Description
Introduction
Foreword
Manual Identification—READ THIS FIRST!
Contents
General Information
Safety
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance
To the Customer
Sound and Vibration Specifications
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Operator Ability
Wear Protective Equipment
Protect Against Noise
Avoid Unauthorized Machine Modifications
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Work In Ventilated Area
Avoid Static Electricity Risk When Refueling
High Debris Applications
Prevent Fires, Clean Debris From Machine
In Case of Machine Fire
Prevent Battery Explosions
Handle Chemical Products Safely
Handle Starting Fluid Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Exhaust Filter Ash Handling and Disposal
Prepare for Emergencies
Clean Debris from Machine
Add Cab Guarding for Special Uses
Use Steps and Handholds Correctly
Start Only From Operator′s Seat
Use and Maintain Seat Belt
Heated and Ventilated Operator’s Seat
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over and Machine Damage
Use Special Care When Operating
Inspect and Maintain ROPS
Travel Safely
Prevent Acid Burns
Add and Operate Attachments Safely
Park and Prepare for Service Safely
Service Machines Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Use Proper Lifting Equipment
Clean Exhaust Filter Safely
Torque Values
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Service Recommendations for 37° Flare and 30° Cone Seat Connectors
Service Recommendations for O-Ring Boss Fittings
Straight Fitting
Angle Fitting
Service Recommendations For O-Ring Boss Fittings With Shoulder
O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators
Service Recommendations for Flared Connections—Straight or Tapered Threads
Service Recommendations for Flat Face O-Ring Seal Fittings
O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations For Inch Series Four Bolt Flange Fittings
Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings
Metric 24° O-Ring Seal DIN 20078 Service Recommendations
Tracks
Track System
Welding On Machine
Track Guides and Rock Guards Remove and Install
Track Guides
Rock Guards—If Equipped
Carrier Roller Wear Inspection
Carrier Roller Remove and Install
Carrier Roller Disassemble and Assemble
DISASSEMBLE
ASSEMBLE
Metal Face Seals Inspection
Carrier Roller Leakage Test
Track Roller Wear Inspection
Track Roller Remove and Install
Track Roller Disassemble and Assemble
Track Roller Disassemble
Track Roller Assemble
Track Roller Leakage Test
Track Shoe Grouser Wear Inspection
Track Shoe Remove and Install
REMOVAL
INSTALLATION
Pivot Shaft Remove and Install
REMOVAL
INSTALLATION
Pivot Shaft Disassemble and Assemble
DISASSEMBLE
ASSEMBLE
Crossbar Remove and Install
REMOVAL
INSTALLATION
Crossbar Bushings and Seals Remove and Install
Track Link Height Inspection
Bushing Outside Diameter for Lubricated Track Chain Inspection
Track Pitch for Lubricated Track Chain Inspection
Lubricated Track Chain Remove and Install
Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble and Assemble
Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble
Track Sag Adjustment
Check Track Sag
Decrease Track Sag:
Increase Track Sag:
Track Adjuster Cylinder and Recoil Spring Remove and Install
Track Adjuster Recoil Spring Disassemble and Assemble
Track Adjuster Cylinder Disassemble and Assemble
DISASSEMBLE
ASSEMBLE
Track Frame Remove and Install
Front Idler Wear Inspection
Front Idler Remove and Install
REMOVAL
INSTALLATION
Front Idler Disassemble and Assemble
Front Idler Disassembly
Front Idler Assembly
Front Idler Adjustment
Sprocket Segment Remove and Install
Axles and Suspension Systems
Drive Axle Housing and Support
Final Drive Remove and Install
REMOVAL
INSTALLATION
Axle Shaft, Bearings, and Reduction Gears
Final Drive Disassemble and Assemble
Final Drive Disassemble
Component Inspection and Repair
Final Drive Assemble
Transmission
Removal and Installation
Hydrostatic Pump and Motor Initial Start-Up Procedure
Hydrostatic Pump Remove and Install
Hydrostatic Motor Remove and Install
Controls Linkage
Transmission Control Lever (TCL) Remove and Install
Decelerator/Brake Pedal Remove and Install
Decelerator/Brake Pedal Disassemble and Assemble
Input Drive Shafts and U-Joints
Damper Drive Remove and Install
REMOVAL
INSTALLATION
Hydraulic System
Hydrostatic Pump Disassemble
Charge Pump Disassemble and Assemble
Pump Displacement Control Valve (PDCV) Disassemble and Assemble
Hydrostatic Pump Assemble
Hydrostatic Motor Disassemble
Hydrostatic Motor Assemble
Hydrostatic Thermal Bypass Valve Remove and Install
Hydrostatic Reservoir Remove and Install
Engine
Removal and Installation
John Deere Engine
Engine Remove and Install
INSTALLATION
Engine Mounts Remove and Install
REMOVAL
INSTALLATION
Belt Routing
Engine Auxiliary System
Cold Weather Starting Aids
Engine Coolant Heater Remove and Install
REMOVAL
INSTALLATION
Cooling Systems
Cooling Package Remove and Install
REMOVAL
INSTALLATION
Cooling Package Disassemble and Assemble
DISASSEMBLE
ASSEMBLE
Intake System
Air Cleaner Remove and Install
Strata™ Cap Precleaner Remove and Install—If Equipped
REMOVAL
INSTALLATION
External Exhaust Systems
Diesel Particulate Filter (DPF) Remove and Install
REMOVAL
INSTALLATION
Aftertreatment Assembly Remove and Install
REMOVAL
INSTALLATION
Exhaust Tube Remove and Install
REMOVAL
INSTALLATION
Diesel Exhaust Fluid (DEF) In-Line Filter Remove and Install
REMOVAL
INSTALLATION
Selective Catalytic Reduction (SCR) Remove and Install
REMOVAL
INSTALLATION
Diesel Exhaust Fluid (DEF) Tank Remove and Install
REMOVAL
INSTALLATION
Diesel Exhaust Fluid (DEF) Tank Header Remove and Install
MACHINE PREPARATION
REMOVAL AND INSTALLATION
Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble
Diesel Exhaust Fluid (DEF) Baffle Remove and Install
Diesel Exhaust Fluid (DEF) Tank Header Suction Filter Remove and Install
Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure
Cleaning Procedure—DEF Tank Removed
Cleaning Procedure—DEF Tank Installed
Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install
REMOVAL
INSTALLATION
Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install
Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install
Diesel Oxidation Catalyst (DOC) Remove and Install
External Fuel Supply Systems
Primary and Secondary Fuel Filter Assembly Remove and Install
REMOVAL
INSTALLATION
Auxiliary Fuel Filter Remove and Install—If Equipped
REMOVAL
INSTALLATION
Fuel Tank Remove and Install
REMOVAL
INSTALLATION
Fuel Tank Assembly Disassemble and Assemble
DISASSEMBLE
ASSEMBLE
Park Brake
Hydraulic System
Park Brake Housing Remove and Install
Park Brake Valve Remove and Install
Park Brake Disassemble and Assemble
Equipment Attaching
Drawbar
Extended Rigid Drawbar Remove and Install
REMOVAL
INSTALLATION
Rigid Drawbar Remove and Install
REMOVAL
INSTALLATION
Electrical System
Removal and Installation
Right-Hand Joystick (JSR) Remove and Install
Left-Hand Joystick (JSL) Remove and Install
Auxiliary Control Lever Remove and Install
REMOVAL
INSTALLATION
Exhaust Filter Sensor Installation
Rotary Sensor Remove and Install
Evaporator Core Thermostat Remove and Install
REMOVAL
INSTALLATION
Controller Remove and Install
Connector Repair Information
Frame or Supporting Structure
Frame Installation
Welding Repair of Major Structures
Frame Bottom Guards
Bottom Guards Remove and Install
REMOVAL
INSTALLATION
Chassis Weights
Front Counterweight Remove and Install
REMOVAL
INSTALLATION
Rear Counterweight Remove and Install
REMOVAL
INSTALLATION
Operator`s Station
Removal and Installation
Cab Remove and Install
REMOVAL
INSTALLATION
Operator Enclosure
Windowpanes Remove and Install
Cab Windowpanes
INSTALLATION
Door Windowpanes
INSTALLATION
Window Wiper Motor Remove and Install
MACHINE PREPARATION
Door-Mounted Window Wiper Motor
INSTALLATION
Front Window Wiper Motor
INSTALLATION
Window Washer Pumps Remove and Install
REMOVAL
INSTALLATION
Seat and Seat Belt
Seat Remove and Install
MACHINE PREPARATION
REMOVAL
INSTALLATION
Seat Belt Remove and Install
MACHINE PREPARATION
REMOVAL
INSTALLATION
Heating and Air Conditioning
R134a Refrigerant Cautions and Proper Handling
R134a Refrigerant Oil Information
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure
Recover R134a Refrigerant
Flush and Purge Air Conditioning System
Procedure Set-Up
Compressor Cleaning
Condenser Flush and Purge
Evaporator and Expansion Valve Flush and Purge
Procedure Wrap-Up
Evacuate R134a System
Charge R134a System
Evaporator or Heater Core Remove and Install
REMOVAL
INSTALLATION
Expansion Valve Remove and Install
REMOVAL
INSTALLATION
Blower Motor Remove and Install
REMOVAL
INSTALLATION
Heater Disassemble and Assemble
DISASSEMBLE
ASSEMBLE
Receiver-Dryer Remove and Install
REMOVAL
INSTALLATION
Condenser Remove and Install
REMOVAL
INSTALLATION
Compressor Remove and Install
MACHINE PREPARATION
REMOVAL
INSTALLATION
Sheet Metal and Styling
Hood or Engine Enclosure
Hood Remove and Install
REMOVAL
INSTALLATION
Engine Side Shields Remove and Install
REMOVAL
INSTALLATION
Hood Support Remove and Install
REMOVAL
INSTALLATION
Grille and Grille Housing
Grille Remove and Install
REMOVAL
INSTALLATION
Fenders
Fenders Remove and Install
REMOVAL
INSTALLATION
Safety and Convenience
Horn and Warning Devices
Backup Alarm Remove and Install
REMOVAL
INSTALLATION
Main Hydraulic System
Hydraulic System
General Oil Cleanup Procedure
Hydraulic Component Failure Cleanup Procedure
Hydraulic Pump Remove and Install
Hydraulic Pump Disassemble and Assemble
Standard Hydraulic Pump
Hydraulic Pump With Drive Through Shaft
Hydraulic Fan Motor Remove and Install
Hydraulic Fan Pump Remove and Install
Hydraulic Fan Motor Disassemble and Assemble
Standard Hydraulic Fan Motor
Reversing Hydraulic Fan Motor
Hydraulic Oil Reservoir Remove and Install
Hydraulic Reservoir Cleanout Cover Remove and Install
Hydraulic Thermal Bypass Valve Remove and Install
Hydraulic Control Valve Remove and Install
Hydraulic Control Valve Disassemble and Assemble
Inlet Section Disassemble and Assemble
Function Section Disassemble and Assemble
Outlet Section Disassemble and Assemble
Bulldozer
Blade
Cutting Edges and End Bits Remove and Install
REMOVAL
INSTALLATION
Blade Remove and Install—PAT
Frames
C-Frame Remove and Install
REMOVAL
INSTALLATION
Hydraulic System
Cylinder Remove and Install—PAT
Blade Lift Cylinder
Blade Angle Cylinder
INSTALLATION
Blade Tilt Cylinder
Hydraulic Cylinder Repair
Ground Conditioning Tool
Ripper
Ripper Remove and Install—If Equipped
REMOVAL
INSTALLATION
Blades, Teeth, and Shanks
Shank and Tooth Remove and Install
REMOVAL
INSTALLATION
Hydraulic System
Ripper Cylinder Remove and Install
Dealer Fabricated Tools
Dealer Fabricated Tools
DF1041 Track Nut Removal Tool
DF1063 Final Drive Lift Bracket
DF1065 Final Drive and Pump Adapter Bracket
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
DFT1119 Pump Support
DFT1130 Adapter
DFT1132 Hydrostatic Motor Removal and Installation Tool
DFT1137 Hydrostatic Motor Removal and Installation Tool
DFT1203 Torque Adapter For Pivot Shaft
DFT1211 Final Drive Lifting Bracket Adapter
DFT1212 Park Brake Spring Compressor
ST4920 Track Recoil Spring Disassembly and Assembly Tool
