John Deere Tractors 9360R, 9410R, 9460R, 9510R, 9560R Repair Service Manual (TM110719)
Catalog:
Price: US$ 59.00
Complete Repair Service Technical Manual for John Deere Tractors 9360R, 9410R, 9460R, 9510R, 9560R, with all the service information to maintain, repair, and rebuild like professional mechanics.
John Deere 4WD Articulated Tractors 9360R, 9410R, 9460R, 9510R and 9560R 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.
tm110719 - 9R Tractors Repair Technical Manual.pdf
tm110719 - 9R Tractors Repair Technical Manual.epub
Total Pages: 2,013 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
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
18-Speed Power Shift Transmission
Component Removal and Installation
In Tractor Repair
Transmission Repair
Transmission Cleanup
Mechanical Shift Transmission (MST)
Component Removal and Installation
Transmission Oil Filter Relief Valve Housing
Transmission Control Valve Housing
Transmission Pump
Transmission Front Cover
Hi-Lo Clutch and Brake
Hi-Lo Planetary
Spacer Housing
Traction Clutch
Transmission Gear Drives
Transmission Cleanup
Shift Levers and Linkage
Drive Systems
Component Removal and Installation
Engine Coupler
Drive Shafts
PTO Clutch
PTO Clutch Valve
PTO Drop Box
Single Reduction Axles
Component Removal and Installation
Repair Preparation
Input Housing
Differential
Final Drives
Brakes
Double Reduction Axles
Component Removal and Installation
Repair Preparation
Input Housing
Differential
Final Drives
Brakes
Steering and Brakes
Steering Column
Steering
Steering Cylinders
Brakes
Hydraulic Trailer Brake
Hydraulics
Component Removal and Installation
Hydraulic System Repair
Hydraulic Pump
Axle Lubrication Pumps
Filter Housings and Control Valves
Hitch Valve, Selective Control Valves, and Couplers
Hitch
Miscellaneous
Hood and Side Panels
Drive Wheels and Dual Hubs
Operator Station
Component Removal and Installation
Heating, Ventilating, and Air Conditioning (HVAC)
Air Conditioning System
Air Suspension Seat
ActiveSeat™
Armrest
Cab Door and Windshield
Hinge and Gudgeon
Hinge
Gudgeon
Dealer Tools
Fabricated Tools
Essential and Recommended Tools
tm110719 - 9R Tractors Repair
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
Use Special Wrench
Install Hydraulic Fittings
Glossary of Terms
Section 20: Engine
Group 00: Component Removal and Installation
List of References
Essential, Recommended and Fabricated Tools
Specifications
Remove 9.0 L Engine
Install 9.0 L Engine
Remove 13.5 L Engine
Install 13.5 L Engine
Remove and Install Engine Oil Pan
Determining Engine Shim Pack
Engine Shim Pack Example and Worksheet
Group 05: Engine Repair
List of References
Repair Engine—Use CTM
Section 30: Fuel and Cooling Systems
Group 05: Diesel Fuel System
List of References
Specifications
Drain Fuel Tanks
Remove and Install Left-Hand Fuel Tank
Remove and Install Right-Hand Fuel Tank
Remove and Install Crossover Tank
Replace Fuel Filter, Fuel Pump, and Bleed Fuel System
Group 10: Air Intake System
List of References
Specifications
Air Intake Pipe Connections
Remove and Install Intake Housing—9.0 L
Remove and Install Intake Housing—13.5 L
Remove and Install Aspirator Hose
Remove and Install Charge Air Cooler Pipes—9.0 L
Remove and Install Charge Air Cooler Pipes—13.5 L
Group 15: Engine Cooling System
List of References
Essential, Recommended, and Fabricated Tools
Specifications
Other Material
Draining, Flushing, and Refilling Cooling System—9.0 L Engine
Draining, Flushing, and Refilling Cooling System—13.5 L Engine
Test Radiator and Deaeration Tank
Test Deaeration Cap
Remove and Install Radiator—9.0 L Engine
Remove and Install Radiator—13.5 L Engine
Remove and Install Charge Air Cooler—9.0 L Engine
Remove and Install Charge Air Cooler—13.5 L Engine
Inspect Belt Tensioner
Drive Belt Routings
Remove and Install Vari-Cool™ Fan Belt—9.0 L Engine
Remove and Install Vari-Cool™ Drive Assembly—9.0 L Engine
Remove and Install Vari-Cool™ Fan Driven Assembly—9.0 L Engine
Repair Vari-Cool™ Drive Assembly—9.0 L Engine
Repair Vari-Cool™ Fan Driven Assembly—9.0 L Engine
Check and Fill Vari-Cool™ Fan Sheaves—9.0L Engine
Remove and Install Vari-Cool™ Fan Belt—13.5 L Engine
Remove and Install Vari-Cool™ Drive Assembly—13.5 L Engine
Remove and Install Vari-Cool™ Fan Driven Assembly—13.5 L Engine
Repair Vari-Cool™ Drive Assembly—13.5 L Engine
Repair Vari-Cool™ Fan Driven Assembly—13.5 L Engine
Check and Fill Vari-Cool™ Fan Sheaves—13.5L Engine
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
Remove and Install Hydraulic Oil and Fuel Cooler
Remove and Install Air Conditioner Condenser
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
Convenience Outlet #2 Harness (Eur Only)
Convenience Outlet #2 Harness (NA Only)
Convenience Outlet #1 Harness (Eur Only)
Convenience Outlet #1 Harness (NA Only)
Roof Control Unit Power Cable
Cab Control Unit Power Cable
9.0L Alternator Power Cable
13L Alternator Power Cable
Positive Battery Cable
Negative Battery Cable
Cab Power Cable
Cab Ground Cable
Rear Chassis Control Unit Power Cable
Battery Disconnect Switch Cable
Auxiliary Power Strip
Power Module Relay Harness (Eur Only)
Hood Light Harness
Left Tail Light Harness (Eur Only)
Right Tail Light Harness (Eur Only)
Front Light Bar Harness (Eur Only)
Rear Light Bar Harness (Eur Only)
Dual Power Mirror Harness
Extremity Light Harness (NA Only)
Front Console Harness (NA Only)
Front Console Harness (Eur Only)
Steering Column Harness
ATC Roof Harness
Manual HVAC Roof Harness
Auxiliary Audio Harness
Microphone Harness
Left Fender Harness (NA Only)
Right Fender Harness (NA Only)
Right Fender Harness (Eur Only)
Left Fender Harness (Eur Only)
Key Switch Control Harness
Rear Implement Lighting and Accessory Harness (NA Only)
Rear Implement Lighting and Accessory Harness (Eur Only)
Optional Roof Lighting Harness
Back-Up Alarm Harness
9L Wheel Chassis Harness
13.5L Wheel Chassis Harness (NA Only)
13.5L Wheel Chassis Harness (Eur Only)
13.5L Wheel Chassis Harness (Scraper Only)
PowerTech™ Wheel Chassis Harness
PowerTech™ Wheel Chassis Harness (Eur Only)
PowerTech™ Wheel Chassis Harness (Scraper Only)
Rear Chassis Harness (Without Hitch)
Rear Chassis Harness (With Hitch)
Rear Chassis Harness (Scraper Only)
MST Transmission Harness
PST Transmission Harness
Right Side Chassis Harness
Exhaust Filter Harness
MST Cab Harness (NA Only)
MST Cab Harness (Eur Only)
PST Cab Harness (NA Only)
PST Cab Harness (Eur Only)
Rear PTO Harness
Main Armrest Control Unit Harness
Standard Armrest Control Unit Harness
Armrest Control Unit Harness
MST Hi/Low Lever Harness
PST Shift Lever Harness
PST Auto Mode Switch Harness
Optional SCV Controls Harness (Scraper Only)
Optional SCV Controls Backlighting Extension Harness (Scraper Only)
CommandCenter™ Display Programming Harness
Single Reduction Axle Harness
Front Double Reduction Axle Harness
Rear Double Reduction Axle Harness
AutoTrac™ Harness
Draft Sensor Extension Harness
Autoload™ Harness
Backup Hydraulic Pump Positive Cable
Backup Hydraulic Pump Negative Cable
JDLink™ (MTG) Harness
JDLink™ (MTG) Satellite Harness
Roof Lighting Harness (NA Only)
Roof Lighting Harness (Eur Only)
ISO 11786 Cornerpost Harness
ActiveSeat™ Harness
Standard Seat Harness
Heated Seat Power Harness
Heated Seat Switch Harness
Heated Seat Heater Element Harness
Power Standard Mirror Harness
Power Extend Mirror Harness
AutoTrac™ Valve Harness
AutoTrac™ Steering Angle Sensor Harness
Group 15: Charging Circuit
List of References
Disconnect Electrical Circuit
Repair Alternator—Use CTM
Replace Alternator
Replace Batteries
Group 20: Starting Circuit
List of References
Specifications
Repair Starter—Use CTM
Remove and Install Starter
Replace Master Fuse
Remove and Install Start Circuit Relay
Group 25: Relays, Fuses, Solenoids, and Switches
List of References
Essential, Recommended and Fabricated Tools
Specifications
General Repair Procedures—Solenoids and Switches
Removal, Repair, and Installation—Engine Electronics
Load Center Fuses and Relays
Replace Differential Lock Solenoid—Single Reduction Axle
Replace Axle Lube Bypass Solenoid—Double Reduction Axle
Replace Two-Speed Clutch Hi-Lo Solenoid—MST
Replace Solenoid Valves—PST
Replace Park Brake Valve Solenoids
Replace Fan Clutch Solenoids
Replace Starting Aid Switch
Replace Ignition Switch
Replace Key Switch Control
Replace Differential Lock Switch
Replace Neutral Start Switch—MST
Replace Neutral Start Switch—PST
Replace Brake Light Switch
Replace Cab Door Light Switch
Replace Seat Raise/Lower Switch
Replace Seat Firmness Switch—ActiveSeat™
Replace Heated Seat Switch
Replace Operator Presence 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 Unit and Display Identification
Replace Control Units
Replace Engine Coolant Level Sensor
Replace Engine Coolant Loss Sensor
Replace Fuel Level Sensor
Remove, Inspect, and Adjust Clutch Position Sensor
Replace Steering Input Device
Replace AutoTrac™ Sensor
Replace Transmission Lube Oil Pressure Sensor—MST
Replace Transmission Oil Filter Restriction Sensor—MST
Replace Axle Filter Restriction Sensor—Double Reduction Axle
Replace Axle Lube Pressure Sensor—Single Reduction Axle
Replace Axle Lube Pressure Sensor—Double Reduction Axle
Replace Hydraulic Oil Temperature Sensor
Replace Hydraulic Oil Filter Restriction Sensor
Replace Wheel Speed Sensor—MST
Replace Radar Sensor
Replace Hitch Position Sensor
Remove, Install, and Adjust Draft Sensor
Replace Proximity Sensor
Replace Front Driveshaft Health Control Unit
Group 35: Armrest Control
List of References
Armrest Test Procedures
Remove and Install CommandARM™ Assembly
Replace Armrest Interface Control Unit (AIC)
Replace Engine Speed Control
Replace SCV Control Lever
Replace Hitch Control
Replace Rear PTO Switch
Replace iTEC™ Sequence Switch
Replace Resume Switch
Replace Transmission Control (PST)
Exploded View—Hi-Lo Clutch Control (MST)
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—Right-Hand Console
Replace Three-Pin Accessory Outlet—Storage Box
Replace and Adjust Field Lights
Group 45: Convenience and Accessory Components
List of References
Specifications
Replace Circulation Blower Motor
Replace Heating, Ventilating, and Air Conditioning (HVAC) Pressurizer Blower Motor
Replace Wiper Motors
Replace Windshield Washer Pumps
Remove Radio and Speakers
Section 50: 18-Speed Power Shift Transmission
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove Power Shift Transmission
Install Transmission in Rollover Stand Bracket
Install Power Shift Transmission
Group 05: In Tractor Repair
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove Filter Relief Valve
Disassemble and Assemble Filter Relief Valve
Replace Transmission Pressure Regulating Valve
Remove, Repair, and Install Filter Relief Valve Housing
Remove and Install Output Yokes
Repair Internal Park Brake
Replace Input and Output Shaft Seals
Group 10: Transmission Repair
List of References
Repair 18-Speed PST
Group 15: Transmission Cleanup
List of References
Essential, Recommended, and Fabricated Tools
Perform Transmission Cleanup
Section 55: Mechanical Shift Transmission (MST)
Group 00: Component Removal and Installation
List of References
Essential, Recommended and Fabricated Tools
Other Material
Specifications
Remove Mechanical Shift Transmission
Install Transmission on Engine Rotation Stand
Install Mechanical Shift Transmission
Transmission/Axle Oil Fill—MST
Check Transmission Oil Level
Group 05: Transmission Oil Filter Relief Valve Housing
List of References
Specifications
Remove Filter Relief Valve Housing
Install Filter Relief Valve Housing
Group 10: Transmission Control Valve Housing
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Repair Clutch Pedal
Remove and Install Clutch Operating Cable
Adjust Clutch Cable
Remove Transmission Control Valve Housing
Cross-Sectional View—Transmission Control Valve
Exploded View—Transmission Control Valve
Disassemble, Inspect, and Assemble Transmission Control Valve Housing
Install Transmission Control Valve
Group 15: Transmission Pump
List of References
Specifications
Remove Transmission Pump
Cross-Sectional View—Transmission Pump and Bearing Quill
Disassemble, Inspect, and Assemble Transmission Pump
Install Transmission Pump
Group 20: Transmission Front Cover
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove Transmission Front Cover
Remove, Inspect, and Install Front Cover Parts
Install Transmission Front Cover
Group 25: Hi-Lo Clutch and Brake
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Cross-Sectional View—Hi-Lo Clutch and Brake
Exploded View—Hi-Lo Clutch and Brake
Remove Clutch and Brake Pack
Disassemble, Inspect, and Assemble Hi-Lo Clutch and Brake Assembly
Install Hi-Lo Clutch and Brake Assembly
Group 30: Hi-Lo Planetary
List of References
Essential, Recommended, and Fabricated Tools
Specifications
Cross-Sectional View—Hi-Lo Planetary
Exploded View—Hi-Lo Planetary
Remove Hi-Lo Planetary Assembly
Disassemble, Inspect, and Assemble Hi-Lo Planetary
Install Hi-Lo Planetary Assembly
Group 35: Spacer Housing
List of References
Other Material
Remove, Inspect, and Install Spacer Housing and Parts
Group 40: Traction Clutch
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove Traction Clutch Assembly
Cross-Sectional View—Traction Clutch
Exploded View—Traction Clutch
Disassemble, Inspect, and Assemble Traction Clutch
Remove and Inspect Traction Clutch Manifold
Install Traction Clutch Manifold
Install Traction Clutch Assembly
Group 45: Transmission Gear Drives
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Cross-Sectional View—Transmission Gear Drives
Remove Transmission Top Shaft, Upper Countershaft, Lower Countershaft, and Output Shaft
Cross-Sectional and Exploded Views—Top Shaft
Cross-Sectional and Exploded Views—Upper Countershaft
Cross-Sectional and Exploded Views—Lower Countershaft
Cross-Sectional and Exploded Views—Output Shaft
Disassemble and Inspect Shafts
Disassemble and Inspect Synchronizer
Assemble Synchronizer
Assemble Lower Countershaft
Assemble Upper Countershaft
Disassemble and Assemble Park Pawl Assembly
Cross-Sectional and Exploded Views—Shifter Cams
Remove and Install Shifter Cams
Adjust Neutral Start and Reverse Switches
Disassemble and Assemble Shifter Fork
Remove and Install Front Case Parts
Remove and Install Reverse Idler Gear
Install Transmission Shafts
Install Rear Case
Adjust Shaft End Play
Install Yoke Seals and Yokes
Group 50: Transmission Cleanup
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Perform Transmission Cleanup
Group 55: Shift Levers and Linkage
List of References
Specifications
Remove and Install Shift Lever Control Assembly
Exploded View—Shifter Lever Control Assembly Components
Disassemble, Inspect, and Assemble Shift Lever Control Assembly
Remove, Disassemble, Assemble, and Install Upper Shift Rods
Remove, Disassemble, Assemble, and Install Shifter Bell Crank Components
Remove, Disassemble, Assemble, and Install Lower Shift Rods
Adjust Lower Shift Rods
Adjust Neutral Lockout Plate
Section 56: Drive Systems
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools
Specifications
Remove and Install PTO Clutch
PTO-to-Transmission Alignment
Remove and Install PTO Drop Box Assembly
Group 05: Engine Coupler
List of References
Specifications
Replace Engine Coupler
Group 10: Drive Shafts
List of References
Specifications
Remove and Install Engine-to-Transmission Drive Shaft—MST
Remove and Install Engine-to-Transmission Drive Shaft—PST
Remove and Install Drive Shaft Retainer
Inspect and Replace Universal Joints
Group 15: PTO Clutch
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Cross-Sectional View—PTO Clutch Assembly
Exploded View—PTO Rear Cover and Brake Assembly
Exploded View—PTO Clutch Housing and Shaft
Exploded View—PTO Clutch Housing with Scavenge Pump
Exploded View—PTO Clutch Assembly
Disassemble, Inspect, and Assemble Scavenge Pump
Disassemble, Inspect, and Assemble PTO Clutch
Group 20: PTO Clutch Valve
List of References
Essential, Recommended, and Fabricated Tools
Specifications
Remove and Install PTO Clutch Valve
Exploded View—PTO Clutch Valve
Disassemble, Inspect, and Assemble PTO Clutch Valve
Group 25: PTO Drop Box
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Cross-Sectional View—PTO Housing Assembly
Disassemble, Inspect, and Assemble PTO Drop Box
Section 57: Single Reduction Axles
Group 00: Component Removal and Installation
List of References
Essential, Recommended and Fabricated Tools
Specifications
Remove and Install Front Axle Assembly
Remove and Install Rear Axle Assembly
Group 03: Repair Preparation
List of References
Essential, Recommended and Fabricated Tools
Specifications
Axle Vertical Play—Quick Check
Install and Remove Axle Assembly Onto Repair Stand
Group 05: Input Housing
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove Input Housing/Cover
Cross-Sectional View—Input Housing/Cover
Disassemble Input Housing/Cover
Assemble Input Housing/Cover
Determine Spiral Bevel Pinion Shaft Cone Point Shim Pack
Continue Assembly of Input Housing Cover
Adjust Differential Drive Shaft
Install Input Housing/Cover
Group 10: Differential
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove Differential
Cross-Sectional View—Differential with Differential Lock
Cross-Sectional View—Standard Differential
Disassemble, Inspect, and Assemble Differential
Install Differential
Adjust Differential Preload
Adjust Differential Backlash
Group 15: Final Drives
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove Final Drive Assemblies
Cross-Sectional View—Final Drive
Disassemble Final Drive
Disassemble, Inspect, and Assemble Planet Pinion Carrier
Remove Axle Housing
Disassemble and Assemble Axle Housing
Disassemble, Inspect, and Assemble Axle Shaft
Install Axle Housing
Adjust Axle Bearings
Install Final Drive Assemblies
Group 20: Brakes
List of References
Specifications
Replace Brakes
Section 58: Double Reduction Axles
Group 00: Component Removal and Installation
List of References
Essential, Recommended and Fabricated Tools
Specifications
Identify Axles
Remove and Install Front Axle Assembly
Remove and Install Rear Axle Assembly
Group 03: Repair Preparation
List of References
Essential, Recommended and Fabricated Tools
Specifications
Axle Vertical Play—Quick Check
Install and Remove Axle Assembly in Repair Stand
Group 05: Input Housing
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove Input Housing
Cross-Sectional View—Input Housing
Disassemble and Assemble Input Housing
Group 10: Differential
List of References
Essential, Recommended, and Fabricated Tools
Other Materials
Specifications
Remove Differential
Cross-Sectional View—Differential
Disassemble and Assemble
Install Differential
Adjust Differential Preload
Set Cone Point and Adjust Backlash
Verify Input Quill Cone Point
Group 15: Final Drives
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove Final Drive Assemblies
Disassemble Final Drive
Disassemble, Inspect, and Assemble First Stage Pinion Carrier
Disassemble, Inspect, and Assemble Second Stage Pinion Carrier
Assemble Final Drive
Remove Axle Housing
Disassemble and Assemble Axle Housing
Disassemble, Inspect, and Assemble Axle Shaft
Install Axle Housing
Adjust Axle Bearings
Install Final Drive Assemblies
Group 20: Brakes
List of References
Specifications
Other Material
Essential, Recommended and Fabricated Tools
Disassemble and Assemble Brakes
Section 60: Steering and Brakes
Group 05: Steering Column
List of References
Specifications
Remove and Install Control Support
Repair Steering Column
Group 10: Steering
List of References
Specifications
General Repair Procedures—Steering
Remove and Install Steering Valve
Exploded View—Steering Valve
Repair Steering Valve
Remove and Install AutoTrac™ Valve
Repair AutoTrac™ Valve
Exploded View—Priority Valve
Remove and Install Priority Valve
Repair Priority Valve
Remove and Install Backup Pump
Remove and Install Backup Manifold
Repair Backup Manifold
Bleed Steering System
Group 15: Steering Cylinders
List of References
Other Material
Specifications
Remove and Install Steering Cylinders
Repair Steering Cylinder
Group 20: Brakes
List of References
Essential, Recommended, and Fabricated Tools
Specifications
General Repair Procedures—Brake Valve
Remove and Install Brake Rod
Remove and Install Brake Valve
Repair Brake Valve
Remove and Install Secondary Brake Valve
Repair Secondary Brake Valve
Bleed Brakes
Check Brakes
Manually Release Park Brake—PST
Group 25: 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
Other Material
Specifications
Remove and Install Hydraulic Pump—Standard Flow Hydraulic System
Remove and Install High-Flow Hydraulic Pumps
Fill Hydraulic Pump Crankcase
Group 05: Hydraulic System Repair
List of References
Specifications
General Repair Procedures—Hydraulic Systems
Drain and Fill Hydraulic Reservoir
Remove and Install Hydraulic Oil Reservoir
Clean Hydraulic Oil System Vent Filter
Hydraulic System Cleanup
Group 10: Hydraulic Pump
List of References
Essential, Recommended and Fabricated Tools
Specifications
Pump Identification—High-Flow Hydraulic
Remove and Install Pump Controller—75cm3 Hydraulic Pump
Replace Shaft Seal
Service Hydraulic Pump Control
Repair Hydraulic Pump
Group 15: Axle Lubrication Pumps
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Remove and Install Axle Lubrication Pump
Disassemble, Inspect, and Assemble Axle Lubrication Pump
Remove and Install Gear Pump Assembly
Remove and Install Rear Scavenge Pump
Group 20: Filter Housings and Control Valves
List of References
Specifications
Remove, Inspect, and Install Primary Hydraulic Filter Housing
Remove and Install Axle Filter Housing
Remove, Inspect, and Install Cooler Bypass Valve
Remove and Install Front and Rear Return Valves
Remove and Install Hydraulic Return Valve
Remove and Install Axle Lube Pressure Control Valve
Group 30: Hitch Valve, Selective Control Valves, and Couplers
List of References
Essential, Recommended, and Fabricated Tools
Specifications
Remove and Install Hitch-SCV Valve Stack
Remove and Install High Flow Valve Stack
Disassemble and Assemble Hitch-SCV Valve Stack
Disassemble and Assemble Scraper High Flow 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
Repair High Flow Couplers
Group 35: Hitch
List of References
Specifications
Remove and Install Lift Cylinder
Repair Hitch Lift Cylinder
Repair Hitch Lift Arm Assembly
Section 80: Miscellaneous
Group 05: Hood and Side Panels
List of References
Specifications
Position Hood Forward
Remove and Install Hood
Remove and Install Hood Screens
Remove and Install Hood Side Panels
Remove and Install Hood Latch
Adjust Fingerguard
Remove and Install Grille and Headlight Assembly
Adjusting Front Grille Lights
Aiming Head Lights
Group 10: Drive Wheels and Dual Hubs
List of References
Essential, Recommended, and Fabricated Tools
Specifications
Wheel Torque Wrench Adapter—JDG679
Wheel Weight Holding Wrench—JDG10958
Wheel Tightening Stand—DFRW219 or JDG10741
Adjusting and Tightening Wheels—Standard Cast Drive Wheel and Dual Hubs
Adjusting and Tightening Wheels—Steel Drive Wheel and Dual Standard Hubs
Adjusting and Tightening Wheels—Heavy-Duty Drive Wheels and Dual Hubs
Adjusting and Tightening—Heavy-Duty Dual Wheel Hubs
Installing Wheel Rim to Cast Wheel
Installing 76x50 B32 Flotation Wheel and Tire Assembly
Section 90: Operator Station
Group 00: Component Removal and Installation
List of References
Essential, Recommended, and Fabricated Tools
Specifications
Remove Cab
Install Cab
Repair Cab
Remove Inner Roof
Install Inner Roof
Group 05: Heating, Ventilating, and Air Conditioning (HVAC)
List of References
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
Replace Receiver-Dryer
Remove and Install Expansion Valve
Group 20: 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: ActiveSeat™
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Purging Air from ActiveSeat™ System
Remove and Install ActiveSeat™
Remove and Install ActiveSeat™ Actuator
Remove and Install ActiveSeat™ Actuator Hoses
Remove and Install ActiveSeat™ Control Valve Assembly
ActiveSeat™ Hydraulic Control Valve Block
Remove and Install ActiveSeat™ Accumulator
Checking and Charging Replacement Accumulators—ActiveSeat™
Repair ActiveSeat™ Air System
Repair ActiveSeat™ Suspension
Repair ActiveSeat™ Back
Repair ActiveSeat™ Control Knobs
Group 30: Armrest
List of References
Remove and Install Left Hand Armrest
Group 35: 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: Hinge and Gudgeon
Group 05: Hinge
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Replace Hinge Pins and Bushings
Group 10: Gudgeon
List of References
Essential, Recommended, and Fabricated Tools
Other Material
Specifications
Exploded View—Standard Gudgeon
Exploded View—Severe Duty Gudgeon
Remove Gudgeon Drive Shaft
Inspect Universal Joint and Gudgeon Drive Shaft
Install Gudgeon Drive Shaft
Replace Gudgeon Journal Bearings, Thrust Bearings, and Wear Plates—Standard Duty Gudgeon
Replace Gudgeon Journal Bearings, Thrust Bearings, and Wear Plates—Severe Duty Gudgeon
Replace Gudgeon Spindle
Section 99: Dealer Tools
Group 05: Fabricated Tools
List of References
Fabricated Tools
DF1057—Axle Adjusting Tool
DFRW7—Differential Lifting Tool
DFRW30A—Axle Jacking Tool
DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses
DFRW72—Gudgeon Spindle Cooling Box
DFRW92—Mounting Guide Pins
DFRW94—Rear Axle Support Stand
DFRW103—Yoke Holding Tool
DFRW117—Transmission-Hydraulic Flusher
DFRW132—Differential Side Bevel Gear End Play Tool
DFRW147—Screw Jack
DFRW148—ActiveSeat™ Control Valve Holding Tool
DFRW150—SCV-Hitch Valve Stack Lifting Bracket
DFRW164—Axle Adjusting Tool
DFRW165—PST Park Brake Pump Off Hose Adapter
DFRW169—Gudgeon Oscillation Stop
DFRW213—Hydraulic Trailer Brake Test / Bleed Assembly
DFRW219—Wheel Tightening Stand
Group 10: Essential and Recommended Tools
List of References
D01006AA Bench-Mounted Holding Fixture
D01019AA Manually Operated Hydraulic Pump
D01045AA Disk Set
D01061AA Blind-Hole Puller Set
D05104ST Radiator Pressure Tester
D05223ST Engine Rollover Stand
JDG19 Lifting Eyes
JDG22 Seal Remover
JDG135 Driver Disk (140 mm or 5-1/2 in.)
JDG141 Extraction Tool
JDG155 Electrical Repair Tool Kit
JDG359 DEUTSCH Electrical Repair Tool Kit
JDG537 Driver Handle
JDG651 Planetary Timing Tool
JDG658 Special Hydraulic Wrench
JDG659 Oscillation Spindle Cap Tool
JDG660B Gudgeon Oscillation Stop
JDG667A 100 mm Axle Wheel Adjusting Tool
JDG668A 110 mm Axle Wheel Adjusting Tool
JDG669 Box-End Adapter
JDG673 Seal Installer Set
JDG679 Wheel Torque Wrench Adapter
JDG707 Crimping Tool
JDG708 AMP Crimping Tool
JDG740 Bearing Race Installer
JDG741 Bearing Installer
JDG744A Transmission Cover Removal Bracket
JDG751 Solenoid Removal Tool
JDG758 Bushing Installer
JDG783 Weather Pack Crimping Tool
JDG820 Flywheel Rotation Tool
JDG865 Crimping Tool
JDG867 Axle Seal Installer
JDG868 Axle Seal Installer
JDG877 Sealing Ring Loading Tool Set
JDG878 Sealing Ring Resizing Tool
JDG880B Differential Bearing Quill Adjustment Tool
JDG882 Mounting Guide Pins
JDG890A Planetary Carrier Lifting Tool
JDG923A Backlash Checking Tool
JDG924 Yoke Holding Tool
JDG926A Bearing Installer
JDG927 Axle Support Bracket
JDG929 Seal Remover and Installer
JDG930 Driver Disk (152 mm or 6 in.)
JDG931 Driver Disk (178 mm or 7 in.)
JDG932 Driver Disk (162 mm or 6-3/8 in.)
JDG933 Driver Disk (137 mm or 5-3/8 in.)
JDG938 Seal Installer
JDG948 Terminal Extractor Tool
JDG986 Driver Disk (133 mm or 5-1/4 in.)
JDG994 Journal Bearing Installer
JDG1005 Axle Support Bracket Adapter Set
JDG1006 PTO Clutch Housing Lifting Fixture
JDG1079 Lifting Bar
JDG1083 Axle Transport Cart
JDG1213 Tie Rod Wrench
JDG1288 Bearing Installer
JDG1289 Seal Installer
JDG1327 Alignment Tool Set
JDG1407 Bearing Installer
JDG1413 Bearing Cone Installer
JDG1419 Lifting Bridle
JDG1424 Support Block
JDG1476 Stand Bracket
JDG1487A Seal Installer Plate
JDG1488 Double Ended Socket Adapter
JDG1562B Axle Seal Installer
JDG1563 Driver Disk 197 mm (7-3/4 in.)
JDG1573 Rear Axle Support Stand
JDG1574 Lifting Bracket
JDG1579 Coupler Tool
JDG1662 Spacer Ring
JDG1666 Park Brake Release Hand Pump Kit
JDG1727 Terminal Crimping Tool
JDG1744 Master Repair Kit
JDG1885 Snap-to-Connect Release Tools
JDG1890 Seal Installer
JDG8092 Driver Handle
JDG10049 Seal Installer
JDG10145 Terminal Crimping Tool
JDG10146 Extraction Tool
JDG10198 Terminal Crimping Tool
JDG10199 Rear Engine Lift Bracket
JDG10200 13.5L Front Engine Lift Bracket
JDG10227 Axle Mounting Bracket
JDG10296 Threaded Quill Adjustment Tool
JDG10353 DEUTSCH Crimp and Extractor Tool Set
JDG10539 Radiator Pressure Tester Adapter
JDG10540 Bearing Installer
JDG10541 Seal Installer
JDG10555 Recovery/Recycling Station
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
JDG10878 Bearing Installer
JDG10927 Terminal Extraction Tool
JDG10958 Wheel Weight Holding Wrench
JDG10974 Recovery/Recycling, and Charging Station
JDG11016 Die Assembly
JDG11017 Crimping Tool
JDG11019 Extraction Tool
JDG11202 Thermostat Seal Installer
JDG11228 Die Set
JDG11229 Die Set
JDG11230 Die Set
JDG11237 Extension Lead Harness Adapter
JDG11244 Radiator Pressure Tester Adapter
JDG11252 Front Lifting Bracket
JDG11255 Terminal Crimping Tool
JDG11258 Rear Lifting Bracket
JDG11306 STC Tool
JDG11324 Front Lifting Bracket
JDG11325 Rear Lifting Bracket
JDT24B Spring Washer Compressor
JDT35 Driver Disk
JT01778 Threaded Adapter (5/8 in. x 12 mm)
JT02044 Support Stands
JT02098 Air Conditioning R-12/R134a Fitting Kit
JT02129 Air Conditioning Oil Injector
JT03473 Coupler
JT03515 Accumulator Charging Set
JT05412 Universal Pressure Test Kit
JT05508 Lift Eye
JT05563 Nitrogen Charging Hose
JT05706 Torque Multiplier Wrench
JT05723 Medium-Duty Splitting Stand
JT05725 Universal Support Stand
JT05746 Portable Filter Caddy
JT07115 Master Hydraulic Kit
JT07115SUP Supplemental Master Hydraulic Kit
JT07119 Test Hose
JT07195B Technician’s Electrical Repair Kit
JT07219 Rear Axle Support Stand
JT07336 Lift Sling
RE37996 Neutral Start Switch Gauge
John Deere Tractors 9360R, 9410R, 9460R, 9510R, 9560R Repair Service Manual (TM110719)
