solenoid valve. See Dual
Specification
Mode Steering Solenoid Valve Remove and Install.
Cab—Weight
(Group 0962.)
(approximate).............................................................................. 1281 kg
2825 lb. 53. Connect hoses to service brake valve.
39. Install shims, washers, cap screw, and nut at cab pivot 54. Remove vacuum if hydraulic reservoir was not drained
mounts as marked during removal. or fill hydraulic reservoir. See Change Hydraulic Oil.
(Operator’s Manual.)
IMPORTANT: Overtightening of cap screws and nuts
can cause cab clevis to deform. 55. Connect service brake pressure switch connector and
engine speed control connector.
40. Tighten nuts until washers are snug.
56. Route heater hoses through hangers and connect.
41. Remove lifting chains and lifting brackets from cab.
57. Route air conditioner suction hose and pressure hose
42. Connect all hydraulic hoses to pilot control valve. through hangers and connect.
43. Connect winch control cable (if equipped) and 58. Install protective sleeve over pressure hose and install
transmission vent hose. clamp in original position.
44. Install all clamps and tie bands in original locations. 59. Lower cab. See Hydraulic Cab Tilt Procedure.
Replace any cut tie bands. (Operator’s Manual.)

Continued on next page SW03989,0000B47 ­19­05OCT10­12/13

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 Removal and Installation

60. Install rear lower cab shields. 64. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.)
CAUTION: Prevent possible crushing injury from
65. Check hydraulic oil level and add oil if necessary.
heavy component. Use appropriate lifting device.
See Check Hydraulic System Oil Level. (Operator’s
Manual.)
61. Install limb risers.
Specification 66. Adjust winch control cable. See Winch Control Cable
Right Limb Adjustment Check. (Group 9030­20.)
Riser—Weight 67. Charge air conditioning system. See R134a System
(approximate).................................................................................. 39 kg Charge. (Group 1830.)
85 lb.
Left Limb Riser 68. Install engine side shields. See Opening Engine Side
with Muffler—Weight Shields. (Operator’s Manual.)
(approximate).................................................................................. 50 kg
110 lb.
69. Remove articulation lock bar.

62. Connect muffler flex pipe to turbocharger outlet elbow.

63. Check and fill cooling system. See Filling the Cooling
System. (Operator’s Manual.)
SW03989,0000B47 ­19­05OCT10­13/13

Cab Isolators Remove and Install

NOTE: If cab isolators become worn or damaged,
replace isolators.

Left Cab Mount Isolators

T114570B —UN—29APR98
1. Raise cab. See Hydraulic Cab Tilt Procedure.
(Operator’s Manual.)
2. Remove isolators from mounts.
3. Apply soap on isolators to aid in installation. Install
isolators.
4. Lower cab, install shims.
5. Install one shim at front of rear cab mount support and
three at rear of support. Align shims and mounting CAUTION: Prevent unexpected machine
holes. Install cap screw. movement and possible injury. Install articulation
locking bar before you work in frame pivot area.
6. Install one shim at front of front cab mount support and
three at rear of support. Align shims and mounting 1. Install articulation locking bar.
holes. Install cap screw.
2. Park machine on level ground, turn battery disconnect
IMPORTANT: Overtightening of nuts can cause switch OFF, and set park brake switch to PARK
cab clevis to deform. position.
7. Tighten nuts until washers are snug and full thread 3. Remove left engine side shields.
engagement is attained.
4. Disconnect both limb risers from top of cab.
Right Cab Mount Isolators
Continued on next page AC12469,00003A1 ­19­10MAR09­1/3

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 Removal and Installation

CAUTION: Left cab mounting pins MUST be

installed before tilting right side of cab. Tilting
cab without opposite side mounting pins installed
could cause serious personal injury.

5. Open and remove lower cab shield (B).

T114970 —UN—29APR98
6. Remove nuts (A).
7. Using hydraulic cab tilting jack, lift cab until weight of
cab is removed from cap screws. Remove cap screws,
washers, and shims. Note location and quantity of
washers and shims to aid in assembling.

A—Nut (2 used) B—Lower Cab Shield

AC12469,00003A1 ­19­10MAR09­2/3

8. Raise cab until mounts clear cab clevises. Support

cab using a wooden block (C) as shown.
9. Remove isolators from mounts.
10. Apply soap on new isolators to aid in installation.
Install isolators.

T131398B —UN—21JUN00
11. Remove wooden block and lower cab.
12. Install one shim at front of rear cab mount support and
three at rear of support. Align shims and mounting
holes. Install cap screw.
13. Install one shim at front of front cab mount support and
three at rear of support. Align shims and mounting
holes. Install cap screw.
C—Wooden Block
IMPORTANT: Overtightening of nuts can cause
cab clevis to deform.
17. Turn battery disconnect switch to ON position.
14. Tighten nuts until washers are snug and full thread
engagement is attained. 18. Install engine side shields.
15. Install lower cab shields. 19. Remove articulation locking bar.
16. Connect limb risers to cab.
AC12469,00003A1 ­19­10MAR09­3/3

Steering Column and Steering Wheel

Remove and Install
1. Remove fire extinguisher from bracket. Remove cap
screws (1 and 3) and bracket (2).
T131257B —UN—31MAY00

1— Cap Screw (2 used) 3— Cap Screw

2— Bracket

Continued on next page AC12469,00003A2 ­19­14JUN07­1/4

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 Removal and Installation

2. Disconnect electrical connectors (3) from windshield

washer pumps and disconnect hoses (4). Close all
openings with caps and plugs.
3. Remove cap screws (1) and remove windshield
washer tank (2).

1— Cap Screws (2 used) 3— Electrical Connector (2

2— Windshield Washer Tank used)
4— Windshield Washer Hose (2
used)

T131258B —UN—31MAY00
AC12469,00003A2 ­19­14JUN07­2/4

4. Remove screws (1) and lower dash panel (2).

1— Screws (4 used) 2— Lower Dash Panel

T131259B —UN—31MAY00
Continued on next page AC12469,00003A2 ­19­14JUN07­3/4

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 Removal and Installation

5. Disconnect horn wire connector (2).

6. Remove cap screws (1 and 4) and slide steering
column with universal joint (3) up and off of steering
valve.
7. Inspect and repair parts as necessary. See Steering
Column and Steering Wheel Disassemble and
Assemble. (Group 1800.)
8. Install cap screws (1—4).
9. Connect horn wire connector (2).
10. Install lower dash panel and cap screws.
11. Install windshield washer tank and cap screws.

T131260B —UN—31MAY00
12. Connect windshield washer pump hoses and electrical
connectors.
13. Install fire extinguisher bracket and cap screws. Install
fire extinguisher.

1— Cap Screw (4 used) 3— Universal Joint

2— Horn Wire Connector 4— Cap Screw

AC12469,00003A2 ­19­14JUN07­4/4

Steering Column and Steering Wheel

Disassemble and Assemble
1. Remove cap in center of steering wheel. Remove nut
(1).

T131263B —UN—31MAY00
CAUTION: Spring behind steering wheel is under
tension. Remove steering wheel with caution.

2. Install puller to steering wheel and slowly remove

wheel from steering column while holding downward
pressure on wheel to restrain spring tension.

1— Steering Wheel Nut

AC12469,00003A3 ­19­19JUL07­1/3

3. Remove covers (2, 4, and 5), horn wiring lead (1) and
knob (3).

1— Horn Wiring Lead 4— Cover

2— Cover 5— Cover
3— Knob
T131265B —UN—31MAY00

Continued on next page AC12469,00003A3 ­19­19JUL07­2/3

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 Removal and Installation

4. Replace parts as necessary.

5. Connect horn wiring connector to cap (7).
6. Install cap.

T131266B —UN—31MAY00
1— Steering Column 5— Steering Wheel
2— Disk 6— Nut
3— Spring 7— Cap
4— Cover

AC12469,00003A3 ­19­19JUL07­3/3

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 Removal and Installation

Cab Tilt Hand Pump Remove and Install

IMPORTANT: For satisfactory operation of the
cab tilt cylinder, it is essential that all air be
bled from the system. Therefore, any time
air is induced into the system, the bleed
procedure MUST be performed.

X9811 —UN—23AUG88
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.

1. Shut engine off and lower equipment to the ground.

Operate all hydraulic functions to relieve pressure.

T131385B —UN—02JUN00
2. Turn battery disconnect switch to OFF position.
3. Disconnect hose (2) and top hose (1). Close all
openings using caps and plugs.
4. Remove cap screws (3) and remove pump.
5. Replace or repair damaged parts. See Cab Tilt Hand
Pump Disassemble and Assemble. (Group 1800.)
1— Head End Lift Hose 3— Cap Screw (3 used)
6. Install pump and cap screws. Tighten cap screws to 2— Head End Retract Hose
specification.
Specification
Hand Pump Mounting 9. Bleed cab tilt hand pump circuit to remove air from
Cap Screws—Torque............................................................ 22—26 N∙m system. See Cab Tilt Hand Pump Bleeding Procedure.
195—230 lb­in. (Group 1800.)
7. Connect hoses (1 and 2). 10. Check oil reservoir level.
8. Fill hand pump oil reservoir. See Transmission, Park 11. Turn battery disconnect switch to ON position.
Brake, Differential, Cab Tilt Hydraulic Pump and Winch
Oil. (Operator’s Manual.)
Specification
Cab Tilt Hand Pump
Reservoir—Capacity.................................................................... 574 mL
20 oz
AC12469,00003A4 ­19­10MAR09­1/1

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 Removal and Installation

Cab Tilt Hand Pump Disassemble and

Assemble
IMPORTANT: For satisfactory operation of the
cab tilt cylinder, it is essential that all
air be bled from the system. Any time a
system component is changed the bleed
procedure MUST be performed.

1. Remove cab tilt hand pump. See Cab Tilt Hand Pump
Remove and Install. (Group 1800.)
2. Remove four cap screws from pump reservoir and
drain oil from reservoir. Check O­ring (C) and replace
if damaged.
3. Remove plastic plug (A) from bottom of pump body
with an O­ring pick.
4. Remove pump handle link (G).
5. Remove snap ring (B) from pump valve (F) and tap
assembly out of the valve body.

T8513AF —UN—05JUL95
6. Inspect and replace damaged parts.
7. Apply clean hydraulic oil to pump valve (F) and install
into valve body.
8. Install snap ring (B) and plastic plug (A).
9. Install pump handle link (G) to pump valve (F).
10. Remove and clean suction screen (D).
A—Plastic Plug E—Fill Plug
11. Install O­ring (C) into reservoir O­ring groove and B—Snap Ring F— Pump Valve
install reservoir to the valve body. Tighten cap screws. C—O­Ring G—Pump Handle Link
D—Suction Screen
Specification
Reservoir­to­Valve Body
Cap Screws—Torque........................................................ 6.6—11.6 N∙m
48—84 lb­in. 13. Oil fill plug (E) is vented; check to see if plug is clean.
Install fill plug (E).
12. Fill hand pump oil reservoir. See Transmission, Park
Brake, Differential, Cab Tilt Hydraulic Pump and Winch 14. Install cab tilt hand pump. See Cab Tilt Hand Pump
Oil. (Operator’s Manual.) Remove and Install. (Group 1800.)
Specification
Cab Tilt Hand Pump
Reservoir—Capacity.................................................................... 574 mL
20 oz
AC12469,00003A5 ­19­14JUN07­1/1

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 Removal and Installation

Cab Tilt Hand Pump Bleeding Procedure

CAUTION: For satisfactory operation of the cab

tilt cylinder, it is essential that all air be bled from
the system. Any time a system component is
changed the bleed procedure MUST be performed.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

1. Attach hoist and chains to cab and raise cab.

2. Support cab and remove cab lift cylinder pin and cap
screw.

T115133B —UN—29APR98
3. Position cylinder so that there is enough clearance to
extend and retract cylinder.
4. Completely retract cylinder using pump.

A—Head End Hose C—Lever

B—Rod End Hose

T115132B —UN—29APR98
Continued on next page AC12469,00003A6 ­19­14JUN07­1/2

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 Removal and Installation

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.

X9811 —UN—23AUG88
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 9. Place a container under head end hose (A) and
from Deere & Company Medical Department operate pump until all air is bled from hose. Connect
in Moline, Illinois, U.S.A. hose (A) to cylinder.

5. Disconnect the rod end hose (B) and install plug in 10. Place a container under cylinder rod end port.
hose. 11. Operate hand pump until cylinder is completely
6. Disconnect head end hose (A) at the base of the extended.
hydraulic cylinder. 12. Remove plug from rod end hose (B). Place a container
IMPORTANT: Keep hand pump reservoir full during under hose end.
bleeding procedure to avoid air entering circuit. 13. Position lever (C) on pump to retract cylinder. Operate
hand pump until all air is bled from line.
7. Fill cab tilt hand pump reservoir and maintain hydraulic
oil level. See Transmission, Park Brake, Differential, 14. Connect hose (B) to cylinder and retract cylinder.
Cab Tilt Hydraulic Pump and Winch Oil. (Operator’s
Manual.) IMPORTANT: Overtightening of cap screw and nut
can cause cab clevis to deform.
Specification
Cab Tilt Hand Pump 15. Install cab tilt cylinder with pin and cap screw.
Reservoir—Capacity.................................................................... 574 mL
20 oz 16. Make sure nut is fully threaded on cap screw. Do not
Cab Tilt Hand Pump overtighten cap screw.
Circuit—Capacity
17. Remove cab support and lower cab.
(approximate)...................................................................................... 2 L
2 qt

8. Position lever (C) on pump to extend cylinder.

AC12469,00003A6 ­19­14JUN07­2/2

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 Removal and Installation

Cab Tilt Cylinder Remove and Install

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before

X9811 —UN—23AUG88
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.

T131387B —UN—02JUN00
IMPORTANT: For satisfactory operation of cab
tilt cylinder, it is essential that all air be
bled from the system. Therefore, any time
air is induced into the system, the bleed
procedure MUST be performed.

1. Raise cab. See Hydraulic Cab Tilt Procedure.

(Operator’s Manual.)

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

T131386B —UN—02JUN00
2. Attach hoist and chains to cab for support and aid of
removal and installation of cylinder pin and cap screw.
3. Remove cap screw and nut (1) from cab. Retract
cylinder.
4. Remove cylinder pin (4) from engine frame.
5. Disconnect hydraulic lines (2 and 3). Close all
openings with caps and plugs.
1— Cap Screw and Nut 3— Head End Lift Hydraulic
6. Remove cylinder. 2— Head End Retract Hydraulic Line
Line 4— Pin
7. Install new cylinder.
8. Connect hydraulic lines (2 and 3).
11. Extend cylinder to line up cylinder rod end with cab
9. Install cylinder. clevis. Install rubber bushings, washers, cap screw
IMPORTANT: Overtightening of cap screw and nut and nut (1). Make sure nut is fully threaded onto cap
can cause cab clevis to deform. screw. Do not overtighten cap screw.
12. Remove cab support and lower cab.
10. Bleed cab tilt hand pump circuit. See Cab Tilt Hand
Pump Bleeding Procedure. (Group 1800.)
AC12469,00003A7 ­19­14JUN07­1/1

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 Removal and Installation

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 Group 1810
Operator Enclosure

Window Remove and Install

Front, Rear, and Side Windows

TX1056818 —UN—06MAR09
TX1056818
Front, Rear, and Side Windows
1— Cap Screw (79 used) 3— Side Windowpane (2 used) 5— Rear Windowpane 7— Front Windowpane
2— Spacer (57 used) 4— Spacer (22 used) 6— Front Windowpane (2 used)

1. Remove cap screws securing window to cab. 3. Install new weather­stripping, windowpane, spacers,
and cap screws. Tighten cap screws to specification.
2. Clean cab­to­windowpane contact area of dirt and old
weather­stripping. Specification
Windowpane Cap
Screw—Torque..............................................................................20 N∙m
CAUTION: DO NOT replace polycarbonate
180 lb­in.
windows with glass or plastic. Polycarbonate
material impact resistance is recommended Door Windows
for forestry use.

IMPORTANT: Spacers must be installed before cap

screws are tightened. Tightening cap screws
without spacers could damage windowpane.
Continued on next page PM10405,0000571 ­19­06OCT10­1/3

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 Operator Enclosure

TX1056817 —UN—06MAR09
TX1056817
Sliding Windows in Doors
8— Window (2 used) 11— Latch 14— Isolator
9— Nut (4 used per side) 12— Cap Screw (4 used per side) 15— Washer (2 used per side)
10— Plate (2 used per side) 13— Screen 16— Cap Screw (2 used per side)

1. Remove cap screws (15) and swing screen (13) open. 2. Remove screen by lifting straight up.
Continued on next page PM10405,0000571 ­19­06OCT10­2/3

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 Operator Enclosure

3. Open locking tab (D) using JDG­128­1 Tool Assembly

(A) from JDG­128 Glass Service Set.
4. Loosen molding (F) around window frame (B) using
JDG­128­2 Insert Tool (E).
5. Carefully remove window frame.

T6148AE —UN—19OCT88
6. Remove molding and inspect for damage. Replace if
necessary.
7. If molding must be replaced, start molding so the joint
is on the side of window. If joint is on top or bottom of
window, water might enter into the cab.

CAUTION: DO NOT replace polycarbonate

windows with glass or plastic. Polycarbonate
material impact resistance is recommended
for forestry use.

8. Install window frame using insert tool.

T6148AF —UN—19OCT88
9. Push locking tab into groove using tool assembly.
10. Install screen and tighten cap screws.

A—JDG­128­1 Tool Assembly D—Molding Locking Tab

B—Window Frame E—JDG­128­2 Insert Tool
C—Cab Frame F— Molding
Locking Tab—Closed Position

T6148AG —UN—19OCT88
T6148AH —UN—19OCT88

Locking Tab—Open Position

PM10405,0000571 ­19­06OCT10­3/3

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 Operator Enclosure

Window Cleaning Procedure

IMPORTANT: NEVER use abrasive or highly alkaline regularly. If surface crazing or cracks are observed,
cleaners on polycarbonate windows. replace window using only John Deere replacement parts
to ensure the original operator protection level. Inspect
NEVER use aromatic or halogenated solvents the windows after any significant impact to the windows
like toluene, benzene, gasoline, acetone, or or frame.
carbon tetrachloride on polycarbonate windows.
Contact with harsh solvents can result in The windows are made of a polycarbonate material, which
surface degradation and possible crazing. is softer but stronger than glass. It will scratch.

IMPORTANT: If cracks or surface crazing are For window cleaning information, see Inspect and Clean
observed, replace windshield. Windows. (Operator’s Manual.)

Windows are important for the protection of the operator

and the safe operation of the machine. Inspect windows
SW03989,0000AC8 ­19­05OCT10­1/1

Cab Door Remove and Install

1. Remove door limiting strap from mount on door by
sliding strap up and pulling it out of notch.

1— Door Strap Mount

TX1025128A —UN—20JUN07
AC12469,00003B5 ­19­23JUL07­1/3

2. Remove nuts retaining gas charged strut and remove

strut from door.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

TX1025130A —UN—21JUN07
3. Support weight of door.

2— Nut (2 used) 3— Gas Charged Strut

Continued on next page AC12469,00003B5 ­19­23JUL07­2/3

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PN=222
 Operator Enclosure

4. Mark position of hinges on cab for ease of installation.

5. Remove hinges and remove door from cab.
6. Inspect and replace parts as necessary.
7. Install door and door hinges. Check alignment to

TX1025131A —UN—21JUN07
ensure door is even all the way around opening.
8. Tighten cap screws to specification.
Specification
Cab Hinge Mounting Cap
Screw—Torque..............................................................................73 N∙m
54 lb­ft

9. Install gas charged strut.

4— Cap Screw (4 used per
10. Install door travel limiting strap. door)

AC12469,00003B5 ­19­23JUL07­3/3

Cab Door and Door Latch Disassemble and

Assemble
NOTE: Lower latch mechanism does not need to be
removed to remove upper latch mechanism.

1. Remove inner door panel.

2. Remove cap screws (3).
3. Remove clip (4) and disconnect linkage rod from door
lock.
4. Remove door lock.

TX1025065A —UN—20JUN07
1— Door Lock 3— Cap Screw (4 used)
2— Bracket (2 used) 4— Clip

Door Latch (lower)

Continued on next page AC12469,00003AA ­19­23JUL07­1/2

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 Operator Enclosure

5. Remove knob and cover from upper door latch.

6. Disconnect spring (8) from bracket (9). Remove upper
two cap screws and remove bracket.
7. Disconnect yoke (11) from latch (7). Remove
remaining cap screws and remove latch.
8. Inspect and replace parts as necessary.
9. Install door lock.
10. Connect rod to lower door latch.
11. Install upper latch (7) and plate (5) using lower two
cap screws.

TX1025064A —UN—20JUN07
12. Connect rod to upper latch. Check for correct
adjustment of yoke.
13. Adjust yoke to allow for full travel of upper latch
mechanism without contacting rod at bottom of travel.
14. Install bracket (9) using remaining two cap screws.
Install spring.
Door Latch (upper)
15. Test operation of latch mechanism and readjust if
necessary.
5— Plate 9— Bracket
16. Install knob and cover on upper latch. 6— Cap Screw (4 used) 10— Clip
7— Latch 11— Yoke
17. Install door panel. 8— Spring 12— Rod

AC12469,00003AA ­19­23JUL07­2/2

Front Windshield Wiper Remove and Install

1. Remove sun visor.
2. Remove trim caps on screws on left and right side of
front trim panel (1).

TX1025739A —UN—29JUN07
3. Remove screws (2) securing trim panel to cab and
remove trim panel.
4. Note position of wiper arm and routing of washer fluid
hose. Remove wiper arm and disconnect washer fluid
hose.

1— Trim Panel 2— Screw (2 used)

Continued on next page AC12469,00003AB ­19­10MAR09­1/3

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 Operator Enclosure

5. Have an assistant support wiper motor from inside

cab.
Remove cap screw (5) and washer securing wiper
motor frame to cab. Remove nut (4) and washer on
wiper shaft (3).

TX1025741A —UN—29JUN07
3— Wiper Shaft 5— Cap Screw
4— Nut

AC12469,00003AB ­19­10MAR09­2/3

6. Disconnect electrical connection (6).

7. Remove wiper motor (8) and wiper motor frame (7).
8. Inspect and replace parts as necessary.
9. Have an assistant position wiper motor inside cab.

TX1025740A —UN—29JUN07
Install cap screw (5) and washer and nut (4) and
washer securing wiper motor to cab.
10. Connect electrical connection.
11. Install wiper arm and connect washer fluid hose.
Tighten nut to specification.
Specification
Wiper Retaining
6— Electrical Connection 8— Wiper Motor
Nut­to­Pivot—Torque............................................................. 14—21 N∙m
7— Wiper Motor Frame
124—186 lb­in.

12. Install trim cover and sun visor.

13. Install trim caps over screws supporting trim cover.
14. Check windshield wiper position. See Windshield
Wiper Adjustment. (Group 1810.)
AC12469,00003AB ­19­10MAR09­3/3

Rear Windshield Wiper Remove and Install

1. Remove switch panel in right rear of cab. Label
electrical connections for assembly.
2. Remove trim caps (1) on screws securing trim panel
TX1025742A —UN—29JUN07

(2) to cab.
3. Remove screws (3) and remove trim panel.
4. Note position of wiper arm and routing of washer fluid
hose. Remove wiper arm and disconnect washer fluid
hose.

1— Trim Cap 3— Screw (4 used)

2— Trim Panel 4— Plastic Washer

Continued on next page AC12469,00003AC ­19­30JUL07­1/3

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PN=225
 Operator Enclosure

5. Have an assistant support wiper motor from inside

cab.
Remove cap screw (5) and washer securing wiper
motor frame to cab. Remove nut (7) and washer on
wiper shaft (6).

TX1025744A —UN—29JUN07
5— Cap Screw 7— Nut
6— Wiper Shaft

AC12469,00003AC ­19­30JUL07­2/3

6. Disconnect electrical connection (9)

7. Remove wiper motor (10) and wiper motor frame (8).
8. Inspect and replace parts as necessary.
9. Have an assistant position wiper motor inside cab.
Install cap screw (5) and washer and nut (7) and
washer securing wiper motor to cab.
10. Connect electrical connection.
11. Install wiper arm and connect washer fluid hose.
Tighten nut to specification.
Specification

TX1025743A —UN—29JUN07
Wiper Retaining
Nut­to­Pivot—Torque............................................................. 14—21 N∙m
124—186 lb­in.

12. Install trim panel.

13. Install switch panel and connect electrical connections.
14. Install trim caps over screws securing trim panel to
cab.
15. Check windshield wiper position. See Windshield 8— Wiper Motor Frame 10— Wiper Motor
9— Electrical Connection
Wiper Adjustment. (Group 1810.)
AC12469,00003AC ­19­30JUL07­3/3

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 Operator Enclosure

Windshield Wiper Adjustment

CAUTION: Keep hands away from linkage when

the motor is in operation. DO NOT adjust park
position when the motor is in operation. Never

T131540B —UN—27MAR01
start a windshield wiper when the blade is
frozen to the windshield or manually stop the
blade when the wiper is operating.

1. If the blade does not park with the tip 63.5 mm (2.50
in.) (1) from the top edge of windshield, adjust the
wiper blade.
Specification Headlight Shown Removed for Illustration Purposes
Blade­to­Top Edge of
Windshield—Distance................................................................ 63.5 mm 1— 63.5 mm (2.50 in.)
2.5 in. Measurement

AC12469,00003AD ­19­10JUL07­1/2

2. Lift wiper arm (3) away from windshield to full

extended position.
3. Lift pivot cover (1) and return wiper arm to windshield.
4. Remove retaining nut (2).

T131542B —UN—09JUN00
5. Pull wiper arm from pivot shaft. Position to
specification and tighten retaining nut just until snug
against wiper arm.
6. Start wiper motor, shut off and note the new park
position.
7. If blade tip still does not park the specified distance
from top edge of windshield, check for bent wiper arm. Headlight Shown Removed for Illustration Purposes

If wiper arm is not bent, repeat adjustment procedure.

1— Pivot Cover 3— Wiper Arm
8. Tighten retaining nut (2) to specification. 2— Retaining Nut

Specification
Wiper Retaining
Nut­to­Pivot—Torque............................................................. 14—21 N∙m
124—186 lb­in. 9. Close pivot cover (1).
AC12469,00003AD ­19­10JUL07­2/2

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 Operator Enclosure

TM11813 (13OCT10) 18­1810­10 748H Repair (S.N. 630436— )

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PN=228
 Group 1821
Seat and Seat Belt

Seat Remove and Install

1. Disconnect electrical connection for air suspension.
2. Remove cap screws (1) securing vent (2) under seat.

TX1025165A —UN—21JUN07
1— Cap Screw (2 used) 2— Vent

AC12469,00003B2 ­19­11JUL07­1/2

3. Lift floor mat (6) out of the way and remove vent from
under seat.
4. Remove cap screws (5) securing seat bracket (4) to
cab floor.

TX1025166A —UN—21JUN07
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.

5. Remove seat from cab.

Specification
Seat—Weight
(approximate).................................................................................. 71 kg
156 lb

6. Inspect and repair parts as necessary. See Seat 3— Vent Inlet 5— Cap Screw (4 used)
Disassemble and Assemble. (Group 1821.) 4— Seat Bracket 6— Floor Mat

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device. 9. Install vent under seat. Align vent with vent inlet (3)
before installing cap screws.
7. Install seat in cab. NOTE: Do not install mat on top of transmission
Specification calibration connections or air seat wiring.
Seat—Weight
(approximate).................................................................................. 71 kg 10. Install floor mat.
156 lb
11. Connect air seat wiring.
8. Install cap screws securing seat bracket to cab floor.
AC12469,00003B2 ­19­11JUL07­2/2

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 Seat and Seat Belt

Seat Disassemble and Assemble 2. Determine which part of seat needs service. Seat can
1. Remove seat from machine. See Seat Remove and be broken down into individual sections and serviced
Install. (Group 1821.) independently.

4 3

3
5
2

5
3 3
6
3
6
8
6
7
9
6
10

11

12

13

3
TX1025108 —UN—18JUL07

TX1025108
Continued on next page AC12469,00003B3 ­19­19JUN07­1/6

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 Seat and Seat Belt

1— Plate 5— Limiting Strap 9— Air Spring 13— Plate

2— Wiring Harness 6— Bearing 10— Air Hose
3— Pivot Shaft 7— Dampener 11— Boot Hardware
4— Compressor 8— Air Seat Frame 12— Boot

3. Disassemble and assemble air suspension. If air lines

are disconnected, check all connections for leaks with
soapy water.
Continued on next page AC12469,00003B3 ­19­19JUN07­2/6

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 Seat and Seat Belt

14

15

28

17

18

19

20

21
TX1025111 —UN—18JUL07

22
23

TX1025111
14— Plate 17— Ball (24 used) 20— Nut (5 used) 23— Cap Screw (5 used)
15— Swivel Plate 18— Spacer 21— Plate
16— Slider 19— Swivel Plate 22— Washer (5 used)

Continued on next page AC12469,00003B3 ­19­19JUN07­3/6

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 Seat and Seat Belt

4. Disassemble and assemble swivel mechanism.

Lubricate rotating parts with light grease.
Continued on next page AC12469,00003B3 ­19­19JUN07­4/6

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 Seat and Seat Belt

25
25
24

25

25

26

27

28

29

30

31
31
34

31
32
33
32
TX1025110 —UN—18JUL07

31
32
33
33

TX1025110
24— Cushion 27— Seat Frame 30— Cushion 33— Cap Screw (4 used)
25— Clip (4 used) 28— Arm Rest 31— Cap Screw (4 used) 34— Riser
26— Pan 29— Air Suspension 32— Washer (4 used)

Continued on next page AC12469,00003B3 ­19­19JUN07­5/6

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 Seat and Seat Belt

5. Disassemble and assemble seat pads.

AC12469,00003B3 ­19­19JUN07­6/6

Seat Belt Remove and Install

T114924 —UN—29APR98
A—Cap Screw (2 used) B—Washer (4 used) C—Seat Belt Assembly

1. Remove covers to gain access to cap screws.

Specification
Remove cap screws.
Seat Belt Cap
2. Inspect and replace parts as necessary. Screw—Torque.......................................... Until retractor is slightly snug,
retractor can rotate 10° either direction
3. Install cap screw (A) with washers (B) through seat
belt and another washer (B) on right and left sides.
4. Tighten bolt until retractor is slightly snug, but retractor
can still be rotated about ten degrees in either
direction.
AC12469,00003B4 ­19­18JUN07­1/1

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 Seat and Seat Belt

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 Group 1830
Heating and Air Conditioning

R134a Refrigerant Cautions and Proper Handling

CAUTION: DO NOT allow liquid refrigerant to IMPORTANT: To meet government standards relating
contact eyes or skin. Liquid refrigerant will to the use of refrigerants, R134a is used in
freeze eyes or skin on contact. Wear goggles, the air conditioning system. Because it does
gloves, and protective clothing. not contain chlorine, R134a is not detrimental
to the ozone in the atmosphere. However,
If liquid refrigerant contacts eyes or skin, DO it is illegal to discharge any refrigerant into
NOT rub the area. Splash large amounts of the atmosphere. It must be recovered using
COOL water on affected area. Go to a physician the appropriate recovery stations.
or hospital immediately for treatment.
Use correct refrigerant recovery/recycling and
DO NOT allow refrigerant to contact open charging stations. Never mix refrigerants,
flames or very hot surfaces such as electric hoses, fittings, components, or refrigerant oils.
welding arc, electric heating element, and
lighted smoking materials. IMPORTANT: Use only John Deere approved R134a
DO NOT heat refrigerant over 52°C (125°F) in a refrigerant products. Mixing of products not
closed container. Heated refrigerant will develop compatible will cause system damage and
high pressure which can burst the container. contaminate recovery/recycling and charging
station equipment. Care must be taken to
Keep refrigerant containers away from heat identify and use equipment, refrigerant oil, and
sources. Store refrigerant in a cool place. refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for
DO NOT handle damp refrigerant container type and purity before recovery, recycling, or
with your bare hands. Skin may freeze to charging of system. JT02167A refrigerant test
container. Wear gloves. instrument should be used before any testing
If skin freezes to container, pour COOL water or repair to system is performed.
over container to free the skin. Go to a physician
or hospital immediately for treatment.
SW03989,0000A7F ­19­21SEP10­1/2

Prism Pro Refrigerant Identification Instrument.. JT02167A To safely identify type and check purity of refrigerant prior
to recovery, recycling and recharging of A/C systems.
SW03989,0000A7F ­19­21SEP10­2/2

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PN=237
 Heating and Air Conditioning

Air Conditioning System Flush and Purge

CAUTION: Liquid refrigerant will freeze eyes or Specification

skin on contact. Wear goggles, gloves, and Flushing Solvent in
protective clothing. See R134a Refrigerant Suction Port—Volume.................................................................. 240 mL
Cautions and Proper Handling. (Group 1830.) 8 fl oz.
Flushing Solvent
NOTE: Flushing can be performed on machine. in Discharge
Port—Volume............................................................................... 120 mL
1. Follow refrigerant cautions and proper handling 4 fl oz.
procedures. See R134a Refrigerant Cautions and
d. Turn compressor end for end and roll it side to side.
Proper Handling. (Group 1830.)
e. Remove both plugs from manifold ports and drain
2. Recover refrigerant. See R134a Refrigerant Recovery.
solvent from compressor.
(Group 1830.)
f. Connect battery power to compressor clutch coil.
3. Add TY25601 ACCFlushII to system with JT02075 Air
Rotate pulley at least 5 revolutions to move solvent
Conditioning Flusher and JT02098 Air Conditioning
out of cylinders.
Fitting Kit.
g. Invert compressor. Roll end for end and side to
4. Remove and discard receiver­dryer. See
side. Drain thoroughly.
Receiver­Dryer Remove and Install. (Group 1830.)
h. Repeat previous two steps at least three times.
5. Connect flusher outlet hose to inlet end of compressor
discharge line using JT02102 Adapter. 10. Divide system into two circuits:
6. Fill flusher tank with 4 L (1 gal) of solvent and fasten • Condenser circuit, including inlet and outlet hoses.
all connections. • Evaporator circuit, including inlet and outlet hoses.
Specification IMPORTANT: DO NOT attempt to flush through
A/C Flusher compressor or receiver­dryer. Flushing through
Tank—Capacity................................................................................... 4 L expansion valve is acceptable if refrigerant oil
1 gal has a normal odor and appearance.
NOTE: Air pressure must be at least 620 kPa (6.2
bar) (90 psi) for flushing and purging. 11. Flush and purge condenser:
Specification a. Remove and discard receiver­dryer.
A/C Flusher Tank
b. Connect flusher outlet hose to inlet end of
Minimum Air Pressure
compressor discharge line using JT02102 Adapter.
for Flushing and
Purging—Pressure...................................................................... 620 kPa c. Fill flusher tank with 4 L (1 gal) of solvent and fasten
6.2 bar all connections.
90 psi
Specification
A/C Flusher
7. Connect a supply line of moisture­free compressed air
Tank—Capacity................................................................................... 4 L
or dry nitrogen to flusher air valve.
1 gal
8. Open air valve to force flushing solvent into condenser
circuit. Flusher tank is empty when hose pulsing stops. NOTE: Air pressure must be at least 620 kPa (6.2
Additional flushing cycles are required if system is bar) (90 psi) for flushing and purging.
heavily contaminated with burned oil or metal particles. Specification
A/C Flusher Tank
9. Clean compressor as follows: Minimum Pressure
a. Remove compressor and measure oil drained from Air Pressure When
both manifold ports. Flushing—Pressure..................................................................... 620 kPa
6.2 bar
b. Connect flusher outlet hose to inlet end of 90 psi
compressor discharge line using JT02102 Adapter.
d. Connect a supply line of moisture­free compressed
c. Pour 240 mL (8 fl oz.) of flushing solvent into
air or dry nitrogen to flusher air valve.
suction port and 120 mL (4 fl oz.) into discharge
port. Plug both ports in compressor manifold, using
JT02099 Adapter and JT03194 Caps.

Continued on next page SW03989,0000A80 ­19­05OCT10­1/2

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 Heating and Air Conditioning

e. Open air valve to force flushing solvent into NOTE: Air pressure must be at least 620 kPa (6.2
condenser circuit. Flusher tank is empty when bar) (90 psi) for flushing and purging.
hose pulsing stops. Additional flushing cycles are
Specification
required if system is heavily contaminated with
A/C Flusher Tank
burned oil or metal particles.
Minimum Pressure
f. Attach a return hose and aerator nozzle to end of Air Pressure When
receiver dryer inlet hose using JT03197 Adapter. Flushing—Pressure..................................................................... 620 kPa
Put nozzle in container to collect flushing solvent. 6.2 bar
90 psi
NOTE: Purging the condenser circuit takes 10—12
minutes to thoroughly remove solvent. c. Connect a supply line of moisture­free compressed
air or dry nitrogen to flusher air valve.
g. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of d. Attach a hose and aerator nozzle to compressor
cardboard; continue purging until cardboard is dry. inlet line using JT02101 Adapter. Put nozzle in a
container to collect solvent.
12. See flush evaporator if evaporator requires flushing.
NOTE: Purging evaporator circuit takes 12—15 minutes
If system is contaminated with burned refrigerant oil to thoroughly remove solvent.
or debris, remove and bench flush evaporator. See
following steps to flush evaporator through expansion 15. Disconnect hose from aeration nozzle to check circuit
valve, if oil appears normal. for solvent. Hold hose close to a piece of cardboard
13. Flush evaporator: and continue purging until cardboard is dry.

a. Remove evaporator. See Evaporator Remove and 16. Install new receiver­dryer. See Receiver­Dryer
Install. (Group 1830.) Remove and Install. (Group 1830.)

b. Force flushing solvent through evaporator inlet with 17. Add required oil. See R134a Refrigerant Oil
compressed air. Information in this group.

c. Purge system until dry. 18. Install compressor and connect refrigerant lines
to compressor manifold. See Air Conditioner
d. Install evaporator and then go to step 14. Compressor Remove and Install. (Group 1830.)
14. Flush evaporator through expansion valve: 19. Evacuate air conditioning system. See R134a System
Evacuate. (Group 1830.)
a. Connect flusher outlet hose to connection of
receiver­dryer outlet hose using JT03188 Adapter. 20. Charge air conditioning system. See R134a System
Charge. (Group 1830.)
b. Fill flusher tank with 4 L (1 gal) of solvent and fasten
all connections.
Specification
A/C Flusher
Tank—Capacity................................................................................... 4 L
1 gal
SW03989,0000A80 ­19­05OCT10­2/2

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 Heating and Air Conditioning

R134a Refrigerant Oil Information

CAUTION: All new compressors are charged 2. When complete system was not flushed add correct
with a mixture of nitrogen, R134a refrigerant, amount of oil for compressor plus amount of oil for
and TY22101 (R134a) refrigerant oil. Wear each component that was serviced.
safety goggles and discharge the compressor
slowly to avoid possible injury. • New compressor or remanufactured
Specification
New Compressor
CAUTION: DO NOT leave system or R134a
Operating Oil
compressor oil containers open. Refrigerant oil
Level—Volume (drain
easily absorbs moisture. DO NOT spill R134a
and return)...................................................................................... 45 mL
compressor oil on acrylic or ABS plastic. This oil
1.5 fl oz.
will deteriorate these materials rapidly. Identify
R134a oil containers and measures to eliminate • Used compressor removed from operation and oil
accidental mixing of different oils. drained.
Specification
IMPORTANT: Do not add any more oil than required Used Compressor
or maximum cooling will be reduced. Drained Oil—Volume...................................................................... 45 mL
1.5 fl oz.
A new compressor from parts depot contains 220—240
mL (7.0—8.4 fl. oz.) of new oil. Oil level visible through • Used compressor removed from operation
suction port normally is below drive shaft. Specification
Normal operating oil level of a compressor removed from Used Compressor
operation is 30—45 mL (1.0—1.5 fl oz.). This level cannot Flushed Oil—Volume...................................................................... 60 mL
be seen through suction port of compressor. 2.0 fl oz.

Compressors can be divided into three categories when • Components listed below which have been removed,
drained, and flushed, require removal of compressor
determining correct oil charge for system.
to determine correct oil charge. Use following chart
• New compressor from parts depot as a guide for adding oil to components:
• Used compressor removed from operation Specification
• Compressor internally washed with flushing solvent Evaporator Oil—Volume............................................................... 130 mL
Determining the amount of system oil charge prior to 4.4 fl oz.
installation of compressor on a machine. Condenser Oil—Volume................................................................. 65 mL
2.2 fl oz.
1. When complete system, lines, and components are Receiver Dryer
flushed, add correct amount of oil as described. Oil—Volume................................................................................... 30 mL
1.0 fl oz.
• New or remanufactured compressor (system Flushed Compressor
requires an additional amount of new oil) Oil—Volume................................................................................... 60 mL
Specification 2.0 fl oz.
New Compressor—Vol­ Hose Oil—Volume
ume.....................................................................................210—250 mL (approximate total
7.0—8.4 fl oz. length)............................................................................. 3 mL per 30 cm
Air Conditioning System 0.1 fl oz. per ft
Additional Oil— Volume................................................................ 182 mL
4.0 fl oz.
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz. per ft)
Compressor Operating
Approximate total length equals 600 cm (20 ft).
Oil Level—Volume...................................................................30—45 mL
1.0—1.5 fl oz. • If any section of hose is removed and flushed or
replaced, measure length of hose and use formula 3
• Used compressor removed from operation, oil mL per 30 cm (0.1 fl oz. per ft) to determine correct
drained, and system flushed amount of oil to be added.
Specification • Drain compressor oil into graduated container while
Used Compressor rotating compressor shaft and record amount.
and System Flushed 3. If oil drained from a compressor removed from
Oil—Volume........................................................................391—479 mL operation is very black or amount of oil is less than
13.2—16.2 fl oz. 6 mL (0.2 fl oz.), perform the following and discard
oil properly:
Continued on next page SW03989,0000A81 ­19­10SEP10­1/2

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 Heating and Air Conditioning

• Determine if R134a leakage was detected, remove 6. Install required amount of TY22101 Refrigerant Oil
component, and repair or replace component. in compressor.
• Remove and discard receiver­dryer.
7. Connect all components.
• Flush complete system with TY25601 Air
Conditioning Flushing Solvent. 8. Evacuate and charge system. See R134a System
4. If component is serviceable, pour flushing solvent in Evacuate and R134a System Charge. (Group 1830.)
ports and internally wash out old oil and discard oil
properly.
5. Install a new receiver­dryer. See Receiver­Dryer
Remove and Install. (Group 1830.)
SW03989,0000A81 ­19­10SEP10­2/2

R134a Refrigerant Recovery/Recycling and

Charging Station Installation Procedure

CAUTION: Liquid refrigerant will freeze eyes

or skin on contact. Wear goggles, gloves and
protective clothing. See R134a Refrigerant
Cautions and Proper Handling. (Group 1830.)

IMPORTANT: Use only John Deere approved R134a

refrigerant products. Mixing of products not
compatible will cause system damage and
contaminate recovery/recycling and charging
station equipment. Care must be taken to
identify and use equipment, refrigerant oil, and
refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type
and purity before recovery/recycling or charging
of system. JT02167A Prism Pro Refrigerant
Identification Instrument should be used before

TX1080093 —UN—22JUL10
any testing or repair to system is performed.

IMPORTANT: Use only John Deere approved

refrigerant recovery/recycling and charging
stations. DO NOT mix refrigerant, hoses,
fittings, components, or refrigerant oils.

Refrigerant Recovery/Recycling and Charging Station Installation

CAUTION: Do not remove high pressure relief
valve (4). Air conditioning station will discharge
rapidly causing possible injury. 1— Cap 4— High Pressure Relief Valve
2— Red Hose 5— Refrigerant Recovery/Recy­
3— Blue Hose cling and Charging Station
1. Follow refrigerant cautions and proper handling
procedures. See R134a Refrigerant Cautions and
Proper Handling. (Group 1830.)
4. Remove cap (1) from high pressure charge port and
2. Close both high­side and low­side valves on refrigerant connect red hose (2).
recovery/recycling and charging station (5).
5. Follow the manufacturer’s instructions when using the
3. Remove cap from low pressure charge port refrigerant recovery/recycling and charging station.
and connect blue hose (3) from refrigerant
recovery/recycling and charging station.
SW03989,0000A82 ­19­04OCT10­1/1

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 Heating and Air Conditioning

R134a Refrigerant Recovery 1. Follow refrigerant cautions and proper handling

procedures. See R134a Refrigerant Cautions and
CAUTION: Liquid refrigerant will freeze eyes Proper Handling. (Group 1830.)
or skin on contact. Wear goggles, gloves,
and protective clothing. 2. Run air conditioning system for 3 minutes to help in
recovery process. Turn air conditioning system off
Do not remove high pressure relief valve. Air before proceeding with recovery steps.
conditioning system will discharge rapidly
causing possible injury. 3. With engine OFF, identify refrigerant type using
JT02167A Refrigerant Identification Instrument.
IMPORTANT: Use correct refrigerant recovery/re­ 4. Connect refrigerant recovery system. See R134a
cycling and charging stations. Do not mix Refrigerant Recovery/Recycling and Charging Station
refrigerant, hoses, fittings, components, or Installation Procedure. (Group 1830.)
refrigerant oils. Damage to air conditioning
system components may occur. 5. Follow manufacturer’s instructions when using the
refrigerant recovery/recycling and charging station.
SW03989,0000A83 ­19­10SEP10­1/1

R134a System Evacuate

Value to Subtract for
CAUTION: Liquid refrigerant will freeze eyes Elevation Above Sea
or skin on contact. Wear goggles, gloves, Level—Vacuum.....................Subtract 3.4 kPa (34 mbar) (1 in. Hg) from
and protective clothing. 98 kPa (980 mbar) (29 in. Hg) for each 300 m
Do not remove high pressure relief valve. Air (1000 ft) elevation above sea level
conditioning system will discharge rapidly If the specified vacuum reading cannot be obtained
causing possible injury. in 15 minutes, check the system for leaks. See
Refrigerant Leak Test. (Group 9031­25.)
1. Follow refrigerant cautions and proper handling
procedures. See R134a Refrigerant Cautions and 6. When vacuum reaches above specification, close
Proper Handling. (Group 1830.) low­side and high­side valves. Turn vacuum pump off.
2. Connect refrigerant recovery system. See R134a 7. If vacuum decreases more than specification in 5
Refrigerant Recovery/Recycling and Charging Station minutes, there is a leak in system.
Installation Procedure. (Group 1830.)
Specification
3. Open low­side and high­side valves on refrigerant Evacuate
recovery/recycling and charging station. System—Vacuum......................................................................... 3.4 kPa
34 mbar
4. Follow charging station manufacturers’ instructions 1 in. Hg
to evacuate system.
8. Repair the leak.
NOTE: Vacuum specifications listed are for sea level
conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) 9. Evacuate system for 30 minutes after 98 kPa (980
from 98 kPa (980 mbar) (29 in. Hg) for each 300 mbar) (29 in. Hg) vacuum is reached.
m (1000 ft) elevation above sea level. Specification
Evacuation
5. Evacuate system until low­side gauge vacuum reading Procedure—Time....................................................................30 minutes
is to specification.
10. Close low­side and high­side valves. Stop evacuation.
Specification
Evacuate 11. Charge air conditioning system. See R134a System
System—Vacuum.......................................................................... 98 kPa Charge. (Group 1830.)
980 mbar
29 in. Hg
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 Heating and Air Conditioning

R134a System Charge

CAUTION: Liquid refrigerant will freeze eyes NOTE: Before beginning to charge air conditioning
or skin on contact. Wear goggles, gloves, system, the following conditions must exist: Engine
and protective clothing. STOPPED, pump must be capable of pulling at least
28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34
IMPORTANT: Use only John Deere approved mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg)
refrigerant recovery/recycling and charging for each 300 m (1000 ft) elevation above sea level.
stations. DO NOT mix refrigerant, hoses, Specification
fittings, components, or refrigerant oils. Evacuate
Damage to seals may occur resulting in air System—Vacuum..................Subtract 3.4 kPa (34 mbar) (1 in. Hg) from
conditioning system leaks. 98 kPa (980 mbar) (29 in. Hg) for each 300 m
(1000 ft) elevation above sea level
1. Follow refrigerant cautions and proper handling
procedures. See R134a Refrigerant Cautions and 5. Follow manufacturer’s instructions and charge system.
Proper Handling. (Group 1830.)
6. Add refrigerant to system.
2. Identify refrigerant type using JT02167A Prism Pro
Refrigerant Identification Instrument. Specification
Air Conditioning System
3. Connect R134a Refrigerant Recovery/Recycling Refrigerant—Refrigerant
and Charging Station. See R134a Refrigerant Quantity........................................................................................ 3.17 kg
Recovery/Recycling and Charging Station Installation 7.00 lb
Procedure. (Group 1830.)
7. Check air conditioning for proper function. See
4. Evacuate system. See R134a System Evacuate. Complete Machine Operational Checkout. (Group
(Group 1830.) 9005­10.)
SW03989,0000A85 ­19­04OCT10­1/1

Compressor Relief Valve Remove and Install

CAUTION: DO NOT allow liquid refrigerant to

contact eyes or skin. DO NOT spill R134a
compressor oil on acrylic or ABS plastic. High

TX1024235A —UN—29MAY07
pressure may exist at the discharge fitting. If this
pressure is released too rapidly, there may be
considerable discharge of refrigerant and oil.

1. Remove front left engine shield.

2. Recover refrigerant. See R134a Refrigerant Recovery.
(Group 1830.)
Relief Valve
3. Slowly remove relief valve (1) from air conditioner
compressor manifold (2).
1— Relief Valve 2— Air Conditioner
NOTE: The relief valve is not serviceable. Replace Compressor Manifold
valve as required.

4. Inspect and replace as necessary.

6. Charge air conditioning system. See R134a System
5. Install relief valve and tighten to specification. Charge. (Group 1830.)
Specification 7. Install engine side shield.
Relief Valve—Torque............................................................. 12—16 N∙m
103—142 lb­in.
SW03989,0000A86 ­19­21SEP10­1/1

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 Heating and Air Conditioning

Air Conditioner Compressor Remove and

Install
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)

TX1024210A —UN—29MAY07
2. Locate air conditioner compressor at front left side
of engine. Remove left­side engine shields. See
Opening Engine Side Shields. (Operator’s Manual.)
3. Remove left fan guard. See Fan Shroud Remove and
Install. (Group 0510.)
4. Recover air conditioner refrigerant. See R134a
Refrigerant Recovery. (Group 1830.) Air Conditioner Compressor

5. Remove serpentine belt. See Serpentine Belt Remove

and Install. (Group 0510.) 3— Cap Screw (3 used) 6— Air Conditioner Refrigerant
4— Air Conditioner Pressure Hose to
6. Disconnect air conditioner refrigerant hoses (5 and Compressor Condenser
6) at compressor. Close all openings using caps and 5— Air Conditioner Refrigerant 7— Electrical Connector
Suction Hose 8— Ground Wire
plugs.
7. Disconnect electrical connector and ground wire (7
and 8). Pressure Hose­to­
Condenser—Torque.............................................................. 20—27 N∙m
8. Remove cap screws (3) and air conditioner 177—239 lb­in.
compressor (4).
9. Inspect and replace as necessary.
15. Install new receiver­dryer. See Receiver­Dryer
10. Install air conditioner compressor. Remove and Install. (Group 1830.)
11. Add compressor oil. See R134a Refrigerant Oil 16. Evacuate and charge the air conditioning system.
Information. (Group 1830.) See R134a System Evacuate and see R134a System
Charge. (Group 1830.)
12. Install serpentine belt. See Serpentine Belt Remove
and Install. (Group 0510.) 17. Install left fan guard. See Fan Shroud Remove and
Install. (Group 0510.)
13. Connect electrical connector and ground wire.
18. Install left­side engine shields. See Opening Engine
IMPORTANT: Always use new O­rings and seals.
Side Shields. (Operator’s Manual.)
Damaged or used O­rings and seals will leak.
19. Before returning machine to service, check operation
14. Connect air conditioner refrigerant hoses at of air conditioning system. See Complete Machine
compressor. Tighten hoses to specification. Operational Checkout. (Group 9005.)
Specification
Suction Hose­to­
Compressor—Torque............................................................ 24—28 N∙m
212—248 lb­in.
SW03989,0000A88 ­19­05OCT10­1/1

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 Heating and Air Conditioning

Air Conditioner Compressor Clutch Remove

and Install
1. Remove compressor (3) from machine. See Air
Conditioner Compressor Remove and Install. (Group
1830.)
2. Install compressor on DFRW20 Compressor Holding
Fixture using two 6 in. x 1/4 in. eyebolts and nuts as
illustrated. See DFRW20 Compressor Holding Fixture.
(Group 9900.)
3. Remove cap screws (12).
4. Remove dust cover (11).

TX1008957 —UN—17JUL06
5. Hold clutch hub (9) using JDG747 Compressor Clutch
Spanner (A) to remove clutch hub­to­shaft cap screw
(10).
6. Remove clutch hub. Remove washers (4, 13, and 14)
from clutch hub and save for installation.
7. Remove and discard ring (8).
Compressor Clutch Components
8. Remove pulley (7) using a 3­jaw puller or a V­belt
pulley pulling attachment.
9. Remove the screw for the ground wire (1) and clamp
for clutch coil wire (2).
10. Remove and discard snap ring (6).
11. Remove clutch coil (5).
12. Repair or replace parts as necessary.
13. Install clutch coil.
14. Install new snap ring, flat side toward coil.
15. Connect clutch coil wire.

TX1056811A —UN—06MAR09
16. Connect ground wire.
17. Install pulley.
18. Install new ring, flat side toward pulley.
19. Apply grease to washers. Install in clutch hub.
20. Install clutch hub.
JDG747 Compressor Clutch Spanner
21. Install clutch hub­to­shaft cap screw. Tighten to
specification. 1— Ground Wire 9— Clutch Hub
Specification 2— Clutch Coil Wire 10— Clutch Hub­to­Shaft Cap
3— Compressor Screw
Clutch Hub­to­Shaft
4— Washer 11— Dust Cover
Bolt—Torque..................................................................................14 N∙m 5— Clutch Coil 12— Cap Screw (6 used)
120 lb­in. 6— Snap Ring 13— Washer
7— Pulley 14— Washer
8— Ring A—JDG747 Compressor
Clutch Spanner

Continued on next page SW03989,0000A89 ­19­10SEP10­1/2

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 Heating and Air Conditioning

NOTE: The clutch coil is NOT polarity sensitive.

22. Check pulley­to­clutch hub clearance using a dial

indicator as illustrated. Connect a set of jumper wires
from the compressor to a 12V supply to engage clutch.
Check clearance at three equally spaced locations
around the clutch hub. Add or remove washers as
required.
Specification
Pulley­to­Clutch
Hub—Clearance...............................................................0.35—0.65 mm
0.014—0.026 in.

23. Install dust cover.

24. Install compressor. See Air Conditioner Compressor
Remove and Install. (Group 1830.)
25. Evacuate and charge air conditioning system. Perform
R134a System Evacuate and perform R134a System
Charge. (Group 1830.)

TX1009690A —UN—18JUL06
Pulley­to­Clutch Hub Clearance

SW03989,0000A89 ­19­10SEP10­2/2

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 Heating and Air Conditioning

Air Conditioner Compressor Manifold

Remove and Install
1. Remove left­side engine shields. Locate air
conditioner compressor at front left side of engine.
2. Recover air conditioning refrigerant. See R134a
Refrigerant Recovery. (Group 1830.)
3. Remove cap screws (2) and the manifold (1).
4. Remove and discard manifold seal (3).
5. Inspect surfaces.
6. Lubricate and install a new seal.

TX1081767A —UN—10SEP10
7. Install manifold and tighten cap screws to specification.
Specification
Cap Screw—Torque......................................................................26 N∙m
230 lb­in.

8. Evacuate and charge the air conditioning system.

See R134a System Evacuate and see R134a System
Charge. (Group 1830.) Compressor Manifold

9. Install left fan guard. See Fan Shroud Remove and

Install. (Group 0510.) 1— Cap Screw 3— Manifold Seal
2— Manifold
10. Install left­side engine shields.
11. Before returning machine to service, check operation
of air conditioning system. See Complete Machine
Operational Checkout. (Group 9005.)
SW03989,0000A8A ­19­05OCT10­1/1

Air Conditioner Condenser Remove and

Install
1. Open grille. See Opening the Grille. (Operator’s
Manual.)

TX1024662A —UN—06JUN07
2. Follow refrigerant cautions and proper handling
procedures. See R134a Refrigerant Cautions and
Proper Handling. (Group 1830.)
3. Recover air conditioner refrigerant. See R134a
Refrigerant Recovery. (Group 1830.)
4. Remove nuts (1) and swing open air conditioner
condenser. Air Conditioner Condenser

1— Nut (2 used) 2— Air Conditioner Condenser

Continued on next page SW03989,0000A8B ­19­10SEP10­1/2

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 Heating and Air Conditioning

5. Disconnect air conditioner refrigerant hose fittings (3).

Close all openings using caps and plugs.
6. Remove nuts (4) and air conditioner condenser (2).
7. Inspect and replace as necessary.

TX1024661A —UN—06JUN07
8. Install air conditioner condenser and tighten nuts to
specification.
Specification
Air Conditioner
Condenser
Nuts—Torque................................................................................73 N∙m
54 lb­ft
Air Conditioner Condenser
IMPORTANT: Always use new O­rings and seals.
Damaged or used O­rings and seals will leak.
2— Air Conditioner Condenser 4— Nut (4 used)
3— Air Conditioner Refrigerant
9. Connect air conditioner refrigerant hoses. Tighten Hose Fitting (2 used)
hose fittings to specification.
Specification
Air Conditioner 10. Swing close air conditioner condenser and secure
Condenser Inlet Hose with nuts.
Fitting (upper)—Torque.................................................................24 N∙m
212 lb­in. 11. Evacuate and charge the air conditioning system.
Air Conditioner See R134a System Evacuate and see R134a System
Condenser Outlet Hose Charge. (Group 1830.)
Fitting (lower)—Torque..................................................................17 N∙m
150 lb­in.
SW03989,0000A8B ­19­10SEP10­2/2

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 Heating and Air Conditioning

Blower Motor Remove and Install

1. Remove cap screws (3) and HVAC compartment
cover (1).
2. Disconnect wiring harness from blower motor
connector (6) and blower resistor (7).

TX1080212A —UN—28JUL10
3. Remove cap screws (5) from HVAC fuse and relay
panel (4).
4. Disconnect cooling hose (9) from blower motor (10).
5. Remove cap screws (8) and blower motor.
6. Inspect and repair as necessary.
7. Install blower motor and cap screws. HVAC and Precleaner Compartment Covers

8. Connect cooling hose to blower motor.

9. Connect wiring harness to blower resistor and blower
motor connector.
10. Install HVAC fuse and relay panel.

TX1080227A —UN—28JUL10
11. Close and secure HVAC compartment cover.

1— HVAC Compartment Cover 6— Blower Motor Connector

2— Precleaner Compartment 7— Blower Resistor
Cover 8— Cap Screw (4 used)
3— Cap Screw (6 used) 9— Cooling Hose
4— HVAC Fuse and Relay Panel 10— Blower Motor
5— Cap Screw (2 used) Heating and Air Conditioning Blower Motor

SW03989,0000A8E ­19­10SEP10­1/1

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101310

PN=249
 Heating and Air Conditioning

Precleaner Blower Assembly Remove and

Install
1. Remove cap screws (3) and open precleaner
compartment cover (2).
2. Release hold­downs (4) and remove precleaner cover

TX1080212A —UN—28JUL10
(5).
3. Disconnect wiring harness from precleaner blower
motor connector (6).
4. Remove cap screws (8) and precleaner blower motor
(7).
5. Inspect and repair as necessary.
HVAC and Precleaner Compartment Covers
6. Install precleaner blower motor.
7. Connect wiring harness to precleaner blower motor
connector.
8. Install precleaner cover and secure with hold­downs.

TX1080232A —UN—28JUL10
9. Close and secure precleaner compartment cover.

1— HVAC Compartment Cover 5— Precleaner Cover

2— Precleaner Compartment 6— Precleaner Blower Motor
Cover Connector
3— Cap Screw (6 used) 7— Precleaner Blower Motor
4— Hold­Down (2 used) 8— Cap Screw (4 used)

Precleaner Blower Assembly

SW03989,0000A94 ­19­10SEP10­1/1

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101310

PN=250
 Heating and Air Conditioning

Refrigerant High/Low Pressure Switch Remove and Install

1. Remove cap screws (3) and HVAC compartment
cover (1).
NOTE: It is not necessary to recover refrigerant
from the system. A valve prevents the
system from discharging when high/low
pressure switch is removed.

TX1080212A —UN—28JUL10
2. Disconnect wiring harness from wire connector (5).
IMPORTANT: Remove pressure switch using a wrench
on hex nut fitting. Damage to switch will occur
if removed by plastic switch housing.

3. Remove high/low pressure switch (4) using a wrench

on hex nut fitting. HVAC and Precleaner Compartment Covers
4. Test switch and replace if necessary. See Air
Conditioning High/Low Pressure Switch Test. (Group
9031­25.)
5. Install high/low pressure switch.

TX1080217A —UN—28JUL10
6. Connect wiring harness to wire connector.
7. Close and secure HVAC compartment cover.

1— HVAC Compartment Cover 4— High/Low Pressure Switch

2— Precleaner Compartment 5— Wire Connector
Cover
3— Cap Screw (6 used)
High/Low Pressure Switch

SW03989,0000A87 ­19­10SEP10­1/1

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101310

PN=251
 Heating and Air Conditioning

Coolant Valve Remove and Install

CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns. Coolant may be hot. Wait until radiator is
cool to the touch before draining radiator.

TX1080212A —UN—28JUL10
1. Drain the coolant system. Perform Draining the
Cooling System. (Operator’s Manual.)
2. Remove cap screws (3) and HVAC compartment
cover (1).
3. Disconnect wire harness connector (5).
4. Move clamps (6) and disconnect coolant hoses. HVAC and Precleaner Compartment Covers
5. Remove cap screws (7) and coolant valve (4).
NOTE: The coolant valve is serviced as an assembly.

6. Inspect and replace as necessary.

7. Install coolant valve with cap screws.
8. Connect coolant hoses and secure with clamps.
9. Connect wire harness connector.

TX1080238A —UN—28JUL10
10. Close HVAC compartment cover.
11. Fill coolant system. Perform Filling the Cooling
System. (Operator’s Manual.)

1— HVAC Compartment Cover 5— Wire Harness Connector

2— Precleaner Compartment 6— Clamp (2 used)
Cover 7— Cap Screw (2 used)
3— Cap Screw (6 used)
4— Coolant Valve Coolant Valve

SW03989,0000A90 ­19­10SEP10­1/1

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PN=252
 Heating and Air Conditioning

Freeze Control Switch Remove and Install

1. Remove cap screws (3) to remove HVAC compartment
cover (1) and open precleaner compartment cover (2).
2. Release hold­downs and remove precleaner cover
and air filter. See Precleaner Blower Assembly
Remove and Install. (Group 1830.)

TX1080212A —UN—28JUL10
3. Remove freeze control switch thermocouple (5) from
evaporator (4).
4. Disconnect electrical connectors (6) from freeze
control switch (7).
5. Remove freeze control switch by guiding freeze control
switch thermocouple (5) back through bulkhead HVAC and Precleaner Compartment Covers
grommet (9).
6. Inspect and replace as necessary.
7. Insert freeze control switch thermocouple through
bulkhead grommet.

TX1080242A —UN—29JUL10
8. Install freeze control switch.
9. Connect electrical connectors.
10. Install freeze control switch thermocouple to
evaporator.
11. Install air filter and precleaner cover using hold­downs.
12. Close HVAC compartment and precleaner Freeze Control Switch Thermocoupler
compartment covers.

1— HVAC Compartment Cover 6— Electrical Connector (2

2— Precleaner Compartment used)
Cover 7— Freeze Control Switch
3— Cap Screw (6 used) 8— Pan Head Screw (2 used)

TX1024652A —UN—06JUN07
4— Evaporator 9— Bulkhead Grommet
5— Freeze Control Switch
Thermocouple

Freeze Control Switch

SW03989,0000A93 ­19­10SEP10­1/1

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PN=253
 Heating and Air Conditioning

Expansion Valve Remove and Install

1. Recover refrigerant from the air conditioning system.
See R134a Refrigerant Recovery. (Group 1830.)
2. Remove HVAC compartment cover (1).
3. Disconnect refrigerant line fittings (4).

TX1080212A —UN—28JUL10
4. Remove cap screw (5) and flange (6) to disconnect
refrigerant lines (7) from expansion valve.
5. Remove cap screws (8) to flange of evaporator.
Remove expansion valve (9).
6. Inspect and replace as necessary.
IMPORTANT: Always use new O­rings and seals. HVAC and Precleaner Compartment Covers
Damaged or used O­rings and seals will leak.

7. Replace O­rings. Install expansion valve to evaporator

using flange and cap screws.
8. Install refrigerant lines and flange to expansion valve.
9. Close HVAC compartment cover.
10. Evacuate and charge the air conditioning system.

TX1080265A —UN—29JUL10
See R134a System Evacuate and see R134a System
Charge. (Group 1830.)

1— HVAC Compartment Cover 6— Flange

2— Precleaner Compartment 7— Refrigerant Line (2 used)
Cover 8— Cap Screw (2 used)
3— Cap Screw (6 used) 9— Expansion Valve
4— Line Fitting (2 used)
5— Cap Screw Refrigerant Lines and Flange

TX1080266A —UN—29JUL10

Expansion Valve

SW03989,0000A8D ­19­10SEP10­1/1

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101310

PN=254
 Heating and Air Conditioning

Heater Core Remove and Install

CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns. Wait until radiator is cool to the
touch before draining radiator.

T131235B —UN—25MAY00
1. Drain the coolant system. Perform Draining the
Cooling System. (Operator’s Manual.)
2. Remove blower motor. See Blower Motor Remove
and Install. (Group 1830.)
3. Remove cap screws (1) and blower housing (3). Blower Housing
4. Disconnect coolant hoses (2) from heater core (8).
5. Remove cap screws (4) and blower mounting plate (5).
6. Remove cap screws (6) and isolator (7).

TX1024560A —UN—05JUN07
7. Remove heater core (8).
8. Inspect and replace as necessary.
9. Install heater core.
10. Install isolator.
11. Install blower mounting plate and cap screws.
12. Connect coolant hoses to heater core. Blower Mounting Plate

13. Install blower housing.

14. Install blower motor. See Blower Motor Remove and
Install. (Group 1830.)
15. Fill the coolaning system. Perform Filling the Cooling

TX1024566A —UN—05JUN07
System. (Operator’s Manual.)

1— Cap Screw (4 used) 5— Blower Mounting Plate

2— Coolant Hose (2 used) 6— Cap Screw (2 used)
3— Blower Housing 7— Isolator
4— Cap Screw (6 used) 8— Heater Core

Heater Core

SW03989,0000A8F ­19­10SEP10­1/1

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101310

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 Heating and Air Conditioning

Evaporator Remove and Install

1. Recover refrigerant from air conditioning system. See
R134a Refrigerant Recovery. (Group 1830.)
2. Remove blower motor. See Blower Motor Remove

TX1024595A —UN—05JUN07
and Install. (Group 1830.)
3. Remove precleaner cover and filter. See Precleaner
Blower Assembly Remove and Install. (Group 1830.)
4. Remove coolant valve. See Coolant Valve Remove
and Install. (Group 1830.)
5. Remove heater core. See Heater Core Remove and
Install. (Group 1830.) Evaporator

6. Remove freeze control switch. See Freeze Control

1— Cap Screw (2 used) 2— Evaporator
Switch Remove and Install. (Group 1830.)
7. Remove cap screws (1).
8. Remove evaporator (2). 14. Install precleaner cover and filter. See Precleaner
Blower Assembly Remove and Install. (Group 1830.)
9. Inspect and replace parts as necessary.
15. Install blower motor. See Blower Motor Remove and
10. Install evaporator. Install. (Group 1830.)
11. Install freeze control switch. See Freeze Control 16. Evacuate and charge the air conditioning system.
Switch Remove and Install. (Group 1830.) See R134a System Evacuate and see R134a System
Charge. (Group 1830.)
12. Install heater core. See Heater Core Remove and
Install. (Group 1830.)
13. Install coolant valve. See Coolant Valve Remove and
Install. (Group 1830.)
SW03989,0000A8C ­19­10SEP10­1/1

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101310

PN=256
 Heating and Air Conditioning

Receiver­Dryer Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Follow refrigerant cautions and proper handling

TX1024542A —UN—05JUN07
procedures. See R134a Refrigerant Cautions and
Proper Handling. (Group 1830.)
3. Recover refrigerant. See R134a Refrigerant Recovery.
(Group 1830.)
4. Open precleaner compartment. See Precleaner
Blower Assembly Remove and Install. (Group 1830.)
5. Disconnect refrigerant lines (1 and 2). Close all Receiver­Dryer
openings using caps and plugs.
1— Refrigerant Line From 3— Receiver­Dryer
6. Loosen clamp cap screws (4) and remove Condenser 4— Clamp Cap Screw (2 used)
receiver­dryer (3). 2— Refrigerant Line to
Expansion Valve
IMPORTANT: A new receiver­dryer must always be
installed after purging system. DO NOT use a
flushed or used receiver­dryer. Contamination
of system can cause component failure. IMPORTANT: Always use new O­rings and seals.
Damaged or used O­rings and seals will leak.
7. Before installing new receiver­dryer, add refrigerant oil.
See R134a Refrigerant Oil Information. (Group 1830.) 9. Lubricate new O­rings with refrigerant oil. Remove
plugs from receiver­dryer and immediately connect
Specification
refrigerant lines.
Refrigerant
Oil—Quantity.................................................................................. 15 mL 10. Evacuate and charge the system. See R134a System
0.5 fl oz Evacuate and see R134a System Charge. (Group
1830.)
8. Install new receiver­dryer and tighten clamp cap
screws.
SW03989,0000A91 ­19­01OCT10­1/1

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PN=257
 Heating and Air Conditioning

TM11813 (13OCT10) 18­1830­22 748H Repair (S.N. 630436— )

101310

PN=258
 Section 19
Sheet Metal and Styling
Contents

Page

Group 1910—Hood or Engine Enclosure

Hood Remove and Install .......................... 19­1910­1
Grille Guard Remove and Install ............... 19­1910­3
Grille Housing Remove and
Install ..................................................... 19­1910­5

TM11813 (13OCT10) 19­1 748H Repair (S.N. 630436— )

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PN=1
 Contents

TM11813 (13OCT10) 19­2 748H Repair (S.N. 630436— )

101310

PN=2
 Group 1910
Hood or Engine Enclosure

Hood Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.

TX1080281A —UN—29JUL10
See Battery Disconnect. (Operator’s Manual.)
3. Remove engine compartment side shields. See
Opening Engine Side Shields. (Operator’s Manual.)
4. Remove muffler­to­turbocharger flex pipe clamp (1).

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device. Muffler­to­Turbocharger Flex Pipe Clamp

5. Remove left limb riser with muffler attached. Close 1— Muffler­to­Turbocharger

turbocharger opening using an appropriate cap or Flex Pipe Clamp
plug.
Specification
Left Limb Riser
6. Remove right side hood panel.
with Muffler—Weight
(approximate).................................................................................. 50 kg
110 lb
MH66088,0000D7C ­19­19AUG10­1/4

7. Remove cap screws (2) securing hydraulic oil return

filter housing (3) to hood (4) and secure to the side.
Hoses remain connected to filter.
8. Remove hydraulic oil return filter electrical harness
clamps from underside of hood.

TX1080303A —UN—29JUL10
2— Cap Screw (4 used) 4— Hood
3— Hydraulic Oil Return Filter
Housing

Hydraulic Oil Return Filter

MH66088,0000D7C ­19­19AUG10­2/4

9. Remove cap screws (5) securing hydraulic fan return

filter housing to hood and secure to the side. Hoses
remain connected to filter.
10. Disconnect air cleaner assembly from hood. See Air
Cleaner Remove and Install. (Group 0520.)
TX1080304A —UN—29JUL10

NOTE: Draining coolant from surge tank is not necessary

for hood removal and installation.

11. Disconnect surge tank from hood, leaving all hoses

attached. Secure to the side.

5— Cap Screw (2 used)

Hydraulic Fan Return Filter Cap Screws

Continued on next page MH66088,0000D7C ­19­19AUG10­3/4

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PN=261
 Hood or Engine Enclosure

12. Install JT01748 Lifting Brackets (6) and lifting device

as shown.
13. Loosen J­bolts (7) and remove hood retaining cap
screws (8).

TX1080308A —UN—29JUL10
NOTE: Make sure hydraulic reservoir filler cap is
installed after removal or installation of hood to
prevent contamination of hydraulic oil.

14. Remove hydraulic tank filler cap.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device. JT01748 Lifting Brackets

15. Attach appropriate lifting device to lifting brackets.

Remove hood. 6— JT01748 Lifting Bracket 8— Hood Retaining Cap Screw
7— J­bolt (2 used) (4 used)
Specification
Hood—Weight
(approximate).................................................................................. 57 kg
125 lb
24. Install hydraulic fan return filter housing.

16. Inspect and replace parts as necessary. 25. Install hydraulic oil return filter.
26. Install hydraulic oil return filter electrical harness
CAUTION: Prevent possible crushing injury from clamps to underside of hood.
heavy component. Use appropriate lifting device.
27. Install right hood panel.
17. Set hood in place.
CAUTION: Prevent possible crushing injury from
Specification
heavy component. Use appropriate lifting device.
Hood—Weight
(approximate).................................................................................. 57 kg
28. Install left limb riser with muffler.
125 lb
Specification
18. Align hood and install hood retaining cap screws. Left Limb Riser
with Muffler—Weight
19. Install hydraulic tank filler cap.
(approximate).................................................................................. 50 kg
20. Remove lifting device and JT01748 Lifting Brackets. 110 lb

21. Install and tighten J­bolts. 29. Install muffler­to­turbocharger flex pipe clamp.
22. Install surge tank. 30. Turn battery disconnect to the ON position.
23. Install air filter assembly. See Air Cleaner Remove 31. Install engine compartment side shields. See Opening
and Install. (Group 0520.) Engine Side Shields. (Operator’s Manual.)
MH66088,0000D7C ­19­19AUG10­4/4

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PN=262
 Hood or Engine Enclosure

Grille Guard Remove and Install

NOTE: The following procedure is for both standard
grille guard and high debris grille guard
removal and installation.

1. Park and prepare machine for service. See Park and

Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
3. Remove cap screws (1) and washers (2). Open grille
guard.

TX1081102A —UN—26AUG10
1— Cap Screw (2 used) 2— Washer (2 used)

Standard Grille Guard Shown

MH66088,0000D90 ­19­14SEP10­1/3

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

4. Support grille guard using lifting straps (3) as shown.

Specification
Standard Grille
Guard—Weight
(approximate).................................................................................. 68 kg
150 lb.
High Debris Grille
Guard—Weight
(approximate).................................................................................. 84 kg
200 lb.

TX1081103A —UN—26AUG10
Remove parts (4—8) and remove grille guard.
5. Inspect and replace as necessary.

3— Lifting Strap (2 used) 6— Washer (2 used)

4— Cap Screw (2 used) 7— Wave Washer (2 used)
5— Nut (2 used) 8— Washer (2 used)

Lifting Straps

Continued on next page MH66088,0000D90 ­19­14SEP10­2/3

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PN=263
 Hood or Engine Enclosure

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

6. Raise grille guard to machine and install parts (4—8)

as shown. Do not tighten cap screws at this time.
7. Remove lifting device and lifting straps from grille
guard.

TX1081104A —UN—26AUG10
8. Close grille guard and adjust for proper alignment.
Tighten cap screws (4) and nuts (5). Open and close
grille guard several times to ensure proper alignment.
9. Close grille guard and install cap screws (1) and
washers (2).
10. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.) Grille Guard Mounting Hardware

4— Cap Screw (2 used) 7— Wave Washer (2 used)

5— Nut (2 used) 8— Washer (2 used)
6— Washer (2 used)

MH66088,0000D90 ­19­14SEP10­3/3

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PN=264
 Hood or Engine Enclosure

Grille Housing Remove and Install 7 9

6
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
5
3. Remove hood. See Hood Remove and Install. (Group
1910.)
3
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device. 4

4. Remove right limb riser.

TX1081428 —UN—01SEP10
1
Specification
Right Limb 2 8
Riser—Weight
(approximate).................................................................................. 39 kg
85 lb.

5. Remove grille guard. See Grille Guard Remove and

Install. (Group 1910.) Fan Assembly

6. Discharge air conditioning system. See R134a

Refrigerant Recovery. (Group 1830.) 1— Fan Motor 6— Fan Shroud
2— Fan Support 7— Cap Screw (2 used)
NOTE: Air conditioner condenser and hydraulic oil 3— Hydraulic Hoses (3 used) 8— Cap Screw (6 used)
4— Fan Blade 9— Grille Housing
cooler share the same mounting bracket on 5— Cap Screw (2 used)
torque converter drive machines and can be
removed as an assembly.

7. Remove air conditioner condenser. See Air

Conditioner Condenser Remove and Install. (Group CAUTION: Prevent possible crushing injury from
1830.) heavy component. Use appropriate lifting device.

8. Remove hydraulic oil cooler. See Hydraulic Oil Cooler 16. Support grille housing (9) using an appropriate lifting
Remove and Install. (Group 0510.) device. Remove cap screws (8) and remove grille
housing.
9. Remove transmission oil cooler. See Transmission Oil
Cooler Remove and Install. (Group 0510.) Specification
Grille Housing—Weight
10. Remove radiator. See Radiator Remove and Install. (approximate)................................................................................ 181 kg
(Group 0510.) 400 lb.

11. Remove aftercooler. See Aftercooler Remove and 17. Inspect and replace as necessary.
Install. (Group 0510.)
12. Remove air baffle enclosure. See Air Baffle Enclosure CAUTION: Prevent possible crushing injury from
Remove and Install. (Group 0510.) heavy component. Use appropriate lifting device.

13. Disconnect all hydraulic hose clamps and electrical 18. Install grille housing.
harness clamps from grille housing.
Specification
NOTE: It is not necessary to disconnect fan motor (1) Grille Housing—Weight
from fan support (2) during fan shroud removal (approximate)................................................................................ 181 kg
and installation. Fan hydraulic hoses (3) and 400 lb.
fan blade (4) do not need to be removed when
disconnecting fan support from fan shroud (6). 19. Attach fan assembly to fan guard.
20. Route all hydraulic hoses and electrical harnesses.
14. While supporting the fan assembly, remove cap Install all hydraulic hose clamps and electrical harness
screws (5) and allow assembly to tilt back and rest clamps to grille housing.
against the engine.
21. Install air baffle enclosure. See Air Baffle Enclosure
15. Remove cap screws (7). Remove and Install. (Group 0510.)
Continued on next page MH66088,0000DB1 ­19­07OCT10­1/2

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PN=265
 Hood or Engine Enclosure

22. Install aftercooler. See Aftercooler Remove and

Install. (Group 0510.) CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.
23. Install radiator. See Radiator Remove and Install.
(Group 0510.) 28. Install right limb riser.
24. Install transmission oil cooler. See Transmission Oil Specification
Cooler Remove and Install. (Group 0510.) Right Limb
Riser—Weight
25. Install hydraulic oil cooler. See Hydraulic Oil Cooler (approximate).................................................................................. 39 kg
Remove and Install. (Group 0510.) 85 lb.
NOTE: Air conditioner condenser and hydraulic 29. Install hood. See Hood Remove and Install. (Group
oil cooler share the same mounting bracket 1910.)
on torque converter drive machines and are
installed as an assembly. 30. Turn battery disconnect switch to the ON position. See
Battery Disconnect. (Operator’s Manual.)
26. Install air conditioner condenser. See Air Conditioner
31. Evacuate air conditioning system. See R134a System
Condenser Remove and Install. (Group 1830.)
Evacuate. (Group 1830.)
27. Install grille guard. See Grille Guard Remove and
32. Charge air conditioning system. See R134a System
Install. (Group 1910.)
Charge. (Group 1830.)
MH66088,0000DB1 ­19­07OCT10­2/2

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 Section 20
Safety, Convenience, and Miscellaneous
Contents

Page

Group 2003—Pressurized Water System

Pressurized Water System—If
Equipped ............................................... 20­2003­1

Group 2004—Horn and Warning Devises

Horn Remove and Install ........................... 20­2004­1
Reverse Warning Alarm Remove
and Install .............................................. 20­2004­1

TM11813 (13OCT10) 20­1 748H Repair (S.N. 630436— )

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PN=1
 Contents

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PN=2
 Group 2003
Pressurized Water System

Pressurized Water System—If Equipped

4 4
2 5
1
3 5 7
8
9

10

10

13 8
6 12
9
11
17 16

19
14
15 23

18 25
23
24
22
24
20 21

TX1081958 —UN—20SEP10
26

TX1081958 27
Pressurized Water System
1— Tank 8— O­Ring (2 used) 15— Cap Screw (2 used) 22— Hose
2— Filler Plug 9— Adapter (2 used) 16— Fitting 23— Cap Screw (2 used)
3— O­Ring 10— Hose 17— Pressure Gauge 24— Adapter (2 used)
4— Cap Screw (8 used) 11— Bracket 18— Relief Valve 25— Valve
5— Washer (8 used) 12— Washer 19— Manifold 26— Cover
6— Reducer 13— Latch 20— Nozzle 27— Label
7— Seal 14— Label 21— Adapter
Continued on next page SW03989,0000B2F ­19­24SEP10­1/2

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PN=269
 Pressurized Water System

1. Repair or replace parts as necessary.

CAUTION: Release pressure by discharging fluid

at hose and before removing fill plug. Injury
may result from plug or cap under force.

TX1081965A —UN—20SEP10
2. Move valve (25) handle to ON position.

CAUTION: Pressurized water system. Release

pressure by discharging fluid at hose end
before removing fill plug. Injury may result
from plug removed under pressure.
Cover and Latch
3. Squeeze nozzle (20) to release water.
4. Slowly remove filler plug (2).
5. For tank removal, remove trim caps on screws
securing trim panel to cab and remove head liner.

TX1081961A —UN—20SEP10
6. Disconnect hose (10) from adapter (9). Close all
openings using caps and plugs.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

7. Remove cap screws (4) and washers (5). Remove

tank using lifting loops. Valve, Hose, and Nozzle
Specification
Tank—Weight................................................................................ 373 kg
822 lb.

8. Replace or repair as necessary.

9. Install tank and connect hose. Install head liner and
trim panel.
10. Fill tank with water. See Fill and Charge Pressurized

TX1081959A —UN—20SEP10
Water System—If Equipped. (Operator’s Manual.)

CAUTION: Plug has a vent cross hole for release

of air pressure. Do not use a substitute plug.

11. Install filler plug.

12. To pressurize system, apply air to fitting (16), add air,
Plug Location
watching pressure gauge (17) to correct air pressure
specification.
2— Filler Plug 17— Pressure Gauge
Specification 4— Cap Screw (8 used) 20— Nozzle
Water Tank—Pressure................................................................ 410 kPa 5— Washer (8 used) 25— Valve
3.8 bar 13— Latch 26— Cover
55 psi 16— Fitting

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 Group 2004
Horn and Warning Devises

Horn Remove and Install

1. Open front grille (3).
2. Disconnect electrical connectors (1).

TX1024377A —UN—05JUN07
3. Remove horn (2).
4. Inspect and replace as necessary.
5. Install horn.
6. Connect electrical connectors.
7. Close front grille.
Horn
1— Electrical Connector 3— Nut
2— Horn 4— Grille

GD61784,000002B ­19­29MAY07­1/1

Reverse Warning Alarm Remove and Install

1. Remove cover (1).

1— Reverse Warning Alarm 2— Cap Screw (4 used)

Cover

TX1024379A —UN—05JUN07
Reverse Warning Alarm Cover

GD61784,000002C ­19­29MAY07­1/2

2. Disconnect electrical connectors (3).

3. Remove reverse warning alarm (5).
4. Inspect and replace as necessary.
5. Install reverse warning alarm.

TX1024378A —UN—05JUN07
6. Connect electrical connectors.
7. Install cover.

3— Electrical Connector 5— Reverse Warning Alarm

4— Nut (2 used)

Reverse Warning Alarm

GD61784,000002C ­19­29MAY07­2/2

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 Horn and Warning Devises

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 Section 21
Main Hydraulic System
Contents

Page

Group 2160—Hydraulic System

General Oil Cleanup Procedure ................ 21­2160­1
Hydraulic Component Failure
Cleanup Procedure................................ 21­2160­3
Hydraulic Pump Remove and
Install ..................................................... 21­2160­5
Priority Valve Remove and Install.............. 21­2160­7
Priority Valve Disassemble and
Assemble............................................... 21­2160­8
Hydraulic Attenuator Remove and
Install ..................................................... 21­2160­9
Fan Variable Speed and Reversing
Manifold Remove and Install ............... 21­2160­10
Fan Variable Speed and Reversing
Manifold Disassemble and
Assemble............................................. 21­2160­11
Hydraulic Fan Motor Remove and
Install ................................................... 21­2160­12
Hydraulic Reservoir Remove and
Install ................................................... 21­2160­14
Hydraulic Fan and Cooling Loop
Pump Remove and Install ................... 21­2160­18

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 Contents

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 Group 2160
Hydraulic System

General Oil Cleanup Procedure

2
This procedure is to be used on machines that have had
1
hydraulic system repair without a catastrophic component
failure. Filter caddy procedure must be done prior to
starting machine after a component has been repaired
or replaced.
IMPORTANT: Intermixing of oils can cause premature
hydraulic component damage and oil
contamination. Oil types and filters must not
be intermixed. Use filter element in same
type oil to avoid intermixing of oils.
Oil contamination could result if filter caddy is
used in dusty or wet conditions. Clean work
practices and cleanliness of filter caddy and
attachments are critical when filtering oil.

NOTE: Filter oil should be at 27°C (80°F) or above for

best Super Caddy performance. Reduce flow
rate to filter oil below 27°C (80°F).

TX1080703 —UN—09AUG10
Super Caddy requires a 20­amp electric circuit. Use
of electrical extension cord is not recommended.

1. Park machine on a flat, level surface with attachments

lowered to the ground and turn engine off.
2. Remove hydraulic tank cap and filler screen.
NOTE: When installing suction and discharge wands into Super Caddy Wand Placement
the hydraulic oil reservoir, locate the submerged
ends of the wands as far away from each other 1— Suction Wand 2— Discharge Wand
as possible to ensure maximum oil movement
during cleanup procedure.
9. Fill hydraulic oil reservoir to operating level. See
3. Install JDG10712 Super Caddy suction wand (1) and
Check Hydraulic System Oil Level. (Operator’s
discharge wand (2) into the reservoir as shown.
Manual.)
4. Secure wands to prevent them from coming out of
10. Run machine at slow idle. Operate each circuit
reservoir during cleaning process.
a minimum of 2 minutes in each direction to flush
5. Cover the wands and reservoir openings with a plastic any remaining contaminants back through hydraulic
tarp to prevent contamination. system filters.
11. Stop engine. Install Super Caddy to machine as
CAUTION: Prevent possible personal injury before.
from unexpected machine movement. Clear all
persons from area before operating machine. 12. Repeat Super Caddy operation procedure until
contaminant value is at specifications per Super
Avoid entanglement and possible electrocution Caddy operator’s manual or see Super Caddy in
from filter caddy power cord. Do not Service ADVISOR™ for operating procedure.
operate machine while filter caddy is
connected to machine. 13. When oil reaches an acceptable level of cleanliness,
disconnect Super Caddy from machine.
6. Use JDG10712 Super Caddy to remove oil
14. Install new hydraulic system filters.
contaminants. Refer to the Super Caddy operator’s
manual or see Super Caddy in Service ADVISOR™ 15. Clean and Install reservoir breather.
for operating procedure.
NOTE: Instrument cleanliness and clean work practices
7. When cleaning process is done, disconnect Super are critical when taking oil samples. Dust, wind,
Caddy from machine. and moisture, as well as contaminated sample
pumps, bottles, and tubing, can affect results.
8. Make sure machine is parked in an area that will allow
all hydraulic functions to be operated.
Continued on next page BR98087,00000B3 ­19­18AUG10­1/2

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 Hydraulic System

16. Obtain oil sample for fluid analysis. Oil sample must be 18. Return machine to service.
taken from system before oil passes through the filter
when oil is warm. See Fluid Analysis Program Test
Kits and 3­Way Coolant Test Kit. (Operator’s Manual.)
17. Fill hydraulic oil reservoir to proper operating level.
See Check Hydraulic System Oil Level and see
Hydraulic System Oil. (Operator’s Manual.)
Service ADVISOR is a trademark of Deere & Company
BR98087,00000B3 ­19­18AUG10­2/2

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 Hydraulic System

Hydraulic Component Failure Cleanup • Fan Variable Speed and Reversing Manifold—See
Procedure Fan Variable Speed and Reversing Manifold
Disassemble and Assemble. (Group 2160.)
This procedure is to be used on machines that have • Hydraulic Fan Motor—See Hydraulic Fan Motor
had a system catastrophic component failure. Cleanup Remove and Install. (Group 2160.)
procedure must be done prior to starting machine after a • Hydraulic Reservoir—See Hydraulic Reservoir
component has been repaired or replaced. The use of Remove and Install. (Group 2160.)
attachments increases the need to monitor and filter oil to • Hydraulic Fan and Cooling Loop Pump—See
a safe contamination value. Hydraulic Fan and Cooling Loop Pump Remove and
IMPORTANT: Intermixing of oils can cause Install. (Group 2100.)
premature hydraulic component damage • Blade Lift Cylinder—See Blade Lift Cylinder Remove
and oil contamination. Oil types and Super and Install. (Group 3260.)
Caddy filters must not be intermixed. Use • Boom or Arch Cylinder—Dual Function
super caddy filter element in same type oil Grapple—See Boom or Arch Cylinder Remove and
to avoid intermixing of oils. Install—Dual Function Grapple. (Group 3860.)
• Grapple Tong Cylinder—See Grapple Tong Cylinder
Oil contamination could result if Super Caddy Remove and Install. (Group 3860.)
is used in dusty or wet conditions. Clean work • Grapple Rotate Motor—See Grapple Rotate Motor
practices and cleanliness of filter caddy and Remove and Install. (Group 3860.)
attachments are critical when filtering oil. • Grapple Rotate Motor—See Grapple Rotate Motor
Disassemble. (Group 3860.)
NOTE: Filter oil should be at 27°C (80°F) or above for • Grapple Rotate Motor—See Grapple Rotate Motor
best Super Caddy performance. Reduce flow Assemble. (Group 3860.)
rate to filter oil below 27°C (80°F). • Pilot Operated Control Valve—See Pilot Operated
Control Valve Remove and Install. (Group 3860.)
Super Caddy requires a 20­amp electric circuit. Use • Dual Function Pilot Operated Control Valve—See
of electrical extension cord is not recommended. Dual Function Pilot Operated Control Valve
Disassemble and Assemble. (Group 3860.)
CAUTION: Avoid possible injury from unexpected • Control Valve Relief Valves—See Control Valve
machine movement. Install articulation locking Relief Valves Remove and Install. (Group 3860.)
bar before working in frame hinge area. • Lift Check Valve—See Lift Check Valve Disassemble
and Assemble. (Group 3860.)
1. Park and prepare machine for service. See Park and • Non­adjustable Circuit Relief Valve—See
Prepare for Service Safely. (Group 0001.) Non­adjustable Circuit Relief Valve Disassemble and
Assemble. (Group 3860.)
2. Remove hydraulic reservoir. See Hydraulic Reservoir • Adjustable Circuit Relief Valve—See Adjustable
Remove and Install. (Group 2160.) Circuit Relief Valve Disassemble and Assemble.
(Group 3860.)
IMPORTANT: To prevent hydraulic system
contamination, after cleaning, disassembling, • Spool Valve—See Spool Valve Disassemble and
Assemble. (Group 3860.)
and assembling each hydraulic component,
store component in a dry, dust­free area • Detent—See Detent Disassemble and Assemble.
(Group 3860.)
until installation.
• Pilot Operated Valve—See Pilot Operated Valve
Remove and Install. (Group 3860.)
3. Clean hydraulic reservoir completely.
• Solenoid Operated Valve—See Solenoid Operated
4. Remove each hydraulic component from the machine. Valve Remove and Install. (Group 3860.)
Disassemble, clean, inspect, and assemble each • Grapple Rotate—See Grapple Rotate Solenoid
component, working one circuit at a time. Repair or Valve Remove and Install. (Group 3860.)
replace damaged components. • Grapple Rotate—See Grapple Rotate Solenoid
Valve Disassemble and Assemble. (Group 3860.)
• Main Hydraulic Pump—See Hydraulic Pump • Flow Divider—See Flow Divider Repair. (Group
Remove and Install. (Group 2160.) 3860.)
• Priority Valve—See Priority Valve Remove and • Rotary Manifold—See Rotary Manifold Remove and
Install. (Group 2160.) Install. (Group 3860.)
• Priority Valve—See Priority Valve Disassemble and • Rotary Manifold—See Rotary Manifold Disassemble
Assemble. (Group 2160.) and Assemble. (Group 3860.)
• Hydraulic Attenuator—See Hydraulic Attenuator • Park Brake Solenoid Valve—See Park Brake
Remove and Install. (Group 2160.) Solenoid Valve Repair. (Group 1160.)
• Fan Variable Speed and Reversing Manifold—See • Service Brake Valve—See Service Brake Valve
Fan Variable Speed and Reversing Manifold Remove and Install. (Group 1060.)
Remove and Install. (Group 2160.) • Service Brake Valve—See Service Brake Valve
Disassemble and Assemble. (Group 1060.)
Continued on next page SW03989,0000B25 ­19­07OCT10­1/2

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 Hydraulic System

• Service Brake Accumulator—See Service Brake lines are cleaned, close all openings with caps
Accumulator Remove and Install. (Group 1060.) and plugs to minimize additional contamination.
• Steering Valve—See Steering Valve Remove and
Install. (Group 0960.) 6. Clean all hydraulic hoses and lines using JDG1770
• Steering Valve—See Steering Valve Disassemble Ultra Clean Hose Kit.
and Assemble. (Group 0960.)
• Steering Cylinder—See Steering Cylinder Remove NOTE: During installation, fill hydraulic components,
and Install. (Group 0960.) hoses, and lines with clean hydraulic oil where
• Transmission Charge Pump—See Transmission possible to prevent a dry start­up.
Charge Pump Remove and Install. (Group 0360.)
• Transmission Charge Pump—See Transmission 7. Install all cleaned hydraulic components, hoses, and
Charge Pump Drive Repair. (Group 0360.) lines.
• Transmission Control Valve—See Transmission 8. Install new hydraulic oil filters. See Replace Hydraulic
Control Valve Repair. (Group 0360.) Oil Filter. (Operator’s Manual.)
• Differential Lock Solenoid Valve—See Differential
Lock Solenoid Valve Repair. (Group 0260.) 9. Install new hydraulic oil breather filter. See Replace
Hydraulic Reservoir Breather Filter. (Operator’s
IMPORTANT: Disconnect hydraulic hoses and lines Manual.)
from all tee fittings before cleaning. Cleaning
sponge will become trapped in hose and lines 10. With all components installed, fill reservoir to proper
as it passes through a tee fitting. level. See Check Hydraulic Oil Level. (Operator’s
Manual.)
5. Disconnect and label all hydraulic hoses and lines.
Close open fittings using caps and plugs. See 11. Remove air from hydraulic system.
Hydraulic System Component Location. (Group 12. Remove residual oil contaminants using JDG10712
9025­15.) Super Caddy. Perform General Oil Cleanup
Procedure. (Group 2160.)
IMPORTANT: Airborne debris can cause premature
hydraulic component failure. After hoses and
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 Hydraulic System

Hydraulic Pump Remove and Install

IMPORTANT: Test main pump for leakage before
starting repair. If pump does not pass the
test, replace it. DO NOT rebuild it.

1. Prepare machine for service. See Park and Prepare

for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

TX1080483A —UN—05AUG10
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate all hydraulic control valves to release

pressure in hydraulic system. Depress brake pedal at
1­second intervals 20 times to drain oil from service
brake accumulator. Hydraulic Pump Hose and Lines

3. Turn battery disconnect switch to the OFF position.

See Battery Disconnect. (Operator’s Manual.)
4. Remove engine side shields. See Opening Engine
Side Shields. (Operator’s Manual.)
5. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)
6. Drain hydraulic reservoir. See Change Hydraulic Oil.
(Operator’s Manual.)

TX1080484A —UN—05AUG10
7. Disconnect hydraulic hose and lines (1—3). Close all
openings using caps and plugs.
8. Disconnect wire harness at electrical connector (4).

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.
Hydraulic Pump Remove or Install
9. Support pump with lifting strap. Remove cap screws
(5) to remove pump.
1— Case Drain­to­Reservoir 4— Electrical Connector
Specification Hose 5— Cap Screw (4 used)
Hydraulic Pump—Weight 2— Supply Line
(approximate).................................................................................. 40 kg 3— Pump­to­Prioity Valve Line
90 lb

10. Inspect and replace pump as necessary.

Continued on next page SW03989,0000B26 ­19­28SEP10­1/2

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 Hydraulic System

IMPORTANT: Always replace O­rings and seals.

Damaged or used O­rings will leak.

11. Replace O­ring (6) on pump flange.

NOTE: Hydraulic pump has a spline coupler that couples
the pump to transmission charge pump.

12. Inspect spline coupler (7). Install on torque converter

spline shaft.
13. Install hydraulic pump to torque converter.
IMPORTANT: The hydraulic pump must be filled with
oil to prevent pump damage at start­up.

TX1080461A —UN—03AUG10
14. Connect pump­to­prioity valve line using a new O­ring
at face seal. Tighten to specification.
Specification
Line Mounting Cap
Screw—Torque............................................................................120 N∙m
89 lb­ft

15. Fill supply and case drain ports with hydraulic oil. See Hydraulic Pump Flange O­Ring
Hydraulic System Oil. (Operator’s Manual.)
16. Connect case drain hose.
17. Connect supply line using a new O­ring at face seal.
Tighten to specification.
Specification
Line Mounting Cap
Screw—Torque............................................................................120 N∙m
89 lb­ft

18. Fill hydraulic reservoir. See Change Hydraulic Oil.

(Operator’s Manual.)
19. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operator’s Manual.)
20. Turn battery disconnect switch to the ON position. See
TX1080486A —UN—05AUG10
Battery Disconnect. (Operator’s Manual.)
21. Start engine and follow hydraulic oil warmup
procedure. See Hydraulic Oil Warmup Procedure.
(Group 9025.)
22. Stop engine and check for leaks.
23. Check hydraulic reservoir oil level. See Check Coupler
Hydraulic System Oil Level. (Operator’s Manual.)
24. Install engine side shields. See Opening Engine Side 6— O­Ring 7— Coupler
Shields. (Operator’s Manual.)
25. Remove articulation locking bar.
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 Hydraulic System

Priority Valve Remove and Install

1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all

TX1080500A —UN—05AUG10
connections before applying pressure.

2. Operate all hydraulic control valves to release

pressure in hydraulic system. Depress brake pedal at
1­second intervals 20 times to drain oil from service
brake accumulator.
3. Turn battery disconnect switch to the OFF position.
Priority Valve
See Battery Disconnect. (Operator’s Manual.)
4. Raise cab. See Hydraulic Cab Tilt Procedure. 1— Hydraulic Line to Main 4— Hydraulic Line to Hydraulic
(Operator’s Manual.) Control Valve Reservoir
2— Hydraulic Line to Steering 5— Hydraulic Line to
5. Apply vacuum or drain hydraulic reservoir. If draining Valve Secondary Steering Valve
hydraulic reservoir, see Change Hydraulic Oil. 3— Hydraulic Line From 6— Cap Screw (2 used)
(Operator’s Manual.) Hydraulic Pump

6. Tag and remove hydraulic lines (1—5). Close all

openings using caps and plugs.
14. Check hydraulic oil level. See Check Hydraulic
7. Remove vacuum if used. System Oil Level. (Operator’s Manual.)
8. Remove cap screws (6) to remove priority valve. 15. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operator’s Manual.)
9. Inspect and repair or replace parts as necessary. See
Priority Valve Disassemble and Assemble. (Group 16. Turn battery disconnect switch to the ON position. See
2160.) Battery Disconnect. (Operator’s Manual.)
10. Secure priority valve with cap screws. Tighten 17. Start engine and allow to run at slow idle for several
securely. minutes.
11. Apply vacuum if hydraulic reservoir was not drained. 18. Stop engine and check for leaks.
12. Install hydraulic lines. 19. Check hydraulic reservoir oil level. See Check
Hydraulic System Oil Level. (Operator’s Manual.)
13. Remove vacuum if hydraulic reservoir was not drained
or fill hydraulic reservoir. See Change Hydraulic Oil. 20. Remove articulation locking bar.
(Operator’s Manual.)
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 Hydraulic System

Priority Valve Disassemble and Assemble

1. Remove priority valve from machine. See Priority
Valve Remove and Install. (Group 2160.)
2. Disassemble parts (2—10) from housing (1).

TX1080501A —UN—05AUG10
3. Clean and inspect parts. Replace as necessary.
4. Check length of spring (4). Replace if not to
specification.
Specification
Spring—Length
(approximate)................................................................................ 62 mm
2.4 in. Priority Valve Disassembled

IMPORTANT: Always replace O­rings. Damaged

1— Housing 6— O­Ring
or used O­rings will leak. 2— Spool 7— Relief Valve Cartridge
3— Orifice (2 used) 8— O­Ring
5. Install new O­rings. 4— Spring 9— Plug
5— Plug 10— O­Ring
6. Lubricate all parts with clean hydraulic oil and
assemble.
7. Tighten orifices (3) to specification. Specification
Specification Relief Valve
Orifices—Torque.................................................................. 7.3—9.7 N∙m Cartridge—Torque................................................................. 34—54 N∙m
65—85 lb­in. 25—40 lb­ft

8. Tighten plugs (5 and 9) to specification.

Specification 10. Install priority valve. See Priority Valve Remove and
Plug—Torque......................................................................... 54—81 N∙m Install. (Group 2160.)
40—60 lb­ft

9. Tighten relief valve cartridge (7) to specification.

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 Hydraulic System

Hydraulic Attenuator Remove and Install

1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate all hydraulic control valves to release

pressure in hydraulic system. Depress brake pedal at
1­second intervals 20 times to drain oil from service

TX1081866A —UN—16SEP10
brake accumulator.
3. Turn battery disconnect switch to the OFF position.
4. Raise cab. See Hydraulic Cab Tilt Procedure.
(Operator’s Manual.)
5. Apply vacuum or drain hydraulic reservoir. If draining
hydraulic reservoir, see Change Hydraulic Oil.
(Operator’s Manual.) Hydraulic Attenuator Remove and Install

6. Remove hydraulic line (1) and hydraulic hose (3) from

1— Hydraulic Line 4— Retaining Clamp (2 used)
hydraulic attenuator (5). Close all openings using 2— Cap Screw (2 used) 5— Hydraulic Attenuator
caps and plugs. 3— Hydraulic Hose

7. Remove cap screws (2) from retaining clamps (4).

Remove hydraulic attenuator.
13. Turn battery disconnect switch to the ON position.
8. Install hydraulic attenuator, retaining clamps, and cap
screws. 14. Remove articulation locking bar.
9. Install hydraulic line and hose. 15. Start machine and allow hydraulic oil to reach
operating temperature. See Hydraulic Oil Warmup
10. Remove vacuum if hydraulic reservoir was not drained Procedure. (Group 9025­25.)
or fill hydraulic reservoir. See Change Hydraulic Oil.
(Operator’s Manual.) 16. Stop machine and check hydraulic oil level. See Check
Hydraulic System Oil Level. (Operator’s Manual.)
11. Check hydraulic oil level. See Check Hydraulic
System Oil Level. (Operator’s Manual.)
12. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operator’s Manual.)
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 Hydraulic System

Fan Variable Speed and Reversing Manifold 2. Operate all hydraulic control valves to release
Remove and Install pressure in hydraulic system. Depress brake pedal at
one­second intervals 20 times to drain oil from service
1. Park and prepare machine for service. See Park and brake accumulator.
Prepare for Service Safely. (Group 0001.)
3. Turn battery disconnect switch to OFF position.
CAUTION: To avoid injury from escaping fluid 4. Remove engine side shields. See Opening Engine
under pressure, stop engine and relieve the Side Shields. (Operator’s Manual.)
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all 5. Remove hood. See Hood Remove and Install. (Group
connections before applying pressure. 1910.)

2
3
2

1 2
2
3

TX1080592 —UN—05AUG10
TX1080592
Fan Manifold Remove and Install
1— Solenoid Electrical Connector 2— Hydraulic Hose (4 used) 3— Cap Screw (2 used)
(2 used)

6. Disconnect wiring harness from solenoid electrical 14. Connect wiring harness to solenoid electrical
connectors (1). connectors.
7. Apply vacuum to hydraulic reservoir. 15. Install hood. See Hood Remove and Install. (Group
8. Tag and disconnect hydraulic hoses (2). Close all 1910.)
openings using caps and plugs. 16. Turn battery disconnect to ON position.
9. Remove cap screws (3). 17. Install engine side shields. See Opening Engine Side
10. Inspect and replace components, as necessary. Shields. (Operator’s Manual.)
See Fan Variable Speed and Reversing Manifold 18. Check hydraulic reservoir oil level. See Check
Disassemble and Assemble. (Group 2160.) Hydraulic System Oil Level. (Operator’s Manual.)
11. Install fan manifold with cap screws. Tighten securely. 19. Check reversing fan operation before returning
12. Connect hydraulic hoses. machine to service. See Complete Machine
Operational Checkout. (Operator’s Manual.)
13. Remove vacuum from hydraulic reservoir.
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 Hydraulic System

Fan Variable Speed and Reversing Manifold

Disassemble and Assemble
1. Remove fan manifold. See Fan Variable Speed and
Reversing Manifold Remove and Install. (Group 2160.)

4 2
4 3

TX1081043 —UN—18AUG10
8
4

4
6
TX1081043 7
Fan Variable Speed and Reversing Manifold
1— Solenoid Valve (2 used) 3— Orifice 5— Pressure Relief Valve 7— Nut (2 used)
2— Check Valve (4 used) 4— Plug (5 used) 6— Solenoid Valve Coil (2 used) 8— Valve Manifold

2. Disassemble and assemble.

3. Install fan manifold. See Fan Variable Speed and
Reversing Manifold Remove and Install. (Group 2160.)
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 Hydraulic System

Hydraulic Fan Motor Remove and Install 2. Operate all hydraulic control valves to release
pressure in hydraulic system. Depress brake pedal at
CAUTION: Avoid possible injury from unexpected 1­second intervals 20 times to drain oil from service
machine movement. Install articulation locking brake accumulator.
bar before working in frame hinge area. 3. Turn battery disconnect switch to OFF position. See
Battery Disconnect. (Operator’s Manual.)
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.) 4. Remove fan blade. See Fan Blade Remove and
Install. (Group 0510.)
CAUTION: To avoid injury from escaping fluid 5. Remove both side grille housing access panels.
under pressure, stop engine and relieve the
pressure in the system before disconnecting or 6. Remove upper air baffle enclosure. See Air Baffle
connecting hydraulic or other lines. Tighten all Enclosure Remove and Install. (Group 0510.)
connections before applying pressure.

TX1080520A —UN—04AUG10
Fan Motor Mounting
1— Fan Reversing Manifold 2— Fan Motor Case Drain Hose 3— Cap Screw (2 used)
­to­Fan Motor Hose (2 used)

7. Disconnect and identify fan reversing manifold­to­fan

IMPORTANT: Installing hydraulic fan motor hoses
motor hoses (1). Close all openings using caps and
backwards will cause engine overheating.
plugs.
8. Disconnect fan motor case drain hose (2). Close all 13. Connect fan reversing manifold­to­fan motor hoses.
openings using caps and plugs.
14. Connect fan motor case drain hose.
9. Remove cap screws (3) securing hydraulic fan motor
15. Install fan blade. See Fan Blade Remove and Install.
to mounting bracket.
(Group 0510.)
10. Remove hydraulic fan motor from machine.
16. Install both upper air baffle panels. See Air Baffle
11. Repair or replace parts as necessary. Enclosure Remove and Install. (Group 0510.)

12. Install hydraulic fan motor to mounting bracket using 17. Install both side grille housing access panels.
cap screws.
18. Check hydraulic oil level. See Check Hydraulic
System Oil Level. (Operator’s Manual.)
Continued on next page MH66088,0000D93 ­19­06OCT10­1/2

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 Hydraulic System

19. Turn battery disconnect switch to ON position. See 20. Check operation of hydraulic fan motor. See Complete
Battery Disconnect. (Operator’s Manual.) Machine Operational Checkout. (Operator’s Manual.)
MH66088,0000D93 ­19­06OCT10­2/2

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 Hydraulic System

Hydraulic Reservoir Remove and Install 4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
1. Park and prepare machine for service. See Park and Manual.)
Prepare for Service Safely. (Group 0001.) 5. Remove engine side shields. See Opening Engine
Side Shields. (Operator’s Manual.)
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the 6. Remove hood. See Hood Remove and Install. (Group
pressure in the system before disconnecting or 1910.)
connecting hydraulic or other lines. Tighten all IMPORTANT: Clean all dirt and debris from
connections before applying pressure. hydraulic reservoir before removing fill cap
or disconnecting hoses. Contamination
2. Operate all hydraulic control valves to release introduced into the hydraulic system can lead
pressure in hydraulic system. Depress brake pedal at to premature equipment failure.
1­second intervals 20 times to drain oil from service
brake accumulator. 7. Drain hydraulic reservoir. See Change Hydraulic Oil.
3. Turn battery disconnect switch to OFF position. See (Operator’s Manual.)
Battery Disconnect. (Operator’s Manual.)

TX1080622 —UN—06AUG10

TX1080622
Hydraulic Reservoir Bottom View
1— Hydraulic Oil Temperature 2— Wire Harness
Sensor Connector

8. Disconnect wire harness (2) from hydraulic oil NOTE: Hoses may vary depending on machine options.
temperature sensor connector (1).
9. Tag and disconnect hydraulic hoses from bottom of
hydraulic reservoir. Close all openings using caps and
plugs.
Continued on next page SW03989,0000A9A ­19­05OCT10­1/5

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 Hydraulic System

NOTE: Do not disconnect hoses or wire connectors.

10. Remove transmission filter (3), breather (5), and

grapple valve bracket (6).

3— Transmission Filter 6— Grapple Valve Bracket

4— Cap Screw (3 used) 7— Cap Screw (2 used)
5— Breather

TX1080603A —UN—06AUG10
Breather, Transmission Filter, and Grapple Valve Mounting

Continued on next page SW03989,0000A9A ­19­05OCT10­2/5

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 Hydraulic System

11. Loosen band clamps (10). Disconnect cooling loop

filter hose (8) and hydraulic return filter hose (9) from
reservoir.
12. Disconnect chain slings (11) and set hoses aside.
13. Remove service accumulator. See Service Brake
Accumulator Remove and Install. (Group 1060.)

8— Cooling Loop Filter Hose 11— Chain Sling (2 used)

9— Hydraulic Return Filter 12— Cap Screw (2 used)
Hose 13— Nut (2 used)
10— Band Clamp (2 used)

TX1080623 —UN—06AUG10
Cooling Loop and Hydraulic Return Filter Hoses

TX1080624 —UN—06AUG10

Hose Chain Slings

Continued on next page SW03989,0000A9A ­19­05OCT10­3/5

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 Hydraulic System

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

14. Attach hoist and chains to reservoir using JT01748

lifting bracket (14) and M12 lifting eyebolt (15).
Specification
Hydraulic
Reservoir—Weight

TX1080625A —UN—06AUG10
(approximate).................................................................................. 60 kg
132 lb.

15. Remove hydraulic reservoir support (16) from machine

frame (17).
16. Lift hydraulic reservoir from machine.
17. Inspect and replace parts as necessary. Hoist, Chain, Lifting Brackets
18. Install fittings on hydraulic reservoir, if removed.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

19. Attach hoist and chains to reservoir using JT01748

Lifting Brackets.
Specification
Hydraulic
Reservoir—Weight
(approximate).................................................................................. 60 kg
132 lb.

20. Install hydraulic reservoir on frame.

TX1080626 —UN—06AUG10
21. Install chain slings and service brake accumulator.
See Service Brake Accumulator Remove and Install.
(Group 1060.).
22. Install transmission filter, grapple valve bracket, and
breather.
23. Install cooling loop and hydraulic return filter hoses. Hydraulic Reservoir Support Mounting
24. Replace hydraulic oil return filters. See Replace
Hydraulic Oil Filter and see Replace Hydraulic Cooler 14— JT01748 Lifting Bracket (2 17— Machine Frame
Filter. (Operator’s Manual.) used) 18— Cap Screw (6 used)
15— M12 Lifting Eyebolt 19— Nut (6 used)
IMPORTANT: Always use new O­rings and seals. 16— Hydraulic Reservoir
Damaged or used O­rings and seals will leak. Support

25. Install hoses to hydraulic reservoir.

31. Start engine and follow hydraulic oil warmup
26. Connect wire harness to hydraulic oil temperature procedure. See Hydraulic Oil Warmup Procedure.
sensor connector. (Group 9025.)
27. Lower cab. See Hydraulic Cab Tilt Procedure. 32. Stop engine. Check for leaks.
(Operator’s Manual.)
33. Check hydraulic reservoir oil level. See Check
28. Install hood. See Hood Remove and Install. (Group Hydraulic System Oil Level. (Operator’s Manual.)
1910.)
34. Install engine side shields. See Opening Engine Side
29. Fill hydraulic reservoir. See Change Hydraulic Oil. Shields. (Operator’s Manual.)
(Operator’s Manual.)
35. Remove articulation locking bar.
30. Turn battery disconnect switch to ON position. See
Battery Disconnect. (Operator’s Manual.)
Continued on next page SW03989,0000A9A ­19­05OCT10­4/5

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 Hydraulic System

SW03989,0000A9A ­19­05OCT10­5/5

Hydraulic Fan and Cooling Loop Pump

Remove and Install
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
2. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s
Manual.)
3. Install a vacuum pump on hydraulic reservoir to
minimize leakage.

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or

TX1025218A —UN—21JUN07
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

4. Disconnect hoses from pump. Close all openings with

caps and plugs.
5. Remove cap screws (1) and washers and remove
pump.

1— Cap Screw (2 used) 3— Cooling Loop Pump

2— Pump Outlet 4— Pump Inlet

SW03989,0000B2E ­19­06OCT10­1/2

6. Inspect and replace parts as necessary.

IMPORTANT: Always use new O­rings and seals.
Damaged or used O­rings and seals will leak.

7. Install drive coupler and O­ring on cooling loop pump.

TX1025219A —UN—21JUN07
8. Install cooling loop pump.
9. Connect hose to pump inlet.
IMPORTANT: Pump must be filled with oil prior to
start­up to prevent pump damage.

10. Fill pump with oil through pump outlet. See

Transmission, Park Brake, Differential, Cab Tilt
Hydraulic Pump and Winch Oil. (Operator’s Manual.) 3— Cooling Loop Pump 6— Drive Coupler
5— O­Ring
11. Connect hose to pump outlet.
12. Remove vacuum pump from hydraulic tank.
13. Check hydraulic oil level. See Check Hydraulic 16. Check for leaks.
System Oil Level. (Operator’s Manual.) 17. Remove articulation locking bar.
14. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operator’s Manual.)
15. Check operation of reversing fan. See Operational
Checkout. (Group 9005­10.)
SW03989,0000B2E ­19­06OCT10­2/2

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 Section 30
Winch
Contents

Page

Group 3000—Removal and Installation

Winch 4000 Series Remove and
Install ..................................................... 30­3000­1
Fastening Cable to Winch
Drum—4000 Series ............................... 30­3000­5
Winch Free Spool Drag
Adjustment............................................. 30­3000­7
Winch 6000 Series Remove and
Install ..................................................... 30­3000­8
Fastening Cable to Winch
Drum—6000 Series ............................. 30­3000­10

Group 3015—Control Linkage

Winch Control Valve Linkage
Remove and Install................................ 30­3015­1
Winch Control Cable Remove and
Install ..................................................... 30­3015­2

Group 3025—Input Drive Shafts and U­Joints

Winch Drive Shaft Remove and
Install ..................................................... 30­3025­1
Winch Drive Shaft Disassemble
and Assemble........................................ 30­3025­1

Group 3050—Drive and Clutch

Winch 4000 Series Drive and
Clutch Repair......................................... 30­3050­1
Winch 6000 Series Drive and
Clutch Repair......................................... 30­3050­1

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 Contents

TM11813 (13OCT10) 30­2 748H Repair (S.N. 630436— )

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 Group 3000
Removal and Installation

Winch 4000 Series Remove and Install

NOTE: Cable must be removed from winch
before servicing.

1. Prepare machine for service. See Park and Prepare 2

for Service Safely. (Group 0001.)
1
CAUTION: To avoid injury from escaping fluid 3

TX1080905 —UN—16AUG10
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
4
2. Operate all hydraulic control valves to release pressure
in hydraulic system. Depress brake pedal at 1­second
intervals 20 times to drain oil from accumulator. Winch Yoke Control Cable and Drive Yoke

3. Turn battery disconnect switch to the OFF position.

1— Pressure Inlet Line 3— Yoke Control Cable
4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s 2— Drive Yoke 4— Return Oil Line
Manual.)
5. Remove winch drive shaft. See Winch Drive Shaft
Remove and Install. (Group 3025.) 8. Disconnect and remove control cable.

6. Disconnect winch yoke control cable (3).

7. Disconnect hydraulic lines (1 and 4). Close all
openings using caps and plugs.
Continued on next page SW03989,0000A9D ­19­05OCT10­1/5

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 Removal and Installation

9. Remove guards.
10. Label and disconnect hydraulic lines (7—12).
11. Remove fittings (13).
12. Disconnect grapple lowering valve (14).

TX1080942A —UN—19AUG10
13. Remove fuel tank mounting cap screws and slide
fuel tank rearward as far as possible. See Fuel Tank
Remove and Install. (Group 0560.)
14. Remove winch mounting cap screws.

5— Cap Screw (6 used) 10— Boom Retract Line

6— Guard (2 used) 11— Boom Extend Line Winch Guard
7— Arch Retract Line 12— Grapple Rotate Line
8— Arch Extend Line 13— Fitting (6 used)
9— Grapple Rotate Line 14— Grapple Lowering Valve

TX1080943A —UN—19AUG10
Hydraulic Connections

TX1080944A —UN—19AUG10
Grapple Lowering Valve
Continued on next page SW03989,0000A9D ­19­05OCT10­2/5

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 Removal and Installation

15. Attach lifting chains to winch as shown.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

16. Remove winch.

T7516AV —UN—05JUN91
Specification
Winch—Weight
(approximate)................................................................................ 630 kg
1390 lb.

Shown with Cable Removed

SW03989,0000A9D ­19­05OCT10­3/5

NOTE: If winch is to be stored or reinstalled without

disassembly, do not drain oil.
If winch is to be disassembled, drain oil using
drain plug on left side of cover.

17. Remove plug (16) to drain oil. See Change Winch

Oil—If Equipped. (Operator’s Manual.)
18. Inspect and repair winch as necessary. See 40 and
4000 Winches. (CTM25.)

15— Fill Plug 17— Return Line Cap

16— Drain Plug

TX1080945A —UN—19AUG10
Winch 4000 Oil Plugs
Continued on next page SW03989,0000A9D ­19­05OCT10­4/5

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 Removal and Installation

19. Clean grease, dirt, oil, and paint from mounting holes.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

20. Install winch.

T7516AV —UN—05JUN91
Specification
Winch—Weight
(approximate)................................................................................ 630 kg
1390 lb.

21. Tighten mounting cap screws to specification.

Specification Shown with Cable Removed
Equipment Frame­
to­Winch Cap
Screw—Torque............................................................................620 N∙m 30. Turn battery disconnect switch to the ON position.
455 lb­ft
IMPORTANT: Oil capacity for winch is greater than
22. Position fuel tank and install mounting cap screws. transmission oil capacity. Check transmission
See Fuel Tank Remove and Install. (Group 0560.) oil level frequently while filling to avoid
transmission pump cavitation.
23. Install fittings to mounting bracket.
24. Connect hydraulic lines. NOTE: Power In position will deliver 7.8—9.5 L (2—2­1/2
gal) per minute to fill winch. Free Spool position
25. Install guards. will take approximately 1/2 hour to fill winch.
26. Lower cab. See Hydraulic Cab Tilt Procedure. 31. Operate winch in either Power In or Free Spool
(Operator’s Manual.) position to finish filling winch. Check transmission oil
27. Connect and adjust control cable yoke. See Winch level frequently and add oil through the transmission
Control Valve Linkage Remove and Install or see dipstick. See Check Transmission Oil Level.
Winch Control Cable Remove and Install. (Group (Operator’s Manual.)
3015.) 32. Install cable. See Fastening Cable to Winch
28. Install winch drive shaft. See Winch Drive Shaft Drum—4000 Series. (Group 3000.)
Remove and Install. (Group 3025.)
29. Fill winch with recommended oil. See Change Winch
Oil—If Equipped. (Operator’s Manual.)
SW03989,0000A9D ­19­05OCT10­5/5

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 Removal and Installation

Fastening Cable to Winch Drum—4000 Series

CAUTION: Prevent possible injury from cable

wire. Wear gloves when handling cable to
protect hands from cable wire cuts. DO NOT

TX1018826A —UN—12MAR07
guide cable on winch with your hands.

IMPORTANT: If a ferruled cable is used, the drum

plug (3) must be installed to prevent cable
from bending cable slot.

1. Attach cable to winch drum using one of the following

methods:
Method 1: Attach a ferrule or cable clamp (1) to end
of cable.
2. Wrap cable around the drum. Slide the ferrule or
cable clamp under the cable and into slot in drum, and
secure with tab (2).
3. Adjust free spool drag to operator’s preference.
NOTE: Factory free spool drag setting was done
without cable; adjust free spool drag to operator’s
preference when cable is added.

NOTE: Ten inch drum only has pocket method of

locating ferrule cable to drum.

1— Cable Clamp 3— Drum Plug

2— Tab

TX1018827A —UN—12MAR07
Continued on next page GD61784,00000B1 ­19­02JUL07­1/3

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 Removal and Installation

IMPORTANT: If cable is unwound below one turn

on drum, cable will come off drum.

1. Method 2: Remove drum plug (2).

CAUTION: Prevent possible injury from cable

wire. Wear gloves when handling cable to
protect hands from cable wire cuts. DO NOT
guide cable on winch with your hands.

2. Thread cable up through small hole and insert cable

back down through lower hole. Pull loop into drum.
3. Adjust free spool drag to operator’s preference.
NOTE: Factory free spool drag setting was done
without cable; adjust free spool drag to operator’s
preference when cable is added.

2— Drum Plug

TX1018825A —UN—12MAR07
TX1018824A —UN—12MAR07
Continued on next page GD61784,00000B1 ­19­02JUL07­2/3

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 Removal and Installation

1. Method 3: Remove drum plug.

CAUTION: Prevent possible injury from cable

wire. Wear gloves when handling cable to
protect hands from cable wire cuts. DO NOT

TX1018822A —UN—12MAR07
guide cable on winch with your hands.

2. Thread cable up through small hole and wrap cable

around wedge (1). Insert cable back down through
lower hole and pull wedge into drum slot (2).
NOTE: Factory free spool drag setting was done
without cable; adjust free spool drag to operator’s
preference when cable is added.

3. Adjust free spool drag to operator’s preference.

1— Wedge 2— Drum Slot

TX1018823A —UN—12MAR07
GD61784,00000B1 ­19­02JUL07­3/3

Winch Free Spool Drag Adjustment

NOTE: The winch drum drag can be adjusted to
operator’s preference.

TX1018816A —UN—12MAR07
1. Start engine.
2. Lower equipment to ground.
3. Engage park brake.
4. Block wheels.
5. Move winch control handle to FREE SPOOL position.
6. Loosen nut (1). 4000 Winch

7. Adjust slotted shaft (2) to desired winch drum drag.

8. Tighten nut.

1— Nut 2— Slotted Shaft

TX1018817A —UN—12MAR07

6000 Winch
GD61784,00000B2 ­19­02JUL07­1/1

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 Removal and Installation

Winch 6000 Series Remove and Install

NOTE: Cable must be removed from winch
before servicing.

1. Prepare machine for service. See Park and Prepare

for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate all hydraulic control valves to release pressure

in hydraulic system. Depress brake pedal at 1­second
intervals 20 times to drain oil from accumulator.
3. Turn battery disconnect switch to OFF position. See
Battery Disconnect. (Operator’s Manual.)
4. Remove cotter pin and pin (2) to disconnect yoke.

TX1080950 —UN—17AUG10
5. Remove cap screws (3) and washers to remove
mounting bracket and winch control cable.
6. Remove cap screws to disconnect winch driveline (5).
7. Disconnect hydraulic lines (1 and 4). Close all
openings using caps and plugs.
Pin, Cap Screws, and Winch Input Yoke
8. Drain winch oil. See Change Winch Oil—If Equipped.
(Operator’s Manual.)
1— Pressure Inlet Line 4— Return Oil Line
2— Pin 5— Driveline
3— Cap Screw (2 used)

Continued on next page SW03989,0000A9E ­19­05OCT10­1/2

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 Removal and Installation

9. Fasten lifting chain around winch as shown and

connect chain to a hoist.
10. Remove front and rear winch mounting cap screws.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

11. Lift winch off equipment frame.

Specification
Winch—Weight
(approximate)................................................................................ 780 kg
1720 lb

12. Inspect and repair winch as necessary. See 60 and

6000 Winches. (CTM41.)

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

13. Install winch.

T7533AX —UN—09JUL91
Specification
Winch—Weight
(approximate)................................................................................ 780 kg
1720 lb

14. Install front and rear mounting cap screws and tighten
to specification.
Specification Chain Around Winch
Winch Mounting Cap
Screw—Torque............................................................................620 N∙m
21. Turn battery disconnect switch to ON position. See
455 lb­ft
Battery Disconnect. (Operator’s Manual.)
15. Connect hydraulic lines.
IMPORTANT: Oil capacity for winch is greater than
16. Connect winch driveline. Install and tighten cap transmission oil capacity. Check transmission
screws to specification. oil level frequently while filling to avoid
transmission pump cavitation.
Specification
Winch Cross­to­Yoke
NOTE: Power In position will deliver 7.8—9.5 L (2—2­1/2
Cap Screw—Torque......................................................................58 N∙m
gal) per minute to fill winch. Free Spool position
43 lb­ft
will take approximately 1/2 hour to fill winch.
17. Install control cable mounting bracket and washers,
and tighten cap screws. 22. Operate the winch in either Power In or Free Spool
position to fill winch. Check transmission oil levels
18. Install and adjust control cable. See Winch Control frequently when filling winch. See Check Transmission
Valve Linkage Remove and Install or see Winch Oil Level. (Operator’s Manual.)
Control Cable Remove and Install. (Group 3015.)
23. Install cable. See Fastening Cable to Winch
19. Connect yoke to valve. Install pin and cotter pin. Drum—6000 Series. (Group 3000.)
20. Fill winch with recommended oil. See Change Winch
Oil—If Equipped. (Operator’s Manual.)
SW03989,0000A9E ­19­05OCT10­2/2

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 Removal and Installation

Fastening Cable to Winch Drum—6000 Series

CAUTION: Prevent possible personal injury from

cutting wire. Wear gloves when handling cable
to protect hands from cable wire cuts. DO NOT

TX1018818A —UN—12MAR07
guide cable on winch with your hands.

1. Insert cable end through small hole (3) of nibble (1).

2. Separate cable end so wedges (2) are positioned tight
against cable wires (4). Pull cable tight against nibble.

1— Nibble 3— Small Hole in Nibble

2— Wedge (2 used) 4— Cable Wires

TX1018820A —UN—12MAR07
GD61784,00000B4 ­19­02JUL07­1/2

3. Lay cable in winch drum slot and install tab (5) tight
against drum.

5— Tab
TX1018821A —UN—12MAR07

GD61784,00000B4 ­19­02JUL07­2/2

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 Removal and Installation

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 Group 3015
Control Linkage

Winch Control Valve Linkage Remove and Install

T131308 —UN—01JUN00

Continued on next page GD61784,00000B5 ­19­02JUL07­1/2

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 Control Linkage

1— Pin (4000 Winch—3 used) 12— Cap Screw (2 used) 23— Boot 34— Ball Joint
2— Yoke 13— Clamp (2 used) 24— Clip (6 used) 35— Washer (3 used)
3— Pin (4000 Winch—3 used) 14— Spring 25— Ring 36— Nut
4— Nut 15— Strap 26— Cap Screw (2 used) 37— Lock Nut
5— Bracket 16— Strap (2 used) 27— Washer (2 used) 38— Wedge
6— Bracket 17— Bellcrank 28— Plate 39— Lever
7— Washer (3 used) 18— Bushing 29— Bracket 40— Ball Joint
8— Nut (3 used) 19— Bolt 30— Strap (2 used) 41— Nut
9— Spacer (2 used) 20— Cap Screw (2 used) 31— U­Bolt 42— Cap Screw (3 used)
10— Cap Screw (2 used) 21— Bushing 32— Cap Screw 43— Washer (2 used)
11— Control Cable 22— Knob 33— Lock Nut (2 used) 44— Label

1. Remove worn or damaged parts and replace as 2. Apply one drop of medium strength thread lock and
necessary. sealer to threads of ball joint (40).
GD61784,00000B5 ­19­02JUL07­2/2

Winch Control Cable Remove and Install

1. Remove old cable.
2. Install new cable into cab. Install straps (30), U­bolt
(31), and lock nuts (33).

T7711AG —UN—13MAR92
3. Install ball joint (34) six turns.
4. Secure the lever to the right rear of the BRAKE OFF
slot.
5. Push cable winch end IN to remove slack. Measure
from end of cable to center of mounting groove
and adjust ball joint (34) until distance (A) is to
specification.
Specification
End of Cable­to­Center
of Mounting
Groove—Distance....................................................................... 159 mm

T129676B —UN—04APR00
6.250 in.

6. Install cable through frame and attach bracket (6),

strap (15), clamp (13), bushing (21) and cap screws
(20) on winch.
7. Install spring (14), washer (7), nut (4) and yoke (2) on
winch end of cable.

A—End of Cable­to­Center of
Mounting Groove Distance

Continued on next page GD61784,00000B6 ­19­02JUL07­1/5

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 Control Linkage

IMPORTANT: Winch valve must be in FREE SPOOL

position to correctly adjust linkage.

8. Push winch valve spool IN, as far as possible, into

FREE SPOOL position.
9. With the 4000 winch bellcrank or 6000 winch valve

T7402AE —UN—06NOV90
spool in free spool position, pull cable with 44.5 N (10
lb­force).
Specification
Cable Pull (Free Spool
Position)—Force.............................................................................44.5 N
10 lb­force
On 4000 Series winch only, apply 22.2 N (5 lb­force)
to bellcrank toward cable end.
10. Adjust the 4000 winch yoke to align with hole in
Specification bellcrank. Adjust the 6000 winch yoke to align with
4000 Series Winch (Only) valve spool.
Bellcrank—Force............................................................................22.2 N
5 lb­force 11. Connect the yoke to the 4000 winch bellcrank (or 6000
winch valve spool) and install pin.
GD61784,00000B6 ­19­02JUL07­2/5

12. Move control lever to BRAKE ON (hold) position.

13. Slide bracket (A) so that lip contacts spring.
14. Tighten bracket and control cable cap screws.

A—Bracket

T113917 —UN—13APR98
4000 Series Winch

T7402AI —UN—26NOV90

6000 Series Winch

Continued on next page GD61784,00000B6 ­19­02JUL07­3/5

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 Control Linkage

T7374AY —19—30OCT90 T7374AZ —19—30OCT90

15. Run engine at slow idle.
16. Move control lever to FREE SPOOL position and
release lever. There must be 3—5 mm (0.120—0.160
in.) distance between lever and stop screw.
Specification
Control Lever­to­Stop
Screw (Free Spool
Position)—Distance....................................................................3—5 mm
0.120—0.160 in.

NOTE: It is normal for engine to pull down when

POWER IN is first engaged. This valve
sequencing is to prevent winch brake from 18. While POWER IN is engaged, release lever. Lever
dropping load before clutch engages. must return to BRAKE ON (hold) when released from
any POWER IN position. If lever does not return,
17. Slowly move control lever to POWER IN position until increase return spring tension as described earlier in
drum turns. There must be 6—8 mm (0.240—0.320 this procedure.
in.) distance between lever and stop screw. Adjust
as required.
Specification
Control Lever­to­Stop
Screw (Power In
Position)—Distance....................................................................6—8 mm
0.240—0.320 in.
GD61784,00000B6 ­19­02JUL07­4/5

T7374AY —19—30OCT90 T7397AZ —19—30OCT90

19. Move winch control lever to free spool position.
20. Pull lever rearward with specified force, then move
lever to left side.
Specification
Winch Control Lever
(Rearward Pull)—Force..................................................................22.2 N
5 lb­force
Lever must move freely through the gate and not rub
against rear of right slot or front of left slot. If lever
rubs slot gate, readjust winch cable yoke as described
earlier in this procedure.
GD61784,00000B6 ­19­02JUL07­5/5

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 Control Linkage

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 Group 3025
Input Drive Shafts and U­Joints

Winch Drive Shaft Remove and Install

1. Engage park brake.

CAUTION: Avoid possible injury from unexpected

TX1025719A —UN—29JUN07
machine movement. Install articulation locking
bar before working in frame hinge area.

2. Install articulation locking bar.

3. Remove guards in frame pivot area as necessary to
gain access to winch drive shaft.
4. Remove cap screws (1) on each end of drive shaft.
5. Remove drive shaft. Inspect and replace parts as
necessary.
6. Install drive shaft with male yoke end (2) toward
transmission and female yoke end (3) toward winch.

TX1025720A —UN—29JUN07
7. Tighten cap screws to specification.
Specification
3/8 in. Cross and Bearing
Assembly­to­Yoke Cap
Screw—Torque...................................................................... 51—57 N∙m
38—42 lb­ft
1/2 in. Cross and Bearing
Assembly­to­Yoke Cap
Screw—Torque.................................................................. 127—142 N∙m
1— Cap Screw (4 used per 3— Female Yoke End
94—105 lb­ft
joint)
2— Male Yoke End
8. Remove articulation locking bar
AC12469,0000420 ­19­30JUL07­1/1

Winch Drive Shaft Disassemble and Assemble

1. Disassemble parts (1—5).
1
2. Inspect for excessively worn or damaged parts. 1
Replace parts as necessary.
3. Assemble parts. 2 4

TX1024077 —UN—04JUN07
5
4. Tighten cap screws (5).
3 3
Specification 5
Winch Drive Shaft
Cross and Bearing
Assembly­to­Yoke 3/8 in. 1
Cap Screw—Torque......................................................................58 N∙m 1
43 lb­ft
Drive Shaft
5. Lubricate shaft after installation on machine.
1— Cap Screw (8 used) 4— Lubrication Fitting
2— Drive Shaft 5— Cap Screw (8 used)
3— Cross and Bearing
Assembly (2 used)

SW03989,0000A9C ­19­06AUG10­1/1

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 Input Drive Shafts and U­Joints

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 Group 3050
Drive and Clutch

Winch 4000 Series Drive and Clutch Repair

For winch repair, go to the appropriate repair story using
the table of contents in component technical manual.
(CTM25.)
GD61784,00000BF ­19­03JUL07­1/1

Winch 6000 Series Drive and Clutch Repair

For winch repair, go to the appropriate repair story using
the table of contents in component technical manual.
(CTM41.)
GD61784,00000C0 ­19­03JUL07­1/1

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 Drive and Clutch

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 Section 32
Stacking Blades
Contents

Page

Group 3201—Blades
Stacking Blade Remove and
Install ..................................................... 32­3201­1
Spherical Bushing Remove and
Install ..................................................... 32­3201­5

Group 3215—Controls Linkage

Blade Control Linkage Remove
and Install .............................................. 32­3215­1
Blade Control Valve Remove and
Install ..................................................... 32­3215­2

Group 3260—Hydraulic System

Blade Lift Cylinder Remove and
Install ..................................................... 32­3260­1

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 Contents

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 Group 3201
Blades

Stacking Blade Remove and Install

1. Lower all equipment to the ground. Operate all control
levers to relieve pressure in the hydraulic system.
NOTE: One front wheel must be removed before
stacking blade pin can be removed.

T195555B —UN—21OCT03
2. Remove one front wheel. See Wheel Remove and
Install. (Group 0110.)

CAUTION: Prevent possible crushing injury from

heavy component. Use proper lifting device.
Right Stacking Blade Cylinder
3. Support blade cylinder using lifting straps.
Specification 1— Cylinder Pin 3— Cap Screw
Blade Cylinder—Weight 2— Retainer
(approximate).................................................................................. 35 kg
77 lb

4. Remove cap screws and retainers (2 and 3) and

cylinder pins (1) to disconnect right and left blade
cylinders.
Continued on next page GD61784,0000031 ­19­10MAR09­1/5

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 Blades

TX1056819 —UN—06MAR09
TX1056819
Exploded View of Stacking Blade
4— Stacking Blade 7— Cap Screw 10— Seal 13— Pin
5— Bushing 8— Bushing 11— Washer 14— Lock Nut
6— Lubrication Fitting 9— Washer 12— Cap Screw

CAUTION: Prevent possible crushing injury from 8. Remove lock nut (14) and cap screw (12).
heavy component. Use proper lifting device.
9. Remove pin (13) and stacking blade (4).
5. Support stacking blade (4). 10. Inspect stacking blade for cracks or damage.
Specification 11. Inspect spherical bushings in cylinder bores and blade
Stacking Blade—Weight pivot bores for wear or damage. If a bushing must be
(approximate).............................................................................. 1360 kg replaced, see Spherical Bushing Remove and Install.
3000 lb (Group 3201.)
6. Lower bottom guard.
7. Remove cap screws (7).
Continued on next page GD61784,0000031 ­19­10MAR09­2/5

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 Blades

T8509AC —UN—19JUN95

Blade Lower Pin

Continued on next page GD61784,0000031 ­19­10MAR09­3/5

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 Blades

A—Washer (as required) D—Seal Washer G—Blade Pin Cap

B—Shim (as required) E—Hardened Washer — Washer
C—Engine Frame F— Cap Screw H—3—6 mm (0.120—0.240 in.)
Clearance Dimension

12. Install stacking blade with washers properly positioned

as shown. IMPORTANT: If blade is sprung so that specified
gap cannot be obtained, the blade must be
13. Replace lubrication fittings if necessary. removed and pushbeams bent back until gap
specification can be obtained.
14. Apply medium strength thread lock and sealer to cap
screw (F). 17. Install seal washer (D) on pin. Install cap or washer
15. Install one washer (A) on pin, then put new cap or (G) and washer (E).
washer (G) on pin, and hold in place. 18. Apply medium strength thread lock and sealer to cap
IMPORTANT: A minimum of 3 mm (0.120 in.) gap (H) screw (F) and tighten to specification.
must be left on each side of pin to prevent a side Specification
impact from breaking off pin cap screws. Blade Pin Cap Assembly
Cap Screw—Torque.....................................................................495 Nm
16. Measure gap (H) between cap and washer. Install or 365 lb­ft
remove shims (B) until specified gap is obtained.
Specification
Cap­to­Washer—Gap.................................................................3—6 mm
0.120—0.240 in.
GD61784,0000031 ­19­10MAR09­4/5

CAUTION: Prevent possible crushing injury from

heavy component. Use proper lifting device.

19. Lift blade using a hoist. Install washer shims (5)

equally to each side of rod end as required so that
cylinders do not bind. Install pin (3) through cylinder,

T195568A —UN—21OCT03
shims and spherical bushing (4).
Specification
Stacking Blade—Weight
(approximate).............................................................................. 1360 kg
3000 lb
Blade Cylinder—Weight
(approximate).................................................................................. 35 kg Cap Screw and Cylinder Pin
77 lb

20. Install cap screw (1) and retainer (2) and tighten. 1— Cap Screw 4— Spherical Bushing
2— Retainer 5— Washer Shim (as required)
21. Install front wheel. See Wheel Remove and Install. 3— Pin
(Group 0110.)
GD61784,0000031 ­19­10MAR09­5/5

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 Blades

Spherical Bushing Remove and Install

1. If bushing (A) in blade pivot bore must be replaced,
remove washer (B) using a grinder to remove weld.

A—Bushing B—Washer

T7502HJ —UN—02JUL91
GD61784,0000032 ­19­30MAY07­1/3

2. Remove bushing (B). See DFT1099 Bushing Drivers.

(Group 9900.)

A—Pipe Assembly D—Washer

B—Spherical Bushing E—Nut
C—Pipe Assembly

T7569AM —UN—09JUL91
Continued on next page GD61784,0000032 ­19­30MAY07­2/3

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 Blades

3. Install bushing. See DFT1099 Bushing Drivers.

(Group 9900.)
4. Turn nut (F) until center line (B) of bushing aligns with
center line (C) of frame.

CAUTION: Have only a qualified welder do the

T7569AL —UN—09JUL91
welding. Be sure the area near the machine is
free of debris and flammable material. Before
welding, clean all dirt and paint from weld
area. Disconnect the battery negative cable.
Connect the welder ground clamp as close
as possible to each weld area.

5. Weld new washers in place at the same location

where old ones were removed. A—Pipe Assembly D—Bar Stock
B—Bushing Center Line E—Washer
See Make Welding Repairs Safely. (Group 9000­01.) C—Frame Center Line F— Nut

See Remove Paint Before Welding or Heating. (Group

9000­01.)
GD61784,0000032 ­19­30MAY07­3/3

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 Group 3215
Controls Linkage

Blade Control Linkage Remove and Install

TX1056821 —UN—06MAR09
TX1056821
Blade Control Linkage
1— Shim 6— Nut 11— Spring Locking Pin 16— Boot Retainer
2— Bushing (2 used) 7— Washer 12— Rod 17— Nut
3— Knob 8— Bushing 13— Jam Nut
4— Control Lever 9— Lock Nut 14— Ball Joint
5— Boot 10— Pin 15— Boot

1. Lower blade and relieve all hydraulic pressure. 4. Clean threads of pivot ball joint (14) and apply medium
strength thread lock and sealer.
CAUTION: Avoid possible injury from unexpected
machine movement. Install articulation locking 5. Adjust length of rod (12) so horizontal leg of control
bar before working in frame hinge area. lever (4) is level.
6. Clean threads of lever (4) and apply medium strength
2. Install articulation locking bar. thread lock and sealer then install knob (3).
3. Inspect and replace blade control linkage parts as
necessary.
GD61784,0000039 ­19­06MAR09­1/1

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 Controls Linkage

Blade Control Valve Remove and Install

TX1056822 —UN—06MAR09
TX1056822
Blade Control Valve
1— Cap Screw (3 used) 3— Blade Valve Support 5— Cap Screw (3 used) 7— Spring Lock Pin
2— Rubber Mount (3 used) 4— Washer (5 used) 6— Rod 8— Pin

1. Lower blade and relieve all hydraulic pressure. 3. Remove blade control valve.

CAUTION: Avoid possible injury from unexpected 4. Inspect and repair as necessary.
machine movement. Install articulation locking 5. Inspect blade control valve support and replace parts
bar before working in frame hinge area. as necessary.
2. Install articulation locking bar. 6. Install blade control valve.
GD61784,000003A ­19­06MAR09­1/1

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 Group 3260
Hydraulic System

Blade Lift Cylinder Remove and Install

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all

X9811 —UN—23AUG88
connections before applying pressure.

1. Operate all hydraulic control valves to release

pressure in hydraulic system.
2. Disconnect lines (5).

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

3. Attach hoist to blade lift cylinder using a lifting strap.

Specification

T195555A —UN—21OCT03
Blade Cylinder—Weight
(approximate).................................................................................. 35 kg
77 lb

4. Remove cap screws and retainers (1).

5. Remove pins (2) to remove blade lift cylinder.
6. Repair or replace blade lift cylinder as required. Wheel Removed for Illustration Purposes Only
7. Install blade lift cylinder.
1— Cap Screw and Retainer 4— Hydraulic Line Guard
2— Pin 5— Hydraulic Lines
3— Cap Screw

GD61784,0000033 ­19­25JUL07­1/1

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 Hydraulic System

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 Section 38
Grapple
Contents

Page Page

Group 3803—Grapple Mechanism Solenoid Operated Valve Remove

Grapple Remove and Install ...................... 38­3803­1 and Install ............................................ 38­3860­35
Grapple Disassemble and Grapple Rotate Solenoid Valve
Assemble............................................... 38­3803­2 Remove and Install.............................. 38­3860­36
Grapple Dampener Disassemble Grapple Rotate Solenoid Valve
and Assemble........................................ 38­3803­4 Disassemble and Assemble ................ 38­3860­37
Grapple Dampener Adjustment ................. 38­3803­6 Flow Divider Repair ................................. 38­3860­38
Dampener, Yoke, and Crosshead Rotary Manifold Remove and
Pins Lubricate........................................ 38­3803­7 Install ................................................... 38­3860­40
Grapple Rotate Yoke Disassemble Rotary Manifold Disassemble and
and Assemble........................................ 38­3803­8 Assemble............................................. 38­3860­41

Group 3840—Frames
Dual Function Grapple Cable
Rollers Remove and Install.................... 38­3840­1
Dual Function Grapple Boom
Remove and Install................................ 38­3840­2
Dual Function Grapple Arch
Remove and Install................................ 38­3840­3

Group 3860—Hydraulic System

Boom or Arch Cylinder Remove
and Install—Dual Function
Grapple.................................................. 38­3860­1
Grapple Tong Cylinder Remove
and Install .............................................. 38­3860­3
Grapple Rotate Motor Remove and
Install ..................................................... 38­3860­5
Grapple Rotate Motor
Disassemble .......................................... 38­3860­7
Grapple Rotate Motor Assemble ............. 38­3860­12
Rotate Motor Drive Gear Remove
and Install ............................................ 38­3860­20
Control Valve Options.............................. 38­3860­20
Pilot Operated Control Valve
Remove and Install.............................. 38­3860­22
Dual Function Pilot Operated
Control Valve Disassemble and
Assemble............................................. 38­3860­25
Control Valve Relief Valves
Remove and Install.............................. 38­3860­27
Lift Check Valve Disassemble and
Assemble............................................. 38­3860­28
Non­adjustable Circuit Relief Valve
Disassemble and Assemble ................ 38­3860­29
Adjustable Circuit Relief Valve
Disassemble and Assemble ................ 38­3860­30
Spool Valve Disassemble and
Assemble............................................. 38­3860­32
Detent Disassemble and
Assemble............................................. 38­3860­33
Pilot Operated Valve Remove and
Install ................................................... 38­3860­34

TM11813 (13OCT10) 38­1 748H Repair (S.N. 630436— )

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 Contents

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 Group 3803
Grapple Mechanism

Grapple Remove and Install

1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate hydraulic control valves to release pressure

in hydraulic system. Depress brake pedal at 1­second
intervals 20 times to drain oil from accumulator.
3. Disconnect rotary manifold­to­cylinder rod end hose
(3) and rotary manifold­to­flow divider hose (4). Close
all openings using caps and plugs.
4. Disconnect shock absorber (2) from rotary yoke.

TX1081158A —UN—27AUG10
CAUTION: Prevent possible crushing injury from
heavy component. Use proper lifting device.

5. Remove grapple by removing pins (1).

Specification
Grapple Head and
Tongs—Weight
(approximate)...............................................................................1134 kg
Grapple Remove and Install
2500 lb

6. Inspect and repair as necessary. See Grapple 1— Pin (2 used) 3— Rotary Manifold­to­Cylinder
Disassemble and Assemble. (Group 3803.) 2— Shock Absorber Rod End Hose
4— Rotary Manifold­to­Flow
Divider Hose
CAUTION: Prevent possible crushing injury from
heavy component. Use proper lifting device.

7. Install grapple using pins. 8. Connect shock absorber to rotary yoke. Tighten nut
Specification snug, then back off 1/2 turn.
Grapple Head and 9. Connect rotary manifold hoses to cylinder rod end and
Tongs—Weight flow divider.
(approximate)...............................................................................1134 kg
2500 lb
SW03989,0000AA4 ­19­02SEP10­1/1

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 Grapple Mechanism

Grapple Disassemble and Assemble

TX1081371 —UN—03SEP10

Grapple Components

Continued on next page SW03989,0000AA5 ­19­03SEP10­1/2

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 Grapple Mechanism

1— Top Cover (2 used) 7— Washer (2 used) 13— Cap Screw (2 used) 19— Nut (2 used)
2— Cap Screw (4 used) 8— Cap Screw (2 used) 14— Bushing (4 used) 20— Lubrication Fitting (2 used)
3— Grapple Frame 9— Grapple Pin (2 used) 15— Cylinder Rod Pin (2 used) 21— Tong (2 used)
4— Shim (2 used) 10— Tong Pin (2 used) 16— Bushing (2 used) 22— Tooth (2 used)
5— Shim (4 used) 11— Washer (2 used) 17— Washer (2 used)
6— Bushing (2 used) 12— Washer (2 used) 18— Cap Screw (2 used)

Grapple Head
CAUTION: Prevent possible crushing injury from Frame—Weight
heavy component. Use proper lifting device. (approximate).................................................................................115 kg
254 lb
IMPORTANT: The pins that attach the head end of Grapple Tong—Weight
the cylinder also attach the opposite tong to (approximate).......................................................................104—194 kg
the frame. Tong cylinders should be removed 230—428 lb
one at a time to prevent both grapple tongs
from falling out of the frame. 2. Inspect for worn or damaged parts. Replace parts as
necessary.
1. Disassemble parts as shown. See Grapple Tong
Cylinder Remove and Install for removal procedure. 3. Assemble parts. Install all washers in the same
(Group 3860.) locations and quantities as removed.
Specification
Grapple Head and
Tongs—Weight
(approximate)...............................................................................1134 kg
2500 lb
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 Grapple Mechanism

Grapple Dampener Disassemble and Assemble

T131307 —UN—01JUN00

Grapple Dampener

Continued on next page SW03989,0000AA6 ­19­02SEP10­1/2

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 Grapple Mechanism

1— Plug (6 used) 9— O­Ring 17— Disk (5 used) 25— Washer

2— Spring (6 used) 10— Plug 18— Cotter Pin 26— Lubrication Fitting (2 used)
3— Washer (18 used) 11— Shaft 19— Pin 27— Bushing (2 used)
4— Snap Ring 12— O­Ring 20— Pin 28— Grapple Dampener Housing
5— O­Ring 13— Snap Ring 21— Washer 29— Pin
6— O­Ring 14— Bushing 22— Cap Screw 30— Spacer
7— Housing 15— Lubrication Fitting (6 used) 23— Lock Nut 31— Washer
8— Bushing 16— Plate (6 used) 24— Shock Absorber Cylinder 32— Cap Screw

assembled, this plate must be installed next to

CAUTION: Prevent possible crushing injury from the springs. Installing this galled plate next to a
heavy component. Use appropriate lifting device. friction element will damage the friction element.
1. Remove grapple using a suitable lifting device. See NOTE: If any friction material remains on disks (17),
Grapple Remove and Install. (Group 3803.) they are considered usable.

CAUTION: Prevent possible crushing injury from 6. Grease plates and disks with a clean coat of grease
heavy component. Use appropriate lifting device. containing 3—5% moly. Wipe off excess grease.

2. Remove grapple dampener using a suitable lifting 7. Install O­rings (9 and 12), shaft, and snap ring (13)
device. into housing.
Specification 8. Alternately install plates and disks, ensuring that the
Grapple Damp­ galled steel plate is toward springs.
ener—Weight (approxi­
mate)............................................................................................. 105 kg
NOTE: Install snap ring (4) with gap located at
231 lb
12 o’clock position. Snap ring helps retain
grease inside the housing.
3. Remove plugs (1), washers (3), and springs (2).
9. Install O­rings (5 and 6) into housing. Push housing
4. Push housing (7) inward to remove snap ring (4). into grapple dampener housing to install snap ring (4)
5. Remove plates (16), disks (17), shaft (11), and snap with snap ring gap at 12 o’clock position.
ring (13) from grapple dampener housing (28). Inspect 10. Adjust dampener. See Grapple Dampener Adjustment.
for wear or damage. (Group 3803.)
IMPORTANT: The plate located next to springs (2) will
show normal wear or galling. When dampener is
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 Grapple Mechanism

Grapple Dampener Adjustment

The grapple dampener limits the motion of the grapple
head when traveling empty and prevents damage to the
structural components, especially the yoke, crosshead,
and pins.
Adjust the dampener if the head swings to extreme
heights or hits the stops. Adjust the dampener by
adding or subtracting the number of shim washers in the
dampener assembly.
1. Slightly loosen adjusting plugs (1) (every other plug or
all six plugs) evenly to remove spring tension and to
keep housing from rotating.
2. Remove three plugs.
3. Remove one shim washer (2) from each of the three
plugs to tighten grapple dampener, or add one shim
washer to each plug to loosen.

TX1019945A —UN—13MAR07
4. Apply 3—5% moly grease to adjusting plug thread and
the inside of plugs. Tighten plugs evenly until plugs
contact shim washers.
5. Repeat for other three plugs. Be sure that all plugs
have an equal number of shims.
TEST CONDITIONS:
Adjusting Plugs and Shim Washer
NOTE: The grapple head should be 10—15° from vertical
under the following test conditions.

a. Close tongs and raise the grapple arch or boom to

full height.
b. Lower the arch or boom slowly and bring to a
smooth stop when the tongs are approximately 300
mm (12 in.) above the ground.
c. When properly adjusted, the grapple head will be
10—15° from vertical. Measure with a magnetic
base inclinometer (3).
IMPORTANT: The snap ring gap is positioned at
vertical top to maintain the grease level in the
dampener housing. Retain this position while
tightening plugs by holding the dampener
housing with a pry bar.
Do not add any washers to the inside of the
adjusting plugs in an attempt to tighten the
TX1019947A —UN—13MAR07

dampener assembly. This will cause the

springs to become a solid member. Damage
to the outer dampener housing will result.
If additional dampening is required after all
shim washers are removed, it is necessary
to replace the disks inside the dampener
assembly. See your authorized dealer.
Magnetic Base Inclinometer
6. If additional tightness is required, remove shim
washers from plugs with the greatest number of shim
washers. If additional looseness is required, add 1— Plug (6 used) 3— Magnetic Base Inclinometer
2— Shim Washer (up to 24
shim washers to plugs with the least number of shim used)
washers. Repeat steps 1—4 until desired tightness
is achieved. Continued on next page SW03989,0000AA7 ­19­02SEP10­1/2

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 Grapple Mechanism

7. To hold dampener housing in place, use a pry bar Specification

between plugs. Tighten plugs to specification. Grapple Dampener
Adjusting Plug—Torque...............................................................184 N∙m
250 lb­ft

SW03989,0000AA7 ­19­02SEP10­2/2

Dampener, Yoke, and Crosshead Pins

Lubricate
IMPORTANT: If dampener spline grease fitting (4)
is not greased at proper intervals, premature

TX1019045A —UN—12MAR07
spline failure could occur.
If grease fitting does not accept grease, make
sure the grapple head is on the ground before
attempting to lubricate again.

NOTE: Lubricate the four fittings until grease

escapes at joints.
Dampener, Yoke and Crosshead Pins
Lubricate fittings until clean grease escapes at joints. For
grease specification, see Grease. (Operator’s Manual.)

1— Top Locating Point 4— Dampener Spline Grease

2— Bushing Next to Dampener Fitting
Assembly Grease Fitting 5— Brake Plate Grease Fitting
3— Dampener Head Outer 6— Dampener Brake Assembly

TX1019054 —UN—12MAR07
Bushing Grease Fitting

Cross Section of Upper Dampener Pin

T102161 —UN—22JUL96

Lower Pin
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 Grapple Mechanism

Grapple Rotate Yoke Disassemble and Assemble

2 3 4 5
6 7 8 9

TX1051670 —UN—20FEB09
10
12
11

TX1051670
Grapple Rotate Yoke
1— Grapple Yoke 4— Seal 7— Upper Bearing Race 10— Shim (as required)
2— Bushing 5— Lower Bearing Cone 8— Upper Bearing Cone 11— Rotate Motor Driven Gear
3— Spacer 6— Lower Bearing Race 9— Shim (as required) 12— Cap Screw (12 or 14 used)

1. Remove grapple. See Grapple Remove and Install. 8. Clean all mating surfaces.
(Group 3803.)
9. Install spacer (3) tight against shoulder of grapple
2. Remove grapple crosshead. See Grapple Dampener yoke.
Disassemble and Assemble. (Group 3803.)
10. Install seal (4) in spacer groove.
3. Remove rotary manifold. See Rotary Manifold
Remove and Install. (Group 3860.)
CAUTION: Prevent possible burn injury.
Hot equipment and fluids can cause burns
CAUTION: Prevent possible crushing injury from to unprotected skin. Wear gloves and
heavy component. Use appropriate lifting device. protective clothing when working with hot
equipment and fluids.
4. Support the grapple yoke (1) using appropriate lifting
device. IMPORTANT: Damage to the bearing may occur;
Specification use proper heating device.
Grapple Yoke—Weight
(approximate).................................................................................. 54 kg 11. Heat lower bearing cone (5) to specification.
119 lb
Specification
IMPORTANT: Use new cap screws to install grapple Lower Bearing
yoke to prevent cap screw failure. Cone—Temperature......................................................................... 78°C
175°F
5. Remove and discard cap screws (12). 12. Install bearing cone with large end toward spacer.
6. Remove parts (1—11). Bearing cone must be tight against spacer.

7. Inspect and replace parts as necessary.

Continued on next page SW03989,0000AA9 ­19­15SEP10­1/9

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 Grapple Mechanism

13. Install upper and lower bearing races (6 and 7).

Bearing races must be tight against housing.
7
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.

TX1056637 —UN—05MAR09
14. Install and support grapple yoke into arch or boom
(13).
Specification
Grapple Yoke—Weight 6
(approximate).................................................................................. 54 kg
119 lb
Bearing Races
CAUTION: Prevent possible burn injury.
Hot equipment and fluids can cause burns
to unprotected skin. Wear gloves and
protective clothing when working with hot 13
equipment and fluids.

TX1081181 —UN—25AUG10
IMPORTANT: Damage to the bearing may occur;
use proper heating device.

15. Heat upper bearing cone (8) to specification. 1

Specification
Upper Bearing
Cone—Temperature......................................................................... 78°C
14
175°F Grapple Yoke

16. Install upper bearing cone.

1— Grapple Yoke 13— Arch or Boom
17. Turn grapple yoke so the pivot pin bore (14) is 90° to 6— Lower Bearing Race 14— Pivot Pin Bore
arch or boom (13) as shown. 7— Upper Bearing Race

Continued on next page SW03989,0000AA9 ­19­15SEP10­2/9

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 Grapple Mechanism

18. Install rotate motor driven gear (11) so cutout (17) is 15

aligned with rotate motor drive gear (15). Align two 4
mm holes (16) as shown.
11
19. Install four cap screws (12) 90° apart as shown from
top.

11— Rotate Motor Driven Gear 16— Hole (4 mm) (2 used) 12 16

12— Cap Screw (12 or 14 used) 17— Cutout
15— Rotate Motor Drive Gear 12

17

TX1081182 —UN—25AUG10
12
16 12

Cap Screw Location (12 cap screw yoke)

15

11

12 16
12

17

TX1081183 —UN—25AUG10
12
16 12

Cap Screw Location (14 cap screw yoke)

Continued on next page SW03989,0000AA9 ­19­15SEP10­3/9

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 Grapple Mechanism

IMPORTANT: Bearing cones and bearing races

must be properly seated to maintain proper
bearing preload. Bearing failure may result
from improper bearing preload.

20. Grapple Yoke Bearing Preload Measurement:

a. Tighten cap screws in order shown to specification.
Specification
Gear­to­Yoke Cap 1
Screw—Torque..............................................................................41 N∙m 4
30 lb­ft

b. Tighten cap screws again in order shown to

specification. 3

TX1056258 —UN—23FEB09
Specification 2
Gear­to­Yoke Cap
Screw—Torque..............................................................................81 N∙m
60 lb­ft

c. Tighten cap screws again in order shown to

specification.
Cap Screw Tighten Order (12 cap screw yoke)
Specification
Gear­to­Yoke Cap
Screw—Torque............................................................................122 N∙m
90 lb­ft

d. Rotate grapple yoke ten revolutions. Tighten cap

screws in order shown to specification.
Specification
Gear­to­Yoke Cap
1
Screw—Torque............................................................................170 N∙m
125 lb­ft
4

e. Rotate grapple yoke a second time ten revolutions.

Tighten cap screws again in order shown to
specification.

TX1056256 —UN—23FEB09
Specification 3
Gear­to­Yoke Cap 2
Screw—Torque............................................................................170 N∙m
125 lb­ft

f. Rotate grapple yoke a third time ten revolutions.

Tighten cap screws again in order shown to
specification.
Cap Screw Tighten Order (14 cap screw yoke)
Specification
Gear­to­Yoke Cap
Screw—Torque............................................................................170 N∙m Specification
125 lb­ft Gear­to­Yoke Cap
Screw—Torque............................................................................170 N∙m
g. Rotate grapple yoke a fourth time ten revolutions. 125 lb­ft
Tighten cap screws again in order shown to
specification.
Continued on next page SW03989,0000AA9 ­19­15SEP10­4/9

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 Grapple Mechanism

21. Measure distance from top surface of rotate motor

driven gear to grapple yoke through both 4 mm holes 18 19 20
using a depth micrometer.
Record the average distance measurement from both
holes.
11
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.
1
22. Support yoke.
Specification
Grapple Yoke—Weight
(approximate).................................................................................. 54 kg
119 lb

23. Remove rotate motor driven gear.

24. Measure rotate motor driven gear thickness (20) at
both locations as shown.

TX1081184 —UN—25AUG10
Record the average thickness measurement from
both locations.
NOTE: The formula for this procedure is: A ­ B +
0.33 mm (0.013 in.) = C.

25. Subtract the average thickness of the rotate motor

driven gear (B) from the average distance from the top Shim Pack Measurement
surface of the gear to the yoke (A). This is the shim
pack thickness (C).
Add 0.33 mm (0.013 in.) to gap difference to obtain
shim pack dimension for bearing preload.
26. Arrange shims in shim pack so thickest shims are on 11
outside of shim pack.

1— Grapple Yoke 18— Shim Pack Thickness

11— Rotate Motor Driven Gear 19— Rotate Motor Driven Gear
16 19 19
16— Hole (4 mm) (2 used) Thickness 16
20— Top of Gear to Yoke

19 19 TX1081185 —UN—25AUG10

Rotate Motor Driven Gear Measurement

Continued on next page SW03989,0000AA9 ­19­15SEP10­5/9

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 Grapple Mechanism

27. Verify grapple yoke is positioned so pivot pin bore is

90° to arch or boom as shown.
28. Install shim pack. 13

1— Grapple Yoke 14— Pivot Pin Bore

TX1081181 —UN—25AUG10
13— Arch or Boom

14
Grapple Yoke

Continued on next page SW03989,0000AA9 ­19­15SEP10­6/9

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 Grapple Mechanism

29. Install rotate motor driven gear so the long

measurement of cutout is aligned with rotate motor 15
drive gear. Align two 4 mm holes as shown.

11— Rotate Motor Driven Gear 16— Hole (4 mm) (2 used) 11

12— Cap Screw (12 or 14 used) 17— Cutout
15— Rotate Motor Drive Gear
16

12

17

TX1081187 —UN—25AUG10
16

Rotate Driven Gear Cap Screw Location (12 cap screw yoke)

15

11

13
16
12

17

TX1081188 —UN—25AUG10
16

Rotate Driven Gear Cap Screw Location (14 cap screw yoke)

Continued on next page SW03989,0000AA9 ­19­15SEP10­7/9

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 Grapple Mechanism

IMPORTANT: Use new cap screws to install grapple

yoke to prevent cap screw failure.

30. Rotate Motor Driven Gear Torque Procedure:

a. Tighten cap screws in order shown to specification.
Specification
Gear­to­Yoke Cap
Screw—Torque..............................................................................41 N∙m
7 1
30 lb­ft 9
b. Tighten cap screws again in order shown to 5 11
specification. 3 4
Specification
12 6

TX1056259 —UN—24FEB09
Gear­to­Yoke Cap
Screw—Torque..............................................................................81 N∙m 10 8
2
60 lb­ft

c. Tighten cap screws again in order shown to

specification.
Specification
Gear­to­Yoke Cap
Cap Screw Tighten Order (12 cap screw yoke)
Screw—Torque............................................................................122 N∙m
90 lb­ft

d. Rotate grapple yoke ten revolutions. Tighten cap

screws in order shown to specification.
Specification
Gear­to­Yoke Cap
Screw—Torque............................................................................170 N∙m
125 lb­ft 1
13 9
e. Rotate grapple yoke a second time ten revolutions. 6 7
Tighten cap screws again in order shown to
specification. 11 3
Specification
4 12
Gear­to­Yoke Cap

TX1056262 —UN—23FEB09
Screw—Torque............................................................................170 N∙m 8 5
125 lb­ft 14 2 10
f. Rotate grapple yoke a third time ten revolutions.
Tighten cap screws again in order shown to
specification.
Specification
Gear­to­Yoke Cap Cap Screw Tighten Order (14 cap screw yoke)
Screw—Torque............................................................................170 N∙m
125 lb­ft
Specification
g. Mark each cap screw. Tighten cap screws in order Gear­to­Yoke Cap
shown to specification. Screw—Torque Turn....................................60° (1 flat on hex cap screw)

Continued on next page SW03989,0000AA9 ­19­15SEP10­8/9

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 Grapple Mechanism

31. Pump grease into arch tube grease fitting (21) while
rotating the grapple yoke until grease comes out from
under driven gear teeth all around gear.
32. Install rotary manifold. See Rotary Manifold Remove
and Install. (Group 3860.)
33. Install grapple crosshead. See Grapple Dampener
Disassemble and Assemble. (Group 3803.)
34. Install grapple. See Grapple Remove and Install.
21
13
(Group 3803.)
IMPORTANT: Grapple dampener must be adjusted
properly. Improper grapple dampener
adjustment may cause bearing damage.

TX1081189 —UN—25AUG10
1
35. Perform grapple dampener adjustment. See Grapple
Dampener Adjustment. (Group 3303.)

1— Grapple Yoke 21— Grease Fitting

13— Arch

Yoke Grease Fitting Location

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 Group 3840
Frames

Dual Function Grapple Cable Rollers Remove and Install

17 13 12
14 13
3 8

2 6 15
11
17

1
7

10
10

7
4
9

T195678 —UN—24OCT03
16

T195678
Dual Function Grapple Cable Rollers
1— Nut (4 used) 6— Washer (2 used) 11— Roller Frame 16— Shaft (2 used)
2— Cap Screw (2 used) 7— Washer (4 used) 12— Lubrication Fitting (2 used) 17— Washer (2 used)
3— Cap Screw (2 used) 8— Horizontal Roller 13— Bushing (2 used)
4— Cap Screw (4 used) 9— Vertical Roller (2 used) 14— Shaft
Lubrication Fitting (4 used) 10— Lubrication Fitting (2 used) 15— Strap
5— Washer (2 used)

1. Remove rollers (8 and 9). 3. Install bushings even with end surface of rollers.
2. Inspect bushings (13) and shafts (14 and 16) for wear 4. Install rollers.
or damage.
GD61784,00000C5 ­19­05JUL07­1/1

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 Frames

Dual Function Grapple Boom Remove and

Install
CAUTION: Avoid possible injury from unexpected
machine movement. Install articulation locking

TX1024405A —UN—05JUN07
bar before working in frame hinge area.

1. Install articulation locking bar.

2. Inspect boom for cracks.
IMPORTANT: Have only a qualified welder do the
welding. Be sure the area near the machine is
free of debris and flammable material. Before Boom
welding, clean all dirt and paint from weld
area. Disconnect the battery ground (—) cable.
Connect the welder ground clamp as close 1— Boom 3— Boom Pin (2 used)
2— Boom Cylinder Pin (2 used)
as possible to each weld area.

3. Weld any cracks using E7018 electrodes or equivalent.

See Make Welding Repairs Safely. (Group 9000­10.) 12. Inspect and repair as necessary.
See Remove Paint Before Welding or Heating. (Group
9000­10.)
CAUTION: Prevent possible crushing injury from
4. Remove Grapple. See Grapple Remove and Install. heavy component. Use proper lifting device.
(Group 3803.)
13. Install boom.
CAUTION: Prevent possible crushing injury from 14. Install boom pins.
heavy component. Use proper lifting device.
15. Install boom cylinder pins.
5. Support boom (1).
16. Install hydraulic hoses in boom.
6. Remove grapple motor. See Grapple Rotate Motor
17. Install rotary manifold. See Rotary Manifold Remove
Remove and Install. (Group 3860.)
and Install. (Group 3860.)
7. Remove rotary manifold. See Rotary Manifold
18. Install grapple motor. See Grapple Rotate Motor
Remove and Install. (Group 3860.)
Remove and Install. (Group 3860.)
8. Remove hydraulic hoses from boom.
19. Install grapple. See Grapple Remove and Install.
9. Remove boom cylinder pins (2). (Group 3803.)
10. Remove boom pins (3). 20. Remove articulation locking bar.
11. Remove boom.
GD61784,00000C6 ­19­25JUL07­1/1

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 Frames

Dual Function Grapple Arch Remove and

Install
CAUTION: Avoid possible injury from unexpected
machine movement. Install articulation locking

TX1024408A —UN—05JUN07
bar before working in frame hinge area.

1. Install articulation locking bar.

2. Inspect arch for cracks.
IMPORTANT: Have only a qualified welder do the
welding. Be sure the area near the machine is
free of debris and flammable material. Before Arch
welding, clean all dirt and paint from weld
area. Disconnect the battery ground (—) cable.
Connect the welder ground clamp as close 1— Arch 3— Arch Pin (2 used)
2— Arch Cylinder Pin (2 used)
as possible to each weld area.

3. Weld any cracks using E7018 electrodes or equivalent.

See Make Welding Repairs Safely. (Group 9000­10.) 9. Inspect and repair as necessary.
See Remove Paint Before Welding or Heating. (Group
9000­10.) CAUTION: Prevent possible crushing injury from
4. Remove boom. See Dual Function Grapple Boom heavy component. Use proper lifting device.
Remove and Install. (Group 3740.)
10. Install arch.
CAUTION: Prevent possible crushing injury from 11. Install arch pins.
heavy component. Use proper lifting device.
12. Install arch cylinder pins.
5. Support arch. 13. Install boom. See Dual Function Grapple Boom
6. Remove arch cylinder pins (2). Remove and Install. (Group 3740.)

7. Remove arch pins (3). 14. Remove articulation locking bar.

8. Remove arch (1).

GD61784,00000C7 ­19­25JUL07­1/1

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 Frames

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 Group 3860
Hydraulic System

Boom or Arch Cylinder Remove and

Install—Dual Function Grapple
1. Lower grapple to the ground.
2. Prepare machine for service. See Park and Prepare

TX1081260A —UN—01SEP10
for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
Arch Cylinder Remove and Install
3. Operate all hydraulic control valves to release
pressure in hydraulic system. Depress brake pedal at
1 second intervals 20 times to drain oil from service
brake accumulator.
4. Turn battery disconnect switch to the OFF position.
5. Disconnect arch cylinder hydraulic hoses (2) or boom
cylinder hydraulic hoses (5). Close all openings using
caps and plugs.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

6. Connect lifting strap to arch cylinder (3) or boom

cylinder (6).
Specification
Boom Cylinder—Weight
(approximate).................................................................................. 66 kg
145 lb
Arch Cylinder—Weight

TX1081259A —UN—01SEP10
(approximate).................................................................................. 62 kg
137 lb

7. Remove pins (1) to remove arch cylinder.

8. Remove pins (4) to remove boom cylinder.
9. Inspect bushings for looseness, wear, or damage.
Remove bushings only if replacement is necessary.
See Spherical Bushing Remove and Install. (Group Boom Cylinder Remove and Install
3201.)
10. Repair hydraulic cylinder as necessary. For additional 1— Pin (4 used) 4— Pin
information, see 120 Series Hydraulic Cylinders. 2— Arch Cylinder Hydraulic 5— Boom Cylinder Hydraulic
Hose (4 used) Hose (4 used)
(CTM114319.) 3— Arch Cylinder (2 used) 6— Boom Cylinder (2 used)

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.
NOTE: Fill hydraulic cylinder with hydraulic oil
11. Install arch cylinder or boom cylinder and pins. before connecting hoses to prevent damage
to O­rings and seals.
Specification
Boom Cylinder—Weight 12. Connect arch cylinder hydraulic hoses or boom
(approximate).................................................................................. 66 kg cylinder hydraulic hoses.
145 lb
Arch Cylinder—Weight 13. Remove articulation locking bar.
(approximate).................................................................................. 62 kg
14. Turn battery disconnect switch to the ON position.
137 lb
Continued on next page SW03989,0000AB0 ­19­05OCT10­1/2

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 Hydraulic System

15. Start engine and follow hydraulic oil warmup 17. Check hydraulic reservoir oil level. See Check
procedure. See Hydraulic Oil Warmup Procedure. Hydraulic System Oil Level. (Operator’s Manual.)
(Group 9025.)
16. Stop engine and check for leaks.
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 Hydraulic System

Grapple Tong Cylinder Remove and Install

10

2
4
3

8
9
7
11

6 5

TX1081258 —UN—01SEP10
TX1081258
Grapple Tong Cylinder Removal and Installation
1— Frame 4— Tong Pin (2 used) 7— Cap Screw (2 used) 10— Cylinder Rod Pin (2 used)
2— Cap Screw (4 used) 5— Washer (2 used) 8— Spacer (2 used) 11— Tong Cylinder (2 used)
3— Top Cover (2 used) 6— Cap Screw (2 used) 9— Washer (2 used)

1. Close grapple and lower to the ground. one­second intervals 20 times to drain oil from service
brake accumulator.
2. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.) 4. Turn battery disconnect switch to the OFF position.
5. Remove top cover (3). Disconnect hose at tong
CAUTION: To avoid injury from escaping fluid cylinder (11) head end. Close all openings using caps
under pressure, stop engine and relieve the and plugs.
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all 6. Disconnect hose at tong cylinder rod end. Close all
connections before applying pressure. openings using caps and plugs.

3. Operate all hydraulic control valves to release CAUTION: Prevent possible crushing injury from
pressure in hydraulic system. Depress brake pedal at heavy component. Use appropriate lifting device.

Continued on next page SW03989,0000AB1 ­19­04OCT10­1/2

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 Hydraulic System

7. Connect lifting strap to tong cylinder.

Specification CAUTION: Prevent possible crushing injury from
Tong Cylinder—Weight heavy component. Use appropriate lifting device.
(approximate).................................................................................. 66 kg
146 lb 12. Install tong cylinder into frame (1).
Specification
8. Remove cap screw (7), washer (9), and spacer (8)
Tong Cylinder—Weight
from cylinder rod pin (10). Remove cylinder rod pin.
(approximate).................................................................................. 66 kg
146 lb
CAUTION: The pin that attaches the cylinder head
end also attaches the opposite tong. Cylinders 13. Install tong pin and cylinder rod pin. Install spacer,
should be removed one at a time to prevent both washers, and cap screws.
grapple tongs from falling out of the frame. 14. Connect hydraulic hoses.
9. Remove cap screw (6) and washer (5). Use either 15. Install top cover.
another pin or round bar stock that is slightly smaller in
diameter and approximately equal to the width of the 16. Turn battery disconnect switch to the ON position.
grapple frame in length to drive out the tong pin and 17. Start engine and follow hydraulic oil warmup
still hold the tong in place. procedure. See Hydraulic Oil Warmup Procedure.
For some grapple head and tong configurations, it (Group 9025.)
is only necessary to push out the pin far enough to 18. Stop engine and check for leaks.
disconnect the head end of the cylinder from the
grapple frame. 19. Check hydraulic reservoir oil level. See Check
Hydraulic System Oil Level. (Operator’s Manual.)
10. Remove tong cylinder.
11. Inspect and repair tong hydraulic cylinder as
necessary. For additional information, see 120 Series
Hydraulic Cylinders. (CTM114319.)
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 Hydraulic System

Grapple Rotate Motor Remove and Install

TX1081257 —UN—01SEP10
Grapple Rotate Motor Removal and Installation
1— Grapple Rotate Motor 3— Case Drain Hose to Tank 5— Case Drain Hose from Rotate 7— Washer (2 used)
2— Rotate Hose from Grapple 4— Rotate Hose from Grapple Manifold
Rotate Solenoid Valve Rotate Solenoid Valve 6— Cap Screw (2 used)

1. Lower grapple to the ground. 3. Operate all hydraulic control valves to release
pressure in hydraulic system. Depress brake pedal at
2. Prepare machine for service. See Park and Prepare 1 second intervals 20 times to drain oil from service
for Service Safely. (Group 0001.) brake accumulator.

CAUTION: To avoid injury from escaping fluid 4. Turn battery disconnect switch to the OFF position.
under pressure, stop engine and relieve the 5. Remove rotate motor cover from top of boom.
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all 6. Tag and disconnect hoses. Close all openings using
connections before applying pressure. caps and plugs.

Continued on next page SW03989,0000AB2 ­19­03SEP10­1/2

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 Hydraulic System

10. Install cap screws and washers. Tighten cap screws

CAUTION: Prevent possible crushing injury from
to specification.
heavy component. Use appropriate lifting device.
Specification
7. Remove cap screws (6) and washers (7). Remove Cap Screw—Torque.......................................................... 117—142 N∙m
rotate motor. 86—105 lb­ft

Specification 11. Connect hoses.

Grapple Rotate
Motor—Weight 12. Remove articulation locking bar.
(approximate).................................................................................. 25 kg
13. Turn battery disconnect switch to the ON position.
55 lb
14. Start engine and follow hydraulic oil warmup
8. Inspect and repair as necessary. procedure. See Hydraulic Oil Warmup Procedure.
(Group 9025.)
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device. 15. Stop engine and check for leaks.
16. Check hydraulic reservoir oil level. See Check
9. Install rotate motor. Hydraulic System Oil Level. (Operator’s Manual.)
Specification
Grapple Rotate
17. Install rotate motor cover.
Motor—Weight
(approximate).................................................................................. 25 kg
55 lb
SW03989,0000AB2 ­19­03SEP10­2/2

TM11813 (13OCT10) 38­3860­6 748H Repair (S.N. 630436— )

101310

PN=354
 Hydraulic System

Grapple Rotate Motor Disassemble

NOTE: Cleanliness is extremely important when repairing Check the shaft and key slot, and remove all
a hydraulic motor. Work in a clean area. Before nicks, burrs, or sharp edges that might damage
disconnecting the lines, clean the port area the bearing housing seals when installing the
of the motor thoroughly. Use a wire brush to shaft and bearing assembly.
remove foreign material and debris from around
the exterior joints of the motor. Before starting the disassembly procedures,
drain the oil from inside the motor.

T214865 —UN—21SEP05

Continued on next page SW03989,0000AB3 ­19­01OCT10­1/12

TM11813 (13OCT10) 38­3860­7 748H Repair (S.N. 630436— )

101310

PN=355
 Hydraulic System

Grapple Rotate Motor Components

1— Shaft Exclusion Seal 9— Wear Plate 17— Outer Face Seal 25— Washer (4 used)
2— Bearing Housing 10— Seal 18— Pin (2 used) 26— Tie Bolt (4 used)
3— Backup Ring 11— Geroler Sub­Assembly 19— Spring (2 used) 27— O­Ring (2 used)
4— Shaft Seal 12— Seal 20— Inner Face Seal 28— Relief Valve (2 used)
5— Bearing and Shaft 13— Valve Plate 21— Seal 29— O­Ring (2 used)
Sub­Assembly 14— Valve Drive 22— Plug with O­Ring 30— Cap (2 used)
6— Seal 15— Valve 23— Valve Housing
7— Shaft Face Seal 16— Balance Ring 24— Name Plate
8— Splined Drive
SW03989,0000AB3 ­19­01OCT10­2/12

1. Place motor upright in vise with output shaft down.

Clamp across mounting flange of bearing housing (2).
Excessive clamping pressure will cause distortion.
When clamping, use some protective device on vise,
such as special soft jaws, pieces of hard rubber or
board.
NOTE: Although not all drawings show motor in vise,
we recommend that you keep motor upright in
vise during disassembly and reassembly.

T214867 —UN—21SEP05
Motor in Vise
SW03989,0000AB3 ­19­01OCT10­3/12

2. Remove four tie bolts (26) and washers (25) from

motor.

25— Washer (4 used) 26— Tie Bolt (4 used) TX1081255 —UN—01SEP10

Remove Tie Bolts and Washers

Continued on next page SW03989,0000AB3 ­19­01OCT10­4/12

TM11813 (13OCT10) 38­3860­8 748H Repair (S.N. 630436— )

101310

PN=356
 Hydraulic System

3. Lift valve housing (23) straight up. If done carefully,

the pins (18), springs (19), balance ring assembly
(16), and valve (15) will remain on the valve plate (13).
4. Carefully remove seal (21) from valve housing.

21— Seal 23— Valve Housing

TX1081254 —UN—01SEP10
Remove Valve Housing and Seal
SW03989,0000AB3 ­19­01OCT10­5/12

5. Remove case drain plug with O­ring (22) from valve

housing.
6. Remove relief valves (26) and O­rings (27 and 29)
from valve housing. Inspect and clean relief valves.
Replace O­rings and install relief valves.

22— Case Drain Plug with 29— O­Ring (2 used)

O­ring 30— Cap (2 used)
27— O­Ring (2 used)
28— Relief Valve (2 used)

TX1081253 —UN—01SEP10

Remove Plug and Relief Valves

Continued on next page SW03989,0000AB3 ­19­01OCT10­6/12

TM11813 (13OCT10) 38­3860­9 748H Repair (S.N. 630436— )

101310

PN=357
 Hydraulic System

7. Remove two pins (18) and springs (19) from balance

ring assembly (16).
8. Remove balance ring assembly.
9. Remove inner and outer face seals (17 and 20) from
balance ring.

TX1081252 —UN—01SEP10
10. Remove valve (15).

15— Valve 18— Pin (2 used)

16— Balance Ring 19— Spring (2 used)
17— Outer Face Seal 20— Inner Face Seal

Remove Balance Ring, Face Seals, and Valve

SW03989,0000AB3 ­19­01OCT10­7/12

11. Remove valve plate (13).

12. Remove seal (12) from valve plate.
13. Remove valve drive (14).

TX1081251 —UN—01SEP10
12— Seal 14— Valve Drive
13— Valve Plate

Remove Valve Plate, Seal, and Valve Drive

SW03989,0000AB3 ­19­01OCT10­8/12

14. Remove geroler sub­assembly (11).

15. Remove splined drive (8).

8— Splined Drive 11— Geroler Sub­Assembly

TX1081250 —UN—01SEP10

Remove Geroler Sub­Assembly and Splined Drive

Continued on next page SW03989,0000AB3 ­19­01OCT10­9/12

TM11813 (13OCT10) 38­3860­10 748H Repair (S.N. 630436— )

101310

PN=358
 Hydraulic System

16. Remove seal (10) from wear plate (9).

17. Remove wear plate.
18. Remove shaft face seal (7) from wear plate.
19. Remove seal (6) from bearing housing.

TX1081249 —UN—01SEP10
2— Bearing Housing 9— Wear Plate
6— Seal 10— Seal
7— Shaft Face Seal

Remove Wear Plate and Seals

SW03989,0000AB3 ­19­01OCT10­10/12

20. Remove bearing and shaft sub­assembly (5) from

bearing housing. Use press, if necessary.
NOTE: Individual parts of shaft and bearing sub­assembly
are not sold separately. Replace as a unit.

TX1081248 —UN—01SEP10
5— Bearing and Shaft 2— Bearing Housing
Sub­Assembly

Remove Bearing and Shaft Sub­Assembly

SW03989,0000AB3 ­19­01OCT10­11/12

21. Use a small screwdriver to remove shaft seal (4),

backup ring (3), and shaft exclusion seal (1) from
bearing housing.

1— Shaft Exclusion Seal 3— Backup Ring

2— Bearing Housing 4— Shaft Seal

TX1081247 —UN—01SEP10

Remove Exclusion Seal and Shaft Seal

SW03989,0000AB3 ­19­01OCT10­12/12

TM11813 (13OCT10) 38­3860­11 748H Repair (S.N. 630436— )

101310

PN=359
 Hydraulic System

Grapple Rotate Motor Assemble

T214865 —UN—21SEP05

Grapple Rotate Motor Components

Continued on next page SW03989,0000AB4 ­19­01OCT10­1/13

TM11813 (13OCT10) 38­3860­12 748H Repair (S.N. 630436— )

101310

PN=360
 Hydraulic System

1— Shaft Exclusion Seal 9— Wear Plate 17— Outer Face Seal 25— Washer (4 used)
2— Bearing Housing 10— Seal 18— Pin (2 used) 26— Tie Bolt (4 used)
3— Backup Ring 11— Geroler Sub­Assembly 19— Spring (2 used) 27— O­Ring (2 used)
4— Shaft Seal 12— Seal 20— Inner Face Seal 28— Relief Valve (2 used)
5— Bearing and Shaft 13— Valve Plate 21— Seal 29— O­Ring (2 used)
Sub­Assembly 14— Valve Drive 22— Plug with O­Ring 30— Cap (2 used)
6— Seal 15— Valve 23— Valve Housing
7— Shaft Face Seal 16— Balance Ring 24— Name Plate
8— Splined Drive

NOTE: Check all mating surfaces. Replace any parts that Check around chamfered area of the shaft for burrs,
have scratches or burrs that could cause leakage. nicks or sharp edges that can damage the seals
Clean all metal parts in clean solvent. Blow dry when reassembling the bearing housing.
with air. Do not wipe dry with cloth or paper
towel because lint or other matter can get in the NOTE: Lubricate all seals, prior to installation,
hydraulic system and cause damage. with petroleum jelly . Use new seals when
reassembling this motor.
Do not use a coarse grit or try to file or
grind these parts.
Continued on next page SW03989,0000AB4 ­19­01OCT10­2/13

TM11813 (13OCT10) 38­3860­13 748H Repair (S.N. 630436— )

101310

PN=361
 Hydraulic System

TX1081246 —UN—01SEP10
Shaft Seals
1. Use a press to install shaft exclusion seal (1) in outer
bore of bearing housing (2).
NOTE: Lip of seal must face outward. If a press is not
available, use a plastic or rubber hammer, being
careful not to damage or cock the seal in the bore.

TX1081247 —UN—01SEP10
2. Place backup ring (3) into seal bore. Place shaft seal
(4) onto Eaton 600496 Seal Installation Tool and press
seal into seal bore of bearing housing.
3. Clamp bearing housing upright in vise.
NOTE: Although not all drawings show motor in vise,
we recommend that you keep motor upright in Install Exclusion Seal and Shaft Seal
vise during disassembly and reassembly.
1— Shaft Exclusion Seal 5— Bearing and Shaft
2— Bearing Housing Sub­Assembly
3— Backup Ring 6— Seal
4— Shaft Seal 7— Shaft Face Seal
9— Wear Plate

Continued on next page SW03989,0000AB4 ­19­01OCT10­3/13

TM11813 (13OCT10) 38­3860­14 748H Repair (S.N. 630436— )

101310

PN=362
 Hydraulic System

4. Place Eaton 600465 Protective Bullet over shaft spline

of bearing and shaft sub­assembly. Apply petroleum
jelly to inside diameter of exclusion seal and shaft seal.
Use press to install bearing and shaft sub­assembly
in bearing housing.

TX1081245 —UN—30AUG10
NOTE: Do not distort shaft seal. Damage to this
seal will cause leakage.

5. Apply small amount of petroleum jelly to seal (6) and

install into bearing housing.

2— Bearing Housing 6— Seal

5— Bearing and Shaft 31— Eaton 600465 Protective Install Bearing and Shaft Sub­Assembly
Sub­Assembly Bullet

SW03989,0000AB4 ­19­01OCT10­4/13

6. Alignment studs (32) can be very helpful in reassembly

of the motor. If studs are used, install two studs
diagonally opposed in the bearing housing.

32— Alignment Stud (2 used)

TX1081243 —UN—30AUG10
Install Alignment Studs

SW03989,0000AB4 ­19­01OCT10­5/13

7. Install shaft face seal (7) in wear plate (9). 16

15
8. Install wear plate onto bearing housing.
9. Apply a light film of petroleum jelly to seal (10) and
install in groove of wear plate. 4

7— Shaft Face Seal 10— Seal 16

9— Wear Plate

5 2 TX1081342 —UN—25AUG10

14

5
6

Install Wear Plate and Seals

Continued on next page SW03989,0000AB4 ­19­01OCT10­6/13

TM11813 (13OCT10) 38­3860­15 748H Repair (S.N. 630436— )

101310

PN=363
 Hydraulic System

10. Install splined drive (8) into bearing and shaft

sub­assembly.

8— Splined Drive

TX1081241 —UN—30AUG10
Install Splined Drive
Continued on next page SW03989,0000AB4 ­19­01OCT10­7/13

TM11813 (13OCT10) 38­3860­16 748H Repair (S.N. 630436— )

101310

PN=364
 Hydraulic System

TX1081240 —UN—30AUG10
Install Geroler Sub­Assembly and Valve—Set Timing
9— Wear Plate 12— Seal 14— Valve Drive
11— Geroler Sub­Assembly 13— Valve Plate 15— Valve

11. Align notch on outside of geroler sub­assembly (11) sub­assembly. Align notch on outside of valve plate
with notch on wear plate and install. with notch on geroler sub­assembly.
12. Install valve drive (14) in geroler sub­assembly. Timing Step #2—Locate slot opening in valve plate in
line with largest open pocket of geroler sub­assembly.
13. Apply a light film of petroleum jelly to seal (12) and
install in groove of valve plate (13). Timing Step #3 —Locate any one of the side openings
of valve (15) and align this opening with open slot
IMPORTANT: Installation at this time involves three of valve plate that is in line with largest open pocket
steps for timing of rotate motor. Timing of geroler sub­assembly. Install valve by rotating it
determines direction of rotation of output shaft. clockwise until spline teeth engage (1/2 spline tooth
Timing parts include: geroler sub­assembly, max.). This will provide the proper rotation when
valve drive, valve plate and valve. pressurized.
14. Timing Step #1—Locate largest open pocket in geroler
sub­assembly and mark it on outside edge of geroler
Continued on next page SW03989,0000AB4 ­19­01OCT10­8/13

TM11813 (13OCT10) 38­3860­17 748H Repair (S.N. 630436— )

101310

PN=365
 Hydraulic System

15. Install two springs (19) and two pins (18) in holes
located in bore of valve housing (23).
16. Apply a light film of petroleum jelly to seal (21) and
install in valve housing (23).

TX1081239 —UN—30AUG10
18— Pin (2 used) 21— Seal
19— Spring (2 used) 23— Valve Housing

Install Pins, Springs, and Seal on Valve Housing

SW03989,0000AB4 ­19­01OCT10­9/13

IMPORTANT: Install face seals in the positions shown,

or the motor will not operate properly. Do not
force or bend the face seals. Any damage to
these seals will affect the operation of the motor.

17. Apply petroleum jelly to inner and outer face seals (17
and 20). Install seals on balance ring (16) as shown.

16— Balance Ring 20— Inner Face Seal

17— Outer Face Seal 33— Pin Notch

TX1081238 —UN—30AUG10
Install Face Seals on Balance Ring

SW03989,0000AB4 ­19­01OCT10­10/13

18. Install balance ring assembly in valve housing. Align

pin notches (33) in balance ring with pins in bore of
valve housing.

16— Balance Ring 23— Valve Housing

TX1081237 —UN—30AUG10

Install Balance Ring in Valve Housing

Continued on next page SW03989,0000AB4 ­19­01OCT10­11/13

TM11813 (13OCT10) 38­3860­18 748H Repair (S.N. 630436— )

101310

PN=366
 Hydraulic System

19. Install valve housing on valve plate.

NOTE: Depending on valve housing model, it may
be possible to insert your finger through port
of valve housing and apply pressure to side of
balance ring. Hold ring in position until valve
housing is in place against valve plate.
After installing valve housing on valve plate, check
for proper placement. Push down on valve housing.
A slight spring action should be felt.

23— Valve Housing

TX1081236 —UN—30AUG10
Install Valve Housing
SW03989,0000AB4 ­19­01OCT10­12/13

20. Install washers (25) and tie bolts (26).

If alignment studs are used, install two tie bolts and
washers opposite studs. Finger tighten bolts. Remove
alignment studs and replace with two remaining
bolts and washers. Tighten tie bolts alternately to

TX1081235 —UN—30AUG10
specification.
Specification
Tie Bolt—Torque............................................................................50 N∙m
450 lb­in.

21. Install new O­ring on plug (22) and install in valve

housing. Tighten plug to specification.
Install Tie Bolts and Plug
Specification
Case Drain
Plug—Torque...................................................................................6 N∙m 22— Plug with O­Ring 26— Tie Bolt (4 used)
50 lb­in. 25— Washer (4 used)

SW03989,0000AB4 ­19­01OCT10­13/13

TM11813 (13OCT10) 38­3860­19 748H Repair (S.N. 630436— )

101310

PN=367
 Hydraulic System

Rotate Motor Drive Gear Remove and Install

1. Remove rotate motor. See Grapple Rotate Motor
Remove and Install. (Group 3860.)
2. Remove bearings (1) and drive gear (2).

TX1081323 —UN—31AUG10
3. Inspect and replace if required.
4. Install bearings and drive gear.

1— Bearing (2 used) 2— Drive Gear

Bearings and Drive Gear

SW03989,0000AB5 ­19­01OCT10­1/1

Control Valve Options

The dual function pilot operated control valve is comprised
of the following sections:
• Inlet Section—Includes main relief valve.
• Tong Section—Solenoid operated, includes two
adjustable circuit relief valves and detent assembly.
• Arch Section—Pilot operated, includes two
non­adjustable circuit relief valves.
• Boom Section—Pilot operated, includes two
non­adjustable circuit relief valves.
• Blade Section—Link operated, includes two
non­adjustable circuit relief valves.
• Outlet Section

1— Inlet Section 4— Boom Section

2— Tong Section 5— Blade Section
3— Arch Section 6— Outlet Section

TX1081063 —UN—18AUG10

Dual Function Pilot Operated Control Valve

SW03989,0000AC3 ­19­30AUG10­1/1

TM11813 (13OCT10) 38­3860­20 748H Repair (S.N. 630436— )

101310

PN=368
 Hydraulic System

TM11813 (13OCT10) 38­3860­21 748H Repair (S.N. 630436— )

101310

PN=369
 Hydraulic System

Pilot Operated Control Valve Remove and Install

TX1025762A —UN—29JUN07

Hydraulic Control Valve (dual function shown)

Continued on next page SW03989,0000ACB ­19­01OCT10­1/5

TM11813 (13OCT10) 38­3860­22 748H Repair (S.N. 630436— )

101310

PN=370
 Hydraulic System

1— Pilot Pressure Hose 4— Grapple Tong Hose (2 used) 7— Blade Hose (2 used) 10— Pilot Pressure Supply Hose
2— Pilot Control Hose (4 used) 5— Arch Hose (2 used) 8— Valve Return Hose 11— Cap Screw (3 used)
3— Pilot Control Valve Supply 6— Boom Hose (2 used) 9— Valve Supply Hose
Hose

1. Prepare machine for service. See Park and Prepare

for Service Safely. (Group 0001.) 3. Turn battery disconnect switch to the OFF position.
See Battery Disconnect. (Operator’s Manual.)
CAUTION: To avoid injury from escaping fluid 4. Remove right side cab cover.
under pressure, stop engine and relieve the
pressure in the system before disconnecting or 5. Attach a vacuum pump to hydraulic reservoir to
connecting hydraulic or other lines. Tighten all minimize oil loss.
connections before applying pressure. 6. Disconnect supply, return, and all hydraulic function
hoses (4—9) at valve. Attach identification tags to
2. Operate all hydraulic control valves to release hoses to aid assembly. Close all openings using caps
pressure in hydraulic system. Depress brake pedal at and plugs.
1­second intervals 20 times to drain oil from service
brake accumulator.
SW03989,0000ACB ­19­01OCT10­2/5

7. Disconnect hoses (2) from pilot control valve to arch

and boom valve sections. Disconnect other pilot
control hoses (1, 3, and 10). Put identification tags
on hoses to aid assembly. Close all openings using
caps and plugs.

TX1025763A —UN—29JUN07
8. Disconnect electrical connector (12) at solenoid
operated tong valve section.

2— Pilot Control Hose (4 used) 12— Grapple Tong Control

Solenoid Electrical
Connector (2 used)

Pilot Control Hoses (dual function shown)

SW03989,0000ACB ­19­01OCT10­3/5

9. Remove cotter pin (14) and clip to disconnect linkage

at control valve blade section.

13— Blade Control Linkage 15— Blade Control Valve Spool

14— Cotter Pin

TX1025764A —UN—29JUN07

Blade Control Linkage (dual function shown)

Continued on next page SW03989,0000ACB ­19­01OCT10­4/5

TM11813 (13OCT10) 38­3860­23 748H Repair (S.N. 630436— )

101310

PN=371
 Hydraulic System

CAUTION: Prevent possible crushing injury from

heavy component. Use proper lifting device.

10. Remove three cap screws (11) to remove control

valve.

TX1025765A —UN—29JUN07
Specification
Control Valve—Single
Function
Grapple—Weight
(approximate).................................................................................. 27 kg
60 lb.

11. Inspect and repair as necessary.

Mounting Cap Screw (dual function shown)

CAUTION: Prevent possible crushing injury from

heavy component. Use proper lifting device. 11— Cap Screw (3 used)

12. Install control valve.

15. Connect remaining hydraulic lines.
Specification
Control Valve—Single 16. Turn battery disconnect switch to the ON position. See
Function Battery Disconnect. (Operator’s Manual.)
Grapple—Weight
(approximate).................................................................................. 27 kg 17. Operate function through several cycles to remove air
60 lb. and fill components with oil. Check hydraulic oil level.
See Check Hydraulic System Oil Level. (Operator’s
13. Connect electrical connector and linkage. Manual.)
14. Install adapters with the orifice check in the pilot cap
ports. Install pilot lines.
SW03989,0000ACB ­19­01OCT10­5/5

TM11813 (13OCT10) 38­3860­24 748H Repair (S.N. 630436— )

101310

PN=372
 Hydraulic System

Dual Function Pilot Operated Control Valve Disassemble and Assemble

TX1081328 —UN—31AUG10

Dual Function Pilot Operated Control Valve

1— Inlet Section 4— Boom Section 7— Tie Rod (4 used) 10— Seal (4 sets of 4 used)
2— Tong Section 5— Blade Section 8— Washer (8 used)
3— Arch Section 6— Outlet Section 9— Nut (8 used)

1. Mark sections to ease assembly. 4. Install tie rods, nuts, and washers to assemble control
2. Remove nuts (9), washers (8), and tie rods (7) to valve. Tighten nuts to specification.
disassemble control valve. Service or replace sections Specification
as necessary. Nut—Torque..................................................................................57 N∙m
42 lb­ft
3. Replace seals (10) between sections.
Continued on next page SW03989,0000AB7 ­19­26AUG10­1/2

TM11813 (13OCT10) 38­3860­25 748H Repair (S.N. 630436— )

101310

PN=373
 Hydraulic System

TX1081329 —UN—31AUG10

Dual Function Pilot Operated Control Valve Fittings

11— Adapter 13— Adapter with Restrictor 15— Elbow 17— Tee
12— Fitting Orifice 16— Test Coupling
14— Elbow Rework AT

5. Install fittings, if removed. Replace O­rings. NOTE: Install adapter with restrictor orifice (13) in blade
work port with grooves facing fitting.
SW03989,0000AB7 ­19­26AUG10­2/2

TM11813 (13OCT10) 38­3860­26 748H Repair (S.N. 630436— )

101310

PN=374
 Hydraulic System

Control Valve Relief Valves Remove and

Install
NOTE: Relief valves can be removed with control
valve on machine. Valve must be removed or
moved away from machine before lift check
poppets can be removed.

1. Close grapple and lower to the ground.

2. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

3. Operate all hydraulic control valves to release

TX1024878 —UN—14JUN07
pressure in hydraulic system. Depress brake pedal at
1­second intervals 20 times to drain oil from service
brake accumulator.
4. Turn battery disconnect switch to the OFF position.
5. Remove relief valves. Inspect, repair, or replace
components as needed.
Relief Valves
NOTE: To inspect lift check valves on back of control
valve, remove control valve.
1— Main Relief Valve 3— Adjustable Circuit Relief
2— Nonadjustable Circuit Valve
6. Install relief valves. Relief Valve
7. Turn battery disconnect switch to the ON position.
8. Start engine and follow hydraulic oil warmup 10. Check hydraulic reservoir oil level. See Check
procedure. See Hydraulic Oil Warmup Procedure. Hydraulic System Oil Level. (Operator’s Manual.)
(Group 9025.)
9. Stop engine and check for leaks.
SW03989,0000AB8 ­19­07SEP10­1/1

TM11813 (13OCT10) 38­3860­27 748H Repair (S.N. 630436— )

101310

PN=375
 Hydraulic System

Lift Check Valve Disassemble and Assemble

1. Remove control valve from machine. See Pilot
Operated Control Valve Remove and Install. (Group
3860.)
2. Remove plugs (2).
3. Remove springs (4) and lift check poppets (5).
4. Inspect and repair or replace components as
necessary.
5. Replace O­rings (3).
6. Install poppets and springs.

TX1081360 —UN—02SEP10
7. Install cap and tighten securely.
8. Install control valve in machine. See Pilot Operated
Control Valve Remove and Install. (Group 3860.)

1— Lift Check Valve (3 used) 4— Spring (3 used)

2— Plug (3 used) 5— Poppet (3 used)
3— O­Ring (3 used)
Lift Check Valve

SW03989,0000AB9 ­19­01OCT10­1/1

TM11813 (13OCT10) 38­3860­28 748H Repair (S.N. 630436— )

101310

PN=376
 Hydraulic System

Non­adjustable Circuit Relief Valve

Disassemble and Assemble

TX1081361 —UN—02SEP10
Non­adjustable Circuit Relief Valve
1— Cap 5— Shims (as required) 9— Poppet 13— Backup Ring
2— O­Ring 6— Spring 10— Poppet Stem 14— O­Ring
3— Rod 7— O­Ring 11— Valve Body
4— Seal 8— Backup Ring 12— O­Ring

1. Remove control valve from machine. See Pilot 6. Installing relief valve on control valve and tighten to
Operated Control Valve Remove and Install. (Group specification.
3860.)
Specification
2. Remove non­adjustable circuit relief valve from control Non­adjustable Circuit
valve. Relief Valve—Torque...................................................................100 N∙m
75 lb­ft
3. Disassemble non­adjustable circuit relief valve as
shown. 7. Install control valve in machine. See Pilot Operated
4. Inspect components for wear or damage. Replace if Control Valve Remove and Install. (Group 3860.)
necessary.
5. Replace O­rings (2, 7, 12, and 14), backup rings (8
and 13), and seal (4).
SW03989,0000ABA ­19­01OCT10­1/1

TM11813 (13OCT10) 38­3860­29 748H Repair (S.N. 630436— )

101310

PN=377
 Hydraulic System

Adjustable Circuit Relief Valve Disassemble

and Assemble

TX1081362 —UN—07SEP10

Adjustable Circuit Relief Valve

1— Lock Nut 7— Retainer 13— Poppet 19— O­Ring
2— Adjusting Screw 8— O­Ring 14— O­Ring 20— Valve Body
3— O­Ring 9— Rod 15— Backup Ring 21— O­Ring
4— Spring 10— Spring 16— Housing
5— Poppet 11— Seal 17— Pin
6— Ball 12— Ring 18— Backup Ring

1. Remove control valve from machine. See Pilot 2. Remove adjustable circuit relief valve from control
Operated Control Valve Remove and Install. (Group valve.
3860.)
3. Disassembled adjustable circuit relief valve as shown.
Continued on next page SW03989,0000ABB ­19­07OCT10­1/2

TM11813 (13OCT10) 38­3860­30 748H Repair (S.N. 630436— )

101310

PN=378
 Hydraulic System

4. Inspect components for wear or damage. Replace as 7. Install control valve in machine. See Pilot Operated
necessary. Control Valve Remove and Install. (Group 3860.)
5. Replace O­rings (3, 8, 14, 19, and 21), backup rings 8. Adjust circuit relief valve. See System and Circuit
(15 and 18), and seal (11). Relief Valve Pressure Test. (Group 9025­25.)
6. Install adjustable circuit relief valve on control valve 9. Tighten lock nut (1) to specification.
and tighten to specification.
Specification
Specification Lock Nut—Torque..........................................................................88 N∙m
Adjustable Circuit Relief 65 lb­ft
Valve—Torque.............................................................................100 N∙m
75 lb­ft
SW03989,0000ABB ­19­07OCT10­2/2

TM11813 (13OCT10) 38­3860­31 748H Repair (S.N. 630436— )

101310

PN=379
 Hydraulic System

Spool Valve Disassemble and Assemble

TX1081364 —UN—02SEP10
Spool Valve
1— Screw (2 used) 5— Spool 9— Rod 13— Rod Cap
2— Plate 6— Lower Spacer 10— Retainer 14— End Cap Housing
3— Upper Spacer 7— Valve Section Housing 11— Spring 15— Screw (2 used)
4— Packing 8— Plate 12— Retainer

1. Remove control valve from machine. See Pilot at bottom of valve section has shallow concave
Operated Control Valve Remove and Install. (Group groove around top surface.
3860.)
5. Replace components as necessary.
2. Disassemble control valve. See Dual Function Pilot
Operated Control Valve Disassemble and Assemble. NOTE: Detent assembly may be used in place of end cap
(Group 3860.) assembly (items 8—15) on some valve sections.
For more information, see Detent Disassemble
NOTE: Keep spool and control valve section together and Assemble. (Group 3860.)
as a matched set. Spools are machined for
specific hydraulic functions. 6. Assemble spool valve.
3. Disassemble spool valve as shown. 7. Assemble control valve. See Dual Function Pilot
Operated Control Valve Disassemble and Assemble.
4. Inspect spool for scratches and straightness. Replace (Group 3860.)
packing (4).
8. Install control valve in machine. See Pilot Operated
NOTE: Spacer (3) used with packing at top of valve Control Valve Remove and Install. (Group 3860.)
section is stepped. Spacer (6) used with packing
SW03989,0000ABC ­19­28SEP10­1/1

TM11813 (13OCT10) 38­3860­32 748H Repair (S.N. 630436— )

101310

PN=380
 Hydraulic System

Detent Disassemble and Assemble

TX1081366 —UN—02SEP10
Detent Assembly
1— Spacer 6— Housing 11— Screw (2 used) 16— Rod Cap
2— Spring Retainer 7— Washer (2 used) 12— Carrier 17— Sleeve
3— Spring 8— Screw (2 used) 13— Detent Ball (6 used)
4— Spring Retainer 9— Plate 14— Retainer
5— Rod 10— Washer (2 used) 15— Spring

1. Remove control valve from machine. See Pilot 6. Assemble detent as shown.
Operated Control Valve Remove and Install. (Group
3860.) 7. Install detent on control valve. Move spool to detent
position center and tighten screws (11) to specification.
2. Remove detent from control valve.
Specification
3. Disassemble detent as shown. Screw—Torque..............................................................................20 N∙m
175 lb­in.
4. Inspect parts for wear or damage. Replace as needed.
5. Apply petroleum jelly to detent balls (13) to hold them 8. Install control valve in machine. See Pilot Operated
in carrier (12) during assembly. Control Valve Remove and Install. (Group 3860.)
SW03989,0000ABD ­19­07SEP10­1/1

TM11813 (13OCT10) 38­3860­33 748H Repair (S.N. 630436— )

101310

PN=381
 Hydraulic System

Pilot Operated Valve Remove and Install

TX1081367 —UN—02SEP10

Pilot Operated Valve

1— Cap Screw (2 used) 3— O­Ring 5— O­Ring (3 used) 7— Bushing
2— Plug 4— Cap 6— Sleeve

1. Remove control valve from machine. See Pilot 4. Assemble pilot operated valve on control valve.
Operated Control Valve Remove and Install. (Group
3860.) 5. Install control valve in machine. See Pilot Operated
Control Valve Remove and Install. (Group 3860.)
2. Disassemble pilot operated valve as shown.
3. Inspect for wear or damage. Replace O­rings (3 and
5) and parts as needed.
SW03989,0000ABE ­19­07SEP10­1/1

TM11813 (13OCT10) 38­3860­34 748H Repair (S.N. 630436— )

101310

PN=382
 Hydraulic System

Solenoid Operated Valve Remove and Install

TX1081368 —UN—02SEP10

Solenoid Operated Valve

1— Solenoid 5— O­Ring 9— Housing 13— O­Ring
2— Cap Screw (2 used) 6— Cap 10— Cap Screw 14— O­Ring
3— O­Ring 7— Plug 11— Cap Screw 15— Bushing
4— O­Ring 8— O­Ring 12— Lock Washer (2 used) 16— O­Ring (2 used)

1. Remove control valve from machine. See Pilot 4. Inspect for wear or damage and replace parts as
Operated Control Valve Remove and Install. (Group needed.
3860.)
5. Replace O­rings (3, 4, 5, 8, 13, 14, and 16).
2. Remove solenoid operated valve from control valve.
3. Disassemble solenoid operated valve as shown.

Continued on next page SW03989,0000ABF ­19­07SEP10­1/2

TM11813 (13OCT10) 38­3860­35 748H Repair (S.N. 630436— )

101310

PN=383
 Hydraulic System

6. Check operation of solenoid (1) by applying voltage 7. Assemble solenoid operated valve as shown.
across solenoid terminals. Solenoid should click. 8. Secure to control valve with cap screws (10 and 11).
Remove voltage from solenoid terminals. Solenoid
should click again. Replace if solenoid fails check. 9. Install control valve in machine. See Pilot Operated
Control Valve Remove and Install. (Group 3860.)
NOTE: There are two small O­rings (16) that must be
installed between housing and valve section.
SW03989,0000ABF ­19­07SEP10­2/2

Grapple Rotate Solenoid Valve Remove and

Install
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the

TX1080208A —UN—28JUL10
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

1. Prepare machine for service. See Park and Prepare

for Service Safely. (Operator’s Manual.)
2. Operate all hydraulic controls to release pressure in
hydraulic system.
3. Remove left engine side shield. 1— Solenoid Valve Electrical 2— Cap Screw (2 used)
Connectors
4. Turn battery disconnect switch to the OFF position.
5. Remove and identify all hydraulic hoses connecting
to grapple rotate solenoid valve. Close all openings 11. Install two solenoid valve electrical connectors.
using caps and plugs.
12. Install hoses on grapple rotate solenoid valve.
6. Remove two solenoid valve electrical connectors (1).
13. Turn battery disconnect switch to the ON position.
7. Remove two mounting cap screws (2).
14. Install left engine side shield.
8. Remove grapple rotate solenoid and bracket from
machine. 15. Operate grapple functions through several cycles to
remove air and fill components with oil.
9. Inspect and replace parts as required. See Grapple
Rotate Solenoid Valve Disassemble and Assemble. 16. Check hydraulic oil level. See Check Hydraulic
(Group 3860). System Oil Level. (Operator’s Manual.)

10. Install grapple rotate solenoid valve using cap screws.

NM00125,0000587 ­19­06OCT10­1/1

TM11813 (13OCT10) 38­3860­36 748H Repair (S.N. 630436— )

101310

PN=384
 Hydraulic System

Grapple Rotate Solenoid Valve Disassemble

and Assemble
1. Remove grapple rotate solenoid valve. See Grapple
Rotate Solenoid Valve Remove and Install. (Group
3860.)

TX1080241A —UN—28JUL10
2. Remove coil nut (4) from cartridge (2).
NOTE: Identify location of coils for ease of installation.

3. Remove coils (3) and coil Spacer (5).

4. Remove cartridge from valve body (1).
Grapple Rotate Solenoid Valve Exploded View
5. Inspect parts for damage, wear, or contamination.
Replace as necessary.
1— Valve Body 4— Coil Nut
2— Cartridge 5— Coil Spacer
3— Coil (2 used)

NM00125,0000588 ­19­08OCT10­1/2

NOTE: Identify location of O­rings and backup

rings for ease of installation.

6. Remove and replace cartridge O­rings (7) and backup

rings (8), using petroleum jelly for installation.

TX1080240A —UN—28JUL10
7. Install cartridge into valve body. Tighten to
specification.
Specification
Cartridge Installation
Torque—Torque.................................................................. 32.7­35.4 Nm
24­26 lb­ft

8. Install coils and spacer to cartridge. Cartridge

9. Install coil nut. Torque to specification.
6— Cartridge­to­Valve Body 8— Backup Ring (6 used)
Specification
O­Ring
Coil Nut 7— O­Ring (3 used)
Installation—Torque........................................................... 9.5—13.6 N∙m
7—10 lb­ft

10. Install grapple rotate solenoid valve. See Grapple 12. Check hydraulic oil level. See Check Hydraulic
Rotate Solenoid Valve Remove and Install. (Group System Oil Level. (Operator’s Manual.)
3860.)
11. Operate grapple through several cycles to remove air
trapped in system and to fill components with oil.
NM00125,0000588 ­19­08OCT10­2/2

TM11813 (13OCT10) 38­3860­37 748H Repair (S.N. 630436— )

101310

PN=385
 Hydraulic System

Flow Divider Repair

TX1081372 —UN—02SEP10
Exploded View of Flow Divider
1— Direct Acting Crossover 3— Cap Screw (2 used) 5— Seal Kit 7— Retainer (2 used)
Relief Valve (2 used) 4— Nut (2 used) 6— Flow Divider Valve
2— Seal Kit (2 used)

1. Open grapple tongs and lower grapple to the ground. 4. Remove bottom access cover on grapple frame.

CAUTION: To avoid injury from escaping fluid 5. Tag and disconnect hydraulic lines from flow divider.
under pressure, stop engine and relieve the Close all openings using caps and plugs. See Grapple
pressure in the system before disconnecting or Tong Cylinder Remove and Install. (Group 3860.)
connecting hydraulic or other lines. Tighten all 6. Remove cap screws (3) and remove flow divider
connections before applying pressure. manifold.
2. Operate all hydraulic control valves to release 7. Remove retainers (7) and relief valves (1).
pressure in hydraulic system. Depress brake pedal at
1­second intervals 20 times to drain oil from service 8. Remove flow divider valve (6).
brake accumulator.
3. Turn battery disconnect switch to the OFF position.
Continued on next page SW03989,0000AC0 ­19­07SEP10­1/4

TM11813 (13OCT10) 38­3860­38 748H Repair (S.N. 630436— )

101310

PN=386
 Hydraulic System

9. Check direct acting relief valve for wear or damage.

Replace if necessary.
10. Replace with new gland ring (8), backup ring (9), and
O­ring (10).

TX1081373A —UN—02SEP10
8— Gland Ring 10— O­Ring
9— Backup Ring

Relief Valve Rings

SW03989,0000AC0 ­19­07SEP10­2/4

11. Check flow divider valve for wear or damage. Replace

if necessary.
12. Replace with new O­rings (12 and 14) and backup
rings (11 and 13).

TX1081374A —UN—02SEP10
11— Backup Ring (6 used) 13— Backup Ring
12— O­Ring (3 used) 14— O­Ring

Flow Divider Valve Rings

SW03989,0000AC0 ­19­07SEP10­3/4

13. Install direct acting crossover relief valves (1) and flow
divider valve (6).
14. Install retainers (7) on direct acting crossover relief
valves.

TX1081376A —UN—02SEP10
15. Install flow divider manifold with cap screws and nuts.
16. Connect hydraulic lines.
17. Turn battery disconnect switch to the ON position.
18. Start engine and follow hydraulic oil warmup
procedure. See Hydraulic Oil Warmup Procedure.
(Group 9025.)
Flow Divider Assembly
19. Stop engine and check for leaks.
20. Check hydraulic reservoir oil level. See Check 1— Direct Acting Crossover 7— Retainer (2 used)
Hydraulic System Oil Level. (Operator’s Manual.) Relief Valve (2 used)
6— Flow Divider Valve
21. Install bottom access cover on grapple frame.
SW03989,0000AC0 ­19­07SEP10­4/4

TM11813 (13OCT10) 38­3860­39 748H Repair (S.N. 630436— )

101310

PN=387
 Hydraulic System

Rotary Manifold Remove and Install

1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

2. Operate all hydraulic control valves to release

pressure in hydraulic system. Depress brake pedal at
1­second intervals 20 times to drain oil from service
brake accumulator.
3. Turn battery disconnect switch to the OFF position.
4. Remove top boom cover.

TX1024840A —UN—14JUN07
5. Remove grapple rotate motor. See Grapple Rotate
Motor Remove and Install. (Group 3860.)
6. Put identification tags on lines to aid assembly.
7. Disconnect hoses (1—3) at rotary manifold. Close all
openings using caps and plugs.
Rotary Manifold
8. Remove cap screws (5).
9. Remove housing cap screw (4). 1— Rotary Manifold­to­Control 4— Housing Cap Screw
Valve Tong Head End Hose 5— Cap Screw (2 used)
2— Rotary Manifold­to­Control
Valve Tong Rod End Hose
3— Rotary Manifold­to­Rotate
Motor Hose

Continued on next page SW03989,0000AC1 ­19­07SEP10­1/2

TM11813 (13OCT10) 38­3860­40 748H Repair (S.N. 630436— )

101310

PN=388
 Hydraulic System

10. Remove bottom access cover on grapple frame.

11. Disconnect rotary manifold­to­flow divider hose (6) at
flow divider.
12. Disconnect rotary manifold­to­grapple cylinder rod end

TX1081377A —UN—02SEP10
hose (7) at tee.
13. Remove rotary manifold and hoses (6 and 7).
14. Inspect and repair rotary manifold as necessary. See
Rotary Manifold Disassemble and Assemble. (Group
3860.)
NOTE: Lines must not be twist as they pass through
the gear and yoke when installing rotary manifold. Rotary Manifold Bottom Hoses
Port marked “A” connects to flow divider.
6— Rotary Manifold­to­Flow 7— Rotary Manifold­to­Grapple
15. Install rotary manifold with hoses. Divider Hose Cylinder Rod End Hose

16. Install cap screws and tighten to specification.

Specification 19. Turn battery disconnect switch to the ON position.
Cap Screw—Torque.................................................................... 115 N∙m
85 lb­ft 20. Start engine and follow hydraulic oil warmup
Housing Cap procedure. See Hydraulic Oil Warmup Procedure.
Screw—Torque............................................................................163 N∙m (Group 9025.)
120 lb­ft
21. Stop engine and check for leaks.
NOTE: Port marked “A” connects to flow divider.
22. Check hydraulic reservoir oil level. See Check
17. Connect hoses. Hydraulic System Oil Level. (Operator’s Manual.)

18. Install grapple rotate motor. See Grapple Rotate Motor 23. Install covers.
Remove and Install. (Group 3860.)
SW03989,0000AC1 ­19­07SEP10­2/2

Rotary Manifold Disassemble and Assemble

1. Remove hoses and fittings from rotary manifold shaft
(1).

TX1081378A —UN—02SEP10
1— Rotary Manifold Shaft

Rotary Manifold Shaft

Continued on next page SW03989,0000AC2 ­19­01OCT10­1/4

TM11813 (13OCT10) 38­3860­41 748H Repair (S.N. 630436— )

101310

PN=389
 Hydraulic System

2. Remove snap ring (3). Remove rotary manifold shaft

from rotary manifold housing (2).

1— Rotary Manifold Shaft 3— Snap Ring

2— Rotary Manifold Housing

TX1081379A —UN—02SEP10
Rotary Manifold Shaft, Housing, and Snap Ring

SW03989,0000AC2 ­19­01OCT10­2/4

3. Remove rotary manifold housing O­rings (4 and 6),

wear rings (5), and expander rings (7).
4. Inspect rotary manifold housing and rotary manifold
shaft for wear or damage. Replace if necessary.
5. Apply clean hydraulic oil to new O­rings and wear
rings.
6. Assemble expander rings into O­rings.
7. Install O­rings, wear rings, and O­ring with expander

TX1081380A —UN—02SEP10
ring assemblies in sequence shown. Position in rotary
manifold housing grooves.
8. Apply petroleum jelly to parts inside of rotary manifold
housing and to rotary manifold shaft. Carefully tap
rotary manifold shaft into rotary manifold housing
using a soft hammer.
9. Install snap ring on rotary manifold shaft. Rotary Manifold Housing and Rings

2— Rotary Manifold Housing 6— O­Ring (4 used)

4— O­Ring (2 used) 7— Expander Ring (4 used)
5— Wear Ring (2 used)

Continued on next page SW03989,0000AC2 ­19­01OCT10­3/4

TM11813 (13OCT10) 38­3860­42 748H Repair (S.N. 630436— )

101310

PN=390
 Hydraulic System

CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

10. Test rotary manifold for leaks before installing on

machine.
Install a cap on port marked "1" (12) of rotary manifold
shaft and port marked "D" (9) of rotary manifold.
Connect a hydraulic hand­operated pump to port
marked "1" (8) of rotary manifold.

TX1081381A —UN—02SEP10
11. Operate pump to test specification.
Specification
Rotary Manifold Test
Ports Marked "1" and
"2"—Pressure......................................................................... 20 685 kPa
207 bar
3000 psi
Turn rotary manifold shaft 10 rpm in both directions. Rotary Manifold Leak Test
Leakage must not exceed 5 drops per minute at ports
marked "2" (10 or 11). Rotary manifold shaft must not
8— Port Marked "1" 11— Port Connected to "2"
bind while turning. 9— Port Marked "D" 12— Port Connected to "1"
10— Port Marked "2"
12. Repeat test, with cap on port marked "2" (11) and
applying pressure to port marked "2" (10). Leakage
must not exceed 5 drops per minute at ports marked
"1". Rotary manifold shaft must not bind while turning. Specification
Rotary Manifold Test Port
13. Install caps or plugs to all ports marked "1" and Marked "D"—Pressure.............................................................. 1379 kPa
"2". Connect hydraulic hand operated pump to port 14 bar
marked "D". Operate pump to pressurize manifold to 200 psi
test specifications. Turn rotary manifold shaft 10 rpm
in both directions. There must be no external leakage
and rotary manifold shaft must not bind.
SW03989,0000AC2 ­19­01OCT10­4/4

TM11813 (13OCT10) 38­3860­43 748H Repair (S.N. 630436— )

101310

PN=391
 Hydraulic System

TM11813 (13OCT10) 38­3860­44 748H Repair (S.N. 630436— )

101310

PN=392
 Section 99
Dealer Fabricated Tools
Contents

Page

Group 9900—Dealer Fabricated Tools

DFT1099 Bushing Drivers ......................... 99­9900­1
DFRW20 Compressor Holding
Fixture.................................................... 99­9900­2

TM11813 (13OCT10) 99­1 748H Repair (S.N. 630436— )

101310

PN=1
 Group 9900
Dealer Fabricated Tools

DFT1099 Bushing Drivers

TX1071962 —UN—05APR10

Continued on next page GD61784,0000077 ­19­31MAR10­1/2

TM11813 (13OCT10) 99­9900­1 748H Repair (S.N. 630436— )

101310

PN=394
 Dealer Fabricated Tools

A—0.5 x 2.0 x 6.0 in. 1020 Cold B—50 mm Bushing—Use 2.825 B—70 or 80 mm Bushing—Use D—0.5 x 8.0 Full Threaded Cap
Rolled in. OD x 2.50 in. ID x 2.5 in. 4.00 in. OD x 3.50 in. ID x 2.5 Screw
B—45 mm Bushing—Use 2.625 B—60 mm Bushing—Use 3.50 in. in. E—Tack Weld With 0.5 in.
in. OD x 2.25 in. ID x 2.5 in. OD x 3.00 in. ID x 2.5 in. C—0.5 x 2.0 x 4.25 in. 1020 Cold Crosshole Centered In Pipe
Rolled OD

These bushing drivers are used to remove and install

spherical bushings.
GD61784,0000077 ­19­31MAR10­2/2

DFRW20 Compressor Holding Fixture

RW13619 —UN—20SEP89
A—102 mm (4 in.) D—6.4 mm (0.25 in.) G—254 mm (10 in.) J— Fillet Weld
B—76 mm (3 in.) E—19 mm (0.75 in.) H—114 mm (4.5 in.) K—Two Holes
C—70 mm (2.75 in.) F— 152 mm (6 in.) I— 178 mm (7 in.)

Material required: • 4—Matching Lock Washers and Nuts

• 2—Steel Plates (4 x 2.75 in.) and (10 x 6 in.) Tool is used to hold air conditioning compressor during
• 2—Threaded Steel Rods (0.5 x 7 in.) assembly and disassembly.
GD61784,0000078 ­19­02JUL07­1/1

TM11813 (13OCT10) 99­9900­2 748H Repair (S.N. 630436— )

101310

PN=395
 Dealer Fabricated Tools

TM11813 (13OCT10) 99­9900­3 748H Repair (S.N. 630436— )

101310

PN=396
 Index
Page Page

A
B
Accumulator, service brake
Remove and install ........................................ 10­1060­4 Bearing
Adjustable circuit relief valve Support, remove and install ........................... 02­0225­2
Disassemble and assemble ......................... 38­3860­30 Belt
Aftercooler Tensioner spring tension check...................... 05­0510­3
Remove and install ........................................ 05­0510­5 Belt tensioner
Air baffle Remove and install ........................................ 05­0510­4
Remove and install ........................................ 05­0510­1 Belt, seat
Air baffle enclosure Remove and install ........................................ 18­1821­7
Remove and install ........................................ 05­0510­1 Blade
Air conditioner Control linkage, remove and install................ 32­3215­1
Compressor, remove and install .................... 18­1830­8 Control valve, remove and install................... 32­3215­2
Air conditioning Lift cylinder, remove and install...................... 32­3260­1
R134a system charge .................................... 18­1830­7 Stacking, remove and install .......................... 32­3201­1
R134a system evacuate ................................ 18­1830­6 Blower motor
Air conditioning system Remove and install ...................................... 18­1830­13
Blower motor remove and install.................. 18­1830­13 Boom
Compressor clutch remove and Remove and install ........................................ 38­3840­2
install ............................................................ 18­1830­9 Boom cylinder—dual function grapple
Compressor manifold remove and Remove and install ........................................ 38­3860­1
install .......................................................... 18­1830­11 Bottom guard
Compressor relief valve remove and Engine frame, remove and install .................. 17­1746­1
install ............................................................ 18­1830­7 Equipment frame, remove and install ............ 17­1746­2
Condenser remove and install ..................... 18­1830­11 Brake accumulator
Evaporator remove and install ..................... 18­1830­20 Remove and install ........................................ 10­1060­4
Expansion valve remove and install............. 18­1830­18 Brake pedal
Flush and purge ............................................. 18­1830­2 Remove and install ........................................ 10­1015­1
Freeze control switch remove and Brake valve, service
install .......................................................... 18­1830­17 Disassemble and assemble ........................... 10­1060­3
High/low pressure switch remove and Remove and install ........................................ 10­1060­1
install .......................................................... 18­1830­15 Brake, park
Precleaner blower assembly remove and Remove and install ......................................... 11­1111­1
install .......................................................... 18­1830­14 Bump shifter
R134a refrigerant cautions and proper Remove and install ........................................ 03­0315­1
handling........................................................ 18­1830­1 Bushing
R134a refrigerant oil information.................... 18­1830­4 Spherical, remove and install......................... 32­3201­5
R134a refrigerant recovery ............................ 18­1830­6
R134a refrigerant recovery/recycling and C
charging station installation.......................... 18­1830­5
Receiver­dryer remove and install ............... 18­1830­21 Cab
Arch Remove and install ........................................ 18­1800­1
Remove and install ........................................ 38­3840­3 Cab door
Arch cylinder—dual function grapple Disassemble and assemble ........................... 18­1810­5
Remove and install ........................................ 38­3860­1 Remove and install ........................................ 18­1810­4
Axle and differential drive shaft Cab isolators
Front, remove and install ............................... 02­0225­1 Remove and install ........................................ 18­1800­8
Axle and transmission drive shaft Cab tilt cylinder
Rear, remove and install ................................ 02­0225­2 Remove and install ...................................... 18­1800­17
Axle, front Cab tilt hand pump
Remove and install ........................................ 02­0200­1 Bleeding procedure...................................... 18­1800­15
Axle, rear Disassemble and assemble ......................... 18­1800­14
Remove and install ........................................ 02­0200­5 Remove and install ...................................... 18­1800­13
Cable rollers, dual function
Remove and install ........................................ 38­3840­1
Charge air cooler
Remove and install ........................................ 05­0510­5

Continued on next page

TM11813 (13OCT10) Index­1 748H Repair (S.N. 630436— )

101310

PN=1
 Index

Page Page

Charge pump Cylinder, cab tilt

Transmission, remove and install .................. 03­0360­1 Remove and install ...................................... 18­1800­17
Charge pump drive, transmission
Repair ............................................................ 03­0360­4 D
Cleanup procedure
General oil...................................................... 21­2160­1 Dampener
Hydraulic component failure .......................... 21­2160­3 Lubricate ........................................................ 38­3803­7
Component failure Remove and install ........................................ 07­0752­1
Hydraulic, cleanup procedure ........................ 21­2160­3 Dampener, grapple
Compressor Adjustment ..................................................... 38­3803­6
Air conditioner, remove and install ................. 18­1830­8 Detent
Compressor clutch Disassemble and assemble ......................... 38­3860­33
Remove and install ........................................ 18­1830­9 DFRW20 tool
Compressor manifold Compressor holding fixture ............................ 99­9900­2
Remove and install ...................................... 18­1830­11 DFT1099 driver
Compressor relief valve Spherical bushings removal........................... 99­9900­1
Remove and install ........................................ 18­1830­7 Differential drive shaft
Condenser Front, remove and install ............................... 02­0225­1
Remove and install ...................................... 18­1830­11 Rear, remove and install ................................ 02­0225­2
Control linkage Differential lock solenoid valve
Blade, remove and install............................... 32­3215­1 Repair ............................................................ 02­0260­1
Winch, remove and install.............................. 30­3015­1 Door latch
Control valve Disassemble and assemble ........................... 18­1810­5
Blade, remove and install............................... 32­3215­2 Door, cab
Options......................................................... 38­3860­20 Disassemble and assemble ........................... 18­1810­5
Control valve relief valves Remove and install ........................................ 18­1810­4
Remove and install ...................................... 38­3860­27 Drive and clutch repair
Control valve, transmisison Winch 4000 .................................................... 30­3050­1
Repair ............................................................ 03­0360­9 Winch 6000 .................................................... 30­3050­1
Control valve­dual function pilot operated Drive shaft
Disassemble and assemble ......................... 38­3860­25 Front axle and differential, remove and
Control valve­pilot operated install ............................................................ 02­0225­1
Remove and install ...................................... 38­3860­22 Rear axle and differential, remove and
Control valve­pilot operated valve install ............................................................ 02­0225­2
Remove and install ...................................... 38­3860­34 Winch, disassemble and assemble................ 30­3025­1
Control valve—adjustable circuit relief valve Drive shaft, engine­to­transmission
Disassemble and assemble ......................... 38­3860­30 Remove and install ........................................ 03­0325­1
Control valve—detent Drive shaft, winch
Disassemble and assemble ......................... 38­3860­33 Remove and install ........................................ 30­3025­1
Control valve—lift check valve Dual mode steering solenoid valve
Disassemble and assemble ......................... 38­3860­28 Remove and install ........................................ 09­0962­1
Control valve—non­adjustable circuit relief Duals wheel installation ..................................... 01­0110­3
valve
Disassemble and assemble ......................... 38­3860­29 E
Control valve—solenoid operated valve
Remove and install ...................................... 38­3860­35 Enclosure, air baffle
Control valve—spool valve Remove and install ........................................ 05­0510­1
Disassemble and assemble ......................... 38­3860­32 Engine
Coolant valve Remove and install ........................................ 04­0400­2
Remove and install ...................................... 18­1830­16 Engine CTM reference
Cooling loop pump Theory of operation........................................ 04­0400­1
Remove and install ...................................... 21­2160­18 Engine dampener
Cooling system Remove and install ........................................ 07­0752­1
Service safely............................................... 00­0001­12 Engine­to­transmission drive shaft
Crosshead pins Remove and install ........................................ 03­0325­1
Lubricate ........................................................ 38­3803­7 Evaporator
Cylinder Remove and install ...................................... 18­1830­20
Blade lift, remove and install .......................... 32­3260­1 Expansion valve
Remove and install ...................................... 18­1830­18

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Grapple rotate yoke

F Disassemble and assemble ........................... 38­3803­8
Grapple tong cylinder
Fabricated tools Remove and install ........................................ 38­3860­3
DFRW20 compressor holding fixture ............. 99­9900­2 Grille guard
DFT1099 bushing driver ................................ 99­9900­1 Remove and install ........................................ 19­1910­3
Fan Grille housing
Hydraulic motor remove and install.............. 21­2160­12 Remove and install ........................................ 19­1910­5
Fan blade Guard
Remove and install ...................................... 05­0510­16 Engine frame bottom, remove and
Fan shroud install ............................................................ 17­1746­1
Remove and install ...................................... 05­0510­16 Equipment frame bottom, remove and
Fan variable speed and reversing manifold install ............................................................ 17­1746­2
Disassemble and assemble ......................... 21­2160­11 Guards, front axle
Remove and install ...................................... 21­2160­10 Remove and install ........................................ 02­0200­8
Fire prevention................................................... 00­0001­4
Flow divider H
Repair .......................................................... 38­3860­38
Flush and purge Heater core
Air conditioning system .................................. 18­1830­2 Remove and install ...................................... 18­1830­19
Frame Heating system
Engine, separate............................................ 17­1740­2 Blower motor remove and install.................. 18­1830­13
Equipment, separate...................................... 17­1740­2 Coolant valve remove and install ................. 18­1830­16
Free spool drag adjustment............................... 30­3000­7 Heater core remove and install .................... 18­1830­19
Freeze control switch High/low pressure switch
Remove and install ...................................... 18­1830­17 Remove and install ...................................... 18­1830­15
Front axle High­pressure oils
Remove and install ........................................ 02­0200­1 Avoid .............................................................. 00­0001­3
Front axle guards Hood
Remove and install ........................................ 02­0200­8 Remove and install ........................................ 19­1910­1
Front axle oscillation supports Horn
Repair ............................................................ 02­0200­8 Remove and install ........................................ 20­2004­1
Front differential Housing, grille
Remove and install ........................................ 02­0200­1 Remove and install ........................................ 19­1910­5
Front windshield wiper Hydraulic
Remove and install ........................................ 18­1810­6 Component faliure cleanup
Fuel tank procedure ..................................................... 21­2160­3
Rremove and install ....................................... 05­0560­1 Fittings, 30° cone seat ........................... 00­0003­5
Fittings, 37° flare .................................... 00­0003­5
G Hydraulic attenuator
Remove and install ........................................ 21­2160­9
General oil Hydraulic fan motor
Cleanup procedure ........................................ 21­2160­1 Remove and install ...................................... 21­2160­12
Grapple Hydraulic fan pump
Disassemble and assemble ........................... 38­3803­2 Remove and install ...................................... 21­2160­18
Remove and install ........................................ 38­3803­1 Hydraulic oil cooler
Rotate bearing repair ..................................... 38­3803­8 Remove and install ...................................... 05­0510­13
Grapple dampener Hydraulic pump
Disassemble and assemble ........................... 38­3803­4 Remove and install ........................................ 21­2160­5
Grapple head Hydraulic reservoir
Dampener adjustment.................................... 38­3803­6 Remove and install ...................................... 21­2160­14
Grapple rotate motor
Assemble ..................................................... 38­3860­12 I
Disassemble .................................................. 38­3860­7
Remove and install ........................................ 38­3860­5 Inch bolt and cap screw
Grapple rotate solenoid valve Torque value .................................................. 00­0003­4
Disassemble and assemble ......................... 38­3860­37 Input shaft, transmission
Remove and install ...................................... 38­3860­36 Remove and install ........................................ 03­0350­7

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Intercooler Disassemble and assemble ......................... 18­1800­14

Remove and install ........................................ 05­0510­5 Remove and install ...................................... 18­1800­13
Isolators, cab
Remove and install ........................................ 18­1800­8 R
L R134a refrigerant
Cautions and proper handling........................ 18­1830­1
Lower pivot pin seal Oil information................................................ 18­1830­4
Remove and install ........................................ 17­1740­6 Recovery........................................................ 18­1830­6
Lubricate Recovery/recycling and charging station
Grapple head dampener, yoke, and installation .................................................... 18­1830­5
crosshead pins ............................................. 38­3803­7 R134a system
Charge ........................................................... 18­1830­7
M Evacuate ........................................................ 18­1830­6
Radiator
Machine modifications Remove and install ........................................ 05­0510­8
Avoid .............................................................. 00­0001­2 Rear axle
Metric bolt and cap screw Remove and install ........................................ 02­0200­5
Torque value .................................................. 00­0003­2 Rear differential
Mount—transmission Remove and install ........................................ 02­0200­5
Remove and install ........................................ 03­0300­6 Rear windshield wiper
Remove and install ........................................ 18­1810­7
O Receiver­dryer
Remove and install ...................................... 18­1830­21
O­ring boss fittings............................................. 00­0003­6 Repair procedures
Oil Transmission.................................................. 03­0350­1
General, cleanup procedure .......................... 21­2160­1 Reverse warning alarm
Lines and fittings ............................................ 00­0003­5 Remove and install ........................................ 20­2004­1
Oil lines and fittings ........................................... 00­0003­5 Rollers, cable, dual function
Oscillation supports Remove and install ........................................ 38­3840­1
Remove and install ........................................ 02­0200­1 ROPS
Repair ............................................................ 02­0200­8 Torque ............................................................ 00­0003­1
Rotary manifold
Disassemble and assemble ......................... 38­3860­41
P Remove and install ...................................... 38­3860­40
Rotate motor drive gear
Park brake Remove and install ...................................... 38­3860­20
Remove and install ......................................... 11­1111­1
Park brake solenoid valve
Repair .............................................................11­1160­1 S
Pilot operated valve
Remove and install ...................................... 38­3860­34 Safety
Pin, upper pivot Add and operate attachments safely ........... 00­0001­11
Remove and install ...................................... 17­1740­12 Avoid backover accidents .............................. 00­0001­9
Pins, metal Avoid machine tip over................................... 00­0001­9
Drive safely .................................................. 00­0001­14 Avoid work site hazards ................................. 00­0001­8
Pivot pin, upper Clean debris from machine ............................ 00­0001­6
Remove and install ...................................... 17­1740­12 Do not use starting fluid with tier 3
Precleaner blower assembly engine .......................................................... 00­0001­3
Remove and install ...................................... 18­1830­14 Inspect and maintain ROPS......................... 00­0001­10
Pressurized water system—if equipped Inspect machine............................................. 00­0001­2
Disassemble and assemble ........................... 20­2003­1 Keep riders off machine ................................. 00­0001­8
Priority valve Keep the operator protective structure in
Disassemble and assemble ........................... 21­2160­8 place........................................................... 00­0001­10
Remove and install ........................................ 21­2160­7 Make welding repairs safely......................... 00­0001­13
Pump drive, transmission charge Operate machine safely ................................. 00­0001­8
Repair ............................................................ 03­0360­4 Operate only if qualified ................................. 00­0001­1
Pump, cab tilt Operating on slopes..................................... 00­0001­10
Bleeding procedure...................................... 18­1800­15 Operating or traveling on public roads ......... 00­0001­10
Park and prepare for service safely ............. 00­0001­11

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Prevent unintended machine

movement .................................................... 00­0001­7 T
Protective equipment ..................................... 00­0001­2
Recognize safety information......................... 00­0001­1 Tensioner, belt
Start only from operator's seat....................... 00­0001­6 Remove and install ........................................ 05­0510­4
Stay clear of moving parts ............................. 00­0001­2 Spring tension check...................................... 05­0510­3
Use and maintain seat belt ............................ 00­0001­7 Tire
Use steps and handholds correctly................ 00­0001­6 Install duals .................................................... 01­0110­3
Seal Remove and install ........................................ 01­0110­2
Lower pivot pin............................................... 17­1740­6 Torque value
Seat 30° cone seat hydraulic fittings .............. 00­0003­5
Disassemble and assemble ........................... 18­1821­2 37° flare hydraulic fittings....................... 00­0003­5
Remove and install ........................................ 18­1821­1 Dual wheel nuts ............................................. 01­0110­3
Seat belt Flat face O­ring seal fitting ............................. 00­0003­7
Remove and install ........................................ 18­1821­7 Hardware specifications................................. 00­0003­1
Secondary Steering Inch SAE four bolt flange fitting...................... 00­0003­9
Remove and install ........................................ 09­0930­1 Metric bolt and cap screw .............................. 00­0003­2
Secondary steering pump Metric cap screw ............................................ 00­0003­3
Remove and install ........................................ 09­0930­1 Metric four bolt flange fitting........................... 00­0003­8
Serpentine belt O­Ring boss fitting ......................................... 00­0003­6
Remove and install ........................................ 05­0510­2 Unified inch bolt and cap screw ..................... 00­0003­4
Serpentine belt tensioner Transmission
Remove and install ........................................ 05­0510­4 Input shaft remove and install ........................ 03­0350­7
Service brake accumulator Remove and install ........................................ 03­0300­1
Remove and install ........................................ 10­1060­4 Repair procedures ......................................... 03­0350­1
Service brake pedal Winch drive repair .......................................... 03­0350­2
Remove and install ........................................ 10­1015­1 Transmission bump shifter
Service brake valve Remove and install ........................................ 03­0315­1
Disassemble and assemble ........................... 10­1060­3 Transmission charge pump
Remove and install ........................................ 10­1060­1 Remove and install ........................................ 03­0360­1
Solenoid operated valve Suction tube repair......................................... 03­0360­8
Remove and install ...................................... 38­3860­35 Transmission charge pump drive
Solenoid valve Repair ............................................................ 03­0360­4
Differential lock, repair ................................... 02­0260­1 Transmission cold weathe disconnect
Solenoid valve, dual mode steering linkage—if equipped
Remove and install ........................................ 09­0962­1 Remove and install ........................................ 07­0752­2
Solenoid valve, park brake Transmission cold weather disconnect—jif
Repair .............................................................11­1160­1 equipped
Spherical bushing Repair ............................................................ 07­0752­4
Remove and install ........................................ 32­3201­5 Transmission control solenoids
Stacking blade Repair ............................................................ 03­0360­9
Remove and install ........................................ 32­3201­1 Transmission control valve
Steering column Repair ............................................................ 03­0360­9
Disassemble and assemble ......................... 18­1800­11 Transmission Gear Selector
Remove and install ........................................ 18­1800­9 Remove and install ........................................ 03­0315­1
Steering cylinder Transmission mount
Remove and install ........................................ 09­0960­9 Remove and install ........................................ 03­0300­6
Steering valve Transmission oil cooler
Disassemble and assemble ........................... 09­0960­5 Remove and install ...................................... 05­0510­10
Remove and install ........................................ 09­0960­1 Transmission suction tube
Steering wheel Repair ............................................................ 03­0360­8
Disassemble and assemble ......................... 18­1800­11 Transmission­to­engine drive shaft
Remove and install ........................................ 18­1800­9 Remove and install ........................................ 03­0325­1
Steering, dual mode solenoild valve
Remove and install ........................................ 09­0962­1 V
Support bearing
Remove and install ........................................ 02­0225­2 Valve
Priority valve disassemble and
assemble...................................................... 21­2160­8

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Priority valve remove and install .................... 21­2160­7 Drive shaft, remove and install....................... 30­3025­1
Valve, blade control Fastening cable­4000 series.......................... 30­3000­5
Remove and install ........................................ 32­3215­2 Fastening cable­6000 series........................ 30­3000­10
Valve, dual mode steering Free spool drag adjustment ........................... 30­3000­7
Remove and install ........................................ 09­0962­1 Winch 4000 series
Valve, grapple rotate solenoid Remove and install ........................................ 30­3000­1
Disassemble and assemble ......................... 38­3860­37 Winch 6000 series
Remove and install ...................................... 38­3860­36 Remove and install ........................................ 30­3000­8
Valve, service brake Winch drive
Disassemble and assemble ........................... 10­1060­3 Repair ............................................................ 03­0350­2
Remove and install ........................................ 10­1060­1 Winch, 4000
Valve, steering Drive and clutch repair ................................... 30­3050­1
Disassemble and assemble ........................... 09­0960­5 Winch, 6000
Remove and install ........................................ 09­0960­1 Drive and clutch repair ................................... 30­3050­1
Window
W Cleaning procedure........................................ 18­1810­4
Remove and install ........................................ 18­1810­1
Water system, pressurized—if equipped Windshield wiper
Disassemble and assemble ........................... 20­2003­1 Adjustment ..................................................... 18­1810­9
Welding.............................................................. 17­1740­1 Windshield wiper, front
Wheel Remove and install ........................................ 18­1810­6
Remove and install ........................................ 01­0110­1 Windshield wiper, rear
Wheel bolt torque Remove and install ........................................ 18­1810­7
Dual wheels ................................................... 01­0110­3
Wheel repair Y
Install duals .................................................... 01­0110­3
Winch Yoke
Control cable, remove and install................... 30­3015­2 Disassemble and assemble ........................... 38­3803­8
Control linkage, remove and install................ 30­3015­1 Lubricate ........................................................ 38­3803­7
Drive shaft, disassemble and
assemble...................................................... 30­3025­1

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TM11813 (13OCT10) Index­7 748H Repair (S.N. 630436— )

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TM11813 (13OCT10) Index­8 748H Repair (S.N. 630436— )

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