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John Deere 9300T, 9400T, 9320T, 9420T, 9520T & 9620T Tractors Repair Technical Manual TM1782 – PDF DOWNLOAD
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John Deere 9300T, 9400T, 9320T, 9420T, 9520T & 9620T Tractors Repair Technical Manual TM1782 – PDF DOWNLOAD
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John Deere 9300T, 9400T, 9320T, 9420T, 9520T & 9620T Tractors Repair Technical Manual TM1782 – PDF DOWNLOAD
FILE DETAILS:
John Deere 9300T, 9400T, 9320T, 9420T, 9520T & 9620T Tractors Repair Technical Manual TM1782 – PDF DOWNLOAD
Language : English
Pages : 1000
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
John Deere 9300T, 9400T, 9320T, 9420T, 9520T & 9620T Tractors Repair Technical Manual TM1782 – PDF DOWNLOAD
Contents........................................................................ 5 General Information......................................................... 7 Safety.................................................................. 9 Follow Safety Instructions.......................................... 9 Recognize Safety Information........................................ 9 Practice Safe Maintenance........................................... 10 Handle Fluids Safely—Avoid Fires.................................... 10 Prevent Battery Explosions.......................................... 11 Prepare for Emergencies............................................. 11 Prevent Acid Burns.................................................. 12 Handle Agricultural Chemicals Safely................................ 13 Avoid High-Pressure Fluids.......................................... 13 Park Machine Safely................................................. 14 Support Machine Properly............................................ 14 Wear Protective Clothing............................................ 14 Protect Against High Pressure Spray................................. 15 Work in Clean Area.................................................. 15 Service Machines Safely............................................. 15 Work In Ventilated Area............................................. 16 Illuminate Work Area Safely......................................... 16 Replace Safety Signs................................................ 16 Use Proper Lifting Equipment........................................ 17 Avoid Harmful Asbestos Dust......................................... 17 Avoid Heating Near Pressurized Fluid Lines.......................... 17 Remove Paint Before Welding or Heating.............................. 18 Use Proper Tools.................................................... 18 Construct Dealer-Made Tools Safely.................................. 18 Dispose of Waste Properly........................................... 19 Live With Safety.................................................... 19 Protect Against Noise............................................... 19 Service Accumulator Systems Safely.................................. 20 Wait Before Opening High-Pressure Fuel System....................... 20 General Information..................................................... 21 General Specifications.............................................. 21 Overall Dimensions.................................................. 22 Sealants and Adhesives Cross-Reference Chart........................ 23 Metric Bolt and Screw Torque Values................................. 25 Unified Inch Bolt and Screw Torque Values........................... 26 Identifying Zinc-Flake Coated Fasteners............................. 26 Glossary of Terms................................................... 27 Engine...................................................................... 31 Component Removal and Installation...................................... 33 Essential or Recommended Tools...................................... 33 Specifications...................................................... 34 Engine Identification............................................... 35 Remove and Install Engine........................................... 35 Engine Repair........................................................... 47 Repair Engine—Use CTM............................................... 47 Specifications...................................................... 47 Fuel, Air, and Cooling Systems.............................................. 49 Diesel Fuel System...................................................... 51 Essential or Recommended Tools...................................... 51 Specifications...................................................... 51 Fuel Tank Components................................................ 52 Remove and Install Left Fuel Tank................................... 53 Remove and Install Right Fuel Tank.................................. 59 Remove and Install Center Fuel Tank................................. 65 Replace Fuel Filter, Fuel Pump, and Bleed Fuel System............... 65 Air Intake and Exhaust Systems.......................................... 67 Specifications...................................................... 67 Install Muffler..................................................... 68 Air Intake Pipe Connections......................................... 68 Turbocharger Inlet Hose............................................. 69 Air Intake Pipe Installation........................................ 69 Inspect Air Intake System........................................... 70 Service Air Intake System........................................... 70 Engine Cooling System................................................... 71 Essential or Recommended Tools...................................... 71 Specifications...................................................... 72 Test Radiator and Coolant Tank...................................... 72 Test Radiator Cap................................................... 73 Remove and Install Radiator......................................... 73 Remove and Install Aftercooler...................................... 76 Remove and Install Viscous Fan Drive................................ 78 Inspect Belt Tensioner.............................................. 79 Drive Belt Routings................................................. 80 Oil Coolers............................................................. 81 Specifications...................................................... 81 Remove and Install Axle-Transmission Oil Cooler—9000T............... 81 Remove and Install Hydraulic Oil Cooler—9000T....................... 83 Remove and Install Oil Cooler—9020T................................. 86 Leak Test Oil Coolers............................................... 87 Electrical.................................................................. 90 Connectors.............................................................. 91 Essential or Recommended Tools...................................... 91 Other Material...................................................... 92 Use Electrical Insulating Compound.................................. 93 Using High-Pressure Washers......................................... 93 Repair AMP Connector................................................ 94 Remove Connector Body from Blade Terminals.......................... 95 Repair CINCH Connectors............................................. 96 Repair 32 and 48 Way CINCH Connectors............................... 98 Repair CPC CPC is a trademark of AMP Incorporated™ Blade Type Co....101 Repair CPCCPC is a trademark of AMP Incorporated™, Large MATE-N-....102 Repair DEUTSCH DEUTSCH is a trademark of Deutsch Company™ Connec....102 Repair Small MATE-N-LOCMATE-N-LOC is a trademark of AMP Incorpor....104 Repair Small MATE-N-LOC MATE-N-LOC is a trademark of AMP Incorpo....105 Repair (Pull Type) METRI-PACKMETRI-PACK is a trademark of Delp......106 Repair (Push Type) METRI-PACKMETRI-PACK is a trademark of Delph.....107 Repair SUMITOMO™ Connectors.........................................109 Repair Weather PackWeather Pack is a trademark of Packard Electr....111 Repair YAZAKI™ Connectors...........................................113 Wiring Harness Routings.................................................115 Wire Number and Color Codes.........................................115 Ground Point Locations..............................................116 # 1 Chassis Single Point Ground Stud................................117 # 2 Cab-To-Chassis Ground...........................................118 # 3 Cab Ground (Floor)..............................................118 # 4 Cab Ground (Roof)...............................................119 # 5 Battery Ground..................................................120 Miscellaneous Grounds...............................................120 Engine/Chassis Harness Routing and Component Identification—Fron....123 Engine/Chassis Harness Routing and Component Identification—Rear....124 Engine/Chassis Harness Routing and Component Identification—Fron....126 Engine/Chassis Harness Routing and Component Identification—Rear....127 Engine/Chassis Harness Routing and Component Identification—Fron....129 Engine/Chassis Harness Routing and Component Identification—Rear....130 Transmission Harness Routing and Component Identification—9020T ....131 Transmission Harness Routing and Component Identification—9020T ....132 Roof Harness Routing and Component Identification—North American....133 Roof Harness Routing and Component Identification—European..........134 Cab Harness Routing and Component Identification—MST................135 Cab Harness Routing and Component Identification—PST................137 Cab Harness Routing and Component Identification—European...........139 GREENSTARGREENSTAR is a trademark of Deere & Company™ Harness Ro....141 Remote Mirror Harness Routing and Component Identification..........142 Charging Circuit........................................................143 Disconnect Electrical Circuit.......................................143 Repair Alternator—Use CTM...........................................143 Exploded View—Alternator............................................144 Replace Alternator..................................................145 Alternator Power Cable Routing......................................145 Replace Batteries...................................................146 Starting Circuit........................................................147 Specifications......................................................147 Repair Starter—Use CTM77............................................147 Remove and Install Starter..........................................147 Replace Fusible Link................................................148 Remove and Install Start Circuit Relay..............................149 Relays, Fuses, Solenoids, and Switches..................................151 Essential or Recommended Tools......................................151 Specifications......................................................151 General Repair Procedures—Solenoids.................................151 Disconnect Electrical Circuit.......................................152 Load Center Fuses...................................................152 Load Center Relays and Diodes.......................................153 Replace Starting Aid Solenoid.......................................153 Replace Two-Speed Clutch Hi-Lo Solenoid—MST.........................154 Replace Solenoid Valves—PST.........................................155 Replace SCV Solenoids...............................................157 Replace Hitch Valve Solenoids.......................................157 Replace Park Brake Valve Solenoids—9020T Series w/PST (S.N. —902....158 Replace Park Brake Valve Solenoids—9020T Series w/PST (S.N. 9022....158 Exploded View—Right Console Controls and Switches—9000T.............159 Exploded View—Right Console Controls and Switches—9020T.............160 Replace Right Console Switches......................................161 Replace Engine Oil Pressure Switch..................................161 Replace Starting Aid and Ignition Switch............................162 Replace Neutral Start Switch—PST....................................164 Neutral Start Switch—MST............................................164 Replace Reverse Switches—MST........................................165 Replace Park Brake Valve Pressure Switch—9020T Series w/PST (S.N....165 Replace Park Brake Valve Pressure Sensor—9020T Series w/PST (S.N....165 Replace Hand Brake Switch and Potentiometer European 9020T Serie....166 Replace Rear PTO Switch.............................................166 Replace Dome Light Switch...........................................166 Replace Cab Door Light Switch.......................................167 Replace Beacon Light Switch.........................................167 Replace Seat Raise/Lower Switch.....................................167 Replace Operator Presence Seat Switch...............................168 Replace External Hitch Raise/Lower Switch...........................169 Replace A/C High- and Low-Pressure Switches.........................170 Replace A/C Deicing Switch and Blower Motor Resistor................171 Monitoring Systems and Sensors..........................................173 Essential or Recommended Tools......................................173 Other Material......................................................173 Specifications......................................................174 Replace Instrument Control Unit and SCV Set-up Panel................174 Replace Bulbs In Instrument Control Unit (ICU)......................175 Replace Bulbs In SCV Set-up Panel (SUP).............................175 Replace Corner Post Display and Bulbs...............................175 Replace Steering Column Module Bulbs................................176 Replace Steering Column Module......................................177 Replace Control Units—9000T.........................................179 Replace Control Units—9020T.........................................180 Replace Engine Cam Speed Sensor.....................................180 Replace Engine Crank Speed Sensor...................................180 Replace Engine Coolant Temperature Sensors..........................181 Replace Air Filter Restriction Sensor...............................181 Replace Fuel Level Sensor...........................................181 Replace Fuel Temperature Sensor.....................................182 Remove, Inspect, and Adjust Clutch Position Sensor..................182 Replace Radar Sensor................................................184 Replace Wheel Speed Sensor—MST......................................184 Replace Transmission Oil Filter Restriction Sensor—MST..............184 Replace Transmission Lube Oil Pressure Sensor—MST...................185 Replace Axle Lube Filter Restriction Sensor (S.N. -902087)..........185 Replace Axle Lube Pressure Sensor (S.N. -902087)....................185 Replace Steering Case Pressure Sensor (S.N. 902088- )...............186 Replace Steering Motor Speed Sensor.................................186 Replace Steering Filter Restriction Sensor..........................187 Replace Steering Oil Temperature Sensor.............................187 Replace Track Tension Pressure Sensor...............................187 Replace Hydraulic Oil Temperature Sensor............................188 Replace Hydraulic Oil Reservoir Level Sensor........................189 Replace Hydraulic Oil Filter Restriction Sensor.....................190 Replace Hitch Position Sensor.......................................190 Replace Draft-Sensing Sensor........................................191 Adjust Draft-Sensing Sensor.........................................192 CLIMATRAKCLIMATRAK is a trademark of Deere & Company™ Wire Harne....193 Replace Outlet Duct Temperature Sensor..............................193 Replace Cab Temperature Sensor......................................194 Replace Evaporator Temperature Sensor...............................194 Armrest Control.........................................................195 Armrest Test Procedures.............................................195 Exploded View—Armrest Control—9000T.................................196 Exploded View—Armrest Control—9020T.................................198 Replace Armrest Control Assembly....................................199 Replace Armrest Control Unit (ACU)..................................201 Replace Armrest Controls—9000T......................................202 Replace Armrest Controls—9020T......................................202 Exploded View—Engine Speed Control..................................203 Exploded View—Transmission Control—PST..............................204 Exploded View—Hi-Lo Clutch Control—MST..............................205 Replace Hitch Control...............................................206 Exploded View—SCV Control Lever.....................................207 Implement and Accessory Connectors......................................209 Replace Seven-Terminal Outlet Socket................................209 TouchSet Depth Control Connector....................................209 Diagnostic Program Connector........................................210 ECU Diagnostic Connector............................................210 Convenience and Accessory Components....................................211 Specifications......................................................211 Replace Circulation Blower Motor....................................211 Replace Pressurizer Blower Motor....................................212 Replace Wiper Motors................................................213 Replace Windshield Washer Pumps.....................................214 Remove Radio and Speakers...........................................215 Power Shift Transmission (PST)..............................................217 Component Removal and Installation......................................219 Essential or Recommended Tools......................................219 Other Material......................................................219 Specifications......................................................220 Remove Transmission.................................................220 Remove Components from Transmission.................................225 Install Transmission to Rollover Stand Bracket......................227 Install Transmission................................................230 Check Transmission Oil Level........................................231 In-Tractor Repair.......................................................233 Essential or Recommended Tools......................................233 Other Material......................................................233 Specifications......................................................234 Remove Filter Relief Valve..........................................234 Disassemble and Assemble Filter Relief Valve........................234 Remove, Repair, and Install Filter Relief Valve Housing.............235 Remove and Install Input and Output Yokes...........................236 Repair Internal Park Brake (S.N. 902242— )..........................238 Replace Input and Output Shaft Seals................................238 Transmission Repair.....................................................241 Repair Power Shift Transmission.....................................241 Transmission Cleanup....................................................243 Essential or Recommended Tools......................................243 Perform Transmission Cleanup........................................244 Clutch Control..........................................................245 Repair Clutch Pedal Assembly........................................245 Mechanical Shift Transmission (MST).........................................249 Component Removal and Installation......................................251 Essential or Recommended Tools......................................251 Other Material......................................................252 Specifications......................................................252 Remove Mechanical Shift Transmission................................253 Install Transmission on Engine Rotation Stand.......................257 Install Mechanical Shift Transmission...............................258 Check Transmission Oil Level........................................259 Transmission Oil Filter Relief Valve Housing............................261 Specifications......................................................261 Remove Filter Relief Valve Housing..................................261 Install Filter Relief Valve Housing.................................261 Transmission Control Valve Housing......................................263 Essential or Recommended Tools......................................263 Other Material......................................................263 Specifications......................................................264 Repair Clutch Pedal.................................................265 Remove and Install Clutch Operating Cable...........................266 Adjust Clutch Cable.................................................268 Remove Transmission Control Valve Housing...........................269 Cross-Sectional View—Transmission Control Valve.....................270 Exploded View—Transmission Control Valve............................271 Disassemble, Inspect, and Assemble Transmission Control Valve Ho....272 Install Transmission Control Valve..................................276 Transmission Pump.......................................................277 Specifications......................................................277 Remove Transmission Pump............................................277 Cross-Sectional View—Transmission Pump and Bearing Quill ...........279 Exploded View—Transmission Pump and Bearing Quill...................280 Disassemble, Inspect, and Assemble Transmission Pump................281 Install Transmission Pump...........................................282 Transmission Front Cover................................................285 Essential or Recommended Tools......................................285 Other Material......................................................286 Specifications......................................................286 Remove Transmission Front Cover.....................................287 Remove, Inspect, and Install Front Cover Parts......................290 Install Transmission Front Cover....................................292 Hi-Lo Clutch and Brake..................................................295 Essential or Recommended Tools......................................295 Other Material......................................................296 Specifications......................................................296 Cross-Sectional View—Hi-Lo Clutch and Brake.........................297 Exploded View—Hi-Lo Clutch and Brake................................298 Remove Clutch and Brake Pack........................................299 Disassemble, Inspect, and Assemble Hi-Lo Clutch and Brake Assemb....299 Install Hi-Lo Clutch and Brake Assembly.............................307 Hi-Lo Planetary.........................................................309 Essential or Recommended Tools......................................309 Specifications......................................................309 Cross-Sectional View—Hi-Lo Planetary................................310 Exploded View—Hi-Lo Planetary.......................................311 Remove Hi-Lo Planetary Assembly.....................................311 Disassemble, Inspect, and Assemble Hi-Lo Planetary..................312 Install Hi-Lo Planetary Assembly....................................314 Spacer Housing..........................................................315 Other Material......................................................315 Remove, Inspect, and Install Spacer Housing and Parts...............315 Traction Clutch.........................................................319 Essential or Recommended Tools......................................319 Other Material......................................................319 Specifications......................................................320 Remove Traction Clutch Assembly.....................................320 Cross-Sectional View—Traction Clutch................................322 Exploded View—Traction Clutch.......................................323 Disassemble, Inspect, and Assemble Traction Clutch..................323 Remove and Inspect Traction Clutch Manifold.........................327 Install Traction Clutch Manifold....................................328 Install Traction Clutch Assembly....................................329 Transmission Gear Drives................................................331 Essential or Recommended Tools......................................331 Service Material and Tools..........................................332 Other Material......................................................332 Specifications......................................................333 Cross-Sectional View—Transmission Gear Drives.......................335 Remove Transmission Top Shaft, Upper Countershaft, Lower Counter....336 Cross-Sectional and Exploded Views—Top Shaft........................338 Cross-Sectional and Exploded Views—Upper Countershaft...............339 Cross-Sectional and Exploded Views—Lower Countershaft...............340 Cross-Sectional and Exploded Views—Output Shaft.....................341 Disassemble and Inspect Shafts......................................342 Disassemble and Inspect Synchronizer................................343 Assemble Synchronizer...............................................346 Assemble Lower Countershaft.........................................347 Assemble Upper Countershaft.........................................348 Disassemble and Assemble Park Pawl Assembly.........................348 Cross-Sectional and Exploded Views—Shifter Cams.....................350 Remove and Install Shifter Cams.....................................351 Adjust Neutral Start and Reverse Switches...........................355 Disassemble and Assemble Shifter Fork...............................358 Remove and Install Front Case Parts.................................358 Remove and Install Reverse Idler Gear...............................359 Install Transmission Shafts.........................................360 Install Rear Case...................................................360 Adjust Shaft End Play...............................................362 Install Yoke Seals and Yokes........................................364 Transmission Cleanup....................................................367 Essential or Recommended Tools......................................367 Service Equipment and Tools.........................................367 Perform Transmission Cleanup........................................368 Shift Levers and Linkage................................................369 Specifications......................................................369 Remove and Install Shift Lever Control Assembly.....................369 Exploded View—Shifter Lever Control Assembly Components.............372 Disassemble, Inspect, and Assemble Shift Lever Control Assembly.....373 Remove, Disassemble, Assemble, and Install Upper Shift Rods.........377 Remove, Disassemble, and Assemble Shifter Bell Crank Assembly.......379 Install Bell Crank Assembly.........................................382 Remove, Disassemble, Assemble, and Install Lower Shift Rods.........383 Adjust Lower Shift Rods.............................................385 Adjust Neutral Lockout Plate........................................386 Drive Systems...............................................................387 Component Removal and Installation......................................389 Essential or Recommended Tools......................................389 Specifications......................................................389 Remove and Install PTO Clutch.......................................389 Replace PTO Clutch Support O-Rings..................................391 Remove and Install PTO Drop Box Assembly............................393 Engine Coupler..........................................................399 Specifications......................................................399 Replace Engine Coupler..............................................399 Drive Shafts............................................................401 Specifications......................................................401 Inspect and Replace Universal Joints................................401 Remove and Install Engine-to-Transmission Driveline.................402 Remove and Install Rear Axle Driveline..............................404 Remove and Install PTO Driveline....................................405 PTO Clutch..............................................................407 Essential or Recommended Tools......................................407 Other Material......................................................407 Specifications......................................................408 Cross-Sectional View—PTO Clutch Assembly............................409 Exploded View—PTO Rear Cover and Brake Assembly.....................410 Exploded View—PTO Clutch Housing and Shaft..........................411 Exploded View—PTO Clutch Assembly...................................412 Disassemble, Inspect, and Assemble PTO Clutch.......................412 PTO Clutch Valve and Linkage............................................421 Other Material......................................................421 Specifications......................................................421 Remove and Install..................................................422 Disassemble, Inspect, and Assemble PTO Clutch Valve.................423 Remove and Install PTO Clutch Lever.................................424 Replace PTO Clutch Operating Cable..................................426 Adjust PTO Clutch Operating Cable...................................427 PTO Drop Box............................................................429 Essential or Recommended Tools......................................429 Other Material......................................................429 Specifications......................................................429 Cross-Sectional View—PTO Housing Assembly...........................430 Disassemble, Inspect, and Assemble PTO Drop Box.....................431 Rear Axle Assembly..........................................................434 Component Removal.......................................................435 Essential or Recommended Tools......................................435 Other Material......................................................436 Specifications......................................................437 Remove and Install Wheel Hub/Axle Assembly..........................437 Remove and Install Park Brake Valve—9020 Series PST Tractors........439 Remove and Install Input Pinion Housing.............................440 Remove and Install Steering Differential Carrier....................441 Remove and Install Differential Case Assembly.......................443 Remove and Install Axle Assembly....................................444 Outboard Planetary Final Drive..........................................445 Essential or Recommended Tools......................................445 Service Material and Tools..........................................446 Other Material......................................................447 Specifications......................................................447 Introduction........................................................447 Cross-Sectional View—Wheel Hub and Axle Shaft—9000T.................448 Cross-Sectional View—Wheel Hub and Axle Shaft—9020T.................450 Remove Wheel Hub Cover..............................................452 Remove Outboard Planetary...........................................453 Disassemble and Inspect Planetary Carrier Assembly..................454 Assemble Planetary Carrier Assembly.................................456 Remove and Install Sun Gear/Axle Shaft..............................458 Remove and Install Outboard Planetary Ring Gear.....................460 Install Outboard Planetary .........................................463 Adjust Axle Shaft Clearance.........................................464 Install Wheel Hub Cover.............................................465 Outboard Planetary Service Brakes.......................................467 Essential or Recommended Tools......................................467 Service Material and Tools..........................................467 Specifications......................................................467 Introduction........................................................468 Cross-Sectional View—Outboard Planetary Service Brakes—9000T........469 Cross-Sectional View—Outboard Planetary Service Brakes—9020T........471 Remove and Install Service Brake Components.........................473 Vacuum Leakdown Test................................................478 Outboard Planetary Park Brake (PST Tractor S.N. —902241)................479 Specifications......................................................479 Introduction........................................................479 Cross-Sectional View—Outboard Planetary Park Brake (PST Tractors....480 Remove and Install Park Brake Components............................481 Wheel Hub and Axle Housing..............................................485 Essential or Recommended Tools......................................485 Service Equipment and Tools.........................................488 Other Material......................................................488 Specifications......................................................489 Introduction........................................................489 Install Wheel Hub/Axle Housing Assembly in Rollover Stand and Di....489 Cross-Sectional View—Wheel Hub/Axle Housing Assembly................491 Disassemble Wheel Hub and Axle Housing..............................493 Remove, Disassemble, and Assemble Wheel Hub.........................497 Disassemble and Inspect Axle Housing................................499 Install Wheel Hub and Brake Housing.................................500 Assemble Wheel Hub/Axle Housing Assembly............................510 Steering Differential Carrier...........................................513 Essential or Recommended Tools......................................513 Specifications......................................................514 Introduction........................................................515 Cross-Sectional View—Steering Differential Carrier..................515 Disassemble Upper Differential Carrier..............................516 Remove and Disassemble Steering Shaft...............................516 Remove and Disassemble Steering Idler Gear..........................519 Assemble and Install Steering Idler Gear............................520 Remove Input Gear...................................................522 Assemble and Install Input Gear.....................................523 Assemble and Install Steering Shaft.................................526 Differential Case Steering Gears........................................529 Essential Tools or Recommended Tools................................529 Service Equipment and Tools.........................................531 Other Material......................................................531 Specifications......................................................531 Introduction........................................................532 Cross-Sectional View—Steering Gears.................................533 Remove Bearing Carrier and Inboard Planetary........................534 Remove Inboard Planetary Carrier from Bearing Carrier...............536 Disassemble and Assemble Bearing Carrier............................538 Disassemble Planetary Carrier.......................................539 Assemble Planetary Carrier..........................................543 Cross-Sectional View—Steering Planetary Drive Gear Assembly.........548 Inspect Steering Planetary Drive Gear Assembly Components...........549 Remove and Install Planetary Drive Ring Gear........................549 Remove and Disassemble Planetary Drive Gear.........................550 Assemble and Install Planetary Drive Gear...........................551 Install Bearing Carrier and Inboard Planetary.......................553 Differential Case Drive Gears...........................................557 Essential or Recommended Tools......................................557 Service Equipment and Tools.........................................557 Other Material......................................................558 Specifications......................................................559 Introduction........................................................559 Cross-Sectional View—Differential Case Assembly.....................560 Remove Spool/Ring Gear Assembly.....................................561 Disassemble and Assemble Spool/Ring Gear Assembly...................564 Install Spool/Ring Gear Assembly....................................568 Adjust Spool/Ring Gear Assembly Bearing Preload and Backlash........571 Input Pinion Housing....................................................575 Essential Tools.....................................................575 Service Equipment and Tools.........................................576 Other Material......................................................577 Specifications......................................................577 Introduction........................................................577 Cross-Sectional View—Input Pinion Housing Assembly..................578 Disassemble and Inspect Input Pinion Housing Assembly...............578 Assemble Input Pinion Housing Assembly..............................583 Determine Input Pinion Shaft Bearing Preload........................585 Continue Assembly of Input Housing..................................589 Adjust Input Housing Assembly Cone Point............................592 Remove and Install Input Yoke.......................................595 Remove and Install Seal Retainer....................................597 Replace O-Ring Packing and/or Oil Seal..............................598 Replace Input Housing-to-Case O-Ring Packing........................599 Steering and Brakes.........................................................601 Steering Column.........................................................603 Specifications......................................................603 Repair Steering Column..............................................604 Steering Wheel Position Input Assembly..................................609 Specifications......................................................609 Remove and Install Steering Wheel Position Input Assembly...........609 Repair Steering Wheel Position Input Assembly.......................610 Steering Pump...........................................................611 Essential or Recommended Tools......................................611 Service Parts Kits..................................................613 Other Material......................................................613 Specifications......................................................614 Remove and Install Steering Pump....................................615 Fill Steering Pump Crankcase........................................617 Exploded View—Steering Charge Pump and Pump Control.................618 Disassemble, Inspect, and Assemble Steering Charge Pump.............619 Disassemble, Inspect, and Assemble Displacement Control Valve.......622 Exploded View—Steering Pump.........................................624 Disassemble, Inspect, and Assemble Hydraulic Steering Pump..........625 Steering Pump Drive Gearbox.............................................643 Essential or Recommended Tools......................................643 Other Material......................................................644 Specifications......................................................644 Remove and Install Steering Pump Drive Gearbox......................644 Disassemble, Inspect, and Assemble Steering Pump Drive Gearbox......647 Steering Motor..........................................................653 Essential or Recommended Tools......................................653 Service Parts Kits..................................................653 Specifications......................................................654 Remove and Install Steering Motor...................................654 Exploded View—Steering Motor........................................657 Disassemble, Inspect, and Assemble Steering Motor...................658 Brake Valve.............................................................665 Essential or Recommended Tools......................................665 Service Parts Kits..................................................665 Specifications......................................................666 General Repair Procedures—Brake Valve...............................667 Remove and Install Brake Valve......................................667 Disassemble, Inspect, and Assemble Brake Valve......................669 Adjust Brake Pedal..................................................677 Bleed Brakes........................................................677 Check Manual Brakes.................................................678 Brake Components........................................................679 Remove and Install Brake Pressure Reducing Valve (9000t S.N. - 9....679 Exploded View—Brake Pressure Reducing Valve Manifold (9000t S.N.....680 Remove and Install Brake Pressure Reducing Valve (9000t S.N. 900....681 Exploded View—Brake Pressure Reducing Valve Manifold (9000t S.N.....682 Park Brake—9020T........................................................683 Essential or Recommended Tools......................................683 Specifications......................................................683 Remove and Install—Park Brake Valve.................................684 Exploded View—Park Brake Valve......................................685 Manual Park Brake Release 9020T Series w-PST (S. N. -902242)........686 Manual Park Brake Release 9020T Series w-PST (S. N. 902243-)........688 Secondary Brake Adjustment—9020T Series w/PST (S. N. 902243-)......690 Hydraulics..................................................................691 Hydraulic System Repair.................................................693 Essential or Recommended Tools......................................693 Specifications......................................................693 General Repair Procedures—Hydraulic Systems.........................694 Disconnect Battery Ground Cable.....................................694 Use Special Wrench..................................................695 Install Hydraulic Fittings..........................................695 Drain and Fill Hydraulic Reservoir..................................696 Remove and Install Hydraulic Oil Reservoir..........................697 Hydraulic Pump..........................................................701 Essential or Recommended Tools......................................701 Service Parts Kits..................................................701 Other Material......................................................701 Specifications......................................................702 Pump Identification.................................................703 Remove and Install Hydraulic Pump...................................703 Fill Hydraulic Pump Crankcase.......................................706 Remove and Install Hydraulic Pump Controller—Vickers................707 Exploded View—Hydraulic Pump Controller—Vickers.....................708 Disassemble, Inspect, and Assemble Pump Controller—Vickers..........708 Exploded View—Hydraulic Pump—Vickers................................710 Disassemble and Inspect Hydraulic Pump—Vickers......................711 Replace Pump Shaft Seal—Vickers.....................................715 Assemble Hydraulic Pump—Vickers.....................................715 Exploded View—Hydraulic Pump—Sauer ..........................720 Service Hydraulic Pump Control—Sauer................................722 Disassemble and Inspect Hydraulic Pump—Sauer........................723 Replace Hydraulic Pump Shaft Seal—Sauer.............................727 Assemble Hydraulic Pump—Sauer.......................................728 Axle Lubrication Pump...................................................733 Essential or Recommended Tools......................................733 Other Material......................................................733 Service Parts Kits..................................................733 Specifications......................................................733 Remove and Install Axle Lubrication Pump............................734 Exploded View—Axle Lubrication Pump.................................735 Disassemble, Inspect, and Assemble Axle Lubrication Pump............735 Filter Housings and Control Valves......................................739 Service Parts Kits..................................................739 Specifications......................................................739 Remove, Inspect, and Install Hydraulic Filter Housing...............739 Remove, Inspect, and Install Axle Filter Housing....................740 Hitch Valve, Selective Control Valves, and Couplers—9000T Series........743 Essential or Recommended Tools......................................743 Service Parts Kits..................................................743 Specifications......................................................744 Remove and Install Hitch-SCV Valve Stack............................745 Disassemble and Assemble Hitch-SCV Valve Stack......................748 Disassemble, Inspect, and Assemble Hitch Manifold...................750 Remove, Inspect, and Install Hitch-SCV Solenoids....................751 Disassemble, Inspect, and Assemble Hitch Valve......................752 Test Surge Relief Valve.............................................754 Disassemble, Inspect, and Assemble Selective Control Valve..........755 Exploded View—Coupler...............................................758 Repair SCV Couplers.................................................758 Hitch Valve, Selective Control Valves, and Couplers—9020T Series........765 Service Equipment and Tools.........................................765 Specifications......................................................766 Top Cover Identification............................................767 Exploded View—Standard End Cover....................................768 Exploded View—Deluxe End Cover......................................769 Remove and Install Hitch SCV Valve Stack............................770 Disassemble and Assemble Hitch-SCV Valve Stack......................772 Disassemble, Inspect, and Assemble Hitch Manifold...................780 Disassemble, Inspect, and Assemble Hitch Valve......................781 Disassemble, Inspect, and Assemble Selective Control Valve..........785 Repair SCV Couplers.................................................791 Hitch...................................................................795 Essential or Recommended Tools......................................795 Other Material......................................................795 Specifications......................................................795 Remove and Install Lift Cylinder....................................796 Cross-Sectional and Exploded View—90 mm Lift Cylinder...............797 Cross-Sectional and Exploded View—100 mm Lift Cylinder..............798 Disassemble, Inspect, and Assemble Lift Cylinder....................799 Repair Hitch Lift Arm Assembly......................................805 Miscellaneous...............................................................807 Hood and Side Panels....................................................809 Essential Tools.....................................................809 Remove and Install Hood.............................................809 Releasing Broken Hood Latch.........................................810 Adjust Hood.........................................................810 Remove and Install Front Screen.....................................812 Remove and Install Left Side Panel..................................813 Remove and Install Right Side Panel.................................814 Adjust Side Panel...................................................814 Platform Step Assembly..................................................817 Specifications......................................................817 Remove and Install Platform Step Assembly...........................818 Frames..................................................................819 Essential or Recommended Tools......................................819 Specifications......................................................820 Remove and Install Front Support....................................821 Remove and Install Front Side Frames................................822 Front Side Frame Torque Sequence....................................825 Hitch Frame and Drawbar.................................................827 Essential or Recommended Tools......................................827 Specifications......................................................828 Remove and Install Drawbar..........................................828 Remove and Install Drawbar Support—Standard.........................831 Remove and Install Drawbar Support—Wide Swing.......................831 Repair Drawbar Roller Carriage—Wide Swing...........................832 Remove and Install Drawbar Support—3-Point Hitch....................834 Operator Station............................................................837 Cab Removal and Installation............................................839 Essential or Recommended Tools......................................839 Other Material......................................................839 Specifications......................................................840 Remove Cab..........................................................840 Exploded View—Cab Mounts............................................844 Install Cab.........................................................845 Repair Cab..........................................................845 Heating, Ventilating, and Air Conditioning (HVAC).......................847 Heater Line Routing.................................................847 Remove HVAC Module..................................................848 Install HVAC Module.................................................852 Remove and Install Heater Core......................................853 Test Heater Core....................................................854 Remove, Test, and Install Heater Control Valve—without ClimaTrak....854 Remove, Test, and Install Heater Control Valve—with CLIMATRAKCLI....856 Remove and Install Heater Control Valve With CLIMATRAKCLIMATRAK ....857 Remove and Install Temperature Control Cable........................857 Adjust Heating/Cooling Control Cable................................859 Air Conditioning System.................................................861 Essential or Recommended Tools......................................861 Other Material......................................................865 Service Parts Kits..................................................865 Specifications......................................................866 Hose and Tubing O-Ring Connection Torques...........................867 Diagram—Air Conditioning System.....................................868 Reference Chart—Air Conditioning System Fittings....................869 Leak Test With Dye..................................................870 Discharge Air Conditioning System...................................871 Flushing, Purging, and Evacuating Information.......................872 Flush Air Conditioning System.......................................873 Purge Air Conditioning System.......................................874 Evacuate Air Conditioning System....................................875 Refrigerant Oil Information.........................................875 Check Compressor Oil Charge.........................................876 Determine Correct Refrigerant Oil Charge............................877 Add Refrigerant Oil to System.......................................878 Add Refrigerant Oil to Pressurized System...........................879 Charge Air Conditioning System......................................880 Remove and Install Compressor.......................................881 Test Volumetric Efficiency..........................................882 Test Shaft Seal Leakage.............................................884 Disassemble and Assemble Compressor Clutch..........................885 Check Clutch Hub Clearance..........................................886 Inspect Compressor Manifold.........................................886 Inspect Compressor Thermal Bypass Valve.............................887 Disassemble, Inspect, and Assemble Compressor.......................888 Remove and Install Compressor Relief Valve..........................890 Replace Receiver-Dryer..............................................890 Leak Test Condenser.................................................891 Remove and Install Air Conditioning Condenser.......................891 Leak Test Evaporator................................................892 Remove and Install Evaporator.......................................893 Remove and Install Expansion Valve..................................894 Air Suspension Seat.....................................................897 Essential or Recommended Tools......................................897 Other Material......................................................897 Remove and Install Seat.............................................898 Repair Air System...................................................899 Remove and Install Ride Zone Protector (RZP)........................901 Repair Suspension...................................................901 Repair Seat Back....................................................905 Repair Control Knobs................................................906 Disassemble and Assemble Adjustable Armrest Support—Style A.........907 Disassemble and Assemble Adjustable Armrest Support—Style B.........910 Cab Door and Windshield.................................................913 Specifications......................................................913 Door Latch Identification—Version "A" and Version "B"...............913 Repair Cab Door Latch...............................................914 Cab Door Adjustments................................................916 Cab Door Latch Adjustment—Step 1....................................917 Door Striker Adjustment—Step 2.....................................918 Cab Door Latch Adjustment—Step 3....................................919 Door Latch Adjustment—Step 4........................................921 Replace Windshield Glass............................................922 Track Frame and Components..................................................925 Tracks..................................................................927 Essential or Recommended Tools......................................927 Specifications......................................................928 Track Tensioning and Detensioning...................................929 Remove and Install Track............................................931 Tension Cylinder and Accumulator........................................933 Essential or Recommended Tools......................................933 Other Material......................................................934 Service Parts Kits..................................................934 Specifications......................................................934 Remove and Install Track Tension Cylinder...........................935 Cross-Sectional and Exploded View—Track Tension Cylinder............936 Disassemble, Inspect, and Assemble Track Tension Cylinder...........936 Charge Tension Accumulator..........................................941 Track Frame.............................................................943 Essential or Recommended Tools......................................943 Other Material......................................................946 Specifications......................................................947 Remove and Install Track Frame......................................948 Replace Oscillation Bearing.........................................951 Remove and Install Walking Beam.....................................953 Replace Walking Beam Pivot Bushing and Isolator Bushing.............954 Repair Pillow Block.................................................957 Replace Tension Link Pivot Bushings.................................958 Repair Front Idler Hubs.............................................960 Remove, Repair, and Install Two Piece Mid-Roller Assembly...........966 Remove, Repair, and Install One Piece Mid-Roller Assembly...........971 Dealer Fabricated Tools.....................................................977 Fabricated Tools........................................................979 Fabricated Tools....................................................979 DFRW7—Differential Lifting Tool.....................................979 DFRW20—Compressor Holding Fixture...................................980 DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses........982 DFRW92—Mounting Guide Pins .........................................983 DFRW103—Yoke Holding Tool Tool may be purchased. Order JDG924.......984 DFRW113—Hood SupportsTool may be purchased. Order JDG1007...........985 DFRW116—Hydraulic Reservoir Siphon Tube.............................986 DFRW117—Transmission-Hydraulic Flusher..............................987 DFRW129—Steering Motor Sensor Gauge.................................989 DFRW139—Thermal Expansion Valve Replacement Tool....................990 DFRW140—Engine Support Bracket......................................991 DFRW147—Screw Jack..................................................992 DFRW150—SCV-Hitch Valve Stack Lifting Bracket.......................993 Page Number..................................................................... 5 Section 10.................................................................. 7 Group 05................................................................ 9 Group 10................................................................ 21 Section 20.................................................................. 31 Group 00................................................................ 33 Group 05................................................................ 47 Section 30.................................................................. 49 Group 05................................................................ 51 Group 10................................................................ 67 Group 15................................................................ 71 Group 20................................................................ 81 Section 40.................................................................. 90 Group 05................................................................ 91 Group 10................................................................115 Group 15................................................................143 Group 20................................................................147 Group 25................................................................151 Group 30................................................................173 Group 35................................................................195 Group 40................................................................209 Group 45................................................................211 Section 50..................................................................217 Group 00................................................................219 Group 05................................................................233 Group 10................................................................241 Group 15................................................................243 Group 20................................................................245 Section 55..................................................................249 Group 00................................................................251 Group 05................................................................261 Group 10................................................................263 Group 15................................................................277 Group 20................................................................285 Group 25................................................................295 Group 30................................................................309 Group 35................................................................315 Group 40................................................................319 Group 45................................................................331 Group 50................................................................367 Group 55................................................................369 Section 56..................................................................387 Group 00................................................................389 Group 05................................................................399 Group 10................................................................401 Group 15................................................................407 Group 20................................................................421 Group 25................................................................429 Section 57..................................................................434 Group 00................................................................435 Group 05................................................................445 Group 10................................................................467 Group 12................................................................479 Group 15................................................................485 Group 20................................................................513 Group 25................................................................529 Group 30................................................................557 Group 35................................................................575 Section 60..................................................................601 Group 05................................................................603 Group 10................................................................609 Group 15................................................................611 Group 20................................................................643 Group 25................................................................653 Group 30................................................................665 Group 35................................................................679 Group 40................................................................683 Section 70..................................................................691 Group 05................................................................693 Group 10................................................................701 Group 15................................................................733 Group 20................................................................739 Group 25................................................................743 Group 30................................................................765 Group 35................................................................795 Section 80..................................................................807 Group 05................................................................809 Group 10................................................................817 Group 15................................................................819 Group 20................................................................827 Section 90..................................................................837 Group 00................................................................839 Group 05................................................................847 Group 10................................................................861 Group 15................................................................897 Group 20................................................................913 Section 95..................................................................925 Group 05................................................................927 Group 10................................................................933 Group 15................................................................943 Section 99..................................................................977 Group 05................................................................979
S.S 08/03/2025
