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John Deere 410E Backhoe Loader Repair Technical Manual TM1611 – PDF DOWNLOAD
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Description
John Deere 410E Backhoe Loader Repair Technical Manual TM1611 – PDF DOWNLOAD
FILE DETAILS:
John Deere 410E Backhoe Loader Repair Technical Manual TM1611 – PDF DOWNLOAD
Language : English
Pages : 792
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 410E Backhoe Loader Repair Technical Manual TM1611 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical Manuals are concise guides for specific machines. They are onthejob guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
TABLE OF CONTENTS:
John Deere 410E Backhoe Loader Repair Technical Manual TM1611 – PDF DOWNLOAD
Contents........................................................................ 5 General Information......................................................... 7 Safety Information...................................................... 9 Handle Fluids Safely—Avoid Fires.................................... 9 Prevent Battery Explosions.......................................... 9 Prepare for Emergencies............................................. 9 Prevent Acid Burns.................................................. 10 Handle Chemical Products Safely..................................... 10 Avoid High-Pressure Fluids.......................................... 11 Park Machine Safely................................................. 11 Support Machine Properly............................................ 11 Wear Protective Clothing............................................ 12 Work in Clean Area.................................................. 12 Service Machines Safely............................................. 12 Work In Ventilated Area............................................. 13 Illuminate Work Area Safely......................................... 13 Replace Safety Signs................................................ 13 Use Proper Lifting Equipment........................................ 14 Remove Paint Before Welding or Heating.............................. 14 Avoid Heating Near Pressurized Fluid Lines.......................... 14 Keep ROPS Installed Properly........................................ 15 Service Tires Safely................................................ 15 Practice Safe Maintenance........................................... 16 Use Proper Tools.................................................... 16 Dispose of Waste Properly........................................... 17 Live With Safety.................................................... 17 General Specifications.................................................. 19 410E Backhoe Loader Dimensions...................................... 19 410E Backhoe Loader Specifications.................................. 24 Other Information—410E Backhoe Loader............................... 26 410E Backhoe Loader Weight.......................................... 26 410E Backhoe and Loader Buckets..................................... 27 410E Backhoe Loader Drain and Refill Capacities..................... 27 410E Backhoe Loader Lifting Capacities—Standard Dipperstick......... 28 410E Backhoe Loader Lifting Capacities—Extendible Dipperstick (R.... 29 410E Backhoe Loader Lifting Capacities—Extendible Dipperstick (E.... 30 Torque Values........................................................... 31 Hardware Torque Specifications...................................... 31 ROPS Torque Specifications.......................................... 31 Metric Bolt and Screw Torque Values................................. 32 Additional Metric Cap Screw Torque Values........................... 33 Unified Inch Bolt and Screw Torque Values........................... 34 O-Ring Groove Connections........................................... 35 Check Oil Lines And Fittings........................................ 35 Service Recommendations for O-Ring Boss Fittings.................... 36 Service Recommendations for Flat Face O-Ring Seal Fittings.......... 37 Service Recommendations for Metric Series Four Bolt Flange Fitti.... 38 Service Recommendations For Inch Series Four Bolt Flange Fitting.... 39 Fuels and Lubricants.................................................... 41 Diesel Fuel......................................................... 41 Low Sulfur Diesel Fuel Conditioner.................................. 41 Handling and Storing Diesel Fuel.................................... 42 Do Not Use Galvanized Containers.................................... 42 Heavy Duty Diesel Engine Coolant.................................... 43 Fuel Tank........................................................... 43 Diesel Engine Oil................................................... 44 Transmission, Axle, and Mechanical Front Wheel Drive Oil............ 45 Hydraulic Oil....................................................... 45 Grease.............................................................. 47 Grease for Extendible Dipperstick, Sideshift Frame, and Stabiliz.... 47 Alternative and Synthetic Lubricants................................ 47 Lubricant Storage................................................... 48 Mixing of Lubricants................................................ 48 Wheels...................................................................... 49 Powered or Non-Powered Wheels and Fastenings............................ 51 Service Equipment and Tools......................................... 51 Specifications...................................................... 51 Remove and Install Rear Wheel Assembly.............................. 52 Remove and Install Front Wheel Assembly............................. 53 Remove and Install Tire............................................. 54 Axles and Suspension Systems................................................ 57 Input Drive Shafts and U-Joints......................................... 59 Specifications...................................................... 59 Remove and Install Drive Shaft...................................... 59 Non-Powered Wheel Axles................................................. 61 Service Equipment and Tools......................................... 61 Other Material...................................................... 61 Specifications...................................................... 61 Remove and Install Hub Assembly..................................... 62 Remove and Install Spindle and Knuckle Assembly..................... 63 Remove and Install Tie Rod.......................................... 64 Remove and Install Non-Powered Front Axle........................... 64 Adjust Non-Powered Front Axle Toe-In................................ 65 Powered Wheel Axle (MFWD)............................................... 67 Service Equipment and Tools......................................... 67 Other Material...................................................... 67 Specifications...................................................... 67 Front Wheel Drive Axles—Use CTM4509................................. 67 Remove and Install Powered Front Axle............................... 68 Adjust MFWD Axle Toe-In............................................. 70 Axle Shaft, Bearings and Reduction Gears................................ 71 Essential Tools..................................................... 71 Service Equipment and Tools......................................... 71 Other Material...................................................... 72 Specifications...................................................... 73 Inspect Service Brakes.............................................. 74 Remove and Install Rear Axle........................................ 75 Disassemble Rear Axle............................................... 76 Disassemble and Assemble Park Brake................................. 85 Assemble Rear Axle..................................................102 Check Service Brakes After Assembly.................................121 Check Gear Tooth Contact Pattern....................................122 Dealer Fabricated Tools.................................................123 DFT1146 Axle Mounting Bracket.......................................123 DFT1147 Axle Rolling Torque Bar.....................................123 Transmission................................................................126 Removal and Installation................................................127 Specifications......................................................127 Remove and Install Transmission.....................................127 Controls Linkage........................................................131 Other Material......................................................131 Specifications......................................................131 Remove and Install Reverser Control.................................132 Remove and Install Transmission Shifter Lever.......................133 Remove Shifter Lever and Housing....................................134 Disassemble and Assemble Shift Lever and Housing....................136 Install Shift Lever and Housing.....................................139 Input Drive Shafts and U-Joint..........................................141 Specifications......................................................141 Remove and Install Drive Shaft......................................141 Gears, Shafts, Bearings, and Powershift Clutches........................143 Essential Tools.....................................................143 Service Equipment and Tools.........................................143 Other Material......................................................144 Other Material......................................................145 Specifications......................................................146 Remove Outer Components to Disassemble Manual Shift Transmission....147 Disassemble Converter Side of Case—Manual Shift.....................151 Remove Oil Suction Tube—Manual Shift................................154 Remove Reverse and Forward Clutch Packs—Manual Shift................154 Disassemble and Assemble Reverse or Forward Clutch Pack—Manual S....154 Remove Drive Shaft—Manual Shift.....................................164 Disassemble and Assemble Drive Shaft—Manual Shift...................164 Remove Rear Output Shaft with Synchronizer—Manual Shift.............166 Remove Intermediate Shaft with Synchronizer—Manual Shift............167 Disassemble Rear Output or Intermediate Shaft with Synchronizer—....167 Rear Output Shaft—Cross Section View—Manual Shift...................172 Intermediate Shaft—Cross Section View—Manual Shift..................173 Assemble Rear Output or Intermediate Shaft—Manual Shift.............174 Remove MFWD Output Shaft (If Equipped)—Manual Shift.................180 Disassemble MFWD Shaft (If Equipped)—Manual Shift...................180 MFWD Shaft—Cross Section View—Manual Shift..........................183 Assemble MFWD Shaft (If Equipped)—Manual Shift......................184 Remove, Disassemble, and Assemble Idler Shaft—Manual Shift..........186 Remove and Install Oil Supply Tube—Manual Shift.....................187 Install Idler and MFWD Shafts to Assemble Transmission (If Equip....187 Install Intermediate and Rear Output Shafts—Manual Shift............190 Install Drive Shaft—Manual Shift....................................191 Install Forward and Reverse Clutch Packs—Manual Shift...............192 Install Oil Suction Tube—Manual Shift...............................194 Assemble Converter Side of Case—Manual Shift........................194 Install Outer Components to Assemble Transmission—Manual Shift......197 Remove Outer Components to Disassemble Powershift Transmission......205 Disassemble Converter Side of Case—Powershift.......................207 Remove Low Range Forward, Reverse and Third Speed Clutch Packs—P....209 Disassemble and Assemble Low Range Forward, Reverse and Third Sp....210 Remove First Speed, Second Speed, and High Range Forward Clutch ....220 Disassemble and Assemble First Speed, Second Speed, and High Ran....220 Remove Drive Shaft—Powershift.......................................229 Disassemble and Assemble Drive Shaft—Powershift.....................230 Remove MFWD Output Shaft (If Equipped)—Powershift...................231 Disassemble MFWD Shaft (If Equipped)—Powershift.....................233 Assemble MFWD Shaft (If Equipped)—Powershift........................235 Remove Oil Suction Tube—Powershift..................................237 Remove and Install Oil Supply Tubes—Powershift......................238 Install Oil Suction Tube—Powershift.................................239 Install MFWD Shaft to Assemble Transmission (If Equipped)—Powers....239 Install Drive Shaft—Powershift......................................240 Install Clutch Packs—Powershift.....................................241 Assemble Converter Side of Case—Powershift..........................242 Install Outer Components to Assemble Transmission—Powershift........246 Hydraulic System........................................................251 Other Material......................................................251 Specifications......................................................251 Remove and Install Control Valve—Manual Shift.......................252 Disassemble and Assemble Control Valve—Manual Shift.................252 Remove and Install Transmission Charge Pump—Manual Shift............262 Remove and Install Transmission Charge Pump—Powershift..............262 Disassemble and Assemble Transmission Charge Pump—Manual Shift a....262 Remove and Install Manifold Plate Solenoids—Manual Shift............266 Remove and Install Control Valve—Powershift.........................268 Disassemble and Assemble Control Valve—Powershift...................269 Remove and Install Shift Valve—Powershift...........................278 Disassemble and Assemble Shift Valve—Powershift.....................279 Remove and Install Manifold Plate and Solenoids—Powershift..........284 Dealer Fabricated Tools.................................................287 DFT1143 Transmission Support Bracket................................287 DFT1162 Powershift Clutch Pack Snap Ring Removal and Installatio....288 DFT1163 MFWD Snap Ring Removal and Installation Tool................289 Engine......................................................................291 Removal and Installation................................................293 Essential Tools.....................................................293 Specifications......................................................293 PowerTech 4.5 L (4045) John Deere Engine—Use CTM104.................294 Remove and Install Engine...........................................294 Dealer Fabricated Tools.................................................305 DFT1145 Transmission Holding Bracket................................305 Engine Auxiliary Systems....................................................307 Cold Weather Starting Aid...............................................309 Specifications......................................................309 Remove and Install Coolant Heater...................................309 Remove and Install Starting Aid Nozzle..............................310 Remove and Install Starting Aid Solenoid............................312 Cooling Systems.........................................................313 Specifications......................................................313 Remove and Install Fan..............................................313 Remove and Install Fan Belt.........................................314 Remove and Install Radiator.........................................314 Speed Controls..........................................................317 Specifications......................................................317 Disassemble and Assemble Speed Control Linkage......................318 Intake System...........................................................321 Essential Tools.....................................................321 Service Equipment and Tools.........................................321 Specifications......................................................321 Remove and Install Air Cleaner......................................322 Air Intake System Leakage Test......................................323 Exhaust System..........................................................325 Remove And Install Muffler..........................................325 Remove And Install Muffler With Turbocharger—If Equipped............326 External Fuel Supply System.............................................327 Other Material......................................................327 Remove and Install Fuel Tank........................................328 Torque Converter............................................................331 Turbine, Gears and Shaft................................................333 Remove and Install Torque Converter.................................333 Disassemble and Assemble Torque Converter...........................333 Steering System.............................................................335 Hydraulic System........................................................337 Service Equipment and Tools.........................................337 Other Material......................................................337 Specifications......................................................338 Remove and Install Steering Column..................................339 Disassemble and Assemble Tilt Steering Wheel and Column.............340 Remove and Install Steering Valve...................................341 Remove and Install Pressure Regulating Valve from Steering Valve....344 Disassemble and Assemble Pressure Regulating Valve..................345 Disassemble Steering Valve..........................................345 Assemble Steering Valve.............................................351 Remove and Install Non-Powered Axle Steering Cylinder...............356 Disassemble Non-Powered Axle Steering Cylinder......................356 Cross Section of Non-Powered Axle Steering Cylinder.................359 Assemble Non-Powered Axle Steering Cylinder.........................359 Remove and Install Steering Cylinder Bushings.......................365 Cross Section of APL-2025 MFWD Axle Steering Cylinder...............366 Disassemble and Assemble APL-2025 MFWD Axle Steering Cylinder.......367 Adjust Tracking Angle for MFWD Axle.................................372 Remove and Install Priority Valve...................................372 Disassemble and Assemble Priority Valve.............................374 Service Brakes..............................................................377 Active Elements.........................................................379 External Service Brake Inspection...................................379 Remove and Install Brake Disk and Pressure Plate....................379 Hydraulic System........................................................381 Service Equipment and Tools.........................................381 Other Material......................................................381 Specifications......................................................382 Remove and Install John Deere Brake Valve (S.N. —887378)............383 Disassemble and Assemble John Deere Brake Valve (S.N.—887378).......384 Disassemble and Assemble Brake Valve Lines (S.N.—887378)............386 Remove and Install MICO Brake Valve (S.N. 887379—)..................387 Disassemble MICO Power Boost Brake Valve (S.N. 887379—).............390 Assemble MICO Power Boost Brake Valve (S.N. 887379—)................392 Adjust Brake Pedals.................................................394 Bleeding Brakes.....................................................396 Park Brake..................................................................397 Active Elements.........................................................399 Remove and Install Park Brake.......................................399 Electrical Systems..........................................................401 Batteries, Support, and Cables..........................................403 Service Equipment and Tools.........................................403 Specifications......................................................403 Service Batteries Carefully.........................................404 Procedure for Testing Batteries.....................................405 Electrolyte Checking Specific Gravity...............................406 Battery Electrolyte Level and Terminals Check.......................407 Battery Charger—Using...............................................409 Using Booster Batteries—12 Volt System..............................410 Charge Battery......................................................411 Remove and Install Batteries........................................412 Alternator, Regulator and Charging System Wiring........................415 Bosch Alternator Repair—Use CTM77...................................415 Specifications......................................................415 Remove and Install Alternator.......................................416 Lighting System.........................................................419 Remove and Install Drive and Work Light.............................419 Remove and Install Halogen Bulb.....................................419 Remove and Install Display Module Bulbs.............................420 Remove and Install Turn, Brake and Tail Light Bulbs.................421 Remove and Install Front Turn Light Bulb............................421 Wiring Harness and Switches.............................................423 Essential Tools.....................................................423 Specifications......................................................424 Remove and Install Cab Roof Harness and Components..................425 Remove and Install Cab Side Console Harness and Components..........427 Remove and Install Front Console Harness and Components.............431 Remove and Install Engine Harness and Components....................433 Remove and Install Blower Harness and Components....................435 Remove and Install Radio Harness and Components.....................437 Remove and Install A/C Compressor Harness and Components—If Equi....439 Remove and Install Auxiliary Flow Control Harness and Components....441 Remove and Install Ride Control Harness and Components—If Equipp....442 Fuse Specifications.................................................443 Kostal Connector 16 Way Replace.....................................443 Kostal Open-Barrel Contact Install..................................444 Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co.™ Connector....445 Install DEUTSCH DEUTSCH is a trademark of Deutsch Co.™ Contact ....447 Replace WEATHER PACK WEATHER PACK is a trademark of Packard Elec....448 WEATHER PACK WEATHER PACK is a trademark of Packard Electric.™ ....449 Remove Connector Body from Blade Terminals..........................450 Remove Blade Terminals from Fuse Block .............................451 System Controls.........................................................453 Remove and Install Return-to-Dig Switch.............................453 Instruments and Indicators..............................................455 Other Material......................................................455 Remove and Install Fuel Gauge Sender................................455 Motors and Actuators....................................................457 Starter Motor Repair—Use CTM77......................................457 Remove and Install Starting Motor...................................457 Remove and Install Starter Relay....................................458 Frames, Chassis or Supporting Structure.....................................459 Frame Installation......................................................461 Essential Tools.....................................................461 Specifications......................................................461 Welding Repair of Major Structures..................................461 Remove and Install RIVNUTRIVNUT is a registered trademark of The....462 Chassis Weights.........................................................465 Specifications......................................................465 Remove and Install Counterweight....................................466 Remove and Install Frame Bumper.....................................467 Operator’s Station..........................................................469 Removal and Installation................................................471 Service Equipment and Tools.........................................471 Specifications......................................................471 Remove and Install Cab/ROPS.........................................471 Operator Enclosure......................................................477 Other Material......................................................477 Specifications......................................................477 Disassemble and Assemble Fixed Right Front Cab Window and Wiper ....478 Disassemble and Assemble Right Cab Door and Wiper Motor.............480 Disassemble and Assemble Left Cab Door and Wiper Motor..............482 Adjust Cab Right Door Latch and Hinges..............................484 Adjust Cab Left Door Latch and Hinges...............................486 Adjust Cab Door Handle Screw........................................487 Disassemble and Assemble Cab Side Windows...........................488 Adjust Cab Side Windows.............................................489 Disassemble and Assemble Upper Rear Window and Wiper Motor..........490 Adjust Upper Rear Window............................................491 Disassemble and Assemble Lower Rear Windows.........................492 Adjust Lower Rear Window............................................493 Remove and Install Windowpanes......................................493 Remove and Install Headliner........................................494 Remove and Install Cab Roof.........................................495 Seat and Seat Belt......................................................497 Specifications......................................................497 Remove and Install Seat Assembly....................................497 Seat and Seat Belt and Arm Rest—Disassemble and Assemble............498 Seat Slide and Swivel and Lumbar Control Levers—Disassemble and ....500 Seat Swivel and Latch Disassemble and Assemble......................502 Disassemble and Assemble Seat Suspension and Shock Absorber.........504 Disassemble and Assemble Seat Base and Support......................506 Disassemble and Assemble Air Seat Suspension (If Equipped)..........507 Heating and Air Conditioning............................................513 Essential Tools.....................................................513 Service Equipment and Tools.........................................514 Other Material......................................................515 Specifications......................................................516 Proper Refrigerant Handling.........................................516 R134a Refrigerant Cautions..........................................517 Refrigerant Hoses and Tubing Inspection.............................517 Refrigerant Theory of Operation.....................................518 Remove and Install Air Conditioning Compressor......................519 R134a Compressor Oil Removal........................................519 Disassemble and Assemble Compressor Clutch..........................520 Clutch Hub Clearance Check..........................................521 Compressor Manifold Inspect.........................................521 Disassemble, Inspect, and Assemble Compressor.......................522 R134a Component Oil Charge..........................................524 R134a Refrigerant Recovery/Recycling and Charging Station Instal....525 Recover R134a System................................................526 Evacuate R134a System...............................................527 Charge R134a System.................................................528 R134a System Leak Testing...........................................528 Remove and Install Heater Core......................................529 Remove and Install Evaporator.......................................530 Remove and Install A/C Freeze Switch................................531 Disassemble and Assemble Heater/Blower Assembly.....................532 Disassemble and Assemble Heater/Blower Assembly with Air Conditi....533 Disassemble and Assemble Blower Assembly............................534 Disassemble and Assemble Condenser..................................535 Disassemble and Assemble Air Ducts..................................537 Dealer Fabricated Tools.................................................539 DFRW20 Compressor Holding Fixture...................................539 DFT1101 Cab and ROPS Lift Bracket...................................540 Sheet Metal and Styling.....................................................541 Hood and Engine Enclosure...............................................543 Disassemble and Assemble Hood and Engine Enclosure..................543 Miscellaneous Shields...................................................545 Disassemble and Assemble Battery Box................................545 Grille and Grille Housing...............................................547 Disassemble and Assemble Grille and Grille Housing..................547 Fenders.................................................................549 Disassemble and Assemble Fenders....................................549 Disassemble and Assemble Fender Extensions..........................550 Safety, Convenience and Miscellaneous.......................................551 Radio...................................................................553 Remove and Install Radio and Speakers...............................553 Remove and Install Antenna..........................................553 Disassemble and Assemble Radio, Speakers and Antenna................554 Horn and Warning Devices................................................557 Remove and Install Horn.............................................557 Remove and Install Back-Up Alarm....................................558 Adjust Back-Up Alarm Volume.........................................558 Main Hydraulic System.......................................................559 Hydraulic System........................................................561 Other Material......................................................561 Specifications......................................................562 Remove and Install Hydraulic Pump...................................563 Hydraulic Pump Cross Section........................................565 Hydraulic Pump Control Piston and Load Sense Module.................567 Hydraulic Pump Flow Limiter.........................................569 Disassemble, Inspect and Assemble Hydraulic Pump....................570 Remove and Install Hydraulic Filter Assembly........................597 Remove and Install Reservoir........................................598 Disassemble and Assemble Reservoir..................................599 Remove and Install Hydraulic Oil Cooler (Standard without Air Co....601 Remove and Install Hydraulic Oil Cooler and Hoses with Air Condi....603 Loader......................................................................605 Loader..................................................................607 Specifications......................................................607 Remove Loader.......................................................607 Install Loader......................................................610 Bucket..................................................................613 Specifications......................................................613 Remove and Install Loader Bucket....................................613 Replace Welded Bucket Cutting Edges.................................614 Bucket Cutting Edge Cracked Repair..................................614 Remove and Install Cutting Edge.....................................615 Disassemble and Assemble Multi-Purpose Bucket and Lines.............620 Control Linkages........................................................623 Other Material......................................................623 Specifications......................................................623 Loader Bucket Self-Leveling Linkage Indicator and Return-to-Dig ....624 Remove and Install Loader Control Valve Linkage.....................626 Loader Control Valve Linkage Adjustment.............................628 Remove and Install Bucket Cylinder Linkage..........................629 Hydraulic System........................................................631 Essential Tools.....................................................631 Service Equipment and Tools.........................................631 Other Material......................................................632 Specifications......................................................633 Disassemble and Assemble Loader Bucket Curl, Load Sense, Boom Ra....635 Disassemble and Assemble Loader Bucket Dump Circuit Relief Valve....636 Disassemble and Assemble Anti-Cavitation Valve......................637 Disassemble and Assemble Auxiliary Circuit Relief Valve.............638 Disassemble and Assemble Auxiliary Shut-off Plug....................638 Remove and Install Loader Control Valve.............................639 Disassemble and Assemble Loader Control Valve.......................640 Replace Wiper Rings and Seals of Loader Control Valve Sections......642 Remove and Install Loader Control Valve Relief Valves...............647 Disassemble and Assemble Loader Inlet Section.......................648 Disassemble and Assemble Loader Bucket Section......................650 Disassemble and Assemble Loader Boom Section........................652 Disassemble and Assemble Loader Auxiliary Section...................654 Remove and Install Loader Boom Cylinder—120 Series..................655 Remove and Install Loader Bucket Cylinder—120 Series................656 Disassemble Loader Bucket and Boom Cylinders—120 Series.............657 Cross Section of Loader Bucket and Boom Cylinder—120 Series.........660 Assemble Loader Bucket and Boom Cylinder—120 Series.................660 Disassemble and Assemble Multi-Purpose Bucket Cylinder—120 Serie....666 Remove and Install Ride Control Valve— If Equipped..................667 Disassemble and Assemble Ride Control Valve— If Equipped............668 Remove and Install Ride Control Valve Solenoid—If Equipped..........671 Remove and Install Ride Control Accumulator—If Equipped.............671 Charging the Ride Control Accumulator...............................673 Charging the Ride Control Accumulator—Procedure “A” (14.2 in. ac....674 Charging the Ride Control Accumulator—Procedure “B” (17.2 in. ac....675 Ride Control Accumulator—Discharge Procedure........................676 Backhoe.....................................................................678 Bucket..................................................................679 Service Equipment and Tools.........................................679 Remove and Install Bucket and Bucket Links..........................679 Remove and Install Bucket Tooth Shank...............................680 Remove and Install Bucket Cutting Edge..............................683 Control Linkage.........................................................685 Other Material......................................................685 Specifications......................................................685 Remove and Install Backhoe Boom Swing Lock Control Lever and Lin....686 Remove and Install Backhoe Boom Swing Lock Arms and Locking Pin.....688 Remove and Install Backhoe Valve Linkage—Two Lever..................689 Backhoe Valve Linkage Adjustment....................................690 Remove and Install Stabilizer Valve Linkage (S.N. —874256)..........691 Remove and Install Stabilizer Valve Linkage (S.N. 874257—)..........693 Stabilizer Valve Linkage Adjustment.................................694 Frames..................................................................695 Other Material......................................................695 Specifications......................................................695 Remove and Install Dipperstick......................................696 Remove and Install Boom.............................................698 Remove and Install Swing Frame......................................702 Remove Extendible Dipperstick Extension.............................703 Install Extendible Dipperstick Extension............................706 Hydraulic System........................................................709 Essential Tools.....................................................709 Service Equipment and Tools.........................................709 Other Material......................................................710 Specifications......................................................711 Remove and Install Backhoe Control Valve............................713 Disassemble and Assemble Backhoe Control Valve......................717 Remove and Install Backhoe Circuit Relief and System Relief Valv....719 Disassemble and Assemble Anti-Cavitation Valve......................720 Disassemble and Assemble Backhoe Boom Raise, Bucket Dump, Crowd ....721 Disassemble and Assemble Backhoe Bucket Curl Circuit Relief Valv....722 Disassemble and Assemble Backhoe Swing, Boom Lower, Crowd In Cir....723 Disassemble and Assemble Backhoe Electro-Hydraulic Auxiliary Cir....724 Disassemble and Assemble Auxiliary Shut-off Plug....................724 Disassemble and Assemble Backhoe Inlet Section......................725 Disassemble and Assemble Backhoe Auxiliary Flow Section (If Equi....727 Disassemble and Assemble Backhoe Swing Section......................729 Disassemble and Assemble Backhoe Boom Section.......................731 Disassemble and Assemble Backhoe Bucket Section.....................733 Disassemble and Assemble Backhoe Crowd Section......................735 Disassemble and Assemble Backhoe Extendible Section.................737 Replace Wiper Rings and Seals of Backhoe Control Valve Sections.....738 Remove and Install Stabilizer Valve.................................742 Disassemble and Assemble Stabilizer Valve...........................744 Remove and Install Backhoe Bucket Cylinder—125 Series...............745 Remove and Install Backhoe Crowd Cylinder—125 Series................746 Remove and Install Backhoe Boom Cylinder—125 Series.................747 Remove and Install Extendible Dipperstick Cylinder..................749 Disassemble Boom, Bucket, and Crowd Cylinders—125 Series............749 Cross Section of Backhoe Crowd (S.N. —837228) and Bucket Cylinde....751 Cross Section of Crowd Cylinder (S.N. 837229—873597) 125 Series.....752 Cross Section of Crowd Cylinder (S.N. 873598—) 125 Series...........753 Cross Section of Backhoe Boom Cylinder—125 Series...................754 Assemble Boom, Bucket, and Crowd Cylinders—125 Series...............755 Indexing Series125 Cylinders........................................761 Remove and Install Swing Cylinder—120 Series........................762 Remove and Install Stabilizer Cylinder—120 Series...................764 Disassemble Swing and Stabilizer Cylinders—120 Series...............764 Cross Section of Swing Cylinder—120 Series..........................767 Cross Section of Stabilizer Cylinder—120 Series.....................768 Assemble Swing and Stabilizer Cylinder—120 Series...................768 Disassemble Extendible Dipperstick Cylinder.........................774 Cross Section of Extendible Dipperstick Cylinder....................777 Assemble Extendible Dipperstick Cylinder............................777 Page Number..................................................................... 5 Section 00.................................................................. 7 Group 0001.............................................................. 9 Group 0002.............................................................. 19 Group 0003.............................................................. 31 Group 0004.............................................................. 41 Section 01.................................................................. 49 Group 0110.............................................................. 51 Section 02.................................................................. 57 Group 0225.............................................................. 59 Group 0230.............................................................. 61 Group 0240.............................................................. 67 Group 0250.............................................................. 71 Group 0299..............................................................123 Section 03..................................................................126 Group 0300..............................................................127 Group 0315..............................................................131 Group 0325..............................................................141 Group 0350..............................................................143 Group 0360..............................................................251 Group 0399..............................................................287 Section 04..................................................................291 Group 0400..............................................................293 Group 0499..............................................................305 Section 05..................................................................307 Group 0505..............................................................309 Group 0510..............................................................313 Group 0515..............................................................317 Group 0520..............................................................321 Group 0530..............................................................325 Group 0560..............................................................327 Section 06..................................................................331 Group 0651..............................................................333 Section 09..................................................................335 Group 0960..............................................................337 Section 10..................................................................377 Group 1011..............................................................379 Group 1060..............................................................381 Section 11..................................................................397 Group 1111..............................................................399 Section 16..................................................................401 Group 1671..............................................................403 Group 1672..............................................................415 Group 1673..............................................................419 Group 1674..............................................................423 Group 1675..............................................................453 Group 1676..............................................................455 Group 1677..............................................................457 Section 17..................................................................459 Group 1740..............................................................461 Group 1749..............................................................465 Section 18..................................................................469 Group 1800..............................................................471 Group 1810..............................................................477 Group 1821..............................................................497 Group 1830..............................................................513 Group 1899..............................................................539 Section 19..................................................................541 Group 1910..............................................................543 Group 1913..............................................................545 Group 1921..............................................................547 Group 1927..............................................................549 Section 20..................................................................551 Group 2001..............................................................553 Group 2004..............................................................557 Section 21..................................................................559 Group 2160..............................................................561 Section 31..................................................................605 Group 3100..............................................................607 Group 3102..............................................................613 Group 3115..............................................................623 Group 3160..............................................................631 Section 33..................................................................678 Group 3302..............................................................679 Group 3315..............................................................685 Group 3340..............................................................695 Group 3360..............................................................709
S.S 23/02/2025
