John Deere Tractors 8320RT, 8345RT, 8370RT Repair Service Manual (TM119319)

tm119319 - 8RT Tractors Repair (S. N. 912001—916999) Technical Manual.pdf

Complete Repair Service Technical Manual for John Deere 8320RT, 8345RT, 8370RT (S.N.: 912001-), with all the service information to maintain, repair, rebuild like professional mechanics.

John Deere 8RT RW Tractors 8320RT, 8345RT & 8370RT workshop technical manual (repair) includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,900 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTION
Foreword
   Dealer Predelivery Information Form
   General Information
      Safety
      General References
   Engine
      Component Removal and Installation
      Engine Repair
   Fuel, Air Intake, Exhaust, and Cooling
      Diesel Fuel System
      Air Intake System
      Auxiliary Drive System
      Radiator and Coolers
      Exhaust System
   Electrical
      Connectors
      Charging Circuit
      Starting Circuit
      Relays, Fuses, Solenoids, and Switches
      Monitoring System
      CommandARM™
      Implement and Accessory Connectors
      Convenience and Accessory
   Infinitely Variable Transmission (IVT™)
      Component Removal and Installation
      In Tractor Repair
      Transmission Repair
      Assemble Transmission
   e23™ Transmission (e23™)
      Component Removal and Installation
      In Tractor Repair
      Transmission Repair
      Assemble Transmission
   Drive Train
      Component Removal and Installation
      Rear Axle Assembly
      Steering Gears
      Final Drives
      PTO
      Mid-Frame Drive Shafts
   Brakes
      Service Brakes
      Hydraulic Trailer Brakes
   Steering
      Steering Column
      Steering Valves
      Steering Pump
      Steering Motor
   Hydraulics
      Component Removal and Installation
      Hydraulic System
      Integrated Hydraulic Pump
      Hitch Valve, Selective Control Valves, and Couplers
      Rear Hitch
   Miscellaneous
      Hood and Side Panels
      Platform Step Assembly
   Track Frame and Components
      Track
      Tension Cylinder and Accumulator
      Track Frame
      Track Suspension
   Cab and Open Operator’s Station
      Component Removal and Installation
      Heating, Ventilating, and Air Conditioning (HVAC)
      ComfortCommand™ Seat
      Cab Door and Windshield
   Dealer Tools
      Dealer Fabricated Tools
Social networks

Table of Contents - Expanded View

Foreword

Dealer Predelivery Information Form

Section 10: General Information

Group 05A: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Wear Protective Clothing

Handle Starting Fluid Safely

In Case of Fire

Avoid Static Electricity Risk When Refueling

Service Machines Safely

Stay Clear of Rotating Drivelines

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Avoid Hot Exhaust

Clean Exhaust Filter Safely

Prevent Acid Burns

Handle Agricultural Chemicals Safely

Clean Vehicle of Hazardous Pesticides

Handling Batteries Safely

Avoid Harmful Asbestos Dust

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Avoid High-Pressure Fluids

Wait Before Opening High-Pressure Fuel System

Service Accumulator Systems Safely

Protect Against High Pressure Spray

Service Cooling System Safely

Prevent Machine Runaway

Keep ROPS Installed Properly

Use Seat Belt Properly

Park Machine Safely

Support Machine Properly

Work in Clean Area

Work In Ventilated Area

Illuminate Work Area Safely

Use Proper Lifting Equipment

Instructional Seat

Passenger Seat

Use Steps and Handholds Correctly

Transport Tractor Safely

Practice Safe Maintenance

Use Proper Tools

Construct Dealer-Made Tools Safely

Replace Safety Signs

Install All Guards

Live With Safety

Group 05B: General References

List of References

Trademarks

Sealants and Adhesives Cross-Reference Chart

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Face Seal Fittings Assembly and Installation—All Pressure Applications

Metric Face Seal And O-ring Stud End Fitting Torque Chart—Standard Pressures

Metric Face Seal and O-ring Stud End Fitting Torque Chart—High Pressure Applications

SAE Face Seal and O-ring Stud End Fitting Torque Chart—Standard Pressures

SAE Face Seal and O-ring Stud End Fitting Torque Chart—High Pressure Applications

Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications

SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications

External Hexagon Port Plug Torque Chart

Prevent Hydraulic System Contamination

Check Oil Lines and Fittings

Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems

Identify Zinc-Flake Coated Fasteners

Use Torque Wrench Adapter

Servicing and Connecting Snap to Connect STC™ Fittings

Use Special Wrench

Install Hydraulic Fittings

Glossary of Terms

Aftertreatment Indicators Overview

Changing Diesel Exhaust Fluid (DEF) Dosing Unit Filter

Cleaning Diesel Exhaust Fluid (DEF) Tank

Section 20: Engine

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 20—00

Other Material 20—00

Specifications 20—00

Remove Engine

Install Engine

Remove Front Frame

Install Front Frame

Group 05: Engine Repair

List of References

Essential, Recommended, and Fabricated Tools 20—05

Specifications 20—05

Replace Torsional Damper

Engine Repair—Use CTM

Section 30: Fuel, Air Intake, Exhaust, and Cooling

Group 05: Diesel Fuel System

List of References

Specifications 30—05

Remove and Install Left-Hand Fuel Tank

Remove and Install Right-Hand Fuel Tank

Remove Center Fuel Tank

Replace Fuel Filter, Fuel Pump, and Bleed Fuel System

Group 10: Air Intake System

List of References

Specifications 30—10

Air Intake Pipe Connections

Remove and Install Air Cleaner Pipe

Remove and Install Aspirator Pipe

Remove and Install Charge Air Cooler Pipes

Group 15: Auxiliary Drive System

List of References

Essential, Recommended, and Fabricated Tools 30—15

Specifications 30—15

Auxiliary Drive Belt Routing

Belt Tensioner Location

Inspect Belt Tensioner

Replace Idler Pulleys and Belt Tensioner

Remove and Install Vari-Cool™ Fan Belt

Replace Auxiliary Drive Pulley

Replace Auxiliary Drive Shaft Seal

Group 20: Radiator and Coolers

List of References

Essential, Recommended, and Fabricated Tools 30—20

Other Material 30—20

Specifications 30—20

Draining, Flushing, and Refilling Cooling System

Test Radiator and Deaeration Tank

Test Radiator Cap

Remove and Install Radiator

Check and Fill Vari-Cool™ Fan Sheaves

Remove and Install Vari-Cool™ Drive Assembly

Remove and Install Vari-Cool™ Fan Driven Assembly

Repair Vari-Cool™ Fan Drive Assembly

Repair Vari-Cool™ Fan Driven Assembly

Remove and Install Vari-Cool™ Control Valve

Repair Vari-Cool™ Control Valve

Remove and Install Air Conditioning Condenser

Remove and Install Fuel Cooler—Hydraulic Oil Cooler

Leak Test Hydraulic Oil Cooler

Group 25: Exhaust System

List of References

Other Material 30—25

Specifications 30—25

Service Exhaust System

Replace NOx Sensor

Remove and Install DEF Tank

Replace Header Assembly

Replace DEF Dosing Unit

Replace DEF Dosing Injector

Section 40: Electrical

Group 05: Connectors

List of References

Essential, Recommended, and Fabricated Tools 40—05

Other Material 40—05

Use Electrical Insulating Compound

Using High-Pressure Washers

Installation of Repair Wire Assembly (RWA)

Repair AMP™ Connector

Repair AMPSEAL 16™ Connectors

Bosch™ Connectors

Remove Connector Body from Blade Terminals

CINCH™ Control Unit Connectors

Exploded View—CINCH™ FlexBox Connectors

CINCH™ FlexBox Connectors

Repair CPC™ Blade Type Connectors

Repair CPC™, Large Mate-N-Loc™, and Metrimate™ Pin Type Connectors

Repair DEUTSCH™ Connectors

Repair DEUTSCH™ Implement Connectors

Repair ITT Connector

Repair Small Mate-N-Loc™ Socket Connector

Repair Small Mate-N-Loc™ Pin Connector

Repair (Pull Type) Metri-Pack™ Connectors

Repair (Push Type) Metri-Pack™ Connectors

Repair Molex™ Control Unit Connectors

Repair Molex™ Connector

Repair SUMITOMO™ Connectors

Repair Tyco™ Fuel Injector Connector

Repair WEATHER PACK™ Connector

Repair YAZAKI™ Connectors

Group 10: Charging Circuit

List of References

Specifications 40—10

Repair Alternator—Use CTM

Disconnect Electrical Circuit

Replace Alternator

Replace Alternator and Battery Fuse

Group 15: Starting Circuit

List of References

Essential, Recommended, and Fabricated Tools 40—15

Specifications 40—15

Repair Starter—Use CTM

Remove and Install Starter Motor

Replace Master Fuse

Replace Starter Circuit Relay

Group 20: Relays, Fuses, Solenoids, and Switches

List of References

Essential, Recommended, and Fabricated Tools 40—20

Other Material 40—20

Specifications 40—20

General Repair Procedures 40—20

Replace Hydraulic Backup Pump Fuse

Replace Hydraulic Backup Pump Relay

Replace Start Aid Solenoid

Replace Sensors e23™ Transmission

Replace Solenoids e23™ Transmission

Replace Park Supply Solenoid (e23™)

Replace Park Sump Block Solenoid (e23™)

Replace Range Clutch R1 and R2 Solenoids (e23™)

Replace Oil Cooler Bypass Solenoid (e23™)

Replace Lube Prioritization Valve Solenoid (e23™)

Replace Sensors and Solenoids PST Transmission

Replace Electrohydraulic Shift Valve Solenoids (PST)

Replace Park Brake Release Solenoid (PST)

Replace Sensors IVT™ Transmission

Replace Solenoids IVT™ Transmission

Replace Clutch Enable Solenoid (IVT™)

Replace Park Supply Solenoid (IVT™)

Replace Park Sump Block Solenoid (IVT™)

Replace Hydro Clutch Unit Solenoid (IVT™)

Replace Ring Unit Hydro Control Solenoid (IVT™)

Replace Loop Flush Cut Off Solenoid (IVT™)

Replace PTO Solenoid

Replace Engine Oil Pressure Switch

Replace Cab Door Light Switch

Replace Starting Aid Switch

Replace Ignition Switch

Replace Key Immobilizer

Replace Seat Raise-Lower Switch

Replace Heated Seat Switch

Replace Operator Presence Seat Switch

Replace Brake Light Switch

Replace Hydraulic Oil Filter Restriction Switch

Replace Hydraulic Clean-Oil Level Switch

Replace Ethernet Switch

Replace Battery Disconnect Switch

Replace External Hitch Raise-Lower Switches

Replace Air Conditioning Dual Pressure Sensor

Replace Air Conditioning Temperature Sensor

Replace Air Conditioning Motor Speed Control

Group 25: Monitoring System

List of References

Essential, Recommended, and Fabricated Tools 40—25

Other Material 40—25

Specifications 40—25

General Information 40—25

Control Units Identification

Replace Control Units

Replace Navigation Bar

Replace Engine Coolant Temperature Sensor

Replace Engine Coolant Level Sensor

Replace Engine Coolant Loss Sensor

Replace Engine Crank Speed Sensor

Replace Fuel Level Sensor

Replace Track Position Sensor

Replace Steering Column Module

Replace Primary Transmission Speed Sensor

Replace Secondary Transmission Speed Sensor

Replace PTO Speed Sensor

Replace Radar Sensor

Replace Hydro Charge Pressure Sensor

Replace Hydro Loop Override 1 Solenoid

Replace Hydro Loop Override 2 Solenoid

Replace Left Hydro Pressure Sensor

Replace Right Hydro Pressure Sensor

Replace Steering Charge Pressure Switch

Replace Hitch Position Sensor

Replace Draft Sensing Sensor

Replace CommandCenter™ Processor

Group 30: CommandARM™

List of References

Specifications 40—30

Armrest Test Procedures

Remove and Install CommandARM™ Assembly

Replace Armrest Interface Control Unit (AIC)

Replace Throttle Control Module

Replace Transmission Control Lever Module

Replace SCV Control Lever Module

Replace Rear Hitch Control Lever and SCV I Control Lever Module

Replace Hitch Controls Module

Replace Rear PTO Switch

Replace Secondary Brake Switch

Replace Cab Controls Module

Replace SCV Lock Module

Group 35: Implement and Accessory Connectors

List of References

Replace Seven-Terminal Outlet Socket

Replace GreenStar™ Terminal Connector

Replace Auxiliary Power Strip

Replace Three-Pin Accessory Outlet

Replace Three-Pin Accessory Outlet—Storage Box

Group 40: Convenience and Accessory

List of References

Specifications 40—40

Replace Wiper Motors

Replace Circulation Blower Motor

Replace HVAC Pressurizer Blower Motor

Replace Air Flow Mode Motor

Replace Windshield Washer Pumps

Remove Radio and Speakers

Replace Refrigerator

Replace Refrigerator Tray

Replace Refrigerator Top Cover

Replace Refrigerator Door

Replace Refrigerator Thermostat

Replace Refrigerator Module

Section 50A: Infinitely Variable Transmission (IVT™)

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 50A—00

Other Material 50A—00

Specifications 50A—00

Remove Transmission—IVT™

Install Transmission—IVT™

Remove and Install Scavenge Pump—IVT™

Group 05: In Tractor Repair

List of References

Essential, Recommended, and Fabricated Tools 50A—05

Other Material 50A—05

Specifications 50A—05

Replace Input Shaft Front Seal—IVT™

Replace Auxiliary Drive Shaft Seal—IVT™

Synchronizer/Shift Assembly Repair—In Chassis—IVT™

Service Hydrostatic Jumper Tubes—IVT™

Group 10: Transmission Repair

List of References

Essential, Recommended, and Fabricated Tools 50A—10

Other Material 50A—10

Specifications 50A—10

General Repair Procedures 50A—10

Hydrostatic Module Replacement—IVT™

Install Transmission Onto Repair Stand—IVT™

Disassemble Transmission—IVT™

Exploded View—Valve Manifold—IVT™

Repair Valve Manifold—IVT™

Repair Synchronizer—IVT™

Cross Sectional View—C1-C2 Shift Assembly—IVT™

Repair C1-C2 Shift Assembly—IVT™

Repair Accumulator—IVT™

Exploded View—Hydrostatic Module Assembly—IVT™

Multi-Function Valves—IVT™

Test Multi-Function Valves—IVT™

Hydrostatic Module Loop Flush Valve—IVT™

Repair Hydrostatic Module Assembly—IVT™

Exploded View—Reverse Brake—IVT™

Repair Reverse Brake Housing—IVT™

Cross Sectional View—High-Low Clutch Assembly—IVT™

Repair High-Low Clutch Assembly—IVT™

Cross Sectional View—Planetary Input Assembly—IVT™

Repair Planetary Input—IVT™

Exploded View—Planetary Assembly—IVT™

Repair Planetary Assembly—IVT™

Cross Sectional View—Park Brake—IVT™

Repair Park Brake—IVT™

Repair Bearing Carrier Assembly—IVT™

Repair Scavenge Pump—IVT™

Group 15: Assemble Transmission

List of References

Essential, Recommended, and Dealer Fabricated Tools 50A—15

Other Material 50A—15

Specifications 50A—15

Install Bearing Cups—IVT™

Install CU Idler—IVT™

Install Planetary Input Gears—IVT™

Install Synchronizer—IVT™

Install PTO Drive Gear—IVT™

Install Front Cover—IVT™

Install Bearing Cover—IVT™

Install Planetary Ring Gear and RU Idler—IVT™

Install Hydrostatic Assembly—IVT™

Install Planetary Assembly—IVT™

Install Reverse Brake and High-Low Clutch Assembly—IVT™

Install Transmission Output Shaft—IVT™

Install Rear Cover—IVT™

Install Manifold—IVT™

Install Scavenge Pump—IVT™

Adjust Bearings—IVT™

Install Auxiliary Drive Shaft—IVT™

Clutch Element Leak Check—IVT™

Section 50B: e23™ Transmission (e23™)

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 50B—00

Other Material 50B—00

Specifications 50B—00

Remove Transmission—e23™

Install Transmission—e23™

Group 05: In Tractor Repair

List of References

Essential, Recommended, and Fabricated Tools 50B—05

Other Material 50B—05

Specifications 50B—05

Replace Auxiliary Drive Shaft Seal—e23™

Replace Input Shaft Front Seal—e23™

Replace Rear PTO Drive Shaft Seal—e23™

Replace Output Shaft Seal—e23™

Group 10: Transmission Repair

List of References

Essential, Recommended, and Fabricated Tools 50B—10

Other Material 50B—10

Specifications 50B—10

General Repair Procedures 50B—10

Install Transmission Onto Repair Stand—e23™

Disassemble Transmission—e23™

Repair Upper Manifold Valves—e23™

Repair Lower Manifold Valves—e23™

Cleaning Procedures—Manifold, Rear Cover, and Valves—e23™

Repair Auxiliary Drive—e23™

Repair Park Brake—e23™

Repair Rear Cover—e23™

Repair Scavenge Pump—e23™

Clutch Backing Plate Orientation—e23™

Cross Sectional View—9 Disk Cast Clutch Pack—e23™

Repair 9 Disk Cast Clutch Pack—e23™

Cross Sectional View—12 Disk Clutch Pack—e23™

Repair 12 Disk Clutch Pack—e23™

6 Disk Clutch Pack Identification—e23™

Cross Sectional View—6 Disk Clutch Pack—e23™

Repair 6 Disk Clutch Pack—e23™

Cross Sectional View—Output Shaft Assembly—e23™

Repair Output Shaft Assembly—e23™

Cross Sectional View—B Countershaft Assembly—e23™

Repair B Countershaft Assembly—e23™

Cross Sectional View—C Countershaft Assembly—e23™

Repair C Countershaft Assembly—e23™

Cross Sectional View—Input Shaft Assembly—e23™

Repair Input Shaft Assembly—e23™

Exploded View—Rear PTO Drive Shaft Assembly—e23™

Repair Rear PTO Shaft Assembly—e23™

Inspect Clutch Disks—e23™

Group 15: Assemble Transmission

List of References

Essential, Recommended, and Fabricated Tools 50B—15

Other Material 50B—15

Specifications 50B—15

Install Transmission Shaft Assemblies—e23™

Install Rear Cover—e23™

Install Auxiliary Drive—e23™

Remove and Install Upper Manifold—e23™

Remove and Install Lower Manifold—e23™

Section 50C: Drive Train

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 50C—00

Other Material 50C—00

Specifications 50C—00

Remove Rear Axle Assembly

Install Rear Axle Assembly

Remove Final Drive Assembly

Install Final Drive Assembly

Group 05: Rear Axle Assembly

List of References

Essential, Recommended and Fabricated Tools 50C—05

Other Material 50C—05

Specifications 50C—05

General Repair Procedures 50C—05

Remove Input Gears

Disassemble and Assemble Input Shaft/Gear Assembly

Disassemble and Assemble Steering Pump Drive Gear

Disassemble and Assemble Integrated Hydraulic Pump Drive Gear

Disassemble and Assemble Idler Gear

Install Input Gears

Adjust Input Shaft Bearing Preload

Remove and Install Pump Drive Housing

Cross-Sectional View—Spiral Bevel Pinion Shaft

Disassemble and Recondition Spiral Bevel Pinion Shaft

Assemble and Install Spiral Bevel Pinion Shaft

Cross-Sectional View—Spiral Bevel Ring Gear Assembly

Remove and Recondition Spiral Bevel Ring Gear Assembly

Install Spiral Bevel Ring Gear Assembly

Side Quill Adjustment Information

Adjust Carrier Assembly Bearing Preload

Adjust Spiral Bevel Ring Gear Backlash

Group 10: Steering Gears

List of References

Essential, Recommended, and Fabricated Tools 50C—10

Other Material 50C—10

Specifications 50C—10

Remove Steering Planetary, Ring Gear, and Sun Gear

Recondition Steering Planetary

Install Steering Planetary, Ring Gear, and Sun Gear

Remove, Recondition, and Install Steering Idler Gears

Remove, Recondition, and Install Steering Motor Output Gear

Remove, Recondition, and Install Cross Shaft Gear Assembly

Group 15: Final Drives

List of References

Essential, Recommended, and Fabricated Tools 50C—15

Other Material 50C—15

Specifications 50C—15

Disassemble Axle Assembly

Assemble Axle Assembly and Determine Shim Pack

Preload Shim Pack Example and Worksheet—Final Drives

Remove, Recondition, Assemble Brakes

Group 20: PTO

List of References

Essential, Recommended, and Fabricated Tools 50C—20

Other Material 50C—20

Specifications 50C—20

Cross-Sectional View—PTO Clutch Assembly

Remove PTO Clutch

Recondition PTO Clutch

Install PTO Clutch

Remove and Install PTO Output Housing Assembly

Cross-Sectional View—PTO Output Housing Assembly

Recondition PTO Output Housing

Group 25: Mid-Frame Drive Shafts

List of References

Other Material 50C—25

Specifications 50C—25

Cross-Sectional View—Mid-Frame Drive Shafts

Remove and Install Drive Shafts

Section 60A: Brakes

Group 05: Service Brakes

List of References

Essential, Recommended, and Fabricated Tools 60A—05

Specifications 60A—05

General Repair Procedures 60A—05

Remove and Install Brake Rod

Remove and Install Brake Valve

Repair Brake Valve

Remove and Install Priority and Load Sense Manifold

Repair Priority and Load Sense Manifold

Remove and Install Secondary Brake and Steering Control Manifold

Repair Secondary Brake and Steering Control Manifold

Remove and Install Primary and Secondary Brake Manifold

Remove and Install Backup Pump

Remove and Install Park Pump Off Manifold

Repair Park Pump Off Manifold

Bleed Brakes

Check Brakes

Manually Release Park Brake—IVT™

Manually Release Park Brake—e23™

Group 10: Hydraulic Trailer Brakes

List of References

Specifications 60A—10

Hydraulic Trailer Brake System

Remove and Install Hydraulic Trailer Brake Valve

Section 60B: Steering

Group 05: Steering Column

List of References

Specifications 60B—05

Remove and Install Control Support

Repair Steering Column

Remove and Install Steering Wheel Position Input Assembly

Repair Steering Wheel Position Input Assembly

Group 10: Steering Valves

List of References

Specifications 60B—10

Remove and Install Loop Override Valve

Repair Loop Override Valve

Group 15: Steering Pump

List of References

Essential, Recommended, and Fabricated Tools 60B—15

Specifications 60B—15

Remove and Install Steering Pump

Exploded View—Steering Charge Pump and Pump Control

Disassemble, Inspect, and Assemble Steering Charge Pump

Disassemble, Inspect, Assemble Displacement Control Valve

Exploded View—Steering Pump

Disassemble, Inspect, and Assemble Hydraulic Steering Pump

Group 20: Steering Motor

List of References

Specifications 60B—20

Remove and Install Steering Motor

Repair Steering Motor

Section 70: Hydraulics

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 70—00

Specifications 70—00

Remove and Install Integrated Hydraulic Pump

Remove and Install Transmission Pump

Remove and Install Hitch-SCV Valve Stack

Remove and Install Hitch Frame

Group 05: Hydraulic System

List of References

Essential, Recommended, and Fabricated Tools 70—05

General Repair Procedures 70—05

Install Hydraulic Fittings 70—05

Drain Hydraulic System

Fill Hydraulic System

Group 10: Integrated Hydraulic Pump

List of References

Essential, Recommended, and Fabricated Tools 70—10

Specifications 70—10

Remove and Install Hydraulic Compensator Valve

Repair Hydraulic Compensator Valve

Repair Hydraulic Pump

Group 15: Hitch Valve, Selective Control Valves, and Couplers

List of References

Essential, Recommended, and Fabricated Tools 70—15

Specifications 70—15

Disassemble and Assemble Hitch-SCV Valve Stack

Service Pressure Compensator

Service Pressure Compensating Check Valve

Service Solenoid Pilot Valve

Service Spool Centering Spring Assembly

Service Electronic Control Unit

Test Surge Relief Valve

Service Surge Relief Valve

Service Shuttle Valve

Remove and Install Coupler Housing

Repair Couplers

Remove and Install Motor Return

Remove and Install Motor Return with Power Beyond

Group 20: Rear Hitch

List of References

Essential, Recommended, and Fabricated Tools 70—20

Other Material 70—20

Specifications 70—20

Remove and Install Lift Cylinder

Disassemble, Inspect, and Assemble Lift Cylinder

Replace Rockshaft Bushings

Repair Draft Sensing

Section 80A: Miscellaneous

Group 05: Hood and Side Panels

List of References

Essential, Recommended, and Fabricated Tools 80A—05

Specifications 80A—05

Position Hood Forward

Optional Forward Hood Position

Remove and Install Hood

Remove and Install Grille and Headlight Assembly

Remove and Install Hood Side Panels

Remove and Install Hood Screens

Remove and Install Hood Latch

Group 10: Platform Step Assembly

List of References

Specifications 80A—10

Remove and Install Platform Step Assembly

Section 80B: Track Frame and Components

Group 05: Track

List of References

Essential, Recommended, and Fabricated Tools 80B—05

Specifications 80B—05

Install Support Stands

Track Tensioning and De-tensioning

Remove and Install Track

Check Track Alignment

Adjust Track Alignment

Drive Wheel And Walking Beam Settings

Adjust Track Tread Settings

Group 10: Tension Cylinder and Accumulator

List of References

Essential, Recommended and Fabricated Tools 80B—10

Other Material 80B—10

Specifications 80B—10

Remove and Install Track Tension Cylinder

Cross-Sectional View—Track Tension Cylinder

Disassemble, Inspect, and Assemble Track Tension Cylinder

Remove and Install Tension Accumulator

Charge Tension Accumulator

Group 15: Track Frame

List of References

Essential, Recommended, and Fabricated Tools 80B—15

Other Material 80B—15

Specifications 80B—15

Remove and Install Track Frame

Replace Walking Beam-to-Track Frame Bushing

Remove and Install Tension Link and Alignment Lever

Replace Alignment Lever Bushings

Replace Tension Link Pivot Bushings

Repair Front Idler Hubs

Repair Mid-Roller Assembly

Remove and Install Drive Hub

Repair Drive Hub

Group 20: Track Suspension

List of References

Essential, Recommended, and Fabricated Tools 80B—20

Other Material 80B—20

Specifications 80B—20

Replace Rubber Walking Beam Bumpers

Replace Shock Absorber

Replace Air Spring

Replace Air Compressor

Remove and Install Walking Beam

Replace Swing Arm Bushings

Replace Walking Beam Pivot Bushing and Isolator Bushing

Inflate Track Air Suspension System

Section 90: Cab and Open Operator’s Station

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools 90—00

Other Material 90—00

Specifications 90—00

Remove Cab

Install Cab

Repair Cab

Remove Inner Roof

Install Inner Roof

Remove and Install Left Hand Armrest

Group 05: Heating, Ventilating, and Air Conditioning (HVAC)

List of References

Essential, Recommended, and Fabricated Tools 90—05

Other Material 90—05

Specifications 90—05

Repair Air Conditioning System—Use CTM

Hose and Tubing O-ring Connection Torques

Discharge Air Conditioning System

Flushing, Purging, and Evacuating Information

Purge Air Conditioning System

Evacuate Air Conditioning System

Charge Air Conditioning System

Refrigerant Oil Information

Check Compressor Oil Charge

Determine Correct Refrigerant Oil Charge

Add Refrigerant Oil to System

Add Refrigerant Oil to Pressurized System

Remove and Install Compressor

Replace Receiver-Dryer

Remove and Install Compressor Relief Valve

Remove and Install Expansion Valve

Remove HVAC Module

Install HVAC Module

Remove and Install Heater Control Valve

Group 10: ComfortCommand™ Seat

List of References

Essential, Recommended, and Fabricated Tools 90—10

Other Material 90—10

Specifications 90—10

Remove and Install Seat—ComfortCommand™

Repair Seat Air System—ComfortCommand™

Repair Seat Suspension—ComfortCommand™

Repair Seat Back—ComfortCommand™

Repair Seat Control Knobs—ComfortCommand™

Group 15: Cab Door and Windshield

List of References

Specifications 90—15

Repair Cab Door Latch

Cab Door Adjustment—Step 1

Cab Door Adjustment—Step 2

Cab Door Adjustment—Step 3

Cab Door Adjustment—Step 4

Preparing Windshield Glass or Side Window For Replacement

Section 300: Dealer Tools

Group 05: Dealer Fabricated Tools

Fabricated Tools

List of References

DFRW2—Needle Valve Test Hose Assembly

DFRW7—Differential Lifting Tool

DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses

DFRW89—Transmission Shaft and Clutch Holding Fixture

DFRW90—Transmission Support Plate

DFRW91—Guide Pins

DFRW97—Transmission Countershaft Rotation Screw

DFRW117—Transmission-Hydraulic Flusher

DFRW123—Steering Motor Bypass Hose

DFRW136—STEERING PUMP REMOVAL TOOL

DFRW144—European Narrow Rear Axle Lift Tool

DFRW168—Park Brake Solenoid Harness

DFRW210—Hole Drilled in JT07201

DFRW211—Transmission Support Plate

DFRW212—Leak Test Assembly

DFRW213—Hydraulic Trailer Brake Test / Bleed Assembly

DFRW220—Clutch Cover Removal Plate

DFRW231—Guide Pins

DFRW233—Support Bar

DFRW234—Hood Support Rod