Skider Giii

G-III and D Series
Skidders
Repair
(S.N. 586337 )
TECHNICAL MANUAL
G-III and D Series Skidders Repair
(Serial No. 586337 )
TM2111 30MAY03 (ENGLISH)
For complete service information also see:

G-III and D Series Skidders Operation and
Tests (S.N. 586337 ) . . . . . . . . . . . . . . . . . .
TM2110
TEAMMATE II 1200, 1400, and 1600 Series
Inboard Planetary Axles . . . . . . . . . . . . . . . .
CTM43
POWERTECH 4.5 L & 6.8 L Diesel Engines,
Base Engine. . . . . . . . . . . . . . . . . . . . . . . . . .
CTM104
POWERTECH 4.5 L & 6.8 L Diesel Engines,
Level 12 Electronic Fuel System with DE10
STANADYNE Pump . . . . . . . . . . . . . . . . . . .
CTM331
POWERTECH 8.1L Diesel Engines, Base
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTM86
POWERTECH 8.1 L Diesel Engines, Level 9
Electronic Fuel System With High Pressure
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . .
CTM255
Starting Motors and Alternators . . . . . . . . . .
CTM77
40 and 4000 Winches . . . . . . . . . . . . . . . . . .
CTM25
60 and 6000 Winches . . . . . . . . . . . . . . . . . .
CTM41
120 Series Hydraulic Cylinders . . . . . . . . . . TMH120A
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
Information is organized in groups for the various

components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
testing, and repair.
Fundamental service information is available from
other sources covering basic theory of operation,
fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.
DX,TMIFC 1929SEP981/1
TM2111 (30MAY03)
G-III and D Series Skidders (S.N. 586337 )

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Introduction
Technical Information Feedback Form

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TM2111 (30MAY03)

053003
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Introduction
TM2111 (30MAY03)

053003
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Contents
00
SECTION 00General Information

Group 01Safety Information
Group 0003Torque Values
SECTION 11Park Brake

Group 1111Active Elements
Group 1160Hydraulic System
SECTION 01Wheels
Group 0110Powered Wheels and Fastenings
SECTION 17Frame, Chassis, or Supporting

Structures
Group 1740Frame Installation
Group 1746Frame Bottom Guards
SECTION 02Axles and Suspension System

Group 0200Removal and Installation
Group 0225Input Drive Shafts and U-Joints
01
SECTION 18Operators Station

Group 1810Operator Enclosure
Group 1821Seat and Seat Belt
Group 1830Heating and Air Conditioning
SECTION 03Transmission
Group 0315Controls
Group 0350Gears, Shafts and Power Shift
Clutches
02
03
SECTION 19Sheet Metal and Styling

Group 1910Hood or Engine Enclosure
Group 1921Grille and Grille Housing
SECTION 04Engine
SECTION 20Safety, Convenience and

Miscellaneous
Group 2003Pressurized Water System
Group 2004Horn and Warning Devices
SECTION 05Engine Auxiliary Systems

Group 0505Cold Weather Starting Aids
Group 0510Cooling Systems
Group 0520Intake System
Group 0530External Exhaust System
Group 0560External Fuel Supply System
04
SECTION 21Main Hydraulic System

05
SECTION 30Winch
Group 3015Controls Linkage
Group 3050Drive and Clutch
SECTION 06Torque Converter

Group 0641Torque Converter Housing
Group 0651Converter Turbine, Gears, and Shaft
SECTION 07Damper Drive
Group 0752Elements
06
SECTION 32Bulldozers (Stacking & Trailbuilding

Blades)
Group 3201Blades
SECTION 09Steering System

Group 0930Secondary Steering
SECTION 37Arch or Boom

Group 3740Frames
SECTION 10Service Brakes

09
Continued on next page
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.
10
COPYRIGHT 2003
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
TM2111 (30MAY03)
07

053003
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Contents
00
01
SECTION 38Grapple
Group 3803Grapple Mechanism
Group 3840Frames
SECTION 99Dealer Fabricated Tools
Group 9900Dealer Fabricated Tools
02
03
04
05
06
07
09
10
TM2111 (30MAY03)
ii

053003
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Contents
11
INDX
17
18
19
20
21
30
32
37
38
TM2111 (30MAY03)
iii

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Contents
INDX
11
17
18
19
20
21
30
32
37
38
TM2111 (30MAY03)
iv

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00
Section 00
General Information
Contents
Page
Page
Group 01Safety Information

Skidder Safety Features . . . . . . . . . . . . . . . . . .00-01-1
Recognize Safety Information . . . . . . . . . . . . . .00-01-2
Follow Safety Instructions . . . . . . . . . . . . . . . . .00-01-2
Operate Only If Qualified. . . . . . . . . . . . . . . . . .00-01-2
Wear Protective Equipment . . . . . . . . . . . . . . . .00-01-3
Avoid Unauthorized Machine Modifications . . . .00-01-3
Inspect Machine . . . . . . . . . . . . . . . . . . . . . . . .00-01-3
Stay Clear Of Moving Parts. . . . . . . . . . . . . . . .00-01-4
Avoid High-Pressure Fluids . . . . . . . . . . . . . . . .00-01-4
Beware Of Exhaust Fumes . . . . . . . . . . . . . . . .00-01-4
Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5
Handle Starting Fluid Safely . . . . . . . . . . . . . . .00-01-5
Prevent Battery Explosions . . . . . . . . . . . . . . . .00-01-6
Handle Chemical Products Safely . . . . . . . . . . .00-01-6
Dispose of Waste Properly . . . . . . . . . . . . . . . .00-01-6
Prepare for Emergencies. . . . . . . . . . . . . . . . . .00-01-7
Use Steps And Handholds Correctly . . . . . . . . .00-01-7
Start Only From Operators Seat . . . . . . . . . . . .00-01-7
Use And Maintain Seat Belt . . . . . . . . . . . . . . .00-01-8
Prevent Unintended Machine Movement . . . . . .00-01-8
Avoid Work Site Hazards . . . . . . . . . . . . . . . . .00-01-9
Operate Machine Safely . . . . . . . . . . . . . . . . . .00-01-9
Keep Riders Off Machine . . . . . . . . . . . . . . . .00-01-10
Avoid Backover Accidents . . . . . . . . . . . . . . . .00-01-10
Avoid Machine Tip Over . . . . . . . . . . . . . . . . .00-01-11
Operating on Slopes . . . . . . . . . . . . . . . . . . . .00-01-11
Operating Or Traveling On Public Roads . . . .00-01-12
Inspect and Maintain ROPS . . . . . . . . . . . . . .00-01-12
Keep the Operator Protective Structure
(OPS) in Place. . . . . . . . . . . . . . . . . . . . . . .00-01-13
Add And Operate Attachments Safely . . . . . . .00-01-13
Park And Prepare For Service Safely . . . . . . .00-01-14
Service Cooling System Safely . . . . . . . . . . . .00-01-14
Remove Paint Before Welding or Heating . . . .00-01-15
Make Welding Repairs Safely . . . . . . . . . . . . .00-01-15
Drive Metal Pins Safely . . . . . . . . . . . . . . . . . .00-01-15
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-16
Unified Inch Bolt and Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-6
Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-7
Service Recommendations for 37 Flare
and 30 Cone Seat Connectors . . . . . . . . .00-0003-8
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-9
Service Recommendations For Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0003-11
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . .00-0003-12
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . .00-0003-13
Group 0003Torque Values

Hardware Torque Specifications . . . . . . . . . .00-0003-1
Keeping ROPS Installed Properly . . . . . . . . .00-0003-1
Metric Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3
TM2111 (30MAY03)
00-1

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Contents
00
TM2111 (30MAY03)
00-2

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Group 01
Safety Information
00
01
1
Skidder Safety Features
1
3
4
13
13
13
7
2
10
12
5
6
11
T161851
UN20NOV02
T161851
Please remember, the operator is the key to

preventing accidents.
1. ROPS/OPS. Structures designed to help protect the
operator are certified to ISO, SAE, and OSHA.
Enclosures also deflect sun and rain.
2. Parking Brake. Is easily engaged simply by moving
the transmission control to the park position or
pushing the park brake switch. The parking brake
engages automatically whenever the engine is
stopped.
Engine Start Protection. A neutral start switch
allows the engine to start only when the
transmission is out-of-gear and the park brake is
engaged. The park brake is always engaged during
start-up.
3. Interior Rearview Mirror. Offers the operator a
view of activity behind him.
4. Front Windshield Wiper. Wiper cleans windshield
area, improving operator visibility in poor weather
conditions.
5. Bypass Start Protection. Shielding over the starter

helps prevent dangerous bypassing starting.
6. Engine Fan Guard. A secondary fan guard inside
the engine compartment helps prevent contact with
the rotating fan blades.
7. Fire Extinguisher. A fire extinguisher is provided in
the cab.
8. Operator Manual Holder. A sealed manual holder
keeps manual on machine clean and dry.
9. Steps. Wide, skid-resistant provide excellent footing
while getting in or out of the operators station.
10. Seatbelt Retractors. Seatbelt retractors help keep
belts clean and convenient to use.
11. Articulation Locking Bar. A self storing locking
bar can be positioned to prevent articulation during
servicing or transport.
12. Backup Alarm. Alerts bystanders when reverse
travel direction is selected by operator.
13. Handholds. Large conveniently placed handholds
make it easy to enter or exit the operators station.
OUO1079,0000566 1915NOV021/1
TM2111 (30MAY03)
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053003
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Safety Information
Recognize Safety Information

UN28AUG00
This is the safety alert symbol. When you see this

symbol on your machine or in this manual, be alert
for the potential of personal injury.
T133555
Follow the precautions and safe operating practices

highlighted by this symbol.
1928AUG00
A signal word DANGER, WARNING, or CAUTION is

used with the safety alert symbol. DANGER identifies the
most serious hazards.
T133588
On your machine, DANGER signs are red in color,

WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.
TX03679,00016CC 1921AUG001/1
Follow Safety Instructions

UN24AUG00
Read the safety messages in this manual and on the

machine. Follow these warnings and instructions carefully.
Review them frequently.
Be sure all operators of this machine understand every
safety message. Replace operators manual and safety
labels immediately if missing or damaged.
T133556
00
01
2
TX03679,00016F9 1914MAR011/1
Operate Only If Qualified

Do not operate this machine unless you have read the
operators manual carefully and you have been
qualified by supervised training and instruction.
Familiarize yourself with the job site and your
surroundings before operating. Try all controls and
machine functions with the machine in an open area

before starting to work.
Know and observe all safety rules that may apply to
your work situation and your work site.
TX03679,00016FA 1930OCT001/1
TM2111 (30MAY03)
00-01-2

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Safety Information
00
01
3
Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
UN23AUG88
Wear close fitting clothing and safety equipment

appropriate to the job.
TS206
Prolonged exposure to loud noise can cause impairment

or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TX03679,00016D0 1930OCT001/1
Avoid Unauthorized Machine Modifications

Modifications of this machine, or addition of
unapproved products or attachments, may affect
machine stability or reliability, and may create a hazard
for the operator or others near the machine.
Always contact an authorized dealer before making

machine modifications that change the intended use,
weight or balance of the machine, or that alter
machine controls, performance or reliability.
TX03679,00016B7 1930OCT001/1
Inspect Machine
T6607AQ
Keep all guards and shields in good condition and

properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
UN18OCT88
Inspect machine carefully each day by walking around it

before starting.
TX03679,0001734 1925SEP001/1
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Safety Information
Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.
T133592
Entanglements in moving parts can cause serious injury.
UN12SEP01
Stay Clear Of Moving Parts
TX03679,00016D2 1930OCT001/1
T133840
If hydraulic fluid penetrates your skin, see a doctor

immediately. Injected fluid must be removed
surgically within hours or gangrene may result.
Contact a knowledgeable medical source or the Deere &
Company Medical Department in Moline, Illinois, U.S.A.
T133509
Never search for leaks with your hands. Protect hands.

Use a piece of cardboard to find location of escaping fluid.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
UN20SEP00
This machine uses a high-pressure hydraulic system.

Escaping fluid under pressure can penetrate the skin
causing serious injury.
UN31OCT00
Avoid High-Pressure Fluids
TX03679,00016D3 1930OCT001/1
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
outside air into the area.
UN24AUG00
Beware Of Exhaust Fumes
T133546
00
01
4
TX03679,00016D4 1914SEP001/1
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Safety Information
00
01
5
Remove Debris And Clean The Surrounding Area:

Before starting repair work, such as welding, clear the
area of any debris or flammable material.
Keep A Fire Extinguisher Available: Always keep a
multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
T133552
UN07SEP00
T133553
Maintain Hoses and Wiring: Replace hydraulic hoses

immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
UN07SEP00
Clean Machine Regularly: Keep trash, debris, grease

and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Store rags
and other combustible materials in a safe, fireproof
location. Use only nonflammable products for cleaning the
machine or components.
T133554
Handle Fuel Safely: Store flammable fluids away from

fire hazards. Never refuel machine while smoking or when
near sparks or flame.
UN14SEP00
Prevent Fires
TX03679,0001808 1911OCT011/1
Handle Starting Fluid Safely
To prevent accidental discharge when storing the

pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
T145705
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
UN18SEP01
Starting fluid is highly flammable.
TX03679,0001807 1918SEP011/1
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Safety Information
Prevent Battery Explosions
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
TS204
Do not charge a frozen battery; it may explode. Warm

battery to 16C (60F).
UN23AUG88
Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.
TX03679,000174A 1914SEP001/1
If uncertain about safe handling or use of these chemical

products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS). The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
T133580
Exposure to hazardous chemicals can cause serious

injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
UN25AUG00
Handle Chemical Products Safely
TX03679,00016D7 1914SEP001/1
Improper disposal of waste can threaten the environment.

Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.
UN25AUG00
Dispose of Waste Properly
T133567
00
01
6
Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your dealer for
more information.
TX03679,0001733 1914SEP001/1
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Safety Information
00
01
7
Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts.
TS291
Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.
UN23AUG88
Keep a first aid kit and fire extinguisher handy.
TX03679,000174B 1914SEP001/1
Use extra care when mud, snow, or moisture present

slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
T133468
Prevent falls by facing the machine when you get on and

off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
UN30AUG00
Use Steps And Handholds Correctly
TX03679,00016F2 1914SEP001/1
Never attempt to start engine from the ground. Do not

attempt to start engine by shorting across the starter
solenoid terminals.
T133715
Avoid unexpected machine movement. Start engine only

while sitting in operators seat. Ensure all controls and
working tools are in proper position for a parked machine.
UN07SEP00
Start Only From Operators Seat
TX03679,0001799 1902MAY011/1
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Safety Information
Use And Maintain Seat Belt
T133716
1914SEP00
Use seat belt when operating machine. Remember to

fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every three years, regardless of appearance.
TX03679,00016DD 1917OCT001/1
Prevent Unintended Machine Movement
UN16OCT01
Be careful not to accidentally actuate controls. Move

transmission out of gear and lower all equipment to the
ground during work interruptions. Follow these steps
before allowing co-workers to approach the machine,
before standing up, leaving the operators seat, or exiting
the machine:
Lower equipment to the ground

Move transmission lever to park
Be sure locking sleeve engages console
Stop the engine
For machines with separate park brake switch:
ACC
OFF
ON
START
Lower equipment to the ground

Move gear selector to neutral position
Press park brake switch to on
Stop the engine
ENGINE
STARTS
"BRAKE ON"
ONLY IN
POSITION
SHIFT LEVER
IN "N" POSIT AND
ION
Always set
park brake
before leavin
g
seat.
After start up,
push to OFF
position to
release park
UN01NOV01
T146609
For machines with transmission lever park position:
brake.
T147558
00
01
8
TX03679,000180C 1911OCT011/1
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Safety Information
00
01
9
Be sure co-workers and bystanders are clear of machine

before operating. Keep co-workers a safe distance away
when skidding, because logs may kick-out unexpectedly.
T146611
Plan your operation before starting work. Check skidding

trails and landings for stumps, large rocks, drop-offs,
muddy areas and standing water. Carefully examine
overhead for trees and branches that might fall or strike
the operators station. Take precautions to avoid these
hazards.
UN22OCT01
Avoid Work Site Hazards
Use extra care if you must drive over logs or saplings that
may be dislodged or spring-up against the machine or
bystanders.
Do not operate under low-hanging electrical wires.
Contact may cause serious injury or death by
electrocution.
TX03679,000180B 1911OCT011/1
Use extra care around landings where bystanders are

more likely to be present. Do not skid logs past people
that are not a safe distance away from logs that may
swing or kick-out.
T146610
Wear the seat belt when operating this machine. Do not

operate the machine if all elements of the operator
protective structure (OPS) are not in place and in good
repair.
UN22OCT01
Operate Machine Safely
Use extra care when backing-up with logs attached. Make

sure the delimbing grate is in good repair and bystanders
are a safe distance away.
Be careful when operating in muddy or frozen conditions
because the machine may slide or tip more easily. Avoid
side slopes when possible. Drive straight up or down
slopes to reduce the possibility of tipping.
TX03679,000180A 1911OCT011/1
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Safety Information
Keep Riders Off Machine
Riders may obstruct operators view or impair his ability to

operate machine safely.
T145263
Riders are subject to injury. They may fall from machine,

be caught between machine parts, or be struck by foreign
objects.
UN06SEP01
Only allow operator on machine.
TX03679,0001800 1918SEP011/1
Before moving machine, be sure all persons are clear

of machine path. Turn around and look directly for best
visibility. Use mirror to assist in checking around machine.
Keep windows and mirror clean, adjusted, and in good
repair.
Be certain reverse warning alarm is working properly.
UN06SEP01
Avoid Backover Accidents
T145264
00
01
10
Use a signal person when backing if view is

obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
TX03679,0001801 1931OCT011/1
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Safety Information
00
01
11
Be careful on slopes. Avoid sharp turns. Avoid stumps,

rocks and drop-offs when possible. Use extra care on soft,
uneven or frozen ground.
Do not overload. Know the capacity of the machine. Be
careful with heavy loads which may affect machine
stability.
T133716
Load and unload from trucks or trailers carefully. Be

sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
UN06SEP01
Do not jump if the machine tips. You will be unlikely to

jump clear and the machine may crush you.
T145266
Use seat belt at all times.
1914SEP00
Avoid Machine Tip Over
T146612
UN06NOV01
Ensure solid footing. Use extra care in soft ground

conditions that may not uniformly support the wheels. Do
not operate close to banks that may cave in and cause
machine to tip or fall.
TX03679,0001802 1931OCT011/1
Select low gear speed before starting down slope. The

slope on which you can operate safely will be limited by
ground condition and the load being handled. Use service
brakes to control speed.
T145730
Avoid side slope travel whenever possible. When working

on steep slopes, travel as straight up and down as
possible to prevent machine tip over.
UN20SEP01
Operating on Slopes
TX03679,0001803 1931OCT011/1
TM2111 (30MAY03)
00-01-11

053003
PN=19
Safety Information
Operating Or Traveling On Public Roads
UN22MAY01
Machines that work near vehicle traffic or travel slower

than normal highway speeds must have proper lighting
and markings to assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle
(SMV) emblems, or other devices and use as required to
make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.
T141891
00
01
12
TX03679,00017C8 1914JUN011/1
Inspect and Maintain ROPS

A damaged roll-over protective structure (ROPS)
should be replaced, not reused.
To maintain the ROPS:
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.
Replace missing hardware using correct grade

hardware.
Check hardware torque.
Check isolation mounts for damage, looseness or
wear; replace them if necessary.
Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason,

inspect it carefully before operating the machine again.
TX03679,000179F 1920APR011/1
TM2111 (30MAY03)
00-01-12

053003
PN=20
Safety Information
00
01
13
Keep the Operator Protective Structure (OPS) in Place

It is important to keep the operator protective structure
(OPS) in place (doors, screens, windows, windshield,
etc.) to minimize hazards from whipping or intruding
objects. To maintain OPS protection, replace damaged
parts immediately.
The protection offered by OPS will be impaired if OPS

is subjected to structural damage, is involved in an
overturn incident, or is altered by welding, bending,
drilling, or cutting. Damaged OPS components should
be replaced, not reused.
Replace 3-piece hard-coated polycarbonate windshield

only with LEXAN Margard 5000 or equivalent.
Keep all bolts and attaching hardware tight.
LEXAN is a trademark of General Electric Corporation
TX,90,JC297 1931OCT011/1
Add And Operate Attachments Safely

Always verify compatibility of attachments by
contacting your authorized dealer. Adding unapproved
attachments may affect machine stability or reliability,
and may create a hazard for others near the machine.
Ensure that a qualified person is involved in
attachment installation. Add guards to machine if
operator protection is required or recommended. Verify
that all connections are secure and attachment

responds properly to controls.
Carefully read attachment manual and follow all
instructions and warnings. In an area free of
bystanders and obstructions, carefully operate
attachment to learn its characteristics and range of
motion.
TX03679,00016F0 1914SEP001/1
TM2111 (30MAY03)
00-01-13

053003
PN=21
Safety Information
Park And Prepare For Service Safely
T133332
Park machine on a level surface and lower equipment

to the ground.
Engage park brake.
Stop engine and remove key.
Install frame locking bar.
Attach a Do Not Operate tag in an obvious place in
the operators station.
1914DEC01
Warn others of service work. Always park and prepare

your machine for service or repair properly.
Understand service procedures before beginning repairs.

Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TS229
Do not support machine with any hydraulically actuated

tools or attachments.
Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
Do not support machine with a single jack or other
devices that may slip out of place.
UN23AUG88
Securely support machine or attachment before working

under it.
TX03679,0001809 1918SEP011/1
Service Cooling System Safely
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
UN23AUG88
Explosive release of fluids from pressurized cooling

system can cause serious burns.
TS281
00
01
14
DX,RCAP 1904JUN901/1
TM2111 (30MAY03)
00-01-14

053003
PN=22
Safety Information
00
01
15
Remove paint to at least 76 mm (3 in.) from area to be

heated. Wear an approved respirator when sanding or
grinding paint. If a solvent or paint stripper is used, wash
area with soap and water. Remove solvent or paint
stripper containers from work area and allow fumes to
disperse at least 15 minutes before welding or heating.
T133546
Hazardous fumes can be generated when paint is heated

by welding or using a torch. Dust from sanding or grinding
paint can also be hazardous.
UN24AUG00
Remove Paint Before Welding or Heating
Work outside or in a well-ventilated area. Dispose of

waste, paint and solvents properly.
TX03679,0001732 1906SEP001/1
Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
T133547
NOTE: Disable electrical power before welding. Turn off

main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and
vehicle microprocessors.
UN31AUG00
Make Welding Repairs Safely
Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
TX03679,00016D5 1902OCT001/1
Use a soft hammer or a brass bar between hammer and

object to prevent chipping.
T133738
Always wear protective goggles or safety glasses and

other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
UN14SEP00
Drive Metal Pins Safely
TX03679,0001745 1925SEP001/1
TM2111 (30MAY03)
00-01-15

053003
PN=23
Safety Information
Safety Signs
WARNING
WARNING
PRESSURIZED TANK
Release pressure by discharging
fluid at hose end before removing
fill plug. Injury may result from
plug or cap under force. Consult
Operator's Manual before service.
T152457
Avoid crushing
DO NOT JUMP
if machine tips
USE
SEAT
BELT
Crushing injury could result.

Do not ride on machine.
T146097
WARNING
ADVERTENCIA
ADVERTISSEMENT
VORSICHT
MACHINE EQUIPPED
WITH SECONDARY
STEERING SYSTEM
WARNING
Stop machine immediately

if light or buzzer warns of
low steering pressure.
Secondary steering
system only functions
with key switch on.
To prevent shock.
M113839
always use grounded
Test secondary system

periodically. See
Operator's Manual.
3-wire extension cord.
WARNING
T146443
CAUTION
See instructions in Operator's
Manual before deactivating
park brake system:
- Secure machine against
movement
- Release brake only from
operator's station
Avoid rotating fan.

Stop engine.
Keep clear to avoid
serious injury.
T188283
WARNING
Crushing injury may result in hinge area if machine is
turned.
Make sure people are clear of machine before starting
engine or moving steering wheel.
Attach locking bar before performing service near center
of machine or transporting on a truck.
CAUTION
Pressurized refrigerant may
penetrate eyes or cause burns.
Wear goggles and protect skin.
T146436
SHIELD
EYES
FLUSH EYES
IMMECIATELY
WITH WATER
SULFURIC ACID
GET MEDICAL
CAN CAUSE
HELP FAST
BLINDNESS OR
NO
SPARKS
FLAMES
BLINDNESS OR INJURY SMOKING SEVERE BURNS
KEEP OUT OF THE REACH OF CHILDREN. DO NOT TIP. KEEP VENT CAPS TIGHT AND LEVEL.
EXPLOSIVE
GASES CAN CAUSE
CAUTION
BOOSTER CABLE INSTRUCTIONS:
1. ON A NEGATIVE GROUNDED SYSTEM,
CONNECT ENDS OF ONE CABLE TO POSITIVE(+)
TERMINAL OF EACH BATTERY.
2. CONNECT ONE END OF OTHER CABLE TO
NEGATIVE(-) TERMINAL OF THE BOOSTER
BATTERY.
T164308
TM2111 (30MAY03)
00-01-16
3. CONNECT THE OTHER END OF THE CABLE,

AWAY FROM THE BATTERY, TO THE ENGINE BLOCK,
FRAME, OR SOME OTHER GOOD METALLIC GROUND.
4. REVERSE PROCEDURE WHEN
DISCONNECTING.
1924JAN03
DANGER/POISON
T164308
00
01
16
OUO1079,0000567 1915NOV021/2

053003
PN=24
Safety Information
T164307
1924JAN03
00
01
17
OUO1079,0000567 1915NOV022/2
TM2111 (30MAY03)
00-01-17

053003
PN=25
Safety Information
00
01
18
TM2111 (30MAY03)
00-01-18

053003
PN=26
Group 0003
Torque Values
00
0003
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.
04T,90,K271 1908AUG911/1
Keeping ROPS Installed Properly
UN31MAR00
CAUTION: Make certain all parts are reinstalled

correctly if the roll-over protective structure
(ROPS) is loosened or removed for any reason.
T129546C
The protection offered by ROPS will be

impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or
is in any way altered by welding, bending,
drilling, or cutting. A damaged ROPS should be
replaced, not reused.
IMPORTANT: Do not over-tighten cap screws as
clevis will be deformed.
UN03APR00
Install lock nuts (A) onto cap screws (B) until full thread
engagement is achieved so nut, washers (C), and head of
cap screw are flush against each clevis.
T129547D
Tighten pin locking cap screws (D) to specification.

Keeping ROPS Installed ProperlySpecification
Pin Locking Cap ScrewTorque .................................. 130 Nm (95 lb-ft)
ALock Nut (2 used)

BCap Screw (2 used)
CWasher (As required)
DPin Locking Cap Screw (2 used)
CED,OUO1079,98 1926MAY001/1
TM2111 (30MAY03)
00-0003-1

053003
PN=27
Torque Values
UN07SEP99
Metric Bolt and Cap Screw Torque Values
TORQ2
00
0003
2
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8
Class 8.8 or 9.8
Class 10.9
Class 12.9
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
M6
4.7 (3.5)
6 (4.4)
9 (6.6)
11.5 (8.5)
13 (9.5)
16.5 (12.2)
15.5 (11.5)
19.5 (14.5)
M8
11.5 (8.5)
14.5 (10.7)
22 (16)
28 (20.5)
32 (23.5)
40 (29.5)
37 (27.5)
47 (35)
M10
23 (17)
29 (21)
43 (32)
55 (40)
63 (46)
80 (59)
75 (55)
95 (70)
M12
40 (29.5)
50 (37)
75 (55)
95 (70)
110 (80)
140 (105)
130 (95)
165 (120)
M14
63 (46)
80 (59)
120 (88)
150 (110)
175 (130)
220 (165)
205 (150)
260 (190)
Size
M16
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
M22
265 (195)
330 (245)
510 (375)
650 (480)
725 (535)
920 (680)
850 (625)
1080 (800)
M24
330 (245)
425 (315)
650 (480)
820 (600)
920 (680)
1150 (850)
1080 (800)
1350 (1000)
M27
490 (360)
625 (460)
950 (700)
1200 (885)
1350 (1000)
1700 (1250)
1580 (1160)
2000 (1475)
M30
660 (490)
850 (625)
1290 (950)
1630 (1200)
1850 (1350)
2300 (1700)
2140 (1580)
2700 (2000)
M33
900 (665)
1150 (850)
1750 (1300)
2200 (1625)
2500 (1850)
3150 (2325)
2900 (2150)
3700 (2730)
M36
1150 (850)
1450 (1075)
2250 (1650)
2850 (2100)
3200 (2350)
4050 (3000)
3750 (2770)
4750 (3500)
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening

procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
Shear bolts are designed to fail under predetermined loads. Always

replace shear bolts with identical property class.
Tighten plastic insert or crimped steel-type lock nuts to approximately

50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher property class.

If higher property class fasteners are used, these should only be
tightened to the strength of the original.
DX,TORQ2 1901OCT991/1
TM2111 (30MAY03)
00-0003-2

053003
PN=28
Torque Values
00
0003
3
UN18OCT88
Additional Metric Cap Screw Torque Values
T6873AA
CAUTION: Use only metric tools on metric

hardware. Other tools may not fit properly. They
may slip and cause injury.
UN18OCT88
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
loads. Always replace shear bolts with identical grade.
T6873AB
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.
UN18OCT88
Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from
failing when tightening.
T6873AC
Tighten cap screws having lock nuts to approximately 50

percent of amount shown in chart.
TM2111 (30MAY03)
00-0003-3
04T,90,M170 1929SEP991/2

053003
PN=29
Torque Values
00
0003
4
METRIC CAP SCREW TORQUE VALUESa

T-Bolt
Nominal
Dia
8
H-Bolt
Nm
lb-ft
29
21
Nm
lb-ft
M-Bolt
Nm
lb-ft
20
15
10
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
Torque tolerance is 10%.
04T,90,M170 1929SEP992/2
TM2111 (30MAY03)
00-0003-4

053003
PN=30
Torque Values
00
0003
5
TM2111 (30MAY03)
00-0003-5

053003
PN=31
Torque Values
UN27SEP99
Unified Inch Bolt and Cap Screw Torque Values
TORQ1A
00
0003
6
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark)
Size
1/4
Grade 2a (No Mark)
Grade 5, 5.1 or 5.2
Grade 8 or 8.2
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
3.8 (2.8)
4.7 (3.5)
6 (4.4)
7.5 (5.5)
9.5 (7)
12 (9)
13.5 (10)
17 (12.5)
5/16
7.7 (5.7)
9.8 (7.2)
12 (9)
15.5 (11.5)
19.5 (14.5)
25 (18.5)
28 (20.5)
35 (26)
3/8
13.5 (10)
17.5 (13)
22 (16)
27.5 (20)
35 (26)
44 (32.5)
49 (36)
63 (46)
7/16
22 (16)
28 (20.5)
35 (26)
44 (32.5)
56 (41)
70 (52)
80 (59)
100 (74)
1/2
34 (25)
42 (31)
53 (39)
67 (49)
85 (63)
110 (80)
120 (88)
155 (115)
9/16
48 (35.5)
60 (45)
76 (56)
95 (70)
125 (92)
155 (115)
175 (130)
220 (165)
5/8
67 (49)
85 (63)
105 (77)
135 (100)
170 (125)
215 (160)
240 (175)
305 (225)
3/4
120 (88)
150 (110)
190 (140)
240 (175)
300 (220)
380 (280)
425 (315)
540 (400)
7/8
190 (140)
240 (175)
190 (140)
240 (175)
490 (360)
615 (455)
690 (510)
870 (640)
285 (210)
360 (265)
285 (210)
360 (265)
730 (540)
920 (680)
1030 (760)
1300 (960)
1-1/8
400 (300)
510 (375)
400 (300)
510 (375)
910 (670)
1150 (850)
1450 (1075)
1850 (1350)
1-1/4
570 (420)
725 (535)
570 (420)
725 (535)
1280 (945)
1630 (1200)
2050 (1500)
2600 (1920)
1-3/8
750 (550)
950 (700)
750 (550)
950 (700)
1700 (1250)
2140 (1580)
2700 (2000)
3400 (2500)
1-1/2
990 (730)
1250 (930)
990 (730)
1250 (930)
2250 (1650)
2850 (2100)
3600 (2650)
4550 (3350)
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening

procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
Shear bolts are designed to fail under predetermined loads. Always

replace shear bolts with identical grade.
Tighten plastic insert or crimped steel-type lock nuts to approximately

50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher grade. If

higher grade fasteners are used, these should only be tightened to
the strength of the original.
DX,TORQ1 1901OCT991/1
TM2111 (30MAY03)
00-0003-6

053003
PN=32
Torque Values
00
0003
7
X9811
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
UN23AUG88
Check Oil Lines And Fittings
If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.
Tubing with dents may cause the oil to overheat. If you
find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified in torque
chart.
When you tighten connections, use two wrenches to
prevent bending or breaking tubing and fittings.
TX,90,DH1559 1901AUG941/1
TM2111 (30MAY03)
00-0003-7

053003
PN=33
Torque Values
Service Recommendations for 37 Flare and

30 Cone Seat Connectors
2. Defects in tube flare cannot be repaired.

Overtightening a defective flared fitting will not stop
leaks.
3. Align tube with fitting before attempting to start nut.
UN18OCT88
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
T6234AC
00
0003
8
4. Lubricate male threads with hydraulic fluid or petroleum

jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on torque
chart. Do not allow hoses to twist when tightening
fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Nm
lb-ft
3/8 - 24 UNF
Thread Size
7/16 - 20 UNF
12
1/2 - 20 UNF
16
12
9/16 - 18 UNF
24
18
3/4 - 16 UNF
46
34
7/8 - 14 UNF
62
46
1-1/16 - 12 UN
102
75
1-3/16 - 12 UN
122
90
1-5/16 - 12 UN
142
105
1-5/8 - 12
190
140
1-7/8 - 12 UN
217
160
NOTE: Torque tolerance is 10%.
T82,BHMA,EL 1929SEP991/1
TM2111 (30MAY03)
00-0003-8

053003
PN=34
Torque Values
00
0003
9
Service Recommendations for O-Ring Boss

Fittings
Straight Fitting
UN18OCT88
1. Inspect O-ring boss seat for dirt or defects.
T6243AE
2. Lubricate O-ring with petroleum jelly. Place electrical

tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
TM2111 (30MAY03)
00-0003-9
04T,90,K66 1929SEP991/2

053003
PN=35
Torque Values
Angle Fitting
2. Turn fitting into threaded boss until back-up washer

contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index
(maximum of one turn).
NOTE: Do not allow hoses to twist when tightening

fittings.
UN18OCT88
1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.
T6520AB
00
0003
10
4. Hold fitting head-end with a wrench and tighten lock

nut and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size
Nm
lb-ft
3/8-24 UNF
7/16-20 UNF
12
1/2-20 UNF
16
12
9/16-18 UNF
24
18
3/4-16 UNF
46
34
7/8-14 UNF
62
46
1-1/16-12 UN
102
75
1-3/16-12 UN
122
90
1-5/16-12 UN
142
105
1-5/8-12 UN
190
140
1-7/8-12 UN
217
160
NOTE: Torque tolerance is 10%.
04T,90,K66 1929SEP992/2
TM2111 (30MAY03)
00-0003-10

053003
PN=36
Torque Values
00
0003
11
Service Recommendations For Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces and O-ring. They
must be free of dirt or defects.
fittings, use backup wrench on straight hose

couplings.
2. Lubricate O-rings and install into grove using

petroleum jelly to hold in place.
IMPORTANT: Tighten fittings to 150% of listed

torque value if indexing is necessary
or if fitting is attached to an
actuating devise.
3. Index angle fittings and tighten by hand pressing

joint together to insure O-ring remains in place.
Tighten fittings to 50% of listed

torque value if used in aluminum
housing.
4. Tighten fitting or nut to torque value shown on the

chart. Do not allow hoses to twist when tightening
FLAT FACE O-RING SEAL FITTING TORQUE*

Nominal Tube O.D.
Thread Size
Swivel Nut
Bulkhead Nut
mm
in.
in.
Nm
lb-ft
Nm
lb-ft
6.35
0.250
9/16-18
16
12
12
9.52
0.375
11/16-16
24
18
24
18
12.70
0.500
13/16-16
50
37
46
34
15.88
0.625
1-14
69
51
62
46
19.05
0.750
1 3/16-12
102
75
102
75
22.22
0.875
1 3/16-12
102
75
102
75
25.40
1.000
1 7/16-12
142
105
142
105
31.75
1.250
1 11/16-12
190
140
190
140
38.10
1.500
2-12
217
160
217
160
*Torque tolerance is +15 -20% unless otherwise specified.

Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size
Straight Hex Size
Locknut Hex Size
Inch
Inch
Inch
Straight Fitting or Locknut Toque

Nm
lb-ft
3/8-24
5/8
9/16
12
7/16-20
5/8
5/8
21
15
1/2-20
3/4
11/16
26
19
9/16-18
3/4
3/4
34
25
3/4-16
7/8
15/16
73
55
7/8-14
1 1/16
1 1/16
104
76
1 1/16-12
1 1/4
1 3/8
176
130
1 3/16-12
1 3/8
1 1/2
230
170
1 5/16-12
1 1/2
1 5/8
285
210
*Torque tolerance is +15 -20% unless otherwise specified.
04T,90,K67 1902MAR001/1
TM2111 (30MAY03)
00-0003-11

053003
PN=37
Torque Values
UN01MAR90
Service Recommendations for Metric Series Four Bolt Flange Fitting
T6890BB
00
0003
12
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange
then tighten the diagonally opposite cap screw.

Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.
1. Clean sealing surfaces (A). Inspect. Scratches

cause leaks. Roughness causes seal wear.
Out-of-flat causes seal extrusion. If defects cannot
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
2. Install the correct O-ring (and backup washer if

required) into groove using petroleum jelly to hold it
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B)

halves. Make sure split is centrally located and
perpendicular to the port. Hand tighten cap screws
to hold parts in place. Do not pinch O-ring (C).
Thread
Nm
lb-ft
M6
12
4. Single piece flange (D): Place hydraulic line in

center of flange and install four cap screws. Flange
must be centrally located on port. Hand tighten cap
screws to hold flange in place. Do not pinch O-ring.
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
5. After components are properly positioned and cap

screws are hand tightened, tighten one cap screw,
M8
30
22
M10
57
42
Tolerance 10%. The torques given are enough for the given
size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
a
Metric standard thread.
04T,90,K175 1929SEP991/1
TM2111 (30MAY03)
00-0003-12

053003
PN=38
Torque Values
00
0003
13
T6890BB
UN01MAR90
Service Recommendations For Inch Series Four Bolt Flange Fittings
ASealing Surface
BSplit Flange
CPinched O-Ring
1. Clean sealing surfaces (A). Inspect. Scratches

cause leaks. Roughness causes seal wear.
Out-of-flat causes seal extrusion. If defects cannot
be polished out, replace component.
2. Install O-ring (and backup washer if required) into
groove using petroleum jelly to hold it in place.
3. Split flange: Loosely assemble split flange (B)
halves. Make sure split is centrally located and
perpendicular to port. Hand tighten cap screws to
hold parts in place. Do not pinch O-ring (C).
4. Single piece flange (D): Place hydraulic line in
center of flange and install cap screws. Flange
must be centrally located on port. Hand tighten cap
screws to hold flange in place. Do not pinch O-ring.
5. Tighten one cap screw, then tighten the diagonally
opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.
DSingle Piece Flange

TORQUE CHART
Nm
Nominal
Flange
Size
1/2
lb-ft
Cap Screw
Size
5/16-18
UNC
Min
Max
Min
Max
20
31
15
23
3/4
3/8-16 UNC
28
54
21
40
3/8-16 UNC
37
54
27
40
1-1/4
7/16-14
UNC
47
85
35
63
1-1/2
1/2-13 UNC
62
131
46
97
1/2-13 UNC
73
131
54
97
2-1/2
1/2-13 UNC
107
131
79
97
5/8-11 UNC
158
264
117
195
3-1/2
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
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
TM2111 (30MAY03)
00-0003-13

053003
PN=39
Torque Values
00
0003
14
TM2111 (30MAY03)
00-0003-14

053003
PN=40
Section 01
Wheels
Contents
01
Page
Group 0110Powered Wheels and Fastenings

Wheel Repair . . . . . . . . . . . . . . . . . . . . . . . .01-0110-1
Dual Wheel Installation . . . . . . . . . . . . . . . . .01-0110-5
TM2111 (30MAY03)
01-1

053003
PN=1
Contents
01
TM2111 (30MAY03)
01-2

053003
PN=2
Group 0110
Powered Wheels and Fastenings

Wheel Repair
Wheel Remove and Install
CAUTION: Avoid possible injury from
unexpected machine movement. Install frame
locking bar before working in frame hinge area.
Install wheel chocks under one or more wheels
not being removed.
01
0110
1
1. Install frame locking bar.

Install wheel chocks under one or more wheels not
being removed.
CAUTION: Heavy component; use a hoist.
WheelSpecification
MachineWeight ........................................................... 998014 745 kg
(22,00032,500 lb) approximate
range
WheelWeight ............................................ 545 kg (1200 lb) approximate
2. Raise machine. Place an 18-t (20-ton) floor stand

under axle.
3. Place wheel lift under wheel. Fasten safety chain
around upper part of tire.
IMPORTANT: The rim dropping onto the cap screws
when loosened can damage the
threads. Install studs before loosening
all the cap screws to keep wheel
centered on axle flange to prevent
thread damage.
4. Remove three cap screws equally spaced around bolt
circle. Install the T45672 Studs.
TM2111 (30MAY03)
01-0110-1
OUT3035,00002EB 1925NOV021/5

053003
PN=43

5. Remove cap screws and washers to remove wheel.
UN27SEP90
T7382AN
01
0110
2
IMPORTANT: Paint, rust, and dirt must be removed

from the cap screws and axle flange
threads, washers, and mating surfaces
of axle flange and rim to ensure good
contact between all surfaces. Paint,
rust, and dirt prevent good contact
between the surfaces and can result in
the wheels coming loose.
6. Clean the threads of cap screws and axle flange; and
the mating surfaces on washers, rim, and axle flange.
Apply a drop of oil to cap screw threads after cleaning
with solvent.
7. Install three studs, equally spaced, into the axle flange.
8. Install wheel.
9. Install cap screws and washers.
Tighten the cap screws just enough to hold wheel in
position. Remove the studs. Install the three remaining
cap screws.
Tighten cap screws to specification in a circular pattern
continuing past the starting point by four cap screws.
WheelSpecification
Rim-to-Axle Flange Cap Screw
Torque ......................................................................... 860 Nm (635 lb-ft)
For machines with dual wheels, apply NEVER-SEEZ

Lubricant or an equivalent to the threads of cap screws
and nuts that fasten the outer dual wheel to the inner dual
wheel. Install a washer on each cap screw and under
each nut. Tighten nuts and cap screws to the initial and
final torque using a crisscross pattern.
WheelSpecification
Inner Dual Wheel-to-Outer Dual
Wheel Cap Screw and Nut
Torque ................................................................ 407 Nm (300 lb-ft) initial
712 Nm (525 lb-ft) final
NEVER-SEEZ is a trademark of Emhart Chemical Group
TM2111 (30MAY03)
01-0110-2
OUT3035,00002EB 1925NOV022/5

053003
PN=44

Tire Remove and Install
CAUTION: Explosive separation of a tire and
rim parts can cause serious injury or death.
01
0110
3
Always maintain the correct tire pressure. DO

NOT inflate tires above the recommended
pressure.
Inspect tires and wheels daily. DO NOT operate
with low pressure, cuts, bubbles, damaged
rims, or missing lug bolts and nuts.
UN23AUG88
Carefully inspect any tire and rim assembly that

has been run flat or severely under-inflated
before reinflating the tire. Damage to the rim
and tire may have developed. Call your
authorized dealer or a qualified repair service to
inspect the rim and tire assembly and make
necessary repairs.
TS211
When inflating tires, use a clip-on 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.
NEVER cut or weld on an inflated tire or rim
assembly. Heat from welding could cause an
increase in pressure and may result in tire
explosion.
Do not attempt to mount a tire if you do not
have the proper equipment and experience to
perform the job. Have it done by your
authorized dealer or a qualified repair service.
1. The tire can be removed without removing the wheel
from the machine. See the Off-The-Road Tire
Maintenance Manual to remove the tire from the wheel.
2. Always completely deflate the tire by removing valve
core from valve before attempting any demounting
operation. Check the valve stem by running a probe
through it to make sure the valve stem is not plugged.
TM2111 (30MAY03)
01-0110-3
OUT3035,00002EB 1925NOV023/5

053003
PN=45

3. To prevent slipping of the rim under load, the inside
and outside of rim must be free of paint, rust, oil,
grease, dirt or other foreign material before installation.
4. Install valve stem in rim base and tighten valve core
housing finger tight.
CAUTION: Serious bodily injury can occur from
explosion when mounting and inflating tires if
safe procedures are not followed.
5. Apply soap lubricant to bead of tire and bead seat area
on rim.
6. Clear area of all persons.
OUT3035,00002EB 1925NOV024/5
7. Turn tire so valve stem (B) is pointing down. Use a

pressure regulating valve (A) with clip-on chuck and
extension hose long enough to allow you to stand to
one side and NOT in front of tire while inflating.
UN25OCT88
Check tire pressure with an accurate gauge having 6.9

kPa (0.07 bar) (1 psi) gradations.
Inflate tire to specified pressure to seat tire bead on
the rim.
WheelSpecification
Seating Tire Bead On Rim
Pressure ........................................................... 207 kPa (2.1 bar) (30 psi)
maximum
T6075AD
01
0110
4
APressure Regulating Valve

BValve Stem
8. Adjust tire pressure to recommended pressure. Use

only recommended air pressure. Pressure over this
limit can cause an explosion. See Check Tire
Pressure. (Operators Manual.)
OUT3035,00002EB 1925NOV025/5
TM2111 (30MAY03)
01-0110-4

053003
PN=46
Dual Wheel Installation

WheelSpecification
Dual WheelWeight ................................... 545 kg (1200 lb) approximate
01
0110
5
1. Position outer dual wheel fange-to-flange with inner

wheel.
2. Align cap screw holes in flanges using punches if
necessary.
3. Lubricate cap screw threads with grease.
4. Insert each cap screw outward through inner washer,
inner flange and outer washer. Install nut.
5. Seat wheels to rim by tightening nuts in a criss-cross
pattern to specification.
Specification
Dual Wheel NutsInitial Torque ................................. 407 Nm (300 lb-ft)
6. Tighten nuts to final specification.

Specification
Dual Wheel NutsFinal Torque ................................. 712 Nm (525 lb-ft)
TX17994,00003BB 1908FEB031/1
TM2111 (30MAY03)
01-0110-5

053003
PN=47
01
0110
6
TM2111 (30MAY03)
01-0110-6

053003
PN=48
Section 02
Axles and Suspension System

Contents
Page

Front Axle, Differential, and Oscillating
Supports . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Rear Axle and Differential . . . . . . . . . . . . . .02-0200-11
Front Axle Guard. . . . . . . . . . . . . . . . . . . . .02-0200-15
02

Front Axle and Differential Drive Shaft . . . . .02-0225-1
Rear Axle and Differential Drive Shaft . . . . . .02-0225-4
Differential Lock
Solenoid Valve. . . . . . . . . . . . . . . . . . . . . .02-0260-1
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . .02-0260-3
PumpCable Skidder . . . . . . . . . . . . . . . .02-0260-5
PumpGrapple Skidder . . . . . . . . . . . . . .02-0260-6
Differential Lock and Axle Hose Routing . . . .02-0260-7
TM2111 (30MAY03)
02-1

053003
PN=1
Contents
02
TM2111 (30MAY03)
02-2

053003
PN=2
Group 0200
Removal and Installation

Front Axle, Differential, and Oscillating
Supports Remove and Install
UN13MAY98
Remove Front Axle, Differential, and Oscillating

Supports
1. Engage park brake.
T115334B

ADrain Plugs

Front Axle, Differential, and Oscillating SupportsSpecification
range
3. Raise front of machine. Place 18-t (20-ton) floor stands

under engine frame.
4. See Wheel Repair for procedure to remove and install
wheels. (Group 0110.)
5. Remove engine frame front and rear bottom guard.
6. Remove drain plugs (A) to drain oil into a container.
Dispose of used oil properly.
17.9 L (18.9 qt) approximate for 1200 Series Axle
31.2 L (33 qt) approximate for 1400 Series Axle
32 L (34 qt) approximate for 1400 Series Super
Wide Extreme Duty Axle (SWEDA)
TM2111 (30MAY03)
02-0200-1
OUT3035,0000337 1922MAY031/15

053003
PN=51
02
0200
1
T151726
19
02
0200
2
Direct Drive Machine Shown

AFront Differential-to-Rear
Differential Line
BDifferential-to-Differential
Lock Solenoid Valve Line
CDifferential-to-Differential
Lock Pump Line
DDifferential-to-Brake Valve
Line
7. Disconnect front differential drive shaft (G). Slide

drive shaft rearward.
EDifferential-to-Differential
Lock Filter Line
FDifferential Vent
8. Disconnect lines (AE) and vent (F).
TM2111 (30MAY03)
GFront Differential Drive

Shaft
02-0200-2
OUT3035,0000337 1922MAY032/15

053003
PN=52
UN23APR91

1200 Series AxleWeight .......................... 726 kg (1600 lb) approximate
1400 Series Super Wide Extreme
Duty Axle (SWEDA)Weight.................... 1374 kg (3030 lb) approximate
T7502AI
9. Install a hydraulic lift scissors jack under axle and

differential. Support axle on each side using wooden
blocks.
Front Axle and Differential Removed
TM2111 (30MAY03)
02-0200-3
OUT3035,0000337 1922MAY033/15

053003
PN=53
02
0200
3
T7502AH
UN29MAY91
02
0200
4
ARear Oscillating Support
BFront Oscillating Support
10. Remove cap screws (C) from front and rear

oscillating supports (A and B). Slowly lower axle
and differential.
CCap Screw (12 used)
DWasher (12 used)
to become familiar with the axle and differential

configuration. (CTM43). Go to the appropriate
repair story using the table of contents in
component technical manual.
11. Repair or replace axle and differential. See Axle

Identification before beginning repair or adjustment
OUT3035,0000337 1922MAY034/15
Disassemble and Assemble Front Axle Front

Oscillating Support
UN09APR91
1. Inspect dowels (A) for looseness, wear, or damage.

Replace if necessary.
T7502AJ
ADowel (2 used)
TM2111 (30MAY03)
02-0200-4
OUT3035,0000337 1922MAY035/15

053003
PN=54

2. Repair or replace oscillating support (AH). See
Remove, Disassemble, and Assemble Oscillating
Support from Opposite End of Input for procedure.
(CTM43.)
AShim (as required)
BThrust Washer
CCover
DWasher (6 used)
ECap Screw (6 used)
FFront Oscillating Support
GBushing
HSeal
T7502AK
UN23APR91
02
0200
5
OUT3035,0000337 1922MAY036/15
Disassemble and Assemble Front Axle Rear

Oscillating Support
UN22APR91
1. Inspect dowels (A) for looseness, wear or damage.

T7502CD
ADowel (2 used)
TM2111 (30MAY03)
02-0200-5
OUT3035,0000337 1922MAY037/15

053003
PN=55

2. Repair or replace parts (B, C, and GK) as needed.
See Remove Input Oscillating Support for procedure.
(CTM43.)
T7742AF
UN08APR92
RW18724
ADFT1055 Yoke Holding Tool

BYoke
CRear Oscillating Support
GCotter Pin
HYoke
ISlotted Nut
JWasher
KO-Ring
OUT3035,0000337 1922MAY038/15
3. Repair or replace oscillating support (AG). See

Remove Input Oscillating Support for procedure.
(CTM43.)
UN23APR91
ASeal
BPipe Plug
COscillating Support
DBushing
ESnap Ring
FSeal
GThrust Washer
HDifferential
T7502AS
02
0200
6
UN07JAN91
See DFT1055 Yoke Holding Tool for instruction to

make tool for the 1200 and 1400 Series Axles with 6C
yoke. (Group 9900.)
TM2111 (30MAY03)
02-0200-6
OUT3035,0000337 1922MAY039/15

053003
PN=56

Install Front Axle, Differential, and Oscillating
Supports
IMPORTANT: When operating in steep conditions,
add an additional 5.7 L (6 qt) of oil to
front axle.
1. Fill axle and differential with recommended oil. See
Change Front Differential Oil for procedure and
quantity. (Operators Manual.)
02
0200
7
2. Clean mounting surface on supports, dowels, and

engine frame.
Install the dowels into supports.
T7502AM
UN09APR91
AFront Oscillating Support-to-Frame Cap Screw (6

used)
BRear Oscillating Support-to-Frame Cap Screw (6
used)
OUT3035,0000337 1922MAY0310/15
3. Carefully raise axle and differential into position.
UN08MAY91
As necessary, loosen the front cover-to-oscillating

support cap screws (A) to align support cap screw
holes with holes in engine frame. Hold thrust washer in
place using a hex key wrench.
T7502EO
4. Install front and rear oscillating support-to-engine frame

cap screws and washers (A and B). Tighten cap
screws to specification.
Oscillating Support-to-Engine
Frame Cap Screw (lubricated)
Torque ......................................................... 542 54 Nm (400 40 lb-ft)
AFront Cover-to-Oscillating Support Cap Screw

BThrust Washer
TM2111 (30MAY03)
02-0200-7
OUT3035,0000337 1922MAY0311/15

053003
PN=57

5. Perform Adjust Axle Assembly End PlayIn Vehicle to
adjust end play to specification. Tighten three cap
screws to specification for adjustment. (CTM43.)
T7502AL
02
0200
8
UN09APR91

Front Axle to Oscillating
SupportEnd Play ................................ 0.0760.330 mm (0.0030.013
in.)
Front Cover-to-Oscillating Support
Cap ScrewTorque .................................... 20 Nm (15 lb-ft) for end play
adjustment
6. After end play adjustment, install the three remaining

cap screws. Tighten the six cap screws to
specification.
Front Cover-to-Oscillating Support
Cap ScrewTorque ...................................................... 100 Nm (74 lb-ft)
TM2111 (30MAY03)
02-0200-8
OUT3035,0000337 1922MAY0312/15

053003
PN=58
T151726
UN21FEB02
02
0200
9

AFront Differential-to-Rear
Differential Line
CDifferential-to-Differential
Lock Pump Line
DDifferential-to-Brake Valve
Line
EDifferential-to-Differential
Lock Filter Line
FDifferential Vent
7. Connect lines (AE). Connect lubrication lines to

oscillating support.
GFront Differential Drive

Shaft
9. Install front differential drive shaft (G).
8. Connect differential vent (F).
OUT3035,0000337 1922MAY0313/15
10. Tighten cap screws (A).
UN09APR91

3/8 in. Cross and Bearing
Assembly-to-Yoke Cap Screw
Torque .............................................................. 5157 Nm (3842 lb-ft)
Torque ........................................................ 127142 Nm (94105 lb-ft)
T7502AA
ACap Screw (4 used)
TM2111 (30MAY03)
02-0200-9
OUT3035,0000337 1922MAY0314/15

053003
PN=59
Adapter Torque =
02
0200
10
Torque Wrench Length x Torque Specification

Torque Wrench Length + Adapter Length
T85624
If an adapter is fastened to the square drive of a

torque wrench, it adds to the wrench length. The real
torque then becomes greater than the force applied
when this happens. The example below can be used
to find the correct torque when an adapter is used.
UN23FEB89
11. EXAMPLE FOR FINDING ADAPTER TORQUE

SPECIFICATION:
A = Distance from the center of the square drive of

the torque wrench to the center of the handle grip.
B = Length of the adapter from the center of the
square drive of the torque wrench to the center of the
nut or cap screw. Use only the length which is parallel
to the handle.
Adapter Torque =
(A) x 163 Nm (120 lb-ft)

(A) + 88.9 mm (3.5 in.)
NOTE: If adapter is used, 90 to torque wrench does not

need conversion.
12. Install bottom guard.
Bottom Guard-to-Engine Frame
Cap ScrewTorque .................................................... 620 Nm (457 lb-ft)
13. Install wheels. See Wheel Repair for procedure.

(Group 0110.)
14. See Service Brake Bleeding Procedure. (Group
9025-20.)
OUT3035,0000337 1922MAY0315/15
TM2111 (30MAY03)
02-0200-10

053003
PN=60
Rear Axle and Differential Remove and Install

Remove Rear Axle and Differential
UN27APR00

T130650B

Rear Axle and DifferentialSpecification
range
1400 Axle Series Shown

ADrain Plug
3. Raise rear of machine. Place 18-t (20-ton) floor stands

under equipment frame.
4. Remove wheels. See Wheel Repair for procedure.
(Group 0110.)
5. Remove equipment frame bottom guard.
6. Remove drain plug (A) to drain oil. Dispose of oil
properly.
24.6 L (26 qt) approximate for 1200 Series Axle
48 L (51 qt) approximate for 1400 Series Axle
50 L (53 qt) approximate for 1400 Series Super
Wide Extreme Duty Axle (SWEDA)
TM2111 (30MAY03)
02-0200-11
OUT3035,00002EE 1924SEP021/5

053003
PN=61
02
0200
11
T112423
UN09DEC97
02
0200
12
ARear Differential-to-Front
Differential Line
CRear Differential Drive

Shaft
DDifferential-to-Service
Brake Valve Line
7. Remove cap screws to disconnect rear differential

drive shaft (C).
ECap Screw (12 used)

FWasher (24 used)
8. Disconnect lines (A, B, and D).
TM2111 (30MAY03)
GNut (12 used)
02-0200-12
OUT3035,00002EE 1924SEP022/5

053003
PN=62

1400 Series Super Wide Extreme
Duty Axle (SWEDA)Weight.................... 1374 kg (3030 lb) approximate
9. Install a hydraulic lift scissors jack under axle and

differential.
02
0200
13
10. Remove just enough nuts, cap screws, and washers

(A) on both sides so wooden blocks can be installed
under axle.
11. Remove remaining nuts, cap screws and washers on
both sides. Lower axle and differential.
T7502AP
UN09APR91
12. Repair or replace axle or differential. See Axle

Identification before beginning repair or adjustment to
become familiar with the axle and differential
configuration. (CTM43.) Go to the appropriate repair
story using the table of contents in component
technical manual.
Install Rear Axle and Differential
1. Fill axle and differential with recommended oil. See
Change Rear Differential Oil for procedure and
quantity. (Operators Manual.)
ACap Screw and Nut (12 used), Washer (24

used)
2. Clean mounting surface on axle housing and

equipment frame.
3. Install axle and differential to frame.
TM2111 (30MAY03)
02-0200-13
OUT3035,00002EE 1924SEP023/5

053003
PN=63
T130651
UN01MAY00
02
0200
14
ARear Differential-to-Front
Differential Line
CRear Differential Drive

Shaft
DDifferential-to-Service
Brake Valve Line
IMPORTANT: The tightening sequence for cap

screws and nuts must be followed to
prevent binding which would result
in an inadequate clamping force
applied to the axle and frame joint.
4. Hold the cap screws (E) and tighten the nuts (G)
until they are snug and then again to specification
in the following sequence:
ECap Screw (12 used)

FWasher (24 used)
GNut (12 used)

HFill Plug
5. Connect drive shaft (C). Tighten cap screws to

specification.
Assembly-to-Yoke Cap
ScrewTorque .......................................... 5157 Nm (3842 lb-ft)
ScrewTorque .................................... 127142 Nm (94105 lb-ft)
a. two inside nuts on each side
6. Connect lines (A, B and D).
b. two middle nuts on each side
7. Check oil level. See Check Rear Differential Oil

Level for procedure. (Operators Manual.)
c. the two outside nuts on each side

8. Install bottom guard. Tighten cap screws to
specification.

Rear Axle and
Differential-to-Equipment Frame
Nut and Cap ScrewTorque ............................... 925 Nm (680 lb-ft)
TM2111 (30MAY03)
02-0200-14
OUT3035,00002EE 1924SEP024/5

053003
PN=64

Bottom Guard-to-Equipment
Frame Cap ScrewTorque.................................. 620 Nm (460 lb-ft)
10. See Service Brake Bleeding Procedure. (Group

9025-20.)
9. Install wheels. See Wheel Repair for procedure.

(Group 0110.)
02
0200
15
OUT3035,00002EE 1924SEP025/5
T7502EM
UN20MAY91
Front Axle Guards Remove and Install
1Washer (4 used per guard)
2Guard (2 usedleft and

right)
3Cap Screw (2 used per

guard)
4Washer (2 used per guard)
Remove and install parts as shown.

Front Axle GuardSpecification
Axle Guard and
Housing-to-Differential Case
Cap ScrewTorque ............................................. 365 Nm (269 lb-ft)
OUT3035,00002EF 1924SEP021/1
TM2111 (30MAY03)
02-0200-15

053003
PN=65
02
0200
16
TM2111 (30MAY03)
02-0200-16

053003
PN=66
Group 0225
Input Drive Shafts and U-Joints

Front Axle Drive Shaft Repair
T8459AN
UN16MAY95
02
0225
1
1Transmission Yoke
2Cap Screw (12 used)
3Cross and Bearing

Assembly (2 used)
4Double Universal Joint

5Cap Screw (4 used)
Hand pressure, a tap with a

soft-faced hammer or a C clamp
can be used to seat a bearing cup in
the yoke. DO NOT use the cap
screws to pull bearing cups into the
yokes.
1. Remove cap screws (2 and 5) to remove double

universal joint (4).
IMPORTANT: Yoke faces, pilots, keyways, and
bearing cup mounting face and key
must be free of foreign material,
burrs, and nicks which will prevent
the cross and bearing assembly and
yoke from becoming properly
seated.
2. Inspect parts for wear or damage. Repair or replace
as required.
IMPORTANT: Universal joints are precision
components. The fit is intended to
be tight and some compression of
seals and thrust washers is required
to seat the bearing cups in the yoke.
3. Assemble universal joint so lubrication fittings are

aligned. Bearing cup keys must engage the keyway
and bearing cups the yoke pilot.
Tighten cap screws to specification in even steps.
Front Axle and Differential Drive ShaftSpecification
ScrewTorque .......................................... 5157 Nm (3842 lb-ft)
ScrewTorque .................................... 127142 Nm (94105 lb-ft)
TM2111 (30MAY03)
6Front Differential Yoke
02-0225-1
OUT3035,00002F0 1924SEP021/2

053003
PN=67

4. Tighten lubrication fittings to specification.
Rear Axle and Differential Drive ShaftSpecification
Lubrication FittingTorque ..................... 516 Nm (48144 lb-in.)
5. See Grease Front Axle Drive Shaft U-Joints and

Transmission Output Shaft Seal for procedure to
lubricate universal joints. (Operators Manual.)
OUT3035,00002F0 1924SEP022/2
02
0225
2
TM2111 (30MAY03)
02-0225-2

053003
PN=68
02
0225
3
TM2111 (30MAY03)
02-0225-3

053003
PN=69
Rear Axle and Transmission Drive Shaft Repair
T162470
UN09DEC02
02
0225
4
TM2111 (30MAY03)
02-0225-4
OUT3035,00002F1 1924SEP021/4

053003
PN=70

1Lock Nut
2Washer
3Yoke
4Cap Screw (8 per universal
joint)
5Snap Ring (1400 Series
Axle with 7C yokes)
6Support Bearing
7Lubrication Fitting
8Coupling Shaft
9Cross and Bearing
Assembly
10Yoke

12Washer (4 used)
13Nut (2 used)
14Nut
15Set Screw
16Arrow

unexpected machine movement. Install
frame locking bar before working in frame
hinge area.
2. Remove shields at the articulation joint as needed
for access. Remove the equipment frame bottom
guard for access at rear axle and differential. See
Equipment Frame Bottom Guard Remove and
Install for procedure. (Group 1746.)
IMPORTANT: Yoke faces, pilots, keyways, and
bearing cup mounting face and key
must be free of foreign material,
burrs, and nicks which will prevent
the cross and bearing assembly and
yoke from becoming properly
seated.
3. Disassemble parts (121) as necessary to repair
or replace. Inspect parts for wear or damage.
Loosen the nut (14) and then the set screw (15) to
remove support bearing (6) from coupling shaft (8).
4. Install snap ring (20) into groove of transmission
yoke (21).
Install yoke on transmission output shaft. Install
special slotted nut (18).
Yoke-to-Transmission Output
Shaft Special Slotted Nut
Torque................................................ 271339 Nm (200250 lb-ft)
plus a maximum of 1/24 turn to
align slot with hole
NEVER-SEEZ is a trademark of Emhart Chemical Group
TM2111 (30MAY03)
17Double Universal Joint

(Telescoping Drive Shaft)
18Special Slotted Nut
19Cotter Pin
20Snap Ring
21Transmission Yoke
Install cotter pin (19). Bend legs of cotter pin against

sides of nut.
IMPORTANT: Double universal joint (telescoping
drive shaft) must be assembled with
arrow and yoke on female spline
yoke and stub yoke aligned. Yokes
not aligned will cause excessive
vibration during turns resulting in
failure of bearings.
5. Assemble double universal joint (telescoping drive
shaft) (17) so arrow and yoke on female spline
yoke and stub yoke are aligned.
Install universal joint so female spline yoke is to the
rear of machine.
6. Apply NEVER-SEEZ Lubricant to support
bearing-to-coupling shaft contact surface of support
bearing (6).
Install support bearing on coupling shaft (8) so set
screw (15) is towards the threaded end of shaft.
Tighten set screw until it contact bottom of slot in
shaft and then loosen one turn. Tighten nut (14).
Support Bearing-to-Coupling
Shaft Slot Set Screw
Clearance................................................ One turn out from bottom of
slot in coupling shaft.
7. For machines with 1400 series axle and 7C yokes,

install snap ring (5) into groove of coupling shaft so
opening is opposite the slot.
02-0225-5
OUT3035,00002F1 1924SEP022/4

053003
PN=71
02
0225
5

8. Install yoke (3) so arrow (16) in keyway is aligned
with arrow on end of coupling shaft.
Install washer (2). Install lock nut (1).
02
0225
6

Yoke-to-Coupling Shaft
M27x1.5 Nut (Machines with
1200 Series Axle)Torque ............... 542610 Nm (400450 lb-ft)
Yoke-to-Coupling Shaft
M33x1.5 Nut (Machines with
1400 Series Axle)Torque ............... 720800 Nm (531590 lb-ft)
9. Install coupling shaft so support bearing is on the

front side of mounting plate. Install washers (12)
under the head of cap screws (11) and nuts (13).
Tighten nuts to specifications.
Support Bearing-to-Mounting
Plate Cap Screw and Nut
Torque................................................................... 325 Nm (240 lb-ft)
TM2111 (30MAY03)
02-0225-6
OUT3035,00002F1 1924SEP023/4

053003
PN=72

IMPORTANT: Universal joints are precision
components. The fit is intended to be
tight and some compression of seals
and thrust washers is required to seat
the bearing cups in the yoke. Hand
pressure, a tap with a soft-faced
hammer or a C clamp can be used to
seat a bearing cup in the yoke. DO NOT
use the cap screws to pull bearing cups
into the yokes.
02
0225
7
UN07FEB96
10. Assemble universal joint so lubrication fittings are

aligned. Bearing cup keys (A) must engage the
keyways and bearing cups engage the yoke pilot (B).

Torque .............................................................. 5157 Nm (3842 lb-ft)
Torque ........................................................ 127142 Nm (94105 lb-ft)
T100216
11. Tighten cap screws to specification in even steps.
ABearing Cup Key

BYoke Pilot
12. Tighten lubrication fittings (7) and air relief valve to

specification.
Lubrication FittingTorque ............................ 516 Nm (48144 lb-in.)
Air Relief ValveTorque ................................ 516 Nm (48144 lb-in.)
13. See Grease Front Axle Drive Shaft U-Joints and

Transmission Output Shaft Seal for procedure to
lubricate U-joints. (Operators Manual.)
OUT3035,00002F1 1924SEP024/4
TM2111 (30MAY03)
02-0225-7

053003
PN=73
02
0225
8
TM2111 (30MAY03)
02-0225-8

053003
PN=74
Group 0260
Hydraulic System
Differential Lock Solenoid Valve Repair
UN08DEC97
1. Remove plate below left side of cab. See Power Train

Component LocationDirect Drive Machines or See
Power Train Component LocationTorque Converter
Machines for location of differential lock solenoid valve.
(Group 9020-15.)
T112425
2. Disconnect wiring connector.

3. Remove nut to remove cover and solenoid coil from
the differential lock solenoid valve (A) on the left end of
park brake and differential lock solenoid valve
manifold. Remove the valve.
ADifferential Lock Solenoid Valve
TM2111 (30MAY03)
02-0260-1
OUT3035,00002F2 1924SEP021/2

053003
PN=75
02
0260
1
Hydraulic System
T7508AE
UN09JUL91
02
0260
2
ANut
BWasher
CCover
DSolenoid
EPlate
FValve (Spool)
GO-Ring
HBackup Ring
IO-Ring
JBackup Ring
KBackup Ring
LO-Ring
MBackup Ring
4. Repair or replace parts as needed.
7. Tighten nut (A).
NOTE: The park brake solenoid valve and differential

lock solenoid valve are the same part number.
Differential Lock Solenoid ValveSpecification

Cover and Solenoid
Coil-to-Valve NutTorque........................ 6.58 Nm (5871 lb-in.)
5. Install new O-rings and backup rings (GM).
8. Connect wiring connector.
6. Tighten valve (F) to specification.
9. Install plate and cap screws.
Differential Lock Solenoid ValveSpecification

Solenoid Valve-to-Park Brake
and Differential Lock Solenoid
Valve ManifoldTorque ............................ 4754 Nm (3540 lb-ft)
IMPORTANT: Overtightening the solenoid valve

cover nut could damage the solenoid
coil. Tighten the nut to specification.
OUT3035,00002F2 1924SEP022/2
TM2111 (30MAY03)
02-0260-2

053003
PN=76
Hydraulic System
Differential Lock Relief Valve Remove and

Install
1. Remove plate below left side of cab.
UN23MAR01
2. Remove differential lock relief valve (1) from the front

side of park brake and differential lock solenoid valve
manifold. See Power Train Component Location
Direct Drive Machines. (Group 9020-05.) Location is
the same for torque converter machines.
T140288B
1Differential Lock Relief Valve (Pressure Sequence

Valve)
TM2111 (30MAY03)
02-0260-3
OUT3035,00002F3 1925SEP021/2

053003
PN=77
02
0260
3
UN05APR01
Hydraulic System
T140455
02
0260
4
1Spring
2Valve Body
3Spring Guide
4Ball
5O-Ring
6Spool Housing
7Backup Ring
8O-Ring
IMPORTANT: Differential lock relief valve, except

O-rings and backup rings, is
serviced as an complete assembly.
There is no adjustment procedure.
9Backup Ring
10O-Ring
5. Perform Differential Lock Pressure Test to verify

pressure setting. (Group 9020-25.)
6. Install plate.
3. Replace O-rings (5, 8, and 10) and backup rings (7

and 9)
4. Install relief valve. Tighten to specification.
Differential Lock Relief ValveSpecification
Relief Valve-to-Park Brake and
Differential Lock Solenoid Valve
ManifoldTorque ................................ 24.229.7 Nm (1822 lb-ft)
OUT3035,00002F3 1925SEP022/2
TM2111 (30MAY03)
02-0260-4

053003
PN=78
Hydraulic System
Differential Lock PumpCable Skidder

Remove and Install
1. See Hydraulic Cab Tilt Procedure. (Operators Manual.)
2. Disconnect lines (2 and 4). Close openings using caps
and plugs.
3. Remove fittings (5 and 6).
02
0260
5
4. Remove cap screws (1) to remove differential lock

pump (3).
UN14JUN00
5. See Replace Differential Lock Return Filter and See

Replace Differential Lock Inlet Filter to check for debris
and replace as needed. (Operators Manual.)
7. Align splines on pump shaft and drive gear and install

pump.
T131254B
6. Install new O-ring on pump.

1Cap Screw (2 used)
2Outlet Port-to-Park Brake and Differential Lock
Solenoid Valve Manifold Line
3Differential Lock Pump
4Front Axle-to-Inlet Port Line
5Fitting
6Fitting
8. Install cap screws.

9. Install fittings.
10. Connect lines.
11. Lower the cab.
OUT3035,00002F4 1925SEP021/1
TM2111 (30MAY03)
02-0260-5

053003
PN=79
Hydraulic System
Differential Lock PumpGrapple Skidder

Remove and Install
Direct drive machine (differential lock pump mounted on
transmission) shown throughout. Procedures for the
torque converter machine (differential lock pump mounted
on converter) are the same except where noted.
UN26MAY00
2. See Hydraulic Pump Remove and InstallDirect Drive

Machines or Hydraulic Pump Remove and Install
Torque Converter Machines. (Group 2160.)
3. Disconnect lines (2 and 5). Close openings using caps
and plugs.
4. Remove fittings (3 and 6).
T131256B
02
0260
6
5. Remove socket head cap screws (1) to remove

differential lock pump (4).
6. See Replace Differential Return Filter and See Replace

Differential Lock Inlet Filter to check for debris and
replace as needed. (Operators Manual.)
7. Install new O-ring on pump.
1Cap Screw (2 used)

2Outlet Port-to-Park Brake and Differential Lock
Solenoid Valve Manifold Line
3Fitting
5Front Axle-to-Inlet Port Line
6Fitting
8. Align splines on pump shaft and drive gear and install

pump.
9. Install cap screws.
10. Install fittings.
11. Connect line.
12. Install hydraulic oil cooler pump.
13. Lower cab.
OUT3035,00002F5 1925SEP021/1
TM2111 (30MAY03)
02-0260-6

053003
PN=80
Hydraulic System
Differential Lock and Axle Hose Routing
T120236
UN02MAR99
02
0260
7
Direct Drive Cable Skidder

AFront Axle-to-Service
Brake Valve Line
BPark Brake
Return-to-Transmission
Line
CTransmission-to-Park
Brake Inlet Line
DDifferential Lock Inlet Line
and Filter
EPark Brake and Differential
Lock Solenoid Valve
Manifold
FPark Brake Solenoid

Valve-to-Park Brake Line
GDifferential Lock Filter
HRear Axle
IRear Axle-to-Service Brake

Valve Line
JDifferential Lock Pump
KFront Axle
See Power Train Component LocationDirect Drive

Machines for additional hose routing. (Group 9020-15.)
TM2111 (30MAY03)
02-0260-7
OUT3035,0000338 1905DEC021/2

053003
PN=81
Hydraulic System
J
M
D
E
02
0260
8
A
F
UN05APR01
T140526
T140526
Torque Converter Grapple Skidder Shown

AFront Axle-to-Service
Brake Valve Line
BPark Brake
Return-to-Transmission
Line
CTransmission-to-Park
Brake Inlet Line
DDifferential Lock Inlet Line

and Filter
EPark Brake and Differential
Lock Solenoid Valve
Manifold
FPark Brake Solenoid

Valve-to-Park Brake Line
GDifferential Lock Filter
HRear Axle
IRear Axle-to-Service Brake
Valve Line
JDifferential Lock Pump

KFront Axle
LDifferential Vent
MTorque Converter
See Power Train Component LocationTorque

Converter Machines for additional hose routing. (Group
9020-15.)
OUT3035,0000338 1905DEC022/2
TM2111 (30MAY03)
02-0260-8

053003
PN=82
Section 03
Transmission
Contents
Page
Page

Transmission Remove. . . . . . . . . . . . . . . . . .03-0300-1
Transmission Install. . . . . . . . . . . . . . . . . . .03-0300-11
First and Third Speed Clutch Packs

(Fourth Stage) Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-70
Second and Fourth Speed Clutch Packs
(Fifth Stage) Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-71
Transmission Clutch Packs
DisassembleDirect Drive Machines . . .03-0350-72
Transmission Clutch Packs AssembleDirect
Drive Machines . . . . . . . . . . . . . . . . . . . .03-0350-79
Seventh Stage (Output) ShaftDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-88
Rear Transmission Housing RepairDirect
Drive Machines . . . . . . . . . . . . . . . . . . . .03-0350-90
Front and Rear Housing AssembleDirect
Drive Machines . . . . . . . . . . . . . . . . . . . .03-0350-91
Transmission Clutch Packs and Gear
Stages RepairTorque Converter
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-94
Input Shaft (First Stage) and Sixth Stage
(Idler Gear) RepairTorque Converter
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-98
Clutch Pack RepairTorque Converter
Machines . . . . . . . . . . . . . . . . . . . . . . . . 03-0350-100
Seventh Stage (Output Gear)
RepairTorque Converter Machines . . . 03-0350-125
Rear Transmission Housing RepairTorque
Converter Machines. . . . . . . . . . . . . . . . 03-0350-127
Front and Rear Housing AssembleTorque
Converter Machines. . . . . . . . . . . . . . . . 03-0350-129
Group 0315Controls
Park Brake and Gear Shift Lever Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .03-0315-1
Engine-to-Transmission Drive Shaft Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .03-0325-1
Group 0350Gears, Shafts and Power Shift
Clutches
Transmission Repair Procedures. . . . . . . . . .03-0350-1
Transmission Lifting and Mounting on
Repair Stand . . . . . . . . . . . . . . . . . . . . . . .03-0350-2
Winch Drive Repair . . . . . . . . . . . . . . . . . . . .03-0350-5
Park Brake Repair. . . . . . . . . . . . . . . . . . . .03-0350-11
Charge Pump Repair . . . . . . . . . . . . . . . . .03-0350-21
Transmission Suction Tube Repair . . . . . . .03-0350-29
Transmission Cover Plates to Front
Housing Remove and InstallTorque Converter
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-30
Transmission Idler Shaft Remove and
InstallTorque Converter Machines . . . .03-0350-32
Transmission Control Valve Repair . . . . . . .03-0350-34
Input Yoke Remove and Install . . . . . . . . . .03-0350-45
Front Housing Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-48
Front Housing Exploded ViewTorque
Converter Machines. . . . . . . . . . . . . . . . .03-0350-52
Front Housing RepairAll Machines . . . . . .03-0350-55
Transmission Clutch Packs and Gear
Stages Remove and InstallDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-60
Input (First Stage) and Idler (Sixth Stage)
Gear Shaft RepairDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-66
High and Low Forward (Second Stage)
Clutch Packs Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-68
High and Low Reverse (Third Stage)
Clutch Pack Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-69
TM2111 (30MAY03)

Transmission Charge Pump Remove and
InstallDirect Drive Machines . . . . . . . . . .03-0360-1
InstallTorque Converter Machines . . . . .03-0360-6
Thermal Bypass Valve RepairTorque
Converter Machines. . . . . . . . . . . . . . . . . .03-0360-8
03-1

053003
PN=1
03
Contents
03
TM2111 (30MAY03)
03-2

053003
PN=2
Group 0300

Transmission Remove
UN13APR98
2. Operate all hydraulic controls to relieve pressure in the

hydraulic system.
T113498B
3. Drain transmission. The approximate capacity of

transmission is 29.3 L (7.75 gal).
4. Raise cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
5. Remove right and left side access covers (A).
6. For direct drive machines, perform the following:
03
0300
1
a. Remove main hydraulic pump. See Hydraulic Pump

Remove and InstallDirect Drive Machines or
Hydraulic Pump Remove and InstallTorque
Converter Machines. (Group 2160.)
b. Remove two cap screws and washers (B) and move
differential lock pump aside.
UN19JUL00
c. Remove spline coupler (C).
T132624B
ASide Access Cover

BCap Screw and Washer (2 used)
CSpline Coupler
T113855D
UN13MAY98
Direct Drive (Grapple) Machines Shown
Spline CouplerDirect Drive Machine

TM2111 (30MAY03)
03-0300-1
CED,OUO1032,3087 1919DEC021/13

053003
PN=85

7. Disconnect hydraulic hoses (A and B) from differential
lock filter housing. Close all openings with caps and
plugs.
8. Remove cap screws (D). Move bracket and filter
assembly (C) aside.
9. Disconnect vent hose (E).
UN11APR01
AFilter Inlet Hose

BFilter Outlet Hose
CBracket and Filter Assembly
DCap Screws
EVent Hose
T113499C
03
0300
2
T140921B
UN11APR01
Differential Lock FilterDirect Drive Machine
Differential Lock FilterTorque Converter Machine
TM2111 (30MAY03)
03-0300-2
CED,OUO1032,3087 1919DEC022/13

053003
PN=86

10. Remove cap screws (B) to disconnect winch drive
shaft (A) (if equipped) from transmission.
11. Remove cap screws (C) to disconnect rear axle drive
shaft (D) from transmission.
T113503B
UN10APR98
AWinch Drive Shaft

BCap Screw (4 used)
CCap Screw (4 used)
DRear Axle Drive Shaft
Winch and Rear Axle Drive ShaftsDirect Drive Machine Shown
TM2111 (30MAY03)
03-0300-3
CED,OUO1032,3087 1919DEC023/13

053003
PN=87
03
0300
3

12. Remove cap screw (1) and yoke (2).
13. Disconnect hydraulic hoses (CE).
T163138B
UN08JAN03
1Cap Screw
2Winch Output Shaft Yoke
CReturn Hose
DReturn Hose from Winch
EPark Brake Valve Hose
T113505B
UN13MAY98
03
0300
4
TM2111 (30MAY03)
03-0300-4
CED,OUO1032,3087 1919DEC024/13

053003
PN=88

a. Disconnect hydraulic hose (B).
b. Remove cap screws (A and C) to remove
engine-to-transmission drive shaft.
15. For torque converter machines, remove cap screws
(A) at both ends of torque converter-to-transmission
drive shaft. Remove drive shaft.
T113506B
UN13APR98
ACap Screw (4 usedDirect Drive) (8 usedTorque

Converter)
BCharge Pump-to-Filter Hose
T113507B
UN13APR98
Drive ShaftDirect Drive Machine Shown
Drive Shaft-to-Engine Cap ScrewsDirect Drive Machine
TM2111 (30MAY03)
03-0300-5
CED,OUO1032,3087 1919DEC025/13

053003
PN=89
03
0300
5

16. Disconnect hydraulic hoses (AE).
17. Remove cap screws (F) to disconnect drive shaft (G)
from transmission.
UN13APR98
AWinch Control Hose

BHose to Oil CoolerDirect Drive Machine
BHose to Torque ConverterTorque Converter
Machine
COutlet Hose from Filter
DPark Brake Valve Hose
EReturn Hose from Oil Cooler
FCap Screw (4 used)
GFront Axle Drive Shaft
T113509B
UN13APR98
T113508B
03
0300
6
TM2111 (30MAY03)
03-0300-6
CED,OUO1032,3087 1919DEC026/13

053003
PN=90

18. Remove cap screws and washers (A).
T119935F
UN05APR01
ALower Transmission Mount Cap Screw and

Washers (2 of each used)
CED,OUO1032,3087 1919DEC027/13

a. Disconnect wiring harness connectors (BG).
b. Remove upper transmission mount cap screws,
nuts, and washers (H). Remove upper half of
isolator (I).
c. Remove dipstick (A).
T113511F
UN05APR01
ADipstick
BInput Speed Pickup Sensor Connector
CPark Brake Pressure On Switch Connector
DPark Brake Release Solenoid Connector
EDifferential Lock Solenoid Connector
FReverse Alarm and Fuel Sender Harness
Connector
GTransmission Harness Connector
HUpper Transmission Mount Cap Screws, Nuts, and
Washers
IIsolator (upper half)
Transmission Mounts and Wire ConnectorsDirect Drive

Machine
TM2111 (30MAY03)
03-0300-7
CED,OUO1032,3087 1919DEC028/13

053003
PN=91
03
0300
7
T140922B
UN09APR01
03
0300
8
Transmission Mounts and Wire ConnectorsTorque Converter Machine
20. For torque converter machines, perform the following:

a. Disconnect wire connectors (AD and K).
b. Remove mounting cap screws from clamps (E and
I).
T140924B
UN05APR01
AReverse Alarm and Fuel Sender Harness

Connector
BPark Brake Release Solenoid Connector
DDifferential Lock Solenoid Connector
EClamp
FDipstick
GUpper Transmission Mount Cap Screws, Nuts,
and Washers
HIsolator (upper half)
IClamp
JVent Hose
KTransmission Harness Connector
LBracket
MTransmission Charge Pump Inlet Hose
NBracket
TM2111 (30MAY03)
03-0300-8
CED,OUO1032,3087 1919DEC029/13

053003
PN=92

c. Remove mounting cap screws from brackets (L
and N).
d. Disconnect hoses (J and M).
e. Remove upper transmission mount nuts, washers,
and cap screws (G). Remove upper half of isolator
(H).
f. Remove dipstick (F).
CED,OUO1032,3087 1919DEC0210/13
21. At upper left transmission mount, remove cap screw

at location shown and install JT01748 Lifting Bracket
(A) using a cap screw 12.7 mm (1/2 in.) longer than
cap screw removed.
UN13APR98
03
0300
9
T113512B
AJT01748 Lifting Bracket
CED,OUO1032,3087 1919DEC0211/13

TransmissionSpecification
TransmissionWeight................................. 590 kg (1300 lb) approximate
22. Attach D01043AA Load Positioning Sling (B) to

overhead hoist.
23. Attach one hook from load positioning sling to lifting
bracket (A).
24. Attach other hook through rear slot in upper right
transmission mount (C).
25. Adjust load positioning sling to lift right side of
transmission first. Carefully raise transmission and
remove from machine.
T113514C
UN23MAR99
AJT01748 Lifting Bracket

BD01043AA Load Positioning Sling
CUpper Right Transmission Mount
TM2111 (30MAY03)
03-0300-9
CED,OUO1032,3087 1919DEC0212/13

053003
PN=93

26. Remove front and rear output shaft yokes. If removal
of input shaft yoke is necessary at this time, see Input
Yoke Remove and Install.. (Group 0350.)
27. Remove lower half of upper transmission isolators
(C).
28. Remove upper transmission mount supports (G).
29. Remove dipstick tube (D) and oil fill hose (E).
30. Remove wire harness (F).
T114058D
32. Remove three cap screws (A) to remove lower

transmission mount block (B).
33. Mount transmission in repair stand. See Transmission
Lifting and Mounting on Repair Stand. (Group 0350.)
TransmissionDirect Drive Shown
UN05APR01
T119924D
UN13APR99
ACap Screw (3 used)

BLower Transmission Mount Block
CUpper Transmission Isolators (lower half)
DDipstick Tube
EOil Fill Hose
FTransmission Wire Harness
GUpper Transmission Mount Supports (2 used)
HLower Transmission Mount Cap Screw
IWasher
JLarge Washer (2 used)
KIsolator (rear half)
LLower Transmission Mount Plate
MIsolator (front half)
T140870
03
0300
10
UN20JUL00
31. Remove lower transmission mount hardware (HJ).
CED,OUO1032,3087 1919DEC0213/13
TM2111 (30MAY03)
03-0300-10

053003
PN=94
Transmission Install
1. Install wire harness (F).
2. Install oil fill hose (E) and dipstick tube (D).
3. Install upper transmission mount supports (G). Tighten
cap screws to specification.
Upper Transmission Mount
Support-to-Transmission Housing
UN20JUL00
4. Install lower half of upper transmission isolators (C).
T114058D
5. Install lower transmission mount block (B). Tighten cap

screws (A) to specification.
Lower Transmission Mount
Block-to-Transmission Housing
Cap ScrewTorque ................................. 230312 Nm (170230 lb-ft)
TransmissionDirect Drive Shown
6. Install lower transmission mount hardware (HM). Do

not tighten cap screw (H) at this time.
UN13APR99
7. Install front axle and rear axle output shaft yokes. Do

not install winch shaft yoke (if equipped) at this time.
T119924D
8. Install rear axle output shaft yoke castellated nut and

tighten to specification. If cotter pin hole does not align
with slot in castellated nut, continue turning nut until
hole aligns with slot. Install new cotter pin.
Rear Axle Output Shaft Yoke
Castellated NutTorque ............................................... 115 Nm (85 lb-ft)
T140870
UN05APR01
ACap Screw (3 used)

BLower Transmission Mount Block
CUpper Transmission Isolators (lower half)
DDipstick Tube
EOil Fill Hose
FTransmission Wire Harness
GUpper Transmission Mount Supports (2 used)
HLower Transmission Mount Cap Screw
IWasher
JLarge Washer (2 used)
KIsolator (rear half)
LLower Transmission Mount Plate
MIsolator (front half)
TM2111 (30MAY03)
03-0300-11
CED,OUO1032,3088 1919DEC021/11

053003
PN=95
03
0300
11
T140871
03
0300
12
T113515D
UN05APR01
UN05APR01

UN05APR01
9. At upper left transmission mount, remove rear cap

screw (if installed) and install JT01748 Lifting Bracket
(I) using a cap screw 12.7 mm (1/2 in.) longer than the
cap screw removed.
T119935G
10. Attach one hook of D01043AA Load Positioning Sling

to lifting bracket (I) and the other hook through rear
slot in upper right transmission support (G).
11. Carefully lower transmission into machine frame until
holes in lower transmission mount plate (J) align with
holes in machine frame. Make sure washer (C) and
lower half of isolator (E) are in position between
supports (G and H) and machine frame.
AUpper Transmission Mount Cap Screw (2

used)
BWasher (2 used)
CLarge Washer (4 used)
DIsolator (upper half)
EIsolator (lower half)
FNut (2 used)
GUpper Right Transmission Support
HUpper Left Transmission Support
IJT01748 Lifting Bracket
JLower Transmission Mount Plate
KLower Transmission Mount Plate-to-Frame
Cap Screw and Washer (2 of each used)
LLower Transmission Mount Cap Screw
12. Fasten mount plate (J) to machine frame with cap

screws and washers (K). Tighten to specification.
Lower Transmission Mount
Plate-to-Frame Cap Screw
Torque ...................................................... 230312 Nm (170230 lb-ft)
TM2111 (30MAY03)
03-0300-12
CED,OUO1032,3088 1919DEC022/11

053003
PN=96

13. Tighten cap screw (L) to specification.
Lower Transmission Mount Cap
ScrewTorque ......................................... 607743 Nm (450550 lb-ft)
14. Install upper transmission mount hardware (AD and

F). Tighten cap screw (A) and nut (F) to specification.
Upper Transmission Mount Cap
Screw and NutTorque ........................... 607743 Nm (450550 lb-ft)
03
0300
13
CED,OUO1032,3088 1919DEC023/11

a. Connect wire connectors (BG).
b. Install dipstick (A).
T113511G
UN05APR01
ADipstick
BInput Speed Pickup Sensor Connector
DPark Brake Release Solenoid Connector
EDifferential Lock Solenoid Connector
FReverse Alarm and Fuel Sender Harness
Connector
GTransmission Harness Connector
Transmission Mounts and Wire ConnectorsDirect Drive

Machine
TM2111 (30MAY03)
03-0300-13
CED,OUO1032,3088 1919DEC024/11

053003
PN=97
T140922C
UN09APR01
03
0300
14
Transmission Mounts and Wire ConnectorsTorque Converter Machine
16. For torque converter machines, perform the following:

a. Connect hoses (H and K).
b. Install brackets (J and L).
c. Connect wire connectors (AD and I).
UN05APR01
d. Install clamps (E and G).

e. Install dipstick (F).
T140924B
AReverse Alarm and Fuel Sender Harness

Connector
BPark Brake Release Solenoid Connector
DDifferential Lock Solenoid Connector
EClamp
FDipstick
GClamp
HVent Hose
ITransmission Harness Connector
JBracket
KTransmission Charge Pump Inlet Hose
LBracket
TM2111 (30MAY03)
03-0300-14
CED,OUO1032,3088 1919DEC025/11

053003
PN=98

17. Install front axle drive shaft (G) and cap screws (F).
Tighten cap screws (F) to specification.
Transmission-to-Front Axle Drive
Shaft universal joint Cap Screw
(3/8 in.)Torque ............................................................. 58 Nm (43 lb-ft)
Transmission-to-Front Axle Drive
(1/2 in.)Torque ........................................................... 109 Nm (81 lb-ft)
18. Connect hydraulic hoses (AE).
T113508B
UN13APR98
T113509B
UN13APR98
AWinch Control Hose

BHose to Oil CoolerDirect Drive Machines
BHose to Torque ConverterTorque Converter
Machines
COutlet Hose from Filter
DPark Brake Valve Hose
EReturn Hose from Oil Cooler
FCap Screw (4 used)
GFront Axle Drive Shaft
TM2111 (30MAY03)
03-0300-15
CED,OUO1032,3088 1919DEC026/11

053003
PN=99
03
0300
15

a. Install engine-to-transmission drive shaft with cap
screws (A and C).
T113507B
UN13APR98
b. To prevent engine flywheel from turning when

tightening drive shaft cap screws, insert timing pin
(D) through flywheel housing as shown and into
timing pin hole in flywheel.
c. Tighten drive shaft cap screws to specification.
UN13APR98
Drive Shaft-to-Damper Cap ScrewsDirect Drive Machines
d. Connect hydraulic hose (B).
T113516B
20. For torque converter machines, fasten both ends of

drive shaft with cap screws (A). Tighten cap screws to
specification.
Torque
Converter-to-Transmission Drive
Shaft Mounting Cap Screw
Torque ............................................................................. 58 Nm (43 lb-ft)
UN13APR98
Auniversal joint Cap Screw (4 usedDirect Drive)

(8 usedTorque Converter)
BCharge Pump-to-Filter Hose (Direct Drive
Machines)
CDrive Shaft-to-Damper Cap Screw (Direct Drive
Machines) (12 used)
DTiming Pin
T113506B
03
0300
16
Drive Shaft-to-Engine Damper
Engine-to-Transmission Drive
Torque ............................................................................. 58 Nm (43 lb-ft)
Drive Shaft and Hydraulic LineDirect Drive Machines

TM2111 (30MAY03)
03-0300-16
CED,OUO1032,3088 1919DEC027/11

053003
PN=100

21. Connect hydraulic hoses (CE).
22. Apply thread lock and sealer (medium strength) to
cap screw (1).
23. Install yoke (2) with cap screw (1). Tighten cap screw
to specification.
Winch Output Shaft Yoke Cap
ScrewTorque ............................................................ 215 Nm (159 lb-ft)
1Cap Screw
2Winch Output Shaft Yoke
CReturn Hose
DReturn Hose from Winch
EPark Brake Valve Hose
T163138B
UN08JAN03
T113505B
UN13MAY98
03
0300
17
TM2111 (30MAY03)
03-0300-17
CED,OUO1032,3088 1919DEC028/11

053003
PN=101

24. Connect rear axle drive shaft (D) to transmission with
four cap screws (C). Tighten cap screws to
specification.
Transmission-to-Rear Axle Drive
(1/2 in.)Torque ........................................................... 109 Nm (81 lb-ft)
25. Connect winch drive shaft (A) (if equipped) to

transmission with four cap screws (B). Tighten cap
AWinch Drive Shaft

BCap Screw (4 used)
CCap Screw (4 used)
DRear Axle Drive Shaft
T113503B
03
0300
18
UN10APR98
Transmission-to-Winch Drive
(3/8 in.)Torque ............................................................. 58 Nm (43 lb-ft)
TM2111 (30MAY03)
03-0300-18
CED,OUO1032,3088 1919DEC029/11

053003
PN=102

26. Connect vent hose (E).
27. Move bracket and filter assembly (C) into position and
install cap screws (D).
28. Install hydraulic hoses (A and B).
T113499C
UN11APR01
AFilter Inlet Hose

BFilter Outlet Hose
CBracket and Filter Assembly
DCap Screw (2 used)
EVent Hose
T140921B
UN11APR01
Differential Lock FilterDirect Drive Machines
Differential Lock FilterTorque Converter Machines
TM2111 (30MAY03)
03-0300-19
CED,OUO1032,3088 1919DEC0210/11

053003
PN=103
03
0300
19

a. Install spline coupler (C).
UN13MAY98
b. Install differential lock pump and fasten with cap

screws (B).
T113855D
c. Install main hydraulic pump. See Hydraulic Pump

Disassemble and Assemble. (Group 2160.)
30. Install right and left side access covers (A).
31. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
32. Fill transmission with oil. See Transmission, Hydraulic
System, Park Brake, Differential, Cab Hydraulic Pump
and Winch Oil. (Operators Manual.)
33. Check transmission oil level. See Check Transmission
Oil Level. (Operators Manual.)
34. Calibrate transmission control unit. See Calibration of
Transmission Control Unit (TCU). (Group 9015-20.)
T132624B
UN19JUL00
ASide Access Cover

BCap Screw (2 used)
CSpline Coupler
UN13APR98
Direct Drive (Grapple) Machines Shown
T113498B
03
0300
20
Spline CouplerDirect Drive Machines
CED,OUO1032,3088 1919DEC0211/11
TM2111 (30MAY03)
03-0300-20

053003
PN=104
Group 0315
Controls
Park Brake and Gear Shift Lever Remove and
Install
NOTE: Illustrations shown are direct drive machines.
Torque converter machines are similar.
1. Remove blade control lever knob (1).
UN15JUN00
2. Remove screws (2).
T131669B
1Blade Control Lever Knob

2Screw (4 used)
03
0315
1
CED,OUO1032,3393 1901NOV021/14
3. Remove screws (1).

4. Remove housing cover (2).
T131670B
UN15JUN00
1Screw (4 used)
2Housing Cover
Direct Drive Housing Cover
CED,OUO1032,3393 1901NOV022/14
5. Disconnect wire connector (1) from Transmission

Controller Unit (TCU).
T131671B
UN15JUN00
1Wire Connector
TM2111 (30MAY03)
03-0315-1
CED,OUO1032,3393 1901NOV023/14

053003
PN=105
Controls
6. Remove cap screws (1) and remove housing cover (2).
T131672C
UN11APR01
1Cap Screw (6 used)

2Housing Cover
03
0315
2
CED,OUO1032,3393 1901NOV024/14
7. Loosen cap screws (1), but do not remove.
T131673B
UN15JUN00
1Cap Screw (2 used)
TM2111 (30MAY03)
03-0315-2
CED,OUO1032,3393 1901NOV025/14

053003
PN=106
Controls
8. Pull park brake and gear shift lever (1) up and toward
seat.
T131674B
UN15JUN00
1Park Brake and Gear Shift Lever
Direct Drive Park Brake and Gear Shift Lever
CED,OUO1032,3393 1901NOV026/14
9. Disconnect wire connectors (1) and remove park brake

and gear shift assembly.
T131675B
UN15JUN00
1Wire Connector (3 used)
CED,OUO1032,3393 1901NOV027/14
10. Connect wire connectors (1).
T131675B
UN15JUN00
TM2111 (30MAY03)
03-0315-3
CED,OUO1032,3393 1901NOV028/14

053003
PN=107
03
0315
3
Controls
11. Insert head of cap screw through large hole and slide
park brake and gear shift lever (1) into position.
UN15JUN00
1Park Brake and Gear Shift Lever
T131674B
03
0315
4
Direct Drive Park Brake and Gear Shift Lever
CED,OUO1032,3393 1901NOV029/14
12. Tighten cap screws (1).
T131673B
UN15JUN00
1Cap Screw (2 used)
TM2111 (30MAY03)
03-0315-4
CED,OUO1032,3393 1901NOV0210/14

053003
PN=108
Controls
13. Install housing cover (2) with cap screws (1).
T131672C
UN11APR01
1Cap Screw (6 used)

2Housing Cover
03
0315
5
CED,OUO1032,3393 1901NOV0211/14
14. Connect wire connector (1) to Transmission Controller

Unit (TCU).
T131671B
UN15JUN00
1Wire Connector
CED,OUO1032,3393 1901NOV0212/14
15. Install housing cover (2).

16. Install screws (1).
T131670B
UN15JUN00
1Screw (4 used)
2Housing Cover
Direct Drive Housing Cover
TM2111 (30MAY03)
03-0315-5
CED,OUO1032,3393 1901NOV0213/14

053003
PN=109
Controls
17. Install screws (2).
18. Install blade control lever knob (1).
T131669B
UN15JUN00
1Blade Control Lever Knob

2Screw (4 used)
03
0315
6
CED,OUO1032,3393 1901NOV0214/14
TM2111 (30MAY03)
03-0315-6

053003
PN=110
Group 0325

Engine-to-Transmission Drive Shaft Remove and Install
T7501BH
UN16MAY95
03
0325
1
1Universal Joint Cap Screw

3/8 in. (4 used)
2Universal Joint Cross
3Cap
4Drive Shaft
5Washer (12 used)

6Cap Screw 1/2 in. (12 used)
NOTE: Illustrations show drive shaft for direct drive

machines. For torque converter machines, a
universal joint is used at both ends of drive
shaft.
1. Remove and inspect drive shaft. Repair as
required.
7Universal Joint Cap Screw

3/8 in. (4 used)
Engine-to-Transmission Drive ShaftSpecification

Drive Shaft-to-Damper Cap
ScrewTorque ..................................................... 150 Nm (110 lb-ft)
Universal Joint Cap Screws 3/8
in.Torque ............................................................... 58 Nm (43 lb-ft)
Universal Joint Cap Screws 1/2
in.Torque ............................................................. 109 Nm (81 lb-ft)
2. Install drive shaft and tighten cap screws to

specifications.
TX,0325,WW945 1920NOV021/1
TM2111 (30MAY03)
03-0325-1

053003
PN=111
03
0325
2
TM2111 (30MAY03)
03-0325-2

053003
PN=112
Group 0350
Gears, Shafts and Power Shift Clutches

Transmission Repair Procedures
Disassembly:
Inspect control valve bores for contamination.

Inspect clutch and brake plates for facing material
condition wear to teeth and flatness of the plate.
Inspect clutch and brake separator plates for
discoloration, teeth wear, scoring and flatness.
Inspect all thrust surfaces for scoring.
Inspect all gear and spline teeth.
Inspect all gasket and sealing surfaces for damage.
Clean all parts and flush any debris from oil

passages.
Use moisture-free air to dry parts (except bearings)
and to clean out oil passages.
IMPORTANT: If the transmission has had a major

failure, replace all bearings, springs,
oil seals, O-rings, ring seals, and
gaskets.
Before beginning repair:

Drain transmission oil.
Thoroughly clean the outside of the transmission
before disassembly to reduce the possibility of
contamination.
IMPORTANT: DO NOT use solvent to clean the

clutch and brake disks; use a
lint-free cloth.
03
0350
1
Assembly:
Lightly oil all bearings after cleaning.

IMPORTANT: Spinning a bearing without
lubrication can damage the bearing.
Inspect bearings for discoloration, roughness of
rotation, and excessive wear of rollers or balls.
Inspect bushings, remove burrs and sharp edges.
Replace bushings if out-of-round, scored or
excessively worn.
Lightly oil all bearings.

Use new O-rings, seal rings, oil seals and gaskets.
Lubricate oil seals and O-rings.
Wet clutch and brake plates with clean hydraulic oil
before assembly.
Clean and prepare all gasket and sealing surfaces.
TX,03,RB546 1920FEB981/1
TM2111 (30MAY03)
03-0350-1

053003
PN=113
Transmission Lifting and Mounting on Repair

Stand
UN23AUG88
Lifting heavy components incorrectly can cause severe

injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.
TS226
Safety Precautions
03
0350
2
CAUTION: Do not allow any part of the body to

be under the transmission while it is being
lifted or after it is suspended on the repair
stand. Do not exceed maximum capacities for
the repair stand. Use only high grade fasteners
in good condition. Personal injury could result.
The transmission repair stand should be used only by
qualified service technicians familiar with this equipment.
Use class 10.9 (SAE Grade 8) or better cap screws to
attach mounting plates to transmission.
Make sure threaded holes in adapters and transmission
are clean and not damaged.
Minimum cap screw thread engagement should be equal
to 1-1/2 times the diameter of the screw.
Do not exceed the maximum capacity rating of the stand.
Be sure transmission is solidly mounted before releasing
from lifting device.
Never permit any part of the body to be positioned under
a load being lifted or suspended. Accidental slippage may
result in personal injury.
TM2111 (30MAY03)
03-0350-2
TX,03,RB555 1919DEC021/4

053003
PN=114

Transmission Lifting and Mounting on Repair StandSpecification
UN09DEC97
Install lifting device into rear housing.
YZ1032
IMPORTANT: When any other stand is used, consult

the manufacturers instructions for
mounting.
1. Use D01003AA Repair Stand or equivalent.
03
0350
3
TX,03,RB555 1919DEC022/4
YZ1035
UN13FEB01
2. Install right plate of JDG1111 Mounting Plates.
Right Plate of JDG1111 Shown

TM2111 (30MAY03)
03-0350-3
TX,03,RB555 1919DEC023/4

053003
PN=115

3. Install left plate of JDG1111 Mounting Plates and
JDG1100 Transmission Mounting Adapters.
YZ1036
UN17FEB98
03
0350
4
Left Plate of JDG1111 and JDG1100 Shown
TX,03,RB555 1919DEC024/4
TM2111 (30MAY03)
03-0350-4

053003
PN=116
Winch Drive Repair
T163170
UN16JAN03
03
0350
5
Winch Drive and Cap Screw Tightening SequenceDirect Drive Machines

AWinch Drive Cover
BCap Screw (11 used)
COil Seal
DV-Ring Seal
ECap Screw
FYoke Washer
GYoke
HDowel Pin
IDowel Pin
JBall Bearing
KOutput Shaft
LBall Bearing
MBall Bearing (2 used)
NGear
OGear
TM2111 (30MAY03)
03-0350-5
PSnap Ring
QWithout Winch Drive
RO-Ring
SCover
OUO1065,0000590 1920NOV021/12

053003
PN=117
T163742
UN21JAN03
03
0350
6
Winch Drive and Cap Screw Tightening SequenceTorque Converter Machines
TM2111 (30MAY03)
03-0350-6
OUO1065,0000590 1920NOV022/12

053003
PN=118

AWinch Drive Cover
COil Seal
DV-Ring Seal
EYoke
FYoke Washer
GCap Screw
HBall Bearing (2 used)
IBall Bearing
JOutput Shaft
KBall Bearing
LGear
MGear
NSnap Ring
ODowel Pin (2 used)
PSnap Ring
QWithout Winch Drive
RO-Ring
SCover
OUO1065,0000590 1920NOV023/12
1. Remove cap screw and washer (1).

2. Remove yoke (2).
UN08JAN03
3. Remove V-ring seal (3).

4. Remove seal (4).
T163169B
UN08JAN03
T163138B
1Cap Screw and Washer

2Yoke
3V-Ring Seal
4Seal
OUO1065,0000590 1920NOV024/12
5. Remove cap screws (A) from winch cover.
YZ1045
UN17FEB98
AWinch Cover Cap Screws
TM2111 (30MAY03)
03-0350-7
OUO1065,0000590 1920NOV025/12

053003
PN=119
03
0350
7

6. Remove winch cover.
7. Remove output shaft (A).
YZ1046A
UN17FEB98
AWinch Output Shaft
OUO1065,0000590 1920NOV026/12
8. Remove idler gear (B).
YZ1048
UN17FEB98
BIdler Gear
OUO1065,0000590 1920NOV027/12
9. Remove snap ring (C).

10. Remove drive gear (D).
UN09DEC97
11. Inspect gears and replace as need.

CSnap Ring
DDrive Gear
YZ1049
03
0350
8
TM2111 (30MAY03)
03-0350-8
OUO1065,0000590 1920NOV028/12

053003
PN=120

12. Install winch output shaft (A).
13. Install idler gear (B).
UN17FEB98
14. Install drive gear (C).

15. Install snap ring (D).
YZ1047
AWinch Output Shaft

BIdler Gear
CDrive Gear
DSnap Ring
03
0350
9
OUO1065,0000590 1920NOV029/12
16. Clean mating surfaces of housings with isopropyl

alcohol or equivalent.
UN17FEB98
IMPORTANT: Excessive amounts of gasket adhesive

may cause incorrect bearing end play,
extend cure time and cause runoff of
material. Using a small roller will help to
apply a thin, even layer of adhesive.
YZ1044D
17. Apply flexible sealant to rear housing mounting

surface, using care to apply a thin layer over the
entire surface. Excess gasket material should be
wiped from joint. Installation should occur within three
minutes of application. Allow a minimum of 30
minutes of cure time before adding oil.
18. Make sure two dowel pins are installed in rear
housing.
19. Install winch drive cover (A).
UN20MAR01
20. Install and tighten cap screws (B) in sequence shown.

Repeat sequence again to check cap screw torques.
YZ4114
Winch DriveSpecification
Winch Cover-to-Rear Housing
Torque ................................................................. 25 5 Nm (18 4 lb-ft)
AWinch Drive Cover

BCap Screw (11 Used)
TM2111 (30MAY03)
03-0350-9
OUO1065,0000590 1920NOV0210/12

053003
PN=121

21. Install new output oil seal (A) using JDG1110 Input
Shaft Seal Installation Tool (B) and JDG1108 Clutch
Bearing Driver (C).
YZ1043
UN18FEB98
AOutput Oil Seal

BJDG1110 Input Shaft Seal Installation Tool
CJDG1108 Clutch Bearing Driver
03
0350
10
OUO1065,0000590 1920NOV0211/12
22. Install seal (4).

23. Install V-ring seal (3).
Winch DriveSpecification
Yoke Cap ScrewTorque........................................... 215 Nm (159 lb-ft)
T163138B
UN08JAN03

2Yoke
3V-Ring Seal
4Seal
T163169B
25. Install and tighten cap screw and washer (1).
UN08JAN03
24. Install yoke (2).
OUO1065,0000590 1920NOV0212/12
TM2111 (30MAY03)
03-0350-10

053003
PN=122
Park Brake Repair

CAUTION: Cover and housing assembly is
spring loaded. Use care removing cap screws
to prevent personal injury.
UN16JAN03
IMPORTANT: Four cap screws are shorter and are

located at the recessed areas in the
housing. Remove only two cap screws
(1). These screws keep the park brake
cover and housing together.
T163607B
1. Remove yoke.
2. Remove two cap screws (1) and attach JT01748 Lifting
Brackets (2) with two 12 mm x 140 mm cap screws.
1Park Brake Cover Cap ScrewShort (4 Used)
2JT01748 Lifting Bracket (2 used)
3Park Brake Cap ScrewLong (10 Used)
3. Remove only park brake cap screws (3).
OUO1065,0000592 1921NOV021/18

Park BrakeSpecification
Park BrakeWeight .......................................... 43 kg (95 lb) approximate
T163608B
UN16JAN03
4. Lift park brake assembly from rear housing.
TM2111 (30MAY03)
03-0350-11
OUO1065,0000592 1921NOV022/18

053003
PN=123
03
0350
11

5. Remove snap ring (A).
6. Remove brake hub (B).
7. Remove and discard gasket (C).
YZ4189
UN10APR01
ASnap Ring
BBrake Hub
CGasket
03
0350
12
OUO1065,0000592 1921NOV023/18
8. Remove lifting brackets (2).
UN16JAN03
CAUTION: Park brake cover is spring loaded.

Loosen each cap screw only 23 turns at a
time. Alternate between cap screws several
times until spring force has been released.
T163609B
9. Remove remaining cap screws (1).

1Cap Screws
2JT01748 Lifting Brackets (2 used)
OUO1065,0000592 1921NOV024/18
10. Remove park brake cover (1).
T163610B
UN16JAN03
1Park Brake Cover

2Park Brake Housing
TM2111 (30MAY03)
03-0350-12
OUO1065,0000592 1921NOV025/18

053003
PN=124

11. Remove Belleville spring (A).
12. Remove brake piston (B).
YZ1062A
UN13MAR01
ABelleville Spring
BBrake Piston
OUO1065,0000592 1921NOV026/18
13. Remove and discard outer piston seal (C) and inner
piston seal (D) from piston (E).
03
0350
13
YZ1063A
UN13MAR01
COuter Piston Seal

DInner Piston Seal
EPiston
OUO1065,0000592 1921NOV027/18
14. Remove separator plates (A) and clutch disks (B).

15. Inspect for wear or damage.
16. Remove and discard O-ring (C).
YZ1064A
UN13MAR01
ASeparator Plates
BClutch Disks
CO-Ring
TM2111 (30MAY03)
03-0350-13
OUO1065,0000592 1921NOV028/18

053003
PN=125
1
2
4
5
6
7
9
10
03
0350
14
11
12
17
13
12
15
T162070
1Gasket
2Brake Hub
3Retaining Ring
4Park Brake Housing
5O-Ring
12
6Clutch Disks (8 used)
7Inner Piston Seal
8Piston
9Outer Piston Seal
10Belleville Spring
11Park Brake Cover
13
12
T162070
13
UN25NOV02
14
16
14Oil Seal
15Grease Seal (2 used)
16Grease Fitting
17Clutch Plates (9 used)
17. Remove and discard seals (14 and 15) from cover
(11).
TM2111 (30MAY03)
03-0350-14
OUO1065,0000592 1921NOV029/18

053003
PN=126

NOTE: Use guide pins during assembly to guide the
brake housing onto the rear housing.
18. Install gasket (A) on transmission housing.
19. Install brake hub (B) in center of rear housing with
small diameter of hub down.
20. Install snap ring (C).
YZ4197
UN10APR01
YZ4196
UN10APR01
AGasket
BBrake Hub
CSnap Ring
TM2111 (30MAY03)
03-0350-15
OUO1065,0000592 1921NOV0210/18

053003
PN=127
03
0350
15

21. Install park brake housing (A) on transmission
housing.
NOTE: Lubricate O-ring to prevent damage during

assembly.
22. Lubricate and install new O-ring (B) on brake housing.
YZ4198
UN10APR01
APark Brake Housing

BO-Ring
YZ4199
UN10APR01
03
0350
16
TM2111 (30MAY03)
03-0350-16
OUO1065,0000592 1921NOV0211/18

053003
PN=128

NOTE: Clutch plate (C) must be last.
23. Starting with clutch plate (A) install alternately clutch
plates and clutch disks (A and B) into brake housing.
Must end with clutch plate (C).
YZ4200
UN24AUG01
YZ4202
UN24AUG01
AClutch Plate (9 Used)

BClutch Disk (8 Used)
CClutch Plate (Last Plate Installed)
TM2111 (30MAY03)
03-0350-17
OUO1065,0000592 1921NOV0212/18

053003
PN=129
03
0350
17

24. Lubricate and install new inner piston seal (A) and
outer piston seal (B) on piston (C).
UN24AUG01
AInner Piston Seal

BOuter Piston Seal
CPiston
YZ4201
03
0350
18
OUO1065,0000592 1921NOV0213/18
25. Install Belleville spring (A) with inner diameter of

Belleville spring contacting piston.
YZ4203
UN24AUG01
ABelleville Spring
TM2111 (30MAY03)
03-0350-18
OUO1065,0000592 1921NOV0214/18

053003
PN=130
CAUTION: Carefully lower park housing cover

watching for pinch points.
UN16JAN03
26. Install park brake cover (1) on park brake housing (2).
T163610B
1Park Brake Cover

2Park Brake Housing
OUO1065,0000592 1921NOV0215/18
IMPORTANT: Install the two cap screws in recessed

holes in park brake cover.
03
0350
19
UN16JAN03
27. Install and alternately tighten two cap screws (1) to

compress Belleville spring.
28. Remove guide pins.
T163609B
29. Attach JT01748 Lifting Brackets.

30. Position park brake housing on transmission housing.
1Cap Screws
2JT01748 Lift Brackets
OUO1065,0000592 1921NOV0216/18
31. Install and tighten all cap screws to proper

specification.
UN14JAN03
Park Brake-to-Rear Housing Cap
ScrewTorque ................................................................ 87 Nm (64 lb-ft)
T163631B
32. Install JDG1519 Seal Protector.
TM2111 (30MAY03)
03-0350-19
OUO1065,0000592 1921NOV0217/18

053003
PN=131

outside diameter of seals.
34. Apply thin layer of petroleum jelly to inner seal lip.
37. Use JDG1738 driver to install third grease seal until

flush with shoulder in park brake cover with inner seal
lip up.
03
0350
20
T163632B
36. Using JDG1737 Seal Driver install second grease

seal to bottom of seal bore in park brake cover with
inner seal lip up.
UN14JAN03
35. Use JDG1736 Seal Driver (1) to install first oil seal
until flush with shoulder in park brake cover (11).
1JDG1738 Seal Driver

2Grease Seal
OUO1065,0000592 1921NOV0218/18
TM2111 (30MAY03)
03-0350-20

053003
PN=132
Charge Pump Repair
YZ1065
UN18FEB98
03
0350
21
AO-Ring
BBearing (2 used)
CDrive Gear
DTransmission Charge
Pump
ECap Screw (4 used)
FCap Screw
GO-Ring
HIdler Shaft
IBall Bearing (2 used)

JIdler Gear
KO-Ring
OUO1020,0001130 1922NOV021/17
1. Remove cap screws (A).

2. Loosen nut (B) to remove suction tube (C).
T115388
UN13MAY98
ACap Screws
BNut
CSuction Tube
TM2111 (30MAY03)
03-0350-21
OUO1020,0001130 1922NOV022/17

053003
PN=133

3. If necessary, remove suction screen (2).
4. Remove and discard O-ring (1).
T163634B
UN13JAN03
1O-Ring
2Suction Screen
OUO1020,0001130 1922NOV023/17
6. Remove cap screws (B).
YZ1067
UN17DEC97
IMPORTANT: Bearing (E) and drive gear (D) are

slip-fit at the base of the charge pump
and may remain in front housing. Use
care to remove charge pump so bearing
and gear are not dropped and damaged.
7. Remove charge pump (C) from front housing.
UN17DEC97
AFlat Face Fitting

BCap Screws
CCharge Pump
DDrive Gear
EBearing
YZ1068
03
0350
22
5. Remove flat face fitting (A) if necessary. Replace both

O-rings if fitting is removed.
TM2111 (30MAY03)
03-0350-22
OUO1020,0001130 1922NOV024/17

053003
PN=134

8. Remove drive gear (A).
ADrive Gear
YZ1090
UN17DEC97
03
0350
23
OUO1020,0001130 1922NOV025/17
9. Remove cap screw (A).
YZ1070
UN17DEC97
ACap Screw
OUO1020,0001130 1922NOV026/17
10. Install an M8 x 35 mm cap screw (B) in tapped hole.
YZ1071
UN17DEC97
BM8 x 35 mm Cap Screw
TM2111 (30MAY03)
03-0350-23
OUO1020,0001130 1922NOV027/17

053003
PN=135

11. Use cap screw to remove idler shaft (C).
UN17DEC97
IMPORTANT: There are two O-rings (D), one at each

end of shaft. The O-ring located on the
bottom of the idler shaft may slip off at
removal of shaft.
12. Remove and discard O-rings (D).
YZ1072
13. Remove idler gear (E).

14. Replace bearings in idler gear if worn or damaged.
CIdler Shaft
DO-Rings
EIdler Gear
03
0350
24
OUO1020,0001130 1922NOV028/17
15. Install idler gear (A) into front housing.
NOTE: Lubricate O-rings to avoid damage during

assembly.
UN23DEC97
16. Install new O-rings (B) on idler shaft.

17. Install idler shaft through idler gear and housing.
YZ1150
AIdler Gear
BO-Rings
OUO1020,0001130 1922NOV029/17
18. Install an M8 x 35 mm cap screw (C) in tapped hole.

Turn shaft using cap screw to align holes in shaft and
housing.
UN21MAR01
19. Remove M8 x 35 mm cap screw (C).
YZ1071D
CM8 x 35 Cap Screw
TM2111 (30MAY03)
03-0350-24
OUO1020,0001130 1922NOV0210/17

053003
PN=136

20. Install and tighten cap screw in idler shaft.
YZ1148
UN23DEC97
Charge Pump Specification

Idler Gear Shaft-to-Front Housing
Cap ScrewTorque ........................................................ 87 Nm (64 lb-ft)
03
0350
25
OUO1020,0001130 1922NOV0211/17
21. Install bearing (A), drive gear (B), and bearing (C).
YZ1155
UN23DEC97
ABearing
BDrive Gear
CBearing
TM2111 (30MAY03)
03-0350-25
OUO1020,0001130 1922NOV0212/17

053003
PN=137

22. Lubricate O-ring with petroleum jelly and install in
groove in housing at (D).
23. Install charge pump.
DO-Ring
T164952B
UN04FEB03
03
0350
26
TM2111 (30MAY03)
03-0350-26
OUO1020,0001130 1922NOV0213/17

053003
PN=138

24. Install and tighten cap screws (14) in the sequence
shown.
Charge PumpSpecification
Transmission Charge
Pump-to-Transmission Housing
Torque ............................................................................. 73 Nm (55 lb-ft)
T114002
UN16MAR98
YZ1156
UN23DEC97
1Bottom Left Cap Screw

2Top Right Cap Screw
3Bottom Right Cap Screw
4Top Left Cap Screw
Cap Screw Torque Sequence

OUO1020,0001130 1922NOV0214/17
25. Install suction screen (2) and new O-ring (1).
T163634B
UN13JAN03
1O-Ring
2Suction Screen
TM2111 (30MAY03)
03-0350-27
OUO1020,0001130 1922NOV0215/17

053003
PN=139
03
0350
27

NOTE: Flat face fitting has two O-rings. Discard and
replace both O-rings.
YZ1067D
Flat Face Fitting-to-Charge Pump
UN12JAN98
26. Install flat face fitting (C) with new O-rings, if

removed.
CFlat Face Fitting
03
0350
28
OUO1020,0001130 1922NOV0216/17
27. Install suction tube (D).
Suction Tube-to-Front Housing
Cap ScrewsTorque ...................................................... 25 Nm (18 lb-ft)
YZ1066D
29. Tighten suction tube nut (F).
UN08MAY98
28. Install and tighten cap screws (E).
DSuction Tube
ECap Screws
FSuction Tube Nut
OUO1020,0001130 1922NOV0217/17
TM2111 (30MAY03)
03-0350-28

053003
PN=140
Transmission Suction Tube Repair

2. Remove suction tube (B).
UN21MAR01
3. If necessary, remove suction screen (D).

4. Remove and discard O-ring (E).
YZ4125
5. Install suction screen (D) and new O-ring (E).

6. Install suction tube (B).
7. Install and tighten cap screws (A).
03
0350
29
UN14JAN03
Transmission Suction TubeSpecification

Suction Tube-to-Front Housing
T163634C
ACap Screws
BSuction Tube
CSuction Tube Baffle
DSuction Screen
EO-Ring
OUO1020,0001135 1922NOV021/1
TM2111 (30MAY03)
03-0350-29

053003
PN=141
Transmission Cover Plates to Front Housing

Remove and InstallTorque Converter
Machines
UN21MAR01
Transmission Cover Plate Remove and InstallFront

Housing (Front View)
1. Remove cap screws (A) and washers (B).
YZ4126
2. Remove cover plate (C).

3. Remove and discard O-ring (D).
UN21MAR01
YZ4127
03
0350
30
ACap Screw (4)

BWasher (4)
CCover Plate
DO-Ring
TM2111 (30MAY03)
03-0350-30
OUO1020,0001136 1922NOV021/3

053003
PN=142

1. Install new O-ring (A).
2. Install cover plate (B).
3. Install washers (C) and cap screws (D). Tighten cap
screws to proper specification.
Transmission Cover PlateSpecification
Cover Plate-to-Transmission
Housing Cap ScrewsTorque ........................................ 50 Nm (37 lb-ft)
YZ4130
UN21MAR01
YZ4129
UN21MAR01
AO-Ring
BCover Plate
CWasher (4 used)
DCap Screw (4 used)
TM2111 (30MAY03)
03-0350-31
OUO1020,0001136 1922NOV022/3

053003
PN=143
03
0350
31

Transmission Cover Plate Remove and InstallFront
Housing (Rear View)
2. Remove cover plate (B).
UN29MAR01
1. Install O-ring (C) on cover plate (B).

2. Install cover plate to housing.
Transmission Cover Plate Specification

Cover Plate-to-Transmission
Housing Cap ScrewsTorque ........................................ 50 Nm (37 lb-ft)
ACap Screw (2 used)

BCover Plate
CO-Ring
OUO1020,0001136 1922NOV023/3
Transmission Idler Shaft Remove and

InstallTorque Converter Machines
UN06APR01
YZ1070E
ACap Screw
OUO1020,0001137 1922NOV021/5
2. Install an M8 x 35 mm cap screw (B) in tapped hole.
UN06APR01
BM8 x 35 Cap Screw
YZ1071E
03
0350
32
YZ4178
3. Install and tighten cap screws (A).
TM2111 (30MAY03)
03-0350-32
OUO1020,0001137 1922NOV022/5

053003
PN=144

3. Use cap screw to remove idler shaft (C).
IMPORTANT: There are two O-rings (D), one at each
end of shaft. The O-ring located on the
bottom of the idler shaft may slip off at
removal of shaft.
4. Remove and discard O-rings (D).
YZ4128
UN21MAR01
CIdler Shaft
DO-Ring (2)
OUO1020,0001137 1922NOV023/5
NOTE: Lubricate O-rings to avoid damage during

assembly.
5. Install new O-rings (A) on idler shaft (B).
6. Install cap screw (C) into idler shaft.
NOTE: Cap screw helps turn the idler shaft, while

installing, to align the shaft properly in the
housing.
7. Install idler shaft (B) using cap screw to align holes in
shaft and housing.
YZ4188
UN06APR01
AO-Rings
BIdler Shaft
CCap Screw
TM2111 (30MAY03)
03-0350-33
OUO1020,0001137 1922NOV024/5

053003
PN=145
03
0350
33

8. Install and tighten cap screw in idler shaft.
YZ1148
UN23DEC97
Transmission Idler ShaftTorque Converter Machines

Specification
Idler Shaft-to-Front Housing Cap
03
0350
34
OUO1020,0001137 1922NOV025/5
Transmission Control Valve Repair

Direct drive machine shown throughout. Procedures for
torque converter machine are the same except where
noted.
TM2111 (30MAY03)
03-0350-34
OUO1020,000113A 1922NOV021/24

053003
PN=146
YZ4135
UN22MAR01
03
0350
35
Torque Converter Machine Shown

AValve Housing
BProportional Solenoid
Torque Converter Machine
(7 used)Direct Drive
Machine (8 used)
CCooler Pressure Relief
Valve
DMain Pressure Regulator

ETemperature Sensor Direct
DriveTorque Converter
Will Have Plug
FO-Ring
GPlug (12 used)

HAuxiliary Pressure
Port-to-Transmission
IPlug (2 used)
TM2111 (30MAY03)
03-0350-35
JProportional Solenoid Plug

Torque Converter Machine
OnlyDirect Drive Machine
Will Have Proportional
Solenoid (B)
OUO1020,000113A 1922NOV022/24

053003
PN=147

1. Remove cap screws from control valve.
UN17DEC97
Transmission Control Valve Specification

Control ValveWeight ................................... 27.5 kg (61 lb) approximate
2. Remove valve (A).
YZ1077
AControl Valve
OUO1020,000113A 1922NOV023/24
4. Discard gaskets and plate.
YZ1078
UN17DEC97
AGasket
BPlate
CGasket
OUO1020,000113A 1922NOV024/24
UN17DEC97
NOTE: Direct drive machines have eight proportional

solenoids in the valve housing, torque converter
machines have seven. All valves can be removed
without removing the control valve from the
transmission.
5. Remove nut (A), washer (B) and coil (C) from
proportional solenoid valve. Flange nut also used in
place of nut and washer.
YZ1079
03
0350
36
3. Remove gasket (A), plate (B) and gasket (C) from front
housing.
ANut or Flanged Nut

BWasher (Not used with Flanged Nut)
CCoil
TM2111 (30MAY03)
03-0350-36
OUO1020,000113A 1922NOV025/24

053003
PN=148

IMPORTANT: When any proportional solenoid valves
are removed or replaced, See
Calibration of Transmission Control
Unit (TCU) procedure. (Group 9015-20.)
UN17DEC97
6. Remove proportional valve (D).

7. Inspect for contamination.
YZ1080
DProportional Valve
OUO1020,000113A 1922NOV026/24
8. Remove proportional solenoid plug (1) on torque

converter machine. Direct drive machine will have a
proportional solenoid.
03
0350
37
UN13JAN03
9. Remove O-rings (2).

T163636B
1Proportional Solenoid Plug

2O-Ring (2 used)
OUO1020,000113A 1922NOV027/24
11. Remove relief valve (A).

12. Inspect for wear or contamination.
YZ1081
UN17DEC97
ACooler Pressure Relief Valve
OUO1020,000113A 1922NOV028/24
13. Remove main pressure regulator (A).

14. Inspect for wear or contamination.
YZ1082
UN17DEC97
AMain Pressure Regulator
TM2111 (30MAY03)
03-0350-37
OUO1020,000113A 1922NOV029/24

053003
PN=149

NOTE: Direct drive has temperature sensor. Torque
converter has plug.
UN17DEC97
15. Remove temperature sensor or plug (A). Direct drive

has temperature sensor. Torque converter has plug.
16. Remove O-ring (B).
YZ1083

ATemperature SensorDirect Drive Machine
BO-Ring
Temperature Sensor and O-RingDirect Drive Machine
03
0350
38
OUO1020,000113A 1922NOV0210/24
18. Remove twelve plugs (A).

19. Inspect for contamination in control valve passages.
UN17DEC97
NOTE: Apply lubricant to all O-rings prior to installing into

valve housing.
20. Install new O-ring.
YZ1084
21. Install plugs (A) and fitting into valve housing.

22. Tighten plugs (A).
Transmission Control ValveSpecification
Plug-to-Valve HousingTorque ................................... 12 Nm (106 lb-in.)
APlugs (12 used)
TM2111 (30MAY03)
03-0350-38
OUO1020,000113A 1922NOV0211/24

053003
PN=150

23. Install new O-ring (B).
24. Install temperature sensor (A). Torque converter
machine will have plug.
UN17DEC97
25. Tighten temperature sensor or plug.
YZ1083

Temperature Sensor or
Plug-to-Valve HousingTorque ................................... 16 Nm (142 lb-in.)
ATemperature SensorDirect Drive Machine

BO-Ring
03
0350
39
OUO1020,000113A 1922NOV0212/24
26. Install new O-rings.

27. Install and tighten main pressure regulator (A).
UN17DEC97

Main Regulator
Assembly-to-Valve Housing
Torque .............................................................. 3447 Nm (2535 lb-ft)
YZ1082
AMain Pressure Regulator
OUO1020,000113A 1922NOV0213/24
28. Install new O-rings (A).

29. Install and tighten relief valve.
UN17DEC97

Cooler Pressure Relief Valve
Assembly-to-Valve Housing
Torque .............................................................. 3447 Nm (2535 lb-ft)
YZ1081
AO-Rings
TM2111 (30MAY03)
03-0350-39
OUO1020,000113A 1922NOV0214/24

053003
PN=151

IMPORTANT: When a valve is replaced or removed,
the transmission must be calibrated.
See Calibration of Transmission Control
Unit (TCU). (Group 9015-20.)
UN24SEP96
30. Install new O-rings (AC) on proportional valve.
YZ327
AO-Ring
BO-Ring
CO-Ring
OUO1020,000113A 1922NOV0215/24
31. Install proportional valve (D) into valve housing.

32. Tighten proportional valve.
UN17DEC97

Proportional Valve-to-Valve
HousingTorque.............................................. 1620 Nm (1215 lb-ft)
YZ1080
DProportional Valve
OUO1020,000113A 1922NOV0216/24
33. Install coil (E) and washer (F) on proportional valve.

34. Clean threads on proportional valve and nut. Apply
cure primer.
UN12JAN98
35. Apply medium strength thread lock and sealer to nut

(G) and install on proportional valve.
ECoil
FWasher (Not used with Flange Nut)
GNut or Flange Nut
YZ1079D
03
0350
40
TM2111 (30MAY03)
03-0350-40
OUO1020,000113A 1922NOV0217/24

053003
PN=152

36. Tighten solenoid coil nut.
UN22MAR01

Proportional Valve
Nut-to-Proportional Solenoid
Torque .......................................................... 4.56.8 Nm (4060 lb-in.)
YZ4136
37. Repeat steps to install remaining proportional

solenoid and valve assemblies.
OUO1020,000113A 1922NOV0218/24
38. Install O-rings (2) to proportional solenoid plug.

03
0350
41
39. Install and tighten proportional solenoid plug (1).
UN13JAN03

Proportional Solenoid
Plug-to-Valve HousingTorque ....................... 1620 Nm (1215 lb-ft)
T163636B
1Proportional Solenoid Plug

2O-Ring
OUO1020,000113A 1922NOV0219/24
40. Install two guide bolts (A) in the front housing.
UN23DEC97
NOTE: The guide bolts help align the gaskets by holding

them in place and ease valve assembly
installation.
YZ1088
AGuide Bolts
TM2111 (30MAY03)
03-0350-41
OUO1020,000113A 1922NOV0220/24

053003
PN=153
UN23DEC97
IMPORTANT: Gaskets (B and D) and plate (C) must

be in correct order and correct side up.
Gasket (B) is cut to the shape of the
front housing. Gasket (D) is cut to the
shape of the control valve. Printed side
of gasket must be towards the control
valve.
YZ1078A
41. Put gasket (B), plate (C) and gasket (D) on front
housing using guide bolts as alignment guide.
BGasket
CPlate
DGasket
03
0350
42
OUO1020,000113A 1922NOV0221/24
42. Install control valve (A) on front housing.

43. Remove guide bolts.
44. Install and tighten cap screws (B) per numerical
sequence drawing.
YZ1087
UN23DEC97
AControl Valve
BCap Screws
TM2111 (30MAY03)
03-0350-42
OUO1020,000113A 1922NOV0222/24

053003
PN=154
T163650
UN14JAN03
03
0350
43
ACap Screw, 45 mm long

and Flat Washer (5 used)
BCap Screw, 90 mm long

CCap Screw, 75 mm long

TM2111 (30MAY03)
03-0350-43
OUO1020,000113A 1922NOV0223/24

053003
PN=155

45. Tighten cap screws (AC) again in sequence
shown.
Control Valve-to-Front Housing
Cap ScrewsTorque ............................................... 39 Nm (29 lb-ft)
OUO1020,000113A 1922NOV0224/24
03
0350
44
TM2111 (30MAY03)
03-0350-44

053003
PN=156
Input Yoke Remove and Install

UN20DEC97
2. Remove washer (B).

3. Remove O-ring (C).
YZ1091
4. Remove yoke (D).

5. Remove oil seal (E).
6. Apply medium strength thread lock and sealer to
outside diameter of oil seal and petroleum jelly to
inside diameter of new oil seal (E). Install using a disk
driver.
03
0350
45
NOTE: Optimal white paste reduces spline wear.

UN20DEC97
7. Apply OPTIMOLY PASTE WHITE T on input shaft

spline before installing yoke.
YZ1092
IMPORTANT: The yoke may need to be moved up and

down until the seal lip is pointing out
over the full circumference. Seal lip of
oil seal must not be rolled when yoke is
installed.
ACap Screw
BWasher
CO-Ring
DYoke
EOil Seal
8. Install yoke (D).

9. Install O-ring (C).
10. Install washer (B).
11. Apply high strength thread lock and sealer to cap
screw (A).
OPTIMOLY PASTE WHITE T is a trademark of Optimal Lubricants, Inc.
TM2111 (30MAY03)
03-0350-45
TX,03,RB605 1925NOV021/2

053003
PN=157

12. Install and tighten cap screw to specification.
Input Yoke Specification
Yoke Cap ScrewTorque........................................... 215 Nm (159 lb-ft)
UN12JAN98
ETorque Wrench
YZ1153
03
0350
46
TX,03,RB605 1925NOV022/2
TM2111 (30MAY03)
03-0350-46

053003
PN=158
03
0350
47
TM2111 (30MAY03)
03-0350-47

053003
PN=159
Front Housing Exploded ViewDirect Drive Machines
1
2
03
0350
48
3
4
21
5
6
8
7
14
20
13
9
10
17
18
19
16
15
11
T162133
UN11DEC02
12
T162133
TM2111 (30MAY03)
03-0350-48
OUO1020,000113F 1925NOV021/4

053003
PN=160

1Front Housing
3O-Ring
4Flat Face Fitting
5O-Ring
6Lube Relief Valve
7Drain Valve
8Plug and O-Ring (2 used)
9O-Ring
10Plug
12Suction Tube
14Oil Seal
15O-Ring
16Suction Screen
17Suction Tube Baffle

18Grease Fitting
19Plug
20Check Ball
21Oil Splash Guard
OUO1020,000113F 1925NOV022/4
03
0350
49
TM2111 (30MAY03)
03-0350-49

053003
PN=161
T163654
UN14JAN03
03
0350
50
Front Housing Rear ViewDirect Drive Machines
TM2111 (30MAY03)
03-0350-50
OUO1020,000113F 1925NOV023/4

053003
PN=162

1Front Housing
2Lube Relief Valve

4Oil Seal
5Dowel Pin (2 used)

6Bearing Cup
7Bore Sleeve (4 used)

8Bearing Cup (2 used)
OUO1020,000113F 1925NOV024/4
03
0350
51
TM2111 (30MAY03)
03-0350-51

053003
PN=163
Front Housing Exploded ViewTorque Converter Machines
1
2
03
0350
52
3
4
5
2
10
21
23
14 24 22
13
25
20
12
19
17
16
18
15
26
T162131
UN15JAN03
11
T162131
TM2111 (30MAY03)
03-0350-52
OUO1020,0001140 1925NOV021/3

053003
PN=164

1Front Housing
3O-Ring
4Idler Shaft
5O-Ring
6Lube Relief Valve
7O-Ring
8Cover Plate
9Washer (4 used)
11Cap Screws (2 used)
12Plug Suction Tube
14Oil Seal
15O-Ring
16Suction Screen
17Suction Tube Baffle
18Grease Fitting
19Plug
20Check Ball
21Oil Splash Guard

22Drain Valve
23Plug (2 used)
24Fitting
25O-Ring
26Suction Tube
OUO1020,0001140 1925NOV022/3
03
0350
53
TM2111 (30MAY03)
03-0350-53

053003
PN=165
YZ4144
UN23MAR01
03
0350
54
Rear View of Front HousingTorque Converter Machines

AFront Housing
BDowel Pin (2 used)
CBearing Cup
DBearing Cup
EBore Sleeve (4 used)
FBearing Cup
GO-Ring
HCover
ICap Screw (2 Used)
OUO1020,0001140 1925NOV023/3
TM2111 (30MAY03)
03-0350-54

053003
PN=166
Front Housing RepairAll Machines

noted.
Front Housing RemoveAll Machines
1. For direct drive machines,see Charge Pump Repair
and suction tube in this group. For torque converter
machines, see Transmission Suction Tube Repair in
this group.
2. See Transmission Control Valve Repair in this group.
03
0350
55
OUO1020,0001142 1918APR011/11
3. Install DFT1156 Transmission Housing Lifting Bracket

(B) in mounting holes. (Group 9900.)
UN14JAN03
4. Remove cap screws (C).
T163695B
BDFT1156 Transmission Housing Lifting Bracket

CCap Screws
OUO1020,0001142 1918APR012/11

Front HousingAll MachinesSpecification
Front HousingWeight ................................... 94 kg (207 lb) approximate
NOTE: Slowly raise transmission front cover. Clutches

may bind and stick in cover.
UN20APR98
5. Lift front housing (A) from rear housing using proper

lifting equipment.
T114930
AFront Housing
TM2111 (30MAY03)
03-0350-55
OUO1020,0001142 1918APR013/11

053003
PN=167

Front Housing Bore Sleeves
IMPORTANT: Disassemble only if parts are damaged
and must be replaced. Sleeves are
pressed into housing.
1. Inspect bore sleeves (A).
YZ1099
UN20DEC97
ABore Sleeves
03
0350
56
OUO1020,0001142 1918APR014/11
YZ1100
UN20DEC97
2. Remove bore sleeves using a blind hole puller.
TM2111 (30MAY03)
03-0350-56
OUO1020,0001142 1918APR015/11

053003
PN=168

IMPORTANT: Install bore sleeves with the internal
chamfer (A) up (toward the inside of the
transmission case).
3. Position front housing with bearing bore side up.
UN12JAN98
4. Install JDG1109 Bushing Driver (B).
YZ1101
5. Install bore sleeves (C) until driver is against casting.

AInternal Chamfer
BJDG1109 Bushing Driver
CBore Sleeves
YZ1102
UN23DEC97
03
0350
57
TM2111 (30MAY03)
03-0350-57
OUO1020,0001142 1918APR016/11

053003
PN=169

Bearing Cups
IMPORTANT: Disassemble only if parts are damaged
and must be replaced.
UN23DEC97
1. Inspect for wear and damage.
YZ1103
2. Remove bearing cups (A) using two pry bars or

two-jaw puller.
ABearing Cups
03
0350
58
OUO1020,0001142 1918APR017/11
IMPORTANT: Use a bearing cup driver to install

bearing cup. Bearing cup must be
installed tight against shoulders.
YZ1104
UN23DEC97
3. Install new bearing cups.
OUO1020,0001142 1918APR018/11
Lube Relief Valve
NOTE: Remove only if lube relief valve is damaged or if a

failure that caused contamination occurred.
UN23DEC97
1. Position front housing with bearing bore side up.

2. Remove lube relief valve (A).
YZ1105
ALube Relief Valve
TM2111 (30MAY03)
03-0350-58
OUO1020,0001142 1918APR019/11

053003
PN=170

IMPORTANT: Use care installing lube relief valve. The
valve seat shoulder on the valve can be
damaged if too much force is applied.
3. Position front housing with bearing bore side down.
UN14JAN03
4. Install new lube relief valve (1) into lube relief valve
bore until the lube relief valve shoulder is flush with the
bore shoulder.
T163657B
1Lube Relief Valve
OUO1020,0001142 1918APR0110/11
Seventh Stage (Output Gear) Oil Seal and Grease

Seals
1. Remove two outer grease seals.
2. Remove oil seal (A).
YZ1099A
UN12JAN98
AOil Seal
OUO1020,0001142 1918APR0111/11
TM2111 (30MAY03)
03-0350-59

053003
PN=171
03
0350
59
Transmission Clutch Packs and Gear Stages

Remove and InstallDirect Drive Machines
1. Remove transmission charge pump, input yoke, park
brake, and winch drive. See Transmission Charge
Pump Remove and InstallDirect Drive Machines,
Transmission Control Valve Repair, Input Yoke
Remove and Install, Park Brake Repair, and Winch
Drive Repair in this group.
UN18SEP97
T111308
OUO1020,00010FD 1925NOV021/11

Transmission Clutch Packs and Gear Stage Assemblies
Specification
Weight............................................................. 30.8 kg (68 lb) approximate
NOTE: Assembly must be tilted in order to be removed.
UN21JAN03
2. Use hoist and JT05548 Lifting Eyebolt (2) to remove

seventh stage output gear (3) and oil splash guard (4).
3. Remove oil splash guard (4) from seventh stage
(output gear).
T163838B
03
0350
60
AInput Shaft (First Stage)

BDirection Clutch Packs (High and Low Reverse)
(Third Stage)
CSecond and Fourth Speed Clutch Packs (Fifth
Stage)
DOutput Shaft (Seventh Stage)
ESixth Stage Gear (Idler Gear)
FFirst and Third Speed Clutch Packs (Fourth Stage)
GDirection Clutch Packs (High and Low Forward)
(Second Stage)
1JDG1101 Clutch Pack Lifting Plate

2JT05548 Metric Lifting Eyebolt
3Seventh Stage Output Gear
4Oil Splash Guard
TM2111 (30MAY03)
03-0350-60
OUO1020,00010FD 1925NOV022/11

053003
PN=172

Specification
First Stage (Input Shaft)Weight ..................... 14 kg (30 lb) approximate
4. Remove input shaft (A) out of housing.

YZ1138
UN23DEC97
03
0350
61
OUO1020,00010FD 1925NOV023/11
CAUTION: Make sure JDG1101 Clutch Pack

Lifting Plate is fastened to each clutch pack to
avoid personal injury.
5. Install JDG1101 Clutch Pack Lifting Plate (B).
YZ1110
UN23DEC97
BJDG1101 Clutch Pack Lifting Plate
TM2111 (30MAY03)
03-0350-61
OUO1020,00010FD 1925NOV024/11

053003
PN=173

Specification
Clutch Packs (SecondFifth
Stage)Weight .......................................... 157.4 kg (347 lb) approximate
6. Remove clutch packs from rear housing. Carefully set

on work bench.
YZ1111
UN23DEC97
7. Remove JDG1101 Clutch Pack Lifting Plate.
03
0350
62
OUO1020,00010FD 1925NOV025/11
UN23DEC97

Specification
Sixth Stage Gear (Idler Gear)
Weight................................................................ 14 kg (30 lb) approximate
8. Remove sixth stage gear (C) from rear housing.
YZ1144
9. Clean and inspect housing and bearing cups for wear

or damage. Replace as required.
CSixth Stage Gear (Idler Gear)
Specification
10. Install sixth stage gear (C).
TM2111 (30MAY03)
03-0350-62
OUO1020,00010FD 1925NOV026/11

053003
PN=174
CAUTION: Make sure lift plate is fastened to

clutch pack to avoid personal injury.
11. Install JDG1101 Clutch Pack Lifting Plate (B) on
clutch pack. Lock holders onto the four clutch pack
assemblies.
T115351
UN13MAY98
BJDG1101 Clutch Pack Lifting Plate
OUO1020,00010FD 1925NOV027/11

Specification
Stage)Weight .......................................... 157.4 kg (347 lb) approximate
IMPORTANT: Carefully lower clutch packs into

position to avoid damage to sixth stage
bearing
YZ1111
UN23DEC97
12. Carefully install clutch packs in rear housing.
TM2111 (30MAY03)
03-0350-63
OUO1020,00010FD 1925NOV028/11

053003
PN=175
03
0350
63

13. Remove JDG1101 Clutch Pack Lifting Plate (D).
YZ1110A
UN23DEC97
DJDG1101 Clutch Pack Lifting Plate
03
0350
64
OUO1020,00010FD 1925NOV029/11

Specification
First Stage (Input Shaft)Weight ..................... 14 kg (30 lb) approximate
14. Install input shaft (A) to rear housing.
YZ1138
UN23DEC97
TM2111 (30MAY03)
03-0350-64
OUO1020,00010FD 1925NOV0210/11

053003
PN=176

Specification
16. Use JT05548 Metric Lifting Eyebolt to install seventh

stage (output gear) with splash guard into rear
housing.
T163838B
NOTE: Seventh stage (output gear) must be tilted to

install.
UN21JAN03
15. Put oil splash guard (4) on large gear of seventh

stage (output gear).

2JT05548 Metric Lifting Eyebolt
3Seventh Stage (Output Gear)
4Oil Splash Guard
OUO1020,00010FD 1925NOV0211/11
TM2111 (30MAY03)
03-0350-65

053003
PN=177
03
0350
65
Input (First Stage) and Idler (Sixth Stage)

Gear Shaft RepairDirect Drive Machines
1. Use D01048AA Puller Set to remove bearing cones (A
and B).
ABearing Cone
BBearing Cone
YZ1133
UN23DEC97
03
0350
66
Input Shaft (First Stage) Shown
TM2111 (30MAY03)
03-0350-66
OUO1020,0001101 1918APR011/2

053003
PN=178

IMPORTANT: Press only on the inner race of bearing
cone. Do not reuse bearing cones if
removed.
NOTE: Gear and shaft assemblies are serviced as an

assembly. If either the gear or shaft is damaged
or worn, entire assembly must be replaced.
2. Use JDG1105 Bearing Driver and JDG1108 Clutch
Bearing Driver (A) to install new bearing cones (B) on
both ends of shaft. Push bearing tight against shoulder
of shaft.
AJDG1108 Clutch Bearing Driver
BBearing Cone
YZ1134
UN23DEC97
03
0350
67

OUO1020,0001101 1918APR012/2
TM2111 (30MAY03)
03-0350-67

053003
PN=179
High and Low Forward (Second Stage) Clutch Packs Exploded ViewDirect Drive
Machines
T163664
UN22JAN03
03
0350
68
1Seal Ring (3 used)

2Ball Bearing (2 used)
3Retaining Ring (2 used)
4Bearing
5Gear
6O-Ring (2 used)
7Bearing with Seal (2 used)
8Internal Snap Ring (2 used)

9Clutch Plate Retainer
10Clutch Plate (18 used)
11Clutch Separator Plate (20
used)
13Snap Ring Retainer (2

used)
14Clutch Return Spring (12
used)
15Lube Shut-Off Washer (2
used)
16O-Ring (2 used)
17Clutch Piston (2 used)
18Piston Outer Seal (2 used)
19Second Stage Shaft
20Gear
21Bearing
OUO1020,0001103 1926NOV021/1
TM2111 (30MAY03)
03-0350-68

053003
PN=180
High and Low Reverse (Third Stage) Clutch Pack Exploded ViewDirect Drive Machines
T163679
UN15JAN03
03
0350
69
1Seal Ring (3 used)

4Bearing (2 used)
5Gear
6O-Ring (2 used)
7Bearing with Seal (2 used)

8Internal Snap Ring (2 used)
9Clutch Plate Retainer
used)

used)
used)
used)
16O-Ring (2 used)
19Third Stage Shaft
20Gear
OUO1020,0001104 1926NOV021/1
TM2111 (30MAY03)
03-0350-69

053003
PN=181
First and Third Speed Clutch Packs (Fourth Stage) Exploded ViewDirect Drive
Machines
T163680
UN15JAN03
03
0350
70
1Seal Ring (3 used)

2Bearing (2 used)
5Clutch Gear
7Snap Ring (2 used)

8Clutch Plate Retainer (2
used)
used)

used)
used)
used)
15O-Ring (2 used)
18Fourth Stage Shaft
19Clutch Gear
OUO1020,0001105 1926NOV021/1
TM2111 (30MAY03)
03-0350-70

053003
PN=182
Second and Fourth Speed Clutch Packs (Fifth Stage) Exploded ViewDirect Drive
Machines
T163681
UN15JAN03
03
0350
71
1Seal Ring (3 used)

2Bearing (2 used)
5Clutch Gear
7Snap Ring (2 used)

8Clutch Plate Retainer (2
used)
used)

used)
used)
used)
15O-Ring (2 used)
18Fifth Stage Shaft
19Clutch Gear
OUO1020,0001106 1926NOV021/1
TM2111 (30MAY03)
03-0350-71

053003
PN=183
Transmission Clutch Packs Disassemble

Direct Drive Machines
CAUTION: Heavy components; use a hoist.
Transmission Clutch Packs DisassembleDirect
Specification
Second Stage AssemblyWeight ................. 43.1 kg
Third Stage AssemblyWeight ..................... 40.8 kg
Fourth Stage AssemblyWeight ................... 34.5 kg
Fifth Stage AssemblyWeight ...................... 39.0 kg
Drive Machines
(95
(90
(76
(86
lb)
lb)
lb)
lb)
approximate
approximate
approximate
approximate
IMPORTANT: DO NOT mix components of individual

shaft assemblies. Keep all clutch pack
components together as a set.
NOTE: The disassembly and assembly of clutch packs

are similar. Second Stage and Fourth Stage
Clutch Packs are shown unless otherwise
indicated.
UN23DEC97
1. If necessary, JDG1106 Clutch Lifting tool can be used

to lift clutch assembly.
YZ1121
Direction Clutch Packs (High and Low Forward) (Second Stage)

Shown
OUO1020,0001107 1918APR011/15
2. Remove seal rings (A).
UN23DEC97
ASeal Rings (3 used)
YZ1122
03
0350
72
TM2111 (30MAY03)
03-0350-72
OUO1020,0001107 1918APR012/15

053003
PN=184

IMPORTANT: Use shaft protector on forcing screw
when using bearing puller.
3. Install bearing puller (B).
UN13AUG96
4. Install gear puller (A) on bearing puller.

5. Remove ball bearing (C).
YZ402
AGear Puller
BBearing Puller
CBall Bearing
03
0350
73
OUO1020,0001107 1918APR013/15
CAUTION: Wear proper eye protection when

installing or removing retaining rings.
6. Remove retaining ring (A).
YZ403
UN02NOV96
ARetaining Ring
TM2111 (30MAY03)
03-0350-73
OUO1020,0001107 1918APR014/15

053003
PN=185

7. Use bearing puller to remove gear (B).
BClutch Gear
YZ404
UN12MAR97
03
0350
74
OUO1020,0001107 1918APR015/15
8. Remove ball bearing (A).
YZ849A
UN12MAR97
ABall Bearing
TM2111 (30MAY03)
03-0350-74
OUO1020,0001107 1918APR016/15

053003
PN=186

9. On direction clutch packs (high and low forward)
(second stage) and direction clutch packs (high and
low reverse) (third stage) assemblies only, remove
O-ring (A). Inspect for wear or damage.
YZ429
UN19APR97
AO-Ring
OUO1020,0001107 1918APR017/15

removing snap ring.
10. Remove snap ring (B).
YZ407
UN25MAR97
BSnap Ring
TM2111 (30MAY03)
03-0350-75
OUO1020,0001107 1918APR018/15

053003
PN=187
03
0350
75

11. Turn shaft assembly over.
UN12MAR97
12. Remove clutch plate retainer, clutch plates and

separator plates.
YZ409
03
0350
76
OUO1020,0001107 1918APR019/15

13. Install bearing puller.
14. Remove and discard bearing (A).
YZ406
UN19APR97
ABearing
TM2111 (30MAY03)
03-0350-76
OUO1020,0001107 1918APR0110/15

053003
PN=188

Remove Clutch Piston Return Spring
CAUTION: Clutch piston return springs are
under pressure.
1. Place shaft assembly on press.
2. Use JDG1103 Clutch Pack Spring Compressor (A) to
compress clutch return springs.
3. Remove retaining ring (B) from shaft groove. Inspect
for wear or damage.
UN29APR97
4. Relieve pressure on compressor tool.
YZ410
AJDG1103 Clutch Pack Spring Compressor

BRetaining Ring
OUO1020,0001107 1918APR0111/15
5. Lift out retaining ring (A), snap ring retainer (B) and
clutch return springs (C).
YZ463
UN21AUG96
ARetaining Ring
BSnap Ring Retainer
CClutch Return Springs
OUO1020,0001107 1918APR0112/15
6. Remove lube shutoff washer (D).
YZ464
UN21AUG96
DLube Shutoff Washer
TM2111 (30MAY03)
03-0350-77
OUO1020,0001107 1918APR0113/15

053003
PN=189
03
0350
77
1. Apply 69 kPa (0.7 bar) (10 psi) maximum, regulated air

pressure through oil passage to force clutch piston
from shaft assembly.
Transmission Clutch Packs DisassembleDirect Drive Machines
Specification
Maximum Regulated Air
Pressure ............................................................. 69 kPa (0.7 bar) (10 psi)
OUO1020,0001107 1918APR0114/15
2. Remove clutch piston (A).

3. Remove piston outer seal (B) and O-ring (C) from
clutch piston.
5. For complete disassembly of this shaft, repeat

disassembly steps for clutch pack assembly on
opposite end of this shaft.
AClutch Piston
BPiston Outer Seal
CO-Ring
UN20AUG96
YZ415
03
0350
78
YZ414
CAUTION: Prevent possible injury from

unexpected release of piston. Clear area of
bystanders. Use a protective blanket for extra
protection against the unexpected release of
piston or flying debris. Wear personal
protection equipment, including eye protection.
Use only regulated, compressed air of 69 kPa
(0.7 bar) (10 psi) maximum to remove piston.
UN20AUG96
Remove Clutch Piston
OUO1020,0001107 1918APR0115/15
TM2111 (30MAY03)
03-0350-78

053003
PN=190
Transmission Clutch Packs Assemble

UN20AUG96
Inspect inside of cylinder for sharp

edges or burrs. Use care not to damage
seals on pistons during installation.
1. Lubricate and install new O-ring (A).
YZ416
2. Lubricate and install new piston outer seal (B).

3. Install clutch piston (C) with raised center boss up.
03
0350
79
AO-Ring
BPiston Outer Seal
CClutch Piston
OUO1020,0001108 1926NOV021/14
4. Install lube shutoff washer (D).
YZ413
UN21AUG96
TM2111 (30MAY03)
03-0350-79
OUO1020,0001108 1926NOV022/14

053003
PN=191
UN20MAR97
IMPORTANT: Install clutch piston return springs as

shown for proper spring force.
5. Install clutch return springs (A) as three pairs with
outer diameters contacting for each pair.
YZ853
AClutch Return Springs
YZ417
UN14AUG96
03
0350
80
OUO1020,0001108 1926NOV023/14
IMPORTANT: Wear proper eye protection when

installing retaining rings.
6. Put snap ring retainer (B) and retaining ring (C) on
shaft.
UN19APR97
7. Compress clutch return springs using JDG1103 Clutch

Pack Spring Compressor.
YZ418
BSnap Ring Retainer

CRetaining Ring
TM2111 (30MAY03)
03-0350-80
OUO1020,0001108 1926NOV024/14

053003
PN=192

8. Install retaining ring (C) in groove.
UN19APR97
9. Release pressure on clutch return springs slowly. Be

sure snap ring retainer is properly positioned.
YZ410A
CRetaining Ring
03
0350
81
TM2111 (30MAY03)
03-0350-81
OUO1020,0001108 1926NOV025/14

053003
PN=193

IMPORTANT: Seal side of bearing must be toward
clutch return springs. Lubricate bearing
to prevent dry start-up of transmission.
Press only on inner race of ball bearing.
10. Install ball bearing (A), with seal side down. Install
bearing until bearing inner race contacts shoulder of
shaft.
ABall Bearing
YZ428
UN19APR97
YZ427
UN19APR97
03
0350
82
TM2111 (30MAY03)
03-0350-82
OUO1020,0001108 1926NOV026/14

053003
PN=194

IMPORTANT: For direction clutch packs (high and
low forward) (second stage) and
direction clutch packs (high and low
reverse) (third stage) ONLY, install two
clutch separator plates first.
UN12MAR97
NOTE: Clutch separator plates are steel with external

spline teeth. Clutch plates have a lining material
on the face and internal spline teeth.
YZ420

low reverse) (third stage) clutch assemblies, install
two clutch separator plates (A). On first and third
speed clutch packs (fourth stage) and second and
fourth speed clutch packs (fifth stage) clutch
assemblies, install one clutch separator plate.
AClutch Separator Plates

03
0350
83
OUO1020,0001108 1926NOV027/14
12. Install one clutch plate (B) and then one clutch
separator plate. Install remaining plates alternately.
NOTE: Last plate is a clutch plate.

13. Last plate is a clutch plate.
YZ421
UN12MAR97
BClutch Plate
TM2111 (30MAY03)
03-0350-83
OUO1020,0001108 1926NOV028/14

053003
PN=195

14. Install clutch plate retainer (A).
installing snap ring.
UN05APR01
YZ4185
AClutch Plate Retainer

BOne-Spline Tooth Missing Location
CTwo-Spline Teeth Missing Location
DSnap Ring
YZ4181
03
0350
84
UN05APR01
IMPORTANT: Second and third shaft assemblies have

three locations with two spline teeth
missing (C) and one location with one
spline tooth missing (B). Fourth and
fifth shaft assemblies have six locations
with one spline tooth missing. The
clutch plate retainer lug (A) fits in any
of the locations with one spline tooth
missing (B).
TM2111 (30MAY03)
03-0350-84
OUO1020,0001108 1926NOV029/14

053003
PN=196

IMPORTANT: Check that clutch and separator plates
do not bind.
16. Make sure piston and clutch plates are to bottom of

bore. Using a depth gauge, measure from top of
clutch pack drum to top of clutch plate retainer (A).
UN18MAY98
Using two screwdrivers, lift clutch plate retainer

against snap ring (B). Again, measure from top of
clutch pack drum to top of clutch plate retainer.
T115376
The difference of the two measurements is the clutch

plate clearance (C).
T115376
Replace clutch plates as necessary to obtain proper

clearance.
Clutch Plate Clearance

03
0350
85

BSnap Ring
CClutch Plate Clearance
Transmission Clutch Packs AssembleDirect Drive Machines

Specification
Clutch Plate (Second and Third
Stage Clutch Packs)Clearance ........ 2.314.47 mm (0.0910.176 in.)
Clutch Plate (Fourth and Fifth
OUO1020,0001108 1926NOV0210/14
17. On second and third stage clutch assemblies only,

lubricate and install new O-ring (B).
YZ429A
UN19APR97
BO-Ring
TM2111 (30MAY03)
03-0350-85
OUO1020,0001108 1926NOV0211/14

053003
PN=197

IMPORTANT: Clutch plate splines must be aligned
before installing bearings on the shaft
assembly to avoid clutch plate damage.
18. Use clutch gear to align clutch plates and separator
plates.
UN12MAR97
IMPORTANT: Forcing clutch gear through clutch

plates can damage clutch plates if
plates are not properly aligned. Use
care not to damage O-ring (A).
20. Install clutch gear. O-ring (A) must fit into bore of
clutch plate retainer.
IMPORTANT: Start bearing (B) into clutch gear. DO
NOT press bearing below ring groove in
shaft. Pressing the bearing all the way
into the gear will preload the bearing.
Preloading bearing will shorten the life
of the bearing.
21. Put new bearing (B) onto clutch gear. Start bearing
into bore only.
UN20AUG96
AO-Ring
BBearing
YZ432
03
0350
86
YZ425
19. Move clutch gear clockwise; then counterclockwise,

working the clutch gear spline through the clutch and
separator plates.
TM2111 (30MAY03)
03-0350-86
OUO1020,0001108 1926NOV0212/14

053003
PN=198
23. Using a press and tool (cylinder), push slowly on

retaining ring until retaining ring fits into groove of
shaft assembly.
YZ433
IMPORTANT: Press only on retaining ring. DO NOT

preload bearing.
UN02NOV96
22. Install retaining ring (A) on shaft assembly.
Clutch gear must turn. Check for 0.25 mm (0.010 in.)

end play of gear using a dial indicator.
NOTE: Disassemble bottom half of directional clutch

assemblies following the steps outlined above.
YZ434
24. Lubricate and install ball bearing (B). Press bearing

onto shaft until bearing contacts retaining ring.
UN20AUG96
Transmission Clutch Packs AssembleDirect Drive Machines

Specification
Clutch GearEnd Play .............................................. 0.25 mm (0.010 in.)
25. Assemble opposite end of shaft by repeating steps.
YZ435
UN02NOV96
ARetaining Ring
BBall Bearing
OUO1020,0001108 1926NOV0213/14
IMPORTANT: Always use new seal rings.

26. Install three seal rings (A) into ring grooves.
YZ1122
UN23DEC97
ASeal Ring (3 used)
OUO1020,0001108 1926NOV0214/14
TM2111 (30MAY03)
03-0350-87

053003
PN=199
03
0350
87
Seventh Stage (Output) ShaftDirect Drive

Machines
CAUTION: Use shaft protector when removing
bearing cones.
1. Use a bearing puller to remove bearing cones (A).
Discard bearing cones.
ABearing Cone
YZ1135
UN12JAN98
03
0350
88
TM2111 (30MAY03)
03-0350-88
OUO1020,000110B 1926NOV021/2

053003
PN=200

IMPORTANT: Push on inner race of bearing only.
2. Install new bearing cones (A) on both ends of gear and
shaft assembly using a press and JDG1107 Bearing
Driver. Push bearing tight against shoulder of shaft.
ABearing Cones
YZ1136
UN23DEC97
03
0350
89
OUO1020,000110B 1926NOV022/2
TM2111 (30MAY03)
03-0350-89

053003
PN=201
Rear Transmission Housing RepairDirect

Drive Machines
1. Remove and discard bearing cups (A).
2. Install new bearing cups.
ABearing Cups
YZ1142
UN23DEC97
03
0350
90
OUO1020,000110D 1926NOV021/1
TM2111 (30MAY03)
03-0350-90

053003
PN=202
Front and Rear Housing AssembleDirect

Drive Machines
1. Attach DFT1156 Transmission Housing Lifting Bracket
to front housing (A). (Group 9900.)
UN20APR98
NOTE: Lubricate all bearings before installing front

housing.
2. Clean mounting surfaces on front and rear housings
with isopropyl alcohol or equivalent.
T114930

material. Using a small roller will help to
apply a thin, even layer of adhesive.
03
0350
91
T163695B
UN14JAN03
3. Apply form-in-place gasket to rear housing mounting

surface, using care to apply a thin layer over the entire
surface. Excess gasket material should be wiped from
joint. Installation should occur within three minutes of
application. Allow a minimum of 30 minutes of cure
time before adding oil.
Rear Transmission Housing RepairSpecification
AFront Housing
BDFT1156 Transmission Housing Lifting
Bracket
IMPORTANT: Use guide pins during assembly to

guide the front housing onto the rear
housing. Pins will help prevent damage
to seal rings.
4. Lower front housing onto rear housing.
5. Install six cap screws evenly spaced through front
housing into rear housing snug tight.
6. Remove guide pins and install remaining cap screws
(C) snug tight.
7. Remove lifting bracket (B).
TM2111 (30MAY03)
03-0350-91
OUO1065,0000593 1926NOV021/3

053003
PN=203
T163697
UN15JAN03
03
0350
92
Cap Screw Torque Sequence
8. Tighten cap screws to specification in sequence

shown. Repeat tightening sequence a second time.
Rear Transmission Housing RepairSpecification
Front Housing-to-Rear Housing
Cap ScrewTorque ................................................. 87 Nm (64 lb-ft)
TM2111 (30MAY03)
03-0350-92
OUO1065,0000593 1926NOV022/3

053003
PN=204

9. Position front housing with bearing bore side down.
1
10. Place JDG1519 Seal Protector over shaft.
outside diameter of oil seal (1) and grease seals (2).
13. Use JDG1736 Seal Driver to install oil seal (1) until
flush with shoulder in transmission housing.
T163701
15. Use JDG1738 Seal Driver to install second grease

seal (2) until flush with shoulder in transmission
housing.
T163700B
UN14JAN03
1Oil Seal
3Grease Fitting
4Seal Driver
5Grease Seal
T163701
3
14. Use JDG1737 Seal Driver to install grease seal (2) to
bottom of seal bore in transmission housing.
UN21JAN03
12. Apply thin layer of petroleum jelly to inner seal lip of

oil seal (1) and grease seals (2).
OUO1065,0000593 1926NOV023/3
TM2111 (30MAY03)
03-0350-93

053003
PN=205
03
0350
93
Transmission Clutch Packs and Gear Stages

RepairTorque Converter Machines
1. Remove transmission control valve, input yoke, park
brake, and winch drive. See Transmission Control
Valve Repair, Input Yoke Remove and Install, Park
Brake Repair and Winch Drive Repair in this group.
2. Remove transmission front housing. See Front Housing
RepairAll Machines in this group.
CAUTION: Make sure clutch pack lifting plate is
fastened to clutch packs and input shaft to
UN04FEB03
IMPORTANT: Sixth stage bearings can contact gear

teeth during removal and installation.
Carefully lift and lower using JDG1101
Clutch Pack Lifting Plate along with
DFT1217 Transmission Input Shaft
Holder to avoid bearing damage.
T163724C
3. Attach clutch pack lifting plate (9) onto clutch stage

assemblies (14) and (7 and 8).
4. Attach transmission input shaft holder (10) to input
shaft (1) using a M8 x 38 mm cap screw. See
DFT1217 Transmission Input Shaft Holder. (Group
9900.)
UN04FEB03
1Input Shaft (First Stage)

2High and Low Reverse (Third Stage)
3Second and Fourth Speed Clutch Pack (Fifth
Stage)
4Idler Gear (Sixth Stage)
5Output Shaft and Gear (Seventh Stage)
6Oil Splash Guard
7First and Third Speed Clutch Pack (Fourth Stage)
8High and Low Forward (Second Stage)
10DFT1217 Input Shaft Holder
T164953B
03
0350
94
TM2111 (30MAY03)
03-0350-94
OUO1020,000110F 1926NOV021/5

053003
PN=206

Transmission Clutch Packs and Gear Stages RepairTorque
Converter MachinesSpecification
Stage) and Input ShaftTorque
Converter MachinesWeight..................... 169.7 kg (374 lb) approximate
5. Remove clutch packs and input shaft from rear

housing. Carefully set on work bench.
6. Remove clutch pack lifting plate.
03
0350
95
OUO1020,000110F 1926NOV022/5

7. Using hoist remove seventh stage (1) from housing.
UN22JAN03
8. Remove oil splash guard (3) from seventh stage.

T163726B

2Sixth Stage (Idler Gear)
3Oil Splash Guard
9. Remove sixth stage gear (2) from rear housing.

10. Clean and inspect housing and bearing cups for wear
or damage. Replace as required.
TM2111 (30MAY03)
03-0350-95
OUO1020,000110F 1926NOV023/5

053003
PN=207

11. Install sixth stage gear (2).
UN22JAN03
03
0350
96
T163726B

12. Put oil splash guard (3) on large gear of seventh

stage.
2Sixth Stage Gear (Idler Gear)
3Oil Splash Guard
13. Install seventh stage (1) into rear housing.
TM2111 (30MAY03)
03-0350-96
OUO1020,000110F 1926NOV024/5

053003
PN=208
14. Attach JDG1101 Clutch Pack Lifting Plate (9) on

clutch packs. Lock holders onto the four clutch pack
assemblies.
15. Attach DFT1217 Transmission Input Shaft Holder on
end of input shaft (1) using a M8 x 38 mm cap screw.
T164953B
IMPORTANT: Sixth stage bearings can contact gear

teeth during removal and installation.
Carefully lift and lower using JDG1101
Clutch Pack Lifting Plate along with
Holder to avoid bearing damage.
UN04FEB03
CAUTION: Make sure clutch pack lifting plate is

fastened to clutch packs and input shaft to

Stage) and Input ShaftTorque
Converter MachinesWeight..................... 169.7 kg (374 lb) approximate
16. Carefully lift and install clutch packs in rear housing.
T163724C
1Input Shaft (First Stage)

2High and Low Reverse (Third Stage)
3Second and Fourth Speed Clutch Pack (Fifth
Stage)
4Idler Gear (Sixth Stage)
5Output Shaft and Gear (Seventh Stage)
6Oil Splash Guard
7First and Third Speed Clutch Pack (Fourth Stage)
8High and Low Forward (Second Stage)
10DFT1217 Input Shaft Holder
UN04FEB03
17. Remove clutch pack lifting plate.
OUO1020,000110F 1926NOV025/5
TM2111 (30MAY03)
03-0350-97

053003
PN=209
03
0350
97
Input Shaft (First Stage) and Sixth Stage

(Idler Gear) RepairTorque Converter
Machines
1. Remove and discard bearing cones (A and B).
UN28MAR01
ABearing Cone
BBearing Cone
YZ4161
UN28MAR01
YZ4160
03
0350
98

TM2111 (30MAY03)
03-0350-98
OUO1065,0000594 1927NOV021/2

053003
PN=210

IMPORTANT: Press only on the inner race of bearing
cone. Do not reuse bearing cones if
removed.
NOTE: Gear and shaft assemblies are serviced as an

assembly. If either the gear or shaft is damaged
or worn, entire assembly must be replaced.
2. Use JDG1105 Bearing Driver and JDG1108 Clutch
Bearing Driver (A) to install new bearing cones (B) on
both ends of shaft. Push bearing tight against shaft
shoulder.
AJDG1108 Clutch Bearing Driver
BBearing Cone
YZ1134
UN23DEC97
03
0350
99

OUO1065,0000594 1927NOV022/2
TM2111 (30MAY03)
03-0350-99

053003
PN=211
Clutch Pack RepairTorque Converter Machines
YZ4152
UN26MAR01
03
0350
,100
High and Low Forward Clutch Packs (Second Stage)

ASeal Ring (3 used)
BBall Bearing (2 used)
CRetaining Ring (2 used)
DBearing (2 used)
EGear
FO-Ring (2 used)
GBearing with Seal (2 used)
HInternal Snap Ring (2 used)

IClutch Plate Retainer (2
used)
JClutch Plate (18 used)
KClutch Separator Plate (20
used)
LRetaining Ring (2 used)

MSnap Ring Retainer (2
used)
NClutch Return Spring (12
used)
OLube Shut-Off Washer (2
used)
TM2111 (30MAY03)
03-0350-100
PO-Ring (2 used)
QClutch Piston (2 used)
RPiston Outer Seal (2 used)
SSecond Stage Shaft
TGear
OUO1065,0000595 1927NOV021/38

053003
PN=212
YZ4153
UN26MAR01
03
0350
,101
High and Low Reverse Clutch Packs (Third Stage)

ASeal Ring (3 used)
BBall Bearing (2 used)
DBearing (2 used)
EGear
FO-Ring (2 used)
GBearing with Seal (2 used)
HInternal Snap Ring (2 used)

IClutch Plate Retainer (2
used)
JClutch Plate (18 used)
KClutch Separator Plate (20
used)
LRetaining Ring (2 used)

MSnap Ring Retainer (2
used)
NClutch Return Spring (12
used)
OLube Shut-Off Washer (2
used)
TM2111 (30MAY03)
03-0350-101
PO-Ring (2 used)
QClutch Piston (2 used)
RPiston Outer Seal (2 used)
SThird Stage Shaft
TGear
OUO1065,0000595 1927NOV022/38

053003
PN=213
YZ4154
UN26MAR01
03
0350
,102
First and Third Speed Clutch (Fourth Stage)

ASeal Ring (3 used)
BBearing (2 used)
DBall Bearing (2 used)
EClutch Gear
FBall Bearing (2 used)
GSnap Ring (2 used)

HClutch Plate Retainer (2
used)
IClutch Plate (20 used)
JClutch Separator Plate (20
used)
KRetaining Ring (2 used)

LSnap Ring Retainer (2
used)
MClutch Return Spring (12
used)
NLube Shut-Off Washer (2
used)
TM2111 (30MAY03)
03-0350-102
OO-Ring (2 used)
PClutch Piston (2 used)
QPiston Outer Seal (2 used)
RFourth Stage Shaft
SClutch Gear
OUO1065,0000595 1927NOV023/38

053003
PN=214
YZ4151
UN24MAR01
Second and Fourth Speed Clutch (Fifth Stage)

ASeal Ring (2 used)
BBearing (2 used)
CRetaining Ring
DBall Bearing
EClutch Gear
FBall Bearing
GSnap Ring
HClutch Plate Retainer
IClutch Plate (10 used)
JClutch Separator Plate (10
used)
KRetaining Ring
LSnap Ring Retainer
MClutch Return Spring (6
used)
NLube Shut-Off Washer
TM2111 (30MAY03)
03-0350-103
OO-Ring
PClutch Piston
QPiston Outer Seal
RFifth Stage Shaft
SSnap Ring
OUO1065,0000595 1927NOV024/38

053003
PN=215
03
0350
,103
YZ4164
UN28MAR01
AFifth Stage - Two Seal Rings

BFifth Stage - Empty Clutch Cavity
YZ4165
UN28MAR01
03
0350
,104
TM2111 (30MAY03)
03-0350-104
OUO1065,0000595 1927NOV025/38

053003
PN=216

Clutch Pack DisassembleTorque Converter
Machines
Clutch PackTorque Converter MachinesSpecification
Second StageWeight ................................ 46.6 kg (103 lb) approximate
Third StageWeight .................................... 45.2 kg (100 lb) approximate
Fourth StageWeight ....................................... 35 kg (77 lb) approximate
Fifth StageWeight ....................................... 26.3 kg (58 lb) approximate

NOTE: The disassembly and assembly of clutch packs

are similar; therefore, procedures for
disassembling and assembling clutch packs are
outlined one time. Follow these procedures when
disassembling and assembling both direction and
speed clutch packs. Second stage clutch packs
are shown, unless otherwise indicated.
UN23DEC97
03
0350
,105
YZ1121
1. If necessary, JDG1106 Clutch Lifting tool can be used

to lift clutch.
JDG1106 Clutch Lifting ToolFourth Stage

Shown
TM2111 (30MAY03)
03-0350-105
OUO1065,0000595 1927NOV026/38

053003
PN=217

NOTE: The second speed clutch pack or fifth stage
differs from the other clutch packs. It has two seal
rings (A), instead of three and one clutch pack.
One end of fifth stage shaft assembly has an
empty clutch cavity (B).
UN28MAR01
2. Remove seal rings.
YZ4164
AFifth StageTwo Seal Rings

BFifth StageEmpty Clutch Cavity
YZ4165
UN28MAR01
03
0350
,106
TM2111 (30MAY03)
03-0350-106
OUO1065,0000595 1927NOV027/38

053003
PN=218

3. Remove seal rings (A).
YZ4167
UN28MAR01
03
0350
,107
TM2111 (30MAY03)
03-0350-107
OUO1065,0000595 1927NOV028/38

053003
PN=219

IMPORTANT: Use shaft protector when using bearing
puller.
4. Install bearing puller (B).
5. Install gear puller (A) on bearing puller.
UN28MAR01
6. Remove ball bearing (C).

installing or removing retaining rings.
UN28MAR01
AGear Puller
BBearing Puller
CBall Bearing
DRetaining Ring
YZ4166
03
0350
,108
YZ4163
7. Remove retaining ring (D).
TM2111 (30MAY03)
03-0350-108
OUO1065,0000595 1927NOV029/38

053003
PN=220

puller.
9. Remove clutch gear (A).
YZ4168
UN28MAR01
AClutch Gear
OUO1065,0000595 1927NOV0210/38
10. Remove ball bearing (A).
YZ4169
UN28MAR01
ABall Bearing
TM2111 (30MAY03)
03-0350-109
OUO1065,0000595 1927NOV0211/38

053003
PN=221
03
0350
,109

low reverse) (third stage) assemblies only, remove
O-ring (A). Inspect for wear or damage.
UN28MAR01
AO-Ring
YZ4170
03
0350
,110
OUO1065,0000595 1927NOV0212/38

removing snap ring.
YZ407
UN25MAR97
BSnap Ring
TM2111 (30MAY03)
03-0350-110
OUO1065,0000595 1927NOV0213/38

053003
PN=222

13. Turn shaft assembly over.
YZ409
UN12MAR97
14. Remove clutch plate retainer, clutch plates and

separator plates.
OUO1065,0000595 1927NOV0214/38

puller.
16. Remove and discard bearing (A).
YZ406
UN19APR97
ABearing
TM2111 (30MAY03)
03-0350-111
OUO1065,0000595 1927NOV0215/38

053003
PN=223
03
0350
,111

Clutch Piston Repair
CAUTION: Clutch piston return springs are
under pressure.
1. Place shaft assembly on press.
2. Use JDG1103 Clutch Pack Spring Compressor (A) to
compress clutch return springs.
3. Remove retaining ring (B) from shaft groove. Inspect
for wear or damage.
YZ410
AJDG1103 Clutch Pack Spring Compressor

BRetaining Ring
OUO1065,0000595 1927NOV0216/38
5. Lift out retaining ring (A), snap ring retainer (B) and
clutch return springs (C).
YZ463
UN21AUG96
ARetaining Ring
BSnap Ring Retainer
CClutch Return Springs
OUO1065,0000595 1927NOV0217/38
6. Remove lube shut off washer (D).
UN21AUG96
YZ464
03
0350
,112
UN29APR97
4. Relieve pressure on compressor tool.
TM2111 (30MAY03)
03-0350-112
OUO1065,0000595 1927NOV0218/38

053003
PN=224
7. Remove piston. If needed apply 69 kPa (0.7 bar) (10

psi) maximum, regulated air pressure through oil
passage to force clutch piston from shaft assembly.
UN20AUG96
Clutch PistonSpecification
Maximum Regulated Air
Pressure ............................................................. 69 kPa (0.7 bar) (10 psi)
YZ414

Use only regulated, compressed air of 69 kPa
(0.7 bar) (10 psi) maximum to remove piston.
03
0350
,113
OUO1065,0000595 1927NOV0219/38
8. Remove clutch piston (A).

9. Remove piston outer seal (B) and O-ring (C) from
clutch piston.
UN20AUG96
11. For complete disassembly of this shaft, repeat

disassembly steps for clutch pack assembly on
opposite end of this shaft.
YZ415
AClutch Piston
BPiston Outer Seal
CO-Ring
TM2111 (30MAY03)
03-0350-113
OUO1065,0000595 1927NOV0220/38

053003
PN=225

Clutch Pack Assemble Torque Converter Machines
UN20AUG96
Inspect clutch piston bore for sharp

edges or wear. Use care not to damage
seals on pistons during installation.
1. Lubricate and install new O-ring (A).
YZ416
2. Lubricate and install new piston outer seal (B).

3. Install clutch piston (C) with raised center boss up.
AO-Ring
BPiston Outer Seal
CClutch Piston
OUO1065,0000595 1927NOV0221/38
4. Install lube shutoff washer (D).
UN21AUG96
YZ413
03
0350
,114
TM2111 (30MAY03)
03-0350-114
OUO1065,0000595 1927NOV0222/38

053003
PN=226
UN20MAR97
IMPORTANT: Install clutch piston return springs as

shown for proper spring force.
5. Install clutch return springs (A) as three pairs with
outer diameters contacting for each pair.
YZ853
AClutch Return Springs
YZ417
UN14AUG96
03
0350
,115
OUO1065,0000595 1927NOV0223/38
IMPORTANT: Wear proper eye protection when

6. Put snap ring retainer (B) and retaining ring (C) on
shaft.
UN19APR97
7. Compress clutch return springs using JDG1103 Clutch

Pack Spring Compressor.
YZ418
BSnap Ring Retainer

CRetaining Ring
TM2111 (30MAY03)
03-0350-115
OUO1065,0000595 1927NOV0224/38

053003
PN=227

8. Install retaining ring (C) in groove.
UN19APR97
9. Release pressure on clutch return springs slowly. Be

sure snap ring retainer is properly positioned.
YZ410A
CRetaining Ring
03
0350
,116
OUO1065,0000595 1927NOV0225/38
IMPORTANT: For direction clutch packs (high and

low forward) (second stage) and
direction clutch packs (high and low
reverse) (third stage) ONLY, install two
clutch separator plates first.
NOTE: Clutch separator plates are steel with external

spline teeth. Clutch plates have a lining material
on the face and internal spline teeth.
YZ4182
UN05APR01

low reverse) (third stage) clutch assemblies, first
install two clutch separator plates (A). On first and
third speed clutch packs (fourth stage) and second
speed clutch pack (fifth stage) clutch assemblies, first
install one clutch separator plate.
AClutch Separator Plates
TM2111 (30MAY03)
03-0350-116
OUO1065,0000595 1927NOV0226/38

053003
PN=228

11. Install one clutch plate (B).
YZ4183
UN05APR01
BClutch Plate
OUO1065,0000595 1927NOV0227/38
12. Install remaining plates alternately and end with clutch

plate.
NOTE: Last plate is a clutch plate.
YZ4186
UN05APR01
CClutch Separator Plate
TM2111 (30MAY03)
03-0350-117
OUO1065,0000595 1927NOV0228/38

053003
PN=229
03
0350
,117

IMPORTANT: Second and third shaft assemblies have
three locations with two spline teeth
missing (C) and one location with one
spline tooth missing (B). Fourth and
fifth shaft assemblies have six locations
with one spline tooth missing. The
clutch plate retainer lug (A) fits in any
of the locations with one spline tooth
missing (B).
13. Install clutch plate retainer (A).
YZ4185
IMPORTANT: Check that clutch and separator plates

do not bind.
IMPORTANT: Fifth stage assembly has one clutch
pack.
15. Check clutch plates for clearance to allow for piston
travel after assembly. Replace clutch plates as
necessary to obtain proper clearance.
Clutch Pack Assemble Torque Converter MachinesSpecification
Clutch Plate (Second and Third
Clutch Plate (Fourth and Fifth
UN05APR01

BOne-Spline Tooth Missing Location
CTwo-Spline Teeth Missing Location
DSnap Ring
YZ4181
03
0350
,118
UN05APR01

installing snap ring.
TM2111 (30MAY03)
03-0350-118
OUO1065,0000595 1927NOV0229/38

053003
PN=230

IMPORTANT: Make sure clutch retainer (A) is in place
and the snap ring (B) is seated.
16. Procedure For Checking Clutch Plate Clearance
At Full Piston Travel.
a. Zero dial indicator.
UN24AUG01

Use only regulated compressed air.
IMPORTANT: There are two cross-drilled holes in the

seal ring end of the shaft. The hole
located between the first and second
seal ring groove (D) applies to the
bottom clutch pack and the hole located
between the second and third seal ring
groove (C) applies to the top clutch
pack. In case the wrong hole is
pressurized, make sure that the other
clutch on the shaft is either completely
built with clutch plate retainer (A) in
place and snap ring (B) seated, or that
there are no parts installed which may
be expelled by the air pressure
YZ4209
b. Position stem of a long-stem dial indicator against

clutch piston, in axial direction of shaft.
AClutch Retainer
BSnap Ring
CClutch Oil Pressure Passage
DClutch Oil Pressure Passage
Fifth stage assembly has one clutch

pack.
c. Apply regulated air pressure to piston, maximum of
620 kPa (6.20 bar) (90 psi) to appropriate hole (C
or D), depending on which clutch pack you are
checking.
d. Read the indicator. This measurement is clutch
pack clearance.
TM2111 (30MAY03)
03-0350-119
OUO1065,0000595 1927NOV0230/38

053003
PN=231
03
0350
,119

IMPORTANT: Clutch plate splines must be aligned
before installing bearings on the shaft
assembly to avoid clutch plate damage.
17. Use clutch gear to align clutch plates and separator
plates.
18. Move clutch gear clockwise, then counterclockwise,
working clutch gear spline through clutch and
separator plates. Remove clutch gear.
OUO1065,0000595 1927NOV0231/38
03
0350
,120
TM2111 (30MAY03)
03-0350-120

053003
PN=232

IMPORTANT: Seal side of bearing must be toward
clutch return springs. Lubricate bearing
to prevent dry start-up of transmission.
Press only on inner race of ball bearing.
19. Install ball bearing (A), with seal side down. Install
bearing until bearing inner race contacts shoulder of
shaft.
ABall Bearing
YZ4179
UN05APR01
YZ4180
UN05APR01
03
0350
,121
TM2111 (30MAY03)
03-0350-121
OUO1065,0000595 1927NOV0232/38

053003
PN=233

20. On second and third stage clutch assemblies only,
lubricate and install new O-ring (A).
UN28MAR01
AO-Ring
YZ4170
03
0350
,122
OUO1065,0000595 1927NOV0233/38
IMPORTANT: Forcing clutch gear through clutch

plates can damage clutch plates if
plates are not properly aligned. Use
care not to damage O-ring (B).
21. Install clutch gear (A). O-ring (B) must fit into bore of
clutch plate retainer (C).
YZ4171
UN29MAR01
AClutch Gear
BO-Ring
CClutch Plate Retainer
TM2111 (30MAY03)
03-0350-122
OUO1065,0000595 1927NOV0234/38

053003
PN=234

IMPORTANT: Start bearing (D) into clutch gear. DO
NOT press bearing below ring groove in
shaft. Pressing the bearing all the way
into the gear will preload the bearing.
Preloading bearing will shorten the life
of the bearing.
22. Put new bearing (D) onto clutch gear. Start bearing
into bore only.
23. Install retaining ring (E) on shaft assembly.
UN29MAR01
IMPORTANT: Press only on retaining ring. DO NOT

preload bearing.
YZ4172
24. Using a press and tool (cylinder) (F), push slowly on

retaining ring until retaining ring fits into groove of
shaft assembly.
Clutch gear must turn. Check for 0.25 mm (0.010 in.)
end play of gear using a dial indicator.
Clutch Pack Assemble Torque Converter MachinesSpecification
Clutch GearEnd Play .............................................. 0.25 mm (0.010 in.)
YZ4173
UN29MAR01
DBearing
ERetaining Ring
FTool
TM2111 (30MAY03)
03-0350-123
OUO1065,0000595 1927NOV0235/38

053003
PN=235
03
0350
,123

25. Lubricate and install ball bearing (G).
26. Press bearing onto shaft until bearing contacts
retaining ring.
27. Assemble opposite end of shaft by repeating these
assembly steps.
GBall Bearing
YZ4174
UN29MAR01
03
0350
,124
OUO1065,0000595 1927NOV0236/38
IMPORTANT: Always use new seal rings. The seal

rings must fit the shaft groove tightly to
avoid damage to the seal during
installation of front housing.
28. Lubricate and install three seal rings (A) into ring
grooves.
YZ4167
UN28MAR01
TM2111 (30MAY03)
03-0350-124
OUO1065,0000595 1927NOV0237/38

053003
PN=236

NOTE: Fifth stage assembly has two seal rings (A).
29. Lubricate and install two seal rings (A) into ring
grooves.
YZ4164
UN28MAR01
5th Stage Seal Rings

03
0350
,125
OUO1065,0000595 1927NOV0238/38
Seventh Stage (Output Gear) RepairTorque

Converter Machines
1. Use a bearing puller to remove bearing cones (A).
Discard bearing cones.
YZ1135
UN12JAN98
ABearing Cones
TM2111 (30MAY03)
03-0350-125
OUO1020,000111D 1914JAN031/2

053003
PN=237

IMPORTANT: Push on inner race of bearing only.
2. Install bearing cones (A) on both ends of gear and
shaft assembly using a press and JDG1107 Bearing
Driver. Push bearing tight against shoulder of shaft.
ABearing Cone
YZ1136
UN23DEC97
03
0350
,126
OUO1020,000111D 1914JAN032/2
TM2111 (30MAY03)
03-0350-126

053003
PN=238
Rear Transmission Housing RepairTorque Converter Machines
YZ4145
UN23MAR01
03
0350
,127
Rear View of Rear Housing

ARear Housing
BO-Ring (2 used)
CCylinder Speed Pickup
Sensor
DMagnetic Pickup Cover (2

used)
EWasher (4 Used)
FLock Washer (4 used)

GCap Screw (4 used)
HOutput Shaft Pickup
Sensor
TM2111 (30MAY03)
03-0350-127
IIdentification Plate
JDrive Screw (2 Used)
OUO1020,0001121 1914JAN031/2

053003
PN=239

NOTE: Disassemble only if parts are damaged and must
be replaced.
1. Inspect bearing cups for wear and damage.
2. Remove bearing cups (A).
IMPORTANT: Always use a bearing cup driver to
install bearing cups.
3. Install new bearing cups. Bearing cups must be
installed tight against housing shoulder.
ABearing Cups
YZ1142
UN23DEC97
03
0350
,128
OUO1020,0001121 1914JAN032/2
TM2111 (30MAY03)
03-0350-128

053003
PN=240
Front and Rear Housing AssembleTorque

Converter Machines
IMPORTANT: Use guide pins during assembly to
guide the front housing onto the rear
housing. Pins will help prevent damage
to seal rings.
UN23MAR01
1. Install guide pins in rear housing.
YZ4146
2. Attach DFT1156 Transmission Housing Lifting Bracket

to front housing (A). See DFT1156 Transmission
Housing Lifting Bracket. (Group 9900.)
3. Clean mounting surfaces on front and rear housings
with isopropyl alcohol or equivalent.
03
0350
,129
4. Lubricate all bearings, bore sleeves and seal rings

before installing front housing.
T163695B
5. Apply high flex form-in-place gasket to rear housing

mounting surface. Using a small roller will help to apply
a thin, even layer of adhesive. Excess gasket material
should be wiped from joint. Installation should occur
within three minutes of application. Allow a minimum of
30 minutes of cure time before adding oil.
UN14JAN03

material.
AFront Housing
BDFT1156 Transmission Housing Lifting
Bracket

Front and Rear Housing AssembleSpecification
6. Lower front housing onto rear housing.

7. Install six cap screws evenly spaced in front housing
snug tight.
8. Remove guide pins and install remaining cap screws
(C) snug tight.
9. Remove lifting bracket (B).
TM2111 (30MAY03)
03-0350-129
OUO1020,0001122 1914JAN031/3

053003
PN=241
T163697
UN15JAN03
03
0350
,130
10. Tighten cap screws to specification in sequence

shown. Repeat tightening sequence a second
time.
Front and Rear Housing AssembleSpecification

Front Housing-to-Rear Housing
Cap ScrewTorque ................................................. 87 Nm (64 lb-ft)
TM2111 (30MAY03)
03-0350-130
OUO1020,0001122 1914JAN032/3

053003
PN=242

11. Position JDG1519 Seal Protector over output shaft.
1
outside diameter of oil seal (1) and grease seals (2).
2
13. Apply thin layer of petroleum jelly to inner seal lip of
oil seal (1) and grease seals (2).
15. Use JDG1737 Seal Driver to install first grease seal

(2) to bottom of seal bore in transmission housing
T163701
T163701
16. Use JDG1738 Seal Driver to install second grease

seal (2) until flush with shoulder in transmission
housing.
UN21JAN03
14. Use JDG1736 Seal Driver to install oil seal (1) until
flush with shoulder in transmission housing.
T163700B
UN14JAN03
1Oil Seal
3Grease Fitting
4JDG1738 Seal Driver
5Grease Seal
OUO1020,0001122 1914JAN033/3
TM2111 (30MAY03)
03-0350-131

053003
PN=243
03
0350
,131
03
0350
,132
TM2111 (30MAY03)
03-0350-132

053003
PN=244
Group 0360
Hydraulic System
InstallDirect Drive Machines
1. Remove hydraulic pump. See Hydraulic Pump
UN19JUL00
IMPORTANT: Differential lock pump must be removed

to eliminate the potential of the
differential lock pump splined coupler
(B) dropping into the transmission
during transmission charge pump
removal.
2. Remove cap screws (A) and washers and lay
differential lock pump aside.
T132624C
3. Remove splined coupler (B).

ACap Screws
BSplined Coupler
T113855C
UN13MAY98
Grapple Machine Shown
TM2111 (30MAY03)
03-0360-1
CED,OUO1032,3395 1914JAN031/5

053003
PN=245
03
0360
1
Hydraulic System
4. Remove cap screw (A) holding clamp and wire
harness.
5. Disconnect hydraulic hoses (B and D).
NOTE: Bearings and splined coupler are slip-fit in both

the charge pump housing and the transmission
housing. The bearings and coupler may or may
not come out with the charge pump when charge
pump is removed.
UN10APR98
T113847B
ACap Screw
BCharge Pump-to-Transmission Filter Hose
CCap Screw (4 used)
DSuction Hose
T113848B
03
0360
2
UN10APR98
6. Remove cap screws (C) to remove charge pump.
TM2111 (30MAY03)
03-0360-2
CED,OUO1032,3395 1914JAN032/5

053003
PN=246
Hydraulic System
7. Inspect O-ring (A) in transmission pump flange for
wear or damage. Replace as required.
8. Remove bearing and splined coupler (B).
UN10APR98
9. Inspect bearings and splined coupler, replace if

necessary.
T113850B
10. Apply OPTIMOLY PASTE WHITE T to pump splines.

11. Install splined coupler on charge pump before
installing on transmission housing.
AO-Ring
BSplined Coupler
T113851B
UN10APR98
03
0360
3
TM2111 (30MAY03)
03-0360-3
CED,OUO1032,3395 1914JAN033/5

053003
PN=247
Hydraulic System
12. Position charge pump on transmission case.
13. Install and tighten cap screws (C).
Transmission Charge PumpDirect Drive MachinesSpecification
Charge Pump-to-Transmission
Housing Cap ScrewTorque.......................................... 73 Nm (55 lb-ft)
14. Install suction hose (D).

IMPORTANT: Pump must be filled with oil prior to
start-up to prevent pump damage.
T113848B
16. Rotate fitting on pump 90 counterclockwise and

install hose (B).
17. Install cap screw (A) which holds clamp and wire
harness.
UN10APR98
ACap Screw
BCharge Pump-to-Transmission Filter Hose
CCap Screw (4 used)
DSuction Hose
T113847B
03
0360
4
UN10APR98
15. Rotate fitting that hose (B) connects to on pump 90

clockwise and fill pump with oil.
TM2111 (30MAY03)
03-0360-4
CED,OUO1032,3395 1914JAN034/5

053003
PN=248
Hydraulic System
18. Install spline coupler (B).
19. Install differential lock pump and fasten with cap
screws (A).
UN13MAY98
20. Install hydraulic pump. See Hydraulic Pump

T113855C
21. Test run machine and check for leaks. See

Transmission, Hydraulic System, Park Brake,
Differential, Cab Hydraulic Pump and Winch Oil
03
0360
5
T132624C
UN19JUL00
ACap Screws
BSpline Coupler

CED,OUO1032,3395 1914JAN035/5
TM2111 (30MAY03)
03-0360-5

053003
PN=249
Hydraulic System

InstallTorque Converter Machines
1. Remove hydraulic pump. See Hydraulic Pump
UN04APR01
2. Disconnect hoses (3 and 4).
3. Remove cap screws (2), pump (1), and splined coupler

assembly.
1Transmission Charge Pump
2Cap Screw (3 used)
3Charge Pump Outlet Hose
4Charge Pump Inlet Hose
OUO1020,00010E4 1902APR011/3
IMPORTANT: Always use NEW O-rings. Old or

damaged O-rings will leak.
UN04APR01
4. Apply petroleum jelly on new O-ring (2) and install on

charge pump flange.
5. Inspect bearings on splined coupler (1) and replace as
necessary.
T140966B
6. Install splined coupler into converter housing (3).

7. Apply OPTIMOLY PASTE WHITE T to pump splines.
UN04APR01
1Splined Coupler
2O-Ring
3Converter Housing
T140967B
03
0360
6
T140965B
NOTE: Bearings and splined coupler assembly are slip-fit

in both the pump housing and the converter
housing. The bearings and coupler may or may
not come out with the pump when pump is
removed.
TM2111 (30MAY03)
03-0360-6
OUO1020,00010E4 1902APR012/3

053003
PN=250
Hydraulic System
8. Install pump (1) and cap screws (2). Tighten cap
Transmission Charge PumpTorque Converter Machines
Specification
Charge Pump-to-Converter
Housing Cap ScrewTorque........................................ 100 Nm (74 lb-ft)
UN04APR01
IMPORTANT: Pump must be filled with oil prior to

start-up to prevent pump damage.
10. Install hose (3).
T140965B
9. Install hose (4). Fill pump with clean transmission oil to

bottom of side fitting. See Transmission, Hydraulic
03
0360
7
1Transmission Charge Pump

2Cap Screw (3 used)
3Charge Pump Outlet Hose
4Charge Pump Inlet Hose
11. Install hydraulic pump. See Hydraulic Pump

12. Start engine and check for leaks. See Transmission,
Hydraulic System, Park Brake, Differential, Cab
Hydraulic Pump and Winch Oil. (Operators Manual.)
OUO1020,00010E4 1902APR013/3
TM2111 (30MAY03)
03-0360-7

053003
PN=251
Hydraulic System
Thermal Bypass Valve RepairTorque

Converter Machines
1. Remove right engine side shields.
UN03APR01
NOTE: After disconnecting line (4) hold end of line as

high as possible and install a plug to retain as
much oil in cooler as possible.
T140853B
2. Disconnect line (4) and close open line with a plug to

retain oil in cooler.
3. Disconnect lines (13) and (7). Close all line openings
with plugs to prevent system contamination.
03
0360
8
4. Remove cap screws and washers (5) and clamp (6).
1Transmission Return Line

2Transmission Filter Relief Valve Line
3Torque Converter Out Line
4Cooler Inlet Line
5Cap Screw and Washer (2 used)
6Clamp
7Cooler Outlet Line
TM2111 (30MAY03)
03-0360-8
OUO1020,00010E2 1914JAN031/2

053003
PN=252
Hydraulic System
NOTE: Throat opening of C-clamp or hand press must be
approximately 76 mm (3 in.) larger than valve
from end of top cover-to-end of bottom cover.
5. Using a hand press or C-clamp with sufficient throat
opening, retain top and bottom covers (2 and 7) to
valve housing (5).
6. Remove nuts (8) and carefully open hand press or
C-clamp to relieve spring (9) tension.
7. Disassemble and replace parts as necessary.
03
0360
9
8. Assemble parts as shown using hand press or C-clamp

to compress spring.
UN03APR01
9. Install cap screws (1) and nuts. Tighten nuts to

specification.
T121110
Thermal Bypass ValveSpecification

Thermal Bypass Valve Housing
NutsTorque ............................................................... 12 Nm (102 lb-in.)
10. Install valve, clamp, cap screws and washers.

11. Connect lines using new O-rings and tighten all hose
fittings.
12. Start engine and check for leaks.
1Cap Screw (4 used)

2Top Cover
3O-Ring
4Thermostat
5Housing
6Seal Assembly
7Bottom Cover
8Nut (4 used)
9Spring
10Repair Kit

14. Install right engine side shields.
OUO1020,00010E2 1914JAN032/2
TM2111 (30MAY03)
03-0360-9

053003
PN=253
Hydraulic System
03
0360
10
TM2111 (30MAY03)
03-0360-10

053003
PN=254
Section 04
Engine
Contents
Page

POWERTECH 4.5 L and 6.8 L Diesel
EnginesBase EngineUse CTM104 . . .04-0400-1
POWERTECH 4.5 L & 6.8 L Diesel Engines
Level 12 Electronic Fuel System with
Stanadyne DE10 PumpUse CTM331 . . .04-0400-2
POWERTECH 8.1 L Diesel Engines
Base EngineUse CTM86 . . . . . . . . . . . .04-0400-3
POWERTECH 8.1 L Level 9 Electronic Fuel
System with High Pressure Common RailUse
CTM255. . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-4
Engine Remove and InstallDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-4
Engine Remove and InstallTorque
Converter Machines. . . . . . . . . . . . . . . . .04-0400-17
TM2111 (30MAY03)
04-1
04

053003
PN=1
Contents
04
TM2111 (30MAY03)
04-2

053003
PN=2
Group 0400

POWERTECH 4.5 L and 6.8 L Diesel
EnginesBase EngineUse CTM104
For additional engine information, the component technical
manual (CTM) is also required.
Refer to the following in CTM104.
General Engine Operation
Lubrication System Operation
Cooling System Operation
Air Intake and Exhaust System Operation
Air Cleaner Operation
Turbocharger Operation
04
0400
1
POWERTECH is a trademark of Deere & Company
TM2111 (30MAY03)
OUO1065,0000585 1904OCT021/1
04-0400-1

053003
PN=257
POWERTECH 4.5 L & 6.8 L Diesel Engines

Level 12 Electronic Fuel System with
Stanadyne DE10 PumpUse CTM331
Fuel System Operation
Fuel Supply Pump Operation
Final Fuel Filter Operation
Fuel Injection Pump Operation
Fuel Injection Nozzle Operation
Electronic Control System Terminology
04
0400
2
Electronic Control System Overview

Electronic Control System Operation
Refer to the following theory of operation in this manual
for more information.
Electronic Fuel Injection System Operation. (Group
9015-15.)
TM2111 (30MAY03)
OUO1065,0000583 1904OCT021/1
04-0400-2

053003
PN=258
POWERTECH 8.1 L Diesel EnginesBase

EngineUse CTM86
General Engine Operation
Lubrication System Operation
Cooling System Operation
Air Intake and Exhaust System Operation
Turbocharger Operation
04
0400
3
TM2111 (30MAY03)
OUO1065,0000588 1908OCT021/1
04-0400-3

053003
PN=259
POWERTECH 8.1 L Level 9 Electronic Fuel

System with High Pressure Common Rail
Use CTM255
Fuel System Operation
Primary Fuel Filter Operation
Fuel Transfer Pump Operation
Final Fuel Filter Operation
High Pressure Fuel Pump Operation
High Pressure Common Rail (HPCR) Operation
04
0400
4
Electronic Injector (EI) Operation

Electronic Control System Overview
Refer to the following theory of operation in this manual
for more information.
Electronic Fuel Injection System Operation (Group
9015-15.)
OUO1065,0000587 1908OCT021/1
Engine Remove and InstallDirect Drive Machines

NOTE: 540G-III, 548G-III, 360D shown. 640G-III,
648G-III, 460D and 748G-III, 560D are similar.
1. Remove engine side shields.
2. Turn battery disconnect switch to OFF position.

3. Remove hood. See Hood Remove and Install.
(Group 1910.)
TM2111 (30MAY03)
04-0400-4
OUO1017,00003A8 1910JAN031/15

053003
PN=260
CAUTION: Coolant may be hot. Wait until

radiator is cool to the touch before draining
coolant.
T6642EK
UN01NOV88
4. Drain coolant from radiator at radiator drain cock (2)

through drain hose (1). The approximate cooling
system capacity for 6.8 L engine is 21.5 L (22.7 qt),
8.1 L engine is 30 L (33.8 qt). Dispose of used coolant
properly.
5. Remove fan guards. See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)
6. Remove radiator overflow reservoir.
UN29OCT02
7. Remove air conditioner condenser mounting cap

screws and set condenser aside. See Air Conditioning
Condenser Remove and Install. (Group 1830.)
T160903B
8. Remove grille and grille housing. See Grille and Grille

Housing Remove and Install. (Group 1921.)
Remove radiator. See Radiator and Oil Cooler Remove
and InstallDirect Drive Machines. (Group 0510.)
9. Remove fan belt. See Fan Belt Remove and Install.
(Group 0510.)
1Drain Hose
2Radiator Drain Cock
OUO1017,00003A8 1910JAN032/15
10. Disconnect compressor clutch wire connector (3).

11. Disconnect ground wire (4).
UN29OCT02
12. Remove cap screws (5) and remove compressor and

lay on left front tire.
T160906B
3Compressor Clutch Wire Connector

4Compressor Ground Wire
5Cap Screw (4 used)
TM2111 (30MAY03)
04-0400-5
OUO1017,00003A8 1910JAN033/15

053003
PN=261
04
0400
5

13. Disconnect connectors (6, 811, and 15).
14. Remove wire harness clamps (7 and 16) and move
harness away from engine. Cut wire ties as
necessary.
15. Disconnect fuel leak-off line (17).
UN30OCT02
16. Disconnect positive battery cable and clamp (18).

17. Disconnect negative battery cable (19) at disconnect
switch.
T160907B
UN30OCT02
540G-III, 548G-III, 360D Shown
T160908B
04
0400
6
3Air Compressor Clutch Connector

4Air Conditioner Compressor Ground Wire
6Harness-to-Manifold Air Temperature Sensor
Connector
7Wire Harness Clamp (2 used)
8Temperature Sender Wire Connector
9Fuel Temperature Sensor Connector
10Fuel Control Solenoid Connector
11Oil Pressure Sender Wire Connector
12ECU Connector
15Crankshaft Position Sensor Connector
16Wire Harness Clamp
17Fuel Leak-off Line
18Positive Battery Cable Clamp
19Negative Battery Cable
TM2111 (30MAY03)
04-0400-6
OUO1017,00003A8 1910JAN034/15

053003
PN=262
T161138B
UN14JAN03

6Manifold Air Temperature
Sensor Connector
20Alternator Positive Wire
21Alternator Harness
Connector
22Start Aid Tubing

23Harness Clamp
24Heater Hose
25Fuel Line
26Heater Hose Clamp
27Heater Hose
18. Disconnect alternator positive wire (20) and

harness (21).
28Starter Solenoid Wires

29Starter Positive Terminal
30Starter Ground Terminal
23. Disconnect start aid tubing (22), if equipped.

24. Disconnect heater hose (24 and 27).
19. Disconnect manifold air temperature sensor

connector (6).
25. Disconnect fuel line (25).
20. Disconnect wires from starter positive terminal (29)

and ground terminal (30).
26. Raise cab.See Hydraulic Cab Tilt Procedure.

(Operators Manual.)
21. Disconnect wires (28) from starter solenoid.
27. Remove engine-to-transmission drive shaft. See

Engine-to-Transmission Drive Shaft Remove and
Install. (Group 0325.)
22. Remove clamps (23 and 26) and move harness

away from engine. Cut wire ties as necessary.
TM2111 (30MAY03)
04-0400-7
OUO1017,00003A8 1910JAN035/15

053003
PN=263
04
0400
7

28. Disconnect cold weather disconnect lever (A), if
equipped.
T7502CV
UN20MAY91
ACold Weather Disconnect Lever
OUO1017,00003A8 1910JAN036/15
CAUTION: Use extreme caution when lifting

engine and NEVER permit any part of the body
to be positioned under an engine being lifted or
suspended.
UN11NOV97
Lift engine with longitudinal loading on lift sling

and lifting brackets only. Angular loading
greatly reduces lifting capacity of sling and
brackets.
RG7784
04
0400
8

648G-III Shown
Engine Remove and InstallDirect DriveSpecification
6.8 L 6068 EngineWeight ........................ 532 kg (1172 lb) approximate
AJDG23 Lifting Sling

BEngine Lifting Straps
IMPORTANT: Front and rear isolators are of different

hardness to control engine vibration.
Mark each one and install in original
position when assembling.
29. Attach JDG23 Lifting Sling (A), or other suitable sling,
to engine lifting straps (B) and overhead hoist or floor
crane.
NOTE: If engine does not have lifting straps, they can be

procured through service parts. Use of an engine
lifting sling (as shown) is the ONLY APPROVED
method for lifting engine.
TM2111 (30MAY03)
04-0400-8
OUO1017,00003A8 1910JAN037/15

053003
PN=264
T130656
UN04MAY00
04
0400
9
1Support
2Angle
3Washer (4 used)
4Cap Screw (8 used)
5Angle
6Cap Screw (2 used)

7Washer (8 used)
8Washer (4 used)
9Isolator (2 used)
10Washer (8 used)
11Nut (4 used)
12Support (without Air
Conditioning)
NOTE: 540G-III, 548G-III, 360D models shown,

640G-III, and 648G-III, 460D, 748G-III, 560D
are similar.

14Isolator (2 used)
15Support (with Air
Conditioning)
31. Lift engine from machine and locate on engine

stand.
32. Inspect and repair engine as necessary.
30. Remove cap screws and nuts (6, 13, and 11).
TM2111 (30MAY03)
04-0400-9
OUO1017,00003A8 1910JAN038/15

053003
PN=265
UN20APR98

suspended.
T114906B

brackets.
540G-III, 548G-III, 360D Cap Screws Shown
33. Install engine into engine frame with rear mounts

attached loosely to engine.
34. Install cap screws (A) for front engine mounts.
T114907B
04
0400
10
UN20APR98
NOTE: 540G-III, 548G-III, 360D shown640G-III,

648G-III, 460D, 748G-III, 560D are similar.
35. Install cap screws (B) for rear engine mounts. Do not
remove hoist from engine at this time. Tighten engine
mount-to-frame cap screws.
Right Side Shown

AFront Engine Mount Cap Screw (2 used)
BRear Engine Mount Cap Screw (2 used)

Front and Rear Engine
Mount-to-Frame Cap Screw
Torque ......................................................................... 620 Nm (457 lb-ft)
36. Install engine-to-transmission drive shaft. See

Engine-to-Transmission Drive Shaft Remove and
TM2111 (30MAY03)
04-0400-10
OUO1017,00003A8 1910JAN039/15

053003
PN=266
04
0400
11
TM2111 (30MAY03)
04-0400-11

053003
PN=267
T114876
1929APR98
04
0400
12
TM2111 (30MAY03)
04-0400-12
OUO1017,00003A8 1910JAN0310/15

053003
PN=268

ATorsional Damper
BDimension at Top of
Damper
CDimension at Bottom of
Damper
DSix-Inch Steel Scale

EDimension at Rear of
Engine Mount (748G-III
only)
FDimension at Front of
Engine Mount (748G-III
only)
GFrame Side Rail
37. Using a six-inch steel scale (D) or depth gauge,

measure distance (B and C) at top and bottom of
torsional damper (A). Measurements for (B and C)
should be less than a 2 mm (0.08 in.) difference.
40. For 748G-III machines only: Rotate front mounts

until measurements (E and F) are less than 1.5
mm (0.06 in.) difference when measured from
frame side rail (G).

Torsional Damper Alignment
540G-III, 548G-III, 360D,
640G-III, 648G-III, 460D
Distance ...................................................................... 2 mm (0.08 in.)

748G-III Front Mount-to-Frame
Side RailDistance ................................ Less than 1.5 mm (0.06 in.)
41. Remove hoist from engine.
38. Raise or lower rear of engine to change

measurement.
39. Once correct measurement is achieved, tighten
mount-to-engine cap screws.
04
0400
13

540G-III, 548G-III, 360D,
640G-III, 648G-III, 460D
Mount-to-Engine Cap Screw
Torque................................................................... 320 Nm (236 lb-ft)
748G-III 560D Mount-to-Engine
OUO1017,00003A8 1910JAN0311/15
42. Connect cold weather disconnect lever (A), if

equipped.
T7502CV
UN20MAY91
ACold Weather Disconnect Lever
TM2111 (30MAY03)
04-0400-13
OUO1017,00003A8 1910JAN0312/15

053003
PN=269
UN14JAN03
T161138B
04
0400
14
548G-III, 360D Shown

Sensor Connector
20Alternator Positive Wire
21Alternator Harness
Connector
22Start Aid Tubing

23Harness Clamp
24Heater Hose
25Fuel Line
26Heater Hose Clamp
27Heater Hose
28Starter Solenoid Wires

29Starter Positive Terminal
30Starter Ground Terminal
43. Install harness with clamps (23 and 26).
47. Connect start aid tubing (22) (if equipped).
44. Connect alternator positive wire (20) and harness

(21).
48. Connect manifold air temperature sensor

connector (6).
45. Connect starter solenoid wires (28).
49. Connect heater hose (24 and 27).
46. Connect starter positive terminal (29) and ground

terminal (30).
50. Connect fuel line (25).
TM2111 (30MAY03)
04-0400-14
OUO1017,00003A8 1910JAN0313/15

053003
PN=270

51. Install wire harness with clamps (7 and 16).
52. Connect connectors (6, 811, and 15).
53. Connect fuel leak-off line (17).
54. Connect positive battery cable and clamp (18).
UN30OCT02
55. Connect negative battery cable (19) at disconnect

switch.
T160907B

(Operators Manual.)
Connector
12ECU Connector
18Positive Battery Cable Clamp
19Negative Battery Cable
T160908B
UN30OCT02
04
0400
15
TM2111 (30MAY03)
04-0400-15
OUO1017,00003A8 1910JAN0314/15

053003
PN=271

57. Connect wire connector (3).
58. Connect ground wire (4).
UN29OCT02
59. Install air conditioning compressor with cap screws

(5).
T160906B
60. Install fan belt. See Fan Belt Remove and Install.
(Group 0510.)
61. Install radiator. See Radiator and Oil Cooler Remove
62. Install fan shroud. See Fan Shroud Remove and

5Cap Screw (4 used)
63. Install grille and grille housing. See Grille and Grille
04
0400
16
64. Install air conditioning condenser. See Air

Conditioning Condenser Remove and Install. (Group
1830.)
65. Install fan guards. See Fan Guards and Fan Blade
66. Install radiator overflow reservoir.
67. Add engine coolant. See Use Correct Fuels and
Lubricants. (Operators Manual.)
68. Add engine oil. See Use Correct Fuels and
69. Install hood. See Hood Remove and Install. (Group
1910.)
70. Turn battery disconnect switch to ON.
71. Test run machine. Check all fluid levels after test run.
72. Install engine side shields.
OUO1017,00003A8 1910JAN0315/15
TM2111 (30MAY03)
04-0400-16

053003
PN=272
Engine Remove and InstallTorque

Converter Machines
3. Remove hood. See Hood Remove and Install. (Group
1910.)
OUO1017,00003A9 1914FEB011/15

coolant.
T6642EK
UN01NOV88

system capacity for 6.8 L engine is 21.5 L (22.7 qt),
8.1 L engine is 30 L (33.8 qt). Dispose of used coolant
properly.
6. Remove radiator overflow reservoir.
UN29OCT02

screws and set condenser aside.
T160903B
9. Remove radiator.See Radiator and Oil Cooler Remove

and InstallDirect Drive Machines (Group 0510.)
10. Remove fan belt. See Fan Belt Remove and Install.
(Group 0510.)
1Drain Hose
TM2111 (30MAY03)
04-0400-17
OUO1017,00003A9 1914FEB012/15

053003
PN=273
04
0400
17

11. Disconnect wire connector (3).
12. Disconnect ground wire (4).
UN29OCT02
13. Remove cap screws (5) and remove compressor and

lay on left front tire.
T160906B

5Cap Screw (4 used)
OUO1017,00003A9 1914FEB013/15
14. Disconnect connectors (6, 811, and 15).

15. Remove wire harness clamps (7 and 16) and move
harness away from engine. Cut wire ties as
necessary.
16. Disconnect fuel leak-off line (17).
UN30OCT02
17. Disconnect negative cables (18) and clamp (19).

18. Disconnect hose clamp (19).
T160907B
19. Disconnect starter wire connections (20).

Connector
12ECU Connector
18Negative Cable
19Clamp
20Starter Wire Connection
UN27JAN03
Engine Left Side
T164346B
04
0400
18
TM2111 (30MAY03)
04-0400-18
OUO1017,00003A9 1914FEB014/15

053003
PN=274
T164350B
UN27JAN03

Sensor Connector
2Alternator Wire Harness
3Charge Air Hose

4Clamp
5Heater Hose
6Fuel Lines
7Radiator Overflow
Reservoir
8Charge Air Hose

9Heater Hose
10Clamp
20. Disconnect alternator wire harness (2).
25. Disconnect start aid tubing (if equipped).

connector (1).
26. Disconnect fuel lines (6).

27. Remove charge air hoses (3 and 8).
22. Remove hose clamp (10).

28. Raise cab. See See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
23. Disconnect heater hoses (5 and 9).

24. Remove clamps (4) and move harness and heater
hose away from engine. Cut wire ties as
necessary.
TM2111 (30MAY03)
04-0400-19
OUO1017,00003A9 1914FEB015/15

053003
PN=275
04
0400
19

29. Remove flywheel access plug (1) and drive plate cap
screw access plug (2).
30. Discard drive plate cap screw access plug (2).
UN27MAR01
31. Install JDE81-1 Flywheel Turning Tool into access

hole (3).
T140270B
32. Rotate engine until drive plate cap screws can be

seen through hole.
33. Continue to rotate engine and remove eight cap
screws and washers (4).
UN27MAR01
1Flywheel Access Plug

2Drive Plate Cap Screw Access Plug
3Access Hole
T140271B
04
0400
20
TM2111 (30MAY03)
04-0400-20
OUO1017,00003A9 1914FEB016/15

053003
PN=276

34. Use DFT1216 Converter Housing Support to support
converter housing. (Group 9900.)
35. Turn adjusting screws (2) to tension tool and support
housing.
36. Disconnect wire connector (4) from speed sensor (5).
37. Remove cap screws (3).
T141080B
UN11APR01
110.9 M12 x 1.75 Cap Screw 30 mm Long (2 used)

2Adjusting Screw (4 used)
4Wire Connector
5Speed Sensor
T141081B
UN11APR01
04
0400
21
TM2111 (30MAY03)
04-0400-21
OUO1017,00003A9 1914FEB017/15

053003
PN=277

suspended.
RG7784
UN11NOV97

brackets.
Engine Remove and InstallTorque ConverterSpecification
T164367B
38. Attach JDG23 Lifting Sling, or other suitable sling, to

engine lifting straps and overhead hoist or floor crane.
NOTE: If engine does not have lifting straps, they can be

procured through service parts. Use of an engine
lifting sling (as shown) is the ONLY APPROVED
method for lifting engine.
UN27JAN03
39. Remove cap screws and nuts (1 and 2).

40. Lift engine up and slide forward away from torque
converter housing.
41. Lift engine out of frame.
T164368B
04
0400
22
UN27JAN03
IMPORTANT: Front and rear isolators are of different

hardness to control engine vibration.
Mark each one and install in original
position when assembling.
42. Repair or replace as required.

AJDG23 Lifting Sling
BEngine Lifting Straps
1Front Mount Cap Screw and Nut
2Rear Mount Cap Screw and Nut
TM2111 (30MAY03)
04-0400-22
OUO1017,00003A9 1914FEB018/15

053003
PN=278

43. Apply anti-seize compound to outside diameter of
converter stub shaft (2) and inside diameter of pilot
sleeve (1), and to flywheel pilot bore. Install pilot
sleeve onto stub shaft.
T140746
UN30MAR01
1Pilot Sleeve
2Converter Stub Shaft
OUO1017,00003A9 1914FEB019/15
04
0400
23
TM2111 (30MAY03)
04-0400-23

053003
PN=279
UN27JAN03

suspended.
T164367B

brackets.
UN27JAN03
44. Install engine in frame.

45. If removed, install engine mount brackets.
640G-III, 648G-III and 460D
Mount Bracket-to-Engine Cap
T164368B
04
0400
24
46. Install cap screws (1 and 2).
1Front Mount Cap Screw

2Rear Mount Cap Screw
47. Tighten cap screws to specifications.

Front Mounts-to-Frame Cap
ScrewsTorque .......................................................... 620 Nm (457 lb-ft)
Rear Mounts-to-Frame Cap
TM2111 (30MAY03)
04-0400-24
OUO1017,00003A9 1914FEB0110/15

053003
PN=280

48. Apply medium strength thread lock and sealer to cap
screws (4).
UN27MAR01
49. Rotate engine and install drive plate cap screws and
washers (4). Tighten to specification.
Drive Plate Cap ScrewsTorque ................................... 47 Nm (35 lb-ft)
T140271B
50. Install plugs (1 and 2).
T140270B
UN27MAR01

3Access Hole
TM2111 (30MAY03)
04-0400-25
OUO1017,00003A9 1914FEB0111/15

053003
PN=281
04
0400
25

51. Use flywheel turning tool, if necessary, to rotate
engine to aid in assembly and align the pilot sleeve
into engine flywheel.
IMPORTANT: Do not use cap screws to pull engine
and housing together. Damage to pilot
sleeve and housings could result.
UN11APR01
52. Install cap screws (3).

T141081B
54. Loosen adjusting screws (2).

55. Remove cap screws (1) and remove DFT1216.
1Cap Screw (2 used)
2Adjusting Screw (4 used)
4Wire Connector
5Speed Sensor
T141080B
UN11APR01
04
0400
26
TM2111 (30MAY03)
04-0400-26
OUO1017,00003A9 1914FEB0112/15

053003
PN=282
T164350B
UN27JAN03

Sensor Connector
2Alternator Wire Harness
3Charge Air Hose

4Clamp
5Heater Hose
6Fuel Lines
7Radiator Overflow
Reservoir
8Charge Air Hose

9Heater Hose
10Clamp
56. Install clamp (10).
60. Connect heater hoses (5 and 9).

connector (1).
61. Install clamps (4).

62. Connect fuel lines (6).
58. Connect alternator wire harness (2).

63. Connect charge air hoses (3 and 8).
59. Connect start aid tubing (if equipped).
TM2111 (30MAY03)
04-0400-27
OUO1017,00003A9 1914FEB0113/15

053003
PN=283
04
0400
27

64. Install wire harness with clamps (7 and 16).
65. Connect connectors (6, 811, and 15).
66. Connect fuel leak-off line (17).
67. Connect negative cables (18) and clamp (19).
UN30OCT02
68. Connect hose clamp (19).

69. Connect starter wire connections (20).

Connector
12ECU Connector
18Negative Cable
19Clamp
20Starter Wire Connection
UN27JAN03
Engine Left Side
T164346B
04
0400
28
T160907B

(Operators Manual.)
TM2111 (30MAY03)
04-0400-28
OUO1017,00003A9 1914FEB0114/15

053003
PN=284

72. Connect ground wire (4).
UN29OCT02
73. Install air conditioning compressor with cap screws

(5).
T160906B
74. Install fan belt. See Fan Belt Remove and Install.
(Group 0510.)
75. Install radiator. See Radiator and Oil Cooler Remove
76. Install fan shroud. See Fan Shroud Remove and

5Cap Screw (4 used)
77. Install grille and grille housing. See See Grille and
Grille Housing Remove and Install. (Group 0510.)
78. Install air conditioner condenser.
04
0400
29
80. Install radiator overflow reservoir.

82. Add engine oil. See Use Correct Fuels and
1910.)
85. Test run machine. Check all fluid levels after test run.
OUO1017,00003A9 1914FEB0115/15
TM2111 (30MAY03)
04-0400-29

053003
PN=285
04
0400
30
TM2111 (30MAY03)
04-0400-30

053003
PN=286
Section 05
Engine Auxiliary Systems

Contents
Page
Group 0505Cold Weather Starting Aids

Starting Aid Solenoid and Nozzle Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1
Engine Coolant Heater Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0505-2
Group 0510Cooling Systems
Fan Guards and Fan Blade Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1
Fan Belt Remove and Install . . . . . . . . . . . . .05-0510-2
Belt TensionerSpring Tension Check . . . . .05-0510-4
Belt Tensioner Remove and Install . . . . . . . .05-0510-5
Fan Shroud Remove and Install . . . . . . . . . .05-0510-5
Radiator and Oil Cooler Remove and
InstallDirect Drive Machines . . . . . . . . . .05-0510-7
Radiator and Oil Cooler Remove and
05
Group 0520Intake System

Air Cleaner Remove and Install. . . . . . . . . . .05-0520-1
Group 0530External Exhaust System
Muffler Remove and Install540G-III,
548G-III, 640G-III, 648G-III . . . . . . . . . . . .05-0530-1
Muffler Remove and Install748G-III . . . . . .05-0530-4
Group 0560External Fuel Supply System
Fuel Tank Remove and Install540G-III,
548G-III, 640G-III. . . . . . . . . . . . . . . . . . . .05-0560-1
748G-III . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-5
TM2111 (30MAY03)
05-1

053003
PN=1
Contents
05
TM2111 (30MAY03)
05-2

053003
PN=2
Group 0505
Cold Weather Starting Aids

Starting Aid Solenoid and Nozzle Remove
and Install
1. Remove start aid tubing (A) from nozzle (F).
UN22JAN98
2. Remove nozzle from holder (B).

3. Clean or replace nozzle as required.
T112888
IMPORTANT: Nozzle must be sealed and tight in

holder to prevent engine damage from
dust. Do not overtighten or nozzle may
break.
4. If nozzle holder is removed, apply thread lock and
sealer (medium strength) to male threads of nozzle
holder.
UN15JUN00
5. Apply thread sealant to threads of nozzle.
T131708B
6. Install nozzle into holder with orifice (G) pointing up

toward center of air inlet so fluid is sprayed into
incoming air flow.
7. Connect start aid tubing (A). Tighten tube nut.
Starting Aid Solenoid and NozzleSpecification
Tube-to-Nozzle Holder Nut
Torque ........................................................................... 6.8 Nm (60 lb-in.)
05
0505
1
UN15JUN00
8. Loosen clamp (E) and lift out canister (D). The base is
part of solenoid (C); they must be removed as an
assembly.
IMPORTANT: To avoid drawing dust into engine,

always keep starting fluid canister in
position, or solenoid cap MUST be in
place when canister is not installed.
10. Install canister and tighten clamp. Install solenoid cap
when a canister is not installed.
T131707B
9. Install base and solenoid.
AStart Aid Tubing

BNozzle Holder
CSolenoid
DCanister
EClamp
FNozzle
GNozzle Orifice
CED,OUO1032,3408 1923JAN031/1
TM2111 (30MAY03)
05-0505-1

053003
PN=289
Cold Weather Starting Aids
Engine Coolant Heater Remove and Install
UN01NOV88

radiator.
T6642EK
1. Drain coolant from radiator into a container. The

approximate cooling system capacity for 6.8 L engine
is 21.5 L (22.7 qt), 8.1 L engine is 30 L (33.8 qt).
Dispose of used coolant properly.
TX,0505,JC576 1923JAN031/2
2. Remove power cord (A). Loosen nut (C) and pull

heating element (G) from block.
UN21OCT88
CAUTION: DO NOT plug coolant heater into

electrical power unless heating element is
immersed in coolant. Element could burst and
result in personal injury.
05
0505
2
3. Put heating element in cylinder block so flats on

threaded portion of element are vertical.
4. Turn element clockwise and then counterclockwise
until element contacts casting. Move element to center
position.
5. Hold element using a wrench and tighten nut (C).
T6427AO
Use a heavy-duty grounded cord to connect

coolant heater to electrical power.
APower Cord
BCap
CNut
DAdapter
EGasket
FO-Ring
GHeating Element
Engine Coolant HeaterSpecification

Heater Element NutTorque .......................................... 34 Nm (25 lb-ft)
IMPORTANT: Air must be removed from cooling

system to prevent cavitation.
6. Loosen engine coolant temperature sender in
thermostat housing or loosen plug at rear of cylinder
head to allow air to escape when filling system.
7. Fill cooling system with proper coolant.See Use
Correct Fuels and Lubricants. (Operators Manual.)
8. Tighten sender or plug when all the air has been
expelled.
TX,0505,JC576 1923JAN032/2
TM2111 (30MAY03)
05-0505-2

053003
PN=290
Group 0510
Cooling Systems
Fan Guards and Fan Blade Remove and
Install
1. If equipped with air conditioning, remove condenser
mounting cap screws move condenser aside.
2. Remove cap screws (1, 4, 5, and 7) to remove fan
guards.
UN27JAN03
3. Remove fan belt (3). See Fan Belt Remove and Install.
(Group 0510.)
T164387B
4. Remove fan (6), and spacer (7).

5. Install spacer.
6. Install fan with convex side of blades toward engine.
Fan Guard (648G-III, 460D Shown)
7. Install cap screws and washers and tighten to

specification.
Fan Guards and Fan BladeSpecification
Fan Blade Cap ScrewM8
Torque ............................................................................. 35 Nm (26 lb-ft)
Fan Blade Cap ScrewM10
Torque ............................................................................. 70 Nm (52 lb-ft)
UN27JAN03
8. Install left and right fan guards.

Fan Guard Cap ScrewTorque ..................................... 39 Nm (29 lb-ft)
T164388B
9. If equipped with air conditioning, install condenser.

Condenser Mounting Cap
T162939B
UN17DEC02
1Cap Screw
2Condenser
3Left Side Fan Guard
4Cap Screw
5Cap Screw
6Right Side Fan Guard
7Cap Screw
Air Conditioning Condenser (648G-III, 460D Shown)
CED,OUO1032,3474 1923JAN031/1
TM2111 (30MAY03)
05-0510-1

053003
PN=291
05
0510
1
Cooling Systems
Fan Belt Remove and Install

1. Remove fan guards (6).
T164388B
UN27JAN03
5Cap Screw
6Right Side Fan Guard
7 Cap Screw
TX,05,BA2215 1917OCT021/4
2. Install a 1/2 in. drive wrench (F) into belt tensioner arm
(G) and pull wrench and arm downward to loosen fan
belt (E).
UN22JAN98
3. Remove fan belt from pulleys and lift over fan to

remove.
4. Check belt for wear or damage, replace if necessary.
EFan Belt
F1/2 in. Drive Wrench
GBelt Tensioner Arm
T112908
05
0510
2
648G-III Shown
TM2111 (30MAY03)
05-0510-2
TX,05,BA2215 1917OCT022/4

053003
PN=292
Cooling Systems
5
4
5
4
3
6
3
T159915
240 x240
T159916
T159916
T159915
UN02OCT02
UN02OCT02
240 x240
8.1 L EngineDashed Line Indicates Machine Without Air

Conditioning
6.8 L EngineWithout Air Conditioning
5
7
4
05
0510
3
T159917
T159917
240 x240
UN02OCT02
T159918
UN02OCT02
2
2
T159918
240 x240
6.8 L EngineDirect DriveWith Air Conditioning
6.8 L EngineTorque ConverterWith Air Conditioning

1Crankshaft Pulley
2Water Pump6.8 L
Engines Only
3Tensioner
4Alternator
5Fan Pulley
6Air Conditioning
CompressorIf Equipped
7Idler6.8 L Engines with

Air Conditioning OnlyIf
Equipped
5. Install fan belt as shown. (Fan belt tension

adjustment is not necessary; belt tension is
self-adjusting.)
TM2111 (30MAY03)
05-0510-3
TX,05,BA2215 1917OCT023/4

053003
PN=293
Cooling Systems
6. Release belt tensioner.
7. Install fan guard. Tighten to specification.
UN22JAN98
Fan BeltSpecification
T112908
EFan Belt
F1/2 in. Drive Wrench
GBelt Tensioner Arm
648G-III Shown
TX,05,BA2215 1917OCT024/4
Belt TensionerSpring Tension Check
3. Release tension on tension arm and remove wrench.

4. Put a mark (A) on swing arm of tensioner as shown.
5. Measure 21 mm (0.83 in.) from mark (A) and put a
mark (B) on tensioner mounting base.
T112909
2. Release tension on belt using a 1/2 in. drive wrench on

tension arm. Remove belt from pulleys.
Belt TensionerSpecification
Belt Tensioner SpringDistance .................................... 21 mm (0.83 in.)
7. Record torque wrench measurement and compare with

specification. Replace tensioner as required.
Spring TensionTorque ............................ 1822 Nm (159195 lb-in.)
UN22JAN98
6. Rotate the swing arm using a torque wrench until

marks (A and B) are aligned (C).
T112910
05
0510
4
UN22JAN98
1. Remove right side fan guard.
ASwing Arm Mark

BTensioner Mark
CAligned Marks
TX,05,BA2216 1923JAN031/1
TM2111 (30MAY03)
05-0510-4

053003
PN=294
Cooling Systems
Belt Tensioner Remove and Install

1. Remove right side fan guard.
UN22JAN98
2. Release tension on belt using a 1/2 in. drive wrench.

3. Remove belt from pulleys.
T112911
4. Remove cap screw (A) and belt tensioner (B), leaving

spacer (C) attached to bracket.
5. Install belt tensioner onto spacer. Install and tighten
cap screw (A).
ACap Screw
BBelt Tensioner
CSpacer
Belt Tensioner Cap Screw
Torque ............................................................................. 50 Nm (37 lb-ft)
6. Install belt making sure that belt is correctly seated in

all pulley grooves.
7. Install fan guard.
TX,05,BA2217 1923JAN031/1
Fan Shroud Remove and Install
UN01NOV88

coolant.
T6642EK
1. Drain coolant from radiator into a container. The

approximate cooling system capacity for 6.8 L engine
is 21.5 L (22.7 qt), 8.1 L engine is 30 L (33.8 qt).
Dispose of used coolant properly.
2. Remove hood and limb risers.See Hood Remove and
3. If equipped with air conditioning, remove condenser
mounting cap screws a move condenser aside.
TM2111 (30MAY03)
05-0510-5
TX,05,BA2219 1923JAN031/2

053003
PN=295
05
0510
5
Cooling Systems
6. Disconnect upper radiator hose (1).
7. Remove fan shroud cap screws (2).
8. Remove fan blade.See Fan Guards and Fan Blade
9. Remove fan shroud. Inspect and replace if necessary.
10. Place fan shroud in position towards engine.
11. Install fan blade. See Fan Guards and Fan Blade
UN05JUN00
12. Install fan shroud and cap screws. Tighten to

specification.
T131357B
Fan ShroudSpecification
Fan Shroud Cap ScrewsTorque .................................. 73 Nm (54 lb-ft)
13. Connect upper radiator hose.

14. Install grille and grille housing.See Grille and Grille
1Upper Radiator Hose

2Cap Screw (6 used)
05
0510
6
16. If equipped with air conditioning, install condenser.

Fan ShroudSpecification
17. Install hood and limb risers. See Hood Remove and
20. Tighten sender or plug when all the air has been
expelled.
TX,05,BA2219 1923JAN032/2
TM2111 (30MAY03)
05-0510-6

053003
PN=296
Cooling Systems
Radiator and Oil Cooler Remove and Install

UN01NOV88

coolant.
T6642EK

system capacity for 6.8 L engine is 21.5 L (22.7 qt) 8.1
L engine is 30 L (33.8 qt). Dispose of used coolant
properly.
2. Drain coolant from engine block.
UN29OCT02
3. Remove Hood and limb risers. See Hood Remove and

4. Remove fan guards.See Fan Guards and Fan Blade
Remove and Install in this group.
T160903B

screws and set condenser aside.
6. Remove radiator over flow reservoir and hose.
1Drain Hose
7. Disconnect horn wire harness.
05
0510
7
8. Remove grille housing and grille. See Grille and Grille

9. Remove fan shroud cap screws and move shroud
toward engine.
TM2111 (30MAY03)
05-0510-7
CED,OUO1048,416 1917OCT021/6

053003
PN=297
Cooling Systems
10. Using a vacuum pump to retain oil in reservoir,
disconnect hoses (27). Close all openings with caps
and plugs.
UN27JAN03
11. Disconnect lower radiator hose (1).
T160904B
1Lower Radiator Hose

2Transmission Oil Cooler Bypass
3Hydraulic Oil Cooler Bypass
4Transmission Oil Cooler Outlet
5Hydraulic Oil Cooler Outlet
6Hydraulic Oil Cooler Inlet
7Transmission Oil Cooler Inlet
CED,OUO1048,416 1917OCT022/6
12. Install grille housing-to-radiator cap screws and

washers and shroud-to-radiator cap screws and
washers. Attach lifting straps to cap screws as shown.
T7502DJ
UN16MAY91
05
0510
8
TM2111 (30MAY03)
05-0510-8
CED,OUO1048,416 1917OCT023/6

053003
PN=298
Cooling Systems
13. Remove nuts and washers (A) from bottom radiator
mounts.
UN03FEB98
Radiator and Oil CoolerSpecification

Radiator and Oil CoolerWeight .................... 95 kg (210 lb) approximate
T113167
14. Carefully remove radiator and oil coolers with hoist.

ANut and Washer (3 used)
CED,OUO1048,416 1917OCT024/6
15. Install isolators (A) in engine frame, if removed.
T7502EL
UN16MAY91
AIsolators
TM2111 (30MAY03)
05-0510-9
CED,OUO1048,416 1917OCT025/6

053003
PN=299
05
0510
9
Cooling Systems
16. Install radiator and oil cooler.
17. Install nuts and washers (A).
UN03FEB98
18. Connect lower radiator hose and oil cooler lines.

19. Install fan shroud.
T113167

Fan Shroud Cap ScrewsTorque .................................. 73 Nm (54 lb-ft)
20. Install grille housing and grille. See Grille and Grille
ANut and Washer (3 used)
21. Connect horn wire harness.

22. Install radiator over flow reservoir and hose.
23. Install air conditioner condenser.
24. Install fan guards.See Fan Guards and Fan Blade
05
0510
10
25. Install Hood. See Hood Remove and Install. (Group

1910.)
26. Check transmission and hydraulic oil level. See
Check Hydraulic System Oil Level. (Operators
Manual.)
28. Fill radiator with proper coolant. See Use Correct
Fuels and Lubricants. (Operators Manual.) Tighten
sender or plug when all the air has been expelled.
CED,OUO1048,416 1917OCT026/6
TM2111 (30MAY03)
05-0510-10

053003
PN=300
Cooling Systems
Radiator and Oil Cooler Remove and Install

Torque Converter Machines
UN01NOV88

radiator is cool to the touch before draining the
coolant.
T6642EK
1. Drain coolant from Radiator.

2. Remove cap screw (1).
3. Disconnect wire leads from horn (2) and remove.
4. Remove cap screws and washers (3) and remove
shield (4).
UN05APR01

NOTE: Seal all openings using caps and plugs.
T140864B
6. Disconnect hydraulic lines (5 and 6).

7. Remove cap screws and spacers (7).
8. Disconnect upper and lower radiator hoses (9 and 10).
05
0510
11
9. Remove cap screws and washers (8). Set shroud back

towards engine.
T164510B
UN27JAN03
1Cap Screw
2Horn
4Shield
5Transmission Oil Cooler Out Line
6Hydraulic Oil Cooler Out Line
7Cap Screw and Spacer (2 used)
TM2111 (30MAY03)
05-0510-11
OUO1017,00003CF 1923JAN031/3

053003
PN=301
Cooling Systems
10. Install JT01748 lifting brackets (5) with cap screws (6)
to radiator.
UN05APR01

Radiator and Oil CoolerWeight ................ 107 kg (235 lbs) approximate
11. Attach a hoist to lifting brackets.
T140867B
12. Disconnect hydraulic hoses (1 and 2).

13. Remove cap screws and nuts (3).
14. Remove nuts (4) from studs.
15. Remove radiator and oil cooler.
IMPORTANT: Rubber isolators must be installed in
frame before radiator is set in place.
18. Connect hydraulic lines (1 and 2).
T140866B
05
0510
12
UN05APR01
17. Install radiator with cap screw and nuts (3) and nuts
(4).
1Hydraulic Oil Cooler Inlet Line

2Transmission Oil Cooler Inlet Line
3Cap Screw and Nut (2 used)
4Nut and Washer (2 used)
5JT01748 Lifting Brackets
6Cap Screw 10.9 M10 X 1.50 25 mm Long (2 used)
TM2111 (30MAY03)
05-0510-12
OUO1017,00003CF 1923JAN032/3

053003
PN=302
Cooling Systems
19. Install cap screws and spacers (7) and cap screws
and washers (8).
20. Connect radiator hoses (9 and 10).
22. Install grille and grille housing. See Grille and Grille
23. Install rubber shield (4) and cap screws and washers
(3).
24. Connect wiring leads to horn (2) and install horn with
cap screw (1).
26. Fill radiator with coolant. See Use Correct Fuels and
Lubricants. (Operators Manual.) Tighten sender or
plug when all the air has been expelled.
T164510B

head to allow air to escape when filling system
UN27JAN03

05
0510
13
T140864B
UN05APR01
1Cap Screw
2Horn
4Shield
5Transmission Oil Cooler Out Line
6Hydraulic Oil Cooler Out Line
7Cap Screw and Spacer (2 used)
OUO1017,00003CF 1923JAN033/3
TM2111 (30MAY03)
05-0510-13

053003
PN=303
Cooling Systems
05
0510
14
TM2111 (30MAY03)
05-0510-14

053003
PN=304
Group 0520
Intake System
Air Cleaner Remove and Install
T114943
UN24APR98
05
0520
1
ACover
BAdapter
CO-Ring
DRestrictor Switch
EUnloading Valve
FHose Clamp
1. Loosen hose clamp (I) and disconnect hose (H)

from turbocharger.
GMounting Clamps
HHose
IHose Clamp
JWashers (4 used)
KCap Screws (4 used)
2. Remove cap screws (K) and remove air cleaner.
CED,OUO1032,3411 1923JAN031/1
TM2111 (30MAY03)
05-0520-1

053003
PN=305
Intake System
05
0520
2
TM2111 (30MAY03)
05-0520-2

053003
PN=306
Group 0530
External Exhaust System

Muffler Remove and Install540G-III,
548G-III, 640G-III, 648G-III
1. Disconnect battery ground cable.
TX,0530,JC591 1920JUN951/5
CAUTION: Clamps and flexible tube become hot

from exhaust. Allow parts to cool before
removing.
UN23AUG88
2. Loosen clamp (A) to remove exhaust tube.
T7502FM
UN29MAY91
TS271
AClamp
TM2111 (30MAY03)
05-0530-1
TX,0530,JC591 1920JUN952/5

053003
PN=307
05
0530
1
CAUTION: Left riser becomes hot from exhaust.

Allow riser to cool before removal.
Muffler540G-III, 548G-III, 640G-III, 648G-IIISpecification
Left Cab Riser with Muffler
Weight.............................................................. 45 kg (100 lb) approximate
T7502CM
UN02MAY91
3. Remove left riser with hoist.
05
0530
2
TM2111 (30MAY03)
05-0530-2
TX,0530,JC591 1920JUN953/5

053003
PN=308
T120327
UN11MAR99
05
0530
3
AExhaust Pipe
BWasher (4 used)
CScrew (2 used)
DLock Nut (4 used)
EMuffler
FExhaust Pipe
GCover (2 used)
HScrew (4 used)
IWasher (4 used)
JClamp
KElbow Fitting
TM2111 (30MAY03)
05-0530-3
LClamp
MU-Bolt (2 used)
NClamp (2 used)
TX,0530,JC591 1920JUN954/5

053003
PN=309

4. Remove and install parts as shown.
TX,0530,JC591 1920JUN955/5
Muffler Remove and Install748G-III
UN23AUG88
CAUTION: Clamps and flexible tube become hot

from exhaust. Allow parts to cool before
removing.
TS271
TX,05,RB733 1923JAN031/4
T115368
UN14MAY98
05
0530
4
ANuts (4 used)
BWashers (4 used)
CClamp (2 used)
DElbow Fitting
EExhaust Pipe
FHood Cap
2. Remove clamp (C) from elbow fitting (D) and

exhaust pipe (E).
TM2111 (30MAY03)
05-0530-4
TX,05,RB733 1923JAN032/4

053003
PN=310
CAUTION: Left riser becomes hot from exhaust.

Allow riser to cool before removal.
Muffler748G-IIISpecification
Left Cab Riser with Muffler
T7502CM
UN02MAY91
3. Remove left cab riser.
TM2111 (30MAY03)
05-0530-5
TX,05,RB733 1923JAN033/4

053003
PN=311
05
0530
5
TP54080
UN08JUL97
05
0530
6
1Exhaust Pipe
2Elbow Fitting
3Screw (2 used)
4Muffler
5U-Bolt (4 used)
6Clamp (4 used)
7Washer (8 used)
8Lock Nut (8 used)
9Line
10Exhaust Pipe
11Cap (2 used)
12Clamp
4. Remove and install parts as shown.
TX,05,RB733 1923JAN034/4
TM2111 (30MAY03)
05-0530-6

053003
PN=312
Group 0560
External Fuel Supply System

548G-III, 640G-III
1. Install locking bar and turn battery disconnect to OFF
position.
2. Drain fuel tank. The approximate fuel tank capacities
are: 540G-III and 640G-III159 L (42 gal), 548G-III
189 L (50 gal).
3. For 540G-III and 640G-III machines remove log arch.
See Log Arch Remove and Install. (Group 3740.) For
548G-III machines fuel tank removal, unhook arch
cylinders.
CED,OUO1032,3079 1923JAN031/6
4. Remove two cap screws (B) and remove frame locking

bar holder and guard (C).
UN23APR98
5. Disconnect fuel tank return line (D) and fuel tank

suction line (E).
T114945B
UN23APR98
T114944B
BCap Screw (2 used)

CGuard
DFuel Return Line
EFuel Suction Line
TM2111 (30MAY03)
05-0560-1
CED,OUO1032,3079 1923JAN032/6

053003
PN=313
05
0560
1
TP63102
UN30NOV99
540G-III, 548G-III, 640G-III Fuel Tank

05
0560
2
1Gasket
2Fuel Sending Unit
3Screw (5 used)
4Washer (6 used)
5Cap Screw (2 used)
6Angle
7Washer (2 used)
8Cap Screw (3 used)
9Fuel Tank
10Bushing (2 used)
11Mounting Cap Screw (4

used)
12Flange Nut (2 used)
13Drain Plug
14O-Ring
15Snap Ring
16Gasket
17Filler Cap
18Strainer
6. Disconnect wiring leads from fuel sending unit (2).

7. Remove mounting cap screws (11) and cap screws
(5).
TM2111 (30MAY03)
05-0560-2
CED,OUO1032,3079 1923JAN033/6

053003
PN=314

8. Attach JT01748 Lifting Brackets (A) to fuel tank.
9. Attach D01043AA Load-Positioning Sling to brackets
and an overhead hoist.
10. Remove fuel tank.
11. Inspect parts. Repair or replace as necessary.
T7502FS
UN29MAY91
AJT01748 Lifting Brackets
TM2111 (30MAY03)
05-0560-3
CED,OUO1032,3079 1923JAN034/6

053003
PN=315
05
0560
3
TP63102
UN30NOV99
540G-III, 548G-III, 640G-III Fuel Tank

05
0560
4
1Gasket
2Fuel Sending Unit
3Screw (5 used)
4Washer (6 used)
5Cap Screw (2 used)
6Angle
7Washer (2 used)
8Cap Screw (3 used)
9Fuel Tank
10Bushing (2 used)

used)
13Drain Plug
14O-Ring
12. Attach tank as described in removal procedure

and lower into equipment frame.
13. Using a piece of wire, pull sending unit wires
through guard tube on tank.
14. Connect wiring leads to fuel sending unit (2).

15. Install mounting cap screws (11) and cap screws
(5).
TM2111 (30MAY03)
15Snap Ring
16Gasket
17Filler Cap
18Strainer
05-0560-4
CED,OUO1032,3079 1923JAN035/6

053003
PN=316

16. Connect fuel tank return line (D) and fuel tank suction
line (E).
UN23APR98
17. Install two cap screws (B) to fasten frame locking bar
holder and guard (C).
T114945B
18. Fill tank with fuel. See Use Correct Fuels and
T114944B
UN23APR98
BCap Screw (2 used)

CGuard
DFuel Return Line
EFuel Suction Line
CED,OUO1032,3079 1923JAN036/6

748G-III
1. Install locking bar and turn battery disconnect to OFF
position.
2. Drain fuel tank. The approximate capacities of the fuel
tanks are: 648G-III Single Function265 L (70 gal),
648G-III Dual Function227 L (60 gal), 748G-III273
L (72 gal).
3. For 648G-III and 748G-III machines equipped with dual
function grapple, remove winch. See Winch 4000
Series Remove and Install. (Group 3000.) See Winch
6000 Series Remove and Install. (Group 3000.) For
648G-III and 748G-III machines equipped with single
function grapple, remove locking bar and guard to
remove fuel tank.
TM2111 (30MAY03)
05-0560-5
CED,OUO1032,3081 1923JAN031/9

053003
PN=317
05
0560
5

4. Disconnect fuel tank return line (A) and fuel tank
suction line (B).
T8473AE
UN17MAY95
AFuel Return Line

BFuel Suction Line
CED,OUO1032,3081 1923JAN032/9
05
0560
6
TM2111 (30MAY03)
05-0560-6

053003
PN=318
TP63101
UN30NOV99
648G-III Single Function
TP63100
UN30NOV99
05
0560
7
648G-III Dual Function and 748G-III

1Gasket
2Fuel Sending Unit
3Screw (5 used)
5Washer (6 used)
6Cap Screw (2 used)

7Angle
8Washer (2 used)
9Cap Screw (3 used)
10Fuel Tank
11Bushing (2 used)
used)
13Drain Plug
14O-Ring
TM2111 (30MAY03)
05-0560-7
15Snap Ring
16Gasket
17Filler Cap
18Strainer
CED,OUO1032,3081 1923JAN033/9

053003
PN=319

5. Disconnect wiring leads from fuel sending unit (2).
6. Remove mounting cap screws (12) and cap screws
(6).
CED,OUO1032,3081 1923JAN034/9

7. Attach JT01748 Lifting Brackets (A) to fuel tank. Attach
D01043AA Load-Positioning Sling to brackets and an
overhead hoist.
8. Remove fuel tank.
9. Inspect parts. Repair or replace as necessary.
T7502FS
UN29MAY91
05
0560
8
TM2111 (30MAY03)
05-0560-8
CED,OUO1032,3081 1923JAN035/9

053003
PN=320

10. Attach JT01748 Lifting Brackets (A) to fuel tank.
Attach D01043AA Load-Positioning Sling to brackets
and an overhead hoist.
11. Lower tank into equipment frame.
T7502FS
UN29MAY91
TM2111 (30MAY03)
05-0560-9
CED,OUO1032,3081 1923JAN036/9

053003
PN=321
05
0560
9
TP63101
UN30NOV99
648G-III Single Function
TP63100
UN30NOV99
05
0560
10
648G-III Dual Function and 748G-III

1Gasket
2Fuel Sending Unit
3Screw (5 used)
5Washer (6 used)
6Cap Screw (2 used)

7Angle
8Washer (2 used)
9Cap Screw (3 used)
10Fuel Tank
11Bushing (2 used)
used)
13Drain Plug
14O-Ring
TM2111 (30MAY03)
05-0560-10
15Snap Ring
16Gasket
17Filler Cap
18Strainer
CED,OUO1032,3081 1923JAN037/9

053003
PN=322

12. Using a piece of wire, pull sending unit wires
through guard tube on tank.
14. Install mounting cap screws (12) and cap screws

(6).
13. Connect wiring leads to fuel sending unit (2).

CED,OUO1032,3081 1923JAN038/9
15. Connect fuel tank return hose (A) and fuel tank
suction hose (B).
16. Install guard and locking bar into guard holder.
17. Fill fuel tank with fuel. See Use Correct Fuels and
T8473AE
UN17MAY95
AFuel Return Line

BFuel Suction Line
CED,OUO1032,3081 1923JAN039/9
TM2111 (30MAY03)
05-0560-11

053003
PN=323
05
0560
11
05
0560
12
TM2111 (30MAY03)
05-0560-12

053003
PN=324
Section 06
Torque Converter
Contents
Page

Torque Converter Housing Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-0600-1
Group 0641Torque Converter Housing
Magnetic Speed Sensor Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-0641-1
Torque Converter Housing Disassemble . . . .06-0641-2
Torque Converter Housing Assemble . . . . .06-0641-18
Group 0651Converter Turbine, Gears, and Shaft
Torque Converter Cover, Drive Plate and
Impeller Hub Tightening Sequence . . . . . .06-0651-1
Torque Converter Drive Plate Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .06-0651-2
Torque Converter Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .06-0651-5
06
TM2111 (30MAY03)
06-1

053003
PN=1
Contents
06
TM2111 (30MAY03)
06-2

053003
PN=2
Group 0600

Torque Converter Housing Remove and
Install
1. Remove hydraulic reservoir. See Hydraulic Reservoir
Remove and InstallDirect Drive Machines. See
Hydraulic Reservoir Remove and InstallTorque
OUO1017,00003C9 1915JAN031/14
2. Remove flywheel access plug (1) and drive plate cap

screw access plug (2).
3. Discard drive plate cap screw access plug (2).
UN27MAR01
4. Install JDE81-1 Flywheel turning tool into access hole

(3).
T140270B
5. Rotate engine until flex plate cap screws can be seen

through hole.
6. Continue to rotate engine and remove eight cap
screws (4).
T140271B
UN27MAR01

3Access Hole
4Cap Screw (8 used)
TM2111 (30MAY03)
06-0600-1
OUO1017,00003C9 1915JAN032/14

053003
PN=327
06
0600
1

NOTE: Mark or tag wire connectors for ease of assembly.
7. Disconnect wire connectors (1).
NOTE: Close all openings using caps and plugs.

8. Disconnect hydraulic line (2) from hydraulic manifold.
UN27MAR01
9. Remove clamps (3 and 4) from hydraulic reservoir

legs.
10. Lay hydraulic manifold (5) back towards rear of
machine behind torque converter housing and pumps.
T140272B

2Hydraulic Line-to-Hydraulic Filter Manifold
3Clamp
4Clamp
5Hydraulic Manifold
OUO1017,00003C9 1915JAN033/14
11. Disconnect wire connector (1) and remove clamp (2).

Move harness away from housing towards engine.
12. Disconnect lines (3 and 4) from transmission charge
pump.
13. Remove cap screws (5) from reservoir leg (6).
UN27MAR01
14. Remove reservoir legs from both sides.

1Wire Connector
2Clamp
3Transmission Charge Pump Pressure Line
4Transmission Charge Pump Suction Line
5Cap Screw (6 used)
6Hydraulic Reservoir Leg (2 used)
T140273B
06
0600
2
TM2111 (30MAY03)
06-0600-2
OUO1017,00003C9 1915JAN034/14

053003
PN=328

UN27MAR01
16. Disconnect drive shaft (2) from torque converter

housing. Lay drive shaft down and towards left side
frame rail.
17. Disconnect wire connector (3).
T140274B
18. Disconnect hydraulic lines (46).
T140275B
UN27MAR01
1Cap Screw (4 used)

2Transmission Drive Shaft
4Converter Out Hydraulic Line
5Converter Line-to-Sump
6Converter In Hydraulic Line
TM2111 (30MAY03)
06-0600-3
OUO1017,00003C9 1915JAN035/14

053003
PN=329
06
0600
3

19. Remove clamp (4) from transmission charge pump.
20. Disconnect hydraulic lines (13) and (58).
T140276B
UN27MAR01
1Hydraulic Oil Cooler Pump-to-Reservoir Line

2Hydraulic Pump Outlet Line
3Hydraulic Pump Case Drain Line
4Clamp
5Differential Lock Pump Inlet Line
6Differential Lock Pump Outlet Line
7Hydraulic Oil Cooler Pump Inlet
Line-from-Reservoir
8Case Drain Line-from-Hydraulic Pump
OUO1017,00003C9 1915JAN036/14
06
0600
4
TM2111 (30MAY03)
06-0600-4

053003
PN=330

21. Attach two JT01748 Lifting Brackets (1) to converter
housing using cap screws (2).
Torque Converter HousingSpecification
Torque Converter and Torque
Converter HousingWeight ........................ 200 kg (440 lbs) approximate
22. Attach a suitable hoist to lifting brackets.
UN27MAR01
23. Remove cap screws (3) securing housing to engine.

T140277B

Torque ConverterWeight.............................. 32 kg (70 lbs) approximate
CAUTION: Torque converter is not fastened to

housing. Housing must be kept level or slightly
tilted back during removal or torque converter
could slide off.
1JT01748 Lifting Brackets (2 used)

2Cap Screw 10.9 M12 X 1.75 30 mm Long (2
used)
24. Slide housing towards rear of machine away from

engine.
25. Remove housing and pumps from machine.
OUO1017,00003C9 1915JAN037/14
27. Apply anti-seize lubricant to outside diameter of

converter stub shaft (2) and inside diameter of pilot
sleeve (1), and flywheel pilot bore. Install pilot sleeve
onto stub shaft.
T140746
UN30MAR01
1Pilot Sleeve
2Converter Stub Shaft
TM2111 (30MAY03)
06-0600-5
OUO1017,00003C9 1915JAN038/14

053003
PN=331
06
0600
5

28. Attach lifting brackets (1) to housing using cap screws
(2).
Torque Converter and Torque
Converter HousingWeight ........................ 200 kg (440 lbs) approximate
UN27MAR01
CAUTION: Torque converter is not fastened to

housing. Housing must be kept level or slightly
tilted back during installation or torque
converter could slide off.
29. Attach housing to a suitable hoist and lift into position.
T140277B
30. Use flywheel turning tool if necessary to rotate engine

to aid in assembly and align the pilot sleeve into
engine flywheel.
IMPORTANT: Do not use cap screws to pull engine
and housing together. Damage to pilot
sleeve and housings could result.
1JT01748 Lifting Brackets

2Cap Screw 10.9 M12 X 1.75 30 mm Long (2
used)
06
0600
6
TM2111 (30MAY03)
06-0600-6
OUO1017,00003C9 1915JAN039/14

053003
PN=332

32. Connect hydraulic lines (13) and (58).
33. Install clamp (4).
T140276B
UN27MAR01
1Hydraulic Oil Cooler Pump-to-Reservoir Line

2Hydraulic Pump Outlet Line
3Hydraulic Pump Case Drain Line
4Clamp
5Differential Lock Pump Inlet Line
6Differential Lock Pump Outlet Line
7Hydraulic Oil Cooler Pump Inlet Line From
Reservoir
8Case Drain Line from Hydraulic Pump
OUO1017,00003C9 1915JAN0310/14
06
0600
7
TM2111 (30MAY03)
06-0600-7

053003
PN=333

34. Connect hydraulic lines (46).
36. Install Drive shaft (2) with cap screws (1). Tighten
Cap screws to specification.
UN27MAR01

Transmission Drive Shaft Cap
ScrewsTorque .............................................................. 58 Nm (43 lb-ft)
T140274B
UN27MAR01
T140275B
1Cap Screw (4 used)

2Transmission Drive Shaft
4Converter Out Hydraulic Line
5Converter Line-to-Sump
6Converter In Hydraulic Line
06
0600
8
OUO1017,00003C9 1915JAN0311/14
37. Install reservoir legs (6) and cap screws (5).

39. Connect wire connector (1) and install clamp (2).
T140273B
UN27MAR01
1Wire Connector
2Clamp
3Transmission Charge Outlet Suction Line
4Transmission Charge Pump Suction Line
5Cap Screw (6 used)
6Reservoir Leg (2 used)
TM2111 (30MAY03)
06-0600-8
OUO1017,00003C9 1915JAN0312/14

053003
PN=334

40. Lift hydraulic manifold (5) and install clamps (3 and 4)
to reservoir legs.
41. Connect hydraulic line (2).
42. Connect wire connectors (1).
T140272B
UN27MAR01

2Hydraulic Line-to-Hydraulic Filter Manifold
3Clamp
4Clamp
5Hydraulic Manifold
OUO1017,00003C9 1915JAN0313/14
43. Apply medium strength thread lock and sealer to cap

screws (4).
45. Install plugs (1 and 2).

46. Install hydraulic reservoir. See Hydraulic Reservoir
Remove and InstallDirect Drive Machines. See
Hydraulic Reservoir Remove and InstallTorque
T140270B
UN27MAR01

3Access Hole
T140271B

Drive Plate Cap ScrewsTorque ................................... 47 Nm (35 lb-ft)
UN27MAR01
44. Rotate engine and install drive plate cap screws and
washers (4). Tighten to specification.
OUO1017,00003C9 1915JAN0314/14
TM2111 (30MAY03)
06-0600-9

053003
PN=335
06
0600
9
06
0600
10
TM2111 (30MAY03)
06-0600-10

053003
PN=336
Group 0641
Torque Converter Housing

Magnetic Speed Sensor Remove and Install
1. Disconnect wiring connector.
2. Remove cap screws and washers (A).
3. Remove magnetic speed cover (B).
5. Lubricate O-ring.
6. Install new O-ring in groove on magnetic speed sensor
(C).
YZ4094A
NOTE: Install magnetic speed sensor after installing

driven gears.
UN10MAR01
4. Remove magnetic speed sensor with O-ring (C).
7. Push magnetic speed sensor into converter cover.

8. Install magnetic speed cover (B).
9. Install cap screws, lock washer and flat washers (A).
ACap Screws, Lock Washers, and Flat Washers (2

used)
BMagnetic Speed Cover
CMagnetic Speed Sensor and O-Ring
YZ4096A
Magnetic Speed SensorSpecification

Magnetic Speed Sensor Cap
ScrewTorque ............................................................... 10 Nm (89 lb-in.)
UN10MAR01
10. Tighten cap screws.
YZ01324,000006D 1928MAR011/1
TM2111 (30MAY03)
06-0641-1

053003
PN=337
06
0641
1
Torque Converter Housing Disassemble
YZ4010
UN09MAR01
06
0641
2
Component Identification of Converter

ACharge Pump
BOutput Yoke
COil In-to-Torque Converter
DDrain-to-Sump
EConverter Cover
FOil Out-to-Cooler
GAuxiliary Pump Adapter
HHydraulic Hose
ITorque Converter
JDrive Plate
TM2111 (30MAY03)
06-0641-2
KMagnetic Speed Sensor

LPump Discharge Port
MPilot Sleeve
OUO1020,00010EF 1915JAN031/22

053003
PN=338
YZ4007
UN10MAR01
1Cap Screw
2Yoke Washer
3O-Ring
4Yoke
5Oil Seal
6Snap Ring
7Bearing
8Turbine Shaft
9Seal Ring
10O-Ring Plug (2 used)
11Socket Head Cap Screw (2
used)
13Idler Shaft (2 used)

14O-Ring (2 used)
15Snap Ring Ball Bearing (4
used)
16Idler Gear (2 used)
17Oil Seal
18O-Ring (2 used)
19Converter Cover
20Sealed Bearing
21Driven Gear (2 used)
22Snap Ring Bearing
23Bearing Spacer
24Snap Ring
25O-Ring
26Hydraulic Pump Adapter
Plate
28O-Ring
29Elbow Fitting and
O-RingsWith Orifice
30Hydraulic Hose
31Elbow Fitting and O-Rings
32Converter Housing
33O-Ring
34Stator Support Tube
35Deflector
TM2111 (30MAY03)
06-0641-3
06
0641
3

37Thrust Race
38Needle Thrust Bearing
39Input Gear
40Bearing
41O-Ring (2 used)
42Bearing (2 used)
43Washer (2 used)
45Lock Washer (2 used)
46Magnetic Speed Cover
47Magnetic Speed Sensor
48O-Ring
OUO1020,00010EF 1915JAN032/22

053003
PN=339

Torque Converter and Drive
PlateWeight .................................................. 32 kg (70 lbs) approximate
1. Remove torque converter (A).
YZ4097
UN10MAR01
ATorque Converter
BTorque Converter Cover
OUO1020,00010EF 1915JAN033/22
2. Remove hose (A), if not removed.
UN05MAR01
AHose
BFitting-to-Converter Housing
CFitting-to-Converter CoverAuxiliary Pump
Adapter
YZ4050
06
0641
4
3. Remove magnetic sensor, if not removed. See

Magnetic Speed Sensor Remove and Install in this
group.
TM2111 (30MAY03)
06-0641-4
OUO1020,00010EF 1915JAN034/22

053003
PN=340

4. Remove parts (AD).
YZ4049
UN05MAR01
ACap Screw
BWasher
CO-Ring
DYoke
OUO1020,00010EF 1915JAN035/22
5. Remove and discard oil seal (A) from housing.
YZ4051
UN05MAR01
AOil Seal
TM2111 (30MAY03)
06-0641-5
OUO1020,00010EF 1915JAN036/22

053003
PN=341
06
0641
5

YZ4052
UN05MAR01
BSnap Ring
OUO1020,00010EF 1915JAN037/22
7. Remove turbine shaft (C) and bearing.
NOTE: Bearing will come out with shaft.

CTurbine Shaft and Bearing
YZ4054
UN05MAR01
06
0641
6
TM2111 (30MAY03)
06-0641-6
OUO1020,00010EF 1915JAN038/22

053003
PN=342
CAUTION: Remove cap screw (E) last. Hold

converter housing while removing cap screw
(E). Converter housing could fall or drop
unexpectedly and cause damage to converter
housing or injury.
8. Remove plugs and O-rings (A) from converter side of
converter cover.
UN09MAR01
9. Remove socket head cap screws (B) from converter

cover.
YZ4064
10. Remove idler cap screws (C) and cap screws (D).
YZ4065
UN07MAR01
APlugs and O-Rings (2 used)

BSocket Head Cap Screws (2 used)
CCap Screws (Idler Shaft)
DCap Screws
ECap Screw
TM2111 (30MAY03)
06-0641-7
OUO1020,00010EF 1915JAN039/22

053003
PN=343
06
0641
7

11. Remove cap screw (D) while holding onto converter
housing (E).
12. Remove converter housing.
YZ4055
UN07MAR01
YZ4066
UN07MAR01
DCap Screw-to-Front Cover

EConverter Housing
06
0641
8
OUO1020,00010EF 1915JAN0310/22
13. Remove O-rings (F) and input gear (G).
YZ4067
UN07MAR01
FO-Ring (2 used)
GInput Gear
TM2111 (30MAY03)
06-0641-8
OUO1020,00010EF 1915JAN0311/22

053003
PN=344

14. Remove needle thrust bearing (A) and thrust race (B).
16. Remove cap screws (E) and oil deflector (F).
17. Remove stator support tube (D) from converter
housing (G).
YZ4059
UN06MAR01
YZ4058
UN06MAR01
ANeedle Thrust Bearing

BThrust Race
CO-Ring
DStator Support Tube
ECap Screws (7 used)
FOil Deflector
GConverter Housing
TM2111 (30MAY03)
06-0641-9
OUO1020,00010EF 1915JAN0312/22

053003
PN=345
06
0641
9

18. Align oil passages and install stator support tube (A)
on converter housing (B).
IMPORTANT: Oil passages and oil deflector must be
in installed correctly to properly direct
oil flow. Install oil deflector (D) with
angle cut flush with outer diameter of
stator support tube (A). Check oil
deflector so tab (E) is below the surface
of thrust race shoulder of stator tube.
19. Install oil deflector (D) and tighten cap screws (C).
Stater Support Tube and Oil
Deflector Cap ScrewTorque ........................................ 37 Nm (27 lb-ft)
YZ4060
UN06MAR01
AStator Support Tube

BConverter Housing
CCap Screws (7 used)
DOil Deflector
EOil Deflector Tab
YZ4059A
UN06MAR01
06
0641
10
TM2111 (30MAY03)
06-0641-10
OUO1020,00010EF 1915JAN0313/22

053003
PN=346

20. Apply grease to new thrust race (A) and needle thrust
bearing (B) and install on stator support tube.
NOTE: Applying grease to thrust race and needle thrust

bearing holds them in place when installing
converter housing in front cover.
21. Lubricate and install new O-ring (C).
22. Set converter housing with stator support tube aside.
YZ4058A
UN06MAR01
AThrust Race
BNeedle Thrust Bearing
CO-Ring
OUO1020,00010EF 1915JAN0314/22
06
0641
11
TM2111 (30MAY03)
06-0641-11

053003
PN=347

23. Remove and discard seal ring (A).
24. Remove and discard bearing (B).
YZ4062
UN06MAR01
ASeal Ring
BBearing
YZ4061
UN06MAR01
06
0641
12
TM2111 (30MAY03)
06-0641-12
OUO1020,00010EF 1915JAN0315/22

053003
PN=348

25. Press on new bearing (A), using driver (B).
IMPORTANT: Press on inner race of bearing.
26. Lubricate and install new seal ring (C).
27. Set stator shaft aside.
YZ4063
UN06MAR01
ABearing
BBearing Driver
CSeal Ring
OUO1020,00010EF 1915JAN0316/22
28. Position converter cover converter side up.
NOTE: Use cap screw (A) to pull idler shafts from front
cover bores. The shafts are a slip fit.
06
0641
13
29. Install a cap screw (A) into threaded hole in idler shaft
(B).
UN07MAR01
30. Remove idler shafts (B).

31. Remove and discard O-rings (C and D). O-rings may
stick in idler shaft housing.
YZ4068
32. Inspect idler shafts for wear or damage.

33. Remove oil seal (E) and bearing (F).
ACap Screw
BIdler Shaft (2 used)
CO-Ring (2 used)
DO-Ring (2 used)
EOil Seal
FBearing
TM2111 (30MAY03)
06-0641-13
OUO1020,00010EF 1915JAN0317/22

053003
PN=349

34. Position converter cover to have pump ports and
driven gear up.
35. Remove driven gear (A) from charge pump side.
NOTE: O-ring not shown.
UN07MAR01
36. Remove O-ring located in groove of hydraulic pump

adapter plate (B).
37. Remove cap screws (C).
YZ4069
38. Remove hydraulic pump adapter plate (B) and O-ring

(D).
ADriven Gear (Charge Pump Side)
BHydraulic Pump Adapter Plate
DO-Ring
YZ4070
UN07MAR01
Driven Gear and Charge Pump Port
YZ4071
UN07MAR01
06
0641
14
TM2111 (30MAY03)
06-0641-14
OUO1020,00010EF 1915JAN0318/22

053003
PN=350

40. Remove spacer and driven gear.
YZ4072
UN08MAR01
ASnap Ring
OUO1020,00010EF 1915JAN0319/22
41. Remove bearings (C and D) from gear (B) using

puller.
42. Inspect bearings and gear and replace as necessary.
YZ4075
UN09MAR01
BDriven Gear (2 used)

CSnap Ring Bearing
DSealed Bearing
Driven GearAuxiliary Pump Side

TM2111 (30MAY03)
06-0641-15
OUO1020,00010EF 1915JAN0320/22

053003
PN=351
06
0641
15

43. Remove idler gear (A) from auxiliary pump port (B).
44. Remove idler gear (C) from charge pump port (D).
YZ4076
UN09MAR01
AIdler Gear
BFront Cover Auxiliary Pump Port
CIdler Gear
DFront Cover Charge Pump Port
UN09MAR01
Idler Gear and Auxiliary Pump Port
YZ4077
06
0641
16
Idler GearCharge Pump Port
TM2111 (30MAY03)
06-0641-16
OUO1020,00010EF 1915JAN0321/22

053003
PN=352

45. Remove bearings (A) from both idler gears (B).
47. Use press to install bearing. Press on bearing outer

race until snap ring contacts outside of gear.
YZ4078
IMPORTANT: Use press to install bearings. Apply

pressure to outer race of bearing until
snap ring contacts outside of gear.
UN08MAR01
46. Inspect bearings and gears for wear or damage.
48. Turn gear over and press bearing into idler gear until
snap ring rests on outside of gear.
49. Repeat for each idler gear.
YZ4079
UN08MAR01
ABearing (2 used)
BIdler Gear
OUO1020,00010EF 1915JAN0322/22
TM2111 (30MAY03)
06-0641-17

053003
PN=353
06
0641
17
Torque Converter Housing Assemble

IMPORTANT: Use press to install bearings. Apply
pressure to bearing inner race only.
UN14MAR98
1. Use press to install bearing (A) onto driven gear (B).

Apply pressure to bearing inner race only.
2. Turn gear over and press bearing (C) onto gear.
YZ555
IMPORTANT: Auxiliary pump port driven gear will

have one snap ring bearing (D) and one
sealed bearing (E). Install snap ring
bearing onto gear with snap ring down.
Install sealed bearing onto gear with
seal side away from driven gear.
3. Press snap ring bearing (D) onto driven gear (B) with
snap ring side toward gear.
4. Turn gear over and press sealed bearing (E) onto gear
with seal side away from gear.
YZ4075A
UN09MAR01
ABearing (Charge Pump)

BDriven Gear
CBearing (Charge Pump)
DSnap Ring Bearing (Auxiliary Pump)
ESealed Bearing (Auxiliary Pump)
Driven Gear and Snap Ring BearingAuxiliary Pump Side

06
0641
18
TM2111 (30MAY03)
06-0641-18
OUO1065,000059C 1915JAN031/21

053003
PN=354

5. Position front cover with converter side up.
IMPORTANT: Make sure oil seal is flush with machine
surface of housing.
NOTE: If outside diameter of oil seal is not already

coated with a sealer, apply medium strength
thread lock.
UN08MAR01
6. Install oil seal (A).

7. Position converter cover with converter side down.
YZ4082
8. Install bearing (B) into front cover.
YZ4083
UN08MAR01
AOil Seal
BBearing
TM2111 (30MAY03)
06-0641-19
OUO1065,000059C 1915JAN032/21

053003
PN=355
06
0641
19

9. Position converter cover with converter side up and
turn housing so auxiliary pump port hangs over work
table.
10. Place idler gear (A) into auxiliary pump port (B).
11. Position idler gear.
UN09MAR01
12. Turn housing so charge pump port hangs over work

table.
YZ4076
13. Install idler gear (C) into charge pump port (D).
UN09MAR01
AIdler Gear
BAuxiliary Pump Port of Converter Cover
CIdler Gear
DCharge Pump Port of Converter Cover
YZ4077
06
0641
20
TM2111 (30MAY03)
06-0641-20
OUO1065,000059C 1915JAN033/21

053003
PN=356

NOTE: Hole in idler shaft must line up with bolt hole in
front cover (input housing). Use a bolt to guide the
alignment while installing.
14. Align bearing bore of idler gear (A) with input housing
shaft bore.
UN08MAR01
15. Lubricate O-ring (C) with petroleum jelly and install in

groove on idler shaft.
16. Use petroleum jelly to hold O-ring (B) to the bottom of
the idler shaft during installation.
YZ4084
ALTERNATE O-RING INSTALLATION

PROCEDURE
Position O-ring (B) at bottom of the shaft bore in input
housing.
17. Use bolt (D) to align through hole in idler shaft with
threaded hole in input cover.
18. Push idler shaft (E) through idler gear into input
housing.
UN08MAR01
19. Install the other idler shaft in same manner.
YZ4085
UN08MAR01
YZ4068A
AIdler Gear (2 used)

BO-Ring (2 used)
CO-Ring (2 used)
DBolt
EIdler Shaft (2 used)
TM2111 (30MAY03)
06-0641-21
OUO1065,000059C 1915JAN034/21

053003
PN=357
06
0641
21

20. Install driven gear (A) in charge pump port of front
cover.
YZ4069
UN07MAR01
ADriven Gear
OUO1065,000059C 1915JAN035/21
21. Install driven gear with snap ring bearing up and seal
side of bearing (A) down toward torque converter
side.
ABearing (Seal Side)
YZ4086
UN08MAR01
06
0641
22
YZ4148
UN24MAR01
Snap Ring Bearing Up and Seal Side of Bearing Down Toward

Engine Side
TM2111 (30MAY03)
06-0641-22
OUO1065,000059C 1915JAN036/21

053003
PN=358

22. Rotate idler gear (A) to align teeth with driven gear
(B).
YZ579
UN14MAR98
AIdler Gear
BDriven Gear
OUO1065,000059C 1915JAN037/21
06
0641
23
TM2111 (30MAY03)
06-0641-23

053003
PN=359

23. Install bearing spacer (C).
CAUTION: Wear eye protection when installing
snap rings.
24. Install snap ring (D) into groove.
YZ4088
UN08MAR01
T163729B
UN14JAN03
CBearing Spacer
DSnap Ring
06
0641
24
TM2111 (30MAY03)
06-0641-24
OUO1065,000059C 1915JAN038/21

053003
PN=360

25. Lubricate and install O-ring (E) to hydraulic pump
adapter plate (F).
YZ4071A
UN08MAR01
EO-Ring
FHydraulic Pump Adapter Plate
OUO1065,000059C 1915JAN039/21
IMPORTANT: Install pump adapter plate to front cover

with screw holes (G) positioned so they
are adjacent to screw holes (H) on
housing.
26. Install hydraulic pump adapter plate.
27. Install and tighten cap screws (I).
UN08MAR01

Hydraulic Pump Adapter Plate
YZ4089
GHydraulic Pump Adapter Plate Screw Holes

HFront CoverAuxiliary Pump Port Screw Holes
IHydraulic Pump Adapter Plate-to-Front Cover Cap
Screw (4 used)
TM2111 (30MAY03)
06-0641-25
OUO1065,000059C 1915JAN0310/21

053003
PN=361
06
0641
25

28. Lubricate and install O-rings (A) to converter cover.
29. Install input gear (B) in housing; mesh with idler
gears.
YZ4090
UN10MAR01
AO-Ring
BInput Gear
OUO1065,000059C 1915JAN0311/21
CAUTION: Hold on to converter housing (C)

while installing cap screw (D) to prevent
component damage.
UN10MAR01
IMPORTANT: Make sure thrust race and needle thrust

bearing are aligned and in place when
installing converter housing into
converter cover.
30. Install converter housing (C) in converter cover.
YZ4055A
31. Install cap screw (D) while holding onto converter

housing. Do not tighten at this time.
UN10MAR01
CConverter Housing
DCap Screw
YZ4066A
06
0641
26
TM2111 (30MAY03)
06-0641-26
OUO1065,000059C 1915JAN0312/21

053003
PN=362

32. Install and tighten cap screws (F) to idler shafts.
33. Install and tighten cap screws (E). Tighten cap screw
(D).
UN10MAR01

Converter Housing Cap Screw
Torque ............................................................................. 87 Nm (64 lb-ft)
34. Apply high strength thread lock to allen head cap

screws (G) and install. Tighten cap screws.
YZ4093

Converter Housing Allen Head
DCap Screw
ECap Screw (2 used)
FCap Screw-to-Idler Shafts (2 used)
GAllen Head Cap Screw (2 used)
OUO1065,000059C 1915JAN0313/21
35. Install and tighten plugs (H) to housing.

Converter Housing PlugTorque ............................... 186 Nm (137 lb-ft)
06
0641
27
YZ4064A
UN10MAR01
HPlug-to-Housing (2 used)
TM2111 (30MAY03)
06-0641-27
OUO1065,000059C 1915JAN0314/21

053003
PN=363

36. Install turbine shaft (I) into converter housing.
YZ4054A
UN10MAR01
ITurbine Shaft
OUO1065,000059C 1915JAN0315/21
37. Install snap ring (J).
UN10MAR01
JSnap Ring
YZ4092
06
0641
28
OUO1065,000059C 1915JAN0316/21
38. Apply medium strength thread lock to outside

diameter of oil seal (K) and install oil seal to converter
housing.
YZ4091
UN10MAR01
KOil Seal
TM2111 (30MAY03)
06-0641-28
OUO1065,000059C 1915JAN0317/21

053003
PN=364

39. Apply petroleum jelly to seal inner lip and yoke seal
surface.
40. Install yoke (D).
UN05MAR01
41. Apply high strength thread lock and sealer to cap

screw.
42. Install O-ring (C), washer (B) and cap screw (A).
YZ4049
NOTE: Install washer with number side out.

43. Tighten cap screw to specification.
Output YokeSpecification
Output Yoke Cap ScrewTorque............................... 216 Nm (160 lb-ft)
ACap Screw
BWasher
CO-Ring
DYoke
44. Install magnetic sensor. See Magnetic Speed Sensor

OUO1065,000059C 1915JAN0318/21
06
0641
29
TM2111 (30MAY03)
06-0641-29

053003
PN=365

45. Install fitting with orifice (C) to converter cover. (If
removed.)
46. Install fitting (B) to converter housing (if removed).
47. Install hydraulic lube hose (A) to fittings and tighten.
Hose Fitting-to-Converter
HousingTorque.......................................................... 12 Nm (106 lb-in.)
Hose Fitting with Orifice-to-Front
CoverPump AdapterTorque .................................. 12 Nm (106 lb-in.)
Hydraulic Lube Hose Fitting
Torque .......................................................................... 16 Nm (142 lb-in.)
YZ4050
UN05MAR01
AHydraulic Lube Hose

BElbow Fitting-to-Converter Housing
CElbow Fitting with Orifice-to-Converter Cover
Auxiliary Pump Adapter
YZ4095
UN10MAR01
06
0641
30
TM2111 (30MAY03)
06-0641-30
OUO1065,000059C 1915JAN0319/21

053003
PN=366

IMPORTANT: Seal ring ends must be hooked
together.
UN25OCT93
48. Apply petroleum jelly to seal ring (A) and install into
groove on impeller hub (B). Lock ends.
YZ4039
UN28FEB01
YZ527
ASeal Ring
BImpeller Hub
OUO1065,000059C 1915JAN0320/21
06
0641
31
TM2111 (30MAY03)
06-0641-31

053003
PN=367

Torque Converter Specification
49. Install torque converter (A) into converter cover (B).

IMPORTANT: Make sure torque converter turns freely
in clockwise rotation.
50. Install pilot sleeve (C) on torque converter. Apply
anti-seize lubricant inside diameter of pilot sleeve.
YZ4097
UN10MAR01
ATorque Converter
BConverter Cover
CPilot Sleeve
YZ4098
UN10MAR01
06
0641
32
OUO1065,000059C 1915JAN0321/21
TM2111 (30MAY03)
06-0641-32

053003
PN=368
Group 0651
Converter Turbine, Gears, and Shaft
YZ4057
UN06MAR01
Torque Converter Cover, Drive Plate and Impeller Hub Tightening Sequence
Torque Procedure:
All torque values listed apply to non-lubricated plain or
zinc plated cap screws which include only residual oil
of the manufacturer. Do Not Add additional lubricants
unless otherwise specified.
Torque four cap screws at zero, 180, 90 and 270

degrees, in order. This pattern is designated in graphic
using numbers 1, 2, 3 and 4.
Preliminary Torque:
Follow by a circular sequence starting at zero degrees,

which is designated as number 5 in graphic. Continue
torquing in a circular pattern, tightening each cap
screw in line back to zero degrees.
If an impact wrench is used, it must be set below the

final torque required.
1. Drive plate: apply high strength thread lock to drive

plate cap screws and tighten to specification.
Final Torque:
Torque Converter Cover, Drive Plate and Impeller Hub

Tightening SequenceSpecification
Drive Plate Ring Cap Screw
Torque....................................................................... 50 Nm (37 lb-ft)
Values listed must be obtained by a certified torque

wrench.
Torque Sequence:
Use this sequence: torque converter cover, drive plate
and impeller hub for preliminary and final torquing.
2. Torque converter cover: apply high strength thread

lock to torque converter cap screws and tighten to
specification.
TM2111 (30MAY03)
06-0651-1
YZ01324,000000A 1916JAN031/2

053003
PN=369
06
0651
1

Torque Converter
Cover-to-Impeller Cap
ScrewsTorque ....................................................... 50 Nm (37 lb-ft)
specification.
Impeller-to-Hub Cap Screws
Torque.................................................................... 25 Nm (221 lb-in.)
3. Impeller hub: apply high strength thread lock to

impeller hub cap screws and tighten to
YZ01324,000000A 1916JAN032/2
Torque Converter Drive Plate Remove and

Install
YZ4011
UN27FEB01
ADrive Plate
BRing
06
0651
2
OUO1065,000059D 1916JAN031/4

Torque Converter Drive PlateSpecification
1. Remove torque converter and place on work surface.
YZ4004
UN28FEB01
2. Drain oil through impeller hub, check for contaminants.

Dispose of oil properly.
TM2111 (30MAY03)
06-0651-2
OUO1065,000059D 1916JAN032/4

053003
PN=370

3. Remove pilot sleeve (A) and cap screws (B).
4. Remove ring (C) and drive plate (D).
5. Inspect for wear or damage. Look closely at drive plate
(D) for signs of fatigue, cracks or elongated bolt holes.
YZ4013
UN27FEB01
YZ4012
UN27FEB01
APilot Sleeve
BCap Screws (12 used)
CRing
DDrive Plate
TM2111 (30MAY03)
06-0651-3
OUO1065,000059D 1916JAN033/4

053003
PN=371
06
0651
3

6. Install drive plate (A) and ring (B).
7. Apply high strength thread lock to cap screws.
Torque Converter Drive PlateSpecification

Drive Plate Ring Cap Screw
Torque ............................................................................. 50 Nm (37 lb-ft)
YZ4014
9. Apply anti-seize lubricant to inside diameter of pilot

sleeve.
UN27FEB01
8. Install and tighten cap screws (C). See Torque

Converter Cover, Drive Plate and Impeller Hub
Tightening Sequence in this group.
10. Install pilot sleeve (D).
YZ4015
UN27FEB01
ADrive Plate
BRing
DPilot Sleeve
YZ4016
UN27FEB01
06
0651
4
OUO1065,000059D 1916JAN034/4
TM2111 (30MAY03)
06-0651-4

053003
PN=372
YZ4008
UN26FEB01
Torque Converter Disassemble and Assemble
ASeal Ring
BImpeller Hub
CO-Ring
DImpeller
EFlat Washer (12 used)
FCap Screws (12 used)
GThrust WasherThick
HNeedle Thrust Bearing

Large Roller
IThrust WasherThick
JRetainer Ring
KFixed Stator Hub
LStator
MRetainer Ring
NThrust WasherThin
ONeedle Thrust Bearing
Small Roller
PThrust WasherThin
QTurbine
TM2111 (30MAY03)
06-0651-5
RTurbine Hub
SBearing
TO-Ring
UFront Cover
VFlat Washers (24 used)
WCap Screws (24 used)
YZ01324,0000055 1916JAN031/18

053003
PN=373
06
0651
5

1. Remove cap screws (B) and flat washers (A).
2. Thread two cap screws (D) three to four turns into front
cover to aid front cover removal.
3. Attach two JT05549 Lifting Eyebolts (C) to front cover.
UN27FEB01
IMPORTANT: Tap lightly on cap screws, with a rubber

mallet, until cover separates from the
impeller. Do not use pry bars to remove
front cover (E), damage to aluminum
impeller casting could result.
YZ4017
4. Lift front cover (E) and lightly tap cap screws (D) to
separate front cover and impeller.
YZ4018
UN27FEB01
AWasher (24 used)

CJT05549 Lifting Eyebolt (2 used)
DWasher and Cap Screw (2 used)
EFront Cover
YZ4019
UN27FEB01
06
0651
6
TM2111 (30MAY03)
06-0651-6
YZ01324,0000055 1916JAN032/18

053003
PN=374

5. Remove and discard O-ring (A).
YZ4020
UN27FEB01
AO-Ring
YZ01324,0000055 1916JAN033/18
6. Remove bearing (A).

7. Remove turbine hub (B).
YZ4022
UN27FEB01
YZ4021
UN27FEB01
ABearing
BTurbine Hub
TM2111 (30MAY03)
06-0651-7
YZ01324,0000055 1916JAN034/18

053003
PN=375
06
0651
7

8. Remove turbine (C) and inspect for wear or damage.
YZ4023
UN27FEB01
CTurbine
06
0651
8
TM2111 (30MAY03)
06-0651-8
YZ01324,0000055 1916JAN035/18

053003
PN=376

9. Remove thrust washers (A) and needle thrust bearing
(B).
10. Remove stator (C).
YZ4025
UN27FEB01
YZ4024
UN27FEB01
AThrust WasherThin (2 used)

BNeedle Thrust BearingSmall Roller
CStator
TM2111 (30MAY03)
06-0651-9
YZ01324,0000055 1916JAN036/18

053003
PN=377
06
0651
9

11. Remove retainer ring (A).
12. Remove fixed stator hub (B).
13. Turn stator (C) over.
14. Remove retainer ring (D).
15. Inspect parts for wear or damage.
YZ4026
UN27FEB01
ARetainer Ring
BFixed Stator Hub
CStator
DRetainer Ring
YZ4027
UN27FEB01
06
0651
10
TM2111 (30MAY03)
06-0651-10
YZ01324,0000055 1916JAN037/18

053003
PN=378

IMPORTANT: Do not assemble stator incorrectly. The
torque converter will not work properly
and damage to converter will occur.
UN27FEB01
NOTE: In assembly process of torque converter the stator

FRONT and BACK sides will be referred to.
The stator casting is not marked; it must be
identified by characteristics of the cast vanes.
YZ4028
16. The FRONT of stator casting is identified by the

vanes being thicker. The BACK of stator casting is
identified by the vanes being thinner.
YZ4029
UN27FEB01
Front Side of Fixed Stator
Back Side of Fixed Stator
TM2111 (30MAY03)
06-0651-11
YZ01324,0000055 1916JAN038/18

053003
PN=379
06
0651
11
CAUTION: Wear eye protection when installing

or removing retaining rings.
17. Position stator with back side up.
18. Install retaining ring (A) in groove.
YZ512
UN10MAR98
ARetaining Ring
YZ01324,0000055 1916JAN039/18
06
0651
12
TM2111 (30MAY03)
06-0651-12

053003
PN=380

19. Turn stator over, with thick vanes up.
IMPORTANT: Stator hub (B) must be installed with
Front side up as shown.
20. Install fixed stator hub (B) (front side up).
21. Install retaining ring (D) into groove.
YZ4031
UN28FEB01
YZ4104
UN13MAR01
BFixed Stator Hub

CStator
DRetaining Ring
TM2111 (30MAY03)
06-0651-13
YZ01324,0000055 1916JAN0310/18

053003
PN=381
06
0651
13

22. Remove thrust washers (A) and needle thrust bearing
(B).
23. Remove cap screws (C) and washers (D).
YZ4033
UN28FEB01
YZ4032
UN24MAR01
AThrust WasherThick (2 used)

BNeedle Thrust BearingLarge Roller
DWasher (12 used)
06
0651
14
TM2111 (30MAY03)
06-0651-14
YZ01324,0000055 1916JAN0311/18

053003
PN=382

24. Lift impeller (A) off impeller hub (B).
25. Remove O-ring (C) and seal ring (D).
26. Inspect splines, seal and bearing surfaces.
YZ4034
UN28FEB01
AImpeller
BImpeller Hub
CO-Ring
DSeal Ring
YZ4035
UN28FEB01
06
0651
15
TM2111 (30MAY03)
06-0651-15
YZ01324,0000055 1916JAN0312/18

053003
PN=383

27. Lubricate O-ring (A) with petroleum jelly and install on
impeller hub (B).
28. Install impeller (C) on impeller hub (B).
29. Align holes in impeller hub (B) with holes in impeller
(C).
UN28FEB01
YZ4036
UN28FEB01
AO-Ring
BImpeller Hub
CImpeller
YZ4034A
06
0651
16
TM2111 (30MAY03)
06-0651-16
YZ01324,0000055 1916JAN0313/18

053003
PN=384

30. Clean cap screws (C). Apply cure primer.
31. Apply high strength thread lock to cap screws.
32. Install cap screws (C) and washers (B) and tighten in
correct sequence to specification. See Torque
UN28FEB01
Torque ConverterSpecification
Impeller-to-Hub Cap Screws
Torque .......................................................................... 25 Nm (221 lb-in.)
YZ4038
BWasher (12 used)

YZ01324,0000055 1916JAN0314/18
06
0651
17
TM2111 (30MAY03)
06-0651-17

053003
PN=385

IMPORTANT: The thrust bearing and thrust washers
used between impeller hub and stator
hub are different from set used between
stator hub and turbine. These have a
smaller outside diameter and larger
diameter needle roller with thicker
thrust washers.
UN26MAR01
33. Lubricate needle thrust bearing and thrust washers

with clean transmission fluid.
YZ4032A
IMPORTANT: Always use new thrust washers and

thrust needle bearings.
34. Install thrust washer (A).
35. Install needle thrust bearing (B).
36. Install thrust washer (C).
37. Install stator (D) with Front side up.
NOTE: If stator is installed improperly it will not turn freely

on thrust bearing.
AThrust WasherThick
BNeedle Thrust BearingLarge Roller
CThrust WasherThick
DFixed Stator
EImpeller
YZ4025A
06
0651
18
UN09MAR01
38. Rotate stator several turns to be sure it is properly

seated on thrust bearing.
TM2111 (30MAY03)
06-0651-18
YZ01324,0000055 1916JAN0315/18

053003
PN=386
UN09MAR01
IMPORTANT: The thrust bearing and thrust washers

used between the stator hub and
turbine are different from set used
between impeller hub and stator hub.
These have a larger outside diameter
and smaller diameter needle roller with
thinner thrust washers.
39. Lubricate needle thrust bearing and thrust washers
with clean transmission fluid.
YZ4024A
IMPORTANT: Always use new thrust washers and

thrust needle bearings.
40. Install thrust washer (A).
AThrust WasherThin
BNeedle Thrust BearingSmall Roller
CThrust WasherThin
DImpeller
41. Install needle thrust bearing (B).

42. Install thrust washer (C).
YZ01324,0000055 1916JAN0316/18
06
0651
19
TM2111 (30MAY03)
06-0651-19

053003
PN=387

43. Install turbine hub (A).
44. Install turbine (B).
45. Lubricate and install bearing (C).
NOTE: Bearing is a slip-fit bearing.
UN28FEB01
46. Rotate turbine several turns to be sure it is properly

seated on thrust bearing.
YZ4041
UN28FEB01
YZ4040
ATurbine Hub
BTurbine
CBearing
06
0651
20
TM2111 (30MAY03)
06-0651-20
YZ01324,0000055 1916JAN0317/18

053003
PN=388

47. Lubricate O-ring (A) with petroleum jelly and install.
Torque ConverterSpecification
Front Cover-to-Impeller Cap
50. Install drive plate. See Torque Converter Drive Plate

YZ4020
49. Install cap screws (D) and washers (C) and tighten in
correct sequence to specification. See Torque
UN27FEB01
48. Install front cover (B). Align cap screw holes of front
cover and impeller.
YZ4017A
UN28FEB01
YZ4019A
UN28FEB01
AO-Ring
BFront Cover
CWasher (24 used)
DCap Screw (24 used)
YZ01324,0000055 1916JAN0318/18
TM2111 (30MAY03)
06-0651-21

053003
PN=389
06
0651
21
06
0651
22
TM2111 (30MAY03)
06-0651-22

053003
PN=390
Section 07
Damper Drive
Contents
Page
Group 0752Elements
Damper Remove and Install . . . . . . . . . . . . .07-0752-1
Transmission Cold Weather Disconnect
Linkage Repair . . . . . . . . . . . . . . . . . . . . .07-0752-4
07
TM2111 (30MAY03)
07-1

053003
PN=1
Contents
07
TM2111 (30MAY03)
07-2

053003
PN=2
Group 0752
Elements
Damper Remove and Install
2. Remove drive shaft. See Input Drive Shafts and
U-Joints. (Group 0325.)
3. Remove cap screws (A) to remove cover (B).
For machines equipped with transmission disconnect.
See Transmission Cold Weather Disconnect Linkage
Repair in this group.
UN23APR98
4. Remove cap screws (C) and remove damper (D).
T114951B
ACap Screw (6 used)

BCover
CCap Screw (6 used)
DTorsional Damper
EDowel Pin (2 used) (540G-III, 548G-III, 640G-III,
648G-III)
TX,07,RB804 1923JAN031/2
07
0752
1
TM2111 (30MAY03)
07-0752-1

053003
PN=393
Elements
5. Position damper (D) on dowel pins (E).
6. Install and tighten cap screws (C).
DamperSpecification
Flywheel-to-Flywheel Housing
7. Install cover (B). Tighten cap screws (A).
8. Install drive shaft. See Input Drive Shafts and U-Joints.

(Group 0325.)
T114951B
On machines equipped with transmission disconnect. See

Transmission Cold Weather Disconnect Linkage Repair in
this group.
UN23APR98
DamperSpecification
Flywheel Cover-to-Flywheel
Housing Cap ScrewTorque..................... 104156 Nm (78115 lb-ft)

ACap Screw (6 used)
BCover
CCap Screw (6 used)
DTorsional Damper
EDowel Pin (2 used) (540G-III, 548G-III, 640G-III,
648G-III)
TX,07,RB804 1923JAN032/2
07
0752
2
TM2111 (30MAY03)
07-0752-2

053003
PN=394
Elements
07
0752
3
TM2111 (30MAY03)
07-0752-3

053003
PN=395
Elements
Transmission Cold Weather Disconnect Linkage Repair
T120461
UN23MAR99
07
0752
4
TM2111 (30MAY03)
07-0752-4
TX,0752,JC612 1923JAN031/9

053003
PN=396
Elements
1Yoke
2Nut
3Pin
4Rod
5Spring Pin
6Washer
7Housing
8Cover
9Washer
11Lever
12Washer (2 used)
13Cap Screw
14Pin
15Pin
16Nut
17Spring
18Plate
19Washer (4 used)
21Bellcrank
22Washer (4 used)
23Linkage
24Cap Screw
25Cap Screw
26Pin (2 used)
27Cotter Pin (2 used)
28Link
29Ball Joint (2 used)
30Washer (6 used)
31Nut (4 used)
33Bushing (2 used)
34Screw (2 used)
35Cotter Pin (2 used)
37Gusset
38Grommet
39Tag
40Disconnect Linkage
1. Remove transmission drive shaft. See Input Drive

Shafts and U-Joints. (Group 0325.)
4. Tighten ball joint-to-housing nut (31) to

specification.
2. Disassemble and assemble parts as shown.
Transmission Cold Weather Disconnect LinkageSpecification

Ball Joint-to-Housing Nut
InitialTorque................................................................ Finger-tighten
Ball Joint-to-Housing Nut
FinalTorque ........................................................... 34 Nm (25 lb-ft)
NOTE: Install bushing (33) into housing (7). Press

bushing into bore until flush. Inline ream bore
ID to 15.916.0 mm (0.6260.630 in.).
5. Remove attaching parts to remove linkage (23).

3. Tighten disconnect housing-to-flywheel housing cap
screws (13 and 20) to specification.
Disconnect
Housing-to-Flywheel Housing
TX,0752,JC612 1923JAN032/9
07
0752
5
TM2111 (30MAY03)
07-0752-5

053003
PN=397
Elements
T8483AD
UN15MAY95
07
0752
6
TM2111 (30MAY03)
07-0752-6
TX,0752,JC612 1923JAN033/9

053003
PN=398
Elements
1Cap Screw (4 used)
2Universal Joint Cross
3Stub Shaft
4Seal
5Cap Screw (6 used)
6Collar
7O-Ring
8Snap Ring
9Inner Collar
10Bushing
11Oil Seal
12Needle Bearing
14Washer (12 used)
15Cover
16Pipe Plug (2 used)
17Thrust Bearing Race (2
used)
18Needle Thrust Bearing

19Compression Spring
20Sliding Shaft
21Bearing
22O-Ring
23Spline Hub
25Snap Ring
26Cap
27Bearing Kit
28Disconnect Spline Kit
29Washer (6 used)
30Transmission Disconnect
31Transmission Disconnect
Kit
6. Remove cap screws (1) from stub shaft (3).
9. Remove cap (26).
7. Remove cap screws (13) and washers (14) to

remove disconnect cover (15) from damper.
10. Remove snap ring (25) to pull out stub shaft (3).
11. Remove seal (4) and collar (6) from stub shaft (3).
8. Remove cap screws (5) and washers (29) to

remove collar (6).
TX,0752,JC612 1923JAN034/9
UN11JUL91
CAUTION: Splined hub (A) is spring loaded.

Follow proper procedure to remove splined hub
and collar (B) to prevent personal injury. If
splined hub is removed improperly the spring
will pull hub up against collar.
12. Press collar (B) down.
T7502HR
ASplined Hub
BCollar
07
0752
7
TX,0752,JC612 1923JAN035/9
T7502HO
UN11JUL91
ASnap Ring
TM2111 (30MAY03)
07-0752-7
TX,0752,JC612 1923JAN036/9

053003
PN=399
Elements
NOTE: Hydraulic press is shown for removal. If press is
not available, a lead hammer and appropriate
drivers can be used.
T7502HP
UN11JUL91
14. Remove collar to remove sliding shaft, using a 35 mm

disk. Collar is a light press fit.
TX,0752,JC612 1923JAN037/9
07
0752
8
TM2111 (30MAY03)
07-0752-8

053003
PN=400
Elements
CAUTION: Splined hub is spring loaded. Follow

proper removal procedure to avoid personal
injury.
UN11JUL91
15. Loosen cap screws (B) until heads are exposed.
T7502HQ
16. Install cap screws (A) in lifting holes of splined hub.

Tighten puller cap screws until hub releases.
17. Disassemble parts from cover.
18. Press seal (4) into collar (6) counterbore. Install on
stub shaft (3) with lip on ground diameter of shaft.
ACap Screw1/4 x 1 in. (2 used)

BCap Screw (2 used)
19. Install O-ring (7) on stub shaft (3).

20. Install all bushings and bearings that were removed.
21. Install sliding shaft bushing (10) to specified depth in
sliding shaft (20).
Sliding Shaft BushingDepth ................ 2.1 0.13 mm (0.08 0.005 in.)
22. Install needle bearing (12) flush with bottom of 81 mm

(3.2 in.) diameter cavity in cover (15).
23. Install cover bearing (21) to specified depth below
end surface of cover (15).
Cover BearingDepth ............................... 1717.5 mm (0.670.69 in.)
24. Install parts (1721) in cover (15) as shown.

25. Apply grease between lips of seal. Install oil seal (11)
into cover after installing sliding shaft (20).
07
0752
9
26. Install O-ring (22) into groove of spline hub (23).
TM2111 (30MAY03)
07-0752-9
TX,0752,JC612 1923JAN038/9

053003
PN=401
Elements
27. Press collar onto sliding shaft past snap ring groove.
Install snap ring (A). Pull collar back against snap
ring.
UN11JUL91
28. Install splined hub (23) on cover (15). Tighten cap

screws (24) to specifications.
T7502HP

Splined Hub-to-Cover Cap
ScrewTorque ............................................................. 14 Nm (124 lb-in.)
29. Apply grease to splines of stub shaft (3). Install cover

with splined hub assembly onto stub shaft (3).
30. Install snap ring (25) in stub shaft groove.
UN11JUL91
31. Install washers (29) into collar (6) counterbores. Apply

thread lock and sealer (medium strength) on cap
screws (5). Install and tighten to specification. Tighten
again.
32. Apply plastic gasket into bore of cap (26) and drive
into splined hub (23).
T7502HO

Collar-to-Collar Cap Screw
InitialTorque .............................................................. 14 Nm (124 lb-in.)
Collar-to-Collar Cap Screw
FinalTorque ............................................................... 14 Nm (124 lb-in.)
ASnap Ring
33. Install and tighten cap screws (13).

Cover-to-Damper Cap Screw
Torque ........................................................................... 113 Nm (83 lb-ft)
34. Remove plug (16) and add 118.4 mL (4 oz.) hydraulic

oil in cover (15).
07
0752
10
35. Install and tighten cap screws (1).

Universal Joint-to-Stub Shaft
36. Install parts to attach linkage (23).

37. Adjust disconnect linkage. See Cold Weather
Disconnect Linkage Adjustment. (Group 9020.)
TX,0752,JC612 1923JAN039/9
TM2111 (30MAY03)
07-0752-10

053003
PN=402
Section 09
Steering System
Contents
Page
Group 0930Secondary Steering

Secondary Steering Pump. . . . . . . . . . . . . . .09-0930-1
Steering Valve. . . . . . . . . . . . . . . . . . . . . . . .09-0960-1
Steering Cylinder. . . . . . . . . . . . . . . . . . . . . .09-0960-9
09
TM2111 (30MAY03)
09-1

053003
PN=1
Contents
09
TM2111 (30MAY03)
09-2

053003
PN=2
Group 0930
Secondary Steering
Secondary Steering Pump Remove and
Install
UN23AUG88
CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
1. Remove right engine side shields.

3. Operate all hydraulic controls to release pressure in
the hydraulic system.
4. Disconnect wiring harness connectors (1) from
secondary steering pump and motor (5).
5. Disconnect lines (2 and 3) from secondary steering
pump (5). Close openings using caps and plugs.
6. Remove cap screws (4) to remove secondary steering
pump (5).
UN15JUN00
7. Inspect and replace components, as required.
T131611B
1Wiring Harness Connectors (3 used)

2Secondary Steering Pump-to-Inlet Manifold Port E
Line
3Oil Filter-to-Secondary Steering Pump Line
4Cap Screw (3 used)
5Secondary Steering Pump and Motor
OUT3035,00002F6 1909DEC021/3
09
0930
1
TM2111 (30MAY03)
09-0930-1

053003
PN=405
Secondary Steering
T162674
UN11DEC02
09
0930
2
Secondary Steering Hydraulic System
TM2111 (30MAY03)
09-0930-2
OUT3035,00002F6 1909DEC022/3

053003
PN=406
Secondary Steering
1Inlet Manifold B
Port-to-Steering Valve Port
P Line
2Inlet Manifold Port
D-to-Hydraulic Reservoir
Line
3Secondary Steering
Pump-to-Inlet Manifold Port
E Line
4Oil Filter-to-Secondary
Steering Pump Line
5Priority Valve Port
CF-to-Inlet Manifold Port A
Line
6Priority Valve Port T-to-Inlet
Manifold Port D Line
7Tee
8O-Ring (7 used)
9Adapter
10O-Ring (2 used)
11O-Ring (2 used)
12Adapter (2 used)
13Secondary Steering Pump
and Motor
14Plate (540G-III, 548G-III,
640G-III, 648G-III, 360D,
460D)
Plate (748G-III, 560D)
15Bracket
16Adapter
17Strap
18O-Ring
8. Install secondary steering pump and motor (13).

9. Connect hoses (3 and 4) to pump.
19O-Ring (2 used)
20O-Ring
2190 Elbow
24O-Ring
2590 Elbow (2 used)
26O-Ring (2 used)
27Tee
28O-Ring (3 used)
2945 Elbow
30O-Ring (2 used)
31Inlet Manifold
32Check Valve
33Pressure Switch
34Plug
36Cap Screw
37Nut
38Not Used
39O-Ring
40Wiring Harness Connector
41Priority Valve
42Cap Screw
43Clamp
44Spacer
45Load Center Harness
46To Starter
47To Secondary Steering
Motor
12. Check hydraulic oil level in the hydraulic reservoir

before starting engine. See Check Hydraulic
System Oil Level. (Operators Manual.)
10. Connect wiring harness connectors (47) to motor.

11. Turn battery disconnect to ON position. Install
engine side shields.
OUT3035,00002F6 1909DEC023/3
09
0930
3
TM2111 (30MAY03)
09-0930-3

053003
PN=407
Secondary Steering
09
0930
4
TM2111 (30MAY03)
09-0930-4

053003
PN=408
Group 0960
Hydraulic System
Steering Valve Repair
Remove Steering Valve
UN15JUN00
1. Operate hydraulic control valves to relive pressure in

T131633B
2. Remove cap screws (1) to remove lower console (2).

As necessary, remove the fire extinguisher and
windshield washer tank.
3. Remove the cap screw from lower end of universal
joint (4).
T131635B
UN15JUN00
1Cap Screw (4 used)

2Lower Console
3Lower Steering Column
4Universal Joint
OUT3035,00002F7 1926SEP021/11
09
0960
1
TM2111 (30MAY03)
09-0960-1

053003
PN=409
Hydraulic System
UN23AUG88

5. Before disconnecting the hydraulic lines (59), take
notice of the orientation of fittings and lines.
X9811
Identify lines to aid in assembly. Close openings using

caps and plugs.
6. Remove nuts and washers (9) to remove steering
valve (8). Seal may come with the valve or remain
stuck to the platform.
T162771B
UN16DEC02
5Port T-to-Return Oil Filter Line

6Priority Valve Port CF-to-Port P Line
7Port L-to-Steering Cylinders Line
8Port R-to-Steering Cylinders Line
9Port LS-to-Priority Valve Port LS Line
10Steering Valve
11Flange Nut (3 used) and Washer (6 used)
Steering ValveTorque Converter Machine
OUT3035,00002F7 1926SEP022/11
7. Take notice of position and location of rubber isolators

(13).

13Rubber Isolator (3 used)
15Mounting Plate
T162768
09
0960
2
UN12DEC02
8. Remove cap screws (14) to remove mounting plate

(15) and lower steering column (12).
TM2111 (30MAY03)
09-0960-2
OUT3035,00002F7 1926SEP023/11

053003
PN=410
T162227B
UN04DEC02
Hydraulic System
Figure 1-Steering Valve Components
Disassemble and Assemble Steering Valve
Use wooden blocks or similar material

to protect steering valve. Tighten vise
just enough to hold valve.
Overtightening can damage the valve.
1
1. Put steering valve in a vise with the gerotor end up.

Tighten just enough to hold valve.
Figure 2-Cap Screws

1Cap Screw (7 used)
2Pins (2 used)
3Anti-Cavitation Steel Balls (2 used)
4End Cap
7Spool
8Gerotor Star
9Gerotor Housing
10Plate Spacer
12Mounting Plate
13Housing
2. Remove the two cap screws (1, Figure 2) to remove

pins (2, Figure 1) and anti-cavitation steel balls (3).
3. Remove the remaining cap screws to remove end cap
(4), gerotor star (8), gerotor housing (9) and plate
spacer (10).
4. Hold spool (7) and reposition valve with lower steering
column (11) end up.
TM2111 (30MAY03)
T162221
UN12DEC02
IMPORTANT: Perform all service on steering valve in

a clean isolated work area. Use proper
tools, cleaning material, and lubricants.
09-0960-3
09
0960
3
OUT3035,00002F7 1926SEP024/11

053003
PN=411
Hydraulic System
5. Remove mounting plate (12) and lower steering
column.
OUT3035,00002F7 1926SEP025/11
6. Assemble tool using a M10 x 120 mm cap screw (22)

and two nuts (28).
7. Install cap screw into housing so head engages into
input spline.
8. Hold drive spline head (20) with 20 mm socket (21).
UN04DEC02
IMPORTANT: Spring tension must be compressed

before spool (7) is removed.
9. Rotate cap screw using a wrench to compress spring
tension.
T162215B
10. Push spool (7) down out of housing (13) while spring
tension is compressed.
Figure 3-Spring Compression Tools
Be careful not to remove pin (14, Figure 6) from spool

(7) and drive spline (19, Figure 6).
11. Inspect all parts for contamination, nicks and burrs.
UN04DEC02
Spool is not serviceable. Do not disassemble spool.
T162222B
12. Replace O-rings (18, Figure 5), dust seal (24, Figure
5), backup washer (25, Figure 5) and seals (26, 27,
Figure 5).
7Spool
13Housing
20Spline Head
2120 mm Socket
22M10 x 120 mm Cap Screw
28Nuts
Figure 4-Spool Removed From Housing
09
0960
4
TM2111 (30MAY03)
09-0960-4
OUT3035,00002F7 1926SEP026/11

053003
PN=412
Hydraulic System
18
26
25
T162216
24
UN20DEC02
27
T162216
Figure 5-Seal Placement

18O-Ring (3 used)
24Dust Seal
25Backup Washer
26Seal
27O-Ring
13. Lubricate O-rings (18 and 27) and seals (24 and
26) with TY24416 Multi-Purpose HD Lithium
Complex Grease. If petroleum jelly is used for
O-ring lubrication, use small enough amount to
avoid spreading on surfaces of other parts.
15. Install spool (7, Figure 1) by compressing spring

tension.
14. Lubricate spool with clean hydraulic oil to ease

assembly.
17. Rotate cap screw (22, Figure 4) using wrench on

nuts (28, Figure 4) to compress spring tension.
16. Hold drive spline head (20, Figure 4) with 20 mm

socket (21, Figure 4).
IMPORTANT: Make sure drive pin (14, Figure 6)

does not slip out of spool and drive
spline.
OUT3035,00002F7 1926SEP027/11
09
0960
5
TM2111 (30MAY03)
09-0960-5

053003
PN=413
Hydraulic System
IMPORTANT: Timing of drive with respect to gerotor
star is critical.
18. Drive pin (14) must be aligned with valley (minor

diameter) of gerotor star.
19. Align pin (14), drive spline (19) and gerotor star (8) as
shown.
9
17
18
20. Install plate spacer (10).
10
21. Install gerotor star (8) and gerotor housing (9).
18
22. Install end cap (4, Figure 1).

19
23. Apply pipe sealant to bottom side of cap screw (1,
Figure 1) heads.
16
UN02DEC02
24. Install the cap screws except in the holes (1, Figure
2) for anti-cavitation steel balls (3, Figure 1) and pins
(2, Figure 1).
14
26. Install remainder cap screws.
T160389
25. Install anti-cavitation steel balls and pins.

15
Figure 6-Component Alignment
8Gerotor Star
9Gerotor Housing
10Plate Spacer
14Drive Pin
15Alignment Line
16Alignment Line
17Alignment Line
18O-Ring (3 used)
19Drive Spline
OUT3035,00002F7 1926SEP028/11
09
0960
6
TM2111 (30MAY03)
09-0960-6

053003
PN=414
Hydraulic System
IMPORTANT: Any cap screw can be tightened first,
but the sequence shown must be
followed.
2
Steering ValveSpecification
Initial TorqueEnd
Cap-To-Housing Cap Screw
Torque ................................................................ 17 Nm (150 lb-in.) Initial
Final TorqueEnd
Cap-To-Housing Cap Screw
Torque ................................................................. 34 Nm (300 lb-in.) Final
T160436
27. Tighten cap screws to the initial specification in the

tightening sequence (17). Then tighten in sequence
to final specification.
UN17OCT02
Figure 7-Tightening Sequence

17Tightening Sequence
OUT3035,00002F7 1926SEP029/11
Install Steering Valve

1. Install lower steering column (12).
UN12DEC02
2. Install mounting plate (15) so the side with single

rubber isolator (13) is towards the port T and P corner
of steering valve.
T162768
3. Install cap screws (14). Tighten to specification.

Mounting Plate and Lower
Steering Column-to-Steering
Valve Cap ScrewTorque ........................................... 26 Nm (234 lb-in.)

13Rubber Isolator (3 used)
15Mounting Plate
4. Install the seal.
OUT3035,00002F7 1926SEP0210/11
09
0960
7
TM2111 (30MAY03)
09-0960-7

053003
PN=415
Hydraulic System
5. Install one washer on each stud.
UN15JUN00
CAUTION: Cab door is heavy. Use caution when

opening cab door while cab is tilted.
T131635B
6. With the help of an assistant working through the right

cab door, install steering valve (10) so the splines of
lower steering column (3) engage splines in lower
universal joint (4) with the flat on shaft towards the cap
screw side of universal joint.
7. Install washers and flange nuts (11).
8. Install cap screw in universal joint.
9. Check that splines are engaged to specification.
Lower Steering Column-to-Lower
Universal Joint Spline
EngagementDistance .................................... 19 mm (0.75 in.) minimum
10. Connect lines (59).

UN16DEC02
11. Lower the cab. Check that lines do not become

pinched as cab is lowered. Adjust the angle of elbows
and hoses as necessary.
1Cap Screw (4 used)

2Console Cover
4Universal Joint
5Port T-to-Return Oil Filter Line
6Priority Valve Port CF-to-Port P Line
7Port L-to-Steering Cylinders Line
8Port R-to-Steering Cylinders Line
9Port LS-to-Priority Valve Port LS Line
10Steering Valve
11Flange Nut (3 used) and Washer (6 used)
T162771B
12. Install lower console cover (2). Install cap screws (1).
T131633B
UN15JUN00
Steering ValveTorque Converter Machine
09
0960
8
OUT3035,00002F7 1926SEP0211/11
TM2111 (30MAY03)
09-0960-8

053003
PN=416
Hydraulic System
Steering Cylinder Remove and Install
1
3
2. Operate all controls to release hydraulic pressure.

6
3. Remove engine frame shields.
T162743
4. Disconnect lines (6 and 7) at rod and head end of

steering cylinder (5). Close openings using caps and
plugs.
4
1
T162743
UN18DEC02

1Cap Screw (2 used)

2Lock Nut (2 used)
3Pin (2 used)
4Thrust Washer (as required)
5Steering Cylinder
6Rod End-to-Steering Valve Line
7Head End-to-Steering Valve Line
5. Remove lock nuts (2) and cap screws (1) to remove

pins (3) and thrust washer (4).
Steering CylinderSpecification
540G-III, 548G-III and 360D
Steering CylinderWeight ............................. 22.7 kg (50 lb) approximate
640G-III, 648G-III, and 460D
Steering CylinderWeight ............................. 27.3 kg (60 lb) approximate
748G-III and 560D Steering
CylinderWeight ............................................... 36 kg (80 lb) approximate
6. Remove the cylinder.

7. Repair or replace cylinder.
See Disassemble Cylinder and See Assemble Cylinder
for repair procedures. (TM-H120A.)
8. Install cylinder so work ports are on the bottom, and
cap screw hole in rod end clevis is on top.
9. Install thrust washers (4) to center cylinder clevises on
the mounting plates.
10. Install the pins (3).
09
0960
9
11. Install cap screws and lock nuts. Tighten to

specifications.
TM2111 (30MAY03)
09-0960-9
OUT3035,00002F8 1926SEP021/2

053003
PN=417
Hydraulic System
Steering CylinderSpecification
Cylinder-to-Pin Cap Screw and
Lock NutTorque ........................................................... 27 Nm (20 lb-ft)
12. Connect hydraulic lines.
OUT3035,00002F8 1926SEP022/2
09
0960
10
TM2111 (30MAY03)
09-0960-10

053003
PN=418
Section 10
Service Brakes
Contents
Page

Service Brake Lining Inspection . . . . . . . . . .10-1011-1
Service Brake Pedal . . . . . . . . . . . . . . . . . . .10-1015-1
Service Brake Valve . . . . . . . . . . . . . . . . . . .10-1060-1
Brake Accumulator . . . . . . . . . . . . . . . . . . . .10-1060-3
10
TM2111 (30MAY03)
10-1

053003
PN=1
Contents
10
TM2111 (30MAY03)
10-2

053003
PN=2
Group 1011
Active Elements
Service Brake Lining Inspection
2. See External Service Brake Inspection for inspection

procedure. (Operators Manual.)
3. Replace brake disk as necessary.
T7417AO1
Remove rear cover plate for access to rear axle brake

inspection port plug (B).
UN02JAN91
1. Lower front bottom guard for access to front axle brake

inspection port plug (A).
See Disassemble and Assemble Brakes for further

inspection and replacement of brake disk. (CTM43.)
T131535B
AFront Axle Brake Inspection Port Plug (2 used)

BRear Axle Brake Inspection Port Plug (2 used)
UN08JUN00
See Axle Identification before beginning repair or

adjustment to become familiar with the axle and
differential configuration. (CTM43.)
OUT3035,0000339 1912DEC021/1
10
1011
1
TM2111 (30MAY03)
10-1011-1

053003
PN=421
Active Elements
10
1011
2
TM2111 (30MAY03)
10-1011-2

053003
PN=422
Group 1015
Controls Linkage
TP63164
UN15APR00
Service Brake Pedal Remove and Install
1Spring
2Bushing (2 used)
3Spring Pin
4Pedal
5Cap Screw (2 used)
6Nut
7Support
8Shaft
1. Remove spring pin (3).
9Cap Screw (3 used)

10Washer (3 used)
4. Perform Brake Pedal Adjustment to adjust

clearance between pedal and brake valve plunger.
(Operators Manual.)
2. Slide out shaft (8).

3. Inspect parts for wear or damage. Replace parts as
necessary.
OUT3035,000033A 1912DEC021/1
10
1015
1
TM2111 (30MAY03)
10-1015-1

053003
PN=423
Controls Linkage
10
1015
2
TM2111 (30MAY03)
10-1015-2

053003
PN=424
Group 1060
Hydraulic System
Service Brake Valve Repair
Remove and Install Service Brake Valve
1. Operate all hydraulic functions, including service
brakes, to relieve pressure in the hydraulic system.
Actuate the brake pedal 20 times at one-second
intervals to relieve oil pressure from brake
accumulator.
2. Perform Hydraulic Tilt Cab Procedure for access to
service brake valve. (Operators Manual.)
OUT3035,0000302 1914OCT021/4
UN23AUG88

3. Identify lines to aid in assembly.
X9811
Disconnect lines (25). Close openings using caps

and plugs.
4. Disconnect wiring connectors for the de-clutch
pressure switch (TC only) (6) and service brake
pressure switch (7).
T161600C
UN17DEC02
1Service Brake Valve

2Port BS-to-Front Axle Service Brake Pistons Line
3Port BR-to-Rear Axle Service Brake Pistons Line
4Brake Accumulator-to-Port P Line
5Port T-to-Hydraulic Reservoir Line
6De-Clutch Pressure Switch (TC Only)
7Service Brake Pressure Switch
TM2111 (30MAY03)
10-1060-1
OUT3035,0000302 1914OCT022/4

053003
PN=425
10
1060
1
Hydraulic System
CAUTION: Cab door is heavy. Use caution when

opening cab door while cab is tilted.
5. While holding valve in place, have an assistant,
working through right cab door, remove cap screws (F)
to remove valve.
6. Repair or replace service brake valve as necessary.
7. Install fittings and pressure switch.
UN10APR98
Service Brake ValveSpecification

Fitting to HousingTorque .............................. 2739 Nm (2029 lb-ft)
Service Brake Pressure Switch to
HousingTorque.......................................................... 12 Nm (106 lb-in.)
T114341B
8. Install valve. Install and tighten cap screws.

Service Brake ValveSpecification
Cab Platform-to-Valve Cap
ScrewTorque .............................................. 2332.5 Nm (1724 lb-ft)
FCap Screw (2 used)
9. Connect the lines and wiring connectors.

10. Lower the cab. Check that lines do not become
pinched as cab is lowered. Adjust angle of elbows
and hoses as necessary.
11. Perform Brake Pedal Adjustment to adjust clearance
between pedal and brake valve plunger. (Operators
Manual.)
CAUTION: Before operating machine, the brake
bleed procedure must be done to remove air
from service brake hydraulic system.
12. See Service Brake Bleeding Procedure before
operating machine. (Group 9025-20.)
OUT3035,0000302 1914OCT023/4
10
1060
2
TM2111 (30MAY03)
10-1060-2

053003
PN=426
Hydraulic System
Disassemble and Assemble Brake Valve
UN23APR91
IMPORTANT: Perform all service on brake valve in a

clean isolated work area. Use proper
tools, cleaning material and lubricants.
Disassemble valve for cleaning and inspection only. Only
a seal repair kit is available for service.
T7516AO
If any parts, except seals, are damaged, replace the valve

as a complete assembly.
T7516AP
UN23APR91
ABoot
BPlug
CO-Ring
DSpring
ESpool
FValve Housing
GSeal
HSpring Retainer
ISpring
JSpring Retainer
KSpring
LPlunger
MO-Ring
NPlug
OPlug
PO-Ring
OUT3035,0000302 1914OCT024/4
Brake Accumulator Remove and Install

1. Operate all hydraulic functions including brakes to
relieve pressure in the hydraulic system. Depress
brake pedal at one-second intervals approximately 20
times to relieve pressure from brake accumulator.
10
1060
3
TM2111 (30MAY03)
10-1060-3
TX,10,RB679 1901NOV021/4

053003
PN=427
Hydraulic System
2. For direct drive machine, remove right rear engine side
shield for access to brake accumulator (1).
UN17DEC02
Perform Hydraulic Tilt Cab Procedure for access to

brake accumulator on torque converter machine.
(Operators Manual.)
T114343C
1Brake Accumulator
2Cap Screw, Lock Nut, Spacer, and Clamp (2 used)
(Direct Drive Machine)
Right Side of Direct Drive Machine
TX,10,RB679 1901NOV022/4
10
1060
4
TM2111 (30MAY03)
10-1060-4

053003
PN=428
Hydraulic System
UN23AUG88

3. Identify lines before disconnecting to aid in assembly.
X9811
Disconnect tee (5) from inlet check valve fitting (4).

Disconnect line (7) from adapter (3). Use adapter in
the new accumulator. Close all openings using caps
and plugs.
NOTE: The inlet check valve fitting is serviced with the

brake accumulator.
4. For direct drive machines, remove cap screws, lock
nuts, spacers, and clamps (2) to remove accumulator
(1).
For torque converter machine, remove cap screws,
washers, and clamps to remove accumulator.
UN17DEC02
5. For direct drive machines, install accumulator so the

inlet check valve fitting is towards the center of
machine.
T114342C
For torque converter machines, install accumulator so

inlet check valve fitting is towards the cab platform.
6. Install new decal on accumulator.
1Brake Accumulator
2Cap Screw, Lock Nut, Spacer, and Clamp (2 used)
(Direct Drive Machine)
Cap Screw, Washer, and Clamp (2 used) (Torque
Converter Machine)
3Adapter
4Inlet Check Valve Fitting
5Tee
6To Grapple Rotate Solenoid Valve
7From Priority Valve (Direct Drive Machine)
From Main Hydraulic Pump (Torque Converter
Machine)
8To Service Brake Valve
T162935B
UN17DEC02
Brake AccumulatorDirect Drive Machine
Brake AccumulatorTorque Converter Machine
10
1060
5
TM2111 (30MAY03)
10-1060-5
TX,10,RB679 1901NOV023/4

053003
PN=429
Hydraulic System
CAUTION: Before operating machine, the brake

bleed procedure must be done to remove air
from hydraulic system.
7. See Service Brake Bleeding Procedure before
operating machine. (Group 9025-20.)
TX,10,RB679 1901NOV024/4
10
1060
6
TM2111 (30MAY03)
10-1060-6

053003
PN=430
Section 11
Park Brake
Contents
Page

Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . .11-1111-1
Park Brake Solenoid Valve . . . . . . . . . . . . . .11-1160-1
TM2111 (30MAY03)
11-1

053003
PN=1
11
Contents
11
TM2111 (30MAY03)
11-2

053003
PN=2
Group 1111
Active Elements
Park Brake Remove and Install
11
1111
1

unexpected machine movement.
Install frame locking bar before working in
frame hinge area.
UN02JAN03
Install wheel chocks under one or more wheels

before disconnecting drive shafts.
T162992B
2. Install wheel chocks under one or more wheels before

disconnecting drive shaft.
3. Remove shields at the articulation joint as needed for
access to park brake.
9Transmission Yoke, Nut, and Cotter Pin

13 Cap Screw (4 used) (Recessed in Cover)
14Cover
17Housing
21Double Universal Joint (Telescoping Drive
Shaft)
22Park Brake and Differential Lock Solenoid
Valve Manifold-to-Park Brake Line
4. Disconnect line (22).

5. Remove cap screws to disconnect double universal
joint (21) from transmission yoke (9).
6. Remove cotter pin and nut to remove yoke (9).
CAUTION: The park brake contains a disk
spring under load. Four of the fourteen cap
screws are shorter and are recessed in the
cover. The four recessed cap screws hold the
cover and housing together.
Heavy component; use a hoist.
Park BrakeWeight .......................................... 43 kg (95 lb) approximate
7. Remove two of the ten cap screws (12). Install guide

pins.
8. Loosen remaining cap screws (12 and 13) in even
steps to relieve spring force.
TM2111 (30MAY03)
11-1111-1
OUT3035,000033B 1917DEC021/2

053003
PN=433
Active Elements
4
11
1111
2
3
7
8
20
10
19
UN02JAN03
11
1
12
18 17 16
T162978
1Transmission Housing
2Transmission Output Shaft
3Disk (8 used)
4O-Ring
5Piston
6Disk Spring
7Oil Seal
9Transmission Yoke, Nut,
and Cotter Pin
11Separator Plate (9 used)
9. Repair or replace parts (38 and 1020) as

necessary. See Park Brake Repair for procedure.
(Group 0350.)
15
T162978
13
14
12M12 x 140 mm Cap Screw

(10 used)
13 M12 x 110 mm Cap Screw
(4 used) (Recessed In
Cover)
14Cover
15Outer Seal Ring

16Inner Seal Ring
17Housing
18Gasket
19Hub
20Snap Ring
10. Install drive shaft. See Rear Axle and Differential

Drive Shaft Repair. (Group 0225.)
OUT3035,000033B 1917DEC022/2
TM2111 (30MAY03)
11-1111-2

053003
PN=434
Group 1160
Hydraulic System
Park Brake Solenoid Valve Repair
11
1160
1
UN15JUN00

T131612B
2. Remove cap screws (1) to remove guard (2) under the

left rear corner of cab. See Power Train Component
LocationDirect Drive Machines or See Power Train
Component LocationTorque Converter Machines for
location of park brake solenoid valve. (Group 9020-15.)
3. Disconnect wiring connector (3).
UN15JUN00
4. Remove nut (4) to remove cover and solenoid coil from

the valve (5) on the right end of park brake and
differential lock solenoid valve manifold. Remove the
valve.
T131614B
1Cap Screw (2 used)

2Guard
3Wiring Connector
4Nut
5Cover, Solenoid Coil, and Valve
TM2111 (30MAY03)
11-1160-1
OUT3035,000033C 1918DEC021/2

053003
PN=435
Hydraulic System
T7508AE
UN09JUL91
11
1160
2
ANut
BWasher
CCover
DSolenoid Coil
EPlate
FValve (Spool)
GO-Ring
HBackup Ring
IO-Ring
JBackup Ring
KBackup Ring
LO-Ring
MBackup Ring
5. Repair or replace parts as needed.
8. Tighten nut to specification.
NOTE: The park brake solenoid valve and differential

lock solenoid valve are the same part number.
Park Brake Solenoid ValveSpecification

Cover and Solenoid
Coil-to-Valve NutTorque........................... 58 Nm (4471 lb-in.)
6. Install new O-rings and backup rings (GM).
9. Connect wiring connector.
7. Tighten valve (F) to specification.
10. Install guard and cap screws.
Park Brake Solenoid ValveSpecification

Solenoid Valve-to-Park Brake
and Differential Lock Solenoid
Valve ManifoldTorque ............................ 4754 Nm (3540 lb-ft)
IMPORTANT: Overtightening the solenoid valve

cover nut could damage the solenoid
coil. Tighten the nut to specification.
OUT3035,000033C 1918DEC022/2
TM2111 (30MAY03)
11-1160-2

053003
PN=436
Section 17
Frame, Chassis, or Supporting Structures

Contents
Page
17
Group 1740Frame Installation

Welding Repair of Major Structure. . . . . . . . .17-1740-1
Engine and Equipment Frames
Separate . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-2
Lower Pivot Pin Repair . . . . . . . . . . . . . . . .17-1740-10
Upper Pivot Pin Repair . . . . . . . . . . . . . . . .17-1740-18
Group 1746Frame Bottom Guards
Bottom Guard
Engine Frame . . . . . . . . . . . . . . . . . . . . . .17-1746-1
Equipment Frame . . . . . . . . . . . . . . . . . . .17-1746-2
TM2111 (30MAY03)
17-1

053003
PN=1
Contents
17
TM2111 (30MAY03)
17-2

053003
PN=2
Group 1740
Frame Installation
Welding Repair of Major Structure
UN23AUG88
CAUTION: Avoid potentially toxic fumes and

dust. Hazardous fumes can be generated when
paint is heated by welding, soldering, or using a
torch. Do all work outside or in a well ventilated
area. Dispose of paint and solvent properly.
TS220
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 before welding or
heating.
Remove paint before welding or heating.
IMPORTANT: Disconnect battery ground strap or turn
battery disconnect switch to "OFF".
Have only a qualified welder do this job.
Connect welder ground clamp close to
each weld area so electrical current
does not pass through any bearings.
Remove or protect all parts that can be
damaged by heat or weld splatter.
Use one of the following weld processes:
AWS-E-7018 covered electrode with shielded metal arc
welding (SMAW) process
AWS-ER-70S-3 wire electrode with gas metal arc
welding (GMAW) process
AWS-E70T-1 or E71T-1 wire electrode with flux core
arc welding (FCAW) process.
Preheat area to be repaired to allow better weld
penetration.
To repair weld metal failure, remove failed weld metal
using arc or grinding equipment. Thoroughly clean area to
be welded. Preheat structural assemblies to a minimum of
38C (100F). Preheat ground engaging tools (cutting
edges, skid shoes, and teeth shanks) to 177C (350F).
TM2111 (30MAY03)
17-1740-1
TX,17,RB682 1924JAN031/2

053003
PN=439
17
1740
1
Frame Installation
To repair base metal failure remove enough material to
allow weld to penetrate to the bottom of crack. Preheat
structural assemblies to a minimum of 38C (100F).
Preheat ground engaging tools (cutting edges, skid shoes,
and teeth shanks) to 177C (350F).
17
1740
2
TX,17,RB682 1924JAN032/2
Engine and Equipment FramesSeparate

1. Park machine on smooth level surface and align
frames straight ahead.
UN09MAY95
2. With engine running, lower blade:
T8465AE
Single Function Grapple: Close grapple tong and

lower arch until grapple tong rests on lift table.
Dual Function Grapple: Close grapple tong, raise
arch and lower boom until grapple tong rest on lift
table.
3. Operate all hydraulic functions including brake to
release pressure in the hydraulic system. Depress
brake pedal at one second intervals 20 times to
discharge oil from accumulator.
TM2111 (30MAY03)
17-1740-2
CED,OUO1032,3476 1924JAN031/15

053003
PN=440
Frame Installation
4. Install floor stands under grille housing and ahead of
lower pivot pin of engine frame.
5. Grapple Skidders onlyinstall chain around winch
drum and arch roller. Connect chains using a hand
winch and tighten.
6. Drain hydraulic reservoir.
17
1740
3
UN29APR98
The approximate capacity of the 540G-III and 548G-III

hydraulic reservoir is 30.3 L (8 gal). The approximate
capacity of the 640G-III, 648G-III and 748G-III
hydraulic reservoir is 41.6 L (11 gal).
T114406B

(Operators Manual.)
CED,OUO1032,3476 1924JAN032/15
8. Remove shields (AD).
T114407B
UN29APR98
ATop Engine Frame Shield

BRight Engine Frame Shield
CLeft Engine Frame Shield
DRight Equipment Frame Shield
TM2111 (30MAY03)
17-1740-3
CED,OUO1032,3476 1924JAN033/15

053003
PN=441
Frame Installation
9. Remove shields (A and B).
UN29APR98
ALeft Equipment Frame Shield

BLeft Equipment Frame Shield
T114408B
17
1740
4
CED,OUO1032,3476 1924JAN034/15
10. Disconnect drive shafts (A and C), winch control

cable (D), and hoses (B and E).
T114409B
UN29APR98
AWinch Drive Shaft

BWinch-to-Transmission Hose
CRear Differential Drive Shaft
DWinch Control Cable
ETransmission-to-Winch Hose
CED,OUO1032,3476 1924JAN035/15
11. Disconnect wire connector (A) and move wires aside

to equipment frame.
T132859B
UN24JUL00
AReverse Alarm and Fuel Sender Wire Connector
TM2111 (30MAY03)
17-1740-4
CED,OUO1032,3476 1924JAN036/15

053003
PN=442
Frame Installation
IMPORTANT: Identify hoses and fittings to bulkhead
before removal, hoses can be
interchanged and may cause machine
damage.
UN22APR99
12. Remove hose guide clamp.
T121221B
13. Identify hydraulic hoses (AG) and disconnect from

bulkhead (H). Close all openings with caps and plugs.
ADifferential Lock Hose
BFuel Supply Line
CFuel Return Hose
DRear Brake Hose
ERotate Hose
FBulkhead
GRotate Hose
HWinch Case Drain
IWinch Control Cable
CED,OUO1032,3476 1924JAN037/15
14. On grapple machines: Identify and disconnect four

hydraulic hoses (AD) at tee fittings. Close all
openings with caps and plugs.
T114412B
UN29APR98
AArch Cylinder Rod End Hose

BArch Cylinder Head End Hose
CGrapple Control Hose
DGrapple Control Hose
Single Function Shown
TM2111 (30MAY03)
17-1740-5
CED,OUO1032,3476 1924JAN038/15

053003
PN=443
17
1740
5
Frame Installation
15. Remove cap screw and nut (A) and spacer (C) from
both sides.
17. Remove upper pivot pins. See Upper Pivot Pin Repair
in this group.
T132687B
18. Remove lower pivot pins. See Lower Pivot Pin Repair
in this group.
19. With the aid of an assistant, carefully roll equipment
frame back while frame is supported on a rolling floor
jack.
APin
BCap Screw and Nut (2 used)
CSpacer (as required)

21. With the aid of an assistant, carefully roll equipment
frame to engine frame to align the upper and lower
pins.
22. Install upper pivot pins. See Upper Pivot Pin Repair in
this group.
23. Install lower pivot pins. See Lower Pivot Pin Repair in
this group.
24. Install pin (A) spacers (C) (if equipped), and cap
screw and nut (B) on both sides.
25. Tighten cap screw and nut then loosen 1/2 turn.
CED,OUO1032,3476 1924JAN039/15
26. Connect hydraulic hoses (AD).
UN29APR98
AArch Cylinder Rod End Hose

BArch Cylinder Head End Hose
CGrapple Control Hose
DGrapple Control Hose
T114412B
17
1740
6
UN20JUL00
16. Place 10-ton floor jack under equipment frame behind

lower pin and raise until frame starts to move upward.
TM2111 (30MAY03)
17-1740-6
CED,OUO1032,3476 1924JAN0310/15

053003
PN=444
Frame Installation
27. Connect hydraulic hoses (AG).
UN22APR99
28. Route and connect hoses at guide loop and install

holding clamp.
T121221B
ADifferential Lock Hose

BFuel Supply Line
CFuel Return Hose
DRear Brake Hose
ERotate Hose
FBulkhead
GRotate Hose
HWinch Case Drain
IWinch Control Cable
CED,OUO1032,3476 1924JAN0311/15
29. Connect wire harness connector (A).
T132859B
UN24JUL00
AReverse Alarm and Fuel Sender Wire Connector
TM2111 (30MAY03)
17-1740-7
CED,OUO1032,3476 1924JAN0312/15

053003
PN=445
17
1740
7
Frame Installation
30. Connect winch hoses (B and E), winch cable (D), and
drive shafts (A and C). Tighten cap screws to
specification.
T114409B
UN29APR98
ADrive Shaft
BWinch-to-Transmission Hose
CDrive Shaft
DWinch Cable
ETransmission-to-Winch Hose
CED,OUO1032,3476 1924JAN0313/15
31. Install shields (A and B).
UN29APR98
ALeft Equipment Frame Shield

BLeft Equipment Frame Shield
T114408B
17
1740
8
Engine and Equipment FramesSpecification

Rear Drive Shaft Cap Screws
(3/8 in.)Torque ............................................................. 60 Nm (45 lb-ft)
Rear Drive Shaft Cap Screws
(1/2 in.)Torque ........................................................... 115 Nm (85 lb-ft)
Winch Drive Shaft Cap Screws
Torque ............................................................................. 60 Nm (45 lb-ft)
TM2111 (30MAY03)
17-1740-8
CED,OUO1032,3476 1924JAN0314/15

053003
PN=446
Frame Installation
32. Install shields (AD).
(Operators Manual.)
34. Fill hydraulic reservoir. See Transmission, Hydraulic
17
1740
9
UN29APR98
Engine and Equipment FramesSpecification

540G-III, 548G-III Hydraulic
ReservoirCapacity ........................................ 30.3 L (8 gal) approximate
Hydraulic ReservoirCapacity...................... 41.6 L (11 gal) approximate
35. Remove shop stand from engine frame and grille

housing.
37. Remove chain and hand winch from winch drum and
arch roller.
T114407B
36. Operate all hydraulic functions to remove any air

trapped in system.
ATop Equipment Frame Shield
CED,OUO1032,3476 1924JAN0315/15
TM2111 (30MAY03)
17-1740-9

053003
PN=447
Frame Installation
Lower Pivot Pin Repair
T130556
UN01MAY00
17
1740
10
TM2111 (30MAY03)
17-1740-10
CED,OUO1048,394 1924JAN031/11

053003
PN=448
Frame Installation
1Upper Pivot Pin
2Cap Screw (6 used)
3Upper Quill
4Shims (as required)
5Pin Sleeve
6Seal (2 used)
7Special Washer
8Cap Screw (3 used)
9Lower Pin
11Snap Ring (4 used)
12Bushing (2 used)
13Locking Collar
14Pin Sleeve
15Pin Retainer Guard
16Special Washer
CAUTION: Grapple Skidders equipment must

be lowered to ground to prevent movement
of equipment frame when lower pin is
removed.
18Lube Fitting (4 used)

19Locking Collar
20Pin Sleeve
21Engine Frame
22Equipment Frame
2. Lower blade and grapple equipment to ground and

operate all hydraulic functions including brake, to
1. Park machine straight and install frame locking bar.
CED,OUO1048,394 1924JAN032/11
3. Remove shields (AD).
T114407B
UN29APR98

TM2111 (30MAY03)
17-1740-11
CED,OUO1048,394 1924JAN033/11

053003
PN=449
17
1740
11
Frame Installation
4. Remove shield (B) and disconnect rear differential
drive shaft (A) from transmission and move to right
side.
UN29APR98
ARear Differential Drive Shaft

BShield
T114278B
17
1740
12
CED,OUO1048,394 1924JAN034/11
5. Place a 10-ton floor jack under engine and equipment

frame at hinge area.
T129738B
UN30MAR00
1Cover
2Cap Screw (6 used)
TM2111 (30MAY03)
17-1740-12
CED,OUO1048,394 1924JAN035/11

053003
PN=450
Frame Installation
T132705
UN20JUL00
17
1740
13
6. Remove cap screws (1) from pin (2).

7. Remove special washer (3).
T132703B
UN20JUL00
8. Using a hydraulic jack, push on underside of pin (2)

and press out of engine frame (5) and equipment
frame (4).
1Cap Screw (3 used)

2Lower Pivot Pin
3Special Washer
4Equipment Frame
5Engine Frame
6Pin Sleeve
7Seal
TM2111 (30MAY03)
17-1740-13
CED,OUO1048,394 1924JAN036/11

053003
PN=451
Frame Installation
3
17
1740
14
4
2
5
7
UN21JUL00
T132704
1
T132704
1Pin Sleeve
2Snap Ring (4 used)
3Bushing (2 used)
4Spherical Bushing
5Engine Frame
6Equipment Frame
7Seal
9. Remove upper pivot pin and separate engine and

equipment frames. See Upper Pivot Pin Repair and
see Engine and Equipment FramesSeparate and
in this group.
13. Using appropriate disk, install spherical bushing

(4) so it is centered in equipment frame (6).
10. Using a bushing driver, remove pin sleeve (1).
15. Install snap rings (2).
11. Remove snap rings (2) and drive out busings (3)
from engine frame (5).
16. Install upper pivot pin a connect engine and

equipment frames.See Upper Pivot Pin Repair and
see Engine and Equipment FramesSeparate
and in this group.
12. Remove spherical bushing (4) from equipment

frame (6) using a bushing driver.
IMPORTANT: Press only on the outer race of
spherical bushing.
14. Install bushings (3) into engine frame.
17. Install new seal (7) into pin sleeve and install pin
sleeve (1) into bushing.
TM2111 (30MAY03)
17-1740-14
CED,OUO1048,394 1924JAN037/11

053003
PN=452
Frame Installation
T132705
UN20JUL00
17
1740
15
1Cap Screw (3 used)

2Lower Pivot Pin
3Special Washer
4Equipment Frame
5Engine Frame
6Pin Sleeve
18. Use a steel plate and floor jacks to support pin

sleeve (6) in bushing.
7Seal
23. Tighten cap screws to specification.

Lower Pivot Pin RepairSpecification
Lower Pivot Pin Cap Screws
Torque................................................................... 319 Nm (235 lb-ft)
19. Install new seal (7) in lower pivot pin (2).

20. Apply grease to pivot pin and bushings.
24. Grease pivot pins.
NOTE: Pivot pin (2) is a press fit into pin sleeve (6).
21. Install pivot pin in pin sleeve.
22. Install special washer (3) and cap screws (1).
Evenly tighten cap screws to draw pivot pin into
pin sleeve.
TM2111 (30MAY03)
17-1740-15
CED,OUO1048,394 1924JAN038/11

053003
PN=453
Frame Installation
25. Install cover (1) and cap screws (2). Tighten cap
Bottom Cover Cap Screws
Torque ......................................................................... 624 Nm (460 lb-ft)
T129738B
UN30MAR00
1Bottom Cover
2Cap Screw (6 used)
CED,OUO1048,394 1924JAN039/11
26. Install rear differential drive shaft (A). Install and

tighten cap screws to specification.
UN29APR98

Rear Drive Shaft Cap Screw 3/8
in.Torque ...................................................................... 60 Nm (45 lb-ft)
Rear Drive Shaft Cap Screw 1/2
in.Torque .................................................................... 115 Nm (85 lb-ft)
27. Install shield (B).
T114278B
17
1740
16
ARear Differential Drive Shaft

BShield
TM2111 (30MAY03)
17-1740-16
CED,OUO1048,394 1924JAN0310/11

053003
PN=454
Frame Installation
28. Install shields (AD).
29. Remove jacks and shop stands.
T114407B
UN29APR98
17
1740
17
CED,OUO1048,394 1924JAN0311/11
TM2111 (30MAY03)
17-1740-17

053003
PN=455
Frame Installation
Upper Pivot Pin Repair
T130556
UN01MAY00
17
1740
18
TM2111 (30MAY03)
17-1740-18
CED,OUO1032,3477 1924JAN031/9

053003
PN=456
Frame Installation
1Upper Pivot Pin
2Cap Screw (6 used)
3Upper Quill
4Shims (as required)
5Pin Sleeve
6Seal (2 used)
7Special Washer
8Cap Screw (3 used)
9Lower Pin
12Bushing (2 used)
13Locking Collar
14Pin Sleeve
15Pin Retainer Guard
16Special Washer
18Lube Fitting (4 used)

19Locking Collar
20Pin Sleeve
21Engine Frame
22Equipment Frame
1. Park machine on a level surface and install frame

locking bar.

2. Lower blade and grapple equipment to ground and

operate all hydraulic functions, including brake, to
release pressure in hydraulic system. Depress
3. Install floor stands under grille housing and ahead

of lower pivot pin of engine frame. Support
equipment frame behind lower pin with 10-ton jack.
CED,OUO1032,3477 1924JAN032/9
4. Remove cap screws (1) and special washer (2).
T132739B
UN21JUL00
1Cap Screw (3 used)

2Special Washer
CED,OUO1032,3477 1924JAN033/9
5. Use the 17-1/2 ton hydraulic push-puller from

D01047AA 17-1/2 and 30-Ton Puller Set, to press on
bottom of upper pivot pin (1).
6. Push pin through spherical bushing (2) in engine frame
(3) and out the top of equipment frame (4).
7. Remove lower pivot pin and separate engine and
equipment frames.See Lower Pivot Pin Repair and see
Engine and Equipment FramesSeparate in this
group.
2
3
4
1
T132740
TM2111 (30MAY03)
17-1740-19
T132740
UN21JUL00
1Upper Pivot Pin

2Spherical Bushing
3Engine Frame
4Equipment Frame
CED,OUO1032,3477 1924JAN034/9

053003
PN=457
17
1740
19
Frame Installation
8. Remove cap screws (1) and quill (2).
9. Using a bushing driver, drive out bushing (3) from the
bottom of engine frame through the top of engine
frame.
UN21JUL00
10. Install new spherical bushing (3) until it bottom in bore

of engine frame.
T132741B
11. Install quill (2) without shims. Contact with spherical

bushing must be made.
1Cap Screw (6 used)
2Quill
3Spherical Bushing
CED,OUO1032,3477 1924JAN035/9
12. Measure gap from quill to frame with a feeler gauge.

Add shims to attain 0.030.13 mm (0.0010.005 in.)
preload on spherical bushing.
T128532
UN17FEB00
Upper Pivot PinSpecification

Shim Pack Less Than Gap
Preload ................................................ 0.030.13 mm (0.0010.005 in.)
CED,OUO1032,3477 1924JAN036/9
UN17FEB00
13. Install seal in quill with sealing lip toward the quill.
T128533
17
1740
20
TM2111 (30MAY03)
17-1740-20
CED,OUO1032,3477 1924JAN037/9

053003
PN=458
Frame Installation
14. Install required shims, quill (2) and cap screws (1).
Tighten cap screws to specification. Ball (3) must
oscillate.
Quill Cap ScrewTorque ........................................... 140 Nm (103 lb-ft)
T132741B
UN21JUL00

2Quill
3Ball
TM2111 (30MAY03)
17-1740-21
CED,OUO1032,3477 1924JAN038/9

053003
PN=459
17
1740
21
Frame Installation
1
11
9
17
1740
22
4
10
UN21JUL00
T132748
1Upper Pivot Pin

2Cap Screw (6 used)
3Quill
T132748
1 mm GAP
4Equipment Frame
5Lower Seal
6Cap Screw (3 used)
7Special Washer
8Lock Collar
9Spherical Bushing
15. Install lower seal (5) into engine frame (10) with
sealing lip facing away from spherical bushing (9).
16. Install lock collar (8) into seal.
17. Install lower pivot pin connect engine and
equipment frames. See Lower Pivot Pin Repair
and see Engine and Equipment Frames
Separate in this group.
18. Make sure that lock collar (8) stays in engine
frame.
19. Apply grease to pivot pin and install into bushing
(9).
10Engine Frame
11Upper Seal

Retaining Cap ScrewsInitial
Torque................................................................ 230.5 Nm (170 lb-ft)
Retaining Cap ScrewsFinal
Torque Turn .................................................................................... 90
22. Grease pivot pin.

IMPORTANT: There must be a 1.0 mm (0.039 in.)
gap between special washer (7) and
upper pivot pin (1) after cap screws
have been tightened to specification.
23. Measure gap between special washer and upper
pivot pin. Gap must be to specification.
Special Washer and Upper
Pivot PinGap ...................................................... 1.0 mm (0.039 in.)
20. Install special washer (7) and cap screws (6).

21. Evenly tighten cap screws to draw pin through
bushing. Tighten cap screws to specification.
CED,OUO1032,3477 1924JAN039/9
TM2111 (30MAY03)
17-1740-22

053003
PN=460
Group 1746
Frame Bottom Guards

Engine Frame Bottom Guard Remove and Install
T114595
UN29APR98
17
1746
1
ARear Bottom Guard

BWasher (2 used)
CCap Screw (4 used)
DCap Screw (2 used)

EFront Bottom Guard
FCotter Pin (2 used)

GWasher (2 used)

Weights may increase due to the buildup of
mud and debris.
Engine Frame Bottom GuardSpecification
Front Bottom GuardWeight ..................... 36 kg (80 lb) approximate
Rear Bottom GuardWeight...................... 25 kg (55 lb) approximate
HWasher (4 used)
ICap Screw (2 used)
The bottom guards are hinged and will swing down

to the front of machine.
2. Tighten cap screws (C, D, and I) to specifications.
Engine Frame Bottom GuardsSpecification
Front and Rear Bottom
Guard-to-Engine Frame Cap
1. Use a service jack to hold the bottom guards (A

and E) in place while removing the cap screws (C
and I).
OUT3035,000033D 1919DEC021/1
TM2111 (30MAY03)
17-1746-1

053003
PN=461
Frame Bottom Guards
Equipment Frame Bottom Guard Remove and Install
T114596
UN29APR98
17
1746
2
AWasher (8 used)
BCap Screw (4 used)
CCover
DPlate (2 used)
EBottom Door
FCap Screw (2 used)
GCap Screw (4 used)

HWasher (4 used)

Weights may increase due to the buildup of
mud and debris.
Equipment Frame Bottom GuardSpecification
Bottom GuardWeight............................... 27 kg (60 lb) approximate
IRear Bottom Guard

JCap Screw (4 used)
2. Tighten cap screws to specifications.

Equipment Frame Bottom GuardSpecification
Bottom Guard-to-Equipment
Frame Cap ScrewTorque.................................. 620 Nm (460 lb-ft)
Bottom Door-to-Equipment
Frame Cap ScrewsTorque .................................. 130 Nm (95 lb-ft)
1. Use a service jack to hold the bottom guard (I) in

place while removing the cap screws (G).
OUT3035,000033E 1919DEC021/1
TM2111 (30MAY03)
17-1746-2

053003
PN=462
Section 18
Operators Station
Contents
Page
Page

Cab Remove and Install . . . . . . . . . . . . . . . .18-1800-1
Cab Isolators Remove and Install . . . . . . . .18-1800-16
Steering Column and Steering Wheel
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-18
Cab Tilt Hand Pump Repair . . . . . . . . . . . .18-1800-23
Cab Tilt Hand Pump Bleed Circuit. . . . . . . .18-1800-25
Cab Tilt Cylinder Remove and Install . . . . .18-1800-27
Expansion Valve Remove and Install . . . . .18-1830-33

Blower Motor Remove and Install . . . . . . . .18-1830-34
Heater Core Remove and Install . . . . . . . . .18-1830-35
Receiver Dryer Remove and Install . . . . . . .18-1830-39
Freeze Control Switch Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-40
Group 1810Operator Enclosure

Window and Window Molding Repair . . . . . .18-1810-1
Clean Windows Regularly . . . . . . . . . . . . . . .18-1810-4
Cab Door and Door Latch Repair . . . . . . . . .18-1810-6
Windshield Wiper and Washer Repair . . . . .18-1810-10
Group 1821Seat and Seat Belt
Seat Repair . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-1
Seat Belt Repair . . . . . . . . . . . . . . . . . . . . . .18-1821-9
Group 1830Heating and Air Conditioning
Proper Refrigerant Handling . . . . . . . . . . . . .18-1830-1
Air Conditioner System
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3
R134A Refrigerant Oil
Information. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6
R134A Refrigerant Recovery, Recycling and
Charging Station
Installation Procedure . . . . . . . . . . . . . . . .18-1830-8
Recover R134a Refrigerant . . . . . . . . . . . . . .18-1830-9
Evacuate R134a System . . . . . . . . . . . . . . .18-1830-10
Charge R134a System . . . . . . . . . . . . . . . .18-1830-11
Compressor Relief Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
High and Low Pressure Switches Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Air Conditioning Compressor Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-14
Air Conditioning Compressor Clutch
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-16
Air Conditioning Compressor Manifold
Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18
Air Conditioning Compressor
Disassemble, Inspect and Assemble . . . .18-1830-19
Air Conditioning Condenser Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-22
Evaporator Remove and Install . . . . . . . . . .18-1830-23
TM2111 (30MAY03)
18-1

053003
PN=1
18
Contents
18
TM2111 (30MAY03)
18-2

053003
PN=2
Group 1800

Cab Remove and Install
the torque converter machine are the same except where
noted.
Remove Cab
1. Install locking bar.
2. Operate all controls to relieve hydraulic pressure from
system. Depress brake pedal 20 times at one-second
intervals to discharge accumulator.
18
1800
1
3. Remove left-side engine shields.

5. Remove right-side engine shields.
OUO1020,00010BE 1906DEC021/23
6. On direct drive machines, close heater shut-off valve

(1).
T131341B
UN02JUN00
1Heater Shut-Off Valve
TM2111 (30MAY03)
18-1800-1
OUO1020,00010BE 1906DEC022/23

053003
PN=465

7. Remove shields (1 and 2) from left side of cab.
8. Remove lower cab shields from left and right side of
cab.
UN13JAN03
1Side Shield
2Side Shield
T163641B
18
1800
2
OUO1020,00010BE 1906DEC023/23

(Operators Manual.)
UN17DEC02
10. Recover refrigerant. See Recover R134a Refrigerant

in this group.
T162930B
11. Disconnect suction line (2) from compressor and

pressure line (1) from condenser. Close open lines
and fittings using caps and plugs. Remove lines from
hangers back to cab. Refrigerant lines will be
removed with cab.
Suction Line and Pressure Line (460D Shown)
1Refrigerant Pressure Line
2Refrigerant Suction Line
TM2111 (30MAY03)
18-1800-2
OUO1020,00010BE 1906DEC024/23

053003
PN=466

12. Disconnect main electrical harness connectors (5 and
8). Remove connector (5) from mount.
13. Disconnect wire connectors (14 and 9).
14. Remove harness clamps (6).
15. Disconnect ground strap (7) from frame.
16. Remove harness from frame and set aside to be
removed with cab.
UN02JUN00
17. Disconnect transmission vent hose (10) and set aside

to be removed with cab.
T131348B
UN02JUN00
T131347B
1Grapple Rotate Solenoid Wire Connector

2Wire Connector
3Secondary Steering Harness-to-Cab Harness Wire
Connector
4Engine Harness Ground-to-Cab Harness Ground
Wire Connector
5Engine Harness-to-Cab Harness Wire Connector
6Harness Clamps (3 used)
7Ground Strap
8Transmission Harness-to-Cab Harness Wire
Connector
9Input Shaft Speed Pickup Wire Connector (Direct
Drive Machine)
10Transmission Vent Hose
OUO1020,00010BE 1906DEC025/23
NOTE: Leave nut (4) finger tight, so it can be removed

later without the use of a wrench.
UN13MAR01
18. Loosen nut (4) but DO NOT remove from cap screw
(1).
T139731B
1Cap Screw
2Shims (as needed)
3Washer (2 used)
4Nut
TM2111 (30MAY03)
18-1800-3
OUO1020,00010BE 1906DEC026/23

053003
PN=467
18
1800
3

radiator is cool to the touch before
disconnecting heater hoses.
T6642EK
19. Disconnect heater hoses (2) from heater core hoses

(8) and connect the two heater hoses (2) together.
Allow heater core to drain. On direct drive machines
remove heater hoses from cab floor supports. On
torque converter machines remove clamps (7) and
heater hoses from cab.
20. Disconnect throttle cable (4).
21. Remove nuts and washers (1) and set steering valve
down inside engine frame.
UN13MAR01

fluids.
T139743B
18
1800
4
UN01NOV88
NOTE: Ends of heater hoses must be above coolant level

in radiator before disconnecting to prevent coolant
loss.

1Nuts and Washers (3 used)
2Heater Hoses (2 used)
3Brake Lines
4Throttle Cable
5Brake Valve Return Line
6Accumulator Lines
7Clamps (4 used)
8Heater Core Hoses (2 used)

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.
22. Mark brake lines (3 and 5) and accumulator line (6).
23. Disconnect lines and remove from cab floor supports.
Close all openings with caps and plugs.
TM2111 (30MAY03)
18-1800-4
OUO1020,00010BE 1906DEC027/23

053003
PN=468
UN13JAN03
IMPORTANT: All components, hydraulic lines, and

electrical harnesses disconnected from
machine and cab must be placed in
areas that will be clear when lowering
cab. Lowering cab on top of such items
will cause damage.
T163639B
24. Lower cab. Remove cap screw (2) and disconnect

tether cable (1).
1Tether Cable
2Cap Screw
18
1800
5
OUO1020,00010BE 1906DEC028/23
25. Remove nut, cap screw (1), washers, and shims.

Move cab tilt cylinder (2) away from clevis. Note
location of shims and washers to aid in assembling.
T131351B
UN02JUN00
1Cap Screw and Nut

2Hydraulic Cab Tilt Cylinder
TM2111 (30MAY03)
18-1800-5
OUO1020,00010BE 1906DEC029/23

053003
PN=469
T131353B
T131352B
UN02JUN00
UN27MAR01
18
1800
6
26. Remove shields (1 and 2) from right side of cab.

27. Disconnect winch control cable (3).
28. Disconnect linkage rods (4).
UN13MAR01
NOTE: Mark pilot lines before disconnecting to aid in

assembling.
29. Disconnect pilot lines (7 and 8).
T139709B
30. Remove cap screws (6) and control valve assembly

(5) from cab.
1Shield
2Shield
3Winch Control Cable
4Linkage Rods
5Control Valve Assembly
7Pilot Control Valve Lines (Torque Converter
Machine)
8Main Control Valve Pilot Lines (Torque Converter
Machine)
TM2111 (30MAY03)
18-1800-6
OUO1020,00010BE 1906DEC0210/23

053003
PN=470
CAUTION: Muffler and left riser may be hot from

exhaust. Allow riser to cool before removal.
31. Remove limb risers using a lifting strap and hoist.
T7502CM
UN02MAY91
18
1800
7
TM2111 (30MAY03)
18-1800-7
OUO1020,00010BE 1906DEC0211/23

053003
PN=471

32. Attach lifting chains to rear lift points (1) on right and
left side of cab.
UN13MAR01
33. Install JDG909 Lifting Brackets in each limb riser

eyelet (2).
34. Attach lifting chains and hoist to JDG909 Lifting

Brackets as shown.
T131354B
UN27MAR01
1Rear Lift Point

2Limb Riser Eyelet
OUO1020,00010BE 1906DEC0212/23
35. Remove nuts (1). Raise cab slightly to remove cap

screws (2). Remove washers (3) and shims (4). Note
quantity and location of washers and shims to aid in
assembling.
UN13MAR01
IMPORTANT: Carefully remove cab making sure all

hydraulic lines, harnesses, and valves
are clear as cab is lifted.
36. Remove cab.
T139720B
18
1800
8
T139764B
Operators StationSpecification
CabWeight ............................................... 875 kg (1930 lb) approximate
1Nut (2 used)
2Cap Screw (2 used)
3Washer (as needed)
4Shim (as needed)
TM2111 (30MAY03)
18-1800-8
OUO1020,00010BE 1906DEC0213/23

053003
PN=472

Install Cab
1. Inspect and replace cab isolators if necessary. See
Cab Isolators Remove and Install in this group.
T139720B
UN13MAR01
IMPORTANT: Hydraulic lines, valves, and electric

harnesses must be clear of cab while
lowering or damage to such items may
occur.
2. Lower cab onto frame mounts, guiding hydraulic lines,
valves, and electrical harnesses into position for
hookup.
1Nut (2 used)
2Cap Screw (2 used)
3Washer (as needed)
4Shim (as needed)
IMPORTANT: Overtightening of cap screws and nuts

can cause cab clevis to deform.
18
1800
9
3. Install cap screws (2), washers (3), shims (4), and nuts
(1). Make sure nuts are fully threaded onto cap screws.
Tighten nuts until washers are snug and full thread
engagement is attained.
4. Remove lifting chains and lifting brackets from cab.
TM2111 (30MAY03)
18-1800-9
OUO1020,00010BE 1906DEC0214/23

053003
PN=473
UN02JUN00
18
1800
10
T139709B
UN13MAR01
T131353B
5. Install control valve assembly (5) with cap screws (6).

6. Connect linkage rods (4).
7. Connect winch control cable (3).
UN27MAR01
8. On torque converter machines, connect pilot lines (7

and 8).
T131352B
9. Install shields (1 and 2).
1Shield
2Shield
3Winch Control Cable
4Linkage Rods
5Control Valve Assembly
7Pilot Control Valve Lines
8Main Control Valve Pilot Lines
TM2111 (30MAY03)
18-1800-10
OUO1020,00010BE 1906DEC0215/23

053003
PN=474

10. Position tilt cylinder (2) into cab clevis. Install cap
screw (1), washers, shims, and nut. Do not tighten
nut at this time.
T131351B
UN02JUN00
1Cap Screw
2Tilt Cylinder
OUO1020,00010BE 1906DEC0216/23
18
1800
11
11. Install tether cable (1) and cap screw (2).
T163639B
UN13JAN03
1Tether Cable
2Cap Screw
TM2111 (30MAY03)
18-1800-11
OUO1020,00010BE 1906DEC0217/23

053003
PN=475

(Operators Manual.)
IMPORTANT: DO NOT overtighten tilt cylinder nut.
Overtightening of nut can cause cab
clevis to deform.
UN13MAR01
13. Tighten tilt cylinder nut until washers are snug and full
thread engagement is attained.
18
1800
12
T139743B
14. Connect brake lines (3 and 5) and accumulator lines

(6).
15. Install steering valve using nuts and washers (1).
16. Connect throttle cable (4).
1Nuts and Washers (3 used)

2Heater Hoses (2 used)
3Brake Lines
4Throttle Cable
5Brake Valve Return Line
6Accumulator Lines (Torque Converter
Machines)
7Clamps (4 used)
8Heater Core Hoses (2 used)
17. For direct drive machines, install heater hoses (2)

through cab floor supports. For torque converter
machines, install heater hoses and clamps (7).
NOTE: Ends of heater hoses must be above coolant level

in radiator before disconnecting to prevent coolant
loss.
18. Disconnect heater hoses (2) and connect to heater
core hoses (8).
TM2111 (30MAY03)
18-1800-12
OUO1020,00010BE 1906DEC0218/23

053003
PN=476

19. Connect transmission vent hose (10).
20. Connect ground strap (7) to frame.
21. Route wiring harness in frame and install harness
clamps (6).
22. Install main electrical connector (5) into mount and
connect main electrical connectors (5 and 8).
23. Connect wire connectors (14 and 9).
T131347B
UN02JUN00
T131348B
UN02JUN00
1Grapple Rotate Solenoid Wire Connector

2Wire Connector
3Secondary Steering Harness-to-Cab Harness Wire
Connector
4Engine Harness Ground-to-Cab Harness Ground
Wire Connector
5Engine Harness-to-Cab Harness Wire Connector
6Harness Clamp (3 used)
7Ground Strap
8Transmission Harness-to-Cab Harness Wire
Connector
9Input Shaft Speed Pickup Wire Connector
10Transmission Vent Hose
TM2111 (30MAY03)
18-1800-13
OUO1020,00010BE 1906DEC0219/23

053003
PN=477
18
1800
13

24. Route air conditioning lines through hangers and
connect suction line (2) to compressor. Tighten to
specification.
UN17DEC02
Suction Line-to-Compressor
Torque ........................................................ 2428 Nm (212248 lb-in.)
T162930B
25. Connect pressure line (1) to condenser. Tighten to

specification.
Pressure Line-to-Condenser
Torque ........................................................ 1420 Nm (124177 lb-in.)
Suction Line and Pressure Line (460D Shown)
18
1800
14
1Refrigerant Pressure Line

2Refrigerant Suction Line
OUO1020,00010BE 1906DEC0220/23
26. Lower cab and install locking pins (2) and shims as
required. Lock pins in place with cap screws (1).
Tighten cap screws to specification.
UN02JUN00
Cab Pin Locking Cap Screws
Torque ............................................................................. 80 Nm (60 lb-ft)
T114910C
27. Install left and right lower cab shields.

1Cap Screws
2Locking Pins
TM2111 (30MAY03)
18-1800-14
OUO1020,00010BE 1906DEC0221/23

053003
PN=478

28. Install shields (1 and 2).
T163641B
UN13JAN03
1Shield
2Shield
OUO1020,00010BE 1906DEC0222/23
29. On direct drive machines, open heater shut-off valve

(1).
30. Install right-side engine shields.
UN02JUN00

32. Install left-side engine shields.
34. Bleed brakes. See Service Brake Bleeding Procedure.

(Group 1060.)
T131341B
33. Check and fill cooling system with proper coolant.

See Diesel Engine Coolant. (Operators Manual.)
1Heater Shut-Off Valve
35. Adjust winch control cable. See Winch Control Cable

36. Install limb risers.
OUO1020,00010BE 1906DEC0223/23
TM2111 (30MAY03)
18-1800-15

053003
PN=479
18
1800
15
Cab Isolators Remove and Install

NOTE: If cab isolators become worn or damaged, replace
isolators.
UN29APR98
Left Cab Mount Isolators
T114570B

(Operators Manual.)
2. Remove isolators from mounts.
18
1800
16
3. Apply soap on isolators to aid in installation. Install

isolators.
4. Lower cab, install pins, shims (as required), washers
and pin locking cap screws. Tighten cap screws to
specification.
Left Cab Mount IsolatorsSpecification
Cab Pin Locking Cap Screws
Torque ............................................................................. 80 Nm (60 lb-ft)
Right Cab Mount Isolators

CAUTION: Prevent unexpected machine
movement and possible injury. Install frame
locking bar before you work in frame pivot area.
2. Park machine on level ground, turn battery disconnect
switch OFF, and move shift lever to PARK.
3. Remove left engine side shields.
4. Disconnect both limb risers from top of cab.
TM2111 (30MAY03)
18-1800-16
OUO1020,00010BF 1906DEC021/3

053003
PN=480
CAUTION: Left cab mounting pins MUST be

installed before tilting right side of cab. Tilting
cab without opposite side mounting pins
installed could cause serious personal injury.
UN29APR98
5. Open and remove lower cab shield (B).
7. Using hydraulic cab tilting jack, lift cab until weight of

cab is removed from cap screws. Remove cap screws,
washers, and shims. Note location and quantity of
washers and shims to aid in assembling.
T114970
6. Remove nuts (A).
18
1800
17
ANut (2 used)
BLower Cab Shield
OUO1020,00010BF 1906DEC022/3
8. Raise cab until mounts clear cab clevises. Support cab

using a wooden block (C) as shown.
9. Remove isolators from mounts.
UN21JUN00
10. Apply soap on new isolators to aid in installation.

Install isolators.
T131398B
11. Remove wooden block and lower cab.

IMPORTANT: Do not overtighten cap screws as
damage to clevises will result.
12. Install cap screws, washers, shims, and nuts. Use
washers and shims as required. Tighten nuts until
washers are snug against clevis.
CWooden Block
13. Install lower cab shields.

14. Connect limb risers to cab.
15. Turn battery disconnect switch to ON position.
17. Remove frame locking bar.
OUO1020,00010BF 1906DEC023/3
TM2111 (30MAY03)
18-1800-17

053003
PN=481
Steering Column and Steering Wheel Repair

Steering Column and Steering Wheel Remove and
Install
the torque converter machine are the same except where
noted.
CED,OUO1048,396 1906DEC021/11
1. Remove fire extinguisher from bracket. Remove cap

screws (1 and 3) and bracket (2).
T131257B
UN31MAY00
1Cap Screw (2 used)

2Bracket
3Cap Screw
CED,OUO1048,396 1906DEC022/11
2. Disconnect electrical connectors (3) from windshield

washer pumps and disconnect hoses (4). Close all
3. Remove cap screws (1) and remove windshield washer
tank (2).
UN31MAY00

2Windshield Washer Tank
3Electrical Connector (2 used)
4Windshield Washer Hose (2 used)
T131258B
18
1800
18
TM2111 (30MAY03)
18-1800-18
CED,OUO1048,396 1906DEC023/11

053003
PN=482

4. Remove screws (1) and lower dash panel (2).
T131259B
UN31MAY00
1Screws (4 used)
2Lower Dash Panel

18
1800
19
CED,OUO1048,396 1906DEC024/11
5. Disconnect horn wire connector (2).

6. Remove cap screws (1 and 4) and slide steering
column with universal joint (3) up and off of steering
valve.
T131260B
UN31MAY00
1Cap Screw (4 used)

2Horn Wire Connector
3Universal Joint
4Cap Screw
TM2111 (30MAY03)
18-1800-19
CED,OUO1048,396 1906DEC025/11

053003
PN=483

7. Remove cap screw (2), universal joint (1) and brackets
(3).
T131261B
UN31MAY00
1Universal Joint
2Cap Screw
3Bracket (2 used)
CED,OUO1048,396 1906DEC026/11
8. Remove steering wheel cap (1) and nut (2).
UN31MAY00
CAUTION: Spring behind steering wheel is

under tension. Remove steering wheel with
caution.
T131262B
9. Install appropriate steering wheel puller to steering

wheel and slowly remove wheel from steering column
while holding downward pressure on wheel to restrain
spring tension.
10. Install steering wheel on steering column.
11. Install steering wheel cap and nut.
12. Install brackets, universal joint and cap screw.
UN31MAY00
1Steering Wheel Cap

2Steering Wheel Nut
T131263B
18
1800
20
TM2111 (30MAY03)
18-1800-20
CED,OUO1048,396 1906DEC027/11

053003
PN=484

14. Connect horn wire connector (2).
15. Install lower dash panel and cap screws.
16. Install windshield washer tank and cap screws.
17. Connect windshield washer pump hoses and
electrical connectors.
UN31MAY00
18. Install fire extinguisher bracket and cap screws. Install

fire extinguisher.
T131260B
1Cap Screw (4 used)

2Horn Wire Connector
3Universal Joint
4Cap Screw
CED,OUO1048,396 1906DEC028/11
Steering Column and Steering Wheel Disassemble

and Assemble
UN31MAY00
1. Remove steering wheel cap (1) and nut (2).
T131262B
CAUTION: Spring behind steering wheel is

under tension. Remove steering wheel with
caution.
2. Install puller (1) to steering wheel and slowly remove
wheel from steering column while holding downward
pressure on wheel to restrain spring tension.
T131263B
UN31MAY00
1Steering Wheel Cap

2Steering Wheel Nut
TM2111 (30MAY03)
18-1800-21
CED,OUO1048,396 1906DEC029/11

053003
PN=485
18
1800
21

3. Remove covers (2, 4, and 5), horn wiring lead (1) and
knob (3).
T131265B
UN31MAY00
1Horn Wiring Lead

2Cover
3Knob
4Cover
5Cover
CED,OUO1048,396 1906DEC0210/11
4. Replace parts as necessary.

5. Connect horn wiring connector to cap (7).
UN31MAY00
6. Install cap.
1Steering Column
2Disk
3Spring
4Cover
5Steering Wheel
6Nut
7Cap
T131266B
18
1800
22
CED,OUO1048,396 1906DEC0211/11
TM2111 (30MAY03)
18-1800-22

053003
PN=486
Cab Tilt Hand Pump Repair

Cab Tilt Hand Pump Remove and Install
X9811
UN23AUG88

under pressure, relieve the pressure in the
system before disconnecting or connecting
hydraulic or other lines. Tighten all connections
before applying pressure.
IMPORTANT: For satisfactory operation of the cab tilt
cylinder, it is essential that all air be
bled from the system. Therefore, any
time air is induced into the system, the
bleed procedure MUST be performed.
18
1800
23
1. Shut engine off and lower equipment to the ground.

Operate all hydraulic functions to relieve pressure.
3. Disconnect hose (2) and top hose (1). Close all
openings using caps and plugs.
UN02JUN00
4. Remove cap screws (3) and remove pump.

5. Replace or repair damaged parts.
T131385B
6. Install pump and cap screws. Tighten cap screws to

specification.
Cab Tilt Hand PumpSpecification
Hand Pump Mounting Cap
ScrewsTorque ........................................ 2226 Nm (195230 lb-in.)
1Head End Lift Hose

2Head End Retract Hose
3Cap Screw (3 used)
7. Connect hoses (1 and 2).

8. Bleed cab tilt hand pump circuit to remove air from
system. See Cab Tilt Hand Pump Bleed Circuit in this
group.
9. Fill hand pump oil reservoir.
Cab Tilt Hand Pump Reservoir
Capacity ........................................................ 574 mL (20 oz) approximate
10. Turn battery disconnect switch to ON position.
TM2111 (30MAY03)
18-1800-23
CED,OUO1032,3379 1906DEC021/2

053003
PN=487

Cab Tilt Hand Pump Disassemble and Assemble
IMPORTANT: For satisfactory operation of the cab tilt
bled from the system. Any time a
system component is changed the
bleed procedure MUST be
performed.See Cab Tilt Hand Pump
Bleed Circuit in this group.
1. Remove four cap screws from pump reservoir and
drain oil from reservoir. Check O-ring (C) and replace if
damaged.
2. Remove plastic plug (A) from bottom of pump body
with an O-ring pick.
3. Remove pump handle link (G).
UN05JUL95
4. Remove snap ring (B) from pump valve (F) and tap
assembly out of the valve body.
5. Inspect and replace damaged parts.
T8513AF
18
1800
24
6. Apply clean hydraulic oil to pump valve (F) and install

into valve body.
7. Install snap ring (B) and plastic plug (A).
APlastic Plug
BSnap Ring
CO-Ring
DSuction Screen
EFill Plug
FPump Valve
GPump Handle Link
8. Install pump handle link (G) to pump valve (F).

9. Remove and clean suction screen (D).
10. Install O-ring (C) into reservoir O-ring groove and
install reservoir to the valve body. Tighten cap
screws.
Reservoir-to-Valve Body Cap
ScrewsTorque ......................................... 6.611.6 Nm (4884 lb-in.)
11. Fill hand pump oil reservoir.

12. Oil fill plug (E) is vented; check to see if plug is clean.
Install fill plug (E).
CED,OUO1032,3379 1906DEC022/2
TM2111 (30MAY03)
18-1800-24

053003
PN=488
Cab Tilt Hand Pump Bleed Circuit

CAUTION: For satisfactory operation of the cab
tilt cylinder, it is essential that all air be bled
from the system. Any time a system component
is changed the bleed procedure MUST be
performed.
1. Attach hoist and chains to cab and raise cab.
UN29APR98
2. Support cab and remove cab lift cylinder pin and cap
screw.
3. Position cylinder so that there is enough clearance to
extend and retract cylinder.
T115133B
4. Completely retract cylinder using pump.

5. Disconnect the rod end hose (B) and install plug in
hose.
6. Disconnect head end hose (A) at the base of the
hydraulic cylinder.
IMPORTANT: Keep hand pump reservoir full during
bleeding procedure to avoid air entering
circuit.
7. Fill cab tilt hand pump reservoir and maintain hydraulic
oil level.
UN29APR98

Cab Tilt Hand Pump Circuit
Capacity .................................................................. 2 L (2 qt) approximate
T115132B
8. Position lever (C) on pump to extend cylinder.

9. Place a container under head end hose (A) and
operate pump until all air is bled from hose. Connect
hose (A) to cylinder.
AHead End Hose
BRod End Hose
CLever
10. Place a container under cylinder rod end port.

11. Operate hand pump until cylinder is completely
extended.
TM2111 (30MAY03)
18-1800-25
OUO1065,0000596 1906DEC021/2

053003
PN=489
18
1800
25

12. Remove plug from rod end hose (B). Place a
container under hose end.
13. Position lever (C) on pump to retract cylinder.
Operate hand pump until all air is bled from line.
14. Connect hose (B) to cylinder and retract cylinder.
IMPORTANT: Overtightening of cap screw and nut
15. Install cab tilt cylinder with pin and cap screw.
18
1800
26
16. Make sure nut is fully threaded on cap screw. Do not

overtighten cap screw.
17. Remove cab support and lower cab.
OUO1065,0000596 1906DEC022/2
TM2111 (30MAY03)
18-1800-26

053003
PN=490
Cab Tilt Cylinder Remove and Install
UN23AUG88

X9811
IMPORTANT: For satisfactory operation of cab tilt

bled from the system. Therefore, any
time air is induced into the system, the
bleed procedure MUST be performed.
18
1800
27

(Operators Manual.)
UN02JUN00
2. Attach hoist and chains to cab for support and aid of

removal and installation of cylinder pin and cap screw.
T131387B
3. Remove cap screw and nut (1) from cab. Retract

cylinder.
4. Remove cylinder pin (4) from engine frame.
5. Disconnect hydraulic lines (2 and 3). Remove cylinder.
6. Install new cylinder.
UN02JUN00

8. Bleed cab tilt hand pump circuit.See Cab Tilt Hand
Pump Bleed Circuit in this group.
T131386B
9. Install cylinder.
IMPORTANT: Overtightening of cap screw and nut
10. Extend cylinder to line up cylinder rod end with cab
clevis. Install rubber bushings, washers, cap screw
and nut (1). Make sure nut is fully threaded onto cap
screw. Do not overtighten cap screw.
1Cap Screw and Nut

2Head End Retract Hydraulic Line
3Head End Lift Hydraulic Line
4Pin
11. Remove cab support and lower cab.
CED,OUO1032,3386 1909DEC021/1
TM2111 (30MAY03)
18-1800-27

053003
PN=491
18
1800
28
TM2111 (30MAY03)
18-1800-28

053003
PN=492
Group 1810
Operator Enclosure
Window and Window Molding Repair
Door Windows
UN19OCT88
1. Open locking tab (D) using JDG-128-1 Tool Assembly

(A) from JDG-128 Glass Service Set.
T6148AE
2. Loosen molding (F) around window frame (B) using

JDG-128-2 Insert Tool (E).
3. Carefully remove window frame.
4. Remove molding and inspect for damage. Replace if
necessary.
18
1810
1
UN19OCT88
5. If molding must be replaced, start molding so the joint

is on the side of window. If joint is on top or bottom of
window, water might enter into the cab.
T6148AF
CAUTION: DO NOT replace polycarbonate

windows with windows made out of glass or
plastic. The impact resistance of polycarbonate
material is recommended for forestry use.
6. Install window frame using insert tool.
Locking TabClosed Position
7. Push locking tab into groove using tool assembly.
T6148AH
UN19OCT88
T6148AG
UN19OCT88
AJDG-128-1 Tool Assembly

BWindow Frame
CCab Frame
DMolding Locking Tab
EJDG-128-2 Insert Tool
FMolding
Locking TabOpen Position
TM2111 (30MAY03)
18-1810-1
CED,OUO1048,398 1910DEC021/3

053003
PN=493
Operator Enclosure
T137008
UN12JAN01
18
1810
2
TM2111 (30MAY03)
18-1810-2
CED,OUO1048,398 1910DEC022/3

053003
PN=494
Operator Enclosure
1Windowpane, Rear
2Isolator (as required)
3Windowpane, Side (2 used)
4Window, Door (2 used)
5Weather-Strip (as required)

6Windowpane, Front (2
used)

8Spacer (57 used)
9Windowpane, Front
Front, Rear, and Side Windows
10Spacer (22 used)

11Cab Door and Rear
Window Glass
screws without spacers could

damage windowpane.
1. Clean cab-to-windowpane contact area of dirt and

old weather-stripping.
CAUTION: DO NOT replace polycarbonate
windows with glass or plastic. Polycarbonate
material impact resistance is recommended
for forestry use. See story in this group for
cleaning instructions.
2. Install new weather-stripping, windowpane, spacers,

and cap screws. Tighten cap screws to
specification.
Window and Window MoldingSpecification
Windowpane Cap Screw
Torque.................................................................... 20 Nm (180 lb-in.)
IMPORTANT: Spacers must be installed before cap

screws are tightened. Tightening cap
CED,OUO1048,398 1910DEC023/3
TM2111 (30MAY03)
18-1810-3

053003
PN=495
18
1810
3
Operator Enclosure
Clean Windows Regularly

The windshield is a polycarbonate material which is softer
but stronger than glass. It will scratch.
IMPORTANT: DO NOT operate windshield wiper on a
dry window, or scrape windows with
sharp objects.
Before washing, flush as much loose dirt off as possible
with water. If there is a heavy concentration of tree sap,
use No. 1 or No. 3 denatured alcohol, Varsol No. 2 or
rubbing alcohol, followed by a water soluble cleaner.
18
1810
4
IMPORTANT: Some cleaning compounds may attack

the polycarbonate material, resulting in
cracks that will weaken the material.
Never use substances such as
Trichloethylene, Carbon Tetrachloride
or petroleum products.
Thoroughly rinse the windows after washing, and dry with
clean, soft towels.
To minimize scratches, and improve visibility by filling in
existing scratches, it is recommended that the windows be
waxed regularly.
IMPORTANT: If cracks or surface crazing are
observed, replace windshield.
TX,90,RR,1393 1922DEC921/1
TM2111 (30MAY03)
18-1810-4

053003
PN=496
Operator Enclosure
18
1810
5
TM2111 (30MAY03)
18-1810-5

053003
PN=497
Operator Enclosure
Cab Door and Door Latch Repair
T130709
UN04MAY00
18
1810
6
TM2111 (30MAY03)
18-1810-6
OUO1065,0000597 1910DEC021/4

053003
PN=498
Operator Enclosure
1Ball Stud and Retainer (2
used)
2Cylinder
3Hinge (2 used)
4Cap Screw and Washer (8
used)
5Hinge (2 used)
6Strap (2 used)
7Lock Washer (2 used)
8Nut (2 used)
9Screw (4 used)
10Yoke
11Weather-Strip (as
required)
12Cover
14Bracket
15Plate
16Lock Washer
17Cap Screw
18Latch
19Knob
20Rod
21Link (2 used)
22Striker
23Spring
24Washer
25Lock Nut
26Guard
27Lock
28Strap
30Washer (as required)
31Bracket (2 used)
32Tape (as required)
33Seal
35Door
Cab Door and Door LatchSpecification

Door Hinge Mounting Cap
ScrewsTorque ....................................................... 73 Nm (54 lb-ft)
Cab Door and Door Latch

1. Remove spring (23).
18
1810
7
2. Close door latch (18).

3. Adjust rod (20) so yoke (10) aligns with hole closest
to lock pivot.
TM2111 (30MAY03)
18-1810-7
OUO1065,0000597 1910DEC022/4

053003
PN=499
Operator Enclosure
TP63077
UN02DEC99
18
1810
8
TM2111 (30MAY03)
18-1810-8
OUO1065,0000597 1910DEC023/4

053003
PN=500
Operator Enclosure
1Right Panel
2Nut (8 used)
3Cap Screw (8 used)

4Left Panel
5Washer (8 used)
6Self-Locking Screw (8
used)
Door Panels Remove and Install

Remove and install door inner panels.
OUO1065,0000597 1910DEC024/4
18
1810
9
TM2111 (30MAY03)
18-1810-9

053003
PN=501
Operator Enclosure
Windshield Wiper and Washer Repair
T130580
UN09JUN00
18
1810
10
TM2111 (30MAY03)
18-1810-10
OUO1065,0000598 1910DEC021/6

053003
PN=502
Operator Enclosure
1Fitting
2Hose
3Tie Strap
4Wiper Motor
5Check Valve
6Cap
7Cap Screw (2 used)
8Washer (2 used)
9Grommet

11Hose
12Bracket
13Tank
14Wiper Blade
15Wiper Arm
16Cap Screw
17Spacer
Front Windshield Wiper and Washer Remove and

Install
Disassemble and assemble.
OUO1065,0000598 1910DEC022/6
18
1810
11
TM2111 (30MAY03)
18-1810-11

053003
PN=503
Operator Enclosure
T130581
UN01MAY00
18
1810
12
TM2111 (30MAY03)
18-1810-12
OUO1065,0000598 1910DEC023/6

053003
PN=504
Operator Enclosure
1Wiper Blade
2Wiper Arm
3Cap Screw
4Wiper Motor
5Fuse
6Hose
7Fitting
8Spacer
9Cap
10Tank
11Check Valve
12Grommet (2 used)
13Bracket (2 used)
15Pump (2 used)
16Tie Strap
Rear Wiper and Washer Remove and Install

OUO1065,0000598 1910DEC024/6
18
1810
13
Front and Rear Windshield Wiper Adjustment
T131540B
UN27MAR01
CAUTION: Keep hands away from linkage when

the motor is in operation. DO NOT adjust park
position when the motor is in operation. Never
start a windshield wiper when the blade is
frozen to the windshield or manually stop the
blade when the wiper is operating.
1. If the blade does not park with the tip 63.5 mm (2.50
in.) (1) from the top edge of windshield, adjust the
wiper blade.
Headlight Shown Removed for Illustration Purposes

163.5 mm (2.50 in.) Measurement
Front and Rear Windshield Wiper AdjustmentSpecification

Blade-to-Top Edge of
WindshieldDistance................................................... 63.5 mm (2.50 in.)
TM2111 (30MAY03)
18-1810-13
OUO1065,0000598 1910DEC025/6

053003
PN=505
Operator Enclosure
2. Lift wiper arm (3) away from windshield to full extended
position.
3. Lift pivot cover (1) and return wiper arm to windshield.
UN09JUN00
4. Remove retaining nut (2).
T131542B
5. Pull wiper arm from pivot shaft. Position to specification

and tighten retaining nut just until snug against wiper
arm.
6. Start motor, shut off and note the new park position.
Headlight Shown Removed for Illustration Purposes
18
1810
14
7. If blade tip still does not park 63.5 mm (2.50 in.) from
top edge of windshield, adjust by following the
procedure outlined in steps 26 until the correct park
position is obtained.
1Pivot Cover
2Retaining Nut
3Wiper Arm
8. Tighten retaining nut (2) to specification.

Front and Rear Windshield Wiper AdjustmentSpecification
Wiper Retaining Nut-to-Pivot
Torque ........................................................ 1421 Nm (124186 lb-in.)
9. Close pivot cover (1).
OUO1065,0000598 1910DEC026/6
TM2111 (30MAY03)
18-1810-14

053003
PN=506
Group 1821
Seat and Seat Belt

Seat Repair
Seat Remove and Install
UN12JUN00
1. Disconnect electrical connector if equipped with air

suspension seat.
T131570B

2. Remove nuts (1), both sides. Remove seat.
3. Install seat.
TM2111 (30MAY03)
18
1821
1
1Nut (2 used)
4. Connect electrical connector if equipped with air

suspension seat.
18-1821-1
CED,OUO1032,3447 1923JUN001/9

053003
PN=507
Seat and Seat Belt
T114920
UN29APR98
18
1821
2
TM2111 (30MAY03)
18-1821-2
CED,OUO1032,3447 1923JUN002/9

053003
PN=508
Seat and Seat Belt

1Cushion
2Cushion
3Right Plate
4Left Plate
5Arm Rest Assembly, Right
6Arm Rest Assembly, Left
7Bracket (2 used)
8Set Screw (2 used)
9Washer (2 used)
10Right Plate
11Left Plate
13Lever
14Knob and Screw Kit
15Cap Screw
16Spring
17Latch
18Spacer
19Plate
21Seat Belt
22Washer (4 used)
24Washer (8 used)
25Cover
27Spacer (2 used)
28Washer (4 used)
29Nut (4 used)
31Lock Nut
32Spring
33Arm Rest, Right
34Arm Rest, Left
Seat Disassemble and Assemble

18
1821
3
TM2111 (30MAY03)
18-1821-3
CED,OUO1032,3447 1923JUN003/9

053003
PN=509
Seat and Seat Belt
T114921
UN29APR98
18
1821
4
1Pad
2Spring
3Shock Absorber Kit
4Shock Absorber
5Bushing (2 used)
6Bearing and Bushing Kit (2
used)
7Bushing
8Bar
9Bar
10Frame
11Bar
12Bar
13Boot
14Plug (25 used)
15Boot Suspension Kit
16Gear
17Angle
18Adjusting Knob Kit
19Adjusting Knob
20Spring Pin
21Washer
22Gear
23Plate
24Lower Tray
TM2111 (30MAY03)
18-1821-4
25Upper Tray
26Guardian Suspension Kit
28Washer (2 used)
29Belt
30Washer (2 used)
31Lock Nut (2 used)
32Belt Kit
CED,OUO1032,3447 1923JUN004/9

053003
PN=510
Seat and Seat Belt

Seat Base Suspension and Shock Absorber
Disassemble and Assemble
a press before disassembling so spring

force can be released slowly.
1. Put base of suspension seat in a press before

removing cap screws and nuts.
CAUTION: Spring under compression is

used in base of suspension seat. Put base in
2. Slowly release press to release spring force.
CED,OUO1032,3447 1923JUN005/9
18
1821
5
TM2111 (30MAY03)
18-1821-5

053003
PN=511
Seat and Seat Belt
T130710
UN04MAY00
18
1821
6
TM2111 (30MAY03)
18-1821-6
CED,OUO1032,3447 1923JUN006/9

053003
PN=512
Seat and Seat Belt

1Slide Set (2 used)
2Spring (2 used)
3Snap Ring (2 used)
4Control Lever
5Spring
6Spring
7Snap Ring (4 used)
8Slide Set (2 used)

9Set Screw (4 used)
Seat Base, Seat Slide and Control Lever

Disassemble and Assemble
CED,OUO1032,3447 1923JUN007/9
18
1821
7
TM2111 (30MAY03)
18-1821-7

053003
PN=513
Seat and Seat Belt
T106768
UN31MAR97
18
1821
8
TM2111 (30MAY03)
18-1821-8
CED,OUO1032,3447 1923JUN008/9

053003
PN=514
Seat and Seat Belt

1Tube (4 used)
2Bushing (2 used)
3Washer (2 used)
4Washer (6 used)
5Cap Screw (2 used)
6Bumper
7Washer (6 used)
8Cover
9Washer
10Shock Absorber
11Nut (5 used)
12Retainer
14Upper Suspension
15Control Lever
17Cap
18Shock Absorber
19Bushing (2 used)
20Washer (4 used)
21Plate (3 used)
22Roller (4 used)
23Bellows
24Bumper (2 used)
25Ring (2 used)
26Bushing (2 used)
27Nut (2 used)
28Bearing (2 used)
30Cap Screw
31Bumper
32Tube
33Belt Tether
34Plug (22 used)
35Lower Suspension
36Retainer
37Nut (5 used)
39Air Spring
40Fastener (5 used)
41Fastener (4 used)
42U-Clamp (2 used)
43Plate
44Compressor
45Cap Screw
46Bracket
47Fitting (2 used)
48Tube
49Cable
50Swing Arm
52Cap Screw
53Washer (2 used)
54Lever
55Washer
56Snap Ring
57Spring
58Rivet (2 used)
59Stop (2 used)
60Retainer
61Retainer
62Bumper
18
1821
9
Seat Air Suspension Disassemble and Assemble

CED,OUO1032,3447 1923JUN009/9
T8415AA
UN09FEB95
Seat Belt Repair
1. Seat belt and mounting hardware must be

inspected for wear or damage before operating the
machine. Replace the belt or mounting hardware if
worn or damaged.
2. Replace the complete seat belt assembly every

three years regardless of appearance. A date label,
to determine the age of the belt, is attached to each
belt.
TM2111 (30MAY03)
18-1821-9
TX,10,DH3548 1910DEC021/3

053003
PN=515
Seat and Seat Belt
T114923
UN29APR98
18
1821
10
ACap Screw (2 used)
BWasher (4 used)
CSeat Belt Assembly
Two-Inch Seat Belt Disassemble and Assemble

TM2111 (30MAY03)
18-1821-10
TX,10,DH3548 1910DEC022/3

053003
PN=516
Seat and Seat Belt
T114924
UN29APR98
18
1821
11
ACap Screw (2 used)
BWasher (4 used)
Anti-Cinch Seat Belt Disassemble and Assemble

Seat Belt Install
1. Install cap screw (A) with washers (B) through seat
belt and another washer (B) on right and left sides.
CSeat Belt Assembly
2. Tighten bolt until retractor is slightly snug, but

retractor can still be rotated about ten degrees in
either direction.
Seat BeltSpecification
Seat Belt Cap ScrewTorque ............ Until retractor is slightly snug,
retractor can rotate 10 either
direction
TX,10,DH3548 1910DEC023/3
TM2111 (30MAY03)
18-1821-11

053003
PN=517
Seat and Seat Belt
18
1821
12
TM2111 (30MAY03)
18-1821-12

053003
PN=518
Group 1830
Heating and Air Conditioning

Refrigerant Cautions and Proper Handling
R134a is used in the air conditioning
system. Because it does not contain
chlorine, R134a is not detrimental to
the ozone in the atmosphere.
However, it is illegal to discharge
any refrigerant into the atmosphere.
It must be recovered using the
appropriate recovery stations.
CAUTION: DO NOT allow liquid refrigerant to

contact eyes or skin. Liquid refrigerant will
freeze eyes or skin on contact. Wear
goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO
NOT rub the area. Splash large amounts of
COOL water on affected area. Go to a
physician or hospital immediately for
treatment.
Use correct refrigerant recovery,

recycling and charging stations.
Never mix refrigerants, hoses,
fittings, components or refrigerant
oils.
DO NOT allow refrigerant to contact open

flames or very hot surfaces such as electric
welding arc, electric heating element and
lighted smoking materials.
18
1830
1
Use only John Deere approved

R134a refrigerant products. Mixing of
products not compatible will cause
system damage and contaminate
recovery, recycling and charging
station equipment. Care must be
taken to identify and use equipment,
refrigerant oil and refrigerant
designed only for R134a refrigerant
systems. Refrigerant should be
tested for type and purity before
recovery, recycling or charging of
system. JT02167A refrigerant test
instrument should be used before
any testing or repair to system is
preformed.
DO NOT heat refrigerant over 52C (125F) in

a closed container. Heated refrigerant will
develop high pressure which can burst the
container.
Keep refrigerant containers away from heat
sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container
with your bare hands. Skin may freeze to
container. Wear gloves.
If skin freezes to container, pour COOL
water over container to free the skin. Go to a
physician or hospital immediately for
treatment.
IMPORTANT: To meet government standards
relating to the use of refrigerants,
TM2111 (30MAY03)
18-1830-1
TX,9031,DY5073 1904MAY011/2

053003
PN=519

Prism Pro Refrigerant Identification
Instrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A
To safely identify type and check purity of refrigerant
prior to recovery, recycling and recharging of A/C
systems.
TX,9031,DY5073 1904MAY012/2
18
1830
2
TM2111 (30MAY03)
18-1830-2

053003
PN=520
Flush and Purge Air Conditioner System

CAUTION: Liquid refrigerant will freeze eyes
or skin on contact. Wear goggles, gloves
and protective clothing. See Refrigerant
Cautions and Proper Handling in this group.
NOTE: Flushing can be performed on machine.

1. Recover refrigerant. See Recover R134a
Refrigerant in this group.
b. Connect flusher outlet hose to inlet end of

compressor discharge line using JT02102
Adapter.
c. Pour flushing solvent into suction port and
discharge port. Plug both ports in compressor
manifold, using JT02099 and JT03194 Caps.
Flush and Purge SystemSpecification
A/C Compressor Flushing
Solvent in Suction Port
Volume ....................................................................... 240 mL (8 fl oz)
A/C Compressor Flushing
Solvent in Discharge Port
Volume ....................................................................... 120 mL (4 fl oz)
Add flushing solvent to system with JT02075

Flusher and JT02098 Fitting Kit.
2. Remove and discard receiver dryer.
3. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102 Adapter.
4. Fill flusher tank with solvent and fasten all
connections. Dispose of solvent properly.
Flusher TankCapacity ..................................................... 4 L (1 gal)
NOTE: Air pressure must be at minimum specification

for flushing and purging.
Air PressureMinimum
Pressure................................................ 620 kPa (90 psi) (6.2 bar) for
flushing and purging
5. Connect a supply line of moisture-free compressed

air or dry nitrogen to flusher air valve.
6. Open air valve to force flushing solvent into
condenser circuit. Flusher tank is empty when hose
pulsing stops. Additional flushing cycles are
required if system is heavily contaminated with
burned oil or metal particles.
d. Turn compressor end for end and roll it side to

side.
e. Remove both plugs from manifold ports and
drain solvent from compressor.
f. Connect battery power to compressor clutch coil.
Rotate pulley at least five revolutions to move
solvent out of cylinders.
g. Invert compressor. Roll end for end and side to
side. Drain thoroughly.
h. Repeat previous two steps at least three times.
8. Divide system into two circuits:
Condenser circuit, including inlet and outlet
hoses.
Evaporator circuit, including inlet and outlet
hoses.
9. Condenser:
7. Clean compressor as follows:

a. Remove compressor and measure oil drained
from both manifold ports.
TM2111 (30MAY03)
18-1830-3
TX,18,DU2461 1910DEC021/3

053003
PN=521
18
1830
3

IMPORTANT: DO NOT attempt to flush through
compressor or receiver dryer.
Flushing through expansion valve is
acceptable if refrigerant oil has a
normal odor and appearance.
a. Flush and Purge Condenser:
NOTE: Purging the condenser circuit takes 1012

minutes to thoroughly remove solvent.
h. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of
cardboard; continue purging until cardboard is
dry.
b. Remove and discard receiver dryer.

c. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102
Adapter.
18
1830
4
Adapter. Put nozzle in container to collect

flushing solvent.
10. See flush evaporator, if evaporator requires

flushing.
d. Fill flusher tank with solvent and fasten all

connections.
If system is contaminated with burned refrigerant

oil or debris, remove and bench flush evaporator.
See following steps to flush evaporator through
expansion valve, if oil appears normal.
11. Flush evaporator:
NOTE: Air pressure must be at minimum specification

for flushing and purging.
Air PressurePressure ............................. 620 kPa (90 psi) (6.2 bar)
minimum for flushing and
purging
a. Remove evaporator. See Evaporator Remove

and Install in this group.
b. Force flushing solvent through evaporator inlet
with compressed air.
c. Purge system until dry.
d. Install evaporator and then go to step 13.
e. Connect a supply line of moisture-free

compressed air or dry nitrogen to flusher air
valve.
12. Flush evaporator through expansion valve:
f. Open air valve to force flushing solvent into

condenser circuit. Flusher tank is empty when
hose pulsing stops. Additional flushing cycles are
required if system is heavily contaminated with
burned oil or metal particles.
g. Attach a return hose and aerator nozzle to end
of receiver dryer inlet hose using JT03197
a. Connect flusher outlet hose to connection of

receiver dryer outlet hose using JT03188
Adapter.
b. Fill flusher tank and fasten all connections.
TM2111 (30MAY03)
18-1830-4
TX,18,DU2461 1910DEC022/3

053003
PN=522

NOTE: Air pressure must be at minimum specification.
Air PressurePressure ............................. 620 kPa (90 psi) (6.2 bar)
minimum for flushing and
purging
c. Connect a supply line of moisture-free

compressed air or dry nitrogen to flusher air
valve.
d. Attach a hose and aerator nozzle to
compressor inlet line using JT02101 Adapter.
Put nozzle in a container to collect solvent.
cardboard and continue purging until cardboard is

dry.
14. Install a new receiver dryer compatible with R134a
refrigerant. Fasten connections and mounting
bracket. See Receiver-Dryer Remove and Install in
this group.
15. Add required oil. See R134a Refrigerant Oil
Information in this group.
16. Install compressor and connect refrigerant lines to
manifold.
18
1830
5
17. Connect clutch coil wire and install drive belt.
NOTE: Purging evaporator circuit takes 1215

minutes to thoroughly remove solvent.
13. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of
TX,18,DU2461 1910DEC023/3
TM2111 (30MAY03)
18-1830-5

053003
PN=523
R134a Refrigerant Oil Information

CAUTION: All new compressors are charged
with a mixture of nitrogen, R134a refrigerant
and TY22025 (R134a) refrigerant oil. Wear
safety goggles and discharge the
compressor slowly to avoid possible injury.
18
1830
6
CAUTION: DO NOT leave system or R134a

compressor oil containers open. Refrigerant
oil easily absorbs moisture. DO NOT spill
R134a compressor oil on acrylic or ABS
plastic. This oil will deteriorate these
materials rapidly. Identify R134a oil
containers and measures to eliminate
accidental mixing of different oils.
IMPORTANT: Do not add any more oil than
required or maximum cooling will be
reduced.
A new compressor from parts depot contains 230 20
mL (7.7 0.7 fl oz) of new oil. The oil level visible
through the suction port normally is below the drive
shaft.
Normal operating oil level of a compressor removed
from operation is 3045 mL (1.01.5 fl oz). This level
cannot be seen through suction port of compressor.
Compressors can be divided into three categories
when determining correct oil charge for system.
Refrigerant Oil CapacitySpecification

New CompressorVolume ................... 230 20 mL (7.7 0.7 fl oz)
Air Conditioning System
Additional Oil Volume.......................................... 182 mL (4.0 fl oz)
Compressor Operating Oil
LevelVolume.......................................... 3045 mL (1.01.5 fl oz)
Used compressor removed from operation, oil

drained, and system flushed
Used Compressor and System
Flushed OilVolume ........................... 435 44 mL (14.7 1.5 fl oz)
2. When complete system was not flushed add correct

amount of oil for compressor plus amount of oil for
each component that was serviced.
New compressor or remanufactured
New Compressor Operating Oil
LevelVolume..................................... Drain and return 45 mL (1.5 fl
oz)
Used compressor removed from operation and oil

drained.
New compressor from parts depot

Used compressor removed from operation
Compressor internally washed with flushing solvent

Used Compressor Drained
OilVolume .............................................................. 45 mL (1.5 fl oz)
Determining the amount of system oil charge prior to

installation of compressor on a machine.
1. When complete system, lines, and components are
flushed add correct amount of oil as described.
New or remanufactured compressor (system
requires an additional amount of new oil)
Used compressor removed from operation

Used Compressor Flushed
OilVolume .............................................................. 60 mL (2.0 fl oz)
TM2111 (30MAY03)
18-1830-6
TX,9031,QQ2365 1910DEC021/2

053003
PN=524

Components listed below which have been
removed, drained and flushed, require removal of
compressor to determine correct oil charge. Use
following chart as a guide for adding oil to
components:
Evaporator OilVolume ......................................... 130 mL (4.4 fl oz)
Condenser OilVolume ........................................... 65 mL (2.2 fl oz)
Receiver Dryer OilVolume .................................... 30 mL (1.0 fl oz)
Flushed Compressor Oil
Volume ...................................................................... 60 mL (2.0 fl oz)
Hose OilVolume ................................ 3 mL per 30 cm (0.1 fl oz per
ft) approximate total length
If oil drained from a compressor removed from

operation is very black or amount of oil is less
than 6 mL (0.2 fl oz), perform the following and
discard oil properly:
Determine if R134a leakage was detected,
remove component and repair or replace
component.
Remove and discard receiver dryer.
Flush complete system with TY16134 Air
Conditioning Flushing Solvent.
3. If component is serviceable, pour flushing solvent in
ports and internally wash out old oil and discard oil
properly.
18
1830
7
4. Install a new receiver dryer. See Receiver-Dryer

NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft)

Approximate total length equals 600 cm (20 ft).
If any section of hose is removed and flushed or
replaced, measure length of hose and use
formula 3 mL per 30 cm (0.1 fl oz per ft) to
determine correct amount of oil to be added.
Drain compressor oil into graduated container
while rotating compressor shaft and record
amount.
5. Install required amount of TY22025 Refrigerant Oil

in compressor.
6. Connect all components, evacuate and charge
system. See Evacuate R134a System and See
Charge R134a System in this group.
TX,9031,QQ2365 1910DEC022/2
TM2111 (30MAY03)
18-1830-7

053003
PN=525
R134a Refrigerant Recovery, Recycling and

Charging Station Installation Procedure
CAUTION: Liquid refrigerant will freeze eyes or
skin on contact. Wear goggles, gloves and
protective clothing. See Refrigerant Cautions
and Proper Handling in this group.)
UN06DEC93
CAUTION: Do not remove high pressure relief

valve (D). Air conditioning station will discharge
rapidly causing possible injury.
IMPORTANT: Use only John Deere approved
refrigerant recovery, recycling and
charging stations. DO NOT mix
refrigerant, hoses, fittings, components
or refrigerant oils.
1. Follow Refrigerant Cautions and Proper Handling
procedures in this group.
2. Close both high-side and low-side valves on refrigerant
recovery, recycling and charging station (E).
T8118AG
18
1830
8
IMPORTANT: Use only John Deere approved R134a

refrigerant products. Mixing of products
not compatible will cause system
damage and contaminate recovery,
recycling and charging station
equipment.
AHigh Pressure Hose Charge Port Cap

BRed Hose
CBlue Hose
DHigh Pressure Relief Valve
ERefrigerant Recovery, Recycling and Charging
Station
3. Remove cap from low-side charge port.

4. Connect blue hose (C) from refrigerant recovery,
recycling and charging station (E) to low-side test port.
5. Remove cap (A) from charge port on high pressure
hose and connect red hose (B).
6. Follow the manufacturers instructions when using
refrigerant recovery, recycling and charging station.
TX,9031,DU1693 1910DEC021/1
TM2111 (30MAY03)
18-1830-8

053003
PN=526
Recover R134a Refrigerant

CAUTION: Liquid refrigerant will freeze eyes or
skin on contact. Wear goggles, gloves and
protective clothing. See Refrigerant Cautions
and Proper Handling in this group.
CAUTION: Do not remove high pressure relief
valve. Air conditioning system will discharge
rapidly causing possible injury.
IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations. DO
NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
18
1830
9
1. Run air conditioning system for three minutes to help in

recovery process. Turn air conditioning system off
before proceeding with recovery steps.
2. With engine OFF identify refrigerant type using
JT02167A Refrigerant Identification Instrument.
3. Connect refrigerant recovery system. See R134a
Refrigerant Recovery, Recycling and Charging Station
Installation Procedure in this group.
4. Follow manufacturers instructions when using
refrigerant recovery, recycling and charging station.
TX,9031,DU1694 1910DEC021/1
TM2111 (30MAY03)
18-1830-9

053003
PN=527
Evacuate R134a System

CAUTION: Do not remove high pressure
relief valve. Air conditioning system will
discharge rapidly causing possible injury.
18
1830
10
4. Evacuate system until low-side gauge registers 98

kPa (980 mbar) (29 in. Hg) vacuum.
Air Conditioning SystemSpecification
Evacuate SystemVacuum ............... 98 kPa (980 mbar) (29 in. Hg)
If above specification vacuum cannot be obtained in 15

minutes, test the system for leaks. See Air
Conditioning System Checks. (Group 9031-25.)
1. Connect refrigerant recovery system. See R134a

Refrigerant Recovery, Recycling and Charging
Station Installation Procedure in this group.
5. When vacuum reaches above specification, close

low-side and high-side valves. Turn vacuum pump
off.
2. Open low-side and high-side valves on refrigerant

recovery, recycling and charging station.
6. If vacuum decreases more than specification in 5

minutes, there is a leak in system.
3. Follow manufacturers instructions and evacuate

system.
NOTE: Vacuum specifications listed are for sea level

conditions. Subtract 3.4 kPa (34 mbar) (1 in.
Hg) from 98 kPa (980 mbar) (29 in. Hg) for
each 300 m (1000 ft) elevation above sea
level.
Evacuate SystemVacuum ................ Subtract 3.4 kPa (34 mbar) (1
in. Hg) from 98 kPa (980 mbar)
(29 in. Hg) for each 300 m
(1000 ft) elevation above sea
level

Evacuate SystemVacuum .................. 3.4 kPa (34 mbar) (1 in. Hg)
7. Repair leak.
8. Evacuate system for 30 minutes after 98 kPa (980
mbar) (29 in. Hg) vacuum is reached.
9. Close low-side and high-side valves. Stop
evacuation.
10. Charge system. See Charge R134a System in this
group.
TX,1830,DT474 1910DEC021/1
TM2111 (30MAY03)
18-1830-10

053003
PN=528
Charge R134a System

Engine STOPPED, the pump must be capable
of pulling at least 28.6 in. Hg vacuum (sea
level). Subtract 3.4 kPa (34 mbar) (1 in. Hg)
from 98 kPa (980 mbar) (29 in. Hg) for each
300 m (1000 ft) elevation above sea level.

IMPORTANT: Use only John Deere approved
refrigerant recovery, recycling and
charging stations. DO NOT mix
refrigerant, hoses, fittings,
components or refrigerant oils.
1. Identify refrigerant type using JT02167A Refrigerant
Identification Instrument.
2. Connect R134a Refrigerant Recovery, Recycling
and Charging Station. See R134a Refrigerant
Recovery, Recycling and Charging Station
Installation Procedure in this group.
3. Evacuate system. See Evacuate R134a System in
this group.
NOTE: Before beginning to charge air conditioning

system, the following conditions must exist:

Evacuate SystemVacuum ................ Subtract 3.4 kPa (34 mbar) (1
in. Hg) from 98 kPa (980 mbar)
(29 in. Hg) for each 300 m
(1000 ft) elevation above sea
level
18
1830
11
4. Follow manufacturers instructions and charge

system.
5. Add refrigerant to system.
Air Conditioning System
RefrigerantRefrigerant
Quantity...................................................................... 1.93 kg (4.25 lb)
6. Check air conditioning for proper function. See

Diagnose Air Conditioning System Malfunctions.
(Group 9031-25.)
TX,18,DU2481 1910DEC021/1
TM2111 (30MAY03)
18-1830-11

053003
PN=529
Compressor Relief Valve Remove and Install
UN10MAY00
CAUTION: High pressure may exist at the

discharge fitting. If this pressure is released too
rapidly, there may be considerable discharge of
refrigerant and oil
T130758B
1. Remove front left engine shield.

2. Recover refrigerant. See Recover R134a Refrigerant in
this group.
3. Slowly remove relief valve (A) from compressor
manifold.
ARelief Valve
NOTE: The relief valve is not serviceable. Replace valve

as required.
4. Install relief valve (A) and tighten to specification.
Compressor Relief ValveSpecification
Relief ValveTorque ................................. 1216 Nm (103142 lb-in.)
5. Charge the system. See Charge R134a System in this

group.
6. Install engine side shield.
CED,OUO1048,406 1910DEC021/1
High and Low Pressure Switches Remove

and Install
UN10MAY00

noted.
1. Open heating and air conditioning compartment cover
located at rear of cab.
T130760B
18
1830
12
2. Remove wing nuts (A) and remove cover (B).

AWing Nut (3 used) (Torque Converter Machine
Uses Cap Screws and Washers)
BCover
TM2111 (30MAY03)
18-1830-12
CED,OUO1048,407 1910DEC021/2

053003
PN=530

IMPORTANT: Remove pressure switches using a
wrench on hex nut fitting. Damage to
switch will occur if removed by plastic
switch housing.
NOTE: Tag high and low pressure switches to aid in

installation.
UN10MAY00
The line that attaches the high pressure switch

has a valve installed to prevent discharging the air
conditioning system when switch is removed, and
the line that attaches the low pressure switch has
a valve to prevent discharging the air conditioning
system when switch is removed.
4. Test switch and replace if necessary. See Air

Conditioning Low Pressure Switch Test or see Air
Conditioning High Pressure Switch Test. (Group
9031-25.)
T130757B
3. Disconnect wiring connector (C or D) and remove

pressure switch (E or F) using a wrench on hex nut
fitting.
CWiring Connector
DWiring Connector
ELow Pressure Switch
FHigh Pressure Switch
5. Install pressure switch. Connect wiring connector to

switch connector.
6. Close and secure heating and air conditioning
compartment cover.
CED,OUO1048,407 1910DEC022/2
TM2111 (30MAY03)
18-1830-13

053003
PN=531
18
1830
13
Air Conditioning Compressor Remove and

Install
1. Remove left-side engine shields.
2. Recover air conditioning refrigerant. See Recover
R134a Refrigerant in this group.
4. Remove belt (4). See Fan Belt Remove and Install.

(Group 0510.)
T162934B
18
1830
14
UN17DEC02
3. Remove fan guard (2). See Fan Guards and Fan Blade
5. Disconnect lines (5 and 6) at compressor.

6. Disconnect electrical connector (8).
1Cap Screw
2Fan Guard
3Cap Screw (2 used)
4Belt
5Suction Line
6Pressure Line
7Ground Lead Screw
8Electrical Connector
9Cap Screw (4 used)
7. Remove screw (7) to disconnect ground lead.

8. Remove cap screws (9) to remove compressor.
9. Replace parts as necessary.
10. Install compressor using cap screws (9).
11. If removed, tighten compressor manifold cap screws
to specification.
Air Conditioning CompressorSpecification
Compressor Manifold Cap
ScrewsTorque ......................................... 2427 Nm (216240 lb-in.)
12. Install belt (4). See Fan Belt Remove and Install.
(Group 0510.)
13. Install ground lead using screw (7).
14. Connect electrical connector (8).
15. Add compressor oil. See R134a Refrigerant Oil
16. Connect lines (5 and 6). Tighten to specification.
Pressure Line-to-Condenser
Torque ........................................................ 2027 Nm (177239 lb-in.)
Suction Line-to-Compressor
Torque ........................................................ 2428 Nm (212248 lb-in.)
TM2111 (30MAY03)
18-1830-14
CED,OUO1032,3389 1910DEC021/2

053003
PN=532

17. Install fan guard (2). See Fan Guards and Fan Blade
18. Install a new receiver dryer. See Receiver-Dryer
19. Evacuate and charge the system. See Evacuate
R134a System in this group. See Charge R134a
System in this group.
CED,OUO1032,3389 1910DEC022/2
18
1830
15
TM2111 (30MAY03)
18-1830-15

053003
PN=533
Air Conditioning Compressor Clutch Repair
T130715
UN04MAY00
RW21157
UN24JUN92
18
1830
16
AJDG747 Hub Holding Tool

BClutch Shaft Bolt
CClutch Hub
DPulley Snap Ring
EPulley
FClutch Coil Snap Ring
TM2111 (30MAY03)
18-1830-16
GClutch Coil
HShims
TX,18,RB761 1910DEC021/3

053003
PN=534

Air Conditioning Compressor Clutch Disassemble
and Assemble
1. Mount compressor on D01006AA Bench Mounted
Holding Fixture or see DFRW20 Compressor
Holding Fixture using two 6 in. x 1/4 in. eye bolts
with nuts as illustrated. (Group 9900.)
NOTE: The bearing in the pulley is NOT serviceable.

7. Check pulley bearing operation. Replace pulley and
bearing as required.
8. Install the clutch coil and new snap ring with flat
side of the snap ring down. Connect the clutch coil
lead wire.
2. Remove dust cover.

3. Hold the clutch hub using JDG747 Hub Holding
Tool (A) and remove the clutch shaft bolt (B).
9. Install the pulley and new snap ring with the flat
side of the snap ring down. Apply grease to the
shims (H) and install to the clutch hub.
4. Remove the clutch hub (C). Remove the shims (H)

from the clutch hub and save for installation.
10. Install clutch hub and shaft bolt and tighten to

specification.
5. Remove and discard snap ring (D). Remove the

pulley (E) using a plastic hammer or JDG220 Puller
Adapter, JDG748 Hub Puller Jaws and JDG771
Forcing Screw.
Air Conditioning Compressor ClutchSpecification

Compressor Hub Retaining
NutTorque .......................................................... 14 Nm (124 lb-in.)
18
1830
17
6. Disconnect the clutch coil lead wire. Remove and

discard the snap ring (F) and remove the clutch coil
(G).
TM2111 (30MAY03)
18-1830-17
TX,18,RB761 1910DEC022/3

053003
PN=535

Check Clutch Hub Clearance
NOTE: The clutch coil is NOT polarity sensitive.

1. Check pulley-to-clutch hub clearance using a dial
indicator. Mount the gauge to the pulley as illustrated
and connect a set of jumper wires from the compressor
to a 12V battery.
2. Rotate the pulley and check clearance in three equally
spaced locations around the clutch hub. Correct
clearance is 0.350.65 mm (0.0140.026 in.). Add or
remove shims as required.
Air Conditioning Clutch
Hub-to-PulleyClearance ................... 0.350.65 mm (0.0140.026 in.)
RW21159

Air Conditioning Clutch Shaft
BoltTorque ............................................................... 14 Nm (124 lb-in.)
UN24JUN92
3. Tighten clutch shaft bolt to specification after correct

clearance is obtained.
TX,18,RB761 1910DEC023/3
Air Conditioning Compressor Manifold

Inspect
1. Remove cap screws (A) and the manifold (B).
2. Remove and discard seal (C). Inspect porting surfaces.
3. Lubricate and install a new seal (C).
4. Install manifold and tighten cap screws to specification.
UN24JUN92
Air Conditioning Compressor ManifoldSpecification

Manifold Through BoltTorque ................................... 26 Nm (230 lb-in.)
AManifold Cap Screw

BManifold
CManifold Seal
RW21160
18
1830
18
TX,18,RB763 1910DEC021/1
TM2111 (30MAY03)
18-1830-18

053003
PN=536
Air Conditioning Compressor Disassemble, Inspect and Assemble
RW21161
UN24JUN92
18
1830
19
ARear Pins
BRear Housing
CRear Gasket
DRear Discharge Reed Valve
ERear Valve Plate
FRear Suction Reed Valve
GRear O-Ring
HFront O-Ring
IFront Suction Reed Valve
JFront Valve Plate
KFront Discharge Reed
Valve
LFront Gasket
MSnap Ring
NLip Seal
OWasher
PThrough Bolt
QFelt Holder
RFelt
SFront Housing
TFront Pins
TM2111 (30MAY03)
18-1830-19
TX,18,RB764 1910DEC021/3

053003
PN=537

1. Clean the compressor using solvent before
disassembly. Mount compressor on holding fixture.
2. Remove clutch. See Air Conditioning Compressor
Clutch Repair in this group.
IMPORTANT: When removing front and rear housing,
be careful NOT to damage the sealing
surfaces.
RW21162
NOTE: The valve plates, reed valves, cylinders, and

cylinder housings are NOT serviceable. Some
cylinder scuffing (light scratches) is normal.
4. Inspect the valves for an even wear pattern and the
cylinders for scoring or excessive wear. Replace
compressor as required.
5. Remove the shaft seal snap ring (M). Turn the housing
over and remove the felt holder (Q) and felt (R) from
the front housing (S).
6. Remove the shaft lip seal (N) from the front housing
(S) using a small tool with 5/8 in. OD.
7. Wash all parts in clean solvent and dry before
assembly.
UN24JUN92
IMPORTANT: Lubricate O-rings, gaskets, and lip seal

using only TY22025 (R134a) refrigerant
oil during assembly. Other oils could
damage the compressor.
8. Apply R134a oil to the bore of the front housing and
install new lip seal (N) to the bottom of the bore using
a socket. Install new snap ring (M) flat side down.
RW21163
18
1830
20
UN24JUN92
3. Disassemble the compressor as illustrated and discard

the O-rings, gaskets, lip seal, snap ring, and through
bolt washers. Replace parts from service kits.
IMPORTANT: Bushing spacer (U) must be in position

before assembling the compressor.
CRear Gasket
DRear Discharge Reed Valve
ERear Valve Plate
FRear Suction Reed Valve
UBushing Spacer
9. Install pins (A) and new O-ring (G) in the rear cylinder.
TM2111 (30MAY03)
18-1830-20
TX,18,RB764 1910DEC022/3

053003
PN=538

NOTE: The rear valve plate is marked with an R and is
installed face up.
10. Install parts (FD) over the pins on the rear cylinder.
11. Install a new gasket (C) flat side down and the rear
housing (B) on the rear cylinder. Mount the
compressor onto the holding fixture.
12. Install pins (T) and new O-ring (H) in the front
cylinder.
NOTE: The front valve plate is marked with an F and is

installed face up.
18
1830
21
13. Install parts (IK) over the pins on the front cylinder.
14. Install a new gasket (L) flat side down. Put JDG746
lip seal protector on the shaft and lubricate with
R134a oil.
15. Install the front housing (S) on the front cylinder and
remove the lip seal protectors. Install through bolts
(P) and new washers (O).
16. Partially tighten the through bolts and then tighten to
specification.
Air Conditioning Compressor
Through BoltTorque .................................................. 26 Nm (230 lb-in.)
17. Install the felt (R) and felt holder (Q) using the clutch
hub.
18. Install the pulley-clutch hub and check clearance.See
Air Conditioning Compressor Clutch Repair in this
group.
TX,18,RB764 1910DEC023/3
TM2111 (30MAY03)
18-1830-21

053003
PN=539
Air Conditioning Condenser Remove and

Install
1. Remove right-side and left-side engine shields.
this group.
UN17DEC02
NOTE: Close all openings with caps or plugs to prevent

contamination.
3. Disconnect condenser inlet line (2) and outlet line (4).
4. Remove cap screws (1 and 3) to remove condenser.
5. Inspect condenser (5) for any visible damage. Repair
or replace as necessary.
6. Install condenser (5) with cap screws (1 and 3).
Tighten cap screw to specification.
Air Conditioning CondenserSpecification
T162939B
18
1830
22
Air Conditioning Condenser (460D Shown)

1Cap Screw (2 used)
2Condenser Inlet Line
3Cap Screw (4 used)
4Condenser Outlet Line
5Condenser
IMPORTANT: Always use new O-rings and seals.

Damaged or used O-rings and seals will
leak.
7. Connect condenser inlet line (2) and outlet line (4) and
tighten to specification.
Air Conditioning Condenser Specification
Condenser Inlet Line
ConnectionTorque..................................................... 24 Nm (212 lb-in.)
Condenser Outlet Line
ConnectionTorque..................................................... 17 Nm (150 lb-in.)

OUO1065,000059A 1916DEC021/1
TM2111 (30MAY03)
18-1830-22

053003
PN=540
Evaporator Remove and Install
UN01NOV88

noted.
Evaporator Remove
T6642EK
1. Evacuate air conditioning system. See Evacuate

R134a System in this group.
this group.
18
1830
23
UN24MAY00

radiator.
3. Drain engine coolant. The approximate engine coolant
capacity is 28.4 L (30 qt).
T131190B
4. Open heating and air conditioning compartment located

at rear of cab.
5. For direct drive machines, remove thumb screw (1)
and precleaner cover (2). For torque converter
machines, release hold downs (3) and remove
precleaner cover (2) and air filter (4).
T140039B
UN22MAR01
1Thumb Screw
2Precleaner Cover
3Hold-Downs
4Air Filter
CED,OUO1043,140 1911DEC021/25

and air filter (2).
T131191B
UN24MAY00
1Thumb Screw
2Air Filter
TM2111 (30MAY03)
18-1830-23
CED,OUO1043,140 1911DEC022/25

053003
PN=541

7. Remove freeze switch thermocouple (1) from
evaporator.
T131192B
UN24MAY00
1Freeze Switch Thermocouple

18
1830
24
CED,OUO1043,140 1911DEC023/25
UN24MAY00
8. For direct drive machines, remove thumb screws (1)

and blower housing cover (2). For torque converter
machines, remove cap screws and washers (3) and
blower housing cover (2).
T131193B
1Thumb Screw (3 used)

2Blower Housing Cover
T140047B
UN22MAR01

TM2111 (30MAY03)
18-1830-24
CED,OUO1043,140 1911DEC024/25

053003
PN=542

9. Disconnect wiring harness from heater valve servo
motor (1), low pressure switch connector (2), high
pressure switch connector (3), freeze switch (4), and
ground connection (5).
T131194B
UN24MAY00
1Heater Valve Servo Motor

2Low Pressure Switch Connector
3High Pressure Switch Connector
4Freeze Switch
5Ground Connection
18
1830
25
CED,OUO1043,140 1911DEC025/25
10. Disconnect coolant hoses (1) from heater core.

11. Remove cap screws (2) and move aside assembled
heater valve and heater valve servo motor (3).
T131195B
UN24MAY00
1Coolant Hose (2 used)

2Cap Screw (2 used)
3Assembled Heater Valve and Heater Valve Servo
Motor
CED,OUO1043,140 1911DEC026/25
12. Remove socket head cap screw (1).
UN24MAY00
13. Loosen tube nuts (2 and 3) and remove line and

flange assembly.
T131196B
1Socket Head Cap Screw

2Tube Nut
3Tube Nut
TM2111 (30MAY03)
18-1830-25
CED,OUO1043,140 1911DEC027/25

053003
PN=543

14. Remove socket head cap screws (1) and expansion
valve (2).
T131197B
UN24MAY00
1Socket Head Cap Screw (2 used)

2Expansion Valve
CED,OUO1043,140 1911DEC028/25
15. Disconnect wiring harness from blower motor

connector (1) and blower resistor (2).
16. Disconnect cooling hose (3) from blower motor (5).
17. Remove cap screws (4) and blower motor (5).
T131198B
UN24MAY00
1Blower Motor Connector

2Blower Resistor
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor
CED,OUO1043,140 1911DEC029/25
NOTE: Rotate housing 90 clockwise to remove blower

motor housing.
UN24MAY00
18. Remove cap screws (1) and blower motor housing

(2).
1Cap Screw (4 used)
2Blower Motor Housing
T131199B
18
1830
26
TM2111 (30MAY03)
18-1830-26
CED,OUO1043,140 1911DEC0210/25

053003
PN=544

19. Remove cap screws (1) and blower mounting plate
(2).
T131200B
UN24MAY00
1Cap Screw (6 used)

2Blower Mounting Plate
CED,OUO1043,140 1911DEC0211/25
18
1830
27
20. Remove mounting screw (1) and isolator (2) from

heater core (3).
UN24MAY00
21. Remove heater core (3).
T131201B
1Mounting Screw (2 used)

2Isolator
3Heater Core
CED,OUO1043,140 1911DEC0212/25
22. Remove freeze switch (1) and move aside.

23. Remove cap screws (2) and evaporator (3).
UN24MAY00
24. Repair or replace evaporator as required.

Evaporator Install
T131202B
1. Install evaporator (3) and cap screws (2).

2. Install freeze switch (1).
1Freeze Switch
2Cap Screw (2 used)
3Evaporator
TM2111 (30MAY03)
18-1830-27
CED,OUO1043,140 1911DEC0213/25

053003
PN=545

3. Install heater core (3).
4. Install mounting screws (1) and isolator (2).
T131201B
UN24MAY00

2Isolator
3Heater Core
CED,OUO1043,140 1911DEC0214/25
5. Install blower mounting plate (2) and cap screws (1).
T131200B
UN24MAY00
1Cap Screw (6 used)

CED,OUO1043,140 1911DEC0215/25
6. Install blower motor housing (2) and cap screws (1).
UN24MAY00
1Cap Screw (4 used)

2Blower Motor Housing
T131199B
18
1830
28
TM2111 (30MAY03)
18-1830-28
CED,OUO1043,140 1911DEC0216/25

053003
PN=546

7. Install blower motor (5) and cap screws (4).
8. Connect wiring harness to blower motor connector (1)
and blower resistor (2).
9. Connect cooling hose (3) to blower motor (5).
T131198B
UN24MAY00

2Blower Resistor
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor
CED,OUO1043,140 1911DEC0217/25

Used or damaged O-rings and seals will
leak.
UN24MAY00
10. Install expansion valve (2) and socket head cap

screws (1).
T131197B

2Expansion Valve
CED,OUO1043,140 1911DEC0218/25
11. Install line and flange assembly and socket head cap
screw (1). Fasten tube nuts (2 and 3).
T131196B
UN24MAY00

2Tube Nut
3Tube Nut
TM2111 (30MAY03)
18-1830-29
CED,OUO1043,140 1911DEC0219/25

053003
PN=547
18
1830
29

12. Install assembled heater valve and heater valve servo
motor (3) and cap screws (2).
13. Connect coolant hoses (1) to heater core.
T131195B
UN24MAY00
1Coolant hose (2 used)

2Cap Screw (2 used)
3Assembled Heater Valve and Heater Valve Servo
Motor
18
1830
30
CED,OUO1043,140 1911DEC0220/25
14. Connect wiring harness to heater valve servo motor

(1), low pressure switch connector (2), high pressure
switch connector (3), freeze switch (4), and ground
connection (5).
T131194B
UN24MAY00
1Heater Valve Servo Motor

2Low Pressure Switch Connector
3High Pressure Switch Connector
4Freeze Switch
5Ground Connection
TM2111 (30MAY03)
18-1830-30
CED,OUO1043,140 1911DEC0221/25

053003
PN=548

15. Install blower cover (2) using cap screw and washer
(1) and thumb screws (3).
T131193B
UN24MAY00

2Blower Cover
T140047B
UN22MAR01
18
1830
31

CED,OUO1043,140 1911DEC0222/25
16. Install freeze switch thermocouple (1) to evaporator.
T131192B
UN24MAY00
TM2111 (30MAY03)
18-1830-31
CED,OUO1043,140 1911DEC0223/25

053003
PN=549

17. For direct drive machines, install air filter (2) and
thumb screw (1).
T131191B
UN24MAY00
1Thumb Screw
2Air Filter
CED,OUO1043,140 1911DEC0224/25
18. For direct drive machines, install precleaner cover (2)

and thumb screw (1). For torque converter machines,
install air filter (4) and precleaner cover (2) using
hold-downs (3).
UN24MAY00

T131190B
NOTE: Loosen engine coolant temperature sender in

thermostat housing or loosen plug at rear of
cylinder head to allow air to escape when filling
system.
19. Fill cooling system with proper coolant. See Diesel

Engine Coolant. (Operators Manual.)
UN22MAR01
20. Tighten sender plug when all the air has been
expelled.
21. Close heating and air conditioning compartment
cover.
T140039B
18
1830
32

1Thumb Screw
2Precleaner Cover
3Hold-Down (2 used)
4Air Filter
CED,OUO1043,140 1911DEC0225/25
TM2111 (30MAY03)
18-1830-32

053003
PN=550
Expansion Valve Remove and Install
UN25MAY00

noted.
this group.
T131234B
2. Open heating and air conditioning compartment cover.
NOTE: Torque converter machines use cap screws and

washers instead of thumb screws.

2Blower Cover
3. Remove thumb screws (1) and blower cover (2).
18
1830
33
CED,OUO1043,141 1912DEC021/3
4. Remove socket head cap screw (1) and disconnect

refrigerant lines (2 and 3) from line and flange
assembly. Remove line and flange assembly.
T131229B
UN24MAY00

2Refrigerant Line
3Refrigerant Line
TM2111 (30MAY03)
18-1830-33
CED,OUO1043,141 1912DEC022/3

053003
PN=551

5. Remove socket head cap screws (1) and expansion
valve (2).
UN24MAY00

leak.
6. Install expansion valve and socket head cap screws.
T131228B
7. Install line and flange assembly with socket head cap

screw.
8. Connect refrigerant lines.
2Expansion Valve

10. Install blower cover.
CED,OUO1043,141 1912DEC023/3
Blower Motor Remove and Install
UN25MAY00

noted.

T131234B
18
1830
34

2Blower Cover
TM2111 (30MAY03)
18-1830-34
CED,OUO1043,142 1912DEC021/2

053003
PN=552

3. Disconnect wiring harness from blower resistor (1) and
blower motor connector (2).
UN25MAY00

T131194C

8. Connect wiring harness to blower resistor (1) and
9. Install blower cover and thumb screws.
18
1830
35
1Blower Resistor
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor

cover.
CED,OUO1043,142 1912DEC022/2
Heater Core Remove and Install
UN01NOV88

noted.
T6642EK

radiator.
1. Drain engine coolant from radiator. The approximate
coolant capacity of radiator is 28.4 L (30 qt).
UN25MAY00

T131234B

2Blower Cover
TM2111 (30MAY03)
18-1830-35
CED,OUO1043,143 1912DEC021/9

053003
PN=553

4. Disconnect wiring harness from blower resistor (1) and
UN25MAY00
T131194C
1Blower Resistor
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor
18
1830
36
CED,OUO1043,143 1912DEC022/9
7. Remove cap screws (1) and blower housing (3).

8. Disconnect coolant hoses (2) from heater core.
T131235B
UN25MAY00
1Cap Screw (4 used)

3Blower Housing
CED,OUO1043,143 1912DEC023/9
9. Remove cap screws (1) and blower mounting plate (2).
T131237B
UN25MAY00
1Cap Screw (6 used)

TM2111 (30MAY03)
18-1830-36
CED,OUO1043,143 1912DEC024/9

053003
PN=554

10. Remove isolator (2).
11. Remove mounting screws (1) and heater core (3).
UN25MAY00
12. Install heater core (3) and mounting screws (1).

13. Install isolator (2).
T131238B

2Isolator
3Heater Core
18
1830
37
CED,OUO1043,143 1912DEC025/9
14. Install blower mounting plate (2) and cap screws (1).
T131237B
UN25MAY00
1Cap Screw (6 used)

CED,OUO1043,143 1912DEC026/9
15. Connect coolant hoses (2) to heater core.

16. Install blower housing (3) and cap screws (1).
T131235B
UN25MAY00
1Cap Screw (4 used)

3Blower Housing
TM2111 (30MAY03)
18-1830-37
CED,OUO1043,143 1912DEC027/9

053003
PN=555

UN25MAY00
19. Connect wiring harness to blower resistor (1) and

T131194C
1Blower Resistor
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor
18
1830
38
CED,OUO1043,143 1912DEC028/9

20. Install blower cover (2) and thumb screws (1).
UN25MAY00
IMPORTANT: Air must be bled from cooling system

to prevent cavitation.
22. Fill cooling system with proper coolant. See Diesel

Engine Coolant. (Operators Manual.)
T131234B

2Blower Cover
23. Tighten sender plug when all the air has been
expelled.
CED,OUO1043,143 1912DEC029/9
TM2111 (30MAY03)
18-1830-38

053003
PN=556
Receiver Dryer Remove and Install

1.
UN01MAY00

this group.
3. Disconnect lines (A and B).
IMPORTANT: A new receiver dryer must always be

installed after purging system. DO NOT
use a flushed or used receiver-dryer.
Contamination of system can cause
component failure.
T129565D
4. Remove receiver dryer.
ALine to Condenser
BLine to Expansion Valve
18
1830
39
5. Remove plug from new receiver dryer and add 15 mL

(0.5 fl oz) of compressor oil. Install plug.
6. Install receiver dryer.
leak.
7. Put compressor oil on new O-rings. Remove plugs
from receiver dryer and immediately connect lines (A
and B).
8. Add compressor oil. See R134a Refrigerant Oil
CED,OUO1048,410 1912DEC021/1
TM2111 (30MAY03)
18-1830-39

053003
PN=557
Freeze Control Switch Remove and Install

1. Open heating and air conditioning compartment located
at rear of cab.
T131190B
1Thumb Screw
2Precleaner Cover
3Hold-Downs
4Air Filter
T140039B
UN22MAR01

CED,OUO1032,3448 1912DEC021/9

and air filter (2).
UN24MAY00
1Thumb Screw
2Air Filter
T131191B
18
1830
40
UN24MAY00

and precleaner cover (2). For torque converter
machines, release hold downs (3) and remove
precleaner cover (2) and air filter (4).
TM2111 (30MAY03)
18-1830-40
CED,OUO1032,3448 1912DEC022/9

053003
PN=558

4. Remove freeze switch thermocouple (1) from
evaporator.
T131192B
UN24MAY00

18
1830
41
CED,OUO1032,3448 1912DEC023/9
UN24MAY00
5. For direct drive machines, remove thumb screws (1)

and blower housing cover (2). For torque converter
machines, remove cap screws and washers (3) and
blower housing cover (2).
T131193B

2Blower Housing Cover
T140047B
UN22MAR01

TM2111 (30MAY03)
18-1830-41
CED,OUO1032,3448 1912DEC024/9

053003
PN=559

6. Disconnect connectors (1) from freeze control switch
(3).
UN15JUN00
7. Remove cap screws (2) and freeze control switch by

guiding freeze switch thermocouple (5) back through
bulkhead grommet (4).
T131706B
8. Insert freeze switch thermocouple through bulkhead

grommet.
9. Install freeze control switch and cap screws.
10. Connect wire harness connectors.
1Connector (2 used)
2Cap Screw (2 used)
3Freeze Control Switch
4Bulkhead Grommet
5Freeze Control Temperature Switch Thermocouple
CED,OUO1032,3448 1912DEC025/9
11. Install blower cover (2).
T131193B
UN24MAY00

2Blower Cover
UN22MAR01
T140047B
18
1830
42

TM2111 (30MAY03)
18-1830-42
CED,OUO1032,3448 1912DEC026/9

053003
PN=560

12. Install freeze switch thermocouple (1) to evaporator.
T131192B
UN24MAY00

18
1830
43
CED,OUO1032,3448 1912DEC027/9
13. For direct drive machines, install air filter (2) and
thumb screw (1).
T131191B
UN24MAY00
1Thumb Screw
2Air Filter
TM2111 (30MAY03)
18-1830-43
CED,OUO1032,3448 1912DEC028/9

053003
PN=561

14. For direct drive machines, install precleaner cover (2)
and thumb screw (1). For torque converter machines,
install air filter (4) and precleaner cover (2) using
hold-downs (3).
UN24MAY00

cover.
T131190B
1Thumb Screw
2Precleaner Cover
3Hold-Down (2 used)
4Air Filter
T140039B
UN22MAR01
18
1830
44

CED,OUO1032,3448 1912DEC029/9
TM2111 (30MAY03)
18-1830-44

053003
PN=562
Section 19
Sheet Metal and Styling

Contents
Page
Group 1910Hood or Engine Enclosure

Hood Remove and Install . . . . . . . . . . . . . . .19-1910-1
Group 1921Grille and Grille Housing
Grille and Grille Housing Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-1921-1
19
TM2111 (30MAY03)
19-1

053003
PN=1
Contents
19
TM2111 (30MAY03)
19-2

053003
PN=2
Group 1910
Hood or Engine Enclosure

Hood Remove and Install
the torque converter machines are the same except where
noted.
CED,OUO1032,3449 1924OCT021/4
1. Remove engine side shields and turn battery

disconnect switch to OFF.
2. Loosen clamps (1 and 2).
UN30MAR01
3. Remove hold-down screws (3) from each corner of

hood.
T131581B
1Turbocharger-to-Exhaust Pipe Clamp

2Turbocharger-to-Air Cleaner Hose Clamp
3Hood Hold-Down Screw (4 used)
TM2111 (30MAY03)
19-1910-1
CED,OUO1032,3449 1924OCT022/4

053003
PN=565
19
1910
1

4. Loosen cap screws (2) and slide brackets away from
exhaust pipe.
UN26JUN00
5. On torque converter machines, remove oil cooler return

line clamped to underside of hood.
T131813B
CAUTION: Muffler and left limb riser become

hot from exhaust. Allow limb riser to cool
before removal.
HoodSpecification
Left Limb Riser with Muffler
Weight................................................................................... 45 kg (100 lb)
6. Remove left limb riser (1) with muffler attached.

Approximate weight of left limb riser with muffler is 45
kg (100 lb).
T131580B
19
1910
2
UN30MAR01
HoodSpecification
Right Limb RiserWeight ...................................................... 32 kg (70 lb)
7. Remove right limb riser. Approximate weight of right

limb riser is 32 kg (70 lb).
1Limb Riser (2 used)
3Hydraulic Reservoir Cap
4Cap Screw (4 used)
8. Remove hydraulic reservoir cap (3). Disconnect air

cleaner hose-to-turbocharger and air filter restriction
switch connector located at rear of air cleaner.
HoodSpecification
Hood with Air CleanerWeight ...................... 91 kg (200 lb) approximate
10. Attach JT01748 Lifting Brackets to hood. Attach lifting

chains to brackets so front of hood hangs 152203
mm (68 in.) higher than rear. Raise hood with air
cleaner attached using hoist. Lift front of hood until it
clears grille housing.
11. Slide hood forward 12.7 mm (1/2 in.) to free rear of
hood and lift hood off machine.
12. Align hood on machine.
TM2111 (30MAY03)
19-1910-2
CED,OUO1032,3449 1924OCT023/4

053003
PN=566

13. Lower hood until rear of hood slides over rear of
reservoir.
14. Lower hood onto grille housing and remove lifting
chains and lifting brackets.
15. Install oil reservoir cap and air cleaner cover.
16. Connect air filter restriction switch and air
cleaner-to-turbocharger hose.
17. Install air cleaner-to-turbocharger hose clamp and
tighten.
18. Install hood mounting cap screws and washers.
19. Install hood hold-down screws and washers. Install
cap screw, spacer, washer and lock nut.
19
1910
3
20. On torque converter machines, install oil cooler return

line clamped to underside of hood.
21. Install right limb riser.
22. Install left limb riser with muffler.
23. Install and tighten turbocharger-to-exhaust pipe
clamp.
IMPORTANT: Exhaust pipe brackets must not touch
exhaust pipe.
24. Slide exhaust pipe brackets toward exhaust pipe (but
not touching) and tighten cap screws.
CED,OUO1032,3449 1924OCT024/4
TM2111 (30MAY03)
19-1910-3

053003
PN=567
19
1910
4
TM2111 (30MAY03)
19-1910-4

053003
PN=568
Group 1921
Grille and Grille Housing

Grille and Grille Housing Remove and Install
Direct drive machine shown throughout. Procedure for
torque converter machine is the same except where
noted.
CED,OUO1032,3390 1924OCT021/7
1. Remove hood.See Hood Remove and Install in this

group.
UN05JUN00

3. Attach lifting straps to grille housing with cap screws
and washers (1).
T131359B
4. Remove cap screws and washers (2).

CED,OUO1032,3390 1924OCT022/7
5. Remove cap screws and washers (1).
T131360B
UN05JUN00
TM2111 (30MAY03)
19-1921-1
CED,OUO1032,3390 1924OCT023/7

053003
PN=569
19
1921
1

6. Install cap screws and washers (2).
T131359B
UN05JUN00

CED,OUO1032,3390 1924OCT024/7

Grille and Grille HousingSpecification
Grille Housing with GrilleWeight ..................................... 184 kg (405 lb)
UN05JUN00
7. Remove cap screws and washers (1) and nuts from

each side of grille housing.
8. Carefully lift and remove grille housing with hoist.
T131361B
19
1921
2
1Cap Screw and Washer (3 or 4 each side)
TM2111 (30MAY03)
19-1921-2
CED,OUO1032,3390 1924OCT025/7

053003
PN=570
TP54346
UN13JAN99
19
1921
3
Grille Housing Parts (540G-III, 548G-III, 360D)

1Grille Housing
2Cover
3Cap Screw (2 used)
4Washer (2 used)
5Bushing (2 used)
6Grille
7Washer (2 used)
8Lock Nut (2 used)
9Cap Screw (2 used)

10Washer (2 used)
11Cap Screw (3 or 4 each
side)
9. Repair or replace parts as necessary.
12Flange Nut (3 or 4 each

side)
13Washer
12. Install cap screws (11), flange nuts (12), and

washers (13). Tighten flange nuts to specification.
10. Install grille housing.

Grille Housing Flange Nut
Torque................................................................... 310 Nm (229 lb-ft)
11. Install and tighten cap screws (3 and 9) to

specification.
Grille-to-Grille Housing Cap
ScrewTorque ....................................................... 125 Nm (92 lb-ft)
TM2111 (30MAY03)
19-1921-3
CED,OUO1032,3390 1924OCT026/7

053003
PN=571

13. Install cap screws and washers (1). Tighten to
specification.
15. Install hood.See Hood Remove and Install in this

group.
T131360B
UN05JUN00

Grille Housing Cap Screws
Torque ............................................................................. 73 Nm (54 lb-ft)
19
1921
4
CED,OUO1032,3390 1924OCT027/7
TM2111 (30MAY03)
19-1921-4

053003
PN=572
Section 20
Safety, Convenience and Miscellaneous

Contents
Page
Group 2003Pressurized Water System

Pressurized Water System . . . . . . . . . . . . . .20-2003-1
Group 2004Horn and Warning Devices
Horn Remove and Install. . . . . . . . . . . . . . . .20-2004-1
Reverse Warning Alarm Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2004-1
20
TM2111 (30MAY03)
20-1

053003
PN=1
Contents
20
TM2111 (30MAY03)
20-2

053003
PN=2
Group 2003
Pressurized Water System

T131760
UN27JUN00
20
2003
1
1Pressure Gauge
2Relief Valve
3Fitting
4Shut-Off Valve
5Adapter (2 used)
6Hose
7Adapter
8Nozzle
9O-Ring (2 used)
10Adapter (2 used)
12Washer (4 used)
13Elbow
14Manifold
15Nut (2 used)
16Bushing
17Hose
18Clip
19Cap Screw
20Lock Nut
21Spacer (2 used)
22Filler Plug
1. Repair or replace parts as necessary.
TM2111 (30MAY03)
20-2003-1
CED,OUO1032,3450 1925JAN031/2

053003
PN=575
CAUTION: Release pressure by discharging

fluid at hose and before removing fill plug.
Injury may result from plug or cap under force.
UN31MAR00
2. Move lever (A) to turn water on.

3. Squeeze water nozzle lever (D) to release water.
T129545C
4. Slowly remove plug (E).

IMPORTANT: Avoid machine water tank damage. Add
25 kg (55 lb) calcium chloride to water
tank before air temperature drops below
0C (32F).
UN04APR00
NOTE: Adding 25 kg (55 lb) calcium chloride will protect

to 29C (20F). When the temperatures are
consistently above freezing, the system should be
flushed thoroughly and refilled with water.
20
2003
2
T129560B
5. Fill tank with water.

Pressurized Water SystemSpecification
Water TankCapacity .................................. 60.6 L (16 gal) approximate
CAUTION: Plug has a vent cross hole for

release of air pressure. Do not use a substitute
plug.
ALever
BFitting
CGauge
DWater Nozzle Lever
EPlug
6. Install plug.
7. To pressurize system, connect air hose to fitting (B)
and add air. Watch gauge (C) for correct air pressure.
Pressurized Water SystemSpecification
Water TankPressure ..................................... 410 kPa (3.8 bar) (55 psi)
CAUTION: Pressurized water system. Release

pressure by discharging fluid at hose end
before removing fill plug. Injury may result from
plug removed under pressure.
CED,OUO1032,3450 1925JAN032/2
TM2111 (30MAY03)
20-2003-2

053003
PN=576
Group 2004
Horn and Warning Devices

Horn Remove and Install
1. Open front grille.
2. Disconnect harness leads (2 and 3) from horn (1).
Remove horn.
UN06MAR01
3. Inspect and replace as necessary.

IMPORTANT: Overtightening horn mounting nut could
cause damage to horn.
T138723B
4. If horn is removed from bracket, tighten nut to

specification.
HornSpecification
Horn Mounting NutTorque ........................................ 20 Nm (177 lb-in.)
5. Connect harness leads.
1Horn
2Harness Lead G05-BLK
3Harness Lead A01-ORG
6. Close front grill and tighten cap screws.
20
2004
1
OUO1020,00010B3 1925JAN031/1
Reverse Warning Alarm Remove and Install

1. Remove rear cover plate.
2. Disconnect harness leads (1 and 2).
UN06MAR01
3. Remove cap screw and lock nuts (3), washers (4), and
reverse warning alarm (5).
4. Install alarm and tighten lock nuts.
T138736B
5. Connect harness leads.

6. Install rear cover plate.
1Harness Leads G01-BLK
2Harness Leads M01-ORG
3Cap Screw and Lock Nut (2 used)
4Washer (4 used)
5Reverse Warning Alarm
OUO1020,00010B4 1925JAN031/1
TM2111 (30MAY03)
20-2004-1

053003
PN=577
Horn and Warning Devices
20
2004
2
TM2111 (30MAY03)
20-2004-2

053003
PN=578
Section 21
Main Hydraulic System

Contents
Page

Hydraulic Pump Remove and InstallDirect
Drive Machines . . . . . . . . . . . . . . . . . . . . .21-2160-1
Converter Machines. . . . . . . . . . . . . . . . . .21-2160-8
Hydraulic Pump Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .21-2160-12
Priority Valve Repair . . . . . . . . . . . . . . . . . .21-2160-23
Cold Start Dump Valve Remove and Install
(If Equipped) . . . . . . . . . . . . . . . . . . . . . .21-2160-26
Hydraulic Reservoir Remove and
InstallDirect Drive Machines . . . . . . . . .21-2160-27
Hydraulic Reservoir Remove and
Oil Cooler Pump Remove and Install . . . . .21-2160-41
Hydraulic Oil Cleanup Procedure Using
Portable Filter Caddy . . . . . . . . . . . . . . . .21-2160-42
21
TM2111 (30MAY03)
21-1

053003
PN=1
Contents
21
TM2111 (30MAY03)
21-2

053003
PN=2
Group 2160
Hydraulic System
Hydraulic Pump Remove and InstallDirect
Drive Machines
T131599B
UN15JUN00
IMPORTANT: Perform Main Hydraulic Pump Leakage

TestCable Skidder, Perform Main
Hydraulic Pump Leakage TestGrapple
Skidder (Group 9025-25.) Then remove
hydraulic pump for repairs. If pump
does not pass the test, replace it, DO
NOT rebuild it.
Hydraulic Pump Remove
1Drain Hose
2Set Screw
1. Remove left and right engine side shields.

2. Operate all hydraulic control valves to release pressure
in hydraulic system.
(Operators Manual.)
4. Lower engine frame front bottom guard. See Engine
Frame Bottom Guard Remove and Install. (Group
1746.)
5. Route drain hose (1) outside of engine frame and
remove drain plug from hose. Put end of hose in a
container. Dispose of waste properly. Dispose of
Waste Properly. (Operators Manual.)
21
2160
1
On machines 540G-III and 548G-III, the approximate

capacity of hydraulic reservoir is 30.3 L (8 gal). On
machines 640G-III, 648G-III and 748G-III, the
approximate capacity of hydraulic reservoir is 41.6 L
(11 gal).
6. Loosen set screw (2) to open drain valve. Drain oil into
container. Dispose of waste properly.
TM2111 (30MAY03)
21-2160-1
CED,OUO1032,3160 1925JAN031/8

053003
PN=581
Hydraulic System
7. Support hydraulic reservoir and remove carriage bolts
and nuts (A) and cap screws and nuts (B). Remove left
side reservoir support leg (C).
T114075B
UN10APR98
ACarriage Bolt and Nut (3 used)

CReservoir Support Leg
CED,OUO1032,3160 1925JAN032/8
21
2160
2
TM2111 (30MAY03)
21-2160-2

053003
PN=582
Hydraulic System
UN23AUG88

fluids.
X9811

8. Remove cap screws (5) and move line (1) away from
pump.
9. Remove O-ring (8). Close all opening with caps and
plugs.
UN09JUN00
10. Disconnect hydraulic lines (24). Close all openings

with caps and plugs.
T114076C
11. Remove fitting (6) from port (7). Close all openings
with caps and plugs.
1Pump Supply Line
2Bypass Line
3Line-to-Priority Valve
4Line-to-Oil Cooler
5Cap Screw (4 used)
6Fitting
7Port
8O-Ring
T131601B
UN14JUN00
Cable Machine Shown
TM2111 (30MAY03)
21-2160-3
CED,OUO1032,3160 1925JAN033/8

053003
PN=583
21
2160
3
Hydraulic System

Hydraulic PumpDirect Drive MachinesSpecification
Hydraulic PumpWeight ................................. 30 kg (67 lb) Approximate
648G-III, 748G-III Hydraulic
PumpWeight................................................ 54 kg (120 lb) Approximate
NOTE: Hydraulic pump has a spline coupler that couples

the pump to transmission charge pump.
UN09JUN00
12. Support pump with lifting strap. Remove cap screws

(1) to remove pump.
T114077C
1Cap Screw (2 used)
CED,OUO1032,3160 1925JAN034/8
Hydraulic Pump Install

IMPORTANT: Spline coupler must have internal snap
ring in place before installation.
1. Support pump with lifting strap. Align splines on pump
shaft with spline coupler on transmission charge pump
shaft. Install and tighten cap screws (1).
UN09JUN00
1Cap Screw (2 used)
T114077C
21
2160
4
TM2111 (30MAY03)
21-2160-4
CED,OUO1032,3160 1925JAN035/8

053003
PN=584
Hydraulic System
IMPORTANT: Always replace O-rings and seals.
Damaged or used O-rings will leak.
2. Install new O-ring (8)
3. Connect pump supply line (1) and install and tighten
cap screws (5) to specification.
Hydraulic PumpDirect Drive MachinesSpecification
Supply Line Mounting Cap
ScrewsTorque ............................................................ 120 Nm (89 lb-ft)
UN09JUN00
4. Connect line (3).
T114076C
1Pump Supply Line

2Bypass Line
3Line-to-Priority Valve
4Line-to-Oil Cooler
5Cap Screw (4 used)
6Fitting
7Port
8O-Ring
T131601B
UN14JUN00
Cable Machine Shown
TM2111 (30MAY03)
21-2160-5
CED,OUO1032,3160 1925JAN036/8

053003
PN=585
21
2160
5
Hydraulic System
5. For 540G-III and 640G-III machines, connect line (4)
and elevate line above pump. Wire tie or strap in
position.
IMPORTANT: The hydraulic pump must be filled with
oil to prevent pump damage at startup.
6. Fill pump at port (7) with proper hydraulic oil.See
Differential, Cab Hydraulic Pump and Winch Oil.
(Operators Manual.)
UN09JUN00
7. Install fitting (6).

8. For 548G-III, 648G-III and 748G-III machines, connect
line (4).
T114078C
9. Connect line (2).

4Line-to-Oil Cooler
Cable Machine Shown
CED,OUO1032,3160 1925JAN037/8
21
2160
6
TM2111 (30MAY03)
21-2160-6

053003
PN=586
Hydraulic System
10. Position reservoir support leg (C) and install carriage
bolts and nuts (A) and cap screws and nut (B) and
tighten.
(Operators Manual.)
13. Start engine and allow to run at slow idle for several
minutes with line (D) still elevated.
14. Stop engine and check for leaks. If no leaks are
present, remove wire or tie strap from line (D).
17. Raise engine frame front bottom guard. See Engine

Frame Bottom Guard Remove and Install. (Group
1746.)
ACarriage Bolt and Nut (3 used)
CReservoir Support Leg
T114075B
UN10APR98
15. Check hydraulic reservoir oil level.
21
2160
7
CED,OUO1032,3160 1925JAN038/8
TM2111 (30MAY03)
21-2160-7

053003
PN=587
Hydraulic System

Converter Machines
X9811
UN23AUG88

Skidder (Group 9025-25 Operation and
Test Manual.) Then remove hydraulic
pump for repairs. If pump does not
meet specifications, replace, DO NOT
rebuild pump.
Hydraulic Pump Remove
UN21FEB01

(Operators Manual.)
21
2160
8
T138093B
4. Drain hydraulic reservoir oil into container. The

(11 gal). Dispose of waste properly. Dispose of Waste
Properly. (Operators Manual.)
1Pump-to-Cooler Line
2Pump-to-Priority Valve Line
3Reservoir-to-Pump Line
5. Disconnect hydraulic lines (13). Close all openings

with caps and plugs. The approximate capacity of
pump and lines is 1.9 L (0.5 gal).
TM2111 (30MAY03)
21-2160-8
OUO1020,0001090 1925JAN031/5

053003
PN=588
Hydraulic System

Hydraulic PumpTorque Converter MachinesSpecification
648G-III Hydraulic PumpWeight ................. 54 kg (120 lb) Approximate
NOTE: Hydraulic pump has a spline coupler that couples

the pump to transmission charge pump.
T138094B
UN21FEB01
6. Support pump with lifting strap and hoist. Remove cap

screws (1) and pull pump away from converter pump
drive housing.
1Cap Screw (2 used)
OUO1020,0001090 1925JAN032/5
Hydraulic Pump Install

IMPORTANT: Always replace O-rings and seals.
Damaged or used O-rings will leak.
UN21FEB01
1. Remove and install pump adaptor O-ring (1).
T138109B
2. Install pump adaptor (2).

1Pump Adaptor O-Ring
2Pump Adaptor
TM2111 (30MAY03)
21-2160-9
OUO1020,0001090 1925JAN033/5

053003
PN=589
21
2160
9
Hydraulic System
IMPORTANT: Spline coupler must have internal snap
ring in place before installation.
3. Install spline coupler (1) (if removed).
UN21FEB01
4. Remove and install pump flange O-ring (2).
T138095B
5. Support pump with lifting strap and hoist. Align splines

on pump shaft with coupler on transmission charge
pump shaft. Install and tighten cap screws.
T138096B
UN21FEB01
1Pump Spline Coupler

2Pump Flange O-Ring
OUO1020,0001090 1925JAN034/5
21
2160
10
TM2111 (30MAY03)
21-2160-10

053003
PN=590
Hydraulic System
6. Connect line (3) using a new O-ring. Tighten mounting
Hydraulic PumpTorque Converter MachinesSpecification
Reservoir-to-Pump Line Mounting
Cap ScrewsTorque .................................................... 120 Nm (89 lb-ft)
UN21FEB01
IMPORTANT: The hydraulic pump must be filled with

oil to prevent pump damage at startup.
8. Connect lines (1 and 2) using a new O-ring at each

connection.
T138093B
7. Fill ports for lines (1 and 2) with proper hydraulic oil.

See Transmission, Hydraulic System, Park Brake,
(Operators Manual.)
1Pump-to-Cooler Line
2Pump-to-Priority Valve Line
3Reservoir-to-Pump Line

(Operators Manual.)
minutes.
12. Stop engine and check for leaks.
21
2160
11

OUO1020,0001090 1925JAN035/5
TM2111 (30MAY03)
21-2160-11

053003
PN=591
Hydraulic System
Hydraulic Pump Disassemble and Assemble
T8483AG
UN19MAY95
21
2160
12
TM2111 (30MAY03)
21-2160-12
TX,2160,JC625 1925JAN031/35

053003
PN=592
Hydraulic System
APin (2 used)
BPiston (9 used)
CSnap Ring
DBushing
ESlipper (9 used)
FSwashplate
GBearing
HSaddle
IPin
JBearing
KSnap Ring
LOutput Shaft
MSnap Ring
NSeal
OPin (2 used)
PBearing
QRetainer
RBushing
SCap Screw (4 used)
TVelocity Fuse
TX,2160,JC625 1925JAN032/35
IMPORTANT: Use only diesel fuel to clean pump

parts. Solvents can damage internal
components.
T8483AH
UN17MAY95

Skidder. (Group 9025-25.) Then remove
hydraulic pump for repairs. If pump
does not pass the test, replace it. DO
NOT rebuild the pump.
1. As pump parts are removed, wash in diesel fuel and
dry using compressed air.
2. Remove velocity fuse.
3. Remove cap screws to remove pump housing cover.
21
2160
13
TX,2160,JC625 1925JAN033/35
4. Remove O-ring (A).
T7553BG
UN24JUN91
AO-Ring
TM2111 (30MAY03)
21-2160-13
TX,2160,JC625 1925JAN034/35

053003
PN=593
Hydraulic System
T8170AC
UN31JAN94
5. Remove cylinder block.
TX,2160,JC625 1925JAN035/35
6. Remove pistons (A), retainer (B), and spring (C).
T7553AD
UN24JUN91
APistons
BRetainer
CSpring
T7553BB
UN24JUN91
21
2160
14
Components Shown Removed

TX,2160,JC625 1925JAN036/35
T7553AE
UN24JUN91
ASnap Ring
TM2111 (30MAY03)
21-2160-14
TX,2160,JC625 1925JAN037/35

053003
PN=594
Hydraulic System
8. Remove bushing (A).
T7553AF
UN24JUN91
ABushing
TX,2160,JC625 1925JAN038/35
9. Remove pump regulator end cover screws. Remove

two cap screws diagonally.
10. Install 5/16 in. guide pins.
T8170AD
UN31JAN94
11. Remove remaining two cap screws to remove pump

regulator.
TX,2160,JC625 1925JAN039/35
12. Remove swashplate.
T7553AH
UN24JUN91
21
2160
15
TX,2160,JC625 1925JAN0310/35
13. Remove bearings (A).
T8170AE
UN31JAN94
ABearings
TM2111 (30MAY03)
21-2160-15
TX,2160,JC625 1925JAN0311/35

053003
PN=595
Hydraulic System
T7553AJ
UN24JUN91
ASnap Ring
TX,2160,JC625 1925JAN0312/35
T7553AK
UN24JUN91
15. Remove bearing and output shaft.
TX,2160,JC625 1925JAN0313/35
16. Remove washer (A).
T7553AM
UN24JUN91
AWasher
TX,2160,JC625 1925JAN0314/35
17. Remove seal (A).
UN24JUN91
ASeal
T7553AL
21
2160
16
TM2111 (30MAY03)
21-2160-16
TX,2160,JC625 1925JAN0315/35

053003
PN=596
Hydraulic System
18. Remove plug on back side of pump (not shown) with
a 1/8" hex wrench to remove spool (G).
19. Remove end cap (K).
20. Remove remaining parts.
21. Inspect spool for wear or erosion.
NOTE: If spool (G) is worn, replace parts (G and H).
T8170AF
UN31JAN94
ASpool
BSpool
CSpool
DSpring Cap
ESpring
FSpring Cap
GSpool
HCompensator Valve Housing
IServo Piston
JSpring
KEnd Cap
LAdjusting Screw
TX,2160,JC625 1925JAN0316/35
22. Inspect valve plate for scratches. If scratches can be

detected with finger nail, pump should be discarded.
T7553AS
UN24JUN91
21
2160
17
TX,2160,JC625 1925JAN0317/35
T7553AT
UN24JUN91
23. Inspect contact area around cylinder block ports for

scratches. If scratches can be detected with finger
nail, pump should be discarded.
TM2111 (30MAY03)
21-2160-17
TX,2160,JC625 1925JAN0318/35

053003
PN=597
Hydraulic System
T7553AO
UN24JUN91
24. Inspect piston slipper for scratches. If scratches can

be detected with finger nail, pump should be
discarded.
TX,2160,JC625 1925JAN0319/35
T7553AQ
UN24JUN91
25. Inspect swashplate for scratches. If scratches can be

detected with finger nail, pump should be discarded.
TX,2160,JC625 1925JAN0320/35
26. Assemble parts (AL).
UN31JAN94
ASpool
BSpool
CSpool
DSpring Cap
ESpring
FSpring Cap
GSpool
HValve Housing
IServo Piston
JSpring
KEnd Cap
LAdjusting Screw
T8170AF
21
2160
18
TM2111 (30MAY03)
21-2160-18
TX,2160,JC625 1925JAN0321/35

053003
PN=598
Hydraulic System
T7553AU
UN24JUN91
27. Install output shaft seal using 36 mm and 50 mm

disks and a seal driver.
TX,2160,JC625 1925JAN0322/35
28. Install washer (A).
T7553AM
UN24JUN91
AWasher
TX,2160,JC625 1925JAN0323/35
29. Install output shaft and bearing in pump housing.
T7553AK
UN24JUN91
21
2160
19
TX,2160,JC625 1925JAN0324/35
30. Install snap ring (A).
T7553AJ
UN24JUN91
ASnap Ring
TM2111 (30MAY03)
21-2160-19
TX,2160,JC625 1925JAN0325/35

053003
PN=599
Hydraulic System
31. Lubricate bearings.
32. Install plastic bearing (A) with angled edges facing out
toward opening in housing.
UN31JAN94
33. Install steel bearing (B).
T8170AG
APlastic Bearing
BSteel Bearing
TX,2160,JC625 1925JAN0326/35
T7553AH
UN24JUN91
34. Install swashplate.
TX,2160,JC625 1925JAN0327/35
21
2160
20
TM2111 (30MAY03)
21-2160-20

053003
PN=600
Hydraulic System
35. Install guide pins.
36. Install gasket on pump housing using grease or
petroleum jelly to hold in place.
UN31JAN94
NOTE: It is important to make sure the O-ring is centered

around the pressure passage in the gasket.
T8170AH
37. Install O-ring (A). Use grease to hold in place.

38. Loosen end cap (D) to remove spring pressure to aid
in assembly of regulator housing.
NOTE: Be sure the control pin has the long end of the
tang pointed toward the rear of the pump.
39. Install pump regulator.
UN31JAN94
40. Pin (B) must be inserted through swashplate bell

crank hole (C).
T8170AI
41. Install two cap screws (E) and tighten to specification.

Hydraulic PumpSpecification
46 cc Pump Regulator
Housing-to-Pump Housing Cap
ScrewTorque .......................................................... 11.3 Nm (100 lb-in.)
42. Remove guide pins and install remaining two cap

screws.
UN23JAN92
75 cc Pump Regulator
Housing-to-Pump Housing Cap
ScrewTorque .......................................................... 22.6 Nm (200 lb-in.)
T7553BH
43. Tighten pump regulator end cap-to-regulator housing

End Cap-to-Regulator Housing
Cap ScrewTorque ...................................................... 2.3 Nm (20 lb-in.)
T7553BT
UN24JUN91
AO-Ring
BPin
CBell Crank Hole
DEnd Cap
ECap Screws
TM2111 (30MAY03)
21-2160-21
TX,2160,JC625 1925JAN0328/35

053003
PN=601
21
2160
21
Hydraulic System
44. Install cylinder block bushing (A). Locating pin should
be positioned face down and at the 7 Oclock position
when looking at the pump from the regulator side.
T8170AJ
UN31JAN94
ACylinder Block Bushing
TX,2160,JC625 1925JAN0329/35
45. Install snap ring (A).
T7553AE
UN24JUN91
ASnap Ring
TX,2160,JC625 1925JAN0330/35
46. Assemble parts (AE).
T7553BE
UN24JUN91
ARetainer
BCylinder Block
CSpring
DBall Guide
EPiston (9 used)
TX,2160,JC625 1925JAN0331/35
UN31JAN94
46 cc Hydraulic PumpWeight ....................... 30 kg (67 lb) Approximate
75 cc Hydraulic PumpWeight ..................... 54 kg (120 lb) Approximate
47. Invert the pump housing and install rotating group

assembly on output shaft. The rotating group must
seat on the swashplate. Hold the rotating group in
place and turn the pump housing to a upright position.
T8170AC
21
2160
22
TM2111 (30MAY03)
21-2160-22
TX,2160,JC625 1925JAN0332/35

053003
PN=602
Hydraulic System
48. Install O-ring (A).
T7553BG
UN24JUN91
AO-Ring
TX,2160,JC625 1925JAN0333/35
49. Install gasket (A).
T7553BA
UN24JUN91
AGasket
TX,2160,JC625 1925JAN0334/35
50. Install cap screws and tighten to specification.
21
2160
23
UN17MAY95
46 cc Pump Cover-to-Housing
Cap ScrewTorque ..................................................... 43.5 Nm (32 lb-ft)
75 cc Pump Cover-to-Housing
Cap ScrewTorque ..................................................... 70.5 Nm (52 lb-ft)
T8483AH
51. Install O-rings. Replace as required before installing

velocity fuse.
TX,2160,JC625 1925JAN0335/35
Priority Valve Repair

1. Operate all controls to relieve hydraulic pressure.
2. Remove right side engine shield.
TM2111 (30MAY03)
21-2160-23
TX,21,RB636 1925JAN031/3

053003
PN=603
Hydraulic System
UN23AUG88

fluids.
X9811

3. Remove hydraulic lines (AF). Close all openings with
caps and plugs. Dispose of waste properly. Dispose of
Waste Properly. (Operators Manual.)
4. Remove two cap screws (G) and remove priority valve.
UN10APR98
T114079B
21
2160
24
ALine-to-Spool Valve
BLine-to-Steering Valve
CLine-from-Hydraulic Pump
DLine-to-Accumulator (Torque Converter Machine
Line-to-Dump Valve)
ELine-to-Hydraulic Reservoir
FLine-to-Steering Valve
GCap Screw (2 used)

TM2111 (30MAY03)
21-2160-24
TX,21,RB636 1925JAN032/3

053003
PN=604
Hydraulic System
5. Remove parts (BJ).
6. Clean and inspect parts. Replace as necessary.
UN16JUL90
7. Assemble parts, install new O-rings.

8. Lubricate all parts with clean hydraulic oil.
T6465AR
9. Tighten spool plugs (E and I).

Priority ValveSpecification
Spool PlugTorque ................................... 54.281.4 Nm (4060 lb-ft)
10. Tighten orifices (C).

Priority Valve Spool Orifices
Torque .......................................................... 7.39.7 Nm (6585 lb-in.)
11. Tighten relief valve cartridge (G).

Priority Valve Relief Valve
CartridgeTorque ...................................... 33.854.3 Nm (2540 lb-ft)
Priority Valve Spring Free
LengthLength .......................................... 62 mm (2.44 in.) Approximate
AHousing
BSpool
COrifice (2 used)
DSpring
EPlug
FO-Ring
GRelief Valve Cartridge
HO-Ring
IPlug
JO-Ring
12. Position priority valve and install cap screws (G).

13. Install lines (AF).
21
2160
25
14. Install engine shield.
TX,21,RB636 1925JAN033/3
TM2111 (30MAY03)
21-2160-25

053003
PN=605
Hydraulic System
Cold Start Dump Valve Remove and Install

(If Equipped)
4. Disconnect hydraulic line (1) and electrical connector

(4).
T138261B
UN27FEB01
3. Drain hydraulic reservoir into container. The

approximate capacity of hydraulic reservoir for 540G-III
and 548G-III, is 30.3 L (8 gal). On machines 640G-III,
648G-III and 748G-III, the approximate capacity of
hydraulic reservoir is 41.6 L (11 gal). Dispose of waste
properly. Dispose of Waste Properly. (Operators
Manual.)
1Priority Valve-to-Dump Valve Line
2Jam Nut
3Dump Valve
5. Loosen jam nut (2) and remove dump valve (3).

6. Install dump valve and tighten jam nut.
7. Connect electrical connector and hydraulic line.
21
2160
26

minutes.
CED,OUO1032,3458 1925JAN031/1
TM2111 (30MAY03)
21-2160-26

053003
PN=606
Hydraulic System
Hydraulic Reservoir Remove and Install

1. Install frame lock bar.
1910.)
brake pedal at one second intervals 20 times to drain
oil from accumulator.
5. Remove plug from drain hose (1) and loosen set screw
(2) to open drain valve.
6. Drain oil into container. On machines 540G-III and
548G-III, the approximate capacity of hydraulic
reservoir is 30.3 L (8 gal). On machines 640G-III,
648G-III and 748G-III, the approximate capacity of
hydraulic reservoir is 41.6 L (11 gal). Dispose of waste
oil properly. Dispose of Waste Properly. (Operators
Manual.)
21
2160
27
TM2111 (30MAY03)
21-2160-27
CED,OUO1032,3161 1925JAN031/13

053003
PN=607
Hydraulic System
UN23AUG88

fluids.
X9811

7. Disconnect hydraulic lines (A, B and GI).
8. Remove cap screw and remove hose clamp (C).
UN29APR98
9. Remove cap screws (D) and remove cold start aid.

10. Remove cap screws (F) and remove valve and chain.
11. Remove cap screw (E) and remove chain.
T114063B
UN10APR98
T114064B
21
2160
28
APriority Valve Return Hydraulic Line

BBrake Return Hydraulic Line
CHose Clamp
DCap Screw (2 used)
ECap Screw
FCap Screw (2 used)
GReservoir-to-Pump Case Relief Valve
HReservoir-to-Velocity Fuse
IOil Cooler Hydraulic Line
TM2111 (30MAY03)
21-2160-28
CED,OUO1032,3161 1925JAN032/13

053003
PN=608
Hydraulic System
12. Disconnect fitting (A) to remove dump valve (B), if
equipped.
T114065B
UN29APR98
AFitting
BDump Valve
Grapple Skidder Shown

CED,OUO1032,3161 1925JAN033/13
13. Remove cap screws (C) and move filter (D) aside.
14. Disconnect fitting (B), loosen cap screw (A) and move
filter (E) aside.
ACap Screw
BFitting
CCap Screw (3 used)
DTransmission Filter
EHydraulic Filter
T114066B
UN10APR98
21
2160
29
TM2111 (30MAY03)
21-2160-29
CED,OUO1032,3161 1925JAN034/13

053003
PN=609
Hydraulic System
15. Remove cap screws (A) and move accumulator (B)
aside.
T114068B
UN10APR98
ACap Screws (2 used)

BAccumulator
CED,OUO1032,3161 1925JAN035/13
16. Attach hoist and chains to reservoir using JT01748

Lifting Brackets (A). Remove slack from chains.
UN10APR98
T114070B
21
2160
30
TM2111 (30MAY03)
21-2160-30
CED,OUO1032,3161 1925JAN036/13

053003
PN=610
Hydraulic System

Hydraulic ReservoirDirect Drive MachinesSpecification
Hydraulic ReservoirWeight ........................... 32 kg (70 lb) Approximate
17.
Remove cap screws and lock nuts (A) from both
sides of reservoir legs. Remove reservoir.
T114071B
UN13APR98
ACap Screws and Lock Nuts
CED,OUO1032,3161 1925JAN037/13
18. Install reservoir using JT01748 Lifting Brackets (A),

chain and hoist.
21
2160
31
T114070B
UN10APR98
TM2111 (30MAY03)
21-2160-31
CED,OUO1032,3161 1925JAN038/13

053003
PN=611
Hydraulic System
19. Install reservoir legs to engine frame using cap
screws and lock nuts (A).
20. Disconnect and remove chains and hoist from
reservoir.
T114071B
UN13APR98
ACap Screws and Lock Nuts
CED,OUO1032,3161 1925JAN039/13
21. Connect accumulator (B) to reservoir leg using cap

screws (A).
UN10APR98
ACap Screw (2 used)

BAccumulator
T114068B
21
2160
32
TM2111 (30MAY03)
21-2160-32
CED,OUO1032,3161 1925JAN0310/13

053003
PN=612
Hydraulic System
22. Connect filter (D) to reservoir using cap screws (C).
23. Connect filter (E) using cap screw (A) and fitting (B).
T114066B
UN10APR98
ACap Screw
BFitting
CCap Screws
DTransmission Filter
EHydraulic Filter
CED,OUO1032,3161 1925JAN0311/13
24. Install dump valve (B) with fitting (A) to reservoir.
21
2160
33
T114065B
UN29APR98
AFitting
BDump Valve
TM2111 (30MAY03)
21-2160-33
CED,OUO1032,3161 1925JAN0312/13

053003
PN=613
Hydraulic System
25. Attach chain to reservoir using cap screw (E).
26. Install valve and chain using cap screw (F).
27. Install cold start aid using cap screws (D).
28. Install hose clamp (C).

1910.)
T114063B
30. Fill hydraulic reservoir and check oil level. See

(Operators Manual.)
UN29APR98
29. Connect hydraulic lines (A, B and GI) to bottom of

reservoir.

APriority Valve Return Line
BBrake Return Line
CHose Clamp
DCap Screw (2 used)
ECap Screw
FCap Screw
GReservoir-to-Pump Case Relief Valve
HReservoir-to-Velocity Fuse
IOil Cooler Hydraulic Line
T114064B
UN10APR98
21
2160
34
CED,OUO1032,3161 1925JAN0313/13
TM2111 (30MAY03)
21-2160-34

053003
PN=614
Hydraulic System
Hydraulic Reservoir Remove and Install

Torque Converter Machines
1. Install frame lock bar.
1910.)
brake pedal at one second intervals 20 times to drain
(Operators Manual.)
6. Drain hydraulic reservoir oil into a container. The
(11 gal) Dispose of Waste Properly. (Operators
Manual.)
OUO1020,0001092 1925JAN031/6
21
2160
35
TM2111 (30MAY03)
21-2160-35

053003
PN=615
Hydraulic System
UN23AUG88

fluids.
X9811

7. Disconnect hydraulic lines (15 and 9).
UN27FEB01
8. Remove clamps (6 and 8).
UN27FEB01
1Priority Valve Return Line

2Reservoir Drain Line
3Cooler Pump Outlet-to-Reservoir Line
4Cooler Pump Inlet Tee-to-Reservoir Line
5Cooler Return Line
6Clamp
7Cap Screw (2 used)
8Clamp
9Dump Valve Line
T138476B
21
2160
36
T138475B
9. Remove cap screws (7) and cold start aid bracket.
TM2111 (30MAY03)
21-2160-36
OUO1020,0001092 1925JAN032/6

053003
PN=616
Hydraulic System
10. Disconnect electrical connectors (3 and 4).
11. Support transmission filter assembly and remove cap
screws (1), allowing filter to rest on converter housing.
12. Disconnect hydraulic lines (5 and 6) and remove tie
strap (2).
UN27FEB01
13. Loosen jam nut to remove dump valve (7) by turning

to the left.
T138477B
14. Loosen reservoir fitting (9).

15. Support hydraulic filter (10) and remove cap screw
and washer (8). Leaving hoses attached, rest filter
assembly on top of converter.
T138478B
UN27FEB01
1Cap Screw (3 used)

2Tie Strap
3Electrical Connection
5Pilot Valve Return Line
6Main Hydraulic Pump Supply Line
7Dump Valve
9Reservoir Fitting
10Hydraulic Filter
TM2111 (30MAY03)
21-2160-37
OUO1020,0001092 1925JAN033/6

053003
PN=617
21
2160
37
Hydraulic System
16. Remove cap screw, washer and support rod (3).
17. Remove lock nut, washer, spacer, and cap screw (2).
18. Attach hoist with lifting chain to hydraulic reservoir (5)
using JT01748 Lifting Brackets (4).
UN27FEB01
T138480B
Hydraulic ReservoirTorque Converter MachinesSpecification

Hydraulic ReservoirWeight ........................... 32 kg (70 lb) Approximate
19. Remove carriage bolts (1) and carefully lift reservoir

from machine.
20. Position hydraulic reservoir in place.
21. Install and tighten carriage bolts.
22. Remove lifting brackets.
UN27FEB01
23. Install pressure reducing valve manifold and one end

of support rod.
T138481B
1Carriage Bolt (6 used)

2Lock Nut, Washer, Spacer, and Cap Screw
3Cap Screw, Washer, and Support Rod
4JT01748 Lifting Bracket (2 used)
5Hydraulic Reservoir
21
2160
38
TM2111 (30MAY03)
21-2160-38
OUO1020,0001092 1925JAN034/6

053003
PN=618
Hydraulic System
IMPORTANT: Use NEW O-rings at all fitting
connections. Old or damaged O-rings
will leak.
24. Install hydraulic filter (10), dump valve (7), and
transmission filter.
UN27FEB01
25. Connect lines (5 and 6) and electrical connectors (3

and 4).
T138477B
UN27FEB01
T138478B
1Cap Screw (3 used)

2Tie Strap
3Electrical Connection
5Pilot Valve Return Line
6Main Hydraulic Pump Supply Line
7Dump Valve
9Reservoir Fitting
10Hydraulic Filter
TM2111 (30MAY03)
21-2160-39
OUO1020,0001092 1925JAN035/6

053003
PN=619
21
2160
39
Hydraulic System
26. Install cold start aid bracket and support rod.
27. Connect lines (15 and 9).
28. Install clamps (6 and 8).
29. Replace all tie straps that were removed or damaged.
T138476B
UN27FEB01
IMPORTANT: If hydraulic pump was drained, fill with

proper oil. The hydraulic pump MUST
be filled with oil to prevent pump
damage at startup.
30. Fill hydraulic reservoir to proper level. See
(Operators Manual.)
(Operators Manual.)
UN27FEB01
minutes.
21
2160
40
T138475B

1910.)
1Priority Valve Return Line

2Reservoir Drain Line
3Cooler Pump Outlet-to-Reservoir Line
4Cooler Pump Inlet Tee-to-Reservoir Line
5Cooler Return Line
6Clamp
7Cap Screw (2 used)
8Clamp
9Dump Valve Line
OUO1020,0001092 1925JAN036/6
TM2111 (30MAY03)
21-2160-40

053003
PN=620
Hydraulic System
Oil Cooler Pump Remove and Install

1. Install vacuum pump or drain hydraulic reservoir.
2. Disconnect hoses (2 and 6).
3. Mark and remove hose fittings (3 and 5).
4. Remove socket head screws (1) and pump (4).
5. Install pump with new O-ring and tighten socket head
cap screws.
UN26MAY00
6. Install hose fittings as marked during disassembly.

7. Connect hydraulic hoses.
T131255B
8. Remove vacuum pump or fill hydraulic reservoir to

proper level.
1Socket Head Screws (2 used)

2Hydraulic Hose
3Hose Fitting
4Oil Cooler Pump
5Hose Fitting
6Hydraulic Hose
21
2160
41
CED,OUO1032,3433 1925JAN031/1
TM2111 (30MAY03)
21-2160-41

053003
PN=621
Hydraulic System
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

machines 640G-III, 648G-III and 748G-III, the
approximate capacity of hydraulic reservoir is
41.6 L (11 gal).
1. Operate all hydraulic controls to release pressure in

2. Remove right half of hood covering reservoir.
3. Remove cap screws to remove filler neck cover.
NOTE: For a failure that creates debris, drain oil from

reservoir. Flush reservoir.
4. Replace machine hydraulic filter.
8. Move filter caddy suction hose across bottom of

reservoir to pick up all debris. Operate filter caddy
20 minutes to circulate oil through the caddy filter.
9. Install filler neck cover and filler cap.
5. Place JT05746 Portable Filter Caddy return hose in

reservoir.
10. Start engine and run at slow idle. Retract each

cylinder. Stop engine and lower all functions by
gravity. Start engine and cycle brakes and
steering. Repeat step a minimum of 5 times.
6. Install filter caddy suction hose at bottom of

reservoir.
11. If oil bypass light comes ON, stop engine. Repeat

steps 38 once more.
7. Start filter caddy. Check that oil is flowing through

filter caddy.
12. Replace machine hydraulic filter.
NOTE: Filtering time for one exchange of reservoir oil

is 0.1 minutes X number of liters (0.3 minutes
X number of gallons). On machines 540G-III
and 548G-III, the approximate capacity of
hydraulic reservoir is 30.3 L (8 gal). On
13. Fill hydraulic reservoir to proper level. See

(Operators Manual.)
14. Install right half of hood covering reservoir.
21
2160
42
TX,2160,UU980 1920AUG911/1
TM2111 (30MAY03)
21-2160-42

053003
PN=622
Section 30
Winch
Contents
Page

Winch 4000 Series Remove and Install. . . . .30-3000-1
Winch Drum Plug 4000 Series Install . . . . . .30-3000-7
Winch 4000 Series Fasten Cable to Drum . .30-3000-7
Winch Free Spool Drag Adjustment . . . . . .30-3000-10
Winch 6000 Series Remove and Install. . . .30-3000-11
Winch 6000 Series Fasten Cable to
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-3000-14
Winch Control Valve Linkage Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-3015-2
Winch Drive Line Remove and Install . . . . . .30-3025-1
Winch 4000 Series Drive Shaft Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . . .30-3025-2
Group 3050Drive and Clutch
Winch 4000 Series Drive and Clutch
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-3050-1
Winch 6000 Series Drive and Clutch
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-3050-1
30
TM2111 (30MAY03)
30-1

053003
PN=1
Contents
30
TM2111 (30MAY03)
30-2

053003
PN=2
Group 3000

Winch 4000 Series Remove and Install
Removal
X9811
UN23AUG88

1. Stop engine and lower all equipment to ground.
2. Operate all hydraulic functions, including brake, to
brake pedal at one-second intervals 20 times to drain
locking bar.
4. Disconnect negative battery cable.
(Operators Manual.)
6. Disconnect winch control cable yoke (C).
UN13APR98
7. Disconnect winch drive line from drive yoke (B).

8. Disconnect hydraulic lines (A and D).
T113916
9. Disconnect and remove control cable.

10. Remove winch mounting cap screws.
APressure Inlet Line

BDrive Yoke
CControl Cable Yoke
DReturn Oil Line
TM2111 (30MAY03)
30-3000-1
OUO1020,000121E 1909JAN031/9

053003
PN=625
30
3000
1

11. Grapple machines onlyremove cap screws (A) to
remove guards.
T8474AF
UN19MAY95
ACap Screw (6 used)
OUO1020,000121E 1909JAN032/9
12. Grapple machines onlylabel and disconnect

hydraulic lines (AF).
13. Remove four fittings (H).
14. Remove fuel tank mounting cap screws and slide fuel
tank rearward as far as possible. See Fuel Tank
Remove and Install540G-III, 548G-III, 640G-III or
Fuel Tank Remove and Install648G-III, 748G-III.
(Group 0560.)
T114091C
UN23MAR99
ATo Port A Rotate Manifold

BTo Port B Rotate Manifold
CTo Arch Cylinder Head
DTo Arch Cylinder Rod End
EFrom Grapple Control Valve
FFrom Arch Control Valve
GMounting Bracket
HFittings (4 used)

30
3000
2
TM2111 (30MAY03)
30-3000-2
OUO1020,000121E 1909JAN033/9

053003
PN=626

15. Attach lifting chains to winch as shown.
UN05JUN91
Winch 4000 SeriesSpecification

WinchWeight ............................................ 545 kg (1200 lb) approximate
T7516AV
16. Remove winch.
Shown with Cable Removed
OUO1020,000121E 1909JAN034/9
NOTE: If winch is to be stored or reinstalled without

disassembly, do not drain oil.
If winch is to be disassembled, drain oil out of left
(gear side) cover drain plug. This will remove
approximately 24 L (6.25 gal) of oil, the rest of the
oil is trapped and winch will have to be
disassembled to remove it.
17. Remove plug (C) to drain oil.
18. Repair or replace winch as necessary. See 40 and
4000 Series Winches. (CTM25.)
30
3000
3
T7306AL
UN22MAY90
AReturn Line Cap

BFill Plug
CDrain Plug
TM2111 (30MAY03)
30-3000-3
OUO1020,000121E 1909JAN035/9

053003
PN=627

Installation
1. Clean grease, dirt, oil, and paint from mounting holes.
UN05JUN91
2. Install winch.
3. Tighten mounting cap screws to specification.
T7516AV

Equipment Frame-to-Winch Cap
4. Position fuel tank and install mounting cap screws.
Shown with Cable Removed
OUO1020,000121E 1909JAN036/9
5. Grapple machines onlyinstall four fittings (H) to

mounting bracket (G).
6. Connect hydraulic lines (AF).
UN23MAR99
ALine to Port A Rotate Manifold

BLine to Port B Rotate Manifold
CTo Line to Arch Cylinder Head
DLine to Arch Cylinder Rod End
ELine from Grapple Control Valve
FLine from Arch Control Valve
GMounting Bracket
HFittings (4 used)
T114091C
30
3000
4
TM2111 (30MAY03)
30-3000-4
OUO1020,000121E 1909JAN037/9

053003
PN=628

7. Grapple machines onlyposition guards and install
cap screws (A).
UN19MAY95

(Operators Manual.)
T8474AF
ACap Screw (6 used)
OUO1020,000121E 1909JAN038/9
30
3000
5
TM2111 (30MAY03)
30-3000-5

053003
PN=629

9. Connect and adjust control cable yoke (C). See Winch
Control Cable Remove and Install. (Group 3015.)
10. Connect hydraulic lines (A and D).
11. Connect winch drive line yoke (B). Tighten cap
Winch Cross-to-Yoke Cap
12. Fill winch with recommended oil. See Change Winch

OilIf Equipped. (Operators Manual.)
Winch OilCapacity..................................... 35.2 L (9.3 gal) approximate
13. Connect negative battery cable.
14. Operate the winch in either Power In or Free Spool

position to finish filling winch. Check transmission oil
level frequently and add oil through the transmission
dipstick. See Check Transmission Oil Level.
(Operators Manual.)
30
3000
6
T113916
NOTE: Power In position will deliver 7.89.5 L (22-1/2

gal) per minute to fill winch. Free Spool position
will take approximately 1/2 hour to fill winch.
UN13APR98
IMPORTANT: Oil capacity for winch is greater than

transmission oil capacity. Check
transmission oil level frequently while
filling to avoid transmission pump
cavitation.
APressure Oil Inlet Line

BDrive Line Yoke
CControl Cable Yoke
DReturn Oil Line
15. Operate winch and check the transmission oil level

again.
16. Install cable. See Winch 4000 Series Fasten Cable to
Drum in this group.
OUO1020,000121E 1909JAN039/9
TM2111 (30MAY03)
30-3000-6

053003
PN=630
Winch Drum Plug 4000 Series Install
UN22MAY90
IMPORTANT: If cable is attached in slot (A), the drum

plug (B) MUST be installed to prevent
cable from bending cable slot.
Install drum plug (B) flush in winch drum.
T7305AW
UN22MAY90
T7305AV
ACable Slot
BDrum Plug
OUO1020,0001222 1910JAN031/1
Winch 4000 Series Fasten Cable to Drum

CAUTION: Prevent possible injury from cable
wire. Wear gloves when handling cable to
protect hands. DO NOT guide cable onto winch
with your hands.
30
3000
7
Attach cable to winch drum using one of the following

methods.
TM2111 (30MAY03)
30-3000-7
OUO1020,0001223 1910JAN031/4

053003
PN=631

Method 1:
UN03OCT90
IMPORTANT: If a ferruled cable is used, the drum

plug (B) must be installed to prevent
cable from bending cable slot.
1. Attach a ferrule or cable clamp (A) to end of cable.
T7382AH
2. Wrap cable around the drum. Slide the ferrule or cable

clamp under the cable and into slot in drum, and
secure with tab (C).
3. Perform Winch Free Spool Drag Adjustment in this
group.
NOTE: Factory free spool drag setting was done without

cable; adjust free spool drag to operators
preference when cable is added.
Ten-inch drum only has pocket method of locating
ferrule cable to drum.
UN27SEP90
ACable Clamp
BDrum Plug
CCable Tab
T7347AS
30
3000
8
TM2111 (30MAY03)
30-3000-8
OUO1020,0001223 1910JAN032/4

053003
PN=632

Method 2:
IMPORTANT: If you unwind cable below one turn on
drum, cable will come off drum.
NOTE: To conform with certain state laws, the cable must

be attached to the drum so that it can come loose
if cable is completely unwound.
1. Remove drum plug (B).
with your hands.
2. Thread cable up through small hole and insert cable
back down through lower hole. Pull loop into drum.
UN27SEP90

group.
T7347AS

T7382AI
UN03OCT90
BDrum Plug
TM2111 (30MAY03)
30-3000-9
OUO1020,0001223 1910JAN033/4

053003
PN=633
30
3000
9

Method 3:
1. Remove drum plug.
T7382AK
UN03OCT90

protect hands. DO NOT guide cable on winch
with your hands.
2. Thread cable up through small hole and wrap cable
around wedge (A). Insert cable back down through
lower hole and pull wedge into drum slot (B).
group.
UN03OCT90

T7382AJ
AWedge
BDrum Slot
OUO1020,0001223 1910JAN034/4
Winch Free Spool Drag Adjustment

The winch drum drag can be adjusted to operators
preference.
UN27MAR00
1. Start engine.
2. Lower equipment to ground.
T129367C

4. Block wheels.
4000 Winch Shown
5. Place winch control handle in FREE SPOOL position.

6. Loosen nut (A).
7. Adjust slotted shaft (B) to desired winch drum drag.
UN10JAN95
8. Tighten nut.
ANut
BSlotted Shaft
T8390AP
30
3000
10
6000 Winch Shown

OUO1020,0001224 1910JAN031/1
TM2111 (30MAY03)
30-3000-10

053003
PN=634
Winch 6000 Series Remove and Install

Removal
UN23AUG88

locking bar.
X9811
1. Stop engine, lower all equipment to ground and install

frame locking bar.
2. Operate all hydraulic control valve levers to release
hydraulic pressure in the system.
3. Disconnect negative battery cable.
4. Remove cotter pin and pin (B) to disconnect yoke.
5. Remove cap screws (C) and washers to remove
mounting bracket and winch control cable.
6. Remove cap screws to disconnect winch drive line (E)
(not shown).
UN09JUL91
7. Disconnect hydraulic lines (A and D). Close all

openings using caps and plugs.
T7508AY
8. Remove drain cap and install a drain hose on fitting to

drain winch. The approximate capacity is 45.5 L (12
gal).

BPin
DReturn Oil Line
EDrive Line
TM2111 (30MAY03)
30-3000-11
OUO1020,0001220 1910JAN031/3

053003
PN=635
30
3000
11

WinchWeight ............................................ 680 kg (1500 lb) approximate
9. Fasten lifting chain around winch as shown and

connect chain to a hoist.
10. Remove front and rear winch mounting cap screws
through access holes in bottom of equipment frame.
11. Carefully lift winch off equipment frame.
Installation
1. Clean grease, dirt, oil, and paint from mounting holes.
2. Install winch.
UN09JUL91
3. Install front and rear mounting cap screws and tighten

to specification.
T7533AX

Winch Mounting Cap Screw
Torque ......................................................................... 620 Nm (455 lb-ft)
OUO1020,0001220 1910JAN032/3
30
3000
12
TM2111 (30MAY03)
30-3000-12

053003
PN=636

4. Connect hydraulic lines (A and D).
5. Connect winch drive line (E) (not shown). Install and
tighten cap screws to specification.
Winch Cross-to-Yoke Cap
6. Install control cable mounting bracket, washers and

tighten cap screws (C).
7. Install and adjust control cable. See See Winch Control
Cable Remove and Install. (Group 3015.)Winch Control
Valve Linkage Remove and Install in this group.
8. Connect yoke to valve. Install pin (B) and cotter pin.
UN09JUL91
9. Fill winch with recommended oil. See Change Winch

OilIf Equipped. (Operators Manual.)
Winch OilCapacity...................................... 45.5 L (12 gal) approximate
IMPORTANT: Oil capacity for winch is greater than

transmission oil capacity. Check
transmission oil level frequently while
filling to avoid transmission pump
cavitation.
NOTE: Power In position will deliver 7.89.5 L (22-1/2

gal) per minute to fill winch. Free Spool position
will take approximately 1/2 hour to fill winch.
T7508AY
10. Connect negative battery cable.

BPin
DReturn Oil Line
EDrive Line
30
3000
13
11. Operate the winch in either Power In or Free Spool

position to fill winch. Check transmission oil levels
frequently when filling winch. See Check
Transmission Oil Level. (Operators Manual.)
OUO1020,0001220 1910JAN033/3
TM2111 (30MAY03)
30-3000-13

053003
PN=637
Winch 6000 Series Fasten Cable to Drum

with your hands.
Attach cable to winch drum using one of the following
methods.
OUO1020,0001225 1910JAN031/3
Method 1
1. Attach a ferrule (A) or cable clamp (B) to end of cable.
UN18OCT88
2. Wrap cable around the drum and slide the ferrule (A)
or cable clamp (B) under the cable and into slot in
drum.
UN07NOV88
T5843AJ
AFerrule
BCable Clamp
T5875AB
30
3000
14
TM2111 (30MAY03)
30-3000-14
OUO1020,0001225 1910JAN032/3

053003
PN=638

Method 2
IMPORTANT: If you unwind cable below one turn on
drum, cable will come off drum.
UN07NOV88
NOTE: To conform with certain state laws, the cable must

be attached to the drum so that it can come loose
if the cable is completely unwound.

with your hands.
T5875AC
1. Attach a ferrule or cable clamp to the end of the cable.
CCable
2. Wrap a piece of heavy wire (No. 9) or light cable (C)

around the drum and over the ferrule or cable clamps.
3. Twist or tie the heavy wire or light cable (C) to prevent
it from loosening.
4. Place the ferrule or cable clamp into the slot in the
drum.
OUO1020,0001225 1910JAN033/3
30
3000
15
TM2111 (30MAY03)
30-3000-15

053003
PN=639
30
3000
16
TM2111 (30MAY03)
30-3000-16

053003
PN=640
Group 3015
Controls Linkage
30
3015
1
TM2111 (30MAY03)
30-3015-1

053003
PN=641
Controls Linkage
Winch Control Valve Linkage Remove and Install
T131308
UN01JUN00
30
3015
2
TM2111 (30MAY03)
30-3015-2
OUO1020,0001226 1910JAN031/7

053003
PN=642
Controls Linkage
1Pin (4000 Winch3 used)
2Yoke
3Pin (4000 Winch3 used)
4Nut
5Bracket
6Bracket
7Washer (3 used)
8Nut (3 used)
9Spacer (2 used)
11Control Cable

13Clamp (2 used)
14Spring
15Strap
16Strap (2 used)
17Bellcrank
18Bushing
19Bolt
21Bushing
22Knob
23Boot
24Clip (6 used)
25Ring
27Washer (2 used)
28Plate
29Bracket
30Strap (2 used)
31U-Bolt
32Cap Screw
33Lock Nut (2 used)
1. Remove worn or damaged parts and replace as

necessary.
34Ball Joint
35Washer (3 used)
36Nut
37Lock Nut
38Wedge
39Lever
40Ball Joint
41Nut
43Washer (2 used)
44Label
2. Apply one drop of medium strength thread lock and

sealer to threads of ball joint (40).
OUO1020,0001226 1910JAN032/7
Winch Control Cable Remove and Install

1. Remove old cable.
UN13MAR92
2. Install new cable into cab. Install straps (30), U-bolt

(31), and lock nuts (33).
3. Install ball joint (34) six turns.
T7711AG
4. Secure the lever to the right rear of the BRAKE OFF

slot.
5. Push cable winch end IN to remove slack. Measure
from end of cable to center of mounting groove and
adjust ball joint (34) until distance (A) is to
specification.
30
3015
3
UN04APR00
Winch Control CableSpecification

End of Cable-to-Center of
Mounting GrooveDistance ....................................... 159 mm (6.250 in.)
T129676B
6. Install cable through frame and attach bracket (6),

strap (15), clamp (13), bushing (21) and cap screws
(20) on winch.
7. Install spring (14), washer (7), nut (4) and yoke (2) on
winch end of cable.
AEnd of Cable-to-Center of Mounting Groove

Distance
TM2111 (30MAY03)
30-3015-3
OUO1020,0001226 1910JAN033/7

053003
PN=643
Controls Linkage
IMPORTANT: Winch valve must be in FREE SPOOL
position to correctly adjust linkage.
UN06NOV90
8. Push winch valve spool IN, as far as possible, into

FREE SPOOL position.
T7402AE
9. With the 4000 winch bellcrank or 6000 winch valve

spool in free spool position, pull cable with 44.5 N (10
lb-force).
Cable Pull (Free Spool
Position)Force .......................................................... 44.5 N (10 lb-force)
On 4000 Series winch only, apply 22.2 N (5 lb-force) to

bellcrank toward cable end.
4000 Series Winch (Only)
BellcrankForce ........................................................... 22.2 N (5 lb-force)
10. Adjust the 4000 winch yoke to align with hole in

bellcrank. Adjust the 6000 winch yoke to align with
valve spool.
11. Connect the yoke to the 4000 winch bellcrank (or
6000 winch valve spool) and install pin.
OUO1020,0001226 1910JAN034/7
30
3015
4
TM2111 (30MAY03)
30-3015-4

053003
PN=644
Controls Linkage
12. Move control lever to BRAKE ON (hold) position.
13. Slide bracket (A) so that lip contacts spring.
UN13APR98
14. Tighten bracket and control cable cap screws.
T113917
ABracket
T7402AI
UN26NOV90
4000 Series Winch
6000 Series Winch

OUO1020,0001226 1910JAN035/7
30
3015
5
TM2111 (30MAY03)
30-3015-5

053003
PN=645
Controls Linkage
1930OCT90
T7374AZ

Control Lever-to-Stop Screw
(Free Spool Position)Distance ................... 35 mm (0.1200.160 in.)
T7374AY
16. Move control lever to FREE SPOOL position and

release lever. There must be 35 mm (0.1200.160
in.) distance between lever and stop screw.
1930OCT90
15. Run engine at slow idle.
NOTE: It is normal for engine to pull down when POWER

IN is first engaged. This valve sequencing is to
prevent winch brake from dropping load before
clutch engages.
17. Slowly move control lever to POWER IN position until
drum turns. There must be 68 mm (0.2400.320
in.) distance between lever and stop screw. Adjust as
required.
Control Lever-to-Stop Screw
(Power In Position)Distance ...................... 68 mm (0.2400.320 in.)
18. While POWER IN is engaged, release lever. Lever

must return to BRAKE ON (hold) when released from
any POWER IN position. If lever does not return,
increase return spring tension as described earlier in
this procedure.
OUO1020,0001226 1910JAN036/7

Winch Control Lever (Rearward
Pull)Force ................................................................... 22.2 N (5 lb-force)
1930OCT90
T7397AZ
20. Pull lever rearward with approximately 22.2 N (5

lb-force), then move lever to left side.
1930OCT90
19. Move winch control lever to free spool position.
T7374AY
30
3015
6
Lever must move freely through the gate and not rub
against rear of right slot or front of left slot. If lever rubs
slot gate, readjust winch cable yoke as described earlier
in this procedure.
OUO1020,0001226 1910JAN037/7
TM2111 (30MAY03)
30-3015-6

053003
PN=646
Group 3025

Winch Drive Line Remove and Install
UN09JUL91

locking bar.
T7553BY
1. Park machine in a straight position. Install frame

locking bar.
2. Remove cap screws (A) from each end of drive line.
3. Install drive line with the female yoke end (C) of
telescoping shaft toward winch.
Direct Drive Machine
4. Install cap screws (A) and tighten to specification.
UN09JUL91
Winch Drive LineSpecification

Cross-to-Yoke 3/8 in. Cap
Flange-to-Yoke 7/16 in. Cap
ScrewTorque .............................................................. 100 Nm (75 lb-ft)
T7553BZ
5. Remove frame locking bar.

ACap Screw
BGrease Fitting
CFemale Yoke End
Direct Drive Machine
OUO1020,0001221 1910JAN031/1
30
3025
1
TM2111 (30MAY03)
30-3025-1

053003
PN=647
TP54250
UN02APR98
Winch 4000 Series Drive Shaft Disassemble and Assemble
Direct Drive Shaft Shown

1Universal Joint Cross (2
used)
3Cap
4Washer (16 used)

1. Disassemble parts (16).
6Drive Shaft
5. Lubricate shaft after installation on machine.
2. Inspect for excessively worn or broken parts and

replace as necessary.
3. Assemble parts.
4. Tighten joint cross-to-yoke cap screws (5).
30
3025
2
Winch 4000 Drive ShaftSpecification

Cross-to-Yoke 3/8 in. Cap
ScrewTorque ......................................................... 58 Nm (43 lb-ft)
OUO1020,0001228 1910JAN031/1
TM2111 (30MAY03)
30-3025-2

053003
PN=648
Group 3050
Drive and Clutch

Winch 4000 Series Drive and Clutch Repair
Repair winch drive and clutch. See Winch Drive and
Clutches. (CTM25.)
OUO1020,000122C 1914JAN031/1
Winch 6000 Series Drive and Clutch Repair

Repair winch drive and clutch. See Winch Drive and
Clutches. (CTM41)
OUO1020,000122D 1914JAN031/1
30
3050
1
TM2111 (30MAY03)
30-3050-1

053003
PN=649
Drive and Clutch
30
3050
2
TM2111 (30MAY03)
30-3050-2

053003
PN=650
Section 32
Bulldozers (Stacking & Trailbuilding Blades)

Contents
Page
Group 3201Blades
Stacking Blade Remove and Install . . . . . . . .32-3201-1
Spherical Bushing Remove and Install . . . . .32-3201-7
Blade Control Linkage Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3215-1
Blade Control Valve Remove and Install . . . .32-3215-2
Blade Lift Cylinder Remove and Install . . . . .32-3260-1
32
TM2111 (30MAY03)
32-1

053003
PN=1
Contents
32
TM2111 (30MAY03)
32-2

053003
PN=2
Group 3201
Blades
Stacking Blade Remove and Install
1. Lower all equipment to the ground. Operate all control
levers to relieve pressure in the hydraulic system.
UN02JUL91
NOTE: One front wheel must be removed before stacking

blade pin can be removed.
T7502HK
2. Remove one front wheel. See Wheel Repair. (Group

0110.)
Right Stacking Blade Cylinder
Stacking BladeSpecification
540G-III, 548G-III Blade
CylinderWeight ............................................ 34.4 kg (76 lb) approximate
640G-III, 648G-III Blade
748G-III Blade CylinderWeight ................. 47.6 kg (105 lb) approximate
ACap Screw
BCylinder Pin
CNut
3. Attach hoist to blade cylinder using lifting straps.

4. Remove cap screws (A), nuts (C), and cylinder pins (B)
to disconnect right and left blade cylinders.
OUO1020,0001213 1908JAN031/6
32
3201
1
TM2111 (30MAY03)
32-3201-1

053003
PN=653
T8474AG
UN22MAY95
Blades
1Cap Screw (2 used)

Cap Screw with Washer
(540G-III, 548G-III only)
2Cap (540G-III, 548G-III)
Washer (640G-III, 648G-III,
748G-III)
3Pin
4Cap Screw
5Lock Nut
6Lubrication Fitting (4 used)
32
3201
2
540G-III, 548G-III Stacking
BladeWeight ...................................... 583 kg (1286 lb) approximate
640G-III, 648G-III Stacking
BladeWeight ...................................... 630 kg (1330 lb) approximate
748G-III Stacking Blade
Weight ................................................... 834 kg (1840 lb) approximate
5. Attach hoist to stacking blade using lifting straps.

8Spherical Bushing
9Spherical Bushing
10Stacking Blade

12Seal
13Pivot
7. Remove cap screws (1), cap (2), lock nut (5) and
cap screw (4).
8. Remove pin (3) and stacking blade (10).
9. Inspect stacking blade for cracks or damage.
10. Inspect spherical bushings in cylinder bores and
blade pivot bores for wear or damage. If a bushing
must be replaced, see Spherical Bushing Remove
6. Lower bottom guard.
TM2111 (30MAY03)
32-3201-2
OUO1020,0001213 1908JAN032/6

053003
PN=654
Blades
11. Lift blade using a lifting strap. Center blade to install
washers between blade and engine frame as required
as pivot pin (A) is installed.
UN02JUL91
12. Replace lubrication fittings (6) if necessary, tighten to

specification.
T7502HI
Lubrication FittingsTorque ........................................... 47 Nm (35 lb-ft)
APivot Pin
OUO1020,0001213 1908JAN033/6
32
3201
3
TM2111 (30MAY03)
32-3201-3

053003
PN=655
Blades
T8509AC
UN19JUN95
32
3201
4
540G-III, 548G-III Shown
TM2111 (30MAY03)
32-3201-4
OUO1020,0001213 1908JAN034/6

053003
PN=656
Blades
AWasher (as required)
BShim (as required)
CEngine Frame
DPolyurethane Foam
Washer
EHardened Washer (540G-III,

548G-III only)
FCap Screw M20 x 40 mm

cap screw (F).
14. Install one washer (A) on pin, then put new cap or
washer (G) on pin, and hold in place.
IMPORTANT: A minimum of 3 mm (0.120 in.) gap
(H) must be left on each side of pin
to prevent a side impact from
breaking off pin cap screws.
15. Measure gap (H) between cap and washer. Install
or remove shims (B) until specified gap is
obtained.
Cap-to-WasherGap ............................. 36 mm (0.1200.240 in.)
GBlade Pin Cap (540G-III,

548G-III)
Washer (640G-III, 648G-III,
748G-III)
H36 mm (0.1200.240 in.)

Clearance Dimension
IMPORTANT: If blade is sprung so that specified

gap cannot be obtained, the blade
must be removed and pushbeams
bent back until gap specification can
be obtained.
16. Install foam washer (D) on pin. Install cap
(540G-III, 548G-III) or washer (640G-III, 648G-III,
748G-III) (G) and washer (E).
cap screw (F) and tighten to specification.
Blade Pin Cap Assembly Cap
OUO1020,0001213 1908JAN035/6
32
3201
5
TM2111 (30MAY03)
32-3201-5

053003
PN=657
Blades
18. Lift blade using a hoist. Install shims (D) as required
so that cylinders do not bind. Install pin (B) through
cylinder (F), shims (D) and spherical bushing (E).
19. Install cap screw (A) and nut (C) and tighten.
T7502HK
UN02JUL91
T7502HL
UN10JUL91
ACap Screw
BPin
CNut
DShim (as required)
ESpherical Bushing
FBlade Cylinder
32
3201
6
OUO1020,0001213 1908JAN036/6
TM2111 (30MAY03)
32-3201-6

053003
PN=658
Blades
Spherical Bushing Remove and Install

1. If bushing (A) in blade pivot bore must be replaced,
remove washer (B) using a grinder to remove weld.
T7502HJ
UN02JUL91
ABushing
BWasher
OUO1020,0001214 1908JAN031/3
2. Remove bushing (B). See DFT1099 Bushing Drivers.

(Group 9900.)
T7569AM
UN09JUL91
APipe Assembly
BSpherical Bushing
CPipe Assembly
DWasher
ENut
TM2111 (30MAY03)
32-3201-7
OUO1020,0001214 1908JAN032/3

053003
PN=659
32
3201
7
Blades
3. Install bushing. See DFT1099 Bushing Drivers. (Group
9900.)
5. Weld new washers in place at the same location where

old ones were removed.
See Make Welding Repairs Safely, and See Remove
Paint Before Welding or Heating. (Group 9000-10.)
T7569AL
CAUTION: Have only a qualified welder do the

welding. Be sure the area near the machine is
free of debris and flammable material. Before
welding, clean all dirt and paint from weld area.
Disconnect the battery negative cable. Connect
the welder ground clamp as close as possible
to each weld area.
UN09JUL91
4. Turn nut (F) until center line (B) of bushing aligns with
center line (C) of frame.
APipe Assembly
BBushing Center Line
CFrame Center Line
DBar Stock
EWasher
FNut
OUO1020,0001214 1908JAN033/3
32
3201
8
TM2111 (30MAY03)
32-3201-8

053003
PN=660
Group 3215
Controls Linkage
TP35542
UN12APR95
Blade Control Linkage Remove and Install
1Shim
2Bushing (2 used)
3Knob
4Control Lever
5Boot
6Nut
7Washer
8Bushing
9Lock Nut
10Pin
11Spring Locking Pin
12Rod
13Jam Nut
14Ball Joint
4. Clean threads of pivot ball joint (14) and apply

medium strength thread lock and sealer.
1. Lower blade and relieve all hydraulic pressure.

hinge area.
5. Adjust length of rod (12) so horizontal leg of control

lever (4) is level.
6. Clean threads of lever (4) and apply medium
strength thread lock and sealer then install knob
(3).
3. Inspect and replace blade control linkage parts as

necessary.
32
3215
1
OUO1020,0001215 1908JAN031/1
TM2111 (30MAY03)
32-3215-1

053003
PN=661
Controls Linkage
T8487AB
UN22MAY95
Blade Control Valve Remove and Install
1Cap Screw (3 used)

2Rubber Mount (3 used)
3Blade Valve Support
4Washer (5 used)
1. Lower blade and relieve all hydraulic pressure.
3. Remove blade control valve. See Blade Control

Valve Disassemble and Assemble. (Group 3860.)

hinge area.
5Cap Screw (3 used)
4. Inspect blade control valve support and replace

parts as necessary.
5. Install blade control valve. See Blade Control Valve
32
3215
2
OUO1020,0001216 1908JAN031/1
TM2111 (30MAY03)
32-3215-2

053003
PN=662
Group 3260
Hydraulic System
Blade Lift Cylinder Remove and Install
UN23AUG88

X9811

2. Disconnect lines (B and C).
UN11JUL91
Blade Lift CylinderSpecification

3. Attach hoist to blade lift cylinder using a lifting strap.
T7569AT
4. Remove cap screws (A and D).

5. Remove pins (E and F) to remove blade lift cylinder.
6. Repair or replace blade lift cylinder as required. See
Disassemble Cylinder and See Assemble Cylinder.
(TM-H120A.)
7. Install blade lift cylinder.
Wheel Removed for Illustration Purposes Only

ACap Screw
BSteering Valve-to-Steering Cylinder Rod End
Line
CSteering Valve-to-Steering Cylinder Head End
Line
DCap Screw
EPin
FPin
OUO1020,0001219 1908JAN031/1
TM2111 (30MAY03)
32-3260-1

053003
PN=663
32
3260
1
Hydraulic System
32
3260
2
TM2111 (30MAY03)
32-3260-2

053003
PN=664
Section 37
Arch or Boom
Contents
Page
Group 3740Frames
Log Arch Remove and Install . . . . . . . . . . . .37-3740-1
Horizontal Roller Remove and Install . . . . . .37-3740-1
Side Roller Remove and Install . . . . . . . . . . .37-3740-3
Roller Brackets Remove and Install. . . . . . . .37-3740-5
37
TM2111 (30MAY03)
37-1

053003
PN=1
Contents
37
TM2111 (30MAY03)
37-2

053003
PN=2
Group 3740
Frames
Log Arch Remove and Install
locking bar.
2. Remove winch cable from log arch.
Log ArchSpecification
Log ArchWeight ......................................... 308 kg (680 lb) approximate
3. Attach hoist to log arch using a lifting strap.

4. Remove cap screws and pins (A).
UN11JUN91
NOTE: The two rear joints are shimmed to remove side

play.
T7553BR
5. Inspect components and replace screws, if necessary.

ACap Screws and Pins
OUO1020,000121A 1909JAN031/1
Horizontal Roller Remove and Install

1. Attach hoist to horizontal roller using a lifting strap.
UN11JUN91
2. Remove cap screw (A) and grease fitting (B).
T7553BJ
ACap Screw
BGrease Fitting
TM2111 (30MAY03)
37-3740-1
OUO1020,000121B 1909JAN031/5

053003
PN=667
37
3740
1
Frames

Horizontal RollerSpecification
Horizontal RollerWeight ................................. 27 kg (60 lb) approximate
T7553BK
UN11JUN91
3. Remove pin using a brass drift.
OUO1020,000121B 1909JAN032/5
T94722
UN20OCT88
4. Remove two bushings using D01061AA Blind-Hole

Puller Set.
OUO1020,000121B 1909JAN033/5
T94723
UN20OCT88
5. Install bushing flush with surface of roller using 44 mm

disk and 52 mm disk from JT01800 Driver Set.
OUO1020,000121B 1909JAN034/5
NOTE: Roller bracket can be moved to mount roller in

different positions, for a variety of load conditions.
6. Install pin with lubrication hole down.
UN11JUN91
7. Install cap screw, nut, and grease fitting.
T7553BL
37
3740
2
OUO1020,000121B 1909JAN035/5
TM2111 (30MAY03)
37-3740-2

053003
PN=668
Frames
Side Roller Remove and Install
T7553BM
UN11JUN91
1. Remove cap screw and plate.
OUO1020,000121C 1909JAN031/8
2. Fasten safety chain around roller and log arch as

shown.
Side RollerSpecification
Side RollerWeight .......................................... 25 kg (55 lb) approximate
T7553BN
UN11JUN91
3. Remove shaft using brass drift and disconnect chain to

remove roller.
OUO1020,000121C 1909JAN032/8
4. Remove washers.
T7553BO
UN11JUN91
37
3740
3
TM2111 (30MAY03)
37-3740-3
OUO1020,000121C 1909JAN033/8

053003
PN=669
Frames
T94729
UN20OCT88
5. Remove two bushings using a D01061AA Blind-Hole

Puller Set.
OUO1020,000121C 1909JAN034/8
T94730
UN20OCT88
6. Install bushings flush with bushing retainer using 28

mm disk and 37 mm disk from JT01800 Driver Set.
OUO1020,000121C 1909JAN035/8
T7553BO
UN11JUN91
7. Install washer on each end of roller.
OUO1020,000121C 1909JAN036/8

Side RollerWeight .......................................... 25 kg (55 lb) approximate
UN11JUN91
8. Position roller on log arch.

9. Fasten safety chain around roller and log arch.
10. Install shaft.
T7553BQ
37
3740
4
TM2111 (30MAY03)
37-3740-4
OUO1020,000121C 1909JAN037/8

053003
PN=670
Frames
11. Install clamp and cap screw. Tighten cap screw to
specification.
T7553BM
UN11JUN91
Cap Screw M12Torque ............................................ 140 Nm (105 lb-ft)
OUO1020,000121C 1909JAN038/8
Roller Brackets Remove and Install

Roller BracketsSpecification
Horizontal RollerWeight ................................. 27 kg (60 lb) approximate
1. Remove horizontal roller. See Horizontal Roller

2. Remove side roller. See Side Roller Remove and
Install in this group.
OUO1020,000121D 1909JAN031/2
37
3740
5
TM2111 (30MAY03)
37-3740-5

053003
PN=671
Frames
3. Remove cap screws (A) on top and bottom brackets to
remove side roller brackets.
4. Remove cap screws (B) on both sides to remove
horizontal roller brackets.
NOTE: The horizontal roller bracket can be positioned for

a variety of load conditions.
T7553BP
UN11JUN91
ACap Screws
BCap Screws
OUO1020,000121D 1909JAN032/2
37
3740
6
TM2111 (30MAY03)
37-3740-6

053003
PN=672
Section 38
Grapple
Contents
Page
Page
Group 3803Grapple Mechanism

Grapple Remove and Install . . . . . . . . . . . . .38-3803-1
Grapple Disassemble and Assemble . . . . . . .38-3803-2
Grapple Damper Repair . . . . . . . . . . . . . . . .38-3803-4
Grapple Damper Adjustment . . . . . . . . . . . . .38-3803-6
Damper, Yoke, and Cross Head Pins
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . .38-3803-8
Grapple Rotate Yoke Repair . . . . . . . . . . . . .38-3803-9
Control Valve Disassemble and

AssembleDual Function Grapple . . . . .38-3860-20
Dual Function Control Valve Sections
Disassemble and Assemble. . . . . . . . . . .38-3860-24
Grapple Rotate Solenoid Valve Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .38-3860-25
Grapple Rotate Solenoid Valve Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . .38-3860-26
Pilot Controller Repair (If Equipped) . . . . . .38-3860-27
Flow Divider Repair. . . . . . . . . . . . . . . . . . .38-3860-30
Rotary Manifold Remove and Install . . . . . .38-3860-34
Rotary Manifold Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .38-3860-35

Single Function Grapple Control Linkage
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3815-1
Dual Function Grapple Control Linkage
Remove and Install . . . . . . . . . . . . . . . . . .38-3815-4
Single Lever Pilot Controller Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3815-6
Group 3840Frames
Single Function Grapple Cable Rollers
Remove and Install . . . . . . . . . . . . . . . . . .38-3840-2
Dual Function Grapple Cable Rollers Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .38-3840-4
Single Function Grapple Arch Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .38-3840-6
Dual Function Grapple Arch Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3840-10
Dual Function Grapple Boom Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3840-13
Arch Cylinder Remove and InstallSingle
Function Grapple . . . . . . . . . . . . . . . . . . . .38-3860-1
Boom or Arch Cylinder Remove and
InstallDual Function Grapple . . . . . . . . .38-3860-3
Grapple Tong Cylinder Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3860-5
Rotate Motor Remove and Install . . . . . . . . .38-3860-7
Rotate Motor Repair . . . . . . . . . . . . . . . . . . .38-3860-8
Rotate Motor Drive Gear Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3860-13
Control Valve Remove and InstallSingle
Function Grapple . . . . . . . . . . . . . . . . . . .38-3860-14
Single Function Control Valve Sections
Disassemble and Assemble. . . . . . . . . . .38-3860-16
Control Valve Remove and InstallDual
Function Grapple . . . . . . . . . . . . . . . . . . .38-3860-18
TM2111 (30MAY03)
38-1
38

053003
PN=1
Contents
38
TM2111 (30MAY03)
38-2

053003
PN=2
Group 3803
Grapple Mechanism
Grapple Remove and Install
GrappleSpecification
Grapple Tong CylinderWeight ..................... 80 kg (180 lb) approximate
Tong CylinderWeight ................................. 179 kg (394 lb) approximate
GrappleWeight ....................................... 1132 kg (2500 lb) approximate
X9811
1. Lower all equipment to the ground.
UN23AUG88
2. Set grapple on a lift table.

3. Operate hydraulic control valves to release pressure in
hydraulic system. Depress brake pedal at one second
intervals 20 times to drain oil from accumulator.
OUO1020,0001229 1910JAN031/2
4. Disconnect rotary manifold lines (C and D) at cylinder

and flow divider. Close all line openings using caps
and plugs.
5. Disconnect shock absorber cylinder (A) from rotary
yoke.
6. Remove pins (B) to remove grapple assembly.
7. Install grapple assembly and connect lines.
8. Connect shock absorber cylinder (A) to rotary yoke.
T8492AG
UN02JUN95
AShock Absorber Cylinder

BPin (2 used)
CRotary Manifold Line
DRotary Manifold Line
OUO1020,0001229 1910JAN032/2
TM2111 (30MAY03)
38-3803-1

053003
PN=675
38
3803
1
Grapple Mechanism
TP54274
UN16JUN98
Grapple Disassemble and Assemble
548G-III Shown
1Cap Screw (2 used)
2Washer (2 used)
3Washer (2 used)
4Pin (2 used)
5Seal (4 used)
7Bushing (4 used)

9Cap Screw (4 used)
10Access Panel
11Washer (4 used)
12Special Washer (2 used)
13Washer (2 used)
14Bushing (2 used)

16Washer (2 used)
17Spacer (2 used)
18Pin (2 used)
19Screw (2 used)
20Grapple Tong Cylinder Pin
(2 used)
21Grapple Tong Frame

22Access Panel
23Tong (2 used)
25Tong Tip (2 used)
38
3803
2
TM2111 (30MAY03)
38-3803-2
OUO1020,000122A 1910JAN031/2

053003
PN=676
Grapple Mechanism
CAUTION: The pin that attaches the cylinder

head end also attaches the opposite tong.
Cylinders should be removed one at a time
to prevent both grapple tongs from falling
out of frame.
GrappleSpecification
GrappleWeight ................................ 1132 kg (2500 lb) approximate
Grapple FrameWeight ......................... 254 kg (115 lb) approximate
548G-III 8.0 Sq Ft Grapple
Tong CylinderSize ................................................ 100 mm x 50 mm
Weight ...................................................... 36.3 kg (80 lb) approximate
Tong CylinderSize ................................................ 100 mm x 50 mm
Weight ...................................................... 40.8 kg (90 lb) approximate
648G-III, 748G-III 11.7 Sq Ft
Grapple Tong CylinderSize .................................. 115 mm x 63 mm
Weight .................................................... 61.2 kg (135 lb) approximate

Tong Cylinder (180 Series)
Size .......................................................................... 125 mm x 63 mm
Weight .................................................... 83.9 kg (185 lb) approximate
TongWeight ......................................... 104 kg (230 lb) approximate
Grapple TongWeight ........................... 179 kg (395 lb) approximate
1. Disassemble parts as shown.

2. Inspect for worn or damaged parts and replace as
necessary.
3. Assemble parts.
OUO1020,000122A 1910JAN032/2
38
3803
3
TM2111 (30MAY03)
38-3803-3

053003
PN=677
Grapple Mechanism
UN01JUN00
Grapple Damper Repair
T131307
38
3803
4
TM2111 (30MAY03)
38-3803-4
OUO1020,000122B 1910JAN031/2

053003
PN=678
Grapple Mechanism
1Plug (6 used)
2Spring (6 used)
3Washer (18 used)
4Snap Ring
5O-Ring
6O-Ring
7Housing
8Bushing
9O-Ring
10Plug
11Pin
12O-Ring
13Snap Ring
14Bushing
15Lubrication Fitting (6
used)
16Plate (4 used 548G-III) (6
used 648G-III, 748G-III)

Grapple DamperSpecification
548G-III DamperWeight ........................ 55 kg (122 lb) approximate
648G-III, 748G-III Damper
Weight ..................................................... 105 kg (231 lb) approximate
1. Remove grapple using a suitable lifting device. See

Grapple Remove and Install in this group.
17Disk (3 used 548G-III) (5

used 648G-III, 748G-III)
18Cotter Pin
19Pin
20Pin
21Washer
22Cap Screw
23Lock Nut
24Shock Absorber Cylinder
25Washer
26Lubrication Fitting (2
used)
27Bushing (2 used)
28Grapple Damper Housing
29Pin
30Spacer
31Washer
32Cap Screw
5. Grease need not be totally removed from plates or

disks, unless obvious contamination is evident.
Wipe excess grease from plates (16) and disks (17)
and coat with fresh grease containing 35% moly.
6. Install O-rings (9) and (12), shaft (11) and snap ring
(13) into housing (28).
7. Alternately install plates (16) and disks (17)
assuring the galled steel plate is toward springs (2).
2. Remove plugs (1), washers (3) and springs (2).

3. Push housing (7) inward to remove snap ring (4).
4. Move grapple tong cylinder hoses out of the way
and use a pry bar to pry damper plates (16), disks
(17), shaft (11) and snap ring (13), out of housing
(28). Inspect for wear or damage.
IMPORTANT: The plate located next to springs (2)
will be worn or galled; this is normal.
When damper is assembled, install
this plate next to the springs.
Installing this galled plate next to a
friction element will damage the
friction element.
NOTE: Install snap ring (4) with gap located at 12

Oclock position. Snap ring helps retain grease
inside the housing.
8. Install O-rings (5) and (6), housing (7). Push
housing (7) inward to install snap ring (4) with gap
at 12 Oclock position.
9. Tighten nut (23) to specification.
Shock Cylinder NutTorque ................. Tighten to snug, back off 1/2
turn
10. Perform Grapple Damper Adjustment in this group.
NOTE: If any friction material remains on disks (17)

they are considered usable.
OUO1020,000122B 1910JAN032/2
38
3803
5
TM2111 (30MAY03)
38-3803-5

053003
PN=679
Grapple Mechanism
Grapple Damper Adjustment

The grapple damper limits the motion of the grapple head
when travelling empty and prevents damage to the
structural components, especially the yoke, crosshead and
pins.
Adjust the damper if the head swings to extreme heights
or hits the stops. Adjust the damper by adding or
subtracting the number of shim washers in the damper
assembly.
OUO1020,000122E 1915JAN031/3
1. Slightly loosen adjusting plugs (every other plug or all

six plugs) evenly to remove spring tension and to keep
housing from rotating.
2. Remove the three adjusting plugs (A).
3. Remove one shim washer (B) from each of the three
adjusting plugs (A) to tighten grapple damper or add
one shim washer to each plug to loosen.
4. Apply 35% moly grease to adjusting plug thread and
the inside of plugs. Tighten plugs evenly until plugs
contact shim washers.
5. Repeat steps 14 for other three plugs.
TEST CONDITIONS:
UN02FEB94
NOTE: The grapple head should be 1015 from vertical

under test conditions.
T8412AQ
Close tongs, raise the grapple arch or boom to full

height.
Lower the arch or boom slowly and bring to a
smooth stop when the tongs are approximately 300
mm (12 in.) above the ground.
AAdjusting Plugs (6 used)
BShim Washer
38
3803
6
TM2111 (30MAY03)
38-3803-6
OUO1020,000122E 1915JAN032/3

053003
PN=680
Grapple Mechanism
When properly adjusted the grapple head will be
1015 from vertical. Measure with a magnetic base
inclinometer (C).
NOTE: If damper plates are replaced, put grease on each

plate before assembling grapple.
6. If additional tightness is required, remove shim

washers from plugs with greatest number of shim
washers. If additional looseness is required, add shim
washers to plugs with the least number of shim
washers. Repeat steps 14 until desired tightness is
achieved.
T8412AR
DO NOT add any washers to the inside

of the adjusting plugs in an attempt to
tighten the damper assembly. This will
cause the springs to become a solid
member. Damage to the outer damper
housing will result. If additional
dampening is required after all shim
washers are removed, it will be
necessary to replace the disks inside
the damper assembly. See Grapple
Damper Repair in this group.
UN02FEB94
IMPORTANT: The snap ring gap is at 12 Oclock

position to maintain the grease level in
the damper housing. During tightening
of plugs it is important to retain this
position by holding the damper housing
with a pry bar.
CInclinometer
7. To hold damper housing in place, use a pry bar

between plugs. Tighten plugs to specification.
Damper PlugTorque................................................. 184 Nm (250 lb-ft)
OUO1020,000122E 1915JAN033/3
38
3803
7
TM2111 (30MAY03)
38-3803-7

053003
PN=681
Grapple Mechanism
Damper, Yoke, and Cross Head Pins

Lubricate
Lubricate eight points until fresh grease escapes at joints.
UN08JUN95
IMPORTANT: If grease fitting (D) does not accept

grease, lower grapple head to the
ground and lubricate again.
T8496AD
NOTE: Using (A) as a locating point on damper, lubricate

the four fittings until grease escapes at joints.
T8499AB
UN08JUN95
ATop Locating Point

BBushing Next to Damper Assembly Grease Fitting
CDamper Head Outer Bushing Grease Fitting
DDamper Spline Grease Fitting
EBrake Plates Grease Fitting
FDamper Brake Assembly
T8412AC
UN03FEB95
Cross Section of Upper Damper Pin
Lower Pin
OUO1020,0001239 1924JAN031/1
38
3803
8
TM2111 (30MAY03)
38-3803-8

053003
PN=682
Grapple Mechanism
TP63038
UN07JUL99
Grapple Rotate Yoke Repair
1Bushing
2Yoke
3Spacer
4Seal
5Lower Bearing Cone
6Lower Bearing Cup

7Shim (as required)
8Shim (as required)
9Gear
10Cap Screw
11Spacer (2 used)
12Washer (2 used)
13Motor Mount Bracket
14Rotate Motor Drive Gear
15Bearing
16Grease Fitting
17Upper Bearing Cup
18Upper Bearing Cone
38
3803
9
TM2111 (30MAY03)
38-3803-9
OUO1020,000122F 1915JAN031/6

053003
PN=683
Grapple Mechanism

Grapple Rotate YokeSpecification
YokeWeight ............................................. 30 kg (66 lb) approximate
1. Remove grapple. See Grapple Remove and Install

in this group.
3. Support yoke (2) and remove cap screws (19).

4. Remove parts (35, 79, and 17 and 18).
Replace parts as needed.
5. Install spacer (3) tight against shoulder of yoke (2).
6. Install seal (4) in spacer groove.
2. Remove rotary manifold. See Rotary Manifold

OUO1020,000122F 1915JAN032/6
UN23AUG88
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 the oil in a well-ventilated area.
Plan a safe handling procedure to avoid burns.
TS227
7. Heat lower bearing cone (5) to 132C (270F). Install

bearing cone with large end toward spacer (3). Bearing
cone must be tight against spacer.
8. Install upper and lower bearing cups (6 and 17) using
a press. Bearing cups must be tight against shoulders
in housing. Apply grease to lower cup bore and outside
diameter of seal.
9. Install yoke (2) into rotate housing. Hold yoke upward
in rotate housing. Install upper bearing cone (18) on
yoke.
OUO1020,000122F 1915JAN033/6
38
3803
10
TM2111 (30MAY03)
38-3803-10

053003
PN=684
Grapple Mechanism
10. Measure thickness (A) of gear. Use the inside hole in
two places 180 apart. Record measurement.
11. Rotate yoke so the crosshead pivot pin bore is 90 to
machine centerline and splined hole for damper pin in
yoke is to the right of the arch when viewed from the
rear.
T8320AJ
UN25MAY95
AGear Thickness
OUO1020,000122F 1915JAN034/6
38
3803
11
TM2111 (30MAY03)
38-3803-11

053003
PN=685
Grapple Mechanism
12. Install gear so the figure "8" cutout is aligned with
machine centerline and 90 to the crosshead pivot pin
bore. Hoses from rotary manifold must not twist as
they pass through the cutout. The two 4 mm holes (B)
should be at 12:30 and 6:30 Oclock positions.
13. Install two cap screws (C) through gear 180 apart in
1 and 7 Oclock positions. Tighten cap screws to
specification. Rotate yoke back and forth 90 three
times to seat bearings. Repeat tightening cap screw
to specification, rotate yoke back and forth 90.
Repeat until cap screws remain tight.
Rotate Yoke Mounting Cap
UN25MAY95
14. Measure through the 4 mm holes (B) using a depth

micrometer from surface of gear to the yoke. Average
the measurements and record.
T8320AK
15. Subtract the average thickness of the gear recorded

earlier, from the surface of gear to yoke
measurement. Subtract an additional 0.58 mm (0.023
in.) to obtain shim pack dimension, for a bearing
preload of 0.560.61 mm (0.0220.024 in.). Use a
0.25 mm (0.10 in.) thick shim on top and on bottom of
shim pack.
Rotate Pivot-to-GearBearing
Preload ................................................ 0.560.61 mm (0.0220.024 in.)
16. Support yoke; remove cap screws (C) and gear.

Install shim pack and gear. Make sure gear is
indexed as explained earlier. Install cap screws (E) in
gear and tighten to specification.
Gear Cap ScrewsTorque .............................. 5481 Nm (4060 lb-ft)
UN03FEB98
17. Rotate yoke back and forth 90 three times to seat

bearings. Tighten cap screws (E) to specification.
T113103

Rotate Pivot-to-Gear Cap
BHoles (4 mm) (2 used)

CCap Screw (2 used)
DHoses (2 used)
ECap Screws (12 used)
38
3803
12
TM2111 (30MAY03)
38-3803-12
OUO1020,000122F 1915JAN035/6

053003
PN=686
Grapple Mechanism
18. Pump grease into arch tube grease fitting while
rotating the yoke, until grease comes out from under
gear teeth all around gear. Apply additional grease to
gear if needed.
NOTE: Hoses (D) must be "straight" and not twist as they

pass through the gear and yoke when installing
rotary manifold.
19. Install rotary manifold with hoses (D) through gear
figure "8" cutout. Install rotate motor mount bracket.
Tighten cap screws to specification.
Rotate Motor Mount Cap
OUO1020,000122F 1915JAN036/6
38
3803
13
TM2111 (30MAY03)
38-3803-13

053003
PN=687
Grapple Mechanism
38
3803
14
TM2111 (30MAY03)
38-3803-14

053003
PN=688
Group 3815
Controls Linkage
TM2111 (30MAY03)
38-3815-1
OUO1020,000123A 1924JAN031/2
TP63075
UN03MAY00
Single Function Grapple Control Linkage Repair

053003
PN=689
38
3815
1
Controls Linkage
1Rocker Switch
2Knob
3Nut
4Boot
5Ring
6Clip (6 used)
7Lever
8Lock Nut (2 used)
9Spring Locking Pin (2
used)
10Ball Joint (2 used)

11Nut (2 used)
12Link
13Pin (2 used)
14Sleeve
15Connector
16Eyebolt
17Nut (2 used)
18Ball Joint
19Spacer
20Screw
21Nut (3 used)
22Seal
23Label
24Washer
25Rubber Mount

hinge area.
2. Inspect and replace parts if necessary.
26Cover
28Support
29Nut (2 used)
30Angle
32Nut (2 used)
3. Clean threads of main pivot ball joint (18) with cure

primer and apply medium strength thread lock and
sealer.
4. Adjust length of linkage so base end of control lever
shafts are straight up and down.
5. Replace grapple rotate switch.
OUO1020,000123A 1924JAN032/2
38
3815
2
TM2111 (30MAY03)
38-3815-2

053003
PN=690
Controls Linkage
38
3815
3
TM2111 (30MAY03)
38-3815-3

053003
PN=691
Controls Linkage
UN28APR98
Dual Function Grapple Control Linkage Remove and Install
T115041
38
3815
4
TM2111 (30MAY03)
38-3815-4
OUO1020,000123B 1924JAN031/2

053003
PN=692
Controls Linkage
ABoot
BLever
CLever
DSpacer
ELock Nut (3 used)
FBall joint
GNut (2 used)
HBall joint (3 used)

INut (3 used)
JLink (2 used)
KLink
LPin (3 used)
MSpring Locking Pin (3
used)
NNut (2 used)
OScrew (2 used)
PBushing (2 used)
QAngle Guide
RSpacer (2 used)
SWasher
TLock Nut

hinge area.
1. Install locking bar.
UInsert
VInsert
WHandle (2 used)
XSpecial Nut (2 used)
YRotate Harness Connector
ZRotate Switch
3. Clean threads of main pivot ball joint (F) and apply

medium strength thread lock and sealer.
4. Adjust length of linkage so base end of control lever
shafts are straight up and down.
5. Replace rotate switch (Z) as needed.
2. Inspect and replace parts, as necessary.
OUO1020,000123B 1924JAN032/2
38
3815
5
TM2111 (30MAY03)
38-3815-5

053003
PN=693
Controls Linkage
UN09OCT00
Single Lever Pilot Controller Remove and Install
T134438
38
3815
6
TM2111 (30MAY03)
38-3815-6
OUO1020,0001230 1922JAN031/2

053003
PN=694
Controls Linkage
1Single Lever Pilot
Controller
2Boot Fastening Ring
3Cap Screw (3 used)
4Clips (6 used)
5Handle
6O-Ring
7Pilot Controller Harness
8O-Ring
9Straight Fitting (1 shown)

10O-Ring
11Console Cover
13Clip (4 used)
14Grapple Latch Indicator
Light
15Cap Screw
16Grapple Control Valve and
Pilot Controller Support

hinge area.
2. Operate all grapple functions with key switch ON.
17Washer (8 used)
18Rubber Mount (4 used)
20Shim
21Bushing (2 used)
22Bushing
23Washer
24Lock Nut
25Lock Nut
26Linkage Ball Joint

27Control Arm
28Boot Fastening Ring
29Boot
30Nut
31Knob
32Fitting
33O-Ring
See Hydraulic Component Location. (Group

9025-05.)
See Hydraulic Component Location. (Group
9025-05.)
See DEUTSCH Rectangular or Triangular
Connectors Replace. (Group 9015-20.)
7. Install pilot controller.
8. Connect harness (7) connectors.
3. Remove top and side console covers.
9. Operate machine to verify repair.
4. Disconnect harness (7) connectors.
10. Install console covers.
5. Disconnect pilot lines from pilot controller.

6. Remove pilot controller (1). Repair as necessary.
For additional information on hose routing and
connector repair:
OUO1020,0001230 1922JAN032/2
38
3815
7
TM2111 (30MAY03)
38-3815-7

053003
PN=695
Controls Linkage
38
3815
8
TM2111 (30MAY03)
38-3815-8

053003
PN=696
Group 3840
Frames
38
3840
1
TM2111 (30MAY03)
38-3840-1

053003
PN=697
Frames
UN16APR98
Single Function Grapple Cable Rollers Remove and Install
T113073
38
3840
2
TM2111 (30MAY03)
38-3840-2
OUO1020,0001231 1922JAN031/2

053003
PN=698
Frames
AWasher (4 used)
BBushing (4 used)
CLubrication Fitting (4 used)
DVertical Roller (2 used)
EShaft (2 used)
FWasher (2 used)
GScrew (2 used)
HPlug (2 used)
IWasher (4 used)
JBushing (2 used)
KLubrication Fitting (2 used)
LShaft

Single Function Grapple Cable RollersSpecification
Horizontal RollerWeight .......................... 29 kg (65 lb) approximate
Vertical RollerWeight ............................... 23 kg (50 lb) approximate
MHorizontal Roller
NStrap
OWasher (2 used)
PCap Screw (2 used)
2. Inspect bushings (B and J) and shafts (E and L) for

wear or damage.
3. Install bushings even with end surface of rollers.
4. Install rollers.
1. Remove rollers (D and M).
OUO1020,0001231 1922JAN032/2
38
3840
3
TM2111 (30MAY03)
38-3840-3

053003
PN=699
Frames
UN01JUN00
Dual Function Grapple Cable Rollers Remove and Install
T131310
38
3840
4
TM2111 (30MAY03)
38-3840-4
OUO1020,0001232 1922JAN031/2

053003
PN=700
Frames
1Washer (2 used)
2Bushing (4 used)
4Vertical Roller (2 used)
5Shaft (2 used)
6Washer (2 used)
7Screw (2 used)
10Shaft

Dual Function Grapple Cable RollersSpecification
Horizontal RollerWeight .......................... 29 kg (65 lb) approximate
Vertical RollerWeight ............................... 23 kg (50 lb) approximate

12Strap
14Cap

16Bushing (2 used)
17Horizontal Roller
18Washer (2 used)
2. Inspect bushings (2) and shafts (5 and 10) for wear

or damage.
3. Install bushings even with end surface of rollers.
4. Install rollers.
1. Remove rollers (4 and 17).
OUO1020,0001232 1922JAN032/2
38
3840
5
TM2111 (30MAY03)
38-3840-5

053003
PN=701
Frames
TP35305
UN27JAN95
Single Function Grapple Arch Remove and Install
548G-III Shown
1Arch
2Screw (6 used)
3Cover
38
3840
6
4Spherical Bushing (2 used)

6Thrust Washer (as
required)
7Pin (2 used)
8Spacer (2 used)
9Washer (2 used)
1. Inspect boom for cracks.
TM2111 (30MAY03)
38-3840-6
OUO1020,0001233 1922JAN031/4

053003
PN=702
Frames
IMPORTANT: Have only a qualified welder do the
welding. Be sure the area near the
machine is free of debris and
flammable material. Before welding,
clean all dirt and paint from weld
area. Disconnect the battery ground
() cable. Connect the welder
ground clamp as close as possible
to each weld area.
2. Weld any cracks using E7018 electrodes or

equivalent. See Make Welding Repairs Safely, and
See Remove Paint Before Welding or Heating.
(Group 9000-10.)
3. Operate all hydraulic control valves to release
pressure in hydraulic system.
OUO1020,0001233 1922JAN032/4
4. Open access covers (E) on both sides of frame.
T8495AD
UN02JUN95
AArch Cylinder Pin (2 used)

BArch
CGrapple
DFrame Pin (2 used)
EAccess Door (left and right side)
OUO1020,0001233 1922JAN033/4
38
3840
7
TM2111 (30MAY03)
38-3840-7

053003
PN=703
Frames
5. Disconnect hoses to arch. Close openings with caps

and plugs.
X9811
NOTE: If pins (D) and bushings need repair the arch can
be carefully raised enough to service these parts
without removing grapple or hoses.
UN23AUG88


Single Function Grapple ArchSpecification
Grapple Log ArchSingle
FunctionWeight .......................................... 351 kg (773 lb) approximate
Grapple BoomSingle
FunctionWeight ........................................ 453 kg (1000 lb) approximate
Grapple Arch with Grapple
Single FunctionWeight ........................... 1483 kg (3275 lb) approximate
6. Remove grapple assembly (C) if required. See Grapple

7. Put wooden blocks under arch cylinders, remove arch
cylinder pins (A).
8. Remove grapple arch (B). Inspect pins (A and D) and
bushings. Remove bushings only if replacement is
necessary. See Spherical Bushing Remove and Install.
(Group 3201.)
OUO1020,0001233 1922JAN034/4
38
3840
8
TM2111 (30MAY03)
38-3840-8

053003
PN=704
Frames
38
3840
9
TM2111 (30MAY03)
38-3840-9

053003
PN=705
Frames
UN01JUN00
Dual Function Grapple Arch Remove and Install
T131309
38
3840
10
TM2111 (30MAY03)
38-3840-10
OUO1020,0001234 1922JAN031/3

053003
PN=706
Frames
1Arch
3Washer
4Pin (2 used)
5Spacer (2 used)
8Cap Screw (2 used)

9Washer (2 used)
10Bushing (2 used)

11Pin (2 used)
12Spherical Bushing (2
used)

to each weld area.
(Group 9000-10.)
OUO1020,0001234 1922JAN032/3
38
3840
11
TM2111 (30MAY03)
38-3840-11

053003
PN=707
Frames
UN23AUG88

X9811
NOTE: If pins (B) and bushings need repair the arch can
be carefully raised enough to service these parts
without removing boom or hoses.
4. Remove covers (H).
5. Disconnect hoses that go to boom and equipment
frame and close all openings with caps and plugs.
Dual Function Grapple ArchSpecification
Grapple Log ArchDual
FunctionWeight ........................................ 465 kg (1025 lb) approximate
Grapple BoomDual Function
Weight.......................................................... 636 kg (1400 lb) approximate
Grapple Arch with GrappleDual
FunctionWeight ...................................... 1770 kg (2900 lb) approximate
6. Remove boom (F) if required. See BoomDual

Function Grapple Boom Remove and Install in this
group.
UN02JUN95
7. Put wooden blocks under arch cylinders (A), remove

arch cylinder rod end pins.
T8412AG1
8. Remove grapple arch (C). Inspect pins and bushings

(B and D). Remove bushings only if replacement is
necessary. See Spherical Bushing Remove and Install.
(Group 3201.)
AArch Cylinder (2 used)
BArch-to-Frame Pins (2 used)
CArch
DBoom-to-Arch Pins (2 used)
EBoom Cylinder (2 used)
FBoom
GGrapple
HArch Hose Cover (2 used)
38
3840
12
OUO1020,0001234 1922JAN033/3
TM2111 (30MAY03)
38-3840-12

053003
PN=708
Frames
UN27JAN95
Dual Function Grapple Boom Remove and Install
TP35308
38
3840
13
Dual Function Boom

TM2111 (30MAY03)
38-3840-13
OUO1020,0001235 1922JAN031/3

053003
PN=709
Frames
1Boom
2Cover
3Cap Screw (6 used)
4Arch Bushings (2 used)
5Arch-to-Boom Pin (2 used)

6Boom Cylinder Spherical
Bushings (2 used)
7Grease Fitting (2 used)

8Cap Screw (2 used)
9Washer (2 used)

10Spacer (2 used)
11Grease Fitting (2 used)

to each weld area.
(Group 9000-10.)
OUO1020,0001235 1922JAN032/3
38
3840
14
TM2111 (30MAY03)
38-3840-14

053003
PN=710
Frames
in hydraulic system. Remove hose covers (H), remove
and cap hoses at arch bulkhead.
BoomDual Function GrappleSpecification
Grapple BoomDual Function
Weight.......................................................... 636 kg (1400 lb) approximate
Grapple Arch with GrappleDual
FunctionWeight ...................................... 1770 kg (2900 lb) approximate
4. Remove grapple (G) if required. See Grapple Rotate

Yoke Repair. (Group 3803.)
5. Connect hoist to boom using a lifting strap.
6. Remove boom cylinder (E) pins and move cylinders
back toward cab.
UN02JUN95
7. Remove boom to arch pins (D).
9. Install grapple (G) if removed. See Grapple Rotate

Yoke Repair. (Group 3803.)
T8412AG1
8. Inspect pins and bushings. Remove bushings only if

replacement is necessary. See Spherical Bushing
AArch Cylinders
BArch-to-Frame Pins (2 used)
CArch
DBoom-to-Arch Pins (2 used)
EBoom Cylinder (2 used)
FBoom
GGrapple
HArch Hose Cover (2 used)
OUO1020,0001235 1922JAN033/3
38
3840
15
TM2111 (30MAY03)
38-3840-15

053003
PN=711
Frames
38
3840
16
TM2111 (30MAY03)
38-3840-16

053003
PN=712
Group 3860
Hydraulic System
Arch Cylinder Remove and InstallSingle
Function Grapple
1. Lower grapple to the ground. Operate all control valves
to release pressure in hydraulic system.
NOTE: The cylinder rod and piston assembly can be

removed from the barrel on the machine.
Disconnect hose to rod end for piston rod
removal.
2. Remove guard cover.
OUO1020,0001236 1922JAN031/2
38
3860
1
TM2111 (30MAY03)
38-3860-1

053003
PN=713
Hydraulic System
UN23AUG88

X9811
3. Disconnect lines (B and C). Close all openings with

caps and plugs.
UN11JUN91
Arch CylinderSingle Function GrappleSpecification

548G-III Arch CylinderSize ........................................... 90 mm x 45 mm
748G-III Arch CylinderSize ......................................... 100 mm x 56 mm
4. Connect hoist to cylinder using a lifting strap.
6. Inspect bushings for looseness, wear, or damage.

Remove bushings only if replacement is necessary.
See Spherical Bushing Remove and Install. (Group
3201.)
7. Repair cylinder as necessary. See Disassemble
Cylinder. (TM-H120A.)
T7533AP
5. Remove pins (A and D).
APin
BBoom Cylinder Head End Line
CBoom Cylinder Rod End Line
DPin
8. Install cylinder and pins (A and D).

9. Connect lines (B and C).
10. Operate cylinder through several cycles to fill it with
oil. Check hydraulic oil level. See Check Hydraulic
OUO1020,0001236 1922JAN032/2
38
3860
2
TM2111 (30MAY03)
38-3860-2

053003
PN=714
Hydraulic System
Boom or Arch Cylinder Remove and Install

Dual Function Grapple
UN23AUG88

X9811
1. Lower grapple to the ground. Operate all control valves

to release pressure in hydraulic system.
NOTE: The cylinder rod and piston assembly can be

removed from the barrel on the machine.
Disconnect hose to rod end for piston rod
removal.
UN11JUN91
2. Disconnect hydraulic lines (F and G) from boom

cylinder or disconnect hydraulic lines (B and C) from
arch cylinder. Close all openings with caps and plugs.
T7533AN
3. Connect hoist to cylinder using lifting strap.

Boom or Arch CylinderDual Function GrappleSpecification
648G-III, 748G-III Boom
CylinderSize .................................................................. 90 mm x 45 mm
Weight........................................................... 46.1 kg (102 lb) approximate
748G-III Arch CylinderSize ......................................... 100 mm x 56 mm
4. Remove pins (E and H) for boom cylinder.

5. Remove pins (A and D) for arch cylinder.
T7533AM
UN11JUN91
APin
BValve-to-Arch Cylinder Head End Line
CValve-to-Arch Cylinder Rod End Line
DPin
EPin
FValve-to-Boom Cylinder Rod End Line
GValve-to-Boom Cylinder Head End Line
HPin
TM2111 (30MAY03)
38-3860-3
OUO1020,0001237 1922JAN031/2

053003
PN=715
38
3860
3
Hydraulic System
6. Remove cylinder.
7. Inspect bushings for looseness, wear, or damage.
Remove bushings only if replacement is necessary.
See Spherical Bushing Remove and Install. (Group
3201.)
8. Repair cylinder as necessary. See Cylinder Repair.
(TM-H120A.)
9. Install arch cylinder and pins (A and D).
10. Connect hydraulic lines (B and C).
11. Install boom cylinder and pins (E and H).
12. Connect hydraulic lines (F and G)
13. Operate cylinder through several cycles to fill it with
oil. Check hydraulic oil level. See Check Hydraulic
OUO1020,0001237 1922JAN032/2
38
3860
4
TM2111 (30MAY03)
38-3860-4

053003
PN=716
Hydraulic System
Grapple Tong Cylinder Remove and Install
UN23AUG88
CAUTION: The pin that attaches the cylinder

head end also attaches the opposite tong.
Cylinders should be removed one at a time to
prevent both grapple tongs from falling out of
frame.
X9811
1. Close grapple and lower to the ground.

in the hydraulic system.
3. Remove cover (C) to disconnect cylinder head end
hose. Install cap on port and hose.
4. Disconnect rod end hose at flow divider. Install cap on
port and hose.
UN05JUN95
5. Remove rod end pin (E) (other side not shown).

6. Remove cap screw (F).
T8412AE1
7. Connect hoist to cylinder using a lifting strap.
NOTE: Use a round 58 mm (2.25 in.) diameter by 300

mm (12 in.) long bar or pipe, slightly smaller in
diameter than pin, to drive pin out of cylinder and
still hold tong in place for reassembly. Removing
other cylinder rod pin aids in alignment of tong for
installation of pin.
ATong and Cylinder Head End Pin (2 used)

BGrapple Frame
CAccess Cover Head End Hose (2 used)
DGrapple Tong Cylinder (2 used)
EGrapple Rod Eye Pin (2 used)
FTong and Cylinder Pin Retaining Cap Screw (2
used)
8. Remove head end pin (A).
OUO1020,0001240 1924JAN031/2
38
3860
5
TM2111 (30MAY03)
38-3860-5

053003
PN=717
Hydraulic System

Grapple Tong CylinderSpecification
548G-III 8.0 Sq Ft Grapple Tong
CylinderSize ................................................................ 100 mm x 50 mm
CylinderSize ................................................................ 100 mm x 50 mm
Grapple Tong CylinderSize......................................... 115 mm x 63 mm
Cylinder (180 Series)Size ........................................... 125 mm x 63 mm
9. Remove cylinder and repair as necessary. See

Cylinder Repair. (TM-H120A.)
NOTE: Foam shims are located only at the cylinder rod

end.
10. Insert grapple tong cylinder into grapple frame and
install pins.
11. Connect hoses to cylinder and tighten.
12. Install cap screw (F) and washer and tighten. Install
cover (C).
OUO1020,0001240 1924JAN032/2
38
3860
6
TM2111 (30MAY03)
38-3860-6

053003
PN=718
Hydraulic System
Rotate Motor Remove and Install

Removal
X9811
UN23AUG88

1. Lower grapple to the ground.
in the hydraulic system.
3. Remove rotate motor cover from top of arch or boom.
4. Mark hoses to aid in assembly.
OUO1020,0001241 1924JAN031/3
5. Disconnect hoses (AC) and close all openings with

caps and plugs.
Rotate MotorSpecification
Rotate MotorWeight ....................................... 25 kg (55 lb) approximate
6. Remove cap screws (D) to remove rotate motor.
T113099
UN03FEB98
AHose from Rotate Solenoid

BHose from Rotate Solenoid
CHose from Rotate Manifold
DCap Screw (2 used)
TM2111 (30MAY03)
38-3860-7
OUO1020,0001241 1924JAN032/3

053003
PN=719
38
3860
7
Hydraulic System
Installation
1. Install rotate motor on mounting plate.

2. Install cap screws (D) and tighten.
Rotate Motor Mount Cap
ScrewsTorque ......................................... 117142 Nm (86105 lb-ft)
3. Connect hoses (AC).
T113099
UN03FEB98
AHose from Rotate Solenoid

BHose from Rotate Solenoid
CHose from Rotate Manifold
DCap Screw (2 used)
OUO1020,0001241 1924JAN033/3
Rotate Motor Repair

Disassemble
UN28APR98
1. Remove screws (A) to remove crossover relief valve

housing.
T114279
AScrews (4 used)
OUO1020,0001242 1924JAN031/13
NOTE: Crossover relief valve is not a repairable item.

Disassemble only to inspect, clean and replace
O-rings and seals.
ABackup Ring (2 used)

BO-Ring
CO-Ring
DRelief Valve (2 used)
T8495AB
38
3860
8
UN02JUN95
2. Remove crossover relief valve (D). Inspect and clean.
TM2111 (30MAY03)
38-3860-8
OUO1020,0001242 1924JAN032/13

053003
PN=720
Hydraulic System
3. Scribe a line across motor sections to aid in assembly.
4. Remove cap screws (A) to disassemble motor.
T8492AO
UN02JUN95
ACap Screw (8 used)
OUO1020,0001242 1924JAN033/13
5. Remove end cap (B) and O-ring (C).

6. Remove housing (A).
T8492AH
UN02JUN95
AMotor Housing
BEnd Cap
CO-Ring
OUO1020,0001242 1924JAN034/13
7. Remove outer ring (A) with steel balls (B).

8. Remove roller bearings (C).
T8492AI
UN02JUN95
AOuter Ring
BSteel Balls (2 used)
CRoller Bearings (8 used)
OUO1020,0001242 1924JAN035/13
38
3860
9
TM2111 (30MAY03)
38-3860-9

053003
PN=721
Hydraulic System
9. Remove snap ring (D).
10. Remove plate (C).
UN02JUN95
11. Measure the tip clearance between roller (A) and

outer member (B). If clearance exceeds specification
replace motor.
T8492AJ
Roller and Outer Member
Clearance ................................................... 0.25 mm (0.010 in.) maximum
12. Remove outer member.
T7529AZ
UN05JUN91
ARoller Bearing (6 used)

BOuter Member
CPlate
DSnap Ring
OUO1020,0001242 1924JAN036/13
13. Remove steel rollers (C) and inner member (B).

14. Remove output shaft (D).
T8492AK
UN02JUN95
AOuter Member
BInner Member
CRoller Bearing (6 used)
DOutput Shaft
OUO1020,0001242 1924JAN037/13
15. Remove dust seal (A) and O-ring (B).
UN02JUN95
ADust Seal
BO-Ring
T8492AL
38
3860
10
TM2111 (30MAY03)
38-3860-10
OUO1020,0001242 1924JAN038/13

053003
PN=722
Hydraulic System
Assemble
UN02JUN95
IMPORTANT: Before assembly, clean all parts with

solvent and coat with clean hydraulic
oil. Inspect parts for nicks or burrs and
repair if possible.
1. Install new O-ring (B).
T8492AL
2. Install dust seal (A) with rubber lips facing outside of

motor. Seat seal using a 26 mm socket and a press.
Coat seal with clean hydraulic oil.
ADust Seal
BO-Ring
OUO1020,0001242 1924JAN039/13
3. Check output shaft (A) for burrs. Remove burrs if

necessary.
4. Install output shaft.
5. Install inner member (G) and six roller bearings.
6. Install outer member (C) and eight roller bearings (D).
7. Install plate (F), top side up as shown.
IMPORTANT: DO NOT stretch new snap ring during
assembly or it may cause damage to
the motor.
8. Install new snap ring (E).
T8493AA
UN02JUN95
AOutput Shaft
BRoller Bearing (6 used)
COuter Member
DRoller Bearing (8 used)
ESnap Ring
FPlate (top side shown)
GInner Member
38
3860
11
TM2111 (30MAY03)
38-3860-11
OUO1020,0001242 1924JAN0310/13

053003
PN=723
Hydraulic System
9. Install steel balls (A) in the two 1/8 inch diameter
holes.
T8492AM
UN02JUN95
ASteel Balls (2 used)
OUO1020,0001242 1924JAN0311/13
10. Install new O-ring (D) in plate.

11. Install plate (C) using scribed line to help locate check
ball cavities over steel balls.
12. Install housing (A).
13. Install oiled cap screws (B).
T8492AN
UN02JUN95
AHousing
BCap Screw (8 used)
CPlate
DO-Ring
OUO1020,0001242 1924JAN0312/13
38
3860
12
TM2111 (30MAY03)
38-3860-12

053003
PN=724
Hydraulic System
14. Tighten cap screws in sequence shown to initial
torque specification. Turn shaft by hand several
rotations and tighten cap screws in sequence to mid
torque specification. Turn shaft by hand several
rotations and tighten cap screws in sequence to final
torque specification.
End Cap Housing Cap Screws
Initial Torque .................................................................... 20 Nm (15 lb-ft)
Mid Torque ...................................................................... 27 Nm (20 lb-ft)
Final Torque ................................................................. 36.6 Nm (27 lb-ft)
15. Install crossover relief valves, if removed, in relief

valve housing.
UN02JUN95
16. Install crossover relief valve housing on rotate motor.

Install and tighten screws (A).
T8493AD
Crossover Relief Valve
Assembly-to-Motor Housing Cap
Cap Screw Tightening Sequence

ACap Screw (4 used)
OUO1020,0001242 1924JAN0313/13
Rotate Motor Drive Gear Remove and Install

UN14JUN95
Rotate Motor Drive GearSpecification

T8495AE
1. Remove rotate motor. See Rotate Motor Remove and

Install in this group.
2. Remove bearings (A) using bearing puller set.
3. Remove drive gear. Inspect and replace if required.
ABearing (2 used)
BDrive Gear
4. Install bearings and drive gear.
OUO1020,0001243 1924JAN031/1
38
3860
13
TM2111 (30MAY03)
38-3860-13

053003
PN=725
Hydraulic System
Control Valve Remove and InstallSingle

Function Grapple
UN23AUG88

X9811

locking bar.
3. Remove right side cab cover.
OUO1020,0001244 1924JAN031/2
38
3860
14
TM2111 (30MAY03)
38-3860-14

053003
PN=726
Hydraulic System
4. Disconnect linkage (BD) if equipped. If equipped with
a single lever pilot controller, remove lines (MP).
5. Disconnect lines (EL). Put identification tags on lines
to aid assembly. Close all openings with caps and
plugs.
Control ValveSingle Function GrappleSpecification
Control ValveWeight ...................................... 27 kg (60 lb) approximate
6. Remove cap screws (A) to remove valve.

7. Install orifice under line (F) with grooved side facing
out.
UN07JUN95
8. After repair, install valve and connect lines and

linkages as shown.
T134259B
UN06OCT00
Control Valve Hoses and LinkagesSingle Function Shown
T134260B
UN06OCT00
AMounting Screw (3 used)

BArch Linkage
CTong Linkage
DBlade Linkage
EInlet Line
FBlade (Head End) Line
GTong (Rod End) Line
HArch (Head End) Line
IBlade (Head End) Line
JTong (Rod End) Line
KArch (Rod End) Line
LOutlet Line
MArch Down Pilot LineFrom Pilot Controller (Port
3) (If Equipped)
NTong Close Pilot LineFrom PRV (TCP Port) (If
Equipped)
OArch Open Pilot LineFrom Pilot Controller (Port
1) (If Equipped)
PTong Open Pilot LineFrom PRV (TOP Port) (If
Equipped)
T8498AB
9. Operate function through several cycles to remove air

and fill components with oil. Check hydraulic oil level.
See Check Hydraulic System Oil Level. (Operators
Manual.)
OUO1020,0001244 1924JAN032/2
TM2111 (30MAY03)
38-3860-15

053003
PN=727
38
3860
15
Hydraulic System
TP35172
UN19OCT94
Single Function Control Valve Sections Disassemble and Assemble
Single Function Control Valve

1Inlet Section
2Blade Section
3Tong Section
4Arch Section
5Pipe Plug
6Outlet Housing
7Bolt (4 used)
8O-Ring
9Fitting
10O-Ring
11Fitting Plug
12O-Ring
13Orifice
14Single Function Control
Valve
OUO1020,0001245 1924JAN031/2
38
3860
16
TM2111 (30MAY03)
38-3860-16

053003
PN=728
T8477AT
UN10MAY94
Hydraulic System
ASeal (4 used)
1. Remove tie bolts to disassemble valve, replace

seals (A) between all sections.
2. Install tie bolts and tighten to specification.
Single Function Control Valve SectionsSpecification
Control Valve Section Tie Bolt
NutsTorque............................................................ 57 Nm (42 lb-ft)
OUO1020,0001245 1924JAN032/2
38
3860
17
TM2111 (30MAY03)
38-3860-17

053003
PN=729
Hydraulic System
Control Valve Remove and InstallDual

Function Grapple
UN23AUG88

X9811

3. Remove right side cab cover.
OUO1020,0001246 1924JAN031/2
38
3860
18
TM2111 (30MAY03)
38-3860-18

053003
PN=730
Hydraulic System
4. Disconnect linkage (AD) or pilot lines (machine
equipped with single lever pilot controller).
5. Disconnect lines (EN). Put identification tags on lines
to aid assembly. Close all openings with caps and
plugs.
Control ValveDual Function GrappleSpecification
Control Valve (Dual Function
Grapple)Weight .............................................. 33 kg (72 lb) approximate
6. Remove cap screws (O) to remove valve.

7. Install orifice under line (E) with grooved side facing
out.
T8498AA

Manual.)
UN07JUN95
8. After repair, install valve and connect lines and

linkages as shown.
ATong Linkage
BArch Linkage
CBoom Linkage
DBlade Linkage
EBlade (Rod End) Line
FBoom (Head End) Line
GArch (Head End) Line
HTong (Head End) Line
IInlet Line
JBlade (Head End) Line
KBoom (Rod End) Line
LArch (Rod End) Line
MTong (Rod End) Line
NOutlet Line
OCap Screw (3 used)
OUO1020,0001246 1924JAN032/2
38
3860
19
TM2111 (30MAY03)
38-3860-19

053003
PN=731
Hydraulic System
Control Valve Disassemble and Assemble

Dual Function Grapple
Control Valve Sections Disassemble and Assemble
X9811
UN23AUG88
NOTE: Relief valves can be removed with control valve

on machine. Valve must be removed or moved
away from machine before lift check poppets can
be removed.
2. Remove control valve. See Control Valve Remove and
InstallDual Function Grapple in this group.
3. Remove plugs (B), inspect springs (D) and lift check
poppets (E) for damage replace O-rings (C).
UN10MAY94
4. Install control valve. See Control Valve Remove and

InstallDual Function Grapple in this group.
T8477AV
ALift Check Poppets

BPlug
CO-Ring
DSpring
EPoppet
T8477AN
UN23MAY95
Lift Check
OUO1020,0001238 1923JAN031/6
38
3860
20
TM2111 (30MAY03)
38-3860-20

053003
PN=732
Hydraulic System
Relief Valves Remove and Install
1. Remove relief valves, inspect for damage, replace
O-rings, backup rings and seals.
Relief ValveSpecification
ReliefPressure........................................... 6895 55 kPa (69 55 bar)
(1000 80 psi)
T8478AC
UN10MAY94
ANon-Adjustable Circuit Relief Valve

BAdjustable Circuit Relief Valve
CAdjustable System Relief Valve
DInlet Section
EDetent Assembly
FOutlet Section
OUO1020,0001238 1923JAN032/6
Circuit Relief and System Relief Valves Disassemble

and Assemble
UN10MAY94
NOTE: Circuit relief and system relief valve removal and

installation procedures are similar.
T8477AP
1. Inspect poppet seal (C) on adjustable circuit relief

valve or (B) on non-adjustable circuit relief valve and
spring (D) for damage.
Circuit Relief and System Relief ValvesSpecification
Circuit Relief ValveTorque ......................................... 100 Nm (75 lb-ft)
System Relief Valve Lock Nut
Torque ............................................................................. 88 Nm (65 lb-ft)
Non-Adjustable Circuit Relief Valve

AO-Ring
BPoppet
CSeal
DSpring
ERod
FShim (as required)
GBackup Ring
Replace O-rings, backup ring and seals.
38
3860
21
TM2111 (30MAY03)
38-3860-21
OUO1020,0001238 1923JAN033/6

053003
PN=733
Hydraulic System
T8477AO
UN10MAY94
AO-Ring
BRod
CPoppet
DSpring
EAdjusting Nut
FBackup Ring
Adjustable Circuit Relief Valve
OUO1020,0001238 1923JAN034/6
Detent Valve Remove and Install

1. Inspect parts for damage. Replace as needed.
UN10MAY94
2. Apply petroleum jelly to detent balls to hold them in the

carrier.
T8477AR
3. Assemble valve. Before tightening screws, move the

control lever to detent position to center the assembly.
Tighten screws.
Detent ValveSpecification
Detent Assembly-to-Valve Cap
ScrewsTorque ........................................................... 20 Nm (175 lb-in.)
Detent Assembly
APlate
BScrews
CSpring
DSleeve
ERetainer
FDetent Balls
GCarrier
HHousing
ISpacer
OUO1020,0001238 1923JAN035/6
38
3860
22
TM2111 (30MAY03)
38-3860-22

053003
PN=734
Hydraulic System
Spool Valves Remove and Install
NOTE: Keep spool and control valve section together as

a matched set.
1. Inspect spool for bends, scratches, or galling. Replace
packing (C).
2. Assemble valve. Before tightening screws, move the
control lever to detent position to center the assembly.
Tighten screws.
Spool ValvesSpecification
Detent Assembly-to-Valve Cap
ScrewsTorque ........................................................... 20 Nm (175 lb-in.)
T8477AS
UN10MAY94
APlate
BSpacer
CPacking
DSpool
ERetainer
FSpring Assembly
GDetent Rod
OUO1020,0001238 1923JAN036/6
38
3860
23
TM2111 (30MAY03)
38-3860-23

053003
PN=735
Hydraulic System
T8499BC
UN19JUN95
Dual Function Control Valve Sections Disassemble and Assemble
Dual Function Control Valve

1Inlet Section
2Blade Section
3Boom Section
4Arch Section
5Tong Section
6Outlet Housing
7Bolt (4 used)
8O-Ring
9Fitting
10O-Ring
11Fitting Plug
12O-Ring
13Pipe Plug
14Restrictor
15Dual Function Grapple
Control Valve
1. Remove tie bolts (7) to disassemble valve, replace

seals between all sections.
2. Install tie bolts and tighten nuts to specification.
Dual Function Control Valve SectionsSpecification
Control Valve Section Tie Bolt
NutsTorque............................................................ 57 Nm (42 lb-ft)
OUO1020,0001247 1924JAN031/1
38
3860
24
TM2111 (30MAY03)
38-3860-24

053003
PN=736
Hydraulic System
Grapple Rotate Solenoid Valve Remove and

Install
UN23AUG88

X9811

2. Disconnect lines (AD).
3. Disconnect two solenoid valve connectors.
B
5. Connect two solenoid valve connectors to transmission

harness.
6. Connect lines (AD).
T134429

and fill components with oil.
8. Check hydraulic oil level. See Check Hydraulic System
ASolenoid
BSolenoid
CSolenoid
DSolenoid
T134429
UN07OCT00
4. Remove four mounting screws and nuts to remove

valve from steering valve rotate solenoid bracket.
Valve-to-Rotate Motor Line

Valve-to-Brake Accumulator Tee
Valve-to-Rotate Motor Line
Valve-to-Reservoir Line
OUO1020,0001248 1924JAN031/1
38
3860
25
TM2111 (30MAY03)
38-3860-25

053003
PN=737
Hydraulic System
T8502AE
UN14JUN95
Grapple Rotate Solenoid Valve Disassemble and Assemble
AScrew (4 used)
BValve Body1
CEnd Cap (2 used)

DRing
EO-Ring (4 used)
FValve Body
GO-Ring (4 used)
HOrifice in P Port
1. Remove grapple rotate valve. See Grapple Rotate

Solenoid Valve Remove and Install in this group.
3. Disassemble parts as shown and inspect. Clean

valve.
2. Remove four screws (A) to remove valve body (B).
4. Use screw (A) to remove orifice (H) from P port.
This part is not repairable.

OUO1020,0001249 1924JAN031/2
38
3860
26
TM2111 (30MAY03)
38-3860-26

053003
PN=738
Hydraulic System
5. Assemble solenoid valve.
6. Check operation of solenoid spools, which move
inward when they are energized. Push in on spool
using a screwdriver. Spool must move freely and not
bind.
T8502AF
UN14JUN95
7. Install grapple rotate valve. See Grapple Rotate

Solenoid Valve Remove and Install in this group.
OUO1020,0001249 1924JAN032/2
Pilot Controller Repair (If Equipped)
UN23AUG88
NOTE: The pressure reducing valve is only on machines

with the single lever pilot controller option
installed.
X9811

1. Operated arch, boom, and grapple functions with key
switch ON to release pressure from pilot circuits.
2. Turn key switch OFF. Disconnect all electrical
connections to valve.
38
3860
27
TM2111 (30MAY03)
38-3860-27
OUO1020,000124A 1924JAN031/3

053003
PN=739
T134271B
UN06OCT00
T134269B
UN06OCT00
Hydraulic System
38
3860
28
TM2111 (30MAY03)
38-3860-28
OUO1020,000124A 1924JAN032/3

053003
PN=740
Hydraulic System
1Tong Rotate
Counterclockwise (RCC
port)To Rotary Manifold
2Arch Down Line (AR
port)From Arch Cylinder
Rod End
3Rotate Clockwise (RC

port)To Rotary Manifold
4Reduced Pressure Line (RP
port)To Pilot Controller
Port P
5Tong Open Line (TOP
port)To Bottom of Tong
Control Valve Section
3. Remove nut and chain support (6).
6Chain Support
7Pressure Line (P port)
From Accumulator
8Tank Line (T port)To
Tank
9Tong Close Line (TCP

port)To Top of Tong
Control Valve Section (TCP
port)
7. Install valve to machine. Connect all lines and

install chain support (6).
4. Remove lines (15) and (79).

8. Start machine and check for leaks.
5. Remove mounting cap screws and valve.
6. Replace valve as necessary.
OUO1020,000124A 1924JAN033/3
38
3860
29
TM2111 (30MAY03)
38-3860-29

053003
PN=741
Hydraulic System
Flow Divider Repair

1. Open grapple tongs and lower grapple to the ground.
X9811
UN23AUG88

3. Remove grapple frame bottom access cover.
4. Put identification tags on lines to aid assembly.
Disconnect lines (AC). Close all openings with caps
and plugs.
T113075
UN05FEB98
AFlow Divider-to-Head End Grapple Tong Cylinder

Line
BFlow Divider-to-Rotary Manifold Line
CFlow Rotate Manifold-to-Rod End Grapple Tong
Cylinder Line
OUO1020,000124B 1924JAN031/6
38
3860
30
TM2111 (30MAY03)
38-3860-30

053003
PN=742
TP35158
UN18FEB95
Hydraulic System
1Direct Acting Crossover

Relief Valve (2 used)
2Seal Kit (2 used)
3Screw (2 used)
4Lock Nut (2 used)
5Seal Kit
6Flow Divider Valve

7Washer (2 used)
TM2111 (30MAY03)
38-3860-31
8Retainer (2 used)
9Flow Divider
38
3860
31
OUO1020,000124B 1924JAN032/6

053003
PN=743
Hydraulic System
5. Remove screws (3) to remove flow divider.
7. Remove flow divider valve (6).
6. Remove retainer (8) to remove relief valves (1).
OUO1020,000124B 1924JAN033/6
8. Check direct acting relief valve for wear or damage.

UN09JUN95
9. Install new gland ring (A), backup ring (B), and O-ring
(C), as shown.
T8500AF
Flow DividerSpecification
Relief ValvePressure ............................. 6895 551 kPa (69 5.5 bar)
(1000 80 psi)
AGland Ring
BBackup Ring
CO-Ring
OUO1020,000124B 1924JAN034/6
10. Check flow divider valve for wear or damage. Replace

if necessary.
UN09JUN95
11. Install new O-rings (B and D) and backup rings (A

and C) as shown.
T8500AE
ABackup Ring (6 used)

BO-Ring (3 used)
CBackup Ring
DO-Ring
OUO1020,000124B 1924JAN035/6
38
3860
32
TM2111 (30MAY03)
38-3860-32

053003
PN=744
Hydraulic System
12. Install flow divider valve (C) and relief valves (B).
15. Connect hydraulic lines.

Manual.)
T8503AF
14. Install flow divider body with cap screw heads on

manifold side.
UN14JUN95
13. Install retainers (A).
17. Install bottom access cover on grapple frame.
T8503AE
UN14JUN95
ARetainer (2 used)
BDirect Acting Crossover Relief Valve (2 used)
CFlow Divider Valve
OUO1020,000124B 1924JAN036/6
38
3860
33
TM2111 (30MAY03)
38-3860-33

053003
PN=745
Hydraulic System
Rotary Manifold Remove and Install

1. Lower grapple to the ground.
UN23AUG88

3. Remove top arch or boom cover.
X9811

5. Disconnect lines (AC) at rotary manifold. Close all
6. Remove two shaft cap screws (D).
7. Remove housing cap screw (E) with washer (F) and
spacer (G).
T113097
UN03FEB98
ARotary Manifold-to-Control Valve Tong Head End

Port
BRotary Manifold-to-Control Valve Arch Rod End
Port
CRotary Manifold-to-Rotate Motor Line
DShaft Cap Screw (2 used)
EHousing Cap Screw
FWasher
GSpacer
OUO1020,000124C 1924JAN031/2
38
3860
34
TM2111 (30MAY03)
38-3860-34

053003
PN=746
Hydraulic System
8. Remove bottom access cover on grapple frame.
9. Disconnect line (A) at flow divider.
UN03FEB98
10. Disconnect line (B) at tee.

11. Remove rotary manifold with lines (A and B).
T113088
12. Install rotary manifold with line in corresponding holes

in gear. Line port marked A connects to flow divider
and other line connects to tee.
NOTE: Lines must be straight and do not twist as they

pass through the gear and yoke when installing
rotary manifold.
ARotary Manifold Line

BRotary Manifold Line
13. Install and tighten cap screws.

Rotary ManifoldSpecification
Shaft Cap ScrewsTorque........................................... 115 Nm (85 lb-ft)
Housing Cap ScrewTorque...................................... 163 Nm (120 lb-ft)
14. Connect lines.

15. Replace top and bottom shields.
OUO1020,000124C 1924JAN032/2
Rotary Manifold Disassemble and Assemble

1. Remove rotary manifold. See Rotary Manifold Remove
UN03FEB98

3. Remove lines and fittings from manifold shaft (A).
T113093
NOTE: Port A identification is stamped in manifold shaft

housing.
AManifold Shaft
38
3860
35
TM2111 (30MAY03)
38-3860-35
OUO1020,000124D 1924JAN031/5

053003
PN=747
Hydraulic System
4. Remove snap ring (C) and manifold shaft (A).
T113090
UN03FEB98
AManifold Shaft
BHousing
CSnap Ring
T113092
UN03FEB98
OUO1020,000124D 1924JAN032/5
AManifold Housing
BO-Ring (2 used)
CWear Ring (2 used)
DO-Ring (4 used)
5. Remove manifold housing (A) seals.
EInner Expander Ring (4

used)
8. Install O-rings (B), wear rings (C) and O-rings (D),

inner expander rings (E) in sequence shown in
manifold housing (A) grooves. Seals must not be
twisted in grooves.
6. Inspect housing and shaft for wear or damage.

7. Apply clean hydraulic oil to seals.
NOTE: Install O-ring (D) and inner expander ring (E)

as an assembly.
38
3860
36
TM2111 (30MAY03)
38-3860-36
OUO1020,000124D 1924JAN033/5

053003
PN=748
Hydraulic System
9. Apply petroleum jelly to seals, shaft and inside of
housing. Carefully tap shaft (A) into housing (B) using
a hammer.
UN03FEB98
10. Install snap ring (C).
T113090
AManifold Shaft
BHousing
CSnap Ring
OUO1020,000124D 1924JAN034/5
UN23AUG88

penetrate the skin causing serious injury.
fluids.
11. Test rotary manifold for leaks before installing on unit.
X9811
Install an ORFS plug in port (E) of manifold. Connect

a hydraulic hand operated pump to port marked "A"
(A) of rotary manifold. Operate pump to pressurize
manifold to test specification.
Rotary Manifold TestPort A
Pressure ................................................. 20 685 kPa (207 bar) (3000 psi)
Turn manifold shaft 10 revolutions in one minute in both

directions. Leakage must not exceed 5 drops per minute
at ports (B or D). Shaft must not bind while turning.
12. Repeat test, with plug in port (D) and applying
pressure to port marked "B" (B). Leakage must not
exceed 5 drops per minute at ports (A or E).
T8502AC
Rotary Manifold TestPort C
Pressure ........................................................ 1379 kPa (14 bar) (200 psi)
UN14JUN95
13. Connect hydraulic hand operated pump to port

marked "C" (C). Operate pump to pressurize manifold
to test specifications. Turn manifold shaft 10
revolutions in one minute in both directions. There
must be no external leakage.
APort Marked "A"

BPort Marked "B"
CPort Marked "C"
DPort Connected to "B"
EPort Connected to "A"
38
3860
37
OUO1020,000124D 1924JAN035/5
TM2111 (30MAY03)
38-3860-37

053003
PN=749
Hydraulic System
38
3860
38
TM2111 (30MAY03)
38-3860-38

053003
PN=750
Section 99
Dealer Fabricated Tools

Contents
Page
Group 9900Dealer Fabricated Tools

DFT1055 Yoke Holding Tool (1200 and 1400
Series Axles) . . . . . . . . . . . . . . . . . . . . . . .99-9900-1
DFT1099 Bushing Drivers . . . . . . . . . . . . . . .99-9900-2
DFT1156 Transmission Housing Lifting
Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-3
DFT1216 Converter Housing Support . . . . . .99-9900-4
Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-5
DFRW20 Compressor Holding Fixture. . . . . .99-9900-6
TM2111 (30MAY03)
99-1

053003
PN=1
99
Contents
99
TM2111 (30MAY03)
99-2

053003
PN=2
Group 9900

DFT1055 Yoke Holding Tool (1200 and 1400 Series Axles)
R40162
UN03JAN89
99
9900
1
Yoke Holding Tool is used to hold yoke while removing

nut.
One piece of 10 x 100 x 915 mm (0.375 x 4 x 36 in.)

flat steel.
Material required:
TX,DF1055 1927NOV021/1
TM2111 (30MAY03)
99-9900-1

053003
PN=753
DFT1099 Bushing Drivers
T7466AA
1911JUL91
99
9900
2
TM2111 (30MAY03)
99-9900-2
TX,99,WW1176 1904AUG991/2

053003
PN=754

A0.5 x 2.0 x 6.0 in. 1020 Cold
Rolled
B45 mm BushingUse 2.625
in. OD x 2.25 in. ID x 2.5 in.

B70 or 80 mm BushingUse
4.00 in. OD x 3.50 in. ID x
2.5 in.
C0.5 x 2.0 x 4.25 in. 1020

Cold Rolled
D0.5 x 8.0 Full Threaded Cap
Screw
ETack Weld With 0.5 in.

Crosshole Centered In Pipe
OD
99
9900
3
These bushing drivers are used to remove and install

spherical bushings.
TX,99,WW1176 1904AUG992/2
T113908
UN20APR98
DFT1156 Transmission Housing Lifting Bracket
TX,03,RB778 1916JAN031/1
TM2111 (30MAY03)
99-9900-3

053003
PN=755
DFT1216 Converter Housing Support
T140536
UN04APR01
99
9900
4
TM2111 (30MAY03)
99-9900-4
OUO1030,000054C 1910APR011/2

053003
PN=756
This tool is used to support the torque converter

housing for engine removal.
Material required:
Angle Iron (2 in. x 2 in. x 0.25 in.)

Steel Plate (6 in. x 0.50 in.)
(4) Cap Screws (7/16 x 1 1/2 in.)
(4) Cap Screws (3/8 x 1 1/2 in.)
99
9900
5
Bar Stock (1.50 in. x 0.50 in.)
OUO1030,000054C 1910APR012/2
DFT1217 Transmission Input Shaft Holder

This tool is used along with JDG1101 Clutch Pack Lifting
Plate to remove clutch packs from transmission
Material required
(57.1 mm)
2.25 in.
Steel Pipe (2.25 in ID x 2.6 in long)

Bar Stock (2.0 in x 3.0 in long .125 thick)
(66.0 mm)
2.6 in.
11/32
DRILL HOLE
(76.2 mm)
3.0 in.
T141655
T141655
1919APR01
(50.8 mm)
2.0 in.
OUO1017,00003D2 1919APR011/1
TM2111 (30MAY03)
99-9900-5

053003
PN=757
DFRW20 Compressor Holding Fixture
RW13619
UN20SEP89
99
9900
6
A102 mm (4 in.)
B76 mm (3 in.)
C70 mm (2.75 in.)
D6.4 mm (0.25 in.)

E19 mm (0.75 in.)
F152 mm (6 in.)
G254 mm (10 in.)

H114 mm (4.5 in.)
I178 mm (7 in.)
JFillet Weld
KTwo Holes
Material required:
4Matching Lock Washers and Nuts
2Steel Plates (4 x 2.75 in.) and (10 x 6 in.)

2Threaded Steel Rods (0.5 x 7 in.)
Tool is used to hold air conditioning compressor during

assembly and disassembly.
TX,18,RB766 1921APR981/1
TM2111 (30MAY03)
99-9900-6

053003
PN=758
Index
Page
Page
A
Accumulator
Remove and install . . . . . . . . . . . . . . . . .10-1060-3
Air cleaner, remove and install . . . . . . . . . .05-0520-1
Air conditioner system
Flush. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3
Air conditioning
Charge R134a system . . . . . . . . . . . . .18-1830-11
Clutch hub clearance . . . . . . . . . . . . . .18-1830-18
Compressor clutch . . . . . . . . . . . . . . . .18-1830-16
Compressor manifold, inspect . . . . . . . .18-1830-18
Compressor relief valve remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Compressor,
disassemble/inspect/assemble. . . . . .18-1830-19
Compressor, remove and install . . . . . .18-1830-14
Condenser, remove and install . . . . . . .18-1830-22
Evacuate R134a system . . . . . . . . . . . .18-1830-10
Evaporator, remove and install . . . . . . .18-1830-23
Expansion valve, remove and install . . .18-1830-33
Freeze control switch . . . . . . . . . . . . . .18-1830-40
High pressure switch, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Low pressure switch, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Pressure blower motor, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-34
Receiver dryer, remove and install . . . .18-1830-39
Recover R134a refrigerant . . . . . . . . . . .18-1830-9
Refrigerant handling . . . . . . . . . . . . . . . .18-1830-1
R134A Refrigerant oil information . . . . . .18-1830-6
Air conditioning (R134A)
Station installation . . . . . . . . . . . . . . . . . .18-1830-8
Air suspension seat, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . . .18-1821-9
Alarm, reverse warning
Anti-cinch seat belt, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-11
Arch cylinder
Arch cylinder, single function grapple
Arch, log
Arch-single function grapple
Armrest
Disassemble and assemble . . . . . . . . . .18-1821-3
Axle and differential
Front guard, remove and install. . . . . . .02-0200-15
TM2111 (30MAY03)
Front oscillating support, disassemble and

assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Hose routing . . . . . . . . . . . . . . . . . . . . . .02-0260-7
Rear oscillating support, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Rear, remove and install . . . . . . . . . . . .02-0200-11
Axle and differential drive shaft
Front, repair . . . . . . . . . . . . . . . . . . . . . .02-0225-1
Rear, repair. . . . . . . . . . . . . . . . . . . . . . .02-0225-4
Axle, differential, and oscillating supports
Front, remove and install . . . . . . . . . . . .02-0200-1
B
Bearing
Support, repair . . . . . . . . . . . . . . . . . . . .02-0225-4
Belt
Fan, remove and install. . . . . . . . . . . . . .05-0510-2
Tensioner spring tension check. . . . . . . .05-0510-4
Tensioner, automatic (spring), remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-5
Belt, seat
Anti-cinch, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . .18-1821-9
Two-inch, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-10
Blade
Control linkage, remove and install . . . . .32-3215-1
Control valve, remove and install . . . . . .32-3215-2
Lift cylinder, remove and install . . . . . . . .32-3260-1
Stacking, remove and install . . . . . . . . . .32-3201-1
Bleed procedure
Cab tilt hand pump circuit . . . . . . . . . . .18-1800-25
Boom cylinder
Boom, dual function
Exploded view. . . . . . . . . . . . . . . . . . . .38-3840-13
Remove and install . . . . . . . . . . . . . . . .38-3840-13
Bottom guard
Engine frame, remove and install . . . . . .17-1746-1
Equipment frame, remove and install . . .17-1746-2
Brake
Park, remove and install . . . . . . . . . . . . .11-1111-1
Park, solenoid valve repair . . . . . . . . . . .11-1160-1
Brake accumulator
Brake lining
Inspection . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1
Brake pedal
Index-1

053003
PN=1
Indx
1
Index
Indx
2
Page
Page
Brake valve
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-1
Brake, park repair. . . . . . . . . . . . . . . . . . .03-0350-11
Bushing
Spherical, remove and install . . . . . . . . .32-3201-7
Manifold, inspect . . . . . . . . . . . . . . . . . .18-1830-18

Relief valve, remove and install. . . . . . .18-1830-12
Condenser
Control linkage
Blade, remove and install . . . . . . . . . . . .32-3215-1
Dual function, remove and install . . . . . .38-3815-4
Single function, remove and install . . . . .38-3815-1
Winch, remove and install . . . . . . . . . . . .30-3015-2
Control valve
Blade, remove and install . . . . . . . . . . . .32-3215-2
Control valve sections, dual function
Disassemble and assemble . . . . . . . . .38-3860-24
Control valve sections, single function
Control valve, transmission
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-34
Converter housing assemble . . . . . . . . . .06-0641-18
Cylinder
Arch, remove and install . . . . . . . . . . . . .38-3860-3
Blade lift, remove and install . . . . . . . . . .32-3260-1
Boom, remove and install . . . . . . . . . . . .38-3860-3
Cab tilt, hand pump circuit bleed
procedure . . . . . . . . . . . . . . . . . . . . .18-1800-25
Cab tilt, remove and install . . . . . . . . . .18-1800-27
Grapple tong, remove and install . . . . . .38-3860-5
Shock absorber, remove . . . . . . . . . . . . .38-3803-2
Steering, remove and install . . . . . . . . . .09-0960-9
Cylinder, arch single function grapple
Remove and Install . . . . . . . . . . . . . . . . .38-3860-1
C
Cab
Door latch, adjust . . . . . . . . . . . . . . . . . .18-1810-6
Door, remove and install . . . . . . . . . . . . .18-1810-6
Isolator, remove and install . . . . . . . . . .18-1800-16
Tilt cylinder, remove and install . . . . . . .18-1800-27
Tilt hand pump circuit bleed
procedure . . . . . . . . . . . . . . . . . . . . .18-1800-25
Cable rollers, dual function
Cable rollers, single function
Charge pump
Remove-direct drive machines . . . . . . .03-0350-21
Charge pump, transmission
Remove and install
Torque converter machines . . . . . . . . .03-0360-6
Clutch hub clearance . . . . . . . . . . . . . . . .18-1830-18
Clutch pack
Assemble-direct drive machines . . . . . .03-0350-79
Assemble-TC mach. . . . . . . . . . . . . . . 03-0350-114
Disassemble-direct drive machines . . . .03-0350-72
Disassemble-TC mach. . . . . . . . . . . . . 03-0350-105
Fourth (first and third speed), exploded view-direct
drive machines . . . . . . . 03-0350-70, 03-0350-71
Repair-torque converter machines . . . .03-0350-94
Second (high/low forward), exploded view-direct
drive machines . . . . . . . . . . . . . . . . .03-0350-68
Third (high/low reverse), exploded view-direct drive
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-69
Clutch pack repair
Torque converter machines. . . . . . . . . 03-0350-100
Cold start dump valve
Column, steering
Compressor
Clutch, disassemble and assemble . . . .18-1830-16
Disassemble, inspect, and assemble . .18-1830-19
TM2111 (30MAY03)
D
Damper drive
Damper, grapple
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3803-4
DFRW20 tool
Compressor holding fixture . . . . . . . . . . .99-9900-6
DFT1055 tool
Yoke holding tool . . . . . . . . . . . . . . . . . .99-9900-1
DFT1099 driver
Spherical bushings removal . . . . . . . . . .99-9900-2
DFT1216 tool
Converter housing support . . . . . . . . . . .99-9900-4
DFT1217 tool
Transmission input shaft holder . . . . . . .99-9900-5
DF1156 tool
Transmission housing lifting bracket . . . .99-9900-3
Index-2

053003
PN=2
Index
Page
Page
Differential and axle

Front oscillating support, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Rear oscillating support, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Rear, remove and install . . . . . . . . . . . .02-0200-11
Differential drive shaft
Front, repair . . . . . . . . . . . . . . . . . . . . . .02-0225-1
Rear, repair. . . . . . . . . . . . . . . . . . . . . . .02-0225-4
Differential lock
Pumpcable skidder, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-5
Pumpgrapple skidder, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-6
Relief valve, remove and install. . . . . . . .02-0260-3
Solenoid valve, repair . . . . . . . . . . . . . . .02-0260-1
Differential lock and axle
Hose routing . . . . . . . . . . . . . . . . . . . . . .02-0260-7
Differential, axle, and oscillating supports
Front, remove and install . . . . . . . . . . . .02-0200-1
Door
Cab, remove and install . . . . . . . . . . . . .18-1810-6
Panel, remove and install . . . . . . . . . . . .18-1810-9
Drive and clutch repair
Winch 4000. . . . . . . . . . . . . . . . . . . . . . .30-3050-1
Winch 6000. . . . . . . . . . . . . . . . . . . . . . .30-3050-1
Drive line, winch, remove and install . . . . .30-3025-1
Drive plate
Assemble drive plate. . . . . . . . . . . . . . . .06-0651-2
Disassemble drive plate . . . . . . . . . . . . .06-0651-2
Torque converter. . . . . . . . . . . . . . . . . . .06-0651-2
Drive shaft
Engine-to-transmission, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .03-0325-1
Front axle and differential, repair. . . . . . .02-0225-1
Rear axle and differential, repair . . . . . . .02-0225-4
Winch, disassemble and assemble . . . . .30-3025-2
Dual function
Grapple arch, remove and install . . . . .38-3840-10
Pilot controller, remove and install . . . . .38-3815-6
Duals wheel installation . . . . . . . . . . . . . . .01-0110-5
Engine coolant heater

Evaporator
Expansion valve, remove and install. . . . .18-1830-33
E
Engine
Remove and install-direct drive
machines . . . . . . . . . . . . . . . . . . . . . . .04-0400-4
Remove and install-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .04-0400-17
TM2111 (30MAY03)
Indx
3
F
Fabricated tools
DFRW20 compressor holding fixture. . . .99-9900-6
DFT1055 yoke holding tool . . . . . . . . . . .99-9900-1
DFT1099 bushing driver . . . . . . . . . . . . .99-9900-2
DFT1216 converter housing support . . . .99-9900-4
DFT1217 transmission input shaft
holder . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-5
DF1156 transmission housing lifting
bracket . . . . . . . . . . . . . . . . . . . . . . . .99-9900-3
Fan
Belt, remove and install. . . . . . . . . . . . . .05-0510-2
Guard, remove and install . . . . . . . . . . . .05-0510-1
Shroud, remove and install . . . . . . . . . . .05-0510-5
First and third speed (fourth stage)
First and third speed (fourth stage assembly)
Exploded view-direct drive machines . .03-0350-70
Flow divider
Flush air conditioner system . . . . . . . . . . . .18-1830-3
Fourth stage assembly (first and third speed)
Exploded view-direct drive
machines . . . . . . . . . . . . 03-0350-70, 03-0350-71
Exploded view-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-100
Fourth stage (first and third speed)
Frame
Engine, separate. . . . . . . . . . . . . . . . . . .17-1740-2
Equipment, separate . . . . . . . . . . . . . . . .17-1740-2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1
Free spool drag adjustment . . . . . . . . . . .30-3000-10
Freeze control switch . . . . . . . . . . . . . . . .18-1830-40
Front axle, differential, and oscillating supports
Front cover group
Remove magnetic speed sensor . . . . . . .06-0641-1
Front housing cover plates
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-30
Index-3

053003
PN=3
Index
Indx
4
Page
Page
Front housing, transmission

Assemble to rear housing-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-129
Exploded view-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-52
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-55
Fuel tank, 540G-III, 548G-III, 640G-III
Remove . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1
Fuel tank, 648G-III, 748G-III
Remove . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-5
Grapple, dual function

Control valve disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .38-3860-20
Control valve remove and install . . . . . .38-3860-18
Grille and grille housing
Guard
Engine frame bottom, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .17-1746-1
Equipment frame bottom, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .17-1746-2
Front axle, remove and install . . . . . . . .02-0200-15
G
Gappple arch, single function
remove and install. . . . . . . . . . . . . . . . . .38-3840-6
Gear shift lever assembly
machines . . . . . . . . . . . . . . . . . . . . . . .03-0315-1
Gear, idler (sixth stage)
Torque converter machine . . . . . . . . . .03-0350-98
Gear, idler (sixth stage assembly)
Repair-direct drive machines. . . . . . . . .03-0350-66
Gear, output (seventh stage assembly)
Assemble-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-125
Disassemble-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-125
Gear, winch drive
Disassemble-direct drive machines . . . . .03-0350-5
Grapple
Control valve-single function . . . . . . . . .38-3860-14
Damper adjustment. . . . . . . . . . . . . . . . .38-3803-6
Damper, repair . . . . . . . . . . . . . . . . . . . .38-3803-4
Rotate yoke repair . . . . . . . . . . . . . . . . .38-3803-9
Specifications . . . . . . . . . . . . . . . . . . . . .38-3803-1
Grapple and tong assembly
Grapple arch, duel function
Grapple control linkage, dual function
Grapple control linkage, single function
Grapple rotate solenoid valve
Grapple tong cylinder
TM2111 (30MAY03)
H
Hand pump
Heater core, remove and install . . . . . . . .18-1830-35
Heater, engine coolant
High pressure switch, air conditioning
High/low forward (second stage)
High/low forward (second stage assembly)
High/low reverse (third stage)
Torque converter machine . . . . . . . . . 03-0350-100
High/low reverse (third stage assembly)
Hood, remove and install . . . . . . . . . . . . . .19-1910-1
Horizontal roller
Horn
Housing, front
Exploded view-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-52
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-55
Housing, rear
Repair-Torque converter machines . . . 03-0350-127
Hydraulic
Fittings, 30 deg cone seat. . . . . . . . . . . .00-0003-8
Fittings, 37 deg flare . . . . . . . . . . . . . . . .00-0003-8
Pump, disassemble and inspect . . . . . .21-2160-12
Pump, remove and install
Index-4

053003
PN=4
Index
Page
Page
Pump, remove and install-direct drive

mach. . . . . . . . . . . . . . . . . . . . . . . . . .21-2160-1
Reservoir, remove and install . . . . . . . .21-2160-27
Torque converter machines . . . . . . . .21-2160-35
Hydraulic oil cleanup procedure . . . . . . . .21-2160-42
Metric torque values . . . . . . . . .00-0003-2, 00-0003-3

Motor
Pressure blower, remove and install . . .18-1830-34
Motor, rotate
Muffler, 540G-III, 548G-III, 640G-III, 648G-III, remove
and install . . . . . . . . . . . . . . . . . . . . . . . .05-0530-1
Muffler, 748G-III, remove and install . . . . . .05-0530-4
I
Idler gear (sixth stage)
Torque converter machines. . . . . . . . . .03-0350-98
Idler gear (sixth stage assembly)
Idler shaft, transmission remove and install
torque converter machines . . . . . . . . . .03-0350-32
Inch torque values . . . . . . . . . . . . . . . . . . .00-0003-6
Input assembly
Remove magnetic speed sensor . . . . . . .06-0641-1
Input shaft (first stage)
Input shaft (first stage assembly)
Input yoke
Isolator, cab
L
Latch, cab door . . . . . . . . . . . . . . . . . . . . .18-1810-6
Linkage, transmission disconnect
Log arch
Horizontal roller, remove and install . . . .37-3740-1
Roller brackets, remove and install . . . . .37-3740-5
Side roller, remove and install. . . . . . . . .37-3740-3
Low pressure switch, air conditioning
Lower pivot pin seal
M
Magnetic speed sensor
Input assembly . . . . . . . . . . . . . . . . . . . .06-0641-1
Manifold, rotary
TM2111 (30MAY03)
O
O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-9
Oil
Lines and fittings. . . . . . . . . . . . . . . . . . .00-0003-7
Oil cooler pump
Oscillating support
Front, front axle, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Rear, front axle, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Output gear (seventh stage assembly)
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-125
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-125
P
Park brake
Solenoid valve, repair . . . . . . . . . . . . . . .11-1160-1
Park brake repair . . . . . . . . . . . . . . . . . . .03-0350-11
Park brake/gear shift lever assembly
machines . . . . . . . . . . . . . . . . . . . . . . .03-0315-1
Pin, upper pivot
Pivot pin, upper
Portable caddy, hydraulic oil cleanup
procedure . . . . . . . . . . . . . . . . . . . . . . .21-2160-42
Pressure blower motor, remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-34
Pressure reducing valve
Pressurized water system
Index-5

053003
PN=5
Indx
5
Index
Indx
6
Page
Page
Priority valve
Pump
Differential lockcable skidder, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-5
Differential lockgrapple skidder, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-6
Secondary steering, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .09-0930-1
Pump, charge
Pump, hand
Pump, hydraulic
Disassemble and inspect . . . . . . . . . . .21-2160-12
Remove and install
Remove and install-direct drive mach . . .21-2160-1
Pump, oil cooler
Pump, transmission charge
Remove
Direct drive machines . . . . . . . . . . . . .03-0360-1
Remove and install
Roller brackets
Rollers, cable, dual function
Rollers, cable, single function
ROPS
Torque . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1
Rotary manifold
Rotate motor
R
Radiator
machines . . . . . . . . . . . . . . . . . . . . . . .05-0510-7
machines . . . . . . . . . . . . . . . . . . . . . .05-0510-11
Rear housing, transmission
Repair-Torque converter machines . . . 03-0350-127
Rear wiper and washer, remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-13
Receiver dryer, remove and install . . . . . .18-1830-39
Refrigerant
Recover R134a, air conditioning . . . . . . .18-1830-9
Relief valve
Differential lock, remove and install. . . . .02-0260-3
Relief valve, compressor, remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Reservoir, hydraulic
Torque converter machines . . . . . . . .21-2160-35
Reverse warning alarm
TM2111 (30MAY03)
S
Safety
Add and operate attachments safely . . . . .00-01-13
Avoid backover accidents . . . . . . . . . . . . .00-01-10
Avoid high-pressure fluids . . . . . . . . . . . . . .00-01-4
Avoid machine tip over . . . . . . . . . . . . . . .00-01-11
Avoid unauthorized machine
modifications . . . . . . . . . . . . . . . . . . . . . .00-01-3
Avoid work site hazards . . . . . . . . . . . . . . .00-01-9
Beware of exhaust fumes . . . . . . . . . . . . . .00-01-4
Dispose of waste properly. . . . . . . . . . . . . .00-01-6
Drive metal pins safely . . . . . . . . . . . . . . .00-01-15
Follow safety instructions . . . . . . . . . . . . . .00-01-2
Handle chemical products safely. . . . . . . . .00-01-6
Handle starting fluid safely . . . . . . . . . . . . .00-01-5
Inspect and maintain ROPS . . . . . . . . . . .00-01-12
Inspect machine . . . . . . . . . . . . . . . . . . . . .00-01-3
Keep riders off machine . . . . . . . . . . . . . .00-01-10
Keep the operator protective structure in
place . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-13
Make welding repairs safely . . . . . . . . . . .00-01-15
Operate machine safely . . . . . . . . . . . . . . .00-01-9
Operate only if qualified . . . . . . . . . . . . . . .00-01-2
Operating on slopes . . . . . . . . . . . . . . . . .00-01-11
Operating or traveling on public roads. . . .00-01-12
Park and prepare for service safely. . . . . .00-01-14
Prepare for emergencies. . . . . . . . . . . . . . .00-01-7
Prevent battery explosions . . . . . . . . . . . . .00-01-6
Prevent fires . . . . . . . . . . . . . . . . . . . . . . . .00-01-5
Prevent unintended machine movement . . .00-01-8
Recognize safety information . . . . . . . . . . .00-01-2
Remove paint before welding or
heating . . . . . . . . . . . . . . . . . . . . . . . . .00-01-15
Safety features . . . . . . . . . . . . . . . . . . . . . .00-01-1
Safety signs . . . . . . . . . . . . . . . . . . . . . . .00-01-16
Index-6

053003
PN=6
Index
Page
Page
Service cooling system safely . . . . . . . . . .00-01-14

Start only from operators seat . . . . . . . . . .00-01-7
Stay clear of moving parts . . . . . . . . . . . . .00-01-4
Use and maintain seat belt . . . . . . . . . . . . .00-01-8
Use steps and handholds correctly . . . . . . .00-01-7
Wear protective equipment . . . . . . . . . . . . .00-01-3
Seal
Lower pivot pin . . . . . . . . . . . . . . . . . . .17-1740-10
Seat
Seat belt
Anti-cinch, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . .18-1821-9
Two-inch, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-10
Seat, air suspension, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . . .18-1821-9
Seat, suspension
Base, disassemble and assemble . . . . . .18-1821-5
Seat slide and control lever, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-7
Shock absorber, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-5
Second and fourth speed (fifth stage assembly)
Exploded view-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-100
Second stage assembly (high/low forward)
Second stage (high/low forward)
Secondary steering pump
Service brake
Lining inspection . . . . . . . . . . . . . . . . . . .10-1011-1
Pedal remove and install. . . . . . . . . . . . .10-1015-1
Service brake valve
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-1
Seventh stage assembly (output gear)
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-125
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-125
Shaft, input (first stage)
Shock absorber cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . .38-3803-2
Shock absorber, seat
Shroud, fan, remove and install . . . . . . . . .05-0510-5

Side roller
Single function
Pilot controller, remove and install . . . . .38-3815-6
Single lever pilot controller
Remove and Install . . . . . . . . . . . . . . . . .38-3815-6
Sixth stage (idler gear)
Solenoid valve
Differential lock, repair . . . . . . . . . . . . . .02-0260-1
Park brake, repair . . . . . . . . . . . . . . . . . .11-1160-1
Solenoid, starting aid, remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1
Spherical bushing
Stacking blade
Stage assembly, gear
Starting aid
Starting aid circuit
Theory of operation. . . . . . . . . . . . . . . . .04-0400-4
Steering column
Steering column and steering wheel
Steering cylinder
Steering valve
Disassemble . . . . . . . . . . . . . . . . . . . . . .09-0960-3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-7
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-1
Steering wheel
Suction Tube
Remove-torque converter machines . . .03-0350-29
Support bearing
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0225-4
Suspension seat
Base, disassemble and assemble . . . . . .18-1821-5
Seat slide and control lever, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-7
Switch, freeze control . . . . . . . . . . . . . . . .18-1830-40
TM2111 (30MAY03)
T
Tank, fuel, 540G-III, 548G-III, 640G-III
Remove . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1
Index-7

053003
PN=7
Indx
7
Index
Indx
8
Page
Page
Tank, fuel, 648G-III, 748G-III

Remove . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-5
Tensioner, belt
Automatic (spring), remove and install . .05-0510-5
Spring tension check. . . . . . . . . . . . . . . .05-0510-4
Thermal bypass valve
Remove and install-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . . .03-0360-8
Third stage assembly (high/low reverse)
Third stage (high/low reverse)
Tire
Install duals. . . . . . . . . . . . . . . . . . . . . . .01-0110-5
Tong and grapple assembly
Torque converter
Drive plate . . . . . . . . . . . . . . . . . . . . . . .06-0651-2
Exploded view. . . . . . . . . . . . . . . . . . . . .06-0641-2
Fixed stator converter drawing . . . . . . . .06-0651-5
Torque converter cover, drive plate and impeller
hub tightening sequence . . . . . . . . . . .06-0651-1
Torque converter housing. . . . . . . . . . . . . .06-0641-2
Torque value
Dual wheel nuts . . . . . . . . . . . . . . . . . . .01-0110-5
Flat face O-ring seal fitting . . . . . . . . . .00-0003-11
Hardware specifications . . . . . . . . . . . . .00-0003-1
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-6
Inch SAE four bolt flange fitting. . . . . . .00-0003-13
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-3
Metric four bolt flange fitting . . . . . . . . .00-0003-12
O-ring boss fitting . . . . . . . . . . . . . . . . . .00-0003-9
30 deg cone seat hydraulic fittings . . . . .00-0003-8
37 deg flare hydraulic fittings . . . . . . . . .00-0003-8
Transmission
Clutch pack, assemble-direct drive
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-79
Clutch pack, assemble-TC mach. . . . . 03-0350-114
Clutch pack, disassemble-direct drive
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-72
Clutch pack, remove-direct drive
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-60
Clutch pack, torque converter
machines . . . . . . . . . . . 03-0350-94, 03-0350-100
Control valve, repair . . . . . . . . . . . . . . .03-0350-34
First and third speed, (fourth stage), torque
converter machines . . . . . . . . . . . . . 03-0350-100
Front and rear housing assemble . . . . .03-0350-91
Front housing to rear housing, assemble-Torque
converter machines . . . . . . . . . . . . . 03-0350-129
Front housing, exploded view-direct drive

machines . . . . . . . . . . . . . . . . . . . . . .03-0350-48
Front housing, exploded view-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-52
Front housing, repair. . . . . . . . . . . . . . .03-0350-55
Gear stage assemby-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-94
Idler shaft, remove and install-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-32
Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-11
Mounting on repair stand . . . . . . . . . . . .03-0350-2
Rear housing, repair-direct drive
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-90
Rear housing, repair-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-127
Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-1
Second stage (high/low forward), torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-100
Third stage (high/low reverse), torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-100
Transmission charge pump
Remove
Direct drive machines . . . . . . . . . . . . .03-0360-1
Remove and install
Transmission disconnect linkage
Tube, suction
Remove-torque converter machines . . .03-0350-29
Two-inch seat belt, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-10
TM2111 (30MAY03)
V
Valve
Differential lock relief, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-3
Differential lock solenoid, repair . . . . . . .02-0260-1
Expansion, remove and install . . . . . . .18-1830-33
Park brake solenoid, repair . . . . . . . . . . .11-1160-1
Priority, remove and install . . . . . . . . . .21-2160-23
Service brake, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .10-1060-3
Service brake, remove and install . . . . . .10-1060-1
Service brake, repair. . . . . . . . . . . . . . . .10-1060-1
Single function grapple control . . . . . . .38-3860-14
Steering, disassemble . . . . . . . . . . . . . . .09-0960-3
Steering, install . . . . . . . . . . . . . . . . . . . .09-0960-7
Steering, repair . . . . . . . . . . . . . . . . . . . .09-0960-1
Valve, blade control
Index-8

053003
PN=8
Index
Page
Page
Valve, cold start dump . . . . . . . . . . . . . . .21-2160-26

Valve, control
Dual function grapple disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .38-3860-20
Dual function grapple remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .38-3860-18
Valve, grapple rotate solenoid
Valve, pressure reducing
Valve, thermal bypass
Remove and install-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . . .03-0360-8
Valve, transmission control
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-34
Window maintenance . . . . . . . . . . . . . . . . .18-1810-4

Windshield wiper and washer, front
Windshield wiper, front and rear
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-13
Wiper and washer, rear, remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-13
Y
Yoke input
Yoke, grapple rotate
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3803-9
W
Warning alarm, reverse
Water system, pressurized
Welding specifications . . . . . . . . . . . . . . . .17-1740-1
Wheel bolt torque
Dual wheels . . . . . . . . . . . . . . . . . . . . . .01-0110-5
Wheel repair
Install duals. . . . . . . . . . . . . . . . . . . . . . .01-0110-5
Winch
Control cable, remove and install . . . . . .30-3015-3
Drag adjustment . . . . . . . . . . . . . . . . . .30-3000-10
Drive line, remove and install . . . . . . . . .30-3025-1
Drive shaft, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .30-3025-2
Winch drive repair
Direct drive machines . . . . . . . . . . . . . . .03-0350-5
Gear, disassemble-direct drive
machines . . . . . . . . . . . . . . . . . . . . . . .03-0350-5
Winch, 4000
Drive and clutch repair . . . . . . . . . . . . . .30-3050-1
Drum plug, install . . . . . . . . . . . . . . . . . .30-3000-7
Fasten cable to drum . . . . . . . . . . . . . . .30-3000-7
Winch, 6000
Drive and clutch repair . . . . . . . . . . . . . .30-3050-1
Fasten cable to drum . . . . . . . . . . . . . .30-3000-14
Window frame and molding, remove and
install . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1
TM2111 (30MAY03)
Index-9

053003
PN=9
Indx
9
Index
Indx
10
TM2111 (30MAY03)
Index-10

053003
PN=10

Skider Giii

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G-III and D Series

For complete service information also see:

Information is organized in groups for the various

G-III and D Series Skidders (S.N. 586337 )

Technical Information Feedback Form

John Deere Dubuque Works

Ideas, Comments (Please State Page Number):

G-III and D Series Skidders (S.N. 586337 )

G-III and D Series Skidders (S.N. 586337 )

SECTION 00General Information

SECTION 11Park Brake

SECTION 17Frame, Chassis, or Supporting

SECTION 02Axles and Suspension System

SECTION 18Operators Station

SECTION 19Sheet Metal and Styling

SECTION 20Safety, Convenience and

SECTION 05Engine Auxiliary Systems

SECTION 21Main Hydraulic System

SECTION 06Torque Converter

SECTION 32Bulldozers (Stacking & Trailbuilding

SECTION 09Steering System

SECTION 37Arch or Boom

SECTION 10Service Brakes

All information, illustrations and specifications in this manual are based on

G-III and D Series Skidders (S.N. 586337 )

G-III and D Series Skidders (S.N. 586337 )

G-III and D Series Skidders (S.N. 586337 )

G-III and D Series Skidders (S.N. 586337 )

Group 01Safety Information

Unified Inch Bolt and Cap Screw Torque

Group 0003Torque Values

G-III and D Series Skidders (S.N. 586337 )

G-III and D Series Skidders (S.N. 586337 )

Skidder Safety Features

Please remember, the operator is the key to

5. Bypass Start Protection. Shielding over the starter

G-III and D Series Skidders (S.N. 586337 )

Recognize Safety Information

This is the safety alert symbol. When you see this

Follow the precautions and safe operating practices

A signal word DANGER, WARNING, or CAUTION is

On your machine, DANGER signs are red in color,

Follow Safety Instructions

Read the safety messages in this manual and on the

Operate Only If Qualified

machine functions with the machine in an open area

G-III and D Series Skidders (S.N. 586337 )

Wear Protective Equipment

Wear close fitting clothing and safety equipment

Prolonged exposure to loud noise can cause impairment

Avoid Unauthorized Machine Modifications

Always contact an authorized dealer before making

Keep all guards and shields in good condition and

Inspect machine carefully each day by walking around it

G-III and D Series Skidders (S.N. 586337 )

Stop engine before examining, adjusting or maintaining

Entanglements in moving parts can cause serious injury.

Stay Clear Of Moving Parts

If hydraulic fluid penetrates your skin, see a doctor

Never search for leaks with your hands. Protect hands.

This machine uses a high-pressure hydraulic system.

Avoid High-Pressure Fluids

Prevent asphyxiation. Engine exhaust fumes can cause