John Deere Tractors 8310RT, 8335RT, 8360RT Repair Service Manual (TM110519)

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John Deere Tractors 8310RT, 8335RT, 8360RT Repair Service Manual (TM110519)

tm110519 - 8RT Tractors Repair (S. N. 902501—912000) Technical Manual.pdf

for Diesel Engine 6090, please refer to CTM115419 & CTM104819 Service Technical Manual :

John Deere Diesel Engine 6090 (Level 21 ECU - Worldwide) Component Technical Manual - CTM104819

John Deere 6090 Diesel Engine (Level 24 ECU - Worldwide) Component Technical Manual - CTM115419

Complete Repair Service Technical Manual for John Deere Tractors 8310RT, 8335RT, 8360RT (S.N. 902501- 912000), with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

John Deere 8RT RW Tractors 8310RT, 8335RT & 8360RT 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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: 1,933 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
Foreword
   Dealer Predelivery Information Form
   General Information
      Safety
      General Information
   Engine
      Component Removal and Installation
      Engine Repair
   Fuel and Cooling Systems
      Diesel Fuel System
      Air Intake System
      Engine Cooling System
      Coolers and Air Conditioning Condenser
      Exhaust System
   Electrical
      Connectors
      Wiring Harness Routings
      Charging Circuit
      Starting Circuit
      Relays, Fuses, Solenoids, and Switches
      Monitoring Systems and Sensors
      Armrest Control
      Implement and Accessory Connectors
      Convenience and Accessory Components
   PowerShift Transmission
      Component Removal and Installation
      Miscellaneous Repair
      Transmission
   AutoPowr/IVT Tranmission
      Component Removal and Installation
      General Repair Procedures
      In Tractor Repair
      Transmission Repair
      Assemble Transmission
   Drive Systems
      Component Removal and Installation
      Rear Axle Assembly
      Final Drives
      PTO
      Steering Gears
      Mid-Frame Drive Shafts
   Steering and Brakes
      Component Removal and Installation
      Steering Column
      Steering Wheel Position Input Assembly
      Steering Pump
      Brakes
      Hydraulic Trailer Brake
   Hydraulics
      Component Removal and Installation
      Hydraulic System Repair and Cleanup
      Integrated Hydraulic Pump
      Hitch Valve, Selective Control Valves, and Couplers
      Hitch
   Miscellaneous
      Hood
      Platform Step Assembly
   Operator Station
      Component Removal and Installation
      Heating, Ventilating, and Air Conditioning (HVAC)
      Air Conditioning System
      Air Suspension Seat
      Armrest
      Cab Door and Windshield
   Track Frame and Components
      Tracks
      Tension Cylinder and Accumulator
      Track Frame
      Track Suspension
   Dealer Tools
      Dealer Fabricated Tools
      Essential and Recommended Tools

tm110519 - 8RT Tractors Repair(S. N. 902501—912000)

Table of Contents

Foreword

Dealer Predelivery Information Form

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Wear Protective Clothing

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

Handle Starting Fluid Safely

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

Avoid Backover Accidents

Park Machine Safely

Support Machine Properly

Work in Clean Area

Work In Ventilated Area

Illuminate Work Area Safely

Use Proper Lifting Equipment

Service Tires Safely

Instructional Seat

Service Front-Wheel Drive Tractor Safely

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 10: General Information

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

Glossary of Terms

Section 20: Engine

Group 00: Component Removal and Installation

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Remove Engine

Install Engine

Remove Front Frame

Install Front Frame

Group 05: Engine Repair

List of References

Essential, Recommended, and Fabricated Tools

Specifications

Replace Flywheel Dampener

Engine Repair—Use the relevant Component Technical Manual

Section 30: Fuel and Cooling Systems

Group 05: Diesel Fuel System

List of References

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

Air Intake Pipe Connections

Service Air Intake System

Group 15: Engine Cooling System

List of References

Essential, Recommended and Fabricated Tools

Specifications

Other Material

Draining, Flushing, and Refilling Cooling System

Test Radiator and Deaeration Tank

Test Radiator Cap

Remove and Install Radiator

Auxiliary Drive Belt Routing

Belt Tensioner Location

Inspect Belt Tensioner

Remove and Install Vari-Cool™ Fan Belt

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

Group 20: Coolers and Air Conditioning Condenser

List of References

Essential, Recommended and Fabricated Tools

Specifications

Other Material

Remove Air Conditioning Condenser

Install Air Conditioning Condenser

Remove Fuel Cooler - Hydraulic Oil Cooler

Install Fuel Cooler - Hydraulic Oil Cooler

Leak Test Hydraulic Oil Cooler

Group 25: Exhaust System

List of References

Specifications

Service Exhaust System

Section 40: Electrical

Group 05: Connectors

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Use Electrical Insulating Compound

Using High-Pressure Washers

Repair AMP Connector

Repair AMPSEAL 16™ Connectors

CAN Controlled SCV Connectors

Remove Connector Body from Blade Terminals

CINCH™ Wedgebox 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: Wiring Harness Routings

List of References

Engine/Chassis Harness Routing and Component Identification

Exhaust Filter Harness

PST Cab Harness—North American

PST Cab Harness—European

AutoPowr™/IVT™ Cab Harness—North American

AutoPowr™/IVT™ Cab Harness—European

Outer Roof Harness—North American

Outer Roof Harness—European

Power Standard Mirror Harness

Dual Power Mirror Harness

ISO Cornerpost Harness

CommandCenter™ Display Programming Harness

JDLink™ (MTG) Harness

JDLink™ (MTG) w/Satellite Harness

Left Convenience Outlet Harness—European

Left Convenience Outlet Harness—North American

Right Convenience Outlet Harness—European

Right Convenience Outlet Harness—North American

Auxiliary Power Strip

Auxiliary Audio Harness

Microphone Harness

Front Console Harness (AutoPowr™/IVT™)

Front Console Harness (PST)

Steering Column Harness

Standard Seat Harness

Heated Seat Power Harness

Heated Seat Switch Harness

Heated Seat Heater Element Harness

PST Transmission Harness

AutoPowr™/IVT™ Transmission Harness

Cab Power Cable

VLC Power Cable

CLC Power Cable

Positive Battery Cable

Negative Battery Cable

Mid-frame Harness

Hood Light Harness

Beacon Light Extension Harness

Extremity Light Harness—North American

Right Clearance Light Harness—European

Right Clearance Light Extension Harness—European

Left Clearance Light Harness—European

Left Fender Harness

Right Fender Harness

Implement Lighting and Accessory Harness—North American

Implement Lighting and Accessory Harness—European

Optional Roof Lighting Harness

Radar Extension Harness

Inner Roof Harness (Manual A/C)

Inner Roof Harness (ATC)

Main Armrest Control Unit Harness

Standard Armrest Control Unit Harness

SCV V and VI Armrest Control Unit Harness

Armrest Control Unit Harness (22 pin) (AutoPowr™/IVT™ Only)

Armrest Control Unit Harness (22 pin) (PST Only)

Draft Sensor Extension Harness

Center Hitch Switch Harness

Back-Up Alarm Harness

Left Track Tension Harness

Right Track Tension Harness

Suspension Harness

Group 15: Charging Circuit

List of References

Repair Alternator—Use CTM

Disconnect Electrical Circuit

Replace Alternator

Group 20: Starting Circuit

List of References

Essential, Recommended and Fabricated Tools

Specifications

Repair Starter—Use CTM

Remove and Install Starter Motor

Replace Master Fuse

Replace Starter Circuit Relay

Replace Neutral Start Switch

Group 25: Relays, Fuses, Solenoids, and Switches

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

General Repair Procedures—Solenoids and Switches

Load Center Fuses and Relays

Replace Starting Aid Solenoid

Replace Electro-Hydraulic Shift Valve Solenoids

Replace Park Brake Release Solenoid

Replace Sensors and Solenoids AutoPowr™ / IVT™ Transmission

Replace PTO Solenoid

Replace Engine Oil Pressure Switch

Replace Transmission Manifold Electrical Switches

Replace Cab Door Light Switch

Replace Starting Aid Switch

Replace Ignition Switch

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 A/C Dual Pressure Switch

Replace A/C Deicing Switch

Replace Manual A/C Blower Motor Resistor

Group 30: Monitoring Systems and Sensors

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

General Information—Monitoring Systems

Replace Steering Column Module

Control Units Identification

Replace Control Units

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 Hitch Position Sensor

Replace Draft Sensing Sensor

Group 35: Armrest Control

List of References

Replace CommandARM™ Assembly

Replace Armrest Control Unit (ACU)

Replace Engine Speed Control

Replace Transmission Control

Replace SCV Control Lever

Replace Hitch Control

Replace Rear PTO Switch

Replace ITEC Sequence Switch

Replace Resume Switch

Group 40: 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 45: Convenience and Accessory Components

List of References

Replace Wiper Motors

Replace Circulation Blower Motor

Replace Heating, Ventilating, and Air Conditioning (HVAC) Pressurizer Blower Motor

Replace Windshield Washer Pumps

Remove Radio and Speakers

Section 50: PowerShift Transmission

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

Remove Transmission

Install Transmission

Remove Scavenge Pump

Install Scavenge Pump

Group 05: Miscellaneous Repair

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

Replace Input Shaft Front Seal—PST

Replace Auxiliary Drive Pulley—PST

Replace Transmission Input Shaft Rear Seal—PST

Group 10: Transmission

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

General Repair Procedures—Power Shift Transmission

Clutch Cover Plate Orientation

Install Transmission Onto Repair Stand

Cross-Sectional View—Transmission Assembly

Disassemble Transmission

Exploded View—Manifold Valves

Manifold and Valves

Cleaning Procedures—Manifold, Rear Cover, and Valves

Remove and Install Electrohydraulic Valves

Inspect and Clean Electrohydraulic Valves

Dissemble and Assemble Manifold

Disassemble and Assemble Transmission Rear Cover

Cross-Sectional View—Transmission Input Shaft

Disassemble Input Shaft

Assemble Input Shaft Gear/Clutch Assemblies

Assemble Input Shaft

Cross-Sectional View—Transmission Countershaft

Disassemble Countershaft

Assemble Countershaft Gear/Clutch Assemblies

Assemble Countershaft

Cross-Sectional View—Transmission Output Shaft Assembly

Service Output Shaft Check Valves

Disassemble Output Shaft Assembly

Disassemble, Inspect, and Assemble Planetary Carrier

Inspect Clutch Disks

Assemble Output Shaft Assembly

Assemble Transmission

Remove Transmission From Repair Stand

Section 51: AutoPowr/IVT Tranmission

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

Remove Transmission

Install Transmission

Remove Scavenge Pump

Install Scavenge Pump

Group 05: General Repair Procedures

List of References

Essential, Recommended, and Fabricated Tools

Other Material

General Repair Procedures—Transmission

Hydrostatic Module Replacement

Group 15: In Tractor Repair

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

Replace Input Shaft Front Seal

Replace Auxiliary Drive Shaft Seal

Synchronizer/Shift Assembly Repair—In Chassis

Group 20: Transmission Repair

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

Install Transmission Onto Repair Stand

Disassemble Transmission

Exploded View—Valve Manifold

Repair Valve Manifold

Repair Synchronizer

Cross Sectional View—C1/C2 Assembly

Repair C1-C2 Shift Assembly

Repair Accumulator

Exploded View—Hydrostatic Module Assembly

Multi-Function Valves

Test Multi-Function Valves

Hydrostatic Module Loop Flush Valve

Repair Hydrostatic Module Assembly

Exploded View—Reverse Brake

Repair Reverse Brake Housing

Cross Sectional View—High-Low Clutch Assembly

Repair High-Low Clutch Assembly

Cross Sectional View—Planetary Input Assembly

Repair Planetary Input

Exploded View—Planetary Assembly

Repair Planetary Assembly

Cross Sectional View—Park Brake

Repair Park Brake

Repair Bearing Carrier Assembly

Repair Scavenge Pump

Group 30: Assemble Transmission

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

Install PTO Drive Gear

Install Bearing Cups

Install CU Idler

Install Planetary Input Gears

Install Synchronizer

Install Front Cover

Install Bearing Cover

Install Planetary Ring Gear and RU Idler

Install Hydrostatic Assembly

Install Planetary Assembly

Install Reverse Brake and High-Low Clutch Assembly

Install Transmission Output Shaft

Install Rear Cover

Install Manifold

Install Scavenge Pump

Service Hydrostatic Jumper Tubes

Adjust Bearings

Install Auxiliary Drive Shaft

Clutch Element Leak Check

Section 56: Drive Systems

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

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

Other Material

Specifications

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: Final Drives

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

Disassemble Axle Assembly

Assemble Axle Assembly and Determine Shim Pack

Preload Shim Pack Example and Worksheet

Remove, Recondition, Assemble Brakes

Group 15: PTO

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

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 20: Steering Gears

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

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 25: Mid-Frame Drive Shafts

List of References

Other Material

Specifications

Cross-Sectional View—Mid-Frame Drive Shafts

Remove and Install Drive Shafts

Section 60: Steering and Brakes

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools

Specifications

Remove and Install Steering Pump

Remove and Install Steering Motor (—907100)

Remove and Install Steering Motor (907101—)

Remove and Install Loop Override Valve (907101—)

Flush Steering System

Repair Steering Motor

Group 05: Steering Column

List of References

Specifications

Remove and Install Control Support

Repair Steering Column

Group 10: Steering Wheel Position Input Assembly

List of References

Specifications

Remove and Install Steering Wheel Position Input Assembly

Repair Steering Wheel Position Input Assembly

Group 15: Steering Pump

List of References

Essential, Recommended, and Fabricated Tools

Specifications

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

Repair Loop Override Valve (907101—)

Group 25: Brakes

List of References

Essential, Recommended, and Fabricated Tools

Specifications

General Repair Procedures—Brakes

Remove and Install Brake Rod

Remove and Install Brake Valve

Repair Brake Valve (—907100)

Repair Brake Valve (907101—)

Remove and Install Priority and Load Sense Manifold (907101—)

Repair Priority and Load Sense Manifold (907101—)

Remove and Install Secondary Brake and Steering Control Manifold (907101—)

Repair Secondary Brake and Steering Control Manifold (907101—)

Remove and Install Primary and Secondary Brake Manifold (907101—)

Remove and Install Backup Pump (907101—)

Remove and Install Park Pump Off Manifold (907101—)

Repair Park Pump Off Manifold (907101—)

Remove and Install Secondary Brake Valve (—907100)

Repair Secondary Brake Valve (—907100)

Bleed Brakes

Check Brakes

Manually Release IVT™ Park Brake (—907100)

Manually Release IVT™ Park Brake (907101—)

Manually Release PST Park Brake (—907100)

Manually Release PST Park Brake (907101—)

Group 30: Hydraulic Trailer Brake

List of References

Specifications

Hydraulic Trailer Brake System

Remove and Install Hydraulic Trailer Brake Valve

Section 70: Hydraulics

Group 00: Component Removal and Installation

List of References

Essential, Recommended, and Fabricated Tools

Specifications

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 Repair and Cleanup

List of References

Essential, Recommended, and Fabricated Tools

Other Material

General Repair Procedures—Hydraulic Systems

Install Hydraulic Fittings

Drain Hydraulic System

Fill Hydraulic System

Group 10: Integrated Hydraulic Pump

List of References

Essential, Recommended, and Fabricated Tools

Specifications

Remove and Install Hydraulic Pump Controller

Repair Hydraulic Pump Controller

Repair Hydraulic Pump

Group 20: Hitch Valve, Selective Control Valves, and Couplers

List of References

Essential, Recommended, and Fabricated Tools

Specifications

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

Group 30: Hitch

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

Remove and Install Lift Cylinder

Disassemble, Inspect, and Assemble Lift Cylinder

Replace Rockshaft Bushings

Repair Draft Sensing

Section 80: Miscellaneous

Group 05: Hood

List of References

Essential, Recommended, and Fabricated Tools

Specifications

Position Hood Forward

Optional Forward Hood Position

Remove and Install Hood

Remove and Install Hood Screens and Louvers

Remove and Install Hood Side Panels

Remove and Install Hood Latch

Group 10: Platform Step Assembly

List of References

Specifications

Remove and Install Platform Step Assembly

Section 90: Operator Station

Group 00: Component Removal and Installation

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Remove Cab

Install Cab

Repair Cab

Remove Inner Roof

Install Inner Roof

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

List of References

Heater Line Routing

Remove HVAC Module

Install HVAC Module

Remove and Install Heater Control Valve (Without ClimaTrak™)

Leak Test Manual Heater Control Valve

Remove and Install Heater Control Valve (With ClimaTrak™)

Remove and Install Mode Control Cable

Group 10: Air Conditioning System

List of References

Essential, Recommended, and Fabricated Tools

Other Material

Specifications

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

Remove and Install Compressor Relief Valve

Replace Receiver-Dryer

Remove and Install Expansion Valve

Group 15: Air Suspension Seat

List of References

Essential, Recommended and Fabricated Tools

Other Material

Specifications

Remove and Install Seat

Repair Seat Air System

Repair Seat Suspension

Repair Seat Back

Repair Seat Control Knobs

Group 25: Armrest

List of References

Remove and Install Left Hand Armrest

Group 30: Cab Door and Windshield

List of References

Specifications

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 95: Track Frame and Components

Group 05: Tracks

List of References

Essential, Recommended, and Fabricated Tools

Specifications

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

Other Material

Specifications

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

Other Material

Specifications

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

Other Material

Specifications

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 99: Dealer Tools

Group 05: Dealer Fabricated Tools

List of References

Fabricated Tools

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

Group 10: Essential and Recommended Tools

List of References

D01006AA Bench-Mounted Holding Fixture

D01019AA Manually Operated Hydraulic Pump

D01044AA Bushing, Bearing and Seal Driver Set

D01045AA Disk Set

D01210AA Slide Hammer Puller

D01300AA Slide Hammer Puller

D05104ST Radiator Pressure Tester

D05114ST Spanner Wrench

D05117ST Spanner Wrench

D05223ST Engine Rollover Stand

JDG-PST Power Shift Transmission Repair Kit

JDG19 Lifting Eyes

JDG135 Driver Disk (140 mm or 5-1/2 in.)

JDG141 Extraction Tool

JDG155 Electrical Repair Tool Kit

JDG236 Bearing Installer

JDG311 Bearing Cup Installer

JDG342 Driver Handle

JDG359 DEUTSCH Electrical Repair Tool Kit

JDG537 Driver Handle

JDG707 Crimping Tool

JDG708 AMP Crimping Tool

JDG751 Solenoid Removal Tool

JDG754 Spring Compressor

JDG766 Clip Removal Tool

JDG768 Pilot Pins

JDG783 Weather Pack Crimping Tool

JDG788 Seal Installer

JDG820 Flywheel Rotation Tool

JDG839 Radiator Pressure Tester Adapter

JDG849A Clutch Disk Guide

JDG850 Clutch Disk Guide Tool

JDG851 Seal Installer

JDG853A Spanner Wrench

JDG854 Spanner Wrench

JDG855 Clutch Assembly Tool

JDG857 Guide Pins

JDG861 Torque Wrench Adapter

JDG864 Park Brake Spring Compression Tool

JDG865 Crimping Tool

JDG881 Pump Drive Baffle Installer

JDG883 Bearing Retainer and Seal Installer

JDG879A Differential and Pinion Lifting Fixture

JDG909 Lifting Eyes

JDG915 Clutch Piston Installer

JDG926A Bearing Installer

JDG929 Seal Remover and Installer

JDG931 Driver Disk (178 mm or 7 in.)

JDG933 Driver Disk (137 mm or 5-3/8 in.)

JDG938 Seal Installer

JDG948 Terminal Extractor Tool

JDG983 Snap Ring Expander Tool

JDG1072 Journal Bearing Sizing Tool

JDG1076A Cone Stand and Adapter

JDG1077 Yoke Installation Tool

JDG1094 Leveling Plate

JDG1119 Rear Axle Lift Tool

JDG1120 Differential Quill Adjustment Tool

JDG1148 Adapter

JDG1149 Driver Disk 171 mm (6-3/4 in.)

JDG1182 Puller Adapter

JDG1198 Bearing Installer

JDG1258 Torque Adapter

JDG1272 Bushing-Seal Installer

JDG1353 Check Valve Removal Tool

JDG1355 Coupler Disengage Tool

JDG1371 Clutch Piston Installer Tools

JDG1413 Bearing Cone Installer

JDG1419 Lifting Bridle

JDG1423 Bearing Puller Tool Set

JDG1424 Support Block

JDG1426 Driver

JDG1427 Driver

JDG1482 Shaft Protector

JDG1505 Test Block

JDG1556 Driver Disk 229 mm (9 in.)

JDG1574 Lifting Bracket

JDG1579 Coupler Tool

JDG1606 Differential Pinion Retaining Tool

JDG1666 Park Brake Release Hand Pump Kit

JDG1727 Terminal Crimping Tool

JDG1744 Master Repair Kit

JDG1758 Seal Installer

JDG1760 Spacer Kit

JDG1761 Spanner Socket

JDG1762 MFWD Clutch Disc Guide

JDG1763 Lifting Eye

JDG1765 CU Idler Shaft Holding Tool

JDG1767 Alignment Plug

JDG1837 Driver Disk

JDG1839 Driver Disk

JDG1841 Bearing Installer

JDG1860 Seal Installer

JDG1861 Seal Installer

JDG1883 Transmission Lifting Fixture Adapter

JDG1885 STC Tools

JDG1888 Shift Valve Plug

JDG1935 Auxiliary Drive Support

JDG2046 Starter Wrench

JDG2058 Disk Guide

JDG2061 Front Adapter

JDG8092 Driver Handle

JDG10008 Jumper Tube Service Kit

JDG10041 Rear Lifting Bracket

JDG10042 Front Lifting Bracket

JDG10049 Seal Installer

JDG10145 Terminal Crimping Tool

JDG10146 Extraction Tool

JDG10198 Terminal Crimping Tool

JDG10353 DEUTSCH Crimp and Extractor Tool Set

JDG10471 Spanner Socket

JDG10472 Spanner Socket

JDG10521 Face Seal Installer

JDG10522 Face Seal Installer

JDG10539 Radiator Pressure Tester Adapter

JDG10555 Recovery/Recycling Station

JDG10577 Spiral Bevel Pinion Holding Tool

JDG10664 Relief Valve Core Removal Tool

JDG10665 Spool Centering Spring Assembly Tool

JDG10666 Pressure Compensator Removal Brush

JDG10667 Shuttle Valve Removal Tool

JDG10741 Wheel Tightening Stand

JDG10757 Rear Final Drive Bearing and Seal Installer

JDG10758 Rear Final Drive Lift Tool

JDG10759 Final Drive Support Stand

JDG10770 Planetary Rotating Tool

JDG10797 Face Seal Installer

JDG10806 Inner Axle Housing Gauge Plate

JDG10808 Rear Differential Lift Tool

JDG10856 Axle/Planetary Carrier Assembly Fixture

JDG10859 Rear Final Drive Ring Gear Lift Tool

JDG10860 Axle Planetary Carrier Rotation Tool

JDG10876 Bushing Installer

JDG10878 Bearing Installer

JDG10927 Terminal Extraction Tool

JDG10929 Track Adjustment Tool

JDG10950 Driver Disk

JDG10974 Recovery/Recycling, and Charging Station

JDG11001 Puller Adapter

JDG11002 Bearing Cup Installation Disk

JDG11016 Die Assembly

JDG11017 Crimping Tool

JDG11019 Extraction Tool

JDG11091 Two-Jaw Puller

JDG11228 Die Set

JDG11229 Die Set

JDG11230 Die Set

JDG11244 Radiator Pressure Tester Adapter

JDG11252 Front Lifting Bracket

JDG11255 Terminal Crimping Tool

JDG11258 Rear Lifting Bracket

JDG11305 MFWD Output Shaft Seal Installer

JDP-10 Bushing Installer

JDT35 Driver Disk

JT02043 Support Stands

JT02044 Support Stands

JT02051 Manifold with Gauges

JT02098 Air Conditioning Fitting Kit

JT02129 Air Conditioning Oil Injector

JT03472 Hydraulic Fitting

JT05412 Universal Pressure Test Kit

JT05420 Nitrogen Accumulator Charging Kit

JT05550 Lifting Eyebolts

JT05706 Torque Multiplier Wrench

JT05711 Nitrogen Accumulator Charging Regulator

JT05746 Portable Filter Caddy

JT07056 Service Jack

JT07115 Master Hydraulic Kit

JT07115SUP Supplemental Master Hydraulic Kit

JT07118 Two-Valve Manifold

JT07119 Test Hose

JT07122 Splitting Stand

JT07122-1 Splitting Stands

JT07122-7 Upright Supports

JT07195B Technician’s Electrical Repair Kit

JT07201A Transmission Lifting Fixture

JT07202 Transmission Shaft Lifting Fixture

JT07203 Transmission Shafts Holding Fixture

JT07204A Transmission Support Plate

JT07205 Rear Cover Lifting Tool

JT07206 Clutch Lifting Tool

JT07210 Manifold Lifting Bracket

JT07211 Rear Differential Support Stands

JT07321 Rear Support Wheels

JT07323 Rear Dolly Adapters

JT07336 Lift Sling

RE164261 Track Charging Hose

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