748H novo monitor Repair BookTM11813.PDF

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TECHNICAL MANUAL

748H Skidder Repair

(S.N. 630436— )

TM11813 13OCT10 (ENGLISH)

748H Skidder Repair

(Serial No. 630436 - )

For complete service information also see:

748H Skidder Operation and Test (S.N.630436— )............................................................. TM11797

H-Series Skidder Operator’s Manual(S.N. 630436— ).................................................... OMT255825

PowerTech™ 4.5L & 6.8L Diesel Engines -Base Engine......................................................... CTM104

PowerTech™ Plus 4.5L & 6.8L DieselEngines—Level 14 Electronic Fuel SystemWith Denso HPCR................................................ CTM320

TeamMate™ IV Axles 1200 - 1400 SeriesInboard Planetary Axles...................................... CTM442

40 and 4000 Winches .......................................... CTM25

60 and 6000 Winches .......................................... CTM41

DF180 Series Powershift Transmission Repair Manual .................................................................. CTM308

120 Series Cylinders ........................................... CTM114319

125 Series Cylinders ........................................... CTM109319

JDLink™ / ZXLink™ Machine MonitoringSystem.................................................................. CTM10006

Specifications Manual......................................... SP458

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A.



Introduction

,0004E4A -19-08SEP08-1/1

Foreword

This manual is written for an experienced technician.Essential tools required in performing certain service workare identified in this manual and are recommended for

use.Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert to thepotential for personal injury.

Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repair the components. Operation and tests sections help youidentify the majority of routine failures quickly.

Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning 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 specificmachines. They are on-the-job guides containing only thevital information needed for diagnosis, analysis, testing,and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentalsof troubleshooting, general maintenance, and basic typeof failures and their causes.

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Introduction

TX,TM,FAX -19-03JUL01-1

Technical Information Feedback Form

We need your help to continually improve our technicalpublications. Please copy this page and FAX or mail your comments, ideas and improvements.

SEND TO: John Deere Dubuque Works

18600 South John Deere Road

Attn: Publications, Dept. 324

Dubuque, IA 52004-0538

USA

FAX NUMBER: 1-563-589-5800 (USA)

Publication Number:

Page Number:

Ideas, Comments:

Name:

Phone:

Email Address:

THANK YOU!

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

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Introduction

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Contents

Section 00—General InformationGroup 0001—SafetyGroup 0003—Torque Values

Section 01—Wheels

Group 0110—Powered Wheels and Fasteners

Section 02—AxlesGroup 0200—Remove and InstallGroup 0225—Input Drive Shaft and U-JointsGroup 0260—Hydraulic System

Section 03—TransmissionGroup 0300—Remove and InstallGroup 0315—ControlsGroup 0325—Input Drive Shafts and U-JointsGroup 0350—Gears, Shafts, and Power Shift ClutchesGroup 0360—Hydraulic System

Section 04—EngineGroup 0400—Removal and Installation

Section 05—Engine Auxiliary SystemsGroup 0505—Cold Weather Starting AidsGroup 0510—Cooling SystemGroup 0520—Intake SystemGroup 0530—Exhaust SystemGroup 0560—External Fuel Supply System

Section 07—Dampener DriveGroup 0752—Elements

Section 09—Steering SystemGroup 0930—Secondary SteeringGroup 0960—Hydraulic SystemGroup 0962—Dual Mode Steering

Section 10—Service BrakesGroup 1015—Controls LinkageGroup 1060—Hydraulic System

Section 11—Park BrakeGroup 1111—Active ElementsGroup 1160—Hydraulic System

Section 17—Frame, Chassis, or SupportingStructures

Group 1740—Frame Installation

Group 1746—Frame Bottom Guards

Section 18—Operator’s StationGroup 1800—Removal and InstallationGroup 1810—Operator Enclosure

Group 1821—Seat and Seat BeltGroup 1830—Heating and Air Conditioning

Section 19—Sheet Metal and StylingGroup 1910—Hood or Engine Enclosure

Section 20—Safety, Convenience, andMiscellaneous

Group 2003—Pressurized Water SystemGroup 2004—Horn and Warning Devises

Section 21—Main Hydraulic SystemGroup 2160—Hydraulic System

Section 30—WinchGroup 3000—Removal and InstallationGroup 3015—Control LinkageGroup 3025—Input Drive Shafts and U-JointsGroup 3050—Drive and Clutch

Section 32—Stacking BladesGroup 3201—BladesGroup 3215—Controls LinkageGroup 3260—Hydraulic System

Section 38—GrappleGroup 3803—Grapple MechanismGroup 3840—Frames

Group 3860—Hydraulic System

Section 99—Dealer Fabricated ToolsGroup 9900—Dealer Fabricated Tools

Original Instructions. All information, illustrations and specifications in thismanual are based on the latest information available at the time of publication.

The right is reserved to make changes at any time without notice.

COPYRIGHT © 2010DEERE & COMPANY

Moline, Illinois All rights reserved.

A John Deere ILLUSTRUCTION ® Manual

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

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Contents

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Section 00General Information

Contents

Page

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

Group 0003—Torque ValuesHardware Torque Specifications................ 00-0003-1Keeping ROPS Installed Properly.............. 00-0003-1Torque Value

Metric Bolt and Cap Screw....................00-0003-2 Additional Metric Cap Screw

Torque Values........................................00-0003-3Unified Inch Bolt and Cap Screw ..........00-0003-4

Check Oil Lines And Fittings ..................... 00-0003-5Service Recommendations for

37° Flare and 30° Cone SeatConnectors ............................................00-0003-5

Service Recommendations for O-Ring Boss Fittings..............................00-0003-6

Service Recommendations For Flat Face O-Ring Seal Fittings .............. 00-0003-7

Service Recommendations for Metric Series Four Bolt FlangeFitting..................................................... 00-0003-8

Service Recommendations For Inch Series Four Bolt FlangeFittings ................................................... 00-0003-9

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Group 0001Safety

TX03679,00016CC -19-03NOV08-1

DX,READ -19-16JUN09-1

TX03679,00016FA -19-03NOV08-1

Recognize Safety Information

This is the safety alert symbol. When you see thissymbol on your machine or in this manual, be alertfor the potential of personal injury.

Follow the precautions and safe operating practiceshighlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION —is used with the safety alert symbol. DANGER identifiesthe most serious hazards.

On your machine, DANGER signs are red in color,WARNING signs are orange, and CAUTION signs areyellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTIONlabels.

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N — 2 8 A U G 0 0

T 1 3 3 5 8 8 — 1 9 — 2 8 A U G 0 0

Follow Safety Instructions

Carefully read all safety messages in this manual and onyour machine safety signs. Keep safety signs in goodcondition. Replace missing or damaged safety signs. Besure new equipment components and repair parts includethe current safety signs. Replacement safety signs areavailable from your John Deere dealer.

There can be additional safety information contained onparts and components sourced from suppliers that is notreproduced in this operator’s manual.

Learn how to operate the machine and how to use controlsproperly. Do not let anyone operate without instruction.

Keep your machine in proper working condition.Unauthorized modifications to the machine may impair thefunction and/or safety and affect machine life.

T S

2 0 1 — U N — 2 3 A U G 8 8

If you do not understand any part of this manual and needassistance, contact your John Deere dealer.

Operate Only If Qualified

Do not operate this machine unless you have read theoperator’s manual carefully and you have been qualifiedby supervised training and instruction.

Familiarize yourself with the job site and your surroundingsbefore operating. Try all controls and machine functionswith the machine in an open area before starting to work.

Know and observe all safety rules that may apply to your work situation and your work site.

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Safety

OUT4001,0000570 -19-12FEB10-1/1

AM40430,00000A9 -19-20AUG09-1/1

TX03679,0001734 -19-03NOV08-1/1

TX03679,00016D2 -19-03NOV08-1/1

Wear Protective Equipment

Guard against injury from flying pieces or metal or debris;wear goggles or safety glasses.

Wear close fitting clothing and safety equipment

appropriate to the job.Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphoneswhile operating machine.

Prolonged exposure to loud noise can cause impairmentor loss of hearing. Wear suitable hearing protection suchas earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Radio or music headphonesare not suitable to use for hearing protection.

T S 2 0 6 — U N — 2 3 A U G 8 8

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deerereplacement parts to ensure machine performance.Never substitute genuine John Deere parts with alternateparts not intended for the application as these cancreate hazardous situations or hazardous performance.Non-John Deere parts, or any damage or failures resultingfrom their use are not covered by any John Deerewarranty.

Modifications of this machine, or addition of unapprovedproducts or attachments, may affect machine stability or

reliability, and may create a hazard for the operator or others near the machine. The installer of any modificationwhich may affect the electronic controls of this machine isresponsible for establishing that the modification does notadversely affect the machine or its performance.

Always contact an authorized dealer before makingmachine modifications that change the intended use,weight or balance of the machine, or that alter machinecontrols, performance or reliability.

Inspect Machine

Inspect machine carefully each day by walking around itbefore starting.

Keep all guards and shields in good condition and properlyinstalled. Fix damage and replace worn or broken partsimmediately. Pay special attention to hydraulic hoses andelectrical wiring.

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Stay Clear of Moving Parts

Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintainingany part of machine with moving parts.

Keep guards and shields in place. Replace any guardor shield that has been removed for access as soon asservice or repair is complete.

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Safety

DX,FLUID -19-20AUG09-1

TX03679,00016D3 -19-03NOV08-1

OUO1065,00001B7 -19-09JUN08-1

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high-pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed withina few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeablemedical source. Such information is available inEnglish from Deere & Company Medical Department in

X 9 8 1 1 — U N — 2 3 A U G 8 8

Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1309-748-5636.

Avoid High-Pressure Oils

This machine uses a high-pressure hydraulic system.Escaping oil under pressure can penetrate the skincausing 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 disconnectinglines or working on hydraulic system.

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgicallywithin hours or gangrene may result. Contact aknowledgeable medical source or the Deere & CompanyMedical Department in Moline, Illinois, U.S.A.

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T 1 3 3 8 4 0 — U N — 2 0 S E P 0 0

Do Not Use Starting Fluid

IMPORTANT: Avoid an explosion or fire. Machineis equipped with electrical cold start assist

system. Do not use starting fluid of anytype on the machine.

This machine is equipped with a Tier III engine. Fire,explosion or engine damage will result from using startingfluids of any type on this machine.

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Safety

DX,AIR -19-17FEB99-1/1

TX03679,00016F5 -19-03NOV08-1/1

Work In Ventilated Area

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

If you do not have an exhaust pipe extension, open thedoors and get outside air into the area.

T S 2 2 0 — U N — 2 3 A U G 8 8

Prevent Fires

Handle Fuel Safely: Store flammable fluids away fromfire hazards. Never refuel machine while smoking or when

near sparks or flame.

Clean Machine Regularly: Keep trash, debris, greaseand oil from accumulating in engine compartment, aroundfuel lines, hydraulic lines, exhaust components, andelectrical wiring. Never store oily rags or flammablematerials inside a machine compartment.

Maintain Hoses and Wiring: Replace hydraulic hosesimmediately if they begin to leak, and clean up any oilspills. Examine electrical wiring and connectors frequentlyfor damage.

Keep A Fire Extinguisher Available: Always keep amultipurpose fire extinguisher on or near the machine.Know how to use extinguisher properly.

T 1 3 3 5 5 2 — U N —

1 4 S E P 0 0

T133553 —UN—07SEP00

T133554 —UN—07SEP00

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Safety

DX,SPARKS -19-03MAR93-1

DX,MSDS,NA -19-03MAR93-1

DX,DRAIN -19-03MAR93-1

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away fromthe 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. Warmbattery to 16°C (60°F).

T S 2 0 4 — U N — 2 3 A U G 8 8

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can causeserious 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 specificdetails on chemical products: physical and health hazards,safety procedures, and emergency response techniques.

Check the MSDS before you start any job using ahazardous chemical. That way you will know exactly whatthe risks are and how to do the job safely. Then followprocedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemicalproducts used with John Deere equipment.)

T S 1 1 3 2 — U N — 2 6 N O V 9 0

Dispose of Waste Properly

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

Use leakproof containers when draining fluids. Do not usefood or beverage containers that may mislead someoneinto drinking from them.

Do not pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulationsmay require a certified air conditioning service center torecover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of wastefrom your local environmental or recycling center, or fromyour John Deere dealer.

T S 1 1 3 3 — U N — 2 6 N O V 9 0

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Safety

DX,FIRE2 -19-03MAR93-1/1

OUT4001,00000E3 -19-20AUG09-1/1

TX03679,00016F2 -19-03OCT07-1/1

TX03679,0001799 -19-03OCT07-1/1

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance

service, hospital, and fire department near your telephone.

T S 2 9 1 — U N — 2 3 A U G 8 8

Clean Debris from Machine

Keep engine compartment, radiator, batteries, hydrauliclines, 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 may go upimmediately after engine is stopped. BE ON GUARDFOR FIRES DURING THIS PERIOD.

Open access door(s) to cool the engine faster, and cleanengine compartment. T

6 6 6 9 A G — U N — 1 8 O C T 8 8

Use Steps and Handholds Correctly

Prevent falls by facing the machine when you get on andoff. Maintain 3-point contact with steps and handrails.Never use machine controls as handholds.

Use extra care when mud, snow, or moisture presentslippery conditions. Keep steps clean and free of greaseor oil. Never jump when exiting machine. Never mount or dismount a moving machine. T

1 3 3 4 6 8 — U N — 3 0 A U G 0 0

Start Only From Operator’s Seat

Avoid unexpected machine movement. Start engine onlywhile sitting in operator’s seat. Ensure all controls and

working tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do notattempt to start engine by shorting across the starter solenoid terminals. T

1 3 3 7 1 5 — U N — 0

7 S E P 0 0

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Safety

TX03679,00016DD -19-03OCT07-1

OU90V02,000042C -19-25MAY10-1

Use and Maintain Seat Belt

Use seat belt when operating machine. Remember tofasten seat belt when loading and unloading from trucksand during other uses.

Examine seat belt frequently. Be sure webbing is notcut or torn. Replace seat belt immediately if any part isdamaged or does not function properly.

The complete seat belt assembly should be replacedevery three years, regardless of appearance.

T 1 3 3 7 1 6

— 1 9 — 1 4 S E P 0 0

Prevent Unintended Machine Movement

Be careful not to accidentally actuate controls. Movetransmission out of gear and lower all equipment to theground during work interruptions. Follow these stepsbefore allowing coworkers to approach the machine,before standing up, leaving the operator’s seat, or exiting

the machine:

• Lower equipment to the ground

• Move transmission gear selector to neutral position

• Engage park brake by pressing park brake switch.Verify park brake indicator light on the standard displaymonitor comes on.

• Stop the engine

1— Gear Selector 2— Gear Enable/Differential

Lock Switch

3— Park Brake Switch

1

2

T X 1 0 7 6 1 8 4 — U N — 1 6 A P R 1 0

Gear Enable/Differential Lock Switch

T X 1 0 7 6 1 8 7 A — U

N — 1 6 A P R 1 0

Park Brake Switch

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Safety

OU90V02,000042D -19-12APR10-1/1

TX03679,000180A -19-03OCT07-1/1

TX03679,0001800 -19-03OCT07-1/1

Avoid Work Site Hazards

Plan your operation before starting work. Check skiddingtrails and landings for stumps, large rocks, drop-offs,muddy areas and standing water. Carefully examineoverhead for trees and branches that might fall or strike

the operator’s station. Take precautions to avoid thesehazards.

Be sure co-workers and bystanders are clear of machine before operating. Keep bystanders awayfrom attachments and unsupported loads over or near personnel. Keep co-workers a safe distance away whenskidding, because logs may kick-out unexpectedly.

Use extra care if you must drive over logs or saplingsthat may be dislodged or spring-up against the machineor bystanders.

Keep bystanders clear at all times. Keep bystandersaway from raised booms, attachments, and unsupportedloads. Avoid swinging or raising booms, attachments, or

loads over or near personnel. Use barricades or a signalperson to keep vehicles and pedestrians away. Use asignal person if moving machine in congested areas or where visibility is restricted. Always keep signal person inview. Coordinate hand signals before starting machine.

T 1 4 6 6 1 1 — U N — 2 2 O C T 0

1

Do not operate under low-hanging electrical wires.Contact may cause serious injury or death byelectrocution.

Reduce machine speed when operating equipment withtool on or near ground when obstacles may be hidden

(e.g., during snow removal or clearing mud, dirt, etc). Athigh speeds, hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seat belt. On units equipped with shoulder belts, alwayswear both the seat and shoulder belts and do not leanforward while operating.

Operate Machine Safely

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

Use extra care around landings where bystanders aremore likely to be present. Do not skid logs past peoplethat are not a safe distance away from logs that mayswing or kick-out.

Use extra care when backing-up with logs attached. Makesure the de-limbing grate is in good repair and bystandersare a safe distance away.

Be careful when operating in muddy or frozen conditionsbecause the machine may slide or tip more easily. Avoid

T 1 4 6 6 1 0 — U N — 2 2 O C T 0 1

side slopes when possible. Drive straight up or downslopes to reduce the possibility of tipping.

Keep Riders Off Machine

Only allow operator on machine.

Riders are subject to injury. They may fall from machine,be caught between machine parts, or be struck by foreignobjects.

Riders may obstruct operator’s view or impair his abilityto operate machine safely.

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Safety

TX03679,0001801 -19-03OCT07-1

TX03679,0001802 -19-03OCT07-1

Avoid Backover Accidents

Before moving machine, be sure all persons are clear of machine path. Turn around and look directly for bestvisibility. Use mirror to assist in checking around machine.Keep windows and mirror clean, adjusted, and in good

repair.

Be certain reverse warning alarm is working properly.

Use a signal person when backing if view isobstructed or when in close quarters. Keep signalperson in view at all times. Use prearranged hand signalsto communicate.

T 1 4 5 2 6 4 — U N —

0 6 S E P 0 1

Avoid Machine Tip Over

Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely to

jump clear and the machine may crush you.

Load and unload from trucks or trailers carefully. Besure truck is wide enough and on a firm level surface. Useloading ramps and attach them properly to truck bed.

Be careful on slopes. Avoid sharp turns. Avoid stumps,rocks and drop-offs when possible. Use extra care onsoft, uneven or frozen ground.

Do not overload. Know the capacity of the machine.Be careful with heavy loads which may affect machinestability.

Ensure solid footing. Use extra care in soft groundconditions that may not uniformly support the wheels. Do

not operate close to banks that may cave in and causemachine to tip or fall.

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— 1 4 S E P 0 0

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Operating on Slopes

Avoid side slope travel whenever possible. When workingon steep slopes, travel as straight up and down aspossible to prevent machine tip over.

Select low gear before starting down slope. The slope onwhich you can operate safely will be limited by groundcondition and the load being handled. Use service brakesto control speed.

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Operating or Traveling On Public Roads

Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lightingand markings to assure they are visible to other drivers.

Install additional lights, beacons, slow moving vehicle

(SMV) emblems, or other devices and use as requiredto make the machine visible and identify it as a workmachine. Check state and local regulations to assurecompliance. Keep these devices clean and in workingcondition.

T 1 4 1 8 9 1 — U N —

2 2 M A Y 0 1

Inspect and Maintain ROPS

A damaged roll-over protective structure (ROPS) shouldbe replaced, not reused.

The protection offered by ROPS will be impaired if ROPSis subjected to structural damage, is involved in anoverturn incident, or is in any way altered by welding,bending, drilling, or cutting.

If ROPS was loosened or removed for any reason, inspectit carefully before operating the machine again.

To maintain the ROPS:

• Replace missing hardware using correct gradehardware.

• Check hardware torque.• Check isolation mounts for damage, looseness or wear;

replace them if necessary.

• Check ROPS for cracks or physical damage.

Keep the Operator Protective Structure (OPS) in Place

It is important to keep the operator protective structure(OPS) in place (doors, screens, windows, windshield,etc.) to minimize hazards from whipping or intrudingobjects. To maintain OPS protection, replace damaged

parts immediately.The polycarbonate windows are part of the operator protection system. Replace if damaged, cloudy, or hasvisible micro-cracking or crazing.

The protection offered by OPS will be impaired if OPS issubjected to structural damage, is involved in an overturnincident, or is altered by welding, bending, drilling, or cutting. Damaged OPS components should be replaced,

not reused.

Keep all bolts and attaching hardware tight.

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Safety

TX03679,00016F0 -19-03OCT07-1

OUTJ003,00007AB -19-17AUG06-1

Add and Operate Attachments Safely

Always verify compatibility of attachments by contactingyour authorized dealer. Adding unapproved attachmentsmay affect machine stability or reliability, and may create

a hazard for others near the machine.Ensure that a qualified person is involved in attachmentinstallation. Add guards to machine if operator protection

is required or recommended. Verify that all connectionsare secure and attachment responds properly to controls.

Carefully read attachment manual and follow all

instructions and warnings. In an area free of bystandersand obstructions, carefully operate attachment to learn itscharacteristics and range of motion.

Park and Prepare for Service Safely

Warn others of service work. Always park and prepareyour machine for service or repair properly.

• Park machine on a level surface and lower equipmentto the ground.

• Engage park brake.

• Stop engine and remove key.

• Install articulation locking bar.• Attach a “Do Not Operate” tag in an obvious place inthe operator’s station.

IMPORTANT: Engine side panels may be warmimmediately after machine shut down andgloves may need to be worn.

Support machine or attachment before working under it.

• Do not support machine with any hydraulically actuatedtools or attachments.

• Do not support machine with cinder blocks or woodenpieces that may crumble or crush.

• Do not support machine with a single jack or other devices that may slip out of place.

Understand service procedures before beginning repairs.Keep service area clean and dry. Use two peoplewhenever the engine must be running for service work.

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Safety

DX,RIM -19-24AUG90-1/1

VD76477,0001157 -19-20DEC06- 1/1

Service Tires Safely

Explosive separation of a tire and rim parts can causeserious 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 inflatethe tires above the recommended pressure. Never weldor heat a wheel and tire assembly. The heat can causean 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 extensionhose long enough to allow you to stand to one side andNOT in front of or over the tire assembly. Use a safetycage if available.

Check wheels for low pressure, cuts, bubbles, damagedrims or missing lug bolts and nuts.

T S 2 1 1 — U N — 2 3 A U G 8 8

Service Cooling System Safely

Explosive release of fluids from pressurized cooling

system can cause serious burns.Do not service radiator through the radiator cap. Only fillthrough the surge tank filler cap. Shut off engine. Onlyremove surge tank filler cap when cool enough to touchwith bare hands. Slowly loosen cap to relieve pressurebefore removing completely.

T S 2 8 1 — U N — 2 3 A U G 8 8

TM11813 (13OCT10) 00-0001-12 748H Repair (S.N. 630436— )101310

PN=20



Safety

DX,WW,ACCLA -19-15APR03-1

DX,PAINT -19-24JUL02-1

TX03679,00016D5 -19-04JUN07-1

Service Accumulator Systems Safely

Escaping fluid or gas from pressurized hydraulicaccumulator systems can cause serious injury. Extremeheat can cause the accumulator to burst, and pressurizedlines can be accidentally cut. Do not weld or use a torch

near a pressurized accumulator or pressurized line.

Relieve pressure from the hydraulic system beforeremoving accumulator. Never attempt to relieve hydraulicsystem or accumulator pressure by loosening a fitting.

Accumulators cannot be repaired. T S 2 8 1 — U N — 2 3 A U G 8 8

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from areato 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 withsoap and water before welding. Remove solvent or paint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

Do not use a chlorinated solvent in areas where weldingwill take place.

T S 2 2 0 — U N — 2 3 A U G 8 8

Do all work in an area that is well ventilated to carry toxicfumes and dust away.

Dispose of paint and solvent properly.

Make Welding Repairs Safely

IMPORTANT: Disable electrical power beforewelding. Turn off main battery switchor disconnect positive battery cable.Separate harness connectors to engineand vehicle microprocessors.

Avoid welding or heating near pressurized fluid lines.Flammable spray may result and cause severe burns if

pressurized lines fail as a result of heating. Do not let heatgo 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.

T 1 3 3 5 4 7 — U N — 3 1 A U G 0 0

Make sure there is good ventilation. Wear eye protectionand protective equipment when welding.

TM11813 (13OCT10) 00-0001-13 748H Repair (S.N. 630436—10

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Safety

TX03679,0001745 -19-07SEP06-1/1

Drive Metal Pins Safely

Always wear protective goggles or safety glasses andother protective equipment before striking hardenedparts. Hammering hardened metal parts such as pins andbucket teeth may dislodge chips at high velocity.

Use a soft hammer or a brass bar between hammer andobject to prevent chipping. T

1 3 3 7 3 8

— U N — 1 4 S E P 0 0

TM11813 (13OCT10) 00-0001-14 748H Repair (S.N. 630436— )101310

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Group 0003Torque Values

04T,90,K271 -19-08AUG91-1

CED,OUO1079,98 -19-26MAY00-1

Hardware Torque Specifications

Check cap screws and nuts to be sure they are tight.If hardware is loose, tighten to torque shown on thefollowing charts unless a special torque is specified.

Keeping ROPS Installed Properly

CAUTION: Make certain all parts are reinstalledcorrectly if the roll-over protective structure(ROPS) is loosened or removed for any reason.

The protection offered by ROPS will be impairedif ROPS is subjected to structural damage, isinvolved in an overturn incident, or is in any wayaltered by welding, bending, drilling, or cutting. Adamaged ROPS should be replaced, not reused.

IMPORTANT: Do not over-tighten cap screws

as clevis will be deformed.

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

Tighten pin locking cap screws (D) to specification.

Keeping ROPS Installed Properly—Specification

Pin Locking Cap

Screw—Torque.............................................................. 130 Nm (95 lb-ft)

A—Lock Nut (2 used)B—Cap Screw (2 used)

C—Washer (As required)D—Pin Locking Cap Screw (2

used)

T 1 2 9 5 4 6 C — U N — 3 1 M A R 0 0

T 1 2 9 5 4 7 D — U N — 0 3 A P R 0 0

TM11813 (13OCT10) 00-0003-1 748H Repair (S.N. 630436—10

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Torque Values

OUT3035,TORQUE2 -19-22MAR06-1/1

Metric Bolt and Cap Screw Torque Values

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

T O R Q 2 — U N — 0 7 S E P 9 9

Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

ThreadSize

Lubricateda

N∙m (lb-ft)Dry

b

N∙m (lb-ft)Lubricated

a

N∙m (lb-ft)Dry

b


a

N∙m (lb-ft)Dry

b


a

N∙m (lb-ft)Dry

b

N∙m (lb-ft)

M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)

M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)

M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)

M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)

M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)

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 (17 00) 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.

CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. Tool may slip and cause injury.

DO NOT use these values if a different torque value or tighteningprocedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Shear bolts are designed to fail under predetermined loads. Alwaysreplace shear bolts with identical property class.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightenedto the strength of the original.

Make sure fastener threads are clean and that you properly start threadengagement. This will prevent them from failing when tightening.

Tighten plastic insert or crimped steel-type lock nuts to approximately50 percent of the dry torque shown in the chart, applied to the nut, notto the bolt head. Tighten toothed or serrated-type lock nuts to the fulltorque value.

TM11813 (13OCT10) 00-0003-2 748H Repair (S.N. 630436— )101310

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Torque Values

04T,90,M170 -19-29SEP99-1

Additional Metric Cap Screw Torque Values

CAUTION: Use only metric tools on metrichardware. Other tools may not fit properly.They may slip and cause injury.

Check tightness of cap screws periodically. Torque valueslisted are for general use only. Do not use these values if a different torque value or tightening procedure is listedfor a specific application.

Shear bolts are designed to fail under predeterminedloads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these shouldonly be tightened to the strength of the original.

Make sure fastener threads are clean and you properlystart thread engagement. This will prevent them fromfailing when tightening.

Tighten cap screws having lock nuts to approximately 50percent of amount shown in chart.

aMETRIC CAP SCREW TORQUE VALUES

T-Bolt H-Bolt M-Bolt

Nomi-nal Dia N∙m lb-ft N∙m lb-ft N∙m lb-ft

8 29 21 20 15 10 7

10 63 46 45 33 20 15

12 108 80 88 65 34 25

14 176 130 137 101 54 40

16 265 195 206 152 78 58

18 392 289 294 217 118 87

20 539 398 392 289 167 12522 735 542 539 398 216 159

24 931 687 686 506 274 202

27 1372 1012 1029 759 392 289

30 1911 1410 1421 1049 539 398

33 2548 1890 1911 1410 735 542

36 3136 2314 2401 1772 931 687aTorque tolerance is ±10%.

T 6 8 7 3 A A — U N — 1 8 O C T 8 8

T 6 8 7 3 A B — U N — 1 8 O C T 8 8

T 6 8 7 3 A C — U N — 1 8 O C T 8 8

TM11813 (13OCT10) 00-0003-3 748H Repair (S.N. 630436—10

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Torque Values

OUT3035,TORQUE1 -19-14JAN04-1/1

Unified Inch Bolt and Cap Screw TorqueValues

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

T O R Q 1 A — U N — 2 7 S E P 9 9

Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings

Grade 1 (No Mark) Grade 2a

(No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2

ThreadSize

Lubricatedb

N∙m (lb-ft)Dry

c


b

N∙m (lb-ft)Dry

c


b

N∙m (lb-ft)Dry

c


b

N∙m (lb-ft)Dry

c

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.

DO NOT use these values if a different torque value or tighteningprocedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Shear bolts are designed to fail under predetermined loads. Alwaysreplace 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 strengthof the original.

Make sure fastener threads are clean and that you properly start threadengagement. This will prevent them from failing when tightening.

Tighten plastic insert or crimped steel-type lock nuts to approximately50 percent of the dry torque shown in the chart, applied to the nut, notto the bolt head. Tighten toothed or serrated-type lock nuts to the fulltorque value.

TM11813 (13OCT10) 00-0003-4 748H Repair (S.N. 630436— )101310

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Torque Values

TX,90,DH1559 -19-01AUG94-1

T82,BHMA,EL -19-29SEP99-1

Check Oil Lines And Fittings

CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury.Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tightenall connections before applying pressure. Searchfor leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately.Any fluid injected into the skin must be surgicallyremoved within a few hours or gangrenemay result. Doctors unfamiliar with thistype of injury may call the Deere & CompanyMedical Department in Moline, Illinois, or other knowledgeable medical source.

Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight.

Make sure hoses are not twisted or touching movingmachine parts. If abrasion or wear occurs, replaceimmediately.

X 9 8 1 1 — U N — 2 3 A U G 8 8

Tubing with dents may cause the oil to overheat. If youfind tubing with dents, install new tubing immediately.

IMPORTANT: Tighten fittings as specifiedin torque chart.

When you tighten connections, use two wrenches toprevent bending or breaking tubing and fittings.

Service Recommendations for 37° Flare and30° Cone Seat Connectors

1. Inspect flare and flare seat. They must be free of dirtor obvious defects.

2. Defects in tube flare cannot be repaired.Overtightening a defective flared fitting will not stopleaks.

3. Align tube with fitting before attempting to start nut.

4. Lubricate male threads with hydraulic fluid or petroleum jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on torquechart. Do not allow hoses to twist when tighteningfittings.

T 6 2 3 4 A C — U N — 1 8 O C T 8 8

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N∙m lb-ft

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 102 751-3/16 - 12 UN 122 90

1-5/16 - 12 UN 142 105

1-5/8 - 12 190 140

1-7/8 - 12 UN 217 160

NOTE: Torque tolerance is ± 10%.

TM11813 (13OCT10) 00-0003-5 748H Repair (S.N. 630436—10

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Torque Values

04T,90,K66 -19-29SEP99-1/2

04T,90,K66 -19-29SEP99-2/2

Service Recommendations for O-Ring BossFittings

Straight Fitting

1. Inspect O-ring boss seat for dirt or defects.

2. Lubricate O-ring with petroleum jelly. Place electricaltape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape.

3. Tighten fitting to torque value shown on chart.

T 6 2 4 3 A E — U N — 1 8 O C T 8 8

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).

NOTE: Do not allow hoses to twist when tightening fittings.

4. Hold fitting head-end with a wrench and tighten locknutand back-up washer to proper torque value.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N∙m lb-ft

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

1-5/16-12 UN 142 105

1-5/8-12 UN 190 140

1-7/8-12 UN 217 160

NOTE: Torque tolerance is ± 10%.

T 6 5 2 0 A B — U N — 1 8 O C T 8 8

TM11813 (13OCT10) 00-0003-6 748H Repair (S.N. 630436— )101310

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Torque Values

04T,90,K67 -19-02MAR00-1

Service Recommendations For Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces and O-ring. Theymust be free of dirt or defects.

2. Lubricate O-rings and install into grove using

petroleum jelly to hold in place.

3. Index angle fittings and tighten by hand pressing jointtogether to insure O-ring remains in place.

4. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tighteningfittings, use backup wrench on straight hose couplings.

IMPORTANT: Tighten fittings to 150% of listed torquevalue if indexing is necessary or if fitting isattached to an actuating devise.

Tighten fittings to 50% of listed torque valueif used in aluminum housing.

FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut

mm in. in. N∙m lb-ft N∙m lb-ft

6.35 0.250 9/16-18 16 12 12 9

9.52 0.375 11/16-16 24 18 24 18

12.70 0.500 13/16-16 50 37 46 34

15.88 0.625 1-14 69 51 62 46

19.05 0.750 1 3/16-12 102 75 102 75

22.22 0.875 1 3/16-12 102 75 102 75

25.40 1.000 1 7/16-12 142 105 142 105

31.75 1.250 1 11/16-12 190 140 190 140

38.10 1.500 2-12 217 160 217 160

*Torque tolerance is +15 -20% unless otherwise specified.

Stud End O-ring Seal Torque for Straight and Adjustable Fittings*

Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque

Inch Inch Inch N∙m lb-ft

3/8-24 5/8 9/16 12 9

7/16-20 5/8 5/8 21 15

1/2-20 3/4 11/16 26 199/16-18 3/4 3/4 34 25

3/4-16 7/8 15/16 73 55

7/8-14 1 1/16 1 1/16 104 76

1 1/16-12 1 1/4 1 3/8 176 130

1 3/16-12 1 3/8 1 1/2 230 170

1 5/16-12 1 1/2 1 5/8 285 210

*Torque tolerance is +15 -20% unless otherwise specified.

TM11813 (13OCT10) 00-0003-7 748H Repair (S.N. 630436—10

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Torque Values

04T,90,K175 -19-29SEP99-1/1

Service Recommendations for Metric Series Four Bolt Flange Fitting

T 6 8 9 0 B B — U N — 0 1 M A R 9 0

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches causeleaks. Roughness causes seal wear. Out-of-flatcauses seal extrusion. If defects cannot be polished

out, replace component.2. Install the correct O-ring (and backup washer if

required) into groove using petroleum jelly to hold itin 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 inplace. 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 becentrally located on port. Hand tighten cap screws tohold flange in place. Do not pinch O-ring.

5. After components are properly positioned and capscrews are hand tightened, tighten one cap screw,then tighten the diagonally opposite cap screw.Tighten two remaining cap screws. Tighten all capscrews as specified in the chart below.

DO NOT use air wrenches. DO NOT tighten one capscrew fully before tightening the others. DO NOT over tighten.

aTORQUE CHARTbThread N∙m lb-ft

M6 12 9

M8 30 22

M10 57 42

M12 95 70

M14 157 116

M16 217 160

M18 334 246

M20 421 318aTolerance ± 10%. The torques given are enough for the given sizeconnection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and

cap screw bending and connection failures.bMetric standard thread.

TM11813 (13OCT10) 00-0003-8 748H Repair (S.N. 630436— )101310

PN=30



Torque Values

04T,90,K174 -19-01AUG94-1

Service Recommendations For Inch Series Four Bolt Flange Fittings

T 6 8 9 0 B B — U N — 0 1 M A R 9 0

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches causeleaks. Roughness causes seal wear. Out-of-flatcauses 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 becentrally located on port. Hand tighten cap screws tohold flange in place. Do not pinch O-ring.

5. Tighten one cap screw, then tighten the diagonallyopposite cap screw. Tighten two remaining capscrews. Tighten all cap screws as specified in thechart below.

DO NOT use air wrenches. DO NOT tighten one capscrew fully before tightening the others. DO NOT over tighten.

TORQUE CHART

N∙m lb-ft

Nominal

FlangeSize

Cap Screw

Size Min Max Min Max

1/2 5/16-18 UNC 20 31 15 23

3/4 3/8-16 UNC 28 54 21 40

1 3/8-16 UNC 37 54 27 40

1-1/4 7/16-14 UNC 47 85 35 63

1-1/2 1/2-13 UNC 62 131 46 97

2 1/2-13 UNC 73 131 54 97

2-1/2 1/2-13 UNC 107 131 79 97

3 5/8-11 UNC 158 264 117 195

3-1/2 5/8-11 UNC 158 264 117 195

4 5/8-11 UNC 158 264 117 195

5 5/8-11 UNC 158 264 117 195

TM11813 (13OCT10) 00-0003-9 748H Repair (S.N. 630436—10

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Torque Values

TM11813 (13OCT10) 00-0003-10 748H Repair (S.N. 630436— )101310

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Section 01Wheels

Contents

Page

Group 0110—Powered Wheels and FastenersWheel Remove and Install......................... 01-0110-1Tire Remove and Install............................. 01-0110-2Dual Wheel Installation.............................. 01-0110-3

TM11813 (13OCT10) 01-1 748H Repair (S.N. 630436—10

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Contents

TM11813 (13OCT10) 01-2 748H Repair (S.N. 630436— )101310

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Group 0110Powered Wheels and Fasteners

SW03989,0000B30 -19-17SEP10-1

Wheel Remove and Install

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

2. Turn battery disconnect switch to the OFF position.

See Battery Disconnect. (Operator’s Manual.)

CAUTION: Avoid possible injury from unexpectedmachine movement. Install wheel chocks under one or more wheels not being removed.

3. Install wheel chocks under one or more wheels notbeing removed.

CAUTION: Prevent possible crushing injury fromheavy component. Use appropriate lifting device.

4. Raise machine. Place an 18-t (20-ton) floor standunder axle.

SpecificationMachine—Weight

(approximate)........................................................................... 17 030 kg

37 540 lb.


5. Place wheel lift under wheel. Fasten safety chainaround upper part of tire.

Specification

Wheel—Weight

(approximate)................................................................................ 545 kg

1200 lb.

IMPORTANT: The rim dropping onto the cap screwswhen loosened can damage the threads.Install studs before loosening all the capscrews to keep wheel centered on axle flangeto prevent thread damage.

6. Remove three cap screws equally spaced around boltcircle. Install T45672 Studs.

7. Remove cap screws and washers to remove wheel.

IMPORTANT: Paint, rust, and dirt must be removedfrom the cap screws and axle flange threads,washers, and mating surfaces of axle flangeand rim to ensure good contact between all

T 7 3 8 2 A N — U N — 2 7 S E P 9 0

Wheel

surfaces. Paint, rust, and dirt prevent goodcontact between the surfaces and can resultin the wheels coming loose.

8. Clean the threads of cap screws and axle flange; and

the mating surfaces on washers, rim, and axle flange. Apply a drop of oil to cap screw threads after cleaningwith solvent.

9. Install three studs, equally spaced, into the axle flange.


10. Install wheel.

Specification

Wheel—Weight

(approximate)................................................................................ 545 kg

1200 lb.

11. Install cap screws and washers.

Tighten the cap screws just enough to hold wheelin position. Remove the studs. Install the threeremaining cap screws.

Tighten cap screws to specification in a circular patterncontinuing past the starting point by four cap screws.

Specification

Rim-to-Axle Flange Cap

Screw—Torque............................................................................868 N∙m

640 lb-ft

For machines with dual wheels, see Dual WheelInstallation. (Group 0110.)

TM11813 (13OCT10) 01-0110-1 748H Repair (S.N. 630436—10

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Powered Wheels and Fasteners

VD76477,000049C -19-12NOV08-1/1

Tire Remove and Install

CAUTION: Tire repair should only be performedby a qualified tire repair service. Do not attemptto mount or demount a tire unless you have theproper equipment and experience to perform the job safely. Failure to follow proper procedureswhen mounting or demounting a tire from a wheelor rim can result in explosive separation of a tireand rim parts, causing serious injury or death

Always maintain the correct tire pressure. Do not inflatethe tires above the recommended pressure. Never weld or heat a wheel and tire assembly, as heating can increaseair pressure and result in tire explosion. Welding can alsostructurally weaken or deform the wheel.

For initial inflation, always use a clip-on chuck andextension hose long enough to allow you to stand to oneside and NOT in front of, or over, the tire assembly. Inflatein a safety cage if available. Use safety chains, cables, or equivalent restraining devices during inflation.

CAUTION: Stand clear when using a cable or chain sling. These devices can snap and lashout, causing serious injury or death.

Check tire and wheel assemblies for low pressure, cuts,bubbles, damaged rim components, or missing lug boltsand nuts.

Check that the tire size exactly matches the rim size.Improperly-sized tires may not perform as intended.

Wheels may contain multi-piece rim components. Inspectall rim components and replace those that are cracked,worn, damaged, or severely rusted. Use only rimcomponents designed to work with one another. Do notcombine rim components from different rim types or rimmanufacturers. Incorrectly assembled or mismatched rimcomponents can fly apart with explosive force.

NOTE: See supplied Off-The-Road Tire MaintenanceManual to remove tire from wheel.

T S 9 5 2 — U N — 1 2 A P R 9 0

Explosive Single Piece Rim and Tire

T S 2 1 1 — U N — 2 3 A U G 8 8

Explosive Multi-Piece Rim and Tire

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AC12469,0000462 -19-06AUG07-1

Dual Wheel Installation


1. Position outer dual wheel flange-to-flange with inner wheel.

Specification

Dual Wheel—Weight

(approximate)................................................................................ 545 kg

1200 lb

2. Align cap screw holes in flanges using punches if necessary.

3. Lubricate cap screw threads with grease.

4. Insert each cap screw outward through inner washer,inner flange and outer washer. Install nut.

5. Seat wheels to rim by tightening nuts in a criss-crosspattern to specification.

SpecificationDual Wheel Nuts—Initial

Torque.........................................................................................407 N∙m

300 lb-ft

6. Tighten nuts to final specification.

Specification

Dual Wheel Nuts—Final

Torque.........................................................................................712 N∙m

525 lb-ft

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Section 02Axles

Contents

Page

Group 0200—Remove and InstallTeamMate™ IV Axles................................02-0200-1Front Axle, Differential, and

Oscillation Supports Removeand Install .............................................. 02-0200-1

Rear Axle and Differential Removeand Install ..............................................02-0200-5

Front Axle Guards Remove andInstall ..................................................... 02-0200-8

Oscillation Supports Repair ....................... 02-0200-8

Group 0225—Input Drive Shaft and U-JointsFront Axle Drive Shaft Remove and

Install .....................................................02-0225-1Rear Axle and Transmission Drive

Shaft Remove and Install ...................... 02-0225-2

Group 0260—Hydraulic SystemDifferential Lock Solenoid Valve

Repair .................................................... 02-0260-1

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Group 0200Remove and Install

AC12469,0000382 -19-01JUN07-1

Continued on next page MH66088,0000D71 -19-10SEP10-1

TeamMate™ IV Axles

For additional information on TeamMate ™ IV axles andcomponents, see TeamMate™ IV 1200 - 1400 SeriesInboard Planetary Axles. (CTM442.)

TeamMate is a trademark of Deere & Company

Front Axle, Differential, and OscillationSupports Remove and Install

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

CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting or connecting hydraulic or other lines. Tighten allconnections before applying pressure.

2. Operate all hydraulic functions, including brake, torelease pressure in the hydraulic system. Depressbrake pedal at 1-second intervals 20 times to removepressure from service brake accumulator.

3. Turn battery disconnect switch to the OFF position.See Battery Disconnect. (Operator’s Manual.)

4. Identify axle fitted to machine. See Axle Identification.(CTM442.)

5. Remove engine frame rear bottom guard.


6. Raise front of machine and support with stands.

Specification

Machine—Weight

(approximate)........................................................................... 17 030 kg

37 540 lb.

7. Remove front wheels. See Wheel Remove and Install.(Group 0110.)

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

9. Remove engine frame side guards.

10. Remove cap screws (2). Disconnect universal jointfrom front axle.

11. Disconnect rear oscillation support lubrication hose(1). Close all openings using caps and plugs.

T X 1 0 2 4 5 3 7 A — U N — 0 6 J U N 0 7

Front Axle-to-Drive Shaft Disconnect

1— Rear Oscillation SupportLubrication Hose

2— Cap Screw (4 used)

3— Drive Shaft4— Front Axle Yoke

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Continued on next page MH66088,0000D71 -19-10SEP10-3/5

12. Disconnect service brake hose (5) and differential lockhose (6) from axle. Close all openings using caps andplugs.

5—Service Brake Hose 6—Differential Lock Hose

T X 1 0 2 4 5 4 6 A — U N — 0 6 J U N 0 7

Service Brake and Differential Lock Hoses

13. Disconnect front axle vent hose (7). Close all openingsusing caps and plugs.

14. Remove front engine frame bottom guard.

7— Front Axle Vent Hose

T X 1 0 8 1 7 6 1 A — U

N — 1 0 S E P 1 0

Front Axle Vent Hose

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Remove and Install


15. Disconnect lubrication hose (8) from front axleoscillation support (9). Close all openings using capsand plugs.

CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.

16. Remove cap screws from front and rear oscillationsupports. Lower axle and remove from under machine.

Specification

1400 Series

Axle—Weight

(approximate)................................................................................ 862 kg

1900 lb.

1400 Series Super

Wide Extreme Duty

Axle (SWEDA)—Weight

(approximate).............................................................................. 1450 kg

3200 lb.

17. Repair or replace axle. See TeamMate™ IV Axles.(Group 0200.)

18. For oscillation supports repair procedure, seeOscillation Supports Repair. (Group 0200.)

19. Clean mounting surfaces on oscillation supports,dowels, and engine frame. Mounting surfaces shouldbe free from dirt, paint, and corrosion.

20. Install dowels in oscillation supports if they wereremoved during removal or repair.


21. Support and raise axle into position.

T X 1 0 8 1 7 6 3 A — U N — 1 0 S E P 1 0

Front Oscillation Support Lubrication Hose

8— Lubrication Hose 9— Front Axle OscillationSupport

Specification

1400 Series

Axle—Weight

(approximate)................................................................................ 862 kg

1900 lb.

1400 Series Super

Wide Extreme Duty Axle (SWEDA)—Weight

(approximate).............................................................................. 1450 kg

3200 lb.

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MH66088,0000D71 -19-10SEP10-5/5

22. Position oscillation supports. Install front and rear oscillation support-to-engine frame cap screws (10and 11 and tighten to specification..

Specification

Oscillation Support-

to-Engine Frame Cap

Screw—Torque.................................................................. 488—596 N∙m

360—440 lb-ft

NOTE: It may be necessary to loosen the front cover-to-oscillation support cap screws (12) inorder to align support cap screws with holesin engine frame. Hold thrust washer (13) in place using a hex key wrench.

23. Adjust axle end play to specification. See Adjust Axle Assembly End Play - In Vehicle. (CTM442.)

24. Connect front oscillation support lubrication line.

25. Install front engine frame bottom guard and tightencap screws to specification.

Specification

Bottom Guard-to-Engine

Frame Cap

Screw—Torque............................................................................620 N∙m

457 lb-ft

26. Connect axle vent tube.

27. Connect service brake and differential lock hoses.

28. Connect rear oscillation support lubrication hose.

29. Install front differential drive shaft and tighten capscrews to specification.

Specification

3/8 in. Cross and Bearing

Assembly-to-Yoke Cap

Screw—Torque......................................................................51—57 N∙m

38—42 lb-ft



Screw—Torque.................................................................. 127—142 N∙m

94—105 lb-ft

30. Install engine frame side guards.

31. Fill axle with oil. See Change Front Axle Oil.(Operator’s Manual.)

32. Install front wheels. See Wheel Remove and Install.(Group 0110.)

33. Lower front of machine to the ground.

34. Install rear engine frame bottom guard.

Specification

Bottom Guard-to-Engine

Frame Cap

Screw—Torque............................................................................620 N∙m

457 lb-ft

T X 1 0 2 4 5 9 7 A — U N — 0 6 J U N 0 7

Oscillation Support Cap Screws

10— Front OscillationSupport-to-Engine FrameCap Screw (6 used)

11— Rear OscillationSupport-to-Engine FrameCap Screw (6 used)

T X 1 0 2 4 5 9 6 A — U N — 0 6 J U N 0 7

Front Oscillation Support Cap Screws

12— Front Cover-to-OscillationSupport Cap Screw (6used)

13— Thrust Washer

35. Bleed service brakes. See Service Brake BleedingPr ocedure. (Group 9025-20.)

36. Turn battery disconnect switch to the ON position.

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Remove and Install


Rear Axle and Differential Remove and Install


CAUTION: To avoid injury from escaping fluid

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

2. Operate all hydraulic functions, including brake, torelease pressure in the hydraulic system. Depressbrake pedal at 1-second intervals 20 times to removepressure from service brake accumulator.


4. Identify axle fitted to machine. See TeamMate™IV 1200 - 1400 Series Inboard Planetary Axles.

(CTM442.)


5. Raise rear of machine and support with stands.

Specification

Machine—Weight

(approximate)........................................................................... 17 030 kg

37 540 lb

6. Remove rear wheels. See Wheel Remove and Install.(Group 0110.)

7. Drain differential oil into an appropriate container for

storage or disposal. See Change Front Axle Oil.(Operator’s Manual.)


Bottom guard weight increases due to trashbuildup in equipment frame.

8. Remove equipment frame rear bottom guard.

Specification

Equipment Frame Rear

Bottom Guard—Weight

(approximate).................................................................................. 34 kg

75 lb.

9. Disconnect transmission-to-rear axle drive shaft (1) byremoving cap screws (2).

T X

1 0 2 4 6 0 8 A — U N — 0 6 J U N 0 7

Rear Drive Shaft

1— Transmission-to-Rear AxleDrive Shaft


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Remove and Install


10. Disconnect service brake hose (3) and differential lockhose (4) from axle. Close all openings using caps andplugs.

3—Service Brake Hose 4—Differential Lock Hose

T X 1 0 8 1 7 6 0 A — U N — 1 0 S E P 1 0

Service Brake and Differential Lock Hoses

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Remove and Install



11. Support rear axle. Remove nuts, washers, andcap screws. Lower axle and differential slightly and

disconnect breather hose.

Specification

1400 Series

Axle—Weight

(approximate)................................................................................ 862 kg

1900 lb.

1400 Series Super

Wide Extreme Duty


(approximate).............................................................................. 1450 kg

3200 lb.

12. Lower axle and differential and remove from under machine.

13. Repair or replace axle. See TeamMate™ IV Axles.(Group 0200.)

14. Clean mounting surface on axle housing andequipment frame. Mounting surface should be freeof dirt and corrosion.


15. Position axle underneath equipment frame.

Specification

1400 Series

Axle—Weight

(approximate)................................................................................ 862 kg1900 lb.

1400 Series Super

Wide Extreme Duty


(approximate).............................................................................. 1450 kg

3200 lb.

16. Connect breather hose.

IMPORTANT: The tightening sequence for cap screwsand nuts must be followed to prevent bindingwhich would result in inadequate clampingforce applied to the axle and frame joint.

NOTE: Apply oil to threads of rear axle and differential-to-equipment frame cap screwsbefore installation.

17. Apply oil to threads of cap screws. Hold the capscrews and tighten the nuts from the inside to theoutside, alternating sides. Tighten nuts until they aresnug.

18. Tighten cap screws to specification, from inside tooutside, alternating sides.

T X 1 0 2 4 6 1 5 A — U N — 0 6 J U N 0 7

Rear Axle Cap Screws

5— Rear Axle Cap Screws

SpecificationRear Axle and

Differential-to-Equipment

Frame Cap

Screws—Torque..........................................................................660 N∙m

487 lb-ft

19. Install rear differential drive shaft and tighten capscrews to specification.

Specification



Screw—Torque......................................................................51—57 N∙m

38—42 lb-ft



Screw—Torque.................................................................. 127—142 N∙m

94—105 lb-ft

20. Connect service brake and differential lock hoses.

21. Bleed service brakes. See Service Brake BleedingProcedure. (Group 9025-20.)

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Remove and Install

MH66088,0000D72 -19-10SEP10-4/4

AC12469,000033E -19-29MAY07-1/1

PM10405,0000576 -19-07OCT10-1/1

22. Install rear equipment frame bottom guard. Tightencap screws to specification.

Specification

Bottom Guard-to-

Equipment Frame Cap

Screw—Torque............................................................................620 N∙m460 lb-ft

23. Fill axle with oil. See Change Rear Axle Oil.(Operator’s Manual.)

24. Install rear wheels. See Wheel Remove and Install.(Group 0110.)

25. Lower rear of machine to ground.

26. Turn battery disconnect switch to the ON position. SeeBattery Disconnect. (Operator’s Manual.)

Front Axle Guards Remove and Install

TX1024347

1 3

2

T X 1 0 2 4 3 4 7 — U N —

0 6 J U N 0 7

1— Cap Screw (2 used per guard) 2— Washer (8 used per guard) 3— Guard (2 used per axle)

Remove and install parts as shown.

Item Measurement Specification

Axle Guard-to-TransmissionCase Cap Screw

Torque 346 N∙m255 lb-ft

Oscillation Supports Repair

See TeamMate™ IV 1200-1400 Axles (CTM442)for disassembly, assembly, adjustment, and repair information for front and rear oscillation supports.

To adjust oscillation supports, front axle must be installedin machine. See Front Axle, Differential, and OscillationSupports Remove and Install. (Group 0200.)

To repair oscillation supports, front axle must be removedfrom machine. See Front Axle, Differential, and OscillationSupports Remove and Install. (Group 0200.)

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Group 0225Input Drive Shaft and U-Joints

SW03989,0000B3A -19-24SEP10-1

Front Axle Drive Shaft Remove and Install

TX1024375

2

1

2

3

3

2

6

4

5

T X 1 0 2 4 3 7 5 — U N — 0 7 J U N 0 7

1— Front Differential Yoke2— Cap Screw (12 used)

3— Cross and Bearing Assembly(2 used)

4—Cap Screw (4 used)

5— Double Universal Joint6— Transmission Yoke


2. Remove bottom guards on engine frame to gainaccess to drive shaft. See Engine Frame BottomGuard Remove and Install. (Group 1746.)

3. Remove cap screws (2 and 4) to remove doubleuniversal joint (5).

IMPORTANT: Yoke faces, pilots, keyways, bearingcup mounting face, and key must be free of foreign material, burrs, and nicks which willprevent the cross and bearing assembly andyoke from becoming properly seated.

4. Inspect parts for wear or damage. Repair or replaceas necessary.

IMPORTANT: Universal joints are precisioncomponents. The fit is intended to be tight andsome compression of seals and thrust washersis required to seat the bearing cups in the yoke.Hand pressure, a tap with a soft-faced hammer or a “C” clamp can be used to seat a bearingcup in the yoke. DO NOT use the cap screwsto pull bearing cups into the yokes.

5. Assemble universal joint so lubrication fittings arealigned. Bearing cup keys must engage the keyway

and bearing cups the yoke pilot.

Tighten cap screws in even steps to specification.

Specification



Screw—Torque......................................................................51—57 N∙m

38—42 lb-ft



Screw—Torque.................................................................. 127—142 N∙m

94—105 lb-ft

6. Install lubrication fittings and tighten to specification.

SpecificationLubrication

Fitting—Torque........................................................................5—16 N∙m

48—144 lb-in.

7. Lubricate universal joints. See Grease Front AxleDrive Shaft U-Joints and Transmission Output ShaftSeal. (Operator’s Manual.)

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Input Drive Shaft and U-Joints

Continued on next page SW03989,0000B3B -19-24SEP10-1/3

Rear Axle and Transmission Drive ShaftRemove and Install

T X 1 0 2 4 4 1 7 — U N — 0 7 J U N 0 7

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Continued on next page SW03989,0000B3B -19-24SEP10-2

1— Transmission Yoke2— Snap Ring3— Slotted Nut4— Cotter Pin5— Cap Screw (8 per universal

joint)

6— Universal Joint7— Lubrication Fitting8— Telescoping Drive Shaft9— Lock Nut10— Washer

11— Drive Shaft Yoke12— Snap Ring13— Nut14— Washer 15— Nut

16— Set Screw17— Support Bearing18— Drive Shaft19— Cap Screw (2 used)20— Alignment Marks

CAUTION: Avoid possible injury from unexpectedmachine movement. Install articulation lockingbar before working in frame hinge area.


2. Remove shields at the articulation joint as needed for access. Remove the equipment frame bottom guardfor access at rear axle and differential. See EquipmentFrame Bottom Guard Remove and Install. (Group1746.)

IMPORTANT: Yoke faces, pilots, keyways, bearingcup mounting face, and key must be free of

foreign material, burrs, and nicks which willprevent the cross and bearing assembly andyoke from becoming properly seated.

3. Disassemble parts as shown. Inspect parts for wear or damage and replace as necessary.

4. Loosen the nut (15) and then the set screw (16) toremove support bearing (17) from drive shaft (18).

5. Install snap ring (2) into groove of transmission yoke(1).

6. Install transmission yoke on transmission output shaft.Install slotted nut (3) and tighten to specification.

Specification

Yoke-to-Transmission

Output Shaft Slotted

Nut—Torque...................................................................... 271—339 N∙m

200—250 lb-ft

NOTE: Slotted nut can be tightened up to an additional 1/24 turn to align slot with hole.

7. Install cotter pin (4). Bend legs of cotter pin againstsides of nut.

IMPORTANT: Both universal joints (6) on telescopingdrive shaft must be assembled with alignmentmark and yokes aligned. Yokes not alignedwill cause excessive vibration during turns

resulting in failure of bearings.

8. Assemble telescoping drive shaft (8) so alignmentmark (20) on drive shaft yoke (11) and transmissionyoke are aligned.

9. Install universal joint so drive shaft yoke is to the rear of machine.

10. Apply PM37566 Anti-Seize Lubricant to supportbearing-to-coupling shaft contact surface of supportbearing (17).

11. Install support bearing on drive shaft so set screw istowards the threaded end of shaft.

12. Install set screw to contact bottom of slot in shaft andthen loosen one turn. Install nut over set screw andtighten.

Specification

Support Bearing-to-

Coupling Shaft Slot SetScrew—Clearance....................................................... One turn out from

bottom of slot in coupling shaft.

13. Install snap ring (12) into groove of drive shaft.Position snap ring opening opposite the slot in thedrive shaft.

14. Install yoke (11) on drive shaft so alignment marks(20) are aligned.

15. Install washer (10) and lock nut (9). Tighten lock nutto specification.

Specification

Lock Nut (Machines

with 1200 Series

Axle)—Torque....................................................................542—610 N∙m

400—450 lb-ft

Lock Nut (Machines

with 1400 Series

Axle)—Torque....................................................................720—800 N∙m

531—590 lb-ft

16. Install drive shaft so support bearing is on the frontside of mounting plate.

17. Install washers (14) under the head of the cap screws(19) and nuts (13). Tighten nuts to specification.

Specification

Nut—Torque................................................................................325 N∙m

240 lb-ft

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SW03989,0000B3B -19-24SEP10-3/3

IMPORTANT: Universal joints are precisioncomponents. The fit is intended to be tight andsome compression of seals and thrust washersis required to seat the bearing cups in the yoke.Hand pressure, a tap with a soft-faced hammer,

or a “C” clamp can be used to seat a bearingcup in the yoke. DO NOT use the cap screwsto pull bearing cups into the yokes.

18. Assemble universal joint so lubrication fittings arealigned. Bearing cup keys (21) must engage thekeyways and bearing cups engage the yoke pilot (22).

19. Install and tighten cap screws to specification.

Specification



Screw—Torque......................................................................51—57 N∙m

38—42 lb-ft



Screw—Torque.................................................................. 127—142 N∙m

94—105 lb-ft

20. Install and tighten lubrication fittings (7) to specification.

Specification

Lubrication


48—144 lb-in.

Air Relief Valve—Torque..........................................................5—16 N∙m

48—144 lb-in.

21. Grease drive shaft. See Grease Rear Axle Drive ShaftU-Joints, Telescoping Splines, Support Bearing, andTransmission Output Shaft Seal. (Operator’s Manual.)

T X 1 0 2 4 4 3 9 A — U N — 0 6 J U N 0 7

21— Bearing Cup Key 22— Yoke Pilot

22. Install shields at the articulation joint and install theequipment frame bottom guard. See EquipmentFrame Bottom Guard Remove and Install. (Group1746.)

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Group 0260Hydraulic System

NM00125,0000583 -19-04OCT10-1

NM00125,0000583 -19-04OCT10-2

Differential Lock Solenoid Valve Repair

1. Prepare machine for service. See Park and PrepareFor Service Saf ely. (Group 0001.)




3. Operate all hydraulic control valves to release pressurein hydraulic system. Depress brake pedal at 1 secondintervals 20 times to drain oil from accumulator.

4. Remove cap screws (1 and 2) to remove access panel(3).

T X 1 0 7 9 2 5 9 A — U N — 2 9 J U N 1 0

Left Access Panel

1— Cap Screw2— Cap Screw

3— Access Panel

5. Disconnect wire connector from differential locksolenoid valve (5).

6. Remove cap screws (4) and remove solenoid fromvalve body (6). Close all openings using caps andplugs.

7. Repair or replace parts as necessary.

8. Install new O-rings and backup rings on solenoid valveusing petroleum jelly for installation.

9. Connect electrical connector to solenoid valve.

10. Install access panel.

11. Turn batter y disconnect switch to the ON position. SeeBattery Disconnect. (Operator’s Manual.)

12. Before returning machine to service, check operationof differential lock solenoid valve. See DifferentialLock Switch. (Operator’s Manual.)

4— Cap Screw (2 used)5— Differential Lock Solenoid

Valve

6— Valve Body 6

4

5 T X 1 0 2 4 4 5 8 — U N — 0 6 J U N 0 7

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Section 03Transmission

Contents

Page

Group 0300—Remove and InstallTransmission Remove and Install.............. 03-0300-1Transmission Mount Remove and

Install ..................................................... 03-0300-6

Group 0315—ControlsTransmission Bump Shifter

Remove and Install................................ 03-0315-1

Group 0325—Input Drive Shafts and U-JointsEngine-to-Transmission Drive

Shaft Remove and Install ...................... 03-0325-1

Group 0350—Gears, Shafts, and Power Shift ClutchesTransmission Repair Procedures ..............03-0350-1Winch Drive Repair.................................... 03-0350-2Input Yoke Remove and Install ..................03-0350-7

Group 0360—Hydraulic SystemTransmission Charge Pump

Remove and Install................................03-0360-1Transmission Charge Pump Drive

Repair ....................................................03-0360-4Transmission Suction Tube

Repair .................................................... 03-0360-8Transmission Control Valve

Repair .................................................... 03-0360-9

TM11813 (13OCT10) 03-1 748H Repair (S.N. 630436—10

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Group 0300Remove and Install

Continued on next page SW03989,0000B37 -19-07OCT10- 1

Transmission Remove and Install




2. Operate all hydraulic controls to relieve pressurein the hydraulic system. Depress brake pedal at1-second intervals 20 times to discharge pressurefrom accumulator.

3. Turn the battery disconnect switch to the OFF position.See Battery Disconnect. (Operator’s Manual.)

4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’sManual.)

5. Remove engine frame side access covers. SeeOpening Engine Side Shields. (Operator’s Manual.)

6. Apply vacuum or drain hydraulic reservoir. If draininghydraulic reservoir, see Change Hydraulic Oil.(Operator’s Manual.)

7. Remove priority valve. See Priority Valve Remove andInstall. (Group 2160.)

8. Remove hydraulic attenuator, (if equipped). SeeHydraulic Attenuator Remove and Install. (Group2160.)

9. Remove hydraulic pump (1). See Hydraulic PumpRemove and Install. (Group 2160.)

10. Remove hydraulic fan and cooling loop pump (3) fromtransmission case. See Hydraulic Fan and CoolingLoop Pump Remove and Install. (Group 2160.)

11. Remove spline coupler (6).

12. Drain transmission oil. See Change Transmission Oil,Replace Filter, and Clean Suction Screen. (Operator’sManual.)

13. Remove engine-to-transmission drive shaft. SeeEngine-to-Transmission Drive Shaft Remove andInstall. (Group 0325.)

14. Disconnect transmission charge pump-to-filter hose

(2). Close all openings using caps and plugs.

15. Disconnect transmission wiring harness plug (9) fromcab.

16. Disconnect transmission harness-to-fuel sender harness connector (4), park brake solenoid connector,

T X 1 0 8 0 8 6 0 A — U N — 1 6 A U

G 1 0

Transmission

T X 1 0 2 5 6 3 8 A — U N — 2 9 J U N 0 7

Spline Coupler

T X 1 0 2 5 6 3 0 A — U N — 2

9 J U N 0 7

Transmission Harness

1— Main Hydraulic Pump2— Transmission Charge

Pump-to-Filter Hose3— Hydraulic Fan and Cooling

Loop Pump4— Transmission Harness-

to-Fuel Sender Harness

Connector 5— Transmission Charge Pump

6— Spline Coupler 7— Clamp and Cap Screw8— Transmission Wiring

Harness9— Transmission Wiring

Harness Plug

differential lock solenoid connector, and park brakepressure switch connector.

TM11813 (13OCT10) 03-0300-1 748H Repair (S.N. 630436—10

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Remove and Install

SW03989,0000B37 -19-07OCT10-2/7

Continued on next page SW03989,0000B 37 -19-07OCT10- 3/7

17. Remove dipstick (10) from transmission.

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

19. Disconnect winch drive shaft (if equipped) from winchoutput yoke. See Winch Drive Shaft Remove andInstall. (Group 3025.)

20. Disconnect rear axle drive shaft from transmission.See Rear Axle and Transmission Drive Shaft Removeand Install. (Group 0225.)

10— Dipstick11— Transmission Fill Hose

12— Transmission Vent Hose

T X 1 0 2 5 6 4 0 A — U N — 2 9 J U N 0

7

Transmission Dipstick

T X 1 0 2 5 6 4 1 A — U N — 2 9 J U N

0 7

Transmission Vent Hose and Fill Hose

21. Identify and disconnect park brake and differential lockvalve return hose (13), winch return hose (17), andpark brake valve hose (18). Close all openings usingcaps and plugs.

22. Remove cap screw (15), washer (16), and winchoutput yoke (14).

13— Park Brake andDifferential Lock ReturnHose

14— Winch Output Yoke15— Cap Screw

16— Washer 17— Winch Return Hose18— Park Brake Valve Hose

14

15

16

13

17

18

TX1081025 T X 1 0 8 1 0 2 5 —

U N — 2 4 A U G 1 0

Winch Drive

TM11813 (13OCT10) 03-0300-2 748H Repair (S.N. 630436— )101310

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Remove and Install


23. Identify and disconnect hoses (19—23) at transmissioncontrol valve. Close all openings using caps andplugs.

24. Remove front axle drive shaft. See Front Axle DriveShaft Remove and Install. (Group 0225.)

19— Transmission-to-OilCooler Hose

20— Charge Pump PressureHose

21— Park Brake andDifferential Valve SupplyHose

22— Oil Cooler Return Hose23— Winch Control Valve

Pressure Hose

T X 1 0 8 1 0 2 3 A — U N — 2 7 A U G 1 0

Transmission Control Valve

TM11813 (13OCT10) 03-0300-3 748H Repair (S.N. 630436—10

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Remove and Install

Continued on next page SW03989,0000B 37 -19-07OCT10- 5/7

25. Remove cap screws (24) and washers (25) securinglower transmission mount to machine frame.

26. Remove upper transmission mounting cap screws(26), washers (27 and 28), nut (31) and upper isolators(29).

24— Cap Screw (2 used)25— Washer (2 used)26— Cap Screw (2 used)27— Washer (4 used)

28— Washer (4 used)29— Upper Isolator (2 used)30— Lower Isolator (2 used)31— Nut (2 used)

T X 1 0 8 1 0 2 7 A — U N — 2 7 A U G 1 0

Lower Transmission Mount

TX1081024

26

27

28

29

30

28

27

31

T X 1 0 8 1 0 2 4 — U N — 0 1 S E P 1 0

Upper Right Transmission Mount

TM11813 (13OCT10) 03-0300-4 748H Repair (S.N. 630436— )101310

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Remove and Install


27. Remove cap screw (32) from upper left transmissionmount. Install JT01748 Lifting Bracket (33) using acap screw 12.7 mm (1/2 in.) longer than cap screwremoved.


28. Attach D01043AA Load Positioning Sling (34) toappropriate lifting device.

29. Attach one hook from load positioning sling to liftingbracket (33).

30. Attach remaining hook to lifting location at rear slot inupper right transmission mount.

31. Adjust load positioning sling to raise right side of transmission first. Carefully remove transmission frommachine and support on an appropriate stand.

Specification

Transmission—Weight

(approximate)................................................................................ 590 kg

1300 lb.


33. Inspect and replace transmission mounts as needed.See Transmission Mount Remove and Install. (Group0300.)

NOTE: Make sure lower isolators are installed in transmission upper mount before setting transmission into place.

34. Install transmission into engine frame.

Specification


(approximate)................................................................................ 590 kg

1300 lb.

35. Install cap screws and washers. Tighten tospecification.

Specification

Lower Transmission

Mount Plate-to-Frame

Cap Screw—Torque.......................................................... 230—312 N∙m

170—230 lb-ft

36. Install upper transmission mounting hardware andtighten to specification.

Specification

Upper Transmission

Mount Cap Screw and

Nut—Torque...................................................................... 607—743 N∙m

450—550 lb-ft

37. Install front axle drive shaft. See Front Axle DriveShaft Remove and Install. (Group 0225.)

T X 1 0 8 1 0 2 6 A — U N — 2 7 A U G 1 0

Lifting Bracket

T X 1 0 8 1 0 2 8 A — U N — 2 7 A

U G 1 0

Load Positioning Sling

32— Cap Screw33— Lifting Bracket

34— Load Positioning Sling

38. Connect hoses to transmission control valve.

39. Install engine-to-transmission drive shaft. SeeEngine-to-Transmission Drive Shaft Remove andInstall. (Group 0325.)

40. Connect park brake and differential lock valve returnhose, winch return hose, and park brake valve hose.

TM11813 (13OCT10) 03-0300-5 748H Repair (S.N. 630436—10

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Remove and Install

SW03989,0000B37 -19-07OCT10-7/7

Continued on next page NM00125,000057C -19-30SEP10-1/3

41. Install winch output yoke on shaft. Apply Thread Lockand Sealer (medium strength) to cap screw and installwith washer. Tighten cap screw to specification.

Specification

Winch Output Shaft Yoke

Cap Screw—Torque....................................................................215 N∙m159 lb-ft

42. Install remaining drive shafts. See Winch Drive ShaftRemove and Install (Group 3025.) and see Rear Axleand Transmission Drive Shaft Remove and Install.(Group 0225.)

43. Install transmission vent hose and transmission fillhose.

44. Connect transmission wiring harness to cab.

45. Connect transmission harness-to-fuel sender harnessconnector, park brake solenoid connector, differentiallock solenoid connector, and park brake pressure

switch connector. Install all harness clamps in originallocations.

46. Install spline coupler.

47. Install hydraulic fan and cooling loop pump. SeeHydraulic Fan and Cooling Loop Pump Remove andInstall. (Group 2160.)

48. Install hydraulic pump. See Hydraulic Pump Removeand Install. (Group 2160.)

49. Connect transmission charge pump-to-filter hose.

50. Install hydraulic attenuator, if equipped. See Hydraulic Attenuator Remove and Install. (Group 2160.)

51. Install priority valve. See Priority Valve Remove and

Install. (Group 2160.)

52. Remove vacuum if hydraulic reservoir was not drainedor fill hydraulic reservoir. See Change Hydraulic Oil.(Operator’s Manual.)

53. Install engine fr ame side access covers. See OpeningEngine Side Shields. (Operator’s Manual.)

54. Lower cab. See Hydraulic Cab Tilt Procedure.(Operator’s Manual.)

55. Fill transmission with proper oil. See ChangeTransmission Oil, Replace Filter, and Clean SuctionScreen. (Operator’s Manual.)

56. Check hydraulic fluid level. See Check HydraulicSystem Oil Level. (Operator’s Manual.)

57. Turn battery disconnect switch to the ON position. SeeBattery Disconnect. (Oper ator’s Manual.)

58. Calibrate transmission. See Transmission Control Unit(TCU) Calibration. (Group 9015-20.)

Transmission Mount Remove and Install


2. Turn the battery disconnect switch to the OFF position.See Battery Disconnect. (Operator’s Manual.)



4. Install JT05552 20-mm Ringbolt (1) to rear half of transmission case and support with appropriatedevice.

Specification


(approximate)................................................................................ 590 kg

1300 lb.

5. Remove dipstick support (2) from upper righttransmission mount.

6. Remove harness clamp (3) from upper lefttransmission mount.

T X 1 0 8 1 4 0 6 A — U N — 0 1 S E P 1 0

Transmission Support

1— JT05552 20-mm Ringbolt2— Dipstick Support

3— Harness Clamp4— Cap Screw (2 used)

TM11813 (13OCT10) 03-0300-6 748H Repair (S.N. 630436— )101310

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Remove and Install

Continued on next page NM00125,000057C -19-30SEP10-2

CAUTION: Prevent possible crushing injuryor death, and damage to machine fromtransmission shifting. Service only onetransmission mount at a time

7. Remove cap screw (5), washers (6 and 7), nut (12),and upper isolator (8).

NOTE: For upper right transmission mount, it may benecessary to disconnect transmission harness at cab for removal of mount bracket cap screws.

8. Remove cap screws (10) and transmission mountbracket (9).

9. Separate lower isolator (11) from mount bracket

10. Inspect and replace parts as necessary.

11. Install lower isolator to mount bracket beforeinstallation.

12. Position mount bracket and install cap screws. Tightento specification.

Specification

Upper Transmission

Mount Bracket-to-

Transmission Housing

Cap Screw—Torque....................................................................319 N∙m

235 lb-ft

13. Install upper isolator with washers. Tighten cap screwand nut to specification.

Specification

Upper Transmission

Mount Cap Screw andNut—Torque...................................................................... 607—743 N∙m

450—550 lb-ft

14. Install harness clamp and dipstick support.

5

6

7

8

9

10

11

12

T X 1 0 8 1 4 0 4 — U N — 0 3 S E P 1 0

Upper Right Transmission Mount

5— Cap Screw (2 used)6— Washer (4 used)7— Washer (4 used)8— Upper Isolator (2 used)

9— Mount Bracket (2 used)10— Cap Screw (8 used)11— Lower Isolator (2 used)12— Nut (2 used)

15. Connect transmission harness to cab.

TM11813 (13OCT10) 03-0300-7 748H Repair (S.N. 630436—10

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Remove and Install

NM00125,000057C -19-30SEP10-3/3

16. Remove lower transmission mount cap screws (19)and remove mount block (17).

17. Remove cap screw (13) and lower mount hardware(14—16 and 18).


19. Install lower transmission mount hardware. Tightencap screws to specification.

Specification

Lower Transmission

Mount Block-to-Frame


170—230 lb-ft

Lower Transmission

Mount Cap

Screw—Torque.................................................................. 607—743 N∙m

450—550 lb-ft

20. Remove JT05552 20-mm Ringbolt.



13

14

15

16

19

18

15

17

T X

1 0 8 1 4 0 5 — U N — 0 3 S E P 1 0

Lower Transmission Mount

13— Cap Screw14— Washer 15— Washer (2 used)16— Front Isolator

17— Mount Block18— Rear Isolator 19— Cap Screw With Washer

(2 used)

TM11813 (13OCT10) 03-0300-8 748H Repair (S.N. 630436— )101310

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Group 0315Controls

OUO1065,0000312 -19-10MAR09-1

Transmission Bump Shifter Remove and Install

T 2 1 0 5 8 5 — U N — 2 3 M A R 0 6

Transmission Bump Shifter

A—Transmission Bump Shifter B—Screws (4 used) C—Wiring Harness Connector

1. Remove four screws (B) securing bump shifter (A).

2. Lift out bump shifter.

3. Disconnect wiring harness connector (C) from bumpshifter.


5. Connect wiring harness connector (C) to bump shifter.

6. Position bump shifter.

7. Install four screws (B) securing bump shifter (A).

TM11813 (13OCT10) 03-0315-1 748H Repair (S.N. 630436—10

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TM11813 (13OCT10) 03-0315-2 748H Repair (S.N. 630436— )101310

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Group 0325Input Drive Shafts and U-Joints

Continued on next page SW03989,0000B3D -19-06OCT10- 1

Engine-to-Transmission Drive Shaft Removeand Install

Machines Without Cold Weather Disconnect

1. Prepare machine for service. See Park and Prepare

for Service Safely. (Group 0001.)

2. Remove engine side shields. See Opening EngineSide Shields. (Operator’s Manual.)

3. Tur n battery disconnect switch to the OFF position.See Battery Disconnect. (Operator’s Manual.)


TX1024482

1

2

3

4

7

5

6

T X 1 0 2 4 4 8 2 — U N — 0 6 J U N 0 7

Drive Shaft—Without Cold Weather Disconnect

1— Cap Screw (8 used per joint)2— Universal Joint

3—Cap4— Drive Shaft

5— Cap Screw (12 used)6— Washer (12 used)

7— Lubrication Fitting

5. Remove and inspect drive shaft. Repair or replaceparts as necessary.


Specification

Lubrication


48—144 lb-in.

IMPORTANT: Universal joints are precisioncomponents. The fit is intended to be tight and

some compression of seals and thrust washersis required to seat the bearing cups in the yoke.Hand pressure, a tap with a soft-faced hammer or a “C” clamp can be used to seat a bearingcup in the yoke. DO NOT use the cap screwsto pull bearing cups into the yokes.

7. Align lubrication fittings and fasten universal joint (2) todrive shaft (4.) Tighten cap screws (1) to specification.

Specification

Cross and Bearing


Screw—Torque......................................................................51—57 N∙m

38—42 lb-ft

8. Install drive shaft and tighten cap screws tospecification.

Specification

Cross and Bearing

Assembly-to-Transmission Input Yoke

Cap Screw—Torque..............................................................51—57 N∙m

38—42 lb-ft

Drive Shaft-to-Damper

Cap Screws—Torque..................................................................150 N∙m

110 lb-ft



TM11813 (13OCT10) 03-0325-1 748H Repair (S.N. 630436—10

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Input Drive Shafts and U-Joints

Continued on next page SW03989,0000B 3D -19-06OCT10- 2/3

11. Install engine side shields. See Opening Engine SideShields. (Operator’s Manual.)

Machines With Cold Weather Disconnect

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

Prepare for Service Safely. (Group 0001.)


3. Turn batter y disconnect switch to the OFF position.See Battery Disconnect. (Operator’s Manual.)


5. Remove bottom guard on cold weather disconnect.See Transmission Cold Weather DisconnectRepair—If Equipped. (Group 0752.)

TM11813 (13OCT10) 03-0325-2 748H Repair (S.N. 630436— )101310

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SW03989,0000B3D -19-06OCT10-3

TX1024664

4

3

5

6

7

2

1 T X 1 0 2 4 6 6 4 — U N — 0 6 J U N

0 7

Drive Shaft—With Cold Weather Disconnect

1— Cap Screw (8 used per universal joint)

2— Universal Joint

3— Lubrication Fitting4— Drive Shaft


7— Cold Weather Disconnect

NOTE: Engine must be rotated to remove all capscrews on cold weather disconnect.

6. Remove and inspect drive shaft. Repair or replaceparts as necessary.

For cold weather disconnect repair, see TransmissionCold Weather Disconnect Repair—If Equipped.(Group 0752).


Specification

Lubrication


48—144 lb-in.

IMPORTANT: Universal joints are precisioncomponents. The fit is intended to be tight and

some compression of seals and thrust washersis required to seat the bearing cups in the yoke.Hand pressure, a tap with a soft-faced hammer or a “C” clamp can be used to seat a bearingcup in the yoke. DO NOT use the cap screwsto pull bearing cups into the yokes.

8. Align lubrication fittings and fasten universal joint (2) todrive shaft (4.) Tighten cap screws (1) to specification.

Specification

Cross and Bearing


Screw—Torque......................................................................51—57 N∙m

38—42 lb-ft

9. Install drive shaft and tighten cap screws tospecification.

Specification

Cross and Bearing

Assembly-to-

Transmission Input Yoke

Cap Screw—Torque..............................................................51—57 N∙m

38—42 lb-ft

Drive Shaft-to-Damper

Cap Screws—Torque..................................................................150 N∙m

110 lb-ft


11. Install cold weather disconnect bottom guard.


13. Install engine side shields. See Opening Engine SideShields. (Operator ’s Manual.)

TM11813 (13OCT10) 03-0325-3 748H Repair (S.N. 630436—10

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TM11813 (13OCT10) 03-0325-4 748H Repair (S.N. 630436— )101310

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Group 0350Gears, Shafts, and Power Shift Clutches

PM10405,0000575 -19-07OCT10-1

Transmission Repair Procedures

For repair procedures not covered in this book suchas clutch replacement and gear replacement, seeDF180 Series Powershift Transmission Repair Manual.(CTM308.)

Before beginning repair:

• Drain transmission oil.

• Thoroughly clean the outside of the transmission beforedisassembly to reduce the possibility of contamination.

Disassembly:

• Clean all parts and flush any debris from oil passages.

• Use moisture-free air to dry parts (except bearings) andto clean out oil passages.

IMPORTANT: DO NOT use solvent to clean theclutch and brake disks; use a lint-free cloth.

•Lightly oil all bearings after cleaning.

IMPORTANT: Spinning a bearing without lubricationcan damage the bearing.

• Inspect bearings for discoloration, roughness of rotation, and excessive wear of rollers or balls.

• Inspect bushings, remove burrs and sharp edges.Replace bushings if out-of-round, scored or excessivelyworn.

• Inspect control valve bores for contamination.

• Inspect clutch and brake plates for facing materialcondition wear to teeth and flatness of the plate.

• Inspect clutch and brake separator plates for discoloration, teeth wear, scoring and flatness.

• Inspect all thrust surfaces for scoring.

• Inspect all gear and spline teeth.

• Inspect all gasket and sealing surfaces for damage.

IMPORTANT: If the transmission has had a major failure, replace all bearings, springs, oil seals,O-rings, ring seals, and gaskets.

Assembly:

• Lightly oil all bearings.

• Use new O-rings, seal rings, oil seals and gaskets.

• Lubricate oil seals and O-rings.

• Wet clutch and brake plates with clean hydraulic oilbefore assembly.

• Clean and prepare all gasket and sealing surfaces.

TM11813 (13OCT10) 03-0350-1 748H Repair (S.N. 630436—10

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Gears, Shafts, and Power Shift Clutches

Continued on next page NM00125,000057F -19-27SEP10-1/6

Winch Drive Repair

T X 1 0 8 1 4 4 8 — U N — 0 1 S E P 1 0

Winch Drive and Cap Screw Tightening Sequence

1— Winch Drive Cover 2— Cap Screw (11 used)3— Oil Seal4— V-Ring Seal

5— Cap Screw

6— Yoke Washer 7— Yoke8— Dowel Pin9— Dowel Pin

10— Bearing

11— Output Shaft12— Bearing13— Bearing (2 used)14— Idler Gear

15— Drive Gear

16— Snap Ring17— Cover Assembly (if winch

option not present)18— O-Ring

19— Cover



TM11813 (13OCT10) 03-0350-2 748H Repair (S.N. 630436— )101310

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Continued on next page NM00125,000057F -19-27SEP10-2

3. Remove cap screw (5), yoke washer (6), and yoke (7).

4. Remove V-ring seal (4) and oil seal (3).

5. Remove cap screws (2) securing winch cover totransmission housing.

2— Cap Screw (11 used)3— Oil Seal4— V-Ring Seal

5— Cap Screw6— Yoke Washer 7— Yoke

T X 1 0 8 1 4 4 1 A — U N — 0 1 S E P 1 0

Winch Output Yoke

T X 1 0 8 1 4 4 2 A — U N — 0 1 S E P 1 0

Output Shaft Seals

T X 1 0 8 1 4 4 4 A — U N — 0 1

S E P 1 0

Winch Cover Cap Screw Removal

TM11813 (13OCT10) 03-0350-3 748H Repair (S.N. 630436—10

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NM00125,000057F -19-27SEP10-3/6

Continued on next page NM00125,000057F -19-27SEP10-4/6

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

7. Remove idler gear (14).

8. Remove snap ring (16) and drive gear (15).


1— Winch Cover 11— Output Shaft14— Idler Gear

15— Drive Gear 16— Snap Ring

T X 1 0 8 1 4 4 3 A — U N — 0 1 S E P 1 0

Winch Cover Removal

T X 1 0 8 1 4 4 5 A — U N — 0 1 S E

P 1 0

Idler Gear

T X 1 0 8 1 4 4 7 A — U N — 0 1

S E P 1 0

Snap Ring Removal

10. Install winch output shaft.

11. Install idler gear.

12. Install drive gear and snap ring.

11— Output Shaft14— Idler Gear

15— Drive Gear 16— Snap Ring

T X 1 0 8 1 4 4 6 A — U N — 0 1 S E P 1 0

Winch Drive Gears

TM11813 (13OCT10) 03-0350-4 748H Repair (S.N. 630436— )101310

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Continued on next page NM00125,000057F -19-27SEP10-5

13. Clean mating surfaces of housings with isopropylalcohol or equivalent.

IMPORTANT: Excessive amounts of gasket adhesivemay cause incorrect bearing end play, extendcure time, and cause runoff of material.Using a small roller will help to apply athin, even layer of adhesive.

14. Apply PM38655 Flexible Form-In-Place Gasket to rear housing mating surface, using care to apply a thinlayer over the entire surface.Excess gasket materialshould be wiped from joint. Installation should occur within three minutes of application. Allow a minimumof 30 minutes of cure time before adding oil.

15. Ensure dowel pins (8 and 9) are installed in rear housing.

16. Install winch drive cover.

17. Install and tighten cap screws to specification insequence shown. Repeat sequence again to checkcap screw torques.

Specification

Winch Cover-to-Rear

Housing Cap

Screw—Torque......................................................................20—30 N∙m

14—22 lb-ft

18. Apply PM37418 Thread Lock and Sealer (mediumstrength) to outside diameter of oil seal. Applypetroleum jelly to inside diameter of oil seal betweenseal lips.

T X 1 0 8 1 4 3 9 A — U N — 0 1 S E P 1 0

Winch Cover Installation

Y Z 4 1 1 4 — U N — 2 0 M A R 0 1

Winch Drive Cover Torque Sequence

1—Winch Drive Cover 2—Cap Screw (11 used)

TM11813 (13OCT10) 03-0350-5 748H Repair (S.N. 630436—10

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NM00125,000057F -19-27SEP10-6/6

19. Install new oil seal using JDG1110 Input Shaft SealInstallation Tool (20) and JDG1108 Clutch BearingDriver (21).

20. Lubricate and install V-ring seal.

NOTE: OPTIMOLY PASTE WHITE T® reducesspline wear.

21. Apply OPTIMOLY PASTE WHITE T® on output shaftspline before installing yoke.

22. Install yoke.

23. Apply PM37421 Thread Lock and Sealer (highstrength) to cap screw.

24. Install yoke washer and cap screw. Tighten cap screwto specification.

Specification


159 lb-ft


3— Oil Seal4— V-Ring Seal

20— JDG1110 Input Shaft SealInstallation Tool

21— JDG1108 Clutch BearingDriver

T X 1 0 8 1 4 4 0 A — U N — 0 1 S E P 1 0

Installing New Output Oil Seal

T X 1 0 8 1 4 4 2 A — U N — 0 1 S E P 1 0

Output Shaft Seals

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

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NM00125,0000580 -19-27SEP10-1

Input Yoke Remove and Install



3. Remove cap screw (1).

4. Remove washer (2).

5. Remove O-ring (3).

6. Remove yoke (4).

7. Remove oil seal (5).

8. Apply PM37418 Thread Lock and Sealer (mediumstrength) to outside diameter of oil seal. Applypetroleum jelly to inside diameter of new oil seal .Install using a disk driver.

NOTE: OPTIMOLY PASTE WHITE T® reducesspline wear.

9. Apply OPTIMOLY PASTE WHITE T® on input shaftspline before installing yoke.

IMPORTANT: The yoke may need to be moved upand down until the seal lip is over the fullcircumference of yoke. Seal lip of oil seal mustnot be rolled when yoke is installed.

10. Install yoke.

11. Install O-ring.

12. Install washer.

13. Apply PM37421 Thread Lock and Sealer (high

strength) to cap screw.

14. Install and tighten cap screw to specification.

Specification

Input Yoke Cap

Screw—Torque............................................................................215 N∙m

159 lb-ft

15. Turn battery disconnect to the ON position.

T X 1 0 8 1 4 4 9 A — U N — 0 1 S E

P 1 0

Transmission Input Yoke

T X 1 0 8 1 4 5 1 A — U N — 0 1 S

E P 1 0

Transmission Input Yoke Removal

T X 1 0 8 1 4 5 0 A — U N — 0 1 S E P 1 0

Torque Wrench

1— Cap Screw2— Washer 3— O-Ring

4— Yoke5— Oil Seal6— Torque Wrench


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Continued on next page NM00125,0000591 -19-30SEP10-1

Transmission Charge Pump Remove andInstall

CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve the

pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten allconnections before applying pressure.

1. Operate all hydraulic functions, including brake, torelease pressure in the hydraulic system. Depressbrake pedal at 1-second intervals 20 times to r emovepressure f rom service brake accumulator.



4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s

Manual.)


IMPORTANT: Cooling loop pump must be removedprior to charge pump removal. This eliminatesthe potential of dropping cooling loopdrive coupler into transmission duringcharge pump removal.

6. Remove cap screws (1) and lay cooling loop pump(2) aside.

7. Remove drive coupler (3).

8. Remove hydraulic pump. See Hydraulic PumpRemove and Install. (Group 2160.)

T X

1 0 2 5 1 8 2 A — U N — 2 1 J U N 0 7

Cooling Loop Pump

T

X 1 0 2 5 1 9 3 A — U N — 2 1 J U N 0 7

Drive Coupler

1— Cap Screw (2 used)2— Cooling Loop Pump

3— Drive Coupler

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NM00125,0000591 -19-30SEP10-2/4

Continued on next page NM00125,0000591 -19-30SEP10-3/4

9. Remove transmission charge pump suction tube (6).See Transmission Suction Tube Repair. (Group 0360.)

10. Remove charge pump-to-transmission filter hose (4).

11. Remove cap screws (5) and remove transmission

charge pump.

4— Charge Pump-to-Transmission Filter Hose


6— Transmission Charge PumpSuction Tube

T X 1 0 8 1 2 3 4 A — U N — 3 0 A U G 1 0

Transmission Charge Pump

12. Inspect spline coupler and drive gear assembly (8).Repair or replace parts as necessary.

IMPORTANT: Always replace charge pump flangeO-ring. Old or damaged O-rings may leak.

13. Apply petroleum jelly to new O-ring (7) and install oncharge pump flange.

14. Apply OPTIMOLY PASTE WHITE T® to pump splines.

IMPORTANT: Install gear assembly with seal side of bearing facing transmission charge pump.

15. Install drive gear assembly to charge pump splines.

7— O-Ring 8— Drive Gear Assembly

T X 1 0 8 1 2 3 3 A — U

N — 3 0 A U G 1 0

Charge Pump Flange

T X 1 0 8 1 2 3 2 A — U N — 3 0 A U G

1 0

Transmission Charge Pump Drive Coupler


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NM00125,0000591 -19-30SEP10-4

16. Position charge pump to transmission housing. Installand tighten cap screws in the sequence shown tospecification.

Specification

Cap Screw—Torque......................................................................73 N∙m

55 lb-ft

17. Install transmission charge pump suction tube. SeeTransmission Suction Tube Repair. (Group 0360.)

IMPORTANT: Transmission charge pump mustbe filled with oil prior to start-up toprevent pump damage.

18. Remove 90-degree fitting from top of transmissioncharge pump and fill pump with proper oil. SeeTransmission, Park Brake, Differential, Cab TiltHydraulic Pump and Winch Oil. (Operator’s Manual.)

19. Install 90-degree fitting and transmission chargepump-to-transmission filter hose.

20. Install hydraulic pump. See Hydraulic Pump Removeand Install. (Group 2160.)

21. Install spline coupler.

22. Install cooling loop pump.


T 1 1 4 0 0 2 — U N — 1 6 M A R 9 8

Cap Screw Torque Sequence

24. Fill transmission with proper oil. See ChangeTransmission Oil, Replace Filter, and Clean SuctionScreen. (Operator’s Manual.)


26. Calibrate transmission control unit. See TransmissionControl Unit (TCU) Calibration. (Group 9025.)

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Continued on next page NM00125,0000592 -19-06OCT10- 1/5

Transmission Charge Pump Drive Repair

CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting or

connecting hydraulic or other lines. Tighten allconnections before applying pressure.

1. Operate all hydraulic functions, including brake, torelease pressure in the hydraulic system. Depressbrake pedal at 1-second intervals 20 times to removepressure from ser vice brake accumulator.




5. Remove transmission charge pump. See TransmissionCharge Pump Remove and Install. (Group 0360.)

6. Remove drive gear (1).

7. Remove cap screw (2).

1— Drive Gear 2— Cap Screw

T X 1 0 8 1 4 0 7 A — U N — 0 1 S E P 1 0

Drive Gear

T X 1 0 8 1 4 0 8 A — U N — 0 1 S E P

1 0

Cap Screw

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Hydraulic System

Continued on next page NM00125,0000592 -19-06OCT10- 2

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

9. Use cap screw to remove idler shaft (4).

IMPORTANT: There are 2 O-rings (5), one at each endof shaft. The O-ring located on the bottom of the

idler shaft may slip off at removal of shaft.

10. Remove and discard O-rings (5).

11. Remove idler gear (6).

12. Replace bearings in idler gear if worn or damaged.

3— M8 x 35 mm Cap Screw4— Idler Shaft

5— O-Ring (2 used)6— Idler Gear

T X 1 0 8 1 4 0 9 A — U N — 0 1 S E P 1 0

M8 x 35 mm Cap Screw

T X 1 0 8 1 4 1 0 A — U N — 0 1 S E

P 1 0

Idler Shaft, O-Rings, and Idler Gear

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Continued on next page NM00125,0000592 -19-06OCT10- 3/5

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

NOTE: Lubricate O-rings to avoid damageduring assembly.

14. Install new O-rings (5) on idler shaft.

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

16. Install idler shaft through idler shaft port and idler gear assembly.

NOTE: Using cap screw (3) turn idler shaft to alignholes in shaft and housing.

17. Use cap screw, align idler shaft with rear housing hole.

18. Remove M8 x 35 mm cap screw.

3— M8 x 35 mm Cap Screw5— O-Ring (2 used)

6— Idler Gear

T X 1 0 8 1 4 1 1 A — U N — 0 1 S E P 1 0

Idler Gear and O-Rings

T X 1 0 8 1 4 0 9 A — U N — 0 1 S E

P 1 0

M8 x 35 mm Cap Screw

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NM00125,0000592 -19-06OCT10-4

NM00125,0000592 -19-06OCT10-5

19. Install and tighten cap screw in idler shaft tospecification.

Specification

Idler Gear Shaft-to-Front

Housing Cap

Screw—Torque..............................................................................87 N∙m

64 lb-ft

2— Cap Screw

T X 1 0 8 1 4 0 8 A — U N — 0 1 S E P 1 0

Cap Screw

Y Z 1 1 4 8 — U N — 2 3 D E C 9 7

Tighten Idler Shaft Cap Screw

IMPORTANT: Seal on bearing must facetransmission charge pump.

20. Install bearing (7), drive gear (8), and bearing (9).

21. Install char ge pump. See Transmission Charge PumpRemove and Install. (Group 0360.)


7— Bearing8— Drive Gear

9— Bearing

T X 1 0 8 1 4 1 2 A — U N — 0 1 S E P 1 0

Drive Gear and Bearings

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AC12469,0000388 -19-09JUL07-1/1

Transmission Suction Tube Repair

1. Remove cap screws (3).

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

3. Remove suction screen (5).

4. Remove and discard O-ring (5).

5. Inspect suction screen for signs of collapse or plugging. Clean or replace suction screen asnecessary.

6. Inspect and replace suction tube as necessary.

7. Install suction screen (5) and new O-ring (4).

8. Install suction tube (2).

9. Install cap screws and tighten to specification.

Specification

Suction Tube-to-Front

Housing CapScrews—Torque............................................................................25 N∙m

18 lb-ft

1— Transmission Charge Pump2— Transmission Suction Tube3— Cap Screw (2 used)

4— O-Ring5— Suction Screen

3

1

2

T X

1 0 2 4 8 1 9 — U N — 1 3 J U N 0 7

T X 1 0 2 4 8 2 1 A — U N — 1 3 J U N 0 7

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Continued on next page AC12469,0000389 -19-13JUL07- 2/2

Transmission Control Valve Repair

Y Z 1 0 4 5 4 3 A

— U N — 1 1 S E P 0 3

Transmission Control Valve

A—Valve HousingB—Proportional Solenoid ( 8

used)

C—Cooler Pressure Relief ValveD—Main Pressure Valve

E—Plug (12 used)F—Plug (2 used)

G—O-RingH—Temperature Sensor

1. Remove cap screws from control valve.



2. Remove valve (A).

Specification

Control Valve—Weight

(approximate)............................................................................... 27.5 kg

61 lb

A—Control Valve Y Z 1 0 7 7 — U N — 1 7 D E C 9 7

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3. Remove gasket (A), plate (B) and gasket (C) fromfront housing and discard gaskets.

A—GasketB—Plate

C—Gasket

Y Z 1 0 7 8 — U N — 1 7 D E C 9 7

4. Remove nut (A), washer (B) and coil (C) fromproportional solenoid valve. Flange nut also used inplace of nut and washer.

A—Nut or Flanged NutB—Washer (Not used with

Flanged Nut)

C—Coil

Y Z 1 0 7 9 — U N — 1 7 D E C 9 7

IMPORTANT: When any proportional solenoid valvesare removed or replaced, Transmission ControlUnit (TCU) must be calibrated.

5. Remove proportional valve (D).

6. Inspect for contamination.

D—Proportional Valve

Y Z 1 0 8 0 — U N — 1 7 D E C 9 7

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7. Remove relief valve (A).

8. Inspect for wear or contamination.

NOTE: Check backup rings for damage.

A—Cooler Pressure Relief Valve

Y Z 1 0 8 1 — U N — 1 7 D E C 9 7

9. Remove main pressure regulator (A).

10. Inspect for wear or contamination.

A—Main Pressure Regulator

Y Z 1 0 8 2 — U N — 1 7 D E C 9 7

11. Remove temperature sensor (A).12. Remove O-ring (B).

13. Inspect for contamination.

A—Temperature Sensor B—O-Ring

Y Z 1 0 8 3 — U N — 1 7 D E C 9 7

Temperature Sensor and O-Ring

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14. Remove twelve plugs (A).

15. Inspect for contamination in control valve passages.

NOTE: Apply lubricant to all O-rings prior toinstalling into valve housing.

16. Install new O-ring.

17. Install plugs (A) and fitting into valve housing.

18. Tighten plugs (A) to specification.

Specification

Plug-to-Valve

Housing—Torque........... ............ ............ ............ ........... ............ .....12 N∙m

106 lb-in.

Y Z 1 0 8 4 — U N — 1 7 D E C 9 7

A—Plugs (12 used)

19. Install new O-ring (B).

20. Install temperature sensor (A).

21. Tighten temperature sensor to specification.

Specification

Temperature

Sensor-to-Valve


142 lb-in.

A—Temperature Sensor B—O-Ring

Y Z 1 0 8 3 — U N — 1 7 D E C 9 7

22. Install new O-rings on main pressure regulator.

23. Install and tighten main pressure regulator (A) tospecification.

Specification

Main Regulator

Assembly-to-Valve

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

25—35 lb-ft

A—Main Pressure Regulator

Y

Z 1 0 8 2 — U N — 1 7 D E C 9 7

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AC12469,0000389 -19-13JUL07-13/

Continued on next page AC12469,0000389 -19-13JUL07-1 4/2

24. Install new O-rings (A) on relief valve.

NOTE: Install new backup rings as needed.

25. Install and tighten relief valve to specifcation.

SpecificationCooler Relief

Valve-to-Valve


25—35 lb-ft

A—O-Rings Y Z 1 0 8 1 — U N — 1 7 D E C 9 7

IMPORTANT: When any proportional solenoid valvesare removed or replaced, Transmission ControlUnit (TCU) must be calibrated.

26. Lubricate and install new O-rings (A—C) onproportional valve.

A—O-RingB—O-Ring

C—O-Ring

Y Z 3 2 7 — U N — 2 4 S E P 9 6

27. Install proportional valve (D) into valve housing.28. Tighten proportional valve.

Specification

Proportional Valve-to-

Valve Housing—Torque.........................................................16—20 N∙m

142—177 lb-ft

D—Proportional Valve

Y Z 1 0 8 0 — U N — 1 7 D E C 9 7

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

NOTE: Make sure nut threads and valve arefree of oil before applying sealer to ensuresealer will set up properly.

30. Clean threads on proportional valve and nut. Applycure primer.

31. Apply high strength thread lock and sealer to nut (G)and install on proportional valve.

E—CoilF—Washer (Not used with

Flange Nut)

G—Nut or Flange Nut Y Z 1 0 7 9 D — U N — 1 2 J A N 9 8

32. Tighten solenoid coil nut.

SpecificationProportional Valve

Nut-to-Proportional

Solenoid—Torque................................................................ 4.5—6.8 N∙m

40—60 lb-in.

33. Repeat steps to install remaining proportional solenoidand valve assemblies.

Y Z 4 1 3 6 — U N — 2 2 M A R 0 1

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

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

A—Guide Pins

Y Z 1 0 8 8 — U N — 2 3 D E C 9 7

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35. Gasket, Plate and Gasket Alignment

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

B—GasketC—Plate

D—Gasket

Y Z 5 0 8 7 — U N — 1 8 S E P 0 3

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

B—GasketC—Plate

D—Gasket

Y Z 1 0 7 8 A — U N

— 2 3 D E C 9 7

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

38. Remove guide pins.

39. Install and tighten cap screws (B) per numericalsequence drawing.

A—Control Valve B—Cap Screws

Y Z 1 0 8 7 — U N — 2 3 D E C 9 7

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T 1 6 3 6 5 0 — U N — 1 4 J A N 0 3

Cap Screw Tightening Sequence

A—Cap Screw, 45 mm long andFlat Washer (5 used)

B—Cap Screw, 90 mm long andFlat Washer (9 used)

C—Cap Screw, 75 mm long andFlat Washer (13 used)

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AC12469,0000389 -19-13JUL07-22/22

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

Control Valve-to-Front

Housing Cap

Screws—Torque............................................................................39 N∙m

29 lb-ft

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Section 04Engine

Contents

Page

Group 0400—Removal and InstallationPowerTech Plus™ 6.8L (6068)

John Deere Engine—6.8L Tier 3/Stage IIIA............................................04-0400-1

PowerTech Plus™ 6.8L (6068)John Deere Engine—6.8L StageII............................................................. 04-0400-1

Engine Remove and Install........................ 04-0400-2

TM11813 (13OCT10) 04-1 748H Repair (S.N. 630436—10

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Group 0400Removal and Installation

PM10405,0000573 -19-07OCT10-1

PM10405,0000574 -19-07OCT10-1

PowerTech Plus™ 6.8L (6068) John DeereEngine—6.8L Tier 3/Stage IIIA

For additional information on John Deere Power Tech™and PowerTech Plus™ engines and components, seethe following component technical manuals:

• PowerTech™ 4.5 L and 6.8 L Diesel Engines—BaseEngine. (CTM104.)

• PowerTech Plus™ 4.5 L and 6.8 L Diesel Engines—Level 14 Electronic Fuel System with Denso HPCR.(CTM320.)

M 4 4 2 1 5 — U N — 0 7 S E P 8 8

PowerTech is a trademark of Deere & Company PowerTech Plus is a trademark of Deere & Company

PowerTech Plus™ 6.8L (6068) John Deere

Engine—6.8L Stage IIFor additional information on John Deere PowerTech™

and PowerTech Plus™ engines and components, seethe following component technical manuals:

• PowerTech™ 4.5 L and 6.8 L Diesel Engines—BaseEngine. (CTM104.)

• PowerTech Plus™ 4.5 L and 6.8 L Diesel Engines—Level 14 Electronic Fuel System with Denso HPCR.(CTM320.)

M 4 4 2 1 5 — U N — 0 7 S E P 8 8

PowerTech is a trademark of Deere & Company PowerTech Plus is a trademark of Deere & Company

TM11813 (13OCT10) 04-0400-1 748H Repair (S.N. 630436—10

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Removal and Installation

Continued on next page MH66088,0000DAC -19-07OCT10- 1/9

Engine Remove and Install



1. Operate all hydraulic functions, including brake, torelease pressure in the hydraulic system. Depressbrake pedal at 1-second intervals 20 times todischarge pressure from br ake accumulator.

2. Park and prepare machine for service. See Park andPrepare for Service Saf ely. (Group 0001.)



5. Drain cooling system. See Draining the CoolingSystem. (Oper ator’s Manual.)

6. Remove hood. See Hood Remove and Install. (Group1910.)

7. Remove hydraulic fan motor. See Hydraulic Fan Motor Remove and Install. (Group 2160.)

8. Remove fan shroud. See Fan Shroud Remove andInstall. (Group 0510.)

9. Disconnect hydraulic oil return hose (1) at hydraulicreservoir (2). Close all openings using caps and plugs.Secure hydraulic filter assembly (3) to the side.

10. Remove air cleaner assembly. See Air Cleaner Remove and Install. (Group 0520.)

T X 1 0 8 0 8 6 6 A — U N — 1 6 A U

G 1 0

Hydraulic Oil Return Filter Assembly

1— Hydraulic Oil Return Hose2— Hydraulic Reservoir

3— Hydraulic Return Filter Assembly

TM11813 (13OCT10) 04-0400-2 748H Repair (S.N. 630436— )101310

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MH66088,0000DAC -19-07OCT10-2

Continued on next page MH66088,0000DAC -19-07OCT10- 3

11. Remove engine deaeration hose (4) from thermostathousing. Disconnect coolant fill hose (5) at engineblock and remove surge tank. Close all openingsusing caps and plugs.

12. Disconnect heater hoses from engine. Remove anyhose clamps or wire ties. Close all openings usingcaps and plugs.

4— Engine Deaeration Hose 5— Coolant Fill Hose

4

5

T X

1 0 8 0 8 6 7 — U N — 1 3 A U G 1 0

Surge Tank Removal

13. Disconnect fuel supply hose (6) at final fuel filter (7) onright side of engine. Disconnect fuel return hose (8)on left side of engine at high pressure fuel pump (9).Close all openings using caps and plugs.

14. Remove serpentine belt. See Serpentine Belt Removeand Install. (Group 0510.)

6— Fuel Supply Hose

7— Final Fuel Filter

8— Fuel Return Hose

9— High Pressure Fuel Pump

T X 1 0 8 0 9 1 1 A —

U N — 1 6 A U G 1 0

Fuel Supply Hose

T X 1 0 8 0 9 0 8 A

— U N — 1 6 A U G 1 0

Fuel Return Hose

TM11813 (13OCT10) 04-0400-3 748H Repair (S.N. 630436—10

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MH66088,0000DAC -19-07OCT10-4/9


NOTE: It is not necessary to disconnect air conditioner lines when removing the compressor for engineremoval and installation.

15. Disconnect wire harness connector (10) and ground

wire (11) at air conditioner compressor (13). Removecap screws (12) and secure compressor to the side.

10— Wire Harness Connector 11— Ground Wire

12— Cap Screw13— Air Conditioner

Compressor

T X 1 0 8 0 9 0 9 A — U N — 1 6 A U G

1 0

Air Conditioner Compressor

16. Remove cap screw (14) and clamp (15). Tag anddisconnect wiring harness connectors (16) from

engine control unit (19).17. Remove cap screws (17) and remove ECU (19) and

ECU mouting bracket (18).

18. Remove wiring harness clamps along right side frame.

19. Tag and disconnect all electrical connections at starter.

20. Tag and disconnect all electrical connections atalternator.

21. Remove ground wire from battery disconnect switch.

22. Remove batteries from machine. See Remove andInstall Batteries. (Operator’s Manual.)

23. Remove two engine wiring harness clamps on backside of engine and on left rear engine mount.


25. Remove ground strap from engine, located near rightrear engine mount.

26. Disconnect cold weather disconnect linkage,if equipped. See Transmission Cold Weather Disconnect Linkage Remove and Install—If Equipped.(Group 0752.)

27. Remove engine-to-transmission drive shaft. SeeEngine-to-Transmission Drive Shaft Remove andInstall. (Group 0325.)

T X 1 0 8 0 9 0 7 A — U

N — 1 6 A U G 1 0

Engine Control Unit (ECU)

14— Cap Screw15— Clamp16— Wiring Harness Connector

(3 used)

17— Cap Screw (3 used)18— Engine Control Unit (ECU)

Mounting Bracket19— Engine Control Unit (ECU)

TM11813 (13OCT10) 04-0400-4 748H Repair (S.N. 630436— )101310

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MH66088,0000DAC -19-07OCT10-6

Continued on next page MH66088,0000DAC -19-07OCT10- 7


NOTE: If engine does not have lifting lugs, they canbe procured through service parts.

Use of an engine lifting sling (as shown) is theONLY APPROVED method for lifting engine.

28. Install engine lifting lugs (20) to engine. Attach JDG23Engine Lifting Sling (21) and appropriate lifting deviceto engine lifting lugs. Support engine.

Specification

Engine—Weight

(approximate)................................................................................ 771 kg

1700 lb.

T X 1 0 8 1 0 3 4 — U N — 2 3 A U G 1 0

Engine Removal

20— Engine Lifting Lug (2used)

21— JDG23 Engine LiftingSling

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


30. Remove engine from machine.

Specification

Engine—Weight

(approximate)................................................................................ 771 kg

1700 lb.

31. Repair or replace engine as necessary.

32. Inspect engine mount rubber isolators (25 and 26) for damage or excessive wear. Replace as necessary.

33. Install engine mount brackets to engine block, if removed, and tighten to specification.

Specification

Engine Mount Bracket


236 lb-ft

34. Install engine isolators to engine mounts.

35. Install engine to machine.

Specification

Engine—Weight(approximate)................................................................................ 771 kg

1700 lb.

36. Tighten engine mount-to-frame cap screws tospecification.

Specification

Front Engine

Mount-to-Frame Cap

Screw—Torque............................................................................620 N∙m

457 lb-ft

T X 1 0 8 1 0 3 5 — U N — 2 3 A U G 1 0

Engine Mounts

22— Cap Screw (4 used)23— Washer (4 used)24— Washer (4 used)25— Upper Isolator

26— Lower Isolator 27— Washer (4 used)28— Nut (4 used)

Rear Engine

Mount-to-Frame Cap

Screw—Torque............................................................................712 N∙m

525 lb-ft

37. Install engine-to-transmission drive shaft. SeeEngine-to-Transmission Drive Shaft Remove andInstall. (Group 0325.)

TM11813 (13OCT10) 04-0400-5 748H Repair (S.N. 630436—10

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Engine-to-Transmission Drive Shaft Alignment

29— Torsional Dampener 30— Top Measurement 31— Bottom Measurement 32— 6-i nch Steel Scal e

38. Using a 6-inch steel scale (32) or depth gauge,measure distance at top and bottom (30 and 31) of torsional dampener (29). Measurements should beless than a 2 mm (0.08 in.) difference. Loosen enginemount-to-engine cap screws and raise or lower rear of engine to change measurement.

39. Once correct measurement is achieved, tighten enginemount-to-engine cap screws to specified torque.

Specification

Engine Mount-to-Engine


236 lb-ft

40. Remove lifting sling and lifting lugs from engine.

41. Connect cold weather disconnect linkage, if equipped.See Transmission Cold Weather Disconnect LinkageRemove and Install—If Equipped. (Group 0752.)

42. Install ground strap to engine.

43. Install batteries. See Remove and Install Batteries.(Operator’s Manual.)

44. Install ground wire to battery disconnect switch.

45. Connect electrical connections at alternator.

46. Connect electrical connections at starter.

47. Install ECU mounting bracket and ECU. Connectelectrical connectors to ECU.

48. Install air conditioner compressor and connect wiringharness connector and ground wire.

49. Connect fuel supply and fuel return hoses.

50. Connect heater hoses.

51. Connect coolant fill hose at engine block. Connectdeaeration hose to thermostat housing.

52. Install air cleaner assembly. See Air Cleaner Removeand Install. (Group 0520.)

53. Connect hydraulic return line at hydraulic reservoir.

54. Install fan shroud. See Fan Shroud Remove andInstall. (Group 0510.)

55. Install hydraulic fan motor. See Hydraulic Fan Motor Remove and Install. (Group 2160.)

56. Install hood. See Hood Remove and Install. (Group1910.)

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R emoval and Installation

MH66088,0000DAC -19-07OCT10-9

57. Fill cooling system. See Filling the Cooling System.(Operator’s Manual.)



60. Check hydraulic oil level. Add hydraulic oil, if necessary. See Check Hydraulic System Oil Level.(Operator’s Manual.)

61. Bleed fuel system. See Bleed Fuel System.(Operator’s Manual.)

62. Check Engine Oil Level. See Check Engine Oil Level.(Operator’s Manual.)

TM11813 (13OCT10) 04-0400-7 748H Repair (S.N. 630436—10

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Section 05Engine Auxiliary Systems

Contents

Page

Group 0505—Cold Weather Starting AidsDo Not Use Ether Start Aid........................ 05-0505-1

Group 0510—Cooling System Air Baffle Enclosure Remove and

Install ..................................................... 05-0510-1Serpentine Belt Remove and

Install .....................................................05-0510-2Serpentine Belt Tensioner—Spring

Tension Check .......................................05-0510-3Serpentine Belt Tensioner Remove

and Install ..............................................05-0510-4 Aftercooler Remove and Install ................. 05-0510-5

Radiator Remove and Install ..................... 05-0510-8Transmission Oil Cooler Remove

and Install ............................................ 05-0510-10Hydraulic Oil Cooler Remove and

Install ................................................... 05-0510-13Fan Blade Remove and Install ................ 05-0510-16Fan Shroud Remove and Install .............. 05-0510-16

Group 0520—Intake System Air Cleaner Remove and Install................. 05-0520-1

Group 0530—Exhaust SystemMuffler Remove and Install........................ 05-0530-1

Group 0560—External Fuel Supply SystemFuel Tank Remove and Install ...................05-0560-1

TM11813 (13OCT10) 05-1 748H Repair (S.N. 630436—10

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Contents

TM11813 (13OCT10) 05-2 748H Repair (S.N. 630436— )101310

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Group 0505Cold Weather Starting Aids

SW03989,0000B39 -19-24SEP10-1

Do Not Use Ether Start Aid

IMPORTANT: Avoid an explosion or fire. Machineis equipped with electrical cold start assistsystem. Do not use ether start aid or any typeof starting fluids on this machine.

This machine is equipped with a Tier III engine. Fire,explosion or engine damage will result from using startingfluids of any type on this machine.

T 1 4 5 7 0 5 — U N — 1 8 S E P 0 1

TM11813 (13OCT10) 05-0505-1 748H Repair (S.N. 630436—10

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Cold Weather Starting Aids

TM11813 (13OCT10) 05-0505-2 748H Repair (S.N. 630436— )101310

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Cooling System

MH66088,0000D7D -19-10SEP10-3/3

Continued on next page MH66088,0000D7E -19-10SEP10-1/2

9. Remove caps screws (5), washers (6), nuts (7), andwashers (8) securing air baffle panels (9—12) to grillehousing.

10. Remove upper right air baffle panel (9).

11. Remove lower left air baffle panel (10).

12. Remove upper left air baffle panel (11).

13. Remove lower right air baffle panel (12).


NOTE: Air baffle panels must be installed inreverse order of removal.

15. Install air baffle panels in reverse order of removal.Install cap screws, nuts, and washers securing air baffle panels to grille housing.

16. Install upper radiator hose.

17. Install upper charge air tube.

18. Install left side engine side shields. See OpeningEngine Side Shields. (Operator’s Manual.)

19. Install hose bracket to grille housing.

20. Install grille housing top left panel.

21. Install grille housing side panels.

22. Fill cooling system. See Filling the Cooling System.(Operator’s Manual.)


9

11

10

7

8

12

65

T X 1 0 8 0 2 0 9 — U N — 1 8 A U G 1 0

Air Baffle Panel Removal (view from front of machine)

5— Cap Screw (20 used)6— Washer (20 used)7— Nut (2 used)8— Washer (2 used)

9— Upper Right Air BafflePanel

10— Lower Left AirBaffle Panel11— Upper Left Air Baffle Panel12— Lower Right Air Baffle

Panel

Serpentine Belt Remove and Install



3. Remove right side grille housing vent panel (1).

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

Enclosure Remove and Install. (Group 0510.)

1— Right Side Grille HousingVent Panel

T X 1 0 8 0 3 5 7 A — U N — 3 0

J U L 1 0

Right Side Grille Housing Vent Panel

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Cooling System

MH66088,0000D7E -19-10SEP10-2

Continued on next page MH66088,0000D7F -19-18AUG10- 1

5. Install a 1/2-in. drive wrench into belt tensioner (4)arm and pull wrench and arm downward to loosenserpentine belt.

6. Remove serpentine belt.

7. Check serpentine belt for wear or damage. Replace if necessary. See Inspect Serpentine Belt. (Operator’sManual.)

8. Install serpentine belt as shown.

9. Install air baffle panel. See Air Baffle EnclosureRemove and Install. (Group 0510).

10. Install right side grille housing vent panel.


2— Crankshaft Pully3— Water Pump Pully

4— Tensioner

5— Alternator Pully6— Idler Pully

7— Air Conditioner Compressor Pully

7

2

3

6

5

4

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Serpentine Belt Routing

Serpentine Belt Tensioner—Spring TensionCheck




4. Remove top right air baffle panel. See Air BaffleEnclosure Remove and Install. (Group 0510).



T X 1 0 8 0 3 5 7 A — U N — 3 0 J

U L 1 0


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Cooling System

MH66088,0000D7F -19-18AUG10-2/2


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

7. Measure 21 mm (0.83 in.) down from swing arm markand put a mark (3) on tensioner mounting base.

SpecificationBelt Tensioner

Spring—Distance.......................................................................... 21 mm

0.83 in.

8. Rotate the swing arm tensioner using a torque wrenchuntil marks (2 and 3) are aligned.

9. Record torque wrench measurement and comparewith specification. Replace tensioner as required.

Specification

Spring Tension—Torque........................................................ 18—22 N∙m

159—195 lb-in.

10. Install serpentine belt. See Serpentine Belt Removeand Install. (Group 0510.)

11. Install top right air baffle panel. See Air BaffleEnclosure Remove and Install. (Group 0510.)


T X 1 0 8 0 3 8 5 A — U N — 3 0 J U L 1 0

Alignment Marks

2— Swing Arm Mark 3— Tensioner Mark


Serpentine Belt Tensioner Remove andInstall




4. Remove top right air baffle panel. See Air BaffleEnclosure Remove and Install. (Group 0510.)

5. Remove serpentine belt from tensioner pulley. SeeSerpentine Belt Remove and Install. (Group 0510.)


T X 1 0 8 0 3 5 7 A — U N — 3 0 J U L 1 0


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Cooling System

MH66088,0000D80 -19-10SEP10-2

Continued on next page MH66088,0000D9A -19-23SEP10-1

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

7. Inspect and replace tensioner as needed.

8. Install belt tensioner (3). Install and tighten cap screw(2) to specification.

Specification

Belt Tensioner Cap

Screw—Torque..............................................................................50 N∙m

37 lb-ft

9. Install serpentine belt, making sure that belt is correctlyseated in all pulley grooves. See Serpentine BeltRemove and Install. (Group 0510.)

10. Install top right air baffle panel. See Air BaffleEnclosure Remove and Install. (Group 0510.)



T X 1 0 8 0 3 9 1 A — U N — 3 0 J U L 1

0

Serpentine Belt Tensioner

2— Cap Screw 3— Belt Tensioner

Aftercooler Remove and Install



3. Open grille. See Opening the Grille. (Operator’sManual.)

NOTE: Air conditioner condenser is hinged on theleft side of the grill housing.

4. Remove cap screws (1) and swing air conditioner condenser (2) open.

T X

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Air Conditioner Condenser

1—Cap Screw (2 used) 2—Air Conditioner Condenser

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MH66088,0000D9A -19-23SEP10-2/6

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5. Support air conditioner condenser. Remove capscrews (3) and move assembly to the side.


T X 1 0 8 0 5 2 6 A — U N — 0 5 A U G 1 0

Air Conditioner Condenser Hinge Mounting Cap Screws

6. Remove cap screws (4) and washers (5). Removelower air baffle insert (6).


6— Lower Air Baffle Insert

T X

1 0 8 0 5 3 7 A — U N — 0 5 A U G 1 0

Lower Air Baffle Insert

7. Remove cap screws (7), washers (8), and lower cooler support (9).

8. Remove cap screws (10) and aftercooler-to-radiator bracket (11).

7— Cap Screw (3 used)8— Washer (3 used)9— Lower Cooler Support

10— Cap Screw (2 used)11— Aftercooler-to-Radiator

Bracket

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Lower Cooler Support

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Cooling System

MH66088,0000D9A -19-23SEP10-5

MH66088,0000D9A -19-23SEP10-6

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

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

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

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13 T X 1 0 8 0 4 5 0 — U N — 0 3 A U G 1 0

Grille Housing Access Panels

11. Remove cap screws (14) securing upper support (16)to top of coolers.

12. Remove nuts (15) and remove upper support andfoam insert (17).


13. Remove aftercooler.

Specification

Aftercooler—Weight

(approximate).................................................................................. 29 kg

64 lb.

14. Inspect and replace as necessary.


15. Install aftercooler.

Specification

Aftercooler—Weight

(approximate).................................................................................. 29 kg

64 lb.

16. Install upper support.

17. Connect upper and lower aftercooler air piping toaftercooler.

18. Install grille housing access panels

19. Install aftercooler-to-radiator bracket.

20. Install lower support.

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Upper Support

14— Cap Screw (8 used)15— Nut (4 used)

16— Upper Support17— Foam Insert

21. Install lower air baffle insert.

22. Install air conditioner condenser.

23. Close grille.


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Cooling System

MH66088,0000D9C -19-15SEP10-1/6

MH66088,0000D9C -19-15SEP10-2/6

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Radiator Remove and Install



See Battery Disconnect. (Operator’s Manual.)3. Open grille. See Opening the Grille. (Operator’s

Manual.)



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6. Perform Draining the Cooling System. (Operator’sManual.)


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Cooling System

MH66088,0000D9C -19-15SEP10-4

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9. Remove cap screws (10), aftercooler-to-radiator bracket (11), and transmission-to-radiator bracket (12).


10— Cap Screw (2 used)11— Aftercooler-to-Radiator

Bracket12— Transmission-to-Radiator

Bracket

T X 1 0 8 0 5 9 4 A — U N — 0 5 A U G 1 0



11. Disconnect upper radiator hose and deaeration hosefrom radiator. Close all openings using caps andplugs.

12. Disconnect lower radiator hose from radiator. Closeall openings using caps and plugs.

13— Grille Housing SideAccess Panel (2 used)

14— Grille Housing Top AccessPanel (2 used)

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Cooling System

MH66088,0000D9C -19-15SEP10-6/6

Continued on next page MH66088,0000DA8 -19-30AUG10-1/6

13. Remove cap screws (14) securing upper cooler support (16) to top of coolers.



15. Remove radiator.

Specification

Radiator—Weight

(approximate).................................................................................. 50 kg

110 lb.



17. Install radiator.

Specification

Radiator—Weight

(approximate).................................................................................. 50 kg

110 lb.

18. Install upper cooler support.

19. Install upper radiator hose and deaeration hose toradiator.

20. Install lower radiator hose to radiator.

21. Install top and side grille housing access panels.

22. Install aftercooler-to-radiator bracket andtransmission-to-radiator bracket.

23. Install lower cooler support.

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16

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Upper Cooler Support


16— Upper Cooler Support17— Foam Insert


25. Install air conditioner condenser assembly.

26. Perform Filling the Cooling System. (Operator’sManual.)

27. Close grille.


Transmission Oil Cooler Remove and Install




NOTE: Air conditioner condenser is hinged on theleft side of the grille housing.


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— U N — 0 5 A U G 1 0



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Cooling System

MH66088,0000DA8 -19-30AUG10-2

MH66088,0000DA8 -19-30AUG10-3

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T X

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8. Remove cap screws (10) and hydraulic oilcooler-to-transmission oil cooler bracket (11).


10— Cap Screw (2 used)11— Hydraulic Oil

Cooler-to-TransmissionOil Cooler Bracket

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Cooling System

MH66088,0000DA8 -19-30AUG10-5/6

MH66088,0000DA8 -19-30AUG10-6/6


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

10. Disconnect transmission oil cooler lines at cooler.Close all openings using caps and plugs.

12— Grille Housing Upper Access Panel (2 used)


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13 T X 1 0 8 0 4 5 0 — U N — 0 3 A U G 1 0



12. Remove nuts (15) and remove upper cooler supportand foam insert (17).


13. Remove transmission oil cooler.

Specification

Transmission Oil

Cooler—Weight

(approximate).................................................................................. 28 kg

62 lb.



15. Install transmission oil cooler.

Specification

Transmission Oil

Cooler—Weight

(approximate).................................................................................. 28 kg

62 lb.


17. Connect transmission oil cooler lines at cooler.

18. Install hydraulic oil cooler-to-transmission oil cooler bracket.

19. Install lower cooler support.


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22. Close grille.


24. Check transmission oil level. See Check TransmissionOil Level. (Operator’s Manual.)

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Cooling System

MH66088,0000DA2 -19-23SEP10-1

Continued on next page MH66088,0000DA2 -19-23SEP10-2

Hydraulic Oil Cooler Remove and Install




2. Operate all hydraulic functions, including brake, torelease pressure in the hydraulic system. Depressbrake pedal at 1-second intervals 20 times to relievepressure from service brake accumulator.





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MH66088,0000DA2 -19-23SEP10-3/6

MH66088,0000DA2 -19-23SEP10-4/6

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7. Remove cap screws (4), washers (5), and lower air baffle insert (6).



T X 1 0 8 0 7 6 2 A — U N — 1 0 A U G

1 0



9. Remove cap screws (10) and remove hydraulic oilcooler-to-transmission oil cooler and hydraulic oilcooler-to-radiator brackets (11 and 12).

7— Cap Screw (3 used)8— Washer (3 used)9— Lower Cooler Support10— Cap Screw (4 used)

11— Hydraulic OilCooler-to-TransmissionOil Cooler Bracket

12— Hydraulic OilCooler-to-Radiator Bracket

13— Hydraulic Oil Cooler T X 1 0 8 0 7 6 3 A — U N — 1 0 A U G 1 0


10. Remove upper and side grille housing access panels(14 and 15).

14— Grille Housing Upper Access Panel (2 used)


14

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Cooling System

MH66088,0000DA2 -19-23SEP10-6



13. Apply vacuum to hydraulic oil reservoir to minimizeoil loss.

14. Disconnect hydraulic oil hoses at hydraulic oil cooler.Close all openings using caps and plugs.

15. Remove hydraulic oil cooler.


17. Install hydraulic oil cooler.

18. Connect hoses to hydraulic oil cooler.

19. Remove vacuum from hydraulic oil reservoir.

20. Install hydraulic oil cooler-to-radiator bracket and

hydraulic oil cooler-to-transmission oil cooler bracket.21. Install lower cooler support.




25. Remove vacuum pump.

26. Close grille.

27. Turn battery disconnect switch to ON position.

TX1080836

1619

17

18

T X

1 0 8 1 4 6 2 — U N — 3 0 A U G 1 0




28. Check hydraulic oil level. See Check HydraulicSystem Oil Level. (Operator’s Manual.)

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Cooling System

SW03989,0000B3E -19-27SEP10-1/1

MH66088,0000D84 -19-30AUG10-1/1

Fan Blade Remove and Install



See Battery Disconnect. (Operator’s Manual.)3. Remove engine side shields. See Opening Engine

Side Shields. (Operator’s Manual.)

4. Remove radiator. See Radiator Remove and Install.(Group 0510.)

5. Remove fan blade retaining lock nut (1). Remove fanblade.

6. Inspect and replace fan blade as necessary.

7. Install fan blade. Install fan blade retaining lock nutand tighten to specification.

Specification

Fan Blade Retaining LockNut—Torque..........................................................................81 ± 16 N∙m

60 ± 12 lb-ft

8. Install radiator. See Radiator Remove and Install.(Group 0510.)



1

T X 1 0 8 0 2 1 1 — U N — 0 3 A U G 1 0

Fan Blade Retaining Lock Nut

1— Fan Blade Retaining LockNut

Fan Shroud Remove and Install

1. Remove grille housing. See Grille Housing Removeand Install. (Group 1910.)


2. Remove fan shroud.

Specification

Fan Shroud—Weight

(approximate).................................................................................. 25 kg

55 lb.



4. Install fan shroud.

Specification

Fan Shroud—Weight

(approximate).................................................................................. 25 kg

55 lb.

5. Install gr ille housing. See Grille Housing Remove andInstall. (Group 1910.)

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Group 0520Intake System

MH66088,0000DA5 -19-30AUG10-1

MH66088,0000DA5 -19-30AUG10-2

MH66088,0000DA5 -19-30AUG10-3

Air Cleaner Remove and Install

1. Park and prepare machine for service. See Park andPrepare for Ser vice Safely. (Operator’s Manual.)


See Battery disconnect. (Operator’s Manual.)3. Remove air cleaner cap (1).

4. Remove left and right engine side shields. SeeOpening Engine Side Shields. (Operator’s Manual.)

1— Air Cleaner Cap 2— Air Cleaner T X 1 0 2 4 2 4 7 A — U N — 2 9 M A

Y 0 7

Air Cleaner Cap

5. Loosen clamp (4) and disconnect turbocharger inletpipe (5). Close all openings using caps and plugs.

6. Disconnect electrical connector.

2— Air Cleaner 4— Clamp

5— Turbocharger Inlet Pipe

T X 1 0 2 4 2 4 8 A — U N — 2 9 M A Y 0 7

Turbocharger Inlet Pipe

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


9. Install air cleaner.

10. Connect electrical connector.

11. Connect turbocharger inlet pipe.

12. Install left and right engine side shields.

13. Install air cleaner cap.


2— Air Cleaner 3— Cap Screw (4 used)

T X 1 0 2 4 2 4 6 A — U N — 2 9 M A Y 0 7

Air Cleaner

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Intake System

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Group 0530Exhaust System

MH66088,0000DA6 -19-30AUG10-1

Muffler Remove and Install

1. Park and prepare machine for service. See Park andPrepare for Ser vice Safely. (Group 0001.)



CAUTION: Prevent possible burn injury. Hotequipment can cause burns to unprotectedskin. Allow equipment to cool before servicing.Wear gloves and protective clothing whenworking with hot equipment.

3. Loosen upper muffler clamp (3).

4. Remove cap screws (2) and muffler outlet tube (1).

5. Loosen lower muffler clamp (5).

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

SpecificationMuffler—Weight

(approximate).................................................................................... 7 kg

17 lb.


8. Install muffler and tighten lower muffler clamp. Leaveupper muffler clamp loose.

T X 1 0 2 4 2 3 8 A — U N — 2 9 M A

Y 0 7

Muffler

1— Muffler Outlet Tube2— Cap Screw (2 used)3— Upper Muffler Clamp

4— Muffler 5— Lower Muffler Clamp6— Muffler Inlet Tube

9. Install muffler outlet tube. Tighten upper muffler clamp.


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Exhaust System

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Group 0560External Fuel Supply System

Continued on next page SW03989,0000AF1 -19-04OCT10-1

Fuel Tank Remove and Install

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

T X

1 0 8 1 6 5 9 — U N — 0 7 S E P 1 0

Standard Fuel Tank

1— Fuel Tank2— Lift Mounting Hole (2 used)3— Wire Guard

4— Cap Screw (4 used)5— Washer (6 used)6— Drain Plug

7— Cap Screw (2 used)8— Washer (2 used)9— Bushing (2 used)

10— Nut (2 used)11— Fuel Level Sending Unit




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Ex ternal Fuel Supply System

SW03989,0000AF1 -19-04OCT10-2/6

Continued on next page SW03989,0000AF 1 -19-04OCT10- 3/6

3. Drain fuel tank (1). For fuel tank capacity, See FuelTank. (Operator’s Manual.)

4. Remove arch. See Dual Function Grapple ArchRemove and Install. (Group 3740.)

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

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

7. Remove reverse warning alarm. See ReverseWarning Alarm Remove and Install. (Group 2004.)

8. Disconnect fuel suction hose (14) and fuel return hose(15). Close all openings using caps and plugs.

12— Guard13— Cap Screw (2 used)

14— Fuel Suction Hose15— Fuel Return Hose T

X 1 0 8 1 6 5 6 A — U N — 0 7 S E P 1 0

Fuel Hose Guard

T X 1 0 8 1 6 5 5 A — U N — 0 7 S E P 1 0

Fuel Hose Connections

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External Fuel Supply System

Continued on next page SW03989,0000AF1 -19-04OCT10-4

9. Remove cover (17).

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

1— Fuel Tank3— Wire Guard16— Cap Screw (2 used)

17— Cover 18— Wire Lead Connection (2

used)

T X 1 0 8 1 6 5 3 A — U N — 0 7 S E P 1 0

Fuel Level Sending Unit—Cover

T X 1 0 8 1 6 5 4 A — U N — 0 7 S E P 1 0

Fuel Level Sending Unit

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Continued on next page SW03989,0000AF 1 -19-04OCT10- 5/6


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

SpecificationFuel Tank—Stan-

dard—Weight (approxi-

mate)............................................................................................. 165 kg

364 lb.

Fuel Tank—Dual

Function—Weight

(approximate)................................................................................ 205 kg

452 lb.

Fuel Tank—Dual

Function Without

Winch—Weight........... ........... ............ ............ ........... ............ ......... 325 kg

718 lb.

12. Remove cap screws (4 and 7), washers (5 and 8),bushings (9), and nuts (10).


13. Remove fuel tank.

Specification

Fuel Tank—Stan-


mate)............................................................................................. 165 kg

364 lb.

Fuel Tank—Dual

Function—Weight

(approximate)................................................................................ 205 kg

452 lb.

Fuel Tank—Dual

Function Without

Winch—Weight........... ........... ............ ............ ........... ............ ......... 325 kg

718 lb.

14. Inspect fuel tank and components. Repair or replaceparts as necessary.


15. Install fuel tank.

SpecificationFuel Tank—Stan-


mate)............................................................................................. 165 kg

364 lb.

Fuel Tank—Dual

Function—Weight

(approximate)................................................................................ 205 kg

452 lb.

T X 1 0 8 1 3 7 5 A — U N — 0 7 S E P 1 0

JT01748 Lifting Brackets (shown on grapple machine)

19— JT01748 Lifting Bracket (2used)

Fuel Tank—DualFunction Without

Winch—Weight.......... ............ ............ ............ ........... ............ ......... 325 kg

718 lb.

16. Install cap screws, washers, bushings, and nuts.

17. Pull unit wire leads through wire guard.

18. Connect wire leads to wire lead connections. Installcover.

19. Connect fuel tank return line and fuel tank suction line.

20. Install guard.

21. Install reverse warning alarm. See Reverse Warning

Alarm Remove and Install. (Group 2004.)

22. Install winch, if equipped. See Winch 4000 SeriesRemove and Install or see Winch 6000 Series Removeand Install. (Group 3000.)

23. Install arch. See Dual Function Grapple Arch Removeand Install. (Group 3740.)

24. Fill tank with fuel. See Diesel Fuel. (Operator’sManual.)

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Ex ternal Fuel Supply System

SW03989,0000AF1 -19-04OCT10-6


26. Remove articulation locking bar.

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Section 07Dampener Drive

Contents

Page

Group 0752—ElementsDampener Remove and Install..................07-0752-1Transmission Cold Weather

Disconnect Linkage Removeand Install—If Equipped ........................ 07-0752-2

Transmission Cold Weather Disconnect Repair—If Equipped ............................................... 07-0752-4

TM11813 (13OCT10) 07-1 748H Repair (S.N. 630436—10

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Group 0752Elements

PM10405,0000572 -19-07OCT10-1

PM10405,0000572 -19-07OCT10-2

Dampener Remove and Install

1. Set battery disconnect switch to OFF position.

2. Remove engine side shields.

3. Remove drive shaft. See Engine-to-Transmission

Drive Shaft Remove and Install. (Group 0325.)

4. Remove cap screws (A) to remove cover (B).

For machines equipped with transmission disconnect,see Transmission Cold Weather Disconnect LinkageRemove and Install—If Equipped. (Group 0752.)

5. Remove cap screws (C) and remove damper (D).

A—Cap Screw (6 used)B—Cover C—Cap Screw (6 used)

D—Torsional Damper E—Dowel Pin (2 used)

T 1 1 4 9 5 1 B — U N — 2 3 A P R 9 8

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

7. Install and tighten cap screws (C) to specification.

Specification

Flywheel-to-Flywheel

Housing Cap

Screw—Torque..............................................................................68 N∙m

50 lb-ft

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

On machines equipped with transmission disconnect,see Transmission Cold Weather Disconnect LinkageRemove and Install—If Equipped. (Group 0752.)

9. Install drive shaft. See Engine-to-Transmission DriveShaft Remove and Install. (Group 0325.)

10. Turn battery disconnect switch to ON.

11. Install engine side shields.

A—Cap Screw (6 used)B—Cover C—Cap Screw (6 used)

D—Torsional Damper E—Dowel Pin (2 used)

T 1 1 4 9 5 1 B — U N — 2 3 A P R 9 8

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Elements


Transmission Cold Weather Disconnect Linkage Remove and Install—If Equipped

NOTE: Before repairing cold weather disconnect, ensure it is properly adjusted. See Cold Weather Disconnect Linkage Adjustment—If Equipped. (Group 9020-20.)

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



4. Remove transmission drive shaft. SeeEngine-to-Transmission Drive Shaft Removeand Install. (Group 0325.)

TX1081470 16

15

15

12

2

3

9

4

6

78

11

14

13

15

10

5

1

T X 1 0 8 1 4 7 0 — U

N — 3 0 A U G 1 0

Transmission Cold Weather Disconnect

1— Cap Screw (6 used)2— Washer (6 used)3— Lever 4— Cotter Pin

5—Pin6— Yoke7—Nut8— Bracket

9— Cap Screw (2 used)10— Flange Nut (2 used)11— Actuator Rod12— Housing

13— Cap Screw (2 used)14— Cover 15— Cap Screw (9 used)16— Cover

5. Remove cap screws (15) securing cover (16).

6. Remove cotter pin (4) and pin (5).

7. Remove cap screws (9) and flange nuts (10).

8. Remove actuator rod and bracket.

9. Remove cap screws (13) and cover (14).


10. Remove cap screws (1) and washers (2) and removehousing (12).

11. Inspect housing for cracks or damage. Inspect linkagefor damage or excessive wear. See Transmission Cold

Weather Disconnect Repair—If Equipped. (Group0752.)



12. Install housing. Tighten cap screws to specification.

Specification

Transmission Disconnect

Housing-to-Flywheel

Housing Cap

Screw—Torque............................................................................217 N∙m

160 lb-ft

13. Install cover (14).

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Elements

NM00125,0000581 -19-29SEP10-2

14. Install actuator rod and bracket.

15. Install cover (16).

16. Install transmission drive shaft. SeeEngine-to-Transmission Drive Shaft Remove

and Install. (Group 0325.)

17. Adjust cold weather disconnect. See Cold Weather Disconnect Linkage Adjustment—If Equipped. (Group9020-20.)


19. Turn battery disconnect switch ON position. SeeBattery Disconnect. (Operator’s Manual.)

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Elements


Transmission Cold Weather DisconnectRepair—If Equipped

T 8 4 8 3 A D — U N — 1 5 M A Y 9 5

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Elements

NM00125,0000582 -19-27SEP10-2

Continued on next page NM00125,0000582 -19-27SEP10-3

1— Cap Screw (4 used)2— Universal Joint Cross3— Stub Shaft4— Seal5— Cap Screw (6 used)6— Collar 7— O-Ring

8— Snap Ring

9— Inner Collar 10— Bushing11— Oil Seal12— Needle Bearing13— Cap Screw (12 used)14— Washer (12 used)15— Cover

16— Pipe Plug (2 used)

17— Thrust Bearing Race (2used)

18— Needle Thrust Bearing19— Compression Spring20— Sliding Shaft21— Bearing22— O-Ring

23— Splined Hub24— Cap Screw (2 used)

25— Snap Ring26— Cap27— Bearing Kit28— Disconnect Spline Kit29— Washer (6 used)30— Transmission Disconnect31— Transmission Disconnect

Kit

1. Remove cap screws (1) from stub shaft (3).

2. Remove cap screws (13) and washers (14) to removedisconnect cover (15) from damper.

3. Remove cap screws (5) and washers (29) to removecollar (6).

4. Remove cap (26).

5. Remove snap ring (25) to pull out stub shaft.

6. Remove seal (4) and collar from stub shaft.

CAUTION: Splined hub is spring loaded. Followproper procedure to remove splined hub and

collar to prevent personal injury. If splinedhub is removed improperly the spring willpull hub up against collar.

7. Press inner collar (9) down to release pressure onsnap ring (8).

8. Remove snap ring.

8— Snap Ring9— Inner Collar

23— Splined Hub T X 1 0 8 1 4 8 6 A — U N — 0 1 S E P 1 0

Splined Hub With Collar

T X 1 0 8 1 4 8 5 A — U N — 0 1 S E P 1 0

Snap Ring Removal

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Elements


NOTE: Hydraulic press is shown for removal. If press is not available, a lead hammer and appropriate drivers can be used.

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

Collar is a light press fit.10. Remove sliding shaft from splined hub.

T 7 5 0 2 H P — U N — 1 1 J U L 9 1

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Elements

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Section 09Steering System

Contents

Page

Group 0930—Secondary SteeringSecondary Steering Pump Remove

and Install .............................................. 09-0930-1

Group 0960—Hydraulic SystemSteering Valve Remove and

Install .....................................................09-0960-1Steering Valve Disassemble and

Assemble...............................................09-0960-5Steering Cylinder Remove and

Install ..................................................... 09-0960-9

Group 0962—Dual Mode Steering

Dual Mode Steering Solenoid ValveRemove and Install................................ 09-0962-1

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Group 0930Secondary Steering


Secondary Steering Pump Remove andInstall

TX1080206 T X 1 0 8 0 2 0 6 — U N — 1 8 A U G 1 0

Secondary Steering Pump Location

CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve the

pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten allconnections before applying pressure.


2. Operate all hydraulic controls to release pressure inthe hydraulic system.

3. Remove right side engine shields. See OpeningEngine Side Shields. (Operator’s Manual.)

4. Turn battery disconnect to the OFF position.

NOTE: Secondary steering pump is located inside right engine frame, forward of front axle.

5. Disconnect all electrical connections at secondarysteering pump and pump relay. See SecondarySteering Harness (W19) Wiring Diagram—If Equipped.(Group 9015-10.)

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Secondary Steering

NM00125,0000598 -19-07OCT10-2/2

TX1080205

8

76

5

4

3

2

1

T X 1 0 8 0 2 0 5 — U N — 2 7 J U L 1 0

Secondary Steering Pump Exploded View

1— Secondary Steering Pump2— Bracket

3— Supply Hose-to-SecondarySteering Valve

4— Pressure Hose-to-SecondarySteering Valve

5— Secondary Steering Relay6— Cap Screw (3 used)

7— Washer (3 used)8— Rubber Bushing (3 used)

6. Disconnect supply hose-to-secondary steering valve

(3) and pressure hose-to-secondary steering valve (4)at secondary steering pump. Close all openings usingcaps and plugs.

7. Support pump (1). Remove cap screws (6) andwashers (7) securing bracket (2) to frame.

8. Remove secondary steering pump and bracket fromframe.

9. Repair or replace components as required.

10. Install secondary steering pump and bracket assemblyto frame using washers and cap screws.

11. Connect pressure hose and supply hose to secondary

steering valve.

12. Connect all electrical connections at secondarysteering pump and pump relay. See SecondarySteering Harness (W19) Wiring Diagram—If Equipped.(Group 9015-10.)

13. Install right side engine shields.


15. Check hydraulic oil level in the hydraulic reservoir before starting engine. See Check Hydraulic SystemOil Level. (Operator’s Manual.)

16. Before returning machine to service, check operationof secondary steering system. See SecondarySteering System Check. (Group 9005-10.)

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Steering Valve Remove and Install


1. Install articulation locking bar.

2. Operate hydraulic control valves to relive pressure inthe hydraulic system.

3. Remove cap screws (1) to remove lower console(2). As necessary, remove the fire extinguisher andwindshield washer tank.

4. Remove the cap screw from lower end of universal joint (4).


1— Cap Screw (4 used)2— Lower Console 3— Lower Steering Column4— Universal Joint

T 1 3 1 6 3 3 B — U N — 1 5 J U N 0

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Hydraulic System


CAUTION: Escaping fluid under pressure canpenetrate the skin causing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting 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 surgicallyremoved within a few hours or gangrenemay result. Doctors unfamiliar with this typeof injury should reference a knowledgeablemedical source. Such information is availablefrom Deere & Company Medical Departmentin Moline, Illinois, U.S.A.

NOTE: Attach labels to all lines before disconnection.

6. Disconnect lines 8—14. Close all openings usingcaps and plugs.

5— Cap Screw (4 used)6— Nut and Washer (3 used)7— Cap Screw (3 used)8— Dual Mode Steering

Solenoid Valve-to-SteeringValve Pressure Hose

10— Dual Mode SteeringSolenoid Valve-to-Steering Valve ReturnHose

11— Port R-to-SteeringCylinders Line

12— Priority Valve PortCF-to-Port P Line

13— Port L-to-SteeringCylinders Line

14— Port T-to-Return Oil Filter Line

X 9 8 1 1 — U N — 2 3 A U G 8 8

T X 1 0 2 4 8 5 8 A — U N — 1 5 J U N 0 7

Steering Valve—Dual Mode Steering

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Hydraulic System

Continued on next page AC12469,0000396 -19-23JUL07- 3

NOTE: Make note of rubber isolator position betweenmounting support and cab for installation.

7. Remove nuts and washers (6) and remove steeringvalve (17) lower steering column, mounting plate (15),

and adapter plate (16) (Dual Mode Steering machinesonly). Seal may come with the valve or remain stuckto the platform.

8. For machines equipped with standard steering,remove cap screws (5) and separate steering valvefrom mounting plate (18) and lower steering column.

For machine equipped with dual mode steering,remove cap screws (7) and separate adapter plate(16) from mounting plate (15). Remove cap screws (5)and separate adapter plate (16) and lower steeringcolumn from steering valve.

9. For machines equipped with standard steering, inspectand repair parts as necessary. See Steering Valve

Disassemble and Assemble. (Group 0960.)

For machines equipped with dual mode steering,inspect and replace parts as necessary.

6— Nut and Washer (3 used)7— Cap Screw (3 used)8— Dual Mode Steering

Solenoid Valve-to-SteeringValve Pressure Hose

9— Port LS-to-Priority ValvePort LS Line

15— Mounting Plate (DualMode Steering)

16— Adapter Plate17— Steering Valve18— Mounting Plate (Standard

Steering)19— Lower Steering Column20— Rubber Isolators (3 Used)

T X 1 0 2 4 8 7 1 A — U N — 1 3 J U N

0 7

Steering Valve Mounting—Standard Steering

T X 1 0 2 4 8 6 0 A — U N — 1 3 J U N 0 7

Steering Valve Mounting—Dual Mode Steering

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Hydraulic System

AC12469,0000396 -19-23JUL07-4/4

10. Install lower steering column (19).

11. For machines with standard steering, install mountingplate (18) so the side with the single rubber isolator istoward the Port T and Port P corner of the steeringvalve.

For machines with dual mode steering, install theadapter plate so the side with two holes faces the inletand outlet ports.

12. Install cap screws (5) and tighten to specification.

Specification

Mounting Plate and

Lower Steering

Column-to-Steering Valve


234 lb-in.

13. For dual mode steering machines, attach adapter plate to mounting plate.

14. Install seal between mounting plate and cab.

15. Install one washer on each stud.

CAUTION: Cab door is heavy. Use caution whenopening cab door while cab is tilted.

16. With the help of an assistant working through the rightcab door, install steering valve (17) so the splines of the lower steering column engage splines in the lower universal joint.

17. Install nuts and washers.

18. Install cap screw in lower universal joint. Check that

splines are engaged to specification.

Specification

Lower Steering

Column-to-Lower

Universal Joint Spline

Engagement—Distance................................................................ 19 mm

0.75 in.

T X 1 0 2 4 8 7 1 A — U N — 1 3 J U N

0 7

Lower Steering Column Installation (standard steering shown)

5— Cap Screw (4 used)17— Steering Valve18— Mounting Plate (Standard

Steering)

19— Lower Steering Column20— Rubber Isolators (3 Used)

19. Connect hydraulic lines.

IMPORTANT: Check for pinched lines when cab islowered. Adjust line position if necessary.

20. Lower the cab. See Hydraulic Cab Tilt Procedure.(Operator’s Manual.)

21. Install lower console cover.

22. Turn battery disconnect to ON position.

23. Check hydraulic oil level in the hydraulic reservoir before starting engine. See Check Hydraulic SystemOil Level. (Operator’s Manual.)

24. Remove articulation lock bar.

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Steering Valve Disassemble and Assemble

T 1 6 2 2 2 7 B — U N — 0 4 D E C 0 2

Steering Valve Components

IMPORTANT: Perform all service on steering valve ina clean isolated work area. Use proper tools,cleaning material, and lubricants.

Use wooden blocks or similar material to protectsteering valve. Tighten vise just enough to holdvalve. Overtightening can damage the valve.

1. Put steering valve in a vise with the gerotor end up.Tighten just enough to hold valve.

2. Remove the two cap screws (1) to remove pins (2)and anti-cavitation steel balls (3).

3. Remove the remaining cap screws to remove endcap (4), gerotor star (8), gerotor housing (9) and platespacer (10).

4. Hold spool (7) and reposition valve with lower steering

column (11) end up.5. Remove mounting plate (12) and lower steering

column.

11 T 1 6 2 2 2 1 — U N — 1 2 D E C 0 2

Cap Screws

1— Cap Screw (7 used)2— Pins (2 used)3— Anti-Cavitation Steel Balls

(2 used)4— End Cap7— Spool8— Gerotor Star

9— Gerotor Housing10— Plate Spacer 11— Lower Steering Column

12— Mounting Plate13— Housing

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Continued on next page AC12469,000039A -19-13JUN07- 2/5

6. Assemble tool using a M10 x 120 mm cap screw (22)and two nuts (28).

7. Install cap screw into housing so head engages intoinput spline.

8. Hold drive spline head (20) with 20 mm socket (21).

IMPORTANT: Spring tension must be compressedbefore spool is removed.

9. Rotate cap screw using a wrench to compress springtension.

10. Push spool (7) down out of housing (13) while springtension is compressed.

Be careful not to remove pin (14) from spool (7) anddrive spline (19).

11. Inspect all parts for contamination, nicks and burrs.

Spool is not serviceable. Do not disassemble spool.

12. Replace O-rings (18), dust seal (24), backup washer (25) and seals (26, 27).

7— Spool13— Housing20— Spline Head

21— 20 mm Socket22— M10 x 120 mm Cap Screw28— Nuts

T 1 6 2 2 1 5 B — U N — 0 4 D E C 0 2

Spring Compression Tools

T 1 6 2 2 2 2 B — U N — 0 4 D E C 0 2

Spool Removed From Housing

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Continued on next page AC12469,000039A -19-13JUN07- 3

27

18

24

2625

T162216 T 1 6 2 2 1 6 —

U N — 2 0 D E C 0 2

Seal Placement

18— O-Ring (3 used)24— Dust Seal

25— Backup Washer 26— Seal

27— O-Ring

13. Lubricate O-rings (18 and 27) and seals (24 and 26)with TY24416 Multi-Purpose HD Lithium ComplexGrease. If petroleum jelly is used for O-ring lubrication,use small enough amount to avoid spreading onsurfaces of other parts.

14. Lubricate spool with clean hydraulic oil to easeassembly.

IMPORTANT: Make sure drive pin does not slipout of spool and drive spline.

15. Install spool (7) by compressing spring tension.

16. Hold drive spline head (20) with 20 mm socket (21).

17. Rotate cap screw (22) using wrench on nuts (28) tocompress spring tension.

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AC12469,000039A -19-13JUN07-5/5

IMPORTANT: Timing of drive with respect togerotor star is critical.

18. Drive pin (14) must be aligned with valley (minor diameter) of gerotor star.

19. Align pin (14), drive spline (19) and gerotor star (8)as shown.

20. Install plate spacer (10).

21. Install gerotor star (8) and gerotor housing (9).

22. Install end cap (4).

23. Apply pipe sealant to bottom side of cap screw (1)heads.

24. Install the cap screws except in the holes (1) for anti-cavitation steel balls (3) and pins (2).

25. Install anti-cavitation steel balls and pins.

26. Install remainder cap screws.

8— Gerotor Star 9— Gerotor Housing10— Plate Spacer 14— Drive Pin15— Alignment Line

16— Alignment Line17— Alignment Line18— O-Ring (3 used)19— Drive Spline

9

8

18

10

18

19

16

17

14

15 T 1 6 0 3 8 9 — U N — 0 2 D E C 0 2

Component Alignment

IMPORTANT: Any cap screw can be tightened first,but the sequence shown must be followed.

27. Tighten cap screws to the initial specification in thetightening sequence (1—7). Then tighten in sequenceto final specification.

Specification

End Cap-To-Housing Cap

Screw—Torque (Initial)..................................................................17 N∙m

150 lb-in.

End Cap-To-Housing Cap

Screw—Torque (Final)........... ............ ............ ........... ............ ......... 34 N∙m

300 lb-in.

1—7— Tightening Sequence

1

3

5

7

6

4

2

T 1 6 0 4 3 6 — U N — 1 7 O C T 0 2

Tightening Sequence

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AC12469,0000397 -19-25JUL07-1

AC12469,0000397 -19-25JUL07-2

Steering Cylinder Remove and Install

1. Engage park brake.

CAUTION: Avoid possible injury from unexpectedmachine movement. Install articulation locking

bar before working in frame hinge area.



Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tightenall connections before applying pressure.


If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be surgicallyremoved within a few hours or gangrenemay result. Doctors unfamiliar with this type

X 9 8 1 1 — U N — 2 3 A U G 8 8

of injury should reference a knowledgeablemedical source. Such information is availablefrom Deere & Company Medical Departmentin Moline, Illinois, U.S.A.

3. Operate all controls to release hydraulic pressure.

4. Remove engine frame shields.

5. Disconnect lines (6 and 7) at rod and head end of steering cylinder (5). Close openings with caps andplugs.

6. Remove lock nuts (2) and cap screws (1) to removepins (3) and thrust washer (4).


7. Remove the cylinder.

Specification

Steering Cylin-

der—Weight (approxi-

mate)............................................................................................... 45 kg

100 lb

8. Repair or replace cylinder.

9. Install cylinder so work ports are on the bottom, andcap screw hole in rod end clevis is on top.

10. Install thrust washers (4) to center cylinder clevises onthe mounting plates.

11. Install the pins (3).

12. Install cap screws and lock nuts. Tighten tospecifications.

1

4

7

3

5

1

3

4

2

6T162743 T

1 6 2 7 4 3 — U N

— 1 8 D E C 0 2

1— Cap Screw (2 used)2— Lock Nut (2 used)3— Pin (2 used)4— ThrustWasher (as required)

5— Steering Cylinder 6— Rod End-to-Steering Valve

Line7— Head End-to-Steering Valve

Line

Specification

Cylinder-to-Pin Cap

Screw and LockNut—Torque..................................................................................27 N∙m

20 lb-ft

13. Connect hydraulic lines and check for leaks.


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Group 0962Dual Mode Steering

AC12469,0000398 -19-10MAR09-1

AC12469,0000398 -19-10MAR09-2

Dual Mode Steering Solenoid Valve Removeand Install

1. Turn battery disconnect switch to OFF.






If an accident occurs, see a doctor immediately.Any fluid injected into the skin must be surgicallyremoved within a few hours or gangrenemay result. Doctors unfamiliar with this type

X 9 8 1 1 — U N — 2 3 A U G 8 8

of injury should reference a knowledgeablemedical source. Such information is availablefrom Deere & Company Medical Departmentin Moline, Illinois, U.S.A.

3. Operate hydraulic control valves to relive pressure in

the hydraulic system.


NOTE: Attach labels to hoses before disconnection.If hoses are reversed, dual mode steering switch operation will be reversed.

5. Disconnect wire connectors from solenoid (6).

6. Disconnect all hydraulic lines. Close all openingsusing caps and plugs.

7. Remove cap screws (2) and remove valve.

8. Inspect valve and repair or replace parts as necessary.

9. Install valve on underside of cab.

10. Connect hydraulic hoses.

11. Connect wiring to solenoid.

12. Lower cab. See Hydraulic Cab Tilt Procedure.(Operators Manual.)

13. Check hydraulic oil level in the hydraulic reser voir before starting engine. See Check Hydraulic SystemOil Level. (Operator’s Manual.)


15. Turn battery disconnect switch to ON.

T X 1 0 2 4 8 5 7 A — U N — 1 3 J U N 0 7

Dual Mode Steering Solenoid Valve

1— Return Hose2— Cap Screw (2 used)3— System Pressure Hose

4— Steering Valve-to-SolenoidValve Return Hose

5— Solenoid Valve-to-SteeringValve Pressure Hose

6— Solenoid

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Section 10Service Brakes

Contents

Page

Group 1015—Controls LinkageService Brake Pedal Remove and

Install ..................................................... 10-1015-1

Group 1060—Hydraulic SystemService Brake Valve Remove and

Install .....................................................10-1060-1Service Brake Valve Disassemble

and Assemble........................................10-1060-3Service Brake Accumulator

Remove and Install................................ 10-1060-4

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Group 1015Controls Linkage

AC12469,000039C -19-06MAR09-1

Service Brake Pedal Remove and Install

TX1056808 T X 1 0 5 6 8 0 8 — U N — 0 6 M A R 0 9

Service Brake Pedal

1— Pedal2— Shaft3— Spring

4— Bushing (2 used)5— Bracket6— Spring Pin

7— Flange Nut8— Cap Screw9— Cap Screw (3 used)

1. Remove spring pin (6).

2. Slide out shaft (2).

3. Inspect parts for wear or damage. Replace parts asnecessary.

4. Assemble parts as shown. Adjust brake pedal to

specifications. See Service Brake Pedal Adjustment.(Group 9025-20.)

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AC12469,000039D -19-13JUN07-1

Continued on next page AC12469,000039D -19-13JUN07- 2

Service Brake Valve Remove and Install


Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tightenall connections before applying pressure.



1. Operate all hydraulic functions, including servicebrakes, to relieve pressure in the hydraulic system.

X 9 8 1 1 — U N — 2 3 A U G 8 8

Actuate the brake pedal 20 times at one-secondintervals to relieve oil pressure from brake accumulator.

2. Tilt cab for access to service brake valve. SeeHydraulic Cab Tilt Procedure. (Operator’s Manual.)

NOTE: Observe position of lines before disconnectionto aid in assembly.

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

4. Disconnect wiring connectors for the service brakepressure switch (7).

1— Service Brake Valve

2— Port BS-to-Front AxleService Brake Pistons Hose

3— Port BR-to-Rear AxleService Brake Pistons Hose

4— Brake Accumulator-to-Port

P Hose5— Port T-to-Hydraulic

Reservoir Hose7— Service Brake Pressure

Switch

T X 1 0 2 4 8 8 9 A — U N — 2 0 J U N 0 7

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AC12469,000039D -19-13JUN07-3/3

CAUTION: Cab door is heavy. Use caution whenopening cab door while cab is tilted.

5. While holding valve in place, have an assistant,working through right cab door, remove cap screws

(F) to remove valve.

6. Repair or replace service brake valve as necessary.See Service Brake Valve Disassemble and Assemble.(Group 1060.)

7. Install fittings and pressure switch.

Specification

Fitting to


20—29 lb-ft

Service Brake

Pressure Switch to


106 lb-in.

8. Install valve. Install and tighten cap screws.

Specification

Cab Platform-to-Valve

Cap Screw—Torque........................................................... 23—32.5 N∙m

17—24 lb-ft

9. Connect hoses and wiring connectors.

10. Lower the cab. Check that hoses do not becomepinched as cab is lowered. Adjust angle of elbowsand hoses as necessary.

11. To adjust clearance between pedal and brake valveplunger, see Service Brake Pedal Adjustment. (Group

9025-20.)

T 1 1 4 3 4 1 B — U N — 1 0 A P R 9 8

F—Cap Screw (2 used)

CAUTION: Before operating machine, the brakebleed procedure must be done to remove air from service brake hydraulic system.

12. Bleed service brakes. See Service Brake BleedingProcedure. (Group 9025-20.)

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AC12469,000039F -19-13JUN07-1

Service Brake Valve Disassemble andAssemble

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

Disassemble valve for cleaning and inspection only. Onlya seal repair kit is available for service.

If any parts, except seals, are damaged, replace the valveas a complete assembly.

A—BootB—PlugC—O-RingD—SpringE—SpoolF— Valve HousingG—SealH—Spring Retainer

I— SpringJ— Spring Retainer K—SpringL—Plunger M—O-RingN—PlugO—PlugP—O-Ring

T 7 5 1 6 A O — U N — 2 3 A P R 9 1

T 7 5 1 6 A P — U N — 2 3 A P R 9

1

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AC12469,000039E -19-23JUL07-1/3

Continued on next page AC12469,000039E -19-23JUL07- 2/3

Service Brake Accumulator Remove andInstall

IMPORTANT: Clean all dirt and debris from servicebrake accumulator before disconnecting hoses.Contamination introduced into the hydraulic

system can lead to premature equipment failure.




If an accident occurs, see a doctor immediately.Any fluid injected into the skin must be surgicallyremoved within a few hours or gangrene

may result. Doctors unfamiliar with this typeof injury should reference a knowledgeablemedical source. Such information is availablefrom Deere & Company Medical Departmentin Moline, Illinois, U.S.A.

X 9 8 1 1 — U N — 2 3 A U G 8 8

1. Operate all hydraulic functions including brakes torelieve pressure in the hydraulic system. Depressbrake pedal at one-second intervals approximately 20times to relieve pressure from brake accumulator.

2. Remove right rear engine side shield for access tobrake accumulator.

3. Tag and disconnect hoses at accumulator. Close allopenings using caps and plugs.

4. Remove two cap screws, spacers, bands and nutssecuring service brake accumulator to reservoir leg.

5. Remove fittings from accumulator. Save fittings for use on new accumulator.

NOTE: The inlet check valve fitting is serviced

with the brake accumulator.

6. Install accumulator so the inlet check valve fitting istowards the center of machine.

7. Install two cap screws, spacers, bands and nutssecuring service brake accumulator to reservoir leg.Note that upper cap screw and spacer are shorter than lower cap screw and spacer.

A—Service Brake Accumulator B—Cap Screw (2 used)C—Nut (2 used)

D—Band (2 used)E—Spacer (2 used)

W C 1 0 0 5 5 8 7 — U N

— 1 2 A P R 0 6

Service Brake Accumulator Mounting

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AC12469,000039E -19-23JUL07-3

IMPORTANT: Always use new O-rings and seals.Damaged or used O-rings and seals will leak.

8. Install fittings on new accumulator.

9. Connect hoses at accumulator as tagged.

10. Install new decal on accumulator.

11. Install right rear engine side shield.

CAUTION: Before operating machine, the brakebleed procedure must be done to removeair from hydraulic system.

12. Before operating machine, see Service Brake BleedingProcedure. (Group 9025-20.)

A—Service Brake Accumulator B—Check ValveC—Swivel Tee Fitting

D—Swivel Tee FittingE—Adapter

F—Hose to Brake Pedal Valveport P

G—Hose from Priority

Valve/Hydraulic PumpH—Hose to Main Control ValveI— Hose to Grapple Rotate

Solenoid Valve port P

W C 1 0 0 6 7 0 1 — U N — 1 9 A P R 0 6

Service Brake Accumulator Hoses and Fittings

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Section 11Park Brake

Contents

Page

Group 1111—Active ElementsPark Brake Remove and Install.................. 11-1111-1

Group 1160—Hydraulic SystemPark Brake Solenoid Valve Repair...............11-1160-1

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Group 1111Active Elements


Park Brake Remove and Install

11

12

13

14151618

10

17

6

8

9

7

3

54

2

1

19

20

T162978 T 1 6 2 9 7 8 — U N — 0 2 J A N 0 3

Park Brake Cross Section

1— Transmission Housing2— Transmission Output Shaft3— Disk (8 used)4— O-Ring

5— Piston

6— Disk Spring7— Oil Seal8— Grease Seal (2 used)9— Transmission Yoke, Nut, and

Cotter Pin10— Lubrication Fitting

11— Separator Plate (9 used)12— M12 x 140 mm Cap Screw

(10 used)13— M12 x 110 mm Cap Screw (4

used) (recessed in cover)14— Cover 15— Outer Seal Ring

16— Inner Seal Ring17— Housing18— Gasket19— Hub

20— Snap Ring



3. Install wheel chocks under one or more wheels beforedisconnecting drive shaft.


5. Remove engine frame shields as needed to accesspark brake assembly.

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NM00125,0000585 -19-06OCT10-2/2


6. Disconnect park brake release hose (22). Close allopenings using caps and plugs.

7. Disconnect rear axle drive shaft and removetransmission output yoke. See Rear Axle andTransmission Drive Shaft Remove and Install. (Group0225.)

CAUTION: Park brake contains a disk spring (6)under load. Four M12 x 110 mm cap screws(13) are shorter and recessed into park brakecover. These four recessed cap screws holdcover (14) and housing (17) together.

Prevent possible crushing injury from heavycomponent. Use appropriate lifting device.

8. Remove 2 of 10 M12 x 140 mm cap screws (12) fromopposite sides of cover. Install guide pins.

9. Only remove remaining 10 M12 x 140 mm cap screws(12), leaving M12 x 110 mm cap screws (13) installedsecuring park brake housing (17) and cover (14)together. Remove park brake as an assembly.

Specification

Park Brake

Assembly—Weight

(approximate).................................................................................. 43 kg

95 lb.

10. Repair or r eplace parts as necessary. See RemovePark Brake and see Install Park Brake. (CTM308.)

11. Install drive shaft and yoke. See Rear Axle andTransmission Drive Shaft Remove and Install. (Group0225.)

12. Connect park brake release hose.

13. Install shields at articulation point.


15. Fill tr ansmission with oil and check transmission oillevel. See Change Transmission Oil, Replace Filter,

and Clean Suction Screen. (Operator’s Manual.)

T X 1 0 2 4 9 2 6 A — U N — 2 0 J U N 0

7

Park Brake Hose

T X 1 0 2 4 9 2 4 A — U N — 2 0 J U N 0 7

Park Brake Housing

9— Transmission Yoke, Nut,and Cotter Pin

12— M12 x 140 mm Cap Screw(10 used)

13— M12 x 110 mm Cap Screw(4 used) (recessed incover)

14— Cover

17— Housing21— Double Universal Joint

(Telescoping Drive Shaft)22— Park Brake Release Hose

16. Before returning machine to service, check parkbrake operation. See Operational Checkout. (Group9005-10.)

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NM00125,0000584 -19-06OCT10-1

NM00125,0000584 -19-06OCT10-2

Park Brake Solenoid Valve Repair


2. Remove cap screws (1 and 2) and remove access

panel (3).

1— Cap Screw2— Cap Screw

3— Access Panel

T X 1 0 7 9 2 5 9 A — U N — 2 9 J U N 1 0

Left Access Panel

3. Disconnect wire connector from park brake solenoidvalve (5).


4. Remove cap screws (4) and pull park brake solenoidfrom valve body (6). Close all openings using capsand plugs.


6. Install new O-Rings and backup rings on solenoidvalve using petroleum jelly for installation.

7. Connect electrical connector to solenoid valve.

8. Install access panel and cap screws.

9. Before returning machine to service check parkbrake operation. See Operational Checkout. (Group9005-10.)

5

6

4

T X 1 0 2 4 4 5 9 — U N — 0 6 J U N 0 7

4— Cap Screw (2 used)5— Park Brake Solenoid Valve

6— Valve Body

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Section 17Frame, Chassis, or Supporting Structures

Contents

Page

Group 1740—Frame InstallationWelding Repair of Major Structure..............17-1740-1Engine and Equipment

Frames—Separate ................................ 17-1740-2Lower Pivot Pin Repair .............................. 17-1740-6Upper Pivot Pin Repair ............................17-1740-12

Group 1746—Frame Bottom GuardsBottom Guard

Engine Frame........................................17-1746-1Equipment Frame..................................17-1746-2

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Group 1740Frame Installation

JW40272,0000028 -19-18APR08-1

Welding Repair of Major Structure

CAUTION: Avoid potentially toxic fumes and dust.Hazardous fumes can be generated when paint isheated by welding, soldering, or using a torch.

Do all work outside or in a well ventilated area.Dispose of paint and solvent properly.

If you sand or grind paint, avoid breathing thedust. Wear an approved respirator. If you usesolvent or paint stripper, remove stripper withsoap and water before welding. Remove solventor paint stripper containers and other flammablematerial from area. Allow fumes to disperse atleast 15 minutes before welding or heating.

1. Remove paint before welding or heating.

IMPORTANT: Electrical current traveling from thewelder through the machine electrical systemmay damage the machine electrical system,

including battery, machine information center,and pump and valve controller. Disconnectbattery ground cable, machine informationcenter, and pump and valve controller electricalconnectors before welding on the machine.

Have only a qualified welder do this job. Connectwelder ground clamp close to each weld areaso electrical current does not pass through anybearings. Remove or protect all parts that canbe damaged by heat or weld splatter.

2. Use one of the following weld processes:

• AWS-E-7018 covered electrode with shielded metal

arc welding (SMAW) process.• AWS-ER-70S-3 wire electrode with gas metal arc

welding (GMAW) process.

• AWS-E70T-1 or E71T-1 wire electrode with flux corearc welding (FCAW) process.

Welding Repair of Major Structure—Specification

Weld Metal—Tensile

Strength...................................................................................482.6 mPa

70 000 psiYield Strength .........................................................................413.7 mPa

60 000 psi

Elongation.........................................................................................22%

IMPORTANT: Area to be repaired must be preheatedto allow better weld penetration.

3. To repair weld metal failure, remove failed weld metalusing arc or grinding equipment. Thoroughly cleanarea to be welded. Preheat structural assemblies to aminimum of 38°C (100°F). Preheat ground engagingtools (cutting edges, skid shoes, and teeth shanks) to177°C (350°F).

To repair base metal failure remove enough material toallow weld to penetrate to the bottom of crack. Preheatstructural assemblies to a minimum of 38°C (100°F).Preheat ground engaging tools (cutting edges, skidshoes, and teeth shanks) to 177°C (350°F).

Welding Repair of Major Structure—Specification

Structural

Assemblies—Preheat

Temperature..................................................................................... 38°C

100°F

Ground Engaging

Tools—Preheat

Temperature................................................................................... 177°C

350°F

TM11813 (13OCT10) 17-1740-1 748H Repair (S.N. 630436—10

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Frame Installation

SW03989,0000A9F -19-07OCT10-1/5

Continued on next page SW03989,0000A9 F -19-07OCT10- 2/5

Engine and Equipment Frames—Separate

1. Park machine on smooth, level surface and alignframes straight ahead.

2. With engine running, lower blade. Close grapple tong

and lower boom to rest grapple tong on lift table (if grapple equipped).



4. Operate all hydraulic functions including brake torelease pressure in the hydraulic system. Depressbrake pedal at 1-second intervals 20 times to

discharge oil from accumulator.

5. Turn battery disconnect switch to OFF position. SeeBattery Disconnect. (Operator’s Manual.)

T 8 4 6 5 A E — U N — 0 9 M A Y 9 5

Grapple Tong on Lift Table

CAUTION: Prevent possible crushing injury fromheavy component. Use proper lifting device.

6. Install floor stands under grille housing.

7. Support grapple arch as shown.


IMPORTANT: Clean all dirt and debris fromhydraulic reservoir before removing fill capor disconnecting hoses. Contaminationintroduced into the hydraulic system can leadto premature equipment failure.

9. Drain hydraulic reservoir. See Change Hydraulic Oil.(Operator’s Manual.)

T 1 1 4 4 0 6 B — U N — 2 9 A P R 9 8

Grapple Arch Support

TM11813 (13OCT10) 17-1740-2 748H Repair (S.N. 630436— )101310

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Frame Installation

Continued on next page SW03989,0000A9F -19-07OCT10-3

10. Remove right equipment frame shield (1) and bottomengine frame shield (2).

11. Remove hose brackets (3).

12. Remove left frame shields (4—6).

13. Remove drive shafts. See Rear Axle and TransmissionDrive Shaft Remove and Install. (Group 0225.) Alsosee Winch Drive Shaft Remove and Install. (Group3025.)

1— Right Equipment FrameShield

2— Bottom Engine FrameShield

3— Hose Bracket (2 used)

4— Top Engine Frame Shield5— Left Equipment Frame

Shield6— Left Engine Frame Shield

T X 1 0 8 0 6 4 6 A — U N — 0 9 A U G 1 0

Right Frame Shields

T X 1 0 8 0 6 4 7 A — U N — 0 9 A U G 1 0

Hose Brackets

T X 1 0 8 0 6 4 8 A

— U N — 0 9 A U G 1 0

Left Frame Shields

TM11813 (13OCT10) 17-1740-3 748H Repair (S.N. 630436—10

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Frame Installation

Continued on next page SW03989,0000A9 F -19-07OCT10- 4/5

14. Disconnect winch control cable (8). See Winch ControlCable Remove and Install. (Group 3015.)

15. Identify and disconnect winch supply hose (7) andwinch return hose (9). Close all openings using capsand plugs.

16. Disconnect rear axle differential lock hose (11). Closeall openings using caps and plugs.

17. Disconnect reverse alarm and fuel sender electricalconnector (10).

18. Identify and disconnect hydraulic and fuel hoses athose junction bracket (12). Close all openings usingcaps and plugs.

7— Winch Supply Hose8— Winch Control Cable9— Winch Return Hose

10— Reverse Alarm andFuel Sender ElectricalConnector

11— Rear Axle DifferentialLock Hose

12— Hose Junction Bracket

9

87

T X 1 0 8 0 6 5 4 — U N — 0 6 A U G 1 0

Winch

T X 1 0 8 0 6 4 9 A — U N — 0 9 A U G 1 0

Differential Lock Valve

T X 1 0 8 0 6 5 1 A — U N — 0 9 A U G 1 0

Hose Junction Bracket

TM11813 (13OCT10) 17-1740-4 748H Repair (S.N. 630436— )101310

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Frame Installation

SW03989,0000A9F -19-07OCT10-5

IMPORTANT: Identify hoses and fittings at bulkheadbefore removal. Hoses can be interchanged,causing machine damage.

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

Close all openings using caps and plugs (grapplemachines only).

20. Disconnect steering cylinder from equipment frame.See Steering Cylinder Remove and Install. (Group0960.)


21. Remove pivot pins. See Upper Pivot Pin Repair andsee Lower Pivot Pin Repair. (Group 1740.)

22. With the aid of an assistant, slowly roll equipmentframe and service jack away from front engine frame.


24. With the aid of an assistant, slowly roll equipmentframe and service jack to engine frame and alignupper and lower pivot pin sleeves.

25. Install pivot pins. See Lower Pivot Pin Repair and seeUpper Pivot Pin Repair. (Group 1740.)

26. Connect steering cylinder to equipment frame. SeeSteering Cylinder Remove and Install. (Group 0960.)

27. Connect all hydraulic hoses to bulkhead (if grappleequipped).

28. Install drive shafts. See Rear Axle and Transmission

Drive Shaft Remove and Install. (Gr oup 0225.) Alsosee Winch Drive Shaft Remove and Install. (Group3025.)

29. Connect reverse alarm and fuel sender electricalconnector.

30. Connect rear axle differential lock hose.

31. Connect hydraulic hoses to junction bracket.

32. Connect winch cable. See Winch Control CableRemove and Install. (Group 3015.)

33. Connect winch hoses.

T X 1 0 8 0 6 5 2 A — U N — 0 9 A U G 1 0

Bulkhead

13— Arch Retract Hose14— Arch Extend Hose15— Grapple Rotate Hose

16— Boom Retract Hose17— Boom Extend Hose18— Grapple Rotate Hose

34. Install left engine frame shield and left equipmentframe shield and hose brackets.

35. Install right equipment frame shield and bottom engineframe shield.


37. Fill hydraulic reservoir. See Change Hydraulic Oil.(Operator’s Manual.)

38. Remove floor stands under grille housing.

39. Turn battery disconnect switch to ON position. SeeBattery Disconnect. (Operator’s Manual.)

40. Start engine and follow hydraulic oil warmupprocedure. Operate all hydraulic functions to removeany air trapped in system. See Hydraulic Oil WarmupProcedure. (Group 9025.)

41. Stop engine. Check for leaks and check hydraulicreservoir oil level. See Check Hydraulic System OilLevel. (Operator’s Manual.)

42. Bleed service brakes. See Service Brake BleedingProcedure. (Group 9025.)


TM11813 (13OCT10) 17-1740-5 748H Repair (S.N. 630436—10

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Frame Installation

Continued on next page SW03989,0000B40 -19-27SEP10-1/9

Lower Pivot Pin Repair

TX1056815 T X 1 0 5 6 8 1 5 — U N — 0 6 M A R 0 9

Lower Pivot Pin

TM11813 (13OCT10) 17-1740-6 748H Repair (S.N. 630436— )101310

PN=186



Frame Installation

SW03989,0000B40 -19-27SEP10-2

Continued on next page SW03989,0000B40 -19-27SEP10-3

2— Cap Screw (6 used)4— Cap Screw (3 used)5— Cap Screw (6 used)8— Seal (2 used)

9— Pin Retainer Guard11— Snap Ring (2 used)12— Lubrication Fitting (2 used)13— O-Ring (2 used)

14— Ring (2 used)20— Seal (2 used)21— Lower Pivot Pin22— Pin Sleeve

23— Bushing (2 used)24— Upper Quill25— Special Washer 31— Spherical Bushing

CAUTION: Avoid possible injury from

unexpected machine movement. Installarticulation locking bar.

1. Park machine on a level surface with frames aligned.Install articulation locking bar.

2. Lower blade and grapple equipment to ground.

Operate all hydraulic functions including brake, torelease pressure in the hydraulic system. Depressbrake pedal at one second intervals 20 times todischarge oil from accumulator.

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

4. Remove drive shafts.

See Winch Drive Shaft Remove and Install. (Gr oup3025.)

See Rear Axle and Transmission Drive Shaft Remove

and Install. (Group 0225.)

32— Left Engine Frame Shield33— Left Equipment Frame

Shield34— Hose Retainer 35— Hose Retainer

36— Top Engine Frame Shield37— Bottom Engine Frame

Shield38— Right Equipment Frame

Shield T

X 1 0 2 6 5 7 8 A — U N — 1 7 J U L 0 7

Left Shields

T X 1 0 2 5 7 1 2 A — U N — 1 3 J U L 0 7

Right Shields

TM11813 (13OCT10) 17-1740-7 748H Repair (S.N. 630436—10

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Frame Installation

SW03989,0000B40 -19-27SEP10-4/9

SW03989,0000B40 -19-27SEP10-5/9


5. Remove bottom cover (9).

9— Bottom Cover 5— Cap Screw (6 used)

T X 1 0 2 5 0 4 2 A — U N — 2 0 J U N 0 7

Bottom Cover

6. Remove upper quill (24).

7. Place 10-ton service jacks under engine andequipment frames at hinge area for support.

2—Cap S crew (6 used) 24— Upper Qui ll

T X 1 0 2 6 4 2 0 A — U

N — 2 7 J U L 0 7

Upper Quill

8. Remove cap screws (4) to remove special washer (25).

4— Cap Screw (3 used)22— Pin Sleeve

25— Special Washer

T X 1 0 2 6 4 1 9 A — U N — 1 3 J U L 0 7

Special Washer

TM11813 (13OCT10) 17-1740-8 748H Repair (S.N. 630436— )101310

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Frame Installation


TX1026427

22

7

3

21 23

31

23

20

T X 1 0 2 6 4 2 7 — U N — 1 6 J U L 0 7

Lower Pivot Pin

3— Engine Frame7— Equipment Frame

20— Seal (2 used)21— Lower Pivot Pin

22— Pin Sleeve23— Bushing (2 used)

31— Spherical Bushing

NOTE: Lower pivot pin is a press fit in the pin sleeve.

9. Press lower pivot pin (21) out of pin sleeve (22).

10. Remove pin sleeve (22).

11. Remove seals from lower pivot pin (21) and from pinsleeve.

12. Clean and inspect seals.

13. Remove seals (20) from lower articulation jointbushings (23). Discard seals.

14. Apply several shots of grease to three articulation joint grease fittings to purge the old grease and to

ensure that the grease is getting through upper andlower bushings in engine frame and through sphericalbushings in equipment frame.

15. Clean all articulation joint components.

TM11813 (13OCT10) 17-1740-9 748H Repair (S.N. 630436—10

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Frame Installation


TX1026459

7 20

3

11

11

20

T X 1 0 2 6 4 5 9 — U N — 1 3 J U L 0 7

Bushing

3— Engine Frame 7— Equipment Frame 11— Snap Ri ng (2 used) 20— Seal (2 used)

16. Remove snap rings (11).

17. Remove bushings (23) using a driver. For bushingswith a groove machined into the end surface, apply

force to that end of bushing to remove.

18. Remove spherical bushing (31) from equipment frame(7) using a driver that applies force to the outer race.


IMPORTANT: Force must only be applied tothe outer race of spherical bushing toavoid damaging bushing.

20. Install spherical bushing into equipment frame usinga driver that applies force to the outer race. Installbushing so it is centered in equipment frame.

IMPORTANT: Bushings with a groove machined

into the end surface must be installedapplying force to that end of the bushing.The bushing shoulders only have a lead-inmachined on one side.

21. Install bushings into engine frame. For bushings withthe groove machined into the end surface, apply forceto that end of bushing to install.

22. Install snap rings.

NOTE: The lip on the upper seal should point down.

The lip on the lower seal should point up.

23. Install new seals into bushings. Install seals with the

slotted side of the seal towards the short side of thebushing.

24. Install new seal into pin sleeve. Install pin sleeve intobushing.

25. Support pin sleeve in bushing.

26. Install new seal in lower pivot pin.

27. Apply grease to lower pivot pin and bushings.

NOTE: Lower pivot pin is a press fit in the pin sleeve.

28. Install pivot pin in pin sleeve.

29. Install special washer and cap screws. Evenly tighten

cap screws to draw pivot pin into pin sleeve.

30. Tighten cap screws to specification.

Specification

Lower Pivot Pin Cap

Screw—Torque............................................................................319 N∙m

235 lb-ft

31. Grease pivot pins.

TM11813 (13OCT10) 17-1740-10 748H Repair (S.N. 630436— )101310

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Frame Installation

SW03989,0000B40 -19-27SEP10-9

32. Clean upper quill, clean and inspect O-ring andpacking.

33. Install upper quill with cap screws.

34. Clean bottom cover, clean and inspect O-ring and

packing.

35. Install bottom cover with cap screws and tighten tospecification.

Specification

Bottom Cover-to-Engine

Frame Cap

Screw—Torque............................................................................624 N∙m

460 lb-ft

36. Install drive shafts.

See Winch Drive Shaft Remove and Install. (Group3025.)

See Rear Axle and Transmission Drive Shaft Removeand Install. (Group 0225.)

37. Install shields.

TM11813 (13OCT10) 17-1740-11 748H Repair (S.N. 630436—10

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Frame Installation

Continued on next page GD61784,0000067 -19-06MAR09 -1/9

Upper Pivot Pin Repair

TX1056816 T X 1 0 5 6 8 1 6 — U N — 0 6 M A R 0 9

Upper Pivot Pin

TM11813 (13OCT10) 17-1740-12 748H Repair (S.N. 630436— )101310

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Frame Installation

GD61784,0000067 -19-06MAR09-2

GD61784,0000067 -19-06MAR09-3

Continued on next page GD61784,0000067 -19-06MAR09- 4

1— Cap Screw (6 used)6— Cap Screw (3 used)10— Spherical Bushing

12— Lubrication Fitting15— Upper Pivot Pin16— Quill

17— Lock Collar 18— Special Washer 26— Seal

27— Shim28— Shim29— Shim

CAUTION: Avoid possible injury fromunexpected machine movement. Install

articulation locking bar.

1. Park machine on a level surface and install articulationlocking bar.

2. Lower blade and grapple equipment to ground andoperate all hydraulic functions, including brake, to

release pressure in hydraulic system. Depress brakepedal at one second intervals 20 times to dischargeoil from accumulator.

3. Install floor stands under grille housing and ahead of lower pivot pin of engine frame. Support equipmentframe behind lower pin with 10-ton jack.

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

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

T X 1 0 2 4 9 7 8 A — U N — 2 0 J U N 0

7

Special Washer

5. Use the 17-1/2 ton hydraulic push-puller fromD01047AA 17-1/2 and 30-Ton Puller Set, to press on

bottom of upper pivot pin (1).

6. Push pin through spherical bushing (2) in engineframe (3) and out the top of equipment frame (4).

3— Engine Frame7— Equipment Frame

10— Spherical Bushing15— Upper Pivot Pin

15

3

10

7

T X 1 0 2 4 9 8 2 — U N

— 2 2 J U N 0 7

Upper Pivot Pin

TM11813 (13OCT10) 17-1740-13 748H Repair (S.N. 630436—10

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Frame Installation

GD61784,0000067 -19-06MAR09-5/9

GD61784,0000067 -19-06MAR09-6/9


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

8. Using a bushing driver, drive out bushing (10) fromthe bottom of engine frame through the top of engineframe.

9. Install new spherical bushing until it bottom in boreof engine frame.

10. Install quill without shims. Contact with sphericalbushing must be made.

1— Cap Screw (6 used)10— Spherical Bushing

16— Quill

T X 1 0 2 4 9 8 0 A — U N — 2 0 J U N 0 7

Cap Screw and Quill

11. Measure gap from quill to frame with a feeler gauge. Add shims to attain 0.03—0.13 mm (0.001—0.005 in.)preload on spherical bushing.

Specification

Shim Pack Less Than

Gap—Preload...................................................................0.03—0.13 mm

0.001—0.005 in.

T 1 2 8 5 3 2 — U N — 1 7 F E B 0 0

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

T 1 2 8 5 3 3 — U N — 1 7 F E B 0 0

TM11813 (13OCT10) 17-1740-14 748H Repair (S.N. 630436— )101310

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Frame Installation


13. Install required shims, quill (16) and cap screws (1).Tighten cap screws to specification. Bushing (10)must oscillate.

Specification

Quill Cap

Screw—Torque............................................................................140 N∙m

103 lb-ft

1— Cap Screw (6 used)10— Spherical Bushing

16— Quill

T X 1 0 2 4 9 8 0 A — U N — 2 0 J U N 0 7

Install Shims

TM11813 (13OCT10) 17-1740-15 748H Repair (S.N. 630436—10

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Frame Installation

GD61784,0000067 -19-06MAR09-9/9

TX1024991

18

17

6

10

26

15 1

16

7

7

263

30

T X 1 0 2 4 9 9 1 — U N — 2 2 J U N

0 7

Lower Seal

1— Cap Screw (6 used)3— Engine Frame6— Cap Screw (3 used)

7— Equipment Frame10— Spherical Bushing15— Upper Pivot Pin

16— Quill17— Lock Collar 18— Special Washer

26— Seal30— Gap

14. Install lower seal (26) into engine frame (3) withsealing lip facing away from spherical bushing (10).

15. Install lock collar (17) into seal.16. Apply grease to pivot pin and install into bushing (10).

17. Install special washer (18) and cap screws (6).

18. Evenly tighten cap screws to draw pin throughbushing. Tighten cap screws to specification.

Specification

Retaining Cap

Screws—Initial—Torque...........................................................230.5 N∙m

170 lb-ft

Retaining Cap

Screws—Final—Torque

Turn.....................................................................................................90°

19. Grease pivot pin.

IMPORTANT: There must be a 1.0 mm (0.039 in.)gap between special washer (7) and upper pivot pin (1) after cap screws have beentightened to specification.

20. Measure gap between special washer and upper pivotpin. Gap must be to specification.

Specification

Special Washer and

Upper Pivot Pin—Gap.................................................................. 1.0 mm

0.039 in.

TM11813 (13OCT10) 17-1740-16 748H Repair (S.N. 630436— )101310

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Group 1746Frame Bottom Guards

GD61784,0000068 -19-02JUL07-1

Engine Frame Bottom Guard Remove andInstall

T 1 1 4 5 9 5 — U

N — 2 9 A P R 9 8

A—Rear Bottom GuardB—Washer (2 used)C—Cap Screw (4 used)

D—Cap Screw (2 used)E—Front Bottom GuardF—Cotter Pin (2 used)

G—Washer (2 used)H—Washer (4 used)I— Cap Screw (2 used)

CAUTION: Heavy component; use a hoist.

Weights may increase due to the buildupof mud and debris.

Specification

Front Bottom

Guard—Weight(approximate).................................................................................. 36 kg

80 lb

Rear Bottom

Guard—Weight

(approximate).................................................................................. 25 kg

55 lb

1. Use a service jack to hold the bottom guards (A andE) in place while removing the cap screws (C and I).

The front bottom guard is hinged and will swing downto the front of machine.

2. Tighten cap screws (C, D, and I) to specifications.

SpecificationFront and Rear Bottom

Guard-to-Engine Frame


460 lb-ft

TM11813 (13OCT10) 17-1746-1 748H Repair (S.N. 630436—10

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Frame Bottom Guards

GD61784,0000069 -19-15JUN07-1/1

Equipment Frame Bottom Guard Removeand Install

T 1 1 4 5 9 6 — U

N — 2 9 A P R 9 8

A—Washer (8 used)B—Cap Screw (4 used)C—Cover

D—Plate (2 used)E—Bottom Door F—Cap Screw (2 used)

G—Cap Screw (4 used)H—Washer (4 used)I— Rear Bottom Guard

J— Cap Screw (4 used)

CAUTION: Heavy component; use a hoist.

Weights may increase due to the buildupof mud and debris.

Specification

Bottom Guard—Weight

(approximate).................................................................................. 27 kg60 lb

1. Use a service jack to hold the bottom guard (I) in placewhile removing the cap screws (G).

2. Tighten cap screws to specifications.

Specification

Bottom Guard-to-

Equipment Frame Cap

Screw—Torque............................................................................620 N∙m

460 lb-ft

Bottom Door-to-

Equipment Frame Cap

Screws—Torque..........................................................................130 N∙m

95 lb-ft

TM11813 (13OCT10) 17-1746-2 748H Repair (S.N. 630436— )101310

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Section 18Operator’s Station

Contents

Page

Group 1800—Removal and InstallationCab Remove and Install ............................18-1800-1Cab Isolators Remove and Install.............. 18-1800-8Steering Column and Steering

Wheel Remove and Install..................... 18-1800-9Steering Column and Steering

Wheel Disassemble and Assemble............................................. 18-1800-11

Cab Tilt Hand Pump Remove andInstall ................................................... 18-1800-13

Cab Tilt Hand Pump Disassembleand Assemble...................................... 18-1800-14

Cab Tilt Hand Pump Bleeding

Procedure ............................................ 18-1800-15Cab Tilt Cylinder Remove and

Install ................................................... 18-1800-17

Group 1810—Operator EnclosureWindow Remove and Install......................18-1810-1Window Cleaning Procedure..................... 18-1810-4Cab Door Remove and Install ...................18-1810-4Cab Door and Door Latch

Disassemble and Assemble ..................18-1810-5Front Windshield Wiper Remove

and Install .............................................. 18-1810-6Rear Windshield Wiper Remove

and Install ..............................................18-1810-7Windshield Wiper Adjustment.................... 18-1810-9

Group 1821—Seat and Seat BeltSeat Remove and Install ...........................18-1821-1Seat Disassemble and Assemble..............18-1821-2Seat Belt Remove and Install .................... 18-1821-7

Group 1830—Heating and Air ConditioningR134a Refrigerant Cautions and

Proper Handling..................................... 18-1830-1 Air Conditioning System Flush and

Purge.....................................................18-1830-2R134a Refrigerant Oil Information.............. 18-1830-4R134a Refrigerant

Recovery/Recycling and

Charging Station InstallationProcedure .............................................. 18-1830-5

R134a Refrigerant Recovery..................... 18-1830-6R134a System Evacuate...........................18-1830-6R134a System Charge ..............................18-1830-7Compressor Relief Valve Remove

and Install ..............................................18-1830-7 Air Conditioner Compressor

Remove and Install................................18-1830-8 Air Conditioner Compressor Clutch

Remove and Install................................18-1830-9

Page

Air Conditioner Compressor Manifold Remove and Install ............... 18-1830-11

Air Conditioner Condenser Removeand Install ............................................ 18-1830-11

Blower Motor Remove and Install............ 18-1830-13Precleaner Blower Assembly

Remove and Install.............................. 18-1830-14Refrigerant High/Low Pressure

Switch Remove and Install ..................18-1830-15Coolant Valve Remove and Install............ 18-1830-16Freeze Control Switch Remove

and Install ............................................ 18-1830-17Expansion Valve Remove and

Install ................................................... 18-1830-18Heater Core Remove and Install ............. 18-1830-19Evaporator Remove and Install ............... 18-1830-20Receiver-Dryer Remove and

Install ................................................... 18-1830-21

TM11813 (13OCT10) 18-1 748H Repair (S.N. 630436—10

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TM11813 (13OCT10) 18-2 748H Repair (S.N. 630436— )101310

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Continued on next page SW03989,0000B47 -19-05OCT10-1/

Cab Remove and Install




2. Operate all hydraulic controls to relieve pressurein the hydraulic system. Depress brake pedal at1-second intervals 20 times to discharge pressurefrom accumulator.




5. Remove right limb riser (1).

Specification

Right Limb

Riser—Weight

(approximate).................................................................................. 39 kg

85 lb.

CAUTION: Muffler and left limb riser may be hotfrom exhaust. Allow riser to cool before removal.

6. Disconnect muffler flex pipe from turbocharger outletelbow. Close opening using cap or plug.


7. Remove left limb riser with muffler (2).

Specification

Left Limb Riser

with Muffler—Weight

(approximate).................................................................................. 50 kg

110 lb.

T X 1 0 8 2 4 7 2 — U N — 0 5 O C T 1 0

Limb Riser Remove and Install

1— Right Limb Riser 2— Left Limb Riser with Muffler

CAUTION: Coolant may be hot. Wait until radiator is cool to the touch before draining radiator.

8. Dr ain cooling system. See Draining the CoolingSystem. (Operator’s Manual.)

9. Remove lower cab shields.

10. Disconnect steering column from steering valve. SeeSteering Valve Remove and Install. (Group 0960.)


12. Recover air conditioning refrigerant. See R134aRefrigerant Recovery. (Group 1830.)

TM11813 (13OCT10) 18-1800-1 748H Repair (S.N. 630436—10

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13. Disconnect air conditioner suction hose (3) at air conditioner compressor.

14. Remove clamp (4) and slide protective sleeve (5)up on hose. Disconnect pressure hose at fitting (6).Close all openings using caps and plugs.

15. Remove hoses from hangers routed to cab. Attachhose temporarily to bottom of cab. Hoses will beremoved with cab.


3— Air Conditioner SuctionHose

4— Clamp

5— Protective Sleeve6— Air Conditioner Pressure

Hose Fitting T

X 1 0 8 2 4 7 3 A — U N — 0 5 O C T 1 0

Air Conditioner Suction Hose

T X 1 0 8 2 4 7 4 A — U N — 0 5 O C T 1 0

Air Conditioner Pressure Hose


17. Identify and disconnect hydraulic lines from servicebrake valve (7). Close all openings using caps andplugs.

18. Remove hydraulic hoses through hanger and setaside.

19. Disconnect service brake pressure switch connector

(8) and engine speed control harness connector (9).20. Disconnect dual mode steering solenoid valve. See

Dual Mode Steering Solenoid Valve Remove andInstall. (Group 0962.)

T X 1 0 8 2 4 7 5 A — U N — 0 5 O C T 1 0

Service Brake Valve and Engine Speed Control

7— Service Brake Valve8— Service Brake Pressure

Switch Connector

9— Engine Speed ControlHarness Connector

TM11813 (13OCT10) 18-1800-2 748H Repair (S.N. 630436— )101310

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21. Disconnect heater hoses (9). Close all openings usingcaps and plugs.

NOTE: Do not disconnect hoses from steering valve.

22. Remove steering valve from bottom of cab. SeeSteering Valve Remove and Install. (Group 0960.)

10— Heater Hose (2 used)

T X 1 0 8 2 4 7 6 A — U N — 0 5 O C T 1 0

Heater Hoses

23. Disconnect wire harness connections (11 and 12)and transmission wire harness connection (13) frombottom of cab. Remove cap screws and clampssecuring wire harnesses to cab.

11— Wire Harness Connection12— Wire Harness Connection

13— Transmission WireHarness Connection

T X 1 0 8 2 4 7 7 A — U N — 0 5 O C T 1 0

Wire Harness Connections

T X 1 0 8 2 4 7 8 A — U N — 0 5 O C T 1 0

Transmission Wire Harness Connection

TM11813 (13OCT10) 18-1800-3 748H Repair (S.N. 630436—10

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24. Disconnect ground strap (14) from cab mount.

14— Ground Strap 15— Cap Screw

T X 1 0 2 5 5 1 6 A — U N — 2 8 J U N 0 7

Cab Ground Strap

NOTE: Leave nut (19) finger tight, so it can be removed later without the use of a wrench.

25. Loosen nut (19) but DO NOT remove from cap screw(16).

16— Cap Screw17— Shim (as needed)

18— Washer (2 used)19— Nut

T X 1 0 8 2 4 8 0 A — U N — 0 5 O C T 1 0

Cab Tilt Cylinder Cap Screw and Nut

IMPORTANT: All components, hydraulic lines, andelectrical harnesses disconnected from machineand cab must be placed in areas that will beclear when lowering cab. Lowering cab ontop of such items will cause damage.


Remove cap screw (20) to disconnect tether cable(21) from cab.

20— Cap Screw 21— Tether Cable T X 1 0

8 2 4 8 1 A — U N — 0 5 O C T 1 0

Cab Tether Cable

TM11813 (13OCT10) 18-1800-4 748H Repair (S.N. 630436— )101310

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NOTE: Mark quantity and location of shims toaid in assembly.

27. Remove nut (19), shims (17), washer (18), and capscrew (16). Move cab tilt cylinder (22) away from

clevis.

16— Cap Screw17— Shim (as needed)18— Washer (2 used)

19— Nut22— Cab Tilt Cylinder

T X 1 0 8 2 4 7 9 A — U N — 0 5 O C T 1 0

Cab Tilt Cylinder

28. Disconnect winch control cable (23), if equipped.

29. Disconnect transmission vent hose (25).

30. Tag and disconnect hydraulic hoses (24, 27—31).Close all openings using caps and plugs.

31. Remove all clamps and ties securing hydraulic hosesto cab.

23— Winch Control Cable (if equipped)

24— Pilot Pressure Hose25— Transmission Vent Hose26— Grapple Tong Hose (2

used)27— Arch Hoses (2 used)

28— Boom Hose (if equipped,2 used)

29— Blade Hose (2 used)30— Valve Return Hose31— Valve Supply Hose

T X 1 0 8 2 4 8 2 A — U

N — 0 5 O C T 1 0

Dual Function Pilot Control Valve Shown

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32. Attach lifting chains to rear lift points (32) on right andleft sides of cab.

33. Install JDG909 Lifting Brackets (33) in both limbriser eyelets. Attach lifting chains to JDG909 LiftingBrackets.

32— Rear Lift P oint 33— JDG909 Lifting Bracket (2used)

T X 1 0 8 2 4 8 3 A — U N — 0 5 O

C T 1 0

Cab Rear Lift Point

T X 1 0 8 2 4 8 4 A — U N — 0 5 O C T 1 0

JDG909 Lifting Brackets

TM11813 (13OCT10) 18-1800-6 748H Repair (S.N. 630436— )101310

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NOTE: Mark quantity and location of washers and shims to aid in assembly.

34. Remove nuts (34). Raise cab slightly to remove capscrews (37), washers (35), and shims (36) from bothcab pivots.


IMPORTANT: Carefully remove cab, making sureall hydraulic lines, harnesses, and valvesare clear as cab is lifted.

35. Remove cab.

Specification

Cab—Weight

(approximate).............................................................................. 1281 kg

2825 lb.

36. Inspect, repair, or replace cab components asnecessary.

37. Inspect and replace cab isolators if necessary. SeeCab Isolators Remove and Install. (Group 1800.)


IMPORTANT: Hydraulic lines, hoses, and electricharnesses must be clear of cab while

lowering, or damage may occur.

38. Install cab onto frame mounts, guiding hydraulic lines,valves, and electrical harnesses into position for hookup.

Specification

Cab—Weight

(approximate).............................................................................. 1281 kg

2825 lb.

39. Install shims, washers, cap screw, and nut at cab pivotmounts as marked during removal.

IMPORTANT: Overtightening of cap screws and nutscan cause cab clevis to deform.

40. Tighten nuts until washers are snug.

41. Remove lifting chains and lifting brackets from cab.

42. Connect all hydraulic hoses to pilot control valve.

43. Connect winch control cable (if equipped) andtransmission vent hose.

44. Install all clamps and tie bands in original locations.Replace any cut tie bands.

T X 1 0 8 2 4 8 5 A — U N — 0 5 O C T 1 0

Cab Pivots

34— Nut (2 used)35— Washer (4 used)

36— Shim (as needed)37— Cap Screw (2 used)

45. Position tilt cylinder into cab clevis and install capscrew, washers, shims, and nut as were markedduring removal. Do not tighten nut at this time.

46. Install tether cable and cap screw.


IMPORTANT: DO NOT overtighten tilt cylinder nut. Overtightening of nut can causecab clevis to deform.

48. Tighten tilt cylinder nut until washers are snug.

49. Install cab ground strap.

50. Connect all electrical harnesses to cab and install allclamps in original positions.

51. Attach steering valve to bottom of cab. See SteeringValve Remove and Install. (Group 0960.)

52. Install dual mode steering solenoid valve. See DualMode Steering Solenoid Valve Remove and Install.(Group 0962.)

53. Connect hoses to service brake valve.

54. Remove vacuum if hydraulic reservoir was not dr ainedor fill hydraulic reservoir. See Change Hydraulic Oil.(Operator’s Manual.)

55. Connect service brake pressure switch connector andengine speed control connector.

56. Route heater hoses through hangers and connect.

57. Route air conditioner suction hose and pressure hosethrough hangers and connect.

58. Install protective sleeve over pressure hose and installclamp in original position.


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60. Install rear lower cab shields.


61. Install limb risers.Specification

Right Limb

Riser—Weight

(approximate).................................................................................. 39 kg

85 lb.

Left Limb Riser

with Muffler—Weight

(approximate).................................................................................. 50 kg

110 lb.

62. Connect muffler flex pipe to turbocharger outlet elbow.

63. Check and fill cooling system. See Filling the CoolingSystem. (Operator ’s Manual.)


65. Check hydraulic oil level and add oil if necessary.See Check Hydraulic System Oil Level. (Operator’sManual.)

66. Adjust winch control cable. See Winch Control Cable Adjustment Check. (Group 9030-20.)

67. Charge air conditioning system. See R134a SystemCharge. (Group 1830.)


69. Remove articulation lock bar.

Cab Isolators Remove and Install

NOTE: If cab isolators become worn or damaged,replace isolators.

Left Cab Mount Isolators

1. Raise cab. See Hydraulic Cab Tilt Procedure.(Operator’s Manual.)

2. Remove isolators from mounts.

3. Apply soap on isolators to aid in installation. Install

isolators.4. Lower cab, install shims.

5. Install one shim at front of rear cab mount support andthree at rear of support. Align shims and mountingholes. Install cap screw.

6. Install one shim at front of front cab mount support andthree at rear of support. Align shims and mountingholes. Install cap screw.

IMPORTANT: Overtightening of nuts can causecab clevis to deform.

7. Tighten nuts until washers are snug and full threadengagement is attained.

Right Cab Mount Isolators

T 1 1 4 5 7 0 B — U N — 2 9 A P R 9 8

CAUTION: Prevent unexpected machinemovement and possible injury. Install articulationlocking bar before you work in frame pivot area.


2. Park machine on level ground, turn battery disconnectswitch OFF, and set park brake switch to PARKposition.

3. Remove left engine side shields.

4. Disconnect both limb risers from top of cab.

TM11813 (13OCT10) 18-1800-8 748H Repair (S.N. 630436— )101310

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AC12469,00003A1 -19-10MAR09-2

AC12469,00003A1 -19-10MAR09-3

Continued on next page AC12469,00003A2 -19-14JUN07- 1

CAUTION: Left cab mounting pins MUST beinstalled before tilting right side of cab. Tiltingcab without opposite side mounting pins installedcould cause serious personal injury.

5. Open and remove lower cab shield (B).

6. Remove nuts (A).

7. Using hydraulic cab tilting jack, lift cab until weight of cab is removed from cap screws. Remove cap screws,washers, and shims. Note location and quantity of washers and shims to aid in assembling.

A—Nut (2 used) B—Lower Cab Shield

T 1 1 4 9 7 0 — U N — 2 9 A P R 9 8

8. Raise cab until mounts clear cab clevises. Support

cab using a wooden block (C) as shown.

9. Remove isolators from mounts.

10. Apply soap on new isolators to aid in installation.Install isolators.

11. Remove wooden block and lower cab.

12. Install one shim at front of rear cab mount support andthree at rear of support. Align shims and mountingholes. Install cap screw.

13. Install one shim at front of front cab mount support andthree at rear of support. Align shims and mountingholes. Install cap screw.

IMPORTANT: Overtightening of nuts can causecab clevis to deform.

14. Tighten nuts until washers are snug and full threadengagement is attained.

15. Install lower cab shields.

16. Connect limb risers to cab.

T 1 3 1 3 9 8 B — U N — 2 1 J U N 0 0

C—Wooden Block


18. Install engine side shields.


Steering Column and Steering WheelRemove and Install

1. Remove fire extinguisher from bracket. Remove capscrews (1 and 3) and bracket (2).

1— Cap Screw (2 used)2— Bracket

3— Cap Screw

T 1 3 1 2 5 7 B — U N — 3 1 M A Y 0 0

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AC12469,00003A2 -19-14JUN07-4

AC12469,00003A3 -19-19JUL07-1

Continued on next page AC12469,00003A3 -19-19JUL07- 2

5. Disconnect horn wire connector (2).

6. Remove cap screws (1 and 4) and slide steeringcolumn with universal joint (3) up and off of steeringvalve.

7. Inspect and repair parts as necessary. See SteeringColumn and Steering Wheel Disassemble and Assemble. (Group 1800.)

8. Install cap screws (1—4).

9. Connect horn wire connector (2).

10. Install lower dash panel and cap screws.

11. Install windshield washer tank and cap screws.

12. Connect windshield washer pump hoses and electricalconnectors.

13. Install fire extinguisher bracket and cap screws. Installfire extinguisher.

1— Cap Screw (4 used)2— Horn Wire Connector

3— Universal Joint4— Cap Screw

T 1 3 1 2 6 0 B — U N — 3 1 M A Y 0 0

Steering Column and Steering WheelDisassemble and Assemble

1. Remove cap in center of steering wheel. Remove nut(1).

CAUTION: Spring behind steering wheel is under tension. Remove steering wheel with caution.

2. Install puller to steering wheel and slowly removewheel from steering column while holding downwardpressure on wheel to restrain spring tension.

1— Steering Wheel Nut

T 1 3 1 2 6 3 B — U N —

3 1 M A Y 0 0

3. Remove covers (2, 4, and 5), horn wiring lead (1) andknob (3).

1— Horn Wiring Lead

2— Cover 3— Knob

4— Cover

5— Cover

T 1 3 1 2 6 5 B — U N — 3 1 M A Y 0 0

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AC12469,00003A3 -19-19JUL07-3/3

4. Replace parts as necessary.

5. Connect horn wiring connector to cap (7).

6. Install cap.

1— Steering Column2— Disk3— Spring4— Cover

5— Steering Wheel6—Nut7—Cap

T 1 3 1 2 6 6 B — U N — 3 1 M A Y 0 0

TM11813 (13OCT10) 18-1800-12 748H Repair (S.N. 630436— )101310

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AC12469,00003A4 -19-10MAR09-1

Cab Tilt Hand Pump Remove and Install

IMPORTANT: For satisfactory operation of thecab tilt cylinder, it is essential that all air bebled from the system. Therefore, any timeair is induced into the system, the bleed

procedure MUST be performed.




If an accident occurs, see a doctor immediately.Any fluid injected into the skin must be surgicallyremoved within a few hours or gangrene

may result. Doctors unfamiliar with this typeof injury should reference a knowledgeablemedical source. Such information is availablefrom Deere & Company Medical Departmentin Moline, Illinois, U.S.A.

1. Shut engine off and lower equipment to the ground.Operate all hydraulic functions to relieve pressure.

2. Turn battery disconnect switch to OFF position.

3. Disconnect hose (2) and top hose (1). Close allopenings using caps and plugs.

4. Remove cap screws (3) and remove pump.

5. Replace or repair damaged parts. See Cab Tilt HandPump Disassemble and Assemble. (Group 1800.)

6. Install pump and cap screws. Tighten cap screws tospecification.

Specification

Hand Pump Mounting

Cap Screws—Torque............................................................22—26 N∙m

195—230 lb-in.

7. Connect hoses (1 and 2).

8. Fill hand pump oil reservoir. See Transmission, ParkBrake, Differential, Cab Tilt Hydraulic Pump and WinchOil. (Operator’s Manual.)

SpecificationCab Tilt Hand Pump

Reservoir—Capacity.................................................................... 574 mL

20 oz

X 9 8 1 1 — U N — 2 3 A U G 8 8

T 1 3 1 3 8 5 B — U N — 0 2 J U N 0 0

1— Head End Lift Hose2— Head End Retract Hose


9. Bleed cab tilt hand pump circuit to remove air fromsystem. See Cab Tilt Hand Pump Bleeding Procedure.(Group 1800.)

10. Check oil reservoir level.


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AC12469,00003A5 -19-14JUN07-1/1

Cab Tilt Hand Pump Disassemble andAssemble

IMPORTANT: For satisfactory operation of thecab tilt cylinder, it is essential that allair be bled from the system. Any time a

system component is changed the bleedprocedure MUST be performed.

1. Remove cab tilt hand pump. See Cab Tilt Hand PumpRemove and Install. (Group 1800.)

2. Remove four cap screws from pump reservoir anddrain oil from reservoir. Check O-ring (C) and replaceif damaged.

3. Remove plastic plug (A) from bottom of pump bodywith an O-ring pick.

4. Remove pump handle link (G).

5. Remove snap ring (B) from pump valve (F) and tap

assembly out of the valve body.

6. Inspect and replace damaged parts.

7. Apply clean hydraulic oil to pump valve (F) and installinto valve body.

8. Install snap ring (B) and plastic plug (A).

9. Install pump handle link (G) to pump valve (F).

10. Remove and clean suction screen (D).

11. Install O-ring (C) into reservoir O-ring groove andinstall reservoir to the valve body. Tighten cap screws.

Specification

Reservoir-to-Valve BodyCap Screws—Torque........................................................ 6.6—11.6 N∙m

48—84 lb-in.

12. Fill hand pump oil reservoir. See Transmission, ParkBr ake, Differential, Cab Tilt Hydraulic Pump and WinchOil. (Operator’s Manual.)

Specification

Cab Tilt Hand Pump

Reservoir—Capacity.................................................................... 574 mL

20 oz

T 8 5 1 3 A F — U N — 0 5 J U L 9 5

A—Plastic PlugB—Snap RingC—O-RingD—Suction Screen

E—Fill PlugF— Pump ValveG—Pump Handle Link

13. Oil fill plug (E) is vented; check to see if plug is clean.Install fill plug (E).

14. Install cab tilt hand pump. See Cab Tilt Hand PumpRemove and Install. (Group 1800.)

TM11813 (13OCT10) 18-1800-14 748H Repair (S.N. 630436— )101310

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Cab Tilt Hand Pump Bleeding Procedure

CAUTION: For satisfactory operation of the cabtilt cylinder, it is essential that all air be bled fromthe system. Any time a system component is

changed the bleed procedure MUST be performed.


1. Attach hoist and chains to cab and raise cab.

2. Support cab and remove cab lift cylinder pin and capscrew.

3. Position cylinder so that there is enough clearance toextend and retract cylinder.

4. Completely retract cylinder using pump.

A—Head End HoseB—Rod End Hose C—Lever T 1 1 5 1 3 3 B — U N — 2 9 A P R 9 8

T 1 1 5 1 3 2 B — U N — 2 9 A P R 9 8

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AC12469,00003A7 -19-14JUN07-1

Cab Tilt Cylinder Remove and Install





IMPORTANT: For satisfactory operation of cabtilt cylinder, it is essential that all air bebled from the system. Therefore, any timeair is induced into the system, the bleedprocedure MUST be performed.



2. Attach hoist and chains to cab for support and aid of removal and installation of cylinder pin and cap screw.

3. Remove cap screw and nut (1) from cab. Retractcylinder.

4. Remove cylinder pin (4) from engine frame.

5. Disconnect hydraulic lines (2 and 3). Close allopenings with caps and plugs.

6. Remove cylinder.

7. Install new cylinder.

8. Connect hydraulic lines (2 and 3).

9. Install cylinder.

IMPORTANT: Overtightening of cap screw and nut

can cause cab clevis to deform.

10. Bleed cab tilt hand pump circuit. See Cab Tilt HandPump Bleeding Procedure. (Group 1800.)

X 9 8 1 1 — U N — 2 3 A U G 8 8

T 1 3 1 3 8 7 B — U N — 0 2

J U N 0 0

T 1 3 1 3 8 6 B — U N

— 0 2 J U N 0 0

1— Cap Screw and Nut2— Head End Retract Hydraulic

Line

3— Head End Lift HydraulicLine

4— Pin

11. Extend cylinder to line up cylinder rod end with cabclevis. Install rubber bushings, washers, cap screwand nut (1). Make sure nut is fully threaded onto cap

screw. Do not overtighten cap screw.12. Remove cab support and lower cab.

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TM11813 (13OCT10) 18-1800-18 748H Repair (S.N. 630436— )101310

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Operator Enclosure

SW03989,0000AC8 -19-05OCT10-1/1

AC12469,00003B5 -19-23JUL07-1/3

Continued on next page AC12469,00003B 5 -19-23JUL07- 2/3

Window Cleaning Procedure

IMPORTANT: NEVER use abrasive or highly alkalinecleaners on polycarbonate windows.

NEVER use aromatic or halogenated solvents

like toluene, benzene, gasoline, acetone, or carbon tetrachloride on polycarbonate windows.Contact with harsh solvents can result insurface degradation and possible crazing.

IMPORTANT: If cracks or surface crazing areobserved, replace windshield.

Windows are important for the protection of the operator and the safe operation of the machine. Inspect windows

regularly. If surface crazing or cracks are observed,replace window using only John Deere replacement partsto ensure the original operator protection level. Inspect

the windows after any significant impact to the windowsor frame.

The windows are made of a polycarbonate material, whichis softer but stronger than glass. It will scratch.

For window cleaning information, see Inspect and CleanWindows. (Operator ’s Manual.)

Cab Door Remove and Install

1. Remove door limiting strap from mount on door bysliding strap up and pulling it out of notch.

1— Door Strap Mount

T X 1 0 2 5 1 2 8 A — U N — 2 0 J U N 0 7

2. Remove nuts retaining gas charged strut and removestrut from door.


3. Support weight of door.

2— Nut (2 used) 3— Gas Charged Strut

T X 1 0 2 5 1 3 0 A — U N — 2 1 J U N 0 7

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AC12469,00003B5 -19-23JUL07-3

Continued on next page AC12469,00003AA -19-23JUL07-1

4. Mark position of hinges on cab for ease of installation.

5. Remove hinges and remove door from cab.


7. Install door and door hinges. Check alignment toensure door is even all the way around opening.


Specification

Cab Hinge Mounting Cap

Screw—Torque..............................................................................73 N∙m

54 lb-ft

9. Install gas charged strut.

10. Install door travel limiting strap.

T X 1 0 2 5 1 3 1 A — U N — 2 1 J U N 0

7

4— Cap Screw (4 used per door)

Cab Door and Door Latch Disassemble andAssemble

NOTE: Lower latch mechanism does not need to beremoved to remove upper latch mechanism.

1. Remove inner door panel.


3. Remove clip (4) and disconnect linkage rod from door lock.

4. Remove door lock.

1— Door Lock2— Bracket (2 used)

3— Cap Screw (4 used)4— Clip

T X 1 0 2 5 0 6 5 A — U N — 2 0 J U N

0 7

Door Latch (lower)

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Operator Enclosure

AC12469,00003AB -19-10MAR09-2

AC12469,00003AB -19-10MAR09-3

Continued on next page AC12469,00003AC -19-30JUL07- 1

5. Have an assistant support wiper motor from insidecab.

Remove cap screw (5) and washer securing wiper motor frame to cab. Remove nut (4) and washer onwiper shaft (3).

3— Wiper Shaft4—Nut

5— Cap Screw

T X 1 0 2 5 7 4 1 A — U N — 2 9 J U N 0

7

6. Disconnect electrical connection (6).

7. Remove wiper motor (8) and wiper motor frame (7).


9. Have an assistant position wiper motor inside cab.

Install cap screw (5) and washer and nut (4) andwasher securing wiper motor to cab.

10. Connect electrical connection.

11. Install wiper arm and connect washer fluid hose.Tighten nut to specification.

Specification

Wiper Retaining

Nut-to-Pivot—Torque.............................................................14—21 N∙m

124—186 lb-in.

12. Install trim cover and sun visor.

13. Install trim caps over screws supporting trim cover.

14. Check windshield wiper position. See WindshieldWiper Adjustment. (Group 1810.)

T X 1 0 2 5 7 4 0 A — U N — 2 9 J U N 0 7

6— Electrical Connection7— Wiper Motor Frame

8— Wiper Motor

Rear Windshield Wiper Remove and Install

1. Remove switch panel in right rear of cab. Labelelectrical connections for assembly.

2. Remove trim caps (1) on screws securing trim panel(2) to cab.

3. Remove screws (3) and remove trim panel.

4. Note position of wiper arm and routing of washer fluidhose. Remove wiper arm and disconnect washer fluidhose.

1— Trim Cap2— Trim Panel

3— Screw (4 used)4— Plastic Washer

T X 1 0 2 5 7 4 2 A — U N — 2 9 J

U N 0 7

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AC12469,00003AC -19-30JUL07-2/3

AC12469,00003AC -19-30JUL07-3/3

5. Have an assistant support wiper motor from insidecab.

Remove cap screw (5) and washer securing wiper motor frame to cab. Remove nut (7) and washer onwiper shaft (6).

5— Cap Screw6— Wiper Shaft

7—Nut

T X 1 0 2 5 7 4 4 A — U N — 2 9 J U N 0

7

6. Disconnect electrical connection (9)

7. Remove wiper motor (10) and wiper motor frame (8).


9. Have an assistant position wiper motor inside cab.

Install cap screw (5) and washer and nut (7) andwasher securing wiper motor to cab.

10. Connect electrical connection.

11. Install wiper arm and connect washer fluid hose.Tighten nut to specification.

Specification

Wiper Retaining


124—186 lb-in.

12. Install trim panel.

13. Install switch panel and connect electrical connections.

14. Install trim caps over screws securing trim panel tocab.

15. Check windshield wiper position. See WindshieldWiper Adjustment. (Group 1810.)

T X 1 0 2 5 7 4 3 A —

U N — 2 9 J U N 0 7

8— Wiper Motor Frame9— Electrical Connection

10— Wiper Motor

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Operator Enclosure

AC12469,00003AD -19-10JUL07-1

AC12469,00003AD -19-10JUL07-2

Windshield Wiper Adjustment

CAUTION: Keep hands away from linkage whenthe motor is in operation. DO NOT adjust parkposition when the motor is in operation. Never

start a windshield wiper when the blade isfrozen to the windshield or manually stop theblade when the wiper is operating.

1. If the blade does not park with the tip 63.5 mm (2.50in.) (1) from the top edge of windshield, adjust thewiper blade.

Specification

Blade-to-Top Edge of

Windshield—Distance................................................................ 63.5 mm

2.5 in.

T 1 3 1 5 4 0 B — U N — 2 7 M A R

0 1

Headlight Shown Removed for Illustration Purposes

1— 63.5 mm (2.50 in.)Measurement

2. Lift wiper arm (3) away from windshield to fullextended position.

3. Lift pivot cover (1) and return wiper arm to windshield.

4. Remove retaining nut (2).

5. Pull wiper arm from pivot shaft. Position tospecification and tighten retaining nut just until snugagainst wiper arm.

6. Start wiper motor, shut off and note the new parkposition.

7. If blade tip still does not park the specified distancefrom top edge of windshield, check for bent wiper arm.

If wiper arm is not bent, repeat adjustment procedure.

8. Tighten retaining nut (2) to specification.

Specification

Wiper Retaining


124—186 lb-in.

T 1 3 1 5 4 2 B — U N — 0 9 J U N 0 0

Headlight Shown Removed for Illustration Purposes

1— Pivot Cover 2— Retaining Nut

3— Wiper Arm

9. Close pivot cover (1).

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Operator Enclosure

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Group 1821Seat and Seat Belt

AC12469,00003B2 -19-11JUL07-1

AC12469,00003B2 -19-11JUL07-2

Seat Remove and Install

1. Disconnect electrical connection for air suspension.

2. Remove cap screws (1) securing vent (2) under seat.

1— Cap Screw (2 used) 2— Vent

T X 1 0 2 5 1 6 5 A — U N — 2 1 J U

N 0 7

3. Lift floor mat (6) out of the way and remove vent fromunder seat.

4. Remove cap screws (5) securing seat bracket (4) to

cab floor.


5. Remove seat from cab.

Specification

Seat—Weight

(approximate).................................................................................. 71 kg

156 lb

6. Inspect and repair parts as necessary. See SeatDisassemble and Assemble. (Group 1821.)


7. Install seat in cab.

Specification

Seat—Weight

(approximate).................................................................................. 71 kg

156 lb

8. Install cap screws securing seat bracket to cab floor.

T X 1 0 2 5 1 6 6 A — U N — 2 1 J U N 0 7

3— Vent Inlet4— Seat Bracket

5— Cap Screw (4 used)6— Floor Mat

9. Install vent under seat. Align vent with vent inlet (3)before installing cap screws.

NOTE: Do not install mat on top of transmissioncalibration connections or air seat wiring.

10. Install floor mat.

11. Connect air seat wiring.

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Seat and Seat Belt

Continued on next page AC12469,00003B3 -19-19JUN07- 1/6

Seat Disassemble and Assemble

1. Remove seat from machine. See Seat Remove andInstall. (Group 1821.)

2. Determine which part of seat needs service. Seat canbe broken down into individual sections and servicedindependently.

TX1025108

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Seat and Seat Belt

Continued on next page AC12469,00003B3 -19-19JUN07- 2

1— Plate2— Wiring Harness3— Pivot Shaft4— Compressor

5— Limiting Strap6— Bearing7— Dampener 8— Air Seat Frame

9— Air Spring10— Air Hose11— Boot Hardware12— Boot

13— Plate

3. Disassemble and assemble air suspension. If air linesare disconnected, check all connections for leaks with

soapy water.

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Seat and Seat Belt

Continued on next page AC12469,00003B3 -19-19JUN07- 3/6

TX1025111

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17

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20

22

15

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21

23

28

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14— Plate15— Swivel Plate16— Slider

17— Ball (24 used)18— Spacer 19— Swivel Plate

20— Nut (5 used)21— Plate22— Washer (5 used)


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Seat and Seat Belt

AC12469,00003B3 -19-19JUN07-6

AC12469,00003B4 -19-18JUN07-1

5. Disassemble and assemble seat pads.

Seat Belt Remove and Install

T 1 1 4 9 2 4 — U N — 2 9 A P R 9 8

A—Cap Screw (2 used) B—Washer (4 used) C—Seat Belt Assembly

1. Remove covers to gain access to cap screws.Remove cap screws.


3. Install cap screw (A) with washers (B) through seatbelt and another washer (B) on right and left sides.

4. Tighten bolt until retractor is slightly snug, but retractor can still be rotated about ten degrees in either direction.

Specification

Seat Belt Cap

Screw—Torque.......................................... Until retractor is slightly snug,

retractor can rotate 10° either direction

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Group 1830Heating and Air Conditioning

SW03989,0000A7F -19-21SEP10-1

SW03989,0000A7F -19-21SEP10-2

R134a Refrigerant Cautions and Proper Handling

CAUTION: DO NOT allow liquid refrigerant tocontact eyes or skin. Liquid refrigerant willfreeze eyes or skin on contact. Wear goggles,

gloves, and protective clothing.

If liquid refrigerant contacts eyes or skin, DONOT rub the area. Splash large amounts of COOL water on affected area. Go to a physicianor hospital immediately for treatment.

DO NOT allow refrigerant to contact openflames or very hot surfaces such as electricwelding arc, electric heating element, andlighted smoking materials.

DO NOT heat refrigerant over 52°C (125°F) in aclosed container. Heated refrigerant will develophigh pressure which can burst the container.

Keep refrigerant containers away from heatsources. Store refrigerant in a cool place.

DO NOT handle damp refrigerant container with your bare hands. Skin may freeze tocontainer. Wear gloves.

If skin freezes to container, pour COOL water over container to free the skin. Go to a physicianor hospital immediately for treatment.

IMPORTANT: To meet government standards relatingto the use of refrigerants, R134a is used inthe air conditioning system. Because it does

not contain chlorine, R134a is not detrimentalto the ozone in the atmosphere. However,it is illegal to discharge any refrigerant intothe atmosphere. It must be recovered usingthe appropriate recovery stations.

Use correct refrigerant recovery/recycling andcharging stations. Never mix refrigerants,hoses, fittings, components, or refrigerant oils.

IMPORTANT: Use only John Deere approved R134arefrigerant products. Mixing of products notcompatible will cause system damage andcontaminate recovery/recycling and chargingstation equipment. Care must be taken to

identify and use equipment, refrigerant oil, andrefrigerant designed only for R134a refrigerantsystems. Refrigerant should be tested for type and purity before recovery, recycling, or charging of system. JT02167A refrigerant testinstrument should be used before any testingor repair to system is performed.

Prism Pro Refrigerant Identification Instrument.. JT02167ATo safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems.

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Heating and Air Conditioning

Continued on next page SW03989,0000A 80 -19-05OCT10- 1/2

Air Conditioning System Flush and Purge

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, andprotective clothing. See R134a Refrigerant

Cautions and Proper Handling. (Group 1830.)

NOTE: Flushing can be performed on machine.

1. Follow refrigerant cautions and proper handlingprocedures. See R134a Refrigerant Cautions andProper Handling. (Group 1830.)

2. Recover refrigerant. See R134a Refrigerant Recovery.(Group 1830.)

3. Add TY25601 ACCFlushII to system with JT02075 Air Conditioning Flusher and JT02098 Air ConditioningFitting Kit.

4. Remove and discard receiver-dryer. See

Receiver-Dryer Remove and Install. (Group 1830.)

5. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

6. Fill flusher tank with 4 L (1 gal) of solvent and fastenall connections.

Specification

A/C Flusher

Tank—Capacity................................................................................... 4 L

1 gal

NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging.

Specification

A/C Flusher Tank

Minimum Air Pressure

for Flushing and

Purging—Pressure......................................................................620 kPa

6.2 bar

90 psi

7. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve.

8. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system isheavily contaminated with burned oil or metal particles.

9. Clean compressor as follows:

a. Remove compressor and measure oil drained fromboth manifold ports.

b. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

c. Pour 240 mL (8 fl oz.) of flushing solvent intosuction port and 120 mL (4 fl oz.) into dischargeport. Plug both ports in compressor manifold, usingJT02099 Adapter and JT03194 Caps.

Specification

Flushing Solvent in

Suction Port—Volume.................................................................. 240 mL

8 fl oz.Flushing Solvent

in Discharge

Port—Volume............................................................................... 120 mL

4 fl oz.

d. Turn compressor end for end and roll it side to side.

e. Remove both plugs from manifold ports and drainsolvent from compressor.

f. Connect battery power to compressor clutch coil.Rotate pulley at least 5 revolutions to move solventout of cylinders.

g. Invert compressor. Roll end for end and side to

side. Drain thoroughly.h. Repeat previous two steps at least three times.

10. Divide system into two circuits:

• Condenser circuit, including inlet and outlet hoses.

• Evaporator circuit, including inlet and outlet hoses.

IMPORTANT: DO NOT attempt to flush throughcompressor or receiver-dryer. Flushing throughexpansion valve is acceptable if refrigerant oilhas a normal odor and appearance.

11. Flush and purge condenser:

a. Remove and discard receiver-dryer.

b. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

c. Fill flusher tank with 4 L (1 gal) of solvent and fastenall connections.

Specification

A/C Flusher

Tank—Capacity................................................................................... 4 L

1 gal


Specification

A/C Flusher Tank

Minimum Pressure

Air Pressure When

Flushing—Pressure.....................................................................620 kPa

6.2 bar

90 psi

d. Connect a supply line of moisture-free compressedair or dry nitrogen to flusher air valve.

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SW03989,0000A80 -19-05OCT10-2

e. Open air valve to force flushing solvent intocondenser circuit. Flusher tank is empty whenhose pulsing stops. Additional flushing cycles arerequired if system is heavily contaminated withburned oil or metal particles.

f. Attach a return hose and aerator nozzle to end of receiver dryer inlet hose using JT03197 Adapter.Put nozzle in container to collect flushing solvent.

NOTE: Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent.

g. Disconnect hose from aeration nozzle to checkcircuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry.

12. See flush evaporator if evaporator requires flushing.

If system is contaminated with burned refrigerant oilor debris, remove and bench flush evaporator. Seefollowing steps to flush evaporator through expansionvalve, if oil appears normal.

13. Flush evaporator:

a. Remove evaporator. See Evaporator Remove andInstall. (Group 1830.)

b. Force flushing solvent through evaporator inlet withcompressed air.

c. Purge system until dry.

d. Install evaporator and then go to step 14.

14. Flush evaporator through expansion valve:

a. Connect flusher outlet hose to connection of

receiver-dryer outlet hose using JT03188 Adapter.

b. Fill flusher tank with 4 L (1 gal) of solvent and fastenall connections.

Specification

A/C Flusher

Tank—Capacity................................................................................... 4 L

1 gal


Specification

A/C Flusher Tank

Minimum Pressure

Air Pressure When

Flushing—Pressure.....................................................................620 kPa

6.2 bar

90 psi

c. Connect a supply line of moisture-free compressedair or dry nitrogen to flusher air valve.

d. Attach a hose and aerator nozzle to compressor inlet line using JT02101 Adapter. Put nozzle in acontainer to collect solvent.

NOTE: Purging evaporator circuit takes 12—15 minutesto thoroughly remove solvent.

15. Disconnect hose from aeration nozzle to check circuitfor solvent. Hold hose close to a piece of cardboardand continue purging until cardboard is dry.

16. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

17. Add required oil. See R134a Refrigerant OilInformation in this group.

18. Install compressor and connect refrigerant linesto compressor manifold. See Air Conditioner Compressor Remove and Install. (Group 1830.)

19. Evacuate air conditioning system. See R134a SystemEvacuate. (Group 1830.)

20.Charge air conditioning system. See R134a SystemCharge. (Group 1830.)

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R134a Refrigerant Oil Information

CAUTION: All new compressors are chargedwith a mixture of nitrogen, R134a refrigerant,and TY22101 (R134a) refrigerant oil. Wear

safety goggles and discharge the compressor slowly to avoid possible injury.

CAUTION: DO NOT leave system or R134acompressor oil containers open. Refrigerant oileasily absorbs moisture. DO NOT spill R134acompressor oil on acrylic or ABS plastic. This oilwill deteriorate these materials rapidly. IdentifyR134a oil containers and measures to eliminateaccidental mixing of different oils.

IMPORTANT: Do not add any more oil than requiredor maximum cooling will be reduced.

A new compressor from parts depot contains 220—240mL (7.0—8.4 fl. oz.) of new oil. Oil level visible throughsuction port normally is below drive shaft.

Normal operating oil level of a compressor removed fromoperation is 30—45 mL (1.0—1.5 fl oz.). This level cannotbe seen through suction port of compressor.

Compressors can be divided into three categories whendetermining correct oil charge for system.

• New compressor from parts depot

• Used compressor removed from operation

• Compressor internally washed with flushing solvent

Determining the amount of system oil charge prior to

installation of compressor on a machine.

1. When complete system, lines, and components areflushed, add correct amount of oil as described.

• New or remanufactured compressor (systemrequires an additional amount of new oil)

Specification

New Compressor—Vol-

ume.....................................................................................210—250 mL

7.0—8.4 fl oz.

Air Conditioning System

Additional Oil— Volume................................................................ 182 mL

4.0 fl oz.

Compressor Operating

Oil Level—Volume...................................................................30—45 mL1.0—1.5 fl oz.

• Used compressor removed from operation, oildrained, and system flushed

Specification

Used Compressor

and System Flushed

Oil—Volume........................................................................391—479 mL

13.2—16.2 fl oz.

2. When complete system was not flushed add correctamount of oil for compressor plus amount of oil for each component that was serviced.

• New compressor or remanufactured

Specification

New Compressor

Operating Oil

Level—Volume (drain

and return)...................................................................................... 45 mL

1.5 fl oz.

• Used compressor removed from operation and oildrained.

Specification

Used Compressor

Drained Oil—Volume...................................................................... 45 mL

1.5 fl oz.

• Used compressor removed from operation

Specification

Used Compressor

Flushed Oil—Volume...................................................................... 60 mL

2.0 fl oz.

• Components listed below which have been removed,drained, and flushed, require removal of compressor to determine correct oil charge. Use following chartas a guide for adding oil to components:

Specification

Evaporator Oil—Volume............................................................... 130 mL

4.4 fl oz.

Condenser Oil—Volume................................................................. 65 mL

2.2 fl oz.

Receiver Dryer

Oil—Volume................................................................................... 30 mL

1.0 fl oz.

Flushed Compressor

Oil—Volume................................................................................... 60 mL

2.0 fl oz.

Hose Oil—Volume

(approximate total

length)............................................................................. 3 mL per 30 cm

0.1 fl oz. per ft

NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz. per ft) Approximate total length equals 600 cm (20 ft).

• If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3mL per 30 cm (0.1 fl oz. per ft) to determine correctamount of oil to be added.

• Drain compressor oil into graduated container whilerotating compressor shaft and record amount.

3. If oil drained from a compressor removed fromoperation is very black or amount of oil is less than6 mL (0.2 fl oz.), perform the following and discardoil properly:

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SW03989,0000A81 -19-10SEP10-2

SW03989,0000A82 -19-04OCT10-1

• Determine if R134a leakage was detected, removecomponent, and repair or replace component.

• Remove and discard receiver-dryer.

• Flush complete system with TY25601 Air Conditioning Flushing Solvent.

4. If component is serviceable, pour flushing solvent inports and internally wash out old oil and discard oilproperly.

5. Install a new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

6. Install required amount of TY22101 Refrigerant Oilin compressor.

7. Connect all components.

8. Evacuate and charge system. See R134a System

Evacuate and R134a System Charge. (Group 1830.)

R134a Refrigerant Recovery/Recycling andCharging Station Installation Procedure

CAUTION: Liquid refrigerant will freeze eyesor skin on contact. Wear goggles, gloves and

protective clothing. See R134a RefrigerantCautions and Proper Handling. (Group 1830.)

IMPORTANT: Use only John Deere approved R134arefrigerant products. Mixing of products notcompatible will cause system damage andcontaminate recovery/recycling and chargingstation equipment. Care must be taken toidentify and use equipment, refrigerant oil, andrefrigerant designed only for R134a refrigerantsystems. Refrigerant should be tested for typeand purity before recovery/recycling or chargingof system. JT02167A Prism Pro RefrigerantIdentification Instrument should be used beforeany testing or repair to system is performed.

IMPORTANT: Use only John Deere approvedrefrigerant recovery/recycling and chargingstations. DO NOT mix refrigerant, hoses,fittings, components, or refrigerant oils.

CAUTION: Do not remove high pressure relief valve (4). Air conditioning station will dischargerapidly causing possible injury.


2. Close both high-side and low-side valves on refrigerantrecovery/recycling and charging station (5).

3. Remove cap from low pressure charge portand connect blue hose (3) from refrigerantrecovery/recycling and charging station.

T X 1 0 8 0 0 9 3 — U N — 2 2

J U L 1 0

Refrigerant Recovery/Recycling and Charging Station Installation

1—Cap2— Red Hose3— Blue Hose

4— High Pressure Relief Valve5— Refrigerant Recovery/Recy-

cling and Charging Station

4. Remove cap (1) from high pressure charge port and

connect red hose (2).

5. Follow the manufacturer’s instructions when using therefrigerant recovery/recycling and charging station.

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SW03989,0000A83 -19-10SEP10-1/1

SW03989,0000A84 -19-10SEP10-1/1

R134a Refrigerant Recovery

CAUTION: Liquid refrigerant will freeze eyesor skin on contact. Wear goggles, gloves,and protective clothing.

Do not remove high pressure relief valve. Air conditioning system will discharge rapidlycausing possible injury.

IMPORTANT: Use correct refrigerant recovery/re-cycling and charging stations. Do not mixrefrigerant, hoses, fittings, components, or refrigerant oils. Damage to air conditioningsystem components may occur.


2. Run air conditioning system for 3 minutes to help inrecovery process. Turn air conditioning system off before proceeding with recovery steps.

3. With engine OFF, identify refrigerant type usingJT02167A Refrigerant Identification Instrument.

4. Connect refrigerant recovery system. See R134aRefrigerant Recovery/Recycling and Charging StationInstallation Procedure. (Group 1830.)

5. Follow manufacturer’s instructions when using therefrigerant recovery/recycling and charging station.

R134a System Evacuate


Do not remove high pressure relief valve. Air conditioning system will discharge rapidlycausing possible injury.


2. Connect refrigerant recovery system. See R134aRefrigerant Recovery/Recycling and Charging Station

Installation Procedure. (Group 1830.)

3. Open low-side and high-side valves on refrigerantrecovery/recycling and charging station.

4. Follow charging station manufacturers’ instructionsto evacuate system.

NOTE: Vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg)from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

5. Evacuate system until low-side gauge vacuum readingis to specification.

SpecificationEvacuate

System—Vacuum..........................................................................98 kPa

980 mbar

29 in. Hg

Value to Subtract for

Elevation Above Sea

Level—Vacuum.....................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

If the specified vacuum r eading cannot be obtainedin 15 minutes, check the system for leaks. SeeRefrigerant Leak Test. (Group 9031-25.)

6. When vacuum reaches above specification, closelow-side and high-side valves. Turn vacuum pump off.

7. If vacuum decreases more than specification in 5minutes, there is a leak in system.

Specification

Evacuate

System—Vacuum.........................................................................3.4 kPa

34 mbar

1 in. Hg

8. Repair the leak.

9. Evacuate system for 30 minutes after 98 kPa (980mbar) (29 in. Hg) vacuum is reached.

Specification

Evacuation

Procedure—Time....................................................................30 minutes

10. Close low-side and high-side valves. Stop evacuation.


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SW03989,0000A85 -19-04OCT10-1

SW03989,0000A86 -19-21SEP10-1

R134a System Charge


IMPORTANT: Use only John Deere approvedrefrigerant recovery/recycling and chargingstations. DO NOT mix refrigerant, hoses,fittings, components, or refrigerant oils.Damage to seals may occur resulting in air conditioning system leaks.

1. Follow r efrigerant cautions and proper handlingprocedures. See R134a Refrigerant Cautions andProper Handling. (Group 1830.)

2. Identify refrigerant type using JT02167A Prism ProRefrigerant Identification Instrument.

3. Connect R134a Refrigerant Recovery/Recyclingand Charging Station. See R134a RefrigerantRecovery/Recycling and Charging Station InstallationProcedure. (Group 1830.)

4. Evacuate system. See R134a System Evacuate.(Group 1830.)

NOTE: Before beginning to charge air conditioning system, the following conditions must exist: EngineSTOPPED, pump must be capable of pulling at least

28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg)for each 300 m (1000 ft) elevation above sea level.

Specification

Evacuate

System—Vacuum..................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. Follow manufacturer’s instructions and charge system.

6. Add refrigerant to system.

Specification

Air Conditioning System

Refrigerant—RefrigerantQuantity........................................................................................ 3.17 kg

7.00 lb

7. Check air conditioning for proper function. SeeComplete Machine Operational Checkout. (Group9005-10.)

Compressor Relief Valve Remove and Install

CAUTION: DO NOT allow liquid refrigerant tocontact eyes or skin. DO NOT spill R134acompressor oil on acrylic or ABS plastic. High

pressure may exist at the discharge fitting. If thispressure is released too rapidly, there may beconsiderable discharge of refrigerant and oil.

1. Remove front left engine shield.


3. Slowly remove relief valve (1) from air conditioner compressor manifold (2).

NOTE: The relief valve is not serviceable. Replacevalve as required.


5. Install relief valve and tighten to specification.

Specification

Relief Valve—Torque.............................................................12—16 N∙m

103—142 lb-in.

T X 1 0 2 4 2 3 5 A — U N — 2 9 M A Y

0 7

Relief Valve

1— Relief Valve 2— Air Conditioner Compressor Manifold


7. Install engine side shield.

TM11813 (13OCT10) 18-1830-7 748H Repair (S.N. 630436—10

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SW03989,0000A88 -19-05OCT10-1/1

Air Conditioner Compressor Remove andInstall


2. Locate air conditioner compressor at front left sideof engine. Remove left-side engine shields. SeeOpening Engine Side Shields. (Operator’s Manual.)

3. Remove left fan guard. See Fan Shroud Remove andInstall. (Group 0510.)

4. Recover air conditioner r efrigerant. See R134aRefrigerant Recovery. (Group 1830.)


6. Disconnect air conditioner refrigerant hoses (5 and6) at compressor. Close all openings using caps andplugs.

7. Disconnect electrical connector and ground wire (7and 8).

8. Remove cap screws (3) and air conditioner compressor (4).


10. Install air conditioner compressor.

11. Add compressor oil. See R134a Refrigerant OilInformation. (Group 1830.)

12. Install serpentine belt. See Serpentine Belt Removeand Install. (Group 0510.)

13. Connect electrical connector and ground wire.


14. Connect air conditioner refrigerant hoses atcompressor. Tighten hoses to specification.

Specification

Suction Hose-to-

Compressor—Torque............................................................ 24—28 N∙m

212—248 lb-in.

T X 1 0 2 4 2 1 0 A — U N — 2 9 M A

Y 0 7

Air Conditioner Compressor

3— Cap Screw (3 used)4— Air Conditioner

Compressor 5— Air Conditioner Refrigerant

Suction Hose

6— Air Conditioner RefrigerantPressure Hose toCondenser

7— Electrical Connector 8— Ground Wire

Pressure Hose-to-

Condenser—Torque..............................................................20—27 N∙m

177—239 lb-in.

15. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

16. Evacuate and charge the air conditioning system.See R134a System Evacuate and see R134a SystemCharge. (Group 1830.)

17. Install left fan guard. See Fan Shroud Remove andInstall. (Group 0510.)

18. Install left-side engine shields. See Opening EngineSide Shields. (Operator’s Manual.)

19. Before returning machine to service, check operationof air conditioning system. See Complete MachineOperational Checkout. (Group 9005.)

TM11813 (13OCT10) 18-1830-8 748H Repair (S.N. 630436— )101310

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SW03989,0000A8A -19-05OCT10-1

Continued on next page SW03989,0000A8B -19-10SEP10-1

Air Conditioner Compressor ManifoldRemove and Install

1. Remove left-side engine shields. Locate air conditioner compressor at front left side of engine.

2. Recover air conditioning refrigerant. See R134aRefrigerant Recovery. (Group 1830.)

3. Remove cap screws (2) and the manifold (1).

4. Remove and discard manifold seal (3).

5. Inspect surfaces.

6. Lubricate and install a new seal.

7. Install manifold and tighten cap screws to specification.

Specification


230 lb-in.


9. Install left fan guard. See Fan Shroud Remove andInstall. (Group 0510.)

10. Install left-side engine shields.

11. Before returning machine to service, check operationof air conditioning system. See Complete MachineOperational Checkout. (Group 9005.)

T X

1 0 8 1 7 6 7 A — U N — 1 0 S E P 1 0

Compressor Manifold

1— Cap Screw2— Manifold

3— Manifold Seal

Air Conditioner Condenser Remove and

Install1. Open grille. See Opening the Grille. (Operator’s

Manual.)


3. Recover air conditioner refrigerant. See R134aRefrigerant Recovery. (Group 1830.)

4. Remove nuts (1) and swing open air conditioner condenser.

1— N ut (2 used) 2— A ir Conditioner Condenser

T X 1 0 2 4 6 6 2 A — U N — 0 6 J U N 0 7


TM11813 (13OCT10) 18-1830-11 748H Repair (S.N. 630436—10

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SW03989,0000A8B -19-10SEP10-2/2

5. Disconnect air conditioner refrigerant hose fittings (3).Close all openings using caps and plugs.

6. Remove nuts (4) and air conditioner condenser (2).


8. Install air conditioner condenser and tighten nuts tospecification.

Specification

Air Conditioner

Condenser

Nuts—Torque................................................................................73 N∙m

54 lb-ft


9. Connect air conditioner refrigerant hoses. Tightenhose fittings to specification.

Specification

Air Conditioner

Condenser Inlet Hose

Fitting (upper)—Torque.................................................................24 N∙m

212 lb-in.

Air Conditioner

Condenser Outlet Hose

Fitting (lower)—Torque..................................................................17 N∙m

150 lb-in.

T X 1 0 2 4 6 6 1 A — U N — 0 6 J U N 0

7


2— Air Conditioner Condenser 3— Air Conditioner Refrigerant

Hose Fitting (2 used)

4— Nut (4 used)

10. Swing close air conditioner condenser and securewith nuts.


TM11813 (13OCT10) 18-1830-12 748H Repair (S.N. 630436— )101310

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SW03989,0000A8E -19-10SEP10-1

Blower Motor Remove and Install

1. Remove cap screws (3) and HVAC compartmentcover (1).

2. Disconnect wiring harness from blower motor

connector (6) and blower resistor (7).3. Remove cap screws (5) from HVAC fuse and relay

panel (4).

4. Disconnect cooling hose (9) from blower motor (10).

5. Remove cap screws (8) and blower motor.

6. Inspect and repair as necessary.

7. Install blower motor and cap screws.

8. Connect cooling hose to blower motor.

9. Connect wiring harness to blower resistor and blower motor connector.

10. Install HVAC fuse and relay panel.

11. Close and secure HVAC compartment cover.

1— HVAC Compartment Cover 2— Precleaner Compartment

Cover 3— Cap Screw (6 used)4— HVAC Fuse and Relay Panel5— Cap Screw (2 used)

6— Blower Motor Connector 7— Blower Resistor 8— Cap Screw (4 used)9— Cooling Hose10— Blower Motor

T X 1 0 8 0 2 1 2 A — U N — 2 8 J U L 1 0

HVAC and Precleaner Compartment Covers

T X 1 0 8 0 2 2 7 A — U N — 2 8 J U L 1 0

Heating and Air Conditioning Blower Motor

TM11813 (13OCT10) 18-1830-13 748H Repair (S.N. 630436—10

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SW03989,0000A94 -19-10SEP10-1/1

Precleaner Blower Assembly Remove andInstall

1. Remove cap screws (3) and open precleaner compartment cover (2).

2. Release hold-downs (4) and remove precleaner cover (5).

3. Disconnect wiring harness from precleaner blower motor connector (6).

4. Remove cap screws (8) and precleaner blower motor (7).


6. Install precleaner blower motor.

7. Connect wiring harness to precleaner blower motor connector.

8. Install precleaner cover and secure with hold-downs.

9. Close and secure precleaner compartment cover.


Cover 3— Cap Screw (6 used)4— Hold-Down (2 used)

5— Precleaner Cover 6— Precleaner Blower Motor

Connector 7— Precleaner Blower Motor 8— Cap Screw (4 used)

T X 1 0 8 0 2 1 2 A — U N — 2 8 J U L 1 0


T X 1 0 8 0 2 3 2 A — U N — 2 8 J U L 1 0

Precleaner Blower Assembly

TM11813 (13OCT10) 18-1830-14 748H Repair (S.N. 630436— )101310

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SW03989,0000A87 -19-10SEP10-1

Refrigerant High/Low Pressure Switch Remove and Install


NOTE: It is not necessary to recover refrigerant

from the system. A valve prevents thesystem from discharging when high/low pressure switch is removed.

2. Disconnect wiring harness from wire connector (5).

IMPORTANT: Remove pressure switch using a wrenchon hex nut fitting. Damage to switch will occur if removed by plastic switch housing.

3. Remove high/low pressure switch (4) using a wrenchon hex nut fitting.

4. Test switch and replace if necessary. See Air Conditioning High/Low Pressure Switch Test. (Group

9031-25.)5. Install high/low pressure switch.

6. Connect wiring harness to wire connector.

7. Close and secure HVAC compartment cover.


Cover 3— Cap Screw (6 used)

4— High/Low Pressure Switch5— Wire Connector

T X 1 0 8 0 2 1 2 A — U N — 2 8 J U L 1 0


T X 1 0 8 0 2 1 7 A — U N — 2 8 J U L 1 0

High/Low Pressure Switch

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SW03989,0000A90 -19-10SEP10-1/1

Coolant Valve Remove and Install

CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns. Coolant may be hot. Wait until radiator iscool to the touch before draining radiator.

1. Drain the coolant system. Perform Draining theCooling System. (Operator’s Manual.)


3. Disconnect wire harness connector (5).

4. Move clamps (6) and disconnect coolant hoses.

5. Remove cap screws (7) and coolant valve (4).

NOTE: The coolant valve is serviced as an assembly.


7. Install coolant valve with cap screws.

8. Connect coolant hoses and secure with clamps.

9. Connect wire harness connector.

10. Close HVAC compar tment cover.

11. Fill coolant system. Perform Filling the CoolingSystem. (Operator ’s Manual.)


Cover 3— Cap Screw (6 used)4— Coolant Valve

5— Wire Harness Connector 6— Clamp (2 used)7— Cap Screw (2 used)

T X 1 0 8 0 2 1 2 A — U N — 2 8 J U L 1 0


T X 1 0 8 0 2 3 8 A — U N — 2 8 J U L 1 0

Coolant Valve

TM11813 (13OCT10) 18-1830-16 748H Repair (S.N. 630436— )101310

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SW03989,0000A93 -19-10SEP10-1

Freeze Control Switch Remove and Install

1. Remove cap screws (3) to remove HVAC compartmentcover (1) and open precleaner compartment cover (2).

2. Release hold-downs and remove precleaner cover

and air filter. See Precleaner Blower AssemblyRemove and Install. (Group 1830.)

3. Remove freeze control switch thermocouple (5) fromevaporator (4).

4. Disconnect electrical connectors (6) from freezecontrol switch (7).

5. Remove freeze control switch by guiding freeze controlswitch thermocouple (5) back through bulkheadgrommet (9).


7. Insert freeze control switch thermocouple throughbulkhead grommet.

8. Install freeze control switch.

9. Connect electrical connectors.

10. Install freeze control switch thermocouple toevaporator.

11. Install air filter and precleaner cover using hold-downs.

12. Close HVAC compartment and precleaner compartment covers.


Cover 3— Cap Screw (6 used)

4— Evaporator 5— Freeze Control Switch

Thermocouple

6— Electrical Connector (2used)

7— Freeze Control Switch8— Pan Head Screw (2 used)

9— Bulkhead Grommet

T X 1 0 8 0 2 1 2 A — U N — 2 8 J U L 1 0


T X 1 0 8 0 2 4 2 A — U N — 2 9 J U L 1 0

Freeze Control Switch Thermocoupler

T X 1 0 2 4 6 5 2 A — U N — 0 6 J U N 0

7

Freeze Control Switch

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SW03989,0000A8D -19-10SEP10-1/1

Expansion Valve Remove and Install

1. Recover refrigerant from the air conditioning system.See R134a Refrigerant Recovery. (Group 1830.)

2. Remove HVAC compartment cover (1).

3. Disconnect refrigerant line fittings (4).

4. Remove cap screw (5) and flange (6) to disconnectrefrigerant lines (7) from expansion valve.

5. Remove cap screws (8) to flange of evaporator.Remove expansion valve (9).



7. Replace O-rings. Install expansion valve to evaporator using flange and cap screws.

8. Install refrigerant lines and flange to expansion valve.9. Close HVAC compartment cover.



Cover 3— Cap Screw (6 used)4— Line Fitting (2 used)5— Cap Screw

6— Flange7— Refrigerant Line (2 used)8— Cap Screw (2 used)9— Expansion Valve

T X 1 0 8 0 2 1 2 A — U N — 2 8 J U L 1 0


T X 1 0 8 0 2 6 5 A — U N — 2 9 J U L 1 0

Refrigerant Lines and Flange

T X 1 0 8 0 2 6 6 A — U N — 2 9 J U L 1 0

Expansion Valve

TM11813 (13OCT10) 18-1830-18 748H Repair (S.N. 630436— )101310

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SW03989,0000A8C -19-10SEP10-1/1

Evaporator Remove and Install

1. Recover refrigerant from air conditioning system. SeeR134a Refrigerant Recovery. (Group 1830.)

2. Remove blower motor. See Blower Motor Remove

and Install. (Group 1830.)3. Remove precleaner cover and filter. See Precleaner

Blower Assembly Remove and Install. (Group 1830.)

4. Remove coolant valve. See Coolant Valve Removeand Install. (Group 1830.)

5. Remove heater core. See Heater Core Remove andInstall. (Group 1830.)

6. Remove freeze control switch. See Freeze ControlSwitch Remove and Install. (Group 1830.)


8. Remove evaporator (2).


10. Install evaporator.

11. Install freeze control switch. See Freeze ControlSwitch Remove and Install. (Group 1830.)

12. Install heater core. See Heater Core Remove andInstall. (Group 1830.)

13. Install coolant valve. See Coolant Valve Remove andInstall. (Group 1830.)

T X 1 0 2 4 5 9 5 A — U N — 0 5 J U

N 0 7

Evaporator

1— Cap Screw (2 used) 2— Evaporator

14. Install precleaner cover and filter. See Precleaner Blower Assembly Remove and Install. (Group 1830.)

15. Install blower motor. See Blower Motor Remove andInstall. (Group 1830.)


TM11813 (13OCT10) 18-1830-20 748H Repair (S.N. 630436— )101310

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SW03989,0000A91 -19-01OCT10-1

Receiver-Dryer Remove and Install


2. Follow refrigerant cautions and proper handling

procedures. See R134a Refrigerant Cautions andProper Handling. (Group 1830.)


4. Open precleaner compartment. See Precleaner Blower Assembly Remove and Install. (Group 1830.)

5. Disconnect refrigerant lines (1 and 2). Close allopenings using caps and plugs.

6. Loosen clamp cap screws (4) and removereceiver-dryer (3).

IMPORTANT: A new receiver-dryer must always beinstalled after purging system. DO NOT use a

flushed or used receiver-dryer. Contaminationof system can cause component failure.

7. Before installing new receiver-dryer, add refrigerant oil.See R134a Refrigerant Oil Information. (Group 1830.)

Specification

Refrigerant

Oil—Quantity.................................................................................. 15 mL

0.5 fl oz

8. Install new receiver-dryer and tighten clamp capscrews.

T X 1 0 2 4 5 4 2 A — U N — 0 5 J U

N 0 7

Receiver-Dryer

1— Refrigerant Line FromCondenser

2— Refrigerant Line toExpansion Valve

3— Receiver-Dryer 4— Clamp Cap Screw (2 used)


9. Lubricate new O-rings with refrigerant oil. Removeplugs from receiver-dryer and immediately connectrefrigerant lines.

10. Evacuate and charge the system. See R134a SystemEvacuate and see R134a System Charge. (Group1830.)

TM11813 (13OCT10) 18-1830-21 748H Repair (S.N. 630436—10

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TM11813 (13OCT10) 18-1830-22 748H Repair (S.N. 630436— )101310

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Section 19Sheet Metal and Styling

Contents

Page

Group 1910—Hood or Engine EnclosureHood Remove and Install ..........................19-1910-1Grille Guard Remove and Install ............... 19-1910-3Grille Housing Remove and

Install ..................................................... 19-1910-5

TM11813 (13OCT10) 19-1 748H Repair (S.N. 630436—10

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Contents

TM11813 (13OCT10) 19-2 748H Repair (S.N. 630436— )101310

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Group 1910Hood or Engine Enclosure

MH66088,0000D7C -19-19AUG10-1

MH66088,0000D7C -19-19AUG10-2

Continued on next page MH66088,0000D7C -19-19AUG10- 3

Hood Remove and Install



See Battery Disconnect. (Operator’s Manual.)3. Remove engine compartment side shields. See

Opening Engine Side Shields. (Operator’s Manual.)

4. Remove muffler-to-turbocharger flex pipe clamp (1).


5. Remove left limb riser with muffler attached. Closeturbocharger opening using an appropriate cap or plug.

Specification

Left Limb Riser

with Muffler—Weight(approximate).................................................................................. 50 kg

110 lb

T X 1 0 8 0 2 8 1 A — U N — 2 9 J U

L 1 0

Muffler-to-Turbocharger Flex Pipe Clamp

1— Muffler-to-Turbocharger Flex Pipe Clamp

6. Remove right side hood panel.

7. Remove cap screws (2) securing hydraulic oil returnfilter housing (3) to hood (4) and secure to the side.Hoses remain connected to filter.

8. Remove hydraulic oil return filter electrical harnessclamps from underside of hood.

2— Cap Screw (4 used)3— Hydraulic Oil Return Filter

Housing

4— Hood

T X 1 0 8 0 3 0 3 A — U N — 2 9 J U L 1 0

Hydraulic Oil Return Filter

9. Remove cap screws (5) securing hydraulic fan returnfilter housing to hood and secure to the side. Hosesremain connected to filter.

10. Disconnect air cleaner assembly from hood. See Air Cleaner Remove and Install. (Group 0520.)

NOTE: Draining coolant from surge tank is not necessary for hood removal and installation.

11. Disconnect surge tank from hood, leaving all hosesattached. Secure to the side.

5— Cap Screw (2 used) T X 1 0 8 0 3 0 4 A — U N — 2 9 J U L 1 0

Hydraulic Fan Return Filter Cap Screws

TM11813 (13OCT10) 19-1910-1 748H Repair (S.N. 630436—10

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Hood or Engine Enclosure

MH66088,0000D7C -19-19AUG10-4/4

12. Install JT01748 Lifting Brackets (6) and lifting deviceas shown.

13. Loosen J-bolts (7) and remove hood retaining capscrews (8).

NOTE: Make sure hydraulic reservoir filler cap isinstalled after removal or installation of hood to prevent contamination of hydraulic oil.

14. Remove hydraulic tank filler cap.


15. Attach appropriate lifting device to lifting brackets.Remove hood.

Specification

Hood—Weight

(approximate).................................................................................. 57 kg

125 lb



17. Set hood in place.

Specification

Hood—Weight

(approximate).................................................................................. 57 kg

125 lb

18. Align hood and install hood retaining cap screws.

19. Install hydraulic tank filler cap.

20. Remove lifting device and JT01748 Lifting Brackets.

21. Install and tighten J-bolts.

22. Install surge tank.

23. Install air filter assembly. See Air Cleaner Removeand Install. (Group 0520.)

T X 1 0 8 0 3 0 8 A — U N — 2 9 J U L 1

0

JT01748 Lifting Brackets

6— JT01748 Lifting Bracket7— J-bolt (2 used)

8— Hood Retaining Cap Screw(4 used)

24. Install hydraulic fan return filter housing.25. Install hydraulic oil return filter.

26. Install hydraulic oil return filter electrical harnessclamps to underside of hood.

27. Install right hood panel.


28. Install left limb riser with muffler.

Specification

Left Limb Riser

with Muffler—Weight(approximate).................................................................................. 50 kg

110 lb

29. Install muffler-to-turbocharger flex pipe clamp.

30. Turn battery disconnect to the ON position.

31. Install engine compartment side shields. See OpeningEngine Side Shields. (Operator’s Manual.)

TM11813 (13OCT10) 19-1910-2 748H Repair (S.N. 630436— )101310

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MH66088,0000D90 -19-14SEP10-1


Grille Guard Remove and Install

NOTE: The following procedure is for both standard grille guard and high debris g rille guard removal and installation.



3. Remove cap screws (1) and washers (2). Open grilleguard.

1—Cap Screw (2 used) 2—Washer (2 used)

T X

1 0 8 1 1 0 2 A — U N — 2 6 A U G 1 0

Standard Grille Guard Shown


4. Support grille guard using lifting straps (3) as shown.

Specification

Standard Grille

Guard—Weight

(approximate).................................................................................. 68 kg

150 lb.

High Debris Grille

Guard—Weight

(approximate).................................................................................. 84 kg

200 lb.

Remove parts (4—8) and remove grille guard.


3— Lifting Strap (2 used)4— Cap Screw (2 used)5— Nut (2 used)

6— Washer (2 used)7— Wave Washer (2 used)8— Washer (2 used)

T X 1 0 8 1 1 0 3 A — U N — 2 6 A U G 1 0

Lifting Straps

TM11813 (13OCT10) 19-1910-3 748H Repair (S.N. 630436—10

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MH66088,0000D90 -19-14SEP10-3/3


6. Raise grille guard to machine and install parts (4—8)as shown. Do not tighten cap screws at this time.

7. Remove lifting device and lifting straps from grilleguard.

8. Close grille guard and adjust for proper alignment.Tighten cap screws (4) and nuts (5). Open and closegrille guard several times to ensure proper alignment.

9. Close grille guard and install cap screws (1) andwashers (2).



6— Washer (2 used)

7— Wave Washer (2 used)8— Washer (2 used)

T X 1 0 8 1 1 0 4 A — U N — 2 6 A U G 1 0

Grille Guard Mounting Hardware

TM11813 (13OCT10) 19-1910-4 748H Repair (S.N. 630436— )101310

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MH66088,0000DB1 -19-07OCT10-2/2

22. Install aftercooler. See Aftercooler Remove andInstall. (Group 0510.)

23. Install radiator. See Radiator Remove and Install.(Group 0510.)

24. Install transmission oil cooler. See Transmission OilCooler Remove and Install. (Group 0510.)

25. Install hydraulic oil cooler. See Hydraulic Oil Cooler Remove and Install. (Group 0510.)

NOTE: Air conditioner condenser and hydraulic oil cooler share the same mounting bracket on torque converter drive machines and areinstalled as an assembly.

26. Install air conditioner condenser. See Air Conditioner Condenser Remove and Install. (Group 1830.)

27. Install grille guard. See Grille Guard Remove andInstall. (Group 1910.)


28. Install right limb riser.

SpecificationRight Limb

Riser—Weight

(approximate).................................................................................. 39 kg

85 lb.



31. Evacuate air conditioning system. See R134a SystemEvacuate. (Group 1830.)

32. Charge air conditioning system. See R134a System

Charge. (Group 1830.)

TM11813 (13OCT10) 19-1910-6 748H Repair (S.N. 630436— )101310

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Section 20Safety, Convenience, and Miscellaneous

Contents

Page

Group 2003—Pressurized Water SystemPressurized Water System—If

Equipped ...............................................20-2003-1

Group 2004—Horn and Warning DevisesHorn Remove and Install ........................... 20-2004-1Reverse Warning Alarm Remove

and Install .............................................. 20-2004-1

TM11813 (13OCT10) 20-1 748H Repair (S.N. 630436—10

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TM11813 (13OCT10) 20-2 748H Repair (S.N. 630436— )101310

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Group 2003Pressurized Water System

Continued on next page SW03989,0000B2F -19-24SEP10-1

Pressurized Water System—If Equipped

TX1081958

2

3

5

44

5 7

8

9

10

10

12

11

13

1823

15

20 21

24

22

27

26

24

25

23

16

14

17

8

9

19

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6

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Pressurized Water System

1— Tank2— Filler Plug3— O-Ring4— Cap Screw (8 used)5— Washer (8 used)6— Reducer 7— Seal

8— O-Ring (2 used)9— Adapter (2 used)10— Hose11— Bracket12— Washer 13— Latch14— Label

15— Cap Screw (2 used)16— Fitting17— Pressure Gauge18— Relief Valve19— Manifold20— Nozzle21— Adapter

22— Hose23— Cap Screw (2 used)24— Adapter (2 used)25— Valve26— Cover 27— Label

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Pressurized Water System

SW03989,0000B2F -19-24SEP10-2/2


CAUTION: Release pressure by discharging fluidat hose and before removing fill plug. Injurymay result from plug or cap under force.

2. Move valve (25) handle to ON position.

CAUTION: Pressurized water system. Releasepressure by discharging fluid at hose endbefore removing fill plug. Injury may resultfrom plug removed under pressure.

3. Squeeze nozzle (20) to release water.

4. Slowly remove filler plug (2).

5. For tank removal, remove trim caps on screwssecuring trim panel to cab and remove head liner.

6. Disconnect hose (10) from adapter (9). Close allopenings using caps and plugs.


7. Remove cap screws (4) and washers (5). Removetank using lifting loops.

Specification

Tank—Weight................................................................................ 373 kg

822 lb.

8. Replace or repair as necessary.

9. Install tank and connect hose. Install head liner and

trim panel.

10. Fill tank with water. See Fill and Charge PressurizedWater System—If Equipped. (Operator’s Manual.)

CAUTION: Plug has a vent cross hole for releaseof air pressure. Do not use a substitute plug.

11. Install filler plug.

12. To pressurize system, apply air to fitting (16), add air,watching pressure gauge (17) to correct air pressurespecification.

Specification

Water Tank—Pressure................................................................410 kPa

3.8 bar

55 psi

T X 1 0 8 1 9 6 5 A — U N — 2 0 S E P 1 0

Cover and Latch

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P 1 0

Valve, Hose, and Nozzle

T X 1 0 8 1 9 5 9 A — U N — 2 0 S E P 1 0

Plug Location

2— Filler Plug4— Cap Screw (8 used)5— Washer (8 used)

13— Latch16— Fitting

17— Pressure Gauge20— Nozzle25— Valve

26— Cover

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Group 2004Horn and Warning Devises

GD61784,000002B -19-29MAY07-1

GD61784,000002C -19-29MAY07-1

GD61784,000002C -19-29MAY07-2

Horn Remove and Install

1. Open front grille (3).

2. Disconnect electrical connectors (1).

3. Remove horn (2).


5. Install horn.


7. Close front grille.

1— Electrical Connector 2— Horn

3—Nut4— Grille

T X 1 0 2 4 3 7 7 A — U N — 0 5 J U

N 0 7

Horn

Reverse Warning Alarm Remove and Install

1. Remove cover (1).

1— Reverse Warning AlarmCover


T X 1 0 2 4 3 7 9 A — U N — 0 5 J U N 0 7

Reverse Warning Alarm Cover

2. Disconnect electrical connectors (3).

3. Remove reverse warning alarm (5).


5. Install reverse warning alarm.


7. Install cover.

3— Electrical Connector 4— Nut (2 used)

5— Reverse Warning Alarm

T X 1 0 2 4 3 7 8 A — U N — 0 5 J U N 0 7

Reverse Warning Alarm

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Horn and Warning Devises

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Section 21Main Hydraulic System

Contents

Page

Group 2160—Hydraulic SystemGeneral Oil Cleanup Procedure ................ 21-2160-1Hydraulic Component Failure

Cleanup Procedure................................21-2160-3Hydraulic Pump Remove and

Install ..................................................... 21-2160-5Priority Valve Remove and Install..............21-2160-7Priority Valve Disassemble and

Assemble...............................................21-2160-8Hydraulic Attenuator Remove and

Install ..................................................... 21-2160-9Fan Variable Speed and Reversing

Manifold Remove and Install ............... 21-2160-10

Fan Variable Speed and ReversingManifold Disassemble and Assemble............................................. 21-2160-11

Hydraulic Fan Motor Remove andInstall ................................................... 21-2160-12

Hydraulic Reservoir Remove andInstall ................................................... 21-2160-14

Hydraulic Fan and Cooling LoopPump Remove and Install ................... 21-2160-18

TM11813 (13OCT10) 21-1 748H Repair (S.N. 630436—10

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Continued on next page BR98087,00000B3 -19-18AUG10- 1

General Oil Cleanup Procedure

This procedure is to be used on machines that have hadhydraulic system repair without a catastrophic componentfailure. Filter caddy procedure must be done prior tostarting machine after a component has been repaired

or replaced.

IMPORTANT: Intermixing of oils can cause prematurehydraulic component damage and oilcontamination. Oil types and filters must notbe intermixed. Use filter element in sametype oil to avoid intermixing of oils.

Oil contamination could result if filter caddy isused in dusty or wet conditions. Clean workpractices and cleanliness of filter caddy andattachments 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. Useof electrical extension cord is not recommended.

1. Park machine on a flat, level surface with attachmentslowered to the ground and turn engine off.

2. Remove hydraulic tank cap and filler screen.

NOTE: When installing suction and discharge wands intothe 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.

3. Install JDG10712 Super Caddy suction wand (1) anddischarge wand (2) into the reservoir as shown.

4. Secure wands to prevent them from coming out of reservoir during cleaning process.

5. Cover the wands and reservoir openings with a plastictarp to prevent contamination.

CAUTION: Prevent possible personal injuryfrom unexpected machine movement. Clear allpersons from area before operating machine.

Avoid entanglement and possible electrocutionfrom filter caddy power cord. Do notoperate machine while filter caddy isconnected to machine.

6. Use JDG10712 Super Caddy to remove oilcontaminants. Refer to the Super Caddy operator’smanual or see Super Caddy in Service ADVISOR™for operating procedure.

7. When cleaning process is done, disconnect Super Caddy from machine.

8. Make sure machine is parked in an area that will allowall hydraulic functions to be operated.

2

1

T X 1 0 8 0 7 0 3 — U N — 0 9 A U G 1 0

Super Caddy Wand Placement

1— Suction Wand 2— Discharge Wand

9. Fill hydraulic oil reservoir to operating level. SeeCheck Hydraulic System Oil Level. (Operator’sManual.)

10. Run machine at slow idle. Operate each circuita minimum of 2 minutes in each direction to flushany remaining contaminants back through hydraulicsystem filters.

11. Stop engine. Install Super Caddy to machine asbefore.

12. Repeat Super Caddy operation procedure untilcontaminant value is at specifications per Super Caddy operator’s manual or see Super Caddy inService ADVISOR™ for operating procedure.

13. When oil reaches an acceptable level of cleanliness,disconnect Super Caddy from machine.

14. Install new hydraulic system filters.

15. Clean and Install reservoir breather.

NOTE: Instrument cleanliness and clean work practicesare critical when taking oil samples. Dust, wind,and moisture, as well as contaminated sample pumps, bottles, and tubing, can affect results.

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Hydraulic System

BR98087,00000B3 -19-18AUG10-2/2

16. Obtain oil sample for fluid analysis. Oil sample must betaken from system before oil passes through the filter when oil is warm. See Fluid Analysis Program TestKits and 3-Way Coolant Test Kit. (Operator’s Manual.)

17. Fill hydraulic oil reservoir to proper operating level.

See Check Hydraulic System Oil Level and seeHydraulic System Oil. (Operator’s Manual.)

18. Return machine to service.

Service ADVISOR is a trademark of Deere & Company

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Hydraulic System


Hydraulic Component Failure CleanupProcedure

This procedure is to be used on machines that havehad a system catastrophic component failure. Cleanupprocedure must be done prior to starting machine after a

component has been repaired or replaced. The use of attachments increases the need to monitor and filter oil toa safe contamination value.

IMPORTANT: Intermixing of oils can causepremature hydraulic component damageand oil contamination. Oil types and Super Caddy filters must not be intermixed. Usesuper caddy filter element in same type oilto avoid intermixing of oils.

Oil contamination could result if Super Caddyis used in dusty or wet conditions. Clean workpractices and cleanliness of filter caddy andattachments 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. Useof electrical extension cord is not recommended.



2. Remove hydraulic reservoir. See Hydraulic Reservoir Remove and Install. (Group 2160.)

IMPORTANT: To prevent hydraulic systemcontamination, after cleaning, disassembling,and assembling each hydraulic component,store component in a dry, dust-free areauntil installation.

3. Clean hydraulic reservoir completely.

4. Remove each hydraulic component from the machine.Disassemble, clean, inspect, and assemble eachcomponent, working one circuit at a time. Repair or replace damaged components.

• Main Hydraulic Pump—See Hydraulic PumpRemove and Install. (Group 2160.)

• Priority Valve—See Priority Valve Remove andInstall. (Group 2160.)

• Priority Valve—See Priority Valve Disassemble and Assemble. (Group 2160.)

• Hydraulic Attenuator—See Hydraulic Attenuator Remove and Install. (Group 2160.)

• Fan Variable Speed and Reversing Manifold—SeeFan Variable Speed and Reversing ManifoldRemove and Install. (Group 2160.)

• Fan Variable Speed and Reversing Manifold—SeeFan Variable Speed and Reversing ManifoldDisassemble and Assemble. (Group 2160.)

• Hydraulic Fan Motor—See Hydraulic Fan Motor Remove and Install. (Group 2160.)

•Hydraulic Reservoir—See Hydraulic Reservoir Remove and Install. (Group 2160.)

• Hydraulic Fan and Cooling Loop Pump—SeeHydr aulic Fan and Cooling Loop Pump Remove andInstall. (Group 2100.)

• Blade Lift Cylinder—See Blade Lift Cylinder Removeand Install. (Group 3260.)

• Boom or Arch Cylinder—Dual FunctionGrapple—See Boom or Arch Cylinder Remove andInstall—Dual Function Grapple. (Group 3860.)

• Grapple Tong Cylinder—See Grapple Tong Cylinder Remove and Install. (Group 3860.)

• Grapple Rotate Motor—See Grapple Rotate Motor Remove and Install. (Group 3860.)

• Grapple Rotate Motor—See Grapple Rotate Motor

Disassemble. (Group 3860.)• Grapple Rotate Motor—See Grapple Rotate Motor Assemble. (Group 3860.)

• Pilot Operated Control Valve—See Pilot OperatedControl Valve Remove and Install. (Group 3860.)

• Dual Function Pilot Operated Control Valve—SeeDual Function Pilot Oper ated Control ValveDisassemble and Assemble. (Group 3860.)

• Control Valve Relief Valves—See Control ValveRelief Valves Remove and Install. (Group 3860.)

• Lift Check Valve—See Lift Check Valve Disassembleand Assemble. (Group 3860.)

• Non-adjustable Circuit Relief Valve—SeeNon-adjustable Circuit Relief Valve Disassemble and Assemble. (Group 3860.)

• Adjustable Circuit Relief Valve—See AdjustableCircuit Relief Valve Disassemble and Assemble.(Group 3860.)

• Spool Valve—See Spool Valve Disassemble and Assemble. (Group 3860.)

• Detent—See Detent Disassemble and Assemble.(Group 3860.)

• Pilot Operated Valve—See Pilot Operated ValveRemove and Install. (Group 3860.)

• Solenoid Operated Valve—See Solenoid OperatedValve Remove and Install. (Group 3860.)

• Grapple Rotate—See Grapple Rotate SolenoidValve Remove and Install. (Group 3860.)

• Grapple Rotate—See Grapple Rotate SolenoidValve Disassemble and Assemble. (Group 3860.)

• Flow Divider—See Flow Divider Repair. (Group3860.)

• Rotary Manifold—See Rotary Manifold Remove andInstall. (Group 3860.)

• Rotary Manif old—See Rotary Manifold Disassembleand Assemble. (Group 3860.)

• Park Brake Solenoid Valve—See Park Br akeSolenoid Valve Repair. (Group 1160.)

• Service Brake Valve—See Service Brake ValveRemove and Install. (Group 1060.)

• Service Brake Valve—See Service Brake ValveDisassemble and Assemble. (Group 1060.)

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Hydraulic System

SW03989,0000B25 -19-07OCT10-2/2

• Service Brake Accumulator—See Service Brake Accumulator Remove and Install. (Group 1060.)

• Steering Valve—See Steering Valve Remove andInstall. (Group 0960.)

• Steering Valve—See Steering Valve Disassembleand Assemble. (Group 0960.)

• Steering Cylinder—See Steering Cylinder Removeand Install. (Group 0960.)

• Transmission Charge Pump—See TransmissionCharge Pump Remove and Install. (Group 0360.)

• Transmission Charge Pump—See TransmissionCharge Pump Drive Repair. (Group 0360.)

• Transmission Control Valve—See TransmissionControl Valve Repair. (Group 0360.)

• Differential Lock Solenoid Valve—See DifferentialLock Solenoid Valve Repair. (Group 0260.)

IMPORTANT: Disconnect hydraulic hoses and linesfrom all tee fittings before cleaning. Cleaningsponge will become trapped in hose and linesas it passes through a tee fitting.

5. Disconnect and label all hydraulic hoses and lines.Close open fittings using caps and plugs. SeeHydraulic System Component Location. (Group9025-15.)

IMPORTANT: Airborne debris can cause prematurehydraulic component failure. After hoses and

lines are cleaned, close all openings with capsand plugs to minimize additional contamination.

6. Clean all hydraulic hoses and lines using JDG1770Ultra Clean Hose Kit.

NOTE: During installation, fill hydraulic components,hoses, and lines with clean hydraulic oil where possible to prevent a dry start-up.

7. Install all cleaned hydraulic components, hoses, andlines.

8. Install new hydraulic oil filters. See Replace HydraulicOil Filter. (Operator’s Manual.)

9. Install new hydraulic oil breather filter. See ReplaceHydraulic Reservoir Breather Filter. (Operator’sManual.)

10. With all components installed, fill reservoir to proper level. See Check Hydraulic Oil Level. (Operator’s

Manual.)

11. Remove air from hydraulic system.

12. Remove residual oil contaminants using JDG10712Super Caddy. Perform General Oil CleanupProcedure. (Group 2160.)

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Hydraulic System


Hydraulic Pump Remove and Install

IMPORTANT: Test main pump for leakage beforestarting repair. If pump does not pass thetest, replace it. DO NOT rebuild it.



2. Operate all hydraulic control valves to releasepressure in hydraulic system. Depress brake pedal at1-second intervals 20 times to drain oil from servicebrake accumulator.






7. Disconnect hydraulic hose and lines (1—3). Close allopenings using caps and plugs.

8. Disconnect wire harness at electrical connector (4).


9. Support pump with lifting strap. Remove cap screws(5) to remove pump.

Specification

Hydraulic Pump—Weight

(approximate).................................................................................. 40 kg

90 lb

10. Inspect and replace pump as necessary.

T X 1 0 8 0 4 8 3 A — U N — 0 5 A U G 1 0

Hydraulic Pump Hose and Lines

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0 4 8 4 A — U N — 0 5 A U G 1 0

Hydraulic Pump Remove or Install

1— Case Drain-to-Reservoir Hose

2— Supply Line3— Pump-to-Prioity Valve Line

4— Electrical Connector 5— Cap Screw (4 used)

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Hydraulic System

SW03989,0000B26 -19-28SEP10-2/2

IMPORTANT: Always replace O-rings and seals.Damaged or used O-rings will leak.

11. Replace O-ring (6) on pump flange.

NOTE: Hydraulic pump has a spline coupler that couplesthe pump to transmission charge pump.

12. Inspect spline coupler (7). Install on torque converter spline shaft.

13. Install hydraulic pump to torque converter.

IMPORTANT: The hydraulic pump must be filled withoil to prevent pump damage at start-up.

14. Connect pump-to-prioity valve line using a new O-ringat face seal. Tighten to specification.

Specification

Line Mounting Cap

Screw—Torque............................................................................120 N∙m

89 lb-ft

15. Fill supply and case drain ports with hydraulic oil. SeeHydraulic System Oil. (Operator’s Manual.)

16. Connect case drain hose.

17. Connect supply line using a new O-ring at face seal.Tighten to specification.

Specification

Line Mounting Cap

Screw—Torque............................................................................120 N∙m

89 lb-ft




21. Start engine and follow hydraulic oil warmupprocedure. See Hydraulic Oil Warmup Procedure.(Group 9025.)

22. Stop engine and check for leaks.

23. Check hydraulic reservoir oil level. See Check

Hydraulic System Oil Level. (Operator’s Manual.)24. Install engine side shields. See Opening Engine Side

Shields. (Operator’s Manual.)


T X 1 0 8 0 4 6 1 A — U N — 0 3 A U G 1 0

Hydraulic Pump Flange O-Ring

T X 1 0 8 0 4 8 6 A — U N — 0 5 A U G 1 0

Coupler

6— O-Ring 7— Coupler

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Hydraulic System

SW03989,0000A97 -19-05OCT10-1

Priority Valve Remove and Install





3. Tur n battery disconnect switch to the OFF position.See Battery Disconnect. (Operator’s Manual.)



6. Tag and remove hydraulic lines (1—5). Close allopenings using caps and plugs.

7. Remove vacuum if used.

8. Remove cap screws (6) to remove priority valve.

9. Inspect and repair or replace parts as necessary. SeePriority Valve Disassemble and Assemble. (Group2160.)

10. Secure priority valve with cap screws. Tighten

securely.

11. Apply vacuum if hydraulic reservoir was not drained.

12. Install hydraulic lines.

13. Remove vacuum if hydraulic reservoir was not drainedor fill hydraulic reservoir. See Change Hydraulic Oil.(Operator’s Manual.)

T X 1 0 8 0 5 0 0 A — U N — 0 5 A U G 1 0

Priority Valve

1— Hydraulic Line to MainControl Valve

2— Hydraulic Line to SteeringValve

3— Hydraulic Line FromHydraulic Pump

4— Hydraulic Line to HydraulicReservoir

5— Hydraulic Line toSecondary Steering Valve





17. Start engine and allow to run at slow idle for several

minutes.


19. Check hydraulic reservoir oil level. See CheckHydraulic System Oil Level. (Operator’s Manual.)


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Hydraulic System

SW03989,0000A9B -19-05AUG10-1/1

Priority Valve Disassemble and Assemble

1. Remove priority valve from machine. See PriorityValve Remove and Install. (Group 2160.)

2. Disassemble parts (2—10) from housing (1).

3. Clean and inspect parts. Replace as necessary.

4. Check length of spring (4). Replace if not tospecification.

Specification

Spring—Length

(approximate)................................................................................ 62 mm

2.4 in.

IMPORTANT: Always replace O-rings. Damagedor used O-rings will leak.

5. Install new O-rings.

6. Lubricate all parts with clean hydraulic oil and

assemble.

7. Tighten orifices (3) to specification.

Specification

Orifices—Torque.................................................................. 7.3—9.7 N∙m

65—85 lb-in.

8. Tighten plugs (5 and 9) to specification.

Specification

Plug—Torque............ ........... ............ ............ ............ ........... ... 54—81 N∙m

40—60 lb-ft

9. Tighten relief valve cartridge (7) to specification.

T X 1 0 8 0 5 0 1 A — U N — 0 5 A U

G 1 0

Priority Valve Disassembled

1— Housing2— Spool3— Orifice (2 used)4— Spring5— Plug

6— O-Ring7— Relief Valve Cartridge8— O-Ring9— Plug10— O-Ring

Specification

Relief Valve

Cartridge—Torque................................................................. 34—54 N∙m

25—40 lb-ft

10. Install priority valve. See Priority Valve Remove andInstall. (Group 2160.)

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Hydraulic System

SW03989,0000B20 -19-05OCT10-1

Hydraulic Attenuator Remove and Install








6. Remove hydraulic line (1) and hydraulic hose (3) fromhydraulic attenuator (5). Close all openings usingcaps and plugs.

7. Remove cap screws (2) from retaining clamps (4).Remove hydraulic attenuator.

8. Install hydraulic attenuator, retaining clamps, and capscrews.

9. Install hydraulic line and hose.

10. Remove vacuum if hydraulic reservoir was not drained

or fill hydraulic reservoir. See Change Hydraulic Oil.(Operator’s Manual.)



T X

1 0 8 1 8 6 6 A — U N — 1 6 S E P 1 0

Hydraulic Attenuator Remove and Install

1— Hydraulic Line2— Cap Screw (2 used)3— Hydraulic Hose

4— Retaining Clamp (2 used)5— Hydraulic Attenuator



15. Start machine and allow hydraulic oil to reachoperating temperature. See Hydraulic Oil WarmupProcedure. (Group 9025-25.)

16. Stop machine and check hydraulic oil level. See CheckHydraulic System Oil Level. (Operator’s Manual.)

TM11813 (13OCT10) 21-2160-9 748H Repair (S.N. 630436—10

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Hydraulic System

SW03989,0000A98 -19-06OCT10-1/1

Fan Variable Speed and Reversing ManifoldRemove and Install



2. Operate all hydraulic control valves to releasepressure in hydraulic system. Depress brake pedal atone-second intervals 20 times to drain oil from servicebrake accumulator.

3. Turn battery disconnect switch to OFF position.



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2

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2

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Fan Manifold Remove and Install

1— Solenoid Electrical Connector (2 used)

2—Hydraulic Hose (4 used) 3—Cap Screw (2 used)

6. Disconnect wiring harness from solenoid electricalconnectors (1).

7. Apply vacuum to hydraulic reservoir.

8. Tag and disconnect hydraulic hoses (2). Close allopenings using caps and plugs.


10. Inspect and replace components, as necessary.See Fan Variable Speed and Reversing ManifoldDisassemble and Assemble. (Group 2160.)

11. Install fan manifold with cap screws. Tighten securely.


13. Remove vacuum from hydraulic reservoir.

14. Connect wiring harness to solenoid electricalconnectors.


16. Turn battery disconnect to ON position.



19. Check reversing fan operation before returningmachine to service. See Complete MachineOperational Checkout. (Operator’s Manual.)

TM11813 (13OCT10) 21-2160-10 748H Repair (S.N. 630436— )101310

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Hydraulic System

SW03989,0000AA0 -19-18AUG10-1

Fan Variable Speed and Reversing ManifoldDisassemble and Assemble

1. Remove fan manifold. See Fan Variable Speed andReversing Manifold Remove and Install. (Group 2160.)

TX1081043

4

8

4

4

67

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2

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1

4

4

3

T X 1 0 8 1 0 4 3 — U N — 1 8 A U G 1 0

Fan Variable Speed and Reversing Manifold

1— Solenoid Valve (2 used)2— Check Valve (4 used)

3— Orifice4— Plug (5 used)

5— Pressure Relief Valve6— Solenoid Valve Coil (2 used)

7— Nut (2 used)8— Valve Manifold

2. Disassemble and assemble.3. Install fan manifold. See Fan Variable Speed and

Reversing Manifold Remove and Install. (Group 2160.)

TM11813 (13OCT10) 21-2160-11 748H Repair (S.N. 630436—10

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Hydraulic System

Continued on next page MH66088,0000D93 -19-06OCT10- 1/2

Hydraulic Fan Motor Remove and Install

CAUTION: Avoid possible injury from unexpectedmachine movement. Install articulation lockingbar before working in fr ame hinge area.



2. Operate all hydraulic control valves to releasepressure in hydraulic system. Depress brake pedal at1-second intervals 20 times to drain oil from servicebr ake accumulator.

3. Turn battery disconnect switch to OFF position. See

Battery Disconnect. (Operator’s Manual.)

4. Remove fan blade. See Fan Blade Remove andInstall. (Group 0510.)

5. Remove both side grille housing access panels.

6. Remove upper air baffle enclosure. See Air BaffleEnclosure Remove and Install. (Group 0510.)

T X 1 0 8 0 5 2 0 A — U N — 0 4 A U

G 1 0

Fan Motor Mounting

1— Fan Reversing Manifold-to-Fan Motor Hose (2 used)

2— Fan Motor Case Drain Hose 3— Cap Screw (2 used)

7. Disconnect and identify fan reversing manifold-to-fanmotor hoses (1). Close all openings using caps andplugs.

8. Disconnect fan motor case drain hose (2). Close allopenings using caps and plugs.

9. Remove cap screws (3) securing hydraulic fan motor to mounting bracket.

10. Remove hydraulic fan motor from machine.


12. Install hydraulic fan motor to mounting bracket usingcap screws.

IMPORTANT: Installing hydraulic fan motor hosesbackwards will cause engine overheating.

13. Connect fan reversing manifold-to-fan motor hoses.

14. Connect fan motor case drain hose.

15. Install fan blade. See Fan Blade Remove and Install.(Group 0510.)

16. Install both upper air baffle panels. See Air BaffleEnclosure Remove and Install. (Group 0510.)

17. Install both side grille housing access panels.


TM11813 (13OCT10) 21-2160-12 748H Repair (S.N. 630436— )101310

PN=286

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Hydraulic System

MH66088,0000D93 -19-06OCT10-2


20. Check operation of hydraulic fan motor. See CompleteMachine Operational Checkout. (Operator’s Manual.)

TM11813 (13OCT10) 21-2160-13 748H Repair (S.N. 630436—10

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Hydraulic System

Continued on next page SW03989,0000A9A -19-05OCT10- 1/5

Hydraulic Reservoir Remove and Install




2. Operate all hydraulic control valves to releasepressure in hydraulic system. Depress brake pedal at1-second intervals 20 times to drain oil from servi cebrake accumulator.


4. Tilt cab. See Hydraulic Cab Tilt Pr ocedure. (Operator’sManual.)



IMPORTANT: Clean all dirt and debris fromhydraulic reservoir before removing fill capor disconnecting hoses. Contaminationintroduced into the hydraulic system can leadto premature equipment failure.


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Hydraulic Reservoir Bottom View

1— Hydraulic Oil TemperatureSensor Connector

2— Wire Harness

8. Disconnect wire harness (2) from hydraulic oiltemperature sensor connector (1).

9. Tag and disconnect hydraulic hoses from bottom of hydraulic reservoir. Close all openings using caps andplugs.

NOTE: Hoses may vary depending on machine options.

TM11813 (13OCT10) 21-2160-14 748H Repair (S.N. 630436— )101310

PN=288

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Hydraulic System

Continued on next page SW03989,0000A9A -19-05OCT10-2

NOTE: Do not disconnect hoses or wire connectors.

10. Remove transmission filter (3), breather (5), andgrapple valve bracket (6).

3— Transmission Filter 4— Cap Screw (3 used)5— Breather

6— Grapple Valve Bracket7— Cap Screw (2 used)

T X 1 0 8 0 6 0 3 A — U N — 0 6 A U G 1 0

Breather, Transmission Filter, and Grapple Valve Mounting

TM11813 (13OCT10) 21-2160-15 748H Repair (S.N. 630436—10

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Hydraulic System

Continued on next page SW03989,0000A9A -19-05OCT10- 3/5

11. Loosen band clamps (10). Disconnect cooling loopfilter hose (8) and hydraulic return filter hose (9) fromreservoir.

12. Disconnect chain slings (11) and set hoses aside.

13. Remove service accumulator. See Service Brake Accumulator Remove and Install. (Group 1060.)

8— Cooling Loop Filter Hose9— Hydraulic Return Filter

Hose10— Band Clamp (2 used)

11— Chain Sling (2 used)12— Cap Screw (2 used)13— Nut (2 used)

T X 1 0 8 0 6 2 3 — U N — 0 6 A U G 1 0

Cooling Loop and Hydraulic Return Filter Hoses

T X 1 0 8 0 6 2 4 — U N — 0 6 A U G 1 0

Hose Chain Slings

TM11813 (13OCT10) 21-2160-16 748H Repair (S.N. 630436— )101310

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Hydraulic System

Continued on next page SW03989,0000A9A -19-05OCT10-4


14. Attach hoist and chains to reservoir using JT01748lifting bracket (14) and M12 lifting eyebolt (15).

Specification

Hydraulic

Reservoir—Weight

(approximate).................................................................................. 60 kg

132 lb.

15. Remove hydraulic reservoir support (16) from machineframe (17).

16. Lift hydraulic reservoir from machine.


18. Install fittings on hydraulic reservoir, if removed.


19. Attach hoist and chains to reservoir using JT01748Lifting Brackets.

Specification

Hydraulic

Reservoir—Weight

(approximate).................................................................................. 60 kg

132 lb.

20. Install hydraulic reservoir on frame.

21. Install chain slings and service brake accumulator.See Service Brake Accumulator Remove and Install.

(Group 1060.).

22. Install transmission filter, grapple valve bracket, andbreather.

23. Install cooling loop and hydraulic return filter hoses.

24. Replace hydraulic oil return filters. See ReplaceHydraulic Oil Filter and see Replace Hydraulic Cooler Filter. (Operator’s Manual.)


25. Install hoses to hydraulic reservoir.

26. Connect wire harness to hydraulic oil temperaturesensor connector.





T X 1 0 8 0 6 2 5 A — U N — 0 6 A U G 1 0

Hoist, Chain, Lifting Brackets

T X 1 0 8 0 6 2 6 — U N — 0 6 A U G 1 0

Hydraulic Reservoir Support Mounting

14— JT01748 Lifting Bracket (2used)

15— M12 Lifting Eyebolt16— Hydraulic Reservoir

Support

17— Machine Frame18— Cap Screw (6 used)19— Nut (6 used)

31. Start engine and follow hydraulic oil warmup

procedure. See Hydraulic Oil Warmup Procedure.(Group 9025.)

32. Stop engine. Check for leaks.


34. Install engine side shields. See Opening Engine SideShields. (Operator ’s Manual.)


TM11813 (13OCT10) 21-2160-17 748H Repair (S.N. 630436—10

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Hydraulic System

SW03989,0000A9A -19-05OCT10-5/5

SW03989,0000B2E -19-06OCT10-1/2

SW03989,0000B2E -19-06OCT10-2/2

Hydraulic Fan and Cooling Loop PumpRemove and Install

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

Prepare for Service Safely. (Group 0001.)


3. Install a vacuum pump on hydraulic reservoir tominimize leakage.


4. Disconnect hoses from pump. Close all openings with

caps and plugs.

5. Remove cap screws (1) and washers and removepump.

1— Cap Screw (2 used)2— Pump Outlet

3— Cooling Loop Pump4— Pump Inlet

T X 1 0 2 5 2 1 8 A — U N — 2 1 J U N 0 7



7. Install drive coupler and O-ring on cooling loop pump.

8. Install cooling loop pump.

9. Connect hose to pump inlet.

IMPORTANT: Pump must be filled with oil prior tostart-up to prevent pump damage.

10. Fill pump with oil through pump outlet. SeeTransmission, Park Brake, Diff erential, Cab TiltHydraulic Pump and Winch Oil. (Operator’s Manual.)

11. Connect hose to pump outlet.

12. Remove vacuum pump from hydraulic tank.



15. Check operation of reversing fan. See OperationalCheckout. (Group 9005-10.)

T X 1 0 2 5 2 1 9 A — U N — 2 1 J U N 0 7

3— Cooling Loop Pump5— O-Ring

6— Drive Coupler

16. Check for leaks.


TM11813 (13OCT10) 21-2160-18 748H Repair (S.N. 630436— )101310

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Section 30Winch

Contents

Page

Group 3000—Removal and InstallationWinch 4000 Series Remove and

Install ..................................................... 30-3000-1Fastening Cable to Winch

Drum—4000 Series ............................... 30-3000-5Winch Free Spool Drag

Adjustment.............................................30-3000-7Winch 6000 Series Remove and

Install ..................................................... 30-3000-8Fastening Cable to Winch

Drum—6000 Series ............................. 30-3000-10

Group 3015—Control Linkage

Winch Control Valve LinkageRemove and Install................................30-3015-1

Winch Control Cable Remove andInstall ..................................................... 30-3015-2

Group 3025—Input Drive Shafts and U-JointsWinch Drive Shaft Remove and

Install .....................................................30-3025-1Winch Drive Shaft Disassemble

and Assemble........................................ 30-3025-1

Group 3050—Drive and ClutchWinch 4000 Series Drive and

Clutch Repair ......................................... 30-3050-1Winch 6000 Series Drive and

Clutch Repair ......................................... 30-3050-1

TM11813 (13OCT10) 30-1 748H Repair (S.N. 630436—10

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Contents

TM11813 (13OCT10) 30-2 748H Repair (S.N. 630436— )101310

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Continued on next page SW03989,0000A9D -19-05OCT10- 1

Winch 4000 Series Remove and Install

NOTE: Cable must be removed from winchbefore servicing.




2. Operate all hydraulic control valves to release pressurein hydraulic system. Depress brake pedal at 1-secondintervals 20 times to drain oil from accumulator.


4. Tilt cab. See Hydraulic Cab Tilt Procedure. (Operator’s

Manual.)

5. Remove winch drive shaft. See Winch Drive ShaftRemove and Install. (Group 3025.)

6. Disconnect winch yoke control cable (3).

7. Disconnect hydraulic lines (1 and 4). Close allopenings using caps and plugs.

4

31

2

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Winch Yoke Control Cable and Drive Yoke

1— Pressure Inlet Line2— Drive Yoke

3— Yoke Control Cable4— Return Oil Line

8. Disconnect and remove control cable.

TM11813 (13OCT10) 30-3000-1 748H Repair (S.N. 630436—10

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Continued on next page SW03989,0000A 9D -19-05OCT10- 2/5

9. Remove guards.

10. Label and disconnect hydraulic lines (7—12).

11. Remove fittings (13).

12. Disconnect grapple lowering valve (14).13. Remove fuel tank mounting cap screws and slide

fuel tank rearward as far as possible. See Fuel TankRemove and Install. (Group 0560.)

14. Remove winch mounting cap screws.

5— Cap Screw (6 used)6— Guard (2 used)7— Arch Retract Line8— Arch Extend Line9— Grapple Rotate Line

10— Boom Retract Line11— Boom Extend Line12— Grapple Rotate Line13— Fitting (6 used)14— Grapple Lowering Valve

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Winch Guard

T X 1 0 8 0 9 4 3 A — U N — 1 9 A U

G 1 0

Hydraulic Connections

T X 1 0 8 0 9 4 4 A — U N — 1 9 A

U G 1 0

Grapple Lowering Valve

TM11813 (13OCT10) 30-3000-2 748H Repair (S.N. 630436— )101310

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SW03989,0000A9D -19-05OCT10-3

Continued on next page SW03989,0000A9D -19-05OCT10- 4

15. Attach lifting chains to winch as shown.


16. Remove winch.

Specification

Winch—Weight

(approximate)................................................................................ 630 kg

1390 lb.

T 7 5 1 6 A V — U N — 0 5 J U N 9 1

Shown with Cable Removed

NOTE: If winch is to be stored or reinstalled without disassembly, do not drain oil.

If winch is to be disassembled, drain oil using drain plug on left sid e of cover.

17. Remove plug (16) to drain oil. See Change WinchOil—If Equipped. (Operator’s Manual.)

18. Inspect and repair winch as necessary. See 40 and4000 Winches. (CTM25.)

15— Fill Plug16— Drain Plug

17— Return Line Cap

T X 1 0 8 0 9 4 5 A — U N — 1 9 A U G 1 0

Winch 4000 Oil Plugs

TM11813 (13OCT10) 30-3000-3 748H Repair (S.N. 630436—10

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SW03989,0000A9D -19-05OCT10-5/5

19. Clean grease, dirt, oil, and paint from mounting holes.


20. Install winch.

Specification

Winch—Weight

(approximate)................................................................................ 630 kg

1390 lb.

21. Tighten mounting cap screws to specification.

Specification

Equipment Frame-

to-Winch Cap

Screw—Torque............................................................................620 N∙m

455 lb-ft

22. Position fuel tank and install mounting cap screws.

See Fuel Tank Remove and Install. (Group 0560.)23. Install fittings to mounting bracket.


25. Install guards.


27. Connect and adjust control cable yoke. See WinchControl Valve Linkage Remove and Install or seeWinch Control Cable Remove and Install. (Group3015.)

28. Install winch drive shaft. See Winch Drive Shaft

Remove and Install. (Group 3025.)29. Fill winch with recommended oil. See Change Winch

Oil—If Equipped. (Operator’s Manual.)

T 7 5 1 6 A V — U N — 0 5 J U N 9 1

Shown with Cable Removed


IMPORTANT: Oil capacity for winch is greater thantransmission oil capacity. Check transmissionoil level frequently while filling to avoidtransmission pump cavitation.

NOTE: Power In position will deliver 7.8—9.5 L (2—2-1/2 gal) per minute to fill winch. Free Spool positionwill take approximately 1/2 hour to fill winch.

31. Operate winch in either Power In or Free Spoolposition to finish filling winch. Check transmission oillevel frequently and add oil through the transmissiondipstick. See Check Transmission Oil Level.(Operator’s Manual.)

32. Install cable. See Fastening Cable to WinchDrum—4000 Series. (Group 3000.)

TM11813 (13OCT10) 30-3000-4 748H Repair (S.N. 630436— )101310

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Continued on next page GD61784,00000B1 -19-02JUL07- 1

Fastening Cable to Winch Drum—4000 Series

CAUTION: Prevent possible injury from cablewire. Wear gloves when handling cable toprotect hands from cable wire cuts. DO NOT

guide cable on winch with your hands.

IMPORTANT: If a ferruled cable is used, the drumplug (3) must be installed to prevent cablefrom bending cable slot.

1. Attach cable to winch drum using one of the followingmethods:

Method 1: Attach a ferrule or cable clamp (1) to endof cable.

2. Wrap cable around the drum. Slide the ferrule or cable clamp under the cable and into slot in drum, andsecure with tab (2).

3. Adjust free spool drag to operator’s preference.

NOTE: Factory free spool drag setting was donewithout cable; adjust free spool drag to operator’s preference when cable is added.

NOTE: Ten inch drum only has pocket method of locating ferrule cable to drum.

1— Cable Clamp2— Tab

3— Drum Plug

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Continued on next page GD61784,00000B1 -19-02JUL07- 2/3

IMPORTANT: If cable is unwound below one turnon drum, cable will come off drum.

1. Method 2: Remove drum plug (2).

CAUTION: Prevent possible injury from cablewire. Wear gloves when handling cable toprotect hands from cable wire cuts. DO NOTguide cable on winch with your hands.

2. Thread cable up through small hole and insert cableback down through lower hole. Pull loop into drum.



2— Drum Plug

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R 0 7

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TM11813 (13OCT10) 30-3000-6 748H Repair (S.N. 630436— )101310

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GD61784,00000B1 -19-02JUL07-3

GD61784,00000B2 -19-02JUL07-1

1. Method 3: Remove drum plug.

CAUTION: Prevent possible injury from cablewire. Wear gloves when handling cable toprotect hands from cable wire cuts. DO NOT


2. Thread cable up through small hole and wrap cablearound wedge (1). Insert cable back down throughlower hole and pull wedge into drum slot (2).



1— Wedge 2— Drum Slot

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0 7

T X 1 0 1 8 8 2 3 A — U N — 1 2

M A R 0 7

Winch Free Spool Drag Adjustment

NOTE: The winch drum drag can be adjusted tooperator’s preference.

1. Start engine.

2. Lower equipment to ground.


4. Block wheels.

5. Move winch control handle to FREE SPOOL position.

6. Loosen nut (1).

7. Adjust slotted shaft (2) to desired winch drum drag.

8. Tighten nut.

1— Nut 2— Slotted Shaft

T X 1 0 1 8 8 1 6 A — U N — 1 2 M A R 0 7

4000 Winch

T X 1 0 1 8 8 1 7 A — U N — 1 2 M A R

0 7

6000 Winch

TM11813 (13OCT10) 30-3000-7 748H Repair (S.N. 630436—10

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Continued on next page SW03989,0000A9E -19-05OCT10- 1/2

Winch 6000 Series Remove and Install

NOTE: Cable must be removed f rom winchbefore servicing.




2. Operate all hydraulic control valves to release pressurein hydraulic system. Depress brake pedal at 1-secondintervals 20 times to drain oil from accumulator.


4. Remove cotter pin and pin (2) to disconnect yoke.

5. Remove cap screws (3) and washers to removemounting bracket and winch control cable.

6. Remove cap screws to disconnect winch driveline (5).

7. Disconnect hydraulic lines (1 and 4). Close allopenings using caps and plugs.

8. Drain winch oil. See Change Winch Oil—If Equipped.(Operator’s Manual.)

T X 1 0 8 0 9 5 0 — U N — 1 7 A U G 1 0

Pin, Cap Screws, and Winch Input Yoke

1— Pressure Inlet Line2— Pin3— Cap Screw (2 used)

4— Return Oil Line5— Driveline

TM11813 (13OCT10) 30-3000-8 748H Repair (S.N. 630436— )101310

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SW03989,0000A9E -19-05OCT10-2

9. Fasten lifting chain around winch as shown andconnect chain to a hoist.

10. Remove front and rear winch mounting cap screws.


11. Lift winch off equipment frame.

Specification

Winch—Weight

(approximate)................................................................................ 780 kg

1720 lb

12. Inspect and repair winch as necessary. See 60 and6000 Winches. (CTM41.)


13. Install winch.

Specification

Winch—Weight

(approximate)................................................................................ 780 kg

1720 lb

14. Install front and rear mounting cap screws and tightento specification.

Specification

Winch Mounting Cap

Screw—Torque............................................................................620 N∙m

455 lb-ft


16. Connect winch driveline. Install and tighten capscrews to specification.

Specification

Winch Cross-to-Yoke


43 lb-ft

17. Install control cable mounting bracket and washers,and tighten cap screws.

18. Install and adjust control cable. See Winch ControlValve Linkage Remove and Install or see WinchControl Cable Remove and Install. (Group 3015.)

19. Connect yoke to valve. Install pin and cotter pin.

20. Fill winch with recommended oil. See Change WinchOil—If Equipped. (Operator’s Manual.)

T 7 5 3 3 A X — U N — 0 9 J U L 9 1

Chain Around Winch


IMPORTANT: Oil capacity for winch is greater thantransmission oil capacity. Check transmissionoil level frequently while filling to avoidtransmission pump cavitation.

NOTE: Power In position will deliver 7.8—9.5 L (2—2-1/2 gal) per minute to fill winch. Free Spool positionwill take approximately 1/2 hour to fill winch.

22. Operate the winch in either Power In or Free Spoolposition to fill winch. Check transmission oil levelsfrequently when filling winch. See Check TransmissionOil Level. (Operator’s Manual.)

23. Install cable. See Fastening Cable to WinchDrum—6000 Series. (Group 3000.)

TM11813 (13OCT10) 30-3000-9 748H Repair (S.N. 630436—10

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GD61784,00000B4 -19-02JUL07-1/2

GD61784,00000B4 -19-02JUL07-2/2

Fastening Cable to Winch Drum—6000 Series

CAUTION: Prevent possible personal injury fromcutting wire. Wear gloves when handling cableto protect hands from cable wire cuts. DO NOT


1. Insert cable end through small hole (3) of nibble (1).

2. Separate cable end so wedges (2) are positioned tightagainst cable wires (4). Pull cable tight against nibble.

1— Nibble2— Wedge (2 used)

3— Small Hole in Nibble4— Cable Wires

T X 1 0 1 8 8 1 8 A — U N — 1 2 M A

R 0 7

T X 1 0 1 8 8 2 0 A — U N — 1 2 M A R 0 7

3. Lay cable in winch drum slot and install tab (5) tightagainst drum.

5— Tab

T X 1 0 1 8 8 2 1 A — U N — 1 2 M A R 0 7

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TM11813 (13OCT10) 30-3000-11 748H Repair (S.N. 630436—10

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Group 3015Control Linkage


Winch Control Valve Linkage Remove and Install

T 1 3 1 3 0 8 — U N — 0 1 J U N 0 0

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Control Linkage

GD61784,00000B6 -19-02JUL07-2/5


IMPORTANT: Winch valve must be in FREE SPOOLposition to correctly adjust linkage.

8. Push winch valve spool IN, as far as possible, intoFREE SPOOL position.

9. With the 4000 winch bellcrank or 6000 winch valvespool in free spool position, pull cable with 44.5 N (10lb-force).

Specification

Cable Pull (Free Spool

Position)—Force........... ........... ............ ............ ........... ............ ........ 44.5 N

10 lb-force

On 4000 Series winch only, apply 22.2 N (5 lb-force)to bellcrank toward cable end.

Specification

4000 Series Winch (Only)

Bellcrank—Force............................................................................22.2 N

5 lb-force

T 7 4 0 2 A E — U N — 0 6 N O V 9 0

10. Adjust the 4000 winch yoke to align with hole inbellcrank. Adjust the 6000 winch yoke to align withvalve spool.

11. Connect the yoke to the 4000 winch bellcrank (or 6000

winch valve spool) and install pin.

12. Move control lever to BRAKE ON (hold) position.

13. Slide bracket (A) so that lip contacts spring.

14. Tighten bracket and control cable cap screws.

A—Bracket

T 1 1 3 9 1

7 — U N — 1 3 A P R 9 8

4000 Series Winch

T 7 4 0

2 A I — U N — 2 6 N O V 9 0

6000 Series Winch

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Control Linkage

GD61784,00000B6 -19-02JUL07-4

GD61784,00000B6 -19-02JUL07-5

15. Run engine at slow idle.

16. Move control lever to FREE SPOOL position andrelease lever. There must be 3—5 mm (0.120—0.160in.) distance between lever and stop screw.

SpecificationControl Lever-to-Stop

Screw (Free Spool

Position)—Distance....................................................................3—5 mm

0.120—0.160 in.

NOTE: It is normal for engine to pull down whenPOWER IN is first engaged. This valvesequencing is to prevent winch brake fromdropping load before clutch engages.

17. Slowly move control lever to POWER IN position untildrum turns. There must be 6—8 mm (0.240—0.320in.) distance between lever and stop screw. Adjustas required.

Specification

Control Lever-to-Stop

Screw (Power In

Position)—Distance....................................................................6—8 mm

0.240—0.320 in.

T 73 74AY —1 9—30O CT 90 T 737 4A Z —19—30 OC T90

18. While POWER IN is engaged, release lever. Lever must return to BRAKE ON (hold) when released fromany POWER IN position. If lever does not return,increase return spring tension as described earlier inthis procedure.

19. Move winch control lever to free spool position.

20. Pull lever rearward with specified force, then movelever to left side.

Specification

Winch Control Lever

(Rearward Pull)—Force..................................................................22.2 N5 lb-force

Lever must move freely through the gate and not rubagainst rear of right slot or front of left slot. If lever rubs slot gate, readjust winch cable yoke as describedearlier in this procedure.

T 73 74AY —1 9—30O CT 90 T 739 7A Z —19—30 OC T90

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Control Linkage

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Group 3025Input Drive Shafts and U-Joints

AC12469,0000420 -19-30JUL07-1

SW03989,0000A9C -19-06AUG10-1

Winch Drive Shaft Remove and Install





3. Remove guards in frame pivot area as necessary togain access to winch drive shaft.

4. Remove cap screws (1) on each end of drive shaft.

5. Remove drive shaft. Inspect and replace parts asnecessary.

6. Install drive shaft with male yoke end (2) towardtransmission and female yoke end (3) toward winch.


Specification



Screw—Torque......................................................................51—57 N∙m

38—42 lb-ft



Screw—Torque.................................................................. 127—142 N∙m

94—105 lb-ft

8. Remove articulation locking bar

T X 1 0 2 5 7 1 9 A — U N — 2 9 J U

N 0 7

T X 1 0 2 5 7 2 0 A — U N — 2 9 J U N 0 7

1— Cap Screw (4 used per joint)

2— Male Yoke End

3— Female Yoke End

Winch Drive Shaft Disassemble and Assemble

1. Disassemble parts (1—5).

2. Inspect for excessively worn or damaged parts.Replace parts as necessary.

3. Assemble parts.

4. Tighten cap screws (5).

Specification

Winch Drive Shaft

Cross and Bearing

Assembly-to-Yoke 3/8 in.


43 lb-ft

5. Lubricate shaft after installation on machine.

5

1

2

11

3

5

1

4

3

T X 1 0 2 4 0 7 7 — U N — 0 4 J U N 0 7

Drive Shaft

1— Cap Screw (8 used)2— Drive Shaft3— Cross and Bearing

Assembly (2 used)

4— Lubrication Fitting5— Cap Screw (8 used)

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Group 3050Drive and Clutch

GD61784,00000BF -19-03JUL07-1

GD61784,00000C0 -19-03JUL07-1

Winch 4000 Series Drive and Clutch Repair

For winch repair, go to the appropriate repair story usingthe table of contents in component technical manual.(CTM25.)

Winch 6000 Series Drive and Clutch Repair

For winch repair, go to the appropriate repair story usingthe table of contents in component technical manual.(CTM41.)

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Drive and Clutch

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Section 32Stacking Blades

Contents

Page

Group 3201—BladesStacking Blade Remove and

Install ..................................................... 32-3201-1Spherical Bushing Remove and

Install ..................................................... 32-3201-5

Group 3215—Controls LinkageBlade Control Linkage Remove

and Install ..............................................32-3215-1Blade Control Valve Remove and

Install ..................................................... 32-3215-2

Group 3260—Hydraulic System

Blade Lift Cylinder Remove andInstall ..................................................... 32-3260-1

TM11813 (13OCT10) 32-1 748H Repair (S.N. 630436—10

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Group 3201Blades


Stacking Blade Remove and Install

1. Lower all equipment to the ground. Operate all controllevers to relieve pressure in the hydraulic system.

NOTE: One front wheel must be removed befor e

stacking blade pin can be removed.

2. Remove one front wheel. See Wheel Remove andInstall. (Group 0110.)


3. Support blade cylinder using lifting straps.

Specification

Blade Cylinder—Weight

(approximate).................................................................................. 35 kg

77 lb

4. Remove cap screws and retainers (2 and 3) andcylinder pins (1) to disconnect right and left bladecylinders.

T 1 9 5 5 5 5 B — U N — 2 1 O C T 0 3

Right Stacking Blade Cylinder

1— Cylinder Pin2— Retainer

3— Cap Screw

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TX1056819 T X 1 0 5 6 8 1 9 — U N — 0 6 M A R

0 9

Exploded View of Stacking Blade

4— Stacking Blade5— Bushing6— Lubrication Fitting

7— Cap Screw8— Bushing9— Washer

10— Seal11— Washer 12— Cap Screw

13— Pin14— Lock Nut


5. Support stacking blade (4).

Specification

Stacking Blade—Weight

(approximate).............................................................................. 1360 kg

3000 lb

6. Lower bottom guard.


8. Remove lock nut (14) and cap screw (12).

9. Remove pin (13) and stacking blade (4).

10. Inspect stacking blade for cracks or damage.

11. Inspect spherical bushings in cylinder bores and bladepivot bores f or wear or damage. If a bushing must bereplaced, see Spherical Bushing Remove and Install.(Group 3201.)

TM11813 (13OCT10) 32-3201-2 748H Repair (S.N. 630436— )101310

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Blades


T 8 5 0 9 A C — U N — 1 9 J U N 9 5

Blade Lower Pin

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Blades

GD61784,0000031 -19-10MAR09-4/5

GD61784,0000031 -19-10MAR09-5/5

A—Washer (as required)B—Shim (as required)C—Engine Frame

D—Seal Washer E—Hardened Washer F—Cap Screw

G—Blade Pin Cap— Washer H—3—6 mm (0.120—0.240 in.)

Clearance Dimension

12. Install stacking blade with washers properly positionedas shown.

13. Replace lubrication fittings if necessary.

14. Apply medium strength thread lock and sealer to capscrew (F).

15. Install one washer (A) on pin, then put new cap or washer (G) on pin, and hold in place.

IMPORTANT: A minimum of 3 mm (0.120 in.) gap (H)must be left on each side of pin to prevent a sideimpact from breaking off pin cap screws.

16. Measure gap (H) between cap and washer. Install or remove shims (B) until specified gap is obtained.

Specification

Cap-to-Washer—Gap.................................................................3—6 mm

0.120—0.240 in.

IMPORTANT: If blade is sprung so that specified

gap cannot be obtained, the blade must beremoved and pushbeams bent back until gapspecification can be obtained.

17. Install seal washer (D) on pin. Install cap or washer (G) and washer (E).

18. Apply medium strength thread lock and sealer to capscrew (F) and tighten to specification.

Specification

Blade Pin Cap Assembly

Cap Screw—Torque.....................................................................495 Nm

365 lb-ft


19. Lift blade using a hoist. Install washer shims (5)equally to each side of rod end as required so thatcylinders do not bind. Install pin (3) through cylinder,shims and spherical bushing (4).

Specification

Stacking Blade—Weight(approximate).............................................................................. 1360 kg

3000 lb


(approximate).................................................................................. 35 kg

77 lb

20. Install cap screw (1) and retainer (2) and tighten.

21. Install front wheel. See Wheel Remove and Install.(Group 0110.)

T 1 9 5 5 6 8 A — U N — 2 1 O C T 0 3

Cap Screw and Cylinder Pin

1— Cap Screw2— Retainer 3— Pin

4— Spherical Bushing5— Washer Shim (as required)

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GD61784,0000032 -19-30MAY07-1

Continued on next page GD61784,0000032 -19-30MAY07-2

Spherical Bushing Remove and Install

1. If bushing (A) in blade pivot bore must be replaced,remove washer (B) using a grinder to remove weld.

A—Bushing B—Washer

T 7 5 0 2 H J — U N — 0 2 J U L 9 1

2. Remove bushing (B). See DFT1099 Bushing Drivers.(Group 9900.)

A—Pipe AssemblyB—Spherical BushingC—Pipe Assembly

D—Washer E—Nut

T 7 5 6 9 A M — U N — 0 9 J U L 9 1

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Blades

GD61784,0000032 -19-30MAY07-3/3

3. Install bushing. See DFT1099 Bushing Drivers.(Group 9900.)

4. Turn nut (F) until center line (B) of bushing aligns withcenter line (C) of frame.

CAUTION: Have only a qualified welder do thewelding. Be sure the area near the machine isfree of debris and flammable material. Beforewelding, clean all dirt and paint from weldarea. Disconnect the battery negative cable.Connect the welder ground clamp as closeas possible to each weld area.

5. Weld new washers in place at the same locationwhere old ones were removed.

See Make Welding Repairs Safely. (Group 9000-01.)

See Remove Paint Before Welding or Heating. (Group9000-01.)

T 7 5 6 9 A L — U N — 0 9 J U L 9 1

A—Pipe AssemblyB—Bushing Center LineC—Frame Center Line

D—Bar StockE—Washer F—Nut

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Group 3215Controls Linkage

GD61784,0000039 -19-06MAR09-1

Blade Control Linkage Remove and Install

TX1056821 T X 1 0 5 6 8 2 1 — U N — 0 6 M A R 0 9

Blade Control Linkage

1— Shim2— Bushing (2 used)3— Knob4— Control Lever 5— Boot

6—Nut7— Washer 8— Bushing9— Lock Nut10— Pin

11— Spring Locking Pin12— Rod13— Jam Nut14— Ball Joint15— Boot

16— Boot Retainer 17— Nut

1. Lower blade and relieve all hydraulic pressure.



3. Inspect and replace blade control linkage parts asnecessary.

4. Clean threads of pivot ball joint (14) and apply mediumstrength thread lock and sealer.

5. Adjust length of rod (12) so horizontal leg of controllever (4) is level.

6. Clean threads of lever (4) and apply medium strengththread lock and sealer then install knob (3).

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Controls Linkage

GD61784,000003A -19-06MAR09-1/1

Blade Control Valve Remove and Install

TX1056822 T X 1 0 5 6 8 2 2 — U N — 0 6 M A R 0 9

Blade Control Valve

1— Cap Screw (3 used)2— Rubber Mount (3 used)

3— Blade Valve Support4— Washer (5 used)

5— Cap Screw (3 used)6—Rod

7— Spring Lock Pin8—Pin

1. Lower blade and relieve all hydraulic pressure.



3. Remove blade control valve.


5. Inspect blade control valve support and replace partsas necessary.

6. Install blade control valve.

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GD61784,0000033 -19-25JUL07-1

Blade Lift Cylinder Remove and Install



1. Operate all hydraulic control valves to releasepressure in hydraulic system.

2. Disconnect lines (5).


3. Attach hoist to blade lift cylinder using a lifting strap.

Specification


(approximate).................................................................................. 35 kg

77 lb

4. Remove cap screws and retainers (1).

5. Remove pins (2) to remove blade lift cylinder.

6. Repair or replace blade lift cylinder as required.

7. Install blade lift cylinder.

X 9 8 1 1 — U N — 2 3 A U G 8 8

T 1 9 5 5 5 5 A — U N — 2

1 O C T 0 3

Wheel Removed for Illustration Purposes Only

1— Cap Screw and Retainer 2—Pin3— Cap Screw

4— Hydraulic Line Guard5— Hydraulic Lines

TM11813 (13OCT10) 32-3260-1 748H Repair (S.N. 630436—10

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Hydraulic System

TM11813 (13OCT10) 32-3260-2 748H Repair (S.N. 630436— )101310

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Contents

TM11813 (13OCT10) 38-2 748H Repair (S.N. 630436— )101310

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Group 3803Grapple Mechanism

SW03989,0000AA4 -19-02SEP10-1

Grapple Remove and Install




2. Operate hydraulic control valves to release pressurein hydraulic system. Depress brake pedal at 1-secondintervals 20 times to drain oil from accumulator.

3. Disconnect rotary manifold-to-cylinder rod end hose(3) and rotary manifold-to-flow divider hose (4). Closeall openings using caps and plugs.

4. Disconnect shock absorber (2) from rotary yoke.


5. Remove grapple by removing pins (1).

Specification

Grapple Head and

Tongs—Weight

(approximate)...............................................................................1134 kg

2500 lb

6. Inspect and repair as necessary. See GrappleDisassemble and Assemble. (Group 3803.)


heavy component. Use proper lifting device.

7. Install grapple using pins.

Specification

Grapple Head and

Tongs—Weight

(approximate)...............................................................................1134 kg

2500 lb

T X 1 0 8 1 1 5 8 A — U N — 2 7 A U G 1 0

Grapple Remove and Install

1— Pin (2 used)2— Shock Absorber

3— Rotary Manifold-to-Cylinder Rod End Hose

4— Rotary Manifold-to-FlowDivider Hose

8. Connect shock absorber to rotary yoke. Tighten nutsnug, then back off 1/2 turn.

9. Connect rotary manifold hoses to cylinder rod end andflow divider.

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Grapple Mechanism

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Grapple Disassemble and Assemble

T X 1 0 8 1 3 7 1 — U N — 0 3 S E P 1 0

Grapple Components

TM11813 (13OCT10) 38-3803-2 748H Repair (S.N. 630436— )101310

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Grapple Mechanism

SW03989,0000AA5 -19-03SEP10-2

1— Top Cover (2 used)2— Cap Screw (4 used)3— Grapple Frame4— Shim (2 used)5— Shim (4 used)6— Bushing (2 used)

7— Washer (2 used)8— Cap Screw (2 used)9— Grapple Pin (2 used)10— Tong Pin (2 used)11— Washer (2 used)12— Washer (2 used)

13— Cap Screw (2 used)14— Bushing (4 used)15— Cylinder Rod Pin (2 used)16— Bushing (2 used)17— Washer (2 used)18— Cap Screw (2 used)

19— Nut (2 used)20— Lubrication Fitting (2 used)21— Tong (2 used)22— Tooth (2 used)


IMPORTANT: The pins that attach the head end of the cylinder also attach the opposite tong tothe frame. Tong cylinders should be removedone at a time to prevent both grapple tongsfrom falling out of the frame.

1. Disassemble parts as shown. See Grapple TongCylinder Remove and Install for removal procedure.(Group 3860.)

Specification

Grapple Head and

Tongs—Weight(approximate)...............................................................................1134 kg

2500 lb

Grapple HeadFrame—Weight

(approximate).................................................................................115 kg

254 lb

Grapple Tong—Weight

(approximate).......................................................................104—194 kg

230—428 lb

2. Inspect for worn or damaged parts. Replace parts asnecessary.

3. Assemble parts. Install all washers in the samelocations and quantities as removed.

TM11813 (13OCT10) 38-3803-3 748H Repair (S.N. 630436—10

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Grapple Mechanism


Grapple Dampener Disassemble and Assemble

T 1 3 1 3 0 7 — U N — 0 1 J U N 0 0

Grapple Dampener

TM11813 (13OCT10) 38-3803-4 748H Repair (S.N. 630436— )101310

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Grapple Mechanism

SW03989,0000AA6 -19-02SEP10-2

1— Plug (6 used)2— Spring (6 used)3— Washer (18 used)4— Snap Ring5— O-Ring6— O-Ring7— Housing

8— Bushing

9— O-Ring10— Plug11— Shaft12— O-Ring13— Snap Ring14— Bushing15— Lubrication Fitting (6 used)

16— Plate (6 used)

17— Disk (5 used)18— Cotter Pin19— Pin20— Pin21— Washer 22— Cap Screw23— Lock Nut

24— Shock Absorber Cylinder

25— Washer 26— Lubrication Fitting (2 used)27— Bushing (2 used)28— Grapple Dampener Housing29— Pin30— Spacer 31— Washer

32— Cap Screw

CAUTION: Prevent possible crushing injur y fromheavy component. Use appropriate lifting device.

1. Remove grapple using a suitable lifting device. SeeGrapple Remove and Install. (Group 3803.)


2. Remove grapple dampener using a suitable liftingdevice.

Specification

Grapple Damp-ener—Weight (approxi-

mate)............................................................................................. 105 kg

231 lb

3. Remove plugs (1), washers (3), and springs (2).

4. Push housing (7) inward to remove snap ring (4).

5. Remove plates (16), disks (17), shaft (11), and snapring (13) from grapple dampener housing (28). Inspectfor wear or damage.

IMPORTANT: The plate located next to springs (2) willshow normal wear or galling. When dampener is

assembled, this plate must be installed next tothe springs. Installing this galled plate next to afriction element will damage the friction element.

NOTE: If any friction material remains on disks (17),they are considered usable.

6. Grease plates and disks with a clean coat of greasecontaining 3—5% moly. Wipe off excess grease.

7. Install O-rings (9 and 12), shaft, and snap ring (13)into housing.

8. Alternately install plates and disks, ensuring that the

galled steel plate is toward springs.

NOTE: Install snap ring (4) with gap located at 12 o’clock position. Snap ring helps retaingrease inside the housing.

9. Install O-rings (5 and 6) into housing. Push housinginto grapple dampener housing to install snap ring (4)with snap ring gap at 12 o’clock position.

10. Adjust dampener. See Grapple Dampener Adjustment.(Group 3803.)

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Grapple Mechanism


Grapple Dampener Adjustment

The grapple dampener limits the motion of the grapplehead when traveling empty and prevents damage to thestructural components, especially the yoke, crosshead,and pins.

Adjust the dampener if the head swings to extremeheights or hits the stops. Adjust the dampener byadding or subtracting the number of shim washers in thedampener assembly.

1. Slightly loosen adjusting plugs (1) (every other plug or all six plugs) evenly to remove spring tension and tokeep housing from rotating.

2. Remove three plugs.

3. Remove one shim washer (2) from each of the threeplugs to tighten grapple dampener, or add one shimwasher to each plug to loosen.

4. Apply 3—5% moly grease to adjusting plug thread andthe inside of plugs. Tighten plugs evenly until plugscontact shim washers.

5. Repeat for other three plugs. Be sure that all plugshave an equal number of shims.

TEST CONDITIONS:

NOTE: The grapple head should be 10—15° from vertical under the following test conditions.

a. Close tongs and raise the grapple arch or boom tofull height.

b. Lower the arch or boom slowly and bring to asmooth stop when the tongs are approximately 300mm (12 in.) above the ground.

c. When properly adjusted, the grapple head will be10—15° from vertical. Measure with a magneticbase inclinometer (3).

IMPORTANT: The snap ring gap is positioned atvertical top to maintain the grease level in thedampener housing. Retain this position whiletightening plugs by holding the dampener housing with a pry bar.

Do not add any washers to the inside of theadjusting plugs in an attempt to tighten thedampener assembly. This will cause the

springs to become a solid member. Damageto the outer dampener housing will result.If additional dampening is required after allshim washers are removed, it is necessaryto replace the disks inside the dampener assembly. See your authorized dealer.

6. If additional tightness is required, remove shimwashers from plugs with the greatest number of shimwashers. If additional looseness is required, addshim washers to plugs with the least number of shimwashers. Repeat steps 1—4 until desired tightnessis achieved.

T X 1 0 1 9 9 4 5 A — U N — 1 3 M

A R 0 7

Adjusting Plugs and Shim Washer

T X 1 0 1 9 9 4 7 A — U N — 1 3 M A R 0 7

Magnetic Base Inclinometer

1— Plug (6 used)2— Shim Washer (up to 24

used)

3— Magnetic Base Inclinometer

TM11813 (13OCT10) 38-3803-6 748H Repair (S.N. 630436— )101310

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Grapple Mechanism

SW03989,0000AA7 -19-02SEP10-2

SW03989,0000AA8 -19-02SEP10-1

7. To hold dampener housing in place, use a pry bar between plugs. Tighten plugs to specification.

Specification

Grapple Dampener

Adjusting Plug—Torque...............................................................184 N∙m

250 lb-ft

Dampener, Yoke, and Crosshead PinsLubricate

IMPORTANT: If dampener spline grease fitting (4)is not greased at proper intervals, prematurespline failure could occur.

If grease fitting does not accept grease, makesure the grapple head is on the ground beforeattempting to lubricate again.

NOTE: Lubricate the four fittings until greaseescapes at joints.

Lubricate fittings until clean grease escapes at joints. For grease specification, see Grease. (Operator’s Manual.)

1— Top Locating Point2— Bushing Next to Dampener

Assembly Grease Fitting3— Dampener Head Outer

Bushing Grease Fitting

4— Dampener Spline GreaseFitting

5— Brake Plate Grease Fitting6— Dampener Brake Assembly

T X 1 0 1 9 0 4 5 A — U N — 1 2 M A R 0 7

Dampener, Yoke and Crosshead Pins

T X 1 0 1 9 0 5 4 — U N — 1 2 M A R 0 7

Cross Section of Upper Dampener Pin

T 1 0 2 1 6 1 — U N — 2 2 J U L 9 6

Lower Pin

TM11813 (13OCT10) 38-3803-7 748H Repair (S.N. 630436—10

PN=3





Grapple Mechanism

Continued on next page SW03989,0000AA9 -19-15SEP10-2

13. Install upper and lower bearing races (6 and 7).Bearing races must be tight against housing.


14. Install and support grapple yoke into arch or boom(13).

Specification

Grapple Yoke—Weight

(approximate).................................................................................. 54 kg

119 lb

CAUTION: Prevent possible burn injury.Hot equipment and fluids can cause burnsto unprotected skin. Wear gloves andprotective clothing when working with hotequipment and fluids.

IMPORTANT: Damage to the bearing may occur;use proper heating device.

15. Heat upper bearing cone (8) to specification.

Specification

Upper Bearing

Cone—Temperature.........................................................................78°C

175°F

16. Install upper bearing cone.

17. Turn grapple yoke so the pivot pin bore (14) is 90° toarch or boom (13) as shown.

7

6

T X 1 0 5 6 6 3 7 — U N — 0 5 M A R 0 9

Bearing Races

13

1

14 T X 1 0 8 1 1 8 1 — U N — 2 5 A U G

1 0

Grapple Yoke

1— Grapple Yoke6— Lower Bearing Race7— Upper Bearing Race

13— Arch or Boom14— Pivot Pin Bore

TM11813 (13OCT10) 38-3803-9 748H Repair (S.N. 630436—10

PN=3



Grapple Mechanism


18. Install rotate motor driven gear (11) so cutout (17) isaligned with rotate motor drive gear (15). Align two 4mm holes (16) as shown.

19. Install four cap screws (12) 90° apart as shown fromtop.

11— Rotate Motor Driven Gear 12— Cap Screw (12 or 14 used)15— Rotate Motor Drive Gear

16— Hole (4 mm) (2 used)17— Cutout

1612

12

12 16

12

17

11

15

T X 1 0 8 1 1 8 2 — U N — 2 5 A U G 1 0

Cap Screw Location (12 cap screw yoke)

16

16

11

12

17

15

12

12

12

T X 1 0 8 1 1 8 3 — U N — 2 5 A U G 1 0

Cap Screw Location (14 cap screw yoke)

TM11813 (13OCT10) 38-3803-10 748H Repair (S.N. 630436— )101310

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Grapple Mechanism


IMPORTANT: Bearing cones and bearing racesmust be properly seated to maintain proper bearing preload. Bearing failure may resultfrom improper bearing preload.

20. Grapple Yoke Bearing Preload Measurement:a. Tighten cap screws in order shown to specification.

Specification

Gear-to-Yoke Cap

Screw—Torque..............................................................................41 N∙m

30 lb-ft

b. Tighten cap screws again in order shown tospecification.

Specification

Gear-to-Yoke Cap

Screw—Torque..............................................................................81 N∙m

60 lb-ft

c. Tighten cap screws again in order shown tospecification.

Specification

Gear-to-Yoke Cap

Screw—Torque............................................................................122 N∙m

90 lb-ft

d. Rotate grapple yoke ten revolutions. Tighten capscrews in order shown to specification.

Specification

Gear-to-Yoke Cap

Screw—Torque............................................................................170 N∙m

125 lb-ft

e. Rotate grapple yoke a second time ten revolutions.Tighten cap screws again in order shown tospecification.

Specification

Gear-to-Yoke Cap

Screw—Torque............................................................................170 N∙m

125 lb-ft

f. Rotate grapple yoke a third time ten revolutions.Tighten cap screws again in order shown tospecification.

Specification

Gear-to-Yoke Cap

Screw—Torque............................................................................170 N∙m

125 lb-ft

g. Rotate grapple yoke a fourth time ten revolutions.Tighten cap screws again in order shown tospecification.

1

4

2

3

T X 1 0 5 6 2 5 8 — U N — 2 3 F E B 0 9

Cap Screw Tighten Order (12 cap screw yoke)

1

4

2

3

T X 1 0 5 6 2 5 6 — U N — 2 3 F E B 0 9


Specification

Gear-to-Yoke Cap

Screw—Torque............................................................................170 N∙m125 lb-ft

TM11813 (13OCT10) 38-3803-11 748H Repair (S.N. 630436—10

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Grapple Mechanism


21. Measure distance from top surface of rotate motor driven gear to grapple yoke through both 4 mm holesusing a depth micrometer.

Record the average distance measurement from bothholes.


22. Support yoke.

Specification

Grapple Yoke—Weight

(approximate).................................................................................. 54 kg

119 lb

23. Remove rotate motor driven gear.

24. Measure rotate motor driven gear thickness (20) atboth locations as shown.

Record the average thickness measurement fromboth locations.

NOTE: The formula for this procedure is: A - B +0.33 mm (0.013 in.) = C.

25. Subtract the average thickness of the rotate motor driven gear (B) from the average distance from the topsurface of the gear to the yoke (A). This is the shimpack thickness (C).

Add 0.33 mm (0.013 in.) to gap difference to obtainshim pack dimension for bearing preload.

26. Arrange shims in shim pack so thickest shims are onoutside of shim pack.

1— Grapple Yoke11— Rotate Motor Driven Gear 16— Hole (4 mm) (2 used)

18— Shim Pack Thickness19— Rotate Motor Driven Gear

Thickness20— Top of Gear to Yoke

11

1

18 2019

T X 1 0 8 1 1 8 4 — U N — 2 5 A U G

1 0

Shim Pack Measurement

16

11

16 19 19

1919

T X 1 0 8 1 1 8 5 — U N — 2 5 A U G 1 0

Rotate Motor Driven Gear Measurement

TM11813 (13OCT10) 38-3803-12 748H Repair (S.N. 630436— )101310

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Grapple Mechanism


29. Install rotate motor driven gear so the longmeasurement of cutout is aligned with rotate motor drive gear. Align two 4 mm holes as shown.

11— Rotate Motor Driven Gear

12— Cap Screw (12 or 14 used)15— Rotate Motor Drive Gear

16— Hole (4 mm) (2 used)

17— Cutout

16

16

12

11

17

15

T X 1 0 8 1 1 8 7 — U N — 2 5 A U G 1 0

Rotate Driven Gear Cap Screw Location (12 cap screw yoke)

13

16

16

11

12

17

15

T X 1 0 8 1 1 8 8 — U N — 2 5 A U G 1 0

Rotate Driven Gear Cap Screw Location (14 cap screw yoke)

TM11813 (13OCT10) 38-3803-14 748H Repair (S.N. 630436— )101310

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Grapple Mechanism


IMPORTANT: Use new cap screws to install grappleyoke to prevent cap screw failure.

30. Rotate Motor Driven Gear Torque Procedure:

a. Tighten cap screws in order shown to specification.

Specification

Gear-to-Yoke Cap

Screw—Torque..............................................................................41 N∙m

30 lb-ft

b. Tighten cap screws again in order shown tospecification.

Specification

Gear-to-Yoke Cap

Screw—Torque..............................................................................81 N∙m

60 lb-ft

c. Tighten cap screws again in order shown tospecification.

Specification

Gear-to-Yoke Cap

Screw—Torque............................................................................122 N∙m

90 lb-ft

d. Rotate grapple yoke ten revolutions. Tighten capscrews in order shown to specification.

Specification

Gear-to-Yoke Cap

Screw—Torque............................................................................170 N∙m

125 lb-ft

e. Rotate grapple yoke a second time ten revolutions.Tighten cap screws again in order shown tospecification.

Specification

Gear-to-Yoke Cap

Screw—Torque............................................................................170 N∙m

125 lb-ft

f. Rotate grapple yoke a third time ten revolutions.Tighten cap screws again in order shown tospecification.

Specification

Gear-to-Yoke Cap

Screw—Torque............................................................................170 N∙m

125 lb-ft

g. Mark each cap screw. Tighten cap screws in order

shown to specification.

19

11

4

6

82

10

12

3

5

7

T X 1 0 5 6 2 5 9 — U N — 2 4 F E B 0 9


91

13

7

11

6

4

8

142

10

5

12

3

T X 1 0 5 6 2 6 2 — U N — 2 3 F E B 0 9


Specification

Gear-to-Yoke Cap

Screw—Torque Turn....................................60° (1 flat on hex cap screw)

TM11813 (13OCT10) 38-3803-15 748H Repair (S.N. 630436—10

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Grapple Mechanism

SW03989,0000AA9 -19-15SEP10-9/9

31. Pump grease into arch tube grease fitting (21) whilerotating the grapple yoke until grease comes out fromunder driven gear teeth all around gear.

32. Install rotary manifold. See Rotary Manifold Removeand Install. (Group 3860.)

33. Install grapple crosshead. See Grapple Dampener Disassemble and Assemble. (Group 3803.)

34. Install grapple. See Grapple Remove and Install.(Group 3803.)

IMPORTANT: Grapple dampener must be adjustedproperly. Improper grapple dampener adjustment may cause bearing damage.

35. Perform grapple dampener adjustment. See GrappleDampener Adjustment. (Group 3303.)

1— Grapple Yoke13— Arch

21— Grease Fitting

13 21

1

T X 1

0 8 1 1 8 9 — U N — 2 5 A U G 1 0

Yoke Grease Fitting Location

TM11813 (13OCT10) 38-3803-16 748H Repair (S.N. 630436— )101310

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Group 3840Frames

GD61784,00000C5 -19-05JUL07-1

Dual Function Grapple Cable Rollers Remove and Install

8

13

1317

17

1

7

7

4

14

11

3

5

15

10

10

9

16

62

12

T195678 T 1 9 5 6 7 8 — U N — 2 4 O C T 0 3

Dual Function Grapple Cable Rollers

1— Nut (4 used)2— Cap Screw (2 used)3— Cap Screw (2 used)4— Cap Screw (4 used)

Lubrication Fitting (4 used)5— Washer (2 used)

6— Washer (2 used)7— Washer (4 used)8— Horizontal Roller 9— Vertical Roller (2 used)10— Lubrication Fitting (2 used)

11— Roller Frame12— Lubrication Fitting (2 used)13— Bushing (2 used)14— Shaft15— Strap

16— Shaft (2 used)17— Washer (2 used)

1. Remove rollers (8 and 9).

2. Inspect bushings (13) and shafts (14 and 16) for wear or damage.

3. Install bushings even with end surface of rollers.

4. Install rollers.

TM11813 (13OCT10) 38-3840-1 748H Repair (S.N. 630436—10

PN=34



Frames

GD61784,00000C6 -19-25JUL07-1/1

Dual Function Grapple Boom Remove andInstall




2. Inspect boom for cracks.

IMPORTANT: Have only a qualified welder do thewelding. Be sure the area near the machine isfree of debris and flammable material. Beforewelding, clean all dirt and paint from weldarea. Disconnect the battery ground (—) cable.Connect the welder ground clamp as closeas possible to each weld area.

3. Weld any cracks using E7018 electrodes or equivalent.See Make Welding Repairs Safely. (Group 9000-10.)


4. Remove Grapple. See Grapple Remove and Install.(Group 3803.)


5. Support boom (1).

6. Remove grapple motor. See Grapple Rotate Motor Remove and Install. (Group 3860.)

7. Remove rotary manifold. See Rotary Manifold

Remove and Install. (Group 3860.)8. Remove hydraulic hoses from boom.

9. Remove boom cylinder pins (2).

10. Remove boom pins (3).

11. Remove boom.

T X 1 0 2 4 4 0 5 A — U N — 0 5 J U

N 0 7

Boom

1— Boom2— Boom Cylinder Pin (2 used)

3— Boom Pin (2 used)



13. Install boom.

14. Install boom pins.

15. Install boom cylinder pins.

16. Install hydraulic hoses in boom.

17. Install rotary manifold. See Rotary Manifold Removeand Install. (Group 3860.)

18. Install grapple motor. See Grapple Rotate Motor Remove and Install. (Group 3860.)

19. Install grapple. See Grapple Remove and Install.(Group 3803.)


TM11813 (13OCT10) 38-3840-2 748H Repair (S.N. 630436— )101310

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Frames

GD61784,00000C7 -19-25JUL07-1

Dual Function Grapple Arch Remove andInstall




2. Inspect arch for cracks.

IMPORTANT: Have only a qualified welder do thewelding. Be sure the area near the machine isfree of debris and flammable material. Beforewelding, clean all dirt and paint from weldarea. Disconnect the battery ground (—) cable.Connect the welder ground clamp as closeas possible to each weld area.

3. Weld any cracks using E7018 electrodes or equivalent.See Make Welding Repairs Safely. (Group 9000-10.)


4. Remove boom. See Dual Function Grapple BoomRemove and Install. (Group 3740.)


5. Support arch.

6. Remove arch cylinder pins (2).

7. Remove arch pins (3).

8. Remove arch (1).

T X 1 0 2 4 4 0 8 A — U N — 0 5 J U

N 0 7

Arch

1— Arch2— Arch Cylinder Pin (2 used)

3— Arch Pin (2 used)



10. Install arch.

11. Install arch pins.

12. Install ar ch cylinder pins.

13. Install boom. See Dual Function Grapple BoomRemove and Install. (Group 3740.)


TM11813 (13OCT10) 38-3840-3 748H Repair (S.N. 630436—10

PN=34

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Frames

TM11813 (13OCT10) 38-3840-4 748H Repair (S.N. 630436— )101310

PN=348




Continued on next page SW03989,0000AB0 -19-05OCT10-1

Boom or Arch Cylinder Remove andInstall—Dual Function Grapple

1. Lower grapple to the ground.




3. Operate all hydraulic control valves to releasepressure in hydraulic system. Depress brake pedal at1 second intervals 20 times to drain oil from servicebrake accumulator.


5. Disconnect arch cylinder hydraulic hoses (2) or boomcylinder hydraulic hoses (5). Close all openings usingcaps and plugs.


6. Connect lifting strap to arch cylinder (3) or boomcylinder (6).

Specification

Boom Cylinder—Weight

(approximate).................................................................................. 66 kg

145 lb

Arch Cylinder—Weight

(approximate).................................................................................. 62 kg137 lb

7. Remove pins (1) to remove arch cylinder.

8. Remove pins (4) to remove boom cylinder.

9. Inspect bushings for looseness, wear, or damage.Remove bushings only if replacement is necessary.See Spherical Bushing Remove and Install. (Group3201.)

10. Repair hydraulic cylinder as necessary. For additionalinformation, see 120 Series Hydraulic Cylinders.(CTM114319.)


11. Install arch cylinder or boom cylinder and pins.

Specification

Boom Cylinder—Weight

(approximate).................................................................................. 66 kg

145 lb

Arch Cylinder—Weight

(approximate).................................................................................. 62 kg

137 lb

T X 1 0 8 1 2 6 0 A — U N — 0 1 S E

P 1 0

Arch Cylinder Remove and Install

T X 1 0 8 1 2 5 9 A — U N — 0 1 S E P 1 0

Boom Cylinder Remove and Install

1— Pin (4 used)2— Arch Cylinder Hydraulic

Hose (4 used)3— Arch Cylinder (2 used)

4— Pin5— Boom Cylinder Hydraulic

Hose (4 used)6— Boom Cylinder (2 used)

NOTE: Fill hydraulic cylinder with hydraulic oil before connecting hoses to prevent damageto O-rings and seals.

12. Connect arch cylinder hydraulic hoses or boomcylinder hydraulic hoses.



TM11813 (13OCT10) 38-3860-1 748H Repair (S.N. 630436—10

PN=34

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SW03989,0000AB0 -19-05OCT10-2/2




TM11813 (13OCT10) 38-3860-2 748H Repair (S.N. 630436— )101310

PN=350

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Hydraulic System

Continued on next page SW03989,0000AB1 -19-04OCT10-1

Grapple Tong Cylinder Remove and Install

TX1081258

4

3

2

11

56

7

89

10

1

T X 1 0 8 1 2 5 8 — U N — 0 1 S E P 1 0

Grapple Tong Cylinder Removal and Installation

1— Frame2— Cap Screw (4 used)3— Top Cover (2 used)

4— Tong Pin (2 used)5— Washer (2 used)6— Cap Screw (2 used)

7— Cap Screw (2 used)8— Spacer (2 used)9— Washer (2 used)

10— Cylinder Rod Pin (2 used)11— Tong Cylinder (2 used)

1. Close grapple and lower to the ground.




3. Operate all hydraulic control valves to releasepressure in hydraulic system. Depress brake pedal at

one-second intervals 20 times to drain oil from servicebrake accumulator.


5. Remove top cover (3). Disconnect hose at tongcylinder (11) head end. Close all openings using capsand plugs.

6. Disconnect hose at tong cylinder rod end. Close allopenings using caps and plugs.


TM11813 (13OCT10) 38-3860-3 748H Repair (S.N. 630436—10

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Hydraulic System

SW03989,0000AB1 -19-04OCT10-2/2

7. Connect lifting strap to tong cylinder.

Specification

Tong Cylinder—Weight

(approximate).................................................................................. 66 kg

146 lb

8. Remove cap screw (7), washer (9), and spacer (8)from cylinder rod pin (10). Remove cylinder rod pin.

CAUTION: The pin that attaches the cylinder headend also attaches the opposite tong. Cylindersshould be removed one at a time to prevent bothgrapple tongs from falling out of the frame.

9. Remove cap screw (6) and washer (5). Use either another pin or round bar stock that is slightly smaller indiameter and approximately equal to the width of thegrapple frame in length to drive out the tong pin andstill hold the tong in place.

For some grapple head and tong configurations, itis only necessary to push out the pin far enough todisconnect the head end of the cylinder from thegrapple frame.

10. Remove tong cylinder.

11. Inspect and repair tong hydraulic cylinder asnecessary. For additional information, see 120 SeriesHydraulic Cylinders. (CTM114319.)


12. Install tong cylinder into frame (1).

SpecificationTong Cylinder—Weight

(approximate).................................................................................. 66 kg

146 lb

13. Install tong pin and cylinder rod pin. Install spacer,washers, and cap screws.


15. Install top cover.





TM11813 (13OCT10) 38-3860-4 748H Repair (S.N. 630436— )101310

PN=352

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Hydraulic System

Continued on next page SW03989,0000AB2 -19-03SEP10-1

Grapple Rotate Motor Remove and Install

T X 1 0 8 1 2 5 7 — U N — 0 1 S E P 1 0

Grapple Rotate Motor Removal and Installation

1— Grapple Rotate Motor 2— Rotate Hose from Grapple

Rotate Solenoid Valve

3— Case Drain Hose to Tank4— Rotate Hose from Grapple

Rotate Solenoid Valve

5— Case Drain Hose from RotateManifold


7— Washer (2 used)

1. Lower grapple to the ground.2. Prepare machine for service. See Park and Prepare



3. Operate all hydraulic control valves to releasepressure in hydraulic system. Depress brake pedal at1 second intervals 20 times to drain oil from servicebrake accumulator.


5. Remove rotate motor cover from top of boom.

6. Tag and disconnect hoses. Close all openings usingcaps and plugs.

TM11813 (13OCT10) 38-3860-5 748H Repair (S.N. 630436—10

PN=3

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Hydraulic System

SW03989,0000AB2 -19-03SEP10-2/2


7. Remove cap screws (6) and washers (7). Removerotate motor.

Specification

Grapple Rotate

Motor—Weight

(approximate).................................................................................. 25 kg

55 lb



9. Install rotate motor.

Specification

Grapple Rotate

Motor—Weight

(approximate).................................................................................. 25 kg

55 lb

10. Install cap screws and washers. Tighten cap screwsto specification.

Specification


86—105 lb-ft

11. Connect hoses.






17. Install rotate motor cover.

TM11813 (13OCT10) 38-3860-6 748H Repair (S.N. 630436— )101310

PN=354

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Hydraulic System

Continued on next page SW03989,0000AB3 -19-01OCT10-1/

Grapple Rotate Motor Disassemble

NOTE: Cleanliness is extremely important when repairing a hydraulic motor. Work in a clean area. Beforedisconnecting the lines, clean the port area

of the motor thoroughly. Use a wire brush toremove foreign material and debris from around the exterior joints of the motor.

Check the shaft and key slot, and remove all nicks, burrs, or sharp edges that might damagethe bearing housing seals when installing the

shaft and bearing assembly.

Before starting the disassembly procedures,drain the oil from inside the motor.

T 2 1 4 8 6 5 — U N — 2 1 S E P 0 5

TM11813 (13OCT10) 38-3860-7 748H Repair (S.N. 630436—10

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Hydraulic System

SW03989,0000AB3 -19-01OCT10-2/12

SW03989,0000AB3 -19-01OCT10-3/12

Continued on next page SW03989,0000AB3 -19-01OCT10-4/12

Grapple Rotate Motor Components

1— Shaft Exclusion Seal2— Bearing Housing3— Backup Ring4— Shaft Seal5— Bearing and Shaft

Sub-Assembly6— Seal7— Shaft Face Seal8— Splined Drive

9— Wear Plate10— Seal11— Geroler Sub-Assembly12— Seal13— Valve Plate

14— Valve Drive15— Valve16— Balance Ring

17— Outer Face Seal18— Pin (2 used)19— Spring (2 used)20— Inner Face Seal21— Seal

22— Plug with O-Ring23— Valve Housing24— Name Plate

25— Washer (4 used)26— Tie Bolt (4 used)27— O-Ring (2 used)28— Relief Valve (2 used)29— O-Ring (2 used)

30— Cap (2 used)

1. Place motor upright in vise with output shaft down.Clamp across mounting flange of bearing housing (2).Excessive clamping pressure will cause distortion.When clamping, use some protective device on vise,such as special soft jaws, pieces of hard rubber or board.

NOTE: Although not all drawings show motor in vise,

we recommend that you keep motor upright invise during disassembly and reassembly.

T 2 1 4 8 6 7 — U N — 2 1 S E P 0 5

Motor in Vise

2. Remove four tie bolts (26) and washers (25) frommotor.

25— Washer (4 used) 26— Tie Bolt (4 used)

T X 1 0 8

1 2 5 5 — U N — 0 1 S E P 1 0

Remove Tie Bolts and Washers

TM11813 (13OCT10) 38-3860-8 748H Repair (S.N. 630436— )101310

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Hydraulic System

SW03989,0000AB3 -19-01OCT10-5/


3. Lift valve housing (23) straight up. If done carefully,the pins (18), springs (19), balance ring assembly(16), and valve (15) will remain on the valve plate (13).

4. Carefully remove seal (21) from valve housing.

21— Seal 23— Valve Housing

T X 1 0 8 1 2 5 4 — U N — 0 1 S E P 1 0

Remove Valve Housing and Seal

5. Remove case drain plug with O-ring (22) from valvehousing.

6. Remove relief valves (26) and O-rings (27 and 29)from valve housing. Inspect and clean relief valves.Replace O-rings and install relief valves.

22— Case Drain Plug withO-ring

27— O-Ring (2 used)28— Relief Valve (2 used)

29— O-Ring (2 used)30— Cap (2 used)

T X 1 0 8 1 2 5 3 — U N — 0 1 S E P 1 0

Remove Plug and Relief Valves

TM11813 (13OCT10) 38-3860-9 748H Repair (S.N. 630436—10

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SW03989,0000AB3 -19-01OCT10-7/12

SW03989,0000AB3 -19-01OCT10-8/12


7. Remove two pins (18) and springs (19) from balancering assembly (16).

8. Remove balance ring assembly.

9. Remove inner and outer face seals (17 and 20) from

balance ring.

10. Remove valve (15).

15— Valve16— Balance Ring17— Outer Face Seal

18— Pin (2 used)19— Spring (2 used)20— Inner Face Seal

T X 1 0 8 1 2 5 2 — U N — 0 1 S E P 1 0

Remove Balance Ring, Face Seals, and Valve

11. Remove valve plate (13).

12. Remove seal (12) from valve plate.

13. Remove valve drive (14).

12— Seal13— Valve Plate

14— Valve Drive

T X 1 0 8 1 2 5 1 — U N — 0 1 S E P 1 0

Remove Valve Plate, Seal, and Valve Drive

14. Remove geroler sub-assembly (11).

15. Remove splined drive (8).

8— S plined Drive 11— Geroler Su b-Assembly

T X 1 0 8 1 2 5 0 — U N — 0 1 S E P 1 0

Remove Geroler Sub-Assembly and Splined Drive

TM11813 (13OCT10) 38-3860-10 748H Repair (S.N. 630436— )101310

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SW03989,0000AB3 -19-01OCT10-11/

SW03989,0000AB3 -19-01OCT10-12/

16. Remove seal (10) from wear plate (9).

17. Remove wear plate.

18. Remove shaft face seal (7) from wear plate.

19. Remove seal (6) from bearing housing.

2— Bearing Housing6— Seal7— Shaft Face Seal

9— Wear Plate10— Seal

T X 1 0 8 1 2 4 9 — U N — 0 1 S E P 1 0

Remove Wear Plate and Seals

20. Remove bearing and shaft sub-assembly (5) frombearing housing. Use press, if necessary.

NOTE: Individual parts of shaft and bearing sub-assembly are not sold separately. Replace as a unit.

5— Bearing and ShaftSub-Assembly

2— Bearing Housing

T X 1 0 8 1 2 4 8 — U N — 0 1 S E P 1 0

Remove Bearing and Shaft Sub-Assembly

21. Use a small screwdriver to remove shaft seal (4),backup ring (3), and shaft exclusion seal (1) frombearing housing.

1— Shaft Exclusion Seal2— Bearing Housing

3— Backup Ring4— Shaft Seal

T X 1 0 8 1 2 4 7 — U N — 0 1 S E P 1 0

Remove Exclusion Seal and Shaft Seal

TM11813 (13OCT10) 38-3860-11 748H Repair (S.N. 630436—10

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Hydraulic System


Grapple Rotate Motor Assemble

T 2 1 4 8 6 5 — U N — 2 1 S E P 0 5

Grapple Rotate Motor Components

TM11813 (13OCT10) 38-3860-12 748H Repair (S.N. 630436— )101310

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Hydraulic System


1— Shaft Exclusion Seal2— Bearing Housing3— Backup Ring4— Shaft Seal5— Bearing and Shaft

Sub-Assembly6— Seal

7— Shaft Face Seal8— Splined Drive

9— Wear Plate10— Seal11— Geroler Sub-Assembly12— Seal13— Valve Plate14— Valve Drive15— Valve

16— Balance Ring

17— Outer Face Seal18— Pin (2 used)19— Spring (2 used)20— Inner Face Seal21— Seal22— Plug with O-Ring23— Valve Housing

24— Name Plate

25— Washer (4 used)26— Tie Bolt (4 used)27— O-Ring (2 used)28— Relief Valve (2 used)29— O-Ring (2 used)30— Cap (2 used)

NOTE: Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage.

Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towel because lint or other matter can get in thehydraulic system and cause damage.

Do not use a coarse grit or try to file or grind these parts.

Check around chamfered area of the shaft for burrs,nicks or sharp edges that can damage the sealswhen reassembling the bearing housing.

NOTE: Lubricate all seals, prior to installation,with petroleum jelly . Use new seals whenreassembling this motor.

TM11813 (13OCT10) 38-3860-13 748H Repair (S.N. 630436—10

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T X 1 0 8 1 2 4 6 — U N — 0 1 S E P 1 0

Shaft Seals

1. Use a press to install shaft exclusion seal (1) in outer bore of bearing housing (2).

NOTE: Lip of seal must face outward. If a press is not available, use a plastic or rubber hammer, being careful not to damage or cock the seal in the bore.

2. Place backup ring (3) into seal bore. Place shaft seal(4) onto Eaton 600496 Seal Installation Tool and pressseal into seal bore of bearing housing.

3. Clamp bearing housing upright in vise.

NOTE: Although not all drawings show motor in vise,we recommend that you keep motor upright invise during disassembly and reassembly.

T X 1 0 8 1 2 4 7 — U N — 0 1 S

E P 1 0

Install Exclusion Seal and Shaft Seal

1— Shaft Exclusion Seal2— Bearing Housing3— Backup Ring4— Shaft Seal

5— Bearing and ShaftSub-Assembly

6— Seal7— Shaft Face Seal9— Wear Plate

TM11813 (13OCT10) 38-3860-14 748H Repair (S.N. 630436— )101310

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SW03989,0000AB4 -19-01OCT10-5/


4. Place Eaton 600465 Protective Bullet over shaft splineof bearing and shaft sub-assembly. Apply petroleum jelly to inside diameter of exclusion seal and shaft seal.Use press to install bearing and shaft sub-assemblyin bearing housing.

NOTE: Do not distort shaft seal. Damage to thisseal will cause leakage.

5. Apply small amount of petroleum jelly to seal (6) andinstall into bearing housing.

2— Bearing Housing5— Bearing and Shaft

Sub-Assembly

6— Seal31— Eaton 600465 Protective

Bullet

T X 1 0 8 1 2 4 5 — U N — 3 0 A U G 1 0

Install Bearing and Shaft Sub-Assembly

6. Alignment studs (32) can be very helpful in reassembly

of the motor. If studs are used, install two studsdiagonally opposed in the bearing housing.

32— Alignment Stud (2 used)

T X 1 0 8 1 2 4 3 — U N — 3 0 A U G 1 0

Install Alignment Studs

7. Install shaft face seal (7) in wear plate (9).

8. Install wear plate onto bearing housing.

9. Apply a light film of petroleum jelly to seal (10) andinstall in groove of wear plate.

7— Shaft Face Seal9— Wear Plate

10— Seal

2

14

4

5

5

6

15

16

16

T X 1 0 8 1 3 4 2 — U N — 2 5 A U G 1 0

Install Wear Plate and Seals

TM11813 (13OCT10) 38-3860-15 748H Repair (S.N. 630436—10

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10. Install splined drive (8) into bearing and shaftsub-assembly.

8— Splined Drive

T X 1 0 8 1 2 4 1 — U N — 3 0 A U G 1 0

Install Splined Drive

TM11813 (13OCT10) 38-3860-16 748H Repair (S.N. 630436— )101310

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T X 1 0 8 1 2 4 0 — U N — 3 0

A U G 1 0

Install Geroler Sub-Assembly and Valve—Set Timing

9— Wear Plate11— Geroler Sub-Assembly

12— Seal13— Valve Plate

14— Valve Drive15— Valve

11. Align notch on outside of geroler sub-assembly (11)with notch on wear plate and install.

12. Install valve drive (14) in geroler sub-assembly.

13. Apply a light film of petroleum jelly to seal (12) andinstall in groove of valve plate (13).

IMPORTANT: Installation at this time involves threesteps for timing of rotate motor. Timingdetermines direction of rotation of output shaft.Timing parts include: geroler sub-assembly,valve drive, valve plate and valve.

14. Timing Step #1—Locate largest open pocket in geroler sub-assembly and mark it on outside edge of geroler

sub-assembly. Align notch on outside of valve platewith notch on geroler sub-assembly.

Timing Step #2—Locate slot opening in valve plate inline with largest open pocket of geroler sub-assembly.

Timing Step #3 —Locate any one of the side openingsof valve (15) and align this opening with open slotof valve plate that is in line with largest open pocketof geroler sub-assembly. Install valve by rotating itclockwise until spline teeth engage (1/2 spline toothmax.). This will provide the proper rotation whenpressurized.

TM11813 (13OCT10) 38-3860-17 748H Repair (S.N. 630436—10

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SW03989,0000AB4 -19-01OCT10-10/13

Continued on next page SW03989,0000AB 4 -19-01OCT10- 11/13

15. Install two springs (19) and two pins (18) in holeslocated in bore of valve housing (23).

16. Apply a light film of petroleum jelly to seal (21) andinstall in valve housing (23).

18— Pin (2 used)19— Spring (2 used)

21— Seal23— Valve Housing

T X 1 0 8 1 2 3 9 — U N — 3 0 A U G 1 0

Install Pins, Springs, and Seal on Valve Housing

IMPORTANT: Install face seals in the positions shown,or the motor will not operate properly. Do notforce or bend the face seals. Any damage tothese seals will affect the operation of the motor.

17. Apply petroleum jelly to inner and outer face seals (17and 20). Install seals on balance ring (16) as shown.

16— Balance Ring17— Outer Face Seal

20— Inner Face Seal33— Pin Notch

T X 1 0 8 1 2 3 8 —

U N — 3 0 A U G 1 0

Install Face Seals on Balance Ring

18. Install balance ring assembly in valve housing. Alignpin notches (33) in balance ring with pins in bore of valve housing.

16— Balance Ring 23— Valve Housing

T X 1 0 8 1 2 3 7 — U N — 3 0 A U

G 1 0

Install Balance Ring in Valve Housing

TM11813 (13OCT10) 38-3860-18 748H Repair (S.N. 630436— )101310

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19. Install valve housing on valve plate.

NOTE: Depending on valve housing model, it may be possible to insert your finger through port of valve housing and apply pressure to side of balance ring. Hold ring in position until valvehousing is in place against valve plate.

After installing valve housing on valve plate, check for proper placement. Push down on valve housing. A slight spring action should be felt.

23— Valve Housing

T X 1 0 8 1 2 3 6 — U N — 3 0 A U G 1 0

Install Valve Housing

20. Install washers (25) and tie bolts (26).

If alignment studs are used, install two tie bolts andwashers opposite studs. Finger tighten bolts. Removealignment studs and replace with two remainingbolts and washers. Tighten tie bolts alternately tospecification.

Specification

Tie Bolt—Torque............................................................................50 N∙m

450 lb-in.

21. Install new O-ring on plug (22) and install in valvehousing. Tighten plug to specification.

Specification

Case Drain

Plug—Torque........... ............ ........... ............ ............ ........... ............ ..6 N∙m

50 lb-in.

T X 1 0 8 1 2 3 5 —

U N — 3 0 A U G 1 0

Install Tie Bolts and Plug

22— Plug with O-Ring25— Washer (4 used)

26— Tie Bolt (4 used)

TM11813 (13OCT10) 38-3860-19 748H Repair (S.N. 630436—10

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SW03989,0000AB5 -19-01OCT10-1/1

SW03989,0000AC3 -19-30AUG10-1/1

Rotate Motor Drive Gear Remove and Install

1. Remove rotate motor. See Grapple Rotate Motor Remove and Install. (Group 3860.)

2. Remove bearings (1) and drive gear (2).

3. Inspect and replace if required.

4. Install bearings and drive gear.

1— Bearing (2 used) 2— Drive Gear

T X 1 0 8 1 3 2 3 — U N — 3 1 A U

G 1 0

Bearings and Drive Gear

Control Valve Options

The dual function pilot operated control valve is comprisedof the following sections:

• Inlet Section—Includes main relief valve.

• Tong Section—Solenoid operated, includes twoadjustable circuit relief valves and detent assembly.

• Arch Section—Pilot operated, includes twonon-adjustable circuit relief valves.

• Boom Section—Pilot operated, includes twonon-adjustable circuit relief valves.

• Blade Section—Link operated, includes twonon-adjustable circuit relief valves.

• Outlet Section

1— Inlet Section2— Tong Section3— Arch Section

4— Boom Section5— Blade Section6— Outlet Section

T X 1 0 8 1 0 6 3 — U N — 1 8 A U G 1 0

Dual Function Pilot Operated Control Valve

TM11813 (13OCT10) 38-3860-20 748H Repair (S.N. 630436— )101310

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TM11813 (13OCT10) 38-3860-21 748H Repair (S.N. 630436—10

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Continued on next page SW03989,0000ACB -19-01OCT10- 1/5

Pilot Operated Control Valve Remove and Install

T X 1 0 2 5 7 6 2 A — U N — 2 9 J U N 0 7

Hydraulic Control Valve (dual function shown)

TM11813 (13OCT10) 38-3860-22 748H Repair (S.N. 630436— )101310

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SW03989,0000ACB -19-01OCT10-2

SW03989,0000ACB -19-01OCT10-3

Continued on next page SW03989,0000ACB -19-01OCT10-4

1— Pilot Pressure Hose2— Pilot Control Hose (4 used)3— Pilot Control Valve Supply

Hose

4— Grapple Tong Hose (2 used)5— Arch Hose (2 used)6— Boom Hose (2 used)

7— Blade Hose (2 used)8— Valve Return Hose9— Valve Supply Hose

10— Pilot Pressure Supply Hose11— Cap Screw (3 used)





See Battery Disconnect. (Operator’s Manual.)4. Remove right side cab cover.

5. Attach a vacuum pump to hydraulic reservoir tominimize oil loss.

6. Disconnect supply, return, and all hydraulic functionhoses (4—9) at valve. Attach identification tags tohoses to aid assembly. Close all openings using capsand plugs.

7. Disconnect hoses (2) from pilot control valve to archand boom valve sections. Disconnect other pilotcontrol hoses (1, 3, and 10). Put identification tagson hoses to aid assembly. Close all openings usingcaps and plugs.

8. Disconnect electrical connector (12) at solenoidoperated tong valve section.

2— Pilot Control Hose (4 used) 12— Grapple Tong ControlSolenoid ElectricalConnector (2 used)

T X 1 0 2 5 7 6 3 A — U N — 2 9 J U N 0 7

Pilot Control Hoses (dual function shown)

9. Remove cotter pin (14) and clip to disconnect linkageat control valve blade section.

13— Blade Control Linkage14— Cotter Pin

15— Blade Control Valve Spool

T X

1 0 2 5 7 6 4 A — U N — 2 9 J U N 0 7

Blade Control Linkage (dual function shown)

TM11813 (13OCT10) 38-3860-23 748H Repair (S.N. 630436—10

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10. Remove three cap screws (11) to remove controlvalve.

Specification

Control Valve—Single

Function

Grapple—Weight

(approximate).................................................................................. 27 kg

60 lb.



12. Install control valve.

Specification

Control Valve—Single

Function

Grapple—Weight

(approximate).................................................................................. 27 kg

60 lb.

13. Connect electrical connector and linkage.

14. Install adapters with the orifice check in the pilot capports. Install pilot lines.

T X 1 0 2 5 7 6 5 A — U N — 2 9 J U N 0

7

Mounting Cap Screw (dual function shown)


15. Connect remaining hydraulic lines.


17. Operate function through several cycles to remove air and fill components with oil. Check hydraulic oil level.See Check Hydraulic System Oil Level. (Operator’sManual.)

TM11813 (13OCT10) 38-3860-24 748H Repair (S.N. 630436— )101310

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Continued on next page SW03989,0000AB7 -19-26AUG10-1

Dual Function Pilot Operated Control Valve Disassemble and Assemble

T X 1 0 8 1 3 2 8 — U N — 3 1 A U G 1 0

Dual Function Pilot Operated Control Valve

1— Inlet Section2— Tong Section3— Arch Section

4— Boom Section5— Blade Section6— Outlet Section

7— Tie Rod (4 used)8— Washer (8 used)9— Nut (8 used)

10— Seal (4 sets of 4 used)

1. Mark sections to ease assembly.

2. Remove nuts (9), washers (8), and tie rods (7) todisassemble control valve. Service or replace sectionsas necessary.

3. Replace seals (10) between sections.

4. Install tie rods, nuts, and washers to assemble controlvalve. Tighten nuts to specification.

Specification

Nut—Torque..................................................................................57 N∙m

42 lb-ft

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T X 1 0 8 1 3 2 9 — U N — 3 1 A U G 1 0

Dual Function Pilot Operated Control Valve Fittings

11— Adapter

12— Fitting

13— Adapter with Restrictor

Orifice14— Elbow Rework AT

15— Elbow

16— Test Coupling

17— Tee

5. Install fittings, if removed. Replace O-rings.NOTE: Install adapter with restrictor orifice (13) in blade

work port with grooves facing fitting.

TM11813 (13OCT10) 38-3860-26 748H Repair (S.N. 630436— )101310

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SW03989,0000AB8 -19-07SEP10-1

Control Valve Relief Valves Remove andInstall

NOTE: Relief valves can be removed with control valve on machine. Valve must be removed or moved away from machine before lift check

poppets can be removed.

1. Close grapple and lower to the ground.





5. Remove relief valves. Inspect, repair, or replacecomponents as needed.

NOTE: To inspect lift check valves on back of control valve, remove control valve.

6. Install relief valves.


8. Start engine and follow hydraulic oil warmup



T X 1 0 2 4 8 7 8 — U N — 1 4 J U N 0 7

Relief Valves

1— Main Relief Valve2— Nonadjustable Circuit

Relief Valve

3— Adjustable Circuit Relief Valve


TM11813 (13OCT10) 38-3860-27 748H Repair (S.N. 630436—10

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SW03989,0000AB9 -19-01OCT10-1/1

Lift Check Valve Disassemble and Assemble

1. Remove control valve from machine. See PilotOperated Control Valve Remove and Install. (Group3860.)

2. Remove plugs (2).3. Remove springs (4) and lift check poppets (5).

4. Inspect and repair or replace components asnecessary.

5. Replace O-rings (3).

6. Install poppets and springs.

7. Install cap and tighten securely.

8. Install control valve in machine. See Pilot OperatedControl Valve Remove and Install. (Group 3860.)

1— Lift Check Valve (3 used)

2— Plug (3 used)3— O-Ring (3 used)

4— Spring (3 used)

5— Poppet (3 used) T

X 1 0 8 1 3 6 0 — U N — 0 2 S E P 1 0

Lift Check Valve

TM11813 (13OCT10) 38-3860-28 748H Repair (S.N. 630436— )101310

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SW03989,0000ABA -19-01OCT10-1

Non-adjustable Circuit Relief ValveDisassemble and Assemble

T X 1 0 8 1 3 6 1 — U N — 0 2 S E P 1 0

Non-adjustable Circuit Relief Valve

1—Cap2— O-Ring3—Rod4— Seal

5— Shims (as required)6— Spring7— O-Ring8— Backup Ring

9— Poppet10— Poppet Stem11— Valve Body12— O-Ring

13— Backup Ring14— O-Ring


2. Remove non-adjustable circuit relief valve from controlvalve.

3. Disassemble non-adjustable circuit relief valve asshown.

4. Inspect components for wear or damage. Replace if necessary.

5. Replace O-rings (2, 7, 12, and 14), backup rings (8and 13), and seal (4).

6. Installing relief valve on control valve and tighten tospecification.

Specification

Non-adjustable Circuit

Relief Valve—Torque...................................................................100 N∙m

75 lb-ft


TM11813 (13OCT10) 38-3860-29 748H Repair (S.N. 630436—10

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Continued on next page SW03989,0000ABB -19-07OCT10-1/2

Adjustable Circuit Relief Valve Disassembleand Assemble

T X 1 0 8 1 3 6 2 — U N — 0 7 S E P 1 0

Adjustable Circuit Relief Valve

1— Lock Nut2— Adjusting Screw3— O-Ring4— Spring5— Poppet6— Ball

7— Retainer 8— O-Ring9—Rod10— Spring11— Seal12— Ring

13— Poppet14— O-Ring15— Backup Ring16— Housing17— Pin18— Backup Ring

19— O-Ring20— Valve Body21— O-Ring


2. Remove adjustable circuit relief valve from controlvalve.

3. Disassembled adjustable circuit relief valve as shown.

TM11813 (13OCT10) 38-3860-30 748H Repair (S.N. 630436— )101310

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SW03989,0000ABB -19-07OCT10-2

4. Inspect components for wear or damage. Replace asnecessary.

5. Replace O-rings (3, 8, 14, 19, and 21), backup rings(15 and 18), and seal (11).

6. Install adjustable circuit relief valve on control valveand tighten to specification.

Specification

Adjustable Circuit Relief

Valve—Torque.............................................................................100 N∙m

75 lb-ft

7. Install control valve in machine. See Pilot Oper atedControl Valve Remove and Install. (Group 3860.)

8. Adjust circuit relief valve. See System and CircuitRelief Valve Pressure Test. (Group 9025-25.)

9. Tighten lock nut (1) to specification.

Specification

Lock Nut—Torque............ ........... ............ ............ ........... ............ ....88 N∙m

65 lb-ft

TM11813 (13OCT10) 38-3860-31 748H Repair (S.N. 630436—10

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SW03989,0000ABC -19-28SEP10-1/1

Spool Valve Disassemble and Assemble

T X 1 0 8 1 3 6 4 — U N — 0 2 S E P 1 0

Spool Valve

1— Screw (2 used)2— Plate3— Upper Spacer 4— Packing

5— Spool6— Lower Spacer 7— Valve Section Housing8— Plate

9—Rod10— Retainer 11— Spring12— Retainer

13— Rod Cap14— End Cap Housing15— Screw (2 used)

1. Remove control valve from machine. See Pilot

Operated Control Valve Remove and Install. (Group3860.)

2. Disassemble control valve. See Dual Function PilotOperated Control Valve Disassemble and Assemble.(Group 3860.)

NOTE: Keep spool and control valve section together as a matched set. Spools are machined for specific hydraulic functions.

3. Disassemble spool valve as shown.

4. Inspect spool for scratches and straightness. Replacepacking (4).

NOTE: Spacer (3) used with packing at top of valvesection is stepped. Spacer (6) used with packing

at bottom of valve section has shallow concave

groove around top surface.

5. Replace components as necessary.

NOTE: Detent assembly may be used in place of end capassembly (items 8—15) on some valve sections.For more information, see Detent Disassembleand Assemble. (Group 3860.)

6. Assemble spool valve.

7. Assemble control valve. See Dual Function PilotOperated Control Valve Disassemble and Assemble.(Group 3860.)

8. Install control valve in machine. See Pilot Operated

Control Valve Remove and Install. (Group 3860.)

TM11813 (13OCT10) 38-3860-32 748H Repair (S.N. 630436— )101310

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SW03989,0000ABD -19-07SEP10-1

Detent Disassemble and Assemble

T X 1 0 8 1 3 6 6 — U N — 0 2 S E P 1 0

Detent Assembly

1— Spacer 2— Spring Retainer 3— Spring4— Spring Retainer 5—Rod

6— Housing7— Washer (2 used)8— Screw (2 used)9— Plate10— Washer (2 used)

11— Screw (2 used)12— Carrier 13— Detent Ball (6 used)14— Retainer 15— Spring

16— Rod Cap17— Sleeve


2. Remove detent from control valve.

3. Disassemble detent as shown.

4. Inspect parts for wear or damage. Replace as needed.

5. Apply petroleum jelly to detent balls (13) to hold themin carrier (12) during assembly.

6. Assemble detent as shown.

7. Install detent on control valve. Move spool to detentposition center and tighten screws (11) to specification.

Specification

Screw—Torque..............................................................................20 N∙m

175 lb-in.


TM11813 (13OCT10) 38-3860-33 748H Repair (S.N. 630436—10

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SW03989,0000ABE -19-07SEP10-1/1

Pilot Operated Valve Remove and Install

T X 1 0 8 1 3 6 7 — U N — 0 2 S E P 1 0

Pilot Operated Valve

1— Cap Screw (2 used)2— Plug

3— O-Ring4—Cap

5— O-Ring (3 used)6— Sleeve

7— Bushing


2. Disassemble pilot operated valve as shown.

3. Inspect for wear or damage. Replace O-rings (3 and5) and parts as needed.

4. Assemble pilot operated valve on control valve.


TM11813 (13OCT10) 38-3860-34 748H Repair (S.N. 630436— )101310

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Continued on next page SW03989,0000ABF -19-07SEP10-1

Solenoid Operated Valve Remove and Install

T X 1 0 8 1 3 6 8 — U N — 0 2 S E P 1 0

Solenoid Operated Valve

1— Solenoid2— Cap Screw (2 used)3— O-Ring4— O-Ring

5— O-Ring6—Cap7— Plug8— O-Ring

9— Housing10— Cap Screw11— Cap Screw12— Lock Washer (2 used)

13— O-Ring14— O-Ring15— Bushing16— O-Ring (2 used)


2. Remove solenoid operated valve from control valve.

3. Disassemble solenoid operated valve as shown.

4. Inspect for wear or damage and replace parts asneeded.

5. Replace O-rings (3, 4, 5, 8, 13, 14, and 16).

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6. Check operation of solenoid (1) by applying voltageacross solenoid terminals. Solenoid should click.Remove voltage from solenoid terminals. Solenoidshould click again. Replace if solenoid fails check.

NOTE: There are two small O-rings (16) that must be

installed between housing and valve section.

7. Assemble solenoid operated valve as shown.

8. Secure to control valve with cap screws (10 and 11).


Grapple Rotate Solenoid Valve Remove andInstall



for Service Safely. (Operator’s Manual.)

2. Operate all hydraulic controls to release pressure inhydraulic system.

3. Remove left engine side shield.


5. Remove and identify all hydraulic hoses connectingto grapple rotate solenoid valve. Close all openingsusing caps and plugs.

6. Remove two solenoid valve electrical connectors (1).

7. Remove two mounting cap screws (2).

8. Remove grapple rotate solenoid and bracket frommachine.

9. Inspect and replace parts as required. See GrappleRotate Solenoid Valve Disassemble and Assemble.(Group 3860).

10. Install grapple rotate solenoid valve using cap screws.

T X 1 0 8

0 2 0 8 A — U N — 2 8 J U L 1 0

1— Solenoid Valve ElectricalConnectors


11. Install two solenoid valve electrical connectors.

12. Install hoses on grapple rotate solenoid valve.


14. Install left engine side shield.

15. Operate grapple functions through several cycles toremove air and fill components with oil.


TM11813 (13OCT10) 38-3860-36 748H Repair (S.N. 630436— )101310

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Hydraulic System

NM00125,0000588 -19-08OCT10-1

NM00125,0000588 -19-08OCT10-2

Grapple Rotate Solenoid Valve Disassembleand Assemble

1. Remove grapple rotate solenoid valve. See GrappleRotate Solenoid Valve Remove and Install. (Group3860.)

2. Remove coil nut (4) from cartridge (2).

NOTE: Identify location of coils for ease of installation.

3. Remove coils (3) and coil Spacer (5).

4. Remove cartridge from valve body (1).

5. Inspect parts for damage, wear, or contamination.Replace as necessary.

T X 1 0 8 0 2 4 1 A — U N — 2 8 J U

L 1 0

Grapple Rotate Solenoid Valve Exploded View

1— Valve Body2— Cartridge3— Coil (2 used)

4— Coil Nut5— Coil Spacer

NOTE: Identify location of O-rings and backuprings for ease of installation.

6. Remove and replace cartridge O-rings (7) and backuprings (8), using petroleum jelly for installation.

7. Install cartridge into valve body. Tighten tospecification.

Specification

Cartridge Installation

Torque—Torque.................................................................. 32.7-35.4 Nm

24-26 lb-ft

8. Install coils and spacer to cartridge.

9. Install coil nut. Torque to specification.

Specification

Coil Nut

Installation—Torque...........................................................9.5—13.6 N∙m

7—10 lb-ft

10. Install grapple rotate solenoid valve. See GrappleRotate Solenoid Valve Remove and Install. (Group3860.)

11. Operate grapple through several cycles to remove air trapped in system and to fill components with oil.

T X 1 0 8 0 2 4 0 A — U N — 2 8 J U L 1 0

Cartridge

6— Cartridge-to-Valve BodyO-Ring

7— O-Ring (3 used)

8— Backup Ring (6 used)


TM11813 (13OCT10) 38-3860-37 748H Repair (S.N. 630436—10

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Continued on next page SW03989,0000AC0 -19-07SEP10-1/4

Flow Divider Repair

T X 1 0 8 1

3 7 2 — U N — 0 2 S E P 1 0

Exploded View of Flow Divider

1— Direct Acting Crossover Relief Valve (2 used)

2— Seal Kit (2 used)


5— Seal Kit6— Flow Divider Valve

7— Retainer (2 used)

1. Open grapple tongs and lower grapple to the ground.




4. Remove bottom access cover on grapple frame.

5. Tag and disconnect hydraulic lines from flow divider.Close all openings using caps and plugs. See GrappleTong Cylinder Remove and Install. (Group 3860.)

6. Remove cap screws (3) and remove flow divider manifold.

7. Remove retainers (7) and relief valves (1).

8. Remove flow divider valve (6).

TM11813 (13OCT10) 38-3860-38 748H Repair (S.N. 630436— )101310

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Hydraulic System

SW03989,0000AC0 -19-07SEP10-2

SW03989,0000AC0 -19-07SEP10-3

SW03989,0000AC0 -19-07SEP10-4

9. Check direct acting relief valve for wear or damage.Replace if necessary.

10. Replace with new gland ring (8), backup ring (9), andO-ring (10).

8— Gland Ring9— Backup Ring

10— O-Ring

T X 1 0 8 1 3 7 3 A — U N — 0 2 S E P 1 0

Relief Valve Rings

11. Check flow divider valve for wear or damage. Replaceif necessary.

12. Replace with new O-rings (12 and 14) and backuprings (11 and 13).

11— Backup Ring (6 used)12— O-Ring (3 used)

13— Backup Ring14— O-Ring

T X 1 0 8 1 3 7 4 A — U N — 0 2 S E P 1 0

Flow Divider Valve Rings

13. Install direct acting crossover relief valves (1) and flowdivider valve (6).

14. Install retainers (7) on direct acting crossover relief valves.

15. Install flow divider manifold with cap screws and nuts.






21. Install bottom access cover on grapple frame.

T X 1 0 8 1 3 7 6 A — U N — 0 2 S E P 1 0

Flow Divider Assembly

1— Direct Acting Crossover Relief Valve (2 used)

6— Flow Divider Valve

7— Retainer (2 used)

TM11813 (13OCT10) 38-3860-39 748H Repair (S.N. 630436—10

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Hydraulic System

Continued on next page SW03989,0000AC1 -19-07SEP10-1/2

Rotary Manifold Remove and Install






4. Remove top boom cover.

5. Remove grapple rotate motor. See Grapple Rotate

Motor Remove and Install. (Group 3860.)6. Put identification tags on lines to aid assembly.

7. Disconnect hoses (1—3) at rotary manifold. Close allopenings using caps and plugs.


9. Remove housing cap screw (4).

T X 1 0 2 4 8 4 0 A — U

N — 1 4 J U N 0 7

Rotary Manifold

1— Rotary Manifold-to-ControlValve Tong Head End Hose

2— Rotary Manifold-to-ControlValve Tong Rod End Hose

3— Rotary Manifold-to-RotateMotor Hose

4— Housing Cap Screw5— Cap Screw (2 used)

TM11813 (13OCT10) 38-3860-40 748H Repair (S.N. 630436— )101310

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Hydraulic System

SW03989,0000AC1 -19-07SEP10-2

Continued on next page SW03989,0000AC2 -19-01OCT10- 1

10. Remove bottom access cover on grapple frame.

11. Disconnect rotary manifold-to-flow divider hose (6) atflow divider.

12. Disconnect rotary manifold-to-grapple cylinder rod end

hose (7) at tee.

13. Remove rotary manifold and hoses (6 and 7).

14. Inspect and repair rotary manifold as necessary. SeeRotary Manifold Disassemble and Assemble. (Group3860.)

NOTE: Lines must not be twist as they pass throughthe gear and yoke when installing rotary manifold.Port marked “A” connects to flow divider.

15. Install rotary manifold with hoses.

16. Install cap screws and tighten to specification.

Specification

Cap Screw—Torque.................................................................... 115 N∙m

85 lb-ft

Housing Cap

Screw—Torque............................................................................163 N∙m

120 lb-ft

NOTE: Port marked “A” connects to flow divider.

17. Connect hoses.

18. Install grapple rotate motor. See Grapple Rotate Motor Remove and Install. (Group 3860.)

T X 1 0 8 1 3 7 7 A — U N — 0 2 S E P 1 0

Rotary Manifold Bottom Hoses

6— Rotary Manifold-to-FlowDivider Hose

7— Rotary Manifold-to-GrappleCylinder Rod End Hose

19. Turn battery disconnect switch to the ON position.20. Start engine and follow hydraulic oil warmup




23. Install covers.

Rotary Manifold Disassemble and Assemble1. Remove hoses and fittings from rotary manifold shaft

(1).

1— Rotary Manifold Shaft

T X 1 0 8 1 3 7 8 A — U N — 0 2 S E P 1 0

Rotary Manifold Shaft

TM11813 (13OCT10) 38-3860-41 748H Repair (S.N. 630436—10

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SW03989,0000AC2 -19-01OCT10-2/4

Continued on next page SW03989,0000A C2 -19-01OCT10- 3/4

2. Remove snap ring (3). Remove rotary manifold shaftfrom rotary manifold housing (2).

1— Rotary Manifold Shaft2— Rotary Manifold Housing

3— Snap Ring

T X 1 0 8 1 3 7 9 A — U N — 0 2 S E P 1 0

Rotary Manifold Shaft, Housing, and Snap Ring

3. Remove rotary manifold housing O-rings (4 and 6),wear rings (5), and expander rings (7).

4. Inspect rotary manifold housing and rotary manifoldshaft for wear or damage. Replace if necessary.

5. Apply clean hydraulic oil to new O-rings and wear rings.

6. Assemble expander rings into O-rings.

7. Install O-rings, wear rings, and O-ring with expander ring assemblies in sequence shown. Position in rotarymanifold housing grooves.

8. Apply petroleum jelly to parts inside of rotary manifoldhousing and to rotary manifold shaft. Carefully taprotary manifold shaft into rotary manifold housingusing a soft hammer.

9. Install snap ring on rotary manifold shaft.

2— Rotary Manifold Housing4— O-Ring (2 used)5— Wear Ring (2 used)

6— O-Ring (4 used)7— Expander Ring (4 used)

T X 1 0 8 1 3 8 0 A — U N — 0 2 S E P 1 0

Rotary Manifold Housing and Rings

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Hydraulic System

SW03989,0000AC2 -19-01OCT10-4


10. Test rotary manifold for leaks before installing onmachine.

Install a cap on port marked "1" (12) of rotary manifoldshaft and port marked "D" (9) of rotary manifold.Connect a hydraulic hand-operated pump to portmarked "1" (8) of rotary manifold.

11. Operate pump to test specification.

Specification

Rotary Manifold Test

Ports Marked "1" and

"2"—Pressure.........................................................................20 685 kPa

207 bar

3000 psi

Turn rotary manifold shaft 10 rpm in both directions.Leakage must not exceed 5 drops per minute at portsmarked "2" (10 or 11). Rotary manifold shaft must notbind while turning.

12. Repeat test, with cap on port marked "2" (11) andapplying pressure to port marked "2" (10). Leakagemust not exceed 5 drops per minute at ports marked"1". Rotary manifold shaft must not bind while turning.

13. Install caps or plugs to all ports marked "1" and"2". Connect hydraulic hand operated pump to portmarked "D". Operate pump to pressurize manifold totest specifications. Turn rotary manifold shaft 10 rpm

in both directions. There must be no external leakageand rotary manifold shaft must not bind.

T X 1 0 8 1 3 8 1 A — U N — 0 2 S E P 1 0

Rotary Manifold Leak Test

8— Port Marked "1"9— Port Marked "D"10— Port Marked "2"

11— Port Connected to "2"12— Port Connected to "1"

Specification

Rotary Manifold Test Port

Marked "D"—Pressure..............................................................1379 kPa

14 bar

200 psi

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Section 99Dealer Fabricated Tools

Contents

Page

Group 9900—Dealer Fabricated ToolsDFT1099 Bushing Drivers ......................... 99-9900-1DFRW20 Compressor Holding

Fixture.................................................... 99-9900-2

TM11813 (13OCT10) 99-1 748H Repair (S.N. 630436—10

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Group 9900Dealer Fabricated Tools


DFT1099 Bushing Drivers

T X 1 0 7 1 9 6 2 — U N — 0 5 A P R 1 0

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Dealer Fabricated Tools

GD61784,0000077 -19-31MAR10-2

GD61784,0000078 -19-02JUL07-1

A—0.5 x 2.0 x 6.0 in. 1020 ColdRolled

B—45 mm Bushing—Use 2.625in. OD x 2.25 in. ID x 2.5 in.

B—50 mm Bushing—Use 2.825in. OD x 2.50 in. ID x 2.5 in.

B—60 mm Bushing—Use 3.50 in.OD x 3.00 in. ID x 2.5 in.

B—70 or 80 mm Bushing—Use4.00 in. OD x 3.50 in. ID x 2.5in.

C—0.5 x 2.0 x 4.25 in. 1020 ColdRolled

D—0.5 x 8.0 Full Threaded CapScrew

E—Tack Weld With 0.5 in.Crosshole Centered In PipeOD

These bushing drivers are used to remove and install

spherical bushings.

DFRW20 Compressor Holding Fixture

R W 1 3

6 1 9 — U N — 2 0 S E P 8 9

A—102 mm (4 in.)B—76 mm (3 in.)C—70 mm (2.75 in.)

D—6.4 mm (0.25 in.)E—19 mm (0.75 in.)F—152 mm (6 in.)

G—254 mm (10 in.)H—114 mm (4.5 in.)I— 178 mm (7 in.)

J— Fillet WeldK—Two Holes

Material required:

• 2—Steel Plates (4 x 2.75 in.) and (10 x 6 in.)

• 2—Threaded Steel Rods (0.5 x 7 in.)

• 4—Matching Lock Washers and Nuts

Tool is used to hold air conditioning compressor duringassembly and disassembly.

TM11813 (13OCT10) 99-9900-2 748H Repair (S.N. 630436—10

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Dealer Fabricated Tools

TM11813 (13OCT10) 99-9900-3 748H Repair (S.N. 630436— )101310

PN=396



Index

Page

A

Accumulator, service brake

Remove and install ........................................ 10-1060-4 Adjustable cir cuit relief valveDisassemble and assemble......................... 38-3860-30

Aftercooler Remove and install ........................................ 05-0510-5

Air baffleRemove and install ........................................ 05-0510-1

Air baffle enclosureRemove and install ................................... ..... 05-0510-1

Air conditioner Compressor, r emove and install .................... 18-1830-8

Air conditioningR134a system charge.................................... 18-1830-7R134a system evacuate ................................ 18-1830-6

Air conditioning system

Blower motor remove and install..................18-1830-13Compressor clutch remove and

install...................................................... ...... 18-1830-9Compressor manifold remove and

install....................................................... ... 18-1830-11Compressor relief valve remove and

install..................................................... ....... 18-1830-7Condenser remove and install ..................... 18-1830-11Evaporator remove and install .....................18-1830-20Expansion valve remove and install............. 18-1830-18Flush and purge............................................. 18-1830-2Freeze control switch remove and

install.......................................................... 18-1830-17High/low pressure switch remove and

install........................................... ............... 18-1830-15

Precleaner blower assembly remove andinstall....................................... ................... 18-1830-14

R134a refrigerant cautions and proper handling........................ ........................... ..... 18-1830-1

R134a refrigerant oil information.................... 18-1830-4R134a refrigerant recovery ............................ 18-1830-6R134a refrigerant recovery/recycling and

charging station installation.......................... 18-1830-5Receiver-dryer remove and install ............... 18-1830-21

ArchRemove and install ........................................ 38-3840-3

Arch cylinder —dual function grappleRemove and install ........................................ 38-3860-1

Axle and differential drive shaft

Front, remove and install ............................... 02-0225-1 Axle and transmission drive shaftRear, remove and install ................................ 02-0225-2

Axle, frontRemove and install ........................................ 02-0200-1

Axle, rear Remove and install ........................................ 02-0200-5

Page

B

BearingSupport, remove and install ........................... 02-0225-2

BeltTensioner spring tension check...................... 05-0510-3

Belt tensioner Remove and install ........................................ 05-0510-4

Belt, seatRemove and install ........................................ 18-1821-7

BladeControl linkage, remove and install................ 32-3215-1Control valve, remove and install................... 32-3215-2Lift cylinder, remove and install...................... 32-3260-1Stacking, remove and install .......................... 32-3201-1

Blower motor Remove and install ...................................... 18-1830-13

BoomRemove and install ........................................ 38-3840-2Boom cylinder—dual function grapple

Remove and install ........................................ 38-3860-1Bottom guard

Engine frame, remove and install .................. 17-1746-1Equipment frame, remove and install ............ 17-1746-2

Brake accumulator Remove and install ........................................ 10-1060-4

Brake pedalRemove and install ........................................ 10-1015-1

Brake valve, ser viceDisassemble and assemble........................... 10-1060-3Remove and install ........................................ 10-1060-1

Brake, park

Remove and install ......................................... 11-1111-1Bump shifter

Remove and install ........................................ 03-0315-1Bushing

Spherical, remove and install......................... 32-3201-5

C

CabRemove and install ........................................ 18-1800-1

Cab door Disassemble and assemble........................... 18-1810-5Remove and install ........................................ 18-1810-4

Cab isolators

Remove and install ........................................ 18-1800-8Cab tilt cylinder Remove and install ...................................... 18-1800-17

Cab tilt hand pumpBleeding procedure...................................... 18-1800-15Disassemble and assemble.........................18-1800-14Remove and install ...................................... 18-1800-13

Cable rollers, dual functionRemove and install ........................................ 38-3840-1

Charge air cooler Remove and install ........................................ 05-0510-5

Continued on next page

TM11813 (13OCT10) Index-1 748H Repair (S.N. 630436—10

PN



Index

Page

Charge pumpTransmission, remove and install .................. 03-0360-1

Charge pump drive, transmissionRepair ............................................................ 03-0360-4

Cleanup procedur e

General oil...................................................... 21-2160-1Hydraulic component failure .......................... 21-2160-3

Component failureHydraulic, cleanup procedure ........................ 21-2160-3

Compressor Air conditioner, remove and install ................. 18-1830-8

Compressor clutchRemove and install ........................................ 18-1830-9

Compressor manifoldRemove and install ...................................... 18-1830-11

Compressor relief valveRemove and install ........................................ 18-1830-7

Condenser Remove and install ...................................... 18-1830-11

Control linkageBlade, remove and install............................... 32-3215-1Winch, remove and install.............................. 30-3015-1

Control valveBlade, remove and install............................... 32-3215-2Options......................................................... 38-3860-20

Control valve relief valvesRemove and install ...................................... 38-3860-27

Control valve, transmisisonRepair ............................................................ 03-0360-9

Control valve-dual function pilot operatedDisassemble and assemble ......................... 38-3860-25

Control valve-pilot operatedRemove and install ...................................... 38-3860-22

Control valve-pilot operated valve

Remove and install ...................................... 38-3860-34Control valve—adjustable circuit relief valve

Disassemble and assemble ......................... 38-3860-30Control valve—detent

Disassemble and assemble ......................... 38-3860-33Control valve—lift check valve

Disassemble and assemble......................... 38-3860-28Contr ol valve—non-adjustable circuit relief

valveDisassemble and assemble......................... 38-3860-29

Control valve—solenoid operated valveRemove and install ...................................... 38-3860-35

Control valve—spool valveDisassemble and assemble......................... 38-3860-32

Coolant valve

Remove and install ...................................... 18-1830-16Cooling loop pump

Remove and install ...................................... 21-2160-18Cooling system

Service safely............................................... 00-0001-12Crosshead pins

Lubricate ........................................................ 38-3803-7Cylinder

Blade lift, remove and install .......................... 32-3260-1

Page

Cylinder, cab tiltRemove and install ...................................... 18-1800-17

D

Dampener Lubricate ........................................................ 38-3803-7Remove and install ........................................ 07-0752-1

Dampener, grapple Adjustment..................................................... 38-3803-6

DetentDisassemble and assemble......................... 38-3860-33

DFRW20 toolCompressor holding fixture............................ 99-9900-2

DFT1099 driver Spherical bushings removal........................... 99-9900-1

Differential drive shaftFront, remove and install ............................... 02-0225-1Rear, remove and install ................................ 02-0225-2

Differential lock solenoid valveRepair ............................................................ 02-0260-1Door latch

Disassemble and assemble........................... 18-1810-5Door, cab

Disassemble and assemble........................... 18-1810-5Remove and install ........................................ 18-1810-4

Drive and clutch repair Winch 4000 .................................................... 30-3050-1Winch 6000.................................................... 30-3050-1

Drive shaftFront axle and differential, remove and

install............................................................ 02-0225-1Rear axle and differential, remove and

install.................................................. .......... 02-0225-2

Winch, disassemble and assemble................ 30-3025-1Drive shaft, engine-to-transmission

Remove and install ........................................ 03-0325-1Drive shaft, winch

Remove and install ........................................ 30-3025-1Dual mode steering solenoid valve

Remove and install ........................................ 09-0962-1Duals wheel installation..................................... 01-0110-3

E

Enclosure, air baffleRemove and install ........................................ 05-0510-1

Engine

Remove and install ........................................ 04-0400-2Engine CTM referenceTheory of operation........................................ 04-0400-1

Engine dampener Remove and install ........................................ 07-0752-1

Engine-to-transmission drive shaftRemove and install ........................................ 03-0325-1

Evaporator Remove and install ...................................... 18-1830-20

Expansion valveRemove and install ...................................... 18-1830-18


TM11813 (13OCT10) Index-2 748H Repair (S.N. 630436— )101310

PN=2



Index

Page

F

Fabricated toolsDFRW20 compressor holding fixture ............. 99-9900-2

DFT1099 bushing driver ................................ 99-9900-1Fan

Hydraulic motor remove and install.............. 21-2160-12Fan blade

Remove and install ...................................... 05-0510-16Fan shroud

Remove and install ...................................... 05-0510-16Fan variable speed and reversing manifold

Disassemble and assemble......................... 21-2160-11Remove and install ...................................... 21-2160-10

Fire prevention................................................... 00-0001-4Flow divider

Repair ....................................................... ...38-3860-38Flush and purge

Air conditioning system.................................. 18-1830-2FrameEngine, separate....................................... ..... 17-1740-2Equipment, separate...................................... 17-1740-2

Free spool dr ag adjustment............................... 30-3000-7Fr eeze control switch

Remove and install ......................................18-1830-17Front axle

Remove and install ........................................ 02-0200-1Front axle guards

Remove and install ........................................ 02-0200-8Front axle oscillation supports

Repair ............................................................ 02-0200-8Front differential

Remove and install ........................................ 02-0200-1

Front windshield wiper Remove and install ........................................ 18-1810-6

Fuel tankRremove and install ....................................... 05-0560-1

G

General oilCleanup procedure ........................................ 21-2160-1

GrappleDisassemble and assemble........................... 38-3803-2Remove and install ........................................ 38-3803-1Rotate bearing repair ..................................... 38-3803-8

Grapple dampener Disassemble and assemble........................... 38-3803-4

Grapple headDampener adjustment.................................... 38-3803-6

Grapple rotate motor Assemble ..................................................... 38-3860-12Disassemble .................................................. 38-3860-7Remove and install ........................................ 38-3860-5

Grapple rotate solenoid valveDisassemble and assemble......................... 38-3860-37Remove and install ...................................... 38-3860-36

Page

Grapple rotate yokeDisassemble and assemble........................... 38-3803-8

Grapple tong cylinder Remove and install ........................................ 38-3860-3

Grille guard

Remove and install ........................................ 19-1910-3Grille housing

Remove and install ........................................ 19-1910-5Guard

Engine frame bottom, remove andinstall............................................................ 17-1746-1

Equipment frame bottom, remove andinstall............................................................ 17-1746-2

Guards, front axleRemove and install ........................................ 02-0200-8

H

Heater cor e

Remove and install ...................................... 18-1830-19Heating systemBlower motor remove and install.................. 18-1830-13Coolant valve remove and install................. 18-1830-16Heater core remove and install.................... 18-1830-19

High/low pressure switchRemove and install ...................................... 18-1830-15

High-pressure oils Avoid.............................................................. 00-0001-3

HoodRemove and install ........................................ 19-1910-1

HornRemove and install ........................................ 20-2004-1

Housing, grilleRemove and install ........................................ 19-1910-5

HydraulicComponent faliure cleanup

procedure..................................................... 21-2160-3Fittings, 30° cone seat ........................... 00-0003-5Fittings, 37° flare.................................... 00-0003-5

Hydraulic attenuator Remove and install ........................................ 21-2160-9

Hydraulic fan motor Remove and install ...................................... 21-2160-12

Hydraulic fan pumpRemove and install ...................................... 21-2160-18

Hydraulic oil cooler Remove and install ...................................... 05-0510-13

Hydraulic pumpRemove and install ........................................ 21-2160-5

Hydraulic reservoir Remove and install ...................................... 21-2160-14

I

Inch bolt and cap screwTorque value .................................................. 00-0003-4

Input shaft, transmissionRemove and install ........................................ 03-0350-7



PN



Index

Page

Intercooler Remove and install ........................................ 05-0510-5

Isolators, cabRemove and install ........................................ 18-1800-8

L

Lower pivot pin sealRemove and install ........................................ 17-1740-6

LubricateGrapple head dampener, yoke, and

crosshead pins............................................. 38-3803-7

M

Machine modifications Avoid.............................................................. 00-0001-2

Metric bolt and cap screwTorque value .................................................. 00-0003-2

Mount—transmissionRemove and install ........................................ 03-0300-6

O

O-ring boss fittings............................................. 00-0003-6Oil

General, cleanup procedure .......................... 21-2160-1Lines and fittings ............................................ 00-0003-5

Oil lines and fittings ........................................... 00-0003-5Oscillation supports

Remove and install ........................................ 02-0200-1Repair ............................................................ 02-0200-8

PPark brake

Remove and install ......................................... 11-1111-1Park brake solenoid valve

Repair .............................................................11-1160-1Pilot operated valve

Remove and install ...................................... 38-3860-34Pin, upper pivot

Remove and install ...................................... 17-1740-12Pins, metal

Drive safely .................................................. 00-0001-14Pivot pin, upper

Remove and install ...................................... 17-1740-12Precleaner blower assembly

Remove and install ...................................... 18-1830-14Pressurized water system—if equipped

Disassemble and assemble........................... 20-2003-1Priority valve

Disassemble and assemble ........................... 21-2160-8Remove and install ........................................ 21-2160-7

Pump drive, transmission chargeRepair ............................................................ 03-0360-4

Pump, cab tiltBleeding procedure...................................... 18-1800-15

Page

Disassemble and assemble......................... 18-1800-14Remove and install ...................................... 18-1800-13

R

R134a refriger antCautions and proper handling........................ 18-1830-1Oil information................................................ 18-1830-4Recovery........................................................ 18-1830-6Recovery/recycling and charging station

installation .................................................... 18-1830-5R134a system

Charge........................................................... 18-1830-7Evacuate........................................................ 18-1830-6

Radiator Remove and install ........................................ 05-0510-8

Rear axleRemove and install ........................................ 02-0200-5

Rear differential

Remove and install ........................................ 02-0200-5Rear windshield wiper Remove and install ........................................ 18-1810-7

Receiver-dryer Remove and install ...................................... 18-1830-21

Repair proceduresTr ansmission.................................................. 03-0350-1

Reverse warning alarmRemove and install ........................................ 20-2004-1

Rollers, cable, dual functionRemove and install ........................................ 38-3840-1

ROPSTorque ............................................................ 00-0003-1

Rotary manifoldDisassemble and assemble ......................... 38-3860-41

Remove and install ...................................... 38-3860-40Rotate motor drive gear

Remove and install ...................................... 38-3860-20

S

Saf ety Add and operate attachments safely ........... 00-0001-11 Avoid backover accidents .............................. 00-0001-9 Avoid machine tip over................................... 00-0001-9 Avoid work site hazards ................................. 00-0001-8Clean debris from machine............................ 00-0001-6Do not use starting fluid with tier 3

engine .......................................................... 00-0001-3

Inspect and maintain ROPS......................... 00-0001-10Inspect machine............................................. 00-0001-2Keep riders off machine................................. 00-0001-8Keep the operator protective structure in

place........................................................... 00-0001-10Make welding repairs safely......................... 00-0001-13Operate machine safely ................................. 00-0001-8Operate only if qualified ................................. 00-0001-1Operating on slopes..................................... 00-0001-10Operating or traveling on public roads ......... 00-0001-10Park and prepare for service safely ............. 00-0001-11



PN=4



Index

Page

Prevent unintended machinemovement ............................................... ..... 00-0001-7

Protective equipment ..................................... 00-0001-2Recognize safety information.................... ..... 00-0001-1Start only from operator's seat....................... 00-0001-6

Stay clear of moving parts ............................. 00-0001-2Use and maintain seat belt ............................ 00-0001-7Use steps and handholds correctly................ 00-0001-6

SealLower pivot pin............................................... 17-1740-6

SeatDisassemble and assemble........................... 18-1821-2Remove and install ........................................ 18-1821-1

Seat beltRemove and install ........................................ 18-1821-7

Secondary SteeringRemove and install ........................................ 09-0930-1

Secondary steering pumpRemove and install ........................................ 09-0930-1

Serpentine beltRemove and install ........................................ 05-0510-2Serpentine belt tensioner

Remove and install ........................................ 05-0510-4Service brake accumulator

Remove and install ........................................ 10-1060-4Service brake pedal

Remove and install ................................... ..... 10-1015-1Service brake valve

Disassemble and assemble........................... 10-1060-3Remove and install ........................................ 10-1060-1

Solenoid operated valveRemove and install ...................................... 38-3860-35

Solenoid valveDifferential lock, repair ................................... 02-0260-1

Solenoid valve, dual mode steeringRemove and install ........................................ 09-0962-1

Solenoid valve, park brakeRepair .............................................................11-1160- 1

Spherical bushingRemove and install ........................................ 32-3201-5

Stacking bladeRemove and install ........................................ 32-3201-1

Steering columnDisassemble and assemble......................... 18-1800-11Remove and install ........................................ 18-1800-9

Steering cylinder Remove and install ........................................ 09-0960-9

Steering valveDisassemble and assemble........................... 09-0960-5

Remove and install ........................................ 09-0960-1Steering wheel

Disassemble and assemble......................... 18-1800-11Remove and install ........................................ 18-1800-9

Steering, dual mode solenoild valveRemove and install ........................................ 09-0962-1

Support bearingRemove and install ........................................ 02-0225-2

Page

T

Tensioner, beltRemove and install ........................................ 05-0510-4

Spring tension check...................................... 05-0510-3Tire

Install duals.................................................... 01-0110-3Remove and install ........................................ 01-0110-2

Torque value30° cone seat hydraulic fittings .............. 00-0003-537° flare hydraulic fittings....................... 00-0003-5Dual wheel nuts ............................................. 01-0110-3Flat face O-ring seal fitting ............................. 00-0003-7Hardware specifications................................. 00-0003-1Inch SAE four bolt flange fitting...................... 00-0003-9Metric bolt and cap screw .............................. 00-0003-2Metric cap scr ew............................................ 00-0003-3Metric four bolt flange fitting ........................... 00-0003-8

O-Ring boss fitting ......................................... 00-0003-6Unified inch bolt and cap screw ..................... 00-0003-4Transmission

Input shaft remove and install........................ 03-0350-7Remove and install ........................................ 03-0300-1Repair procedures ......................................... 03-0350-1Winch drive repair.......................................... 03-0350-2

Transmission bump shifter Remove and install ........................................ 03-0315-1

Transmission charge pumpRemove and install ........................................ 03-0360-1Suction tube repair......................................... 03-0360-8

Transmission charge pump driveRepair ............................................................ 03-0360-4

Transmission cold weathe disconnect

linkage—if equippedRemove and install ........................................ 07-0752-2

Transmission cold weather disconnect—jif equipped

Repair ............................................................ 07-0752-4Transmission control solenoids

Repair ............................................................ 03-0360-9Transmission control valve

Repair ............................................................ 03-0360-9Transmission Gear Selector

Remove and install ........................................ 03-0315-1Transmission mount

Remove and install ........................................ 03-0300-6Transmission oil cooler

Remove and install ...................................... 05-0510-10

Transmission suction tubeRepair ............................................................ 03-0360-8

Transmission-to-engine drive shaftRemove and install ........................................ 03-0325-1

V

ValvePriority valve disassemble and

assemble...................................................... 21-2160-8



PN



Index

Page

Priority valve remove and install .................... 21-2160-7Valve, blade control

Remove and install ........................................ 32-3215-2Valve, dual mode steering


Valve, grapple rotate solenoidDisassemble and assemble ......................... 38-3860-37Remove and install ...................................... 38-3860-36

Valve, service brakeDisassemble and assemble ........................... 10-1060-3Remove and install ........................................ 10-1060-1

Valve, steeringDisassemble and assemble........................... 09-0960-5Remove and install ........................................ 09-0960-1

W

Water system, pressurized—if equippedDisassemble and assemble........................... 20-2003-1

Welding.............................................................. 17-1740-1WheelRemove and install ........................................ 01-0110-1

Wheel bolt torqueDual wheels ................................................... 01-0110-3

Wheel repair Install duals.................................................... 01-0110-3

WinchControl cable, remove and install................... 30-3015-2Control linkage, remove and install................ 30-3015-1Drive shaft, disassemble and

assemble...................................................... 30-3025-1

Page

Drive shaft, remove and install....................... 30-3025-1Fastening cable-4000 series.......................... 30-3000-5Fastening cable-6000 series........................ 30-3000-10Free spool drag ad justment ........................... 30-3000-7

Winch 4000 series

Remove and install ........................................ 30-3000-1Winch 6000 series

Remove and install ........................................ 30-3000-8Winch drive

Repair ............................................................ 03-0350-2Winch, 4000

Drive and clutch repair ................................... 30-3050-1Winch, 6000

Drive and clutch repair ................................... 30-3050-1Window

Cleaning procedure........................................ 18-1810-4Remove and install ........................................ 18-1810-1

Windshield wiper Adjustment..................................................... 18-1810-9

Windshield wiper, frontRemove and install ........................................ 18-1810-6Windshield wiper, rear


Y

YokeDisassemble and assemble........................... 38-3803-8Lubricate ........................................................ 38-3803-7


PN=6



Index

Documents

748H novo monitor Repair BookTM11813.PDF