JD TM1404

450G, 455G, 550G,
555G, 650G Crawler

Repair
TECHNICAL MANUAL
450G, 455G, 550G, 555G, 650G
Crawler Repair
TM1404 14JUN11 (ENGLISH)
For complete service information also see:
450G, 455G, 550G, 555G, 650G

Operation and Test (Complete) .......................... TM1403
450G, 455G, 550G, 555G, 650G
Repair (Complete)................................................ TM1404
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. beginning of each group are summary listings of all
Essential tools required in performing certain service work applicable essential tools, service equipment and tools,
are identified in this manual and are recommended for other materials needed to do the job, service parts kits,
use. specifications, wear tolerances, and torque values.
Live with safety: Read the safety messages in the Technical Manuals are concise guides for specific
introduction of this manual and the cautions presented machines. They are onthejob guides containing only the
throughout the text of the manual. vital information needed for diagnosis, analysis, testing,
and repair.
This is the safetyalert symbol. When you see this Fundamental service information is available from other
symbol on the machine or in this manual, be alert to the sources covering basic theory of operation, fundamentals
potential for personal injury. of troubleshooting, general maintenance, and basic type
Technical manuals are divided in two parts: repair and of failures and their causes.
operation and tests. Repair sections tell how to repair See DB1990 Service Publications Catalog to order a
the components. Operation and tests sections help you Technical Manual (TM).
identify the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
TX,450GIFC 1916SEP931/1
Help!! Help!! Help!! Help!! P.O. Box 538

Dubuque, Iowa 520040538
We need your help to continually improve our technical Dept. 317
publications. Please FAX or mail your comments, ideas Attn: Publications Supervisor
and improvements.
FAX NUMBER: 5635895800
SEND TO: John Deere Dubuque Works
tm140400 450G/455G/550G/555G/650G Crawler General Info Repair Manual
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TX,INTR,RB241 1922JAN981/1
TM1404 (14JUN11) GSeries Crawlers

061411
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Contents
Section 00General Information Group 1673Lighting System
Group 0001Safety Information Group 1674Wiring Harness and Switches
Group 0002General Specifications Group 1676Instruments and Indicators
Group 0003Torque Values Group 1677Motors and Actuators
Group 0004Fuels and Lubricants
Section 17Frames, Chassis, or Supporting
Section 01Tracks Structure
Group 0130Track System Group 1740Frame Installation
Group 0199Dealer Fabricated Tools Group 1749Chassis Weights
Group 1799Dealer Fabricated Tools
Section 02Axles and Suspension Systems
Group 0250Axle Shaft, Bearings, and Reduction Section 18Operators Station
Gears Group 1800Removal and Installation
Group 0260Hydraulic System Group 1821Seat and Seat Belt
Section 19Sheet Metal and Styling
Section 03Transmission Group 1910Hood and Engine Enclosure
Group 0315Control Linkage Group 1913Miscellaneous Guards
Group 0325Input Drive Shafts and UJoints Group 1921Grille and Grille Housing
Group 0350Gears, Shafts, Bearings and Clutch Group 1927Fenders
Group 0360Hydraulic System
Group 0399Dealer Fabricated Tools Section 20Safety, Convenience and
Miscellaneous
Section 04Engine Group 2004Horn and Warning Devices
Group 0400Removal and Installation
Section 21Main Hydraulic System
Section 05Engine Auxiliary Systems Group 2160Hydraulic System
Group 0505Cold Weather Starting Aid
Group 0510Cooling System Section 31Loader
Group 0515Speed Controls and Fuel ShutOff Group 3102Bucket
Linkage Group 3115Controls Linkage
Group 0520Intake System Group 3140Frames
Group 0560External Fuel Supply System Group 3160Hydraulics
Section 06Torque Converter Section 32Bulldozer

Group 0600Removal and Installation Group 3201Blades
Group 0651Turbine, Gears and Shaft Group 3215Controls Linkage
Group 3240Frames
Section 07Dampener Drive Group 3260Hydraulic System
Section 33Backhoe
Section 09Steering Systems Group 3300Removal and Installation
Group 0920Power Steering Linkage Group 3302Buckets
Group 0960Hydraulic System Group 3315Controls Linkage
Group 3340Frames
Section 16Electrical System Group 3360Hydraulic System
Group 1671Batteries, Support and Cables
Group 1672Alternator, Regulator, and Charging
System Wiring
Original Instructions. All information, illustrations and specifications in this

manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT 2011
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright 1998, 1993,1992,1991,1988,1987,2003
TM1404 (14JUN11) i GSeries Crawlers

061411
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Contents
TM1404 (14JUN11) ii GSeries Crawlers

061411
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Section 00
General Information
Contents
Page Page
Group 0001Safety Information 550GLGP Drain and Refill

Handle Fluids SafelyAvoid Capacities............................................ 00000218
Fires....................................................... 0000011 555G Crawler Loader
Prevent Battery Explosions ....................... 0000011 Specifications ...................................... 00000219
Prepare for Emergencies........................... 0000011 555G Drain and Refill Capacities ............ 00000221
Prevent Acid Burns.................................... 0000012 650G Crawler Dozer
Handle Chemical Products Safely.............. 0000012 Specifications ...................................... 00000222
Avoid HighPressure Fluids ....................... 0000013 650G Drain and Refill Capacities ............ 00000224
Park Machine Safely.................................. 0000013 650GLGP Crawler Dozer
Support Machine Properly ......................... 0000013 Specifications ...................................... 00000225
Wear Protective Clothing........................... 0000014 650GLGP Drain and Refill
Work in Clean Area ................................... 0000014 Capacities............................................ 00000227
Service Machines Safely ........................... 0000014 9310 Backhoe Specifications .................. 00000227
Work In Ventilated Area............................. 0000015 9310 Backhoe Lift Capacity (G
Illuminate Work Area Safely ...................... 0000015 Series Loaders) ................................... 00000228
Replace Safety Signs ................................ 0000015 9310 Backhoe Lift Capacity
Use Proper Lifting Equipment.................... 0000016 (GSeries Dozers)................................ 00000229
Remove Paint Before Welding or
Heating .................................................. 0000016 Group 0003Torque Values
Avoid Heating Near Pressurized Specifications ............................................ 0000031
Fluid Lines ............................................. 0000016 Hardware Torque Specifications................ 0000031
Keep ROPS Installed Properly .................. 0000017 ROPS Torque Specifications ..................... 0000031
Service Tires Safely................................... 0000017 Checking Track Shoe Cap Screw
Avoid Harmful Asbestos Dust.................... 0000018 Torque.................................................... 0000032
Practice Safe Maintenance........................ 0000018 Unified Inch Bolt and Screw Torque
Use Proper Tools ....................................... 0000019 Values .................................................... 0000033
Dispose of Waste Properly ........................ 0000019 Metric Bolt and Screw Torque
Live With Safety......................................... 0000019 Values .................................................... 0000034
Additional Metric Cap Screw
Group 0002General Specifications Torque Values ........................................ 0000035
450G Crawler Dozer Check Oil Lines And Fittings ..................... 0000036
Specifications ........................................ 0000021 Service Recommendations for
450G Drain and Refill Capacities .............. 0000023 37 Flare and 30 Cone Seat
450GLT Crawler Dozer Connectors ............................................ 0000036
Specifications ........................................ 0000024 Service Recommendations for
450GLT Drain and Refill ORing Boss Fittings.............................. 0000037
Capacities.............................................. 0000026 Service Recommendations For
450GLGP Crawler Dozer Flat Face ORing Seal Fittings .............. 0000038
Specifications ........................................ 0000027 Service Recommendations For
450GLGP Drain and Refill Inch Series Four Bolt Flange
Capacities.............................................. 0000029 Fittings ................................................... 0000039
455G Crawler Loader Service Recommendations for
Specifications ...................................... 00000210 Metric Series Four Bolt Flange
455G Crawler Loader Fitting................................................... 00000310
Specificationscont. ........................... 00000212
455G Drain and Refill Capacities ............ 00000212 Group 0004Fuels and Lubricants
550GLT Crawler Dozer Fuel Specifications .................................... 0000041
Specifications ...................................... 00000213 Storing Fuel ............................................... 0000041
550GLT Drain and Refill Do Not Use Galvanized Containers...........0000041
Capacities............................................ 00000215 Diesel Engine Oil ....................................... 0000042
550GLGP Crawler Dozer Final Drive Oil ............................................ 0000043
Specifications ...................................... 00000216
Continued on next page
TM1404 (14JUN11) 001 GSeries Crawlers

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Contents
Page
Track Roller, Front Idler, and

Carrier Roller Oil.................................... 0000043
Transmission, Steering Clutches,
Hydraulic and Winch Oil ........................ 0000044
Grease....................................................... 0000045
Heavy Duty Diesel Engine
Coolant .................................................. 0000046
Alternative and Synthetic
Lubricants .............................................. 0000046
Lubricant Storage ...................................... 0000047

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Group 0001
Safety Information
Handle Fluids SafelyAvoid Fires
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
TS227 UN23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags they can ignite and burn
spontaneously.
DX,FLAME 1929SEP981/1
Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
TS204 UN23AUG88
Do not charge a frozen battery it may explode. Warm
battery to 16C (60F).
DX,SPARKS 1903MAR931/1
Prepare for Emergencies

Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your telephone.
TS291 UN23AUG88
DX,FIRE2 1903MAR931/1

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Safety Information
Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong
enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a wellventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 1530 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not
TS203 UN23AUG88
exceed 2 L (2 quarts).
3. Get medical attention immediately.
DX,POISON 1921APR931/1
Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
TS1132 UN26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDSs on chemical
products used with John Deere equipment.)
DX,MSDS,NA 1903MAR931/1

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Safety Information
Avoid HighPressure Fluids

Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
X9811 UN23AUG88
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from highpressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
with this type of injury should reference a knowledgeable
medical source. Such information is available in Moline, Illinois, U.S.A., by calling 18008228262 or +1
English from Deere & Company Medical Department in 3097485636.
DX,FLUID 1920AUG091/1
Park Machine Safely

Before working on the machine:
Lower all equipment to the ground.
Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.
TS230 UN24MAY89
DX,PARK 1904JUN901/1
Support Machine Properly

Always lower the attachment or implement to the ground
before you work on the machine. If the work requires
that the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
TS229 UN23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
When implements or attachments are used with a
machine, always follow safety precautions listed in the
implement or attachment operators manual.
DX,LOWER 1924FEB001/1

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Safety Information
Wear Protective Clothing

Wear close fitting clothing and safety equipment
appropriate to the job.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
TS206 UN23AUG88
while operating machine.
DX,WEAR2 1903MAR931/1
Work in Clean Area

Before starting a job:
Clean work area and machine.
Make sure you have all necessary tools to do your job.
Have the right parts on hand.
T6642EJ UN18OCT88
Read all instructions thoroughly do not attempt
shortcuts.
DX,CLEAN 1904JUN901/1
Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
TS228 UN23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
DX,LOOSE 1904JUN901/1

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PN=10
Safety Information
Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.
TS220 UN23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
DX,AIR 1917FEB991/1
Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use
a portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
TS223 UN23AUG88
DX,LIGHT 1904JUN901/1
Replace Safety Signs

Replace missing or damaged safety signs. See the
machine operators manual for correct safety sign
placement.
TS201 UN23AUG88
DX,SIGNS1 1904JUN901/1

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Safety Information
Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.
TS226 UN23AUG88
DX,LIFT 1904JUN901/1
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:
TS220 UN23AUG88
Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes Do all work in an area that is well ventilated to carry toxic
before welding or heating. fumes and dust away.
Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly.
will take place.
DX,PAINT 1924JUL021/1
Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders. Do not heat by welding, soldering,
or using a torch near pressurized fluid lines or other
flammable materials. Pressurized lines can accidentally
TS953 UN15MAY90
burst when heat goes beyond the immediate flame area.
DX,TORCH 1910DEC041/1

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Safety Information
Keep ROPS Installed Properly

Make certain all parts are reinstalled correctly if the
rollover protective structure (ROPS) is loosened or
removed for any reason. Tighten mounting bolts to proper
torque.
TS212 UN23AUG88
The protection offered by ROPS will be impaired if ROPS
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting. A damaged ROPS should be
replaced, not reused.
DX,ROPS3 1903MAR931/1
Service Tires Safely

Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the proper
equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clipon chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.
TS211 UN23AUG88
DX,RIM 1924AUG901/1

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PN=13
Safety Information
Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when
handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos
TS220 UN23AUG88
fibers are brake pads, brake band and lining assemblies,
clutch plates, and some gaskets. The asbestos used in
these components is usually found in a resin or sealed in
some way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator.
A special vacuum cleaner is recommended to clean Keep bystanders away from the area.
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
DX,DUST 1915MAR911/1
Practice Safe Maintenance

Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet , and clothing from powerdriven
parts. Disengage all power and operate controls to relieve
pressure. Lower equipment to the ground. Stop the
engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On selfpropelled equipment, disconnect battery ground
cable () before making adjustments on electrical systems
or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.
TS218 UN23AUG88
DX,SERV 1917FEB991/1

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Safety Information
Use Proper Tools

Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.
TS779 UN08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR 1917FEB991/1
Dispose of Waste Properly

Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
TS1133 UN26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN 1903MAR931/1
Live With Safety

Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
TS231 1907OCT88
DX,LIVE 1925SEP921/1

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Group 0002
General Specifications
450G Crawler Dozer Specifications
T7347AC UN23JUL90
NOTE: Specifications and design subject to change structure, full fuel tank, 80 kg (175 lb) operator,
without notice. Whenever applicable, specifications and standard equipment.
are in accordance with ICED and SAE standards.
Except where otherwise noted, these specifications Blade capacity shown is for a 2230 mm (7 ft
are based on a unit with rollover protective 3.8 in.) blade. All blades are interchangeable
between the 450G, 550G, and the 650G.
Item Measurement Specification
Operator Weight 80 kg (175 lb)

Blade Angled Width 2230 mm (7 ft 3.8 in.)
ACanopy extension 60 mm (2.4 in.)
BCanopy height 2.70 m (8 ft 10 in.)
CBlade height 827 mm (2 ft 8.6 in.)
DBlade lift height 815 mm (2 ft 8.1 in.)
EDigging depth 504 mm (1 ft 7.9 in.)
FBlade tilt (right side):
Standard blade 330 mm (1 ft 1 in.)
Wide blade 391 mm (1 ft 3.4 in.)
GBlade tilt (left side):
HDrawbar extension 280 mm (11 in.)
IOverall length 3917 mm (12 ft 10.2 in.)
JBlade width:
Standard blade (angled width) 2230 mm (7 ft 3.8 in.)
Wide blade (angled width) 2686 mm (8 ft 9.7 in.)
Standard 2464 mm (8 ft 1 in.)
Wide 2921 mm (9 ft 7 in.)
Continued on next page TX,115,FF1816 1912JAN931/2

061411
PN=16
Track gauge: 1450 mm (57 in.)

Blade capacity:
3 3
Standard blade 1.3 m (1.63 yd )
3 3
Wide blade 1.6 m (2.1 yd )
Engine: John Deere 4045D (Direct Drive only) or 4045T (S.N. 840460) or John Deere PowerTech 4.5L engine type 4045TT061 (S.N. 840461 )
Type Naturally aspirated (4045D) altitude compensating
turbocharge (4045T)
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Fuel consumption, typical (S.N. 840460) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Fuel consumption, typical (S.N. 840461 ) 6.3 to 9.5 L/h (1.7 to 2.5 gal/hr)
Compression ratio (S.N. 840460) 17.8 to 1
Compression ratio (S.N. 840461 ) 17 to 1
Electrical system 12 volt (with battery disconnect switch, if equipped)
Battery 12 volt
Alternator 65 amp
SAE net power at 2100 rpm 52 kW (70 hp)
SAE gross power at 2100 rpm 54.5 kW (73 hp)
Maximum net torque at 1300 rpm 309 Nm (228 lbft)
Drawbar 38 kW (51 hp)
Displacement (S.N. 840460) 4.524 L (276 cu in.)
Displacement (S.N. 840461 ) 4.5 L
Transmission: Powershift (4F4R) with torque converter or direct drive. Full power shift, DuraShift with torque converter or direct drive, designed
and built by John Deere. You can power shift easily from one gear to another as conditions change without stopping the machine or using a clutch.
Power control inching pedal adds versatility. Four speeds forward and reverse allow the operator to match speeds to the working conditions.
Hydraulic pump: Gear

Pressure 18 961 kPa (2750 psi)
Flow at 2100 rpm 64 L/min (17 gpm)
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Grouser, closedcenter 406 mm (16 in.)
Track shoes, each side 37
2 2
Ground contact area 15 690 cm (2432 in. )
Ground pressure (direct drive) 44.6 kPa (6.47 psi)
Ground pressure (torque converter) 45.2 kPa (6.55 psi)
Operating Weight (with ROPS):

Direct Drive 7152 kg (15 732 lb)
Torque Converter 7243 kg (15 932 lb)
450GTC with Wide Shoes (Direct Drive) 7586 kg (16 688 lb)
450GTC with Wide Shoes (Torque Converter) 7677 kg (16 888 lb)
TX,115,FF1816 1912JAN932/2

061411
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450G Drain and Refill Capacities

Metric English
Fuel tank 155 L 41 gal
Engine coolant 17 L 18 qt
Engine oil, including filter change (S.N. 840460) 8.5 L 9 qt
Engine oil, including filter change (S.N. 840461 ) 14 L 14.8 qt
Transmission:
Transmission, direct drive (S.N. 790984) 80.25 L 21.2 gal add 34 L (9 gal) w/winch if equipped
Transmission, direct drive (S.N. 790985 ) 102 L 27 gal add 34 L (9 gal) w/winch if equipped
Transmission, torque converter 102 L 27 gal add 34 L (9 gal) w/winch if equipped
Hydraulic reservoir 38 L 10 gal
Hydraulic system 55.3 L 14.6 gal
Final drive (each side) 6.6 L 7 qt
TX,115,FF1917 1908OCT931/1

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450GLT Crawler Dozer Specifications
T7347AC UN23JUL90

JBlade width:

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Blade capacity:
3 3
3 3
Type Naturally aspirated (4045D) or altitute compensating
turbocharge (4045T)
No. of cylinders 4
Battery 12 volt
Alternator (S.N. 840460) 65 amp
Alternator (S.N. 840461 ) 95 amp

Steering:
Brakes Wet band
Undercarriage:
2 2

TX,115,FF1816 1912JAN932/2

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450GLT Drain and Refill Capacities

Metric English
Transmission:
Transmission, direct drive (S.N.790985 ) 102 L 27 gal add 34 L (9 gal) w/winch if equipped
TX,115,FF1917 1908OCT931/1

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450GLGP Crawler Dozer Specifications
T7347AC UN23JUL90

JBlade width:

061411
PN=22

Blade capacity:
3 3
3 3
Type Naturally aspirated or altitude compensating turbocharge
No. of cylinders 4
Battery 12 volt
Alternator 65 amp

Steering:
Brakes Wet band
Undercarriage:
2 2

450GLGP Direct Drive 7833 kg (17 232 lb)
450GLGP Torque Converter 7924 kg (17 432 lb)
TX,115,FF1816 1912JAN932/2

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450GLGP Drain and Refill Capacities

Metric English
Transmission:
TX,115,FF1917 1908OCT931/1

061411
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455G Crawler Loader Specifications
T8196BD UN14APR94
NOTE: Specifications and design subject to change are based on a machine with rollover protective
without notice. Wherever applicable, specifications structure, full fuel tank, 80 kg (175 lb) operator,
are in accordance with ICED and SAE Standards. and standard equipment.
Except where otherwise noted, these specifications

Standard Track WideTrack Multipurpose
ACanopy top 60 mm (2.4 in.) 60 mm (2.4 in.) 60 mm (2.4 in.)
BOverall height:
Standard height ROPS 2708 mm (106.6 in.) 2708 mm (106.6 in.) 2708 mm (106.6 in.)
Lowprofile ROPS 2588 mm (101.9 in.) 2588 mm (101.9 in.) 2588 mm (101.9 in.)
Cab 2769 mm (109 in.) 2769 mm (109 in.) 2769 mm (109 in.)
CDump clearance, maximum height (45 discharge) 2620 mm (103.1 in.) 2635 mm (103.7 in.) 2485 mm (97.8 in.)
DDigging depth 135 mm (5.3 in.) 135 mm (5.3 in.) 135 mm (5.3 in.)
EHeight to hinge pin 3251 mm (128 in.) 3251 mm (128 in.) 3251 mm (128 in.)
FTow bar 533 mm (1 ft 9 in.) 533 mm (1 ft 9 in.) 533 mm (1 ft 9 in.)
GaOverall length 4564 mm (179.7 in.) 4448 mm (175.1 in.) 4638 mm (182.6 in.)
HReach at max height (45discharge) 871 mm (34.3 in.) 773 mm (30.4 in.) 880 mm (34.6 in.)
IMaximum operating height 4285 mm (168.7 in.) 4169 mm (164.1 in.) 4304 mm (169.4 in.)
Track gauge:
Standard Track 1450 mm (57 in.)
Wide Track 1727 mm (68 in.)
a
Includes 2 counterweights. Each counterweight is 50.5 mm (2 in.) thick.
Engine:
Type (S.N. 840460) John Deere 4045T and 4045D
Type (S.N. 840461 ) John Deere 4.5 L engine type 4045TT067
Continued on next page TX,9000,RB178 1914JUN111/2

061411
PN=25
Rated power at 2100 rpm SAE net 52.2 kW (70 hp)

SAE gross 54.5 kW (73 hp)
No. of cylinders 4
Electrical system 12 volt (with battery disconnect switch if equipped)
Alternator 65 amp
Cooling system pressure 69 kPa (10 psi)
Transmission: Full power shift, DuraShift direct drive transmission is designed and built by John Deere. You can power shift easily from one gear
to another as conditions change without stopping the machine or using a clutch. Power control inching pedal adds versatility. Four speeds forward
and reverse allow the operator to match speeds to the working conditions.
Hydraulics:
Pump Gear
Cylinders:
Boom (bore x stroke) 100 mm (3.93 in.) x 827 mm (32.55 in.)
Bucket (bore x stroke) 90 mm (3.5 in.) x 744 mm (29.30 in.)
Cylinder rod dia. 50 mm (1.96 in.)
Steering:
Clutches Wet multiple disks
Brakes Wet band
Undercarriage:
Standard Track:
Twobar grouser, closedcenter 356 mm (14 in.)
Ground clearance 330 mm (13 in.)
No. of track rollers 5
2 2
Ground pressure, Direct Drive 60.1 kPa (8.71 psi)
Ground pressure, Torque Converter 60.7 kPa (8.8 psi)
Carrier roller 1
Wide Track:
Twobar grouser, closed center 533 mm (21 in.)
Ground clearance 330 mm (13 in.)
2 2
Carrier roller 1
TX,9000,RB178 1914JUN112/2

061411
PN=26
455G Crawler Loader Specificationscont.

General Purpose
a b
Bucket Type Wide Track Standard Multipurpose
3 3 3
Capacity, heaped, SAE 1.0 m (1.3 cu yd) 1.0 m (1.3 cu yd) 1.0 m (1.3 cu yd)
Capacity, struck, SAE 0.79 m 3 (1.03 cu yd) 0.80 m 3 (1.05 cu yd) 0.80 m 3 (1.05 cu yd)
Bucket width 2.4 m (92.1 in.) 1.91 m (75.4 in.) 1.90 m (74.8 in.)
Bucket weight, w/teeth 546 kg (1204 lb) 477 kg (1053 lb) 989 kg (2180 lb)
Breakout force, SAE 78.3 kN (17 600 lb) 70 kN (15 735 lb) 59.6 kN (13 400 lb)
Bucket raise time 6.5 sec 6.5 sec 6.6 sec
Bucket dump time 1.5 sec 1.5 sec 1.5 sec
Bucket lower time 2.7 sec 2.7 sec 2.3 sec
a
With three counterweights, zero sprocket weight
b
With four counterweights and two spocket weights
Maximum Travel Speeds
455G Loader:
Forward Gear
Speeds: km/h mph
1 3.7 2.3
2 5.3 3.3
3 6.6 4.1
4 9.5 5.9
Reverse Gear
Speeds: km/h mph
1 4.0 2.5
2 5.8 3.6
3 7.2 4.5
4 10.3 6.4
Operating Weight:
Standard Track w/ROPS 8503 kg (18 745 lb)
Wide Track w/ROPS 8866 kg (19 545 lb)
Adjustment to operating weights:
Cab add 306 kg (676 lb)
Bucket teeth, bolton minus 63 kg (139 lb)
Radial ripper w/3shanks, w/o drawbar and counterweight add 32 kg (70 lb)
Counterweight add 136 kg (300 lb)
TX,115,RR3026 1914APR941/1

Metric English
Engine oil, including filter change (S.N. 840461 ) 14 L 15 qt
Transmission 102 L 27 gal
add 34 L (9 gal) w/winch if equipped
Hydraulic reservoir 37.8 L 10 gal
TX,115,RR3044 1914APR941/1

061411
PN=27
550GLT Crawler Dozer Specifications
T7347AC UN23JUL90

Standard blade 357 mm (1 ft 2.1 in.)
JBlade width:

061411
PN=28

Blade capacity:
3 3
3 3
Engine: John Deere 4045T (S.N. 840460) or John Deere PowerTech 4.5L engine type 4045TT062 (S.N. 840461 )
Type Turbocharged
No. of cylinders 4
Fuel consumption, typical (S.N. 840460) 7.0 to 10.5 L/h (1.8 to 2.8 gal/h)
Fuel consumption, typical (S.N. 840461 ) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Battery 12 volt
SAE net power at 2100 rpm 59.5 kW (80 hp)
SAE gross power at 2100 rpm 62 kW (83 hp)

Steering:
Brakes Wet band
Undercarriage:
2 2

TX,115,FF1816 1912JAN932/2

061411
PN=29
550GLT Drain and Refill Capacities

Metric English
Transmission:
TX,115,FF1917 1908OCT931/1

061411
PN=30
T7347AC UN23JUL90

JBlade width:

061411
PN=31

Blade capacity:
3 3
3 3
Type Turbocharged
No. of cylinders 4
Battery 12 volt
SAE gross power at 2100 rpm 62 kW (83 hp)

Steering:
Brakes Wet band
Undercarriage:
2 2
Ground contact arean 26 447 cm (4099 in. )

TX,115,FF1816 1912JAN932/2

061411
PN=32

Metric English
Transmission:
TX,115,FF1917 1908OCT931/1

061411
PN=33
555G Crawler Loader Specifications
T8196BD UN14APR94
NOTE: Specifications and design subject to change are based on a machine with rollover protective
without notice. Wherever applicable, specifications structure, full fuel tank, 80 kg (175 lb) operator,
are in accordance with ICED and SAE Standards. and standard equipment.
Except where otherwise noted, these specifications

a
Standard Track WideTrack Multipurpose
ACanopy top 60 mm (2.4 in.) 60 mm (2.4 in.) 60 mm (2.4 in.)
BOverall height:
Standard height ROPS 2819 mm (111 in.) 2819 mm (111 in.) 2819 mm (111 in.)
Lowprofile ROPS 2699 mm (106.3 in.) 2699 mm (106.3 in.) 2699 mm (106.3 in.)
Cab 2845 mm (112 in.) 2845 mm (112 in.) 2845 mm (112 in.)
CDump clearance, maximum height (45 discharge) 2670 mm (105.1 in.) 2700 mm (106.3 in.) 2695 mm (106.1 in.)
DDigging depth 135 mm (5.3 in.) 135 mm (5.3 in.) 135 mm (5.3 in.)
EHeight to hinge pin 3340 mm (131.5 in.) 3340 mm (131.5 in.) 3340 mm (131.5 in.)
FTow bar 414 mm (1 ft 4.3 in.) 414 mm (1 ft 4.3 in.) 414 mm (1 ft 4.3 in.)
GaOverall length 4628 mm (182.2 in.) 4559 mm (179.5 in.) 4696 mm (184.9 in.)
HReach at max height (45discharge) 868 mm (34.2 in.) 780 mm (30.7 in.) 863 mm (34 in.)
IMaximum operating height 4424 mm (174.1 in.) 4334 mm (170.6 in.) 4430 mm (174.4 in.)
Track gauge:
Standard Track 1450 mm (57 in.)
Wide Track 1727 mm (68 in.)
a
Includes two counterweights. Each counterweight is 50.5 mm (2 in.) thick.
Engine:
Type (S.N. 840460) John Deere 4045T and 4045D
Type (S.N. 846461 ) John Deere 4.5 L engine type 4045TT063

061411
PN=34
SAE net power at 2100 rpm SAE net 67.1 kW (90 hp)
SAE gross 74 kW (99 hp)
No. of cylinders 4
Electrical system 12 volt (with battery disconnect switch if equipped)
Battery 12 volt
Alternator 65 amp
Maximum net torque rise at 1300 rpm 339 Nm (250 lbft)
Transmission: Full power shift, DuraShift direct drive transmission is designed and built by John Deere. Four speeds forward and reverse
allow the operator to match speeds to the working conditions. Shift easily from one gear to another as conditions change without stopping the
machine or using a clutch. Power control inching pedal adds versatility.
Maximum Travel Speeds

555G Loader:
Forward Gear Speeds: km/h mph
1 3.7 2.3
2 5.3 3.3
3 6.5 4.1
4 9.4 5.8
Reverse Gear Speeds: km/h mph
1 4.0 2.5
2 5.8 3.6
3 7.1 4.4
4 10.2 6.3
Hydraulics:
Pump Gear
Pressure 17927 kPa (2600 psi)
Flow 148 L/min (39 gpm)
Cylinders:
Boom (bore x stroke) 115 mm (4.53 in.) x 811 mm (31.93 in.)
Bucket (bore x stroke) 100 mm (3.94 in.) x 744 mm (29.30 in.)
Bucket cylinder rod dia. 50 mm (1.96 in.)
Boom cylinder rod dia. 63 mm (2.48 in.)
Steering:
Brakes Wet band
Undercarriage:
Standard Track:
Twobar grouser, closedcenter 410 mm (16 in.)
Ground clearance 362 mm (14.25 in.)
2 2
Ground pressure, Direct Drive 57 kPa (8.27 psi)
Carrier roller 1
Track gauge 1550 mm (61 in.)
Wide Track:

061411
PN=35
Twobar grouser, closed center 610 mm (24 in.)

Ground clearance 375 mm (14.75 in.)
2 2
Carrier roller 1
Track gauge 1753 mm (69 in.)
Operating Weight with ROPS:

555G Standard Track, Direct Drive 9461 kg (20 858 lb)
555G Standard Track, Torque Converter 9552 kg (21 058 lb)
Loader Operating Information:

Bucket type Standard Track WideTrack Multipurpose
Bucket width 2.09 m (82.5 in.) 2.42 m (95.1 in.) 2.08 m (82.0 in.)
Bucket weight, w/teeth 567 kg (1250 lb) 694 kg (1530 lb) 1052 kg (2320 lb)
Breakout force, SAE 90.0 kN (20 250 lb) 97.0 kN (21 900 lb) 81.4 kN (18 300 lb)
Bucket raise time 6.5 sec 6.5 sec 6.6 sec
Bucket dump time 1.6 sec 1.6 sec 1.6 sec
Bucket lower time 3.8 sec 3.8 sec 3.4 sec
TX,9000,RB179 1914JUN113/3

Metric English
Engine oil, including filter change (S.N. 840461 ) 14 L 15 qt
Transmission 102 L 27 gal
add 34 L (9 gal) w/winch if equipped
Hydraulic reservoir 37.8 L 10 gal
TX,9000,RB180 1906JAN981/1

061411
PN=36
650G Crawler Dozer Specifications
T7347AC UN23JUL90

BCanopy height 2794 mm (9 ft 2 in.)
IOverall length 4070 mm (13 ft 4 in.)
JBlade width:

061411
PN=37

Blade capacity:
3 3
3 3
Type Turbocharged
No. of cylinders 4
Battery 12 volt
SAE gross power at 2100 rpm (direct drive) 71 kW (95 hp)
SAE gross power at 2100 rpm (torque converter) 74 kW (99 hp)

Steering:
Brakes Wet band
Undercarriage:
2 2

TX,115,FF1816 1912JAN932/2

061411
PN=38

Metric English
Transmission:
Hydraulic system 56.8 L 15 gal
TX,115,FF1917 1908OCT931/1

061411
PN=39
T7347AC UN23JUL90

BCanopy height 2794 mm (9 ft 2 in.)
IOverall length 4070 mm (13 ft 4 in.)
JBlade width:

061411
PN=40

Blade capacity:
3 3
3 3
Type Turbocharged
No. of cylinders 4
Battery 12 volt
SAE gross power at 2100 rpm (direct drive) 71 kW (95 hp)
SAE gross power at 2100 rpm (torque converter) 74 kW (99 hp)

Steering:
Brakes Wet band
Undercarriage:
Grouser, closedcenter (standard shoe) 610 mm (24 in.)
Grouser, closedcenter (wide shoe) 660 mm (26 in.)
2 2
Ground contact area (standard shoe) 26 510 cm (4109 in. )
2
Ground contact area (wide shoe) 28 717 cm (4451 in. 2)
Ground pressure (direct drive, standard shoe) 32.1 kPa (4.65 psi)
Ground pressure (torque converter, standard shoe) 32.4 kPa (4.70 psi)
Ground pressure (direct drive, wide shoe) 30.4 kPa (4.41 psi)
Ground pressure (torque converter, wide shoe 30.7 kPa (4.45 psi)

TX,115,FF1816 1912JAN932/2

061411
PN=41

Metric English
Transmission:
Hydraulic system 56.8 L 15 gal
TX,115,FF1917 1908OCT931/1
9310 Backhoe Specifications

A 3.25 m (10 ft 8 in.)
B 5.30 m (17 ft 4.5 in.)
CFlat Bottom 4.00 m (13 ft 1.2 in.)
2440 mm (8 ft)
DFlat Bottom 4.35 m (14 ft 3.4 in.)
610 mm (2 ft)
E 4.40 m (14 ft 5.3 in.)
T7394BK UN20DEC90
TX,115,FF2056 1914APR941/1

061411
PN=42
9310 Backhoe Lift Capacity (G Series Loaders)
T7395DA 1912OCT90
A1700 kg (3750 lb) F 910 kg (2010 lb) K795 kg (1755 lb) P785 kg (1730 lb)
B1525 kg (3365 lb) G900 kg (1990 lb) L 770 kg (1700 lb) QDipper Lift, Boom at 65
C1530 kg (3370 lb) H880 kg (1940 lb) M750 kg (1660 lb) RSwing Pivot
D1640 kg (3620 lb) I 850 kg (1880 lb) N740 kg (1630 lb) SBoom Lift
E880 kg (1950 lb) J 820 kg (1814 lb) O740 kg (1630 lb)
Lifting capacity ratings made from bucket hinge pin, Specification

loader bucket and stabilizer on firm, level ground. Lifting Trenching
capacities are 87 percent of the maximum lift over any BucketLength............................................................... 610 mm (24 in.)
point on the swing arc and do not exceed 75 percent of
the tipping load. Angle between boom and ground at
65 degrees. Machine equipped with 610 mm (24 in.)
trenching bucket and standard dipperstick.
TX,115,FF2057 1908FEB931/1

061411
PN=43
9310 Backhoe Lift Capacity (GSeries Dozers)
T7395DA1 UN12DEC92
A1700 kg (3750 lb) F 960 kg (2120 lb) K845 kg (1865 lb) P835 kg (1845 lb)
B1525 kg (3365 lb) G955 kg (2105 lb) L 820 kg (1810 lb) QDipper Lift, Boom at 65
C1530 kg (3370 lb) H930 kg (2050 lb) M800 kg (1765 lb) RSwing Pivot
D1670 kg (3685 lb) I 900 kg (1990 lb) N790 kg (1740 lb) SBoom Lift
E930 kg (2050 lb) J 870 kg (1925 lb) O790 kg (1740 lb)
Lifting capacity ratings made from bucket hinge pin,

Specification
loader bucket and stabilizer on firm, level ground. Lifting
Trenching
capacities are 87 of the maximum lift over any point on
BucketLength............................................................... 610 mm (24 in.)
the swing arc and do not exceed 75 of the tipping load.
Angle between boom and ground at 65 degrees. Machine
equipped with 610 mm (24 in.) trenching bucket and
standard dipperstick.
TX,115,FF2058 1912JAN931/1

061411
PN=44
Group 0003
Torque Values
Specifications
RollOver Protective Structure Torque 410 82 Nm (300 60 lbft)

Mounting Bolts
Track Shoe Cap Screw Torque 149 Nm (100 lbft)
TX,00,RB401 1930JAN981/1
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.
T82,SKMA,AT 1901AUG941/1
ROPS Torque Specifications
CAUTION: Make certain all parts are reinstalled

correctly if the rollover protective structure
(ROPS) is loosened or removed for any reason.
Tighten mounting bolts to proper torque.
TS176 UN23AUG88
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident,
or is in any way altered. A damaged ROPS
should be replaced, not reused.
When installation of equipment on a machine necessitates

loosening or removing ROPS, mounting bolts must be
tightened to 410 82 Nm (300 60 lbft).
ROPS Mounting Bolts Torque 410 82 Nm (300 60 lbft)

CED,OUTX782,575 1927JUL991/1

061411
PN=45
Torque Values
Checking Track Shoe Cap Screw Torque

Track shoe cap screw torque should be periodically
checked. If the cap screws do not meet the minimum
torque specifications, remove the shoes and clean the
mating surfaces of the shoes and links before tightening
the cap screws.
T82862 UN08NOV88
If machine is operated with loose track shoes, the cap
screw holes in the shoes and links will wear and it may be
difficult to keep the track shoes tight. Loose shoes can
also cause hardware failure and loss of track shoes.
Install all track shoe nuts with rounded edges (A) against
the link and chamfered edges (B) away from the link. Be
sure nut is properly positioned in the link so there is full
contact area between the nut and the link.
450G, 455G, 550GSpecification
Track Shoe Cap
Screw(1/2
T6794AM UN23FEB89
in.)Torque........................................................61 Nm (45 lbft) second
passadditional 1/3 (120) turn
Track Shoe Cap
Screw(9/16
in.)Torque........................................................88 Nm (65 lbft) second
555G, 650GSpecification
Track Shoe Cap
Screw(5/8 ARounded Edge BChamfered Edge
in.)Torque.................................................... 149 Nm (110 lbft) second
450G, 455G, 550GSpecification 555G, 650GSpecification
Track Shoe/Split Link Track Shoe/Split Link
Cap Screw(1/2 Cap Screw(5/8
in.)Torque........................................................61 Nm (45 lbft) second in.)Torque.................................................... 149 Nm (110 lbft) second
passadditional 1/2 (180) turn passadditional 1/2 (180) turn
Track Shoe/Split Link
Cap Screw(9/16 NOTE: Replacement hardware should be lubricated
in.)Torque........................................................88 Nm (65 lbft) second and tightened to above specification.
TX,90,RR2494 1903AUG921/1

061411
PN=46
Torque Values
Unified Inch Bolt and Screw Torque Values

TS1671 UN01MAY03
Bolt or Screw SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c
Size Lubricated Dry Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
Nm lb.ft. Nm lb.ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
Nm lb.ft. Nm lb.ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
Nm lb.ft. Nm lb.ft. Nm lb.ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
Nm lb.ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
11/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
11/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
13/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
11/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt Replace fasteners with the same or higher grade. If higher
or screw. DO NOT use these values if a different torque value or tightening grade fasteners are used, tighten these to the strength of the
procedure is given for a specific application. For plastic insert or crimped steel original. Make sure fastener threads are clean and that you
type lock nuts, for stainless steel fasteners, or for nuts on Ubolts, see the properly start thread engagement. When possible, lubricate
tightening instructions for the specific application. Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts, wheel bolts
under predetermined loads. Always replace shear bolts with identical grade. or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
b
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
c
Dry means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ1 1912JAN111/1

061411
PN=47
Torque Values
Metric Bolt and Screw Torque Values

TS1670 UN01MAY03
4.8 8.8 9.8 10.9 12.9 12.9
4.8 8.8 9.8 10.9 12.9 12.9
Bolt or Screw Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
Nm lb.ft. Nm lb.ft. Nm lb.ft. Nm lb.ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
Nm lb.ft. Nm lb.ft. Nm lb.ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
Nm lb.ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength of Shear bolts are designed to fail under predetermined loads. Always
the bolt or screw. DO NOT use these values if a different torque value or replace shear bolts with identical property class. Replace fasteners with
tightening procedure is given for a specific application. For stainless steel the same or higher property class. If higher property class fasteners are
fasteners or for nuts on Ubolts, see the tightening instructions for the used, tighten these to the strength of the original. Make sure fastener
specific application. Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement. When
by turning the nut to the dry torque shown in the chart, unless different possible, lubricate plain or zinc plated fasteners other than lock nuts,
instructions are given for the specific application. wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
b
Dry means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ2 1912JAN111/1

061411
PN=48
Torque Values
Additional Metric Cap Screw Torque Values
T6873AA UN18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly.
They may slip and cause injury.
Check tightness of cap screws periodically. Torque values

listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
Shear bolts are designed to fail under predetermined
T6873AB UN18OCT88
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
Make sure fastener threads are clean and you properly
start thread engagement. This will prevent them from
failing when tightening.
T6873AC UN18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
METRIC CAP SCREW TORQUE VALUESa
TBolt HBolt MBolt
Nomi
nal Dia Nm lbft Nm lbft Nm lbft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is 10%.
04T,90,M170 1929SEP991/1

061411
PN=49
Torque Values
Check Oil Lines And Fittings
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
disconnecting hydraulic or other lines. Tighten
X9811 UN23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this
type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other Tubing with dents may cause the oil to overheat. If you
knowledgeable medical source. find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified
Check all oil lines, hoses, and fittings regularly for leaks or in torque chart.
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving When you tighten connections, use two wrenches to
machine parts. If abrasion or wear occurs, replace prevent bending or breaking tubing and fittings.
immediately.
T82,FLMA,AI 1914MAR901/1
Service Recommendations for 37 Flare and

30 Cone Seat Connectors
1. Inspect flare and flare seat. They must be free of dirt
or obvious defects.
2. Defects in tube flare cannot be repaired.
T6234AC UN18OCT88
Overtightening a defective flared fitting will not stop
leaks.
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or
petroleum jelly.
5. Index angle fittings and tighten by hand.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
6. Tighten fitting or nut to torque value shown on torque Thread Size Nm lbft
chart. Do not allow hoses to twist when tightening
3/8 24 UNF 8 6
fittings.
7/16 20 UNF 12 9
1/2 20 UNF 16 12
9/16 18 UNF 24 18
3/4 16 UNF 46 34
7/8 14 UNF 62 46
11/16 12 UN 102 75
13/16 12 UN 122 90
15/16 12 UN 142 105
15/8 12 190 140
17/8 12 UN 217 160
NOTE: Torque tolerance is 10%.
T82,BHMA,EL 1929SEP991/1

061411
PN=50
Torque Values
Service Recommendations for ORing Boss

Fittings
Straight Fitting
1. Inspect Oring boss seat for dirt or defects.
T6243AE UN18OCT88
2. Lubricate Oring with petroleum jelly. Place electrical
tape over threads to protect Oring. Slide Oring over
tape and into Oring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
04T,90,K66 1929SEP991/2
Angle Fitting
1. Backoff lock nut (A) and backup washer (B)
completely to headend (C) of fitting.
2. Turn fitting into threaded boss until backup washer
contacts face of boss.
T6520AB UN18OCT88
3. Turn fitting headend counterclockwise to proper index
(maximum of one turn).
NOTE: Do not allow hoses to twist when tightening fittings.
4. Hold fitting headend with a wrench and tighten locknut

and backup washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size Nm lbft
3/824 UNF 8 6
7/1620 UNF 12 9
1/220 UNF 16 12
9/1618 UNF 24 18
3/416 UNF 46 34
7/814 UNF 62 46
11/1612 UN 102 75
13/1612 UN 122 90
15/1612 UN 142 105
15/812 UN 190 140
17/812 UN 217 160
NOTE: Torque tolerance is 10%.
04T,90,K66 1929SEP992/2

061411
PN=51
Torque Values
Service Recommendations For Flat Face 4. Tighten fitting or nut to torque value shown on the
ORing Seal Fittings chart. Do not allow hoses to twist when tightening
1. Inspect the fitting sealing surfaces and Oring. They fittings, use backup wrench on straight hose couplings.
must be free of dirt or defects. IMPORTANT: Tighten fittings to 150% of listed torque
2. Lubricate Orings and install into grove using value if indexing is necessary or if fitting is
petroleum jelly to hold in place. attached to an actuating device.
3. Index angle fittings and tighten by hand pressing joint Tighten fittings to 50% of listed torque value
together to insure Oring remains in place. if used in aluminum housing.
FLAT FACE ORING SEAL FITTING TORQUE*

Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. Nm lbft Nm lbft
6.35 0.250 9/1618 16 12 12 9
9.52 0.375 11/1616 24 18 24 18
12.70 0.500 13/1616 50 37 46 34
15.88 0.625 114 69 51 62 46
19.05 0.750 1 3/1612 102 75 102 75
22.22 0.875 1 3/1612 102 75 102 75
25.40 1.000 1 7/1612 142 105 142 105
31.75 1.250 1 11/1612 190 140 190 140
38.10 1.500 212 217 160 217 160
*Torque tolerance is +15 20% unless otherwise specified.
Stud End Oring Seal Torque for Straight and Adjustable Fittings*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch Nm lbft
3/824 5/8 9/16 12 9
7/1620 5/8 5/8 21 15
1/220 3/4 11/16 26 19
9/1618 3/4 3/4 34 25
3/416 7/8 15/16 73 55
7/814 1 1/16 1 1/16 104 76
1 1/1612 1 1/4 1 3/8 176 130
1 3/1612 1 3/8 1 1/2 230 170
1 5/1612 1 1/2 1 5/8 285 210
*Torque tolerance is +15 20% unless otherwise specified.
OUO6092,00010A4 1931MAY111/1

061411
PN=52
Torque Values
Service Recommendations For Inch Series Four Bolt Flange Fittings
T6890BB UN01MAR90
ASealing Surface BSplit Flange CPinched ORing DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause TORQUE CHART

leaks. Roughness causes seal wear. Outofflat Nm lbft
causes seal extrusion. If defects cannot be polished Nominal Cap Screw
out, replace component. Flange Size
Size Min Max Min Max
2. Install Oring (and backup washer if required) into 1/2 5/1618 UNC 20 31 15 23
groove using petroleum jelly to hold it in place.
3/4 3/816 UNC 28 54 21 40
3. Split flange: Loosely assemble split flange (B) halves. 1 3/816 UNC 37 54 27 40
Make sure split is centrally located and perpendicular 11/4 7/1614 UNC 47 85 35 63
to port. Hand tighten cap screws to hold parts in place. 11/2 1/213 UNC 62 131 46 97
Do not pinch Oring (C).
2 1/213 UNC 73 131 54 97
4. Single piece flange (D): Place hydraulic line in center 21/2 1/213 UNC 107 131 79 97
of flange and install cap screws. Flange must be 3 5/811 UNC 158 264 117 195
centrally located on port. Hand tighten cap screws to 31/2 5/811 UNC 158 264 117 195
hold flange in place. Do not pinch Oring.
4 5/811 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 5 5/811 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.
DO NOT use air wrenches. DO NOT tighten one cap
screw fully before tightening the others. DO NOT over
tighten.
04T,90,K174 1901AUG941/1

061411
PN=53
Torque Values
Service Recommendations for Metric Series Four Bolt Flange Fitting
T6890BB UN01MAR90
ASealing Surface BSplit Flange CPinched ORing DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause

DO NOT use air wrenches. DO NOT tighten one cap
leaks. Roughness causes seal wear. Outofflat
screw fully before tightening the others. DO NOT over
causes seal extrusion. If defects cannot be polished
tighten.
out, replace component.
TORQUE CHARTa
2. Install the correct Oring (and backup washer if Thread b
Nm lbft
required) into groove using petroleum jelly to hold it
M6 12 9
in place.
M8 30 22
3. Split flange: Loosely assemble split flange (B) halves. M10 57 42
Make sure split is centrally located and perpendicular M12 95 70
to the port. Hand tighten cap screws to hold parts in
M14 157 116
place. Do not pinch Oring (C).
M16 217 160
4. Single piece flange (D): Place hydraulic line in center M18 334 246
of flange and install four cap screws. Flange must be M20 421 318
centrally located on port. Hand tighten cap screws to a
Tolerance 10%. The torques given are enough for the given size
hold flange in place. Do not pinch Oring. connection with the recommended working pressure. Increasing
cap screw torque beyond these amounts will result in flange and
5. After components are properly positioned and cap cap screw bending and connection failures.
screws are hand tightened, tighten one cap screw, b
Metric standard thread.
then tighten the diagonally opposite cap screw.
Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.
04T,90,K175 1929SEP991/1

061411
PN=54
Group 0004
Fuels and Lubricants
Fuel Specifications
Use ONLY clean, highquality fuel. Use fuel with less than 1.0 per cent
Use Grade No. 2D fuel above 40F (4C). sulfur. If possible, use fuel with less
than 0.5 per cent sulfur.
Specification
Grade No. 2D For maximum filter life, sediment and water should not
FuelTemperature....................................................... Above 40F (4C) be more than 0.10 per cent.
Use Grade No. 1D fuel below 40F (4C). The cetane number should be 40 minimum. If you operate
Specification your machine where air temperatures are normally low or
Grade No. 1D where altitudes are high, you may need fuel with a higher
FuelTemperature....................................................... Below 40F (4C) cetane number.
Use Grade No. 1D fuel for all air temperatures at altitudes Cloud PointFor cold weather operation, cloud point
above 5000 ft (1 500 m). should be 10F (6C) below lowest normal air temperature.
Specification Specification
Grade No. 1D Cloud PointTempera
FuelHeight.................................................................5000 ft (1 500 m) ture.......................................................................................... 10F (6C)
below lowest normal air temperature
IMPORTANT: If fuel sulfur content exceeds 0.5 per
cent, the engine oil drain interval must be
reduced by 50 per cent (to 125 hours).
TX,45,DH1223 1915MAY921/1
Storing Fuel conditioner to prevent water condensation. Contact your

John Deere dealer for proper service or maintenance
If there is a very slow turnover of fuel in the fuel tank recommendations.
or supply tank, it may be necessary to add a fuel
DX,FUEL 1903MAR931/1
Do Not Use Galvanized Containers

IMPORTANT: Diesel fuel stored in galvanized Store fuel in:
containers reacts with zinc coating on the
container to form zinc flakes. If fuel contains plastic containers.
water, a zinc gel will also form. The gel and aluminum containers.
flakes will quickly plug fuel filters and damage specially coated steel containers made for diesel fuel.
fuel injectors and fuel pumps.
DO NOT USE brasscoated containers: brass is an alloy
DO NOT USE a galvanized container to store diesel fuel. of copper and zinc.
MX,FLBT,C 1904JUN901/1

061411
PN=55
Diesel Engine Oil
T8358AJ 1927MAR95
Use oil viscosity based on the expected air temperature
range during the period between oil changes. Other oils may be used if they meet one or more of the
following:
The following oil is preferred.
John DeereUNIGARD
John Deere PLUS50 API Service Classification CG4
If John Deere PLUS50 engine oil and a John Deere oil
API Service Classification CF4
filter are used, the service interval for oil and filter changes Viscosity grade SAE 15W40 is preferred.
may be extended by 50 hours.
If diesel fuel with sulfur content greater than 0.5% is used,
The following oil is also recommended: reduce the service interval by 50%.
John DeereTORQGARD SUPREME
PLUS50 is a registered trademark of Deere & Company
TORQGARD SUPREME is a registered trademark of Deere & Company
UNIGARD is a trademark of Deere & Company
TX,45,JC276 1914JUN111/1

061411
PN=56
Final Drive Oil
T100663 1910MAY96
range during the period between oil changes. John Deere BIOHYGARD
* 1BIOHYGARD meets or exceeds the minimum
The following oils are preferred:
biodegradability of 80% within 21 days according to
JOHN DEEREHYGARD CECL33T82 test method.
John Deere Low ViscosityHYGARD *BIOHYGARD should not be mixed with mineral oils
Other oils may be used if they meet one of the following: because this reduces the biodegradability and makes
proper oil recycling impossible.
John Deere Standard JDM J20C
John Deere Standard JDM J20D
Use the following oil when a biodegradable fluid is
required:
HYGARD is a registered trademark of Deere & Company
BIOHYGARD is a trademark of Deere & Company
02T,45,RR2760 1914JUN111/1
Track Roller, Front Idler, and Carrier Roller

Oil
Use SAE 80W90 gear oil meeting API Service GL5
(MILL2105B or MILL2105C).
T82,CRFL,D 1909APR911/1

061411
PN=57
Transmission, Steering Clutches, Hydraulic and Winch Oil
T100663 1910MAY96
range during the period between oil changes. John DeereBIOHYGARD 1
* 1BIOHYGARD meets or exceeds the minimum
The following oils are preferred:
biodegradability of 80% within 21 days according to
JOHN DEEREHYGARD CECL33T82 test method.
John Deere Low ViscosityHYGARD *BIOHYGARD should not be mixed with mineral oils
Other oils may be used if they meet one of the following: because this reduces the biodegradability and makes
proper oil recycling impossible.
John Deere Standard JDM J20C
John Deere Standard JDM J20D
Use the following oil when a biodegradable fluid is
required:
HYGARD is a registered trademark of Deere & Company
BIOHYGARD is a trademark of Deere & Company
TX,45,RR2761 1914JUN111/1

061411
PN=58
Grease
T6722AA 1927JAN89
Depending on the expected air temperature range, use SAE Multipurpose Grease with Extreme Pressure
grease shown on chart above. (EP) performance and containing 3 to 5 per cent
molybdenum disulfide
Greases recommended are:
SAE multipurpose EP Grease
John Deere Moly High Temperature/EP Grease Grease meeting MILG10924C specifications may be
(Preferred) used as arctic grease.
02T,45,C49 1901AUG941/1

061411
PN=59
Heavy Duty Diesel Engine Coolant

The engine cooling system is filled to provide yearround
protection against corrosion and cylinder liner pitting, and
Is formulated with a quality nitritefree additive package.
winter freeze protection to 37C (34F). If protection at
Provides cylinder liner cavitation protection according to
either the John Deere Cavitation Test Method or a fleet
lower temperatures is required, consult your John Deere study run at or above 60% load capacity
dealer for recommendations.
Protects the cooling system metals (cast iron, aluminum
The following engine coolants are preferred: alloys, and copper alloys such as brass) from corrosion
John Deere COOLGARD II Premix The additive package must be part of one of the following
John Deere COOLGARD II PG Premix coolant mixtures:
Use John Deere COOLGARD II PG Premix when a ethylene glycol or propylene glycol base prediluted
nontoxic coolant formulation is required. (4060%) heavy duty coolant
ethylene glycol or propylene glycol base heavy
Additional Recommended Coolants duty coolant concentrate in a 4060% mixture of
concentrate with quality water
The following engine coolant is also recommended:
Water Quality
John Deere COOLGARD II Concentrate in a 4060%
mixture of concentrate with quality water. Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
John Deere COOLGARD II Premix, COOLGARD II PG
water is recommended for mixing with ethylene glycol and
Premix, and COOLGARD II Concentrate coolants do not
propylene glycol base engine coolant concentrate.
require use of supplemental coolant additives.
IMPORTANT: Do not use cooling system sealing
Other Coolants additives or antifreeze that contains
John Deere COOLGARD II and COOLGARD II PG sealing additives.
coolants might not be available in the geographical area Do not mix ethylene glycol and propylene
where service is performed. glycol base coolants.
If these coolants are unavailable, use a coolant Do not use coolants that contain nitrites.
concentrate or prediluted coolant intended for use with
heavy duty diesel engines and with a minimum of the
following chemical and physical properties:
COOLGARD is a trademark of Deere & Company

DX,COOL3 1914APR111/1
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require

The temperature limits and service intervals shown in
lubricant recommendations different from those printed in
this manual apply to both conventional and synthetic
this manual.
lubricants.
Some John Deere brand coolants and lubricants may not
Rerefined base stock products may be used if the
be available in your location.
finished lubricant meets the performance requirements.
Consult your John Deere dealer to obtain information and
recommendations.
Synthetic lubricants may be used if they meet the
performance requirements as shown in this manual.
DX,ALTER 1911APR111/1

061411
PN=60
Lubricant Storage
Your equipment can operate at top efficiency only when
clean lubricants are used. Make certain that all containers are properly marked to
identify their contents.
Use clean containers to handle all lubricants.
Properly dispose of all old containers and any residual
Store lubricants and containers in an area protected from lubricant they may contain.
dust, moisture, and other contamination. Store containers
on their side to avoid water and dirt accumulation.
DX,LUBST 1911APR111/1

061411
PN=61

061411
PN=62
Section 01
Tracks
Contents
Page Page
Group 0130Track System Measure Front Idler Wear........................ 01013052

Special or Essential Tools.......................... 0101301 Remove and Install Front Idler
Service Equipment and Tools .................... 0101302 Assembly ............................................. 01013052
Other Material............................................ 0101305 Disassemble and Inspect Front
Specifications ............................................ 0101306 Idler Assembly ..................................... 01013052
Measure Carrier Roller Wear..................... 0101309 Assemble Front Idler Assembly............... 01013054
Remove and Install Carrier Roller Idler Adjustment Procedure ..................... 01013058
Assembly ............................................... 0101309 Check Front Idler Oil Level ...................... 01013062
Disassemble and Assemble Carrier Remove and Disassemble
Roller ................................................... 01013010 Hydraulic Track Tension Adjuster
Check Carrier Roller Oil Level ................. 01013013 (S.N. 745426)................................... 01013063
Measure Track Roller Wear..................... 01013014 Assemble and Install Hydraulic
Remove and Install Track Rollers............ 01013014 Track Tension Adjuster (S.N.
Disassemble and Assemble Track 745426)............................................ 01013064
Roller (S.N. XXXXXX)...................... 01013015 Remove and Disassemble
Disassemble and Assemble Track Hydraulic Track Tension Adjuster
Roller (S.N. XXXXXX )..................... 01013019 (S.N. 745427781708)....................... 01013066
Checking Track Roller Oil Level Remove and Disassemble
(S.N. XXXXXX) ................................ 01013020 Hydraulic Track Tension Adjuster
Checking Track Roller Oil Level (S.N. 781709 ).................................. 01013067
(S.N. XXXXXX ) ............................... 01013020 Assemble and Install Hydraulic
Adding Oil to the Roller (S.N. Track Tension Adjuster (S.N.
XXXXXX) ......................................... 01013021 745427)............................................ 01013068
Adding Oil to the Roller (S.N. Remove and Install Track Idler
XXXXXX ) ........................................ 01013021 Recoil Spring ....................................... 01013069
Measure Track Shoe Grouser Disassemble and Assemble Recoil
Wear .................................................... 01013022 Spring .................................................. 01013070
Remove and Install Track Shoe .............. 01013023 Remove and Install Sprocket................... 01013074
Measure Link Height................................ 01013024 Remove and Install Track Frame ............ 01013074
Measure Track Bushing Outer Remove and Install Frame Wear
Diameter .............................................. 01013025 Strips ................................................... 01013076
Measure Track Pitch................................ 01013026
Adjust Track Sag ..................................... 01013026 Group 0199Dealer Fabricated Tools
Remove Sealed Track Chain................... 01013028 DF1041 Track Nut Removal Tool .............. 0101991
Turn Sealed Track Chain Pins and DF1067 Lubricated Track
Bushings.............................................. 01013031 Split Master Link Separator
Disassemble and Assemble Sealed ToolEarlier Machines.......................... 0101992
Track Chain Using Track Press............ 01013031 DFT1087 Track Recoil Spring
Install Sealed Track Chain....................... 01013032 Disassembly and Assembly
Remove and Install Lubricated Guard Tool ............................................. 0101994
Track ChainInterlock Master ST4920 Track Recoil Spring
Link ...................................................... 01013034 Disassembly and Assembly
Remove and Install Lubricated Tool ........................................................ 0101995
Track ChainSingle or Saw
Tooth Master Split Link ........................ 01013037
Disassemble Lubricated Track
Chain to Turn Bushings and
Relubricate Chain ................................ 01013040
Assemble Lubricated Track
Chain to Turn Bushings and
Relubricate Chain ................................ 01013041
Disassemble and Assemble
Lubricated Track Chain to Turn
Pins and Not Relubricate..................... 01013048

061411
PN=1
Contents

061411
PN=2
Group 0130
Track System
T6926BA UN06DEC88
Special or Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICEGARDCatalog or in the
European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company.

DX,TOOLS 1914JUN111/3
Stopper Installer ................................................... JDG589

Used to install stopper in lubricated track pins.
Continued on next page DX,TOOLS 1914JUN112/3

061411
PN=65
Track System
T6926BB UN06DEC88
Install stopper in lubricated track pins.
Seal Centering Fixture Tool .................................. JDG798
Used to install seal ring on front idler assembly for
555G and 650G machines (S.N. 771024 ).
To install seal ring on front idler assembly for 555G and
T6926BB UN06DEC88
650G machines (S.N. 771024 ).
Seal Centering Fixture Tool ..................................JT30018
Used to install seal ring on front idler assembly for
450G, 455G and 550G machines, and 555G and
650G machines (S.N. 771023).
T6926BB UN06DEC88
To install seal ring on front idler assembly for 450G, 455G
and 550G machines, and 555G and 650G machines (S.N.
771023).
Seal Centering Fixture Tool ..................................JT30019
Used to install seal ring in track roller assembly.
T6926BC UN06DEC88
To install seal ring in track roller assembly.
Hydraulic Track Adjuster Service Set ...................... JD284
Used to install track adjuster seals.
To install track adjuster seals.
Special Bolt (18 UNC2A x 151/2 JDM A17D) .... T16678 T6926BD UN06DEC88
Used to remove and install idler recoil spring.

To remove and install idler recoil spring.
Seal Tester and Lubricator1 .................................... D0890
To be applied lubricant to track pins. T6926BE UN06DEC88
Apply lubricant to track pins.

Nozzle1 ................................................................... A2679
Used to inject oil into lubricated track pin with
selfsealing stopper.
To inject oil into lubricated track pin with selfsealing T6926BF UN06DEC88
stopper.
1
Order from: Centurin Industries Inc., 45 Capitol Dr., Oconomowoc, WI
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche

Continued on next page TX,01,DY71 1914JUN111/20

061411
PN=66
Track System
Undercarriage Inspection Service Tool Kit Used to measure undercarriage wear.

TX,01,DY71 1914JUN112/20
Master Pin Pusher

Used to remove master track pin.
TX,01,DY71 1914JUN113/20
Bearing, Bushing and Seal Driver Set Used to remove and install bushings.
TX,01,DY71 1914JUN114/20
200Ton Twin Head Track Press

Used to disassemble and assemble track chain.
TX,01,DY71 1914JUN115/20
Track Press Tooling Set Used with track press to disassemble and
assemble track chain.
TX,01,DY71 1914JUN116/20
450G, 455G, 550G Sealed Track Tool Set .....A2656139

Used with track press to disassemble and
TX,01,DY71 1914JUN117/20
Saddle ......................................................................40989
TX,01,DY71 1914JUN118/20
555G, 650G Sealed Track Tool Set................A2656199

TX,01,DY71 1914JUN119/20
Saddle ......................................................................42101
TX,01,DY71 1914JUN1110/20
450G, 455G, 550G Lubed Track Tool Set ......A2656213

TX,01,DY71 1914JUN1111/20
Saddle ......................................................................40989
Continued on next page TX,01,DY71 1914JUN1112/20

061411
PN=67
Track System
Saddle (Used for Stepped Bushing Design) .. 052657001 Used with track press to disassemble and
TX,01,DY71 1914JUN1113/20
555G, 650G Lubed Track Tool Set .................A2656217

TX,01,DY71 1914JUN1114/20
Saddle ......................................................................42101
TX,01,DY71 1914JUN1115/20
Saddle (Used for Stepped Bushing Design) .. 052657001 Used with track press to disassemble and
TX,01,DY71 1914JUN1116/20
1/8 in. NPT Grease Fitting Used to add oil to idler, carrier roller and track roller.
TX,01,DY71 1914JUN1117/20
Adapter .................................................... AN142253 (7/16 Used with grease fitting to add oil to idler and rollers.
Male ORing Boss C 1/8 Female Pipe
TX,01,DY71 1914JUN1118/20
Master Link Separator1 .........................................DF1067

Used to separate lubricated track master link.
1
Fabricated tool, dealer made. (See Group 0199 for in
structions to make tool.)
TX,01,DY71 1914JUN1119/20
Track Nut Removal Tool1 ......................................DF1041

Used to remove and install track nuts.
1
TX,01,DY71 1914JUN1120/20

061411
PN=68
Track System
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Lubricant Apply to threads of master bolt
and mating surfaces of split link
on track chain.
Low carbon AWSASTM, E7018 Weld wears strips on track frame.

electrode (5/32 in. diameter)
T43514 (U.S.) Plastic Gasket To be applied to second through tenth

TY9475 (Canadian) threads of idler brackettoshaft
277 (LOCTITE) cap screws.
NEVERSEEZ is a registered trademark of Emhart Chemical Group.

LOCTITE is a registered trademark of Loctite Corp.
TX,0130,BD733 1914JUN111/1

061411
PN=69
Track System
Specifications
Carrier Roller:
450G, 455G, 550G Outside Diameter 152.4 mm (6.0 in.)
100% Worn 139.7 mm (5.5 in.)
555G, 650G Outside Diameter 160.0 mm (6.3 in.)
100% worn 147.0 mm (5.8 in.)
BrackettoFrame Cap Screw Torque 675 Nm (500 lbft)
Upper Plate Socket Head Cap Torque 54 Nm (40 lbft)
Screws
Upper Cover Cap Screws Torque 47 Nm (35 lbft)
Upper Oil Level Check Cap Screw Torque 41 Nm (30 lbft)
Oil Level Plug Torque 41 4 Nm (30 3 lbft)
Track Roller:
450G, 455G, 550G Outside Diameter 182.6 mm (7.2 in.)
100% Worn 168.2 mm (6.6 in.)
555G, 650G Outside Diameter 182.6 mm (7.2 in.)
100% Worn 164.0 mm (6.5 in.)
RollertoBracket Cap Screw Torque 225 Nm (160 lbft)
Roller Bushing Inside Diameter 60.416.44 mm (2.37852.3795 in.)
Oil Level Plug Torque 41 4 Nm (30 3 lbft)
Seal Ring Socket Head Cap Torque 68 Nm (50 lbft)
Screws
Track Shoe:
Single Bar Grouser 450G, 455G, Height 48.0 mm (1.89 in.)
550G New Shoe
Single Bar Grouser 450G, 455G, Height 20.0 mm (0.8 in.)
550G 100% Worn
Single Bar Grouser 555G, 650G Height 50.0 mm (1.97 in.)
New Shoe
Single Bar Grouser 555G, 650G Height 23.0 mm (0.9 in.)
100% Worn
Two Bar Grouser 450G, 455G, Height 25.0 mm (0.98 in.)
550G New Shoe
Two Bar Grouser 450G, 455G, Height 16.0 mm (0.63 in.)
550G 100% Worn
Two Bar Grouser 555G, 650G New Height 30.0 mm (1.18 in.)
Shoe
Two Bar Grouser 555G, 650G Height 12.0 mm (0.47 in.)
100% Worn
Three Bar Grouser 450G, 455G, Height 21.1 mm (0.83 in.)
550G New Shoe
Three Bar Grouser 450G, 455G, Height 12.0 mm (0.47 in.)
550G 100% Worn
Continued on next page TX,0130,BD805 1926AUG021/4

061411
PN=70
Track System
Cap Screws (450G, 455G, 550G) Torque 61 Nm (45 lbft) Second

(1/2 in.) PassAdditional 1/3 (120) turn
Cap Screws (450G, 455G, 550G) Torque 88 Nm (65 lbft) Second
Cap Screw (555G, 650G) (5/8 in.) Torque 149 Nm (110 lbft) Second
PassAdditional 1/3 (120) turn
Split Link Cap Screw (450G, 455G, Torque 61 Nm (45 lbft) Seconds
550G) (1/2 in.) PassAdditional 1/2 (180) turn
Split Link Cap Screw (450G, 455G, Torque 88 Nm (65 lbft) Second
Split Link Cap Screw (555G, 650G) Torque 149 Nm (110 lbft) Second
Track Chain:
Chain Link 450G, 455G, 550G New Height 90 mm (3.5 in.)
Chain Link 450G, 455G, 550G Height 82.8 mm (3.26 in.)
100% Worn
Chain Link 555G, 650G New Height 96 mm (3.8 in.)
Chain Link 555G, 650G 100% Height 86.7 mm (3.4 in.)
Worn
Sealed Bushing 450G, 455G, 550G OD 51.0 mm (2.01 in.)
New
100% Worn (Normal Impact)
100% Worn (High Impact)
Sealed Bushing 555G, 650G New OD 53.8 mm (2.12 in.)
Sealed Bushing 555G, 650G 100% OD 49.0 mm (1.93 in.)
Worn (Normal Impact)
Sealed Bushing 555G, 650G 100% OD 50.8 mm (2.00 in.)
Worn (High Impact)
Lubricated Bushing 450G, 455G, OD 51.8 mm (2.01 in.)
550G New
550G 100% Worn (Normal Impact)
550G 100% Worn (High Impact)
Lubricated Bushing 555G, 650G OD 53.8 mm (2.12 in.)
New
100% Worn (Normal Impact)
100% Worn (High Impact)
Lubricated Step Bushings 450G, OD 51 mm (20 in.)
455G, 550G New

061411
PN=71
Track System
Lubricated Step Bushings 450G, OD 44.5 mm (1.75 in.)

455G, 550G 100% Worn (Normal
Impact)
455G, 550G 100% Worn (High
Impact)
650G New
650G 100% Worn (Normal Impact)
650G 100% Worn (High Impact)
Chain Pitch 450G, 455G, 550G Distance Across Four Pins of New 640.1 mm (25.2 in.)
Sealed Chain
100% Worn 652.8 mm (25.7 in.)
Chain Pitch 450G, 455G, 550G Distance Across Four Pins of New 160 mm (6.3 in.)
Lubricated Chain
100% Worn 171 mm (6.7 in.)
Chain Pitch 555G, 650G Sealed Distance Across Four Pins of New 685.2 mm (27.0 in.)
Chain
100% Worn 697.5 mm (27.5)
Chain Pitch 555G, 650G Lubricated Distance Across Single Joint 171 mm (6.7 in.)
100% Worn 185 mm (8.7 in.)
Idler and Carrier Roller Track Sag 51 6 mm (2 1/4 in.)
Pressure Relief Valve Setting Force (Maximum) 284 088 N (63,840 lb force)
450G, 455G, 550G
Pressure Relief Valve Setting Force (Maximum) 35 5100 N (79,800 lb force)
555G, 650G
Front Idler
450G, 455G, 550G Flange New Height 19.5 mm (0.77 in.)
450G, 455G, 550G Flange 100% Height 24.4 mm (0.96 in.)
Worn
555G, 650G Flange New Height 17.5 mm (0.69 in.)
555G, 650G Flange 100% Worn Height 23.0 mm (0.91 in.)
BrackettoShaft Cap Screws Torque 612 Nm (450 lbft)
Recoil Spring Approximate Free Length 447 mm (18.0 in.)
Test Length @ 37900 3790 N (8514 378 3 mm (14.88 0.12 in.)
851 lb force)
Adjusting Cylinder YoketoIdler Torque 163 Nm (120 lbft)
Bracket Cap Screws
Drive SprockettoAxle Shaft Cap Torque 576 Nm (425 lbft)
Screws
Seal Ring Socket Head Cap Torque 68 Nm (50 lbft)
Screws

061411
PN=72
Track System
Idler Shaft Retainer Cap Screw Torque 54 Nm (40 lbft)

Bracket Guide Cap Screws Torque 115 Nm (85 lbft)
Track Frame:
Cap Screws Torque 600 Nm (443 lbft)
Rocks Guards:
GuardtoFrame Cap Screws Torque 230 Nm (170 lbft)
InnertoOuter Guard Cap Screws Torque 163 Nm (120 lbft)
TX,0130,BD805 1926AUG024/4
Measure Carrier Roller Wear

1. Use calipers to measure most worn area of roller
running surface.
2. Measure caliper tip spread to the nearest 0.5 mm
(0.002 in.) using the scale.
T5819AC UN01NOV88
3. Flat spots on roller thread indicates roller is not free
to turn.
Specification
450G, 455G,
550GOutside
Diameter...................................................................... 152.4 mm (6.0 in.)
100% Worn................................................................. 139.7 mm (5.5 in.)
555G, 650GOutside Tread Wear, Carrier Roller Flange Wear, and
Diameter...................................................................... 160.0 mm (6.3 in.) Carrier Roller Flange Top Wear in Undercarriage
100% worn.................................................................. 147.0 mm (5.8 in.) Appraisal Manual SP326.
NOTE: For additional information on measuring carrier
roller wear, refer to Carrier Roller, Carrier Roller
0130,BB5 1908OCT931/1
Remove and Install Carrier Roller Assembly

Specification
BrackettoFrame Cap
ScrewTorque........................................................... 675 Nm (500 lbft)
T6674AC UN01NOV88
0130,BB6 1924AUG931/1

061411
PN=73
Track System
Disassemble and Assemble Carrier Roller

1. Remove cover (A) and gasket.
T93565 UN01NOV88
0130,BB7 1924AUG931/9
2. Remove plate (A) and roller assembly (B).
T93566 UN01NOV88
0130,BB7 1924AUG932/9
3. Remove oil seal.

NOTE: Keep metal face of seals lubricated and together
at all times while disassembled.
T93567 UN01NOV88
Continued on next page 0130,BB7 1924AUG933/9

061411
PN=74
Track System
4. Inspect shaft for wear or damage, replace only if

necessary. Remove shaft using a press and a piece
of pipe with 101.5 mm (4 in.) O.D. and a minimum
length of 51 mm (2 in.).
Specification
PipeOD....................................................................... 101.5 mm (4 in.)
T93568 UN01NOV88
Minimum Length ................................................................. 51 mm (2 in.)
0130,BB7 1924AUG934/9
5. Replace bushings if necessary, using 35 mm and 39

mm disks.
T93569 UN01NOV88
0130,BB7 1924AUG935/9
6. Install new shaft 145.0145.5 mm (5.715.73 in.)

above the face of seal bore using a press.
Specification
ShaftDistance.......................................145.0145.5 mm (5.715.73
in.) above the face of seal bore
T93570 UN01NOV88
Continued on next page 0130,BB7 1924AUG936/9

061411
PN=75
Track System
IMPORTANT: The metal face seal bore in support and

roller must be degreased with clean solvent
and dried before installing seal.
DO NOT remove plastic retaining ring
from new seal.
T93567 UN01NOV88
7. A new seal kit should be installed. Install oil seal into
support with the retainer ring side going into support.
0130,BB7 1924AUG937/9
8. Install roller assembly (A), plate (B) and socket head

screws. Tighten screws.
Specification
Upper Plate Socket Head
Cap ScrewsTorque..................................................... 54 Nm (40 lbft)
T93571 UN01NOV88
0130,BB7 1924AUG938/9
9. Install washer and gasket on longer cap screw (A).

10. Install cover with three cap screws (A and B). Tighten
cap screws to specification.
Specification
Upper Oil Level Check
T94007 UN01NOV88
Cap ScrewTorque....................................................... 41 Nm (30 lbft)
Upper Cover Cap
ScrewTorque............................................................... 47 Nm (35 lbft)
11. Fill roller assembly with approximately 710 mL (24 oz)

of recommended oil.
Specification
OilVolume..................................................................... 710 mL (24 oz)
(See procedure in this group.)
0130,BB7 1924AUG939/9

061411
PN=76
Track System
Check Carrier Roller Oil Level

NOTE: Removing the roller oil level plug does not
always indicate oil level. Possible vacuum in the
oil cavity can keep oil from flowing out. Rollers
that appear low or out of oil may have sufficient
T6499EF1 UN09FEB89
oil. A small amount of low volume air forced into
the roller will overcome the vacuum and allow a
small amount of oil to flow from roller.
1. Put the oil level plug (B) at the three oclock or nine
oclock position.
2. Remove the oil fill plug (A).
If oil flows out, oil level is correct and install plug
quickly.
If oil does not flow, remove the oil level plug (B). Insert
the nozzle of a plastic bottle (C) into the hole and
squeeze air pressure into roller. A slight amount of
T7883AN UN09NOV92
pressure inside the roller will relieve any vacuum and
allow oil to flow from hole (A).
Oil level must be level with fill hole (A) or not more
than 3 mm (0.12 in.) below the bottom of hole.
Specification
OilMaximum Distance...........3 mm (0.12 in.) below the bottom of hole
3. Add proper oil as necessary.

d. Add oil to grease fitting until oil flows from oil level
a. Install oil level plug hole.
Early machinesRemove fill plug (A) and
IMMEDIATELY install an (1/8 in. NPT) grease fitting. e. Install and tighten oil level plug.
Later machinesRemove the fill plug (A) and
Specification
IMMEDIATELY install AN142253 adapter and (1/8
Oil Level PlugTorque....................................... 41 4 Nm (30 3 lbft)
in. NPT) grease fitting.
f. Quickly remove grease fitting and adapter (if used)
b. Remove the oil level plug (B).
and install fill plug.
c. Fill grease gun with recommended oil. (See Section
00, Group 0004.)
TX,0130,BD782 1908OCT931/1

061411
PN=77
Track System
Measure Track Roller Wear

1. Raise machine off the ground and block it for support.
Release track tension by loosening track adjusting
cylinder nut and turning set screw counterclockwise
approximately three turns. (See Adjust Track Sag in
this group.)
T93617 UN23FEB89
2. Clean track roller to be measured.
3. Measure track roller using roller calipers and a scale.
Measure inside and outside tread diameters of the
roller at the area of most wear using the calipers. Then
measure caliper tip spread with the scale to nearest
0.020 in.
Specification 555G, 650GOutside
450G, 455G, Diameter...................................................................... 182.6 mm (7.2 in.)
550GOutside 100% Worn................................................................. 164.0 mm (6.5 in.)
Diameter...................................................................... 182.6 mm (7.2 in.)
100% Worn................................................................. 168.2 mm (6.6 in.)
0130,BB16 1908OCT931/1
Remove and Install Track Rollers

1. Track rollers can be removed without disconnecting
track. Release track tension to provide sufficient
clearance. (See Adjust Track Sag in this group.)
2. If machine is equipped with rock guards, remove outer
T113330 UN12FEB98
rock guard and loosen inner rock guard cap screws.
If machine is equipped with chain guides, remove rear
chain guide.
3. Raise crawler to provide a clearance for roller removal.
Block securely.
4. Remove four roller bracket cap screws (B) to remove
roller assembly.
NOTE: On machines (S.N. XXXXXX), put roller on
track frame with special cap screw (A) toward
the outside of the machine.
5. Install roller assembly and tighten cap screws (B). T6556AB UN01NOV88
IMPORTANT: Replace older special cap screws

(A) and washers with new cap screw with
washer forged into head.
6. If removed, tighten cap screw (A) to specification.

Specification
RollertoBracket Cap
TX,01,RB541 1926AUG021/1

061411
PN=78
Track System
Disassemble and Assemble Track Roller

(S.N. XXXXXX)
and washers with new cap screw with
T93589 UN01NOV88
1. Remove cap screws and Orings to remove roller
brackets (A).
TX,01,RB542 1917FEB981/7
2. Remove seal ring (A) and oil seal (B) on each side.
NOTE: Keep metal face of seals lubricated and together
at all times while disassembled.
3. Remove thrust plate (C), gasket (D) and shaft.
T93590 UN01NOV88
4. Inspect parts for wear or damage. Replace as
required.
ASeal Ring CThrust Plate

BOil Seal DGasket
T93591 UN01NOV88
Continued on next page TX,01,RB542 1917FEB982/7

061411
PN=79
Track System
NOTE: Replacement roller bushings are presized and

therefore do not need to be sized after installation.
5. The I.D. of the roller bushing is 60.4160.44 mm

(2.37852.3795 in.).
Specification
T93592 UN01NOV88
Roller BushingID.....................60.4160.44 mm (2.37852.3795 in.)
If necessary to replace bushings, use 60 mm and 63
mm disks. Install new bushings 0.79 mm (0.031 in.)
below face of roller with open ends of oil grooves to
the inside.
Specification
BushingDistance.....................0.79 mm (0.031 in.) below face of roller
TX,01,RB542 1917FEB983/7
6. Lubricate bushings (B) with oil and install shaft (A).

7. Install gasket (D) and thrust plate (C) with chamfered
edge facing toward outside of track rollers.
AShaft CThrust Plate

BBushing (2 used) DGasket
T93593 UN01NOV88
T93591 UN01NOV88

061411
PN=80
Track System
8. Install seal ring (A).

9. Install three socket head cap screws (C) equally
spaced and finger tighten to position thrust plates,
gasket, and seal ring.
10. Center seal ring on shaft using a JT30019 Seal
T6044AH UN01NOV88
Centering Fixture (B).
TX,01,RB542 1917FEB985/7
11. Install the other three cap screws and tighten all six
cap screws.
12. Remove seal centering fixture.
13. Install a new oil seal kit (A) with plastic retainer ring in
place. Side with retainer ring goes into seal ring. Seal
T6044AA UN01NOV88
must be straight in bore.
14. Tighten cap screws. Repeat steps 814 on the other
side.
Specification
Seal Ring Socket Head
T6044AC UN01NOV88

061411
PN=81
Track System
15. Remove grease from sealing surface of roller bracket.

and washers with new cap screw with
16. Install roller bracket without plugs on the shaft end
T93595 UN01NOV88
without the pin. Install Oring, washer and cap screw.
Tighten finger tight.
17. Install roller bracket with plugs on pin end of shaft.
Install Oring and special cap screw. Tighten finger
tight.
18. Tighten inner roller and outer roller bracket cap screws.
Specification
RollertoBracket Cap 19. Fill roller with oil. (See Adding Oil to the Roller in this
ScrewTorque........................................................... 407 Nm (300 lbft) group.)
TX,01,RB542 1917FEB987/7

061411
PN=82
Track System
Disassemble and Assemble Track Roller

(S.N. XXXXXX )
T113331 UN10FEB98
ASpring Pin (2 used) CORing (2 used) ERoller GShaft
BBracket (2 used) DSeal Kit (2 used) F Plug HBushing (2 used)
NOTE: Spring pins (A) are tapered on top (flat of 6. Remove grease from sealing surfaces in roller and
bracket). Drive pin out from the bottom. roller brackets.
1. Remove parts (AD) from both ends of roller. 7. Install new oil seal kits (D) in roller.
NOTE: Keep metal faces of seals (D) lubricated and 8. Install Orings (C) in both brackets.
together at all times while disassembled.
9. Install brackets (B).
2. Remove shaft (G) and bushings (H). 10. Install new spring pins in through top (flat of bracket).
3. Inspect parts for wear or damage. Replace as Tapered end of pin should be flush with top of bracket.
required. 11. Fill roller with oil. (See Adding Oil to the Roller in this
4. Install bushings (H) in roller. group.)
5. Lubricate both bushings with oil and install shaft (G).

TX,01,RB416 1910FEB981/1

061411
PN=83
Track System
Checking Track Roller Oil Level (S.N.

XXXXXX)
Removing the oil check plug in the track roller does not
always show oil due to a vacuum in the oil cavity. Track
rollers that appear low or out of oil may have sufficient oil.
T6499EB1 UN09FEB89
A small amount of low volume air forced into the roller will
overcome the vacuum inside the roller and force a small
amount of oil to flow out fill hole.
1. Remove the oil level fill plug (B). If oil runs out, oil
level is correct.
If oil does not run out, remove the oil level check plug
(A). Insert the nozzle of the plastic bottle (C) into the (S.N. XXXXXX)
oil check hole and squeeze air pressure inside the
roller assembly. A slight amount of air pressure inside
the roller will relieve any vacuum inside the roller and
allow oil to flow out of the fill hole.
2. Install the plugs.
T7896AX UN07JAN93
(S.N. XXXXXX)
TX,01,BA2225 1916FEB981/1
Checking Track Roller Oil Level (S.N.

XXXXXX )
1. Remove oil fill plug (B) in center of track roller.
2. Rotate plug opening to 45 angle. If oil runs out of
opening, roller is full.
T113532 UN17FEB98
IMPORTANT: Oil fill plug has bakedon sealant.
Discard old fill plug and install a new one.
3. Install new fill plug.
(S.N. XXXXXX )
TX,01,RB595 1902MAR981/1

061411
PN=84
Track System
Adding Oil to the Roller (S.N. XXXXXX)

1. To add oil, remove the oil level check plug (A).
2. Remove the fill plug (B) and IMMEDIATELY install a
John Deere adapter fitting AN142253 (D) or equivalent
adapter (male 7/16 x 20 Oring thread to female 1/8 in.
T6499EB1 UN09FEB89
NPT grease fitting).
3. Install a grease zerk (E) into adapter fitting.
4. Fill a grease gun (F) with oil. (See Fuels and
Lubricants Group 0004.)
5. Add oil to grease fitting until it comes out of oil level
Inside of Crawler
check hole (C).
6. Install and tighten oil level plug.
Specification
7. Remove grease fitting, adapter, and install fill plug.
T8055AO UN03AUG93
ACheck Plug DAN142253 Adapter Fitting
BFill Plug EGrease Zerk
CCheck Hole F Grease Gun
TX,01,RB501 1917FEB981/1
Adding Oil to the Roller (S.N. XXXXXX )

NOTE: Rollers are serviced off of the machine.
1. Remove plug (B) from roller.

2. Rotate plug opening to 45 angle.
T113532 UN17FEB98
3. Fill roller with oil until the oil starts to drip out. (See
Fuels and Lubricants Group 00004.)
IMPORTANT: Oil fill plug has bakedon sealant.
Discard old fill plug and install a new one.
4. Install new fill plug.

TX,01,RB502 1917FEB981/1

061411
PN=85
Track System
Measure Track Shoe Grouser Wear

Measure grouser height of several track shoes to find
an average using a depth gauge such as the JT05521
200 mm Ruler, JT05534 Right Angle Attachment and
D05231ST 300 mm Ruler from JT05518 or JT05523
Undercarriage Inspection Service Tool Kit.
T93612 UN23FEB89
Specification
Single Bar Grouser
450G, 455G, 550G New
ShoeHeight.............................................................. 48.0 mm (1.89 in.)
Single Bar Grouser
450G, 455G, 550G 100%
Worn Height............................................................... 20.0 mm (0.8 in.)
Single Bar Grouser
Three Bar Grouser
555G, 650G New
450G, 455G, 550G 100%
ShoeHeight.............................................................. 50.0 mm (1.97 in.)
WornHeight.............................................................. 12.0 mm (0.47 in.)
Single Bar Grouser
555G, 650G 100% NOTE: See Undercarriage Appraisal Manual SP326
WornHeight................................................................ 23.0 mm (0.9 in.) for additional information.
Two Bar Grouser 450G,
455G, 550G New See Grouser Wear
ShoeHeight.............................................................. 25.0 mm (0.98 in.) See Grouser Bar Height
Two Bar Grouser 450G,
455G, 550G 100% See 450G, 455G, 550G Single Bar Grouser Height
WornHeight.............................................................. 16.0 mm (0.63 in.)
Two Bar Grouser
See 450G, 455G, 550G Two Bar Grouser Height
555G, 650G New See 450G, 455G, 550G Three Bar Grouser Height
ShoeHeight.............................................................. 30.0 mm (1.18 in.)
Two Bar Grouser 555G, See 555G, 650G Single Bar Grouser Height
650G 100% Worn
See 555G, 650G Two Bar Grouser Height
Height.......................................................................... 12.0 mm (0.47 in.)
Three Bar Grouser
450G, 455G, 550G New
ShoeHeight.............................................................. 21.1 mm (0.83 in.)
TX,0130,BD776 1914JUN111/1

061411
PN=86
Track System
Remove and Install Track Shoe

CAUTION: The approximate weight of a
swamp shoe is 25 kg (54 lb).
NOTE: For lubricated chain, cap screws hold a shoe

and split master link together.
T96291 UN23FEB89
1. Remove nuts using DF1041 Track Nut Removal
Tool. (See Group 0199 for instructions to make tool.)
Remove cap screws and shoes.
2. Before installing shoes, clean paint, dirt and debris
from mounting surfaces of shoes and links.
3. For all cap screws except split master links cap
screws, apply SAE 30W oil to threads and bearing
surface under head.
For split master link and shoe cap screws, apply John
Deere NEVERSEEZ Lubricant (or equivalent) to
T96292 UN23FEB89
threads and bearing surface under head.
IMPORTANT: Never use an impact wrench to
start cap screws in a split master link to
avoid crossthreading.
4. Install new cap screws. Install new nuts with rounded

edges (A) against link and chamfered edges (B) away
from link.
TX,01,RB503 1914JUN111/2
IMPORTANT: Tighten cap screws to torque

specification using a crisscross pattern.
Then repeat torque pattern again.
5. Check torque after 50100 hours of operation to be

sure cap screws are tightened to specified torque. If
T6352AH UN23FEB89
not, repeat Steps 25.
Specification
Cap Screws (450G,
455G, 550G) (1/2
in.)Torque....................................................... 61 Nm (45 lbft) Second
Cap Screws (450G,
455G, 550G) (9/16
in.)Torque....................................................... 88 Nm (65 lbft) Second Split Link Cap Screw
PassAdditional 1/3 (120) turn (450G, 455G, 550G)
Cap Screw (555G, 650G) (9/16 in.)Torque.............................................. 88 Nm (65 lbft) Second
(5/8 in.)Torque............................................ 149 Nm (110 lbft) Second PassAdditional 1/2 (180) turn
PassAdditional 1/3 (120) turn Split Link Cap Screw
Split Link Cap Screw (555G, 650G) (5/8
(450G, 455G, 550G) (1/2 in.)Torque................................................... 149 Nm (110 lbft) Second
in.)Torque..................................................... 61 Nm (45 lbft) Seconds PassAdditional 1/2 (180) turn
TX,01,RB503 1914JUN112/2

061411
PN=87
Track System
Measure Link Height

Measure link height to nearest 0.5 mm (0.020 in.) using a
depth gauge from undercarriage inspection service tool
kit. Put the depth gauge on outside of track link against
pin boss as shown. Measure several links to the nearest
T5802AD UN02NOV88
0.5 mm (0.020 in.).
Specification
Chain Link 450G, 455G,
550G NewHeight.......................................................... 90 mm (3.5 in.)
Chain Link 450G, 455G,
550G 100% Worn
Height.......................................................................... 82.8 mm (3.26 in.)
Chain Link 555G, 650G
NewHeight.................................................................... 96 mm (3.8 in.)
Chain Link 555G, 650G
100% WornHeight...................................................... 86.7 mm (3.4 in.)
0130,BB33 1908OCT931/1

061411
PN=88
Track System
Measure Track Bushing Outer Diameter

Measure reverse drive side wear (A) and forward drive
side wear (B) of the bushing using a caliper and scale
from undercarriage inspection tool kit.
Position the caliper so that as it is passed back and forth
over the bushing, one tip will slide parallel along with worn
surface. Close caliper until the opposite tip just touches
the unworn side of the bushing.
Measure several bushings to the nearest 0.5 mm (0.020
in.).
Specification
Sealed Bushing 450G,
455G, 550G NewOD................................................ 51.0 mm (2.01 in.)
T6033CD UN01JUN89
455G, 550G 100% Worn
(Normal Impact)OD.................................................. 46.2 mm (1.82 in.)
455G, 550G 100% Worn
(High Impact)OD...................................................... 48.0 mm (1.89 in.)
650G NewOD.......................................................... 53.8 mm (2.12 in.)
650G 100% Worn
Lubricated Step Bushings
450G, 455G, 550G
NewOD.......................................................................... 51 mm (20 in.)
650G 100% Worn (High
Impact)OD............................................................... 50.8 mm (2.00 in.)
450G, 455G, 550G
Lubricated Bushing
100% Worn (Normal
450G, 455G, 550G
Impact)OD............................................................... 44.5 mm (1.75 in.)
NewOD.................................................................... 51.8 mm (2.01 in.)
Lubricated Bushing
450G, 455G, 550G
450G, 455G, 550G
100% Worn (High
100% Worn (Normal
Impact)OD............................................................... 46.3 mm (1.82 in.)
Impact)OD............................................................... 44.5 mm (1.75 in.)
Lubricated Bushing
555G, 650G NewOD................................................ 56.8 mm (2.24 in.)
450G, 455G, 550G
100% Worn (High
555G, 650G 100% Worn
Impact)OD............................................................... 46.3 mm (1.82 in.)
Lubricated Bushing
555G, 650G NewOD................................................ 53.8 mm (2.12 in.)
555G, 650G 100% Worn
Lubricated Bushing
(High Impact)OD...................................................... 50.8 mm (2.00 in.)
555G, 650G 100% Worn
Lubricated Bushing
555G, 650G 100% Worn
(High Impact) OD..................................................... 48.8 mm (1.92 in.)
TX,0130,BD785 1908OCT931/1

061411
PN=89
Track System
Measure Track Pitch

1. Place a pin or block between sprocket and chain.
Move machine in reverse until chain is tight.
2. Measure track pitch using a tape measure. Measure a
straight section of chain, such as between carrier roller
T93611 UN23FEB89
and idler. Measure from the left edge of one track pin
to the left edge of fifth track pin. This measurement
covers wear in four pin and bushing joints.
3. Record measurement to the nearest 0.5 mm (0.020
in.) and repeat for several sections.
Do not measure across the master pin joint.
Specification
Chain Pitch 555G, 650G
Chain Pitch 450G, 455G,
Sealed Distance
550G SealedDistance
Across Four Pins of
Across Four Pins of New
New Chain................................................................. 685.2 mm (27.0 in.)
Chain......................................................................... 640.1 mm (25.2 in.)
100% Worn....................................................................697.5 mm (27.5)
100% Worn............................................................... 652.8 mm (25.7 in.)
Chain Pitch 555G, 650G
Chain Pitch 450G,
LubricatedDistance
455G, 550G
Across Single Joint......................................................... 171 mm (6.7 in.)
LubricatedDistance
100% Worn.................................................................... 185 mm (8.7 in.)
Across Four Pins of New
Chain.............................................................................. 160 mm (6.3 in.)
100% Worn.................................................................... 171 mm (6.7 in.)
TX,0130,BD806 1908OCT931/1
Adjust Track Sag

SPECIFICATIONS
Idler and Carrier Roller Track Sag 51 6 mm (2 1/4 in.)
Grease Gun Pressure 55,200 kPa (550 bar) (8000 psi)
T6044CJ UN23FEB89
NOTE: Check sag after a short period of operation when
changing from one ground condition to another or
when operating in extreme soil packing conditions.
1. Allow machine to slowly roll to a stop in the forward

direction. For the most accurate measurement, a link
pin must be centered on the carrier roller.
2. Use a straightedge across the top track shoes at the
longest span of the track chain to measure sag:
450G, 455GBetween carrier roller and sprocket
Specification 550G, 650GBetween carrier rollers
Idler and Carrier 555GBetween idler and carrier roller
RollerTrack Sag................................................ 51 6 mm (2 1/4 in.)
Continued on next page TX,0130,BD740 1908OCT931/2

061411
PN=90
Track System
CAUTION: When working near the track adjuster

or recoil spring, USE EXTREME CARE. DO NOT
disassemble parts unless the correct procedure
and tools are used to prevent bodily injury.
3. For 450G, 455G and 550G machines (S.N. 791496),
T7756AC UN03NOV92
and 555G and 650G machines (S.N. 791415 ),
remove cap screw to open cover (D) over adjuster
fittings.
IMPORTANT: Track adjuster cylinder has a
special high pressure fitting. Replace with
correct type fitting only.
(S.N. 781708)
4. To decrease track sag (tighten chain), apply grease to
special high pressure fitting (C) using a 55,200 kPa
(550 bar) (8000 psi) capacity grease gun.
Specification
Grease GunPressure......................... 55,200 kPa (550 bar) (8000 psi)
After adding grease, operate machine to allow track

adjuster cylinder to fully adjust and then check sag
again.
CAUTION: Grease for track adjuster cylinder is

under high pressure. Never remove special high
pressure fitting (C) to release the grease.
If grease does not escape immediately from vent
hole when relief or check valve is open, slowly
drive machine forward and reverse until grease
escapes then close relief or check valve.
5. To increase track sag (loosen chain), loosen

relief valve or check valve (B) one to two turns
counterclockwise to release grease through vent hole
T7756AA UN03NOV92
(A). DO NOT loosen special fitting (C). Tighten valve.
After releasing grease, operate machine to allow track
adjuster cylinder to fully adjust. Check sag again.
AVent Hole CSpecial High Pressure

BRelief/Check Valve Fitting
DCover
(S.N. 781709 )
T8055BE UN29JUL93
Latest Units
TX,0130,BD740 1908OCT932/2

061411
PN=91
Track System
Remove Sealed Track Chain

1. Rotate track to position the master pin on the front
idler as shown.
NOTE: Master pin is identified by drill point in end of pin.
T93554 UN01NOV88
CAUTION: Make sure track is off floor
before rotating.
2. Remove track shoes on each side of master pin. (See

procedure in this group.)
TX,01,RB504 1917FEB981/5

hole when relief or check valve is open, slowly
T8043AG UN29JUL93
3. Release track tension:

a. If equipped, remove cap screw to open fitting cover.
b. Turn relief valve (A) or check valve (B) one to three
(S.N. 781708)
turns counterclockwise to release grease through
vent hole.
c. DO NOT loosen special fitting (C).
d. Tighten valve.
T8055BF UN29JUL93
(S.N. 781709 )

061411
PN=92
Track System
IMPORTANT: Do not remove the track master pin with

a hammer. This will enlarge the link pin bore
requiring installation of a new track link.
4. Remove master pin from track link using master pin

pusher. Install aligning adapter (A) into master pin
pusher Cframe securing with holding screw (B). Put
T93556 UN01NOV88
aligning bushings (C) over forcing pin (D) and install
adapter (E) in Cframe.
AAligning Adapter DForcing Pin

BHolding Screw EPin Adapter
CAligning Bushing
TX,01,RB504 1917FEB983/5
5. Position master pin pusher and forcing pin in alignment

with master pin using load positioning sling and hoist.
6. Turn ram adjusting screw (B) clockwise with crank
until forcing pin (A) contacts master pin.
7. Connect hand pump to pin pusher. Activate pump to
T93557 UN01NOV88
remove master pin.
8. Remove forcing pin to separate track.
T93644 UN01NOV88

061411
PN=93
Track System
9. Pull track chain apart. Remove spacers (B) and seals

(A) from between left and right track links.
10. Lift side of machine or operate crawler and rotate
track in the reverse direction. Slowly, unwrap track off
drive sprocket.
T93558 UN01NOV88
11. Place a jack under both crossbars and raise crawler to
provide clearance. Block crawler up securely.
T59376 UN17MAY89
1 Track Chain 4 Bushing 7 Master Bushing
2 Right Track Link 5 Left Track Link 8 Spacer (Master Bushing)
3 Belleville Seals 6 Pin, Standard Pin, Master 9 Pin and Bushing Repair Kit
(Drill Point On End)
TX,01,RB504 1917FEB985/5

061411
PN=94
Track System
Turn Sealed Track Chain Pins and Bushings

NOTE: Wear on pins and bushings does not extend
over the entire surface. Turning pins and bushings
are determined by the amount of wear. (See
Measure Track Bushing Wear and Measure
Track Pitch Wear in this group.)
T6044AY UN01NOV88
1. Sealed track must be removed and disassembled to
turn bushings and pins. (See procedures in this
group.)
2. Mark lines (5 and 4) on worn sides of pins (1) and
bushings (2) in respect to links. Mark lines (3 and 6)
on link 180 from lines (4 and 5).
3. Turn pins and bushings 180 in saddle until location 1 Pin 4 Bushing Worn Side
2 Bushing Reference Mark
marks (4 and 5) on pins and bushings align with marks 3 New Position Reference 5 Pin Worn Side Reference
(3 and 6) on link. Mark Mark
6 New Position Reference
4. Assemble track chain and install on machine. (See Mark
procedures in this group.)
TX,01,RB418 1910FEB981/1
Disassemble and Assemble Sealed Track

Chain Using Track Press
Tooling Set A2656139
Saddle 40989
See your track press manufacturers operators manual to 555G, 650G:
disassemble and assemble sealed track chain.
Use following tooling:
Saddle 42101
450G, 455G, 550G:
0130,BB39 1924AUG931/1

061411
PN=95
Track System
Install Sealed Track Chain

IMPORTANT: Track chain MUST be installed
under track frame with wide end of links
toward rear of machine or accelerated wear
to track chain will occur.
T113175 UN29JAN98
1. Position track chain under crawler with wide part of
links (A) toward rear of crawler.
2. Put end of chain on sprocket then slowly turn sprocket
in forward direction to pull chain across top of frame
to front idler.
3. Put two seals (5) into counterbore of end link with seal Drive Sprocket End Shown
inside diameters touching.
4. Install master bushing spacers (3) with flat side against
seal and push end links together.
5. Install forcing pin to align links (1 and 6), bushing (4),
seals (5), and spacers (3).
1 Right Track Link 4 Master Bushing

2 Forcing Pin 5 Seals
3 Master Bushing Spacer 6 Left Track Link
T6043AR UN01NOV88

061411
PN=96
Track System
6. Apply oil to master pin (5).

7. Position master pin pusher (1) on track.
8. Press master pin (5) into end links.
NOTE: If master pin does not fit securely into links, an
T6552AD UN01NOV88
oversize master pin is recommended.
9. Install track shoes. (See procedure in this group.)

10. Adjust track sag. (See procedure in this group.)
1 100 Ton Master Pin Pusher 4 Aligning Bushings

2 Guide Pin 5 Master Pin
3 Aligning Adapter 6 Rear Forcing Pin
T6043AQ UN01NOV88
TX,01,RB505 1917FEB982/2

061411
PN=97
Track System
Remove and Install Lubricated Track

ChainInterlock Master Link
T8043AG UN29JUL93
hole (D) when relief or check valve is open, slowly

(S.N. 781708)
vent hole. DO NOT loosen special fitting (C).
c. Tighten valve.
T8055BF UN29JUL93
2. Rotate track until split link pin is at 11 oclock position
for the right side and 1 oclock position for the left side
with respect to idler.
3. Block track at front idler.
4. Put a block on top of recoil spring cover to keep chain
at proper height. (S.N. 781709 )
5. Remove shoe at master split link. (See procedure in

this group.)
ARelief Valve CSpecial Fitting

BCheck Valve DVent Hole
Continued on next page T8055AE UN27JUL93

TX,0130,BD744 1914JUN111/6

061411
PN=98
Track System
6. Put (1/4 in.) nuts (A) on pin end of split link.

DF1067 Master Link Separator Tool (A) can be used
instead of nuts to separate track chain. Longer cap
screws are also required. Refer to Group 0199 to
make and use tool.
T6549BR UN10FEB89
T6913AN UN10FEB89
TX,0130,BD744 1914JUN112/6
7. Install shoe using two cap screws in bushing half of

split link. Tighten bolts evenly to disassemble links.
Strike shoe while tightening cap screws if necessary.
8. Remove shoe.
T6549BS UN10FEB89
Continued on next page TX,0130,BD744 1914JUN113/6

061411
PN=99
Track System
9. Install four shoe cap screws fully into links. Cap

screws will protect link surface during separation and
joining of master link.
CAUTION: Track chain will fall to the ground

when separating master link. DO NOT
T6549BT UN10FEB89
stand at end of track.
10. Use a heavy hammer to hit down on pin end of master

link, alternately hitting each side of master link. Hit
bushing end links up by striking up on bottom of shoe
alternately on each side.
TX,0130,BD744 1914JUN114/6

(A) toward rear of machine or accelerated
wear to track chain will occur.
11. To join master link, locate master link pin end at 11
T113175 UN29JAN98
oclock for the right side, 1 oclock for the left side (12
oclock for new track) in relation to the front idler.
12. Bring other end of chain over carrier roller.
13. Apply John Deere NEVERSEEZ Lubricant to mating
surfaces of master link.
14. Use a comealong device to bring master link halves Drive Sprocket Rear End Shown
together. Bushing end must go over pin end.
T6549BU UN10FEB89


061411
PN=100
Track System
15. Alternately strike bushing end cap screws with lead

hammer while holding a bar under pin end of master
link.
16. Remove cap screws. Apply John Deere
NEVERSEEZ Lubricant to cap screw threads.
T6352AH UN23FEB89
17. Install shoe. Start cap screws by hand to avoid
crossthreading.
Specification
Split Link Cap Screw
(450G, 455G, 550G) (1/2
in.)Torque..................................................... 61 Nm (45 lbft) Seconds
(450G, 455G, 550G)
IMPORTANT: Tighten cap screws to the initial torque
(9/16 in.)Torque.............................................. 88 Nm (65 lbft) Second
using a crisscross pattern. Repeat pattern for
a second time. Finally turn each cap screw the
additional turn using the same pattern.
(555G, 650G) (5/8
in.)Torque................................................... 149 Nm (110 lbft) Second
TX,0130,BD744 1914JUN116/6
Remove and Install Lubricated Track

ChainSingle or Saw Tooth Master Split Link
1. Rotate track until split link pin is at the top of front idler.
2. Block track at front idler.
T8055BG UN29JUL93
3. Put a block on top of recoil spring cover, near front
idler to keep chain supported.

061411
PN=101
Track System

hole (D) when relief or check valve is open, slowly
T8043AG UN29JUL93

(S.N. 781708)
vent hole (D). DO NOT loosen special fitting (C).
c. Tighten valve.
CAUTION: Track chain will fall to the ground when

removing cap screws from shoe to separate
T8055BF UN29JUL93
master link. DO NOT stand at end of track.
5. Remove shoe at master split link. (See procedure in

this group.)
ARelief Valve CSpecial Fitting

BCheck Valve DVent Hole
(S.N. 781709 )
T8055AE UN27JUL93

061411
PN=102
Track System

(A) toward rear of machine or accelerated
wear to track chain will occur.
6. To join master link, locate master link pin end at the top
T113175 UN29JAN98
of the front idler. Put a block at the front of the idler.
7. Apply John Deere NEVERSEEZ Lubricant to mating
surfaces of master link.
8. Use a comealong device to bring master link halves
together.
9. Install shoe and new caps screws. Apply John Deere Drive Sprocket End Shown
NEVERSEEZ Lubricant to cap screw threads. Start
cap screws by hand to avoid crossthreading.
TX,01,RB506 1914JUN113/4
IMPORTANT: Tighten cap screws to the initial torque

using a crisscross pattern. Repeat pattern for
a second time. Finally turn each cap screw the
additional turn using the same pattern.
T6352AH UN23FEB89
Split Link Cap Screw (450G, Torque 88 Nm (65 lbft) Second

455G, 550G) (9/16 in.) PassAdditional 1/2 (180) turn
Split Link Cap Screw (555G, Torque 149 Nm (110 lbft) Second
TX,01,RB506 1914JUN114/4

061411
PN=103
Track System
Disassemble Lubricated Track Chain to Turn Bushings and Relubricate Chain

NOTE: The following procedure is for disassembly of
track chain to inspect, clean, replace damaged or
worn parts, turn bushings, and relubricate chain.
If track chain is disassembled only to turn pins
and bushings and no parts will be replaced, see
Disassemble Lubricated Track Chain to Turn Pins
T96266 UN27OCT88
and Not Relubricate, in this group.
1. Remove track shoes and track chain. (See procedure

in this group.)
NOTE: A clean track is necessary for proper disassembly.
2. Wash chain with high pressure water. It will not be

necessary to wash links before reassembly if chain in
ALeft Ram EBushing
thoroughly cleaned. BSaddle F Left Link
CRight Ram GPin
3. Use the following track press tool sets: DRight Link
450G, 455G, 550G
Saddle 40989 CAUTION: Always wear safety glasses when
operating the press. Parts may break or chip,
555G, 650G which could create a risk of personal injury.
Saddle 42101 1 6. Extend right ram (C) to push pin (G) and bushing (E)
from the right link (D). The right link is forced against
IMPORTANT: Track press disassembly tools must the side of saddle (B) as pin and bushing are pushed
be in proper alignment with links to prevent out.
broaching of pin and bushing. Damaged
link bores cannot be reused. 7. Retract right ram. The right link, with seals and thrust
ring, will stay on the ram tools.
4. Start disassembly at penend half of split link. Check
for proper alignment of tools with pin and bushing.
5. Make an index mark on bushings to aid in reassembly,
when turning bushings 1/2 turn (180) to expose a
new wear surface.
1
For stepped bushing design, use 052657001 saddle.
TX,01,RB507 1917FEB981/4
8. Extend left ram (A) to push the pin (C) and bushing (F)
from left link (G). The left link is forced against the side
of saddle (B) as pin and bushing are pushed out.
9. Retract left ram. The left link, with seal and thrust ring,
will remain on the ram tools.
T96267 UN27OCT88
10. Remove links, bushing, and thrust rings from press.
ALeft Ram ERight Link

BSaddle F Bushing
CPin GLeft Link
DRight Ram

061411
PN=104
Track System
11. Inspect parts as they are disassembled to determine

which ones can be reused.
If there is internal wear at any joint, replace seal ring,
pin, bushing, thrust ring, and load ring. These parts
must be replaced to successfully relubricate chain.
T6682AJ UN01NOV88
12. If pin and bushing contains oil when disassembled,
new pins, seal rings, bushings, thrust ring and load
rings are not necessary. Do not remove usable seals
from link counterbore. Do not remove any dirt from
around seals.
13. Repeat steps 412 to disassemble rest of chain.
14. Remove rubber stopper (F) from pins using a drill.
ABushing DThrust Ring
BSeal Ring EPin
CLoad Ring F Stopper
TX,01,RB507 1917FEB983/4
15. Inspect pin ends. If the chamfer is missing due to

wear, grind a 3 mm (0.12 in.) x 10 chamfer on pin. If
chamfer is missing in stopper hole, add new 4 mm
(0.16 in.) x 30 chamfer.
Specification
PinChamfer......................................................... 3 mm (0.12 in.) x 10
T96269 UN27OCT88
16. Clean pins, bushings, and thrust rings in solvent.
A4 mm (0.16 in.) C10

B30 D3 mm (0.12 in.)
TX,01,RB507 1917FEB984/4
Assemble Lubricated Track Chain to Turn

Bushings and Relubricate Chain
CAUTION: Prevent possible injury from

unexpected machine movement. Make
sure all control levers of press are in the
NEUTRAL position. T96272 UN27OCT88
1. Assemble track using following track press tool sets.

450G, 455G, 550G
Saddle 40989
555G, 650G
2. Apply a mixture of 50% alcohol and 50% water to
Tooling Set A2656217 stopper (A) and install using JDG589 Stopper Installer
Saddle 421011 (B).
1

061411
PN=105
Track System
NOTE: The pin end halves of master split link must be

temporarily assembled to bushing end halves of
link for proper positioning on plungers. Pin end
halves will have to be separated later for installation
at end of chain. Split links are a matched set
and must be assembled as a set.
T96273 UN27OCT88
3. Assemble master split link halves using master shoe
bolts and washers (as required). Tighten bolts just
enough to hold links together.
4. Install assembled split links on ram plungers.
5. Install bushing (A) in front seat of saddle (B) so the
mark is 180 opposite original location to expose a
new wear surface.
TX,01,RB508 1914JUN112/14
6. Adjust track press pressure relief valve setting.

Specification
Pressure Relief
Valve Setting 450G,
455G, 550GForce
(Maximum)................................................... 284 088 N (63,840 lb force)
Pressure Relief
Valve Setting
555G, 650GForce
7. Advance left ram until left split link contacts saddle.

Advance right ram until it stops to press split link and
bushing assembly together.
T96274 UN27OCT88

061411
PN=106
Track System
8. Measure bushing projection from shoulder of link using

a depth micrometer. Bushing projection determines
clearance between overlapping links and proper
spacing of link bolt holes.
Specification
Bushing Protec
T96275 UN27OCT88
tion450G, 455,
550GDistance.................................... 1.88 0.25 mm (.074 .010 in.)
Bushing Protec
tion555G, 650GDis
tance...................................................... 1.70 0.25 mm (0.67 .010 in.)
9. If bushing projection does not meet specification,

check pressure setting or adjust shim packs behind
plungers. Only first two joints must be checked for
proper bushing projection.
TX,01,RB508 1914JUN114/14
10. Apply track chain lubricant to bushing ends before

next set of links are installed.
T96276 UN27OCT88
TX,01,RB508 1914JUN115/14
IMPORTANT: Pins must be installed so crossdrilled

hole is toward link wear surface or they may
break when chain is used. To make assembly
easier, install all pins so holes in end are
toward same side of chain.
11. Install pin in bushing so crossdrilled hole (B) is toward
T96277 UN27OCT88
link wear surface. Install all pins so hole (A) in end is
toward same side of chain, either left or right.

061411
PN=107
Track System
12. Install a thrust ring on each end of pin.

13. Move completed split link assembly to rear seat of
saddle.
T96278 UN27OCT88
TX,01,RB508 1914JUN117/14
14. Apply LOCTITE plastic gasket to link bore. The

sealant prevents loss of vacuum or lubricant leakage
through pin to link joint.
T96279 UN27OCT88

061411
PN=108
Track System
15. Install bushing (D) in front saddle seat. Install left link
(A) and right link on ram plungers.
Assemble load ring (C) and seal ring (B). Install
assembly into link (A) counterbore so pointed lip of
seal ring is toward bushing (D).
ALink Counterbore CLoad Ring

BSeal Ring DBushing
T7158AU UN12APR90
TX,01,RB508 1914JUN119/14
16. Advance left ram until left link contacts saddle.

Advance right ram until it stops (plungers in both rams
against shim pack).
ALeft Ram F Right Link

BSaddle GBushing
CPin HShims
T96282 UN27OCT88
DPlunger I Left Link
ERight Ram
T96283 UN27OCT88

061411
PN=109
Track System
NOTE: To ensure zero end play in joint, special

spacers must be fabricated using a section of
bushing. A different size spacer is used for
450G, 455G, 550G, 555G, and 650G.
17. Retract left ram. Install special spacer (A) between the
joint in rear seat of saddle and ram.
T96284 UN27OCT88
IMPORTANT: Too much pressure will crush
the thrust rings.
18. Advance left ram using only minimum force required

to push joint tight. Pressure must be approximately
onehalf the relief valve setting.
TX,01,RB508 1914JUN1111/14
19. After one complete joint has been assembled, check

end play of track links to make sure bushing, thrust
rings, and link counterbore faces are pressed solid
against each other. Position base of dial indicator on
one link assembly and pointer against the other link
assembly.
20. Pry link assemblies in one direction then in opposite
direction to measure the amount of end play. End
play must be zero.
21. As track chain is being further assembled, end play
may be checked by flexing each joint after each link
assembly is pressed together. End play is correct if
links cannot be rotated by hand.
T96285 UN27OCT88

061411
PN=110
Track System
22. As chain is being assembled, check to make sure

there is some clearance between the overlapping face
of links, using a feeler gauge. If links contact each
other, check bushing projection.
Specification
Bushing Protec
T96286 UN27OCT88
tion450G, 455,
550GDistance.................................... 1.88 0.25 mm (.074 .010 in.)
Bushing Protec
tion555G, 650GDis
tance...................................................... 1.70 0.25 mm (0.67 .010 in.)
TX,01,RB508 1914JUN1113/14
23. Add oil (SAE 80W 90) using a D0890 Seal Tester and
Lubricator and A2679 Nozzle (C). Push nozzle through
stopper all the way into pin. Depress control lever on
the handle enough to draw a vacuum of 68102 kPa
(2030 in. Hg) as indicated on the gauge.
Specification
T96287 UN01NOV88
GaugeVacuum........................................68102 kPa (2030 in. Hg)
24. Release lever. If there is no decrease in vacuum for

a minimum of five seconds, the joints are sealed. If
there is a vacuum decrease, seals are not sealing and
the joint must be taken apart and repaired.
25. Add oil by depressing the second lever. Oil pressure
(read on the same gauge) must be 140205 kPa
(1.42.0 bar) (2030 psi) after both levers are
released.
Specification
OilPressure.........................140205 kPa (1.42.0 bar) (2030 psi)
T6465AY UN01NOV88
26. Slowly pull nozzle out to allow any compressed air to
escape through nozzle from first hole (A) to second
hole (B).
27. Repeat Steps 1025 for all joints.
28. Install assembled split links on ram plungers, and
advance rams to press split links together.
29. Install lubricated track chain. (See procedure in this
group.) 30. Install track shoes. (See procedure in this group.)
TX,01,RB508 1914JUN1114/14

061411
PN=111
Track System
Disassemble and Assemble Lubricated Track Chain to Turn Pins and Not Relubricate
NOTE: The following procedure is for disassembly of
track chain only to turn pins and bushings. (Chain
is not relubricated after assembly.)
If this procedure does not apply to repair job,
see Disassemble Lubricated Track Chain to Turn
Bushings and Relubricate Chain.
T96266 UN27OCT88
1. Remove track shoes. (See procedure in this group.)
2. Use the following track press tool sets:
450G, 455G, 550G
Saddle 40989
ALeft Ram EBushing
555G, 650G BSaddle F Left Link
CRight Ram GPin
Tooling Set A2656217 DRight Link
Saddle 421011
IMPORTANT: Track press disassembly tools must
be in proper alignment with links to prevent
broaching of pin and bushing. Damaged CAUTION: Always wear safety glasses when
links cannot be reused. operating the press. Parts may break or chip,
which could create a risk of personal injury.
3. Check for proper alignment of tools with pin and
bushing. 5. Extend right ram (C) to push pin (G) and bushing (E)
from the right link (D). The right link is forced against
4. Make an index mark on bushings and pins to aid in the side of saddle (B) as the pin and bushing are
assembly, when turning bushings 1/2 turn (180) to pushed out.
expose a new wear surface.
6. Retract right ram. The right link, with seals and thrust
ring, will stay on the ram tools.
1
TX,01,RB509 1914JUN111/10
7. Extend left ram (A) to push the pin (C) and bushing (F)
from the left link (G). The left link is forced against the
side of saddle (B) as pin and bushing are pushed out.
8. Retract left ram. The left link, with seal and thrust ring,
will remain on the ram tools.
T96267 UN27OCT88
9. Remove links and bushing from press.

10. Repeat Steps 49 to disassemble rest of chain.
11. All pins, bushings, seals, and thrust rings are used for
reassembly, because chain is not relubricated. Do not
remove stopper and plug from pins. Do not remove
seals from track links.
ALeft Ram ERight Link

BSaddle F Bushing
CPin GLeft Link
DRight Ram

061411
PN=112
Track System
12. Inspect pin ends for wear. If there is no chamfer, grind

a new 3 mm (0.12 in.) x 10 chamfer.
Specification
A10 B3 mm (0.12 in.)
T5798AJ UN26OCT88
TX,01,RB509 1914JUN113/10
13. Smooth area of track link wear (A) using a grinder, if

necessary.
T96289 UN27OCT88
TX,01,RB509 1914JUN114/10
14. Assemble track links using the following track press

tool sets:
450G, 455G, 550G
Saddle 40989
T96273 UN27OCT88
555G, 650G
Saddle 421011
NOTE: Pin end halves of master split link must be
temporarily assembled to bushing end halves of
link for proper positioning on plungers. Pin end
halves will later have to be separated for installation
at end of chain. Split links are a matched set 16. Install assembled split links on ram plungers.
and must be assembled as a set. 17. Install bushing (A) in front seat of saddle (B) so the
mark is 180 opposite original location to expose a
15. Assemble master split link halves using master shoe new wear surface.
bolts and washers (as required). Tighten bolts just
enough to hold link together.
1

061411
PN=113
Track System
18. Adjust track press pressure relief valve setting.

Specification
Pressure Relief
Valve Setting 450G,
455G, 550GForce
Pressure Relief
Valve Setting
555G, 650GForce
T96274 UN27OCT88
TX,01,RB509 1914JUN116/10
IMPORTANT: Pins must be installed so crossdrilled

hole is toward link wear surface or they
may break when chain is used.
19. Turn pin endforend to get a new wear surface, then

install it into bushing so crossdrilled hole (B) is toward
link wear surface. Install all pins so hole (A) in end
T96277 UN27OCT88
of pin is toward the same side of chain, either left or
right side.

061411
PN=114
Track System
20. Install a thrust ring on each end of pin.

21. Move completed link assemble to rear seat of saddle.
T96278 UN27OCT88
TX,01,RB509 1914JUN118/10
22. Install bushing (G) on front saddle seat. Install left and
right links on ram plungers.
23. Advance left ram until left link contacts the saddle.
Advance right ram until link is pressed together and
bolts can be installed.
T96283 UN27OCT88
ALeft Ram F Right Link
BSaddle GBushing
CPin HPlunger Shims
DPlunger I Left Link
ERight Ram
TX,01,RB509 1914JUN119/10
24. As chain is being assembled, check to make sure

there is some clearance between the overlapping face
of links using a feeler gauge. If links contact each
other, check bushing projection.
Specification
Bushing Protec
T96286 UN27OCT88
tion450G, 455,
550GDistance.................................... 1.88 0.25 mm (.074 .010 in.)
Bushing Protec
tion555G, 650GDis
tance...................................................... 1.70 0.25 mm (0.67 .010 in.)
25. Repeat Steps 1425 to assemble rest of chain.

26. Install assembled split link on ram plungers and 29. See Remove and Install Track Shoe in this group for
advance rams to press split links together. procedure to install shoes and tighten cap screws.
See Install Lubricated Track Chain in this group for
27. Install assembled split links on ram plungers. procedure to assemble split link and shoe.
28. Advance ram to press split links together until the joint
is tight. Protect split link ends from damage during
handling.
TX,01,RB509 1914JUN1110/10

061411
PN=115
Track System
Measure Front Idler Wear

100% worn is the maximum allowable height of flange
for rebuilding wear surface.
Measure height of flange using a depth gauge such as
JT05521 200 mm Ruler, JT05534 Right Angle Attachment,
T7225BA UN21FEB90
and D05231ST 300 mm Ruler from JT05518 or JT05523
Undercarriage Inspection Service Tool Kit.
Specification
450G, 455G, 550G
Flange NewHeight................................................... 19.5 mm (0.77 in.)
450G, 455G, 550G
Flange 100%
WornHeight.............................................................. 24.4 mm (0.96 in.)
555G, 650G Flange
See Front Idler Visual Checks
NewHeight............................................................... 17.5 mm (0.69 in.)
555G, 650G Flange See Front Idler Vertical Adjustment Check
100% WornHeight.................................................... 23.0 mm (0.91 in.)
See 450G, 455G, 550G Front Idler Flange Height
NOTE: See Undercarriage Appraisal Manual SP326
for additional information. See 555G and 650G Front Idler Flange Height
See Front Idler

TX,0130,QQ460 1914JUN111/1
Remove and Install Front Idler Assembly

1. Disconnect track chain. (See procedure in this group.)
2. Remove cap screws (A) from both sides.
3. Attach hoist and slide front idler forward off track
T113329 UN12FEB98
frame.
4. Install idler on track frame. Install and tighten four cap
screws and washers (A).
Specification
Adjusting Cylinder
YoketoIdler Bracket
Cap ScrewsTorque................................................. 163 Nm (120 lbft)
5. Connect track chain. (See procedure in this group.) 6. Adjust idler. (See procedure in this group.)
TX,01,RB510 1917FEB981/1
Disassemble and Inspect Front Idler

Assembly
1. Remove two cap screws (F) and lock washers on
bottom of both sides to remove shims (E) and wear
strap (D). Remove four cap screws (A) and lock
washers on both sides to remove guide (B) and shims
T93573 UN01NOV88
(C).
ACap Screw (8 used) DWear Strap (2 used)

BGuide (2 used) EShims
CShims F Cap Screw (4 used)
450G Shown

061411
PN=116
Track System
2. Remove idler brackets:

a. For 450G, 455G, 550G machines and 555G, 650G
machines (S.N. 771023), remove cap screw,
washer and Oring to remove bracket (A) on each
side. Heat may be required to loosen plastic gasket
on cap screws.
T93574 UN01NOV88
TX,01,RB511 1917FEB982/4
b. For 555G and 650G machines (S.N. 771024 ),

remove cap screws (B), washers (C) and tapered
locks (F). Tap on head of cap screw to loosen
tapered lock.
c. Remove brackets (E and I) and Orings (D).
APipe Plug (2 used) F Tapered Lock (2 used)

BCap Screw (2 used) GORing
CWasher (2 used) HPlug
DORing (2 used) I Right Bracket
ELeft Bracket J Idler Shaft
T8056AX UN09AUG93

061411
PN=117
Track System
T113189 UN19FEB98
AORing (555G and 650G, S.N. DPlate (2 used) GShaft (S.N. 771024 ) J Bushing (2 used)
771024 ) (2 used) ECap Screw (12 used) HDowel Pin (S.N. 771023) KIdler
BSeal Assembly (2 used) F Gasket (2 used) I Shaft (S.N. 771023)
CRing (2 used)
IMPORTANT: Keep metal face of seals (B) lubricated 4. Remove shaft (G or I) and inspect bushings (J) for
and together at all times while disassembled. wear or damage. Replace if necessary.
3. Remove parts (AF) on both sides of idler.
TX,01,RB511 1917FEB984/4
Assemble Front Idler Assembly

1. Clean all parts thoroughly.
Install new bushing using 66 mm and 71 mm disks.
Install bushing 0.79 mm (0.031 in.) below face of roller.
Specification
T93578 UN01NOV88
BushingDistance.....................0.79 mm (0.031 in.) below face of roller
NOTE: Replacement idler bushing are presized

after installation.
TX,01,RB512 1914JUN111/8
IMPORTANT: Lubricate idler bushing (B) with

oil before installing shaft.
2. Apply clean hydraulic oil to bushing (B). Install shaft

(A).
NOTE: Oil cross hole in shaft must be facing down on
T93577 UN01NOV88
machines 555G and 650G. After installation, the oil

fill hole should be on outside of idler on the left side
of machine. The fill hole should be on the inside
of idler on the right hand side of the machine.

061411
PN=118
Track System
3. Install thrust plate (A) and a new gasket (B) with

chamfered edge of thrust plate facing toward inside
of front idler.
T93576 UN01NOV88
TX,01,RB512 1914JUN113/8
4. Install seal ring (B).

5. Install three socket head cap screws and finger tighten
to position thrust plate, and seal ring.
6. Center seal ring on shaft using a JT30018 Seal
Centering Fixture (A) for 450G, 455G, 550G machines
T6044AK UN01NOV88
and 555G, 650G machines (S.N. 771023).
For 555G and 650G machines (S.N. 771024 ), use
JDG798 Seal Centering Fixture.

061411
PN=119
Track System
7. Install other three cap screws and tighten them all.

8. Remove seal centering fixture.
NOTE: DO NOT remove plastic retaining ring
from new seal.
T6044AI UN01NOV88
9. Install a new oil seal kit (A) with plastic retainer ring in
place. Side with retainer ring goes into seal ring. Seal
must be straight in bore.
10. Tighten cap screws. Repeat Steps 410 on other
side.
Specification
Seal Ring Socket Head
T6044AJ UN01NOV88
TX,01,RB512 1914JUN115/8
11. For 450G, 455G, 550G machines and 555G, 650G

machines (S.N. 771023):
a. Install outer bracket with pipe plug, on shaft end
with pin. Install inner bracket on opposite side. Use
care not to damage metal face seals.
T93580 UN01NOV88
IMPORTANT: DO NOT hit or strike brackets to
compress seals components can be damaged.
b. Push on brackets to compress metal face seals.

c. Apply plastic gasket to second through tenth thread
of brackettoshaft screws. Install washer, cap
screw and new Oring.
d. Tighten outer bracket special cap screw with Oring
plug and inner bracket cap screw.
Specification
BrackettoShaft Cap
ScrewsTorque......................................................... 612 Nm (450 lbft)

061411
PN=120
Track System
12. For 555G and 650G machines (S.N. 771024 ):

a. Install Orings (D) in groove of idler shaft (J).
b. Apply NEVERSEEZ on ends of idler shaft, from
Oring to the end of the shaft and to the tapered
locks (F).
c. Install brackets (E and I) on shaft, using care not to
damage Orings or metal face seals.
IMPORTANT: DO NOT hit or strike brackets to
compress seals, components can be damaged.
d. Push on brackets to compress metal face seals

and install tapered locks.
T8056AX UN09AUG93
e. Install and tighten cap screws (B) and washers (C).
Specification
Idler Shaft Retainer Cap
f. Seat tapered locks by tapping bottom of lock with

a punch and hammer. Tighten cap screw again.
Repeat this step two more times.
Specification APipe Plug (2 used) F Tapered Lock (2 used)
BCap Screw (2 used) GORing
Idler Shaft Retainer Cap
CWasher (2 used) HPlug
ScrewTorque............................................................... 54 Nm (40 lbft) DORing (2 used) I Right Bracket
ELeft Bracket J Idler Shaft
g. If removed, install plugs (A and H) and Oring (G).
TX,01,RB512 1914JUN117/8
13. Install shims (A), guide (B), and four cap screws and
lock washers on each side. Tighten cap screws.
Specification
Bracket Guide Cap
ScrewTorque..............................................................115 Nm (85 lbft)
14. Assemble wear plate (C) to bracket on each side using
T93581 UN01NOV88
same shims (D) as removed.
AShims CWear Plate (2 used)

BGuide (2 used) DShims
450G Shown
TX,01,RB512 1914JUN118/8

061411
PN=121
Track System
Idler Adjustment Procedure

SPECIFICATIONS
Idler450G, 455G, 550G, 555G, 8 mm (0.31 in.)
650G Maximum Height
Grouser Tip Maximum Height 2 mm [0.08 in.] off the ground
Track Chain And Wear Surface Of 3.5 mm (0.13 in.)
T6555DI UN10FEB89
Front Roller Clearance
Wear Strip and Clearance 0.8 mm 0.25 mm (0.030 0.010
in.)
Cap Screw Distance 05 mm (00.2 in.) below wear
strip surface
Adjust idler height to get optimum gradeability.

IMPORTANT: Adjust inside and outside shim packs at
the same time for proper idler adjustment. Specification
Idler450G, 455G,
Do Steps 14 if the track chain is removed. Do Steps 550G, 555G,
58, if track chain is still on machine. 650GMaximum
Height............................................................................... 8 mm (0.31 in.)
1. Rotate idler 360 to find maximum runout point.
Position maximum runout point at (C). Place straight 3. Adjust shims as required. Follow Steps 1114 and
edge on bottom side of several track rollers (A) and 1618 as follows.
under each tread surface of idler.
4. Install track chain.
2. Measure distance (B) from straight edge to idler.
TX,01,RB513 1917FEB981/9
5. Place machine on flat concrete or asphalt.

NOTE: Shoe tips (grousers) wear in a crown, make
measurements in middle of shoe width.
6. Check idler adjustment:
T6555DK UN25MAY89
a. Move machine so tip (dozer) or track pin (loader) is
directly under center line of idler.
b. Dozer machines onlyIf grouser tip touches floor
before it gets to center line or if too high (over 2 mm
[0.08 in.] off the ground), adjust idler height (Steps
720).
Specification
Grouser TipMaximum
Height........................................................ 2 mm [0.08 in.] off the ground

061411
PN=122
Track System
c. Loader machines onlyRemove rock guard. Check

clearance (C) (freetoturn to 3.5 mm [0.13 in.])
between track chain and wear surface of front roller.
Specification
Track Chain And
Wear Surface Of Front
T6744BA UN23AUG93
RollerClearance......................................................... 3.5 mm (0.13 in.)
If roller cannot be turned freely or clearance is too
great, adjust idler height (Steps 720).
TX,01,RB513 1917FEB983/9
7. Raise and block blade or bucket.

8. Idler height is adjusted by adding or subtracting shims
(D). Then adjust bottom shim pack (F) to obtain vertical
clearance specification. The adjustment procedure
is given in Steps 917.
AGuide Plate EWear Strip

BGuide Outer Shims F Bottom Shims
CIdler Block GTrack Frame
DTop Shims
T6555DJ UN25MAY89

061411
PN=123
Track System
9. Remove track shoe (A) for access to shims and cap

screws on inside if necessary.
NOTE: Track tension may need to be released to
align cap screws retaining bottom wear strip
with access slots in track frame.
T6549BV UN10FEB89
10. Remove cap screws (B).
11. Remove bottom wear strip and shims from both sides.
TX,01,RB513 1917FEB985/9
12. Remove inner and outer guide plates and shims.

13. Remove or add top shims as needed to position idler
as indicated in Step 6. Be sure to put thickest shim
next to track frame.
A different number of shims may be required on each
T6549BW UN10FEB89
side of idler to keep front idler in a vertical position.
14. Install inner and outer shims and guide plates.
15. Lower blade or bucket to raise track frame. Install
block under first roller for safety to prevent machine
from moving if oil moves from cylinders.
TX,01,RB513 1917FEB986/9
16. Install bottom wear strips (A). Add or remove shims (B)
under wear strip to obtain 0.8 mm 0.25 mm (0.030
0.010 in.) clearance (C).
Specification
Wear StripClearance................ 0.8 mm 0.25 mm (0.030 0.010 in.)
T6926BG UN06DEC88

061411
PN=124
Track System
NOTE: Cap screws can be installed by lifting front idler.
17. Check cap screw thread engagement before inserting

cap screws. End of cap screw should be 05 mm
(00.2 in.) below (A) wear strip surface.
Specification
T6555DM UN25MAY89
Cap ScrewDistance................................................................05 mm
(00.2 in.) below wear strip surface
Washers can be added under head of cap screw if
needed.
TX,01,RB513 1917FEB988/9
18. Check guide plate clearance (B). Plate must be close

to frame but not tight. Adjust shims (A) as needed.
Use equal number of shims on both sides to center
idler on track frame.
19. Remove block and lower machine.
T6555DN UN25MAY89
20. Install shoe, if removed. (See procedure in this group.)
21. Repeat this procedure for other idler.
TX,01,RB513 1917FEB989/9

061411
PN=125
Track System
Check Front Idler Oil Level

Removing the idler oil level plug does not always indicate
oil level. Possible vacuum in the oil cavity can keep oil
from flowing out. Idlers that appear low or out of oil may
have sufficient oil. Applying a small amount of low volume
T7883AP UN10NOV92
forced air into the idler will overcome the vacuum and
allow a small amount of oil to flow from idler.
NOTE: For the 555G and 650G machines, the oil fill hole
should be on outside of idler on the left side of
machine. The oil fill hole should be on the inside
of idler on the right hand side of the machine. On
555G and 650G machines (S.N. 771024 ), there
are no special cap screws on end of idler shafts.
Oil fill plug (B) is in the end of shaft.
1. Remove the oil fill plug (B).

If oil flows out, oil level is correct and install plug
T7883AS UN10NOV92
quickly.
If oil does not flow, remove the oil level plug (A). Insert
the nozzle of a plastic bottle (C) into the hole and
squeeze air pressure into idler. A slight amount of
pressure inside the idler will relieve any vacuum and
allow oil to flow from hole (B).
2. Add proper oil as necessary:
a. Install oil level plug (A).
f. Install and tighten oil level plug.
b. Remove the fill plug (B) and IMMEDIATELY install
Specification
AN142253 adapter and (1/8 in. NPT) grease fitting
into the adapter.
g. Quickly remove grease fitting and adapter and
c. Remove the oil level plug (A).
install fill plug.
d. Fill grease gun with recommended oil. (See Section
00, Group 0004.)
e. Add oil to grease fitting until oil flows from oil level
hole.
TX,01,RB424 1912FEB981/1

061411
PN=126
Track System
Remove and Disassemble Hydraulic Track Tension Adjuster (S.N. 745426)
T6676AA UN04OCT93
APiston DGrease Fitting GYoke
BPiston Seal EGrease Fitting HWasher (4 used)
CScraper Seal F Relief Valve I Cap Screw (4 used)
CAUTION: Grease for track adjuster cylinder 1. Remove front idler. (See procedure in this group.)
is under high pressure. Never remove special
2. Remove adjuster assembly from track frame.
grease fitting to release the grease. If grease
does not escape immediately from vent hole IMPORTANT: Do not pull piston from track adjusting
with relief valve open, slowly drive machine yoke unless seal and piston seal are to be
in forward and reverse until grease escapes. replaced or seals will be damaged.
DO NOT disassemble parts unless you know
the correct procedure and have correct tools. 3. To aid disassembly, remove grease fitting (E) to
(See your authorized dealer.) prevent suction.
If an accident occurs, see a doctor immediately. 4. Pull track adjusting piston (A) from yoke (G).
removed within a few hours or gangrene 5. Remove and discard piston seal (B).
may result. Doctors unfamiliar with this 6. Remove and discard yoke scraper seal (C).
Medical Department in Moline, Illinois, or other 7. Inspect and clean all parts.
knowledgeable medical source.
TX,01,RB514 1917FEB981/1

061411
PN=127
Track System
Assemble and Install Hydraulic Track

Tension Adjuster (S.N. 745426)
NOTE: If grease has been removed from track adjusting
yoke cylinder or if a new yoke cylinder is installed,
bleed yoke cylinder as follows: (a) with cylinder
release screw loosened, place a small amount of
T93583 UN01NOV88
grease in bottom cylinder, (b) move piston to bottom
of bore without seating oil seal. A small amount
of grease should be forced out the bleed hole.
If necessary, add grease and repeat procedure
until grease is observed at bleed hole.
1. Install scraper seal (A) on piston, metal side up.

2. Set conical seal installation tool (D) from JD284 AScraper Seal DConical Seal Installation
Hydraulic Adjuster Service Kit on piston (B) and BPiston Tool
lubricate tool. CPiston Seal ESeal Installation Driver
3. Insert piston seal (C), groove side up, on conical tool.

Using seal installation driver (E), drive the piston seal
onto recessed area of piston.
TX,01,RB515 1917FEB981/2
4. Insert approximately two tablespoons of grease in

cylinder and lubricate top 50 mm (2.0 in.) of cylinder
wall.
Specification
Cylinder WallDistance............................................ Top 50 mm (2.0 in.)
5. Place piston seal installing guide (A) from JD284
T93584 UN01NOV88
Hydraulic Adjuster Service Kit on piston seal. Tighten
cap screws. Force piston in by hand until seal clears
the flange. Remove piston guide.
6. Install scraper seal (B) into recess of cylinder using
driver (C).
7. Install track adjuster in track frame.
8. Install front idler. (See procedure in this group.)
TX,01,RB515 1917FEB982/2

061411
PN=128
Track System

061411
PN=129
Track System
Remove and Disassemble Hydraulic Track Tension Adjuster (S.N. 745427781708)
T7247BM UN04OCT93
APiston DYoke GCap Screw (4 used)
BScraper Seal EGrease Fitting HWasher (4 used)
CSeal F Relief Valve I Vent Hole
CAUTION: Grease for track adjuster cylinder 1. Remove front idler. (See procedure in this group.)
is under high pressure. Never remove special
grease fitting to release the grease. If grease
does not escape immediately from vent hole IMPORTANT: Do not pull piston from track adjusting
with relief valve open, slowly drive machine yoke unless seal and piston seal are to be
in forward and reverse until grease escapes. replaced or seals will be damaged.
the correct procedure and have correct tools. 3. To aid disassembly, remove grease fitting (E) to
(See your authorized dealer.) prevent suction.
If an accident occurs, see a doctor immediately. 4. Pull track adjusting piston (A) from yoke (D).
removed within a few hours or gangrene 5. Remove and discard scraper seal (B).
may result. Doctors unfamiliar with this 6. Remove and discard yoke seal (C).
Medical Department in Moline, Illinois, or other 7. Inspect and clean all parts.
TX,01,RB425 1912FEB981/1

061411
PN=130
Track System
Remove and Disassemble Hydraulic Track Tension Adjuster (S.N. 781709 )
T113174 UN29JAN98
APiston DYoke GCap Screw (4 used) J Cover (Later Units)
BScraper Seal EGrease Fitting HWasher (4 used) KCap Screw (Later Units)
CSeal F Check Valve I Vent Hole L Spring Pin (Later Units)
CAUTION: Grease for track adjuster cylinder IMPORTANT: Do not pull piston from track adjusting
is under high pressure. Never remove special yoke unless seal and piston seal are to be
grease fitting to release the grease. If grease replaced or seals will be damaged.
does not escape immediately from vent hole
with relief valve open, slowly drive machine NOTE: Grease fitting cover parts (J, K and L) will be
in forward and reverse until grease escapes. found on the following machines:
the correct procedure and have correct tools. 450G, 455G, 550G (S.N. 791496 )
(See your authorized dealer.) 555G, 650G (S.N. 791415 )
If an accident occurs, see a doctor immediately. 3. To aid disassembly, remove grease fitting (E) to
Any fluid injected into the skin must be surgically prevent suction.
4. Pull track adjusting piston (A) from yoke (D).
type of injury may call the Deere & Company 5. Remove and discard scraper seal (B) and yoke seal
Medical Department in Moline, Illinois, or other (C).
6. Inspect and clean all parts.
1. Remove front idler. (See procedure in this group.)
TX,01,RB426 1912FEB981/1

061411
PN=131
Track System
Assemble and Install Hydraulic Track

Tension Adjuster (S.N. 745427)
1. Fold seal (B) as shown and install into yoke (A) with
seal lip into bore first.
2. Install scraper seal (C) using 57 mm and 73 mm disks.
T7247BP UN09APR90
3. Install piston.
4. Install grease fitting.
T7247BQ UN09APR90
T7247BR UN09APR90
TX,01,RB516 1917FEB981/2
5. Install track adjuster in track frame.

6. Install idler and tighten cap screws (A).
Specification
Adjusting Cylinder
YoketoIdler Bracket
T93572 UN01NOV88
TX,01,RB516 1917FEB982/2

061411
PN=132
Track System
Remove and Install Track Idler Recoil Spring

IMPORTANT: When sliding idler assembly forward,
do not pull track adjusting piston from yoke
as scraper seal may damage piston seal.
1. Slide front idler with hydraulic track tension adjuster
T6555DH UN01JUN89
assembly forward.
2. Remove cover.
3. Thoroughly clean threads of rear cap.
CAUTION: Always use the special bolt to prevent

accidental release of idler recoil spring.
immediate or eventual failure creating a risk
4. Apply John Deere NEVERSEEZ Lubricant and of personal injury. Put a heavy protective
insert a T16678 Special Bolt and a 51 mm (2.0 in.) covering around spring assembly when handling,
spacer through track spring retainer plate and into transporting or disassembling.
rear cap.
Specification
A compression tool must be used for
SpacerWidth................................................................. 51 mm (2.0 in.)
disassembly and assembly because of the
extreme preload on spring.
Tighten bolt until spring compresses to 404 mm (15.9
in.) between outer end of front cap and rear cap. 5. Remove spring.
Specification 6. Release compression on track spring immediately
SpringLength............................................................ 404 mm (15.9 in.) after removal. (See Disassemble and Assemble
Recoil Spring in this group.)
CAUTION: Spring or rod may break if dropped
while handling, transporting or disassembling. 7. Install spring and cover.
Nicks or weld craters in spring and rod 8. Slide front idler with hydraulic track tension adjuster
assembly can cause stress concentration back, aligning spring nut with piston.
resulting in a weak spot that may result in
TX,01,RB517 1914JUN111/1

061411
PN=133
Track System
Disassemble and Assemble Recoil Spring
CAUTION: Spring or rod may break if dropped

while handling, transporting or disassembling.
Nicks or weld craters in spring and rod
assembly can cause stress concentration
resulting in a weak spot that may result in
immediate or eventual failure creating a risk
of personal injury. Put a heavy protective
covering around spring assembly when handling,
transporting or disassembling.
A compression tool must be used for
disassembly and assembly because of the
extreme preload on spring.
1. Put a 10ton jack on bottom of compression tool (A).

(See Group 0199 for instructions to make tool.)
Remove nuts (B) and top plate (C).
2. Put recoil spring in compression tool.
T6557DY UN25OCT88
Specification
Recoil SpringApproxi
mate Free Length......................................................... 447 mm (18.0 in.)
Test Length at 37 900
3790 N @ 8514 851 lb
force.......................................................... 378 3 mm (14.88 0.12 in.)

061411
PN=134
Track System
3. Install DFT1087 Recoil Spring Guard Tool (F). (See

Group 0199 for instructions to make tool.)
4. Install plate (A) and nuts (B) from ST4920 Recoil
Spring Tool to secure spring.
5. Be sure cap screw head (C) fits through hole in plate.
IMPORTANT: Cap screw head MUST be centered
through hole in plate for proper operation of tool.
6. Compress spring until cap screw (C) fully extends

through hole in plate.
7. Remove cap screw (C).
8. Slowly release jack pressure.
9. Remove nuts and plate.
10. Remove spring.
APlate DRecoil Spring

BNut (4 used) EHole in Plate
CCap Screw Head F DFT1087 Recoil Spring
T7126AA UN15SEP89
Guard Tool
T7247BN UN09APR90

061411
PN=135
Track System
T7247BO UN09APR90
ARear End Cap BSpring CStop Tube DFront End Cap
11. Remove parts. 13. Install parts.

12. Check spring for nicks or weld craters. Replace as
necessary.

061411
PN=136
Track System
14. Install 10ton jack on bottom of compression tool.

15. Put caps, tube and recoil spring (D) in compression
tool so spring is centered.
16. Install DFT1087 Recoil Spring Guard Tool (F). (See
Group 0199 for instructions to make tool.)
17. Install plate (A) and nuts (B) to secure spring.
18. Operate jack to compress spring.
19. Apply John Deere NEVERSEEZ Lubricant to
threads of special cap screw (C). Install special cap
screw through hole (E). Be sure cap screw threads
fully engage end cap.
20. Slowly release jack and remove nuts and plate.
21. Install spring assembly. (See procedure in this group.)
APlate DRecoil Spring

BNut (4 used) EHole in Plate
CCap Screw Head F DFT1087 Recoil Spring
Guard Tool
T7126AA UN15SEP89
T7247BN UN09APR90
TX,01,RB429 1914JUN114/4

061411
PN=137
Track System
Remove and Install Sprocket

1. Disconnect track chain.
2. Raise rear of machine using a 89 000 N (10 ton) floor
jack and block securely.
Specification
T93560 UN01NOV88
Floor JackForce........................................................ 89 000 N (10 ton)
CAUTION: Approximate weight of sprocket

is 59 kg (130 lb).
3. Remove nine cap screws (twelve cap screws on 555G,

650G) and lift sprocket from final drive.
Specification
Specification
SprocketWeight.............................................................. 59 kg (130 lb)
Drive Sprocketto
4. Sprocket is not repairable. If excessively worn or Axle Shaft Cap
damaged, replace. ScrewsTorque........................................................420 Nm Lubricated
(310 lbft) Lubricated
5. Install sprocket. Tighten cap screws.
6. Install track chain.
TX,01,RB518 1910OCT051/1
Remove and Install Track Frame

1. Remove track.
CAUTION: Approximate weight of track

frame is 464 kg (1000 lb).
T6674AE UN01NOV88
2. Attach hoist to frame using two chains to balance
track frame.
Specification
Track FrameWeight.................................................... 464 kg (1000 lb)
3. Position two 10ton floor stands to support machine

when removing frame.
4. Remove attaching hardware. Pull frame assembly
Specification
free of crossbars. Inspect and repair.
Track Frame Cap
5. Install frame. Tighten cap screws. ScrewsTorque......................................................... 600 Nm (443 lbft)
TX,01,RB431 1912FEB981/1

061411
PN=138
Track System

061411
PN=139
Track System
Remove and Install Frame Wear Strips
T8058AH UN13SEP93
ATrack Frame C450G, 455G, 550G 6 1.5 mm EWelded Areas

BWear Strip (2 used) (0.23 0.06 in.) 555G, 650G
8.4 1.5 mm (0.33 0.06 in.)
D30.8 mm (1.21 in.)
1. Remove front idler. (See procedure in this group.) 3. Grind track frame (A) wear strip surfaces smooth.
2. Remove wear strips (B). Area must be free of any weld spatter.

061411
PN=140
Track System
IMPORTANT: Good welds are important. Have 5. Clamp wear strip in position, using dimensions (C and
only a qualified welder do the procedure. D).
Use E7018 electrodes.
6. Weld each wear strip in eight places as indicated using
Before welding, clean all dirt and paint from E7018 electrodes.
the weld areas and turn battery disconnect
switch to OFF. Connect the welder ground clamp 7. Install and adjust front idler. (See procedures in this
close to each weld area so electrical current group.)
does not pass through any bearings.
4. If track frame is still on machine, make sure the battery

disconnect switch is turned to the OFF position.
TX,0130,BD826 1908OCT932/2

061411
PN=141
Track System

061411
PN=142
Group 0199
Dealer Fabricated Tools
DF1041 Track Nut Removal Tool
TX1074246 UN22APR10
DF1041 Track Nut Removal Tool
1 3/8 in. Drill and Tap 2 Weld Block Grind Round 3 2 Slots 9.5 mm x 19.0 mm (3/8 4 3/8 in. Drill and Tap Locates
in. x 3.4 in.) Nut with Cap Screw in
Assembly
Tool can be made in dealers shop. Used to remove and

install track shoe nuts. Material: 1020 Flat Stock
9900,WW11 1922MAR101/1

061411
PN=143
DF1067 Lubricated Track Split Master Link

Separator ToolEarlier Machines
Separator tool can be made in dealers shop. (See next
page to make part.) The "G" series, lube track, split
master link separation is simplified with the use of DF1067
Tool when placed between the track shoe and the master
link. Tool is designed using longer shoe cap screws, the
bushing half of the link can be pulled upward with out tool
interference.
Material:
19 mm (3/4 in.) Steel
450G, 455G, 550G(1/2 x 21/2 in.) FGrade (Fine
Thread Cap Screw (4 used)
555G, 650G(5/8 x 21/2 in.) FGrade, Fine (Thread
Cap Screw (4 used)
Procedure:
1. Remove track shoe from master link with link at 11
oclock position on front idler.
T7306AA 1930MAY90
2. Put DF1067 Tool on pin end of master link, making
sure there is no interference preventing separation.
3. Put track shoe over Tool and tighten cap screws at pin
end of master link.
4. Alternately tighten bushing end cap screws of master
link until there is approximately 10 mm (3/8 in.) of
separation.
IMPORTANT: Cap screw threads may strip
if overtightened.
5. Loosen master link pin end cap screws slightly to

allow for movement. Tighten bushing end cap screws
until bottomed.
6. Replace bushing end cap screws with original shoe
cap screws. Tighten until bushing end of link contacts
shoe.
7. Remove pin end cap screws and use a pry bar to
complete separation. T7306AB 1930MAY90

061411
PN=144
T7306AC 1930MAY90
DF1067 Separator Tool

TX,01,RB433 1912FEB982/2

061411
PN=145
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
T7162AF UN17OCT89
A3/16 in. 1020 CR Steel Plate C1/2 in. Nut (2 used) E1/2 x 3 in. Steel Round Stock
B9/16 in. Hole (2 places) D1/2 x 2 in. Cap Screw (2 used) (2 used)
Track Disassembly and Assembly Guard Tool is used with

ST4920 Track Recoil Spring Disassembly and Assembly 3/16 in. 1020 CR Steel Plate (A)
Tool. 1/2 in. Nut (C) (2 used)
1/2 x 2 in. Cap Screw (D) (2 used)
Material required: 1/2 x 3 in. Steel Round Stock (E) (2 used)
TX,01,RB432 1912FEB981/1

061411
PN=146
ST4920 Track Recoil Spring Disassembly

and Assembly Tool
NOTE: It is recommended that DFT1087 Track
Recoil Spring Disassembly and Assembly
Guard Tool be used with track recoil spring
disassembly and assembly tool.
Dimensions given are metric.
Tool is the same as used on other machines except the

holder (C). For each track adjuster use the holder with the
correct size hole for the nut on that track adjuster.
Track Recoil Spring Disassembly and Assembly Tool
(compression tool) is used with hydraulic jack to compress
recoil spring in track adjuster repair.
Material required:
1020 HR Steel for Holder (C), Supporting Plate (E),
Base Plate (F), and Base (G).
"D" Grade (SAE Grade 5) for Eyebolts (D), Nuts (A),
T6585UY UN24MAR98
and Cap Screws (H).
"F" Grade (SAE Grade 8) for Studs (B).
Print Numbers:
AST4050 Nut
BST4045 Bolt
CST4035 Holder (Plate)
ST4036 Holder (Plate)
ST4037 Holder (Plate)
ANut (12 used) F Base Plate
DST4047 Eyebolt BStud (4 used) GBase (4 used)
EST4040 Supporting Base CHolder HCap Screw (8 used)
FST4042 Base Plate DEyebolt (2 used) I Lock Washer (8 used)
GST4041 Base ESupporting Plate
HST4046 Cap Screw
IST4049 Lock Washer

061411
PN=147
T7029CI UN06JUL89

061411
PN=148
T7029CH UN06JUL89

061411
PN=149
T7029CG UN06JUL89
ANut (12 used) DEyebolt (2 used) GBase (4 used)

BStud (4 used) ESupporting Plate HCap Screw (8 used)
CHolder F Base Plate I Lock Washer (8 used)
TX,01,RB519 1917FEB984/4

061411
PN=150
Section 02
Axles and Suspension Systems
Contents
Page Page
Group 0250Axle Shaft, Bearings, and Remove and Install Steering Clutch
Reduction Gears Valve ...................................................... 0202601
Service Equipment and Tools .................... 0202501 Disassemble and Assemble
Other Material............................................ 0202502 Steering Clutch Valve (S.N.
Specifications ............................................ 0202503 770807).............................................. 0202602
Remove and Install Final Drive.................. 0202505 Disassemble and Assemble
Disassemble and Assemble Final Steering Clutch Valve (S.N.
Drive .................................................... 02025010 770808 )............................................. 0202603
Adjust Pinion Shaft Preload..................... 02025017 Adjust Steering Clutch Valve ..................... 0202604
Adjust Idler Shaft Preload for Remove and Install Steering Brake
Double Reduction Drives..................... 02025018 Cylinder ................................................. 0202606
Adjust Axle Shaft Preload........................ 02025020
Remove and Install Steering Group 0299Dealer Fabricated Tools
Clutch .................................................. 02025022 DF1030 Brake Assembly Tool ................... 0202991
Disassemble and Assemble DF1063 Final Drive Lift Bracket................. 0202992
Steering Clutch (S.N. DF1063A Single Reduction
770807)............................................ 02025028 Adapter Plate......................................... 0202993
Disassemble and Assemble DF1063B Double Reduction
Steering Clutch (S.N. 770808 Adapter Plate......................................... 0202993
) ........................................................... 02025030
Steering Brake Anchor (S.N.
770807)............................................ 02025032
Steering Brake Anchor (S.N.
770808 )........................................... 02025034
Steering Brake Linkage (S.N.
770807)............................................ 02025035
Steering Brake Linkage (S.N.
770808 )........................................... 02025039
Adjust Steering Brake Linkage ................ 02025043
Adjust Steering Brake SelfAdjuster
Linkage (S.N. 770807) ..................... 02025045
Manual Steering Brake Adjustment
(S.N. 770807)................................... 02025046
Manual Steering Brake Adjustment
(S.N. 770808 ).................................. 02025048
Adjust Steering Brakes
LinkagePedal Steer.......................... 02025050
LinkageLever Steer (S.N.
770807)............................................ 02025052
LinkageLever Steer (S.N.
770808)............................................ 02025054
Engage Tow Disconnect Pins
Manually .............................................. 02025056

Other Material............................................ 0202601
Specifications ............................................ 0202601

061411
PN=1
Contents

061411
PN=2
Group 0250
Axle Shaft, Bearings, and Reduction Gears
Service Equipment and Tools
NOTE: Order tools from the U.S. SERVICEGARD or
from the European Microfiche Tool Catalog (MTC).
Some tools may be available from a local supplier.

TX,02,RB520 1914JUN111/9
Slide Hammer and Attachment

Used to remove final drive pinion.
TX,02,RB520 1914JUN112/9
Lifting Bracket.......................................................JT01748 Used to remove and install transmission components.

TX,02,RB520 1914JUN113/9
Adapter .................................................................JT01773
Used to remove pinion and steering clutch shafts.
TX,02,RB520 1914JUN114/9
Service Stand
Used to hold final drives for service.
TX,02,RB520 1914JUN115/9
Assembly Tool1 ......................................................DF1030 Used to install brake anchor.

1
Dealer fabricated tool. (See Group 0299 for instructions to make tool.)
TX,02,RB520 1914JUN116/9
Final Drive Lift Bracket1 .........................................DF1063

Remove and install final drive.
1
TX,02,RB520 1914JUN117/9
Single Reduction Adapter Plate1 ........................ DF1063A Remove and install final drive.
1
TX,02,RB520 1914JUN118/9
Double Reduction Adapter Plate1 ....................... DF1063B

Remove and install final drive.
1
TX,02,RB520 1914JUN119/9

061411
PN=153
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to cap screw threads.
TY9473 (Canadian) Strength)
242 (LOCTITE)
TY9375 (U.S.) Pipe Sealant To be applied to steering clutch

TY9480 (Canadian) elbow fitting.
592 (LOCTITE)

TX,02,RB435 1912FEB981/1

061411
PN=154
Specifications
Transverse Case Capacity 83 L (22 gal)

Final Drive
450G, 455G, 555G Capacity 5.5 L (1.5 gal)
450GLT Capacity 8.5 L (2.25 gal)
550G, 650G Capacity 9.8 L (2.50 gal)
HousingtoFinal Drive Housing Torque 320 Nm (236 lbft)
Cap Screw
Single Reduction Final Drive Weight 169 kg (374 lb)
Double Reduction Final Drive Weight 282 kg (580 lb)
Flanged Axle Shaft Weight 25 kg (56 lb)
Final Drive Gear Weight 35 kg (78 lb)
Final Drive Spacer Weight 59 kg (129 lb)
Rear Counterweight Weight 134 kg (304 lb)
Steering Clutch Assembly Weight 43 kg (95 lb)
Pinion Shaft
Bushing Depth Below End of Shaft 1.0 0.5 mm (0.04 0.02 in.)
Bearing Preload 450G, 455G, 555G 0.00.08 mm (0.00.003 in.)
Preload to Endplay 550G, 650G 0.025 mm to 0.080 mm (0.001 in. to
0.003 in.)
Bearing Quill Cap Screw (S.N. Torque 149 Nm (110 lbft)
785187)
Bearing Quill Cap Screw 450G, Torque 149 Nm (110 lbft)
455G, 555G (S.N. 785188 )
Bearing Quill Cap Screw 550G, Torque 278 Nm (205 lbft)
650G (S.N. 785188 )
Idler Shaft
ShafttoHousing Cap Screw Torque 130 Nm (96 lbft)
450GLT, 450GLGP
Bearing Quill Cap Screws 550G, Torque 278 Nm (205 lbft)
650G
Axle Shaft
Retainer Cap Screw (S.N. Torque 149 Nm (110 lbft)
785187)
Retainer Cap Screw 450G, 455G, Torque 149 Nm (110 lbft)
555G (S.N. 785188 )
Retainer Cap Screw 550G, 650G Torque 278 Nm (205 lbft)
(S.N. 785188 )
Bearing 450GLGP (S.N. 795143 Preload 0.13 0.03 mm (0.005 0.001 in.)
)
Bearing (All Other Models) Preload 0.23 0.05 mm (0.009 0.002 in.)
Continued on next page 0250,EE2 1908SEP931/2

061411
PN=155

Final Drive Pan Cap Screws
450G, 450GLT and 450GLGP Initial Torque 61 12 Nm (45 9 lbft)
(S.N. 795142), 455G, 555G
Final Torque (after 20 min.) 81 Nm (60 lbft) but do not exceed a
90 turn
450GLT and 450GLGP (S.N. Initial Torque 130 26 Nm (96 20 lbft)
795143 ), 550G, 650G
Final Torque (after 20 min.) 170 Nm (125 lbft) but do not exceed a
90 turn
Transverse Case Cover
Cap Screws
Small Rear Cover Cap Screws Torque 130 26 Nm (96 19 lbft)
(M12)
Large Rear Cover Cap Screws Torque 620 124 Nm (458 91 lbft)
(M20)
Steering Clutch
Piston HousingtoBrake Drum Torque 61 Nm (45 lbft)
Cap Screws
Thrust RingtoPiston Housing Torque 68 Nm (50 lbft)
Cap Screws
0250,EE2 1908SEP932/2

061411
PN=156
Remove and Install Final Drive

NOTE: Single reduction final drive is used on 450G,
455G and 555G machines. Double reduction final
drive is used on 550G and 650G machines.
T113221 UN03FEB98
1. Disconnect track chain and remove drive
sprocket. (See procedures in Group 0130.)
Single Reduction450GLT
T113222 UN03FEB98
Single Reduction450GLGP
T113223 UN03FEB98
Double Reduction (S.N. 785187)
T113224 UN03FEB98
Double Reduction (S.N. 785188 )

061411
PN=157
2. Remove drain plug (A) to drain final drive housing.

Approximate oil capacity is:
Specification
450G, 455G,
555GCapacity................................................................. 5.5 L (1.5 gal)
450GLTCapacity.......................................................... 8.5 L (2.25 gal)
T6656DQ UN19OCT88
550G, 650GCapacity.................................................... 9.8 L (2.50 gal)
IMPORTANT: DO NOT lock out brakes with tow

pins. Tow pins must be up and brakes applies
to hold steering clutch drum in place during
final drive pinion removal.
NOTE: The jack screw will support the steering clutch

when the final drive pinion shafts are removed.
3. Remove plug (B) from under the transverse case.

Turn jack screw (C) up into the transverse case until
contact is made with the steering clutch (D).
T6656DR UN19OCT88
ADrain Plug CJack Screw
BPlug DSteering Clutch
T7247AR UN09APR90
Transmission Removed for Clarity
TX,02,RB521 1917FEB982/9
NOTE: Idler quill shown removed. Idler quill does not

have to be removed to remove final drive assembly.
4. Remove pinion quill, shims, bearing cup and Oring.

5. Use a slide hammer and JT01773 Adapter to remove
pinion assembly (A).
T6645AD UN27OCT88

061411
PN=158
CAUTION: Approximate weight of final drives:

Single Reduction.............169 kg (374 lb)
Double Reduction............282 kg (580 lb)
IMPORTANT: Single reduction final drive and
T6926BM UN17JUL93
spacer cannot be removed as an assembly.
Remove final drive and then hidden cap
screw (A) to remove spacer.
6. Install DF1063 and DF1063A or DF1063B Final Drive

Lift Bracket and Adapter (B) to remove final drive.
(See Group 0299 for instructions to make tool.) Repair
final drive. (See procedure in this group.)
Specification
Single Reduction Final
DriveWeight.................................................................. 169 kg (374 lb)
Double Reduction Final
DriveWeight.................................................................. 282 kg (580 lb)
7. Clean all mating surfaces of spacer (if used), final

drive and transverse case.
Specification
Final Drive Cap
ScrewSingle
ReductionQuantity
Per Side.................................................................................................. 8
T113173 UN19FEB98
Final Drive Cap
ScrewSingle Reduction
with SpacerQuantity
Per Side................................................................................................ 23
Final Drive Cap
ScrewSingle Reduction
for Long TrackQuantity
Per Side................................................................................................ 16 Single Reduction450G Standard and Wide Track
Final Drive Cap
ScrewDouble
Specification
Reduction (550G and
HousingtoFinal
650G Only)Quantity
Drive Housing Cap
Per Side................................................................................................ 17
8. Install new seals between transverse case and spacer
(if used) and final drive.
9. Apply thread lock and sealer (medium strength) to
threads of cap screws. Install spacer (if used), final
drive and cap screws. Tighten cap screws.

061411
PN=159
a. Single Reduction Final Drive 450G, 455G:

Transverse CasetoFinal Drive Housing
AInner Cap Screws (3 used per side)
Final Drive HousingtoTransverse Case
BOuter Cap Screws (2 used per side)
T8046AA UN17JUL93
COuter Cap Screws (3 used per side)
Single Reduction450G, 455G
TX,02,RB521 1917FEB985/9
IMPORTANT: Install spacer and hidden cap screw

(F) before installing final drive.
b. Single Reduction Final Drive with Spacer450G,

455G Wide Track:
Final Drive SpacertoTransverse Case
T113172 UN29JAN98
ACap Screw (13 used per side)
BCap Screw (2 used per side)
Final Drive HousingtoFinal Drive Spacer
CCap Screw (2 used per side)
DCap Screw (4 used per side)
ECap Screw (1 used per side)
Single Reduction450G, 455G Wide Track
FCap Screw (1 used per side)
TX,02,RB521 1917FEB986/9
IMPORTANT: Install spacer and hidden cap screw

(F) before installing final drive.
c. Single Reduction Final Drive with Spacer555G:

T113171 UN29JAN98

Final Drive HousingtoFinal Drive Spacer
DCap Screw (2 used per side)
ECap Screw (3 used per side)
Final Drive SpacertoTransverse Case Single Reduction555G
FCap Screw (1 used per side)

061411
PN=160
d. Single Reduction Final Drive450GLT and

450GLGP:
T8046AD UN17JUL93
Double Reduction 550G, 650G:
Single Reduction 450GLT/LGP or Double Reduction 550G, 650G
TX,02,RB521 1917FEB988/9
10. Install final drive pinion:

a. Apply high temperature grease to bushing in pinion
shaft and bearing cup in quill.
b. Install final drive pinion shaft and bearing quill with
Oring and shim pack.
T8081AB UN28SEP93
c. Apply thread lock and sealer (medium strength) to
threads of cap screws (A). Install and tighten cap
screws.
Specification
Bearing Quill Cap
Screws (S.N.
785187)Torque....................................... 149 Nm (110 lbft) Second
PassTighten to 196 Nm (145 lbft), but do
not exceed more than 60 (1/6 turn) 11. Turn jack screw counterclockwise until screw is free of
Bearing Quill Cap Screws steering clutch. Install plug.
450G, 455G, 555G (S.N. 12. Install drain plug and fill final drive housing with
785188 )Torque...................................... 149 Nm (110 lbft) Second recommended oil. (Refer to Section 00, Group 0004.)
not exceed more than 60 (1/6 turn) 13. Install drive sprocket and connect chain. (See
Bearing Quill Cap Screws procedure in Group 0130.)
550G, 650G (S.N.
785188 )Torque................................................... 278 Nm (205 lbft)
TX,02,RB521 1917FEB989/9

061411
PN=161
Disassemble and Assemble Final Drive
T112980 UN30JAN98
Single Reduction Final Drive

061411
PN=162
1 Seal 10 ORing 19 Outer Spacer 28 Set Screw (2 used)

2 Oil Seal 11 Shim (as required) 20 Final Drive Gear 29 Gasket
3 Bearing Cup 12 Pinion Quill 21 Inner Spacer 30 Final Drive Pan
4 Bearing Cone 13 Washer (3 used) 22 Bearing Cup 31 Pipe Plug (2 used)
5 Final Drive Housing 14 Cap Screw (3 used) 23 Bearing Cone 32 Pipe Plug
6 Pinion Bushing 15 Axle Shaft 24 Shim (as required) 33 Cap Screw (12 used)
7 Final Drive Pinion 16 Oil Seal 25 Retainer 34 Washer (12 used)
8 Bearing Cone 17 Bearing Cone 26 Cap Screw (3 used)
9 Bearing Cup 18 Bearing Cup 27 Seal
CAUTION: Approximate component weights: 4. Install final drive pinion shaft assembly parts (39
and 1114):
Flanged Axle Shaft..........25 kg (56 lb)
a. Use disk driver to install bearing cups tight to bottom
Final Drive Gear............35 kg (78 lb) of bores.
NOTE: Steps 17 are for repair of 450G, 455G and b. Adjust final drive pinion shaft preload. (See
555G crawler final drives only. procedure in this group.)
NOTE: The design of the final drive housing NOTE: Pinion shaft assembly will be removed and
varies between production models. Repair installed again after other adjustments are made.
procedures remain the same.
5. Remove final drive pinion shaft assembly, keeping
1. SINGLE REDUCTION FINAL DRIVES required shim pack with quill.
Remove parts as shown. Use a press to remove 6. Apply a thin layer of Gasket Maker to ID of housing
flanged axle shaft (15). bore before installing pinion shaft seal. Install seal (2)
with seal lip and spring side towards mounting surface
Specification of final drive (as shown). Push seal into housing until
Flanged Axle even with shoulder of bore.
ShaftWeight...................................................................... 25 kg (56 lb)
Final Drive 7. Install axle shaft assembly parts (1526):
GearWeight....................................................................... 35 kg (78 lb)
2. Inspect parts, replace as necessary. of bores.
3. Install bushing (6) into pinion shaft using a disk driver. b. Adjust axle shaft preload. (See procedure in this
Push bushing into bore until bushing is 1.0 0.5 mm group.)
(0.04 0.02 in.) below end of shaft.
Specification
BushingDepth Below
End Of Shaft.............................................. 1.0 0.5 mm (0.04 0.02 in.)

061411
PN=163
T112981 UN30JAN98
Double Reduction Final Drive

061411
PN=164
1 Cap 12 Bearing Cone 23 Bearing Cone 34 Gasket

2 Cap Screw (3 used) 13 Pinions Shaft Bushing 24 Bearing Cup 35 Final Drive Pan
3 Retainer 14 Pinion Shaft 25 Idler Pinion Quill 36 Cap Screw (15 used)
4 Shim (as required) 15 Bearing Cone 26 Outer Spacer 37 Washer (15 used)
5 Bearing Cone 16 Bearing Cup 27 Bearing Cup 38 ORing
6 Bearing Cup 17 ORing (2 used) 28 Bearing Cone 39 Plug
7 Inner Spacer 18 Shim (as required) 29 Axle Shaft Oil Seal 40 Axle Shaft Gear
8 Seal 19 Pinion Shaft Quill 30 Axle Shaft 41 ORing
9 Final Drive Housing 20 Washer (6 used) 31 Bearing Cup 42 Plug
10 Pinion Shaft Oil Seal 21 Cap Screw (6 used) 32 Bearing Cone
11 Bearing Cup 22 Idler Pinion 33 Idler Shaft Gear
CAUTION: Approximate component weights: 12. Remove final drive pinion shaft assembly, keeping
required shim pack with quill.
Flanged Axle Shaft..........25 kg (56 lb)
13. Apply a thin layer of Gasket Maker to ID of housing
Final Drive Gear............35 kg (78 lb) bore before installing pinion shaft seal (10). Install seal
NOTE: Steps 815 are for repair of 550G and of final drive (as shown). Push seal into housing until
650G crawler final drives only. even with shoulder of bore.
NOTE: The design of the final drive housing 14. Install idler shaft assembly parts (17, 18, 2025 and
varies between production models. Repair 3133):
of bores.
8. DOUBLE REDUCTION FINAL DRIVES
b. Adjust idler shaft preload. (See procedure in this
Remove parts as shown. Use a press to remove
group.)
flanged axle shaft (30).
IMPORTANT: On 550G and 650G machines (S.N.
9. Inspect parts, replace as necessary.
785188 ), BOTH halves of the seal must
10. Install bushing (13) into pinion shaft using a disk driver. be installed on the axle shaft before outer
Push bushing into bore until bushing is 1.0 0.5 mm bearing cone is installed.
(0.04 0.02 in.) below end of shaft.
15. Install axle shaft assembly parts (27, 2630 and
11. Install final drive pinion shaft assembly parts (1116 38):
and 1821):
a. Use disk driver to install bearing cups tight to bottom of bores.
of bores.
b. Adjust axle shaft preload. (See procedure in this
b. Adjust final drive pinion shaft preload. (See group.)
NOTE: Pinion shaft assembly will be removed and
installed again after other adjustments are made.

061411
PN=165
T112982 UN30JAN98
Single Reduction Final Drive 450GLT and 450GLGP

061411
PN=166
1 Cap Screw (3 used) 13 Bearing Cone 25 Axle Shaft 37 Axle Shaft Gear
2 Retainer 14 Pinion Shaft 26 Snap Ring 38 Plug
3 Shim (as required) 15 Bushing 27 Bearing Cone (2 used) 39 ORing
4 Bearing Cone 16 Bearing Cone 28 Bearing Cup (2 used) 40 Seal
5 Bearing Cup 17 Bearing Cup 29 Idler Gear 41 Socket Screw
6 Spacer 18 Oil Seal 30 Spacer 42 Cap Screw (3 used)
7 Cap Screw (3 used) 19 Final Drive Housing 31 Gasket 43 ORing
8 Washer (3 used) 20 Seal 32 Plug (2 used) 44 Idler Gear Shaft
9 Pinion Shaft Quill 21 Outer Spacer 33 Final Drive Pan 45 ORing
10 Shim (as required) 22 Bearing Cone 34 Cap Screw (12 used)
11 ORing 23 Bearing Cup 35 Washer (12 used)
12 Bearing Cup 24 Oil Seal 36 Plug

CAUTION: Approximate component weights: of final drive (as shown). Push seal into housing until
Flanged Axle Shaft......25 kg (56 lb) even with shoulder of bore.
Final Drive Gear............35 kg (78 lb) 22. Install idler shaft gear parts (2630) into final drive
housing:
NOTE: Steps 1624 are for repair of 450GLT and a. Use disk driver to install bearing cups in idler gear.
450GLGP crawler final drives only.
b. Use wire or string to keep bearings and gear in
NOTE: The design of the final drive housing housing and away from axle shaft assembly. Idler
varies between production models. Repair shaft will be installed later.
23. Install axle shaft assembly parts (16, 2125 and
16. SINGLE REDUCTION, 450GLT AND 450GLGP 37):
FINAL DRIVES a. Use disk driver to install bearing cups tight to bottom
Remove parts as shown. Use a press to remove of bores.
flanged axle shaft (25). b. Adjust axle shaft preload. (See procedure in this
17. Inspect parts, replace as necessary. group.)
18. Install bushing (15) into pinion shaft using a disk driver. 24. Install idler shaft parts (4245):
Push bushing into bore until bushing is 1.0 0.5 mm a. Install shaft through housing, bearing cones and
(0.04 0.02 in.) below end of shaft. gear. Align tapped holes in shaft with holes in
19. Install final drive pinion shaft assembly parts (710 housing.
and 1217): b. Use three M12 X 1.75 X 170 mm full threaded cap
a. Use disk driver to install bearing cups tight to bottom screws to align and pull shaft into position. Tighten
of bores. cap screws until shaft bottoms against housing and
bearings.
b. Adjust final drive pinion shaft preload. (See
procedure in this group.) c. Remove alignment cap screws. Apply thread lock
and sealer (medium strength) to cap screws (42).
NOTE: Pinion shaft assembly will be removed and Install and tighten cap screws.
installed again after other adjustments are made.
Specification
ShafttoHousing Cap
20. Remove final drive pinion shaft assembly, keeping
Screw, 450GLT and
required shim pack with quill.
450GLGPTorque...................................................... 130 Nm (96 lbft)
21. Apply a thin layer of Gasket Maker to ID of housing
bore before installing pinion shaft seal (18). Install seal

061411
PN=167
25. Install gasket and final drive pan:

a. Clean mounting surface of all grease, oil and dirt.
b. Install and tighten cap screws and washers to
specified torque using proper sequence shown.
Final Drive Pan Cap ScrewsSpecification
T7931BL UN28JAN93
450G, 450GLT and
450GLGP (S.N.
795142), 455G,
555GInitial Torque
........................................................................ 61 12 Nm (45 9 lbft)
Final Torque (after 20
min.).................................. 81 Nm (60 lbft) but do not exceed a 90 turn 450G, 455G, 555G
450GLT and 450GLGP
(S.N. 795143 ), 550G,
650GInitial Torque.................................... 130 26 Nm (96 20 lbft)
Final Torque (after 20
min.)................................................................................... 170 Nm (125
lbft) but do not exceed a 90 turn
T7931BK UN28JAN93
26. Install final drive assembly on transverse case. (See
550G, 650G
TX,0250,BD794 1908OCT937/7

061411
PN=168
Adjust Pinion Shaft Preload

SPECIFICATIONS
Shim Maximum Thickness 0.08 mm (0.003 in.)
Bearing Preload 0.00.08 mm (0.00.003 in.)
Bearing Preload to Endplay 0.025 mm (0.001 in.)
T6567AC UN09APR90
Bearing Quill Cap Screws (S.N. 149 Nm (110 lbft) Second
785187) Torque PassTighten to 196 Nm (145
lbft), but do not exceed more than
60 (1/6 turn)
Bearing Quill Cap Screws 450G, 149 Nm (110 lbft) Second
455G, 555G (S.N. 785188 ) PassTighten to 196 Nm (145
Torque lbft), but do not exceed more than
60 (1/6 turn)
Bearing Quill Cap Screws 550G, 278 Nm (205 lbft)
650G (S.N. 785188 ) Torque
This will provide a maximum pinion shaft preload of
OTHER MATERIAL 0.00.08 mm (0.00.003 in.).
T43512 U.S. Thread Lock and Sealer (Medium Strength) Specification
TY9473 Canadian Thread Lock and Sealer (Medium Strength) BearingPreload.....................................0.00.08 mm (0.00.003 in.)
242 LOCTITE Thread Lock and Sealer (Medium Strength)
6. For 550G and 650G, remove bearing quill. Remove
1. 450G, 455G, 555GInstall outer bearing cone on enough shims to provide a maximum of 0.08 mm
shorter end of pinion shaft tight against shoulder. endplay to a preload of 0.025 mm (0.001 in.).
Specification
Install inner bearing cone in mating bearing cup (in
BearingPreload to
final drive housing).
Endplay................................................................... 0.025 mm (0.001 in.)
550G, 650GInstall inner and outer bearing cones on
pinion shaft tight against shoulders.
retainer cap screws. Tighten cap screws. Retighten
2. Install pinion shaft in housing. Install quill with enough cap screws per following specifications.
shims to provide a measurable amount of end play. Specification
On 550G and 650G machines, make sure arrow on Bearing Quill Cap
quill points toward idler shaft bore. Tighten three cap Screws (S.N.
screws: All machines (S.N. 785187) and 450G, 785187)Torque....................................... 149 Nm (110 lbft) Second
455G, 555G (S.N. 785188 ) to 149 Nm (110 lbft) PassTighten to 196 Nm (145 lbft), but do
550G and 650G (S.N. 785188 ) to 278 Nm (205 not exceed more than 60 (1/6 turn)
lbft). Bearing Quill Cap Screws
3. Rotate pinion shaft a minimum of three turns to seat 450G, 455G, 555G (S.N.
bearings. 785188 )Torque...................................... 149 Nm (110 lbft) Second
4. With the pinion shaft in the vertical position, measure not exceed more than 60 (1/6 turn)
and record pinion shaft endplay. Bearing Quill Cap Screws
550G, 650G (S.N.
5. For 450G, 455G and 555G machines, remove bearing 785188 )Torque................................................... 278 Nm (205 lbft)
quill. Remove shims to just eliminate endplay. Then
remove up to an additional 0.08 mm (0.003 in.)
maximum thickness of shims.
Specification
ShimMaximum
Thickness.................................................................. 0.08 mm (0.003 in.)

TX,02,RB437 1912FEB981/1

061411
PN=169
Adjust Idler Shaft Preload for Double Reduction Drives
T8059FE UN16AUG93
AInner Bearing Cup DIdler Pinion Shaft GORing J Washer (3 used)
BInner Bearing Cone EOuter Bearing Cone HShims (as required) KCap Screw (3 used)
CIdler Shaft Gear F Outer Bearing Cup I Idler Pinion Quill L Final Drive Housing
SPECIFICATIONS Rotate shaft back and forth to seat bearings.

Cap Screws Torque 37 Nm (27 lbft)
4. Loosen cap screws completely and tighten again to
Cap Screws Torque 13 Nm (115 lbin.)
13 Nm (115 lbin.).
Shim Pack Thickness 0.33 mm (0.013 in.)
Specification
Idler Shaft Maximum Preload 0.1 mm (0.004 in.)
Cap ScrewsTorque..................................................13 Nm (115 lbin.)
Bearing Quill Cap Screws Torque 278 Nm (205 lbft)
Rotate shaft a minimum of three revolutions using an
OTHER MATERIAL oscillating motion to seat bearings.
T43512 U.S. Thread Lock and Sealer (Medium Strength)
5. Use a feeler gauge to measure the gap between quill
TY9473 Canadian Thread Lock and Sealer (Medium Strength) and housing near each cap screw.
6. Calculate the average of the three measurements and
IMPORTANT: Double reduction final drives require add 0.33 mm (0.013 in.) to the average.
an idler shaft preload adjustment. Specification
Shim PackThickness............................................. 0.33 mm (0.013 in.)
1. Install outer bearing cone (E) on shorter end of idler
shaft (D), tight against shoulder. This is the required shim pack thickness.
Install inner bearing cone (B) in mating bearing cup. This will provide a maximum idler shaft preload of 0.1
mm (0.004 in.).
2. Install idler shaft gear (C) and shaft in housing (L).
Specification
Install quill (I) without Oring (G) or shims (H). Make
Idler ShaftMaximum
sure arrow on quill points toward pinion shaft bore.
Preload........................................................................ 0.1 mm (0.004 in.)
3. Tighten three cap screws (K) to 37 Nm (27 lbft).
7. Remove quill. Put calculated shim pack on quill.
Specification

061411
PN=170
8. Apply high temperature grease to bearing cup (F) in Specification

quill. (See Fuels and Lubricants, Group 0004.) Install Bearing Quill Cap
Oring and quill. ScrewsTorque......................................................... 278 Nm (205 lbft)
9. Apply thread lock and sealer (medium strength) to 10. Apply thread lock and sealer (medium strength) to
threads of cap screws. Install and tighten cap screws. edges of shims.
TX,02,RB438 1912FEB982/2

061411
PN=171
Adjust Axle Shaft Preload

SPECIFICATIONS
Bearing End Play 0.25 mm (0.010 in.)
Shim Pack Thickness 1.52 mm (0.060 in.)
Bearing450GLGP Preload 0.13 0.03 mm (0.0050.001 in.)
T6565AC UN20APR89
Bearing(All Other Models) 0.23 0.05 mm (0.009 0.002 in.)
Preload
Bearing Quill Cap Screws (S.N. 149 Nm (110 lbft) Second
785187) Torque PassTighten to 196 Nm (145
lbft), but do not exceed more than
60 (1/6 turn)
Bearing Quill Cap Screws 450G, 149 Nm (110 lbft) Second
455G, 555G (S.N. 785188 ) PassTighten to 196 Nm (145
Torque lbft), but do not exceed more than
60 (1/6 turn)
Bearing Quill Cap Screws 550G, 278 Nm (205 lbft)
650G (S.N. 785188 ) Torque
OTHER MATERIAL
T7942AE UN08FEB93
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
IMPORTANT: On 550G and 650G machines (S.N.

785188 ), BOTH halves of the seal must be
installed on the axle shaft before outer bearing
cone. Leave plastic retainer band on seal.
ASealing Surface DShim (as required)
1. Make sure rubber rings (B) and all surfaces that BSeal Rubber Ring (2 used) EBearing Retainer
contact rubber rings of seal are clean, dry and free of CRetention Barb F Retainer Cap Screw (3
any oil. Remove plastic retainer band. Install half of used)
seal on axle shaft and half into the final drive housing.
If seal has retention barb (C) on only one of the rubber
rings, install that half on axle shaft with retention barb housing over. With the axle flange down, the weight of
towards axle flange. the housing will compress seals and help seat outer
bearings.
2. Apply oil to sealing surfaces (A) only of oil seal.
6. Install inner bearing cone, retainer (E) and enough
3. Install outer bearing cone on axle shaft tight against shims (D) to provide approximately 0.25 mm (0.010
shoulder. in.) end play.
4. Install outer spacer, gear, inner spacer and axle shaft Specification
into final drive housing. Make sure small diameter of BearingEnd Play.................................................... 0.25 mm (0.010 in.)
inner spacer is toward the inner bearing cone.
This will be a shim pack of approximately 1.52 mm
Carefully guide seal into leadin chamfer of final drive (0.060 in.).
housing to make sure rubber rings of seal do not roll in
Specification
bore.
Shim PackThickness............................................. 1.52 mm (0.060 in.)
5. Use a (1/213 UNC in.) cap screw and a metal strap
to retain axle shaft in housing while turning final drive

061411
PN=172
7. Tighten retainer cap screws (F): All machines (S.N.

785187) and 450G, 455G, 555G (S.N. 785188 )
to 149 Nm (110 lbft) 550G and 650G (S.N. 785188
) to 278 Nm (205 lbft). Rotate housing and lightly
tap retainer plate using a hammer and punch, then
tighten cap screws again. Repeat this step until the
T7942AE UN08FEB93
cap screws do not turn when tightened to specification
after tapping plate.
8. Attach final drive housing to a hoist.
9. Put a dial indicator at the center of retainer.
NOTE: On some machines, the weight of the housing
may not be enough to fully compress the oil seal
to prevent false end play reading. Additional
downward force may be required.
10. Oscillate housing to seat bearings and prevent false

end play measurement. Adjust the dial indicator to
zero.
T7247AS UN09APR90
11. Lift the housing and rotate axle to insure the bearings
are seated. Measure end play of axle shaft.
12. Remove enough shims (D) to just eliminate measured
end play. Then remove an additional 0.13 0.03
mm (0.0050.001 in.) thickness of shims on the
450GLGP and 0.23 0.05 mm (0.009 0.002 in.)
thickness of shims on all other machines to provide
the necessary preload. Specification
Specification Bearing Quill Cap
Bearing450G Screws (S.N.
LGPPreload................................... 0.13 0.03 mm (0.0050.001 in.) 785187)Torque....................................... 149 Nm (110 lbft) Second
Bearing(All Other PassTighten to 196 Nm (145 lbft), but do
Models)Preload.............................. 0.23 0.05 mm (0.009 0.002 in.) not exceed more than 60 (1/6 turn)
Bearing Quill Cap Screws
13. Install shim pack and retainer. 450G, 455G, 555G (S.N.
785188 )Torque...................................... 149 Nm (110 lbft) Second
14. Apply thread lock and sealer (medium strength) to PassTighten to 196 Nm (145 lbft), but do
retainer cap screws. Tighten cap screws. Retighten not exceed more than 60 (1/6 turn)
cap screws per following specifications. Bearing Quill Cap Screws
550G, 650G (S.N.
785188 )Torque................................................... 278 Nm (205 lbft)
TX,02,RB522 1917FEB982/2

061411
PN=173
Remove and Install Steering Clutch

NOTE: Steering clutches can be removed and installed
without removing transmission. Remove sprocket
on 450G, 455G and 555G. (See Remove and
Install Sprocket, Group 0130.) Remove rear
T6926BU UN06DEC88
carrier roller on 550G and 650G. (See Remove
and Install Carrier Roller, Group 0130.)
1. Lock out park brake. (See Engage Tow Disconnect

Pin Manually, Group 0250.)
CAUTION: Each rear counterweight weighs

approximately 138 kg (304 lb).
2. Remove all rearmounted equipment. Specification

Transverse
Specification
CaseCapacity................................................................... 83 L (22 gal)
Rear Counter
weightWeight................................................................ 138 kg (304 lb)
NOTE: Transverse case oil capacity is 83 L (22 gal).
3. Remove drain plug (A) and drain transverse case.

TX,02,RB523 1914JUN111/10
CAUTION: Approximate weight of rear

cover is 36 kg (80 lb).
4. Remove upper left and upper right cap screws from

rear cover.
T6645AC UN27OCT88
Specification
Rear CoverWeight............................................................ 36 kg (80 lb)
Install two M162 x 150 mm metric hex screws (B) as
guide pins. Remove all other rear cover cap screws.
5. Install two JT01748 Lifting Brackets (A) using 16 mm
(0.625 in.) cap screws and nuts. Remove rear cover.

061411
PN=174
NOTE: Transmission is removed for clarity of

photographs. Remove transmission first if doing
a complete overhaul, see Remove And Install
Transmission in Group 0350.
6. Remove brake anchor assembly (See Disassemble
T6589BC UN19OCT88
and Assemble Internal Brake Control Linkage in Group
0250).
7. On machines (S.N. 770807), disconnect line (A) to
remove fitting (B) from steering clutch housing.
On machines (S.N. 770808 ), disconnect lines (D
and E) to remove fittings (F and G).
APressure Line ELube Line

BElbow Fitting F Elbow Fitting
CCap Screw GElbow Fitting
DPressure Line
T7247AN UN09APR90
TX,02,RB523 1914JUN113/10
8. Remove plug (B) from bottom of transverse housing.

Turn hex head screw (C) inward until contact is made
with brake band.
T6656DR UN19OCT88

061411
PN=175
IMPORTANT: Use care when removing final

drive pinion and steering clutch shaft to
prevent damage to seal.
9. Remove quill. Use slide hammer and attachment

JT01773 to remove final drive pinion (A) and steering
T6645AD UN27OCT88
clutch shaft (B). Pinion puller hole is tapped 12 mm x
1.75. Keep shim pack with quill for reinstallation and
preload adjustment.
T6645AE UN27OCT88
TX,02,RB523 1914JUN115/10
10. Place a 2 in. x 4 in. block (B) in transverse housing.

11. Remove special shoulder bolt (A).
CAUTION: Approximate weight of steering

clutch is 43 kg (95 lb).
12. Roll steering clutch housing onto block.

Specification
Steering Clutch
AssemblyWeight............................................................... 43 kg (95 lb)
13. Put a sling through center hole and hoist out of

transverse housing.
14. Repair steering clutch as required (see Disassemble
and Assemble Steering Clutch in this group).
T6582AA UN01NOV88

061411
PN=176
IMPORTANT: Anchor levers must engage brake band

ears or brakes will not function correctly.
15. Place brake anchor assembly over steering clutch so

anchor levers engage brake band ears. Tighten brake
adjuster till anchor is tight on brake band.
16. Hold brake anchor to steering clutch with DF1030
Assembly Tool (A). (See Group 0299 for instructions
to make tool.)
T6582AB UN01NOV88

061411
PN=177
17. Lift steering clutch housing onto 2 in. x 4 in. block (B)
in transverse housing.
NOTE: Clutch housing must slide onto the front pin
easily, if interference, remove and inspect
brake band to clutch housing fit.
18. Push clutch housing into position. Apply thread lock

and sealer (medium strength) to threads of shoulder
bolt (A). Secure housing with bolt.
T6582AA UN01NOV88
TX,02,RB523 1914JUN118/10
19. Install pins (B) to secure brake anchor assembly to

transverse housing. Install plugs (A). Connect lines.
T6585BI UN19OCT88

061411
PN=178
IMPORTANT: Install clutch steering shaft and

pinion shaft carefully to prevent damage
to final drive seal.
NOTE: Rotate transmission clutch assemblies by hand

to align shaft splines with ring gear.
T6589BC UN19OCT88
NOTE: If pinion shaft bearings were replaced, adjust
pinion shaft preload. (See procedure in this group.)
20. Carefully install steering clutch shaft and pinion shaft.

21. Apply thread lock and sealer (medium strength) to cap
screw threads. Install quill and tighten cap screws.
Specification
Pinion Shaft Bearing
Quill Cap Screws (S.N.
785187)Torque....................................... 149 Nm (110 lbft) Second
T7247AN UN09APR90
not exceed more than 60 (1/6 turn)
Pinion Shaft Bearing Quill
Cap Screws 450G, 455G,
555G (S.N. 785188
)Torque....................................................... 149 Nm (110 lbft) Second
not exceed more than 60 (1/6 turn)
Pinion Shaft Bearing
Quill Cap Screws 550G,
650G (S.N. 785188 APressure Line ELube Line
)Torque.................................................................... 278 Nm (205 lbft) BElbow Fitting F Elbow Fitting
CCap Screw GElbow Fitting
22. Turn hexagon cap screw (C) counterclockwise until DPressure Line
even with casting. Install plug in bottom of transfer
case.
27. Install transmission if removed. (See Group 0350.)
23. On machines (S.N. 770807), apply pipe sealant with
TEFLON to fitting (B) and install. Install pressure 28. Clean mounting surface of transverse case and rear
line (A). cover.
On machines (S.N. 770808 ), apply pipe sealant 29. Install gasket with rubber bead facing rear cover.
with TEFLON to fittings (F and G) and install. Install Install rear cover.
pressure line (D) and lube line (E).
30. Install small rear cover cap screws from center of
IMPORTANT: Anchor assembly tool must be housing toward corners. Tighten cap screws.
removed to prevent damage to anchor or
Specification
steering clutch housing.
Transverse Case Cover
Cap Screws (Small
24. Remove brake anchor assembly tool. Install washer
Rear)Torque.............................................. 130 26 Nm (96 19 lbft)
and tighten cap screw.
Specification 31. Install large rear cover cap screws from center of
Piston Housingto housing toward corners. Tighten cap screws.
Brake Drum Cap Specification
ScrewsTorque............................................................. 61 Nm (45 lbft) Transverse Case Cover
Cap Screws (Large
25. Connect brake anchor linkage.
Rear)Torque.......................................... 620 124 Nm (458 91 lbft)
26. Adjust brakes. (See procedure in this group.)
TEFLON is a registered trademark of Du Pont Co.
TX,02,RB523 1914JUN1110/10

061411
PN=179
Disassemble and Assemble Steering Clutch (S.N. 770807)
T7247AA UN09APR90

061411
PN=180
1 Brake Steering Drum 6 Steering Clutch Lining (6 11 Hardened Washer (10 used) 16 Thrust Ring
2 Snap Ring used) 12 Cap Screw (6 used) 17 Pressure Port
3 Snap Ring 7 Piston 13 Sealing Ring (2 used)
4 Steering Clutch Hub 8 Inner Sealing Ring 14 Clutch Pressure Manifold
5 Steering Clutch Disk (6 used) 9 Outer Sealing Ring 15 Cap Screw (4 used)
10 Piston Housing
6. Assemble steering clutch with a steering clutch lining

CAUTION: Approximate weight of steering (6) first into the brake steering drum (1).
clutch assembly is 43 kg (95 lb).
Specification
1. Remove cap screws (15), hardened washers (11), Steering Clutch
clutch pressure manifold (14), and sealing rings (13). AssemblyWeight............................................................... 43 kg (95 lb)
2. Remove cap screws (12), hardened washers (11), and Alternately install steering clutch disc (5) and steering
piston housing (10). clutch lining (6). A total of six linings and disc are used.
Specification
3. Remove piston (7) from piston housing (10).
Piston HousingtoBrake
4. Remove the inner (8) and outer (9) sealing ring. Drum (12) Cap
ScrewsTorque............................................................. 61 Nm (45 lbft)
5. Remove steering clutch lining (6), steering clutch disc Thrust RingtoPiston
(5), steering clutch hub (4), snap ring (3) and snap Housing (15) Cap
ring (2). ScrewsTorque............................................................. 68 Nm (50 lbft)
NOTE: Steering clutch linings (6) are reusable until the
groove pattern is no longer visible. Steering clutch
disc (5) must be flat and free of any defects.
TX,02,RB524 1917FEB982/2

061411
PN=181
Disassemble and Assemble Steering Clutch (S.N. 770808 )
T7247AB UN01AUG90

061411
PN=182
1 Brake Steering Drum 6 Steering Clutch Lining (6 11 Hardened Washer (10 used) 16 Thrust Ring
2 Snap Ring used) 12 Cap Screw (6 used) 17 Pressure Port
3 Snap Ring 7 Piston 13 Sealing Ring (2 used) 18 Lube Port
4 Steering Clutch Hub 8 Inner Sealing Ring 14 Clutch Pressure Manifold
5 Steering Clutch Disk (7 used) 9 Outer Sealing Ring 15 Cap Screw (4 used)
10 Piston Housing
6. Assemble steering clutch with a steering clutch disc

CAUTION: Approximate weight of steering (5) first into the brake steering drum (1).
clutch assembly is 43 kg (95 lb).
Specification
1. Remove cap screws (15), hardened washers (11), Steering Clutch
clutch pressure manifold (14), and sealing rings (13). AssemblyWeight............................................................... 43 kg (95 lb)
2. Remove cap screws (12), hardened washers (11), and Alternately install steering clutch lining (6) and steering
piston housing (10). clutch disc (5). A total of six linings and seven discs
are used.
3. Remove piston (7) from piston housing (10).
Specification
4. Remove the inner (8) and outer (9) sealing ring. Piston HousingtoBrake
Drum (12) Cap
5. Remove steering clutch lining (6), steering clutch disc ScrewsTorque............................................................. 61 Nm (45 lbft)
(5), steering clutch hub (4), snap ring (3) and snap Thrust RingtoPiston
ring (2). Housing (15) Cap
NOTE: Steering clutch linings (6) are reusable until the
groove pattern is no longer visible. Steering clutch
disc (5) must be flat and free of any defects.
TX,02,RB442 1912FEB982/2

061411
PN=183
Disassemble and Assemble Steering Brake Anchor (S.N. 770807)
T6677AF UN19OCT88
1 Bearing (2 used) 5 Spring 9 Yoke 13 Lock Nut
2 Lever 6 Pin 10 Yoke 14 Snap Ring (4 used)
3 Trigger 7 Anchor 11 Snap Ring (4 used) 15 Washer
4 Nut 8 Lever (2 used) 12 Link
NOTE: Steering brake anchor assembly are same for

left and right except for lever (2). 8. Put end of yoke (9) through hole in pin (6).
9. Install yoke (9) and lever (8) in anchor (7) using pin
1. Remove lever (2) from link (12). and snap rings (14).
2. Remove link (12) and trigger (3) from yoke (10). 10. Install spring (5) and nut (4) on yoke end (9). Short leg
3. Remove lock nut (13), nut (4) and spring (5) from yoke of spring (5) goes to left side when viewed from nut (4)
(9) shaft. end of assembly. Install lock nut (13) flush with end of
yoke (9), then turn one revolution.
4. Remove yoke (9) and lever (8) from anchor (7).
11. Attach link (12) and trigger (3) to yoke (10). Tang on
5. Remove yoke (10) and lever (8) in anchor (7). trigger below nut (4) must be installed rearward of
coils on spring (5).
6. Install yoke (10) and lever (8) in anchor (7).
12. Attach lever (2) to link (12).
7. Install pin (6) in yoke (10) with snap ring (14) on right
side.
TX,02,RB525 1917FEB981/1

061411
PN=184

061411
PN=185
Disassemble and Assemble Steering Brake Anchor (S.N. 770808 )
T7247AC UN01AUG90
ABearing (2 used) EPin I Yoke MSnap Ring (4 used)
BLever F Anchor J Snap Ring (4 used) NShim (as required)
CNut GLever (2 used) KLink OSnap Ring
DRetainer HYoke L Lock Nut
NOTE: Steering brake anchor assembly are same for

left and right except for lever (B). 8. Install retainer on pin (E).
9. Put end of yoke (H) through hole in pin (E) and retainer
1. Remove lever (B) from link (K). (D).
2. Remove link (K) from yoke (I). 10. Install yoke (H) and lever (G) in anchor (F) using pin
3. Remove lock nut (L), nut (C), retainer (D) and pin (E) and snap rings (M).
from yoke (H) shaft. 11. Install nut (C) on yoke (H) end. Install lock nut (L)
4. Remove yoke (H) and lever (G) from anchor (F). flush with end of yoke (H), then turn one additional
revolution.
5. Remove yoke (I) and lever (G) in anchor (F).
12. Attach link (K) to yoke (I).
6. Install yoke (I) and lever (G) in anchor (F).
13. Attach lever (B) to link (K).
7. Install pin (E) in yoke (I) with snap ring (M) on right
side.
TX,02,RB444 1912FEB981/1

061411
PN=186
Disassemble and Assemble Steering Brake Linkage (S.N. 770807)
T113200 UN17FEB98

061411
PN=187
1 Brake Lever 9 Rod 17 Quad Lever 25 Brake Locking Spring

2 Seal 10 Anchor 18 Nut 26 Spacer (4 used)
3 Bearing Cover 11 Lever (2 used) 19 Spring 27 Lock Nut
4 Bearing 12 Yoke 20 Pin 28 Washer
5 Needle Bearing (2 used) 13 Yoke 21 Lockout Pin 29 Cylinder Stop Screw
6 Shaft 14 HLink 22 Spring 30 Shim (as required)
7 Spring Lever 15 Trigger 23 Seal
8 OverCenter Brake Lever 16 Bearing (2 used) 24 Cylinder
NOTE: Steering brake control linkage can be 1. Remove transmission. (See Group 0350.)
disassembled and assembled with transmission in
place, but it is faster and easier to remove
transmission first.
Do not stop track with grouser in front of plugs.
Pin removal may be difficult or impossible.
TX,02,RB445 1912FEB982/6
2. Remove two rear plugs (A) from side of transverse

case.
3. Install a M8 x 1.25 cap screw in pins (B) and remove
pins.
T6585BI UN19OCT88
TX,02,RB445 1912FEB983/6
IMPORTANT: Length of rod (D) is critical to operation

of manual brake adjusters. Do not loosen
lock nuts on swivel ends.
4. Disconnect oil lines.

5. Remove snap ring (A) to separate link (B) from anchor
T7247AF UN09APR90
assembly (C). Remove anchor assembly.
ASnap Ring CAnchor Assembly

BLink DRod

061411
PN=188
6. Remove steering clutch valve, brake cylinder and

brake locking spring. (See procedure in Group 0260.)
7. Remove overcenter brake lever (A) to remove linkage
assembly from transverse case.
8. Remove nut (C) to remove lockout pin assembly.
9. Inspect and replace parts as necessary.
threads of lockout pin (B). Use special nut (D) to retain
assembly.
11. Install linkage assemble in transverse case. Attach
overcenter brake lever (A) to shaft.
12. Install brake locking spring, brake cylinder and
steering clutch valve. (See procedure in Group 0260.)
ALever CNut
BPin DSpecial Nut
T6926BS UN05JAN89

061411
PN=189
T7247BE UN09APR90
1 Brake Lever 8 OverCenter Brake Lever 15 Trigger 22 Spring
2 Seal 9 Rod 16 Bearing (2 used) 23 Seal
3 Bearing Cover 10 Anchor 17 Lever 24 Lock Nut
4 Bearing 11 Lever (2 used) 18 Nut 25 Spacer (4 used)
5 Needle Bearing (2 used) 12 Yoke 19 Spring 26 Cap Screw (2 used)
6 Shaft 13 Yoke 20 Pin 27 Shims (as required)
7 Spring Lever 14 Link 21 Lockout Pin
IMPORTANT: Anchor levers must engage brake band If length of rod (9) has NOT been
ears or brakes will not function properly. changed, do Steering Brakes Linkage
Adjustment in this group.
13. Position anchor assembly on brake band so anchor
levers (11) engage break band ears. 18. Apply thread lock and sealer (medium strength) to cap
14. Move anchor (10) and brake assembly to top of clutch screw (26). Align rod (9) hole with levers (8 and 17).
housing until anchor assembly is stopped by front pin. Install spacers (25) and cap screws.
15. Install rear pin to hold anchor in position. 19. Install transmission but DO NOT install transverse
case rear cover. (See procedure in Group 0350.)
16. Connect link (14) to lever (17). Install retainer.
20. Adjust steering brakes and linkage as necessary. (See
17. Use shims (27) to align lever (17) with center of link procedure in this group.)
(14). Use minimum of one shim on end of lever
towards center of crawler. 21. Install transverse case cover.
IMPORTANT: If length of rod (9) has been changed,

do Internal Steering Brake Control Linkage
TX,02,RB445 1912FEB986/6

061411
PN=190
Disassemble and Assemble Steering Brake Linkage (S.N. 770808 )
T8067AB UN09SEP93

061411
PN=191
1 Brake Lever 9 Rod 17 Nut 25 Spacer (4 used)

2 Seal 10 Anchor 18 Retainer 26 Lock Nut
3 Bearing Cover 11 Lever (2 used) 19 Pin 27 Cylinder Stop Screw
4 Bearing 12 Yoke 20 Lockout Pin 28 Shims (as required)
5 Needle Bearing (2 used) 13 Yoke 21 Spring 29 Second Brake Locking
6 Shaft 14 HLink 22 Seal Spring (S.N. 786471 Only)
7 Spring Lever 15 Bearing (2 used) 23 Cylinder 30 Spring Lever
8 OverCenter Brake Lever 16 Quad Lever 24 Brake Locking Spring
NOTE: Steering brake control linkage can be 1. Remove transmission. (See Group 0350.)
disassembled and assembled with transmission in
place, but it is faster and easier to remove
transmission first.
Do not stop track with grouser in front of plugs.
Pin removal may be difficult or impossible.
TX,02,RB526 1917FEB982/6
2. Remove two rear plugs (A) from side of transverse

case.
3. Install a M8 x 1.25 cap screw in pins (B) and remove
pins.
T6585BI UN19OCT88
TX,02,RB526 1917FEB983/6
IMPORTANT: Length of rod (D) is critical to operation

of manual brake adjusters. Do not loosen
lock nuts on swivel ends.
4. Disconnect oil lines.

5. Remove snap ring (A) to separate link (B) from anchor
T7247AF UN09APR90
assembly (C). Remove anchor assembly.
ASnap Ring CAnchor Assembly

BLink DRod

061411
PN=192
6. Remove steering clutch valve, brake cylinder and

brake locking spring. (See procedure in Group 0260.)
7. Remove overcenter brake lever (A) to remove linkage
assembly from transverse case.
8. Remove nut (C) to remove lockout pin assembly.
threads of lockout pin (B). Use special nut (D) to retain
assembly.
11. Install linkage assemble in transverse case. Attach
overcenter brake lever (A) to shaft.
12. Install brake locking spring, brake cylinder and
steering clutch valve. (See procedure in Group 0260.)
ALever CNut
BPin DSpecial Nut
T6926BS UN05JAN89

061411
PN=193
T7247AG UN09APR90
ABrake Lever HOverCenter Brake Lever OBearing (2 used) VSeal
BSeal I Rod PLever WLock Nut
CBearing Cover J Anchor QNut XSpacer (4 used)
DBearing KLever (2 used) RRetainer YCap Screw (2 used)
ENeedle Bearing (2 used) L Yoke SPin Z Shims (as required)
F Shaft MYoke T Lockout Pin
GSpring Lever NLink USpring
IMPORTANT: Anchor levers must engage brake band If length of rod (I) has NOT been changed, do
ears or brakes will not function properly. Steering Brakes Linkage Adjustment in
this group.
13. Position anchor assembly on brake band so anchor
levers (K) engage break band ears. 18. Apply thread lock and sealer (medium strength) to cap
14. Move anchor (J) and brake assembly to top of clutch screw (Y). Align rod (I) hole with levers (H and P).
housing until anchor assembly is stopped by front pin. Install spacers (X) and cap screws.
15. Install rear pin to hold anchor in position. 19. Install transmission. (See procedure in Group 0350.)
16. Connect link (N) to lever (P). Install retaining clip. 20. Adjust steering brakes and linkage as necessary. (See
17. Use shims (Z) to align lever (P) with center of link (N).
Use minimum of one shim on end of lever toward
center of crawler.
IMPORTANT: If length of rod (I) has been changed,
do Internal Steering Brake Control Linkage
TX,02,RB526 1917FEB986/6

061411
PN=194
Adjust Steering Brake Linkage

SPECIFICATIONS
Chisel Mark Distance From 195 2 mm (7.67 0.08 in.)
Machined Surface
OTHER MATERIAL
T6589BF UN09APR90
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
1. Engage lockout pins. Loosen brake band on steering

drum.
2. Remove cap screw (B) and install in hole (A). Cap
screw will fit loose.
3. Carefully release tow disconnect pin (D).
4. Remove ball joint screw from brake lever.
T6926BX UN06DEC88
5. Install a center punch (C) in brake lever. Punch must
fit tightly in hole.
NOTE: Later transverse housings have chisel mark at
195 mm (7.67 in.) from machined surface. Punch
tip must align with chisel mark (E).
AHole DTow Disconnect Pin

BCap Screw EChisel Mark
CCenter Punch


061411
PN=195
6. If chisel mark is not visible, position a tape measure

from machined surface (D) of transverse case to
under punch.
7. Loosen locking nuts on rod (A).
8. Turn rod (A) until lever (B) is tight against cap screw
T6589BD UN09APR90
(C) and punch is distance (E) from machined surface
(D) or aligns with chisel mark in top of case.
9. Push lever forward to check that all free travel has bee
eliminated. If not, turn rod (A) to remove free travel.
10. Turn brake lever rearward enough to remove cap
screw (C).
cap screw (C).
NOTE: Tow disconnect pin must be up.
12. Install cap screw (C) with lock nut in hole (F) until
T6589BE UN09APR90
punch distance (E) is 195 2 mm (7.67 0.08 in.)
from machined surface (D) or punch tip aligns with
chisel mark while holding lever forward.
Specification
Chisel MarkDistance
From Machined Surface.............................. 195 2 mm (7.67 0.08 in.)
13. Install ball joint in lever. (Do Steering Brakes Linkage

Adjustments in this group.) ARod DMachined Surface
BLever E195 2 mm (7.67 0.08 in.)
CCap Screw F Hole
TX,02,RB447 1912FEB982/2

061411
PN=196
Adjust Steering Brake SelfAdjuster Linkage

(S.N. 770807)
SPECIFICATIONS
Brake Pedal Distance Traveled 13 mm (1/2 in.)
Brake PedalLever Steer 25 mm (1 in.)
T6685AK UN19OCT88
Machines Distance Traveled
Lever Travel Distance 127 mm (5 in.)
Pedal Travel Distance From 279 mm (11 in.)
Firewall
NOTE: Steering brakes may require some initial

adjustment due to wearin of brake band and
seating of brake linkages. After several hours of
operation, brake bands and linkages will stabilize.
Brakes adjust when pedals are pushed/levers pulled AAdjuster CStop Screw
BSelfAdjuster Tab DInspection Plug
to stops during operation. The 450G, 455G and
555G adjust in reverse, 550G and 650G adjust in
forward. If operator consistently pushes pedals or
pull levers to stops, brakes may over tighten. Specification
Brake PedalDistance
The sensitivity of selfadjusting mechanism can be Traveled............................................................................ 13 mm (1/2 in.)
adjusted to function with higher or lower forces. Brake PedalLever
Stop screw (C) should be adjusted in increments Steer MachinesDis
of 1/4 turn. The maximum up or down movement tance Traveled..................................................................... 25 mm (1 in.)
should be one full turn. More than one full turn
up causes linkage to go over center or steering LEVER STEER:
spool linkage to bottom out on stop screws. More
than one full turn down restricts lever and pedal a. Adjust one side at a time. Slowly pull back on lever
motion. If brakes over adjust, turn stop screw (C) until track stops.
in. If they do not selfadjust, turn stop screw (C) b. Measure lever travel at top of lever handles. Track
out. Increasing the sensitivity of the selfadjusting should stop at approximately 127 mm (5 in.) of
mechanism can cause over adjustment. lever travel.
1. Position machine on smooth flat surface. Specification
Lever TravelDistance..................................................... 127 mm (5 in.)
2. Operate machine to warm brake bands and clutch
drum. PEDAL STEER:
3. Operate machine in 1st gear at low idle. a. Adjust one side at a time. Slowly push on brake
pedal until track stops.
NOTE: It is normal for brake pedals to vary up to
13 mm (1/2 in.) in travel when checked to b. Measure pedal travel from firewall to bottom
forward and reverse stop track position. Lever center of pedal. Track should stop when pedal is
steer machines can vary up to 25 mm (1 in.) approximately 279 mm (11 in.) from firewall.
difference at stop track positions. Specification
Pedal TravelDistance
4. Adjust brakes to specifications. From Firewall................................................................... 279 mm (11 in.)

061411
PN=197
5. Mark a notch on adjuster (A) with paint to be used as

a reference point.
6. Remove fender below fuel tank or hydraulic reservoir
to access stop screw.
7. Operate machine in first gear at fast idle, in a
T6677AH 1921DEC92
forward/reverse cycle, pulling steering lever or pushing
steering pedal to stop ten times. Check number
of notches adjuster (A) has moved. In ten brake
applications, adjuster should move only one notch.
8. To slow down the rate of selfadjustment, loosen lock
nut and turn stop screw 1/4turn IN.
9. To increase the rate of selfadjustment, loosen lock
nut and turn stop screw 1/4turn OUT.
IMPORTANT: If stop screw has been adjusted more
than 1/2turn, see Steering Brakes Linkage
Adjustment in this group, to adjust lower
pedal/lever stops ONLY. Lower stops must be
T8065AA 1903SEP93
adjusted to prevent damage to brake linkage.
TX,02,RB527 1917FEB982/2
Manual Steering Brake Adjustment (S.N.

770807)
SPECIFICATIONS
Brake Pedal Distance From 279 mm (11 in.)
Firewall
T6766BZ UN19OCT88
Adjuster Resistance 55 N (12 lb)
Adjuster Distance 127 mm (5 in.)
CAUTION: Install cap screw (P) through

shift control console to lock shift lever in
neutral to prevent accidental shifting into
gear during this adjustment.
IMPORTANT: Over adjustment (too tight) of

steering brakes can cause erratic steering
clutch operation.

061411
PN=198
1. Remove large plug from side of transverse

case.
2. Start engine and shift to neutral.
IMPORTANT: Adjuster (A) must tighten easily. Do not
hammer or pry. Damage to adjuster notches
T6499CK UN09FEB89
could occur. When loosening brakes, the
selfadjuster tab (B) may have to be held away
from notches to reduce resistance.
3. Turn adjuster with large straight screwdriver:

PEDAL STEER:
a. Turn adjuster (A) until, when applying brake by
hand, brake pedal is firm when pedal is 279 mm
(11 in.) from firewall.
Specification
Brake PedalDistance
From Firewall................................................................... 279 mm (11 in.)
T6677AH 1921DEC92
b. Push pedal to lower stop several times to seat
linkage, then check step a again.
LEVER STEER:
a. Turn adjuster (A) until approximately 55 N (12 lb) of
resistance is felt when lever travels 127 mm (5 in.)
as measured at top of handles from forward stop.
Specification
AdjusterResistance............................................................ 55 N (12 lb)
Distance............................................................................ 127 mm (5 in.)
b. Pull levers to rear stop several times to seat linkage.

Repeat step a.
T8065AA 1903SEP93
IMPORTANT: If brakes selfadjust too tight or too
loose, see Adjust Steering Brake SelfAdjuster
Linkage in this group.
NOTE: Brakes can be selfadjusted tighter to operators

preference by pulling steering levers to rear
stop during operation. 450G, 455G and 555G
adjust in reverse travel 550G and 650G
b. Measure lever travel at top lever handles. Track
adjust in forward travel. Brakes can only be
should stop at approximately 127 mm (5 in.) of
loosened by manual adjustment.
lever travel.
4. Check adjustment by operating machine in first gear Specification
at low idle. Brake PedalDistance
Traveled............................................................................ 13 mm (1/2 in.)
PEDAL STEER: Brake PedalLever
a. Slowly push on brake pedal until track stops. Steer MachinesDis
tance Traveled..................................................................... 25 mm (1 in.)
b. Measure pedal travel from firewall to bottom
center of pedal. Track should stop when pedal is NOTE: It is normal for brake pedals to vary up to
approximately 279 mm (11 in.) from firewall. 13 mm (1/2 in.) in travel when checked to
forward and reverse stop track position. Lever
LEVER STEER: steer machines can vary up to 25 mm (1 in.)
difference at stop track positions.
a. Slowly pull back on lever until track stops.
TX,02,RB528 1917FEB982/2

061411
PN=199
Manual Steering Brake Adjustment (S.N.

770808 )
SPECIFICATIONS
Brake Pedal Distance From 279 mm (11 in.)
Firewall
T6766BZ UN19OCT88
Adjuster Resistance 55 N (12 lb)
Adjuster Distance 127 mm (5 in.)

IMPORTANT: Over adjustment (too tight) of

steering brakes can cause erratic steering
clutch operation.

061411
PN=200
1. Remove large plug from side of transverse case.

2. Start engine and shift to neutral.
IMPORTANT: Adjuster (A) must tighten easily. Do
not hammer or pry. Damage to adjuster
notches could occur. End of retainer (B)
T6499CK UN09FEB89
must be springloaded against teeth on
adjuster. Do not pry on retainer.
3. Turn adjuster with large straight screwdriver:

PEDAL STEER:
a. Turn adjuster (A) until, when applying brake by
hand, brake pedal is firm when pedal is 279 mm
(11 in.) from firewall.
Specification
Brake PedalDistance
From Firewall................................................................... 279 mm (11 in.)
T7247AH UN09APR90
b. Push pedal to lower stop several times to seat
linkage, then check step a again.
LEVER STEER:
a. Turn adjuster (A) until approximately 55 N (12 lb) of
resistance is felt when lever travels 127 mm (5 in.)
as measured at top of handles from forward stop.
Specification
AdjusterResistance............................................................ 55 N (12 lb)
Distance............................................................................ 127 mm (5 in.)
b. Pull levers to rear stop several times to seat linkage.

Repeat step a.
T8065AB 1903SEP93
4. Check adjustment by operating machine in first gear
at low idle.
PEDAL STEER: Slowly push on brake pedal until
track stops. Measure pedal travel from firewall to
bottom center of pedal. Track should stop when pedal
is approximately 279 mm (11 in.) from firewall.
LEVER STEER: Slowly pull back on lever until track
stops. Measure lever travel at top lever handles. NOTE: It is normal for brake pedals to vary up to
Track should stop at approximately 127 mm (5 in.) of 13 mm (1/2 in.) in travel when checked to
lever travel. forward and reverse stop track position. Lever
Specification steer machines can vary up to 25 mm (1 in.)
Brake PedalDistance difference at stop track positions.
Traveled............................................................................ 13 mm (1/2 in.)
Brake PedalLever
Steer MachinesDis
tance Traveled..................................................................... 25 mm (1 in.)
TX,02,RB529 1917FEB982/2

061411
PN=201
Adjust Steering Brakes LinkagePedal Steer
T7247AJ UN09APR90
AUpper Pedal Stop DUpper Rod GTow Disconnect Pins J Stop Screw
BLower Pedal Stop ELower Bellcrank HRear Bellcrank KInspection Plug
CPedals F Brake Rod I Brake Adjuster L Return Spring (2 used)
SPECIFICATIONS
3. Adjust upper pedal stop (A) until distance from firewall
Firewall To Bottom Edge Of Pedal 362 3 mm (14.25 0.125 in.)
Distance
to bottom edge of pedal (C), at the center, is 362
3 mm (14.25 0.125 in.).
Pedals Distance From Firewall 197 3 mm (7.75 0.125 in.)
Center Of Bottom Hole In 91 2 mm (3.58 0.08 in.) Specification
Bellcranks Distance From Firewall Firewall To Bottom Edge
Bottom Center of Pedal Distance 338 3 mm (13.25 0.125 in.) Of PedalDistance................................. 362 3 mm (14.25 0.125 in.)
From Firewall Adjust other pedal upper stop until pedals are even
at center.
IMPORTANT: The internal linkage of the transverse
case must be adjusted properly before Adjust lower pedal stops (B) until bottom edge of
starting this adjustment. Linkage is set at the pedals are 197 3 mm (7.75 0.125 in.) from firewall.
factory and needs service only if damaged Specification
or length of rod was changed. PedalsDistance From
This adjustment must be performed in the Firewall...................................................... 197 3 mm (7.75 0.125 in.)
following order to adjust the linkage properly. 4. Adjust length of rods (D) until center of bottom hole in
bellcranks (E) are 91 2 mm (3.58 0.08 in.) from
NOTE: Pedal steer brake linkage adjustment is firewall.
the same for all machines.
Specification
1. Remove floor panels. Remove fenders under reservoir Center Of Bottom Hole
and fuel tank. In BellcranksDistance
From Firewall................................................. 91 2 mm (3.58 0.08 in.)
2. Remove pins from lower bellcranks (E).

061411
PN=202
CAUTION: Machine can move when both tow

disconnect pins are down and engine is off
because brakes are NOT applied. Block tracks
to prevent machine movement.
5. Install pins in lower bellcranks (E). Pull brake pedal to
T6766BZ UN19OCT88
upper stop hold down tow disconnect pin (G) then
release pedal. Tow disconnect pin must stay down.
Repeat step for other side.
6. Hold one pedal upward until freeplay is gone, turn
brake rod (F) until bottom center of pedal is 338 3
mm (13.25 0.125 in.) from firewall.
Specification linkage until quadlever is against stop screw (J) when
Bottom Center of engine is off.
PedalDistance From
Firewall.................................................... 338 3 mm (13.25 0.125 in.) IMPORTANT: Quadlever must be visible and even
with bottom of inspection plug (K) hole.
Release pedal, adjust other brake rod (F) until pedals If not, see Adjust Internal Steering Brake
are even at the center. Control Linkage in this group.
7. Remove large plug in side of transverse housing.
NOTE: Step 10 will insure that stop screw (J) is
8. Pull pedals to upper stop to release tow disconnect contacted before lower stop (B).
pins. Push pedals to lower stop (B).
10. With quadlever against stop screw (J), turn pedal
CAUTION: Install cap screw (P) through shift lower stop screw (B) in until freeplay is evident. Then
control console locking shift lever in neutral turn screw in one turn.
position to prevent accidental shifting into
11. Check and adjust steering valve. (See Adjust Steering
Valve in Group 0260.)
9. Remove inspection plug (K). Check that stop screw 12. Check brake adjustment. (See Manual Steering Brake
(J) is contacting quadlever. If not, start engine and Adjustment in this group.)
shift to neutral. Turn brake adjuster (I) to loosen brake
TX,02,RB530 1917FEB982/2

061411
PN=203
Adjust Steering Brakes LinkageLever Steer (S.N. 770807)
T7247AP UN09APR90
ASteering Valve Pull Rod EUpper Pedal Stop I Lockout (Tow) Pin MAdjuster
BBrake Lever Pull Rod F Pull Rod J Ball Joint NInspection Plug
CLower Lever (Rear) Stop GLower Bellcrank KRear Brake Lever OStop Screw
DLower Pedal Stop HBrake Pedal Pull Rod L Clutch Valve Bellcrank
SPECIFICATIONS
Specification
Bottom Edge of Pedal Distance 362 3 mm (14.25 0.125 in.)
Bottom Edge of
From Firewall
PedalDistance From
Firewall.................................................... 362 3 mm (14.25 0.125 in.)
From Firewall
Center Of Bottom Hole In Bellcrank 91 2 mm (3.58 0.08 in.) 3. Adjust brake pedal lower stop (D) until bottom edge of
Distance From Firewall pedal is 197 3 mm (7.75 0.125 in.) from firewall.
Lever Travel Distance 241 mm (9.5 in.)
Specification
Bottom Edge of
PedalDistance From
case must be adjusted properly before
Firewall...................................................... 197 3 mm (7.75 0.125 in.)
starting this adjustment. Linkage is set at the
factory and needs service only if damaged 4. Adjust length of rod (F) until center of bottom hole
or length of rod was changed. in bellcrank (G) is 91 2 mm (3.58 0.08 in.) from
firewall when pedal is against upper stop.
This adjustment must be performed in the
following order to adjust the linkage properly. Specification
Center Of Bottom Hole
1. Remove floor panels and slide seat back. Remove In BellcrankDistance
fenders under fuel tank and reservoir. From Firewall................................................. 91 2 mm (3.58 0.08 in.)
2. Adjust brake pedal upper stop (E) until bottom edge of 5. Adjust lower lever (rear) stops (C) to stop lever at
pedal is 362 3 mm (14.25 0.125 in.) from firewall. 241 mm (9.5 in.) of lever travel, measured at top of
handles from forward stop.
Specification
Lever TravelDistance.................................................. 241 mm (9.5 in.)

061411
PN=204

6. Remove inspection plug (N) to check that stop screw
T6766BZ UN19OCT88
(O) is contacting quadlever. If not, remove large plugs
in side of transverse case. Start engine and shift to
neutral. Turn adjuster (M) to loosen brake linkage until
quadlever is against stop screw (O) when the engine
is off.
IMPORTANT: Quadlever must be visible and even
with bottom of inspection plug (N) hole. If
not, see Internal Steering Brake Control
Linkage Adjustment in this group. 10. Shorten rod (H) one turn and tighten lock nuts. This
ensures that quadlever stop screw (O) is contacted
7. Adjust length of rod (B) so rear lever stop and before the brake pedal stop.
quadlever contact at the same time. 11. Check and adjust steering valve. (See procedure in
8. Shorten rod (B) one turn and tighten lock nut. This Group 0260.)
ensures that quadlever stop screw (O) is contacted 12. Check brake adjustment. (See Manual Steering Brake
before the steering lever stop. Adjustment in this group.)
9. Adjust length of rod (H) so lower brake pedal stop and
quadlever stop contact at the same time.

061411
PN=205
Adjust Steering Brakes LinkageLever Steer (S.N. 770808)
T7247AK UN09APR90
ASteering Valve Pull Rod EUpper Pedal Stop I Lockout (Tow) Pin MAdjuster
BBrake Lever Pull Rod F Pull Rod J Ball Joint NInspection Plug
CLower Lever (Rear) Stop GLower Bellcrank KRear Brake Lever OStop Screw
DLower Pedal Stop HBrake Pedal Pull Rod L Clutch Valve Bellcrank
SPECIFICATIONS
Specification
Bottom Edge of
From Firewall
PedalDistance From
Firewall.................................................... 362 3 mm (14.25 0.125 in.)
From Firewall
Center Of Bottom Hole In Bellcrank 91 2 mm (3.58 0.08 in.) 3. Adjust brake pedal lower stop (D) until bottom edge of
Distance From Firewall pedal is 200 3 mm (7.87 0.125 in.) from firewall.
Lever Travel Distance 273 mm (10.75 in.)
Specification
Bottom Edge of
PedalDistance From
case must be adjusted properly before
Firewall...................................................... 200 3 mm (7.87 0.125 in.)
starting this adjustment. Linkage is set at the
factory and needs service only if damaged 4. Adjust length of rod (F) until center of bottom hole
or length of rod was changed. in bellcrank (G) is 91 2 mm (3.58 0.08 in.) from
firewall when pedal is against upper stop.
This adjustment must be performed in the
following order to adjust the linkage properly. Specification
Center Of Bottom Hole
1. Remove floor panels and slide seat back. Remove In BellcrankDistance
fenders under fuel tank and reservoir. From Firewall................................................. 91 2 mm (3.58 0.08 in.)
2. Adjust brake pedal upper stop (E) until bottom edge of 5. Adjust lower lever (rear) stops (C) to stop lever at 273
pedal is 362 3 mm (14.25 0.125 in.) from firewall. mm (10.75 in.) of lever travel, measured at top of
handles from forward stop.
Specification
Lever TravelDistance.............................................. 273 mm (10.75 in.)

061411
PN=206

6. Remove inspection plug (N) to check that stop screw
T6766BZ UN19OCT88
(O) is contacting quadlever. If not, remove large plugs
in side of transverse case. Start engine and shift to
neutral. Turn adjuster (M) to loosen brake linkage until
quadlever is against stop screw (O) when the engine
is off.
IMPORTANT: Quadlever must be visible and even
with bottom of inspection plug (N) hole. If
not, see Internal Steering Brake Control
Linkage Adjustment in this group. 10. Shorten rod (H) one turn and tighten lock nuts. This
ensures that quadlever stop screw (O) is contacted
7. Adjust length of rod (B) so rear lever stop and before the brake pedal stop.
quadlever contact at the same time. 11. Check and adjust steering valve. (See procedure in
8. Shorten rod (B) one turn and tighten lock nut. This Group 0260.)
ensures that quadlever stop screw (O) is contacted 12. Check brake adjustment. (See Manual Steering Brake
before the steering lever stop. Adjustment in this group.)
9. Adjust length of rod (H) so lower brake pedal stop and
quadlever stop contact at the same time.

061411
PN=207
Engage Tow Disconnect Pins Manually

SERVICE EQUIPMENT AND TOOLS
Long Shank Screwdriver
1/2 in. Drive Ratchet Wrench (Loader Only)
15 mm Combination Wrench (Loader Only)
T6624AM UN19OCT88
CAUTION: Engaging tow disconnect pins
will release brakes and machine could
move if on a grade.
Pedal Steer
1. Remove center floor plate.
2. Pull brake pedal up to upper stop, hold down tow AScrewdriver DLockout (Tow) Pin
disconnect pin (D), then release pedal. Tow disconnect BBall Joint ECombination Wrench
CClutch Spool Rod F Ratchet Wrench
pin must stay down.
Repeat for other side.
Lever Steer Loader Machines OnlyUse ratchet wrench (F) and
15 mm combination wrench (E).
1. Remove left and right floor panels. Remove fender
under reservoir and fuel tank. a. Insert ratchet into box end of wrench at about 90
angle to the wrench.
2. On left side, insert screwdriver (A) in front of ball joint
(B) and behind control valve spool rod (C). b. Insert open end of wrench under link (C) and head
of ball joint.
3. Pull back on screwdriver until brake linkage hits stop
and depress and hold tow disconnect pin (D). Release c. Push ratchet rearward until brake linkage hits stop.
screwdriver. Push tow disconnect pin down and hold. Slowly
release wrench.
Tow disconnect pin must stay down.
d. Tow disconnect pin must stay down.
4. Dozer Machines OnlyRepeat procedure on right
side.
TX,02,RB533 1917FEB981/1

061411
PN=208
Group 0260
Hydraulic System
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to threads of steering
TY9473 (Canadian) Strength) clutch valve and cylinder cap screws.
242 (LOCTITE)

TX,0260,BD915 1908SEP931/1
Specifications
Steering Clutch Valve Test Port Plugs Torque 11 Nm (97 lbft)

ValvetoPlate Cap Screws Torque 27 Nm (20 lbft)
ElbowtoSteering Clutch Valve Body Torque 11 Nm (97 lbft)
Brake CylindertoPlate Cap Screws Torque 73 Nm (54 lbft)
Steering Valve PlatetoTransverse Torque 73 Nm (54 lbft)
Housing Cap Screws
TX,0260,BD913 1903SEP931/1
Remove and Install Steering Clutch Valve

1. Remove rear panels. Remove battery box cap screws.
Slide battery box and seat rearward.
IMPORTANT: Spring pressure behind spool will force
spool out of valve when linkage (B) is removed.
T6563AA UN25OCT88
2. Disconnect hose (A) and linkage (B). Remove valve.
CAUTION: Do not remove or turn spool eye

bolts. Steering control of machine can be
lost. If spool eye bolts have been removed,
install eye bolts 10 turns in spool, then do
Steering Clutch Valve Adjustment in this
group before operating machine. ValveToPlate Cap
3. Install gasket and valve. Apply thread lock and sealer
(medium strength) to threads of cap screws. Tighten 4. Connect linkage and hose.
cap screws to specification. If new or repaired valve is installed, steering valve
Specification pressure will have to be adjusted. (See procedure in this
Steering Clutch Valve group.)
Test Port PlugsTorque................................................11 Nm (97 lbin.)
TX,0260,BD848 1903SEP931/1

061411
PN=209
Hydraulic System
Disassemble and Assemble Steering Clutch Valve (S.N. 770807)
T6561AA UN01JUN89
ASeal (2 used) CSpool (Lever Steer) (2 used) EHousing
BSpool (Pedal Steer) (2 used) DSpring (2 used)
CAUTION: Do not remove or turn spool eye 3. Install spool seals (A), spring lip to inside of housing,
bolts. Steering control of machine can be to bottom of bores.
4. Install elbow in valve housing (E) and tighten.
reinstall them 10 turns in spool, then do
Steering Clutch Valve Adjustment in this Specification
group before operating machine. ElbowtoSteering Clutch
Valve BodyTorque......................................................11 Nm (97 lbin.)
1. Disassemble valve as shown.
2. Inspect spools (B and C) for wear or damage. If spools
are damaged, replace housing and valves.
TX,02,RB534 1917FEB981/1

061411
PN=210
Hydraulic System
Disassemble and Assemble Steering Clutch Valve (S.N. 770808 )
T7247AL UN09APR90
ASeal (2 used) CSpool (Lever Steer) (2 used) EHousing
BSpool (Pedal Steer) (2 used) DSpring (2 used)
CAUTION: Do not remove or turn spool eye 3. Install spool seals (A), spring lip to inside of housing,
bolts. Steering control of machine can be to bottom of bores.
4. Install elbow in valve housing (E) and tighten.
reinstall them 10 turns in spool, then do
Steering Clutch Valve Adjustment in this Specification
group before operating machine. ElbowtoSteering Clutch
Valve BodyTorque......................................................11 Nm (97 lbin.)
1. Disassemble valve as shown.
2. Inspect spools (B and C) for wear or damage. If spools
are damaged, replace housing and valves.
TX,02,RB535 1917FEB981/1

061411
PN=211
Hydraulic System
T6688AN UN23AUG93
Adjust Steering Clutch Valve
SPECIFICATIONS
Spool Preset Length in Nertral
Lever Steer Units Length 35 mm (1.38 in.)
Pedal Steer Units Length 33 mm (1.30 in.)
Engine Approximate Speed 1500 rpm
OilDirect Drive Units 40 6 10F)
Temperature
OilTorque Converter Units 65 6C (150 10F)
Temperature
Steering Clutch Valve
Direct Drive Units Pressure 1241 103 kPa (12.4 1.0 bar)
(180 15 psi)
Torque Converter Units Pressure 1724 103 kPa (17.2 1.0 bar)
T6688AO UN25OCT88
(250 15 psi)
Lever Units(S.N. 770807) 38 2 mm (1.50 0.08 in.)
Pressure Drops to Zero After
Travel
Lever Units(S.N. 770808 ) 55 2 mm (2.20 0.08 in.)
Travel
Pedal Units(S.N. 770807) 22 2 mm (0.87 0.08 in.)
Travel
Pedal Units(S.N. 770808 40 2 mm (1.60 0.08 in.)
) Pressure Drops to Zero After
Travel
T6766BZ UN19OCT88
ESSENTIAL TOOLS
JT03111 (B) Adapter (7/16 M 37 x 9/16 M ORB)
Parker No. 050364 (B) Adapter (7/16 M 37 x 9/16 M ORB)
JT05483 90 Elbow (7/16 M 37 x 7/16 F 37)
(Parker No. 390344) 90 Elbow (7/16 M 37 x 7/16 F 37)
SERVICE EQUIPMENT AND TOOLS

(P) Cap Screw and NutM10 x 100 mm (3/8 x 4 in.)
Gauge 02000 kPa (020 bar) (0300 psi) ASteering Valve Pull CSpool Neutral Preset
Digital Thermometer RodLever Steer Shown Length
B7/16 M 37 x 9/16 M ORB PCap Screw
Adapter
1. Remove cap screws to slide battery box and seat
rearward to access steering clutch valve.

shift control console to lock shift lever in Repeat step for other side.
neutral and prevent accidental shifting into
3. Connect gauges to test ports on valve and install
thermometer.
NOTE: Use Step 2 to establish a starting point when 4. Start engine and heat oil to specification.
steering valve has been disassembled or replaced.
Specification
If adjusting only, go to Step 3.
EngineApproximate
Speed........................................................................................ 1500 rpm
2. With steering levers or pedals at rest, install valve
OilDirect Drive
spool eye bolt 10 turns, and adjust rod (A) to get
UnitsTemperature.......................................................... 40 6 10F)
specified spool preset length (C) from spool seal face
OilTorque Converter
to end of cylindrical surface of spool.
UnitsTemperature.............................................. 65 6C (150 10F)
Spool Preset Length in NeutralSpecification
Lever Steer
(Refer to procedure in TM1403, Group 902025.)
UnitsLength................................................................. 35 mm (1.38 in.)
Pedal Steer
UnitsLength................................................................. 33 mm (1.30 in.)

061411
PN=212
Hydraulic System
IMPORTANT: Steering spools MUST be adjusted (S.N. 770808 ) 55 2 mm (2.20 0.08 in.)
EVEN to synchronize steering before final Specification
adjustments are made. Lever Units(S.N.
770808 )Pressure
5. Steering clutch valve pressure must be to specification. Drops to Zero After
Travel............................................................. 55 2 mm (2.20 0.08 in.)
Steering Clutch ValveSpecification
Direct Drive PEDAL STEER UNITSSlowly depress pedal, one at
UnitsPressure.............................................................. 1241 103 kPa a time and watch pressure gauge. Pedal must travel
(12.4 1.0 bar) (180 15 psi) specified distance (measured at bottom center of
Torque Converter pedal) before pressure drops to zero.
UnitsPressure.............................................................. 1724 103 kPa
(17.2 1.0 bar) (250 15 psi) (S.N. 770807) 22 2 mm (0.87 0.08 in.)
If not, turn steering spool OUT (counterclockwise) to Specification
increase pressure. Pedal Units(S.N.
770807)Pressure
If pressure will not adjust up to specification, check for Drops to Zero After
restricted line to clutch valve or low system pressure. Travel............................................................. 22 2 mm (0.87 0.08 in.)
Do Steering Clutch Pressure Test in TM1403 Group
902025. (S.N. 770808 ) 40 2 mm (1.60 0.08 in.)
Specification
NOTE: Move lever or pedal to specified distance and hold
Pedal Units(S.N.
in position using a block or threaded rod.
770808 )Pressure
Drops to Zero After
6. Move lever or pedal specified distance for pressure
Travel............................................................. 40 2 mm (1.60 0.08 in.)
drop:
7. If lever or pedal travel is not to specification, block or
LEVER STEER UNITSSlowly pull back on lever,
hold lever or pedal to specified travel position. Adjust
one at a time and watch pressure gauge. Lever must
point of pressure drop by turning steering spool into or
travel specified distance (measured at top of handle)
out of housing.
before pressure drops to zero.
NOTE: Loosen nut on spool eye bolt and turn spool
(S.N. 770807) 38 2 mm (1.50 0.08 in.) OUT (counterclockwise) to increase pedal or lever
Specification travel IN (clockwise) to decrease travel.
Lever Units(S.N.
770807)Pressure 8. Adjust brakes. (See Manual Steering Brake
Drops to Zero After Adjustment in Group 0250.)
Travel............................................................. 38 2 mm (1.50 0.08 in.)
TX,02,RB536 1917FEB982/2

061411
PN=213
Hydraulic System
Remove and Install Steering Brake Cylinder
T8066AD UN09SEP93
ASteering Clutch Valve DGasket GBrake Cylinder J Cap Screw and Washer (2
BCap Screw and Washer (11 EGasket HBrake Piston (2 used) used)
used) F Spring Pin I Pipe PlugPedal Steer Units KBrake Locking Spring
CPlate Only (2 used) L Second Brake Locking Spring
(S.N. 786471 ) Only
NOTE: Brake cylinder is pressurized to release Engage lock out pins again.
steering brakes whenever speed control valve
is not in P (PARK) position. 6. Push spring pin (F) into brake cylinder (G) until just
below machined surface.
1. Engage lock out pins.
7. For pedal steer machines only, apply thread lock and
2. Remove steering clutch valve (A). (See procedure in sealer (medium strength) to threads of pipe plugs (I).
this group.) Install plugs into plate (C) until even with or just below
surface of plate.
3. Remove cap screw (B) to remove parts (CJ).
4. Inspect parts replace as necessary. threads of cap screws (J). Install gasket, cylinder,
5. Slowly release lockout pins to relieve spring (K and L) washers and cap screws tighten to specification.
tension. Replace springs if necessary.

061411
PN=214
Hydraulic System
Steering Valve
9. Install gasket and plate assembly. Apply thread
PlateToTransverse
lock and sealer (medium strength) to threads of cap
Housing Cap Screws
screws (B). Install washers and cap screws tighten
(B)Torque.................................................................... 73 Nm (54 lbft)
to specification.
Steering ValveToPlate
Specification Cap ScrewsTorque......................................... 27 5 Nm (20 4 lbft)
Brake CylinderToPlate
Cap Screws (J)Torque................................................. 73 Nm (54 lbft) 10. Install steering clutch valve. (See procedure in this
group.)
TX,02,RB537 1917FEB982/2

061411
PN=215
Hydraulic System

061411
PN=216
Group 0299
DF1030 Brake Assembly Tool
Tool can be made in dealers shop. Used to hold brake
anchor assembly to steering clutch during removal and
installation of steering clutch.
Material: 1020 Flat stock 1/4 x 3/4 in.
T6579AM UN19MAY89
A10 mm (0.39 in.) E8 mm (0.39 in.)
B45 F 20 mm (0.79 in.)
C20 mm (0.79 in.) G50 mm (1.97 in.)
D20 mm (0.79 in.)
9900,U95 1903AUG901/1

061411
PN=217
DF1063 Final Drive Lift Bracket
2
2
2
5
3
5 4
9
6
7
11
12 10
6
5
4
TX1072724 UN05MAR10
13
5 14
13
8 15
TX1072724
Final Drive Lift Bracket
1 508 mm (20.0 in.) 5 203.2 mm (8.00 in.) 9 3/4 in. Drill Through Both 13 15.9 mm (0.625 in.)
2 50.8 mm (2.00 in.) 6 63.5 mm (2.50 in.) Sides (8 holes) 14 82.6 mm (3.25 in.)
3 25.4 mm (1.00 in.) 7 2286 mm (90.00 in.) 10 3/8 in. Drill Through (4 15 114.3 mm (4.50 in.)
4 38.1 mm (1.50 in.) 8 152.4 mm (6.00 in.) holes)
11 44.5 mm (1.75 in.)
12 76.2 mm (3.00 in.)
Tool used to remove and install final drives.

11/2 in. x 3 in. Square Tube
Material required: 1/2 in. 1020 Steel
3/8 in. x 11/2 in. Cap Screw with Nut (4 used)
TX,02,RB538 1914JUN101/1

061411
PN=218
DF1063A Single Reduction Adapter Plate
T113230 1903FEB98
Adapter is used with DF1063 Lift Bracket to remove and
install single reduction final drives. 1/2 in. 1020 Steel Plate
11/2 in. x 3 in. x 3/16 in. Square Tube
Material required: 5/8 in. x 5 in. Cap Screw
TX,02,RB539 1917FEB981/1
DF1063B Double Reduction Adapter Plate
T113229 1903FEB98
Adapter is used with DF1063 Lift Bracket to remove and

install double reduction final drives. Material required:
1/2 in. 1020 Steel Plate
TX,02,RB540 1917FEB981/1

061411
PN=219

061411
PN=220
Section 03
Transmission
Contents
Page Page
Group 0315Control Linkage Disassemble and Assemble

Other Material............................................ 0303151 Transmission Decelerator
Specifications ............................................ 0303151 Assembly ............................................. 03036012
Disassemble and Assemble Remove and Install Transmission
Transmission Linkage (S.N. Oil PumpTorque Converter
768272).............................................. 0303152 Machines ............................................. 03036014
Disassemble and Assemble Remove and Install Transmission
Transmission Linkage (S.N. Oil PumpDirect Drive
768273 )............................................. 0303154 Machines ............................................. 03036015
Transmission Control Linkage Disassemble and Assemble
Adjustment............................................. 0303156 Transmission Oil PumpTorque
Converter Machines ............................ 03036016
Group 0325Input Drive Shafts and UJoints Disassemble and Assemble
Remove and Install Drive Shaft ................. 0303251 Transmission Oil PumpDirect
Drive Machines.................................... 03036017
Group 0350Gears, Shafts, Bearings and Clutch Charge Transmission
Special or Essential Tools.......................... 0303501 Accumulator......................................... 03036019
Service Equipment and Tools .................... 0303501 Remove and Install Transmission
Other Material............................................ 0303502 Oil Filter ............................................... 03036020
Specifications ............................................ 0303503 Remove and Install Transverse
Remove and Install Transmission.............. 0303504 Case Suction Screen........................... 03036022
Disassemble Transmission...................... 03035010 Remove and Install Transmission
Check Backing Plates Movement............ 03035013 Oil Cooler............................................. 03036023
Transmission Cover............................. 03035014 Group 0399Dealer Fabricated Tools
Disassemble and Assemble DF1126 Bearing Installer ........................... 0303991
First/Second and Third/Fourth DF1127 Support Tubing............................. 0303992
Clutch Packs........................................ 03035016 DF1128 Bearing Installer ........................... 0303993
Disassemble and Assemble DF1031 Clutch Assembly Tool .................. 0303993
Forward/Reverse Clutch Pack............. 03035027 DFT1121 Rivet Forming Tool..................... 0303994
Replace Ring Gear .................................. 03035038 JT38000 Differential Lifting Tool ................ 0303995
Adjust Cone Point.................................... 03035039
Adjust Ring Gear Bearing Preload............ 03035040
Adjust Output Shaft Bearing
Preload ................................................ 03035041
Assemble Transmission .......................... 03035042
Transmission Air Test .............................. 03035046
Transverse Housing............................. 03035048

Service Equipment and Tools .................... 0303601
Other Material............................................ 0303601
Specifications ............................................ 0303602
Remove and Install Transmission
Control Valve ......................................... 0303603
Transmission Control Valve ................... 0303605
Transmission Control Valve
Manifold ............................................... 03036010
Adjust Rate of Shift.................................. 03036010

061411
PN=1
Contents

061411
PN=2
Group 0315
Control Linkage
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads of bellcrank mount
TY9473 (Canadian) Strength) and cap screws.
242 (LOCTITE)
TY15147 (U.S.) John Deere Instant Super Bonder Apply to threads of levers.

0315,SS2 1931JUL901/1
Specifications
Bellcrank Mount Torque 175 87 Nm (130 65 lbft)

Lower Bellcrank Bracket Cap Screws Torque 37 7.4 Nm (27 5.5 lbft)
Drive Shaft Bearing StraptoYoke Torque 47.5 9 Nm (35 7 lbft)
Cap Screw
450G, 550G, 650G:
Speed Selector Horizontal Rod Length 332.5 mm (13.1 in.)
Direction Selector Horizontal Rod Length 230 mm (9.1 in.)
455G, 555G:
Speed Selector Horizontal Rod Length 89.23 mm (3.5 in.)
Direction Selector Horizontal Rod Length 193 mm (7.6 in.)
0315,SS1 1931JUL901/1

061411
PN=223
Control Linkage
Disassemble and Assemble Transmission Linkage (S.N. 768272)
T7247AU UN09APR90
Continued on next page TX,0315,QQ429 1919OCT931/2

061411
PN=224
Control Linkage
1 Knob 9 Cap Screw 17 Cap Screw 25 Cap Screw

2 Gear Shift Lever 10 Vertical Direction Selector 18 Spacer 26 Horizontal Direction
3 Shift Quadrant Rod 19 Nut Selector Rod
4 Park Brake Lock Lever 11 Power Control Pedal 20 Power Control Return 27 Bellcrank Mount
5 Knob 12 Bent Vertical Rod Spring 28 Power Control Bellcrank
6 Lock Nut 13 Forward Bellcrank 21 Spring Rod 29 Park Brake Lock Bellcrank
7 Bushing 14 Power Control Tie Rod 22 Horizontal Speed Selector 30 Ball Bearing
8 Cap Screw 15 Direction Selector Bellcrank Rod 31 Vertical Speed Selector Rod
16 Bellcrank Support 23 Speed Selector Bellcrank (Early Machines)
24 Cap Screw (3 used) 32 Vertical Speed Selector Rod
(Later Machines)
NOTE: Power control pedal and linkage is used on Cap Screw (17)
direct drive machines only. Cap Screw (24)
Cap Screw (25)
1. Disassemble and assemble parts (130). Bellcrank Mount (27)
Specification Shift Quadrant (3) Cap Screws (use Loctite 271,
450G, 550G, highstrength thread lock and sealer).
650G: Speed
Selector Horizontal 3. Tighten bellcrank mount.
RoadLength........................................................... 332.5 mm (13.1 in.) Specification
450G, 550G, Bellcrank
650G: Direction MountTorque........................................... 175 87 Nm (130 65 lbft)
Selector Horizontal
RoadLength................................................................ 230 mm (9.1 in.) 4. Tighten cap screws (24 and 25).
455G, 555G: Speed Specification
Selector Horizontal Lower Bellcrank Bracket
RoadLength............................................................. 89.23 mm (3.5 in.) Cap ScrewsTorque................................... 37 7.4 Nm (27 5.5 lbft)
455G, 555G: Direction
Selector Horizontal 5. Apply instant bonder to thread of levers (2 and 4).
RoadLength................................................................ 193 mm (7.6 in.) Install knobs (1 and 5).
2. Apply thread lock and sealer (medium strength) to the 6. On early machines, adjust spring nut on rod (31) to
following threads: preload spring 0.5 mm (0.02 in.). (Not used on later
machines.)
Cap Screw (8)
Cap Screw (9)
TX,0315,QQ429 1919OCT932/2

061411
PN=225
Control Linkage
Disassemble and Assemble Transmission Linkage (S.N. 768273 )
T8074AC UN13SEP93
Continued on next page TX,0315,BD885A 1919OCT931/2

061411
PN=226
Control Linkage
1 Knob 13 Cap Screw 25 Park Brake Lock Bellcrank 37 Snap Ring

2 Gear Shift Lever 14 Spacer 26 Ball Bearing 38 Shoulder Bolt
3 Shift Quadrant 15 Nut 27 Vertical Speed Selector Rod 39 Bushing (2 used)
4 Park Brake Lock Lever 16 Power Control Return 28 Tie Rod 40 Shock Absorber
5 Knob Spring 29 Forward Bellcrank 41 Washer (2 used)
6 Lock Nut 17 Spring Rod 30 Power Control Tie Rod 42 Nut
7 Washer 18 Horizontal Speed Selector 31 Lower Stop 43 Spacer (S.N. 785405)
8 Cap Screw Rod 32 Power Control Pedal 44 Power Control Tie Rod (S.N.
9 Cap Screw 19 Speed Selector Bellcrank 33 Upper Stop 785405)
10 Vertical Direction Selector 20 Cap Screw (3 used) 34 Bearing (2 used) 45 Cap Screw (S.N. 785405)
Rod 21 Cap Screw 35 Seal (2 used)
11 Direction Selector Bellcrank 22 Horizontal Direction 36 Washer (2 used)
12 Bellcrank Support Selector Rod
23 Bellcrank Mount
24 Power Control Bellcrank
NOTE: Power control pedal and linkage is used on Cap Screw (9)
direct drive machines only. Cap Screw (13)
Cap Screw (20)
1. Disassemble and assemble parts (145). Cap Screw (21)
Specification
Bellcrank Mount (23)
450G, 550G,
Cap Screw (45)
650G: Speed Shift Quadrant (3) Cap Screws (use Loctite 271, high
Selector Horizontal strength, thread lock and sealer).
RoadLength........................................................... 332.5 mm (13.1 in.)
450G, 550G, 3. Tighten bellcrank mount (23).
650G: Direction Specification
Selector Horizontal Bellcrank
RoadLength................................................................ 230 mm (9.1 in.) MountTorque........................................... 175 87 Nm (130 65 lbft)
455G, 555G: Speed
Selector Horizontal 4. Tighten cap screws (20 and 21).
RoadLength............................................................. 89.23 mm (3.5 in.) Specification
455G, 555G: Direction Lower Bellcrank Bracket
Selector Horizontal Cap ScrewsTorque................................... 37 7.4 Nm (27 5.5 lbft)
RoadLength................................................................ 193 mm (7.6 in.)
5. Apply instant bonder to thread of levers (2 and 4).
2. Apply thread lock and sealer (medium strength) to the Install knobs (1 and 5).
following threads:
Cap Screw (8)
TX,0315,BD885A 1919OCT932/2

061411
PN=227
Control Linkage
Transmission Control Linkage Adjustment
T6820AA UN19OCT88
APark Lock Fork Roller CShift Lever Pivot Ball Joint ESpeed Selector Horizontal
BVertical Speed Selector Rod DDirection Selector Vertical Rod
Rod F Direction Selector Horizontal
Rod
toward neutral. Measurement is taken at quadrant

CAUTION: Prevent possible injury from cover front edge to shift lever front edge.
unexpected machine movement. Machine
will not shift properly if the following linkage 3. Move shift lever to neutral. Speed selector spool
adjustment procedure is not followed. should move from its fully bottomed position in housing
to first detent.
NOTE: To properly adjust shift linkage, all console,
quadrant and linkage hardware MUST be tight and 4. Adjust vertical speed selector rod (B) to position shift
linkage MUST be free. Shortening rod (D) (turning lever approximately 0.51.0 mm (0.020.04 in.)
counterclockwise) moves spool into housing. ahead of center section of quadrant.
Specification
1. Put park and brake lock lever down. Shift LeverApproxi
mate Position..............................................0.51.0 mm (0.020.04 in.)
2. Adjust ball joint (C) until roller (A) contacts shift lever.
Shift lever should not move more than 2 mm (0.08 in.) 5. Move shift lever into park detent then neutral.
Continued on next page 902020,QQ26 1919OCT931/3

061411
PN=228
Control Linkage
there is contact, loosen ball joint (C) and slide to rear.

6. Move shift lever sidetoside. There must not be
Repeat steps 24. Recheck park lock clearance.
contact with park lock lever inside of quadrant. If
902020,QQ26 1919OCT932/3
7. Position shift lever against right edge of quadrant

(G) in neutral slot. Hold shift lever against quadrant
and shorten direction selector vertical rod (D) (turn
counterclockwise) until spool bottoms in housing and
shift lever moves away from right edge of quadrant.
(Apply pressure to shift lever to ensure that linkage is
not binding and spool is bottomed in housing. Lever
will not touch right edge of quadrant.)
8. While maintaining pressure on lever, lengthen
direction selector vertical rod (D) (turn clockwise) until
shift lever just contacts right edge of quadrant. Turn
an additional 1/4 turn and tighten jam nuts.
9. Shift lever must move freely and contact both
forward and reverse sides of quadrant neutral slot. If
adjustment is not to specification, repeat steps 78.
10. Shift through each detent to be sure every gear is
firmly in detent.
11. Move park lock lever down. Lever must move
smoothly and push shift lever into park detent.
T8103AA UN11OCT93
12. After all linkage adjustments have been made, the
shift lever when in park position, must not move
more than 2 mm (0.08 in.) towards neutral position.
Measurement is taken at quadrant cover front edge
to shift lever front edge.
902020,QQ26 1919OCT933/3

061411
PN=229
Control Linkage

061411
PN=230
Group 0325
Input Drive Shafts and UJoints
Remove and Install Drive Shaft
NOTE: Torque converter machine shown procedures
for direct drive machines are the same.
1. Remove center floor plates.
T112893 UN20JAN98
2. Remove four cap screws (B).
3. Slide drive shaft (A) toward transmission to remove.
4. Install drive shaft (A). Tighten bearing straptoyoke
cap screws (B).
5. Install floor plates.
(S.N. 803601 ) Shown
Specification
Drive Shaft Bearing
StraptoYoke Cap
ScrewsTorque.............................................. 47.5 9 Nm (35 7 lbft)
TX,03,RB243 1922JAN981/1

061411
PN=231
Input Drive Shafts and UJoints

061411
PN=232
Group 0350
Gears, Shafts, Bearings and Clutch
SERVICEGARD is a trademark of Deere & Company

T8078AB UN28SEP93
Puller Legs............................................................ JDG831
To remove and install gears and bearings.
To remove and install gears and bearings.


TX,03,DY59 1914JUN111/4
Lifting Bracket.......................................................JT01748 Used with slide hammer to remove final drive

Remove and install transmission in transverse case. pinion and steering clutch shafts.
Remove and install transverse cover. Remove and Repair Stand
install transmission control valve.
Mounting transmission for repair.
Adapter .................................................................JT01773
TX,03,DY59 1914JUN112/4
Differential Lifting Tool ........................................ JT380001 Support Tube..................................................... DFT11271

Remove and install ring gear assembly. Support clutch pack assembly for bearing installation.
Clutch Assembly Tool .......................................... DF10311 Bearing Installer................................................. DFT11281
To compress spring washers for removal and Install clutch pack bearings.
installation of clutch pack. Rivet Forming Tool............................................. DFT11211
Bearing Installer................................................. DFT11261
To form rivets when installing ring gear to ring gear hub.
Install clutch pack bearings.
1
TX,03,DY59 1914JUN113/4
400 mm (16 in.) Nylon Tie Band KD Tools No. 1114 Piston Ring Compressor Pliers and
No. 1126 Piston Ring Compressor Band
To compress clutch pack sealing ring.
To compress clutch pack sealing ring.
TX,03,DY59 1914JUN114/4

061411
PN=233
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to cap screw threads as
TY9473 (Canadian) Strength) specified.
242 (LOCTITE)
T43514 (U.S.) Plastic Gasket Apply between mating surfaces

TY9475 (Canadian) as specified.
277 (LOCTITE)
T43515 (U.S.) LOCTITE Retaining Compound Apply to ring gear and ring gear hub.
TY9479 (Canadian)
635 (LOCTITE)

0350,BB80 1931JUL901/1

061411
PN=234
Specifications
Rear Counterweight Weight 138 kg (304 lb)

Transverse Case Rear Cover Weight 36 kg (80 lb)
Transmission Assembly Weight 265 kg (584 lb)
Ring Gear Assembly Weight 71 kg (156 lb)
Transverse Case:
Transverse Case Approximate Oil Capacity 83 L (22 gal)
Rear Cover Cap Screws M12 Torque 149 Nm (110 lbft)
Rear Cover Cap Screws M20 Torque 620 Nm (457 lbft)
Suction Tube Cap Screws Torque 73 Nm (54 lbft)
Dipstick Tube Cap Screws Torque 73 Nm (54 lbft)
Transmission Support Rod Cap Torque 73 Nm (54 lbft)
Screws
Transmission Cover:
Reverse Idler Gear ShafttoCover Torque 73 Nm (54 lbft)
Cap Screw
Tube ClamptoCover Cap Screw Torque 73 Nm (54 lbft)
Forward and Reverse Tube Cap Torque 10 Nm (8 lbft)
Screw
Cover Mounting Cap Screw Torque 130 Nm (96 lbft)
Transmission:
Clutch Pack Disks/Plates Wear Minimum Backing Plate Movement 2.03 mm (0.080 in.)
Clutch Packs Disks/Plates Wear Maximum Backing Plate Movement 3.05 mm (0.120 in.)
Ring Gear Bearing Quill Cap Screw Torque 73 Nm (54 lbft)
Ring Gear Hub Bearing Preload 0.050.13 mm (0.0020.005 in.)
Pinion Shaft Gear Retaining Nut Torque 407 Nm (300 lbft)
Spiral Bevel Pinion Rolling Torque 1.11.7 Nm (1015 lbin.)
Spiral Bevel Pinion/Ring Gear Backlash 0.180.23 mm (0.0070.009 in.)
TransmissiontoTransverse Case Torque 320 Nm (236 lbft)
Cap Screw
ORing Retainer PlatetoManifold Torque 15 Nm (133 lbin.)
Cap Screw
Tube Support PlatetoTransverse Torque 73 Nm (54 lbft)
Case Cap Screw
Final Drive Pinion Quill Cap Screw Torque 149 Nm (110 lbft)
Pinion Shaft Bearing Seat Cap Screw Torque 204 Nm (150 lbft)
TX,0350,BD890 1919OCT931/1

061411
PN=235
T6645AB UN27OCT88
1 Rear Cover 8 Transverse Case 15 Steering Clutch Shaft 22 Washer (18 used)
2 Cap Screw (2 used) 9 Cap Screw (3 used) 16 Socket Head Cap Screw (2 23 Cap Screw (18 used)
3 Washer (2 used) 10 Washer (3 used) used) 24 Washer (13 used)
4 Lifting Bracket (2 used) 11 Pinion Quill 17 Pipe Plug (3 used) 25 Cap Screw (13 used)
5 Transmission Assembly 12 ORing 18 Drain Plug 26 Cap Screw (2 used)
6 Washer (2 used) 13 Shim Pack (as required) 19 Tube Clamp Support
7 Cap Screw (2 used) 14 Final Drive Pinion 20 Washer
21 Cap Screw
Continued on next page 0350,BB82 1919OCT931/7

061411
PN=236
NOTE: Transmission can be removed with the transverse

case in machine by removing one pinion shaft.
Transverse case oil capacity is approximately
83 L (22 gal).
1. Remove drain plug (A) to drain transverse case.
T6499DQ UN09FEB89
Specification
Transverse
CaseApproximate
Oil Weight............................................................................. 83 L (22 gal)
CAUTION: Approximate weight of each rear

Early Machines
counterweight is 138 kg (304 lb).
2. Remove rear counterweights, drawbar or other rear

mounted equipment.
Specification
Rear Counter
weightApproximate
T6891AR UN10FEB89
Weight.............................................................................. 138 kg (304 lb)
Later Machines
0350,BB82 1919OCT932/7
3. Remove upper left and upper right cap screws from

rear cover. Install two M162 x 150 mm metric hex
screws (B) as guide pins. Remove all other rear cover
cap screws.
CAUTION: Approximate weight of rear
T6645AC UN27OCT88
cover is 36 kg (80 lb).
4. Install two JT01748 Lifting Brackets (A) using 16 mm

or 5/8 in. cap screws and nuts.
Specification
Transverse Case Rear
CoverApproximate
Weight.................................................................................. 36 kg (80 lb)
Remove rear cover.

061411
PN=237
IMPORTANT: The jack screw (C) will support

the steering clutch when the final drive
pinion shafts are removed.
DO NOT lock out brakes with tow pins.
Tow pins must be up and brakes applied to
hold steering clutch drum in place during
T6656DR UN19OCT88
final drive pinion removal.
NOTE: Transmission removal for 450G, 455G and

555G will require removal of one sprocket
to remove pinion shaft. (See Remove and
Install Sprocket in Group 0130.)
550G and 650G will require removal of one
rear carrier support roller to remove pinion
shaft. (See Remove and Install Carrier Support
Roller in Group 0130.)
5. Remove plug (B) from under transverse case. Turn
T6656DS UN19OCT88
jack screw up into the transverse case until contact is
made with the steering clutch (D).
0350,BB82 1919OCT934/7
6. Remove quill with shim pack to remove final drive

pinion (A) and steering clutch shaft (B) using JT01773
Adapter and a slide hammer.
NOTE: To prevent unnecessary work on other sprocket
or pinion shaft, pull opposite steering clutch
shaft into center of transmission after one pinion
T6645AD UN27OCT88
and shaft have been removed.
7. Pull opposite steering clutch shaft into center of

transmission using JT01773 Adapter and slide
hammer.
T6645AE UN27OCT88

061411
PN=238
8. Remove cap screws (A, B, and E).
CAUTION: Approximate weight of transmission

assembly is 265 kg (584 lb).
9. Pull the transmission assembly out of case just enough
T6926BZ UN06DEC88
to install JT01748 Lifting Brackets (D).
Specification
Transmission
AssemblyApproximate
Weight.............................................................................. 265 kg (584 lb)
10. Remove cap screws (C) to remove transmission.

Repair or replace as needed. See procedure in this
group.
11. Install transmission so weight is on rails. Remove
lifting brackets.
IMPORTANT: Be sure lube and clutch pressure tubes
T6645AG UN27OCT88
align with control valve manifold.
12. Push transmission into case, and install cap screws

(C).
13. Install cap screws (B) and tighten.
Specification
Transmissionto
Transverse Case Cap ACap Screw (4 used) DJT01748 Lifting Bracket (2
ScrewTorque........................................................... 320 Nm (236 lbft) BCap Screw (2 used) used)
CCap Screw (2 used) ECap Screw
14. Install cap screws (A) and tighten.
Specification
ORing Retainer Specification
PlatetoManifold Cap Tube Support
ScrewTorque................................................................15 Nm (11 lbft) PlatetoTransverse Case
15. Install support plate and tighten cap screw (E).

061411
PN=239
16. Install both steering clutch shafts.

17. Install final drive pinion (E).
18. Install quill (B), Oring (C), and correct shim pack (D).
19. Thoroughly clean mounting surface of transverse case
T6562AB UN01NOV88
and rear cover.
20. Install gasket with continuous rubber bead facing in.
Install rear cover.
21. Install small cap screws from center of housing toward
corners. Tighten cap screws.
Specification
Rear Cover Cap Screws
(M12)Torque............................................................149 Nm (110 lbft) ACap Screw (3 used) DShims (as needed)
BQuill EPinion
22. Install large cap screws from center of housing toward CORing F Slide Hammer and Adapter
corners. Tighten cap screws.
Specification
Rear Cover Cap Screws 24. Apply thread lock and sealer (medium strength) to
(M20)Torque........................................................... 620 Nm (458 lbft) threads of cap screws (A). Install quill and cap screws
and tighten.
23. Install drain plug. Fill transmission with approximately
83 L (22 gal) of oil. Specification
Final Drive Pinion Quill
Specification Cap ScrewsTorque..................................................149 Nm (110 lbft)
TransmissionApproxi
mate Oil Capacity................................................................. 83 L (22 gal)
0350,BB82 1919OCT937/7

061411
PN=240

061411
PN=241
Disassemble Transmission
T8075AA UN13SEP93

061411
PN=242
1 Bearing Cone (2 used) 12 Shims (as required) 23 Thrust Race (2 used) 34 Shims (as required)
2 Spiral Bevel Ring Gear 13 Cap Screw (12 used) 24 Roller Bearing (2 used) 35 Nut
3 Rivet (10 used) 14 Quill (2 used) 25 Idler Cluster Gear 36 Plate
4 Ring Gear Hub 15 Bearing Cup (2 used) 26 Thrust Spacer 37 Washer (4 used)
5 Cap Screw (S.N. 762832) 16 Shims (as required) 27 Washer (4 used) 38 Cap Screw (4 used)
6 Washer 17 Transmission Housing 28 Cap Screw (4 used) 39 1st/2nd Speed Clutch Pack
7 Snap Ring 18 Dowel Pin (2 used) 29 Ball Bearing (3 used) 40 Forward/Reverse Clutch
8 Splined Coupler 19 Sealing Ring (12 used) 30 Retaining Ring (3 used) Pack
9 Spiral Bevel Pinion Shaft 20 3rd/4th Speed Clutch Pack 31 Snap Ring (3 used) 41 Transmission Cover
10 Bearing Cone 21 High Range Gear 32 Bearing Cup 42 Snap Ring (S.N. 762833 )
11 Bearing Cup 22 Thrust Bearing (2 used) 33 Bearing Cone
TX,0350,BD892 1919OCT932/4
1. Install transmission in repair stand.
CAUTION: Approximate weight of ring gear

assembly is 71 kg (156 lb).
2. Install JT38000 Differential Lifting Tool (A).

Specification
Ring Gear
AssemblyApproximate
Weight................................................................................ 71 kg (156 lb)
Remove bearing quills (B) with shims and remove ring
gear assembly.
Keep shims with respective quills.
T6645AJ UN27OCT88

061411
PN=243
3. Remove plate (A).

4. Install a 2 in. x 4 in. piece of wood (H), minimum of 12
in. long through differential bearing quill supports to
support pinion shaft during removal.
IMPORTANT: Soft metal wedge (brass) must be
used to retain high range gear (I) to remove
pinion nut (F). Pinion shaft (G) must be
retained at high range gear to prevent damage
to transmission housing.
5. Install soft metal wedge (brass) to retain high range

gear (I) and remove nut (F). Remove pinion shaft (G)
using a driver.
6. Remove snap rings (B), cap screws and cover (D).
(For disassembly of cover, see procedure in this
group.)
7. Remove cap screw or snap ring to remove washer
and coupler (E) from forward/reverse clutch pack (C).
8. Remove forward/reverse clutch pack and then the
T6645AK UN27OCT88
remaining cluster gears, gears and clutch packs.
9. Clean and inspect all components.
APlate F Nut
BSnap Ring (3 used) GPinion Shaft
CForward/Reverse Clutch HWood Block (2 in. x 4 in. x
Pack 12 in.)
DCover I High Range Gear
ESplined Coupler
T7247BD UN09APR90
TX,0350,BD892 1919OCT934/4

061411
PN=244
Check Backing Plates Movement

1. Put clutch pack assembly in vertical position.
NOTE: A feeler gauge can also be used to check
backing plate movement. Put feeler gauge between
snap ring (B) and backing plate (A).
2. Position a dial indicator on a tab of the backing plate

(A).
3. Adjust dial indicator to zero.
T8088AB UN30SEP93
4. Using two pry bars, lift backing plate against snap ring
(B). Record measurement.
Repeat step 24 at two other tabs.
5. Set clutch pack assembly so opposite end is up to
check other clutch pack. Repeat steps 24.
Specification
Clutch Pack Disks/Plates
WearBacking Plate
Minimum Movement.................................................. 2.03 mm (0.080 in.)
Backing Plate Maximum
Movement................................................................. 3.05 mm (0.120 in.)
T8088AC UN30SEP93
6. Repeat procedure for other clutch pack assemblies.
TX,0350,BD949 1919OCT931/1

061411
PN=245
Disassemble and Assemble Transmission Cover
T8076AZ UN23SEP93

061411
PN=246
1 Cap Screw 8 Cap Screw (2 used) 15 1st/2nd Clutch Lubrication 22 3rd/4th Clutch Lubrication
2 Washer 9 Bearing Cone (2 used) Line Line
3 Transmission Cover 10 Bearing Cup (2 used) 16 1st Speed Clutch Pressure 23 3rd Speed Clutch Pressure
4 Cap Screw 11 Snap Ring Line Line
5 Washer 12 Reverse Idler Gear 17 Output Shaft Pressure Line 24 Cap Screw (4 used)
6 Clamp 13 Idler Shaft 18 Forward Clutch Pressure 25 Plate
7 Washer (2 used) 14 2nd Speed Clutch Pressure Line 26 ORing (7 used)
Line 19 Forward/Reverse 27 ORing (3 used)
Lubrication Line 28 Bearing Cup
20 Reverse Clutch Pressure
Line
21 4th Speed Clutch Pressure
Line
1. Remove clamp (6) to remove lines (1423) with plate

(25). 7. Install plate (25) on line approximately 20 mm (3/4 in.)
from end of lines.
2. Remove cap screw (1) to remove idler gear assembly
(913). 8. Apply thread lock and sealer (medium strength) to line
clamp cap screws (8) and cap screw (4). Install clamp
3. Remove bearing cup (28). Repair or replace and cap screws. Tighten cap screws to specification.
components as necessary. Specification
4. Install bearing cup (28) to bottom of bore. Reverse Idler Gear Cap
Screw (1)Torque......................................................... 73 Nm (54 lbft)
5. Assemble idler gear assembly (913). Apply thread Tube ClamptoCover
lock and sealer (medium strength) to threads of cap Cap Screws
screw (1). Install reverse idler gear assembly and cap (8)Torque.................................................................... 73 Nm (54 lbft)
screw. Tighten cap screw to specification. Forward and Reverse
Tube Cap Screw
6. Install lines (1423) in the numerical order of the
(4)Torque...................................................................... 10 Nm (8 lbft)
callout numbers.
TX,0350,BD898 1919OCT932/3
9. Install Orings on lines (AJ).
A4th Clutch Line F Forward Clutch Line

B3rd Clutch Line G1st and 2nd Gear Lube Line
C3rd and 4th Gear Lube Line HOutput Shaft Lube Line
DReverse Clutch Line I 1st Clutch Line
EForward/Reverse Lube Line J 2nd Clutch Line
T6656DN UN27OCT88
TX,0350,BD898 1919OCT933/3

061411
PN=247
Disassemble and Assemble First/Second and Third/Fourth Clutch Packs

NOTE: Disassembly and assembly of the 1st/2nd and
3rd/4th clutch packs are the same.
T6942AA UN06DEC88
Speed Clutch Packs (S.N. 794171)

1 Sealing Ring (4 used) 9 Snap Ring (2 used) 17 1st Speed Piston or 3rd 25 2nd Speed Gear with
2 Shaft 10 Seat (2 used) Speed Piston Bushing or 4th Speed Gear
3 Shaft Key (2 used) 11 Bleed Ball (2 used) 18 Spring Washer (12 used) with Bushing
4 Spacer 12 Spring (2 used) 19 Snap Ring (2 used) 26 1st/2nd Low Range Output
5 Dowel Pin 13 Outer Sealing Ring (2 used) 20 Steel Plate (7 used) Gear
6 Thrust Washer (4 used) 14 Inner Sealing Ring (2 used) 21 Clutch Disk with Facing (7 27 3rd/4th High Range Output
7 1st Speed Gear with Bushing 15 Drum used) Gear
or 3rd Speed Gear with 16 Pin 22 Backing Plate (2 used) 28 Ball Bearing
Bushing 23 Snap Ring (2 used) 29 Notched Wavy Steel Plate (2
8 Snap Ring (4 used) 24 2nd Speed Piston or 4th used)
Speed Piston
NOTE: Disassembly and assembly of the 1st/2nd and

3rd/4th clutch packs are the same.

061411
PN=248
T8078AD UN28SEP93
Speed Clutch Packs (S.N. 794172 )
1 Sealing Ring (4 used) 8 Snap Ring (2 used) 15 Pin 22 Snap Ring (2 used)
2 Shaft 9 Seat (2 used) 16 1st Speed Piston or 3rd 23 2nd Speed Piston or 4th
3 Shaft Key (2 used) 10 Bleed Ball (2 used) Speed Piston Speed Piston
4 Ball Bearing (4 used) 11 Spring (2 used) 17 Spring Washer (12 used) 24 2nd Speed Gear with
5 Snap Ring (2 used) 12 Outer Sealing Ring (2 used) 18 Snap Ring (2 used) Bushing or 4th Speed Gear
6 1st Speed Gear with Bushing 13 Inner Sealing Ring (2 used) 19 Steel Plate (7 used) with Bushing
or 3rd Speed Gear with 14 Drum 20 Clutch Disk with Facing (7 25 1st/2nd Low Range Output
Bushing used) Gear
7 Snap Ring (4 used) 21 Backing Plate (2 used) 26 3rd/4th High Range Output
Gear
27 Ball Bearing
28 Notched Wavy Steel Plate (2
used)

061411
PN=249
T6942AB UN21SEP93
(S.N. 794171) 3rd/4th Clutch Pack
T8078AC UN28SEP93
(S.N. 794172 ) 3rd/4th Clutch Pack
1. Remove bearing (A) using a knife edge puller.

2. Remove parts (BK).
For (S.N. 794172 ) machines, use an Hbeam,
forcing screw and JDG831 Puller Legs (N) to remove
gears (C or D) and second ball bearing (L).
NOTE: Bearings (L) must be replaced when
removed from shaft.
ABearing HBacking Plate

BSnap Ring (3 used) I Disk with Facing (3 used)
CLow Range Output Gear J Steel Plate (2 used)
DHigh Range Output Gear KNotched Wavy Steel Plate
EThrust Washer (2 used) L Ball Bearing (2 used)
F 2nd Speed Gear with MSnap Ring
T8083AC UN28SEP93
Bushing or 4th Speed Gear NJDG831 Puller Legs

with Bushing
GSnap Ring
Puller Legs to Remove 2nd Ball Bearing

061411
PN=250
3. Compress spring washers using DF1031 Clutch

Assembly Tool (A) and a press. (See Group 0399 for
instructions to make tool.)
If shaft has been removed from clutch pack, JDT24A
Spring Compressor can be used.
T6645AR UN27OCT88
4. Remove snap ring and spring washers.
5. Remove piston (B) and sealing rings.
TX,03,RB409 1902JUN114/14
6. Remove shaft using a press and a knife edge puller.

7. Remove remaining parts on opposite side.
8. Disassemble shaft.
T6645AS UN27OCT88

061411
PN=251
9. Use a press to install pin (E) into drum (D).

NOTE: Bleed ball (H) can be installed in either
side of drum.
10. If bleed ball and seat (I) were removed, install new
seat and bleed ball. Apply plastic gasket to the outside
diameter of seat (I). Install parts (GI).
11. Install sealing rings (B) on pistons (A and F).
IMPORTANT: Lip of sealing ring must be to inside
of drum for proper sealing function.
12. Install sealing rings (C).

NOTE: Pistons can be installed in either side of drum.
13. Align pin cavity in piston (F) with pin (E). Install pistons
into drum.
A2nd or 4th Speed Piston F 1st or 3rd Speed Piston

BSealing Ring (2 used) GSpring
CSealing Ring (2 used) HBleed Ball
T6645AU UN27OCT88
DDrum I Seat
EPin J Snap Ring
Drum Assembly & Components Installation
TX,03,RB409 1902JUN116/14
14. Install six spring washers. Be sure concave sides face

each other. Compress spring washers to install snap
ring using DF1031 Clutch Assembly Tool (A). (See
Group 0399 for instructions to make tool.) JDT24A
Spring Compressor can also be used.
NOTE: Side of drum with thickest piston (2nd or 4th speed)
T6645AV UN27OCT88
uses only two steel plates and a notched wavy plate.
Thinner piston (1st or 3rd speed) uses three steel
plates and a notched wavy plate.
15. Alternately install steel plates and disks starting with a

wavy steel plate (notched tang) next to piston.
16. Install backing plate and snap ring.
If not within 23 mm (0.0800.120 in.), check for
17. Complete assembly of the other side of drum following proper assembly or replace disks and plates.
Steps 1416.
18. Check backing plate movement on both sides of clutch
drum. (See procedure in this group.)

061411
PN=252
19. Use 1st or 3rd gear (A) to align disks in clutch drum.
Carefully remove gear.
20. Turn drum so the end with two steel plates and a wavy
plate are down.
T6645AX UN27OCT88
TX,03,RB409 1902JUN118/14
21. For machines (S.N. 794171), assemble shaft in

order indicated. Install new thrust washers (D).
AShaft E1st or 3rd Gear

BDowel Pin F Snap Ring
CSpacer GShaft Key (2 used)
DThrust Washer (2 used) HSealing Ring (4 used)
T6645AT UN27OCT88
Shaft Assembly for Machines S.N. 79471

061411
PN=253
22. For machines (S.N. 794172 ):

NOTE: Do not reuse bearings (C and G). New
bearings must be installed.
a. Install snap ring (A) in gear (B).

b. Use a press to install outer ball bearing (C) tight
against snap ring.
c. Use a press and DF1126 Bearing Installer (D)
to install gear and ball bearing assembly tight
against shoulder of shaft (E). (See Group 0399 for
d. Use a press, DF1126, DF1128 (F), and DF1127 (H)
to install inner ball bearing (G) tight against snap
T8083AD UN30SEP93
ring. (See Group 0399 for instructions to make
tools.)
e. Install snap ring on shaft next to inner ball bearing.
f. Carefully install sealing rings (I) so not to damage
or break rings.
Snap Ring, Gear, Ball Bearing Installation
ASnap Ring F DFT1128 Bearing Installer
B1st or 3rd Gear GInner Ball Bearing
COuter Ball Bearing HDFT1127 Support Tube
DDFT1126 Bearing Installer I Sealing Ring (4 used)
EClutch Shaft
T8083AE UN30SEP93
Ball Bearing & Sealing Ring Installation

061411
PN=254
IMPORTANT: Use care not to damage clutch disks or

gear while pressing. Move gear to make sure
teeth engage and do not interfere.
23. For machines (S.N. 794171), install shaft keys. Put

the end of the clutch drum with only three steel plates,
T8083AF UN28SEP93
down. Align drum keyway with shaft keys and push
shaft through drum.
As gear enters clutch drum, move gear back and forth
to make sure clutch teeth engage with gear. Push
shaft tight against drum hub.
Middle, End and Upper Keyways Location
a. Put the two keys into middle and end keyways (A
and B).
b. Put the end of the clutch drum assembly (D) with
only three steel plates, down. Align drum keyway
with shaft keys.
c. Push shaft into drum until end key (B) is just clear
of clutch drum hub. Remove key and put key in
upper keyway (C).
d. As gear (E) enters clutch drum, move gear back

and forth to make sure clutch teeth engage with
gear. Push shaft tight against drum hub.
AMiddle Keyway DClutch Drum Assembly

BEnd Keyway E1st or 3rd Gear
CUpper Keyway
T8083AG UN15OCT93
Keyways, Clutch Drum Assy & Gear Position

061411
PN=255
NOTE: Low range output gear is put on 1st/2nd clutch

pack shaft and high range output gear is put
on 3rd/4th clutch pack shaft.
25. For machines (S.N. 794171), install snap rings (A),

thrust washers (B), 2nd or 4th gear (C) and high (D) or
T8083AJ UN23SEP93
low (E) range output gear.
ASnap Ring (3 used) DHigh Range Output Gear

BThrust Washer (2 used) ELow Range Output Gear
C2nd Speed Gear with
Bushing or 4th Speed Gear
with Bushing

061411
PN=256
NOTE: Do not reuse bearings (C) and (G). New


b. Use a press to install inner ball bearing (C) tight
against snap ring.
c. Use a press, DF1126 (E) and DF1127 (D) to install

gear and ball bearing assembly. As gear (B) enters
clutch drum, move gear back and forth to make sure
clutch teeth engage with gear. Push ball bearing
tight against snap ring
d. Use a press, DF1126 (E), DF1128 (F), and
DF1127 (D) to install outer ball bearing (G) tight
against snap ring (A).
e. Install snap ring on shaft next to outer bearing.
Specification
Heated OilMaximum
Temperature...................................................................... 182C (360F)
Oil FumesIgnited
Temperature...................................................................... 193C (380F)
ASnap Ring EDFT1126 Bearing Installer

B2nd or 4th Gear F DFT1128 Bearing Installer
CInner Ball Bearing GOuter Bearing
DDFT1127 Support Tube
T8083AH UN30SEP93
Gear and Ball Bearing Installation

T8083AI UN30SEP93
Outer Bearing Installation

061411
PN=257
CAUTION: DO NOT heat oil above 182C (360F).

Oil fumes or oil can ignite above 193C (380F).
Use a thermometer. DO NOT allow a flame or
heating element to come in direct contact with
the oil. Heat oil in a wellventilated area.
T81191 UN23FEB89
IMPORTANT: Do not install new end bearing (A) with
supplied snap ring. Remove and discard snap
ring before installing bearing. Install bearing
with snap ring groove toward clutch pack.
27. Heat end bearing (A) and install with snap ring groove
toward clutch pack as shown. End bearing must be
Do Not Overheat Oil
installed tight against shoulder of shaft.
AEnd Bearing
T8084AA UN28SEP93
End Bearing Installation
TX,03,RB409 1902JUN1114/14

061411
PN=258
Disassemble and Assemble Forward/Reverse Clutch Pack
T6942AE UN06DEC88
(S.N. 794171)
1 Sealing Ring (4 used) 7 Reverse Gear with Bushing 13 Steel Plate (8 used) 19 Inner Sealing Ring (2 used)
2 Shaft Key (2 used) 8 Sealing Ring (2 used) 14 Snap Ring (2 used) 20 Drum with Piston Mounting
3 Shaft 9 Snap Ring (2 used) 15 Spring Washer (12 used) Ring
4 Spacer (2 used) 10 Snap Ring (2 used) 16 Lube ShutOff Washer (2 21 Forward Gear with Bushing
5 Dowel Pin (2 used) 11 Backing Plate (2 used) used) 22 Ball Bearing
6 Thrust Washer (4 used) 12 Clutch Disk with Facing (8 17 Outer Sealing Ring (2 used) 23 Notched Wavy Steel Plate (2
used) 18 Piston (2 used) used)

061411
PN=259
T8083AK UN23SEP93
(S.N. 794172 )
1 Sealing Ring (4 used) 7 Snap Ring (3 used) 13 Notched Wavy Steel Plate (2 19 Inner Sealing Ring (2 used)
2 Shaft Key (2 used) 8 Snap Ring (2 used) used) 20 Drum with Piston Mounting
3 Shaft 9 Snap Ring (2 used) 14 Snap Ring (2 used) Ring
4 Ball Bearing (4 used) 10 Backing Plate (2 used) 15 Spring Washer (12 used) 21 Forward Gear
5 Reverse Gear 11 Clutch Disk with Facing (8 16 Lube ShutOff Washer (2 22 Ball Bearing
6 Sealing Ring (2 used) used) used)
12 Steel Plate (8 used) 17 Outer Sealing Ring (2 used)
18 Piston (2 used)

061411
PN=260
T6942AD UN06DEC88
T8083AL UN23SEP93
(S.N. 794171) (S.N. 794172 )
1. Remove bearing (A) using a knife edge puller.
NOTE: Bearings (O and Q) must be replaced
when removed from shaft.
2. Remove parts (BP).
T8078AE UN20OCT93
For (S.N. 794172 ) machines, use an Hbeam,
forcing screw and JDG831 Puller Legs to remove gear
with ball bearing (Q) and then second ball bearing.
ABall Bearing J Snap Ring

BSnap Ring KOuter Backing Plate
CSpacer L Steel Plate
DDowel Pin MDisk with Facing (4 used) Ball Bearing Replacement
EThrust Washer NNotched Wavy Steel Plate
F Forward Gear OBall Bearing
GSealing Ring PSnap Ring
HThrust Washer QBall Bearing
I Snap Ring

061411
PN=261
3. Compress spring washers using DF1031 Clutch

Assembly Tool (A) and a press. (See Group 0399 for
4. Remove snap ring and spring washers (B).
T6645AZ UN27OCT88
TX,0350,BD927 1902JUN114/15
NOTE: Piston mounting rings in clutch drum are not

serviceable. Do not remove rings replace drum
assembly if rings are worn or damaged.
5. Remove parts (AD) from drum (E).

6. Remove shaft from drum assembly using a press.
T6656DC UN27OCT88
7. Repeat Steps 25 for other end of drum assembly.
8. Remove keys, reverse gear and sealing rings from
shaft.
ALube ShutOff Washer DInner Sealing Ring

BPiston EDrum with Piston Mounting Drum Assembly Removal
COuter Sealing Ring Rings

061411
PN=262
T6942AC UN06DEC88
Clutch Drum Assembly Installation
ASnap Ring (2 used) DOuter Sealing Ring (2 used) GDrum with Piston Mounting J Backing Plate
BSpring Washer (12 used) EPiston (2 used) Rings KSnap Ring
CLube ShutOff Washer (2 F Inner Sealing Ring (2 used) HSteel Plate (3 used) L Notched Wavy Steel Plate
used) I Disk with Facing (4 used)
9. Install inner sealing ring (F) to O.D. of piston mounting Repeat Steps 911 for other end of clutch drum.
ring. Install outer sealing ring (D) to O.D. of piston (E).
13. Assemble one side of clutch drum. Install notched
10. Apply oil to I.D. of drum (G) and O.D. of inner sealing wavy steel plate (L). Alternately install plates (H) and
ring (F) and install piston in drum. disks with facing (I) starting with a disk. Install outer
11. Install washer (C) into drum, over piston seal ring and backing plate (J) and snap ring (K).
install six spring washers (B). Be sure concave sides 14. Check backing plate movement. (See procedure in
are toward each other. this group.)
12. Compress spring washers (B) to install snap ring (A) If not within 23 mm (0.0800.120 in.), check for
using DF1031 Clutch Assembly Tool. (See Group proper assembly or replace disks and plates.
0399 for instructions to make tool.)

061411
PN=263
15. Align disks with reverse gear (A) to aid in shaft

installation. Carefully remove gear.
T6656DE UN27OCT88
TX,0350,BD927 1902JUN117/15
16. For machines (S.N. 794171), assemble shaft in

order indicated. Install new thrust washers (D and G).
Install spacer (C) with notch aligned over dowel pin
(B).
T6656DF UN27OCT88
AShaft F Sealing Ring
BDowel Pin GThrust Washer
CSpacer HSnap Ring
DThrust Washer I Shaft Key (2 used)
EReverse Gear J Sealing Ring (4 used)
Shaft Assembly for Machines S.N. 794171

061411
PN=264

NOTE: Do not reuse bearings (C and G). New
a. Install snap rings (A) in gear (B).

b. Use a press to install outer ball bearing (C) tight
against snap ring.
c. Use a press, DF1126, DF1128 (F), and DF1127 (H)
to install inner ball bearing (G) tight against snap
ring. (See Group 0399 for instructions to make
tools.)
d. Install snap ring on shaft next to inner bearing.
T8083AM UN30SEP93
e. Carefully install sealing rings (I and J) so not to
damage or break rings
ASnap Ring (2 used) F DFT1128 Bearing Installer

BReverse Gear GInner Bearing
COuter Ball Bearing HDFT1127 Support Tube
DDFT1126 Bearing Installer I Sealing Ring (4 used)
EClutch Shaft J Sealing Ring Snap Ring, Gear, Ball Bearing Installation
T8083AN UN30SEP93
Ball Bearing & Sealing Ring Installation

061411
PN=265
18. For machines (S.N. 794171):

NOTE: If tie bands are not available, remove snap ring
and carefully slide backing plate up and on sealing
ring. Install snap ring after shaft is pushed into drum.
a. Put a nylon tie band (A) on sealing ring to compress

ring during installation.
b. Install two shaft keys. Put the end of the clutch drum
with steel plates and disks up. Align drum keyway
with shaft keys and push shaft through drum.
c. As gear (B) enters clutch drum, move gear back

and forth to make sure clutch teeth engage with
T6656DG UN27OCT88

061411
PN=266
a. Put keys into middle keyway (A) and end keyway

(B).
b. Position the end of the clutch drum assembly (D)
with steel plates and disks up. Align drum keyway
with shaft keys.
c. Put the shaft into drum until end key (B) is just clear
of clutch drum hub. Remove key and put key in
upper keyway (C).
NOTE: If tie bands are not available, remove snap ring
and carefully slide backing plate up and on sealing
ring. Install snap ring after shaft is pushed into drum.
d. Put a nylon tie band on sealing ring (F) to compress
T8083AO UN28SEP93
ring during installation.
e. As gear (E) enters clutch drum, move gear back

Keyways and Sealing Ring Location and forth to make sure clutch teeth engage with
AMiddle Keyway DClutch Drum Assembly

BEnd Keyway EReverse Gear
CUpper Keyway F Sealing Ring
T8083AP UN30SEP93
Cross Section of Clutch Drum Assembly

061411
PN=267
20. Install snap ring (F) (with points up) against drum hub.
21. Assemble other side of clutch drum. Install notched
wavy steel plate (A). Alternately install plates (B) and
disks with facing (C) starting with a disk. Install outer
backing plate (D) and snap ring (E).
T8083AQ UN23SEP93
22. Check backing plate movement. (See procedure in
this group.)
If not within 23 mm (0.0800.120 in.), check for
proper assembly or replace disks and plates.
23. For machines (S.N. 794171) only, install thrust
washer (G).
Steel Plate Assembly Installation
ANotched Wavy Steel Plate ESnap Ring

BSteel Plate (3 used) F Snap Ring
CDisk with Facing (4 used) GThrust Washer
DBacking Plate
TX,0350,BD927 1902JUN1112/15
NOTE: KD Tools No. 1114 Piston Ring Compressor

Pliers and No. 1126 Piston Ring Compressor
Band can be used instead of tie band.
24. For machines (S.N. 794171), put a nylon tie band (A)
on sealing ring (B) to compress ring during installation.
T6580AA UN27OCT88
As forward gear (C) enters clutch drum, move gear
back and forth to make sure clutch teeth engage with
gear.
Install parts (DG).
ANylon Tie Band EDowel Pin

BSealing Ring F Spacer Nylon Tie Band on Sealing Ring
CForward Gear GSnap Ring
DThrust Washer
T8083AR UN23SEP93
Forward Gear Assembly Installation

061411
PN=268
NOTE: Do not reuse bearings (C and H). New

bearings must be installed

b. Use a press to install inner ball bearing (C) tight
against snap ring.
c. Use a press, DF1126 (F) and DF1127 (E) to install

gear and ball bearing assembly. As gear (B) enters
clutch drum, move gear back and forth to make sure
clutch teeth engage with gear. Push ball bearing
tight against snap ring.
d. Use a press, DF1126 DF1128 (G), and DF1127 to
install outer ball bearing (H) tight against snap ring.
e. Install snap ring on shaft next to outer bearing.
Specification
Heated OilMaximum
Temperature...................................................................... 182C (360F)
Oil FumesIgnited
Temperature...................................................................... 193C (380F)
ASnap Ring EDFT1127 Support Tube

BForward Gear F DFT1126 Bearing Installer
CInner Ball Bearing GDFT1128 Bearing Installer
DSealing Ring HOuter Bearing
T8083AS UN30SEP93
Cross Section of Gear & Ball Bearing Assy

T8083AT UN30SEP93
Outer Bearing Installation

061411
PN=269
CAUTION: DO NOT heat oil over 182C (360F).

Oil fumes or oil can ignite above 193C (380F).
Use a thermometer. DO NOT allow a flame or
heating element to come in direct contact with
the oil. Heat oil in a wellventilated area.
T81191 UN23FEB89
IMPORTANT: Do not install new end bearing (A) with
supplied snap ring. Remove and discard snap
ring before installing bearing. Install bearing
with snap ring groove toward clutch pack.
26. Heat end bearing (A) and install with snap ring grove
toward clutch pack as shown. End bearing must be
Do Not Overheat Oil
installed tight against shoulder of shaft.
T8083AU UN28SEP93
End Bearing Installation
TX,0350,BD927 1902JUN1115/15
Replace Ring Gear

1. Remove rivets if replacement of housing is necessary
using a chisel or drill. Use a press to remove old
housing from ring gear.
2. Clean riveted mating surfaces (C) using clean and
cure primer.
NOTE: Fit between ring gear and ring gear hub can range
T112877 UN21JAN98
from 0.000.02 mm (0.000.001 in.) interference.
3. Install ring gear (A) using the following procedure:
CAUTION: Ring gear is hot! Use hand

protection when handling ring gear to
prevent personal injury.
Heat the ring gear in an oven to 110C (230F) ARing Gear DRivet (10 used)
maximum. BRing Gear Hub EDFT1121 Rivet Forming
Apply retaining compound to mating surfaces of CRiveted Mating Surfaces Tool
ring gear and ring gear hub (B). Install ring gear on
ring gear hub and turn ring gear slightly to distribute
compound evenly. Use a press and DFT1121 tool (E) (see Group 0399
Use cap screws to hold ring gear in position while for instructions to make tool) to form rivets. Do not
installing rivets. exceed 267 kN (30 tons force) to form rivet. Use a
disk support under head of rivets. Make sure rivets
IMPORTANT: Use dealer fabricated tool to form rivets. are tight. Install rivets in a crisscross pattern.
A flat tool causes the entire rivet to expand
and possibly break the ring gear hub.
TX,03,RB244 1922JAN981/1

061411
PN=270
Adjust Cone Point

NOTE: Cone point is controlled by a shim pack (D)
between the pinion shaft bearing cup (C) and
the transmission housing (E).
T6645AL UN27OCT88
1. Press the bearing cone (B) on the pinion shaft (A) and
install the bearing cup (C).
2. With the bearing cup (C) tight against the cone,
measure the width from the mounting shoulder on the
cone (B) to the mounting shoulder on the cup (C).
Add 0.06 mm (0.0025 in.) to measurement to get
dimension.
Specification
Cone Point Shim
PackWidth.................................. Width from the mounting shoulder on
the cone to the mounting shoulder on the cup
at 0.06 mm (0.0025 in.)
T6645AM UN27OCT88
Make a record of this dimension.
3. Add the dimension in Step 2 to the dimension etched
on the face of the pinion shaft (A). Make a record of
this dimension.
4. Make a record of dimension (F) stamped on the side
of the transmission case.
5. Determine shim pack (D) required by subtracting the
sum of Step 3 from dimension in Step 4. Measure
each shim separately to obtain shim pack required.
Example for finding cone point shim pack
Width of bearing cup and cone in 36.78 mm (1.448 in.)
T7247BJ UN09APR90
Step 2
Standard press tolerance 00.06 mm (0.0025 in.)
Dimension stamped on pinion +160.91 mm (6.335 in.)
shaft in Step 3
Sum of Step 2 and 3 197.75 mm (7.785 in.)
Dimension stamped on housing 198.35 mm (7.809 in.)
(E) (Step 4)
Sum of Step 2 and 3 197.75 mm (7.785 in.)
Shim pack required 0.60 mm (0.024 in.) APinion Shaft DShim Pack (as required)
BBearing Cone ETransmission Housing
CBearing Cup F Dimension
6. Install the required shim pack (D) and press bearing
cup (C) into the transmission housing. DO NOT install
pinion shaft.
TX,0350,QQ451 1919OCT931/1

061411
PN=271
Adjust Ring Gear Bearing Preload

1. Use a press to install bearing cups (H) into quills (G)
and bearing cones (B) onto the ring gear hub (E).
CAUTION: Make sure ring gear assembly is
T6645AN UN27OCT88
installed properly in transmission housing.
Machine will move in the opposite direction
if installed the wrong way.
Install ring gear on left side of pinion for use
with double reduction final drive and single
reduction final drive long track.
Install ring gear on right side for single
reduction standard track. ATransmission Housing F Cap Screw (12 used)
BBearing Cone (2 used) GQuill (2 used)
2. Install ring gear assembly into transmission housing CSpiral Bevel Ring Gear HBearing Cup (2 used)
(A) with just enough shims to obtain end play. Tighten DRivet (10 used) I Shims (as required)
cap screws (F). ERing Gear Hub
Specification
Ring Gear Bearing Quill
Cap ScrewsTorque..................................................... 73 Nm (54 lbft) Specification
Ring Gear Hub
3. Turn ring gear several revolutions to seat bearings. BearingPreload...............................0.050.13 mm (0.0020.005 in.)
Install dial indicator and measure end play.
5. Remove ring gear assembly. Keep shims with
4. Remove enough shims (I) to just eliminate measured respective bearing quills.
end play. Then remove additional 0.050.13 mm
(0.0020.005 in.) thickness of shims to provide the
necessary preload.
TX,0350,BD896 1919OCT931/1

061411
PN=272
Adjust Output Shaft Bearing Preload

1. Install transmission housing cover (B) on housing
using four cap screws and washers.
2. Position high range gear (E) in transmission housing.
Put pinion shaft (D) through bearing cup (G), high
range gear (E) and bearing cup (C).
3. Support pinion shaft (D) using a 2 in. x 4 in. piece of
wood, minimum 12 in. long and a 2 in. x 6 in. piece of
wood on its edge to hold pinions shaft.
4. Install pressfit bearing cone (H) on pinion shaft.
5. Install and tighten nut (A) to 204 Nm (150 lbft) to seat
bearings while turning pinion shaft.
Specification
Pinion Shaft Bearing Seat
Remove nut and turn shaft again.
6. Put two pieces of wire solder 13 mm (0.50 in.) long
T6645AI UN27OCT88
and 180 apart on pinion shaft (D) below nut. Install
and tighten nut until rolling drag torque on shaft is
1.11.7 Nm (1015 lbin.).
Specification
Spiral Bevel
PinionRolling Torque................................ 1.11.7 Nm (1015 lbin.)
7. While counting turns, remove nut. Measure thickness

of wire solder at point of contact to determine required ANut EHigh Range Gear
shim pack thickness. BTransmission Housing F Bearing Cone
Cover GBearing Cup
8. Install shim pack equal to wire solder thickness. CBearing Cup HBearing Cone
Tighten nut the same number of turns as removed. DPinion Shaft
Check rolling drag torque.
9. Remove nut, shims, bearing cone, high range gear,
pinion shaft and transmission cover. Keep shim pack
together for final transmission assembly.
TX,0350,BD897 1919OCT931/1

061411
PN=273
Assemble Transmission
NOTE: Assembly of bushingtype and bearingtype
transmissions is the same. Bushingtype
is shown here.
1. Position 3rd/4th speed clutch pack (A) and high range

gear (E), large gear down, in transmission housing.
2. Make sure 3rd/4th clutch pack bearing fits into housing
counterbore.
3. Position 1st/2nd clutch pack (B) in transmission
housing. Move high range gear to install 1st/2nd
clutch pack completely.
4. Install thrust bearing (C) and thrust race (D).
A3rd/4th Speed Clutch Pack DThrust Race

B1st/2nd Speed Clutch Pack EHigh Range Gear
CThrust Bearing
T6656DI UN27OCT88

061411
PN=274
5. Apply multipurpose grease to roller bearings (A).

Install roller bearings in each end of the idler gear (B).
Install the idler gear (B) with the largest diameter gear
down into the transmission housing.
6. Reposition high range gear to install forward/reverse
clutch pack (D).
7. Install a thrust race (F) and thrust bearing (G) on top
of the idler gear (B).
8. Install thrust spacer (C) on back side of transmission
housing cover using petroleum jelly to hold in place.
Thrust spacer must have the bevel edge up.
9. Put oil on all sealing rings (E). Tabs must be engaged
and rings must rotate on shafts. Position tabs opposite
to inlet slots in cover.
ARoller Bearing (2 used) ESealing Ring (12 used)

BIdler Gear F Thrust Race
CThrust Spacer GThrust Bearing
DForward/Reverse Clutch
Pack
T6656DJ UN27OCT88

061411
PN=275
NOTE: It may be necessary to rotate the clutch packs and

gear assemblies to position the transmission cover.
10. Position the transmission cover (E) without ball

bearings (C) over the three clutch packs. Move cover
until it slips over sealing rings on shafts and dowel
T6656DK UN27OCT88
pins (G).
11. Apply thread lock and sealer (medium strength) and
install washers and cap screws (F). Tighten cap
screws.
Specification
Transmission Cover Cap
ScrewsTorque........................................................... 130 Nm (96 lbft)
IMPORTANT: If ball bearings are in cover, remove

ball bearings from cover before installing
cover. This will prevent damage to sealing
rings and clutch packs.
NOTE: The clutch packs may require lifting slightly with

a pry bar to install the three snap rings (B).
12. Install ball bearings (C), snap rings (A and B). Do

Transmission Air Test (see procedure in this group).
13. Install pinion shaft (N) through high range gear (O),
idler cluster gear (P), and cover (E).
14. Support pinion shaft using a 2 in. x 4 in. wood block
(L), minimum 12 in. long, and a 2 in. x 6 in. wood
block (M) on its edge to hold pinion shaft.
15. Install bearing cone (I), required shim pack (D), and
nut (H). Apply thread lock sealer (medium strength) to
the threads of the pinion shaft and install nut (H).
T6657AC UN27OCT88
16. Retain gear (O) with soft metal wedge (brass). On
later machines, nut (H) has a groove on one side.
Apply thread lock and sealer (medium strength) and
install with groove out. Tighten nut and remove wedge.
Specification
Pinion Shaft Gear
Retainer NutTorque................................................. 407 Nm (300 lbft)
17. Apply plastic gasket to plate cover (J). Apply thread ASnap Ring (3 used) I Bearing Cone
lock and sealer (medium strength) to cap screws (K) BSnap Ring (3 used) J Plate Cover
and install plate cover, washer and cap screws. CBall Bearing (3 used) KCap Screw (4 used)
DShim (As Required) L 2 in. x 4 in. x 12 in. Wood
ETransmission Cover Block
F Cap Screw (4 used) M2 in. x 6 in. Wood Block
GDowel Pin (2 used) NPinion Shaft
HNut OHigh Range Gear
PIdler Cluster Gear

061411
PN=276
18. Install JT38000 Differential Lifting Tool (A). (See Group

0399 for instructions to make tool.)
CAUTION: Make sure ring gear assembly is

installed properly in transmission housing.
Machine will move in the opposite direction
if installed the wrong way.
Install ring gear on left side of pinion (opposite of
photo) for use with double reduction final drive
and single reduction final drive long track.
Install ring gear on right side (as shown in photo)
for single reduction standard track.
NOTE: Housing is stamped (D) S for single reduction

and B for double reduction.
19. Install ring gear assembly and bearing quills with

proper shims. Tighten bearing quill cap screws).
Specification
Ring Gear Bearing Quill
T113186 UN30JAN98
20. Check backlash at three positions 120 apart and

adjust shim packs. Move shims from one quill to
another to provide 0.180.23 mm (0.0070.009 in.)
backlash between the spiral bevel pinion and ring gear.
Specification
Spiral Bevel Pinion and
Ring GearBacklash.........................0.180.23 mm (0.0070.009 in.)
21. Install splined coupler (B) and snap ring on

forward/reverse shaft with short side (first) facing
toward transmission.
T6656DM UN27OCT88
22. For machines (S.N. 762832), apply thread lock and
sealer (medium strength) on threads of cap screw (C).
Install washer and cap screw). Tighten cap screw.
For machines (S.N. 762833 ), install snap ring on
forward/reverse shaft to retain coupler to shaft.
ALifting Tool CCap Screw

BSplined Coupler DStamp on Housing
TX,0350,BD908 1919OCT934/4

061411
PN=277
Transmission Air Test

The purpose of this test is to check if clutch pistons are
moving after assembly. Check may also be used before
transmission is removed to identify if problem is in cover
or clutch pack.
T6656DN UN27OCT88
1. Use JDG185 Air Test Plug to apply 350550 kPa
(3.55.5 bar) (5080 psi) of air to clutch ports (D and
F) and note air leakage.
Specification
Reverse and Forward
ClutchAir Pressure..............350550 kPa (3.55.5 bar) (5080 psi)
Look at each clutch to see if piston moves and is
returned by spring washers. Clutch plate tangs must
be loose when no air is applied.
2. Apply air to each lube tube while lightly holding finger
over each clutch tube, note air flow.
T6656DO UN27OCT88
Clutch packs 1st (I), 2nd (J), 3rd (B) and 4th (A) should
make a clunking sound when air is applied. This sound
is the piston moving against the spring return washers.
Clutch packs for forward (F) and reverse (D) will leak
more air and will not make as loud a noise when air is
applied. Observe clutch plate tangs exposed through
clutch drum packs to see if piston moves and retracts.
Tangs of separator plates must more freely when
piston is not pressurized. A4th Clutch F Forward Clutch
B3rd Clutch G1st and 2nd Gear Lube
Air leakage from lube tube while pressurizing adjacent C3rd and 4th Gear Lube HOutput Shaft Lube
DReverse Clutch I 1st Clutch
clutches should be slight and even for all packs. EForward/Reverse Lube J 2nd Clutch
Excessive leakage from lube to clutch tubes is caused
by defective sealing ring on clutch shaft.
Air leakage to lube tubes, when clutch tubes are IMPORTANT: Check tubetomanifold connection,
pressurized, should be slight and even for all clutches. reseat tubes after air test.
Excessive air leakage to sump could indicate a clutch
shaft sealing rings or piston seal failure.
0350,WW20 1919OCT931/1

061411
PN=278

061411
PN=279
Disassemble and Assemble Transverse Housing
T6942AS UN13JAN89
1 Suction Line 5 Plug 9 Snap Ring 13 Support Shaft (2 used)
2 Dipstick 6 Suction Screen 10 Shaft 14 Plug (2 used)
3 Tube 7 Yoke 11 Bearing 15 Jack Screw (2 used)
4 Strainer Housing 8 Seal 12 Snap Ring (2 used) 16 Plug
1. Remove yoke (7) from shaft (10). 7. Install seal (8) using a disk driver. Push seal into bore
2. Remove seal (8). until seal is approximately 3 mm (0.12 in.) below
machined counterbore.
3. Remove snap ring (9). Pull shaft assembly out of front
of housing. 8. Install suction line (1). Apply thread lock and sealer
(medium strength) to cap screw threads and install.
4. Remove snap rings (12) to remove bearing (11). Tighten cap screws to specification.
Remove remaining parts if necessary.
9. Install dipstick tube (3). Apply plastic gasket to
5. Install bearing (11) and snap rings (12) onto shaft (10). underside of mounting flange and install. Apply
thread lock and sealer (medium strength) to cap
6. Install shaft through front of housing. Install snap ring
screw threads and install. Tighten cap screws to
(9).
specification.

061411
PN=280
Transmission Support
10. Use a press to install support shafts until shafts are
Rod ScrewsTorque..................................................... 73 Nm (54 lbft)
even with front surface of gussets. Tighten cap screws
Rear Cover Cap Screws
to specification.
(M12)Torque............................................................149 Nm (110 lbft)
Specification Rear Cover Cap Screws
Suction Tube Cap (M20)Torque........................................................... 620 Nm (457 lbft)
Dipstick Tube Cap 11. Apply pipe sealant to threads of plugs (5, 14 and 16)
ScrewsTorque............................................................. 73 Nm (54 lbft) and install.
TX,0350,BD910 1919OCT932/2

061411
PN=281

061411
PN=282
Group 0360
Hydraulic System

TX,0360,BA945 1914JUN111/2
Polishing Table Bushing, Bearing and Seal Driver Set

Recondition lapped surfaces. Remove and install shaft seals.
171/2 and 30Ton Puller Set Spring Compression Tester
Remove and install pump and motor components. Measure springs.
TX,0360,BA945 1914JUN112/2
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium Applied to threads of cap screws.
242 (LOCTITE)

TX,0360,DSAA1 1931JUL901/1

061411
PN=283
Hydraulic System
Specifications
Transmission Control Valve Weight 48 kg (105 lb)

Control ValvetoTransmission Torque 36 Nm (27 lbft)
Socket Head Cap Screws
Regulating ValvetoTransmission Torque 36 Nm (27 lbft)
Control Valve Socket Head
Cap Screws
Speed Selector Spool Plug Torque 102 Nm (75 lbft)
Transmission PumptoHydraulic Torque 271 Nm (200 lbft)
Pump Cap Screws and Nutswith
Direct Drive
Transmission Pump Assembly Cap Torque 319 Nm (235 lbft)
Screwswith Torque Converter
Transmission Filter Assemblyto Torque 49 9 Nm (36 7 lbft)
Filter Bracket Cap Screws
Transmission Accumulator Pressure 1034 52 kPa (150 8 psi)
Charge Pressure
Power Control Valve Spool Spring Approximate Free Length 93 mm (3.66 in.)
Test Length at 177 N (39.8 lb force) 74.7 mm (2.94 in.)
Modulating Valve Spring OD 22.1 mm (0.87 in.)
Free Length 98.6 mm (3.88 in.)
Test Length at 135 N (30.6 lb force) 77 mm (3.03 in.)
Test Length at 177.6 N (40 lb force) 68.1 mm (2.68 in.)
ORing Port Spring Approximate Free Length 83.7 mm (3.3 in.)
Test Length at 19.6 N (4.4 lb force) 55 mm (2.17 in.)
Detent Cone Compression Spring Approximate Free Length 50.8 mm (2.0 in.)
Test Length at 28.5 N (6.4 lb force) 23.8 mm (0.94 in.)
Lubrication Relief Valve Spring Free Length (approximate) 103.9 mm (4.1 in.)
Power Control Pedal Return Spring Compression 142 mm (5.6 in.)
Oil Cooler Relief Valve Spring Free Length 73 mm (2.87 in.)
Transmission Pressure Regulating OD 15.8 mm (0.62 in.)
Springwith Direct Drive
Free Length 113 mm (4.45 in.)
Test Length at 267 N (60 lb force) 81.5 mm (3.21 in.)
Test Length at 280 N (63 lb force) 65 mm (2.56 in.)

061411
PN=284
Hydraulic System

Springwith Torque Converter
TX,0360,BD942 1919OCT932/2
Remove and Install Transmission Control

Valve
NOTE: Transmission removed for clarity of photographs.
1. Remove rear fender and panels. (See Group 1927.)
T6560AK UN25OCT88
2. Remove rear platform plate.
3. Disconnect hose (A) and all wiring harness leads.
4. Loosen nuts to release compression of power control
pedal return spring (C) (if equipped).
5. Disconnect linkages (B).
Continued on next page TX,0360,BA946 1919OCT931/3

061411
PN=285
Hydraulic System
6. Remove four manifold blocktocontrol valve cap

screws (A).
7. Loosen or remove 29 control valvetotransverse case
cap screws. Use rubber bands to hold up cap screws
which cannot be removed.
T8081AA UN28SEP93
8. Place 25.4 mm (1 in.) wooden block under plug
bosses on each side of valve.
CAUTION: Approximate weight of control

valve is 48 kg (105 lb).
9. Slide control valve rearward until lifting device can be

attached.
Specification
Transmission Control
ValveApproximate
Weight................................................................................ 48 kg (105 lb)
T6560AL UN25OCT88
10. Use 7/1614 UNC cap screw to install lifting eye in
tapped hole (B).
11. Remove valve.
12. Repair valve. (See procedure in this group.)
threads of all cap screws.
14. Install cap screws into front half of control valve and Specification
hold them up with rubber bands. Control Valve
15. Place two 25.4 mm (1 in.) wooden blocks on toTransmission
transverse case. Socket Head Cap
16. Slide valve into place.
17. Remove blocks. Install remaining cap screws. Tighten
cap screws beginning with the center screws and
working outward in a spiral.
TX,0360,BA946 1919OCT932/3
18. Connect hose (A), linkages (B) and wiring harness

leads.
19. Tighten nuts to compress power control pedal return
spring (C) (if equipped).
Specification
T6560AK UN25OCT88
Power Control
Pedal Return
SpringCompression.................................................... 142 mm (5.6 in.)
20. Adjust power control pedal linkage (if equipped). (See

Power Control Pedal Adjustment in TM1403, Group
902020.)
21. Install rear platform plate.
22. Install rear fender and panels. (See Group 1927.)
TX,0360,BA946 1919OCT933/3

061411
PN=286
Hydraulic System
Disassemble and Assemble Transmission Control Valve
T112894 UN21JAN98
1 Guide 10 Neutral Start Switch 19 Speed Selector Spool 28 Oil Cooler Relief Valve
2 Seal 11 Modulating Valve Spring 20 Plug Spring
3 Pin 12 Accumulator Piston 21 Detent Spool 29 Oil Cooler Relief Valve
4 Power Control Valve Spool 13 Modulating Spool 22 Plug 30 Transmission Pressure
Spring 14 Modulating Valve Spring 23 Detent Cone Compression Regulating Valve
5 Direction Selector Spool 15 Orifice Spring 31 Transmission Pressure
6 Groove Pin 16 Special Screw 24 Detent Cones Regulating Valve Spring
7 Power Control Spool 17 ORing Port Spring 25 Lubrication Relief Valve 32 Transmission Pressure
8 Transmission Low Pressure 18 Sump Spool 26 Lubrication Relief Valve Regulating Valve Spring
Switch Spring 33 Shims (as required)
9 Reverse Warning Switch 27 Plug (3 used) 34 Seal
35 Plunger
36 Seal
NOTE: Early machines may have an extra spring

placed with springs (11 and 14).
Power Control Valve Spool Spring Approximate Free Length 93 mm (3.66 in.)
Test Length at 177 N (39.8 lb force) 74.7 mm (2.94 in.)
Test Length at 135 N (30.6 lb force) 77 mm (3.03 in.)
ORing Port Spring Approximate Free Length 83.7 mm (3.3 in.)

061411
PN=287
Hydraulic System
Detent Cone Compression Spring Approximate Free Length 50.8 mm (2.0 in.)
Lubricating Relief Valve Spring Approximate Free Length 103.9 mm (4.1 in.)
Oil Cooler Relief Valve Spring Free Length 73 mm (2.87 in.)
Test Length at 280 N (63 lb force) 65 mm (2.56 in.)
Test Length at 645 N 145 lb force) 65.5 mm (2.57 in.)
TX,0360,BA949 1919OCT932/9
1. Remove two socket head cap screws (A) to separate

regulating valve housing (D), separator plate (C) and
control valve housing (B).
ACap Screw (2 used) CSeparator Plate

BTransmission Control Valve DRegulating Valve Housing
T6560AB UN19MAY89
Housing

061411
PN=288
Hydraulic System
2. Unscrew plug (A) 41/2 turns.
T6560AC UN19MAY89
TX,0360,BA949 1919OCT934/9
3. Push speed selector spool (A) into housing until it

bottoms against plug.
T6560AD UN25OCT88
TX,0360,BA949 1919OCT935/9
4. Remove plug, spring, and detent cone.

5. Push a 3 mm (1/8 in.) drift down detent bore, through
hole in detent spool and against bottom detent cone to
bottom it. Hold drift against cone.
T6560AE UN25OCT88

061411
PN=289
Hydraulic System
6. Insert another drift in small hole under detent section

of housing.
7. Hold detent cone down with second drift. Remove first
drift. Remove spools (F) from plug end.
8. Install detent plug to prevent spring from pushing cone
T6942AR UN09JAN89
out of hole when drift is removed.
9. Put petroleum jelly on spring to hold it in detent cone.
Install spring (A) and detent cone (B).
Compress spring solid using a rod. Retain detent cone
by inserting a drift into hole below detent. Hold drift
until spools are installed.
IMPORTANT: Arrow (G) stamped in end of detent
spool must point up to prevent spool drag.
10. Install spools. Look into upper detent bore. If notch (E)
is visible, rotate spools 180 by turning clevis on front
T6560AH UN19MAY89
end. If notch is not visible (F), spool location is good.
Release detent cone. Tighten plug to specification.
Specification
Speed Selector Spool
PlugTorque................................................................ 102 Nm (75 lbft)
11. Install upper detent cone (C), spring (D), and plug.
ASpring ENotch
BDetent Cone F Spools
CUpper Detent Cone GArrow
DSpring
T6666AC UN25OCT88
TX,0360,BA949 1919OCT937/9
IMPORTANT: Screw can run out of threads if

turned out more than 12 turns.
12. Install special screw (B) into orifice (A) until it bottoms,
then unscrew seven turns (machines with direct drive)
or ten turns (machines with torque converter).
T6560AI UN19MAY89

061411
PN=290
Hydraulic System
13. Install and center groove pin (A) into power control
spool.
14. Apply oil to guide (B) and install.
15. Assemble regulating valve housing, separator plate,
and control valve housing.
T6560AJ UN19MAY89
threads of cap screws. Tighten socket head screws.
Specification
Regulating Valveto
Transmission Control
Valve Socket Head Cap
TX,0360,BA949 1919OCT939/9

061411
PN=291
Hydraulic System
Disassemble and Assemble Transmission

Control Valve Manifold
AManifold DSpring Pin
BOrifice Fitting ELube Port
CGasket
T7247AZ UN09APR90
(S.N. 768272)
T7247BA UN09APR90
(S.N. 768273 )
TX,0360,QQ437 1919OCT931/1
Adjust Rate of Shift

1. Turn special screw (A) clockwise until it bottoms. Then,
turn screw counterclockwise seven turns (machines
with direct drive) or ten turns (machines with torque
converter) to obtain a rate of shift of 3/41 second.
T6576AE UN25OCT88
2. To adjust rate of shift to operator preference, turn

screw in to increase shift time or out to decrease shift
time.
IMPORTANT: Screw can run out of threads if
turned out more than 12 turns.
TX,0360,BA973 1919OCT931/1

061411
PN=292
Hydraulic System

061411
PN=293
Hydraulic System
Disassemble and Assemble Transmission Decelerator Assembly
T8081AD UN30SEP93

061411
PN=294
Hydraulic System
ASolenoid Cartridge F Solenoid Valve Assembly KAdapter PBackup Alarm Switch

BORing GElbow Fitting (2 used) L Fitting Plug (2 used) QCrawler Wiring Harness
CORing HORing (3 used) MORing (2 used) RLimit Switch
DBackup Ring I Adapter NHydraulic Hose SFlywheel Housing
EHousing Kit J ORing (4 used) ODecelerator Wiring Harness
1. Remove rear fender and covers. 6. Disassemble and assemble solenoid valve (F) (if
2. Remove parts (FN) and (R). necessary).
3. Disconnect wire leads (O) at switch (P) and crawler 7. Install parts (R) and (FO) and connect wire leads.
wiring harness (Q). 8. Check and adjust engine high and low idle positions
4. Remove decelerator wiring harness (O). (if necessary).
5. Inspect for worn or damaged parts. Replace as 9. Install rear fender and covers.
necessary.
TX,0360,BA954 1919OCT932/2

061411
PN=295
Hydraulic System
Remove and Install Transmission Oil

PumpTorque Converter Machines
2. Remove torque converter bottom access cover.
3. Remove drain plug from bottom of suction screen
housing to drain oil.
4. Disconnect hose (D) at pump (loaders with torque
converter only) or remove hose (D). Use caps and
plugs to close all openings.
5. Remove hose (B) on (S.N. 803600) or disconnect
hose (B) on (S.N. 803601 ). Use caps and plugs to
close all openings.
6. Disconnect clamps (C) and move line and harness to
right.
CAUTION: Pump is heavy. Use a lifting

device for heavy objects.
T8081AE UN28SEP93
7. Attach lifting device to pump.
8. Remove two cap screws (A) to remove pump (E).
9. Repair pump as necessary. (See Disassemble and
Assemble Transmission Oil PumpWith Torque
Converter, this group.)
(S.N. 803600)
APumptoTorque Converter DSuction ScreentoPump
Housing Cap Screw (2 Inlet Hose
used) ETransmission Oil Pump
BPump Outletto
Transmission Filter Hose
CClamp (2 used)
T112930 UN22JAN98
(S.N. 803601 )

061411
PN=296
Hydraulic System
10. Install new Oring on pump flange and install pump.

Tighten cap screws (A) to 319 Nm (235 lbft).
Specification
Transmission Pump
Assembly Cap
Screwswith Torque
ConverterTorque..................................................... 319 Nm (235 lbft)
11. Install hose (B) on (S.N. 803600) or connect hose

(B) on (S.N. 803601 ).
12. Install drain plug in suction screen housing.
IMPORTANT: Damage to pump may occur if pump
is not primed with oil. The transmission oil
reservoir is lower than pump inlet and pump
cannot draw oil fast enough after initial start up.
NOTE: Steps 1315 apply to loaders with a

torque converter only.
13. Connect hose (D) to pump.
T8081AE UN28SEP93
14. Remove fill plug from top of suction screen housing
and fill hose (D) and housing with oil. (See Section 00,
Group 0004 for oil recommendations.)
15. Install fill plug.
NOTE: Steps 16 and 17 apply to all machines except
loaders with a torque converter. (S.N. 803600)
16. Squirt oil into inlet side of pump. Install hose (D) on
pump only.
17. Fill hose with oil and install on strainer. (See Section
00, Group 0004 for oil recommendations.)
18. Connect clamps (C).
T112930 UN22JAN98
19. Install bottom access cover and floor plates.
APumptoTorque Converter DSuction ScreentoPump

Housing Cap Screw (2 Inlet Hose
used) ETransmission Oil Pump
BPump Outletto
Transmission Filter Hose (S.N. 803601 )
CClamp (2 used)
TX,0360,BA974 1919OCT932/2
Remove and Install Transmission Oil be removed to service transmission oil pump. Refer
PumpDirect Drive Machines to Group 2160 for removal procedure.
NOTE: On direct drive machines, transmission oil pump

is on back of hydraulic pump. Hydraulic pump must
TX,0360,BA975 1919OCT931/1

061411
PN=297
Hydraulic System
Disassemble and Assemble Transmission Oil PumpTorque Converter Machines
T8072AB UN13SEP93
AVent F Washer (4 used) KGear Housing PSeal
BReducer Bushing GCap Screw (4 used) L Front Housing QSeal Retainer
CSquare Seal (2 used) HRear Housing MSeal RSeal Lip
DThrust Plate (2 used) I Gear/Shaft Set NORing
EChannel Seal (2 used) J Dowel Pin (2 used) ORetaining Ring
NOTE: For repair of shaft seals (M and P) only, NOTE: Pump parts (CE and HL) are not
do steps 13. serviceable. If any of these parts are worn
or damaged, replace pump.
1. Remove retaining ring (O) to remove seal retainer (Q).
2. Remove seals (M and P). 6. Apply petroleum jelly to seal lip (R) of seals.
3. Install seals: 7. Put a light coat of clean hydraulic oil on all internal
parts.
Seal (M) must be installed flush with face of recess
in housing (L) and with lip (R) toward gear as shown. 8. Assemble parts as shown. Tighten cap screws (G).
Seal (P) must be installed flush with counterbore in Specification
retainer (Q) and with seal lip (R) away from gear. Transmission Pump
Assembly Cap
4. Put a mark on housings (H, K and L) to aid in assembly.
Screws with Torque
5. Remove parts and inspect for wear. Mark gear set ConverterTorque..................................................... 319 Nm (235 lbft)
to aid in assembly.
TX,0360,BD945 1919OCT931/1

061411
PN=298
Hydraulic System
Disassemble and Assemble Transmission Oil PumpDirect Drive Machines
T6550AA UN01JUN89
ASeal Retainer F Driven Gear KSeal PGasket (2 used)
BRear Carrier GCover L Nut (2 used) QDriven Gear
CBushing (4 used) HDriven Shaft Assembly MStud (5/8 x 111/2 in.)
DThrust Plate (2 used) I ORing NStud (5/8 x 131/2 in.)
EHousing J Seal Retainer OWasher (4 used)
TX,0360,BA976 1919OCT931/4
NOTE: Transmission oil pump can be repaired without

disassembling hydraulic pump. Refer to Group
2160 for hydraulic pump repair procedures.
1. Put a mark on housing sections to aid in assembly.

2. Remove parts.
T6550AB UN25OCT88
AMain Hydraulic Pump ECap Screw (5/8 x 41/2 in.)
BStud (5/8 x 131/2 in.) F Nut (2 used)
CTransmission Oil Pump GWasher (2 or 4 used)
DCap Screw (5/8 x 61/2 in.) HStud (5/8 x 111/2 in.)

061411
PN=299
Hydraulic System
T6534AN UN25OCT88
AHousing EDriven Shaft Assembly I Set Screw (2 used) MGasket
BDowel Pin (2 used) F ORing J Gear (2 used)
CBushing (2 used) GSeal Retainer KThrust Plate (2 used)
DCover HSeal L Seal (2 used)
3. Put a mark on gears and thrust plates to aid in NOTE: Install seal (H) with flat side toward seal
assembly. retainer. Cover groove on shaft with shim
4. Remove parts. stock when installing seal.
NOTE: Set screws (I) must be removed before 7. Install new Oring (F) and seals (H and L). Apply
removing seal retainer (G). petroleum jelly to seal lips.
5. Remove set screws (I). Remove seal retainer (G), 8. Put a light coat of clean hydraulic oil on all parts.
using a punch, through holes provided. Assemble parts as shown.
NOTE: Seal retainer unscrews counterclockwise.
6. Inspect parts for wear or damage. Driven shaft

assembly (E) has no service parts. Replace assembly
if required.

061411
PN=300
Hydraulic System
9. Install transmission oil pump. Tighten cap screws (D

and E) and nuts (F).
Specification
Transmission
PumptoHydraulic
Pump Cap Screw
T6550AB UN25OCT88
and Nutswith Direct
DriveTorque............................................................ 271 Nm (200 lbft)

10. Prime transmission oil pump and install hydraulic

AMain Hydraulic Pump ECap Screw (5/8 x 41/2 in.)
pump. (See Remove and Install Hydraulic Pump and BStud (5/8 x 131/2 in.) F Nut (2 used)
Drive ShaftWith Direct Drive, Group 2160 for proper CTransmission Oil Pump GWasher (2 or 4 used)
procedure.) DCap Screw (5/8 x 61/2 in.) HStud (5/8 x 111/2 in.)
TX,0360,BA976 1919OCT934/4
Charge Transmission Accumulator is noncombustible. It will not cause oxidation

or condensation inside accumulator and is not
CAUTION: For safety reasons a pressure harmful to piston seal. DO NOT use air or any
regulator valve and gauge must be ordered combustible gas as these can cause oxidation
from your local nitrogen gas supplier. and condensation. Oxidation and condensation
are harmful to the piston seal and accumulator.
IMPORTANT: Charge accumulator using only dry
nitrogen. Dry nitrogen does not mix with oil. It NOTE: Accumulator is used on direct drive machines only.
TX,03,RB410 1928JAN081/3
Nitrogen Accumulator Charging Kit ......................JT05562 Valve Extension Adapter ......................................JT05626

Used to charge accumulator. Used to connect the accumulator.
TX,03,RB410 1928JAN082/3
1. Connect nitrogen accumulator charging kit. Be sure

extension adapter (A) is tight.
IMPORTANT: If the accumulator is charged too
fast, initial surge of charge pressure through
gas check valve can force check valve seal
out of place. It should take at lease three T6942AH UN15FEB91
seconds to charge accumulator.
2. Slowly open the pressure regulating valve. Adjust the

pressure regulating valve.
Specification
Transmission
Accumulator Charge
PressurePressure..................................... 1034 52 kPa (150 8 psi)
3. Remove nitrogen charging kit.
NOTE: When precharging an accumulator on machine,
make sure oil side of accumulator has zero
pressure. Shut machine off.
TX,03,RB410 1928JAN083/3

061411
PN=301
Hydraulic System
Remove and Install Transmission Oil Filter

X9811 UN23AUG88
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Continued on next page 0360,SS1 1919OCT931/2

061411
PN=302
Hydraulic System
1. Disconnect lines (DF and H).

2. Disconnect switch wire lead (A).
3. Remove cap screws (B) to remove oil filter base.
4. Replace parts as necessary.
5. Put clean hydraulic oil on gasket on filter element (G).
Tighten until gasket contacts filter base. Turn 1/2 turn.
6. Install filter assembly. Tighten cap screws (B).
Specification
Transmission Filter
AssemblytoFilter
Bracket Cap
ScrewTorque................................................... 49 9 Nm (36 7 lbft)
7. Connect lines (DF and H) and switch wiring lead (A).
ATransmission Temperature EFilter Bypassto

Switch Wiring Lead Transmission Control
BCap Screw (4 used) Valve Lube Line
CBypass Valve F Oil Filter Return Port from
T6670AQ UN02APR90
DOil Filter Outletto Transmission Oil Cooler
Transmission Control Line (S.N. 803600)
Valve Line GFilter Element
HOil Filter Port from Pump
Outlet Line
(S.N. 803600)
T112931 UN28JAN98
(S.N. 803601 )
0360,SS1 1919OCT932/2

061411
PN=303
Hydraulic System
Remove and Install Transverse Case Suction

Screen
2. Remove torque converter bottom access cover (if
equipped).
T8081AG UN05OCT93
3. Remove drain plug from bottom of suction screen
housing to drain oil. Install drain plug after oil has
drained.
4. Loosen clamp (A) to disconnect hose at housing
(loaders with torque converter only) or loosen two
clamps (A) to remove hose. Loader Torque Converter Machines (S.N. 794020 )
5. Remove cap screws (B) to remove housing cover with

suction screen.
6. Clean screen as necessary.
7. Apply a thin film of oil to new Oring and install Oring,
suction screen and cap screws. Tighten cap screws.
T6520AK UN10FEB89
NOTE: Step 8 applies only to loaders with a torque

All Other Machines
converter. These machines have a fill plug on
top of suction screen housing.
AClamp CHousing
8. Connect suction hose to housing and tighten clamp. BCap Screws DFill Plug (Loaders with
Torque Converter only)
Remove fill plug (D). Fill screen housing with oil and
install fill plug. (Refer to Section 00, Group 0004, for
transmission oil recommendation.)
suction hose with oil. (Refer to Section 00, Group
NOTE: Step 9 applies to all machines which do not have 0004, for transmission oil recommendation.) Connect
a fill plug on top of suction screen housing. other end of hose to pump inlet. Tighten hose clamps.
9. Install one end of suction hose to suction screen.

Squirt oil into transmission pump inlet port and fill
TX,0360,BA980 1919OCT931/1

061411
PN=304
Hydraulic System
Remove and Install Transmission Oil Cooler

NOTE: If machine is equipped with front counterweights,
either the counterweights have to be removed to tilt
the grille forward or the grille has to be removed.
1. Tilt grille housing forward or remove grille housing.

(See Remove and Install Radiator in Group 0510 for
procedure.)
2. Remove six cap screws to move fan shroud and guard
rearward.
3. Tag transmission oil cooler lines (A and B) to aid in
assembly. Disconnect oil cooler lines. Use caps and
plugs to close all openings.
4. Remove hydraulic oil coolertoradiator cap screws (if
equipped) to move cooler aside.
5. Remove transmission oil cooler mounting cap screws
to remove cooler.
6. Inspect and repair oil cooler. (See Repair Hydraulic
T6687AD UN20OCT88
Oil Cooler in Group 2160.)
7. Install oil cooler. Tighten cap screws.
8. Install hydraulic oil cooler (if equipped).
9. Connect transmission oil cooler lines.
10. Install fan shroud and guard assembly.
11. Tilt grille housing rearward or install grille housing.
(See Remove and Install Radiator in Group 0510 for
procedure.)
TX,0360,BA981 1919OCT931/1

061411
PN=305
Hydraulic System

061411
PN=306
Group 0399
DF1126 Bearing Installer
T8080AC UN30SEP93
Bearing Installer is used to install ball bearings in
transmission clutch packs. Steel tubing machined to dimensions shown.
Material Required:
TX,0399,BD918 1920SEP931/1

061411
PN=307
DF1127 Support Tubing

Support Tubing is used to support clutch pack shaft
assembly during bearing installation.
Material Required:
Steel tubing machined to dimensions shown.
T8080AD UN30SEP93
TX,0399,BD919 1920SEP931/1

061411
PN=308
DF1128 Bearing Installer

Bearing Installer is used to install ball bearings in
transmission clutch packs.
Material Required:
Steel tubing machined to dimensions shown.
T8080AE UN30SEP93
TX,0399,BD920 1920SEP931/1
DF1031 Clutch Assembly Tool

Tool can be made in dealers shop. Used to compress
spring washers in all three clutch packs.
Material Required:
T6579AL UN19MAY89
3 1/2 in. black steel pipe (4.00 in. O.D. x 0.226 in. wall)
A241 mm (9.50 in.) C38 mm (1.50 in.)
B51 mm (2.0 in.)
9900,U96 1921OCT871/1

061411
PN=309
DFT1121 Rivet Forming Tool
T7947AY 1914MAR94
Tool is used to install rivets in differential ring gear.
22 mm (7/8 in.) round bar stock
Material Required:
TX,03,RB245 1922JAN981/1

061411
PN=310
JT38000 Differential Lifting Tool
RW5335L 1912MAY89
Differential Lifting Tool is used to remove and install One piece of (13 x 305 mm) 1/2 x 12 in. round bar stock.
differential ring gear. One piece of 1/213 UNC x 9.5 in. ready rod.
Make tool as shown from specified material mild steel
One piece of (7 x 51 x 25 mm) 1/4 x 2 x 1 in. flat steel.
(1020).
One piece of (13 x 51 x 292 mm) 1/2 x 2 x 111/2 in.
flat steel.
Material Required:
Two 1/213 UNC nuts.
9900,415 1921OCT871/1

061411
PN=311

061411
PN=312
Section 04
Engine
Contents
Page

4276 John Deere Engine
RepairUse CTM4 (S.N.
299999).............................................. 0404001
4045 John Deere Engine
300000840460).................................. 0404001
Engine AccessoriesUse
CTM11 ................................................... 0404001
PowerTech 4.5 L Engine
840461 )............................................. 0404002
Special or Essential Tools.......................... 0404002
Specifications ............................................ 0404003
Remove EngineWith Torque
Converter............................................... 0404003
Install EngineWith Torque
Converter............................................... 0404007
Remove EngineWith Direct
Drive .................................................... 04040011
Install EngineWith Direct Drive ............ 04040014
Bleed Fuel System .................................. 04040017

061411
PN=1
Contents

061411
PN=2
Group 0400
Removal and Installation
4276 John Deere Engine RepairUse CTM4
(S.N. 299999)
For complete repair information the component technical
manual (CTM) is also required.
Use the component manual in conjunction with this
M44215 UN07SEP88
machine manual.
TX,04,RB248 1922JAN981/1
4045 John Deere Engine RepairUse CTM8

(S.N. 300000840460)
M44215 UN07SEP88
machine manual.
TX,04,RB247 1922JAN981/1
Engine AccessoriesUse CTM11

machine manual.
M44215 UN07SEP88
TX,04,RB247 1922JAN981/1

061411
PN=315
PowerTech 4.5 L Engine RepairUse

CTM104 (S.N. 840461 )
M44215 UN07SEP88
machine manual.
TX,04,RB247 1922JAN981/1
T8015AG UN01JUN93
the U.S. SERVICEGARD Catalog or in the

DX,TOOLS 1920JUL951/3
LoadPositioning Sling...................................... D01043AA Used to remove and install engine.

T6585NN UN03NOV88
To remove and install engine.
Lifting Bracket.......................................................JT01748
Used to remove and install hood.
To remove and install hood.

061411
PN=316
Specifications
Engine SupporttoMain Frame Torque 840 Nm (620 lbft)

Cap Screws
Engine Front SupporttoEngine Torque 290 Nm (215 lbft)
Block Cap Screws
Hydraulic PumptoTorque Converter Torque 149 Nm (110 lbft)
Housing Cap Screws
Transmission PumptoTorque Torque 319 Nm (235 lbft)
Converter Housing Cap Screws
Drive Shaft Bearing StraptoYoke Torque 48 Nm (35 lbft)
Cap Screws
Injection Line Connections Torque 27 Nm (20 lbft)
Engine with Torque Converter Weight 820 kg (1800 lb) (Approximately)
Engine with Direct Drive Weight 658 kg (1450 lb) (Approximately)
TX,0400,BA853 1907JUL931/1
Remove EngineWith Torque Converter

1. Lower all equipment to ground.
2. Remove engine side shields, precleaner, exhaust pipe
and hood. (See Group 1910.)
3. On loader equipped machines, raise loader and install
boom lock bar (A). Stop engine and operate hydraulic
controls to relieve pressure in the system.
4. Turn battery disconnect switch to "OFF" (if equipped)
or disconnect battery () ground strap.
T7931AI UN02FEB93
Crawler Loader
Continued on next page TX,04,RB253 1923JAN981/6

061411
PN=317
CAUTION: Grille housing is heavy. Use a lifting

device for heavy components.
5. Use a lifting sling and hoist to support grille housing.

6. Remove two cap screws (B) from each side of
T6670AA UN25OCT88
machine.
7. If machine is equipped with front counterweight,
remove cap screw (A) on each side and remove grille
housing.
8. If machine is NOT equipped with front counterweight,
loosen, but do not remove, cap screw (A) on each side
of machine and tilt grille housing forward.
9. Remove hydraulic oil cooler (if equipped) from front
of radiator without disconnecting hoses. (See Group
2160.)
TX,04,RB253 1923JAN982/6
10. Disconnect speed control linkage (A).

11. Close fuel shutoff valve under fuel tank. Disconnect
fuel return hose (B) at engine.
12. Open or remove clamp (C) and disconnect wiring
harness (D) from oil pressure sender and injection
pump.
13. Remove clamp (E) from engine block.
ASpeed Control Linkage DWiring Harness

BFuel Return Hose EClamp
CClamp
T112622 UN03FEB98
(S.N. 840461 ) Shown


061411
PN=318
14. Remove cab or ROPS platform center floor plates.

15. Disconnect hose (A) from torque converter housing.
Use caps and plugs to close openings.
16. On machines (S.N. 803600), disconnect hose (C)
from transmission oil filter.
T8043AB UN15JUL93
17. Remove four cap screws (D) to disconnect drive shaft
from torque converter.
18. Disconnect transmission pump (B) from torque
converter housing without disconnecting hoses.
19. Disconnect hydraulic pump (E) from torque converter
housing without disconnecting hoses. (S.N. 840460)
20. Disconnect wire lead from transmission oil temperature

switch (F).
21. Remove oil temperature switch and adapter before
removing engine. Use caps and plugs to close
openings.
ATorque Converterto DBearing StraptoYoke Cap

Transmission Control Valve Screw (4 used)
Hose EHydraulic Pump
BTransmission Oil Pump F Transmission Oil
CTransmission Oil Temperature Switch and
FiltertoTransmission Adapter
Oil Cooler Hose (S.N.
803600)
T112623 UN03FEB98
(S.N. 840461 )
TX,04,RB253 1923JAN984/6
22. Disconnect fuel supply line (A) at flywheel housing

connection.
23. Remove ground strap (B) from flywheel housing.
24. Remove two engine rear mounttomain frame cap
screws (C).
T112625 UN21JAN98
(S.N. 840461 ) Shown


061411
PN=319
25. Remove air cleaner (H) and muffler (A).

26. Disconnect start aid tube (if equipped) at fitting (B).
27. Tag wire leads and disconnect wiring harness (F) from
alternator (D) and starter (E) (or remove starter and
alternator from engine and leave on machine with
wiring harness connected.)
28. Remove wiring harness clamp (G) from engine.
29. Remove two front supporttoframe cap screws (C).
CAUTION: Use a lifting device for heavy

components.
30. On loader equipped machines, attach a lifting strap

to boom and a hoist. Put loader in float position and
lower loader using the hoist.
CAUTION: Engine with torque converter and

housing weighs approximately 820 kg (1800 lb).
T112624 UN21JAN98
31. Install JT01748 Lifting Brackets on cylinder head at
left front and right rear corners. Connect D01043AA
LoadPositioning Sling to Lifting Brackets and a hoist.
32. Remove engine just enough to disconnect coolant
temperature switch wire lead and remove harness
clamp from rear of engine.
(S.N. 840461 ) Shown
Specification
Engine with Torque
ConverterWeight............................... 820 kg (1800 lb) (Approximately) AMuffler EStarter
BStart Aid Tube Fitting F Wiring Harness
33. Remove engine. CFront SupporttoFrame GClamp
Cap Screw (2 used) HAir Cleaner
34. Put engine in engine repair stand. DAlternator
35. Remove and install torque converter. (See Group

0651.) Specification
36. Remove and install radiator. (See Group 0510.) Engine Front
SupporttoEngine Block
37. Remove and install engine front support if necessary. Cap ScrewsTorque................................................. 290 Nm (215 lbft)
Tighten engine supporttoengine block cap screws.
TX,04,RB253 1923JAN986/6

061411
PN=320
Install EngineWith Torque Converter
CAUTION: Engine with torque converter and

housing weighs approximately 820 kg (1800 lb).

left front and right rear corners.Connect D01043AA
2. Install resilient mount halves at engine front and rear
supports.
3. Install engine into machine just enough to connect
harness clamp and coolant temperature switch wire
lead to rear of engine.
Specification
Engine with Torque
ConverterWeight............................... 820 kg (1800 lb) (Approximately)
Install engine and install four engine supporttomain
frame cap screws. Tighten cap screws.
Specification
T112624 UN21JAN98
Engine SupporttoMain
Frame Cap

components.
(S.N. 840461 ) Shown
AMuffler EStarter
raise boom using the hoist. Install boom lock bar. BStart Aid Tube Fitting F Wiring Harness
CFront SupporttoFrame GClamp
5. Connect wiring harness (F) to alternator (D) and Cap Screw (2 used) HAir Cleaner
starter (E) (or install alternator and starter (if removed). DAlternator
(See Groups 1672 and 1677, respectively.)
6. Install air cleaner (H) and muffler (A).
7. Connect start aid tube (if equipped) at fitting (B).
TX,04,RB252 1923JAN981/6
8. Connect fuel supply line (A) at flywheel housing

connection.
9. Install ground strap (B) at flywheel housing. T112625 UN21JAN98
(S.N. 840461 ) Shown


061411
PN=321
10. Connect transmission oil pump (B) to torque converter

housing. Tighten pumptotorque converter housing
cap screws.
11. Connect hydraulic pump (E) to torque converter
housing. Tighten pumptotorque converter housing
cap screws.
T8043AB UN15JUL93
Specification
Hydraulic Pumpto
Torque Converter
Housing Cap
ScrewsTorque..........................................................149 Nm (110 lbft)
Transmission
PumptoTorque (S.N. 840460)
Converter Housing Cap
12. Install oil temperature switch adapter and switch (F) to

torque converter housing and connect wire lead.
13. Connect hose (A) to torque converter housing.
14. On machines (S.N. 803600), connect hose (C) to
transmission oil filter.
15. Connect drive shaft to torque converter. Tighten
bearing straptoyoke cap screws (D).
Specification
Drive Shaft Bearing
StraptoYoke Cap
T112623 UN03FEB98
16. Install cab or ROPS platform center floor plates.
ATorque Converterto DBearing StraptoYoke Cap

Transmission Control Valve Screw (4 used)
Hose EHydraulic Pump
BTransmission Oil Pump F Transmission Oil
CTransmission Oil Temperature Switch and (S.N. 840461 )
FiltertoTransmission Adapter
Oil Cooler Hose (S.N.
803600)

061411
PN=322
17. Connect speed control linkage (A).

18. Connect fuel return hose (B) at engine. Open fuel
shutoff valve under fuel tank.
19. Connect wiring harness (D) and install clamp (C).
20. Install clamp (E) to engine block.
ASpeed Control Linkage DWiring harness

CClamp
T112622 UN03FEB98
(S.N. 840461 ) Shown
TX,04,RB252 1923JAN984/6
21. Install hydraulic oil cooler (if equipped) to front of

radiator. (See Group 2160.)

T6670AA UN25OCT88
22. Use a sling and hoist to lift grille housing into position.
Install cap screws (A and B) on each side of machine.

061411
PN=323
23. Check engine oil level. Add oil if necessary. (See

Section 00, Group 0004.)
24. Check radiator coolant level. Add coolant if
necessary. (See Section 00, Group 0004.)
25. Install hood, precleaner and exhaust pipe. (See Group
1910.)
26. Turn battery disconnect switch to "ON" (if equipped) or
connect battery () ground strap.
27. Bleed fuel system. (See procedure in this group.)
28. Start machine and operate all hydraulic and drive
functions.
29. Shut engine off. Recheck all fluid levels.
30. Adjust fast and slow idle positions. (See Operation
and Test Manual, TM1403, Section 9010.)
31. Install engine side shields.
32. On loader equipped machines, remove boom lock bar
(A) and lower loader to ground.
T7931AI UN02FEB93
Crawler Loader
TX,04,RB252 1923JAN986/6

061411
PN=324
Remove EngineWith Direct Drive

2. Remove engine side shields, precleaner, exhaust pipe
and hood. (See Group 1910.)
3. On loader equipped machines, raise loader and install
boom lock bar (A). Stop engine and operate hydraulic
controls to relieve pressure in the system.
4. Turn battery disconnect switch to "OFF" (if equipped)
or disconnect battery () ground strap.

5. Use a lifting sling and hoist to support grille housing.
T7931AI UN02FEB93
TX,04,RB251 1923JAN981/6
6. Remove two cap screws (B) from each side of

machine.
7. If machine is equipped with front counterweight,
remove cap screw (A) on each side and remove grille
housing.
T6670AA UN25OCT88
8. If machine is NOT equipped with front counterweight,
loosen, but do not remove, cap screw (A) on each side
of machine and tilt grille housing forward.
of radiator without disconnecting hoses. (See Group
2160.)

061411
PN=325
10. Disconnect transmission oil cooler hoses (A) and

remove nylon strap (B).
T8043AE UN15JUL93
TX,04,RB251 1923JAN983/6
11. Disconnect speed control linkage (A).

12. Close fuel shutoff valve under fuel tank. Disconnect
fuel return hose (B) at engine.
13. Open or remove clamp (C) and disconnect wiring
harness (D) from oil pressure sender and injection
pump.
14. Remove clamp (E) from engine block.
15. Remove cab or ROPS platform center floor plates.
16. Disconnect hydraulic pump from flywheel housing
without disconnecting hoses. (See Remove and Install
Hydraulic Pump and Drive Shaft, Group 2160.) Use a
chain to support pump and leave in machine.
17. Disconnect fuel supply line at flywheel housing
connection.

CClamp
T112622 UN03FEB98
(S.N. 840461 ) Shown


061411
PN=326
18. Remove ground strap (A) from flywheel housing.

19. Remove two engine rear mounttomain frame cap
screws.
T6578AE UN18OCT88
TX,04,RB251 1923JAN985/6
20. Remove air cleaner (H) and muffler (A).

21. Disconnect start aid tube (if equipped) at fitting (B).
22. Tag wire leads and disconnect wiring harness (F) from
alternator (D) and starter (E) (or remove starter and
alternator from engine and leave on machine with
wiring harness connected).
23. Remove wiring harness clamp (G) from engine.
24. Remove two front supporttoframe cap screws (C).

components.

lower loader using the hoist.
CAUTION: Engine weighs approximately

658 kg (1450 lb).
T112624 UN21JAN98
27. Remove engine just enough to disconnect coolant
temperature switch wire lead and remove harness
clamp from rear of engine.
(S.N. 840461 ) Shown
28. Remove engine.
Specification AMuffler EStarter
Engine with Direct BStart Aid Tube Fitting F Wiring Harness
DriveWeight...................................... 658 kg (1450 lb) (Approximately) CFront SupporttoFrame GClamp
Cap Screw (2 used) HAir Cleaner
29. Put engine in a engine repair stand. DAlternator
30. Remove and install radiator. (See Group 0510.)

31. Remove and install engine front support if necessary. Specification
Tighten engine supporttoengine block cap screws. Engine Front
SupporttoEngine Block
TX,04,RB251 1923JAN986/6

061411
PN=327
Install EngineWith Direct Drive
CAUTION: Engine weighs approximately

658 kg (1450 lb).

2. Install resilient mount halves at engine front and rear
supports.
3. Install engine into machine part way.
Specification
Engine with Direct
DriveWeight...................................... 658 kg (1450 lb) (Approximately)
Connect harness clamp and coolant temperature
switch wire lead to rear of engine. Install engine rest
of way and install four engine supporttomain frame
cap screws. Tighten cap screws.
Specification
T112624 UN21JAN98
Engine SupporttoMain
Frame Cap

components.
(S.N. 840461 ) Shown
AMuffler EStarter
raise boom using the hoist. Install boom lock bar. BStart Aid Tube Fitting F Wiring Harness
CFront SupporttoFrame GClamp
5. Connect wiring harness (F) to alternator (D) and starter Cap Screw (2 used) HAir Cleaner
(E) (or install starter and alternator [if removed]). (See DAlternator
Groups 1672 and 1677, respectively.)
6. Install air cleaner (H) and muffler (A).
7. Connect start aid tube (if equipped) at fitting (B).
TX,04,RB250 1923JAN981/6
8. Connect fuel supply line at flywheel housing

connection.
9. Install ground strap (A) to flywheel housing.
10. Connect hydraulic pump to flywheel housing. (See
Remove and Install Hydraulic Pump and Drive
T6578AE UN18OCT88
Shaft, Group 2160.) Tighten bearing straptoyoke

cap screws.
Specification
Drive Shaft Bearing
StraptoYoke Cap
11. Install cab or ROPS platform center floor plates.


061411
PN=328
12. Connect speed control linkage (A).

13. Connect fuel return hose (B) at engine. Open fuel
shutoff valve under fuel tank.
14. Connect wiring harness (D) and install clamp (C).
15. Install clamp (E) to engine block.

CClamp
T112622 UN03FEB98
(S.N. 840461 ) Shown
TX,04,RB250 1923JAN983/6
16. Connect transmission oil cooler hoses (A) and install

new nylon strap (B).
T8043AE UN15JUL93

061411
PN=329
17. Install hydraulic oil cooler (if equipped) to front of

radiator. (See Group 2160.)

T6670AA UN25OCT88
18. Use a sling and hoist to lift grille housing into position.
Install cap screws (A and B) on each side of machine.
TX,04,RB250 1923JAN985/6
19. Check engine oil level. Add oil if necessary. (See

20. Check radiator coolant level. Add coolant if
necessary. (See Section 00, Group 0004.)
21. Install hood, precleaner and exhaust pipe. (See Group
1910.)
22. Turn battery disconnect switch to "ON" (if equipped) or
connect battery ground strap.
23. Bleed fuel system. (See procedure in this group.)
24. Start machine and operate all hydraulic and drive
functions.
25. Shut engine off. Recheck all fluid levels.
26. Adjust fast and slow idle positions. (See Operation
and Test Manual, TM1403, Section 9010.)
27. Install engine side shields.
28. On loader equipped machines, remove boom lock bar
(A) and lower loader to ground.
T7931AI UN02FEB93
TX,04,RB250 1923JAN986/6

061411
PN=330
Bleed Fuel System

1. Loosen fuel filter bleed screw (A).
2. Operate primer lever (B) until only fuel flows out of
bleed screw. Tighten screw.
T6077AN UN20OCT88
NOTE: If there is no fuel flow, push primer lever
toward engine, turn crankshaft using starting
motor to reposition camshaft.
(S.N. 840460)
T112375 UN16DEC97
(S.N. 840461 )
TX,04,RB255 1923JAN981/3
3. Purge air from filtertoinjection pump line by

continuing to operate primer lever several times or by
loosening connection (I) at injection pump and operate
primer lever until only fuel flows out of connection.
Tighten connection using two wrenches.
Specification
T112626 UN21JAN98
Injection Line
ConnectionsTorque..................................................... 27 Nm (20 lbft)

061411
PN=331

X9811 UN23AUG88
Medical Department in Moline, Illinois, or other
NOTE: If may not always be necessary to purge

air from injection lines if engine starts easily
and runs smoothly.
T92924 UN01NOV88
4. Loosen injection line connections using two wrenches.
5. Move speed control lever to approximately half speed.
Crank engine until a small amount of fuel leaks from
injection lines.
6. Tighten injection line connections using two wrenches.
Specification
Injection Line
Start engine.
ConnectionsTorque..................................................... 27 Nm (20 lbft)
TX,04,RB255 1923JAN983/3

061411
PN=332
Section 05
Engine Auxiliary Systems
Contents
Page
Group 0505Cold Weather Starting Aid

Specifications ............................................ 0505051
Other Material............................................ 0505051
Remove and Install Coolant
Heater.................................................... 0505051
Remove and Install Starting Aid
Nozzle.................................................... 0505053
Remove and Install Starting Aid
Solenoid................................................. 0505055
Group 0510Cooling System

Specifications ............................................ 0505101
Check and Adjust VBelt Tension
(S.N. 840460)..................................... 0505101
Checking Serpentine Belt
Tensioner Spring Tension
and Belt Wear (S.N. 840461
) ............................................................. 0505102
Remove and Install Sand
Screens ................................................. 0505103
Remove and Install Fan............................. 0505104
Adjust Reversible Fan Blade
Angle ..................................................... 0505105
Remove and Install Radiator ..................... 0505105
Group 0515Speed Controls and Fuel

ShutOff Linkage
Remove and Install Speed Control
Cable ..................................................... 0505151
LinkageWithout Declutch ................... 0505152
LinkageWith Declutch ........................ 0505154
Group 0520Intake System

Disassemble and Assemble Air
Cleaner .................................................. 0505201
Group 0560External Fuel Supply System

Specifications ............................................ 0505601
Remove and Install Fuel Tank ................... 0505601

061411
PN=1
Contents

061411
PN=2
Group 0505
Cold Weather Starting Aid
Specifications
Engine Coolant Heater Element Nut Torque 34 Nm (25 lbft)

Engine Cooling System Capacity 17 L (18 qt) (Approximately)
0505,VV47 1918AUG931/1
Other Material
Number Name Use
TY9375 (U.S.) Pipe Sealant Applied to nozzle holder male threads.
TY9480 (Canadian)
592 (LOCTITE)

TX,0505,BA831 1918AUG931/1
Remove and Install Coolant Heater

1. On loaders, raise loader and install boom lock bar.
2. Drain coolant. Cooling system capacity is
approximately 17 L (18 qt).
Specification
T96052 UN24JAN90
Engine Cooling
SystemCapacity........................................17 L (18 qt) (Approximately)
3. Disconnect cord (C) from heater assembly.

4. Loosen lock nut (B).
5. Remove adapter (A) and heater element from cylinder (S.N. 840460)
block.
CAUTION: TEST COOLANT HEATER IN LIQUID

ONLY. DO NOT plug coolant heater into
electrical power unless heating element is
immersed in coolant. Sheath could burst
and result in personal injury.
AAdapter CCord
BLock Nut
T112796 UN13JAN98
(S.N. 840461 )

061411
PN=335
7. Install new gasket (E) on heater element and a new

Oring (F) on adapter (D). Install heater element
through adapter, and install nut (C), but do not tighten.
ACord EGasket
BCap F ORing
T105617 UN06DEC96
CNut GHeater Element
DAdapter
TX,05,RB256 1923JAN982/4
8. Install heater into cylinder block with element pointing

to the rear.
9. Tighten adapter (A).
T91790 UN13FEB90
TX,05,RB256 1923JAN983/4
10. Turn element clockwise and then counterclockwise

until element contacts casting. Move element midway
between contact points.
11. Hold element with a wrench and tighten lock nut (A).
Specification
Engine Coolant Heater
T96053 UN24JAN90
Element NutTorque..................................................... 34 Nm (25 lbft)
12. Connect cord to heater. Install engine left side shield.

13. Fill system with proper amount of correct engine
coolant. (See Section 00, Group 0002.)
TX,05,RB256 1923JAN984/4

061411
PN=336
Remove and Install Starting Aid Nozzle

1. On loaders, raise loader and install boom lock bar.
Remove engine right side shield.
2. Disconnect starting aid tube (B) and remove nozzle
holder (A).
T112628 UN21JAN98
(S.N. 840461 ) Shown
TX,05,RB257 1923JAN981/5
3. On machines (S.N. 840461 ):

Clean or replace nozzle as required.
Replace Oring (A).
T112630 UN21JAN98
TX,05,RB257 1923JAN982/5
4. On machines (S.N. 840460):

Remove nozzle from holder.
Clean or replace nozzle as required.
Install nozzle in holder
T88491 UN21OCT88

061411
PN=337
NOTE: Notch on nozzle holder (B) indicates

direction of nozzle (A).

Apply pipe sealant to threads and install nozzle
holder (B) in air inlet with notch pointing up.
T112631 UN21JAN98
Connect starting aid tube (C).
Install engine right side shield. On loaders, remove
boom lock bar and lower loader to ground.
T112629 UN21JAN98
TX,05,RB257 1923JAN984/5

Apply pipe sealant to threads and install nozzle
holder (B) in air inlet with arrow point up.
Connect starting aid tube (A).
Install engine right side shield. On loaders, remove
boom lock bar and lower loader to ground.
T8056AL UN29JUL93
NOTE: Arrow on nozzle holder indicates
direction of nozzle.
TX,05,RB257 1923JAN985/5

061411
PN=338
Remove and Install Starting Aid Solenoid

1. Open access door on hydraulic reservoir.
2. Disconnect wiring lead connector (A) and starting aid
tube (B).
T112632 UN21JAN98
(S.N. 803601 ) Shown
TX,05,RB258 1923JAN981/3
3. Remove container (D) to remove starting fluid can (C).

4. Remove two cap screws (B) and solenoid (A).
5. Remove parts (EG) from solenoid housing.
6. Install parts (EG) into solenoid housing.
7. Install solenoid using two cap screws.
ASolenoid ELarge ORing

BCap Screw and Washer (2 F Adapter
used) GSmall ORing
CStarting Fluid Can (Ether)
DContainer
T8056AN UN09AUG93

061411
PN=339
8. Connect starting aid tube (B) and wiring lead (A).

9. Install starting fluid can and container. Close access
door.
T112632 UN21JAN98
(S.N. 803601 ) Shown
TX,05,RB258 1923JAN983/3

061411
PN=340
Group 0510
Cooling System

0510,VV59 1914JUN111/2
Belt Tension Gauge Used to adjust fan belt tension.

0510,VV59 1914JUN112/2
Specifications
Fan VBeltNew Deflection Midway Between Pulleys 8 mm (5/16)

with 111 N (25 lb force) Applied
Fan VBeltUsed Deflection Midway Between Pulleys 11 mm (7/16)
with 111 N (25 lb force) Applied
FantoEngine Cap Screws Torque 41 Nm (30 lbft)
Transmission Oil CoolertoRadiator Torque 16 Nm (144 lbin.)
Cap Screws
TX,0510,BA867 1918AUG931/1
Check and Adjust VBelt Tension (S.N.

840460)
1. A force of 111 N (25 lb) on a new belt halfway between
pulleys should deflect belt 8 mm (5/16 in.).
Specification
Fan VBeltNew
(Midway Between Pulleys
with 111 N (25 lb force)
Applied)Deflection........................................................ 8 mm (0.31 in.)
A force of 111 N (25 lb) on a used belt halfway between
pulleys should deflect belt 11 mm (7/16 in.).
Specification
Fan VBeltUsed
(Midway Between Pulleys
with 111 N (25 lb force)
Applied)Deflection...................................................... 11 mm (0.44 in.)
2. If belt deflection is not within specifications, loosen

alternator mounting cap screws.
T6030AT1 UN18OCT88
3. Apply force to FRONT alternator housing only (near

the belt) until tension is correct.
4. Tighten cap screws.
AAlternator Pulley DStraight Edge

BFan Pulley EBelt Deflection Gauge
CCrankshaft Pulley
TX,05,RB259 1923JAN981/1

061411
PN=341
Cooling System
Checking Serpentine Belt Tensioner Spring

Tension and Belt Wear (S.N. 840461 )
Belt drive systems equipped with automatic (spring) belt
tensioners cannot be adjusted or repaired. The automatic
belt tensioner is designed to maintain proper belt tension
over the life of the belt. If tensioner spring tension is not
T112840 UN21JAN98
within specification, replace tensioner.
Checking Belt Wear
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops when correct
belt length and geometry is used.
1. Visually inspect cast stops on belt tensioner assembly.
2. If the tensioner stop on swing arm is hitting the
fixed stop, check mounting brackets (alternator, belt
tensioner, etc.) and the belt length. Replace belt as
needed.
T112841 UN21JAN98
Checking Tensioner Spring Tension
A belt tension gauge will not give an accurate measure of
the belt tension when automatic spring tensioner is used.
Measure tensioner spring tension using a torque wrench
and procedure outlined below:
1. Release tension on belt using a breaker bar on tension
arm. Remove belt from pulleys.
5. Rotate the swing arm using a torque wrench until
2. Release tension on tension arm and remove breaker marks (A and B) are aligned (C).
bar.
6. Record torque wrench measurement and compare
3. Put a mark (A) on swing arm of tensioner as shown. with specification below. Replace tensioner assembly
as required.
4. Measure 21 mm (0.83 in.) from (A) and put a mark (B)
on tensioner mounting base. Specification
Tensioner
Specification
SpringTension.............................................. 1822 Nm (1316 lbft)
Tensioner Swing Arm
toTensioner Mounting
BaseDistance.............................................................. 21 mm (0.83 in.)
TX,05,RB260 1923JAN981/1

061411
PN=342
Cooling System
Remove and Install Sand Screens

1. Raise loader (if equipped) and install boom lock bar.
Remove engine side shields.
2. Open hood access door.
3. Remove cap screws (A) to remove screen access
cover (B).
4. Remove six cap screws (C) (three per side).
5. Move fan guard away from shroud to gain access to
back of radiator through fan blade openings.
6. Loosen cap screw on right side of bottom sand screen.
Push screen toward left channel of radiator until right
side is clear of cap screw.
7. Remove screen through screen access cover opening
in top of shroud.
8. Repeat steps 6 and 7 for center and top screens.
9. Clean and inspect screens.
T8056AO UN29JUL93
10. Place offset side of screen in upper left gusset of
radiator with slotted opening of screen over cap screw.
11. Push screen against left channel of radiator and
tighten cap screw.
12. Place the next two screens under the first and repeat
step 10 for each screen. (S.N. 840460) Shown
13. Install fan guard and screen access cover.

14. Install engine side shields and close hood door.
Remove boom lock bar and lower loader to ground
(if equipped).
TX,0510,BA868 1918AUG931/1

061411
PN=343
Cooling System
Remove and Install Fan

NOTE: This procedure is for nonreversible fan. For
reversible fan, radiator must be removed to
remove and install fan. (See Remove and
Install Radiator in this group.)

Remove hood and engine side shields. (See Group
1910.)
2. Remove six cap screws (B) (three per side) to remove
fan guard (A).
3. Remove four fantoengine cap screws to remove fan
and spacer (C).
4. Install spacer and fan using four cap screws. Tighten
cap screws.
Specification
FantoEngine Cap
T8056AP UN29JUL93
5. Install fan guard using six cap screws.
6. Install hood and engine side shields. Remove boom
lock bar and lower loader to ground (if equipped).
(S.N. 840460) Shown

TX,0510,BA869 1918AUG931/1

061411
PN=344
Cooling System
Adjust Reversible Fan Blade Angle

Remove engine right side shield.
2. Remove fan guard.
3. Fan blade is springloaded push blade toward center
and turn to change angle. Make sure all blades are
at the same angle.
For blower fan (A) operation, concave side of blades
must face radiator for sucker fan (B) operation,
concave side must face away from radiator.
4. Install fan guard.
5. Install engine right side shield. Remove boom lock bar
and lower loader to ground (if equipped).
T95938 UN25MAY89
TX,0510,BA870 1908OCT931/1
Remove and Install Radiator

1. Remove precleaner and exhaust pipe.
Remove hood and engine side shields. (See Group
1910.)
T6670AA UN25OCT88
3. Loosen, but do not remove, rearmost cap screw (A)
on each side of machine.
4. If machine is equipped with front counterweights,
either remove the counterweights and continue or
remove the grille housing as detailed in Group 1921
and go to step 7.
CAUTION: Grille housing is heavy. Use a lifting 6. Remove two cap screws (B) from each side and tilt
device for heavy components. grille housing forward using a hoist.
5. Install a lifting strap to top of grille housing and a hoist.


061411
PN=345
Cooling System
CAUTION: Explosive release of fluids

from pressurized cooling system can
cause serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
TS281 UN23AUG88
before removing completely.
NOTE: Cooling system capacity is 17 L (18 qt).
7. Drain radiator.
Specification
Cooling SystemCapac
ity...........................................................................................17 L (18 qt.)
8. Disconnect hoses (B and D).

9. Disconnect coolant overflow hose from radiator at
clips (G).
10. Disconnect coolant recovery hose (H) from radiator.
11. Remove six cap screws (E) (three per side) to
disconnect fan shroud (F). On right side, remove
mounting strip (if equipped).
12. Remove two support brackettoradiator cap screws
(A) and washers.
13. Loosen (do not remove) three cap screws (C).
ACap Screws (2 used) ECap Screw (6 used)

BUpper Radiator Hose F Fan Shroud
CCap Screw (3 used) GClip (2 used)
DLower Radiator Hose HOverflow Hose
(S.N. 840461 ) Shown T112633 UN21JAN98

061411
PN=346
Cooling System

of radiator. (See Remove and Install Hydraulic Oil
Cooler, Group 2160.)
15. Remove two transmissiontooil cooler hoses (A). Use
caps and plugs to close all openings.
T8056AR UN29JUL93
CAUTION: Radiator with oil cooler weighs
16. Remove two radiatortofront support cap screws (B),

washers and bottom isolator lower halves.
17. Remove radiator and oil cooler as an assembly.
Specification
Radiator with Oil 23. Install radiator and oil cooler assembly. Install bottom
CoolerWeight.................................................................... 34 kg (75 lb) isolator lower halves, washers and cap screws.
Securely tighten cap screws.
18. Remove transmission oil coolertoradiator mounting
bracket (if equipped). Specification
Transmission Oil
19. Remove air baffles and transmission oil cooler from CoolertoRadiator Cap
right side of radiator. ScrewsTorque......................................................... 16 Nm (144 lbin.)
20. Assemble transmission oil cooler to radiator. 24. Connect transmissiontooil cooler hoses.
21. Install air baffles. Tighten cap screws. 25. Install hydraulic oil cooler (if equipped). (See Remove
Specification and Install Hydraulic Oil Cooler, Group 2160.)
Air Baffle Mounting Cap
ScrewsTorque........................................................... 16 Nm (144 lbft)
22. Place bottom isolator upper halves on top of front

support.

061411
PN=347
Cooling System
26. Install two washers and support brackettoradiator

cap screws (A). Tighten cap screws.
27. Tighten three cap screws (C).
28. Connect hoses (B, D, and H).
29. Install fan shroud (F) using six cap screws (E)
(three per side) and on right side, mounting strip (if
equipped).
30. Place hose into clips (G).
NOTE: Cooling system capacity is 17 L (18 qt).
31. Fill radiator to bottom of filler neck with proper

coolant. (See Section 00, Group 0004.)
ACap Screws (2 used) ECap Screw (6 used)

BUpper Radiator Hose F Fan Shroud
CCap Screw (3 used) GClip (2 used)
DLower Radiator Hose HOverflow Hose
T112633 UN21JAN98
(S.N. 840461 ) Shown
TX,05,RB261 1923JAN984/5

32. Tilt grille housing rearward and secure using three

cap screws (A and B) on each side (or install grille
housing if removedsee Group 1921).
T6670AA UN25OCT88
33. Install hood and engine side shields. (See Group
1910.)
34. Install precleaner and exhaust pipe.
35. Start machine and allow engine to come up to
operating temperature.
NOTE: On machines equipped with coolant recovery
system, check and add fluid (if necessary) at 37. Remove boom lock bar and lower loader to ground
the coolant recovery bottle. (if equipped).
36. Shut off engine and allow system to cool. Check for
leaks. Check coolant level. Add coolant if necessary.
TX,05,RB261 1923JAN985/5

061411
PN=348
Group 0515
Speed Controls and Fuel ShutOff Linkage
Remove and Install Speed Control Cable
T112801 UN21JAN98
(S.N. 840461 ) Shown
ANut CCable Bracket Cap Screw ECable Yoke Pin
BSpring DCable Bracket Cap Screw

Remove engine left side shield. 8. Install parts (AE).
2. Remove four cap screws and lower cover from front of 9. Adjust cable length. (See TM1403, Group 901020.)
transmission control console. 10. Install lower cover to front of transmission control
3. Remove floor plate. console using four cap screws.
4. Remove nut (A) to disconnect speed control cable 11. Install floor plate.
from injection pump. 12. Install engine left side shield.
5. Remove cable bracket cap screws (C and D). 13. Remove boom lock bar and lower loader to ground.
6. Remove yoke pin (E).
7. Install injection pump end of cable through grommet
in firewall.
TX,05,RB262 1923JAN981/1

061411
PN=349
Remove and Install Speed Control LinkageWithout Declutch
T112802 UN21JAN98
(S.N. 840461 ) Shown
1 Snap Ring (2 used) 10 Snap Ring 19 Cotter Pin 28 Washer
2 Bearing (2 used) 11 Shaft 20 Angle 29 Cotter Pin
3 Washer 12 Speed Control Cable 21 Angle 30 Cotter Pin
4 Snap Ring 13 Washer 22 Spring 31 Washer
5 Decelerator Pedal 14 Cotter Pin 23 Arm 32 Pin
6 Low Idle Stop Screw 15 Rod 24 Arm 33 Cap Screw
7 Spring Pin (2 used) 16 Nut (2 used) 25 Yoke 34 Washer (2 used)
8 Bushing (2 used) 17 Yoke 26 Nut 35 Nut
9 Washer 18 Pin 27 Rod 36 Lock Nut
1. On loaders, raise loader and install boom lock bar. 6. Assemble parts.
2. Remove engine left side shield. 7. Adjust speed control linkage. (See TM1403, Group
3. Remove floor plates. 901020.)
4. Disassemble parts. 8. Install floor plates and engine left side shield.
5. Inspect for worn or damaged parts. Replace parts as 9. Remove boom lock bar and lower loader to ground
necessary. (if equipped).
TX,05,RB263 1923JAN981/1

061411
PN=350

061411
PN=351
Remove and Install Speed Control LinkageWith Declutch
T112803 UN21JAN98
(S.N. 840461 ) Shown

061411
PN=352
ASpring Pin F Arm KYoke PInjection Pump Yoke

BSpring GShaft L Cap Screw QSpring
CRetainer Ring HSwitch MWasher
DBellcrank with Bushing I Low Idle Stop Screw NRetainer
ESpring Pin J Support Bracket (2 used) OInjection Pump Rod
1. On loaders, raise loader and install boom lock bar. 9. Install switch (H). Connect ground wire to terminal
2. Remove engine left side shield. marked COMMON. Connect wire from harness to
terminal marked N.C. or NORMALLY CLOSED.
3. Remove floor plates.
10. Assemble parts (KQ).
4. Remove parts (AH) and (KP).
11. Adjust speed control linkage and declutch switch
5. Inspect for worn or damaged parts. Replace as setting. (See TM1403, Group 901020.)
necessary.
12. Install floor plates and engine left side shield.
6. Install parts (AD) and (F) on decelerator shaft (G).
13. Remove boom lock bar and lower loader to ground
7. Place shaft assembly in a vice. Rotate bellcrank (D) (if equipped).
putting tension on spring (B). Index arm (F) to align
with hole in shaft (G) and install spring pin (E).
8. Install decelerator shaft assembly using support
brackets (J). Install and tighten cap screws.
TX,05,RB264 1923JAN982/2

061411
PN=353

061411
PN=354
Group 0520
Intake System
Disassemble and Assemble Air Cleaner
T8056AT UN09AUG93
1 Base 5 Seal 9 Wing Nut 13 Air Cleaner Assembly
2 Bowl 6 Clamp 10 Secondary Element
3 Cover 7 Hose 11 Cover
4 Precleaner Assembly 8 Clamp 12 Primary Element
1. Raise loader (if equipped) and install boom lock bar. 8. Assemble parts (912)
2. Remove engine side shields, precleaner (4), seal (5), 9. Install air cleaner assembly using three cap screws.
exhaust pipe and hood. Tighten hose clamp.
3. Loosen hose clamp (6). 10. Install hood, exhaust pipe, seal, precleaner and
4. Remove three cap screws to remove air cleaner engine shields.
assembly (13). 11. Remove boom lock bar and lower loader to ground
5. Disassemble parts (912). (if equipped).
6. Clean or replace filter elements (10 and 12).

7. Test air intake system. (See TM1403 Manual, Group
901025.)
TX,0520,BA884 1918AUG931/1

061411
PN=355
Intake System

061411
PN=356
Group 0560
External Fuel Supply System
Specifications
Fuel Tank (Empty) Weight 80 kg (175 lb) (Approximately)

Rear Fuel Tank BrackettoFuel Torque 320 Nm (236 lbft)
Tank Cap Screws and Nuts
TX,05,RB414 1909FEB981/1
Remove and Install Fuel Tank

1. Remove cap screw (C).
2. Remove four cap screws to remove cover (B).
3. Remove two transmission control consoletofuel tank
cap screws (A).
T8056AU UN29JUL93
Continued on next page TX,0560,BA885 1918AUG931/5

061411
PN=357
4. Remove left armrest (A) and handrail (C).

5. Lift up on and move console (E) away from fuel tank
without disconnecting linkage.
6. Remove cap screw (D) to remove speed control cable
clamp from fuel tank.
7. Disconnect fuel return hose (B) (later machines only).
ALeft Armrest DCap Screw

BFuel Return Hose ETransmission Control
CLeft Handrail Console
T8056AV UN29JUL93

061411
PN=358
8. Open petcock (A) (later machines) or turn valve lever

(A) (early machines) to drain fuel tank.
9. Disconnect fuel return hose (C) (earlier machines
only). Use caps and plugs to close openings.
10. Disconnect fuel supply hose at valve (B). Use a cap
T6683AA UN20OCT88
and plug to close openings.
11. Remove three fuel tank front brackettotransmission
housing cap screws (D).
12. Remove two cross member supporttofuel tank front
bracket cap screws (E).
13. Remove two fuel tank rear brackettofuel tank nuts
(F).
CAUTION: Empty fuel tank weighs approximately

80 kg (175 lb). Use a lifting device for
heavy components.
T8056AW UN29JUL93
14. Remove fuel tank.
Specification
Fuel Tank
(Empty)Weight................................................................ 80 kg (175 lb)
15. Inspect and repair as necessary.

16. Install fuel tank. Tighten nuts (F) and cap screws (D
and E). ATank Drain Petcock or Valve DCap Screw (3 used)
Lever ECap Screw (2 used)
Specification BFuel Supply Hose ShutOff F Nut (2 used)
Rear Fuel Tank Valve
BrackettoFuel Tank CFuel Return Hose (Early
Machines)
Cap Screws and
NutsTorque............................................................. 320 Nm (236 lbft)
17. Connect fuel supply hose (B). 19. Connect fuel return hose (C) (early machines).
18. Close petcock (A) (later machines) or turn valve lever
(A) (early machines) to close fuel tank drain opening.

061411
PN=359
20. Connect fuel return hose (B) (later machines only).

21. Install speed control cable clamp to fuel tank using
cap screw (D).
22. Install left armrest (A) and handrail (C).
ALeft Armrest DCap Screw

BFuel Return Hose ETransmission Control
CLeft Handrail Console
T8056AV UN29JUL93
TX,0560,BA885 1918AUG934/5
23. Install transmission control console to fuel tank using

cap screws (A).
24. Install cover (B) using four cap screws.
25. Install cap screw (C).
T8056AU UN29JUL93
TX,0560,BA885 1918AUG935/5

061411
PN=360
Section 06
Torque Converter
Contents
Page

Other Material............................................ 0606001
Specifications ............................................ 0606001
Remove and Install Torque
Converter............................................... 0606002
Group 0651Turbine, Gears and Shaft

Other Material............................................ 0606511
Specifications ............................................ 0606511
Torque Converter Cross Section ............... 0606512
Replace Torque Converter Rear
Seal and Turbine Shaft .......................... 0606514
Disassemble and Assemble Torque
Converter............................................... 0606516
Air Test Torque Converter........................ 06065111
Disassemble and Assemble Torque
Converter Housing............................... 06065112

061411
PN=1
Contents

061411
PN=2
Group 0600
T7522AA UN25APR91

Flywheel Turning Tool..............................................JDE83 Used to turn flywheel when installing torque

converter cap screws.
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Applied to torque converter
pilot sleeve.

TX,0600,BD872 1914JUN111/1
Specifications
Torque Converter Housingto Torque 61 Nm (45 lbft)

Flywheel Housing Cap Screws
Flex PlatetoFlywheel Cap Screws Torque 57 Nm (42 lbft)
TX,0600,BD871 1916SEP931/1

061411
PN=363
Remove and Install Torque Converter

1. Remove engine. (See procedure in Group 0400.)
2. Disconnect engine manifoldtotorque converter
housing hose (A) from torque converter.
3. Remove plate (B) from bottom of flywheel housing.
4. Use JDE83 to turn flywheel while removing 12 flex
platetoflywheel cap screws and washers through
bottom access hole.
IMPORTANT: Torque converter can slide from housing
when housing is removed from engine. Hold
converter in housing or put housing at a slight
angle so converter does not slide out.
T8059FD UN09AUG93
NOTE: There are 12 cap screws that secure torque
converter to flywheel housing. One cap screw
was removed during engine removal.
5. Remove 11 cap screws and washers (C) to remove

torque converter from engine. Remove pilot sleeve.
6. Repair or replace torque converter as necessary. (See
AEngine ManifoldtoTorque CCap Screw and Washer (11
procedure in Group 0651.) Converter Hose used)
BFlywheel Housing Bottom
7. Apply NEVERSEEZ to both ends of pilot sleeve. Access Plate
Install sleeve in flywheel.
8. Remove any wire or string holding torque converter in
housing. Keep torque converter assembly horizontal 11. Use JDE83 Flywheel Turning Tool to rotate flywheel.
while installing on engine. Make sure drive plate is Install all 12 flex platetoflywheel cap screws first,
flat against flywheel. then tighten cap screws.
9. Push torque converter rearward into housing. Torque Specification
converter must move easily. If not, remove torque Flex PlatetoFlywheel
converter assembly and check for cause of binding. Cap ScrewsTorque..................................................... 57 Nm (42 lbft)
10. Install and tighten 11 torque converter 12. Install bottom plate on flywheel housing.
housingtoflywheel housing cap screws.
13. Connect engine manifoldtotorque converter hose.
Specification
Torque Converter 14. Install engine. (See procedure in Group 0400.)
HousingtoFlywheel
Housing Cap
TX,06,RB415 1914JUN111/1

061411
PN=364
Group 0651
Turbine, Gears and Shaft
T8084AC UN23SEP93

Test Plug with Port................................................ JDG835 Used to close opening and provide an inlet
port for pressure testing
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Applied to splines of gears.
T43513 (U.S.) Thread Lock and Sealer (High Applied to torque converter
TY9474 (Canadian) Strength) cap screws.
271 (LOCTITE)

TX,0600,BD874 1914JUN111/1
Specifications
Torque Converter
HubtoImpeller Cap Screw Torque 25 Nm (18 lbft)
Flex PlatetoCover Cap Screws Torque 50 Nm (37 lbft)
Idler Shaft/HousingtoManifold Torque 87 Nm (64 lbft)
Cap Screw
Support TubetoManifold Cap Torque 25 Nm (18 lbft)
Screw
Pump AdaptertoHousing Cap Torque 87 Nm (64 lbft)
Screw
CovertoImpeller Screws
450G, 455G, 550G, 555G Torque 57 Nm (42 lbft)
650G Torque 50 Nm (37 lbft)
Drive Shaft
Bearing StraptoYoke Cap Screws Torque 47.5 9 Nm (35 7 lbft)
Turbine Shaft Cap Screw Torque 215 Nm (159 lbft)
TX,0651,BD873 1916SEP931/1

061411
PN=365
Torque Converter Cross Section
T7926AA UN29JAN93
650G Torque Converter Shown

061411
PN=366
1 Cap Screw 14 Oil Seal 27 Turbine Hub 40 Ball Bearing

2 Yoke 15 Cap Screw (7 used) 28 Freewheel (Sprag) Clutch 41 Snap Ring
3 Washer 16 Impeller Hub 29 Inner Race 42 Spacer
4 Oil Seal 17 Impeller 30 Thrust Bearing and Races (2 43 Pump Drive Gear
5 Snap Ring 18 Stator used) 44 Hydraulic Pump Adapter
6 Ball Bearing 19 Turbine 31 Seal Ring 45 Cap Screw (4 used)
7 Check Valve 20 Cap Screw (24 used) 32 Cap Screw and Washer (12 46 Ball Bearing and Snap Ring
8 Stator Support Tube 21 Flex Plate Adapter used) 47 Ball Bearing and Snap Ring
9 Housing 22 Cover 33 Retainer (2 used) (2 used)
10 Seal Ring 23 Cap Screw (12 used) 34 Outer Race 48 Idler Shaft (2 used)
11 Thrust Bearing and Race 24 Ring 35 Snap Ring (2 used) 49 Idler Gear (2 used)
12 Accessary Drive Gear 25 Turbine Shaft 36 Pilot Sleeve 50 Cap Screw (7 used)
13 Ball Bearing 26 Ball Bearing 37 Cap Screw and Washer (12 51 Lubrication Orifice
used) 52 Manifold
38 Cap Screw (3/8 x 11/4
in.) and Washer (11 used),
Cap Screw (3/8 x 11/2 in.),
Washer and Clamp (1 used)
39 Cap Screw (7 used)
NOTE: Orings and seals are shown in black. The cross section shown is for 650G. The 450G, 455G,
550G and 555G are similar with the following exceptions:
Differences 650G All Other Units
Torque Converter Size 330.2 mm (13 in.) 298.5 mm (11.75 in.)
Torque Converter CovertoImpeller Hardware Cap screw (20)24 used. Cap screw, two washers and nut20 sets used
Impeller Hub Flange outside and 12 cap screws and washers Flange inside and 8 cap screws and washers
(32) installed from inside torque converter installed from outside torque converter impeller.
impeller (17).
Turbine Shaft Front Bearing Ball bearing (26). Needle bearing and thrust bearing with races.
Flex PlatetoCover Spacer Ring Not used. Installed between cover and flex plate.
TX,0651,BD802 1920AUG932/2

061411
PN=367
Replace Torque Converter Rear Seal and

Turbine Shaft
NOTE: Rear oil seal and turbine shaft can be removed
with torque converter in the machine.
Torque converter shown removed for clarity
T7935AD UN29JAN93
of photograph.
To replace the rear oil seal (D), ball bearing (E), turbine
shaft (G) and seal ring with torque converter in the
machine:
1. Disconnect drive shaft.
2. Remove cap screw (A) to remove yoke (C), washer
(B), and Oring.
3. Remove oil seal.
4. Remove snap ring (F).
T7935AB UN29JAN93
5. Remove turbine shaft and ball bearing.
6. Replace parts as necessary.
7. Use a piece of pipe to install rear seal. Install seal
with seal lip (spring side) towards ball bearing until
even with housing.
8. Tighten cap screw (A).
Drive ShaftSpecification ACap Screw EBall Bearing
Turbine Shaft Cap BWasher F Snap Ring
CYoke GTurbine Shaft
ScrewTorque........................................................... 215 Nm (159 lbft) DOil Seal
9. Tighten drive shaft bearing straptoyoke cap screws.
Drive ShaftSpecification
Bearing StraptoYoke
Cap ScrewsTorque...................................... 47.5 9 Nm (35 7 lbft)
TX,0651,BD801 1916SEP931/1

061411
PN=368

061411
PN=369
Disassemble and Assemble Torque Converter
T112858 1910FEB98

061411
PN=370
1 Cap Screw (12 used) 8 ORing 15 Thrust Bearing (2 used) 22 Impeller Hub
2 Ring 9 Needle Bearing 16 Snap Ring (2 used) 23 ORing
3 Flex Plate 10 Bearing Race (2 used) 17 Retainer (2 used) 24 Impeller
4 Spacer Ring 11 Thrust Bearing 18 Stator 25 Seal Ring
5 Nut (20 used) 12 Turbine Hub 19 Outer Clutch Race 26 Washer (8 used)
6 Washer (40 used) 13 Turbine 20 Freewheel (Sprag) Clutch Washer650G (12 used)
7 Cover 14 Bearing Race (4 used) 21 Inner Clutch Race 27 Cap Screw (8 used), Cap
Screw650G (12 used)
28 Socket Head Screw (20
used) Cap Screw650G (24
used)
NOTE: Procedures shown 450G, 455G, 550G, and 555G 3. Remove cap screws (650G) or socket head screws,
torque converter. 650G torque converter is similar. washers and nuts (450G, 455G, 550G) to remove
torque converter cover and Oring.
1. Slide torque converter from housing.
4. Remove remaining parts as necessary.
2. Remove cap screws to remove ring, flex plate and
spacer ring (if equipped).
TX,06,RB265 1923JAN982/6
5. Remove snap ring to remove freewheel clutch (D),

races (B and C) and retainers (E) as an assembly
from stator (A).
Remove retainers to inspect parts (BD).
6. Install freewheel clutch assembly. Make sure the
T7935AC UN29JAN93
flange side (F) of clutch cage is on the same side as
the thicker end of the stator blades.
7. Install retainers and snap rings, making sure ring is
fully in groove.
AStator DFreewheel Clutch

BOuter Race ERetainer (2 used)
CInner Race F Flange Side
T7943AB UN10FEB93
T7934BL UN13SEP93

061411
PN=371
8. Check clutch operation:

a. Install stator (A) with clutch (C) assembly on
support tube (B) with thicker end of the stator blades
away from housing.
b. Looking at thick stator blade end (engine side of
torque converter), turn stator:
Stator MUST freewheel (turn) in clockwise
direction.
Stator MUST lockup (not turn) in counter
clockwise direction.
Remove stator and clutch assembly.
c. If stator does not turn properly, assemble freewheel
clutch again, repeating Steps 6 and 7 or replace
freewheel clutch.
T7935AE UN29JAN93

061411
PN=372
T112858 1910FEB98

061411
PN=373
1 Cap Screw (12 used) 8 ORing 15 Thrust Bearing (2 used) 22 Impeller Hub
2 Ring 9 Needle Bearing 16 Snap Ring (2 used) 23 ORing
3 Flex Plate 10 Bearing Race (2 used) 17 Retainer (2 used) 24 Impeller
4 Spacer Ring 11 Thrust Bearing 18 Stator 25 Seal Ring
5 Nut (20 used) 12 Turbine Hub 19 Outer Clutch Race 26 Washer (8 used)
6 Washer (40 used) 13 Turbine 20 Freewheel (Sprag) Clutch Washer650G (12 used)
7 Cover 14 Bearing Race (4 used) 21 Inner Clutch Race 27 Cap Screw (8 used) Cap
Screw650G (12 used)
28 Socket Head Screw (20
used), Cap Screw650G (24
used)
9. Apply thread lock and sealer (high strength) to threads

CovertoImpeller ScrewsSpecification
of cap screws (27). Install Oring (23), hub (22),
450G, 455G, 550G,
washers (26) and cap screws on impeller (24). Tighten
555GTorque................................................................ 57 Nm (42 lbft)
cap screws to specification.
Torque Converter Specification 12. For 650G machines:
HubtoImpeller Cap a. Install ball bearing in cover until bearing is tight
ScrewTorque............................................................... 25 Nm (18 lbft) against bottom of bore.
10. Install thrust bearings (15) and races (14), stator and b. Install Oring, cover and cap screws. Tighten cap
clutch assembly (1621), turbine hub (12) and turbine screws to specification.
(13).
CovertoImpeller ScrewsSpecification
Be sure stator and clutch assembly is installed with 650GTorque............................................................... 50 Nm (37 lbft)
thick end of stator blades away from impeller.
13. Install seal ring (25) on hub.
11. For 450G, 455G, 550G, 555G and 650G machines:
14. Install spacer ring (450G, 455G, 550G, and 555G
a. Use a disk driver to install needle bearing (9) in only), flex plate (3), ring (2) and cap screws (1).
cover (7) until bearing is 1 mm (0.04 in.) below Tighten cap screws to specification.
cover bore.
Torque Converter Specification
b. Install thrust bearing (11) and races (10), Oring Flex PlatetoCover Cap
(8), cover (7), socket head screws (28), washers ScrewsTorque............................................................. 50 Nm (37 lbft)
(6) and nuts (5). Tighten socket head screws to
specification. 15. Carefully slide torque converter into housing so not to
damage seal or seal ring.
TX,06,RB265 1923JAN986/6

061411
PN=374
Air Test Torque Converter

1. Remove torque converter. (See procedure in Group
0600.)
2. Install JDG835 plug (A) in end of torque converter
shaft.
CAUTION: Be sure specified air pressure is not

exceeded. Serious personal injury could result
from busting excessive pressure.
3. Use an air regulator to limit pressure to 68.95 kPa

(0.68 bar) (10 psi).
Specification
Torque ConverterPres
sure............................................................ 68.95 kPa (0.68 bar) (10 psi)
Connect air regulator and hose (B) to fitting in plug.
4. Put torque converter in water deep enough to
completely cover converter and hose. Check for air
bubbles around torque converter. If any air bubbles
T8084AB UN28SEP93
are seen, repair or replace torque converter.
TX,0651,BD827 1916SEP931/1

061411
PN=375
Disassemble and Assemble Torque Converter Housing
T8054AP UN13SEP93
NOTE: Rear oil seal and turbine shaft can be replaced
without removing torque converter from the
machine. See procedure in this group.
IMPORTANT: Torque converter can slide from housing

when housing is removed from engine. Hold
T8055BB UN29JUL93
converter in housing or put housing at a slight
angle so converter does not slide out.
1. Slide torque converter from housing.

2. Remove cap screw (A) to remove washer (B), Oring
(C) and yoke (D).
3. Remove oil seal (E), snap ring (F) and turbine shaft
(H) with ball bearing (G) and ring seal (I).
4. Remove seven cap screws to remove manifold and
support tube assembly, thrust bearing and race and
accessory drive gear. T8055BC UN29JUL93
ACap Screw F Snap Ring

BWasher GBall Bearing
CORing HTurbine Shaft
DYoke I Ring Seal
EOil Seal

061411
PN=376
T8055AP UN13SEP93
1 Cap Screws (7 used) 9 Ball Bearing (2 used) 17 Pump Drive Gear 25 Manifold
2 Idler Shaft (2 used) 10 Pump Driven Gear (2 used) 18 Thrust Bearing 26 Ball Plug
3 ORing (2 used) 11 Ball Bearing (2 used) 19 Bearing Race 27 Cooler/Switch Tee Fitting
4 Ball Bearing (4 used) 12 Retainer (2 used) 20 Stator Support Tube with ORings
5 Idler Gear (2 used) 13 Snap Ring (2 used) 21 Cap Screw (7 used) 28 Drain Elbow with ORings
6 ORing (2 used) 14 ORing (2 used) 22 ORing 29 Hydraulic Pump Adapter
7 Cotter Pin (2 used) 15 Oil Seal 23 Check Valve with ORings 30 Cap Screw (4 used)
8 Torque Converter Housing 16 Torque Converter Ball 24 Inlet Elbow with ORings 31 Hydraulic Pump Stub Shaft
Bearing 32 ORing
5. Remove seven cap screws (1) to remove manifold and 6. Remove seven cap screws (21) to remove support
support tube assembly (2027), thrust bearing (18), tube (20) from manifold (25).
race (19) and pump drive gear (17).

061411
PN=377
7. Install cap screw or slide hammer in tapped hole of 16. Apply petroleum jelly to Orings. Install ball bearings,
idler shafts (2). Remove shaft and Orings (3 and 6) to idler gear, idler shaft and Orings. Make sure shaft
remove idler gear (5) and ball bearings (4). throughhole aligns with tapped hole in housing.
8. Remove four cap screws (30) to remove pump adapter 17. Install support tube on manifold using seven cap
(29) and Orings (14 and 32). screws. Tighten cap screws (21) to specification.
9. Remove snap ring (13) to remove retainer (12), ball Torque Converter Specification
bearings (9 and 11) and pump driven gear (10). Support TubetoManifold
10. Remove torque converter ball bearing (16) and oil
seal (15). 18. Install pump drive gear, thrust bearing and race
manifold and support tube assembly and seven cap
11. Repair or replace parts as necessary. screws. Tighten cap screws (1) to specification.
12. Install torque converter ball bearing to bottom of bore. Torque Converter Specification
Idler Shaft/Housing
13. Install seal with seal lip (spring side) toward bearing. toManifold Cap
Push seal into bore until even with housing. ScrewTorque............................................................... 87 Nm (64 lbft)
14. Install ball bearings, pump driven gears, retainers and
snap rings. Apply NEVERSEEZ to splines of driven
gears. 19. Install ball bearing (G) and ring seal (I) on turbine
shaft (H). Make sure bearing is tight against shoulder
15. Install Oring, pump adapter and four cap screws. of shaft.
Tighten cap screws (30) to specification.
Torque Converter Specification
Pump Adapter
toHousing Cap

061411
PN=378
T8054AP UN13SEP93
20. Install turbine shaft and snap ring (F).
21. Use a piece of pipe to install oil seal (E). Install seal
with seal lip (spring side) towards ball bearing. Push
seal into bore until even with top of bore.
22. Install yoke (D), Oring (C), washer (B), and cap screw
T8055BC UN29JUL93
(A). Tighten cap screw.
Drive ShaftSpecification
Turbine Shaft Cap
23. Carefully install torque converter assembly in housing.
ACap Screw F Snap Ring

BWasher GBall Bearing
CORing HTurbine Shaft
DYoke I Ring Seal
EOil Seal
T8055BB UN29JUL93
TX,0651,BD790 1914JUN114/4

061411
PN=379

061411
PN=380
Section 07
Dampener Drive
Contents
Page

Other Material............................................ 0707001
Specifications ............................................ 0707001
Remove and Install Dampener
DriveDirect Drive Machines
Only ....................................................... 0707002

061411
PN=1
Contents

061411
PN=2
Group 0700
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Lubricant Applied to splines to pump shaft.
T43512 (U.S.) Thread Lock and Sealer (Medium Applied to threads of dampener
TY9473 (Canadian) Strength) toflywheel cap screws and drive
242 (LOCTITE) shaft cap screws.

TX,0700,BD760 1914JUN111/1
Specifications
DampenertoFlywheel Cap Screws Torque 61 Nm (45 lbft)

PumptoFlywheel Cover Cap Torque 149 Nm (110 lbft)
Screws
Drive Shaft Cap Screws Torque 47 Nm (35 lbft)
TX,0700,BD868 1920AUG931/1

061411
PN=383
Remove and Install Dampener DriveDirect

Drive Machines Only
1. Remove hydraulic pump and drive shaft. (See
procedure in Group 2160.)
2. Remove cap screws (F) to remove flywheel cover (A).
3. Remove cap screws (C) to remove dampener drive
(D) from flywheel (B).
4. Inspect dampener drive for wear or damage. Replace
if necessary.
5. Install dampener (D) with protruding hub away from
flywheel.
Apply thread lock and sealer (medium strength) to cap
screws (C). Install and tighten cap screws.
Specification
DampenertoFlywheel
NOTE: Longer cap screws are used for battery
T6681AA UN07NOV88
cable and strap connections.
6. Install flywheel cover and cap screws.

7. Apply NEVERSEEZ Lubricant to both pump shafts.
8. Install pump and cap screws (E). Tighten cap screws.
(Refer to Group 2160.)
Specification
AFlywheel Cover DDampener Drive
PumptoFlywheel Cover BFlywheel EPumptoFlywheel Cover
Cap ScrewsTorque..................................................149 Nm (110 lbft) CDampenertoFlywheel Cap Cap Screws (4 used)
Screws (8 used) F Flywheel CovertoFlywheel
9. Install drive shaft. Apply thread lock and sealer to Housing Cap Screws (12
threads of cap screws and tighten. used)
Specification
Drive Shaft Cap
(Refer to Group 2160.)
TX,0700,BD761 1914JUN111/1

061411
PN=384
Section 09
Steering Systems
Contents
Page
Group 0920Power Steering Linkage

Specifications ............................................ 0909201
Remove and Install Steering
LinkagePedal Steer............................ 0909202
Adjust StopsPedal Steer ........................ 0909204
Adjust LinkagePedal Steer..................... 0909205
Remove and Install Steering
LinkageLever Steer............................ 0909206
Adjust StopsLever Steer (S.N.
770807)............................................ 09092012
Adjust StopsLever Steer (S.N.
770808 )........................................... 09092013
Adjust LinkageLever Steer................... 09092014

Hydraulic System....................................... 0909601

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PN=1
Contents

061411
PN=2
Group 0920
Power Steering Linkage
Specifications
Pedal Steer Linkage
Pedal Stop Jam Nut Torque 12.2 Nm (108 lbin.)
Upper Brake Rod Jam Nuts Torque 30.5 Nm (22.5 lbft)
Lower Brake Rod Jam Nuts Torque 13.6 Nm (120 lbin.)
Lower Brake RodtoRear Bellcrank Torque 30 Nm (22 lbft)
Cap Screw
Lever Steer Linkage
Brake Pedal Stop Jam Nut Torque 12.2 Nm (108 lbin.)
Upper Brake Rod Jam Nuts Torque 30.5 Nm (22.5 lbft)
Front Lower Brake Rod Yoke Jam Torque 30.5 Nm (22.5 lbft)
Nuts
Rear Lower Brake Rod Yoke Jam Torque 13.6 Nm (120 lbin.)
Nuts
Rear Brake RodtoBellcrank Cap Torque 30 Nm (22 lbft)
Screw
Steering Lever Stop Jam Nuts Torque 24.4 Nm (18 lbft)
Steering RodtoSteering Hub Cap Torque 6.8 Nm (60 lbin.)
Screw and Nut
Front and Rear Brake Torque 13.6 Nm (120 lbin.)
RodstoFloating Lever Cap
Screw and Nut
TX,0920,BD774 1920AUG931/1

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PN=387
Remove and Install Steering LinkagePedal Steer
T8043AQ UN15JUL93
1 Support 9 Vertical Tie Rod Assembly (2 17 Tie Rod End (2 used) 25 Spring (2 used)
2 Seal (8 used) used) 18 Rear Bellcrank (2 used, right 26 Lower Support (2 used)
3 Needle Bearing (8 used) 10 Cotter Pin (6 used) shown) 27 Lower Bellcrank (2 used)
4 Right Steering Pedal 11 Jam Nut (4 used) 19 Key (2 used) 28 Yoke (2 used)
5 Snap Ring (4 used) 12 Stop Cap Screw (2 used) 20 Lock Washer 29 Washer (4 used)
6 Washer (as required) 13 Left Steering Pedal 21 Cap Screw (2 used) 30 Cap Screw (10 used)
7 Pin (4 used) 14 Cap Screw (2 used) 22 Horizontal Tie Rod (2 used) 31 Washer (10 used)
8 Washer (8 used) 15 Washer (2 used) 23 RightHand Thread Nut (2 32 Stop Cap Screw (2 used)
16 LeftHand Thread Nut (2 used)
used) 24 Pin (2 used)
1. Remove floor plates and fenders under reservoir and if any adjustments are necessary, they can
fuel tank. be made equally on each side.
2. Repair or replace parts as necessary. NOTE: Horizontal tie rod (22) has righthand and
3. Install needle bearings (3) until even with bottom of lefthand threads. The lefthand thread engages
counterbore in pedals (4 and 13) and lower bellcranks the rear tie rod end (17).
(27). Apply multipurpose grease to bearings.
5. When rods (9 and 22) are assembled, install tie rod
4. Install washers (6) as necessary to provide a minimum ends and yokes onto rods six turns. This will keep the
clearance between pedals. There must be no pedal right and left rods at equal lengths.
interference when pedals are moved individually.
6. Connect spring (25) to bellcrank and rear most hole
Also use washers to align bellcranks with pedals. in floor support.
IMPORTANT: Right and left paired rods MUST be
assembled to the same length initially so

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PN=388
Stop Jam Nuts

CAUTION: Machine can lose steering and brake (11)Torque............................................................ 12.2 Nm (108 lbin.)
control if linkage is not adjusted before machine Tie Rod Jam Nuts (16
is operated. For complete steering/brake and 23)Torque...................................................... 13.6 Nm (120 lbin.)
adjustment, see TM1403, Section 9020. Cap Screw
(21)Torque.................................................................. 30 Nm (22 lbft)
7. Adjust stops and linkage. (See procedures in this
9. Install fenders and floor plates.
group.)
8. Tighten hardware to specification after adjustment:
Specification
Tie Rod (9) Jam
NutsTorque........................................................... 30.5 Nm (22.5 lbft)
TX,0920,BD762 1920AUG932/2

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PN=389
Adjust StopsPedal Steer
T7247AJ UN09APR90
AUpper Pedal Stop DUpper Rod GLockout (Tow) Pins J Stop Screw
CSteering Pedals F Horizontal Brake Rod I Brake Adjusting Nut L Return Spring
NOTE: For complete steering adjustment, see procedures

in TM1403, Section 9020, Group 20. 3. Adjust lower pedal stops (B) until bottom edge of pedal
is 197 3 mm (73/4 1/8 in.) from firewall.
1. Remove pin from right and left lower bellcranks (E). Specification
Firewall to Bottom Edge
2. Adjust upper pedal stop (A) of one pedal until distance of PedalDistance....................................... 197 3 mm (73/4 1/8 in.)
from firewall to bottom edge of steering pedal pad (C)
is 362 3 mm (141/4 1/8 in.). 4. Adjust length of upper rods (D) so bottom holes of
Specification
bellcranks (E) are 91 2 mm (39/16 1/16 in.) from
Firewall to Bottom
firewall.
Edge of Steering Pedal Specification
PadDistance........................................... 362 3 mm (141/4 1/8 in.) Firewall to Bottom Holes
of BellcranksDistance............................. 91 2 mm (39/16 1/16 in.)
Adjust other pedal upper stop screw until pedals are
even at the center. 5. Install pins in lower bellcranks.
TX,0920,BD763 1931MAR941/1

061411
PN=390
Adjust LinkagePedal Steer
T7247AJ UN09APR90
AUpper Pedal Stop DUpper Rod GTow Disconnect Pins J Stop Screw
CSteering Pedals F Horizontal Brake Rod I Brake Adjusting Nut L Return Spring
NOTE: For complete steering adjustment, see procedures 3. If stop contacts are not sequenced properly, adjust
in TM1403, Section 9020, Group 20. horizontal brake rod (F):
1. Remove plugs (K). Adjust rod (F) so stops are contacted at the same
time.
2. Depress one pedal and observe lower pedal stop (B)
and inside end of stop screw (J). Contact must be
Shorten rod one turn and tighten jam nuts.
made at stop screw (J) before pedal contacts stop (B). 4. Repeat Steps 2 and 3 for opposite side linkage.
TX,0920,BD764 1931MAR941/1

061411
PN=391
Remove and Install Steering LinkageLever Steer
T8043AR UN15JUL93
Brake Linkage
1 Pin (2 used) 15 Pedal Shaft 29 RightHand Thread Nut (2 43 Jam Nut (2 used)
2 Washer (12 used) 16 Key (5 used) used) 44 Spring (2 used)
3 Left Pedal Bellcrank 17 Brake Pedal 30 Tie Rod End (2 used) 45 Bracket (2 used)
4 Seal (4 used) 18 Pedal Rod (2 used) 31 Lock Washer (2 used) 46 Yoke (2 used)
5 Needle Bearing (6 used) 19 Cotter Pin (6 used) 32 Cap Screw (2 used) 47 Washer (4 used)
6 Bracket 20 Cap Screw (10 used) 33 Cotter Pin (2 used) 48 Pin (2 used)
7 Jam Nut 21 Washer (10 used) 34 Pin (2 used) 49 Pedal Return Spring
8 Cap Screw 22 Three Platform Plates 35 Yoke (2 used) 50 Lower Bellcrank (2 used)
9 Seal (4 used) 23 Left Steering Valve Bellcrank 36 Jam Nut (2 used) 51 Snap Ring (2 used)
10 Right Pedal Bellcrank 24 Left Brake Bellcrank 37 Steering Lever Tie Rod (2 52 Washer (as required)
11 Washer (3 used) 25 Right Brake Bellcrank used) 53 Support (2 used)
12 Cap Screw (3 used) 26 Tie Rod End (4 used) 38 Snap Ring (2 used)
13 Jam Nut 27 LeftHand Thread Nut (4 39 Washer (4 used)
14 Cap Screw used) 40 Ball Bearing (2 used)
28 Rear Brake Tie Rod (2 used) 41 Right Steering Valve
Bellcrank
42 Front Brake Tie Rod (2 used)
1. Remove floor plates and fenders under reservoir and 4. Install washers (52) as necessary to provide a
fuel tank. minimum side play between supports (53), lower
2. Repair or replace parts as necessary. bellcranks (50) and snap rings (51). Lower bellcranks
must pivot freely.
3. Install needle bearings (5) until even with bottom of
counterbore in bracket (6) and lower bellcranks (50). Also use washers to align bellcranks with pedal rods
Apply multipurpose grease to bearings. (18).

061411
PN=392
IMPORTANT: Right and left paired rods MUST be unit is operated. For complete steering/brake
assembled to the same length initially so adjustment, see TM1403, Section 9020.
if any adjustments are necessary, they can
be made equally on each side. 7. Adjust stops and linkage. (See procedures in this
group.)
NOTE: Rods (28 and 42) have righthand and 8. Tighten hardware to specification after adjustment:
lefthand threads. The lefthand thread engages
the rear tie rod end (26). Specification
Tie Rod (18) Jam
5. When rods (18, 28, 37 and 42) are assembled, install NutsTorque........................................................... 30.5 Nm (22.5 lbft)
tie rod ends and yokes onto rods six turns. This will Stop Jam Nuts (7 and
keep the right and left rods at equal lengths. 13)Torque............................................................. 12.2 Nm (108 lbin.)
Tie Rod Jam Nuts (27
6. Connect springs (44) to bracket (45) and forward most and 29)Torque...................................................... 13.6 Nm (120 lbin.)
hole in floor support. Cap Screw
(32)Torque.................................................................. 30 Nm (22 lbft)
CAUTION: Machine can lose steering and Tie Rod Jam Nuts
brake control if linkage is not adjusted before (43)Torque............................................................ 30.5 Nm (22.5 lbft)

061411
PN=393
T8043AS UN15JUL93
Lever Linkage (S.N. 770807)

061411
PN=394
1 Left Steer Lever 8 Left Floating Lever 15 Cap Screw (2 used) 22 Lock Washer (4 used)
2 Right Steer Lever 9 Support (2 used) 16 Nut (2 used) 23 Right Floating Lever
3 Snap Ring (2 used) 10 Sleeve (3 used) 17 Right Hub 24 Front Brake Tie Rod (2 used)
4 Lever Shaft 11 Cap Screw (4 used) 18 Nut (2 used) 25 Cap Screw (2 used)
5 Washer (as required) 12 Washer (10 used) 19 Cap Screw (2 used) 26 Rear Brake Tie Rod (2 used)
6 Seal (8 used) 13 Left Hub 20 Steering Lever Tie Rod (2 27 Cap Screw (6 used)
7 Needle Bearing (8 used) 14 Center Support used, right shown)
21 Nut (2 used)
9. For lever linkage of machines (S.N. 770807): Adjust stops and linkage. (See procedures in this
group.)
Repair or replace parts as necessary. Tighten hardware to specification after adjustment:
Install needle bearings (7) until even with bottom of
counterbore in hubs (13 and 17) and floating levers Specification
(8 and 23). Apply multipurpose grease to bearings. Stop Jam Nuts
Install washers (5) as necessary to provide a (16)Torque............................................................... 24.4 Nm (18 lbft)
minimum side play between supports (9 and 14), Tie Rod Cap Screw and
hubs, floating levers and snap rings (3). Hubs and Nut (18)Torque......................................................... 6.8 Nm (60 lbin.)
floating levers must pivot freely. Tie Rod Cap Screw and
Nut (21)Torque..................................................... 13.6 Nm (120 lbin.)
CAUTION: Machine can lose steering and brake

control if linkage is not adjusted before machine
is operated. For complete steering/brake
adjustment, see TM1403, Section 9020.

061411
PN=395
T8043AT UN15JUL93
Lever Linkage (S.N. 770808 )

061411
PN=396
1 Left Steer Lever 8 Left Floating Lever 15 Left Hub 22 Right Floating Lever
2 Right Steer Lever 9 Support (2 used) 16 Right Hub 23 Front Brake Tie Rod (2 used)
3 Snap Ring (2 used) 10 Cap Screw (2 used) 17 Nut (2 used) 24 Cap Screw (2 used)
4 Lever Shaft 11 Jam Nut (2 used) 18 Cap Screw (2 used) 25 Rear Brake Tie Rod (2 used)
5 Washer (as required) 12 Sleeve (3 used) 19 Steering Lever Tie Rod (2 26 Cap Screw (4 used)
6 Seal (8 used) 13 Cap Screw (4 used) used, right shown)
7 Needle Bearing (8 used) 14 Washer (10 used) 20 Nut (2 used)
21 Lock Washer (4 used)
10. For lever linkage of machines (S.N. 770808 ): Adjust stops and linkage. (See procedures in this
group.)
Repair or replace parts as necessary. Tighten hardware to specification after adjustment:
Install needle bearings (7) until even with bottom of
counterbore in hubs (15 and 16) and floating levers Specification
(8 and 22). Apply multipurpose grease to bearings. Stop Jam Nuts
Install washers (5) as necessary to provide a (11)Torque................................................................ 24.4 Nm (18 lbft)
minimum side play between supports (9), hubs, Tie Rod Cap Screw and
floating levers and snap rings (3). Hubs and floating Nut (17)Torque......................................................... 6.8 Nm (60 lbin.)
levers must pivot freely. Tie Rod Cap Screw and
Nut (20)Torque..................................................... 13.6 Nm (120 lbin.)
CAUTION: Machine can lose steering and brake 11. Install fenders and floor plates.
control if linkage is not adjusted before machine
is operated. For complete steering/brake
adjustment, see TM1403, Section 9020.
TX,0920,BD765 1920AUG936/6

061411
PN=397
Adjust StopsLever Steer (S.N. 770807)
T7247AP UN09APR90
ASteering Valve Tie Rod ELower Brake Pedal Stop I Tow Disconnect Pin MAdjuster
BBrake Tie RodRear F Vertical Brake Tie Rod J Tie Rod End NInspection Plug
CLever Stop Screw GLower Bellcrank KRear Brake Lever OStop Screw
DUpper Brake Pedal Stop HBrake Tie RodFront L Steering Valve Bellcrank
1. Remove pin from lower bellcrank (G). Specification

2. Adjust upper brake pedal stop (D) until bottom edge of Center of Bottom Hole
pedal is 362 3 mm (141/4 1/8 in.) from firewall. in Lower Bellcrank
from Firewall when
Specification Pedal is Against Upper
Bottom Edge of Pedal StopDistance.......................................... 91 2 mm (39/16 1/16 in.)
from FirewallDistance............................. 362 3 mm (141/4 1/8 in.)
5. Adjust lever stop screw (C) to stop levers after 241
3. Adjust lower brake pedal stop (E) until bottom edge mm (91/2 in.) of travel, measured at top of handles
of pedal is 197 3 mm (73/4 1/8 in.) from firewall from forward rest position.
when pedal is pushed.
Specification
Specification PedalDistance..........................................................241 mm (91/2 in.)
Bottom Edge of Pedal
from Firewall when Pedal 6. Install pin in lower bellcrank (G).
is PushedDistance.................................... 197 3 mm (73/4 1/8 in.)
4. Adjust length of rod (F) until center of bottom hole in

lower bellcrank (G) is 91 2 mm (39/16 1/16 in.)
from firewall when pedal is against upper stop.
TX,0920,BD771 1931MAR941/1

061411
PN=398
Adjust StopsLever Steer (S.N. 770808 )
T7247AK UN09APR90
ASteering Valve Tie Rod ELower Brake Pedal Stop I Tow Disconnect Pin MAdjuster
CLever Stop Screw GLower Bellcrank KRear Brake Lever OStop Screw
1. Remove pin from lower bellcrank (G).

5. Adjust length of rod (F) until center of bottom hole in
2. Adjust brake pedal upper stop (D) until bottom edge of lower bellcrank (G) is 91 2 mm (39/16 1/16 in.)
pedal is 362 3 mm (141/4 1/8 in.) from firewall. from firewall when pedal is against upper stop.
Specification Specification
Bottom Edge of Pedal Bottom Edge of Pedal
from FirewallDistance............................. 362 3 mm (141/4 1/8 in.) from Firewall when
Pedal is Against Upper
3. Adjust lower brake pedal stop (E) until bottom edge StopDistance............................................ 197 3 mm (73/4 1/8 in.)
of pedal is 197 3 mm (73/4 1/8 in.) from firewall
when pedal is pushed. 6. Adjust lever stop screw (C) to stop levers after 273
mm (103/4 in.) of travel, measured at top of handles
Specification from forward rest position.
Bottom Edge of Pedal
from Firewall when Pedal Specification
is PushedDistance.................................... 197 3 mm (73/4 1/8 in.) PedalDistance........................................................273 mm (103/4 in.)
4. If removed, install center floor plate with rubber 7. Install pin in lower bellcrank (G).
stopblock.
TX,0920,BD772 1931MAR941/1

061411
PN=399
Adjust LinkageLever Steer
T7247AK UN09APR90
ASteering Valve Tie Rod ELower Brake Pedal Stop I Lockout (Tow) Pin MAdjuster
CLever Stop Screw GRear Lower Bellcrank KRear Brake Lever OStop Screw
1. Remove inspection plugs (N). made at stop screw (O) before lever contacts pedal
stop (E).
2. Pull one lever and observe lower lever stop screw (C)
and inside end of stop screw (O). Contact must be 6. If stop contacts are not sequenced properly, adjust
made at stop screw (O) before lever contacts stop front brake tie rod (H):
screw (C).
Adjust tie rod (H) so stops are contacted at the same
3. If stop contacts are not sequenced properly, adjust time.
rear brake tie rod (B): Shorten rod one turn and tighten jam nuts.
Adjust rod (B) so stops are contacted at the same 7. Repeat Steps 5 and 6 for opposite side linkage.
time.
8. Install inspection plugs.
Shorten rod one turn and tighten jam nuts.
4. Repeat Steps 2 and 3 for opposite side linkage.
5. Depress pedal and observe lower brake pedal stop
(E) and inside end of stop screw (O). Contact must be
TX,0920,BD773 1931MAR941/1

061411
PN=400
Group 0960
Hydraulic System
Hydraulic System
See Group 0260.
TX,0920,BD773 1931MAR941/1

061411
PN=401
Hydraulic System

061411
PN=402
Section 16
Electrical System
Contents
Page Page
Group 1671Batteries, Support and Cables Remove and Install Logic Module or
Specifications ............................................ 1616711 Circuit Breaker (S.N. 768318 )
Battery Safety ............................................ 1616711 (Module Package) ................................. 1616762
Check Battery Electrolyte Level Remove and Install Display
and Terminals ........................................ 1616712 Monitor................................................... 1616763
Procedure for Testing Batteries ................. 1616714 Remove and Install Display Monitor
Using Booster Batteries12Volt Lights ..................................................... 1616764
System................................................... 1616715 Remove and Install Switch, Gauge,
Remove and Install Batteries..................... 1616716 Hour Meter or Indicator Light................. 1616764
Group 1672Alternator, Regulator, and Group 1677Motors and Actuators

Charging System Wiring John Deere Engine
John Deere Engine AccessoriesUse CTM11..................... 1616771
AccessoriesUse CTM11..................... 1616721 Remove and Install Starting Motor
Service Equipment and Tools .................... 1616721 (S.N. 742459)..................................... 1616771
Specifications ............................................ 1616721 Remove and Install Starting Motor
Remove and Install Alternator ................... 1616722 (S.N. 742460 ).................................... 1616772
Group 1673Lighting System

Replace Halogen Bulbs ............................. 1616731
Work Light Adjustment .............................. 1616732
Group 1674Wiring Harness and Switches

Specifications ............................................ 1616741
Replace DEUTSCH
Connectors ............................................ 1616742
Install DEUTSCH Contact...................... 1616743
Replace WEATHER
PACKConnector ................................. 1616744
Install WEATHER
PACKContact ..................................... 1616745
Remove Connector Body from
Blade Terminals ..................................... 1616745
Remove and Install Battery
Disconnect Switch ................................. 1616746
Low Pressure, Reverse Warning
Alarm and Neutral Start
Switches ................................................ 1616746
Remove and Install Start Circuit
Relay (S.N. 768317) .......................... 1616747
Remove and Install Start Circuit
Relay (S.N. 768318 ) ......................... 1616747
Remove and Install ReturntoDig
Switch .................................................... 1616748
Remove and Install ReturntoDig
Switch Assembly ................................... 1616749
ReturntoDig Adjustment ........................ 16167410
Group 1676Instruments and Indicators

Remove and Install Logic Module or
Circuit Breaker (S.N. 768317)
(Module Package) ................................. 1616761

061411
PN=1
Contents

061411
PN=2
Group 1671
Batteries, Support and Cables
Specifications
Volts Voltage 12
Cold Cranking Amps at 18 (0F) 625 Amps
Reserve Capacity at 25 Amps and 27C (80F) 160 minutes
SAE Group 9H9A
Fully Charged Electrolyte Specific Gravity 1.2651.280
TX,1671,AA8 1904APR901/1
Battery Safety
Prevent Battery Explosions:
Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
TS204 UN23AUG88
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery it may explode. Warm
battery to 16C (60F).
Specification
BatteryTemperature........................................................... 16C (60F)
Prevent Acid Burns:

Sulfuric acid in battery electrolyte is poisonous. It is strong
enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
To avoid battery related hazards:
1. Fill batteries in a wellventilated area.
2. Wear eye protection and rubber gloves.
3. Do not breath fumes when electrolyte is added.
4. Do not spill or drip electrolyte.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 1015 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
TS203 UN23AUG88
vegetable oil.
TX,16,DY49 1915OCT961/1

061411
PN=405
Check Battery Electrolyte Level and

Terminals
CAUTION: Battery gas can explode. Keep sparks
and flames away from batteries. Use a flashlight
to check battery electrolyte level.
NEVER check battery charge by placing
a metal object across the posts. Use a
voltmeter or hydrometer.
ALWAYS remove grounded () battery clamp
first and replace it last.
Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness
if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a wellventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when
TS203 UN23AUG88
electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
2. Apply baking soda or lime to help
neutralize the acid.
3. Flush your eyes with water for 1530 minutes.
Get medical attention immediately.
IMPORTANT: If water is added to batteries during
If acid is swallowed: freezing weather, batteries must be charged
after water is added to prevent batteries from
1. Do not induce vomiting. freezing. Charge battery using a battery
2. Drink large amounts of water or milk, but charger or by running the engine.
do not exceed 1.9 L (2 quarts).
Specification 1. Remove battery box cover.
Milk or WaterMaximum
Volume.............................................................................1.9 L (2 quarts)
Continued on next page TX,75,DH1574 1928APR931/3

061411
PN=406
2. Fill each cell to within specified range with distilled

water. DO NOT overfill.
CAUTION: Prevent possible injury. ALWAYS

remove grounded () battery clamp first
and replace it last.
T6996DB UN10FEB89
3. Disconnect battery clamps, grounded clamp first.
ABattery Post CElectrolyte Level Range

BFill Tube
T6996DA UN10FEB89
TX,75,DH1574 1928APR932/3
4. Clean battery terminals (A) and clamps with a stiff

brush.
5. Apply lubricating grease (B) around battery terminal
base only.
6. Install and tighten clamps, grounded clamp last.
T6758AA UN21OCT88
TX,75,DH1574 1928APR933/3

061411
PN=407
Procedure for Testing Batteries Record specific gravity reading for each cell.
Visual Check If high and low readings vary LESS than 0.050 and
1. Check for damage such as cracked or broken case average specific gravity is between 1.225 and 1.280,
and electrolyte leakage. battery is fully charged, go to LOAD TEST.
If damage is seen, replace battery. If high and low readings vary LESS than 0.050 and
average specific gravity is LESS than 1.225, charge
2. Check electrolyte level. (See procedure in this group) battery and repeat test. If average specific gravity is still
LESS than 1.225, replace both batteries.
If low, add distilled water to specified level and charge
battery. If high and low readings vary MORE than 0.050, charge
battery and repeat test. If high and low readings still vary
3. Check terminals for corrosion. MORE than 0.050, replace both batteries.
If corroded, clean using a wire brush or battery post Load Test
cleaner such as JT05838 Battery Post/Clamp Cleaner.
Check battery capacity with a load tester such as JT05832
4. Check posts for looseness.
Battery Load Tester. Follow tester manufacturers
If posts are loose, replace battery. instructions for proper load test procedures.
Hydrometer Test If one battery fails load test, replace both batteries.
Check specific gravity with a hydrometer or battery tester

such as JT05460 Coolant/Battery Tester.
TX,16,DY47 1914OCT961/1

061411
PN=408
Using Booster Batteries12Volt System

Before boost starting, machine must be properly shut
down and secured to prevent unexpected machine
movement when engine starts.
CAUTION: An explosive gas is produced while

batteries are in use or being charged. Keep flames
or sparks away from the battery area. Make sure
the batteries are charged in a well ventilated area.
IMPORTANT: The machine electrical system is

a 12volt negative () ground. Use only
12volt booster batteries.
Connect booster battery(s) as shown for your battery

application. Make last connection to frame.
AMachine Battery(s) BBooster Battery(s)
T6508AE1 UN24OCT91
SingleBattery Application
T6713AI1 UN24OCT91
TwoBattery Application
TX,1671,BA909 1910AUG931/1

061411
PN=409
Remove and Install Batteries

1. Tilt seat forward.
2. Turn battery disconnect switch OFF.
3. Disconnect ground cables from negative () post.
4. Disconnect positive (+) cables.
5. Remove hold down clamp and batteries (H).
6. Check cables and clamps for wear or corrosion.
7. Install batteries and tighten hold down clamp.
8. Connect cables to battery positive (+) post.
9. Connect battery ground cables to negative () post.
T6766BG UN18OCT88
TX,1671,AA9 1904APR901/1

061411
PN=410
Group 1672
Alternator, Regulator, and Charging System Wiring
John Deere Engine AccessoriesUse CTM11
For additional engine information, the component
technical manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
M44215 UN07SEP88
TX,901505,QQ994 1910AUG951/1

TX,16,RB402 1914JUN111/2
Belt Tension Gauge Used to measure vbelt tension.

TX,16,RB402 1914JUN112/2
Specifications
Alternator Adjusting Strap Cap Screw Torque 27 Nm (20 lbft)

Alternator VBelt Tension 13 mm (0.50 in.) deflection with 45N
(10 lb) force applied halfway between
alternator and crankshaft pulleys
TX,16,RB420 1910FEB981/1

061411
PN=411
Remove and Install Alternator

IMPORTANT: Turn battery disconnect switch to
OFF (if equipped) or disconnect battery
ground () cable to prevent accidental
grounding of alternator leads.

2. Turn battery disconnect switch to OFF or disconnect
battery ground () cable.
3. Remove engine right side shield.
4. Tag and disconnect wire leads to alternator.
Release belt tension using tensioner.
6. Remove cap screw (A) and washer.
Remove nut (B) to move alternator toward water
T8059BK UN16AUG93
pump.
Remove fan belt from alternator.
Remove washer and cap screw to remove alternator
and guard (C).
Remove nut (B), cap screw and washer to remove (S.N. 840460)
alternator.
Loosely install alternator and guard (C) using nut (B)
with washer and cap screw. Head of cap screw must
be on side of bracket toward fan belt.
Install fan belts.
Adjust belt tension. Use belt tension gauge applied
halfway between alternator and crankshaft pulleys.
Belt deflection should be 13 mm at 45 N force (1/2
in. at 10 lb force).
Specification
Alternator
VBeltTension........................ 13 mm (0.50 in.) deflection with 45N (10
lb) force applied halfway between alternator
T113143 UN30JAN98
and crankshaft pulleys
Tighten alternator adjusting cap screw.

Specification
Alternator Adjusting Strap
10. On machines (S.N. 840461 ): (S.N. 840461 )
Install alternator using cap screw (A) and nut (B)

with washer and cap screw. Head of cap screw must Install fan belt.
be on side of bracket toward fan belt.

061411
PN=412
12. Install engine right side shield.

13. Turn battery disconnect switch to ON or connect
14. Remove boom lock bar and lower loader (if equipped).
T8059BL UN16AUG93
65Amp Alternator (S.N. 768317)
T8059BM UN16AUG93

T8059BN UN16AUG93

061411
PN=413
TX,1672,BA890 1910AUG933/3

061411
PN=414
Group 1673
Lighting System
Replace Halogen Bulbs
IMPORTANT: To get the correct lighting pattern,
lens must be installed so the word TOP is
on top when the lamp is installed in machine.
Bezel must be installed so wider section is
T5894AG1 UN17APR89
on top when lamp is installed.
1. Before disassembling, take notice of how bezel and

lens are installed with respect to mounting stud.
2. Remove four screws to remove bezel and lens.
1673,AA1 1902AUG901/2
3. Disconnect wiring lead and release retainer clip to

remove bulb (D). To disconnect ground wiring lead,
push tab up then pull connector from terminal.
IMPORTANT: Do not touch the halogen bulb with bare
hands. Oil and moisture may cause premature
T5894AI1 UN20OCT88
bulb failure. If bulb glass is touched, clean
using a soft, oilfree cloth and alcohol.
4. Install new bulb so square notch is aligned with square

tab on reflector back.
5. Install retainer clip into locking tabs on reflector back.
6. Connect wiring leads. Check that wiring leads are
free of clip.
7. Install the gasket (E) into housing (C).
8. Install lens (F) into housing so the word TOP is on
top when lamp is installed on machine. Check that
T6249AU UN19OCT88
wiring leads are not crimped.
9. Install bezel (G) so wider section is on top. Sealing
flange must be inside housing on all four sides before
tightening screws.
10. Tighten screws (H) alternately. Do not overtighten as
screws may strip out plastic.
ANut EGasket
BWasher F Lens
CHousing GBezel
DBulb HScrew (4 used)
1673,AA1 1902AUG902/2

061411
PN=415
Lighting System
Work Light Adjustment

1. Loosen nut and adjust work light to desired position.
IMPORTANT: Mounting isolators will become
ridged when cap screw is over tightened.
Vibrations will pass through isolators, causing
T6287AP UN20OCT88
premature failure of halogen bulbs.
2. Tighten cap screw just enough to keep work light from

moving.
1673,AA3 1904APR901/1

061411
PN=416
Group 1674
Wiring Harness and Switches
RW18164 UN20APR90

Extraction Tool ...................................................... JDG364

Used to remove contacts from electrical connectors.
T6514ET UN23AUG88
Remove contacts from electrical connectors.
Crimping Pliers .................................................... JDG144
Used to crimp open barrel connectors to wire.
Crimp open barrel connectors to wire.
Electrical Repair Tool Kit DEUTSCH ................ JDG359 T6606AB UN23AUG88
Used to remove and install DEUTSCH

electrical connectors.
Used to remove and install DEUTSCH electrical
connectors.
DEUTSCH is a trademark of Deutsch Co.

Specifications
Neutral Start Switch Torque 40 Nm (30 lbft)

Low Pressure and Neutral Start Torque 40 Nm (30 lbft)
Reverse Warning Alarm Switch
Start Relay Terminal Screws Torque 2 Nm (18 lbin.)
ReturntoDig Switch Cylinder Straps Torque 17 Nm (12.5 lbft)
ReturntoDig Magnet Support to Torque 73 Nm (54 lbft)
Cylinder Head Cap Screws
1674,BB25 1904APR901/1

061411
PN=417
Replace DEUTSCH Connectors

1. Select correct size extractor tool for size of wire to be
removed:
JDG361 Extractor Tool for 12 to 14 gauge wire.
JDG362 Extractor Tool for 16 to 18 gauge wire.
TS0124 UN23AUG88
JDG363 Extractor Tool for 20 gauge wire.
2. Start correct size extractor tool over wire at handle (A).
3. Slide extractor tool rearward along wire until tool tip
snaps onto wire.
IMPORTANT: Do NOT twist tool when inserting
in connector.
4. Slide extractor tool along wire into connector body

until it is positioned over terminal contact.
5. Pull wire out of connector body, using extractor tool.
TS120 UN23AUG88
DEUTSCH is a trademark of the Deutsch Co.
DX,ECONN,J 1903NOV941/2
IMPORTANT: Install contact in proper location

using correct size grommet.
6. Push contact straight into connector body until positive

stop is felt.
7. Pull on wire slightly to be certain contact is locked in
TS122 UN23AUG88
place.
8. Transfer remaining wires to correct terminal in new
connector.
DX,ECONN,J 1903NOV942/2

061411
PN=418
Install DEUTSCH Contact

1. Strip 6 mm (1/4 in.) insulation from wire.
2. Adjust selector (A) on JDG360 Crimper for correct
wire size.
3. Loosen lock nut (B) and turn adjusting screw (C) in
TS117 UN23AUG88
until it stops.
DEUTSCH is a trademark of the Deutsch Co.

DX,ECONN,W 1904JUN901/4
IMPORTANT: Select proper size contact "sleeve"

or "pin" to fit connector body.
4. Insert contact (A) and turn adjusting screw (D) until

contact is flush with cover (B).
5. Tighten lock nut (C).
TS0134 UN23AUG88
IMPORTANT: Contact must remain centered between

indentors while crimping.
6. Insert wire in contact and crimp until handle touches

stop.
7. Release handle and remove contact.
TS118 UN23AUG88
Continued on next page DX,ECONN,W 1904JUN903/4

061411
PN=419
IMPORTANT: If all wire strands are not crimped into

contact, cut off wire at contact and repeat
contact installation procedures.
NOTE: Readjust crimping tool for each crimp

ing procedure.
TS0135 UN23AUG88
8. Inspect contact to be certain all wires are in crimped
barrel.
Replace WEATHER PACKConnector

IMPORTANT: Identify wire color locations with
connector terminal letters.
1. Open connector body.
TS0128 UN23AUG88
2. Insert JDG364 Extraction Tool over terminal contact in
connector body.
3. Hold extractor tool fully seated and pull wire from
connector body.
NOTE: If terminal cannot be removed, insert wire
or nail through extractor tool handle and push
terminal contact from connector.
WEATHER PACK is a trademark of Packard Electric.
DX,ECONN,O 1903NOV941/2
IMPORTANT: Carefully spread contact lances to

assure good seating on connector body.
NOTE: Connector bodies are "keyed" for proper contact

mating. Be sure contacts are in proper alignment.
4. Push contact into new connector body until fully TS0130 UN23AUG88
seated.
5. Pull on wire slightly to be certain contact is locked in
place.
6. Transfer remaining wires to correct terminal in new
connector.
7. Close connector body.
DX,ECONN,O 1903NOV942/2

061411
PN=420
Install WEATHER PACKContact

NOTE: Cable seals are color coded for three sizes of wire:
Green 18 to 20 gauge wire
Gray 14 to 16 gauge wire
Blue 10 to 12 gauge wire
TS0136 UN23AUG88
1. Slip correct size cable seal on wire.
2. Strip insulation from wire to expose 6 mm (1/4 in.) and
align cable seal with edge of insulation.
NOTE: Contacts have numbered identification for two
sizes of wire: a) #15 for 14 to 16 gauge wire
b) #19 for 18 to 20 gauge wire
3. Put proper size contact on wire and crimp in place with

a "W" type crimp, using JDG783 Terminal Applicator.
TS1623 UN02NOV94
WEATHER PACK is a trademark of Packard Electric.
DX,ECONN,AA 1904JUN901/2
IMPORTANT: Proper contact installation for "sleeve"

(A) and "pin (B) is shown.
4. Secure cable seal to contact as shown, using JDG783

Terminal Applicator.
TS0139 UN02DEC88
DX,ECONN,AA 1904JUN902/2
Remove Connector Body from Blade

Terminals
1. Depress locking tang (A) on terminal, using a small
screw driver. Slide connector body off.
2. Be sure to bend locking tang back to its original
RW4218 UN23AUG88
position (B) before installing connector body.
DX,ECONN,V1 1902NOV941/1

061411
PN=421
Remove and Install Battery Disconnect

Switch
Tilt seat forward.
IMPORTANT: Disconnect battery ground straps to
prevent accidental ground of battery cable.
T6563AE UN19OCT88
AScrew EMounting Nut
BSwitch Lever F Switch
CMounting Nut GBattery Cable Terminal
DLock Washer HStarter Cable Terminal
1674,AA22 1904APR901/1
Remove and Install Transmission Low

Pressure, Reverse Warning Alarm and
Neutral Start Switches
1. Remove and install transmission dipstick to relieve
back pressure.
T6809AA UN07OCT93
2. Remove panel at rear of unit.
3. Remove transmission low pressure switch (A), reverse
warning alarm switch (B) and neutral start switch (C).
4. Inspect parts for wear and damage.
5. Install switches (AC). Tighten switches.
Specification
Low Pressure, Reverse
Warning Alarm
and Neutral Start
SwitchesTorque.......................................................... 40 Nm (30 lbft)
TX,1674,QQ479 1911OCT931/1

061411
PN=422
Remove and Install Start Circuit Relay (S.N.

768317)
1. Turn battery disconnect switch to OFF position.
2. Replace relay (A). Tighten terminal screws (B).
T6552AA UN19OCT88
Specification
Start Circuit
Relay Terminal
ScrewsTorque............................................................. 2 Nm (18 lbin.)
START CIRCUIT RELAY CONNECTIONS
Terminal Wire No. Color
30 B02B Red
85 G01B Black
86 E02 White
87 E04 White
T6567AA UN07OCT93
TX,1674,BA892 1910AUG931/1
Remove and Install Start Circuit Relay (S.N.

768318 )
2. Turn battery disconnect switch to OFF position or
disconnect ground () cable.
T113146 UN30JAN98
3. Remove engine right side shield.
4. Remove two cap screws (A) to remove relay (B) from
firewall.
5. Disconnect wires (CF).
6. Connect wires. (S.N. 794618 ) Shown
7. Install relay. ACap Screw (2 used) DWire Lead (G01 Black)

BRelay EWire Lead (E02 White)
8. Install engine shield. CWire Lead (E04 White) F Wire Lead (B02 Red)
9. Turn battery disconnect switch to ON position or
connect ground () cable.
10. Remove boom lock bar and lower loader to ground
(if equipped).
TX,16,RB403 1930JAN981/1

061411
PN=423
Remove and Install ReturntoDig Switch

1. Disconnect wiring lead connector at switch (B).
2. Remove cap screws (A).
3. Install switch 9 3 mm (3/8 1/8 in.) (D) from magnet
T6576AF UN20APR89
(C) with indicator light toward the front of machine.
Specification
Switch from
MagnetDistance............................................... 9 3 mm (3/8 1/8 in.)
4. Connect wiring leads.

5. Cycle returntodig. If adjustment is needed, see
procedure in this group.
ACap Screw (2 used) CMagnet
BSwitch D9 3 mm (3/8 1/8 in.)
TX,1674,BB29 1911OCT931/1

061411
PN=424
Remove and Install ReturntoDig Switch

Assembly
1. Remove and replace damaged parts.
2. Install switch bracket (E) parallel with cylinder center
line (F) and 83 mm (3.25 in.) (G) from cylinder barrel
T8080AA UN13SEP93
rod end.
Specification
Cylinder Center Line
From Cylinder Barrel Rod
EndDistance............................................................... 83 mm (3.25 in.)
Tighten strap bolts.
Specification
ReturntoDig Switch
Strap BoltsTorque.................................................... 17 Nm (12.5 lbft)
3. Position switch surface (B) so it is aligned with cylinder

center line (F).
T6475AZ1 UN25MAY89
4. Hand tighten magnet (C) to magnet support bracket
(H). Put cylinder in full rollback position. Attach
magnet support bracket (H) to cylinder rod 6 mm (0.25
in.) (J) from front of cylinder barrel.
5. Pivot magnet support until there is 9 mm (3/8 in.) gap
(D) between returntodig switch (B) and magnet (C).
Tighten cap screws (A).
Specification
ReturntoDig
Switch Assembly
Bracket Mounting
T6575AA1 UN10FEB89
6. Adjust returntodig (see procedure in this group).
ACap Screw (2 used) F Cylinder Center Line

BSwitch G83 mm (3.25 in.)
CMagnet HMagnet Support Bracket
D9 mm (3/8 in.) I Visual Indicator
ESwitch Support Bracket J 6 mm (0.25 in.)
TX,1674,BB30 1931MAR941/1

061411
PN=425
ReturntoDig Adjustment
SPECIFICATIONS
Support to Cylinder Distance 83 mm (3.25 in.)
Boom Height 600 mm (2 ft) off ground
Magnet Support To Cylinder (With 6 mm (0.250 in.)
T8080AA UN13SEP93
Bucket Rolled back) Distance
Magnet Air Gap 9 3 mm (3/8 1/8 in.)
Rear Wear Stips Height 15 mm (9/16 in.) above ground
Indicator to Magnet Air Gap 8 4 mm (0.31 0.16 in.)
T6475AZ1 UN25MAY89
T6575AA1 UN10FEB89
ACap Screw (2 used) F Cylinder Center Line
BSwitch G83 mm (3.25 in.)
CMagnet HMagnet Support Bracket
D9 mm (3/8 in.) I Visual Indicator
ESwitch Support Bracket J 6 mm (0.25 in.)
Support to Cylinder Distance 83 mm (3.25 in.)

1. Raise boom 600 mm (2 ft) off ground and rollback
2. Adjust gap (D) between returntodig switch (B) and
bucket to stop.
magnet (C) to 9 3 mm (3/8 1/8 in.)
Specification
Specification
BoomHeight....................................................600 mm (2 ft) off ground
Magnet AirGap................................................. 9 3 mm (3/8 1/8 in.)
Adjust magnet support (H) to 6 mm (0.25 in.) (J) from
end of cylinder. 3. Start engine, raise boom and dump bucket.
Specification NOTE: Bucket must be dumped once to activate
Magnet Support to returntodig switch.
Cylinder (With Bucket
Rolled back)Distance.................................................. 6 mm (0.250 in.)
Continued on next page TX,1674,BB31 1931MAR941/2

061411
PN=426
4. Move bucket control lever to returntodig position and

For bucket without teeth, move bucket until bottom is
release. Bucket should roll back to approximately level
flat on ground.
position and control lever should return to neutral.
9. Move returntodig magnet to position marked on
5. Lower bucket to the ground.
support (E).
6. Stop engine.
10. Position indicator (I) even with end of magnet support
7. Mark position of rear edge of magnet on support (E) (H). Gap between indicator and support should be 8
just above switch (B). This is position for magnet when 4 mm (0.31 0.16 in.).
bucket is level. Specification
8. For bucket with teeth, move bucket until rear wear Indicator to Magnet
strips are 15 mm (9/16 in.) above ground with teeth AirGap.......................................................... 8 4 mm (0.31 0.16 in.)
on ground. 11. Operate returntodig to check adjustment.
Specification
Rear Wear
StripsHeight.........................................15 mm (9/16 in.) above ground
TX,1674,BB31 1931MAR942/2

061411
PN=427

061411
PN=428
Group 1676
Instruments and Indicators
Remove and Install Logic Module or Circuit
Breaker (S.N. 768317) (Module Package)
1. Remove instrument panel with logic module (A).
2. Disconnect 6wire (B) and 4wire (C) harness
connectors from logic module.
3. Remove two cap screws (D) and logic module.
4. Install screws and logic module, connect harness
connectors to logic module connectors.
5. Remove nuts (E) and nuts holding harness leads to
circuit breaker.
6. Install nuts (E) and nuts to harness leads.
7. Connect harness leads as follows:
Circuit Breaker Terminal Key Wire
Number/Color
T8059BP UN16AUG93
LMain F P00 and P03
RED
(25amp) G B01 RED
MAuxiliary H P01 RED
(15amp) I P02 RED, P10
RED
NLights J L01 BRN
(15amp) K L02 BRN, E05
WHT
ALogic Module F KCircuit Breaker
B6Wire Connector Terminals
C4Wire Connector L Main Circuit Breaker
DCap Screw (2 used) MAuxiliary Circuit Breaker
EHex Nut (3 used) NLight Circuit Breaker
OHour Meter Relay
TX,1676,BA894 1911OCT931/1

061411
PN=429
Remove and Install Logic Module or Circuit

Breaker (S.N. 768318 ) (Module Package)
2. Remove instrument panel.
3. Disconnect 6wire (H) and 4wire (C) harness
connectors from logic module (A).
4. Remove two cap screws and logic module.
5. Install logic module and alternator relay (B) using cap
screws.
6. Connect harness connectors to logic module.
7. Tag and disconnect wire leads from circuit breaker.
8. Remove cap screw to remove circuit breaker.
T8059BQ UN16AUG93
9. Install circuit breaker using cap screw.
10. Connect wire leads as follows:
Key Terminal Wire Nos. (Color)
D BAT L01 (BRN)
AUX (15amp) P10 (RED), L02 (BRN)
F BAT P01 (RED)
AUX (15amp) P02 (RED), E05 (WHT)
G BAT B01 (RED) ALogic Module EHour Meter Relay
BAlternator Relay F Auxiliary Circuit Breaker
AUX (25amp) P00, P03, P03A (ALL RED) C4Wire Connector (15Amp)
DLights Circuit Breaker GMain Circuit Breaker
11. Turn battery disconnect switch to ON or connect (15Amp) (25Amp)
battery ground () cable. H6Wire Connector
TX,1676,BA895 1911OCT931/1

061411
PN=430
Remove and Install Display Monitor

1. Remove instrument panel with display monitor (A).
2. Remove four screws (B) to remove display monitor
from instrument panel.
T8059BR UN16AUG93
3. Tag harness connectors to aid assembly and
disconnect harness from display monitor at connectors
(F and G).
4. Disconnect STOP and CAUTION bulb holders from
monitor.
5. Install bulb holders and connect harness in proper
(S.N. 768318794617) Shown
locations.
Key Wire Number Wire No. (Color) (S.N. 768318 )
(S.N.
768317)
C Z04B, Z05A Z04 (RED), Z05 (RED)
D Z04D, Z05B Z04 (GRY), Z05 (GRY)
T6567AI1 UN19OCT88
E Z04C, Z01 Z01 (YEL), Z04 (YEL)
F Z04A, X01, Z04 (GRY), X01 (YEL), N02 (YEL), R01
N02A, R01, (BLK), Z03 (GRY), Z02 (GRY)
Z03, Z02
G N01, N03, X00, N01 (YEL), N03 (YEL), X00 (YEL), M00B
M00B (PUR)
H N04 N04 YEL
(S.N. 768317) Shown
6. Install instrument panel to machine.
NOTE: On machines (S.N. 794618 ), a fuel gauge is
added to the instrument panel and the location
of the hour meter will vary. Repair of the display
monitor remains the same.
T6196AH1 UN19OCT88
ADisplay Monitor ECAUTION Light Bulb Holder
BMonitortoPanel Screw (4 F Left Connector (6Wire)
used) GCenter Connector (6Wire)
CSTOP Light Bulb Holder HRight Connector (4Wire)
DBuzzer
TX,1676,BA896 1911OCT931/1

061411
PN=431
Remove and Install Display Monitor Lights

1. Remove display monitor (A) from instrument panel.
2. Remove screws (E) holding bulb holder (D) to display
monitor.
T6196AJ UN20OCT88
3. Pull bulbs (C) from holders and replace as required.
4. Install gasket (B) and bulb holder to display monitor.
5. Install display monitor to instrument panel, connect
harness connectors and warning bulbs.
6. Install instrument panel in machine.
ADisplay Monitor DBulb Holder

BGasket EScrews (3 used)
CBulbs (6 used)
TX,1676,AA4 1911OCT931/1
Remove and Install Switch, Gauge, Hour

Meter or Indicator Light
T8059DC UN16AUG93
2. Remove instrument panel.
3. Disconnect wiring and remove component(s) as
required.
4. Install component(s) as required.
5. Connect wiring leads on module package as follows:
MODULE PACKAGE Module Package
Key Termi Wire Number Wire No. (Color)
nal (S.N. 794617) (S.N. 794618 )
AKey Switch CStart Aid Switch
A ACC L01, J00, J01 L01, J00, J01 BHour Meter DLight Switch
BAT P00 P00
IGN P01, E00 P01, P01A, E00
ST E01 (WHITE) E01 (WHITE) NOTE: On machines (S.N. 794618823918), the
G R01, R01A R01, R01A hour meter was moved to the R.H. side
Housing G01, G01A G01, G01A filter access compartment.
B N00, P02, P02A N00, P02
C E05, E03 E05, E03
D L02, L04, L02, L04

061411
PN=432
6. Connect wiring leads on gauge package as follows:

GAUGE PACKAGE
Key Terminal Wire Number
A G01E, G01F, P01B, P01E, X01
B N04, P02D
C N03, P02B
D N01, P02D
E M00A, P02F
F ACC J00, L01
BAT P00
T113147 UN30JAN98
IGN E00, P01, P01A
ST E01
G Not used
Housing G01, G01A
G N00A, P02A
H G01H, P02, P02E, Y00 Gauge Package
I G01G, G01H, P01D, P01G, X00
J E03, E05 AEngine Water Temperature GHour Meter
K G01F, G01G, N02, P01C, P01F Gauge HFuel Gauge
BTransmission Low Oil I Transmission Oil
L L02, L04
Pressure Indicator Temperature Gauge
CTransmission Oil Filter J Start Aid Switch
NOTE: On machines (S.N. 794618823918), the Restriction Indicator KEngine Oil Pressure Gauge
hour meter was moved to the R.H. side DHydraulic Oil Filter L Light Switch
filter access compartment. Restriction Indicator
EEngine Alternator Low
Voltage Indicator
7. Install instrument panel. F Key Switch

TX,1676,BA897 1911OCT932/2

061411
PN=433

061411
PN=434
Group 1677
Motors and Actuators
John Deere Engine AccessoriesUse CTM11
For additional engine information, the component
technical manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
M44215 UN07SEP88
TX,901505,QQ994 1910AUG951/1
Remove and Install Starting Motor (S.N.

742459)
2. Push fuel shutoff valve stem (A) in to shut off fuel flow
T7883AK UN09NOV92
to pump.
TX,1677,BA898 1910AUG931/2
3. Remove parts (AC).
CAUTION: Starting motor weighs approximately

23 kg (50 lb).
4. Remove three cap screws (D) to remove starting
T6569AA UN19OCT88
motor.
Specification
Starting MotorWeight........................................................ 23 kg (50 lb)
5. Install starting motor using cap screws.

6. Connect harness to solenoid.
7. Install parts (AC).
ADipstick Tube CSolenoid Terminals
8. Open fuel shutoff valve. BFuel Pump DCap Screw (3 used)
TX,1677,BA898 1910AUG932/2

061411
PN=435
Motors and Actuators
Remove and Install Starting Motor (S.N.

742460 )
2. Remove nut (A) to disconnect wire leads to large
T8059BS UN16AUG93
terminal on solenoid.
3. Remove screw (B) to remove cover over solenoid
small terminals.
4. Disconnect remaining wire leads to solenoid.
CAUTION: Starting motor weighs approximately (S.N. 742460840460)

23 kg (50 lb).
5. Remove three cap screws (C) to remove starting

motor.
Specification
Starting MotorWeight........................................................ 23 kg (50 lb)
6. Install starting motor using cap screws.

7. Connect small wire leads to solenoid.
T113148 UN09FEB98
8. Install cover and screw.
9. Connect large wire leads to solenoid.
(S.N. 840461 )
TX,1677,BA900 1910AUG931/1

061411
PN=436
Section 17
Frames, Chassis, or Supporting Structure
Contents
Page
Group 1740Frame Installation

Other Material............................................ 1717401
Specifications ............................................ 1717401
Welding Repair of Major
Structures .............................................. 1717401
Remove and Install Transverse
Housing ................................................. 1717402
Group 1749Chassis Weights

Specifications ............................................ 1717491
Remove and Install Sprocket
Counterweight ....................................... 1717491
Remove and Install Rear
Counterweights...................................... 1717492
Remove and Install Front
Counterweight ....................................... 1717493

JT38022 Sprocket Weight Lifting
Tool ........................................................ 1717991

061411
PN=1
Contents

061411
PN=2
Group 1740
Frame Installation
Other Material
Number Name Use
T43514 (U.S.) Plastic Gasket To be applied to threads of main frame
TY9475 (Canadian) to transverse housing cap screws.
277 (LOCTITE)

TX,1740,BD730 1919AUG931/1
Specifications
Main FrametoTransverse Housing Torque 600 Nm (442 lbft)

Cap Screws
TX,DS1837 1902AUG901/1
Welding Repair of Major Structures

IMPORTANT: Disconnect battery ground strap or turn
To repair weld metal failure, remove failed weld metal
battery disconnect switch to OFF to prevent
using arc or grinding equipment.
voltage spikes through alternator or monitor.
Specification
Have only a qualified welder do this job. Tensile StrengthPres
Connect welder ground clamp close to each sure.....................................................................482.6 mPa (70,000 psi)
weld area so electrical current does not Yield StrengthPres
pass through any bearings. sure.....................................................................413.7 mPa (60,000 psi)
Remove or protect all parts that can be ElongationPercent............................................................................ 22
damaged by heat or weld splatter. Thoroughly clean area to be welded. Preheat structural
assemblies to a minimum of 38C (100F).
If machine is equipped with a controller
(microprocessor) like Engine Controller, (EC) or Specification
Pump and Valve Controller (PVC) disconnect Structural
harness connector from controller to prevent AssembliesMinimum
voltage spikes through microprocessor. Temperature........................................................................ 38C (100F)
Connect welder ground clamp close to Preheat ground engaging tools (cutting edges, skid shoes,
each weld area so electrical current does and teeth shanks) to 177C (350F).
not arc inside any bearings. Specification
Ground Engaging
Use one of the following weld processes: ToolsTemperature.......................................................... 177C (350F)
AWSE7018 covered electrode with shielded metal arc To repair base metal failure remove enough material to
welding (SMAW) process allow weld to penetrate to the bottom of crack. Preheat
AWSER70S3 wire electrode with gas metal arc structural assemblies to a minimum of 38C (100F).
welding (GMAW) process Preheat ground engaging tools (cutting edges, skid shoes,
AWSE70T1 or E71T1 wire electrode with flux core and teeth shanks) to 177C (350F).
arc welding (FCAW) process.
Preheat area to be repaired to allow better weld
penetration.
T52,1740,C1 1905FEB941/1

061411
PN=439
Frame Installation
Remove and Install Transverse Housing
T6942AP UN07OCT93
1. Remove ROPS or cab. (See Group 1800.)
6. Remove cap screws (A and B) from both sides of
2. Remove hydraulic reservoir. (See Group 2160.) transverse housing through opening on both sides of
main frame.
3. Remove fuel tank. (See Group 0560.)
7. Install transverse housing using a lifting device.
4. Remove ROPS/cab support. (See Group 1800.)
8. Apply plastic gasket to threads of upper cap screws
CAUTION: The approximate weight of transverse (A). Install and tighten cap screws (A and B).
housing is 454 kg (1000 lb). Specification
Main Frameto
5. Attach lifting device to transverse housing. Transverse Housing
Specification
Transverse
HousingWeight........................................................... 454 kg (1000 lb)
TX,1740,DB729 1911OCT931/1

061411
PN=440
Group 1749
Chassis Weights

TX,1749,BD731 1914JUN111/2
Sprocket Weight Lifting Tool1 ...............................JT38022 Used to remove and install sprocket counterweight.
1
TX,1749,BD731 1914JUN112/2
Specifications
Sprocket Counterweight Cap Screw Torque 576 Nm (425 lbft)

Rear CounterweighttoTransverse Torque 620 Nm (458 lbft)
Case Cap Screw
TX,1749,BD783 1919AUG931/1
Remove and Install Sprocket Counterweight
CAUTION: Sprocket counterweight weighs

Use dealermade sprocket weight lifting tool to remove

and install sprocket counterweight.
Specification
Sprocket
CounterweightWeight................................................... 128 kg (282 lb)
Tighten sprocket counterweight cap screws.
Specification
Sprocket Counterweight
T35235 UN03NOV88
TX,1749,BD784 1914JUN111/1

061411
PN=441
Chassis Weights
Remove and Install Rear Counterweights
CAUTION: Rear counterweight weighs

1. Remove cap screws (A) and install two M20 x 2.5 mm

x 340 mm hex cap screws as guide pins.
2. Remove cap screws (E) and remove counterweight
(C).
Specification
Rear Counter
IMPORTANT: Never reuse rear counterweight

totransverse cap screws.
3. Install counterweight on guide pins.

4. Apply 30W engine oil to new screw threads before
installation.
5. Install new cap screws and washers, and tighten.
T6942AJ UN07OCT93
Specification
Rear Counterweightto
Transverse Case Cap
ACap Screw (6 used) DHitch

BTransverse Housing ECap Screw (4 used)
CCounterweights
1749,VV74 1911OCT931/1

061411
PN=442
Chassis Weights
Remove and Install Front Counterweight
CAUTION: Front counterweight weighs

Remove cap screws (D) to remove counterweight (B).

Specification
Front Counter
AGrille Housing CPullhook

BFront Counterweight DCap Screws (6 used)
T6686AD UN07OCT93
1749,VV75 1919AUG931/1

061411
PN=443
Chassis Weights

061411
PN=444
Group 1799
JT38022 Sprocket Weight Lifting Tool
Sprocket Weight Lifting Tool can be made in dealer shop
to remove and install sprocket weights.
1 69.9 mm (23/4 in.) 5 Taper End

2 38.1 mm (11/2 in.) 6 184.2 mm (71/4 in.)
3 Weld 7 308.4 mm (12 in.)
4 15.9 mm (5/8 in.)
T35238 UN26MAY89
9900,VV75 1921OCT871/1

061411
PN=445

061411
PN=446
Section 18
Operators Station
Contents
Page

Other Material............................................ 1818001
Specifications ............................................ 1818001
Remove and Install RollOver
Protective Structure (ROPS) or
Cab ........................................................ 1818003
Remove and Install ROPS/Cab
Supports ................................................ 1818005
Repair Foam Headliner ............................. 1818006
Group 1821Seat and Seat Belt

NonSuspension Seat............................ 1818211
Disassemble and Assemble Deluxe
Seat (ROPS).......................................... 1818212
Disassemble and Assemble Arm
Rest ....................................................... 1818213
Exploded View of Suspension
Seat ....................................................... 1818214

061411
PN=1
Contents

061411
PN=2
Group 1800
Other Material
Number Name Use
AT63519 (U.S.) Nitritebase rubber adhesive To be applied to headliner.
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to threads of ROPS
TY9473 (Canadian) Strength) support cap screws.
242 (LOCTITE)

TX,1800,BD875 1908SEP931/1
Specifications
ROPS SupporttoTransverse Torque 1070 Nm (790 lbft)

Case Cap Screw
ROPStoROPS Support Cap Screw Torque 407 Nm (300 lbft)
TX,1800,BD876 1908SEP931/1

061411
PN=449

061411
PN=450
Remove and Install RollOver Protective

Structure (ROPS) or Cab
1. For machines with cab, tag, disconnect or remove:
Angle plate (A). (Dozer only.)
Windshield wiper pump hoses and wire harness at
washer pump (if equipped).
Wiring harness at lower front right corner of cab.
Remove cowl and disconnect wire harness
connector.
Heater hoses.
T8070AB UN13SEP93

061411
PN=451
T6657AD UN07OCT93
ALifting Hook DAlarm Harness (Early Models GShim (as required) J Cap Screw (2 used)
BGround Wire only) HIsolator (8 used)
CLight Harness EWasher (8 used) I Nut (4 used)
F Cap Screw (2 used)
2. Disconnect ground wire (B), backup alarm harness 7. Apply a soap and water solution to isolator (H).
(D), and light harness (C).
8. Install rear of ROPS/Cab using parts (EI).
CAUTION: The approximate weight of ROPS is 9. Tighten cap screw (F).
250 kg (550 lb). Cab weight is 545 kg (1200 lb). Specification
ROPStoROPS
3. Attach lifting strap to hooks (A). Support Cap Screw
4. Remove parts (EJ). (Rear)Torque........................................................... 407 Nm (300 lbft)
5. Carefully remove ROPS/Cab using overhead hoist. NOTE: Install shims equally to both sides.
Specification 10. Install parts (E, G, H, I and J) to front of ROPS.
ROPSWeight................................................................ 250 kg (550 lb)
CabWeight.................................................................. 545 kg (1200 lb) 11. Tighten cap screw (J).
6. Inspect ROPS/Cab for structural damage and replace Specification
if necessary. ROPStoROPS
Support Cap Screw
IMPORTANT: Do not use grease or petroleum (Front)Torque.......................................................... 407 Nm (300 lbft)
based lubricants on isolator. It will cause
deterioration of isolator. 12. Connect wire leads (B, C and D).

061411
PN=452
13. For machines with cab, connect or install.

Angle plate (A). (Dozer only.)
Windshield wiper pump hoses and wiring at washer
pump (if equipped).
Wiring harness at lower front right corner of cab.
Reconnect wire harness and install cowl.
Heater hoses.
T8070AB UN13SEP93
TX,1800,BD877 1911OCT933/3
Remove and Install ROPS/Cab Supports

1. Remove ROPS/cab. (See procedure in this group.)
2. Remove rear panel between reservoir and fuel tank.
3. Remove fuel tank. (See procedure in Group 0560).
4. Remove hydraulic reservoir. (See procedure in Group
2160).
CAUTION: The approximate weight of ROPS

Support is 23 kg (50 lb).
5. Remove cap screws (A and B) from both sides.

6. Remove ROPS support using a hoist.
Specification
ROPS Sup
portsWeight....................................................................... 23 kg (50 lb)
7. Inspect ROPS support for structural damage and

replace if necessary.
T6674AD UN07OCT93
8. Install ROPS support.

cap screw threads. Install cap screws (A and B) and
tighten.
Specification
ROPS Supportto
Transverse Case Cap
ScrewTorque......................................................... 1070 Nm (790 lbft)
11. Install ROPS/cab. (See procedure in this group.)
10. Install hydraulic reservoir, fuel tank, and panel.
TX,1800,BD880 1908SEP931/1

061411
PN=453
Repair Foam Headliner

1. Clean mating surface of ROPS/Cab to remove any
oil or dust.
2. Apply AT63519 nitritebase rubber adhesive on the
foam side of the headliner using zig zag pattern shown
in diagram below.
3. Put headliner in place and push softly against the
headliner. Continue pushing the entire bonded area for
a few minutes or until the headliner remains in place.
NOTE: Adhesive becomes more aggressive with up
and down movement of foam.
T8070AE UN13SEP93
TX,1800,BD881 1908SEP931/1

061411
PN=454
Group 1821
Seat and Seat Belt
Disassemble and Assemble NonSuspension
Seat
ASeat HWasher
BBracket I Nut
CRod J Adjuster
DAdjuster KCap Screw
EWasher L Washer
F Washer MAngle
GScrew
T8070AC UN13SEP93
TX,1821,BD882 1908SEP931/1

061411
PN=455
Seat and Seat Belt
Disassemble and Assemble Deluxe Seat (ROPS)
T113198 UN03FEB98
1 Cushion Seat 9 Spacer Bar 17 Spacer (2 used) 25 Flat Washer (4 used)
2 Cushion Back 10 Nut (2 used) 18 Strap (2 used) 26 Cap Screw (2 used)
3 Nut (2 used) 11 Nut (2 used) 19 Bracket (2 used) (Welded 27 Cap Screw (4 used)
4 Tilt Plate (2 used) 12 Spacer (2 used) to Seat Frames on Late 28 Left Seat Frame
5 Washer (2 used) 13 Flat Washer (2 used) Models) 29 Nut (4 used)
6 Cap Screw (2 used) 14 Cap Screw (2 used) 20 Flat Washer 30 Cap
7 Spring (2 used) 15 Nut (2 used) 21 Seat Belt 31 Tilt Latch Weldment
8 Right Seat Frame 16 Flat Washer (4 used) 22 Cap Screw (2 used) 32 Spring (2 used)
1821,QQ1 1902AUG901/1

061411
PN=456
Seat and Seat Belt
Disassemble and Assemble Arm Rest
T6694AC UN19OCT88
1821,QQ2 1902AUG901/1

061411
PN=457
Seat and Seat Belt
Exploded View of Suspension Seat
T113190 UN11FEB98
Continued on next page TX,1821,BD883 1908SEP931/2

061411
PN=458
Seat and Seat Belt
1 Cushion 11 Holder 21 Bar 31 Cap Screw (4 used)

2 Cushion 12 Rivet (4 used) 22 Bar 32 Washer (4 used)
3 Plate (2 used) 13 Cushion 23 Bar 33 Bracket (2 used (S.N.
4 Lock nut (2 used) 14 Pin 24 Bar 832374) (1 used S.N.
5 Washer (2 used) 15 Knob 25 Boot 832375 )
6 Screw (2 used) 16 Gear 26 Screw (as required) 34 Cap Screw (4 used)
7 Spacer 17 Spring 27 Washer (4 used) 35 Washer (8 used)
8 Washer (2 used) 18 Bushing (2 used) 28 Nut (4 used) 36 Nut (4 used)
9 Bolt (2 used) 19 Shock Absorber 29 Guide 37 Cap Screw (2 used)
10 Spring (2 used) 20 Bushing (4 used) 30 Base 38 Nut (2 used)
39 Armrest (2 used)
40 Swivel Control (Backhoe
only)
CAUTION: Release tension on spring. Spring NOTE: Backhoe has a onepiece seat.
under pressure can cause injury when released.
Remove spring tension by turning adjusting knob

counterclockwise.
TX,1821,BD883 1908SEP932/2

061411
PN=459
Seat and Seat Belt

061411
PN=460
Section 19
Sheet Metal and Styling
Contents
Page
Group 1910Hood and Engine Enclosure

Other Material............................................ 1919101
Disassemble and Assemble Hood
and Engine Side Shields ....................... 1919101
Disassemble and Assemble Cowl.............. 1919102
Group 1913Miscellaneous Guards

Remove and Install Bottom Guards
and Access Covers................................ 1919131
Group 1921Grille and Grille Housing

Disassemble and Assemble Grille
Housing ................................................. 1919211
Group 1927Fenders
Disassemble and Assemble Side
Fenders ................................................. 1919271
Disassemble and Assemble Back
Fender (S.N. 763492) ........................ 1919272
Disassemble and Assemble Back
Fender (S.N. 763493 ) ....................... 1919274

061411
PN=1
Contents

061411
PN=2
Group 1910
Hood and Engine Enclosure
Other Material
Number Name Use
T43513 (U.S.) Thread Lock and Sealer (High Used to install hasp onto cowl.
271 (LOCTITE)

TX,1910,BA842 1908JUL931/1
Disassemble and Assemble Hood and Engine Side Shields
T8033AO UN17JUL93
AEngine Left Side Shield EClamp I Cap Screw MHood
BNut F Spring (2 used) J Rubber Bumper (3 used)
CWasher (2 used) GWeldon Strap (4 used) KCap Screw (13 used)
DExhaust Pipe HEngine Right Side Shield L Washer (13 used)
1. Remove precleaner. 4. Assemble parts.

2. Disassemble parts as shown. 5. Install precleaner.
3. Inspect parts and replace as necessary.
TX,1910,BA840 1908JUL931/1

061411
PN=463
Hood and Engine Enclosure
Disassemble and Assemble Cowl

1. Disassemble parts as shown.
2. Apply retaining compound (maximum strength) to
hasp (A). Attach hasp to cowl.
T8033AP UN17JUL93
3. Assemble parts.
AHasp F Panel
BCowl GScrew (4 used)
CBracket HCap Screw (4 used)
DSeal I Strap (2 used455G and
ELabel 555G only)
J Grab Bar
TX,1910,BA841 1914JUN111/1

061411
PN=464
Group 1913
Miscellaneous Guards
Remove and Install Bottom Guards and
Access Covers
ABottom Guard F Cap Screw (2 used)
BAccess Cover (Loaders S.N. GCover (Oil Pan Access)
768272 and all Dozers) HWasher (6 used)
T8033AQ UN17JUL93
CAccess Cover (Loaders I Cap Screw (6 used)
S.N. 768273 )
DWasher (2 used)
ECap Screw (2 used)
TX,1913,BA843 1908JUL931/1

061411
PN=465
Miscellaneous Guards

061411
PN=466
Group 1921
Grille and Grille Housing
Disassemble and Assemble Grille Housing


3. Assemble parts.
AGrille Housing EScreen or Plate

BLock Nut (4 used) F Cap Screw (6 used)
CWasher (8 used) GWasher (6 used)
DCap Screw (7 or 11 used)
T8033AR UN17JUL93
TX,1921,BA844 1908JUL931/1

061411
PN=467
Grille and Grille Housing

061411
PN=468
Group 1927
Fenders
Disassemble and Assemble Side Fenders
T8033AS UN17JUL93
ACap Screw (2 used) ESpring (S.N. 763492) I Right Front Fender (left front MWasher (8 used)
BWasher (2 used) F Strap (S.N. 763492) fender similar) NRight Rear Fender
CCover GWasher (S.N. 763492) J Cap Screw (4 used)
DLeft Rear Fender HCap Screw (S.N. 763492) KWasher (4 used)
L Cap Screw (8 used)
1. Disassemble parts as shown. 3. Assemble parts.

TX,1927,BA845 1908JUL931/1

061411
PN=469
Fenders
Disassemble and Assemble Back Fender (S.N. 763492)
T8033AU UN17JUL93

061411
PN=470
Fenders
1 Lid 10 Washer 19 Cap Screw (2 used) 28 Cap Screw (2 used)

2 Rod (2 used) 11 Rubber Bumper (2 used) 20 Hardened Washer (2 used) 29 Plate
3 Cap Screw (3 used) 12 Angle (2 used) 21 Back Fender (Loader only) 30 Cap Screw (4 used)
4 Washer (3 used) 13 Cap Screw (2 used) 22 Washer (2 used) 31 Washer (4 used)
5 Retaining Washer (3 used) 14 Hardened Washer (2 used) 23 Cap Screw (2 used) 32 Cap Screw (2 used)
6 Cable 15 Grommet (2 used) 24 Angle (Dozer only) 33 Washer (2 used)
7 Nut (8 used) 16 Left Bracket 25 Back Fender (Dozer only) 34 Bolt (8 used)
8 Latch (2 used) 17 Right Bracket 26 Angle 35 Washer (8 used)
9 Washer 18 Angle (Loader only) 27 Washer (2 used) 36 Cap Screw
1. Disassemble parts as shown. 3. Assemble parts.

TX,19,RB406 1905FEB982/2

061411
PN=471
Fenders
Disassemble and Assemble Back Fender (S.N. 763493 )
T8033AT UN17JUL93
(S.N. 763493816937)
ALatch GCap Screw (2 used) MBack Fender (Dozer only) SCap Screw (2 used)
BLid HHardened Washer (2 used) NAngle T Washer (2 used)
CRubber Bumper (2 used) I Back Fender (Loader only) ONut (4 used) UCap Screw (2 used)
DAngle (2 used) J Cap Screw (2 used) PHardened Washer (4 used) VWasher (2 used)
ECap Screw (2 used) KWasher (2 used) QHardened Washer (2 used)
F Angle (Loader only) L Angle (Dozer only) RPlate

061411
PN=472
Fenders

3. Assemble parts.
T113199 UN03FEB98
(S.N. 816938 )
TX,19,RB407 1905FEB982/2

061411
PN=473
Fenders

061411
PN=474
Section 20
Safety, Convenience and Miscellaneous
Contents
Page
Group 2004Horn and Warning Devices

Remove and Install Horn ........................... 2020041
Remove and Install Reverse
Warning AlarmIf Equipped ................. 2020041
Adjust Reverse Warning Alarm
VolumeIf Equipped............................. 2020042

061411
PN=1
Contents

061411
PN=2
Group 2004
Horn and Warning Devices
Remove and Install Horn
1. Remove right engine side shield.
2. Disconnect wire lead (A).
3. Remove nut to remove horn.
T113149 UN30JAN98
4. Install horn and tighten nut.
5. Connect wire lead (A). Install engine side shield.
(S.N. 840461 ) Shown
TX,20,RB408 1905FEB981/1
Remove and Install Reverse Warning

AlarmIf Equipped
1. Remove rear panel on machines (S.N. 840461 ).
2. Disconnect wiring harness.
T113150 UN30JAN98
3. Remove two cap screws to remove reverse warning
alarm (A).
4. Remove ground wire (B).
5. Install reverse warning alarm ground wire and two
cap screws.
(S.N. 840461 ) Shown
TX,DS1843 1911OCT931/1

061411
PN=477
Horn and Warning Devices
Adjust Reverse Warning Alarm VolumeIf

Equipped
IMPORTANT: The reverse warning alarm is set on high
volume at the factory. It may be necessary to
adjust the volume to meet local regulations.
T6782AG UN18OCT88
NOTE: Alarm removed from machine for clarity
of photograph.
1. To change alarm to low volume, remove nut (A) and

disconnect wire from POS HI terminal.
2. Remove nut (C) and shorting bar (B).
3. Attach wire to POS LOW terminal (D). Install nut and
tighten securely. Save shorting bar for future use.
ANut CNut
BShorting Bar DTerminal
T6782AH UN18OCT88
TX,DS1844 1902AUG901/1

061411
PN=478
Section 21
Main Hydraulic System
Contents
Page

Other Material............................................ 2121601
Specifications ............................................ 2121601
Remove and Install Hydraulic
Pump and/or Drive ShaftDirect
Drive Machines...................................... 2121602
Hydraulic PumpDirect Drive
Machines ............................................... 2121604
PumpTorque Converter
Machines ............................................... 2121608
Hydraulic PumpTorque
Converter Machines ............................ 21216010
Remove and Install Hydraulic Oil
Filter..................................................... 21216011
Hydraulic Oil Filter ............................... 21216012
Remove and Install Hydraulic Oil
Cooler .................................................. 21216013
Reservoir ............................................. 21216013

061411
PN=1
Contents

061411
PN=2
Group 2160
Hydraulic System
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Lubricant Apply to splines on pump shaft.
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads on front
TY9473 (Canadian) Strength) yoketooutput shaft cap screw.
242 (LOCTITE)

TX,2160,BA915 1931AUG931/1
Specifications
Reservoir Approximate Capacity 41.5 L (11 gal)

Hydraulic PumptoHousing Torque 149 Nm (110 lbft)
Cap Screws
Bearing StraptoYoke Cap Screws Torque 47.5 9 Nm (35 7 lbft)
Pump Assembly Hardware Torque 271 Nm (200 lbft)
Suction Hose ElbowtoPump Torque 6090 Nm (4467 lbft)
Inlet Cap Screws
Pressure LinetoPump Outlet Torque 3448 Nm (2535 lbft)
Cap Screws
Filter Base Fittings Torque 115 23 Nm (85 17 lbft)
Reservoir Mounting Cap Screws Torque 320 64 Nm (236 47 lbft)
Reservoir CleanOut Cover Nuts Torque 2734 Nm (2025 lbft)
Hydraulic Pump Weight 36 kg (79 lb)
TX,21,RB404 1903FEB981/1

061411
PN=481
Hydraulic System
Remove and Install Hydraulic Pump and/or

Drive ShaftDirect Drive Machines
1.
Remove floor plates.
X9811 UN23AUG88
NOTE: For repair of drive shaft only, go to Step 4.
NOTE: Hydraulic reservoir capacity is approximately

41.5 L (11 gal).
2. Drain hydraulic reservoir.

Specification
ReservoirApproximate
Capacity............................................................................ 41.5 L (11 gal)

T7247AQ UN09APR90
may result. Doctors unfamiliar with this type ASuction ScreentoPump DPump OutlettoControl
of injury should reference a knowledgeable Inlet Hose Valve Line
medical source. Such information is available BReservoirtoPump Inlet ETransmission Pump
from Deere & Company Medical Department Hose F Pump Outletto
CHydraulic Pump Transmission Filter and
in Moline, Illinois, U.S.A. Accumulator Line
3. Disconnect hoses and lines (A, B, D and F). Use caps

and plugs to close all openings.

061411
PN=482
Hydraulic System
T6675AK UN25OCT88
ACap Screw (4 used per yoke) CCap Screw (4 used) EFront Yoke GRear Yoke
BCap Screw DSnap Ring F Drive Shaft
NOTE: For repair of drive shaft only, do not drain

8. Remove cap screws (C).
reservoir. Do steps 46.
9. Remove pump.
4. Remove cap screws (A).
10. Repair pump. (See procedure in this group.)
5. Slide drive shaft toward transverse case to remove
drive shaft (F) and rear yoke (G). 11. Apply antiseize lubricant to splines on pump input
and output shafts.
6. Remove cap screw (B) to remove front yoke (E).
12. Install pump. Tighten cap screws (C).
CAUTION: The approximate weight of Specification
pump is 36 kg (79 lb). Hydraulic Pump
toHousing Cap
7. Install strap around pump, connect to hoist. ScrewsTorque..........................................................149 Nm (110 lbft)
Specification 13. Apply thread lock and sealer (medium strength) to

Hydraulic threads of cap screw (B). Install front yoke (E) using
PumpApproximate cap screw.
Weight.................................................................................. 36 kg (79 lb)

061411
PN=483
Hydraulic System
IMPORTANT: Damage to pumps can occur if pump is

not primed with oil. The transmission reservoir
is lower than pump inlet and pump can not
supply oil fast enough after initial startup.
14. Squirt oil into inlet side (A) of transmission pump (E).
T7247AQ UN09APR90
15. Connect hoses and lines (A, B, D and F) and install
drive shaft. Tighten drive shaft bearing straptoyoke
cap screws.
Specification
Bearing StraptoYoke
Cap ScrewsTorque...................................... 47.5 9 Nm (35 7 lbft)
Suction Hose
ElbowtoPump Inlet
Cap ScrewsTorque...................................... 6090 Nm (4467 lbft) ASuction ScreentoPump DPump OutlettoControl
Inlet Hose Valve Line
Pressure Lineto BReservoirtoPump Inlet ETransmission Pump
Pump Outlet Cap Hose F Pump Outletto
ScrewsTorque.............................................. 3448 Nm (2535 lbft) CHydraulic Pump Transmission Filter and
Accumulator Line
TX,21,RB405 1914JUN113/3
Disassemble and Assemble Hydraulic PumpDirect Drive Machines
T6534AO UN18NOV89
1 Snap Ring 9 Drive Gear Shaft 17 Housing 25 Stud

2 Bearing 10 Front Carrier 18 Drive Gear 26 Stud
3 Seal (3 used) 11 ORing (2 used) 19 Cover 27 Washer (6 used)
4 Cover 12 Air Vent 20 Driven Shaft Assembly 28 Gasket (2 used)
5 Bushing (4 used) 13 Seal Retainer 21 ORing 29 Driven Gear
6 Seal (2 used) 14 Rear Carrier 22 Seal Retainer 30 Cap Screw (2 used)
7 Thrust Plate 15 Bushing (4 used) 23 Seal 31 Driven Gear
8 Housing 16 Thrust Plate (2 used) 24 Nut (2 used)

061411
PN=484
Hydraulic System
1. Put a mark on gears and housing sections to aid in

assembly.
2. Remove parts as shown.
AMain Hydraulic Pump ECap Screw

BStud (5/8 in. x 13 1/2 in.) F Nut (2 used)
T6550AB UN25OCT88
CTransmission Pump GWasher (4 used)
DCap Screw HStud (5/8 in. x 11 1/2 in.)

061411
PN=485
Hydraulic System
T7247BH UN01AUG90
Transmission Pump
AHousing EDriven Shaft I Groove MSeal (2 used)
BDowel Pin (2 used) F ORing J Set Screw (2 used) NGasket
CBushing (2 used) GSeal Retainer KGear (2 used)
DCover HSeal L Thrust Plate (2 used)
NOTE: Set screws must be removed before NOTE: Install seal (H) with flat side toward seal retainer.
removing seal retainer.
Cover groove (I) with tape when installing seal
3. Remove parts as shown. retainer (G) to prevent damage to seal (H).
4. To remove seal retainer (G), turn counterclockwise 7. Install new Oring (F) and seals (H and M). Apply
using a punch through holes provided. petroleum jelly to seal lips.
5. Inspect parts for wear or damage. Driven shaft 8. Put a light coat of clean hydraulic oil on all parts.
assembly (E) has no service parts. Assemble parts as shown.
6. Replace assembly if required.

061411
PN=486
Hydraulic System
9. Install transmission pump. Tighten cap screws and

nuts.
Specification
Pump Assembly
HardwareTorque..................................................... 271 Nm (200 lbft)
T6550AB UN25OCT88
AMain Hydraulic pump ECap Screw
BStud (5/8 in. x 13 1/2 in.) F Nut (2 used)
CTransmission Pump GWasher (4 used)
DCap Screw HStud (5/8 in. x 11 1/2 in.)
TX,2160,BA920 1911OCT934/5
T6534AL UN25OCT88
Hydraulic Pump
ASnap Ring F Dowel Pin (4 used) KSeal Retainer PSeal (2 used)
BBearing GHousing L Cap Screw (2 used) QSeal (3 used)
CCover HFront Carrier MORing (2 used)
DBushing (4 used) I Air Vent NDriven Gear Shaft
EDrive Gear Shaft J Rear Carrier OThrust Plate (2 used)
10. Remove parts as shown. 14. Assemble parts. Tighten cap screws.
11. Inspect parts for wear or damage. Specification
Pump Assembly Cap
12. Install new Orings (M) and seals (Q and P).
13. Apply clean hydraulic oil to all parts and petroleum
jelly on lip of seals.
TX,2160,BA920 1911OCT935/5

061411
PN=487
Hydraulic System
Remove and Install Hydraulic PumpTorque

Converter Machines
NOTE: Hydraulic reservoir capacity is approximately
41.5 L (11 gal).
T8071AV UN08SEP93
2. Drain hydraulic reservoir.
Specification
Capacity............................................................................ 41.5 L (11 gal)
APumptoHousing Cap DDrive Shaft (not applicable) (S.N. 803600)

Screws (2 used) EPump OutlettoControl
BHydraulic Pump Valve Line
CBearing CaptoYoke Cap F ReservoirtoPump Inlet
Screws (4 used per yoke) Line
(not applicable)
T112878 UN20JAN98
(S.N. 803601 )
TX,2160,BA921 1911OCT931/3

X9811 UN23AUG88
from Deere & Company Medical Department 5. Repair pump. (See procedure in this group.)
6. Apply antiseize lubricant to splines on pump input
3. Disconnect lines (E and F). Use caps and plugs to shaft.
close all openings.
4. Remove cap screws (A) to remove pump (B).

061411
PN=488
Hydraulic System
7. Install pump (B). Tighten cap screws (A).

Specification
PumptoHousing Cap
ScrewsTorque..........................................................149 Nm (110 lbft)
8. Connect hydraulic lines.
T8071AV UN08SEP93
9. Fill reservoir with recommended hydraulic fluid. (See
10. Install floor plates.
APumptoHousing Cap DDrive Shaft (not applicable)

Screws (2 used) EPump OutlettoControl
BHydraulic Pump Valve Line (S.N. 803600)
CBearing CaptoYoke Cap F ReservoirtoPump Inlet
Screws (4 used per yoke) Line
(not applicable)
T112878 UN20JAN98
(S.N. 803601 )
TX,2160,BA921 1911OCT933/3

061411
PN=489
Hydraulic System
Disassemble and Assemble Hydraulic PumpTorque Converter Machines
T8071AW UN13SEP93
AVent F Washer (4 used) KGear Housing PSeal
BReducer Bushing GCap Screw (4 used) L Front Housing QSeal Retainer
CSquare Seal (2 used) HRear Housing MSeal RSeal Lip
DThrust Plate (2 used) I Gear/Shaft Set NORing
EChannel Seal (2 used) J Dowel Pin (4 used) ORetaining Ring
NOTE: For repair of shaft seals (M and P) only, 6. Inspect parts for wear or damage.
do steps 13.
NOTE: Pump parts (CE and HL) are not
1. Remove retaining ring (O) to remove seal retainer (Q). serviceable. If any of these parts are worn
or damaged, replace pump.
2. Remove seals (M and P).
3. Install seals: 7. Apply petroleum jelly to lip of seal lip (R).
a. Install seal (M) flush with face of recess in housing 8. Put a light coat of clean hydraulic oil on all internal
(L) and with lip (R) toward gear. parts.
b. Install seal (P) flush with counterbore in retainer 9. Assemble parts as shown. Tighten cap screws (G).
(Q) and with lip (R) away from gear. Specification
Pump Assembly Cap
4. Put a mark on housings (H, K and L) to aid in assembly.
5. Remove parts. Mark gear/shaft set (I) and thrust
plates (D) to aid in assembly.
TX,2160,BA922 1911OCT931/1

061411
PN=490
Hydraulic System
Remove and Install Hydraulic Oil Filter

NOTE: Machines (S.N. 803601 ) have both the hydraulic
filter (R.H. side) and transmission filter (L.H. side)
mounted in the reservoir access compartment.
Machines equipped with a hydraulic oil cooler have
a tee fitting and an orifice (A). Machines without an
oil cooler have an adapter fitting (not shown).
Machines (S.N. 791182) have an 11 mm
(0.43 in.) orifice (A). Machines (S.N. 791183
) have a 13 mm (0.51 in.) orifice.
1. Open access door.

2. Remove start aid solenoid (if necessary). (See Group
0505.)
3. Disconnect lines (C and D).
4. Disconnect switch wiring lead (B).
5. Loosen nut (E) to remove filter.
T6672AA UN07OCT93
6. Install filter.
7. Connect lines and wiring lead.
8. Install start aid solenoid (if necessary).
9. Start engine and check for leaks.
Specification
Filter Base
FittingsTorque............................................115 23 Nm (85 17 lbft) AOrifice (if equipped with DFiltertoHydraulic Oil
hydraulic oil cooler) Cooler Line
BFilter Restriction Switch ENut
Wiring Lead
CControl ValvetoFilter Line
TX,2160,BA923 1911OCT931/1

061411
PN=491
Hydraulic System
Disassemble and Assemble Hydraulic Oil

Filter
1. Remove parts (AI). Inspect and replace if necessary.
2. Put clean hydraulic oil on gasket on filter (I). Tighten
until gasket contacts filter base (B). Turn an additional
3/4 turn.
AORing (2 used) F Spring

BBase GPiston
CNut (2 used) HORing
DPlug I Filter with Gasket
EORing
T6675AN UN20OCT88
TX,2160,BA924 1911OCT931/1

061411
PN=492
Hydraulic System
Remove and Install Hydraulic Oil Cooler

1. Remove grill.
2. Disconnect lines (A and B). Plug all openings with
caps and plugs.
3. Remove cap screws (C).
4. Remove oil cooler.
5. Install oil cooler, connect lines.
AOil CoolertoReservoir CCap Screw (4 used)

Line
BOil CoolertoHydraulic Oil
Filter Line
T6675AM UN20OCT88
2160,SS5 1911OCT931/1
Remove and Install Hydraulic Reservoir

X9811 UN23AUG88

061411
PN=493
Hydraulic System
1. For dozers, perform the following:

Drain reservoir. Capacity is approximately 41.5 L
(11 gal).
Specification
Capacity............................................................................ 41.5 L (11 gal)
Disconnect lines (LX).

Disconnect all wiring leads and line to ether start aid
solenoid (if equipped).
NOTE: On machines (S.N. 803600), the transmission
oil filter was located under the center floor plate.
L Return Oil CoolertoTop SControl Valve Tilt
T112880 UN20JAN98
Port of Hydraulic Reservoir SectiontoCylinder Head
(if equipped) End
MControl ValvetoOutlet T Control Valve Angle
Port of Pump SectiontoRight Cylinder
NControl Valve Blade Head End and Left Cylinder
SectiontoCylinder Rod Rod End
End UReservoirtoTop Port of
OControl Valve Tilt Hydraulic Oil Cooler (if
SectiontoCylinder Rod equipped) (S.N. 834561 ) Dozer Shown
End VTransmission Oil
PReservoirtoInlet Port of FiltertoPressure
Pump Regulating Valve
QControl Valve Blade WTransmission Oil
SectiontoCylinder Head FiltertoTransmission
End Pump
RControl Valve Angle XTransmission Oil
SectiontoRightCylinder FiltertoTransmission
Rod End and Left Cylinder Lube Circuit (TFitting on
Head End Control Valve) (Tfitting
located on transmission
filter on early machines.)

061411
PN=494
Hydraulic System
2. For loaders, perform the following:

Drain reservoir. Capacity is approximately 41.5 L
(11 gal).
Disconnect lines (AK).
Disconnect all wiring leads and line to ether start aid
solenoid (if equipped).
AReturn FiltertoLower Port GReservoirtoInlet Port of

of Hydraulic Oil Cooler (if Pump
equipped) HReservoirtoTop Port of
BControl ValvetoOutlet Port Hydraulic Oil Cooler (if
of Pump equipped)
CControl Vale Bucket Section I Transmission Oil
T112879 UN20JAN98
to Cylinder Rod End FiltertoPressure
DControl Vale Boom Regulating Valve
SectiontoCylinder Head J Transmission Oil
End FiltertoTransmission
EControl Valve Bucket Pump
SectiontoCylinder Head KTransmission Oil
F Control Valve Boom Lube Circuit (TFitting on
SectiontoCylinder Rod Control Valve) (Tfitting (S.N. 803601 ) Loader Shown
End located on transmission

061411
PN=495
Hydraulic System
T6942AK UN07OCT93
ACap Screw (3 used) BCap Screw (2 used) CNut (2 used) DNut (2 used)
3. 5. Install lifting straps around reservoir.

Remove rear plate(s) and right side fenders. (See Specification
Group 1927.) ReservoirApproximate
Weight.............................................................................. 103 kg (226 lb)
4. Remove transmission fill tube. Use tape to cover
opening. 6. Remove cap screws and nuts (AD).
7. Remove reservoir.
CAUTION: The approximate weight of
reservoir is 103 kg (226 lb).

061411
PN=496
Hydraulic System
T6942AK UN07OCT93
8. Remove nuts (F), cover (E) and strainer (H). Replace
or repair as necessary.
9. Tighten nuts (F).
Specification
Reservoir CleanOut
Cover NutsTorque........................................ 2734 Nm (2025 lbft)
10. Install reservoir and cap screws. Tighten cap screws

and nuts (A and D).
Specification
Reservoir Mounting Cap
ScrewsTorque......................................... 320 64 Nm (236 47 lbft)
ACap Screw (3 used) ECleanOut Cover

BCap Screw (2 used) F Nut (10 used)
CNut (2 used) GBreather
DNut (2 used) HStrainer
T6677AA UN07OCT93

061411
PN=497
Hydraulic System
11. For dozers, perform the following:

Connect lines (LX).
Connect all wiring leads and ether start aid line (if
equipped).
Fill reservoir with oil to proper level. (See Section
00, Group 0004.)
L Return Oil CoolertoTop SControl Valve Tilt

Port of Hydraulic Reservoir SectiontoCylinder Head
(if equipped) End
MControl ValvetoOutlet T Control Valve Angle
Port of Pump SectiontoRight Cylinder
NControl Valve Blade Head End and Left Cylinder
T112880 UN20JAN98
SectiontoCylinder Rod Rod End
End UReservoirtoTop Port of
OControl Valve Tilt Hydraulic Oil Cooler (if
SectiontoCylinder Rod equipped)
End VTransmission Oil
PReservoirtoInlet Port of FiltertoPressure
Pump Regulating Valve
QControl Valve Blade WTransmission Oil
SectiontoCylinder Head FiltertoTransmission (S.N. 834561 ) Dozer Shown
End Pump
RControl Valve Angle XTransmission Oil
SectiontoRightCylinder FiltertoTransmission
Rod End and Left Cylinder Lube Circuit (TFitting on
Head End Control Valve) (Tfitting
located on transmission
TX,2160,BA926 1911OCT936/7
12. For loaders, perform the following:

Connect lines (AK).
Connect all wiring leads and ether start aid line (if
equipped).
Fill reservoir with oil to proper level. (See Section
00, Group 0004.)
AReturn FiltertoLower Port GReservoirtoInlet Port of

of Hydraulic Oil Cooler (if Pump
equipped) HReservoirtoTop Port of
BControl ValvetoOutlet Port Hydraulic Oil Cooler (if
of Pump equipped)
CControl Vale Bucket Section I Transmission Oil
T112879 UN20JAN98
to Cylinder Rod End FiltertoPressure

DControl Vale Boom Regulating Valve
SectiontoCylinder Head J Transmission Oil
EControl Valve Bucket Pump
SectiontoCylinder Head KTransmission Oil
F Control Valve Boom Lube Circuit (TFitting on
SectiontoCylinder Rod Control Valve) (Tfitting (S.N. 803601 ) Loader Shown
End located on transmission
TX,2160,BA926 1911OCT937/7

061411
PN=498
Section 31
Loader
Contents
Page
Group 3102Bucket
Specifications ............................................ 3131021
Remove and Install Bucket Tooth
Shanks................................................... 3131021
Remove and Install Bucket Tooth
Tips ........................................................ 3131021
Remove and Install Loader
Bucket.................................................... 3131022
Repair Cracked Cutting Edge.................... 3131023
Replace Cutting Edge................................ 3131023
Group 3115Controls Linkage

Other Material............................................ 3131151
Disassemble and Assemble Loader
Control Linkage ..................................... 3131151
Group 3140Frames
Specifications ............................................ 3131401
Remove Loader Boom............................... 3131401
Install Loader Boom................................... 3131403
Group 3160Hydraulics
Other Material............................................ 3131601
Specifications ............................................ 3131602
Loader Hydraulic Component
Location ................................................. 3131603
Remove and Install Loader Control
Valve ...................................................... 3131604
Disassemble and Assemble Loader
Control Valve ......................................... 3131605
Disassemble and Assemble Bucket
Section................................................... 3131606
Disassemble and Assemble Boom
Section................................................... 3131609
Auxiliary Section .................................. 31316012
Cross Section of System Relief
Valve .................................................... 31316013
Inspect System Relief Valve .................... 31316014
Inspect AntiCavitation Bucket
Circuit Relief Valve .............................. 31316014
Inspect Bucket and Boom Adjusting
Circuit Relief Valves............................. 31316015
Disassemble and Inspect Boom
and Bucket Cylinders........................... 31316015
Cross Section of Bucket and Boom
Cylinder ............................................... 31316018
Assemble Boom and Bucket
Cylinders.............................................. 31316018
Disassemble and Assemble Ripper
Cylinder ............................................... 31316024

061411
PN=1
Contents

061411
PN=2
Group 3102
Bucket
Specifications
Bucket Tooth Shank Cap Screw Torque 620 Nm (458 lbft)

Center Tooth Shank (Early Models) Torque 620 Nm (458 lbft)
Corner Tooth Shank (Early Models) Torque 1070 Nm (790 lbft)
TX,3102,BD866 1908SEP931/1
Remove and Install Bucket Tooth Shanks

1. Remove tooth shanks. Replace as necessary.
IMPORTANT: Shanks MUST be seated against cutting
edge as nuts are tightened to put load on
cutting edge and NOT on cap screws.
T91397 UN27OCT88
2. Install tooth shanks.
Install cap screws to tooth shanks with cap screw
heads on bottom. Tighten cap screws.
Install cap screws to corner tooth shanks with cap
screw heads to outside. Tighten cap screws.
Specification
Corner Tooth Shank Cap
ScrewsTorque....................................................... 1070 Nm (790 lbft)
Tooth Shank Cap
TX,31,RB411 1905FEB981/1
Remove and Install Bucket Tooth Tips

IMPORTANT: Washer may be damaged if pin is
removed or installed incorrectly.
1. Drive out pin from washer side of shank and remove

tooth tip.
T91479 UN25MAY89
2. Drive new tooth tip on shank until pin can be installed
or until center of hole (A) in shank is centered to the
rear of slot in tooth tip.
3. Install pin from washer side of shank.
4. Pin should not contact front edge of tooth tip slot (B).
If it does, pin will fail under load. Try another tooth
tip or lengthen slot.
T6972BF UN30JAN89
Continued on next page TX,3102,BD855 1908SEP931/2

061411
PN=501
Bucket
5. Side impacting or wedging of rocks between bucket

teeth can cause the tooth shank attaching hardware
to loosen or fail. To prevent this, tooth shanks can
be welded (A and B) to the bucket using E7018
Electrode.
6. Be sure tooth shank is properly positioned and
T91480 UN25MAY89
hardware tight before welding.
A25.4 mm (1 in.) Weld B7.9 mm (5/16 in.) Weld
TX,3102,BD855 1908SEP932/2
Remove and Install Loader Bucket

1. Lower boom and position bucket so it sits flat on floor.
2. Remove cap screws, pins, and shims from boom and
bucket pivots. Remove pins from end without grease
fittings.
T6672AB UN27OCT88
3. Remove bucket.
4. Inspect bushings in boom and link arm replace if
necessary.
TX,3102,BD856 1908SEP931/2
NOTE: Shim boom to bucket using the least number

of shims. Allow a maximum gap equal to
the thinnest shim used.
Shim bucket link to bucket allowing a
maximum gap of 1 mm.
T91399 UN27OCT88
5. Install bucket, shims and pins.
6. Install cap screws.
7. Lubricate all pivot points.
TX,3102,BD856 1908SEP932/2

061411
PN=502
Bucket
Repair Cracked Cutting Edge 5. Fill the Vgrooves with weld. Use E7018 electrodes.
1. Clean the area to find end of crack. Extend the weld approximately 13 mm (0.5 in.) beyond
end of crack.
2. Drill a small hole at end of crack to prevent spreading.
Specification
3. Grind Vgrooves along crack on top and bottom of WeldApproximate
cutting edge. Distance......................................... 13 mm (0.5 in.) beyond end of crack
4. Preheat the cracked area to approximately

150260C (300500F).
Specification
Cracked AreaApproxi
mate Temperature.......................................... 150260C (300500F)
3102,04 1920APR901/1
Replace Cutting Edge
CAUTION: Prevent bodily injury caused by

accidental lowering of bucket. Always support a
raised bucket. Use a floor stand with a minimum
capacity of 5000 kg (10,000 lb).
T6439AC UN18OCT88
1. Level bucket and lower onto stand. Remove teeth.
2. Tack weld or clamp a straightedge along weld.
IMPORTANT: Use a straightedge to avoid cutting into
bucket. This will minimize gaps during welding.
3. Remove weld using a cutting torch or air arc

equipment.
3102,05 1908SEP931/4
4. Grind smooth all surfaces.

5. Install new cutting edge and clamp in position.
6. Tack weld (A) cutting edge to bucket. Remove clamps.
T6439AM UN18NOV89
Continued on next page 3102,05 1908SEP932/4

061411
PN=503
Bucket
7. Preheat cutting edge to approximately 150260C

(300500F).
Specification
Cutting EdgeApproxi
mate Temperature.......................................... 150260C (300500F)
T6439AD UN18OCT88
8. Use E7018 electrodes. Weld full length of cutting edge
with an 8 mm (0.315 in.) fillet weld.
Specification
Cutting EdgeLength.............................8 mm (0.315 in.) with fillet weld
3102,05 1908SEP933/4
9. Lower bucket onto floor stand.

10. Weld full length of cutting edge with a 6 mm (0.25 in.)
weld.
Specification
Cutting EdgeLength...................................... 6 mm (0.25 in.) with weld
T6439AE UN18OCT88
3102,05 1908SEP934/4

061411
PN=504
Group 3115
Controls Linkage
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Lubricant Apply to bushing cap screw joint.
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to all linkage hardware that
TY9473 (Canadian) Strength) do not have locking nuts.
242 (LOCTITE)

TX,31,DY83 1930OCT961/1
Disassemble and Assemble Loader Control Linkage
T8067AC 1903SEP93
ABall Joint CHex Nut EShim (as required)
BBushing DCap Screw (2 used)
1. Remove linkage assembly. 5. Apply thread lock and sealer (medium strength) to ball
2. Disassemble parts. joint (A), hex nut (C) and cap screws (D).
3. Inspect linkage for worn or damaged parts. Replace if 6. Assemble parts.

necessary. 7. Install linkage assembly.
4. Apply antiseize lubricant to bushing (B).
TX,3115,BD858 1911OCT931/1

061411
PN=505
Controls Linkage

061411
PN=506
Group 3140
Frames
Specifications
Hose Clamp Cap Screw Torque 130 Nm (96 lbft)

Loader Boom Weight 592 kg (1305 lb) (Approximately)
TX,3140,BD916 1908SEP931/1
Remove Loader Boom
T6676AD UN07OCT93
ABucket Cylinder (2 used) BPin (2 used) CLifting Strap DBoom Cylinder (2 used)
1. Lower all equipment to ground and stop engine. 6. Disconnect wire leads from returntodig switch.
2. Operate control valves to release pressure in hydraulic 7. Attach lifting strap (C) to boom cylinder (D).
system.
8. Remove pin (B) and lower cylinder using a hoist.
3. Remove bucket. (See procedure in Group 3102). Check seals for wear. Repeat procedure on other side.
4. Raise boom approximately 24inches above ground 9. Install a 3inch wooden block under cylinder (A) at
and support with blocks. head end of both cylinders.
5. With engine OFF, operate hydraulics to retract bucket
cylinder (A).
Continued on next page 3140,QQ1 1911OCT931/3

061411
PN=507
Frames
CAUTION:
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard
by relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections
X9811 UN23AUG88
before applying pressure. Search for leaks
with a piece of cardboard. Protect hands and
body from high pressure fluids.
of injury should reference a knowledgeable 10. Loosen hose clamps.
3140,QQ1 1911OCT932/3
T113213 UN03FEB98
AChain CLink (2 used) EHydraulic Line (Bucket GPin (2 used)
BChain DHydraulic Line (Bucket Cylinder Head End)
Cylinder Rod End) F Pin (2 used)
11. Tag and disconnect hydraulic lines (D and E) from

cylinders on both sides. CAUTION: Loader boom weighs approximately
592 kg (1305 lb).
12. Attach chains (A and B) on boom. Connect to
overhead hoist.
16. Remove loader boom from machine.
13. Attach chains around links (C) and boom on both Specification
sides. Loader BoomApproxi
14. Remove pins (F). Check seals for wear. mate Weight................................................................... 592 kg (1305 lb)
15. Remove pins (G) from loader boom. Check seals for 17. Inspect all bushings and pivot points for excess wear
wear. or damage. Replace as necessary.
3140,QQ1 1911OCT933/3

061411
PN=508
Frames
Install Loader Boom
T113213 UN03FEB98
AStrap CLink (2 used) EHydraulic Line (Bucket GPin (2 used)
BChain DHydraulic Line (Bucket Cylinder Head End)
Cylinder Rod End) F Pin (2 used)
1. Install seals with lip of seal facing out. 4. Connect hydraulic lines (D and E) to bucket cylinders.
2. Lubricate all pivot points. Tighten hose clamp cap screws.
Specification
3. Install loader boom, links (C), pins (F and G), and cap
Hose Clamp Cap
screws.
ScrewTorque............................................................. 130 Nm (96 lbft)
NOTE: Use shims (as required) between main frame
boss and boom to remove end play.

061411
PN=509
Frames
T6942AL UN07OCT93
ABucket Cylinder (2 used) BPin (2 used) CLifting Strap DBoom Cylinder (2 used)
5. Connect rod end of boom cylinder (D) and install pin 6. Connect wiring lead to returntodig switch. Adjust
(B). returntodig switch (See procedure in Group 1674).
NOTE: The returntodig switch must be adjusted 7. Install bucket. (See procedure in Group 3102).
whenever switch is disconnected.
TX,31,RB412 1905FEB982/2

061411
PN=510
Group 3160
Hydraulics
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to cylinder rod
TY9473 (Canadian) Strength) guide threads.
242 (LOCTITE)
T43513 (U.S.) Thread Lock and Sealer (High To be applied to threads of magnetic
TY9474 (Canadian) Strength) shell cap screw, spool end cap screw,
271 (LOCTITE) and shoulder cap screws.

3160,BB1 1930JUL901/1

061411
PN=511
Hydraulics
Specifications
Loader Control Valve Tie Rod Torque 65 Nm (48 lbft)

Nuts (7/16 in.)
Loader Control Valve Tie Rod Torque 100 Nm (74 lbft)
Nut (1/2 in.)
Spool CaptoMagnetic Shell Torque 7 Nm (60 lbin.)
Cap Screw (Bucket)
SpooltoSpool End Screw (Bucket) Torque 2027 Nm (1520 lbft)
Shoulder Cap ScrewtoSpool Torque 911 Nm (8496 lbin.)
End Screw (Bucket)
Spool CaptoValve Section Cap Torque 16 2 Nm (144 18 lbin.)
Screws (Bucket)
Seal PlatetoValve Section Cap Torque 16 2 Nm (144 18 lbin.)
Screws (Bucket)
SpooltoSpool End Screw (Boom Torque 911 Nm (8496 lbin.)
and Auxiliary)
Spool CaptoValve Section Cap Torque 7 0.7 Nm (60 6 lbin.)
Screws (Boom and Auxiliary)
AntiCavitation Plug (Boom) Torque 81108 Nm (6080 lbft)
System Relief Valve Lock Nut Torque 61 6 Nm (45 4 lbft)
Adjusting Circuit Relief Valve Body Torque 3038 Nm (2228 lbft)
Adjusting Circuit Relief Valve Nut Torque 14 Nm (123 lbin.)
455G Boom Cylinder Size 100 x 50 mm
Weight 53 kg (116 lb)
Snug Torque 340 Nm (250 lbft)
Torque Turn 1/12 Turn (30)
555G Boom Cylinder Size 115 x 63 mm
455G Bucket Cylinder Size 90 x 50 mm
555G Bucket Cylinder Size 100 x 50 mm
MultiPurpose Bucket Cylinder Size 100 x 50 mm
Continued on next page TX,3160,QQ448 1930JUL901/2

061411
PN=512
Hydraulics
Ripper Cylinder Size 2.50 Bore x 15.19 Stroke

Piston Nut Torque 203285 Nm (150210 lbft)
Control Valve Weight 40 kg (88 lb)
TX,3160,QQ448 1930JUL902/2
Loader Hydraulic Component Location
T112517 1905JAN98
AReservoir F Boom Section KOil Cooler PStabilizer Valve
BBreather GHydraulic Pump (Torque L Return Filter QBackhoe Control Valve
CAuxiliary Section Converter) MFrom Power Beyond Port RBackhoe System (if equipped)
DBucket Section HHydraulic Pump (Direct Drive) NDiverter Valve SLoader Hydraulic System
EPower Beyond Port I Bucket Cylinders OReturn To Loader Valve End T Transmission Filter (S.N.
J Boom Cylinders Cap 803601 )
TX,3160,BD869 1911OCT931/1

061411
PN=513
Hydraulics
Remove and Install Loader Control Valve

X9811 UN23AUG88
3160,SS1 1911OCT931/2
1. Disconnect oil lines (AF), linkage, and wire lead.
CAUTION: The approximate weight of control

valve is 40 kg (88 lb).
2. Remove nuts to remove valve.

3. Install control valve and tighten nuts.
Specification
Control ValveWeight......................................................... 40 kg (88 lb)
4. Connect oil lines, linkage, and wire lead.
ABottom Outlet DTop Port of Boom

PorttoReturn Filter Line SectiontoBoom Cylinder
BTop Inlet PorttoHydraulic Head End Line
Pump Line EBottom Port of Boom
CTop Port of Bucket SectiontoBoom Cylinder
SectiontoBucket Cylinder Rod End Line
Rod End Line F Bottom Port of Bucket
SectiontoCylinder Head
End Line
T6680AA UN18OCT88
3160,SS1 1911OCT932/2

061411
PN=514
Hydraulics
Disassemble and Assemble Loader Control

Valve
IMPORTANT: For proper operation, control
valve must be assembled in the correct
order. Keep all components for each valve
section together as a set.
1. Disassemble valve.
2. Inspect parts for wear or damage.
3. Replace Orings.
4. Assemble parts. Tighten nuts (H and I).
Specification
Loader Control
Valve Tie Rod Nuts
(7/16)Torque............................................................... 65 Nm (48 lbft)
Loader Control Valve Tie
Rod Nuts (1/2)Torque............................................... 100 Nm (74 lbft)
5. If removing system relief (M) or bucket circuit relief
T6680AB UN18OCT88
with anticavitation (L), place wrench on nut (N).
6. If removing circuit reliefs (E and G) place wrench on
nut (O).
ATie Rod (2 used) I Nut (2 used)

BTie Rod J End Cap
CInlet and Outlet Section KAntiCavitation Plug
DBucket Section L Bucket Cylinder Head
EBucket Cylinder Rod End End Circuit Relief with
Circuit Relief AntiCavitation
F Boom Section MSystem Relief
GBoom Cylinder Head End NNut
Circuit Relief ONut
HNut (4 used)
T6680BA UN18OCT88
T6680BB UN18OCT88
3160,SS2 1911OCT931/1

061411
PN=515
Hydraulics
Disassemble and Assemble Bucket Section
T6680BC UN18OCT88
IMPORTANT: Keep valve section components
together as a matched set.
1. Disassemble valve section.

2. Disassemble and assemble spool cap (22). Apply
thread lock and sealer (high strength) to threads of
T6680BD UN18OCT88
cap screw (30). Tighten cap screw.
Specification
Spool CaptoMagnetic
Shell Cap Screw
(Bucket)Torque........................................................... 7 Nm (60 lbin.)
3. Check spool and valve section for nicks or scratches.

Spool and valve section must be replaced as a set.
1 Cam Detent 17 Spool Cap Spacer
4. Lubricate parts with clean hydraulic oil. 2 Spring 18 Spring Seat (2 used)
3 Ball (8 used) 19 Spring
5. Replace Orings. 4 Spool 20 Spool End Screw
5 Adjusting Circuit Relief 21 Clapper
with AntiCavitation 22 Spool Cap
6 Spring 23 Cap Screw (2 used)
7 Lift Check 24 Shoulder Screw
8 ORing 25 Spacer (2 used)
9 Adjusting Circuit Relief 26 Valve Section
10 Spacer (2 used) 27 Magnetic Shell
11 Seal Plate 28 Snap Ring
12 Cap Screw (2 used) 29 Retaining Ring
13 Wiper Seal 30 Cap Screw
14 ORing (2 used) 31 Screen
15 Spool Spacer Cap
16 ORing (2 used)

061411
PN=516
Hydraulics
6. Install cap spool spacer (A) in valve body.

7. Install spring (E) and cam detent (F) in spool (B).
8. Install balls (C) using petroleum jelly (two balls per
hole) in spool.
T6680BE UN18OCT88
9. Install spring seat (D) and spool end screw (G).
Tighten spool end screw finger tight.
10. Compress cam detent and spring using a punch to
seat balls. Slide spring seat down to hold balls in
place.
11. Remove spool end screw (G).
ACap Spool Spacer ESpring

BSpool F Cam Detent
CBalls (8 used) GSpool End Screw
DSpring Seat
T6680BF UN18OCT88
3160,BB2 1911OCT932/4
12. Install spring (A) and spring seat (B).

of spool end screw. Tighten spool end screw.
Specification
SpooltoSpool
T6680BG UN18OCT88
End Screw
(Bucket)Torque............................................ 2027 Nm (1520 lbft)

061411
PN=517
Hydraulics
14. Install spool assembly (M) in valve body.

15. Install parts (AL). Apply thread lock and sealer (high
strength) to cap screw (C).
Specification
Shoulder Cap Screw
T6680BH UN18OCT88
toSpool End Screw
(Bucket)Torque.............................................911 Nm (8496 lbin.)
Spool CaptoValve
Section Cap Screw
(Bucket)Torque......................................... 16 2 Nm (144 18 lbin.)
Seal PlatetoValve
Section Cap Screw
16. Install spool cap (N). ACap Screw (2 used) HCap Screw (2 used)
BSpacer (2 used) I Seal Plate
CShoulder Cap Screw J Spacer (2 used)
DClapper KWiper Seal
ELift Check L Spool Spacer Cap
F Spring MSpool Assembly
GORing NSpool Cap
3160,BB2 1911OCT934/4

061411
PN=518
Hydraulics
Disassemble and Assemble Boom Section
T6680BI UN18OCT88
1 Cam Detent 8 ORing 15 Cap Screw (2 used) 22 Spring Seat
2 Spring 9 Backup Ring 16 Seal Plate 23 Spool End Screw
3 Ball (4 used) 10 Poppet 17 Wiper Seal 24 Spool Cap
4 Spool 11 Spring 18 Oring (2 used) 25 ORing
5 AntiCavitation Plug 12 Lift Check 19 Valve Section 26 Detent Sleeve
6 ORing 13 ORing 20 Detent Spring Seal 27 Cap Screw (2 used)
7 Spring 14 Adjusting Circuit Relief 21 Spring

3. Lubricate parts with clean hydraulic oil.
4. Replace Orings and backup ring.

061411
PN=519
Hydraulics
5. Install detent sleeve (A) in valve body.

IMPORTANT: Cam detent (E) must be installed
with ramp away from spring.
6. Install spring (D) and cam detent (E) in spool (B).
T6680BJ UN18OCT88
7. Install balls (C) using petroleum jelly (one ball per
hole) in spool.
8. Install detent spring seat (F).
9. Compress cam detent and spring using a punch to
seat balls. Side detent spring seat down to hold balls
in place.
ADetent Sleeve DSpring

BSpool ECam Detent
CBall (4 used) F Detent Spring Seat
T6680BV UN18OCT88
3160,BB3 1911OCT932/4
10. Install spring (A) and spring seat (B).

of spool end screw. Tighten spool end screw.
Specification
SpooltoSpool End
T6680BW UN18OCT88
ScrewTorque.................................................911 Nm (8496 lbin.)

061411
PN=520
Hydraulics
12. Install spool assembly (K) into valve body.

13. Install parts (AJ).
Specification
Spool CaptoValve
Section Cap
T6680BX UN18OCT88
ScrewTorque................................................ 7 0.7 Nm (60 6 lbin.)
AntiCavitation
PlugTorque................................................. 81108 Nm (6080 lbft)
Seal PlatetoValve
Section Cap Screws
14. Install spool cap (L).
ACap Screw (2 used) GORing

BPlug HWiper Seal
CSpring I Cap Screw (2 used)
DPoppet J Seal Plate
ESpring KSpool Assembly
F Lift Check L Spool Cap
3160,BB3 1911OCT934/4

061411
PN=521
Hydraulics
Disassemble and Assemble Auxiliary Section
T8067AD UN09SEP93
ACircuit Relief (2 used) EWiper Seal (2 used) I Spool End Screw MFilter
BCap Screw (2 used) F ORing (2 used) J Spring
CSpool GCap Screw (2 used) KSpool Cap
DSeal Plate (2 used) HSpring Seat Retainer (2 used) L Spool Housing
IMPORTANT: Keep valve section components Specification

together as a matched set. Spool CaptoValve
Section Cap
1. Disassemble valve section (AM). ScrewsTorque.............................................. 7 0.7 Nm (60 6 lbin.)
2. Check spool and valve section for nicks or scratches. SpooltoSpool End
Spool and valve section must be replaced as a set. ScrewTorque.................................................911 Nm (8496 lbin.)
Seal PlatetoValve
3. Lubricate parts with clean hydraulic oil. Section Cap Screws
4. Replace Orings.
5. Assemble parts (AM).
TX,3160,BD862 1908SEP931/1

061411
PN=522
Hydraulics
Cross Section of System Relief Valve
T7050AM UN25APR89
System Relief Valve
APiston GSpring MORing SCap
BRelief Valve Poppet HBackup Ring (2 used) NHousing T ORing
CBackup Ring I ORing ONut UBackup Ring
DORing J Poppet PShims (as required)
EORing KSpring QPiston
F AntiCavitation Valve Poppet L Housing RORing
TX,3160,QQ485 1930JUL901/1

061411
PN=523
Hydraulics
Inspect System Relief Valve

NOTE: Repair parts are not available for the
system relief valve. If damaged, replace
relief valve as an assembly.
T6683AC UN18OCT88
1. Scribe a line on adjusting cap (I) and pilot body (D).
Loosen lock nut and count the number of turns to
remove adjusting cap (I).
2. Disassemble system relief valve.
3. Check relief valve parts for wear, plugged ports or
damaged Orings. Replace complete relief valve
assembly if any part is worn or damaged.
IMPORTANT: Pilot poppet (E) must be free ABackup Ring (2 used) KSpring
of contaminates, nicks or damage for BORing L Poppet (Orificed)
CORing MSpool
valve to work properly. DPilot Body NORing
EPilot Poppet OBackup Ring
Orifice of poppet (L) must be free of obstructions. F Spring PPoppet Sleeve
GShim (as required) QBackup Ring
4. Assemble valve. Install adjusting screw the same HSpool RORing
number of turns as removed. Tighten lock nut. I Cap SRelief Valve Body
J ORing T ORing
Specification
System Relief Valve Lock
NutTorque.................................................. 61 6 Nm (45 4.5 lbin.)
5. Check valve pressure setting after installation. (See

Group 902525 in TM1403.)
TX,3160,BD863 1908SEP931/1
Inspect AntiCavitation Bucket Circuit Relief

Valve
NOTE: Repair parts are not available for the bucket
circuit relief valve. If damaged, replace relief
valve as an assembly.
T8068AA UN08SEP93
1. Scribe a line on adjusting cap (I) and pilot body (D).
Loosen lock nut and count the number of turns to
remove adjusting cap (I).
2. Disassemble bucket circuit relief valve.
assembly if any part is worn or damaged. ABackup Ring (2 used) KSpring
BORing L Spring
IMPORTANT: Pilot poppet (E) must be free CORing MPoppet
of contaminates, nicks or damage for DPilot Body NSpool
valve to work properly. EPilot Poppet OORing
F Spring PBackup Ring
Passage in poppet (M) must be free GShim (as required) QPoppet Sleeve
of obstructions. HSpool RRelief Valve Body
I Cap SORing
J ORing
4. Assembly valve. Install adjusting screw the same
number of turns as removed. Tighten lock nut.
Specification
Circuit Relief Valve Lock
5. Check valve pressure setting after installation. (See
NutTorque.................................................. 61 6 Nm (45 4.5 lbin.)
Group 902525 in TM1403.)
TX,3160,BD864 1908SEP931/1

061411
PN=524
Hydraulics
Inspect Bucket and Boom Adjusting Circuit

Relief Valves
NOTE: Repair parts are not available for the circuit
relief valves. If damaged, replace relief
valve as an assembly.
T6683AE UN18OCT88
Bucket and boom circuit reliefs are similar.
Bucket circuit relief shown.
1. Disassemble circuit relief.

assembly if any part is worn or damaged.
IMPORTANT: Valve body must be on its seat AORing GCap
BNut HAdjusting Screw
before tightening nut. CPoppet I ORing (2 used)
DSpring Retainer J Valve Body
3. Assemble valve. Nut (B) must be against valve body ESpring KORing
(J) as valve body is installed. Tighten valve body and F Lock Nut
nut (B).
Specification
Adjusting Circuit Relief 4. Check valve pressure setting after installation. (See
Valve BodyTorque........................................ 3038 Nm (2228 lbft) Group 902525 in TM1403.)
Adjusting Circuit Relief
Valve NutTorque..................................................... 14 Nm (123 lbin.)
3160,BB5 1930JUL901/1
Disassemble and Inspect Boom and Bucket

Cylinders
IMPORTANT: Extend rod to remove oil or air between
rod piston and rod guide. Excessive amount
of trapped oil or air will force seals to expand
T6190AS UN19OCT88
making disassembly more difficult.
1. Extend rod so piston is approximately 25 mm (1 in.)

from rod guide.
Specification
PistontoRod
GuideDistance................................................................. 25 mm (1 in.)
TX,31,RB290 1927JAN981/7
2. Make a mark on rod guide and spanner nut (A) to aid

in assembly.
3. Remove nut using adjustable spanner wrench or blunt
chisel and a hammer.
NOTE: If nut and rod guide turn as an assembly, put
T6119AL UN19OCT88
cylinder in a vise. Vise jaws must contact cylinder

barrel behind nut and over rod guide area. Tighten
vise just enough to hold rod guide.

061411
PN=525
Hydraulics
NOTE: Filler rings (used for disassembly only) are

installed between spanner nut and rod guide to
aid in disassembly (later units only).
4. Move rod guide rearward, using a wooden dowel

or brass drift, just enough to remove snap ring (A).
T6119AM UN12APR91
Remove snap ring. Do not damage rod guide threads
or seal.
TX,31,RB290 1927JAN983/7
NOTE: Rod piston assembly removed for clarity

of photograph.
5. Install filler ring in snap ring groove.

6. Remove rod and piston assembly.
T6119AN UN19OCT88
TX,31,RB290 1927JAN984/7
7. Remove nut (A) to remove piston (B).

8. Remove wear ring (C) and cap seals (D).
ANut CWear Ring

BPiston DCap Seals
T6172BQ UN19OCT88

061411
PN=526
Hydraulics
9. Remove rod guide (A).

10. Remove Oring (C), backup ring (D), remove seals (B,
E, and G), and wear ring (F).
ARod Guide ESeal

BSeal F Wear Ring
T6119AK UN19OCT88
CORing GSeal
DBackup Ring
TX,31,RB290 1927JAN986/7
11. Inspect snap ring groove. If necessary, clean groove

of nicks or burrs.
T6119AO UN19OCT88
TX,31,RB290 1927JAN987/7

061411
PN=527
Hydraulics
Cross Section of Bucket and Boom Cylinder
T6223AZ UN26MAY89
ANut F Rod KSnap Ring PSeal Expander
BPiston GWiper Seal L Backup Ring QWear Ring
CBarrel HWear Ring MORing
DNut I Rod Seal NBackup Ring (2 used)
ERod Guide J Buffer Seal OCap Seal
TX,3160,BR302 1924OCT941/1
Assemble Boom and Bucket Cylinders

Use a cylinder repair kit when assembling cylinder. Put
clean hydraulic oil on all internal parts before assembling.
1. Install wiper seal. Push seal to bottom bore.
T6122AA UN19OCT88

061411
PN=528
Hydraulics
2. Install seals (B and C).

3. Install wear ring (A).
4. Install backup ring (D) and Oring (E).
AWear Ring DBackup Ring

BSeal EORing
CSeal
T6126AN UN27OCT88
TX,3160,BD917 1914JUN112/11
IMPORTANT: To prevent damage of cap seal during

assembly, the lands on piston must be clean
and free of nicks or burrs.
5. Inspect the piston lands. If necessary, clean lands of

any nicks or burrs that can cut cap seal.
T6122AB UN19OCT88

061411
PN=529
Hydraulics
6. Install seal expander.

NOTE: The cap seal can be made more pliable by
warming it with your hands or by putting seal in
hot water for approximately 5 minutes.
Once started, install cap seal as quickly as
T6122AC UN06AUG90
possible to keep the amount of time that seal
is stretched to a minimum.
7. Push seal on end of piston.

8. Install a plastic tie band around cap seal with the
smooth side against seal.
9. Pull cap seal across land into position over seal
expander using the plastic tie band.
T6122AE UN19OCT88
TX,3160,BD917 1914JUN114/11
IMPORTANT: For proper fit, the backup rings must be

installed with the radius toward seal expander.
10. Install backup rings (A) with radius (B) toward seal
expander (D).
11. Check if cap seal (C) is loose seal must fit tight
against seal expander and not turn. If seal can be
turned, it has been stretched too much and can be
damaged during assembly into barrel.
ABackup Ring (2 used) CCap Seal

BRadius DSeal Expander T6126AO UN19OCT88

061411
PN=530
Hydraulics
12. If necessary, shrink cap seal to its original size using

a ring compressor or a plastic tie band (A) and hose
clamp (C).
When using a ring compressor, put a piece of shim
stock between cap seal and compressor at the joint so
it does not damage seal.
When using a plastic tie band and hose clamp, grind
a taper (B) on one end of tie band. Install tie band
with the taper against cap seal. Before tightening the
hose clamp, tie band must be under hose clamp all
around piston.
T86565 UN09NOV88
TX,3160,BD917 1914JUN116/11
13. Install wear ring.
T6122AF UN19OCT88

061411
PN=531
Hydraulics
14. Install nut, snap ring, rod guide and piston assembly
on rod.
15. Install nut. Tighten nut to initial torque specification.
Specification
455G Boom
CylinderSize..................................................................... 100 x 50 mm
Weight ................................................................................53 kg (116 lb)
Snug Torque .............................................................. 340 Nm (250 lbft)
555G Boom
CylinderSize......................................................................115 x 63 mm
Weight ............................................................................... 73 kg (162 lb)
455G Bucket
CylinderSize....................................................................... 90 x 50 mm
Weight ................................................................................. 40 kg (88 lb)
555G Bucket
CylinderSize..................................................................... 100 x 50 mm
T6684AC UN19OCT88
Weight ................................................................................50 kg (110 lb)
16. Put tape around socket to divide socket into twelfths.

17. Put a piece of wire on the rod, over the piston. Use
tape to hold in position.
18. With wire pointing to a mark continue to tighten nut to 455G Bucket
final torque turn specification. CylinderTorque Turn..................................................... 1/12 Turn (30)
Specification 555G Bucket
455G Boom CylinderTorque Turn..................................................... 1/12 Turn (30)
CylinderTorque Turn..................................................... 1/12 Turn (30)
555G Boom
CylinderTorque Turn..................................................... 1/12 Turn (30)
TX,3160,BD917 1914JUN118/11
19. Apply petroleum jelly on seals and chamfer of barrel.

Apply a light coat of clear hydraulic oil to rod guide
threads and threads of spanner nut.
IMPORTANT: To prevent seal damage, the barrel,
piston, and rod must be in alignment
during installation.
T6122AH UN19OCT88
20. Carefully push piston and rod guide into barrel. Keep
piston and rod guide together.

061411
PN=532
Hydraulics
21. Push rod guide into barrel just enough to install snap
ring. Install snap ring.
22. Pull rod guide against snap ring.
23. Apply a light film of oil to ID of barrel at void between
rod guide and spanner nut to help minimize rust.
T6133AE UN27OCT88
24. Place filler ring between rod guide and spanner nut.
TX,3160,BD917 1914JUN1110/11
25. Clean spanner nut and rod guide threads using clean
and cure primer.
Apply thread lock and sealer (medium strength) to
threads.
26. Install nut and tighten nut until rod guide and nut
T6119AR UN27OCT88
marks, made before disassembly, align. Be sure nut
is tight.
TX,3160,BD917 1914JUN1111/11

061411
PN=533
Hydraulics
Disassemble and Assemble Ripper Cylinder
T6693AR UN19OCT88
ABushing (2 used) F Retainer KBackup Washer PSnap Ring
BGrease Fitting GVPacking L Snap Ring QWiper Seal
CBarrel HORing MVPacking RSpanner Nut
DLock Nut I Piston NWear Ring SRod
EWear Ring J ORing ORod Guide T Bushing
Tighten piston nut (D). Specification

Ripper CylinderSize...................................... 2.50 Bore x 15.19 Stroke
Weight ................................................................................. 14 kg (30 lb)
Piston Nut Torque ................................... 203285 Nm (150210 lbft)
TX,3160,BD867 1908SEP931/1

061411
PN=534
Section 32
Bulldozer
Contents
Page
Group 3201Blades
Other Material............................................ 3232011
Specifications ............................................ 3232011
Remove and Install Dozer Blade
(S.N. 785733)..................................... 3232012
Remove and Install Dozer Blade
(S.N. 785734 ).................................... 3232014
Remove and Install Cutting Edges
and End Bits .......................................... 3232015
Group 3215Controls Linkage

Other Material............................................ 3232151
Disassemble and Assemble Two
Lever Control Linkage (S.N.
763492).............................................. 3232151
Disassemble and Assemble Two
Lever Control Linkage (S.N.
763493 )............................................. 3232152
TBar Control Linkage (S.N.
763492).............................................. 3232153
Disassemble and Assemble TBar
Control Linkage (S.N. 763493
) ............................................................. 3232154
Group 3240Frames
Remove and Install Dozer
CFrame ................................................ 3232401
Disassemble and Assemble Blade
Pitch Strut .............................................. 3232405

Specifications ............................................ 3232601
Dozer Hydraulic Component
Location (S.N. 834560) ...................... 3232602
Dozer Hydraulic Component
Location (S.N. 834561 ) ..................... 3232603
Remove and Install Dozer Control
Valve ...................................................... 3232603
Disassemble and Assemble Dozer
Control Valve ......................................... 3232604
Inspect System Relief Valve ...................... 3232605
Inspect Lift Checks .................................... 3232605
Disassemble and Assemble Angle,
Tilt and Auxiliary Sections...................... 3232606
Disassemble and Assemble Blade
Section................................................... 3232607
Repair Cylinders ...................................... 32326010

061411
PN=1
Contents

061411
PN=2
Group 3201
Blades
Other Material
Number Name Use
PT569 (U.S.) NEVERSEEZ Lubricant Apply to blade pin (S.N. 785734).
T43513 (U.S.) Thread Lock and Sealer (High To be applied to threads of pitch
TY9474 (Canadian) Strength) pin retaining cap screw.
271 (LOCTITE)

TX,3201,BA901 1914JUN111/1
Specifications
Cutting Edge Nut Torque 350 Nm (260 lbft)

Blade Weight 379 kg (836 lb)
TX,3201,BA902 1930AUG931/1

061411
PN=537
Blades
Remove and Install Dozer Blade (S.N. 785733)
T6675AP UN07OCT93
APin CRubber Bushing (6 used) EPin GBushing

BSpacer (6 used) DPin F Pin
Continued on next page TX,3201,BA903 1914JUN111/2

061411
PN=538
Blades
1. Lower all equipment to ground. 5. Carefully remove blade using a hoist.

2. Stop engine and operate control valves to release 6. Inspect all parts and replace as necessary.
pressure in hydraulic system.
7. Apply NEVERSEEZ lubricant to pin (F).
CAUTION: Blade weighs approximately IMPORTANT: Tilt cylinder MUST be installed with
379 kg (836 lb). head end attached to blade.
3. Attach lifting chain to blade. 8. Install blade and pins (A, D, and E).
Specification
BladeWeight................................................................. 379 kg (836 lb)
9. Install pin (F), bushing (G), and retaining plates. Apply
thread lock sealer (high strength) to retaining plate
4. Remove parts (AF). cap screws.
TX,3201,BA903 1914JUN112/2

061411
PN=539
Blades
Remove and Install Dozer Blade (S.N. 785734 )
T8068AB UN09SEP93

061411
PN=540
Blades
APin DPin GCap Screw (4 used) J Blade

BSpacer (6 used) ECap Screw HCap
CRubber Bushing (6 used) F Pin I Shims

4. Remove parts (AI) to remove blade (J).
2. Stop engine and operate control valves to relieve
5. Inspect all parts and repair or replace as necessary.
IMPORTANT: Tilt cylinder MUST be installed with
CAUTION: Blade weighs approximately head end attached to blade.
379 kg (836 lb).
6. Install blade using pins (A, D and F) and cap (H).
3. Attach lifting chain to blade. Install same quantity of shims (I) as removed.
Specification
BladeWeight................................................................. 379 kg (836 lb)
TX,3201,BA904 1911OCT932/2
Remove and Install Cutting Edges and End Bits
T6676AL UN07OCT93
ACutting Edge CEnd Bit (2 used) ENut (13 used)

BCap Screw (13 used) DWasher (13 used)
1. Block frame with cutting edge above ground level. Specification

2. Remove parts (AE). Cutting Edge
NutsTorque............................................................. 350 Nm (260 lbft)
4. Install parts (AE). Tighten nuts (E).
TX,3201,BA906 1911OCT931/1

061411
PN=541
Blades

061411
PN=542
Group 3215
Controls Linkage
Other Material
Number Name Use
T43513 (U.S.) Thread Lock and Sealer (High To be applied to all linkage hardware
TY9474 (Canadian) Strength) that do not have locking nuts.
271 (LOCTITE)
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to ball joint threads.
242 (LOCTITE)

TX,32,DY84 1930OCT961/1
Disassemble and Assemble Two Lever Control Linkage (S.N. 763492)
T8061AA UN08SEP93
NOTE: Auxiliary lever (B) is used when an auxiliary 4. Apply high strength thread lock sealer to threads of
hydraulic function is required. ball joint (A).
1. Remove linkage assembly. 5. Assemble parts.
2. Disassemble parts.
3. Inspect linkage for worn or damaged parts. Replace
as necessary.
TX,3215,BA907 1911OCT931/1

061411
PN=543
Controls Linkage
Disassemble and Assemble Two Lever Control Linkage (S.N. 763493 )
T7269BI UN12APR90
ABall Joint BBall Joint CNut DAuxiliary Lever
Continued on next page TX,3215,QQ493 1909AUG901/2

061411
PN=544
Controls Linkage
NOTE: Auxiliary lever (D) is used when an auxiliary 3. Apply medium strength thread lock and sealer to
hydraulic function is required. threads of ball joints (A and B) and nut (C).
2. Disassemble and inspect parts for wear or damage.
Replace as necessary.
TX,3215,QQ493 1909AUG902/2
Disassemble and Assemble TBar Control Linkage (S.N. 763492)
T6679AA UN20OCT88
NOTE: Auxiliary lever (C) is used when an auxiliary IMPORTANT: Overtightening nut (A) will cause
hydraulic function is required. linkage to stay in one position and not
move freely to other functions.
1. Remove linkage assembly as shown.
2. Inspect linkage for worn or damaged parts. Replace 4. Tighten nut (A).
as necessary. 5. Assemble parts.
of ball joint (B).
TX,3215,QQ496 1911OCT931/1

061411
PN=545
Controls Linkage
Disassemble and Assemble TBar Control Linkage (S.N. 763493 )
T112881 UN20JAN98
ABall Joint BBall Joint CNut DAuxiliary Lever
Continued on next page TX,3215,QQ495 1909AUG901/2

061411
PN=546
Controls Linkage
NOTE: Auxiliary lever (D) is used when an auxiliary 3. Apply medium strength thread lock and sealer to
function is required. threads of ball joints (A and B) and nut (C) when used.
2. Disassemble and inspect parts for wear or damage.
Replace as necessary.
TX,3215,QQ495 1909AUG902/2

061411
PN=547
Controls Linkage

061411
PN=548
Group 3240
Frames

3240,QQ2 1914JUN111/3
Puller Set
Used to remove Cframe mounting pins.
3240,QQ2 1914JUN112/3
Disks
Used to remove and install bushings.
3240,QQ2 1914JUN113/3
Remove and Install Dozer CFrame

X9811 UN23AUG88
medical source. Such information is available Machines (S.N. 790251834650) use two
from Deere & Company Medical Department hoses which are coupled together to aid
in Moline, Illinois, U.S.A. in Cframe removal.
Machines (S.N. 834651) have bulkhead
NOTE: Cframe can be removed with blade attached.
connectors on the front grille to aid in
Cframe removal.
2. Stop engine. Operate all control valves to release 4. Machines (S.N. 790250):
Remove shields.
3. If desired, remove dozer blade. (See Group 3201.) Tag and disconnect hoses on angle and tilt cylinders.
Use caps and plugs to close all openings.
NOTE: Machines (S.N. 790250) have one hose
from control valve or crossover tube to tilt
and angle cylinders.

061411
PN=549
Frames
5. Machines (S.N. 790251834650):

Remove cap screws (B and D), clamps and spacers.
Slide sleeves (C) down to expose tilt cylinder hose
couplings.
Tag and disconnect six hoses (A) at couplings. Use
caps and plugs to close all openings.
AHoses CCover
BClamp DClamp
T112892 UN20JAN98
(S.N. 790251834650)
TX,3240,BA908 1911OCT932/6
6. Machines (S.N. 834651):

Remove clamp (B).
Disconnect cable (A) from shield (D).
Remove shield (D).
Tag and disconnect four hoses (C) from bulkhead
fittings.
T112883 UN20JAN98

061411
PN=550
Frames
T8073AB UN13SEP93
Legend for Dozer CFrame
APin (2 used) CBushing (4 used) ECap Screw (2 used)
BLifting Chain DPin (2 used)
7. Attach lifting chain (B) to Cframe. 12. Remove and install bushings (C) using disks from
NOTE: Early style Cframe shown. Later style is similar. driver set.
13. Install Cframe using pins and cap screws.
NOTE: Cframe can be removed with blade attached.
14. Install lift cylinders using pins and cap screws.
8. Remove cap screws and pins (A).
15. Install new Orings and connect hydraulic lines.
9. Remove cap screws (E) and pins (D)
16. Machines (S.N. 790250):
10. Use a hoist to remove Cframe from unit.
Install shields.
11. Inspect all parts and replace as necessary.

061411
PN=551
Frames
17. Machines (S.N. 790251834650):

Position covers (C) and install clamps (B and D).
AHoses CCover
BClamp DClamp
T112892 UN20JAN98
(S.N. 790251834650)
TX,3240,BA908 1911OCT935/6
18. Machines (S.N. 834651 ):

Install shield (D) and connect cable (A).
19. Install dozer blade (if removed). (See procedure in
Group 3201.)
20. Start engine and check dozer blade for proper
T112883 UN20JAN98
operation.
ACable CHoses
BClamp DShield
(S.N. 834651 )
TX,3240,BA908 1911OCT936/6

061411
PN=552
Frames
Disassemble and Assemble Blade Pitch Strut

1. Remove parts (AC) and (E).
3. Remove bushing (D) using 50 mm and 90 mm disks
from driver set.
4. Install all parts.
ACap Screw (2 used) ESnap Ring (2 used)

BCover (3 used) F Spacer
CBushing GGrease Fitting (2 used)
DBushing
T6690AC UN07OCT93
3240,QQ7 1911OCT931/1

061411
PN=553
Frames

061411
PN=554
Group 3260
Hydraulic System
Specifications
Dozer Control Valve Tie Bolt Nuts Torque 43 Nm (32 lbft)

Control Valve with Mounting Plate Weight 27 kg (60 lb)
Lift Cylinder Size 80 x 40 mm
Angle Cylinder Size 80 x 45 mm
450G and 550G Tilt Cylinders Size 90 x 45 mm
650G Tilt Cylinder Size 100 x 50 mm
Ripper Cylinder Size 2.50 Bore x 15.19 Stroke
Piston Nut Torque 203285 Nm (150210 lbft)
3260,SS1 1909AUG901/1

061411
PN=555
Hydraulic System
Dozer Hydraulic Component Location (S.N. 834560)
T8037BF 1923JUL93
(S.N. 834560)
AReservoir F Blade Lift Section KAngle Cylinders PStabilizer Valve
BReturn Filter GPower Beyond Port L Oil Cooler (if equipped) QBackhoe Control Valve
CAuxiliary Section HHydraulic Pump (Torque MTilt Cylinder RTo Return Filter Inlet
DAngle Section Converter) NBreather SBackhoe System (if equipped)
ETilt Section I Hydraulic Pump (Direct Drive) OFrom Power Beyond Port T Dozer Hydraulic System (S.N.
J Blade Lift Cylinders 834560)
TX,32,RB291 1927JAN981/1

061411
PN=556
Hydraulic System
Dozer Hydraulic Component Location (S.N. 834561 )
T112518 1909JAN98
(S.N. 834561 )
AReservoir F Blade Lift Section KAngle Cylinders PStabilizer Valve
BReturn Filter GPower Beyond Port L Oil Cooler (if equipped) QBackhoe Control Valve
CAuxiliary Section HHydraulic Pump (Torque MTilt Cylinder RTo Return Filter Inlet
DAngle Section Converter) NBreather SBackhoe System (if equipped)
ETilt Section I Hydraulic Pump (Direct Drive) OFrom Power Beyond Port T Dozer Hydraulic System (S.N.
J Blade Lift Cylinders 834561 )
TX,3260,BA910 1930AUG931/1
Remove and Install Dozer Control Valve

all connections before applying pressure. Search X9811 UN23AUG88


061411
PN=557
Hydraulic System
1. Disconnect lines (AD) and (GJ).

2. Disconnect linkages (F).
CAUTION: The approximate weight of control

valve with mounting plate is 27 kg (60 lb).
T6685AG UN18OCT88
3. Remove valve mounting plate (E) with valve.
Specification
Mounting PlateWeight....................................................... 27 kg (60 lb)
4. Remove valve from mounting plate.

5. Install valve on mounting plate. (S.N. 834560)
6. Install valve and mounting plate. Tighten cap screws.
7. Connect lines and linkages.
AAngle SectiontoLeft F Linkages

Cylinder Head End and GAngle SectiontoLeft
Right Cylinder Rod End Cylinder Rod End and Right
T112884 UN20JAN98
Line Cylinder Head End Line
BTilt SectiontoCylinder HTilt SectiontoCylinder
Rod End Line Head End Line
CBlade Raise/Lower I Blade Raise/Lower
SectiontoCylinder Head SectiontoCylinder Rod
End Line End Line
DControl ValvetoPump J Control ValvetoReturn
Outlet Port Line Filter Line
EValve Mounting Plate (S.N. 834561 )
TX,3260,BA911 1930AUG932/2
Disassemble and Assemble Dozer Control

Valve
IMPORTANT: For proper operation, control valve
must be assembled in the correct order.
Keep all components for each valve
T6685AH UN18OCT88
1. Disassemble valve.
2. Inspect parts for wear or damage.
3. Replace Orings (E) in each section.
4. Assemble parts. Tighten nuts (C).
Specification AEnd Plate F System Relief Valve
BCap Screw (3 used) GInlet and Outlet Port Plate
Dozer Control Valve Tie CNut (3 used) HBlade Raise Section
Bolt NutsTorque.......................................................... 43 Nm (32 lbft) DLift Checks I Tilt Section
EORings J Angle Section
3260,SS3 1911OCT931/1

061411
PN=558
Hydraulic System
Inspect System Relief Valve

1. Inspect relief valve parts for wear or damage. Replace
with new valve if necessary. Install new Oring (A) and
backup ring (C).
2. Install new Oring (B) in housing bore.
T6033AE UN03NOV88
3. Install relief valve.
3260,SS4 1926JAN881/1
Inspect Lift Checks

1. Remove lift check poppet (A) to disassemble plug.
2. Inspect parts for wear or damage. Install new backup
rings (F and G) and new Orings (CE).
T6024AL UN03NOV88
ALift Check Poppet EORing
BSpring F Backup Ring
CORing GBackup Ring (2 used)
DORing
3260,SS5 1926JAN881/1

061411
PN=559
Hydraulic System
Disassemble and Assemble Angle, Tilt and Auxiliary Sections
T6685AM UN18OCT88
ACap Screw (2 used) EWasher (2 used) I Orifice (2 or 4 used) Angle MSpring Retainer (2 used)
BSeal Retainer Plate F Washer (2 used) and Tilt Sections Only NSpring
CWiper Seal Retainer GORing (2 used) J Cap Screw (2 used) OSpool
DWiper Seal HSpring (2 or 4 used) Angle Tilt KCap PValve Section
Sections Only L Spool End Screw
IMPORTANT: Keep valve section components 4. Replace Orings.

5. Orifice (I) and spring (H) are used in:
Tilt section workports only (S.N. 780677)
2. Check spool and valve section for nicks or scratches. Tilt and angle sections workports (S.N. 780678)
6. Assemble parts. Tighten cap screws.
TX,3260,BA914 1911OCT931/1

061411
PN=560
Hydraulic System
Disassemble and Assemble Blade Section
T6685AL UN18OCT88
ACap Screw (2 used) GORing MSpring Retainer (2 used) SDetent Cone
BSeal Retainer Plate HValve Section NSpring T Spring
CWiper Seal Retainer I Cap Screw (2 used) ODetent Collar UBall (4 used)
DWiper Seal J Lock Washer (2 used) PORing VSpool
EWasher KEnd Cap QORing
F Washer L Snap Ring RSpacer

4. Replace Orings.

061411
PN=561
Hydraulic System
5. Install spring (I) and detent cone (K) in spool (H).

6. Install Oring (E) in detent collar (D).
7. Assemble spacer (G), Oring (F), and detent collar (D)
on spool (H).
T6023AP UN03NOV88
8. Put petroleum jelly on detent balls (J) and install in
holes in spool.
9. Carefully slide detent collar (D) over balls while holding
detent cone (K) and spring (I) in spool using a punch.
ASnap Ring GSpacer

BSpring Retainer (2 used) HSpool
CSpring I Spring
DDetent Collar J Detent Balls (4 used)
EORing KDetent Cone
F ORing
T6023AQ UN03NOV88
3260,SS7 1911OCT932/5
10. Install spring retainer (C) and spring (B). Compress

spring and install snap ring (A) on end of spool.
ASnap Ring CSpring Retainer (2 used)

BSpring DDetent Collar
T6023AR UN03NOV88

061411
PN=562
Hydraulic System
11. Install spool (C) in valve section.

12. Install end cap (B). Tighten two cap screws (A).
T6023AK UN03NOV88
3260,SS7 1911OCT934/5
13. Install parts (AG).

14. Tighten cap screws (A).
ACap Screw (2 used) EWasher

BSeal Retainer Plate F ORing
CWiper Retainer GWiper Seal
T6685AI UN18OCT88
DWasher
3260,SS7 1911OCT935/5

061411
PN=563
Hydraulic System
Repair Cylinders
1. Remove snap rings (A).
2. Use disks from driver set to remove and install bushing
(B or C).
T8068AE UN09SEP93
NOTE: Tilt and angle cylinders use selfaligning bushing
(B). Lift cylinders use bushing (C).
3. Install snap rings.

Specification
Lift CylinderSize................................................................. 80 x 40 mm
Weight ............................................................................... 72 kg (160 lb)
Dozer Lift Cylinder Piston
NutSnug Torque...................................................... 425 Nm (313 lbft) 650G Tilt
Torque Turn ..................................................................... 1/12 Turn (30) CylinderSize..................................................................... 100 x 50 mm
Angle CylinderSize............................................................ 80 x 45 mm Weight ................................................................................50 kg (110 lb)
Weight ............................................................................... 75 kg (165 lb) Dozer 650G Cylinder
Dozer Angle Cylinder Piston NutSnug
Piston NutSnug Torque........................................................................ 340 Nm (250 lbft)
Torque........................................................................ 425 Nm (313 lbft) Torque Turn ..................................................................... 1/12 Turn (30)
Torque Turn ..................................................................... 1/12 Turn (30) Ripper CylinderSize...................................... 2.50 Bore x 15.19 Stroke
450G and 550G Tilt Weight ................................................................................. 14 kg (30 lb)
CylindersSize..................................................................... 90 x 45 mm Ripper Piston
Weight ............................................................................... 63 kg (139 lb) NutTorque..........................................203285 Nm (150210 lbft)
Dozer 450G and
550G Cylinder Piston NOTE: For cylinder repair, see Group 3160.
NutSnug Torque...................................................... 130 Nm (100 lbft)
Torque Turn ..................................................................... 1/12 Turn (30)
TX,3260,BA912 1930AUG931/1

061411
PN=564
Section 33
Backhoe
Contents
Page Page
Group 3300Removal and Installation Disassemble and Assemble

Remove Backhoe Assembly...................... 3333001 Backhoe Control Valve ........................ 33336021
Install Backhoe Assembly.......................... 3333003 Disassemble and Assemble
Circuit Relief Valve With
Group 3302Buckets AntiCavitation ..................................... 33336021
Service Equipment and Tools .................... 3333021 Disassemble and Assemble Circuit
Remove and Install Bucket and Relief Valve.......................................... 33336022
Bucket Links .......................................... 3333021 Disassemble and Assemble Crowd
Remove and Install Bucket and Bucket Valve Section .................... 33336023
Bushings................................................ 3333022 Disassemble and Assemble Boom
Remove and Install Tooth Shank............... 3333022 Valve Section ....................................... 33336024
Remove and Install Cutting Disassemble and Assemble Swing
Edges .................................................... 3333024 Valve Section ....................................... 33336025
Group 3315Controls Linkage Outlet Valve Section (With Low
Specifications ............................................ 3333151 Pressure Regenerative Relief
Remove, Install, and Adjust Valve)................................................... 33336026
Backhoe Control Valve Linkage.............. 3333151 Backhoe Relief Valve
Remove, Install, and Adjust Specifications ...................................... 33336026
Stabilizer Valve Linkage ........................ 3333151 Remove and Install Stabilizer
Valve .................................................... 33336027
Group 3340Frames Cross Section View of Stabilizer
Service Equipment and Tools .................... 3333401 Control Valve ....................................... 33336028
Other Material............................................ 3333401 Disassemble Stabilizer Control
Specifications ............................................ 3333401 Valve .................................................... 33336029
Remove and Install Dipperstick ................. 3333402 Assemble Stabilizer Control
Remove and Install Boom ......................... 3333404 Valve .................................................... 33336031
Remove and Install Swing Frame.............. 3333407
Remove and Install Stabilizer .................... 3333407
Remove and Install Valve Box................... 3333408

Other Material............................................ 3333601
Specifications ............................................ 3333602
Disassemble Bucket, Crowd,
Boom, Swing and Stabilizer
Cylinder ................................................. 3333603
Cross Section of Bucket
Cylinder9300G, 9310G
and Boom Cylinder9300G.................. 3333608
Cross Section of Boom
Cylinder9310G ................................... 3333609
Cross Section of Crowd
Cylinder9300G ................................. 33336010
Cross Section of Crowd
Cylinder9310G ................................. 33336011
Cross Section of Stabilizer
Cylinder9300G, 9310G .................... 33336012
Cross Section of Swing
Cylinder9300G, 9310G .................... 33336013
Assemble Bucket, Crowd, Boom,
Swing and Stabilizer Cylinder.............. 33336014
Remove and Install Backhoe
Control Valve ....................................... 33336019

061411
PN=1
Contents

061411
PN=2
Group 3300
Remove Backhoe Assembly
1. Park unit on level surface. Lower equipment as shown.
T6662AA UN08NOV88
T54,3300,J75 1917SEP871/4
CAUTION: Swing lock pin must be installed to

prevent backhoe assembly from tipping.
2. Install lock pin (A).

3. Start engine. Use stabilizer hydraulics to remove
T6662AB UN08NOV88
weight from upper mounting pins.
NOTE: Early style backhoe uses cotter pins (C) to secure
pins (B) later style uses quick lock pins.
4. Remove cotter pin (C) (or quick lock pin, if equipped)

and pin (B) from both sides.
Continued on next page T54,3300,J75 1917SEP872/4

061411
PN=567
5. Use stabilizer hydraulics to raise backhoe frame off

lower mounting hooks (A).
6. Carefully drive crawler ahead just enough to clear
mounting hooks (A).
7. Carefully lower backhoe.
8. Stop engine. Operate control valves to release
hydraulic pressure.
9. Disconnect line (C) from quick coupler (B).
10. Disconnect line (D) from quick coupler (E).
11. Connect line (C) with coupler (E).
AMounting Hooks DHydraulic Return Line

BQuick Couplers EQuick Couplers
CHydraulic Pressure Line
T6662AC UN08NOV88
T54,3300,J75 1917SEP873/4
12. Connect line (D) with coupler (B)
T6662AD UN08NOV88
T54,3300,J75 1917SEP874/4

061411
PN=568
Install Backhoe Assembly
CAUTION: Do not disconnect hydraulic lines

while engine is running.
1. Move machine close enough to connect hydraulic

lines.
2. Stop engine. Operate control valves to release
3. Connect lines.
4. Start engine, use stabilizer hydraulics to lower
backhoe frame on mounting hooks (A).
AMounting Hooks DHydraulic Return Line

BQuick Coupler EQuick Coupler
CHydraulic Pressure Line
T6662AC UN08NOV88
T54,3300,J79 1911OCT931/2
5. Install pin (B) and cotter pin (C) (or quick lock pin, if
equipped) on both sides. Remove lock pin (A).
T6662AB UN08NOV88
T54,3300,J79 1911OCT932/2

061411
PN=569

061411
PN=570
Group 3302
Buckets

T54,3302,J62 1914JUN111/2
31 mm 49 mm Disk 37 mm 55 mm Disk
Used to install ripper bushings. Used to install 457 mm, 610 mm, 762 mm, 914 mm
37 mm 55 mm Disk 18 in. and 24 in. bucket bushings.
31 mm 49 mm Disk
Used to install ripper bushings.
31 mm 43 mm Disk Used to install heavyduty bucket bushings.
37 mm 55 mm Disk
Used to install 406 mm (16 in.) Bucket Bushings.
37 mm 49 mm Disk Used to install heavyduty bucket bushings.
31 mm 43 mm Disk
Used to install 406 mm (16 in.) Bucket Bushings.
31 mm 49 mm Disk Used to install cemetery bucket bushings.
37 mm 49 mm Disk
Used to install 457 mm, 610 mm, 762 mm, 914 mm
18 in. and 24 in. bucket bushings. Used to install cemetery bucket bushings.
T54,3302,J62 1914JUN112/2
Remove and Install Bucket and Bucket Links

CAUTION: Bucket weighs approximately
159 kg (350 lb).
NOTE: Early style backhoe uses cotter pins to secure
T93210 UN01NOV88
pins (A) later style uses snap rings.
1. Remove cotter pins (or snap rings) to remove pins (A),

links, and bucket.
2. Inspect bushings, replace if necessary. (See
3. Inspect snap rings (if equipped), replace if necessary.
4. Install bucket, links, pins (A) and cotter pins or snap
rings (if equipped).
Specification
BucketWeight................................................................ 159 kg (350 lb)
TX,3302,BA930 1916SEP931/1

061411
PN=571
Buckets
Remove and Install Bucket Bushings

1. Remove bushing by welding three straight beads the
inside length of bushing.
2. Allow bushing to cool before removing with a punch.
3. Install new bushing even with outside surface of
bucket. See information below for driver sizes.
T92506 UN25MAY89
TX,3302,BA972 1916SEP931/1
Remove and Install Tooth Shank

1. Remove top and bottom welds using air arc equipment
or cutting torch.
T92509 UN31OCT88
T92510 UN31OCT88
Continued on next page T54,3302,21 1920MAY831/5

061411
PN=572
Buckets
T92511 UN31OCT88
T54,3302,21 1920MAY832/5
3. Install tooth shank on cutting edge. Be sure shank is

positioned correctly.
A12.7 3 mm (0.50 .12 in.) B180.8 3 mm (7.12 .12 in.)
T92512 UN25MAY89
T54,3302,21 1920MAY833/5
NOTE: The corner shanks require a continuous 9.5

mm (0.38 in.) fillet weld at B and C. Weld
at A on corner shanks must fill groove flush
with cutting edge surface.
4. Weld tooth shank to top side of cutting edge using a

continuous 9.5 mm (0.38 in.) fillet weld on three sides.
T92513 UN31OCT88
Leave 19 mm 3 mm (0.75 0.12 in.) on the front of
the cutting edge free of weld.

061411
PN=573
Buckets
5. Weld tooth shank to bottom side of cutting edge using

a continuous 9.5 mm (0.38 in.) fillet weld on three
sides. Leave 19 mm 3 mm (0.75 0.12 in.) on the
front of the cutting edge free of weld.
T92514 UN31OCT88
T54,3302,21 1920MAY835/5
Remove and Install Cutting Edges

1. Remove cutting edges using air arc equipment or a
cutting torch.
T92515 UN31OCT88
T92516 UN31OCT88

061411
PN=574
Buckets
T92517 UN31OCT88
T54,3302,26 1920MAY832/5
3. Install cutting edges using service jack and clamps.

Tack weld cutting edges in correct position.
T92518 UN31OCT88

061411
PN=575
Buckets
4. Finish welding the cutting edges using a 9.5 mm (0.38

in.) fillet weld (A), a 6.4 mm (0.25 in.) fillet weld (B),
and a 9.5 mm (0.38 in.) fillet weld (C).
T92519 UN31OCT88
T54,3302,26 1920MAY834/5
5. Weld the bottom side of cutting edges using 9.5 mm

(0.38 in.) weld (A), 15.7 mm (0.62 in.) weld (B), and a
6.4 (0.25 in.) fillet weld (C).
6. Install tooth shanks and tips.
T92520 UN31OCT88
T54,3302,26 1920MAY835/5

061411
PN=576
Group 3315
Controls Linkage
Specifications
Control Valve Rod Ball Torque 25 5 Nm (18 4 lbft)

JointtoLever Nut
T54,3315,J2 1901AUG901/1
Remove, Install, and Adjust Backhoe Control

Valve Linkage
1. Remove control valve cover.
2. Inspect parts (AG) and replace as necessary.
3. Adjust control lever base plate horizontally. Adjust
base plate perpendicular to backside of valve
mounting plate.
4. Adjust ball joints to get full spool travel. Tighten nut.
Specification
Control Valve Rod
Ball JointtoLever
NutTorque....................................................... 25 5 Nm (18 4 lbft)
5. Install cover.
ABall Joint (2 used) ERodBucket Section

BLink (2 used) F RodBoom Section
CBall Joint (4 used) GRodSwing Section
DRod Arm Section
T6668AB UN31OCT88
T54,3315,K1 1901AUG901/1
Remove, Install, and Adjust Stabilizer Valve

Linkage
1. Remove control valve cover.
2. Inspect parts (AG) and replace as necessary.
T6668AC UN31OCT88
3. Tighten cap screw (C) and nut (F) until side play is
removed.
4. Install cover.
AWasher (2 used) EWasher (3 used)

BCotter Pin (2 used) F Nut
CCap Screw GSpring Washer
DBushing (2 used)
T54,3315,K2 1928SEP871/1

061411
PN=577
Controls Linkage

061411
PN=578
Group 3340
Frames

T54,3340,K1 1914JUN111/2
64 mm and 74 mm Disks
Used to install boom bushings.
Used to install swing frame to main frame bushings. 38 mm and 50 mm Disks
Used to install dipperstick to bucket links bushings.
Used to install swing frame to boom bushings. 38 mm and 55 mm Disks
Used to install dipperstick to bucket bushings.
T54,3340,K1 1914JUN112/2
Other Material
Number Name Use
TY15969 (U.S.) Retaining Compound (Maximum Applied to new bushings.
680 (LOCTITE)

TX,33,RB413 1905FEB981/1
Specifications
Dipperstick (With Bucket Cylinder) Weight 204 kg (450 lb)

Boom (With Boom And Crowd Weight 341 kg (750 lb)
Cylinders)
Swing Frame Weight 91 kg (200 lb)
Valve Box Cap Screws Torque 115 Nm (85 lbft)
T54,3340,K2 1901AUG901/1

061411
PN=579
Frames
Remove and Install Dipperstick

X9811 UN23AUG88
medical source. Such information is available NOTE: If bucket linkage is removed, put a chain around
from Deere & Company Medical Department cylinder rod. Use a rag to protect rod.
3. Relieve pressure in the hydraulic system. Disconnect
1. Remove bucket. (See procedure in Group 3302.) both bucket cylinder hydraulic lines. Close all openings
using caps and plugs.
2. Install a floor stand under boom. Put a wooden block
under crowd cylinder.
T54,3340,K3 1911OCT931/5
4. Remove hose clamps (C).
CAUTION: The approximate weight of

dipperstick is 204 kg (450 lb).
5. Connect dipperstick to a hoist with a lifting strap.
T6124AQ1 UN31OCT88
Specification
Dipperstick (With Bucket
Cylinder)Weight............................................................ 204 kg (450 lb)
6. Remove pins (A and B) to remove dipperstick.
T54,3340,K3 1911OCT932/5
7. Inspect bushings (A and B).

8. Remove bushings by welding three straight beads the
inside length of the bushing.
9. Allow sufficient time for bushing to cool before
removing with a punch.
T92545 UN18APR89
10. Apply retaining compound to outside of new bushings.

Install bushings (A) with 38 mm and 50 mm disks and
bushings (B) with 38 mm and 55 mm disks. Press
bushing even with outside edge of dipperstick.
Continued on next page T54,3340,K3 1911OCT933/5

061411
PN=580
Frames
11. Install dipperstick using hoist and lifting strap. Install

pins (A and B) and cap screws.
T6124AT UN31OCT88
T54,3340,K3 1911OCT934/5
12. Connect hydraulic lines.

13. Install hose clamp (A and B) and tighten.
14. Install bucket.
T6124AU UN31OCT88
T54,3340,K3 1911OCT935/5

061411
PN=581
Frames
Remove and Install Boom

1. Remove dipperstick. (See procedure in this group.)
CAUTION: The approximate weight of boom with

boom and crowd cylinders is 341 kg (750 lb).
2. Connect boom to hoist using a lifting strap.

Specification
Boom (With
Boom And Crowd
Cylinders)Weight.......................................................... 341 kg (750 lb)
T6669BA UN31OCT88
Continued on next page T54,3340,K7 1928SEP871/3

061411
PN=582
Frames
3. Remove cap screw (G) and pin (H). Carefully lower

boom cylinder rod.
4. Identify lines to aid in assembly. Disconnect lines
(AE). Close all openings with caps and plugs.
5. Remove cap screws (J) and pins (I). Remove boom.
ACrowd Section Top F Boom Section Bottom

PorttoCylinder Rod and PorttoCylinder Rod End
Line Line
BCrowd Section Bottom GCap Screw
PorttoCylinder Head End HPin
Line I Pin (2 used)
CBucket Section Top J Cap Screw (2 used)
PorttoCylinder Head
End Line
DBucket Section Bottom
PorttoCylinder Head Rod
End Line
EBoom Section Top
PorttoCylinder Head
End Line
T6669BB UN31OCT88
Continued on next page T54,3340,K7 1928SEP872/3

061411
PN=583
Frames
6. Inspect bushings (A). Remove, if necessary, by

welding three straight beads the inside length of the
bushings.
7. Allow sufficient time for bushings to cool before
removing with a punch.
8. Apply retaining compound to outer surface of
bushings.
9. Install new bushings even with outer edge of boom
using 54 mm and 64 mm disks.
10. Install boom (shim as required).
11. Install hydraulic lines, pins, cap screws and nuts.
T6130AG UN25MAY89
T54,3340,K7 1928SEP873/3

061411
PN=584
Frames
Remove and Install Swing Frame

1. Remove boom and dipperstick. (See procedure in
this group.)
2. Position swing frame to the side.
CAUTION: The approximate weight of swing

frame is 91 kg (200 lb).
3. Connect swing frame to hoist with a lifting strap.

Specification
Swing FrameWeight....................................................... 91 kg (200 lb)
4. Remove cap screw (B) and pins (A).

5. Remove cap screws (C) and pins (D). Remove swing
frame.
6. Inspect bushings and replace, if necessary. Apply
retaining compound to outside surface of new
bushings.
T6669BC UN31OCT88
7. Install swing frame, thrust washer (E), pins (A and D)
and cap screws (B and C).
8. Install boom and dipperstick. (See procedure in this
group.)
APin (2 used) DPin (2 used)

BCap Screw EThrust Washer
CCap Screw (2 used)
T54,3340,K10 1911OCT931/1
Remove and Install Stabilizer

1. Remove stabilizer cylinder.
2. Attach hoist to stabilizer.
3. Remove locknut and cap screw (A) and drive pin out.
T93378 UN01NOV88
4. Remove stabilizer.
5. Install stabilizer and mounting pin using cap screw
and locknut.
T54,3340,K11 1920OCT871/1

061411
PN=585
Frames
Remove and Install Valve Box

1. Remove valve box cover.
2. Disconnect linkages (A).
3. Remove four cap screws (B).
NOTE: Support valve when removing valve box.
4. Remove three cap screws attaching valve to valve

box. Remove valve box using a hoist.
5. Install valve box and three cap screws attaching valve
and valve box.
6. Install and tighten cap screws, washers and nuts (B).
Specification
Valve Box Cap
ScrewsTorque............................................................115 Nm (85 lbft)
7. Connect linkages (A).

8. Install valve box cover.
T6679AC UN31OCT88
T54,3340,K12 1911OCT931/1

061411
PN=586
Group 3360
Hydraulic System
Other Material
Number Name Use
TY16285 (U.S.) Cure Primer Applied to clean threads of
TY9485 (Canadian) spanner nut.
7649 (LOCTITE)
T43512 (U.S.) Thread Lock and Sealer (Medium Applied to spanner nut threads.
242 (LOCTITE)

TX,3360,QQ500 1919NOV921/1

061411
PN=587
Hydraulic System
Specifications
Tie Bolt Nuts (1/2 inch) Torque 102 Nm (75 lbft)

Tie Bolt Nuts (7/16 inch) Torque 68 Nm (50 lbft)
Relief Valve (Circuit) Torque 54 Nm (40 lbft)
ORing Nut Torque 4 Nm (35 lbin.)
Relief Valve (Circuit with Torque 95 Nm (70 lbft)
AntiCavitation)
Screws Spool Cap Torque 7 Nm (60 lbin.)
SpooltoSpool End Screw Torque 10 Nm (90 lbin.)
Seat Retainer (Stabilizer Torque 4754 Nm (3540 lbft)
Control Valve)
Spool Plugs (Stabilizer Control Valve) Torque 4754 Nm (3540 lbft)
Stabilizer Cylinder Size 90 x 45 mm
Cap Screw Torque 913 46 Nm (673 34 lbft)
Crowd Cylinder9300G Size 90 x 50 mm
Crowd Cylinder9310G Size 100 x 56 mm
Swing Cylinder Size 100 x 50 mm
Boom Cylinder9300G Size 100 x 50 mm
Boom Cylinder9310G Size 115 x 56 mm
Bucket Cylinder9300G Size 80 x 45 mm
Bucket Cylinder9310G Size 90 x 50 mm
TX,3360,BA931 1921JUL941/1

061411
PN=588
Hydraulic System
Disassemble Bucket, Crowd, Boom, Swing

and Stabilizer Cylinder
IMPORTANT: Extend rod to remove oil or air between
the rod piston and rod guide. Excessive amount
of trapped oil or air will force seals to expand
T6190AS UN19OCT88
making disassembly more difficult.
NOTE: Repair procedures for cylinders are similar

except as shown.
1. Extend rod so rod piston is approximately 25.4 mm (1

in.) from rod guide.
Specification
Rod PistontoRod
GuideDistance............................................................. 25.4 mm ( 1 in.)
TX,3360,BR412 1924OCT941/8
2. Make a mark on rod guide and spanner nut (A) to aid

in assembly.
3. Remove nut using adjustable spanner wrench or blunt
chisel and a hammer.
NOTE: If nut and rod guide turn as an assembly, put
T6119AL UN19OCT88
cylinder in a vise. Vise jaws must contact cylinder
barrel behind nut and over rod guide area. Tighten
vise just enough to hold rod guide.
TX,3360,BR412 1924OCT942/8
NOTE: Filler rings (used for disassembly only)

are installed between spanner nut and rod
guide to aid in disassembly.
4. Move rod guide rearward with a wooden dowel or

brass drift far enough to remove snap ring (A). Remove
T6119AM UN12APR91
snap ring. Do not damage rod guide threads or seals.
Continued on next page TX,3360,BR412 1924OCT943/8

061411
PN=589
Hydraulic System
NOTE: Rod piston assembly removed for clarity

of photograph.
5. Install filler ring in snap ring groove.

6. Remove rod and piston assembly.
T6119AN UN19OCT88

061411
PN=590
Hydraulic System
7. Repair piston assembly.

Remove wear ring and cap seal assembly. Remove
piston assembly from rod, if necessary.
Remove wear ring, cap seal assembly and brake
seal rings. Remove piston assembly from rod, if
T6172BQ UN19OCT88
necessary
seal ring. Remove piston assembly from rod, if
necessary.
Bucket Cylinder9300G, 9310G

Boom Cylinder9300G
ANut CWear Ring

BPiston DCap Seal Assembly
T8079AD UN23SEP93
Boom Cylinder9310G
T7535AB UN16MAY91
Swing Cylinder9300G, 9310G

061411
PN=591
Hydraulic System
Remove wear ring and cap seal assembly. Remove

piston assembly from rod, if necessary.
seal ring. Remove piston assembly from rod, if
necessary.
T7976AW UN14APR93
ANut DCap Seal Assembly
BBrake Seal Ring (2 used) EPiston
CWear Ring
ACap Seal Assembly DNut

BWear Ring EPiston
Crowd Cylinder9300G
CBrake Seal Ring Stabilizer Cylinder9300G, 9310G
ACap Screw DWear Ring

BWasher ECap Seal Assembly
CPiston
T8079AF UN23SEP93
ACap Screw DBrake Seal Ring
BWear Ring EPiston
CCap Seal Assembly
Crowd Cylinder9310G

061411
PN=592
Hydraulic System
8. Remove rod guide (A).

9. Remove Oring (C), backup ring (D), seals (B, E and
G) and wear ring (F).
ARod Guide ESeal

BSeal F Wear Ring
T6119AK UN19OCT88
CORing GSeal
DBackup Ring
All Cylinders Except Swing Cylinder
T7545BS UN19JUN91
Swing Cylinder Only
TX,3360,BR412 1924OCT947/8
10. Inspect snap ring groove. If necessary, clean groove

of nicks or burrs.
T6119AO UN19OCT88
TX,3360,BR412 1924OCT948/8

061411
PN=593
Hydraulic System
Cross Section of Bucket Cylinder9300G, 9310G and Boom Cylinder9300G
T6223AZ UN26MAY89
ANut F Rod KSnap Ring PSeal Expander
CBarrel HWear Ring MORing
DSpanner Nut I Rod Seal NBackup Ring (2 used)
ERod Guide J Buffer Seal OCap Seal Assembly
TX,3360,BA944 1916SEP931/1

061411
PN=594
Hydraulic System
Cross Section of Boom Cylinder9310G
T8079AK UN23SEP93
ASpecial Lock Nut F Rod KFiller Ring PBackup Ring (2 used)
BPiston GWiper Seal L Snap Ring QCap Seal
CBarrel HWear Ring MBackup Ring RSeal Expander
DSpanner Nut I Rod Seal NORing SWear Ring
ERod Guide J Buffer Seal OBrake Seal Ring (2 used)
TX,3360,BA960 1916SEP931/1

061411
PN=595
Hydraulic System
Cross Section of Crowd Cylinder9300G
T6223BA UN26MAY89
ANut F Rod Guide KBuffer Seal PCap Seal
BWasher GRod L Snap Ring QExpander Seal
CPiston HWiper Seal MBackup Ring RWear Ring
DBarrel I Wear Ring NORing
ENut J Rod Seal OBackup Ring (2 used)
TX,3360,BA956 1916SEP931/1

061411
PN=596
Hydraulic System
Cross Section of Crowd Cylinder9310G
T6717BJ UN19OCT88
ANut F Buffer Seal KBackup Ring PSeal Expander
BWasher GRod Seal L ORing QWear Ring
CBarrel HWear Ring MBrake Seal Ring
DNut I Wiper Seal NBackup Ring (2 used)
ERod Guide J Snap Ring OCap Seal Assembly
TX,3360,BA957 1916SEP931/1

061411
PN=597
Hydraulic System
Cross Section of Stabilizer Cylinder9300G, 9310G
T6223BA UN26MAY89
ANut F Rod Guide KBuffer Seal PCap Seal
BWasher GRod L Snap Ring QExpander Seal
CPiston HWiper Seal MBackup Ring RWear Ring
DBarrel I Wear Ring NORing
ENut J Rod Seal OBackup Ring (2 used)
TX,3360,BA958 1916SEP931/1

061411
PN=598
Hydraulic System
Cross Section of Swing Cylinder9300G, 9310G
T6223BC UN26MAY89
ANut F Rod KSnap Ring PExpander Seal
CBarrel HWear Ring MORing RBrake Seal Ring
DSpanner Nut I Rod Seal NBackup Ring (2 used)
ERod Guide J Buffer Seal OCap Seal
TX,3360,BA959 1916SEP931/1

061411
PN=599
Hydraulic System
Assemble Bucket, Crowd, Boom, Swing and

Stabilizer Cylinder
1. Put clean hydraulic oil on all internal parts before
assembly.
2. Install seals (B, E and G).
T6119AK UN19OCT88
3. Install wear ring (F).
4. Install backup ring (D) and Oring (C).
ARod Guide ESeal

BSeal F Wear Ring
CORing GSeal
All Cylinders Except Swing Cylinder
DBackup Ring
T7545BS UN19JUN91
Swing Cylinder Only
TX,3360,BA961 1911OCT931/12
IMPORTANT: To prevent damage of cap seal during

assembly, the lands on piston must be clean
and free of nicks or burrs.
5. Inspect the piston lands. If necessary, clean the lands

of any nicks or burrs that may cut cap seal.
T6122AB UN19OCT88

061411
PN=600
Hydraulic System
6. Install seal expander.

NOTE: The cap seal can be made more pliable by
warming it with your hands or by putting seal in
hot water for approximately five minutes.
Once started, install cap seal as quickly as
T6122AC UN06AUG90
possible to keep the amount of time that seal
is stretched to a minimum.
7. Push seal on end of piston.

8. Install a plastic tie band around cap seal with the
smooth side against seal.
9. Pull cap seal across land into position over seal
expander using the plastic tie band.
T6122AE UN19OCT88
TX,3360,BA961 1911OCT933/12
IMPORTANT: For proper fit, the backup rings must be

installed with the radius toward seal expander.
10. Install backup rings (A) with radius (B) toward seal
expander (D).
ABackup Ring (2 used) CCap Seal

BRadius DSeal Expander
T6126AO UN19OCT88

061411
PN=601
Hydraulic System
11. Check if cap seal is loose seal must fit tight against
seal expander and not turn. If seal can be turned, it
has been stretched too much and can be damaged
during assembly into barrel.
12. If necessary, shrink cap seal to its original size using
a ring compressor or a plastic tie band (A) and hose
clamp (C).
When using a ring compressor, put a piece of shim
stock between cap seal and compressor at the joint so
it does not damage seal.
When using a plastic tie band and hose clamp, grind
a taper (B) on one end of tie band. Install tie band
with the taper against cap seal. Before tightening the
hose clamp, tie band must be under hose clamp all
around piston.
T86565 UN09NOV88
TX,3360,BA961 1911OCT935/12
13. Install wear ring (A).

NOTE: Brake seal ring (B) is marked on one side with
"UP". Be sure the seal is installed with the "UP"
side toward the head end of cylinder.
9310G boom cylinder has a brake seal ring (B)
T6213BP UN11APR90
on each end of piston. (See Cross Section of
Boom Cylinder9310G, this group.)
14. Install brake seal ring or rings (B) with "UP" mark
toward the head end of cylinder.
Crowd Cylinder9310G Shown

061411
PN=602
Hydraulic System
15. Install spanner nut, snap ring, rod guide and piston
assembly on rod.
NOTE: Steps 1619 apply to swing, boom and
bucket cylinders, only. For crowd and stabilizer
cylinders, go to step 20.
T6172BP UN19OCT88
16. Install piston retaining nut. Tighten nut to snug torque
specification.
Specification
Bucket Cylin
der9300GSize................................................................ 80 x 45 mm
Weight ............................................................................... 57 kg (125 lb)
Snug Torque .................................................................. 95 Nm (70 lbft)
Bucket Cylin
Boom Cylin
der9310GSize................................................................ 90 x 50 mm
der9310GSize...............................................................115 x 56 mm
Weight ............................................................................. 101 kg (223 lb)
Weight ............................................................................... 87 kg (192 lb)
Snug Torque .................................................................. 95 Nm (70 lbft)
Swing CylinderSize.......................................................... 100 x 50 mm
Weight ................................................................................. 32 kg (70 lb)
Boom Cylin
der9300GSize.............................................................. 100 x 50 mm
Weight ............................................................................... 56 kg (124 lb)
TX,3360,BA961 1911OCT937/12
17. Put tape around a socket. Make marks on the tape to

divide the socket into twelfths.
T6149AG UN19OCT88

061411
PN=603
Hydraulic System
18. Put a piece of wire on the rod, over the piston, to point
to one of the marks.
19. Tighten to final torque specification.
Specification
Swing CylinderTorque
T6172BR UN19OCT88
Turn.................................................................................. 1/12 Turn (30)
Boom Cylin
der9300GTorque
Turn.................................................................................. 1/12 Turn (30)
Boom Cylin
der9310GTorque
Turn.................................................................................. 1/12 Turn (30)
Bucket Cylin
der9300GTorque
Crowd Cylin
Turn.................................................................................. 1/12 Turn (30)
der9300GSize................................................................ 90 x 50 mm
Bucket Cylin
Weight ............................................................................... 47 kg (103 lb)
der9310GTorque
Cap Screw Torque ..................................... 913 46 Nm (673 34 lbft)
Turn.................................................................................. 1/12 Turn (30)
Crowd Cylin
20. Install piston retaining cap screw (crowd or stabilizer der9310GSize.............................................................. 100 x 56 mm
cylinder, only). Tighten cap screw to specification. Weight ............................................................................... 59 kg (130 lb)
Specification
Stabilizer
CylinderSize....................................................................... 90 x 45 mm
Weight ................................................................................. 29 kg (64 lb)
TX,3360,BA961 1911OCT939/12
21. Apply petroleum jelly on seals and chamfer of barrel.

IMPORTANT: To prevent seal damage, the barrel,
piston, and rod must be in alignment
during installation.
22. Carefully push piston and rod guide into barrel. Keep
T6122AH UN19OCT88
piston and rod guide together.

061411
PN=604
Hydraulic System
23. Push rod guide into barrel just enough to install snap
ring. Install snap ring.
24. Pull rod guide against snap ring.
25. Clean threads of spanner nut with clean and cure
primer. Put thread lock and sealer (medium strength)
T6133AE UN27OCT88
on spanner nut threads.
26. Place filler ring between rod guide and spanner nut.
TX,3360,BA961 1911OCT9311/12
NOTE: Factory specification for tightening nut is 173237

Nm (128175 lbft) with cylinder pressurized
to 35000 kPa (350 bar) (5076 psi).
27. Install and tighten nut until marks (on spanner nut and
rod guide) made before disassembly are even.
T6119AR UN27OCT88
TX,3360,BA961 1911OCT9312/12
Remove and Install Backhoe Control Valve

X9811 UN23AUG88
medical source. Such information is available 2. Disconnect linkage from valve.
in Moline, Illinois, U.S.A. 3. Operate all hydraulic control valves to release
1. Remove valve cover.
Continued on next page 09T,3360,K10 1911OCT931/4

061411
PN=605
Hydraulic System
4. Disconnect lines (AC and HJ).
ACrowd Section Top F Inlet

PorttoCylinder Rod End GOutlet to Filter
Line HCrowd Section Bottom
BBucket Section Top PorttoCylinder Head End
PorttoCylinder Head Line
T6684BB UN18OCT88
End Line I Bucket Section Bottom
CBoom Section Top PorttoCylinder Rod End
End Line J Boom Section Bottom
DLeft Swing Top Port PorttoCylinder Rod End
ERight Swing Bottom Port Line
09T,3360,K10 1911OCT932/4
CAUTION: The approximate weight of valve

is 45.40 kg (100 lbs).
5. Install lifting strap on valve.

Specification
T6685AE UN18OCT88
ValveWeight............................................................. 45.40 kg (100 lbs)
6. Remove cap screws (A) and valve using a hoist.

7. Install control valve and cap screws (A).
09T,3360,K10 1911OCT933/4
8. Connect hydraulic lines (AC and HJ).

9. Install valve linkage and cover.
ACrowd Section Top F Inlet

PorttoCylinder Rod End GOutlet to Filter
Line HCrowd Section Bottom
T6684BB UN18OCT88
BBucket Section Top PorttoCylinder Head End
End Line I Bucket Section Bottom
CBoom Section Top PorttoCylinder Rod End
End Line J Boom Section Bottom
DLeft Swing Section Top Port PorttoCylinder Rod End
ERight Swing Section Line
Bottom Port
09T,3360,K10 1911OCT934/4

061411
PN=606
Hydraulic System
Disassemble and Assemble Backhoe Control

Valve
IMPORTANT: Keep all components for each valve
T6684BD UN18OCT88
1. Remove nuts and tie rods from control valve.
3. Inspect parts for wear or damage and replace as
necessary.
4. Lubricate all parts with clean hydraulic oil.
5. Install parts (A, H and I).
ALift Check (4 used) F Crowd Valve Section
6. Install tie rods and nuts. BInlet End Plate GOutlet End Plate
Specification CSwing Valve Section HSpring (4 used)
DBoom Valve Section I ORing (5 used)
Tie Bolt Nuts (1/2 EBucket Valve Section
inch)Torque............................................................... 102 Nm (75 lbft)
Tie Bolt Nuts (7/16
inch)Torque................................................................. 68 Nm (50 lbft)
TX,3360,BA932 1916SEP931/1
Disassemble and Assemble Circuit Relief

Valve With AntiCavitation
NOTE: Anticavitation relief valve is not adjustable.
Anticavitation relief valves are used in
boom and swing section.
T6684BC UN18OCT88
1. Disassemble relief valve with anticavitation.
necessary.
3. Lubricate all parts with clean hydraulic oil.
4. Assemble relief valve. Tighten cap (A).
Specification ACap DORing
Relief Valve BORing EORing
(Circuit with Anti CSpring F Valve
Cavitation)Torque........................................................ 95 Nm (70 lbft)
09T,3360,K15 1911OCT931/1

061411
PN=607
Hydraulic System
Disassemble and Assemble Circuit Relief

Valve
1. Remove parts (AL).
necessary.
T6687AB UN18OCT88
IMPORTANT: Relief valve MUST be installed in
same section as removed.
3. Assemble parts (AL). Put flat side of retaining ring

(F) against spring (G).
IMPORTANT: If parts (EL) are removed,
relief pressure must be adjusted. (See
Specifications in this group.) AORing GSpring
BORing HScrewAdjust
CLock Nut I Cap
DValve Body J ORing
EPoppet KLock Nut
F Retaining Ring L ORing
09T,3360,K16 1911OCT931/1

061411
PN=608
Hydraulic System
Disassemble and Assemble Crowd and Bucket Valve Section
T6497AM UN18OCT88
ACircuit Relief Valve (2 used) EScrews (2 used) I ORing (2 used) MPlate (2 used)
BORing Nut (2 used) F Cap J Spool NScrew (2 used)
CORing (2 used) GSpring KSpring
DHousing HBackup Ring (2 used) L Left Check
1. Disassemble parts (AN).

IMPORTANT: Relief valve body must be on its seat
2. Put spool (J) in protective cover and place in a vise. before tightening Oring nut (B).
3. Remove spring (G) and spring retainers. 8. Install parts (AN). Tighten screws (E), relief valve
4. Inspect parts for wear or damage. (A) and Oring nut (B).
Specification
5. Replace all Orings and backup ring. Relief Valve
6. Lubricate all parts with clean hydraulic oil. (Circuit)Torque............................................................ 54 Nm (40 lbft)
ORing NutTorque....................................................... 4 Nm (35 lbin.)
7. Assemble spring retainers and spring (G). Tighten Screws Spool
screw. CapTorque.................................................................. 7 Nm (60 lbin.)
Specification
SpooltoSpool End
ScrewTorque............................................................. 10 Nm (90 lbin.)
TX,3360,BA933 1916SEP931/1

061411
PN=609
Hydraulic System
Disassemble and Assemble Boom Valve Section
T6497AK UN18OCT88
ACircuit Relief Valve F Valve Body with KScrew (2 used) PSpool
BORing AntiCavitation L Cap QSpring
CSpring Retainer GHousing MSpring RLift Check
DSpring HORing NBackup Ring (2 used) SPlate (2 used)
EORing I ORing Nut OORing (2 used) T Screw (2 used)
J Circuit Relief Valve
1. Disassemble parts (AT). Specification

2. Put spool (P) in protective cover in a vise. Screws Spool
CapTorque.................................................................. 7 Nm (60 lbin.)
3. Remove spring (M) and spring retainers.
IMPORTANT: Relief valve body must be against its
4. Inspect parts for wear or damage. seat before tightening Oring nut (I).
5. Replace all Orings and backup ring.
9. Tighten cap (A), relief valve (J) and Oring nut (I).
6. Lubricate all parts with clean hydraulic oil. Specification
7. Assemble spring retainers and spring (M). Tighten Relief Valve
screw. (Circuit)Torque............................................................ 54 Nm (40 lbft)
ORing NutTorque....................................................... 4 Nm (35 lbin.)
Specification Relief Valve
SpooltoSpool End (Circuit with Anti
ScrewTorque............................................................. 10 Nm (90 lbin.) Cavitation)Torque........................................................ 95 Nm (70 lbft)
8. Install parts (AT). Tighten screw (K).
TX,3360,BA934 1916SEP931/1

061411
PN=610
Hydraulic System
Disassemble and Assemble Swing Valve Section
T6497AL UN18OCT88
ACap (2 used) F Valve Body with KBackup Ring (2 used) PPlate (2 used)
BORing (2 used) AntiCavitation (2 used) L ORing (2 used) QScrew (2 used)
CSpring Retainer (2 used) GHousing MSpool
DSpring (2 used) HScrew (2 used) NSpring
EORing (2 used) I Cap OLift Check
J Spring
1. Disassemble parts (AQ).

8. Install parts (AQ).
2. Put spool (M) in protective cover and place in a vise.
9. Tighten screws (H) and cap (A).
3. Remove spring (J) and spring retainers. Specification
4. Inspect parts for wear or damage. Relief Valve
(Circuit with Anti
5. Replace all Orings and backup ring. Cavitation)Torque........................................................ 95 Nm (70 lbft)
Screws Spool
6. Lubricate all parts with clean hydraulic oil. CapTorque.................................................................. 7 Nm (60 lbin.)
7. Assemble spring retainers and spring (J). Tighten
screw.
Specification
SpooltoSpool End
ScrewTorque............................................................. 10 Nm (90 lbin.)
TX,3360,BA935 1916SEP931/1

061411
PN=611
Hydraulic System
Disassemble and Assemble Outlet Valve

Section (With Low Pressure Regenerative
Relief Valve)
1. Disassemble parts (AO).
2. Remove relief valve (P) with an 832 screw.
necessary.
IMPORTANT: Relief valve (P) must be installed
with threaded hole facing out, to prevent
damage to the other sections.
5. Install relief valve (P).

6. Assemble parts (AO).
AOutlet Housing I ORing

BORing J ORing
CPlug KORing
T6688AP UN18OCT88
DPlug L Unloading Valve
EORing MPlug
F Spring NORing
GCheck valve OSpring
HORing PLow Pressure Regenerated
Relief Valve
TX,3360,BA936 1916SEP931/1
Backhoe Relief Valve Specifications

Specification
EngineSpeed......................................................................... 1000 rpm
Relief ValveTempera
ture...........................................................................40 5 (100 20F)
T7247BS UN18APR90
System Relief
ValvePressure............................................................... + 1400 kPa0
kPa (+140 bar) (+ 2000 psi)
Circuit Relief ValveSpecification
Crowd OutRod
EndPressure...................................... 19 000 kPa (129 bar) (2750 psi)
Bucket DumpPres
sure..............................................................24 100 kPa (241) (3500 psi)
Boom RaisePressure......................... 12 900 kPa (129 bar) (1875 psi)
Crowd InHead
Swing LeftPressure............................ 19 000 kPa (190 bar) (2750 psi)
EndPressure...................................... 24 100 kPa (241 bar) (3500 psi)
Swing RightPressure........................ 19 000 kPa (190 bar) ( 2750 psi)
Boom LowerPressure........................ 26 200 kPa (262 bar) (3800 psi) See TM1403, Group 902525 for testing relief valves.
Bucket CurlPressure.......................... 24 100 kPa (241 bar) (3500 psi)
TX,3360,BA937 1911OCT931/1

061411
PN=612
Hydraulic System
Remove and Install Stabilizer Valve

X9811 UN23AUG88
09T,3360,K25 1911OCT931/2
1. Remove cotter pins (D) to disconnect linkage.

2. Operate all hydraulic valves to release pressure in
hydraulic system.
CAUTION: Stabilizer cylinder lines have
T6684BA UN18OCT88
lockouts. Lines MUST be opened slowly
to release hydraulic pressure.
3. Disconnect lines (C, E, G and H) and release pressure.

4. Remove cap screws (B) and washers to remove valve.
NOTE: Washers must be installed between valve and
mounting plate to prevent spool bindings.
AStabilizertoBackhoe Valve F Power BeyondtoStabilizer
5. Install valve, cap screws (B) and washers. Line Valve Line
BCap Screw (2 used) GControl ValvetoStabilizer
6. Connect hydraulic lines. CControl ValvetoStabilizer Cylinder Head End Line
Cylinder Rod End Line HControl ValvetoStabilizer
DCotter Pin (2 used) Cylinder Head End Line
EControl ValvetoStabilizer I StabilizertoBackhoe Valve
Line Line
09T,3360,K25 1911OCT932/2

061411
PN=613
Hydraulic System
Cross Section View of Stabilizer Control

Valve
ASpool (2 used) GSeat (2 used)
BSeal (2 used) HLockout Poppet (2 used)
CORing (2 used) I Spring (2 used)
DLockout Plunger (2 used) J Lockout Seat Retainer (2
EORing (2 used) used)
F ORing (2 used) KSpool Assembly (2 used)
L ORing (2 used)
T6172AY UN25MAY89
T58,3360,J163 1901AUG901/1

061411
PN=614
Hydraulic System
Disassemble Stabilizer Control Valve

1. Remove plugs (B) to remove spool assemblies (A).
2. Carefully remove snap ring (C) to disassemble parts
(DJ). Inspect parts for wear or damage.
ASpool Assembly (2 used) F Spring (2 used)

BPlug (2 used) GSpring (2 used)
CSnap Ring (2 used) HBushing (2 used)
DWasher (4 used) I ORing (2 used)
ESpacer (2 used) J Spool (2 used)
T6017AF UN03NOV88
T58,3360,J164 1911SEP851/3
3. Remove seal (A) and Oring (B).
T6172AZ UN25MAY89
Continued on next page T58,3360,J164 1911SEP852/3

061411
PN=615
Hydraulic System
IMPORTANT: DO NOT use a metal punch against

seating surfaces. Damage to surface can result.
4. Remove and inspect parts (AH).
APlunger (2 used) ESpring (2 used)

BSeat (2 used) F Seat Retainer (2 used)
CORing (2 used) GORing (2 used)
DPoppet (2 used) HFitting (2 used)
T6017AG1 UN03NOV88
T58,3360,J164 1911SEP853/3

061411
PN=616
Hydraulic System
Assemble Stabilizer Control Valve

1. Clean and dry all parts.
2. Put clean hydraulic oil on all internal parts. DO NOT
touch seating surfaces on lockout seat or plunger with
fingers.
IMPORTANT: DO NOT touch or use a metal punch
against seating surfaces. Use a wooden dowel
to push seat to bottom of bore.
3. Install plunger (A).

4. Install new Oring (C) and install seat (B). Be sure
plunger end is through hole in seat.
5. Install poppet (D), spring (E), and seat retainer (F).
Tighten retainers.
Specification
Seat Retainer (Stabilizer
Control Valve)Torque................................... 4754 Nm (3540 lbft)
T6017AG1 UN03NOV88
APlunger (2 used) ESpring (2 used)
BSeat (2 used) F Seat Retainer (2 used)
CORing (2 used) GORing (2 used)
DPoppet (2 used) HFitting (2 used)
Continued on next page T58,3360,J167 1911OCT931/4

061411
PN=617
Hydraulic System
6. Early units only (retainer with screw driver slot)Stake

the seat retainer in four places using a punch.
Later units only (retainer with 9/16 hex drive)Tighten
the seat retainer.
Specification
T90867 UN28OCT88
Seat Retainer (Stabilizer
Early Units
T7273AB UN04APR90
Later Units
T58,3360,J167 1911OCT932/4
7. Install new Oring (B) and seal (A).
T6172AZ UN25MAY89
Continued on next page T58,3360,J167 1911OCT933/4

061411
PN=618
Hydraulic System
8. Apply LUBRIPLATE or an equivalent on parts

(DG).
9. Install parts (DJ).
10. Install snap ring (C) using a valve spring compressor.
11. Install spool assembly (A) and plug (B). Tighten plugs.
Specification
Spool Plugs (Stabilizer
ASpool Assembly (2 used) F Spring (2 used)

BPlug (2 used) GSpring (2 used)
CSnap Ring (2 used) HBushing (2 used)
DWasher (4 used) I ORing (2 used)
ESpacer (2 used) J Spool (2 used)
T6017AF UN03NOV88
LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.
T58,3360,J167 1911OCT934/4

061411
PN=619
Hydraulic System

061411
PN=620
Index
Page Page
A Disassemble and assemble,

forward/reverse .......................................... 03035027
Accumulator Cone point, adjust............................................ 03035039
Transmission charge.................................... 03036019 Coolant
Acid burns.......................................................... 1616712 Diesel engine ................................................. 0000046
Adjustment Coolant heater
Vbelt tension ................................................. 0505101 Remove and install ........................................ 0505051
Air cleaner Counterweight
Disassemble and assemble ........................... 0505201 Rear, remove and install ..............1717492, 1717493
Alternator Sprocket......................................................... 1717491
Remove and install ........................................ 1616722 Cowl
Disassemble and assemble ........................... 1919102
Crowd cylinder, backhoe
B Disassemble .................................................. 3333603
Backhoe
9310G specifications.................................... 00000227 D
Backhoe boom cylinder
Disassemble .................................................. 3333603 Dampener drive
Backhoe bucket cylinder Remove and install ........................................ 0707002
Disassemble .................................................. 3333603 Dealer fabricated tool
Backhoe crowd cylinder DF1041 Track nut removal tool...................... 0101991
Disassemble .................................................. 3333603 DF1063 Final drive lift bracket ....................... 0202992
Backhoe swing cylinder Dealer fabricated tools
Disassemble .................................................. 3333603 DFT1087 track recoil spring guard................. 0101994
Backing plate movement ................................. 03035013 ST4920 track recoil spring assembly ............. 0101995
Battery Diesel engine oil ................................................ 0000042
Acid burns ...................................................... 1616712 Display monitor
Electrolyte level check ................................... 1616712 Remove and install ........................................ 1616763
Explosion ....................................................... 1616712
Terminals........................................................ 1616712 E
Testing............................................................ 1616714
Belt wear Engine oil
Serpentine...................................................... 0505102 Diesel ............................................................. 0000042
Bleed fuel system ............................................ 04040017 Engine side shields
Bolt and screw torque values Disassemble and assemble ........................... 1919101
Metric ............................................................. 0000034 Enginedirect drive
Unified inch .................................................... 0000033 Install............................................................ 04040014
Boom cylinder, backhoe Remove........................................................ 04040011
Disassemble .................................................. 3333603 Enginetorque converter
Bucket cylinder, backhoe Install.............................................................. 0404007
Disassemble .................................................. 3333603 Remove.......................................................... 0404003
C F
Cable Fan
Speed control................................................. 0505151 Remove and install ........................................ 0505104
Carrier roller Fanreversible
Disassemble and assemble ......................... 01013010 Adjust ............................................................. 0505105
Measure wear ................................................ 0101309 Fenders
Oil level ........................................................ 01013013 Disassemble and assemble .....1919271,
Remove and install ........................................ 0101309 1919272, 1919274
Carrier roller oil specification ............................. 0000043 Filter, oil ........................................................... 03036020
Charge Final drive
Transmission accumulator ........................... 03036019 Axle shaft preload ........................................ 02025020
Clutch packs Disassemble and assemble ......................... 02025010
Disassemble and assemble ......................... 03035016 Idler shaft preload, double reduction............ 02025018
Oil specification.............................................. 0000043
TM1404 (14JUN11) Index1 GSeries Crawlers

061411
PN=1
Index
Page Page
Pinion shaft preload ..................................... 02025017

Remove and install ........................................ 0202505 M
Front idler
Assemble ..................................................... 01013054 Metric bolt and screw torque values .................. 0000034
Disassemble and inspect ............................. 01013052
Measure wear .............................................. 01013052 O
Oil level ........................................................ 01013062
Oil specification.............................................. 0000043 Oring boss fittings............................................. 0000037
Remove and install ...................................... 01013052 Oil
Fuel Adding to roller (S.N. XXXXXX).................. 01013021
Specifications................................................. 0000041 Adding to roller (S.N. XXXXXX )................. 01013021
Storage .......................................................... 0000041 Final drive ...................................................... 0000043
Fuel system Final drives..................................................... 0000044
Bleed............................................................ 04040017 Hydraulic ........................................................ 0000044
Fuel tank Lines and fittings ............................................ 0000036
Remove and install ........................................ 0505601 Specification carrier roller .............................. 0000043
Specification front idler................................... 0000043
G Specification track roller................................. 0000043
Steering clutches ........................................... 0000044
Grease Transmission.................................................. 0000044
Specification................................................... 0000045 Winch ............................................................. 0000044
Grille housing Oil cooler, transmission, remove and
Disassemble and assemble ........................... 1919211 install.............................................................. 03036023
Guard Oil level
Engine bottom................................................ 1919131 Track roller (S.N. XXXXXX) ........................ 01013020
Track roller (S.N. XXXXXX) ........................ 01013020
H Oil lines and fittings ........................................... 0000036
Output shaft bearing preload, adjust ............... 03035041
Hardware
Torque specifications ..................................... 0000031 P
Hardware torque values
Metric ............................................................. 0000034 Preload adjust, output shaft bearing................ 03035041
Unified inch .................................................... 0000033 Preload adjust, ring gear bearing .................... 03035040
Heater, coolant
Remove and install ........................................ 0505051 R
Hood
Disassemble and assemble ........................... 1919101 Radiator
Hydraulic Remove and install ........................................ 0505105
Fittings, 30&deg cone seat ........................... 0000036 Rate of shift adjust........................................... 03036010
Fittings, 37&deg flare .................................... 0000036 Rear covers
L Rear lid
Linkage Recoil spring
Speed control...............................0505152, 0505154 Disassemble and assemble ......................... 01013070
Loader boom cylinder Remove and install ...................................... 01013069
Cross section ............................................... 31316018 Ring gear
Disassemble and inspect ............................. 31316015 Replace........................................................ 03035038
Loader bucket cylinder Ring gear bearing preload, adjust ................... 03035040
Cross section ............................................... 31316018 Rollover protective structure
Disassemble and inspect ............................. 31316015 Torque specifications ..................................... 0000031
Lubricant Storage Roller
Storage, Lubricant.......................................... 0000047 Adding oil (S.N. XXXXXX) .......................... 01013021
Lubricants, Safety Adding oil (S.N. XXXXXX ) ......................... 01013021
Safety, Lubricants .......................................... 0000046 Oil level (S.N. XXXXXX) ............................. 01013020
Oil level (S.N. XXXXXX) ............................. 01013020

061411
PN=2
Index
Page Page
ST4920 track recoil spring assembly ............. 0101995

S Torque charts
Metric ............................................................. 0000034
Sand screens..................................................... 0505103 Unified inch .................................................... 0000033
Screen, traverse case, suction ........................ 03036022 Torque converter
Serpentine belt tensioner................................... 0505102 Disassemble and assemble ........................... 0606516
Shear lift cylinder Housing, disassemble and assemble .......... 06065112
Assemble (S.N. 778149 )............................ 31316018 Remove and install ........................................ 0606002
Shear tilt cylinder Torque specifications
Assemble (S.N. 778149 )............................ 31316018 Hardware ....................................................... 0000031
Shift rate of speed ........................................... 03036010 Rollover protective structure ......................... 0000031
Specification Torque value
450G machine................................................ 0000021 30&deg cone seat hydraulic fittings .............. 0000036
450GLGP machine ....................................... 0000027 37&deg flare hydraulic fittings....................... 0000036
450GLT machine .......................................... 0000024 Flat face Oring seal fitting ............................. 0000038
455G drain and refill capacities.................... 00000212 Inch SAE four bolt flange fitting...................... 0000039
455G machine.............................................. 00000210 Metric cap screw ............................................ 0000035
550GLGP machine ..................................... 00000216 Metric four bolt flange fitting......................... 00000310
550GLT machine ........................................ 00000213 ORing boss fitting ......................................... 0000037
555G drain and refill capacities.................... 00000221 Track shoe cap screw .................................... 0000032
555G machine.............................................. 00000219 Track
650G machine.............................................. 00000222 Roller oil specification .................................... 0000043
9310 backhoe lift capacities......................... 00000228 Shoe cap screw torque value......................... 0000032
Carrier roller oil .............................................. 0000043 Track chain
Final drive oil.................................................. 0000043 Adjust sag .................................................... 01013026
Front idler oil .................................................. 0000043 Measure bushing outer diameter ................. 01013025
Fuel ................................................................ 0000041 Measure link height...................................... 01013024
Grease ........................................................... 0000045 Measure pitch .............................................. 01013026
Track roller oil ................................................ 0000043 Track chain, lubricated
Specifications Assemble to turn bushings........................... 01013041
Hardware torque ............................................ 0000031 Disassemble to turn bushings...................... 01013040
Speed control cable........................................... 0505151 Install, single tooth master link..................... 01013037
Speed control linkage Remove and install, interlock link................. 01013034
Remove and install ......................0505152, 0505154 Remove, single tooth master link................. 01013037
Sprocket Repair to turn pins........................................ 01013048
Remove and install ...................................... 01013074 Track chain, sealed
Stabilizer cylinder Disassemble and assemble ......................... 01013031
Disassemble .................................................. 3333603 Install............................................................ 01013032
Starting aid Remove........................................................ 01013028
Remove and install nozzle ............................. 0505053 Turn pins and bushings................................ 01013031
Steering linkagelever Track frame
Adjust linkage............................................... 09092014 Remove and install ...................................... 01013074
Adjust stops (S.N. 770807)......................... 09092012 Track roller
Adjust stops (S.N. 770808 )........................ 09092013 Disassemble ................................................ 01013015
Remove and install ........................................ 0909206 Measure wear .............................................. 01013014
Steering linkagepedal Remove and install ...................................... 01013014
Adjust linkage................................................. 0909205 Track roller oil fill (S.N. XXXXXX)................... 01013020
Adjust stops ................................................... 0909204 Track roller oil fill (S.N. XXXXXX)................... 01013020
Remove and install ........................................ 0909202 Track shoe
Swing cylinder, backhoe Measure grouser wear ................................. 01013022
Disassemble .................................................. 3333603 Remove and install ...................................... 01013023
Track tension adjuster
T Assemble, (S.N. 745426)............................. 01013064
Assemble, (S.N. 781709 )........................... 01013068
Tool, dealer fabricated Disassemble, (S.N. 745426)....................... 01013063
DF1041 Track nut removal tool...................... 0101991 Disassemble, (S.N. 745427781708)........... 01013066
DF1063 Final drive lift bracket ....................... 0202992 Disassemble, (S.N. 781709 )...................... 01013067
Tools, dealer fabricated Transmission
DFT1087 track recoil spring guard................. 0101994 Adjust trans. control linkage .......................... 0303156

061411
PN=3
Index
Page Page
Air test.......................................................... 03035046 Remove and installdirect drive.................... 03036015

Assemble ..................................................... 03035042 Remove and installtorque converter ........... 03036014
Disassemble ................................................ 03035010 Transverse case suction screen...................... 03036022
Disassemble/assemble linkage............03 Transverse housing
03152, 0303154 Remove and install ........................................ 1717402
Oil................................................................... 0000044 Transverse housing, disassemble and
Oil filter......................................................... 03036020 assemble ....................................................... 03035048
Remove and install ........................................ 0303504
Transmission control valve U
Remove and install ........................................ 0303603 Unified inch bolt and screw torque
Transmission control valve manifold values .............................................................. 0000033
Disassemble and assemble ......................... 03036010
Transmission cover, disassemble and V
assemble ....................................................... 03035014
Transmission decelerator, disassemble and Vbelt tension..................................................... 0505101
assemble ....................................................... 03036012
Transmission oil cooler, remove and
install.............................................................. 03036023 W
Transmission oil pump
Disassemble and assembledirect Welding repair of major structures..................... 1717401
drive ........................................................... 03036017
Disassemble and assembletorque
converter .................................................... 03036016

061411
PN=4
Index

061411
PN=5
Index

061411
PN=6

JD TM1404

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Droits d'auteur :

Formats disponibles

450G, 455G, 550G,

555G, 650G Crawler

For complete service information also see:

450G, 455G, 550G, 555G, 650G

Help!! Help!! Help!! Help!! P.O. Box 538

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TM1404 (14JUN11) GSeries Crawlers

Section 06Torque Converter Section 32Bulldozer

Original Instructions. All information, illustrations and specifications in this

TM1404 (14JUN11) i GSeries Crawlers

TM1404 (14JUN11) ii GSeries Crawlers

Group 0001Safety Information 550GLGP Drain and Refill

Continued on next page

TM1404 (14JUN11) 001 GSeries Crawlers

Track Roller, Front Idler, and

TM1404 (14JUN11) 002 GSeries Crawlers

Prevent Battery Explosions

Prepare for Emergencies

TM1404 (14JUN11) 0000011 GSeries Crawlers

Prevent Acid Burns

Handle Chemical Products Safely

TM1404 (14JUN11) 0000012 GSeries Crawlers

Avoid HighPressure Fluids

Park Machine Safely

Support Machine Properly

TM1404 (14JUN11) 0000013 GSeries Crawlers

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

TM1404 (14JUN11) 0000014 GSeries Crawlers

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

TM1404 (14JUN11) 0000015 GSeries Crawlers

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

burst when heat goes beyond the immediate flame area.

TM1404 (14JUN11) 0000016 GSeries Crawlers

Keep ROPS Installed Properly

Service Tires Safely

TM1404 (14JUN11) 0000017 GSeries Crawlers

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

TM1404 (14JUN11) 0000018 GSeries Crawlers

Use Proper Tools

Dispose of Waste Properly

Live With Safety

TM1404 (14JUN11) 0000019 GSeries Crawlers

Item Measurement Specification

Operator Weight 80 kg (175 lb)

TM1404 (14JUN11) 0000021 GSeries Crawlers

Track gauge: 1450 mm (57 in.)

Hydraulic pump: Gear

Operating Weight (with ROPS):

TM1404 (14JUN11) 0000022 GSeries Crawlers

450G Drain and Refill Capacities

TM1404 (14JUN11) 0000023 GSeries Crawlers

450GLT Crawler Dozer Specifications

Item Measurement Specification

Operator Weight 80 kg (175 lb)

TM1404 (14JUN11) 0000024 GSeries Crawlers

Track gauge: 1450 mm (57 in.)

Hydraulic pump: Gear