Académique Documents
Professionnel Documents
Culture Documents
Repair
(Serial No. 630436
TECHNICAL MANUAL
748H Skidder
Repair
(S.N. 630436 )
TM11813 13OCT10
TM11797
OMT255825
CTM104
CTM320
CTM442
CTM25
CTM41
CTM308
CTM114319
CTM109319
CTM10006
SP458
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
(ENGLISH)
Introduction
Foreword
This manual is written for an experienced technician.
Essential tools required in performing certain service work
are identified in this manual and are recommended for
use.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
This is the safetyalert symbol. When you see this
symbol on the machine or in this manual, be alert to the
potential for personal injury.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
TM11813 (13OCT10)
Introduction
Name:
Phone:
Email Address:
THANK YOU!
TX,TM,FAX 1903JUL011/1
TM11813 (13OCT10)
Introduction
TM11813 (13OCT10)
Contents
Section 00General Information
Group 0001Safety
Group 0003Torque Values
Section 01Wheels
Group 0110Powered Wheels and Fasteners
Section 02Axles
Section 03Transmission
Group 0300Remove and Install
Group 0315Controls
Group 0325Input Drive Shafts and UJoints
Group 0350Gears, Shafts, and Power Shift Clutches
Group 0360Hydraulic System
Section 04Engine
Section 30Winch
Section 38Grapple
Group 3803Grapple Mechanism
Group 3840Frames
Group 3860Hydraulic System
TM11813 (13OCT10)
Contents
TM11813 (13OCT10)
ii
Contents
Section 00
General Information
Page
TM11813 (13OCT10)
001
Contents
TM11813 (13OCT10)
002
Group 0001
Safety
Recognize Safety Information
T133555 UN28AUG00
T133588 1928AUG00
TX03679,00016CC 1903NOV081/1
TS201 UN23AUG88
Know and observe all safety rules that may apply to your
work situation and your work site.
TM11813 (13OCT10)
0000011
Safety
TS206 UN23AUG88
OUT4001,0000570 1912FEB101/1
Inspect Machine
T6607AQ UN18OCT88
TX03679,0001734 1903NOV081/1
T133592 UN12SEP01
TX03679,00016D2 1903NOV081/1
TM11813 (13OCT10)
0000012
Safety
X9811 UN23AUG88
T133840 UN20SEP00
T133509 UN17MAR06
TX03679,00016D3 1903NOV081/1
T145705 UN18SEP01
OUO1065,00001B7 1909JUN081/1
TM11813 (13OCT10)
0000013
Safety
TS220 UN23AUG88
DX,AIR 1917FEB991/1
T133552 UN14SEP00
Prevent Fires
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
materials inside a machine compartment.
T133553 UN07SEP00
T133554 UN07SEP00
TX03679,00016F5 1903NOV081/1
TM11813 (13OCT10)
0000014
Safety
TS204 UN23AUG88
DX,SPARKS 1903MAR931/1
TS1132 UN26NOV90
TS1133 UN26NOV90
TM11813 (13OCT10)
0000015
Safety
TS291 UN23AUG88
DX,FIRE2 1903MAR931/1
T6669AG UN18OCT88
OUT4001,00000E3 1920AUG091/1
T133468 UN30AUG00
TX03679,00016F2 1903OCT071/1
T133715 UN07SEP00
TX03679,0001799 1903OCT071/1
TM11813 (13OCT10)
0000016
Safety
TX03679,00016DD 1903OCT071/1
2
1
TX1076184 UN16APR10
1 Gear Selector
2 Gear Enable/Differential
Lock Switch
TX1076187A UN16APR10
TM11813 (13OCT10)
0000017
Safety
T146611 UN22OCT01
T146610 UN22OCT01
T145263 UN06SEP01
TX03679,0001800 1903OCT071/1
TM11813 (13OCT10)
0000018
Safety
T145264 UN06SEP01
TX03679,0001801 1903OCT071/1
T133716 1914SEP00
T146612 UN06NOV01
T145266 UN06SEP01
TX03679,0001802 1903OCT071/1
TM11813 (13OCT10)
0000019
Safety
Operating on Slopes
T145730 UN20SEP01
TX03679,0001803 1903OCT071/1
TX03679,00017C8 1903OCT071/1
OU90V02,0000477 1920MAY101/1
TM11813 (13OCT10)
00000110
Safety
T133332 1914DEC01
TS229 UN23AUG88
tools or attachments.
OUTJ003,00007AB 1917AUG061/1
TM11813 (13OCT10)
00000111
Safety
TS211 UN23AUG88
DX,RIM 1924AUG901/1
TS281 UN23AUG88
VD76477,0001157 1920DEC061/1
TM11813 (13OCT10)
00000112
Safety
TS281 UN23AUG88
DX,WW,ACCLA 1915APR031/1
T133547 UN31AUG00
TM11813 (13OCT10)
00000113
Safety
T133738 UN14SEP00
TX03679,0001745 1907SEP061/1
TM11813 (13OCT10)
00000114
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
T129546C UN31MAR00
T129547D UN03APR00
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.
CED,OUO1079,98 1926MAY001/1
TM11813 (13OCT10)
0000031
Torque Values
TORQ2 UN07SEP99
METRIC BOLT AND CAP SCREW TORQUE VALUESTolerance is 10% unless otherwise specified
TopProperty Class and Head Markings BottomProperty Class and Nut Markings
Class 4.8
Thread
Size
Lubricateda
Nm (lbft)
Dryb
Nm (lbft)
Class 10.9
Lubricateda
Nm (lbft)
Dryb
Nm (lbft)
Class 12.9
Lubricateda
Nm (lbft)
Dryb
Nm (lbft)
Lubricateda
Nm (lbft)
Dryb
Nm (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)
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
Make sure fastener threads are clean and that you properly start thread
engagement. This will prevent them from failing when tightening.
DO NOT use these values if a different torque value or tightening
procedure is given for a specific application. Torque values listed are for
Tighten plastic insert or crimped steeltype lock nuts to approximately
general use only. Check tightness of fasteners periodically.
50 percent of the dry torque shown in the chart, applied to the nut, not
to the bolt head. Tighten toothed or serratedtype lock nuts to the full
Shear bolts are designed to fail under predetermined loads. Always
torque value.
replace shear bolts with identical property class.
OUT3035,TORQUE2 1922MAR061/1
TM11813 (13OCT10)
0000032
Torque Values
TBolt
Nomi
nal Dia
8
HBolt
Nm
lbft
29
21
Nm
20
lbft
15
MBolt
Nm
10
lbft
T6873AB UN18OCT88
T6873AC UN18OCT88
T6873AA UN18OCT88
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
TM11813 (13OCT10)
0000033
Torque Values
TORQ1A UN27SEP99
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUESTolerance is 10% unless otherwise specified
TopSAE Grade and Head Markings BottomSAE Grade and Nut Markings
Grade 2a (No Mark)
Lubricated
Nm (lbft)
Dry
Nm (lbft)
Lubricatedb
Nm (lbft)
Dryc
Nm (lbft)
Dryc
Nm (lbft)
Grade 8 or 8.2
Lubricatedb
Nm (lbft)
Dryc
Nm (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)
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)
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.
TM11813 (13OCT10)
0000034
Torque Values
X9811 UN23AUG88
Nm
lbft
3/8 24 UNF
7/16 20 UNF
12
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
TM11813 (13OCT10)
0000035
Torque Values
T6243AE UN18OCT88
04T,90,K66 1929SEP991/2
Angle Fitting
T6520AB UN18OCT88
Nm
lbft
3/824 UNF
7/1620 UNF
12
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
TM11813 (13OCT10)
0000036
Torque Values
Thread Size
Bulkhead Nut
Swivel Nut
in.
Nm
lbft
Nm
lbft
6.35
0.250
9/1618
16
12
12
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
Inch
Inch
Inch
3/824
5/8
9/16
12
7/1620
5/8
5/8
21
15
1/220
3/4
11/16
26
19
9/1618
3/4
3/4
34
25
55
lbft
3/416
7/8
15/16
73
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
TM11813 (13OCT10)
0000037
Torque Values
T6890BB UN01MAR90
ASealing Surface
BSplit Flange
CPinched ORing
Thread
Nm
M6
12
M8
30
22
M10
57
42
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
lbft
Tolerance 10%. The torques given are enough for the given size
connection with the recommended working pressure. Increasing
cap screw torque beyond these amounts will result in flange and
cap screw bending and connection failures.
b
Metric standard thread.
04T,90,K175 1929SEP991/1
TM11813 (13OCT10)
0000038
Torque Values
T6890BB UN01MAR90
ASealing Surface
BSplit Flange
CPinched ORing
Nominal
Flange
Size
lbft
Cap Screw
Size
Min
Max
Min
Max
1/2
5/1618 UNC
20
31
15
23
3/4
3/816 UNC
28
54
21
40
3/816 UNC
37
54
27
40
11/4
7/1614 UNC
47
85
35
63
11/2
1/213 UNC
62
131
46
97
1/213 UNC
73
131
54
97
21/2
1/213 UNC
107
131
79
97
5/811 UNC
158
264
117
195
31/2
5/811 UNC
158
264
117
195
5/811 UNC
158
264
117
195
5/811 UNC
158
264
117
195
TM11813 (13OCT10)
0000039
Torque Values
TM11813 (13OCT10)
00000310
Contents
Section 01
Wheels
Page
TM11813 (13OCT10)
011
Contents
TM11813 (13OCT10)
012
Group 0110
Powered Wheels and Fasteners
Wheel Remove and Install
1. Prepare machine for service. See Park and Prepare
for Service Safely. (Group 0001.)
T7382AN UN27SEP90
Wheel
Specification
WheelWeight
(approximate)................................................................................ 545 kg
1200 lb.
Specification
WheelWeight
(approximate)................................................................................ 545 kg
1200 lb.
TM11813 (13OCT10)
0101101
TS952 UN12APR90
TS211 UN23AUG88
VD76477,000049C 1912NOV081/1
TM11813 (13OCT10)
0101102
TM11813 (13OCT10)
0101103
TM11813 (13OCT10)
0101104
Contents
Section 02
Axles
Page
TM11813 (13OCT10)
021
Contents
TM11813 (13OCT10)
022
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
TX1024537A UN06JUN07
3 Drive Shaft
4 Front Axle Yoke
TM11813 (13OCT10)
0202001
MH66088,0000D71 1910SEP101/5
TX1024546A UN06JUN07
13. Disconnect front axle vent hose (7). Close all openings
using caps and plugs.
14. Remove front engine frame bottom guard.
TX1081761A UN10SEP10
TM11813 (13OCT10)
0202002
MH66088,0000D71 1910SEP103/5
TX1081763A UN10SEP10
Specification
1400 Series
AxleWeight
(approximate)................................................................................ 862 kg
1900 lb.
1400 Series Super
Wide Extreme Duty
Axle (SWEDA)Weight
(approximate).............................................................................. 1450 kg
3200 lb.
8 Lubrication Hose
Specification
1400 Series
AxleWeight
(approximate)................................................................................ 862 kg
1900 lb.
1400 Series Super
Wide Extreme Duty
Axle (SWEDA)Weight
(approximate).............................................................................. 1450 kg
3200 lb.
TM11813 (13OCT10)
0202003
MH66088,0000D71 1910SEP104/5
10 Front Oscillation
SupporttoEngine Frame
Cap Screw (6 used)
11 Rear Oscillation
SupporttoEngine Frame
Cap Screw (6 used)
TX1024596A UN06JUN07
Specification
3/8 in. Cross and Bearing
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
1/2 in. Cross and Bearing
AssemblytoYoke Cap
ScrewTorque.................................................................. 127142 Nm
94105 lbft
12 Front CovertoOscillation
Support Cap Screw (6
used)
13 Thrust Washer
TM11813 (13OCT10)
0202004
TX1024608A UN06JUN07
1 TransmissiontoRear Axle
Drive Shaft
Specification
MachineWeight
(approximate)........................................................................... 17 030 kg
37 540 lb
TM11813 (13OCT10)
0202005
MH66088,0000D72 1910SEP101/4
TX1081760A UN10SEP10
TM11813 (13OCT10)
0202006
MH66088,0000D72 1910SEP102/4
Specification
Rear Axle and
DifferentialtoEquipment
Frame Cap
ScrewsTorque..........................................................................660 Nm
487 lbft
TM11813 (13OCT10)
0202007
MH66088,0000D72 1910SEP103/4
23. Fill axle with oil. See Change Rear Axle Oil.
(Operators Manual.)
Specification
Bottom Guardto
Equipment Frame Cap
ScrewTorque............................................................................620 Nm
460 lbft
TX1024347 UN06JUN07
TX1024347
1 Cap Screw (2 used per guard) 2 Washer (8 used per guard)
Measurement
Specification
Axle GuardtoTransmission
Case Cap Screw
Torque
346 Nm
255 lbft
AC12469,000033E 1929MAY071/1
TM11813 (13OCT10)
0202008
Group 0225
Input Drive Shaft and UJoints
Front Axle Drive Shaft Remove and Install
2
3
2
3
2
TX1024375 UN07JUN07
4
TX1024375
1 Front Differential Yoke
2 Cap Screw (12 used)
TM11813 (13OCT10)
0202251
TX1024417 UN07JUN07
TM11813 (13OCT10)
0202252
SW03989,0000B3B 1924SEP101/3
6 Universal Joint
7 Lubrication Fitting
8 Telescoping Drive Shaft
9 Lock Nut
10 Washer
16 Set Screw
17 Support Bearing
18 Drive Shaft
19 Cap Screw (2 used)
20 Alignment Marks
Specification
Support Bearingto
Coupling Shaft Slot Set
ScrewClearance....................................................... One turn out from
bottom of slot in coupling shaft.
4. Loosen the nut (15) and then the set screw (16) to
remove support bearing (17) from drive shaft (18).
15. Install washer (10) and lock nut (9). Tighten lock nut
to specification.
Specification
Lock Nut (Machines
with 1200 Series
Axle)Torque.................................................................... 542610 Nm
400450 lbft
Lock Nut (Machines
with 1400 Series
Axle)Torque.................................................................... 720800 Nm
531590 lbft
TM11813 (13OCT10)
0202253
SW03989,0000B3B 1924SEP102/3
22 Yoke Pilot
21. Grease drive shaft. See Grease Rear Axle Drive Shaft
UJoints, Telescoping Splines, Support Bearing, and
Transmission Output Shaft Seal. (Operators Manual.)
SW03989,0000B3B 1924SEP103/3
TM11813 (13OCT10)
0202254
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. (Operators Manual.)
TX1079259A UN29JUN10
3 Access Panel
NM00125,0000583 1904OCT101/2
6 Valve Body
TX1024458 UN06JUN07
NM00125,0000583 1904OCT102/2
TM11813 (13OCT10)
0202601
Hydraulic System
TM11813 (13OCT10)
0202602
Contents
Section 03
Transmission
Page
TM11813 (13OCT10)
031
Contents
TM11813 (13OCT10)
032
Group 0300
Remove and Install
Transmission Remove and Install
TX1080860A UN16AUG10
Transmission
TX1025630A UN29JUN07
Transmission Harness
1 Main Hydraulic Pump
2 Transmission Charge
PumptoFilter Hose
3 Hydraulic Fan and Cooling
Loop Pump
4 Transmission Harness
toFuel Sender Harness
Connector
5 Transmission Charge Pump
6 Spline Coupler
7 Clamp and Cap Screw
8 Transmission Wiring
Harness
9 Transmission Wiring
Harness Plug
TM11813 (13OCT10)
0303001
SW03989,0000B37 1907OCT101/7
TX1025640A UN29JUN07
Transmission Dipstick
TX1025641A UN29JUN07
10 Dipstick
11 Transmission Fill Hose
14
15
16
17
TX1081025 UN24AUG10
13
18
TX1081025
Winch Drive
Continued on next page
TM11813 (13OCT10)
0303002
SW03989,0000B37 1907OCT103/7
TX1081023A UN27AUG10
19 TransmissiontoOil
Cooler Hose
20 Charge Pump Pressure
Hose
21 Park Brake and
Differential Valve Supply
Hose
TM11813 (13OCT10)
0303003
SW03989,0000B37 1907OCT104/7
TX1081027A UN27AUG10
26
27
28
29
28
27
31
TX1081024
TX1081024 UN01SEP10
30
TM11813 (13OCT10)
0303004
SW03989,0000B37 1907OCT105/7
TX1081026A UN27AUG10
TX1081028A UN27AUG10
Specification
Lower Transmission
Mount PlatetoFrame
Cap ScrewTorque.......................................................... 230312 Nm
170230 lbft
32 Cap Screw
33 Lifting Bracket
Specification
Upper Transmission
Mount Cap Screw and
NutTorque...................................................................... 607743 Nm
450550 lbft
37. Install front axle drive shaft. See Front Axle Drive
Shaft Remove and Install. (Group 0225.)
TM11813 (13OCT10)
0303005
SW03989,0000B37 1907OCT106/7
Transmission Support
TM11813 (13OCT10)
0303006
3 Harness Clamp
4 Cap Screw (2 used)
NM00125,000057C 1930SEP101/3
10
11
Specification
Upper Transmission
Mount Bracketto
Transmission Housing
Cap ScrewTorque....................................................................319 Nm
235 lbft
12
Upper Right Transmission Mount
TX1081404 UN03SEP10
TM11813 (13OCT10)
0303007
NM00125,000057C 1930SEP102/3
17
15
16
15
19
18
TX1081405 UN03SEP10
Specification
Lower Transmission
Mount BlocktoFrame
Cap ScrewTorque.......................................................... 230312 Nm
170230 lbft
Lower Transmission
Mount Cap
ScrewTorque.................................................................. 607743 Nm
450550 lbft
13
14
Lower Transmission Mount
13 Cap Screw
14 Washer
15 Washer (2 used)
16 Front Isolator
17 Mount Block
18 Rear Isolator
19 Cap Screw With Washer
(2 used)
NM00125,000057C 1930SEP103/3
TM11813 (13OCT10)
0303008
Group 0315
Controls
T210585 UN23MAR06
BScrews (4 used)
TM11813 (13OCT10)
0303151
Controls
TM11813 (13OCT10)
0303152
Group 0325
Input Drive Shafts and UJoints
EnginetoTransmission Drive Shaft Remove
and Install
Machines Without Cold Weather Disconnect
6
5
4
3
TX1024482 UN06JUN07
2
1
TX1024482
7
Drive ShaftWithout Cold Weather Disconnect
3 Cap
4 Drive Shaft
7 Lubrication Fitting
Specification
Cross and Bearing
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
TM11813 (13OCT10)
0303251
SW03989,0000B3D 1906OCT101/3
TM11813 (13OCT10)
0303252
SW03989,0000B3D 1906OCT102/3
7
6
5
4
TX1024664 UN06JUN07
2
TX1024664
1
Drive ShaftWith Cold Weather Disconnect
3 Lubrication Fitting
4 Drive Shaft
Specification
Cross and Bearing
AssemblytoYoke Cap
ScrewTorque...................................................................... 5157 Nm
3842 lbft
TM11813 (13OCT10)
0303253
TM11813 (13OCT10)
0303254
Group 0350
Gears, Shafts, and Power Shift Clutches
Inspect bushings, remove burrs and sharp edges.
Disassembly:
Clean all parts and flush any debris from oil passages.
Use moisturefree air to dry parts (except bearings) and
to clean out oil passages.
Assembly:
before assembly.
PM10405,0000575 1907OCT101/1
TM11813 (13OCT10)
0303501
TX1081448 UN01SEP10
6 Yoke Washer
7 Yoke
8 Dowel Pin
9 Dowel Pin
10 Bearing
11 Output Shaft
12 Bearing
13 Bearing (2 used)
14 Idler Gear
15 Drive Gear
TM11813 (13OCT10)
16 Snap Ring
17 Cover Assembly (if winch
option not present)
18 ORing
19 Cover
0303502
NM00125,000057F 1927SEP101/6
3. Remove cap screw (5), yoke washer (6), and yoke (7).
4. Remove Vring seal (4) and oil seal (3).
TX1081441A UN01SEP10
TX1081442A UN01SEP10
TX1081444A UN01SEP10
TM11813 (13OCT10)
0303503
NM00125,000057F 1927SEP102/6
1 Winch Cover
11 Output Shaft
14 Idler Gear
TX1081443A UN01SEP10
TX1081445A UN01SEP10
TX1081447A UN01SEP10
Idler Gear
11 Output Shaft
14 Idler Gear
TX1081446A UN01SEP10
TM11813 (13OCT10)
0303504
NM00125,000057F 1927SEP104/6
TX1081439A UN01SEP10
YZ4114 UN20MAR01
TM11813 (13OCT10)
0303505
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.
TX1081440A UN01SEP10
Specification
Cap ScrewTorque....................................................................215 Nm
159 lbft
3 Oil Seal
4 VRing Seal
TX1081442A UN01SEP10
TM11813 (13OCT10)
0303506
Torque Wrench
1 Cap Screw
2 Washer
3 ORing
4 Yoke
5 Oil Seal
6 Torque Wrench
TM11813 (13OCT10)
0303507
TM11813 (13OCT10)
0303508
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.
TX1025182A UN21JUN07
TX1025193A UN21JUN07
Drive Coupler
1 Cap Screw (2 used)
2 Cooling Loop Pump
Continued on next page
TM11813 (13OCT10)
0303601
3 Drive Coupler
NM00125,0000591 1930SEP101/4
Hydraulic System
TX1081234A UN30AUG10
4 Charge Pumpto
Transmission Filter Hose
5 Cap Screw (4 used)
TX1081233A UN30AUG10
TX1081232A UN30AUG10
7 ORing
TM11813 (13OCT10)
0303602
NM00125,0000591 1930SEP103/4
Hydraulic System
T114002 UN16MAR98
Specification
Cap ScrewTorque......................................................................73 Nm
55 lbft
TM11813 (13OCT10)
0303603
Hydraulic System
2 Cap Screw
TX1081408A UN01SEP10
Drive Gear
Cap Screw
Continued on next page
TM11813 (13OCT10)
0303604
NM00125,0000592 1906OCT101/5
Hydraulic System
TX1081409A UN01SEP10
M8 x 35 mm Cap Screw
TX1081410A UN01SEP10
3 M8 x 35 mm Cap Screw
4 Idler Shaft
TM11813 (13OCT10)
0303605
NM00125,0000592 1906OCT102/5
Hydraulic System
3 M8 x 35 mm Cap Screw
5 ORing (2 used)
M8 x 35 mm Cap Screw
Continued on next page
TM11813 (13OCT10)
0303606
NM00125,0000592 1906OCT103/5
Hydraulic System
TX1081408A UN01SEP10
Specification
Idler Gear ShafttoFront
Housing Cap
ScrewTorque..............................................................................87 Nm
64 lbft
2 Cap Screw
YZ1148 UN23DEC97
Cap Screw
9 Bearing
TM11813 (13OCT10)
0303607
Hydraulic System
Suction TubetoFront
Housing Cap
ScrewsTorque............................................................................25 Nm
18 lbft
4 ORing
5 Suction Screen
TX1024821A UN13JUN07
TX1024819 UN13JUN07
AC12469,0000388 1909JUL071/1
TM11813 (13OCT10)
0303608
Hydraulic System
YZ104543A UN11SEP03
GORing
HTemperature Sensor
AC12469,0000389 1913JUL071/22
Specification
Control ValveWeight
(approximate)............................................................................... 27.5 kg
61 lb
AControl Valve
Continued on next page
TM11813 (13OCT10)
0303609
YZ1077 UN17DEC97
AC12469,0000389 1913JUL072/22
Hydraulic System
YZ1078 UN17DEC97
AGasket
BPlate
AC12469,0000389 1913JUL073/22
AC12469,0000389 1913JUL074/22
TM11813 (13OCT10)
03036010
AC12469,0000389 1913JUL075/22
Hydraulic System
AC12469,0000389 1913JUL076/22
YZ1082 UN17DEC97
AC12469,0000389 1913JUL077/22
ATemperature Sensor
TM11813 (13OCT10)
03036011
AC12469,0000389 1913JUL078/22
Hydraulic System
YZ1084 UN17DEC97
Specification
Temperature
SensortoValve
HousingTorque...........................................................................16 Nm
142 lbin.
ATemperature Sensor
BORing
YZ1083 UN17DEC97
AC12469,0000389 1913JUL0710/22
Specification
Main Regulator
AssemblytoValve
HousingTorque................................................................... 3447 Nm
2535 lbft
AMain Pressure Regulator
TM11813 (13OCT10)
03036012
YZ1082 UN17DEC97
AC12469,0000389 1913JUL0711/22
Hydraulic System
Specification
Cooler Relief
ValvetoValve
HousingTorque................................................................... 3447 Nm
2535 lbft
AORings
YZ1081 UN17DEC97
AC12469,0000389 1913JUL0712/22
AORing
BORing
YZ327 UN24SEP96
AC12469,0000389 1913JUL0713/22
Specification
Proportional Valveto
Valve HousingTorque......................................................... 1620 Nm
142177 lbft
DProportional Valve
TM11813 (13OCT10)
03036013
YZ1080 UN17DEC97
AC12469,0000389 1913JUL0714/22
Hydraulic System
AC12469,0000389 1913JUL0715/22
Specification
Proportional Valve
NuttoProportional
SolenoidTorque................................................................ 4.56.8 Nm
4060 lbin.
YZ4136 UN22MAR01
AC12469,0000389 1913JUL0716/22
YZ1088 UN23DEC97
AGuide Pins
TM11813 (13OCT10)
03036014
AC12469,0000389 1913JUL0717/22
Hydraulic System
YZ5087 UN18SEP03
BGasket
CPlate
AC12469,0000389 1913JUL0718/22
36. Put gasket (B), plate (C) and gasket (D) on front
housing using guide bolts as alignment guide.
DGasket
YZ1078A UN23DEC97
BGasket
CPlate
TM11813 (13OCT10)
03036015
AC12469,0000389 1913JUL0719/22
Hydraulic System
YZ1087 UN23DEC97
AControl Valve
TM11813 (13OCT10)
03036016
AC12469,0000389 1913JUL0720/22
T163650 UN14JAN03
Hydraulic System
TM11813 (13OCT10)
03036017
AC12469,0000389 1913JUL0721/22
Hydraulic System
40. Tighten cap screws (AC) again in sequence shown.
Specification
Control ValvetoFront
Housing Cap
ScrewsTorque............................................................................39 Nm
29 lbft
AC12469,0000389 1913JUL0722/22
TM11813 (13OCT10)
03036018
Section 04
Engine
Contents
Page
TM11813 (13OCT10)
041
Contents
TM11813 (13OCT10)
042
Group 0400
Removal and Installation
M44215 UN07SEP88
M44215 UN07SEP88
TM11813 (13OCT10)
0404001
TX1080866A UN16AUG10
TM11813 (13OCT10)
0404002
MH66088,0000DAC 1907OCT101/9
TX1080867 UN13AUG10
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.
TX1080911A UN16AUG10
TX1080908A UN16AUG10
TM11813 (13OCT10)
0404003
MH66088,0000DAC 1907OCT103/9
TX1080909A UN16AUG10
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.
TX1080907A UN16AUG10
14 Cap Screw
15 Clamp
16 Wiring Harness Connector
(3 used)
TM11813 (13OCT10)
0404004
MH66088,0000DAC 1907OCT105/9
TX1081034 UN23AUG10
Engine Removal
20 Engine Lifting Lug (2
used)
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
EngineWeight
(approximate)................................................................................ 771 kg
1700 lb.
TX1081035 UN23AUG10
Engine Mounts
Rear Engine
MounttoFrame Cap
ScrewTorque............................................................................712 Nm
525 lbft
TM11813 (13OCT10)
26 Lower Isolator
27 Washer (4 used)
28 Nut (4 used)
0404005
MH66088,0000DAC 1907OCT107/9
TX1081054 UN23AUG10
30 Top Measurement
31 Bottom Measurement
Specification
Engine MounttoEngine
Cap ScrewTorque....................................................................320 Nm
236 lbft
TM11813 (13OCT10)
0404006
MH66088,0000DAC 1907OCT108/9
62. Check Engine Oil Level. See Check Engine Oil Level.
(Operators Manual.)
TM11813 (13OCT10)
0404007
TM11813 (13OCT10)
0404008
Section 05
Engine Auxiliary Systems
Contents
Page
TM11813 (13OCT10)
051
Contents
TM11813 (13OCT10)
052
Group 0505
Cold Weather Starting Aids
Do Not Use Ether Start Aid
T145705 UN18SEP01
SW03989,0000B39 1924SEP101/1
TM11813 (13OCT10)
0505051
TM11813 (13OCT10)
0505052
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. (Operators Manual.)
3. Drain cooling system. See Draining the Cooling
System. (Operators Manual.)
TX1080338A UN29JUL10
TX1080210 UN29JUL10
TM11813 (13OCT10)
0505101
MH66088,0000D7D 1910SEP102/3
Cooling System
11
12
10
7
TX1080209 UN18AUG10
TM11813 (13OCT10)
0505102
MH66088,0000D7E 1910SEP101/2
Cooling System
5
6
TX1080369 UN30JUL10
5 Alternator Pully
6 Idler Pully
7 Air Conditioner
Compressor Pully
MH66088,0000D7E 1910SEP102/2
TM11813 (13OCT10)
0505103
MH66088,0000D7F 1918AUG101/2
Cooling System
TX1080385A UN30JUL10
Specification
Belt Tensioner
SpringDistance.......................................................................... 21 mm
0.83 in.
Alignment Marks
3 Tensioner Mark
TM11813 (13OCT10)
0505104
MH66088,0000D80 1910SEP101/2
Cooling System
TX1080391A UN30JUL10
2 Cap Screw
TM11813 (13OCT10)
0505105
Cooling System
TX1080526A UN05AUG10
TX1080539A UN05AUG10
TM11813 (13OCT10)
0505106
MH66088,0000D9A 1923SEP104/6
Cooling System
12
TX1080450
13
TX1080450 UN03AUG10
16
17
14
TX1080515 UN04AUG10
15
TX1080515
Upper Support
Specification
AftercoolerWeight
(approximate).................................................................................. 29 kg
64 lb.
16 Upper Support
17 Foam Insert
TM11813 (13OCT10)
0505107
Cooling System
TX1080526A UN05AUG10
TM11813 (13OCT10)
0505108
MH66088,0000D9C 1915SEP103/6
Cooling System
TX1080594A UN05AUG10
14
TX1080595
13
TX1080595 UN05AUG10
TM11813 (13OCT10)
0505109
MH66088,0000D9C 1915SEP105/6
Cooling System
16
17
14
TX1080515 UN04AUG10
15
TX1080515
Specification
RadiatorWeight
(approximate).................................................................................. 50 kg
110 lb.
TM11813 (13OCT10)
05051010
Cooling System
TX1080526A UN05AUG10
TX1080655A UN26AUG10
TM11813 (13OCT10)
05051011
MH66088,0000DA8 1930AUG104/6
Cooling System
12
TX1080450 UN03AUG10
TX1080450
13
Grille Housing Access Panels
MH66088,0000DA8 1930AUG105/6
17
16
14
TX1080515 UN04AUG10
15
TX1080515
Specification
Transmission Oil
CoolerWeight
(approximate).................................................................................. 28 kg
62 lb.
TM11813 (13OCT10)
05051012
Cooling System
TX1080521A UN05AUG10
TX1080526A UN05AUG10
TM11813 (13OCT10)
05051013
MH66088,0000DA2 1923SEP102/6
Cooling System
TX1080763A UN10AUG10
MH66088,0000DA2 1923SEP104/6
15
TX1080766A UN10AUG10
14
TM11813 (13OCT10)
05051014
MH66088,0000DA2 1923SEP105/6
Cooling System
19
18
16
17
TX1081462 UN30AUG10
TX1080836
MH66088,0000DA2 1923SEP106/6
TM11813 (13OCT10)
05051015
Cooling System
Specification
Fan Blade Retaining Lock
NutTorque..........................................................................81 16 Nm
60 12 lbft
TM11813 (13OCT10)
05051016
Group 0520
Intake System
Air Cleaner Remove and Install
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Operators Manual.)
TX1024247A UN29MAY07
2 Air Cleaner
Air Cleaner Cap
MH66088,0000DA5 1930AUG101/3
TX1024248A UN29MAY07
2 Air Cleaner
4 Clamp
Air Cleaner
MH66088,0000DA5 1930AUG103/3
TM11813 (13OCT10)
0505201
Intake System
TM11813 (13OCT10)
0505202
Group 0530
Exhaust System
Muffler Remove and Install
1. Park and prepare machine for service. See Park and
Prepare for Service Safely. (Group 0001.)
TX1024238A UN29MAY07
4 Muffler
5 Lower Muffler Clamp
6 Muffler Inlet Tube
TM11813 (13OCT10)
0505301
Exhaust System
TM11813 (13OCT10)
0505302
Group 0560
External Fuel Supply System
Fuel Tank Remove and Install
TX1081659 UN07SEP10
TM11813 (13OCT10)
10 Nut (2 used)
11 Fuel Level Sending Unit
0505601
SW03989,0000AF1 1904OCT101/6
3. Drain fuel tank (1). For fuel tank capacity, See Fuel
Tank. (Operators Manual.)
TX1081656A UN07SEP10
TX1081655A UN07SEP10
TM11813 (13OCT10)
0505602
SW03989,0000AF1 1904OCT103/6
TX1081653A UN07SEP10
1 Fuel Tank
3 Wire Guard
16 Cap Screw (2 used)
TX1081654A UN07SEP10
TM11813 (13OCT10)
0505603
SW03989,0000AF1 1904OCT104/6
TX1081375A UN07SEP10
Fuel TankDual
Function Without
WinchWeight.............................................................................. 325 kg
718 lb.
19. Connect fuel tank return line and fuel tank suction line.
20. Install guard.
TM11813 (13OCT10)
0505604
SW03989,0000AF1 1904OCT105/6
TM11813 (13OCT10)
0505605
TM11813 (13OCT10)
0505606
Contents
Section 07
Dampener Drive
Page
Group 0752Elements
Dampener Remove and Install .................. 0707521
Transmission Cold Weather
Disconnect Linkage Remove
and InstallIf Equipped ........................ 0707522
Transmission Cold Weather
Disconnect RepairIf
Equipped ............................................... 0707524
TM11813 (13OCT10)
071
Contents
TM11813 (13OCT10)
072
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 InstallIf Equipped. (Group 0752.)
T114951B UN23APR98
PM10405,0000572 1907OCT101/2
DTorsional Damper
EDowel Pin (2 used)
T114951B UN23APR98
PM10405,0000572 1907OCT102/2
TM11813 (13OCT10)
0707521
Elements
4
6
7
3
5
9
11
10
2
14
13
12
TX1081470 UN30AUG10
15
15
15
TX1081470
16
Transmission Cold Weather Disconnect
5 Pin
6 Yoke
7 Nut
8 Bracket
Specification
Transmission Disconnect
HousingtoFlywheel
Housing Cap
ScrewTorque............................................................................217 Nm
160 lbft
TM11813 (13OCT10)
0707522
NM00125,0000581 1929SEP101/2
Elements
NM00125,0000581 1929SEP102/2
TM11813 (13OCT10)
0707523
Elements
T8483AD UN15MAY95
TM11813 (13OCT10)
0707524
NM00125,0000582 1927SEP101/5
Elements
1 Cap Screw (4 used)
2 Universal Joint Cross
3 Stub Shaft
4 Seal
5 Cap Screw (6 used)
6 Collar
7 ORing
8 Snap Ring
9 Inner Collar
10 Bushing
11 Oil Seal
12 Needle Bearing
13 Cap Screw (12 used)
14 Washer (12 used)
15 Cover
16 Pipe Plug (2 used)
25 Snap Ring
26 Cap
27 Bearing Kit
28 Disconnect Spline Kit
29 Washer (6 used)
30 Transmission Disconnect
31 Transmission Disconnect
Kit
TX1081486A UN01SEP10
23 Splined Hub
TX1081485A UN01SEP10
TM11813 (13OCT10)
0707525
NM00125,0000582 1927SEP103/5
Elements
T7502HP UN11JUL91
TM11813 (13OCT10)
0707526
NM00125,0000582 1927SEP104/5
Elements
Cap Screws
Specification
CollartoCollar Cap
ScrewTorque..............................................................................14 Nm
124 lbin.
28. Apply plastic gasket into bore of cap and drive into
splined hub.
Specification
Cover BearingDepth........................................................1717.5 mm
0.670.69 in.
Specification
Cap ScrewTorque.................................................................... 113 Nm
83 lbft
Specification
Cold Weather
DisconnectCapacity.................................................................. 118 mL
4 oz
23. Press collar onto sliding shaft past snap ring groove.
Install snap ring (8). Pull collar back against snap ring.
Specification
Cap ScrewTorque......................................................................60 Nm
45 lbft
21. Apply grease between lips of seal. Install oil seal (11)
into cover after installing sliding shaft.
Specification
Cap ScrewTorque......................................................................14 Nm
124 lbin.
TM11813 (13OCT10)
0707527
Elements
TM11813 (13OCT10)
0707528
Section 09
Steering System
Contents
Page
TM11813 (13OCT10)
091
Contents
TM11813 (13OCT10)
092
Group 0930
Secondary Steering
TX1080206 UN18AUG10
TX1080206
Secondary Steering Pump Location
TM11813 (13OCT10)
0909301
NM00125,0000598 1907OCT101/2
Secondary Steering
4
2
1
TX1080205 UN27JUL10
8
7
TX1080205
Secondary Steering Pump Exploded View
1 Secondary Steering Pump
2 Bracket
3 Supply HosetoSecondary
5 Secondary Steering Relay
Steering Valve
6 Cap Screw (3 used)
4 Pressure HosetoSecondary
Steering Valve
7 Washer (3 used)
8 Rubber Bushing (3 used)
TM11813 (13OCT10)
0909302
Group 0960
Hydraulic System
Steering Valve Remove and Install
T131633B UN15JUN00
T131635B UN15JUN00
TM11813 (13OCT10)
0909601
AC12469,0000396 1923JUL071/4
Hydraulic System
X9811 UN23AUG88
TX1024858A UN15JUN07
TM11813 (13OCT10)
0909602
AC12469,0000396 1923JUL072/4
Hydraulic System
TX1024871A UN13JUN07
TX1024860A UN13JUN07
TM11813 (13OCT10)
0909603
AC12469,0000396 1923JUL073/4
Hydraulic System
TX1024871A UN13JUN07
Specification
Lower Steering
ColumntoLower
Universal Joint Spline
EngagementDistance................................................................ 19 mm
0.75 in.
AC12469,0000396 1923JUL074/4
TM11813 (13OCT10)
0909604
Hydraulic System
T162227B UN04DEC02
T162221 UN12DEC02
Cap Screws
1 Cap Screw (7 used)
2 Pins (2 used)
3 AntiCavitation Steel Balls
(2 used)
4 End Cap
7 Spool
8 Gerotor Star
TM11813 (13OCT10)
0909605
9 Gerotor Housing
10 Plate Spacer
11 Lower Steering Column
12 Mounting Plate
13 Housing
AC12469,000039A 1913JUN071/5
Hydraulic System
T162222B UN04DEC02
7 Spool
13 Housing
20 Spline Head
TM11813 (13OCT10)
0909606
AC12469,000039A 1913JUN072/5
Hydraulic System
18
26
25
24
T162216
T162216 UN20DEC02
27
Seal Placement
18 ORing (3 used)
24 Dust Seal
25 Backup Washer
26 Seal
27 ORing
13. Lubricate Orings (18 and 27) and seals (24 and 26)
with TY24416 MultiPurpose HD Lithium Complex
Grease. If petroleum jelly is used for Oring lubrication,
use small enough amount to avoid spreading on
surfaces of other parts.
TM11813 (13OCT10)
0909607
AC12469,000039A 1913JUN073/5
Hydraulic System
9
17
18
10
18
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.
8 Gerotor Star
9 Gerotor Housing
10 Plate Spacer
14 Drive Pin
15 Alignment Line
T160389 UN02DEC02
16
14
16 Alignment Line
17 Alignment Line
18 ORing (3 used)
19 Drive Spline
15
Component Alignment
AC12469,000039A 1913JUN074/5
Specification
End CapToHousing Cap
ScrewTorque (Initial)..................................................................17 Nm
150 lbin.
End CapToHousing Cap
ScrewTorque (Final)...................................................................34 Nm
300 lbin.
T160436 UN17OCT02
Tightening Sequence
17 Tightening Sequence
AC12469,000039A 1913JUN075/5
TM11813 (13OCT10)
0909608
Hydraulic System
X9811 UN23AUG88
1
3
5
3
T162743
Steering Cylin
derWeight (approxi
mate)............................................................................................... 45 kg
100 lb
Specification
T162743 UN18DEC02
5 Steering Cylinder
6 Rod EndtoSteering Valve
Line
7 Head EndtoSteering Valve
Line
Specification
CylindertoPin Cap
Screw and Lock
NutTorque..................................................................................27 Nm
20 lbft
TM11813 (13OCT10)
0909609
Hydraulic System
TM11813 (13OCT10)
09096010
Group 0962
Dual Mode Steering
Dual Mode Steering Solenoid Valve Remove
and Install
1. Turn battery disconnect switch to OFF.
X9811 UN23AUG88
1 Return Hose
2 Cap Screw (2 used)
3 System Pressure Hose
4 Steering ValvetoSolenoid
Valve Return Hose
5 Solenoid ValvetoSteering
Valve Pressure Hose
6 Solenoid
AC12469,0000398 1910MAR092/2
TM11813 (13OCT10)
0909621
TM11813 (13OCT10)
0909622
Contents
Section 10
Service Brakes
Page
TM11813 (13OCT10)
101
Contents
TM11813 (13OCT10)
102
Group 1015
Controls Linkage
TX1056808 UN06MAR09
TX1056808
Service Brake Pedal
1 Pedal
2 Shaft
3 Spring
7 Flange Nut
8 Cap Screw
9 Cap Screw (3 used)
4 Bushing (2 used)
5 Bracket
6 Spring Pin
AC12469,000039C 1906MAR091/1
TM11813 (13OCT10)
1010151
Controls Linkage
TM11813 (13OCT10)
1010152
Group 1060
Hydraulic System
Service Brake Valve Remove and Install
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
X9811 UN23AUG88
TM11813 (13OCT10)
1010601
AC12469,000039D 1913JUN072/3
Hydraulic System
T114341B UN10APR98
Specification
Fitting to
HousingTorque................................................................... 2739 Nm
2029 lbft
Service Brake
Pressure Switch to
HousingTorque...........................................................................12 Nm
106 lbin.
AC12469,000039D 1913JUN073/3
TM11813 (13OCT10)
1010602
Hydraulic System
T7516AP UN23APR91
ABoot
BPlug
CORing
DSpring
ESpool
F Valve Housing
GSeal
HSpring Retainer
T7516AO UN23APR91
AC12469,000039F 1913JUN071/1
TM11813 (13OCT10)
1010603
Hydraulic System
X9811 UN23AUG88
AC12469,000039E 1923JUL071/3
TM11813 (13OCT10)
1010604
AC12469,000039E 1923JUL072/3
Hydraulic System
WC1006701 UN19APR06
TM11813 (13OCT10)
1010605
Hydraulic System
TM11813 (13OCT10)
1010606
Contents
Section 11
Park Brake
Page
TM11813 (13OCT10)
111
Contents
TM11813 (13OCT10)
112
Group 1111
Active Elements
Park Brake Remove and Install
4
3
7
8
20
10
19
T162978 UN02JAN03
11
1
12
13
T162978
18 17 16
15
14
6 Disk Spring
7 Oil Seal
8 Grease Seal (2 used)
9 Transmission Yoke, Nut, and
Cotter Pin
10 Lubrication Fitting
TM11813 (13OCT10)
1111111
NM00125,0000585 1906OCT101/2
Active Elements
TX1024926A UN20JUN07
TX1024924A UN20JUN07
17 Housing
21 Double Universal Joint
(Telescoping Drive Shaft)
22 Park Brake Release Hose
TM11813 (13OCT10)
1111112
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).
3 Access Panel
TX1079259A UN29JUN10
1 Cap Screw
2 Cap Screw
TX1024459 UN06JUN07
6 Valve Body
NM00125,0000584 1906OCT102/2
TM11813 (13OCT10)
1111601
Hydraulic System
TM11813 (13OCT10)
1111602
Section 17
Frame, Chassis, or Supporting Structures
Contents
Page
TM11813 (13OCT10)
171
Contents
TM11813 (13OCT10)
172
Group 1740
Frame Installation
AWSE70T1 or E71T1 wire electrode with flux core
JW40272,0000028 1918APR081/1
TM11813 (13OCT10)
1717401
Frame Installation
T114406B UN29APR98
TM11813 (13OCT10)
1717402
SW03989,0000A9F 1907OCT102/5
Frame Installation
TX1080646A UN09AUG10
TX1080647A UN09AUG10
TX1080648A UN09AUG10
Hose Brackets
TM11813 (13OCT10)
1717403
SW03989,0000A9F 1907OCT103/5
Frame Installation
Winch
TX1080649A UN09AUG10
TX1080654 UN06AUG10
TX1080651A UN09AUG10
TM11813 (13OCT10)
1717404
SW03989,0000A9F 1907OCT104/5
Frame Installation
Bulkhead
21. Remove pivot pins. See Upper Pivot Pin Repair and
see Lower Pivot Pin Repair. (Group 1740.)
25. Install pivot pins. See Lower Pivot Pin Repair and see
Upper Pivot Pin Repair. (Group 1740.)
SW03989,0000A9F 1907OCT105/5
TM11813 (13OCT10)
1717405
Frame Installation
TX1056815 UN06MAR09
TX1056815
Lower Pivot Pin
TM11813 (13OCT10)
1717406
SW03989,0000B40 1927SEP101/9
Frame Installation
2 Cap Screw (6 used)
4 Cap Screw (3 used)
5 Cap Screw (6 used)
8 Seal (2 used)
14 Ring (2 used)
20 Seal (2 used)
21 Lower Pivot Pin
22 Pin Sleeve
23 Bushing (2 used)
24 Upper Quill
25 Special Washer
31 Spherical Bushing
SW03989,0000B40 1927SEP102/9
TX1026578A UN17JUL07
TX1025712A UN13JUL07
Left Shields
Right Shields
Continued on next page
TM11813 (13OCT10)
1717407
SW03989,0000B40 1927SEP103/9
Frame Installation
TX1025042A UN20JUN07
9 Bottom Cover
Bottom Cover
SW03989,0000B40 1927SEP104/9
TX1026420A UN27JUL07
Upper Quill
SW03989,0000B40 1927SEP105/9
Special Washer
Continued on next page
TM11813 (13OCT10)
1717408
SW03989,0000B40 1927SEP106/9
Frame Installation
21
23
31
20
TX1026427 UN16JUL07
23
22
TX1026427
Lower Pivot Pin
3 Engine Frame
7 Equipment Frame
20 Seal (2 used)
21 Lower Pivot Pin
22 Pin Sleeve
23 Bushing (2 used)
31 Spherical Bushing
TM11813 (13OCT10)
1717409
SW03989,0000B40 1927SEP107/9
Frame Installation
11
20
TX1026459 UN13JUL07
20
11
TX1026459
Bushing
3 Engine Frame
7 Equipment Frame
20 Seal (2 used)
23. Install new seals into bushings. Install seals with the
slotted side of the seal towards the short side of the
bushing.
24. Install new seal into pin sleeve. Install pin sleeve into
bushing.
25. Support pin sleeve in bushing.
Specification
Lower Pivot Pin Cap
ScrewTorque............................................................................319 Nm
235 lbft
TM11813 (13OCT10)
17174010
SW03989,0000B40 1927SEP108/9
Frame Installation
Specification
Bottom CovertoEngine
Frame Cap
ScrewTorque............................................................................624 Nm
460 lbft
SW03989,0000B40 1927SEP109/9
TM11813 (13OCT10)
17174011
Frame Installation
TX1056816 UN06MAR09
TX1056816
Upper Pivot Pin
TM11813 (13OCT10)
17174012
GD61784,0000067 1906MAR091/9
Frame Installation
1 Cap Screw (6 used)
6 Cap Screw (3 used)
10 Spherical Bushing
12 Lubrication Fitting
15 Upper Pivot Pin
16 Quill
17 Lock Collar
18 Special Washer
26 Seal
27 Shim
28 Shim
29 Shim
TX1024978A UN20JUN07
Special Washer
GD61784,0000067 1906MAR093/9
5.
10
10 Spherical Bushing
15 Upper Pivot Pin
TX1024982 UN22JUN07
15
TM11813 (13OCT10)
17174013
GD61784,0000067 1906MAR094/9
Frame Installation
TX1024980A UN20JUN07
Specification
Shim Pack Less Than
GapPreload...................................................................0.030.13 mm
0.0010.005 in.
T128532 UN17FEB00
GD61784,0000067 1906MAR096/9
T128533 UN17FEB00
12. Install seal in quill with sealing lip toward the quill.
TM11813 (13OCT10)
17174014
GD61784,0000067 1906MAR097/9
Frame Installation
13. Install required shims, quill (16) and cap screws (1).
Tighten cap screws to specification. Bushing (10)
must oscillate.
TX1024980A UN20JUN07
Specification
Quill Cap
ScrewTorque............................................................................140 Nm
103 lbft
16 Quill
Install Shims
Continued on next page
TM11813 (13OCT10)
17174015
GD61784,0000067 1906MAR098/9
Frame Installation
15
26
16
10
26
TX1024991 UN22JUN07
17
30
18
TX1024991
6
Lower Seal
7 Equipment Frame
10 Spherical Bushing
15 Upper Pivot Pin
14. Install lower seal (26) into engine frame (3) with
sealing lip facing away from spherical bushing (10).
15. Install lock collar (17) into seal.
16. Apply grease to pivot pin and install into bushing (10).
17. Install special washer (18) and cap screws (6).
18. Evenly tighten cap screws to draw pin through
bushing. Tighten cap screws to specification.
Specification
Retaining Cap
ScrewsInitialTorque...........................................................230.5 Nm
170 lbft
Retaining Cap
ScrewsFinalTorque
Turn.....................................................................................................90
16 Quill
17 Lock Collar
18 Special Washer
26 Seal
30 Gap
GD61784,0000067 1906MAR099/9
TM11813 (13OCT10)
17174016
Group 1746
Frame Bottom Guards
T114595 UN29APR98
GWasher (2 used)
HWasher (4 used)
I Cap Screw (2 used)
Specification
Front Bottom
GuardWeight
(approximate).................................................................................. 36 kg
80 lb
Rear Bottom
GuardWeight
(approximate).................................................................................. 25 kg
55 lb
GD61784,0000068 1902JUL071/1
TM11813 (13OCT10)
1717461
T114596 UN29APR98
AWasher (8 used)
BCap Screw (4 used)
CCover
DPlate (2 used)
EBottom Door
F Cap Screw (2 used)
Specification
Bottom Guardto
Equipment Frame Cap
ScrewTorque............................................................................620 Nm
460 lbft
Bottom Doorto
Equipment Frame Cap
ScrewsTorque..........................................................................130 Nm
95 lbft
Specification
Bottom GuardWeight
(approximate).................................................................................. 27 kg
60 lb
GD61784,0000069 1915JUN071/1
TM11813 (13OCT10)
1717462
Contents
Section 18
Operators Station
Page
Page
TM11813 (13OCT10)
181
Contents
TM11813 (13OCT10)
182
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. (Operators Manual.)
TX1082472 UN05OCT10
TM11813 (13OCT10)
1818001
SW03989,0000B47 1905OCT101/13
TX1082473A UN05OCT10
TX1082474A UN05OCT10
TX1082475A UN05OCT10
TM11813 (13OCT10)
1818002
SW03989,0000B47 1905OCT103/13
Heater Hoses
SW03989,0000B47 1905OCT104/13
TX1082477A UN05OCT10
TX1082478A UN05OCT10
TM11813 (13OCT10)
1818003
SW03989,0000B47 1905OCT105/13
TX1025516A UN28JUN07
14 Ground Strap
16 Cap Screw
17 Shim (as needed)
TX1082480A UN05OCT10
25. Loosen nut (19) but DO NOT remove from cap screw
(16).
18 Washer (2 used)
19 Nut
TX1082481A UN05OCT10
21 Tether Cable
Cab Tether Cable
Continued on next page
TM11813 (13OCT10)
1818004
SW03989,0000B47 1905OCT108/13
16 Cap Screw
17 Shim (as needed)
18 Washer (2 used)
TX1082479A UN05OCT10
27. Remove nut (19), shims (17), washer (18), and cap
screw (16). Move cab tilt cylinder (22) away from
clevis.
19 Nut
22 Cab Tilt Cylinder
TM11813 (13OCT10)
1818005
SW03989,0000B47 1905OCT1010/13
32. Attach lifting chains to rear lift points (32) on right and
left sides of cab.
TX1082483A UN05OCT10
TX1082484A UN05OCT10
TM11813 (13OCT10)
1818006
SW03989,0000B47 1905OCT1011/13
TX1082485A UN05OCT10
34 Nut (2 used)
35 Washer (4 used)
45. Position tilt cylinder into cab clevis and install cap
screw, washers, shims, and nut as were marked
during removal. Do not tighten nut at this time.
46. Install tether cable and cap screw.
47. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operators
Manual.)
Specification
CabWeight
(approximate).............................................................................. 1281 kg
2825 lb.
39. Install shims, washers, cap screw, and nut at cab pivot
mounts as marked during removal.
IMPORTANT: Overtightening of cap screws and nuts
can cause cab clevis to deform.
40. Tighten nuts until washers are snug.
41. Remove lifting chains and lifting brackets from cab.
TM11813 (13OCT10)
1818007
SW03989,0000B47 1905OCT1012/13
TM11813 (13OCT10)
1818008
AC12469,00003A1 1910MAR091/3
8.
CWooden Block
T131257B UN31MAY00
TM11813 (13OCT10)
1818009
AC12469,00003A2 1914JUN071/4
T131258B UN31MAY00
AC12469,00003A2 1914JUN072/4
T131259B UN31MAY00
1 Screws (4 used)
TM11813 (13OCT10)
18180010
AC12469,00003A2 1914JUN073/4
T131260B UN31MAY00
3 Universal Joint
4 Cap Screw
AC12469,00003A2 1914JUN074/4
T131263B UN31MAY00
3. Remove covers (2, 4, and 5), horn wiring lead (1) and
knob (3).
4 Cover
5 Cover
T131265B UN31MAY00
TM11813 (13OCT10)
18180011
AC12469,00003A3 1919JUL072/3
1 Steering Column
2 Disk
3 Spring
4 Cover
T131266B UN31MAY00
6. Install cap.
5 Steering Wheel
6 Nut
7 Cap
AC12469,00003A3 1919JUL073/3
TM11813 (13OCT10)
18180012
X9811 UN23AUG88
T131385B UN02JUN00
Specification
Hand Pump Mounting
Cap ScrewsTorque............................................................ 2226 Nm
195230 lbin.
Specification
Cab Tilt Hand Pump
ReservoirCapacity.................................................................... 574 mL
20 oz
AC12469,00003A4 1910MAR091/1
TM11813 (13OCT10)
18180013
T8513AF UN05JUL95
5. Remove snap ring (B) from pump valve (F) and tap
assembly out of the valve body.
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).
11. Install Oring (C) into reservoir Oring groove and
install reservoir to the valve body. Tighten cap screws.
Specification
ReservoirtoValve Body
Cap ScrewsTorque........................................................ 6.611.6 Nm
4884 lbin.
APlastic Plug
BSnap Ring
CORing
DSuction Screen
EFill Plug
F Pump Valve
GPump Handle Link
13. Oil fill plug (E) is vented check to see if plug is clean.
Install fill plug (E).
14. Install cab tilt hand pump. See Cab Tilt Hand Pump
Remove and Install. (Group 1800.)
Specification
Cab Tilt Hand Pump
ReservoirCapacity.................................................................... 574 mL
20 oz
AC12469,00003A5 1914JUN071/1
TM11813 (13OCT10)
18180014
2. Support cab and remove cab lift cylinder pin and cap
screw.
3. Position cylinder so that there is enough clearance to
extend and retract cylinder.
4. Completely retract cylinder using pump.
CLever
T115132B UN29APR98
TM11813 (13OCT10)
18180015
AC12469,00003A6 1914JUN071/2
X9811 UN23AUG88
TM11813 (13OCT10)
18180016
T131387B UN02JUN00
T131386B UN02JUN00
6. Remove cylinder.
7. Install new cylinder.
TM11813 (13OCT10)
18180017
TM11813 (13OCT10)
18180018
Group 1810
Operator Enclosure
Window Remove and Install
TX1056818 UN06MAR09
TX1056818
Front, Rear, and Side Windows
1 Cap Screw (79 used)
2 Spacer (57 used)
5 Rear Windowpane
6 Front Windowpane (2 used)
7 Front Windowpane
Door Windows
TM11813 (13OCT10)
1818101
PM10405,0000571 1906OCT101/3
TX1056817 UN06MAR09
Operator Enclosure
TX1056817
Sliding Windows in Doors
8 Window (2 used)
9 Nut (4 used per side)
10 Plate (2 used per side)
11 Latch
14 Isolator
12 Cap Screw (4 used per side) 15 Washer (2 used per side)
13 Screen
16 Cap Screw (2 used per side)
TM11813 (13OCT10)
1818102
PM10405,0000571 1906OCT102/3
Operator Enclosure
T6148AF UN19OCT88
T6148AH UN19OCT88
T6148AG UN19OCT88
TM11813 (13OCT10)
1818103
Operator Enclosure
SW03989,0000AC8 1905OCT101/1
AC12469,00003B5 1923JUL071/3
TX1025130A UN21JUN07
TM11813 (13OCT10)
1818104
AC12469,00003B5 1923JUL072/3
Operator Enclosure
AC12469,00003B5 1923JUL073/3
1 Door Lock
2 Bracket (2 used)
TX1025065A UN20JUN07
TM11813 (13OCT10)
1818105
AC12469,00003AA 1923JUL071/2
Operator Enclosure
TX1025064A UN20JUN07
11. Install upper latch (7) and plate (5) using lower two
cap screws.
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)
5 Plate
6 Cap Screw (4 used)
7 Latch
8 Spring
9 Bracket
10 Clip
11 Yoke
12 Rod
AC12469,00003AA 1923JUL072/2
2 Screw (2 used)
Continued on next page
TM11813 (13OCT10)
TX1025739A UN29JUN07
1818106
AC12469,00003AB 1910MAR091/3
Operator Enclosure
3 Wiper Shaft
4 Nut
TX1025741A UN29JUN07
AC12469,00003AB 1910MAR092/3
6 Electrical Connection
7 Wiper Motor Frame
8 Wiper Motor
3 Screw (4 used)
4 Plastic Washer
Continued on next page
TM11813 (13OCT10)
TX1025742A UN29JUN07
1818107
AC12469,00003AC 1930JUL071/3
Operator Enclosure
5 Cap Screw
6 Wiper Shaft
TX1025744A UN29JUN07
AC12469,00003AC 1930JUL072/3
Specification
Wiper Retaining
NuttoPivotTorque............................................................. 1421 Nm
124186 lbin.
10 Wiper Motor
AC12469,00003AC 1930JUL073/3
TM11813 (13OCT10)
1818108
Operator Enclosure
T131540B UN27MAR01
Specification
BladetoTop Edge of
WindshieldDistance................................................................ 63.5 mm
2.5 in.
2.
1 Pivot Cover
2 Retaining Nut
3 Wiper Arm
TM11813 (13OCT10)
1818109
Operator Enclosure
TM11813 (13OCT10)
18181010
Group 1821
Seat and Seat Belt
Seat Remove and Install
1. Disconnect electrical connection for air suspension.
TX1025165A UN21JUN07
AC12469,00003B2 1911JUL071/2
3. Lift floor mat (6) out of the way and remove vent from
under seat.
TX1025166A UN21JUN07
3 Vent Inlet
4 Seat Bracket
9. Install vent under seat. Align vent with vent inlet (3)
before installing cap screws.
NOTE: Do not install mat on top of transmission
calibration connections or air seat wiring.
Specification
SeatWeight
(approximate).................................................................................. 71 kg
156 lb
TM11813 (13OCT10)
1818211
4
3
5
2
5
3
6
3
6
8
9
6
10
11
12
13
TX1025108 UN18JUL07
TX1025108
Continued on next page
TM11813 (13OCT10)
1818212
AC12469,00003B3 1919JUN071/6
5 Limiting Strap
6 Bearing
7 Dampener
8 Air Seat Frame
9 Air Spring
10 Air Hose
11 Boot Hardware
12 Boot
13 Plate
TM11813 (13OCT10)
1818213
AC12469,00003B3 1919JUN072/6
14
15
28
17
18
19
20
TX1025111 UN18JUL07
21
22
23
TX1025111
14 Plate
15 Swivel Plate
16 Slider
20 Nut (5 used)
21 Plate
22 Washer (5 used)
Continued on next page
TM11813 (13OCT10)
1818214
AC12469,00003B3 1919JUN073/6
TM11813 (13OCT10)
1818215
AC12469,00003B3 1919JUN074/6
25
25
24
25
25
26
27
28
29
30
31
31
34
31
32
31
33
TX1025110 UN18JUL07
33
32
32
33
TX1025110
24 Cushion
25 Clip (4 used)
26 Pan
27 Seat Frame
28 Arm Rest
29 Air Suspension
30 Cushion
31 Cap Screw (4 used)
32 Washer (4 used)
Continued on next page
TM11813 (13OCT10)
1818216
AC12469,00003B3 1919JUN075/6
T114924 UN29APR98
BWasher (4 used)
Specification
Seat Belt Cap
ScrewTorque.......................................... Until retractor is slightly snug,
retractor can rotate 10 either direction
TM11813 (13OCT10)
1818217
TM11813 (13OCT10)
1818218
Group 1830
Heating and Air Conditioning
R134a Refrigerant Cautions and Proper Handling
CAUTION: DO NOT allow liquid refrigerant to
contact eyes or skin. Liquid refrigerant will
freeze eyes or skin on contact. Wear goggles,
gloves, and protective clothing.
If liquid refrigerant contacts eyes or skin, DO
NOT rub the area. Splash large amounts of
COOL water on affected area. Go to a physician
or hospital immediately for treatment.
DO NOT allow refrigerant to contact open
flames or very hot surfaces such as electric
welding arc, electric heating element, and
lighted smoking materials.
DO NOT heat refrigerant over 52C (125F) in a
closed container. Heated refrigerant will develop
high pressure which can burst the container.
Keep refrigerant containers away from heat
sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container
with your bare hands. Skin may freeze to
container. Wear gloves.
If skin freezes to container, pour COOL water
over container to free the skin. Go to a physician
or hospital immediately for treatment.
SW03989,0000A7F 1921SEP101/2
TM11813 (13OCT10)
1818301
Specification
Flushing Solvent in
Suction PortVolume.................................................................. 240 mL
8 fl oz.
Flushing Solvent
in Discharge
PortVolume............................................................................... 120 mL
4 fl oz.
Specification
A/C Flusher Tank
Minimum Air Pressure
for Flushing and
PurgingPressure...................................................................... 620 kPa
6.2 bar
90 psi
TM11813 (13OCT10)
1818302
SW03989,0000A80 1905OCT101/2
Specification
A/C Flusher
TankCapacity................................................................................... 4 L
1 gal
SW03989,0000A80 1905OCT102/2
TM11813 (13OCT10)
1818303
Specification
New Compressor
Operating Oil
LevelVolume (drain
and return)...................................................................................... 45 mL
1.5 fl oz.
Specification
Used Compressor
Drained OilVolume...................................................................... 45 mL
1.5 fl oz.
Specification
Used Compressor
Flushed OilVolume...................................................................... 60 mL
2.0 fl oz.
Specification
New CompressorVol
ume.....................................................................................210250 mL
7.08.4 fl oz.
Air Conditioning System
Additional Oil Volume................................................................ 182 mL
4.0 fl oz.
Compressor Operating
Oil LevelVolume...................................................................3045 mL
1.01.5 fl oz.
Specification
Evaporator OilVolume............................................................... 130 mL
4.4 fl oz.
Condenser OilVolume................................................................. 65 mL
2.2 fl oz.
Receiver Dryer
OilVolume................................................................................... 30 mL
1.0 fl oz.
Flushed Compressor
OilVolume................................................................................... 60 mL
2.0 fl oz.
Hose OilVolume
(approximate total
length)............................................................................. 3 mL per 30 cm
0.1 fl oz. per ft
Specification
Used Compressor
and System Flushed
OilVolume........................................................................391479 mL
13.216.2 fl oz.
TM11813 (13OCT10)
1818304
SW03989,0000A81 1910SEP101/2
TX1080093 UN22JUL10
1 Cap
2 Red Hose
3 Blue Hose
TM11813 (13OCT10)
1818305
Specification
Evacuate
SystemVacuum.......................................................................... 98 kPa
980 mbar
29 in. Hg
SW03989,0000A84 1910SEP101/1
TM11813 (13OCT10)
1818306
TX1024235A UN29MAY07
1 Relief Valve
2 Air Conditioner
Compressor Manifold
SW03989,0000A86 1921SEP101/1
TM11813 (13OCT10)
1818307
Pressure Hoseto
CondenserTorque.............................................................. 2027 Nm
177239 lbin.
SW03989,0000A88 1905OCT101/1
TM11813 (13OCT10)
1818308
TX1056811A UN06MAR09
1 Ground Wire
2 Clutch Coil Wire
3 Compressor
4 Washer
5 Clutch Coil
6 Snap Ring
7 Pulley
8 Ring
TM11813 (13OCT10)
1818309
9 Clutch Hub
10 Clutch HubtoShaft Cap
Screw
11 Dust Cover
12 Cap Screw (6 used)
13 Washer
14 Washer
AJDG747 Compressor
Clutch Spanner
SW03989,0000A89 1910SEP101/2
TX1009690A UN18JUL06
TM11813 (13OCT10)
18183010
Compressor Manifold
1 Cap Screw
2 Manifold
3 Manifold Seal
TX1024662A UN06JUN07
TM11813 (13OCT10)
18183011
SW03989,0000A8B 1910SEP101/2
4 Nut (4 used)
SW03989,0000A8B 1910SEP102/2
TM11813 (13OCT10)
18183012
TX1080212A UN28JUL10
TX1080227A UN28JUL10
SW03989,0000A8E 1910SEP101/1
TM11813 (13OCT10)
18183013
TX1080232A UN28JUL10
5 Precleaner Cover
6 Precleaner Blower Motor
Connector
7 Precleaner Blower Motor
8 Cap Screw (4 used)
Precleaner Blower Assembly
SW03989,0000A94 1910SEP101/1
TM11813 (13OCT10)
18183014
TX1080212A UN28JUL10
TM11813 (13OCT10)
18183015
TX1080212A UN28JUL10
TX1080238A UN28JUL10
SW03989,0000A90 1910SEP101/1
TM11813 (13OCT10)
18183016
TX1080212A UN28JUL10
TX1080242A UN29JUL10
TX1024652A UN06JUN07
TM11813 (13OCT10)
18183017
6 Flange
7 Refrigerant Line (2 used)
8 Cap Screw (2 used)
9 Expansion Valve
Refrigerant Lines and Flange
TX1080266A UN29JUL10
TX1080265A UN29JUL10
Expansion Valve
SW03989,0000A8D 1910SEP101/1
TM11813 (13OCT10)
18183018
T131235B UN25MAY00
Blower Housing
TX1024560A UN05JUN07
TX1024566A UN05JUN07
Heater Core
SW03989,0000A8F 1910SEP101/1
TM11813 (13OCT10)
18183019
Evaporator
1 Cap Screw (2 used)
2 Evaporator
TM11813 (13OCT10)
18183020
3 ReceiverDryer
4 Clamp Cap Screw (2 used)
TM11813 (13OCT10)
18183021
TM11813 (13OCT10)
18183022
Section 19
Sheet Metal and Styling
Contents
Page
TM11813 (13OCT10)
191
Contents
TM11813 (13OCT10)
192
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.)
TX1080281A UN29JUL10
1 MufflertoTurbocharger
Flex Pipe Clamp
Specification
Left Limb Riser
with MufflerWeight
(approximate).................................................................................. 50 kg
110 lb
MH66088,0000D7C 1919AUG101/4
TX1080303A UN29JUL10
TM11813 (13OCT10)
1919101
MH66088,0000D7C 1919AUG103/4
TX1080308A UN29JUL10
Specification
HoodWeight
(approximate).................................................................................. 57 kg
125 lb
Specification
Left Limb Riser
with MufflerWeight
(approximate).................................................................................. 50 kg
110 lb
MH66088,0000D7C 1919AUG104/4
TM11813 (13OCT10)
1919102
TX1081102A UN26AUG10
TX1081103A UN26AUG10
Specification
Standard Grille
GuardWeight
(approximate).................................................................................. 68 kg
150 lb.
High Debris Grille
GuardWeight
(approximate).................................................................................. 84 kg
200 lb.
6 Washer (2 used)
7 Wave Washer (2 used)
8 Washer (2 used)
Lifting Straps
Continued on next page
TM11813 (13OCT10)
1919103
MH66088,0000D90 1914SEP102/3
TX1081104A UN26AUG10
MH66088,0000D90 1914SEP103/3
TM11813 (13OCT10)
1919104
Specification
Right Limb
RiserWeight
(approximate).................................................................................. 39 kg
85 lb.
1 Fan Motor
2 Fan Support
3 Hydraulic Hoses (3 used)
4 Fan Blade
5 Cap Screw (2 used)
6 Fan Shroud
7 Cap Screw (2 used)
8 Cap Screw (6 used)
9 Grille Housing
Fan Assembly
TM11813 (13OCT10)
TX1081428 UN01SEP10
1919105
MH66088,0000DB1 1907OCT101/2
TM11813 (13OCT10)
1919106
Section 20
Safety, Convenience, and Miscellaneous
Contents
Page
TM11813 (13OCT10)
201
Contents
TM11813 (13OCT10)
202
Group 2003
Pressurized Water System
Pressurized Water SystemIf Equipped
4
4
2
5
7
8
9
10
10
13
6
12
9
11
17
16
19
14
23
15
18
25
23
24
22
24
21
26
27
TX1081958
TX1081958 UN20SEP10
20
8 ORing (2 used)
9 Adapter (2 used)
10 Hose
11 Bracket
12 Washer
13 Latch
14 Label
TM11813 (13OCT10)
2020031
22 Hose
23 Cap Screw (2 used)
24 Adapter (2 used)
25 Valve
26 Cover
27 Label
SW03989,0000B2F 1924SEP101/2
TX1081965A UN20SEP10
TX1081961A UN20SEP10
Specification
TankWeight................................................................................ 373 kg
822 lb.
10. Fill tank with water. See Fill and Charge Pressurized
Water SystemIf Equipped. (Operators 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,
watching pressure gauge (17) to correct air pressure
specification.
Specification
Water TankPressure................................................................ 410 kPa
3.8 bar
55 psi
Plug Location
2 Filler Plug
4 Cap Screw (8 used)
5 Washer (8 used)
13 Latch
16 Fitting
17 Pressure Gauge
20 Nozzle
25 Valve
26 Cover
SW03989,0000B2F 1924SEP102/2
TM11813 (13OCT10)
2020032
Group 2004
Horn and Warning Devises
Horn Remove and Install
1. Open front grille (3).
TX1024377A UN05JUN07
Horn
3 Nut
4 Grille
GD61784,000002B 1929MAY071/1
TM11813 (13OCT10)
2020041
TM11813 (13OCT10)
2020042
Section 21
Main Hydraulic System
Contents
Page
TM11813 (13OCT10)
211
Contents
TM11813 (13OCT10)
212
Group 2160
Hydraulic System
General Oil Cleanup Procedure
TX1080703 UN09AUG10
1 Suction Wand
TM11813 (13OCT10)
2 Discharge Wand
2121601
BR98087,00000B3 1918AUG101/2
Hydraulic System
16. Obtain oil sample for fluid analysis. Oil sample must be
taken from system before oil passes through the filter
when oil is warm. See Fluid Analysis Program Test
Kits and 3Way Coolant Test Kit. (Operators Manual.)
TM11813 (13OCT10)
2121602
Hydraulic System
TM11813 (13OCT10)
2121603
SW03989,0000B25 1907OCT101/2
Hydraulic System
TM11813 (13OCT10)
2121604
Hydraulic System
TX1080483A UN05AUG10
TX1080484A UN05AUG10
1 Case DraintoReservoir
Hose
2 Supply Line
3 PumptoPrioity Valve Line
4 Electrical Connector
5 Cap Screw (4 used)
TM11813 (13OCT10)
2121605
SW03989,0000B26 1928SEP101/2
Hydraulic System
TX1080461A UN03AUG10
15. Fill supply and case drain ports with hydraulic oil. See
Hydraulic System Oil. (Operators Manual.)
16. Connect case drain hose.
17. Connect supply line using a new Oring at face seal.
Tighten to specification.
Specification
Line Mounting Cap
ScrewTorque............................................................................120 Nm
89 lbft
Coupler
6 ORing
7 Coupler
TM11813 (13OCT10)
2121606
Hydraulic System
TX1080500A UN05AUG10
Priority Valve
17. Start engine and allow to run at slow idle for several
minutes.
TM11813 (13OCT10)
2121607
Hydraulic System
1 Housing
2 Spool
3 Orifice (2 used)
4 Spring
5 Plug
6 ORing
7 Relief Valve Cartridge
8 ORing
9 Plug
10 ORing
Specification
Relief Valve
CartridgeTorque................................................................. 3454 Nm
2540 lbft
TM11813 (13OCT10)
2121608
Hydraulic System
TX1081866A UN16SEP10
1 Hydraulic Line
2 Cap Screw (2 used)
3 Hydraulic Hose
TM11813 (13OCT10)
2121609
Hydraulic System
2
3
1
2
TX1080592 UN05AUG10
TX1080592
Fan Manifold Remove and Install
1 Solenoid Electrical Connector 2 Hydraulic Hose (4 used)
(2 used)
TM11813 (13OCT10)
21216010
Hydraulic System
2
4
4
5
TX1081043 UN18AUG10
4
8
4
4
6
TX1081043
3 Orifice
4 Plug (5 used)
7 Nut (2 used)
8 Valve Manifold
TM11813 (13OCT10)
21216011
Hydraulic System
TX1080520A UN04AUG10
TM11813 (13OCT10)
21216012
MH66088,0000D93 1906OCT101/2
Hydraulic System
TM11813 (13OCT10)
21216013
Hydraulic System
TX1080622 UN06AUG10
TX1080622
Hydraulic Reservoir Bottom View
1 Hydraulic Oil Temperature
Sensor Connector
2 Wire Harness
TM11813 (13OCT10)
21216014
SW03989,0000A9A 1905OCT101/5
Hydraulic System
TX1080603A UN06AUG10
3 Transmission Filter
4 Cap Screw (3 used)
5 Breather
TM11813 (13OCT10)
21216015
SW03989,0000A9A 1905OCT102/5
Hydraulic System
TX1080623 UN06AUG10
TX1080624 UN06AUG10
TM11813 (13OCT10)
21216016
SW03989,0000A9A 1905OCT103/5
Hydraulic System
TX1080625A UN06AUG10
Specification
Hydraulic
ReservoirWeight
(approximate).................................................................................. 60 kg
132 lb.
17 Machine Frame
18 Cap Screw (6 used)
19 Nut (6 used)
TM11813 (13OCT10)
21216017
SW03989,0000A9A 1905OCT104/5
Hydraulic System
SW03989,0000A9A 1905OCT105/5
TX1025218A UN21JUN07
6 Drive Coupler
TM11813 (13OCT10)
21216018
Contents
Section 30
Winch
Page
TM11813 (13OCT10)
301
Contents
TM11813 (13OCT10)
302
Group 3000
Removal and Installation
Winch 4000 Series Remove and Install
NOTE: Cable must be removed from winch
before servicing.
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.
TX1080905 UN16AUG10
TM11813 (13OCT10)
3030001
SW03989,0000A9D 1905OCT101/5
9. Remove guards.
10. Label and disconnect hydraulic lines (712).
11. Remove fittings (13).
TX1080942A UN19AUG10
Winch Guard
TX1080943A UN19AUG10
TX1080944A UN19AUG10
Hydraulic Connections
TM11813 (13OCT10)
3030002
SW03989,0000A9D 1905OCT102/5
TX1080945A UN19AUG10
15 Fill Plug
16 Drain Plug
TM11813 (13OCT10)
3030003
SW03989,0000A9D 1905OCT104/5
19. Clean grease, dirt, oil, and paint from mounting holes.
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.
T7516AV UN05JUN91
TM11813 (13OCT10)
3030004
TX1018826A UN12MAR07
TX1018827A UN12MAR07
1 Cable Clamp
2 Tab
TM11813 (13OCT10)
3030005
GD61784,00000B1 1902JUL071/3
TX1018824A UN12MAR07
TX1018825A UN12MAR07
2 Drum Plug
TM11813 (13OCT10)
3030006
GD61784,00000B1 1902JUL072/3
TX1018822A UN12MAR07
TX1018823A UN12MAR07
1 Wedge
GD61784,00000B1 1902JUL073/3
TX1018816A UN12MAR07
4000 Winch
TX1018817A UN12MAR07
1 Nut
6000 Winch
GD61784,00000B2 1902JUL071/1
TM11813 (13OCT10)
3030007
TM11813 (13OCT10)
3030008
SW03989,0000A9E 1905OCT101/2
T7533AX UN09JUL91
14. Install front and rear mounting cap screws and tighten
to specification.
Specification
Winch Mounting Cap
ScrewTorque............................................................................620 Nm
455 lbft
TM11813 (13OCT10)
3030009
TX1018820A UN12MAR07
1 Nibble
2 Wedge (2 used)
TX1018818A UN12MAR07
GD61784,00000B4 1902JUL071/2
3. Lay cable in winch drum slot and install tab (5) tight
against drum.
TX1018821A UN12MAR07
5 Tab
GD61784,00000B4 1902JUL072/2
TM11813 (13OCT10)
30300010
TM11813 (13OCT10)
30300011
Group 3015
Control Linkage
T131308 UN01JUN00
TM11813 (13OCT10)
3030151
GD61784,00000B5 1902JUL071/2
Control Linkage
1 Pin (4000 Winch3 used)
2 Yoke
3 Pin (4000 Winch3 used)
4 Nut
5 Bracket
6 Bracket
7 Washer (3 used)
8 Nut (3 used)
9 Spacer (2 used)
10 Cap Screw (2 used)
11 Control Cable
23 Boot
24 Clip (6 used)
25 Ring
26 Cap Screw (2 used)
27 Washer (2 used)
28 Plate
29 Bracket
30 Strap (2 used)
31 UBolt
32 Cap Screw
33 Lock Nut (2 used)
34 Ball Joint
35 Washer (3 used)
36 Nut
37 Lock Nut
38 Wedge
39 Lever
40 Ball Joint
41 Nut
42 Cap Screw (3 used)
43 Washer (2 used)
44 Label
T129676B UN04APR00
T7711AG UN13MAR92
AEnd of CabletoCenter of
Mounting Groove Distance
Continued on next page
TM11813 (13OCT10)
3030152
GD61784,00000B6 1902JUL071/5
Control Linkage
ABracket
T7402AI UN26NOV90
TM11813 (13OCT10)
3030153
GD61784,00000B6 1902JUL073/5
Control Linkage
T7374AY 1930OCT90
T7374AZ 1930OCT90
Specification
Control LevertoStop
Screw (Power In
Position)Distance....................................................................68 mm
0.2400.320 in.
GD61784,00000B6 1902JUL074/5
T7374AY 1930OCT90
T7397AZ 1930OCT90
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
TM11813 (13OCT10)
3030154
Control Linkage
TM11813 (13OCT10)
3030155
Group 3025
Input Drive Shafts and UJoints
Winch Drive Shaft Remove and Install
1. Engage park brake.
TX1025719A UN29JUN07
TX1025720A UN29JUN07
AC12469,0000420 1930JUL071/1
3. Assemble parts.
1
2
4
3
Specification
1
1
TX1024077 UN04JUN07
Drive Shaft
4 Lubrication Fitting
5 Cap Screw (8 used)
SW03989,0000A9C 1906AUG101/1
TM11813 (13OCT10)
3030251
TM11813 (13OCT10)
3030252
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
TM11813 (13OCT10)
3030501
TM11813 (13OCT10)
3030502
Section 32
Stacking Blades
Contents
Page
Group 3201Blades
Stacking Blade Remove and
Install ..................................................... 3232011
Spherical Bushing Remove and
Install ..................................................... 3232015
Group 3215Controls Linkage
Blade Control Linkage Remove
and Install .............................................. 3232151
Blade Control Valve Remove and
Install ..................................................... 3232152
Group 3260Hydraulic System
Blade Lift Cylinder Remove and
Install ..................................................... 3232601
TM11813 (13OCT10)
321
Contents
TM11813 (13OCT10)
322
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.
T195555B UN21OCT03
1 Cylinder Pin
2 Retainer
3 Cap Screw
TM11813 (13OCT10)
3232011
GD61784,0000031 1910MAR091/5
TX1056819 UN06MAR09
Blades
TX1056819
Exploded View of Stacking Blade
4 Stacking Blade
5 Bushing
6 Lubrication Fitting
7 Cap Screw
8 Bushing
9 Washer
10 Seal
11 Washer
12 Cap Screw
13 Pin
14 Lock Nut
Specification
Stacking BladeWeight
(approximate).............................................................................. 1360 kg
3000 lb
TM11813 (13OCT10)
3232012
GD61784,0000031 1910MAR092/5
T8509AC UN19JUN95
Blades
TM11813 (13OCT10)
3232013
GD61784,0000031 1910MAR093/5
Blades
AWasher (as required)
BShim (as required)
CEngine Frame
DSeal Washer
EHardened Washer
F Cap Screw
Specification
CaptoWasherGap.................................................................36 mm
0.1200.240 in.
GD61784,0000031 1910MAR094/5
T195568A UN21OCT03
20. Install cap screw (1) and retainer (2) and tighten.
21. Install front wheel. See Wheel Remove and Install.
(Group 0110.)
4 Spherical Bushing
5 Washer Shim (as required)
GD61784,0000031 1910MAR095/5
TM11813 (13OCT10)
3232014
Blades
T7502HJ UN02JUL91
ABushing
GD61784,0000032 1930MAY071/3
2.
APipe Assembly
BSpherical Bushing
CPipe Assembly
TM11813 (13OCT10)
3232015
GD61784,0000032 1930MAY072/3
Blades
T7569AL UN09JUL91
DBar Stock
EWasher
F Nut
TM11813 (13OCT10)
3232016
Group 3215
Controls Linkage
TX1056821 UN06MAR09
TX1056821
Blade Control Linkage
1 Shim
2 Bushing (2 used)
3 Knob
4 Control Lever
5 Boot
6 Nut
7 Washer
8 Bushing
9 Lock Nut
10 Pin
16 Boot Retainer
17 Nut
GD61784,0000039 1906MAR091/1
TM11813 (13OCT10)
3232151
Controls Linkage
TX1056822 UN06MAR09
TX1056822
Blade Control Valve
1 Cap Screw (3 used)
2 Rubber Mount (3 used)
TM11813 (13OCT10)
3232152
Group 3260
Hydraulic System
Blade Lift Cylinder Remove and Install
X9811 UN23AUG88
T195555A UN21OCT03
Specification
Blade CylinderWeight
(approximate).................................................................................. 35 kg
77 lb
GD61784,0000033 1925JUL071/1
TM11813 (13OCT10)
3232601
Hydraulic System
TM11813 (13OCT10)
3232602
Contents
Section 38
Grapple
Page
Page
Group 3840Frames
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 3860Hydraulic System
Boom or Arch Cylinder Remove
and InstallDual 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
Contents
TM11813 (13OCT10)
382
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.
TX1081158A UN27AUG10
1 Pin (2 used)
2 Shock Absorber
3 Rotary ManifoldtoCylinder
Rod End Hose
4 Rotary ManifoldtoFlow
Divider Hose
TM11813 (13OCT10)
3838031
Grapple Mechanism
TX1081371 UN03SEP10
Grapple Components
TM11813 (13OCT10)
3838032
SW03989,0000AA5 1903SEP101/2
Grapple Mechanism
1 Top Cover (2 used)
2 Cap Screw (4 used)
3 Grapple Frame
4 Shim (2 used)
5 Shim (4 used)
6 Bushing (2 used)
7 Washer (2 used)
8 Cap Screw (2 used)
9 Grapple Pin (2 used)
10 Tong Pin (2 used)
11 Washer (2 used)
12 Washer (2 used)
19 Nut (2 used)
20 Lubrication Fitting (2 used)
21 Tong (2 used)
22 Tooth (2 used)
Grapple Head
FrameWeight
(approximate).................................................................................115 kg
254 lb
Grapple TongWeight
(approximate).......................................................................104194 kg
230428 lb
Specification
Grapple Head and
TongsWeight
(approximate)...............................................................................1134 kg
2500 lb
SW03989,0000AA5 1903SEP102/2
TM11813 (13OCT10)
3838033
Grapple Mechanism
T131307 UN01JUN00
Grapple Dampener
TM11813 (13OCT10)
3838034
SW03989,0000AA6 1902SEP101/2
Grapple Mechanism
1 Plug (6 used)
2 Spring (6 used)
3 Washer (18 used)
4 Snap Ring
5 ORing
6 ORing
7 Housing
8 Bushing
9 ORing
10 Plug
11 Shaft
12 ORing
13 Snap Ring
14 Bushing
15 Lubrication Fitting (6 used)
16 Plate (6 used)
17 Disk (5 used)
18 Cotter Pin
19 Pin
20 Pin
21 Washer
22 Cap Screw
23 Lock Nut
24 Shock Absorber Cylinder
25 Washer
26 Lubrication Fitting (2 used)
27 Bushing (2 used)
28 Grapple Dampener Housing
29 Pin
30 Spacer
31 Washer
32 Cap Screw
Specification
Grapple Damp
enerWeight (approxi
mate)............................................................................................. 105 kg
231 lb
TM11813 (13OCT10)
3838035
Grapple Mechanism
TX1019945A UN13MAR07
3838036
SW03989,0000AA7 1902SEP101/2
Grapple Mechanism
Specification
Grapple Dampener
Adjusting PlugTorque...............................................................184 Nm
250 lbft
SW03989,0000AA7 1902SEP102/2
TX1019054 UN12MAR07
T102161 UN22JUL96
Lower Pin
SW03989,0000AA8 1902SEP101/1
TM11813 (13OCT10)
3838037
Grapple Mechanism
10
12
11
TX1051670
TX1051670 UN20FEB09
4 Seal
5 Lower Bearing Cone
6 Lower Bearing Race
Specification
Grapple YokeWeight
(approximate).................................................................................. 54 kg
119 lb
TM11813 (13OCT10)
3838038
SW03989,0000AA9 1915SEP101/9
Grapple Mechanism
TX1056637 UN05MAR09
Bearing Races
14
TX1081181 UN25AUG10
13
Grapple Yoke
TM11813 (13OCT10)
3838039
13 Arch or Boom
14 Pivot Pin Bore
SW03989,0000AA9 1915SEP102/9
Grapple Mechanism
15
11
16
12
12
TX1081182 UN25AUG10
17
12
16
12
15
11
16
12
12
12
16
12
TX1081183 UN25AUG10
17
TM11813 (13OCT10)
38380310
SW03989,0000AA9 1915SEP103/9
Grapple Mechanism
1
4
TX1056258 UN23FEB09
3
2
Specification
GeartoYoke Cap
ScrewTorque..............................................................................81 Nm
60 lbft
Specification
GeartoYoke Cap
ScrewTorque............................................................................122 Nm
90 lbft
1
4
TX1056256 UN23FEB09
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
TM11813 (13OCT10)
38380311
SW03989,0000AA9 1915SEP104/9
Grapple Mechanism
18
19
20
11
TX1081184 UN25AUG10
11
16
19
19
16
19
19
TX1081185 UN25AUG10
1 Grapple Yoke
11 Rotate Motor Driven Gear
16 Hole (4 mm) (2 used)
TM11813 (13OCT10)
38380312
SW03989,0000AA9 1915SEP105/9
Grapple Mechanism
14
TX1081181 UN25AUG10
1 Grapple Yoke
13 Arch or Boom
13
Grapple Yoke
Continued on next page
TM11813 (13OCT10)
38380313
SW03989,0000AA9 1915SEP106/9
Grapple Mechanism
15
11
16
12
TX1081187 UN25AUG10
17
16
Rotate Driven Gear Cap Screw Location (12 cap screw yoke)
15
11
13
16
12
TX1081188 UN25AUG10
17
16
Rotate Driven Gear Cap Screw Location (14 cap screw yoke)
Continued on next page
TM11813 (13OCT10)
38380314
SW03989,0000AA9 1915SEP107/9
Grapple Mechanism
11
Specification
12
GeartoYoke Cap
ScrewTorque..............................................................................81 Nm
60 lbft
6
10
TX1056259 UN24FEB09
13
11
12
8
5
14
10
Specification
GeartoYoke Cap
ScrewTorque Turn....................................60 (1 flat on hex cap screw)
Continued on next page
TM11813 (13OCT10)
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
TX1056262 UN23FEB09
Specification
GeartoYoke Cap
ScrewTorque............................................................................170 Nm
125 lbft
38380315
SW03989,0000AA9 1915SEP108/9
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.)
13
21
1
35. Perform grapple dampener adjustment. See Grapple
Dampener Adjustment. (Group 3303.)
1 Grapple Yoke
13 Arch
21 Grease Fitting
TX1081189 UN25AUG10
TM11813 (13OCT10)
38380316
Group 3840
Frames
Dual Function Grapple Cable Rollers Remove and Install
17 13
12
14
13
8
3
5
2
15
11
17
1
7
10
10
7
4
T195678 UN24OCT03
16
T195678
Dual Function Grapple Cable Rollers
1 Nut (4 used)
2 Cap Screw (2 used)
3 Cap Screw (2 used)
4 Cap Screw (4 used)
Lubrication Fitting (4 used)
5 Washer (2 used)
6 Washer (2 used)
7 Washer (4 used)
8 Horizontal Roller
9 Vertical Roller (2 used)
10 Lubrication Fitting (2 used)
11 Roller Frame
12 Lubrication Fitting (2 used)
13 Bushing (2 used)
14 Shaft
15 Strap
16 Shaft (2 used)
17 Washer (2 used)
2. Inspect bushings (13) and shafts (14 and 16) for wear
or damage.
4. Install rollers.
GD61784,00000C5 1905JUL071/1
TM11813 (13OCT10)
3838401
Frames
TX1024405A UN05JUN07
Boom
1 Boom
2 Boom Cylinder Pin (2 used)
TM11813 (13OCT10)
3838402
Frames
TX1024408A UN05JUN07
Arch
1 Arch
2 Arch Cylinder Pin (2 used)
TM11813 (13OCT10)
3838403
Frames
TM11813 (13OCT10)
3838404
Group 3860
Hydraulic System
Boom or Arch Cylinder Remove and
InstallDual Function Grapple
1. Lower grapple to the ground.
TX1081260A UN01SEP10
TX1081259A UN01SEP10
Specification
Boom CylinderWeight
(approximate).................................................................................. 66 kg
145 lb
Arch CylinderWeight
(approximate).................................................................................. 62 kg
137 lb
TM11813 (13OCT10)
4 Pin
5 Boom Cylinder Hydraulic
Hose (4 used)
6 Boom Cylinder (2 used)
3838601
SW03989,0000AB0 1905OCT101/2
Hydraulic System
TM11813 (13OCT10)
3838602
Hydraulic System
10
4
3
11
TX1081258 UN01SEP10
TX1081258
Grapple Tong Cylinder Removal and Installation
1 Frame
2 Cap Screw (4 used)
3 Top Cover (2 used)
TM11813 (13OCT10)
3838603
SW03989,0000AB1 1904OCT101/2
Hydraulic System
7. Connect lifting strap to tong cylinder.
CAUTION: Prevent possible crushing injury from
heavy component. Use appropriate lifting device.
Specification
Tong CylinderWeight
(approximate).................................................................................. 66 kg
146 lb
13. Install tong pin and cylinder rod pin. Install spacer,
washers, and cap screws.
14. Connect hydraulic hoses.
15. Install top cover.
16. Turn battery disconnect switch to the ON position.
17. Start engine and follow hydraulic oil warmup
procedure. See Hydraulic Oil Warmup Procedure.
(Group 9025.)
18. Stop engine and check for leaks.
19. Check hydraulic reservoir oil level. See Check
Hydraulic System Oil Level. (Operators Manual.)
TM11813 (13OCT10)
3838604
Hydraulic System
TX1081257 UN01SEP10
TM11813 (13OCT10)
3838605
SW03989,0000AB2 1903SEP101/2
Hydraulic System
SW03989,0000AB2 1903SEP102/2
TM11813 (13OCT10)
3838606
Hydraulic System
T214865 UN21SEP05
TM11813 (13OCT10)
3838607
SW03989,0000AB3 1901OCT101/12
Hydraulic System
9 Wear Plate
10 Seal
11 Geroler SubAssembly
12 Seal
13 Valve Plate
14 Valve Drive
15 Valve
16 Balance Ring
25 Washer (4 used)
26 Tie Bolt (4 used)
27 ORing (2 used)
28 Relief Valve (2 used)
29 ORing (2 used)
30 Cap (2 used)
SW03989,0000AB3 1901OCT102/12
T214867 UN21SEP05
Motor in Vise
SW03989,0000AB3 1901OCT103/12
25 Washer (4 used)
TM11813 (13OCT10)
3838608
SW03989,0000AB3 1901OCT104/12
Hydraulic System
TX1081254 UN01SEP10
21 Seal
TX1081253 UN01SEP10
TM11813 (13OCT10)
3838609
SW03989,0000AB3 1901OCT106/12
Hydraulic System
9. Remove inner and outer face seals (17 and 20) from
balance ring.
10. Remove valve (15).
15 Valve
16 Balance Ring
17 Outer Face Seal
18 Pin (2 used)
19 Spring (2 used)
20 Inner Face Seal
Remove Balance Ring, Face Seals, and Valve
SW03989,0000AB3 1901OCT107/12
12 Seal
13 Valve Plate
TX1081251 UN01SEP10
8 Splined Drive
TM11813 (13OCT10)
38386010
SW03989,0000AB3 1901OCT109/12
Hydraulic System
2 Bearing Housing
6 Seal
7 Shaft Face Seal
TX1081249 UN01SEP10
TX1081248 UN01SEP10
TX1081247 UN01SEP10
TM11813 (13OCT10)
38386011
Hydraulic System
T214865 UN21SEP05
TM11813 (13OCT10)
38386012
SW03989,0000AB4 1901OCT101/13
Hydraulic System
1 Shaft Exclusion Seal
2 Bearing Housing
3 Backup Ring
4 Shaft Seal
5 Bearing and Shaft
SubAssembly
6 Seal
7 Shaft Face Seal
8 Splined Drive
9 Wear Plate
10 Seal
11 Geroler SubAssembly
12 Seal
13 Valve Plate
14 Valve Drive
15 Valve
16 Balance Ring
TM11813 (13OCT10)
25 Washer (4 used)
26 Tie Bolt (4 used)
27 ORing (2 used)
28 Relief Valve (2 used)
29 ORing (2 used)
30 Cap (2 used)
38386013
SW03989,0000AB4 1901OCT102/13
TX1081246 UN01SEP10
Hydraulic System
Shaft Seals
TX1081247 UN01SEP10
TM11813 (13OCT10)
38386014
Hydraulic System
TX1081245 UN30AUG10
6 Seal
31 Eaton 600465 Protective
Bullet
SW03989,0000AB4 1901OCT104/13
16
15
16
10 Seal
14
5
6
TX1081342 UN25AUG10
TM11813 (13OCT10)
38386015
SW03989,0000AB4 1901OCT106/13
Hydraulic System
TX1081241 UN30AUG10
8 Splined Drive
TM11813 (13OCT10)
38386016
SW03989,0000AB4 1901OCT107/13
TX1081240 UN30AUG10
Hydraulic System
14 Valve Drive
15 Valve
12 Seal
13 Valve Plate
TM11813 (13OCT10)
38386017
SW03989,0000AB4 1901OCT108/13
Hydraulic System
15. Install two springs (19) and two pins (18) in holes
located in bore of valve housing (23).
18 Pin (2 used)
19 Spring (2 used)
TX1081239 UN30AUG10
TX1081238 UN30AUG10
16 Balance Ring
17 Outer Face Seal
16 Balance Ring
TM11813 (13OCT10)
38386018
SW03989,0000AB4 1901OCT1011/13
Hydraulic System
TX1081236 UN30AUG10
23 Valve Housing
TX1081235 UN30AUG10
Specification
Case Drain
PlugTorque...................................................................................6 Nm
50 lbin.
SW03989,0000AB4 1901OCT1013/13
TM11813 (13OCT10)
38386019
Hydraulic System
2 Drive Gear
4 Boom Section
5 Blade Section
6 Outlet Section
TX1081063 UN18AUG10
1 Inlet Section
2 Tong Section
3 Arch Section
TM11813 (13OCT10)
38386020
Hydraulic System
TM11813 (13OCT10)
38386021
Hydraulic System
TX1025762A UN29JUN07
TM11813 (13OCT10)
38386022
SW03989,0000ACB 1901OCT101/5
Hydraulic System
1 Pilot Pressure Hose
2 Pilot Control Hose (4 used)
3 Pilot Control Valve Supply
Hose
TX1025763A UN29JUN07
TM11813 (13OCT10)
38386023
SW03989,0000ACB 1901OCT104/5
Hydraulic System
TX1025765A UN29JUN07
Specification
Control ValveSingle
Function
GrappleWeight
(approximate).................................................................................. 27 kg
60 lb.
14. Install adapters with the orifice check in the pilot cap
ports. Install pilot lines.
SW03989,0000ACB 1901OCT105/5
TM11813 (13OCT10)
38386024
Hydraulic System
TX1081328 UN31AUG10
4 Boom Section
5 Blade Section
6 Outlet Section
TM11813 (13OCT10)
38386025
SW03989,0000AB7 1926AUG101/2
TX1081329 UN31AUG10
Hydraulic System
15 Elbow
16 Test Coupling
17 Tee
TM11813 (13OCT10)
38386026
Hydraulic System
Relief Valves
1 Main Relief Valve
2 Nonadjustable Circuit
Relief Valve
TM11813 (13OCT10)
38386027
Hydraulic System
4 Spring (3 used)
5 Poppet (3 used)
Lift Check Valve
SW03989,0000AB9 1901OCT101/1
TM11813 (13OCT10)
38386028
Hydraulic System
TX1081361 UN02SEP10
9 Poppet
10 Poppet Stem
11 Valve Body
12 ORing
13 Backup Ring
14 ORing
Specification
Nonadjustable Circuit
Relief ValveTorque...................................................................100 Nm
75 lbft
TM11813 (13OCT10)
38386029
Hydraulic System
TX1081362 UN07SEP10
7 Retainer
8 ORing
9 Rod
10 Spring
11 Seal
12 Ring
13 Poppet
14 ORing
15 Backup Ring
16 Housing
17 Pin
18 Backup Ring
19 ORing
20 Valve Body
21 ORing
TM11813 (13OCT10)
38386030
SW03989,0000ABB 1907OCT101/2
Hydraulic System
Specification
Adjustable Circuit Relief
ValveTorque.............................................................................100 Nm
75 lbft
Specification
Lock NutTorque..........................................................................88 Nm
65 lbft
SW03989,0000ABB 1907OCT102/2
TM11813 (13OCT10)
38386031
Hydraulic System
TX1081364 UN02SEP10
Spool Valve
1 Screw (2 used)
2 Plate
3 Upper Spacer
4 Packing
5 Spool
6 Lower Spacer
7 Valve Section Housing
8 Plate
9 Rod
10 Retainer
11 Spring
12 Retainer
13 Rod Cap
14 End Cap Housing
15 Screw (2 used)
TM11813 (13OCT10)
38386032
Hydraulic System
TX1081366 UN02SEP10
Detent Assembly
1 Spacer
2 Spring Retainer
3 Spring
4 Spring Retainer
5 Rod
6 Housing
7 Washer (2 used)
8 Screw (2 used)
9 Plate
10 Washer (2 used)
11 Screw (2 used)
12 Carrier
13 Detent Ball (6 used)
14 Retainer
15 Spring
16 Rod Cap
17 Sleeve
TM11813 (13OCT10)
38386033
Hydraulic System
TX1081367 UN02SEP10
3 ORing
4 Cap
5 ORing (3 used)
6 Sleeve
7 Bushing
TM11813 (13OCT10)
38386034
Hydraulic System
TX1081368 UN02SEP10
9 Housing
10 Cap Screw
11 Cap Screw
12 Lock Washer (2 used)
5 ORing
6 Cap
7 Plug
8 ORing
13 ORing
14 ORing
15 Bushing
16 ORing (2 used)
TM11813 (13OCT10)
38386035
SW03989,0000ABF 1907SEP101/2
Hydraulic System
SW03989,0000ABF 1907SEP102/2
TX1080208A UN28JUL10
TM11813 (13OCT10)
38386036
Hydraulic System
TX1080241A UN28JUL10
1 Valve Body
2 Cartridge
3 Coil (2 used)
4 Coil Nut
5 Coil Spacer
NM00125,0000588 1908OCT101/2
TX1080240A UN28JUL10
Cartridge
6 CartridgetoValve Body
ORing
7 ORing (3 used)
TM11813 (13OCT10)
38386037
Hydraulic System
TX1081372 UN02SEP10
5 Seal Kit
6 Flow Divider Valve
7 Retainer (2 used)
TM11813 (13OCT10)
38386038
SW03989,0000AC0 1907SEP101/4
Hydraulic System
8 Gland Ring
9 Backup Ring
TX1081373A UN02SEP10
10. Replace with new gland ring (8), backup ring (9), and
Oring (10).
10 ORing
TX1081374A UN02SEP10
12. Replace with new Orings (12 and 14) and backup
rings (11 and 13).
13 Backup Ring
14 ORing
13. Install direct acting crossover relief valves (1) and flow
divider valve (6).
TX1081376A UN02SEP10
7 Retainer (2 used)
TM11813 (13OCT10)
38386039
Hydraulic System
1 Rotary ManifoldtoControl
Valve Tong Head End Hose
2 Rotary ManifoldtoControl
Valve Tong Rod End Hose
3 Rotary ManifoldtoRotate
Motor Hose
Continued on next page
TM11813 (13OCT10)
38386040
SW03989,0000AC1 1907SEP101/2
Hydraulic System
7 Rotary ManifoldtoGrapple
Cylinder Rod End Hose
TX1081378A UN02SEP10
TM11813 (13OCT10)
38386041
SW03989,0000AC2 1901OCT101/4
Hydraulic System
6 ORing (4 used)
7 Expander Ring (4 used)
TM11813 (13OCT10)
38386042
SW03989,0000AC2 1901OCT103/4
Hydraulic System
TX1081381A UN02SEP10
Specification
Rotary Manifold Test Port
Marked "D"Pressure.............................................................. 1379 kPa
14 bar
200 psi
SW03989,0000AC2 1901OCT104/4
TM11813 (13OCT10)
38386043
Hydraulic System
TM11813 (13OCT10)
38386044
Contents
Section 99
Dealer Fabricated Tools
Page
TM11813 (13OCT10)
991
Group 9900
Dealer Fabricated Tools
TX1071962 UN05APR10
TM11813 (13OCT10)
9999001
GD61784,0000077 1931MAR101/2
RW13619 UN20SEP89
A102 mm (4 in.)
B76 mm (3 in.)
C70 mm (2.75 in.)
J Fillet Weld
KTwo Holes
Material required:
TM11813 (13OCT10)
9999002
TM11813 (13OCT10)
9999003
Index
Page
Page
Bearing
Support, remove and install ........................... 0202252
Belt
Tensioner spring tension check...................... 0505103
Belt tensioner
Remove and install ........................................ 0505104
Belt, seat
Remove and install ........................................ 1818217
Blade
Control linkage, remove and install................ 3232151
Control valve, remove and install................... 3232152
Lift cylinder, remove and install...................... 3232601
Stacking, remove and install .......................... 3232011
Blower motor
Remove and install ...................................... 18183013
Boom
Remove and install ........................................ 3838402
Boom cylinderdual function grapple
Remove and install ........................................ 3838601
Bottom guard
Engine frame, remove and install .................. 1717461
Equipment frame, remove and install ............ 1717462
Brake accumulator
Remove and install ........................................ 1010604
Brake pedal
Remove and install ........................................ 1010151
Brake valve, service
Disassemble and assemble ........................... 1010603
Remove and install ........................................ 1010601
Brake, park
Remove and install ......................................... 1111111
Bump shifter
Remove and install ........................................ 0303151
Bushing
Spherical, remove and install......................... 3232015
C
Cab
Remove and install ........................................ 1818001
Cab door
Disassemble and assemble ........................... 1818105
Remove and install ........................................ 1818104
Cab isolators
Remove and install ........................................ 1818008
Cab tilt cylinder
Remove and install ...................................... 18180017
Cab tilt hand pump
Bleeding procedure...................................... 18180015
Disassemble and assemble ......................... 18180014
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
PN=1
Index
Page
Page
Charge pump
Transmission, remove and install .................. 0303601
Charge pump drive, transmission
Repair ............................................................ 0303604
Cleanup procedure
General oil...................................................... 2121601
Hydraulic component failure .......................... 2121603
Component failure
Hydraulic, cleanup procedure ........................ 2121603
Compressor
Air conditioner, remove and install ................. 1818308
Compressor clutch
Remove and install ........................................ 1818309
Compressor manifold
Remove and install ...................................... 18183011
Compressor relief valve
Remove and install ........................................ 1818307
Condenser
Remove and install ...................................... 18183011
Control linkage
Blade, remove and install............................... 3232151
Winch, remove and install.............................. 3030151
Control valve
Blade, remove and install............................... 3232152
Options......................................................... 38386020
Control valve relief valves
Remove and install ...................................... 38386027
Control valve, transmisison
Repair ............................................................ 0303609
Control valvedual function pilot operated
Disassemble and assemble ......................... 38386025
Control valvepilot operated
Remove and install ...................................... 38386022
Control valvepilot operated valve
Remove and install ...................................... 38386034
Control valveadjustable circuit relief valve
Disassemble and assemble ......................... 38386030
Control valvedetent
Disassemble and assemble ......................... 38386033
Control valvelift check valve
Disassemble and assemble ......................... 38386028
Control valvenonadjustable circuit relief
valve
Disassemble and assemble ......................... 38386029
Control valvesolenoid operated valve
Remove and install ...................................... 38386035
Control valvespool valve
Disassemble and assemble ......................... 38386032
Coolant valve
Remove and install ...................................... 18183016
Cooling loop pump
Remove and install ...................................... 21216018
Cooling system
Service safely............................................... 00000112
Crosshead pins
Lubricate ........................................................ 3838037
Cylinder
Blade lift, remove and install .......................... 3232601
D
Dampener
Lubricate ........................................................ 3838037
Remove and install ........................................ 0707521
Dampener, grapple
Adjustment ..................................................... 3838036
Detent
Disassemble and assemble ......................... 38386033
DFRW20 tool
Compressor holding fixture ............................ 9999002
DFT1099 driver
Spherical bushings removal........................... 9999001
Differential drive shaft
Front, remove and install ............................... 0202251
Rear, remove and install ................................ 0202252
Differential lock solenoid valve
Repair ............................................................ 0202601
Door latch
Disassemble and assemble ........................... 1818105
Door, cab
Disassemble and assemble ........................... 1818105
Remove and install ........................................ 1818104
Drive and clutch repair
Winch 4000 .................................................... 3030501
Winch 6000 .................................................... 3030501
Drive shaft
Front axle and differential, remove and
install ............................................................ 0202251
Rear axle and differential, remove and
install ............................................................ 0202252
Winch, disassemble and assemble................ 3030251
Drive shaft, enginetotransmission
Remove and install ........................................ 0303251
Drive shaft, winch
Remove and install ........................................ 3030251
Dual mode steering solenoid valve
Remove and install ........................................ 0909621
Duals wheel installation ..................................... 0101103
E
Enclosure, air baffle
Remove and install ........................................ 0505101
Engine
Remove and install ........................................ 0404002
Engine CTM reference
Theory of operation........................................ 0404001
Engine dampener
Remove and install ........................................ 0707521
Enginetotransmission drive shaft
Remove and install ........................................ 0303251
Evaporator
Remove and install ...................................... 18183020
Expansion valve
Remove and install ...................................... 18183018
Continued on next page
TM11813 (13OCT10)
Index2
PN=2
Index
Page
Page
F
Fabricated tools
DFRW20 compressor holding fixture ............. 9999002
DFT1099 bushing driver ................................ 9999001
Fan
Hydraulic motor remove and install.............. 21216012
Fan blade
Remove and install ...................................... 05051016
Fan shroud
Remove and install ...................................... 05051016
Fan variable speed and reversing manifold
Disassemble and assemble ......................... 21216011
Remove and install ...................................... 21216010
Fire prevention................................................... 0000014
Flow divider
Repair .......................................................... 38386038
Flush and purge
Air conditioning system .................................. 1818302
Frame
Engine, separate............................................ 1717402
Equipment, separate...................................... 1717402
Free spool drag adjustment............................... 3030007
Freeze control switch
Remove and install ...................................... 18183017
Front axle
Remove and install ........................................ 0202001
Front axle guards
Remove and install ........................................ 0202008
Front axle oscillation supports
Repair ............................................................ 0202008
Front differential
Remove and install ........................................ 0202001
Front windshield wiper
Remove and install ........................................ 1818106
Fuel tank
Rremove and install ....................................... 0505601
G
General oil
Cleanup procedure ........................................ 2121601
Grapple
Disassemble and assemble ........................... 3838032
Remove and install ........................................ 3838031
Rotate bearing repair ..................................... 3838038
Grapple dampener
Disassemble and assemble ........................... 3838034
Grapple head
Dampener adjustment.................................... 3838036
Grapple rotate motor
Assemble ..................................................... 38386012
Disassemble .................................................. 3838607
Remove and install ........................................ 3838605
Grapple rotate solenoid valve
Disassemble and assemble ......................... 38386037
Remove and install ...................................... 38386036
H
Heater core
Remove and install ...................................... 18183019
Heating system
Blower motor remove and install.................. 18183013
Coolant valve remove and install ................. 18183016
Heater core remove and install .................... 18183019
High/low pressure switch
Remove and install ...................................... 18183015
Highpressure oils
Avoid .............................................................. 0000013
Hood
Remove and install ........................................ 1919101
Horn
Remove and install ........................................ 2020041
Housing, grille
Remove and install ........................................ 1919105
Hydraulic
Component faliure cleanup
procedure ..................................................... 2121603
Fittings, 30° cone seat ........................... 0000035
Fittings, 37° flare .................................... 0000035
Hydraulic attenuator
Remove and install ........................................ 2121609
Hydraulic fan motor
Remove and install ...................................... 21216012
Hydraulic fan pump
Remove and install ...................................... 21216018
Hydraulic oil cooler
Remove and install ...................................... 05051013
Hydraulic pump
Remove and install ........................................ 2121605
Hydraulic reservoir
Remove and install ...................................... 21216014
I
Inch bolt and cap screw
Torque value .................................................. 0000034
Input shaft, transmission
Remove and install ........................................ 0303507
Continued on next page
TM11813 (13OCT10)
Index3
PN=3
Index
Page
Page
Intercooler
Remove and install ........................................ 0505105
Isolators, cab
Remove and install ........................................ 1818008
L
Lower pivot pin seal
Remove and install ........................................ 1717406
Lubricate
Grapple head dampener, yoke, and
crosshead pins ............................................. 3838037
M
Machine modifications
Avoid .............................................................. 0000012
Metric bolt and cap screw
Torque value .................................................. 0000032
Mounttransmission
Remove and install ........................................ 0303006
O
Oring boss fittings............................................. 0000036
Oil
General, cleanup procedure .......................... 2121601
Lines and fittings ............................................ 0000035
Oil lines and fittings ........................................... 0000035
Oscillation supports
Remove and install ........................................ 0202001
Repair ............................................................ 0202008
P
Park brake
Remove and install ......................................... 1111111
Park brake solenoid valve
Repair .............................................................1111601
Pilot operated valve
Remove and install ...................................... 38386034
Pin, upper pivot
Remove and install ...................................... 17174012
Pins, metal
Drive safely .................................................. 00000114
Pivot pin, upper
Remove and install ...................................... 17174012
Precleaner blower assembly
Remove and install ...................................... 18183014
Pressurized water systemif equipped
Disassemble and assemble ........................... 2020031
Priority valve
Disassemble and assemble ........................... 2121608
Remove and install ........................................ 2121607
Pump drive, transmission charge
Repair ............................................................ 0303604
Pump, cab tilt
Bleeding procedure...................................... 18180015
R
R134a refrigerant
Cautions and proper handling........................ 1818301
Oil information................................................ 1818304
Recovery........................................................ 1818306
Recovery/recycling and charging station
installation .................................................... 1818305
R134a system
Charge ........................................................... 1818307
Evacuate ........................................................ 1818306
Radiator
Remove and install ........................................ 0505108
Rear axle
Remove and install ........................................ 0202005
Rear differential
Remove and install ........................................ 0202005
Rear windshield wiper
Remove and install ........................................ 1818107
Receiverdryer
Remove and install ...................................... 18183021
Repair procedures
Transmission.................................................. 0303501
Reverse warning alarm
Remove and install ........................................ 2020041
Rollers, cable, dual function
Remove and install ........................................ 3838401
ROPS
Torque ............................................................ 0000031
Rotary manifold
Disassemble and assemble ......................... 38386041
Remove and install ...................................... 38386040
Rotate motor drive gear
Remove and install ...................................... 38386020
S
Safety
Add and operate attachments safely ........... 00000111
Avoid backover accidents .............................. 0000019
Avoid machine tip over................................... 0000019
Avoid work site hazards ................................. 0000018
Clean debris from machine ............................ 0000016
Do not use starting fluid with tier 3
engine .......................................................... 0000013
Inspect and maintain ROPS......................... 00000110
Inspect machine............................................. 0000012
Keep riders off machine ................................. 0000018
Keep the operator protective structure in
place........................................................... 00000110
Make welding repairs safely......................... 00000113
Operate machine safely ................................. 0000018
Operate only if qualified ................................. 0000011
Operating on slopes..................................... 00000110
Operating or traveling on public roads ......... 00000110
Park and prepare for service safely ............. 00000111
Continued on next page
TM11813 (13OCT10)
Index4
PN=4
Index
Page
Page
T
Tensioner, belt
Remove and install ........................................ 0505104
Spring tension check...................................... 0505103
Tire
Install duals .................................................... 0101103
Remove and install ........................................ 0101102
Torque value
30° cone seat hydraulic fittings .............. 0000035
37° flare hydraulic fittings....................... 0000035
Dual wheel nuts ............................................. 0101103
Flat face Oring seal fitting ............................. 0000037
Hardware specifications................................. 0000031
Inch SAE four bolt flange fitting...................... 0000039
Metric bolt and cap screw .............................. 0000032
Metric cap screw ............................................ 0000033
Metric four bolt flange fitting........................... 0000038
ORing boss fitting ......................................... 0000036
Unified inch bolt and cap screw ..................... 0000034
Transmission
Input shaft remove and install ........................ 0303507
Remove and install ........................................ 0303001
Repair procedures ......................................... 0303501
Winch drive repair .......................................... 0303502
Transmission bump shifter
Remove and install ........................................ 0303151
Transmission charge pump
Remove and install ........................................ 0303601
Suction tube repair......................................... 0303608
Transmission charge pump drive
Repair ............................................................ 0303604
Transmission cold weathe disconnect
linkageif equipped
Remove and install ........................................ 0707522
Transmission cold weather disconnectjif
equipped
Repair ............................................................ 0707524
Transmission control solenoids
Repair ............................................................ 0303609
Transmission control valve
Repair ............................................................ 0303609
Transmission Gear Selector
Remove and install ........................................ 0303151
Transmission mount
Remove and install ........................................ 0303006
Transmission oil cooler
Remove and install ...................................... 05051010
Transmission suction tube
Repair ............................................................ 0303608
Transmissiontoengine drive shaft
Remove and install ........................................ 0303251
V
Valve
Priority valve disassemble and
assemble...................................................... 2121608
Continued on next page
TM11813 (13OCT10)
Index5
PN=5
Index
Page
Page
W
Water system, pressurizedif equipped
Disassemble and assemble ........................... 2020031
Welding.............................................................. 1717401
Wheel
Remove and install ........................................ 0101101
Wheel bolt torque
Dual wheels ................................................... 0101103
Wheel repair
Install duals .................................................... 0101103
Winch
Control cable, remove and install................... 3030152
Control linkage, remove and install................ 3030151
Drive shaft, disassemble and
assemble...................................................... 3030251
TM11813 (13OCT10)
Y
Yoke
Disassemble and assemble ........................... 3838038
Lubricate ........................................................ 3838037
Index6
PN=6
Index
TM11813 (13OCT10)
Index7
PN=7
Index
TM11813 (13OCT10)
Index8
PN=8