Beruflich Dokumente
Kultur Dokumente
Repair
Table of contents
FOREWORD
MANUAL IDENTIFICATION—READ THIS FIRST!
Section 00 - GENERAL INFORMATION
Group 0001 - Safety
Group 0003 - Torque Values
Section 01 - WHEELS
Group 0110 - Powered or Non-Powered Wheels and Fastenings
Section 02 - AXLES AND SUSPENSION SYSTEMS
Group 0225 - Input Drive Shafts and U-Joints
Group 0230 - Non-Powered Wheel Axles
Group 0240 - Powered Wheel Axle (MFWD)
Group 0250 - Axle Shaft, Bearings, and Reduction Gears
Section 03 - TRANSMISSION
Group 0300 - Removal and Installation
Group 0315 - Controls Linkage
Group 0350 - Gear, Shafts, and Power Shift Clutches
Group 0360 - Hydraulic System
Section 04 - ENGINE
Group 0400 - Removal and Installation
Section 05 - ENGINE AUXILIARY SYSTEM
Group 0505 - Cold Weather Starting Aids
Group 0510 - Cooling Systems
Group 0515 - Speed Controls
Group 0520 - Intake System
Group 0530 - Exhaust Systems
Group 0560 - External Fuel Supply Systems
Section 06 - TORQUE CONVERTER
Group 0651 - Turbine, Gears, and Shaft
Section 09 - STEERING SYSTEM
Group 0960 - Hydraulic System
Section 10 - SERVICE BRAKES
Group 1011 - Active Elements
Group 1060 - Hydraulic System
Section 11 - PARK BRAKE
Group 1111 - Active Elements
Section 17 - FRAME OR SUPPORTING STRUCTURE
Group 1740 - Frame Installation
Group 1749 - Chassis Weights
Section 18 - OPERATOR′S STATION
Group 1800 - Removal and Installation
Group 1810 - Operator Enclosure
Group 1821 - Seat and Seat Belt
Group 1830 - Heating and Air Conditioning
Section 19 - SHEET METAL AND STYLING
Group 1910 - Hood or Engine Enclosure
Group 1913 - Miscellaneous Shields
Group 1921 - Grille and Grille Housing
Section 20 - SAFETY AND CONVENIENCE
Group 2001 - Radio
Group 2004 - Horn and Warning Devices
Section 21 - MAIN HYDRAULIC SYSTEM
Group 2160 - Hydraulic System
<- Go to Global Table of contents 315SK Backhoe Loader Repair
315SK Backhoe Loader Repair (g) by Belgreen v2.1
Section 31 - LOADER
Group 3100 - Loader
Group 3102 - Bucket
Group 3115 - Control Linkage
Group 3160 - Hydraulic System
Section 33 - BACKHOE
Group 3302 - Bucket
Group 3315 - Control Linkage
Group 3340 - Frames
Group 3360 - Hydraulic System
Section 99 - DEALER FABRICATED TOOLS
Group 9900 - Dealer Fabricated Tools
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.
CAUTION:
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.
The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level,
and machine serial number.
1 T 0 3 1 5 S K C 2 1 9 6 0 7
The following is an example for a 315SK machine that meets Tier 2 and Stage II emission levels:
PIN Identification
1T0315SK_ _C219607
C .......... 2012
D .......... 2013
E .......... 2014
F .......... 2015
G .......... 2016
F .......... Tier 4
Recommendations ....................................................................................................................... 35
Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 37
Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 38
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations ............................ 39
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings ........................................ 40
Service Recommendations For O-Ring Boss Fittings With Shoulder ................................................... 42
Metric 24° O-Ring Seal DIN 20078 Service Recommendations ........................................................... 45
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.
Follow the precautions and safe operating practices highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious
hazards.
On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and
WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
Safety Messages
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.
Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new
equipment components and repair parts include the current safety signs. Replacement safety signs are available from your
John Deere dealer.
There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in
this operator′s manual.
Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety
and affect machine life.
If you do not understand any part of this manual and need assistance, contact your John Deere dealer.
Protective Clothing
Guard against injury from flying pieces or metal or debris; wear goggles or safety glasses.
Wear close fitting clothing and safety equipment appropriate to the job.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating
machine.
Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs
or earplugs to protect against objectionable or uncomfortable loud noises. Radio or music headphones are not suitable to use
for hearing protection.
Inspect Machine
Inspect Machine
High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion,
exposed wire braid or any other signs of wear or damage.
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours
or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling
1-800-822-8262 or +1 309-748-5636.
This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.
Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop
engine and relieve pressure before disconnecting lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within
hours or gangrene could result. Contact a knowledgeable medical source or the Deere & Company Medical Department in
Moline, Illinois, U.S.A.
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust
fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
Prevent Fires
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks
or flame.
Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines,
hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine
compartment.
<- Go to Section TOC Section 00 page 6 315SK Backhoe Loader Repair
Section 00 - GENERAL INFORMATION Group 0001: Safety
Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine
electrical wiring and connectors frequently for damage.
Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use
extinguisher properly.
Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere
equipment include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and
how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)
Recycle Waste
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or
component. These measures include the following:
Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the
removal or handling of objects and materials.
Follow instructions for specialized components.
Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other
electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.
Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides.
Handle and dispose of these components appropriately.
Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use
leak-proof containers when draining fluids. Do not use food or beverage containers.
Do not pour waste fluids onto the ground, down a drain, or into any water source.
Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids
(example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or
components in other than specially designed incinerators may be prohibited by law and could result in exposure to
harmful fumes or ashes.
Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service
center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape.
Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in
part or completely.
Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to
recycle or dispose of waste.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator′s station clean and
free of debris.
Clean any oil spills or fuel spills on machine surfaces.
Temperature in engine compartment could go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS
PERIOD.
Open access door(s) to cool the engine faster, and clean engine compartment.
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.
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.
Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure that all controls and working
tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid
terminals.
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 that 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.
LOCKED Position
Always move the park lock levers to the up (locked) position before leaving the operator′s seat for any reason .
Be careful not to accidentally actuate controls when coworkers are present. Engage park lock and lower work equipment to the
ground during work interruptions. Stop the engine before allowing anyone to approach the machine. Follow these same
precautions before standing up, leaving the operator′s seat, or exiting the machine.
Be careful not to accidentally actuate control levers when coworkers are present. Always lock hydraulics on backhoe during
work interruptions. Lock hydraulics before allowing anyone to approach machine.
Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all
underground utilities before you dig.
Prepare work site properly . Avoid operating near structures or objects that could fall onto the machine. Clear away debris
that could move unexpectedly if run over.
Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move any part of
machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.
Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid
swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles
and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep
signal person in view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or
excavations.
Avoid working under over-hanging embankments or stockpiles that could collapse on machine.
Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow
removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden
stop. Always wear your seat belt.
Keep Riders Off
Before moving machine, be sure all persons are clear of the machine travel path. Turn around and look directly for
best visibility. Use mirror to assist in checking behind the machine. Keep windows and mirror clean and in good repair.
Be certain backup warning alarm is working properly.
Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all
times. Use prearranged hand signals to communicate.
machine stability or reliability and could 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.
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.
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.
Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge
tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.
Toxic Fumes
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an
approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or
heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
IMPORTANT:
Disable electrical power before welding. Turn off main battery switch and disconnect positive (+) and
negative (-) battery cables.
Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can
cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic.
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines
malfunction as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.
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.
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 could dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and object to prevent chipping.
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a
wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally
weaken or deform the wheel.
When inflating tires, use a 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.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings
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)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
Fasteners should be replaced with the same or higher property class. If higher
CAUTION: property class fasteners are used, these should only be tightened to the strength
Use only metric tools on metric hardware. Other tools may not fit of the original.
properly. Tool may slip and cause injury. Make sure fastener threads are clean and that you properly start thread
DO NOT use these values if a different torque value or tightening engagement. This will prevent them from failing when tightening.
procedure is given for a specific application. Torque values listed are for Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent
general use only. Check tightness of fasteners periodically. of the dry torque shown in the chart, applied to the nut, not to the bolt head.
Shear bolts are designed to fail under predetermined loads. Always Tighten toothed or serrated-type lock nuts to the full torque value.
replace shear bolts with identical property class.
T-Bolt
H-Bolt
M-Bolt
CAUTION:
Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause
injury.
Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different
torque value or tightening procedure is listed for a specific application.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened
to the strength of the original.
Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when
tightening.
Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings
Grade 1 (No Mark) Grade 2 a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
b c b c b c b c
Lubricated N˙m Dry Lubricated N˙m Dry Lubricated N˙m Dry Lubricated N˙m Dry
Thread Size
(lb-ft) N˙m (lb-ft) (lb-ft) N˙m (lb-ft) (lb-ft) N˙m (lb-ft) (lb-ft) N˙m (lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
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)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of
bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
Service Recommendations for 37° Flare and 30° Cone Seat Connectors
[1] - Inspect flare and flare seat. They must be free of dirt or obvious defects.
[2] - Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks.
[6] - Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings.
3/8 - 24 UNF 8 6
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
→NOTE:
Torque tolerance is ± 10%.
Straight Fitting
[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.
Angle Fitting
Angle Fitting
[1] - Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of 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).
[4] -
→NOTE:
Do not allow hoses to twist when tightening fittings.
Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value.
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
→NOTE:
Torque tolerance is ± 10%.
Straight or Adjustable Fitting Stud End Nut with Metric Thread in Aluminum Housing Torque Values
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH METRIC THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ±
10% unless otherwise specified
Straight or Adjustable Fitting Stud End Nut with Inch Thread in Aluminum Housing Torque Values
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10%
unless otherwise specified
Thread Size
Nm (lb-ft)
in.
1/8 —
1/4 28 (20)
3/8 39 (29)
1/2 75 (55)
1 165 (122)
1-1/8 —
1-3/8 —
1-3/4 —
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10%
unless otherwise specified
Thread Size
Nm (lb-ft)
in.
2 —
O-Ring Boss Plug Stud End with Inch Thread in Aluminum Housing Torque Values
O-RING BOSS PLUG STUD END WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified
Thread Size
Nm (lb-ft)
in.
3/8 23 (17)
1/2 39 (29)
3/4 55 (41)
1 86 (64)
2 204 (150)
[1] - Inspect fitting and O-ring boss sealing surfaces and the O-ring. They must be free of dirt, scratches, nicks, or burrs. O-ring
must be free of dirt, cuts, cracks, swelling or flatten condition.
[2] - Back the stud end hex nut (5) off as far as possible. Push backup washer (6) towards the nut to fully expose the turn down
section of stud end. Washer must fit turned down section and not be too loose
[3] - Wrap electrical tape over threads to protect O-ring. Slide O-ring over the tape into turned down section. Remove tape.
Apply hydraulic oil to the threads of stud end, turned down section, and O-ring.
[4] - Turn fitting into the boss by hand until face of nut or backup washer squeezes O-ring into the seat and contacts face of
boss. Loosen an adjustable fitting no more than one turn for alignment.
[5] - Tighten straight fitting or hex nut to the torque value given. Hold body of adjustable fitting using a second wrench when
tightening hex nut.
Straight Thread
Tapered Thread
[1] - Inspect flare and flare seat. They must be free of dirt or obvious defects.
[2] - Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks.
[3] - Align the tube with the fitting before attempting to start the nut.
[4] - Lubricate the male threads with hydraulic fluid or petroleum jelly.
[6] - Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings.
Torque Chart
TORQUE CHART
[ Torque tolerance is ±10%. ]
Straight Thread
Tapered Thread
[ With seat face. ]
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
TORQUE CHART
[ Torque tolerance is ±10%. ]
→NOTE:
If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced
approximately 10%.
[2] - Lubricate O-rings and install into grove using petroleum jelly to hold in place.
[3] - Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place.
[4] - Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup
wrench on straight hose couplings.
IMPORTANT:
Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an
actuating devise.
Tighten fittings to 50% of listed torque value if used in aluminum housing.
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High
Pressure Service Recommendations
O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End for High Pressure Torque Values
O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE
VALUES—Tolerance is +15 -20% unless otherwise specified
Metric Tube OD Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
5 -3 4.78 (0.188) — — — — —
8 -5 7.92 (0.312) — — — — —
16 -10 15.88 (0.625) 1-14 1-1/8 103 (76) 1-5/16 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 1-3/8 152 (112) 1-1/2 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 1-5/8 214 (158) 1-3/4 247 (182)
38 -24 38.10 (1.500) 2-12 2-1/4 326 (240) 2-3/8 374 (276)
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi),
TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a
Thread Size Straight Hex Size Adjustable Nut Hex Size Steel or Gray Iron Torque
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi),
TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a
Thread Size Straight Hex Size Adjustable Nut Hex Size Steel or Gray Iron Torque
[1] - Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-
ring must be free of dirt, cuts, cracks, swelling or flatten condition.
[2] - Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down
section. Washer must fit turned down section and not be too loose
[3] - Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place.
Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause
it to pop out.
To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down
section. Remove the tape.
[4] - Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss.
Loosen adjustable fittings no more than one turn for alignment.
Hold connections together while tightening nut to ensure O-ring remains in place.
[5] - Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from
twisting while tightening nut.
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For
Standard Pressure Service Recommendations
O-Ring Face Seal Fittings with Metric Hex and Stud End for Standard Pressure Torque Values
O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi),
TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Metric Tube OD Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
8 -5 7.92 (0.312) — — — — —
28 — — — — — — —
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar)
(4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a b
Thread Size Straight Hex Size Adjustable Nut Hex Size Steel or Gray Iron Torque Aluminum or Brass Torque
M8 x 1 12 12 8 (6) 5 (4)
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar)
(4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a b
Thread Size Straight Hex Size Adjustable Nut Hex Size Steel or Gray Iron Torque Aluminum or Brass Torque
[1] - Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-
ring must be free of dirt, cuts, cracks, swelling or flatten condition.
[2] - Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down
section. Washer must fit turned down section and not be too loose
[3] - Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place.
Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause
it to pop out.
To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down
section. Remove the tape.
[4] - Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss.
Loosen adjustable fittings no more than one turn for alignment.
Hold connections together while tightening nut to ensure O-ring remains in place.
[5] - Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from
twisting while tightening nut.
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High
Pressure Service Recommendations
O-Ring Face Seal Fittings with Metric Hex Nut and Stud End For Standard Pressure Torque Values
O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000 psi), TORQUE
VALUES—Tolerance is +15 -20% unless otherwise specified
Metric Tube OD Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
8 -5 7.92 (0.312) — — — — —
28 — — — — — — —
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 KPA (275.8 BAR) (4,000
PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a b
Thread Size Straight Hex Size Adjustable Nut Hex Size Steel or Gray Iron Torque
mm. mm mm Nm (lb-ft)
M8 x 1 12 12 8 (6)
M10 x 1 14 14 15 (11)
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 KPA (275.8 BAR) (4,000
PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a b
Thread Size Straight Hex Size Adjustable Nut Hex Size Steel or Gray Iron Torque
mm. mm mm Nm (lb-ft)
[1] - Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-
ring must be free of dirt, cuts, cracks, swelling or flatten condition.
[2] - Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down
section. Washer must fit turned down section and not be too loose
[3] - Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place.
Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause
it to pop out.
To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down
section. Remove the tape.
[4] - Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss.
Loosen adjustable fittings no more than one turn for alignment.
Hold connections together while tightening nut to ensure O-ring remains in place.
[5] - Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from
twisting while tightening nut.
[2] - Install the correct 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 the 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 four cap screws. Flange must be centrally
located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring.
[5] - After components are properly positioned and cap screws are hand tightened, 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.
DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
Torque Chart
TORQUE CHART
[ 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. ]
Thread
N˙m lb-ft
[ Metric standard thread. ]
M6 12 9
M8 30 22
M10 57 42
M12 95 70
Flange Fittings
LEGEND:
A Sealing Surface
B Split Flange
C Pinched O-Ring
D Single Piece Flange
[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.
DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
TORQUE CHART
N˙m lb-ft
Nominal Flange Size Cap Screw Size Min Max Min Max
1 3/8-16 UNC 37 54 27 40
Inch Series Four Bolt Flange Fitting For High Pressure Service
Recommendations
Inch Series Four Bolt Flange Fitting High Pressure Torque Values
INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa (414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES—Tolerance is ± 10% unless
otherwise specified
a
Nominal Flange Size Cap Screw Size Min—Max Torque
b
in. in. Nm (lb-ft)
[1] - Clean sealing surfaces (A). Inspect. Scratches, nicks, and burrs cause leaks. Roughness causes O-ring wear. Out-of-flat
causes O-ring extrusion. If imperfection cannot be polished out, replace component.
[2] - Install the O-ring (and backup ring, if used) into groove. Use petroleum jelly to hold it in place.
[3] -
IMPORTANT:
DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over
tighten.
Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand
tighten cap screws to hold flange halves and line in place. Do not pinch O-ring (C).
Single piece flange (D): Make sure flange is centrally located on port and line is centered in flange. Install the cap screws. Hand
tighten cap screws to hold flange and line in place. Do not pinch O-ring.
[4] - Tighten one cap screw and then the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten cap
screws within the specified torque values.
[1] - Inspect all fitting sealing surfaces. They must be free of dirt and defects.
[5] - Tighten stud (C) to torque value shown on the chart. Do not allow body to twist when tightening stud.
→NOTE:
The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy”
designed fitting.
Torque Value—Metric
Torque Value
6L M 10 x 1 30 22
8L M 12 x 1.5 40 30
10 L M 14 x 1.5 60 44
12 L M 16 x 1.5 100 74
15 L M 18 x 1.5 130 96
28 L M 33 x 2 400 295
35 L M 42 x 2 600 443
6S M 12 x 1.5 40 30
Torque Value
8S M 14 x 1.5 60 44
10 S M 16 x 1.5 100 74
12 S M 18 x 1.5 130 96
20 S M 27 x 2 250 184
25 S M 33 x 2 400 295
30 S M 42 x 2 600 443
38 S M 48 x 2 800 590
Torque Value—Inch
Torque Value
6L 1/8 25 18
8L 1/4 50 37
10 L 1/4 50 37
12 L 3/8 90 66
15 L 1/2 130 96
28 L 1 400 295
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 100 74
14 S 1/2 130 96
25 S 1 400 295
[2] - Inspect EOlastic seal (A) for damage. Replace seal or fitting as necessary.
To replace seal, put electrical tape over threads to protect seal. Slide seal over tape and into seal groove of fitting. Remove
tape.
IMPORTANT:
Do not allow hoses to twist when tightening fittings.
→NOTE:
The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy”
designed fitting.
Torque Value—Metric
Torque Value
6L M 10 x 1 20 15
8L M 12 x 1.5 30 22
10 L M 14 x 1.5 45 33
12 L M 16 x 1.5 60 44
15 L M 18 x 1.5 80 59
18 L M 22 x 1.5 130 96
28 L M 33 x 2 300 221
35 L M 42 x 2 600 443
6S M 12 x 1.5 40 30
8S M 14 x 1.5 60 44
10 S M 16 x 1.5 80 59
12 S M 18 x 1.5 110 81
20 S M 27 x 2 250 184
25 S M 33 x 2 450 332
Torque Value
30 S M 42 x 2 600 443
38 S M 48 x 2 800 590
Torque Value—Inch
Torque Value
6L 1/8 20 15
8L 1/4 40 30
10 L 1/4 40 30
12 L 3/8 80 59
18 L 1/2 100 74
28 L 1 300 221
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 90 66
25 S 1 400 295
Torque Value
M 10 x 1 13 10
M 12 x 1.5 30 22
M 14 x 1.5 40 30
M 16 x 1.5 60 44
M 18 x 1.5 70 52
M 20 x 1.5 90 66
M 22 x 1.5 100 74
M 26 x 1.5 120 89
M 27 x 2 150 111
M 33 x 2 250 184
M 42 x 2 400 295
M 48 x 2 500 369
1/8 15 11
1/4 33 24
3/8 70 52
1/2 90 66
Torque Value
1 220 162
Connection
Fitting Tube OD Size Heavy Fitting Size Light Fitting Size Torque
mm mm mm Turns
6 — M12 x 1.5
Hand tighten so O-ring contacts seat plus an additional 1/4—1/3 turn using a wrench
Connection
Fitting Tube OD Size Heavy Fitting Size Light Fitting Size Torque
mm mm mm Turns
14 M22 x 1.5 —
15 — M22 x 1.5
16 M24 x 1.5 —
18 — M26 x 1.5
20 M30 x 2 —
22 — M30 x 2
25 M36 x 2 —
28 — M36 x 2
30 M42 x 2 —
35 — M45 x 2
38 M52 x 2 —
[1] -
→NOTE:
These fittings are also referred to as EO and EO-2 Bite Type or Ermeto style fittings.
IMPORTANT:
In this style of fittings, there are “heavy” and “light” designs. Usually “heavy” is used for pressure lines
and “light” for return lines.
Some “heavy” and “light” sizes can be threaded together but do not seal properly. Be sure not to mix
“heavy” and “light” fittings.
Inspect the fitting sealing surfaces. They must be free of dirt scratches, nicks, and burrs.
[2] - Inspect the O-ring. It must be free dirt, cuts, cracks, swelling or flatten condition.
[5] - Tighten nut (A) hand tight so O-ring contacts seat and then an additional 1/4—1/3 turn using a wrench.
Section 01 - WHEELS
Table of contents
Group 0110 - Powered or Non-Powered Wheels and Fastenings ..................................................... 1
Rear Wheel Assembly Remove and Install ........................................................................................... 1
Front Wheel Assembly Remove and Install ........................................................................................... 3
Tire Remove and Install ........................................................................................................................ 5
Specifications
SPECIFICATIONS
115—166 kg
Rear Wheel (without fluid) Weight (approximate)
254—365 lb.
368—448 kg
Rear Wheel (with fluid) Weight (approximate)
811—988 lb.
725 N·m
Rear Wheel Nut Torque
535 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Lift wheel off ground and put shop floor stand under axle housing.
Shop Floor Stand
Used to support unit while removing and installing wheels.
[4] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Position wheel lift (2) under wheel. Fasten safety chain around upper portion of tire.
Item Measurement Specification
254—365 lb.
811—988 lb.
[5] - Remove wheel fasteners. Pull wheel assembly away from axle.
[7] - Thoroughly clean wheel fasteners, mounting surfaces, and wheel studs in flanged axle. Use compressed air to dry all
parts and tapped holes.
[9] -
IMPORTANT:
Install wheel fasteners several turns by hand to prevent thread damage. If a power wrench is used, be
sure wheel fasteners are fully engaged to prevent stripping.
535 lb.-ft.
[10] -
IMPORTANT:
Prevent possible damage to machine. Verify wheel fasteners are tightened to specification.
Tighten wheel fasteners to specification after first 50—100 hours of loaded operation after installing wheel. After first 50—100
hours, tighten wheel fasteners as required.
Specifications
SPECIFICATIONS
41—65 kg
Front Wheel (without fluid) Weight (approximate)
90—143 lb.
90—121 kg
Front Wheel (with fluid) Weight (approximate)
198—267 lb.
230 N·m
Wheel Fastener (non-powered front axle) Torque
170 lb.-ft.
725 N·m
Wheel Fastener (MFWD) Torque
535 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Lift wheel off ground and put shop floor stand under axle housing.
90—143 lb.
198—267 lb.
[4] - Put wheel lift under wheel assembly (2). Fasten safety chain around upper portion of tire.
[5] - Remove wheel fasteners. Pull wheel assembly away from axle.
[7] - Clean wheel fasteners and tapped studs. Use compressed air to dry all parts.
[9] -
IMPORTANT:
Prevent thread damage to hub studs and wheel fasteners. Install wheel fasteners several turns by hand.
If a power wrench is used be sure wheel fasteners are fully engaged to prevent stripping.
170 lb.-ft.
535 lb.-ft.
[11] -
IMPORTANT:
Prevent possible damage to machine. Verify wheel fasteners are tightened to specification.
Tighten wheel fasteners to specification after first 50—100 hours of loaded operation after installing wheel. After first 50—100
hours, tighten wheel fasteners as required.
CAUTION:
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have proper equipment and experience to perform job.
Always maintain correct tire pressure. Do not inflate tires above recommended pressure. Never weld or
heat a wheel and tire assembly. Heat can cause an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform wheel.
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 tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
→NOTE:
Tire can be removed without removing wheel from machine.
LEGEND:
1 Valve Core
2 Valve Nut
[3] -
LEGEND:
3 Rim
4 Valve Core
5 Side Flange
[4] - Make sure all parts are clean and free from rust or grease before assembly.
[5] - To prevent slipping of wheel under load, inside and outside of wheel must be free of paint, rust, oil, grease, dirt or other
foreign material before installation.
[6] - Install valve stem in rim base and tighten valve core (4) housing finger tight.
[7] - Before mounting tire on rim, add soap lubricant to bead of tire.
[10] -
CAUTION:
Tire repair should only be performed by a qualified service technician. Do not attempt to mount or
demount a tire unless you have proper equipment and experience to perform job safely. Failure to follow
proper procedures when mounting or demounting a tire from a wheel or rim can result in explosive
separation of a tire and rim parts, causing serious injury or death
LEGEND:
6 Pressure Regulating Valve With Clip-On Chuck
Turn Tire
Turn tire so valve stem is positioned at 12 o′clock. Use a pressure regulating valve with clip-on chuck (6) and extension hose
long enough to allow you to stand to one side and NOT in front of tire while inflating.
[11] - Use only recommended air pressure. Pressure over this limit can cause an explosion.
[12] - Add air until side flange of tire slides out against rim.
SPECIFICATIONS
32 N·m
Rear Drive Shaft Cap Screw Torque
24 lb·ft
92 N·m
Universal Joint Yoke Cap Screw Torque
67 lb·ft
32 N·m
Mechanical Front Wheel Drive (MFWD) Drive Shaft Cap Screw Torque
24 lb·ft
Other Material
OTHER MATERIAL
7 Yoke
8 Seal
9 U-Joint (2 used)
10 Snap Ring (6 used)
11 Cap Screw (4 used)
12 Half Clamp (2 used)
71 Drive Shaft (rear)
79 Mechanical Front Wheel Drive (MFWD) Drive Shaft (if equipped)
[1] - Remove cap screws (4 and 5), half clamps (6), and rear drive shaft (71).
[5] - Install drive shaft, half clamps, and cap screws. Tighten to specification.
Item Measurement Specification
24 lb·ft
67 lb·ft
[1] - Remove cap screws (11), half clamps (12), and mechanical front wheel drive (MFWD) drive shaft (79).
[6] - Install drive shaft, half clamps, and cap screws. Tighten to specification.
Item Measurement Specification
24 lb·ft
[3] -
LEGEND:
13 Bearing Cap
14 Cross
[4] - Remove bearing cap and cross (14). Remove opposite bearing cap. Replace parts if necessary.
[5] -
LEGEND:
14 Cross
15 Needle Bearing
16 Seal
[8] - Push bearing caps into yoke until bearing caps clear snap ring grooves. Install snap rings.
[9] - Install grease fitting and inject grease into U-joint. Do not force grease out seal.
SPECIFICATIONS
120 N·m
Thrust Plate Cap Screws Torque
89 lb.-ft.
15 N·m
Wheel Hub Cover Plug Torque
133 lb.-in.
Other Material
OTHER MATERIAL
[1] -
[2] - Raise machine and install jack stands so front wheels are off ground.
CAUTION:
Prevent possible crushing injury from heavy component. Secure wheel hub (3) with a lifting strap before
removing any components.
[3] - Remove front wheel. See Front Wheel Assembly Remove and Install . (Group 0110.)
[4] - Remove wheel hub cover plug (10) and remove wheel hub cover (9). Remove and inspect O-ring (4), replace if necessary.
[7] - Remove and inspect wheel hub (3) with bearing cups. To replace bearing cups, place wheel hub on flat surface and drive
bearing cups out.
[8] -
IMPORTANT:
Removing seal ring (1) will destroy the seal. Do not remove seal ring unless damage is noted.
[9] - Clean all dirt and grease from bearings, spindle, and hub assembly.
[10] - Inspect grease seals for damage or hardened lips. Replace as necessary.
[15] - Apply PM37421 Thread Lock and Sealer (high strength) to cap screws. Position thrust plate on spindle in hub and install
cap screws. Tighten cap screws to specification.
89 lb.-ft.
[16] - Grease and install O-ring on wheel hub cover. Install wheel hub cover into wheel hub.
133 lb.-in.
[18] - Install wheel. See Front Wheel Assembly Remove and Install . (Group 0110.)
SPECIFICATIONS
120 N·m
Lower King Pin Cap Screws Torque
86 lb.-ft.
120 N·m
Upper King Pin Cap Screws Torque
86 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Remove wheel hub. See Hub Assembly Remove and Install . (Group 0110.)
[3] -
LEGEND:
1 Locking Nut
2 Ball Joint Separator
[4] - Break loose ball joint using ball joint separator (2).
[5] - Remove and discard locking nut and remove tie rod threaded pin from swivel housing.
[6] -
CAUTION:
Prevent possible crushing injury from heavy component. Secure swivel housing with lifting strap.
LEGEND:
3 Cap Screw (8 used)
4 King Pin (upper)
5 King Pin (lower)
[7] -
→NOTE:
Be aware of Belleville washer placement between king pins and swivel housing.
[8] -
→NOTE:
King pin is serviced as an assembly.
LEGEND:
4 King Pin (upper)
5 King Pin (lower)
King Pins
Inspect king pins for wear or damage. Replace if necessary.
[9] -
Swivel Housing
LEGEND:
6 Swivel Housing
7 Axle Beam
8 Washer (2 used)
9 Bushing (2 used)
10 Bushing (2 used)
11 Washer (2 used)
Remove swivel housing (6) and washers (8 and 11).
[12] -
IMPORTANT:
Bushings must be fully seated or king pins will be damaged.
[15] - Install lower king pin with washer (11) positioned as shown. Tighten cap screws to specification.
Item Measurement Specification
86 lb.-ft.
[16] -
→NOTE:
Upper king pin must be installed with grease fitting pointed towards center of axle.
86 lb.-ft.
[18] - Install tie rod threaded pin into swivel housing with new locking nut.
[19] - Install wheel hub. See Hub Assembly Remove and Install . (Group 0110.)
[20] -
→NOTE:
If tie rod, spindle assembly, or steering cylinder are adjusted or serviced, perform the following
procedures.
Adjust tracking angle. See Tracking Angle Check and Adjust . (Group 9020-20.)
[21] - Adjust toe-in. See Toe-In Check and Adjust . (Group 9020-20.)
[22] - Adjust steering angle. See Steering Angle Check and Adjust . (Group 9020-20.)
[2] - Remove front wheels. See Front Wheel Assembly Remove and Install . (Group 0110.)
[3] -
→NOTE:
Start engine and turn wheel to extend cylinder rod beyond machine main frame for left or right side tie
rod.
LEGEND:
1 Lock Nut
2 Ball Joint Separator
[4] - Break loose ball joint using ball joint separator (2).
[5] - Remove and discard lock nut and remove tie rod threaded pin from swivel housing.
[6] -
LEGEND:
3 Tie Rod
4 Jam Nut
5 Ball Joint
6 Cylinder Rod
[9] - Install front wheels. See Front Wheel Assembly Remove and Install . (Group 0110.)
[10] -
→NOTE:
If tie rod, spindle assembly, or steering cylinder are adjusted or serviced, perform the following
procedures.
Adjust tracking angle. Perform Tracking Angle Check and Adjust . (Group 9020-20.)
[11] - Adjust toe-in. See Toe-In Check and Adjust . (Group 9020-20.)
[12] - Adjust steering angle. See Steering Angle Check and Adjust . (Group 9020-20.)
SPECIFICATIONS
8391 kg
Machine Weight (approximate)
18 500 lb.
215 N·m
Axle Pivot Pin Cap Screw Torque
158 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Raise loader and install boom lock bar. See Loader Boom Service Lock . (Operator’s Manual.)
[3] - Remove counterweights, if equipped. See Counterweight Remove and Install—If Equipped . (Group 1749.)
[4] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[5] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Item Measurement Specification
18 500 lb.
Raise and support front of machine. Position floor stands under main frame.
[6] - Remove front wheels. See Front Wheel Assembly Remove and Install . (Group 0110.)
[7] -
[9] - Position JT01642A Low Lift Jack under center of front axle. Attach adjustable-grip arms and safety chains from lift jack to
axle housing.
Low-Lift Transmission Jack
JT01642A
Used to remove axle
[10] - Remove cap screw (3), washer (4), and bushing (5).
[13] -
→NOTE:
Surfaces must be free of grease, oil, dirt, or paint.
[15] -
→NOTE:
Use as many thrust washers as will fit between axle and frame.
Apply multipurpose grease on pin. Install pin into bore with thrust washers.
[16] - Install axle pivot pin bushing, washer, and cap screw. Tighten to specification.
Item Measurement Specification
158 lb.-ft.
[18] - Install front wheels. See Front Wheel Assembly Remove and Install . (Group 0110.)
[19] - Install counterweights. See Counterweight Remove and Install—If Equipped . (Group 1749.)
[20] - Remove boom lock bar and lower loader. See Loader Boom Service Lock . (Operator’s Manual.)
SPECIFICATIONS
6237—8391 kg
Machine Weight (approximate)
13 750—18 500 lb.
335 kg
Mechanical Front Wheel Drive (MFWD) Axle Weight (approximate)
739 lb.
215 N·m
Axle Pivot Pin Cap Screw Torque
158 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Raise loader and install boom lock bar. See Loader Boom Service Lock . (Operator’s Manual.)
[3] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Item Measurement Specification
Raise and support front of machine. Position floor stands under main frame.
[5] - Remove front wheels. See Front Wheel Assembly Remove and Install . (Group 0110.)
[6] - Remove MWFD drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[7] -
MFWD Axle
LEGEND:
1 Steering Hose (2 used)
2 Lubrication Line
3 Cap Screw
4 Washer
5 Bushing
6 Pin
7 Thrust Washer (as needed)
8 Pivot Bushing (2 used)
80 Mechanical Front Wheel Drive (MFWD) Axle
125 Steering Cylinder
Tag and disconnect steering hoses (1). Close all openings using caps and plugs.
[8] - Disconnect lubrication line (2) from mechanical front wheel drive (MFWD) axle (80).
[9] - Position JT01642A Low Lift Jack under center of front axle. Attach adjustable-grip arms and safety chains from lift jack to
axle housing.
Low-Lift Transmission Jack
JT01642A
Used to remove axle
[10] - Remove cap screw (3), washer (4), and bushing (5).
[11] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
739 lb.
[13] -
→NOTE:
Surfaces must be free of grease, oil, dirt, or paint.
[15] - Apply multipurpose grease on pin. Install pin into bore with thrust washers.
[16] - Install axle pivot pin bushing, washer, and cap screw. Tighten to specification.
Item Measurement Specification
158 lb.-ft.
[18] - Install drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[19] - Install front wheels. See Front Wheel Assembly Remove and Install . (Group 0110.)
[20] - Remove boom lock bar and lower loader. See Loader Boom Service Lock . (Operator’s Manual.)
ESSENTIAL TOOLS
For more information on specific mechanical front wheel drive axle components:
See Planetary Drive Remove.
See Ring Gear Remove.
See Planetary Gears Remove.
See Wheel Hub Remove and Disassemble.
See Tie Rods Remove.
See Steering Cylinder Remove.
See Knuckle Housing Remove.
See Drive Shaft Remove.
See Knuckle Housing Disassemble.
See Drive Shaft Disassemble.
See Axle Housing Disassemble.
[1] -
LEGEND:
1 Axle
2 D01003AA Repair Stand
[2] -
→NOTE:
Pressure can build up in planetary carrier housing. To relieve pressure, turn hub until plug is in top
position and carefully remove plug. Then turn hub until oil drain bore is in bottom position and drain oil.
Slowly remove drain plug. Drain planetary housing oil, see Change MFWD Planetary Housing Oil—If Equipped . (Operator′s
Manual.)
[3] -
LEGEND:
3 Cap Screw (2 used)
4 Planetary Carrier
[1] -
LEGEND:
1 Cap Screw (8 used)
2 Ring Gear
[2] -
LEGEND:
2 Ring Gear
3 Wheel Hub
4 17 1/2-Ton Capacity Puller
Ring Gear
Remove ring gear (2) from wheel hub (3) using 17 1/2-ton capacity puller (4).
17 1/2 - Ton Capacity Puller Set
D01048AA
For removing and installing gears and bearings.
[1] -
LEGEND:
1 Snap Ring (3 used)
2 Planetary Gear (3 used)
[2] -
LEGEND:
2 Planetary Gear (3 used)
3 Two-Armed Puller
Planetary Gear
Using a two-armed puller (3), remove planetary gears (2) with roller bearings.
[1] -
→NOTE:
Support tapered roller bearing when removing wheel hub.
LEGEND:
1 Knuckle Housing
2 Wheel Hub
3 Tapered Roller Bearing
Wheel Hub
Pull wheel hub (2) with tapered roller bearing (3) from knuckle housing (1).
[2] -
LEGEND:
1 Knuckle Housing
3 Tapered Roller Bearing
[3] -
LEGEND:
2 Wheel Hub
4 Seal Ring
Seal Ring
Remove seal ring (4) from wheel hub (2).
[4] -
LEGEND:
2 Wheel Hub
5 O-Ring
6 Tapered Roller Bearing Cup (2 used)
[5] -
LEGEND:
2 Wheel Hub
7 Wheel Hub Stud (8 used)
[1] -
LEGEND:
1 Tie Rod
2 Lock Nut
Self-Locking Nut
Remove lock nut (2) from tie rod (1).
[2] -
LEGEND:
1 Tie Rod
3 Knuckle Housing
4 Tie Rod End Separating Tool
[3] -
LEGEND:
1 Tie Rod
5 Steering Cylinder Piston Rod
[1] -
LEGEND:
1 Axle Housing
2 Steering Cylinder Cap Screw (3 used)
[2] -
LEGEND:
1 Axle Housing
3 Steering Cylinder
Steering Cylinder
Remove steering cylinder (3) from axle housing.
[3] - For disassembly of steering cylinder, see Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Disassemble and
Assemble . (Group 0960.)
[1] -
LEGEND:
1 Cap Screw (8 used)
2 Upper King Pin
3 Lower King Pin
[2] - Remove cap screws (1) from upper king pin (2) and lower king pin (3).
[4] -
→NOTE:
Use caution when removing knuckle housing to avoid damaging shaft seal ring in axle housing.
LEGEND:
4 Axle Housing
5 Knuckle Housing With Drive Shaft
[1] -
LEGEND:
1 External Snap Ring
2 Sun Gear Shaft
Sun Gear
Open external snap ring (1) and remove sun gear shaft (2).
[2] -
→NOTE:
For aid in removal of drive shaft internal snap ring (3), tap on drive shaft (5) universal joint towards
knuckle housing (6).
LEGEND:
3 Drive Shaft Internal Snap Ring
4 Snap Ring Pliers
5 Drive Shaft
6 Knuckle Housing
Drive Shaft
Using snap ring pliers (4), remove drive shaft internal snap ring (3).
Snap Ring Pliers
JDG10939
Use to remove drive shaft internal snap ring.
[1] -
LEGEND:
1 Tapered Roller Bearing
2 Shaft Seal
3 King Pin
[2] -
LEGEND:
4 Shaft Seal
[3] -
LEGEND:
5 Snap Ring
6 Ball Bearing
Knuckle Bearing
Remove snap ring (5) and remove ball bearing (6) from knuckle housing.
[4] -
LEGEND:
7 Bushing (8 used)
[1] -
LEGEND:
1 Snap Ring (8 used)
[2] -
LEGEND:
2 Cross and Bearing Assembly (2 used)
[1] -
LEGEND:
1 Tapered Roller Bearing Cup (2 used)
2 Axle Housing
[2] -
LEGEND:
3 Shaft Seal
4 Bushing
[3] -
LEGEND:
5 Axle Housing Cap Screw (15 used)
[4] -
LEGEND:
6 Differential Tapered Roller Bearing Cup
7 Shim
8 O-Ring
[5] -
LEGEND:
8 Differential
Differential
Remove differential (8) from axle housing.
[7] -
LEGEND:
9 Differential Tapered Roller Bearing Cup
10 Shim
[8] -
LEGEND:
11 Lock Nut
12 Washer
13 Clamping Fork
[9] -
LEGEND:
14 Universal Joint Yoke
15 Bevel Gear Drive
Yoke
Remove universal joint yoke (14) from bevel gear drive (15).
[10] -
LEGEND:
14 Universal Joint Yoke
16 Guard
Guard
Remove guard (16) from universal joint yoke (14).
[11] -
LEGEND:
15 Bevel Gear Drive
[12] -
LEGEND:
18 Spacer
19 Bushing
[13] -
LEGEND:
20 Tapered Roller Bearing
[14] -
LEGEND:
21 Shaft Seal
22 Tapered Roller Bearing
[15] -
LEGEND:
23 Outer Tapered Roller Bearing Cup
[16] -
LEGEND:
24 Inner Tapered Roller Bearing Cup
[17] -
LEGEND:
25 Bushing (2 used)
SPECIFICATIONS
95°C
Tapered Roller Bearing Temperature (approximate)
205°F
450 N·m
Universal Joint Yoke Torque
330 lb.-ft.
1.0—3.0 N·m
Bevel Gear Drive Tapered Roller Bearings Rolling Drag Torque (without shaft seal)
10—30 lb.-in.
0.90 mm
Tapered Roller Bearing Cup Shim Size (recommended)
0.035 in.
0.10 mm
Dimension III Tapered Roller Bearing Preload
0.004 in.
0.10 mm
Axle Housings Gap (approximate)
0.004 in.
280 N·m
Axle Housing Cap Screws Torque
210 lb.-ft.
0.12—0.24 mm
Differential Bevel Gear Drive Backlash
0.005—0.009 in.
450 N·m
Yoke Lock Nut Torque
330 lb.-ft.
117 N·m
King Pin Cap Screws Torque
85 lb.-ft.
90 N·m
Ring Gear Cap Screws Torque
65 lb.-ft.
95°C
Planetary Gear Assembly Temperature (approximate)
205°F
32 N·m
Planetary Carrier Cap Screws Torque
25 lb.-ft.
240 N·m
Steering Cylinder Cap Screws Torque
175 lb.-ft.
300 N·m
Tie Rod Assembly to Steering Cylinder Piston Rod Torque
220 lb.-ft.
100 N·m
Tie Rod Lock Nut Torque
70 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
OTHER MATERIAL
[1] -
LEGEND:
1 Inner Tapered Roller Bearing Cup
2 JDG10599 Assembly Fixture
3 JDG10600 Assembly Ring
[2] -
LEGEND:
4 Outer Tapered Roller Bearing Cup
5 D01045AA Bushing, Bearing, and Seal Driver Set
[3] -
→NOTE:
Step 3—6 are used to determine thickness of shim used with bevel gear drive.
LEGEND:
6 Axle Housing Stamping
7 Bevel Gear Drive Stamping
8 Tapered Roll Bearing Width
[5] - Measure and record tapered roller bearing width (8) as dimension III.
[6] - Calculate shim thickness by subtracting the sum of dimensions II and III from dimension I. See example:
119.80 mm
Dimension I (axle housing stamping)
(4.72 in.)
88.00 mm
Dimension II (bevel gear drive stamping)
(3.46 in.)
28.30 mm
Dimension III (tapered roll bearing width)
(1.11 in.)
[7] -
LEGEND:
9 Shim
[8] -
CAUTION:
Prevent possible burn injury. Use appropriate hand protection when handling hot components.
LEGEND:
10 Tapered Roller Bearing
205°F
[9] -
LEGEND:
11 Bushing
12 Spacer Ring
[10] -
CAUTION:
Prevent possible burn injury. Use appropriate hand protection when handling hot components.
LEGEND:
13 Tapered Roller Bearing
14 Bevel Gear Drive
205°F
[11] -
LEGEND:
15 Guard
16 Universal Joint Yoke
[12] -
→NOTE:
Shaft seal ring is mounted after bevel gear drive contact pattern is checked.
LEGEND:
17 Universal Joint Yoke
18 Lock Nut
330 lb.-ft.
[13] -
LEGEND:
19 Tapered Roller Bearing (2 used)
Bevel Gear Drive Tapered Roller Bearings Rolling Drag Torque (without shaft seal) 1.0—3.0 N·m
10—30 lb.-in.
[14] -
LEGEND:
20 Shim
21 Tapered Roller Bearing Cup
0.035 in.
[15] -
LEGEND:
22 Gear
23 Differential
[16] -
LEGEND:
23 Differential
Differential
Install differential (23) in axle housing.
[17] -
LEGEND:
24 Bearing Cup
25 Tapered Roller Bearing
[18] - Rotate differential and tapered roller bearing cup in both directions to ensure rollers are positioned correctly.
[19] -
LEGEND:
27 Depth Gauge
28 Straight Edge
Dimension I
Dimension II
Using a depth gauge (27) and straight edge (28), measure distance between axle housing contact face and front face of
tapered roller bearing cup. Take several measurements at different locations to find the average value and record as
dimension I.
[20] - Using a depth gauge and straight edge, measure distance between axle housing contact face and contact face of
tapered roller bearing cup. Take several measurements at different locations to find the average value and record as
dimension II.
[21] - Calculate shim thickness by adding dimension III to difference of dimensions I and II. See example:
Item Measurement Specification
0.004 in.
9.50 mm
Dimension I (example)
0.374 in.
8.80 mm
Dimension II (example)
0.346 in.
0.10 mm
Dimension III
0.004 in.
[22] -
LEGEND:
30 Tapered Roller Bearing Cup
31 Shim
[23] -
→NOTE:
Install axle housings together without O-ring to get accurate shim calculations.
LEGEND:
32 O-Ring
33 Axle Housing (2 used)
Axle Housings
[24] -
→NOTE:
If shim calculation was done correctly, the gap width should be at approximate specification.
LEGEND:
34 Gap
0.004 in.
[25] -
LEGEND:
35 Axle Housing Cap Screw (5 used)
210 lb.-ft.
[26] -
LEGEND:
36 JDG10817 Cone Connection
37 JDG10816 Torsion Bar
Insert JDG10816 Torsion Bar (37) with JDG10817 Cone Connection (36) into differential.
Torsion Bar
JDG10816
For checking backlash on differential bevel gear drive.
Cone Connection
JDG10817
For checking backlash on differential bevel gear drive.
[27] -
LEGEND:
39 Axle Oil Drain Hole
40 Dial Indicator
0.005—0.009 in.
[28] -
LEGEND:
20 Shim
31 Shim
[29] - Check gear tooth contact pattern. See Gear Tooth Contact Pattern Check . (Group 0250.)
[30] -
LEGEND:
23 Differential
Differential Installation
Install differential (23) in axle housing.
[31] -
LEGEND:
32 O-Ring
33 Axle Housing (2 used)
35 Axle Housing Cap Screw (15 used)
Axle Housings
[32] - Assemble axle housings (33) and install axle housing cap screws (35). Tighten to specification.
Item Measurement Specification
210 lb.-ft.
[33] -
LEGEND:
15 Lock Nut
16 Yoke
[34] -
→NOTE:
Shaft seal ring must be installed with seal lip facing inward on axle housing. Lubricate seal before
installation. Confirm seal is recessed in axle housing.
LEGEND:
44 Shaft Seal Ring
45 JDG10590 Axle Housing Seal Ring Driver
[35] -
LEGEND:
15 Lock Nut
16 Yoke
Yoke
Install yoke (16) with lock nut (15). Tighten to specification.
Item Measurement Specification
330 lb.-ft.
[36] -
→NOTE:
Bushing must be installed in axle housing with joint of bushing facing upward or 12 o′clock position.
LEGEND:
46 Axle Housing Bushing
[37] -
LEGEND:
47 Shaft Seal
48 JDG10818 Seal Driver
49 JDG10819 Seal Driver
[38] - With seal lip facing inwards, install shaft seal using JDG10818 Seal Driver (48) and JDG10819 Seal Driver (49).
Seal Driver
JDG10818
For installing shaft seal in axle housing.
Seal Driver
JDG10819
For installing shaft seal in axle housing.
[39] -
LEGEND:
51 King Pin Bearing Cup (2 each)
[1] -
→NOTE:
Upper and lower king pin seals are different sizes.
LEGEND:
1 Seal (2 used)
2 King Pin (2 used)
[2] -
→NOTE:
Upper and lower king pin bearings are different sizes.
LEGEND:
3 Bearing (2 used)
2 King Pin (2 used)
[3] -
LEGEND:
6 Bushing (8 used)
[4] -
LEGEND:
8 Ball Bearing
9 Snap Ring
[6] -
LEGEND:
11 Seal
12 JDG10820 Seal Driver
Lubricate outside edge of seal (11) and install flush with knuckle housing using JDG10820 Seal Driver (12).
Seal Driver
JDG10820
For installing seal in knuckle housing.
[1] -
LEGEND:
1 Cross and Bearing Assembly (2 used)
[2] -
LEGEND:
3 Snap Ring (8 used)
[1] -
LEGEND:
1 Drive Shaft
Drive Shaft
Install drive shaft (1) in knuckle housing.
[2] -
LEGEND:
3 Drive Shaft Snap Ring
[3] -
LEGEND:
1 Drive Shaft
4 Sun Gear Shaft Retaining Ring
[4] -
LEGEND:
4 Sun Gear Shaft Retaining Ring
5 Sun Gear Shaft
[1] -
→NOTE:
For ease of assembly, turn drive shaft during installation until splines engage in differential.
LEGEND:
1 Knuckle Housing and Drive Shaft
2 Axle Housing
[2] -
LEGEND:
1 Knuckle Housing and Drive Shaft
3 Lower King Pin
4 Upper King Pin
[3] -
LEGEND:
3 Lower King Pin
4 Upper King Pin
5 King Pin Cap Screw (8 used)
85 lb.-ft.
[4] - Fill axle housing with oil. See Change MFWD Front Axle Housing Oil—If Equipped . (Operator′s Manual.)
[1] -
LEGEND:
1 Wheel Hub
2 Tapered Roller Bearing Cup (2 used)
[2] -
IMPORTANT:
To prevent seal damage, seal ring label outside needs to be facing toward seal ring driver tool.
LEGEND:
1 Wheel Hub
3 Seal Ring
4 JDG10593 Seal Ring Driver
5 27489 Large Handle
Seal Ring
Using JDG10593 Seal Ring Driver (4) and 27489 Large Handle (5), install seal ring (3) flush with wheel hub (1).
Seal Ring Driver
JDG10593
Installing seal ring in wheel hub.
Large Handle
27489
Use with seal ring driver tool.
[1] -
CAUTION:
Prevent possible burn injury. Use appropriate hand protection when handling hot components.
LEGEND:
1 Knuckle Bearing
2 Tapered Roller Bearing
205°F
[2] -
→NOTE:
For ease of installation, lightly coat wheel hub and knuckle housing surface with oil.
LEGEND:
3 Wheel Hub
Wheel Hub
Install wheel hub (3).
[3] -
CAUTION:
Prevent possible burn injury. Use appropriate hand protection when handling hot components.
LEGEND:
3 Wheel Hub
4 Taper Roller Bearing
205°F
[1] -
LEGEND:
1 Cap Screw (8 used)
2 Ring Gear
[2] - Apply PM37418 Thread Lock and Sealer (medium strength) to threads of cap screws (1).
65 lb.-ft.
[1] -
→NOTE:
The packaging sleeve is used as an assembly aid.
LEGEND:
1 Roller Bearing (3 used)
2 Packaging Sleeve (3 used)
3 Snap Ring (3 used)
4 Planetary Gear (3 used)
[2] -
CAUTION:
Prevent possible burn injury. Use appropriate hand protection when handling hot components.
LEGEND:
4 Planetary Gear (3 used)
5 Planetary Carrier
Planetary Gear
Heat planetary gears (4) to specification and install in planetary carrier (5) with beveled edge of roller bearing inner ring facing
downward.
Item Measurement Specification
195—215°F
[3] -
LEGEND:
4 Planetary Gear (3 used)
6 Snap Ring (3 used)
[1] -
LEGEND:
1 O-Ring
2 Wheel Hub
[2] -
LEGEND:
3 Planetary Carrier
4 Cap Screw (2 used)
25 lb.-ft.
[3] - Fill planetary drive with oil. See Change MFWD Planetary Housing Oil—If Equipped . (Operator′s Manual.)
[1] -
LEGEND:
1 Steering Cylinder Contact Surface
[2] -
LEGEND:
2 Steering Cylinder
3 Steering Cylinder Cap Screw (3 used)
Steering Cylinder
Install steering cylinder (2) and steering cylinder cap screws (3). Tighten to specification.
175 lb.-ft.
[1] -
LEGEND:
1 Tie Rod
2 Nut
3 Tie Rod End
Tie Rod
Install nut (2) and tie rod (1) on tie rod end (3).
[2] - Apply PM37418 Thread Lock and Sealer (medium strength) to tie rod end.
[3] -
LEGEND:
4 Tie Rod Assembly
5 Steering Cylinder Piston Rod
Tie Rod Assembly to Steering Cylinder Piston Rod Torque 300 N·m
220 lb.-ft.
[4] -
LEGEND:
1 Tie Rod
6 Lock Nut
Install lock nut (6) to tie rod (1) and tighten to specification plus an additional 180°—225° of rotation.
Item Measurement Specification
70 lb.-ft.
SPECIFICATIONS
120°C
Bevel Gear Temperature
248°F
68 N·m
Bevel Gear Cap Screw Torque
50 lb.-ft.
120°C
Tapered Roller Bearing Temperature
248°F
Other Material
OTHER MATERIAL
[1] -
LEGEND:
1 Bearing Puller
2 Tapered Roller Bearing (2 used)
3 Differential
[2] -
LEGEND:
3 Differential
4 Bevel Gear Cap Screw (16 used)
[3] -
LEGEND:
5 Cover
6 Bevel Gear
Bevel Gear
Remove cover (5) and bevel gear (6) from differential.
[4] -
LEGEND:
8 Bevel Gear
9 Thrust Washer
10 Spacer
[5] -
LEGEND:
12 Pinion Shaft Pin
13 Pinion Shaft
14 Bevel Gear (2 used)
15 Thrust Washer (2 used)
[6] - Remove pinion shaft, bevel gears (14), and thrust washers (15).
[7] -
LEGEND:
8 Bevel Gear
9 Thrust Washer
10 Spacer
[9] - Assemble bevel gear (8), thrust washer (9), and spacer (10) and install in bottom of differential.
[10] -
LEGEND:
12 Pinion Shaft Pin
13 Pinion Shaft
14 Bevel Gear (2 used)
15 Thrust Washer (2 used)
[12] -
Bevel Gear
LEGEND:
8 Bevel Gear
9 Thrust Washer
10 Spacer
Assemble bevel gear (8), thrust washer (9), and spacer (10). Install in top of differential.
[13] -
LEGEND:
5 Cover
17 Alignment Pin (2 used)
[14] -
CAUTION:
Prevent possible burns from heated components. Use appropriate hand protection when handling heated
components.
LEGEND:
6 Bevel Gear
Bevel Gear
Heat bevel gear (6) to specification and install on differential.
Item Measurement Specification
248°F
[15] -
LEGEND:
3 Differential
4 Bevel Gear Cap Screw (9 used)
50 lb.-ft.
[16] -
CAUTION:
Prevent possible burns from heated components. Use appropriate hand protection when handling heated
components.
LEGEND:
1 Tapered Roller Bearing (2 used)
248°F
SPECIFICATIONS
0.152—0.508 mm
Bevel Gear Drive Axial Play
0.006—0.020 in.
95°C
Bevel Gear Drive Temperature
205°F
68 N·m
Bevel Gear Cap Screw Torque
50 lb.-ft.
95°C
Tapered Roller Bearing Temperature
205°F
Other Material
OTHER MATERIAL
[1] -
LEGEND:
1 Bearing Puller
2 Tapered Roller Bearing (2 used)
3 Differential
[2] -
LEGEND:
3 Differential
4 Bevel Gear Cap Screw (16 used)
[3] -
LEGEND:
5 Cover
6 Bevel Gear
[4] -
[5] -
LEGEND:
12 Pinion Shaft
13 Spring Pin
[6] -
LEGEND:
15 Bevel Gear (2 used)
16 Thrust Washer (2 used)
[7] -
[9] -
→NOTE:
In order to achieve an accurate measurement for axial play on bevel gear drives (8), install parts first
without lubrication.
[10] -
LEGEND:
12 Pinion Shaft
15 Bevel Gear (2 used)
16 Thrust Washer (2 used)
[11] -
LEGEND:
8 Bevel Gear Drive
14 Differential Opening
18 Dial Indicator
0.006—0.020 in.
[12] - If axial play is out of specification, install clutch plates of different thicknesses to meet specification.
[14] - Install oiled bevel gear drive, thrust washer (9), clutch disks, and clutch plates.
[15] - Install bevel gears, thrust washers (16), and pinion shaft.
[16] -
→NOTE:
Be aware of depth on spring pin when installing through differential housing and pinion shaft.
LEGEND:
2 Differential
12 Pinion Shaft
13 Spring Pin
Spring Pin
Install spring pin through differential and pinion shaft.
[17] -
→NOTE:
Thickness and coating of clutch disks must be identical on both sides of differential housing.
[18] -
LEGEND:
5 Cover
20 Alignment Pin (2 used)
Differential Cover
Install alignment pins (20) and cover (5).
[19] -
CAUTION:
Prevent possible burn injury. Use hand protection when handling heated components.
LEGEND:
6 Bevel Gear Drive
205°F
[20] -
LEGEND:
3 Differential
4 Bevel Gear Cap Screw (16 used)
50 lb.-ft.
[21] -
CAUTION:
Prevent possible burn injury. Use hand protection when handling heated components.
LEGEND:
1 Tapered Roller Bearing (2 used)
205°F
[2] -
→NOTE:
If axle is removed from machine, skip steps 2 and 3 and apply hydraulic pressure directly to axle service
brake ports using a manually operated hydraulic pump.
[4] -
→NOTE:
When service brakes are applied, gap measurement (4) will equal overall thickness of brake disks (6).
A piece of metal bar stock with a thickness of 4.5 mm (0.177 in.) can be used as a gauge to check gap. If
the 4.5 mm (0.177 in.) gauge cannot fit between two separator plates, replace brake disks.
Disk Clearance
LEGEND:
3 Brake Inspection Port
4 Gap Measurement
5 Separator Plate (4 used)
6 Brake Disk (3 used)
Check gap measurement between two separator plates using a feeler gauge.
[5] - Replace brake disks if gap is less than 4.5 mm (0.177 in.). See Rear Axle Disassemble . (Group 0250.)
Item Measurement Specification
Rear Axle
Service Brake Disk Thickness (minimum) 4.5 mm
0.177 in.
SPECIFICATIONS
5103—8163 kg
Rear of Machine Weight (approximate)
11 250—18 000 lb.
490 kg
Rear Axle Weight
1080 lb.
620 N·m
Mounting Cap Screw Torque
457 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
CAUTION:
Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Raise and support rear of machine. Position floor stands under main frame.
Item Measurement Specification
[4] - Remove both rear wheels. See Rear Wheel Assembly Remove and Install . (Group 0110.)
[5] - Drain rear axle. See Change Rear Axle and Planetary Housing Oil . (Operator’s Manual.)
[6] - Remove rear drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
<- Go to Section TOC Section 02 page 74 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
[7] -
Rear Axle
LEGEND:
73 Rear Axle
75 Park Brake Valve-to-Park Brake Line
77 Service Brake Valve-to-Service Brake Line (2 used)
78 Differential Lock Valve-to-Differential Lock Line
B13 Park Brake Pressure Switch
Tag and disconnect park brake valve-to-park brake line (75), service brake valve-to-service brake lines (77), and differential
lock valve-to-differential lock line (78) from rear axle (73). Close all openings using caps and plugs.
[9] - Position a JT01642 Low Lift Jack under center of rear axle. Attach the adjustable-grip arms and safety chains of the low lift
jack to the axle housing.
Low Lift Jack
JT01642A
Used to remove and install rear axle.
[10] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
1 Cap Screw (8 used)
1080 lb.
[11] - Repair axle as necessary. See Rear Axle Disassemble . (Group 0250.)
457 lb.-ft.
[14] - Connect lines to service brakes, differential lock, and park brake.
[16] - Install rear wheels and lower machine to ground. See Rear Wheel Assembly Remove and Install . (Group 0110.)
[17] - Fill rear axle with proper oil. See Change Rear Axle and Planetary Housing Oil and see Transmission, Axles, and
Mechanical Front Wheel Drive (MFWD) Oil . (Operator’s Manual.)
SPECIFICATIONS
490 kg
Rear Axle Weight (approximate)
1080 lb.
36 kg
Planetary Weight (approximate)
79 lb.
23 kg
Rear Axle Hub Weight (approximate)
50 lb.
82 kg
Axle Housing Weight (approximate)
181 lb.
23 kg
Differential Weight (approximate)
50 lb.
[1] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Using appropriate lifting device, place rear axle on stand or steel table.
Item Measurement Specification
1080 lb.
[2] -
→NOTE:
Procedures for left and right sides of rear axle disassembly are the same. Differential lock components
are located behind left side axle housing.
LEGEND:
1 Cap Screw (2 used)
[3] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
2 Planetary
Planetary
Using appropriate lifting device, remove planetary (2).
Item Measurement Specification
79 lb.
[4] -
LEGEND:
3 Snap Ring (4 used)
[5] -
LEGEND:
4 Planetary Gear (4 used)
Planetary Gear
Remove planetary gears (4).
[6] -
<- Go to Section TOC Section 02 page 78 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
5 Sun Gear Shaft
6 O-Ring
[7] -
LEGEND:
7 Cap Screw (8 used)
[8] -
LEGEND:
8 M14 Guide Screw (2 used)
9 Jack Screw (2 used)
10 Hub
[9] - Install jack screws (9) into threaded holes of internal gear.
[10] - Pull internal gear away from hub (10) by evenly tightening jack screws until internal gear is loose.
[11] -
→NOTE:
Remove bushings (12) only if necessary.
LEGEND:
12 Bushing (8 used)
Bushings
If necessary, remove bushings (12).
[12] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
10 Hub
50 lb.
[13] -
LEGEND:
14 Hub Seal
15 Outer Bearing Cup (2 used)
[14] -
LEGEND:
18 Bearing Inner Ring
[15] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
20 Cap Screw (12 used)
21 Axle Housing
181 lb.
[16] -
LEGEND:
23 M16 Guide Screw (2 used)
Axle Housing
Install M16 guide screws (23) and remove axle housing.
[17] -
LEGEND:
24 Axle Shaft
Axle Shaft
Remove axle shaft (24) from axle housing.
[18] -
LEGEND:
25 Snap Ring
[19] -
LEGEND:
26 Brake Disk Package
27 O-Ring
28 O-Ring
29 O-Ring
Disk Package
Remove brake disk package (26).
[21] -
LEGEND:
30 Cap Screw (3 used)
31 Coupling Ring
Coupling Ring
Remove cap screws (30) and remove coupling ring (31).
[22] -
LEGEND:
33 Disk Spring
34 Snap Ring
35 Washer
[24] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
Brake Piston
[25] -
<- Go to Section TOC Section 02 page 83 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
36 Brake Piston
38 Brake Piston Lip Seal
39 Backup Ring
41 Brake Piston Lip Seal
42 Backup Ring
Piston Seals
[26] - Remove brake piston lip seal (41) and backup ring (42) from piston.
[27] -
LEGEND:
44 Differential Cover
Differential Cover
Remove differential cover (44).
[28] -
LEGEND:
46 O-Ring
47 Piston
Piston
<- Go to Section TOC Section 02 page 84 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
[29] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
[30] -
LEGEND:
49 Bearing Cup
50 Shim
[31] -
LEGEND:
52 O-Ring (2 used)
O-Rings
Remove O-rings (52).
[32] -
LEGEND:
54 O-Ring (2 used)
55 Differential Lock
[33] -
<- Go to Section TOC Section 02 page 85 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
→NOTE:
Differential lock is on left side only.
b.
Differential Lock
Remove needle bearing (57), locking slide (58), and compression spring (59) from differential lock.
[34] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
61 Differential
Differential
Using appropriate lifting device, remove differential (61).
Item Measurement Specification
50 lb.
[35] -
LEGEND:
62 Bearing
63 Bearing
Differential Bearings
Remove bearings (62 and 63).
[36] -
LEGEND:
64 Cap Screw (20 used)
[37] -
LEGEND:
66 Differential Case Half
67 Differential Case Half
68 Thrust Washer (2 used)
69 Bevel Gear
70 Thrust Washer (4 used)
71 Side Gear (4 used)
72 Pinion Shaft
73 Bevel Gear
74 Spacer
Differential
Separate differential case halves (66 and 67).
[39] - Remove thrust washers (70), side gears (71), and pinion shaft (72).
[40] - Remove bevel gear (73), lower thrust washer (68), and spacer (74).
[41] -
LEGEND:
76 Ring Gear
Ring Gear
Remove ring gear (76).
[42] -
→NOTE:
To aid in assembly, mark shim location.
LEGEND:
78 Differential Bearing Cup
79 Shim
SPECIFICATIONS
135 N·m
Differential Case Cap Screw Torque
100 lb.-ft.
1.7 mm
Outer Bearing Cup Shim Thickness
0.067 in.
23 kg
Differential Weight (approximate)
50 lb.
195 N·m
Differential Housing Cover Cap Screw Torque
144 lb.-ft.
0.15—0.25 mm
Rear Axle Ring Gear Backlash
0.006—0.010 in.
23 N·m
Coupling Ring Cap Screw Torque
17 lb.-ft.
82 kg
Axle Housing Weight
181 lb.
195 N·m
Axle Housing Cap Screw Torque
144 lb.-ft.
120°C
Inner Bearing Temperature
248°F
23 kg
Rear Axle Hub Weight (approximate)
50 lb.
120°C
Outer Bearing Temperature
248°F
250 N·m
Internal Gear Cap Screw Torque
184 lb.-ft.
120°C
Planetary Gear Temperature
248°F
36 kg
Planetary Weight (approximate)
79 lb.
55 N·m
Planetary Carrier Cap Screw Torque
41 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
JDG10524 Driver
JDG10525 Handle
JDG10526 Driver
Other Material
OTHER MATERIAL
[1] -
LEGEND:
1 Cap Screw (4 used)
2 Differential Half
[2] -
IMPORTANT:
Differential damage may occur if thrust washer is installed improperly. Install with dimpled side facing
bevel gear.
LEGEND:
4 Thrust Washer
5 Bevel Gear
[3] -
LEGEND:
2 Differential Half
7 Differential Shaft
8 Side Gear (4 used)
9 Thrust Washer (4 used)
Differential Assembly
Assemble side gears (8) and thrust washers (9) on differential shaft (7). Install in differential half (2) with thrust washer locking
tabs facing upwards.
[4] -
LEGEND:
11 Bevel Gear
12 Thrust Washer
13 Spacer Ring
[5] -
LEGEND:
2 Differential Half
15 Differential Half
16 Stamped Number
[6] -
LEGEND:
17 Ring Gear
Ring Gear
Install ring gear (17) and press until bottomed.
[7] -
LEGEND:
18 Cap Screw (20 used)
100 lb.-ft.
[8] -
IMPORTANT:
Bearing damage may occur if force is applied to bearing cage. Make sure force is applied to inner race of
bearing only.
LEGEND:
19 Bearing
20 Bearing
Bearing Installation
Press bearings (19 and 20) until bottomed.
[9] -
→NOTE:
It is recommended to use shim found in disassembly.
LEGEND:
22 Shim
23 Outer Bearing Cup
0.067 in.
[11] -
LEGEND:
16 Ring Gear
24 Differential
Differential Installation
Apply marking ink to teeth of ring gear (16) for checking contact pattern later.
[12] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
50 lb.
[13] -
LEGEND:
25 Straight Edge
26 Depth Gauge
Dimension I
Measure and record dimension I using straight edge (25) and a depth gauge (26).
Example
6.64 mm
Flange mounting surface-to-outer bearing cup
0.261 in.
[14] -
LEGEND:
25 Straight Edge
26 Depth Gauge
Dimension II
Measure and record dimension II using straight edge (25) and a depth gauge (26).
Example
5.35 mm
Brake housing flange-to-shoulder of outer bearing cup
0.217 in.
[15] -
LEGEND:
28 Shim (as required)
29 Bearing Cup
30 Differential Housing Cover
6.64 mm
Dimension I
0.261 in.
—5.35 mm
Subtract Dimension II
—0.217 in.
+0.10 mm
Add New Bearing Preload (only if installing new bearings)
+0.003 in.
1.39 mm
Equals
0.055 in.
=1.40 mm
Equals Total Differential Bearing Shim (rounded value)
=0.051 in.
[16] - Install predetermined shims (28) and bearing cup (29) into differential housing cover (30).
[17] -
LEGEND:
30 Differential Housing Cover
31 Cap Screw (3 used)
Differential Housing
Install differential housing cover (30) and cap screws (31). Tighten to specification.
Item Measurement Specification
144 lb.-ft.
[18] -
LEGEND:
33 DFT1286 Backlash Measurement Tool
34 Dial Indicator
35 Input Flange
Backlash Tool
Install DFT1286 Backlash Measurement Tool (33) onto input flange (35). For information on DFT1286 Backlash Measurement
Tool, see DFT1286 Backlash Measurement Tool . (Group 9900.)
Backlash Measurement Tool
DFT1286
Used to measure backlash between ring gear and pinion.
[19] -
→NOTE:
Straightedge of DFT1286 Backlash Measurement Tool indicates position to record backlash.
Install dial indicator (34) so it is positioned 126 mm from center of input flange to correspond to outer tooth diameter of ring
gear. Hold ring gear stationary and check backlash.
Item Measurement Specification
0.006—0.010 in.
[20] -
LEGEND:
22 Shim
23 Outer Bearing Cup
28 Shim (as required)
29 Bearing Cup
30 Differential Housing Cover
Install thicker shim (22) behind outer bearing cup (23). Shim (28) thickness must be reduced accordingly.
[23] - Check gear tooth contact pattern. See Gear Tooth Contact Pattern Check . (Group 0250.)
[25] -
LEGEND:
36 Needle Bearing
37 Locking Slide
38 Compression Spring
39 O-Ring (2 used)
40 Differential Lock
[26] - Install compression spring (38) onto locking slide and install differential lock (40) assembly.
[27] - Apply grease to O-rings (39) and install onto axle housing.
[28] -
LEGEND:
30 Differential Housing Cover
42 O-Ring
43 O-Ring
44 O-Ring
O-Rings
Apply oil to O-rings (42—44) and install onto differential housing cover (30).
[29] -
LEGEND:
45 Piston
[30] -
LEGEND:
30 Differential Housing Cover
46 M16 Guide Screw (2 used)
[31] -
[32] -
→NOTE:
Spring pins may have moved in brake piston to compensate for friction material wear and require
resetting in brake piston.
If required, drive spring pins (52) flush with the face of the brake piston (53).
[33] - Install brake piston lip seal (51) and backup ring (50) so open face of brake piston lip seal faces into axle housing.
[34] -
<- Go to Section TOC Section 02 page 100 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
55 Disk Spring
56 Washer
Disk Spring
Install disk spring (55) and washer (56).
[35] -
LEGEND:
49 Axle Housing
53 Brake Piston
57 Two-Armed Puller
[36] -
LEGEND:
59 Washer
60 Disk Spring
61 Coupling Ring
[37] -
<- Go to Section TOC Section 02 page 101 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
59 Disk Spring
62 Snap Ring
Snap Ring
Compress disk spring (59) and install snap ring (62).
[38] -
LEGEND:
61 Coupling Ring
64 Cap Screw (3 used)
Coupling Ring
Install coupling ring (61) and cap screws (64). Tighten to specification.
Item Measurement Specification
17 lb.-ft.
[39] -
LEGEND:
66 Separator Plate (4 used)
67 Brake Disk (3 used)
68 O-Ring
69 O-Ring
70 O-Ring
Brake Disk
Alternately install separator plates (66) and brake disks (67) starting with a separator plate.
<- Go to Section TOC Section 02 page 102 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
[41] -
LEGEND:
72 Disk Carrier
73 Snap Ring
74 Axle Shaft
Axle Shaft
Install disk carrier (72) and snap ring (73) on axle shaft (74).
[42] -
LEGEND:
49 Axle Housing
74 Axle Shaft
[43] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
46 M16 Guide Screw (2 used)
49 Axle Housing
181 lb.
[44] -
<- Go to Section TOC Section 02 page 103 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
77 Cap Screw (12 used)
144 lb.-ft.
[45] -
LEGEND:
79 Wheel Stud (10 used)
80 Wheel Hub
Wheel Studs
Press wheel studs (79) into wheel hub (80) until bottomed.
[46] -
IMPORTANT:
Prevent wheel studs from pushing out of wheel hub and damaging threads. Wheel hub must not be
supported by wheel studs.
LEGEND:
81 Outer Bearing Cup (2 used)
82 JDG10524 Driver
83 JDG10525 Handle
<- Go to Section TOC Section 02 page 104 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
JDG10525
Handle for JDG10524 driver tool.
[47] -
LEGEND:
84 Hub Seal
85 JDG10526 Driver
Hub Seal
Hub Seal
Apply PM37509 Klean ‘N Prime and PM38657 High Flex Form-In-Place Gasket to outer face of hub seal (84).
[48] -
IMPORTANT:
Axle damage and leaking may occur if old seal is used. Replace with new seal.
[49] -
CAUTION:
Prevent possible burn injury when handling heated components. Use appropriate hand protection.
<- Go to Section TOC Section 02 page 105 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
86 Inner Bearing
87 Sun Gear Shaft
Inner Bearing
Heat inner bearing (86) to specification and install.
Item Measurement Specification
248°F
[51] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
80 Wheel Hub
84 Hub Seal
88 Outer Bearing
50 lb.-ft.
[52] -
CAUTION:
Prevent possible burn injury when handling heated components. Use appropriate hand protection.
248°F
[53] -
<- Go to Section TOC Section 02 page 106 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
89 Bushing (8 used)
90 Internal Gear Housing
Bushing
If removed, install bushings (89) into internal gear housing (90) using a press.
[54] -
LEGEND:
90 Internal Gear Housing
92 Cap Screw (8 used)
[56] -
IMPORTANT:
Rear axle damage may occur if old cap screws are used. Cap screws are designed for one time use only,
replace with new cap screws.
184 lb.-ft.
[57] -
LEGEND:
93 Assembly Sleeve (4 used)
94 Planetary Gear (4 used)
95 Planetary Bearing (4 used)
96 Stop Pin
Planetary Gear
<- Go to Section TOC Section 02 page 107 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
[58] -
CAUTION:
Prevent possible burn injury when handling heated components. Use appropriate hand protection.
Heat planetary gear to specification and install with larger opening facing downward.
Item Measurement Specification
248°F
[60] -
LEGEND:
97 Snap Ring (4 used)
Snap Ring
Install snap rings (97).
[61] -
LEGEND:
87 Sun Gear Shaft
99 O-Ring
O-Ring
<- Go to Section TOC Section 02 page 108 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
[62] - Remove sun gear shaft (87) from axle housing and install into planetary.
[63] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
100 Planetary Carrier
Planetary Carrier
Install planetary carrier (100).
Item Measurement Specification
79 lb.
[64] -
LEGEND:
101 Cap Screw (2 used)
<- Go to Section TOC Section 02 page 109 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
41 lb.-ft.
<- Go to Section TOC Section 02 page 110 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
SPECIFICATIONS
195 N·m
Park Brake Housing Cap Screw Torque
144 lb.-ft.
120°C
Inner Pinion Bearing Temperature
248°F
120°C
Outer Pinion Bearing Temperature
248°F
600 N·m
Input Flange Nut Torque
443 lb.-ft.
2 N·m
New Bearing Rolling Drag Torque
20 lb.-in.
1 N·m
Old Bearing Rolling Drag Torque
7 lb.-in.
46 N·m
Park Brake Cover Cap Screw and Nut Torque
34 lb.-ft.
29 mm
Park Brake Release Cap Screw Height
1.1 in.
46 N·m
Park Brake Release Cap Screw Torque
34 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
Other Material
OTHER MATERIAL
[1] -
LEGEND:
1 Nut
2 Input Flange
[2] -
<- Go to Section TOC Section 02 page 111 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
4 Shaft Seal
5 Cap Screw (4 used)
6 Nut (2 used)
[4] -
LEGEND:
8 Park Brake Release Screw (2 used)
9 Cover
[6] -
LEGEND:
11 Disk Carrier
12 Outer Spring (14 used)
13 Inner Spring (14 used)
[8] -
<- Go to Section TOC Section 02 page 112 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
→NOTE:
For ease of assembly, mark piston alignment in brake housing.
LEGEND:
14 Piston
15 O-Ring
[10] -
LEGEND:
17 Inner O-Ring
18 Outer O-ring
Piston O-Rings
Remove inner O-ring (17) and outer O-ring (18) from park brake piston.
[11] -
LEGEND:
20 Disk and Plate Assembly
[12] -
<- Go to Section TOC Section 02 page 113 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
22 Pin (2 used)
Pin Removal
Remove pins (22).
[13] -
LEGEND:
24 Pinion
25 Outer Pinion Bearing
26 Two-Armed Puller
Pinion Removal
Remove pinon (24) and outer pinion bearing (25) using a two-armed puller (26) from D01047AA 17-1/2—30 Ton Puller Set.
[14] -
LEGEND:
28 Spacer Ring
29 Inner Pinion Bearing
[15] -
→NOTE:
For aid in assembly, mark shim location.
<- Go to Section TOC Section 02 page 114 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
31 Inner Bearing Cup
32 Shim
[16] -
LEGEND:
33 Outer Bearing Cup
34 Two-Armed Puller
[17] -
LEGEND:
36 Cap Screw (6 used)
37 M16 Jack Screw (2 used)
38 Dead Blow Hammer
39 Park Brake Housing
[18] - Tighten M16 jack screws while lightly tapping on back of park brake housing (39) with dead blow hammer (38) until
loose.
[20] -
→NOTE:
It is recommended to reuse shim found in disassembly of park brake.
<- Go to Section TOC Section 02 page 115 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
32 Shim
Shim Installation
Install shim (32).
[21] -
LEGEND:
33 Outer Bearing Cup
[22] -
LEGEND:
31 Inner Bearing Cup
[23] -
IMPORTANT:
To prevent oil leakage, make sure area around return port (34) is completely covered with PM38657 High
Flex Form-in-Place Gasket.
<- Go to Section TOC Section 02 page 116 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
34 Return Port
[24] - Apply PM38657 High Flex Form-In-Place Gasket to park brake housing all the way around return port (34).
[25] -
LEGEND:
36 Cap Screw (6 used)
39 Park Brake Housing
144 lb.-ft.
a. Dimension I is the measurement from axle center line to inner bearing contact position.
<- Go to Section TOC Section 02 page 117 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
Dimension I
Example of Dimension I
165 mm
Axle Center Line-to-Inner Bearing Contact
6.5 in.
LEGEND:
41 Dimension II
b.
Dimension II
Record etched number at end of pinion shaft as dimension II (41).
Dimension II
Example of Dimension II
127 mm
Dimension II Etched on Top of Pinion Gear
5 in.
LEGEND:
29 Inner Pinion Bearing
31 Inner Bearing Cup
c.
Dimension III
Rotate inner pinion bearing (29) in both directions several times while recessed in inner bearing cup (31) to determine
roller setting.
d. Measure and record bearing width from flat side of inner bearing cup to flat surface of inner pinion bearing as dimension
III.
Dimension III
e. Subtract dimension I from sum of dimensions II and III to determine number of shims required behind pinion shaft inner
bearing cup.
<- Go to Section TOC Section 02 page 118 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
Shim Calculation
=1.59 mm
Result
=0.10 in.
=1.60 mm
Required Shim
=0.10 in.
[27] -
CAUTION:
Prevent possible burn injury when handling heated components. Use appropriate hand protection.
LEGEND:
24 Pinion
29 Inner Pinion Bearing
248°F
[28] -
→NOTE:
If shim (32) was replaced, install a spacer ring (28) adjusted by same correction value.
LEGEND:
28 Spacer Ring
<- Go to Section TOC Section 02 page 119 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
[29] -
LEGEND:
24 Pinion
25 Outer Pinion Bearing
[30] -
CAUTION:
Prevent possible burn injury when handling heated components. Use appropriate hand protection.
248°F
[31] -
LEGEND:
1 Nut
2 Input Flange
11 Disk Carrier
<- Go to Section TOC Section 02 page 120 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
443 lb.-ft.
20 lb.-in.
7 lb.-in.
[35] -
LEGEND:
28 Spacer Ring
[36] -
LEGEND:
1 Nut
2 Input Flange
11 Disk Carrier
<- Go to Section TOC Section 02 page 121 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
[37] -
LEGEND:
22 Pin (2 used)
Pin Installation
Install pins (22).
[38] -
LEGEND:
20 Disk and Plate Assembly
<- Go to Section TOC Section 02 page 122 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
[39] -
LEGEND:
14 Piston
15 O-Ring
17 Inner O-Ring
18 Outer O-Ring
Piston O-Rings
[42] -
LEGEND:
12 Outer Spring (14 used)
13 Inner Spring (14 used)
Spring Installation
Install outer springs (12) and inner springs (13).
[43] -
<- Go to Section TOC Section 02 page 123 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
5 Cap Screw (4 used)
6 Nut (2 used)
9 Cover
11 Disk Carrier
34 lb.-ft.
[45] -
LEGEND:
4 Shaft Seal
42 JDG10527 Park Brake Seal Drive
[46] - Install park brake seal using JDG10527 Park Brake Seal Driver (42).
Park Brake Seal Driver
JDG10527
Used to install park brake seal.
[47] -
LEGEND:
2 Input Flange
43 Dust Cover
[48] - Install dust cover into input flange (2) until bottomed.
[49] -
LEGEND:
1 Nut
2 Input Flange
Input Flange
Install input flange (2).
[50] - Rotate pinion in both directions several times while tightening input flange nut (1).
Item Measurement Specification
443 lb.-ft.
[51] -
LEGEND:
8 Park Brake Release Screw (2 used)
44 Locking Nut (2 used)
1.1 in.
34 lb.-ft.
<- Go to Section TOC Section 02 page 125 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
[2] - Apply pressure to park brake using a hydraulic hand pump or park brake release screws. If park brake release screws are
used, return them to original position after test is complete.
[3] - Turn pinion in both directions to determine gear-tooth contact pattern. If pattern is not correct, cone point distance must
be increased or decreased.
Action:
LEGEND:
1 Coast Side (concave)
2 Drive Side (convex)
Result:
YES:Checks complete.
NO:Contact pattern at top of gear tooth indicates pinion shim is too thick. Go to Cone Point Decrease . Contact pattern at
bottom of gear tooth indicated pinion shim is too thin. Go to Cone Point Increase.
( 2 ) Cone Point Increase
Action:
<- Go to Section TOC Section 02 page 126 315SK Backhoe Loader Repair
Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
LEGEND:
1 Coast Side (concave)
2 Drive Side (convex)
Result:
Action:
LEGEND:
1 Coast Side (concave)
2 Drive Side (convex)
<- Go to Section TOC Section 02 page 127 315SK Backhoe Loader Repair
TRANSMISSION (g) by Belgreen v2.0
Result:
<- Go to Section TOC Section 03 page 128 315SK Backhoe Loader Repair
315SK Backhoe Loader Repair (g) by Belgreen v2.1
Section 03 - TRANSMISSION
Table of contents
Group 0300 - Removal and Installation ................................................................................................ 1
Transmission Remove and Install ......................................................................................................... 1
Group 0315 - Controls Linkage ............................................................................................................ 11
Transmission Control Lever (TCL) Remove and Install ........................................................................ 11
Group 0350 - Gear, Shafts, and Power Shift Clutches ..................................................................... 13
Transmission Outer Components Removal ......................................................................................... 13
Transmission Case Disassemble—Torque Converter Side .................................................................. 17
Clutch Packs Remove ......................................................................................................................... 20
High Range Forward, Low Range Forward, and Reverse Clutch Packs Disassemble and Assemble
..................................................................................................................................................... 25
First Speed and Third Speed Clutch Disassemble and Assemble ....................................................... 41
Second Speed Clutch Disassemble and Assemble .............................................................................. 57
Mechanical Front Wheel Drive (MFWD) Clutch Disassemble and Assemble ....................................... 66
Pump Drive Shaft Install ..................................................................................................................... 75
Clutch Packs Install ............................................................................................................................. 77
Transmission Case Assemble—Torque Converter Side ....................................................................... 82
Transmission Outer Components Install ............................................................................................. 86
Group 0360 - Hydraulic System ........................................................................................................... 90
Transmission Charge Pump Remove and Install ................................................................................. 90
Transmission Charge Pump Disassemble and Assemble .................................................................... 95
SPECIFICATIONS
247 kg
Transmission Weight (approximate)
545 lb.
73 N·m
Transmission-to-Flywheel Housing Cap Screw Torque
54 lb.-ft.
320 N·m
Mounting Bracket-to-Transmission Cap Screw Torque
236 lb.-ft.
275 N·m
Isolator-to-Frame Cap Screw Torque
203 lb.-ft.
73 N·m
Flex Plate Cap Screw Torque
54 lb.-ft.
[1] -
[4] - Remove rear axle drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[5] -
LEGEND:
1 Cap Screw (4 used)
2 Washer (4 used)
3 Floor Plate
4 Cap Screw (4 used)
5 Washer (4 used)
6 Floor Plate
[6] - Remove cap screws (4), washers (5), and floor plate (6).
[7] -
LEGEND:
Y1 Transmission Forward Direction Solenoid
Y2 Transmission Reverse Direction Solenoid
Y3 Transmission Speed Solenoid 1
Y7 Park Brake Release Solenoid
Y10 Differential Lock Solenoid
[8] - Drain transmission and hydraulic reservoir. See Change Transmission Oil and Replace Filter and see Change Hydraulic
Reservoir Oil . (Operator’s Manual.)
[9] -
LEGEND:
8 Transmission Oil Cooler Hose (2 used)
B6 Torque Converter Oil Temperature Sensor
B14 Transmission Output Speed Sensor (if equipped)
[10] - Tag and disconnect torque converter oil temperature sensor (B6) and transmission output speed sensor (B14) (if
equipped).
[11] -
LEGEND:
9 Cap Screw (3 used)
10 Transmission Solenoid Guard
[12] -
LEGEND:
Y4 Transmission Speed Solenoid 2
Y5 Transmission Speed Solenoid 3
Y6 Transmission Speed Solenoid 4 (if equipped)
Y11 Mechanical Front Wheel Drive (MFWD) Solenoid
[13] - Remove hydraulic pump. See Hydraulic Pump Remove and Install . (Group 2160.)
[14] -
[15] - Tag and disconnect differential lock hose and park brake hose (13 and 14). Close all openings with caps and plugs.
[16] -
LEGEND:
16 Cap Screw (2 used)
17 Transmission Fill Tube
[17] -
LEGEND:
19 Cap Screw (2 used)
20 Access Plate
21 Flywheel Housing
22 Plug
23 JDG820 Flywheel Turning Tool
24 Flex Plate Cap Screw (4 used)
25 Transmission-To-Flywheel Housing Cap Screw (12 used)
[18] - Remove plug (22) located at right front side of flywheel housing, and insert JDG820 Flywheel Turning Tool (23). Turn
flywheel to remove flex plate cap screws (24).
Flywheel Turning Tool
JDG820
Used to turn flywheel when installing flex plate-to-flywheel cap screws.
[19] -
→NOTE:
Upper six transmission-to-flywheel housing cap screws (25) must be left in place until engine and
transmission are supported.
[20] -
Kremnut Fasteners
LEGEND:
27 RIVNUT® (kremnut) (2 used)
Install RIVNUT ™ ® fasteners (27) in outside holes in frame near flywheel housing. See RIVNUT® (KREMNUT) Fasteners
Remove and Install . (Group 1740.)
[21] -
→NOTE:
When installing the DFT1285 or DFT1285A Engine Support Bracket (30), use M10 cap screws that are at
least 80 mm (3 in.) in length and with 40 mm (1.5 in.) of thread.
and nuts (34). See DFT1285 Engine Support Bracket . (Group 9900.)
[22] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Item Measurement Specification
545 lb.
LEGEND:
36 JT01642A Low-Lift Transmission Jack
37 Shim (2 used)
38 D01004AA Universal Mounting Arm (2 used)
39 Angle Bracket
a. Install appropriately sized shim (37) between jack and bottom of transmission as shown.
b. Raise and adjust low-lift jack until jack mounting plate and block are tight against bottom of transmission.
c. Fasten jack to transmission using D01004AA Universal Mounting Arms (38).
d. To provide as much offset and stability as possible, fasten angle brackets (39) to transmission so each points in opposite
direction, then fasten mounting arms to opposite (diagonal) corners of mounting plate.
e. Make sure all mounting arm hardware is tight before removing transmission.
[23] -
[24] - Remove mounting bracket-to-transmission cap screws (43), washers (44), and mounting brackets (42) from
transmission.
[26] -
IMPORTANT:
Torque converter can fall out of housing. Care must be taken when removing transmission with torque
converter.
LEGEND:
45 Torque Converter
Torque Converter
Move transmission away from engine until torque converter (45) clears flywheel housing.
[27] - Lower transmission until top of transmission clears bottom of battery box or fuel tank.
[28] - Carefully move jack and transmission out from under machine.
[29] - Repair or replace transmission as necessary. See Transmission Outer Components Removal . (Group 0350.)
[30] - Position transmission (with torque converter) under machine using low lift jack. Carefully raise transmission and slide
into engine.
[31] - Install transmission-to-flywheel housing cap screws (25) and torque to specification.
Item Measurement Specification
54 lb.-ft.
[32] -
IMPORTANT:
Prevent possible damage to transmission case and mounting bracket-to-transmission cap screws (43).
Ensure washers (44) are installed. If washers are not installed damage to cap screws (43) may occur.
Install mounting brackets (42), mounting bracket-to-transmission cap screws (43), washers (44), and isolator-to-frame cap
screws (41). Tighten to specification.
Item Measurement Specification
236 lb.-ft.
203 lb.-ft.
[33] - Remove angle brackets, D01004AA Universal Mounting Arms, and JT01642A Low-Lift Transmission Jack.
[34] - Remove nuts, cap screws, washers, spacers, and DFT1285 Engine Support Bracket.
[35] - Use JDG820 Flywheel Turning Tool to turn flywheel and install four flex plate cap screws. Tighten cap screws to
specification.
Item Measurement Specification
54 lb.-ft.
[39] - Connect brake boost return hose and brake boost pressure hose.
[40] - Install hydraulic pump. See Hydraulic Pump Remove and Install . (Group 2160.)
[43] - Connect torque converter oil temperature sensor and transmission cooler hoses.
[44] - Fill transmission and hydraulic reservoir. See Change Transmission Oil and Replace Filter and see Change Hydraulic
Reservoir Oil . (Operator’s Manual.)
[46] - Install floor plate (6), washers (5), and cap screws (4).
[47] - Install floor plate (3), washers (2), cap screws (1), and floor mat.
[48] - Install rear axle drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[50] - Remove shop stands from under machine and lower machine to ground.
[3] -
LEGEND:
4 Cap Screw (2 used)
5 Transmission Control Lever (TCL)
X48 Transmission Control Lever (TCL) Connector
[9] - Install upper steering console cover and cap screws (1).
ESSENTIAL TOOLS
JDG10476 Bracket
[1] -
→NOTE:
Following procedure is to remove all transmission outer components in order to disassemble inner
transmission.
[3] -
LEGEND:
1 Filter Head
2 Cap Screw (2 used)
Filter Head
[4] -
LEGEND:
3 O-Ring (2 used)
[5] -
LEGEND:
5 Dipstick Tube
[6] -
LEGEND:
7 Output Flange
Output Flange
Remove output flange (7).
[7] -
LEGEND:
Y1 Transmission Forward Direction Solenoid
Y2 Transmission Reverse Direction Solenoid
Y3 Transmission Speed Solenoid 1
Y4 Transmission Speed Solenoid 2
Y5 Transmission Speed Solenoid 3
Transmission Speed Solenoid 4 (not used on 210K and
Y6
310K machines)
Y7 Park Brake Release Solenoid
Y10 Differential Lock Solenoid
Y11 Mechanical Front Wheel Drive (MFWD) Solenoid
Transmission Solenoids
Tag and remove solenoids (Y1—Y7, Y10, and Y11).
[8] -
LEGEND:
14 Directional Clutch Orifice
15 1st Speed Clutch Orifice
16 2nd Speed Clutch Orifice
17 3rd Speed Clutch Orifice
[9] -
LEGEND:
18 Plug
19 Plug
20 Plug
Plugs
Remove plugs (18—20).
[2] -
→NOTE:
Transmission pump cannot be removed until transmission case is separated and transmission pump inner
cap screws have been removed.
Remove transmission charge pump. See Transmission Charge Pump Remove and Install . (Group 0360.)
[3] -
[4] -
LEGEND:
4 Plug
5 O-Ring
6 Torque Converter Bell Housing
[6] -
LEGEND:
11 Plug
12 O-Ring
13 Piston
14 O-Ring (2 used)
15 Compression Spring
16 System Relief Port
[7] -
LEGEND:
18 Torque Converter Safety Valve
[8] -
→NOTE:
Remove pins (20) only if necessary.
LEGEND:
20 Pin (2 used)
21 Screen
22 Set Screw
SPECIFICATIONS
42 kg
Transmission Case Half Weight (approximate)
93 lb.
27 kg
Second, Third, and MFWD Clutch Pack Weight (approximate)
60 lb.
[1] - Remove torque converter. See Torque Converter Remove and Install . (Group 0651.)
[2] -
LEGEND:
1 Cap Screw (2 used)
2 Transmission Filter Assembly
[3] -
LEGEND:
3 Dowel Pin (2 used)
4 Socket Head Cap Screw (24 used)
[4] - Remove socket head cap screws (4) from transmission housing.
[5] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
6 Lifting Bracket (2 used)
7 MFWD Output Shaft (if equipped)
8 Seal Guard
9 Cap Screw (8 used)
93 lb.
93 lb.
[6] -
→NOTE:
Shown with 5X3 transmission clutch pack assembly with MFWD, 210K and 310K machines do not have
third speed clutch pack.
LEGEND:
12 High Range Forward Clutch Pack
13 Low Range Forward Clutch Pack
14 Reverse Clutch Pack
15 First Speed Clutch Pack
16 Second Speed Clutch Pack
17 Third Speed Clutch Pack
Mechanical Front Wheel Drive (MFWD) Clutch Pack (if
18
equipped)
Clutch
Before removing clutch packs from case, mark clutch packs and transmission case for aid of assembly.
[8] - Remove low range forward clutch pack (13) and reverse clutch pack (14) together.
[9] - Slightly lift second speed clutch pack (16) and remove first speed clutch pack (15).
[10] -
LEGEND:
16 Second Speed Clutch Pack
17 Third Speed Clutch Pack
Mechanical Front Wheel Drive (MFWD) Clutch Pack (if
18
equipped)
19 Eyebolt M8 X 1 (2 used)
20 Screen Sheet
[11] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
60 lb.
[12] -
LEGEND:
21 Snap Ring
22 Pump Drive Shaft
[13] -
LEGEND:
22 Pump Drive Shaft
23 Snap Ring
24 Ball Bearing
[14] -
LEGEND:
25 O-Ring (2 used)
26 Bearing Cup (5 used)
[15] -
IMPORTANT:
Internal transmission damage can occur if bearing cone and cup are replaced separately. If either bearing
cone or cup requires replacement, replace both as a set.
→NOTE:
Mark bearing cup (26) and transmission case for aid of assembly.
[16] -
LEGEND:
27 Cap Screw (2 used)
28 Oil Suction Tube
29 Bearing Cup (7 used)
[17] -
IMPORTANT:
Internal transmission damage can occur if bearing cone and cup are replaced separately. If either bearing
cone or cup requires replacement, replace both as a set.
→NOTE:
Mark bearing cup (29) and transmission case for aid of assembly.
High Range Forward, Low Range Forward, and Reverse Clutch Packs
Disassemble and Assemble
Specifications
SPECIFICATIONS
20 N
Clutch End Plate Force (approximate)
4.5 lbf
1.4—1.7 mm
High Range Forward Clutch (K4) Pack Plate Clearance
0.055—0.067 in
2.0—2.3 mm
Low Range Forward Clutch (KV) and Reverse Clutch (KR) Pack Plate Clearance
0.079—0.091 in
Essential Tools
ESSENTIAL TOOLS
[1] -
→NOTE:
Disassembly and assembly of high range forward directional clutch (K4) pack, low range forward clutch
(KV) pack, and reverse clutch (KR) packs are the same.
LEGEND:
5 Seal Ring
Seal Ring
Remove seal ring (5).
[2] -
LEGEND:
6 Bearing Puller
7 Inner Disc Carrier
8 Thrust Washer
9 Needle Bearing
10 Beveled Thrust Washer
11 Bearing
Bearing Puller
[3] -
LEGEND:
12 Needle Bearing (2 used)
[4] -
LEGEND:
8 Thrust Washer
9 Needle Bearing
10 Beveled Thrust Washer
[5] -
LEGEND:
13 Snap Ring
Snap Ring
Remove snap ring (13).
[6] -
LEGEND:
14 Retainer
15 Disc and Plate Assembly
16 End Plate
[7] -
LEGEND:
17 Snap Ring
Snap Ring
Remove snap ring (17).
[8] -
LEGEND:
18 JDG10510 Assembly Aid
19 Snap Ring
Snap Ring
Use JDG10510 Assembly Aid (18) to remove snap ring (19).
Assembly Aid
JDG10510
Used to preload compression spring to remove and install snap ring.
[9] -
LEGEND:
20 Compression Spring
21 Retainer
[10] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
LEGEND:
22 Oil Passage
23 Piston
Piston
Remove piston (23) using compressed air through oil passage (22).
[11] -
<- Go to Section TOC Section 03 page 30 315SK Backhoe Loader Repair
Section 03 - TRANSMISSION Group 0350: Gear, Shafts, and Power Shift Clutches
LEGEND:
23 Piston
24 O-Ring
25 O-Ring
Piston O-Rings
Remove O-rings (24 and 25) from piston (23).
[12] -
LEGEND:
26 Seal Ring
27 Bearing
28 Snap Ring
29 Gear
30 Drum
31 Shaft
[13] -
IMPORTANT:
Prevent damage to gear (29), drum (30), and shaft (31). Do not disassemble. Gear, drum, and shaft are
serviced as an assembly.
[14] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
[16] -
LEGEND:
26 Seal Ring
27 Bearing
Install bearing (27) onto clutch shaft with a press, applying pressure to bearing inner race with appropriate diameter driver.
[18] -
IMPORTANT:
Prevent damage to clutch pack. Inspect O-rings before installing piston.
LEGEND:
23 Piston
24 O-Ring
25 O-Ring
Piston O-Rings
Apply transmission oil to O-rings (24 and 25).
[20] -
LEGEND:
23 Piston
Piston
[21] -
LEGEND:
20 Compression Spring
21 Retainer
[22] -
LEGEND:
18 JDG10510 Assembly Aid
19 Snap Ring
Snap Ring
Preload compression spring using JDG10510 Assembly Aid and install snap ring (19).
[23] -
LEGEND:
17 Snap Ring
Snap Ring
Install snap ring (17).
[24] -
LEGEND:
14 Retainer
20 Compression Spring
23 Piston
32 Input Shaft
Retainer
[25] -
→NOTE:
High range forward clutch (K4) uses seven plates and seven discs. Low range forward clutch (KV) and
reverse clutch (KR) uses 10 plates and 10 discs.
LEGEND:
33 Disc (K4, 7 used; KV and KR, 10 used)
34 Plate (K4, 7 used; KV and KR, 10 used)
[26] -
LEGEND:
13 Snap Ring
16 End Plate
End Plate
Install end plate (16) with flat side facing down.
[28] -
a. Apply specified force to end plate (16) and set dial indicator to zero.
Item Measurement Specification
4.5 lbf
0.055—0.067 in
Low Range Forward and Reverse Clutch Pack Plate Clearance 2.0—2.3 mm
0.079—0.091 in
c. Allowable clearance is obtained with end plate snap ring (13) thickness.
[29] -
LEGEND:
8 Thrust Washer
9 Needle Bearing
10 Beveled Thrust Washer
[30] -
IMPORTANT:
Prevent internal transmission damage. Do not install beveled thrust washer with bevel side toward
needle bearing. Install flat surface of thrust washer facing needle bearings.
Install beveled thrust washer (10) with beveled side facing toward snap ring of clutch pack.
[32] -
LEGEND:
12 Needle Bearing (2 used)
[33] -
LEGEND:
7 Inner Disc Carrier
8 Thrust Washer
9 Needle Bearing
10 Beveled Thrust Washer
11 Bearing
[35] -
IMPORTANT:
Prevent internal transmission damage. Do not install beveled thrust washer with bevel side toward
needle bearing. Install flat surface of thrust washer facing needle bearings.
Install beveled thrust washer (10) with beveled side facing toward bearing (11).
[36] - Install bearing (11) onto clutch shaft with a press, applying pressure to bearing inner race with appropriate diameter
driver.
[37] -
LEGEND:
5 Seal Ring
22 Oil Passage
Seal Ring
Install seal ring (5).
[38] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
Check closing and opening of clutch by applying compressed air through oil passage (22).
SPECIFICATIONS
20 N
Applied to Clutch End Plate Force (approximate)
4.5 lb.
2.0—2.3 mm
First Speed Clutch (K1) Distance
0.079—0.118 in.
1.8—2.1 mm
Third Speed Clutch (K3) Distance
0.071—0.083 in.
Essential Tools
ESSENTIAL TOOLS
[1] -
LEGEND:
1 Seal Ring
Seal Ring
Remove seal ring (1).
[2] -
LEGEND:
2 Disk Carrier
3 Bearing
4 Beveled Thrust Washer
5 Needle Bearing
6 Thrust Washer
Disk Carrier
[3] -
LEGEND:
7 Needle Bearing (2 used)
35 Bushing
[5] -
LEGEND:
8 Thrust Washer
9 Needle Bearing
10 Beveled Thrust Washer
[6] -
LEGEND:
11 Snap Ring
Snap Ring
Remove snap ring (11).
[7] -
LEGEND:
12 End Plate
13 Disk and Plate Assembly
14 Disk Spring
[10] -
LEGEND:
15 Snap Ring (2 used)
30 JDG10510 Assembly Aid
Snap Ring
Press compression spring using JDG10510 Assembly Aid (30) to remove snap rings (15).
Assembly Aid
JDG10510
Used to remove compression spring snap ring.
[11] -
LEGEND:
16 Retainer
17 Compression Spring
[12] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
LEGEND:
18 Oil Passage
19 Piston
Piston
Remove piston (19) by applying compressed air through oil passage (18).
[13] -
LEGEND:
19 Piston
20 O-Ring
21 O-Ring
Piston O-Rings
Remove O-rings (20 and 21) from piston (19).
[14] -
LEGEND:
22 Seal Ring
23 Bearing
[15] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
IMPORTANT:
Damage will occur if gear (24), drum (25), and input shaft (26) are disassembled. Gear, drum, and shaft
are serviced as an assembly.
LEGEND:
24 Gear
25 Drum
26 Input Shaft
[17] -
LEGEND:
22 Seal Ring
23 Bearing
[19] -
LEGEND:
19 Piston
20 O-Ring
21 O-Ring
Piston O-Rings
Install O-rings (20 and 21) onto piston (19).
[20] -
LEGEND:
30 JDG10510 Assembly Aid
Piston
Install piston using JDG10510 Assembly Aid (30).
Assembly Aid
JDG10510
Used to install clutch piston.
[21] -
LEGEND:
16 Retainer
17 Compression Spring
[22] -
LEGEND:
15 Snap Ring (2 used)
30 JDG10510 Assembly Aid
Snap Ring
Press compression spring using JDG10510 Assembly Aid (30) and install snap rings (15).
[23] -
LEGEND:
14 Disk Spring
17 Compression Spring
19 Piston
26 Input Shaft
Disk Spring
[24] -
→NOTE:
Third speed clutch uses nine plates and nine disks.
LEGEND:
27 Disk (10 used)
28 Plate (10 used)
[25] -
LEGEND:
11 Snap Ring
12 End Plate
[27] -
LEGEND:
12 End Plate
a. Apply approximately 20 N (4.5 lb.-force) of force to end plate (12) and set dial indicator to zero.
Item Measurement Specification
4.5 lb.
b. Using screwdrivers, pry up on end plate and record the disk clearance.
Item Measurement Specification
0.079—0.118 in.
0.071—0.083 in.
c. Allowable clearance is obtained with end plate snap ring (11) thickness.
[28] -
IMPORTANT:
Internal transmission damage will occur if beveled thrust washer is installed with bevel side toward
needle bearing. Install flat surface of thrust washer facing needle bearings.
LEGEND:
8 Thrust Washer
9 Needle Bearing
10 Beveled Thrust Washer
[29] - Install beveled thrust washer (10) with beveled side facing toward snap ring of clutch pack.
[31] -
LEGEND:
7 Needle Bearing (2 used)
35 Bushing
[33] -
LEGEND:
2 Disk Carrier
3 Bearing
4 Beveled Thrust Washer
5 Needle Bearing
6 Thrust Washer
[34] -
IMPORTANT:
Internal transmission damage will occur if beveled thrust washer is installed with bevel side toward
needle bearing. Install flat surface of thrust washer facing needle bearings.
[35] - Install beveled thrust washer (4) with beveled side facing toward bearing (3).
[36] - Install bearing (3) onto clutch shaft with a press, applying pressure to bearing inner race with appropriate diameter
driver.
[37] -
LEGEND:
1 Seal Ring
29 Oil Passage
[38] - Check closing and opening of clutch by applying compressed air through oil passage (29).
SPECIFICATIONS
20 N
End Plate Force (approximate)
4.5 lbf
2.20—2.50 mm
Second Speed Clutch (K2) Clearance
0.087—0.098 in
Essential Tools
ESSENTIAL TOOLS
DISASSEMBLE
[1] -
LEGEND:
1 Seal Ring
[2] -
LEGEND:
2 Bearing Puller
3 Tapered Roller Bearing
4 Snap Ring
Snap Ring
[5] -
Bearing Puller
LEGEND:
5 Bearing Puller
6 Tapered Roller Bearing
7 Disc Carrier
8 Gear Hub
[6] - Remove tapered roller bearing (6) and gear hub (8).
[7] -
IMPORTANT:
Avoid transmission component damage. DO NOT reuse end plate snap ring when servicing second speed
clutch (K2) assembly. Always replace with new snap ring.
LEGEND:
11 End Plate Snap Ring
12 End Plate
14 Clutch Plate (13 used)
15 Clutch Disc (13 used)
16 Cup Spring
[9] - Remove clutch plates (14), clutch discs (15), and cup spring (16).
[10] -
LEGEND:
9 Tapered Roller Bearing
10 Bearing Puller
Bearing Puller
Attach bearing puller (10) to tapered roller bearing (9).
[12] -
LEGEND:
13 JDG10510 Assembly Aid
18 Thrust Washer
23 Disc Spring (7 used)
24 Snap Ring (2 used)
Snap Rings
Apply pressure to thrust washer (18) using JDG10510 Assembly Aid (13) and remove snap rings (24).
[14] -
CAUTION:
Using compressed air can cause the piston to come out at a high rate of speed. Personal injury can
occur. Wear proper face and body protection when using compressed air.
LEGEND:
17 Oil Passage
25 O-Ring (2 used)
26 Piston
Piston
Remove piston (26) by applying compressed air through oil passage (17).
[16] -
IMPORTANT:
Damage to clutch will occur if gears (19 and 20), shaft (21), and disc carrier (7) are disassembled. Gears,
shaft, and disc carrier are serviced as an assembly.
LEGEND:
7 Disc Carrier
19 Gear
20 Helical Gear
21 Shaft
ASSEMBLE
LEGEND:
18 Thrust Washer
23 Disc Spring (7 used)
IMPORTANT:
Beginning with convex side facing thrust washer, install disc springs (23) by alternating between convex
side and concave side to avoid transmission component damage.
[1] -
Dimension I and II
a. Using a depth gauge and straight edge, measure distance between top of gear hub (8) and bottom of tapered roller
bearing (9) and record as dimension I (32).
b. Using a depth gauge and straight edge, measure distance between top of gear hub (8) and top of tapered roller bearing
(6) and record as dimension II (33).
c. Calculate inner disc carrier dimension (34) by subtracting dimension I by dimension II.
d. Using a depth gauge and straight edge, measure distance between top of snap ring groove and top of snap ring (24) and
record as dimension III (35).
e. Calculate snap ring (4) thickness (36) by subtracting dimension III (35) by inner disc carrier dimension (34). See example:
→NOTE:
Snap ring (4) is available in following thicknesses between 2.00 mm—4.00 mm (0.08 in—0.16 in), in 0.25
mm (0.01 in) increments.
Example
89.75 mm
Dimension I (example)
3.533 in
32.85 mm
Dimension II (example)
1.293 in
59.50 mm
Dimension III (example)
2.343 in
[2] -
LEGEND:
31 Dial Indicator
a. Apply specified force to end plate (12) and set dial indicator (31) to zero.
Item Measurement Specification
4.5 lbf
0.087—0.098 in
SPECIFICATIONS
120°C
Bearing Temperature
248°F
20 N
End Plate Force (approximate)
4.5 lb
2.3—2.8 mm
MFWD Clutch (VA) End Plate Distance
0.091—0.110 in
Essential Tools
ESSENTIAL TOOLS
[1] -
LEGEND:
1 Seal Ring
2 Bearing
[3] -
LEGEND:
3 Beveled Thrust Washer
4 Inner Disc Carrier
[5] -
IMPORTANT:
Avoid transmission component damage. DO NOT reuse end plate snap ring (5) when servicing MFWD
clutch assembly. Always replace with new snap ring.
LEGEND:
5 End Plate Snap Ring
[6] -
LEGEND:
6 Plate and Disc Assembly
7 End Plate
[7] -
LEGEND:
8 Snap Ring
DFT1163 MFWD Snap Ring Removal and Installation
9
Tool
10 Washer
11 Disc Spring (7 used)
[9] -
CAUTION:
Using compressed air can cause the piston to come out at a high rate of speed. Personal injury can
occur. Wear proper face and body protection when using compressed air.
LEGEND:
12 Oil Passage
13 Piston
14 Bearing
Piston Removal
<- Go to Section TOC Section 03 page 69 315SK Backhoe Loader Repair
Section 03 - TRANSMISSION Group 0350: Gear, Shafts, and Power Shift Clutches
Apply compressed air through oil passage (12) to remove piston (13).
[11] -
IMPORTANT:
Damage will occur to shaft (15) and drum (16) if disassembled. Shaft and drum are serviced as an
assembly only.
LEGEND:
15 Shaft
16 Drum
[12] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
LEGEND:
12 Oil Passage
13 Piston
14 Bearing
25 JDG10510 Clutch Assembly Aid
Bearing Installation
[13] -
CAUTION:
Prevent possible burns. Use appropriate hand protection when handling hot components.
248°F
[14] - Install piston (13) using JDG10510 Clutch Assembly Aid (25).
Clutch Assembly Aid
JDG10510
Press piston into place.
[15] -
LEGEND:
10 Washer
11 Disc Spring (7 used)
[16] -
LEGEND:
8 Snap Ring
9 DFT1163 MFWD Snap Ring Removal and Installation Tool
[17] -
LEGEND:
22 Disc (12 used)
23 Plate (12 used)
[18] -
LEGEND:
5 Snap Ring
7 End Plate
[19] -
IMPORTANT:
Avoid transmission component damage. DO NOT reuse end plate snap ring (5) when servicing MFWD
clutch assembly. Always replace with new snap ring.
[20] -
LEGEND:
7 End Plate
17 Dial Indicator
a. Apply specified force to end plate (7) and set dial indicator (17) to zero.
Item Measurement Specification
4.5 lb
0.091—0.110 in
[21] -
LEGEND:
3 Beveled Thrust Washer
4 Inner Disc Carrier
[23] -
CAUTION:
Prevent possible burns. Use appropriate hand protection when handling hot components.
LEGEND:
1 Seal Ring
2 Bearing
24 Oil Passage
248°F
[25] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
Check closing and opening of clutch by use of compressed air through oil passage (24).
[3] -
LEGEND:
2 Pump Drive Shaft
4 Snap Ring
SPECIFICATIONS
27 kg
Second, Third, and MFWD Clutch Pack Weight (approximate)
60 lb.
42 kg
Transmission Case Half Weight (approximate)
93 lb.
20 N·m
Transmission Case Mounting Cap Screw Initial Torque
177 lb.-in.
65 N·m
Transmission Case Mounting Cap Screw Final Torque
48 lb.-ft.
Other Material
OTHER MATERIAL
[1] -
LEGEND:
27 Cap Screw (2 used)
28 Oil Suction Tube
29 Bearing Cup (7 used)
[2] - Install oil suction tube (28) and cap screws (27).
[3] -
LEGEND:
25 O-Ring (2 used)
26 Bearing Cup (5 used)
[4] -
→NOTE:
Use petroleum jelly to hold O-rings (25) in place during assembly.
[5] -
→NOTE:
210K and 310K machines do not have a third speed clutch pack.
LEGEND:
16 Second Speed Clutch Pack
17 Third Speed Clutch Pack
18 MFWD Clutch Pack (if equipped)
19 Eyebolt (M8 X 1.0) (2 used)
20 Screen Sheet
30 Sealing Ring (2 used)
31 Sealing Ring
32 Pilot Hole (2 used)
33 Alignment Pin (2 used)
[6] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Align alignment pins (33) with pilot holes (32) and install clutch packs (16—18) together with screen sheet.
Item Measurement Specification
60 lb.
[7] -
LEGEND:
15 First Speed Clutch
34 Sealing Ring (2 used)
[8] -
LEGEND:
13 Low Range Forward Clutch Pack
14 Reverse Clutch Pack
35 Sealing Ring (2 used)
36 Sealing Ring (3 used)
[9] -
LEGEND:
12 High Range Forward Clutch
37 Sealing Ring (2 used)
[10] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
→NOTE:
Alignment pins (33) must be installed properly into pilot holes (32) when transmission halves are joined.
LEGEND:
6 Lifting Bracket (2 used)
33 Alignment Pin (2 used)
Transmission Case
Install lifting brackets (6) and attach appropriate lifting device.
[11] - Clean mating surfaces of transmission case halves with PM37509 Klean ‘N Prime.
[12] - Apply PM38657 High Flex Form-In-Place Gasket to mating surfaces of transmission halves.
93 lb.
[14] -
LEGEND:
3 Dowel Pin (2 used)
4 Cap Screw (24 used)
5 Wiring Harness Retaining Bracket (2 used)
7 Lifting Bracket
[15] - Install wiring harness retaining brackets (5), lifting bracket (7), and cap screws (4). Tighten to initial torque specification.
Item Measurement Specification
177 lb.-in.
48 lb.-ft.
SPECIFICATIONS
50 N·m
System Relief Plug Torque
37 lb.-ft.
46 N·m
Transmission Bell Housing Cap Screw Torque
34 lb.-ft.
25 N·m
Plug Torque
18 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
Other Material
OTHER MATERIAL
[1] -
IMPORTANT:
Damage to clutches and torque converter will result if cooling and lubrication pressure is reduced. On
210K and 310K only, install set screw into front transmission case.
LEGEND:
20 Pin (2 used)
21 Screen
22 Set Screw
[4] -
LEGEND:
18 Torque Converter Safety Valve
19 JDG10480 Valve Installer
[5] -
→NOTE:
Transmission system pressure must be checked after system relief piston has been removed or replaced.
See Transmission System Pressure Test . (Group 9020-25).
LEGEND:
11 Plug
12 O-Ring
13 Piston
14 O-Ring (2 used)
15 Compression Spring
16 System Relief Port
37 lb.-ft.
[7] -
LEGEND:
6 Torque Converter Bell Housing
10 M10 Guide Screw (2 used)
[8] -
IMPORTANT:
Transmission case may leak if gasket sealer is applied to transmission case. Apply gasket sealer to
mating surface of torque convertor bell housing (6) only.
Apply PM37509 Klean ‘N Prime and PM38657 High Flex Form-In-Place Gasket to mating surfaces of torque converter bell
housing (6).
[9] - Install torque converter bell housing and remove M10 guide screws.
[10] -
34 lb.-ft.
[11] -
LEGEND:
4 Plug
5 O-Ring
6 Torque Converter Bell Housing
18 lb.-ft.
[12] - Install charge pump. See Transmission Charge Pump Remove and Install . (Group 0360.)
SPECIFICATIONS
15 N·m
Plug (18) Torque
133 lb.-in.
28 N·m
Plug (19) Torque
21 lb.-ft
6 N·m
Plug (20) Torque
53 lb.-in.
10 N·m
Orifice Torque
89 lb.-in.
23 N·m
Filter Head Cap Screw Torque
204 lb.-in.
Essential Tools
ESSENTIAL TOOLS
[1] -
LEGEND:
18 Plug
19 Plug
20 Plug
Plugs
Install plugs (18—20). Tighten to specification.
Item Measurement Specification
133 lb.-in.
21 lb.-ft
53 lb.-in.
[2] -
LEGEND:
14 Directional Clutch Orifice
15 First Speed Clutch Orifice
16 Second Speed Clutch Orifice
17 Third Speed Clutch Orifice
89 lb.-in.
[3] -
LEGEND:
Y1 Transmission Forward Direction Solenoid
Y2 Transmission Reverse Direction Solenoid
Y3 Transmission Speed Solenoid 1
Y4 Transmission Speed Solenoid 2
Y5 Transmission Speed Solenoid 3
Transmission Speed Solenoid 4 (not used on 210K and
Y6
310K machines)
Y7 Park Brake Release Solenoid
Y10 Differential Lock Solenoid
Y11 Mechanical Front Wheel Drive (MFWD) Solenoid
Transmission Solenoids
Install transmission forward and reverse direction solenoids (Y1 and Y2).
[4] - Install transmission speed solenoids 1, 2, 3, and 4 (Y3, Y4, Y5, and Y6).
[5] - Install park brake release solenoid (Y7), differential lock solenoid (Y10), and mechanical front wheel drive (MFWD)
solenoid (Y11).
[6] -
LEGEND:
7 Rear Output Flange
9 Seal
10 Seal Guard
11 Dust Cover
12 Transmission Housing
[7] - Press dust cover (11) into rear output flange (7) until bottomed.
[9] -
LEGEND:
5 Dipstick Tube
[10] -
LEGEND:
1 Filter Head
2 Cap Screw (2 used)
3 O-Ring (2 used)
Filter Head
Install new O-rings (3) on filter head (1).
[11] - Install filter head and cap screws (2). Tighten to specification.
Item Measurement Specification
204 lb.-in.
SPECIFICATIONS
42 kg
Transmission Case Half Weight (approximate)
93 lb.
23 N·m
Transmission Charge Pump Inner Cap Screw Torque
17 lb.-ft.
20 N·m
Transmission Case Cap Screw Initial Torque
177 lb.-in.
65 N·m
Transmission Case Cap Screw Final Torque
48 lb.-ft.
23 N·m
Filter Assembly Cap Screw Torque
17 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
Other Material
OTHER MATERIAL
[1] - Park and Prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Remove transmission. See Transmission Remove and Install . (Group 0300.)
[3] - Remove torque converter. See Torque Converter Remove and Install . (Group 0651.)
[4] -
→NOTE:
Transmission charge pump cannot be removed until the transmission case is separated and the
transmission charge pump inner cap screws have been removed.
LEGEND:
1 Cap Screw (2 used)
2 Transmission Oil Filter Assembly
[5] -
LEGEND:
3 Dowel Pin (2 used)
4 Socket Head Cap Screw (24 used)
[6] - Remove socket head cap screws (4) from transmission housing.
[7] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
6 Lifting Bracket (2 used)
7 MFWD Output Shaft
8 Seal Guard
9 Cap Screw (8 used)
93 lb.
[10] -
→NOTE:
Mark transmission charge pump and transmission housing for aid in assembly.
LEGEND:
11 Guide Pin (2 used)
Guide Pins
Install guide pins (11).
[11] -
IMPORTANT:
Avoid damage to transmission charge pump. Transmission charge pump may fall out of transmission case
while removing cap screws (13 and 14) causing damage to transmission charge pump. Hold transmission
charge pump in place while removing cap screws.
LEGEND:
13 Cap Screw (2 used)
14 Cap Screw (2 used)
[15] - Install cap screws (13 and 14) and tighten to specification.
Item Measurement Specification
17 lb.-ft.
17 lb.-ft.
[18] - Clean mating surfaces of transmission halves and apply PM37509 Loctite ™ Klean ′N Prime.
[19] - Apply PM38657 Loctite ™ High Flex Form-In-Place Gasket to mating surfaces of transmission halves.
[20] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Attach appropriate lifting device to lifting brackets and assemble transmission case halves.
Item Measurement Specification
93 lb.
[21] - Align dowel pin holes in transmission case halves and install dowel pins until flush with case.
177 lb.-in.
48 lb.-ft.
[24] -
LEGEND:
8 Seal Guard
16 JDG10482 MFWD Output Shaft Seal Installer
17 MFWD Output Shaft
[25] - Install transmission filter assembly and cap screws. Tighten to specification.
Item Measurement Specification
17 lb.-ft.
[26] - Install torque converter. See Torque Converter Remove and Install . (Group 0651.)
[27] - Install transmission. See Transmission Remove and Install . (Group 0300.)
ESSENTIAL TOOLS
Other Material
OTHER MATERIAL
LEGEND:
1 O-Ring
2 Seal
3 Transmission Charge Pump
[4] - Apply Loctite ™ Klean ‘N Prime™ Primer and Loctite ™ High Flex Form-in-Place Gasket to new seal.
[5] -
→NOTE:
If transmission charge pump is left on transmission while installing new seal, JDG10478 Seal Installer will
not seat seal fully onto pump.
If transmission charge pump has been removed from transmission, install new seal using JDG10478 Seal Installer.
Seal Installer
JDG10478
To install seal on transmission charge pump
<- Go to Section TOC Section 03 page 95 315SK Backhoe Loader Repair
ENGINE (g) by Belgreen v2.0
[6] - If transmission charge pump has not been removed from transmission, install new seal using aftermarket seal installation
tool.
[8] - Fill area between seal lip and dust cover lip with multipurpose grease.
Section 04 - ENGINE
Table of contents
Group 0400 - Removal and Installation ................................................................................................ 1
John Deere Engine Operation ............................................................................................................... 1
Engine Remove .................................................................................................................................... 2
Engine Install ...................................................................................................................................... 19
For additional engine information on John Deere engines and components, see the following component technical manuals
(CTM).
Engine 4045TT096
For additional engine information on John Deere engines and components, see the following component technical manuals
(CTM).
Engine Remove
Engines 4045HT054, 4045HT086, 4045HT087
Specifications
SPECIFICATIONS
247 kg
Transmission Weight (approximate)
545 lb.
483 kg
Engine Weight (approximate)
1065 lb.
Essential Tools
ESSENTIAL TOOLS
[1] - Raise loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Remove grille. See Grille Remove and Install . (Group 1921.)
[5] - Remove hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[6] - Remove cooling package. See Cooling Package Remove and Install . (Group 0510.)
[7] - Remove serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.)
[8] -
LEGEND:
1 Cap Screw (3 used)
Y19 Air Conditioner Compressor Clutch Solenoid
a. Tag and disconnect air conditioner compressor clutch solenoid (Y19) connector.
b. Remove cap screws (1) and lay compressor aside.
[9] -
LEGEND:
2 Battery Power Cable
3 Ground Strap
M1 Starter Motor
W1 Frame Ground Near Starter Motor
Starter Motor
Tag and disconnect battery power cable (2) and ground strap (3) from starter motor (M1).
[10] - Tag and disconnect frame ground near starter motor (W1). See Engine Harness (W10) Component Location . (Group
9015-10.)
[11] - Remove tool box. See Battery Box Remove and Install . (Group 1913.)
[12] -
LEGEND:
4 Cap Screw (2 used)
F1 Main 250 A Fuse
R5 CAN Termination Resistor 1
W10 Engine Harness
X101 MTG 3-Pin Connector (if equipped)
X102 MTG CAN 1 Connector (if equipped)
[13] - Tag and disconnect engine harness (W10) from main 250 A fuse (F1).
[15] - Remove turbocharger and muffler. See Muffler Remove and Install . (Group 0530.)
[16] -
LEGEND:
13 Cap Screw (2 used)
14 Bracket
15 Low Pressure Fuel Line
16 Fuel Filter
B60 Water-in-Fuel Sensor
M17 Fuel Lift Pump
[17] - Disconnect low pressure fuel line (15). Close all openings using caps and plugs.
[18] - Loosen cap screws (13), remove bracket (14), and lay fuel filter (16) assembly aside.
[19] -
LEGEND:
17 Heater Hose (2 used)
Heater Hoses
Disconnect heater hoses (17) and close all openings using caps and plugs.
[20] - Remove start aid solenoid (if equipped). See Start Aid Solenoid Remove and Install—If Equipped . (Group 0505.)
[21] -
[22] - Remove drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0230.)
[23] -
LEGEND:
21 Cap Screw (2 used)
22 Access Plate
23 Flywheel Housing
24 Plug
25 JDG820 Flywheel Turning Tool
26 Flexplate-to-Flywheel Cap Screw (4 used)
27 Transmission-to-Flywheel Housing Cap Screw (12 used)
[24] - Remove plug (24), located at right front side of flywheel housing, and insert JDG820 Flywheel Turning Tool (25).
Flywheel Turning Tool
JDG820
Used to turn flywheel when installing flexplate-to-flywheel cap screws.
[25] - Remove four flexplate-to-flywheel cap screws (26). Use flywheel turning tool to rotate flywheel as necessary.
[26] - Remove eight transmission-to-flywheel housing cap screws (27) from below the machine.
[27] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
545 lb.
[28] -
LEGEND:
29 Cap Screw (8 used)
30 Floor Access Plate
31 Floor Access Plate
Floor Plates
Remove cab floor mat, cap screws (29), and floor access plates (30 and 31).
[29] - Remove the four remaining transmission-to-flywheel housing cap screws through front floor access.
[30] -
LEGEND:
X20 Engine Harness-to-Cab/Canopy Harness Connector
X49 Start Aid Switch Harness Connector
X86 Fuel Lift Pump Relay Harness Connector
[31] -
LEGEND:
32 Cap Screw (2 used)
33 Steering and Brake Valve Access Door
[32] - Remove cap screws (32) and open steering and brake valve access door (33).
[33] -
LEGEND:
34 Cap Screw
35 Cap Screw (2 used)
A2 ECU
K5 Starter Relay
X41 ECU 32-Pin Connector
X42 ECU 48-Pin Connector
[34] - Remove cap screw (34 and 35). Lay starter relay (K5) aside.
[35] -
LEGEND:
36 JDG244-1 Lifting Eye
37 JDG244-2 Lifting Eye
38 D01043A Load Positioning Sling
Lifting Eyes
[36] - Install D01043A Load Positioning Sling (38) to lifting eyes (36 and 37).
Load-Positioning Sling
D01043A
Used to remove and install engine.
[37] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Item Measurement Specification
1065 lb.
[38] -
IMPORTANT:
Torque converter and flexplate damage may result. Make sure torque converter stays with transmission,
and take care not to damage torque converter flexplate as engine is being removed.
Engine 4045TT096
Specifications
SPECIFICATIONS
483 kg
Engine Weight (approximate)
1065 lb.
Essential Tools
ESSENTIAL TOOLS
[1] - Raise loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Remove grille. See Grille Remove and Install . (Group 1921.)
[5] - Remove hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[6] - Remove cooling package. See Cooling Package Remove and Install . (Group 0510.)
[7] - Remove serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.)
[8] -
LEGEND:
1 Cap Screw (4 used)
Y19 Air Conditioner Compressor Clutch Solenoid
a. Tag and disconnect air conditioner compressor clutch solenoid (Y19) connector.
b. Remove cap screws (1) and lay compressor aside.
[9] -
LEGEND:
2 Battery Power Cable
3 Ground Strap
M1 Starter Motor
W1 Frame Ground Near Starter Motor
Starter Motor
Tag and disconnect battery power cable (2) and ground strap (3) from starter motor (M1).
[10] - Tag and disconnect frame ground near starter motor (W1). See Engine Harness (W10) Component Location . (Group
9015-10.)
[11] - Remove tool box. See Battery Box Remove and Install . (Group 1913.)
[12] -
LEGEND:
4 Cap Screw (2 used)
F1 Main 250 A Fuse
R5 CAN Termination Resistor 1
W10 Engine Harness
X101 MTG 3-Pin Connector (if equipped)
[13] - Tag and disconnect engine harness (W10) from main 250 A fuse (F1).
[15] - Remove turbocharger and muffler. See Muffler Remove and Install . (Group 0530.)
[16] -
LEGEND:
13 Cap Screw (2 used)
14 Bracket
15 Low Pressure Fuel Line
16 Fuel Filter
B60 Water-in-Fuel Sensor
R26 Fuel Filter Heater (if equipped)
[17] - Disconnect low pressure fuel line (15). Close all openings using caps and plugs.
[18] - Loosen cap screws (13), remove bracket (14), and lay fuel filter (16) assembly aside.
[19] -
LEGEND:
17 Heater Hose (2 used)
Heater Hoses
Disconnect heater hoses (17) and close all openings using caps and plugs.
[20] - Remove start aid solenoid (if equipped). See Start Aid Solenoid Remove and Install—If Equipped . (Group 0505.)
[21] -
[22] - Remove drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0230.)
[23] -
LEGEND:
21 Cap Screw (2 used)
22 Access Plate
23 Flywheel Housing
24 Plug
25 JDG820 Flywheel Turning Tool
26 Flexplate-to-Flywheel Cap Screws (4 used)
Transmission-to-Flywheel Housing Cap Screws (12
27
used)
[24] - Remove plug (24), located at right front side of flywheel housing, and insert JDG820 Flywheel Turning Tool (25).
Flywheel Turning Tool
JDG820
Used to turn flywheel when installing flexplate-to-flywheel cap screws.
[25] - Remove four flexplate-to-flywheel cap screws (26). Use flywheel turning tool to rotate flywheel as necessary.
[26] - Remove eight transmission-to-flywheel housing cap screws (27) from below the machine.
[27] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
545 lb.
[28] -
LEGEND:
29 Cap Screw (8 used)
30 Floor Access Plate
31 Floor Access Plate
Floor Plates
Remove cab floor mat, cap screws (29), and floor access plates (30 and 31).
[29] - Remove the four remaining transmission-to-flywheel housing cap screws through front floor access.
[30] -
LEGEND:
X20 Engine Harness-to-Cab/Canopy Harness Connector
X49 Start Aid Switch Harness Connector
[31] -
LEGEND:
32 Cap Screw (2 used)
33 Steering and Brake Valve Access Door
[32] - Remove cap screws (32) and open steering and brake valve access door (33).
[33] -
LEGEND:
35 Cap Screw (2 used)
A2 ECU
K5 Starter Relay
X10 Engine Control Unit (ECU) Connector
[34] - Remove cap screws (35) and lay starter relay (K5) aside.
[35] -
LEGEND:
36 JDG244-1 Lifting Eye
37 JDG244-2 Lifting Eye
38 D01043A Load Positioning Sling
Lifting Eyes
[36] - Install D01043A Load Positioning Sling (38) to lifting eyes (36 and 37).
Load-Positioning Sling
D01043A
Used to remove and install engine.
[37] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Item Measurement Specification
1065 lb.
[38] -
IMPORTANT:
Torque converter and flexplate damage may result. Make sure torque converter stays with transmission,
and take care not to damage torque converter flexplate as engine is being removed.
Engine Install
Engines 4045HT054, 4045HT086, 4045HT087
Specifications
SPECIFICATIONS
483 kg
Engine Weight (approximate)
1065 lb.
73 N·m
Tansmission-to-Flywheel Housing Cap Screw Torque
54 lb.-ft.
73 N·m
Torque Converter Flexplate-to-Flywheel Cap Screw Torque
54 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
[1] -
LEGEND:
36 JDG244-1 Lifting Eye
37 JDG244-2 Lifting Eye
[2] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Item Measurement Specification
1065 lb.
IMPORTANT:
Torque converter and flexplate damage may result. Make sure torque converter is fully seated on
transmission input shaft, and take care not to damage torque converter flexplate as engine is being
installed.
Carefully lower engine into position using appropriate lifting device. Adjust engine height and angle using D01043A Load
Positioning Sling (38), so front of oil pan clears frame and engine aligns with transmission.
Load-Positioning Sling
D01043A
Used to remove and install engine.
LEGEND:
38 D01043A Load Positioning Sling
[3] -
[4] - Install engine mount cap screws (41), washers (40), and nuts (39).
[5] - Install remaining transmission-to-flywheel housing cap screws through floor access. Tighten to specification.
Item Measurement Specification
54 lb.-ft.
[6] - Use JDG820 (26) to rotate flywheel and install flexplate-to-flywheel cap screws (24). Tighten to specification.
Item Measurement Specification
54 lb.-ft.
[8] -
LEGEND:
21 Cap Screw (2 used)
22 Access Plate
23 Flywheel Housing
[9] - Remove JDG820 Flywheel Turning Tool and install plug (24).
Flywheel Turning Tool
JDG820
Used to turn flywheel when installing flexplate-to-flywheel cap screws.
[10] - Install drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0230.)
[11] -
<- Go to Section TOC Section 04 page 21 315SK Backhoe Loader Repair
Section 04 - ENGINE Group 0400: Removal and Installation
[12] - Install start aid solenoid (if equipped). See Start Aid Solenoid Remove and Install—If Equipped . (Group 0505.)
[13] -
LEGEND:
17 Heater Hose (2 used)
Heater Hoses
Connect heater hoses (17).
[14] -
LEGEND:
13 Cap Screw (2 used)
14 Bracket
15 Low Pressure Fuel Line
16 Fuel Filter
B60 Water-in-Fuel Sensor
M17 Fuel Lift Pump
[15] - Connect low pressure fuel line (15), fuel lift pump (M17) electrical connector, and water-in-fuel sensor (B60) electrical
connector.
[16] -
LEGEND:
34 Cap Screw
35 Cap Screw (2 used)
A2 ECU
K5 Starter Relay
X41 ECU 32-Pin Connector
X42 ECU 48-Pin Connector
[17] - Install starter relay (K5) and cap screws (34 and 35).
[18] -
LEGEND:
X20 Engine Harness-to-Cab/Canopy Harness Connector
X49 Start Aid Switch Harness Connector
X86 Fuel Lift Pump Relay Harness Connector
[19] -
LEGEND:
32 Cap Screw (2 used)
33 Steering and Brake Valve Access Door
[20] - Install engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[21] -
LEGEND:
29 Cap Screw (8 used)
30 Floor Access Plate
31 Floor Access Plate
[22] - Install muffler and turbocharger. See Muffler Remove and Install . (Group 0530.)
[23] -
LEGEND:
4 Cap Screw (2 used)
F1 Main 250 A Fuse
R5 CAN Termination Resistor 1
W10 Engine Harness
Modular Telematics Gateway (MTG) 3-Pin Connector
X101
(if equipped)
Modular Telematics Gateway (MTG) CAN 1 Connector
X102
(if equipped)
[25] - Connect engine harness (W10) to main 250 A fuse (F1) and install cap screws (4).
[26] - Install tool box. See Battery Box Remove and Install . (Group 1913.)
[27] -
LEGEND:
2 Battery Power Cable
3 Ground Strap
M1 Starter Motor
W1 Frame Ground Near Starter Motor
Starter Motor
Connect battery power cable (2) to starter motor (M1).
[28] - Connect ground strap (3) to starter motor and connect frame ground near starter motor (W1).
[29] -
LEGEND:
1 Cap Screw (3 used)
Y19 Air Conditioner Compressor Clutch Solenoid
[30] - Install serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.)
[31] - Install cooling package. See Cooling Package Remove and Install . (Group 0510.)
[32] - Install hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[33] - Install grille. See Grille Remove and Install . (Group 1921.)
[34] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[35] - Remove service lock and lower loader boom. See Loader Boom Service Lock . (Operator’s Manual.)
Engine 4045TT096
Specifications
[1] - SPECIFICATIONS
483 kg
Engine Weight (approximate)
1065 lb.
73 N·m
Tansmission-to-Flywheel Housing Cap Screw Torque
54 lb.-ft.
73 N·m
Torque Converter Flexplate-to-Flywheel Cap Screw Torque
54 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
LEGEND:
36 JDG244-1 Lifting Eye
37 JDG244-2 Lifting Eye
[2] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Item Measurement Specification
1065 lb.
IMPORTANT:
Torque converter and flexplate damage may result. Make sure torque converter is fully seated on
transmission input shaft, and take care not to damage torque converter flexplate as engine is being
installed.
Carefully lower engine into position using appropriate lifting device. Adjust engine height and angle using D01043A Load
Positioning Sling (38), so front of oil pan clears frame and engine aligns with transmission.
Load-Positioning Sling
D01043A
Used to remove and install engine.
LEGEND:
38 D01043A Load Positioning Sling
[3] -
[4] - Install engine mount cap screws (41), washers (40), and nuts (39).
54 lb.-ft.
[6] - Use JDG820 (26) to rotate flywheel and install flexplate-to-flywheel cap screws (24). Tighten to specification.
Item Measurement Specification
54 lb.-ft.
[8] -
LEGEND:
21 Cap Screw (2 used)
22 Access Plate
23 Flywheel Housing
[9] - Remove JDG820 Flywheel Turning Tool and install plug (24).
Flywheel Turning Tool
JDG820
Used to turn flywheel when installing flexplate-to-flywheel cap screws.
[10] - Install drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0230.)
[11] -
<- Go to Section TOC Section 04 page 29 315SK Backhoe Loader Repair
Section 04 - ENGINE Group 0400: Removal and Installation
[12] - Install start aid solenoid (if equipped). See Start Aid Solenoid Remove and Install—If Equipped . (Group 0505.)
[13] -
LEGEND:
17 Heater Hose (2 used)
Heater Hoses
Connect heater hoses (17).
[14] -
LEGEND:
13 Cap Screw (2 used)
14 Bracket
15 Fuel Line
16 Fuel Filter
B60 Water-in-Fuel Sensor
R26 Fuel Filter Heater (if equipped)
[16] - Connect water-in-fuel sensor (B60) and fuel filter heater (R26) (if equipped) electrical connectors.
[17] -
LEGEND:
35 Cap Screw (2 used)
A2 ECU
K5 Starter Relay
X10 ECU Connector
[19] -
LEGEND:
X20 Engine Harness-to-Cab/Canopy Harness Connector
X49 Start Aid Switch Harness Connector
[20] -
LEGEND:
32 Cap Screw (2 used)
33 Steering and Brake Valve Access Door
[21] - Install engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[22] -
LEGEND:
29 Cap Screw (8 used)
30 Floor Access Plate
31 Floor Access Plate
Floor Plates
Install floor access plates (30 and 31), cap screws (29), and cab floor mat.
[23] - Install muffler and turbocharger. See Muffler Remove and Install . (Group 0530.)
[24] -
LEGEND:
4 Cap Screw (2 used)
F1 Main 250 A Fuse
R5 CAN Termination Resistor 1
W10 Engine Harness
X101 MTG 3-Pin Connector (if equipped)
[25] - Connect engine harness (W10) to main 250 A fuse (F1) and install cap screws (4).
[26] - Install tool box. See Battery Box Remove and Install . (Group 1913.)
[27] -
LEGEND:
2 Battery Power Cable
3 Ground Strap
M1 Starter Motor
W1 Frame Ground Near Starter Motor
Starter Motor
Connect battery power cable (2) to starter motor (M1).
[28] - Connect ground strap (3) to starter motor and connect frame ground near starter motor (W1).
[29] -
LEGEND:
1 Cap Screw (4 used)
Y19 Air Conditioner Compressor Clutch Solenoid
[30] - Install serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.)
[31] - Install cooling package. See Cooling Package Remove and Install . (Group 0510.)
[32] - Install hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[33] - Install grille. See Grille Remove and Install . (Group 1921.)
[34] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[35] - Disengage service lock and lower loader boom. See Loader Boom Service Lock . (Operator’s Manual.)
Coolant Heater
Specifications
SPECIFICATIONS
34 N·m
Coolant Heater Lock Nut Torque
25 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Raise loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[4] - Drain cooling system. See Draining the Cooling System . (Operator′s Manual.)
[7] - Remove adapter (4) and heater element (7) from engine block.
[8] -
CAUTION:
Prevent possible personal injury from bursting sheath. Test coolant heater in liquid only. Do not plug
coolant heater into electrical power unless heating element is immersed in coolant.
[11] - Turn heater element until it comes in contact with engine casting. Move heater element to centered position.
[12] - Hold heater element in centered position and tighten lock nut to specification.
Item Measurement Specification
25 lb.-ft.
[13] - Connect power cord and secure with plastic tie bands.
[14] - Refill cooling system. See Filling the Cooling System . (Operator′s Manual.)
[2] - Raise loader boom and install boom service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[4] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Station.)
[5] -
LEGEND:
1 Starting Aid Tube
2 Nozzle
3 Nozzle Holder
[10] -
→NOTE:
Arrow on nozzle holder indicates direction of nozzle.
[12] - Turn battery disconnect switch (if equipped) to ON or connect the battery ground cable.
[14] - Disengage boom service lock and lower loader boom to ground.
[2] - Raise loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[4] -
LEGEND:
1 Start Fluid Container
2 Start Aid Tube
3 Cap Screw and Nut (2 used)
4 Electrical Connector
Y15 Start Aid Solenoid
[7] - Disconnect electrical connector (4) and remove start aid solenoid (Y15).
[14] - Disengage boom lock bar and lower loader boom to ground.
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[4] - Remove serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.)
[5] -
LEGEND:
1 Cap Screw (3 used)
2 Fan Guard
3 Cap Screw (4 used)
4 Grille Housing Support
[6] - Remove cap screws (3) and remove grille housing support (4).
[7] -
LEGEND:
5 Hose Clamp
6 Charge Air Cooler Tube
[8] -
LEGEND:
7 Fan Cap Screw (4 used)
8 Fan
9 Spacer Cap Screw (4 used)
10 Spacer
Engine Fan
Remove fan cap screws (7) and slide fan (8) toward engine.
[9] - Remove spacer cap screws (9) and remove spacer (10) with fan.
[14] - Connect charge air cooler tube and tighten hose clamp.
[15] - Install serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.)
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[4] -
LEGEND:
1 Square Hole
2 Serpentine Belt Tensioner
[8] -
[10] - Disengage loader boom service lock and lower loader to ground.
SPECIFICATIONS
24 kg
Hydraulic/Transmission Radiator Weight (approximate)
64 lb.
28 kg
Radiator Weight (approximate)
75 lb.
[1] - Raise loader boom and install boom service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Remove grille. See Grille Remove and Install . (Group 1921.)
[4] - Remove hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[5] - Drain cooling system. See Draining the Cooling System . (Operator’s Manual.)
[6] -
LEGEND:
1 Latch (2 used)
2 Air Conditioner Condenser/Fuel Cooler Bracket
3 Socket Head Cap Screw (2 used)
[8] -
LEGEND:
5 Cap Screw (2 used)
[9] - Machines Equipped with Engines 4045HT4054, 4045HT063, 4045HT072, or 4045HT073 Only.
Remove charge air cooler. See Charge Air Cooler Remove and Install . (Group 0520.)
[10] - Remove horn. See Horn Remove and Install . (Group 2004.)
[11] -
LEGEND:
8 Hydraulic/Transmission Radiator Vent Hose (2 used)
9 Hydraulic/Transmission Radiator Inlet Hose
10 Hydraulic/Transmission Radiator Outlet Hose
[12] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
12 Hydraulic/Transmission Radiator
13 Clip (2 used)
14 Lockout Bracket
15 Latch (2 used)
16 Cap Screw (2 used)
Hydraulic/Transmission Radiator
Remove clips (13) and lockout bracket (14).
64 lb.
[16] -
LEGEND:
18 Hose Clamp
19 Upper Radiator Hose
20 Radiator Vent Hose
[17] -
LEGEND:
22 Cap Screw (3 used)
23 Fan Guard
24 Hose Clamp
25 Lower Radiator Hose
26 Radiator
27 Cap Screw (6 used)
28 Bracket (2 used)
[18] - Loosen hose clamp (24) and disconnect lower radiator hose (25). Close all openings using caps and plugs.
[19] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
75 lb.
[21] -
<- Go to Section TOC Section 05 page 10 315SK Backhoe Loader Repair
Section 05 - ENGINE AUXILIARY SYSTEM Group 0510: Cooling Systems
LEGEND:
30 Hose Clamp
31 Radiator Drain Hose
32 Cap Screw (4 used)
33 Washer (4 used)
34 Fan Shroud
35 Clip (4 used)
36 Pin (4 used)
37 Bracket (2 used)
Radiator
Loosen hose clamp (30) and remove lower radiator hose. Close all openings using caps and plugs.
[22] - Disconnect radiator drain hose (31). Close all openings using caps and plugs.
[23] - Remove cap screws (32), washers (33), and fan shroud (34).
[24] - Remove clips (35), push out pins (36), and remove brackets (37).
[28] - Connect radiator drain hose and lower radiator hose. Tighten hose clamp (30).
[29] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
75 lb.
[31] - Connect lower radiator hose and tighten hose clamp (24)
[33] - Install radiator vent hose, upper radiator hose, and tighten hose clamp (18).
[34] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
64 lb.
[36] - Connect latches (15), install lockout bracket, and clips (13).
[37] - Connect hydraulic/transmission radiator vent hoses, hydraulic/transmission radiator inlet hose, and
hydraulic/transmission radiator outlet hose.
[38] - Install horn. See Horn Remove and Install . (Group 2004.)
[39] - Machines Equipped with Engines 4045HT4054, 4045HT063, 4045HT072, or 4045HT073 Only.
Install charge air cooler. See Charge Air Cooler Remove and Install . (Group 0520.)
[40] - Install air conditioner condenser/fuel cooler bracket and cap screws (5).
[42] - Close air conditioner condenser/fuel cooler bracket, and hook latches (1).
[43] - Fill cooling system. See Filling the Cooling System . (Operator’s Station.)
[44] - Install hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[45] - Install grille. See Grille Remove and Install . (Group 1921.)
[46] - Remove boom service lock and lower loader boom to ground. See Loader Boom Service Lock . (Operator’s Manual.)
SPECIFICATIONS
88 kg
Cooling Package Weight (approximate)
236 lb.
[1] - Raise loader boom and install boom service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Remove grille. See Grille Remove and Install . (Group 1921.)
[4] - Remove hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[5] - Drain cooling system. See Draining the Cooling System . (Operator’s Manual.)
[6] -
LEGEND:
1 Latch (2 used)
2 Air Conditioner Condenser/Fuel Cooler Bracket
3 Socket Head Cap Screw (2 used)
[8] -
LEGEND:
5 Cap Screw (2 used)
[9] - Remove horn. See Horn Remove and Install . (Group 2004.)
[10] -
LEGEND:
8 Cap Screw (6 used)
9 Fan Gaurd (2 used)
10 Cap Screw (8 used)
11 Washer (8 used)
12 Grille Housing support (2 used)
[11] - Remove cap screws (10), washers (11), and grille housing supports (12).
[12] -
LEGEND:
14 Hose Clamp (4 used)
15 Charge Air Cooler Tube (2 used)
16 Hose Clamp (2 used)
17 Air Intake Tube
18 Hose Clamp (2 used)
19 Upper Radiator Hose
20 Thermostat Housing Vent Hose
B109 Air Filter Restriction Switch
[14] - Loosen hose clamps (16) and remove air intake tube (17). Close all openings with caps and plugs.
[15] - Loosen hose clamps (18) and remove upper radiator hose (19).
[17] -
LEGEND:
22 Thermal Bypass Valve Supply Hose
23 Oil Cooler Supply Hose
24 Coolant Pump Supply Hose
25 Hose Clamp
26 Lower Radiator Hose
Coolant Hoses
[18] -
LEGEND:
29 Cap Screw (2 used)
30 Washer (2 used)
31 Bushing (2 used)
32 Cap Screw (2 used)
33 Washer (4 used)
34 Nut (2 used)
35 Grille Housing
36 Cooling Package
Cooling Package
Remove cap screws (29), washers (30), and bushings (31).
[19] - Remove cap screws (32), washers (33), and nuts (34).
[20] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
<- Go to Section TOC Section 05 page 15 315SK Backhoe Loader Repair
Section 05 - ENGINE AUXILIARY SYSTEM Group 0515: Speed Controls
236 lb.
[26] - Connect lower radiator hose, tighten hose clamp (25), and connect hose (22—24).
[28] - Connect thermostat housing vent hose, install upper radiator hose, and tighten hose clamps (18).
[29] - Install air intake tube, tighten hose clamps (16), and connect air filter restriction switch.
[31] - Install grille housing supports, washers (11), and cap screws (10).
[33] - Install horn. See Horn Remove and Install . (Group 2004.)
[34] - Install air conditioner condenser/fuel cooler bracket and cap screws (5).
[36] - Fold in air conditioner condenser/fuel cooler bracket and hook latches (1).
[37] - Fill cooling system. See Filling the Cooling System . (Operator’s Manual.)
[38] - Install hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[39] - Install grille. See Grille Remove and Install . (Group 1921.)
[40] - Remove boom service lock and lower loader boom to ground. See Loader Boom Service Lock . (Operator’s Manual.)
[2] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to OFF position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[3] -
LEGEND:
1 Engine Speed Control Pedal Cover
2 Cap Screw (3 used)
B20 Engine Speed Control Pedal
[4] -
LEGEND:
3 Engine Speed Control Pedal Electrical Connector
4 Cap Screw (3 used)
B20 Engine Speed Control Pedal
[5] - Remove cap screws (4) and engine speed control pedal.
[7] - Install engine speed control pedal and cap screws (4).
[9] - Install engine speed control pedal cover and cap screws (2).
[10] - Turn battery disconnect switch (if equipped) to ON or connect battery ground cable.
[11] - Check operation of engine speed control pedal. See Engine Speed Check . (Group 9010-25.)
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[4] -
LEGEND:
1 Cap Screw (3 used)
2 Fan Guard
3 Cap Screw (4 used)
4 Grille Housing Support
5 Hose Clamp (2 used)
6 Turbocharger-to-Charge Air Cooler Tube
7 Hose Clamp (2 used)
8 Air Cleaner-to-Turbocharger Tube
B109 Air Filter Restriction Switch
Fan Guard
Remove cap screws (1) and remove fan guard (2).
[5] - Remove cap screws (3) and remove grille housing support (4).
[6] -
→NOTE:
Machines with engine 4045TT096 are not equipped with a charge air cooler.
If equipped, loosen hose clamps (5) and remove turbocharger-to-charge air cooler tube (6).
[7] - Loosen hose clamps (7) and remove air cleaner-to-turbocharger tube (8).
[9] -
LEGEND:
9 Nut (2 used)
10 Thermal Bypass Valve
11 Cap Screw (4 used)
12 Washer (4 used)
13 Air Cleaner
14 Bolt (2 used)
15 Mounting Bracket
[11] - Remove cap screws (11), washers (12), and air cleaner (13).
[14] - Install thermal bypass valve, pressing bolts through mounting bracket holes.
[15] - Slide thermal bypass valve towards engine and tighten nuts (9).
[17] - Install air cleaner-to-turbocharger tube and tighten hose clamps (7).
[18] - Install turbocharger-to-charge air cooler tube and tighten hose clamps (5).
[21] - Close hood, disengage service lock, and lower loader boom. See Loader Boom Service Lock . (Operator’s Manual.)
[2] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Remove grille. See Grille Remove and Install . (Group 1921.)
[5] -
LEGEND:
1 Rubber Deflector (2 used)
2 Clamp (2 used)
3 Latch (2 used)
4 Cap Screw with Bushing (2 used)
5 Charge Air Cooler
[8] - Remove cap screws with bushings (4) and charge air cooler (5).
[10] - Install charge air cooler and cap screws with bushings.
[14] - Disengage boom service lock and lower loader boom to ground.
SPECIFICATIONS
70 N·m
Turbocharger Cap Screws Torque
52 lb.-ft.
7.5 N·m
Muffler Clamp Torque
66 lb.-in.
24 N·m
Oil Inlet Line Torque
212 lb.-in.
24 N·m
Oil Return Line Cap Screw Torque
212 lb.-in.
6 N·m
Hose Clamp Torque
53 lb.-in.
[1] - Raise loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[4] -
LEGEND:
1 Hose Clamp
2 Hose Clamp
3 Turbocharger Intake Tube
4 Turbocharger Outlet Tube
5 Muffler Clamp
6 Oil Inlet Line
7 Cap Screw (2 used)
8 Oil Return Line with Gasket
9 Cap Screw (4 used)
10 Turbocharger with Gasket
Engine 4045TT096
Loosen hose clamps (1 and 2).
[5] - Disconnect turbocharger intake tube (3) and turbocharger outlet tube (4).
[6] - Disconnect oil Inlet line (6), remove cap screws (7), and disconnect oil return line with gasket (8). Close all openings using
caps and plugs.
[8] - Remove muffler clamp (5), cap screws (9), and turbocharger with gasket (10).
[10] -
LEGEND:
11 Cap Screw (2 used)
12 Muffler
Muffler
Remove cap screws (11), rotate muffler (12) clockwise, and remove.
[13] - Install turbocharger with gasket and cap screws (9). Tighten to specification.
Item Measurement Specification
52 lb.-ft.
66 lb.-in.
212 lb.-in.
[16] - Connect oil return line with gasket, and cap screws (7). Tighten to specification.
Item Measurement Specification
212 lb.-in.
[17] - Connect turbocharger intake tube and turbocharger outlet tube. Tighten hose clamps to specification.
Item Measurement Specification
53 lb.-in.
[19] - Disengage service lock and lower loader boom to ground. See Loader Boom Service Lock . (Operator’s Manual.)
SPECIFICATIONS
155 L
Fuel Tank Capacity (approximate)
41 gal.
56 kg
Fuel Tank Weight (approximate)
124 lb.
Other Material
OTHER MATERIAL
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
CAUTION:
Prevent fire or explosion, handle fuel carefully. If engine is hot or running, DO NOT drain fuel tank. DO
NOT smoke while draining fuel tank or working on fuel system.
→NOTE:
To ensure that all of fuel drains properly, use right stabilizer to lift right rear wheel off ground.
LEGEND:
1 Drain Screw
41 gal.
[3] -
LEGEND:
2 Fuel Tank Vent Hose
3 Fuel Return Hose
4 Fuel Supply Hose
5 Electrical Connector
B8 Fuel Level Sensor
[4] - Disconnect electrical connector (5) from fuel level sensor (B8).
[5] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
124 lb.
LEGEND:
7 Cap Screw (6 used)
8 Washer (6 used)
9 Fuel Tank
Fuel Tank
[6] - Remove cap screws (7) and washers (8). Remove fuel tank (9) using appropriate lifting device.
[10] - Connect fuel tank vent hose, fuel return hose, and fuel supply hose.
[11] - Apply PM37509 Cure Primer and then PM37418 Thread Lock and Sealer (medium strength) to drain screw.
[12] - Install drain screw and fill fuel tank to proper level. See Handling and Storing Diesel Fuel . (Operator’s Manual.)
SPECIFICATIONS
46 N·m
Cap Screw Torque
34 lb.-ft.
Other Material
OTHER MATERIAL
[1] -
→NOTE:
Torque converter has no internal service parts. If replacement is necessary, install a new torque
converter.
[2] - Remove cap screws (1), washers (2), and flexplate (3).
[5] - Apply Loctite ™ Klean ‘N Prime™ Primer and Loctite ™ 242® Threadlocker (medium strength) to threads of cap screws.
34 lb.-ft.
[7] - Install transmission. See Transmission Remove and Install . (Group 0300.)
SPECIFICATIONS
30 N·m
Steering Column Nut Torque
22 lb-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain hydraulic reservoir or apply a vacuum to the reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[6] - Remove front console. See Front Console Remove and Install . (Group 1810.)
[7] -
LEGEND:
X48 Transmission Control Lever (TCL) Connector
[8] -
LEGEND:
1 Turn Signal Connector
2 Cap Screw
3 Upper Steering Column Cover
S30 Turn Signal Switch
[9] - Remove cap screw (2) and upper steering column cover (3).
[10] -
LEGEND:
4 Cap Screw (4 used)
5 Lower Steering Column Cover
[11] - Mark steering column for proper alignment to steering valve during assembly.
[12] -
LEGEND:
6 Nut (4 used)
→NOTE:
If cap screws spin, the steering valve needs to be removed to secure cap screw head. See Steering Valve
Remove and Install—Tilt Steering . (Group 0960.)
[14] -
CAUTION:
If steering valve and steering column splines do not line up, loss of steering control will result. Check for
proper spline alignment and engagement.
22 lb-ft.
[18] - Install front console. See Front Console Remove and Install . (Group 1810.)
[20] - Fill hydraulic reservoir to proper level or remove vacuum from reservoir. See Check Hydraulic Reservoir Oil Level .
(Operator′s Manual.)
[21] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
SPECIFICATIONS
48 N·m
Steering Wheel Nut Torque
35 lb.-ft.
[1] -
[2] -
[3] - Remove nut (8), lock washer (9), and steering wheel.
[6] -
[8] - Install steering wheel, lock washer, and nut (8). Tighten to specification.
Item Measurement Specification
35 lb.-ft.
ESSENTIAL TOOLS
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
CAUTION:
Release hydraulic pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain hydraulic reservoir or apply a vacuum to the reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[6] - Remove front console. See Front Console Remove and Install . (Group 1810.)
[7] - Remove engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[8] -
LEGEND:
1 Cap Screw (4 used)
2 Front Floor Access Panel
[9] -
LEGEND:
3 Cap Screw (2 used)
[10] -
LEGEND:
4 Steering Valve-to-Priority Valve Hose (yellow)
5 Steering Valve-to-Steering Cylinder Hose (green)
6 Steering Valve-to-Steering Cylinder Hose (orange)
7 Priority Valve-to-Steering Valve Hose (red)
8 Steering Valve-to-Hydraulic Oil Reservoir Hose (blue)
9 Nut (4 used)
124 Steering Valve
Escaping Fluid
IMPORTANT:
DO NOT pry against release sleeve or damage to fitting may result.
DO NOT force release sleeve beyond normal range of travel, otherwise, release sleeve may fall off
when hose is disconnected. If this happens and fitting is connected without the release sleeve
installed, fitting will not be able to be disconnected again.
→NOTE:
Cap and plug steering valve and hoses using special STC plugs, 62H1028 and 62H1029 and caps
62H1036 and 62H1035. Order caps and plugs through your authorized dealer.
Insert JDG1385 Disconnect Tool between release sleeve and shoulder of fitting.
Snap-to-Connect (STC) ™ Hose and Line Fitting Tool
JDG1385
Used to disconnect quick disconnect hoses.
c. Gently push, DO NOT PRY , release sleeve away from shoulder to disconnect the fitting.
d. Pull hose to disconnect.
[15] - Repair or replace steering valve. See Steering Valve Disassemble and Assemble . (Group 0960.)
[17] -
CAUTION:
Prevent possible injury or death. If steering valve and steering column splines do not line up, loss of
steering control will result. Check for proper spline alignment and engagement.
[18] - Connect hydraulic hoses to the steering valve following color coded guide on access door.
STC Quick Disconnect Lines
a. Make sure fitting halves are clean and free from contaminants.
b. Make sure release sleeve is on male half of fitting before connecting fitting halves together.
c. Push fitting halves together until a definite snap and solid stop is felt.
d. Pull back on hose to make sure fitting halves are locked together.
[19] - Close the steering and brake valve access door and install cap screws.
[21] - Install engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[22] - Install front console. See Front Console Remove and Install . (Group 1810.)
[24] - Fill hydraulic reservoir to proper level or remove vacuum from reservoir. See Check Hydraulic Reservoir Oil Level .
(Operator′s Manual.)
[25] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
<- Go to Section TOC Section 09 page 9 315SK Backhoe Loader Repair
Section 09 - STEERING SYSTEM Group 0960: Hydraulic System
SPECIFICATIONS
17 N·m
End Cap Mounting Cap Screw Initial Torque
150 lb.-in.
28—34 N·m
End Cap Mounting Cap Screw Final Torque
250—300 lb.-in.
50 N·m
Elbow (1) Torque
37 lb.-ft.
73 N·m
Priority Valve Supply Check Valve (2) Torque
54 lb.-ft.
24 N·m
Elbow (3) Torque
18 lb.-ft.
73 N·m
Adaptor (4) Torque
54 lb.-ft.
73 N·m
Elbow (5) Torque
54 lb.-ft.
21 N·m
Elbow (6) Torque
15 lb.-ft.
73 N·m
Elbow (7) Torque
54 lb.-ft.
[1] -
4 Adaptor
5 Elbow
6 Elbow
7 Elbow
124 Steering Valve
Remove elbows (1,3, and 5—7), priority valve supply check valve (2), and adaptor (4) from steering valve.
[2] -
End Cap
LEGEND:
8 Cap Screw
9 Cap Screw
10 Cap Screw
11 Pin
12 Ball
13 Pin (2 used)
14 Ball (2 used)
15 End Cap
16 Gerotor
17 Spacer
18 Housing
19 Cap Screw (4 used)
20 O-Ring
Remove cap screws (8—10) in sequential order. Identify holes to aid in assembly.
[3] - Remove pin (11) and manual steering ball (12) from cap screw (8) hole.
[4] - Remove pins (13) and steel balls (14) from cap screw (9 and 10) holes.
[5] - Mark outside of end cap (15), gerotor (16), spacer (17), and housing (18) to aid in assembly.
[6] - Remove remaining cap screws (19), end cap, and O-ring (20).
[7] -
[8] -
[10] -
[13] -
→NOTE:
Only O-rings (20, 22, 23, and 27), seal (28), and dust seal (29) are serviceable.
[15] - Install seal and O-ring (27). O-ring (27) should rest on lip of seal.
[22] -
Torque Pattern
LEGEND:
30 Cap Screw
31 Cap Screw
32 Cap Screw
33 Cap Screw
34 Cap Screw
35 Cap Screw
36 Cap Screw
Install cap screws (30—36). Tighten to initial specification.
Item Measurement Specification
150 lb.-in.
250—300 lb.-in.
[24] -
37 lb.-ft.
54 lb.-ft.
18 lb.-ft.
54 lb.-ft.
54 lb.-ft.
15 lb.-ft.
54 lb.-ft.
SPECIFICATIONS
7440—12 143 kg
Machine Weight (approximate)
16 387—26 747 lb.
460 N·m
Steering Cylinder Mounting Cap Screw Torque
339 lb.-ft.
300 N·m
Tie Rod-to-Cylinder Rod Torque
221 lb.-ft.
Other Material
OTHER MATERIAL
→NOTE:
Steering cylinder must be removed from machine for service.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device and floor stands
for supporting machine.
Item Measurement Specification
Raise and support front of machine. Position floor stands under main frame.
[4] -
LEGEND:
1 Steering Cylinder Hose (2 used)
2 Tie Rod (2 used)
3 Cylinder Rod
4 Cap Screw (6 used)
125 Steering Cylinder
[6] - Remove mounting cap screws (4) and steering cylinder (125).
[7] - Repair or replace as necessary. See Non-Powered Axle Steering Cylinder Disassemble and Assemble . (Group 0960.)
[8] - Apply PM37421 Thread Lock and Sealer (high strength) to threads of cylinder mounting cap screws, and install cylinder.
Tighten cap screws to specification.
339 lb.-ft.
221 lb.-ft.
[11] - If tie rod, spindle assembly, or steering cylinder are adjusted or serviced, perform the following procedures:
Adjust tracking angle. See Tracking Angle Check and Adjust . (Group 9020-20.)
Adjust toe-in. See Toe-In Check and Adjust . (Group 9020-20.)
Adjust steering angle. See Steering Angle Check and Adjust . (Group 9020-20.)
[2] -
→NOTE:
To aid in assembly, note location of each seal before removal.
LEGEND:
4 External Wiper Seal (2 used)
5 Wear Ring (2 used)
6 Backup Ring (2 used)
7 Internal Wiper Seal (2 used)
8 Wear Ring (2 used)
9 Seal Ring (2 used)
10 Groove
Rod Guide
Inspect wiper seals (4 and 7) and rings (5, 6, 8, and 9) and replace if necessary.
[3] -
LEGEND:
11 Wear Ring (2 used)
12 Cylinder Rod Piston
13 O-Ring
14 Seal Ring
[4] -
[6] - Install rod guides onto cylinder rod (2) and into cylinder body (3).
SPECIFICATIONS
240 N·m
Steering Cylinder Cap Screw Torque
177 lb.-ft.
300 N·m
Steering Cylinder Rod Torque
221 lb.-ft.
Other Material
OTHER MATERIAL
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Raise loader and install boom lock bar. See Loader Boom Service Lock . (Operator’s Manual.)
[3] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[5] -
IMPORTANT:
To avoid damaging seals, do not overheat piston rod. Use a butane torch with low flame. Stop before
heat reaches seals.
→NOTE:
Wrench flats on left end of piston rod are covered by stop collar. Remove left ball joint first if stop collars
are installed on piston rod.
LEGEND:
1 Cylinder Rod
2 Tie Rod
[6] -
[8] - Repair or replace as necessary. See Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Disassemble and
Assemble . (Group 0960.)
[9] -
LEGEND:
6 Anti-Seize Location (2 used)
Anti-Seize Location
177 lb.-ft.
[12] - Apply PM37509 Klean ‘N Prime then PM37418 Thread Lock and Sealer (medium strength) to threads of tie rods.
221 lb.-ft.
[15] - Remove boom lock bar and lower loader. See Loader Boom Service Lock . (Operator’s Manual.)
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.
Steering Cylinder
LEGEND:
1 Snap Ring
2 Snap Ring
3 Seal
4 Seal
5 Seal
6 Plug
7 Piston Rod
8 Hydraulic Cylinder Barrel
9 Seal
10 Seal
11 Seal
12 Bushing
13 Plug (2 used)
15 Snap Ring
16 Flange
17 Seal
18 Seal
Remove snap rings (1 and 2).
[3] -
→NOTE:
Cylinder is full of oil. Use a container to catch oil.
Remove plug (6) and piston rod (7) from hydraulic cylinder barrel (8).
[8] - Remove seals (17 and 18) from hydraulic cylinder barrel.
→NOTE:
The piston seal can be made more pliable by warming it with your hands or by putting seal in hot water
for approximately 5 minutes.
[10] - Apply clean hydraulic oil to seals to aid in assembly of rod and plug.
→NOTE:
Once started, install piston seal as quickly as possible to keep the amount of time the seal is stretched to
a minimum.
[17] - Install seals (5, 4, and 3) and snap rings (2 and 1).
For brake disc and pressure plate remove and install, see Rear Axle Remove and Install , see Rear Axle Disassemble , and see
Rear Axle Assemble . (Group 0250.)
ESSENTIAL TOOLS
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain hydraulic reservoir or apply a vacuum to the reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[6] - Remove front console. See Front Console Remove and Install . (Group 1810.)
[7] - Remove engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[8] -
LEGEND:
1 Cap Screw (4 used)
2 Front Floor Access Panel
[9] -
LEGEND:
3 Cap Screw (2 used)
[10] - Remove cap screws (3) and open the steering and brake valve access door.
[11] -
LEGEND:
4 Protective Boot (2 used)
5 Steering and Brake Valve Drain Line
6 Transmission-to-Brake Valve Line (2 used)
7 Brake Valve-to-Transmission Oil Cooler Line
8 Cap Screw (2 used)
9 Cap Screw (2 used)
76 Service Brake Valve
77 Service Brake Valve-to-Service Brake Line (2 used)
S26 Brake Light Switch 1
S27 Brake Light Switch 2
[12] - Tag and disconnect lines (5—7 and 77) from service brake valve (76). Remove lines with quick disconnect hose fittings
using JDG1385 Disconnect Tool.
Insert JDG1385 Disconnect Tool between release sleeve and shoulder of fitting.
STC Line and Fitting Disconnect Tool
JDG1385
Used to disconnect quick disconnect hoses.
c. Gently push, DO NOT PRY , release sleeve away from shoulder to disconnect the fitting.
d. Pull hose to disconnect.
[14] - Turn out lower cap screws (8) as far as possible without removing cap screws.
[15] - Remove upper cap screws (9) and remove brake valve from pedals.
[16] - Disassemble and repair valve as needed. See Brake Valve Disassemble and Assemble . (Group 1060.)
[17] -
→NOTE:
Fill brake valve with oil and bleed out air before installing on machine.
[20] - Connect lines to appropriate valve port using color coding guide.
[21] - Install electrical connectors to brake light switches and protective boots.
[22] - Close the steering and brake valve access door and install cap screws.
[25] - Install engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[26] - Install front console. See Front Console Remove and Install . (Group 1810.)
[27] - Fill hydraulic oil reservoir to proper level or remove vacuum from hydraulic oil reservoir. See Check Hydraulic Reservoir
Oil Level . (Operator′s Manual.)
[28] - Bleed brake system. See Brake System Bleeding Procedure . (Group 1060.)
[29] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
SPECIFICATIONS
44 N·m
Brake Adapter Valve Assembly Torque
33 lb.-ft.
71 N·m
Brake Valve Fitting and Reducer Torque
53 lb.-ft.
58 N·m
Brake Valve Plug Torque
43 lb.-ft.
34 N·m
Brake Valve Assembly Cap Screws Torque
24 lb.-ft.
[1] -
[2] -
→NOTE:
Do not remove snap rings (4) from push rods (5).
→NOTE:
Note direction of seals (9) and wiper seals (6).
[3] -
→NOTE:
Retainers (8) are held in position by Loctite. ™ It is not necessary to remove retainers (8) to service seals
(6 and 9).
[4] - Check retainers (8) for wear; if necessary, remove snap rings (4) and seals (6 and 9). With housing (3) flange face down in
a vise, use a plastic or wooden dowel through housing (3) bore to evenly tap on retainers (8). An inside bearing puller from
housing (3) flange end can also be used to remove retainers (8).
[5] - Remove retainers (10), O-rings (11), springs (12), and seals (13).
[6] - Remove rings (14), pistons (15), and piston rings (16).
[7] - Remove snap rings (17), lock washers (18), and balls (19) from pistons.
[8] - Remove plugs (20), O-rings (21), springs (22), and washers (23).
[9] -
→NOTE:
Be careful not to scratch or damage spool (25) or housing bore.
[10] - Remove reducer (26), fitting plug (30), O-ring (27), adapter valves (28), and O-rings (21) from housing (29).
[12] - Thoroughly clean housings and all parts with clean solvent and allow to dry before proceeding. Lubricate all rubber
components with clean fluid used in the system.
[13] -
→NOTE:
When servicing brake valve, install all of the brake valve kit parts.
Install O-rings (21) and adapter valves. Tighten adapter valves to specification.
33 lb.-ft.
[14] -
Install O-rings (27), reducer, and fitting plug to housing (29). Tighten fittings to specification.
Item Measurement Specification
53 lb.-ft.
[16] - Install washers (23), springs (22), O-rings (21), and plugs. Tighten plugs to specification.
Item Measurement Specification
43 lb.-ft.
[18] -
→NOTE:
Seals (13) will stretch and become oversized when being installed. These seals must be resized before
final assembly. To resize seals (13), lubricate seals (13), pistons, and housing (3) bores with clean type
fluid used in the system.
[26] - Install cap screws (1) and washers (2). Tighten to specification.
24 lb.-ft.
Remove and install park brake. See Rear Axle Remove and Install and see Park Brake Disassemble and Assemble . (Group
0250.)
Fastener Removal
[1] - Remove flange of RIVNUT ™ using a hammer and chisel. Use care not to damage equipment’s surface under the flange or
the hexagon hole.
Use a punch to remove threaded portion of fastener.
[2] -
LEGEND:
A Hexagon Hole
Hexagon Hole
Select the proper length fastener for the thickness of the material where the fastener will be installed. Fasteners are color-
coded as well as stamped on the flange surface. (Coding indicates the nominal plate thickness for which the fastener can be
used.)
[3] -
IMPORTANT:
DO NOT force or drive fastener into hole. Fastener can be damaged and will not hold securely.
Make sure the new fastener fits easily into the existing hexagon hole (A). If necessary, use a small file to clean the edges of the
hole.
[4] -
LEGEND:
A Large Threads
B Tool Shoulder
C Rivnut Fastener
D Small Threads
JDG894
[6] -
LEGEND:
A Socket Head Screw
B Nut
C Flange
[7] -
IMPORTANT:
NEVER turn or tighten JDG894 Installation Tool socket head screw. Damage to threads of fastener can
occur.
While holding socket head screw (A) stationary, tighten large (1-1/16 in.) nut (B) to specifications using a crowsfoot wrench.
Item Measurement Specification
Front Counterweight
Specifications
SPECIFICATIONS
204—567 kg
Front Counterweight Weight (approximate)
450—1250 lb.
275 N·m
Front Counterweight Cap Screw Torque (lubricated)
205 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Item Measurement Specification
450—1250 lb.
205 lb.-ft.
[9] - Disengage loader boom service lock and lower loader to ground.
SPECIFICATIONS
2.38 kg
Refrigerant Charge (actual) Capacity
5.25 lb.
34.8 qt.
Cooling System Capacity
32.9 L
746 kg
Cab Weight (approximate)
1645 lb.
420 N·m
Operator Station Mounting Cap Screw Torque
310 lb.-ft.
REMOVAL
[1] -
→NOTE:
Cab and canopy operator station remove and install procedures are similar. Cab is shown in illustrations.
Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
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.
Relieve hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025.)
Recover R134a refrigerant. See R134a Refrigerant Recover, Recycle, and Charge Station Installation Procedure and see
R134a Refrigerant Charge Capacity . (Group 1830.)
Drain coolant. See Draining the Cooling System . (Operator’s Manual.)
Item Measurement Specification
5.25 lb.
32.9 L
[4] - Drain hydraulic reservoir or apply a vacuum. See Change Hydraulic Reservoir Oil (Operator’s Manual) or see Apply
Vacuum to Hydraulic Oil Reservoir . (Group 2160.)
[8] - Remove front console. See Front Console Remove and Install . (Group 1810.)
[10] - Disconnect hydraulic hoses (9, 10) from brake valve (129).
LEGEND:
A2 Engine Control Unit (ECU)
X5501 ECU Connector 1
X5502 ECU Connector 2
X5503 ECU Connector 3
[12] - Cab Machines Only: Disconnect heater hoses (11) and air conditioner lines (12) (if equipped).
LEGEND:
11 Heater Hose (2 used)
12 Air Conditioner Line (2 used)
13 Ground Strap
14 Cap Screw
15 Electrical Connector (up to 5 used)
X20 Engine Harness-to-Cab/Canopy Harness Connector
Transmission Harness-to-Cab/Canopy Harness
X21
Connector
[14] - Remove cap screw (14) to disconnect air conditioner lines from bracket.
[16] -
→NOTE:
There may be up to five electrical connectors (15) grouped together depending on machine options.
[17] - Disconnect linkage (16, 17) from loader and stabilizer control valve (190).
LEGEND:
16 Loader Linkage Rod (2—3 used)
17 Stabilizer Linkage Cable (2—3 used)
18 Bracket
190 Loader and Stabilizer Control Valve
[19] - Manual Backhoe Controls: Disconnect backhoe lever linkage and auxiliary pedal(s) (if equipped) from backhoe control
valve.
See Backhoe Control Valve Linkage Remove and Install—Two Lever . (Group 3315.)
See Backhoe Auxiliary Pedal Remove and Install—Fifth and Sixth Functions . (Group 3315.)
→NOTE:
Cap and plug pilot control valve and hoses using 62H1028 and 62H1029 Snap-to-Connect (STC) ™ Plugs,
and 62H1036 and 62H1035 Caps. Order caps and plugs through your authorized dealer.
a. If equipped, disconnect auxiliary pedal linkage from backhoe control valve see Backhoe Auxiliary Pedal Remove and
Install—Fifth and Sixth Functions . (Group 3315.)
b. Disconnect hydraulic hoses (22—25) from pilot enable and pattern select (PEPS) valve (137).
c. Disconnect hydraulic hoses (26, 27) from upper and lower backhoe control valve (145).
d. Disconnect electrical connectors (X52, X53).
[21] - Disconnect cab power lead (35) from starter motor (M1).
LEGEND:
35 Cab Power Lead
M1 Starter Motor
LEGEND:
38 Boom Lock Hook
39 Rod
Boom Lock
[23] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Install DFT1101 Lift Bracket (40) using chains and lifting straps. See DFT1101 Cab and ROPS Lift Bracket . (Group 9900.)
Cab and ROPS Lift Bracket
DFT1101
Used to remove and install cab.
LEGEND:
40 DFT1101 Lift Bracket
41 Lifting Location
42 Lifting Location
1645 lb.
[24] -
→NOTE:
Remove upper half of rubber isolators (47 and 52) after cab is lifted from machine frame.
INSTALLATION
[1] - Install operator station mounting hardware (45—52). Tighten cap screws to specification.
Item Measurement Specification
310 lb.-ft.
[3] - Fill hydraulic reservoir or remove vacuum. See Change Hydraulic Reservoir Oil (Operator’s Manual) or see Apply Vacuum
to Hydraulic Oil Reservoir . (Group 2160.)
If equipped, charge air conditioning system. See R134a Refrigerant Recover, Recycle, and Charge Station Installation
Procedure . (Group 1830.)
Fill radiator with proper coolant. See Heavy Duty Diesel Engine Coolant and see Filling the Cooling System (Operator’s
Manual.)
SPECIFICATIONS
20 N·m.
Jam Nut Torque
177 lb.-in.
10 N·m
Cap Screw Torque
88 lb.-in.
18 N·m
Wiper Arm Nut Torque
160 lb.-in.
[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Remove front console. See Front Console Remove and Install . (Group 1810.)
[3] - Raise hood assembly and remove stationary hood from frame above hydraulic reservoir. See Hood and Engine Enclosure
Disassemble and Assemble . (Group 1910.)
[4] -
LEGEND:
1 Wiper Arm Nut
2 Wiper Arm
3 Pivot Shaft Jam Nut Cover
Wiper Arm
Remove wiper arm nut (1) and wiper arm (2).
[6] -
LEGEND:
5 Cap Screw (2 used)
6 Jam Nut
7 Washer
[8] -
LEGEND:
8 Wiper Motor Electrical Connector
M13 Front Wiper Motor
Wiper Motor
Disconnect front wiper motor electrical connector (8) and remove front wiper motor (M13).
[10] - Install front wiper motor and connect front wiper motor electrical connector.
[11] - Install cap screws, washer, and jam nut. Tighten to specification.
Item Measurement Specification
177 lb.-in.
88 lb.-in.
[12] - Install wiper arm and wiper arm nut. Tighten to specification.
Item Measurement Specification
160 lb.-in.
SPECIFICATIONS
18 N·m
Wiper Arm-to-Pivot Torque
160 lb.-in.
20 N·m
Pivot Shaft Jam Nut Torque
177 lb.-in.
10 N·m
Wiper Motor Mount Cap Screw Torque
88 lb.-in.
[1] - Remove interior headliner. See Headliner Remove and Install . (Group 1810.)
[2] - Remove cab roof. See Cab Roof Remove and Install . (Group 1810.)
[3] -
160 lb.-in.
177 lb.-in.
88 lb.-in.
[12] - Install lock nut and close bottom portion of wiper arm.
[13] - Install headliner See Headliner Remove and Install (Group 1810.)
[14] - Install cab roof. See Cab Roof Remove and Install . (Group 1810.)
[2] -
LEGEND:
1 Cap Screw (4 used)
2 Upper Steering Console Cover
E75 Bucket Position Indicator
[4] - Cab Machines: Disconnect blower mode door motor harness connector (X47).
LEGEND:
4 Cap Screw (2 used)
Blower Mode Door Motor Harness Connector (if
X47
equipped)
[6] -
LEGEND:
5 Cap Screw (4 used)
6 Front Console
[9] - Cab Machines: Connect blower mode door motor harness connector.
[12] - Install upper steering console cover and cap screws (1).
Use Quick Cure Primerless Autoglass Windshield Sealant or equivalent to hold windowpanes in place. DO NOT use any other
type of adhesive other than a urethane. It is also recommended that an auto glass dealer install windowpanes.
IMPORTANT:
Windowpanes must have an ultra-violet barrier around edge of glass since ultra-violet rays will
deteriorate adhesive. Windowpanes ordered through John Deere Parts have ultra-violet barrier. If
windowpane is purchased through a glass dealer, dealer must put an ultra-violet barrier on glass. DO
NOT apply paint to border of glass.
If an auto glass dealer is not installing windowpanes, use the following procedure:
[1] - Purchase urethane adhesive from your local auto glass dealer.
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[4] - Scrape broken glass off existing adhesive. DO NOT remove adhesive from window frame or cab.
[6] - Apply a 12.5 mm (1/2 in.) bead of adhesive on top of existing adhesive.
[7] - Place a new windowpane into position. Use light hand pressure to force windowpane down around edges until even with
metal frame. DO NOT over press adhesive.
[8] - If windowpane is installed directly on cab, use tape to hold it in place while adhesive cures.
Specifications
SPECIFICATIONS
25 N·m
Window-to-Hinge Cap Screw Torque
221 lb.-in.
To remove and install rear side windows (14 and 15) see Fixed Window Remove and Install . (Group 1810.)
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Move middle sliding window (12) and upper sliding window (11) to full down position.
→NOTE:
When removing and installing middle sliding window (12) only. Upper sliding window (11) should be in
full up position. Middle sliding window will start in full down position.
[3] - Remove old flocked rubber from both sides, to just above top of upper and middle sliding windows (11 and 12). A screw
driver may help get end started. Cut rubber approximately 5 cm (2 in.) above top of upper and middle sliding windows.
→NOTE:
Upper sliding window can be removed by guiding side without lock into deep portion of channel until
other side clears the channel.
[4] - Starting with upper sliding window (11), remove one of the latches (9) and raise the upper sliding window until it clears
flocked rubber.
[7] - With lower portion of flocked rubber still in place install middle sliding window (12). Move middle sliding window to full
down position.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Slide middle and upper sliding windows (11 and 12) to full up position.
[3] - Remove cap screws (22) and lower rack step (5) from each side of window.
→NOTE:
Lower fixed window (13) can be removed by guiding into deep portion of aluminum channel on one side
until opposite side is clear of frame.
[4] - Raise lower fixed window (13) until it clears flocked rubber.
[6] - Install lower fixed window (13) by sliding into flocked rubber installed in channel.
→NOTE:
A small rubber disk on bottom of each rack step is present to prevent direct contact between glass and
rack step.
[7] - Install lower rack step (5) to each side of window with cap screws (22).
[1] - Unlock window latches (1) on side window (3) and cab upper door window (4).
[2] - Remove cap screws (2), side window, cab upper door window, and hinges from machine.
[5] - Install hinges to windows with cap screws (5) and tighten to specifications.
221 lb.-in.
[6] - Install windows and hinges to cab with cap screws (2).
[7] - Lock latches on side window and cab upper door window.
[8] - Adjust cab door upper window and side window as necessary. See Non-Fixed Window Adjustment . (Group 1810.)
SPECIFICATIONS
25 N·m
Window-to-Hinge Cap Screw Torque
221 lb-in.
2.93 N·m
Window Open Lock Mount Torque
26 lb-in.
→NOTE:
Cab door upper window must be adjusted prior to adjusting side window.
LEGEND:
1 Window Latch
2 Cap Screw (2 used)
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Loosen cap screws (2) and position window equally in door frame opening.
221 lb-in.
Side Windows
→NOTE:
Cab door upper window must be adjusted prior to adjusting side window.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
LEGEND:
1 Window Latch (2 used)
2 Cap Screw (2 used)
3 Window Open Lock Knob
Side Window
Unlock window latches (1).
[3] - Loosen cap screws (2) and position window equally in door frame opening.
221 lb-in.
[5] - Tighten window open lock knob (3) to allow knob to move freely.
[6] - Loosen window open lock knob mount in door window to adjust position to knob.
26 lb-in.
LEGEND:
1 Latch
2 Seal
3 Striker
Window Latch
[3] - Open window. Bend striker (3) to obtain equal compression of seal.
SPECIFICATIONS
75 N·m
Cap Screws Torque
55 lb.-ft.
10—12 mm
Cab Frame-to-Door Frame Clearance
0.4—0.5 in.
65 N·m
Door Latch Striker Pin Nut Torque
48 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
LEGEND:
1 Cap Screw (4 used)
2 Cap Screw (4 used)
[3] - Move door and hinge to position door frame in cab frame front to rear.
55 lb.-ft.
[5] -
→NOTE:
Hinge mounting holes are slotted to provide adjustments. Hinges attached to cab frame have horizontal
slotted holes which provide forward and rearward adjustments. Hinges attached to door frame have
vertical slotted holes for upward and downward adjustments.
Loosen cap screws (2). Move door to position door frame in cab frame up and down.
55 lb.-ft.
[7] - Check door seal for proper compression. Seal should be evenly compressed around door to provide a seal between door
frame and cab frame.
[9] -
→NOTE:
It may be possible to view latch jaw engagement with latch cover in place. If not remove cover.
If gap (8) between latch jaw ends (7) is approximately 10 mm (0.4 in.) latch is only in first detent position. Adjust latch to
obtain second (primary) detent position. Loosen striker pin and move it forward approximately 0.8 mm (0.03 in.). Tighten
striker pin and check gap to make sure that jaws are in second detent as described. If necessary, repeat until second
detent engagement is obtained.
If gap between latch jaw ends is approximately 1—2 mm (0.04—0.08 in.) latch is in second (primary) detent position. To
decrease clearance at door center, loosen striker pin and move it rearward about 0.8 mm (0.03 in.). Tighten striker pin
and check clearance. If necessary, repeat until clearance of 10—12 mm (0.4—0.5 in.) exists between cab frame and door
frame.
Item Measurement Specification
0.4—0.5 in.
48 lb.-ft.
LEGEND:
1 Screw (3 used)
2 Sun Visor
3 Plug (9 used)
E20 Dome Light
Cab Headliner
Remove self-locking screws (1) and remove sun visor (2).
[7] - Locate retainers through headliner and cab frame support and install plugs.
SPECIFICATIONS
6.78 N·m
Cab Roof Cap Screw Torque
60 lb.-in.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
Cab Roof
LEGEND:
1 Cap Screw
2 Cap Screw (8 used)
3 Washer (8 used)
4 Sealing Washer (8 used)
5 Lock Nut (8 used)
W3 Roof Ground
W17 Roof Harness
X26 Cab/Canopy Harness-to-Roof Harness Connector
Remove cap screw (1) and disconnect roof ground (W3).
[3] - Disconnect cab/canopy harness-to-roof harness connector (X26) from roof harness (W17).
[4] - Disconnect antenna. See Antenna Remove and Install . (Group 2001.)
[5] - Remove cap screws (2), washers (3), sealing washers (4), and lock nuts (5).
[9] - Install cap screws (2), washers, sealing washers, and lock nuts. Tighten to specification.
Item Measurement Specification
60 lb-in.
[10] - Connect antenna. See Antenna Remove and Install . (Group 2001.)
Seat Assembly
Specifications
SPECIFICATIONS
66 kg
Seat Assembly with Base Weight (approximate)
145 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Tag and disconnect seat position sensor electrical connector (2) and air seat motor electrical connector (3).
[5] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Use appropriate lifting device and remove seat assembly with seat belts through left cab door or canopy opening.
Item Measurement Specification
145 lb.
[7] - Install seat assembly using lifting device through left cab door or canopy opening.
[9] - Connect seat position sensor electrical connector and air seat motor electrical connector.
[3] -
[4] - Disconnect seat swivel cable (8) from seat swivel latch. Remove upper seat assembly.
[5] -
[8] -
→NOTE:
Lever (37) and seat position sensor are keyed.
Lever and base (35) removal is not necessary to remove seat position sensor.
[9] - Remove socket head screws (34), and seat position sensor.
→NOTE:
Lever (37) is attached (inserted) into base (35) using a friction fit only. Lever can be separated by lightly
pulling lever and base apart by hand and out of the center diameter of swivel seat assembly.
[10] - If needed, remove remaining components (35, 37, 38) from swivel seat assembly (36) as shown.
[11] -
Boot Removal
LEGEND:
15 Plastic Fastener (27 used)
16 Boot
Remove plastic fasteners (15) and boot (16).
[12] -
[13] - Remove upper suspension tray by sliding back until rollers clear channel and lifting up.
[14] -
Seat Pedestal
LEGEND:
21 Lock Nut (4 used)
22 Washer (4 used)
23 Cap Screw (4 used)
24 Lower Suspension Tray
Remove lock nuts (21), washers (22), and cap screws (23) from lower suspension tray (24).
[16] -
[18] - Remove spring assembly (29), pin (30), adjustment shaft (31), and adjustment plate (32).
[20] - Install adjustment plate, adjustment shaft, pin, and spring assembly.
[23] - Install seat pedestal, cap screws (23), washers (22), and lock nuts (21) to lower suspension tray.
[24] - Install upper suspension tray, lower pivot shaft, and lock nut (18).
[26] - If removed, install seat position lever (37), base (35), and screw (38)
[27] -
→NOTE:
Line up raised keyway strip on seat position sensor to slot in end of lever (37) for proper engagement
and orientation.
Install seat position sensor (B9) to base (35) in seat swivel assembly (36) with socket head cap screws (34).
[30] - Install rear plate (12), front plate (11), and cap screws (10).
[31] - Connect seat swivel cable to seat swivel latch. Install upper seat assembly.
[32] - Install cap screws (6), washers (9), and lock nuts (7).
[2] - Remove cap screws (1), washers (2), and armrests (5).
[4] -
[5] - Disconnect seat swivel cable (8) from seat swivel latch. Remove upper seat assembly.
[6] -
[9] -
→NOTE:
Lever (37) and seat position sensor are keyed.
Lever and base (35) removal is not necessary to remove seat position sensor.
[10] - Remove socket head screws (34), and seat position sensor.
→NOTE:
Lever (37) is attached (inserted) into base (35) using a friction fit only. Lever can be separated by lightly
pulling lever and base apart by hand and out of the center diameter of swivel seat assembly.
[11] - If needed, remove remaining components (35, 37, 38) from swivel seat assembly (36) as shown.
[12] -
Boot Removal
LEGEND:
15 Plastic Fastener (27 used)
16 Boot
Remove plastic fasteners (15) and boot (16).
[13] -
[14] - Remove upper suspension tray by lifting and moving tray forward until rollers clear channel.
[15] -
Seat Pedestal
LEGEND:
21 Cap Screw (4 used)
22 Lock Nut (4 used)
23 Seat Pedestal
Remove cap screws (21), lock nuts (22), and seat pedestal (23) from lower suspension tray.
[16] -
[19] - Remove lock nut (28) and lower pivot shaft (29).
[20] - Remove scissor frame assembly by turning and lifting assembly until rollers clear channel.
[22] - Clean all bushings, rollers, and pivots. Lubricate with multipurpose grease.
[23] - Install scissor frame assembly, lower pivot shaft, and lock nut (28).
[26] - Install seat pedestal, cap screws (21), and lock nuts (22) to lower suspension tray.
[27] - Install upper suspension tray, upper pivot shaft, and lock nut (18).
[29] - If removed, install seat position lever (37), base (35), and screw (38)
[30] -
→NOTE:
Line up raised keyway strip on seat position sensor to slot in end of lever (37) for proper engagement
and orientation.
Install seat position sensor (B9) to base (35) in seat swivel assembly (36) with socket head cap screws (34).
[33] - Install rear plate (12), front plate (11), and cap screws (10).
[34] - Connect seat swivel cable to seat swivel latch. Install upper seat assembly.
[35] - Install cap screws (6), washers (9), and lock nuts (7).
[2] - Remove seat belt buckle (3) and seat belt (4) from seat (5).
[4] - Install seat belt buckle (3) and seat belt (4).
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 area. Splash large amounts of COOL water on
affected area. Go to a physician or hospital immediately for treatment.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc,
electric heating element and lighted smoking materials.
DO NOT heat refrigerant over 52 °C (125 °F) 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, 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.
Use correct refrigerant recovery/recycling and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils.
IMPORTANT:
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery/recycling and charging station equipment. Care must be taken
to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of
system. JT02167A Prism Pro Refrigerant Identification Instrument should be used before any testing or
repair to system is performed.
[2] - Remove compressor from machine. See Compressor Remove and Install . (Group 1830.)
[3] - Drain oil into graduated container while rotating compressor shaft.
[5] - Install new oil. See R134a Component Oil Charge . (Group 1830.)
[6] - Install compressor. See Compressor Remove and Install . (Group 1830.)
SPECIFICATIONS
306 mL
210K Backhoe—Total System Oil Volume
10.35 fl. oz.
363 mL
310K-410K Backhoe—Total System Oil Volume
12.3 fl. oz.
319 mL
710K Backhoe—Total System Oil Volume
10.8 fl. oz.
Other Material
OTHER MATERIAL
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See
Refrigerant Cautions and Proper Handling . (Group 1830.)
CAUTION:
All new compressors are charged with a mixture of nitrogen and TY22101 (R134a) Refrigerant Oil. Wear
safety goggles and discharge the compressor slowly to avoid possible injury.
IMPORTANT:
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 to eliminate accidental mixing of different oils.
IMPORTANT:
Avoid adding more oil than required, or maximum cooling will be reduced.
→NOTE:
A compressor from parts depot contains 160 mL (5.4 fl. oz.) of new oil.
1. Determine if R134a leakage was detected. Remove and repair, or replace component. See Air Conditioning System Leak
Test . (Group 9031-25.)
→NOTE: Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if
equipped) must be installed.
Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
→NOTE: Flush and purge air conditioning system only if machine had a catastrophic air conditioner
compressor malfunction.
→NOTE: Air conditioner compressor is not to be flushed and purged.
→NOTE: Determine if condenser is continuous loop or parallel flow style. Continuous loop style has
either multiple round tubes or an extruded serpentine construction. Use an adapter and connect
hoses at a continuous loop condenser. If condenser is parallel flow style construction, do not flush, it
should be replaced. A parallel flow condenser with potential blockages probably will not flush
completely and could result in system malfunction.
Flush and purge air conditioning system, only if needed. See Flush and Purge Air Conditioning System . (Group 1830.)
→NOTE: Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if
equipped) must be installed.
Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
5. Add required amount of TY22101 Refrigerant Oil to air conditioning system according to vehicle platform requirements
and type of service performed. Determine vehicle platform requirements by engine code and serial number.
Item Measurement Specification
10.35 fl. oz.
12.3 fl. oz.
10.8 fl. oz.
[2] - A soap and water solution can be sprayed on components in system to form bubbles at source of leak.
[3] - If a leak detector is used, move leak detector probe under hoses and around connections at specified rate.
Electronic Leak Detector
JT02081
Used to detect refrigerant leaks.
[4] - Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.
When a component is disconnected from system, special care should be given to inspecting hoses and tubing for moisture,
grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or fittings and cannot be removed
by cleaning, then replace parts.
Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated solvents (such
as trichloroethylene) are contaminants, and must not be used for cleaning.
To assist in making leak-proof joints in R134a systems, use a small amount of clean polyakyleneglycol (PAG) refrigerant oil on
all hoses and tube connections. Dip O-rings in PAG oil before assembly.
<- Go to Section TOC Section 18 page 48 315SK Backhoe Loader Repair
Section 18 - OPERATOR′S STATION Group 1830: Heating and Air Conditioning
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See
Refrigerant Cautions and Proper Handling . (Group 1830.)
IMPORTANT:
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery/recycling and charging station equipment. Care must be taken
to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery/recycling or charging of
system. JT02167A Prism Pro Refrigerant Identification Instrument should be used before any testing or
repair to system is performed.
Prism Pro Refrigerant Identification Instrument
JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of air
conditioning systems.
IMPORTANT:
Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix
refrigerant, hoses, fittings, components, or refrigerant oils.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
LEGEND:
1 High Pressure Charge Port Cap
2 Red Hose
3 Blue Hose
4 High Pressure Relief Valve
5 Refrigerant Recovery/Recycling and Charging Station
[3] - Remove cap from low pressure charge port and connect blue hose (3) from refrigerant recovery/recycling and charging
station (5).
[4] - Remove high pressure charge port cap (1) and connect red hose (2).
[5] - Follow manufacturer′s instructions when using refrigerant recovery/recycling and charging station.
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.
See Refrigerant Cautions and Proper Handling . (Group 1830.)
IMPORTANT:
Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
[1] - Run air conditioning system for 3 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.
Prism Pro Refrigerant Identification Instrument
JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling, and recharging of air conditioning systems.
[3] - Connect refrigerant recovery system. See R134a Refrigerant Recover, Recycle, and Charge Station Installation Procedure
. (Group 1830.
[4] - Follow manufacturer’s instructions when using refrigerant recovery/recycling and charging station.
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.
See R134a Refrigerant Cautions and Proper Handling . (Group 1830.)
[1] - Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging
Station Installation Procedure . (Group 1830.)
R134a Refrigerant Recovery/Recycling and Charging Station
[ JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station. ]
JT02045
Removes refrigerant from system, recycles it and recharges it.
[2] - Open low-side and high-side valves on refrigerant recovery/recycling and charging station.
[4] -
→NOTE:
The 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.
980 mbar
29 in. Hg
Pressure Above Sea Level Subtract 3.4 kPa from 98 kPa for each 300 m elevation
[5] - When vacuum reaches specified level, close low-side and high-side valves. Turn vacuum pump off.
[6] - If vacuum decreases more than specified amount in 5 minutes, there is a leak in system.
Item Measurement Specification
34 mbar
1 in. Hg
[8] - Evacuate system for 30 minutes after initial specified vacuum is reached.
[10] - Charge air conditioning system. See Charge R134a System . (Group 1830.)
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.
See Refrigerant Cautions and Proper Handling . (Group 1830.)
IMPORTANT:
Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix
refrigerant, hoses, fittings, components, or refrigerant oils.
[2] - Connect JT02045 R134a refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recover, Recycle,
and Charge Station Installation Procedure . (Group 1830.)
R134a Refrigerant Recovery/Recycling and Charging Station
[ JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station. ]
JT02045
Removes refrigerant from system, recycles it and recharges it.
[4] -
→NOTE:
Before beginning to charge air conditioning system, the following conditions must exist: Engine
STOPPED, 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.
[5] -
→NOTE:
Recommended specification charge includes additional 0.11 kg (0.25 lb) of R134a refrigerant remaining in
charge station hoses.
5.50 lb.
5.25 lb.
[6] - Perform Air Conditioner Check. See Operational Checkout Procedure . (Group 9005.)
IMPORTANT:
Determine if condenser is continuous loop or parallel flow style. Continuous loop style has either multiple
round tubes or an extruded serpentine construction. Use an adapter and connect hoses at a continuous
loop condenser.
If condenser is parallel flow style construction, do not flush, it should be replaced. A parallel flow
condenser with potential blockages will not flush completely and could result in system malfunction.
Flushing
Flushing a component is a cleaning process using a liquid solvent to remove oil and debris. Purging is always necessary after
flushing to remove solvent from system or component.
Flushing air conditioner components is only necessary after following have occurred:
TY25601 ACC-Flush-II Flushing Solution is recommended for flushing air conditioner system components. Use only solvents with
an equivalent MSDS.
Purging
Purging system or a component is a cleaning process using a gas to force liquid from system. Purging alone will not remove
refrigerant oil from system.
Following is a list of situations that require a purging procedure be done:
Evacuating
Evacuating system is a process to remove air and moisture from system by creating a vacuum. See Evacuate R134a System .
(Group 1830.)
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See
Refrigerant Cautions and Proper Handling . (Group 1830.)
→NOTE:
Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if equipped) must
be installed.
[1] - Recover R134a refrigerant. See Recover R134a System . (Group 1830.)
[2] -
IMPORTANT:
DO NOT attempt to flush through compressor or receiver-dryer. Flushing solution may not be completely
removed from these components and could cause system malfunction.
Remove air conditioner compressor. See Compressor Remove and Install . (Group 1830.)
[3] -
→NOTE:
Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if equipped) must
be installed.
Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
[4] - Remove and discard expansion valve. See Expansion Valve Remove and Install . (Group 1830.)
[5] -
→NOTE:
Determine if condenser is continuous loop or parallel flow style. Continuous loop style has either multiple
round tubes or an extruded serpentine construction. Use an adapter and connect hoses at a continuous
loop condenser.
If condenser is parallel flow style construction, do not flush, it should be replaced. A parallel flow
condenser with potential blockages probably will not flush completely and could result in system
malfunction.
Divide system into evaporator or condenser circuits, including hoses. Flush and purge procedure is same for both circuits.
[6] - Flush and purge air conditioner continuous loop condenser circuit:
Connect flusher outlet hose to inlet end of air conditioner compressor discharge line using adapter JT02102 Adaptor.
Adapter, O-Ring Tube
JT02102
Adapter to connect flusher outlet hose to inlet end of compressor discharge line.
Connect hoses at continuos loop condenser with an adapter from JT02098 Air Conditioning Fitting Kit.
Air Conditioning Flushing Kit
JT02098
Adapter to connect hoses at continuos loop condenser.
Attach a return hose and aerator nozzle to end of receiver-dryer inlet hose using JT03197 Reducer. Put nozzle in
container to collect flushing solvent.
Reducer Fitting, Straight
JT03197
Attach a return hose and aerator nozzle to outlet end of receiver-dryer inlet hose.
Add TY25601 ACC-Flush-II Flushing Solution to system with JT02075 Air Conditioning Flusher using fittings from
JT02098 Air Conditioning Fitting Kit.
Number Name Use
▪ TY25601 (us) ACC-Flush-II Flushing Solution Used to flush R134a air conditioning system.
Air Conditioning Flusher
JT02075
To be used with air conditioning flushing kit.
Air Conditioning Flushing Kit
JT02098
Flush air conditioning system and adjust expansion valve.
Fill air conditioning system flusher tank with 4 L (1 gal) of solvent and tighten all connections.
Item Measurement Specification
1 gal
→NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging.
Item Measurement Specification
Air Conditioning System Air Pressure (minimum for flushing and purging) 620 kPa
6.2 bar
90 psi
Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve.
Open air valve to force flushing solvent into air conditioner circuit. Flusher tank is empty when hose pulsing stops.
Disconnect flusher tank and connect to flushed circuit discharge hose end.
IMPORTANT: Additional flushing cycles are required if system is heavily contaminated with
burned oil or metal particles.
Fill flusher tank and repeat flushing procedure in reverse direction.
→NOTE: Purging takes 10—12 minutes to thoroughly remove solvent.
Disconnect hose from aeration nozzle to check circuit for solvent. Hold discharge hose close to a piece of cardboard.
Continue purging until cardboard is dry, and proceed to next step.
a. Remove evaporator. See Evaporator or Heater Core Remove and Install . (Group 1830.)
b. Follow same flush and purge procedure used on condenser, using adapters from JT02098 Air Conditioning Fitting Kit.
Adapter, O-Ring Tube
JT02102
Adapter to connect flusher outlet hose to inlet end of compressor discharge line.
c. Install evaporator and proceed to next step. See Evaporator or Heater Core Remove and Install . (Group 1830.)
[7] -
→NOTE:
Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if equipped) must
be installed.
Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
[8] - Install new expansion valve. See Expansion Valve Remove and Install . (Group 1830.)
[9] -
→NOTE:
Determine if condenser is continuous loop or parallel flow style. Continuous loop style has either multiple
round tubes or an extruded serpentine construction. Use an adapter and connect hoses at a continuous
loop condenser.
If condenser is parallel flow style construction, do not flush, it should be replaced. A parallel flow
condenser with potential blockages probably will not flush completely and could result in system
malfunction.
Install new condenser, if needed. See Condenser Remove and Install . (Group 1830.)
[10] - Install new compressor. See Compressor Remove and Install . (Group 1830.)
[11] - Add required R134a refrigerant oil to air conditioning system. See R134a Component Oil Charge . (Group 1830.)
[12] - Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System . (Group
1830.)
[2] -
LEGEND:
1 Cap Screw (3 used)
2 Cap Screw
3 Defrost Air Duct
4 Front Console
[5] -
LEGEND:
6 Cap Screw (3 used)
M11 Blower Mode Door Motor
W40 Blower Mode Door Motor Harness
[6] - Remove cap screws (6) and blower mode door motor.
[8] - Install blower mode door motor and cap screws (6).
<- Go to Section TOC Section 18 page 56 315SK Backhoe Loader Repair
Section 18 - OPERATOR′S STATION Group 1830: Heating and Air Conditioning
[10] - Install defrost air duct on front console and install cap screws (1 and 2).
[11] - Install front console. See Front Console Remove and Install . (Group 1810.)
Middle Cover
LEGEND:
3 Heater Hose (2 used)
4 Refrigerant hose (2 used)
[3] - Drain radiator See Draining the Cooling System . (Operator′s Manual.)
[7] - Disconnect heater hoses (3) at heater core connectors (below cab floor) and drain heater core.
[9] - Remove seat. See Seat Assembly Remove and Install . (Group 1821.)
LEGEND:
5 Air Filter Grille
6 Cap Screw (2 used)
7 Cap Screw (8 used)
8 Stabilizer Cover
9 Lower Console Cover
Evaporator Housing
[10] - Remove air filter grille (5) from lower console cover (9).
[12] - Remove stabilizer cover (8) and lower console cover (9).
[13] -
LEGEND:
10 Cap Screw (2 used)
11 Air Duct
12 Cap Screw (4 used)
13 Heater Hose (2 used)
14 Refrigerant Hose (2 used)
15 Evaporator
Evaporator
Remove cap screws (10) and remove air duct (11).
[16] -
CAUTION:
Wear gloves when removing and installing heater core to prevent cuts from fins on heater core.
[24] - Connect heater hoses at heater core connectors (below cab floor).
[26] - Fill radiator with proper coolant. See Heavy Duty Diesel Engine Coolant . (Operator′s Manual.) Fill radiator to proper
level. See Filling the Cooling System . (Operator′s Manual.)
IMPORTANT:
A new receiver-dryer must always be installed after system is flushed or purged. DO NOT use a flushed or
used receiver-dryer. Contamination of system will cause component malfunction.
[2] - Relieve pressure to hydraulics. See Hydraulic Circuit Pressure Release . (Group 9025.)
[3] - Disconnect negative (-) battery cable or turn battery disconnect switch to OFF position. See Battery Disconnect—If
Equipped . (Operator’s Manual.)
[4] - Recover R134a from air conditioning system. See R134a Refrigerant Recover, Recycle, and Charge Station Installation
Procedure . (Group 1830.)
[6] -
LEGEND:
5 Air Filter Grille
6 Cap Screw (2 used)
7 Cap Screw (8 used)
8 Stabilizer Cover
9 Lower Console Cover
[8] - Remove stabilizer cover (8) and lower console cover (9).
[9] -
LEGEND:
10 Refrigerant Hose (2 used)
11 Cap Screw
12 Expansion Valve
Expansion Valve
Disconnect and tag refrigerant hoses (10). Close all openings using caps and plugs.
[12] - Install expansion valve (12) and cap screw (11).Tighten cap screw (11) to specification.
Item Measurement Specification
46—55 lb-in.
[18] - Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
[19] - Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System . (Group
1830.)
[20] - Connect negative (-) battery cable or turn battery disconnect switch to ON position. See Battery Disconnect—If Equipped
. (Operator’s Manual.)
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Remove cap screws (1), washers (2), and cap screws (3).
[4] -
LEGEND:
5 Air Filter Grille
6 Cap Screw (8 used)
7 Washer (8 used)
8 Lower Console Cover
[7] -
LEGEND:
10 Cap Screw (2 used)
11 Washer (2 used)
12 Upper Housing
13 Rubber Grommet
Upper Housing
Remove cap screws (10) and washers (11).
[10] -
LEGEND:
15 Temperature Sensor
16 Cap Screw (2 used)
B2 Air Conditioner Freeze Control Switch
[11] - Remove cap screws (16) and air conditioner freeze control switch (B2).
[13] - Install air conditioner freeze control switch and cap screws.
[16] - Install lower console cover, washers (7), and cap screws (6).
[18] - Install stabilizer linkage access cover and cap screws (3).
[2] -
IMPORTANT:
A new receiver dryer must always be installed after system is flushed or purged. DO NOT use a flushed or
used receiver dryer. Contamination of system will cause component malfunction.
Open engine hood. See Opening and Closing Engine Hood . (Operator’s Manual)
Schrader Valve Tool
JT02130
Use to replace Schrader valve in A/C high and low pressure switches
[3] - Recover refrigerant from system. See Recover R134a System . (Group 1830.)
[4] - Remove tool box. See Battery Box Remove and Install . (Group 1913.)
[5] -
LEGEND:
1 Tube Nut (2 used)
2 Refrigerant Line
3 Refrigerant Line
4 Clamp (2 used)
5 Receiver-Dryer
Receiver-Dryer Location
Loosen tube nuts (1).
[6] - Disconnect refrigerant lines (2 and 3). Close all openings using caps and plugs.
→NOTE:
If air conditioning system is flushed or purged a new receiver dryer must be installed.
<- Go to Section TOC Section 18 page 64 315SK Backhoe Loader Repair
Section 18 - OPERATOR′S STATION Group 1830: Heating and Air Conditioning
[9] - Clean components See Air Conditioning System Cleaning Procedures . (Group 1830.) Flush components, if needed see
Flush and Purge Air Conditioning System . (Group 1830.) Purge components, if needed see Flush and Purge Air Conditioning
System . (Group 1830.)
[15] -
IMPORTANT:
Hood must be closed before lowering the loader boom or damage to hood will result.
Close engine hood. See Opening and Closing Engine Hood . (Operator’s Manual).
[16] - Install tool box. See Battery Box Remove and Install . (Group 1913.)
[17] - Remove boom service lock and lower loader boom to ground.
[2] -
CAUTION:
Prevent injury from unexpected machine movement. Install boom lock bar before working on machine
with loader boom in raised position.
Condenser
LEGEND:
1 Condenser Outlet Line
2 Condenser Inlet Line
3 Condenser
4 Fuel Cooler
5 Cap Screw (2 used)
6 Hood
7 Latch (2 used)
Latch
Raise loader boom and install boom lock bar.
[3] - Remove grille. See Grille Remove and Install . (Group 1921.)
[4] - Recover refrigerant from system. See Recover R134a System . (Group 1830.)
[5] - Disconnect condenser outlet line (1) and condenser inlet line (2). Close all openings using caps and plugs.
[6] - Open hood (6), unhook latches on both sides (7), and close hood.
[10] - Flush and purge components, if needed. See Flush and Purge Air Conditioning System . (Group 1830.)
[13] - Open hood, hook latches on both sides, and close hood.
[14] -
IMPORTANT:
Avoid system contamination. A new receiver-dryer must be installed after system is flushed or purged.
Install new receiver-dryer if air conditioning system was flushed or purged. See Receiver-Dryer Remove and Install . (Group
1830.)
[15] - Install grille. See Grille Remove and Install . (Group 1921.)
[16] - Evacuate system see Evacuate R134a System . (Group 1830.) Charge system. See Charge R134a System . (Group
1830.)
[17] - Remove boom lock bar and lower loader boom to ground.
SPECIFICATIONS
120 N·m
Air Conditioner Compressor Mount Torque
89 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
→NOTE:
Battery is accessed by removing top cover on left side step.
Disconnect negative (-) battery cable or turn battery disconnect switch to OFF position. See Battery Disconnect—If Equipped .
(Operator’s Manual.)
[3] -
CAUTION:
Prevent injury from unexpected machine movement. Install boom lock bar before working on machine
with loader boom in raised position.
[4] - Open engine hood to full open position. See Opening and Closing Engine Hood . (Operator’s Manual.)
[5] - Recover refrigerant from system. See Recover R134a System . (Group 1830.)
[6] - Remove serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.)
[7] -
LEGEND:
1 Pressure Line (to condenser)
2 Suction Line (from expansion valve)
3 Electrical Connector from Y19
4 Cap Screw (2 used)
5 Lock Nut (2 used)
6 Washer (2 used)
7 Cap Screw (2 used)
8 Air Conditioning Compressor
Y19 Air Conditioner Compressor Clutch Solenoid
[9] - Remove cap screws (4), lock nuts (5), and washers (6).
[12] -
<- Go to Section TOC Section 18 page 68 315SK Backhoe Loader Repair
SHEET METAL AND STYLING (g) by Belgreen v2.0
IMPORTANT:
If compressor is being replaced due to an internal failure, flush and purge each component in air
conditioning system individually. See Air Conditioning System Cleaning Procedures . (Group 1830.)
Flush components, if needed. See Flush and Purge Air Conditioning System . (Group 1830.)
[13] - Purge system, if needed. See Flush and Purge Air Conditioning System . (Group 1830.)
89 lb.-ft.
[15] - Install cap screws (4), washers, and lock nuts. Tighten to specification.
Item Measurement Specification
89 lb.-ft.
[18] - Install fan belt. See Serpentine Belt Remove and Install . (Group 0510.)
[19] -
IMPORTANT:
Avoid system contamination. A new receiver-dryer must be installed after system is flushed or purged.
Install new receiver-dryer if air conditioning system was flushed or purged. See Receiver-Dryer Remove and Install . (Group
1830.)
[22] - Connect negative (-) battery cable or turn battery disconnect switch to ON position. See Battery Disconnect—If Equipped
. (Operator’s Manual.)
[23] -
IMPORTANT:
Avoid damage to hood. Hood must be closed before lowering loader boom or damage to hood will result.
Close engine hood. See Opening and Closing Engine Hood . (Operator’s Manual.)
[24] - Remove boom lock bar and lower loader boom to ground.
SPECIFICATIONS
45 kg
Hood Assembly (210K) Weight (approximate)
121 lb.
32 kg
Hood Assembly (310K—410K) Weight (approximate)
85 lb.
65 N·m
Hood Pivot Cap Screw and Nut Torque
48 lb.-ft.
[1] - Raise loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[4] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
1 Hood
2 Extension Spring (2 used)
3 Gas Operated Cylinder
4 Cap Screw (2 used)
5 Washer (2 used)
6 Lock Nut (2 used)
7 Cap Screw (2 used)
8 Washer (2 used)
9 Guide
10 Prop Rod
121 lb.
85 lb.
[7] - Remove cap screws (4), washers (5), and lock nuts (6).
[9] - Separate guide (9) and prop rod (10) by sliding prop rod roller to hole at back of guide.
[13] - Install prop rod roller into hole at back of guide. Install washers (8) and cap screws (7).
[14] - Install washers (5), cap screws (4), and lock nuts. Tighten to specification.
Item Measurement Specification
48 lb.-ft.
[17] - Lower loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
SPECIFICATIONS
29 kg
Battery Weight (approximate)
64 lb.
44 kg
Battery Box Weight (approximate)
96 lb.
Dual Batteries
[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Raise loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[3] -
LEGEND:
1 Cap Screw (3 used)
2 Washer (3 used)
3 Tool Box
Tool Box
Remove cap screws (1) and washers (2).
[5] -
LEGEND:
4 Negative (–) Battery Cable
5 Positive (+) Battery Cable
6 Flange Nut
7 Nut (4 used)
8 Washer (4 used)
9 Bracket (2 used)
G1 Battery 1
G2 Battery 2
Batteries
Disconnect negative (–) battery cable (4) first, then disconnect positive (+) battery cable (5).
[9] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Remove battery 1 and battery 2 (G1 and G2) using appropriate lifting device.
Item Measurement Specification
64 lb.
[10] -
LEGEND:
10 Cap Screw (2 used)
11 Cap Screw (4 used)
12 Cap Screw (4 used)
13 Washer (4 used)
14 Battery Box
A6000 Modular Telematics Gateway (MTG) Control Unit
F1 Main 250 A Fuse
Battery Box
Remove cap screws (10) and set main 250 A fuse (F1) and bracket aside.
[11] - Remove cap screws (11) and set modular telematics gateway (MTG) control unit (A6000) aside.
[12] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
96 lb.
[16] - Install battery box, washers (13), and cap screws (12).
[18] - Install main 250 A fuse, bracket, and cap screws (10).
[20] - Install positive (+) battery cable first, then install negative (–) battery cable.
[22] - Install tool box, washers (2), and cap screws (1).
Single Battery
[1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Raise loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[3] -
LEGEND:
1 Cap Screw (3 used)
2 Washer (3 used)
3 Tool Box
Tool Box
<- Go to Section TOC Section 19 page 5 315SK Backhoe Loader Repair
Section 19 - SHEET METAL AND STYLING Group 1913: Miscellaneous Shields
[5] -
LEGEND:
4 Negative (–) Battery Cable
5 Positive (+) Battery Cable
6 Flange Nut
7 Nut (2 used)
8 Washer (2 used)
9 Bracket
G1 Battery 1
Battery
Disconnect negative (–) battery cable (4) first, then disconnect positive (+) battery cable (5).
[9] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
64 lb.
[10] -
LEGEND:
10 Cap Screw (4 used)
11 Cap Screw (4 used)
12 Washer (4 used)
13 Battery Box
A6000 Modular Telematics Gateway (MTG) Control Unit
Battery Box
Remove cap screws (10) and set modular telematics gateway (MTG) control unit (A6000) aside.
[11] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
96 lb.
[15] - Install battery box, washers (12), and cap screws (11).
[18] - Install positive (+) battery cable first, then install negative (–) battery cable.
[20] - Install tool box, washers (2), and cap screws (1).
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Raise loader boom and install boom service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[7] - Disengage boom service lock and lower loader boom to ground.
[2] - Remove headliner. See Headliner Remove and Install . (Group 1810.)
[3] -
LEGEND:
1 Wire Harness Connector (2 used)
2 Cap Screw (6 used)
3 Speaker (2 used)
Speaker Location
Disconnect wire harness connectors (1) from speaker (3).
[8] -
LEGEND:
4 Antenna Coaxial Cable
5 Radio Connector
6 Cap Screw
7 Bracket
Radio Removal
Disconnect antenna coaxial cable (4) and radio connector (5).
[15] - Install headliner. See Headliner Remove and Install . (Group 1810.)
Antenna Location
Specifications
SPECIFICATIONS
Antenna
1.3 N·m
Antenna Pivot Torque
12 lb.-in.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Loosen cap screw (1) and washer (2), and move antenna (3) to horizontal position.
[3] - Remove cap screw and washer, slide over antenna to remove antenna base from bracket.
[4] - Remove headliner. See Headliner Remove and Install . (Group 1810.)
[6] - From outside cab pull antenna cable through grommet (5) in cab.
[7] - Install antenna cable through grommet in cab and connect to radio.
[8] - Install headliner. See Headliner Remove and Install . ( Group 1810.)
[10] - Move antenna to upright position and tighten cap screw to specification.
Item Measurement Specification
Antenna
Antenna Pivot Torque 1.3 N·m
12 lb.-in.
Horn Location
LEGEND:
1 Electrical Connector (2 used)
2 Cap Screw
H40 Horn
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Open engine hood to full open position. See Opening and Closing Engine Hood . (Operator’s Manual.)
[4] -
→NOTE:
Horn is located on left side above radiator in engine compartment.
[9] - Close engine hood. See Opening and Closing Engine Hood . (Operator’s Manual.)
[10] - Remove boom service lock and lower loader boom to ground.
LEGEND:
1 Lock Nut (2 used)
2 Cap Screw (2 used)
3 Electrical Connector (2 used)
H3 Backup Alarm
Backup Alarm
→NOTE:
Backup alarm is located inside main frame on left-rear side.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
IMPORTANT:
The backup alarm is set on high volume at the factory. It may be necessary to adjust the volume to meet
local regulations.
The procedure will change the factory set high volume to low volume.
[1] - Remove backup alarm. See Backup Alarm Remove and Install . (Group 2004.)
[2] - Remove nut (2) and electrical connector (3) from shorting bar (4).
[3] - Remove nut (1) and shorting bar from backup alarm.
[5] - Install backup alarm. See Backup Alarm Remove and Install . (Group 2004.)
ESSENTIAL TOOLS
This procedure is to be used on machines that have had hydraulic system repair without a catastrophic component failure.
Filter caddy procedure must be done prior to starting machine after a component has been repaired or replaced.
IMPORTANT:
Intermixing of oils can cause premature hydraulic component damage and oil contamination. Oil types
and filters must not be intermixed. Use filter element in same type oil to avoid intermixing of oils.
Oil contamination could result if filter caddy is used in dusty or wet conditions. Clean work practices and
cleanliness of filter caddy and attachments are critical when filtering oil.
→NOTE:
Filter oil should be at 27°C (80°F) or above for best Super Caddy ™ performance. Reduce flow rate to
filter oil below 27°C (80°F).
Super Caddy requires a 20-amp electric circuit. Use of electrical extension cord is not recommended.
[1] -
→NOTE:
Park machine in an area that will allow all hydraulic functions to be operated.
Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Clean exterior of oil fill cap and surrounding area to prevent contamination.
[4] -
→NOTE:
When installing suction and discharge wands into the hydraulic oil reservoir, locate the submerged ends
of the wands as far away from each other as possible to ensure maximum oil movement during cleanup
procedure.
Install suction and discharge wands from JDG10712 Super Caddy into the hydraulic oil reservoir through the oil fill tube.
Super Caddy
JDG10712
Used to clean hydraulic oil
[5] - Seal suction and discharge wands to oil fill tube to secure wands to hydraulic oil reservoir and prevent contamination.
[6] -
CAUTION:
Prevent possible personal injury from unexpected machine movement. Clear all persons from area before
operating machine.
Avoid entanglement and possible electrocution from filter caddy power cord. Do not operate machine
while filter caddy is connected to machine.
Use JDG10712 Super Caddy to remove oil contaminants. Refer to the Super Caddy operator′s manual or see Super Caddy in
Service ADVISOR ™ for operating procedure.
[7] - When cleaning process is done, disconnect Super Caddy from machine.
[8] - Fill hydraulic oil reservoir to operating level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
[9] - Run machine at slow idle. Operate each circuit a minimum of 2 minutes in each direction to flush any remaining
contaminants back through hydraulic system filters.
[11] - Repeat Super Caddy operation procedure until contaminant value is at specifications per Super Caddy operator′s manual
or see Super Caddy in Service ADVISOR for operating procedure.
[12] - When oil reaches an acceptable level of cleanliness, disconnect Super Caddy from machine.
[13] - Install new hydraulic oil filter. See Replace Hydraulic Oil Filter . (Operator’s Manual.)
[14] -
→NOTE:
Instrument cleanliness and clean work practices are critical when taking oil samples. Dust, wind, and
moisture, as well as contaminated sample pumps, bottles, and tubing, can affect results.
Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the filter when oil is warm.
See Take Fluid Samples . (Operator′s Manual.)
[15] - Fill hydraulic oil reservoir to proper operating level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
ESSENTIAL TOOLS
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
LEGEND:
1 Vent Hose
2 Hydraulic Oil Reservoir Fill Tube
[3] - Connect D15032NU Vacuum Pump Kit or equivalent to hydraulic oil reservoir fill tube as shown.
Vacuum Pump Kit
D15032NU
Create vacuum in hydraulic oil reservoir
SPECIFICATIONS
26 kg
Hydraulic Pump Weight (approximate)
57 lb.
130 N·m
Hydraulic Pump Mounting Cap Screw Torque
96 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
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.
Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[5] - Remove rear drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[6] -
CAUTION:
Prevent possible crushing injury from heavy component. Use an appropriate lifting device.
57 lb.
[10] -
→NOTE:
Only serviceable parts are seal kits and O-rings.
[12] -
CAUTION:
Prevent possible crushing injury from heavy component. Use an appropriate lifting device.
96 lb.-ft.
[16] - Install rear drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[17] - Fill hydraulic reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[18] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
SPECIFICATIONS
271 N·m
Nut-to-Stud Torque
200 lb.-ft.
61 N·m
Unloader Relief Valve Torque
45 lb.-ft.
181 N·m
Pump Section Cap Screw Torque
134 lb.-ft.
Other Material
OTHER MATERIAL
[1] -
[2] - Mark port end housing (1), gear housings (2 and 4), unloader valve (3), and shaft end cover (5) to aid in assembly.
[3] - Mount pump in bench vice with shaft pointing down and vice jaws camping pump mounting flanges.
[4] - Remove cap screws (6), washers (7), and port end housing.
[5] - Remove channel backup seals (8), channel seals (9), thrust plates (10), gasket seals (11), gear housing (2), matched gear
set (12), and connecting shaft (13).
[8] - Remove relief valve (16), spring (17), spool (18), and plug (19).
[10] - Remove channel backup seals (22), channel seals (23), thrust plates (24), gasket seals (25), and matched gear set (26).
[15] - Apply 58730 ULTRA BLUE RTV Silicone Form-in-Place gasket to drive shaft seal OD and bore ID.
[17] - Install matched gear set (26), gasket seals (25), thrust plates (24), channel seals (23), and channel backup seals (22).
[18] - Install unloader valve, washers (21), and nuts (20). Tighten to specification in a cross pattern.
Item Measurement Specification
200 lb.-ft.
45 lb.-ft.
[23] - Install connecting shaft, matched gear set (12), gear housing, gasket seals (11), thrust plates (10), channel seals (9),
and channel backup seals (8).
[24] - Install port end housing, washers (7), and cap screws. Tighten to specification in a cross pattern.
Item Measurement Specification
134 lb.-ft.
SPECIFICATIONS
32 kg
Hydraulic Oil Reservoir Weight (approximate)
70 lb.
LEGEND:
1 Cap Screw (3 used)
2 Engine Control Unit Mounting Plate
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
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.
Release pressure in hydraulic system. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Switch battery disconnect to OFF (if equipped) or disconnect the battery ground cable. See Battery Disconnect—If
Equipped . (Operator’s Manual.)
[4] - Drain hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[5] - Remove cab or canopy. See Operator′s Station Remove and Install . (Group 1800.)
[6] - Remove cap screws (1) and engine control unit mounting plate (2) from hydraulic reservoir.
[7] -
[8] - Disconnect electrical connector to hydraulic oil temperature sensor (B10), if equipped.
[9] - Remove plastic fasteners (11), cap screws (12), and isolator (13).
[10] -
LEGEND:
14 Cap Screw (4 used)
15 Hood Cowling
Cowling Removal
Remove cap screws (14) and hood cowling (15).
[11] -
LEGEND:
16 Vent Hose
17 Cap Screw (2 used)
18 Rear Hood Cowling Support
[12] - Remove cap screws (17) and rear hood cowling support (18).
[13] -
LEGEND:
19 Lift Point
20 Cap Screw (4 used)
Lifting Bracket
JT01748
Used to remove and install reservoir.
[15] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Raise hydraulic oil reservoir with hoist slightly to provide access to hydraulic oil reservoir drain hose (10).
Item Measurement Specification
70 lb.
[16] - Disconnect drain hose. Close all openings using caps and plugs.
[19] - Move hydraulic oil reservoir into position slightly above standard placement and connect hydraulic pump supply hose
and hydraulic oil reservoir drain hose.
[26] - Connect remaining hoses and hydraulic oil temperature sensor (if equipped).
[27] - Install engine control unit mounting plate and cap screws.
[28] - Install cab or canopy. See Operator′s Station Remove and Install . (Group 1800.)
[29] - Fill hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)
[30] - Switch battery disconnect to ON (if equipped) or connect the battery ground cable. See Battery Disconnect—If Equipped
. (Operator’s Manual.)
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
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.
Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain coolant. See Draining the Cooling System . (Operator’s Manual.)
[5] - Drain hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[6] -
4 Coolant Hose
5 Cap Screw (3 used)
6 Coolant Hose
7 Transmission Hose (2 used)
8 Cap Screw (3 used)
39 Transmission Oil Cooler
120 Hydraulic Oil Cooler
Tag and disconnect hydraulic hoses (1 and 2) and coolant hoses (3 and 4). Close all openings using caps and plugs.
[7] - Remove cap screws (5) and hydraulic oil cooler (120).
[3] - Fill hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[4] - Fill coolant system. See Filling the Cooling System . (Operator’s Manual.)
[5] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[1] -
LEGEND:
1 Hydraulic Oil Filter Return Hose
2 Hydraulic Oil Cooler Return Hose
3 Coolant Hose
4 Coolant Hose
5 Cap Screw (3 used)
6 Coolant Hose
7 Transmission Hose (2 used)
8 Cap Screw (3 used)
39 Transmission Oil Cooler
120 Hydraulic Oil Cooler
Remove hydraulic oil cooler, see Hydraulic Oil Cooler Remove at beginning of this procedure.
[2] - Tag and disconnect coolant hoses (3 and 6). Close all openings using caps or plugs.
[3] -
→NOTE:
If hose clamps are inaccessible from underneath machine, remove front floor mat and floor access panel
to access hose clamps.
Tag and disconnect transmission hoses (7). Close all openings using caps or plugs.
[4] - Remove cap screws (8) and transmission oil cooler (39).
[4] - Install hydraulic oil cooler, see Hydraulic Oil Cooler Install at beginning of this procedure.
[5] - Check transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.)
[2] -
CAUTION:
Release pressure in hydraulic system. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[6] -
LEGEND:
1 Cap Screw (4 used)
2 Floor Access Panel
[7] -
[8] - Tag and disconnect hoses (3—5). Close all openings using caps and plugs.
[10] -
IMPORTANT:
Hydraulic filter restriction switch (B12) connector is hidden. To prevent possible damage to wiring and
switch, support filter assembly when removing cap screws.
[11] - Disconnect electrical connector from hydraulic oil filter restriction switch (B12) and remove hydraulic filter assembly.
[18] - Apply clean hydraulic oil to filter seal. Turn hydraulic oil filter clockwise until seal touches base and tighten additional 3/4
turn.
[20] - Check hydraulic oil level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual)
[21] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
Section 31 - LOADER
Table of contents
Group 3100 - Loader ................................................................................................................................ 1
Loader Boom Remove and Install ......................................................................................................... 1
Group 3102 - Bucket ................................................................................................................................ 4
Loader Bucket Remove and Install ....................................................................................................... 4
Welded Bucket Cutting Edges Replacement Procedure ....................................................................... 5
Group 3115 - Control Linkage ................................................................................................................ 6
Loader Control Valve Linkage Remove and Install—Two Function ....................................................... 6
Single Lever Loader Auxiliary Control Lever Remove and Install .......................................................... 8
Manual Third Function Loader Control Valve Linkage Remove and Install ......................................... 10
Stabilizer Linkage Remove and Install (S.N. —000470) ...................................................................... 13
Loader Bucket Cylinder Linkage Remove and Install .......................................................................... 15
Loader Bucket Self-Leveling Linkage and Return-to-Dig Switch Adjustment ...................................... 16
Group 3160 - Hydraulic System ........................................................................................................... 17
Loader and Stabilizer Control Valve Remove and Install .................................................................... 17
Loader and Stabilizer Control Valve Spool Disassemble and Assemble .............................................. 20
Loader and Stabilizer Control Valve Relief Valves Remove and Install ............................................... 32
Loader Boom Anticavitation Valve Disassemble and Assemble .......................................................... 34
Loader Boom Raise and Bucket Curl Circuit Relief Valve Disassemble and Assemble ........................ 37
Loader Bucket Dump Circuit Relief Valve With Anticavitation Disassemble and Assemble ................ 39
Loader Auxiliary Circuit Relief Valve Disassemble and Assemble ....................................................... 41
Loader Auxiliary Shutoff Plug Disassemble and Assemble ................................................................. 42
Loader Boom Cylinder Remove and Install ......................................................................................... 44
Loader Boom Cylinder Disassemble and Assemble ............................................................................ 45
Loader Bucket Cylinder Remove and Install ....................................................................................... 46
Loader Bucket Cylinder Disassemble and Assemble .......................................................................... 48
Loader Multi-Purpose Bucket Cylinder Disassemble and Assemble .................................................... 48
Loader Auxiliary Manifold Remove and Install .................................................................................... 50
Ride Control Valve Remove and Install ............................................................................................... 52
Ride Control Valve Disassemble and Assemble .................................................................................. 54
Ride Control Valve Solenoid Disassemble and Assemble ................................................................... 55
Ride Control Accumulator Remove and Install ................................................................................... 56
Specifications
SPECIFICATIONS
399 kg
Loader Boom Weight (approximate)
880 lb.
57 kg
Boom Cylinder Weight (approximate)
126 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release pressure in hydraulic system. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] -
CAUTION:
Be careful when removing bucket linkage pins. Linkage can fall and cause bodily injury. If necessary,
support bucket linkage using blocks.
Remove loader linkage. See Loader Bucket Cylinder Linkage Remove and Install . (Group 3115.)
[4] - Remove bucket cylinder. See Loader Bucket Cylinder Remove and Install . (Group 3160.)
[5] - Remove bucket. See Loader Bucket Remove and Install . (Group 3102.)
[6] - Install lifting straps at locations (1) and (3). Make sure lifting straps are installed as follows:
Attach rear lifting straps to boom arms (1) using choker method.
Attach front lifting straps around each boom arm just in front of cross tube (2).
[7] -
LEGEND:
4 Return-to-Dig Switch Connector
5 Snap Ring (2 used)
6 Washer (as needed)
7 Pivot Pin
8 Hydraulic Hose
9 Hydraulic Hose
Loader Removal
Disconnect return-to-dig switch connector (4).
[8] - Tag and disconnect hydraulic hoses (8) and (9). Cap and plug all openings.
[10] - Remove snap rings (5), washers (6), and pin (7)
[11] -
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.
LEGEND:
10 Cap Screw
11 Pin Retainer Plate
12 Pivot Pin
13 Lift Arm
[12] - Remove cap screw (10) and pin retainer plate (11).
[13] - Remove boom cylinder pivot pin (12) from lift arm (13). Lower rod end of boom cylinder and allow it to rest on the block.
[15] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
880 lb.
[22] - Connect and adjust bucket self-leveling linkage. See Loader Bucket Self-Leveling Linkage and Return-To-Dig Switch
Adjustment . (Group 9025-20.)
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Item Measurement Specification
126 lb.
880 lb.
[23] - Install loader bucket. See Loader Bucket Remove and Install . (Group 3102.)
[24] - Install bucket linkage. See Loader Bucket Cylinder Linkage Remove and Install . (Group 3115.)
[25] - Install bucket cylinder. See Loader Bucket Cylinder Remove and Install . (Group 3160.)
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device. Be careful when
removing bucket linkage pins. Bucket cylinder and links will fall forward and cause bodily injury. If
necessary, support bucket linkage using blocks.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[4] - Remove snap rings (1) and washers (2) from pins (3).
[5] -
Attach a hoist and lifting strap to bucket cylinder (4). Remove pins (3) from bucket cylinder and linkage (5).
[6] - Remove lock nuts (6), cap screws (7), and pins (8).
[11] - Align bucket cylinder rod with bucket. Install pin (3), washers, and snap ring.
[12] - Align bucket linkage with bucket and install pin (3), washers, and snap ring.
<- Go to Section TOC Section 31 page 4 315SK Backhoe Loader Repair
Section 31 - LOADER Group 3115: Control Linkage
[2] - Clean all joints to be welded of all foreign matter such as dirt, rust, mill scale, oil, etc. with grinders and/or solvents.
[3] - Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: gas
metal arc welding (CO 2 or argon CO 2 ) AWS-E70S6 or flux cored arc welding AWS-E70T1.
[4] - Preheat parts to be welded (both tack and final welds) to minimum of 204°C (400°F). PREHEAT TEMPERATURE MUST BE
THROUGHOUT THE ENTIRE THICKNESS OF THE PARTS JOINED AND AT LEAST 51 mm (2 in.) BACK FROM THE JOINT. Maintain
preheat throughout the entire welding operation. Tempilstiks should be used if possible.
[5] - Tack weld preheated plates starting at center of bucket and working toward the outside ends.
[6] - Final weld preheated plates starting at the center of the front edge of the bucket backing plate and working toward the
outside ends.
Repeat this operation at back edge of loader blade.
Tack welds may be incorporated into the final weld, providing they have been made with electrodes that meet the
requirements of the final welds and no cracking has occurred in the weld metal. Tack welds not meeting these requirements
must be completely removed by grinding or air arc gouging just prior to making the final weld in that area.
[7] - Do not remove bucket from welding environment until weld metal temperature has dropped to the ambient temperature.
Do not force cooling rate of weld metal.
[3] -
LEGEND:
1 Cap Screw (4 used)
2 Middle Floor Panel
[4] -
LEGEND:
3 Cap Screw (4 used)
4 Washer (4 used)
5 Cab Cover
[5] -
LEGEND:
6 Cap Screw
7 Washer
8 Floor Plate
9 Cap Screw (2 used)
10 Cover
[8] -
LEGEND:
11 Pin Retainer (2 used)
12 Pin Fastener (2 used)
[9] -
LEGEND:
13 Lock Nut (3 used)
14 Ball Joint (2 used)
15 Loader Control Valve Linkage (2 used)
[12] - Install pin fasteners and pin retainers into control valve linkages.
[13] - Adjust linkage as necessary. See Loader and Stabilizer Lever Adjustment . (Group 9025.)
[15] - Install floor plate, cap screw (6), and washer (7).
[16] - Install cab cover, cap screws (3), and washers (4).
[2] -
LEGEND:
3 Cap Screw (4 used)
4 Washer (4 used)
5 Loader Control Cover
[3] -
LEGEND:
X58 Loader Control Lever Connector
X58 Connector
Disconnect loader control lever connector (X58).
[4] -
LEGEND:
7 Boot
[5] -
<- Go to Section TOC Section 31 page 8 315SK Backhoe Loader Repair
Section 31 - LOADER Group 3115: Control Linkage
[7] - Install single lever auxiliary loader control lever and cap screws (9).
[10] - Install loader control cover, washers, and cap screws (3).
Manual Third Function Loader Control Valve Linkage Remove and Install
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] -
LEGEND:
1 Cap Screw (4 used)
2 Middle Floor Panel
[4] -
LEGEND:
3 Cap Screw (4 used)
4 Washer (4 used)
5 Cover
[5] -
LEGEND:
6 Cap Screw
7 Washer
8 Floor Plate
9 Cap Screw (2 used)
10 Cover
[7] -
LEGEND:
11 Pin Retainer (3 used)
12 Pin Fastener (3 used)
13 Linkage Rod (3 used)
[8] -
LEGEND:
13 Lock Nut (2 used)
14 Pivot Spacer
15 Linkage Rod Assembly
[14] - Adjust linkage as necessary. See Loader and Stabilizer Lever Adjustment . (Group 9025.)
[15] - Install floor plate with cap screw (6) and washer (7).
[17] - Install cab cover with cap screws (3) and washers (4).
[2] -
LEGEND:
1 Cap Screw (3 used)
2 Washer (3 used)
3 Cap Screw (2 used)
4 Stabilizer Linkage Access Cover
[4] -
LEGEND:
5 Retaining Ring (2 used)
6 Pivot Shaft
7 Cotter Pin (2 used)
8 Push/Pull Stabilizer Cable (2 used)
9 Stabilizer Lever (2 used)
10 Stabilizer Lever Mounting Tower
Stabilizer Levers
Remove retaining rings (5) from the pivot shaft (6).
[5] - Remove cotter pins (7) from the push/pull stabilizer cables (8).
[9] - Install push/pull stabilizer cables and stabilizer levers with cotter pins.
[12] - Install stabilizer linkage access cover, cap screws (1), and washers.
SPECIFICATIONS
45 kg
Loader Bucket Cylinder Weight (approximate)
100 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve pressure in system before
disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
Release pressure in hydraulic system. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] -
LEGEND:
1 Self-Leveling Rod
2 Snap Ring
3 Bucket Link (2 used)
4 Snap Ring (6 used)
5 Washer (as needed)
6 Pin (3 used)
7 Bucket Link (2 used)
[5] -
CAUTION:
Prevent possible injury from falling linkage. Bucket cylinder and links will fall when pins are removed.
Support or block linkage and cylinder before removing pins.
[7] - Remove snap rings (4), washers (5), pins (6), and bucket links (3) from machine.
Item Measurement Specification
100 lb.
[8] - Remove snap rings (4), washers (5), pin (6), and bucket links (7) from machine.
[9] - Inspect links. Repair or replace as needed. Remove and install bushings using D01045AA Bushing, Bearing and Seal
Driver Set.
Bushing, Bearing and Seal Driver Set
D01045AA
Used to remove and install loader bucket linkage bushings.
[10] -
IMPORTANT:
Do not use a graphite based grease on the synthetic bushings when assembling. Graphite will deteriorate
synthetic bushings.
[11] - Install bucket links to loader boom with pin, washers, and snap rings.
[12] - Install bucket links to bucket with pin, washers, and snap rings.
[13] - Align bucket links with cylinder and attach links to cylinder using washers and snap rings. Shim as required to reduce
looseness on bucket links and bucket links to cylinder.
[2] - Remove right rear wheel. See Rear Wheel Assembly Remove and Install . (Group 0110.)
[3] - Release hydraulic pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[5] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil (Operator’s Manual) or see Apply
Vacuum to Hydraulic Oil Reservoir . (Group 2160.)
[6] -
[7] - Remove loader control valve linkage. See Loader Control Valve Linkage Remove and Install—Two Function . (Group 3115.)
[8] -
[9] - Tag and disconnect all hydraulic hoses. Close all openings using caps and plugs.
[11] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
[12] - Attach and secure lifting device to loader and stabilizer control valve.
Item Measurement Specification
181 lb.
[13] - Remove cap screws (5) and loader and stabilizer control valve.
[14] - Repair or replace loader and stabilizer control valve as necessary. See Loader and Stabilizer Control Valve Spool
Disassemble and Assemble . (Group 3160.)
[15] - Install loader and stabilizer control valve and cap screws (5).
[19] - Install loader control valve linkage. See Loader Control Valve Linkage Remove and Install—Two Function . (Group 3115.)
[20] - Fill hydraulic reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[21] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[23] - Install loader and stabilizer control valve cover and cap screws (1).
[24] - Install right rear wheel. See Rear Wheel Assembly Remove and Install . (Group 0110.)
SPECIFICATIONS
9.5 N·m
Spool End Screw Torque
84 lb.-in.
9.5 N·m
Retaining Plate Cap Screw (2 used) Torque
84 lb.-in.
Essential Tools
ESSENTIAL TOOLS
Other Material
OTHER MATERIAL
→NOTE:
Left stabilizer thermal relief valve is located in top of valve. Right stabilizer thermal relief valve is located
in bottom of valve.
→NOTE:
Stabilizer spool disassemble and assemble is identical for left and right stabilizers. Left stabilizer is
shown in illustrations.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] -
LEGEND:
1 Lock Nut (3 used)
2 Cap Screw
3 Bellcrank (2 used)
[4] -
LEGEND:
4 Cap Screw (2 used)
5 Base
6 Cap Screw (2 used)
7 Spacer
8 Plate
9 Spool Wiper Seal
10 Lip Seal
11 Cap Screw (2 used)
12 Cap
13 Cap Screw
14 Retainer (2 used)
15 Spring
16 Plate
17 Seal
18 Seal
190 Loader and Stabilizer Control Valve
191 Left Stabilizer Spool
192 Right Stabilizer Spool
[5] - Remove cap screws (6), spacer (7), and plate (8).
[6] - Use an O-ring pick to remove spool wiper seal (9) and lip seal (10).
[8] - Remove cap screw (13), retainers (14), and spring (15).
[10] - Remove left stabilizer spool from loader and stabilizer control valve (190).
[13] -
IMPORTANT:
Do not damage OD or ID of new seal during installation. JDG734 Hydraulic Valve Seal Replacer must be
used to install lip seal (10).
Lube seals with hydraulic oil prior to installation.
Installation Tool
LEGEND:
10 Lip Seal
28 Tool Sleeve
30 Tool Driver
Use
Hydraulic Valve Seal Replacer
JDG734
Install new seals
JDG734 Hydraulic Valve Seal Replacer and place lip seal (10) on end of tool driver (30) with open side of seal away from tool
driver.
[14] -
→NOTE:
Lip end of sleeve ID is cone-shaped to compress seal for installation.
Carefully slide tool sleeve (28) over lip seal and tool driver with raised lip of sleeve away from driver. Do not push seal through
tool sleeve.
[15] - Place tool assembly over end of spool with raised lip into counterbore of valve section.
[16] - Push tool driver to install lip seal into valve housing.
[17] - Spin tool driver 180 degrees and hold down for several seconds. This will allow air to escape and seal will seat in valve
counterbore.
[22] - Apply PM37509 and PM37421 Loctite ™ Thread Lock and Sealer (high strength) to threads of spool and cap screws.
84 lb.-in.
[24] - Install cap (12) and cap screws (11). Tighten cap screws to specification.
Item Measurement Specification
84 lb.-in.
[25] - Install spacer (7), plate (8) and cap screws (6). Tighten cap screws to specification.
Item Measurement Specification
84 lb.-in.
[26] - Install bellcranks (3), cap screws (2) and lock nuts (1).
[27] - Check for correct seal installation by pushing down on stabilizer spool. Spool must return to neutral position.
[1] -
LEGEND:
1 Filter
2 Cap Screw (2 used)
3 Cap
4 End
5 Valve Seat Insert
6 Spring
7 Valve Seat Insert
8 Ball (4 used)
9 Cam
10 Spring
11 Sleeve
12 Sleeve
13 Spool End Cap Screw (2 used)
14 Plate
15 Spool Wiper Seal
16 Lip Seal
17 Seal
18 O-Ring
19 Seat
20 O-Ring
21 Spring
22 Poppet
190 Loader and Stabilizer Control Valve
193 Loader Boom Spool
[4] - Remove spring (6) from both valve seat inserts (5 and 7).
[5] - Remove balls (8), cam (9), and spring (10) from sleeves (11 and 12).
[6] - Remove spool end cap screws (13) and plate (14).
[8] - Use an O-ring pick to remove spool wiper seal (15) and lip seal (16) from loader and stabilizer control valve (190).
[9] - Use an O-ring pick to remove seal (17) and O-ring (18) from loader and stabilizer control valve.
[10] - Remove seat (19), O-ring (20), spring (21), and poppet (22) from loader and stabilizer control valve.
[11] - Install seat, O-ring (20), spring (21), and poppet to loader and stabilizer control valve.
[13] -
IMPORTANT:
Do not damage OD or ID of new seal during installation. JDG734 Hydraulic Valve Seal Replacer must be
used to install lip seal (16).
Lube seals with hydraulic oil prior to installation.
Installation Tool
LEGEND:
16 Lip Seal
23 Tool Sleeve
24 Tool Driver
Use
Hydraulic Valve Seal Replacer
JDG734
Install new seals
JDG734 Hydraulic Valve Seal Replacer and place lip seal (16) on end of tool driver (24) with open side of seal away from tool
driver.
[14] -
→NOTE:
Lip end of sleeve ID is cone-shaped to compress seal for installation.
Carefully slide tool sleeve (23) over seal and tool driver with raised lip of sleeve away from driver. Do not push seal through
tool sleeve.
[15] - Place tool assembly over end of spool with raised lip into counterbore of valve section.
[16] - Push tool driver to install lip seal into valve housing.
[17] - Spin tool driver 180 degrees and hold down for several seconds. This will allow air to escape and seal will seat in valve
counterbore.
[18] - Install seal (18), lip seal (16), and wiper spool seal (15) to loader and stabilizer control valve.
[19] - Install loader boom spool to loader and stabilizer control valve.
[20] - Apply PM38623 and PM37421 Loctite ™ Thread Lock and Sealer (high strength) to threads of spool and cap screws.
[21] - Install plate and spool end cap screws. Tighten spool end cap screws to specifications.
Item Measurement Specification
84 lb.-in.
→NOTE:
There should be a 1/8” gap between cap and loader and stabilizer control valve.
[23] - Install spring into both valve seat inserts and screw in end.
[1] -
Remove lock nut (1), cap screw (2), and tube (3) from loader bucket spool (194).
[2] -
LEGEND:
1 Lock Nut
2 Cap Screw
3 Tube
4 Spool End Cap Screw (2 used)
5 Plate
6 Spacer
7 Spool Wiper Seal
8 Lip Seal
9 Cap Screw (2 used)
10 Magnet Housing
11 Magnet Assembly
12 Spacer
13 Ring
14 Clapper
15 Spool End
16 Plate
17 Spacer
18 Spring Seat
19 Ring
20 Spring
21 Spring Seat
22 Plate
23 Seal
24 Fitting Plug
25 O-Ring
26 Spring
27 Poppet
190 Loader and Stabilizer Control Valve
194 Loader Bucket Spool
Remove spool end cap screws (4), plate (5), and spacer (6).
[3] - Use an O-ring pick remove spool wiper seal (7) and lip seal (8) from loader and stabilizer control valve.
[4] - Remove cap screws (9), magnet housing (10), and magnet assembly (11).
[6] - Remove ring (13), clapper (14), spool end (15), and plate (16).
[7] - Remove spacer (17), spring seat (18), and ring (19).
[8] - Remove spring (20), spring seat (21), and plate (22).
[9] - Remove loader bucket spool from loader and stabilizer control valve (190).
[10] - Use an O-ring pick to remove seal (23) from loader and stabilizer control valve.
[11] - Remove fitting plug (24), O-ring (25), spring (26), and poppet (27).
[12] - Install poppet, spring (26), O-ring (25), and fitting plug.
[13] -
IMPORTANT:
Do not damage OD or ID of new seal during installation. JDG734 Hydraulic Valve Seal Replacer must be
used to install lip seal.
Lube seals with hydraulic oil prior to installation.
Installation Tool
LEGEND:
8 Lip Seal
28 Tool Sleeve
29 Tool Driver
Use
Hydraulic Valve Seal Replacer
JDG734
Install new seals
JDG734 Hydraulic Valve Seal Replacer and place lip seal (8) on end of tool driver (29) with open side of seal away from tool
driver.
[14] -
→NOTE:
Lip end of sleeve ID is cone-shaped to compress seal for installation.
Carefully slide tool sleeve (28) over seal and tool driver with raised lip of sleeve away from driver. Do not push seal through
tool sleeve.
[15] - Place tool assembly over end of spool with raised lip into counterbore of valve section.
[16] - Push tool driver to install lip seal into valve housing.
[17] - Spin tool driver 180 degrees and hold down for several seconds. This will allow air to escape and seal will seat in valve
counterbore.
[18] - Install spool wiper seal (7), lip seal (8), and seal (23) to loader and stabilizer control valve.
[19] - Install loader bucket spool into loader and stabilizer control valve.
[20] - Install plate (22), spring seat (21), and spring (20).
[21] - Install ring (19), spring seat (18), and spacer (17).
[22] - Install plate (16), spool end (15), clapper (14), and ring (13).
[24] - Install magnet assembly, magnet housing, and cap screws (9).
[25] - Apply PM38623 and PM37421 Loctite ™ Thread Lock and Sealer (high strength) to threads of spool and cap screws.
[26] - Install spacer (6), plate (5), and spool end cap screws (4). Tighten spool end cap screws to specifications.
Item Measurement Specification
84 lb.-in.
[1] -
[2] - Use an O-ring pick to remove spool wiper seal (3) and lip seal (4).
[4] - Remove cap screw (7), retainers (8 and 10), and spring (9).
[6] - Remove loader auxiliary spool (195) from loader and stabilizer control valve (190).
[7] - Use an O-ring pick to remove seals (12 and 13) from loader and stabilizer control valve.
[9] - Remove fitting plug (16), O-ring (17), spring (18), and poppet (19).
[10] - Install poppet, spring (18), O-ring (17), and fitting plug (16).
[12] -
IMPORTANT:
Do not damage OD or ID of new seal during installation. JDG734 Hydraulic Valve Seal Replacer must be
used to install lip seal.
Lube seals with hydraulic oil prior to installation.
Installation Tool
LEGEND:
23 Tool Sleeve
4 Lip Seal
24 Tool Driver
Use
Hydraulic Valve Seal Replacer
JDG734
Install new seals
JDG734 Hydraulic Valve Seal Replacer and place lip seal (4) on end of tool driver (24) with open side of seal away from tool
<- Go to Section TOC Section 31 page 30 315SK Backhoe Loader Repair
Section 31 - LOADER Group 3160: Hydraulic System
driver.
[13] -
→NOTE:
Lip end of sleeve ID is cone-shaped to compress seal for installation.
Carefully slide tool sleeve (23) over seal and tool driver with raised lip of sleeve away from driver. Do not push seal through
tool sleeve.
[14] - Place tool assembly over end of spool with raised lip into counterbore of valve section.
[15] - Push tool driver to install lip seal into valve housing.
[16] - Spin tool driver 180 degrees and hold down for several seconds. This will allow air to escape and seal will seat in valve
counterbore.
[17] - Install seals (13 and 12) and plate to loader and stabilizer control valve.
[19] - Install loader auxiliary spool to loader and stabilizer control valve.
[20] - Install retainers (10 and 8), spring (9), and cap screw (7).
[21] - Apply PM38623 and PM37421 Loctite ™ Thread Lock and Sealer (high strength) to threads of spool and cap screws.
[22] - Install cap and retaining screws (5). Tighten cap screws to specifications.
Item Measurement Specification
84 lb.-in.
[23] - Install plate (2) and spool end cap screws (1). Tighten spool end cap screws to specifications.
Item Measurement Specification
84 lb.-in.
Loader and Stabilizer Control Valve Relief Valves Remove and Install
Specifications
SPECIFICATIONS
45 N·m
Relief Valve 22.35 mm (0.88 in.) Torque
33 lb.-ft.
61 N·m
Relief Valve 26 mm (1.06 in.) Torque
45 lb.-ft.
45 N·m
System Relief Valve Torque
33 lb.-ft.
[2] -
→NOTE:
Relief valves must be installed in the correct ports for proper valve function.
To aid in assembly, put identification marks on relief valve and corresponding control valve port.
See Loader and Stabilizer Control Valve Spool Disassemble and Assemble . (Group 3160.)
See Loader and Stabilizer Control Valve System Relief Valve Disassemble and Assemble . (Group 3160.) (310K)
See Loader Boom Anticavitation Valve Disassemble and Assemble . (Group 3160.) (310K—325SK)
See Loader Boom Anticavitation Check Valve Disassemble and Assemble . (Group 3160.) (410K—710K)
See Loader Boom Raise and Bucket Curl Circuit Relief Valve Disassemble and Assemble . (Group 3160.)
See Loader Bucket Dump Circuit Relief Valve with Anticavitation Disassemble and Assemble . (Group 3160.)
See Loader Auxiliary Circuit Relief Valve Disassemble and Assemble . (Group 3160.)
See Loader Auxiliary Shutoff Plug Disassemble and Assemble . (Group 3160.)
[5] - Remove and inspect O-rings and backup rings for damage. If damaged, check housing for cause.
[6] -
IMPORTANT:
Avoid O-ring or component damage. Apply clean hydraulic oil to all internal parts before assembly and
petroleum jelly to O-rings and backup rings before installation.
Apply petroleum jelly to new O-rings and backup rings. Install new O-rings and backup rings.
[7] -
→NOTE:
Relief valves must be installed in the correct ports for proper valve function.
Relief valve installation torque is port size specific. Verify diameter of port with specifications listed
below.
33 lb.-ft.
45 lb.-ft.
33 lb.-ft.
[8] - To install loader and stabilizer control valve, see Loader and Stabilizer Control Valve Remove and Install . (Group 3160.)
[9] -
IMPORTANT:
To prevent possible hydraulic system damage, relief valves MUST be adjusted anytime they are
disassembled or replaced.
Adjust circuit relief valve pressures. See Circuit Relief Valve Test—With Remote Pump . (Group 9025-25.)
[10] - Adjust system relief valve. See System Relief Valve Pressure Test . (Group 9025-25.)
SPECIFICATIONS
58—72 N·m
Loader Boom Anticavitation Valve Torque
43—52 lb.-ft.
[1] -
LEGEND:
1 Valve Body
2 O-Ring
3 Spring
4 O-Ring
5 Backup Ring
6 Poppet
[2] - Remove O-ring (4), backup ring (5), and poppet (6).
43—52 lb.-ft.
Loader Boom Raise and Bucket Curl Circuit Relief Valve Disassemble
and Assemble
Specifications
SPECIFICATIONS
58—72 N·m
Circuit Relief Valve 26 mm (1.06 in.) Torque
43—53 lb.-ft.
[1] -
LEGEND:
1 Lock Nut
2 Adjustment Screw
3 O-Ring
4 Spring
5 Seal
6 O-Ring
7 Poppet
8 Relief Valve Body
9 O-Ring
10 Backup Ring
11 O-Ring
→NOTE:
If parts (1, 2, 7, and 8) need service, replace entire assembly.
→NOTE:
If seals are damaged, inspect port on control valve for wear or damage.
[2] - Remove seal (5), O-ring (6), poppet (7), and relief valve body (8).
[3] - Remove O-ring (9), backup ring (10), and O-ring (11).
[6] - Install O-ring (11), backup ring, O-ring (9), and relief valve body (8).
[8] - Install O-ring (3), adjustment screw, and lock nut. Tighten to specification.
Item Measurement Specification
43—53 lb.-ft.
SPECIFICATIONS
58—72 N·m
Circuit Relief Valve With Anticavitation 26 mm (1.06 in.) Torque
43—53 lb.-ft.
[1] -
LEGEND:
1 Lock Nut
2 Adjustment Screw
3 O-Ring
4 Pilot Spring
5 Pilot Poppet
6 Valve Body
7 O-Ring (2 used)
8 Anticavitation Spring
9 Backup Ring (2 used)
10 O-Ring
11 Main Spring
12 Piston
13 Poppet
14 O-Ring
15 Backup Ring
16 Main Poppet
17 Valve Body
→NOTE:
If parts (1, 2, 4—6,8,11—13,16, and 17) need service, replace entire assembly.
If seals are damaged, inspect port on control valve for wear or damage.
[2] - Remove pilot poppet (5), valve body (6), O-rings (7), anticavitation spring (8), and backup rings (9).
[3] - Remove O-ring (10), main spring (11), piston (12), poppet (13), and O-ring (14).
[4] - Remove backup ring (15), main poppet (16), and valve body (17).
[7] - Install valve body (17), main poppet, backup ring (15), and O-ring (14).
[9] - Install backup rings (9), anticavitation spring, O-rings (7), valve body (6), and pilot poppet.
[11] -
IMPORTANT:
Relief valves must be installed in the correct ports for proper valve function.
IMPORTANT:
Relief valve installation torque is port size specific. Verify diameter of port with specifications listed
below.
Circuit Relief Valve With Anticavitation 26 mm (1.06 in.) Torque 58—72 N·m
43—53 lb.-ft.
SPECIFICATIONS
58—72 N·m
Loader Auxiliary Circuit Relief Valve Torque
43—53 lb.-ft.
[1] -
LEGEND:
1 Valve Body
2 Spring
3 Retaining Ring (2 used)
4 O-Ring
5 Backup Ring (2 used)
6 O-Ring
7 Backup Ring
8 Adjusting Screw
9 Spring
10 Flat Washer (4 used)
11 Poppet
12 Valve Sleeve
13 O-Ring
[2] - Remove backup rings (5), O-ring (6), backup ring (7), and adjusting screw (8).
[3] - Remove spring (9), flat washers (10), poppet (11), valve sleeve (12), and O-ring (13).
[6] - Install O-ring (13), valve sleeve, poppet, flat washers, and spring (9).
[7] - Install adjusting screw, backup ring (7), O-ring (6), and backup rings (5).
[8] - Install O-ring (4), retaining rings, spring (2), and valve body.
[9] - Install loader auxiliary circuit relief valve and torque to specification.
Item Measurement Specification
43—53 lb.-ft.
Shutoff Plug
Specifications
SPECIFICATIONS
58—72 N·m
Loader Auxiliary Shutoff Plug Torque
43—53 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
[1] -
43—53 lb.-ft.
SPECIFICATIONS
36 kg
210K, 310K, 310SK, 315SK, 410K Weight (approximate)
80 lb.
64 kg
310SK TMC, 325K, 325SK, 410K TMC Weight (approximate)
141 lb.
55 kg
710K Weight (approximate)
122 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
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.
Release pressure in hydraulic system. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] -
LEGEND:
1 Snap Ring
2 Washer
3 Pin
4 Boom Cylinder Head End Hydraulic Hose
5 Clamp
6 Boom Cylinder Rod End Hydraulic Hose
7 Pin
8 Cap Screw
9 Plate
202 Boom Cylinder
[5] - Tag and disconnect head end hydraulic hose (4) and rod end hydraulic hose (6) from boom cylinder (202). Close all
openings using caps and plugs.
[6] -
CAUTION:
Prevent crushing injury from heavy component. Use appropriate lifting device.
80 lb.
141 lb.
122 lb.
[8] - While supporting rod end of boom cylinder, remove cap screw (8), plate (9), and pin (7). Lower rod end of cylinder away
from loader arm and slide boom cylinder off pin (3).
[9] - Inspect and repair loader boom cylinder as necessary. See Loader Boom Cylinder Disassemble and Assemble . (Group
3160.)
[10] - Apply multipurpose grease to inside of all bushings before installing cylinder.
[11] -
CAUTION:
Prevent crushing injury from heavy component. Use appropriate lifting device.
[12] - Slide head end of boom cylinder onto pin (3). Install washer and snap ring.
[13] - Align hole in rod end of boom cylinder with pin boss holes in loader arm. Install pin (7), plate, and cap screw.
[14] - Connect hydraulic hoses to boom cylinder and install clamp. Tighten securely.
[15] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position.
SPECIFICATIONS
53 kg
210K, 310K, 310SK, 315SK, 410K Weight (approximate)
117 lb.
65 kg
310SK TMC, 325K, 325SK, and 410K TMC Weight (approximate)
144 lb.
75 kg
710K Weight (approximate)
165 lb.
44 kg
Front Link Weight (approximate)
97 lb.
26 kg
Rear Link Weight (approximate)
58 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] -
LEGEND:
1 Bucket Cylinder Head End Hydraulic Hose
2 Bucket Cylinder Rod End Hydraulic Hose
3 Clamp
4 Snap Ring (2 used)
5 Washer (6 used)
6 Loader Bucket Cylinder Pivot
7 Loader Bucket Cylinder Rear Link (2 used)
8 Grease Fitting
9 Washer
10 Snap Ring (2 used)
11 Washer (2 used)
12 Loader Bucket Cylinder Rear Link-to-Loader Pin
13 Loader Bucket Leveling Linkage
203 Loader Bucket Cylinder
[5] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system
before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying
pressure.
Tag and disconnect head end and rod end hydraulic hoses (1 and 2) from loader bucket cylinder (203). Close all openings using
caps and plugs.
[6] -
CAUTION:
Prevent crushing injury from heavy component. Use appropriate lifting device.
117 lb.
144 lb.
165 lb.
[7] - Remove grease fitting (8) and washer (9) from loader bucket leveling linkage (13).
[8] - Remove loader bucket leveling linkage from loader bucket rear link.
[9] - Remove snap rings (4 and 10) and washers (5 and 11).
[11] -
CAUTION:
Prevent crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
5 Washer (6 used)
14 Loader Bucket Front Link
15 Snap Ring
16 Washer (2 used)
Loader Bucket Cylinder Front Link-to-Loader Bucket
17
Pin
203 Loader Bucket Cylinder
97 lb.
58 lb.
[14] -
LEGEND:
5 Washer (6 used)
18 Snap Ring
Loader Bucket Cylinder Front Link-to-Loader Bucket
19
Pin
203 Loader Bucket Cylinder
[16] - Repair or replace loader bucket cylinder as necessary. See Loader Bucket Cylinder Disassemble and Assemble . (Group
3160.)
[18] -
CAUTION:
Prevent crushing injury from heavy component. Use appropriate lifting device.
[19] - Move loader bucket cylinder into position and install loader bucket cylinder-to-loader bucket pin (19) and snap ring (18).
[20] - Attach appropriate lifting device to loader bucket cylinder front link.
[21] - Install washer (5) onto loader bucket cylinder pivot (6).
[22] - Install loader bucket cylinder front link, washers (5 and 16), and snap ring (15).
[23] - Install loader bucket cylinder rear link, washers (5 and 11), and snap rings (4 and 10).
[24] - Install loader bucket leveling linkage, washer (9), and grease fitting.
[25] - Connect head end and rod end hydraulic hoses to loader bucket cylinder and install clamp. Tighten securely.
[26] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position.
[2] - For location of loader auxiliary manifold (197), See Hydraulic System Component Location . (Group 9025-15.)
[3] - Drain hydraulic oil reservoir or apply a vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[4] -
[5] - Tag and disconnect electrical connectors to loader auxiliary extend solenoid (Y20) and loader auxiliary retract solenoid
(Y21).
[11] - Fill hydraulic oil reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
SPECIFICATIONS
37 N·m
Ride Control Valve Mounting Cap Screw Torque
27 lb.-ft.
50 N·m
Ride Control Valve Hydraulic Hose Torque
37 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
→NOTE:
Before performing service on ride control valve, see Ride Control Operation—If Equipped . (Group
9025-05.) See Hydraulic System Component Location . (Group 9025-15.)
CAUTION:
Prevent possible injury from unexpected boom or bucket movement when equipped with ride control.
Ride control accumulator energy must be discharged when working on hydraulic components.
Relieve pressure in ride control system. See Ride Control Accumulator Hydraulic Pressure Release Procedure . (Group 9025-20.)
[3] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve hydraulic pressure in system
before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying
pressure.
Relieve hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] -
→NOTE:
Ride control valve is located inside battery box.
Disconnect battery cables and remove battery box. See Battery Box Remove and Install . (Group 1913.)
[5] -
LEGEND:
1 Hydraulic Supply Hose
2 Hydraulic Supply Hose
3 Ride Control Valve Mounting Cap Screw (2 used)
4 Hydraulic Supply Hose
5 Hydraulic Return Hose
204 Ride Control Valve
205 Ride Control Accumulator
Y50 Ride Control Solenoid 1
Y51 Ride Control Solenoid 2
[6] - Tag and disconnect hydraulic hoses (1, 2, 4, and 5) from ride control valve. Close all openings using caps and plugs.
[7] - Remove ride control valve mounting cap screws (3) and ride control valve (204).
[8] - Repair or replace ride control valve as necessary. See Ride Control Valve Disassemble and Assemble . (Group 3160.)
[9] - Install ride control valve with ride control valve mounting cap screws. Tighten to specification.
Item Measurement Specification
27 lb.-ft.
37 lb.-ft.
[12] - Install battery box and connect battery cables. See Battery Box Remove and Install . (Group 1913.)
[13] - Charge ride control accumulator. See Ride Control Accumulator Charge Procedure . (Group 9025-20.)
[2] - If removal of ride control solenoids (Y50 and Y51) from ride control valve (204) is necessary, see Ride Control Valve
Solenoid Disassemble and Assemble . (Group 3160.)
[3] -
IMPORTANT:
Prevent component or O-ring damage. Apply clean hydraulic oil to all internal parts before assembling
and apply petroleum jelly to all O-rings before installation.
[4] - Apply clean hydraulic oil to all internal parts. Assemble all parts. Tighten securely.
SPECIFICATIONS
41 N·m
Solenoid Valve Spool Torque
30 lb.-ft.
5 N·m
Ride Control Solenoid Nut Torque
48 lb.-in.
[1] -
→NOTE:
Ride control valve solenoids can be serviced with ride control valve installed on machine.
→NOTE:
To remove ride control valve, see Ride Control Valve Remove and Install . (Group 3160.)
LEGEND:
1 O-Ring (2 used)
2 O-Ring (2 used)
3 Solenoid Valve Spool (2 used)
4 Nut (2 used)
5 Orifice (2 used)
204 Ride Control Valve
Y50 Ride Control Solenoid 1
Y51 Ride Control Solenoid 2
[2] - Remove ride control solenoids (Y50 and Y51) from solenoid valve spools (3).
[3] - Remove solenoid valve spools from ride control valve (204).
[6] -
IMPORTANT:
Prevent O-ring or component damage. Apply clean hydraulic oil to all internal parts before assembly and
petroleum jelly to O-rings before installation.
[7] - Apply clean hydraulic oil to all internal parts. Install solenoid valve spool in ride control valve. Tighten to specification.
Item Measurement Specification
30 lb.-ft.
48 lb.-in.
[9] - To install ride control valve (if removed), see Ride Control Valve Remove and Install . (Group 3160.)
SPECIFICATIONS
73 N·m
Ride Control Accumulator Mounting Strap Cap Screw Torque
54 lb.-ft.
37 N·m
Ride Control Accumulator-to-Ride Control Valve Hydraulic Hose Torque
27 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
CAUTION:
Prevent possible injury from unexpected boom or bucket movement when equipped with ride control.
Ride control accumulator energy must be discharged when working on hydraulic components.
Relieve pressure in ride control system. See Ride Control Accumulator Hydraulic Pressure Release Procedure . (Group 9025-20.)
[3] - Relieve hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] -
→NOTE:
Ride control accumulator is located inside battery box attached to left frame rail.
Disconnect battery cables and remove battery box. See Battery Box Remove and Install . (Group 1913.)
[5] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve hydraulic pressure in system
before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying
pressure.
LEGEND:
1 Cap Screw (2 used)
2 Upper Mounting Strap
3 Lower Mounting Strap
4 Cap Screw (2 used)
Ride Control Accumulator-to-Ride Control Valve
5
Hydraulic Hose
204 Ride Control Valve
205 Ride Control Accumulator
[6] -
→NOTE:
The ride control valve (204) does not have to be removed from the lower mounting strap (3).
Remove cap screws (1 and 4) and upper and lower mounting straps (2 and 3) to remove ride control accumulator.
[7] -
→NOTE:
Ride control accumulator has no serviceable internal parts.
[8] - Install ride control accumulator. Fasten with upper and lower mounting straps. Tighten mounting strap cap screws (1 and
4) to specification.
Item Measurement Specification
54 lb.-ft.
27 lb.-ft.
[10] - Install battery box and connect battery cables. See Battery Box Remove and Install . (Group 1913.)
[11] - Charge ride control accumulator. See Ride Control Accumulator Charge Procedure . (Group 9025-20.)
Section 33 - BACKHOE
Table of contents
Group 3302 - Bucket ................................................................................................................................ 1
Backhoe Bucket and Bucket Links Remove and Install ......................................................................... 1
Backhoe Bucket Tooth Tips Remove and Install ................................................................................... 2
Bucket Tooth Shank Remove and Install .............................................................................................. 3
Backhoe Bucket Cutting Edge Remove and Install ............................................................................... 6
Group 3315 - Control Linkage ................................................................................................................ 8
Backhoe Control Valve Linkage Remove and Install—Two Lever .......................................................... 8
Backhoe Control Valve Linkage Disassemble and Assemble—Two Lever ........................................... 11
Backhoe Auxiliary Pedal Remove and Install—Fifth and Sixth Functions ............................................ 15
Backhoe Auxiliary Pedal Disassemble and Assemble—Fifth and Sixth Functions ............................... 19
Backhoe Pilot Control Valve Remove and Install ................................................................................ 25
Backhoe Pilot Control Valve Disassemble and Assemble .................................................................... 32
Backhoe Pilot Control Tower Remove and Install ............................................................................... 36
Backhoe Pilot Control Tower Disassemble and Assemble ................................................................... 42
Group 3340 - Frames ............................................................................................................................. 51
Dipperstick Remove and Install .......................................................................................................... 51
Backhoe Boom Remove and Install .................................................................................................... 54
Swing Frame Remove and Install ....................................................................................................... 56
Dipperstick Extension Remove and Install .......................................................................................... 58
Sideshift Frame Remove and Install ................................................................................................... 63
Group 3360 - Hydraulic System ........................................................................................................... 66
Backhoe Control Valve Remove and Install ........................................................................................ 66
Backhoe Control Valve Disassemble and Assemble ........................................................................... 78
Backhoe Control Valve Spool Seals Remove and Install ..................................................................... 81
Backhoe Control Valve Relief Valves Remove and Install ................................................................... 86
Backhoe Inlet Section Disassemble and Assemble ............................................................................. 88
Backhoe Boom Section Disassemble and Assemble ........................................................................... 91
Backhoe Bucket Section Disassemble and Assemble ......................................................................... 98
Backhoe Crowd Section Disassemble and Assemble ........................................................................ 104
Backhoe Swing Section Disassemble and Assemble ........................................................................ 111
Backhoe Auxiliary Section Disassemble and Assemble—If Equipped ............................................... 117
Backhoe Auxiliary Selective Flow Control Section Disassemble and Assemble—If Equipped ........... 121
Pilot Enable and Pattern Select Valve Remove and Install ............................................................... 125
Pilot Enable and Pattern Select Valve Disassemble and Assemble ................................................... 128
Backhoe Boom Cylinder Remove and Install .................................................................................... 130
Backhoe Boom Cylinder Disassemble and Assemble ....................................................................... 132
Backhoe Bucket Cylinder Remove and Install .................................................................................. 133
Backhoe Bucket Cylinder Disassemble and Assemble ...................................................................... 134
Backhoe Crowd Cylinder Remove and Install ................................................................................... 135
Backhoe Crowd Cylinder Disassemble and Assemble ....................................................................... 137
Backhoe Stabilizer Cylinder Remove and Install ............................................................................... 138
Backhoe Stabilizer Cylinder Disassemble and Assemble .................................................................. 139
Backhoe Swing Cylinder Remove and Install .................................................................................... 140
Backhoe Swing Cylinder Disassemble and Assemble ....................................................................... 142
Backhoe Extendable Dipperstick Cylinder Remove and Install ......................................................... 143
Backhoe Extendable Dipperstick Cylinder Disassemble and Assemble ............................................ 144
Backhoe Boom Lock Cylinder Remove and Install ............................................................................ 145
Backhoe Boom Lock Valve Remove and Install—(S.N. —232969) .................................................... 147
Backhoe Sideshift Lock Valve Remove and Install—(S.N. —232969) ................................................ 149
Backhoe Sideshift Lock Valve Disassemble and Assemble—(S.N. —232969) ................................... 152
Backhoe Sideshift Lock Valve Disassemble and Assemble—(S.N. 255930—) ................................... 154
Backhoe Sideshift Lock Piston and Bushing Remove and Install ...................................................... 157
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[11] - Inspect bushings and replace as necessary. For ease of removing bushings, weld three straight beads the inside length
of the bushing. Allow bushing to cool before removing with a punch. Install new bushings even with outside surface of bucket
using D01072AA Seal Driver Set.
Bushing, Bearing and Seal Driver Set
D01072AA
Used to install bushings in bucket links.
[16] - Align bucket with pin boss holes. Install pins (5).
Top Weld
Remove top and bottom welds using air arc equipment or cutting torch.
[2] -
Bottom Weld
Grind all surfaces to a smooth finish.
[3] -
IMPORTANT:
Shanks and cutting edge must be preheated to 177°C (350°F) to prevent under bead cracking in shank
and brittleness in cutting edge. Preheat each shank and cutting edge area just before welding. Use low
hydrogen E-7018 dry rods or E-70T-4 flux core process.
Position shanks on cutting edge. Preheat area to be welded just before welding to 177°C (350°F).
[4] -
<- Go to Section TOC Section 33 page 3 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3302: Bucket
[5] - Weld area of corner shank with an angle weld (2), 6 mm (0.24 in.) deep and 11 mm (0.43 in.) across face.
[6] - Weld area of corner shank with a bevel weld (3). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cap that
weld with a 11 mm (0.43 in.) fillet weld. Leave area (4) free of weld for 19 mm (0.75 in.).
[7] - On center shanks, weld areas with a bevel weld (5). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cover
with a 9 mm (0.35 in.) fillet weld (5).
[8] - Weld area with an angle weld (6), 6 mm (0.24 in.) deep and 11 mm (0.43 in.) across face.
[9] -
LEGEND:
7 Bevel Weld and Fillet Weld
8 Bevel Weld and Fillet Weld
9 Bevel Weld and Fillet Weld
10 Weld Free Area
11 Bevel Weld and Fillet
12 Angle Weld
[10] - Weld area with bevel weld (8). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cover with 9 mm (0.35 in.)
fillet weld (8).
[11] - Weld area of corner shank with bevel weld (9). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cover with
11 mm (0.43 in.) fillet weld (9). Leave area (10) free of weld for 19 mm (0.75 in.).
[12] - On center shanks, weld areas with bevel weld (11). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cover
with a 9 mm (0.35 in.) fillet weld (11). Leave area (10) free of weld for 19 mm (0.75 in.).
[13] - Weld area with angle weld (12). Penetrate 6 mm (0.24 in.) and leave a 11 mm (0.43 in.) face.
[2] -
Remove Welds
Use air arc equipment or cutting torch to remove welds. Remove all welds from cutting edge to side cutters.
[4] -
[5] - Cut new cutting edge to proper length for bucket, approximately 11 mm (0.43 in.) protruding beyond side cutter on each
side.
[6] -
IMPORTANT:
Cutting edge must be preheated to 177°C (350°F) to prevent brittleness in cutting edge. Preheat area
just before welding. Use low hydrogen E-7018 dry rods or E-70T-4 flux core process.
[7] - Make 11 mm (0.43 in.) fillet weld outside bucket at cutting edge to side cutter joint. Continue weld down back edge.
[8] -
[9] - Install shanks. See Bucket Tooth Shank Remove and Install . (Group 3302.)
[2] -
Control Console
LEGEND:
1 Cap Screw (4 used)
2 Console Cover
Remove rear floor mat.
[4] -
[5] -
[6] - Repair or replace parts as necessary. See Backhoe Control Valve Linkage Disassemble and Assemble—Two Lever . (Group
3315.)
[9] - Adjust valve linkage. See Backhoe Control Lever to Valve Linkage (Two Lever) Adjustment . (Group 9025-20.)
[1] -
→NOTE:
Follow same procedure to disassemble and assemble left control lever linkage.
[2] - Replace parts as necessary. See Linkage Assembly Disassemble and Assemble at the end of this procedure.
[3] - Remove nut (4), link (5), washer (6), and cap screw (7) from lever base.
[4] - Replace parts as necessary. See Link Disassemble and Assemble at the end of this procedure.
[1] -
Linkage Assembled
Linkage Disassembled
LEGEND:
1 Nut
8 Ball Joint
9 Yoke
10 Lock Nut (2 used)
11 Rod
Loosen lock nuts (10).
[2] - Remove ball joint (8), yoke (9), and lock nuts (10) from rod (11).
[1] -
Link Assembled
Link Disassembled
LEGEND:
4 Nut
5 Link
6 Washer
7 Cap Screw
12 Nut
Remove nut (12) from link (5).
[1] -
→NOTE:
Pedal remove and install is the same for fifth and sixth function pedal assemblies. This procedure utilizes
the fifth function pedal to describe remove and install steps.
Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
[4] -
[6] - Repair or replace parts as necessary. See Backhoe Auxiliary Pedal Disassemble and Assemble—Fifth and Sixth Functions .
(Group 3315.)
Pilot Controls
[1] -
→NOTE:
Pedal remove and install is the same for fifth and sixth function pedal assemblies. This procedure utilizes
the sixth function pedal to describe remove and install steps.
Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
Auxiliary Pedals
LEGEND:
1 Cap Screw (4 used) (if equipped)
2 Fifth Function Pedal
3 Sixth Function Pedal (if equipped)
4 Cap Screw (4 used)
5 Linkage Cover
Remove rear floor mat.
[3] - Remove cap screws (1) and fifth and sixth function pedals (2 and 3).
[5] -
Pedal Linkage
LEGEND:
6 Retainer
7 Pin
8 Cap Screw (2 used)
9 Pedal Linkage Assembly
Remove retainer (6) and pin (7).
[6] - Remove cap screws (8) and pedal linkage assembly (9).
[7] - Repair or replace parts as necessary. See Backhoe Auxiliary Pedal Disassemble and Assemble—Fifth and Sixth Functions .
(Group 3315.)
[11] - Install fifth and sixth function pedals and cap screws (1).
[1] -
→NOTE:
Pedal disassemble and assemble is the same for fifth and sixth function pedal assemblies. This procedure
utilizes the fifth function pedal to describe disassemble and assemble steps.
Pedal Assembly
LEGEND:
1 Nut
2 Linkage Assembly
3 Pedal
Remove nut (1) and linkage assembly (2) from pedal (3).
[2] - Replace linkage assembly parts as necessary. See Linkage Disassemble and Assembleat end of this procedure.
[3] -
Pedal Assembled
Pedal Disassembled
LEGEND:
3 Pedal
4 Nut
5 Spring Washer (2 used)
6 Bushing (2 used)
7 Washer
8 Cap Screw
9 Grommet
Remove nut (4), spring washers (5), bushings (6), washer (7), and cap screw (8) from pedal (3).
[7] - Install cap screw, washer, bushings, spring washers, and nut (4) to pedal.
0.06 in.
Pilot Controls
[1] -
→NOTE:
Pedal disassemble and assemble is the same for fifth and sixth function pedal assemblies. This procedure
utilizes the fifth function pedal to describe disassemble and assemble steps.
[2] - Replace linkage assembly parts as necessary. See Linkage Disassemble and Assemble.
[3] -
Remove nut (13), washer (14), bushings (15), pedal pivot, and cap screw (16) from mounting bracket (17).
[5] - Install cap screw, pedal pivot, bushings, washer, and nut (13) to mounting bracket.
[1] -
Linkage Assembled
Linkage Disassembled
LEGEND:
18 Ball Joint
19 Yoke
20 Lock Nut (2 used)
21 Rod
Loosen lock nuts (20).
[2] - Remove ball joint (18), yoke (19), and lock nuts, from rod (21).
ESSENTIAL TOOLS
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[5] -
[6] -
[7] - Remove cap screws (3) and upper control tower cover (4).
[8] -
Insert JDG1385 STC Hose and Line Fitting Tool between release sleeve and shoulder of fitting.
Snap-to-Connect (STC) ™ Hose and Line Fitting Tool
JDG1385
Disconnect Snap-to-Connect® Fittings.
c. Gently push, do not pry, release sleeve away from shoulder to disconnect the STC fitting.
d. Pull hydraulic hose to disconnect.
[10] - Repair or replace pilot controller as necessary. See Backhoe Pilot Control Valve Disassemble and Assemble . (Group
3315.)
[13] - Install upper control tower cover and cap screws (3).
[15] - Install lower control tower cover and cap screws (1).
[17] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[5] -
LEGEND:
1 Cap Screw (3 used)
2 Lower Control Tower Cover
Remove cap screws (1) and lower control tower cover (2).
[6] -
[7] -
Insert JDG1385 STC Hose and Line Fitting Tool between release sleeve and shoulder of fitting.
Snap-to-Connect (STC) ™ Hose and Line Fitting Tool
JDG1385
Disconnect Snap-to-Connect® Fittings.
c. Gently push, do not pry, release sleeve away from shoulder to disconnect the STC fitting.
d. Pull hydraulic hose to disconnect.
[8] - Repair or replace pilot controller as necessary. See Backhoe Pilot Control Valve Disassemble and Assemble . (Group
3315.)
[11] - Install upper control tower cover and cap screws (3).
[12] - Install lower control tower cover and cap screws (1).
[14] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
SPECIFICATIONS
34 N·m
Hex Nut-to-Universal Joint Torque
25 lb.-ft.
45 N·m
Universal Joint-to-Housing Torque
33 lb.-ft.
24 N·m
Adapter-to-Housing Torque
18 lb.-ft.
[1] -
→NOTE:
There is one orifice used for each pilot control valve. Left pilot control valve uses an orifice in work port 2
and right pilot control valve used an orifice in work port 3.
The orifices function one-way, they restrict flow only for oil returning to the pilot control valve. Flow out
of the pilot control valve is free flowing.
17 Washer (4 used)
18 Cap Screw (4 used)
19 Universal Joint
20 Plate
21 Nut
22 Handle
Plunger Assembly
LEGEND:
12 Plunger
13 O-Ring (4 used)
14 Bearing
15 Seal (4 used)
Remove fitting (1), O-rings (2), adapters (3), O-rings (4), and orifice (5).
[2] - Remove housing (6), springs (7), spools (8), retainer rings (9), and springs (10).
[3] - Remove seats (11), plungers (12), O-rings (13), and bearings (14).
[4] - Remove seals (15), plate (16), cap screws (18), washers (17), and universal joint (19).
[6] - Lubricate all seals and O-rings with hydraulic oil before assembly.
[10] - Install bearings, O-rings (13), plungers, seats (11), and springs (10).
[12] - Install orifice (5) in proper work port as needed, depending on right or left side valve.
[14] - Tighten nut (21), adapters (3), and universal joint (19) to specification.
Item Measurement Specification
25 lb.-ft.
33 lb.-ft.
18 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil (Operator′s Manual) or see Apply
Vacuum to Hydraulic Oil Reservoir . (Group 2160.)
[5] -
[6] - If equipped, remove cap screws (1) and auxiliary control pedals (2).
[9] - Remove console cover (5) by sliding it over backhoe boom lock lever (6).
[10] - Remove cap screws (7) and rear floor access plate (8).
[11] -
Insert JDG1385 STC Hose and Line Fitting Tool between release sleeve and shoulder of fitting.
STC Hose and Line Fitting Tool
JDG1385
Disconnect Snap-to-Connect® Fittings.
c. Gently push, do not pry, release sleeve away from shoulder to disconnect the STC fitting.
d. Pull hydraulic line to disconnect.
[13] - Remove cap screws (10) and right pilot control tower (11).
[15] - Install right pilot control tower and cap screws (10).
[18] - Install rear floor access plate, console cover, and cap screws (4 and 7).
[21] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[22] - Fill hydraulic oil reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil (Operator′s Manual) see Apply Vacuum
to Hydraulic Oil Reservoir . (Group 2160.)
[5] -
[6] - If equipped, remove cap screws (1) and auxiliary control pedals (2).
[9] - Remove console cover (5) by sliding it over backhoe boom lock control lever (6).
[10] - Remove cap screws (7) and rear floor access plate (8).
[11] -
LEGEND:
9 Cap Screw (3 used)
10 Washer (3 used)
11 Cap Screw (2 used)
12 Stabilizer Console Cover
[12] - Remove cap screws (11) and stabilizer console cover (12).
[13] -
Insert JDG1385 STC Hose and Line Fitting Tool between release sleeve and shoulder of fitting.
STC Hose and Line Fitting Tool
JDG1385
Disconnect Snap-to-Connect® Fittings.
c. Gently push, do not pry, release sleeve away from shoulder to disconnect the STC fitting.
d. Pull hydraulic line to disconnect.
[14] - Remove cap screws (14) and left pilot control tower (15).
[16] - Install left pilot control tower and cap screws (14).
[18] - Install stabilizer console cover, washers, and cap screws (9 and 11).
[19] - Install rear floor access plate, console cover, and cap screws (4 and 7).
[20] - If equipped, install auxiliary control pedals and cap screws (1).
[23] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[24] - Fill hydraulic oil reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[1] - Remove pilot control valve and shields. See Backhoe Pilot Control Valve Remove and Install . (Group 3315.)
[2] -
[5] -
Wrist Support
LEGEND:
4 Adjustment Lever
5 Washer
6 Cap Screw
7 Washer
8 Spring Washer
9 Nut
10 Wrist Support
Remove adjustment lever (4) and washer (5).
[6] - Remove cap screw (6), washer (7), spring washer (8), nut (9), and wrist support (10).
[7] -
Cylinder Removal
LEGEND:
11 Cap Screw
12 Washer (3 used)
13 Nut
14 Cap Screw
15 Washer (4 used)
16 Spacer
17 Nut
18 Shock
Remove cap screw (11), washers (12), and nut (13).
[8] - Remove cap screw (14), washers (15), spacer (16), nut (17), and shock (18).
[9] -
Arm Removal
LEGEND:
19 Snap Ring
20 Washer
21 Arm
22 Bearing (2 used)
23 Cap Screw (2 used)
24 Washer (2 used)
25 Spacer
26 Nut (2 used)
27 Bushing
Remove snap ring (19), washer (20), and arm (21).
[11] - Remove cap screws (23), washers (24), spacer (25), nuts (26), and bushing (27).
[13] - Install bushing, spacer (25), nuts (26), washers (24), and cap screws (23).
[16] -
→NOTE:
Shock should be installed rod end down to extend shock life.
Install shock, nuts (13 and 17), spacer, washers (12 and 15), and cap screws (11 and 14).
[17] - Install wrist support, nut (9), spring washer, washer (7), and cap screw (6).
[22] - Install pilot control valve and shields. See Backhoe Pilot Control Valve Remove and Install . (Group 3315.)
[1] - Remove pilot control valve and shields. See Backhoe Pilot Control Valve Remove and Install . (Group 3315.)
[2] -
[4] -
[5] - Remove cap screw (6), washer (7), spring washer (8), nut (9), and wrist support (10).
[6] -
Shock Removal
LEGEND:
11 Cap Screw
12 Washer (3 used)
13 Nut
14 Cap Screw
15 Washer (2 used)
16 Shock
Remove cap screw (11), washers (12), and nut (13).
[7] - Remove cap screw (14), washers (15), and shock (16).
[8] -
Arm Removal
LEGEND:
17 Snap Ring
18 Washer
19 Arm
20 Bearing (2 used)
21 Cap Screw (2 used)
22 Spacer (2 used)
23 Washer (2 used)
24 Nut (2 used)
Remove snap ring (17), washer (18), and arm (19).
[10] - Remove cap screws (21), spacers (22), washers (23), and nuts (24).
[12] - Install nuts (24), washers (22), spacers, and cap screws (21).
[15] -
→NOTE:
Shock should be installed rod end down to extend shock life.
Install shock, washers (12 and 15), cap screws (11 and 14), and nut (13).
[16] - Install wrist support, nut (9), spring washer, washer (7), and cap screw (6).
[19] - Install pilot control valve and shields. See Backhoe Pilot Control Valve Remove and Install . (Group 3315.)
SPECIFICATIONS
204 kg
Dipperstick with Bucket Cylinder and Links Weight (approximate)
450 lb.
620 N·m
Dipperstick-to-Boom Connecting Pin Cap Screw Torque
460 lb.-ft.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
[3] - Stop engine. Place transmission control lever (TCL) in neutral and set park brake.
[4] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025.)
[5] - Remove backhoe bucket and bucket links. See Backhoe Bucket and Bucket Links Remove and Install . (Group 3302.)
[6] -
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.
Tag and remove bucket cylinder lines (1). Close all openings using caps and plugs.
[8] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
→NOTE:
If bucket links are removed, fasten rod end of bucket cylinder to dipperstick.
Remove boom-to-dipperstick pin (3), washers, and shims.Remove dipperstick using a hoist.
Item Measurement Specification
450 lb.
[10] -
Dipperstick Adjustment
LEGEND:
<- Go to Section TOC Section 33 page 52 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3340: Frames
3 Boom-to-Dipperstick Pin
6 Outer Plate
7 Shim (as required)
8 Cap Screw
9 Washer
10 Shim (as required)
11 Washer
Install boom to dipperstick with pin (5).
Use shims (10) if pin (6) does not extend to surface of outer plate (6). Shim until flush with outer plate surface.
Use shims (7) if pin (6) extends beyond surface of outer plate. Shim until flush with end of pin.
[12] - Install cap screw (8) and washer (9). Tighten cap screw to specifications.
Item Measurement Specification
460 lb.-ft.
[13] - Align crowd cylinder; install pin, shims, washer, and cap screw.
[15] - Install backhoe bucket and bucket links. See Backhoe Bucket and Bucket Links Remove and Install . (Group 3302.)
SPECIFICATIONS
385 kg
Boom with Cylinders Weight (approximate)
850 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely (Group 0001.)
[2] - Stop engine. Place transmission control lever (TCL) in neutral and set park brake.
[3] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025.)
[4] - Remove dipperstick. See Dipperstick Remove and Install . (Group 3340.)
[5] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
850 lb.
[6] -
CAUTION:
LEGEND:
1 Hydraulic Line (4 used)
2 Pivot (2 used)
3 Cap Screw (2 used)
4 Collar (2 used)
5 Pin
6 Snap Ring (2 used)
[7] - Remove pivots (2) and boom cylinder rod end pin.
[9] - Remove snap rings (6), pin (5), and collars (4).
[13] - Install pivots, boom cylinder rod end pin, collar, and snap rings.
[15] - Install dipperstick to boom. See Dipperstick Remove and Install . (Group 3340.)
SPECIFICATIONS
129 kg
Swing Frame (310K-410K) Weight (approximate)
284 lb.
298 kg
Swing Frame (710K) Weight (approximate)
657 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
Swing Frame
LEGEND:
1 Swing Frame
2 Boom Lock Rod
3 Boom Lock Hook
4 Cap screw (2 used)
5 Washer (2 used)
6 Hose Guard
7 Swing Cylinder Locking Snap Ring and Rod
8 Pin (2 used)
9 Upper Pivot Locking Cap Screw
10 Lock Nut (2 used)
11 Lower Pivot Locking Cap Screw
12 Upper Pivot Pin
13 Thrust Washer
Lower Pivot Joint
14 Lower Shim
Remove dipperstick. See Dipperstick Remove and Install . (Group 3340.)
[3] - Remove boom. See Backhoe Boom Remove and Install . (Group 3340.)
[4] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
284 lb.
657 lb.
[5] - Remove boom lock rod (2) from boom lock hook (3).
[8] - Remove swing cylinder locking snap ring and rod (7) from swing frame.
[10] - Remove upper pivot locking cap screw (9) and lock nut (10) from the swing frame.
[11] - Remove lower pivot locking cap screw (11) and lock nut (10) from the swing frame.
[12] - Remove upper pivot pin (12), thrust washer (13), and lower shim (14) from both the top and lower mainframe pivot boss
of the swing frame.
[15] -
→NOTE:
Weight of backhoe is supported at the lower pivot. There must be clearance between upper main frame
pivot boss and the ears of the swing frame.
[16] -
→NOTE:
Install swing frame pins so that cross-drilled holes align with holes in swing frame to ease hardware
installation.
Position swing frame and install upper pivot pin. Secure in position with upper pivot locking cap screw and nut.
[17] - Align thrust washer with pin bore. Install lower pivot pin and secure in position with lower pivot locking cap screw and
nut.
[18] - Align swing cylinders and install pins from the bottom. Top of pins should be even with casting. Secure in position with
swing cylinder locking snap ring and rod.
[21] - Install boom. See Backhoe Boom Remove and Install . (Group 3340.)
[22] - Install dipperstick. See Dipperstick Remove and Install . (Group 3340.)
SPECIFICATIONS
385 kg
Dipperstick Extension Weight (approximate)
850 lb.
73 N·m
Rod End Hose-to-Fitting Torque
54 lb.-ft.
73 N·m
Head End Hose-to-Elbow Fitting Torque
54 lb.-ft.
100 N·m
Elbow Fitting-to-Extendable Cylinder Head End Torque
74 lb.-ft.
22—27 N·m
Extendable Dipperstick Hex Socket Cap Screws for Internal Wear Plates Torque
16—20 lb.-ft.
104 N·m
Extendable Cylinder Head End 90° Fitting Torque
76 lb.-ft.
47—54 N·m
Extendable Dipperstick Hex Socket Cap Screws for Outer Pads Torque
35—40 lb.-ft.
Other Material
OTHER MATERIAL
[1] -
LEGEND:
1 Bucket Cylinder
2 Lifting Strap
3 Dipperstick (extending member)
4 Extension Locking Pin
5 Extending Cylinder Rod End Pin
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[3] - Remove bucket and bucket links. See Backhoe Bucket and Bucket Links Remove and Install . (Group 3302.)
[4] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[5] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve pressure in system before
disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
Tag and disconnect hydraulic hoses from bucket cylinder (1). Close all openings using caps and plugs.
[6] - Secure bucket cylinder to dipperstick. Let hoses and lines hang to side.
[7] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device. Make sure hoist
is attached to dipperstick extension. When extendable cylinder rod end pin is removed, dipperstick
extension can drop suddenly.
850 lb.
[8] - Remove extension locking pin (4) and extending cylinder rod end pin (5).
[9] - Extend stabilizers fully, raise boom, and place dipperstick extension in vertical position. While raising boom and moving
dipperstick toward machine with extension supported on ground, raise boom until extension can be removed.
[11] -
LEGEND:
8 Hose, Rod End
9 Hose, Head End
10 Snap Ring
11 Pin
Disconnect rod end hose (8) and head end hose (9) from top of dipperstick.
[13] - Slowly raise dipperstick and support extendible dipperstick cylinder with appropriate lifting device.
[14] -
[15] - Remove wear plates (17 and 19) and shims (18) (if equipped).
[18] -
[19] - Remove O-rings (24) and fitting (25) from rod end hose.
[20] - Remove O-rings (26 and 28) and elbow fitting (27) from head end hose.
[22] - Install O-rings (26 and 28) and elbow fitting to head end hose, tighten to specifications.
Item Measurement Specification
54 lb.-ft.
74 lb.-ft.
[24] - Install O-rings (24) and fitting (25) to rod end hose, tighten to specifications.
Item Measurement Specification
54 lb.-ft.
[25] -
IMPORTANT:
It is important to maintain running clearance between pad, inner, and outer members of extension.
Do not damage shims. Only put in enough shims to fill clearance, then remove one shim.
Locking nuts should be replaced if removed to prevent loosening.
Install shims as required, to fill clearance and remove one shim. For every three shims added, remove a washer from under
[26] - Install wear plates (17 and 19) with cap screws (16), washers (15), and lock nuts (14).
[27] - Apply PM37509 Klean ‘N Prime™ and PM37418 Thread Lock and Sealer to threads of cap screws.
[28] -
IMPORTANT:
Do not over tighten cap screws or wear plate deformation may result.
Extendable Dipperstick Cap Screws for Internal wear plates Torque 22—27 N·m
16—20 lb.-ft.
Extendable Dipperstick Cap Screws for Outer Pads Torque 47—54 N·m
35—40 lb.-ft.
[30] - Install extendible dipperstick cylinder to dipperstick. Install pin and snap ring.
[31] - Connect rod end hose and head end hose to fittings at top dipperstick.
[32] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Using proper lifting device, lift extension to vertical position. With stabilizers fully extended, raise boom and install dipperstick
into extension.
Item Measurement Specification
850 lb.
[33] - Install extension locking pin (4) and extending cylinder rod end pin (5).
[36] - Install bucket cylinder. See Backhoe Bucket Cylinder Remove and Install . (Group 3360.)
[37] - Install bucket, links, and quick couplers (if equipped). See Backhoe Bucket and Bucket Links Remove and Install . (Group
3302.)
SPECIFICATIONS
363 kg
Sideshift Frame with Swing Cylinders Weight (approximate)
800 lb
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Lower stabilizers and backhoe to the ground. Stop engine and release pressure in the system. See Hydraulic Circuit
Pressure Release . (Group 9025-25.)
[3] -
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.
Tag and disconnect hydraulic hose supplying pressure oil to boom lock cylinders.
[4] - Tag and disconnect hydraulic hose supplying pressure oil to sideshift lock piston circuit (four pistons total).
[5] - Remove backhoe boom. See Backhoe Boom Remove and Install . (Group 3340.)
[6] - Remove swing frame. See Swing Frame Remove and Install . (Group 3340.)
[7] -
Sideshift Frame
LEGEND:
1 Swing Cylinder Plumbing Line
2 Lock Valve Line
3 Extendible Dipper, Supply Line
4 Extendible Dipper, Return Line
5 Crowd, Supply Line
6 Crowd, Return Line
[8] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
14 Lock Bar
15 Cap Screw
16 Sideshift Frame
17 Shim (as needed)
Sideshift Frame
Attach a lifting strap and hoist to frame.
Item Measurement Specification
800 lb
[9] - Remove lock bar (14) by removing cap screws (15) and shims (17).
[11] - Inspect lock pistons, pivot bushing, and lock bar for wear.
[13] - Install frame. Frame must fit completely on top and bottom rail.
[14] - Install lock bar with as many shims (17) as possible. Use as many shims as necessary for each side.
[15] - Remove 2.0 mm (0.08 in.) thickness of shims. Check to see if frame slides without binding. Add or subtract shims as
necessary.
[17] - Install boom. See Backhoe Boom Remove and Install . (Group 3340.)
[18] - Install swing frame. See Swing Frame Remove and Install . (Group 3340.)
SPECIFICATIONS
50 kg
Backhoe Control Valve and Mount Plate (manual) Weight (approximate)
110 lb.
68 kg
Backhoe Control Valve and Mount Plate (pilot) Weight (approximate)
150 lb.
129 N·m
Frame Mount Cap Screw Torque
95 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
Manual Controls
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil (Operator′s Manual.) or see Apply
Vacuum to Hydraulic Oil Reservoir . (Group 2160.)
[5] - Remove rear window. See Non-Fixed Window Remove and Install . (Group 1810.)
[7] -
[8] - Remove fifth and sixth function control pedals (2 and 3), if equipped. See Backhoe Auxiliary Pedal Remove and
Install—Fifth and Sixth Functions . (Group 3315.)
[10] - Remove cap screws (5) and rear floor access plate (6).
[11] -
[12] - Tag and disconnect load sense pressure sensor (B16) and selective flow control solenoid (Y53) electrical connectors, if
equipped.
[13] -
Backhoe Control Valve Front and Side Connections (310SK six function shown)
LEGEND:
15 Loader Auxiliary Manifold Supply Hose (if equipped)
16 Hydraulic Supply Hose
17 Hydraulic Return Hose
18 Loader and Stabilizer Hydraulic Supply Hose
19 Cap Screw (2 used)
20 Hose Guide (2 used)
21 Backhoe Control Valve Mounting Plate
22 Auxiliary Selective Flow Control Return Hose (if equipped)
Tag and disconnect hoses (15—18). Close all openings using caps and plugs.
[14] - Remove cap screws (19) to remove hose guides (20) from backhoe control valve mounting plate (21).
[15] - Disconnect hose (22), if equipped, and route out of backhoe control valve mounting plate. Close all openings using caps
and plugs.
[16] -
CAUTION:
110 lb.
[18] - Move backhoe control valve and mounting bracket toward front of machine and carefully remove assembly.
[19] - Repair backhoe control valve as necessary. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.)
[20] - Move backhoe control into proper position and install cap screws (24). Tighten to specification.
Item Measurement Specification
95 lb.-ft.
[21] - Route hose (22) through backhoe control valve mounting plate and connect.
[22] - Install hose guides and cap screws (19) to backhoe control valve mounting plate.
[24] - Connect load sense pressure sensor (B16) and selective flow control solenoid (Y53) electrical connectors, if equipped.
[25] - Install rear floor access plate and cap screws (5).
[27] - Install fifth and sixth function control pedals if equipped. See Backhoe Auxiliary Pedal Remove and Install—Fifth and
Sixth Functions . (Group 3315.)
[28] - Install backhoe control valve levers and linkage. See Backhoe Control Valve Linkage Remove and Install—Two Lever .
(Group 3315.)
[30] - Install rear window. See Non-Fixed Window Remove and Install . (Group 1810.)
[31] - Refill or remove vacuum to hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)
[32] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
Pilot Controls
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Drain or apply vacuum to hydraulic oil reservoir. See Change Hydraulic Reservoir Oil (Operator′s Manual.) or see Apply
Vacuum to Hydraulic Oil Reservoir . (Group 2160.)
[5] - Remove rear window. See Non-Fixed Window Remove and Install . (Group 1810.)
[7] -
[9] - Remove cap screws (4) and rear floor access plate (5).
[10] -
[11] - Tag and disconnect load sense pressure sensor (B16) and selective flow control solenoid (Y53) electrical connectors, if
equipped.
[12] -
Backhoe Control Valve Front and Side Connections (310SK six function shown)
LEGEND:
14 Pilot Enable and Pattern Select (PEPS) Manifold Supply Hose
15 Hydraulic Supply Hose
16 Hydraulic Return Hose
17 Loader and Stabilizer Control Valve Supply Hose
18 Swing Spool Pilot Control Hose
19 Boom Spool Pilot Control Hose
20 Bucket Spool Pilot Control Hose
21 Crowd Spool Pilot Control Hose
22 Crowd Spool Pilot Control Hose
23 Bucket Spool Pilot Control Hose
24 Boom Spool Pilot Control Hose
25 Swing Spool Pilot Control Hose
26 Cap Screw (2 used)
27 Hose Guide (2 used)
28 Backhoe Control Valve Mounting Plate
29 Auxiliary Selective Flow Control Return Hose (if equipped)
Tag and disconnect hoses (14—25). Disconnect pilot enable and pattern select valve STC fitting lines by performing the
following:
Insert JDG1385 STC Hose and Line Fitting Tool between release sleeve and shoulder of fitting.
c. Gently push, do not pry, release sleeve away from shoulder to disconnect the STC fitting.
d. Pull hydraulic line to disconnect.
[13] - Remove cap screws (26) to remove hose guides (27) from backhoe control valve mounting plate (28).
[14] - Disconnect hose (29), if equipped, and route out of backhoe control valve mounting plate. Close all openings using caps
and plugs.
[15] -
[16] -
[17] -
CAUTION:
150 lb.
[19] - Move backhoe control valve mounting assembly toward front of machine and carefully remove assembly.
[20] - Repair backhoe control valve as necessary. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.)
[21] - Move backhoe control valve into proper position and install cap screws (34) to frame. Tighten to specification.
Item Measurement Specification
95 lb.-ft.
[22] - Connect pilot control console harness connector and pilot enable switch harness connector.
[23] - Route hose (29) if equipped, through backhoe control valve mounting plate and connect.
[24] - Install hose guides and cap screws (26) to backhoe control valve mounting plate.
[26] - Connect load sense pressure sensor (B16) and selective flow control solenoid (Y53) electrical connectors, if equipped.
[27] - Install rear floor access plate and cap screws (5).
[29] - Install fifth and sixth function control pedals if equipped. See Backhoe Auxiliary Pedal Remove and Install—Fifth and
Sixth Functions . (Group 3315.)
[31] - Install rear window. See Non-Fixed Window Remove and Install . (Group 1810.)
[32] - Fill hydraulic oil reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)
[33] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
5 Inlet Section
6 Auxiliary Selective Flow Control Section (if equipped)
7 Auxiliary Section (if equipped)
8 Swing Section
9 Boom Section
10 Bucket Section
11 Crowd Section
12 Extendable Dipperstick Section or Auxiliary Section (if equipped)
13 O-Ring (as needed)
14 Load Check (4 used)
15 Spring (4 used)
16 Load Check
17 Spring
145 Backhoe Control Valve
Specifications
SPECIFICATIONS
50 kg.
Manual Controls Weight (approximate)
110 lb.
68 kg.
Pilot Controls Weight (approximate)
150 lb.
100 N·m
Nut (1/2 in. tie rod) Torque
74 lb.-ft.
65 N·m
Nut (7/16 in. tie rod) Torque
48 lb.-ft.
[1] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
110 lb.
150 lb.
[3] - Remove nuts (1) and washers (2) from top of backhoe control valve.
[4] -
IMPORTANT:
Prevent possible damage to backhoe control valve. Keep all components for an individual section
together as a set.
Carefully remove sections (5—12). Take care to not lose or damage O-rings (13), load checks (14 and 16), and springs (15 and
17).
[6] - For complete section disassembly and assembly, see corresponding procedures:
Inlet Section (5) See Backhoe Inlet Section Disassemble and Assemble . (Group 3360.)
Auxiliary Selective Flow Control Section (6) See Backhoe Auxiliary Selective Flow Control Section Disassemble and Assemble—If Equipped . (Group 3360.)
Auxiliary Section (7) See Backhoe Auxiliary Section Disassemble and Assemble—If Equipped . (Group 3360.)
Swing Section (8) See Backhoe Swing Section Disassemble and Assemble . (Group 3360.)
Boom Section (9) See Backhoe Boom Section Disassemble and Assemble . (Group 3360.)
Bucket Section (10) See Backhoe Bucket Section Disassemble and Assemble . (Group 3360.)
Crowd Section (11) See Backhoe Crowd Section Disassemble and Assemble . (Group 3360.)
[7] -
IMPORTANT:
Prevent possible damage to hydraulic components. Load check (16) must be installed after spring (17).
This is a different style check and should not be used in other sections.
Assemble sections in marked order. Ensure O-rings, load checks, and springs remain in correct position.
[10] -
IMPORTANT:
Prevent possible damage to backhoe control valve. Tighten rods evenly in several steps to prevent valve
spool binding or leakage between sections.
74 lb.-ft.
48 lb.-ft.
[2] - Remove two socket head cap screws (5) and retainer plate (4) from top of valve section.
[3] - Use an O-ring pick to remove spool wiper ring (3) and lip seal (2).
[4] -
[5] - Remove spool end screw (12) to remove spring seats (13), spring (9), and retainer plate (10).
[6] - Use an O-ring pick to remove spool wiper ring (8) and lip seal (7).
[7] -
IMPORTANT:
Do not damage OD or ID of new seal during installation. Installation tool JDG734 must be used to install
lip seal.
Lube seals with hydraulic oil prior to installation.
Installation Tool
LEGEND:
15 Tool Sleeve
16 Lip Seal
17 Tool Driver
Use
Hydraulic Valve Seal Replacer
JDG734
Install new seals
JDG734 Hydraulic Valve Seal Replacer to install new lip seal at each end of spool.
[8] - Place lip seal (16) on end of tool driver (17) with open side of seal away from tool driver.
[9] -
→NOTE:
Lip end of sleeve ID is cone-shaped to compress lip seal for installation.
Carefully slide sleeve (15) over lip seal (16) and tool driver (17) with raised lip of sleeve away from driver. Do not push lip seal
(16) through sleeve (15).
[10] - Place tool assembly over end of spool with raised lip into counterbore of valve section.
[11] - Push tool driver (17) to install lip seal (16) into valve housing.
[12] - Spin tool driver 180 degrees and hold down for several seconds. This will allow air to escape and seal will seat in valve
counter bore.
[13] -
[15] - Install retainer plate (10), spring seats (13) and spring (9).
84 lb-in.
[17] - Install cap (14) and cap screws (6). Torque screws to specification.
Item Measurement Specification
84 lb-in.
[18] -
84 lb-in.
[19] - Check for correct installation of seals by pushing down on spool (1). Spool must return to neutral position.
SPECIFICATIONS
45 N·m
Relief Valve Torque 22.35 mm (0.88 in.)
33 lb.-ft.
61 N·m
Relief Valve Torque 26 mm (1.06 in.)
45 lb.-ft.
45 N·m
System Relief Valve Torque
33 lb.-ft.
[2] -
→NOTE:
Relief valves must be installed in the correct ports for proper valve function performance.
To aid in assembly, put identification marks on the relief valves and corresponding control valve ports.
[4] - Remove and inspect O-rings and backup rings for damage. If damaged, check housing for cause.
[6] -
IMPORTANT:
Avoid O-ring or component damage. Apply clean hydraulic oil to all internal parts before assembly and
petroleum jelly to O-rings and backup rings before installation
Apply petroleum jelly to new O-rings and backup rings. Install new rings.
[7] -
→NOTE:
Relief valve installation torque is port size specific. Verify diameter of port with specifications listed
below.
Apply clean hydraulic oil to all internal parts. Install and tighten relief valves to specification.
Item Measurement Specification
33 lb.-ft.
45 lb.-ft.
33 lb.-ft.
[8] - For installation of backhoe control valve, see Backhoe Control Valve Remove and Install . (Group 3360.)
[9] -
IMPORTANT:
Some relief valves are adjustable. Adjustable relief valves MUST be adjusted after they are disassembled
or replaced. Failure to do so can cause damage to hydraulic system components.
Adjust relief valves. See Circuit Relief Valve Test—With Remote Pump and see System Relief Valve Pressure Test . (Group
9025-25.)
SPECIFICATIONS
65 N·m
Plug Torque
48 lb.-ft.
45 N·m
System Relief Valve Torque
33 lb.-ft.
[1] -
5 Spring
6 Spool
150 System Relief Valve
Remove system relief valve (150). Repair or replace as necessary. See System Relief Valve Disassemble and Assemble.
[3] - Remove plug (3), O-ring (4), spring (5), and spool (6).
[4] -
→NOTE:
Spool is not serviceable individually.
[6] - Install spool, spring, O-rings (2 and 4), and plugs (1 and 3). Tighten to specification.
Item Measurement Specification
48 lb.-ft.
33 lb.-ft.
[8] -
IMPORTANT:
Prevent possible damage to hydraulic components. Relief valves must be adjusted after they are
disassembled or replaced.
After installation of backhoe control valve to machine, adjust system relief valve pressure. See System Relief Valve Pressure
Test . (Group 9025-25.)
[1] -
1 Plug
2 Valve Body
3 O-Ring
4 Nut
5 Spring
6 Washer
7 Poppet
8 Plug
9 O-Ring
10 O-Ring
11 Backup Ring (2 used)
12 Seal
Separate plug (1) from valve body (2).
[2] - Remove O-ring (3) and nut (4) from plug (1).
[4] - Remove plug (8), O-rings (9 and 10), and backup rings (11).
[8] - Install backup rings, O-rings (9 and 10), and plug (8).
SPECIFICATIONS
9.5 N·m
Spool Detent Cap Screw Torque
84 lb.-in.
9.5 N·m
Detent Body Cap Screw Torque
84 lb.-in.
5.5 N·m
Plate Cap Screw Torque
48 lb.-in.
9.5 N·m
Spool Detent Cap Screw and Plug Torque
84 lb.-in.
9.5 N·m
End Cap, Cap Screw Torque
84 lb.-in.
65 N·m
Plug Torque
48 lb.-ft.
61 N·m
Relief Valve Torque
45 lb.-ft.
Other Material
OTHER MATERIAL
[1] -
19 Spring
231 Boom Circuit Relief Valve (no anticavitation)
232 Boom Circuit Relief Valve (with anticavitation)
Remove boom circuit relief valve (no anticavitation) (231). Repair or replace as necessary. See Relief Valve Disassemble and
Assemble—No Anticavitation.
[2] - Remove boom circuit relief valve (with anticavitation) (232). Repair or replace as necessary. See Relief Valve Disassemble
and Assemble—With Anticavitation.
[3] - Remove plug (1), O-ring (2), washer (3), spring (4), and poppet (5).
[4] - Remove cap screws (6), plate (7), wiper (8), and O-ring (9).
[6] - Remove O-ring (11), wiper (12), and plate (13) from spool (14).
[9] - Remove cap screw (16), O-ring (17), spring seats (18), and spring (19).
[10] -
→NOTE:
Washer, poppet, and spool are not serviceable individually.
[12] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool
and cap screw (16).
[13] - Install spring seats, spring (19), O-ring (17), and cap screw (16) to spool. Tighten to specification.
Item Measurement Specification
84 lb.-in.
[14] - Install plate (13), wiper (12), and O-ring (11) to spool.
[15] - Instal spool assembly, detent body, and cap screws (10). Tighten to specification.
Item Measurement Specification
84 lb.-in.
[16] - Install O-ring (9), wiper (8), plate (7), and cap screws (6). Tighten to specification.
Item Measurement Specification
48 lb.-in.
[17] - Install poppet, spring (4), washer, O-ring (2), and plug. Tighten to specification.
Item Measurement Specification
48 lb.-ft.
45 lb.-ft.
[1] -
25 Spool
26 Cap
27 Cap Screw
28 Spring Seat (2 used)
29 Spring
30 Retainer
31 Plug
32 O-Ring
33 O-Ring
231 Boom Circuit Relief Valve (no anticavitation)
232 Boom Circuit Relief Valve (with anticavitation)
Remove boom circuit relief valve (no anticavitation) (231). Repair or replace as necessary. See Relief Valve Disassemble and
Assemble—No Anticavitation.
[2] - Remove boom circuit relief valve (With Anticavitation) (232). Repair or replace as necessary. See Relief Valve
Disassemble and Assemble—With Anticavitation.
[3] - Remove plug (1), O-ring (2), washer (3), spring (4), and poppet (5).
[4] - Remove cap screws (20), cap (21), and O-ring (22).
[9] - Remove cap screw (27), spring seats (28), spring (29), retainer (30), plug (31), and O-rings (32 and 33).
[10] -
→NOTE:
Washer, poppet, and spool are not serviceable individually.
[12] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool,
plug (31), and cap screw (27).
[13] - Install O-rings (32 and 33), plug (31), retainer, spring (29), spring seats, and cap screw (27) to spool. Tighten to
specification.
Item Measurement Specification
84 lb.-in.
[14] - Install spool assembly, O-rings (22 and 24), caps, and cap screws (20 and 23). Tighten to specification.
Item Measurement Specification
84 lb.-in.
[15] - Install poppet, spring (4), washer, O-ring (2), and plug (1). Tighten to specification.
Item Measurement Specification
48 lb.-ft.
45 lb.-ft.
[1] -
[4] -
IMPORTANT:
Prevent possible damage to hydraulic components. Do not disassemble sleeve assembly. Relief is not
adjustable. Internals of sleeve assembly are not serviceable individually.
→NOTE:
Only valve body, spring, backup ring and O-ring are serviceable.
[1] -
[2] - Remove spring (5), sleeve (6), O-ring (7), and poppet (8).
[3] - Remove O-rings (9 and 10) and backup ring (11) from valve body.
SPECIFICATIONS
9.5 N·m
Spool Detent Cap Screw Torque
84 lb.-in.
9.5 N·m
Detent Body Cap Screw Torque
84 lb.-in.
5.5 N·m
Plate Cap Screw Torque
48 lb.-in.
9.5 N·m
Spool Detent Cap Screw and Plug Torque
84 lb.-in.
9.5 N·m
End Cap, Cap Screw Torque
84 lb.-in.
61 N·m
Relief Valve Torque
45 lb.-ft.
Other Material
OTHER MATERIAL
[1] -
[2] - Remove cap screws (1), plate (2), wiper (3), and O-ring (4).
[4] - Remove O-ring (6), wiper (7), and plate (8) from spool (9).
[7] - Remove cap screw (11), spring seats (12), and spring (13).
[8] -
→NOTE:
Spool is not serviceable individually.
[10] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool
and cap screw (11).
[11] - Install spring seats, spring, and cap screw (11) to spool. Tighten to specification.
Item Measurement Specification
84 lb.-in.
[12] - Install plate (8), wiper (7), and O-ring (6) to spool.
[13] - Instal spool assembly, detent body, and cap screws (5). Tighten to specification.
Item Measurement Specification
84 lb.-in.
[14] - Install O-ring (4), wiper (3), plate (2), and cap screws (1). Tighten to specification.
Item Measurement Specification
48 lb.-in.
45 lb.-ft.
[1] -
<- Go to Section TOC Section 33 page 100 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[2] - Remove cap screws (20), cap (21), and O-ring (22).
<- Go to Section TOC Section 33 page 101 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[7] - Remove cap screw (27), spring seats (28), spring (29), retainer (30), and O-ring (31).
[10] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool
and cap screw (27).
[11] - Install O-ring (31), retainer, spring (29), spring seats, and cap screw (27) to spool. Tighten to specification.
Item Measurement Specification
84 lb.-in.
[12] - Install spool assembly, O-rings (22 and 24), caps, and cap screws (20 and 23). Tighten to specification.
Item Measurement Specification
84 lb.-in.
45 lb.-ft.
[1] -
2 Adjustment Screw
3 O-Ring
4 Valve Body
5 Spring
6 Sleeve
7 O-Ring
8 Poppet
9 O-Ring
10 O-Ring
11 Backup RIng
Remove nut (1), adjustment screw (2), and O-ring (3) from valve body (4). Note number of revolutions for removal of
adjustment screw.
[2] - Remove spring (5), sleeve (6), O-ring (7), and poppet (8).
[3] - Remove O-rings (9 and 10) and backup ring (11) from valve body.
<- Go to Section TOC Section 33 page 103 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
9.5 N·m
Spool Detent Cap Screw Torque
84 lb.-in.
9.5 N·m
Detent Body Cap Screw Torque
84 lb.-in.
5.5 N·m
Plate Cap Screw Torque
48 lb.-in.
65 N·m
Plug Torque
48 lb.-ft.
45 N·m
Relief Valve 22 mm (0.88 in.) Torque
33 lb.-ft.
61 N·m
Relief Valve 26 mm (1 in.) Torque
45 lb.-ft.
9.5 N·m
End Cap, Cap Screw Torque
84 lb.-in.
24 N·m
Relief Valve Nut Torque
18 lb.-ft.
Other Material
OTHER MATERIAL
[1] -
<- Go to Section TOC Section 33 page 104 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
<- Go to Section TOC Section 33 page 105 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[2] - Remove plug (3), O-ring (4), washer (5), spring (6), and poppet (7).
[3] - Remove cap screws (8), plate (9), wiper (10), and O-ring (11).
[5] - Remove O-ring (13), wiper (14), and plate (15) from spool (16).
[8] - Remove cap screw (18), spring seats (19), and spring (20).
[10] -
→NOTE:
Washer, poppet, and spool are not serviceable individually.
[13] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool
and cap screw (18).
[14] - Install spring seats, spring (20), and cap screw (18) to spool. Tighten to specification.
Item Measurement Specification
84 lb.-in.
[15] - Install plate (15), wiper (14), and O-ring (13) to spool.
[16] - Install spool assembly, detent body, and cap screws (12). Tighten to specification.
Item Measurement Specification
84 lb.-in.
[17] - Install O-ring (11), wiper (10), plate (9), and cap screws (8). Tighten to specification.
Item Measurement Specification
48 lb.-in.
[18] - Install poppet, spring (6), washer, O-ring (3), and plug. Tighten to specification.
Item Measurement Specification
48 lb.-ft.
<- Go to Section TOC Section 33 page 106 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
33 lb.-ft.
45 lb.-ft.
[1] -
6 Spring
7 Poppet
25 Cap Screw (2 used)
26 Cap
27 O-Ring
28 Cap Screw (2 used)
29 O-Ring
30 Spool
31 Cap
32 Cap Screw
33 Spring Seat (2 used)
34 Spring
35 Retainer
36 O-Ring
37 O-Ring
Remove relief valves (1 and 2). Repair or replace as necessary. See Relief Valve 22 mm (0.88 in.) Disassemble and Assembleor
see Relief Valve 26 mm (1 in.) Disassemble and Assemble.
[2] - Remove plug (3), O-ring (4), washer (5), spring (6), and poppet (7).
[3] - Remove cap screws (25), cap (26), and O-ring (27).
[8] - Remove cap screw (32), spring seats (33), spring (34), retainer (35), and O-rings (36 and 37).
[9] -
→NOTE:
Washer, poppet, and spool are not serviceable individually.
[11] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool
and cap screw (32).
[12] - Install O-rings (36 and 37), retainer, spring (34), spring seats, and cap screw (32) to spool. Tighten to specification.
Item Measurement Specification
84 lb.-in.
[13] - Install spool assembly, O-rings (27 and 29), caps, and cap screws (25 and 28). Tighten to specification.
Item Measurement Specification
84 lb.-in.
[14] - Install poppet, spring (6), washer, O-ring (4), and plug (3). Tighten to specification.
Item Measurement Specification
48 lb.-ft.
<- Go to Section TOC Section 33 page 108 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
33 lb.-ft.
45 lb.-ft.
[1] -
[5] - Remove shim (7), spring (8), retainer (9) and poppet (10).
[6] -
→NOTE:
Only nuts, O-rings, and seal are serviceable.
[8] - Install adjustment screw, using alignment marks and noted revolutions.
<- Go to Section TOC Section 33 page 109 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
18 lb.-ft.
[1] -
[2] - Remove spring (5), sleeve (6), O-ring (7), and poppet (8).
[3] - Remove O-rings (9 and 10) and backup ring (11) from valve body.
<- Go to Section TOC Section 33 page 110 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
9.5 N·m
Spool Detent Cap Screw Torque
84 lb.-in.
9.5 N·m
Detent Body Cap Screw Torque
84 lb.-in.
5.5 N·m
Plate Cap Screw Torque
48 lb.-in.
9.5 N·m
End Cap, Cap Screw Torque
84 lb.-in.
61 N·m
Relief Valve Torque
45 lb.-ft.
Other Material
OTHER MATERIAL
[1] -
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Section 33 - BACKHOE Group 3360: Hydraulic System
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Section 33 - BACKHOE Group 3360: Hydraulic System
Assemble.
[2] - Remove cap screws (1), plate (2), wiper (3), and O-ring (4).
[4] - Remove O-ring (6), wiper (7), and plate (8) from spool (9).
[7] - Remove cap screw (11), O-ring (12), spring seats (13), and spring (14).
[9] -
→NOTE:
Spool is not serviceable individually.
[12] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool
and cap screw (11).
[13] - Install spring seats, spring (14), O-ring (12), and cap screw (11) to spool. Tighten to specification.
Item Measurement Specification
84 lb.-in.
[14] - Install plate (8), wiper (7), and O-ring (6) to spool.
[15] - Install spool assembly, detent body, and cap screws (5). Tighten to specification.
Item Measurement Specification
84 lb.-in.
[16] - Install O-ring (4), wiper (3), plate (2), and cap screws (1). Tighten to specification.
Item Measurement Specification
48 lb.-in.
45 lb.-ft.
[1] -
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Section 33 - BACKHOE Group 3360: Hydraulic System
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Section 33 - BACKHOE Group 3360: Hydraulic System
[2] - Remove cap screws (20), cap (21), and O-ring (22).
[7] - Remove cap screw (27), spring seats (28), spring (29), retainer (30), and O-rings (31 and 32).
[9] -
→NOTE:
Spool is not serviceable individually.
[11] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool,
cap screw (27), and plug.
[13] - Install O-rings (31 and 32), retainer, spring, spring seats, and cap screw (27) to spool. Tighten to specification.
Item Measurement Specification
84 lb.-in.
[14] - Install spool assembly, O-rings (22 and 24), caps, and cap screws (20 and 23). Tighten to specification.
Item Measurement Specification
84 lb.-in.
45 lb.-ft.
[1] -
<- Go to Section TOC Section 33 page 115 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[4] -
IMPORTANT:
Prevent possible damage to hydraulic components. Do not disassemble sleeve assembly. Relief is not
adjustable. Internals of sleeve assembly are not serviceable individually.
→NOTE:
Only valve body, spring, backup ring, and O-ring are serviceable.
<- Go to Section TOC Section 33 page 116 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
9.5 N·m
Spool Detent Cap Screw Torque
84 lb.-in.
9.5 N·m
Detent Body Cap Screw Torque
84 lb.-in.
5.5 N·m
Plate Cap Screw Torque
48 lb.-in.
65 N·m
Relief Valve or Plug Torque
48 lb.-ft.
Other Material
OTHER MATERIAL
→NOTE:
This procedure covers backhoe auxiliary hydraulic sections and extendable dipperstick section in the
backhoe control valve.
[1] -
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Section 33 - BACKHOE Group 3360: Hydraulic System
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Section 33 - BACKHOE Group 3360: Hydraulic System
[2] - Remove cap screws (4), plate (5), wiper (6), and O-ring (7).
[4] - Remove O-ring (9), wiper (10), and plate (11) from spool (12).
[7] - Remove cap screw (14), spring seats (15), and spring (16).
[8] -
→NOTE:
Spool is not serviceable individually.
[10] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool
and cap screw (14).
[11] - Install spring seats, spring, and cap screw (14) to spool. Tighten to specification.
Item Measurement Specification
84 lb.-in.
[12] - Install plate (11), wiper (10), and O-ring (9) to spool.
[13] - Instal spool assembly, detent body, and cap screws (8). Tighten to specification.
Item Measurement Specification
84 lb.-in.
[14] - Install O-ring (7), wiper (6), plate (5), and cap screws (4). Tighten to specification.
Item Measurement Specification
48 lb.-in.
[15] - Install relief valves (if equipped) or install plugs and O-rings (3) (if equipped). Tighten to specification.
Item Measurement Specification
48 lb.-ft.
[1] -
<- Go to Section TOC Section 33 page 119 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[4] -
IMPORTANT:
Prevent possible damage to hydraulic components. Do not disassemble sleeve assembly. Relief is not
adjustable. Internals of sleeve assembly are not serviceable individually.
→NOTE:
Only valve body, spring, backup ring and O-ring are serviceable.
<- Go to Section TOC Section 33 page 120 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
34 N·m
Solenoid Valve Torque
25 lb.-ft.
65 N·m
Selective Flow Spool Plug Torque
48 lb.-ft.
5 N·m
Selective Flow Knob Nut Torque
48 lb.-in.
65 N·m
Poppet Plug Torque
48 lb.-ft.
45 N·m
Relief Valve Torque
33 lb.-ft.
24 N·m
Relief Valve Nut Torque
18 lb.-ft.
[1] -
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Section 33 - BACKHOE Group 3360: Hydraulic System
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Section 33 - BACKHOE Group 3360: Hydraulic System
19 Spool
20 Nut
21 Solenoid Coil
22 Solenoid Spool
Remove relief valve (1). Repair or replace as necessary. See Relief Valve Disassemble and Assemble.
[2] - Remove plug (2), O-ring (3), spring (4), and poppet (5).
[5] - Remove selector nut (10), O-rings (11—14), and selector (15).
[6] - Remove plug (16), O-ring (17), spring (18), and spool (19).
[7] - Remove nut (20), solenoid coil (21), and solenoid spool (22).
[9] - Install O-rings (23—25), backup rings, and solenoid spool. Tighten to specification.
Item Measurement Specification
25 lb.-ft.
[11] - Install spool, spring (18), O-ring (17), and plug (16).
Item Measurement Specification
48 lb.-ft.
[13] - Install selector knob, plunger, and nuts (6 and 8). Tighten to specification.
Item Measurement Specification
48 lb.-in.
[14] - Install poppet, spring (4), O-ring (3), and plug (2). Tighten to specification.
Item Measurement Specification
48 lb.-ft.
33 lb.-ft.
[1] -
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Section 33 - BACKHOE Group 3360: Hydraulic System
[5] - Remove shim (7), spring (8), retainer (9), and poppet (10).
[6] -
→NOTE:
Only nuts, O-rings, and seal are serviceable.
[8] - Install adjustment screw, using alignment marks and noted revolutions.
18 lb.-ft.
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Section 33 - BACKHOE Group 3360: Hydraulic System
ESSENTIAL TOOLS
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil . (Operator′s Manual.) or see Apply
Vacuum to Hydraulic Oil Reservoir . (Group 2160.)
[5] -
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Section 33 - BACKHOE Group 3360: Hydraulic System
[8] - Remove console cover (5) by sliding it over backhoe boom lock control lever (6).
[9] - Remove cap screws (7) and rear floor access plate (8).
[10] -
LEGEND:
9 Cap Screw (2 used)
137 Pilot Enable and Pattern Select (PEPS) Manifold
140 Pilot Control Accumulator
Y52 Pilot Enable Solenoid
Y58 Pattern Select Solenoid 1
Y59 Pattern Select Solenoid 2
Insert JDG1385 STC Hose and Line Fitting Tool between release sleeve and shoulder of fitting.
STC Hose and Line Fitting Tool
JDG1385
Disconnect Snap-to-Connect Fittings.
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Section 33 - BACKHOE Group 3360: Hydraulic System
c. Gently push, do not pry, release sleeve away from shoulder to disconnect the STC fitting.
d. Pull hydraulic line to disconnect.
[11] - Tag and disconnect pilot enable solenoid (Y52), pattern select solenoid 1 (Y58), and pattern select solenoid 2 (Y59)
electrical connectors.
[14] - Repair or replace pilot enable and pattern select valve as required. See Pilot Enable and Pattern Select Valve
Disassemble and Assemble . (Group 3360.)
[17] - Connect all hoses using identification tags and hose port identification decal on top of PEPS manifold.
[18] - Install rear floor access plate, console cover, and cap screws (7).
[19] - Install auxiliary control pedals and cap screws (4), if equipped.
[22] - Fill hydraulic oil reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)
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Section 33 - BACKHOE Group 3360: Hydraulic System
[2] - Remove nuts (2), pattern select solenoids (Y58 and Y59), and spools (3).
[6] -
LEGEND:
2 Nut (2 used)
3 Spool (2 used)
4 Check Valve
138 Pilot Control Pressure Reducing Valve
Y52 Pilot Enable Solenoid
Y58 Pattern Select Solenoid 1
Y59 Pattern Select Solenoid 2
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Section 33 - BACKHOE Group 3360: Hydraulic System
Check Valve
Inspect O-rings and seals for damage. Replace as necessary.
[7] - Inspect and test solenoids. See Electrical Component Specifications . (Group 9015-20.) Replace as necessary.
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Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
Boom Cylinder
86 kg
310K Weight (approximate)
190 lb.
100 kg
310SK, 310SK TMC, 315SK, 325K, 325SK Weight (approximate)
220 lb.
125 kg
410K, 410K TMC Weight (approximate)
275 lb.
230 kg
710K Weight (approximate)
505 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Operator’s Manual.)
[2] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system
before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying
pressure.
[3] - Turn battery disconnect switch to the OFF position or remove battery negative (-) cables. See Battery Disconnect—If
Equipped . (Operator’s Manual.)
[4] -
LEGEND:
1 Head End Hydraulic Hose
2 Rod End Hydraulic Hose
3 Head End Pin
4 Snap Ring (2 used)
5 Washer (4 used)
162 Backhoe Boom Cylinder
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Section 33 - BACKHOE Group 3360: Hydraulic System
[5] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Connect appropriate lifting device to backhoe boom cylinder using lifting straps.
Item Measurement Specification
Boom Cylinder
310K Weight (approximate) 86 kg
190 lb.
220 lb.
275 lb.
505 lb.
[6] - Remove snap rings (4) and washers (5) from head end pin (3).
[8] -
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Section 33 - BACKHOE Group 3360: Hydraulic System
LEGEND:
6 Pin
7 Boom Lock Pivot
8 Pin
9 Snap Ring (2 used)
10 Washer (2 used)
11 Rod End Pin
[9] - Remove snap rings (9) and washers (10) from backhoe boom cylinder rod end pin (11).
[12] - Repair or replace backhoe boom cylinder as necessary. See Backhoe Boom Cylinder Disassemble and Assemble . (Group
3360.)
[16] - Install backhoe boom lock pivot and pins (6 and 8).
[18] - Turn battery disconnect switch to ON or connect battery negative (-) cables.
[19] - Operate backhoe to check for leaks and proper backhoe boom cylinder operation.
<- Go to Section TOC Section 33 page 132 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
45 kg
310K Weight (approximate)
99 lb.
59 kg
310SK, 310SK TMC, 315SK, 325K, 325SK Weight (approximate)
130 lb.
66 kg
410K, 410K TMC Weight (approximate)
145 lb.
105 kg
710K Weight (approximate)
230 lb.
[1] - Extend bucket to bucket dump position and lower to the ground.
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Operator’s Manual.)
[3] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system
before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying
pressure.
[4] - Turn battery disconnect switch to the OFF position or remove battery negative (-) cables. See Battery Disconnect—If
Equipped . (Operator’s Manual.)
[5] -
LEGEND:
1 Hose Clamp
2 Snap Ring (3 used)
3 Washer (3 used)
4 Rod End Pin
5 Head End Pin
163 Backhoe Bucket Cylinder
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Section 33 - BACKHOE Group 3360: Hydraulic System
[6] - Tag and disconnect hydraulic hoses from backhoe bucket cylinder. Close all openings using caps and plugs.
[7] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Install appropriate lifting device to backhoe bucket cylinder using lifting straps.
Item Measurement Specification
99 lb.
130 lb.
145 lb.
230 lb.
[8] - Remove snap ring (2) and washer (3) from rod end pin (4).
[10] - Remove snap rings and washers from head end pin (5).
[13] - Repair or replace backhoe bucket cylinder as necessary. See Backhoe Bucket Cylinder Disassemble and Assemble .
(Group 3360.)
[15] - Install pins at head and rod ends of backhoe bucket cylinder.
[17] - Connect backhoe bucket cylinder hydraulic hoses and install hose clamp.
[18] - Turn battery disconnect switch to ON or connect battery negative (-) cables.
[19] - Operate backhoe to check for leaks and proper bucket cylinder operation.
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Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
58 kg
310K Weight (approximate)
127 lb.
84 kg
310SK, 310SK TMC, 315SK Weight (approximate)
186 lb.
186 lb.
310SK, 310SK TMC, 315SK
98 kg
98 kg
325K, 325SK Weight (approximate)
216 lb.
96 kg
410K, 410K TMC Weight (approximate)
212 lb.
156 kg
710K Weight (approximate)
344 lb.
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Operator’s Manual.)
[3] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system
before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying
pressure.
[4] - Turn battery disconnect switch to the OFF position or remove battery negative (-) cables. See Battery Disconnect—If
Equipped . (Operator’s Manual.)
[5] -
<- Go to Section TOC Section 33 page 135 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
LEGEND:
1 Head End Hydraulic Hose
2 Rod End Hydraulic Hose
3 Snap Ring (3 used)
4 Washer (11 used)
5 Wear Plate (2 used)
6 Spacer (2 used)
7 Rod End Pin
8 Head End Pin
164 Backhoe Crowd Cylinder
[6] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
127 lb.
186 lb.
216 lb.
212 lb.
344 lb.
[7] - Remove snap ring (3) and washers (4) from rod end pin (7).
[8] - Remove rod end pin, wear plates (5) and spacers (6).
[9] - Remove snap rings and washers from head end pin (8).
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Section 33 - BACKHOE Group 3360: Hydraulic System
[12] - Repair or replace backhoe crowd cylinder as necessary. See Backhoe Crowd Cylinder Disassemble and Assemble .
(Group 3360.)
[18] - Turn battery disconnect switch to the ON position or connect battery negative (-) cables.
[19] - Operate backhoe to check for leaks and proper backhoe crowd cylinder operation.
<- Go to Section TOC Section 33 page 137 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
LEGEND:
1 Cap Screw
2 Stabilizer Cover
3 Hydraulic Hose (2 used)
4 Snap Ring
5 Washer (10 used)
6 Pin
201 Stabilizer Cylinder
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Section 33 - BACKHOE Group 3360: Hydraulic System
[1] - Lower stabilizer to the ground and remove foot. Retract cylinder.
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Operator’s Manual.)
[3] -
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.
Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] - Turn battery disconnect switch to OFF or remove battery negative (-) cables. See Battery Disconnect—If Equipped .
(Operator’s Manual.)
[6] - Tag and disconnect hydraulic hoses (3). Close all openings using caps and plugs.
[7] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
61 lb.
[8] - Remove snap ring (4), pin (6), and washers (5).
[10] - Repair or replace stabilizer cylinder as necessary. See Backhoe Stabilizer Cylinder Disassemble and Assemble . (Group
3360.)
[13] - Connect hydraulic hoses. See Hydraulic System Component Location . (Group 9025-15.)
[14] - Turn battery disconnect switch to ON or connect battery negative (-) cables.
[17] - Operate backhoe to check for leaks and proper stabilizer cylinder operation.
<- Go to Section TOC Section 33 page 139 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
39 kg
310K Weight (approximate)
86 lb.
45 kg
315K, 325K, 325SK, 410K Weight (approximate)
99 lb.
66 kg
710K Weight (approximate)
146 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Swing backhoe to one side and lower backhoe bucket to ground.
[3] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025.)
[4] -
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.
LEGEND:
1 Snap Ring (2 used)
2 Washer (2 used)
3 Pin
4 Snap Ring (2 used)
5 Washer (2 used)
6 Hose Guard
7 Pin (2 used)
[7] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
<- Go to Section TOC Section 33 page 140 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
86 lb.
99 lb.
146 lb.
[8] -
LEGEND:
9 Hydraulic Hose (4 used)
10 Cap Screw (4 used)
11 Washer (8 used)
12 Trunnion
13 Swing Cylinder
[12] -
LEGEND:
14 Swing Cylinder Bushing (2 used)
[13] - Install new bushings flush with trunnion using 49 mm and 59 mm disks.
[14] - Inspect upper and lower trunnion block bushings. Replace as necessary using 60 mm and 69 mm disks.
[15] - Install new bushings with 60 mm and 69 mm disks. Align grease passages in trunnion block and frame with passage in
bushing. Be sure lower trunnion bushing is pushed into seat flange.
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Section 33 - BACKHOE Group 3360: Hydraulic System
[17] -
IMPORTANT:
Be sure hydraulic fittings in swing cylinder are tightened to specification. Cylinder movement and
hydraulic pressure can loosen fittings and cause a leak.
If hydraulic fittings were removed from cylinder, install and tighten fittings to specification.
Item Measurement Specification
25 lb.-ft.
<- Go to Section TOC Section 33 page 142 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
SPECIFICATIONS
32 kg
310K Weight (approximate)
70 lb.
41 kg
310SK, 315SK, 325K, 325SK, 410K Weight (approximate)
90 lb.
59 kg
710K Weight (approximate)
129 lb.
[1] -
LEGEND:
1 Pin
2 Hose Clamp (2 used)
160 Backhoe Extendable Dipperstick
165 Backhoe Extendable Dipperstick Cylinder
[2] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Operator’s Manual.)
[3] - Turn battery disconnect switch to the OFF position or remove battery negative (-) cables. See Battery Disconnect—If
Equipped . (Operator’s Manual.)
[4] -
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.
Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[6] - Tag and disconnect hydraulic hoses from backhoe extendable dipperstick cylinder (165). Close all openings using caps
and plugs.
<- Go to Section TOC Section 33 page 143 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[7] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
70 lb.
90 lb.
129 lb.
[8] - Remove backhoe extendable dipperstick cylinder head end pin (1) and slowly remove cylinder.
[10] - Position backhoe extendable dipperstick cylinder in place and install backhoe extendable dipperstick cylinder head end
pin.
[11] - Connect backhoe extendable dipperstick cylinder hydraulic hoses and install hose clamps.
[12] - Install backhoe extendable dipperstick. See Dipperstick Extension Remove and Install . (Group 3340.)
[13] - Turn battery disconnect switch to the ON position or install battery negative (-) cables.
[14] - Operate backhoe to check for leaks and proper backhoe extendable dipperstick operation.
<- Go to Section TOC Section 33 page 144 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual)
[4] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve pressure in the system
before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying
pressure.
LEGEND:
1 Hydraulic Hose
2 Snap Ring
3 Washer
4 Pin
5 Return Spring
6 Washer (2 used)
7 Cap Screw
8 Nut
168 Boom Lock Cylinder
[5] - Remove snap ring (2), washer (3), and return spring (5) from pin (4).
[6] - Remove nut (8), cap screw (7), washers (6), and return spring.
[9] - Install boom lock cylinder rod end onto pin (4).
[10] - Install boom lock cylinder head end, washers (6), return spring, cap screw, and nut. Tighten securely.
[11] - Install return spring, washer (3), and snap ring onto pin.
[12] - Retract boom lock cylinder and connect hydraulic hose to boom lock cylinder.
[13] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position.
<- Go to Section TOC Section 33 page 145 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[14] - Start engine and cycle boom lock several times. Raise boom and engage boom lock to check for proper operation.
<- Go to Section TOC Section 33 page 146 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve pressure in system before
disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
<- Go to Section TOC Section 33 page 147 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
LEGEND:
1 Hydraulic Hose (3 used)
2 Cap Screw (2 used)
167 Boom Lock Solenoid Valve
Y35 Boom Lock Solenoid
[6] - Remove cap screws (2) and boom lock solenoid valve (167).
[11] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[12] - Start engine and cycle boom lock several times. Raise boom and engage boom lock to check for proper operation.
<- Go to Section TOC Section 33 page 148 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[2] - Relieve hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] -
LEGEND:
1 Rear Floor Mat
2 Cap Screw
3 Washer
4 Foot Pedal (if equipped)
[6] -
→NOTE:
Lever assembly bracket and levers do not have to be removed.
LEGEND:
5 Cap Screw (4 used)
6 Console Cover
7 Cap Screw (4 used)
8 Cab Floor Rear Access Panel
[7] - Remove cap screws (7) and cab floor rear access panel (8).
[8] -
<- Go to Section TOC Section 33 page 149 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
LEGEND:
9 Hydraulic Return Hose
10 Hydraulic Supply Hose
11 Hydraulic Supply Hose
12 Nut (2 used)
13 Cap Screw (2 used)
169 Sideshift Lock Solenoid Valve
Y34 Sideshift Lock Solenoid
[9] -
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.
Disconnect hydraulic hoses (9—11) from sideshift lock solenoid valve. Close all openings using caps and plugs.
→NOTE:
A bracket attaches boom lock valve to sideshift lock solenoid valve. Bracket and boom lock valve will
hang free when cap screws are removed.
[10] - Remove nuts (12) and cap screws (13) to remove boom lock valve, bracket, and sideshift lock solenoid valve (169).
[11] - Repair or replace sideshift lock solenoid valve as necessary. See Backhoe Sideshift Lock Valve Disassemble and
Assemble—(S.N. —232969) . (Group 3360.)
[12] - Install boom lock valve, bracket, and sideshift lock solenoid valve using cap screws and nuts. Tighten securely.
[13] - Connect hydraulic hoses (9—11) to sideshift lock solenoid valve. Tighten securely.
[15] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[16] -
<- Go to Section TOC Section 33 page 150 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
LEGEND:
15 Backhoe Sideshift Frame Hydraulic Hose
16 Backhoe Sideshift Frame
[17] - Check hydraulic oil level and add if necessary. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
[18] - Install cab floor rear access panel with cap screws (7). Tighten securely.
[19] - Install console cover using cap screws (5). Tighten securely.
[21] - Install foot pedal (if equipped) using cap screw (2) and washer.
<- Go to Section TOC Section 33 page 151 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
Spool O-Rings
LEGEND:
1 Nut
2 Spool
3 Relief Valve
4 Backup Ring (2 used)
5 O-Ring
6 O-Ring
7 O-Ring
<- Go to Section TOC Section 33 page 152 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
8 O-Ring
9 Backup Ring (2 used)
10 O-Ring
11 Backup Ring (2 used)
Y34 Sideshift Lock Solenoid
Remove nut (1) and sideshift lock solenoid (Y34).
<- Go to Section TOC Section 33 page 153 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
Spool O-Rings
<- Go to Section TOC Section 33 page 154 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
<- Go to Section TOC Section 33 page 155 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
→NOTE:
It is not recommended to remove orifice plug (12). If removal is necessary apply Loctite ™ 272
Threadlocker and tighten to specification.
Item Measurement Specification
10 lb.-ft.
<- Go to Section TOC Section 33 page 156 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Remove backhoe sideshift frame. See Sideshift Frame Remove and Install . (Group 3340.)
[4] -
→NOTE:
Put cardboard or rags under pistons to avoid damage.
[5] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve hydraulic pressure in the
system before disconnecting or connecting hydraulic or other lines. Tighten all connections before
applying pressure.
LEGEND:
1 Hydraulic Supply Hose (3 used)
2 Hydraulic Fitting (4 used)
3 Sideshift Frame
4 Bushing (4 used)
Sideshift Frame
Disconnect hydraulic supply hoses (1) and remove hydraulic fittings (2) from bushings (4). Close all openings using caps and
plugs.
[6] -
LEGEND:
4 Bushing (4 used)
5 Opening
170 Sideshift Lock Piston (4 used)
<- Go to Section TOC Section 33 page 157 315SK Backhoe Loader Repair
Section 33 - BACKHOE Group 3360: Hydraulic System
[7] -
LEGEND:
3 Sideshift Frame
4 Bushing (4 used)
6 Seal (2 used)
170 Sideshift Lock Piston (4 used)
[8] - Inspect seals and piston for damage or wear. Replace as necessary.
[9] - Use D01044AA Bushing, Bearing, and Seal Driver Set to remove bushing (4).
[11] -
IMPORTANT:
Avoid O-ring or component damage. Apply clean hydraulic oil to seals and all internal parts before
assembly.
Apply clean hydraulic oil to all internal parts. Install seals into bushing.
[12] - Use D01044AA Bushing, Bearing, and Seal Driver Set to install bushing.
[14] - Install hydraulic fitting into bushing and connect hydraulic supply hose. Tighten securely.
[15] - Install backhoe sideshift frame. See Sideshift Frame Remove and Install . (Group 3340.)
[16] -
LEGEND:
15 Backhoe Sideshift Frame Hydraulic Hose
16 Backhoe Sideshift Frame
Carefully loosen backhoe sideshift frame hydraulic hose (15) at sideshift frame (16).
Tighten hose connection when oil flows clear from hose connection (no air bubbles).
Tighten hose connection.
Check for leaks.
<- Go to Section TOC Section 99 page 159 315SK Backhoe Loader Repair
315SK Backhoe Loader Repair (g) by Belgreen v2.1
MATERIALS:
Two pieces of steel plate, approximately 70 x 120 mm (2-3/4 x 4 in.) and 152 x 254 mm (6 x 10 in.)
Two pieces of threaded rod, 13 mm (1/2 in.) threads x 178 mm (7 in.) long
Four lock washers and nuts
→NOTE:
If available, DFT1285 Engine Support Bracket (B) can be used to make DFT1285A Engine Support Bracket
(A).
DFT1285A Spacers
DFT1285A Engine Support Bracket supports engine while transmission is being removed and installed.
MATERIALS:
DFT1285 Spacers
Used to support engine during while transmission is being removed and installed.
MATERIALS:
Material required:
3 in. Inside Diameter x 6 in. Long Pipe