tm401519 - W540, W550, W650, W660, T550, T560, T660,
T670 and C670 Including HillMaster Combines Repair -:
(European Edition) Technical Manual
Table of Contents
Foreword
Section 10: General
Group 05: Safety
Recognize Safety Information
Understand Signal Words
Prevent Battery Explosions
Prepare for Emergencies
Handle Fluids Safely—Avoid Fires
Prevent Acid Burns
Avoid High-Pressure Fluids
Park Machine Safely
Live With Safety
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Service Tires Safely
Avoid Heating Near Pressurized Fluid Lines
Remove Paint Before Welding or Heating
Use Proper Tools
Practice Safe Maintenance
Protect Against Noise
Dispose of Waste Properly
Avoid Harmful Asbestos Dust
Group 10: Specifications
Operating Speeds
Specifications - W540 and W550 Combines
Specifications - W650 and W660 Combines
Specifications - T550 and T560 Combines
Specifications - T660 and T670 Combines
Specifications - C670 Combine
Dimension Reference Points (W Series)
Dimensions (W Series)
Dimension Reference Points (T Series)
Dimensions (T Series)
Dimension Reference Points (C Series)
Dimensions (C Series)
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Assemble and Install Flat Face Seal Fittings - All Pressure Applications
Torque Chart for Metric Flat Face Seal Fittings - Standard Pressure Applications
Torque Chart for Metric Flat Face Seal Fittings - High Pressure Applications
Torque Chart for SAE Flat Face Seal Fittings - Standard Pressure Applications
Torque Chart for SAE Flat Face Seal Fittings - High Pressure Applications
Assemble and Install Four-Bolt Flange Fittings - All Pressure Applications
Torque Values for SAE Four-Bolt Flange - Standard Pressure Applications
Torque Values for SAE Four-Bolt Flange - High Pressure Applications
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer
Controlled Systems
Group 15: Fuel, Lubricants, Oils, Coolant and Capacities
Diesel Fuel
Storing Fuel
Heavy Duty Diesel Engine Coolant
Supplemental Coolant Additives
Liquid Coolant Conditioner
Diesel Engine Oil
Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils
Transmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger
Elevator and Dual-Range Cylinder Drive Gear Cases
Grease
Lubricant Storage
Alternative and Synthetic Lubricants
Capacities
Section 20: Engine
Group 05: Remove and Install Engine
Essential and Recommended Special Tools
Specifications
Remove Engine
Install the Engine
Group 10: Lower Engine Repair
Remove and Install Engine Oil Pan Access Sheet (W Series, T Series)
Remove and Install Engine Oil Pan Access Sheet (C Series)
Group 15: Cooling System
Remove and Install Rotary Screen
Remove and Install Rotary Screen Drive
Remove and Install Rotary Screen Idler Arm and Sheaves
Remove and Install Rotary Screen Brush Kit (Optional)
Remove and Install Radiator (W Series, T Series)
Remove and Install Radiator (C Series)
Test Radiator
Test Radiator Cap
Replace Thermostat
Repair or Replace Water Pump
Section 30: Fuel and Air Intake Systems
Group 05: Air Intake System
Remove and Install Charge Air Cooler (W Series, T Series)
Remove and Install Charge Air Cooler (C Series)
Group 10: Diesel Fuel System
Specifications
Remove Fuel Tank
Replace Fuel Filter (6.8-Liter Engine)
Replace Water Separator Filter (6.8-Liter Engine)
Remove and Install Fuel Filters (9.0-Liter Engine)
Clean the Fuel Precleaner (9.0-Liter Engine)
Section 40: Electrical System
Group 05: Harness and Connector Repair
Essential and Recommended Special Tools
Other Material
Use Electrical Insulating Compound
Connector Repair Procedures
Repair Procedure R-A
Repair Procedure R-B
Repair Procedure R-C
Repair Procedure R-D
Repair Procedure R-E
Repair Procedure R-F
Repair Procedure R-G
Repair Procedure R-I
Repair Procedure R-J
Repair Procedure R-K
Repair Procedure R-M
Repair Procedure R-N
Repair Procedure R-AE
Group 10: Wiring Harness Routings
Cab Main Wiring Harness
Left Main Wiring Harness
Right Main Wiring Harness With GreenStar GreenStar is a trademark of Deere & Company
Engine Wiring Harness
Group 15: Fuses, Circuit Breakers and Relays
Replace Circuit Boards
Group 20: Lights
Safety Rules When Replacing Halogen Bulbs
Replace and Adjust Cab Headlight Bulb
Remove and Install HID-Xenon Light
Replace Auxiliary Field and Access Door Lights
Replace Residue Discharge Light Bulb
Replace Side Finder Light Bulb
Replace Grain Tank and Unloading Auger Light Bulbs
Replace Cleaning Shoe Light Bulb
Replace Turn Signal and Maximum Tilt Indicator Light Bulbs
Replace Dome and Console Light Bulb
Replace Bulbs of CommandTouch CommandTouch is a trademark of Deere & Company.
CornerPost Monitor
Replace Warning Display Panel Bulb
Group 25: Operator's Station
Specifications
Remove and Install Overhead Console
Replace Warning Display Panel Circuit Board
Remove and Install Light Panel Dimmer Switch
Remove and Install Overhead Console Rocker Switches
Remove and Install ClimaTrak ClimaTrak is a trademark of Deere & Company Automatic Air
Conditioning/Heater Temperature Control Switch and Fan Switch
Replace Cornerpost Main Circuit Board
Remove Header Control Module
Remove Automatic Combine Adjustment (ACA) Display
Remove Performance Monitor and Digital Tachometer Module
Remove and Install CommandTouch CommandTouch is a trademark of Deere & Company.
Console
Remove and Install Header and Separator Engage Switches
Remove and Install Switches for DIAL-A-SPEED DIAL-A-SPEED is a trademark of Deere &
Company. and Header Height/Ground Pressure Control
Remove and Install Back Light Bulbs for DIAL-A-SPEED and Header Height/Ground Pressure
Control Switches
Remove and Install CommandTouch CommandTouch is a trademark of Deere & Company.
Console Membrane Switches
Remove and Install CommandTouch CommandTouch is a trademark of Deere & Company.
Console Circuit Board
Replace Neutral Start Switch
Replace Mini Harness
Remove and Install Multifunction Lever
Remove and Install Start Switch
Remove and Install Horn Switch
Remove and Install Mirrors
Remove and Install Mirror Switch
Group 30: Sensors and Switches
Other Material
Shaft Speed Sensor Locations (W Series, T Series, C Series)
Shaft Speed Sensor Locations (W Series, T Series)
Shaft Speed Sensor Locations (C Series)
Remove and Install Sensors for Conveyor Auger, Tailings Elevator, Clean Grain Elevator,
Beater and Separator
Remove and Install Sensors for Cleaning Fan, Cylinder Speed, Beater and Feeder House
Backshaft
Remove and Install Straw Chopper Sensor
Remove and Install Grain Tank Sensor
Remove and Install Tailings Sensor
Remove and Install VisionTrak VisionTrak is a trademark of Deere & Company Sensors
(Shoe/Separator)
Remove and Install Header Height/Ground Pressure Control Sensors (Return to Cut and Tilt)
Remove and Install Coolant Temperature Sensor
Remove and Install Coolant Temperature Sensor
Remove and Install Fuel Level Sensor
Remove and Install Park Brake Switch
Remove and Install Air Filter Restriction Switch
Remove and Install Engine Gear Case Temperature and Pressure Switches
Remove and Install Hydrostatic Charge Pressure Switch
Remove and Install Hydraulic Oil Reservoir Temperature Sensor
Remove and Install Engine Oil Pressure Switch
Remove and Install Service and Cleaning Shoe Light Switch
Remove and Install Chaffer/Sieve Sensor and Adjusting Motor
Group 35: Wiper
Specifications
Remove and Install Wiper Motor
Remove and Install Windshield Washer
Group 40: Alternator
Specifications
Remove and Install Alternator
Group 45: Starter Motor
Specifications
Remove and Install Starting Motor
Remove and Install Starting Motor Relay
Group 50: GreenStar Components
Specifications
Remove and Install GreenStar Mass Flow Sensor
Remove and Install GreenStar Paddle Wheel
Remove and Install GreenStar Moisture Sensor
Remove and Install Position Receiver
Section 50: Drive Train
Group 05: Transmission and Differential
Other Material
Specifications
Remove and Repair Shifter Forks and Shifter Cam
Install Shifter Forks and Shifter Cam
Remove and Install Transmission Oil Pump
Remove and Install Suction Screen
Remove Transmission
Recondition Transmission
Disassemble and Repair Transmission
Assemble Transmission
Install Transmission
Remove and Install Gearshift Lever and Linkage
Adjust Gear Shift Linkage
Group 10: Final Drive
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Remove and Install Final Drive
Disassemble and Assemble Final Drive
Adjust Spindle Bearing (Preferred Method)
Adjust Spindle Bearing (Alternative Method)
Group 15: Hydrostatic System
Essential and Recommended Special Tools
Service Equipment and Tools
Other Material
Specifications
Flush the Hydrostatic System
Remove and Install Hydrostatic Motor
Disassemble Hydrostatic Motor
Replace Cylinder Block Spring
Assemble Motor
Remove and Install Motor Valve Block (Manifold)
Repair Motor Valve Block
Remove Hydrostatic Pump
Disassemble Hydrostatic Pump
Assemble Hydrostatic Pump
Replace High-Pressure Line Center Pivot O-Rings
Disassemble and Assemble End Cover
Repair Control Valve
Displacement Control Valve with Feed Rate - Exploded View
Install Hydrostatic Pump
Remove and Install Charge Pump
Repair Charge Pump
Remove and Install Hydrostatic Control Cable
Adjust Hydrostatic Control Linkage
Adjust Neutral Position of Displacement Control Valve
Start-Up Procedure After Hydrostatic System Repair
Group 20: Cam Lobe Motor
Essential and Recommended Special Tools
Service Equipment and Tools
Other Material
Specifications
Flush Cam Lobe Motors
Remove Cam Lobe Motor
Install Cam Lobe Motor
Remove and Install Cam Lobe Motor Control Valve
Disassemble and Assemble Cam Lobe Motor Control Valve
Remove and Install Steering Yoke
Disassemble and Assemble Pivot Pins, Bushings, and Seals
Remove and Install Solenoid Valve and Valve Block
Remove and Install Displacement Control Valve
Remove and Install Cam and Piston Carrier
Remove and Install Valve Block Seals
Remove and Install Axle Bearings and Seals
Group 25: HillMaster II
HillMaster II Rocker Assembly - Right
HillMaster II Rocker Assembly - Left
Section 60: Power Steering and Brakes
Group 05: Steering
Essential and Recommended Special Tools
Service Equipment and Tools
Other Material
Specifications
Remove Steering Valve
Steering Valve
Disassemble Steering Valve
Assemble Steering Valve
Install Steering Valve
Steering Column Components (Upper)
Steering Column Components (Lower)
Disassemble And Assemble Steering Column
Replace Telescoping Shaft Bearings
Remove and Install Steering Cylinder
Repair Steering Cylinder
Adjust Toe-In
Remove and Install Steering Tie Rod
Remove and Install Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel
Drive
Remove and Install Rear Axle Pivot Bushing
Rear Axle Adjustment
Group 10: Brake
Service Equipment and Tools
Other Material
Specifications
Remove Brake Drum
Remove Brake Shoes - Heavy Duty Version
Recondition Brakes - Heavy Duty Version
Assemble Brakes - Heavy Duty Version
Install Brake Drum
Remove and Install Master Cylinder
Disassemble and Assemble Master Cylinder (Double Bleed Screw)
Adjust Master Cylinder
Bleed Brake System (Double Bleed Screw)
Remove and Install Slave Cylinders
Disassemble and Assemble Slave Cylinder
Disassemble and Assemble Brake Pedals
Disassemble and Assemble Park Brake Pedal
Adjust Park Brake Pedal
Group 15: Trailer Hitch
Remove Trailer Hitch
Section 70: Hydraulic System Repair
Group 05: Hydraulic Reservoir
Service Equipment and Tools
Specifications
Remove and Install Reservoir
Flush the Hydraulic System
Flush the Reel/Belt Pickup Drive System
Start-Up Procedure After Hydrostatic System Repair
Group 10: Hydraulic Pumps
Essential and Recommended Special Tools
Service Equipment and Tools
Specifications
Remove Main Hydraulic Pump
Mark Hydraulic Pump
Disassemble Hydraulic Pump
Replace Seal
Install Gasket and Support
Triple Hydraulic Pump
Assemble Hydraulic Pump
Install Main Hydraulic Pump
Reel/Belt Pickup Pump
Remove Chaff Spreader Pump
Chaff Spreader Pump
Disassemble Chaff Spreader Pump
Assemble Chaff Spreader Pump
Install Chaff Spreader Pump
Group 15: Hydraulic Valves
Essential and Recommended Special Tools
Specifications
Remove and Install Hydraulic Valve Block
Remove and Install Header Height/Ground Pressure Control Valve
Remove and Install Shut-Off Valve
Relief Valve Block (Solenoid Valve)
Reel Raise/Lower Valve
Electro-Hydraulic Feeder House Reverser Valve - General Information
Disassemble Electro-Hydraulic Feeder House Reverser Valve
Threshing Cylinder Speed Valve Module
Auger Swing Valve Module
HillMaster II Solenoid Valve Block
Reel Fore/Aft Valve Module
HeaderTrak Tilt System Valve Module
Replace Pilot Solenoid Valve Assemblies
Replace Pilot Sleeve O-Rings
Remove Reel/Belt Speed Flow Control Valve
Repair Reel/Belt Speed Flow Control Valve
Install Reel/Belt Speed Flow Control Valve
Reel Reversing Control Valve
Remove and Install Reel Reversing Control Valve
Feeder House Multi-Coupler Check Valves - General View
Disassemble, Inspect and Assemble Feeder House Multi-Coupler
Group 20: Hydraulic Cylinders
Specifications
Remove and Install Header Lift Cylinder
Disassemble and Assemble Header Lift Cylinder
Remove and Install Unloading Auger Swing Cylinder
Adjust Unloading Auger Swing Cylinder
Remove and Install Unloading Auger Drive Cylinder
Adjust Unloading Auger Drive Cylinder
Group 21: HillMaster II Hydraulic Cylinders
Special Tool (Dealer-Fabricated)
Other Material
Specifications
General Information
Components of HillMaster II Cylinder
Check Valve Components
Components of Compensating Valve
Compensating Valve Installed in Piston
Attachment of HillMaster II Cylinders
Group 25: Motors
Remove and Install Chaff Spreader Motor
Group 30: Accumulators
Service Equipment and Tools
Accumulator (General Information)
Check Header Float System Accumulator
Accumulator Charge Pressure
Section 80: Separator Shell
Group 05: Gull Wing Doors
Remove and Install Gull Wing Doors
Group 10: Hood - W Series, T Series
Specifications
Remove and Install Lower Hood Panels
Remove and Install Rear Hood
Group 15: Hood - C Series
Specifications
Remove and Install Lower Hood Panels
Remove and Install Rear Hood
Section 90: Operator's Station Repair
Group 05: Air-Conditioning System (R134a)
Essential and Recommended Special Tools
Service Equipment and Tools
Other Material
Specifications
Discharge and Recovery of Air Conditioning Refrigerant
Remove and Install Compressor
Test Volumetric Efficiency
Test Shaft Seal Leakage
Disassemble and Assemble Compressor Clutch
Check Clutch Hub Clearance
Inspect Compressor Manifold
Disassemble, Inspect, and Assemble Compressor
Remove and Install Compressor Relief Valve
Flush Air Conditioning System
Purge Air Conditioning System
Evacuate Air Conditioning System
Compressor Oil Information
Determine Correct Oil Charge
Check Refrigerant Oil Charge
Charge Air Conditioning System
Leak Testing Procedure
Group 10: System Components
Essential and Recommended Special Tools
Other Material
Remove and Install Receiver/Dryer
Replace Blower Motor
Replace Recirculator Motor Drive Module
Replace Heater Valve
Remove Condenser
Repair Condenser
Install Condenser
Replace Evaporator
Remove and Install Evaporator Temperature Sensor
Replace Low Pressure Switch
Replace High Pressure Switch
Replace Air Temperature Sensors
Group 15: Cab
Specifications
Remove and Install Cab Windshield
Remove Cab
Install Cab
Replace Rear Window
Remove and Install Cab Roof
Remove and Install Operator's Seat
Remove and Install Operator Presence Switch
Operator's Seat - Exploded View
Operator's Seat Air Suspension Assembly - Exploded View
Disassemble and Assemble Operator's Seat Air Suspension Assembly
Cab Door Latch Striker
Remove and Install Cab Door
Disassemble and Assemble Cab Door (Serial No. 074502—)
Section 110: Feeder House Repair
Group 05: Conveyor
Other Material
Specifications
Remove and Install Feeder House
Remove and Install Conveyor Chain
Measure Conveyor Chain Wear
Remove Conveyor Chain Link
Replace Conveyor Chain Slats
Replace Conveyor Chain Wear Strips
Adjust Drum Height
Remove and Install Conveyor Drum
Conveyor Drum Exploded View - HillMaster II
Conveyor Drum Exploded View - Standard Combines and HeaderTrak Tilt
Remove And Install Mid-Floor Assembly
Remove And Install Sub-Floor Assembly
Remove and Install Pea Kit Sub-Floor Assembly (Optional)
Feed Plate Support - Exploded View
Group 10: Upper Shaft and Slip Clutch
Specifications
Remove and Install Top Shaft Supports
Disassemble and Assemble Conveyor Top Shaft
Group 15: Feeder House Drives and Reverser Gear Case
Other Material
Specifications
Top Shaft Idler - Exploded View
Feeder House Countershaft and Tensioner - Exploded View
Remove and Install Reverser Gear Case
Feeder House Reverser Gear Case - Exploded View
Disassemble and Assemble Feeder House Reverser Gear Case
Remove and Install Lower Shaft
Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides
Group 20: HeaderTrak Tilt Cylinder and Frame
Specifications
HeaderTrak Tilt Cylinder Hoses and Fittings - Exploded View
Remove and Install HeaderTrak Tilt Cylinder
Feeder House Shell, Wear Plates and Seals, Location
Tilt Beam and Closure Plates,Location
Remove and Install Tilt Frame
Remove and Install Tilt Beam
Adjust Fore-Aft Turnbuckles
Remove Fore-Aft Tilt Frame
Install Fore-Aft Tilt Frame
Group 25: HillMaster II Tilt Cylinder and Frame
Tilt Frame - Exploded View
Section 120: Separator - W Series
Group 05: Separator Repair
Essential and Recommended Special Tools
Other Material
Specifications
Remove and Install Rasp Bars
Static Balance Cylinder
Remove Threshing Cylinder
Install Threshing Cylinder
Remove Concave
Install Concave
Level Concave (Rasp Bar)
Level Concave (Spike Tooth)
Adjust Second Concave
Concave Position Sensor and Linkage
Remove and Install Concave Adjusting Motor
Second Cylinder Exploded View
Disassemble and Assemble Second Cylinder
Remove and Install Second Cylinder
Group 10: Cylinder Drives
Essential and Recommended Special Tools
Other Material
Specifications
Remove Dual Range Cylinder Drive Gear Case
Dual Range Cylinder Drive, Exploded View
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
Remove and Install Intermediate Cylinder Drive
Repair Intermediate Cylinder Drive
Remove and Install Intermediate Cylinder Drive Support
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
Group 15: Straw Walkers, Crankshafts and Walker Return Pan
Essential and Recommended Special Tools
Other Material
Specifications
All Walkers - Timing Procedure
Remove and Install Straw Walker Bearings and Walker Return Pan
Remove and Install Rear Crankshaft
Remove and Install Front Crankshaft
Remove and Install Straw Walker Gear Case
Disassemble and Assemble Straw Walker Gearcase
Remove and Install Power Separator
Group 20: Straw Chopper and Chaff Spreader
Service Equipment and Tools
Other Material
Specifications
Chopper and Blades
Chopper Housing and Knife Bank
Remove Straw Chopper
Replace Chopper Blades
Replace Knife Sections
Remove and Install Rotor Bearings
Remove and Install Straw Chopper Jackshaft
Disassemble and Assemble Straw Chopper Jackshaft
Remove and Install Straw Chopper Idler Assembly
Group 25: Shoe Supply Augers, Cleaning Fan and Chaffer and Sieve Frame
Other Material
Specifications
Replace Shoe Supply Augers
Replace Shoe Supply Auger Wooden Bearings
Remove and Install Shoe Supply Auger Drive Shaft
Remove and Install Shoe Supply Auger Trough
Remove Separator Drive Jackshaft
Install Separator Drive Jackshaft
Remove and Install Cleaning Fan Drive
Fan Drive Speed Control
Remove Cleaning Fan
Install Cleaning Fan
Remove and Install Cleaning Fan Housing
Adjust Fan Speed Actuator
Remove Chaffer, Sieve and Frames
Install Chaffer, Sieve and Frames
Remove and Install Shoe Pitman Arms
Group 30: Tailings Elevator and Augers
Disassemble Tailings Elevator and Augers
Group 35: Primary Countershaft
Essential and Recommended Special Tools
Specifications
Remove and Install Primary Countershaft Gear Case
Disassemble and Assemble Primary Countershaft Gear Case
Remove and Install Primary Countershaft with Variable Sheave Assembly
Remove and Install Beater Curtain
Group 40: Header Electromagnetic Clutch Assembly
Specifications
Remove Header Electromagnetic Clutch
Disassemble and Assemble Header Electromagnetic Clutch
Install Header Electromagnetic Clutch
Section 121: Separator - C Series
Group 05: Beaters
Specifications
Remove Concave
Install Concave
Idler of Gear Case for Serrated Beater Drive
Removal of Gear Case for Serrated Beater Drive
Gear Case for Serrated Beater Drive
Disassemble Gear Case for Serrated Beater Drive
Install Gear Case for Serrated Beater Drive
Serrated Beater and Shaft
Remove Left Serrated Beater Shaft Bearing
Remove Right Serrated Beater Shaft Bearing
Remove Serrated Beater Shaft
Install Serrated Beater Shaft
Remove Beater Drive Sheave
Install Beater Drive Sheave
Remove/Install Serrated Beater Wings
Beater
Remove Beater Drive Sheave
Remove and Install Beater Shaft
Remove and Install Beater
Serrated Beater Cover
Remove Serrated Beater Cover
Remove Beater Cover
Install Beater Cover
Install Serrated Beater Cover
Remove Module Feed Assembly
Install Module Feed Assembly
Remove Serrated Beater Lower Covers
Install Serrated Beater Lower Covers
Remove and Install Beater Curtain
Group 10: Engine Gear Case to Module Drives
Engine Gear Case to Module Drives - Exploded View
Group 15: Tine Separator Module
Essential and Recommended Special Tools
Specifications
Roll Out Tine Separator
Remove Tine Separator Module
Tine Separator Front Bearings and Lube Lines
Tine Separator Tubes
Remove Tine Separators
Install Tine Separators
Repair Tine Separators
Replace Tine Separator Drive Coupler
Replace Tine Separator Flow Dividers
Replace Tines
Replace Discharge Paddles
Module Frame and Covers
Discharge Beater
Discharge Beater Drive
Remove Front Feed Section Assembly
Install Front Feed Section Assembly
Module Grate Assembly
Remove Separator Grates
Install Separator Grates
Replace Grate Fingerbar
Tine Separator Module Crank-Out System
Remove Tine Separator Module Crank-Out System
Install Tine Separator Module Crank-Out System
Group 20: Tine Separator Gear Cases
Specifications
Module Drive Gearcase, Shaft and Coupling
Module Drive Gear Case
Remove Module Drive Gear Case
Disassemble Module Drive Gear Case
Assemble Module Drive Gear Case
Install Module Drive Gear Case
Group 25: Supply Augers (Shoe), Chaffer and Sieve Frame
Shaker Pan Exploded View
Group 30: Straw Chopper
Remove and Install Straw Chopper
Chopper and Blades
Remove and Install Rotor Bearings
Chopper Housing and Knife Bank
Replace Knife Sections
Remove and Install Straw Chopper Idler Assembly
Section 122: Separator - T Series
Group 01: Common Separator Components
Common Separator Components
Group 10: Separator Components and Separator Drive
Separator Components
Separator Drive
Group 30: Straw Walker Drive
Remove Straw Walker Drive
Disassemble and Assemble Straw Walker Gearcase
Install Straw Walker Drive
Group 60: Remove and Install Beater Grate
Remove Beater Grate
Install Beater Grate
Group 65: Remove and Install Beater
Remove and Install Beater
Remove Speed Sensor (Left Side)
Remove Locking Collar
Remove Beater Pulley (Right Side)
Remove Hub and Speed Sensor (Right Side)
Disassemble Beater
Remove Bearing
Remove Shaft
Install Beater
Group 70: Remove and Install Separator Rotor
Remove and Install Separator Rotor
Measure Distance from Pulley to Sidewall
Remove Pulley (Left Side)
Remove Pulley (Right Side)
Remove Hub
Remove Finger Bars and Retaining Plates
Loosen Segment Clamping Screws
Remove Bearings
Install Separator Rotor
Group 75: Remove and Install Separator Grate
Remove and Install Separator Grate
Remove Finger Bars of Separator Rotor
Remove Separator Grate Inserts
Position Separator Grate
Lift Out Separator Grate
Install and Adjust Separator Grate
Group 80: Remove and Install Overshot Beater
Remove and Install Overshot Beater
Remove Pulley
Remove Gearcase
Disassemble Overshot Beater
Remove Locking Collar (Right Side)
Install Overshot Beater
Group 85: Remove and Install Stripper Roll
Remove and Install Stripper
Remove Pulley
Remove Locking Collar (Right Side)
Remove stripper from the front
Stripper Roll, Exploded View
Install Stripper
Section 130: Grain Tank and Unloading System
Group 05: Grain Tank Cross Augers
Remove and Install Grain Tank Cross Augers
Group 10: Unloading Auger System Drives
Specifications
Replace Unloading Auger Drive Belts
Remove and Install Cross Auger Countershaft Hub and Shear Bolt
Remove Unloading Auger Drive Countershaft
Install Unloading Auger Drive Countershaft
Align Unloading Auger Drive
Adjust Unloading Auger Drive Cylinder
Replace Unloading Auger Grain Saver Door
Group 15: Vertical Auger and Lower Gear Case
Essential and Recommended Special Tools
Specifications
Remove Vertical Auger Lower Gear Case And Vertical Auger
Disassemble and Assemble Vertical Auger Lower Gear Case
Install Vertical Auger and Vertical Auger Lower Gear Case
Group 20: Horizontal Auger and Gear Case
Essential and Recommended Special Tools
Other Material
Specifications
Inspection of Horizontal Unloading Auger
17 ft. (5.18 m) and 20 ft. (6.1 m) Augers - Two-Piece
Remove Horizontal Auger
Install Horizontal Auger
Remove Horizontal Auger Gear Case
Disassemble And Assemble Horizontal Unloading Auger Gear Case
Install Horizontal Auger Gear Case
Remove Horizontal Unloading Auger Tube
Unloading Auger Elbow, Exploded View
Remove Horizontal Unloading Auger Elbow
Install Horizontal Unloading Auger Elbow
Remove Unloading Auger Charge Housing
Group 25: Clean Grain Elevator and Loading Auger Gear Case
Other Material
Specifications
Adjust Clean Grain Elevator Chain
Replace Clean Grain Elevator Belt
Clean Grain Loading Auger, Exploded View
Replace Clean Grain Loading Auger Bearing
Remove Clean Grain Loading Auger Assembly
Remove and Install Clean Grain Elevator Gear Case
Disassemble and Assemble Clean Grain Elevator Gear Case
Remove Clean Grain Elevator
Group 30: Grain Tank and Extensions
Grain Tank Base
Grain Tank
Grain Tank Covers - 8,000 and 9,000 Liters
Grain Tank Cover Seals - 8,000 and 9,000 Liters
Grain Tank Cover Supports - 8,000 and 9,000 Liters
Grain Tank Cover Cylinders - 8,000 and 9,000 Liters
Grain Tank Cover Actuator - 8,000 and 9,000 Liters
Grain Tank, General View - 11,000 Liters
Grain Tank Covers - 11,000 Liters
Grain Tank Lift Cylinders and Linkage - 11,000 Liters
Section 140: Engine Gear Case and Control Valve, Repair
Group 05: Engine Gear Case and Valve
Essential and Recommended Special Tools
Other Material
Specifications
General Information
Remove and Install Engine Gear Case
Engine Gear Case Specifications
Disassemble and Assemble Separator Drive Wet Clutch
Disassemble and Assemble Hydrostatic Gear Set
Set Gear Position
Preload Bearings
Disassemble and Assemble Straw Chopper/Unloading System
Set Separator Drive Gear Position
Preload Bearings
Disassemble and Assemble Separator Drive
Preload Separator Drive Bearings
Set Separator Drive Gear Backlash
Disassemble and Assemble Hydrostatic Pump Drive
Preload Hydrostatic Pump Drive Bearings
Set Hydrostatic Pump Drive Gear Backlash
Disassemble and Assemble Oil Screen
Disassemble and Assemble Oil Trough
Disassemble and Assemble Dipstick Tube
Remove and Install Filter
Remove and Install Pressure Regulating Valve
Disassemble and Assemble Pressure Regulating Valve
Section 199: Special Tools
Group 05: Essential Special Tools
Tools (Section 20)
Tools (Section 40)
Tools (Section 60)
Tools (Section 70)
Tools (Section 80)
Tools (Section 90)
Tools (Section 120)
Tools (Section 121)
Tools (Section 130)
Tools (Section 140)
Group 10: Recommended Special Tools
DFRW20—Compressor Holding Fixture
Cooling Fin Straightener
Special Tool for Disassembling Valve Seat and Piston
Foreword
Foreword
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.
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the
potential for personal injury.
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 on-the-job guides containing only the vital
information needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals
of troubleshooting, general maintenance, and basic type of failures and their causes.
DX,TMIFC-19-20140415
27
Table of Contents
Section 10: General
Group 05: Safety
Recognize Safety Information
Understand Signal Words
Prevent Battery Explosions
Prepare for Emergencies
Handle Fluids Safely—Avoid Fires
Prevent Acid Burns
Avoid High-Pressure Fluids
Park Machine Safely
Live With Safety
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Service Tires Safely
Avoid Heating Near Pressurized Fluid Lines
Remove Paint Before Welding or Heating
Use Proper Tools
Practice Safe Maintenance
Protect Against Noise
Dispose of Waste Properly
Avoid Harmful Asbestos Dust
Group 10: Specifications
Operating Speeds
Specifications - W540 and W550 Combines
Specifications - W650 and W660 Combines
Specifications - T550 and T560 Combines
Specifications - T660 and T670 Combines
28
Table of Contents
Specifications - C670 Combine
Dimension Reference Points (W Series)
Dimensions (W Series)
Dimension Reference Points (T Series)
Dimensions (T Series)
Dimension Reference Points (C Series)
Dimensions (C Series)
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Assemble and Install Flat Face Seal Fittings - All Pressure Applications
Torque Chart for Metric Flat Face Seal Fittings - Standard Pressure Applications
Torque Chart for Metric Flat Face Seal Fittings - High Pressure Applications
Torque Chart for SAE Flat Face Seal Fittings - Standard Pressure Applications
Torque Chart for SAE Flat Face Seal Fittings - High Pressure Applications
Assemble and Install Four-Bolt Flange Fittings - All Pressure Applications
Torque Values for SAE Four-Bolt Flange - Standard Pressure Applications
Torque Values for SAE Four-Bolt Flange - High Pressure Applications
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer
Controlled Systems
Group 15: Fuel, Lubricants, Oils, Coolant and Capacities
Diesel Fuel
Storing Fuel
Heavy Duty Diesel Engine Coolant
Supplemental Coolant Additives
Liquid Coolant Conditioner
Diesel Engine Oil
Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils
Transmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger
Elevator and Dual-Range Cylinder Drive Gear Cases
Grease
Lubricant Storage
Alternative and Synthetic Lubricants
Capacities
29
Recognize Safety Information
Recognize Safety Information
T81389-UN: Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the
potential for personal injury.
Follow recommended precautions and safe operating practices.
Go to Section_10:Group_05
DX,ALERT-19-19980929
30
Recognize Safety Information
Recognize Safety Information
T81389-UN: Safety-alert symbol
This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the
potential for personal injury.
Follow recommended precautions and safe operating practices.
Go to Section_10:Group_05
DX,ALERT-19-19980929
31
Understand Signal Words
Understand Signal Words
TS187-19: Signal Words
A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
Go to Section_10:Group_05
DX,SIGNAL-19-19930303
32
Prevent Battery Explosions
Prevent Battery Explosions
TS204-UN: Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Go to Section_10:Group_05
DX,SPARKS-19-19930303
33
Prepare for Emergencies
Prepare for Emergencies
TS291-UN: First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Go to Section_10:Group_05
DX,FIRE2-19-19930303
34
Handle Fluids Safely—Avoid Fires
Handle Fluids Safely—Avoid Fires
TS227-UN: Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn spontaneously.
Go to Section_10:Group_05
DX,FLAME-19-19980929
35
Prevent Acid Burns
Prevent Acid Burns
TS203-UN: Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1.
2.
3.
4.
5.
Filling batteries in a well-ventilated area.
Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is added.
Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3. Get medical attention immediately.
36
Prevent Acid Burns
Go to Section_10:Group_05
DX,POISON-19-19930421
37
Avoid High-Pressure Fluids
Avoid High-Pressure Fluids
X9811-UN: High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs of wear or damage.
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections
before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable
medical source. Such information is available in English from Deere & Company Medical Department in Moline,
Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.
Go to Section_10:Group_05
DX,FLUID-19-20111012
38
Park Machine Safely
Park Machine Safely
TS230-UN: Remove the Key
Before working on the machine:
Lower all equipment to the ground.
Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.
Go to Section_10:Group_05
DX,PARK-19-19900604
39
Live With Safety
Live With Safety
TS231-19: Safety Systems
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems.
Install all guards and shields.
Go to Section_10:Group_05
DX,LIVE-19-19920925
40
Support Machine Properly
Support Machine Properly
TS229-UN: Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If the work requires
that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do
not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions listed in the
implement or attachment operator's manual.
Go to Section_10:Group_05
DX,LOWER-19-20000224
41
Wear Protective Clothing
Wear Protective Clothing
TS206-UN: Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones
while operating machine.
Go to Section_10:Group_05
DX,WEAR-19-19900910
42
Work in Clean Area
Work in Clean Area
T6642EJ-UN: Clean Work Area
Before starting a job:
Clean work area and machine.
Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt shortcuts.
Go to Section_10:Group_05
DX,CLEAN-19-19900604
43
Service Machines Safely
Service Machines Safely
TS228-UN: Moving Parts
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
Go to Section_10:Group_05
DX,LOOSE-19-19900604
44
Work In Ventilated Area
Work In Ventilated Area
TS220-UN: Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
Go to Section_10:Group_05
DX,AIR-19-19990217
45
Illuminate Work Area Safely
Illuminate Work Area Safely
TS223-UN: Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can
ignite spilled fuel or oil.
Go to Section_10:Group_05
DX,LIGHT-19-19900604
46
Replace Safety Signs
Replace Safety Signs
TS201-UN: Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
Go to Section_10:Group_05
DX,SIGNS1-19-19900604
47
Use Proper Lifting Equipment
Use Proper Lifting Equipment
TS226-UN: Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
Go to Section_10:Group_05
DX,LIFT-19-19900604
48
Service Tires Safely
Service Tires Safely
TS211-UN: Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Go to Section_10:Group_05
DX,RIM-19-19900824
49
Avoid Heating Near Pressurized Fluid Lines
Avoid Heating Near Pressurized Fluid Lines
TS953-UN: Flammable Spray
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself
and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other
flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.
Go to Section_10:Group_05
DX,TORCH-19-20041210
50
Remove Paint Before Welding or Heating
Remove Paint Before Welding or Heating
TS220-UN: Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be
removed, wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent
or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15
minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Go to Section_10:Group_05
DX,PAINT-19-20020724
51
Use Proper Tools
Use Proper Tools
TS779-UN: Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric
fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
Go to Section_10:Group_05
DX,REPAIR-19-19990217
52
Practice Safe Maintenance
Practice Safe Maintenance
TS218-UN: Keep Area Clean
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven
parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the
engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical
systems or welding on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or
welding on machine.
Go to Section_10:Group_05
DX,SERV-19-19990217
53
Protect Against Noise
Protect Against Noise
TS207-UN: Noise Exposure
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Go to Section_10:Group_05
DX,NOISE-19-19930303
54
Dispose of Waste Properly
Dispose of Waste Properly
TS1133-UN: Recycle Waste
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with
John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or
from your John Deere dealer.
Go to Section_10:Group_05
DX,DRAIN-19-19930303
55
Avoid Harmful Asbestos Dust
Avoid Harmful Asbestos Dust
TS220-UN: Asbestos Dust
Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies,
clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in
some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on the material containing asbestos.
Keep bystanders away from the area.
Go to Section_10:Group_05
DX,DUST-19-19910315
56
Operating Speeds
Operating Speeds
Speeds shown are average and can vary from machine to machine. Speeds are rated at high idle with separator
engaged, no load.
-: Operating Speeds
Threshing cylinder
Speed
475 - 1030 rpm
Threshing cylinder, drive with reduction gear
High speed
475-1030 rpm
Low speed
240-510 rpm
Power separator (W Series)
Speed
150 rpm
Tine separator (C Series)
High speed
740 rpm
Low speed
570 rpm
High speed
900 rpm
Low speed
450 rpm
Lower feeder house shaft
Speed
520 rpm
Cleaning fan
Speed
750 - 1600 rpm
Clean grain elevator
Speed
400 rpm
Tailings elevator
Speed
430 rpm
Straw walkers
Speed
150 rpm
Straw chopper (basic model)
High speed
3620 rpm
Medium speed
2720 rpm
Low speed
1920 rpm
High speed
3600 rpm
Low speed
1900 rpm
Chaff spreader (basic model)
Speed
235 rpm
Chaff spreader (Premium model)
High speed
700 rpm
Low speed
400 rpm
Separator rotor (T Series)
Straw chopper (Premium model)
Go to Section_10:Group_10
ZX09263,0002729-19-20080121
57
Operating Speeds
Operating Speeds
Speeds shown are average and can vary from machine to machine. Speeds are rated at high idle with separator
engaged, no load.
-: Operating Speeds
Threshing cylinder
Speed
475 - 1030 rpm
Threshing cylinder, drive with reduction gear
High speed
475-1030 rpm
Low speed
240-510 rpm
Power separator (W Series)
Speed
150 rpm
Tine separator (C Series)
High speed
740 rpm
Low speed
570 rpm
High speed
900 rpm
Low speed
450 rpm
Lower feeder house shaft
Speed
520 rpm
Cleaning fan
Speed
750 - 1600 rpm
Clean grain elevator
Speed
400 rpm
Tailings elevator
Speed
430 rpm
Straw walkers
Speed
150 rpm
Straw chopper (basic model)
High speed
3620 rpm
Medium speed
2720 rpm
Low speed
1920 rpm
High speed
3600 rpm
Low speed
1900 rpm
Chaff spreader (basic model)
Speed
235 rpm
Chaff spreader (Premium model)
High speed
700 rpm
Low speed
400 rpm
Separator rotor (T Series)
Straw chopper (Premium model)
Go to Section_10:Group_10
ZX09263,0002729-19-20080121
58
Specifications - W540 and W550 Combines
Specifications - W540 and W550 Combines
-: Specifications
Engine:
Manufacturer
John Deere
Engine type
W540 —6068HZ480C
W550 —6068HZ482
Engine power (according to ECE-R120) at 2300 rpm
W540 — 187 kW (252 hp)
W550 — 217 kW (290 hp)
Fuel tank:
Max. engine power (according to ECE-R120) at 2200
rpm
W540 — 191 kW (257 hp)
Displacement
6.8 L (414 cu. in.)
Air cleaner
Dry-type with safety element
Thermostats (two)
82°C (180°F)
Capacity
800 L (210 U.S.gal.)
Electrical system:
12-volt, 120-amp alternator
Transmission:
Three speeds
Brakes:
Hydraulic drum brakes
W550 — 224 kW (300 hp)
Threshing
cylinder:
Number of rasp bars
10
Concave:
Type
13 open bar
Beater:
Number of wings
8
Second concave: Type
open bars, adjustable to two
positions
Number of bars
10
Finger rake:
Type
adjustable
Separator:
Type
straw walkers
Straw walkers:
Type
perforated plate
Number of walkers:
5
Power separator: Type
Grain tank:
Weight:
retractable
Number of fingers
15
Capacity
8000 L (227 bu.)
Average unloading rate
4200 L/min. (120 bu./min.)
Without header
W540 —12720 kg (28,000 lb.)
W550 —12580 kg (27,700 lb.)
Go to Section_10:Group_10
ZX09263,000271E-19-20080128
59
Specifications - W650 and W660 Combines
Specifications - W650 and W660 Combines
-: Specifications
Engine:
Manufacturer
John Deere
Engine type
W650 —6090HZ003C
W660 —6090HZ003B
Engine power (according to ECE-R120) at 2100 rpm
W650 — 238 kW (320 hp)
W660 — 260 kW (345 hp)
Fuel tank:
Max. engine power (according to ECE-R120) at 2000
rpm
W650 — 250 kW (335 hp)
Displacement
9.0 L (554 cu. in.)
Air cleaner
Dry-type with safety element
Thermostats (two)
82°C (180°F)
Capacity
800 L (210 U.S.gal.)
Electrical system:
12-volt, 120-amp alternator
Transmission:
Three speeds
Brakes:
hydraulic drum brakes
W660 — 277 kW (370 hp)
Threshing
cylinder:
Number of rasp bars
10
Concave:
Type
13 open bar
Beater:
Number of wings
8
Second concave: Type
open bars, adjustable to two
positions
Finger rake:
Type
adjustable
Separator:
Type
straw walkers
Straw Walkers:
Type
perforated plate
Number of walkers:
6
Power separator: Type
Grain tank:
Weight:
retractable
Number of fingers
18
Capacity (W650)
8000 L (227 bu.)
Capacity (W660)
11000 L (317 bu.)
Average unloading rate
4200 L/min. (120 bu./min.)
Without header
W650 —13530 kg (29,800 lb.)
W660 —13620 kg (30,000 lb.)
Go to Section_10:Group_10
ZX09263,000271F-19-20080121
60
Specifications - T550 and T560 Combines
Specifications - T550 and T560 Combines
-: Specifications
Engine:
Manufacturer
John Deere
Engine type
T550 —6068HZ482
T560 —6090HZ003B
Engine power (according to ECE-R120) at 2300 rpm
T550 — 217 kW (290 hp)
Engine power (according to ECE-R120) at 2100 rpm
T560 — 260 kW (345 hp)
Max. engine power (according to ECE-R120) at 2200
rpm
T550 — 224 kW (300 hp)
Max. engine power (according to ECE-R120) at 2000
rpm
T560 — 277 kW (370 hp)
Displacement
T550 —6.8 L (414 cu. in.)
T560 —9.0 L (554 cu. in.)
Fuel tank:
Air cleaner
Dry-type with safety element
Thermostats (two)
82°C (180°F)
Capacity
800 L (210 U.S.gal.)
Electrical system:
12-volt, 120-amp alternator
Transmission:
Three speeds
Brakes:
Hydraulic drum brakes
Threshing
cylinder:
Number of rasp bars
10
Concave:
Type
13 open bar
Beater:
Number of wings
8
Second concave: Type
open bars, adjustable to two
positions
Number of bars
10
Finger rake:
Type
adjustable
Separator:
Type
Separator rotor/straw walkers
Straw walkers:
Type
perforated plate
Number of walkers
5
Capacity
8000 L (227 bu.)
Average unloading rate
4200 L/min. (120 bu./min.)
Without header
T550 —12720 kg (28,000 lb.)
Grain tank:
Weight:
T560 —12580 kg (27,700 lb.)
Go to Section_10:Group_10
ZX09263,0002720-19-20080121
61
Specifications - T660 and T670 Combines
Specifications - T660 and T670 Combines
-: Specifications
Engine:
Manufacturer
John Deere
Engine type
T660 —6090HZ003B
T670 —6090HZ003D
Engine power (according to ECE-R120) at 2100 rpm
T660 — 260 kW (345 hp)
T670 — 300 kW (400 hp)
Fuel tank:
Max. engine power (according to ECE-R120) at 2100
rpm
T660 — 277 kW (370 hp)
Displacement
9.0 L (554 cu. in.)
Air cleaner
Dry-type with safety element
Thermostats (two)
82°C (180°F)
Capacity
800 L (210 U.S.gal.)
Electrical system:
12-volt, 120-amp alternator
Transmission:
Three speeds
Brakes:
Hydraulic drum brakes
T670 — 318 kW (425 hp)
Threshing
cylinder:
Number of rasp bars
10
Concave:
Type
13 open bar
Beater:
Number of wings
8
Second concave: Type
open bars, adjustable to two
positions
Number of bars
10
Finger rake:
Type
adjustable
Separator:
Type
Separator rotor/straw walkers
Straw walkers:
Type
perforated plate
Number of walkers:
6
Number of fingers
15
Capacity
11000 L (312 bu.)
Average unloading rate
4200 L/min. (120 bu./min.)
Without header
T660 —12720 kg (28,000 lb.)
Grain tank:
Weight:
T670 —12580 kg (27,700 lb.)
Go to Section_10:Group_10
ZX09263,0002721-19-20080121
62
Specifications - C670 Combine
Specifications - C670 Combine
-: Specifications
Engine:
Manufacturer
John Deere
Engine type
6090HZ003A
Engine power (according to ECE-R120) at 2100 rpm
300 kW (400 hp)
Max. engine power (according to ECE-R120) at 2000 rpm 318 kW (425 hp)
Fuel tank:
Displacement
9.0 L (554 cu. in.)
Air cleaner
Dry-type with safety element
Thermostats (two)
82°C (180°F)
Capacity
800 L (210 U.S.gal.)
Electrical system:
12-volt, 120-amp alternator
Transmission:
Three speeds
Brakes:
Hydraulic drum brakes
Threshing cylinder: Types
Rasp bar or spike tooth
Number of rasp bars/spike teeth
10 rasp bars
12 spike teeth
Concave:
Types
13/14 open bar or spike tooth
Beater:
Number of wings
8
Separator:
Type
Tine module
Grain tank:
Capacity
10000 L (297 bu.)
Average unloading rate
4200 L/min. (120 bu./min.)
Without header (standard equipment)
14750 kg (32,518 lb.)
Weight:
Go to Section_10:Group_10
ZX09263,0002722-19-20080121
63
Dimension Reference Points (W Series)
Dimension Reference Points (W Series)
ZX25212-UN: Reference Points
Go to Section_10:Group_10
ZX09263,0002723-19-20080121
64
Dimensions (W Series)
Dimensions (W Series)
-: Dimensions
DIMENSION W540, W550, W650, W660
HillMaster
A
9.00 m (29 ft. 5 in.) with 5.2 m (17 ft.) unloading
auger
9.00 m (29 ft. 5 in.) with 5.2 m (17 ft.) unloading
auger
B
9.9 m (32 ft. 5 in.) with 6.10 m (20 ft.) unloading
auger
9.9 m (32 ft. 5 in.) with 6.10 m (20 ft.) unloading
auger
C
8.45 m (27 ft. 8 in.)
8.53 m (27 ft. 11 in.)
D
9.2 m (29 ft. 10 in.)
9.25 m (29 ft. 11 in.)
E
3.98 m (12 ft. 11 in.)
3.98 m (12 ft. 11 in.)
F
3.95 m (12 ft. 9 in.)
4.00 m (13 ft. 1 in.)
G
0.61 m (2 ft. 0 in.)
0.61 m (2 ft. 0 in.)
H
3.77 m (12 ft. 4 in.)
3.80 m (12 ft. 5 in.)
I
4.20 m (13 ft. 9 in.) with 6.10 m (20 ft.) unloading 4.20 m (13 ft. 9 in.) with 6.10 m (20 ft.) unloading
auger
auger
J
4.04 m (13. ft. 3 in.) with 5.2 m (17 ft.) unloading 4.04 m (13. ft. 3 in.) with 5.2 m (17 ft.) unloading
auger
auger
K
3.92 m (12 ft. 10 in.) with 5.2 m (17 ft.) unloading 3.92 m (12 ft. 10 in.) with 5.2 m (17 ft.) unloading
auger
auger
4.07 m (13 ft. 4 in.) with 6.10 m (20 ft.) unloading 4.07 m (13 ft. 4 in.) with 6.10 m (20 ft.) unloading
auger
auger
L
3.66 m (11 ft. 11 in.) with 480/80R26 Tires [ Rear 3.66 m (11 ft. 11 in.) with 480/80R26 Tires [ Rear
axles can be adjusted to various widths. ]
axles can be adjusted to various widths. ]
M
3.77 m (12 ft. 5 in.) with 800/65R32 tires
3.77 m (12 ft. 5 in.) with 800/65R32 tires
Go to Section_10:Group_10
ZX09263,0002724-19-20080121
65
Dimension Reference Points (T Series)
Dimension Reference Points (T Series)
ZX25212-UN: Reference Points
Go to Section_10:Group_10
ZX09263,0002725-19-20080121
66
Dimensions (T Series)
Dimensions (T Series)
-: Dimensions
DIMENSION T550, T560, T660, T670
HillMaster
A
9.00 m (29 ft. 5 in.) with 5.2 m (17 ft.) unloading
auger
9.00 m (29 ft. 5 in.) with 5.2 m (17 ft.) unloading
auger
B
9.9 m (32 ft. 5 in.) with 6.10 m (20 ft.) unloading
auger
9.9 m (32 ft. 5 in.) with 6.10 m (20 ft.) unloading
auger
C
8.45 m (27 ft. 8 in.)
8.53 m (27 ft. 11 in.)
D
9.2 m (29 ft. 10 in.)
9.25 m (29 ft. 11 in.)
E
3.98 m (12 ft. 11 in.)
3.98 m (12 ft. 11 in.)
F
3.95 m (12 ft. 9 in.)
4.00 m (13 ft. 1 in.)
G
0.61 m (2 ft. 0 in.)
0.61 m (2 ft. 0 in.)
H
3.77 m (12 ft. 4 in.)
3.80 m (12 ft. 5 in.)
I
4.20 m (13 ft. 9 in.) with 6.10 m (20 ft.) unloading 4.20 m (13 ft. 9 in.) with 6.10 m (20 ft.) unloading
auger
auger
J
4.04 m (13 ft. 3 in.) with 5.2 m (17 ft.) unloading
auger
K
4.04 m (13 ft. 3 in.) with 5.2 m (17 ft.) unloading
auger
3.92 m (12 ft. 10 in.) with 5.2 m (17 ft.) unloading 3.92 m (12 ft. 10 in.) with 5.2 m (17 ft.) unloading
auger
auger
4.07 m (13 ft. 4 in.) with 6.10 m (20 ft.) unloading 4.07 m (13 ft. 4 in.) with 6.10 m (20 ft.) unloading
auger
auger
L
3.66 m (11 ft. 11 in.) with 480/80R26 Tires [ Rear 3.66 m (11 ft. 11 in.) with 480/80R26 Tires [ Rear
axles can be adjusted to various widths. ]
axles can be adjusted to various widths. ]
M
3.77 m (12 ft. 5 in.) with 800/65R32 tires
3.77 m (12 ft. 5 in.) with 800/65R32 tires
Go to Section_10:Group_10
ZX09263,0002726-19-20080121
67
Dimension Reference Points (C Series)
Dimension Reference Points (C Series)
ZX25210-UN: Dimension reference points (C670)
Go to Section_10:Group_10
ZX09263,0002727-19-20080121
68
Dimensions (C Series)
Dimensions (C Series)
-: Dimensions
DIMENSION C670
HillMaster
A
8.98 m (29 ft. 5 in.) with 5.2 m (17 ft.) unloading
auger
B
9.89 m (32 ft. 5 in.) with 6.10 m (20 ft.) unloading 9.89 m (32 ft. 5 in.) with 6.10 m (20 ft.) unloading
auger
auger
C
9.10 m (29 ft. 10 in.)
9.14 m (29 ft. 11 in.)
D
4.00 m (13 ft. 1 in.)
4.00 m (13 ft. 1 in.)
E
3.94 m (12 ft. 11 in.)
3.94 m (12 ft. 11 in.)
F
0.61 m (2 ft. 0 in.)
0.61 m (2 ft. 0 in.)
G
3.77 m (12 ft. 4 in.)
3.80 m (12 ft. 5 in.)
H
4.20 m (13 ft. 9 in.) with 6.10 m (20 ft.) unloading 4.20 m (13 ft. 9 in.) with 6.10 m (20 ft.) unloading
auger
auger
I
4.04 m (13 ft. 3 in.) with 5.2 m (17 ft.) unloading
auger
J
8.98 m (29 ft. 5 in.) with 5.2 m (17 ft.) unloading
auger
4.04 m (13 ft. 3 in.) with 5.2 m (17 ft.) unloading
auger
3.92 m (12 ft. 10 in.) with 5.2 m (17 ft.) unloading 3.92 m (12 ft. 10 in.) with 5.2 m (17 ft.) unloading
auger
auger
4.07 m (13 ft. 4 in.) with 6.10 m (20 ft.) unloading 4.07 m (13 ft. 4 in.) with 6.10 m (20 ft.) unloading
auger
auger
K
3.65 m (11 ft. 11 in.) with 480/80R26 Tires [ Rear 3.65 m (11 ft. 11 in.) with 480/80R26 Tires [ Rear
axles can be adjusted to various widths. ]
axles can be adjusted to various widths. ]
L
3.77 m (12 ft. 5 in.) with 800/65R32 tires
3.77 m (12 ft. 5 in.) with 800/65R32 tires
Go to Section_10:Group_10
ZX09263,0002728-19-20080121
69
Metric Bolt and Screw Torque Values
Metric Bolt and Screw Torque Values
TS1670-UN: Metric Bolt and Screw
-: Metric Torque Values
Class 4.8
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
M20 and
larger
fasteners
with JDM
Bolt F13C, F13F
or F13J zinc
or
flake
Screw
coating. ]
Size
Class 8.8 or 9.8
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or M6 to
M18
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
M20 and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Class 10.9
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or M6 to
M18
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
M20 and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Class 12.9
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or M6 to
M18
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
M20 and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or M6 to
M18
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
M6
4.7
42
6
53
8.9
79
11.3
100
13
N˙m
M8
11.5
102
14.5
128
22
N˙m lb.-ft. N˙m
M10
23
204
N˙m
lb.-ft.
M12
40
M14
194
27.5
243
115
16.5
146
15.5
137
19.5
172
lb.-ft. N˙m lb.-ft. N˙m
lb.-ft. N˙m lb.-ft.
32
23.5
40
29.5
37
27.5
47
35
lb.-ft. N˙m lb.-ft.
29
21
43
32
55
40
63
46
80
59
75
55
95
70
29.5
50
37
75
55
95
70
110
80
140
105
130
95
165
120
63
46
80
59
120
88
150
110
175
130
220
165
205
150
260
190
M16
100
74
125
92
190
140
240
175
275
200
350
255
320
235
400
300
M18
135
100
170
125
265
195
330
245
375
275
475
350
440
325
560
410
M20
190
140
245
180
375
275
475
350
530
390
675
500
625
460
790
580
M22
265
195
330
245
510
375
650
480
725
535
920
680
850
625
1080 800
70
Metric Bolt and Screw Torque Values
Class 4.8
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
M20 and
larger
fasteners
with JDM
Bolt F13C, F13F
or F13J zinc
or
flake
Screw
coating. ]
Size
Class 8.8 or 9.8
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or M6 to
M18
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
M20 and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Class 10.9
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or M6 to
M18
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
M20 and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Class 12.9
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or M6 to
M18
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
M20 and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or M6 to
M18
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
1150 850
1080
1350 1000
M24
330
245
425
315
650
480
820
600
920
680
M27
490
360
625
460
950
700
1200 885
1350
1000 1700 1250 1580
1160 2000 1475
M30
660
490
850
625
1290
950
1630 1200 1850
1350 2300 1700 2140
1580 2700 2000
M33
900
665
1150 850
1750
1300 2200 1625 2500
1850 3150 2325 2900
2150 3700 2730
M36
1150
850
1450 1075 2250
1650 2850 2100 3200
2350 4050 3000 3750
2770 4750 3500
Torque values listed are for general use only, based
on the strength of the bolt or screw. DO NOT use
these values if a different torque value or tightening
procedure is given for a specific application. For
stainless steel fasteners or for nuts on U-bolts, see the
tightening instructions for the specific application.
Tighten plastic insert or crimped steel type lock nuts
by turning the nut to the dry torque shown in the chart,
unless different instructions are given for the specific
application.
800
Shear bolts are designed to fail under predetermined loads.
Always replace shear bolts with identical property class.
Replace fasteners with the same or higher property class. If
higher property class fasteners are used, tighten these to the
strength of the original. Make sure fastener threads are clean
and that you properly start thread engagement. When
possible, lubricate plain or zinc plated fasteners other than
lock nuts, wheel bolts or wheel nuts, unless different
instructions are given for the specific application.
Go to Section_10:Group_10
DX,TORQ2-19-20110112
71
Unified Inch Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
TS1671-UN: Unified Inch Bolt and Screw
-: Unified Inch Bolt and Screw Torque Values
SAE Grade 2 [ Grade 2
applies for hex cap
screws (not hex bolts)
up to 6 in. (152 mm)
long. Grade 1 applies for
hex cap screws over 6
in. (152 mm) long, and
for all other types of
bolts and screws of any
length. ]
SAE Grade 5, 5.1 or 5.2
SAE Grade 1
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners
with JDM
Bolt F13C, F13F
or F13J zinc
or
flake
Screw
coating. ]
Size
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or 1/4 to
3/4 in.
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or 1/4 to
3/4 in.
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or 1/4 to
3/4 in.
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
SAE Grade 8 or 8.2
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or 1/4 to
3/4 in.
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
1/4
3.7
33
4.7
42
6
53
7.5
66
9.5
84
12
106
13.5
N˙m
5/16
7.7
68
9.8
86
12
106
15.5
137
19.5
N˙m
3/8
13.5
120
17.5
155
22
N˙m lb.-ft. N˙m
7/16
22
194
N˙m
lb.-ft.
28
20.5
35
194
27
240
172
25
221
120
17
150
lb.-ft. N˙m lb.-ft.
28
20.5
35
26
lb.-ft. N˙m lb.-ft.
35
26
44
32.5
49
36
63
46
56
41
70
52
80
59
100
74
lb.-ft. N˙m lb.-ft.
26
44
32.5
72
Unified Inch Bolt and Screw Torque Values
SAE Grade 2 [ Grade 2
applies for hex cap
screws (not hex bolts)
up to 6 in. (152 mm)
long. Grade 1 applies for
hex cap screws over 6
in. (152 mm) long, and
for all other types of
bolts and screws of any
length. ]
SAE Grade 5, 5.1 or 5.2
SAE Grade 1
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners
with JDM
Bolt F13C, F13F
or F13J zinc
or
flake
Screw
coating. ]
Size
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or 1/4 to
3/4 in.
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or 1/4 to
3/4 in.
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or 1/4 to
3/4 in.
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
SAE Grade 8 or 8.2
Lubricated [
“Lubricated”
means
coated with
a lubricant
such as
engine oil,
fasteners
with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners
with JDM
F13C, F13F
or F13J zinc
flake
coating. ]
Dry [ “Dry”
means
plain or
zinc plated
without
any
lubrication,
or 1/4 to
3/4 in.
fasteners
with JDM
F13B, F13E
or F13H
zinc flake
coating. ]
1/2
34
25
42
31
53
39
67
49
85
63
110
80
120
88
155
115
9/16
48
35.5
60
45
76
56
95
70
125
92
155
115
175
130
220
165
5/8
67
49
85
63
105
77
135
100
170
125
215
160
240
175
305
225
3/4
120
88
150
110
190
140
240
175
300
220
380
280
425
315
540
400
7/8
190
140
240
175
190
140
240
175
490
360
615
455
690
510
870
640
1
285
210
360
265
285
210
360
265
730
540
920
680
1030
760
1300 960
1-1/8
400
300
510
375
400
300
510
375
910
670
1150 850
1450
1075 1850 1350
1-1/4
570
420
725
535
570
420
725
535
1280
945
1630 1200 2050
1500 2600 1920
1-3/8
750
550
950
700
750
550
950
700
1700
1250 2140 1580 2700
2000 3400 2500
1-1/2
990
730
1250 930
990
730
1250 930
2250
1650 2850 2100 3600
2650 4550 3350
Torque values listed are for general use only, based on the
strength of the bolt or screw. DO NOT use these values if a
different torque value or tightening procedure is given for a
specific application. For plastic insert or crimped steel type
lock nuts, for stainless steel fasteners, or for nuts on U-bolts,
see the tightening instructions for the specific application.
Shear bolts are designed to fail under predetermined loads.
Always replace shear bolts with identical grade.
73
Replace fasteners with the same or higher grade. If
higher grade fasteners are used, tighten these to the
strength of the original. Make sure fastener threads
are clean and that you properly start thread
engagement. When possible, lubricate plain or zinc
plated fasteners other than lock nuts, wheel bolts or
wheel nuts, unless different instructions are given for
the specific application.
Unified Inch Bolt and Screw Torque Values
Go to Section_10:Group_10
DX,TORQ1-19-20110112
74
Assemble and Install Flat Face Seal Fittings - All Pressure Applications
Assemble and Install Flat Face Seal Fittings - All Pressure Applications
Flat Face Seal O-Ring to Stud End Installation
1. Inspect the fitting surfaces. They must be free of dirt and damage.
2. Inspect the O-ring. It must be clean and free of damage.
3. Lubricate O-rings and install into groove using petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly.
5. Align fitting and tighten by hand. Take care not to displace the O-ring.
6. Tighten fitting or nut to torque value shown in chart. Pay attention to the size (with dash) stamped on the
fitting. DO NOT allow hoses to twist when tightening fittings.
O-Ring Installation (Flat Face Seal and Adjustable Stud End )
1. Back off lock nut and washer to fully exposed turned down section of the fitting.
2. Install a thimble over the fitting threads to protect the O-ring from nicks.
3. Slide the O-ring over the thimble into the turned down section of the fitting.
4. Remove thimble.
Fitting Installation (Flat Face Seal and Straight Stud End)
1. Install a thimble over the fitting threads to protect the O-ring from nicks.
2. Slide the O-ring over the thimble into the turned down section of the fitting.
3. Remove thimble.
Fitting Installation
1. Install fitting by hand until snug.
2. Position adjustable fittings by unscrewing the fitting no more than one turn.
3. Apply assembly torque per table.
Assembly Torque
1. Use one wrench to hold the connector body and one wrench to tighten nut.
2. For a hydraulic hose, it may be necessary to use three wrenches to prevent twisting; one on the
connector body, one on the nut, and one on the body of the hose fitting.
Go to Section_10:Group_10
OUO6435,0001557CONV1-19-20011217
75
Torque Chart for Metric Flat Face Seal Fittings - Standard Pressure Applications
Torque Chart for Metric Flat Face Seal Fittings - Standard Pressure Applications
H70406-UN: Fitting
LEGEND:
A - 90° Swivel Elbow and Tube Nut
B - 90° Adjustable Elbow
C - Straight Stud and Tube Nut
D - Bulkhead Union and Bulkhead Lock Nut
E - Stud End
F - Tube Nut
G - Swivel Nut
H - Lock Nut
-: Metric Flat Face Seal Fittings (Standard Pressure)
Torque Chart for Metric Flat Face Seal Fittings - Standard Pressure - Below 27.6 MPa (4000 psi), Working
Pressure - 27.6 MPa (4000 psi)
Nominal Tube
OD/Hose ID
Flat Face Seal Tube/Hose End
O-Ring Stud Ends
Metric Inch Tube Thread Hex.
Tube
Bulkhead Lock Thread Hex. Steel or Gray- Aluminum
Tube
OD
Size Size Nut/Swivel Nut
Size Size
Cast Iron
Nut Torque [
Torque [
OD
Torque [
Torque [
Tolerance is
Tolerance is
Tolerance is +15%, minus 20%
Tolerance is +15%, minus
+15%, minus
+15%, minus
of average
20% of
20% of average tightening torque
20% of
average
tightening
average
unless otherwise
tightening
torque unless
tightening
specified. ]
torque
otherwise
torque unless
unless
specified. ]
otherwise
otherwise
specified. ]
specified. ]
mm
Size
(with
Dash)
6
-4
8
in.
in.
mm
N˙m
lb-ft
N˙m
lb-ft
in.
mm
N˙m
lb-ft
N˙m
lb-ft
0.250 9/1618
17
16
12
12
9
M12 x
1.5
17
21
15.5
9
6.6
-5
0.312
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
M14 x
1.5
19
33
24
15
11
10
-6
0.375 11/16- 22
16
24
18
24
18
M16 x
1.5
22
41
30
18
13
76
Torque Chart for Metric Flat Face Seal Fittings - Standard Pressure Applications
12
-8
0.500 13/16- 24
16
50
37
46
34
M18 x
1.5
24
50
37
21
15
16
-10 0.625 1-14
30
69
51
62
46
M22 x
1.5
27
69
51
28
21
20
-12 0.750 1-3/16- 36
12
102
75
102
75
M27 x
2
32
102
75
46
34
22
-14 0.875 1-3/16- 36
12
102
75
102
75
M30 x
2
36
25
-16 1.000 1-7/16- 41
12
142
105
142
105
M33 x
2
41
158
116
71
52
28
—
—
—
—
—
—
M38 x
2
46
176
130
79
58
32
-20
1.25
190
140
190
140
M42 x
2
50
190
140
85
63
38
-24
1.50
217
160
217
160
M48 x
2
55
217
160
98
72
—
—
150
11/1612
2-12
60
Not Established
Go to Section_10:Group_10
OUO6435,000154DCONV1-19-20011129
77
Torque Chart for Metric Flat Face Seal Fittings - High Pressure Applications
Torque Chart for Metric Flat Face Seal Fittings - High Pressure Applications
H70406-UN: Fitting
LEGEND:
A - 90° Swivel Elbow and Tube Nut
B - 90° Adjustable Elbow
C - Straight Stud and Tube Nut
D - Bulkhead Union and Bulkhead Lock Nut
E - Stud End
F - Tube Nut
G - Swivel Nut
H - Lock Nut
-: Metric Flat Face Seal Fittings (High Pressure)
Torque Chart for Metric Flat Face Seal Fittings - High Pressure - Above 27.6 MPa (4000 psi), Working
Pressure - 41.3 MPa (6000 psi)
Nominal Tube
OD/Hose ID
Flat Face Seal Tube/Hose End
O-Ring Stud Ends
Metric Inch Tube Thread Hex. Tube Nut/Swivel Nut
Thread Hex. Steel or GrayBulkhead Lock Nut
Tube
OD
Size Size Torque [ Tolerance Torque [ Tolerance is
Size Size Cast Iron Torque [
OD
is +15%, minus 20% +15%, minus 20% of
Tolerance is
of average
average tightening
+15%, minus
tightening torque torque unless otherwise
20% of average
unless otherwise
specified. ]
tightening torque
specified. ]
unless otherwise
specified. ]
mm
Size
(with
Dash)
6
-4
8
in.
in.
mm
N˙m
lb-ft
N˙m
lb-ft
in.
mm
N˙m
lb-ft
0.250 9/1618
17
16
12
12
9
M12 x
1.5
17
35
26
-5
0.312
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
M14 x
1.5
19
45
33
10
-6
0.375 11/16- 22
16
24
18
24
18
M16 x
1.5
22
55
40
12
-8
0.500 13/16- 24
16
50
37
46
34
M18 x
1.5
24
70
50
78
Torque Chart for Metric Flat Face Seal Fittings - High Pressure Applications
16
-10 0.625 1-14
30
69
51
62
46
M22 x
1.5
27
100
75
20
-12 0.750 1-3/16- 36
12
102
75
102
75
M27 x
2
32
170
125
22
-14 0.875 1-3/16- 36
12
102
75
102
75
M30 x
2
36
215
160
25
-16 1.000 1-7/16- 41
12
142
105
142
105
M33 x
2
41
310
225
28
—
—
—
—
—
—
—
—
M38 x
2
46
320
235
32
-20
1.25
111/1612
—
—
—
—
—
M42 x
2
50
330
240
38
-24
1.50
2-12
—
—
—
—
—
M48 x
2
55
420
300
Go to Section_10:Group_10
OUO6435,000154E-19-20011129
79
Torque Chart for SAE Flat Face Seal Fittings - Standard Pressure Applications
Torque Chart for SAE Flat Face Seal Fittings - Standard Pressure Applications
H70406-UN: Fitting
LEGEND:
A - 90° Swivel Elbow and Tube Nut
B - 90° Adjustable Elbow
C - Straight Stud and Tube Nut
D - Bulkhead Union and Bulkhead Lock Nut
E - Stud End
F - Tube Nut
G - Swivel Nut
H - Lock Nut
-: Flat Face Seal Fittings (Standard Pressure)
Torque Chart for SAE Inch Flat Face Seal Fittings - Standard Pressure - Below 27.6 MPa (4000 psi),
Working Pressure - 27.6 MPa (4000 psi)
Nominal Tube OD/Hose
ID
Metric
Tube
OD
Inch Tube OD
mm
Size
(with
Dash)
5
in.
Flat Face Seal Tube/Hose End
O-Ring Stud Ends
Thread Tube Nut/Swivel Nut
Thread Straight Fitting or
Bulkhead Lock Nut
Size Torque [ Tolerance
Size
Lock Nut Torque [
Torque [ Tolerance is
is +15%, minus 20% +15%, minus 20% of
Tolerance is +15%,
of average
average tightening
minus 20% of
tightening torque
torque unless otherwise
average tightening
unless otherwise
specified. ]
torque unless
specified. ]
otherwise specified. ]
mm
in.
N˙m
lb-ft
N˙m
lb-ft
in.
N˙m
lb-ft
-3
0.188 4.76
—
—
—
—
—
3/8-24
8
6
6
-4
0.250 6.35
9/1618
16
12
12
9
7/1620
12
9
8
-5
0.312 7.94
—
—
—
—
—
1/2-20
16
12
10
-6
0.375 9.52 11/1616
24
18
24
18
9/1618
24
18
12
-8
0.500 12.70 13/1616
50
37
46
34
3/4-16
46
34
16
-10 0.625 15.88 1-14
69
51
62
46
7/8-14
62
46
80
Torque Chart for SAE Flat Face Seal Fittings - Standard Pressure Applications
20
-12 0.750 19.05 1-3/1612
102
75
102
75
1-1/1612
102
75
22
-14 0.875 22.22 1-3/1612
102
75
102
75
1-3/1612
122
90
25
-16 1.000 25.40 1-7/1612
142
105
142
105
1-5/1612
142
105
32
-20
1.25 31.75
190
140
190
140
1-5/812
190
140
38
-24
1.50 38.10 2-12
217
160
217
160
1-7/812
217
160
111/1612
Go to Section_10:Group_10
OUO6435,0001546CONV1-19-20011116
81
Torque Chart for SAE Flat Face Seal Fittings - High Pressure Applications
Torque Chart for SAE Flat Face Seal Fittings - High Pressure Applications
H70406-UN: Fitting
LEGEND:
A - 90° Swivel Elbow and Tube Nut
B - 90° Adjustable Elbow
C - Straight Stud and Tube Nut
D - Bulkhead Union and Bulkhead Lock Nut
E - Stud End
F - Tube Nut
G - Swivel Nut
H - Lock Nut
-: SAE Inch Flat Face Seal Fittings (High Pressure)
Torque Chart for SAE Inch Flat Face Seal Fittings - High Pressure - Above 27.6 MPa (4000 psi), Working
Pressure - 41.3 MPa (6000 psi)
Nominal Tube OD/Hose
ID
Metric
Tube
OD
Inch Tube OD
mm
Size
(with
Dash)
5
in.
Flat Face Seal Tube/Hose End
O-Ring Stud Ends
Thread Tube Nut/Swivel Nut
Thread Straight Fitting or
Bulkhead Lock Nut
Size Torque [ Tolerance
Size
Lock Nut Torque [
Torque [ Tolerance is
is +15%, minus 20% +15%, minus 20% of
Tolerance is +15%,
of average
average tightening
minus 20% of
tightening torque
torque unless otherwise
average tightening
unless otherwise
specified. ]
torque unless
specified. ]
otherwise specified. ]
mm
in.
N˙m
lb-ft
N˙m
lb-ft
in.
N˙m
lb-ft
-3
0.188 3.76
—
—
—
—
—
3/8-24
—
—
6
-4
0.250 6.35
9/1618
16
12
12
9
7/1620
21
15
8
-5
0.312 7.94
—
—
—
—
—
1/2-20
—
—
10
-6
0.375 9.52 11/1616
24
18
24
18
9/1618
34
25
12
-8
0.500 12.70 13/1616
50
37
46
34
3/4-16
73
55
16
-10 0.625 15.88 1-14
69
51
62
46
7/8-14
104
76
82
Torque Chart for SAE Flat Face Seal Fittings - High Pressure Applications
20
-12 0.750 19.05 1-3/1612
102
75
102
75
1-1/1612
176
130
22
-14 0.875 22.22 1-3/1612
102
75
102
75
1-3/1612
230
170
25
-16 1.000 25.40 1-7/1612
142
105
142
105
1-5/1612
285
210
Go to Section_10:Group_10
OUO6435,000154A-19-20011120
83
Assemble and Install Four-Bolt Flange Fittings - All Pressure Applications
Assemble and Install Four-Bolt Flange Fittings - All Pressure Applications
1. Inspect the sealing surfaces for nicks or scratches, roughness or out-of-flat condition. Scratches cause
leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If these defects cannot be
polished out, replace the component.
2. Install the correct O-ring (and backup washer if required) into the groove using petroleum jelly to hold it
in place.
3. For split flange: loosely assemble split flange halves, being sure that the split is centrally located and
perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring.
4. For single piece flange: put hydraulic line in the center of the flange and install four cap screws. With the
flange centrally located on the port, hand tighten cap screws to hold it in place. Do not pinch O-ring.
5. For both single piece flange and split flange, be sure the components are properly positioned and cap
screws are hand tight. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten
the two remaining cap screws. Tighten all cap screws to the values shown in the chart.
DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT
overtighten.
Go to Section_10:Group_10
OUO6435,000189FCONV1-19-20020820
84
Torque Values for SAE Four-Bolt Flange - Standard Pressure Applications
Torque Values for SAE Four-Bolt Flange - Standard Pressure Applications
H70423-UN: Split Flange
-: Split Flange Cap Screw Torque Values - 27,600 kPa (4000 psi) Pressure Range
Torque Values for SAE Four-Bolt Flange - 27,600 kPa (4000 psi) Pressure Applications
Torque
Newton
Meters
Nominal
Flange
Size
Foot
Pounds
Screw Size [ JDM A17D, SAE Grade 5 or higher grade screws with zinc-plated Min. Max. Min. Max.
hardware. ] [ 1.5.1.2 Lock washers are permissible but not recommended. ]
1/2
5/16-18 UNC
20
31
15
23
3/4
3/8-16 UNC
28
54
21
40
1
3/8-16 UNC
37
54
27
40
1-1/4
7/16-14 UNC
47
85
35
63
1-1/2
1/2-13 UNC
62
131 46
97
2
1/2-13 UNC
73
131 54
97
2-1/2
1/2-13 UNC
107 131 79
97
3
5/8-11 UNC
187 264 138 195
3-1/2
5/8-11 UNC
158 264 117 195
4
5/8-11 UNC
158 264 117 195
5
5/8-11 UNC
158 264 117 195
Go to Section_10:Group_10
OUO6435,0001549-19-20011120
85
Torque Values for SAE Four-Bolt Flange - High Pressure Applications
Torque Values for SAE Four-Bolt Flange - High Pressure Applications
H70423-UN: Split Flange
-: Split Flange Cap Screw Torque Values - 41,400 kPa (6000 psi) Pressure Range
Torque Values for SAE Four-Bolt Flange - 41,400 kPa (6000 psi) Pressure Applications
Torque
Newton
Meters
Foot
Pounds
Nominal
Flange
Size
Screw Size [ JDM A17D, SAE Grade 5 or higher grade screws with zinc-plated Min. Max. Min. Max.
hardware. ] [ 1.5.1.2 Lock washers are permissible but not recommended. ]
1/2
5/16-18 UNC
20
31
15
23
3/4
3/8-16 UNC
34
54
25
40
1
7/16-14 UNC
57
85
42
63
1-1/4
1/2-13 UNC
85
131 63
63
1-1/2
5/8-11 UNC
159 264 117 195
2
3/4-10 UNC
271 468 200 345
Go to Section_10:Group_10
OUO6435,000154C-19-20011129
86
Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems
Basic Electrical Component Handling / Precautions For Vehicles Equipped With
Computer Controlled Systems
Electrical Precautions To Take:
Never disconnect the batteries with the ignition turned on. Reason: This can cause electrical voltage spikes that
can damage electronic components.
Do not connect jumper cables with the ignition turned on. Reason: This can cause electrical voltage spikes that
can damage electronic components.
Disconnect batteries prior to recharging (if possible). Reason: Electrical loads in the combine can slow the
recharging process. Battery chargers can cause electrical voltage spikes that can damage electronic components.
Never jump start the machine with a voltage higher than the machine is designed to operate on. Reason: This can
damage electronic components.
Do not connect or disconnect electrical connectors while the ignition is on or the engine is running. Reason: This
can cause computer system errors from interrupting a computer program while it is running and electrical voltage
spikes that are produced can damage electronic components.
Do not apply power or ground to any component as a test unless specifically instructed to do so. Reason:
Connecting the wrong voltage to the wrong point of an electronic system can cause electronic component failures.
When welding on the machine, make sure to connect ground lead to the parts being welded. For maximum
protection, disconnect all connectors of electronic control units before welding. Reason: High currents associated
with welding can damage wiring harnesses that are involved in the ground path. Welding can also cause electrical
voltage spikes that can damage electronic components.
Go to Section_10:Group_10
AG,OUO1026,231-19-20030206
87
Diesel Fuel
Diesel Fuel
Consult your local fuel distributor for properties of the diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which
they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are recommended. Renewable diesel fuel produced by
hydrotreating animal fats and vegetable oils is basically identical to petroleum diesel fuel. Renewable diesel that
meets EN 590 or ASTM D975 is acceptable for use at all percentage mixture levels.
Required Fuel Properties
In all cases, the fuel shall meet the following properties:
Cetane number of 43 minimum. Cetane number greater than 47 is preferred, especially for temperatures below
–20°C (–4°F) or elevations above 1500 m (5000 ft.).
Cold Filter Plugging Point (CFPP) should be at least 5°C (9°F) below the expected lowest temperature or
Cloud Point below the expected lowest ambient temperature.
Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.
Diesel fuel quality and sulfur content must comply with all existing emissions regulations for the area in which
the engine operates. DO NOT use diesel fuel with sulfur content greater than 10 000 mg/kg (10 000 ppm).
Sulfur content for Interim Tier 4 and Stage III B engines
Use ONLY ultra low sulfur diesel (ULSD) fuel with a maximum of 15 mg/kg (15 ppm) sulfur content.
Sulfur Content for Tier 3 and Stage III A Engines
Use of diesel fuel with sulfur content less than 1000 mg/kg (1000 ppm) is RECOMMENDED
Use of diesel fuel with sulfur content 1000–5000 mg/kg (1000–5000 ppm) REDUCES oil and filter
change intervals.
BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm), contact your John
Deere dealer
Sulfur Content for Tier 2 and Stage II Engines
Use of diesel fuel with sulfur content less than 500 mg/kg (500 ppm) is RECOMMENDED.
Use of diesel fuel with sulfur content 500–5000 mg/kg (500–5000 ppm) REDUCES the oil and filter
change interval
BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm), contact your John
Deere dealer
Sulfur Content for Other Engines
Use of diesel fuel with sulfur content less than 5000 mg/kg (5000 ppm) is recommended.
Use of diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) REDUCES the oil and filter
change intervals.
IMPORTANT:
Do not mix used diesel engine oil or any other type of lubricating oil with diesel fuel.
88
Diesel Fuel
IMPORTANT:
Improper fuel additive usage may cause damage on fuel injection equipment of diesel engines.
Go to Section_10:Group_15
DX,FUEL1-19-20110411
89
Diesel Fuel
Diesel Fuel
Consult your local fuel distributor for properties of the diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which
they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are recommended. Renewable diesel fuel produced by
hydrotreating animal fats and vegetable oils is basically identical to petroleum diesel fuel. Renewable diesel that
meets EN 590 or ASTM D975 is acceptable for use at all percentage mixture levels.
Required Fuel Properties
In all cases, the fuel shall meet the following properties:
Cetane number of 43 minimum. Cetane number greater than 47 is preferred, especially for temperatures below
–20°C (–4°F) or elevations above 1500 m (5000 ft.).
Cold Filter Plugging Point (CFPP) should be at least 5°C (9°F) below the expected lowest temperature or
Cloud Point below the expected lowest ambient temperature.
Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.
Diesel fuel quality and sulfur content must comply with all existing emissions regulations for the area in which
the engine operates. DO NOT use diesel fuel with sulfur content greater than 10 000 mg/kg (10 000 ppm).
Sulfur content for Interim Tier 4 and Stage III B engines
Use ONLY ultra low sulfur diesel (ULSD) fuel with a maximum of 15 mg/kg (15 ppm) sulfur content.
Sulfur Content for Tier 3 and Stage III A Engines
Use of diesel fuel with sulfur content less than 1000 mg/kg (1000 ppm) is RECOMMENDED
Use of diesel fuel with sulfur content 1000–5000 mg/kg (1000–5000 ppm) REDUCES oil and filter
change intervals.
BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm), contact your John
Deere dealer
Sulfur Content for Tier 2 and Stage II Engines
Use of diesel fuel with sulfur content less than 500 mg/kg (500 ppm) is RECOMMENDED.
Use of diesel fuel with sulfur content 500–5000 mg/kg (500–5000 ppm) REDUCES the oil and filter
change interval
BEFORE using diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm), contact your John
Deere dealer
Sulfur Content for Other Engines
Use of diesel fuel with sulfur content less than 5000 mg/kg (5000 ppm) is recommended.
Use of diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) REDUCES the oil and filter
change intervals.
IMPORTANT:
Do not mix used diesel engine oil or any other type of lubricating oil with diesel fuel.
90
Diesel Fuel
IMPORTANT:
Improper fuel additive usage may cause damage on fuel injection equipment of diesel engines.
Go to Section_10:Group_15
DX,FUEL1-19-20110411
91
Storing Fuel
Storing Fuel
If there is a very slow turnover of fuel in the fuel tank or supply tank, it may be necessary to add a fuel conditioner
to prevent water condensation. Contact your John Deere dealer for proper service or maintenance
recommendations.
Go to Section_10:Group_15
DX,FUEL-19-19930303
92
Heavy Duty Diesel Engine Coolant
Heavy Duty Diesel Engine Coolant
The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting,
and winter freeze protection to -37°C (-34°F). If protection at lower temperatures is required, consult your John
Deere dealer for recommendations.
The following engine coolants are preferred:
John Deere COOL-GARD ™ II Premix
John Deere COOL-GARD II PG Premix
Use John Deere COOL-GARD II PG Premix when a non-toxic coolant formulation is required.
Additional Recommended Coolants
The following engine coolant is also recommended:
John Deere COOL-GARD II Concentrate in a 40–60% mixture of concentrate with quality water.
John Deere COOL-GARD II Premix, COOL-GARD II PG Premix, and COOL-GARD II Concentrate coolants do
not require use of supplemental coolant additives.
Other Coolants
John Deere COOL-GARD II and COOL-GARD II PG coolants might not be available in the geographical area
where service is performed.
If these coolants are unavailable, use a coolant concentrate or prediluted coolant intended for use with heavy duty
diesel engines and with a minimum of the following chemical and physical properties:
Is formulated with a quality nitrite-free additive package.
Provides cylinder liner cavitation protection according to either the John Deere Cavitation Test Method or
a fleet study run at or above 60% load capacity
Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from
corrosion
The additive package must be part of one of the following coolant mixtures:
ethylene glycol or propylene glycol base prediluted (40—60%) heavy duty coolant
ethylene glycol or propylene glycol base heavy duty coolant concentrate in a 40—60% mixture of
concentrate with quality water
Water Quality
Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is
recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.
IMPORTANT:
Do not use cooling system sealing additives or antifreeze that contains sealing additives.
Do not mix ethylene glycol and propylene glycol base coolants.
Do not use coolants that contain nitrites.
Go to Section_10:Group_15
DX,COOL3-19-20110414
93
Supplemental Coolant Additives
Supplemental Coolant Additives
Some coolant additives will gradually deplete during engine operation. For nitrite-containing coolants, replenish
coolant additives between drain intervals by adding a supplemental coolant additive as determined necessary by
coolant testing.
John Deere Liquid Coolant Conditioner is recommended as a supplemental coolant additive for nitrite-containing
coolants.
John Deere Liquid Coolant Conditioner is not designed for use with John Deere COOL-GARD ™ II Premix,
COOL-GARD II PG Premix, or COOL-GARD II Concentrate.
IMPORTANT:
Do not add a supplemental coolant additive when the cooling system is drained and refilled with any of the
following:
John Deere COOL-GARD II
John Deere COOL-GARD II PG
If other coolants are used, consult the coolant supplier and follow the manufacturer's recommendation for use of
supplemental coolant additives.
The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the
coolant.
Add the manufacturer's recommended concentration of supplemental coolant additive. DO NOT add more than
the recommended amount.
Go to Section_10:Group_15
DX,COOL4-19-20110414
94
Liquid Coolant Conditioner
Liquid Coolant Conditioner
John Deere Liquid Coolant Conditioner TY16004 is recommended for wet-sleeve diesel engines not having a
coolant filter option. Other conditioners may be used if they contain non-chromate inhibitors.
IMPORTANT:
John Deere Liquid Coolant Conditioner does not protect against freezing.
Various sizes of coolant conditioner are available from your John Deere dealer.
Go to Section_10:Group_15
H01,XHXR,K-19-20030206
95
Diesel Engine Oil
Diesel Engine Oil
TS1687-UN: Oil Viscosities for Air Temperature Ranges
Use oil viscosity based on the expected air temperature range during the period between oil changes.
John Deere Plus-50 ™ II oil is preferred.
John Deere Plus-50 ™ is also recommended.
Other oils may be used if they meet one or more of the following:
John Deere Torq-Gard ™
API Service Category CJ-4
API Service Category CI-4 PLUS
API Service Category CI-4
API Service Category CH-4
API Service Category CG-4
API Service Category CF-4
ACEA Oil Sequence E9
ACEA Oil Sequence E7
ACEA Oil Sequence E6
ACEA Oil Sequence E5
ACEA Oil Sequence E4
ACEA Oil Sequence E3
96
Diesel Engine Oil
ACEA Oil Sequence E2
If oils meeting API CG-4, API CF-4, or ACEA E2 are used, reduce the service interval by 50%.
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply with all existing emissions regulations for the area in which
the engine operates.
If diesel fuel with sulfur content greater than 5000 mg/kg (5000 ppm) is used, reduce the service interval by 50%.
DO NOT use diesel fuel with sulfur content greater than 10 000 mg/kg (10 000 ppm).
Go to Section_10:Group_15
DX,ENOIL-19-20110414
97
Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils
Hydrostatic Drive System, Main Hydraulic System and Main Engine Gear Case Oils
NOTE:
Ex factory, the combine is filled with SAE 10W oil. If you change oil, you can use any of the oils
listed below.
1. SAE 10W engine oils, if they meet API Service Classification CD or CE.
2. John Deere Low Viscosity HY-GARD ™
3. John Deere All-Weather Hydrostatic Fluid outside U.S.A. and Canada must meet:
Ford M2C33F specification
Ford M2C33G specification
Go to Section_10:Group_15
ZX08798,0000645-19-20071212
98
nsmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger Elevator and Dual-Range Cylinder Drive Gear Ca
Transmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger
Elevator and Dual-Range Cylinder Drive Gear Cases
John Deere API GL-5 80W90 Gear Lubricant is recommended. If other oils are used, they must meet
requirements of:
API Service Classification GL-5
Military Specification MIL-L-2105B
Military Specification MIL-L-2105C
Depending on the expected prevailing temperature for the fill period, use oil of viscosity as shown in the chart.
-: Fuel, Lubricants, Coolant and Capacities
Product number Description
Size
Quantity delivered
TY6252
80W/90 GL5 Gear Lube 16 kg pail
(35 lb. pail)
TY6296
80W/90 GL5 Gear Lube 0.9 l (1 qt.) can 12
TY6256
80W/140 GL5 Gear Lube 16 kg pail
(35 lb. pail)
TY6345
80W/140 GL5 Gear Lube 0.9 l (1 qt.) can 12
99
1
1
nsmission, Final Drives, Feeder House Reverser, Primary Countershaft, Loading Auger Elevator and Dual-Range Cylinder Drive Gear Ca
Go to Section_10:Group_15
ZX08798,0000646-19-20071212
100
Grease
Grease
TS1667-UN: Grease
Use grease based on NLGI consistency numbers and the expected air temperature range during the service
interval.
The following grease is recommended:
John Deere SD POLYUREA GREASE (TY6341)
Other greases may be used if they meet the following:
NLGI Performance Classification GC-LB
IMPORTANT:
John Deere SD POLYUREA GREASE (TY6341) is the required grease for the feeder house torque sensing
cams.
Some types of grease thickeners are not compatible with others.
If grease fitting is missing, replace immediately. Clean fittings thoroughly before using grease gun.
-: Grease
Product
number
TY6341
Description
Multi-Purpose, High-Temperature, Extreme Pressure Grease, especially effective in rolling
contact applications.
Go to Section_10:Group_15
AG,OUO1035,1175-19-20030206
101
Grease
102
Lubricant Storage
Lubricant Storage
Your equipment can operate at top efficiency only when clean lubricants are used.
Use clean containers to handle all lubricants.
Store lubricants and containers in an area protected from dust, moisture, and other contamination. Store
containers on their side to avoid water and dirt accumulation.
Make certain that all containers are properly marked to identify their contents.
Properly dispose of all old containers and any residual lubricant they may contain.
Go to Section_10:Group_15
DX,LUBST-19-20110411
103
Alternative and Synthetic Lubricants
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require lubricant recommendations different from those printed in
this manual.
Some John Deere brand coolants and lubricants may not be available in your location.
Consult your John Deere dealer to obtain information and recommendations.
Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.
The temperature limits and service intervals shown in this manual apply to both conventional and synthetic
lubricants.
Re-refined base stock products may be used if the finished lubricant meets the performance requirements.
Go to Section_10:Group_15
DX,ALTER-19-20110411
104
Capacities
Capacities
-: Capacities
Fuel tank
800 L (211 U.S. gal)
Cooling system (with heater) (6.8-L engine)
40 L (10.56 U.S. gal)
Cooling system (with heater) (9.0-L engine)
45 L (11.88 U.S. gal)
Engine crankcase with filter (6.8-L engine)
32 L (8.45 U.S. gal)
Engine crankcase with filter (9.0-L engine)
29 L (7.6 U.S. gal)
Transmission
9.6 L (2.53 U.S. gal)
Final drives (each)
8.5 L (2.24 U.S. gal)
Feeder house reverser gearcase
2.0 L (0.5 U.S. gal)
Countershaft drive gearcase
1.2 L (2.53 U.S. pts)
Cylinder drive reduction gear
1.9 L (4.01 U.S. pts.)
Main gearcase
16 L (4.22 U.S. gal)
Hydrostatic/hydraulic oil reservoir
34 L (9.51 U.S. gal)
Tine separator gearcase
2.2 L (0.58 U.S. gal)
Loading auger gearcase on clean grain elevator 3.8 L (1.0 U.S. gal)
Beater gearcase (C Series)
0.6 L (0.16 U.S. gal)
Go to Section_10:Group_15
ZX09263,000272E-19-20080123
105
Table of Contents
Section 20: Engine
Group 05: Remove and Install Engine
Essential and Recommended Special Tools
Specifications
Remove Engine
Install the Engine
Group 10: Lower Engine Repair
Remove and Install Engine Oil Pan Access Sheet (W Series, T Series)
Remove and Install Engine Oil Pan Access Sheet (C Series)
Group 15: Cooling System
Remove and Install Rotary Screen
Remove and Install Rotary Screen Drive
Remove and Install Rotary Screen Idler Arm and Sheaves
Remove and Install Rotary Screen Brush Kit (Optional)
Remove and Install Radiator (W Series, T Series)
Remove and Install Radiator (C Series)
Test Radiator
Test Radiator Cap
Replace Thermostat
Repair or Replace Water Pump
106
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Engine lifting sling.......JDG23
Engine removal and installation
RW18149-UN: Lifting sling
Lifting eye.......JD244
To attach engine sling
H69145-UN: Lifting eye
Go to Section_20:Group_05
ZX09263,0002731-19-20080130
107
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Engine lifting sling.......JDG23
Engine removal and installation
RW18149-UN: Lifting sling
Lifting eye.......JD244
To attach engine sling
H69145-UN: Lifting eye
Go to Section_20:Group_05
ZX09263,0002731-19-20080130
108
Specifications
Specifications
Item
Measurement Specification Item
6068
Weight
Engine
600 kg
(1320 lb)
6090
Weight
Engine
901 kg
(1986 lb)
Engine- Torque
to-Gear
Case
Cap
Screws
340 Nm
(250 lb-ft)
Cooling System (With Heater):
6068
Capacity
Engine
40 L
(10.6 U.S.
gal)
6090
Capacity
Engine
45 L
(11.9 U.S.
gal)
Measurement Specification Item
Radiator Torque, M8
Fan
Screws
Cap
Screws
(6068
Engine)
35 Nm
(26 lb-ft)
Radiator Torque, M10
Fan
Screws
Cap
Screws
(6068
Engine)
70 Nm
(52 lb-ft)
Measurement Specification
Radiator Torque
Fan
Cap
Screws
(6090
Engine)
47 Nm
(35 lb-ft)
Front Engine Mount Cap Screws
(6090 Engine)
Block Torque
Cap
Screws
70 Nm
(50 lb-ft)
Channel Torque
Cap
Screws
70 Nm
(50 lb-ft)
Front Engine Mount Cap Screws
(6068 Engine)
Block Torque
Cap
Screws
205 Nm
(150 lb-ft)
Channel Torque
Cap
Screws
70 Nm
(50 lb-ft)
Rear Engine Mount Cap Screws
(transmission side)
Channel Torque
Cap
Screws
123 Nm
(91 lb-ft)
NOTE:
For further specifications, see relevant CTM for 6068 or 6090 engine.
Go to Section_20:Group_05
ZX09263,00027A5-19-20080303
109
Remove Engine
Remove Engine
1. Disconnect the battery cables.
2. Remove shields as necessary.
3. Drain:
Engine oil
CAUTION:
Coolant may be hot. Wait until radiator is cool before draining coolant.
Engine coolant
4. Shut off fuel supply on bottom of tank.
5. Disconnect:
Radiator and heater hoses
Engine wiring harness
Rotary screen drive belt
Fuel supply and return lines
6. Remove:
Intake duct and air cleaner assembly
Exhaust tube and muffler assembly
Upper and lower air intake lines
Starting motor
NOTE:
DO NOT disconnect refrigerant lines.
Air-conditioning compressor
Alternator
Upper and lower fan shroud, cooling fan and spacer
7.
CAUTION:
The approximate engine weight is 600 kg (1320 lb) (6.8 L engine) or 900 kg (1986
lb) (9.0 L engine).
110
Remove Engine
H67862-UN: Lifting Eye
H67863-UN: Lifting Sling
LEGEND:
A - JDG19 Special Mounting Bracket
B - JDG23 Lifting Sling
Install JDG19 Special Mounting Bracket (A) and JDG23 Lifting Sling (B). Take up slack in lift chains
before removing engine mount cap screws.
8. Remove:
Front engine mounts
Dust cover-to-gear case cap screws
Gear case-to-engine cap screws
9.
CAUTION:
Use extreme care when lifting and NEVER permit any part of the body to be
positioned under a load being lifted or suspended.
Carefully move engine away from gear case. Lift engine out of combine.
10. For repair of the engine, refer to relevant CTM for 6.8 L or 9.0 L engine.
Go to Section_20:Group_05
ZX09263,00027A7-19-20080303
111
Install the Engine
Install the Engine
H67864-UN: Engine Sling
LEGEND:
A - Engine Lifting Sling
CAUTION:
Use extreme care when lifting and NEVER permit any part of the body to be positioned
under a load being lifted or suspended.
1. Carefully lower engine to align with gear case.
2. Installation:
Gear case-to-engine cap screws; then tighten to specification
Item
Measurement Specification
Engine-to-Gear Case Cap Screws Torque
340 N·m
(250 lb.-ft.)
Front engine mount; then tighten to specification
Item
Measurement Specification
Front Engine Mount Cap Screws (6090 Engine)
Block Cap Screws
Torque
90 N·m
(75 lb.-ft.)
Channel Cap Screws Torque
70 N·m
(50 lb.-ft.)
Front Engine Mount Cap Screws (6068 Engine)
Block Cap Screws
Torque
Channel Cap Screws Torque
205 N·m
(150 lb.-ft.)
70 N·m
(50 lb.-ft.)
NOTE:
Remove JDG23 Lifting Sling and JDG19 Special Mounting Brackets from
112
Install the Engine
engine.
Air-conditioning compressor
Cooling fan and spacer; then tighten to specification
Item
Measurement Specification Item
Cooling Fan Cap Torque, M8
Screws (6068
Screws
Engine)
35 N·m
(26 lb.-ft.)
Cooling Fan Cap Torque, M10
Screws (6068
Screws
Engine)
70 N·m
(52 lb.-ft.)
Cooling Fan
Cap Screws
(6090
Engine)
Measurement Specification
Torque
47 N·m
(35 lb.-ft.)
Upper and lower fan shroud
Upper and lower radiator hoses; then tighten clamps to specification
Item
Measurement Specification
Radiator Hose Clamps Torque
4.5 N·m
(40 lb-in.)
Upper and lower air intake lines; then tighten clamps to specification
Item
Measurement Specification
Charge Air Cooler Tube Clamp Torque
11 N·m
(97 lb-in.)
Intake duct and air cleaner assembly
Exhaust tube and muffler assembly
Starting motor
Alternator
Rotary screen drive belt
3. Connect:
Engine wiring harness
Fuel supply and return lines
4. Install engine shields.
5. Fill:
Engine with correct oil (see Fuel, Lubricants, Coolant and Capacities in Section 10, Group 15.)
Cooling system with coolant
Open fuel supply valve on bottom of tank.
IMPORTANT:
The cooling system is only bled properly when coolant escapes from the open bleed opening
(A).
113
Install the Engine
ZX1038772-UN: Bleeding Air from Cooling System
LEGEND:
A - Bleed Opening at EGR Cooler
B - Radiator Drain Cock at Engine Block
6. Connect battery cables.
7. Perform engine start-up procedure.
Go to Section_20:Group_05
ZX09263,00027A6-19-20100805
114
Remove and Install Engine Oil Pan Access Sheet (W Series, T Series)
Remove and Install Engine Oil Pan Access Sheet (W Series, T Series)
ZX1044506-UN: Engine Oil Pan Access Sheet
LEGEND:
A - Access Sheet
IMPORTANT:
Engine oil pan access sheet can be reached by removing walker access cover in grain tank. If additional
clearance is necessary, remove power separator (W series only).
Removing this sheet gives access to the engine oil pan area. The engine does not have to be removed.
1. Remove access sheet (A).
2. Install access sheet (A).
Go to Section_20:Group_10
ZX09263,00027A8-19-20100730
115
Remove and Install Engine Oil Pan Access Sheet (W Series, T Series)
Remove and Install Engine Oil Pan Access Sheet (W Series, T Series)
ZX1044506-UN: Engine Oil Pan Access Sheet
LEGEND:
A - Access Sheet
IMPORTANT:
Engine oil pan access sheet can be reached by removing walker access cover in grain tank. If additional
clearance is necessary, remove power separator (W series only).
Removing this sheet gives access to the engine oil pan area. The engine does not have to be removed.
1. Remove access sheet (A).
2. Install access sheet (A).
Go to Section_20:Group_10
ZX09263,00027A8-19-20100730
116
Remove and Install Engine Oil Pan Access Sheet (C Series)
Remove and Install Engine Oil Pan Access Sheet (C Series)
ZX1044507-UN: Engine Oil Pan Access Sheet
LEGEND:
A - Access Sheet
IMPORTANT:
Engine oil pan access sheet can be reached through the rear of the combine above the tine separator, when
module is in the service position.
Removing this sheet gives access to the engine oil pan area. The engine does not have to be removed.
1. Move tine separator to the service position.
2. Remove access sheet (A).
3. Install access sheet (A).
Go to Section_20:Group_10
ZX09263,00027A9-19-20100730
117
Remove and Install Rotary Screen
Remove and Install Rotary Screen
ZX25346-UN: Rotary Screen
LEGEND:
1 - Flange nut
2 - Cap screw (2 used)
3 - Bracket
4 - Bumper
5 - Flange nut (2 used)
6 - Pin (2 used)
7 - Cap screw (16 used)
8 - Lock washer (16 used)
9 - Decal
10 - Door
11 - Cap screw
12 - Screw (2 used)
13 - Washer
14 - Wiring harness
15 - Lock washer
16 - Hub
17 - Brush
118
Remove and Install Rotary Screen
18 - Screen
19 - Roller bearing
20 - Snap ring
21 - Nut (16 used)
22 - Washer (16 used)
23 - Strap (2 used)
24 - Screw (16 used)
25 - Screen
26 - Hub
27 - Rake
28 - Washer (7 used)
29 - Cap screw (7 used)
30 - Cap screw (3 used)
31 - Washer (3 used)
32 - Rake
33 - Air duct
34 - Bushing
35 - Washer
36 - Cap screw
37 - Flange nut (2 used)
38 - Screen
39 - Decal
Go to Section_20:Group_15
OUO6435,0001536-19-20011018
119
Remove and Install Rotary Screen
Remove and Install Rotary Screen
ZX25346-UN: Rotary Screen
LEGEND:
1 - Flange nut
2 - Cap screw (2 used)
3 - Bracket
4 - Bumper
5 - Flange nut (2 used)
6 - Pin (2 used)
7 - Cap screw (16 used)
8 - Lock washer (16 used)
9 - Decal
10 - Door
11 - Cap screw
12 - Screw (2 used)
13 - Washer
14 - Wiring harness
15 - Lock washer
16 - Hub
17 - Brush
120
Remove and Install Rotary Screen
18 - Screen
19 - Roller bearing
20 - Snap ring
21 - Nut (16 used)
22 - Washer (16 used)
23 - Strap (2 used)
24 - Screw (16 used)
25 - Screen
26 - Hub
27 - Rake
28 - Washer (7 used)
29 - Cap screw (7 used)
30 - Cap screw (3 used)
31 - Washer (3 used)
32 - Rake
33 - Air duct
34 - Bushing
35 - Washer
36 - Cap screw
37 - Flange nut (2 used)
38 - Screen
39 - Decal
Go to Section_20:Group_15
OUO6435,0001536-19-20011018
121
Remove and Install Rotary Screen Drive
Remove and Install Rotary Screen Drive
H66033-UN: Rotary Screen Drive
LEGEND:
1 - Belt
2 - Retaining screw
3 - Washer
4 - Sheave
5 - Sheave
6 - Screw
7 - Nut
8 - Arm
122
Remove and Install Rotary Screen Drive
9 - Hook bolt
10 - Snap ring
11 - Washer
12 - Pin
13 - Guide
14 - Gauge
15 - Spring
16 - Washer
17 - Nut
18 - Locking collar
19 - Flange
20 - Retaining screw
21 - Ball bearing
22 - Flange nut
23 - Support
24 - Sheave
25 - Washer
26 - Retaining screw
27 - Shaft key
28 - Shaft
29 - Shaft key
30 - Spring locking pin
31 - Washer
Go to Section_20:Group_15
OUO6435,000139A-19-20010222
123
Remove and Install Rotary Screen Idler Arm and Sheaves
Remove and Install Rotary Screen Idler Arm and Sheaves
H56011-UN: Idler arm and sheaves
LEGEND:
1 - Spring
2 - Washer
3 - Retaining screw
4 - Arm
5 - Sheave
6 - Washer
7 - Washer
8 - Flange nut
124
Remove and Install Rotary Screen Idler Arm and Sheaves
9 - Sheave
10 - Screw
11 - Screw
12 - Bushing
13 - Belt
14 - Screw
15 - Washer
16 - Seal
17 - Bushing
18 - Support
Go to Section_20:Group_15
AG,OUO6022,1713-19-20000724
125
Remove and Install Rotary Screen Brush Kit (Optional)
Remove and Install Rotary Screen Brush Kit (Optional)
ZX25371-UN: Large Cooling Package Shown
LEGEND:
A - Washer (5 used)
B - Brush (5 used)
C - Spacer
D - Rod
E - Cap screw (2 used)
F - Cap screw (3 used)
G - Nut (3 used)
H - Bracket
Go to Section_20:Group_15
OUO6435,0001945-19-20021015
126
Remove and Install Radiator (W Series, T Series)
Remove and Install Radiator (W Series, T Series)
1.
CAUTION:
Coolant may be hot. Wait until radiator is cool before draining coolant.
Slowly loosen radiator cap.
2.
H67880-UN: Radiator drain cock
H67881-UN: Engine block drain cock
LEGEND:
A - Radiator drain cock
B - Engine block drain cock
127
Remove and Install Radiator (W Series, T Series)
Drain radiator (A) and engine block (B).
3. Remove shields and brackets surrounding radiator.
4. Remove cap screws to remove support.
5.
H67884-UN: Duct Mounting Cap Screws
H67882-UN: Wiring Harness Channel
H67883-UN: Intake duct
LEGEND:
A - Cap screw (4 used)
B - Nut
C - Harness retainer (2 used)
D - Cap screw and nut (2 used)
128
Remove and Install Radiator (W Series, T Series)
E - Cap screw
F - Cap screw and nut (3 used)
G - Clamp
H - Channel
I - Intake duct
Remove cap screws (A).
6. Remove nut (B) and slightly bend harness retainers (C) to allow removal of harness from channel (H).
7. Remove cap screws and nuts (D), cap screws (E) and cap screws and nuts (F) to remove channel (H).
8. Loosen clamp (G) and remove intake duct (I).
9.
H67917-UN: Bracket
LEGEND:
A - Cap screw and nut (2 used)
B - Bracket
Remove cap screws and nuts (A) to remove bracket (B).
10.
H67819-UN: Charge air cooler tubes
129
Remove and Install Radiator (W Series, T Series)
H67895-UN: Clamp
LEGEND:
A - Clamp (4 used)
B - Cap screw and nut
C - Charge air cooler tubes
Loosen clamps (A) and remove cap screw, nut (B) and charge air cooler tubes (C).
11.
H67822-UN: Hose and Shroud Removal
LEGEND:
A - Clamp (4 used)
B - Cap screw
C - Hose (2 used)
D - Cap screw and nut (10 used)
E - Upper fan shroud
Loosen clamps (A) and remove cap screw (B) to remove hoses (C).
12. Remove cap screws, nuts (D) and upper fan shroud (E).
130
Remove and Install Radiator (W Series, T Series)
13.
H67823-UN: Fan Removal
LEGEND:
A - Cap screw (6 used)
B - Radiator fan
C - Spacer
Remove cap screws (A), radiator cooling fan (B) and spacer (C).
14.
H67909-UN: Installing lifting eyes
LEGEND:
A - JDG19 Special Mounting Bracket
B - Strap
C - Lifting Device
Install JDG19 Special Mounting Brackets (A) and strap (B).
15. Using an appropriate lifting device (C), remove the slack from strap (B) applying just enough tension to
support the radiator when the attaching screws are removed.
131
Remove and Install Radiator (W Series, T Series)
16.
H67910-UN: Radiator Mounting
H67911-UN: Radiator Mounting
H67912-UN: Radiator Mounting
LEGEND:
A - Overflow hose
B - Cap screw and nut (2 used)
C - Cap screw (3 used)
D - Cap screw and nut
E - Cap screw
Remove overflow hose (A).
17. Remove cap screws and nuts (B), cap screws (C), cap screw and nut (D) and cap screw (E).
18.
NOTE:
Be careful not to damage fins and/or seals when lifting the radiator from combine.
132
Remove and Install Radiator (W Series, T Series)
H67631-UN: Remove Radiator
Carefully lift radiator from combine.
19. Clean and inspect radiator for damage. Repair or replace radiator as necessary.
20. Inspect seals for damage. Replace as necessary.
21. Install in reverse order and tighten radiator hose clamps to specification.
Item
Measurement Specification
Radiator Hose Clamp Torque
4.5 Nm
(40 lb-in.)
22. Fill radiator with coolant and bleed air from the cooling system.
IMPORTANT:
The cooling system is only bled properly when coolant escapes from the open bleed opening (A).
ZX1038772-UN: Bleeding air from cooling system
LEGEND:
A - Bleed opening at EGR cooler
B - Radiator drain cock at engine block
133
Remove and Install Radiator (W Series, T Series)
Go to Section_20:Group_15
ZX09263,00027AA-19-20080303
134
Remove and Install Radiator (C Series)
Remove and Install Radiator (C Series)
CAUTION:
1.
Coolant may be hot. Wait until radiator is cool before draining coolant.
Slowly loosen radiator cap.
2. IMPORTANT:
The approximate coolant capacity is 40 L (42 qt).
Drain radiator.
Item
Measurement Specification
Cooling system (with heater) Capacity
40 L
(42 qt)
3. Remove shields and brackets surrounding radiator.
4.
H67476-UN: Air flow tube
LEGEND:
A - Air flow tube
Remove three nuts attaching air flow tube (A) to fan shroud and two cap screws attaching air flow tube
to floor.
135
Remove and Install Radiator (C Series)
5.
H67481-UN: Intake Tube
LEGEND:
A - Cap screw (4 used)
Open rotary screen door.
6. Remove cap screws (A) and remove air filter intake tube.
7. Disconnect radiator hoses from radiator.
8.
NOTE:
Charge air cooler lines removed for clarity.
H67515-UN: Shroud
136
Remove and Install Radiator (C Series)
H67633-UN: Shroud
LEGEND:
A - Cap screws (4 used)
B - Cap screws (6 used)
C - Fan shroud
D - Cap screws (6 used)
E - Cap screw (2 used)
F - Fan shroud
G - Bracket
Remove cap screws (A) and (B) and fan shroud (C).
9. Remove cap screws (D) and remove fan.
10. Remove cap screws (E) and fan shroud (F).
11. Remove bracket (G).
12.
H67630-UN: Bracket
LEGEND:
A - Cap screw (2 used)
B - Recovery tank hose
Remove cap screws (A) and recovery tank hose (B).
137
Remove and Install Radiator (C Series)
13.
H67672-UN: Bracket
H67673-UN: Bracket
LEGEND:
A - Cap screw
B - Cap screw (4 used)
Remove screws (A) and (B).
14.
NOTE:
Be careful not to damage fins and/or seals when lifting radiator from frame.
H67631-UN: Lifting
Lift radiator from frame.
15. Clean and inspect radiator for cracks and other damage. Replace as necessary.
16. Inspect seals for damage. Replace as necessary.
138
Remove and Install Radiator (C Series)
17. Install radiator in reverse order using the following special instructions.
18. Install fan using six cap screws. Tighten to specification.
Item
Measurement Specification
Cooling Fan Cap Screws Torque
80 Nm
(60 lb-ft)
19. Fill radiator with coolant and bleed air from the cooling system.
IMPORTANT:
The cooling system is only bled properly when coolant escapes from the open bleed opening (A).
ZX1038772-UN: Bleeding air from cooling system
LEGEND:
A - Bleed opening at EGR cooler
B - Radiator drain cock at engine block
Go to Section_20:Group_15
ZX09263,00027AB-19-20080303
139
Test Radiator
Test Radiator
Remove cap and visually check radiator for leaks or damage.
Attach D05104ST tester in radiator neck. Pressurize radiator according to specifications. Repair radiator if
pressure will not hold.
Item
Measurement Specification
Radiator Pressure
124 kPa
(1.2 bar)
(18 psi)
Go to Section_20:Group_15
AG,OUO6022,1718-19-20000724
140
Test Radiator Cap
Test Radiator Cap
Install D05104ST tester.
Pressurize cap according to specifications. The cap should hold this pressure. Relief should occur close to 69 kPa
(0.7 bar) (10 psi).
Item
Measurement Specification
Radiator cap Pressure
124 kPa
(1.2 bar)
(18 psi)
Go to Section_20:Group_15
AG,OUO6022,1719-19-20000724
141
Replace Thermostat
Replace Thermostat
For replacing thermostat, see relevant CTM for 6068 or 6090 engine.
Go to Section_20:Group_15
ZX09263,00027AC-19-20080303
142
Repair or Replace Water Pump
Repair or Replace Water Pump
For repairing or replacing the water pump, see relevant CTM for 6068 or 6090 engine.
Go to Section_20:Group_15
ZX09263,00027AD-19-20080303
143
Table of Contents
Section 30: Fuel and Air Intake Systems
Group 05: Air Intake System
Remove and Install Charge Air Cooler (W Series, T Series)
Remove and Install Charge Air Cooler (C Series)
Group 10: Diesel Fuel System
Specifications
Remove Fuel Tank
Replace Fuel Filter (6.8-Liter Engine)
Replace Water Separator Filter (6.8-Liter Engine)
Remove and Install Fuel Filters (9.0-Liter Engine)
Clean the Fuel Precleaner (9.0-Liter Engine)
144
Remove and Install Charge Air Cooler (W Series, T Series)
Remove and Install Charge Air Cooler (W Series, T Series)
1.
H67884-UN: Intake Tube
H67882-UN: Wiring Harness
H67883-UN: Fresh Air Tube
LEGEND:
A - Cap Screw (4 used)
B - Nut
C - Harness Retainer (2 used)
D - Cap Screw and Nut (2 used)
E - Cap Screw (2 used)
F - Cap Screw and Nut (3 used)
G - Clamp
H - Channel
I - Intake Duct
145
Remove and Install Charge Air Cooler (W Series, T Series)
Remove covers, shields and supports surrounding charge air cooler.
2. Open rotary screen door. Remove cap screws (A).
3. Remove nut (B).
4. Remove wiring harness from harness retainer (C).
5. Remove cap screws and nuts (D), cap screws (E) and (F) to remove channel (H).
6. Remove clamp (G) to remove intake duct (I).
7. IMPORTANT:
Clean area surrounding charge air cooler tubes to help prevent contamination of system during service.
H67819-UN: Charge Air Cooler Tubes
H67895-UN: Charge Air Cooler Clamps
LEGEND:
A - Clamp (4 used)
B - Cap Screw And Nut
C - Charge Air Cooler Tube (2 used)
Loosen clamps (A) and remove cap screw, nut (B) and charge air cooler tubes (C).
146
Remove and Install Charge Air Cooler (W Series, T Series)
8.
H67917-UN: Channel Bracket
LEGEND:
A - Cap Screw and Nut (2 used)
B - Bracket
Remove cap screws and nuts (A) to remove bracket (B).
9.
CAUTION:
T6642EK-UN: Coolant
Coolant may be hot. Wait until radiator is cool before draining coolant.
147
Remove and Install Charge Air Cooler (W Series, T Series)
H67822-UN: Fan Shroud
LEGEND:
A - Clamp (4 used)
B - Cap Screw
C - Radiator hose (2 used)
D - Cap Screw and Nut (10 used)
E - Upper Fan Shroud
Loosen clamps (A) and remove cap screw (B); then remove radiator hoses (C).
10. Remove cap screws, nuts (D) and upper fan shroud (E).
11.
H67823-UN: Fan
LEGEND:
A - Cap Screw (6 used)
B - Cooling Fan
C - Spacer
Remove cap screws (A), cooling fan (B) and spacer (C).
12.
H67824-UN: Fan Shroud
LEGEND:
A - Cap Screw and Nut (2 used)
B - Lower Fan Shroud
Remove cap screws, nuts (A) and lower fan shroud (B).
148
Remove and Install Charge Air Cooler (W Series, T Series)
13.
H67975-UN: Charge Air Cooler Removal
Connect strap and suitable lifting device to charge air cooler and apply just enough tension to support
charge air cooler before removing attaching screws.
14.
H67632-UN: Charge Air Cooler
H67634-UN: Charge Air Cooler
LEGEND:
A - Cap Screw and Nut (2 used)
B - Cap Screw and Nut (2 used)
Remove cap screws and nuts (A) and (B).
149
Remove and Install Charge Air Cooler (W Series, T Series)
15.
H67655-UN: Rear Of Charge Air Cooler
LEGEND:
A - Cap Screw And Nut
B - Cap Screw and Nut (2 used)
Remove cap screws and nuts (A) and (B).
16.
NOTE:
Be careful not to damage fins and/or seals when lifting the cooler from combine.
H67656-UN: Charge Air Cooler Removal
Lift charge air cooler from combine.
Item
Measurement Specification
Charge Air Cooler Weight
35 kg
(77 lb)
17. Clean and inspect cooler for cracks and other damage. Replace parts as necessary.
18. Inspect seals for damage. Replace parts as necessary.
19.
NOTE:
Be careful not to damage fins and/or seals when installing charge air cooler. Damaged
fins may be repaired using fin straightener JT02072.
Install charge air cooler.
150
Remove and Install Charge Air Cooler (W Series, T Series)
20.
H67655-UN: Rear Of Charge Air Cooler
LEGEND:
A - Cap Screw And Nut
B - Cap Screw and Nut (2 used)
Install cap screws and nuts (A) and (B).
21.
H67632-UN: Charge Air Cooler
H67634-UN: Charge Air Cooler
LEGEND:
A - Cap Screw and Nut (2 used)
B - Cap Screw and Nut (2 used)
151
Remove and Install Charge Air Cooler (W Series, T Series)
Install cap screws and nuts (A) and (B).
22.
H67824-UN: Fan Shroud
LEGEND:
A - Cap Screw and Nut (2 used)
B - Lower Fan Shroud
Install lower fan shroud (B) using cap screws and nuts (A).
23.
H67823-UN: Fan
LEGEND:
A - Cap Screws (6 used)
B - Cooling Fan
C - Spacer
Install spacer (C) and cooling fan (B) using cap screws (A).
152
Remove and Install Charge Air Cooler (W Series, T Series)
24.
H67822-UN: Radiator Hose
LEGEND:
A - Clamp (4 used)
B - Cap Screw
C - Radiator Hose (2 used)
D - Cap Screw and Nut (10 used)
E - Upper Fan Shroud
Install upper fan shroud (E) using cap screws and nuts (D).
25. Install radiator hoses (C) using clamps (A) and cap screw (B). Tighten clamps (A) to specified torque.
Item
Measurement Specification
Radiator Hose Clamp Torque
4.5 Nm
(40 lb-in.)
26.
H67917-UN: Bracket
LEGEND:
A - Cap Screw and Nut (2 used)
B - Bracket
Attach bracket (B) using cap screws and nuts (A).
27. IMPORTANT:
Be certain that tubes are free from dirt and debris before installing to charge air cooler.
153
Remove and Install Charge Air Cooler (W Series, T Series)
H67819-UN: Charge Air Cooler Tubes
H67895-UN: Charge Air Cooler Clamps
LEGEND:
A - Clamp (4 used)
B - Cap Screw And Nut
C - Charge Air Cooler Tube (2 used)
Install charge air cooler tubes (C) using clamps (A) and cap screw and nut (B). Tighten clamps (A) to
specified torque.
Item
Measurement Specification
Charge Air Cooler Tube Clamp Torque
11 Nm
(97.4 lb-in.)
28.
H67884-UN: Intake Tube
154
Remove and Install Charge Air Cooler (W Series, T Series)
H67882-UN: Wiring Harness
H67883-UN: Air Intake Duct
LEGEND:
A - Cap Screws (4 used)
B - Nut
C - Harness Retainer (2 used)
D - Cap Screw and Nut (2 used)
E - Cap Screws (2 used)
F - Cap Screw and Nut (3 used)
G - Clamp
H - Channel
I - Intake Duct
Install air intake duct (I) using clamp (G) and cap screws (A).
29. Attach wiring harness to bottom of channel (H) using harness retainer (C).
30. Install channel (H) using cap screws and nuts (D), cap screws (E), cap screws and nuts (F) and nut (B).
31. Install all covers and shields removed previously.
Go to Section_30:Group_05
ZX09263,00027AE-19-20100714
155
Remove and Install Charge Air Cooler (W Series, T Series)
Remove and Install Charge Air Cooler (W Series, T Series)
1.
H67884-UN: Intake Tube
H67882-UN: Wiring Harness
H67883-UN: Fresh Air Tube
LEGEND:
A - Cap Screw (4 used)
B - Nut
C - Harness Retainer (2 used)
D - Cap Screw and Nut (2 used)
E - Cap Screw (2 used)
F - Cap Screw and Nut (3 used)
G - Clamp
H - Channel
I - Intake Duct
156
Remove and Install Charge Air Cooler (W Series, T Series)
Remove covers, shields and supports surrounding charge air cooler.
2. Open rotary screen door. Remove cap screws (A).
3. Remove nut (B).
4. Remove wiring harness from harness retainer (C).
5. Remove cap screws and nuts (D), cap screws (E) and (F) to remove channel (H).
6. Remove clamp (G) to remove intake duct (I).
7. IMPORTANT:
Clean area surrounding charge air cooler tubes to help prevent contamination of system during service.
H67819-UN: Charge Air Cooler Tubes
H67895-UN: Charge Air Cooler Clamps
LEGEND:
A - Clamp (4 used)
B - Cap Screw And Nut
C - Charge Air Cooler Tube (2 used)
Loosen clamps (A) and remove cap screw, nut (B) and charge air cooler tubes (C).
157
Remove and Install Charge Air Cooler (W Series, T Series)
8.
H67917-UN: Channel Bracket
LEGEND:
A - Cap Screw and Nut (2 used)
B - Bracket
Remove cap screws and nuts (A) to remove bracket (B).
9.
CAUTION:
T6642EK-UN: Coolant
Coolant may be hot. Wait until radiator is cool before draining coolant.
158
Remove and Install Charge Air Cooler (W Series, T Series)
H67822-UN: Fan Shroud
LEGEND:
A - Clamp (4 used)
B - Cap Screw
C - Radiator hose (2 used)
D - Cap Screw and Nut (10 used)
E - Upper Fan Shroud
Loosen clamps (A) and remove cap screw (B); then remove radiator hoses (C).
10. Remove cap screws, nuts (D) and upper fan shroud (E).
11.
H67823-UN: Fan
LEGEND:
A - Cap Screw (6 used)
B - Cooling Fan
C - Spacer
Remove cap screws (A), cooling fan (B) and spacer (C).
12.
H67824-UN: Fan Shroud
LEGEND:
A - Cap Screw and Nut (2 used)
B - Lower Fan Shroud
Remove cap screws, nuts (A) and lower fan shroud (B).
159
Remove and Install Charge Air Cooler (W Series, T Series)
13.
H67975-UN: Charge Air Cooler Removal
Connect strap and suitable lifting device to charge air cooler and apply just enough tension to support
charge air cooler before removing attaching screws.
14.
H67632-UN: Charge Air Cooler
H67634-UN: Charge Air Cooler
LEGEND:
A - Cap Screw and Nut (2 used)
B - Cap Screw and Nut (2 used)
Remove cap screws and nuts (A) and (B).
160
Remove and Install Charge Air Cooler (W Series, T Series)
15.
H67655-UN: Rear Of Charge Air Cooler
LEGEND:
A - Cap Screw And Nut
B - Cap Screw and Nut (2 used)
Remove cap screws and nuts (A) and (B).
16.
NOTE:
Be careful not to damage fins and/or seals when lifting the cooler from combine.
H67656-UN: Charge Air Cooler Removal
Lift charge air cooler from combine.
Item
Measurement Specification
Charge Air Cooler Weight
35 kg
(77 lb)
17. Clean and inspect cooler for cracks and other damage. Replace parts as necessary.
18. Inspect seals for damage. Replace parts as necessary.
19.
NOTE:
Be careful not to damage fins and/or seals when installing charge air cooler. Damaged
fins may be repaired using fin straightener JT02072.
Install charge air cooler.
161
Remove and Install Charge Air Cooler (W Series, T Series)
20.
H67655-UN: Rear Of Charge Air Cooler
LEGEND:
A - Cap Screw And Nut
B - Cap Screw and Nut (2 used)
Install cap screws and nuts (A) and (B).
21.
H67632-UN: Charge Air Cooler
H67634-UN: Charge Air Cooler
LEGEND:
A - Cap Screw and Nut (2 used)
B - Cap Screw and Nut (2 used)
162
Remove and Install Charge Air Cooler (W Series, T Series)
Install cap screws and nuts (A) and (B).
22.
H67824-UN: Fan Shroud
LEGEND:
A - Cap Screw and Nut (2 used)
B - Lower Fan Shroud
Install lower fan shroud (B) using cap screws and nuts (A).
23.
H67823-UN: Fan
LEGEND:
A - Cap Screws (6 used)
B - Cooling Fan
C - Spacer
Install spacer (C) and cooling fan (B) using cap screws (A).
163
Remove and Install Charge Air Cooler (W Series, T Series)
24.
H67822-UN: Radiator Hose
LEGEND:
A - Clamp (4 used)
B - Cap Screw
C - Radiator Hose (2 used)
D - Cap Screw and Nut (10 used)
E - Upper Fan Shroud
Install upper fan shroud (E) using cap screws and nuts (D).
25. Install radiator hoses (C) using clamps (A) and cap screw (B). Tighten clamps (A) to specified torque.
Item
Measurement Specification
Radiator Hose Clamp Torque
4.5 Nm
(40 lb-in.)
26.
H67917-UN: Bracket
LEGEND:
A - Cap Screw and Nut (2 used)
B - Bracket
Attach bracket (B) using cap screws and nuts (A).
27. IMPORTANT:
Be certain that tubes are free from dirt and debris before installing to charge air cooler.
164
Remove and Install Charge Air Cooler (W Series, T Series)
H67819-UN: Charge Air Cooler Tubes
H67895-UN: Charge Air Cooler Clamps
LEGEND:
A - Clamp (4 used)
B - Cap Screw And Nut
C - Charge Air Cooler Tube (2 used)
Install charge air cooler tubes (C) using clamps (A) and cap screw and nut (B). Tighten clamps (A) to
specified torque.
Item
Measurement Specification
Charge Air Cooler Tube Clamp Torque
11 Nm
(97.4 lb-in.)
28.
H67884-UN: Intake Tube
165
Remove and Install Charge Air Cooler (W Series, T Series)
H67882-UN: Wiring Harness
H67883-UN: Air Intake Duct
LEGEND:
A - Cap Screws (4 used)
B - Nut
C - Harness Retainer (2 used)
D - Cap Screw and Nut (2 used)
E - Cap Screws (2 used)
F - Cap Screw and Nut (3 used)
G - Clamp
H - Channel
I - Intake Duct
Install air intake duct (I) using clamp (G) and cap screws (A).
29. Attach wiring harness to bottom of channel (H) using harness retainer (C).
30. Install channel (H) using cap screws and nuts (D), cap screws (E), cap screws and nuts (F) and nut (B).
31. Install all covers and shields removed previously.
Go to Section_30:Group_05
ZX09263,00027AE-19-20100714
166
Remove and Install Charge Air Cooler (C Series)
Remove and Install Charge Air Cooler (C Series)
1.
H67476-UN: Air Flow Tube
LEGEND:
A - Air Flow Tube
Remove covers, shields and supports surrounding charge air cooler.
2. Remove three nuts attaching air flow tube (A) to fan shroud and two cap screws attaching air flow tube
(A) to floor.
3.
H67481-UN: Intake Tube
LEGEND:
A - Cap Screw (4 used)
Open rotary screen door.
4. Remove cap screws (A) and remove fresh air filter intake tube.
167
Remove and Install Charge Air Cooler (C Series)
5.
H67513-UN: Air Intake Lines
LEGEND:
A - Clamp (8 used)
B - Clamp
C - Charge Air Cooler Tube (2 used)
Loosen clamps (A) and remove clamp (B) to remove charge air cooler tubes (C).
6.
H67515-UN: Fan Shroud
H67633-UN: Fan Shroud
LEGEND:
A - Cap Screws (4 used)
B - Cap Screws (6 used)
C - Fan Shroud
D - Cap Screws (6 used)
E - Cap Screw (2 used)
F - Fan Shroud
G - Bracket
168
Remove and Install Charge Air Cooler (C Series)
Remove cap screws (A) and (B) and fan shroud segment (C).
7. Remove cap screws (D) and remove fan.
8. Remove cap screws (E) and fan shroud (F).
9. Remove bracket (G).
10.
H67632-UN: Radiator
H67634-UN: Bracket
LEGEND:
A - Cap Screw (2 used)
B - Cap Screws (2 used)
Remove screws (A) and (B).
169
Remove and Install Charge Air Cooler (C Series)
11.
H67655-UN: Bracket
LEGEND:
A - Cap Screw
B - Cap Screw (2 used)
Remove cap screw (A) and cap screws (B).
12.
NOTE:
Be careful not to damage fins and/or seals when lifting cooler from frame.
H67656-UN: Lifting Charge Air Cooler
Lift charge air cooler from frame.
Item
Measurement Specification
Charge Air Cooler Weight
35 kg
(77 lb.)
13. Clean and inspect cooler for cracks and other damage. Replace as required.
14. Inspect seals for damage. Replace parts as necessary.
15.
NOTE:
Be careful not to damage fins and/or seals when installing charge air cooler. Damaged
fins may be repaired using fin straightener JT02072.
Install charge air cooler in reverse order using the following special instructions.
16. Attach fan using cap screws. Tighten to specified torque.
170
Remove and Install Charge Air Cooler (C Series)
Item
Measurement Specification
Cooling Fan Cap Screws Torque
47 N·m
(35 lb.-ft.)
17. Install charge air cooler tubes using clamps. Tighten to specified torque.
Item
Measurement Specification
Charge Air Cooler Tube Clamp Torque
11 N·m
(8 lb.-ft.)
Go to Section_30:Group_05
ZX09263,00027AF-19-20100714
171
Specifications
Specifications
Item
Measurement Specification
Fuel tank
Capacity
800 L
(211 gal)
Fuel tank
Weight
57 kg
(126 lb)
Diagnostic port
Torque
14 Nm
(10 lb-ft)
High pressure fuel lines Torque
27 Nm
(20 lb-ft)
Go to Section_30:Group_10
OUO6037,000147E-19-20080122
172
Specifications
Specifications
Item
Measurement Specification
Fuel tank
Capacity
800 L
(211 gal)
Fuel tank
Weight
57 kg
(126 lb)
Diagnostic port
Torque
14 Nm
(10 lb-ft)
High pressure fuel lines Torque
27 Nm
(20 lb-ft)
Go to Section_30:Group_10
OUO6037,000147E-19-20080122
173
Remove Fuel Tank
Remove Fuel Tank
ZX25314-UN: Fuel Tank
LEGEND:
1 - Fuel tank
2 - Breather
3 - Clip (2 used)
4 - Hose
5 - Adapter
6 - Filler cap
7 - O-ring
8 - Strainer
174
Remove Fuel Tank
9 - Chain
10 - Ring
11 - Grommet
12 - Fitting
13 - Clamp (2 used)
14 - Fitting
15 - Drain valve
16 - Fitting
17 - Fuel filter
18 - Valve
19 - Fuel sending unit
20 - Hose
21 - Clamp
22 - Cap screw
23 - Seal ring
24 - Seal ring
25 - O-ring (2 used)
26 - Anchor
27 - Cap screw
28 - Hose
NOTE:
Fuel tank configuration will vary depending on model. Removal procedures may be slightly
different.
1.
ZX25129-UN: Fuel Tank
LEGEND:
A - Drain Cock
Drain fuel from tank by opening drain cock (A).
Item
Measurement Specification
Fuel tank Capacity
2.
700 L
(185 gal)
CAUTION:
The approximate weight of engine access door is 46 kg (102 lb).
175
Remove Fuel Tank
NOTE:
Use a suitable lifting device to support engine access door.
Remove engine access door.
3.
ZX25317-UN: Tank Bracket
LEGEND:
A - Tube
B - Door
C - Panel
Remove tube (A), panel (C) and door (B).
4. Disconnect hose from fuel tank breather located under radiator housing.
5.
H67085-UN: Ladder Assembly
LEGEND:
A - Wiring harness
B - Cap screw (2 used)
176
Remove Fuel Tank
C - Light assembly
D - Rear ladder and landing
E - Hinge bolt (2 used)
Remove wiring harness (A) from rear ladder and landing assembly (D).
6. Remove cap screws (B) and light assembly (C).
CAUTION:
7.
The approximate weight of the rear ladder and landing assembly is 102 kg (225
lb). Use appropriate lifting device.
Remove hinge bolts (E) and landing assembly (D).
8.
ZX25130-UN: Brace
LEGEND:
A - Cap screws (2 used)
B - Brace
Remove cap screws (A) and brace (B).
177
Remove Fuel Tank
9.
ZX25319-UN: Fuel Level Sensor Connector
LEGEND:
A - Connector
Disconnect connector (A) from fuel level sensor.
10.
ZX25131-UN: Return Line
LEGEND:
A - Fuel return line
B - Fitting
Disconnect fuel return line (A).
11. Disconnect fuel line at fitting (B).
12.
H67087-UN: Brace
LEGEND:
178
Remove Fuel Tank
A - Cap screw (2 used)
B - Brace
Remove cap screws (A) and brace (B).
13.
H67152-UN: Brace
H67153-UN: Bracket
LEGEND:
A - Flange nut
B - Cap screw
Loosen flange nut (A).
14. Remove cap screw (B).
179
Remove Fuel Tank
15.
ZX25315-UN: Tank Supports
LEGEND:
A - Cap screw
B - Flange nut (3 used)
C - Cap screw (3 used)
D - Fuel tank support
Remove cap screw (A).
16. Remove cap screws (C), flange nuts (B) and fuel tank support (D).
17.
CAUTION:
The approximate weight of fuel tank is 57 kg (126 lb).
Item
Measurement Specification
Fuel tank Weight
57 kg
(126 lb)
Slide fuel tank out right side of combine.
18. Install in reverse order.
Go to Section_30:Group_10
OUO6037,0001463-19-20010730
180
Replace Fuel Filter (6.8-Liter Engine)
Replace Fuel Filter (6.8-Liter Engine)
H69357-UN: Fuel Filter
LEGEND:
A - Ring
B - Filter element
CAUTION:
Always shut off engine, remove key and set park brake before performing maintenance
work on fuel filter.
Unscrew ring (A) and remove filter element (B).
Insert new filter element and retighten ring.
Use the following procedure to bleed the fuel filter:
1. Turn key to the on position so that the fuel transfer pump is operating.
2. Allow 40 seconds for transfer pump to complete priming.
3. Repeat procedure if necessary.
Go to Section_30:Group_10
ZX09263,000272A-19-20080122
181
Replace Water Separator Filter (6.8-Liter Engine)
Replace Water Separator Filter (6.8-Liter Engine)
ZX1031203-UN: Separator Filter
LEGEND:
A - Fuel cock
B - Drain
C - Fuel line
Close cock (A).
Drain fuel from separator at drain (B). Replace filter.
Open cock (A). Let air bleed through drain (B) and fuel line (C).
Go to Section_30:Group_10
ZX09263,000272B-19-20080122
182
Remove and Install Fuel Filters (9.0-Liter Engine)
Remove and Install Fuel Filters (9.0-Liter Engine)
IMPORTANT:
The primary and secondary filters must be changed at the same time.
RG14250-UN: Primary and Secondary Filters
LEGEND:
A - Primary filter head
B - Drain valve on primary filter housing
C - Water-in-fuel-sensor connector
D - Primary filter housing
E - Primary filter element
F - Gasket on primary filter
G - Lip on primary filter housing
H - Lip on primary filter head
I - Secondary fuel filter head
J - Drain valve on secondary filter
K - Secondary fuel filter
L - Gasket on secondary filter
Remove and install the primary fuel filter element
1. Thoroughly clean the primary filter head (A) and surrounding area to keep dirt and debris from getting
into fuel system.
2. On the underside of the filter, connect a fuel-drain line to filter drain valve (B) and drain all the fuel out of
primary filter housing (D).
3. Disconnect connector (C) for water-in-fuel sensor.
4. To remove, turn primary filter housing (D) counter-clockwise.
5. After removing the primary filter housing, remove primary filter element (E) by pulling it out of primary
filter head (A) from below.
6. Examine the surface of the primary filter-head gasket. Clean as required.
183
Remove and Install Fuel Filters (9.0-Liter Engine)
7. IMPORTANT:
Never put fuel in the filter. Doing so allows residue to get into the fuel system.
Put a new gasket on the primary filter housing.
8. Apply some fuel to the primary filter gasket.
9. Insert the primary filter element into the housing so that the lugs fit on the underside of the housing.
10. Screw the housing into the primary filter head (turn it clockwise). Tighten housing lip (G) until it is just
touching the lip (H) on the head, then tighten to 14 N˙m (120 lb-in).
11. Connect connector for water-in-fuel sensor.
Remove and install the secondary fuel filter
RG14250-UN: Primary and Secondary Filters
LEGEND:
A - Primary filter head
B - Drain valve on primary filter housing
C - Water-in-fuel-sensor connector
D - Primary filter housing
E - Primary filter element
F - Gasket on primary filter
G - Lip on primary filter housing
H - Lip on primary filter head
I - Secondary fuel filter head
J - Drain valve on secondary filter
K - Secondary fuel filter
L - Gasket on secondary filter
1. Thoroughly clean filter head (I) and surrounding area to keep dirt and debris from getting into fuel
system.
2. On the underside of the filter, connect a fuel-drain line to filter drain valve (J) and drain all the fuel out of
filter.
184
Remove and Install Fuel Filters (9.0-Liter Engine)
3. To remove, turn filter (K) counter-clockwise.
4. Examine the surface of the secondary filter-head gasket. Clean as required.
5. Install a new fuel filter drain valve and tighten it to 3.4 - 4 N˙m (30 - 35 lb-in).
6. Put a new gasket (L) on the filter.
7. Apply some fuel to the gasket.
8. IMPORTANT:
Never put fuel in the filter. Doing so allows residue to get into the fuel system.
Screw the fuel filter into the filter head. Tighten the fuel filter so that it is tight against secondary filter
head (I).
9. Then tighten it by a further 1/2 to 3/4 turn.
NOTE:
Before starting the engine, turn the ignition key to ON for 60 seconds so that the fuel system can
be primed.
Go to Section_30:Group_10
ZX09263,000272C-19-20080122
185
Clean the Fuel Precleaner (9.0-Liter Engine)
Clean the Fuel Precleaner (9.0-Liter Engine)
H78631-UN: Fuel Precleaner
RG11516-UN: Fuel Precleaner Components
LEGEND:
A - Filter bowl
B - O-ring
Clean the fuel precleaner if deposits appear on the screen in the filter bowl and whenever diagnostic trouble code
A00 1347.07 appears on the corner post display.
NOTE:
Do not clean fuel precleaner and change primary and secondary fuel filters on the engine at the
same time. Doing so will make it more difficult to restart the engine. Perform this procedure, then
run the engine for a time before changing the primary and secondary fuel filters.
1. Start engine and run for 3 to 5 minutes at low idle, if machine has not been in operation previously.
2. Shut off the engine.
3. To prevent fuel running back into the supply line, close the fuel shut-off on the underside of the tank.
4. Thoroughly clean the fuel precleaner assembly and surrounding area.
5. Take off precleaner bowl (A) using a 25 mm (1 in.) socket wrench on the underside of the bowl.
186
Clean the Fuel Precleaner (9.0-Liter Engine)
6. Clean the screen and the bowl. Inspect O-ring (B).
7. Insert the screen and tighten the bowl.
8. Open the fuel shut-off to fill the precleaner bowl.
9. Start engine and run for 3 to 5 minutes at low idle.
Go to Section_30:Group_10
ZX09263,000272D-19-20080122
187
Table of Contents
Section 40: Electrical System
Group 05: Harness and Connector Repair
Essential and Recommended Special Tools
Other Material
Use Electrical Insulating Compound
Connector Repair Procedures
Repair Procedure R-A
Repair Procedure R-B
Repair Procedure R-C
Repair Procedure R-D
Repair Procedure R-E
Repair Procedure R-F
Repair Procedure R-G
Repair Procedure R-I
Repair Procedure R-J
Repair Procedure R-K
Repair Procedure R-M
Repair Procedure R-N
Repair Procedure R-AE
Group 10: Wiring Harness Routings
Cab Main Wiring Harness
Left Main Wiring Harness
Right Main Wiring Harness With GreenStar GreenStar is a trademark of Deere & Company
Engine Wiring Harness
Group 15: Fuses, Circuit Breakers and Relays
Replace Circuit Boards
Group 20: Lights
Safety Rules When Replacing Halogen Bulbs
Replace and Adjust Cab Headlight Bulb
Remove and Install HID-Xenon Light
Replace Auxiliary Field and Access Door Lights
Replace Residue Discharge Light Bulb
188
Table of Contents
Replace Side Finder Light Bulb
Replace Grain Tank and Unloading Auger Light Bulbs
Replace Cleaning Shoe Light Bulb
Replace Turn Signal and Maximum Tilt Indicator Light Bulbs
Replace Dome and Console Light Bulb
Replace Bulbs of CommandTouch CommandTouch is a trademark of Deere & Company.
CornerPost Monitor
Replace Warning Display Panel Bulb
Group 25: Operator's Station
Specifications
Remove and Install Overhead Console
Replace Warning Display Panel Circuit Board
Remove and Install Light Panel Dimmer Switch
Remove and Install Overhead Console Rocker Switches
Remove and Install ClimaTrak ClimaTrak is a trademark of Deere & Company Automatic Air
Conditioning/Heater Temperature Control Switch and Fan Switch
Replace Cornerpost Main Circuit Board
Remove Header Control Module
Remove Automatic Combine Adjustment (ACA) Display
Remove Performance Monitor and Digital Tachometer Module
Remove and Install CommandTouch CommandTouch is a trademark of Deere & Company.
Console
Remove and Install Header and Separator Engage Switches
Remove and Install Switches for DIAL-A-SPEED DIAL-A-SPEED is a trademark of Deere &
Company. and Header Height/Ground Pressure Control
Remove and Install Back Light Bulbs for DIAL-A-SPEED and Header Height/Ground Pressure
Control Switches
Remove and Install CommandTouch CommandTouch is a trademark of Deere & Company.
Console Membrane Switches
Remove and Install CommandTouch CommandTouch is a trademark of Deere & Company.
Console Circuit Board
Replace Neutral Start Switch
Replace Mini Harness
Remove and Install Multifunction Lever
Remove and Install Start Switch
Remove and Install Horn Switch
189
Table of Contents
Remove and Install Mirrors
Remove and Install Mirror Switch
Group 30: Sensors and Switches
Other Material
Shaft Speed Sensor Locations (W Series, T Series, C Series)
Shaft Speed Sensor Locations (W Series, T Series)
Shaft Speed Sensor Locations (C Series)
Remove and Install Sensors for Conveyor Auger, Tailings Elevator, Clean Grain Elevator,
Beater and Separator
Remove and Install Sensors for Cleaning Fan, Cylinder Speed, Beater and Feeder House
Backshaft
Remove and Install Straw Chopper Sensor
Remove and Install Grain Tank Sensor
Remove and Install Tailings Sensor
Remove and Install VisionTrak VisionTrak is a trademark of Deere & Company Sensors
(Shoe/Separator)
Remove and Install Header Height/Ground Pressure Control Sensors (Return to Cut and Tilt)
Remove and Install Coolant Temperature Sensor
Remove and Install Coolant Temperature Sensor
Remove and Install Fuel Level Sensor
Remove and Install Park Brake Switch
Remove and Install Air Filter Restriction Switch
Remove and Install Engine Gear Case Temperature and Pressure Switches
Remove and Install Hydrostatic Charge Pressure Switch
Remove and Install Hydraulic Oil Reservoir Temperature Sensor
Remove and Install Engine Oil Pressure Switch
Remove and Install Service and Cleaning Shoe Light Switch
Remove and Install Chaffer/Sieve Sensor and Adjusting Motor
Group 35: Wiper
Specifications
Remove and Install Wiper Motor
Remove and Install Windshield Washer
Group 40: Alternator
Specifications
190
Table of Contents
Remove and Install Alternator
Group 45: Starter Motor
Specifications
Remove and Install Starting Motor
Remove and Install Starting Motor Relay
Group 50: GreenStar Components
Specifications
Remove and Install GreenStar Mass Flow Sensor
Remove and Install GreenStar Paddle Wheel
Remove and Install GreenStar Moisture Sensor
Remove and Install Position Receiver
191
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Electrical Repair Tool Kit .......JDG155
Used to repair connectors.
RW40022-UN: JDG155 Repair Tool Kit
DEUTSCH ™ Electrical Repair Tool Kit .......JDG359
Used to remove and install DEUTSCH connector
terminals.
T6606AB-UN: JDG359 Repair Tool Kit
Packard Crimping Tool.......JDG783
Used to crimp WEATHER PACK ™ male and female
connectors on 14—20 gauge wires.
H79330-UN: JDG783 Tool
Technician's Electrical Repair Kit.......JT07195B
Used to repair wire connectors.
RW40022-UN: JT07195B Technician's Electrical
Repair Kit
WEATHER PACK Extractor.......JDG364 [ Included in
JT07195B Electrical Repair Kit ]
Repair WEATHER PACK Connectors.
H75562-UN: JDG364 WEATHER PACK Extractor
192
Essential and Recommended Special Tools
Electrician's Pliers.......JDG145 [ Included in JDG155
Electrical Repair Tool Kit ]
Strip insulation from wires.
H75563-UN: JDG145 Electrician's Pliers
12-14 Gauge Extractor.......JDG361 [ Included in
JDG359 Electrical Repair Kit (DEUTSCH) ]
To extract contacts from DEUTSCH connector bodies.
H75578-UN: JDG361 - Extraction Tool
16-18 Gauge Extractor.......JDG362 [ Included in
JDG359 Electrical Repair Kit (DEUTSCH) ]
To extract contacts from DEUTSCH connector bodies.
H75578-UN: JDG362 - Extraction Tool
20 Gauge Extractor.......JDG363 [ Included in JDG359
Electrical Repair Kit (DEUTSCH) ]
To extract contacts from DEUTSCH connector bodies.
H75578-UN: JDG363 - Extraction Tool
Crimper.......JDG360 [ Included in JDG359 Electrical
Repair Kit (DEUTSCH) ]
To crimp closed-barrel contacts.
H75583-UN: JDG360 Crimper
DEUTSCH Terminal Tool.......JDG1383 [ Included in
JDG359 Electrical Repair Kit (DEUTSCH) ]
To remove secondary lock and terminals.
H75625-UN: JDG1383 DEUTSCH Terminal Tool
193
Essential and Recommended Special Tools
Crimping Pliers.......JDG144 [ Included in JDG155
Electrical Repair Tool Kit ]
Used for crimping contacts
H80211-UN: JDG144 - Crimping Pliers
Terminal Extraction Tool.......JDG777 [ Included in
JT07195B Electrical Repair Kit ]
Remove contacts from connectors.
H75627-UN: JDG777 Terminal Extraction Tool
Terminal Extraction Tool.......JDG140 [ Included in
JT07195B Electrical Repair Kit ]
Remove contacts from connectors.
H75633-UN: Extraction tool JDG140
Go to Section_40:Group_05
ZX09263,0002733-19-20080131
194
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Electrical Repair Tool Kit .......JDG155
Used to repair connectors.
RW40022-UN: JDG155 Repair Tool Kit
DEUTSCH ™ Electrical Repair Tool Kit .......JDG359
Used to remove and install DEUTSCH connector
terminals.
T6606AB-UN: JDG359 Repair Tool Kit
Packard Crimping Tool.......JDG783
Used to crimp WEATHER PACK ™ male and female
connectors on 14—20 gauge wires.
H79330-UN: JDG783 Tool
Technician's Electrical Repair Kit.......JT07195B
Used to repair wire connectors.
RW40022-UN: JT07195B Technician's Electrical
Repair Kit
WEATHER PACK Extractor.......JDG364 [ Included in
JT07195B Electrical Repair Kit ]
Repair WEATHER PACK Connectors.
H75562-UN: JDG364 WEATHER PACK Extractor
195
Essential and Recommended Special Tools
Electrician's Pliers.......JDG145 [ Included in JDG155
Electrical Repair Tool Kit ]
Strip insulation from wires.
H75563-UN: JDG145 Electrician's Pliers
12-14 Gauge Extractor.......JDG361 [ Included in
JDG359 Electrical Repair Kit (DEUTSCH) ]
To extract contacts from DEUTSCH connector bodies.
H75578-UN: JDG361 - Extraction Tool
16-18 Gauge Extractor.......JDG362 [ Included in
JDG359 Electrical Repair Kit (DEUTSCH) ]
To extract contacts from DEUTSCH connector bodies.
H75578-UN: JDG362 - Extraction Tool
20 Gauge Extractor.......JDG363 [ Included in JDG359
Electrical Repair Kit (DEUTSCH) ]
To extract contacts from DEUTSCH connector bodies.
H75578-UN: JDG363 - Extraction Tool
Crimper.......JDG360 [ Included in JDG359 Electrical
Repair Kit (DEUTSCH) ]
To crimp closed-barrel contacts.
H75583-UN: JDG360 Crimper
DEUTSCH Terminal Tool.......JDG1383 [ Included in
JDG359 Electrical Repair Kit (DEUTSCH) ]
To remove secondary lock and terminals.
H75625-UN: JDG1383 DEUTSCH Terminal Tool
196
Essential and Recommended Special Tools
Crimping Pliers.......JDG144 [ Included in JDG155
Electrical Repair Tool Kit ]
Used for crimping contacts
H80211-UN: JDG144 - Crimping Pliers
Terminal Extraction Tool.......JDG777 [ Included in
JT07195B Electrical Repair Kit ]
Remove contacts from connectors.
H75627-UN: JDG777 Terminal Extraction Tool
Terminal Extraction Tool.......JDG140 [ Included in
JT07195B Electrical Repair Kit ]
Remove contacts from connectors.
H75633-UN: Extraction tool JDG140
Go to Section_40:Group_05
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197
Other Material
Other Material
Number
Name
Use
TY16329 (US)
(U.S.)
Electrical Contact
Cleaner
Used to prevent contact failure or malfunction by dissolving and rinsing
away contaminants.
AT66865 (US)
(U.S.)
Di-Electric Grease
Used to provide a moisture barrier on electrical connectors
Go to Section_40:Group_05
AG,OUO6038,1684-19-20000321
198
Use Electrical Insulating Compound
Use Electrical Insulating Compound
Apply AT66865 Compound directly to the terminals between the wire seal and connector body. This provides a
moisture barrier, especially in wet and humid conditions.
Go to Section_40:Group_05
OUO6090,000001A-19-20010518
199
Connector Repair Procedures
Connector Repair Procedures
Repair Procedure R-A
This procedure applies to Weather-Pack connectors
Extraction Tool: JDG-364
Crimping Tool: JDG-144 or JDG-707 or JDG-783
Repair Procedure R-B
This procedure applies to Deutsch circular metal and plastic body connectors.
Extraction Tool: JDG363 for 20-24 gauge terminals
Extraction Tool: JDG362 for 16-18 gauge terminals
Extraction Tool: JDG361 for 12-14 gauge terminals
Extraction Tool: JDG-785 for 6-8 gauge terminals
Crimping Tool: JDG-360
Repair Procedure R-C
This procedure applies to Deutsch rectangular plastic body connectors.
Extraction Tool: JDG-363 for 20-24 gauge terminals
Extraction Tool: JDG362 for 16-18 gauge terminals
Extraction Tool: JDG361 for 12-14 gauge terminals
Extraction Tool: JDG-785 for 6-8 gauge terminals
Crimping Tool: JDG-360
Repair Procedure R-D
This procedure applies to Packard "56" series connectors
Extraction Tool: JDG-776
Crimping Tool: JDG-144
Repair Procedure R-E
This procedure applies to Metri-Pack 280 connectors.
Extraction Tool: JDG-777
Crimping Tool: JDG-144
Repair Procedure R-F
This procedure applies to Metri-Pack 150 connectors.
200
Connector Repair Procedures
Extraction Tool: JDG-777
Crimping Tool: JDG-144
Repair Procedure R-G
This procedure applies to Metri-Pack 150 (pull to seat) connectors.
Extraction Tool: JDG-777
Crimping Tool: JDG-144
Repair Procedure R-I
This procedure applies to Metri-Pack 150.2 connectors.
Extraction Tool: JDG-777
Crimping Tool: JDG-144
Repair Procedure R-J
This procedure applies to hazard/marker light connectors.
Extraction Tool: JDG-364
Crimping Tool: JDG-144 or JDG-707 or JDG-783
Repair Procedure R-K
This procedure applies to AMP CPC connectors.
Extraction Tool: JDG-140
Crimping Tool: JDG-144 or JDG-708
Repair Procedure R-M
This procedure applies to Molex connectors (cornerpost, header and separator engage switches).
Extraction Tool: JDG-10205
Crimping Tool: JDG-144 or JDG-707
Repair Procedure R-N
This procedure applies to Eaton rocker switch connectors.
Extraction Tool: JDG-777
Crimping Tool: JDG-144
Repair Procedure R-AE
This procedure applies to armrest harness/cab main harness junction.
201
Connector Repair Procedures
Extraction Tool: JDG-777
Crimping Tool: JDG-144 or JDG-155
Go to Section_40:Group_05
ZX08994,00002BD-19-20050117
202
Repair Procedure R-A
Repair Procedure R-A
Remove Contact From Connector Body
1.
H74026-UN: Female Terminal Sleeve
H74027-UN: Male Terminal Sleeve
LEGEND:
A - Locking tab
B - Locking stud
C - Secondary lock
Open secondary lock (C) by gently prying locking tabs (A) off locking studs (B).
2.
H74028-UN: Female Terminal Sleeve
203
Repair Procedure R-A
H74011-UN: Female Terminal, Sectional View
H74029-UN: Male Terminal Sleeve
204
Repair Procedure R-A
H74012-UN: Male Terminal, Sectional View
LEGEND:
A - JDG364 WEATHER PACK Extractor
B - Locking tabs
C - Mating face
D - Wire entry
Insert JDG364 WEATHER PACK ™ Extractor [ Included in JT07195B Electrical Repair Kit ] (A) into
connector body socket from mating face (C) as shown depressing locking tabs (B) and gently pull
contact out in the direction of arrow.
Install New Contact
1.
H74030-UN: Install Seal
LEGEND:
A - Wire
B - Seal
Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
2. Insert wire (A) through seal (B) and position as shown.
205
Repair Procedure R-A
3.
H74031-UN: Install Contact
H74032-UN: JDG783
H74034-UN: Contact Crimped
LEGEND:
A - Wire and seal
B - Seal crimp
C - Wire crimp
D - Contact
Place wire and seal (A) in contact (D) as shown and crimp both wire (C) and seal (B) using JDG783
Packard Crimping Tool.
4. IMPORTANT:
Make sure contact is fully seated and locked.
206
Repair Procedure R-A
H74033-UN: Insert Contact
Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place.
5.
NOTE:
If secondary lock is difficult to close, contact may not be properly seated or locked.
H74035-UN: Close Lock
LEGEND:
A - Locking stud
B - Locking tab
C - Secondary lock
Close secondary lock (C) until locking tabs (B) securely lock over locking studs (A).
Go to Section_40:Group_05
OUO6030,00001D7-19-20030219
207
Repair Procedure R-B
Repair Procedure R-B
Remove Contact From Connector Body
1. Select correct size extractor tool for size of wire to be removed:
JDG361 Extractor Tool [ Included in JDG359 Electrical Repair Kit (DEUTSCH) ] for 12—14
gauge wires
JDG362 Extractor Tool [ Included in JDG359 Electrical Repair Kit (DEUTSCH) ] for 16—18
gauge wires
JDG363 Extractor Tool [ Included in JDG359 Electrical Repair Kit (DEUTSCH) ] for 20 gauge
wires
2.
H75297-UN: Inserting Tool Into Connector
H75290-UN: Sectional View
208
Repair Procedure R-B
H75296-UN: Pull Wire
LEGEND:
A - Extractor tool
B - Locking tabs
Start correct size extractor tool (A) over wire and slide rearward along wire until tool tip snaps onto wire.
3. IMPORTANT:
Do NOT twist tool when inserting in connector.
Slide extractor tool along wire into connector body until it is positioned over terminal contact and
depressing locking tabs (B).
4. Pull wire out of connector body, using extractor tool.
Install New Contact
1. Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
2.
H75295-UN: Position Crimping Tool
H75294-UN: Insert Contact
209
Repair Procedure R-B
H75293-UN: Crimp
H75292-UN: Crimped Contacts
LEGEND:
A - Selector
B - Lock nut
C - Adjusting screw
D - Contact
E - Cover
F - Wire
Adjust selector (A) on JDG360 Crimper for correct wire size.
3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops.
4. Insert contact (D) and turn adjusting screw (C) until contact is flush with cover (E). Tighten lock nut (B).
5. Insert wire (F) in contact (D) and crimp until handle touches stop.
6. Release handle and remove contact.
7. IMPORTANT:
If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation
procedures.
Inspect contact to be certain all wires are in crimped barrel.
210
Repair Procedure R-B
8.
H75291-UN: Insert Contact
Push contact straight into connector body until positive stop is felt.
9. Pull on wire slightly to be certain contact is locked in place.
Go to Section_40:Group_05
OUO6030,00001D9-19-20030224
211
Repair Procedure R-C
Repair Procedure R-C
Remove Contact From Connector Body
1.
H74116-UN: Male Contact Body
H74117-UN: Female Contact Body
LEGEND:
A - Slot
B - Lock
C - Seal
D - Lock
Remove secondary lock from male contact body by inserting hooked end of JDG1383 Deutsch Terminal
Tool [ Included in JDG359 Deutsch Electrical Repair Tool Kit ] in slot (A) and gently pulling lock (B) from
contact body, or from female contact body by inserting flat end of tool between seal (C) and lock (D) and
gently prying lock from contact body.
2.
212
Repair Procedure R-C
H74118-UN: Male Contact Body
H74013-UN: Male Contact Body, Sectional View
H74119-UN: Female Contact Body
213
Repair Procedure R-C
H74014-UN: Female Contact Body, Sectional View
LEGEND:
A - Locking tab
B - Seal
C - Mating face
Insert JDG1383 Deutsch Terminal Tool [ Included in JDG359 Deutsch Electrical Repair Tool Kit ] into
connector body socket from mating face (C) as shown and lift locking tab (A) and gently pull contact out
through seal (B) in direction of arrow.
Install New Contact
1. Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
2.
H74120-UN: Install Contact
214
Repair Procedure R-C
H74122-UN: Crimp Contact
H74121-UN: Crimped Contacts
LEGEND:
A - Wire
B - Insulation crimp
C - Wire crimp
D - Contact
Place wire (A) in contact (D) as shown and crimp both the wire (C) and insulation (B) using JDG144
Crimping Pliers [ Included in JDG155 Electrical Repair Tool Kit ] .
3. IMPORTANT:
Make sure contact is fully seated and locked.
H74123-UN: Insert Contact
Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place.
4.
NOTE:
If secondary lock is difficult to install, contact
215 may not be properly seated or locked.
Repair Procedure R-C
If secondary lock is difficult to install, contact may not be properly seated or locked.
H74124-UN: Install Lock
H74125-UN: Install Lock
LEGEND:
A - Secondary lock
Install secondary lock (A) and push down until firmly seated.
Go to Section_40:Group_05
OUO6030,00001D8-19-20040204
216
Repair Procedure R-D
Repair Procedure R-D
Remove Contact From Connector Body
1.
H75319-UN: Loosen Contact
H75303-UN: Sectional View
LEGEND:
A - JDG777 Terminal Extraction Tool
B - Locking tab
C - Mating face
Insert JDG777 Terminal Extraction Tool [ Included in JT07195B Electrical Repair Kit ] (A) into connector
body socket from mating face (C) as shown and depress locking tab (B).
2. Gently pull contact out in the direction of arrow.
Install New Contact
1. Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
217
Repair Procedure R-D
2.
H75320-UN: Install Contact
H75321-UN: Contact Crimped
LEGEND:
A - Wire
B - Insulation crimp
C - Wire crimp
D - Contact
Place wire in contact as shown and crimp both the wire (C) and insulation (B) using JDG144 Crimping
Pliers [ Included in JDG155 Electrical Repair Tool Kit ] .
3. IMPORTANT:
Make sure contact is fully seated and locked.
H75322-UN: Insert Contact in Connector Body Socket
Install contact in connector body in appropriate socket. Slide contact in until locking tab clicks into place.
218
Repair Procedure R-D
Go to Section_40:Group_05
OUO6030,00001DA-19-20040204
219
Repair Procedure R-E
Repair Procedure R-E
Remove Contact From Connector Body
1.
H75324-UN: Remove Lock
LEGEND:
A - Secondary lock
B - Locking tabs
C - Locking stud
Remove secondary lock (A) by gently prying locking tabs (B) off locking studs (C).
2.
H75325-UN: Loosen Contact
H75312-UN: Sectional View
LEGEND:
A - JDG777 Terminal Extraction Tool
220
Repair Procedure R-E
B - Locking tab
C - Mating face
Insert JDG777 Terminal Extraction Tool [ Included in JT07195B Electrical Repair Kit ] (A) into connector
body socket from mating face (C) as shown and depress locking tabs (B) and gently pull contact out in
the direction of arrow.
Install New Contact
1.
H75326-UN: Strip Insulation from Wire and Install Seal
LEGEND:
A - Wire
B - Seal
Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
2. Insert wire (A) through seal (B) and position as shown.
3.
H75327-UN: Install Contact
221
Repair Procedure R-E
H75328-UN: Contact Crimped
LEGEND:
A - Seal
B - Seal crimp
C - Wire crimp
D - Contact
Place wire and seal (A) in contact (D) as shown and crimp both wire (C) and seal (B) using JDG144
Crimping Pliers [ Included in JDG155 Electrical Repair Tool Kit ] .
4. IMPORTANT:
Make sure contact is fully seated and locked.
H75329-UN: Install Contact in Connector
Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place.
5.
NOTE:
If secondary lock is difficult to install, contact may not be properly seated or locked.
222
Repair Procedure R-E
H75324-UN: Install Lock
LEGEND:
A - Secondary lock
B - Locking tabs
C - Locking stud
Install secondary lock (A) by aligning with connector body and wires and pushing down until locking tabs
(B) lock on locking studs (C).
Go to Section_40:Group_05
OUO6030,00001DB-19-20030226
223
Repair Procedure R-F
Repair Procedure R-F
Remove Contact From Connector Body
1.
H75333-UN: Remove Lock
LEGEND:
A - Secondary lock
B - Locking tabs
C - Locking stud
Remove secondary lock (A) by gently prying locking tabs (B) off locking studs (C).
2.
H75334-UN: Insert Tool
H75314-UN: Sectional View
LEGEND:
224
Repair Procedure R-F
A - JDG777 Terminal Extraction Tool
B - Locking tab
C - Mating face
Insert JDG777 Terminal Extraction Tool [ Included in JT07195B Electrical Repair Kit ] (A) into connector
body socket from mating face (C) as shown and depress locking tab (B) and gently pull contact out in
the direction of arrow.
Install New Contact
1.
H75335-UN: Strip Insulation from Wire and Install Seal
LEGEND:
A - Wire
B - Seal
Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
2. Insert wire (A) through seal (B) and position as shown.
3.
H75336-UN: Install Contact
225
Repair Procedure R-F
H75337-UN: Contact Crimped
LEGEND:
A - Seal
B - Seal crimp
C - Wire crimp
D - Contact
Place wire and seal (A) in contact (D) as shown and crimp both wire (C) and seal (B) using JDG144
Crimping Pliers [ Included in JDG155 Electrical Repair Tool Kit ] .
4. IMPORTANT:
Make sure contact is fully seated and locked.
H75338-UN: Install Contact in Connector
Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place.
5.
NOTE:
If secondary lock is difficult to install, contact may not be properly seated or locked.
226
Repair Procedure R-F
H75333-UN: Install Lock
LEGEND:
A - Secondary lock
B - Locking tabs
C - Locking stud
Install secondary lock (A) by aligning with connector body and wires and pushing down until locking tabs
(B) lock on locking studs (C).
Go to Section_40:Group_05
OUO6030,00001DC-19-20040204
227
Repair Procedure R-G
Repair Procedure R-G
Remove Contact From Connector Body
1.
H75465-UN: Loosen Contact
H75429-UN: Sectional View
LEGEND:
A - T-pin
B - Locking tab
C - Mating face
Insert a T-pin (A) or other similar device into connector body socket from mating face (C) as shown and
depress locking tab (B).
2. Gently push contact out in the direction of arrow.
Install New Contact
1. Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
228
Repair Procedure R-G
2.
H75466-UN: Install Contact
H75467-UN: Contact Crimped
LEGEND:
A - Wire
B - Insulation crimp
C - Wire crimp
D - Contact
Place wire (A) in contact (D) as shown and crimp both the wire (C) and insulation (B) using JDG144
Crimping Pliers [ Included in JDG155 Electrical Repair Tool Kit ] .
3. IMPORTANT:
Make sure contact is fully seated and locked.
NOTE:
Terminal will seat only one way. If terminal does not pull into the connector body socket,
check to make sure terminal is aligned correctly.
229
Repair Procedure R-G
H75468-UN: Install Contact in Connector
Make sure locking tab on the new contact is in the outward position. Pull on wire until contact locks in
connector body socket.
Go to Section_40:Group_05
OUO6030,00001DD-19-20040204
230
Repair Procedure R-I
Repair Procedure R-I
Remove Contact From Connector Body
1.
H75460-UN: Press Down Locking Tab
H75430-UN: Sectional View
LEGEND:
A - JDG777 Terminal Extraction Tool
B - Locking tab
C - Mating face
Insert JDG777 Terminal Extraction Tool [ Included in JT07195B Electrical Repair Kit ] (A) into connector
body socket from mating face (C) as shown and depress locking tab (B).
2. Gently push contact out in the direction of arrow.
Install New Contact
231
Repair Procedure R-I
1.
H75461-UN: Install Contact
H75462-UN: Contact Crimped
LEGEND:
A - Wire
B - Insulation crimp
C - Wire crimp
D - Contact
Remove contact and strip wire using JDG145 Electrician’s Pliers
2. Place wire in contact as shown and crimp both the wire (C) and insulation (B) using JDG144 Crimping
Pliers [ Included in JDG155 Electrical Repair Tool Kit ] .
3. IMPORTANT:
Make sure contact is fully seated and locked.
NOTE:
Terminal will seat only one way. If terminal does not pull into the connector body socket,
check to make sure terminal is aligned correctly.
232
Repair Procedure R-I
H75463-UN: Install Contact in Connector
Make sure locking tab on the new contact is in the outward position. Pull on wire until contact locks in
connector body socket.
Go to Section_40:Group_05
OUO6030,00001DE-19-20040204
233
Repair Procedure R-J
Repair Procedure R-J
Remove Contact From Connector Body
1.
H73987-UN: Remove Lock
LEGEND:
A - Secondary lock
B - Locking tabs
C - Locking stud
Remove secondary lock (A) by gently prying locking tabs (B) off locking studs (C).
2.
H73988-UN: Placement of Extraction Tool for Small Contact
H73972-UN: Sectional View of Small Contact
234
Repair Procedure R-J
H73989-UN: Placement of Extraction Tool for Large Contact
H73971-UN: Sectional View of Large Contact
LEGEND:
A - Locking tab
B - Wire entry
C - Mating face
Insert JDG777 Terminal Extraction Tool [ Included in JT07195B Electrical Repair Kit ] into connector
body socket from mating face (C) as shown and depress locking tab (A) and gently pull contact out in
the direction of arrow.
Install New Contact
1.
235
Repair Procedure R-J
H73990-UN: Large Contact Seal
H73991-UN: Small Contact Seal
LEGEND:
A - Wire
B - Seal
Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
2. Insert wire (A) through seal (B) and position as shown.
3.
H73992-UN: Large Contact
H73994-UN: Large Contact
236
Repair Procedure R-J
H73993-UN: Small Contact
H73995-UN: Small Contact
LEGEND:
A - Wire and seal
B - Seal crimp
C - Wire crimp
D - Contact
Place wire and seal (A) in contact (D) as shown and crimp both wire (C) and seal (B) using JDG144
Crimping Pliers [ Included in JDG155 Electrical Repair Tool Kit ] .
4. IMPORTANT:
Make sure contact is fully seated and locked.
H73996-UN: Large Contact
237
Repair Procedure R-J
H73997-UN: Small Contact
Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place.
5.
NOTE:
If secondary lock is difficult to install, contact may not be properly seated or locked.
H73998-UN: Install Lock
LEGEND:
A - Secondary lock
B - Locking tabs
C - Locking stud
Install secondary lock (A) by aligning with connector body and wires and pushing down until locking tabs
(B) lock on locking studs (C).
Go to Section_40:Group_05
OUO6030,00001CD-19-20040204
238
Repair Procedure R-K
Repair Procedure R-K
Remove Contact From Connector Body
1.
H73956-UN: Insert JDG140
H73955-UN: Depress Plunger
H73953-UN: Sectional View
LEGEND:
A - Extraction tool JDG140 [ Included in JT07195B Electrical Repair Kit ]
B - Plunger
C - Locking tabs
Insert JDG140 Terminal Extraction Tool [ Included in JT07195B Electrical Repair Kit ] (A) in connector
body over contact to depress locking tabs (C).
239
Repair Procedure R-K
2. While holding extraction tool firmly in place, depress plunger (B) and pull contact out of connector body
socket.
Install New Contact
1. Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
2.
H73957-UN: Install Contact
H73958-UN: Crimp Contact
H73981-UN: Correctly Crimped Contact
LEGEND:
A - Wire
B - Insulation crimp
C - Wire crimp
240
Repair Procedure R-K
D - Contact
Place wire (A) in contact (D) and crimp both wire (C) and insulation (B) using JDG783 PACKARD
Crimping Tool.
3. IMPORTANT:
Make sure contact is fully seated and locked.
H73982-UN: Install Contact
Install contact in connector body in appropriate socket. Slide contact in until locking tabs click into place.
Go to Section_40:Group_05
OUO6030,00001CC-19-20021030
241
Repair Procedure R-M
Repair Procedure R-M
Remove Contact From Connector Body
1.
H73857-UN: Slide-Type Lock
H73858-UN: Door-Type Lock
LEGEND:
A - Slide-Type Lock
B - Teeth
C - Door-Type Lock
Unlock slide-type secondary lock (A) by disengaging teeth (B) and sliding lock in direction of arrow, or
door-type secondary lock by opening door (C).
2.
H73879-UN: Open Lock
242
Repair Procedure R-M
H73765-UN: Lock
LEGEND:
A - Locking tab
B - Secondary lock
C - Wire entry
D - Mating face
Insert JDG777 Terminal Extraction Tool [ Included in JT07195B Electrical Repair Kit ] into connector
body socket from mating face (D) as shown, depress locking tab (A) and gently pull terminal out past
secondary lock in direction of arrow.
Install New Contact
1. Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
2.
H73921-UN: Install Contact
243
Repair Procedure R-M
H73922-UN: Crimp Contact
H73983-UN: Correctly Crimped Contact
LEGEND:
A - Wire
B - Insulation crimp
C - Wire crimp
D - Contact
Place wire (A) in contact (D) as shown and crimp both the wire (C) and insulation (B) using JDG144
Crimping Pliers [ Included in JDG155 Electrical Repair Tool Kit ] .
3. IMPORTANT:
Make sure contact is fully seated and locked.
H73978-UN: Install Contact
Install contact in connector body in appropriate socket. Slide contact in until lock clicks into place.
4.
NOTE:
If secondary lock is difficult to close, contact
244 may not be properly seated or locked.
Repair Procedure R-M
If secondary lock is difficult to close, contact may not be properly seated or locked.
H73977-UN: Close Lock
H73858-UN: Door-Type Lock
Firmly push slide-type secondary lock (A) in direction of arrow. Teeth will hold it in locked position.
Engage door-type secondary lock (C) by closing door until it locks in place.
Go to Section_40:Group_05
OUO6030,00001CB-19-20040204
245
Repair Procedure R-N
Repair Procedure R-N
Remove Contact From Connector Body
1.
H75453-UN: Lock
H75454-UN: Lock
LEGEND:
A - Secondary lock door
B - Locking tabs
C - Locking stud
Open secondary lock doors (A) by gently prying locking tabs (B) off locking studs (C).
2.
H75455-UN: Loosen Contact
246
Repair Procedure R-N
H75431-UN: Sectional View
LEGEND:
A - JDG777 Terminal Extraction Tool
B - Locking tab
C - Mating face
Insert JDG777 Terminal Extraction Tool [ Included in JT07195B Electrical Repair Kit ] (A) into connector
body socket from mating face (C) as shown and depress locking tab (B) and gently pull contact out in
the direction of arrow.
Install New Contact
1. Remove contact and strip wire using JDG145 Electrician’s Pliers [ Included in JDG155 Electrical Repair
Tool Kit ] .
2.
H75456-UN: Install Contact
247
Repair Procedure R-N
H75457-UN: Contact Crimped
LEGEND:
A - Wire
B - Insulation crimp
C - Wire crimp
D - Contact
Place wire in contact as shown and crimp both the wire (C) and insulation (B) using JDG144 Crimping
Pliers [ Included in JDG155 Electrical Repair Tool Kit ] .
3. IMPORTANT:
Make sure contact is fully seated and locked.
H75458-UN: Install Contact in Connector
Install contact in connector body in appropriate socket. Slide contact in until locking tab clicks into place.
4.
NOTE:
If secondary lock door is difficult to close, contact may not be properly seated or locked.
248
Repair Procedure R-N
H75454-UN: Close Secondary Lock Door
LEGEND:
A - Secondary lock door
B - Locking tabs
C - Locking stud
Close secondary lock door (A) until locking tabs (B) securely lock over locking studs (C).
Go to Section_40:Group_05
OUO6030,00001DF-19-20040204
249
Repair Procedure R-AE
Repair Procedure R-AE
1.
RXA0070459-UN: CINCH Connector
RXA0070462-UN: CINCH Cover Locking Tabs
RXA0070463-UN: CINCH Cover
LEGEND:
A - Tab
B - Locking cam
C - Cover locks
D - Cover
Press tab (A) and rotate locking cam (B) 90° to disconnect connector from flexbox.
2. Move cover locks (C) slightly outward with a small screwdriver.
3. Remove cover (D) away from wires.
250
Repair Procedure R-AE
4.
RXA0070464-UN: Terminal Lock
LEGEND:
A - Terminal Lock
Pull terminal lock (A) out as far as it will go, but do not force its removal.
5.
NOTE:
JDG1725 Terminal Extractor Tool has two different sizes of pins, 0.6 for smaller 20
gauge holes (A), and 1.5 for larger 16 and 18 gauge holes (B).
RXA0070471-UN: Connector Holes
RXA0070472-UN: CINCH Connector Terminal Holes
251
Repair Procedure R-AE
RXA0070473-UN: CINCH Terminal Extraction Tool
LEGEND:
A - 20 gauge holes
B - 16 and 18 gauge holes
C - Holes
D - Terminal hole
E - Terminal
Insert JDG1725 Terminal Extractor Tool into holes (C) next to terminal hole (D) to unlock terminal (E).
6. Pull wire and terminal (E) from connector body.
7.
RXA0070479-UN: Crimp Terminal
RXA0070480-UN: Terminal Crimping Tool
252
Repair Procedure R-AE
RXA0070481-UN: Terminal Crimping Tool
LEGEND:
A - CINCH Terminal Crimping Tool
B - Terminal Receptacle
C - Terminal
D - Wire
Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.
8. Grip JDG1727 Terminal Crimping Tool (A) securely and squeeze ratcheting mechanism until it bottoms
out. Then allow it to open completely.
9. With tool in ready position (open handle), open terminal receptacle (B).
10. Insert terminal (C) into proper wire gauge window, crimp wings facing up.
11. Close terminal receptacle (B).
12. Squeeze handle until two clicks are heard.
13. Insert stripped wire (D) into terminal.
14. Hold wire stationary and squeeze tool together until ratchet releases.
15. Remove wire with terminal from tool.
16. Push terminal into connector body until fully seated. Pull on wire slightly to ensure terminal is locked in
position.
17. Close terminal lock.
18. Install cover.
19. Install connector to control unit and close connector body locking cam.
Go to Section_40:Group_05
OUO6083,0000802-19-20040526
253
Cab Main Wiring Harness
Cab Main Wiring Harness
H67968-UN: Cab Main Wiring Harness
Go to Section_40:Group_10
AG,OUO6435,492-19-20000503
254
Cab Main Wiring Harness
Cab Main Wiring Harness
H67968-UN: Cab Main Wiring Harness
Go to Section_40:Group_10
AG,OUO6435,492-19-20000503
255
Left Main Wiring Harness
Left Main Wiring Harness
ZX25286-UN: Left Main Wiring Harness
Go to Section_40:Group_10
OUO6037,000145C-19-20010723
256
Right Main Wiring Harness With GreenStar ™
Right Main Wiring Harness With GreenStar ™
ZX25287-UN: Right Main Wiring Harness With GreenStar
Go to Section_40:Group_10
OUO6037,000145F-19-20010723
257
Engine Wiring Harness
Engine Wiring Harness
ZX25288-UN: Engine Wiring Harness
Go to Section_40:Group_10
OUO6037,000145B-19-20010723
258
Replace Circuit Boards
Replace Circuit Boards
1.
NOTE:
Removal is the same for all circuit boards in the Central Electronics Box (CEB). To
eliminate damage from static electricity, keep all new replacement boards in their
protective packaging until ready to install.
IMPORTANT:
Handle a circuit board with care. Hold it by its edges when installing. It is fragile and expensive. Use
grounding strap during installation of circuit board.
ZX25138-UN: Remove Cover
LEGEND:
A - Cap screw (6 used)
Open access door and brush out any dust.
2. Remove cap screws (A) to remove Central Electronics Box cover.
3.
NOTE:
Mark locations of wiring harness connectors for re-installation into correct position.
259
Replace Circuit Boards
ZX25245-UN: Connectors
LEGEND:
A - Connectors
B - Cap Screws
C - Latches
Disconnect wiring harness connectors (A) by depressing lock release with a flat tip screwdriver.
4. Loosen cap screws (B) and disconnect remaining connectors.
5. Release latches (C). Remove Central Electronics Box to access selected circuit board.
6.
H67370-UN: Locking Clips
LEGEND:
A - Locking Clips
Squeeze locking clips (A) on circuit board and slide board from mounting bracket.
7. Install circuit board in reverse order.
NOTE:
Ensure pins on all connectors are properly seated prior to installation.
Go to Section_40:Group_15
OUO6037,0001414-19-20010611
260
Replace Circuit Boards
Replace Circuit Boards
1.
NOTE:
Removal is the same for all circuit boards in the Central Electronics Box (CEB). To
eliminate damage from static electricity, keep all new replacement boards in their
protective packaging until ready to install.
IMPORTANT:
Handle a circuit board with care. Hold it by its edges when installing. It is fragile and expensive. Use
grounding strap during installation of circuit board.
ZX25138-UN: Remove Cover
LEGEND:
A - Cap screw (6 used)
Open access door and brush out any dust.
2. Remove cap screws (A) to remove Central Electronics Box cover.
3.
NOTE:
Mark locations of wiring harness connectors for re-installation into correct position.
261
Replace Circuit Boards
ZX25245-UN: Connectors
LEGEND:
A - Connectors
B - Cap Screws
C - Latches
Disconnect wiring harness connectors (A) by depressing lock release with a flat tip screwdriver.
4. Loosen cap screws (B) and disconnect remaining connectors.
5. Release latches (C). Remove Central Electronics Box to access selected circuit board.
6.
H67370-UN: Locking Clips
LEGEND:
A - Locking Clips
Squeeze locking clips (A) on circuit board and slide board from mounting bracket.
7. Install circuit board in reverse order.
NOTE:
Ensure pins on all connectors are properly seated prior to installation.
Go to Section_40:Group_15
OUO6037,0001414-19-20010611
262
Safety Rules When Replacing Halogen Bulbs
Safety Rules When Replacing Halogen Bulbs
H39474-UN: Halogen Bulb
LEGEND:
A - Halogen Bulb
CAUTION:
Halogen bulbs (A) contain gas under pressure. Handling a bulb improperly could cause it
to shatter into flying fragments. To avoid possible injury:
1. Turn off the light switch and allow the bulb to cool before changing bulbs. Leave
the switch off until bulb change is complete.
2. Wear eye protection when changing a halogen bulb.
3. Handle the bulb by its base. Avoid touching the glass.
4. Do not drop or scratch the bulb. Keep moisture away.
5. Place used bulb in the new bulb's carton and dispose of properly. Keep out of
reach of children.
Go to Section_40:Group_20
AG,OUO6030,231-19-19990602
263
Safety Rules When Replacing Halogen Bulbs
Safety Rules When Replacing Halogen Bulbs
H39474-UN: Halogen Bulb
LEGEND:
A - Halogen Bulb
CAUTION:
Halogen bulbs (A) contain gas under pressure. Handling a bulb improperly could cause it
to shatter into flying fragments. To avoid possible injury:
1. Turn off the light switch and allow the bulb to cool before changing bulbs. Leave
the switch off until bulb change is complete.
2. Wear eye protection when changing a halogen bulb.
3. Handle the bulb by its base. Avoid touching the glass.
4. Do not drop or scratch the bulb. Keep moisture away.
5. Place used bulb in the new bulb's carton and dispose of properly. Keep out of
reach of children.
Go to Section_40:Group_20
AG,OUO6030,231-19-19990602
264
Replace and Adjust Cab Headlight Bulb
Replace and Adjust Cab Headlight Bulb
H39475-UN: Cab Headlight Bulb
LEGEND:
A - Screw (3 used)
B - Headlight
C - Lead
D - Retaining ring
IMPORTANT:
Overtightening the screws until they bottom out can break the headlight.
NOTE:
The two center headlights use infrared bulbs, the other ones use halogen bulbs.
1. Unscrew three screws (A) and remove headlight (B).
2. Disconnect wiring lead (C). Clean dirt from headlight.
3. Push in and twist retaining ring (D) counterclockwise. Bulb pulls straight out.
4. When reinstalling headlight, adjust as follows:
Start with the two end screws first, then the bottom screw last. Adjust the screws until all three tabs are
flush with the panel.
Go to Section_40:Group_20
AG,OUO6030,232-19-20030206
265
Remove and Install HID-Xenon Light
Remove and Install HID-Xenon Light
CAUTION:
Avoid serious injury or death from electric shock or lamp explosion. This lamp is powered
by 25,000 volts. Do not begin installation of HID-Xenon lights unless the lights are turned
off, the engine is shut off, the key is removed, and appropriate eye protection is worn.
H73136-UN: Cab Lights
LEGEND:
A - HID-Xenon Lights (2 used)
HID-Xenon lights (A) are located in the second and fifth hole in the cab light panel.
1.
H74153-UN: Adjusting Screws
LEGEND:
A - Adjusting Screws (3 used)
Remove adjusting screws (A).
266
Remove and Install HID-Xenon Light
2.
H71388-UN: Rubber Boot
H73137-UN: Light Connector
LEGEND:
A - Rubber Boot
C - Ballast Wiring Harness Connector
Remove and store springs and screws from light assembly.
3. Pull down rubber boot (A) to access connector (C).
4. Disconnect ballast wiring harness connector (C) from light by turning counterclockwise.
5. IMPORTANT:
To prevent damage to ballast, assembly must be mounted to plastic boss located on the cab roof. If
assembly is attached directly to metal portion of cab or chassis, the ballast will be damaged.
NOTE:
Ballast assembly should be installed with wiring connector pointing towards the rear of
the machine.
267
Remove and Install HID-Xenon Light
H74156-UN: Ballast Assembly
LEGEND:
A - Harness connector
B - Cap screws
Disconnect harness connector (A) and remove cap screws (B). Remove ballast assembly from cab.
6. Repair or replace parts as necessary.
7. Install ballast and light in reverse order using the following special instructions:
For the initial adjustment of the light, top surface of the adjusting screws should be flush with
flat surface of the cab light panel. Continue adjustment until desired position is achieved.
Go to Section_40:Group_20
ZX08994,00002AE-19-20041203
268
Replace Auxiliary Field and Access Door Lights
Replace Auxiliary Field and Access Door Lights
1.
H57676-UN: Side Access Work Lights and Auxiliary Field Lights
H57677-UN: Side Access Work Lights and Auxiliary Field Lights
LEGEND:
A - Screw
B - Bulb Retainer
C - Connector
D - Bulb
Remove screw (A) and bulb retainer (B).
2. Disconnect connector (C).
3. Turn bulb (D) counterclockwise and remove.
4. Install bulb in reverse order.
Go to Section_40:Group_20
AG,OUO6435,500-19-20000503
269
Replace Residue Discharge Light Bulb
Replace Residue Discharge Light Bulb
1.
H57678-UN: Discharge Light No. 1
H57679-UN: Discharge Light No. 2
LEGEND:
A - Bulb
B - Housing
C - Leads
Remove bulb (A) from housing (B).
2. Disconnect wiring leads (C).
3. Install bulb in reverse order.
Go to Section_40:Group_20
AG,OUO6030,234-19-20030206
270
Replace Side Finder Light Bulb
Replace Side Finder Light Bulb
H57680-UN: Side Finder Light Bulb
LEGEND:
A - Harness Lead
B - Retaining Ring
CAUTION:
Read SAFETY WHEN REPLACING HALOGEN BULBS.
1. Disconnect harness lead (A) and clean dirt from light.
2. Push in and twist retaining ring (B) counterclockwise. Bulb pulls straight out.
Go to Section_40:Group_20
AG,OUO6030,235-19-20030206
271
Replace Grain Tank and Unloading Auger Light Bulbs
Replace Grain Tank and Unloading Auger Light Bulbs
1.
H51670-UN: Grain Tank and Unloading Auger Light Bulb
LEGEND:
A - Connector
B - Housing
C - Leads
Disconnect connector (A).
2. Remove bulb from housing (B).
3. Disconnect wiring leads (C).
4. Install bulb in reverse order.
Go to Section_40:Group_20
AG,OUO6030,236-19-20030206
272
Replace Cleaning Shoe Light Bulb
Replace Cleaning Shoe Light Bulb
H57686-UN: Cleaning shoe
LEGEND:
A - Harness Lead
B - Retaining Ring
1. Disconnect harness lead (A) and clean dirt from light.
2. Push in and twist retaining ring (B) counterclockwise. Bulb pulls straight out.
Go to Section_40:Group_20
OUO6435,0001912-19-20020919
273
Replace Turn Signal and Maximum Tilt Indicator Light Bulbs
Replace Turn Signal and Maximum Tilt Indicator Light Bulbs
NOTE:
Bulb replacement for maximum tilt indicator applies only to machines equipped with the
HillMaster II option.
H65622-UN: Indicator
LEGEND:
A - Steering Column Cover
B - Bulb Socket
1. Tilt steering column toward operator’s seat.
2. Remove four screws and remove steering column cover (A).
3. Pull out bulb socket (B). Bulb pulls straight out.
4. Check wiring harness connections before installing cover.
Go to Section_40:Group_20
OUO6037,0001442-19-20010717
274
Replace Dome and Console Light Bulb
Replace Dome and Console Light Bulb
1.
H51673-UN: Dome and Console Lights
LEGEND:
A - Dome Light
B - Console Light
Remove lens cover by pressing sides of cover.
2. Replace bulb (A) or (B).
3. Replace lens cover by snapping in place.
Go to Section_40:Group_20
AG,OUO6030,242-19-20030206
275
Replace Bulbs of CommandTouch ™ CornerPost Monitor
Replace Bulbs of CommandTouch ™ CornerPost Monitor
1. Determine which bulb is defective.
H51571-UN: CommandTouch ™
H51572-UN: CommandTouch ™ Nr. 1
H51573-UN: CommandTouch ™ Nr. 2
LEGEND:
A - Screw (4 used)
B - CommandTouch ™ Monitor
C - Bulb
D - Circuit Board
E - Connector (2 used)
F - Ribbon Connector (3 used)
G - Screw (8 used)
2. Disconnect wiring harness connector from back of GreenStar ™ display and mapping sensor if
equipped.
276
Replace Bulbs of CommandTouch ™ CornerPost Monitor
3. Remove two cap screws from back of mapping sensor. Remove GreenStar ™ display if equipped.
4. Remove mounting screws (A), bracket and monitor (B).
5. Remove defective bulb (C).
6. IMPORTANT:
Always handle electronic cards/components by edges to prevent damage.
NOTE:
Connector bodies are keyed for proper contact mating. Be sure contacts are in proper
alignment.
NOTE:
If defective bulb is located under circuit board (D), disconnect two connectors (E),
carefully remove three ribbon connectors (F) and eight screws (G). Move circuit board
for access to additional light bulbs.
Remove defective bulb by turning counterclockwise.
7. Install bulb.
8. Install monitor.
9. Install GreenStar ™ display if previously removed.
10. Install wiring harness.
Go to Section_40:Group_20
AG,OUO6022,1797-19-20000724
277
Replace Warning Display Panel Bulb
Replace Warning Display Panel Bulb
1.
H67443-UN: Warning Display Panel
H51562-UN: Warning Display Panel
H65677-UN: Control Panel
LEGEND:
A - Screw (6 used)
B - Screw (6 used)
C - Screw (6 used)
Remove six screws (A) attaching warning display panel and lower panel.
2. IMPORTANT:
Always handle electronic cards/components by edges to prevent damage.
Remove screws (B) attaching circuit board to panel.
3. Remove screws (C) attaching bulb holder.
278
Replace Warning Display Panel Bulb
4. Remove defective bulb by pulling straight out.
5. Replace bulb in reverse order.
Go to Section_40:Group_20
AG,OUO6435,510-19-20000503
279
Specifications
Specifications
Item
Measurement Specification
Multifunction lever installation
Multifunction Lever Shoulder Bolts Torque
6 N˙m
(53 lb-in.)
Go to Section_40:Group_25
OUO6037,000147F-19-20010821
280
Specifications
Specifications
Item
Measurement Specification
Multifunction lever installation
Multifunction Lever Shoulder Bolts Torque
6 N˙m
(53 lb-in.)
Go to Section_40:Group_25
OUO6037,000147F-19-20010821
281
Remove and Install Overhead Console
Remove and Install Overhead Console
1.
H51561-UN: Overhead Display Console
H54504-UN: Overhead Display Panel
LEGEND:
A - Screw (6 used)
B - Connector (2 used)
C - Screw (2 used)
Loosen screws (A) and lower panel until cables are exposed.
2. Disconnect connectors (B) from circuit board.
3. Disconnect harness from all switches and radio.
4. Disconnect antenna from radio.
5. Remove screws (C) from support cables. Remove warning display panel.
6. Remove radio, all switches and circuit board.
7. Install radio, all switches and circuit board.
8. Connect support cables.
9. Connect antenna and harness.
10. Install new warning display panel.
11. Install console.
282
Remove and Install Overhead Console
Go to Section_40:Group_25
AG,OUO6030,256-19-20030206
283
Replace Warning Display Panel Circuit Board
Replace Warning Display Panel Circuit Board
H51712-UN: Warning Display Panel Circuit Board
LEGEND:
A - Circuit Board
IMPORTANT:
Always handle electronic cards/components by edges to prevent damage.
NOTE:
The warning display panel is used in several different applications. For proper operation, the CAL
switches must be set to match the application.
Set calibration switches prior to starting the combine (refer to Warning Display Panel Diagnostics
in Diagnosis and Tests manual, Section 240).
1. Remove circuit board (A) (see Replace Warning Display Panel Bulb in Group 20).
2. Install circuit board in reverse order.
Go to Section_40:Group_25
AG,OUO6435,517-19-20000503
284
Remove and Install Light Panel Dimmer Switch
Remove and Install Light Panel Dimmer Switch
1. Remove screws (A) and lower overhead panel.
H66186-UN: Warning Display Panel
H51577-UN: Light Panel Dimmer Switch
LEGEND:
A - Screw (6 used)
B - Connector
C - Switch
2. Disconnect connector (B).
3. Depress four clips and remove switch (C) and bracket from rear of panel.
4. Remove switch (C) from bracket.
5. Install switch.
6. Connect connector.
7. Install overhead panel.
Go to Section_40:Group_25
AG,OUO6022,1552-19-20000503
285
Remove and Install Overhead Console Rocker Switches
Remove and Install Overhead Console Rocker Switches
1.
NOTE:
Procedure for removal and installation is similar for all switches.
Remove screws (A) attaching warning display panel.
H66186-UN: Warning Display Panel
H51576-UN: Air-Conditioning Switch
LEGEND:
A - Screw (6 used)
B - Connector
C - Switch
2. Disconnect connector (B).
3. Depress clips on switch (C) and remove from front of control panel.
4. Install switch.
5. Connect connector.
6. Install overhead panel.
Go to Section_40:Group_25
AG,OUO6022,1553-19-20000503
286
Remove and Install ClimaTrak ™ Automatic Air Conditioning/Heater Temperature Control Switch and Fan Switch
Remove and Install ClimaTrak ™ Automatic Air Conditioning/Heater Temperature Control
Switch and Fan Switch
1.
H51574-UN: ClimaTrak ™ control
H51575-UN: Air Conditioning Control Switches #1
LEGEND:
A - Screw (6 used)
B - Control Knobs
C - Connectors
D - Lock Nut and Switch
Remove screws (A) attaching warning display panel.
2. Remove control knobs (B).
3. Disconnect connectors (C).
4. Remove lock nut and switch (D) from rear of control panel.
5. Install switch.
6. Connect connectors.
7. Install control knobs (B).
8. Install overhead panel.
Go to Section_40:Group_25
AG,OUO6030,259-19-20030206
287
Replace Cornerpost Main Circuit Board
Replace Cornerpost Main Circuit Board
1. IMPORTANT:
Prior to removing old cornerpost, enter diagnostics mode and record values in C03 addresses working
backwards from 133 through 100. These values will be needed when programming new cornerpost.
NOTE:
Keep hardware for reinstallation of components.
H61993-UN: Cornerpost Screws
LEGEND:
A - Self Tapping Screw (4 used)
Remove four screws (A).
2.
H62017-UN: GreenStar
288
Replace Cornerpost Main Circuit Board
H62018-UN: GreenStar
H62019-UN: GreenStar
LEGEND:
A - Wiring Harness Connectors
B - M10 Cap Screw (2 used)
C - Self Tapping Screw (4 used)
If equipped with GreenStar: Disconnect wiring harness connectors (A).
3. Remove two M10 cap screws (B) and monitor.
4. Remove four self-tapping screws (C) and monitor bracket from cornerpost.
5. Pull out at bottom and pull down on cornerpost.
6.
H70523-UN: Circuit Board
LEGEND:
A - Wiring Harness Connector (4 used)
B - Ribbon Connector (4 used)
C - Screw (8 used)
D - Main Circuit Board
Disconnect wiring harness connectors (A). (Harness removed for clarity on photo.)
7. Remove ribbon connectors (B), screws (C) and main circuit board (D).
8. Install main circuit board (D) and retain with screws (C).
9. Attach ribbon connectors (B) and wiring harness connectors (A).
289
Replace Cornerpost Main Circuit Board
10.
H66428-UN: Cornerpost
LEGEND:
A - Cornerpost
B - Self Tapping Screw (4 used)
Reinstall cornerpost (A) and retain using four self-tapping screws (B).
11. IMPORTANT:
Addresses 125 and 129 must be entered before address 124. After five hours of operation, addresses
125 and 129 will be locked.
Enter diagnostic mode and select cornerpost control unit (C03). Enter the values recorded from the old
cornerpost working down from address 133 to address 100.
12. If equipped with GreenStar: Install cornerpost and retain with two self-tapping screws in bottom two
holes only.
13.
H62017-UN: GreenStar
290
Replace Cornerpost Main Circuit Board
H62018-UN: GreenStar
H62019-UN: GreenStar
LEGEND:
A - Wiring Harness Connectors
B - M10 Cap Screw (2 used)
C - Self Tapping Screw (2 used)
If equipped with GreenStar: Attach mounting bracket to cornerpost using two self-tapping screws (C) in
top two holes.
14. Attach monitor to mounting bracket using two M10 cap screws (B).
15. Attach wiring harness connectors (A) to monitor.
Go to Section_40:Group_25
OUO6083,00003AE-19-20020920
291
Remove Header Control Module
Remove Header Control Module
IMPORTANT:
If you need to replace cornerpost display, the following steps need to be performed:
Record all data in C03 addresses 100 to 129.
Replace cornerpost main circuit board and input data for addresses 129 to 100.
If procedure is not followed and the engine hours exceed 5 hours, then the cornerpost board will not allow any
inputs and the board will be ruined.
1. Remove cornerpost and main circuit board (see procedure in this Group).
2.
H51580-UN: Cornerpost Header Control Module
LEGEND:
A - Ribbon Connector (2 used)
B - Screw (6 used)
C - Circuit Board
Remove ribbon connectors (A) and screws (B) from header control module circuit board (C).
3. Remove circuit board (C) and header control module.
4. Install header control module in reverse order.
Go to Section_40:Group_25
AG,OUO6435,525-19-20000503
292
Remove Automatic Combine Adjustment (ACA) Display
Remove Automatic Combine Adjustment (ACA) Display
1.
H70524-UN: Automatic Combine Adjustment Display
LEGEND:
A - Ribbon Connector
B - Screw (4 used)
C - Circuit Board of Automatic Combine Adjustment Display
Disconnect ribbon connectors (A) and screws (B) from module circuit board (C).
2. Remove circuit board (C) and ACA display module.
3. Install ACA display module in reverse order.
Go to Section_40:Group_25
ZX08994,00002AF-19-20041203
293
Remove Performance Monitor and Digital Tachometer Module
Remove Performance Monitor and Digital Tachometer Module
1. IMPORTANT:
If you need to replace cornerpost display, the following steps need to be performed:
Record all data in C03 addresses 100 to 129.
Replace cornerpost main circuit board and input data for addresses 129 to 100.
If procedure is not followed and the engine hours exceed 5 hours, then the cornerpost board will not
allow any inputs and the board will be ruined.
NOTE:
For installation of performance monitor (C) and digital tachometer (D), reverse removal
procedure.
H51581-UN: Performance Monitor and Digital Tachometer Module
LEGEND:
A - Ribbon Connector
B - Screw (6 used)
C - Performance Monitor
D - Digital Tachometer
Remove cornerpost and main circuit board (see procedure in this Group).
2. Remove ribbon connector (A) and screws (B) from circuit board of performance monitor (C).
3. Remove performance monitor (C) and digital tachometer (D).
4. Install in reverse order.
Go to Section_40:Group_25
AG,OUO6435,526-19-20000503
294
Remove and Install CommandTouch ™ Console
Remove and Install CommandTouch ™ Console
1. IMPORTANT:
Always handle electronic cards/components by edges to prevent damage.
NOTE:
Connector bodies are keyed for proper contact mating. Be sure contacts are in proper
alignment.
Remove screws (A).
H54311-UN: CommandTouch ™ Console
H70765-UN: CommandTouch ™ Console
H54313-UN: CommandTouch ™ Console
LEGEND:
A - Screw (3 used)
295
Remove and Install CommandTouch ™ Console
B - Linkage
C - Screw
D - Wiring Harness
2. Remove nut and disconnect linkage (B).
3. Take out screw (C).
4. IMPORTANT:
When lifting top console assembly, reach back between console base and top console assembly and
pull harness upwards to create enough slack to aid in lifting top console assembly. Pulling harness up by
the top assembly can damage harness connectors and/or console circuit board.
Disconnect three connectors from wiring harness (D) and remove console.
5. Connect harness.
6. IMPORTANT:
When reassembling top console, reach under base of console and pull excess harness out through
bottom. Make sure top console assembly is properly aligned with console base while lowering into place.
Forcing top console assembly down may cause circuit board damage.
Install console.
7. Connect linkage.
Go to Section_40:Group_25
OUO6435,000191B-19-20020924
296
Remove and Install Header and Separator Engage Switches
Remove and Install Header and Separator Engage Switches
1. Lift switches (A) up far enough to depress two clips on each side and remove from socket. Switches
should hang outside socket.
H70762-UN: Header/Separator Engage Switches
H51538-UN: Connectors To Header And Separator Engage Switches
LEGEND:
A - Switches
B - Connectors
2. Remove console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
3. Note position and remove connectors (B) from circuit board. Remove switches through top of console.
4. Install switches and connect connectors in same position as removed.
5. Install console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
Go to Section_40:Group_25
OUO6435,000191C-19-20020924
297
Remove and Install Switches for DIAL-A-SPEED ™ and Header Height/Ground Pressure Control
Remove and Install Switches for DIAL-A-SPEED ™ and Header Height/Ground Pressure
Control
1. Remove console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
H51528-UN: CommandTouch ™ Console
H70757-UN: CommandTouch ™ Console DIAL-A-SPEED, ™ Header Height and Ground Pressure Control
H51527-UN: CommandTouch ™ Console, Dial-A-Speed, Header Height and Ground Pressure Control
Switches
LEGEND:
A - Screw (3 used)
B - Cover
C - Knob
D - Connector
E - Switch
2. Remove three screws (A) and cover (B) from right side (bottom) of console.
298
Remove and Install Switches for DIAL-A-SPEED ™ and Header Height/Ground Pressure Control
3. Remove knobs (C) from top of switch.
4. Remove nut and washer from top of switch.
5. Disconnect connector (D) and remove switch (E).
6. Install switch.
7. Install console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
Go to Section_40:Group_25
OUO6435,000191D-19-20020924
299
Remove and Install Back Light Bulbs for DIAL-A-SPEED and Header Height/Ground Pressure Control Switches
Remove and Install Back Light Bulbs for DIAL-A-SPEED and Header Height/Ground
Pressure Control Switches
1.
H51528-UN: COMMANDTOUCH Console Bottom Cover
H51529-UN: Background Light Bulb DIAL-A-SPEED
LEGEND:
A - Screw (3 used)
B - Cover
C - Socket
D - Bulb
Remove screws (A) and cover (B).
2. Remove bulb (D) from socket (C).
3. Install bulb.
Go to Section_40:Group_25
OUO6435,00014E1-19-20010925
300
Remove and Install CommandTouch ™ Console Membrane Switches
Remove and Install CommandTouch ™ Console Membrane Switches
1.
H70761-UN: CommandTouch ™ Console Graphic Label
H70759-UN: Armrest Bezel
H70758-UN: Armrest Rubber Key Pad
LEGEND:
A - Main Graphic Label
B - Screw (8 used)
C - Bezel
D - Rubber Key Pad
E - Plastic Cover
Remove console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
2. Remove DIAL-A-SPEED ™ and header height/ground pressure control knobs. See REMOVE AND
INSTALL SWITCHES FOR DIAL-A-SPEED ™ AND HEADER HEIGHT/GROUND PRESSURE
CONTROL in this Group.
301
Remove and Install CommandTouch ™ Console Membrane Switches
3. Remove header/separator engage switches. See REMOVE AND INSTALL HEADER AND
SEPARATOR ENGAGE SWITCHES in this Group.
4. Peel main graphic label (A) from bezel and discard.
5. Remove screws (B) and bezel (C).
6. Remove rubber key pad (D).
NOTE:
Switches not used have brown plastic covers (E). Note locations for reinstallation.
7.
H64424-UN: Multifunction Lever
LEGEND:
A - Cap screw (3 used)
B - Multifunction Lever Wiring Harness
C - Multifunction Lever
Remove three cap screws (A) and disconnect multifunction lever wiring harness connector (B) from
circuit board.
8. Move multifunction lever (C) to access circuit board.
9.
H64425-UN: Circuit Board
LEGEND:
302
Remove and Install CommandTouch ™ Console Membrane Switches
A - Screw (6 used)
B - Ribbon Connectors
C - Circuit Board
Remove six screws (A) and disconnect ribbon connectors (B).
10. Move circuit board assembly (C) to access ground connector.
11.
H64426-UN: Armrest
LEGEND:
A - Ground Connector
Disconnect ground connector (A).
12.
H70760-UN: Membrane Switch
LEGEND:
A - Membrane Switch
Remove membrane switch assembly.
13. Install new membrane switch assembly and route ribbon connector to back of console.
303
Remove and Install CommandTouch ™ Console Membrane Switches
14.
H64426-UN: Armrest
LEGEND:
A - Ground Connector
Attach ground connector (A) from membrane switch to wiring harness connector.
15.
H64425-UN: Circuit Board
LEGEND:
A - Screw (6 used)
B - Ribbon Connectors
C - Circuit Board
Reinstall circuit board (C) and retain with screws (A).
16. Attach ribbon connectors (B) to circuit board.
17.
NOTE:
Make sure multifunction lever wiring harness is correctly positioned (as shown) and
retained with clamp.
304
Remove and Install CommandTouch ™ Console Membrane Switches
H64424-UN: Multifunction Lever
LEGEND:
A - Cap screw (3 used)
B - Multifunction Lever Wiring Harness
C - Multifunction Lever
Reposition multifunction lever assembly (C) onto circuit board and retain with cap screws (A).
18. Attach multifunction lever wiring harness connector (B) to circuit board connector.
19.
H70764-UN: Armrest
H70763-UN: Armrest
LEGEND:
A - Rubber Key Pad
B - Plastic Cover
C - Bezel
305
Remove and Install CommandTouch ™ Console Membrane Switches
D - Screw (8 used)
Install rubber key pad (A) and plastic covers (B).
20. Install bezel (C) and retain with screws (D).
21.
H70761-UN: Armrest
LEGEND:
A - Main Graphic Label
Install new graphic label (A).
22. Install header and separator engage switches. See REMOVE AND INSTALL HEADER AND
SEPARATOR ENGAGE SWITCHES in this Group.
23. Install DIAL-A-SPEED ™ and header height/ground pressure switches. See REMOVE AND INSTALL
SWITCHES FORDIAL-A-SPEED AND HEADER HEIGHT/GROUND PRESSURE CONTROL in this
Group.
24. Install console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
Go to Section_40:Group_25
OUO6435,000191E-19-20020924
306
Remove and Install CommandTouch ™ Console Circuit Board
Remove and Install CommandTouch ™ Console Circuit Board
1. IMPORTANT:
Always handle electronic cards/components by edges to help prevent damage.
Remove console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
H51549-UN: CommandTouch ™ Circuit Board
LEGEND:
A - Screw (3 used)
B - Screw (5 used)
C - Circuit Board
2. Disconnect all connectors from circuit board.
3. Remove cap screws (A) from multifunction lever mounting bracket.
4. Remove screws (B) and circuit board (C) from console.
5. Carefully install circuit board.
6. Install multifunction lever.
7. Connect all connectors to circuit board.
8. Install console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
Go to Section_40:Group_25
AG,OUO6022,1569-19-20000503
307
Replace Neutral Start Switch
Replace Neutral Start Switch
1. IMPORTANT:
Always handle electronic cards/components by edges to help prevent damage.
Remove console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
H51552-UN: CommandTouch ™ Circuit Board
H51553-UN: Neutral Start Switch
LEGEND:
A - Circuit Board
B - Screw (3 used)
C - Screw (5 used)
D - Screw (2 used)
E - Neutral Start Switch
2. Disconnect all connectors from circuit board (A).
3. Remove screws (B) at multifunction lever mounting bracket and screws (C). Carefully remove circuit
board.
4. Remove screws (D). Disconnect connector and remove switch (E).
5. Install switch.
6. Install circuit board and multifunction lever.
7. Connect all connectors to circuit board.
8. Install console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
308
Replace Neutral Start Switch
Go to Section_40:Group_25
AG,OUO6022,1570-19-20000503
309
Replace Mini Harness
Replace Mini Harness
1. IMPORTANT:
Always handle electronic cards/components by edges to help prevent damage.
H51528-UN: CommandTouch ™ Console
H51529-UN: Backlight of Switches for Dial-A-Speed, Header Height and Ground Pressure Control
H51550-UN: CommandTouch ™ Cigarette Lighter Console
310
Replace Mini Harness
H51551-UN: Mini Harness
LEGEND:
A - Screw (3 used)
B - Cover
C - Socket (2 used)
D - Bulb (2 used)
E - Lead
F - Screw (3 used)
G - Screw (5 used)
H - Circuit Board
I - Sockets
J - Mini Harness
Remove console.
2. Remove screws (A) and cover (B).
3. Remove two sockets (C) from bottom cover and two light bulbs (D).
4. Disconnect wire leads (E) from cigarette lighter.
5. Disconnect all connectors from circuit board.
6. Remove three cap screws (F) from multifunction lever mounting bracket and screws (G) from circuit
board (H). Carefully remove circuit board.
7. Remove sockets and bulbs (I).
8. Disconnect remaining connectors and remove harness (J).
9. Install harness.
10. Install bulbs.
11. Install circuit board and multifunction lever.
12. Connect all connectors to circuit board.
13. Install cigarette lighter.
14. Install cover.
15. Install console.
311
Replace Mini Harness
Go to Section_40:Group_25
OUO6435,00014E3-19-20010925
312
Remove and Install Multifunction Lever
Remove and Install Multifunction Lever
1. Remove console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
H51554-UN: Multifunction Lever
H64405-UN: Multifunction Lever
LEGEND:
A - Connector
B - J-Clamp
C - Shoulder Bolt (2 used)
D - Spring
E - Arm
F - Multifunction Lever
2. Disconnect connector (A) from circuit board.
3. Remove J-clamp (B).
4. Remove shoulder bolts (C) and spring (D) from arm (E).
5. Remove multifunction lever (F) from top of console.
6. Install multifunction lever through top of console.
7. Apply TY43513 Thread Lock and Sealer to shoulder bolts (C); then install shoulder bolts and attach
spring (D) to arm (E). Tighten to specifications.
313
Remove and Install Multifunction Lever
Item
Measurement Specification
Multifunction Lever Installation
Multifunction Lever Shoulder Bolts Torque
6 N˙m
(53 lb-in.)
8. Install harness correctly using J-clamp (B).
9. Connect connector (A) to circuit board.
10. Install console. See REMOVE AND INSTALL COMMANDTOUCH ™ CONSOLE in this Group.
Go to Section_40:Group_25
OUO6435,00014BA-19-20021120
314
Remove and Install Start Switch
Remove and Install Start Switch
H65605-UN: Start Switch
H65445-UN: Wiring Diagram
LEGEND:
A - Cover
B - Connector
C - Lock Nut
D - Switch
E - Wire
1. Remove four screws and cover (A).
2. Unplug connector (B) and single wire (E) from switch, making certain to identify each connector for
installation on new switch.
3. Remove lock nut (C) and switch (D).
4. Install switch.
NOTE:
A new switch will use the same key as the old one. This key also works for the door lock.
315
Remove and Install Start Switch
Go to Section_40:Group_25
AG,OUO6022,1573-19-20010112
316
Remove and Install Horn Switch
Remove and Install Horn Switch
1.
H41333-UN: Steering Column
H51558-UN: Horn Switch
LEGEND:
A - Cover
B - Cap
C - Horn Switch
D - Connector
Remove four screws and cover (A).
2. Remove cap (B) from switch (C).
3. Remove horn switch (C). Switch cannot be repaired. A defective switch must be replaced.
4. Disconnect wiring lead at connector (D).
5. Install switch.
6. Connect connector.
7. Install cover.
Go to Section_40:Group_25
AG,OUO6030,262-19-20030206
317
Remove and Install Mirrors
Remove and Install Mirrors
1.
H66195-UN: Mirrors
LEGEND:
A - Connector
B - Cap screw (2 used)
C - Mounting Post
Disconnect connector (A) from mirror
2. Loosen screws (B).
3. Slide mirror off mounting post (C).
4. Inspect mirror, replace as necessary.
5. Slide mirror onto mounting post (C).
6. Tighten cap screws (B).
7. Connect connector (A).
Go to Section_40:Group_25
OUO1073,0001394-19-20010207
318
Remove and Install Mirror Switch
Remove and Install Mirror Switch
1.
H66186-UN: Panel
LEGEND:
A - Screw (6 used)
Remove screws (A) attaching warning display panel.
2.
H66196-UN: Switch
LEGEND:
A - Connector
B - Switch
Disconnect connector (A) from switch (B).
3. Press in clips on sides of switch (B) and remove by pushing through front of overhead panel.
4. Install switch (B) into overhead panel.
5. Connect connector (A).
319
Remove and Install Mirror Switch
6.
H66186-UN: Panel
LEGEND:
A - Screw (6 used)
Install overhead panel and screws (A).
Go to Section_40:Group_25
OUO1073,0001395-19-20010207
320
Other Material
Other Material
Number
Name
Use
TY9375 (U.S.) TEFLON Pipe Sealant Seal threads to prevent escape of liquids or gases.
Go to Section_40:Group_30
AG,OUO6022,1662-19-20000713
321
Other Material
Other Material
Number
Name
Use
TY9375 (U.S.) TEFLON Pipe Sealant Seal threads to prevent escape of liquids or gases.
Go to Section_40:Group_30
AG,OUO6022,1662-19-20000713
322
Shaft Speed Sensor Locations (W Series, T Series, C Series)
Shaft Speed Sensor Locations (W Series, T Series, C Series)
ZX1038774-UN: Right Side
LEGEND:
A - Cleaning Fan
B - Cylinder Speed
C - Feeder House Backshaft
D - Beater (T series only)
Go to Section_40:Group_30
ZX09263,00027B1-19-20080303
323
Shaft Speed Sensor Locations (W Series, T Series)
Shaft Speed Sensor Locations (W Series, T Series)
ZX1038773-UN: Left Side
LEGEND:
A - Tailings Elevator
B - Conveyor Auger
C - Clean Grain Elevator
D - Straw Chopper
E - Separator
F - Power Separator
G - Beater (T series only)
Go to Section_40:Group_30
ZX09263,00027B0-19-20080303
324
Shaft Speed Sensor Locations (C Series)
Shaft Speed Sensor Locations (C Series)
H59147-UN: Left Side
LEGEND:
A - Tailings Elevator
B - Conveyor Auger
C - Clean Grain Elevator
D - Straw Chopper
E - Separator
Go to Section_40:Group_30
ZX09263,00027B2-19-20080303
325
Remove and Install Sensors for Conveyor Auger, Tailings Elevator, Clean Grain Elevator, Beater and Separator
Remove and Install Sensors for Conveyor Auger, Tailings Elevator, Clean Grain Elevator,
Beater and Separator
1.
NOTE:
The following procedure applies to the sensors for conveyor auger, tailings elevator,
clean grain elevator, beater (T series only, right-hand side) and separator.
H57780-UN: Separator Sensor
LEGEND:
A - Connector
B - Screw (2 used)
C - Screw (2 used)
Remove debris buildup and disconnect connector (A).
2. Remove screws (B) and sensor.
3. Remove two screws (C) and magnet.
4. Reinstall sensor.
5. Connect connector (A).
Go to Section_40:Group_30
ZX09263,00027B3-19-20080303
326
Remove and Install Sensors for Cleaning Fan, Cylinder Speed, Beater and Feeder House Backshaft
Remove and Install Sensors for Cleaning Fan, Cylinder Speed, Beater and Feeder House
Backshaft
1.
NOTE:
The following steps also apply to sensors for cleaning fan, cylinder speed, beater (T
series, left-hand side) and feeder house backshaft speed.
H57781-UN: Feeder House Backshaft Speed Sensor
LEGEND:
A - Connector
B - Sensor
C - Tone Wheel
Disconnect connector (A).
2. Turn sensor (B) counterclockwise and remove.
3. Reinstall sensor. Turn sensor clockwise until it contacts tone wheel (C). Back sensor off 1/2 turn
counterclockwise.
4. Connect connector (A).
Go to Section_40:Group_30
ZX09263,00027B4-19-20080303
327
Remove and Install Straw Chopper Sensor
Remove and Install Straw Chopper Sensor
1.
ZX25271-UN: Sensor
ZX25270-UN: Collar
LEGEND:
A - Connector
B - Screw (2 used)
C - Screw (2 used)
Disconnect sensor harness at connector (A).
2. Remove screws (B) and sensor from bracket.
3. Remove screws (C) from magnetic collar.
4. Install collar using screws (C).
5. Install sensor to bracket using screws (B).
6. Connect sensor harness connector (A).
Go to Section_40:Group_30
OUO6037,0001443-19-20010718
328
Remove and Install Grain Tank Sensor
Remove and Install Grain Tank Sensor
1.
H57692-UN: Grain Tank Sensor
LEGEND:
A - Connector
B - Sensor
Disconnect connector (A).
2. Remove attaching hardware.
3. Remove sensor (B).
4. Install sensor.
Go to Section_40:Group_30
AG,OUO6030,300-19-20030206
329
Remove and Install Tailings Sensor
Remove and Install Tailings Sensor
CAUTION:
1.
Disconnect harness connectors before servicing tailings sensor(s).
NOTE:
There are two sensors located on the tailings elevator. Inside sensor is the master and
outside is the slave.
H57693-UN: Tailings Sensor
LEGEND:
A - Connector (2 used)
B - Spring
C - Sensor (2 used)
Disconnect harness connectors (A) from each sensor.
2. Remove spring (B).
3. Remove sensors (C).
4. Install sensors.
5. Install sensor by aligning tabs on sensor with holes in elevator. Install retaining spring.
Go to Section_40:Group_30
AG,OUO6030,301-19-20030206
330
Remove and Install VisionTrak ™ Sensors (Shoe/Separator)
Remove and Install VisionTrak ™ Sensors (Shoe/Separator)
1.
H57694-UN: VisionTrak ™
LEGEND:
A - Connector
B - Screw (4 used)
C - Sensor
Disconnect connector (A).
2. Remove screws (B) and sensor (C).
3. Install sensor.
Go to Section_40:Group_30
AG,OUO6030,303-19-20030206
331
Remove and Install Header Height/Ground Pressure Control Sensors (Return to Cut and Tilt)
Remove and Install Header Height/Ground Pressure Control Sensors (Return to Cut and
Tilt)
1.
H54216-UN: Right-Hand Feeder House Shield
H54217-UN: HeaderTrak Tilt Sensor
H54763-UN: HeaderTrak Return to Cut Sensor
LEGEND:
A - Shield
B - Clip
C - Connector
D - Sensor
Remove shield (A) as necessary.
2. Remove attaching hardware and clip (B).
3. Disconnect connector (C).
332
Remove and Install Header Height/Ground Pressure Control Sensors (Return to Cut and Tilt)
4. Remove attaching hardware and sensor (D).
5.
H54218-UN: HeaderTrak Sensor
H54219-UN: HeaderTrak Sensor Mounting
LEGEND:
A - Key
B - Notch
Align key (A) with notch (B) and install sensor.
6. Install attaching hardware.
7. Install shield.
Go to Section_40:Group_30
OUO6435,00014D0-19-20010925
333
Remove and Install Coolant Temperature Sensor
Remove and Install Coolant Temperature Sensor
1.
CAUTION:
Coolant may be hot. Wait until radiator is cool to the touch before draining
coolant.
T6642EK-UN: Radiator Cap
Slowly loosen radiator cap.
2.
H67482-UN: Radiator Drain Cock
H67483-UN: Engine Block Drain Cock
LEGEND:
334
Remove and Install Coolant Temperature Sensor
A - Radiator Drain Cock
B - Engine Block Drain Cock
Drain coolant at radiator drain cock (A) and engine block drain cock (B) until coolant level is below
coolant temperature sensor.
3. Close radiator drain cock (A) and engine block drain cock (B).
4. Close radiator cap to prevent contamination from entering cooling system.
5.
H67484-UN: Sensor
LEGEND:
A - Connector
B - Sensor
Disconnect sensor connector (A).
6. Turn sensor (B) counterclockwise using a wrench ONLY on the hex portion of the sensor.
Sensor cannot be repaired. Replace, if defective.
7. Apply TY9375 pipe sealant with TEFLON to threads of sensor. Turn sensor (B) clockwise using a
wrench ONLY on the hex portion of the sensor.
8. Connect connector (A) to sensor.
9. Open radiator cap and fill radiator with coolant to capacity.
10. Close radiator cap.
Go to Section_40:Group_30
OUO6037,000145A-19-20010723
335
Remove and Install Coolant Temperature Sensor
Remove and Install Coolant Temperature Sensor
1.
H57701-UN: Sensor
LEGEND:
A - Connector
B - Sensor
Disconnect wiring lead connector (A).
2. Remove sensor (B).
Sensor cannot be repaired. Replace, if defective.
3. Apply TEFLON ™ pipe sealant to threads of sensor. Install sensor (B).
Go to Section_40:Group_30
OUO6037,000143A-19-20021120
336
Remove and Install Fuel Level Sensor
Remove and Install Fuel Level Sensor
1. Clean area around fuel level sensor to avoid contaminating the fuel system when sensor is removed.
ZX25247-UN: Fuel Sensor
LEGEND:
A - Connector
B - Screw (5 used)
C - Fuel Level Sensor
D - Gasket
2. Disconnect connector (A) from fuel level sensor.
3.
NOTE:
Observe how float arm is positioned in relation to fuel tank. This will simplify sensor
installation.
Remove screws (B), fuel sensor (C) and gasket (D). Sensor cannot be repaired. If damaged, it must be
replaced.
4. Install fuel sensor using new gasket (D). Guide fuel level sensor (C) through top of fuel tank with float
arm positioned toward center of tank. Install five screws (B).
5. Connect connector (A) to fuel level sensor.
Go to Section_40:Group_30
OUO6037,0001439-19-20010712
337
Remove and Install Park Brake Switch
Remove and Install Park Brake Switch
1.
H57687-UN: Park Brake Switch
LEGEND:
A - Connector
B - Retaining Nut
C - Switch
Disconnect connector (A).
2. Loosen retaining nut (B) and remove switch (C).
3. Switch cannot be repaired. A defective switch must be replaced.
4. Install switch.
5. Connect connector.
Go to Section_40:Group_30
AG,OUO6030,261-19-19990602
338
Remove and Install Air Filter Restriction Switch
Remove and Install Air Filter Restriction Switch
1.
H57695-UN: Air Filter Restriction Switch
LEGEND:
A - Connector
B - Switch
Disconnect connector (A).
2. Remove switch (B). Switch cannot be repaired. It must be replaced.
3. Install switch (B).
4. Connect connector (A).
Go to Section_40:Group_30
AG,OUO6030,305-19-20030206
339
Remove and Install Engine Gear Case Temperature and Pressure Switches
Remove and Install Engine Gear Case Temperature and Pressure Switches
1.
H57697-UN: Engine Gear Case Temperature and Pressure Switches
LEGEND:
A - Connector
B - Temperature Switch
C - Pressure Switch
Disconnect wiring lead connectors (A).
2. Remove temperature (B) and pressure (C) switches. Switches cannot be repaired. If defective, they
must be replaced.
3. Install switches (B) and (C) using new O-rings.
4. Connect wiring lead connectors (A).
Go to Section_40:Group_30
AG,OUO6030,307-19-20030206
340
Remove and Install Hydrostatic Charge Pressure Switch
Remove and Install Hydrostatic Charge Pressure Switch
1.
H57698-UN: Hydrostatic Charge Pressure Switch
LEGEND:
A - Connector
B - Switch
Disconnect wiring lead connector (A).
2. Remove switch (B). Switch cannot be repaired. Replace, if defective.
3. Install switch (B) using new O-ring.
4. Connect wiring lead connector (A).
Go to Section_40:Group_30
AG,OUO6030,308-19-19990602
341
Remove and Install Hydraulic Oil Reservoir Temperature Sensor
Remove and Install Hydraulic Oil Reservoir Temperature Sensor
1.
H57696-UN: Hydraulic Oil Reservoir Temperature Sensor
LEGEND:
A - Connector
B - Temperature Sensor
Drain reservoir to level below sensor.
2. Disconnect connector (A).
3. Remove sensor (B). Sensor cannot be repaired. Replace, if defective.
4. Install sensor (B) using new O-ring.
5. Connect connector (A).
6. Fill reservoir with recommended oil.
Go to Section_40:Group_30
AG,OUO6030,306-19-20030206
342
Remove and Install Engine Oil Pressure Switch
Remove and Install Engine Oil Pressure Switch
1.
H57699-UN: Engine Oil Pressure Switch
LEGEND:
A - Connector
B - Pressure Switch
Disconnect wiring lead connector (A).
2. Remove switch (B). Switch cannot be repaired. Replace, if defective.
3. Apply TEFLON ™ pipe sealant to threads of switch and install switch (B).
4. Connect wiring lead (A).
Go to Section_40:Group_30
AG,OUO6030,309-19-20021120
343
Remove and Install Service and Cleaning Shoe Light Switch
Remove and Install Service and Cleaning Shoe Light Switch
1.
NOTE:
Procedure to remove and install all switches is the same.
H57689-UN: Service and Cleaning Shoe Light Switch
H57688-UN: Engine Service Light Switch
LEGEND:
A - Connector
B - Nut
C - Switch
Disconnect connector (A).
2. On face of mounting bracket, remove nut (B) from switch.
3. Remove switch (C). Switch cannot be repaired. A defective switch must be replaced.
4. Install switch.
5. Connect connector.
Go to Section_40:Group_30
AG,OUO6030,264-19-19990602
344
Remove and Install Chaffer/Sieve Sensor and Adjusting Motor
Remove and Install Chaffer/Sieve Sensor and Adjusting Motor
1.
ZX25352-UN: Chaffer adjusting motor
LEGEND:
A - Connector
B - Strip
C - Lock Nut
D - Cap Screw and Nut (4 used)
Remove chaffer/sieve element. See Remove and Install Chaffer, Sieve and Frames in Section 120.
2. Disconnect connector (A).
3. Remove nut (C), cap screws (D) and motor.
4. Install in reverse order using the following special instructions:
NOTE:
Hold strip (B) in its released position while tightening nut (C) so that no binding will
occur.
5. Install chaffer/sieve element. See Remove and Install Chaffer, Sieve and Frames in Section 120.
6. Calibrate chaffer/sieve sensors. See operator's manual.
Go to Section_40:Group_30
OUO6435,0001564-19-20011220
345
Specifications
Specifications
Item
Measurement Specification
Windshield Wiper Main Arm Lock Nut Torque
18 N˙m
(164 lb-in.)
Go to Section_40:Group_35
OUO6037,0001482-19-20010821
346
Specifications
Specifications
Item
Measurement Specification
Windshield Wiper Main Arm Lock Nut Torque
18 N˙m
(164 lb-in.)
Go to Section_40:Group_35
OUO6037,0001482-19-20010821
347
Remove and Install Wiper Motor
Remove and Install Wiper Motor
1.
NOTE:
Make sure wipers are in the parked position before starting removal procedures.
H63271-UN: Sun Visor
LEGEND:
A - Cap Screw (3 used)
B - Sun Visor
Remove cap screws (A) and sun visor (B).
2.
H63270-UN: Front Cab Headliner
LEGEND:
A - Tab (5 used)
B - Headliner
Remove front headliner (A) from cab by pulling back and down on front edge of headliner to clear tabs
(B).
348
Remove and Install Wiper Motor
3.
H63269-UN: Wiper Motor Connector
LEGEND:
A - Wiring Harness Connector
Disconnect harness connector (A).
4.
H63265-UN: Wiper Motor
LEGEND:
A - Lock Nut
B - Cap Screw (3 used)
Remove lock nut (A) and disconnect linkage from motor shaft.
5. Remove cap screws (B) and wiper motor.
6. Inspect all parts for wear and damage, replace as necessary.
7.
349
Remove and Install Wiper Motor
H63275-UN: Motor Installation
LEGEND:
A - Cap Screw (3 used)
B - Lock Nut
Install motor and retain with cap screws (A).
8. Install wiper linkage to motor and retain with lock nut (B).
9.
H63269-UN: Wiper Motor Connector
LEGEND:
A - Wiring Harness Connector
Connect harness connector (A).
10.
H63270-UN: Front Cab Headliner
LEGEND:
A - Headliner
B - Tab (5 used)
Connect front headliner (A) in cab by pulling back and lifting up on front edge of headliner until it is held
by tabs (B).
350
Remove and Install Wiper Motor
11.
H63276-UN: Sun Visor
LEGEND:
A - Sun Visor
B - Cap Screw (3 used)
Install sun visor (A) and retain with cap screws (B).
Go to Section_40:Group_35
AG,OUO6022,1617-19-20000503
351
Remove and Install Windshield Washer
Remove and Install Windshield Washer
1.
H63360-UN: Windshield Washer
LEGEND:
A - Nozzle (2 used)
B - Grommet (2 used)
C - Hose (2 used)
D - T-Fitting
E - Hose
F - Grommet
G - Grommet
H - Fitting
I - Hose Clamp (3 used)
J - Cap
K - Filter
352
Remove and Install Windshield Washer
L - Washer
M - Reservoir
N - Flange Nut (4 used)
O - Screw
P - Grommet
Q - Pump
Remove washer parts as necessary.
2. Inspect parts. Replace if necessary.
3.
NOTE:
Pump cannot be repaired. If defective, it must be replaced.
Install washer parts.
Go to Section_40:Group_35
AG,OUO6435,595-19-20000503
353
Specifications
Specifications
Item
Measurement Specification
Alternator Mounting Cap Screw Torque
28 ± 6 N˙m
(21 ± 4 lb-ft)
Nut, 5/16 in.
Torque
11 N˙m
(97 lb-in.)
Nut, 1/4 in.
Torque
11 N˙m
(97 lb-in.)
Go to Section_40:Group_40
OUO6037,0001483-19-20010821
354
Specifications
Specifications
Item
Measurement Specification
Alternator Mounting Cap Screw Torque
28 ± 6 N˙m
(21 ± 4 lb-ft)
Nut, 5/16 in.
Torque
11 N˙m
(97 lb-in.)
Nut, 1/4 in.
Torque
11 N˙m
(97 lb-in.)
Go to Section_40:Group_40
OUO6037,0001483-19-20010821
355
Remove and Install Alternator
Remove and Install Alternator
1.
ZX25194-UN: Battery Ground Disconnect
LEGEND:
A - Handle
Turn and remove handle (A) from post to disconnect battery ground.
2.
H67490-UN: Belt Tensioner
LEGEND:
A - Breaker Bar
B - Belt
Insert a 1/2 inch drive breaker bar (A) into square hole in idler to release tension on belt. Remove belt
(B) from alternator.
3.
ZX25250-UN: Alternator Wiring
LEGEND:
356
Remove and Install Alternator
A - Lead (2 used)
Remove nuts, lock washers and leads (A).
4.
ZX25225-UN: Attaching Screw
LEGEND:
A - Cap Screw
B - Cap Screw and Nut
Remove cap screw (A) and cap screw and nut (B) to remove alternator.
5. To repair alternator, refer to relevant CTM.
6. Install alternator and retain with previously removed hardware (A) and (B).
7. Tighten cap screw (A) to specification.
Item
Measurement Specification
Alternator Mounting Cap Screw Torque
28 ± 6 N˙m
(21 ± 4 lb-ft)
8.
ZX25250-UN: Alternator Wiring
LEGEND:
A - Lead (2 used)
Install leads (A) and retain with previously removed hardware. Tighten nuts to specified torque.
357
Remove and Install Alternator
Item
Measurement Specification
Nut, 5/16 in. Torque
11 N˙m
(97 lb-in.)
Nut, 1/4 in. Torque
11 N˙m
(97 lb-in.)
9.
H67490-UN: Belt Tensioner
LEGEND:
A - 1/2 Inch Breaker Bar
B - Belt
Insert a 1/2 inch breaker bar (A) into the square hole in idler to release tension on the belt. Remove
breaker bar after installing belt (B).
10. Install belt (B).
Go to Section_40:Group_40
OUO6037,0001440-19-20010717
358
Specifications
Specifications
Item
Measurement Specification
Starting Motor Installation
Cap Screws Torque
47 N˙m
(35 lb-ft)
Go to Section_40:Group_45
OUO6037,0001484-19-20010821
359
Specifications
Specifications
Item
Measurement Specification
Starting Motor Installation
Cap Screws Torque
47 N˙m
(35 lb-ft)
Go to Section_40:Group_45
OUO6037,0001484-19-20010821
360
Remove and Install Starting Motor
Remove and Install Starting Motor
1.
ZX25194-UN: Battery Ground Disconnect
LEGEND:
A - Handle
Turn and remove handle (A) from post to disconnect battery ground.
2. Remove engine access panel.
3. Clean area around starting motor.
4.
H67497-UN: Starting Motor
LEGEND:
A - Lead
B - Lead
C - Cap Screw (3 used)
Disconnect relay leads (A) and (B).
5. Remove cap screws (C) and lift out starting motor. Use JDE80 wrench to remove the screw behind the
starting motor.
6. To repair starting motor, refer to relevant CTM.
7. Position motor and install three cap screws (C). Tighten to specified torque.
361
Remove and Install Starting Motor
Item
Measurement Specification
Starting Motor Installation
Cap Screws Torque
47 N˙m
(35 lb-ft)
8. Connect leads (A) and (B).
9. Install engine access panel.
10. Connect battery ground.
Go to Section_40:Group_45
OUO6037,000141C-19-20010613
362
Remove and Install Starting Motor Relay
Remove and Install Starting Motor Relay
1.
ZX25194-UN: Battery Ground Disconnect
LEGEND:
A - Handle
Turn and remove handle (A) from post to disconnect battery ground.
2.
H57705-UN: Starting Motor Relay
H57706-UN: Starting Motor Relay
LEGEND:
A - Cap Screw (2 used)
B - Cover
C - Nut (3 used)
D - Cap Screw (2 used)
Remove engine access panel.
3. Clean area around starting motor relay.
363
Remove and Install Starting Motor Relay
3. Clean area around starting motor relay.
4. Remove cap screws (A) and cover (B).
5. Remove nuts (C) to remove leads from starting motor relay.
6. Remove cap screws (D) to remove starting motor relay. Relay cannot be repaired. If defective, it must be
replaced.
7. Install relay using cap screws (D).
8. Connect leads using nuts (C).
9. Install cover (B) using cap screws (A).
10. Install engine access panel.
11. Connect battery ground.
Go to Section_40:Group_45
OUO6037,000143C-19-20010712
364
Specifications
Specifications
Item
Measurement Specification
Mass Flow Sensor-to-Impact Plate, Nuts Torque
30 N˙m
(22 lb-ft)
Mass Flow Sensor-to-Transition Housing Torque
30 N˙m
(22 lb-ft)
Go to Section_40:Group_50
OUO6037,0001485-19-20010821
365
Specifications
Specifications
Item
Measurement Specification
Mass Flow Sensor-to-Impact Plate, Nuts Torque
30 N˙m
(22 lb-ft)
Mass Flow Sensor-to-Transition Housing Torque
30 N˙m
(22 lb-ft)
Go to Section_40:Group_50
OUO6037,0001485-19-20010821
366
Remove and Install GreenStar Mass Flow Sensor
Remove and Install GreenStar Mass Flow Sensor
1.
ZX25313-UN: Mass Flow Sensor
LEGEND:
A - Connector
B - Wing Screw (2 used)
Retain grain tank covers in the open position and disconnect linkage from loading auger. Lower loading
auger.
2. Disconnect connector (A) from wiring harness.
3. Remove two wing screws (B) and cover.
4.
H62608-UN: Mass Flow Sensor
LEGEND:
A - Nut (2 used)
Remove nuts (A) and sensor assembly from inside of housing.
367
Remove and Install GreenStar Mass Flow Sensor
5.
H62868-UN: Recent Mass Flow Sensor Shown
LEGEND:
A - Nut (2 used)
B - Washer
C - Mass Flow Sensor
D - Impact Plate
Remove nuts (A) and mass flow sensor (C) from impact plate (D).
6.
H62868-UN: Recent Mass Flow Sensor Shown
LEGEND:
A - Nut (2 used)
B - Washer
C - Mass Flow Sensor
D - Impact Plate
Install mass flow sensor (C) on impact plate (D). Tighten nuts (A) to specified torque.
Item
Measurement Specification
Mass Flow Sensor-to-Impact Plate, Nuts Torque
7.
30 N˙m
(22 lb-ft)
NOTE:
Make sure clearance between inside edge of impact plate and transition housing is
368
Remove and Install GreenStar Mass Flow Sensor
equal along entire length of impact plate.
H65836-UN: Mass Flow Sensor
LEGEND:
A - Nut (2 used)
B - Sensor Assembly
Install mass flow sensor (B) into transition housing and tighten nuts (A) to specification.
Item
Measurement Specification
Mass Flow Sensor-to-Transition Housing Torque
8.
30 N˙m
(22 lb-ft)
NOTE:
Make sure wiring harness rests in cover notch before tightening wing screws.
ZX25313-UN: Mass Flow Sensor
LEGEND:
A - Connector
B - Wing Screw (2 used)
Install cover and wing screws (B).
9. Connect connector (A).
10. Raise loading auger and connect grain tank linkage.
369
Remove and Install GreenStar Mass Flow Sensor
Go to Section_40:Group_50
OUO6435,0001445-19-20010803
370
Remove and Install GreenStar Paddle Wheel
Remove and Install GreenStar Paddle Wheel
1.
H69261-UN: Paddle Wheel
LEGEND:
A - Paddle Wheel
Remove moisture sensor cover.
2. Pull paddle wheel (A) off motor shaft.
3. Replace parts as necessary.
4. Reinstall cover on moisture sensor.
Go to Section_40:Group_50
OUO6083,00000C2-19-20010712
371
Remove and Install GreenStar Moisture Sensor
Remove and Install GreenStar Moisture Sensor
1. Open right front gull wing door.
2.
H63381-UN: Moisture Sensor
LEGEND:
A - Connector
B - Tab (7 used)
C - Cover
Disconnect connector (A) and remove wiring harness from clamp.
3. Carefully press in on tabs (B) and remove cover (C) from moisture sensor.
4.
H63380-UN: Bracket
LEGEND:
372
Remove and Install GreenStar Moisture Sensor
A - Cap Screw (2 used)
Remove cap screws (A) from bracket located at top of sensor.
5.
H63382-UN: Bracket
LEGEND:
A - Cap Screw (2 used)
Remove nuts and screws (A) from sensor. Slide sensor from between top and bottom brackets.
6.
NOTE:
Do not tighten screws at this time.
H62444-UN: Moisture Sensor
H62840-UN: Moisture Sensor
LEGEND:
A - Screws and Nuts
373
Remove and Install GreenStar Moisture Sensor
B - Screws and Nuts
C - Cap Screw (2 used)
Install moisture sensor on 45° bracket using screws and nuts (A) and (B).
7.
NOTE:
Make sure that the moisture sensor rests tightly against the elevator before tightening
sensor mounting hardware.
Position moisture sensor on the top of upper 90° bracket and install cap screws (C).
8. Tighten lower sensor mounting hardware.
9.
H62841-UN: Moisture Sensor
LEGEND:
A - Bracket
B - Surface
C - Nut (2 used)
Slide bracket (A) out so that surfaces (B) rest tightly against elevator.
10. Tighten nuts (C).
374
Remove and Install GreenStar Moisture Sensor
11.
H63381-UN: Moisture Sensor
LEGEND:
A - Connector
B - Moisture Sensor Tabs (7 used)
C - Cover
Connect connector (A).
12. Align cover (C) and press into tabs (B) on moisture sensor.
Go to Section_40:Group_50
OUO6030,00000C0-19-20010712
375
Remove and Install Position Receiver
Remove and Install Position Receiver
1.
H68110-UN: Position Receiver
H68134-UN: Position Receiver
H68109-UN: Position Receiver Bracket
LEGEND:
A - Wiring Harness
376
Remove and Install Position Receiver
B - Connector Latch
C - Pin
D - Mounting Bracket Slots
Disconnect harness (A) from position receiver.
2. Lift connector latch (B) to remove position receiver.
3. Inspect position receiver for damage. Replace if necessary.
4. Install position receiver by aligning pins (C) with slots (D) in position receiver mounting bracket and
snapping into place.
5. Attach harness (A) to position receiver.
Go to Section_40:Group_50
AG,OUO6435,162-19-20000710
377
Table of Contents
Section 50: Drive Train
Group 05: Transmission and Differential
Other Material
Specifications
Remove and Repair Shifter Forks and Shifter Cam
Install Shifter Forks and Shifter Cam
Remove and Install Transmission Oil Pump
Remove and Install Suction Screen
Remove Transmission
Recondition Transmission
Disassemble and Repair Transmission
Assemble Transmission
Install Transmission
Remove and Install Gearshift Lever and Linkage
Adjust Gear Shift Linkage
Group 10: Final Drive
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Remove and Install Final Drive
Disassemble and Assemble Final Drive
Adjust Spindle Bearing (Preferred Method)
Adjust Spindle Bearing (Alternative Method)
Group 15: Hydrostatic System
Essential and Recommended Special Tools
Service Equipment and Tools
Other Material
Specifications
Flush the Hydrostatic System
Remove and Install Hydrostatic Motor
Disassemble Hydrostatic Motor
378
Table of Contents
Replace Cylinder Block Spring
Assemble Motor
Remove and Install Motor Valve Block (Manifold)
Repair Motor Valve Block
Remove Hydrostatic Pump
Disassemble Hydrostatic Pump
Assemble Hydrostatic Pump
Replace High-Pressure Line Center Pivot O-Rings
Disassemble and Assemble End Cover
Repair Control Valve
Displacement Control Valve with Feed Rate - Exploded View
Install Hydrostatic Pump
Remove and Install Charge Pump
Repair Charge Pump
Remove and Install Hydrostatic Control Cable
Adjust Hydrostatic Control Linkage
Adjust Neutral Position of Displacement Control Valve
Start-Up Procedure After Hydrostatic System Repair
Group 20: Cam Lobe Motor
Essential and Recommended Special Tools
Service Equipment and Tools
Other Material
Specifications
Flush Cam Lobe Motors
Remove Cam Lobe Motor
Install Cam Lobe Motor
Remove and Install Cam Lobe Motor Control Valve
Disassemble and Assemble Cam Lobe Motor Control Valve
Remove and Install Steering Yoke
Disassemble and Assemble Pivot Pins, Bushings, and Seals
Remove and Install Solenoid Valve and Valve Block
Remove and Install Displacement Control Valve
Remove and Install Cam and Piston Carrier
379
Table of Contents
Remove and Install Valve Block Seals
Remove and Install Axle Bearings and Seals
Group 25: HillMaster II
HillMaster II Rocker Assembly - Right
HillMaster II Rocker Assembly - Left
380
Other Material
Other Material
Number Name
Use
TY6304 Flexible Sealant
(U.S.)
To seal shifter rail cap.
TY16021 Form-in-Place Gasket To seal front cover to transmission.
(U.S.)
TY6252 80W90 GL5 GEAR
(U.S.)
LUBE
To coat rotor and stator of transmission oil pump during assembly and fill
transmission.
AR41870 Corrosion Inhibitor
(U.S.)
To protect components in storage.
TY16285 Clean and Cure Primer To prime seal shims on lube pump before applying flexible sealant.
(U.S.)
T43512
(U.S.)
Thread Lock and
Sealer (medium
strength)
TY6341 Multipurpose SD
(U.S.)
Polyurea Grease
To coat threads of cap screws attaching transmission oil pump, differential
ring gear, differential cradle, and transmission pinion shaft carrier.
Especially effective in rolling contact applications.
TY15130 Form-in-Place Gasket To seal hydrostatic motor mount.
(U.S.)
Go to Section_50:Group_05
AG,OUO6435,610-19-20000503
381
Other Material
Other Material
Number Name
Use
TY6304 Flexible Sealant
(U.S.)
To seal shifter rail cap.
TY16021 Form-in-Place Gasket To seal front cover to transmission.
(U.S.)
TY6252 80W90 GL5 GEAR
(U.S.)
LUBE
To coat rotor and stator of transmission oil pump during assembly and fill
transmission.
AR41870 Corrosion Inhibitor
(U.S.)
To protect components in storage.
TY16285 Clean and Cure Primer To prime seal shims on lube pump before applying flexible sealant.
(U.S.)
T43512
(U.S.)
Thread Lock and
Sealer (medium
strength)
TY6341 Multipurpose SD
(U.S.)
Polyurea Grease
To coat threads of cap screws attaching transmission oil pump, differential
ring gear, differential cradle, and transmission pinion shaft carrier.
Especially effective in rolling contact applications.
TY15130 Form-in-Place Gasket To seal hydrostatic motor mount.
(U.S.)
Go to Section_50:Group_05
AG,OUO6435,610-19-20000503
382
Specifications
Specifications
Item
Measurement Specification
Transmission
Capacity
9.6 L
(10 qt)
Shifter Cam
End Play
0.000—0.254 mm
(0.000—0.010 in.)
Transmission Cover-to-Housing Cap Screws
Torque
73 N˙m
(55 lb-ft)
Transmission Oil Pump
Pressure
0.103 kPa
(1.0 bar)
(14.5 psi)
Transmission Oil Pump-to-Housing Cap Screws
Torque
73 N˙m
(55 lb-ft)
Input Shaft Orifice
Torque
17 N˙m
(12 lb-ft)
Pinion Shaft Orifice
Torque
17 N˙m
(12 lb-ft)
Ring Gear-to-Differential Cap Screws
Torque
130 N˙m
(97 lb-ft)
Differential
Preload
0.076—0.254 mm
(0.003—0.010 in.)
Differential Cradles-to-Housing Cap Screws
Torque
320 N˙m
(235 lb-ft)
Pinion Shaft Bearing Carrier Cap Screws (For determining shim pack) Torque
2.2 N˙m
(20 lb-in.)
Pinion Shaft
Preload
0.127 mm
(0.005 in.)
Pinion Shaft Bearing Carrier Cap Screws
Torque
73 N˙m
(55 lb-ft)
Hydrostatic Motor Mount-to-Transmission Cap Screws
Torque
320 N˙m
(235 lb-ft)
Input Shaft Assembly
End Play
0.01—0.2 mm
(0.0005—0.008 in.)
Transmission Mounting Cap Screws
Torque
320 N˙m
(235 lb-ft)
Gearshift Linkage
Distance
237 mm
(9.3 in.)
Transmission
Weight
306 kg
(675 lb)
Go to Section_50:Group_05
OUO6037,0001456-19-20010723
383
Remove and Repair Shifter Forks and Shifter Cam
Remove and Repair Shifter Forks and Shifter Cam
NOTE:
Shifter fork and/or shifter cam can be replaced without removing transmission.
1. Drain transmission oil. Remove transmission front cover.
Item
Measurement Specification
Transmission Capacity
9.6 L
(10 qt)
2.
H40160-UN: Transmission
LEGEND:
A - Dowel Pin
Remove dowel pin (A).
3.
H73038-UN: Transmission
LEGEND:
A - Shifter Rail
B - Shifter Fork
C - Shifter Fork
D - Roller (2 used)
E - Clip (2 used)
Remove rail (A) and shifter forks (B) and (C).
4.
CAUTION:
Shifter cam compresses a strong spring. Use caution when removing shifter cam.
384
Remove and Repair Shifter Forks and Shifter Cam
Shifter cam compresses a strong spring. Use caution when removing shifter cam.
Check shifter cam. Make sure grooves are free of burrs and there are no flat spots. Inspect spring pins in
shifter cam. Replace any spring pins that are excessively worn or burred. Also inspect mating shifting
surfaces on shifter rail.
There are no wear tolerances for any of the shifter forks, clips (E) or rollers (D). Replace these parts if
they appear damaged or worn.
5. When replacing rollers (D) or pins, press in pins until they are flush with rollers. Roller must be able to
turn freely on pin. The usual cause for a roller pin to break is clash shifting.
6. Inspect all shift collars in the transmission for wear. Worn or damaged shift collars can cause the
transmission to jump out of gear and may damage shifter forks. Incorrectly adjusted shift linkage can
cause excessive wear to shift collars.
Go to Section_50:Group_05
OUO6435,00017B3-19-20020613
385
Install Shifter Forks and Shifter Cam
Install Shifter Forks and Shifter Cam
H72548-UN: Transmission
LEGEND:
A - Shifter Fork
B - Roller (2 used)
C - Pin (2 used)
D - Shifter Fork
E - Shifter Rail
F - Dowel Pin
G - Cap
H - Clip (2 used)
1. Install clips (H) on shifter fork (A).
2. Install shifter forks (A) and (D) on shifter rail (E) and install spring pin.
3. Install dowel pin (F).
4. Install rollers and pins (B) and (C).
Rollers must be able to turn freely on pins. Pins must be flush with top of rollers.
5. Check for adequate shifter fork movement. All gears must turn freely when transmission is turned by
hand.
NOTE:
Apply 1.4 mm (1/16 in.) bead of flexible sealant to counterbore of housing when
installing cap (G).
386
Install Shifter Forks and Shifter Cam
6.
H66703-UN: Transmission
LEGEND:
A - Cap Screw (12 used)
B - Cover
C - Spring
D - Detent Ball
E - Spring Pin (2 used)
F - Cam
G - O-Ring
H - Washer
I - Spring Pin
J - Arm
K - Piston
L - Plunger
M - Solenoid
N - Cap Screw (2 used)
O - Switch
P - Spacer
Q - Screw
Install detent ball (D). Ball must rest against spring. Install arm (J) with washer (H) and O-ring (G). Install
spring pin (I).
7. If shifter cam (F) was removed, adjust cam and arm to specified end play to obtain proper adjustment of
cam. Measure distance between inside edge of cam and boss on cover to check end play.
Item
Measurement Specification
Shifter Cam End Play
0.000-0.254 mm
(0.000-0.010 in.)
387
Install Shifter Forks and Shifter Cam
8. Apply a continuous 1.5 mm (1/16 in.) wide bead of form-in-place gasket to transmission housing. Install
cover (B) and tighten cap screws (A) to specification.
Item
Measurement Specification
Transmission Cover-to-Housing Cap Screws Torque
73 N˙m
(55 lb-ft)
9. Fill transmission with TY6252 80W90 GL5 Gear Lube or an approved alternative oil. (See Fuel,
Lubricants, Coolant and Capacities in Section 10.) Level must be within 13 mm (1/2 in.) from bottom of
fill hole.
Item
Measurement Specification
Transmission Capacity
9.6 L
(10 qt)
NOTE:
If transmission is placed in rebuilt service parts storage, add 0.006 L (2 oz) of corrosion
inhibitor.
Go to Section_50:Group_05
OUO6435,00018FD-19-20020903
388
Remove and Install Transmission Oil Pump
Remove and Install Transmission Oil Pump
H66763-UN: Transmission Oil Pump
LEGEND:
A - Oil Tube
B - Cap Screws (3 used)
C - Pump Housing
NOTE:
Use 100 psi (690 kPa) gauge to test oil pump pressure. See procedure in diagnostic and test
manual.
If pump is not delivering specified oil pressure, it must be repaired. Pump can be removed without
removing transmission.
Item
Measurement Specification
Transmission Oil Pump Pressure
0.103 kPa
(1.0 bar)
(14.5 psi)
This style lube pump consists of the internal pump parts separate from the bearing cup and
sleeve.
1. Slide oil tube (A) up and out of port in strainer and insert a 1/2 in. plug into port. This will prevent
excessive loss of oil.
2. Remove cap screws (B) securing pump housing (C) to transmission.
3. Carefully pull pump housing (C) away from assembly to catch pump drive pin which, in most cases, will
fall from drive shaft. Be careful not to disturb shim pack.
4. Remove oil tubes from pump housing and lay complete assembly aside. Remove rotor and stator
assembly. Save drive pin.
389
Remove and Install Transmission Oil Pump
5.
H44859-UN: Transmission Oil Pump
LEGEND:
A - Screw (3 used)
B - Housing
C - Shim
D - O-Ring
E - Bushing
F - Sleeve
G - Bearing Cup
H - Bearing Cone
I - Washer
J - Plate
K - Rotor
L - Dowel Pin
M - O-Ring (4 used)
Install new parts (B), (K), (J) and (M) to ensure satisfactory oil pressure. Be certain grooves in the new
housing (B) for oil tubes are clean before installing new O-rings (M).
6. Clean paint from ends of oil tubes, approximately 52 mm (2 in.), and blow all paint scales from inside of
tubes. Install oil tubes in pump housing.
7. Press bearing cup (G) into sleeve (F) and install over bearing cone on input shaft.
8. If possible, rotate transmission shafts so that hole in input shaft is horizontal and insert pump drive pin. If
shafts cannot be rotated, use grease to hold pin in place.
9. Assemble bushing (E) and washer (I) on port plate (J) and install on input shaft in that order.
10. Coat rotor and stator (K) with 80W90 GL5 Gear Lube oil. Carefully place rotor and stator assembly into
eccentric bore and over drive pin.
11. Position radial stop on port plate (J) to mate with slot in new housing (B) at approximately 5 o'clock
position.
390
Remove and Install Transmission Oil Pump
12. Determine proper shim pack (see Assemble Transmission in this Group). After verifying proper bearing
setting, install shim pack. Clean surfaces and prime with TY16285 Primer. Apply 1.5 mm (0.06 in.) bead
of flexible sealant to housing corner to seal shims.
13. Coat threads of attaching screws with T43512 Thread Lock and Sealer (medium strength). Tighten
screws to specified torque.
Item
Measurement Specification
Transmission Oil Pump-to-Housing Cap Screws Torque
73 N˙m
(55 lb-ft)
14. Force oil tubes into respective ports. Make certain the ends of the tubes are past O-ring seals and are
against bottom of port.
15. Secure oil tube with clamp and attach lead on sending unit.
Go to Section_50:Group_05
AG,OUO6022,1809-19-20021120
391
Remove and Install Suction Screen
Remove and Install Suction Screen
H54293-UN: Transmission Suction Screen
LEGEND:
A - Cap Screw
B - Fitting
C - Screen
D - Oil Pump Housing
E - Oil Tube
1. Push tube (E) into oil pump housing (D).
2. Remove cap screw (A), fitting (B) and screen (C).
3. Clean screen in solvent.
4. Install screen (C), fitting (B) and cap screw (A).
5. Pull tube (E) down into fitting (B).
Go to Section_50:Group_05
AG,OUO6435,615-19-20000503
392
Remove Transmission
Remove Transmission
H66682-UN: Pump and Shield
LEGEND:
A - Nut (4 used)
B - Shield
CAUTION:
Approximate weight of transmission is 306 kg (675 lb).
Item
Measurement Specification
Transmission Weight
306 kg
(675 lb)
1. Remove header from combine.
2. Fully raise feeder house and lower safety stop.
3. Block front drive tires.
4. Shut off engine.
5. Disengage park brake.
6. Place transmission in neutral.
7. Remove nuts (A). Remove hydrostatic motor without disconnecting lines and place on a suitable stand.
8. Remove shield (B).
393
Remove Transmission
9.
H66681-UN: Shift Cable
LEGEND:
A - Wire Connector (2 used)
B - Connector
C - Shift Cable
Disconnect solenoid wire connectors (A) and connector (B).
10. Disconnect and remove shift cable (C) from transmission.
11.
H66680-UN: Brake Lines
LEGEND:
A - Brake Line (2 used)
B - Connector
Disconnect service brake lines (A).
12. Disconnect ground speed sensor connector (B).
394
Remove Transmission
13.
H66687-UN: Axle
LEGEND:
A - Snap Ring (2 used)
B - Sleeve (2 used)
C - Pin (2 used)
D - Coupling (2 used)
Disconnect both axles:
1. Remove snap rings (A).
2. Slide sleeves (B) toward wheel.
3. Remove pins (C) and slide couplings (D) toward wheel.
14.
ZX25185-UN: Park Brake
LEGEND:
A - Nut (2 used)
B - Balancer
Remove nuts (A) from mechanical park brake balancer (B) cables.
15. Remove park brake cables from balancer (B) under cab.
395
Remove Transmission
16.
H66685-UN: Attaching Screws
LEGEND:
A - Nut (4 used)
Place a jack under the transmission.
17. Remove two lower attaching nuts (A). Raise transmission slightly and remove two upper nuts.
18. IMPORTANT:
Be careful not to bend brake lines while removing transmission.
Remove transmission.
Go to Section_50:Group_05
OUO6435,00015EA-19-20020123
396
Recondition Transmission
Recondition Transmission
Transmission recondition includes the input shaft and the pinion shaft.
For removal of shifter forks and shifter cam, refer to instructions in this Group.
For removal of transmission oil pump, refer to instructions in this Group. Remove oil screen.
Remove the bearing carrier on the side of transmission.
Go to Section_50:Group_05
AG,OUO6435,618-19-20000503
397
Disassemble and Repair Transmission
Disassemble and Repair Transmission
H53096-UN: Input Shaft Assembly
LEGEND:
1 - Rotor
2 - Plate
3 - Washer
4 - Bushing
5 - Bearing
6 - Bearing Cone
7 - O-Ring (8 used)
8 - Oil Pump
9 - Screw (3 used)
10 - Plug
11 - Tube
12 - Shim Pack
13 - O-Ring
14 - Tube
15 - Cap Screw
16 - Fitting
17 - O-Ring (2 St.)
18 - Screen
19 - Breather
20 - Screw (4 used)
21 - Stud (4 used)
22 - Hydrostatic Motor Mount
23 - Bearing Cup
24 - Bearing Cone
25 - Snap Ring
26 - Shift Collar
398
Disassemble and Repair Transmission
27 - Gear
28 - Gear
29 - Key
30 - Dowel Pin
31 - Orifice
32 - Input Shaft
33 - Input Shaft Repair Kit
34 - Coupling
35 - Snap Ring (2 used)
36 - Flange Nut (4 used)
1.
H63009-UN: Input Shaft Bearing Removal
Remove shifter forks. (See procedure in this group.)
2. Remove transmission oil pump. (See procedure in this group.)
3. Remove hydrostatic motor. (See instructions in Group 15.)
4. Remove input shaft assembly.
5. Press bearings off both ends of shaft.
6. Remove snap ring from shift collar end of shaft.
7.
H40168-UN: Transmission Input Shaft
LEGEND:
A - Gear
B - Shift Collar
C - Gear
399
Disassemble and Repair Transmission
Press gear (A) off shaft and slide gear (C) and shift collar (B) off shaft.
8. Check orifice (31) and oil passage through input shaft for restriction. Clean thoroughly. Tighten orifice to
specification.
Item
Measurement Specification
Input Shaft Orifice Torque
17 N˙m
(12 lb-ft)
9. Replace parts as necessary.
10.
H40169-UN: Transmission Input Shaft
LEGEND:
A - Oil Pump Drive Pin
B - Bearing Cone
C - Input Shaft
D - Gear
E - Shift Collar
F - Gear
G - Snap Ring
H - Bearing Cone
I - Key
Assemble input shaft parts.
400
Disassemble and Repair Transmission
H53095-UN: Pinion Shaft Assembly
LEGEND:
A - Pinion Carrier
B - Cap Screw (3 used)
C - Shim Pack
D - O-Ring
E - Bearing Cup
F - Bearing Cone
G - Snap Ring (4 used)
H - Washer
I - Gear
J - Gear
K - Shift Collar
L - Gear
M - Gear
N - Key
O - Orifice
P - Pinion Shaft (Heavy Duty Transmission)
Q - Pinion Shaft (Standard Duty Transmission)
R - Pinion Shaft Repair Kit
S - Bearing Cone
T - Bearing Cup
U - Cap
V - O-Ring
W - Snap Ring
401
Disassemble and Repair Transmission
11.
H40170-UN: Bearing Removal
Remove right differential bearing carrier to allow removal of the pinion shaft.
12. Press bearings off both ends of shaft.
NOTE:
Move ring gear end of differential toward rear of transmission.
13. Remove snap rings (G) to remove gears.
14.
H40171-UN: Standard Duty Transmission Shown
Press gear off shaft.
15. Check orifice (O) and oil passage through pinion shaft (P) or (Q) for restriction. Clean thoroughly.
Tighten orifice to specification.
Item
Measurement Specification
Pinion Shaft Orifice Torque
17 N˙m
(12 lb-ft)
16. Replace parts as necessary.
17. Install parts on shaft.
18.
CAUTION:
Use a lifting device for heavy components.
IMPORTANT:
402
Disassemble and Repair Transmission
Do not damage plastic or aluminum shims between transmission case and cradles.
H53097-UN: Differential
LEGEND:
A - Seal (2 used)
B - Snap Ring (4 used)
C - Roller Bearing (2 used)
D - Drive Shaft (2 used)
E - Cap Screw (12 used)
F - Cradle (2 used)
G - O-Ring (2 St.)
H - Bearing Cone (2 used)
I - Cup (2 used)
J - Cap Screw (14 used)
K - Ring Gear (Heavy Duty Transmission)
L - Ring Gear (Standard Duty Transmission)
M - Housing
N - Shim
O - Thrust Washer (2 used)
P - Thrust Washer (2 used)
Q - Pinion (2 used)
R - Thrust Washer (2 used)
S - Snap Ring (2 used)
T - Needle Bearing (52 used)
403
Disassemble and Repair Transmission
U - Washer (2 used)
V - Gear (2 used)
W - Pin
X - Spring Pin
Remove drive shafts and remove cradles.
19.
H40176-UN: Differential
LEGEND:
A - Bearing
B - Snap Ring
Remove snap ring (B) to remove bearing (A).
20.
H54054-UN: Heavy Duty Differential Shown
LEGEND:
A - Cap Screw (14 used)
B - Ring Gear
Remove cap screws (A) to remove ring gear (B).
21.
H40177-UN: Differential
Remove spring pin.
404
Disassemble and Repair Transmission
22.
H40178-UN: Differential
Remove snap rings.
23. Remove shaft, pinion gears and bevel gears.
24. Replace parts as necessary.
25.
H40178-UN: Differential
Pack all bearings with Multi-Purpose SD Polyurea Grease. Apply a light coat of grease to housing before
pressing in bearing cups.
26. Coat thrust surfaces and bores of bevel gears and pinion gears with oil.
27. Install bevel gears, pinion gears, thrust washers and differential pins. Install snap rings. All gears must
rotate freely.
28.
H54054-UN: Heavy Duty Differential Shown
LEGEND:
405
Disassemble and Repair Transmission
A - Cap Screw (14 used)
B - Ring Gear
Install ring gear (B). Apply thread lock and sealer (medium strength) to cap screw threads. Install cap
screws (A) and tighten to specification.
Item
Measurement Specification
Ring Gear-to-Differential Cap Screws Torque
130 N˙m
(97 lb-ft)
29.
H40176-UN: Differential
LEGEND:
A - Bearing
B - Snap Ring
Install inner snap ring and press bearing (A) into cradle. Install outer snap ring (B) and seal. Seal must
be flush with housing. Apply Multipurpose SD Polyurea Grease to seal lip.
Go to Section_50:Group_05
AG,OUO6435,619-19-20000503
406
Assemble Transmission
Assemble Transmission
1.
CAUTION:
H54055-UN: Heavy Duty Transmission Shown
LEGEND:
A - Differential
B - Wooden Block
Use a lifting device of adequate capacity for heavy components.
Install differential (A) in transmission case. Use a wooden block (B) to position differential.
2.
NOTE:
H54056-UN: Heavy Duty Transmission Shown
LEGEND:
A - Differential Gear
B - Pinion Shaft Gear
Move the gear end of differential toward rear of transmission to allow installation of
pinion assembly.
Install gears. Be sure pinion shaft gear (B) meshes with differential gear (A).
3. If old shims (behind cradle) were not damaged, they may be used. Otherwise, assemble a new pack.
Start with several shims to ensure end play.
4. Install cradles.
407
Assemble Transmission
5. Check differential preload. Add or remove shims as needed. Apply Thread Lock and Sealer (medium
strength) to cap screw threads. Tighten to specifications.
Item
Measurement Specification Item
Differential Preload
0.076—0.254
mm
(0.003—
0.010 in.)
Differential Cradles-toHousing Cap Screws
6.
H40223-UN: Bearing Cup
LEGEND:
A - Bearing Cup
B - Cap
C - O-Ring
D - Retaining Ring
Install bearing cup, cap, O-ring and retaining ring (A—D).
7. IMPORTANT:
H41158-UN: Bearing Cap
LEGEND:
A - Cap Screw (3 used)
B - Bearing Carrier
C - Shim (as required)
408
Measurement Specification
Torque
320 N˙m
(235 lb-ft)
Assemble Transmission
D - O-Ring
E - Bearing Cup
The following procedure must be followed when determining required shim pack for the pinion shaft.
This prevents false end play readings caused by retaining ring.
Install bearing carrier (B). Leave O-ring (D) off at this time.
8. Tighten the screws evenly to the specified torque.
Item
Measurement Specification
Pinion Shaft Bearing Carrier Cap Screws (For determining shim pack) Torque
2.2 N˙m
(20 lb-in.)
9. Rotate pinion shaft at least two complete revolutions. Tighten the screws evenly to the specified torque.
Item
Measurement Specification
Pinion Shaft Bearing Carrier Cap Screws (For determining shim pack) Torque
2.2 N˙m
(20 lb-in.)
10. Measure gap between bearing carrier (B) and housing at two places exactly 180° apart. Install shim
pack (C) equal to average of these two readings. This shim pack will provide specified preload.
Item
Measurement Specification
Pinion Shaft Preload
0.127 mm
(0.005 in.)
11. Install O-ring on carrier and install shim pack and carrier.
12. Apply Thread Lock and Sealer (medium strength) to cap screw threads. Install cap screws and tighten to
specification.
Item
Measurement Specification
Pinion Shaft Bearing Carrier Cap Screws Torque
73 N˙m
(55 lb-ft)
13. Install input shaft assembly in transmission.
14. Apply form-in-place gasket to face of hydrostatic motor mount. Install on transmission. Tighten cap
screws to specification.
Item
Measurement Specification
Hydrostatic Motor Mount-to-Transmission Cap Screws Torque
320 N˙m
(235 lb-ft)
15. Install transmission oil pump. (See procedure in this group.)
16. Adjust transmission oil pump shim pack to provide specified axial end play of input shaft assembly.
Item
Measurement Specification
Input Shaft Assembly Axial play
0.01—0.2 mm
(0.0005—0.008 in.)
17. Install hydrostatic motor. (See instructions in Group 15.)
409
Assemble Transmission
17. Install hydrostatic motor. (See instructions in Group 15.)
Go to Section_50:Group_05
OUO6037,0001452-19-20010723
410
Install Transmission
Install Transmission
H66685-UN: Attaching Screws
LEGEND:
A - Nut (4 used)
CAUTION:
Use a lifting device for heavy components.
Raise feeder house and lower safety stop.
1. Use jack to position transmission. Install two lower attaching nuts (A) and upper nuts. Tighten to
specification.
Item
Measurement Specification
Transmission Mounting Cap Screws Torque
320 N˙m
(235 lb-ft)
2. Fill transmission with 9.6 L (10 qt) of 80W90GL5 Gear Lube. (See Fuel, Lubricants, Coolant and
Capacities in Section 10). Level must be within 13 mm (1/2 in.) from bottom of fill plug.
3.
H66680-UN: Brake Lines
LEGEND:
A - Brake Line (2 used)
B - Connector
Connect service brake lines (A). Bleed air from service brake system. (See procedure in Section 60).
411
Install Transmission
4. Connect ground speed sensor connector (B).
5.
H66687-UN: Axle
LEGEND:
A - Snap Ring (2 used)
B - Sleeve (2 used)
C - Pin (2 used)
D - Coupling (2 used)
Slide couplers (D) onto shaft and install pins (C).
6. Slide sleeves (B) over couplers (D) and retain with snap rings (A).
7.
H66681-UN: Shift Cable
LEGEND:
A - Wire Connector (2 used)
B - Connector
C - Shift Cable
Connect wire connectors (A) and connector (B).
8. Connect shift cable (C) to transmission.
9. Adjust gearshift linkage. (See Adjust Gearshift Linkage in this group.)
412
Install Transmission
10.
H66682-UN: Pump and Shield
LEGEND:
A - Hydrostatic Motor
B - Shield
Install hydrostatic motor and install nuts (A). Tighten to specification.
Item
Measurement Specification
Hydrostatic Motor-to-Transmission Mount Cap Screws Torque
115 N˙m
(85 lb-ft)
11. Install shield (B).
12.
ZX25185-UN: Park Brake
LEGEND:
A - Nut (2 used)
B - Balancer
Install park brake cables in balancer (B).
13. Install nuts (A) on park brake cables.
14. Adjust park brake. (See procedure in Section 60).
Go to Section_50:Group_05
OUO6037,0001420-19-20010618
413
Remove and Install Gearshift Lever and Linkage
Remove and Install Gearshift Lever and Linkage
H73330-UN: Shift Linkage
LEGEND:
A - Knob
B - Shift Lever
C - Decal
D - Cap Screw
E - Bearing
F - Cap Screw
G - Clamp
H - Nut
414
Remove and Install Gearshift Lever and Linkage
I - Ball Joint
J - Bracket
K - Round Head Bolt
L - Nut
M - Cap Screw
N - Clamp
O - Cable
P - Isolator
Q - Bracket
R - Nut
S - Cap Screw
T - Cap Screw
U - Washer
V - Housing
W - Seal
X - Boot
1. Remove knob (A).
2. Remove parts as needed.
3. Inspect and replace parts as necessary.
4. Install parts as needed. Install knob (A).
5. Adjust gearshift linkage. (See procedure in this group.)
Go to Section_50:Group_05
OUO6435,0001951-19-20021028
415
Adjust Gear Shift Linkage
Adjust Gear Shift Linkage
H55103-UN: Shift Linkage
H66753-UN: Transmission Shift Linkage
LEGEND:
A - Nut
B - Ball Joint
C - Dimension
D - Clamp
E - Shift Arm
F - Nut
G - Ball Joint
H - Dimension
I - Clamp
1. Shift transmission into second gear. Gearshift lever should be leaning slightly forward.
2. From under cab, loosen nut (A). Remove and adjust ball joint (B) to specified dimension (C). Do not
adjust clamp (D).
Item
Measurement Specification
Gearshift Linkage Distance
237 mm
(9.3 in.)
3. At transmission, remove ball joint (G) from shift arm (E). Shift arm should be straight down.
4. Loosen nut (F) and adjust ball joint (G) until stud on ball joint aligns with hole in shift arm (E). Reinstall
ball joint (G) to shift arm (E).
5. Check for specified dimension (H). Do not adjust clamp (I).
416
Adjust Gear Shift Linkage
Item
Measurement Specification
Gearshift linkage Distance
237 mm
(9.3 in.)
Go to Section_50:Group_05
OUO6037,0001403-19-20010314
417
Essential or Recommended Tools
Essential or Recommended Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
To remove and install final drives.
H40598-UN: Service Jack
Final Drive Adapter.......JT05874
Use with D05070ST service jack to remove and install
final drives.
H40599-UN: Final Drive Adapter
Final Drive Spindle Nut Socket.......JDG665
To remove and install spindle nut.
H46365-UN: Final Drive Spindle Nut Socket
418
Essential or Recommended Tools
Final Drive Repair Kit .......JDG690
To repair final drive.
H44021-UN: Final Drive Repair Kit
Final Drive Repair Kit (Heavy Duty) .......JDG1296
Used in conjunction with JDG690 to repair heavy duty
final drive.
H55333-UN: Final Drive Repair Kit (Heavy Duty)
Go to Section_50:Group_10
ZX09263,0002732-19-20080131
419
Essential or Recommended Tools
Essential or Recommended Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
To remove and install final drives.
H40598-UN: Service Jack
Final Drive Adapter.......JT05874
Use with D05070ST service jack to remove and install
final drives.
H40599-UN: Final Drive Adapter
Final Drive Spindle Nut Socket.......JDG665
To remove and install spindle nut.
H46365-UN: Final Drive Spindle Nut Socket
420
Essential or Recommended Tools
Final Drive Repair Kit .......JDG690
To repair final drive.
H44021-UN: Final Drive Repair Kit
Final Drive Repair Kit (Heavy Duty) .......JDG1296
Used in conjunction with JDG690 to repair heavy duty
final drive.
H55333-UN: Final Drive Repair Kit (Heavy Duty)
Go to Section_50:Group_10
ZX09263,0002732-19-20080131
421
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
17-1/2 and 30-Ton
Puller Set
To remove and
install bearings and
seals.
Bushing, Bearing, and
Seal Driver Set
Used to remove and install
bushings, bearings and
seals.
Dial Indicator
Used to check pinion
gear shaft preload/end
play.
Go to Section_50:Group_10
ZX09263,0002734-19-20080131
422
Other Material
Other Material
Number
Name
Use
TY15130
(U.S.)
Form-in-Place Gasket
Seal inner and outer housing.
TY6252 (U.S.) 80W90 GL5 GEAR LUBE
To service final drives.
TY6304 (U.S.) Flexible Sealant
Seal final drive end cap and final drive pinion cap.
TY6341 (U.S.) Multipurpose SD Polyurea
Grease
To pack bearings and lubricate drive shaft splines and
coupler.
AR41870
(U.S.)
Protect components in storage.
Corrosion Inhibitor
Go to Section_50:Group_10
AG,OUO6435,626-19-20000503
423
Specifications
Specifications
Item
Measurement
Specification
Front Tire and Wheel
Approximate Weight (without
ballast)
400 kg
(882 lb)
Final Drive
Weight
233 kg
(514 lb)
Final Drive Cap Screws (Standard Duty)
Torque
500 ± 150 N˙m
(369 ± 111 lb-ft)
Final Drive Cap Screws (Heavy Duty)
Torque
620 ± 186 N˙m
(457 ± 137 lb-ft)
Front Wheel Bolts
Torque
200 N˙m + 90°
(150 lb-ft plus an additional 1/4
turn)
Dowel Pin
Exposed Length
20 mm
(13/16 in.)
Inner Housing-to-Outer Housing Cap
Screws
Torque
320 N˙m
(235 lb-ft)
Bearing Cap-to-Outer Housing Cap Screws Torque (Preload Measurement)
12 N˙m
(106 lb-in.)
Pinion Shaft Gear
-0.1— +0.05 mm
(-0.004—+0.002 in.)
Axial Play
Bearing Cap-to-Outer Housing Cap Screws Torque
73 N˙m
(55 lb-ft)
Spindle Bearing Adjustment (preferred
method)
Deflection
0.30—0.36 mm
(0.003—0.010 in.)
Spindle Bearing Adjustment (alternative
method)
Torque
375 N˙m
(275 lb-ft)
Go to Section_50:Group_10
OUO6435,0001906-19-20020904
424
Remove and Install Final Drive
Remove and Install Final Drive
H65640-UN: Jackstand
LEGEND:
A - Service Jack
B - Front Axle
CAUTION:
Before removing final drive, empty the grain tank and remove the header.
1. Set park brake and block up wheels.
2. Loosen wheel bolts one turn. Do not remove at this time.
CAUTION:
3.
Block up front axle before removing wheels.
CAUTION:
The jack must have a minimum rating of 5443 kg (6 tons).
Raise combine using jack (A) positioned in jack pocket. Jack pockets are located on either side on
combine near the feeder house lift cylinder attachment points.
4. Block up front axle (B) or install JT02043 12-Ton Support Stand.
5. Support the wheel. Remove wheel bolts to remove the wheel.
Item
Measurement
Specification
Front Tire and Wheel Approximate Weight (without ballast) 400 kg
(882 lb)
425
Remove and Install Final Drive
6.
H40059-UN: Final Drive Shaft
LEGEND:
A - Spiral Snap Ring
B - Sleeve
C - Pin
D - Drive Coupler
Pry out spiral snap ring (A) and slide sleeve (B) inward.
7. Drive out pin (C) and drive coupler (D) inward.
8. Drain final drive.
9.
CAUTION:
The approximate weight of final drive is 233 kg (514 lb).
Item
Measurement Specification
Final Drive Weight
233 kg
(514 lb)
426
Remove and Install Final Drive
H50245-UN: Final Drive
Use D05070ST Service Jack (C) with JT05874 Final Drive Adapter (B) to remove final drive (A).
10.
H72006-UN: Final Drive
H72007-UN: Final Drive
LEGEND:
427
Remove and Install Final Drive
A - Cap Screw (6 used)
Remove cap screws (A).
11. If dowel pins do not come out with final drive, remove from axle and install in housing.
12. Remove and repair final drive as necessary. See Disassemble and Assemble Final Drive in this Group.
13. Install axle spacers if necessary. See Specifications in this group for torques.
14.
CAUTION:
The approximate weight of final drive is 233 kg (514 lb).
Item
Measurement Specification
Final Drive Weight
233 kg
(514 lb)
H50245-UN: Final Drive
Use D05070ST Service Jack (C) with JT05874 Final Drive Adapter (B) to install final drive (A).
428
Remove and Install Final Drive
15.
H72006-UN: Final Drive
H72007-UN: Final Drive
LEGEND:
A - Cap Screw (6 used)
Lubricate threads of cap screws (A) with grease or oil.
16. Install cap screws and tighten to specification.
Item
Measurement Specification
Final Drive Cap Screws (Standard Duty) Torque
500 ± 150 N˙m
(369 ± 111 lb-ft)
Final Drive Cap Screws (Heavy Duty)
620 ± 186 N˙m
(457 ± 137 lb-ft)
Torque
17. Apply Multipurpose SD Polyurea Grease to drive shaft splines and coupler.
18.
H40059-UN: Final Drive Shaft
LEGEND:
429
Remove and Install Final Drive
A - Spiral Snap Ring
B - Sleeve
C - Pin
D - Coupler
Drive coupler (D) toward final drive and drive in pin (C) flush with coupler.
19. Slide sleeve (B) on and install spiral snap ring (A).
20. Fill final drive with 8.5 L (9 qt) of 80W90 GL5 Gear Lube. (See Fuel, Lubricants, Coolant and Capacities
in Section 10).
CAUTION:
21.
The approximate weight of tire and wheel is 400 kg (882 lb) (without liquid
ballast).
Install wheel. Tighten to specification.
Item
Measurement Specification
Front Wheel Bolts Torque
200 N˙m + 90°
(150 lb-ft plus an additional 1/4 turn)
Go to Section_50:Group_10
OUO6435,0001905-19-20020904
430
Disassemble and Assemble Final Drive
Disassemble and Assemble Final Drive
N60012-UN: Final Drive
LEGEND:
1 - Axle
2 - Oil Seal
3 - Oil Seal Cup
4 - Bearing Cone
5 - Bearing Cup
6 - Seal
7 - Grease Fitting
8 - Outer Housing
9 - Fitting (2 used)
10 - Line
11 - Dowel Pin (2 used)
12 - Ring Gear
13 - Inner Housing
14 - Plug
15 - Snap Ring
16 - Spacer
17 - Bearing Cup
18 - Bearing Cone
19 - Dust Cap
20 - Retaining Ring
21 - Key
22 - Nut
23 - Bearing Cup
24 - Bearing Cone
25 - Pinion Gear
26 - Bearing Cone
27 - Bearing Cup
431
Disassemble and Assemble Final Drive
28 - Shim (as required)
29 - Cap
30 - Cap Screw (4 used)
31 - Cap Screw (12 used)
32 - Seal
CAUTION:
1.
The approximate weight of final drive is 233 kg (514 lb). Always use appropriate
lifting device to avoid injury or death.
Item
Measurement Specification
Final Drive Weight
233 kg
(514 lb)
Stand final drive on axle flange.
2.
H44787-UN: Final Drive
H44022-UN: Final Drive
LEGEND:
A - Nut
B - Key
C - Cap
D - Retaining Ring
E - Socket
Pry off cap (C). Remove retaining ring (D) and key (B).
432
Disassemble and Assemble Final Drive
3. Remove nut (A) using JDG665 Final Drive Spindle Nut Socket (E).
4.
H71548-UN: JDG690-3 Adapter
LEGEND:
A - Adapter
Install adapter JDG690-3 (A) from JDG690 Final Drive Repair Kit to shaft end.
5. Remove cap screws holding outer housing to inner housing.
6.
NOTE:
Earlier made JDG690-1 Puller Adapter Plates may need to be modified for servicing
heavy duty final drives. Mounting holes will need to be enlarged to 25 mm (1 in.).
H71547-UN: Adapter Plate
LEGEND:
A - JDG690-1 Adapter Plate
B - Inner Housing
C - Cap Screw (4 used)
D - Spacer (4 used)
Attach JDG690-1 Adapter Plate (A) from JDG690 Final Drive Repair Kit to inner housing (B). Do this
using the 102 mm (4 in.) cap screws (C) and 57 mm (2-1/4 in.) spacers (D).
433
Disassemble and Assemble Final Drive
7.
H71549-UN: Disassemble Drive
LEGEND:
A - 17-1/2 and 30-Ton Puller Set
B - Cross Strap
C - Puller Screw
D - JDG690-3 Adapter
Attach D1047AA 17-1/2 and 30 ton puller set (A) to plate.
8. Install lifting device to cross strap (B) of puller set.
9. Thread puller screw (C) into JDG690-3 adapter (D) on axle shaft.
10. Separate inner housing using 17-1/2 and 30 ton puller set.
11.
CAUTION:
Ring gear and outer housing are heavy and can cause serious injury. Use two
persons or lifting device to remove parts.
IMPORTANT:
Lift ring gear using two blocks of wood, while removing inner housing from outer housing.
Remove inner housing from outer housing using hoist.
12. Remove bearing cone and spacer.
13. Clean gasket material from housings. Run a wire through vent/fill plug to be sure it is open.
14.
H40230-UN: Final Drive
434
Disassemble and Assemble Final Drive
LEGEND:
A - Bearing Cup
Inspect bearing cup (A). If replacement is necessary, drive bearing cup from inner housing.
15.
H40231-UN: Final Drive
Apply a light coat of TY6341 Multi-Purpose SD Polyurea grease to inner housing bore.
16. Install bearing cup into bore of inner housing.
17.
H40232-UN: Final Drive
LEGEND:
A - Bearing Cup
Remove pinion gear and bearing cup (A).
18. Remove seal from pinion shaft bore.
19.
H40233-UN: Final Drive
LEGEND:
A - Bearing Cup
Inspect bearing cup (A). If replacement is necessary, drive bearing cup from pinion shaft bore.
435
Disassemble and Assemble Final Drive
20. Apply a light coat of TY6341 Multi-Purpose SD Polyurea Grease to pinion shaft bore. Drive in bearing
cup.
21.
H40234-UN: Final Drive
LEGEND:
A - Seal
Install seal (A) flush with housing.
22. Inspect and replace pinion shaft bearings as necessary. Go to Step 27, if replacement is not necessary.
23.
H44026-UN: Pinion Gear
LEGEND:
A - Block Bearing Remover
B - Bearing (2 used)
Remove bearing (B) from pinion shaft, using JDG1296-3 Block Bearing Remover (A) from JDG1296
Final Drive Repair Kit, and a puller.
24. Pack bearings with TY6341 Multi-Purpose SD Polyurea Grease (or equivalent).
436
Disassemble and Assemble Final Drive
25.
H40236-UN: Pinion Gear
LEGEND:
A - Bearing (2 used)
Install bearings (A) on pinion shaft using JDG1296-6 driver from JDG1296 Final Drive Repair Kit.
26. Install pinion shaft and bearing cup in inner housing.
27.
CAUTION:
Ring gear and outer housing are heavy and can cause serious injury or death to
you or others if they fall. Use two persons or lifting device to remove parts.
H71559-UN: Ring Gear
LEGEND:
A - Beveled Spacer
B - Ring Gear
C - Outer Housing
Remove beveled spacer (A).
28. Lift ring gear (B) off axle shaft.
29. Remove outer housing (C) from axle shaft.
30. Turn outer housing over.
437
Disassemble and Assemble Final Drive
31.
H40247-UN: Outer Housing
LEGEND:
A - Bearing Cup
Remove bearing cup (A) and inner seal.
32. Apply a light coat of TY6341 Multi-Purpose SD Polyurea Grease to bore of outer housing.
33.
H40246-UN: Outer Housing
LEGEND:
A - Oil Seal
B - Seal Cup
Coat oil seal lip with TY6341 Multi-Purpose SD Polyurea Grease.
34. Install oil seal (A) with lip to inside of housing. Drive seal until fully seated against housing bore.
35. Press bearing cup into housing.
36. Press oil seal cup (B) into housing, until flange is seated against housing.
37. Press dowel pins into finished flanged surface until exposed length meets the specification.
Item
Measurement
Specification
Dowel Pin Exposed Length 20 mm
(13/16 in.)
438
Disassemble and Assemble Final Drive
38.
H44027-UN: Axle
LEGEND:
A - V-Ring Seal
B - Bearing Cone
C - Seal
D - Long Puller Leg (2 used)
Remove V-ring seal (A), bearing cone (B), and seal (C) from axle using puller from JDG1296 Final Drive
Repair Kit and D1047AA 17-1/2 and 30 ton puller set.
NOTE:
Long puller legs (D) must be used.
39. Apply Multi-Purpose SD Polyurea Grease to seal lips.
40. IMPORTANT:
Metal edge of seal (C) must face toward outer housing when placed over axle.
H44028-UN: Axle
LEGEND:
A - JDG1296-2 Driver
B - JDG1296-5 Driver
C - Seal
Install seal (C) using JDG1296-2 driver (A) and JDG1296-5 (B) from JDG1296 Final Drive Repair Kit and
D1047AA 17-1/2 and 30 ton puller set.
41.
NOTE:
Pack all bearing cones with TY6341 Multi-Purpose SD Polyurea Grease before
assembly.
439
Disassemble and Assemble Final Drive
H44029-UN: Axle
LEGEND:
A - JDG1296-2 Driver
B - Bearing Cone
C - JDG690-3 Adapter
D - Puller Screw
Thread puller screw (D) into JDG690-3 adapter (C) on axle shaft. Install bearing cone (B) on axle using
JDG1296-2 driver (A) from JDG1296 Final Drive Repair Kit and D1047AA 17-1/2 and 30 ton puller set.
42. Install V-ring seal next to bearing cone. V-lip must be pointed away from bearing cone.
43. Install snap ring inside ring gear.
44.
H71559-UN: Ring Gear
LEGEND:
A - Beveled Spacer
B - Ring Gear
C - Outer Housing
Set axle on flat surface, shaft up.
45. Install outer housing (C) on axle.
440
Disassemble and Assemble Final Drive
46. Place wood blocks on outer housing.
47. Install ring gear (B) on axle, snap ring side up.
48. Install spacer (A) with beveled side toward bearing.
49. Apply a 1.5 mm (0.06 in.) continuous bead of TY15130 form-in-place gasket around flange of outer
housing.
50. Install inner housing on outer housing. Tighten cap screws to specification.
Item
Measurement Specification
Inner Housing-to-Outer Housing Cap Screws Torque
320 N˙m
(235 lb-ft)
51. Install inner bearing. Seat into bearing cup.
52.
H44787-UN: Housing
H44022-UN: Socket
LEGEND:
A - Nut
B - Key
C - Cap
D - Retaining Ring
E - Socket
Install nut (A). Tighten nut until SNUG using JDG665 socket (E). Do not overtighten bearings. (See
Adjust Spindle Bearing in this group.)
441
Disassemble and Assemble Final Drive
53. IMPORTANT:
Install plastic shims against each housing cast surface.
H71258-UN: Final Drive
LEGEND:
A - Cap Screw (4 used)
B - Bearing Cap
C - Shim (as required)
D - Housing
Install shim pack (C). If old shims have not been damaged, they may be used. If damaged, assemble a
new pack as follows:
0.13 mm (0.005 in.) - Plastic - 2 used
0.25 mm (0.010 in.) - Steel - 1 used
0.50 mm (0.020 in.) - Steel - 1 used
54. Attach bearing cap (B) with entire shim pack to housing (D). Tighten cap screws (A) to specification.
Item
Measurement
Specification
Bearing Cap-to-Outer Housing Cap Screws Torque (Preload Measurement) 12 N˙m
(106 lb-in.)
55.
Adjust pinion gear end play using the following special instructions:
442
Disassemble and Assemble Final Drive
1. Measure and record pinion gear shaft end play with dial indicator.
2. Remove bearing cap and add or remove shims as needed to achieve specification.
Item
Measurement Specification
Pinion Shaft Gear End Play
-0.1—+0.05 mm
(-0.004—+0.002 in.)
3. Remove cap and apply 1.5 mm (0.06 in.) bead of TY6304 Flexible Sealant to lip of cap and
install.
4. Tighten cap screws to specification.
Item
Measurement Specification
Bearing Cap-to-Outer Housing Cap Screws Torque
73 N˙m
(55 lb-ft)
56. Apply TY6341 Multi-Purpose SD Polyurea Grease at lubrication fitting until grease leaks out around seal.
NOTE:
If final drive is to be placed in service parts storage, add 29.6 mL (1 oz.) of AR41870 Corrosion
Inhibitor.
Go to Section_50:Group_10
OUO6435,0001888-19-20020818
443
Adjust Spindle Bearing (Preferred Method)
Adjust Spindle Bearing (Preferred Method)
1.
H41196-UN: Final Drive
LEGEND:
A - Dial Indicator
B - Flat Bar
C - Nut
D - Axle
Rotate final drive assembly two revolutions to seat lower bearing.
2. Install flat bar (B) across mounting flange.
3. Install dial indicator (A) on bar with indicator tip on axle (D). Set dial at zero.
4. Tighten nut (C) until specified housing deflection is observed.
Item
Measurement Specification
Spindle Bearing Adjustment (preferred method) Deflection
0.30—0.36 mm
(0.012—0.014 in.)
5. Advance nut until it can be locked.
6. Apply a bead of flexible sealant to lip of cap and install cap.
Go to Section_50:Group_10
AG,OUO6435,630-19-20000503
444
Adjust Spindle Bearing (Alternative Method)
Adjust Spindle Bearing (Alternative Method)
1.
H63013-UN: Spindle Bearing
LEGEND:
A - Nut
Rotate final drive assembly two revolutions to seat bearings.
2. Tighten nut (A) to specification.
Item
Measurement Specification
Spindle Bearing Adjustment (alternative method) Torque
375 N˙m
(275 lb-ft)
3. Advance nut until it can be locked.
4. Apply a bead of flexible sealant to lip of cap and install cap.
Go to Section_50:Group_10
OUO6435,0001714-19-20020419
445
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Hydrostatic Transmission Tool
Kit.......JDG630
To repair hydrostatic pump and motor.
H55899-UN: JDG630
Seal Remover.......JDG351
To install rotating seal.
H40189-UN: Seal Remover
Snap Ring Pliers.......JDG114
Used to remove and install internal snap rings.
H40188-UN: Snap Ring Pliers
Go to Section_50:Group_15
ZX09263,0002735-19-20080131
446
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Hydrostatic Transmission Tool
Kit.......JDG630
To repair hydrostatic pump and motor.
H55899-UN: JDG630
Seal Remover.......JDG351
To install rotating seal.
H40189-UN: Seal Remover
Snap Ring Pliers.......JDG114
Used to remove and install internal snap rings.
H40188-UN: Snap Ring Pliers
Go to Section_50:Group_15
ZX09263,0002735-19-20080131
447
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Portable Filter Caddy.......JT05746
Used to flush hydraulic/hydrostatic systems.
H68347-UN: JT05746
Vacuum Pump.......D15032NU
To perform service work without draining reservoir.
H68348-UN: D15032NU
SAE Dial
Indicator.......D17526C1
To measure shaft end
play
Metric Dial
Indicator.......D17527C1
To measure shaft end
play
Slide
Hammer.......D01399AA
To remove pump
trunnions.
Micrometer.......D17511C1
To measure piston slipper flange
and slipper retainer flange
thickness.
Spring Scale
To check
swashplate
movement.
448
Service Equipment and Tools
Depth
Micrometer
Checking zero
angle of
swashplate.
Magnetic
Base.......D17525C1
To hold dial
indicator.
Low Clearance
Bearing Puller
To remove bearing
cone from pump
shaft.
Spring Scale
To check
swashplate
movement.
Go to Section_50:Group_15
ZX09263,0002736-19-20080131
449
Other Material
Other Material
Number
Name
Use
TY22000 (U.S.)
HY-GARD Hydraulic Oil
To service/flush hydraulic/hydrostatic systems and prelube parts during assembly.
T43512 (U.S.)
Thread Lock and Sealer
(Medium Strength)
Apply to threads of piston shoulder bolts and holes in
swashplate.
T43513 (U.S.)
Thread Lock and Sealer (High Apply to holes in swashplate.
Strength)
SCOTCH ™ 3M
#1606 (U.S.)
Electrical Contact Cleaner
To clean parts.
Go to Section_50:Group_15
AG,OUO6435,634-19-20021120
450
Specifications
Specifications
Item
Measurement
Specification
Hydraulic/Hydrostatic Reservoir
Approximate Capacity
34 L
(36 qt)
Motor
Weight
40 kg
(90 lb)
Hydrostatic Motor-to-Transmission Mount
Cap Screws
Torque
115 N˙m
(85 lb-ft)
Connecting Screws
Torque
22—26 N˙m (16—19 lb-ft).
Swashplate Mounting Screws
Torque
27—33 N˙m (20—24 lb-ft).
Motor Cover-to-Housing Cap Screws
Torque
53 N˙m (39 lb-ft) (final drive with ring gear
and pinion)
Shaft End Play
Movement
0.05—0.17 mm (0.002—0.007 in.)
Valve Block-to-Motor Cap Screws
Torque
38 N˙m
(28 lb-ft)
Control Valves in Valve Block
Torque
163—197 N˙m (120—145 lb-ft)
Hex. Plugs
Torque
92—111 N˙m (68—82 lb-ft)
Pump
Weight
68 kg
(160 lb)
Shoulder Bolt-to-Servo Piston Cap Screw
Torque
22—26 N˙m
(192—228 lb-in.)
Plug (A)
Torque
81 N˙m
(60 lb-ft)
Plug (B)
Torque
12 N˙m
(9 lb-ft)
Plugs (C)
Torque
7 N˙m
(5 lb-ft)
Plug (D)
Torque
12 N˙m
(9 lb-ft)
Rotating Group
Fixed Clearance
0.20 mm
(0.008 in.)
Swashplate Retaining Strap Cap Screws
Torque
24 N˙m
(17.5 lb-ft)
Pump Trunnion Cap Screws
Torque
60 N˙m
(44 lb-ft)
Swashplate Zero Angle
Maximum Allowable
Difference
0.12 mm
(0.005 in.)
Maximum Allowable
Rock
0.03 mm
(0.010 in.)
Pump Mounting Flange Cap Screws
Torque
60 N˙m
(44 lb-ft)
End Cover-to-Drive Pump Cap Screws
Torque
85 N˙m
(63 lb-ft)
Pump Drive Shaft
End Play
0.05—0.18 mm
(0.002—0.007 in.)
Valve Plate-to-End Cover Cap Screws
Torque
85 N˙m
(63 lb-ft)
Charge Pump-to-End Cover Cap Screws
Torque
27—33 N˙m
(20—24 lb-ft)
Hydrostatic drive pump cover plugs
451
Specifications
Item
Measurement
Specification
Control Valve-to-Pump Cap Screws
Torque
22 N˙m
(16 lb-ft)
Spring Box (A)
Torque
81 N˙m (60 lb-ft)
Plug (E)
Torque
12 N˙m (9 lb-ft)
Plug (F)
Torque
7 N˙m (5 lb-ft)
Plug (G)
Torque
7 N˙m (5 lb-ft)
Plug (I)
Torque
12 N˙m (9 lb-ft)
Attaching Screws
Torque
22—26 N˙m (264—312 lb-in.)
Pump
Weight
68 kg
(160 lb)
Hydrostatic Pump-to-Engine Gear Case
Cap Screws
Torque
130 ± 50 N˙m
(96 ± 36 lb-ft)
Low Pressure Relief Valve
Torque
108 N˙m (80 lb-ft)
Charge Pump-to-Pump Cover Cap Screws Torque
27—33 N˙m (20—24 lb-ft)
Go to Section_50:Group_15
OUO6037,0001489-19-20010821
452
Flush the Hydrostatic System
Flush the Hydrostatic System
NOTE:
If the original failure occurred in the hydraulic or reel drive area, the hydrostatic system has inlet
filtration which protects all components and lines EXCEPT the charge pump. Flush the charge
pump (steps 6 and 7), but the remaining steps are not necessary.
1. Remove hydrostatic units. The hydro units cannot be flushed. These units must be disassembled and
cleaned, or rebuilt units ordered.
2. Remove reservoir and clean thoroughly.
3. Remove and discard the filter element.
4. The cooler cannot be thoroughly cleaned. With inlet filtration to the hydrostatic pump this is not a
concern.
5. Remove charge pump.
6. Using hoses supplied with the transfer unit, and proper hose fittings, connect from outlet port of the
transfer unit to the inlet port of the charge pump. Connect hose from the outlet port of the charge pump
to drum of flushing oil.
7. Activate the transfer unit and slowly rotate the charge pump shaft by hand while flushing.
8. Flush all hoses and lines thoroughly.
Go to Section_50:Group_15
1401,DV475-19-20030206
453
Remove and Install Hydrostatic Motor
Remove and Install Hydrostatic Motor
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
IMPORTANT:
When disconnecting a line, hose, or transfer tube from a hydrostatic component, always mark end and port from
which it was removed so that it can be connected to proper port when reassembling.
Also, when disconnecting a line, hose, or transfer tube from a component, always plug them to keep dirt out of
system. Use a plastic plug or plastic bag - never a cloth. Cloth contains lint which can damage hydrostatic system.
High pressure hoses have clamp-type bolted fittings with O-rings. When this type of fitting is disassembled, inner
surfaces must be cleaned thoroughly and new O-rings installed. This is to ensure a tight seal and reduce
possibility of leakage.
1. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2. Install D15032NU vacuum pump on reservoir or drain reservoir.
Item
Measurement
Specification
Hydraulic/Hydrostatic Reservoir Approximate Capacity 34 L
(36 qt)
454
Remove and Install Hydrostatic Motor
3.
H65658-UN: Hydrostatic Motor
LEGEND:
A - Lines
B - Nut (4 used)
Disconnect lines (A). Plug lines or cover with plastic bags.
CAUTION:
4.
The approximate weight of motor is 40 kg (90 lb).
Item Measurement Specification
Motor Weight
40 kg
(90 lb)
Remove nuts (B) and pull motor away from transmission mount.
5. Repair motor as necessary.
6. Attach motor to mount with nuts (B). Tighten to specification.
Item
Measurement Specification
Hydrostatic Motor-to-Transmission Mount Cap Screws Torque
115 N˙m
(85 lb-ft)
7. Replace O-rings in lines (A). Connect hoses to motor.
8. Check oil levels. Start engine and bleed system. (See procedure in this group.)
Go to Section_50:Group_15
OUO6030,000009A-19-20010601
455
Disassemble Hydrostatic Motor
Disassemble Hydrostatic Motor
H52972-UN: Hydrostatic Motor
LEGEND:
A - Cap Screw (4 used)
B - Valve Block
C - Motor
1. Set motor on a sleeve, at least 50 mm (2 in.) high, or wooden support.
2. IMPORTANT:
Do not drop block on motor end cover while removing.
Remove cap screws (A) that hold valve block (B) to motor (C).
3. Remove valve block.
4.
NOTE:
Clean dirt out of seal area using a spray lubricant or solvent prior to disassembly. Do not
use cloth or brush.
H68382-UN: Hydrostatic Motor
LEGEND:
A - Snap Ring
Remove snap ring (A) using JDG114 Snap Ring Pliers, or equivalent.
456
Disassemble Hydrostatic Motor
5.
H68383-UN: Remove Stationary Seal
LEGEND:
A - Sheet Metal Screw
B - Seal
Use a center punch or ice pick to make a small hole in the side of seal (B). Be careful not to damage
bearing or sealing surfaces.
6. Remove stationary seal (B) after taking out sheet metal screw (A).
457
Disassemble Hydrostatic Motor
7.
H51946-UN: Motor
H51947-UN: Valve Plates
458
Disassemble Hydrostatic Motor
LEGEND:
A - Cap Screw (8 used)
B - End Cover
C - Gasket
D - Shims
E - Bearing Cup
F - Pump Valve Plate
G - Dowel Pin (2 used)
H - Motor Valve Plate
I - Metering Slots
Internal parts are spring loaded. To avoid internal damage, remove six of eight cap screws (A) securing
end cover (B) to motor housing, leaving two opposite screws tight. Gradually and evenly remove those
two screws. End cover should raise. If not, carefully tap end cover from housing.
8. Carefully remove end cover (B), gasket (C) and two dowel pins (G). If valve plate (F) is stuck to end
cover, hold in place and remove with cover. Avoid dropping parts.
NOTE:
Pump valve plates (F) are all unidirectional (clockwise) with two metering slots (I). Motor
valve plates (H) are bidirectional with four metering slots (I). PUMP AND MOTOR
VALVE PLATES ARE NOT INTERCHANGEABLE.
9. Remove bearing cup (E) from end cover (B). Use a slight twisting motion. Bearing cup is a slip fit in end
cover.
10. Remove shims (D) from end cover. Do not misplace shims as they are used to adjust end play of motor
output shaft.
11. IMPORTANT:
Handle bearing and valve plates with extreme care. Plates are lapped to extremely close tolerances for
flatness.
If valve plate is not removed with end cover, insert a small screwdriver in oil drain slots of valve plate.
Carefully pry valve plate away from bearing plate.
12. Insert a small screwdriver in oil drain slot of bearing plate. Carefully lift plate from cylinder barrel. Wrap
both parts separately in clean paper.
459
Disassemble Hydrostatic Motor
13.
H41407-UN: Hydrostatic Motor
Place a small block under motor shaft to raise it. Protect cylinder barrel with a clean cloth or paper
before pulling bearing.
14. Use low clearance puller from JDG630 Hydrostatic Transmission Tool Kit to remove end cover bearing
cone.
15. Lay motor on its side. Take out the two cap screws that secure the swashplate in the housing.
16. Remove and discard washers from cap screws. Replace with NEW washers.
17. Push output shaft assembly inward to dislodge swashplate from housing.
18. Carefully remove cylinder barrel assembly and output shaft from housing.
460
Disassemble Hydrostatic Motor
19.
H44037-UN: Output Shaft
LEGEND:
A - Output Shaft Assembly
Position cylinder barrel and output shaft assembly (A) in up position.
20. Remove output shaft.
21. IMPORTANT:
Caution must be used when replacing the motor output shaft bearing. Bearings are pressed to a
dimension, NOT to the shoulder on the shaft.
NOTE:
Use dimensions in table to construct the special stop limit tool (made of steel).
461
Disassemble Hydrostatic Motor
H45052-UN: Dimensions
When output shaft bearing cone must be replaced, use a press to remove cone from shaft.
-: Dimensions
Stop Limit Tool
Type
Dimension
A
± 0.025 mm (0.001 in.)
B
C
D
(min.)
1
Standard Duty
147.4 mm
(5.803 in.)
25.4/30.5 mm
(1.00/1.20 in)
55.9/58.4 mm 76.2 mm
(2.20/2.30 in) (3.0 in.)
2
Heavy Duty
169.7 mm
(6.682 in.)
33.0/ 33.5 mm
(1.30/1.32 in.)
57.2/59.7 mm 76.2 mm
(2.25/2.35 in.) (3.0 in.)
22. Use a special stop limit tool (see illustration) when installing NEW cone on shaft.
462
Disassemble Hydrostatic Motor
23.
H44038-UN: Hydrostatic Motor
Use bearing puller or punch to remove shaft bearing cup from housing.
24. Carefully reposition cylinder barrel and swashplate with swashplate in down position.
25.
463
Disassemble Hydrostatic Motor
H44039-UN: Hydrostatic Motor
LEGEND:
A - Cap Screw (2 used)
B - Retaining Strap
C - Spacer (2 used)
Remove cap screws (A) from retaining strap (B) and spacers (C) on one side of swashplate.
26. Loosening cap screws on other retaining strap will make it easier to remove cylinder barrel from
swashplate.
27.
H44040-UN: Hydrostatic Motor
LEGEND:
A - Swashplate
B - Cylinder Barrel
C - Retaining Strap
D - Cap Screw (2 used)
E - Spacer (2 used)
F - Piston Assembly
G - Thrust Plate
Carefully position cylinder barrel (B) and swashplate (A) with swashplate in up position. Lift swashplate
slightly, slide over to disengage from retaining strap (C) and remove.
464
Disassemble Hydrostatic Motor
28. Remove cap screws (D), retaining strap (C), spacers (E) and thrust plate (G) from swashplate (A).
29. Disassemble cylinder barrel assembly (B). Place on clean protective surface for inspection and cleaning.
Go to Section_50:Group_15
OUO6435,0001651-19-20020305
465
Replace Cylinder Block Spring
Replace Cylinder Block Spring
LEGEND:
A - Outer Retaining Ring
B - Spiral Retaining Ring
C - Spring
D - Inner Retainer (Beveled)
1. Press outer retaining ring (A) down to compress spring (C).
2. Remove spiral retaining ring (B).
3. Remove retaining ring (A), spring, and beveled inner retainer (D).
4. Replace spring and reinstall parts.
5. Install beveled inner retainer (D) with beveled side toward splined end of block.
6. Install outer retaining ring (A) with shoulder towards open end of block.
7. Compress spring and outer retaining ring, then install spiral retaining ring.
Go to Section_50:Group_15
AG,OUO6435,657-19-20000503
466
Assemble Motor
Assemble Motor
H68386-UN: Hydrostatic Motor
LEGEND:
1 - Dowel Pin (5 used)
2 - Gasket
3 - Bearing
4 - Shim (as required)
5 - End Cover
6 - Lifting Strap (2 used)
7 - Cap Screw (6 used)
8 - Square Cut Seal
467
Assemble Motor
9 - Back-Up Washer (2 used)
10 - O-Ring (2 used)
11 - Valve Block
12 - Cap Screw (4 used)
13 - Cap Screw (2 used)
14 - Valve Plate
15 - Bearing Plate
16 - Cylinder Barrel
17 - Cap Screw (4 used)
18 - Retaining Strap (2 used)
19 - Spacer (4 used)
20 - Slipper Retainer Plate
21 - Piston and Slipper Assembly
22 - Thrust Plate
23 - Swashplate
24 - Drive Shaft
25 - Retaining Ring
26 - Output Shaft Bearing
27 - Motor Housing
28 - Cap Screw (2 used)
29 - Washer (2 used)
30 - Dowel Pin
31 - Socket Pipe Plug
32 - I.D. Tag and Screws
33 - Drain Plug and O-Ring
34 - Stationary Seal
35 - Retaining Ring
1. Assemble motor using exploded view for parts reference. Install new O-rings and gaskets. Apply
petroleum jelly to O-rings and finished surfaces. Apply clean hydraulic oil to parts as specified.
2. Clean parts in clean solvent. Dry with compressed air. Replace all damaged parts. Do not use coarse grit
paper, files, or grinders on finished surfaces. Replace gaskets and O-rings.
3. Lubricate O-rings with petroleum jelly for retention during assembly. Lubricate bearings and finished part
surfaces with clean hydraulic oil.
468
Assemble Motor
4.
H44041-UN: Piston Slipper Assembly and Cylinder Barrel
LEGEND:
A - Piston Slipper Assembly
B - Cylinder Barrel
Lubricate and install piston slipper assembly (A) in cylinder barrel (B). Lubricate brass slipper faces with
clean hydraulic oil.
5.
H67750-UN: Fixed Clearance
LEGEND:
A - Spacer Height
B - Retainer Plate
C - Slipper Flange
D - Piston Slipper
Check fixed clearance of assembly:
Measure height of spacer (A). Spacers are critical and can not be adjusted.
Measure thickness of piston slipper flange (C) and slipper retainer plate (B). Subtract this measurement
469
Assemble Motor
from spacer measurement (A) to get fixed clearance of assembly.
Fixed clearance must not exceed specification. If more, replace worn parts, i.e., piston slipper
assemblies, thrust plate, retaining strap, and slipper retainer plate.
Item
Measurement Specification
Fixed Clearance of Assembly Clearance
0.20 mm
(0.008 in.)
Fixed clearance = A - (C + B)
6. IMPORTANT:
Thread Lock and Sealer must contact only those parts intended before assembly. Apply non-petroleum
base solvent with cloth to wipe excess from swashplate.
H44043-UN: Motor Assembly
LEGEND:
A - Cap Screw (4 used)
B - Retainer (2 used)
C - Spacer (4 used)
D - Swashplate
E - Thrust Plate
Apply one or two drops of Thread Lock and Sealer (medium strength) in first or second thread down in
each of four holes in swashplate (D).
7. Lubricate and install thrust plate (E).
8. Align cap screw holes. Install spacers (C), retaining strap (B) and cap screws (A) on one side of
swashplate (D). Do not tighten cap screws at this time.
470
Assemble Motor
9. Put cylinder barrel assembly on clean, flat surface with piston slippers pointing up.
10. Carefully install swashplate on cylinder barrel by slightly lifting side without retaining strap. Slide
swashplate over to engage installed retaining strap around piston retainer.
11.
H44039-UN: Motor Assembly
LEGEND:
A - Cap Screw (2 used)
B - Retainer
C - Spacer
Carefully reposition cylinder barrel and swashplate with swashplate in down position. Install remaining
spacers (C), retainer (B), and cap screws (A). Tighten all four cap screws to specification.
Item
Measurement Specification
Swashplate Cap Screws Torque
22—26 N˙m
(16—19 lb-ft)
NOTE:
If a feeler gauge is used, make certain gauge is inserted between retaining strap and
slipper retainer plate ONLY. Slipper faces could be damaged if gauge is inserted
between piston slipper and thrust plate.
12. Position cylinder barrel and swashplate so cylinder barrel face is on a clean, flat surface.
13. Lubricate and install output shaft in cylinder barrel.
471
Assemble Motor
14.
H67749-UN: Motor Assembly
LEGEND:
A - Headless Cap Screw
Install two headless 5/16 X 6 in. cap screws (A) in swashplate to guide swashplate into pocket in
housing. Make certain to align dowel pin in housing with notch in swashplate.
15. Carefully slide housing over output shaft, swashplate and cylinder barrel assemblies.
472
Assemble Motor
16.
H44045-UN: Motor Assembly
LEGEND:
A - Headless Cap Screw (2 used)
B - Cap Screw (2 used)
C - Washer (2 used)
Hold cylinder barrel assembly in position in housing. Position motor on its side and remove headless cap
screws (A).
17. Install swashplate cap screws (B) with new special washers (C). Tighten cap screws to specification.
Item
Measurement Specification
Swashplate Mounting Cap Screws Torque
27—33 N˙m
(20—24 lb-ft)
473
Assemble Motor
18.
H67751-UN: Motor Assembly
Set motor on block with shaft down, being careful not to bump shaft and cause it to move up out of ball
guide.
19. Use a press or bearing driver to install end cover bearing cone on output shaft. Bearing cone must seat
against shoulder of output shaft.
20. Install two dowel pins and gasket on end cover.
474
Assemble Motor
21.
H44046-UN: Motor Assembly
LEGEND:
A - Bearing Cup
B - Shims
C - Cover
Lubricate and install shims (B) and bearing cup (A) into cover (C).
22. Check output shaft end play by installing end cover without installing valve or bearing plates. This
removes cylinder barrel spring tension against output shaft.
23. Install cap screws in end cover and evenly tighten to specification.
Item
Measurement Specification
Cover-to-Pump Cap Screws
On combines with standard duty final drives Torque
53 N˙m
(39 lb-ft)
On combines with heavy duty final drives
85 N˙m
(63 lb-ft)
Torque
24. Support motor assembly on end cover. Tap output shaft inward.
475
Assemble Motor
25.
H44047-UN: Motor Assembly
LEGEND:
A - Dial Indicator
B - Mounting Flange
C - Pliers
Install dial indicator (A) on mounting flange (B) with pointer on output shaft end. Use pliers (C) to grip
output shaft as low as possible.
26. Pry upward to determine shaft end play. End play must be within specification. Adjust as necessary by
adding or removing shims under bearing cup in end cover.
Item
Measurement Specification
Motor Shaft End Play
0.05—0.18 mm
(0.002—0.007 in.)
27. Generously coat with petroleum jelly then install bearing plate (brass) on cylinder barrel.
476
Assemble Motor
28.
H67752-UN: Motor Assembly
LEGEND:
A - Gasket
B - Valve Plate
C - End Cover
D - Dowel Pin (2 used)
Install end cover gasket (A) on motor.
29. Coat valve plate (B) (side towards cover) with petroleum jelly and set on end cover (C). Align dowel pin
(D) in end cover with slot in plate.
30. While holding valve plate inside end cover, align scribe marks and install end cover.
31. Install cap screws in end cover. Slowly and evenly tighten. Tighten cap screws to specification.
477
Assemble Motor
Item
Measurement Specification
End Cover-to-Hydrostatic Motor Cap Screws
On combines with standard duty final drives Torque
53 N˙m
(39 lb-ft)
On combines with heavy duty final drives
85 N˙m
(63 lb-ft)
Torque
32. Torque screws in a star pattern; then torque each screw a second time to compensate for gasket
compression.
33. IMPORTANT:
Do not use solvent from parts cleaning tank. This solvent may be contaminated and defeat the purpose
of cleaning shaft area.
Clean shaft area with a spray cleaner, such as an electrical contact cleaner or clean solvent in a spray
bottle.
34.
CAUTION:
During installation of seal use care not to damage the seal or the sealing surface.
H68384-UN: Install Seal
LEGEND:
A - Seal Installer
Coat new seal with clean hydraulic oil and install using a suitable seal installer (A).
478
Assemble Motor
35.
H68382-UN: Install snap ring.
Using JDG114 Snap Ring Pliers, install new snap ring (A), BEVELED EDGE OUT. Make sure snap ring
is fully expanded in its groove. Avoid damaging finished surfaces.
36. Rotate shaft, being careful not to damage splines. If shaft binds, recheck end play and reshim.
Go to Section_50:Group_15
OUO6030,000009C-19-20010601
479
Remove and Install Motor Valve Block (Manifold)
Remove and Install Motor Valve Block (Manifold)
1.
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other
lines. Tighten all connections before applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin
must be surgically removed within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a knowledgeable medical
source. Such information is available from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2. IMPORTANT:
Clean outside of motor thoroughly. Either steam clean or wash with solvent. Also clean surrounding area
so dirt will not get into system. If internal work is to be performed, keep work bench, tools and equipment
clean.
When disconnecting a line, hose or transfer tube from a hydrostatic component, always mark end and
port from which it was removed so that it can be connected to proper port when reassembling.
Also, when disconnecting a line, hose, or transfer tube from a component, always plug them and
component to keep dirt out of system. Use a plastic plug or plastic bag - never a cloth. Cloth contains lint
which can damage hydrostatic system.
High pressure hoses have clamp-type bolted fittings with O-rings. When this type of fitting is
disassembled, inner surfaces must be cleaned thoroughly and new O-rings installed. This is to ensure a
tight seal and reduce possibility of leakage.
Scribe a line between valve block and motor to assist in proper reassembly.
480
Remove and Install Motor Valve Block (Manifold)
3.
H68271-UN: Hydrostatic Motor
LEGEND:
A - Cap Screw (4 used)
B - Valve Block (Manifold)
C - Motor
Remove four cap screws (A) to remove valve block (B) from motor (C). It is not necessary to remove
motor to service valve block. Place a container under valve block to catch any oil that drains when block
is removed. Do not save drained oil.
4. Plug holes in end cap of motor with plastic plugs to minimize oil loss.
5. Cover motor end cap with plastic to keep dirt out of motor.
6. Repair valve block as necessary.
7. Attach valve block (B) to motor (C) with four cap screws (A). Tighten to specification.
Item
Measurement Specification
Valve Block-to-Motor Cap Screws Torque
38 N˙m
(28 lb-ft)
8. Check oil level. Start engine and bleed system. See procedure in this Group.
Go to Section_50:Group_15
OUO6030,000009D-19-20010601
481
Repair Motor Valve Block
Repair Motor Valve Block
H63624-UN: Motor Valve Block
LEGEND:
1 - Plug (2 used)
2 - O-Ring (2 used)
3 - Spring (2 used)
4 - Valve (2 used)
5 - O-Ring
6 - Ring
7 - Spool
8 - Washer (2 used)
9 - O-Ring (2 used)
10 - Seal
11 - Charge Pressure Relief Valve
12 - O-Ring (3 used)
13 - Ring (4 used)
14 - O-Ring (3 used)
15 - Valve (2 used)
16 - Block
482
Repair Motor Valve Block
17 - Plug (3 used)
18 - O-Ring (3 used)
19 - Cap Screw (4 used)
20 - Valve
1. Remove plugs (1) to remove shuttle valve spool (7) and components from both sides of valve block.
2. Remove pressure control valve (11).
3. Remove high pressure relief valves (15) from both sides of valve block. Wrench only on hex section next
to block body.
4. Clean all parts in solvent and dry thoroughly.
5. Check parts for excessive wear and scoring. Replace seal if necessary. If a high pressure relief valve or
low pressure control valve is defective, the complete valve must be replaced. Individual parts are NOT
available.
6. Install new O-rings on plugs and valves.
7. Install high pressure relief valves and low pressure control valve in valve block. Tighten valves to
specification.
Item
Measurement Specification
High Pressure Relief Valve Torque
100 N˙m
(75 lb-ft)
Low Pressure Control Valve Torque
165 N˙m
(125 lb-ft)
8. Install shuttle valve components. Tighten cap screws to the specification.
Item
Measurement Specification
Shuttle Valve Plugs Torque
92—111 N˙m
(68—82 lb-ft)
Go to Section_50:Group_15
AG,OUO6022,1854-19-20000725
483
Remove Hydrostatic Pump
Remove Hydrostatic Pump
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
1. Clean pump and surrounding area thoroughly.
2. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine and close accumulator shut-off valve.
3. IMPORTANT:
When disconnecting a line, hose, or transfer tube from a hydrostatic component, always mark end and
port from which it was removed so that it can be connected to proper port when reassembling.
Also, when disconnecting a line, hose, or transfer tube from a component, always plug them and
component to keep dirt out of system. Use a plastic plug or plastic bag - never a cloth. Cloth contains lint
which can damage hydrostatic system.
High pressure hoses have clamp-type bolted fittings with O-rings. When this type of fitting is
disassembled, inner surfaces must be cleaned thoroughly and new O-rings installed. This is to ensure a
tight seal and reduce possibility of leakage.
Install D15032NU vacuum pump on reservoir. If pump is not available, drain reservoir.
Item
Measurement
Specification
Reservoir Approximate Capacity 34 L
(36 qt)
484
Remove Hydrostatic Pump
4.
H55765-UN: Main Hydraulic Pump
LEGEND:
A - Main Hydraulic Pump
B - Charge Pump
C - Hydrostatic Pump
D - Cap Screw (4 used)
Disconnect lines to main hydraulic pump (A) and charge pump (B). Remove these items as one unit.
Plug or cover lines.
5. Disconnect lines and control cable to hydrostatic pump (C).
6. Put a nylon strap or chain around pump.
7.
CAUTION:
Approximate weight of the pump is 68 kg (160 lb).
Item
Measurement Specification
Main Hydraulic Pump Weight
68 kg
(160 lb)
Remove cap screws (D) and remove pump.
Go to Section_50:Group_15
AG,OUO6022,1855-19-20000725
485
Disassemble Hydrostatic Pump
Disassemble Hydrostatic Pump
1.
H67016-UN: Input Shaft Seal
LEGEND:
A - Snap Ring
Clean pump and drain oil.
2. Use JDG114 Snap Ring Pliers to remove snap ring (A).
3.
H67017-UN: Hydrostatic Pump
LEGEND:
A - Sheet Metal Screw
B - Stationary Seal
Use a center punch or other suitable tool to make a small hole in the side of seal (B). Be careful not to
damage bearing behind seal.
4. Remove stationary seal (B) after taking out sheet metal screw (A).
486
Disassemble Hydrostatic Pump
5.
H67074-UN: Hydrostatic Pump
LEGEND:
A - Cap Screw (6 used)
B - Valve
Remove six cap screws (A) that hold control valve (B) to pump.
6.
H67086-UN: Hydrostatic Pump
LEGEND:
A - Gasket
B - Linkage, Swashplate
C - Linkage, Control Valve
D - Valve
Lift valve (D) away from pump and disengage linkages (B) and (C).
7. Remove gasket (A).
8. Set pump on wooden blocks.
487
Disassemble Hydrostatic Pump
9.
H67075-UN: Charge Pump Housing
H67117-UN: Charge Pump Gasket and Pins
LEGEND:
A - Cap Screw (4 used)
B - Cap Screw (2 used)
C - Dowel Pin (2 used)
D - Gasket
Remove four cap screws (A). Do not remove two cap screws (B) as they hold charge pump together.
Remove charge pump. DO NOT pry charge pump to loosen. Tap with soft mallet.
10. Remove gasket (D) and dowel pins (C).
488
Disassemble Hydrostatic Pump
11.
H44050-UN: Hydrostatic Pump
LEGEND:
A - Tool
B - Check Valve (2 used)
C - Screwdriver
Inspect check valves (B). If oil is visible in bores, they are functioning properly. If no oil, valve may be
leaking and should be replaced.
If one valve has to be replaced, replace both valves to provide uniform operation.
12. Remove the two check valves. Insert a screwdriver (C) through high pressure port of end cover to
remove check valves (B), or a tool (A) may be made from stiff wire to remove valves. Insert hook inside
valve cross hole, then pull from end cover.
13. IMPORTANT:
Internal parts are spring loaded. Damage to pump may occur if end cover is removed incorrectly. Use
care when handling parts. These parts are machined to EXTREMELY close tolerances.
489
Disassemble Hydrostatic Pump
H44150-UN: Hydrostatic Pump
LEGEND:
A - Cap Screw (8 used)
490
Disassemble Hydrostatic Pump
B - Gasket
C - Shim (as required)
D - Bearing Cup
E - Dowel Pin
F - Valve Plate
G - Bearing Plate
H - Cover
I - Dowel Pin (2 used)
Remove six of eight cap screws (A). Leave two cap screws opposite each other.
14. Loosen remaining two cap screws one or two turns. The cover (H) should rise. If not, tap cover with a
soft mallet to break gasket seal.
15. Loosen two cap screws slowly and evenly until spring tension is relieved.
16. Remove cap screws and end cover (H). Turn end cover over and set it on a clean cloth.
17. IMPORTANT:
Valve plate (F) may lift away with end cover. Do not drop valve plate.
Remove valve plate (F) and dowel pin (E).
18. Remove bearing cup (D). Cup is a slip fit. Remove shims (C).
19. Remove bearing plate (G) and gasket (B).
20. Remove two dowel pins (I).
21.
H67080-UN: Hydrostatic Pump
491
Disassemble Hydrostatic Pump
H67079-UN: Scribe Mark
LEGEND:
A - Screw (6 used)
B - Retainer (2 used)
C - Marks
Remove screws (A) and retainers (B).
22. IMPORTANT:
DO NOT interchange parts. Mark parts and housing clearly using a scribe to help prevent re-installing
sleeves and pistons in the wrong configuration.
Scribe marks (C) on each sleeve. Make a horizontal mark where sleeve and housing meet; then make a
vertical line starting on sleeve and ending on housing. These marks will identify mounting depth of
sleeves during assembly.
23.
H67477-UN: Pump Block Retaining Strap
LEGEND:
A - Retaining Strap
Install a self-manufactured retaining strap (A) to pump housing to help prevent block from falling out
during removal of trunnions.
492
Disassemble Hydrostatic Pump
24.
H67171-UN: Servo Piston Removal
LEGEND:
A - Sleeve
B - O-Ring (2 used)
C - O-Ring (2 used)
D - Piston (2 used)
Carefully remove sleeves (A) from pistons (D).
25. Remove O-rings (B) and (C).
26. Position pump with control valve mount up.
27.
H67078-UN: Hydrostatic Pump
LEGEND:
A - Mounting Flange
B - Gasket
C - Dowel Pins (2 used)
D - Bearing Cup
Remove twelve cap screws and mounting flange (A). Tap with soft mallet if necessary to break loose.
28. Remove gasket (B) and pins (C).
493
Disassemble Hydrostatic Pump
28. Remove gasket (B) and pins (C).
29. Remove bearing cup (D) and shims. Be careful not to damage shims.
30. Inspect bearing cup and replace if necessary.
31.
H67458-UN: Retaining Ring
H67459-UN: Hydrostatic Pump
LEGEND:
A - Retaining Ring (2 used)
B - Pin (2 used)
C - Piston (2 used)
D - Drain Hole
Remove retaining rings (A) from pins (B) connecting pistons (C) to swashplate. Slide pins out through
case drain holes (D), and remove pistons.
494
Disassemble Hydrostatic Pump
32.
H44154-UN: Hydrostatic Pump
LEGEND:
A - Cap Screw (6 used)
B - O-Ring (2 used)
C - Shim (as required)
D - Trunnion (2 used)
E - Bearing Cone (2 used)
Mark pump housing and trunnions (D) so they will be installed in the same position.
33. Remove cap screws (A).
34. IMPORTANT:
Keep shims with each trunnion. They must be installed on same trunnion. The shims pre-load the
bearings.
Trunnions fit tight. Use slide hammer to loosen trunnions. Screw slide hammer into threaded hole in a
trunnion (use a 7/16—14 screw). Remove trunnions (D) and shims (C).
35. Remove O-rings (B).
36. Remove bearing cones (E) if damaged. Bearings are a press fit.
37. Carefully remove swashplate, cylinder barrel, and shaft through mounting flange end of housing.
495
Disassemble Hydrostatic Pump
38.
H44155-UN: Bearing Puller
LEGEND:
A - Bearing Puller
B - Spacer
Remove bearing cone from shaft using a special low clearance bearing puller (A) and spacer (B). Spacer
prevents slotted end of shaft from spreading.
39. Remove shaft and bearing assembly from swashplate and cylinder barrel making certain that cylinder
barrel and pistons remain together.
496
Disassemble Hydrostatic Pump
40.
H44156-UN: Shaft
LEGEND:
A - Sealing Area
B - Bearing Cone
Remove bearing cone (B) from shaft if damaged. Bearing is a press fit.
41. IMPORTANT:
DO NOT damage sealing area (A) between bearing journal and keyway. This area is extremely critical.
Press bearing cone on shaft using JDG630 Hydrostatic Transmission Tool Kit. Position of bearing cone
on shaft is IMPORTANT.
497
Disassemble Hydrostatic Pump
42.
H44157-UN: Swashplate
LEGEND:
A - Cap Screw (4 used)
B - Retaining Strap (2 used)
C - Spacer (4 used)
D - Cylinder Barrel
E - Bearing Cup (2 used)
F - Swashplate
Set swashplate (F) and cylinder barrel (D) assembly on one of the trunnions making it easier to remove
retaining strap cap screws (A). Remove one retaining strap (B) and loosen the other.
43. IMPORTANT:
Keep cylinder barrel and pistons together.
Position swashplate and cylinder barrel so barrel is on the bottom. Remove swashplate by lifting it
slightly and sliding it over to disengage retaining strap.
44. Remove retaining strap and thrust plate from swashplate.
45. Remove bearing cups (E) if damaged. Use a long punch to remove the old bearing cups; then carefully
press new bearing cups into swashplate.
46. IMPORTANT:
For reassembly, identify pistons, sleeves, housing, and swashplate link-ups with a letter, number, color,
498
Disassemble Hydrostatic Pump
For reassembly, identify pistons, sleeves, housing, and swashplate link-ups with a letter, number, color,
etc.
NOTE:
Disassemble servo piston assemblies only if replacement parts are required.
H67307-UN: Servo Assembly
LEGEND:
A - Clip (8 used)
B - Pin (4 used)
C - Link (2 used)
D - Servo Piston (2 used)
Remove retaining clips (A) and pins (B) connecting link (C) to piston (D).
CAUTION:
47.
Retain spring load when disassembling servo piston.
H67303-UN: Piston Assembly
LEGEND:
A - Springs
B - Retainer
C - Shoulder Bolt
D - Pistons
Compress spring retainer and springs.
48. Carefully and gradually loosen shoulder bolt (C) and remove from piston (D).
499
Disassemble Hydrostatic Pump
48. Carefully and gradually loosen shoulder bolt (C) and remove from piston (D).
49. Remove retainer (B) and springs (A).
50. Install springs (A) and spring retainer (B) in piston (D).
51. Compress spring assembly.
52. Apply thread lock and sealer (medium strength) to shoulder bolt (C), then install. Tighten to
specifications.
Item
Measurement Specification
Shoulder Bolt-to-Servo Piston Cap Screw Torque
22—26 N˙m
(192—228 lb-in.)
53.
N36010-UN: Cylinder Barrel
LEGEND:
A - Retaining Ring
B - Outer Retaining Ring
C - Spring
D - Inner Retainer
If spring (C) appears damaged or contaminated, press retaining ring (A) down to compress spring.
54. Remove outer retaining ring (B).
55. Remove retaining ring, spring and inner retainer (D).
56. Wash parts with clean solvent and replace spring.
57. Install beveled inner retainer (D) with beveled side toward splined end of block.
58. Install retainer (A) with shoulder toward open end of block.
59. Compress spring and outer retaining ring, then install other retaining ring.
500
Disassemble Hydrostatic Pump
60.
H63625-UN: Hydrostatic Pump Cover
LEGEND:
A - Holder
B - Plug (includes O-Ring)
C - Plug (Includes O-Ring) (2 used)
D - Plug (includes O-Ring)
E - O-Ring
F - Shim Kit
G - O-Ring (4 used)
H - Needle Roller
I - Needle Roller
J - Cover
K - Orifice
L - Valve Spool
M - Washer
N - Compression Spring
After end cover has been removed, flush end cover internal passages and wash parts with clean solvent.
Blow parts dry with compressed air.
61. Inspect parts and replace if worn or damaged.
62. Inspect orifice and, if plugged after flushing, replace it.
63. To remove plugged orifice, strike it in the center with center punch. This will curl the orifice so it can be
removed.
64. Install NEW orifice of the same size.
NOTE:
Orifice size is stamped on orifice in thousandths
of an inch; example: 57 = 0.057 in.
501
Disassemble Hydrostatic Pump
Orifice size is stamped on orifice in thousandths of an inch; example: 57 = 0.057 in.
65. Place orifice in orifice pocket so size is visible.
66. IMPORTANT:
Do not flatten and reuse orifices.
Stake orifice in six places with center punch making certain orifice is properly seated after staking.
67. Reassemble end cover. Install NEW O-rings and tighten plugs to specifications:
Item
Measurement Specification
Hydrostatic Pump Cover Plugs
Plug (A) Torque
81 N˙m
(60 lb-ft)
Plug (B) Torque
12 N˙m
(9 lb-ft)
Plugs (C) Torque
7 N˙m
(5 lb-ft)
Plug (D) Torque
12 N˙m
(9 lb-ft)
Go to Section_50:Group_15
OUO6030,000009E-19-20010601
502
Assemble Hydrostatic Pump
Assemble Hydrostatic Pump
H63626-UN: Hydrostatic Pump
LEGEND:
1 - Swashplate Assembly
2 - Retaining Ring (8 used)
3 - Pin (4 used)
4 - Thrust Plate
5 - Piston and Slipper Assembly
6 - Slipper Retaining Plate
7 - Cylinder Barrel
8 - Dowel Pin (9 used)
9 - Bearing Plate
10 - Retaining Strap and Bolts (2 used)
11 - Rotating Group
503
Assemble Hydrostatic Pump
12 - Valve Plate
13 - O-Ring (3 used)
14 - O-Ring (2 used)
15 - Servo Sleeve (2 used)
16 - Servo Piston Assembly (2 used)
17 - Trunnion Bolt (6 used)
18 - Trunnion Assembly (2 used)
19 - Bearing (as required)
20 - O-Ring (2 used)
21 - Trunnion Shims (as required)
22 - Cap Screw (6 used)
23 - Servo Sleeve Retainer (2 used)
24 - Pump Housing
25 - Plug and O-Ring
26 - Plug and O-Ring
27 - End Cover Bearing
28 - Shaft Shims (as required)
29 - End Cover Gasket
30 - Check Valve Assembly (2 used)
31 - O-Ring (2 used)
32 - Back-Up O-Ring (2 used)
33 - Spring Strap (2 used)
34 - End Cover Screw (6 used)
35 - End Cover Screw (2 used)
36 - End Cover
37 - O-Ring
38 - O-Ring
39 - Shaft Seal Kit
40 - Mounting Flange Screw (12 used)
41 - Bearing Kit (as required)
42 - Mounting Flange
43 - Bearing Cup
44 - Mounting Flange Gasket
45 - Drive Shaft Assembly
1. Wash pump body and parts with clean solvent. Dry with compressed air. Keep parts clean.
2.
NOTE:
Refer to Inspect Parts, which follows hydrostatic drive motor disassembly procedure, for
examples of parts damage and probable causes.
Inspect middle land of slippers on pistons (5, exploded view) for nicks and scratches.
3. Inspect the following for wear or damage:
Races in Swashplate (1)
Bearing Plate (9)
Valve Plate (12)
Ball Guide
504
Assemble Hydrostatic Pump
Bearings (19)
Internal Splines of Cylinder Barrel (7)
Replace parts as necessary.
NOTE:
If bearing plate (9) is scored, eroded or smeared, replace it.
4. Assemble pump using exploded view. Install O-rings and gaskets. Apply petroleum jelly to O-rings and
finished surfaces. Apply clean hydraulic oil to parts when specified in following instructions.
5.
H41418-UN: Fixed Clearance
LEGEND:
A - Piston
B - Slipper Retainer Plate
C - Piston Slipper
D - Thrust Plate
E - Swashplate
F - Spacer
G - Retaining Strap
H - Cap Screw
Install slipper retainer plate and piston slippers in cylinder barrel.
6. Check fixed clearance of unit. Measure height of spacer with a micrometer or calipers.
Measure thickness of both piston slipper flange and slipper retainer plate (B) and (C). Subtracting this
measurement from spacer (F) measurement gives fixed clearance of unit. Fixed clearance must not
exceed specification. If fixed clearance exceeds specification, replace worn parts, as required.
Item
Measurement
Specification
Rotating Group Fixed Clearance 0.20 mm
(0.008 in.)
Fixed Clearance = Spacer height - (slipper flange + retainer plate)
505
Assemble Hydrostatic Pump
7.
H67176-UN: Swashplate Assembly
H67177-UN: Swashplate Assembly
LEGEND:
A - Hole (4 used)
B - Thrust Plate
C - Spacer (2 used)
D - Retainer
E - Cap Screw (2 used)
Apply thread lock and sealer (high strength) in first or second thread down, in each of four holes (A) in
swashplate.
8. Install thrust plate (B). Install spacers (C), retainer (D), and cap screws (E) on one retaining strap. Do not
tighten cap screws.
9. Put cylinder barrel assembly on clean flat surface with piston slippers up. Carefully install swashplate on
cylinder barrel by slightly lifting side without retaining strap. Slide swashplate over to engage installed
retaining strap around piston retainer.
506
Assemble Hydrostatic Pump
10.
H67178-UN: Swashplate Assembly
LEGEND:
A - Spacer (2 used)
B - Retainer
C - Cap Screw (2 used)
Carefully reposition cylinder barrel and swashplate with swashplate in down position. Install remaining
spacers (A), retainer (B), and cap screws (C). Tighten cap screws to specification.
Item
Measurement Specification
Swashplate Retaining Strap Cap Screws Torque
24.0 N˙m
(17.5 lb-ft)
11.
H67172-UN: Swashplate Assembly
Slide shaft and bearing assembly through swashplate and cylinder barrel.
12. Carefully install swashplate, cylinder barrel and shaft in pump housing. Be sure feedback linkage is at
control valve mount.
13. IMPORTANT:
Do not let cylinder barrel slide off pistons.
507
Assemble Hydrostatic Pump
H67173-UN: Trunnion
H67183-UN: Trunnion
Lubricate and install new O-rings (A) on trunnions (B).
14. IMPORTANT:
Trunnion shims on each side of pump should be of equal thickness. Maximum allowable difference
between sides is 0.3 mm (0.010 in.).
Install shims (C) and trunnions in original position. Tighten cap screws (D) to specification.
Item
Measurement Specification
Pump Trunnion Cap Screws Torque
60 N˙m
(44 lb-ft)
15. Remove shaft and bearing assembly from swashplate.
508
Assemble Hydrostatic Pump
16.
H54325-UN: Hydrostatic pump
LEGEND:
A - Spring Scale
B - Control Link
Check movement of swashplate by attaching spring scale (A) to control link (B). If more than 9-22 N (2-5
lb) is required to move swashplate, disassemble and add more shims.
17. IMPORTANT:
Do not let cylinder barrel slide off pistons.
H67180-UN: Servo Assembly
509
Assemble Hydrostatic Pump
H67174-UN: Servo Assembly
LEGEND:
A - Servo Piston
B - Pin
C - Case Drain Hole
D - Snap Ring
Install servo piston (A) into pump housing and align servo link to swashplate.
18. Install pin (B) through case drain holes (C) and apply snap ring (D). Repeat procedure for second servo
piston.
19. Cover pistons with CLEAN hydraulic oil.
20. Position pump so it is sitting on mounting flange surface.
21.
H67171-UN: Install Sleeve
LEGEND:
A - Sleeve
B - O-Ring
C - O-Ring
D - Piston
Lubricate and install new O-rings (B) and (C) on sleeves (A).
22. Install each sleeve in its original position, start by lifting one piston (D) and tilting swashplate to
510
Assemble Hydrostatic Pump
maximum angle.
23. Carefully fit sleeve over piston. Lower sleeve and piston into pump housing until threads meet. Screw in
sleeve until scribe marks line up. Repeat procedure for second sleeve.
24. IMPORTANT:
Zeroing swashplate ensures that springs on pistons will return swashplate to neutral when control lever
is centered.
H44160-UN: Swashplate
LEGEND:
A - Parallel Bar
B - Swashplate
C - Depth Micrometer
Check zero angle of swashplate (B).
25. Place parallel bars (A) across end cover gasket surface and measure depth to swashplate on each side
of cylinder barrel using a depth micrometer (C).
511
Assemble Hydrostatic Pump
Item
Measurement
Specification
Swashplate Zero Angle Maximum Allowable Difference 0.12 mm
(0.005 in.)
Maximum Allowable Rock
0.03 mm
(0.010 in.)
26. Screw servo sleeves in or out to adjust swashplate zero angle.
27.
H67179-UN: Hydrostatic Pump
LEGEND:
A - Retainer
B - Cap Screw (3 used)
C - Slot
Install retainer (A) and cap screws (B).
28. Take a punch and dent retainer (A) at slot (C).
29.
NOTE:
DO NOT let cylinder barrel slide off pump.
Position pump so control valve mount is on top.
30. Carefully slide shaft and bearing assembly into pump.
512
Assemble Hydrostatic Pump
31.
H67298-UN: Hydrostatic Pump
LEGEND:
A - Dowel Pin
B - Gasket
C - Bearing
D - Mounting Flange
Install dowel pins (A) in pump housing.
32. Install new gasket (B). Hold in place with petroleum jelly.
33. Lubricate bearing (C) with clean hydraulic oil.
34. Install mounting flange (D). Tighten cap screws to specification.
Item
Measurement Specification
Pump Mounting Flange Cap Screws Torque
60 N˙m
(44 lb-ft)
513
Assemble Hydrostatic Pump
35.
H45061-UN: Hydrostatic Pump
Turn pump over so shaft is vertical and mounting flange is down.
36. Support pump shaft and use a bearing driver to install end cover bearing cone. Be sure bearing cone is
seated against shoulder of shaft.
37. Remove shaft support.
38.
514
Assemble Hydrostatic Pump
H44162-UN: Pump
LEGEND:
A - Bearing Cup
B - Shim (as required)
C - End Cover
D - Dowel Pin (2 used)
Install dowel pins (D) in holes in pump housing.
39. Install new gasket.
40. Check shaft end play before installing bearing and valve plates.
Be sure shims (B) and bearing cup (A) are in end cover (C).
41. Install end cover. Tighten cap screws alternately to specifications.
Item
Measurement Specification
End Cover-to-Hydrostatic Pump Cap Screws Torque
85 N˙m
(63 lb-ft)
42. Turn pump over so mounting flange and shaft are up. Place a wood block under end cover so pump
weight is not on servo sleeves.
43. Remove pump from blocks.
44. Using a rubber mallet, tap end of shaft to seat bearings.
45.
N37736-UN: Pump Drive Shaft
LEGEND:
A - End Play
B - D17525C1 Magnetic Base
C - Pliers
D - Shaft
Using D17525C1 Magnetic Base (B) and D17526C1 Dial Indicator, measure total shaft end play. Grip
515
Assemble Hydrostatic Pump
shaft (D) with pliers (C), pry shaft out for total end play. If not within specifications remove cover and
reshim behind end cover bearing cup.
Item
Measurement Specification
Pump Drive Shaft End Play
0.05—0.18 mm
(0.002—0.007 in.)
46.
H67294-UN: End Cover
H67293-UN: End Cover
LEGEND:
A - Dowel Pin (2 used)
B - Bearing Plate
C - Engagement Hole (2 used)
Turn pump back over and remove end cover.
47. Install dowel pins (A) in holes in cylinder barrel face.
48. Place bearing plate (B) on cylinder barrel and engage holes (C) with previously installed dowel pins (A).
516
Assemble Hydrostatic Pump
49.
H67292-UN: Hydrostatic Pump
Install dowel pins (A) and gasket (B).
50. Liberally lubricate bronze surface of bearing plate with clean hydraulic oil.
51. Place valve plate (C) on bearing plate.
52.
H67295-UN: End Cover
H67182-UN: End Cover
Install end cover (A) and start cap screws (B).
53. Align dowel pin (C) in end cover with engagement hole (D) in valve plate.
517
Assemble Hydrostatic Pump
54. Tighten cap screws evenly so cylinder barrel spring preload is taken up gradually. Tighten cap screws to
specification.
Item
Measurement Specification
Valve Plate-to-End Cover Cap Screws Torque
85 N˙m
(63 lb-ft)
55.
H67184-UN: Check Valves
LEGEND:
A - O-Ring/Back-up Ring
B - Check Valve
C - Surface
Lubricate and install new O-ring and back-up ring (A) on check valves. Back-up ring must be installed on
charge pump side.
56. Install check valves. Push valves down until tops are flush with surface (C) of end cover.
57.
H67300-UN: Charge Pump
518
Assemble Hydrostatic Pump
H67365-UN: Charge Pump
LEGEND:
A - Dowel Pin (2 used)
B - Gasket
C - Charge Pump
D - Cap Screw (4 used)
Install dowel pins (A) in end cover.
58. Install new gasket (B).
59. Rotate charge pump shaft so tang and dowel pin holes line up with pump. Install charge pump (C).
60. IMPORTANT:
Be sure to use the correct torque when tightening charge pump mounting cap screws. Using a higher
torque reduces the internal clearance of the pump which can result in pump failure.
Install cap screws (D) and tighten alternately to specification.
Item
Measurement Specification
Charge Pump-to-End Cover Cap Screws Torque
61. Position pump so control valve mount is on top.
62.
H67348-UN: Valve
519
27—33 N˙m
(20—24 lb-ft)
Assemble Hydrostatic Pump
H67357-UN: Valve
LEGEND:
A - Gasket
B - Linkage
C - Linkage
D - Valve
E - Cap Screw (6 used)
Install new control valve gasket (A).
63. IMPORTANT:
Be sure linkage points toward end cover.
Connect linkages (B) and (C) and place control valve (D) on pump.
64. Install cap screws (E). Tighten finger tight.
65. Move control lever back and forth. It should move freely in both directions and self-center. If not, check
linkage.
66. Tighten cap screws to specification.
Item
Measurement Specification
Control Valve-to-Pump Cap Screws Torque
22 N˙m
(16 lb-ft)
67. Place pump on its side. Do not set pump on control lever arm.
520
Assemble Hydrostatic Pump
68.
H67020-UN: Seal Driver
LEGEND:
A - Lip Seal
B - Seal Protector
Grease surface of seal (A) which contacts shaft.
69.
NOTE:
Closed face of seal should face closed end of seal protector.
Press the new seal onto JDG1503-2 Seal Protector (B).
70.
H67019-UN: Seal Driver
H67015-UN: Seal Driver
LEGEND:
521
Assemble Hydrostatic Pump
A - Seal Protector
B - Seal Driver
C - Surface
D - Surface
Install JDG1503-2 Seal Protector (A) over input shaft.
71. Install JDG1503-1 Lip Seal Installer (B) over JDG1503-2 Seal Protector.
72. Using a rubber mallet, drive seal in until surfaces (C) and (D) touch.
73. Using JDG114 Snap Ring Pliers, install snap ring, BEVELED EDGE OUT. Make sure snap ring is fully
expanded in its groove. Avoid damaging finished surfaces.
74. Rotate shaft being careful not to damage splines. If shaft binds, check end play and correct.
Go to Section_50:Group_15
OUO6030,000009F-19-20021119
522
Replace High-Pressure Line Center Pivot O-Rings
Replace High-Pressure Line Center Pivot O-Rings
H50230-UN: Connecting High Pressure Lines
LEGEND:
A - Clamps
B - O-Rings
When a high-pressure line is removed from the machine, replace center pivot O-ring as follows:
1. Remove clamps (A) from high-pressure line couplings.
2. Remove O-rings (B) from center coupling of both high-pressure lines.
3. Clean coupler joint surfaces before assembly.
4. Coat new O-rings with clean hydrostatic oil and install.
5. Assemble high-pressure lines, hoses, and steel lines. Loosely install clamps.
Go to Section_50:Group_15
HX,50,DD37-19-19971003
523
Disassemble and Assemble End Cover
Disassemble and Assemble End Cover
LEGEND:
A - Spring Box
B - O-Ring
C - Spring
D - Spacer
E - Plug
F - Plug
G - Plug
H - Pin
I - Plug
J - Pin
K - Spool
L - Shim (as required)
M - Control Orifice
1. Remove parts (A—L).
2. Flush end cover passages and parts with clean solvent. Blow parts dry with compressed air.
3. Replace worn or damaged parts.
4. Inspect control orifice (M). Replace if plugged. Remove by striking in center with a punch.
5. Install new orifice of same size. Size is stamped on orifice in thousandths of an inch. Example: 57 =
0.057 in. Install orifice so size is visible. Stake in six places.
6. Assemble parts (A—L).
524
Disassemble and Assemble End Cover
Item
Measurement Specification
Hydrostatic Pump End Cover
Spring Box (A) Torque
81 N˙m
(60 lb-ft)
Plug (E)
Torque
12 N˙m
(9 lb-ft)
Plug (F)
Torque
7 N˙m
(5 lb-ft)
Plug (G)
Torque
7 N˙m
(5 lb-ft)
Plug (I)
Torque
12 N˙m
(9 lb-ft)
Go to Section_50:Group_15
AG,OUO6022,1859-19-20000725
525
Repair Control Valve
Repair Control Valve
H63627-UN: Valve
LEGEND:
1 - Cap Screw (2 used)
2 - Housing
3 - Spool
4 - Washer
5 - Spring
6 - Retainer
7 - Cap Screw
8 - Repair Kit
9 - O-Ring
10 - Adjusting Screw
11 - Screw
12 - Set Screw
13 - Gasket
14 - Link
15 - Snap Ring (2 used)
16 - Control Link
17 - Connector
18 - Spring Pin
19 - O-Ring (2 used)
526
Repair Control Valve
20 - Plug (2 used)
21 - Nut
22 - Washer
23 - Link
24 - O-Ring
25 - Shaft
26 - Cap Screw (4 used)
27 - Seal
28 - Complete Valve
Valve may be removed from pump without removing pump from combine. Disconnect control linkage.
1. Remove six screws to remove valve.
2. Disengage control link (16).
3. Discard drained oil and cover opening in pump housing to keep dirt out.
4. Unhook link (14) from connector (17), loosen set screw (12), remove spring pin (18) and pull shaft (25)
out of valve.
5. Scribe two lines on adjusting screw (10) to indicate setting.
6. Loosen set screw and remove adjusting screw (10) and spool (3).
7. Clean all parts in solvent and dry thoroughly. Replace all worn or damaged parts and install new Orings.
8. Insert spool kit (8) into housing. Screw in adjusting screw (10) until scribe marks align. Tighten set
screw.
9. If new spool, spring or adjusting screw is installed, turn adjusting screw into housing until just contacting
spring. DO NOT compress spring.
10. Install shaft, new seal ring and O-ring. Tighten set screw (12) and install pin (18) and connect link (14) in
connector (17).
11. Check spool (3) for end play by moving it back and forth. If there is end play, tighten adjusting screw (10)
until it touches spring. Exert a slight back and forth force on spool while adjusting screw. DO NOT
compress spring beyond its installed length.
12. Hook link (16) into control link. Make sure control link is pointing toward end cover of housing or unit will
not function properly.
13. Tighten attaching screws to specification.
Item
Measurement Specification
Control Valve-to-Pump Cap Screws Torque
22—26 N˙m
(264—312 lb-in.)
Go to Section_50:Group_15
AG,OUO6022,1860-19-20000725
527
Displacement Control Valve with Feed Rate - Exploded View
Displacement Control Valve with Feed Rate - Exploded View
H81114-UN: Displacement Control Valve with Feed Rate
LEGEND:
A - Cap Screw (3 used)
B - Cap Screw (2 used)
C - Cap Screw (1 used)
D - Wiring Harness
E - Retainer (2 used)
F - O-Ring (2 used)
G - Solenoid Valve (2 used)
H - Coil (2 used)
I - Switch
J - O-Ring
K - Plug
L - Gasket
IMPORTANT:
Solenoid coils (H) are numbered and must be installed on correct side of valve.
Go to Section_50:Group_15
ZX08994,00002BB-19-20050113
528
Install Hydrostatic Pump
Install Hydrostatic Pump
H55765-UN: Main hydraulic pump
LEGEND:
A - Main Hydraulic Pump
B - Charge Pump
C - Hydrostatic Pump
D - Cap Screw (4 used)
CAUTION:
1.
Approximate weight of the pump is 68 kg (160 lb).
Item
Measurement Specification
Main Hydraulic Pump Weight
68 kg
(160 lb)
Attach pump to engine gear case with cap screws (D). Tighten to specification.
Item
Measurement Specification
Hydrostatic Pump-to-Engine Gear Case Cap Screws Torque
130 ± 50 N˙m
(96 ± 36 lb-ft)
2. Connect lines and cable to pump (C). Use new O-rings. Connect lines to pumps (A) and (B).
3. Check oil level. Start engine and bleed system. (See procedure in this group.)
Go to Section_50:Group_15
AG,OUO6022,1861-19-20000725
529
Remove and Install Charge Pump
Remove and Install Charge Pump
1.
CAUTION:
X9811-UN: High Pressure
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other
lines. Tighten all connections before applying pressure. Use a piece of cardboard
to search for leaks. Protect hands and body from high pressure fluids.
If injured by escaping fluid, see a doctor immediately. Any fluid injected into the
skin must be surgically removed within a few hours or gangrene may result.
Doctors unfamiliar with this type of injury should reference a knowledgeable
medical source. Such information is available from Deere & Company Medical
Department in Moline, Illinois, U.S.A.
Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2.
H40581-UN: Charge Pump Removal
LEGEND:
A - Main Pump
B - Line to Filter Head
C - Line to Charge Head
D - Charge Pump
Remove main pump (A).
3. Disconnect line to filter head (B) and line to pump (C).
530
Remove and Install Charge Pump
3. Disconnect line to filter head (B) and line to pump (C).
4. Remove charge pump (D).
5. Repair pump as necessary.
6. Install charge pump (D).
7. Connect line to filter head (B) and line to pump (C).
8. Install main pump (A).
Go to Section_50:Group_15
OUO6037,0001453-19-20010723
531
Repair Charge Pump
Repair Charge Pump
H54198-UN: Charge Pump
LEGEND:
1 - Shaft
2 - Pin
3 - O-Ring
4 - O-Ring
5 - Pressure Relief Valve
6 - Housing
7 - Bushing
8 - Needle Bearing
9 - O-Ring (2 used)
10 - Spacer
11 - Cover
12 - Cap Screw
13 - Cap Screw
14 - Oil Pump
15 - Ball Bearing
16 - Snap Ring (2 used)
17 - O-Ring
18 - Filter Base
19 - Retaining Screw
20 - O-Ring
21 - Plug
22 - Coupler
23 - Cover
24 - Filter
25 - O-Ring
26 - Pin
27 - Gasket
532
Repair Charge Pump
28 - Charge Pump
29 - Poppet
30 - Spring
31 - O-Ring
32 - Plug
33 - Pressure Sensor
1. Scribe a line across pump sections.
2. Remove cap screws (12) and (13).
3. Inspect rotor assembly (14), shaft (1) and body (6) for excessive wear or scoring. Replace gasket if
necessary.
4. Remove and clean low pressure relief valve (5).
5. Install new O-rings and packings.
6. Assemble pump, aligning scribe marks.
7. Tighten low pressure relief valve (5) to specification.
Item
Measurement Specification
Charge Pump Low Pressure Relief Valve Torque
108 N˙m
(80 lb-ft)
8. Tighten cap screws (12) and (13) to specification.
Item
Measurement Specification
Charge Pump Cover-to-Pump Housing Cap Screws Torque
27—33 N˙m
(20—24 lb-ft)
Go to Section_50:Group_15
AG,OUO6022,1863-19-20000725
533
Remove and Install Hydrostatic Control Cable
Remove and Install Hydrostatic Control Cable
H65603-UN: Cable
H72463-UN: Hydrostatic Control Cable
LEGEND:
A - Cable
534
Remove and Install Hydrostatic Control Cable
B - Lever
C - Cable Clamp
D - Nut
E - Lever
1. Remove cable (A) from hydrostatic pump control lever (B).
2. Remove passenger seat from cab.
3. Remove cable clamp (C) on cab floor behind heater blower motor.
4.
NOTE:
Tie a rope to cable end before removing from cab to aid installation of new cable.
Remove nut (D) from cable ball joint at lever (E).
5. Remove cable assembly from combine.
6. Install cable assembly in cab first.
7. Attach cable ball joint to lever (E) with nut (D).
8. Install cable clamp (C) on cab floor.
9. Install passenger seat.
10. Route cable and secure with clamps to sidesheet.
11. Move lever (E) through full forward and reverse range.
NOTE:
If lever will not move through full range, adjust cable ball joint at cab end.
12. Move hydro pump control lever (B) side to side by hand. Control lever is spring loaded and will return to
neutral position by itself.
13.
NOTE:
Do not move control lever to attach ball joint. Adjust ball joint on threaded cable to
install.
Attach rear cable ball joint (A) to control lever (B).
Attach ball joint (A) in one of these holes:
-: Settings
Combines with standard duty final drives. outside hole
Combines with heavy duty final drives.
inside hole
14. Start engine with hydrostatic lever in neutral. Combine
must not creep. If it does, adjust cable ball joint at
535
Remove and Install Hydrostatic Control Cable
14. Start engine with hydrostatic lever in neutral. Combine must not creep. If it does, adjust cable ball joint at
hydro pump.
Go to Section_50:Group_15
OUO6435,0001899-19-20020820
536
Adjust Hydrostatic Control Linkage
Adjust Hydrostatic Control Linkage
H65603-UN: Neutral Linkage
LEGEND:
A - Ball Joint
B - Arm
1. Shut off engine.
2. Place hydrostatic lever (multi-function lever) in neutral.
3. Remove ball joint (A) from arm (B).
4.
CAUTION:
The gear shift assembly must be in neutral so the combine will not move.
Place gear shift lever in neutral. Start engine and run for 15 seconds. Shut off engine and remove key.
Operating engine with linkage disconnected will cause hydrostatic unit to come to neutral.
5. Do not move arm (B) on hydrostatic unit. Cable must not be connected to pump arm.
6. Push cable forward (all the way in) to remove backlash.
7. Align ball joint with hole in arm by adjusting bulkhead fitting on cable at cable support. If further
adjustment is needed, adjust at rear ball joint. Do not bottom out ball joint. Keep a minimum of three
turns for later adjustment.
8. Turn ball joint in three full turns when ball joint stud aligns with hole in arm and cable is pushed all the
way in.
9. Pull cable out so it aligns with hole in arm. Secure in place.
Go to Section_50:Group_15
OUO6435,0001934-19-20021008
537
Adjust Neutral Position of Displacement Control Valve
Adjust Neutral Position of Displacement Control Valve
H65446-UN: Valve
H54264-UN: Displacement Control Valve
LEGEND:
A - Plug (2 used)
B - Set Screw
C - Adjusting screw
D - Control Lever
E - Return Spring
NOTE:
The control valve can be adjusted for neutral position as follows without removing it from the
hydrostatic unit.
1. Check linkage neutral adjustment before checking control valve neutral.
2. Remove two plugs (A) on the side of valve (same side as control lever).
3. Loosen set screw (B).
4. Use pliers to turn out adjusting screw (C) two full turns.
538
Adjust Neutral Position of Displacement Control Valve
5. Look into two ports (A) and move control lever (D) slightly in both directions.
6. Do not move lever enough to compress return spring (E). Turn in adjusting screw (C) slowly while
moving lever (D) in both directions.
7. When end play of spool is eliminated, the adjustment is made. End play should be observed while
looking through holes at spool (A). Movement in control lever (D), after end play is eliminated, is caused
by wear in the linkage.
8. Tighten screw (B) and install plugs (A).
Go to Section_50:Group_15
AG,OUO6435,673-19-20000503
539
Start-Up Procedure After Hydrostatic System Repair
Start-Up Procedure After Hydrostatic System Repair
1. Fill system with John Deere HY-GARD transmission and hydraulic oil and leave cap off reservoir.
2. Disconnect the two multi-pin connectors to injection pump from the engine control unit.
3. Crank engine, with starting motor, several times for 15 seconds at one-minute intervals. This starts oil
flowing into the hydrostatic pump.
4. Reconnect multi-pin connector.
CAUTION:
Keep all bystanders away from machine while performing start-up procedure.
Hazard of personal injury or death! Machine may move unexpectedly.
5. Place transmission in neutral and engage park brake.
6. Start engine and run at slow idle speed for 5 minutes to bleed air from system.
7. Move hydrostatic lever (multi-function lever) slightly forward out of neutral. After 30 seconds, return
hydrostatic lever to neutral position.
8. Move hydrostatic lever slightly into reverse position. After 30 seconds, return to neutral.
9. Repeat steps 7 and 8 until maximum forward and reverse travel is reached.
10. Release park brake.
11. Increase engine speed to full throttle.
12. Shift transmission to second gear and run machine in forward and reverse several times to check the
drive system.
13. Check for system leaks, fill reservoir with oil and install cap.
Go to Section_50:Group_15
AG,OUO6435,153-19-20000627
540
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Weatherpack Extractor (blue handle).......JDG776
Used to extract wire terminals from connectors.
H68294-UN: JDG776
Block, Bearing Remover.......JDG-690-7
Spindle removal
H68314-UN: JDG690-7
Bearing Puller Attachment.......DO1243AA
Spindle bearing and seal removal
H68295-UN: DO1243AA
541
Essential and Recommended Special Tools
17 1/2 Ton Push-Puller (Hydraulic).......DO1219AA
Spindle bearing and seal removal
H68296-UN: DO1219AA
30 Ton Push-Puller (Hydraulic).......DO1246AA
Spindle removal
H68297-UN: DO1246AA
Bushing Driver.......JDG1376
Install inner pivot bushing.
H68298-UN: JDG1376
Bearing
Puller.......DO12009AA
Used with JDG1377 to
remove tapered wedges
from cam.
Slide Hammer
Adapter.......JDG1377
Used to remove tapered
wedges from cam.
H68299-UN: JDG1377
H68300-UN: DO12009AA
542
Essential and Recommended Special Tools
Bearing Installer.......JDG1378
Used to install outer spindle bearing race.
H68301-UN: JDG1378
Bearing Installer.......JDG1379
Used to install inner spindle bearing race.
H68302-UN: JDG1379
Seal Installer.......JDG1380
Used to install the inner spindle seals.
H68303-UN: JDG1380
Seal/Bearing Installer.......JDG1381
Used to install outer spindle seal and bearing.
H68304-UN: JDG1381
543
Essential and Recommended Special Tools
Bearing Installer.......JDG1382
Used to preload inner spindle bearing enough to
remove and install snap ring.
H68305-UN: JDG1382
Go to Section_50:Group_20
ZX09263,0002737-19-20080131
544
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Weatherpack Extractor (blue handle).......JDG776
Used to extract wire terminals from connectors.
H68294-UN: JDG776
Block, Bearing Remover.......JDG-690-7
Spindle removal
H68314-UN: JDG690-7
Bearing Puller Attachment.......DO1243AA
Spindle bearing and seal removal
H68295-UN: DO1243AA
545
Essential and Recommended Special Tools
17 1/2 Ton Push-Puller (Hydraulic).......DO1219AA
Spindle bearing and seal removal
H68296-UN: DO1219AA
30 Ton Push-Puller (Hydraulic).......DO1246AA
Spindle removal
H68297-UN: DO1246AA
Bushing Driver.......JDG1376
Install inner pivot bushing.
H68298-UN: JDG1376
Bearing
Puller.......DO12009AA
Used with JDG1377 to
remove tapered wedges
from cam.
Slide Hammer
Adapter.......JDG1377
Used to remove tapered
wedges from cam.
H68299-UN: JDG1377
H68300-UN: DO12009AA
546
Essential and Recommended Special Tools
Bearing Installer.......JDG1378
Used to install outer spindle bearing race.
H68301-UN: JDG1378
Bearing Installer.......JDG1379
Used to install inner spindle bearing race.
H68302-UN: JDG1379
Seal Installer.......JDG1380
Used to install the inner spindle seals.
H68303-UN: JDG1380
Seal/Bearing Installer.......JDG1381
Used to install outer spindle seal and bearing.
H68304-UN: JDG1381
547
Essential and Recommended Special Tools
Bearing Installer.......JDG1382
Used to preload inner spindle bearing enough to
remove and install snap ring.
H68305-UN: JDG1382
Go to Section_50:Group_20
ZX09263,0002737-19-20080131
548
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Portable Filter Caddy.......JT05746
Used to flush cam lobe motors
H68347-UN: JT05746
Vacuum Pump.......D15032NU
Used to pull vacuum on hydraulic system for removing
cam lobe motor with minimum oil loss.
H68348-UN: D15032NU
Handle, Bushing Driver.......JDG537
Used with JDG1376 to install inner pivot bushing.
H68349-UN: JDG537
Go to Section_50:Group_20
ZX09263,0002738-19-20080131
549
Other Material
Other Material
Number
Name
Use
TY22000 (U.S.)
HY-GARD Hydraulic Oil
Used to service/flush hydraulic/hydrostatic systems.
TY6341 (U.S.)
Multipurpose SD Polyurea
Grease
Used to lubricate pivot bushings, seals, O-rings and
bearings during assembly.
TY6304 (U.S.)
515 LOCTITE
(LOCTITE®)
Flexible Form-In-Place Gasket Used to seal yoke to sealing rings.
TY24445 (U.S.)
454 LOCTITE
(LOCTITE®)
Gel Super Glue
TY9371 (U.S.)
271 LOCTITE
(LOCTITE®)
High Strength Thread Locking Used to retain cap screws and seal housing.
Compound
Used to retain pivot thrust bushing to motor housing.
Go to Section_50:Group_20
AG,OUO6435,158-19-20000630
550
Specifications
Specifications
Item
Measurement
Specification
Yoke
Weight
33 kg
(73 lb-ft)
Steering Cylinder and Tie Rod, Slotted Nuts Torque
150 N˙m
(111 lb-ft)
Wheel Bolts, Powered Rear Axles (M20 Bolt) Torque
200 N˙m plus an additional 1/4 turn
(150 lb-ft plus an additional 1/4 turn)
Seal Ring Screws
Torque
10 N˙m
(7 lb-ft)
Pivot Pin Screws
Torque
70 N˙m
(50 lb-ft)
Solenoid Valve
Torque
27 N˙m
(20 lb-ft)
Nut
Torque
3 N˙m
(27 lb-in.)
Cam Lobe Motor-to-Axle Cap Screws
Torque
560 N˙m
(413 lb-ft)
Hydraulic Oil Reservoir
Capacity
34 L
(36 qt)
Solenoid Valve Block, Screw
Torque
15 N˙m
(11 lb-ft)
Displacement Control Valve Plug
Torque
280 N˙m
(200 lb-ft)
Cam Lobe Motor
Weight
195 kg
(425 lb)
Spindle
Weight
41 kg
(90 lb)
Specified Torque
Rolling Drag Torque 37 N˙m
(27 lb-ft)
Hex. Socket Screw
Torque
355 N˙m
(260 lb-ft)
Go to Section_50:Group_20
AG,OUO6435,176-19-20010112
551
Flush Cam Lobe Motors
Flush Cam Lobe Motors
1. Disassemble, clean and flush the cam lobe motor control valve and tee block.
2. Disconnect and flush all hoses associated with the cam lobe motor system.
3. Connect hose from oil transfer unit to bottom port of cam lobe motor. Plug the charge pressure port.
Connect and route hose from return port to drum of flushing oil.
4. Activate transfer unit and flush cam lobe motor for 30 minutes, rotating wheel occasionally.
5. Repeat procedure on the opposite cam lobe motor.
6. Assemble all components, hoses and lines.
Go to Section_50:Group_20
AG,OUO6435,679-19-20000503
552
Remove Cam Lobe Motor
Remove Cam Lobe Motor
1.
H64127-UN: Two-Speed Cam Lobe Motor
H64126-UN: Two-Speed Cam Lobe Motor
LEGEND:
A - Slotted Nut (2 used)
B - Tie Rod
C - Steering Cylinder
D - Hydraulic Hose (3 used)
E - Cap Screw (4 used)
F - Connector
Lift unit and block rear axle. Remove rear wheel (see instructions in Group 25).
2.
CAUTION:
553
Remove Cam Lobe Motor
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other
lines. Tighten all connections before applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin
must be surgically removed within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a knowledgeable medical
source. Such information is available from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
3. Install D15032NU Vacuum Pump to reservoir or drain reservoir.
Item
Measurement Specification
Hydraulic Oil Reservoir Capacity
34 L
(36 qt)
4. Clean outside of cam lobe motor thoroughly.
5. Disconnect wire connector (F).
6. Disconnect three hoses (D) from motor. Plug all open ports.
7. Remove slotted nut (A) from tie rod (B) and steering cylinder (C). Disconnect steering cylinder and tie
rod.
8.
CAUTION:
Approximate weight of cam lobe motor is 195 kg (425 lb).
Item
Measurement Specification
Cam Lobe Motor Weight
195 kg
(425 lb)
Support motor with a suitable hoist. Remove four cap screws (E) securing yoke to rear axle.
9. Remove motor from axle.
Go to Section_50:Group_20
OUO6046,0001581-19-20010809
554
Install Cam Lobe Motor
Install Cam Lobe Motor
CAUTION:
1.
Approximate weight of cam lobe motor is 195 kg (425 lb).
Item
Measurement Specification
Cam Lobe Motor Weight
195 kg
(425 lb)
H64126-UN: Two-Speed Cam Lobe Motor
H64127-UN: Two-Speed Cam Lobe Motor
LEGEND:
A - Slotted Nut (2 used)
B - Tie Rod
C - Steering Cylinder
D - Hydraulic Hose (3 used)
E - Cap Screw (4 used)
F - Connector
Position motor on rear axle.
2. Install motor on axle using cap screws (E). Tighten to specification.
Item
Measurement Specification
Cam Lobe Motor-to-Axle Cap Screws Torque
3. Connect hoses (D) to motor.
555
560 N˙m
(413 lb-ft)
Install Cam Lobe Motor
3. Connect hoses (D) to motor.
4. Connect wire connector (F).
5. Connect steering cylinder (C) and tie rod (B). Retain with slotted nuts (A) and tighten to specification.
Tighten further, if necessary, to install cotter pin.
Item
Measurement Specification
Steering Cylinder and Tie Rod, Slotted Nuts Torque
150 N˙m
(111 lb-ft)
6. Fill reservoir.
Item
Measurement Specification
Hydraulic Oil Reservoir Capacity
34 L
(36 qt)
7. Install rear wheel. Tighten to specification.
Item
Measurement Specification
Wheel Bolts, Powered Rear Axles (M20 Bolt) Torque
200 N˙m plus an additional 1/4 turn
(150 lb-ft plus an additional 1/4 turn)
Go to Section_50:Group_20
AG,OUO6435,681-19-20000503
556
Remove and Install Cam Lobe Motor Control Valve
Remove and Install Cam Lobe Motor Control Valve
H53003-UN: Control Valve Connections
H53004-UN: Cam Lobe Motor Control Valve
LEGEND:
A - Hydraulic Line
B - Hydraulic Line
C - Hydraulic Line
D - Hydraulic Line
E - Hydraulic Line (2 used)
F - Hydraulic Line (2 used)
G - Electrical Connector
H - Cap Screw (3 used)
I - Valve
557
Remove and Install Cam Lobe Motor Control Valve
1.
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other
lines. Tighten all connections before applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin
must be surgically removed within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a knowledgeable medical
source. Such information is available from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
NOTE:
Marking hoses and valve ports prior to disconnecting hydraulic lines will make
reassembly easier and prevent incorrect hose connections.
Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2. Disconnect lines (A to F).
3. Disconnect electrical connector (G) from solenoid valve.
4. Remove three cap screws (H) and valve (I).
5. Repair or replace valve as necessary.
6.
H53003-UN: Control Valve Connections
558
Remove and Install Cam Lobe Motor Control Valve
H53004-UN: Cam Lobe Motor Control Valve
LEGEND:
A - Hydraulic Line
B - Hydraulic Line
C - Hydraulic Line
D - Hydraulic Line
E - Hydraulic Line (2 used)
F - Hydraulic Line (2 used)
G - Electrical Connector
H - Cap Screw (3 used)
I - Valve
Install valve (I) using three cap screws (H).
7. Connect electrical connector (G) to solenoid valve.
8. Connect lines (A to F).
9. Be sure hoses do not rub on wheel rim by steering combine fully left and fully right. Also be sure hoses
do not kink or collapse when turning fully left or fully right.
Go to Section_50:Group_20
AG,OUO6435,682-19-20000503
559
Disassemble and Assemble Cam Lobe Motor Control Valve
Disassemble and Assemble Cam Lobe Motor Control Valve
1.
H53006-UN: Cam Lobe Motor Control Valve
LEGEND:
1 - Back-Up Ring
2 - O-Ring
3 - Back-Up Ring
4 - O-Ring
5 - Snap Ring
6 - Valve Spool
7 - Spring Pin
8 - O-Ring
9 - Plunger
10 - Spring
560
Disassemble and Assemble Cam Lobe Motor Control Valve
11 - O-Ring
12 - Guide
13 - Lock Nut
14 - Electrical Coil
15 - Solenoid Valve Repair Kit
16 - Solenoid Valve
17 - Adapter (4 used)
18 - O-Ring (4 used)
19 - O-Ring (5 used)
20 - Adapter
21 - Fitting (2 used)
22 - Fitting
23 - Spring
24 - O-Ring
25 - Fitting
26 - Flange Nut (3 used)
27 - O-Ring (2 used)
28 - Plug
29 - O-Ring (2 used)
30 - Valve
Disassemble parts (1 to 30).
2. Inspect parts and replace as necessary.
3. Assemble parts (1 to 30).
Go to Section_50:Group_20
OUO6030,00000A4-19-20010601
561
Remove and Install Steering Yoke
Remove and Install Steering Yoke
H64387-UN: Yoke
LEGEND:
A - Seal Ring (2 used)
B - Hex. Socket Screw (8 used)
C - O-Ring (2 used)
D - Tube
E - Tube
F - O-Ring (2 used)
G - Upper Pivot
H - Hex. Socket Screw (5 used)
562
Remove and Install Steering Yoke
I - O-Ring
J - Lower Pivot
K - Hex. Socket Screw (4 used)
1.
NOTE:
Tag or mark wires to simplify reassembly.
H63946-UN: Connector
Use JDG776 Weatherpack Extractor (blue handle) and release pins out of solenoid valve wiring harness
connector.
2. Remove solenoid valve harness from yoke.
3.
H63934-UN: Upper Pivot
563
Remove and Install Steering Yoke
H63932-UN: Lower Pivot
LEGEND:
A - Hex. Socket Screw (9 used)
B - Threaded Hole (2 used)
Remove screws (A).
4.
NOTE:
When removing pivot pins from yoke, a vacuum is created making it difficult to remove
pins completely. Removal of the lubrication fittings will vent this area and aid in removal
of pivot pins.
Thread two of the previously removed screws into threaded holes (B) to pull pivots from yoke.
5.
CAUTION:
Approximate weight of yoke (A) is 33 kg (73 lb). Use proper lifting device to
prevent injury.
Item Measurement Specification
Yoke Weight
33 kg
(73 lb)
H63937-UN: Upper Pivot
H63933-UN: Lower Pivot
LEGEND:
564
Remove and Install Steering Yoke
A - Yoke
B - Hex. Socket Screw (8 used)
Support yoke (A) with suitable lifting device.
6.
NOTE:
Upper and lower pivots use different length screws. Upper pivot uses longer screws.
Remove screws (B).
7.
H63949-UN: Yoke Removal
Carefully remove yoke from cam lobe motor.
8.
H63950-UN: Seal Ring
LEGEND:
A - Seal Ring (2 used)
Gently pry seal rings (A) off motor.
9. Inspect pivots, seals and bushings for wear or damage.
10. Apply TY6341 Multi-Purpose SD Polyurea Grease to both upper and lower pivot bushings and seals.
11. Install seal rings.
565
Remove and Install Steering Yoke
12.
H64055-UN: Seal Support
LEGEND:
A - Seal Ring (2 used)
Apply TY6304 Flexible Form-In-Place Gasket to mating surfaces of seal rings (A) and yoke.
13.
NOTE:
Use longer screws on upper pivot.
H63936-UN: Yoke Installation
H63937-UN: Upper Pivot
566
Remove and Install Steering Yoke
H63933-UN: Lower Pivot
LEGEND:
A - Yoke
B - Hex. Socket Screw (8 used)
Install yoke (A) over seal rings and install screws (B). Tighten to specification.
Item
Measurement Specification
Seal Ring Screws Torque
10 N˙m
(7 lb-ft)
14.
H63150-UN: Upper Pivot
LEGEND:
A - Tube
B - Tube
Remove tubes (A) and (B).
15.
NOTE:
O-rings (A) are not a serviceable item. If wear and/or damage is evident, tube
replacement is necessary.
567
Remove and Install Steering Yoke
H63156-UN: Pivot Tubes
LEGEND:
A - O-Ring (4 used)
Inspect O-rings (A). Replace tubes as necessary.
16.
H63153-UN: Upper Pivot
LEGEND:
A - O-Ring
Remove and discard O-ring (A).
17. Install new O-ring.
18.
H63948-UN: Upper Pivot
Lubricate O-rings with clean hydraulic oil and install tubes into pivot.
19. Lightly coat both upper and lower pivot pins with TY6341 Multi-Purpose SD Polyurea Grease.
568
Remove and Install Steering Yoke
19. Lightly coat both upper and lower pivot pins with TY6341 Multi-Purpose SD Polyurea Grease.
20.
H63975-UN: Pivot Installation
H63976-UN: Pivot Installation
LEGEND:
A - Pivot Pin (2 used)
B - Hex. Socket Screw (9 used)
Install pivot pins (A) into yoke and motor and retain with screws (B).
21. Tighten screws to specified torque.
Item
Measurement Specification
Pivot Pin Screws Torque
70 N˙m
(50 lb-ft)
22. Install solenoid valve harness through yoke and install wires into wire connector.
Go to Section_50:Group_20
AG,OUO6022,1878-19-20021119
569
Disassemble and Assemble Pivot Pins, Bushings, and Seals
Disassemble and Assemble Pivot Pins, Bushings, and Seals
H64389-UN: Pivot Bushings
LEGEND:
A - Motor Housing
B - Seal Ring (2 used)
C - Bushing (2 used)
D - Bushing (2 used)
1. Remove steering yoke (see procedure in this Group).
2.
CAUTION:
Be careful not to damage bushing bores when removing bushings.
NOTE:
Bushing (A) is retained to motor housing with super glue.
570
Disassemble and Assemble Pivot Pins, Bushings, and Seals
H64053-UN: Pivot Bushing Removal
LEGEND:
A - Bushing (2 used)
B - Bushing (2 used)
C - Seal Ring (2 used)
Remove bushings (A) and (B) and seal ring (C).
3.
H64331-UN: Pivot Bushings
LEGEND:
A - Grease Hole
B - Grease Hole
Align grease hole (A) in bushing with grease hole (B) in motor.
4.
H64330-UN: Pivot Bushings
LEGEND:
A - Bushing
571
Disassemble and Assemble Pivot Pins, Bushings, and Seals
B - JDG1376 Bushing Driver
Use JDG1376 Bushing Driver (B) and JDG537 Handle to install bushing (A).
5.
H63155-UN: Pivot Thrust Bushing
Apply TY24445 Gel Super Glue to back side of pivot thrust bushing. Install bushing.
6.
H64332-UN: Pivot Seal
LEGEND:
A - Seal
Apply TY24445 Gel Super Glue to back side of pivot seal. Install seal.
Go to Section_50:Group_20
AG,OUO6435,138-19-20000522
572
Remove and Install Solenoid Valve and Valve Block
Remove and Install Solenoid Valve and Valve Block
H64388-UN: Valve
LEGEND:
A - Motor Housing
B - O-Ring (4 used)
C - Plug
D - Snap Ring
E - Washer
F - Spring
G - Spool
H - Lubrication Fitting (2 used)
I - Solenoid Valve Assembly
J - Solenoid Valve Block
K - Hex. Socket Screw (4 used)
L - Plug
1.
H63946-UN: Connector
Use JDG776 Weatherpack Extractor (Narrow Metripack) tool and release pins out of solenoid wiring
harness connector.
2. Observe harness routing; then remove solenoid valve harness from yoke.
573
Remove and Install Solenoid Valve and Valve Block
3.
H63939-UN: Cover
LEGEND:
A - Hex. Socket Screw (3 used)
B - Cover
Remove screws (A) and cover (B).
4.
NOTE:
There are four small O-rings between valve block and motor.
H63940-UN: Solenoid Valve
LEGEND:
A - Hex. Socket Screw (4 used)
B - Solenoid Valve Block
Remove screws (A) and solenoid valve block (B).
5. Remove and discard O-rings.
574
Remove and Install Solenoid Valve and Valve Block
6.
H63942-UN: Solenoid Valve
LEGEND:
A - Nut
B - Coil
C - Valve Block
Remove nut (A) and coil (B) from valve block (C).
7.
H63941-UN: Solenoid Valve
LEGEND:
A - Solenoid Valve
B - Valve Block
Remove solenoid valve (A) from valve block (B).
8. Inspect all parts for wear and damage, replace as necessary.
9. Inspect valve block for dirt and debris, clean as needed.
10. Replace seals on solenoid valve and coat with clean hydraulic oil.
575
Remove and Install Solenoid Valve and Valve Block
11.
H63979-UN: Torque of Valve
Install valve and tighten to specification.
Item
Measurement Specification
Solenoid Valve Torque
27 N˙m
(20 lb-ft)
12.
H63982-UN: Torque of Coil
Install coil and tighten nut to specification.
Item Measurement Specification
Nut Torque
3 N˙m
(27 lb-in.)
13.
H63944-UN: O-Rings
LEGEND:
576
Remove and Install Solenoid Valve and Valve Block
A - O-Ring (4 used)
Coat new O-rings (A) with TY6341 Multi-Purpose SD Polyurea Grease.
14.
H63983-UN: Installation of Solenoid Valve
LEGEND:
A - Hex. Socket Screw (4 used)
Install solenoid valve assembly. Tighten screws (A) to specified torque.
Item
Measurement Specification
Solenoid Valve Block, Screw Torque
15 N˙m
(11 lb-ft)
15.
H63984-UN: Cover
LEGEND:
A - Cover
B - Hex. Socket Screws
Install cover (A) using screws (B).
16. Route solenoid valve wires through yoke and connect wire connector.
Go to Section_50:Group_20
AG,OUO6435,141-19-20010112
577
Remove and Install Displacement Control Valve
Remove and Install Displacement Control Valve
H64388-UN: Valve
LEGEND:
A - Motor Housing
B - O-Ring (4 used)
C - Plug
D - Snap Ring
E - Washer
F - Spring
G - Spool
H - Lubrication Fitting (2 used)
I - Solenoid Valve Assembly
J - Solenoid Valve Block
K - Hex. Socket Screw (4 used)
L - Plug
1. Remove solenoid valve block (see procedure in this Group).
2.
H63944-UN: O-Rings
LEGEND:
578
Remove and Install Displacement Control Valve
A - O-Ring (4 used)
Remove and discard O-rings (A).
3.
H63943-UN: Plug
LEGEND:
A - Plug
Remove plug (A).
4.
H63945-UN: Spool for Displacement Control
LEGEND:
A - Spool
B - Washer
C - Spring
Remove spool (A), washer (B) and spring (C).
5.
H63978-UN: Spool
579
Remove and Install Displacement Control Valve
Inspect parts for wear and damage. Replace parts as necessary.
6.
H63980-UN: Spool
Coat spool, washer and spring with clean hydraulic oil.
7. Reassemble spool assembly as shown and install.
8.
H63981-UN: Install Plug
LEGEND:
A - Plug
B - O-Ring (4 used)
Replace seal on plug (A).
9. Install plug (A) and tighten to specification.
Item
Measurement Specification
Displacement Control Valve Plug Torque
280 N˙m
(200 lb-ft)
10. Coat new O-rings (B) with TY6341 Multi-Purpose SD Polyurea Grease.
11. Install solenoid valve assembly (see procedure in this Group).
Go to Section_50:Group_20
AG,OUO6435,142-19-20010112
580
Remove and Install Cam and Piston Carrier
Remove and Install Cam and Piston Carrier
H64390-UN: Valve Block
LEGEND:
A - Motor Housing
B - Seat
C - Wedge
D - Seal
E - Seal
F - Seal
G - Seal
H - Valve Block
I - Spring (9 used)
J - Piston Carrier
K - O-Ring
L - Cam
M - O-Ring
1. Remove yoke (see procedure in this Group).
581
Remove and Install Cam and Piston Carrier
2.
H63148-UN: Motor Screws
LEGEND:
A - Hex. Socket Screw (6 used)
B - Hex. Socket Screw (4 used)
Remove screws (A).
3. Loosen screws (B).
4.
CAUTION:
Approximate weight of cam lobe motor is 195 kg (425 lb). Use proper lifting
device to prevent injury.
Item
Measurement Specification
Cam Lobe Motor Weight
195 kg
(425 lb)
H63154-UN: Motor Disassembly
LEGEND:
A - Scribe Line
B - Hex. Socket Screw (4 used)
C - Spindle Assembly
Position motor assembly as shown.
582
Remove and Install Cam and Piston Carrier
5. Scribe a line (A) across the spindle, cam and valve block.
6.
CAUTION:
Approximate weight of spindle assembly is 41 kg (90 lb).
Item
Measurement Specification
Spindle Weight
41 kg
(90 lb)
Remove screws (B) and lift spindle assembly (C) from cam.
7.
H63166-UN: Piston Carrier
LEGEND:
A - Piston Carrier
Lift piston carrier (A) from cam.
8.
NOTE:
There are tapered wedges in two of the cam holes.
583
Remove and Install Cam and Piston Carrier
H64054-UN: Remove Cam
LEGEND:
A - JDG1377 Slide Hammer Adapter
B - DO12009AA Bearing Puller
Screw JDG1377 Slide Hammer Adapter (A) into the tapered wedge and use DO12009AA Bearing Puller
(B) to remove tapered wedges.
9. Strike both sides of cam at the dowel pins with a lead or brass hammer.
10. IMPORTANT:
Be careful not to damage the sealing surfaces of cam and valve block.
Pry cam loose from the outer cover using screwdrivers between the cam and the valve block. Pry evenly
since dowel pin breakage is possible. Lift cam straight up and off dowel pins.
11.
H63986-UN: Cam
LEGEND:
A - Lobe Surface
Inspect cam lobes (A) for pitting, scratches or nicks.
12. Pour clean hydraulic oil on inside cam surfaces.
584
Remove and Install Cam and Piston Carrier
13.
H63985-UN: O-Ring Replacement
LEGEND:
A - O-Ring
Fill O-ring groove with TY6341 Multi-Purpose SD Polyurea Grease and install O-ring (A).
14. IMPORTANT:
Make sure scribe mark on cam aligns with mark on valve block, incorrect orientation of holes may result
in machine damage.
H63989-UN: Cam Assembly
LEGEND:
A - Scribe Line
B - Scribe Line
Align scribe line on cam with scribe line on valve block and install cam onto dowel pins.
15. Install dowel pin wedges into cam holes where dowel pins exist.
16. Using a hammer and brass punch, lightly drive wedges into dowel pins.
17. IMPORTANT:
Before installing piston carrier, be certain valve block tabs are aligned with the relevant notches.
Be certain that oil passages in piston carrier mate up with valve block.
585
Remove and Install Cam and Piston Carrier
H63233-UN: Valve Block Assembly
Carefully lower piston carrier into cam.
18.
H63234-UN: Spindle Assembly
LEGEND:
A - O-Ring
Fill O-ring groove with TY6341 Multi-Purpose SD Polyurea Grease and install O-ring.
19.
CAUTION:
Approximate weight of spindle assembly is 41 kg (90 lb).
Item
Measurement Specification
Spindle Weight
41 kg
(90 lb)
586
Remove and Install Cam and Piston Carrier
H63235-UN: Install Spindle Assembly
LEGEND:
A - Hex. Socket Screw (4 used)
B - Scribe Line
C - Spindle Assembly
Apply TY9371 Thread Lock and Sealer to threads of screws (A).
20. Tilt cam lobe motor enough to install short screws (A).
21. Using a suitable lifting device, carefully lower spindle assembly (C) onto cam lobe motor while aligning
both the spindle shaft with the piston carrier and the scribe line on the spindle housing with the scribe
line on cam (B).
22.
NOTE:
Be certain that the O-ring is still seated in its groove in the spindle housing before
pulling the two units together.
Tighten screws (A) until the units are pulled together.
23.
H63236-UN: Assembly Screws
LEGEND:
A - Hex. Socket Screw (10 used)
587
Remove and Install Cam and Piston Carrier
Apply TY9371 Thread Lock and Sealer to threads of the remaining six screws (A).
24. Install the remaining six screws (A) and tighten to specification.
Item
Measurement Specification
Hex. Socket Screw (10 used) Torque
355 N˙m
(260 lb-ft)
Go to Section_50:Group_20
AG,OUO6435,139-19-20010112
588
Remove and Install Valve Block Seals
Remove and Install Valve Block Seals
H64390-UN: Valve Block
LEGEND:
A - Motor Housing
B - Seat
C - Wedge
D - Seal
E - Seal
F - Seal
G - Seal
H - Valve Block
I - Spring (9 used)
J - Piston Carrier
K - O-Ring
L - Cam
M - O-Ring
1. Remove cam and piston carrier (see procedure in this Group).
589
Remove and Install Valve Block Seals
2.
H63152-UN: Valve Block
LEGEND:
A - O-Ring
B - Tab
C - Valve Block
Remove and discard O-ring (A).
3. Note and record orientation of tabs (B) to valve block for reassembly.
4.
NOTE:
There are nine springs under the valve block; retain these springs with the valve block.
Remove valve block (C).
5.
H63158-UN: Valve Block
LEGEND:
A - Spring (9 used)
Remove springs (A) from valve block.
590
Remove and Install Valve Block Seals
6.
H63213-UN: Valve Block Seals
LEGEND:
A - Seal Ring (4 used)
Remove and discard seal rings (A).
7.
H63212-UN: Valve Block Seals
LEGEND:
A - Back-Up Ring (4 used)
Remove and discard back-up rings (A).
8.
NOTE:
Avoid excessive bending or twisting of seals during installation.
H63209-UN: Valve Block Seals
591
Remove and Install Valve Block Seals
H63210-UN: Valve Block Seals
Lubricate seal grooves.
9. Install new back-up rings and seal rings.
10.
H63158-UN: Valve Block
LEGEND:
A - Spring (9 used)
Fill spring holes with TY6341 Multi-Purpose SD Polyurea Grease and insert springs (A).
11.
NOTE:
Make sure that tabs (B) align with notches in valve block.
H63231-UN: Valve Block
592
Remove and Install Valve Block Seals
LEGEND:
A - O-Ring
B - Tab (2 used)
Apply a thin coat of TY6341 Multi-Purpose SD Polyurea Grease to valve block seals and install valve
block.
12. Fill O-ring groove with TY6341 Multi-Purpose SD Polyurea Grease and install O-ring (A).
13. Install cam and piston carrier (see procedure in this Group).
14. Install yoke (see procedure in this Group).
Go to Section_50:Group_20
AG,OUO6435,143-19-20000523
593
Remove and Install Axle Bearings and Seals
Remove and Install Axle Bearings and Seals
H64391-UN: Spindle
LEGEND:
A - Snap Ring
B - Shim Support
C - Shim Pack
D - Bearing
E - Seal Housing
F - Seal
G - Seal Housing
H - Seal
I - Spindle Housing
J - Bearing
K - Seal
L - Spindle
1. Remove yoke (see procedure in this Group).
594
Remove and Install Axle Bearings and Seals
2.
H63148-UN: Motor Screws
LEGEND:
A - Hex. Socket Screw (6 used)
B - Hex. Socket Screw (4 used)
Remove screws (A).
3. Loosen screws (B).
4.
CAUTION:
Approximate weight of cam lobe motor is 195 kg (425 lb). Use proper lifting
device to prevent injury.
Item
Measurement Specification
Cam Lobe Motor Weight
195 kg
(425 lb)
H63154-UN: Motor Disassembly
LEGEND:
A - Scribed Line
B - Hex. Socket Screw (4 used)
C - Spindle Assembly
Position motor assembly as shown.
595
Remove and Install Axle Bearings and Seals
5. Scribe a line (A) across the spindle, cam, and valve block to ensure proper reassembly.
6.
CAUTION:
Approximate weight of spindle assembly is 41 kg (90 lb).
Item
Measurement Specification
Spindle Weight
41 kg
(90 lb)
Remove screws (B) and lift spindle assembly (C) from cam.
7.
H63161-UN: Spindle Assembly
LEGEND:
A - O-Ring
Remove and discard O-ring (A).
8.
NOTE:
A press with a minimum capacity of 27000 kg (30 tons) is required.
596
Remove and Install Axle Bearings and Seals
H63168-UN: Press
H63169-UN: Snap Ring
LEGEND:
A - Snap Ring
Mount spindle assembly into press as shown.
9. Align notch in JDG1382 Bearing Installer with snap ring ends.
10. Apply pressure onto inner race of bearing until snap ring (A) can be removed from groove.
11.
H63214-UN: Spindle Shim Pack
LEGEND:
A - Shim Pack
Remove shim pack (A).
597
Remove and Install Axle Bearings and Seals
12.
H63171-UN: Press
LEGEND:
A - JDG-690-7
B - DO1246AA
Press spindle from housing using JDG-690-7 Bearing Remover (A) and DO1246AA 30-Ton Push-Puller
(Hydraulic) (B).
13.
H64049-UN: Spindle Bearing Removal
LEGEND:
A - Bearing
B - Seal
Use DO1243AA Bearing Puller Attachment and DO1219AA 17-1/2 Ton Push-Puller (Hydraulic) to
remove bearing (A) and seal (B) from spindle.
14.
598
Remove and Install Axle Bearings and Seals
H64050-UN: Spindle Bearing Races
Using a brass punch and hammer, remove both inner and outer spindle bearing cups from spindle
housing.
15. Clean and inspect all parts, replace as needed.
16.
H64051-UN: Spindle Housing Seals
LEGEND:
A - Seal Ring (2 used)
B - JDG1381 Seal/Bearing Installer
Use JDG1381 Seal/Bearing Installer (B) to remove spindle housing seals (A).
17.
H64052-UN: Spindle Seals
LEGEND:
A - Seal
B - Seal and Back-Up Ring
Remove seal (A), seal and back-up ring (B).
18.
NOTE:
Avoid excessive bending or twisting of neoprene seal.
599
Remove and Install Axle Bearings and Seals
H63218-UN: Spindle Center Seal
Lubricate seal grooves using TY6341 Multi-Purpose SD Polyurea Grease.
19. Install new back-up ring and seal in seal support.
20.
H63220-UN: Spindle Housing Seal
Apply TY9371 High Strength Thread Lock to outer rim of seal support.
21.
H64047-UN: Inner Spindle Seals
600
Remove and Install Axle Bearings and Seals
H64046-UN: Inner Spindle Seals
LEGEND:
A - Seal
B - JDG1380 Seal Installer
Press outer seal (A) into place using JDG1380 Seal Installer (B).
22.
H64048-UN: Seal Support
H64046-UN: Inner Spindle Seals
LEGEND:
A - Seal
B - JDG1380 Seal Installer
Install inner seal (A) and press into place using JDG1380 Seal Installer.
601
Remove and Install Axle Bearings and Seals
23.
H63991-UN: Spindle Housing Bearing Outer Race
LEGEND:
A - Bearing Cup
B - JDG1378 Bearing Installer
Install outer bearing cup (A) using JDG1378 Bearing Installer (B).
24.
H64045-UN: Spindle Housing Bearing Inner Race
LEGEND:
A - Bearing Cup
B - JDG1379 Bearing Installer
Install inner bearing cup (A) using JDG1379 Bearing Installer (B).
25.
H63992-UN: Spindle Outer Seal
LEGEND:
A - Seal
B - JDG1381 Seal/Bearing Installer
602
Remove and Install Axle Bearings and Seals
Press outer seal (A) onto spindle using JDG1381 Seal/Bearing Installer (B).
26. Coat seal with TY6341 Multi-Purpose SD Polyurea Grease.
27.
H63990-UN: Spindle Outer Seal
LEGEND:
A - Bearing
B - JDG1381 Seal/Bearing Installer
Press outer spindle bearing (A) onto spindle using JDG1381 Seal/Bearing Installer (B).
28. Pack bearing with TY6341 Multi-Purpose SD Polyurea Grease.
29. Lubricate spindle housing seals; then lower spindle housing onto spindle.
30.
NOTE:
Do not place shim pack on top of bearing while pressing bearing on spindle.
H63217-UN: Spindle Bearing Installation
Install inner spindle bearing using JDG-690-7 Bearing Remover and DO1246AA 30 Ton Push-Puller
603
Remove and Install Axle Bearings and Seals
(Hydraulic).
31.
H63169-UN: Spindle Inner Snap Ring
LEGEND:
A - Snap Ring
Position snap ring over shaft.
32. Align notch in JDG1382 Bearing Installer with snap ring ends.
33. Apply pressure on inner race of bearing until snap ring is fully seated in its groove.
34.
H63221-UN: Line Art
604
Remove and Install Axle Bearings and Seals
H64150-UN: Line Art
LEGEND:
A - Specified Torque with Offset Factor
B - Specified Torque (37 N˙m)
C - Length of Torque Wrench
D - Distance from Spindle Center to Bolt Hole Center
Adjust spindle rolling drag torque using the following method:
NOTE:
The length of the torque wrench used (offset) will have to be measured so that a correct
torque value is achieved. Use the formula shown to determine what torque value should
be seen on the wrench (paying attention to the offset value). Use meters as the unit of
measurement.
EXAMPLE:
The torque wrench being used has a length (C) of 500 mm (0.5 m).
Distance (D) from spindle center to bolt hole center is 140 mm (0.14 m).
The torque wrench must read 28.9 N˙m (A) to obtain the specified rolling drag torque.
35.
Rotate spindle in spindle housing a minimum of five revolutions.
Install M12 cap screw into one of the perimeter spindle housing holes as shown.
Measure length of torque wrench (C).
Measure distance (D) from center of spindle to center of previously installed cap screw.
Prevent spindle from turning.
NOTE:
A direct reading or beam type torque wrench is required for accurate readings.
Use torque wrench to turn spindle housing, record amount of torque needed to rotate spindle
housing and compare to specification.
Item
Measurement
Specification
Specified Torque (B) Rolling Drag Torque 37 N˙m
(27 lb-ft)
Add or remove shims to obtain specified value.
605
Remove and Install Axle Bearings and Seals
36.
H63161-UN: Spindle Assembly
LEGEND:
A - O-Ring
Fill O-ring groove with TY6341 Multi-Purpose SD Polyurea Grease and install O-ring (A).
37.
CAUTION:
Approximate weight of spindle assembly is 41 kg (90 lb).
Item
Measurement Specification
Spindle Weight
41 kg
(90 lb)
H63154-UN: Motor Disassembly
LEGEND:
A - Scribed Line
B - Hex. Socket Screw (4 used)
C - Spindle Assembly
Align splines on spindle with piston carrier; then lower spindle housing making certain alignment marks
(A) on housing are correct.
38. Lower spindle housing onto cam and install screws (B).
39.
NOTE:
606
Remove and Install Axle Bearings and Seals
Be certain that the O-ring is still seated in its groove in the spindle housing before
pulling the two units together.
Tighten screws evenly on both sides of housing until all sections are pulled together.
40.
H63236-UN: Assembly Screws
LEGEND:
A - Hex. Socket Screw (10 used)
Install the remaining six screws (A) and tighten to specification.
Item
Measurement Specification
Hex. Socket Screw Torque
355 N˙m
(260 lb-ft)
41. Install yoke (see procedure in this Group).
Go to Section_50:Group_20
AG,OUO6435,144-19-20021119
607
HillMaster II Rocker Assembly - Right
HillMaster II Rocker Assembly - Right
ZX25216-UN: HillMaster II
LEGEND:
1 - Bushing (2 used)
2 - Washer (2 used)
3 - Shim
4 - Washer
5 - Lever
6 - Cap Screw
7 - Pin
8 - Cap Screw
608
HillMaster II Rocker Assembly - Right
9 - Lock Washer
10 - Nut
11 - Rocker
12 - Washer
13 - Shim
14 - Snap Ring
15 - Cap Screw
16 - Cap Screw
17 - Lock Washer
18 - Cover
19 - Ring (2 used)
20 - Cylinder
21 - Ring
22 - Lock Washer
23 - Cap Screw
Go to Section_50:Group_25
OUO6037,0001436-19-20010710
609
HillMaster II Rocker Assembly - Right
HillMaster II Rocker Assembly - Right
ZX25216-UN: HillMaster II
LEGEND:
1 - Bushing (2 used)
2 - Washer (2 used)
3 - Shim
4 - Washer
5 - Lever
6 - Cap Screw
7 - Pin
8 - Cap Screw
610
HillMaster II Rocker Assembly - Right
9 - Lock Washer
10 - Nut
11 - Rocker
12 - Washer
13 - Shim
14 - Snap Ring
15 - Cap Screw
16 - Cap Screw
17 - Lock Washer
18 - Cover
19 - Ring (2 used)
20 - Cylinder
21 - Ring
22 - Lock Washer
23 - Cap Screw
Go to Section_50:Group_25
OUO6037,0001436-19-20010710
611
HillMaster II Rocker Assembly - Left
HillMaster II Rocker Assembly - Left
ZX25215-UN: HillMaster II
LEGEND:
1 - Bushing (2 used)
2 - Lever
3 - Bushing (5 used)
4 - Cap Screw (5 used)
5 - Washer (2 used)
6 - Cap Screw
7 - Washer
8 - Shim
612
HillMaster II Rocker Assembly - Left
9 - Pin
10 - Cap Screw
11 - Lock Washer
12 - Nut
13 - Cylinder
14 - Lubrication Fitting
15 - Pin
16 - Cap Screw
17 - Screw
18 - Cap Screw
19 - Rocker
20 - Washer (3 used)
21 - Shim
22 - Snap Ring
23 - Cover
24 - Ring (2 used)
25 - Cylinder
26 - Ring (2 used)
27 - Lock Washer
28 - Cap Screw
29 - Cap Screw
30 - Lock Washer
31 - Cap Screw
Go to Section_50:Group_25
OUO6037,0001437-19-20010710
613
Table of Contents
Section 60: Power Steering and Brakes
Group 05: Steering
Essential and Recommended Special Tools
Service Equipment and Tools
Other Material
Specifications
Remove Steering Valve
Steering Valve
Disassemble Steering Valve
Assemble Steering Valve
Install Steering Valve
Steering Column Components (Upper)
Steering Column Components (Lower)
Disassemble And Assemble Steering Column
Replace Telescoping Shaft Bearings
Remove and Install Steering Cylinder
Repair Steering Cylinder
Adjust Toe-In
Remove and Install Steering Tie Rod
Remove and Install Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel
Drive
Remove and Install Rear Axle Pivot Bushing
Rear Axle Adjustment
Group 10: Brake
Service Equipment and Tools
Other Material
Specifications
Remove Brake Drum
Remove Brake Shoes - Heavy Duty Version
Recondition Brakes - Heavy Duty Version
Assemble Brakes - Heavy Duty Version
Install Brake Drum
614
Table of Contents
Remove and Install Master Cylinder
Disassemble and Assemble Master Cylinder (Double Bleed Screw)
Adjust Master Cylinder
Bleed Brake System (Double Bleed Screw)
Remove and Install Slave Cylinders
Disassemble and Assemble Slave Cylinder
Disassemble and Assemble Brake Pedals
Disassemble and Assemble Park Brake Pedal
Adjust Park Brake Pedal
Group 15: Trailer Hitch
Remove Trailer Hitch
615
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
Used with JT05874 final drive adapter to remove and
install rear spindle.
H40598-UN: Service Jack
Final Drive Adapter.......JT05874
Used with D05070ST jack to remove and install rear
spindle.
H40599-UN: Final Drive Adapter
Snap Ring Pliers.......JDG114 [ RECOMMENDED
TOOL ]
Used to remove and install internal snap rings.
H40188-UN: Snap Ring Pliers
Spindle Repair
Kit.......JDG1301
Used to remove and
install bearing and
seal.
Go to Section_60:Group_05
ZX09263,0002739-19-20080131
616
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
Used with JT05874 final drive adapter to remove and
install rear spindle.
H40598-UN: Service Jack
Final Drive Adapter.......JT05874
Used with D05070ST jack to remove and install rear
spindle.
H40599-UN: Final Drive Adapter
Snap Ring Pliers.......JDG114 [ RECOMMENDED
TOOL ]
Used to remove and install internal snap rings.
H40188-UN: Snap Ring Pliers
Spindle Repair
Kit.......JDG1301
Used to remove and
install bearing and
seal.
Go to Section_60:Group_05
ZX09263,0002739-19-20080131
617
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
17-1/2 and 30-Ton Puller
Set.......D01047AA
Used to remove and install
outer bearing of rear
spindle.
Bushing, Bearing and
Seal Driver
Set.......D01044AA
Used to install rear spindle
bushings and seals.
Steering Wheel
Puller.......JDG17
Used to remove steering
wheel from steering
shaft.
12-Ton Support Stand .......JT02043
Used to support rear axle.
RW25751-UN: 12-Ton Support Stand
Go to Section_60:Group_05
ZX09263,000273A-19-20080131
618
Other Material
Other Material
Number
Name
Use
TY9370 (U.S.) Thread Lock and Sealer (medium strength) To coat threads of spindle-to-housing cap screw.
TY15969 (U.S.) Retaining Compound, Maximum Strength
To coat spindle shaft prior to seal installation.
TY6341 (U.S.) Multipurpose SD Polyurea Grease
To lubricate king pins and bearings.
Go to Section_60:Group_05
OUO6030,000000E-19-20010423
619
Specifications
Specifications
Item
Measurement
Specification
First sequence
Torque
11 to 17 Nm
(100 to 150 lb-in.)
Final sequence
Torque
25 to 31 Nm
(225 to 275 lb in.)
Steering Column Bearing Nut
Torque
40 ± 4 Nm
(29 ± 3 lb-ft)
Steering Column Couplings
Clearance
2.5 ± 0.5 mm
(0.100 ± 0.020 in.)
Steering Column Upper Coupling, Clamping
Screw
Torque
28 ± 2.8 Nm
(29 ± 3 lb-ft)
Steering Wheel Nut
Torque
47 Nm
(35 lb-ft)
Steering Cylinder Castle Nuts
Torque
150 ± 15 Nm; tighten to align cotter pin.
(111 ± 11 lb-ft); tighten to align cotter
pin.
Steering Cylinder Lock Nut
Torque
215 Nm
(160 lb-ft)
Front of Steered Wheels
Toe-in
13 mm
(1/2 in.)
Steering Tie Rod Nut
Torque
200 Nm
(150 lb-ft)
Tie Rod Castle Nuts
Torque
150 ± 15 Nm; tighten to align cotter pin.
(111 ± 11 lb-ft); tighten to align cotter
pin.
Rear Spindle Assembly - Heavy Duty
Approximate
Weight
80 kg
(176 lb)
Rear Spindle-to-Axle Cap Screws
Torque
646 ± 97 Nm
(475 ± 71 lb-ft)
Spindle Pin-to-Yoke Cap Screws
Torque
70 ± 18 Nm
(52 ± 13 lb-ft)
Rear Spindle Stake Nut
Torque
101 Nm; then back off 10 degrees
(75 lb-ft); then back off 10 degrees
Axle Tube Cap Screws
Torque
620 Nm
(460 lb-ft)
Tie Rod Cap Screws
Torque
130 Nm
(96 lb-ft)
Steering Valve Cap Screws
Go to Section_60:Group_05
OUO6435,000195C-19-20021113
620
Remove Steering Valve
Remove Steering Valve
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
1.
H65681-UN: Steering Valve
LEGEND:
A - Oil Line to Steering Cylinder
B - Cap Screw (4 used)
C - Steering Valve
D - Oil Return Line to Filter
E - Oil Supply Line from Pump
F - Oil Line to Steering Cylinder
Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2. Disconnect oil lines (A) and (D - F).
621
Remove Steering Valve
3. Plug and cap all openings.
4. Remove screws (B) to remove steering valve (C) and plate.
5.
H40577-UN: Steering Valve
LEGEND:
A - Support
B - Cap Screw (4 used)
C - Steering Valve
D - Coupler
Remove coupler (D).
6. Remove cap screws (B).
7. Remove support (A) from steering valve (C).
Go to Section_60:Group_05
OUO6089,0000067-19-20010709
622
Steering Valve
Steering Valve
H66668-UN: Steering Valve
LEGEND:
1 - End Cover Screw (7 used)
2 - End Cover
3 - O-Ring (3 used)
4 - Rotor
5 - Drive Shaft
6 - Spacer
7 - Spool
8 - Sleeve
9 - Leaf Spring (4 used)
10 - Pin
11 - Control Housing
12 - Plunger/Relief Valve
13 - Spring
14 - O-Ring
623
Steering Valve
15 - Cap
16 - Retainer
17 - Check Valve Ball
18 - Plunger/Relief Valve
19 - Spring
20 - Set Screw
21 - Bearing Race (2 used)
22 - Thrust Bearing
23 - O-Ring
24 - Seal
25 - Seal
26 - Bushing
27 - Snap Ring
28 - Seal Ring (2 used)
29 - Housing
30 - Screw (4 used)
31 - Check Valve Ball
32 - Roll Pin
33 - Screw Insert
34 - Check Valve Ball (2 used)
35 - Roll Pin (2 used)
NOTE:
Only parts (3), (21), (26 - 28) are available as repair kit.
Go to Section_60:Group_05
AG,OUO6022,1905-19-20000725
624
Disassemble Steering Valve
Disassemble Steering Valve
IMPORTANT:
Perform all service work on steering valve in clean area. Use proper tools, cleaning material and lubricants.
NOTE:
Only a seal repair kit is available for service.
1.
H57564-UN: Front Housing
LEGEND:
A - Screw (4 used)
B - Front Housing
Remove screws (A) to remove front housing (B).
2.
H57565-UN: Snap Ring
LEGEND:
A - Snap Ring
Remove snap ring (A).
625
Disassemble Steering Valve
3.
H57566-UN: Seal Gland Bushing
Remove seal gland bushing assembly.
4.
H57567-UN: O-Ring
LEGEND:
A - O-Ring
Remove O-ring (A).
5.
T87425-UN: Oil Seal
Remove oil seal.
626
Disassemble Steering Valve
6.
H57568-UN: O-Ring
Remove O-ring.
7.
H55447-UN: Thrust Bearing
LEGEND:
A - Races (2 used)
B - Bearing
Remove bearing races (A) and thrust bearing (B).
8.
H57569-UN: Steering Valve
Remove cap screws to remove gerotor assembly.
627
Disassemble Steering Valve
9.
H57570-UN: O-Rings
LEGEND:
A - O-Ring (3 used)
Remove O-rings (A).
10. IMPORTANT:
If it is necessary to remove spool and sleeve assembly from housing for cleaning, be careful to prevent
these parts from binding. Tolerances in this area are very close and when replacement is necessary the
steering valve must be ordered as an assembly.
T87428-UN: Steering Valve
To prevent binding, turn spool and sleeve assembly as it is removed from housing. Do not disassemble
spool and sleeve assembly.
11.
H57571-UN: Check Valve
628
Disassemble Steering Valve
H66670-UN: Shock Valve
LEGEND:
A - Screw Insert
B - Roll Pin
C - Ball
D - Ball
E - Roll Pin
Remove and inspect parts (A - E).
Go to Section_60:Group_05
OUO6046,00013DA-19-20010305
629
Assemble Steering Valve
Assemble Steering Valve
H57571-UN: Check Valve
H66670-UN: Shock Valve
T87428-UN: Steering Valve
LEGEND:
A - Screw Insert
B - Roll Pin
C - Ball
D - Ball
E - Roll Pin
1. Thoroughly clean all parts (A - E).
2. Apply clean hydraulic oil to all internal parts.
3. Use a steering valve seal repair kit when assembling steering valve.
4. To prevent binding, turn spool and sleeve assembly as it is installed.
630
Assemble Steering Valve
5. IMPORTANT:
For correct operation, the drive shaft must be installed into gerotor star so groove is in alignment with
one of the roots of gerotor star teeth.
T5835AG-UN: Rotor
LEGEND:
A - Gerotor Star
B - Drive Shaft
Install gerotor star (A) on drive shaft so root of tooth is in alignment with groove in the end of drive shaft
(B).
6.
H57572-UN: Drive Shaft
LEGEND:
A - Drive Shaft
B - Spacer
C - Slot
D - O-Ring (2 used)
Install O-rings (D).
7. Install drive shaft (A) and spacer (B). The pin in the spool and sleeve assembly must engage in slot (C).
631
Assemble Steering Valve
8.
H57573-UN: Rotor
LEGEND:
A - Gerotor Ring
B - Spacer
C - O-Ring (2 used)
D - End Cover
Install O-ring (C) on gerotor ring (A).
9. Install gerotor ring and spacer (B).
10.
RW25138A-UN: End Cover
Install end cover.
11. Clean and dry cap screws before installing.
12. IMPORTANT:
Any cap screw can be tightened first, but the sequence shown must be followed.
Install and tighten the cap screws to specified torque using sequence (1 through 7) shown:
Item
Measurement Specification
Steering Valve Cap Screws
First sequence Torque
11 to 17 Nm
(100 to 150 lb-in.)
Final sequence Torque
25 to 31 Nm
(225 to 275 lb in.)
632
Assemble Steering Valve
13.
H55447-UN: Thrust Bearing
LEGEND:
A - Races (2 used)
B - Bearing
Install bearing races (A) and thrust bearing (B).
14.
H57568-UN: O-Ring
Install O-ring.
15.
T87433-UN: Seal
Install oil seal with lip of seal opposite bottom of bore using 30 mm and 24 mm disks.
Push oil seal to the bottom of bore.
Apply petroleum jelly to lip of seal.
633
Assemble Steering Valve
16.
H57567-UN: Gland
LEGEND:
A - O-Ring
Install O-ring (A). Apply petroleum jelly to seal.
17.
H57566-UN: Gland
Install seal gland bushing assembly.
18.
H55450-UN: Snap Ring
LEGEND:
A - Steering Valve
B - Snap Ring
Install snap ring (B) into steering valve (A).
634
Assemble Steering Valve
19.
H57564-UN: Steering Valve
LEGEND:
A - Screw (4 used)
B - Housing
Install housing (B) using screws (A).
Go to Section_60:Group_05
AG,OUO6022,1909-19-20000725
635
Install Steering Valve
Install Steering Valve
LEGEND:
A - Support
B - Cap Screw (4 used)
C - Steering Valve
D - Coupler
1. Attach support (A) to steering valve (C) with cap screws (B). Tighten the cap screws.
2. Slide coupler (D) on valve shaft.
3.
NOTE:
Get help from a second service technician to align valve shaft.
H57590-UN: Steering Couplings
Install valve aligning coupling with steering column.
4. With 2.5 mm (0.01 in.) clearance between couplings, tighten set screw on lower coupling.
636
Install Steering Valve
5.
H53029-UN: Steering Valve
LEGEND:
A - Oil Line to Steering Cylinder
B - Screw (4 used)
C - Steering Valve
D - Oil Return Line to Filter
E - Oil Supply Line from Pump
F - Oil Line to Steering Cylinder
Install four screws (B) to attach valve (C). Tighten the screws.
6. Connect oil lines (A) and (D - F).
7. Start engine and operate at slow idle for 3 minutes without using any hydraulic functions or steering.
8. Build pressure intermittently for 3 minutes by turning steering wheel.
9. Increase engine speed to fast idle and build pressure intermittently for 3 minutes. Shut off engine and
visually check the valve for leakage. Eliminate leakage as necessary.
Go to Section_60:Group_05
OUO6030,0000014-19-20010423
637
Steering Column Components (Upper)
Steering Column Components (Upper)
H73591-UN: Steering Column Components (Upper)
LEGEND:
1 - Cover
2 - O-Ring
3 - Cap Screw
4 - Knob
5 - Nut
6 - Nut
7 - Lock Washer
8 - Steering Wheel
638
Steering Column Components (Upper)
9 - Snap Ring
10 - Turn Signal Switch
11 - Snap Ring
12 - Label
13 - Guard
14 - Screw (4 used)
15 - Support
16 - Key
17 - Nut
18 - Switch
19 - Switch
20 - Housing
21 - Cap
22 - Cap
23 - Safety Decal
24 - Switch
25 - Guide
26 - Screw
27 - Nut (2 used)
28 - Washer (2 used)
29 - Snap Ring
30 - Clip
31 - Screw (2 used)
32 - Cam
33 - Screw (2 used)
34 - Panel
35 - Panel
36 - Screw (2 used)
37 - Bulb
38 - Retainer
39 - Screw
40 - Clip
41 - Screw (4 used)
42 - Cover
Go to Section_60:Group_05
OUO6435,0001937-19-20021011
639
Steering Column Components (Lower)
Steering Column Components (Lower)
H73590-UN: Steering Column Components (Lower)
LEGEND:
1 - Nut
2 - Pin
3 - Snap Ring
4 - Ball Bearing
5 - Washer
6 - Steering Shaft
7 - Shaft Key
8 - O-Ring
640
Steering Column Components (Lower)
9 - Steering Shaft
10 - Washer
11 - Housing
12 - Ball Bearing
13 - Snap Ring
14 - Spring Pin
15 - Universal Joint with Shaft
16 - Screw (2 used)
17 - Bearing
18 - Lock Nut (2 used)
19 - Coupling
20 - Nut
21 - Screw
22 - Isolator
23 - Splined Coupling
24 - Set Screw (2 used)
25 - Rod
26 - Clip
27 - Clip
28 - Arm
29 - Spring
30 - Screw (3 used)
31 - Isolator
32 - Housing
33 - Nut (2 used)
34 - Gasket
35 - Disk (2 used)
36 - Screw (4 used)
37 - Washer (4 used)
38 - Grommet
39 - Support
40 - Washer (4 used)
41 - Disk
42 - Screw (4 used)
43 - Pump
44 - Housing
45 - Pawl
46 - Screw (2 used)
47 - Crank
48 - Screw (2 used)
49 - Screw (4 used)
50 - Snap Ring
51 - Washer
52 - Spring Pin
53 - Shaft
54 - Spring Pin
55 - Spring
56 - Rod
641
Steering Column Components (Lower)
57 - Pedal
58 - Cover
59 - Screw (4 used)
Go to Section_60:Group_05
OUO6435,0001935-19-20021011
642
Disassemble And Assemble Steering Column
Disassemble And Assemble Steering Column
1. Disconnect battery ground cable.
H67658-UN: Steering Column
LEGEND:
A - Knob
B - Cap
2.
NOTE:
It is not necessary to remove cap (B) from knob unless it is loose or must be replaced. If
cap is loose, remove by carefully prying upward using a screwdriver. Inspect O-ring and
replace if required.
Turn knob (A) counterclockwise to remove.
3. Bend down tabs on lock washer (A). Remove nut (B).
H67659-UN: Steering Wheel Nut
LEGEND:
A - Washer
B - Nut
4. Pull steering wheel off of shaft. If steering wheel does not come off easily, tap lightly upward using a
rubber mallet.
5. Remove snap ring (A).
643
5. Remove snap ring (A).
Disassemble And Assemble Steering Column
H67660-UN: Steering Shaft Snap Ring
LEGEND:
A - Snap Ring
6. Remove screws (A) from both sides of housing and remove top cover. Leave harness connected and set
cover aside.
H67661-UN: Steering Column Top Cover
LEGEND:
A - Screw (2 used per side)
7. Disconnect turn signal switch from connector (A).
644
Disassemble And Assemble Steering Column
H57381-UN: Turn Signal Switch Connector
LEGEND:
A - Connector
B - Cap Screw (4 used)
8. Loosen cap screws (B) enough to allow connector to fit between housing and steering column. Remove
turn signal switch.
9. Remove screws (A) from both sides of housing and remove lower cover.
H57395-UN: Lower Steering Column Cover
LEGEND:
A - Screw (2 used per side)
10. Remove spring pin (A) and cap screws (B).
645
Disassemble And Assemble Steering Column
H57399-UN: Steering Shaft Retainer
LEGEND:
A - Spring Pin
B - Cap Screw (4 used)
C - Clamp
11. Remove clamp (C).
12. Remove telescoping shaft.
13. Remove screw (A) and nuts (B) to remove U-joint and shaft (C).
H57405-UN: Steering Shaft Coupling
H57506-UN: Steering Shaft Coupling
646
Disassemble And Assemble Steering Column
LEGEND:
A - Screw
B - Nuts
C - U-Joint with Shaft
D - Isolator
E - Set Screw
F - Coupling
14. Remove isolator (D).
15. Loosen set screw (E) to remove lower coupling half (F).
16. Clean and inspect all parts. Replace worn or damaged parts as needed.
17. Install lower coupling half and tighten set screw.
18. Install bearing and upper coupling half on U-joint with shaft. Do not tighten the clamping screw yet.
19. Position isolator and install U-joint and shaft assembly. Tighten nuts on bearing screws to specification.
Item
Measurement Specification
Steering Column Bearing Nut Torque
40 ± 4 Nm
(29 ± 3 lb-ft)
20. Tilt steering column to lowest position.
21. Slide upper coupler half onto the shaft until specified clearance is obtained between jaws of upper
coupler and hub of lower coupler.
Item
Measurement Specification
Steering Column Couplings Clearance
2.5 ± 0.5 mm
(0.100 ± 0.020 in.)
22. Tighten nut on upper coupler clamping screw to specification.
Item
Measurement Specification
Steering Column Upper Coupling, Clamping Screw Torque
23.
28 ± 2.8 Nm
(29 ± 3 lb-ft)
NOTE:
Be sure to position the turn signal switch connector between housing and telescoping
shaft before tightening telescoping shaft clamp.
Tighten steering wheel nut to specification and bend up tabs on lock washer.
Item
Measurement Specification
Steering Wheel Nut Torque
47 Nm
(35 lb-ft)
24. After assembly, be sure steering column turns freely.
25. Connect battery ground cable.
647
Disassemble And Assemble Steering Column
Go to Section_60:Group_05
OUO6030,0000078-19-20010518
648
Replace Telescoping Shaft Bearings
Replace Telescoping Shaft Bearings
1.
H57404-UN: Telescoping Steering Shaft
LEGEND:
A - Snap Ring
Remove the telescoping shaft (see Disassemble And Assemble Steering Column in this group.)
2. Remove snap ring (A).
3. Separate the three shaft sections and remove key (A), spring washer (B) and bearing (C).
H57421-UN: Telescoping Shaft Components
LEGEND:
A - Key
B - Washer
C - Bearing
4. Remove snap ring (A) and bearing (B).
649
Replace Telescoping Shaft Bearings
H57425-UN: Steering Shaft Bearing
LEGEND:
A - Snap Ring
B - Bearing
C - Washer
5. Remove spring washer (C).
6. Inspect all parts for wear and damage. Replace parts as necessary.
7. Assemble and install the telescoping shaft (see Disassemble And Assemble Steering Column in this
group.)
Go to Section_60:Group_05
OUO6089,000000F-19-20010611
650
Remove and Install Steering Cylinder
Remove and Install Steering Cylinder
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
1.
H53030-UN: Steering Cylinder
LEGEND:
A - Line (2 used)
B - Castle Nut (2 used)
C - Steering Cylinder
Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2. Disconnect oil lines (A). Cap oil lines.
3. Remove castle nuts (B) to remove cylinder (C). Recondition cylinder as necessary.
651
Remove and Install Steering Cylinder
4. Install steering cylinder (C).
5. Install castle nuts (B) and tighten to specification.
Item
Measurement Specification
Steering Cylinder Castle Nuts Torque
150 ± 15 Nm; tighten to align cotter pin.
(111 ± 11 lb-ft); tighten to align cotter pin.
6. Connect oil lines (A).
Go to Section_60:Group_05
OUO6089,0000068-19-20010709
652
Repair Steering Cylinder
Repair Steering Cylinder
H54095-UN: Steering Cylinder
LEGEND:
A - Seal
B - Seal
C - Rod Guide
D - Snap Ring
E - Ring
F - Washer
G - O-Ring
H - Rod
I - O-Ring
J - Piston
K - Piston Ring
L - O-Ring
M - Wear Ring
N - Lock Nut
O - Barrel
1. Pull on the piston rod (H) to remove internal parts from cylinder barrel (O).
2. IMPORTANT:
Do not slide the rod guide (C) off the threaded end of the piston rod.
Remove lock nut (N) and snap ring (D) to remove parts (A - C and E - M). Do not clamp or mark the
sealing surface of the piston rod.
3. Wash parts in a clean, safe solvent.
4. Inspect parts for wear or damage. Replace seal if necessary. If piston ring (K) is damaged, replace both
rings (K and M). Heat TEFLON ™ ring (K) in oil for easier installation on the piston; do not to exceed 77
°C (170 °F).
5. IMPORTANT:
Install a new kit of O-rings and seals when assembling the cylinder. Check all new O-rings and seals
653
Repair Steering Cylinder
before installation to be certain they are still elastic.
To prevent damage, install parts from the piston end of the rod and not over the threads. Lubricate seals
and O-rings with SAE 10W oil before assembling.
6. Tighten lock nut (N) on piston rod (H) to specification.
Item
Measurement Specification
Steering Cylinder Lock Nut Torque
7.
215 Nm
(160 lb-ft)
CAUTION:
Connecting oil lines to the steering cylinder incorrectly will result in opposite
steering.
Install cylinder and connect oil lines. Fill and bleed system.
Go to Section_60:Group_05
OUO6030,0000019-19-20021120
654
Adjust Toe-In
Adjust Toe-In
H53039-UN: Tie Rod
LEGEND:
A - Lock Nut (2 used)
B - Tie Rod
With steered wheels straight ahead, loosen lock nuts (A) on both ends. Turn tie rod (B) until the toe-in complies
with the specification.
Item
Measurement Specification
Front of Steered Wheels Toe-in
13 mm
(1/2 in.)
Tighten nuts (A) to specified torque.
Item
Measurement Specification
Steering Tie Rod Nut Torque
200 Nm
(150 lb-ft)
Go to Section_60:Group_05
OUO6030,000001A-19-20010423
655
Remove and Install Steering Tie Rod
Remove and Install Steering Tie Rod
H53036-UN: Tie Rod
LEGEND:
A - Cotter Pin
B - Nut
C - Tie Rod End
D - Tube
E - Fitting
1. Remove cotter pin (A).
2. Remove nut (B).
3. Force tie rod end (C) from bore.
4. Turn tire out for clearance.
5. Remove tie rod end from tube (D).
6. Inspect parts. Replace as necessary.
7. Install tie rod end (C) to tube (D).
8. Install tie rod end through bore.
9. Install nut (B), tighten to specification and re-install cotter pin (A).
Item
Measurement Specification
Tie Rod Castle Nuts Torque
150 ± 15 Nm; tighten to align cotter pin.
(111 ± 11 lb-ft); tighten to align cotter pin.
10. Lubricate tie rod at fitting (E).
Go to Section_60:Group_05
OUO6030,000001B-19-20010423
656
Remove and Install Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
Remove and Install Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel
Drive
1.
H54772-UN: Rear Spindle Assembly
H54774-UN: Rear Spindle Assembly
LEGEND:
A - Nut
B - Tie Rod
C - Nut
D - Steering Cylinder
E - Cap Screw (4 used)
F - Rear Spindle Assembly
Apply park brake.
2. Raise rear axle and position support stand.
3. Remove rear wheel (see Section 50).
4. Remove cotter pin and castle nut (A) to disconnect tie rod (B).
5. Remove cotter pin and castle nut (C) to disconnect steering cylinder (D).
6. Suspend the spindle assembly using a suitable hoist.
Item
Measurement
Specification
Rear Spindle Assembly - Heavy Duty Weight (Approx.) 80 kg
(176 lb)
7. Remove cap screws (E) to remove rear spindle (F).
657
Remove and Install Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
7. Remove cap screws (E) to remove rear spindle (F).
8.
H54772-UN: Rear Spindle Assembly
H54774-UN: Rear Spindle Assembly
LEGEND:
A - Nut
B - Tie Rod
C - Nut
D - Steering Cylinder
E - Cap Screw (4 used)
F - Rear Spindle Assembly
Position rear spindle assembly on axle.
9. Install four cap screws (E) and tighten to specification. Remove the hoist.
Item
Measurement Specification
Rear Spindle-to-Axle Cap Screws Torque
646 ± 97 Nm
(475 ± 71 lb-ft)
10. Install steering cylinder (D). Install castle nut (C). Tighten nut to specification and install cotter pin.
Tighten further, if necessary, to install cotter pin.
Item
Measurement Specification
Steering Cylinder Castle Nut Torque
150 ± 15 Nm
(111 ± 11 lb-ft)
11. Install tie rod (B). Install castle nut (A). Tighten nut to specification and install cotter pin. Tighten further, if
658
Remove and Install Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
necessary, to install cotter pin.
Item
Measurement Specification
Tie Rod Castle Nut Torque
150 ± 15 Nm
(111 ± 11 lb-ft)
12. Install rear wheel (see Section 50).
13. Lower rear axle and remove support stand.
Go to Section_60:Group_05
OUO6030,000001E-19-20010423
659
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without RearWheel Drive
ZX1041674-UN: Rear Spindle Assembly
LEGEND:
1 - Axle
2 - Seal
3 - Bearing Cone
4 - Oil Cup
5 - Bearing Cup
6 - Lubrication Fitting
7 - Housing
660
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
8 - Lubrication Fitting (2 used)
9 - Bearing Cup
10 - Bearing Cone
11 - Washer
12 - Castle Nut
13 - Key
14 - Snap Ring
15 - Ring
16 - Snap Ring
17 - Bushing (2 used)
18 - Seal Ring (2 used)
19 - Washer (2 used)
20 - Yoke
21 - Cap Screw (4 used)
22 - Pin (2 used)
23 - Cap Screw (6 used)
1. Apply park brake.
2. Raise rear axle and position support stand.
3. Disconnect tie rod end from spindle assembly (see Remove and Install Steering Tie Rod in this Group.)
4. Remove rear wheel (see Section 50).
5.
H54789-UN: Rear Spindle Snap Ring and Plug
LEGEND:
A - Snap Ring
B - Plug
Remove snap ring (A) using JDG114 Snap Ring Pliers.
6.
NOTE:
For reassembly a new plug (B) is required. Install new bearing cups in spindle housing if
bearing cones are replaced.
Remove plug (B) by punching a hole in center and prying out with pry bar.
661
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
7.
H72679-UN: Serial No. 074502—
LEGEND:
A - Nut
E - Key
F - Snap Ring
Remove snap ring (F), key (E) and nut (A).
8. Clean and inspect all parts. Replace as necessary.
9.
H55547-UN: Adapter
662
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
H55548-UN: Bearing Removal
LEGEND:
A - Threaded Adapter
B - Axle
C - Seal
D - Bearing Cone
E - 17-1/2 and 30 Ton Puller
Install JDG1301-1 Threaded Adapter (A) from JDG1301 Spindle Repair Kit on axle (B).
10. Remove seal (C) and bearing cone (D) from axle (B) using D01047AA 17-1/2 and 30 Ton Puller Set.
663
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
11.
H55549-UN: Bearing Installation
LEGEND:
A - Seal
B - Bearing Cone
C - Bearing Installer
D - Threaded Adapter
E - 17-1/2 and 30-Ton Puller Set
Install seal (A) and bearing (B) using bearing installer (C) and JDG1301-1 Threaded Adapter (D) from
JDG1301 Spindle Repair Kit and 17-1/2 and 30 ton puller set (E).
12.
H54791-UN: Rear Spindle Assembly
LEGEND:
A - Cap Screw (6 used)
B - Pin (2 used)
C - Housing
D - Washer
E - Yoke
Remove cap screws (A) and pins (B) to remove housing (C) and washers (D) from yoke (E). Inspect
664
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
seals and bushings and replace as necessary.
13.
H54871-UN: Seal
H54872-UN: Bushing
LEGEND:
A - Seal
B - Bushing Seam
Remove seal (A) by prying up with a screwdriver.
14. Inspect bushing for wear.
15. Remove bushing from bore by peeling the bushing starting at seam (B).
16.
H54873-UN: Bushing Replacement
665
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
H54874-UN: Seal Replacement
LEGEND:
A - Bushing
B - Seal
Install bushing (A) using 2-1/2 in. disk from D01044AA Bushing, Bearing and Seal Driver Set.
17. Install seal (B) using 2-9/16 in. disk from D01044AA Bushing, Bearing and Seal Driver Set.
18.
NOTE:
Remove lubrication fittings from housing and coat bushings and pins with Multi-Purpose
SD Polyurea Grease prior to installation of pins (B). This will allow air to escape as pins
are installed. Replace lubrication fittings after pins are installed.
H54791-UN: Rear Spindle Assembly
LEGEND:
A - Cap Screw (6 used)
B - Pin (2 used)
C - Housing
D - Washer
E - Yoke
Install housing (C), washers (D) and pins (B) on yoke (E). Install cap screws (A) and tighten to
specification.
Item
Measurement Specification
Spindle Pin-to-Yoke Cap Screws Torque
70 ± 18 Nm
(52 ± 13 lb-ft)
666
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
19.
H72679-UN: Serial No. 074502—
LEGEND:
A - Nut
E - Key
F - Snap Ring
Install spindle, inner bearing, washer and nut (A). Tighten nut to specification.
Item
Measurement Specification
Rear Spindle Nut Torque
100 Nm ± 25 Nm; then back off 10°
(74 lb-ft ± 18 lb-ft; then back off 10°)
20. Rotate spindle one revolution and retighten nut (A) to specification. Loosen nut (A) 10°.
21. If key (E) cannot be installed, loosen nut until first set of slots aligns with slots in shaft. Install key (E) and
snap ring (F).
22.
H74210-UN: Lubrication Fitting
667
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
H74211-UN: Spindle Nut
LEGEND:
A - Lubrication Fitting
B - Bearing
C - Hex. Nut
Lubricate fitting (A) using 840 cc of Multi-Purpose SD Polyurea Grease or until grease is visible at
bearing (B) and around hex nut (C).
23.
H54789-UN: Rear Spindle Plug
H54948-UN: Lubrication Fitting
LEGEND:
A - Snap Ring
B - Plug
C - Lubrication Fitting
D - Washer Interface
Install new plug (B) using an appropriate driver. Install snap ring (A) using JDG114 snap ring pliers.
24. Lubricate fittings (C) using Multi-Purpose SD Polyurea
Grease until pressure builds up. Grease should
668
Disassemble and Assemble Rear Spindle Assembly - Heavy-Duty Version without Rear-Wheel Drive
24. Lubricate fittings (C) using Multi-Purpose SD Polyurea Grease until pressure builds up. Grease should
be visible at mating surface of washer (D) after 2—5 minutes.
25. Connect tie rod end to spindle assembly (see Remove and Install Steering Tie Rod in this Group.)
26. Install rear wheel (see Section 50).
27. Lower rear axle and remove support stand.
Go to Section_60:Group_05
ZX09263,00027B5-19-20080303
669
Remove and Install Rear Axle Pivot Bushing
Remove and Install Rear Axle Pivot Bushing
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
1. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2. If equipped, remove chaff spreader (see instructions in Section 120).
3.
ZX25126-UN: Hitch
670
Remove and Install Rear Axle Pivot Bushing
LEGEND:
A - Hitch
If equipped, remove hitch (A). (See instructions in Group 15.)
4.
CAUTION:
Always empty grain tank before jacking up the combine.
CAUTION:
The jack must have a minimum rating of 9072 kg (10 tons).
H68085-UN: Service Jack
LEGEND:
A - Jack (2 used)
Raise combine until rear tires are just touching the ground. Support rear axle support frame using jacks
(A).
5.
H68089-UN: Lines
LEGEND:
A - Steering Line (4 used)
B - Clamp (2 used)
Disconnect steering lines (A) and remove clamps (B). Cap all lines and fittings.
671
Remove and Install Rear Axle Pivot Bushing
6.
H68090-UN: Collar
LEGEND:
A - Cotter Pin
B - Pin
C - Bushing
Remove cotter pin (A), pin (B), bushing (C) and shims.
7.
H68091-UN: Support Axle
Support rear axle using D265025A, 10 Ton Hydraulic Jack or equivalent.
8. Use a suitable stabilizer bar attached to jack, as illustrated, to prevent axle roll over.
9.
CAUTION:
Be certain area is clear of bystanders to avoid injuring others.
Remove axle from rear axle support frame.
672
Remove and Install Rear Axle Pivot Bushing
10.
H68092-UN: Bushing
LEGEND:
A - Seal Ring (2 used)
B - Bushing (2 used)
Remove seal ring (A) and bushing (B) from both sides of rear axle support frame.
11.
H68108-UN: Install Bushing
H68132-UN: Seal
LEGEND:
A - Bushing (2 used)
B - Seal Ring (2 used)
Install bushings (A) using a suitable bushing driver.
12. Install seal rings (B).
13. Apply TY6341 Multi-purpose SD Polyurea Grease to bushings, seals and axle pivot shaft.
673
Remove and Install Rear Axle Pivot Bushing
14.
H68091-UN: Support
Slide rear axle pivot shaft into axle support frame.
15.
H68090-UN: Collar
LEGEND:
A - Cotter Pin
B - Pin
C - Bushing
Install shims, bushing (C), pin (B) and cotter pin (A).
16.
H68089-UN: Steering Lines
LEGEND:
A - Steering Line (4 used)
B - Clamp (2 used)
674
Remove and Install Rear Axle Pivot Bushing
Route steering lines through rear axle support frame.
17. Connect steering lines (A) and install clamps (B).
18.
ZX25126-UN: Hitch
LEGEND:
A - Hitch
If equipped, install hitch (A). (See instructions in Group 15.)
19. If equipped, install chaff spreader (see instructions in Section 120).
Go to Section_60:Group_05
OUO6435,00018F2-19-20020829
675
Rear Axle Adjustment
Rear Axle Adjustment
H59912-UN: Rear axle components
H54340-UN: With Chaff Spreader
H40963-UN: Hose Clamps and Hose Tie Strap
LEGEND:
A - Axle
B - Screws
C - Screws
D - Cylinder Screws
E - Tie Rod Screws
F - Power Steering Hose Clamps
G - Clamp
676
Rear Axle Adjustment
H - Tie Strap
The axle is adjustable to let the rear tires track the drive tires.
CAUTION:
When changing axle widths, the rear frame of combine must be raised and blocked
properly.
Jack up one end of the axle (A). Remove screws (B), (C), cylinder screws (D) and tie rod screws (E).
Loosen power steering hose clamps (F) to adjust hoses. Extra long hoses must be stored in axle frame. Tighten
clamps after moving hoses.
If combine is equipped with four-wheel drive, loosen hose clamp (G) and tie strap (H). Pull enough hose through
clamp to be able to reposition axle. Tighten clamp and tie strap after moving axle.
Tie rod holes will go in or out the same amount of holes and align correctly.
A drift may be needed to align axle holes and start upper screws (C). Re-install screws (B, C, D and E) in correct
holes.
Tighten cap screws (B, C, D and E) to specification.
Item
Measurement Specification Item
Axle Tube Cap Screws Torque
620 Nm
(460 lb-ft)
Measurement Specification
Tie Rod Cap Screws Torque
130 Nm
(96 lb-ft)
IMPORTANT:
This sequence must be followed since the screws will "relax".
Repeat the steps on the other side.
Re-tighten the first side to specification then re-tighten the second side.
Go to Section_60:Group_05
OUO6435,000195A-19-20021112
677
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Brake Shoe
Adjustment
Tool.......JDG699
Used to set service
brake shoe
clearance.
Go to Section_60:Group_10
ZX09263,000273B-19-20080131
678
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Brake Shoe
Adjustment
Tool.......JDG699
Used to set service
brake shoe
clearance.
Go to Section_60:Group_10
ZX09263,000273B-19-20080131
679
Other Material
Other Material
Number
Name
Use
SAE J1703D or
DOT 3 (U.S.)
Hydraulic Brake Fluid
To service brakes.
T43512 (U.S.)
Thread Lock and Sealer (Medium
TY9473 (Canadian) Strength)
TY6341 (U.S.)
Locks and seals while preventing parts
loosening due to vibration.
Multi-Purpose, High-Temperature Extreme Especially effective in rolling contact
Pressure Grease
applications.
Go to Section_60:Group_10
AG,OUO6435,722-19-20000503
680
Specifications
Specifications
Item
Measurement
Specification
Brake Backing Plate-to-Transmission
Screws
Torque
620 Nm
(460 lb-ft)
Slave Cylinder-to-Backing Plate Cap
Screws
Torque
27 Nm
(20 lb-ft)
Shoe Lining
Minimum Thickness
0.8 mm above rivets at thinnest point.
(0.031 in.) above rivets at thinnest point.
Brake Drum
Maximum turn down
1.52 mm from diameter or 0.76 mm on each
side.
0.060 in. from diameter or 0.030 in. on each
side.
Maximum Out of Round 0.15 mm
(0.006 in.)
Brake Drum
Maximum Scoring
0.25 mm
(0.010 in.)
Brake Drum
Maximum Bellmouth
0.25 mm
(0.010 in.)
Brake Drum
Maximum Surface
Variance
0.13 mm
(0.005 in.)
Brake Anchor Screw
Torque
45 Nm
(33 lb-ft)
Master and Slave Cylinder Bleed
Screws
Torque
7.3—9.0 Nm
(65—80 lb-in.)
Slave Cylinder-to-Piston (New)
Maximum Bore
Clearance
0.15 mm
(0.006 in.)
Go to Section_60:Group_10
AG,OUO6435,723-19-20000503
681
Remove Brake Drum
Remove Brake Drum
H61072-UN: Feeder House
LEGEND:
A - Stop
CAUTION:
Raise feeder house and lower safety stop.
Engine must be off and key removed.
1. Lower safety stop (A) onto feeder house lift cylinder rod.
2.
LEGEND:
A - Brake Drum
B - Pin
C - Sleeve
D - Drive Shaft
E - Coupling
F - Snap Ring
Remove snap ring (F) to slide coupling (E) from sleeve (C).
3. Remove pin (B) from sleeve (C).
4. Remove drive shaft (D) from brake drum (A).
5. Remove the brake drum.
6. Remove the plug from the bore in brake drum. Disconnect park brake cable at equalizer bar. Also
682
Remove Brake Drum
disconnect the brake line. Remove five cap screws that secure brake assembly to transmission. Lower
assembly to the ground and remove brake drum.
Go to Section_60:Group_10
OUO6089,0000033-19-20010620
683
Remove Brake Shoes - Heavy Duty Version
Remove Brake Shoes - Heavy Duty Version
H53035-UN: Heavy Duty Brake Assembly
LEGEND:
A - Brake Shoe (2 used)
B - Cable
C - Cam
D - Anchor Screw
E - Park Brake Lever
F - Slave Cylinder
G - Retainer (2 used)
H - Screw (2 used)
I - Washer (5 used)
J - Cap Screw (5 used)
K - Cable
L - Threaded Pin
M - Adjusting Sleeve
N - Pawl
O - Spring
P - Spring
Q - Spring
R - Spring
1. Remove the brake drum. (See procedure in this group.)
IMPORTANT:
Keep hands clean when handling brake shoes. Do not permit oil or grease to come in contact with
linings.
NOTE:
Only remove screw (D) if it is necessary to recondition the park brake mechanism.
684
Remove Brake Shoes - Heavy Duty Version
Only remove screw (D) if it is necessary to recondition the park brake mechanism.
2. Remove spring (O) and pawl (N).
3. Remove springs (Q) and (R).
4. Remove screws (H) and retainer (G) to remove brake shoes (A).
Go to Section_60:Group_10
AG,OUO6435,729-19-20000503
685
Recondition Brakes - Heavy Duty Version
Recondition Brakes - Heavy Duty Version
H53038-UN: Heavy Duty Brake Assembly
LEGEND:
1 - Snap Ring
2 - Washer
3 - Cam
4 - Park Brake Lever
5 - Sleeve
6 - Anchor Screw
7 - Park Brake Kit
8 - Spring
686
Recondition Brakes - Heavy Duty Version
9 - Retainer (2 used)
10 - Screw (2 used)
11 - Spring
12 - Cover
13 - Pin
14 - Cable
15 - Guide
16 - Spring
17 - Pawl
18 - Adjuster Kit
19 - Adjusting Sleeve
20 - Threaded Pin
21 - Drum (2 used)
22 - Snap Ring (2 used)
23 - Brake Shoes
24 - Brake/Transmission Cap Screw (5 used)
25 - Washer (5 used)
26 - Guide (2 used)
27 - Backing Plate
28 - Dust Seal
29 - Cable (to Pedal)
30 - Fluid Line
31 - Screw (6 used)
32 - Washer (6 used)
1. Clean backing plate (27). Be sure shoe support points are smooth and free of rough edges.
2. Attach dust seal (28) to backing plate (27) with screws (31) and washers (32).
3. Clean the thread of adjusting sleeve (19) and check for damage. The adjusting sleeve must turn freely
on threaded pin (20).
4. Check springs (5), (8), (11) and (16) and other parts for loss of tension and damage. Replace weak
springs and any damaged or worn parts.
5. Brake shoe linings must not be glazed, soiled with grease or brake fluid or otherwise damaged. Make
sure that linings are within specification.
Item
Measurement
Specification
Shoe Lining Minimum Thickness 0.8 mm above rivets at thinnest point.
(0.031 in.) above rivets at thinnest point.
6. Brake shoes (23) must not be distorted, cracked or have broken welds.
7. Check slave cylinder by pulling back edge of dust boot. There should be no brake fluid inside the boot. If
inside of boot is wet, recondition the cylinder as described.
8. Each brake drum (21) that does not meet turn down specifications must be replaced.
687
Recondition Brakes - Heavy Duty Version
Item
Measurement
Specification
Brake Drum Maximum Turn Down
1.52 mm from diameter or 0.76 mm on each side.
0.060 in. from diameter or 0.030 in. on each side.
Maximum Out of Round 0.15 mm
(0.006 in.)
9.
H38267-UN: Brake Drum
LEGEND:
A - Scored Drum
B - Bellmouthed Drum
Re-bore or replace brake drum if the contact surface has scoring (A) deeper than specification. The best
method of checking scoring depth is to mount the brake drum on a lathe.
Item
Measurement
Specification
Brake Drum Maximum Scoring 0.25 mm
(0.010 in.)
10. Re-bore or replace brake drum if the inside diameter of the drum at the open end exceeds the inside
diameter at the closed end by more than the specified limit (B). Use a micrometer for measuring.
Item
Measurement
Specification
Brake Drum Maximum Bellmouth 0.25 mm
(0.010 in.)
688
Recondition Brakes - Heavy Duty Version
11.
H38268-UN: Brake Drum
LEGEND:
A - Convex Drum
B - Concave Drum
Re-bore or replace the drum if the surface variance exceeds specification. Measure this with a
straightedge and narrow feeler gauge.
Item
Measurement
Specification
Brake Drum Maximum Surface Variance 0.13 mm
(0.005 in.)
12.
H38269-UN: Brake Drum
LEGEND:
A - Hard or Chill Spots
B - Heat Cracks
Re-bore or replace the drum if hard or chill spots (A) cause noticeable pedal pulsations or rough braking.
13. Re-bore or replace the drum if heat cracks (B) are plainly visible or can be felt with a fingernail.
Go to Section_60:Group_10
AG,OUO6435,730-19-20000503
689
Assemble Brakes - Heavy Duty Version
Assemble Brakes - Heavy Duty Version
H53035-UN: Brake Shoe Assembly, Heavy Duty
LEGEND:
A - Brake Shoe (2 used)
B - Cable
C - Cam
D - Anchor Screw
E - Park Brake Lever
F - Slave Cylinder
G - Retainer (2 used)
H - Screw (2 used)
I - Washer (5 used)
J - Screw (5 used)
K - Cable
L - Threaded Pin
M - Adjusting Sleeve
N - Pawl
O - Spring
P - Spring
Q - Spring
R - Spring
1. Apply a small amount of multipurpose type grease to cam mechanism (C) behind the anchor screw (D).
Make sure that parts can move freely, but do not over-lubricate. Also apply a small amount of this grease
to the dimples on the backing plate on which the brake shoes (A) ride.
2. Install parts (A) to (R).
3. Tighten anchor screw (D) to specification.
690
Assemble Brakes - Heavy Duty Version
Item
Measurement Specification
Brake Anchor Screw Torque
45 Nm
(33 lb-ft)
4. Tighten screws (J) to specification.
Item
Measurement Specification
Brake Backing Plate-to-Transmission Screws Torque
620 Nm
(460 lb-ft)
Go to Section_60:Group_10
AG,OUO6435,731-19-20000503
691
Install Brake Drum
Install Brake Drum
H40510-UN: Drive Shaft
LEGEND:
A - Brake Drum
B - Pin
C - Sleeve
D - Drive Shaft
E - Coupling
F - Snap Ring
Install parts (A) to (F).
Go to Section_60:Group_10
AG,OUO6435,732-19-20000503
692
Remove and Install Master Cylinder
Remove and Install Master Cylinder
H63398-UN: Master Cylinder
LEGEND:
A - Master Cylinder
B - Yokes
C - Cap Screws (4 used)
1. Thoroughly clean all around master cylinder (A).
2. Disconnect and cap lines going to cylinder.
3. Disconnect yokes (B).
4. Remove cap screws (C) to remove cylinder.
5. Install new master cylinder using cap screws (C).
6. Connect yokes (B).
7. Connect lines to cylinder.
8. Add brake fluid.
9. Bleed the brake system. (See Bleed Brake System in this group.)
Go to Section_60:Group_10
AG,OUO6435,733-19-20081126
693
Disassemble and Assemble Master Cylinder (Double Bleed Screw)
Disassemble and Assemble Master Cylinder (Double Bleed Screw)
H71003-UN: Master Cylinder
LEGEND:
1 - Seat
2 - Connector
3 - Bleed Valve (2 used)
4 - O-Ring (2 used)
5 - Valve (2 used)
6 - Springs (2 used)
7 - Ball (2 used)
8 - Valve Seat (2 used)
9 - Seal Ring (2 used)
10 - Housing
694
Disassemble and Assemble Master Cylinder (Double Bleed Screw)
11 - Springs (2 used)
12 - O-Ring (2 used)
13 - Bearing (2 used)
14 - Poppet (2 used)
15 - Springs (2 used)
16 - O-Ring (2 used)
17 - Plug (2 used)
18 - Switch
19 - Retainer (2 used)
20 - Screw (2 used)
21 - Retainer (2 used)
22 - Springs (2 used)
23 - Retainer (2 used)
24 - Oil Cup (2 used)
25 - Seal Ring (2 used)
26 - Piston (2 used)
27 - O-Ring (2 used)
28 - Snap Ring
29 - Boot (2 used)
30 - Screw
1. Wash all parts in clean denatured alcohol. Do not use kerosene, gasoline or petroleum base cleaners.
Allow the parts to air dry before coating them with brake fluid and assembling them.
2.
NOTE:
Before cleaning internal parts, wash hands with soap and water. Hands must be clean.
Do not use gasoline or petroleum base fluids to clean hands.
Clean cylinder bore and inspect for corrosion, scratches and burrs. Check clearance between new piston
and cylinder bore with feeler gauge. If clearance exceeds specification, the cylinder must be replaced.
Item
Measurement
Specification
Slave Cylinder-to-Piston (New) Maximum Bore Clearance 0.15 mm
(0.006 in.)
3. IMPORTANT:
Honing of the cylinder wall is not recommended. If the condition of the wall would indicate honing,
replace the cylinder.
Install repair kits as needed. Swollen or damaged rubber parts can indicate that the wrong brake fluid is
in the system. If this is the case, drain all fluid, refill with fresh fluid and bleed the system.
4. Coat parts with clean brake fluid when assembling cylinder. Be careful not to cut or tear rubber parts.
5. Add brake fluid and bleed the cylinder. (See procedure in this group.)
Go to Section_60:Group_10
OUO6435,0001950-19-20021028
695
Adjust Master Cylinder
Adjust Master Cylinder
H63399-UN: Master Cylinder
LEGEND:
A - Lock Nut
B - Boot
C - Push Rod
D - Yoke
E - Master Cylinder
Follow this procedure only if parts in the brake system have been replaced or if excessive free play between the
pedal and the master cylinder is noticed.
Loosen nut (A). Slide boot (B) off the master cylinder and onto push-rod (C) to expose inside of cylinder.
IMPORTANT:
Outer edge of piston must be touching snap ring in the cylinder. Remove all dirt between the cylinder and the
snap ring.
Screw push-rod (C) in or out of yoke (D) until the push-rod just touches the piston in the cylinder (E), then turn the
push-rod away from the piston by a 1/4 turn.
IMPORTANT:
Use your fingers to adjust each push-rod. Do not move piston away from snap ring.
Hold push-rod carefully in place when tightening lock nut (A).
Slide the boot back onto the cylinder.
Repeat for the other cylinder.
Go to Section_60:Group_10
AG,OUO6435,736-19-20081126
696
Bleed Brake System (Double Bleed Screw)
Bleed Brake System (Double Bleed Screw)
CAUTION:
Park combine on a flat, level surface and place chock blocks in front of and behind drive
wheels.
1. Disengage park brake.
2. Remove the drive shafts (see Remove Transmission in Section 50).
3. Check brake shoe-to-drum clearance by rotating brake drums. If a slight drag is felt, proceed to brake
bleeding procedure.
4. If no drag, or excess drag is felt, remove brake drums.
5. Check brake shoe-to-drum clearance using JDG699 brake setting gauge.
6. Check the outer diameter of the brake shoes and adjust as needed using the adjusting sleeve. (The
outer diameter of the brake shoes should be 0.76 mm (0.030 in.) less than the outer diameter of the
brake drum.) If brakes are too tight, pull locking pawl (self-adjusting) away from the adjusting sleeve,
and then turn the adjusting sleeve back.
7. Install brake drums and proceed to brake bleeding.
All brake connections must be tight. Keep brake fluid off painted surfaces. Check fluid level in brake
reservoir and fill as needed. Leave cap off reservoir to avoid creating a vacuum during bleeding.
NOTE:
Two persons are needed to bleed the brakes: one to pump the brakes and to fill the
reservoir, and one to bleed the brakes.
Use only clean brake fluid (SAE J1703D or DOT-3).
8. Check the bleed screws on the master cylinder and on the slave cylinder and make sure they are tight.
9.
697
Bleed Brake System (Double Bleed Screw)
H63400-UN: Bleed Screw
LEGEND:
A - Bleed Screw
Install one 5 mm (3/16 in.) ID clean clear plastic tubing, approximately 915 mm (36 in.) long, to right
master cylinder bleed screw (A).
10. Loosen the bleed screw by 1/4 turn.
11. Add fluid to reservoir and bleed the system until there is a clear flow of fluid.
12. Close the bleed screw.
13. Loosen the bleed screw by 1/4 turn.
14. Lock the brake pedals together and slowly depress to the floor.
15. Tighten the bleed screw and release brake pedals. Repeat until there is a clear fluid flow.
16.
H53024-UN: Transmission
LEGEND:
A - Right Bleed Screw
B - Left Bleed Screw
Install tubing on left slave cylinder bleed screw (B). Route tubing so that it is higher than the bleed screw.
17. Loosen the bleed screw by 1/4 turn.
18. Lock brake pedals together and slowly depress to the floor. Tighten the bleed screw and slowly release
the pedals. Repeat until there is a clear fluid flow.
19. Install tubing on right slave cylinder bleed screw (A). Route tubing so that it is higher than the bleed
screw.
20. Unlock the pedals.
21. Loosen the bleed screw by 1/4 turn and slowly depress right pedal to the floor. Tighten the bleed screw
and slowly release the pedal. Repeat until there is a clear fluid flow.
698
Bleed Brake System (Double Bleed Screw)
22.
H63400-UN: Master Cylinder
H63401-UN: Bleed Screw
LEGEND:
A - Right Bleed Screw
B - Left Bleed Screw
Install tubing on left master cylinder bleed screw (B).
23. Loosen the bleed screw by 1/4 turn.
24. Lock brake pedals together and slowly depress to the floor. Tighten the bleed screw and slowly release
the pedals. Repeat until there is a clear fluid flow.
25. Install the cap on the reservoir.
26. Install tubing on right master cylinder bleed screw (A).
27. Loosen the bleed screw by 1/4 turn.
28. Unlock the pedals and rapidly depress right pedal to maximum possible stroke and hold momentarily.
Tighten the bleed screw and slowly release the pedal. Repeat until no more air bubbles appear and fluid
flow stops.
NOTE:
By rapidly depressing pedal, an internal relief valve is opened which allows that passage
to be bled.
29. With tubing still on right master cylinder bleed screw, loosen the bleed screw by 1/4 turn.
699
Bleed Brake System (Double Bleed Screw)
29. With tubing still on right master cylinder bleed screw, loosen the bleed screw by 1/4 turn.
30. Rapidly depress left pedal to the maximum possible stroke and hold momentarily. Tighten the bleed
screw and slowly release the pedal. Repeat until no more air bubbles appear and fluid flow stops.
31. Check each pedal for firm, solid feel.
32. Tighten all bleed screws to specification.
Item
Measurement Specification
Master Cylinder and Slave Cylinder Bleed Screws Torque
7.3—9.0 Nm
(65—80 lb-in.)
33. Check the fluid level in the reservoir.
34. Install the drive shafts and engage the park brake.
35. Perform a test drive.
Go to Section_60:Group_10
AG,OUO6435,737-19-20081126
700
Remove and Install Slave Cylinders
Remove and Install Slave Cylinders
H53062-UN: Heavy Duty Brake System Shown
LEGEND:
A - Slave Cylinder
B - Bleed Screw
C - Cap Screw (2 used)
D - Brake Line
1. Remove the brake drum. (See procedure in this group.)
2. Disconnect and cap line (D) to slave cylinder (A).
3. Remove five cap screws that secure brake assembly to transmission. Lower assembly to the ground.
4. IMPORTANT:
Keep hands clean when handling brake shoes. Do not permit oil or grease to come in contact with
linings.
Disassemble the brakes. (See procedure in this group.)
5. Remove cap screws (C) and remove slave cylinder.
6. Inspect parts. Replace as necessary.
7. Install parts. Tighten cap screws (C) to specified torque.
Item
Measurement Specification
Slave Cylinder-to-Backing Plate Cap Screws Torque
27 Nm
(20 lb-ft)
8. Add brake fluid and bleed slave cylinders. (See procedure in this group.)
Go to Section_60:Group_10
AG,OUO6435,738-19-20000503
701
Disassemble and Assemble Slave Cylinder
Disassemble and Assemble Slave Cylinder
H40513-UN: Slave Cylinder
LEGEND:
A - Link (2 used)
B - Boot (2 used)
C - Piston (2 used)
D - Boot (2 used)
E - Housing
F - Oil Cup (2 used)
G - Spring
1. Disassemble parts (A - G) to disassemble cylinder.
2. Wash all parts in clean denatured alcohol. Do not use kerosene, gasoline or petroleum base cleaners.
Allow the parts to air dry before coating them with brake fluid and assembling them.
3.
NOTE:
Before cleaning internal parts, wash hands with soap and water. Hands must be clean.
Do not use gasoline or petroleum base fluids to clean hands.
Clean cylinder bore and inspect for corrosion, scratches and burrs. Check clearance between new piston
and cylinder bore with feeler gauge. If clearance exceeds specification, the cylinder must be replaced.
Item
Measurement
Specification
Slave Cylinder-to-Piston (New) Maximum Bore Clearance 0.15 mm
(0.006 in.)
4. IMPORTANT:
Honing of the cylinder wall is not recommended. If the condition of the wall would indicate honing,
replace the cylinder.
Install repair kits as needed. Swollen or damaged rubber parts can indicate that the wrong brake fluid is
in the system. If this is the case, drain all fluid, refill with fresh fluid and bleed the system.
5. Coat parts with clean brake fluid when assembling cylinder. Be careful not to cut or tear rubber parts.
Go to Section_60:Group_10
AG,OUO6435,739-19-20000503
702
Disassemble and Assemble Brake Pedals
Disassemble and Assemble Brake Pedals
H63415-UN: Brake Pedals
LEGEND:
A - Master Cylinder
B - Support (2 used)
C - Cap Screw (4 used)
D - Push Rod (2 used)
E - Nut (2 used)
F - Cotter Pin (2 used)
G - Pin (2 used)
H - Washer (2 used)
I - Yoke (2 used)
J - Pedal (2 used)
K - Isolator (2 used)
L - Pedal Coupler
M - Spring
N - Spring Pin
O - Bushing (4 used)
P - Springs (2 used)
Q - Pad (2 used)
R - Shaft
S - Shaft
703
Disassemble and Assemble Brake Pedals
H67670-UN: Floor Mat
LEGEND:
A - Mat
1. Lower feeder house to ground.
2. Shut off engine and remove key.
3. Pull floor mat (A) away from pedals.
4. Remove screws (A) and floor plate (B).
H67671-UN: Floor Plate
LEGEND:
A - Cap Screws
B - Floor Plate
5. Loosen cap screws (A) and remove lower cab panel.
704
Disassemble and Assemble Brake Pedals
ZX25123-UN: Screws on Cab
LEGEND:
A - Cap Screws
6.
NOTE:
It is not necessary to disconnect lines from master cylinder to service brake pedals.
Remove cap screw (A) on both sides.
H63402-UN: Support Cap Screws
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (2 used)
7. Loosen cap screw (B) on both sides.
8. Disconnect springs (A) from pedals.
705
Disassemble and Assemble Brake Pedals
H63406-UN: Springs
LEGEND:
A - Springs
9. Remove cotter pin, washer and pin (A). Remove cap screws on both sides.
H63416-UN: Pin
LEGEND:
A - Pin
10. Remove cap screw (A) from support.
H63408-UN: Cap Screw
LEGEND:
A - Cap Screw
706
Disassemble and Assemble Brake Pedals
11.
H63407-UN: Cap Screw
LEGEND:
A - Cap Screw (2 used)
NOTE:
It is not necessary to remove cap screws from support on both sides to remove pedals.
Remove bushing (A) and pedal(s) (B) from shaft on both sides.
12. Lift pedal(s) (B) through hole in cab floor to remove.
13. Inspect bushings, shaft and pedals. Replace as necessary.
14. Install pedal(s) through cab floor.
15.
H63421-UN: Bushing
LEGEND:
A - Bushing
B - Pedal
Install bushings and pedal(s) to shaft.
16. Install pedal assembly to holes in supports and install cap screws (A).
707
Disassemble and Assemble Brake Pedals
H63407-UN: Cap Screw (Cylinder)
LEGEND:
A - Cap Screw (4 used)
17. Install springs (A).
H63406-UN: Springs
LEGEND:
A - Springs
18. Install cap screws (A) and (B) on both sides.
H63402-UN: Support Cap Screws
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (2 used)
708
Disassemble and Assemble Brake Pedals
19. Install pin (A), washers and cotter pin through yoke and pedal.
H63416-UN: Pin
LEGEND:
A - Pin (2 used)
20. Install lower cab panel and tighten cap screws (A).
ZX25123-UN: Screws on Cab
LEGEND:
A - Cap Screws
21. Install floor plate (B) with cap screws (A).
H67671-UN: Floor Plate
709
Disassemble and Assemble Brake Pedals
LEGEND:
A - Cap Screws
B - Floor Plate
22. Install floor mat.
23. Adjust the push rods of the master cylinder (see Adjust Master Cylinder in this Group).
Go to Section_60:Group_10
OUO6089,0000012-19-20081126
710
Disassemble and Assemble Park Brake Pedal
Disassemble and Assemble Park Brake Pedal
H63732-UN: Park Brake
LEGEND:
1 - Isolator
2 - Arm
3 - Spring Pin
4 - Spring Pin
5 - Frame
6 - Pipe
7 - Pedal
8 - Toothed Segment
711
Disassemble and Assemble Park Brake Pedal
9 - Pawl
10 - Switch
11 - Screw
12 - Pin
13 - Plate
14 - Washer
15 - Spring
16 - Hook
17 - Screw
18 - Spring
19 - Screw
20 - Screw
21 - Plate
22 - Screw
23 - Pin
24 - Cotter Pin
25 - Pin (5 used)
26 - Pin (3 used)
27 - Balancer (2 used)
28 - Link (2 used)
29 - Link (2 used)
30 - Clevis
31 - Spring
32 - Bushing (2 used)
33 - Retaining Screw (5 used)
34 - Pad
35 - Washer (2 used)
36 - Nut (2 used)
1. Lower feeder house to ground.
2. Shut off engine and remove key.
3. Pull back floor mat (A).
H57558-UN: Floor Mat
LEGEND:
A - Floor Mat
712
Disassemble and Assemble Park Brake Pedal
4. Remove screws (A) and loosen cap screw (B) to remove floor plate.
H57987-UN: Floor Plate
LEGEND:
A - Screws (2 used)
B - Cap Screw
5. Loosen cap screws (A) and remove lower cab panel.
ZX25123-UN: Screws on Cab
LEGEND:
A - Cap Screws
6.
H57992-UN: Connector
713
Disassemble and Assemble Park Brake Pedal
LEGEND:
A - Connector
Disconnect wiring connector (A).
7.
H58190-UN: Pin
LEGEND:
A - Pin
Remove cotter pin and pin (A) from pedal.
8.
H57800-UN: Park Brake
LEGEND:
A - Nuts (2 used)
B - Springs (2 used)
C - Spring Pin
D - Shoulder Bolt
E - Cap Screws (2 used)
F - Shoulder Bolt
G - Cap Screws (2 used)
Loosen lock nuts (A) to relieve tension on balancers.
9. Disconnect springs (B).
714
Disassemble and Assemble Park Brake Pedal
9. Disconnect springs (B).
10. Remove spring pin (C), hook and washer from release lever.
11. Remove shoulder bolts (D) and (F) from pawl.
12. Remove cap screws from supports on cab floor.
13. Remove cap screws (E) and (G) and supports.
14.
H58156-UN: Park Brake Spring
LEGEND:
A - Spring
B - Pedal
C - Spring Pin
D - Lever
Disconnect spring (A) from pedal and support.
15. Remove pedal (B) from support and down through cab floor.
16. Remove spring pin (C).
17. Slide lever (D) through support to remove. Replace worn or damaged parts as needed.
715
Disassemble and Assemble Park Brake Pedal
18.
H57988-UN: Pedal
LEGEND:
A - Bushing (2 used)
B - Toothed Segment
Inspect bushing (A) on both sides, and toothed segment (B). Replace as necessary.
NOTE:
If replacing bushings, apply a thin coat of light oil on bushing prior to installation. This
will aid breaking in the bushing and provide for a longer service life.
NOTE:
If replacing toothed segment, apply thread lock and sealer. This will prevent screws from
loosening during normal use and vibration.
19.
H58156-UN: Park Brake Spring
LEGEND:
A - Spring
716
Disassemble and Assemble Park Brake Pedal
B - Pedal
C - Spring Pin
D - Lever
Install lever (D) and spring pin (C).
20. Install pedal (B) up through cab floor and insert pin into support.
21. Install spring (A) to support and pedal.
22.
H57800-UN: Park Brake
LEGEND:
A - Nuts (2 used)
B - Springs (2 used)
C - Spring Pin
D - Shoulder Bolt
E - Cap Screws (2 used)
F - Shoulder Bolt
G - Cap Screws (2 used)
Install supports and cap screws (E) and (G).
23. Install cap screws through supports and into cab floor.
24. Install pawl and shoulder bolts (D) and (F).
25. Install washer, hook and spring pin (C) to brake release pedal.
26. Connect springs (B).
717
Disassemble and Assemble Park Brake Pedal
27.
H58190-UN: Pin
LEGEND:
A - Pin
Install pin (A) and cotter pin to pedal.
28. Adjust the park brake cables (see Adjust Park Brake Pedal in this Group).
29.
H57992-UN: Connector
LEGEND:
A - Connector
Connect wiring connector (A).
30.
ZX25123-UN: Screws on Cab
LEGEND:
A - Cap Screws
718
Disassemble and Assemble Park Brake Pedal
Install lower cab panel and tighten cap screws (A).
31.
H57987-UN: Floor Plate
LEGEND:
A - Screw (2 used)
B - Cap Screw
Install floor plate and screws (A).
32. Tighten cap screw (B).
33.
H57558-UN: Floor Mat
LEGEND:
A - Floor Mat
Install floor mat (A).
Go to Section_60:Group_10
OUO6089,0000013-19-20081118
719
Adjust Park Brake Pedal
Adjust Park Brake Pedal
H57102-UN: Park Brake Balancer
LEGEND:
A - Threaded Cable Ends
B - Balancer Bar
1. Inspect park brake actuator mechanism under cab floor for interference and wear.
2. Measure threaded cable ends (A) sticking out of balancer bar (B). 17 mm (11/16 in.) to 19 mm (3/4 in.)
should be sticking out past balancer bar (B).
3. Push park brake pedal down and count number of tooth clicks. Pedal should go to fifth click.
4. If pedal goes past fifth click, tighten cable nuts (A) 1 mm and recheck.
5. If pedal cannot reach fifth click, loosen cable nuts 1 mm and recheck.
Go to Section_60:Group_10
AG,OUO6435,742-19-20000503
720
Remove Trailer Hitch
Remove Trailer Hitch
1.
NOTE:
Support trailer hitch while removing.
ZX25213-UN: Trailer Hitch
LEGEND:
A - Lock Nut (2 used)
B - Washer (4 used)
C - Nut (4 used)
D - Lock Nut (4 used)
E - Cap Screw (4 used)
F - Hitch
G - Cap Screw
H - Washer
I - Socket
J - Cap Screw
K - Washer
L - Bracket
M - Hitch
N - Strap
O - Lock Nut
721
Remove Trailer Hitch
P - Cap Screw
Q - Stop
R - Screw (2 used)
S - U-Bolt
Remove lock nut (A) and strap (N).
2. Remove nut (C), washer (B) and screw (R).
3. Install in reverse order.
Go to Section_60:Group_15
OUO6089,000004B-19-20010626
722
Remove Trailer Hitch
Remove Trailer Hitch
1.
NOTE:
Support trailer hitch while removing.
ZX25213-UN: Trailer Hitch
LEGEND:
A - Lock Nut (2 used)
B - Washer (4 used)
C - Nut (4 used)
D - Lock Nut (4 used)
E - Cap Screw (4 used)
F - Hitch
G - Cap Screw
H - Washer
I - Socket
J - Cap Screw
K - Washer
L - Bracket
M - Hitch
N - Strap
O - Lock Nut
723
Remove Trailer Hitch
P - Cap Screw
Q - Stop
R - Screw (2 used)
S - U-Bolt
Remove lock nut (A) and strap (N).
2. Remove nut (C), washer (B) and screw (R).
3. Install in reverse order.
Go to Section_60:Group_15
OUO6089,000004B-19-20010626
724
Table of Contents
Section 70: Hydraulic System Repair
Group 05: Hydraulic Reservoir
Service Equipment and Tools
Specifications
Remove and Install Reservoir
Flush the Hydraulic System
Flush the Reel/Belt Pickup Drive System
Start-Up Procedure After Hydrostatic System Repair
Group 10: Hydraulic Pumps
Essential and Recommended Special Tools
Service Equipment and Tools
Specifications
Remove Main Hydraulic Pump
Mark Hydraulic Pump
Disassemble Hydraulic Pump
Replace Seal
Install Gasket and Support
Triple Hydraulic Pump
Assemble Hydraulic Pump
Install Main Hydraulic Pump
Reel/Belt Pickup Pump
Remove Chaff Spreader Pump
Chaff Spreader Pump
Disassemble Chaff Spreader Pump
Assemble Chaff Spreader Pump
Install Chaff Spreader Pump
Group 15: Hydraulic Valves
Essential and Recommended Special Tools
Specifications
Remove and Install Hydraulic Valve Block
Remove and Install Header Height/Ground Pressure Control Valve
Remove and Install Shut-Off Valve
725
Table of Contents
Relief Valve Block (Solenoid Valve)
Reel Raise/Lower Valve
Electro-Hydraulic Feeder House Reverser Valve - General Information
Disassemble Electro-Hydraulic Feeder House Reverser Valve
Threshing Cylinder Speed Valve Module
Auger Swing Valve Module
HillMaster II Solenoid Valve Block
Reel Fore/Aft Valve Module
HeaderTrak Tilt System Valve Module
Replace Pilot Solenoid Valve Assemblies
Replace Pilot Sleeve O-Rings
Remove Reel/Belt Speed Flow Control Valve
Repair Reel/Belt Speed Flow Control Valve
Install Reel/Belt Speed Flow Control Valve
Reel Reversing Control Valve
Remove and Install Reel Reversing Control Valve
Feeder House Multi-Coupler Check Valves - General View
Disassemble, Inspect and Assemble Feeder House Multi-Coupler
Group 20: Hydraulic Cylinders
Specifications
Remove and Install Header Lift Cylinder
Disassemble and Assemble Header Lift Cylinder
Remove and Install Unloading Auger Swing Cylinder
Adjust Unloading Auger Swing Cylinder
Remove and Install Unloading Auger Drive Cylinder
Adjust Unloading Auger Drive Cylinder
Group 21: HillMaster II Hydraulic Cylinders
Special Tool (Dealer-Fabricated)
Other Material
Specifications
General Information
Components of HillMaster II Cylinder
Check Valve Components
726
Table of Contents
Components of Compensating Valve
Compensating Valve Installed in Piston
Attachment of HillMaster II Cylinders
Group 25: Motors
Remove and Install Chaff Spreader Motor
Group 30: Accumulators
Service Equipment and Tools
Accumulator (General Information)
Check Header Float System Accumulator
Accumulator Charge Pressure
727
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Portable Filter Caddy .......JT05746
Used to flush hydraulic/hydrostatic systems.
RW25352-UN: Caddy
Go to Section_70:Group_05
ZX09263,000273C-19-20080201
728
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Portable Filter Caddy .......JT05746
Used to flush hydraulic/hydrostatic systems.
RW25352-UN: Caddy
Go to Section_70:Group_05
ZX09263,000273C-19-20080201
729
Specifications
Specifications
Item
Measurement
Specification
Hydraulic Oil Reservoir
Capacity
34 L
(36 qt)
Hydraulic Oil Reservoir
Weight (Approx.) 18 kg
(40 lb)
Hydraulic Reservoir Pressure Test Pressure
35 kPa
(0.34 bar)
(5 psi)
Go to Section_70:Group_05
OUO6037,000148F-19-20010821
730
Remove and Install Reservoir
Remove and Install Reservoir
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
1. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2. Loosen reservoir cap.
3.
ZX25198-UN: Cap
LEGEND:
A - Drain cap
Remove drain cap (A) to drain hydraulic oil. Dispose of the oil properly.
731
Remove and Install Reservoir
Item
Measurement Specification
Hydraulic Oil Reservoir Capacity
34 L
(36 qt)
4. Install and tighten drain cap (A).
5.
LEGEND:
A - Hydraulic Oil Reservoir
B - Reservoir Cap
C - Cap Screw (4 used)
D - Oil Temperature Sensor
E - Oil Line to Hydraulic Filter
F - Oil Line to Main Hydraulic Pump
G - Oil Line from Main Hydraulic Pump
H - Oil Line (Rear Wheel Drive Solenoid Valve Return)
I - Oil Line to Oil Cooler
J - Filter Screen
Remove parts (B) to (J). Plug lines and hoses.
732
Remove and Install Reservoir
6. Remove hydraulic reservoir (A).
Item
Measurement
Specification
Hydraulic Oil Reservoir Weight (Approx.) 18 kg
(40 lb)
7.
NOTE:
Leaks may be caused by cracks in sight glass. If cracked, replace sight glass with
respective field installation kit. Install sight glass field installation kit in reservoir using
thread sealer to avoid leaks.
Plug reservoir ports and pressure test at specified pressure while submerged in water. Repair leaks by
soldering.
Item
Measurement Specification
Hydraulic Reservoir Pressure Test Pressure
35 kPa
(0.34 bar)
(5 psi)
8. Install oil reservoir.
9. Install parts (B) to (J).
10. Refill reservoir with clean hydraulic oil. See Fuel, Lubricants, Coolant and Capacities in Section 10).
Item
Measurement Specification
Hydraulic Oil Reservoir Capacity
34 L
(36 qt)
Go to Section_70:Group_05
OUO6037,0001421-19-20010622
733
Flush the Hydraulic System
Flush the Hydraulic System
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
IMPORTANT:
It is recommended to flush the system as soon as possible after a failure has occurred so debris will not be
carried through the system.
NOTE:
The information below concentrates on those areas where there is continuous oil flow.
NOTE:
Information on flushing cam lobe motor can be found in Section 50, Groups 25 and 30.
1. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine and close accumulator shut-off valve.
2. Remove the pilot solenoid valve. The valve cannot be flushed. Disassemble and clean the valve.
3. Remove the main hydraulic pump.
4. Connect a hose from the outlet port of the JT05746 portable filter caddy to the inlet port on the main
hydraulic pump by using the hoses supplied with the filter caddy and the proper hose fittings. Connect
another hose from the hydraulic pump outlet to a drum of flushing oil.
5. Activate the transfer unit and slowly rotate the hydraulic pump shaft, by hand, while flushing.
734
Flush the Hydraulic System
6. Flush all hoses and lines thoroughly. Flush out quick couplers at the feeder house.
Go to Section_70:Group_05
OUO6435,00018A5-19-20020820
735
Flush the Reel/Belt Pickup Drive System
Flush the Reel/Belt Pickup Drive System
IMPORTANT:
It is recommended to flush the system as soon as possible after a failure has occurred so debris will not be
carried through the system.
NOTE:
The information below concentrates on those areas where there is continuous oil flow.
NOTE:
Information on flushing cam lobe motor can be found in Section 50, Groups 25 and 30.
1. Remove the control valve. The control valve cannot be flushed. Disassemble and clean the valve.
2. Remove the reel/belt pickup pump.
3. Using the hoses supplied with the JT05746 Filter Caddy, and the proper hose fittings, connect a hose
from the outlet port of the Filter Caddy to the inlet port of the pump. Connect another hose from the
pump outlet to a drum of flushing oil.
4. Activate the filter caddy and slowly rotate the pump shaft, by hand, while flushing.
5. Remove the motor on the header. The motor cannot be flushed. Disassemble and clean the motor.
6. Flush all hoses and lines on the combine and header thoroughly. Flush out quick couplers at the feeder
house.
Go to Section_70:Group_05
OUO6037,000146C-19-20010806
736
Start-Up Procedure After Hydrostatic System Repair
Start-Up Procedure After Hydrostatic System Repair
1. Fill system with John Deere HY-GARD transmission and hydraulic oil and leave cap off reservoir.
2. Disconnect the two multi-pin connectors to injection pump from the engine control unit.
3. Crank engine, with starting motor, several times for 15 seconds at one-minute intervals. This starts oil
flowing into the hydrostatic pump.
4. Reconnect multi-pin connectors to injection pump.
CAUTION:
Keep all bystanders away from machine while performing start-up procedure.
Hazard of personal injury or death! Machine may move unexpectedly.
5. Place transmission in neutral and engage park brake.
6. Start engine and run at slow idle speed for 5 minutes to bleed air from system.
7. Move multi-function lever slightly forward out of neutral. After 30 seconds, return multi-function lever to
neutral position.
8. Move multi-function lever slightly into reverse travel position. After 30 seconds, return to neutral.
9. Repeat steps 7 and 8 until maximum forward and reverse travel is reached.
10. Release park brake.
11. Increase engine speed to full throttle.
12. Shift transmission to second gear and run machine in forward and reverse several times to check the
drive system.
13. Check for system leaks, fill reservoir with oil and install cap.
Go to Section_70:Group_05
AG,OUO6435,154-19-20000627
737
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Snap Ring
Pliers.......JDG114 [
RECOMMENDED TOOL ]
Used to remove internal snap
rings.
Go to Section_70:Group_10
ZX09263,000273D-19-20080201
738
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Snap Ring
Pliers.......JDG114 [
RECOMMENDED TOOL ]
Used to remove internal snap
rings.
Go to Section_70:Group_10
ZX09263,000273D-19-20080201
739
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Vacuum Pump Kit.......D15032NU
To pull vacuum on the reservoir when
removing and installing system
components.
Go to Section_70:Group_10
ZX09263,000273E-19-20080201
740
Specifications
Specifications
Item
Measurement
Specification
Hydraulic Oil Reservoir
Approximate Capacity 34 L
(36 qt)
Main Hydraulic Pump Front-to-Rear Section Cap Screws Torque
35 Nm
(25 lb-ft)
Main Hydraulic Pump Mounting Cap Screws
Torque
75 Nm
(55 lb-ft)
Reel/Belt Pickup Pump Bearing Cavity
Approximate Capacity 133 ml
(4-1/2 oz.)
Drive Pump Nut
Torque
38 Nm
(28 lb-ft)
Reel/Belt Pickup Pump Cap Screws
Torque
75 Nm
(55 lb-ft)
Reel/Belt Pickup and Chaff Spreader Pump Cap Screws Torque
35 Nm
(25 lb-ft)
Chaff Spreader Pump Adapter Flange Nut
38 Nm
(28 lb-ft)
Torque
Go to Section_70:Group_10
OUO6037,000146D-19-20010806
741
Remove Main Hydraulic Pump
Remove Main Hydraulic Pump
CAUTION:
X9811-UN: High Pressure
Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Use a piece of cardboard to search for leaks.
Protect hands and body from high pressure fluids.
If injured by escaping fluid, see a doctor immediately. Any fluid injected into the skin must
be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
1. Fully lower header and reel to ground and continue depressing switch for 5 to 10 seconds to relieve
hydraulic system pressure. Shut off engine.
2. Connect D15032NU Vacuum Pump to reservoir. This will allow removing the pump without draining the
reservoir. If vacuum pump is not available, drain reservoir. Approximate capacity is 34 L (36 qt.).
3.
H65985-UN: Triple Pump
LEGEND:
A - Oil Line (5 used)
B - Pump
742
Remove Main Hydraulic Pump
C - Cap Screw (2 used)
Disconnect five oil lines (A) from triple pump (B).
4. Remove two cap screws (C) to remove pump.
Go to Section_70:Group_10
OUO6046,0001391-19-20010219
743
Mark Hydraulic Pump
Mark Hydraulic Pump
H50898-UN: Triple Pump Marked
IMPORTANT:
Mark all pump parts prior to removal to ensure correct reinstallation.
Go to Section_70:Group_10
AG,OUOE014,114-19-19980930
744
Disassemble Hydraulic Pump
Disassemble Hydraulic Pump
NOTE:
Eight cap screws hold together the hydraulic pump which consists of three pump units.
1.
H50900-UN: Separated Pump Units
H50901-UN: Triple Pump Components
LEGEND:
A - Steering Pump
B - Main Hydraulic Pump
C - AHC-Pump
D - Mounting Flange
To disassemble, remove eight long cap screws.
2.
H50899-UN: Shaft Keys
745
Disassemble Hydraulic Pump
LEGEND:
A - Triple Pump
B - Shaft Key (Long)
C - Shaft Key (Short)
Disassemble parts of pump which have to be repaired.
3.
NOTE:
Mark all parts prior to removal to ensure correct reinstallation.
H50902-UN: Disassemble Pump
LEGEND:
A - Diaphragm
B - Gear
C - Drive Gear
D - Plate
E - Housing
Remove housing (E).
4. Remove diaphragm (A), gear (B) and drive gear (C).
5. Remove plate (D).
Go to Section_70:Group_10
OUO6046,0001392-19-20100202
746
Replace Seal
Replace Seal
1.
H50904-UN: Shaft Seal
LEGEND:
A - O-Ring
B - Gasket
C - Gasket
D - Gasket
E - Seal and Washer
F - Mounting Flange
Press out seal and washer (E), taking care not to damage seal seat surface.
2. When installing seal, make sure sealing lip faces toward the inside.
Go to Section_70:Group_10
AG,OUOE014,116-19-19980930
747
Install Gasket and Support
Install Gasket and Support
1.
H50903-UN: Gaskets and Seal Rings
LEGEND:
A - Gasket
B - Gasket
C - Gasket
D - O-Ring
E - O-Ring
F - Seal and Washer
Install gaskets (A), (B) and (C) in housing.
2. Install O-rings (D and E).
Go to Section_70:Group_10
AG,OUOE014,117-19-19980930
748
Triple Hydraulic Pump
Triple Hydraulic Pump
H73727-UN: Triple Hydraulic Pump
LEGEND:
1 - O-Ring
2 - Cap Screw (2 used)
3 - Screw (8 used)
4 - Seal
5 - Washer (3 used)
6 - Plate
7 - Gasket (3 used)
8 - Gasket (3 used)
749
Triple Hydraulic Pump
9 - Gasket (3 used)
10 - Diaphragm (3 used)
11 - Dowel Pin (12 used)
12 - O-Ring (6 used)
13 - Housing (2 used)
14 - Drive Gear (2 used)
15 - Gear (2 used)
16 - Seal (2 used)
17 - Plate (2 used)
18 - Plate (2 used)
19 - Shaft Key
20 - Gear
21 - Gear
22 - Link Body
23 - Plate
24 - O-Ring
25 - Diagnostic Receptacle
26 - Dust Cover
Go to Section_70:Group_10
OUO6435,0001954-19-20100202
750
Assemble Hydraulic Pump
Assemble Hydraulic Pump
1. Use new gaskets.
2. Coat all moving parts with clean hydraulic oil before assembling.
3. Assemble hydraulic pump, noting marks made before disassembly.
4. Install and tighten eight cap screws to 33 - 37 Nm (25 - 28 lb-ft).
Item
Measurement Specification
Triple Pump Assembly Cap Screws Torque
33 - 37 N˙m (25 - 28 lb-ft)
Go to Section_70:Group_10
AG,OUOE014,119-19-19980930
751
Install Main Hydraulic Pump
Install Main Hydraulic Pump
ZX1040687-UN: Triple Pump
LEGEND:
A - Oil Line (5 used)
B - Pump
C - Cap Screw (2 used)
1. Install pump (B) and tighten cap screws (C) to 75 N˙m (55 lb-ft).
Item
Measurement Specification
Cap Screws Torque
75 N˙m (55 lb-ft)
2. Connect oil lines (A).
3. Perform start-up procedure. (See Start-up Procedure after Hydrostatic System Repair in this Section.)
Go to Section_70:Group_10
OUO6046,0001393-19-20070514
752
Reel/Belt Pickup Pump
Reel/Belt Pickup Pump
H63426-UN: Reel/Belt Pickup Pump
LEGEND:
A - Cap Screw (8 used)
B - Snap Ring
C - Seal
D - Washer
E - Front Plate
F - Seal
G - Seal
H - Gasket
I - Diaphragm
J - Dowel Pin (4 used)
K - O-Ring (2 used)
L - Key
M - Drive Gear
N - Idler Gear
753
Reel/Belt Pickup Pump
O - Pump Body
P - Back Plate
Q - Pump, Complete
Go to Section_70:Group_10
OUO6046,00013A2-19-20010219
754
Remove Chaff Spreader Pump
Remove Chaff Spreader Pump
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
1. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2. Install D15032NU Vacuum Pump on reservoir. This will allow removing the pump without draining
reservoir. If vacuum pump is not available, drain reservoir.
Item
Measurement
Specification
Hydraulic Oil Reservoir Approximate Capacity 34 L (36 qt)
3.
H51890-UN: Chaff Spreader Pump
LEGEND:
755
Remove Chaff Spreader Pump
A - Line (2 used)
B - Cap Screw (5 used)
C - Cover
Remove lines (A) from pump. Cap all lines and fittings.
4. Remove cap screws and nuts (B) to remove cover (C).
5.
H68170-UN: Chaff Spreader Pump
LEGEND:
A - Cap Screws
B - Hub
C - Pump
Remove cap screws (A), hub (B) and pump (C).
6.
H54363-UN: Chaff Spreader Pump
LEGEND:
A - Nut
B - Hub
C - Bracket
D - Pump
E - Cap Screw and Nut (2 used)
Remove nut (A) to remove hub (B).
7. Remove cap screws and nuts (E) to remove bracket (C) from pump (D).
756
Remove Chaff Spreader Pump
Go to Section_70:Group_10
ZX09263,00027B6-19-20080303
757
Chaff Spreader Pump
Chaff Spreader Pump
H63426-UN: Chaff Spreader Pump
LEGEND:
A - Cap Screw (8 used)
B - Snap Ring
C - Seal
D - Washer
E - Front Plate
F - Seal
G - Seal
H - Gasket
I - Diaphragm
J - Dowel Pin (4 used)
K - O-Ring (2 used)
L - Key
M - Drive Gear
N - Idler Gear
758
Chaff Spreader Pump
O - Pump Body
P - Back Plate
Q - Pump, Complete
Go to Section_70:Group_10
OUO6037,000144A-19-20010718
759
Disassemble Chaff Spreader Pump
Disassemble Chaff Spreader Pump
1.
H40172-UN: Chaff Spreader Pump
Scribe a line across front plate, body and back plate for proper reassembly of pump.
2.
H40156-UN: Reel/Belt Pickup and Chaff Spreader Pump
LEGEND:
A - Snap Ring
Remove snap ring (A).
3.
H40157-UN: Reel/Belt Pickup and Chaff Spreader Pump
LEGEND:
A - Cap Screw (8 used)
Remove eight cap screws (A).
760
Disassemble Chaff Spreader Pump
4.
H40159-UN: Reel/Belt Pickup and Chaff Spreader Pump
LEGEND:
A - Back Plate
B - O-Ring (2 used)
C - Pump Body
D - Dowel Pin (4 used)
E - Idler Gear
F - Key
G - Diaphragm
H - Front Plate
I - Cap Screw (8 used)
J - Snap Ring
K - Gasket
L - Seal
M - Seal
N - Drive Gear
O - Bushing (2 used)
Remove parts (A) to (N).
5. Inspect parts for wear or damage. Replace parts as necessary.
6. IMPORTANT:
Inspect seal ring. Do not remove seal ring unless replacement is necessary as seal ring will be damaged
when removing. Use care to prevent damage to front plate when removing seal ring.
H40343-UN: Reel/Belt Pickup and Chaff Spreader Pump
LEGEND:
A - Plate
B - Washer
C - Seal
Remove washer (B) and seal (C) from front plate (A).
761
Disassemble Chaff Spreader Pump
Go to Section_70:Group_10
ZX09263,00027B7-19-20080303
762
Assemble Chaff Spreader Pump
Assemble Chaff Spreader Pump
1.
H40345-UN: Reel/Belt Pickup and Chaff Spreader Pump
LEGEND:
A - Front Plate
B - 27505 Seal Driver
C - Washer
D - Seal
Install washer (C) and seal ring (D) into front plate (A) using 27505 Driver (B).
2. IMPORTANT:
Diaphragm (G) must be placed with bronze face toward idler gear (E) and drive gear (N).
H40159-UN: Reel/Belt Pickup and Chaff Spreader Pump
LEGEND:
A - Back Plate
B - O-Ring (2 used)
C - Pump Body
D - Dowel Pin (4 used)
E - Idler Gear
F - Key
G - Diaphragm
H - Front Plate
I - Cap Screw (8 used)
J - Snap Ring
K - Gasket
L - Seal
M - Seal
N - Drive Gear
O - Bushing (2 used)
Install parts (A) to (N). Lubricate parts with a thin film of clean hydraulic oil.
763
Assemble Chaff Spreader Pump
NOTE:
Install gasket (K) with recess towards body (C).
3.
H40158-UN: Reel/Belt Pickup and Chaff Spreader Pump
LEGEND:
A - Cap Screw (8 used)
Align scribe marks, install and tighten eight cap screws (A) to specification.
Item
Measurement Specification
Reel/Belt Pickup and Chaff Spreader Pump Cap Screws Torque
35 Nm
(25 lb-ft)
4.
H40156-UN: Reel/Belt Pickup and Chaff Spreader Pump
LEGEND:
A - Snap Ring
Install snap ring (A).
Go to Section_70:Group_10
ZX09263,00027B8-19-20080303
764
Install Chaff Spreader Pump
Install Chaff Spreader Pump
1.
H54363-UN: Chaff Spreader Pump
LEGEND:
A - Nut
B - Hub
C - Plate
D - Pump
E - Cap Screw and Nut (2 used)
Install plate (C) on pump (D) using cap screws and nuts (E).
2. Install hub (B) on pump (D) using nut (A). Tighten nut to specification.
Item
Measurement Specification
Chaff Spreader Pump Adapter Flange Nut Torque
3.
H68170-UN: Chaff Spreader Pump
LEGEND:
A - Cap Screws
B - Hub
C - Pump
Install pump (B) using cap screws (A).
765
38 Nm
(28 lb-ft)
Install Chaff Spreader Pump
4.
H51890-UN: Chaff Spreader Pump
LEGEND:
A - Lines (2 used)
B - Cap Screw (5 used)
C - Cover
Install cover (C) using cap screws (B).
5. Connect lines (A).
6. Start engine and operate at slow idle for 3 minutes.
7. Increase engine speed to fast idle and operate function for 3 minutes.
8. Check pump for leaks. Check oil level in reservoir.
Go to Section_70:Group_10
ZX09263,00027B9-19-20080303
766
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Spanner
Wrench.......AH201808
Used to remove and install
multi-coupler check valves.
Vacuum Pump Kit.......D15032NU
To pull vacuum on the reservoir when
removing and installing system
components.
Go to Section_70:Group_15
ZX09263,000273F-19-20080201
767
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Spanner
Wrench.......AH201808
Used to remove and install
multi-coupler check valves.
Vacuum Pump Kit.......D15032NU
To pull vacuum on the reservoir when
removing and installing system
components.
Go to Section_70:Group_15
ZX09263,000273F-19-20080201
768
Specifications
Specifications
Item
Measurement
Specification
Hydraulic Oil Reservoir
Approximate Capacity 34 L
(36 qt)
Solenoid to Valve (Except No. 4, 5 and 6) Torque
14 Nm
(125 lb-in.)
Solenoid No. 4, 5 and 6
Torque
11 Nm
(97 lb-in.)
Multi-Coupler Check Valve
Torque
92 Nm
(68 lb-ft)
Go to Section_70:Group_15
OUO6435,0001911-19-20020917
769
Remove and Install Hydraulic Valve Block
Remove and Install Hydraulic Valve Block
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
CAUTION:
Cracking hydraulic line fitting to lower header will result in an instantaneous dropping of
the header and expulsion of the seal ring in the fitting.
1. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2.
ZX1040679-UN: Valve Block
LEGEND:
770
Remove and Install Hydraulic Valve Block
A - Hydraulic Line
ZX1040680-UN: Connector
LEGEND:
B - Connector
C - Cap Screws (2 used)
Install D15032NU vacuum pump on reservoir. This will allow removing the valve without draining
reservoir. If vacuum pump is not available, drain reservoir.
NOTE:
DO NOT leave vacuum pump running for extended period of time. Remove component
and plug the lines. Extended use may cause the vacuum pump to overheat.
3. Disconnect hydraulic lines (A).
4. Disconnect wiring harness connectors (B).
5. Any work to the valve should be done in a clean area away from dust and dirt. Repair as necessary.
6. Install valve and tighten four cap screws (C).
7. Connect wiring harness connectors (B).
8. Fill reservoir.
Item
Measurement
Specification
Hydraulic Oil Reservoir Approximate Capacity 34 L
(36 qt)
Go to Section_70:Group_15
ZX09263,00027BA-19-20080303
771
Remove and Install Header Height/Ground Pressure Control Valve
Remove and Install Header Height/Ground Pressure Control Valve
CAUTION:
X9811-UN: Escaping Fluid
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
1.
ZX1040681-UN: Header Height Control
LEGEND:
A - Connector (2 used)
B - Hydraulic Hoses (2 used)
C - Cap Screw (2 used)
Start engine and lower header or feeder house to the ground. Hold switch for 5 to 10 seconds to relieve
hydraulic system pressure. Shut off engine.
2.
NOTE:
Cap or plug all openings to avoid hydraulic system contamination.
772
Remove and Install Header Height/Ground Pressure Control Valve
Disconnect connectors (A).
3. Remove hydraulic hoses (B).
4. Remove cap screws (C) and remove valve.
5. Install valve using new O-rings.
Go to Section_70:Group_15
ZX09263,00027BB-19-20080303
773
Remove and Install Shut-Off Valve
Remove and Install Shut-Off Valve
ZX25204-UN: Shut-Off Valve
LEGEND:
A - Connector
B - Cap Screws (2 used)
C - Header Height/Ground Pressure Control Valve
D - Hydraulic Hose
1. Fully lower header and reel to ground and continue to depress switch for 5 to 10 seconds to relieve
hydraulic system pressure. Shut off engine.
2. Disconnect power supply and pressure sensor connectors (A).
3. Disconnect header height/ground pressure control valve (C) and hydraulic line (D) from shut-off valve.
4. Disconnect accumulator from shut-off valve.
5. Remove cap screws (B) and remove shut-off valve.
6. Install a new valve with new O-rings.
7. Start engine and operate header lift system. Lower header to the ground and shut off engine. Visually
check for leaks.
Go to Section_70:Group_15
OUO6037,0001424-19-20100202
774
Relief Valve Block (Solenoid Valve)
Relief Valve Block (Solenoid Valve)
ZX1040682-UN: Relief Valve Module
LEGEND:
1 - Adapter
2 - Washer
3 - Plug
4 - Screw
5 - Spring
6 - Solenoid Valve
7 - Solenoid Valve
8 - Nut
9 - Cover
775
Relief Valve Block (Solenoid Valve)
10 - Valve Cover
11 - Valve
12 - Plug
13 - Solenoid Coil
14 - Valve
15 - Valve Block
16 - Pressure Relief Valve
17 - Ring
18 - Pressure Relief Valve
19 - Solenoid Valve
20 - Plug
Go to Section_70:Group_15
ZX09263,00027BC-19-20080303
776
Reel Raise/Lower Valve
Reel Raise/Lower Valve
H64284-UN: Reel Raise/Lower Valve
LEGEND:
1 - Sheet Metal Nut
2 - Cover
3 - Coil
4 - Sleeve
5 - Washer
6 - Spring
7 - Poppet
8 - Armature
9 - Solenoid
10 - Orifice
11 - O-Ring
12 - O-Ring
13 - Housing
14 - O-Ring
15 - Fitting
16 - Seal
17 - Valve
18 - Seal Kit
777
Reel Raise/Lower Valve
Go to Section_70:Group_15
OUO6435,00015F1-19-20020130
778
Electro-Hydraulic Feeder House Reverser Valve - General Information
Electro-Hydraulic Feeder House Reverser Valve - General Information
The feeder house reverser is electronically actuated by pulling the header engagement switch rearward.
Switching direction of the gear case can only be done after the drum comes to a complete stop. The valve,
located on the left side beneath the main hydraulic pump, receives pressurized hydraulic oil from the charge
pump. When the valve coil is energized, hydraulic pressure moves a piston in the reverser gear case to reverse
direction of the feeder house. Excess oil is returned to the main hydraulic reservoir.
Go to Section_70:Group_15
OUO6037,000149F-19-20010823
779
Disassemble Electro-Hydraulic Feeder House Reverser Valve
Disassemble Electro-Hydraulic Feeder House Reverser Valve
H73074-UN: Reverser Valve
LEGEND:
A - Lock Nut
B - Coil
C - Guide
D - O-Ring
E - Spring
F - Plunger
G - O-Ring
H - Valve Spool
I - Snap Ring
J - Back-Up Ring (2 used)
K - O-Ring (2 used)
L - Valve Block
M - O-Ring (8 used)
N - Fitting (4 used)
780
Disassemble Electro-Hydraulic Feeder House Reverser Valve
O - Spring Pin
Go to Section_70:Group_15
OUO6435,000192A-19-20021004
781
Threshing Cylinder Speed Valve Module
Threshing Cylinder Speed Valve Module
H64291-UN: Cylinder Speed
LEGEND:
1 - Sheet Metal Nut
2 - Cover
3 - Coil
4 - Sleeve
5 - Washer
6 - Spring
7 - Poppet
8 - Armature
9 - Solenoid
10 - Orifice
11 - O-Ring
12 - O-Ring
13 - Housing
14 - O-Ring
15 - Fitting
16 - Poppet
17 - Spring
18 - Shim
19 - O-Ring
782
Threshing Cylinder Speed Valve Module
20 - Plug
21 - Seal
22 - Valve
23 - Orifice
24 - Seal Kit
Go to Section_70:Group_15
AG,OUO6435,150-19-20010112
783
Auger Swing Valve Module
Auger Swing Valve Module
H63139-UN: Auger Swing Valve
LEGEND:
1 - Sheet Metal Nut
2 - Cover
3 - Coil
4 - Sleeve
5 - Washer
6 - Spring
7 - Poppet
8 - Armature
9 - Solenoid
10 - Orifice
11 - O-Ring
12 - O-Ring
13 - Housing
14 - Washer (2 used)
15 - Spring (2 used)
16 - O-Ring (2 used)
17 - Plug (2 used)
18 - Check Valve (2 used)
19 - Spring (2 used)
20 - O-Ring (2 used)
21 - Cap (2 used)
784
Auger Swing Valve Module
22 - Valve, Complete
23 - Tube
Go to Section_70:Group_15
AG,OUO6435,775-19-20000503
785
HillMaster II Solenoid Valve Block
HillMaster II Solenoid Valve Block
ZX25282-UN: HillMaster II Solenoid Valve Block
LEGEND:
1 - Support
2 - Lock Washer (6 used)
3 - Nut (6 used)
4 - End Plate (2 used)
5 - Seal (2 used)
6 - Adapter
7 - Valve
8 - Coil (4 used)
9 - Cover (4 used)
10 - Nut (4 used)
11 - Cover
12 - Screws (4 used)
786
HillMaster II Solenoid Valve Block
13 - O-Ring (6 used)
14 - Adapter
15 - O-Ring (2 used)
16 - Valve
17 - Elbow Fitting
18 - Valve
19 - O-Ring (5 used)
20 - Seal
21 - Adapter (3 used)
22 - Stud (3 used)
23 - Fitting
24 - Valve
Go to Section_70:Group_15
OUO6037,0001466-19-20010802
787
Reel Fore/Aft Valve Module
Reel Fore/Aft Valve Module
H63137-UN: Reel Fore/Aft
LEGEND:
1 - Sheet Metal Nut
2 - Cover
3 - Coil
4 - Sleeve
5 - Washer
6 - Spring
7 - Poppet
8 - Armature
9 - Solenoid
10 - Orifice
11 - O-Ring
12 - O-Ring
13 - Housing
14 - Washer (2 used)
15 - Spring (2 used)
16 - O-Ring (2 used)
17 - Pipe Plug (2 used)
18 - Check Valve (2 used)
19 - Spring (2 used)
20 - O-Ring (2 used)
21 - Cap (2 used)
788
Reel Fore/Aft Valve Module
22 - Valve, Complete
23 - Orifice (2 used)
24 - Tube
25 - Plug
Go to Section_70:Group_15
AG,OUO6435,776-19-20000503
789
HeaderTrak Tilt System Valve Module
HeaderTrak Tilt System Valve Module
H63138-UN: HeaderTrak
LEGEND:
1 - Sheet Metal Nut
2 - Cover
3 - Coil
4 - Sleeve
5 - Washer
6 - Spring
7 - Poppet
8 - Armature
9 - Solenoid
10 - Orifice
11 - O-Ring
12 - O-Ring
13 - Housing
14 - Washer (2 used)
15 - Spring (2 used)
16 - O-Ring (2 used)
17 - Pipe Plug (2 used)
18 - Check Valve (2 used)
19 - Spring (2 used)
20 - O-Ring (2 used)
21 - Cap (2 used)
790
HeaderTrak Tilt System Valve Module
22 - Valve, Complete
23 - Orifice (2 used)
24 - Tube
25 - Plug
Go to Section_70:Group_15
OUO6435,00014D1-19-20010925
791
Replace Pilot Solenoid Valve Assemblies
Replace Pilot Solenoid Valve Assemblies
H46547-UN: Pilot Sleeve Assembly
HXC65968-UN: Valve Block
LEGEND:
A - Solenoid Valve
B - Orifice
1. Use a 5/8 in. open end wrench to remove solenoid valve (A) including all internal parts and put aside.
792
Replace Pilot Solenoid Valve Assemblies
NOTE:
Leave the orifice (B) (pressed in the cast iron valve body) in place.
2. Remove solenoid valve assembly CAREFULLY from repair kit. Loosely hold finger over bottom of
solenoid valve assembly to make sure that parts remain in place.
3. IMPORTANT:
Replace the correct coil on the solenoid valve.
Replace valves by aligning NEW solenoid valve over the orifice and threading in place. Tighten solenoid
valves (except solenoids 4, 5 and 6) to specification. These functions have a plastic seat and are
torqued to a lower specification.
Item
Measurement Specification Item
Solenoid to Valve (Except
No. 4, 5 and 6)
Torque
14 Nm
(125 lb-in.)
Measurement Specification
Solenoid No. Torque
4, 5 and 6
11 Nm
(97 lb-in.)
NOTE:
Repeat this procedure if changing more than one solenoid.
4. Install coil cover and bracket.
5. Install nuts.
NOTE:
Install coils slightly angled to allow connector to nest between coils. After coils are installed on the
valve, make a functional check of all hydraulic functions to make sure that no pins have been
dislodged from the connections and that all coils are positioned correctly.
Go to Section_70:Group_15
OUO6046,0001398-19-20010219
793
Replace Pilot Sleeve O-Rings
Replace Pilot Sleeve O-Rings
794
Replace Pilot Sleeve O-Rings
HXC65968-UN: Valve Block
LEGEND:
A - Solenoid Valve
B - Orifice
C - O-Ring
1.
NOTE:
Leave the orifice (B) (pressed in the cast iron valve body) in place. A black O-ring (C) is
installed on the inside of the cavity. Remove the O-ring. A thin sharp tool works well as a
pick when removing O-ring.
Install NEW O-ring into the cavity.
NOTE:
Work the O-ring below the thread with your finger; then use a thin, blunt instrument to
guide the O-ring into the groove. Make sure that the NEW O-ring is not damaged during
the installation. Make sure that the O-ring is completely seated (all the way around). Be
careful not to scratch orifice (B).
2. IMPORTANT:
Replace the correct coil on the solenoid valve.
Replace valves by aligning solenoid valve over the orifice and threading in place. Tighten solenoid
valves (except solenoids 4, 5 and 6) to specification. These functions have a plastic seat and are
795
Replace Pilot Sleeve O-Rings
torqued to a lower specification.
Item
Measurement Specification Item
Solenoid to Valve (Except
No. 4, 5 and 6)
Torque
14 Nm
(125 lb-in.)
Measurement Specification
Solenoid No. Torque
4, 5 and 6
11 Nm
(97 lb-in.)
NOTE:
Repeat this procedure if changing more than one O-ring.
3. Install coil cover and bracket.
4. Install nuts.
NOTE:
Install coils slightly angled to allow connector to nest between coils. After coils are installed on the
valve, make a functional check of all hydraulic functions to make sure that no pins have been
dislodged from the connections and that all coils are positioned correctly.
Go to Section_70:Group_15
OUO6046,0001399-19-20010219
796
Remove Reel/Belt Speed Flow Control Valve
Remove Reel/Belt Speed Flow Control Valve
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
1. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2.
ZX25205-UN: Reel Speed Flow Control Valve
LEGEND:
A - Wiring Harness
B - Coupler
C - Motor
D - Hydraulic Lines
E - Nut (2 used)
797
Remove Reel/Belt Speed Flow Control Valve
Disconnect harness (A) from electric actuator motor.
3. Loosen screw (B) through coupler and remove motor (C).
4. Install D15032NU vacuum pump on reservoir. This will allow removing the valve without draining
reservoir.
5. Disconnect and plug three hydraulic lines (D) from the valve.
6. Remove nuts (E), cap screws and valve from mounting bracket.
Go to Section_70:Group_15
OUO6037,0001425-19-20010625
798
Repair Reel/Belt Speed Flow Control Valve
Repair Reel/Belt Speed Flow Control Valve
H63140-UN: Repair Reel/Belt Speed Flow Control Valve
LEGEND:
1 - Pin
2 - Spool
3 - Back-Up Ring
4 - O-Ring
5 - Metering Plug
6 - Shim(s)
7 - Back-Up Ring
8 - O-Ring
9 - O-Ring
10 - O-Ring (2 used)
11 - Plug
12 - Shim
13 - Spring
14 - Housing
15 - Pressure Relief Valve
16 - Plug
17 - O-Ring
18 - Coupler
19 - Dust Cover
Refer to the exploded view to disassemble valve and install repair kit.
799
Repair Reel/Belt Speed Flow Control Valve
NOTE:
Clean valve with solvent before assembling with repair kit. Clean screened passage in outlet port
with solvent and compressed air (refer to diagram in Reel/Belt Speed System Theory of
Operation in relevant TM). Lubricate all parts with SAE 10W oil during assembly.
Go to Section_70:Group_15
OUO6037,000144C-19-20010719
800
Install Reel/Belt Speed Flow Control Valve
Install Reel/Belt Speed Flow Control Valve
1.
ZX25205-UN: Reel Speed Flow Control Valve
LEGEND:
A - Wiring harness
B - Coupler
C - Motor
D - Hydraulic Lines
E - Nut (2 used)
Install valve on bracket and install cap screws and nuts (E).
2. Connect hydraulic lines (D) to valve.
3. IMPORTANT:
When installing motor be sure to rotate spool all the way closed and run the motor at slowest speed.
Then install the coupler.
Install motor (C) and coupler (B) on valve.
4. Connect harness (A) to motor.
Go to Section_70:Group_15
OUO6037,0001426-19-20010625
801
Reel Reversing Control Valve
Reel Reversing Control Valve
ZX25358-UN: Reel Reversing Valve
LEGEND:
A - Plug
B - O-Ring
C - Hex. Socket Screw (4 used)
D - Valve Solenoid
E - Coil
F - O-Ring
G - Nut
H - Distributor Block
I - O-Ring (4 used)
Go to Section_70:Group_15
ZX09263,00027BD-19-20080303
802
Remove and Install Reel Reversing Control Valve
Remove and Install Reel Reversing Control Valve
1.
H73613-UN: Reel Reversing Control Valve
LEGEND:
A - Harness Connector Screw
B - Hydraulic Hoses
C - Hydraulic Lines
D - Nuts
E - Reel Reversing Control Valve
Loosen screw (A) and disconnect harness connector.
2. Install D15032NU vacuum pump on reservoir. This will allow removing the valve without draining
reservoir.
3. Disconnect and plug hydraulic fittings (B) and (C).
4. Remove nuts (D) and reel reversing control valve (E).
5. Install in reverse order.
Go to Section_70:Group_15
ZX09263,00027BE-19-20080303
803
Feeder House Multi-Coupler Check Valves - General View
Feeder House Multi-Coupler Check Valves - General View
H71037-UN: Multi Coupler
LEGEND:
A - Reel Drive Pressure
B - Reel Drive Return
C - Electrical Connector Cavity
D - Reel Fore/Aft, Retract
E - Reel Fore/Aft, Extend
F - Reel Lift
Go to Section_70:Group_15
OUO6435,00015F6CONV1-19-20020204
804
Disassemble, Inspect and Assemble Feeder House Multi-Coupler
Disassemble, Inspect and Assemble Feeder House Multi-Coupler
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
While valve repair is illustrated as a bench top procedure, valves can be repaired on the machine, provided they
(and surrounding areas) are thoroughly cleaned and all openings are capped or plugged to prevent internal
contamination.
1.
H71050-UN: Multi-Coupler
LEGEND:
A - Inner Groove
B - Center Groove
C - Outer Groove
Clean all dirt and debris from multi-coupler.
2.
CAUTION:
805
Disassemble, Inspect and Assemble Feeder House Multi-Coupler
Wear safety equipment suitable to the job.
Have an assistant start the engine and operate header functions. Wearing appropriate safety equipment,
inspect valves for leakage at (A, B and C).
3. Fully lower header and reel to ground and continue to depress switch for 5 to 10 seconds to relieve
hydraulic system pressure.
4. IMPORTANT:
Be careful not to scratch inner sleeve when depressing center ring. If scratches are found on inner
sleeve, the valve must be replaced completely.
NOTE:
Tool tip: Wrap a piece of black tape around the end of a drift punch to depress center
ring.
H71035-UN: Multi-Coupler Check Valve
LEGEND:
A - Center Ring
If leakage is determined to be coming from the inner or center groove, use a blunt instrument and
depress center ring (A). Clean around inner and outer mating surfaces using TY6350 Multi-Purpose
Spray Lubricant while moving ring in and out several times.
5.
H71036-UN: Multi-Coupler
LEGEND:
806
Disassemble, Inspect and Assemble Feeder House Multi-Coupler
A - Spanner Wrench
If leakage is determined to be coming from the outer ring, remove check valve using AH201808 Spanner
Wrench (A).
6.
H71051-UN: Reel Drive Pressure, Return and Reel Lift
H71034-UN: Reel Fore/Aft, Extend and Retract
LEGEND:
A - O-Ring
B - Back-Up Ring
Inspect O-rings (A) for wear or damage. Replace as necessary.
7.
NOTE:
If wear or damage is evident on back-up ring (B), the check valve must be replaced
completely.
Inspect back-up ring (B) for wear or damage.
807
Disassemble, Inspect and Assemble Feeder House Multi-Coupler
8.
H71038-UN: Reel Drive Pressure, Return and Reel Lift
LEGEND:
A - O-Ring
Inspect O-ring (A) for wear or damage. Replace as necessary.
9.
H71033-UN: Multi-Coupler Block
LEGEND:
A - Valve Inlet
Clean valve inlet (A) of all dirt and oil.
10. Coat valve O-rings and back-up ring slightly with clean oil or grease. Install check valve and tighten to
specification.
Item
Measurement Specification
Multi-Coupler Check Valve Torque
92 Nm
(68 lb-ft)
Go to Section_70:Group_15
OUO6435,0001639CONV1-19-20020225
808
Specifications
Specifications
Item
Measurement Specification
Unloading Auger Swing Cylinder Piston Torque
100—125 Nm
(75—90 lb-ft)
Go to Section_70:Group_20
AG,OUO6022,1670-19-20000725
809
Specifications
Specifications
Item
Measurement Specification
Unloading Auger Swing Cylinder Piston Torque
100—125 Nm
(75—90 lb-ft)
Go to Section_70:Group_20
AG,OUO6022,1670-19-20000725
810
Remove and Install Header Lift Cylinder
Remove and Install Header Lift Cylinder
CAUTION:
To avoid personal injury or damage to the combine, remove header from combine before
removing lift cylinder.
1. Place a suitable stand under front of feeder house.
2. Start engine and lower feeder house onto stand. Engage park brake and shut off engine.
3.
CAUTION:
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other
lines. Tighten all connections before applying pressure. Use a piece of cardboard
to search for leaks. Protect hands and body from high pressure fluids.
If injured by escaping fluid, see a doctor immediately. Any fluid injected into the
skin must be surgically removed within a few hours or gangrene may result.
Doctors unfamiliar with this type of injury should reference a knowledgeable
medical source. Such information is available from Deere & Company Medical
Department in Moline, Illinois, U.S.A.
X9811-UN: High Pressure
811
Remove and Install Header Lift Cylinder
H66016-UN: Lift Cylinder
H66493-UN: Front Pin
LEGEND:
A - Line
B - Pin (2 used)
Disconnect oil line (A).
4. Remove pins (B) to remove cylinder.
NOTE:
Safety stop will come off with left cylinder.
5. Repair as required.
6. Install cylinder with pins (B).
7. Connect oil line (A).
8. Install header.
9. Start engine, raise feeder house and remove stand.
Go to Section_70:Group_20
OUO6435,000139C-19-20010222
812
Disassemble and Assemble Header Lift Cylinder
Disassemble and Assemble Header Lift Cylinder
1.
H63611-UN: Header Lift Cylinder
LEGEND:
A - Port
B - Screwdriver
Remove paint and rust from rod with fine emery cloth. Wash cylinder and dry.
2. Remove fitting from port on lift cylinder. Slide piston until snap ring can be seen through port (A). Use a
screwdriver (B) to slide snap ring into groove, then remove piston.
3.
H63494-UN: Left Lift Cylinder Shown
LEGEND:
A - Rod
B - Snap Ring
C - Seal
813
Disassemble and Assemble Header Lift Cylinder
D - Wear Ring
E - Cup
F - Back-Up Ring
G - Seal
H - Wear Ring
I - Hydraulic Cylinder
J - Cotter Pin
K - Pin
L - Bushing
M - Snap Ring
N - Stop
O - Stop
Remove seal kit (B) to (H).
4. Thoroughly clean and dry all parts.
5. Check hydraulic cylinder rod and barrel for wear and damage. Replace as necessary.
6. Install seal kit (H) to (B).
7. Lubricate barrel prior to reassembling cylinder.
Go to Section_70:Group_20
OUO6037,0001431-19-20010703
814
Remove and Install Unloading Auger Swing Cylinder
Remove and Install Unloading Auger Swing Cylinder
ZX25311-UN: Unloading Auger Swing Cylinder
LEGEND:
A - Hose (2 used)
B - Pin
C - Pin
D - Cylinder
E - Spacer
1. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2.
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other
lines. Tighten all connections before applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin
must be surgically removed within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a knowledgeable medical
source. Such information is available from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Disconnect and plug hoses (A).
815
Remove and Install Unloading Auger Swing Cylinder
3. Remove pin (B).
4. Remove pin (C) and spacer (E).
5. Remove cylinder (D).
6. Inspect parts and repair as necessary.
7. Install cylinder.
8. Connect hoses.
Go to Section_70:Group_20
OUO6037,000146B-19-20010803
816
Adjust Unloading Auger Swing Cylinder
Adjust Unloading Auger Swing Cylinder
H65676-UN: Augers
LEGEND:
A - Plate
B - Stop
C - Stud
D - Hole
NOTE:
Make the following adjustments ONLY when the auger does not completely swing back.
Swing unloading auger all of the way in.
Make sure that unloading auger swings in completely until it comes to a stop.
H57945-UN: Unloading Auger Swing Cylinder
LEGEND:
A - Nut
B - Pin
C - Eyebolt
D - Spacer
With a distance to the stop, loosen nut (A) and remove pin (B). Screw cylinder rod eyebolt (C) in or out to obtain
correct starting position (cylinder rod must be completely retracted). Reinstall pin (B). Tighten nut (A).
Go to Section_70:Group_20
ZX08994,00002B4-19-20041208
817
Remove and Install Unloading Auger Drive Cylinder
Remove and Install Unloading Auger Drive Cylinder
1.
H67965-UN: Unloading Auger Drive Cylinder
LEGEND:
A - Hose
B - Pin
C - Pin
D - Breather
Disconnect and plug hose (A).
2. Remove pins (B) and (C) to remove cylinder.
NOTE:
This cylinder is not repairable. However a little oil "weeping" from breather (D) is normal
and cylinder replacement may not be required.
3. Install cylinder and insert pins (B) and (C).
4. Install hose (A).
Go to Section_70:Group_20
OUO1073,000141A-19-20010518
818
Adjust Unloading Auger Drive Cylinder
Adjust Unloading Auger Drive Cylinder
H68172-UN: Cylinder
LEGEND:
A - Rod
B - Nut
C - Cap Screws
D - Stop
If the unloading auger drive will not shut off (disengage), or if the belts jump off as they stretch from use, the
cylinder rod stop may need adjustment. A belt that has stretched can cause the drive not to shut off. The belt
rotating around the belt trap can fold over and make contact with the upper sheave.
To adjust the stop:
CAUTION:
1.
Shut off engine and remove key.
Mark present stop position on rod with tape (A).
2. Loosen nut (B) to relieve spring tension.
3. Loosen cap screws (C) and slide stop (D) toward cylinder 13 mm (1/2 in.).
4. Tighten cap screws (C).
5. Tighten nut (B) to its original position.
NOTE:
When installing new belts, adjust stop to its original position (stop positioned against barrel of
cylinder with rod fully retracted).
Go to Section_70:Group_20
AG,OUO6435,793-19-20000503
819
Special Tool (Dealer-Fabricated)
Special Tool (Dealer-Fabricated)
ZX009054-UN: Tool for Disassembling Valve Seat and Piston
LEGEND:
A - 200 mm (7.9 in.)
B - 100 mm (4.0 in.)
C - Diameter 4 mm (0.16 in)
D - M4 thread, 10 mm (0.4 in.)
Tool for disassembling and assembling the valve seat and piston in the check valve.
Go to Section_70:Group_21
ZX,TMXZCO006620-19-19960801
820
Special Tool (Dealer-Fabricated)
Special Tool (Dealer-Fabricated)
ZX009054-UN: Tool for Disassembling Valve Seat and Piston
LEGEND:
A - 200 mm (7.9 in.)
B - 100 mm (4.0 in.)
C - Diameter 4 mm (0.16 in)
D - M4 thread, 10 mm (0.4 in.)
Tool for disassembling and assembling the valve seat and piston in the check valve.
Go to Section_70:Group_21
ZX,TMXZCO006620-19-19960801
821
Other Material
Other Material
Number
Name
Use
T43513 (U.S.)
TY9474 (Canadian)
271 LOCTITE ™
(LOCTITE®)
Thread Lock and Sealer (High
Strength)
Prevents loosening of parts due to
vibrations.
Go to Section_70:Group_21
OUO6037,000144F-19-20021120
822
Specifications
Specifications
Item
Measurement Specification
HillMaster II Cylinder Nut Torque
1400 ± 140 Nm
(1033 ± 130 lb-ft)
Go to Section_70:Group_21
OUO6037,0001491-19-20010821
823
General Information
General Information
CAUTION:
Never work on the HillMaster II cylinders unless the combine has already been fully
lowered.
CAUTION:
HillMaster II cylinders weigh approximately 55 kg (121 lb).
Go to Section_70:Group_21
OUO6037,0001430-19-20010703
824
Components of HillMaster II Cylinder
Components of HillMaster II Cylinder
ZX009055-UN: HillMaster II Cylinder Components
LEGEND:
A - Cylinder Barrel
B - Piston
C - Piston Rod
D - Guide
E - Compensating Valve
F - Check Valve
G - Nut
H - Washer
J - O-Ring
K - Guide Ring
L - Glyd Ring
M - Guide Band
N - Spiral Back-up Ring
O - Wiper Ring
P - Grooved Ring
Q - Secure with LOCTITE ®
Disassembly and Changing the Seals
Heat the area of the cylinder around the thread on guide (D) to a temperature of at least 300°C (572°F), break the
thread lock sealant and use assembly pliers to unscrew guide (D).
Pull out piston rod (C) and piston (B).
Remove nut (G), washers (H), piston (B) and guide (D) from the piston rod.
Use a blunt inscribing tool to remove all seals, and replace them with new ones.
IMPORTANT:
Take care not to damage the base of the groove.
Assemble the cylinder in reverse order.
Tighten nut (G) to 1400 ± 140 Nm (1033 ± 130 lb-ft).
825
Components of HillMaster II Cylinder
Item
Measurement Specification
HillMaster II Cylinder Nut Torque
1400 ± 140 Nm
(1033 ± 130 lb-ft)
Apply T43513 Thread Lock and Sealer (High Strength) to the thread of guide (D) before inserting and tightening.
Go to Section_70:Group_21
OUO6037,000144E-19-20021120
826
Check Valve Components
Check Valve Components
ZX009056-UN: Check Valve Components
LEGEND:
A - O-Ring
B - Piston
C - Bushing
D - Pin
E - Spring
F - Valve Seat
G - Poppet
H - Sleeve
827
Check Valve Components
J - Plug
Remove the Check Valve
Use a hex. socket wrench with a width across flats of 17 mm to take out plug (J).
One after the other, remove spring (E), sleeve (H) and poppet (G).
ZX009057-UN: Remove Check Valve
Screw the (self-manufactured) disassembly tool into pin (D) (refer to Check Valve Components).
Pulling on the disassembly tool (fig. I) releases the valve seat (F) and allows spring (E), bushing (C) and pin (D) to
be removed.
Now screw the disassembly tool (fig. II) into piston (B), and pull out the piston.
Refer to Check Valve Components for the identifying letters.
Use a blunt inscribing tool to remove all seal rings, and replace them with new ones.
IMPORTANT:
Take care not to damage the base of the groove.
Assemble in reverse order.
Tighten plug (J) to 130 ± 13 Nm (96 ± 10 lb-ft).
Go to Section_70:Group_21
ZX,TMXZCO006626-19-19960901
828
Components of Compensating Valve
Components of Compensating Valve
ZX009058-UN: Compensating Valve Components
LEGEND:
A - O-Ring
B - Valve Seat
C - Poppet
D - Spring
Go to Section_70:Group_21
ZX,TMXZCO006627-19-19960801
829
Compensating Valve Installed in Piston
Compensating Valve Installed in Piston
ZX009059-UN: Compensating Valve Installed in Piston
LEGEND:
A - Compensating Valve
B - Piston
C - Nut
D - Washer
E - Cylinder Barrel
Go to Section_70:Group_21
ZX,TMXZCO006628-19-19960801
830
Attachment of HillMaster II Cylinders
Attachment of HillMaster II Cylinders
ZX009060-UN: Ball-and-Socket Joint and Retaining Ring
LEGEND:
A - Ball-and-Socket Joint on Piston Rod
B - Retaining Ring
The ball-and-socket joint is maintenance-free.
ZX009061-UN: Lubricate Ball-and-Socket Joint
LEGEND:
A - Ball-and-Socket Joint on Base
B - Retaining Ring
C - Grease Fitting
The ball-and-socket joint must be lubricated via the grease fitting. Lubricate every 50 hours.
Go to Section_70:Group_21
ZX,TMXZCO006630-19-19960801
831
Remove and Install Chaff Spreader Motor
Remove and Install Chaff Spreader Motor
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
NOTE:
Procedure is the same for BOTH motors.
1.
H46395-UN: Chaff Spreader
LEGEND:
A - Cap Screw (5 used)
B - Spinner
Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
832
Remove and Install Chaff Spreader Motor
pressure. Shut off engine.
2. Remove cap screws (A).
3. Remove spinner (B).
4.
H46396-UN: Chaff Spreader
LEGEND:
A - Hub
B - Cap Screw (4 used)
C - Oil Line
Remove hub (A).
5. Remove cap screws (B).
6. Remove oil line (C).
7. Remove motor from frame.
8. Install motor on frame.
9. Install cap screws (B) to motor through frame.
10. Install oil line (C).
11. Install hub (A) with shaft key.
12.
833
Remove and Install Chaff Spreader Motor
H46395-UN: Chaff Spreader
LEGEND:
A - Cap Screw (5 used)
B - Spinner
Install spinner (B) on hub.
13. Install cap screws (A).
Go to Section_70:Group_25
AG,OUO6435,796-19-20000503
834
Remove and Install Chaff Spreader Motor
Remove and Install Chaff Spreader Motor
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the
hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable medical source. Such information is
available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
NOTE:
Procedure is the same for BOTH motors.
1.
H46395-UN: Chaff Spreader
LEGEND:
A - Cap Screw (5 used)
B - Spinner
Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
835
Remove and Install Chaff Spreader Motor
pressure. Shut off engine.
2. Remove cap screws (A).
3. Remove spinner (B).
4.
H46396-UN: Chaff Spreader
LEGEND:
A - Hub
B - Cap Screw (4 used)
C - Oil Line
Remove hub (A).
5. Remove cap screws (B).
6. Remove oil line (C).
7. Remove motor from frame.
8. Install motor on frame.
9. Install cap screws (B) to motor through frame.
10. Install oil line (C).
11. Install hub (A) with shaft key.
12.
836
Remove and Install Chaff Spreader Motor
H46395-UN: Chaff Spreader
LEGEND:
A - Cap Screw (5 used)
B - Spinner
Install spinner (B) on hub.
13. Install cap screws (A).
Go to Section_70:Group_25
AG,OUO6435,796-19-20000503
837
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Nitrogen Cylinder
Used with JT05420
nitrogen charging
kit.
Nitrogen
Charging
Kit.......JT05420
Used to charge
accumulators.
High Pressure Nitrogen
Accumulator Charging
Regulator.......JT05711
Used with JT05420 Nitrogen
Accumulator Charging Kit to charge
accumulator.
Go to Section_70:Group_30
ZX09263,0002740-19-20091112
838
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Nitrogen Cylinder
Used with JT05420
nitrogen charging
kit.
Nitrogen
Charging
Kit.......JT05420
Used to charge
accumulators.
High Pressure Nitrogen
Accumulator Charging
Regulator.......JT05711
Used with JT05420 Nitrogen
Accumulator Charging Kit to charge
accumulator.
Go to Section_70:Group_30
ZX09263,0002740-19-20091112
839
Accumulator (General Information)
Accumulator (General Information)
ZX25208-UN: Accumulator
The accumulator is connected to the header lift system between the lift cylinders and the solenoid control valve. It
suspends the header over uneven ground by compressing nitrogen gas with a piston in the accumulator tank.
The accumulator is a diaphragm type with a 6998 kPa (70 bar) (1015 psi) charge pressure.
Pressure relief is set at 21994 kPa (220 bar) (3190 psi).
Gas pressure is dependent on header size, lift cylinder diameter and feeder house type.
Go to Section_70:Group_30
OUO6037,0001428-19-20010625
840
Check Header Float System Accumulator
Check Header Float System Accumulator
NOTE:
Before connecting test device FKM10448 to accumulator, slightly loosen accumulator hex. socket
screw. This will avoid damage to the test device when accumulator is opened.
1.
ZX25206-UN: Test Device Attached
LEGEND:
A - Accumulator
B - Test Device
Relieve pressure in hydraulic line to header lift cylinders by actuating switch for lowering header.
2. For checking accumulator (A), connect device FKM10448 (B) to accumulator.
3.
ZX25207-UN: Accumulator
LEGEND:
A - Ratchet
Use a ratchet located on test device to open accumulator valve. Accumulator charge pressure is
indicated by the pressure gauge. If charging pressure is too low, the accumulator must be charged with
nitrogen.
841
Check Header Float System Accumulator
4.
ZX25209-UN: Pressure Setting
The accumulator may be charged by loosening knurled screw. If the accumulator is not connected to an
external nitrogen source (under pressure), pressure is reduced by opening knurled screw.
5. Adjust charge pressure according to the table.
Go to Section_70:Group_30
OUO6037,0001427-19-20010625
842
Accumulator Charge Pressure
Accumulator Charge Pressure
-: Accumulator Charge Pressure
NOTE:
Refer to the following chart to determine if charge pressure needs to be changed. The factory
charge pressure setting is 6895 kPa (1000 psi).
Header Model
Header Weight
56 mm Lift Cylinders
63 mm Lift Cylinders
614
1406 kg (3100 lb.)
5000 kPa (725 psi)
4500 kPa (650 psi)
615
1501 kg (3310 lb.)
6000 kPa (870 psi)
5000 kPa (725 psi)
618
1691 kg (3730 lb.)
7000 kPa (1015 psi)
6000 kPa (870 psi)
620
1818 kg (4010 lb.)
8500 kPa (1230 psi)
8000 kPa (1160 psi)
622
1945 kg (4290 lb.)
9000 kPa (1305 psi)
8000 kPa (1160 psi)
625
2135 kg (4710 lb.)
10000 kPa (1450 psi)
9000 kPa (1305 psi)
630
2452 kg (5410 lb.)
11000 kPa (1595 psi)
10000 kPa (1450 psi)
625R
2500 kg (5512 lb.)
11500 kPa (1668 psi)
10500 kPa (1523 psi)
630R
2790 kg (6151 lb.)
12834 kPa (1861 psi)
11718 kPa (1700 psi)
Go to Section_70:Group_30
OUO6435,00014CB-19-20091216
843
Table of Contents
Section 80: Separator Shell
Group 05: Gull Wing Doors
Remove and Install Gull Wing Doors
Group 10: Hood - W Series, T Series
Specifications
Remove and Install Lower Hood Panels
Remove and Install Rear Hood
Group 15: Hood - C Series
Specifications
Remove and Install Lower Hood Panels
Remove and Install Rear Hood
844
Remove and Install Gull Wing Doors
Remove and Install Gull Wing Doors
H68171-UN: Gull Wing Door Removal
H55007-UN: Decal
LEGEND:
A - Cap Screw (4 used)
B - Cap Screw (4 used)
C - Gull Wing Panel
D - Cylinder
E - Connector
F - Decal
G - Decal
CAUTION:
Cylinder contents under pressure. Do not take apart, puncture, apply heat or fire.
1. Disconnect connector (E) and remove cylinder (D) at both ends of gull wing panel.
2.
CAUTION:
Use two or more people to remove gull wing panel to prevent injury to yourself
and others.
845
Remove and Install Gull Wing Doors
NOTE:
Do not remove cap screws (B). Used for vertical adjustment only.
Remove cap screws (A) and nuts at both ends of gull wing panel.
3. Remove gull wing panel.
4. Repair or replace parts as necessary.
5. Position gull wing panel on hinge bracket.
6. Align holes on hinge bracket and retain using cap screws (A) and nuts at both ends. Do not fully tighten.
7. Loosen cap screws (B) at both ends of panel if required to align decals (F) and (G).
8. Tighten cap screws (A) at both ends of panel.
9. Tighten cap screws (B) at both ends of panel.
10. Attach cylinder (D) to gull wing panel and connect wiring harness connector (E).
Go to Section_80:Group_05
OUO6030,0000080-19-20010518
846
Remove and Install Gull Wing Doors
Remove and Install Gull Wing Doors
H68171-UN: Gull Wing Door Removal
H55007-UN: Decal
LEGEND:
A - Cap Screw (4 used)
B - Cap Screw (4 used)
C - Gull Wing Panel
D - Cylinder
E - Connector
F - Decal
G - Decal
CAUTION:
Cylinder contents under pressure. Do not take apart, puncture, apply heat or fire.
1. Disconnect connector (E) and remove cylinder (D) at both ends of gull wing panel.
2.
CAUTION:
Use two or more people to remove gull wing panel to prevent injury to yourself
and others.
847
Remove and Install Gull Wing Doors
NOTE:
Do not remove cap screws (B). Used for vertical adjustment only.
Remove cap screws (A) and nuts at both ends of gull wing panel.
3. Remove gull wing panel.
4. Repair or replace parts as necessary.
5. Position gull wing panel on hinge bracket.
6. Align holes on hinge bracket and retain using cap screws (A) and nuts at both ends. Do not fully tighten.
7. Loosen cap screws (B) at both ends of panel if required to align decals (F) and (G).
8. Tighten cap screws (A) at both ends of panel.
9. Tighten cap screws (B) at both ends of panel.
10. Attach cylinder (D) to gull wing panel and connect wiring harness connector (E).
Go to Section_80:Group_05
OUO6030,0000080-19-20010518
848
Specifications
Specifications
Item
Measurement Specification
Rear Hood Corner Cap Screws Torque
80 N˙m
(59 lb-ft)
Go to Section_80:Group_10
OUO6435,00017C8CONV2-19-20020627
849
Specifications
Specifications
Item
Measurement Specification
Rear Hood Corner Cap Screws Torque
80 N˙m
(59 lb-ft)
Go to Section_80:Group_10
OUO6435,00017C8CONV2-19-20020627
850
Remove and Install Lower Hood Panels
Remove and Install Lower Hood Panels
Deflection shields, located behind straw walkers, will vary depending on chopper configuration.
1. Shut off engine and remove key.
2. Remove chopper and shields. (See procedures in Section 120.)
3.
H72072-UN: Chopper Door and Rear Deflection Shield
LEGEND:
A - Door
B - Shield
Remove chopper door (A) (if equipped) and rear deflection shield (B).
4.
NOTE:
Remove bulbs from harness to avoid possible breakage.
851
Remove and Install Lower Hood Panels
H71871-UN: Rear Light Harness Removal
LEGEND:
A - Shield (2 used)
B - Lamp Connector (4 used)
C - Wiring Harness
Remove harness shields (A) and lamp connectors (B) from rear light assemblies. Route harness (C)
through hole in panel. Move harness out of the way on both sides.
5.
H71866-UN: Harness Shields
LEGEND:
A - Cap Screw (2 used)
B - Shield (2 used)
C - Cap Screws (6 used)
Remove cap screw (A), shield (B) and cap screws (C) on both sides.
6.
CAUTION:
Be careful when entering and exiting engine platform with ladder/landing support
852
Remove and Install Lower Hood Panels
Be careful when entering and exiting engine platform with ladder/landing support
partially disconnected.
H71868-UN: Ladder Support Nut and Cap Screw
LEGEND:
A - Nut
B - Nut (3 used)
Remove nuts (A and B) and cap screws from ladder/landing support.
7.
H71870-UN: Lower Rear Hood Panel Removal
Note position of remaining cap screws; then remove lower rear hood using a fork lift (as shown) or two
additional persons.
8. Install in reverse order.
Go to Section_80:Group_10
OUO6435,00018A7-19-20020820
853
Remove and Install Rear Hood
Remove and Install Rear Hood
1.
H71874-UN: Straw Walker Plugging Sensor Connector
LEGEND:
A - Connector
Remove lower hood panels. (See procedure in this group.)
2.
NOTE:
Straw walker plugging sensor connector is located below relay/fuse box in engine
compartment.
Disconnect straw walker plugging sensor connector (A) and push through hole in hood.
3.
CAUTION:
Be careful when entering and exiting engine platform with ladder/landing support
partially disconnected.
854
Remove and Install Rear Hood
H71875-UN: Remove Rail from Hood
LEGEND:
A - Nut (2 used)
B - Nut (4 used)
Remove nuts (A) and disconnect rail from top of hood.
4. Remove nuts (B) and cap screws.
5.
H72066-UN: Remove Rear Hood
LEGEND:
855
Remove and Install Rear Hood
A - Nut (4 used)
Remove harness from clamps; then remove nuts (A), cap screws and washers.
6. IMPORTANT:
Be careful not to drop cap screws into separator area.
H71873-UN: Rear Hood Cap Screws
LEGEND:
A - Cap Screw (8 used)
Remove cap screws (A).
7. Position a fork lift under hood.
8.
H71867-UN: Rear Hood Mounting Cap Screws
856
Remove and Install Rear Hood
H71872-UN: Remove Rear Hood
LEGEND:
A - Cap Screw (8 used)
B - Cap Screw (6 used)
Remove cap screws (A and B) on both sides.
9. IMPORTANT:
Be careful not to damage walker seals attached to left and right side of hood sidesheets.
Slowly remove hood using fork lift.
10.
H72067-UN: Install Rear Hood Connector
LEGEND:
A - Connector
B - Hole
Install in reverse order using the following special instructions:
Slowly position hood next to machine and route connector (A) through hole (B) in rear panel of
engine platform.
NOTE:
Do NOT tighten any nuts or cap screws until all have been loosely installed.
857
Remove and Install Rear Hood
H72068-UN: Install Rear Hood
LEGEND:
A - Cap Screw (6 used)
Align hood and loosely install rear hood corner cap screws (A) on both sides to hold in place.
Install remaining nuts and cap screws, then tighten to the following specifications.
Item
Measurement Specification
Rear Hood Corner Cap Screws Torque
80 N˙m
(59 lb-ft)
Go to Section_80:Group_10
OUO6037,00015C0-19-20020501
858
Specifications
Specifications
Item
Measurement Specification
Rear Hood Corner Cap Screws Torque
80 N˙m
(59 lb-ft)
Go to Section_80:Group_15
OUO6435,00017C8CONV1-19-20020627
859
Specifications
Specifications
Item
Measurement Specification
Rear Hood Corner Cap Screws Torque
80 N˙m
(59 lb-ft)
Go to Section_80:Group_15
OUO6435,00017C8CONV1-19-20020627
860
Remove and Install Lower Hood Panels
Remove and Install Lower Hood Panels
1. Park combine on a flat level surface.
2. Disconnect ground cable (-) from battery.
3.
NOTE:
Left lower hood panel is shown. Procedure for right lower hood panel is similar.
Remove straw chopper. (See Remove and Install Straw Chopper in Section 120, Group 55.)
4.
H72638-UN: Support
LEGEND:
A - Round Head Bolt (3 Used)
Remove round head bolts (A) and swing rear door open.
5.
NOTE:
Remove bulbs from sockets to avoid breaking.
H72639-UN: Lights
861
Remove and Install Lower Hood Panels
LEGEND:
A - Lamp connector
B - Clamp
C - Cap Screw (2 used)
Disconnect lamp connectors (A).
6. Remove wiring harness from clamp (B). Pull wiring harness out of door channel.
7. Remove cap screws (C) and rear door.
8.
H72635-UN: Discharge Light
LEGEND:
A - Connector
B - Connector
C - Clamp
On right side of machine, disconnect rear residue discharge light connector (A) and tail light connector
(B).
9.
H72643-UN: Upper Panel
862
Remove and Install Lower Hood Panels
H72642-UN: Cap Screws
LEGEND:
A - Nut (7 used)
Remove nuts (A).
10.
H72640-UN: Support
LEGEND:
A - Cap Screw and Washer (4 used)
B - Panel
Remove cap screws and washers (A) and panel (B).
11.
H72645-UN: Spreader Bar
LEGEND:
A - Spreader Bar
B - Cap Screw (4 used)
Remove cap screws (B) and spreader bar (A).
863
Remove and Install Lower Hood Panels
12.
H72664-UN: Chopper Doors
LEGEND:
A - Door (2 used)
Remove inside chopper doors (A).
13.
H72669-UN: Chopper Shields
LEGEND:
A - Shield (2 used)
Remove chopper sensor harness shields (A).
14.
H72670-UN: Support
864
Remove and Install Lower Hood Panels
H72671-UN: Side Sheet Mounting
LEGEND:
A - Rail
B - Cap Screw (5 used)
C - Cap Screw (3 used)
Remove cap screws (B) and rail (A).
15. Remove cap screws (C).
16.
H72672-UN: Side Panel
LEGEND:
A - Cap Screw (5 used)
B - Lower Rear Hood Panel
C - Bracket
D - Cap Screw (7 used)
Remove cap screws (A).
17.
NOTE:
It is highly recommended to have a second person to help removing the lower rear hood
panel.
Remove cap screws (D), bracket (C) and lower rear hood panel (B).
18. Assemble in reverse order, tighten all cap screws. (See Metric Bolt and Cap Screw Torque Values in
Section 10.)
865
Remove and Install Lower Hood Panels
Go to Section_80:Group_15
OUO6045,0000168-19-20020621
866
Remove and Install Rear Hood
Remove and Install Rear Hood
1. Park combine on a flat level surface.
2. Disconnect battery ground cable (-).
3.
H72638-UN: Round Head Bolts
LEGEND:
A - Round Head Bolt (3 Used)
Remove round head bolts (A) and swing rear door open.
4.
NOTE:
Remove bulbs from sockets to avoid breaking.
H72639-UN: Wiring Harness
LEGEND:
A - Rear lamp connector (2 used)
B - Clamp
C - Cap Screw (2 used)
Disconnect rear lamp connectors (A).
5. Remove wiring harness from clamp (B). Pull wiring harness out of door channel.
867
Remove and Install Rear Hood
6. Remove cap screws (C) and rear door.
7.
H72675-UN: Panel Removal
LEGEND:
A - Connector
B - Connector
C - Clamp
D - Cap Screw (2 used)
E - Warning Lamp
Disconnect connectors (A and B) and remove wiring harness from clamp (C).
8. Remove cap screws (D) and warning lamp (E).
9.
H72643-UN: Upper Panel
868
Remove and Install Rear Hood
H72642-UN: Cap Screws
LEGEND:
A - Nut (7 used)
Remove nuts (A).
10.
H72640-UN: Panel
LEGEND:
A - Cap Screw and Washer (4 used)
B - Panel
Remove cap screws and washers (A) and panel (B).
11.
H72683-UN: Wiring Harness
LEGEND:
A - Connector
B - Connector
C - Clamp (3 used)
869
Remove and Install Rear Hood
D - Cap Screw (6 used)
Disconnect harness connectors (A and B).
12. Remove harness from clamps (C) and tie harness to roof of rear hood.
13. Remove cap screws (D).
14.
H72698-UN: Module Mounting
LEGEND:
A - Cap Screw (3 used)
Remove cap screws (A) from module drive coupling.
15.
H72688-UN: Drive Tightener
LEGEND:
A - Lock Nut
B - Nut
C - Belt
Loosen lock nut (A).
16. Loosen nut (B) until drive belt (C) can be removed from rear module drive sheave.
870
Remove and Install Rear Hood
17.
H72690-UN: Mounting
H72689-UN: Drive
LEGEND:
A - Cap Screw
B - Nut
C - Cap Screw (4 used)
D - Drive Shaft
Remove cap screw (A) and loosen nut (B).
18. Remove cap screws (C). Drive shaft (D) will be moved out of the way.
19.
H72691-UN: Bracket
871
Remove and Install Rear Hood
H72692-UN: Screws and Nuts
LEGEND:
A - Round Head Bolt (8 used)
B - Cap Screw and Washer (8 used)
C - Cap Screw (6 used)
Remove cap screws and washers (B), round head bolts (A) and cap screws (C) from both sides.
20.
H72693-UN: Handrail
LEGEND:
A - Round Head Bolt (2 used)
B - Handrail
C - Cap Screw (2 used)
Remove round head bolts (A).
21. Remove one cap screw (C). Loosen one cap screw (C) and pivot handrail (B) out of the way.
872
Remove and Install Rear Hood
22.
H72701-UN: Rear Hood
LEGEND:
A - Bracket (2 used)
B - Cap Screw (16 used)
Remove brackets (A) and cap screws (B) from both sides.
23.
H72699-UN: Bracket
LEGEND:
A - Hinge (2 used)
B - Round Head Bolt and Clamp
C - Cap Screw (4 used)
Remove hinges (A), cap screws (C) and round head bolt and clamp (B).
24.
873
Remove and Install Rear Hood
H72700-UN: Rail Mounting
LEGEND:
A - Round Head Bolt (21 used)
Remove round head bolts (A) from both sides.
25. Position a fork lift under rear hood or use an overhead hoist.
26. IMPORTANT:
Rear hood lip (C) is sandwiched between module drive bracket (A) and lower rear hood panel (B).
H72707-UN: Lip
LEGEND:
A - Module Drive Bracket
B - Lower Hood Panel
C - Rear Hood Lip
While slowly raising hood, push rear hood lip (C) out so it clears module drive bracket (A).
27.
H72708-UN: Remove Rear Hood
Remove rear hood from machine.
28. Install in reverse order.
874
Remove and Install Rear Hood
29.
H45474-UN: Alignment Tool
LEGEND:
A - JDG1292 Alignment Tool
Align module drive shaft to module gearcase using JDG1292 Alignment Coupler. Position coupler in
place of U-joint assembly.
30.
H72702-UN: Corner Cap Screws
LEGEND:
A - Cap Screw (6 used)
Use the following instructions during reassembly.
Do NOT tighten any hardware until all hardware is installed.
Tighten cap screws (A) on both sides to specification.
Item
Measurement Specification
Rear Hood Corner Cap Screws Torque
80 Nm
(59 lb-ft)
Tighten remaining cap screws and round head bolts to correct torque. (See Metric Bolt and
Cap Screw Torque Values in Section 10.)
Check tail lights to be sure they are working correctly.
Operate machine and retighten tine separator drive belt if needed.
Retighten all hardware after 1 hour of machine operation.
Go to Section_80:Group_15
OUO6045,0000169-19-20020625
875
Table of Contents
Section 90: Operator's Station Repair
Group 05: Air-Conditioning System (R134a)
Essential and Recommended Special Tools
Service Equipment and Tools
Other Material
Specifications
Discharge and Recovery of Air Conditioning Refrigerant
Remove and Install Compressor
Test Volumetric Efficiency
Test Shaft Seal Leakage
Disassemble and Assemble Compressor Clutch
Check Clutch Hub Clearance
Inspect Compressor Manifold
Disassemble, Inspect, and Assemble Compressor
Remove and Install Compressor Relief Valve
Flush Air Conditioning System
Purge Air Conditioning System
Evacuate Air Conditioning System
Compressor Oil Information
Determine Correct Oil Charge
Check Refrigerant Oil Charge
Charge Air Conditioning System
Leak Testing Procedure
Group 10: System Components
Essential and Recommended Special Tools
Other Material
Remove and Install Receiver/Dryer
Replace Blower Motor
Replace Recirculator Motor Drive Module
Replace Heater Valve
Remove Condenser
Repair Condenser
Install Condenser
876
Table of Contents
Replace Evaporator
Remove and Install Evaporator Temperature Sensor
Replace Low Pressure Switch
Replace High Pressure Switch
Replace Air Temperature Sensors
Group 15: Cab
Specifications
Remove and Install Cab Windshield
Remove Cab
Install Cab
Replace Rear Window
Remove and Install Cab Roof
Remove and Install Operator's Seat
Remove and Install Operator Presence Switch
Operator's Seat - Exploded View
Operator's Seat Air Suspension Assembly - Exploded View
Disassemble and Assemble Operator's Seat Air Suspension Assembly
Cab Door Latch Striker
Remove and Install Cab Door
Disassemble and Assemble Cab Door (Serial No. 074502—)
877
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
HFC134A Recovery/Recycling Station .......JT02050 [
Used with JT02046 Charging Station. JT02047
Recovery, Recycling, and Charging Station can be
substituted for JT02046 and JT02050. ]
Servicing air conditioning system using R134a
refrigerant.
RW21613-UN: Recovery and Recycling Station
Air Conditioning R12/R134a Fitting Kit .......JT02098
Connect flushing, purging and pressure equipment.
RW40022-UN: Air Conditioning R12/R134a Fitting Kit
Manifold Pressure Gauge Assembly.......JT02051
Check A/C system pressure.
RW25172-UN: Manifold Pressure Gauge Assembly
Electronic Leak Detector.......JT02081
Checking A/C system for leaks.
RW25567-UN: Electronic Leak Detector
878
Essential and Recommended Special Tools
Air Conditioning Compressor Clutch
Spanner.......JDG747
To remove and install compressor clutch.
Pulley Remover.......D05277ST
Remove compressor pulley.
RW40022-UN: Pulley Remover
Jaws.......JDG748
Removing compressor pulley (used with D05277ST
Puller and JDG771 Hub Protector)
RW19935-UN: Jaws
Hub Protector.......JDG771
To protect end of shaft when removing hub.
RW21598-UN: Hub Protector
Compressor Seal and Clutch Repair Kit .......JDG215
Remove and install seal and clutch components on air
conditioning compressor.
RW40022-UN: Compressor Seal and Clutch Repair
Kit
Compressor Seal Protector.......JDG746
Install seal on compressor.
RW19943-UN: Seal Protector
879
Essential and Recommended Special Tools
HFC134A Charging Station .......JT02046 [ Used with
JT02050 Recovery and Recycling Station. JT02047
Recovery, Recycling and Charging Station can be
substituted for JT02046 and JT02050. ]
Servicing air conditioning system using R134a
refrigerant.
RW21595-UN: HFC134A Charging Station
A/C Leak Detection
Kit.......JT02178
To detect leaks in the
air conditioning
system.
Go to Section_90:Group_05
ZX09263,0002741-19-20080201
880
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
HFC134A Recovery/Recycling Station .......JT02050 [
Used with JT02046 Charging Station. JT02047
Recovery, Recycling, and Charging Station can be
substituted for JT02046 and JT02050. ]
Servicing air conditioning system using R134a
refrigerant.
RW21613-UN: Recovery and Recycling Station
Air Conditioning R12/R134a Fitting Kit .......JT02098
Connect flushing, purging and pressure equipment.
RW40022-UN: Air Conditioning R12/R134a Fitting Kit
Manifold Pressure Gauge Assembly.......JT02051
Check A/C system pressure.
RW25172-UN: Manifold Pressure Gauge Assembly
Electronic Leak Detector.......JT02081
Checking A/C system for leaks.
RW25567-UN: Electronic Leak Detector
881
Essential and Recommended Special Tools
Air Conditioning Compressor Clutch
Spanner.......JDG747
To remove and install compressor clutch.
Pulley Remover.......D05277ST
Remove compressor pulley.
RW40022-UN: Pulley Remover
Jaws.......JDG748
Removing compressor pulley (used with D05277ST
Puller and JDG771 Hub Protector)
RW19935-UN: Jaws
Hub Protector.......JDG771
To protect end of shaft when removing hub.
RW21598-UN: Hub Protector
Compressor Seal and Clutch Repair Kit .......JDG215
Remove and install seal and clutch components on air
conditioning compressor.
RW40022-UN: Compressor Seal and Clutch Repair
Kit
Compressor Seal Protector.......JDG746
Install seal on compressor.
RW19943-UN: Seal Protector
882
Essential and Recommended Special Tools
HFC134A Charging Station .......JT02046 [ Used with
JT02050 Recovery and Recycling Station. JT02047
Recovery, Recycling and Charging Station can be
substituted for JT02046 and JT02050. ]
Servicing air conditioning system using R134a
refrigerant.
RW21595-UN: HFC134A Charging Station
A/C Leak Detection
Kit.......JT02178
To detect leaks in the
air conditioning
system.
Go to Section_90:Group_05
ZX09263,0002741-19-20080201
883
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Dial Indicator,
Metric
Scale.......D17527C1
To check pulley-toclutch hub clearance.
Dial Indicator,
English
Scale.......D17526C1
To check pulley-toclutch hub clearance.
Magnetic Base with
Adjustable
Arms.......D17525C1
To hold dial indicator
during use.
Compressor Holding
Fixture.......DFRW20
To hold compressor during
disassembly and assembly.
Go to Section_90:Group_05
ZX09263,0002742-19-20080201
884
Other Material
Other Material
Number
Name
Use
TY22100 (12 oz) (U.S.) R134a Compressor Oil (12 oz) Used to lubricate R134a air conditioning systems.
TY16134 (U.S.)
R134a Flushing Solvent
Used to flush R134a air conditioning systems.
TY15949 (12 oz) (U.S.) R134a (12 oz)
Used to charge R134a air conditioning systems.
TY15951 (30 lb) (U.S.) R134a (30 lb)
Used to charge R134a air conditioning systems.
Go to Section_90:Group_05
OUO6435,0001867-19-20020816
885
Specifications
Specifications
Item
Measurement
Specification
Evacuating System
Required Vacuum at Sea Level
94.4 kPa
(0.9 bar)
(28.6 in. Hg)
Refrigerant
R134a Capacity
1.8—2.1 kg
(4—4.5 lb)
Compressor
Oil Charge
255 ml
(8.5 fl oz)
Discharge Pressure at 2000 rpm
690—2590 kPa
(6.9—25.9 bar)
(100—375 psi)
Suction Pressure at 2000 rpm
7—200 kPa
(0.07—2.0 bar)
(1—30 psi)
Clutch Hub Cap Screw
Torque
14 N˙m
(10 lb-ft)
Hub-to-Pulley
Clearance
0.35—0.65 mm
(0.014—0.026 in.)
Clutch Coil
Current Draw at 12 volts, 20°C (68°F) 2.6 amps
Resistance at 20°C (68°F)
3.5—4.0 Ohms
Compressor Manifold Cap Screws Torque
26 N˙m
(19 lb-ft)
Compressor Through Bolts
Torque
26 N˙m
(19 lb-ft)
Compressor Relief Valve
Opening Pressure
3450—4140 kPa
(34.5—41.4 bar)
(500—600 psi)
Torque
12—16 N˙m
(9—12 lb-ft)
Compressor Suction Line
Torque
34—42 N˙m
(25—31 lb-ft)
Compressor Discharge Line
Torque
32—40 N˙m
(24—29 lb-ft)
Go to Section_90:Group_05
AG,OUO6030,120-19-20000725
886
Discharge and Recovery of Air Conditioning Refrigerant
Discharge and Recovery of Air Conditioning Refrigerant
Operate the air conditioning system for 10 minutes with engine at 2000 rpm if the compressor is operable. Set
temperature control for maximum cooling and blower switch at high. This allows the refrigerant oil to be circulated
through the system and indicates the quantity of oil in the compressor.
Stop the engine and use the following procedure to discharge refrigerant from the system.
1. Connect JT02050 R134a Refrigerant Recovery and Recycling Station to a JT02046 HFC134a
Refrigerant Charging Station.
NOTE:
Used with JT02046 Charging Station. JT02047 Recovery, Recycling, and Charging
Station can be substituted for JT02046 and JT02050.
2.
H55403-UN: Charging Points
LEGEND:
A - Suction Fitting
B - Discharge Fitting
Connect low-side hose (blue) from the charging station to suction fitting (A). Connect high-side hose
(red) to discharge fitting (B).
3. Follow the manufacturer's instructions and discharge refrigerant from the system. Cap the fittings to
prevent contamination from entering the system.
Go to Section_90:Group_05
HX,90,DD5-19-20000725
887
Remove and Install Compressor
Remove and Install Compressor
1.
H68192-UN: Hydraulic Hose Bracket
H68051-UN: Connector
H68050-UN: Compressor
LEGEND:
A - Cap Screw
B - Hydraulic Hoses and Bracket
C - Connector
D - Hex. Socket Screw (4 used)
E - Manifold
F - Clutch Coil Wire
G - Belt
H - Cap Screw (3 used)
Discharge air conditioning refrigerant. (See Discharge and Recovery of Air Conditioning Refrigerant in
this Group.)
888
Remove and Install Compressor
2. Remove rear panel in grain tank to gain access to compressor.
3. Remove cap screw (A) and move hydraulic hoses and bracket (B) out of the way.
4. Remove belt (G) from the compressor pulley.
5. Disconnect clutch coil wire (F) and connector (C).
6. IMPORTANT:
Corrosion sometimes develops between the hose fittings and the compressor manifold making
disassembly difficult or impossible without damaging manifold port threads. Leave hoses attached to the
manifold to aid disassembly and assembly.
Remove hex. socket screws (D) and manifold (E) from the compressor. Cap all lines and fittings to
prevent contamination.
7. Remove cap screws (H) and compressor.
8. Flush the complete system if the compressor failed internally due to damaged parts or seizure (see
Flush Air Conditioning System in this group).
9. Determine correct compressor oil charge (see procedure in this group).
10.
NOTE:
Alignment spring pins (A) must be in the front two holes of the mounting bracket. If
spring pins are not in place, misalignment can occur causing premature belt failure.
H63793-UN: Compressor Mounting
LEGEND:
A - Spring Pin (2 used)
Check that spring pins (A) are in place in mounting bracket.
889
Remove and Install Compressor
11.
H68192-UN: Hydraulic Hose Bracket
H68051-UN: Connector
H68050-UN: Compressor
LEGEND:
A - Cap Screw
B - Hydraulic Hoses and Bracket
C - Connector
D - Hex. Socket Screw (4 used)
E - Manifold
F - Clutch Coil Wire
G - Belt
H - Cap Screw (3 used)
Install compressor using cap screws (H).
12. Install manifold (E) and retain with hex. socket screws (D).
13. Connect (C) and (F).
890
Remove and Install Compressor
14. Install belt (G).
15. Install hydraulic hoses and bracket (B) using cap screw (A).
16. Evacuate and charge system. (See procedures in this group.)
IMPORTANT:
If NEW compressor clutch was installed, turn compressor on and off (engine running) in 1-second intervals for 5
seconds (cycle five times in 5 seconds). This will burnish clutch and hub drive surfaces.
Go to Section_90:Group_05
OUO6089,000005C-19-20010705
891
Test Volumetric Efficiency
Test Volumetric Efficiency
RW40028A-UN: Compressor
LEGEND:
A - Suction Test Port
1. Drain oil from compressor and record amount.
2. Remove front cover from compressor pulley and rotate drive shaft 30 revolutions using a speed wrench
and 10 mm socket.
3. Drain remaining oil from compressor and record amount.
NOTE:
If no oil was removed, add 60 ml (2 oz.) of R134a refrigerant oil to suction port. Slowly
roll compressor in each direction at least two times. Repeat steps 1 - 3.
4. Secure compressor in a vise with ports upward.
5. Install JT02099 [ Included in JT02098 Air Conditioning Fitting Kit ] Adapter in suction port with JT03194 [
Included in JT02098 Air Conditioning Fitting Kit ] Cap.
6. Connect suction hose coupler of manifold pressure gauge assembly to test port (A).
7. Close suction side valve of manifold pressure gauge assembly and open valve on suction hose coupler.
892
Test Volumetric Efficiency
8. Rotate compressor drive shaft with speed wrench to obtain peak vacuum on low side gauge. Check for
even suction (no pulsing) while turning wrench at a slow rate to maintain peak vacuum (635 mm; 25 in.
Hg. minimum).
9. Stop rotating shaft and check leak-down time. Compressor should hold peak vacuum for a minimum of
three seconds. If compressor does not hold for three seconds, inspect compressor valve plates and
cylinder walls for damage.
10. Open suction port of compressor to atmosphere.
11.
RW40029A-UN: Compressor
LEGEND:
A - Discharge Port
Connect suction hose of manifold pressure gauge assembly to discharge port (A) using JT02100 [
Included in JT02098 Air Conditioning Fitting Kit ] Adapter and JT02108 [ Included in JT02098 Air
Conditioning Fitting Kit ] Hose.
12. Close suction side valve of manifold pressure gauge assembly.
13. Rotate compressor drive shaft no faster than two turns per second for six turns.
14. Record pressure after six complete turns. Pressure should be 380 kPa (3.8 bar) (55 psi) minimum.
NOTE:
Pressure normally leaks down when rotation stops.
15. Continue to rotate compressor shaft at a uniform speed to obtain peak pressure. Compression pressure
893
Test Volumetric Efficiency
15. Continue to rotate compressor shaft at a uniform speed to obtain peak pressure. Compression pressure
should increase smoothly and should not vary more than 34 kPa (0.34 bar) (5 psi) at peak pressure.
Bleed off pressure and repeat Steps 13, 14 and 15 four times.
NOTE:
Pressure varying more than 34 kPa (0.34 bar) (5 psi) indicates a leaking reed-valve or
piston seal. Inspect compressor valve plates and cylinder walls for damage. Repair
compressor as required.
16. Leak test compressor (see Test Shaft Seal Leakage in this group).
Go to Section_90:Group_05
AG,OUO6045,1127-19-20000725
894
Test Shaft Seal Leakage
Test Shaft Seal Leakage
RW41334A-UN: Compressor
LEGEND:
A - Suction Port
1. Remove front plate from compressor pulley.
2. Remove clutch hub and screw.
IMPORTANT:
Do not lose inner clutch hub shims.
3. Install JT02099 [ Included in JT02098 Air Conditioning Fitting Kit ] Adapter in suction port and JT02100 [
Included in JT02098 Air Conditioning Fitting Kit ] Adapter in discharge port. Cap discharge port adapter
using JT03194 [ Included in JT02098 Air Conditioning Fitting Kit ] .
4. Connect manifold pressure gauge assembly and/or container of R134a refrigerant to suction port (A) of
compressor.
5. Open valves to pressurize compressor.
IMPORTANT:
Do not exceed range of low pressure gauge.
6. Check the following for leaks using leak detector JT02081 or 50-50 mixture of soap and water:
Shaft seal
Manifold seal
Housing seals at front, rear and mid-section of compressor body
895
Test Shaft Seal Leakage
Pressure relief valve
Schrader valve of suction port
Leakage should not exist. Repair compressor if required, and repeat test.
7. Assemble compressor and add required quantity of oil (see Determine Correct Oil Charge in this group).
Go to Section_90:Group_05
AG,OUO6045,1128-19-20000725
896
Disassemble and Assemble Compressor Clutch
Disassemble and Assemble Compressor Clutch
RW21157-UN: Compressor
H65447-UN: Compressor Clutch
LEGEND:
A - JDG747 Compressor Clutch Spanner
B - Clutch Hub Cap Screw
C - Clutch Hub
D - Pulley Snap Ring
E - Pulley
F - Clutch Coil Snap Ring
G - Clutch Coil
H - Shim
1. Mount compressor on DFRW20 Compressor Holding Fixture using two 6 in. x 1/4 in. eye bolts with nuts
as illustrated. (See Section 199 for instructions to fabricate Compressor Holding Fixture.)
2. Remove dust cover.
897
Disassemble and Assemble Compressor Clutch
3. Hold the clutch hub using JDG747 Compressor Clutch Spanner (A) and remove the clutch hub cap
screw (B).
4. Remove clutch hub (C). Remove shims (H) from clutch hub and save for installation.
5. Remove and discard snap ring (D). Remove pulley (E) using a plastic hammer or D05277ST Puller,
JDG748 Jaws and JDG771 Hub Protector.
6. Disconnect the clutch coil lead. Remove and discard snap ring (F) using D05327ST [ Included in
JDG215 ] Retaining Ring Pliers, and remove clutch coil (G).
NOTE:
The bearing in the pulley is not serviceable.
7. Check pulley bearing operation. Replace pulley and bearing as required.
8. Install the clutch coil (G) and new snap ring (F) with flat side down. Connect clutch coil lead.
9. Install pulley (E) and new snap ring (D) with flat side of snap ring down. Apply grease to shims (H) and
install to the clutch hub (C).
10. Install cap screw (B) and tighten to specification.
Item
Measurement Specification
Clutch Hub Cap Screw Torque
14 N˙m
(10 lb-ft)
11. Install dust cover.
Go to Section_90:Group_05
AG,OUO6045,1129-19-20000725
898
Check Clutch Hub Clearance
Check Clutch Hub Clearance
RW21159-UN: Compressor
NOTE:
The clutch coil is NOT polarity sensitive.
1. Check pulley-to-clutch hub clearance using a dial indicator. Mount the gauge to the pulley as illustrated
and connect a set of jumper wires from the compressor to a 12-volt battery.
2. Rotate the pulley and check clearance at three equally spaced locations around the clutch hub. Add or
remove shims as required to adjust clearance to specification.
Item
Measurement Specification
Hub-to-Pulley Clearance
0.35—0.65 mm
(0.014—0.026 in.)
3. Tighten clutch hub cap screw to specification after correct clearance is obtained.
Item
Measurement Specification
Clutch Hub Cap Screw Torque
14 N˙m
(10 lb-ft)
Go to Section_90:Group_05
AG,OUO6030,109-19-20000725
899
Inspect Compressor Manifold
Inspect Compressor Manifold
RW21160A-UN: Compressor
LEGEND:
A - Manifold Cap Screw
B - Manifold
C - Manifold Seal
1. Remove screws (A) and manifold (B).
2. Remove and discard seal (C).
3. Inspect the contact surfaces.
4. Lubricate and install a new seal (C).
5. Install manifold (B) using cap screws (A) and tighten to specification.
Item
Measurement Specification
Compressor Manifold Cap Screws Torque
26 N˙m
(19 lb-ft)
Go to Section_90:Group_05
AG,OUO6030,110-19-20000725
900
Disassemble, Inspect, and Assemble Compressor
Disassemble, Inspect, and Assemble Compressor
H63259-UN: Compressor
LEGEND:
A - Rear Pins
B - Rear Housing
C - Rear Gasket
D - Rear Discharge Reed Valve
E - Rear Valve Plate
F - Rear Suction Reed Valve
G - Rear O-Ring
H - Front O-Ring
I - Front Suction Reed Valve
J - Front Valve Plate
K - Front Discharge Reed Valve
L - Front Gasket
M - Snap Ring
N - Lip Seal
O - Washer
P - Through Bolt
Q - Felt Seal Holder
R - Felt Seal
S - Front Housing
T - Front Pins
1. Clean the compressor using solvent before disassembly.
2. Mount compressor on DFRW20 compressor holding fixture.
3. Remove the clutch (see Disassemble and Assemble Compressor Clutch in this group.)
4. IMPORTANT:
When removing front and rear housing, be careful NOT to damage the sealing surfaces.
Disassemble the compressor as illustrated and discard the O-rings, gaskets, lip seal, snap ring and
901
Disassemble, Inspect, and Assemble Compressor
through bolt washers. Replace with new parts from service kits.
5.
NOTE:
Valve plates, reed valves, cylinders, and cylinder housing are NOT serviceable. Some
cylinder scuffing (light scratches) is normal.
Inspect the valves for an even wear pattern and the cylinders for scoring or excessive wear. Replace
compressor as required.
6. Remove the shaft seal snap ring (M).
7. Turn the housing over and remove the felt seal holder (Q) and felt seal (R) from the front housing (S).
8. Remove the shaft lip seal (N) from the front housing (S) using a small tool with 5/8 in. OD.
9.
Wash all parts in clean solvent and dry using moisture-free compressed air before assembly.
10. IMPORTANT:
Lubricate O-rings, gaskets and lip seal using only TY22100 (R134a) compressor oil during assembly.
Other oils could damage the compressor.
Apply R134a oil to the bore of the front housing and install new lip seal (N) to the bottom of the bore
902
Disassemble, Inspect, and Assemble Compressor
using a socket.
11. Install new snap ring (M), flat side down.
12. IMPORTANT:
Bushing spacer (U) must be in position before assembling the compressor.
Install pins (A) and new O-ring (G) in rear cylinder.
NOTE:
The rear valve plate is marked with an "R" and is installed face up.
13. Install parts (F - D) over the pins on the rear cylinder.
14. Install a new gasket (C) flat side down and rear housing (B) on rear cylinder.
15. Mount the compressor on DFRW20 compressor holding fixture.
16. Install pins (T) and new O-ring (H) in the front cylinder.
NOTE:
The front valve plate is marked with an "F" and is installed face up.
17. Install parts (I - K) over the pins on the front cylinder.
18. Install a new gasket (L) flat side down. Put JDG746 lip seal protector on the shaft and lubricate with R134a oil.
19. Install front housing (S) on the front cylinder and remove the lip seal protector.
20. Install through bolts (P) and new washers (O).
21. Partially tighten through bolts and then tighten to specification.
Item
Measurement Specification
Compressor Through Bolts Torque
26 N˙m
(19 lb-ft)
22. Install felt seal (R) and felt seal holder (Q) using the clutch hub.
23. Install the pulley-clutch hub and check clearance (see Disassemble and Assemble Compressor Clutch in
this group).
Go to Section_90:Group_05
AG,OUO6045,1130-19-20000725
903
Remove and Install Compressor Relief Valve
Remove and Install Compressor Relief Valve
H68194-UN: Pressure Relief Valve
LEGEND:
A - Relief Valve
CAUTION:
High pressure may exist at the discharge fitting. If this pressure is relieved too rapidly,
there may be a considerable discharge of refrigerant and oil.
1. Discharge refrigerant from air conditioning system (see Discharge and Recovery of Air Conditioning
Refrigerant in this group).
2. Slowly remove relief valve (A) from compressor. Clean, inspect or replace the valve as required.
3. Install relief valve (A) and tighten to specification.
Item
Measurement Specification
Compressor Relief Valve Torque
12—16 N˙m
(9—12 lb-ft)
4. Charge the system. See Evacuate Air Conditioning System and Charge Air Conditioning System in this
group.
Go to Section_90:Group_05
AG,OUO6045,1131-19-20000725
904
Flush Air Conditioning System
Flush Air Conditioning System
Add flushing solvent to system with JT02075 Air Conditioning Flusher and JT02098 Air Conditioning Fitting Kit.
1. Discharge refrigerant from air conditioning system (see Discharge and Recovery of Air Conditioning
Refrigerant in this group).
NOTE:
If compressor is being replaced, go to step 4.
2. Remove compressor and measure oil drained from both manifold ports.
3. Clean compressor as follows:
1. Pour 240 mL (8 fl oz) of TY16134 Air Conditioning System Flush into suction port and 120 mL
(4 fl oz) into discharge port. Plug both ports in compressor manifold, using JT02099 [ Included
in JT02098 Air Conditioning Fitting Kit ] and JT02100 [ Included in JT02098 Air Conditioning
Fitting Kit ] with JT03194 [ Included in JT02098 Air Conditioning Fitting Kit ] Caps.
2. Turn compressor end for end and roll compressor side to side.
3. Remove both plugs from manifold ports and drain solvent from compressor.
4. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move
solvent out of cylinders.
5. Invert compressor, roll to all sides, and drain thoroughly.
6. Let compressor sit inverted for three to five minutes.
7. Repeat previous two steps at least three times.
4. Remove and discard receiver-dryer.
5. Flushing can be performed on combine. Divide system into two circuits:
Condenser including inlet and outlet hoses (steps 6 to 13)
Evaporator including inlet and outlet hoses (steps 14 to 30)
Flush/Purge Condenser:
IMPORTANT:
DO NOT attempt to flush through compressor or receiver-dryer. Flushing through expansion valve or
orifice tube is acceptable if refrigerant oil has a normal odor and appearance.
6. Connect flusher outlet hose to inlet connection of compressor discharge line using JT02102 [ Included in
JT02098 Air Conditioning Fitting Kit ] Adapter to flush condenser.
7. Attach a return hose and aerator nozzle to receiver-dryer inlet line using JT03197 [ Included in JT02098
Air Conditioning Fitting Kit ] Adapter. Put nozzle in container to collect flushing solvent.
NOTE:
New solvent used in the parts cleaning
tank can be used, providing a final flush with
905
Flush Air Conditioning System
New solvent used in the parts cleaning tank can be used, providing a final flush with
TY16134 Air Conditioning System Flush is performed. Parts tank solvents will not
evaporate at temperatures below 60° C (140° F). Therefore, TY16134 is necessary for
the final flush because it evaporates at 30° C (85° F) and is easily removed when
evacuating the system.
8. Fill flusher tank with 4 L (1 gal) of solvent and fasten all connections.
NOTE:
Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging.
9. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve.
10. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing
stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal
particles.
11. Continue forcing air through system to purge out solvent. Purging the condenser circuit takes 10 - 12
minutes to thoroughly remove solvent.
12. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of
cardboard; continue purging until cardboard is dry.
13. Solvent from condenser can be used to flush evaporator if solvent is not contaminated with burnt oil or
metal particles. Used solvent should be put in shop parts cleaner.
Flush/Purge Evaporator:
14. Flush evaporator through expansion valve if oil appears normal.
15. Connect flusher outlet hose to compressor suction line using JT02101 [ Included in JT02098 Air
Conditioning Fitting Kit ] Adapter.
16. Attach a hose and aerator nozzle to receiver-dryer outlet line using JT03188 [ Included in JT02098 Air
Conditioning Fitting Kit ] Adapter. Put nozzle in container to collect flushing solvent.
17. Repeat Steps 8, 9 and 10 to flush evaporator.
18. Purging the evaporator circuit takes 12 - 15 minutes to thoroughly remove solvent.
19. If system is contaminated with burned refrigerant oil or debris, remove expansion valve to flush
evaporator.
20. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of
cardboard; continue purging until cardboard is dry.
21. Reinstall expansion valve.
Final Flush
22. Final flush uses the same procedure as primary flush for condenser and evaporator, except for solvent
used.
906
Flush Air Conditioning System
1. Add 1.9 L (0.5 gal) of Genesolv 2004 Flushing Solvent (TY16134) to the flusher tank.
IMPORTANT:
Genesolv 2004 Flushing Solvent (TY16134) evaporates at 30° C (85° F), to keep losses at a
minimum, keep container lids on at all times when not in use.
2. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve.
NOTE:
Air pressure must be at least 490 kPa (4.9 bar) (70 psi) but not more than 620
kPa (6.2 bar) (90 psi) maximum for final flushing and purging.
3. Open the air valve to force flushing solvent into the condenser or evaporator circuit. Flusher
tank is empty when hose pulsing stops. Reuse the same solvent to do both circuits.
NOTE:
Only one final flushing cycle is necessary, providing that another solvent was
used prior to the Final Flush.
4. After flushing the circuits with Genesolv 2004 Flushing Solvent (TY16134), continue to purge
with shop air through the flushing equipment.
5. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of
cardboard; continue purging until cardboard is dry.
6. After flushing both circuits, put used Genesolv 2004 in a separate, clean container and cap
immediately.
NOTE:
Identify the container as Genesolv 2004 Flushing Solvent (TY16134). This
solvent can be used to flush additional machines. When the solvent has an
excessive amount of dilution from the parts solvent used for the primary flush,
properly dispose of the solvent in compliance with local and state regulations.
7. Cap the system hoses or lines immediately after removal of service equipment to prevent
moisture from entering the system.
23. Install a new receiver-dryer compatible with R134a refrigerant. Fasten connections and mounting
brackets.
24. Add required quantity of oil (see Determine Correct Oil Charge in this group).
25. Install compressor and connect refrigerant lines to manifold.
26. Connect clutch coil wire and install drive belt.
27. Purge the air conditioning system (see Purge Air Conditioning System in this group).
907
Flush Air Conditioning System
Go to Section_90:Group_05
AG,OUO6030,141-19-20000725
908
Purge Air Conditioning System
Purge Air Conditioning System
IMPORTANT:
Air compressors used for purging systems require a water separator. Purging without a separator adds moisture,
creating hydrofluoric acid when combined with refrigerant oil. Acid is corrosive to metal tubing.
1. Connect dry nitrogen hose to center hose of manifold pressure gauge assembly.
2. Connect suction hose of manifold pressure gauge assembly to compressor suction port, and open
valves.
3. Connect discharge hose of manifold pressure gauge assembly to compressor discharge port, and open
valve. Disconnect discharge hose from manifold pressure gauge assembly to allow purging nitrogen to
atmosphere.
4. Open nitrogen tank valve and adjust regulator to 275 kPa (2.75 bar) (40 psi). Purge system for two
minutes. Disconnect nitrogen supply.
5. Evacuate the system. See Evacuate Air Conditioning System in this group.
Go to Section_90:Group_05
AG,OUO6030,142-19-20000725
909
Evacuate Air Conditioning System
Evacuate Air Conditioning System
TYK337-UN: Evacuate System
H55403-UN: Service Ports
LEGEND:
A - Low Side
B - High Side
C - Charging Hose
D - Vacuum Pump
E - Compressor
IMPORTANT:
DO NOT run compressor (E) while evacuating system.
910
Evacuate Air Conditioning System
Use only R134a Recovery and Recycling Stations JT02050 [ Used with JT02046 Charging Station. JT02047
Recovery, Recycling, and Charging Station can be substituted for JT02046 and JT02050. ] or vacuum pump (D)
when servicing a system charged with R134a.
Air conditioning system must be flushed and purged prior to evacuating.
1. Connect low side hose (blue) (A) from the manifold pressure gauge assembly to low-side service port.
2. Connect high side hose (red) (B) to the high side port.
3. Attach center charging hose (yellow) (C) to vacuum pump or to recovery and recycling station. Open
vacuum pump outlet port.
NOTE:
Pump must be capable of pulling at least 94.4 kPa (28.6 in. Hg) vacuum (sea level).
4. Start vacuum pump or recovery and recycling station (refer to station operator's manual for instructions).
5. Open both low and high side valves of manifold pressure gauge assembly.
6. Evacuate system until low-side gauge registers 94.4 kPa (28.6 in. Hg) vacuum or as close as possible
for a minimum of 30 minutes.
NOTE:
The perfect vacuum may not be achievable.
Vacuum specifications listed are for sea level conditions. Deduct 3.3 kPa (1 in. Hg) from
94.4 kPa (28.6 in. Hg) for each 300 m (1000 ft.) elevation above sea level.
7. If 94.4 kPa (28.6 in. Hg.) (as close as possible) vacuum cannot be reached in 30 minutes, or if the low
pressure gauge needle moves toward the atmospheric pressure side (gauge pressure 0), test system
for leaks and correct (go to step 11).
8. When a vacuum of 94.4 kPa (28.6 in. Hg.) (as close as possible) is reached, close low-side and highside valves Turn vacuum pump off.
9. If the vacuum does not decrease more than 3.3 kPa (1 in. Hg) in 5 minutes, the system is ready to be
charged with refrigerant.
NOTE:
If the vacuum decreases more than 3.3 kPa (1 in. Hg.) in 5 minutes, the system has a
leak. Go to step 11.
10. Charge the system.
11. If a leak is present, add 0.5 kg (1 lb) of R134a to system and use leak detector to locate leak. Correct
any leaks.
12. Remove refrigerant.
911
Evacuate Air Conditioning System
13. Start vacuum pump, open both high-side and low-side valves and evacuate system for at least 30
minutes after 94.4 kPa (28.6 in. Hg) vacuum is reached.
14. Close both high-side and low-side valves and stop vacuum pump.
15. If the vacuum does not decrease more than 3.3 kPa (1 in. Hg) in 5 minutes, the system is ready to be
charged with refrigerant.
NOTE:
If the vacuum decreases more than 3.3 kPa (1 in. Hg.) in 5 minutes, repeat steps 11
through 15 until all leaks are corrected.
16. Charge the system. (See Charge Air Conditioning System in this group.)
Go to Section_90:Group_05
OUO6435,00014BD-19-20010830
912
Compressor Oil Information
Compressor Oil Information
CAUTION:
All new compressors are charged with a mixture of nitrogen, R134a refrigerant and
TY22100 (R134a) compressor oil. Wear safety goggles.
A new compressor from parts depot contains 230 - 255 mL (7.7 - 8.5 fl oz) of new oil. The oil level visible through
the suction port is normally below the drive shaft. The amount of oil that cannot be drained is 81 mL (2.7 fl oz).
Approximately 60 mL (2.0 fl oz) will have seeped into the cylinders during shipping and storage.
Typically 21 mL (0.7 fl oz) of oil covers internal surfaces of the compressor exposed to refrigerant gas and cannot
be drained.
When 255 mL (8.5 fl oz) is installed in a dry compressor the oil level will be above the drive shaft.
The normal operating oil level of a compressor removed from operation is 30 - 45 mL (1.0 - 1.5 fl oz). This level
cannot be seen through the suction port of the compressor.
Go to Section_90:Group_05
HX,1401,9006,AN-19-20000725
913
Determine Correct Oil Charge
Determine Correct Oil Charge
Compressors can be divided into three categories when determining the correct oil charge for the system.
New compressor from parts depot
Used compressor removed from operation
Compressor internally washed with flushing solvent
Determine the amount of system oil charge prior to installation of compressor on a combine.
1. When the complete system, lines and components were flushed, add the correct amount of oil as shown
in the tables that follow.
2. When the complete system was not flushed, add the correct amount of oil for the compressor plus
amount of oil for each component that was serviced.
New compressor from parts depot, drain and return 50 mL (1.7 fl oz) of oil to the compressor.
Used compressor removed from operation and oil drained, add 45 mL (1.5 fl oz) of new oil.
Used compressor removed from operation, oil drained and flushed add 50 mL (1.7 fl oz) of new
oil.
NOTE:
Components listed below that have been removed, drained or flushed, require the removal of the
compressor to determine the correct oil charge. Use the following chart as a guide for adding oil
to components:
-: Determine Correct Oil Charge
Evaporator
40 ml (1.4 fl oz.)
Condenser
40 ml (1.4 fl oz.)
Receiver-Dryer 10 ml (0.35 fl oz.)
Compressor
50 ml (1.7 fl oz.)
-: Oil
A/C System Hose Lengths
Hose Routing
Length
Approximate
Oil Quantity Needed
Compressor-to- 1800 mm
Condenser
(5.9 ft)
17 ml (0.59 fl oz)
Condenser-toreceiver/dryer
55 ml (1.86 fl oz)
5655 mm
(18.6 ft)
Receiver/dryer-to- 1030 mm
evaporator
(3.4 ft)
10 ml (0.34 fl oz)
914
Determine Correct Oil Charge
A/C System Hose Lengths
Hose Routing
Length
Approximate
Oil Quantity Needed
Evaporator-tocompressor
1058 mm
10 ml (0.35 fl oz.)
(3.5 ft)
49 ml (1.64 fl oz)
5007 mm
(16.4 ft)
NOTE:
Hoses = 3 ml per 30 cm (0.1 fl oz per ft). Approximate total length equals 1.671 cm (54.8 ft).
If any section of hose is removed and flushed or replaced, use the table to determine the correct amount of oil to
be added.
If any component is removed because of damage, and/or leakage is evident, remove compressor and determine
amount of oil needed to bring system to full charge (see Check Refrigerant Oil Charge in this group).
IMPORTANT:
DO NOT leave the system or R134a compressor oil containers open. This oil easily absorbs moisture. Keep
R134a compressor oil away from acrylic or ABS plastics. Identify containers to eliminate accidental mixing of
different oils.
Go to Section_90:Group_05
OUO6435,00014BE-19-20100426
915
Check Refrigerant Oil Charge
Check Refrigerant Oil Charge
Remove compressor if R134a leakage was detected and repaired. See Remove and Install Compressor in this
group.
Drain oil from compressor and record amount.
NOTE:
Drain oil and save if this is a new compressor.
If the oil drained from a compressor removed from operation is very black or the amount of oil is less than 6 mL
(0.2 fl oz), perform the following:
1. Remove and discard the receiver-dryer.
2. Remove, clean and bench test the expansion valve, but do not disassemble the valve.
3. Flush the complete system with air conditioning flushing solvent.
4. Perform a volumetric efficiency test on compressor to determine serviceable condition. If the compressor
is serviceable, pour flushing solvent in the manifold ports and internally wash out the old oil.
5. Install a new receiver-dryer.
6. Add 60 mL (2.0 fl oz) of TY22100 compressor oil to the compressor.
7. Connect all components, evacuate and charge the system.
Go to Section_90:Group_05
AG,OUO6030,114-19-20000725
916
Charge Air Conditioning System
Charge Air Conditioning System
1. Evacuate the system (see Evacuate Air Conditioning System in this group).
2. IMPORTANT:
Use only R134a Refrigerant Recovery, Recycling and Charging Stations. Eliminate mixing R134a
equipment, refrigerant and refrigerant oils with R12 systems to prevent compressor damage.
Use a JT02046 HFC134a Refrigerant Charging Station to charge the system.
NOTE:
Used with JT02050 Recovery and Recycling Station. JT02047 Recovery, Recycling and
Charging Station can be substituted for JT02046 and JT02050.
3. Connect low-side hose (blue) from the charging unit to suction hose fitting on the compressor. Connect
high-side hose (red) to the pressure hose fitting on the condenser.
4. IMPORTANT:
Before beginning to charge air conditioning system, the following conditions must exist:
Engine stopped
System holding a vacuum of at least 94.4 kPa (28.6 in. Hg), less 3.3 kPa (1 in. Hg) from 94.4
kPa (28.6 in. Hg) for each 300 m (1000 ft) elevation above sea level.
Follow the manufacturer's instructions and charge the system.
5. Add R134a refrigerant until system is charged with 1.81—2,0 kg (4—4.5 lb). Check the sight glass to be
sure no bubbles appear.
6. Check ambient temperature, cab temperature and system pressures (see relevant Diagnostic Manual,
Section 290).
Go to Section_90:Group_05
OUO6089,000007B-19-20010730
917
Leak Testing Procedure
Leak Testing Procedure
See Diagnosis and Test Manual for procedures to leak test the system. Two methods are detailed: Leak testing
using an electronic leak detector and leak testing using dye.
Go to Section_90:Group_05
OUO6089,000007C-19-20010730
918
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
HFC134A Recovery/Recycling Station .......JT02050 [
Used with JT02046 Charging Station. JT02047
Recovery, Recycling, and Charging Station can be
substituted for JT02046 and JT02050. ]
Servicing air conditioning system using R134a
refrigerant.
RW21613-UN: Recovery and Recycling Station
Go to Section_90:Group_10
ZX09263,0002743-19-20080201
919
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
HFC134A Recovery/Recycling Station .......JT02050 [
Used with JT02046 Charging Station. JT02047
Recovery, Recycling, and Charging Station can be
substituted for JT02046 and JT02050. ]
Servicing air conditioning system using R134a
refrigerant.
RW21613-UN: Recovery and Recycling Station
Go to Section_90:Group_10
ZX09263,0002743-19-20080201
920
Other Material
Other Material
Number
Name
TY15949 (U.S.) Refrigerant 134A
Use
Purge and charge system.
TY22100 (U.S.) 525 Viscosity Compressor Oil Replace oil lost during condenser removal and repair.
Go to Section_90:Group_10
HX,90,CH12-19-20000725
921
Remove and Install Receiver/Dryer
Remove and Install Receiver/Dryer
H55407-UN: Receiver-Dryer
LEGEND:
A - Line
B - Line
C - Clamp (2 used)
1. Recover refrigerant from the system (see procedure in group 05).
2. Disconnect lines (A and B). Plug lines to keep dirt out.
3. Loosen clamps (C) and remove receiver/dryer.
4. IMPORTANT:
Replace receiver/dryer as often as required to prevent moisture from contaminating the system. Always
install a new receiver/dryer when the system is opened up for service, or when the compressor shaft
seal leaks. Be sure to keep the new receiver/dryer capped until installing. Install receiver/dryer last.
Install new receiver/dryer and clamps (C).
5. Connect lines (A and B).
6. Check and add compressor oil (see Compressor Oil Information in Group 05).
7. Evacuate and charge the system (see procedures in group 05).
Go to Section_90:Group_10
OUO6046,0001585-19-20010809
922
Replace Blower Motor
Replace Blower Motor
H55566-UN: Blower Motor Cover
H55567-UN: Blower Motor
LEGEND:
A - Cap Screw (5 used)
B - Connector
C - Cover
D - Motor
1. Remove eight screws and lift out instructional seat and cover.
2. Remove screws (A).
3. Disconnect wire (B) and remove cover (C).
4. Remove motor (D).
5.
NOTE:
The motor cannot be repaired; it must be replaced.
Replace a cracked fan. Note direction of fan fins and remove fan from old motor and install on new
motor.
6. Install motor (D) and cover (C) using cap screws (A).
7. Connect wire (B).
8. Install instructional seat and cover using eight screws.
923
Replace Blower Motor
Go to Section_90:Group_10
AG,OUO6030,125-19-20000725
924
Replace Recirculator Motor Drive Module
Replace Recirculator Motor Drive Module
H55582-UN: Recirculator Motor Drive Module
LEGEND:
A - Connector
B - Connector
C - Screw (3 used)
D - Module
1. Remove eight screws and lift out instructional seat and cover.
2. Disconnect wires (A) and (B).
3. Remove screws (C) and module (D).
4. Inspect parts. Replace as necessary.
5. Install module (D) using screws (C).
6. Connect wires (A) and (B).
7. Install instructional seat and cover using eight screws.
Go to Section_90:Group_10
AG,OUO6030,127-19-20000725
925
Replace Heater Valve
Replace Heater Valve
1.
CAUTION:
Coolant may be hot. Wait until radiator is cool to the touch before replacing
heater valve.
T6642EK-UN: Safety
H55584-UN: Heater Control Servo Actuator
H55592-UN: Heater Valve
926
Replace Heater Valve
H55607-UN: Heater Valve
LEGEND:
A - Wiring Harness
B - Cap Screw (3 used)
C - Servo Actuator
D - Screw
E - Adapter
F - Flange Nut (2 used)
G - Mounting Plate
H - Cap Screw (2 used)
I - Hose (2 used)
J - Valve
Remove eight screws and lift out instructional seat and cover.
2. Disconnect harness (A).
3. Remove cap screws (B) and servo actuator (C).
4. Remove screw (D) and adapter (E).
5. Remove flange nuts (F).
6. Remove cap screws (H) and mounting plate (G).
7. Clamp off inlet and outlet hoses (I).
8.
NOTE:
Some coolant may be present when heater hoses are disconnected.
Disconnect hoses and remove valve (J).
9. Connect inlet and outlet hoses (I) to new valve (J) and remove clamps.
10. Attach mounting plate (G) to valve (J) with cap screws (H) and install using flange nuts (F).
11. Install adapter (E) using screw (D).
12. Install servo actuator (C) using cap screws (B).
13. Connect harness (A).
927
Replace Heater Valve
14. Run engine, check coolant level and watch for leaks. Add coolant as necessary.
15. Install instructional seat and cover using eight screws.
Go to Section_90:Group_10
AG,OUO6030,128-19-20000725
928
Remove Condenser
Remove Condenser
1.
H63893-UN: Lines
H63898-UN: Cap Screw
LEGEND:
A - Line (2 used)
B - Cap Screw
Recover refrigerant from system. See Discharge and Recovery of Air Conditioning Refrigerant in Group
05.
2. Open rotary screen door.
3.
NOTE:
Cap and plug all lines and fittings to prevent system contamination.
Disconnect lines (A).
4. Loosen cap screw (B) and remove spacer washers.
5. Tighten cap screw (B) making sure it is aligned in pivot hole.
929
Remove Condenser
6.
H63894-UN: Cooler
H63899-UN: Swivel
LEGEND:
A - Nut
B - Lower Pivot
Install nut (A) on cap screw and tighten nut until lower pivot (B) is clear of lower frame.
7. Tie the other end of cooler assembly to the top channel of cooling package housing.
8.
H63892-UN: Cap Screw
LEGEND:
A - Cap Screw (5 used)
Remove cap screws (A) and condenser.
930
Remove Condenser
Go to Section_90:Group_10
HX,1401,9010,BA-19-20000725
931
Repair Condenser
Repair Condenser
1. If contamination appears in the condenser, flush entire system.
2. Inspect condenser. Fins must be straight and clean.
3. Cap outlet and install a Schrader type service valve in inlet.
4. Place refrigerant container in a pail of water heated to a maximum of 51.5 °C (125 °F), which gives a
pressure of 12 bar (170 psi).
5. Connect refrigerant supply to the Schrader-type valve.
6. Open refrigerant container valve and test condenser for leaks with a leak detector. If the condenser
leaks, replace it.
7. Plug or cap openings until ready to install.
Go to Section_90:Group_10
1401,9010,I-19-20000725
932
Install Condenser
Install Condenser
1.
ZX25239-UN: Cap Screw
H63908-UN: Cap Screw
LEGEND:
A - Cap Screw
B - Cap Screw (5 used)
Position condenser in cooler frame and install cap screws (B).
2. Align lower pivot in frame, tip the top in and install cap screw (A).
3. If the condenser was repaired or replaced with a new one, pour 30 mL (1.0 fl oz) of oil into condenser. If
there were any major leaks in the system, refer to Add Refrigerant Oil to System in Group 05.
4.
NOTE:
Always install new O-rings on A/C lines anytime they are removed.
933
Install Condenser
H68191-UN: Lines
LEGEND:
A - Line (2 used)
Connect lines (A).
5. Use torque chart in Section 10, Group 15 for tightening connections on pipes and hoses.
6.
H68190-UN: Hose
LEGEND:
A - Clamp (2 used)
B - Hose (2 used)
Install fuel cooler hoses (B) and tighten clamps (A).
7.
H63905-UN: Door
934
Install Condenser
H63904-UN: Pins
H63915-UN: Sheave
LEGEND:
A - Cap Screw
B - Sheave
C - Spring Pin (2 used)
D - Pin (2 used)
Position rotary screen door and install pins (D) and spring pins (C).
8. Install sheave (B) using cap screw (A).
9.
H63903-UN: Belt
LEGEND:
A - Drive Belt
Install rotary screen drive belt (A).
935
Install Condenser
10. Evacuate and charge the system (see procedures in group 05).
11. Perform an operational test.
Go to Section_90:Group_10
OUO6089,0000062-19-20010706
936
Replace Evaporator
Replace Evaporator
H72755-UN: Evaporator Cover
H72756-UN: Evaporator
LEGEND:
A - Wiring Harness (2 used)
B - Cap Screw (6 used)
C - Cover
D - Wiring Harness
E - Wiring Harness
F - Lines
G - Heater Hose (2 used)
H - Evaporator
1. IMPORTANT:
Water build up in evaporator case may be caused by a plugged drain hose. Clean weep valve and drain
hose as needed.
Install manifold pressure gauge assembly and recover refrigerant from system (see Discharge and
Recovery of Air Conditioning Refrigerant in Group 05).
2. Remove eight screws and lift out instructional seat and cover.
3. Disconnect harnesses (A).
937
Replace Evaporator
4. Remove cap screws (B) and cover (C).
5. Disconnect harnesses (D and E).
6. Disconnect lines (F) and heater hoses (G).
7. Remove evaporator (H).
8. Install new evaporator (H).
9. Connect heater hoses (G) and lines (F).
10. Connect harnesses (D and E).
11. Install cover (C) using cap screws (B).
12. Install harnesses (A).
13. Install instructional seat and cover. Attach using eight screws.
14. Charge the system (see procedure in Group 05).
Go to Section_90:Group_10
OUO6083,00002EF-19-20020702
938
Remove and Install Evaporator Temperature Sensor
Remove and Install Evaporator Temperature Sensor
H72755-UN: Evaporator Cover
H72757-UN: Evaporator Temperature Sensor
LEGEND:
A - Wiring Harness (2 used)
B - Cap Screw (6 used)
C - Cover
D - Wiring Harness
E - Evaporator Temperature Sensor
1. Remove eight screws and lift out instructional seat and cover.
2. Disconnect harnesses (A).
3. Remove cap screws (B) and cover (C).
4. Disconnect harness (D).
5. Remove temperature sensor (E) from evaporator.
6. Install temperature sensor (E) and connect harness (D).
7. Install cover (C) using cap screws (B).
8. Connect harnesses (A).
939
Remove and Install Evaporator Temperature Sensor
9. Install instructional seat and cover. Attach using eight screws.
Go to Section_90:Group_10
OUO6083,00002F0-19-20020702
940
Replace Low Pressure Switch
Replace Low Pressure Switch
H55674-UN: Low Pressure Switch
LEGEND:
A - Wiring Harness
B - Low Pressure Switch
1. Install manifold pressure gauge assembly and recover refrigerant from system (see Discharge and
Recovery of Air Conditioning Refrigerant in Group 05).
2. Disconnect harness (A).
3. Remove low pressure switch (B).
4. Install low pressure switch (B).
5. Connect harness (A).
6. Charge the system (see procedure in Group 05).
Go to Section_90:Group_10
AG,OUO6030,131-19-20000725
941
Replace High Pressure Switch
Replace High Pressure Switch
H68193-UN: High Pressure Switch
LEGEND:
A - Connector
B - High Pressure Switch
1. Install manifold pressure gauge assembly and recover refrigerant from system (see Discharge and
Recovery of Air Conditioning Refrigerant in Group 05).
2. Disconnect connector (A).
3. Remove high pressure switch (B).
4. Install high pressure switch (B).
5. Connect connector (A).
6. Evacuate and charge the system (see procedures in group 05).
Go to Section_90:Group_10
AG,OUO6030,132-19-20000725
942
Replace Air Temperature Sensors
Replace Air Temperature Sensors
H72713-UN: Air Temperature Sensors
LEGEND:
A - Wiring Harness
B - Inlet Air Temperature Sensor
C - Rubber Grommet
D - Wiring Harness
E - Cab Air Temperature Sensor
F - Mounting Bracket
G - Wiring Harness
H - Outlet Air Temperature Sensor
I - Rubber Grommet
1. Remove eight screws and lift out instructional seat and cover.
2. Remove harness (A) and inlet air temperature sensor (B) from rubber grommet (C).
3. Install new sensor in rubber grommet (C) and connect harness (A).
4. Disconnect harness (D) and cab air temperature sensor (E) from mounting bracket (F).
5. Install new sensor in mounting bracket (F) and connect harness (D).
6. Disconnect harness (G) and outlet air temperature sensor (H) from rubber grommet (I).
7. Install new sensor in rubber grommet (I) and connect harness (G).
8. Install instructional seat and cover using eight screws.
Go to Section_90:Group_10
OUO6435,00017C7-19-20020627
943
Specifications
Specifications
Item
Measurement
Windshield Clamps
Approximate Spacing 600 mm
(24 in.)
Radiator
Approximate Capacity 38 L
(40 qt)
Operator's Seat
Weight
29 kg
(65 lb)
Seat Nuts
Torque
15 N˙m
(133 lb-in.)
Cab
Weight
578 kg
(1275 lb)
Door Latch Striker Bolt
Torque
80 N˙m
(60 lb-ft)
Striker Plate Hex. Socket Screws Torque
72 N˙m
(53 lb-ft)
Cab Door Cap Screws
20 N˙m
(177 lb-in.)
Torque
Specification
Go to Section_90:Group_15
OUO6435,0001900-19-20020903
944
Specifications
Specifications
Item
Measurement
Windshield Clamps
Approximate Spacing 600 mm
(24 in.)
Radiator
Approximate Capacity 38 L
(40 qt)
Operator's Seat
Weight
29 kg
(65 lb)
Seat Nuts
Torque
15 N˙m
(133 lb-in.)
Cab
Weight
578 kg
(1275 lb)
Door Latch Striker Bolt
Torque
80 N˙m
(60 lb-ft)
Striker Plate Hex. Socket Screws Torque
72 N˙m
(53 lb-ft)
Cab Door Cap Screws
20 N˙m
(177 lb-in.)
Torque
Specification
Go to Section_90:Group_15
OUO6435,0001900-19-20020903
945
Remove and Install Cab Windshield
Remove and Install Cab Windshield
ZX25237-UN: Windshield
Do not attempt to install a replacement windshield unless you are qualified in glass replacement.
The original factory adhesive used to bond the windshield in place is a urethane type. When installing this glass,
use an adhesive method that is compatible with urethane adhesive. These types of adhesive ARE NOT available
from John Deere.
Refer to the manufacturer's adhesive/primer label and the SAFETY DATA SHEET for safety precautions.
Curing time of this type adhesive is dependent on weather conditions (heat and humidity). After installing this
glass, it is recommended not to operate the combine during the cure time. However, if it is necessary to operate
the combine, for the first 48 hours use caution to avoid bumps and shock loads, such as when crossing a border,
etc.
1. Raise feeder house all the way and lower safety stop. The feeder house will be used as a work platform.
2.
NOTE:
Make sure wipers are in the parked position before starting removal procedures.
H63271-UN: Sun Visor
LEGEND:
A - Cap Screw (3 used)
B - Sun Visor
Remove cap screws (A) and sun visor (B).
946
Remove and Install Cab Windshield
3.
H63270-UN: Front Cab Headliner
LEGEND:
A - Tab (5 used)
B - Headliner
Remove front headliner (A) from cab by pulling back and down on front edge of headliner to clear tabs
(B).
4.
ZX25236-UN: Cab
LEGEND:
A - Wiper Blades
B - Wiper Motor Mounting
C - Screw (12 used)
Remove wiper blades (A) and wiper motor mounting (B).
5. From inside cab, remove wiper motor.
6. Remove upper panel screws (C). Pull out panel and disconnect headlights by disconnecting harness
connector from light bulb.
7. Disconnect windshield washer hoses, if equipped, and remove upper panel.
947
Remove and Install Cab Windshield
8.
ZX25123-UN: Cab
LEGEND:
A - Cap Screw (3 used)
Remove cap screws (A) and lower cab panel.
9.
NOTE:
The H128392 clips in the windshield kit will be required for the purpose of installing and
securing the windshield during adhesive cure time of 2.5 hours.
H40068-UN: Windshield
LEGEND:
A - Area for Adhesive
B - Clamp
C - Clamp Placement
D - Clamp Leg
Completely remove all of old windshield glass. Also remove the two old clamps from head panel (two
new clamps (B) are supplied with the glass). Try to leave a layer of the old adhesive on the frame.
948
Remove and Install Cab Windshield
However, if you remove all of the old adhesive, leaving bare metal, use the correct primer to ensure a
good bond between metal and adhesive.
10. Apply a thin coat of adhesive to area (A) on both clamps (B) provided.
11. Slip clamps (B) on windshield as specified (C).
Item
Measurement
Specification
Windshield Clamps Approximate Spacing 600 mm
(24 in.)
12. Bend leg (D) up on both clamps.
13. IMPORTANT:
Edges of glass on both sides must not contact cab frame.
949
Remove and Install Cab Windshield
H67759-UN: Windshield
LEGEND:
A - Bracket
B - Head Panel
C - Clamps on Cab Floor
D - Shims
E - Clamp Leg
Apply adhesive to cab frame and position new glass by pushing it up until the two new brackets (A)
contact the head panel (B).
14. Tighten two clamps attached to cab floor (C).
15. Use non-metallic shims (D) to hold glass in place.
16. Bend leg (E) up on both clamps to secure glass.
17. Tape sides of glass with duct tape to hold glass in position.
18. Install all parts.
19. Remove tape after 48 hours.
Go to Section_90:Group_15
OUO6089,000005D-19-20010705
950
Remove Cab
Remove Cab
1.
H58346-UN: Receiver-Dryer
LEGEND:
A - Nut
B - Clamp
C - Line (2 used)
Discharge air conditioning refrigerant (see procedure in Group 05).
2. Remove nut (A) and clamp (B).
3.
NOTE:
Cap all lines to prevent system contamination
Disconnect air conditioning lines (C).
4.
CAUTION:
Coolant may be hot. Wait until radiator is cool to the touch before draining
coolant.
Drain coolant into an approved container.
951
Remove Cab
5.
H67905-UN: Lower Cab Panel
LEGEND:
A - Cap Screw (3 used)
Remove cap screws (A) and lower cab panel.
6.
H67994-UN: Cab Connectors
H67995-UN: Heater Hoses
LEGEND:
A - Connector (2 used)
B - Bracket
C - Heater Hose (2 used)
Disconnect wiring harness connectors (A).
7. Remove bracket (B) under cab wall plate.
952
Remove Cab
8. Disconnect and drain heater hoses (C).
9.
H58589-UN: Brake Lines
H67996-UN: Brake Line Clamp
LEGEND:
A - Brake Line (3 used)
B - Clamp (3 used)
Disconnect three lines (A) at brake master cylinder.
10. Remove clamps (B) securing lines to cab floor.
11.
H68005-UN: Steering Metering Pump
LEGEND:
953
Remove Cab
A - Cable (2 used)
B - Balancer
C - Oil Line (4 used)
Disconnect park brake cables (A) and assembly (B).
12. Disconnect and cap oil lines (C) at steering valve.
13.
H67997-UN: Reverser Linkage
H67998-UN: Reverser Cable Mounting
LEGEND:
A - Cotter Pin
B - Pin
C - Nut
D - Cable
Remove cotter pin (A) and pin (B).
14. Remove nut (C) and reverser cable (D) from bracket.
954
Remove Cab
15.
H67999-UN: Shift Lever Linkage
LEGEND:
A - Ball Joint
B - Cap Screws
C - Clamp
Disconnect shifter cable ball joint (A) and remove cap screws (B) and clamp (C).
16.
H68002-UN: Ground Strap
LEGEND:
A - Nut
B - Ground Strap
Remove nut (A) and ground strap (B).
17.
H68001-UN: Connector
955
Remove Cab
H68000-UN: Evaporator Drain Tube
LEGEND:
A - Connector
B - Evaporator Drain Tube
Disconnect harness connector (A).
18. Disconnect evaporator drain tube (B).
19.
H58575-UN: Hydrostatic Control Cable
H68003-UN: Hydrostatic Control Cable Mount
956
Remove Cab
H68004-UN: Hydrostatic Control Cable Mount
LEGEND:
A - Nut
B - Nut and Washer
C - Hydrostatic Control Cable
D - Bracket
E - Clamp (2 used)
Remove nuts (A and B).
20. Remove hydrostatic control cable (C) from bracket (D).
21. Remove clamps (E) securing hydrostatic control cable (C) to combine.
22.
H58552-UN: Windshield Washer Line
LEGEND:
A - Windshield Washer Line
Disconnect windshield washer line (A) at left upper rear corner of cab.
23.
CAUTION:
The approximate weight of cab is 578 kg (1275 lb).
Item Measurement Specification
Cab Weight
578 kg
(1275 lb)
957
Remove Cab
H40452-UN: Cab Lifting Brackets
LEGEND:
A - Lifting Brackets at Rear of Cab
B - Lifting Brackets at Cab Roof
Attach lifting brackets at rear of cab (A) and cab roof (B) on both sides. Attach hoist to brackets.
24.
H55773-UN: Cap Screws on Rear Cab Mountings
LEGEND:
A - Cap Screw (2 used)
Remove cap screws (A).
25. IMPORTANT:
Windshield can be broken if cab door is not securely closed and latched prior to removing cab.
Remove cab.
26. Inspect all parts. Repair or replace as necessary.
Go to Section_90:Group_15
OUO6435,00018AB-19-20020820
958
Install Cab
Install Cab
1.
CAUTION:
The approximate weight of cab is 578 kg (1275 lb).
Item Measurement Specification
Cab Weight
578 kg
(1275 lb)
IMPORTANT:
Windshield can be broken if cab door is not securely closed and latched prior to installing cab.
With hoist, carefully lift cab into position.
2.
H55773-UN: Rear Cab Mounting Screws
LEGEND:
A - Cap Screw (2 used)
Install cap screws (A).
3.
H58552-UN: Windshield Washer Line
LEGEND:
A - Windshield Washer Line
Connect windshield washer line (A) at left upper rear cab corner.
959
Install Cab
4.
H58575-UN: Hydrostatic Control Cable
H68003-UN: Hydrostatic Control Cable Mount
H68004-UN: Hydrostatic Control Cable Mount
LEGEND:
A - Nut
B - Nut and Washer
C - Hydrostatic Control Cable
D - Bracket
E - Clamp (4 used)
Install hydrostatic control cable (C) through bracket (D) using nut and washer (B). Attach cable to pump
lever using nut (A).
5. Attach hydrostatic control cable (C) to combine in four places using clamps (E).
960
Install Cab
6.
H68001-UN: Connector
H68000-UN: Evaporator Drain Tube
LEGEND:
A - Connector
B - Evaporator Drain Tube
Connect harness connector (A).
7. Connect evaporator drain tube (B).
8.
H68002-UN: Ground Strap
LEGEND:
A - Nut
B - Ground Strap
Install ground strap (B), cap screw, and nut (A).
961
Install Cab
9.
H67999-UN: Shift Lever
LEGEND:
A - Ball Joint
B - Cap Screws
C - Clamp
Install shifter cable ball joint (A) and clamp (C) using cap screws (B).
10.
H67997-UN: Linkage
H67998-UN: Cable
LEGEND:
A - Cotter Pin
B - Pin
C - Nut
D - Reverser Cable
Install reverser cable (D) using nut (C).
11. Install reverser linkage to arm using pin (B) and cotter pin (A).
962
Install Cab
12.
H68005-UN: Metering Pump
LEGEND:
A - Cables (2 used)
B - Balancer
C - Oil Line (4 used)
Connect park brake balancer (B) and cables (A). Adjust park brake pedal (see Adjust Park Brake Pedal
in Section 60, Group 10).
13. Remove caps and connect oil lines (C) to steering valve.
14. IMPORTANT:
Brake lines use O-ring seal fittings. When replacing fitting O-rings, use white TEFLON O-rings that will
not be damaged by brake fluid.
H58589-UN: Brake Lines
963
Install Cab
H67996-UN: Brake Line Clamp
LEGEND:
A - Brake Line (3 used)
B - Clamp (3 used)
Connect three lines (A) at brake master cylinders and attach to cab floor using clamps (B). Bleed the
brakes (see Bleed Brake System - Double Bleed Screw in Section 60, Group 10.)
15.
H67994-UN: Cab Connectors
H67995-UN: Heater Hoses
LEGEND:
A - Cab Connectors
B - Bracket
C - Heater Hose (2 used)
Connect harness connectors (A) and install bracket (B).
16. Connect heater hoses (C).
964
Install Cab
17. Fill radiator with recommended coolant (see Fuels and Lubricants in Section 10, Group 25).
18.
H67905-UN: Lower Cab Panel
LEGEND:
A - Cap Screw
Install lower cab panel using cap screws (A).
19.
H58346-UN: Receiver-Dryer
LEGEND:
A - Nut
B - Clamp
C - Line (2 used)
Connect air conditioning lines (C) and install clamp (B) and nut (A).
20. Charge the air conditioning system (see instructions in Group 10).
21. Adjust hydrostatic control cable. See Adjust Hydrostatic Control Linkage in Section 50, Group 15.
Go to Section_90:Group_15
OUO6435,00018AA-19-20020820
965
Replace Rear Window
Replace Rear Window
Do not attempt to install replacement window (A) unless you are qualified in glass replacement.
The original factory adhesive used to bond the window in place is a urethane type. When installing this glass, use
an adhesive method that is compatible with urethane adhesive. These types of adhesive ARE NOT available from
John Deere.
Refer to the manufacturer's adhesive/primer label and the SAFETY DATA SHEET for safety precautions.
Curing time of this type adhesive is dependent on weather conditions (heat and humidity). After installing this
glass, it is recommended not to operate the combine during the cure time. However, if it is necessary to operate
the combine, for the first 48 hours use caution to avoid bumps and shock loads, such as when crossing a border,
etc.
Go to Section_90:Group_15
HX,1401,9020,M-19-20000725
966
Remove and Install Cab Roof
Remove and Install Cab Roof
H58626-UN: Headliner
LEGEND:
A - Front Cab Headliner
B - Overhead Control Panel
C - Rear Cab Headliner
D - Dome Light
E - Speaker (2 used)
F - Screw (6 used)
G - Coat Hook
1. Push up and pull back on forward edge of front headliner (A) to release from clips. Remove headliner.
2. Remove rear window trim.
3. Remove coat hook (G).
4.
NOTE:
The rear headliner has one mounting screw that is hidden underneath the cab door
weather-strip seal.
Push up on back edge of rear headliner (C) to release, and pull rear headliner back to remove.
5. Remove screws (F) and lower overhead control panel (B).
6. Disconnect the following:
Radio Antenna Coupler
Radio Connector
Wiper Motor Connector
VISIONTRAK Performance Monitor Connector
Warning Display Panel Connector
Wiper Switch Connector
Light Switch Connector
Panel Lights Dimmer Connector
Auxiliary Field Light Switch Connector
7. Remove speakers (E) on both sides of cab.
8. Disassemble and remove dome light (D) so that harness can be pulled out.
967
Remove and Install Cab Roof
9.
NOTE:
It may be necessary to remove the grain tank window to gain access to cab exterior aft
trim panel hardware.
H67758-UN: Roof
LEGEND:
A - Eyebolt (2 used)
B - Cap Screw (2 used)
C - Washer (2 used)
D - Seal Washer (2 used)
E - Antenna
968
Remove and Install Cab Roof
F - Screw (27 used)
G - Cover
H - Cover (2 used)
I - Cover
J - Cap Screw (4 used)
K - Mounting Frame of Overhead Control Panel
L - Cap Screw (4 used)
M - Bonding Cable (2 used)
N - Cover
O - Nut (4 used)
P - Roof
Remove screws (F), covers (G), (H) and (I).
10. Remove cap screws (L) and bonding cables (M) to remove overhead control panel.
11. Remove cap screws (J) and overhead control panel mounting frame (K).
12. Remove nuts (O) to loosen roof (P).
13. Remove cap screws (B) and replace with eyebolts (A).
14. Partially remove staples that secure headliner at dome light mount area. Pull dome light wiring harness
to right side of cable.
15. Connect lifting device to eyebolts (A) and remove roof (P).
16. Inspect parts. Repair or replace as necessary.
17. Install roof (P). Remove eyebolts (A) and replace with cap screws (B). Tighten nuts (O).
18. Insert dome light wiring harness into headliner until harness connectors are accessible at dome light
mount area. Install headliner in cab roof.
19. Install parts (B - N) as shown.
20.
H58626-UN: Headliner
LEGEND:
A - Front Cab Headliner
B - Overhead Control Panel
C - Rear Cab Headliner
969
Remove and Install Cab Roof
D - Dome Light
E - Speaker (2 used)
F - Screw (6 used)
G - Coat Hook
Install speakers (E) on both sides of cab.
21. Assemble and install dome light (D).
22. Connect the following:
Radio Antenna Connector
Radio Connector
Wiper Motor Connector
VISIONTRAK Performance Monitor Connector
Warning Display Panel Connector
Wiper Switch Connector
Light Switch Connector
Panel Lights Dimmer Connector
Auxiliary Field Light Switch Connector
23. Install rear headliner (C).
24. Install coat hook (G).
25. Install rear window trim.
26. Position overhead control panel (B) into headliner and install screws (F).
27. Install front headliner (A).
Go to Section_90:Group_15
OUO6089,0000063-19-20010706
970
Remove and Install Operator's Seat
Remove and Install Operator's Seat
1.
H57413-UN: CommandTouch ™ Console
LEGEND:
A - Armrest
B - Compartment Lid
Open compartment lid (B) on armrest (A).
2.
H57414-UN: Screws
LEGEND:
A - Cap Screw (4 used)
Remove cap screws (A).
3.
H57419-UN: Drive Control Cable
LEGEND:
A - Hydrostatic Control Cable
971
Remove and Install Operator's Seat
Disconnect hydrostatic control cable (A).
4. Lift off armrest control panel.
5.
H57418-UN: Control Cable
LEGEND:
A - Hydrostatic Control Cable
Disconnect cable (A) from bracket.
6.
H57415-UN: Electrical Connections
LEGEND:
A - Connector (2 used)
Disconnect harness connectors (A) behind seat.
7.
CAUTION:
Approximate weight of the operator's seat is 29 kg (65 lb).
Item
Measurement Specification
Operator's Seat Weight
29 kg
(65 lb)
972
Remove and Install Operator's Seat
H57416-UN: Nuts
H57417-UN: Nuts
LEGEND:
A - Nut (4 used)
Remove four nuts (A) to remove seat assembly.
8.
CAUTION:
Approximate weight of the operator's seat is 29 kg (65 lb).
Item
Measurement Specification
Operator's Seat Weight
29 kg
(65 lb)
H57416-UN: Nuts
973
Remove and Install Operator's Seat
H57417-UN: Nuts
LEGEND:
A - Nut (4 used)
Install seat assembly using four nuts (A). Tighten nuts to specified torque.
Item
Measurement Specification
Seat Nuts Torque
15 N˙m
(133 lb-in.)
9.
H57415-UN: Electrical Connections
LEGEND:
A - Connector (2 used)
Connect harness connectors (A).
10.
H57418-UN: Control Cable
LEGEND:
974
Remove and Install Operator's Seat
A - Hydrostatic Control Cable
Connect cable (A) to bracket.
11. Install armrest control panel.
12.
H57419-UN: Drive Control Cable
LEGEND:
A - Hydrostatic Control Cable
Connect hydrostatic control cable (A).
13.
H57414-UN: Screws
LEGEND:
A - Cap Screw (4 used)
Attach armrest using cap screws (A).
Go to Section_90:Group_15
AG,OUO6045,56-19-20000725
975
Remove and Install Operator Presence Switch
Remove and Install Operator Presence Switch
1.
H68721-UN: Connector
LEGEND:
A - Connector
Disconnect electrical connector (A), located below right armrest.
2.
H68722-UN: Seat Cushion
LEGEND:
A - Screw (3 used)
B - Seat Cushion
Remove screws (A) and lift out seat cushion (B).
3.
H68723-UN: Switch Mounting
LEGEND:
A - Rivets (4 used)
976
Remove and Install Operator Presence Switch
B - Reed Switch
C - Actuator
Remove two rivets (A) and pull switch (B) through seat frame.
4. Install new switch (B) and actuator (C) as needed.
5.
H68721-UN: Connector
Reinstall seat and connect wiring harness (A).
6. To test the switch after installation, sit in the seat, turn the ignition on and engage separator and header.
Overhead panel lights will come on for low shaft speed. Raise up off of seat. In five seconds the
overhead lights will go off if the switch is working correctly.
Go to Section_90:Group_15
OUO6083,000009D-19-20010614
977
Operator's Seat - Exploded View
Operator's Seat - Exploded View
H68823-UN: Operator's Seat - Exploded View
LEGEND:
A - Back Cushion
B - Seat Cushion
C - Armrest
D - Reed Switch
E - Actuator
F - Plate
G - Support
H - Seat Belt Latch
978
Operator's Seat - Exploded View
I - Seat Belt
J - Base
K - Spring
L - Spring
Go to Section_90:Group_15
OUO6083,000009F-19-20010614
979
Operator's Seat Air Suspension Assembly - Exploded View
Operator's Seat Air Suspension Assembly - Exploded View
H68824-UN: Operator's Seat Air Suspension Assembly
LEGEND:
A - Lower Housing
B - Compressor
C - Air Line
D - Wiring Harness
E - Boot
F - Air Spring
G - Seat Rocker
H - Shock Absorber
980
Operator's Seat Air Suspension Assembly - Exploded View
I - Rail (2 used)
J - Height Adjustment Control
K - Upper Housing
L - Isolator
M - Firmness Control
N - Plate
O - Cover
Go to Section_90:Group_15
OUO6083,00000AA-19-20010622
981
Disassemble and Assemble Operator's Seat Air Suspension Assembly
Disassemble and Assemble Operator's Seat Air Suspension Assembly
1.
H72740-UN: Lower Seat Assembly
H72735-UN: Wooden Blocks
LEGEND:
A - Plastic Cover
B - Plastic Cover
C - Wooden Blocks (2 used)
Remove the operator's seat. (See procedure in this group.)
2. Remove adjusting rails.
3. Remove rubber boot and plastic covers (A and B).
NOTE:
For easier disassembly of lower seat section, place two wooden blocks (C)
approximately 115 mm (4-1/2 in.) long into U-rails of frame as shown.
982
Disassemble and Assemble Operator's Seat Air Suspension Assembly
4.
H72739-UN: Shock Absorber
LEGEND:
A - Snap Ring
B - Horizontal Shock Absorber
C - Bowden Cable
D - Snap Rings
E - Shock Absorber
Remove snap ring (A) and remove horizontal shock absorber (B).
5.
NOTE:
Note cable and air line routing and location of cable ties to aid in reassembly.
Disconnect Bowden cable (C) at shock absorber (E) and loosen cable clamps.
6. Remove snap rings (D) from bearing pins and remove shock absorber.
7.
H72762-UN: Spring
983
Disassemble and Assemble Operator's Seat Air Suspension Assembly
H72759-UN: Frame
LEGEND:
A - Screw
B - Adjusting Handle
C - Rivets (2 used)
D - Emergency Stop (2 used)
E - Frame
F - Cap Screw (2 used)
G - Horizontal Spring Assembly
H - Spring
I - Locking Lever
J - Indicator
K - Snap Ring
Remove screw (A) from horizontal adjusting handle (B) and disconnect handle with linkage.
8. Drill out rivets (C) of emergency stops (D) and remove stops from frame (E).
9. Disconnect indicator (J), slide frame to recess and remove.
10. Remove cap screws (F) and horizontal spring assembly (G).
11. Disconnect spring (H) and remove snap ring (K) from bearing pin. Remove locking lever (I).
12.
H72738-UN: Adjusting Lever
LEGEND:
A - Screw (3 used)
B - Air Line
984
Disassemble and Assemble Operator's Seat Air Suspension Assembly
C - Support
Remove three screws (A) from weight and height adjuster. Disconnect air line (B) and remove support
(C).
13.
H72761-UN: Air Spring
H72758-UN: Bracket
LEGEND:
A - Cap Screw
B - Cap Screw
C - Air Spring
D - Nut (2 used)
E - Bearing Bracket (2 used)
F - Seat Rocker
Loosen hose clamp and pull hose off compressor.
14. Remove cap screws (A and B) of air spring (C) and remove air spring.
15. Remove nuts (D) and bearing brackets (E).
16. Remove seat rocker (F).
985
Disassemble and Assemble Operator's Seat Air Suspension Assembly
17.
H72760-UN: Compressor
LEGEND:
A - Cap Screw
B - Compressor
C - Hose
Remove cap screw (A) from compressor (B). Disconnect hose (C) and connector. Remove compressor.
18. Assemble in reverse order.
Go to Section_90:Group_15
OUO6435,00018AC-19-20020820
986
Cab Door Latch Striker
Cab Door Latch Striker
H73480-UN: Striker Plate
LEGEND:
A - Hex. Socket Screw (2 used)
B - Striker Plate
C - Washer (2 used)
D - Strap Nut
1.
NOTE:
Make sure that washer (C) is not lost when removing striker plate (B).
Remove hex. socket screws (A), striker plate (B), spring washers (C) and strap nut (D).
2. Inspect parts for wear. Replace as necessary.
3. Install striker plate (B) and washer (C), with cup side toward cab frame, using hex. socket screws. Do not
tighten screws at this time.
4. Check alignment of striker plate with door latch assembly. Loosen striker plate and realign as required.
5. Check proper operation of door latch from inside and outside of cab. Make further adjustments as
required.
6. Tighten hex. socket screws (A) to specification.
Item
Measurement Specification
Striker Plate Hex. Socket Screws Torque
72 Nm
(53 lb-ft)
987
Cab Door Latch Striker
Go to Section_90:Group_15
ZX09263,00027BF-19-20080303
988
Remove and Install Cab Door
Remove and Install Cab Door
1.
CAUTION:
Support cab door prior to removing hinge pins. Door may shatter if dropped.
H73474-UN: Upper Cab Door Hinge
H73475-UN: Lower Cab Door Hinge
LEGEND:
A - Snap Ring
B - Hinge Pin
Remove snap rings (A) and hinge pins (B).
2. Remove cab door.
3. Repair or replace cab door as necessary.
4. Install cab door using hinge pins (B) and snap rings (A).
Go to Section_90:Group_15
ZX09263,00027C0-19-20080303
989
Disassemble and Assemble Cab Door (Serial No. 074502—)
Disassemble and Assemble Cab Door (Serial No. 074502—)
H73479-UN: Cab Door Assembly
LEGEND:
1 - Strap Nut
2 - Spring (2 used)
3 - Striker Plate
4 - Hex. Socket Screw (2 used)
5 - Screw
6 - Cover
7 - Latch
8 - Bearing
9 - Tube
990
Disassemble and Assemble Cab Door (Serial No. 074502—)
10 - Nut (2 used)
11 - Washer (2 used)
12 - Screw (2 used)
13 - Bracket
14 - Spacer
15 - Door
16 - Bushing
17 - Gasket
18 - Handle
19 - Seal Ring
20 - Bushing
21 - Washer
22 - Cap
23 - Screw
24 - Pin (2 used)
25 - Hinge (2 used)
26 - Snap Ring (2 used)
27 - Bushing
28 - Washer (8 used)
29 - Lock Washer (4 used)
30 - Screws (4 used)
31 - Lock Nut (2 used)
32 - Washer (2 used)
33 - Washer
34 - Screw
35 - Isolator
36 - Washer
37 - Lock Nut
Disassemble and assemble door as required to make repairs.
Go to Section_90:Group_15
OUO6435,000192F-19-20021007
991
Table of Contents
Section 110: Feeder House Repair
Group 05: Conveyor
Other Material
Specifications
Remove and Install Feeder House
Remove and Install Conveyor Chain
Measure Conveyor Chain Wear
Remove Conveyor Chain Link
Replace Conveyor Chain Slats
Replace Conveyor Chain Wear Strips
Adjust Drum Height
Remove and Install Conveyor Drum
Conveyor Drum Exploded View - HillMaster II
Conveyor Drum Exploded View - Standard Combines and HeaderTrak Tilt
Remove And Install Mid-Floor Assembly
Remove And Install Sub-Floor Assembly
Remove and Install Pea Kit Sub-Floor Assembly (Optional)
Feed Plate Support - Exploded View
Group 10: Upper Shaft and Slip Clutch
Specifications
Remove and Install Top Shaft Supports
Disassemble and Assemble Conveyor Top Shaft
Group 15: Feeder House Drives and Reverser Gear Case
Other Material
Specifications
Top Shaft Idler - Exploded View
Feeder House Countershaft and Tensioner - Exploded View
Remove and Install Reverser Gear Case
Feeder House Reverser Gear Case - Exploded View
Disassemble and Assemble Feeder House Reverser Gear Case
Remove and Install Lower Shaft
Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides
992
Table of Contents
Group 20: HeaderTrak Tilt Cylinder and Frame
Specifications
HeaderTrak Tilt Cylinder Hoses and Fittings - Exploded View
Remove and Install HeaderTrak Tilt Cylinder
Feeder House Shell, Wear Plates and Seals, Location
Tilt Beam and Closure Plates,Location
Remove and Install Tilt Frame
Remove and Install Tilt Beam
Adjust Fore-Aft Turnbuckles
Remove Fore-Aft Tilt Frame
Install Fore-Aft Tilt Frame
Group 25: HillMaster II Tilt Cylinder and Frame
Tilt Frame - Exploded View
993
Other Material
Other Material
Number
Name
Use
T43512 (U.S.)
Thread Lock and Sealer (Medium Strength) To retain cap screws.
TY9473 (Canadian)
242 LOCTITE ™ (LOCTITE®)
Go to Section_110:Group_05
OUO6435,000141A-19-20021120
994
Other Material
Other Material
Number
Name
Use
T43512 (U.S.)
Thread Lock and Sealer (Medium Strength) To retain cap screws.
TY9473 (Canadian)
242 LOCTITE ™ (LOCTITE®)
Go to Section_110:Group_05
OUO6435,000141A-19-20021120
995
Specifications
Specifications
Item
Measurement Specification
Feeder House Clamp-to-Frame Cap Screws Torque
620 N˙m
(457 lb-ft)
Feeder House Drum Shield Cap Screws
Torque
130 N˙m
(95 lb-ft)
Conveyor Drum Bearing Cap Screws
Torque
130 N˙m
(95 lb-ft)
Go to Section_110:Group_05
OUO6435,00014AF-19-20010821
996
Remove and Install Feeder House
Remove and Install Feeder House
CAUTION:
Remove feeder house only with combine on level and solid ground.
IMPORTANT:
Cap all hydraulic lines and fittings during removal to prevent hydraulic system contamination.
1.
ZX25096-UN: Reverser Line
LEGEND:
A - Fitting
B - Hydraulic Line
Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine.
2. Remove feeder house side shields.
3. Disconnect hydraulic line (A) from reverser and remove line (B) from feeder house pivot casting.
4.
ZX25098-UN: Left Side Disconnection
997
Remove and Install Feeder House
ZX25099-UN: Left Side Disconnection
LEGEND:
A - Harness Connector
B - Fitting
C - Coupler
D - Linkage, Height Sensor
E - Cap Screw (4 used)
F - Cover
G - Hydraulic Lines
H - Reel Control Valve
I - Cap Screw (4 used)
Disconnect harness connector (A), fitting (B) and coupler (C).
5. Disconnect linkage (D) and connector of height sensor. Remove wiring harness from pivot casting.
6. Remove cap screws (E) and cover (F).
7. Disconnect lines (G) at reel control valve (H).
8. Remove cap screws (I) and multi-coupler from feeder house.
9.
ZX25101-UN: Tilt Sensor
998
Remove and Install Feeder House
ZX25104-UN: Tilt Sensor
LEGEND:
A - Fittings
B - Tilt Cylinder
C - Harness Connector
HeaderTrak Tilt Only: Disconnect fittings (A) from tilt cylinder (B) and remove hydraulic lines from feeder
house.
10. Disconnect harness connector (C) from tilt sensor and remove from feeder house pivot casting.
11.
ZX25100-UN: HillMaster II
LEGEND:
A - Harness Connector
B - Fitting
C - Fitting
HillMaster II ™ Only: Disconnect harness connector (A), hydraulic fittings (B), (C) and remove harness
and lines from feeder house pivot casting.
999
Remove and Install Feeder House
12.
H56016-UN: Electric Clutch
ZX25368-UN: Later Models
LEGEND:
A - Cap Screw
B - Harness Connector
C - Cotter Pin
D - Tensioner Nut
E - Belt
Remove electric clutch module strap cap screw (A) and disconnect connector (B).
13. Remove cotter pin (C) and loosen nuts (D) on header drive tensioner.
14. Remove drive belt (E) from electric clutch and place on top of feeder house.
1000
Remove and Install Feeder House
15.
ZX25095-UN: Park Brake Balancer
LEGEND:
A - Cables
B - Support
Disconnect park brake cables (A) from support (B) and pull through feeder house pivot casting.
CAUTION:
16.
The approximate weight of feeder house is 816 kg (1,800 lb).
ZX25103-UN: Feeder House
LEGEND:
A - Cotter Pin
B - Pin
Support front end of feeder house, using suitable jack.
17. Remove cotter pin (A) and drive out pin (B) on both sides. Place hydraulic cylinders on the ground.
18. Block feeder house securely.
19. Lower feed plate.
1001
Remove and Install Feeder House
20.
ZX25102-UN: Feeder House Pivot
LEGEND:
A - Cap Screw (2 used)
B - Retainer (2 used)
Remove cap screw (A) from pivot casting retainers (B) on both sides.
21. Back combine away slowly.
22. Inspect feeder house components. Repair or replace as required.
23.
ZX25102-UN: Feeder House Pivot
LEGEND:
A - Cap Screw (2 used)
B - Retainer (2 used)
Install feeder house in the reverse order using the following special instructions:
Apply T43512 Thread Lock and Sealer (Medium Strength) to cap screw threads.
Install retainer (B) and cap screw (A). Tighten to specification.
Item
Measurement Specification
Feeder House Clamp-to-Frame Cap Screws Torque
620 Nm
(457 lb-ft)
Go to Section_110:Group_05
OUO6435,0001932-19-20080129
1002
Remove and Install Conveyor Chain
Remove and Install Conveyor Chain
1.
ZX25128-UN: Chain Tensioner
LEGEND:
A - Nut (2 used)
B - Cap Screw
Remove side shields.
2. Loosen nuts (A) and cap screw (B) on both sides to relieve tension on conveyor chain.
3.
H55318-UN: HeaderTrak
ZX25141-UN: HillMaster II
LEGEND:
A - Cap Screw
B - Cap Screw
1003
Remove and Install Conveyor Chain
C - Closure Plate
Remove cap screws (A), (B) and closure plates (C).
4. Rotate conveyor to gain access to master link.
5.
H58526-UN: Conveyor Chain Links
LEGEND:
A - ”S” Hooks
Remove ”S” hooks (A) to remove connector links.
6. Pull conveyor out of feeder house.
7. Inspect chain and slats. Repair or replace parts as necessary (see Measure Conveyor Chain Wear in
this group).
8.
H40370-UN: Slats
LEGEND:
A - Slats
Grind off rivets to replace slats (A).
9. Rivet slats to chain. If riveting is not possible, a cap screw and two nuts can be used. Be sure cap screw
head is on chain link side.
10.
NOTE:
Be sure angle leg of slat is on trailing edge.
1004
Remove and Install Conveyor Chain
Pull conveyor into feeder house using a rope.
11. IMPORTANT:
When shortening conveyor chain, remove an offset link from each strand using a chain breaker.
Connector link can be reused to connect chain.
H58526-UN: Hooks
LEGEND:
A - ”S” Hooks
Connect chain ends with connector links and new ”S” hooks (A). On outside chains, install connector
links so hooks are toward inside edge of feeder house to prevent pins from striking drum ring.
12. Install closure plates in the reverse order using the special instructions found in the specific group.
13. Adjust conveyor chain tension (see Adjust Conveyor Chain in this group).
14. Install side shields.
Go to Section_110:Group_05
OUO6435,00013D4-19-20010607
1005
Measure Conveyor Chain Wear
Measure Conveyor Chain Wear
1. Stretch chain assembly out on a smooth surface.
2. Measure from center of holes in end links.
3. Divide length by number of links to get average pitch length.
-: Conveyor chain wear
New chain pitch length 41 mm (1-5/8 in.)
A chain worn more than 4 percent may jump drive sprocket teeth or cause sprocket wear.
4. Do not replace worn chain unless average pitch is at least 43 mm (1-11/16 in.), or if one chain strand is
more than 36 mm (1-13/32 in.) longer than adjacent strand.
Go to Section_110:Group_05
AG,OUO6435,889-19-20021119
1006
Remove Conveyor Chain Link
Remove Conveyor Chain Link
1.
NOTE:
When replacing chain links, always check sprockets for wear.
H72536-UN: Chain Links
LEGEND:
A - Offset Links
B - Inside Links
For first adjustment (when sidesheet slots limit chain tension), remove offset links (A).
2. Remove offset links (B) for second adjustment. When adjusting is all used up from second adjustment,
1007
Remove Conveyor Chain Link
the chain is worn out and must be replaced.
Go to Section_110:Group_05
OUO6435,000179D-19-20020524
1008
Replace Conveyor Chain Slats
Replace Conveyor Chain Slats
1.
H68211-UN: Safety Stop
LEGEND:
A - Safety Stop
Raise feeder house and lower safety stop (A). Shut off engine, engage park brake and remove key.
2.
H72999-UN: Conveyor Slat
H73000-UN: Conveyor Slat
LEGEND:
A - Rivet (4 used per slat)
B - Slat
C - Cap Screw and Lock Nut (4 used per slat)
Rotate feeder house drive belt to access damaged slat.
3. Grind off rivet heads (A) on each end of slat (B) and remove slat. Remove the rest of the rivet in the
1009
Replace Conveyor Chain Slats
conveyor chain with a punch and hammer.
4. Install slat in the same direction as before and retain with four cap screws and lock nuts (C). Tighten cap
screws to specification.
Item
Measurement Specification
Conveyor Chain Slat Hardware Torque
25 ± 6 N˙m
(18 ± 4 lb-ft)
Go to Section_110:Group_05
OUO6435,0001860-19-20020815
1010
Replace Conveyor Chain Wear Strips
Replace Conveyor Chain Wear Strips
1.
H68128-UN: Top Door
LEGEND:
A - Top Door
Lower feeder house to ground.
2. Remove top door (A).
3.
H57135-UN: Slat
H63609-UN: Standard and HeaderTrak Tilt
1011
Replace Conveyor Chain Wear Strips
ZX25133-UN: HillMaster II
LEGEND:
A - Slat
B - Wear Strip
Block conveyor slat (A) up on both sides to provide clearance to replace wear strips (B).
Go to Section_110:Group_05
OUO6435,00013D6-19-20010608
1012
Adjust Drum Height
Adjust Drum Height
ZX25134-UN: HeaderTrak
ZX25291-UN: HillMaster II
LEGEND:
A - Pin
B - Handle
C - Notch
Float cams are located on both sides of feeder house.
To set float:
1. For small grain, rotate handle (B) until pin (A) engages with notch (C).
2. For large grain, rotate handle (B) until pin (A) engages in existing position.
Go to Section_110:Group_05
OUO6435,00013D7-19-20010608
1013
Remove and Install Conveyor Drum
Remove and Install Conveyor Drum
1.
NOTE:
It is not necessary to remove feeder house to service drum.
H55318-UN: HeaderTrak Tilt
ZX25141-UN: HillMaster II
LEGEND:
A - Cap Screw
B - Cap Screw
C - Closure Plate
Remove cap screws (A), (B) and closure plates (C).
2.
ZX25140-UN: Drum Tension Screw
1014
Remove and Install Conveyor Drum
LEGEND:
A - Nut (4 used)
Loosen nuts (A) on both sides to relieve tension on conveyor chain.
3. Rotate chain so chain links are accessible.
4.
H58526-UN: Master Link
LEGEND:
A - ”S” Hook (4 used)
Remove hooks (A) and chain link.
5.
ZX25114-UN: Conveyor Drum
LEGEND:
A - Cap Screw
B - Nut
C - Drum
D - Washer
E - Bushing
1015
Remove and Install Conveyor Drum
Remove lock nut (B) on right and left sides.
CAUTION:
6.
The approximate weight of conveyor drum is 36 kg (80 lb).
Remove cap screw (A). When cap screw (A) is removed, bushing (E) and washers (D) are free to fall out
of place.
7. Remove drum assembly (C) from feeder house.
8. Repair or replace parts as necessary. See Conveyor Drum Exploded View in this group.
9.
H55318-UN: HeaderTrak Tilt
Install closure plates in the reverse order using the following special instructions.
10. HeaderTrak Tilt Only: Tighten cap screws (B) to specification.
Item
Measurement Specification
Feeder House Drum Shield Cap Screws Torque
130 N˙m
(95 lb-ft)
11. Adjust conveyor tension (see procedure in this group).
Go to Section_110:Group_05
OUO6435,00013D9-19-20010611
1016
Conveyor Drum Exploded View - HillMaster II
Conveyor Drum Exploded View - HillMaster II
ZX25115-UN: Conveyor Drum
LEGEND:
A - Drum
B - Shaft
C - Ball Bearing (2 used)
D - Housing (2 used)
E - Collar with Set Screw (2 used)
F - Lock Washer (6 used)
G - Cotter Pin (2 used)
H - Pin (2 used)
I - Cap Screw (6 used)
J - Arm (2 used)
K - Nut (4 used)
L - Bushing (2 used)
M - Eyebolt (2 used)
N - Flange Nut (6 used)
O - Screw
P - Nut (2 used)
Q - Washer (10 used)
R - Lever (4 used)
S - Cam (2 used)
T - Screw (2 used)
Apply T43512 Thread Lock and Sealer (Medium Strength) to cap screws (I), then insert and tighten to
1017
Conveyor Drum Exploded View - HillMaster II
specification.
Item
Measurement Specification
Conveyor Drum Bearing Cap Screws Torque
130 N˙m
(95 lb-ft)
Go to Section_110:Group_05
OUO6435,00013DC-19-20021120
1018
Conveyor Drum Exploded View - Standard Combines and HeaderTrak Tilt
Conveyor Drum Exploded View - Standard Combines and HeaderTrak Tilt
ZX25227-UN: HeaderTrak Conveyor Drum
LEGEND:
A - Lock Nut (2 used)
B - Washer (2 used)
C - Handle (2 used)
D - Lock Nut (2 used)
E - Eyebolt (2 used)
F - Flange Nut (2 used)
G - Washer (6 used)
H - Bushing (2 used)
I - Arm (2 used)
J - Cap Screw (2 used)
K - Bearing (2 used)
L - Drum
Go to Section_110:Group_05
OUO6435,00014D3-19-20010925
1019
Remove And Install Mid-Floor Assembly
Remove And Install Mid-Floor Assembly
1.
ZX25142-UN: Hardware Location
LEGEND:
A - Mid-Floor Assembly
B - Carriage Bolt (2 used)
C - Flange Nut (10 used)
D - Cap Screw (8 used)
E - Sub-Floor
F - Cap Screw (6 used)
G - Flange Nut (6 used)
H - Flange Nut (12 used)
I - Cap Screw (12 used)
Remove shields from both sides of feeder house.
2. Raise feeder house. Lower safety stop.
3. Remove conveyor chain and drum (see procedure in this group).
4. Remove carriage bolts (B) and cap screws (D) from both sides of feeder house.
1020
Remove And Install Mid-Floor Assembly
5. Remove mid-floor assembly.
6. Inspect mid-floor and wear strips. Repair or replace parts as necessary.
7. Install mid-floor, carriage bolts (B), cap screws (D) and extensions.
8. Install conveyor drum and chain (see procedure in this group).
Go to Section_110:Group_05
OUO6435,00013DA-19-20010611
1021
Remove And Install Sub-Floor Assembly
Remove And Install Sub-Floor Assembly
1.
ZX25142-UN: Hardware Location
LEGEND:
A - Mid-Floor Assembly
B - Carriage Bolt (2 used)
C - Flange Nut (10 used)
D - Cap Screw (8 used)
E - Sub-Floor
F - Cap Screw (6 used)
G - Flange Nut (6 used)
H - Flange Nut (12 used)
I - Cap Screw (12 used)
Remove shields from both sides of feeder house.
2. Raise feeder house. Lower safety stop.
3.
NOTE:
Raising the conveyor drum (large grain position) aids removal of the sub floor by lifting
1022
Remove And Install Sub-Floor Assembly
the conveyor chain off the floor.
Raise conveyor drum.
4. Remove cap screws (F) and (I) from both sides of feeder house.
5. Remove sub-floor assembly.
6. Inspect feeder house floor for wear and/or damage, replace as necessary.
7. Install sub-floor in reverse order.
8. Put conveyor drum in desired position.
Go to Section_110:Group_05
OUO6435,0001416-19-20010723
1023
Remove and Install Pea Kit Sub-Floor Assembly (Optional)
Remove and Install Pea Kit Sub-Floor Assembly (Optional)
1.
ZX25367-UN: Pea Kit Assembly
LEGEND:
A - Cap Screw (6 used)
B - Cap Screw (8 used)
C - Sub-Floor
D - Flange Nut (10 used)
E - Panel
F - Panel
G - Flange Nut (12 used)
H - Flange Nut (16 used)
Remove shields from both sides of feeder house.
2. Raise feeder house. Lower safety stop.
1024
Remove and Install Pea Kit Sub-Floor Assembly (Optional)
3.
NOTE:
Raising the conveyor drum (large grain position) aids removal of the sub floor by lifting
the conveyor chain off the floor.
Raise conveyor drum.
4. Remove cap screws (A) and (B) from both sides of feeder house.
5. Remove sub-floor assembly.
6. Inspect feeder house floor for wear and/or damage, replace as necessary.
7. Install sub-floor in reverse order.
8. Put conveyor drum in desired position.
Go to Section_110:Group_05
OUO6435,000192B-19-20021004
1025
Feed Plate Support - Exploded View
Feed Plate Support - Exploded View
H65449-UN: Feed plate support
LEGEND:
1 - Cap Screw
2 - Cotter Pin (2 used)
3 - Washer (2 used)
4 - Cap Screw (2 used)
5 - Washer (4 used)
6 - Strap (2 used)
7 - Sleeve
8 - Bushing
9 - Lock Nut (3 used)
10 - Handle
11 - Lock Nut (4 used)
12 - Cam (2 used)
13 - Support
14 - Arm (2 used)
15 - Cap Screw (2 used)
16 - Cap Screw (2 used)
Go to Section_110:Group_05
OUO6435,00013EA-19-20010627
1026
Specifications
Specifications
Item
Measurement Specification
Top Shaft Slip Clutch
Gap (X)
12 mm
(0.47 in.)
Top Shaft Support Cap Screws and Nuts Torque
520 N˙m
(383 lb-ft)
Top Shaft Bearing Cap Screws
Torque
122 N˙m
(90 lb-ft)
Top Shaft Sprocket Set Screws
Torque
50 N˙m
(37 lb-ft)
Go to Section_110:Group_10
OUO6435,000141C-19-20010724
1027
Specifications
Specifications
Item
Measurement Specification
Top Shaft Slip Clutch
Gap (X)
12 mm
(0.47 in.)
Top Shaft Support Cap Screws and Nuts Torque
520 N˙m
(383 lb-ft)
Top Shaft Bearing Cap Screws
Torque
122 N˙m
(90 lb-ft)
Top Shaft Sprocket Set Screws
Torque
50 N˙m
(37 lb-ft)
Go to Section_110:Group_10
OUO6435,000141C-19-20010724
1028
Remove and Install Top Shaft Supports
Remove and Install Top Shaft Supports
1. Shut off engine and remove key.
2. Remove feeder house side shields.
3. Loosen idler and remove drive belt from side of feeder house.
4. Remove feeder house from combine. See Remove and Install Feeder House in Group 05.
5.
ZX25140-UN: Adjuster
LEGEND:
A - Nut (4 used)
Loosen nuts (A) on both sides to relieve conveyor chain tension.
6.
H40433-UN: Connector Links
LEGEND:
A - ”S” Hooks
Rotate chain so ”S” hooks and pins (A) are accessible.
1029
Remove and Install Top Shaft Supports
7.
ZX25148-UN: Adjuster
LEGEND:
A - Nut
Loosen nut (A) to release tension on conveyor drive chain.
8. Remove top shaft and slip clutch (see procedure in this group).
9.
H58516-UN: Conveyor Drive Support
LEGEND:
A - Nuts and Screws
B - Nuts
C - Bracket
D - Drive Support
Remove nuts and screws (A), nuts (B), bracket (C) and top shaft support (D) on both sides.
10.
LEGEND:
A - Lift Chain
1030
Remove and Install Top Shaft Supports
B - Conveyor Drive Support (2 used)
C - Nut (6 used)
D - Cap Screw (6 used)
E - Stripper (3 used)
Install lifting device (A) to conveyor drive supports (B) on both sides.
11. Remove nuts (C) and cap screws (D) to remove strippers (E).
12. Slowly remove conveyor drive assembly.
13. Inspect support assembly and repair or replace as required.
14. Install conveyor drive assembly.
15. Install strippers (E) using cap screws (D) and nuts (C).
16.
H58516-UN: Conveyor Drive Support
LEGEND:
A - Nuts and Screws
B - Nuts
C - Bracket
D - Drive Support
Install bracket (C), nuts and screws (A) and nuts (B) on conveyor drive support (D). Tighten (A) to
specification.
Item
Measurement Specification
Top Shaft Support Cap Screws and Nuts Torque
520 N˙m
(383 lb-ft)
17. Remove lifting device from conveyor drive supports.
18. Install top shaft and slip clutch (see procedure in this group).
1031
Remove and Install Top Shaft Supports
19.
ZX25148-UN: Adjuster
LEGEND:
A - Nut
Adjust chain tension and tighten nut (A).
20.
H40433-UN: Connector Links
LEGEND:
A - ”S” Hooks
Attach conveyor chain ends using connecting links and hooks (A). On outside chains, install connector
links so hooks are toward inside edge of feeder house to prevent pins from striking drum ring.
21. Adjust conveyor tension (see Adjust Conveyor Chain in Group 05).
22. Install feeder house side shields.
Go to Section_110:Group_10
OUO6435,00013DC-19-20010612
1032
Disassemble and Assemble Conveyor Top Shaft
Disassemble and Assemble Conveyor Top Shaft
H68715-UN: Top Shaft Assembly
LEGEND:
A - Spacer
B - Ball Bearing
C - Housing (2 used)
D - Cap Screw (6 used)
E - Sprocket
F - Shaft Key
G - Shaft
H - Bracket/Stripper
I - Support
J - Set Screw
1.
NOTE:
It is not necessary to remove pivot casting to service top shaft.
1033
Disassemble and Assemble Conveyor Top Shaft
Start engine and lower feeder house to the ground. Shut off engine and remove key.
2.
H68129-UN: Doors
LEGEND:
A - Upper Door
B - Access Door
Remove feeder house upper rear door (A) and cylinder top access door (B).
3. Remove shields on both sides and slip clutch cover on right side.
4.
ZX25140-UN: Adjuster
LEGEND:
A - Nut (4 used)
Loosen nuts (A) on both sides to relieve conveyor chain tension.
5. Rotate conveyor chain so connecting links are over top shaft.
1034
Disassemble and Assemble Conveyor Top Shaft
6.
H40433-UN: Master Links
LEGEND:
A - ”S” Hooks
Remove ”S” hooks (A) and connecting links on outside strands to separate chains.
7. Secure chain halves to feeder house to prevent conveyor from sliding down.
8. Remove ”S” hooks from middle strands.
9. Lay upper half of chain on top of feeder house and secure.
10. Secure lower half of chain to underside of feeder house.
11.
ZX25148-UN: Drive Chain Adjuster
LEGEND:
A - Nut
Loosen nut (A) to relieve tension on chain. Remove chain from slip clutch sprocket.
12.
1035
Disassemble and Assemble Conveyor Top Shaft
ZX1034856-UN: Slip Clutch
Remove clamping nut and slip clutch (A).
13.
ZX25162-UN: Clutch Removed
LEGEND:
A - Key
B - Carrier Disk
Remove key (A) and carrier disk (B).
14. Remove two outer top shaft strippers. Do not remove the center stripper.
15.
H55867-UN: Sprocket
LEGEND:
A - Set Screw
B - Outer Sprockets
C - Cap Screw (3 used)
Loosen set screws (A) in all sprockets.
16. Drive two outer sprockets (B) inward away from the bearings approximately 25 mm (1 in.).
17. Remove three cap screws (C) from left bearing housing.
18.
NOTE:
"Right" and "left" sides are determined by facing the direction of forward travel.
Pull left bearing housing away from side of feeder house. Move left end of shaft down.
1036
Disassemble and Assemble Conveyor Top Shaft
CAUTION:
19.
Lower safety stop.
Start engine, raise feeder house completely, and lower safety stop onto cylinder piston. Shut off engine
and remove key.
20. Lower feed plate under feeder house.
21. Pull shaft out of right bearing housing.
22.
NOTE:
When reversing sprockets worn on one side only, the right and left sprockets change
places and the inner sprocket is reversed (combines with six walkers have two inner
sprockets).
H50599-UN: Outer Sprocket
LEGEND:
A - Bearing housing
B - Sprocket
C - Shaft
Remove bearing housing (A) and sprocket (B), both ends, from shaft (C). Keep sprockets in order.
23. Inspect shaft and sprockets for excessive wear. Replace sprockets as necessary.
24.
1037
Disassemble and Assemble Conveyor Top Shaft
H44700-UN: Bearing Housing
LEGEND:
A - Bearing
B - Cut-Out
C - Housing
Tap down on one side of bearing (A) until bearing is vertical in housing.
25. Rotate bearing to cut-out (B) in housing. Remove bearing.
26. Inspect parts. Replace as necessary.
27. Install bearing (A) through cut-out (B).
28. IMPORTANT:
Be sure teeth of all sprockets are aligned.
H50599-UN: Outer Sprocket
LEGEND:
A - Bearing Housing
B - Sprocket
C - Shaft
Slide sprockets (B) and left bearing housing (A) onto new shaft (C).
29.
H50510-UN: Outer Bearing
LEGEND:
A - Bearing Housing
B - Cap Screw
1038
Disassemble and Assemble Conveyor Top Shaft
C - Slot
D - Sprocket
E - Screw
F - Shaft
G - Stripper
Install right end of shaft (F) into right bearing from under feeder house.
30. Position left end of shaft and bearing housing (A) through slot (C) in upper shaft support.
31. Raise safety stop from feeder house cylinder piston. Start engine and lower feeder house completely.
Remove key.
32. IMPORTANT:
Be sure sprocket bores are aligned with screw indents, both sides.
Install and tighten three cap screws (B) in left bearing housing.
33. Tighten cap screws (B) to specification.
Item
Measurement Specification
Top Shaft Bearing Cap Screws Torque
122 Nm
(90 lb-ft)
34.
H65820-UN: Combines with 6.8 L engine
Position center of right sprocket teeth 56 mm (2-1/4 in.) from right bearing housing.
35. (Combines with five walkers) Position remaining sprockets 603 mm (23-3/4 in.) apart.
36.
H65450-UN: Combines with 9.0 L engine
1039
Disassemble and Assemble Conveyor Top Shaft
(Combines with six walkers) Position remaining sprockets 493 mm (19-3/8 in.) apart.
37. Install set screws in sprockets and tighten to specification.
Item
Measurement Specification
Top Shaft Sprocket Set Screws Torque
50 Nm
(37 lb-ft)
38.
ZX25162-UN: Clutch Removed
LEGEND:
A - Key
B - Carrier Disk
Install carrier disk (B) and key (A).
39.
ZX1034856-UN: Slip Clutch
Install clutch (A).
40. Tighten retaining nut.
41. Install top shaft strippers and set each stripper within 3 mm (1/8 in.) of shaft.
1040
Disassemble and Assemble Conveyor Top Shaft
42.
H40433-UN: Master Link
LEGEND:
A - ”S” Hooks
Connect conveyor chains using new ”S” hooks (A). Be certain the hooks are on the inside of the chain so
they will not hit the strippers.
43. Adjust conveyor chains.
44.
H68131-UN: Right Shields
LEGEND:
A - Right Shields
B - Slip Clutch Cover
Install left and right shields (A) and slip clutch cover (B).
45.
H68129-UN: Top Doors
LEGEND:
A - Upper Door
B - Access Door
1041
Disassemble and Assemble Conveyor Top Shaft
Install feeder house doors (A and B).
Go to Section_110:Group_10
ZX08994,00002B3-19-20080206
1042
Other Material
Other Material
Number
Name
TY6252 (U.S.) 80W90 GL-5 Gear Lubricant
Use
Feeder House Reverser Gear Case
TY6341 (U.S.) Multipurpose SD Polyurea Grease To Lubricate parts during assembly.
TY16135 (U.S.) RTV Silicone Adhesive Sealant
To seal parts during assembly.
Go to Section_110:Group_15
OUO6435,000141D-19-20010724
1043
Other Material
Other Material
Number
Name
TY6252 (U.S.) 80W90 GL-5 Gear Lubricant
Use
Feeder House Reverser Gear Case
TY6341 (U.S.) Multipurpose SD Polyurea Grease To Lubricate parts during assembly.
TY16135 (U.S.) RTV Silicone Adhesive Sealant
To seal parts during assembly.
Go to Section_110:Group_15
OUO6435,000141D-19-20010724
1044
Specifications
Specifications
Item
Measurement Specification
Reverser Gear Case Mounting Screws
Torque
170 N˙m
(125 lb-ft)
Reverser Gear Case (Standard)
Capacity
2.0 L
(0.5 U.S. gal)
Reverser Gear Case Planetary Cap Screws Torque
73 N˙m
(54 lb-ft)
Bearing Quill Screws
Torque
50 N˙m
(37 lb-ft)
Conveyor Drive Chain Idler Screw
Torque
130 N˙m
(97 lb-ft)
Go to Section_110:Group_15
ZX08994,00002B2-19-20041207
1045
Top Shaft Idler - Exploded View
Top Shaft Idler - Exploded View
ZX25231-UN: Top Shaft Idler
LEGEND:
A - Shaft
B - Snap Ring (2 used)
C - Sheave
D - Bearing
E - Snap Ring
F - Washer
G - Cap Screw
Go to Section_110:Group_15
AG,OUO6435,905-19-20000503
1046
Feeder House Countershaft and Tensioner - Exploded View
Feeder House Countershaft and Tensioner - Exploded View
ZX25235-UN: Countershaft and Tensioner
LEGEND:
1 - Nut
2 - Washer
3 - Rubber Strap
4 - Spacer
5 - Carriage Bolt (2 used)
6 - Bracket, Reel Pump
7 - Carriage Bolt
8 - Reel Pump
9 - Nut (2 used)
1047
Feeder House Countershaft and Tensioner - Exploded View
10 - Bracket, Countershaft
11 - Cap Screw (4 used)
12 - Snap Ring
13 - Bearing
14 - Housing
15 - Bearing
16 - Countershaft Sheave
17 - Washer
18 - Nut
19 - Cap
20 - Lubrication Fitting
21 - Cap Screw (4 used)
22 - Washer (4 used)
23 - Guide
24 - Bracket, Tensioner
25 - Gauge
26 - Spring
27 - Washer
28 - Nut (2 used)
29 - Seal
30 - Bushings
31 - Tensioner Arm
32 - Gasket
33 - Washer
34 - Washer
35 - E-Clip
36 - Idler
37 - Cap Screw
Go to Section_110:Group_15
OUO6435,0001412-19-20010719
1048
Remove and Install Reverser Gear Case
Remove and Install Reverser Gear Case
1. Remove feeder house side shields on both sides.
2. Raise feeder house and lower safety stop.
3. Drain oil from reverser gear case.
4. Relieve belt tension and remove belt from sheave.
5.
ZX25182-UN: Reverser
LEGEND:
A - Fitting
Disconnect fitting (A).
6.
NOTE:
If servicing internal parts of gear case, it may be easier to remove drive sheave(s) while
reverser gear case is mounted on feeder house.
ZX25183-UN: Reverser Gear Case
LEGEND:
A - Cap Screw (3 used)
Remove cap screws (A), washers and bushings.
1049
Remove and Install Reverser Gear Case
7.
ZX25234-UN: Fixed Speed Feeder House Shown
LEGEND:
A - Cap Screw (3 used)
B - Washer
C - Washer
D - Cushion (2 used)
E - Support (3 used)
F - Spacer (3 used)
G - Support
H - Cushion
I - Washer
J - Cap Screw
K - Sheave
L - Nut
M - Bracket
N - Plug
O - Dipstick
P - Tube
Q - O-Ring
1050
Remove and Install Reverser Gear Case
R - Plug
S - O-Ring
T - Key (2 used)
Remove attaching hardware.
8. Remove gear case from feeder house.
9. Install feeder house reverser in reverse order using the following special instructions.
10. Tighten attaching screws to specification.
Item
Measurement Specification
Reverser Gear Case Mounting Screws Torque
170 N˙m
(125 lb-ft)
11. IMPORTANT:
Feeder house must be in raised position to check oil level in gear case.
Install plug using new O-ring. Fill gear case to mark on dipstick with 80W90 GL-5 Gear Lubricant.
Item
Measurement Specification
Reverser Gear Case (Standard) Capacity
0.95 L
(2 pt)
Go to Section_110:Group_15
OUO6435,00013DE-19-20010618
1051
Feeder House Reverser Gear Case - Exploded View
Feeder House Reverser Gear Case - Exploded View
ZX25280-UN: Standard Reverser Gear Case Shown
LEGEND:
1 - Cap Screw (3 used)
2 - Lock Washer (3 used)
3 - Cup
4 - Spring
5 - Cap Screw
6 - Lock Washer
1052
Feeder House Reverser Gear Case - Exploded View
7 - Piston
8 - Seal
9 - Cap Screw (6 used)
10 - O-Ring (2 used)
11 - Fitting
12 - Dipstick
13 - Tube
14 - Plug
15 - O-Ring
16 - Seal
17 - Cap Screw
18 - Cap Screw (4 used)
19 - Cover
20 - O-Ring
21 - Plug
22 - O-Ring (2 used)
23 - Plug
24 - Snap Ring
25 - Bearing
26 - Snap Ring
27 - Shaft
28 - Shifter Fork
29 - Gear
30 - Shift Collar
31 - Gear
32 - Gear (3 used)
33 - Thrust Washer (6 used)
34 - Needle Roller (174 used)
35 - Washer (3 used)
36 - Cover
37 - Pin (3 used)
38 - Spacer (3 used)
39 - Ball (3 used)
40 - Bearing
41 - Input Gear
42 - Bearing
43 - Seal
44 - Bearing
45 - Snap Ring
46 - Quill
47 - Cap Screw (6 used)
48 - Seal
49 - Key (2 used)
50 - Set Screw (2 used)
51 - Ball
52 - Spring Pin
53 - Sheave
1053
Feeder House Reverser Gear Case - Exploded View
Go to Section_110:Group_15
OUO6435,0001414-19-20010723
1054
Disassemble and Assemble Feeder House Reverser Gear Case
Disassemble and Assemble Feeder House Reverser Gear Case
1.
H67588-UN: Quill Removal
LEGEND:
A - Cap Screw (6 used)
B - Quill
Remove sheave.
2.
CAUTION:
Approximate weight of reverser gear case is 68 kg (150 lb). Use a suitable lifting
device to remove gear case.
Remove gear case from feeder house using a suitable lifting device (see Remove and Install Reverser
Gear Case in this group).
3. Remove plug on bottom of gear case and drain oil.
4. Remove cap screws (A) and quill (B).
5.
1055
Disassemble and Assemble Feeder House Reverser Gear Case
H67589-UN: Spacer Removal
LEGEND:
A - Spacer (3 used)
Remove spacers (A).
6.
H67590-UN: Disassemble Planetary Assembly
LEGEND:
A - Cap Screw (6 used)
Remove six cap screws (A) and separate planetary assembly from housing.
7.
H67687-UN: Snap Ring and Shaft
1056
Disassemble and Assemble Feeder House Reverser Gear Case
H67688-UN: Bearing Removal
H67689-UN: Bearing Snap Ring
LEGEND:
A - Snap Ring
B - Shaft
C - Snap Ring
Remove snap ring (A) and press shaft (B) out of bearing.
8. Remove bearing from housing using a punch.
9. Remove snap ring (C) from bearing.
1057
Disassemble and Assemble Feeder House Reverser Gear Case
10.
H67593-UN: Pinion Alignment
LEGEND:
A - Mark (3 used)
B - Pinion (3 used)
C - Gear
Turn pinions (B) so numbers point straight out. Pinions are numbered one, two and three in a
counterclockwise direction. Place a mark (A) on housing at each pinion for alignment during assembly.
11. Remove gear (C).
12. IMPORTANT:
Needle rollers will fall out when pin is removed from planetary gear. Be certain that carrier is placed on a
clean surface to help prevent loss of needle rollers.
H67664-UN: Planetary Pin
1058
Disassemble and Assemble Feeder House Reverser Gear Case
H67666-UN: Shaft Ball
LEGEND:
A - Ball
Drive pin out far enough to remove ball (A).
13.
H67665-UN: Planetary Assembly
LEGEND:
A - Needle Roller (186 used)
B - Thrust Washer (6 used)
C - Washer (3 used)
D - Pin (3 used)
Remove pin (D) and pinion gear assembly from carrier.
14. Remove thrust washers (B), needle rollers (A) and washers (C). Inspect parts and replace as necessary.
1059
Disassemble and Assemble Feeder House Reverser Gear Case
15.
H67592-UN: Ring Gear
LEGEND:
A - Ring Gear
Remove ring gear (A).
16.
H67591-UN: Retainer Cap Screws
H67668-UN: Retainer Cap and Spring
1060
Disassemble and Assemble Feeder House Reverser Gear Case
H67680-UN: Piston Cap Screw
LEGEND:
A - Cap Screw (3 used)
B - Retainer Cap
C - Spring
D - Cap Screw
Remove cap screws (A) evenly and incrementally to relieve spring pressure.
17. Remove retainer cap (B), spring (C) and cap screw (D).
18.
H67678-UN: Piston
1061
Disassemble and Assemble Feeder House Reverser Gear Case
H67679-UN: Shift Collar and Fork
LEGEND:
A - Piston
B - Collar
C - Fork
Remove piston (A). Inspect seals and replace as necessary.
19. Remove shift collar (B) and fork (C).
20.
H67594-UN: Shaft Removal
1062
Disassemble and Assemble Feeder House Reverser Gear Case
H67737-UN: Seal
LEGEND:
A - Housing
B - Shaft
C - Snap Ring
D - Seal
Remove snap ring (C) and shaft (B) from housing (A).
21. Inspect seal (D) and replace as necessary.
22. Install shaft (B) into bore of housing (A). Install snap ring (C).
23. IMPORTANT:
Install collar with tabs facing outward.
H67681-UN: Fork and Collar
LEGEND:
A - Fork
B - Collar
Install fork (A) to collar (B); then install in housing.
1063
Disassemble and Assemble Feeder House Reverser Gear Case
24.
H67678-UN: Piston
LEGEND:
A - Piston
Lubricate seals on piston (A) using clean hydraulic oil; then install piston in bore of housing with the
raised center facing outward.
25.
H67680-UN: Piston Cap Screw
H67668-UN: Retainer Cap and Spring
1064
Disassemble and Assemble Feeder House Reverser Gear Case
H67591-UN: Retainer Cap Screws
LEGEND:
A - Cap Screw (3 used)
B - Retainer Cap
C - Spring
D - Cap Screw
Install cap screw (D) and spring (C).
26. Install retainer cap (B) using cap screws (A).
27.
H67592-UN: Ring Gear
LEGEND:
A - Ring Gear
Install ring gear (A).
1065
Disassemble and Assemble Feeder House Reverser Gear Case
28.
H67665-UN: Pinion Assembly
H67667-UN: Needle Rollers
LEGEND:
A - Needle Roller (186 used)
B - Thrust Washer (6 used)
C - Washer (3 used)
D - Pin (3 used)
Install washer (C) to inner circumference of pinion gear.
29. Apply a layer of TY6341 Multi-Purpose, SD Polyurea Grease to inner circumference of gear to help hold
needle rollers in place.
30. Install needle rollers (A) to inner circumference of gear.
31. Place a thin layer of TY6341 Multi-Purpose, SD Polyurea Grease to one side of each thrust washer (B)
to hold in place while installing pinion assembly to carrier.
32.
NOTE:
Install pinions consecutively (one, two and three) in a counterclockwise direction.
Install pinion gear assembly to carrier.
33. Inspect needle rollers (A) to be certain they are seated against inner circumference of gear before
attempting to install pin (D).
1066
Disassemble and Assemble Feeder House Reverser Gear Case
34.
H67666-UN: Pin Ball
LEGEND:
A - Ball
Install ball (A) to pin and align with hole in carrier; then drive pin until fully seated.
35.
NOTE:
Snap ring (C) is used to seat the bearing at a specified depth. Install snap ring to
bearing before driving bearing into bore of housing.
H67689-UN: Bearing Snap Ring
H67687-UN: Snap Ring and Shaft
LEGEND:
A - Snap Ring
1067
Disassemble and Assemble Feeder House Reverser Gear Case
B - Shaft
C - Snap Ring
Install snap ring (C) to new bearing.
36. Install bearing in bore of carrier housing.
37. Install shaft (B) and snap ring (A).
38.
H67593-UN: Pinion Alignment
LEGEND:
A - Mark
B - Pinion (3 used)
C - Gear
Line up numbers on pinions (B) with marks (A) made on cover during disassembly. Install gear (C).
39. IMPORTANT:
If gears are not installed correctly and timed, the gear case could overheat and will not turn over easily.
Clean mating surfaces of housing and carrier. Apply a bead of TY16135 Clear RTV Silicone Adhesive
Sealant on flange toward the inside of the six tapped holes.
1068
Disassemble and Assemble Feeder House Reverser Gear Case
40.
H67590-UN: Gear Case Cap Screws
LEGEND:
A - Cap Screw (6 used)
Install planetary carrier assembly into gear case.
41. Install cap screws (A) and tighten to specification.
Item
Measurement Specification
Reverser Gear Case Planetary Cap Screws Torque
42.
73 N˙m
(54 lb-ft)
NOTE:
Apply a small amount of Multi-Purpose SD Polyurea Grease to spacers during assembly
to hold in place.
H67589-UN: Spacers, Install
LEGEND:
A - Spacer (3 used)
Install spacers (A).
43. Clean mating surfaces of carrier and quill.
1069
Disassemble and Assemble Feeder House Reverser Gear Case
43. Clean mating surfaces of carrier and quill.
44. Apply a bead of TY16135 Clear RTV Silicone Adhesive Sealant to outside edge of lubrication groove
and outside of quill.
45.
H67588-UN: Quill, Install
LEGEND:
A - Cap Screw (6 used)
B - Quill
Install quill (B) and cap screws (A). Tighten to specification.
Item
Measurement Specification
Bearing Quill Screws Torque
50 N˙m
(37 lb-ft)
46. Install gear case (see Remove and Install Reverser Gear Case in this group).
Go to Section_110:Group_15
OUO6435,0001415-19-20010723
1070
Remove and Install Lower Shaft
Remove and Install Lower Shaft
1.
ZX25289-UN: Lower Feeder House Shaft
ZX25290-UN: Lower Feeder House Shaft
LEGEND:
A - Chain Tensioner
B - Chain
C - Speed Sensor
D - Cap Screw (3 used)
E - Lower Shaft
F - Reverser
Loosen chain tensioner (A).
2. Remove chain (B) from lower shaft.
3. Disconnect speed sensor (C).
4. Remove cap screws (D).
5. Slide lower shaft (E) out of reverser (F) and out of feeder house.
6. Inspect parts and replace as necessary.
Go to Section_110:Group_15
AG,OUO6435,915-19-20000503
1071
Remove and Install Lower Shaft
1072
Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides
Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides
H55818-UN: Chain Bracket and Guides
LEGEND:
A - Lock Nut (4 used)
B - Support (2 used)
C - Plate
D - Bracket
E - Screw (4 used)
F - Chain
G - Bracket
H - Flange Nut (3 used)
1073
Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides
I - Screw
J - Spacer (2 used)
K - Sprocket (2 used)
L - Screw
M - Screw
N - Washer
O - Nut
P - Guide (4 used)
Q - Sprocket
1. Disassemble parts (A - Q) as needed.
2. Inspect all parts. Replace as necessary. If bushing(s) in sprocket(s) (K) is/are worn, complete sprocket
must be replaced.
3. Assemble parts (A—Q). Tighten screw (L) to specification.
Item
Measurement Specification
Conveyor Drive Chain Idler Screw Torque
130 N˙m
(97 lb-ft)
Go to Section_110:Group_15
AG,OUO6435,918-19-20000503
1074
Specifications
Specifications
Item
Measurement Specification
Tilt Frame Cap Screw
Torque
315 N˙m
(230 lb-ft)
Tilt Frame Shield Cap Screw
Torque
130 N˙m
(95 lb-ft)
Tilt Beam Pivot Cap Screw
Torque
610 N˙m
(450 lb-ft)
Fore/Aft Tilt Frame Mounting Nuts Torque
215 N˙m
(159 lb-ft)
Go to Section_110:Group_20
OUO6435,0001423-19-20010724
1075
Specifications
Specifications
Item
Measurement Specification
Tilt Frame Cap Screw
Torque
315 N˙m
(230 lb-ft)
Tilt Frame Shield Cap Screw
Torque
130 N˙m
(95 lb-ft)
Tilt Beam Pivot Cap Screw
Torque
610 N˙m
(450 lb-ft)
Fore/Aft Tilt Frame Mounting Nuts Torque
215 N˙m
(159 lb-ft)
Go to Section_110:Group_20
OUO6435,0001423-19-20010724
1076
HeaderTrak Tilt Cylinder Hoses and Fittings - Exploded View
HeaderTrak Tilt Cylinder Hoses and Fittings - Exploded View
H72149-UN: Tilt Cylinder
LEGEND:
A - Rod
B - O-Ring
C - Snap Ring
D - Seal
E - Back-Up Ring
F - Rod Guide
G - Seal
H - Snap Ring
I - Pin
J - Wear Ring
K - Washer
L - O-Ring
M - Piston Ring
N - Piston
O - Cap Screw
1077
HeaderTrak Tilt Cylinder Hoses and Fittings - Exploded View
P - O-Ring
Q - Cylinder Barrel
R - Elbow Fitting
S - O-Ring
T - Hydraulic Hose
Go to Section_110:Group_20
OUO6435,0001907-19-20020905
1078
Remove and Install HeaderTrak Tilt Cylinder
Remove and Install HeaderTrak Tilt Cylinder
H55429-UN: Remove Cylinder
LEGEND:
A - Cap Screw
B - Hoses
C - Cap Screw
D - Pins
E - Cylinder
CAUTION:
Remove header before attempting to remove cylinder.
1. Start combine, tilt frame to the left and retract cylinder. Shut off engine and remove key.
2. Clean area around cylinder to prevent contamination of hydraulic system when hydraulic hoses are
disconnected from cylinder.
3. Remove cap screw (A), washer, bracket and spacer.
4.
CAUTION:
Tilt frame will tilt with very little effort when hydraulic hoses are disconnected.
Disconnect hoses from cylinder (E). Plug hoses (B) and cap cylinder fittings.
5. Remove cap screw (C), spacer and washer.
6. Remove pins (D).
7. Level tilt frame by hand to provide clearance to remove cylinder.
8. Remove cylinder (E).
9. Repair or replace parts as necessary.
10. Attach hoses (B) to cylinder (E).
1079
Remove and Install HeaderTrak Tilt Cylinder
H55429-UN: Remove Cylinder
LEGEND:
A - Cap Screw
B - Hoses
C - Cap Screw
D - Pins
E - Cylinder
NOTE:
Larger diameter hose connects to cylinder rod end port.
11. Attach cylinder to feeder house frame and rod end to tilt frame.
12. Install pins (D).
13. Install spacer, washer and cap screw (C).
14. Install spacer, bracket, washer and cap screw (A).
NOTE:
Clean the tilt cylinder area regularly to avoid compaction of foreign material which can limit tilt
travel. Clean more often in wet or freezing conditions.
Go to Section_110:Group_20
OUO6435,00014D8-19-20010925
1080
Feeder House Shell,
Wear Plates and Seals,
Location
H63972-UN: Feeder House Shell,
Wear Plates and Seals,
Location
LEGEND:
A - Feeder House
B - Wear Plate (2 used)
C - O-Ring (2 used)
D - Pipe
E - Seal
F - Spring Locking Pin (2 used)
G - Wear Plate, Bottom Left
H - Wear Plate, Bottom Right
I - Plate
Go to Section_110:Group_20
AG,OUO6037,31-19-20000725
1081
Tilt Beam and Closure Plates,
Location
ZX25228-UN: Tilt Beam and Closure Plates,
Location
LEGEND:
1 - Pin (4 used)
2 - Cotter Pin (4 used)
3 - Rear Eyebolt (2 used)
4 - Turnbuckle (2 used)
5 - Lock Nut (2 used)
6 - Front Eyebolt (2 used)
1082
7 - Flange Nut (4 used)
8 - Washer (4 used)
9 - Carriage Bolt (4 used)
10 - Cap Screw (2 used)
11 - Washer (2 used)
12 - Spacer (2 used)
13 - Washer (2 used)
14 - Cap Screw (2 used)
15 - Flange Nut
16 - Bracket
17 - Cap Screw (2 used)
18 - Carriage Bolt (4 used)
19 - Cap Screw (2 used)
20 - Washer (2 used)
21 - Washer (4 used)
22 - Flange Nut (4 used)
23 - Tilt Beam
24 - Springs (2 used)
25 - Screw (2 used)
26 - Pin (2 used)
27 - Bushing
28 - Pin
29 - Carriage Bolt (6 used)
30 - Pivot Plate
31 - Nut (6 used)
32 - Cap Screw
33 - Rivet (12 used)
34 - Wear Pad (2 used)
35 - Cap Screw (5 used)
36 - Tilt Frame
37 - Cap Screw (8 used)
38 - Closure Plate, Left
39 - Cap Screw
40 - Plate
41 - Closure Plate, Right
Go to Section_110:Group_20
AG,OUO6037,30-19-20000725
1083
Remove and Install Tilt Frame
Remove and Install Tilt Frame
H66451-UN: Frame Hardware
LEGEND:
A - Screws
B - Cap Screw
1. Level tilt frame.
2. Remove pin from rod end of tilt cylinder.
3. Remove eight screws (A) from lower left and lower right corners of tilt frame.
4. Remove cap screw (B), washer, spacer and nut from both sides of tilt frame.
NOTE:
It may be necessary to heat screws due to the use of thread lock.
5.
H66455-UN: Frame Removal
LEGEND:
A - Frame
Attach hoist to frame (A).
6.
CAUTION:
Approximate weight of frame is 95 kg (209 lb).
1084
Remove and Install Tilt Frame
Item
Measurement Specification
Tilt Frame Weight
95 kg
(209 lb)
Remove tilt frame (A) from feeder house.
7.
H66516-UN: Wear Pad
LEGEND:
A - Wear Pad
Install wear pad (A) on both sides of feeder house.
NOTE:
Wear pads (A) can be held in place to frame by using O-rings as retainers on wear pad
posts.
8. IMPORTANT:
Be sure mating surfaces of frame (A) and tilt beam (B) are free of dirt, oil or foreign material.
H66520-UN: Frame
LEGEND:
A - Frame
B - Tilt Beam
1085
Remove and Install Tilt Frame
Install tilt frame (A) to feeder house.
9.
NOTE:
Be sure all screws have proper torque.
H66451-UN: Frame Removal
LEGEND:
A - Cap Screw (8 used)
B - Cap Screw (2 used)
Apply T43512 Thread Lock and Sealer to cap screws (A) and install on both sides. Torque cap screws
to specification.
Item
Measurement Specification
Tilt Frame Cap Screw Torque
315 N˙m
(230 lb-ft)
10. Install cap screw (B), washer and spacer through tilt beam. Install washer and lock nut. Tighten cap
screw to specification.
Item
Measurement Specification
Tilt Frame Shield Cap Screw Torque
130 N˙m
(95 lb-ft)
11. Install pin at rod end of tilt cylinder.
Go to Section_110:Group_20
OUO6046,00013BC-19-20021120
1086
Remove and Install Tilt Beam
Remove and Install Tilt Beam
1.
CAUTION:
Approximate weight of tilt beam is 54 kg (119 lb).
Item
Measurement Specification
Tilt Beam Weight
54 kg
(119 lb)
Level tilt frame.
2. Remove tilt angle sensor mounting bracket.
3. Remove pin from rod end of tilt cylinder.
4. Remove tilt frame (see procedure in this group).
5. Remove nut (A) from cap screw (B) at rear of tilt beam.
H55402-UN: Tilt Beam
LEGEND:
A - Nut
B - Cap Screw
C - Cap Screw
D - Retainer Plate
E - Pivot Pin
F - Tilt Beam
6. Remove cap screws (C) from retainer plate (D).
7. Remove cap screw (B) from pivot pin (E).
8. Support tilt beam (F).
9. Remove pivot pin (E) from rear of tilt beam. Pivot pin (E) is threaded for a M24 cap screw to be used as
1087
Remove and Install Tilt Beam
a puller.
10. Remove tilt beam.
11.
H66519-UN: Wear Pad
LEGEND:
A - Wear Pad
Install wear pad (A) in left and right lower frame holes.
12.
CAUTION:
Approximate weight of tilt beam is 54 kg (119 lb).
Item
Measurement Specification
Tilt Beam Weight
54 kg
(119 lb)
Install tilt beam (F) to feeder house with hoist.
H55402-UN: Tilt Beam
LEGEND:
A - Nut, M20
B - Cap Screw, M20 x 150
C - Cap Screw, M12
1088
Remove and Install Tilt Beam
D - Retainer Plate
E - Pivot Pin
F - Tilt Beam
13. Install pivot pin (E) through rear of tilt beam (F).
14. Install retainer plate (D) with cap screws (C).
15. Install cap screw (B) through front of feeder house with nut (A) on back side. Tighten to specification.
Item
Measurement Specification
Tilt Beam Pivot Cap Screw Torque
610 N˙m
(450 lb-ft)
16. Install tilt frame (see Remove and Install Tilt Frame in this group).
Go to Section_110:Group_20
OUO6046,00013BD-19-20010221
1089
Adjust Fore-Aft Turnbuckles
Adjust Fore-Aft Turnbuckles
1.
H66554-UN: Fore-aft Frame
H66553-UN: Turnbuckles
LEGEND:
A - Nuts (8 used)
B - Lock Nut
C - Turnbuckle
Loosen nuts (A) on both sides of feeder house
2. Loosen lock nut (B) and turn turnbuckle (C) until desired angle is reached. In normal operating
conditions the distance from eye to eye is 324 mm (12.75 in.).
3. Tighten lock nut (B).
4. Tighten nuts (A) to specified torque.
Item
Measurement Specification
Fore/Aft Tilt Frame Mounting Nuts Torque
215 N˙m
(159 lb-ft)
Go to Section_110:Group_20
OUO6046,00013D5-19-20010222
1090
Remove Fore-Aft Tilt Frame
Remove Fore-Aft Tilt Frame
1.
H66435-UN: Tilt Frame
LEGEND:
A - Tilt Frame
Remove tilt frame (A) (see Remove and Install Tilt Frame in this group).
2.
H66556-UN: Plates
1091
Remove Fore-Aft Tilt Frame
H66557-UN: Plates
LEGEND:
A - Cap Screw (16 used)
B - Top Plate (2 used)
C - Bottom Plate (2 used)
Remove cap screws (A) and plates (B) and (C) from feeder house.
3.
H66437-UN: Tilt Frame Grain Loss Seal
LEGEND:
A - Cap Screw
B - Seal (2 used)
Remove cap screw (A) and plastic seal (B) on both sides.
1092
Remove Fore-Aft Tilt Frame
4.
H66438-UN: Attaching Screws
LEGEND:
A - Round Head Bolt (8 used)
B - Nut (8 used)
Remove round head bolts (A), washers and nuts on both sides.
5. Remove nuts (B), washers and round head bolts on both sides.
6.
H66444-UN: Tilt Frame Seal
LEGEND:
A - Strap
Remove eight self-tapping screws, strap (A) and seal.
1093
Remove Fore-Aft Tilt Frame
7.
H66480-UN: Turnbuckles
LEGEND:
A - Nut
B - Turnbuckle
C - Spring Locking Pin
Loosen lock nut (A) and rotate turnbuckle (B) until frame is tilted to its extreme forward position.
8. Remove spring locking pin (C), washers and pin.
9.
H66466-UN: Tilt Frame with Hoist
1094
Remove Fore-Aft Tilt Frame
H66473-UN: Pivot Cap Screw
LEGEND:
A - Cap Screw (2 used)
Attach suitable lifting device to frame; apply tension to lifting device.
10. Remove pivot point cap screw (A) on both sides.
11. Remove frame using lifting device.
12. Make repairs as necessary.
Go to Section_110:Group_20
OUO6037,0001394-19-20010216
1095
Install Fore-Aft Tilt Frame
Install Fore-Aft Tilt Frame
1.
H66466-UN: Tilt Frame with Hoist
H66473-UN: Pivot Cap Screw
LEGEND:
A - Cap Screw (2 used)
Position tilt frame to front of feeder house using lifting device.
2. Install pivot point cap screw (A) on both sides.
3.
CAUTION:
Danger of crushing! Frame can suddenly rotate downward creating a pinch point.
Avoid personal injury and be certain that turnbuckles are connected before
attempting to install lower adjusting screws.
1096
Install Fore-Aft Tilt Frame
H66480-UN: Turnbuckles
LEGEND:
A - Nut
B - Turnbuckle
C - Spring Locking Pin
Connect turnbuckle using pin, washers and spring locking pin (C) on both sides.
4. Loosen lock nut (A); then tighten turnbuckle (B) to tilt frame upwards far enough to install lower round
head bolts.
5.
H66437-UN: Tilt Frame Grain Loss Seal
LEGEND:
A - Cap Screw
B - Seal (2 used)
Install plastic seal (B) and retain using cap screw (A) on both sides.
1097
Install Fore-Aft Tilt Frame
6.
H66438-UN: Attaching Screws
LEGEND:
A - Round Head Bolt (8 used)
B - Nut (8 used)
Install round head bolts (A), washers and nuts (B) on both sides. Do not tighten at this time.
7. Tighten set screw and lock nut.
8.
H66444-UN: Tilt Frame Seal
LEGEND:
A - Strap
Install rubber seal and strap (A) using cap screws.
1098
Install Fore-Aft Tilt Frame
9.
H66508-UN: Turnbuckle
LEGEND:
A - Turnbuckle
B - Nut
Adjust turnbuckles (A) to obtain desired tilt, then tighten lock nut (B).
10.
H66556-UN: Plates
1099
Install Fore-Aft Tilt Frame
H66557-UN: Plates
LEGEND:
A - Cap Screw (16 used)
B - Top Plate (2 used)
C - Bottom Plate (2 used)
Install plates (B) and (C) using cap screws (A).
11.
H66452-UN: Pivot Mounting Hardware
LEGEND:
A - Nuts (8 used)
B - Cap Screw (2 used)
Tighten nuts (A) and cap screw (B) on both sides of feeder house to specification.
1100
Install Fore-Aft Tilt Frame
Item
Measurement Specification
Fore/Aft Tilt Frame Mounting Nuts Torque
215 N˙m
(159 lb-ft)
12.
H66435-UN: Tilt Frame
LEGEND:
A - Tilt Frame
Install tilt frame (A) (see procedure in this group).
Go to Section_110:Group_20
OUO6037,00000A1-19-20010220
1101
Tilt Frame - Exploded View
Tilt Frame - Exploded View
ZX25122-UN: HillMaster II Tilt Frame
LEGEND:
1 - Feeder House Frame
2 - Rear Eyebolt (2 used)
3 - Cotter Pin (4 used)
4 - Pin (4 used)
5 - Turnbuckle (2 used)
6 - Nut (2 used)
7 - Front Eyebolt (2 used)
8 - Tilt Frame
9 - Carriage Bolt (12 used)
10 - Pivot Plate (2 used)
11 - Flange Nut (12 used)
12 - Flange Nut (2 used)
13 - Shim Pack
14 - Washer
15 - Nut
16 - Nut
17 - Lubrication Fitting
18 - Tilt Frame
1102
Tilt Frame - Exploded View
19 - Wear Plate
20 - Carriage Bolt (4 used)
21 - Wear Plate (2 used)
22 - Washer (4 used)
23 - Spacer (2 used)
24 - Screws (4 used)
25 - Wear Pad (2 used)
26 - Support Plate (2 used)
27 - Lock Nut (4 used)
28 - Cap Screw (4 used)
29 - Cap Screw (4 used)
30 - Flange Nut (2 used)
31 - Washer (4 used)
32 - Flange Nut (4 used)
Tighten pivot plate flange nuts (11) to specification.
Item
Measurement Specification
Pivot Plate Flange Nuts Torque
240 N˙m
(177 lb-ft)
IMPORTANT:
Make certain to retorque tilt frame flange nuts (12), (30) and (32) to specification after 50 and 200 hours.
Tighten tilt frame flange nuts (12), (30) and (32) to specification. Retorque after 50 and 200 hours.
Item
Measurement Specification
Tilt Frame Flange Nuts (Retorque after 50 and 200 Hours) Torque
240 N˙m
(177 lb-ft)
Adjust plate (26) by adding or subtracting washers (22) to gain specified gap.
Item
Measurement
Specification
Wear Pad to Pivot Panel Gap, Maximum Allowed (Without Header Installed) 3.0 mm
(0.118 in.)
Tighten cap screws (28) to specification.
Item
Measurement Specification
Wear Pad Cap Screws Torque
310 N˙m
(229 lb-ft)
Attach frame (18) to frame (8). If binding occurs, use shims (13) to compensate tolerances of the
manufacturing process.
Adjust pivot plate to tilt frame gap by adding or subtracting washers (14) to gain specified gap.
Item
Measurement Specification
Pivot Plate to Tilt Frame Distance
3 mm ± 1 mm
(0.118 in. ± 0.039 in.)
NOTE:
Distance is measured from center of eyebolt to center of eyebolt.
The feeder house tilt frame was factory set at 315 mm (12 in.). Setting tilt frame in the
field may be necessary due to various tire configurations and ground conditions to gain
optimum cutting performance.
Adjust turnbuckles (5) to specification.
1103
Tilt Frame - Exploded View
Item
Measurement Specification
Turnbuckle (Factory Setting) Distance
315 mm
(12 in.)
Go to Section_110:Group_25
OUO6435,0001411-19-20010719
1104
Tilt Frame - Exploded View
Tilt Frame - Exploded View
ZX25122-UN: HillMaster II Tilt Frame
LEGEND:
1 - Feeder House Frame
2 - Rear Eyebolt (2 used)
3 - Cotter Pin (4 used)
4 - Pin (4 used)
5 - Turnbuckle (2 used)
6 - Nut (2 used)
7 - Front Eyebolt (2 used)
8 - Tilt Frame
9 - Carriage Bolt (12 used)
10 - Pivot Plate (2 used)
11 - Flange Nut (12 used)
12 - Flange Nut (2 used)
13 - Shim Pack
14 - Washer
15 - Nut
16 - Nut
17 - Lubrication Fitting
18 - Tilt Frame
1105
Tilt Frame - Exploded View
19 - Wear Plate
20 - Carriage Bolt (4 used)
21 - Wear Plate (2 used)
22 - Washer (4 used)
23 - Spacer (2 used)
24 - Screws (4 used)
25 - Wear Pad (2 used)
26 - Support Plate (2 used)
27 - Lock Nut (4 used)
28 - Cap Screw (4 used)
29 - Cap Screw (4 used)
30 - Flange Nut (2 used)
31 - Washer (4 used)
32 - Flange Nut (4 used)
Tighten pivot plate flange nuts (11) to specification.
Item
Measurement Specification
Pivot Plate Flange Nuts Torque
240 N˙m
(177 lb-ft)
IMPORTANT:
Make certain to retorque tilt frame flange nuts (12), (30) and (32) to specification after 50 and 200 hours.
Tighten tilt frame flange nuts (12), (30) and (32) to specification. Retorque after 50 and 200 hours.
Item
Measurement Specification
Tilt Frame Flange Nuts (Retorque after 50 and 200 Hours) Torque
240 N˙m
(177 lb-ft)
Adjust plate (26) by adding or subtracting washers (22) to gain specified gap.
Item
Measurement
Specification
Wear Pad to Pivot Panel Gap, Maximum Allowed (Without Header Installed) 3.0 mm
(0.118 in.)
Tighten cap screws (28) to specification.
Item
Measurement Specification
Wear Pad Cap Screws Torque
310 N˙m
(229 lb-ft)
Attach frame (18) to frame (8). If binding occurs, use shims (13) to compensate tolerances of the
manufacturing process.
Adjust pivot plate to tilt frame gap by adding or subtracting washers (14) to gain specified gap.
Item
Measurement Specification
Pivot Plate to Tilt Frame Distance
3 mm ± 1 mm
(0.118 in. ± 0.039 in.)
NOTE:
Distance is measured from center of eyebolt to center of eyebolt.
The feeder house tilt frame was factory set at 315 mm (12 in.). Setting tilt frame in the
field may be necessary due to various tire configurations and ground conditions to gain
optimum cutting performance.
Adjust turnbuckles (5) to specification.
1106
Tilt Frame - Exploded View
Item
Measurement Specification
Turnbuckle (Factory Setting) Distance
315 mm
(12 in.)
Go to Section_110:Group_25
OUO6435,0001411-19-20010719
1107
Table of Contents
Section 120: Separator - W Series
Group 05: Separator Repair
Essential and Recommended Special Tools
Other Material
Specifications
Remove and Install Rasp Bars
Static Balance Cylinder
Remove Threshing Cylinder
Install Threshing Cylinder
Remove Concave
Install Concave
Level Concave (Rasp Bar)
Level Concave (Spike Tooth)
Adjust Second Concave
Concave Position Sensor and Linkage
Remove and Install Concave Adjusting Motor
Second Cylinder Exploded View
Disassemble and Assemble Second Cylinder
Remove and Install Second Cylinder
Group 10: Cylinder Drives
Essential and Recommended Special Tools
Other Material
Specifications
Remove Dual Range Cylinder Drive Gear Case
Dual Range Cylinder Drive, Exploded View
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
Remove and Install Intermediate Cylinder Drive
Repair Intermediate Cylinder Drive
Remove and Install Intermediate Cylinder Drive Support
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
Group 15: Straw Walkers, Crankshafts and Walker Return Pan
Essential and Recommended Special Tools
1108
Table of Contents
Other Material
Specifications
All Walkers - Timing Procedure
Remove and Install Straw Walker Bearings and Walker Return Pan
Remove and Install Rear Crankshaft
Remove and Install Front Crankshaft
Remove and Install Straw Walker Gear Case
Disassemble and Assemble Straw Walker Gearcase
Remove and Install Power Separator
Group 20: Straw Chopper and Chaff Spreader
Service Equipment and Tools
Other Material
Specifications
Chopper and Blades
Chopper Housing and Knife Bank
Remove Straw Chopper
Replace Chopper Blades
Replace Knife Sections
Remove and Install Rotor Bearings
Remove and Install Straw Chopper Jackshaft
Disassemble and Assemble Straw Chopper Jackshaft
Remove and Install Straw Chopper Idler Assembly
Group 25: Shoe Supply Augers, Cleaning Fan and Chaffer and Sieve Frame
Other Material
Specifications
Replace Shoe Supply Augers
Replace Shoe Supply Auger Wooden Bearings
Remove and Install Shoe Supply Auger Drive Shaft
Remove and Install Shoe Supply Auger Trough
Remove Separator Drive Jackshaft
Install Separator Drive Jackshaft
Remove and Install Cleaning Fan Drive
Fan Drive Speed Control
1109
Table of Contents
Remove Cleaning Fan
Install Cleaning Fan
Remove and Install Cleaning Fan Housing
Adjust Fan Speed Actuator
Remove Chaffer, Sieve and Frames
Install Chaffer, Sieve and Frames
Remove and Install Shoe Pitman Arms
Group 30: Tailings Elevator and Augers
Disassemble Tailings Elevator and Augers
Group 35: Primary Countershaft
Essential and Recommended Special Tools
Specifications
Remove and Install Primary Countershaft Gear Case
Disassemble and Assemble Primary Countershaft Gear Case
Remove and Install Primary Countershaft with Variable Sheave Assembly
Remove and Install Beater Curtain
Group 40: Header Electromagnetic Clutch Assembly
Specifications
Remove Header Electromagnetic Clutch
Disassemble and Assemble Header Electromagnetic Clutch
Install Header Electromagnetic Clutch
1110
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
To remove/install cylinder and concave.
H40598-UN: Service Jack
Lower Bracket.......JT05876
To remove/install cylinder and concave.
H41228-UN: Lower Bracket
Cylinder and Concave Remover/Installer
Bracket.......JT05875
To remove/install cylinder and concave.
H41229-UN: Cylinder and Concave Remover/Installer
Bracket
1111
Essential and Recommended Special Tools
Concave Checking and Setting Gauge [
RECOMMENDED TOOL ] .......JDG700A
Used to adjust concave clearance.
H72818-UN: Concave Clearance Gauge
Offset Wrench.......JDG701
Used to adjust concave clearance.
H45151-UN: Offset Wrench
Remote Control.......JDG702
Used to adjust concave clearance.
H45150-UN: Remote Control
Go to Section_120:Group_05
ZX09263,0002744-19-20080201
1112
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
To remove/install cylinder and concave.
H40598-UN: Service Jack
Lower Bracket.......JT05876
To remove/install cylinder and concave.
H41228-UN: Lower Bracket
Cylinder and Concave Remover/Installer
Bracket.......JT05875
To remove/install cylinder and concave.
H41229-UN: Cylinder and Concave Remover/Installer
Bracket
1113
Essential and Recommended Special Tools
Concave Checking and Setting Gauge [
RECOMMENDED TOOL ] .......JDG700A
Used to adjust concave clearance.
H72818-UN: Concave Clearance Gauge
Offset Wrench.......JDG701
Used to adjust concave clearance.
H45151-UN: Offset Wrench
Remote Control.......JDG702
Used to adjust concave clearance.
H45150-UN: Remote Control
Go to Section_120:Group_05
ZX09263,0002744-19-20080201
1114
Other Material
Other Material
Number
Name
Use
PT569 or PT506 (U.S.) NEVER-SEEZ Use to coat beater shaft.
Go to Section_120:Group_05
AG,OUO6435,937-19-20000503
1115
Specifications
Specifications
Item
Measurement Specification
Rasp Bar Deflector Cap Screws
Torque
67 N˙m
(51 lb-ft)
Rasp Bar Cap Screws and Nuts
Torque
130 N˙m
(96 lb-ft)
Spike Tooth Retaining Nuts
Torque
60 N˙m
(45 lb-ft)
Dual Range Cylinder
Length
135 mm (5-5/16 in.)
Single Range Cylinder
Length
134.4 mm (5-19/64 in.)
Threshing Cylinder Head Hardware
Torque
123 N˙m
(91 lb-ft)
Concave Nose Screws and Nuts
Torque
130 N˙m
(96 lb-ft)
Concave Retaining Screws
Torque
285 N˙m
(200 lb-ft)
Spike Tooth Concave Retaining Nut
Torque
285 N˙m
(200 lb-ft)
Cylinder and Concave Tooth Adjusting Nuts Torque
285 N˙m
(200 lb-ft)
Second Concave Linkage
Distance
220 mm (8-21/32 in.)
Second Cylinder Blade Cap Screws
Torque
50 N˙m
(37 lb-ft)
Go to Section_120:Group_05
ZX08798,00008CE-19-20090923
1116
Remove and Install Rasp Bars
Remove and Install Rasp Bars
H65714-UN: Adjust Idler
LEGEND:
A - Belt
B - Nut (2 used)
NOTE:
It is recommended that left and right five pack of weight matched rasp bars be purchased in lieu
of single bars when replacing ALL rasp bars. Rasp bars should be replaced when serration depth
is less than 6 mm (1/4 in.).
1. Remove feeder house from combine (see instructions in Section 110).
2. Loosen nuts (B) from cylinder drive idler.
3. Remove belt (A) from cylinder drive gear case.
4.
ZX25153-UN: Idler
LEGEND:
A - Nut (2 used)
B - Belt
Loosen nuts (A) on beater drive tensioner.
5. Remove beater drive belt (B) from cylinder drive sheave.
1117
Remove and Install Rasp Bars
6.
H50579-UN: Filler Plates
LEGEND:
A - Rasp Bars
B - Filler Plates
Remove all filler plates (B).
7. Clean all dirt and debris from cylinder.
8. Remove or replace rasp bars (A) one at a time. Serrations on rasp bars must be in same direction as
removed.
9. Static balance cylinder in combine (see procedure in this group).
NOTE:
Balance cylinder after replacing any rasp bar to prevent vibration.
10. Install filler plates (B).
11.
ZX25153-UN: Idler
LEGEND:
A - Nut (2 used)
B - Belt
Install beater drive belt (B) on cylinder drive sheave.
12. Tighten idler tension nuts (A) to gauge. Tighten lock nut.
1118
Remove and Install Rasp Bars
13.
H65714-UN: Adjust Idler
LEGEND:
A - Drive Belt
B - Nut (2 used)
Install cylinder drive belt (A) on cylinder drive gear case.
14. Tighten idler tension nuts (B) to gauge. Tighten lock nut.
15. Install feeder house (see instructions in Section 110).
Go to Section_120:Group_05
OUO6089,000004D-19-20010627
1119
Static Balance Cylinder
Static Balance Cylinder
NOTE:
Static balance is recommended after replacing any rasp bars or row of teeth in spike tooth
cylinder.
1. Remove filler plates if equipped.
2. Clean dirt and debris from inside of cylinder.
3. Remove drive belts from both ends of cylinder.
4. Inspect cylinder shaft bearings and lubricate to minimize drag during shaft rotation.
5. Rotate cylinder, BY HAND, 90 degrees and release. Repeat rotation several times.
6. If cylinder stays at rest (no rotation) after release, NO balance is required.
7. If cylinder rotates more than 25 mm (1 in.) after release, at the circumference (rasp bar/spike tooth tip),
balancing is required.
8.
1120
Static Balance Cylinder
H46371-19: Static Balance Cylinder
Spin cylinder by hand.
9. After cylinder has stopped rotating, observe position of balance weight washers on outside bulkheads of
cylinder.
10. Add 5/16 in. washers, of various thickness to top side of cylinder. Attach washers with 5/16 in. screws to
holes in cylinder bulkhead at top.
NOTE:
Avoid stacking excessive amounts of washers. It may be necessary to remove weight
from heavy side (bottom) to achieve balance.
11. Add or subtract weight washers as required until cylinder can be rotated 90 degrees and stays at rest
(no rotation) within the 25 mm (1 in.) circumference distance (rasp bar/spike tooth tip).
12. Split the additional amount of weight added into two equal amounts.
13. Add an equal amount of balance weight washers to each outside bulkhead in the same location hole
with 5/16 in. screws.
Go to Section_120:Group_05
AG,OUO6435,940-19-20000503
1121
Remove Threshing Cylinder
Remove Threshing Cylinder
H68077-UN: Door
LEGEND:
A - Door
B - Screw (2 used)
C - Support (2 used)
D - Cap Screw (2 used)
E - Spacer (2 used)
1. Remove feeder house (see instructions in Section 110).
2. Remove door (A).
3. Remove screw (B), cap screw (D), spacer (E) and support (C) from both sides.
4.
H41198-UN: Door
LEGEND:
A - Cap Screw and Nut (6 used)
B - Plate
C - Deflector
D - Door
Remove nuts and cap screws (A) from both sides.
5. Remove plate (B) and deflector (C).
6. Remove door (D).
1122
Remove Threshing Cylinder
7.
H41199-UN: Concave
LEGEND:
A - Screw and Nut (6 used)
B - Concave Nose
Remove nuts and screws (A) and concave nose (B).
8.
H67947-UN: Idler
LEGEND:
A - Nut (2 used)
B - Belt (2 used)
Loosen nuts (A) to relieve belt tension.
9. Remove beater drive belt (B).
1123
Remove Threshing Cylinder
10.
ZX25370-UN: Sheave
LEGEND:
A - Cap Screw (3 used)
B - Sheave
Remove cap screws (A) and beater drive sheave (B) from shaft hub.
11.
H41224-UN: Hub
LEGEND:
A - Cap Screw
B - Hub
Loosen cap screw (A).
12. Use a puller to remove hub (B) from cylinder shaft.
13. Remove dual range cylinder drive gear case or sheave from right end of cylinder shaft (see instructions
in Group 10).
1124
Remove Threshing Cylinder
14.
H50571-UN: Concave Adjusting Motor
LEGEND:
A - Pin
B - Rod
C - Cam
D - Concave Adjusting Motor
E - Connector
F - Pin
Disconnect rod (B) and connector (E).
15. Rotate cam (C) slightly counterclockwise and remove pin (A).
16. Remove pin (F) and concave adjusting motor (D).
17. Place a block under concave to keep it from dropping.
18.
H50272-UN: Concave Adjusting Linkage
LEGEND:
A - Threaded Stud
B - Lock Nut
C - Washer
D - Seal
E - Cam
F - Shaft
Remove threaded stud (A), lock nut (B), washer (C), seal (D) and cam (E) from right side.
19. Remove screw, washer, seal, spacer and cam from left side.
1125
Remove Threshing Cylinder
20. Remove shaft (F).
21. Remove block. Lower concave.
22.
H50579-UN: Threshing Cylinder
LEGEND:
A - Shaft Clamps
B - Filler Plates
Rotate cylinder until nuts on cylinder shaft clamps (A) are accessible.
23. Remove filler plates (B) as needed.
24.
H41205-UN: Shaft
LEGEND:
A - Shaft
B - Clamp (2 used)
C - Nut (2 used)
Clean shaft (A) with emery cloth to aid removal.
25. Loosen nuts (C) on two clamps (B).
26.
CAUTION:
The approximate weight of cylinder is 147 kg (325 lb).
1126
Remove Threshing Cylinder
H41206-UN: Remove Threshing Cylinder
LEGEND:
A - Cylinder
B - Remover/installer Bracket
Attach D05070ST Service Jack, JT05876 Lower Bracket and JT05875 Cylinder and Concave
Remover/Installer Bracket (B) for removal of cylinder (A).
27.
ZX1041988-UN: Distance (X)
LEGEND:
A - Locking Collar
B - Shaft
X - Distance (X) from Shaft End to Sidewalll
Remove locking collar (A) from shaft (B).
28. Remove screws and disconnect lubrication oil line.
29.
H41212-UN: Shaft
LEGEND:
A - Shaft
B - Key (2 used)
1127
Remove Threshing Cylinder
Remove keys (B) from shaft (A).
30. Slide shaft with right bearing out right side of combine.
31.
ZX1042021-UN: Bearing Housing
LEGEND:
A - Cap Screw (4 used)
B - Housing (2 used)
C - Bearing (2 used)
D - Lubrication Line (2 used)
Disconnect lubrication line (D) from left housing.
32. Remove cap screws (A), housing (B) and bearing (C) from left side.
1128
Remove Threshing Cylinder
33.
H72473-UN: Threshing Cylinder
LEGEND:
1 - Key (2 used)
2 - Shaft
3 - Housing
4 - Lock Washer (8 used)
5 - Cap Screw (8 used)
6 - Set Screw (2 used)
7 - Locking Collar (2 used)
8 - Bearing (2 used)
9 - Lubrication Fitting (2 used)
10 - Hose (2 used)
11 - Fitting (2 used)
12 - Cylinder Head (2 used)
13 - Cylinder Head (2 used)
1129
Remove Threshing Cylinder
14 - Cylinder Head
15 - Cap Screw and Lock Washer (2 used)
16 - Nut (2 used)
17 - Rasp Bar
18 - Lock Nut
(rasp bar; W540, W550, T560—60 used)
(rasp bar; W650, W660—70 used)
(deflector; W540, W550, T560—120 used)
(deflector; W650, W660—140 used)
19 - Washer
(rasp bar; W540, W550, T560—60 used)
(rasp bar; W650, W660—70 used)
(deflector; W540, W550, T560—120 used)
(deflector; W650, W660—140 used)
20 - Cap Screw
(W540, W550, T560—60 used)
(W650, W660—70 used)
21 - Washer (2 used)
22 - Deflector (10 used)
23 - Self-Tapping Screw
(W540, W550, T560—60 used)
(W650, W660—70 used)
24 - Cylinder
25 - Nut
(W540, W550, T560—120 used)
(W650, W660—140 used)
Inspect cylinder parts for wear or damage. Repair or replace parts as necessary.
34. Tighten rasp bar deflector cap screws to specification.
Item
Measurement Specification
Rasp Bar Deflector Cap Screws Torque
67 N˙m
(51 lb-ft)
Tighten rasp bar cap screws and nuts to specification.
Item
Measurement Specification
Rasp Bar Cap Screws and Nuts Torque
130 N˙m
(96 lb-ft)
1130
Remove Threshing Cylinder
35.
H64461-UN: Spike Tooth Cylinder
LEGEND:
1 - Key (2 used)
2 - Shaft
3 - Housing (2 used)
4 - Lock Washer (8 used)
5 - Cap Screw (8 used)
6 - Locking Collar (2 used)
7 - Ball Bearing (2 used)
8 - Fitting (2 used)
9 - Hose (2 used)
10 - Lubrication Fitting (2 used)
11 - Tooth (312 used on machines with 5 walkers; 378 used on machines with 6 walkers)
12 - Lock Washer, 1/2 in. (314 used on W540, W550, T560; 378 used on W650, W660)
13 - Nut, 1/2 in. (314 used on W540, W550, T560; 380 used on W650, W660)
1131
Remove Threshing Cylinder
14 - Cap screw, 1/2 x 3 in. (2 used)
15 - Tool
16 - Cylinder
Replace worn or broken teeth (11).
36. Drive in new teeth using a hammer and wooden block. Tighten nuts (13) on teeth to specification.
Item
Measurement Specification
Spike Tooth Retaining Nuts Torque
60 N˙m
(45 lb-ft)
Go to Section_120:Group_05
ZX61739,000045C-19-20080527
1132
Install Threshing Cylinder
Install Threshing Cylinder
ZX1042021-UN: Bearing Housing
LEGEND:
A - Cap Screw (4 used)
B - Housing (2 used)
C - Bearing (2 used)
D - Lubrication Line (2 used)
1. Install bearing (C) in housing (B).
2. Install bearing and housing as an assembly on both sides of combine.
3. Connect lubrication lines (D).
4.
CAUTION:
The approximate weight of cylinder is 147 kg (325 lb).
H41206-UN: Install Threshing Cylinder
1133
Install Threshing Cylinder
LEGEND:
A - Cylinder
B - Remover/installer Bracket
Position cylinder (A) in place using D05070ST Service Jack and JT05875 Cylinder and Concave
Remover/Installer Bracket (B).
5.
H41212-UN: Shaft
LEGEND:
A - Shaft
B - Key (2 used)
Coat shaft (A) with PT569 NEVER-SEEZ Lubricant.
6. Insert shaft (A).
7. Install two keys (B) in shaft.
8. Complete shaft installation.
9. IMPORTANT:
Adjust distance (X) between shaft end and sidewall.
Item
Measurement Specification
Distance (X) from Shaft End to Sidewalll Length
ZX1041988-UN: Distance (X)
LEGEND:
A - Locking Collar
B - Shaft
X - Distance (X) from Shaft End to Sidewalll
1134
198 mm (7.80 in.)
Install Threshing Cylinder
Install locking collar (A) on shaft (B).
10. Center cylinder between side sheets.
11.
H41205-UN: Shaft
LEGEND:
A - Shaft
B - Clamp (2 used)
C - Nut (2 used)
Install nuts (C) on clamps (B) to secure shaft (A). Tighten to specification.
Item
Measurement Specification
Threshing Cylinder Head Hardware Torque
123 N˙m
(91 lb-ft)
12.
H41214-UN: Deflectors
LEGEND:
A - Deflectors
Install deflectors (A).
13. Raise and block concave into position.
1135
Install Threshing Cylinder
14.
H41215-UN: Shaft
LEGEND:
A - Shaft
B - Concave
Install shaft (A) through front of concave (B).
15.
H50272-UN: Concave Adjusting Linkage
LEGEND:
A - Threaded Stud
B - Lock Nut
C - Washer
D - Seal
E - Cam
F - Shaft
Install cam (E), seal (D), washer (C), lock nut (B), and threaded stud (A) on right side.
16. Install spacer, cam, seal, washer, and screw on left side.
17.
1136
Install Threshing Cylinder
H50571-UN: Concave Adjusting Motor
LEGEND:
A - Pin
B - Rod
C - Cam
D - Concave Adjusting Motor
E - Connector
F - Pin
Install concave adjusting motor (D) and pin (F).
18. Rotate cam (C) slightly counterclockwise to install pin (A).
19. Connect rod (B) and connector (E).
20. Install dual range cylinder drive or sheave (see instructions in Group 10).
21.
H41225-UN: Hub
LEGEND:
A - Hub
B - Cap Screw
Install hub (A) and tighten cap screw (B).
1137
Install Threshing Cylinder
22.
ZX25370-UN: Sheave
LEGEND:
A - Cap Screw (3 used)
B - Sheave
Install sheave (B) using cap screws (A).
NOTE:
Inner side of sheave has to be set 34.0 mm (1.3 in.) from side sheet.
23.
ZX25153-UN: Idler
LEGEND:
A - Nut (2 used)
B - Belt
1138
Install Threshing Cylinder
Install belt (B) and adjust belt tension with nuts (A).
24.
H41199-UN: Concave
LEGEND:
A - Screw and Nut (machines with 5 walkers—6 used) (machines with 6 walkers—8 used)
B - Concave Nose
Install concave nose (B). Tighten nuts (A) to specified torque.
Item
Measurement Specification
Concave Nose Screws and Nuts Torque
130 N˙m
(96 lb-ft)
25.
H41198-UN: Door
LEGEND:
A - Cap Screw and Nut (6 used)
B - Plate
C - Deflector
D - Door
Install door (D).
26. Install deflector (C) and plate (B).
27. Install cap screws and nuts (A) on both sides.
1139
Install Threshing Cylinder
28.
H68077-UN: Door
LEGEND:
A - Door
B - Cap Screw (2 used)
C - Support (2 used)
D - Cap Screw (2 used)
E - Spacer (2 used)
Install support (C), spacer (E), cap screw (D) and cap screw (B) on both sides.
29. Install door (A).
30. Install feeder house (see instructions in Section 110).
Go to Section_120:Group_05
ZX61739,0000301-19-20080526
1140
Remove Concave
Remove Concave
1.
H41216-UN: Second Concave
LEGEND:
A - Second Concave
B - Eyebolt
C - Concave
Remove feeder house (see instructions in Section 110).
2.
NOTE:
Cylinder does not have to be removed to remove concave.
Loosen two eyebolts (B) attaching second concave (A).
3.
H50571-UN: Concave Adjusting Motor
LEGEND:
A - Pin
B - Rod
C - Cam
D - Concave Adjusting Motor
E - Connector
F - Pin
Disconnect rod (B) and connector (E).
4. Rotate cam (C) slightly counterclockwise and remove pin (A).
5. Remove pin (F) to remove concave adjusting motor (D).
1141
Remove Concave
6. Place a block under concave to keep it from dropping.
7.
H50272-UN: Concave Adjusting Linkage
LEGEND:
A - Threaded Stud
B - Lock Nut
C - Washer
D - Seal
E - Cam
F - Shaft
Remove threaded stud (A), lock nut (B), washer (C), seal (D) and cam (E) from right side.
8. Remove screw, washer, seal, spacer and cam from left side.
9. Remove shaft (F).
10. Remove block. Lower concave.
11.
CAUTION:
The approximate weight of concave is 113 kg (250 lb).
Attach D05070ST Service Jack with JT05876 Lower Bracket and JT05875 Cylinder and Concave
Remover/Installer Bracket to concave.
12.
1142
Remove Concave
H41218-UN: Remove Concave
LEGEND:
A - Cap Screw
Remove cap screw (A) on both sides.
13. Remove concave. Second concave will swing away from concave.
14.
CAUTION:
The approximate weight of second concave is 29 kg (65 lb).
ZX1042020-UN: Second Concave
LEGEND:
A - Cap Screw
B - Second Concave
Remove cap screw (A) from both sides and second concave (B).
15. Inspect concave for wear and damage. Repair or replace parts as necessary.
1143
Remove Concave
H41227-UN: Spike-Tooth Second Concave
LEGEND:
A - Flange Nut (2 used)
B - Washer (2 used)
C - Bushing (2 used)
D - Cap Screw
E - Finger (as required)
F - Cap Screw
G - Support
H - Cover
I - Cotter Pin (2 used)
J - Rod
K - Cap Screw (4 used)
L - Washer (8 used)
M - Flange Nut (4 used)
N - Eyebolt (2 used)
O - Lock Nut
1144
Remove Concave
H50594-UN: Second Concave
LEGEND:
1 - Cotter Pin (2 used)
2 - Screw
3 - Bushing (2 used)
4 - Washer (2 used)
5 - Flange Nut (2 used)
6 - Grate
7 - Pin
8 - Eyebolt (2 used)
9 - Lock Nut (2 used)
10 - Eyebolt (2 used)
11 - Cap Screw (2 used)
12 - Nut (4 used)
13 - Flange Nut (4 used)
14 - Screw (2 used)
15 - Bushing (2 used)
16 - Cover
1145
Remove Concave
17 - Link (2 used)
18 - Eyebolt
H50595-UN: Rasp Bar Concave
LEGEND:
1 - Cam
2 - Screw
3 - Washer
4 - Strap
5 - Cover
6 - Retainer
7 - Washer
8 - Seal
9 - Spacer
10 - Cover
11 - Cover (as required)
12 - U-Bolt (as required)
13 - Bracket
14 - Insert (as required)
15 - Lock Nut (as required)
16 - Wire (as required)
17 - Concave
18 - Shaft
19 - Lock Nut (6 used)
20 - Spacer (8 used)
21 - Cam
1146
Remove Concave
22 - Screw (6 used)
23 - Screw (6 used)
24 - Concave Insert
25 - Washer
26 - Adjusting Strap (2 used)
27 - Bushing (2 used)
28 - Retainer (2 used)
29 - Adjusting Strap
H50596-UN: Spike-Tooth Concave
LEGEND:
1 - Concave
2 - Shaft
3 - Grate
4 - Tooth (as required)
5 - Bracket
6 - Lock Washer (as required)
7 - Nut (as required)
8 - Bar assembly (as required)
1147
Remove Concave
9 - Concave Bar (as required)
10 - Screw (8 used)
11 - Crop Divider (5 used)
12 - Cap Screw (2 used)
13 - Cap Screw (2 used)
14 - Adjusting Strap (2 used)
15 - Bushing (2 used)
16 - Retainer (2 used)
17 - Adjusting Strap
H50597-UN: Concave Adjusting Cams
LEGEND:
1 - Screw
2 - Washer
3 - Screw (2 used)
4 - Eyebolt (2 used)
1148
Remove Concave
5 - Adjusting Strap
6 - Cam
7 - Flange Nut (4 used)
8 - Spacer
9 - Washer (2 used)
10 - Seal Ring (2 used)
11 - Flange Nut (4 used)
12 - Bushing (4 used)
13 - Link (2 used)
14 - Cover
15 - Screw (2 used)
16 - Cover
17 - Eyebolt
18 - Cam
19 - Screw
20 - Spacer
Go to Section_120:Group_05
ZX61739,000045A-19-20080526
1149
Install Concave
Install Concave
1.
CAUTION:
The approximate weight of second concave is 29 kg (65 lb).
ZX1042020-UN: Second Concave
LEGEND:
A - Cap Screw
B - Second Concave
Install second concave (B) using cap screw (A) on both sides.
2.
H41226-UN: Second Concave
LEGEND:
A - Second Concave
Tie second concave (A) up to allow clearance for concave.
3.
CAUTION:
The approximate weight of concave is 113 kg (250 lb).
Use D05070ST Service Jack with JT05876 Lower Bracket and JT05875 Cylinder and Concave
Remover/Installer Bracket to install concave.
1150
Install Concave
4.
H41218-UN: Screw
LEGEND:
A - Cap Screw
Install cap screw (A) on both sides to secure concave.
5.
H41216-UN: Attach Second Concave
LEGEND:
A - Second Concave
B - Eyebolt (2 used)
C - Concave
Lower second concave (A) and attach to concave (C) with two eyebolts (B).
6. Raise and block concave into position.
7.
H41215-UN: Install Shaft
LEGEND:
A - Shaft
B - Concave
Install shaft (A) through front of concave (B).
1151
Install Concave
8.
H50272-UN: Install Cam
LEGEND:
A - Threaded Stud
B - Lock Nut
C - Washer
D - Seal
E - Cam
F - Shaft
Install cam (E), seal (D), washer (C), lock nut (B) and threaded stud (A) on right side.
9.
H50571-UN: Concave Adjusting Motor
LEGEND:
A - Pin
B - Rod
C - Cam
D - Concave Adjusting Motor
E - Connector
F - Pin
Install concave adjusting motor (D) and pin (F).
10. Rotate cam (C) slightly counterclockwise to install pin (A).
11. Connect rod (B) and connector (E).
12. Level the concave (see procedure in this Group).
13. Install feeder house (see instructions in Section 110).
1152
Install Concave
Go to Section_120:Group_05
ZX61739,000045B-19-20080526
1153
Level Concave (Rasp Bar)
Level Concave (Rasp Bar)
H72818-UN: Concave Clearance Gauge
JDG700A Concave Checking and Setting Gauge, JDG701 Offset Wrench and JDG702 Remote Control are
required to adjust concave.
NOTE:
Tools are used to adjust concave for levelness or proper clearance.
1.
H72807-UN: Adjust Concave
LEGEND:
A - Connector
B - Inspection Hole (4 used)
Disconnect concave actuator connector (A) and connect remote control.
2. Connect remote control battery leads to a good 12 volt supply.
3. Remove front and rear inspection hole covers (B) on both sides of combine.
1154
Level Concave (Rasp Bar)
4.
H72808-UN: Eyebolt Adjustment
LEGEND:
A - Notch in Eyebolt
B - Notch in Sidesheet
C - 4 mm (5/16 in.)
Adjust eyebolts (both sides) so that notch (A) on eyebolt is 4 mm (5/16 in.) above notch (B) in sidesheet.
5. Remove pin from dual range cylinder drive, if equipped, to make rotating cylinder easier.
6.
NOTE:
Opening concave completely assures all mechanical play is out of linkage when
checking clearance with gauge.
Use remote control to open concave fully until a ratcheting sound is heard.
7.
H44776-UN: Loosen Stop
LEGEND:
B - Cap Screw (2 used)
Loosen concave stop cap screws (B).
1155
Level Concave (Rasp Bar)
8.
H72809-UN: Rotate Cylinder
LEGEND:
A - Washer
B - Crossbar
C - Rasp Bar
D - Gauge
Rotate cylinder clockwise until rasp bar (C) with washer (A) appears in front right inspection hole. Mark
both ends of bar for reference.
9. Close concave until crossbar (B) appears in front inspection hole.
10. Using JDG700A Concave Checking and Setting Gauge (D), insert end marked A into front right
inspection hole.
11. Slowly close concave until gauge is a slip fit between rasp bar and concave bar.
IMPORTANT:
If concave is closed too far and gauge becomes lodged, concave MUST be opened; then repeat steps 9
to 11.
12.
H72810-UN: Removing Play in Linkage
Go to left side of concave. Insert a 1/2 in. breaker bar in cam and apply pressure (counterclockwise) to
remove all mechanical play out of linkage before checking clearance with gauge.
1156
Level Concave (Rasp Bar)
13.
H72811-UN: Adjust Concave
LEGEND:
A - Gauge
B - Retaining Screw
C - Nuts
Using JDG700A Concave Checking and Setting Gauge (A), insert end marked A into front left inspection
hole. Gauge should be a slip fit.
14. Use JDG701 Offset Wrench to loosen retaining screw (B) and adjust nuts (C) to achieve desired fit.
15. Tighten retaining screw (B) to specification.
Item
Measurement Specification
Concave Retaining Screws Torque
285 N˙m
(200 lb-ft)
16.
H72812-UN: Right Inspection Hole
LEGEND:
A - Gauge
B - Retaining Screw
C - Nuts
Go to rear right inspection hole.
17. Rotate cylinder clockwise until rasp bar with washer is visible in rear inspection hole.
18. Using JDG700A Concave Checking and Setting Gauge (A), insert end marked A into rear right
inspection hole. Gauge should be a slip fit.
1157
Level Concave (Rasp Bar)
19. Use JDG701 Offset Wrench to loosen retaining screw (B) and adjust nuts (C) to achieve desired fit.
20. Tighten retaining screw (B) to specification.
Item
Measurement Specification
Concave Retaining Screws Torque
285 N˙m
(200 lb-ft)
21.
H72817-UN: Level Concave
LEGEND:
A - Gauge
B - Retaining Screw
C - Nuts
Go to left side of concave. Using JDG700A Concave Checking and Setting Gauge (A), insert end
marked A into rear left inspection hole. Gauge should be a slip fit.
22. Use JDG701 Offset Wrench to loosen retaining screw (B) and adjust nuts (C) to achieve desired fit.
23. Tighten retaining screw (B) to specification.
Item
Measurement Specification
Concave Retaining Screws Torque
285 N˙m
(200 lb-ft)
24. Fully open the concave.
25. Rotate cylinder counterclockwise until rasp bar with washer is visible in front inspection hole.
26. Close concave until concave bar is visible.
27. Insert gauge in front inspection hole.
28. Slowly close concave until gauge is a slip fit.
1158
Level Concave (Rasp Bar)
29. Check gauge fit in three remaining holes. If gauge is not a slip fit, repeat steps 6 to 23.
30.
H44776-UN: Stop
LEGEND:
B - Cap Screw (2 used)
Position stop against concave and tighten cap screws (B).
31.
H72807-UN: Adjust Concave
LEGEND:
A - Connector
B - Inspection Holes
Install pin (A) in dual range cylinder drive (if equipped).
32. Install inspection hole covers (B).
33. Disconnect remote control from concave actuator connector (A). Connect combine harness to actuator
connector.
34. Go to cab cornerpost and calibrate concave indicator.
Go to Section_120:Group_05
OUO6435,00018A3-19-20081110
1159
Level Concave (Spike Tooth)
Level Concave (Spike Tooth)
1.
H44776-UN: Stop
LEGEND:
B - Cap Screw (2 used)
Loosen stop cap screws (B).
2.
H39689-UN: Cylinder and Concave
LEGEND:
A - Tooth Overlap
Close concave until cylinder just touches the concave when cylinder is spun by hand.
3.
CAUTION:
Raise feeder house and lower safety stop.
Open stone trap door.
4. Measure cylinder tooth to concave tooth overlap (A) on right and left sides.
1160
Level Concave (Spike Tooth)
5.
H67956-UN: Eyebolt
LEGEND:
A - Screw
B - Nut (2 used)
Overlap must be the same on both sides. If not, loosen nuts (B) and screw (A) on left front eyebolt.
6. Adjust eyebolt with nuts (B) to equalize tooth overlap.
7. Tighten screw (A) to the specified torque.
Item
Measurement Specification
Spike Tooth Concave Retaining Nut Torque
285 N˙m
(200 lb-ft)
8. Tighten nuts (B).
9.
ZX25149-UN: Right Gauge
LEGEND:
A - Distance
Remove right rear inspection hole cover. Rotate cylinder until tooth is visible.
10. Measure distance (A) between cylinder tooth and concave crossbar using a gauge.
1161
Level Concave (Spike Tooth)
11.
ZX25151-UN: Eyebolt
LEGEND:
A - Screw
B - Nuts (2 used)
C - Gauge
Go to left rear inspection hole.
12. Measure distance between cylinder tooth and concave crossbar using a gauge.
13. Left side measurement should equal right side measurement. If not, adjust left rear side to equal right
rear side.
14. Loosen nuts (B) and screw (A). Adjust nuts (B) to obtain correct clearance equal to right rear side.
15. Tighten screw (A) to specification.
Item
Measurement Specification
Cylinder and Concave Tooth Adjusting Nuts Torque
16. Tighten nuts (B).
17.
H43931-UN: Stop
LEGEND:
A - Stop
Hold stop (A) and mark location of stop.
1162
285 N˙m
(200 lb-ft)
Level Concave (Spike Tooth)
Open concave. Move stop 2 mm (1/16 in.) closer to concave from marked position.
Go to Section_120:Group_05
OUO6089,000001A-19-20010618
1163
Adjust Second Concave
Adjust Second Concave
1.
ZX25233-UN: Second Concave
LEGEND:
A - Locking Lever
B - Second Concave
C - Handle
D - Distance
Unlock lever (A).
2. Adjust second concave (B) using handle (C).
3. Lock lever (A).
4. Distance (D) must meet the specification.
Item
Measurement Specification
Second Concave Linkage Distance
220 mm (8-21/32 in.)
Go to Section_120:Group_05
OUO6435,0001457-19-20010809
1164
Concave Position Sensor and Linkage
Concave Position Sensor and Linkage
H64637-UN: Concave Position Sensor and Linkage
LEGEND:
A - Potentiometer
B - Screw (2 used)
C - Bracket
D - Nut (2 used)
E - Nut (2 used)
F - O-Ring (2 used)
G - Seal
H - Guide
I - Shaft
J - Spring Pin
K - Arm
L - Nut
M - Snap Ring
N - Grommet
O - Ball Joint (2 used)
1165
Concave Position Sensor and Linkage
P - Rod End (2 used)
Q - Lock Nut (2 used)
R - Linkage
Go to Section_120:Group_05
AG,OUO6435,948-19-20000503
1166
Remove and Install Concave Adjusting Motor
Remove and Install Concave Adjusting Motor
H51938-UN: Adjusting Motor
LEGEND:
A - Pin (2 used)
B - Spring Pin (2 used)
C - Actuator
D - Connector
E - Stop
1.
H50576-UN: Adjusting Motor
LEGEND:
A - Spring Locking Pin
B - Pin
Operate concave so pin (B) is accessible.
2. Remove spring locking pin (A) and pin (B).
1167
Remove and Install Concave Adjusting Motor
3.
H40564-UN: Wiring Harness
H63442-UN: Concave Motor
LEGEND:
A - Pin
B - Spring Locking Pin
C - Motor
D - Wiring Harness
E - For Rasp Bar Concave
F - For Spike-Tooth Concave
Disconnect wiring harness (D).
4. Remove spring locking pin (B), pin (A) and adjusting motor (C).
NOTE:
Adjusting motor cannot be repaired. A defective motor must be replaced.
5. Install motor (C), pin (A) and spring locking pin (B).
6. Connect wiring harness (D).
1168
Remove and Install Concave Adjusting Motor
7.
H50576-UN: Adjusting Motor
LEGEND:
A - Spring Locking Pin
B - Pin
Install pin (B) and spring locking pin (A).
Go to Section_120:Group_05
AG,OUO6435,950-19-20000503
1169
Second Cylinder Exploded View
Second Cylinder Exploded View
H68328-UN: Second Cylinder
LEGEND:
1 - Cap Screw (32 used)
2 - Screw (58 used)
3 - Blade (8 used)
4 - Cap Screw
5 - Flange Nut (as required)
6 - Flange Nut (8 used)
7 - Second Cylinder Head (2 used)
8 - Screw (24 used)
1170
Second Cylinder Exploded View
9 - Second Cylinder Head (2 used)
10 - Shaft
11 - Woodruff Key (2 used)
12 - Belt
13 - Set Screw
14 - Locking Collar (2 used)
15 - Flange Housing (2 used)
16 - Bearing (2 used)
17 - Flange Housing (2 used)
18 - Sheave
19 - Elbow Fitting (2 used)
20 - Nut (8 used)
21 - Hose (2 used)
22 - Nut (2 used)
23 - Lubrication Fitting (2 used)
24 - Screw (8 used)
25 - Seal (4 used)
26 - Flange Nut (24 used)
27 - Clip
28 - Washer (16 used)
29 - Lubrication Fitting
30 - Washer (14 used)
Go to Section_120:Group_05
OUO6089,0000015-19-20010611
1171
Disassemble and Assemble Second Cylinder
Disassemble and Assemble Second Cylinder
CAUTION:
1.
To prevent accidental starting of the engine, disconnect battery ground cable,
remove key from switch and install a DO NOT OPERATE tag in operator's cab.
CAUTION:
Place a thick tarpaulin, plywood or cardboard on the straw walkers. This is
necessary to avoid injuries when repairing second cylinder (some of the work
must be performed lying down).
H41263-UN: Power Separator Removed for Clarity
LEGEND:
A - Seal (4 used)
B - Second Cylinder Blades
Remove seals (A) from one side of second cylinder.
2. Remove second cylinder blades (B) in a set of two; opposite each other to keep correct balance.
3. Install new blades and tighten cap screws to specification.
Item
Measurement Specification
Second Cylinder Blade Cap Screws Torque
50 N˙m
(37 lb-ft)
NOTE:
The second cylinder does not require balance weights and will not require balancing.
4. IMPORTANT:
Blades must clear seals. Adjust if needed.
Install seals (A).
Go to Section_120:Group_05
OUO6089,000006D-19-20010710
1172
Remove and Install Second Cylinder
Remove and Install Second Cylinder
1.
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable,
remove key from switch and install a DO NOT OPERATE tag in operator's cab.
ZX25153-UN: Idler
H67989-UN: Sheave
LEGEND:
A - Nuts (2 used)
B - Belt (2 used)
C - Cap Screw (3 used)
D - Sheave
Loosen nuts (A) to relieve belt tension. Remove belts (B).
2. Remove three cap screws (C) and sheave (D).
1173
Remove and Install Second Cylinder
3.
H67990-UN: Drive Hub
LEGEND:
A - Cap Screw
B - Hub
Loosen cap screw (A) on hub (B). Use a puller to remove hub.
4.
H67991-UN: Locking Collar of Second Cylinder
LEGEND:
A - Key
B - Locking Collar
C - Lubrication Hose
Remove key (A) and locking collar (B).
5. Remove lubrication hose (C).
6.
CAUTION:
Place a thick tarpaulin, plywood or cardboard on the straw walkers. This is
necessary to avoid injuries when removing second cylinder (some of the work
must be performed lying down).
1174
Remove and Install Second Cylinder
H41264-UN: Beater
LEGEND:
A - Seal (2 used on each side)
B - Blade
C - Hole
D - Clamp (2 used)
E - Key
F - Shaft
Remove seals (A) from one side of second cylinder.
7. Look through holes (C) in blades and rotate second cylinder until shaft clamps (D) and key (E) are
accessible.
8. Remove blade (B).
9. Loosen clamps (D).
10. Support second cylinder so it will not drop when shaft (F) is removed.
11. Move shaft (F) toward right side of combine until key (E) is completely exposed and can be removed.
12.
H67962-UN: Bearing
LEGEND:
A - Locking Collar
B - Flanged Housing
Remove locking collar (A) from right side.
13. Remove flanged housing (B) with bearing on both sides.
14. Remove shaft and second cylinder.
1175
Remove and Install Second Cylinder
15. Clean shaft with emery cloth and file to remove nicks and burrs. Coat shaft with NEVER-SEEZ
Lubricant.
16. Install shaft from right side of combine. Do not install all the way to allow installation of hub key on left
side.
17. Install flanged housing with bearing on right side and connect lubrication hose.
18.
H41264-UN: Second Cylinder
H45462-UN: Shaft
LEGEND:
A - Seal (2 used on each side)
B - Blade
C - Hole
D - Clamp (2 used)
E - Key
F - Shaft
G - Dimension, 51 mm (2 in.)
Install key (E) into second cylinder hub and slide shaft (F) through left side of combine.
19. Install flanged housing with bearing on left side.
20. Shaft must extend 51 mm (2 in.) (G) from inner race of bearing to end of shaft with locking collar off.
21. Install locking collar and key on left end of shaft. Connect lubrication hose on left bearing.
22. Adjust second cylinder side to side on shaft (F).
23. Tighten clamps (D).
24. Install blade (B). Tighten cap screws to specification.
1176
Remove and Install Second Cylinder
Item
Measurement Specification
Second Cylinder Blade Cap Screws Torque
50 N˙m
(37 lb-ft)
25. IMPORTANT:
Blades must clear seals. Adjust if necessary.
Install seals (A).
26.
H67993-UN: Drive Hub
LEGEND:
A - Hub
B - Cap Screw
Install hub (A) and tighten cap screw (B).
27.
H67989-UN: Sheave
1177
Remove and Install Second Cylinder
ZX25153-UN: Idler
LEGEND:
A - Nut (2 used)
B - Belt (2 used)
C - Cap Screw (3 used)
D - Sheave
Install sheave (D) using three cap screws (C).
28. Install belts (B) and tighten nuts (A) until washer aligns with gauge.
Go to Section_120:Group_05
OUO6435,0001458-19-20010809
1178
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
To remove and install various components.
H40598-UN: Service Jack
Pedestal.......D05071ST
To remove and install various components.
H41163-UN: Pedestal
Sheave Remover/Installer Bracket.......JT05875
Use with D05070ST Service Jack and D05071ST
Pedestal to remove and install Dual Range cylinder
drive gear case.
H41164-UN: Sheave Remover/Installer
1179
Essential and Recommended Special Tools
Spanner Wrench.......D01053AA
Remove nut.
H41220-UN: Spanner Wrench
Axial Play Adjustment Tool.......JDG277
Adjust axial play on dual range cylinder drive.
H41221-UN: Axial Play Adjustment Tool
Variable Drive
Countershaft
Remover/Installer
Bracket.......JT05873
Use with D05070ST
pedestal to remove and
install intermediate
cylinder drive.
H41165-UN:
Variable Drive
Countershaft
Remover/Installer
Bracket
Sheave Remover/Installer
Bracket.......JT05872
Use with D05070ST Service
Jack and D05071ST Pedestal
to remove and install Dual
Range cylinder drive gear
case.
H41164-UN: Sheave
Remover/Installer
Go to Section_120:Group_10
ZX09263,0002745-19-20080201
1180
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
To remove and install various components.
H40598-UN: Service Jack
Pedestal.......D05071ST
To remove and install various components.
H41163-UN: Pedestal
Sheave Remover/Installer Bracket.......JT05875
Use with D05070ST Service Jack and D05071ST
Pedestal to remove and install Dual Range cylinder
drive gear case.
H41164-UN: Sheave Remover/Installer
1181
Essential and Recommended Special Tools
Spanner Wrench.......D01053AA
Remove nut.
H41220-UN: Spanner Wrench
Axial Play Adjustment Tool.......JDG277
Adjust axial play on dual range cylinder drive.
H41221-UN: Axial Play Adjustment Tool
Variable Drive
Countershaft
Remover/Installer
Bracket.......JT05873
Use with D05070ST
pedestal to remove and
install intermediate
cylinder drive.
H41165-UN:
Variable Drive
Countershaft
Remover/Installer
Bracket
Sheave Remover/Installer
Bracket.......JT05872
Use with D05070ST Service
Jack and D05071ST Pedestal
to remove and install Dual
Range cylinder drive gear
case.
H41164-UN: Sheave
Remover/Installer
Go to Section_120:Group_10
ZX09263,0002745-19-20080201
1182
Other Material
Other Material
Number
Name
Use
PT506 (U.S.)
NEVER-SEEZ
Apply to cylinder shaft and splines.
TY6304 (U.S.)
Form-in-Place Gasket
Apply to gear case.
To seal planetary mating surfaces.
TY6382 (U.S.)
80W90 API-GL-5 Gear Lube
Lubricate gear case.
T43512 (U.S.)
TY9473 (Canadian)
242 LOCTITE ™
(LOCTITE®)
Thread Lock and Sealer (Medium
Strength)
To retain cap screws.
T43513 (U.S.)
TY9474 (Canadian)
271 LOCTITE ™
(LOCTITE®)
Thread Lock and Sealer (High Strength)
Apply to threads on drain plug.
TY6341 (U.S.)
Multipurpose SD Polyurea Grease
To lubricate components.
PT507 (U.S.)
Multi-Purpose Grease (Lithium-Saponified) Grease all bearing surfaces and
seals.
Go to Section_120:Group_10
OUO6435,0001459-19-20021120
1183
Specifications
Specifications
Item
Measurement
Specification
Dual-Range Cylinder Drive
Maximum Runout
0.76 mm
(0.030 in.)
Gear Case to Cylinder Shaft, Lock Nut
Torque
203 N˙m
(150 lb-ft)
Cylinder Shaft
Runout
0.25 mm
(0.010 in.)
Single Speed Extended Range Cylinder Drive Sheave
Approximate Weight 25 kg
(55 lb)
Single Speed Extended Range Cylinder Drive Nut
Torque
Dual Range Cylinder Drive Gear Case
Approximate Weight 113 kg
(250 lb)
Dual Range Cylinder Drive Gear Case Shim Pack
Torque
203 N˙m
(150 lb-ft)
Dual Range Cylinder Drive Gear Case
Capacity
1.2 L
(1.3 qt)
Input Sun Gear, Dual Range Cylinder Drive
Axial Play
0.00—0.10 mm
(0.00—0.004 in.)
Dual Range Cylinder Drive Gear Case, Lock Nut
Torque
203 N˙m
(150 lb-ft)
Dual Range Cylinder Drive Planetary Assembly
Torque
50 N˙m
(37 lb-ft)
Dual Range Cylinder Drive Sheave Cap Screws
Torque
54—81 N˙m
(40—60 lb-ft)
Intermediate Cylinder Drive
Approximate Weight 107 kg
(236 lb)
Intermediate Cylinder Drive Bearing Cap Screws
Torque
135 N˙m
(100 lb-ft)
Intermediate Cylinder Drive Variable Sheaves
Gap
6.0 mm
(0.24 in.)
Intermediate Cylinder Drive Eyebolt
Torque
175 N˙m
(130 lb-ft)
Intermediate Cylinder Drive without Pivot Casting
Approximate Weight 57 kg
(125 lb)
Intermediate Cylinder Drive Sheave Cap Screws
Torque
130 N˙m
(95 lb-ft)
Intermediate Cylinder Drive Bearing Housing, Cap Screw
Torque
192 N˙m
(142 lb-ft)
Intermediate Cylinder Drive, Sheave Hub Assembly
Torque
130 N˙m
(95 lb-ft)
Intermediate Cylinder Drive Sheave Assembly
Torque
192 N˙m
(142 lb-ft)
Intermediate Cylinder Drive Upper Sheave
Approximate Weight 27 kg
(60 lb)
Intermediate Cylinder Drive Upper Sheave, Cap Screws
Torque
475 ± 100 N˙m
(350 ± 75 lb-ft)
52 N˙m
(38 lb-ft)
Intermediate Cylinder Drive Upper Sheave and Housing Assembly Approximate Weight 31 kg
(68 lb)
1184
Specifications
Item
Measurement
Specification
Intermediate Cylinder Drive Sheave Nut
Torque
328 N˙m
(243 lb-ft)
Intermediate Cylinder Drive Sheave
Torque
44 N˙m
(33 lb-ft)
Intermediate Cylinder Drive Sheave Shim Pack
Torque
52 N˙m
(38 lb-ft)
Dual Range Cylinder Drive Variable Sheave
Clearance
39.5 mm
(1.6 in.)
Extended Range Cylinder Drive Variable Sheave
Clearance
54.9 mm
(2.2 in.)
Cylinder Drive Bracket Cap Screws
Torque
175 N˙m
(130 lb-ft)
Dual Range Cylinder Drive Grooved Sheave
Axial Play
2.0—3.2 mm
(0.08—0.13 in.)
Sun Gear Cover Cap Screw
Torque
35 N˙m
(26 lb-ft)
Inner Drive Wheel Cap Screws
Torque
70 N˙m
(52 lb-ft)
Outer Drive Wheel Cap Screws
Torque
50 N˙m
(37 lb-ft)
Torque Sensing Sheaves
Gap
6 mm
(1/4 in.)
Go to Section_120:Group_10
OUO6089,0000080-19-20010731
1185
Remove Dual Range Cylinder Drive Gear Case
Remove Dual Range Cylinder Drive Gear Case
ZX25154-UN: Idler
LEGEND:
A - Belt
B - Nut (2 used)
1. Remove right front wheel (see Section 50, Group 25).
2. Loosen nuts (B) to relieve belt tension.
3. Remove belt (A).
4.
ZX25175-UN: Gear Case
LEGEND:
A - Gear Case
B - Cap Screw
C - Lockout Arm
Disconnect lockout arm (C).
5.
CAUTION:
Weight of gear case is approximately 113 kg (250 lb).
Install D05070ST Service Jack with D05071ST Pedestal and JT05872 Sheave Remover/Installer
Bracket to remove gear case.
1186
Remove Dual Range Cylinder Drive Gear Case
6. Remove cap screw (B) and lift off gear case.
7. Replace gear case assembly, or repair as described in this section.
Go to Section_120:Group_10
ZX61739,000046D-19-20080711
1187
Dual Range Cylinder Drive, Exploded View
Dual Range Cylinder Drive, Exploded View
ZX25139-UN: Dual-Range Cylinder Drive
LEGEND:
1 - Cap Screw (6 used)
2 - Outer Drive Wheel
3 - Cap Screw
4 - Lug
5 - Snap Ring
6 - Bearing
7 - Oil Seal
8 - Outer Sun Gear
1188
Dual Range Cylinder Drive, Exploded View
9 - Oil Seal
10 - Spring Ring
11 - Bearing
12 - Snap Ring
13 - Needle Bearing
14 - Snap Ring
15 - Magnetic Plug
16 - Seal Ring
17 - Pin
18 - Plate
19 - Cap Screw (6 used)
20 - Retainer (3 used)
21 - Quick Lock Pin
22 - Spring Pin
23 - Pin
24 - Housing
25 - Inner Sun Gear
26 - Planet Pinion (3 used)
27 - Needle Bearing (6 used)
28 - Pinion Shaft (3 used)
29 - Bearing
30 - Gasket
31 - Cover
32 - Cap Screws (6 used)
33 - Snap Ring
34 - Oil Seal
35 - O-Ring
36 - Inner Drive Wheel
37 - Cap Screw (8 used)
Go to Section_120:Group_10
OUO6089,0000051-19-20010702
1189
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
1. Drain oil from gear case.
Item
Measurement Specification
Dual Range Cylinder Drive Gear Case Capacity
2.
ZX25249-UN: Locking Pin
LEGEND:
A - Locking Pin
Remove pin (A).
3.
ZX25248-UN: Outer Drive Wheel
LEGEND:
A - Cap Screw (6 used)
B - Outer Drive Wheel
Remove cap screw (A) and outer drive wheel (B).
1190
1.2 L
(1.3 qt)
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
4.
ZX25242-UN: Inner Drive Wheel
LEGEND:
A - O-Ring
B - Cap Screw (8 used)
C - Inner Drive Wheel
Remove O-ring (A), cap screw (B) and inner drive wheel (C).
5.
ZX25261-UN: Case
LEGEND:
A - Cover
Place gear case on blocks of wood with cover (A) facing upward.
6.
ZX25243-UN: Cover
1191
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
ZX25244-UN: Gasket
LEGEND:
A - Cap Screw (6 used)
B - Cover
C - Gasket
Remove cap screw (A), cover (B) and gasket (C).
7.
ZX25252-UN: Cover Gasket
LEGEND:
A - Seal
B - Cover
Remove seal (A) from cover (B).
8.
ZX25251-UN: Sun Gear Assembly
LEGEND:
A - Sun Gear Assembly
1192
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
B - Bearing Puller
Remove sun gear assembly (A) using bearing puller (B).
9.
ZX25253-UN: Sun Gear Assembly
LEGEND:
A - Snap Ring
B - Bearing
C - Sun Gear Assembly
Remove snap ring (A) and bearing (B) from sun gear (C).
10.
NOTE:
Pinions are marked, one, two and three, in a counterclockwise direction.
ZX25254-UN: Gear Timing
LEGEND:
A - Numbers
B - Gear
Line up pinions so numbers (A) are at locations shown.
11. Mark locations on gear (B).
1193
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
12.
ZX25255-UN: Pinion Shaft Removal
LEGEND:
A - Pinion Shaft (3 used)
B - Cap Screw
Remove pinion shaft (A) using cap screw (B).
13.
ZX25256-UN: Snap Ring
LEGEND:
A - Pinion (3 used)
B - Snap Ring
C - Outer Sun Gear
Slide pinions (A) toward outside to provide access to snap ring.
14. Remove snap ring (B).
15. Drive outer sun gear (C) out using a wood block and hammer.
1194
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
16.
ZX25262-UN: Outer Bearing
LEGEND:
A - Snap Ring
B - Bearing
Remove snap ring (A) and bearing (B).
17.
ZX25259-UN: Sun Gear Assembly
LEGEND:
A - Snap Ring
B - Bearing
C - Seal
Remove snap ring (A), bearing (B) and seal (C).
18. Turn housing over.
19.
1195
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
ZX25257-UN: Outer Seal
LEGEND:
A - Seal
Remove seal (A).
20.
ZX25258-UN: Outer Bearing
LEGEND:
A - Snap Ring
B - Bearing
Remove snap ring (A).
21. Remove bearing (B) using a puller.
22. Remove pinion gears from housing at this time.
23.
NOTE:
Pinion bearings may fall out when removing pinions.
ZX25263-UN: Pinion Bearings
LEGEND:
A - Bearing (6 used)
B - Pinion (3 used)
Remove bearings (A) from pinions (B).
24. IMPORTANT:
Grease all bearing surfaces and seals with Multi-Purpose Lithium Grease (PT507) before assembly. The
1196
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
Grease all bearing surfaces and seals with Multi-Purpose Lithium Grease (PT507) before assembly. The
cavity between dust seal and lip seal must be filled with grease.
ZX25263-UN: Pinion Bearings
LEGEND:
A - Bearing (6 used)
B - Pinion (3 used)
Install bearings (A) into pinions (B).
25. Install pinion gears to outside in housing. Do not install pinion shafts at this time.
26.
ZX25258-UN: Outer Bearing
LEGEND:
A - Snap Ring
B - Bearing
Install bearing (B) and snap ring (A).
1197
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
27.
ZX25257-UN: Outer Seal
LEGEND:
A - Seal
Install outer seal (A).
28.
ZX25259-UN: Sun Gear Assembly
LEGEND:
A - Snap Ring
B - Bearing
C - Seal
Install seal (C), bearing (B) and snap ring (A).
29.
ZX25262-UN: Outer Bearing
LEGEND:
A - Snap Ring
B - Bearing
1198
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
Install bearing (B) and snap ring (A).
30. IMPORTANT:
Pinion gears must be to outside when driving outer sun gear in.
ZX25266-UN: Outer Bearing
ZX25267-UN: Snap Ring
LEGEND:
A - Outer Sun Gear
B - Snap Ring
Install outer sun gear (A) using a wooden block and hammer.
31. Turn housing over.
32. Install snap ring (B).
33. IMPORTANT:
Outer sun gear and planetary pinions must be timed.
NOTE:
Pinions are marked, one, two and three, in a counterclockwise direction.
1199
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
ZX25254-UN: Gear Timing
LEGEND:
A - Numbers
B - Gear
Line up pinions so numbers (A) are aligned with marks (B) made earlier.
34.
ZX25255-UN: Install Pin
LEGEND:
A - Pinion Shaft (3 used)
B - Cap Screw
Install pinion shafts (A) using cap screw (B).
35.
ZX25253-UN: Sun Gear Assembly
LEGEND:
A - Snap Ring
B - Bearing
1200
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
C - Sun Gear Assembly
Install bearing (B) and snap ring (A) on sun gear (C).
36.
ZX25265-UN: Inner Bearing
LEGEND:
A - Inner Sun Gear
Install inner sun gear (A) using a wooden block and hammer.
37.
ZX25252-UN: Cover Seal
LEGEND:
A - Seal
B - Cover
Install seal (A) in cover (B).
38.
ZX25243-UN: Cover
1201
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
ZX25244-UN: Gasket
LEGEND:
A - Cap Screw (6 used)
B - Cover
C - Gasket
Install gasket (C) and cover (B).
39. Apply T43512 Thread Lock and Sealer (Medium Strength) to cover cap screws (A); then install and
tighten to specification.
Item
Measurement Specification
Sun Gear Cover Cap Screw Torque
35 N˙m
(26 lb-ft)
40.
ZX25242-UN: Inner Drive Wheel
LEGEND:
A - O-Ring
B - Cap Screw (8 used)
C - Inner Drive Wheel
Install O-ring (A) and inner drive wheel (C).
41. Apply T43512 Thread Lock and Sealer (Medium Strength) to cap screws (B); then install and tighten to
specification.
Item
Measurement Specification
Inner Drive Wheel Cap Screws Torque
70 N˙m
(52 lb-ft)
1202
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
42. Turn housing over.
43.
ZX25248-UN: Outer Drive Wheel
LEGEND:
A - Cap Screw (6 used)
B - Outer Drive Wheel
Install outer drive wheel (B).
44. Apply T43512 Thread Lock and Sealer (Medium Strength) to cap screws (A); then install and tighten to
specification.
Item
Measurement Specification
Outer Drive Wheel Cap Screws Torque
50 N˙m
(37 lb-ft)
45.
ZX25249-UN: Locking Pin
LEGEND:
A - Locking Pin
Install locking pin (A).
46. Fill gear case with specified amount of TY6382 GL5 Gear Lubricant.
1203
Disassemble and Assemble Dual Range Cylinder Drive Gear Case
Item
Measurement Specification
Dual Range Cylinder Drive Gear Case Capacity
1.2 L
(1.3 qt)
Go to Section_120:Group_10
OUO6435,000145A-19-20021120
1204
Remove and Install Intermediate Cylinder Drive
Remove and Install Intermediate Cylinder Drive
NOTE:
During disassembly, if it is discovered that the intermediate cylinder drive is lacking adequate
grease, it may be necessary to drill two 4 mm (3/16 in.) holes through inner sheave hub at grease
fitting and breather fitting mounting holes. This will open grease passage on hub.
1. Start the engine. Set cylinder speed to slowest speed. Shut off engine. Remove key.
2. Remove wheel (see Section 50, Group 25).
3.
H68014-UN: Threshing Cylinder
LEGEND:
A - Nut (2 used)
B - Nut (2 used)
C - Cotter Pin
D - Eyebolt
Loosen nuts (B) to relieve dual range cylinder drive belt tension. Pull belt off of cylinder sheave.
4. Loosen nuts (A) to relieve intermediate drive belt tension.
5. Remove cotter pin (C).
6. Remove eyebolt (D) from slot in pivot casting so assembly can be pulled out.
7.
CAUTION:
The approximate weight of the intermediate cylinder drive is 107 kg (236 lb).
1205
Remove and Install Intermediate Cylinder Drive
H67963-UN: Bracket
H67964-UN: Plate
LEGEND:
A - Screw and Nut
B - Remove/Installer Bracket
C - Cylinder
D - Cap Screw (2 used)
E - Inner Cap Screw (2 used)
F - Bearing Housing
G - Plate
H - Screws and Nuts
I - Nut
J - Clamp
K - Cap Screw (2 used)
Loosen nut (A) (do NOT remove) on outer side of pivot casting to allow countershaft assembly to rotate.
8. Use D05070ST Service Jack with D05071ST Pedestal and JT05873 Remover/Installer Bracket (B) to
remove cylinder (C).
9. Remove cap screws (D).
10. Loosen two inner cap screws (E) holding bearing housing on pivot casting. Rotate bearing housing (F)
up and remove intermediate drive belt. Tighten inner cap screws (E).
11. Disconnect plate (G) by removing hardware (H). Do NOT change eyebolt positions. Mark position of
nuts (I) and remove.
12. Position service jack under cylinder drive and install cap screws (D).
1206
Remove and Install Intermediate Cylinder Drive
13. Tighten clamp (J) on cylinder mount.
14. Remove cap screws (A) and (K).
15. Move cylinder drive slightly away from combine and disconnect lubrication line from intermediate
cylinder drive.
16. Remove cylinder drive.
17. Repair or replace cylinder drive as necessary.
CAUTION:
18.
The approximate weight of intermediate drive is 107 kg (236 lb).
H67963-UN: Threshing Cylinder
H67964-UN: Plate
LEGEND:
A - Screw and Nut
B - Remove/Installer Bracket
C - Cylinder
D - Cap Screw (2 used)
E - Inner Cap Screw (2 used)
F - Bearing Housing
G - Plate
H - Screws and Nuts
1207
Remove and Install Intermediate Cylinder Drive
I - Nut
J - Clamp
K - Cap Screw (2 used)
Use D05070ST Service Jack with D05071ST Pedestal and JT05873 Remover/Installer Bracket (B) to
install cylinder drive.
19. Connect lubrication line to cylinder drive before installing all the way.
20. Attach adjustable plate (G) with hardware (H) and (I) in previously marked position. Eyebolt at (H) does
NOT need to be adjusted. If eyebolts are moved, the intermediate drive sheaves MUST be aligned with
the cylinder sheave using a straight edge (see Operator's Manual).
21. Attach cylinder drive to combine using cap screws (A) and (K). Leave (A) loose to allow cylinder
countershaft assembly to rotate.
22. Remove outer bearing cap screws (D) from service stand. Rotate bearing housing and install variable
belt. Remove stand. Tighten inner and outer bearing cap screws to specification.
Item
Measurement Specification
Intermediate Cylinder Drive Bearing Cap Screws Torque
135 N˙m
(100 lb-ft)
23.
H67972-UN: Plate
LEGEND:
A - Eyebolt
B - Pin and Cotter Pin
C - Nut (2 used)
D - Belt
E - Screw and Lock Nut
Install eyebolt (A) and cotter pin (B).
24. Install belt (D) and tighten nuts (C) on tensioner until washer aligns with gauge.
25. After cylinder countershaft assembly has been reassembled, adjust eyebolts bolts (A) to obtain specified
gap between driven variable sheaves when driver variable sheaves are in the open position. Lock nuts in
place.
1208
Remove and Install Intermediate Cylinder Drive
Item
Measurement Specification
Intermediate Cylinder Drive Variable Sheaves Gap
6 mm
(0.2 in.)
26. Tighten screw and lock nut (E) on countershaft pivot to specification.
Item
Measurement Specification
Intermediate Cylinder Drive Eyebolt Torque
175 N˙m
(130 lb-ft)
27. Install the wheel (see Section 50, Group 25).
Go to Section_120:Group_10
OUO6045,0000138-19-20010515
1209
Repair Intermediate Cylinder Drive
Repair Intermediate Cylinder Drive
H64464-UN: Intermediate Cylinder Drive
LEGEND:
1 - Sheave
2 - Cap Screw (3 used)
3 - Belt
4 - Lubrication Fitting
5 - Sheave
6 - Lubrication Fitting
7 - Seal (2 used)
8 - Snap Ring (2 used)
1210
Repair Intermediate Cylinder Drive
9 - Bushing (2 used)
10 - Hub
11 - Cam (2 used)
12 - Washer
13 - Washer
14 - Spring Assembly
15 - Seal
16 - Ring
17 - Hub
18 - Sheave
19 - Cap Screw (3 used)
20 - Belt
21 - Breather
22 - Key
23 - Shaft
CAUTION:
1.
The approximate weight of intermediate cylinder drive without pivot casting is 57
kg (125 lb).
H40503-UN: Cylinder Drive
LEGEND:
A - Washer
B - Housing with Ball Bearing
C - Cap Screw and Washer
D - Cap Screw (3 used)
E - Sheave
Remove cylinder from support.
2. Remove cap screw and washer (C), housing with ball bearing (B) and washer (A).
3. Remove cap screws (D).
4.
CAUTION:
Sheave is under spring pressure. Make certain to reinstall cap screw and washer
(C) BEFORE removing sheave from shaft.
1211
Repair Intermediate Cylinder Drive
H40504-UN: Remove Sheave
Remove sheave from shaft.
5.
H40505-UN: Sheave
LEGEND:
A - Housing with Ball Bearing
B - Washer
C - Cap Screw and Washer
D - Sheave
Remove cap screw and washer (C), housing with ball bearing (A) and washer (B) from sheave (D).
6.
H40506-UN: Remove Sheave
LEGEND:
A - Sheave
Remove sheave (A).
1212
Repair Intermediate Cylinder Drive
7.
H40507-UN: Remove Hub
LEGEND:
A - Sheave
B - Cap Screw (3 used)
Remove cap screws (B) and sheave (A).
8. Remove hub assembly with bushing, cam and spring canister.
9.
H40508-UN: Hub
LEGEND:
A - Hub
Remove hub (A). Remove cam.
10.
H40509-UN: Hub
LEGEND:
A - Seal
B - Bushing (2 used)
1213
Repair Intermediate Cylinder Drive
C - Hub
D - Seal
E - Snap Ring (2 used)
Remove seals (A) and (D).
11. Remove snap rings (E).
12. Remove bushings (B).
13. Apply Multipurpose SD Polyurea Grease to bushings and install new bushings (B).
14. Install snap rings (E).
15. IMPORTANT:
Install seal (A) with lip facing away from flange of hub (C). Install seal (D) with lip facing toward hub
flange.
Apply Multipurpose SD Polyurea Grease to lips of seals (A and D). Install seals.
16.
H40515-UN: Sheave
LEGEND:
A - Ring
B - Seal
Remove ring (A) if necessary to replace seal (B).
17. Apply TY6341 Multipurpose SD Polyurea Grease to seal lip. Install seal and ring.
18.
H45371-UN: Hub
1214
Repair Intermediate Cylinder Drive
H45372-UN: Hub Installation
LEGEND:
A - Hub
B - Sheave
C - Cap Screw (3 used)
D - Shaft
E - Washer
F - Bearing
G - Cap Screw and Washer
Install hub (A), sheave (B) and cam. Tighten cap screws (C) to specified torque.
Item
Measurement Specification
Intermediate Cylinder Drive Sheave Cap Screws Torque
130 N˙m
(95 lb-ft)
Install hub assembly on shaft (D).
19. Install washer (E), housing with ball bearing (F) and washer and cap screw (G). Tighten to specification.
Item
Measurement Specification
Intermediate Cylinder Drive Bearing Housing, Cap Screw Torque
192 N˙m
(142 lb-ft)
20.
H40507-UN: Install Bushing
LEGEND:
A - Hub Assembly
B - Cap Screw (3 used)
Install sheave hub assembly (A) (with bushings) and cam using cap screws (B). Tighten to specification.
Slide assembly onto shaft.
Item
Measurement Specification
Intermediate Cylinder Drive, Sheave Hub Assembly Torque
1215
130 N˙m
(95 lb-ft)
Repair Intermediate Cylinder Drive
21.
H45377-UN: Washers
LEGEND:
C - Spring Canister
D - Washers
Turn sheave assembly over and place spring canister (C) inside cam. Place washers (D) on top of
spring canister.
22.
H40505-UN: Sheave
LEGEND:
A - Housing with Ball Bearing
B - Washer
C - Cap Screw and Washer
D - Sheave
Install sheave (D).
23. Install washer (B), housing with ball bearing (A) and cap screw and washer (C). Tighten to specification.
Item
Measurement Specification
Intermediate Cylinder Drive Sheave Assembly Torque
Lubricate cap screw at lubrication fitting.
1216
192 N˙m
(142 lb-ft)
Repair Intermediate Cylinder Drive
24.
H40524-UN: Install Cylinder
LEGEND:
A - Hub Grease Fitting
Fill hub cavity at (A) with 1-1/2 tubes of TY6341 Multipurpose SD Polyurea Grease.
25. Install cylinder drive on support.
NOTE:
DO NOT over grease. Too much grease causes sheaves not to open fully and may cause
variable belt breakage.
Go to Section_120:Group_10
AG,OUO6435,962-19-20000503
1217
Remove and Install Intermediate Cylinder Drive Support
Remove and Install Intermediate Cylinder Drive Support
H40519-UN: Drive Support
LEGEND:
A - Nut (2 used)
B - Washer (2 used)
C - Spring
D - Gauge
E - Hook
F - Cotter Pin
G - Washer
H - Snap Ring
I - Washer
J - Washer
K - Arm
L - Cap Screw
M - Bracket (2 used)
N - Idler
O - Flange Nut
1. Remove intermediate cylinder drive (see procedure in this group).
2. Remove cylinder drive from support.
1218
Remove and Install Intermediate Cylinder Drive Support
3. Remove parts (A) to (O). Replace parts as necessary.
4. Install parts (A) to (O).
5.
H40520-UN: Cylinder Drive Support
LEGEND:
A - Seal (2 used)
B - Bushing (2 used)
C - Snap Ring
D - Pin
E - Cap Screw (2 used)
F - Flange Nut (2 used)
G - Washer (4 used)
H - Cap Screw (2 used)
I - Eyebolt
J - Cotter Pin
K - Pin
L - Flange Nut (2 used)
M - Cap Screw (2 used)
N - Support
O - Washer
1219
Remove and Install Intermediate Cylinder Drive Support
Disassemble parts (A) to (O).
6. Install new bushings (B) to 7 mm (0.28 in.) from end of bore.
7. Install seals (A) flush, with lips facing outward.
8. Apply TY6341 Multipurpose SD Polyurea Grease to bushings before installing drive tensioner arm.
9. Assemble parts (A) to (O).
10. Install cylinder drive on support.
11. Install cylinder drive on combine (see procedure in this group).
Go to Section_120:Group_10
OUO6089,0000052-19-20010702
1220
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
H41166-UN: Drive Upper Sheave
LEGEND:
1 - Cap Screw (4 used)
2 - Housing
3 - Flange Nut (4 used)
4 - Locking Collar
5 - Set Screw
6 - Cap Screw (12 used)
7 - Housing
8 - Sheave Half
9 - Seal
10 - Snap Ring
11 - Bushing
12 - Sheave
13 - Bushing
14 - Snap Ring
15 - Seal
16 - Washer
17 - Lock Nut
18 - Bumper
19 - Pin
20 - Washer (2 used)
21 - Cap Screw (2 used)
22 - Shim (as required)
23 - Barrel
24 - Seal
25 - Piston
26 - Lock Washer (6 used)
1221
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
27 - Cap Screw (6 used)
28 - O-Ring (2 used)
29 - Fitting
30 - Snap Ring
31 - Ball Bearing
32 - Lubrication Fitting (2 used)
1.
H55161-UN: Cylinder Drive
LEGEND:
A - Cap Screw
B - Nut (2 used)
C - Nut (2 used)
Start the engine. Set cylinder speed to slowest setting. Shut off engine.
2. Loosen cap screw (A).
3. Loosen nuts (B) to relieve intermediate cylinder drive belt tension.
4. Loosen nuts (C) to relieve secondary countershaft belt tension.
1222
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
5.
H67980-UN: Upper Sheave
LEGEND:
A - Cap Screw (6 used)
B - Piston Assembly
C - Sheave
D - Oil Line
E - Cap Screw (2 used)
F - Pin
Disconnect oil line (D) from piston assembly (B) and remove belts.
6. Remove cap screws (A).
7. Remove piston assembly.
8. Remove cap screws (E), two washers and pin (F) and sheave (C).
1223
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
9.
H41169-UN: Piston
LEGEND:
A - Shim (as required)
B - Barrel
C - Seal
D - Piston
E - Lock Washer (6 used)
F - Cap Screw (6 used)
G - O-Ring (2 used)
H - Fitting
I - Snap Ring
Disassemble parts (A) to (I).
10.
CAUTION:
The approximate weight of sheave is 27 kg (60 lb).
H41170-UN: Sheave
LEGEND:
1224
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
A - Seal
B - Snap Ring
C - Bushing
D - Sheave
E - Bushing
F - Snap Ring
G - Seal
Remove seals (A) and (G), snap rings (B) and (F), and bushings (C) and (E) from sheave (D). Bushings
are a press fit.
11.
H41171-UN: Housing and Sheave
LEGEND:
A - Nut
B - Sheave
C - Puller
Remove nut (A).
12.
CAUTION:
The approximate weight of housing and sheave is 31 kg (68 lb).
Use a puller (C) to remove housing and sheave (B).
13.
H41172-UN: Housing and Sheave
LEGEND:
A - Sheave
B - Housing
C - Cap Screw (6 used)
Disassemble parts (A) to (C).
1225
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
14.
H68019-UN: Lubrication Fitting
LEGEND:
A - Housing
B - Locking Collar
Remove bearing locking collar (B) and housing (A) from shaft.
15.
H41174-UN: Bearing
LEGEND:
A - Bearing
B - Housing
Turn bearing (A) to remove from housing (B).
16. Inspect all parts for wear and damage. Replace parts as necessary.
17. Install bearing (A) in housing (B).
18. Remove header electromagnetic clutch from left end of shaft (see Remove Header Electromagnetic
Clutch in Group 40).
19. Remove primary countershaft assembly.
20. Install primary countershaft.
21. Install header electromagnetic clutch on left end of shaft (see Install Header Electromagnetic Clutch in
Group 40).
1226
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
22.
H68019-UN: Lubrication Fitting
LEGEND:
A - Housing
B - Bearing and Locking Collar
Install housing (A) and bearing (B) with locking collar.
NOTE:
There is NO dimension to locate shaft on right end. Location of shaft is determined by
electric clutch on left end.
23.
H41172-UN: Sheave
LEGEND:
A - Sheave
B - Housing
C - Cap Screw (6 used)
Assemble parts (A) to (C). Tighten cap screws to specification.
1227
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
Item
Measurement Specification
Intermediate Cylinder Drive Upper Sheave, Cap Screws Torque
52 N˙m
(38 lb-ft)
CAUTION:
24.
The approximate weight of sheave and housing assembly is 31 kg (68 lb).
H41177-UN: Sheave and Housing
LEGEND:
A - Shaft
B - Sheave/Housing Assembly
C - Washer
D - Nut
Install sheave and housing assembly (B) and shaft (A). Tighten nut (D) to specification.
Item
Measurement Specification
Intermediate Cylinder Drive Sheave Nut Torque
25.
328 N˙m
(243 lb-ft)
CAUTION:
The approximate weight of sheave is 27 kg (60 lb).
1228
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
H41175-UN: Sheave
H41176-UN: Sheave and Bushings
LEGEND:
A - Bushing
B - Bushing
C - Housing
Install bushings (A) and (B) in sheave housing (C). Bushings are a press fit.
26.
H41169-UN: Piston
LEGEND:
A - Shim (as required)
B - Barrel
C - Seal
D - Piston
E - Lock Washer (6 used)
F - Cap Screw (6 used)
G - O-Ring (2 used)
H - Fitting
I - Snap Ring
1229
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
Assemble parts (A) to (I).
27.
H67980-UN: Upper Sheave
LEGEND:
A - Cap Screw (6 used)
B - Piston Assembly
C - Sheave
D - Oil Line
E - Cap Screw (2 used)
F - Pin
Install sheave (C) and piston assembly (B).
28. Install pin (F), two washers and two cap screws (E). Tighten cap screws to specification.
1230
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
Item
Measurement Specification
Intermediate Cylinder Drive Sheave Torque
44 N˙m
(33 lb-ft)
29. Adjust shim pack as explained below. Tighten screws (A) to specification.
Item
Measurement Specification
Intermediate Cylinder Drive Sheave Shim Pack Torque
52 N˙m
(38 lb-ft)
30. Connect oil line (D) to piston assembly fitting.
31. Pump approximately 74 mL (2.5 oz) of Multipurpose SD Polyurea Grease into each one of two grease
fittings in sheave (C), for a total of 148 mL (5.0 oz).
32.
H41178-UN: Measure Clearance
LEGEND:
A - Clearance
B - Sheave
C - Sheave
1231
Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
With sheaves (B) and (C) spread apart, measure clearance (A). Clearance must be as specified.
Item
Measurement Specification
Dual Range Cylinder Drive Variable Sheave
Clearance
39.5 mm
(1.6 in.)
Extended Range Cylinder Drive Variable Sheave Clearance
54.9 mm
(2.2 in.)
33. Adjust using shims (Key A, Step 26) with a maximum of five shims.
34.
H68024-UN: Idler
LEGEND:
A - Cap Screw
B - Nut (2 used)
C - Nut (2 used)
Tighten nuts (C) to adjust secondary countershaft belt. Tighten according to gauge.
35.
NOTE:
For cylinder drive alignment procedure refer to Operators' Manual.
Tighten nuts (B) to adjust intermediate cylinder drive belt. Set torque sensing gap to specification.
Item
Measurement Specification
Torque Sensing Sheaves Gap
6 mm
(1/4 in.)
36. Tighten screw (A) to specification.
Item
Measurement Specification
Cylinder Drive Bracket Cap Screw Torque
175 N˙m
(130 lb-ft)
Go to Section_120:Group_10
OUO6435,000145B-19-20010809
1232
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Straw Walker Gear Case Puller.......JDG643A
To remove straw walker gear case.
H41135-UN: Straw Walker Gear Case Puller
Go to Section_120:Group_15
ZX09263,0002746-19-20080201
1233
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Straw Walker Gear Case Puller.......JDG643A
To remove straw walker gear case.
H41135-UN: Straw Walker Gear Case Puller
Go to Section_120:Group_15
ZX09263,0002746-19-20080201
1234
Other Material
Other Material
Number
Name
Use
TY6341 (U.S.)
Multipurpose SD Polyurea Grease Lubricate zinc bearings.
AN102562 (U.S.) Corn Head Grease
Lubricate straw walker gear case.
TY6304 (U.S.)
To seal gear case mating surfaces.
Form-in-Place Gasket
Go to Section_120:Group_15
AG,OUO6435,966-19-20000503
1235
Specifications
Specifications
Item
Measurement Specification
Front Straw Walker Bearing Nuts
Torque
25 Nm
(18 lb-ft)
Rear Straw Walker Bearing Nuts
Torque
45 Nm
(33 lb-ft)
Front Straw Walker Bearing Nuts
Initial Torque 25 Nm
(18 lb-ft)
Gear Case Retaining Cap Screw
Torque
160 Nm
(120 lb-ft)
Gear Case Sheave Cap Screws
Torque
70 Nm
(52 lb-ft)
Straw Walker Gear Case
Capacity
414 mL (14 oz.) (1 tube)
Outer Gear Case Cap Screws
Torque
25 Nm
(18 lb-ft)
Gear Case Hub Cap Screw
Torque
35 Nm
(26 lb-ft)
Power Separator Tensioner Spring Length
172 mm ± 3 mm
(6.772 in. ± 0.118 in.)
Go to Section_120:Group_15
OUO6435,00018F3-19-20080229
1236
All Walkers - Timing Procedure
All Walkers - Timing Procedure
NOTE:
When bearings or crankshafts were replaced, re-timing is required. If not timed correctly, straw
walkers will fail in a very short time.
Timing of the straw walkers is performed as follows:
1. Remove the straw walker drive belt.
2. Tighten hardware on the front bearings to specification.
Item
Measurement Specification
Front Straw Walker Bearing Nuts Torque
25 Nm
(18 lb-ft)
3. Tighten the nuts on all the rear bearings and then back them off slightly.
4. For each rear bearing, rotate the crank one full revolution until the throw of the crank is at its lowest
position. Tighten the bearing.
5. Tighten the bearings in the following sequence:
1.
2.
3.
4.
5.
Outside Left
Outside Right
Inside Left
Inside Right
Center (if applicable, on W650, W660 and T670)
6. If a tight area is noted during the revolution of the crank, loosen and retighten the previously set bearing.
7. With all hardware tight, rotate walkers by hand and check for any resistance.
8. If any resistance is detected, repeat the complete timing procedure.
9. Walkers should rotate freely.
10. Tighten all hardware to specification.
Item
Measurement Specification
Rear Straw Walker Bearing Nuts Torque
45 Nm
(33 lb-ft)
Go to Section_120:Group_15
OUO6089,0000020-19-20080220
1237
Remove and Install Straw Walker Bearings and Walker Return Pan
Remove and Install Straw Walker Bearings and Walker Return Pan
ZX25180-UN: Walker Bearings
LEGEND:
1 - Seal
2 - Strap
3 - Riser
4 - Flange Nut (3 used)
5 - Seal
6 - Seal
7 - Seal
8 - Straw Walker (4 used)
1238
Remove and Install Straw Walker Bearings and Walker Return Pan
9 - Cap Screw (As Required)
10 - Cap Screw
11 - Nut
12 - Bracket (2 used)
13 - Deflector
14 - Lock Nut (2 used)
15 - Support Strap
16 - Washer
17 - Walker Pan
18 - Flap (4 used)
19 - Cap Screw (2 used)
20 - Cap Screw (As Required)
21 - Rivet (2 used)
22 - Riser (as required)
23 - Cap Screw
24 - Cap Screw (4 used)
25 - Retainer (2 used)
26 - Bearing (2 used)
27 - Cover
28 - Lock Nut
29 - Cap Screw
30 - Strap
31 - Tie Band (10 used)
1.
ZX25155-UN: Panel
LEGEND:
A - Cap Screw (12 used)
Remove cap screws (A) from inside of rear panel.
1239
Remove and Install Straw Walker Bearings and Walker Return Pan
2.
ZX25156-UN: Side Panel
LEGEND:
A - Cap Screws
B - Panel
Remove cap screws (A) on both sides and panel (B).
3.
ZX25160-UN: Shield
LEGEND:
A - Cap Screws and Nuts
B - Retainer
C - Shield
Remove nuts and cap screws (A) from both sides, retainer (B) and shield (C).
4.
ZX25157-UN: Monitor Wires
LEGEND:
A - Clamp (3 used)
1240
Remove and Install Straw Walker Bearings and Walker Return Pan
Loosen clamps (A) and remove monitor wires from outside straw walkers.
5.
H40532-UN: Straw Walker Monitor
LEGEND:
A - Cap Screw and Nut (4 used)
B - Monitor
Remove nuts and cap screws (A) to remove monitor (B) from outside straw walkers.
6.
ZX104319-UN: Walker Return Pan
Remove brace and walker return pan.
ZX104317-UN: Walker Return Pan
LEGEND:
A - Screw, Font Right
B - Screw, Front Left
1241
Remove and Install Straw Walker Bearings and Walker Return Pan
ZX104318-UN: Walker Return Pan
LEGEND:
C - Screw, Rear Right
D - Screw, Rear Left
Remove screws (A, B, C and D) from return pan bearings. Lift return pan out of the machine from the
rear.
CAUTION:
The walker return pan is very heavy; an additional person is required for removal.
7.
ZX25158-UN: Wooden Bearings
LEGEND:
A - Cap Screw
B - Nuts
C - Bearing
Remove cap screw (A), nuts (B) and bearing (C).
8. Move straw chopper toward front of combine.
9. Remove side access panels for access to front bearings.
10.
CAUTION:
Straw walkers are heavy, use a lifting device or one additional person to remove
from machine.
1242
Remove and Install Straw Walker Bearings and Walker Return Pan
Lift access door in floor of engine compartment. Lift straw walker front end so bearing block clears
crank.
11. Remove straw walker from rear of combine.
12. Inspect all parts. Repair or replace parts as necessary.
13. Install straw walker from rear of combine.
14. Lift front of straw walker over front crank.
15. Install front bearings through side access openings. Attach using four nuts. Tighten to specification.
Item
Measurement Specification
Front Straw Walker Bearing Nuts Initial Torque 25 Nm
(18 lb-ft)
16. Move straw chopper toward rear of combine.
17.
ZX25158-UN: Bearing
LEGEND:
A - Cap Screw
B - Nuts
C - Bearing
Install bearing (C), nuts (B) and cap screw (A). After all bearings have been installed, rotate the walker
system by rotating the walker drive sheave until walkers have turned two complete revolutions. Tighten
nuts (B) only when walker is at top or bottom of crank stroke. Tighten nuts to specified torque.
Item
Measurement Specification
Rear Straw Walker Bearing Nuts Torque
45 Nm
(33 lb-ft)
1243
Remove and Install Straw Walker Bearings and Walker Return Pan
18.
H40532-UN: Straw Walker Monitor
LEGEND:
A - Cap Screw and Nut (4 used)
B - Monitor
Install monitor (B) on outside straw walkers using nuts and cap screws (A).
19.
ZX25157-UN: Monitor Wires
LEGEND:
A - Clamp (3 used)
Attach monitor wires to outside straw walkers using clamps (A).
20.
ZX25160-UN: Shield
LEGEND:
A - Nut and Cap Screw (2 used)
B - Retainer
C - Shield
Install shield (C) and retainer (B) using nuts and cap screws (A) on both sides.
1244
Remove and Install Straw Walker Bearings and Walker Return Pan
21.
ZX25156-UN: Panel
LEGEND:
A - Cap Screw (3 used)
B - Panel
Attach panel (B) using cap screws (A) on both sides.
22.
ZX25155-UN: Panel
LEGEND:
A - Cap Screw (12 used)
Install cap screws (A) to inside of rear panel.
Go to Section_120:Group_15
OUO6089,000001F-19-20080213
1245
Remove and Install Rear Crankshaft
Remove and Install Rear Crankshaft
ZX25158-UN: Crankshaft
LEGEND:
A - Cap Screw (2 used)
B - Nut (4 used)
C - Bearing
NOTE:
A NEW crankshaft measures 38.1 mm (1.5 in.) in diameter. When crankshaft has worn to a
diameter of less than 35 mm (1.375 in.), replace complete crankshaft.
1. Remove cap screw (A), nuts (B) and bearing (C) on each walker unit.
2. Support straw walkers up and off the crankshaft.
3.
H40535-UN: Housing
LEGEND:
A - Flange Nut (3 used)
B - Locking Collar
C - Ball Bearing
D - Flange Housing (2 used)
Remove collar (B) from both sides.
4.
CAUTION:
Crankshaft will drop when flange housing and bearings are removed.
1246
Remove and Install Rear Crankshaft
Remove flange nuts (A), flange housing (D) and bearing (C) from both sides.
5. Remove crankshaft.
6. Inspect parts. Replace parts as necessary.
7. IMPORTANT:
Keyway end of crankshaft goes toward left side of combine.
Install crankshaft. Center crankshaft between sidesheets of separator.
8.
H40535-UN: Housing
LEGEND:
A - Flange Nut (3 used)
B - Locking Collar
C - Ball Bearing
D - Flange Housing (2 used)
Install flange housings (D) and bearing (C) using flange nuts (A) on both sides.
9. Install locking collar (B) on both sides.
10. Install straw walkers on crankshaft using bearings, seals and lock nuts.
11.
ZX25158-UN: Crankshaft
LEGEND:
A - Cap Screw
B - Nuts
1247
Remove and Install Rear Crankshaft
C - Bearing
Install bearing (C), nuts (B) and cap screw (A). SNUG tighten nuts (B) on REAR crankshaft and torque to
specification on FRONT crankshaft.
Item
Measurement Specification
Front Straw Walker Bearing Nuts Torque
25 Nm
(18 lb-ft)
12. Rotate walker drive sheave on right side of combine (with drive belt removed) so walkers are rotated
through one complete revolution. Tighten bearings in the following sequence rotating straw walkers each
time.
1. On center walker (5-walker combines) or on one of the two center walkers (6-walker
combines).
2. On the walker beside (right side)
3. On the walker beside (left side)
4. Alternately tighten left and right bearing in this sequence. Tighten the outer bearings last.
Tighten walker bearing nuts to specification on REAR walker crankshaft when crankshaft is at BOTTOM
of stroke.
Item
Measurement Specification
Rear Straw Walker Bearing Nuts Torque
45 Nm
(33 lb-ft)
If resistance or tight spot is found while rotating, loosen and retighten previously set bearing.
13. When all bearings have been tightened, measure rolling drag torque of rear shaft. For this purpose,
place the self-manufactured adapter (see Section 199, Group 10) on a torque wrench and position it
against left stub shaft (rear crankshaft). The rolling drag torque must not exceed 30 Nm (22 lb-ft). If
resistance is too high, repeat adjusting procedure. Walkers should rotate freely.
Item
Measurement Specification
Rear Crankshaft Rolling Drag Torque Torque
30 Nm
(22 lb-ft)
Go to Section_120:Group_15
ZX09263,0002752-19-20080220
1248
Remove and Install Front Crankshaft
Remove and Install Front Crankshaft
NOTE:
A NEW crankshaft measures 38.1 mm (1.5 in.) in diameter. When crankshaft has worn to a
diameter of less than 35 mm (1.375 in.), replace complete crankshaft.
1. Remove inside access panels for access to front crankshaft.
2.
ZX25158-UN: Crankshaft
LEGEND:
A - Cap Screw (2 used)
B - Nut (4 used)
C - Bearing
Remove cap screw (A), nuts (B) and bearing (C) on each walker unit.
3. Support straw walkers up and off the crankshaft.
4.
H40536-UN: Actuator
LEGEND:
A - Switch
B - Flange Nut (3 used)
C - Flange Housing (3 used)
D - Actuator
E - Locking Collar
F - Ball Bearing
1249
Remove and Install Front Crankshaft
Remove switch (A) and actuator (D).
5. Remove locking collar (E).
6. Remove flange nuts (B).
7. Remove flange housings (C) and bearing (F).
8. Remove straw walker gear case (see procedure in this group).
9.
H40537-UN: Housing
LEGEND:
A - Flange Nut (3 used)
B - Key
C - Flange Housing (2 used)
D - Ball Bearing
Remove key (B).
10. Remove flange nuts (A), flange housing (C) and bearing (D).
NOTE:
Bearing (D) is press fit.
11. Remove crankshaft.
12. Inspect all parts. Replace parts as necessary.
13. IMPORTANT:
Keyway end of crankshaft goes toward right side of combine.
Install crankshaft.
NOTE:
A spacer, which locates length of shaft, is located between straw walker throw and
bearing on right end.
14. Install flange housing (C), bearing (D) and flange nuts (A).
15. Install key (B).
1250
Remove and Install Front Crankshaft
16. Install straw walker gear case (see procedure in this group).
17.
H40536-UN: Actuator
LEGEND:
A - Switch
B - Flange Nut (3 used)
C - Flange Housing (2 used)
D - Actuator
E - Locking Collar
F - Ball Bearing
Install flange housing (C) and bearing (F).
18. Install flange nuts (B).
19. Install actuator (D) and switch (A).
20.
ZX25158-UN: Crankshaft
LEGEND:
A - Cap Screw
B - Nuts
C - Bearing
Install straw walkers on crankshaft using bearings (C), nuts (B) and cap screw (A).
21. SNUG tighten nuts (B) on REAR crankshaft and torque to specification on FRONT crankshaft.
1251
Remove and Install Front Crankshaft
Item
Measurement Specification
Front Straw Walker Bearing Nuts Torque
25 N˙m
(18 lb-ft)
22. Rotate walker drive sheave on right side of combine (with drive belt removed) so walkers are rotated
through one complete revolution. Tighten walker bearing nuts to specification on REAR walker
crankshaft when crankshaft is at TOP or BOTTOM of stroke.
Item
Measurement Specification
Rear Straw Walker Bearing Nuts Torque
45 N˙m
(33 lb-ft)
Go to Section_120:Group_15
OUO6435,000145C-19-20010809
1252
Remove and Install Straw Walker Gear Case
Remove and Install Straw Walker Gear Case
NOTE:
Before removing straw walker gear case, it will be necessary to loosen the following belts : Belts
for clean grain elevator, lower tailings auger and elevator, secondary countershaft, shoe, straw
walkers and conveyor auger on right side of combine.
NOTE:
The straw walker gear case is lubricated for life and is not vented. Gear case is lubricated with
corn head grease. If disassembled for repair, repack using 414 mL (14 oz.) of AN102562 Corn
Head Grease.
1.
H64196-UN: Remove Gear Case
LEGEND:
A - Cap Screw (2 used)
B - Shield
Remove cap screws (A) and auger drive shield (B).
2.
H64198-UN: Sheave
1253
Remove and Install Straw Walker Gear Case
H50578-UN: Crankshaft
LEGEND:
A - Cap Screw (4 used)
B - Sheave
C - Cap Screw (3 used)
Remove cap screws (A) and sheave (B).
3. Remove cap screws (C) from bearing flangettes on straw walker crankshaft.
4.
H64197-UN: Gear Case
LEGEND:
A - Cap Screw and Washer
B - Pin and Bracket
Remove pin (B) and bracket.
5. Remove cap screw and washer (A).
6. Install JDG643A Straw Walker Gear Case Puller and remove gear case.
7. IMPORTANT:
The puller must be installed in the 1 o'clock / 7 o'clock orientation. Install one leg of puller over gear case
at the 1 o'clock position. Then, slide bottom leg on cross bar into 7 o'clock position.
1254
Remove and Install Straw Walker Gear Case
NOTE:
Rotate gear case clockwise to move sheave drive hub out of the way (4 o'clock).
Turn puller center screw to remove gear case. Move the gear case approximately 25 mm (1 in.) and
stop.
8. IMPORTANT:
Rotating the assembly will clear the clean grain elevator sheave support and tension spring.
H41134-UN: Remove Gear Case
LEGEND:
A - Puller
Rotate gear case and puller combination (A) counterclockwise until puller is in 11 o'clock / 5 o'clock
orientation.
NOTE:
A tolerance situation may be present in which puller may have to be removed and gear
case removed the last 4 mm (0.2 in.) by hand.
9. Complete gear case removal.
H50578-UN: Crankshaft
LEGEND:
C - Cap Screw (3 used)
1255
Remove and Install Straw Walker Gear Case
10. Install cap screws (C) on bearing flangettes for straw walker crankshaft.
11.
H40544-UN: Gear Case
LEGEND:
A - Gear Case
B - Crankshaft
Install gear case (A) on crankshaft (B)
H64197-UN: Gear Case
LEGEND:
A - Cap Screw and Washers
B - Pin
12. Install washers and cap screw (A). Tighten cap screw to specification.
Item
Measurement Specification
Gear Case Cap Screw Torque
160 N˙m
(120 lb-ft)
13. Install bracket on gear case and install pin (B).
1256
Remove and Install Straw Walker Gear Case
14.
H64198-UN: Sheave
LEGEND:
A - Cap Screw (4 used)
B - Sheave
Install sheave (B) and cap screws (A). Tighten cap screws to specification.
Item
Measurement Specification
Gear Case Sheave Cap Screws Torque
70 N˙m
(52 lb-ft)
15. Install secondary countershaft sheaves.
16. Install auger drive shield and pulley.
17. Tension the following belts:
Clean grain elevator belt
Lower tailings auger and elevator belt
Secondary countershaft belt
Shoe, walker and conveyor auger belt
Go to Section_120:Group_15
OUO6435,000145D-19-20010809
1257
Disassemble and Assemble Straw Walker Gearcase
Disassemble and Assemble Straw Walker Gearcase
H71522-UN: Gear Case
LEGEND:
A - Nut (9 used)
B - Arm (2 used)
C - Cap Screw (2 used)
D - Seal
E - Gear Case
F - Snap Ring
G - Ball Bearing (2 used)
H - Pinion
I - Seal
J - Fitting
K - Seal
L - Spring Pin (2 used)
M - Gear Case
N - Fitting
O - Cap Screw (4 used)
1258
Disassemble and Assemble Straw Walker Gearcase
P - Ball Bearing (2 used)
Q - Gear
R - Snap Ring
1.
H40542-UN: Disassemble
LEGEND:
A - Hub
B - Cap Screw
Loosen cap screw (B).
2. Remove hub (A). Hub is a tight fit. It may be necessary to use a puller to remove hub.
3.
H51942-UN: Gear Case
LEGEND:
A - Arms
B - Housing
C - Cap Screw (10 used)
Remove cap screws (C) and arms (A) from housing (B).
1259
Disassemble and Assemble Straw Walker Gearcase
4.
H63882-UN: Gear Case
LEGEND:
A - Slot (2 used)
Separate housing by prying apart at slots (A) on both ends of gear case.
5.
H51943-UN: Gear Case
LEGEND:
A - Shaft
B - Pinion
C - Surfaces
Remove shaft (A) and pinion (B).
6. Remove gasket material from gear case mating surfaces (C).
1260
Disassemble and Assemble Straw Walker Gearcase
7.
H40339-UN: Gears
LEGEND:
A - Bearing (2 used)
Remove ball bearings (A) from gearshaft, if they require replacement. Bearings are a press fit.
8. Lubricate all bearings with AN102562 Corn Head grease. After assembly of bearings and gears, gear
case must be lubricated with 414 mL (14 oz.) (1 tube) of AN102562 Corn Head Grease, bearings
included.
Item
Measurement Specification
Straw Walker Gear Case Capacity
414 mL (14 oz.) (1 tube)
9.
H40340-UN: Gears
LEGEND:
A - Bearing (2 used)
Install ball bearings (A) on gears. Bearing inner races must rest against shaft shoulders. Bearings are a
press fit.
10.
H51944-UN: Seals
LEGEND:
A - Seal (3 used)
Remove seals (A) if they require replacement.
1261
Disassemble and Assemble Straw Walker Gearcase
11.
H63883-UN: Seals
LEGEND:
A - Seal Driver
Install seal in outer gear case half using appropriate driver (A). Seal must be installed as shown.
12. Install seals in inner gear case half.
13. Install all seals with spring-loaded lip toward bearings and flush with housings.
14.
H51943-UN: Gear Case
LEGEND:
A - Shaft
B - Pinion
C - Groove
Apply a bead of TY6304 Form-in-Place Gasket to flange groove (C) of outer gear case half.
15. Install shaft (A) and pinion (B).
1262
Disassemble and Assemble Straw Walker Gearcase
16.
H51942-UN: Gear Case
LEGEND:
A - Arms
B - Housing
C - Cap Screw (10 used)
Assemble housing (B).
17. Install arms (A) and cap screws (C). Tighten cap screws to specification.
Item
Measurement Specification
Outer Gear Case Cap Screws Torque
25 N˙m
(18 lb-ft)
NOTE:
It is normal for the gear and pinion bearings to move back and forth in the gear case. If
excessive movement is thought to exist, separate gear case and apply TY15969
Retaining Compound (Maximum Strength) to outer race of bearings.
18.
H40543-UN: Hub Installation
LEGEND:
A - Hub
B - Cap Screw
1263
Disassemble and Assemble Straw Walker Gearcase
Install hub (A). Hub is a tight fit.
19. Tighten cap screw (B) to specification.
Item
Measurement Specification
Gear Case Hub Cap Screw Torque
35 N˙m
(26 lb-ft)
Go to Section_120:Group_15
OUO6435,00018C1-19-20020820
1264
Remove and Install Power Separator
Remove and Install Power Separator
1. Remove gull wing doors. (See Section 80, Group 05.)
2.
ZX25106-UN: Chopper Jackshaft Shield
LEGEND:
A - Belt Tensioner
B - Cap Screws
C - Cap Screw
D - Shield
E - Belt
F - Support Rod
Loosen belt tensioner (A), remove cap screws (B), (C), belt (E) and support rod (F). Let shield (D) hang.
3.
ZX25107-UN: Support Rod and Bracket
LEGEND:
A - Bracket
B - Support Rod
Loosen bracket (A). Remove support rod (B).
1265
Remove and Install Power Separator
4.
ZX25373-UN: Later Model
LEGEND:
A - Belt Tensioner
B - Belt
C - Sheave
Loosen belt tensioner (A). Remove belt (B) and sheave (C).
5.
ZX25109-UN: Speed Sensor
LEGEND:
A - Actuator
B - Pick-up
C - Cap Screws
D - Support Rod
Remove actuator (A), pick-up (B), cap screws (C) and support rod (D).
1266
Remove and Install Power Separator
6.
ZX25110-UN: Straw Walkers
LEGEND:
A - Left Walker
B - Plywood
Align straw walkers so that extreme left walker is at lowest point (A). Slide a piece of plywood (B) under
power separator.
7. Rotate power separator so that fingers are at the 4 o'clock or 8 o'clock position.
8. Block power separator to support.
9.
ZX25111-UN: Power Separator Attachment Point
LEGEND:
A - Cap Screws
B - Set Screw
Remove cap screws (A) and set screw (B).
1267
Remove and Install Power Separator
10.
ZX25112-UN: Side Panel
LEGEND:
A - Bearing and Flange
B - Side Panel
Remove bearing and flange (A) and side panel (B).
11.
ZX25113-UN: Power Separator
Remove power separator using fork lift and a person to assist to prevent power separator from rolling
and damaging walkers.
12. Install in reverse order using the following special instructions:
Center power separator between side sheets before tightening set screw and bearing locking
collar.
Adjust belt tension according to specification.
Item
Measurement Specification
Power Separator Tensioner Spring Length
172 mm ± 3 mm
(6.772 in. ± 0.118 in.)
Go to Section_120:Group_15
OUO6435,00017E7-19-20080130
1268
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Vacuum
Pump.......D15032NU
To remove and install
chaff spreader pump.
Chaff Spreader
Pump
Driver.......27505
Install washer and
seal into front plate.
Go to Section_120:Group_20
ZX09263,0002747-19-20080201
1269
Service Equipment and Tools
Service Equipment and Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
Some tools may be available from a local supplier.
Vacuum
Pump.......D15032NU
To remove and install
chaff spreader pump.
Chaff Spreader
Pump
Driver.......27505
Install washer and
seal into front plate.
Go to Section_120:Group_20
ZX09263,0002747-19-20080201
1270
Other Material
Other Material
Number
Name
Use
T43513 (U.S.) High Strength Thread Lock (271) To retain jackshaft bearings to jackshaft.
TY6341 (U.S.) Multipurpose SD Polyurea Grease Apply to bushings of front drive.
Go to Section_120:Group_20
OUO6045,0000121-19-20010504
1271
Specifications
Specifications
Item
Measurement Specification
Chopper Blade Lock Nuts Torque
60 N˙m
(45 lb-ft)
Sheave Cap Screw
70 N˙m
(52 lb-ft)
Torque
Go to Section_120:Group_20
OUO6435,00018F1-19-20020829
1272
Chopper and Blades
Chopper and Blades
ZX1034915-UN: Chopper Rotor
LEGEND:
A - Chopper Rotor
B - Blades
C - Washers
D - Bushings
E - Bolt
Go to Section_120:Group_20
ZX08994,00002F0-19-20050323
1273
Chopper Housing and Knife Bank
Chopper Housing and Knife Bank
ZX25240-UN: Chopper Housing
LEGEND:
1 - Cap Screw (4 used)
2 - Washer (2 used)
3 - Sheet (2 used)
4 - Tailboard
5 - Screw (13 used)
6 - Strap
7 - Cap Screw (11 used)
8 - Holder
1274
Chopper Housing and Knife Bank
9 - Knife (66 used)
10 - Washer (2 used)
11 - Cap Screw (2 used)
12 - Plate (2 used)
13 - Main Frame
14 - Rasp Bar
15 - Main Frame
16 - Springs (2 used)
17 - Retainer (2 used)
18 - Handle (2 used)
19 - Washer (2 used)
20 - Spring (2 used)
21 - Rod
22 - Cap Screw (7 used)
23 - Nut (7 used)
Go to Section_120:Group_20
OUO6089,0000073-19-20010719
1275
Remove Straw Chopper
Remove Straw Chopper
CAUTION:
The approximate weight of straw chopper is 159 kg (350 lb).
IMPORTANT:
If combine is equipped with chaff spreader, remove chaff spreader before lowering straw chopper.
1.
ZX25163-UN: Sensor
LEGEND:
A - Shield
B - Wiring Harness
Remove chopper belt shield (A). Disconnect harness (B).
2.
NOTE:
Support tailboard assembly. Use a suitable lifting device to remove.
ZX25165-UN: Tailboard
LEGEND:
A - Cap Screws (5 used)
B - Support Arms
C - Pins
D - Cap Screws (2 used)
Remove cap screw (A).
1276
Remove Straw Chopper
3. Disconnect support arms (B).
4. Pull pins (C).
5. Remove cap screw (D).
6.
NOTE:
Support chopper assembly. Use suitable lifting device to remove.
ZX25164-UN: Straw Chopper
LEGEND:
A - Belt
B - Wiring Harness
C - Cap Screws (10 used)
Remove belt (A) from chopper drive sheave.
7. Disconnect wiring harness (B).
8. Remove cap screws (C) on both sides.
Go to Section_120:Group_20
OUO6435,000145E-19-20010809
1277
Replace Chopper Blades
Replace Chopper Blades
CAUTION:
1.
Engine must be off, key removed and park brake set.
IMPORTANT:
Replace any broken or damaged blades immediately. A broken blade will unbalance the chopper and
cause serious damage. Be sure to mark blades being removed but not replaced, and rotor. Blades must
be installed in their original position to maintain chopper balance.
ZX25179-UN: Chopper Blades
LEGEND:
A - Washer
B - Cap Screw
C - Lock Nut
D - Key
E - Rotor
F - Blades
G - Cap Screw
H - Washer
I - Bushing
J - Lock Nut
Install new blades; remove nut (J), cap screw (G), flat washers (H), blades (F) and bushings (I).
2. Install bushings (I), new blades (F), flat washers (H), cap screw (G) and lock nut (J). Tighten to
1278
Replace Chopper Blades
specification.
Item
Measurement Specification
Chopper Blade Lock Nuts Torque
60 N˙m
(45 lb-ft)
3. IMPORTANT:
Chopper balance must be maintained. When replacing one broken blade, six must be replaced in the
proper locations to maintain chopper balance.
H55902-UN: Replace Chopper Blades
LEGEND:
A—F - Chopper Blades
If blade (A) is broken, adjacent blades (B) and (C) must be replaced, as well as corresponding blades
(D), (E) and (F) on the opposite end of rotor.
Go to Section_120:Group_20
OUO6089,0000056-19-20010702
1279
Replace Knife Sections
Replace Knife Sections
ZX25268-UN: Chopper Blades
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (6 used)
C - Shield
CAUTION:
Engine must be off and key removed.
1. Remove right and left side cap screw (A) and pull frame rearward.
2. Remove hardware on left side and pull frame out.
3.
CAUTION:
Knife sections are sharp.
Remove cap screw (B) and shield (C).
Go to Section_120:Group_20
OUO6089,0000072-19-20010717
1280
Remove and Install Rotor Bearings
Remove and Install Rotor Bearings
ZX1046198-UN: Rotor Bearings
LEGEND:
A - Bearing Quill
B - Castle Nut
C - Bearing
D - Clamping Ring
E - Felt Ring Seal
F - Quill
G - Plate
H - Guard
I - Bearing Assembly with Clamping Ring Bearing
Item
Measurement Specification
Castle Nut Torque
100 N·m (74 lb.-ft.)
Bearing, right side:
1. Remove bearing quill (A).
1281
Remove and Install Rotor Bearings
2. Loosen castle nut (B) and clamping ring (D).
3. Remove quill (F) with bearing (C).
4. Inspect bearing (C) and replace, if necessary.
5. For installation, follow removal procedure in reverse order. Tighten the clamp nut to specification and
secure it.
Bearing, left side:
1. Loosen clamping ring of bearing.
2. Pull bearing assembly (I) with bearing off the shaft.
3. Inspect the bearing and replace, if necessary.
4. For installation, follow removal procedure in reverse order.
Go to Section_120:Group_20
ZX61739,000046C-19-20140613
1282
Remove and Install Straw Chopper Jackshaft
Remove and Install Straw Chopper Jackshaft
1.
ZX25186-UN: Belt Shield
LEGEND:
A - Cap Screws (4 used)
B - Jackshaft Shield
C - Shield
Remove cap screws (A), jackshaft shield (B) and shield (C).
2.
ZX25174-UN: Chopper Drive Belt
LEGEND:
A - Nuts
B - Belt
Loosen nuts (A).
3. Remove belt (B).
4. Remove chopper drive belt.
1283
Remove and Install Straw Chopper Jackshaft
5.
H62905-UN: Replace
LEGEND:
A - Bracket
B - Flange Nut
Remove bracket (A) and flange nut (B).
6.
H62906-UN: Replace
LEGEND:
A - Cap Screw and Nut
Remove cap screw and nut (A).
7.
CAUTION:
The approximate weight of the chopper rear drive is 29 kg (65 lb). The use of two
service technicians is required during the removal and installation procedures.
Failure to do so may result in equipment damage and/or bodily injury.
1284
Remove and Install Straw Chopper Jackshaft
H62904-UN: Support Rods
LEGEND:
A - Flange Nut
B - Flange Nut
C - Support Rod (2 used)
D - Jackshaft
Loosen flange nuts (A) and (B).
8. Remove support rods (C) from jackshaft (D).
9. Slide jackshaft out from side sheet mounting bracket, and remove drive assembly.
10.
H60831-UN: Remove Old Sheave
1285
Remove and Install Straw Chopper Jackshaft
H60832-UN: New Sheave
LEGEND:
A - Flange Nut
B - Sheave
C - Key
D - Cap Screw
E - Flange Nut
Loosen flange nut (A) and remove sheave (B).
11. Position key (C) on right end of jackshaft and install NEW sheave with larger diameter grooves toward
machine, and hub against bearing.
12. Install sheave cap screw (D) in hole on hub, and retain with nut (E).
13. Tighten screw to specified torque.
Item
Measurement Specification
Sheave Cap Screw Torque
70 N˙m
(52 lb-ft)
Go to Section_120:Group_20
OUO6089,0000024-19-20010619
1286
Disassemble and Assemble Straw Chopper Jackshaft
Disassemble and Assemble Straw Chopper Jackshaft
ZX25232-UN: Chopper Jackshaft
LEGEND:
1 - Sheave
2 - Arm
3 - Seal (2 used)
4 - Bushing (2 used)
5 - Bearing (2 used)
6 - Lubrication Fitting
7 - Woodruff Key (2 used)
8 - Jackshaft
9 - Sheave
1287
Disassemble and Assemble Straw Chopper Jackshaft
10 - Washer
11 - Flange Nut
12 - Belt (3 used)
13 - Nut
14 - Eyebolt
15 - Eyebolt
16 - Flange Nut (4 used)
17 - Washer (2 used)
18 - Snap Ring
19 - Pin
20 - Screw
21 - Stud
22 - Nut (2 used)
23 - Flange Nut
24 - Sheave (3 used)
25 - Support
26 - Screw (2 used)
27 - Flange Nut (2 used)
28 - Actuator
29 - Actuator
30 - Screw (2 used)
31 - Screw
32 - Flange Nut
33 - Stud
34 - Flange Nut (4 used)
1. Disassemble parts (1) - (11).
2. Inspect all parts, replace as needed.
3. Apply T43513 Thread Lock and Sealer (High Strength) between jackshaft bearings and jackshaft during
reassembly.
4. Assemble parts (1) - (11).
Go to Section_120:Group_20
OUO6089,000006F-19-20010710
1288
Remove and Install Straw Chopper Idler Assembly
Remove and Install Straw Chopper Idler Assembly
ZX25178-UN: Chopper Idler Assembly
LEGEND:
1 - Flange Nut
2 - Idler
3 - Screw
4 - Cap Screw
5 - Pin
6 - Pivot
7 - Gauge
8 - Spring
9 - Washer
10 - Nut (2 used)
11 - Cap Screw
12 - Washer
13 - Snap Ring
14 - Washer
15 - Flange Nut
16 - Pulley
17 - Belt
18 - Bushing
19 - Seal
20 - Arm
1289
Remove and Install Straw Chopper Idler Assembly
1.
ZX25174-UN: Rear Drive
LEGEND:
A - Nuts (2 used)
B - Belt
Loosen nuts (A).
2. Remove belt (B).
3.
H51887-UN: Front Drive
LEGEND:
A - Snap Ring
B - Idler Assembly
Remove snap ring (A) and chopper idler assembly (B).
4. Inspect all parts. Replace parts as necessary.
5.
1290
Remove and Install Straw Chopper Idler Assembly
H40481-UN: Housing
LEGEND:
A - Seals
B - Bushings
Install new bushings (B) flush with edge of chamfer in housing. Bushings are a press fit.
6. Install seals (A) with lips facing out. Seals are a press fit.
7. Apply TY6341 Multipurpose SD Polyurea Grease to inner circumference of bushings and between
bushings.
8. Install in reverse order.
Go to Section_120:Group_20
OUO6089,000001E-19-20010618
1291
Other Material
Other Material
Number
Name
Use
TY6341 (U.S.) Multipurpose SD Polyurea Grease
Lubricate fan shaft sheave seals.
TY9370 (U.S.) Thread Lock and Sealer (Medium Strength) Fan speed actuator threads.
Go to Section_120:Group_25
OUO6045,000014B-19-20010601
1292
Other Material
Other Material
Number
Name
Use
TY6341 (U.S.) Multipurpose SD Polyurea Grease
Lubricate fan shaft sheave seals.
TY9370 (U.S.) Thread Lock and Sealer (Medium Strength) Fan speed actuator threads.
Go to Section_120:Group_25
OUO6045,000014B-19-20010601
1293
Specifications
Specifications
Item
Measurement Specification
Auger Drive Shaft Gears
Backlash
0.76 mm
(0.03 in.)
Separator Drive Jackshaft
Distance
65 mm
(2.56 in.)
Separator Drive Jackshaft Sheave and Cap Screws Torque
70 N˙m
(52 lb-ft)
Separator Drive Jackshaft Nut
Torque
308 N˙m
(225 lb-ft)
Cleaning Fan Shaft to Side Beam
Distance
117 mm
(4.60 in.)
Fan Speed Actuator Lock Nuts
Torque
24 N˙m
(18 lb-ft)
Precleaner/Chaffer Frame
Weight
45 kg
(100 lb)
Sieve Frame
Weight
39 kg
(86 lb)
Chaffer Frame
Weight
57 kg
(125 lb)
Shaker Pan
Weight
71 kg
(157 lb)
Cover
Weight
23 kg
(50 lb)
A
Torque
140 N˙m
(105 lb-ft)
B
Torque
350 N˙m
(258 lb-ft)
Shoe Pitman Arm Bearing Race
Distance
161 mm
(6.34 in.)
Shoe Pitman Arm Flange Housing, Cap Screws
Torque
320 N˙m
(236 lb-ft)
Swing Arms
Go to Section_120:Group_25
OUO6435,0001908-19-20020905
1294
Replace Shoe Supply Augers
Replace Shoe Supply Augers
H67928-UN: Shoe Supply Augers
LEGEND:
1 - Support
2 - Trough
3 - Screw (as Required)
4 - Stripper
5 - Bearing (as required)
6 - Lock Nut (21 used)
7 - Cap Screw (4 used)
8 - Screw (as Required)
1295
Replace Shoe Supply Augers
9 - Auger (6 used)
10 - Cap Screw (2 used)
11 - Bracket
12 - Flange Nut (as required)
13 - Drive Shaft
14 - Bushing (as Required)
15 - Flange Housing (16 used)
16 - Screw (as Required)
17 - Locking Collar (8 used)
18 - Gear (12 used)
19 - Woodruff Key (2 used)
20 - Washer (2 used)
21 - Key (As Required)
22 - Spring Pin (As Required)
23 - Cap Screw (2 used)
24 - Bearing (as required)
25 - Flange Nut (10 used)
26 - Clamp (7 used)
27 - Actuator
28 - Actuator
29 - Cap Screw (4 used)
30 - Bracket
31 - Bearing
32 - Screw (3 used)
33 - Cap Screw
34 - Cap Screw (as required)
35 - Fitting
36 - Screw (3 used)
37 - Bearing (2 used)
38 - Flange Housing (2 used)
39 - Bearing
40 - Shim
41 - Locking Collar
42 - Bracket
43 - Clamp (2 used)
44 - Sheet
45 - Cap Screw (2 used)
46 - Washer (2 used)
47 - Wing Nut (2 used)
48 - Shim
49 - Shield
50 - Sheet (2 used)
51 - Strap (2 used)
52 - Clamp (4 used)
1296
Replace Shoe Supply Augers
1.
H68211-UN: Safety Stop
Raise feeder house and lower safety stop (A).
2.
H67992-UN: Panel
H68375-UN: Door
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (2 used)
C - Panel
D - Latch (2 used)
E - Door
Remove cap screws (A) and (B) and panel (C).
3. Rotate latches (D) and remove door (E).
1297
Replace Shoe Supply Augers
4.
H68364-UN: Shoe Supply Augers
LEGEND:
A - Clamp
B - Set Screw
C - Locking Collar
D - Spring Pin
Loosen clamp (A) and slide gear over to free auger.
5. Loosen set screw (B) and locking collar (C).
6. Drive spring pin (D) out of gear.
7.
H68370-UN: Access Hole Cover
LEGEND:
A - Wing Nut (2 used)
B - Access Hole Cover
Loosen wing nuts (A) and remove access cover (B).
1298
Replace Shoe Supply Augers
8.
H68365-UN: Wooden Bearings
LEGEND:
A - Cap Screw (2 used)
Loosen rear auger bearing (A) on the auger being removed.
9.
H68367-UN: Auger Removal
LEGEND:
A - Auger (6 used)
Push auger (A) out of front bearing then lift up, rotate out slot above drive shaft.
10.
NOTE:
There are two different types of auger flightings (counterclockwise and clockwise
rotation). If more than one auger is being replaced, note orientation of auger flightings.
1299
Replace Shoe Supply Augers
H67932-UN: Removal
LEGEND:
A - Left Auger ( 3 used)
B - Right Auger ( 3 used)
Turn auger (A) clockwise or auger (B) counterclockwise to remove.
11.
H68372-UN: Bearing
LEGEND:
A - Nut (3 used)
B - Bearing Assembly
Remove nuts (A) and flanged housing, shim and bearing (B).
12. Inspect parts and replace as necessary.
13. Install flanged housing, shim and bearing (B) with nuts (A).
14. Install augers in reverse order of removal.
1300
Replace Shoe Supply Augers
15.
H68364-UN: Bevel Gears
LEGEND:
A - Clamp
B - Set Screw
C - Locking Collar
D - Spring Pin
Install locking collar (C), gear and spring pin (D).
16. Tighten set screw (B).
17. Adjust gear backlash as follows:
1. Align gears until they touch.
2. Loosen clamp (A) until specified backlash is obtained, then tighten.
Item
Measurement Specification
Auger Drive Shaft Gears Backlash
0.76 mm
(0.03 in.)
Go to Section_120:Group_25
OUO6089,0000028-19-20021125
1301
Replace Shoe Supply Auger Wooden Bearings
Replace Shoe Supply Auger Wooden Bearings
1.
H68370-UN: Access Hole Cover
LEGEND:
A - Wing Nut (2 used)
B - Access Hole Cover
Loosen wing nuts (A) and remove access cover (B).
2.
H50277-UN: Wooden Bearings
LEGEND:
A - Cap Screw and Nut (4 used)
B - Support
C - Bearing
Remove nuts and cap screws (A) from both sides and support (B).
3. Remove bearings (C) as needed to replace.
4. Attach support (B) using cap screws and nuts (A).
Go to Section_120:Group_25
ZX09263,00027C1-19-20080303
1302
Remove and Install Shoe Supply Auger Drive Shaft
Remove and Install Shoe Supply Auger Drive Shaft
1.
H68211-UN: Safety Stop
Raise feeder house and lower safety stop (A).
2. Remove right front wheel (see Section 50, Group 25).
3.
H67992-UN: Panel
H68375-UN: Door
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (2 used)
C - Panel
D - Latch (2 used)
E - Door
1303
Remove and Install Shoe Supply Auger Drive Shaft
Remove cap screws (A) and (B) and panel (C).
4. Rotate latches (D) and remove door (E).
5.
ZX25167-UN: Shield
LEGEND:
A - Wing Nut (2 used)
B - Access Hole Cover
Remove wing nuts (A) and access cover (B).
6.
H67984-UN: Idler
LEGEND:
A - Nut (2 used)
Loosen nuts (A) to relieve belt tension. Remove belt from sheave.
7.
1304
Remove and Install Shoe Supply Auger Drive Shaft
ZX25269-UN: Auger Drive Shaft
LEGEND:
A - Cap Screw
B - Sheave
C - Bearing
Remove cap screw (A), sheave (B) and bearing (C).
8.
H68008-UN: Actuator
LEGEND:
A - Screw (2 used)
B - Sensor
C - Screw (2 used)
D - Actuator (2 used)
Remove screws (C) and sensor (B).
9. Remove screws (A) and actuators (D).
10.
H68021-UN: Remove Shaft
LEGEND:
A - Bevel Gears
B - Nut (3 used)
C - Clamp
D - Drive Shaft
E - Flanged Housing with Bearing
Loosen clamps (C) to free gears (A).
1305
Remove and Install Shoe Supply Auger Drive Shaft
11. Remove nuts (B) to loosen flanged housing with bearing (E).
12. Move drive shaft (D) toward front and left side of machine.
13. Remove sheave, locking collar and flanged housing with bearing from right side of drive shaft and
remove shaft.
14. Install in reverse order.
15. Adjust gear backlash as follows:
1. Align gears until they touch.
2. Loosen clamp until specified backlash is obtained, then tighten.
Item
Measurement Specification
Auger Drive Shaft Gears Backlash
0.76 mm
(0.03 in.)
Go to Section_120:Group_25
OUO6089,0000029-19-20010619
1306
Remove and Install Shoe Supply Auger Trough
Remove and Install Shoe Supply Auger Trough
1.
H68211-UN: Safety Stop
Raise feeder house and lower safety stop (A).
2. Remove shoe supply augers (see procedure in this group).
3. Remove shoe supply auger drive shaft (see procedure in this group).
CAUTION:
4.
The approximate weight of trough is 29 kg (65 lb).
H41314-UN: Trough
LEGEND:
A - Cap Screw (12 used)
B - Cap Screw (4 used)
C - Trough
Remove cap screws (A) and (B) from both sides; then trough (C).
5. Install in reverse order.
Go to Section_120:Group_25
OUO6089,0000036-19-20010620
1307
Remove Separator Drive Jackshaft
Remove Separator Drive Jackshaft
NOTE:
It may be necessary to remove the tailings elevator to facilitate removal of the shaft.
1. Turn on ignition switch and engage separator switch in cab.
CAUTION:
Do not start engine when adjusting fan speed.
2.
H65799-UN: Separator Sheave
LEGEND:
A - Nut (2 used)
B - Cap Screw, Spacer and Nut
Press cleaning fan speed decrease switch on armrest. Allow cleaning fan speed adjusting arm to move
to end of threaded rod on electric motor. Do not move lock nuts (A) on threaded rod.
3. Remove cap screw, nut and spacer (B) from arm. Allow arm to swing down.
1308
Remove Separator Drive Jackshaft
4.
H45524-UN: Sheave
LEGEND:
A - Belt
B - Sheave
C - Cap Screw and Washer
Remove cap screw and washer (C) from end of shaft.
5. Remove bearing and outer half of sheave (B) and belt (A) from shaft.
6. Remove inner sheave half clamp cap screw.
7. Remove sheave half from shaft.
8.
H45521-UN: Shaft
LEGEND:
A - Locking Collar
B - Key
Remove key (B), shims and locking collar (A).
9. Remove bearing flangettes and bearing.
10. On right side remove clean grain elevator drive belt from jackshaft pulley.
11. Remove tailings auger drive belt from jackshaft pulley.
1309
Remove Separator Drive Jackshaft
12. Remove secondary countershaft drive belt from jackshaft sheave.
13.
H73227-UN: Separator Drive
LEGEND:
A - Cap Screws (6 used)
B - Sheave
C - Sheave
Remove cap screws (A), sheaves (B) and (C).
14.
H73226-UN: Separator Drive
LEGEND:
A - Washer And Nut
B - Belt
C - Pulley
Remove nut and washer (A).
15. Remove shoe drive belt (B) and jackshaft pulley (C).
1310
Remove Separator Drive Jackshaft
16.
H73225-UN: Separator Drive
LEGEND:
A - Key
B - Locking Collar
C - Cap Screw and Nut (3 used)
D - Bearing and Flangettes
Remove key (A), locking collar (B), cap screws (C), flangettes and bearing (D) from shaft.
17. Remove shaft from left side of combine.
Go to Section_120:Group_25
OUO6435,000190E-19-20020916
1311
Install Separator Drive Jackshaft
Install Separator Drive Jackshaft
1.
H46400-UN: Jackshaft
LEGEND:
A - Bearing
B - Bearing Flangette (2 used)
C - Cap Screw and Nut (3 used)
D - Jackshaft
Install jackshaft (D) through separator body from left side, threaded end to right side.
2. Install left bearing (A) and flangettes (B) with cap screws and nuts (C).
3.
H73224-UN: Separator Drive
LEGEND:
A - Bearing and Flangettes
B - Cap Screw and Nut (3 used)
Install right bearing and flangettes (A) with grease fitting located as shown. Install cap screws and nuts
(B).
1312
Install Separator Drive Jackshaft
4.
H73228-UN: Separator Drive
LEGEND:
A - End of Shaft Taper
B - Inner Bearing Race
Locate right end of shaft to obtain specified dimension from inner bearing race (B) to end of shaft taper
(A).
Item
Measurement Specification
Separator Drive Jackshaft Distance
65 mm
(2.56 in.)
5. Install locking collar. Set counterclockwise.
6. Install shaft key.
7.
H73226-UN: Separator Drive
LEGEND:
A - Washer And Nut
B - Belt
C - Sheave
Install sheave (C), washer and nut (A). Tighten to specification.
Item
Measurement Specification
Separator Drive Jackshaft Nut Torque
308 N˙m
(225 lb-ft)
8. Install shoe drive belt (B).
1313
Install Separator Drive Jackshaft
9.
H73227-UN: Separator Drive
LEGEND:
A - Cap Screws (6 used)
B - Sheave
C - Sheave
Install sheaves (C) and (B).
10. Install cap screws (A). Tighten to specification.
Item
Measurement Specification
Separator Drive Jackshaft Sheave and Cap Screws Torque
11. Install secondary countershaft drive belt to large diameter sheave.
12. Install tailings auger drive belt.
13. Install clean grain elevator drive belt to outside sheave.
14.
H45521-UN: Shaft
LEGEND:
A - Locking Collar
B - Key
Install locking collar (A) on left end of shaft.
15. Install shim washers on shaft if removed earlier.
1314
70 N˙m
(52 lb-ft)
Install Separator Drive Jackshaft
16. Install key (B) in shaft.
17.
H45522-UN: Inner Sheave
LEGEND:
A - Cap Screw
Install inner sheave on shaft. Tighten cap screw.
18.
H45524-UN: Outer Sheave
LEGEND:
A - Belt
B - Bearing
C - Washers and Screw
Install cleaning fan belt (A) over shaft.
19. Install outer sheave half with bearing (B) on shaft.
20. Install spacer washers and screw (C) on end of shaft.
21. Install adjusting arm over outer bearing on shaft.
1315
Install Separator Drive Jackshaft
22.
H65799-UN: Separator Sheave
LEGEND:
A - Nut (2 used)
B - Cap Screw, Spacer and Nut
Install cap screw, spacer and nut (B). Do not move nuts (A). Pry open lower fan sheaves and push belt
down to gain slack, if needed, to install adjusting arm.
Go to Section_120:Group_25
OUO6435,000190F-19-20020916
1316
Remove and Install Cleaning Fan Drive
Remove and Install Cleaning Fan Drive
H72547-UN: Fan Drive
LEGEND:
1 - Cap Screw
2 - Washer
3 - Washer
4 - Bearing
5 - Seal (2 used)
6 - Sheave Half
7 - Lubrication Fitting (2 used)
8 - Seal (2 used)
9 - Dowel Pin
1317
Remove and Install Cleaning Fan Drive
10 - Sheave Half
11 - Cap Screw
12 - Nut
13 - Belt
14 - Lock Nut (6 used)
15 - Cap Screw (6 used)
16 - Clamp
17 - Stripper
18 - Key
19 - Shaft
20 - Locking Collar
21 - Set Screw
22 - Cap Screw
23 - Lubrication Fitting
24 - Flanged Housing
25 - Bearing
26 - Flanged Housing
27 - Flange Nut
28 - Key
29 - Lock Nut (4 used)
30 - Washer
31 - Spring (4 used)
32 - Bushing (4 used)
33 - Seal
34 - Lubrication Fitting
35 - Sheave Half
36 - Seal
37 - Dowel Pin
38 - Sheave Half
39 - Cap Screw (4 used)
40 - Washer
41 - Screw
42 - Belt
Go to Section_120:Group_25
OUO6435,0001700-19-20020411
1318
Fan Drive Speed Control
Fan Drive Speed Control
H68331-UN: Fan Drive Speed Control
LEGEND:
A - Shaft
B - Nut (4 used)
C - Thrust Washer (3 used)
D - Thrust Washer (3 used)
E - Trunnion
F - Snap Ring
G - Washer
H - Cap Screw (3 used)
1319
Fan Drive Speed Control
I - Cotter Pin
J - Pin
K - Support
L - Bushing
M - Washer
N - Nut (3 used)
Go to Section_120:Group_25
AG,OUO6435,1000-19-20000503
1320
Remove Cleaning Fan
Remove Cleaning Fan
1. IMPORTANT:
Remove drive motor or connect an outside 12-volt power source to motor to spread sheaves if power is
not available through switch. Do not turn gear by hand with motor installed and not operable.
H40545-UN: Sheaves
LEGEND:
A - Sheaves
Loosen fan drive belt tension by spreading drive sheaves (A). (Move control switch to slow position.)
Move outer two nuts to end of shaft if belt is not slack enough to remove.
2.
H68206-UN: Fan Drive Sheave
LEGEND:
A - Cap Screw
B - Cap Screw (4 used)
C - Sheave
Remove belt from fan shaft sheave (C).
3. Remove cap screws (B).
4. Remove cap screw (A) and sheave (C).
1321
Remove Cleaning Fan
5.
H68213-UN: Inner Fan Drive
LEGEND:
A - Key
B - Sheave
Remove key (A) and sheave (B).
6.
H45386-UN: Seals and Pins
LEGEND:
A - Seal (2 used)
B - Spring Pin
Inspect seals (A) and spring pins (B) in sheave. Replace parts as necessary.
7.
ZX25375-UN: Bearing
LEGEND:
A - Locking Collar
Loosen set screw and locking collar (A) on right side.
1322
Remove Cleaning Fan
8.
H68046-UN: Idler
LEGEND:
A - Nut (2 used)
B - Belt Tensioner
Loosen nuts (A) on straw walker, cleaning shoe and shoe supply auger belt tensioner (B).
9.
H68201-UN: Sheave
LEGEND:
A - Sheave
B - Cap Screw (4 used)
Remove belt from sheave (A).
10. Remove cap screws (B) and sheave (A).
11.
H68205-UN: Pitman Arms
1323
Remove Cleaning Fan
LEGEND:
A - Cap Screw
B - Cap Screw (4 used)
C - Flange Housing (2 used)
D - Hub
Remove cap screw (A) and hub (D).
12. Remove cap screws (B) and flange housings (C).
13.
H68226-UN: Key
LEGEND:
A - Key
Remove key (A) from shaft.
14.
H50512-UN: Housing and Bearings
LEGEND:
A - Sensor
B - Nut (3 used)
C - Flange Housing (2 used) and Bearing
D - Cap Screw (4 used)
E - Flange Housing (2 used)
F - Bearing
G - Nut (5 used)
H - Support
Disconnect wiring from sensor (A).
15. Remove nuts (B) and flanged housings and bearing (C).
1324
Remove Cleaning Fan
15. Remove nuts (B) and flanged housings and bearing (C).
16. Remove cap screws (D), flanged housing (E) and bearing (F).
17. Remove nuts (G) and support (H).
18.
H68198-UN: Shield
LEGEND:
A - Cap Screw (4 used)
B - Air Duct
Remove cap screws (A) and air duct (B).
19.
H57324-UN: Cleaning Fan
LEGEND:
A - Clamp (2 used)
B - Set Screw
C - Cap Screw (2 used)
D - Wheel
E - Shroud
F - Rotor
Loosen set screw (B) and remove wheel (D).
20. Remove cap screws (C).
21. IMPORTANT:
Note direction of rotor vanes for correct installation.
Loosen clamps (A) and remove rotor (F) and shroud (E).
1325
Remove Cleaning Fan
22. Repeat procedure for remaining fans.
23. Remove shaft from right side of machine.
24. Inspect all parts. Replace parts as necessary.
Go to Section_120:Group_25
OUO6435,000194B-19-20021023
1326
Install Cleaning Fan
Install Cleaning Fan
1. Clean both ends of fan shaft.
2.
ZX25374-UN: Bearing
LEGEND:
A - Side of Beam
B - End of Shaft
C - Specified Distance
D - Locking Collar
Install shaft from right side of combine.
3. Slide locking collar (D) on fan shaft. Slide shaft through bearing until specified distance (C) is achieved.
Install locking collar and tighten set screw.
Item
Measurement Specification
Cleaning Fan Shaft to Side Beam Distance
117 mm
(4.60 in.)
4. Install rotors and shrouds from right side of combine.
5.
H57289-UN: Replace Rotors
1327
Install Cleaning Fan
LEGEND:
A - Shrouds
B - Clamps
C - Rotors
Install rotors (C) and shrouds (A) together. Install clamps (B). Do not tighten clamps until rotor and
shroud are positioned correctly.
6. Move assembly to left side of combine and attach shroud.
7. Adjust rotor so it clears shroud.
8. Tighten clamps (B).
9. Repeat procedures for remaining rotors and shrouds.
10.
H68198-UN: Air Duct
LEGEND:
A - Cap Screw (4 used)
B - Air Duct
Install air duct (B) using cap screws (A).
11.
H57324-UN: Cleaning Fan
LEGEND:
A - Clamp (2 used)
B - Set Screw
C - Cap Screw (2 used)
D - Wheel
E - Shroud
F - Rotor
1328
Install Cleaning Fan
Install wheel (D) and tighten set screw (B).
12.
H50512-UN: Bearing and Housing
LEGEND:
A - Sensor
B - Nut (3 used)
C - Flanged Housing (2 used) and Bearing
D - Cap Screw (4 used)
E - Flange Housing (2 used)
F - Bearing
G - Nut (5 used)
H - Support
Install support (H) using nuts (G).
13. Install flanged housings and bearing (C) using nuts (B).
14. Install cap screws (D), flanged housing (E) and bearing (F).
15. Connect wiring lead to sensor (A).
16.
H68226-UN: Key
LEGEND:
A - Key
Install key (A) on shaft.
1329
Install Cleaning Fan
17.
H68205-UN: Pitman Arms
LEGEND:
A - Cap Screw
B - Cap Screw (4 used)
C - Flange Housing (2 used)
D - Hub
Install flanged housings (C) using cap screws (B).
18. Install hub (D) using cap screw (A).
19.
H68201-UN: Sheave
LEGEND:
A - Sheave
B - Cap Screw (4 used)
Install sheave.
20. Install belt on sheave.
1330
Install Cleaning Fan
21.
H68046-UN: Idler
LEGEND:
A - Nut (2 used)
B - Gauge
Tighten belts with nuts (A), until tip of gauge (B) aligns with washer.
22.
H68213-UN: Sheave
LEGEND:
A - Key
B - Sheave
Add TY6341 Multipurpose SD Polyurea Grease to inner circumference of sheave (B) and lubricate seals
at each end. Install sheave (B).
23. Install key (A).
24.
1331
Install Cleaning Fan
H68206-UN: Outer Sheave
LEGEND:
A - Cap Screw
B - Cap Screw (4 used)
C - Sheave
Install sheave (C) using cap screw (A). Tighten to specification.
Item
Measurement Specification
Variable Fan Speed Drive, Cap Screw Torque
123 N˙m
(91 lb-ft)
25. Install cap screws (B). Tighten nuts to spacer.
26.
NOTE:
Do not roll belt onto sheave (C) by turning shaft with a wrench on cap screw (A). This
will overtorque cap screw (A).
Install fan drive belt.
Go to Section_120:Group_25
OUO6435,0001901-19-20020904
1332
Remove and Install Cleaning Fan Housing
Remove and Install Cleaning Fan Housing
1.
H57296-UN: Support and Shields
LEGEND:
A - Nut and Cap Screw (6 used)
B - Shield
C - Nut and Cap Screw (24 used)
D - Nut and Cap Screw (18 used)
E - Support
Remove nuts and cap screws (A) and shield (B).
2. Remove nuts and cap screws (C), nuts and cap screws (D) and support (E).
3.
H68198-UN: Air Duct
LEGEND:
A - Cap Screw (4 used)
B - Air Duct
Remove cap screws (A) and air duct (B).
1333
Remove and Install Cleaning Fan Housing
4.
H57445-UN: Cleaning Fan Housing
LEGEND:
A - Cap Screw (2 used)
B - Fan Housing
Remove cap screws (A) and fan housing (B).
5.
H57445-UN: Cleaning Fan Housing
LEGEND:
A - Cap Screw (2 used)
B - Housing
Install fan housing (B) and cap screws (A).
6.
H68198-UN: Air Duct
LEGEND:
A - Cap Screw (4 used)
B - Air Duct
1334
Remove and Install Cleaning Fan Housing
Install air duct (B) using cap screws (A).
7.
H57296-UN: Support and Shield
LEGEND:
A - Cap Screw (6 used)
B - Shield
C - Nut and Cap Screw (24 used)
D - Nut and Cap Screw (18 used)
E - Support
Install support (E) using nuts and cap screws (C) and (D).
8. Install shield (B) using nuts and cap screws (A).
Go to Section_120:Group_25
AG,OUO6435,1003-19-20000503
1335
Adjust Fan Speed Actuator
Adjust Fan Speed Actuator
H40565-UN: Actuator
LEGEND:
A - Nut (2 used)
B - Trunnion
C - Lock Nut (2 used)
1. Start combine engine and set cleaning fan speed to mid speed to gain clearance to inside set of lock
nuts. Shut off combine engine.
2. Loosen lock nuts (C) and turn both nuts toward speed actuator.
3. Start combine engine and set fan speed to 1600 rpm. Shut off combine engine.
4. Apply TY9370 or T43512 Thread Lock and Sealer (medium strength) on threads next to trunnion (B)
where nuts (A) will be located. Tighten lock nuts snug against trunnion (B). Start combine engine and
decrease cleaning fan speed to gain clearance to lock nuts. Shut off combine engine. Tighten lock nuts
to specification.
Item
Measurement Specification
Fan Speed Actuator Lock Nuts Torque
24 N˙m
(18 lb-ft)
Go to Section_120:Group_25
AG,OUO6435,1004-19-20000503
1336
Remove Chaffer, Sieve and Frames
Remove Chaffer, Sieve and Frames
H68333-UN: Shaker Pan
LEGEND:
A - Nut (5 used)
B - Arm (2 used)
C - Cap Screw (2 used)
D - Washer (8 used)
E - Flange Nut (8 used)
F - Cap Screw (8 used)
G - Cap Screw (2 used)
H - Shaker Pan
I - Seal (2 used)
J - Seal
K - Nut (4 used)
L - Arm
M - Cap Screw (2 used)
N - Nut (2 used)
O - Nut (2 used)
CAUTION:
Be certain combine engine cannot be accidentally started.
1337
Remove Chaffer, Sieve and Frames
Be certain combine engine cannot be accidentally started.
1. Disconnect battery ground cable.
2. Remove key from key switch.
3. Install a CAUTION - DO NOT OPERATE tag in operator's cab.
4. Move straw chopper toward rear of combine.
5.
H57629-UN: Connector/Wiring Lead
LEGEND:
A - Cap Screw, Washer and Nut
B - Electrical Connector
C - Wiring Lead
Disconnect wiring lead (C).
6. Disconnect electrical connector (B) from both sides.
7. Remove cap screw, washer and nut (A) from both sides.
8.
CAUTION:
The approximate weight of cover is 23 kg (50 lb).
H41231-UN: Remove Shaker Pan
LEGEND:
A - Cover
B - Cap Screw and Nut
1338
Remove Chaffer, Sieve and Frames
Remove cap screw and nut (B) from both sides and cover (A).
9.
CAUTION:
The approximate weight of shaker pan is 71 kg (157 lb).
NOTE:
It is not necessary to remove shaker pan if only chaffer and sieve elements are
removed.
Remove shaker pan.
10.
ZX25169-UN: Straw Walkers
ZX25168-UN: Shaker Pan
LEGEND:
A - Cap Screw and Nut (4 used)
B - Cap Screw and Nut (4 used)
Remove nuts and cap screws (B) from both sides; then remove brace under shaker pan.
11. Remove nuts and cap screws (A) from both sides and shaker pan.
NOTE:
Shims between shaker pan and swing arms are used only during production process to
allow paint to run out. Shims can be discarded if shaker pan or swing arms are replaced.
1339
Remove Chaffer, Sieve and Frames
12.
ZX25363-UN: Chaffer Element
LEGEND:
A - Cap Screws
B - Chaffer Elements
C - Adjusting Motors (serial no. 074502—)
Remove cap screws (A). Lift rear of chaffer and disconnect harness connector of adjusting motor (C).
Remove chaffer elements (B).
13.
ZX25365-UN: Sieve Elements
LEGEND:
A - Cap Screws
B - Sieve Elements
C - Adjusting Motors (serial no. 074502—)
Remove cap screws (A). Lift rear of sieve and disconnect harness connector of adjusting motor (C).
Remove sieve elements (B).
1340
Remove Chaffer, Sieve and Frames
14.
ZX25364-UN: Precleaner Elements
LEGEND:
A - Cap Screws
B - Precleaner Elements
C - Adjusting Motors (serial no. 074502—)
Remove cap screws (A). Lift rear of precleaner and disconnect harness connector of adjusting motor
(C). Remove precleaner elements (B).
15.
ZX25170-UN: Chaffer
LEGEND:
A - Cap Screws (4 used)
B - Chaffer Frame
Remove nuts and cap screws (A) from both sides and chaffer frame (B).
1341
Remove Chaffer, Sieve and Frames
H68344-UN: Chaffer Frame
LEGEND:
A - Seal (2 used)
B - Frame
C - Cap Screw (2 used)
D - Cap Screw (2 used)
E - Cap Screw (2 used)
F - Link (2 used)
G - Flange Nut (as required)
H - Cap Screw (2 used)
I - Arm
J - Flange Nut (as required)
K - Key
L - Key
M - Cap Screw (2 used)
1342
Remove Chaffer, Sieve and Frames
N - Bar (2 used)
O - Screw (as required)
P - Ball Bearing (2 used)
Q - Screw (as required)
R - Flanged Housing (4 used)
S - Seal (2 used)
T - Snap Ring (2 used)
U - Cam
V - Shaft
16.
CAUTION:
The approximate weight of precleaner/chaffer frame is 45 kg (100 lb).
H57630-UN: Precleaner/Chaffer Frame
H41242-UN: Precleaner/Chaffer Frame
LEGEND:
A - Cap Screws
B - Cap Screws
C - Precleaner/Chaffer Frame
Remove nuts and cap screws (A) and (B) and precleaner/chaffer frame (C).
1343
Remove Chaffer, Sieve and Frames
H65455-UN: Precleaner/Chaffer Frame
LEGEND:
1 - Lock Nut (as required)
2 - Finger (9 used; 12 used on 9640, 9660 and 9680)
3 - Seal (2 used)
4 - Frame
5 - Screw (2 used)
6 - Link (2 used)
7 - Flange Nut (as required)
8 - Nut (2 used)
9 - Cap Screw (2 used)
10 - Cap Screw (2 used)
11 - Arm (2 used)
1344
Remove Chaffer, Sieve and Frames
12 - Cap Screw
13 - Cap Screw
14 - Seal
15 - Strip
16 - Flange Housing (4 used)
17 - Screw (as required)
18 - Ball Bearing (2 used)
19 - Screw (as required)
21 - Flange Nut (2 used)
22 - Screw (as required)
23 - Sheet (optional)
24 - Bracket
25 - Lock Nut (as required)
26 - Seal (2 used)
27 - Cam (1 right; 1 left)
28 - Snap Ring (2 used)
29 - Shaft
30 - Shaft Key
31 - Shaft Key
Go to Section_120:Group_25
OUO6435,0001916-19-20020923
1345
Install Chaffer, Sieve and Frames
Install Chaffer, Sieve and Frames
1.
CAUTION:
The approximate weight of precleaner/chaffer frame is 45 kg (100 lb).
Item
Measurement Specification
Precleaner/Chaffer Frame Weight
45 kg
(100 lb)
H57630-UN: Precleaner/Chaffer Frame
H41242-UN: Precleaner/Chaffer Frame
LEGEND:
A - Cap Screws and Nuts
B - Cap Screws and Nuts
C - Precleaner/Chaffer Frame
Install precleaner/chaffer frame (C) using cap screws and nuts (A and B) on both sides. DO NOT
TIGHTEN.
1346
Install Chaffer, Sieve and Frames
2.
ZX25364-UN: Precleaner Elements
LEGEND:
A - Cap Screws
B - Precleaner Elements
C - Adjusting Motors (serial no. 074502—)
Install precleaner elements (B). Lift rear of elements and connect harness connector of adjusting motor
(C), lower elements and install cap screws (A).
3.
CAUTION:
The approximate weight of sieve frame is 39 kg (86 lb).
Item
Measurement Specification
Sieve Frame Weight
39 kg
(86 lb)
H68812-UN: Sieve Frame
LEGEND:
A - Cap Screws and Nuts
B - Cap Screws and Nuts
C - Sieve Frame
Install sieve frame (C) using cap screws and nuts (A and B) on both sides. DO NOT TIGHTEN.
4.
CAUTION:
The approximate weight of chaffer frame is 57 kg (125 lb).
1347
Install Chaffer, Sieve and Frames
Item
Measurement Specification
Chaffer Frame Weight
57 kg
(125 lb)
H68811-UN: Frame
LEGEND:
A - Cap Screws and Nuts
B - Chaffer Frame
Install chaffer frame (B) using cap screws and nuts (A) on both sides. DO NOT TIGHTEN.
5.
ZX25365-UN: Sieve Elements
LEGEND:
A - Cap Screws
B - Sieve Elements
C - Adjusting Motors
Install sieve elements (B). Lift rear of elements and connect harness connector of adjusting motor (C),
lower elements and install cap screws (A).
1348
Install Chaffer, Sieve and Frames
6.
ZX25363-UN: Chaffer Elements
LEGEND:
A - Cap Screws
B - Chaffer Elements
C - Adjusting Motors
Install chaffer elements (B). Lift rear of elements and connect harness connector of adjusting motor (C),
lower elements and install cap screws (A).
7.
CAUTION:
The approximate weight of shaker pan is 71 kg (157 lb).
Item
Measurement Specification
Shaker Pan Weight
71 kg
(157 lb)
H68810-UN: Shaker Pan
LEGEND:
A - Screws and Nuts
B - Screws and Nuts
Install shaker pan using screws and nuts (A) on both sides. DO NOT TIGHTEN.
8. Install brace under pan using screws and nuts (B) on both sides.
9.
CAUTION:
1349
Install Chaffer, Sieve and Frames
The approximate weight of cover is 23 kg (50 lb).
Item
Measurement Specification
Cover Weight
23 kg
(50 lb)
H41231-UN: Cover
LEGEND:
A - Cover
B - Screws and Nuts
Install cover (A) using screws and nuts (B) on both sides. DO NOT TIGHTEN.
10.
H57629-UN: Wiring Lead
LEGEND:
A - Screws, Washers and Nuts
B - Connector
C - Lead
Install screws, washers and nuts (A) on both sides. DO NOT TIGHTEN.
11. Connect electrical connector (B) on both sides.
12. Connect wiring lead (C).
1350
Install Chaffer, Sieve and Frames
13.
H70893-UN: Bushings
LEGEND:
A - 140 Nm (105 lb-ft)
B - 350 Nm (258 lb-ft)
Rotate separator by hand until shoe swinger arms are in mid-stroke.
14. Torque swinger arms to specifications.
Item Measurement Specification
Swing Arms
A
Torque
140 Nm
(105 lb-ft)
B
Torque
350 Nm
(258 lb-ft)
Go to Section_120:Group_25
ZX09263,00027C2-19-20080303
1351
Remove and Install Shoe Pitman Arms
Remove and Install Shoe Pitman Arms
H68201-UN: Sheave
LEGEND:
A - Sheave
B - Cap Screw (4 used)
1. Loosen belt idler and remove belt from sheave.
2. Remove cap screws (B) and sheave (A).
3.
H68205-UN: Pitman Arms
LEGEND:
A - Cap Screw
B - Cap Screws
C - Flange Housing (2 used)
D - Hub
Remove cap screw (A) and hub (D).
4. Remove cap screws (B) and flange housings (C).
1352
Remove and Install Shoe Pitman Arms
5.
H41256-UN: Bearing
LEGEND:
A - Shaft
B - Locking Collar
C - Bearing
Remove locking collar (B) and flanged housing with bearing (C) from shaft (A).
NOTE:
Parts removal is similar on other side of unit.
6.
H41257-UN: Housing
LEGEND:
A - Snap Ring
Remove snap ring (A).
7.
H41258-UN: Eccentric
LEGEND:
A - Eccentric disk
Remove eccentric (A). Eccentric is a press fit.
1353
Remove and Install Shoe Pitman Arms
8.
H41259-UN: Flanged Housing
LEGEND:
A - Nuts and Screws
B - Housing Halves
C - Bearing
Remove nuts and screws (A) to separate flanged housing halves (B). Remove bearing (C).
9. Install bearing (C) in flanged housing halves (B). Install screws and nuts (A).
10. IMPORTANT:
Correct location of eccentric cams is critical for shoe swing timing. If shoe/precleaner does not run
correctly, check for correct location of eccentric cams.
H41260-UN: Eccentric
LEGEND:
A - Eccentric
Install eccentric (A) in flanged housing bearing. Eccentric is a press fit.
11.
H41257-UN: Housing
LEGEND:
A - Snap Ring
Install snap ring (A).
1354
Remove and Install Shoe Pitman Arms
12.
H50288-UN: Flanged Housing
LEGEND:
A - Shaft
B - Bearing
C - Flanged Housing
Install shaft (A) and flanged housing (C) with bearing (B).
13. Adjust shaft to obtain the specified dimension from bearing race to end of shaft. Install locking collar.
Tighten locking collar.
Item
Measurement Specification
Shoe Pitman Arm Bearing Race Distance
135 mm
(5.3 in.)
14.
H68205-UN: Pitman Arms
LEGEND:
A - Cap Screw
B - Cap Screw (4 used)
C - Flange Housing (2 used)
D - Hub
Install flanged housings (C) using cap screws (B). Tighten cap screws to specification.
Item
Measurement Specification
Shoe Pitman Arm Flange Housing, Cap Screws Torque
15. Install hub (D) using cap screw (A).
1355
320 N˙m
(236 lb-ft)
Remove and Install Shoe Pitman Arms
16.
H68201-UN: Sheave
LEGEND:
A - Sheave
B - Cap Screw (4 used)
Install sheave (A) using cap screws (B).
Go to Section_120:Group_25
OUO6045,0000127-19-20090929
1356
Disassemble Tailings Elevator and Augers
Disassemble Tailings Elevator and Augers
1.
H41282-UN: Sheave
LEGEND:
A - Belt Tension Nut (2 used)
B - Belt
C - Nut
D - Sheave
E - Cap
F - Spring
Loosen nuts (A) to relieve belt tension.
2. Remove belt (B).
3. Remove nut (C), cap (E), spring (F) and sheave (D).
4.
H41283-UN: Flanged Housing
LEGEND:
A - Nut (3 used)
B - Key
C - Hub
D - Clutch (2 used)
1357
Disassemble Tailings Elevator and Augers
E - Locking Collar
F - Flanged Housing with Bearing
Remove clutches (D), hub (C), key (B) and locking collar (E).
5. Remove nuts (A) and flanged housing with bearing (F).
6.
ZX1034861-UN: Chain Tensioner
LEGEND:
A - Chain Tensioner
B - Nut (4 used)
Remove chain tensioner (A), nuts (B) and flanged housing with locking collar and bearing.
7. Disconnect electrical connectors (A).
H53001-UN: Connector
LEGEND:
A - Electrical Connectors
8.
CAUTION:
Disconnect harness connectors (A) before servicing tailings sensor(s).
1358
Disassemble Tailings Elevator and Augers
H55381-UN: Sensors
LEGEND:
A - Harness Connectors
B - Spring
C - Sensors
Disconnect harness connectors (A).
9. Remove spring (B) and sensors (C).
10.
H41287-UN: Auger
LEGEND:
A - Nut and Cap Screw (6 used)
B - Housing
Remove cap screws and nuts (A) and housing (B).
1359
Disassemble Tailings Elevator and Augers
11.
H68078-UN: Auger
LEGEND:
A - Master Link
B - Cap Screw
C - Chain Adjusting Nut
Loosen cap screw (B).
12. Loosen chain adjusting nut (C).
13. Remove master link (A) and chain.
14.
H55792-UN: Remove Tailings Elevator
LEGEND:
A - Cap Screw and Nut (2 used)
B - Cap Screw and Nut
C - Strap
Remove cap screws and nuts (A).
15. Remove cap screw and nut (B) and brush module strap (C).
1360
Disassemble Tailings Elevator and Augers
16.
H41288-UN: Brace
LEGEND:
A - Elevator
B - Nut and Cap Screw (2 used)
C - Brace
Remove nuts and cap screws (B), rest elevator (A) on brace (C).
17.
ZX25171-UN: Elevator
LEGEND:
A - Clamp
B - Cap Screws (4 used)
Remove wiring harness from clamp (A).
18.
CAUTION:
The approximate weight of elevator is 82 kg (180 lb).
Remove cap screws (B) and elevator.
19.
1361
Disassemble Tailings Elevator and Augers
H41292-UN: Chain
LEGEND:
A - Chain
B - Rope To Chain
C - Master Link
Remove master link (C).
20. Attach a rope to chain at (B). This will aid in assembly.
21. Remove chain (A) from elevator.
22.
H41295-UN: Sprocket
LEGEND:
A - Spacer
B - Sprocket
C - Nut and Screw (3 used)
D - Flanged Housing and Bearing
E - Lock Nut
F - Sprocket
G - Shaft
Remove lock nut (E) and sprocket (F).
23. Remove nuts and screws (C) and flanged housing with bearing (D) from both sides.
24. Slide shaft to the right and remove spacer (A) and sprocket (B). Remove shaft (G).
25.
H68079-UN: Guard
1362
Disassemble Tailings Elevator and Augers
ZX25241-UN: Sprocket
LEGEND:
A - Guard
B - Spacer
C - Cap Screw and Nut (2 used)
D - Sprocket
Remove cap screw and nut (C), spacer (B) and guard (A).
26. Remove sprocket (D).
27.
H41302-UN: Actuator
LEGEND:
A - Sensor
B - Actuators
Remove sensor (A) and actuators (B).
28.
H41303-UN: Flanged Housing
LEGEND:
A - Locking Collar
B - Bracket
1363
Disassemble Tailings Elevator and Augers
C - Flanged Housing and Bearing
D - Nut and Screw (3 used)
E - Cover
F - Key
Remove key (F).
29. Remove locking collar (A).
30. Remove nuts and screws (D), bracket (B), flanged housing with bearing (C) and cover (E).
31.
H41304-UN: Auger
LEGEND:
A - Auger
Remove auger (A).
32.
H41305-UN: Auger Tube
LEGEND:
A - Nut and Cap Screw (2 used)
B - Tube
Remove nuts and cap screws (A) securing auger tube (B).
1364
Disassemble Tailings Elevator and Augers
33.
H68267-UN: Auger Housing
LEGEND:
A - Cap Screw and Nut
B - Hose Lubrication Fitting (2 used)
C - Nut and Cap Screw (2 used)
D - Auger Tube Assembly
Disconnect hose lubrication fittings (B) from auger tube (D).
34.
CAUTION:
The approximate weight of auger tube assembly is 27 kg (60 lb).
Remove nuts and cap screws (A) and (C); then remove auger assembly (D).
35.
H55825-UN: Auger Tube
LEGEND:
A - Nut (3 used)
B - Flangettes
Remove nuts (A) and flangettes (B).
Go to Section_120:Group_30
ZX08994,00002BA-19-20050110
1365
Disassemble Tailings Elevator and Augers
Disassemble Tailings Elevator and Augers
1.
H41282-UN: Sheave
LEGEND:
A - Belt Tension Nut (2 used)
B - Belt
C - Nut
D - Sheave
E - Cap
F - Spring
Loosen nuts (A) to relieve belt tension.
2. Remove belt (B).
3. Remove nut (C), cap (E), spring (F) and sheave (D).
4.
H41283-UN: Flanged Housing
LEGEND:
A - Nut (3 used)
B - Key
C - Hub
D - Clutch (2 used)
1366
Disassemble Tailings Elevator and Augers
E - Locking Collar
F - Flanged Housing with Bearing
Remove clutches (D), hub (C), key (B) and locking collar (E).
5. Remove nuts (A) and flanged housing with bearing (F).
6.
ZX1034861-UN: Chain Tensioner
LEGEND:
A - Chain Tensioner
B - Nut (4 used)
Remove chain tensioner (A), nuts (B) and flanged housing with locking collar and bearing.
7. Disconnect electrical connectors (A).
H53001-UN: Connector
LEGEND:
A - Electrical Connectors
8.
CAUTION:
Disconnect harness connectors (A) before servicing tailings sensor(s).
1367
Disassemble Tailings Elevator and Augers
H55381-UN: Sensors
LEGEND:
A - Harness Connectors
B - Spring
C - Sensors
Disconnect harness connectors (A).
9. Remove spring (B) and sensors (C).
10.
H41287-UN: Auger
LEGEND:
A - Nut and Cap Screw (6 used)
B - Housing
Remove cap screws and nuts (A) and housing (B).
1368
Disassemble Tailings Elevator and Augers
11.
H68078-UN: Auger
LEGEND:
A - Master Link
B - Cap Screw
C - Chain Adjusting Nut
Loosen cap screw (B).
12. Loosen chain adjusting nut (C).
13. Remove master link (A) and chain.
14.
H55792-UN: Remove Tailings Elevator
LEGEND:
A - Cap Screw and Nut (2 used)
B - Cap Screw and Nut
C - Strap
Remove cap screws and nuts (A).
15. Remove cap screw and nut (B) and brush module strap (C).
1369
Disassemble Tailings Elevator and Augers
16.
H41288-UN: Brace
LEGEND:
A - Elevator
B - Nut and Cap Screw (2 used)
C - Brace
Remove nuts and cap screws (B), rest elevator (A) on brace (C).
17.
ZX25171-UN: Elevator
LEGEND:
A - Clamp
B - Cap Screws (4 used)
Remove wiring harness from clamp (A).
18.
CAUTION:
The approximate weight of elevator is 82 kg (180 lb).
Remove cap screws (B) and elevator.
19.
1370
Disassemble Tailings Elevator and Augers
H41292-UN: Chain
LEGEND:
A - Chain
B - Rope To Chain
C - Master Link
Remove master link (C).
20. Attach a rope to chain at (B). This will aid in assembly.
21. Remove chain (A) from elevator.
22.
H41295-UN: Sprocket
LEGEND:
A - Spacer
B - Sprocket
C - Nut and Screw (3 used)
D - Flanged Housing and Bearing
E - Lock Nut
F - Sprocket
G - Shaft
Remove lock nut (E) and sprocket (F).
23. Remove nuts and screws (C) and flanged housing with bearing (D) from both sides.
24. Slide shaft to the right and remove spacer (A) and sprocket (B). Remove shaft (G).
25.
H68079-UN: Guard
1371
Disassemble Tailings Elevator and Augers
ZX25241-UN: Sprocket
LEGEND:
A - Guard
B - Spacer
C - Cap Screw and Nut (2 used)
D - Sprocket
Remove cap screw and nut (C), spacer (B) and guard (A).
26. Remove sprocket (D).
27.
H41302-UN: Actuator
LEGEND:
A - Sensor
B - Actuators
Remove sensor (A) and actuators (B).
28.
H41303-UN: Flanged Housing
LEGEND:
A - Locking Collar
B - Bracket
1372
Disassemble Tailings Elevator and Augers
C - Flanged Housing and Bearing
D - Nut and Screw (3 used)
E - Cover
F - Key
Remove key (F).
29. Remove locking collar (A).
30. Remove nuts and screws (D), bracket (B), flanged housing with bearing (C) and cover (E).
31.
H41304-UN: Auger
LEGEND:
A - Auger
Remove auger (A).
32.
H41305-UN: Auger Tube
LEGEND:
A - Nut and Cap Screw (2 used)
B - Tube
Remove nuts and cap screws (A) securing auger tube (B).
1373
Disassemble Tailings Elevator and Augers
33.
H68267-UN: Auger Housing
LEGEND:
A - Cap Screw and Nut
B - Hose Lubrication Fitting (2 used)
C - Nut and Cap Screw (2 used)
D - Auger Tube Assembly
Disconnect hose lubrication fittings (B) from auger tube (D).
34.
CAUTION:
The approximate weight of auger tube assembly is 27 kg (60 lb).
Remove nuts and cap screws (A) and (C); then remove auger assembly (D).
35.
H55825-UN: Auger Tube
LEGEND:
A - Nut (3 used)
B - Flangettes
Remove nuts (A) and flangettes (B).
Go to Section_120:Group_30
ZX08994,00002BA-19-20050110
1374
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Spanner Wrench.......JDG685
Tighten primary countershaft gear case yoke nut.
RW78173-UN: Spanner Wrench
Go to Section_120:Group_35
ZX09263,0002748-19-20080201
1375
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Spanner Wrench.......JDG685
Tighten primary countershaft gear case yoke nut.
RW78173-UN: Spanner Wrench
Go to Section_120:Group_35
ZX09263,0002748-19-20080201
1376
Specifications
Specifications
Item
Measurement
Specification
Primary Countershaft Gear Case
Approximate
Weight
52 kg
(115 lb)
Drive Shaft U-joint Screws
Torque
40 N˙m
(29 lb-ft)
Primary Countershaft Gear Case Cap
Screws
Torque
100 N˙m
(74 lb-ft)
Header Electromagnetic Clutch Lock
Nut
Torque
328 N˙m
(242 lb-ft)
Input Housing to Gear Case, Cap
Screws
Torque
73 N˙m
(54 lb-ft)
Primary Countershaft Gear Case Shaft
Axial Play
0.22—0.32 mm + 1/4 turn
(0.008—0.012 in. + 1/4 turn)
Primary Countershaft Gear Case Input
Gear
Backlash
+ 0.1 mm — -0.0 mm to number stamped on gear
heel
(+0.004 in. — -0.000 in. to number stamped on
gear heel)
Output Housing to Gear Case Cap
Screws
Torque
73 N˙m
(54 lb-ft)
Go to Section_120:Group_35
OUO6435,0001909-19-20020905
1377
Remove and Install Primary Countershaft Gear Case
Remove and Install Primary Countershaft Gear Case
1. Remove header electromagnetic clutch (see Remove Header Electromagnetic Clutch in Group 40).
2.
H53084-UN: Mounting Hardware
LEGEND:
A - Cap Screw (2 used)
B - Washer (4 used)
C - Spacer (2 used)
D - Bushing (4 used)
E - Cup (4 used)
F - Primary Countershaft
Remove cap screws (A), washers (B) and spacers (C).
3. Remove bushings (D) and cups (E) from both sides of gear case.
4. Remove intermediate cylinder drive upper sheave (see Disassemble and Assemble Intermediate
Cylinder Drive Upper Sheave in Group 10).
5. Remove primary countershaft (F) from right side of combine.
6.
ZX25196-UN: Primary Countershaft
LEGEND:
A - Cap Screw and Nut (4 used)
B - Bracket
1378
Remove and Install Primary Countershaft Gear Case
C - Shield
Remove cap screws and nuts (A), bracket (B) and shield (C).
7.
H68107-UN: Drive Shaft
LEGEND:
A - Cap Screw (4 used)
B - Strap (2 used)
C - Cap Screw (12 used)
D - Cover
Disconnect drive shaft by removing cap screws (A) and straps (B).
8. Wrap end of drive shaft with tape to protect bearings.
9. Remove cap screws (C) and cover (D).
10.
CAUTION:
The approximate weight of gear case is 52 kg (115 lb).
1379
Remove and Install Primary Countershaft Gear Case
H68094-UN: Gear Case
LEGEND:
A - Gear Case
B - Wrap
Remove gear case (A).
11. Repair or replace gear case as necessary. (See procedure in this Group.)
12. Set gear case (A) in place.
13. Remove wrap (B) from end of drive shaft.
1380
Remove and Install Primary Countershaft Gear Case
14.
H68107-UN: Cover
LEGEND:
A - Cap Screw (4 used)
B - Strap (2 used)
C - Cap Screw (12 used)
D - Cover
Install cover (D) and cap screws (C).
15. Connect drive shaft using straps (B) and cap screws (A). Tighten cap screws (A) to specification.
Item
Measurement Specification
Drive Shaft U-joint Screws Torque
40 N˙m
(29 lb-ft)
16. Apply NEVER-SEEZ to inner splines in the gear case and outer splines on primary countershaft.
17. Install primary countershaft (see Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave
in group 10).
18.
ZX25196-UN: Primary Countershaft
LEGEND:
A - Cap Screw and Nut (4 used)
B - Bracket
C - Shield
Inspect seal between drive shaft shields (C). Replace seal if necessary.
19. Install drive shaft shield (C) using cap screws and nuts (A) and bracket (B).
1381
Remove and Install Primary Countershaft Gear Case
20.
NOTE:
Header clutch removed for clarity.
H56094-UN: Electromagnetic Clutch Removed for Clarity
LEGEND:
A - Cap Screw (2 used)
B - Washer (4 used)
C - Spacer (2 used)
D - Bushing (4 used)
E - Cup (4 used)
F - Lubrication Fitting
Install parts (A) - (E) hand tight.
21. Install header electromagnetic clutch (see Install Header Electromagnetic Clutch in Group 40).
IMPORTANT:
A new lock nut must be used to install electromagnetic clutch.
NOTE:
Tighten electromagnetic clutch lock nut until clutch is snug on countershaft to allow
grease to lubricate countershaft splines.
22. Tighten cap screws (previously hand tightened in step 20) to specification.
Item
Measurement Specification
Primary Countershaft Gear Case Cap Screws Torque
100 N˙m
(74 lb-ft)
23. Fill splined shaft cavity with TY6341 Multipurpose SD Polyurea Grease through fitting (F) before
tightening clutch lock nut.
24. Tighten electromagnetic clutch lock nut to specification.
1382
Remove and Install Primary Countershaft Gear Case
Item
Measurement Specification
Header Electromagnetic Clutch Lock Nut Torque
328 N˙m
(242 lb-ft)
Go to Section_120:Group_35
OUO6089,0000058-19-20010702
1383
Disassemble and Assemble Primary Countershaft Gear Case
Disassemble and Assemble Primary Countershaft Gear Case
H53025-UN: Gear Case
LEGEND:
1 - Seal
2 - O-Ring
3 - Dipstick
4 - Screws (4 used)
5 - Cover
6 - Gear Case
7 - Shims (as required)
8 - Bearing Cup
1384
Disassemble and Assemble Primary Countershaft Gear Case
9 - Bearing Cone
10 - Fitting
11 - Bearing Cone
12 - Bearing Cup
13 - Ring
14 - Shims (as required)
15 - Housing
16 - Seal
17 - Screw (6 used)
18 - Gear
19 - Threaded Nipple
20 - Screw (5 used)
21 - Screw
22 - Housing
23 - Bearing Cup
24 - Bearing Cone
25 - Seal
26 - Nut
27 - Lock Washer
28 - Lock Washer
29 - Yoke
30 - Ring 177.1 x 5.3 mm
31 - Lubrication Fitting
32 - Retainer
33 - Bearing Cup
34 - Bearing Cone
35 - Gear Case
1. Drain gear case.
Item
Measurement Specification
Primary Countershaft Gear Case Capacity
2.
1.2 L
(2.5 pt)
CAUTION:
The approximate weight of gear case is 52 kg (115 lb).
NOTE:
Gears are a matched set and must be replaced as a set.
1385
Disassemble and Assemble Primary Countershaft Gear Case
H54833-UN: Gear Case
LEGEND:
A - Housing
B - Lock Washer
C - Yoke
D - Cap Screw (5 used)
E - Cap Screw
F - O-Ring and Shim Pack
Bend tab of lock washer (B) out of nut. Use spanner wrench JDG685 to remove nut. Pull off yoke (C).
3. Remove cap screws (D), cap screw (E) and housing (A).
4. Remove O-ring and shim pack (F). Do not damage shims, so they can be used in reassembly. Keep
these shims separate from shims that will be removed from output housing. Remove gear from input
housing. Remove bearing cone as gear is being removed.
5.
H40559-UN: Remove Bearing
LEGEND:
A - Bearing Cup
Use a bearing puller to remove bearing cup (A).
1386
Disassemble and Assemble Primary Countershaft Gear Case
6.
H40560-UN: Retainer
LEGEND:
A - Retainer
Remove retainer (A).
7.
H54754-UN: Remove Bearing
LEGEND:
A - Seal
B - Bearing Cup
Remove seal (A) and bearing cup (B).
8.
H40566-UN: Remove Bearing
LEGEND:
A - Bearing Cone
Remove bearing cone (A) from input gear. Bearing is a press fit.
1387
Disassemble and Assemble Primary Countershaft Gear Case
9.
H40569-UN: Gear Case
LEGEND:
A - Housing
B - Cap Screws (6 used)
Remove cap screws (B) and housing (A).
10.
H40570-UN: Housing Plate
LEGEND:
A - Bearing Cup
B - Seal
C - O-Ring and Shim Pack
Remove bearing cup (A) and seal (B).
11. Remove O-ring and shim pack (C). Do not damage shims, so they can be used in reassembly. Keep
shim pack (C) separate from shim pack removed from input housing. Remove the O-ring.
12.
H57076-UN: Output Shaft
LEGEND:
A - Output Shaft
Remove output shaft (A) from gear case.
1388
Disassemble and Assemble Primary Countershaft Gear Case
13.
H40572-UN: Output Gear
LEGEND:
A - Bearing Cone
Remove bearing cone (A) from output gear. Bearing is a press fit. Remove bearing cone from gear end
of output shaft.
14.
H40574-UN: Gear Case
LEGEND:
A - Seal
Remove seal (A) from gear case. Remove bearing cup from left output bore of gear case. Remove
shims from behind bearing cup.
15. Inspect parts and replace as necessary.
Check following shim packs if following parts are replaced:
Left output shims
Output gear
Straw walker gear case
Right output shims
Output gear
Straw walker gear case
Output bearing sets
Output housing
Input housing shims
Output gear
Straw walker gear case
All bearing sets
Output housing
Input retainer and snap ring
Input housing
Yoke
16. Install seal (A) flush with gear case face with spring loaded lip toward bearing.
1389
Disassemble and Assemble Primary Countershaft Gear Case
16. Install seal (A) flush with gear case face with spring loaded lip toward bearing.
17.
H40573-UN: Bearing
LEGEND:
A - Bearing Cone
Install bearing cone (A) on output gear so it seats against shoulder. Bearing is a press fit. Install bearing
cone on output shaft and seat against gear.
18.
H54755-UN: Shaft
LEGEND:
A - Gear Case
B - Shim (as required)
C - Bearing Cup
D - Output Gear
To determine left output shim pack (B):
1. Add dimension etched on back of output gear (D) to dimension stamped on gear case (A).
2. Subtract dimension etched on output gear tube from above total and also subtract 25.45 mm
(1.002 in.).
3. Select a shim pack equal to calculated dimension ± 0.05 mm (0.002 in.).
-: Example
EXAMPLE
1390
Disassemble and Assemble Primary Countershaft Gear Case
EXAMPLE
Dimension on case
98.00 mm (3.856 in.)
Plus dimension on gear
93.50 mm (3.681 in.)
Result
191.50 mm (7.539 in.)
Minus gear tube dimension
164.50 mm (6.476 in.)
Result
27.00 mm (1.063 in.)
Minus bearing width (always the same) 25.45 mm (1.002 in.)
Required shim pack
1.55 mm (0.061 in.)
Note: Convert mm (metric) to inches by dividing by 25.4
NOTE:
If dimension is not stamped on case, use 98.00 mm (3.856 in.) to determine
shim pack. If dimension is not stamped on gear, use 93.50 mm (3.681 in.) to
determine shim pack. If dimension is not stamped on gear tube, use 164.50
mm (6.476 in.) to determine shim pack.
19. Install parts in gear case in following order: shim pack (B), bearing cup (C) and output gear (D).
20.
H40570-UN: Housing Plate
LEGEND:
A - Bearing Cup
B - Seal
C - Shim Pack
Install bearing cup (A) and seal (B).
21. Install shim pack (C) and O-ring.
NOTE:
If shim pack was damaged during disassembly, measure shim pack thickness and
replace with new shims. Do not use more than one plastic shim.
To determine right side output shim pack (C), install right output housing and use a shim
pack thickness that will preload bearings 0.03—0.13 mm (0.001—0.005 in.)
1391
Disassemble and Assemble Primary Countershaft Gear Case
22.
H40569-UN: Gear Case
LEGEND:
A - Housing
B - Cap Screws (6 used)
Install housing (A). Install cap screws (B) and tighten to specification.
Item
Measurement Specification
Input Housing to Gear Case, Cap Screws Torque
73 N˙m
(54 lb-ft)
23.
H40567-UN: Input Gear
LEGEND:
A - Bearing Cone
Install bearing cone (A) on input gear. Bearing must rest on shoulder of shaft. Bearing is a press fit.
Record backlash stamped on heel of input gear (mm, in.) to be used when determining input housing
shims.
24.
H41190-UN: Retainer
1392
Disassemble and Assemble Primary Countershaft Gear Case
LEGEND:
A - Bearing Cup
B - Retainer
C - Housing
Install retainer (B) and bearing cup (A) in housing (C). Install snap ring.
25.
H41188-UN: Housing
LEGEND:
A - Housing
B - Bearing Cup
C - Bearing Cone
D - Seal
Install bearing cup (B) and slide gear in housing. Install bearing cone (C) and seal (D) in housing (A).
Install seal with spring-loaded lip toward bearing. Press flush in housing (A).
26.
H54833-UN: Gear Case
LEGEND:
A - Housing
B - Nut and Lock Washer
C - Yoke
D - Cap Screw (5 used)
E - Cap Screw
F - Shim (as required)
Install yoke (C). Install washer (end washer with concave side outward). Apply thread lock and sealer
T43512 (medium strength) to gear shaft threads. Tighten nut with JDG685 wrench to get specified axial
1393
Disassemble and Assemble Primary Countershaft Gear Case
play and tighten an additional 90° (1/4 turn). Bend one tab of washer to lock in place.
Item
Measurement Specification
Primary Countershaft Gear Case Input Shaft Axial Play
27.
0.22—0.32 mm + 1/4 turn
(0.008—0.0120 in. + 1/4 turn)
NOTE:
If shim pack was damaged during disassembly, measure shim pack thickness and
replace with new shims. Do not use more than one plastic shim.
Install housing (A), O-ring and shim pack (F) on gear case. Determine input housing shim pack (F) by
using backlash stamped on heel of input gear. Select shims to provide specified backlash.
Item
Measurement Specification
Primary Countershaft Gear Case Input Backlash
Gear
+ 0.1 mm — -0.0 mm to number stamped on
gear heel
Install and tighten cap screws (D) and (E) to specification.
Item
Measurement Specification
Output Housing to Gear Case Cap Screws Torque
73 N˙m
(54 lb-ft)
28. Fill gear case with TY6252 80W90 GL5 Gear Lube. See Fuel, Lubricants, Coolant and Capacities in
Section 10, Group 25.
Go to Section_120:Group_35
OUO6435,000190A-19-20020905
1394
Remove and Install Primary Countershaft with Variable Sheave Assembly
Remove and Install Primary Countershaft with Variable Sheave Assembly
H71763-UN: Belt Tensioners
LEGEND:
A - Cap Screw
B - Nut (2 used)
C - Nut (2 used)
D - Cap Screw (2 used)
This procedure is for gaining access to the beater curtain or top of the beater and NOT for repairing the sheave. If
repair to the sheave is necessary, see Disassemble and Assemble Intermediate Cylinder Drive Upper Sheave in
Group 10 of this section.
1. Remove gull wing doors.
2. Remove electromagnetic clutch. See Remove Header Electromagnetic Clutch in Group 40 of this
section.
3. Loosen cap screw (A).
4. Loosen nuts (B) to relieve intermediate cylinder drive belt tension.
5. Loosen nuts (C) to relieve secondary countershaft belt tension.
6. Remove cap screws (D). This will allow intermediate drive to move upwards for belt removal.
7.
CAUTION:
Watch for pinch points when rolling belt off sheave.
Carefully roll belt off intermediate sheave.
1395
Remove and Install Primary Countershaft with Variable Sheave Assembly
8.
H71750-UN: Upper Variable Hydraulic Line
LEGEND:
A - Fitting
Disconnect hydraulic oil line at fitting (A); then remove belts from sheave.
9.
H71731-UN: Bearing Carrier Bearings
LEGEND:
A - Nut (4 used)
Remove four nuts (A) and cap screws from bearing carrier.
10.
CAUTION:
Approximate weight of shaft assembly is 245 kg (540 lb).
NOTE:
It may be necessary to strike opposite end of shaft using a block of wood and hammer
to unseat carrier.
1396
Remove and Install Primary Countershaft with Variable Sheave Assembly
H71730-UN: Removal of Primary Countershaft
LEGEND:
A - Belt
Position fork lift under both sheaves; then slide shaft assembly onto forks far enough to place a 100 x
150 mm (4 x 6 in.) block of wood under shaft. Slowly remove shaft from machine with fork lift.
11. Install in reverse order using the following special instructions:
NOTE:
Position secondary countershaft belt (A) on shaft as shown, prior to installation.
Slowly install shaft halfway into machine using a fork lift.
IMPORTANT:
Do NOT force end of shaft into gear case or damage to threads and gear case can occur.
Get an additional person to help guide shaft into primary gear case. Once shaft is started
through gear case, it may be necessary to rotate shaft to align the second set of splines.
H71749-UN: Bearing Carrier
LEGEND:
A - Nut (4 used)
B - Lubrication Fitting
Position bearing carrier in bracket with lubrication fitting (B) facing downward.
1397
Remove and Install Primary Countershaft with Variable Sheave Assembly
NOTE:
Use a pen magnet to help install cap screws through rear of bracket and
bearing carrier.
Install cap screws and nuts (A); then tighten.
Go to Section_120:Group_35
ZX08994,00001B0-19-20030226
1398
Remove and Install Beater Curtain
Remove and Install Beater Curtain
1.
H71728-UN: Bearing Support Sheet
H71732-UN: Nuts Retaining Top of Beater Seals
LEGEND:
A - Bearing Support Sheet
B - Nut (2 used)
Start engine and set cylinder speed to lowest speed.
2.
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable,
remove key from switch and install a DO NOT OPERATE tag in operator's cab.
Shut off engine and remove key.
3. Remove electromagnetic clutch. See Remove Header Electromagnetic Clutch in Group 40 of this
section.
4. Remove primary countershaft assembly. See Remove and Install Primary Countershaft with Variable
Sheave Assembly in this group.
1399
Remove and Install Beater Curtain
5. IMPORTANT:
To avoid dropping parts into separator, do NOT completely remove nuts (B) until support sheet is tilted
forward to access round head bolts.
Loosen, DO NOT remove, nuts (B).
6. Note location of wiring harness clamps; then remove nuts and cap screws from bearing support sheet
(A).
7. Tilt sheet (in direction of arrow) and move tube towards the front to access round head bolts; then
remove nuts (B).
8.
H71729-UN: Input Shaft Tube
LEGEND:
A - Tube
B - Seal (2 used)
C - Round Head Bolt
D - Curtain
Remove shaft protection tube (A).
9. Remove nuts, seal, round head bolts (C) and curtain (D).
10. Install in reverse order using the following special instructions:
Inspect seals (B) on tube (A) and replace as necessary.
Install end of tube to primary gear case.
1400
Remove and Install Beater Curtain
H71728-UN: Bearing Support Sheet
H71744-UN: Nuts Retaining Top of Beater Seals
LEGEND:
A - Bearing Support Sheet
B - Nut (2 used)
Install bearing support sheet, bottom end first; then tilt sheet in at the top far enough to install
round head bolts. Loosely install nuts (B).
Align tube with hole in sheet and loosely install all cap screws and nuts before tightening.
Go to Section_120:Group_35
ZX08994,00001B1-19-20030226
1401
Specifications
Specifications
Item
Measurement
Specification
Electromagnetic Clutch Assembly
Approximate Weight 28 kg
(63 lb)
Electromagnetic Clutch Sheave Cap Screws Torque
123 Nm
(91 lb-ft)
Electromagnetic Clutch Lock Nut
328 Nm
(242 lb-ft)
Torque
Electromagnetic Clutch Flange Cap Screws Torque
100 Nm
(74 lb-ft)
Brush Module to Drive Shaft
Torque
33 Nm
(24 lb-ft)
Electromagnetic Clutch Gap
Gap
1.5 to 2.2 mm
(0.059 to 0.087 in.)
Go to Section_120:Group_40
AG,OUO6435,1017-19-20080303
1402
Specifications
Specifications
Item
Measurement
Specification
Electromagnetic Clutch Assembly
Approximate Weight 28 kg
(63 lb)
Electromagnetic Clutch Sheave Cap Screws Torque
123 Nm
(91 lb-ft)
Electromagnetic Clutch Lock Nut
328 Nm
(242 lb-ft)
Torque
Electromagnetic Clutch Flange Cap Screws Torque
100 Nm
(74 lb-ft)
Brush Module to Drive Shaft
Torque
33 Nm
(24 lb-ft)
Electromagnetic Clutch Gap
Gap
1.5 to 2.2 mm
(0.059 to 0.087 in.)
Go to Section_120:Group_40
AG,OUO6435,1017-19-20080303
1403
Remove Header Electromagnetic Clutch
Remove Header Electromagnetic Clutch
1.
H56016-UN: Electric Clutch
ZX25097-UN: Earlier Models
1404
Remove Header Electromagnetic Clutch
ZX25368-UN: Later Models
LEGEND:
A - Cap Screw
B - Harness Connector
C - Cotter Pin
D - Tensioner Nut
E - Belt
Remove electric clutch module strap cap screw (A) and disconnect connector (B).
2. Earlier models: Loosen nuts (D) on header drive tensioner.
3. Later models: Remove cotter pin (C) and loosen nuts (D) on header drive tensioner.
4. Remove drive belt (E) from electric clutch and place on top of feeder house.
5. Remove brush module by turning counterclockwise.
1405
Remove Header Electromagnetic Clutch
6.
H51775-UN: Header Electromagnetic Clutch
LEGEND:
A - Nut
B - Washer
C - Primary Countershaft
D - Electromagnetic Clutch and Sheave Assembly
Remove nut (A) and washer (B) from shaft (C).
7.
CAUTION:
Approximate weight of electromagnetic clutch assembly is 28 kg (63 lb).
Remove clutch assembly (D).
8. Remove woodruff key from shaft (C).
9. Remove cap screws (A) and separate sheave from clutch.
H51777-UN: Header Electromagnetic Clutch Sheave
LEGEND:
A - Cap Screw (4 used)
Go to Section_120:Group_40
OUO6435,000194A-19-20021018
1406
Disassemble and Assemble Header Electromagnetic Clutch
Disassemble and Assemble Header Electromagnetic Clutch
H57088-UN: Header Clutch
LEGEND:
1 - Screw
2 - Strap
3 - Flange Nut
4 - Carbon Brush Holder
5 - Plug
6 - Wiring Harness
7 - Lock Nut
8 - Washer
9 - Shaft Key
10 - Screws (4 used)
11 - Clip
12 - Clutch
13 - Field Winding Coil
14 - Nut
15 - Washer
16 - Hub
17 - Belt
18 - Screw
19 - Armature
20 - Sheave
21 - Snap Ring
1407
Disassemble and Assemble Header Electromagnetic Clutch
1.
H53091-UN: Electromagnetic Clutch
H53090-UN: Armature and Hub
LEGEND:
A - Cap Screws (4 used)
B - Cover with Coil
C - Snap Ring
D - Armature
E - Hub
Remove cap screws (A) and cover with coil (B).
2. Remove snap ring (C) and separate armature (D) from hub (E).
3. Inspect all parts for wear and damage, replace as necessary.
4. Slide armature (D) on hub (E) and install snap ring (C).
5. Install cover with coil (B) using cap screws (A).
Item
Measurement Specification
Electromagnetic Clutch Flange Cap Screws Torque
100 N˙m
(74 lb-ft)
Go to Section_120:Group_40
OUO6435,0001462-19-20010809
1408
Install Header Electromagnetic Clutch
Install Header Electromagnetic Clutch
1.
H51777-UN: Clutch Sheave Cap Screws
LEGEND:
A - Cap Screw (4 used)
Install sheave to clutch using cap screws (A). Tighten to specification.
Item
Measurement Specification
Electromagnetic Clutch Sheave Cap Screws Torque
2.
123 Nm
(91 lb-ft)
CAUTION:
Approximate weight of electromagnetic clutch assembly is 28 kg (63 lb).
Install woodruff key on shaft (C). Install electromagnetic clutch assembly (D) on shaft.
H51775-UN: Header Electromagnetic Clutch Assembly
LEGEND:
A - Nut
B - Washer
C - Primary Countershaft
D - Electromagnetic Clutch and Sheave Assembly
3. IMPORTANT:
A new lock nut (A) is required to install clutch and sheave assembly.
Install washer (B) and new nut (A) on primary countershaft (C).
1409
Install Header Electromagnetic Clutch
Item
Measurement Specification
Electromagnetic Clutch Lock Nut Torque
328 Nm
(242 lb-ft)
4.
H56016-UN: Electric Clutch
ZX25368-UN: Later Models
LEGEND:
A - Cap Screw
B - Harness Connector
C - Cotter Pin
D - Tensioner Nut
E - Belt
Install drive belt (E).
1410
Install Header Electromagnetic Clutch
5. Install brush module on countershaft by turning clockwise.
6. Install screws between wire leads and into clutch assembly.
7. Install safety strap cap screw (A).
8. Connect harness connector (B).
9. Tighten nuts (D) and install cotter pin (C) (if equipped) on header drive tensioner.
Go to Section_120:Group_40
ZX09263,00027C3-19-20080303
1411
Table of Contents
Section 121: Separator - C Series
Group 05: Beaters
Specifications
Remove Concave
Install Concave
Idler of Gear Case for Serrated Beater Drive
Removal of Gear Case for Serrated Beater Drive
Gear Case for Serrated Beater Drive
Disassemble Gear Case for Serrated Beater Drive
Install Gear Case for Serrated Beater Drive
Serrated Beater and Shaft
Remove Left Serrated Beater Shaft Bearing
Remove Right Serrated Beater Shaft Bearing
Remove Serrated Beater Shaft
Install Serrated Beater Shaft
Remove Beater Drive Sheave
Install Beater Drive Sheave
Remove/Install Serrated Beater Wings
Beater
Remove Beater Drive Sheave
Remove and Install Beater Shaft
Remove and Install Beater
Serrated Beater Cover
Remove Serrated Beater Cover
Remove Beater Cover
Install Beater Cover
Install Serrated Beater Cover
Remove Module Feed Assembly
Install Module Feed Assembly
Remove Serrated Beater Lower Covers
Install Serrated Beater Lower Covers
Remove and Install Beater Curtain
Group 10: Engine Gear Case to Module Drives
1412
Table of Contents
Engine Gear Case to Module Drives - Exploded View
Group 15: Tine Separator Module
Essential and Recommended Special Tools
Specifications
Roll Out Tine Separator
Remove Tine Separator Module
Tine Separator Front Bearings and Lube Lines
Tine Separator Tubes
Remove Tine Separators
Install Tine Separators
Repair Tine Separators
Replace Tine Separator Drive Coupler
Replace Tine Separator Flow Dividers
Replace Tines
Replace Discharge Paddles
Module Frame and Covers
Discharge Beater
Discharge Beater Drive
Remove Front Feed Section Assembly
Install Front Feed Section Assembly
Module Grate Assembly
Remove Separator Grates
Install Separator Grates
Replace Grate Fingerbar
Tine Separator Module Crank-Out System
Remove Tine Separator Module Crank-Out System
Install Tine Separator Module Crank-Out System
Group 20: Tine Separator Gear Cases
Specifications
Module Drive Gearcase, Shaft and Coupling
Module Drive Gear Case
Remove Module Drive Gear Case
Disassemble Module Drive Gear Case
1413
Table of Contents
Assemble Module Drive Gear Case
Install Module Drive Gear Case
Group 25: Supply Augers (Shoe), Chaffer and Sieve Frame
Shaker Pan Exploded View
Group 30: Straw Chopper
Remove and Install Straw Chopper
Chopper and Blades
Remove and Install Rotor Bearings
Chopper Housing and Knife Bank
Replace Knife Sections
Remove and Install Straw Chopper Idler Assembly
1414
Specifications
Specifications
Item
Measurement Specification
Deflector Cap Screws
Torque
67 N˙m
(51 lb-ft)
Rasp Bar Cap Screws and Nuts
Torque
130 N˙m
(96 lb-ft)
Spike Tooth Retaining Nuts
Torque
60 N˙m
(45 lb-ft)
Dual-Range Cylinder Drive
Length
135 mm (5-5/16 in.)
Single-Range Cylinder Drive
Length
134.4 mm (5-19/64 in.)
Threshing Cylinder Head Hardware
Torque
123 N˙m
(91 lb-ft)
Concave Nose Screws and Nuts
Torque
130 N˙m
(96 lb-ft)
Concave Retaining Screws
Torque
285 N˙m
(200 lb-ft)
Spike Tooth Concave Retaining Nut
Torque
285 N˙m
(200 lb-ft)
Cylinder and Concave Tooth Adjusting Nuts
Torque
285 N˙m
(200 lb-ft)
Module Side Rail Screws
Torque
191 N˙m
(141 lb-ft)
Module Drive Shaft U-Joint Cap Screws
Torque
100 ± 20 N˙m
(74 ± 7 lb-ft)
Module-to-Separator Screws
Torque
77 N˙m
(57 lb-ft)
Gear Case Housing Cap Screws
Torque
50 N˙m
(37 lb-ft)
Beater Gear Case
Capacity
0.5 l
(1.0 pt)
Gear Case Retaining Screw and Washer
Torque
100 N˙m
(74 lb-ft)
Serrated Beater Shaft
Runout
0.05 mm
(0.002 in.)
End Of Beater Shaft-to-Side Sheet
Distance
148 mm
(5-13/16 in.)
Beater Drive Sheave-to-Electromagnetic Clutch, Cap Screws Torque
123 ± 30 N˙m
(90 ± 22 lb-ft)
Beater Shaft
Runout
0.02 mm
(0.008 in.)
End of Beater Shaft to Inner Bearing Race
Distance
55.2 mm
(2-11/16 in.)
Beater Hub Shaft Clamping Screws
Torque
87 N˙m
(64 lb-ft)
Beater Wing Retaining Screws
Torque
45 N˙m
(35 lb-ft)
Go to Section_121:Group_05
ZX08798,00008CF-19-20090923
1415
Specifications
Specifications
Item
Measurement Specification
Deflector Cap Screws
Torque
67 N˙m
(51 lb-ft)
Rasp Bar Cap Screws and Nuts
Torque
130 N˙m
(96 lb-ft)
Spike Tooth Retaining Nuts
Torque
60 N˙m
(45 lb-ft)
Dual-Range Cylinder Drive
Length
135 mm (5-5/16 in.)
Single-Range Cylinder Drive
Length
134.4 mm (5-19/64 in.)
Threshing Cylinder Head Hardware
Torque
123 N˙m
(91 lb-ft)
Concave Nose Screws and Nuts
Torque
130 N˙m
(96 lb-ft)
Concave Retaining Screws
Torque
285 N˙m
(200 lb-ft)
Spike Tooth Concave Retaining Nut
Torque
285 N˙m
(200 lb-ft)
Cylinder and Concave Tooth Adjusting Nuts
Torque
285 N˙m
(200 lb-ft)
Module Side Rail Screws
Torque
191 N˙m
(141 lb-ft)
Module Drive Shaft U-Joint Cap Screws
Torque
100 ± 20 N˙m
(74 ± 7 lb-ft)
Module-to-Separator Screws
Torque
77 N˙m
(57 lb-ft)
Gear Case Housing Cap Screws
Torque
50 N˙m
(37 lb-ft)
Beater Gear Case
Capacity
0.5 l
(1.0 pt)
Gear Case Retaining Screw and Washer
Torque
100 N˙m
(74 lb-ft)
Serrated Beater Shaft
Runout
0.05 mm
(0.002 in.)
End Of Beater Shaft-to-Side Sheet
Distance
148 mm
(5-13/16 in.)
Beater Drive Sheave-to-Electromagnetic Clutch, Cap Screws Torque
123 ± 30 N˙m
(90 ± 22 lb-ft)
Beater Shaft
Runout
0.02 mm
(0.008 in.)
End of Beater Shaft to Inner Bearing Race
Distance
55.2 mm
(2-11/16 in.)
Beater Hub Shaft Clamping Screws
Torque
87 N˙m
(64 lb-ft)
Beater Wing Retaining Screws
Torque
45 N˙m
(35 lb-ft)
Go to Section_121:Group_05
ZX08798,00008CF-19-20090923
1416
Remove Concave
Remove Concave
NOTE:
Cylinder does not have to be removed to remove concave.
1.
H50571-UN: Concave Actuator
LEGEND:
A - Pin
B - Rod
C - Cam
D - Concave Adjusting Motor
E - Connector
F - Pin
Disconnect rod (B) and connector (E).
2. Rotate cam (C) slightly counterclockwise and remove pin (A).
3. Remove pin (F) to remove concave adjusting motor (D).
4. Place a block under concave to keep it from dropping.
5.
H50272-UN: Concave Cam
LEGEND:
A - Threaded Stud
B - Lock Nut
1417
Remove Concave
C - Washer
D - Seal
E - Cam
F - Shaft
Remove threaded stud (A), lock nut (B), washer (C), seal (D) and cam (E) from right side.
6. Remove screw, washer, seal, spacer, and cam from left side.
7. Remove shaft (F).
8. Remove block. Lower concave.
9.
CAUTION:
The approximate weight of concave is 113 kg (250 lb).
Attach D05070ST Service Jack with JT05876 Lower Bracket and JT05875 Cylinder and Concave
Remover/Installer Bracket to concave.
10.
H41218-UN: Adjustment Eyebolt
LEGEND:
A - Screw
Remove screw (A) from both sides.
11. Remove concave.
12. Inspect concave for wear and damage. Repair or replace as required.
1418
Remove Concave
H50896-UN: Concave Adjusting Linkage
LEGEND:
1 - Retaining Screw
2 - Bushing (2 used)
3 - Washer (2 used)
4 - Flange Nut (2 used)
5 - Eyebolt (2 used)
6 - Cap Screw (2 used)
7 - Nut (4 used)
8 - Flange Nut (4 used)
9 - Screw (2 used)
10 - Bushing (2 used)
11 - Cover
12 - Link (2 used)
13 - Eyebolt
1419
Remove Concave
H50595-UN: Rasp Bar Concave
LEGEND:
1 - Cam
2 - Retaining Screw
3 - Washer
4 - Bracket
5 - Cover
6 - Retainer
7 - Washer
8 - Seal
9 - Spacer
10 - Cover
11 - Cover (As Required)
12 - U-Bolt (As Required)
13 - Angle
14 - Insert (As Required)
15 - Retaining Nut (As Required)
16 - Wire (As Required)
17 - Concave
18 - Shaft
19 - Retaining Nut (6 used)
20 - Spacer (8 used)
21 - Cam
22 - Screw (6 used)
23 - Screw (6 used)
1420
Remove Concave
24 - Insert
25 - Washer
26 - Adjusting Strap (2 used)
27 - Bushing (2 used)
28 - Retainer (2 used)
29 - Adjusting Strap
H50833-UN: Opening Handle
LEGEND:
A - Plate (24 used)
B - Spacer (3 used)
C - Nut
D - Handle
E - Nut (4 used)
F - Screw
G - Bracket
H - Screw (4 used)
I - Washer
K - Sheet
1421
Remove Concave
L - Rod (3 used)
M - Nut (3 used)
H50596-UN: Spike-Tooth Concave
LEGEND:
1 - Concave
2 - Shaft
3 - Grate
4 - Tooth (As Required)
5 - Angle
6 - Lock Washer (As Required)
7 - Nut (As Required)
8 - Bar Assembly (As Required)
9 - Insert (As Required)
10 - Screw (8 used)
11 - Crop Divider (5 used)
12 - Screw (2 used)
13 - Cap Screw (2 used)
14 - Adjusting Strap (2 used)
1422
Remove Concave
15 - Bushing (2 used)
16 - Retainer (2 used)
17 - Adjusting Strap
H50597-UN: Concave Cam
LEGEND:
1 - Retaining Screw
2 - Washer
3 - Screw (2 used)
4 - Eyebolt (2 used)
5 - Adjusting Strap
6 - Cam
7 - Flange Nut (4 used)
8 - Spacer
9 - Washer (2 used)
10 - Seal (2 used)
1423
Remove Concave
11 - Flange Nut (4 used)
12 - Bushing (4 used)
13 - Link (2 used)
14 - Cover
15 - Screw (2 used)
16 - Cover
17 - Eyebolt
18 - Cam
19 - Retaining Screw
20 - Spacer
Go to Section_121:Group_05
OUO6435,0001468-19-20010820
1424
Install Concave
Install Concave
1.
CAUTION:
The approximate weight of concave is 113 kg (250 lb).
Use D05070ST Service Jack with JT05876 Lower Bracket and JT05875 Cylinder and Concave
Remover/Installer Bracket to install concave.
2.
H41218-UN: Eyebolt, Adjust Concave
LEGEND:
A - Screw
Install screw (A) on both sides to secure concave.
3. Raise and block concave into position.
4.
H41215-UN: Concave Shaft
LEGEND:
A - Shaft
B - Concave
Install shaft (A) through front of concave (B).
1425
Install Concave
5.
H50272-UN: Concave Cam
LEGEND:
A - Threaded Stud
B - Lock Nut
C - Washer
D - Seal
E - Cam
F - Shaft
Install cam (E), seal (D), washer (C), lock nut (B), and threaded stud (A) on right side.
6.
H50571-UN: Actuator for Concave Adjustment
LEGEND:
A - Pin
B - Rod
C - Cam
D - Concave Adjusting Motor
E - Connector
F - Pin
Install concave adjusting motor (D) and pin (F).
7. Rotate cam (C) slightly counterclockwise to install pin (A).
8. Connect rod (B) and connector (E).
9. Level concave.
Go to Section_121:Group_05
HX,120,DM131-19-20030206
1426
Idler of Gear Case for Serrated Beater Drive
Idler of Gear Case for Serrated Beater Drive
H58972-UN: Air Suspension, Exploded View
LEGEND:
1 - Idler
2 - Spring
3 - Washer
4 - Nut
5 - Gauge
6 - Hose
7 - Guide
8 - Rod
1427
Idler of Gear Case for Serrated Beater Drive
9 - Pin
10 - Washer
11 - Bracket
12 - Spacer
13 - Outer Plate
14 - Spacer
15 - Inner Plate
16 - Retaining Screw
17 - Bushing
18 - Arm
19 - Retaining Screw
20 - Retaining Screw
21 - Plate
22 - Retaining Screw
23 - Retaining Screw
24 - J-Clamp
25 - Seal
Go to Section_121:Group_05
AG,OUO6045,135-19-20030206
1428
Removal of Gear Case for Serrated Beater Drive
Removal of Gear Case for Serrated Beater Drive
1.
H68736-UN: Beater Drive Belt
LEGEND:
A - Nut
B - Belt
C - Cap Screw (4 used)
D - Cap Screw and Nut
Loosen nut and lock nut (A) to relieve belt tension.
2. Remove belt (B) from pulley.
3. Remove four cap screws (C) and pulley.
4. Remove cap screw and nut (D).
5.
H68737-UN: Sheave Hub, Beater
LEGEND:
A - Hub
Remove hub (A).
6. Remove key from keyway.
1429
Removal of Gear Case for Serrated Beater Drive
7.
H68738-UN: Beater Gear Case
LEGEND:
A - Screw and Washer
B - Cap Screw with Nut
C - Cap Screw with Nut
D - Cap Screw, Spacer and Nut
E - Nut
Remove screw and washer (A) from shaft.
8. Remove cap screws and nuts (B) and (C).
9. Remove cap screw, spacer and nut (D).
10. Loosen nut (E) and set idler aside.
11.
NOTE:
It will be necessary to use H-frame (A), forcing screw (B), washer (C) and nut (D) of
JDG643A Straw Walker Gear Case Puller, in addition to JDG729 Beater Gear Case
Puller, to remove beater gear case.
H55350-UN: JDG643A
LEGEND:
A - H-Frame
B - Forcing Screw
C - Washer
D - Nut
1430
Removal of Gear Case for Serrated Beater Drive
12.
H68739-UN: Beater Gear Case Puller
LEGEND:
A - Puller
B - Puller
C - Gear Case
Install JDG729 Beater Gear Case Puller (A) and JDG643A Straw Walker Gear Case Puller (B) and
remove gear case (C).
13. Repair or replace gear case as necessary.
Go to Section_121:Group_05
OUO6046,00014E8-19-20010618
1431
Gear Case for Serrated Beater Drive
Gear Case for Serrated Beater Drive
H58973-UN: Air Suspension, Exploded View
LEGEND:
1 - Nut (8 used)
2 - Lock Washer
3 - Bearing (2 used)
4 - Shaft Key
5 - Seal
6 - Cap Screw
7 - Seal (2 used)
8 - Bearing (2 used)
1432
Gear Case for Serrated Beater Drive
9 - Screw Plug (2 used)
10 - Plug
11 - Gear, 30-Tooth
12 - Gear, 54-Tooth
13 - Pin (2 used)
14 - Gear Case
15 - Belt
16 - Flange Nut
17 - Retaining Screw
18 - Two-Speed Sheave
19 - Pulley
20 - Cap Screw (4 used)
Go to Section_121:Group_05
AG,OUO6045,262-19-20030206
1433
Disassemble Gear Case for Serrated Beater Drive
Disassemble Gear Case for Serrated Beater Drive
1.
H73515-UN: Gear Case
LEGEND:
A - Cap Screw (10 used)
Remove cap screws (A) from gear case.
2.
H63882-UN: Gear Case
LEGEND:
A - Slot (2 used)
Separate housing by prying apart at slots (A) on both ends of gear case.
1434
Disassemble Gear Case for Serrated Beater Drive
3.
H51943-UN: Gear Case
LEGEND:
A - Gear
B - Pinion
C - Surfaces
Remove gear (A) and pinion (B).
4. Remove gasket material from gear case mating surfaces (C).
5.
H40339-UN: Gears
LEGEND:
A - Bearing (2 used)
Remove ball bearings (A) from gearshaft, if they require replacement. Bearings are a press fit.
6. Lubricate all bearings with AN102562 Corn Head grease. After assembly of bearings and gears, gear
case must be lubricated with 414 mL (14 oz.) (1 tube) of AN102562 Corn Head Grease, bearings
included.
Item
Measurement Specification
Gear case Capacity
414 ml (1 tube)
1435
Disassemble Gear Case for Serrated Beater Drive
7.
H40340-UN: Gears
LEGEND:
A - Bearing (2 used)
Install ball bearings (A) on gears. Bearing inner races must rest against shaft shoulders. Bearings are a
press fit.
8.
H51944-UN: Seals
LEGEND:
A - Seal (3 used)
Remove seals (A) if they require replacement.
9.
H63883-UN: Seals
LEGEND:
A - Seal Driver
Install seal in outer gear case half using appropriate driver (A). Seal must be installed as shown.
10. Install seals in inner gear case half.
11. Install all seals with spring-loaded lip toward bearings and flush with housings.
1436
Disassemble Gear Case for Serrated Beater Drive
12.
H51943-UN: Gear Case
LEGEND:
A - Gear
B - Pinion
C - Groove
Apply TY6304 Sealant to flange groove (C) of outer gear case half.
13. Install gear (A) and pinion (B).
14.
H73515-UN: Gear Case
LEGEND:
A - Cap Screw (10 used)
Assemble gear case.
15. Install cap screws (A). Tighten cap screws to specification.
1437
Disassemble Gear Case for Serrated Beater Drive
Item
Measurement Specification
Gear Case Housing Cap Screws Torque
25 N˙m
(18 lb-ft)
NOTE:
It is normal for the gear and pinion bearings to move back and forth in the gear case. If
excessive movement is supposed to exist, separate gear case and apply TY15969
Retaining Compound (Maximum Strength) to outer bearing race.
16.
H40543-UN: Hub Installation
LEGEND:
A - Hub
B - Cap Screw
Install hub (A). Hub is a tight fit.
17. Tighten cap screw (B) to specification.
Item
Measurement Specification
Gear Case Hub Cap Screw Torque
35 N˙m
(26 lb-ft)
Go to Section_121:Group_05
OUO6435,0001926-19-20021120
1438
Install Gear Case for Serrated Beater Drive
Install Gear Case for Serrated Beater Drive
H68738-UN: Gear Case Mounting
LEGEND:
A - Screw and Washer
B - Cap Screw with Nut
C - Cap Screw with Nut
D - Cap Screw, Spacer and Nut
E - Nut
1. Install key on beater shaft.
2. Install gear case on beater shaft.
3. Install cap screws and nuts (B), (C) and (E) through idler bracket on gear case.
4. Install cap screw, nut and spacer (D).
5. Install screw and washer (A) on shaft end. Tighten to specified torque.
Item
Measurement Specification
Gear Case Retaining Screw and Washer Torque
6. Install key in keyway of gear case input shaft.
7.
H68737-UN: Hub
LEGEND:
1439
100 N˙m
(74 lb-ft)
Install Gear Case for Serrated Beater Drive
A - Hub
Install hub (A) on input shaft.
8.
H68736-UN: Beater Drive Sheave
LEGEND:
A - Nut (2 used)
B - Belt
C - Cap Screw (4 used)
D - Cap Screw and Nut
Install cap screw and nut (D).
9. Install sheave and cap screws (C).
10. Install belt (B).
11. Tighten belt by tightening tension nuts (A) until washer aligns with spring gauge.
Go to Section_121:Group_05
OUO6046,00014E9-19-20010618
1440
Serrated Beater and Shaft
Serrated Beater and Shaft
H67915-UN: Beater
LEGEND:
1 - Screw (40 used)
2 - Screw (68 used)
3 - Blade (8 used)
4 - Screw (2 used)
5 - Flange Nut (68 used)
6 - Flange Nut (2 used)
7 - Beater Head (2 used)
8 - Screw (24 used)
9 - Beater Head (3 used)
10 - Shaft
1441
Serrated Beater and Shaft
11 - Key (2 used)
12 - Set Screw
13 - Locking Collar (2 used)
14 - Flange (2 used)
15 - Bearing (2 used)
16 - Flange (2 used)
17 - Lubrication Fitting (2 used)
18 - Hose
19 - Nut (2 used)
20 - Lubrication Fitting (2 used)
21 - Nut (8 used)
22 - Lubrication Fitting
23 - Cap Screw (8 used)
24 - Seal (4 used)
25 - Flange Nut (24 used)
26 - Lock Washer (24 used)
27 - Washer (16 used)
28 - Screw (6 used)
29 - Bracket
30 - Clip
31 - Bushing
32 - Set Screw
33 - Gear
34 - Wear plate (56 used)
Go to Section_121:Group_05
OUO6046,0001462-19-20010521
1442
Remove Left Serrated Beater Shaft Bearing
Remove Left Serrated Beater Shaft Bearing
1.
H68740-UN: Speed Monitoring Sensor
LEGEND:
A - Set Screw
B - Tone Wheel
C - Harness Connector
Remove beater drive gear case. (See procedure in this Group.)
2. Loosen set screw (A) and remove tone wheel (B).
3. Disconnect harness connector (C).
4.
H68741-UN: Bearing and Locking Collar
LEGEND:
A - Set Screw
B - Locking Collar
Loosen set screw (A) and remove locking collar (B).
5. Remove four nuts and remove sensor bracket, outer bearing retainer and bearing.
6. Repair or replace parts as necessary.
Go to Section_121:Group_05
OUO6046,00014EA-19-20010618
1443
Remove Right Serrated Beater Shaft Bearing
Remove Right Serrated Beater Shaft Bearing
1. Remove the intermediate cylinder drive (see instructions in Group 10).
2.
H45593-UN: Bearing Housing
LEGEND:
A - Locking Collar
B - Nut (4 used)
Remove bearing locking collar (A).
3. Remove four nuts (B) and remove bearing and bearing retainer.
4. Repair or replace parts as necessary.
Go to Section_121:Group_05
OUO6046,000154A-19-20010727
1444
Remove Serrated Beater Shaft
Remove Serrated Beater Shaft
1.
H67916-UN: Serrated Beater
LEGEND:
A - Inspection Holes
Remove left serrated beater shaft bearing. (See procedure in this Group.)
2. Remove right serrated beater shaft bearing. (See procedure in this Group.)
3. Look through holes (A) in beater wings. Rotate beater until shaft clamping bolts are accessible.
4.
H45741-UN: Clamp, Beater
LEGEND:
B - Nut (2 used)
Loosen nuts on clamping bolts (B). Do not remove nuts.
1445
Remove Serrated Beater Shaft
CAUTION:
5.
The approximate weight of serrated beater is 86 kg (190 lb).
Support beater so it will not drop when the shaft is removed.
6. Move shaft towards the right side of the combine.
7. Remove shaft key and shaft.
8. Inspect shaft for wear and runout. The following runout is acceptable:
Item
Measurement Specification
Serrated Beater Shaft Runout
0.05 mm
(0.002 in.)
Go to Section_121:Group_05
OUO6046,0001463-19-20010521
1446
Install Serrated Beater Shaft
Install Serrated Beater Shaft
CAUTION:
1.
The approximate weight of serrated beater is 86 kg (190 lb).
Insert shaft into beater from right side of combine.
2. Align shaft key seat on right end with beater hub.
3. Insert key in hub and shaft.
4.
H45593-UN: Beater Bearing
LEGEND:
A - Bearing
B - Bearing Flangette (2 used)
Install right bearing (A) and bearing flangettes (B) using four nuts.
5. Install left bearing, bearing flangettes and sensor bracket using four nuts.
6. Position shaft end as specified.
Item
Measurement Specification
End of Beater Shaft-to-Side Sheet Distance
148 mm
(5-13/16 in.)
7.
H68741-UN: Bearing and Locking Collar
1447
Install Serrated Beater Shaft
LEGEND:
A - Set Screw
B - Locking Collar
Install locking collar (B) and tighten set screw (A).
8.
H68740-UN: Speed Monitoring Sensor
LEGEND:
A - Set Screw
B - Tone Wheel
C - Harness Connector
Install tone wheel (B) on shaft and tighten set screw (A).
9. Set distance between tone wheel (B) and sensor. Turn sensor in until it contacts tone wheel. Back off
sensor ONE TURN. Make sure that sensor is centered with tone wheel.
10. Connect harness (C).
11.
H45977-UN: Right Beater Bearing
LEGEND:
A - Bearing and Locking Collar
Install locking collar (A) on right beater bearing.
12. Insert key into end of shaft.
13. Install beater drive gear case, idler, hub and sheave. Install belt and adjust tension. (See procedure in
this Group.)
14. Install intermediate cylinder drive. (See instructions in Group 10.)
1448
Install Serrated Beater Shaft
15.
H45741-UN: Beater Clamp
H67916-UN: Serrated Beater
LEGEND:
A - Inspection Hole (2 used)
B - Retaining Nut (2 used)
Tighten retaining nuts (B) through inspection holes (A) to the specified torque.
Item
Measurement Specification
Retaining Nuts, Beater Shaft Torque
87 N˙m
(64 lb-ft)
Go to Section_121:Group_05
OUO6046,000154B-19-20010727
1449
Remove Beater Drive Sheave
Remove Beater Drive Sheave
1.
H68742-UN: Beater Belt
LEGEND:
A - Nut
B - Belt
Loosen idler nuts (A) and remove drive belt (B).
2.
H55413-UN: Electromagnetic Clutch Module
LEGEND:
A - Strap
B - Connector
Disconnect electromagnetic clutch module strap (A) and connectors (B).
3.
NOTE:
For removal of the pulley, it is not necessary to remove the brush module.
1450
Remove Beater Drive Sheave
H55414-UN: Clutch Pulley
LEGEND:
A - Cap Screw (4 used)
Remove cap screws (A). Remove pulley. While removing pulley, route wires through slot in pulley.
Go to Section_121:Group_05
OUO6046,00014EC-19-20010618
1451
Install Beater Drive Sheave
Install Beater Drive Sheave
H55414-UN: Beater Drive Sheave
LEGEND:
A - Cap Screw (4 used)
1. Install pulley. While installing pulley on clutch, route wires through slot in pulley.
2. Install cap screws (A) and tighten to specification.
Item
Measurement Specification
Beater Drive Sheave-to-Electromagnetic Clutch, Cap Screws Torque
123 ± 30 N˙m
(90 ± 22 lb-ft)
3.
H55413-UN: Electromagnetic Clutch Brush Module
LEGEND:
A - Strap
B - Connector
Be certain belt is routed around clutch pulley and connect module connectors (B).
4. Install strap (A).
5. Place drive belt (B) on pulleys and tighten nuts (A) until washer aligns with gauge.
1452
Install Beater Drive Sheave
H68742-UN: Beater Drive Belt
LEGEND:
A - Nut (2 used)
B - Belt
Go to Section_121:Group_05
OUO6046,00014ED-19-20010618
1453
Remove/Install Serrated Beater Wings
Remove/Install Serrated Beater Wings
1.
CAUTION:
Engine MUST be off and key removed.
Crank separator out (See Move Tine Separator Module to the Service Position in this Group). Access is
gained through door in engine compartment.
2.
H68742-UN: Beater Drive Belt
H67918-UN: Beater Wing
LEGEND:
1454
Remove/Install Serrated Beater Wings
A - Lock Nut
B - Belt
C - Beater Seal
D - Cap Screw (4 used)
E - Flat Washer (4 used)
F - Lock Washer (4 used)
G - Nut (4 used)
H - Cap Screw
Loosen nut and lock nut (A) to relieve belt tension.
3. Remove belt (B).
4.
NOTE:
If beater is removed from combine, or has loosened clamp cap screws, tighten clamp
cap screws through access hole before tightening wing cap screws. Tighten screws to
specified torque.
Item
Measurement Specification
Beater Clamp Carriage Bolts Torque
87 N˙m
(64 lb-ft)
Remove lower left beater seal (C) by removing cap screws (D), flat washers (E), lock washers (F) and
nuts (G).
5. Remove cap screw (H) per section and disassemble beater wing.
6. Repair or replace wings as necessary.
7.
NOTE:
Beater wings can be replaced without removing beater from combine. Replace beater
wings in a set of two opposite to each other on the beater to maintain balance.
Install new wing and tighten cap screws (H) to specification.
Item
Measurement Specification
Serrated Beater Wing Cap Screws Torque
45 N˙m
(35 lb-ft)
8. IMPORTANT:
Wings must clear seals. Adjust as necessary.
Replace left beater seal (C).
9. Crank separator in (See Move Tine Separator Module to the Working Position in this Group).
Go to Section_121:Group_05
OUO6435,000146A-19-20010820
1455
Beater
Beater
H59141-UN: Beater, Exploded View
LEGEND:
A - Seal (2 used)
B - Screw (3 used)
C - Belt
D - Set Screw (2 used)
E - Lock nut (2 used)
F - Pulley
G - Set Screw
H - Locking Collar
1456
Beater
I - Flange
J - Bearing (2 used)
K - Flange (2 used)
L - Screw (3 used)
M - Beater
N - Key
O - Shaft
P - Flange
Q - Lubrication Hose
R - Lubrication Fitting
Go to Section_121:Group_05
OUO6046,0001510-19-20010621
1457
Remove Beater Drive Sheave
Remove Beater Drive Sheave
ZX25294-UN: Drive Tightener
H68763-UN: Beater Tightener
LEGEND:
A - Drive Belt Idler
B - Idler Sheave
C - Belt Tension
D - Pulley
1. Loosen idler (A) for feeder house drive belt.
2. Remove idler sheave (B) from idler arm.
3. Loosen belt tension on idler at (C) and remove belt.
4. Loosen set screws on sheave hub.
5. Remove sheave (D).
6. Repair or replace sheave as necessary.
Go to Section_121:Group_05
OUO6435,0001437-19-20010726
1458
Remove and Install Beater Shaft
Remove and Install Beater Shaft
ZX25296-UN: Idler
ZX25295-UN: Left Side
LEGEND:
A - Nut
B - Lock Nut
C - Set Screws
D - Pulley
1. Loosen nuts (A).
2. Remove belt.
3. Loosen lock nuts (B) and screw out set screws (C).
4. Install puller. Remove sheave (D) and shaft key.
1459
Remove and Install Beater Shaft
5.
H68746-UN: Left Side
LEGEND:
A - Locking Collar
B - Nut (3 used)
C - Lubrication Oil Line
Loosen set screw and remove locking collar (A).
6. Remove three nuts (B) and remove outer bearing flangette.
7. Disconnect lubrication oil line (C).
8. Remove bearing and inner bearing flangette.
9.
H68748-UN: Right Side
LEGEND:
A - Locking Collar
B - Nut (3 used)
Loosen set screw and remove locking collar (A) from bearing on the right side.
10. Remove three nuts (B) and remove outer bearing flangette.
1460
Remove and Install Beater Shaft
11.
H68749-UN: Right Side
LEGEND:
A - Bearing
Remove bearing (A) and inner bearing flangette.
CAUTION:
12.
Approximate weight of the beater is 20 kg (44 lb).
Support beater so it will not drop when the shaft is removed.
13. Pull shaft (A) out from left side of combine.
14. Repair or replace parts as necessary.
15. Check beater shaft for total runout. The following runout is acceptable:
Item
Measurement Specification
Beater Shaft Runout
0.02 mm
(0.008 in.)
16. Install shaft (A) from left side of combine.
17.
H68749-UN: Right Side
LEGEND:
A - Bearing
1461
Remove and Install Beater Shaft
Install right bearing (A).
18.
H68748-UN: Right Side
H68750-UN: Left Side
LEGEND:
A - Locking Collar
B - Nut (3 used)
C - Locking Collar
D - Nut (3 used)
E - Lubrication Oil Line
Install outer bearing flangette using three nuts (B).
19. Install left inner bearing flangette and bearing.
20. Connect lubrication oil line (E).
21. Install outer bearing flangette using three nuts (D).
22. Position shaft from end of shaft to inner bearing race as specified.
Item
Measurement Specification
End of Beater Shaft to Inner Bearing Race Distance
23. Install left (C) and right (A) locking collar.
1462
55.2 mm
(2-11/16 in.)
Remove and Install Beater Shaft
24.
ZX25295-UN: Left Side
ZX25296-UN: Left Side
LEGEND:
A - Nut
B - Lock Nut
C - Set Screw (2 used)
D - Pulley
Install pulley (D). Align the pulley with the pulley on the cylinder shaft. Tighten set screw (C).
25. Install belt.
26. Tighten nut (A) and lock nuts (C).
Go to Section_121:Group_05
OUO6435,000167A-19-20020320
1463
Remove and Install Beater
Remove and Install Beater
H68764-UN: Beater Idler
H67918-UN: Beater
LEGEND:
A - Cap Screw (3 used)
B - Idler Pulley
C - Beater Seal
D - Screw (4 used)
E - Flat Washer (4 used)
F - Lock Washer (4 used)
G - Nut (4 used)
H - Cap Screw (As Required)
1.
CAUTION:
1464
Remove and Install Beater
Engine must be off and key removed.
Crank separator out (See Move Tine Separator Module to the Service Position in this Group). Access is
gained through door in engine compartment.
2. Remove cap screws (A) and idler pulley (B).
3. Remove lower left beater seal (C) by removing screws (D), flat washers (E), lock washers (F) and nuts
(G).
4. Remove cap screws (H) as required, and remove all beater wings.
5.
H45352-UN: Beater Hubs
LEGEND:
A - Cap Screw (4 used)
B - Hub (4 used)
Loosen cap screw (A) and slide all hubs (B) over to the right.
6. Remove beater shaft See Remove and Install Beater Shaft in this group.
7.
H45354-UN: Beater Cover
LEGEND:
A - Cap Screw (8 used)
B - Beater Cover
1465
Remove and Install Beater
Remove cap screws (A) and the lower beater cover (B).
8.
H45353-UN: Beater Seal
LEGEND:
A - Carriage Bolt (2 used)
B - Stripper Seal
C - Carriage Bolt (4 used)
D - Beater Seal
Remove carriage bolts (A) and stripper seal (B).
9. Remove carriage bolts (C) and beater seal (D).
10.
H45385-UN: Beater
LEGEND:
A - Beater
Remove beater (A) as shown.
11. Repair or replace parts as necessary.
1466
Remove and Install Beater
12.
H45353-UN: Beater Seal
LEGEND:
A - Carriage Bolt (2 used)
B - Stripper Seal
C - Carriage Bolt (4 used)
D - Beater Seal
Position beater and stripper seal (B) and install carriage bolts (A).
13. Install beater seal (D) and carriage bolts (C).
14. Install shaft from left side of combine.
15.
H68749-UN: Bearing
LEGEND:
A - Bearing
Install right bearing (A).
1467
Remove and Install Beater
16.
H68748-UN: Locking Collar
H68750-UN: Bearing Flangette
LEGEND:
A - Locking Collar
B - Nut (3 used)
C - Locking Collar
D - Nut (3 used)
E - Lubrication Oil Line
Install outer bearing flangette using three nuts (B).
17. Install left inner bearing flangette and bearing.
18. Connect lubrication oil line (E).
19. Install outer bearing flangette using three nuts (D).
20. Position shaft from end of shaft to inner bearing race as specified.
Item
Measurement Specification
End of Beater Shaft to Inner Bearing Race Distance
21. Install left (C) and right (A) locking collar.
1468
55.2 mm
(2-11/64 in.)
Remove and Install Beater
22.
ZX25295-UN: Beater Sheave
ZX25296-UN: Beater Sheave
LEGEND:
A - Nut
B - Lock Nut (2 used)
C - Set Screw (2 used)
D - Pulley
Install pulley (D). Align the pulley with the pulley on the cylinder shaft. Tighten set screw (C).
23. Install belt.
24. Tighten nut (A) and lock nuts (B).
25.
1469
Remove and Install Beater
H45352-UN: Beater Hubs
LEGEND:
A - Cap Screw (4 used)
B - Hub (4 used)
Slide hubs (B) back to the left.
26. Leave cap screw (A) loose on left hub until beater wings have been installed.
27.
H67918-UN: Beater Seal
1470
Remove and Install Beater
H47000-UN: Beater Clamp
LEGEND:
A - Carriage Bolt
B - Nut
C - Left Seal
D - Screw (4 used)
E - Flat Washer (4 used)
F - Lock Washer (4 used)
G - Nut (4 used)
H - Cap Screw
Install wing and tighten cap screws (H) to specification.
Item
Measurement Specification
Beater Wing Cap Screws Torque
45 N˙m
(35 lb-ft)
28. Center beater and replace left seal (C), cap screws (D), flat washers (E), lock washers (F) and nuts (G).
29. Tighten carriage bolt (A) with nut (B) on left hub to specification to clamp hub to shaft.
Item
Measurement Specification
Beater Hub Shaft Clamping Bolts Torque
87 N˙m
(64 lb-ft)
Go to Section_121:Group_05
OUO6046,0001588-19-20010809
1471
Serrated Beater Cover
Serrated Beater Cover
H59146-UN: Serrated Beater Cover
LEGEND:
1 - Channel
2 - Isolator
3 - Flange Nut (5 used)
4 - Screw (5 used)
5 - Angle
6 - Cover
7 - Isolator
8 - Support (2 used)
1472
Serrated Beater Cover
9 - Cover
10 - Cover
11 - Cap Screw (2 used)
12 - Cover
13 - Cover
14 - Screw (As Required)
15 - Flange Nut (As Required)
16 - Bracket
17 - Screw (As Required)
18 - Flange Nut (As Required)
19 - Screw (6 used)
20 - Leaf Spring
21 - Washer (6 used)
22 - Flange Nut (6 used)
23 - Leaf Spring
24 - Screw (6 used)
25 - Crop Divider
Go to Section_121:Group_05
AG,OUO1026,78-19-20030206
1473
Remove Serrated Beater Cover
Remove Serrated Beater Cover
1.
CAUTION:
Engine must be off and key removed.
Crank separator out (See Move Tine Separator Module to the Service Position in this Group). Access is
gained through door in engine compartment.
2.
H45622-UN: Right Side
H45624-UN: Right Side
H68753-UN: Left Side
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (2 used)
1474
Remove Serrated Beater Cover
Remove two cap screws (A) from angle on right side.
3. Remove two cap screws (B) from angle on left side.
4.
H45382-UN: Deflector
LEGEND:
A - Cap Screw (3 used)
Remove three cap screws (A) at top of deflector.
5. Push up on feed assembly to disengage from lip, lower and remove from combine.
6.
H67919-UN: Beater Seal
LEGEND:
A - Beater Seal
1475
Remove Serrated Beater Cover
B - Screw (4 used)
C - Flat Washer (4 used)
D - Lock Washer (4 used)
E - Nut (4 used)
F - Cap Screw (as required)
Remove rear left beater seal (A) by removing screws (B), flat washers (C), lock washers (D) and nuts
(E).
7. Remove cap screws (F) as required, and remove all beater wings.
8.
H45353-UN: Beater Seal
LEGEND:
A - Carriage Bolt (2 used)
B - Stripper Seal
C - Carriage Bolt (4 used)
D - Beater Seal
Remove carriage bolts (C) and front beater seal (D).
9. Remove carriage bolts (A) and stripper seal (B).
10.
H45628-UN: Left Side
LEGEND:
A - Cap Screw (4 used)
Remove cap screws (A) attaching serrated beater cover from left side of combine.
1476
Remove Serrated Beater Cover
11.
H45625-UN: Right Side
LEGEND:
B - Cap Screw (4 used)
Remove cap screws (B) attaching serrated beater cover from right side of combine.
12.
CAUTION:
The approximate weight of rear cover is 29.6 kg (65 lb). Two people will be
required to remove cover.
H45685-UN: Serrated Beater Cover
LEGEND:
C - Cover
Remove serrated beater cover (C).
Go to Section_121:Group_05
OUO6046,0001556-19-20010731
1477
Remove Beater Cover
Remove Beater Cover
H68766-UN: Right Side
H68765-UN: Left Side
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (2 used)
C - Cap Screw (5 used)
1. Remove two cap screws (A) on right side of combine.
2. Remove two cap screws (B) on left side of combine.
3. Remove five cap screws (C) located under operator's station.
4. Remove beater cover and replace or repair as necessary.
Go to Section_121:Group_05
OUO6046,00014F1-19-20010618
1478
Install Beater Cover
Install Beater Cover
1.
H68766-UN: Right Side
H68765-UN: Left Side
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (2 used)
C - Cap Screw (5 used)
Install cover into position and attach on right side to sidesheet with two cap screws (A).
2. Attach cover to left sidesheet with two cap screws (B).
3. Install five cap screws (C) located under operator's station.
4.
H45353-UN: Left Side
1479
Install Beater Cover
LEGEND:
A - Carriage Bolt (2 used)
B - Beater Seal
C - Carriage Bolt (4 used)
D - Beater Seal
Install beater seal (B) using carriage bolts (A).
5. Install front beater seal (D) using carriage bolts (C).
Go to Section_121:Group_05
OUO6046,00014F2-19-20010618
1480
Install Serrated Beater Cover
Install Serrated Beater Cover
CAUTION:
1.
The approximate weight of rear cover is 29.6 kg (65 lb). Two people will be
required to install cover.
H45628-UN: Left Side
H45648-UN: Serrated Beater Cover
H45353-UN: Beater Seal
LEGEND:
A - Cap Screw (4 used)
B - Beater Seal
C - Carriage Bolt (4 used)
D - Beater Seal
E - Slot
Install serrated beater cover and attach with cap screws (A) through the left side sheet.
NOTE:
Front edge of cover MUST engage slot (E) of serrated beater cover.
1481
Install Serrated Beater Cover
2. Install cap screws (A) through right side sheet.
3. Install front beater seal (D) using carriage bolts (C).
4.
H67919-UN: Beater Wing
LEGEND:
A - Beater Seal
B - Screw (4 used)
C - Flat Washer (4 used)
D - Lock Washer (4 used)
E - Nut (4 used)
F - Cap Screw
Install all beater wings with cap screws (F) and tighten to specification.
Item
Measurement Specification
Beater Wing Retaining Screws Torque
45 N˙m
(35 lb-ft)
5. Install rear beater seal (A) with screws (B), flat washers (C), lock washers (D) and nuts (E).
6. Position feed assembly to engage lip of serrated beater cover.
1482
Install Serrated Beater Cover
7.
H45382-UN: Deflector
LEGEND:
A - Cap Screw (3 used)
Attach top of deflector with three cap screws (A).
8.
H68754-UN: Right Side - Exterior View
H45624-UN: Right Side - Interior View
LEGEND:
A - Cap Screw (2 used)
Install feed deflector right side angle to sidesheet with two cap screws (A).
1483
Install Serrated Beater Cover
9.
H68753-UN: Left Side
LEGEND:
B - Cap Screw (2 used)
Install feed deflector left side angle to sidesheet with two cap screws (B).
Go to Section_121:Group_05
OUO6046,0001469-19-20010521
1484
Remove Module Feed Assembly
Remove Module Feed Assembly
1.
CAUTION:
Engine must be off and key removed.
Crank separator out (See Move Tine Separator Module to the Service Position in this Group). Access is
gained through door in engine compartment.
2.
H45382-UN: Deflector
LEGEND:
A - Cap Screw (3 used)
Remove three cap screws (A) at top of deflector.
3.
H68754-UN: Right Side - Exterior View
1485
Remove Module Feed Assembly
H45624-UN: Right Side - Interior View
H68753-UN: Left Side
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (2 used)
Remove four cap screws and nuts (A) and (B) from deflector.
4. Push up on assembly to disengage front mounting lip.
5. Lower assembly and remove from combine.
6. Repair or replace as required.
Go to Section_121:Group_05
OUO6046,0001557-19-20010731
1486
Install Module Feed Assembly
Install Module Feed Assembly
H68754-UN: Right Side - Exterior View
H45624-UN: Right Side - Interior View
H68753-UN: Left Side
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (2 used)
1. Install assembly and engage front mounting lip.
2. Install four cap screws and nuts (A) and (B).
1487
Install Module Feed Assembly
3.
H45382-UN: Cover
LEGEND:
A - Cap Screw (3 used)
Install three cap screws (A).
4. Move module to working position (see Move Tine Separator Module to the Working Position in this
Group).
Go to Section_121:Group_05
OUO6046,0001558-19-20010731
1488
Remove Serrated Beater Lower Covers
Remove Serrated Beater Lower Covers
1.
H68755-UN: Access Panel
LEGEND:
A - Access Panel (2 used)
Remove left and right access panels (A).
2.
H45637-UN: Serrated Beater Cover
H45638-UN: Serrated Beater Cover
LEGEND:
A - Cap Screw (4 used)
B - Cap Screw (6 used)
C - Cap Screw (4 used)
Remove nuts (A) from left and right side.
3. Remove screws (B) and nuts.
4. Remove rear cover.
1489
Remove Serrated Beater Lower Covers
5. (Front Cover Only) Remove nuts (C) from left and right side.
6. Remove covers through access panels.
7. Replace or repair as required.
Go to Section_121:Group_05
OUO6046,00014F5-19-20010618
1490
Install Serrated Beater Lower Covers
Install Serrated Beater Lower Covers
1.
H45637-UN: Side View
H45638-UN: Front View - Isolated
H45654-UN: Front View - Full
LEGEND:
A - Cap Screw (4 used)
B - Cap Screw (6 used)
C - Cap Screw (4 used)
Install covers through left or right access panel, position over studs at (C) and/or (A) and secure with
nuts.
2. Install cap screws (B).
1491
Install Serrated Beater Lower Covers
3.
H68755-UN: Access Panel
LEGEND:
A - Access Panel
Install left and right access panels (A).
Go to Section_121:Group_05
OUO6046,00014F6-19-20010618
1492
Remove and Install Beater Curtain
Remove and Install Beater Curtain
1.
H71728-UN: Bearing Support Sheet
H71732-UN: Nuts Retaining Top of Beater Seals
LEGEND:
A - Bearing Support Sheet
B - Nut (2 used)
Start engine and set cylinder speed to lowest speed.
2.
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable,
remove key from switch and install a DO NOT OPERATE tag in operator's cab.
Shut off engine and remove key.
3. Remove electromagnetic clutch. See Remove Header Electromagnetic Clutch in Group 50 of this
section.
4. Remove primary countershaft assembly. See Remove and Install Primary Countershaft with Variable
Sheave Assembly in this group.
1493
Remove and Install Beater Curtain
5. IMPORTANT:
To avoid dropping parts into separator, do NOT completely remove nuts (B) until support sheet is tilted
forward to access round head bolts.
Loosen, DO NOT remove, nuts (B).
6. Note location of wiring harness clamps; then remove nuts and cap screws from bearing support sheet
(A).
7. Tilt sheet (in direction of arrow) and move tube towards the front to access round head bolts; then
remove nuts (B).
8.
H71729-UN: Input Shaft Tube
LEGEND:
A - Tube
B - Seal (2 used)
C - Round Head Bolt
D - Curtain
Remove shaft protection tube (A).
9. Remove nuts, seal, round head bolts (C) and curtain (D).
10. Install in reverse order using the following special instructions:
Inspect seals (B) on tube (A) and replace as necessary.
Install end of tube to primary gear case.
1494
Remove and Install Beater Curtain
H71728-UN: Bearing Support Sheet
H71744-UN: Nuts Retaining Top of Beater Seals
LEGEND:
A - Bearing Support Sheet
B - Nut (2 used)
Install bearing support sheet, bottom end first; then tilt sheet in at the top far enough to install
round head bolts. Loosely install nuts (B).
Align tube with hole in sheet and loosely install all cap screws and nuts before tightening.
Go to Section_121:Group_05
OUO6037,00015BB-19-20020422
1495
Engine Gear Case to Module Drives - Exploded View
Engine Gear Case to Module Drives - Exploded View
H50725-UN: Module Drives
LEGEND:
1 - Intermediate Shaft
2 - Key (chopper option only)
3 - Woodruff Key
4 - Bearing Housing
5 - Lubrication Fitting
6 - Bearing
7 - Locking Collar
8 - Shim (3 maximum)
1496
Engine Gear Case to Module Drives - Exploded View
9 - Support
10 - Chopper Drive Sheave (option)
11 - Screw (6 used)
12 - Sheave, High Speed
13 - Input Sheave
14 - Nut (2 used)
15 - Washer
16 - Spring
17 - Gauge
18 - Pivot
19 - Eyebolt
20 - Washer
21 - Screw
22 - Washer
23 - Idler Arm Assembly
24 - Wiper
25 - Idler Pulley (2 used)
26 - Spacer
27 - Wiper
28 - Spacer
29 - Plate
30 - Nut
31 - Spacer
32 - Pivot
33 - Washer (2 used)
34 - Screw (4 used)
35 - Snap Ring
36 - Screw
37 - Brace
38 - Screw
39 - Screw
40 - Brace
41 - Nut
42 - Washer
43 - Screw (3 used)
44 - Nut and Washer
45 - Plate
46 - Spacer
47 - Bearing Housing
48 - Bearing
49 - Washer (2 used)
50 - Screw
51 - Screw
52 - Lubrication Fitting
53 - Nut and Washer (2 used)
54 - Nut (4 used)
55 - Eyebolt
56 - Nut (3 used)
1497
Engine Gear Case to Module Drives - Exploded View
57 - Screw (3 used)
58 - Screw (2 used)
59 - Brace
60 - Screw (2 used)
61 - Eyebolt
62 - Nut and Washer (2 used)
63 - Nut and Washer
64 - Bearing
65 - Lubrication Fitting
66 - Bearing Housing
67 - Screw (4 used)
68 - Plate
69 - Screw
70 - Spacer
71 - Lubrication Fitting
72 - Washer
73 - Screw
74 - Bearing
75 - Bearing Housing
76 - Input Sheave
77 - Screw (3 used)
78 - Brace
79 - Nut (3 used)
80 - Chaff Spreader Drive Sheave (option)
81 - Bearing
82 - Cotter Pin
83 - Flange Nut (3 used)
84 - Bracket
85 - Woodruff Key
86 - Key (Chaff Spreader Option)
87 - Rotor Shaft
88 - Nut (2 used)
89 - Nut (2 used)
NOTE:
For replacement of engine gear case 3-groove module drive sheave, refer to Section 140.
Go to Section_121:Group_10
OUO6435,0001475-19-20010820
1498
Engine Gear Case to Module Drives - Exploded View
Engine Gear Case to Module Drives - Exploded View
H50725-UN: Module Drives
LEGEND:
1 - Intermediate Shaft
2 - Key (chopper option only)
3 - Woodruff Key
4 - Bearing Housing
5 - Lubrication Fitting
6 - Bearing
7 - Locking Collar
8 - Shim (3 maximum)
1499
Engine Gear Case to Module Drives - Exploded View
9 - Support
10 - Chopper Drive Sheave (option)
11 - Screw (6 used)
12 - Sheave, High Speed
13 - Input Sheave
14 - Nut (2 used)
15 - Washer
16 - Spring
17 - Gauge
18 - Pivot
19 - Eyebolt
20 - Washer
21 - Screw
22 - Washer
23 - Idler Arm Assembly
24 - Wiper
25 - Idler Pulley (2 used)
26 - Spacer
27 - Wiper
28 - Spacer
29 - Plate
30 - Nut
31 - Spacer
32 - Pivot
33 - Washer (2 used)
34 - Screw (4 used)
35 - Snap Ring
36 - Screw
37 - Brace
38 - Screw
39 - Screw
40 - Brace
41 - Nut
42 - Washer
43 - Screw (3 used)
44 - Nut and Washer
45 - Plate
46 - Spacer
47 - Bearing Housing
48 - Bearing
49 - Washer (2 used)
50 - Screw
51 - Screw
52 - Lubrication Fitting
53 - Nut and Washer (2 used)
54 - Nut (4 used)
55 - Eyebolt
56 - Nut (3 used)
1500
Engine Gear Case to Module Drives - Exploded View
57 - Screw (3 used)
58 - Screw (2 used)
59 - Brace
60 - Screw (2 used)
61 - Eyebolt
62 - Nut and Washer (2 used)
63 - Nut and Washer
64 - Bearing
65 - Lubrication Fitting
66 - Bearing Housing
67 - Screw (4 used)
68 - Plate
69 - Screw
70 - Spacer
71 - Lubrication Fitting
72 - Washer
73 - Screw
74 - Bearing
75 - Bearing Housing
76 - Input Sheave
77 - Screw (3 used)
78 - Brace
79 - Nut (3 used)
80 - Chaff Spreader Drive Sheave (option)
81 - Bearing
82 - Cotter Pin
83 - Flange Nut (3 used)
84 - Bracket
85 - Woodruff Key
86 - Key (Chaff Spreader Option)
87 - Rotor Shaft
88 - Nut (2 used)
89 - Nut (2 used)
NOTE:
For replacement of engine gear case 3-groove module drive sheave, refer to Section 140.
Go to Section_121:Group_10
OUO6435,0001475-19-20010820
1501
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Tine Separator Adapter.......JT07089
To remove and install complete tine separator module.
H45579-UN: JT07089
Tine Separator Module
Service Stand.......JT07090
To service and/or store
complete tine separator
module.
Backbone Sheet Metal Repair
Kit.......AH155237
To repair backbone sheet metal
damage between both tine separator
modules.
Go to Section_121:Group_15
ZX09263,0002749-19-20080201
1502
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Tine Separator Adapter.......JT07089
To remove and install complete tine separator module.
H45579-UN: JT07089
Tine Separator Module
Service Stand.......JT07090
To service and/or store
complete tine separator
module.
Backbone Sheet Metal Repair
Kit.......AH155237
To repair backbone sheet metal
damage between both tine separator
modules.
Go to Section_121:Group_15
ZX09263,0002749-19-20080201
1503
Specifications
Specifications
Item
Measurement Specification
Set Screw
Torque
25 N˙m
(19 lb-ft)
Front Feed Section Vane
Clearance
6 mm (0.25 in.)
Grate to Module Side Rail Screws
Torque
140 N˙m
(105 lb-ft)
Fingerbar Screws
Torque
70 ± 18 N˙m
(52 ± 14 lb-ft)
Module Side Rail Screws
Torque
191 N˙m
(141 lb-ft)
Module U-Joint Drive Shaft Screws
Torque
100 ± 20 N˙m
(74 ± 7 lb-ft)
Module Front to Separator Side Sheets Torque
77 N˙m
(57 lb-ft)
Go to Section_121:Group_15
OUO6435,000148A-19-20010820
1504
Roll Out Tine Separator
Roll Out Tine Separator
ZX019109-UN: Right and Left Panels
LEGEND:
A - Side Access Panel
Take off side access panels (A) on right and left side.
Remove Front Attaching Screws
ZX019110-UN: Front Attaching Screws
Remove screws (A) and spacers.
IMPORTANT:
Torque screws (A) to specification after service.
Item
Measurement Specification
Screws (A) Torque
77 N˙m
(57 lb-ft)
Open the Access Panels
1505
Roll Out Tine Separator
ZX1034871-UN: Rear View
LEGEND:
A - Access Panel on Top
B - Access Panel at the Rear
On top, raise access panel (A) and secure it with locking strap.
Swing out access panel (B).
Move the adjusting lever on the straw chopper to its windrow position.
Disconnect Gear Case Drive
ZX019112-UN: Gear Case Drive
Remove cap screws (A). Slide the joint to one side.
Remove Rear Attaching Screws
ZX019113-UN: Rear Attaching Screws
1506
Roll Out Tine Separator
On both sides, take out round-head bolts (A).
IMPORTANT:
Torque bolts (A) to specification after service.
Item
Measurement Specification
Bolts (A) Torque
190 N˙m
(140 lb-ft)
Disconnect Sensor
ZX1034872-UN: Connector
ZX1034873-UN: Connector
LEGEND:
A - Connector (Loss Sensors)
B - Connector (Rotational Speed Sensor)
Disconnect harness connectors (A and B).
1507
Roll Out Tine Separator
ZX1034876-UN: Sensor Cover
Remove sensor cover (C).
Pull out the Intermediate Panel
ZX1034869-UN: Intermediate Panel
Remove intermediate panel (D).
Roll Out Tine Separator
ZX1034874-UN: Crank
LEGEND:
E - Crank
Remove crank (E).
ZX1034875-UN: Pivot
LEGEND:
E - Crank
1508
Roll Out Tine Separator
F - Pivot
Connect crank (E) to pivot (F) and roll out the tine separator as far as it will go.
ZX1034885-UN: Yoke End
LEGEND:
G - Yoke End
NOTE:
When retracting the tine separator, make sure that the spigot for adjusting the chopper deflector
is properly engaged in the yoke (G) of the shift lever.
Go to Section_121:Group_15
ZX08994,0000269-19-20040928
1509
Remove Tine Separator Module
Remove Tine Separator Module
1. Move tine separator module to the service position.
2.
H45692-UN: Remove Module
Attach JT07089 tine separator adapter to the module using a fork lift.
3.
CAUTION:
Approximate weight of module is 1023 kg (2250 lb). Use JT07089 adapter and 480
fork lift or unit of equal capacity.
Remove module from combine.
4.
H45660-UN: Tine Separator Service Stand
Place module assembly on JT07090 module service stands.
1510
Remove Tine Separator Module
Go to Section_121:Group_15
ZX08994,00002B5-19-20041213
1511
Tine Separator Front Bearings and Lube Lines
Tine Separator Front Bearings and Lube Lines
H45672-UN: Tine Separator Front Bearings
LEGEND:
1 - Cover
2 - Lubrication Fitting (2 used)
3 - Nut, 1/8 in. (2 used)
4 - Hose
5 - Lubrication Fitting (2 used)
6 - Housing (2 used)
7 - Bearing (2 used)
8 - Housing (2 used)
9 - Hose, 41 x 1/8 in.
10 - Lubrication Fitting
11 - Screw (6 used)
12 - Screw (8 used)
13 - Screw (8 used)
Go to Section_121:Group_15
OUO6435,000146F-19-20010820
1512
Tine Separator Tubes
Tine Separator Tubes
H45680-UN: Tine Separator Tubes
LEGEND:
1 - Right Tube
2 - Bracket (44 used)
3 - Paddle (2 used)
4 - Bracket (2 used)
5 - Strip (4 used)
6 - Screw (8 used)
7 - Screws (4 used)
8 - Coupling
9 - Screw (10 used)
10 - Lock Nut (as required)
1513
Tine Separator Tubes
11 - Washer (as required)
12 - Weight (as required)
13 - Screw (as required)
14 - Tine (16 used)
15 - Screw (88 used)
16 - Flow Divider
17 - Screw (as required)
18 - Weight (as required)
19 - Right Separator
20 - Left Tube
21 - Flow Divider
22 - Weight (as required)
23 - Washer (As Required)
24 - Left Separator
Go to Section_121:Group_15
OUO6435,0001470-19-20010820
1514
Remove Tine Separators
Remove Tine Separators
H45660-UN: Module Removed
NOTE:
Replacement of tine separator front bearings may be done without removing module assembly
from combine. To begin bearing removal, refer to Step 17. Module must be in service position for
access to bearings.
1. For removal of module assembly from combine, refer to Group 15. Set module assembly on JT07090
service stands.
2.
H45640-UN: Cross Brace
LEGEND:
A - Screw (2 used)
B - Cross Brace
C - Flange Screw (2 used)
Remove two screws (A) from cross brace center support.
3. Remove two flange screws (C) with nuts from top of cross brace (B).
4. Remove cross brace (B).
1515
Remove Tine Separators
5.
H45641-UN: Remove Tine Cover
LEGEND:
A - Screw (30 used)
B - Screw (2 used)
C - Cover
D - Cover
Remove screws (A) and flange nuts retaining cover center seam.
6. Remove screws (B) from front covers (C) and (D).
7.
H45642-UN: Side Rail Cover Removal
LEGEND:
A - Screw (as required)
B - Front Cover
1516
Remove Tine Separators
Remove screws (A) from top of side rails on left and right side through all covers.
8. Remove front covers (B).
9.
H45643-UN: Rear Cover Removal
LEGEND:
A - Center Covers
B - Rear Covers
C - Screw (as required)
Remove center covers (A).
10. Remove screws (C) from rear covers (B).
11. Remove rear covers (B).
12.
H50834-UN: Separator Gear Case
LEGEND:
A - Connector
B - Set Screw (2 used)
Disconnect low shaft speed monitor connector (A).
13. Remove set screws (B) in U-joint.
1517
Remove Tine Separators
14.
CAUTION:
Block up tine separators at grates to prevent them from dropping when removing
gear cases.
H50835-UN: Remove Gear Case
LEGEND:
A - Screw (4 used)
B - Screw (4 used)
Remove four screws with washers, spacers, and shim washers at (A and B).
15. Remove gear case from tine coupler.
NOTE:
Be careful not to lose shim washers from top of gear cases.
16. Slide gear case shaft out of U-joint, then remove U-joint from other gear case shaft.
1518
Remove Tine Separators
17.
H45644-UN: Bearing Cover
LEGEND:
A - Nut (4 used)
B - Bearing Cover
C - Nut (6 used)
Remove four nuts (A) from lower edge of bearing cover (B).
18. Remove six nuts (C) from screws and remove cover (B).
19.
H45645-UN: Shaft Bearing Removal
LEGEND:
A - Retaining Screw
B - Retaining Nuts
C - Bearing
Remove retaining screw (A) from front tine separator shaft.
20. Remove bearing retaining nuts (B).
21. Remove bearing (C).
22.
CAUTION:
1519
Remove Tine Separators
Approximate weight of tine separator tube assembly is 159 kg (350 lb).
H45646-UN: Tine Separator Tube
Attach hoist to tine separator and remove.
Go to Section_121:Group_15
1702,DV1913-19-19980908
1520
Install Tine Separators
Install Tine Separators
1.
CAUTION:
Approximate weight of tine separator tube assembly is 159 kg (350 lb).
H45646-UN: Tine Separator Tube
Attach hoist to tine separator and install in module frame.
2.
H45978-UN: Shaft Bearing Installation
LEGEND:
B - Nuts
C - Bearing
Install bearing (C) with retainers on shaft.
3. Install retainer flange nuts (B) to screws on top and bottom.
4. Install shaft retaining screw with washer. DO NOT TIGHTEN.
1521
Install Tine Separators
5.
H50835-UN: Gear Case Installation
LEGEND:
A - Screw (4 used)
B - Screw (4 used)
Install left gear case with U-joint on module splined shaft.
6. IMPORTANT:
For positioning of shim washers, see Install Module Drive Gear Casein Group 30.
Install hex. flange screws, flat washers, spacers and shim washers (A). DO NOT TIGHTEN.
7. Install right gear case onto U-joint at module splined shaft.
8. Install hex. flange screws, flat washers, spacers and shim washers (B). DO NOT TIGHTEN.
9. Tighten screws (A and B). Tighten to specification.
Item
Measurement Specification
Screws from Gear Case to Coupler Torque
131 N˙m
(96 lb-ft)
10.
H50834-UN: Sensor Connector, Speed Monitoring System
LEGEND:
A - Connector
B - Set Screw (2 used)
Install two set screws (B) on U-joint end fittings.
11. Connect low shaft speed monitor connector (A).
1522
Install Tine Separators
12.
H45645-UN: Shaft Bearing
LEGEND:
A - Screw
Torque shaft retaining screw (A) to specification.
Item
Measurement Specification
Tine Separator Shaft Retaining Screw Torque
318 N˙m ± 64 N˙m
(234 ± 47 lb-ft)
13.
H45644-UN: Bearing Cover
LEGEND:
A - Screws
B - Cover
C - Bolt (6 used)
Install two flat washers on screws (A).
14. Install bearing cover (B) over screws (A) and install flange nuts.
15. Install six round head bolts (C) and flange nuts.
1523
Install Tine Separators
16.
H45642-UN: Front Module Covers
LEGEND:
A - Screw (as required)
B - Front Cover
Install front module covers (B).
17. Install front cover side rail hex. flange screws (A). DO NOT TIGHTEN.
18.
H45643-UN: Center Cover Installation
LEGEND:
A - Center Covers
B - Rear Covers
C - Bolt (2 used)
Install center covers (A) and rear covers (B).
19. Install bolts through covers on side rails. DO NOT TIGHTEN.
20. Install round head bolts (C) with flange nuts.
21. Tighten all cover side rail, top seam and front and rear cover bolts.
1524
Install Tine Separators
22.
H45640-UN: Cross Brace Installation
LEGEND:
A - Bolt (2 used)
B - Cross Brace
C - Flange Screw (2 used)
Install cross brace (B).
23. Install square neck bolts (A) through cross brace center bracket to cover seam.
24. Install hex. flange screws with flange nuts (C) through top of brace (B).
Go to Section_121:Group_15
OUO6435,0001471-19-20010820
1525
Repair Tine Separators
Repair Tine Separators
NOTE:
Tine separator repair may be done without removing module from combine. Module must be in
service position for accessibility.
Go to Section_121:Group_15
HX1543,12020,CA-19-20030206
1526
Replace Tine Separator Drive Coupler
Replace Tine Separator Drive Coupler
1. Remove gear case from splined coupler. See Remove Module Drive Gear Case in this section.
2.
H55598-UN: Module Drive Coupler
LEGEND:
A - Flange Screw
B - Coupler
Remove four bolts (A) from drive coupler (B).
3. Remove drive coupler. Inspect and replace as necessary.
4. Install drive coupler (B) using four hex. flange screws (A). Tighten to specification.
Item
Measurement Specification
Drive Coupler Screws Torque
87 ± 17 N˙m
(64 ± 13 lb-ft)
5. Install module drive gear case. See Install Module Drive Gear Case in this section.
Go to Section_121:Group_15
AG,OUO1026,99-19-20030206
1527
Replace Tine Separator Flow Dividers
Replace Tine Separator Flow Dividers
H45649-UN: Flow Divider
LEGEND:
A - Bolts
B - Flow Divider
1. Remove round head bolts (A) and nuts securing flow divider (B).
2. IMPORTANT:
Some flow divider hardware may have balance weights attached. Replace balance weights EXACTLY
as removed.
Replace flow divider (B) and secure with round head bolts (A) and flange nuts. Tighten nuts to specified
torque.
Item
Measurement Specification
Round Head Bolts to Flow Divider Torque
70 ± 18 N˙m
(52 ± 13 lb-ft)
Go to Section_121:Group_15
OUO6435,0001472-19-20010820
1528
Replace Tines
Replace Tines
IMPORTANT:
If one tine is broken or worn, replace all four tines around tube to keep in balance.
1. IMPORTANT:
DO NOT MIX TINE LENGTHS.
H45650-UN: Separator Tines
LEGEND:
A - Tines
B - Lock Nut
Replace first four rows of tines (A) of feed section inside separator.
NOTE:
First four rows of tines are SHORTER than the remaining tines. LONGER tines in the
first four rows will damage separator feed section.
2. Remove flange lock nuts (B) securing tine.
3. Install tine (A) with NEW flange lock nuts (B). Torque flange lock nuts to specification.
Item
Measurement Specification
Flange Lock Nuts to Tine Torque
150 N˙m
(111 lb-ft)
1529
Replace Tines
4.
H44994-UN: Tine Dimension
LEGEND:
A - Tine Length
Check long and short tines for wear. Replace long tines if dimension (A) is less than 94 mm (3-23/32 in.)
from mounting base of tine.
Item
Measurement
Specification
Long Tines Minimum Length 94 mm (3-23/32 in.)
5. Replace short tines if dimension (A) is less than 77 mm (3 in.) from mounting base of tine.
Item
Measurement
Specification
Short Tines Minimum Length 77 mm (3 in.)
6.
H45651-UN: Separator Grate
H45652-UN: Grate Lowered
LEGEND:
1530
Replace Tines
A - Screws
B - Screws
C - Grate
Remove screws (A) through outside edge of separator grates.
7. Remove screws (B) through grates to bulkheads.
8. Swing grate (C) down.
9. Access remaining seven rows of tines.
10. Replace tines as described in Step 3.
11.
H45653-UN: Balancer Weights
LEGEND:
A - Weight
DO NOT remove balance weights (A).
12.
H45652-UN: Grate Lowered
1531
Replace Tines
H45651-UN: Grate Closed
LEGEND:
A - Screws
B - Flange Screw (2 used)
C - Grate
Swing grate (C) up.
13. Install screws (A) through outside edge of separator grates. Tighten to specification.
Item
Measurement Specification
Screws through outside edge of separator grates Torque
140 N˙m
(105 lb-ft)
14. Install screws (B) through rear grate to rear bulkhead.
15. Install lock nuts.
16. Install screws through grates and center bulkhead with flanged lock nuts.
17. Install screws through front of grate to front bulkhead with flanged lock nuts.
Go to Section_121:Group_15
OUO6435,0001473-19-20010820
1532
Replace Discharge Paddles
Replace Discharge Paddles
1.
H45656-UN: Discharge Paddles
LEGEND:
A - Wear Strip
B - Bolt (4 used)
C - Paddle
D - Bolt (5 used)
E - Bracket
Remove wear strips (A) from paddle at bolts (B).
2. Remove paddle (C) at bolts (D) from reinforcement bracket (E).
3. Install paddle (C) to tube.
4. Install reinforcement bracket (E) with leg away from tube using round head bolts (D) and flanged lock
nuts.
NOTE:
Leading edge is counterclockwise direction from rear of combine.
5. Install wear strip (A) bent edge on leading edge of paddle.
6. Install round head bolts (B) through wear strip (A) on paddle (C).
7. Install flanged lock nuts.
Go to Section_121:Group_15
OUO6435,0001474-19-20010820
1533
Module Frame and Covers
Module Frame and Covers
H50651-UN: Module Frame and Covers
LEGEND:
1 - Crop Divider
2 - Crop Divider
3 - Screw (30 used)
4 - Bracket
5 - Angle
6 - Seal
7 - Strap
8 - Module Frame (not serviceable)
1534
Module Frame and Covers
9 - Screw (as required)
10 - Flange Nut (4 used)
11 - Collar (4 used)
12 - Cap Screw (4 used)
13 - Rear Cover
14 - Cover (2 used)
15 - Cover (2 used)
16 - Front Cover
17 - Screw
18 - Angle (2 used)
19 - Stop
20 - Screw (2 used)
Go to Section_121:Group_15
OUO6435,000146B-19-20010820
1535
Discharge Beater
Discharge Beater
ZX1034913-UN: Discharge Beater
LEGEND:
A - Beater Head with Clamp (2 used)
B - Beater Head (3 used)
C - Blade (6 used)
D - Discharge Beater Shaft
Go to Section_121:Group_15
ZX08994,00002C4-19-20050126
1536
Discharge Beater Drive
Discharge Beater Drive
NOTE:
To get access to the discharge beater drive, roll out the tine separator.
ZX1034912-UN: Discharge Beater Drive
ZX1034911-UN: Discharge Beater Drive
LEGEND:
A - Pulley
B - Drive Shaft
C - Pulley
D - Guide Pulley
E - Drive Belt Tensioner
F - Side Wall
Go to Section_121:Group_15
ZX08994,00002C3-19-20050125
1537
Remove Front Feed Section Assembly
Remove Front Feed Section Assembly
1.
H45640-UN: Front Feed Section
LEGEND:
A - Screws
B - Cross Brace
C - Screws
Remove screws (A and C) from cross brace (B).
2. Remove cross brace (B).
3.
H45641-UN: Front Cover Removal
LEGEND:
A - Screws
B - Screws
C - Front Cover
D - Front Cover
Remove screws (A) retaining front cover center seam.
4. Remove screws (B) from front covers (C) and (D).
1538
Remove Front Feed Section Assembly
5.
H45642-UN: Front Cover Removal
LEGEND:
A - Screws
B - Front Cover
Remove screws (A) from side rails through front covers (B).
6. Remove front covers (B).
7.
H45665-UN: Tine Separator Removed for Clarity
LEGEND:
A - Screw (8 used)
Remove eight screws (A) from both sides of front feed section.
1539
Remove Front Feed Section Assembly
8.
H45666-UN: Front Feed Section
LEGEND:
A - Screw (2 used)
Remove two front screws (A) from front feed section to bulkhead.
9. Rotate feed section up and over tine separator from side rail.
Go to Section_121:Group_15
HX,120,SD27-19-20030206
1540
Install Front Feed Section Assembly
Install Front Feed Section Assembly
1. Install front feed section from top of tine separators.
2. Rotate feed section between module side rail and tine separator.
3.
H45665-UN: Tine Separator Removed for Clarity
LEGEND:
A - Screw (8 used)
Install eight screws (A) retaining sides of feed section. DO NOT TIGHTEN.
4.
H45667-UN: Front Feed Section
LEGEND:
A - Screw (2 used)
Install two screws (A) through feed section to front bulkhead. DO NOT TIGHTEN.
5. Adjust feed section to obtain 6 mm (0.25 in.) gap between vanes of feed section to first four rows of
separator tines at 6 o'clock position.
Item
Measurement Specification
Front Feed Section Vane Clearance
6. Tighten feed section screws.
6 mm (0.25 in.)
1541
Install Front Feed Section Assembly
6. Tighten feed section screws.
7.
H45642-UN: Front Cover Installation
LEGEND:
A - Screws
B - Front Covers
Install front module covers (B).
8. Install screws (A) through front covers to side rails.
9.
H45641-UN: Front Cover Installation
LEGEND:
A - Screws
B - Front Screws
C - Cover
1542
Install Front Feed Section Assembly
D - Cover
Install front screws (B) through covers (C and D).
10. Install screws (A) through front cover top seam.
11.
H45640-UN: Cross Brace Installation
LEGEND:
A - Screws
B - Cross Brace
C - Screws
Install module cross brace (B).
12. Install screws (A and C) to cross brace (B).
Go to Section_121:Group_15
HX,1543,12010AO-19-20030206
1543
Module Grate Assembly
Module Grate Assembly
H45673-UN: Grate Assembly - Exploded View
LEGEND:
1 - Finger Grate (4 used)
2 - Screw (as required)
3 - Filler Plate (18 used, Rice; 12 used, Grain)
4 - Finger Plate (36 used, Rice; 72 used, Grain)
5 - Screw (36 used, Grain) with Washer
6 - Housing
Go to Section_121:Group_15
OUO6435,000167D-19-20020321
1544
Remove Separator Grates
Remove Separator Grates
1.
CAUTION:
Grate can unhook from hinge bar without clips in place. Stand clear while
swinging down grates.
H45668-UN: Grate Retaining Clips
LEGEND:
A - Clip
B - Hinge Bar
Remove grate retaining clips (A) from center grate hinge bar (B).
2.
H45651-UN: Module Grate Removal
LEGEND:
A - Screws
B - Screw (2 used)
Remove two screws (B) through grates to bulkheads at front and rear of grate.
3. Remove screws (A) and spacers through outside edge of grate to module side rail.
1545
Remove Separator Grates
4.
H45652-UN: Grate Swung Down
LEGEND:
C - Grate
Swing grate (C) down.
5.
CAUTION:
Approximate weight of one grate is 44 kg (99 lb).
IMPORTANT:
Mark grates for location as they are removed. Do not mix locations of grates.
Lift grate off hinge bar.
Go to Section_121:Group_15
HX,1543,12010AT-19-20030206
1546
Install Separator Grates
Install Separator Grates
H45668-UN: Grate Retaining Clips
LEGEND:
A - Retaining Clips
B - Hinge Bar
1.
CAUTION:
Approximate weight of one grate is 44 kg (99 lb).
Lift grate and hang on center hinge bar (B).
2. Install grate retaining clips (A).
3.
H45652-UN: Grate Swung Down
1547
Install Separator Grates
H45651-UN: Grate Installation
LEGEND:
A - Screws
B - Screws
C - Grate
Swing grate (C) up.
4. Install screws (A) and spacers through outside edge of grate to module side rail. Tighten to specification.
Item
Measurement Specification
Grate to Module Side Rail Screws Torque
140 N˙m
(105 lb-ft)
5. Install two screws (B) through grates to bulkheads at front and rear of grate.
Go to Section_121:Group_15
HX,1543,12010AW-19-20030206
1548
Replace Grate Fingerbar
Replace Grate Fingerbar
1.
H45670-UN: Grate Fingerbar
LEGEND:
A - Screws
B - Filler Plates
Remove screws (A) retaining fingerbar.
2. Replace fingerbar.
3. Install screws (A). Tighten to specification.
Item
Measurement Specification
Fingerbar Screws Torque
70 ± 18 N˙m
(52 ± 14 lb-ft)
4. Do NOT remove or relocate grate filler plates (B).
Go to Section_121:Group_15
OUO6435,000146D-19-20010820
1549
Tine Separator Module Crank-Out System
Tine Separator Module Crank-Out System
H45675-UN: Crank-Out System - Exploded View
LEGEND:
1 - Snap Ring (2 used)
2 - Sprocket (2 used)
3 - Blade
4 - Screw (4 used)
5 - Spring Pin
6 - Shaft
7 - Spring Pin
8 - U-Joint
9 - Cap Screw
10 - Crank
11 - Gear
12 - Housing (4 used)
13 - Bearing (2 used)
1550
Tine Separator Module Crank-Out System
14 - Screw (6 used)
15 - Set Screw (2 used)
16 - Nut (2 used)
17 - Gear
18 - Shaft
Go to Section_121:Group_15
OUO6435,000146E-19-20010820
1551
Remove Tine Separator Module Crank-Out System
Remove Tine Separator Module Crank-Out System
1. Remove module assembly from combine as explained in this Group.
2.
H45635-UN: Crank-Out Gear
LEGEND:
A - Set Screws
B - Gear
Loosen set screws (A) on gear (B).
3.
H45632-UN: Remove Sprocket
LEGEND:
A - Snap Ring
B - Shaft
C - Sprockets
Remove snap ring (A) from BOTH ends of shaft (B).
4. Remove sprockets (C) from BOTH ends of shaft (B).
1552
Remove Tine Separator Module Crank-Out System
5.
H45630-UN: Left Side
LEGEND:
A - Bearing
B - Gear
C - Shaft
D - Plate
Remove shaft (C) from left side of module bearings (A).
6. Remove gear (B).
7. Remove shaft (C) from module.
8. Remove bearings (A) and retainers from plate (D).
9.
H45633-UN: Worm Gear
LEGEND:
A - Spring Pins
B - Shaft
C - Worm Gear
Remove spring pins (A) from shaft (B).
10. Remove shaft (B) from worm gear (C) and module assembly.
Go to Section_121:Group_15
1543TH,12015,AW-19-20030206
1553
Install Tine Separator Module Crank-Out System
Install Tine Separator Module Crank-Out System
1.
H45634-UN: Module Shaft
LEGEND:
A - Shaft
Install shaft assembly (A) to module.
2.
H45633-UN: Worm Gear
LEGEND:
A - Spring Pins
B - Shaft
C - Worm Gear
Install worm gear (C) on shaft (B) (NOTCH in worm gear to REAR of module).
3. Install spring pins (A) through shaft (B).
1554
Install Tine Separator Module Crank-Out System
4.
H45630-UN: Shaft/Gear Assembly
LEGEND:
A - Bearing
B - Gear
C - Shaft
D - Plate
Install both bearings (A) and retainers on INSIDE of plates (D).
5. Install shaft (C) through left bearing.
6. Install gear (B) on shaft (C) with set screws to the INSIDE of module.
7.
H45632-UN: Right Side
LEGEND:
A - Snap Ring
B - Shaft
C - Sprocket
Install right sprocket (C) on shaft (B).
8. Install snap ring (A).
9. Move shaft (B) to the left until sprocket is tight against bearing race.
1555
Install Tine Separator Module Crank-Out System
10.
H45631-UN: Gear Installation
LEGEND:
A - Gear
Move gear (A) to the right until tight against bearing race.
11.
H45635-UN: Gear Assembly
LEGEND:
A - Set Screws
B - Gear
Tighten set screws (A) on gear (B).
12.
1556
Install Tine Separator Module Crank-Out System
H45629-UN: Sprocket Installation
LEGEND:
A - Sprocket
B - Shaft
C - Snap Ring
Install left sprocket (A) in time with right sprocket on shaft (B).
13. Install snap ring (C) on shaft.
Go to Section_121:Group_15
TM1543,HX10,F-19-20030206
1557
Specifications
Specifications
Item
Measurement Specification
Output Bearings of Module Gear Case
Axial Play
0.02 to 0.09 mm
(0.0008 to 0.0035 in.)
Module Gear Case Bevel Gears
Backlash
0.20 to 0.40 mm
(0.008 to 0.016 in.)
Module Gear Case Input Shaft Bearings Axial Play
0.04 to 0.12 mm
(0.0016 to 0.0048 in.)
Module Gear Case Cover Cap Screws
Torque
35 N˙m
(25 lb-ft)
Module Drive Gear Case
Capacity
2.2 L
(2.3 qt)
Gear Case Cap Screws
Torque
130 N˙m
(96 lb-ft)
Module Gear Case U-Joint Cap Screws Torque
100 N˙m
(74 lb-ft)
Go to Section_121:Group_20
OUO6435,0001491-19-20010821
1558
Specifications
Specifications
Item
Measurement Specification
Output Bearings of Module Gear Case
Axial Play
0.02 to 0.09 mm
(0.0008 to 0.0035 in.)
Module Gear Case Bevel Gears
Backlash
0.20 to 0.40 mm
(0.008 to 0.016 in.)
Module Gear Case Input Shaft Bearings Axial Play
0.04 to 0.12 mm
(0.0016 to 0.0048 in.)
Module Gear Case Cover Cap Screws
Torque
35 N˙m
(25 lb-ft)
Module Drive Gear Case
Capacity
2.2 L
(2.3 qt)
Gear Case Cap Screws
Torque
130 N˙m
(96 lb-ft)
Module Gear Case U-Joint Cap Screws Torque
100 N˙m
(74 lb-ft)
Go to Section_121:Group_20
OUO6435,0001491-19-20010821
1559
Module Drive Gearcase, Shaft and Coupling
Module Drive Gearcase, Shaft and Coupling
ZX25285-UN: Gearcase Mounting
LEGEND:
1 - Sensor
2 - Clamp
3 - Flange Nut (4 used)
4 - Shield (2 used)
5 - Gearcase, Right
6 - Screw (8 used)
7 - Washer (8 used)
8 - Spacer (8 used)
1560
Module Drive Gearcase, Shaft and Coupling
9 - Fitting (2 used)
10 - Coupling (2 used)
11 - Threaded Nipple (2 used)
12 - Elbow Fitting (2 used)
13 - Wiring Harness
14 - U-Joint Drive Assembly
15 - Washer
16 - Gearcase, Left
17 - U-Joint Yoke
18 - Cap Screw (3 used)
19 - Screw (4 used)
20 - Shield (2 used)
21 - Pipe Bushing (2 used)
22 - Bushing (2 used)
Go to Section_121:Group_20
OUO6046,0001550-19-20010727
1561
Module Drive Gear Case
Module Drive Gear Case
H58864-UN: Gear Case
LEGEND:
1 - Output Shaft
2 - Snap Ring (2 used)
3 - Seal
4 - Shim
5 - Bearing Cup
6 - Bearing Cone
7 - Snap Ring
8 - Pinion (18-Tooth)
1562
Module Drive Gear Case
9 - Bearing Cone
10 - Bearing Cup
11 - Shim
12 - Snap Ring (2 used)
13 - Seal
14 - Shaft With Gear (35-Teeth)
15 - Bearing Cone
16 - Bearing Cup
17 - Bearing Cup
18 - Bearing Cone
19 - Shim
20 - Washer
21 - Snap Ring
22 - Seal
23 - Housing
24 - Cover
25 - Plug
26 - Plug (2 used)
27 - Cap Screw (10 used)
Go to Section_121:Group_20
ZX08994,00002C0-19-20050125
1563
Remove Module Drive Gear Case
Remove Module Drive Gear Case
1.
H58794-UN: Drive Assembly
LEGEND:
A - Cap Screw (3 used)
B - Drive Assembly
Remove cap screws (A) and drive assembly (B).
2.
H55543-UN: Gear Case Drives
LEGEND:
A - Cap Screw (6 used)
B - Channel
C - Harness Connector for Speed Monitoring System
D - Coupling (2 used)
Remove cap screws (A) from couplings (D).
3. Disconnect connector (C) of speed monitoring system sensor.
4. Remove channel (B).
5.
CAUTION:
Approximate weight of one gear case is 38 kg (84 lb).
1564
Remove Module Drive Gear Case
H58818-UN: Module Gear Case Mounting
LEGEND:
A - Cap Screw (8 used)
Remove cap screws (A) to remove right or left gear case.
Go to Section_121:Group_20
AG,OUO6045,112-19-19990713
1565
Disassemble Module Drive Gear Case
Disassemble Module Drive Gear Case
IMPORTANT:
Make sure all shims, bearings and snap rings are installed in the same location as removed. Failure to do so
could result in gear case failure.
1.
H55638-UN: Left Module Gear Case
LEGEND:
A - Plug
B - Cap Screw (10 used)
Remove gear case from module and move to bench. See Remove Module Drive Gear Case in this
group.
2. Remove pipe plug (A) and drain oil.
Item
Measurement Specification
Module drive gear case Capacity
2.2 L
(2.3 qt)
3. Remove cap screws (B) and cover.
4.
H55639-UN: Speed Sensor Bracket
LEGEND:
A - Shield
B - Cap Screw (4 used)
Remove dust shield (A) by removing two round head bolts.
1566
Disassemble Module Drive Gear Case
5. Remove four cap screws (B) and sensor mounting bracket.
6.
H55640-UN: Gear Case Snap Rings
LEGEND:
A - Snap Ring
B - Seal
Remove snap ring (A) and seals (B) from both sides of gear case.
7.
H55642-UN: Left Gear Case
LEGEND:
A - Snap Ring (4 used)
B - Seal (2 used)
C - Shim (as required)
D - Bearing Cup (2 used)
E - Bearing Cone (2 used)
F - Shaft
Remove snap ring (A) and shims (C) from input shaft.
8.
1567
Disassemble Module Drive Gear Case
H55643-UN: Left Gear Case
LEGEND:
A - Input Shaft
B - Snap Ring
C - Bevel Gear
Remove shaft (A) from gear case. Slide shaft with left bearing cup, cone and snap ring (B) from left side
of gear case. Remove bevel gear (C). Right bearing cup, shims and snap ring will remain in housing.
9.
H55754-UN: Sectional View
LEGEND:
A - Output Gear Shaft
B - Seal
C - Snap Ring
D - Shim
E - Shim
F - Bearing Cups
G - Bearing Cone
H - Bearing Cone
Remove seal (B), snap ring (C), shim (D) and shims (E) from outer end of output shaft.
10. Remove bevel gear shaft (A) with inner bearing cone (G) by pressing shaft towards open end of gear
case.
1568
Disassemble Module Drive Gear Case
11. Remove bearing cone (H) and cups (F).
Go to Section_121:Group_20
ZX08994,00002C2-19-20050125
1569
Assemble Module Drive Gear Case
Assemble Module Drive Gear Case
1.
H55754-UN: Sectional View
LEGEND:
A - Gear Shaft
B - Seal
C - Snap Ring
D - Shim
E - Shim
F - Bearing Cups
G - Bearing Cone
H - Bearing Cone
Install bearing cups (F) in gear case.
2. Install bearing cone (G) on bevel gear shaft.
3. Install bevel gear shaft with bearing in gear case.
4. Install bearing cone (H) on output end of bevel gear shaft.
5. Install shims (E), shim (D) and snap ring (C) on shaft. Seat snap ring and shims against bearing.
6. Adjust output shaft bearing end play to specification. Add or remove shims between snap ring, shim
washer and bearing cone as required.
1570
Assemble Module Drive Gear Case
Item
Measurement Specification
Output Bearings of Module Gear Case Axial Play
0.02 to 0.09 mm
(0.0008 to 0.0035 in.)
7. Coat oil seal lip with TY6296 80W/90 GL5 Gear Lube. Install seal flush with case with seal lip facing
bearing. Protect seal lip from damage during assembly.
8.
H55644-UN: Input Shaft
LEGEND:
A - Groove
B - Snap Ring
Install snap ring (B) on input shaft groove (A).
9.
H55643-UN: Gear Case Snap Ring
LEGEND:
A - Shaft
B - Snap Ring
C - Gear
Install shaft (A).
10.
NOTE:
Make sure that bevel gear is tight against snap ring (B) and bearing cone is tight against
gear.
1571
Assemble Module Drive Gear Case
Install bevel gear (C) on shaft splines against snap ring (B).
11.
H55642-UN: Left Gear Case
LEGEND:
A - Snap Ring
B - Seal
C - Shim
D - Bearing Cup
E - Bearing Cone
F - Shaft
Install bearing cones (E) on shaft. Bearing taper MUST be toward outside of gear case.
12. Position shaft with bearings in housing and install bearing cups (D) in both bores of gear case.
13. Install shim (C) in right bore against bearing cup (D). Begin with 1.25 mm (0.049 in.) thickness or original
shim removed. DO NOT use plastic shims against snap ring.
NOTE:
Gear backlash and bearing preload should be correct if ALL snap rings, bearings and
shims are assembled in original positions.
14. Install snap ring (A) into right bore. Be sure bearing cup (D), shim (C) and snap ring (A) on right side are
in contact.
15. Install shim (C) in left bore of gear case. Begin with 1.25 mm (0.049 in.) thickness or original shim
removed. DO NOT use plastic shim against snap ring.
16. Install snap ring (A) in left bore. Be sure cup (D), shim (C) and snap ring (A) are in contact. Shims (C) at
small bevel gear end of shaft are used to adjust gear backlash. Shims on opposite end are used to
adjust bearing end play.
1572
Assemble Module Drive Gear Case
17.
H55770-UN: Dial Indicator
LEGEND:
A - Shaft
B - Bevel Gear
Check that bearing cones are seated against step in shaft (A) and against bevel gear (B).
18. Check gear backlash with dial indicator. Adjust backlash to specification by adding or removing shims at
bearing next to small bevel gear.
Item
Measurement Specification
Module Gear Case Bevel Gears Backlash
0.20 to 0.40 mm
(0.008 to 0.016 in.)
H55771-UN: Gear Case
LEGEND:
A - Shim
IMPORTANT:
Bevel gear backlash must be set before input shaft end play is set. Failure to do so could result in
premature gear case failure.
Adjust input shaft bearing end play to specification.
Item
Measurement Specification
Module Gear Case Input Shaft Bearings Axial Play
0.04 to 0.12 mm
(0.0016 to 0.0048 in.)
Add or remove shims (A) at bearing away from small bevel gear. Adjusting backlash will change bearing
end play. Therefore, backlash has to be adjusted first. Final adjustment of bearing end play must be
done after setting gear backlash.
1573
Assemble Module Drive Gear Case
19.
H55640-UN: Gear Case Seal
LEGEND:
A - Snap Ring
B - Seal
Coat oil seal lips with TY6296 80W/90 Gear Lube. Install all seals (B) with a seal driver. Tape shaft
splines to protect seal lips from damage during assembly.
20. Install snap rings (A) to retain seals.
21.
H55639-UN: Sensor Bracket
LEGEND:
A - Shield
B - Cap Screw (4 used)
Install shield mounting bracket over output shaft on gear case using four cap screws (B).
22. Install dust shield (A) to mounting bracket with two round head bolts.
1574
Assemble Module Drive Gear Case
23.
H55638-UN: Gear Case Drain Plug
LEGEND:
A - Drain Plug
B - Cap Screw
Apply a 6 mm (1/4 in.) bead of TY15130 Form-in-Place gasket to gear case cover flange.
24. Install cover with offset vent hole to the top.
25. Install cap screws (B) through cover and tighten to specification.
Item
Measurement Specification
Module Gear Case Cover Cap Screws Torque
35 N˙m
(25 lb-ft)
26. Seal drain plug (A) with TY9374 sealant and install.
27. Fill gear case with TY6296 80W/90 GL5 gear lube as specified.
Item
Measurement Specification
Module drive gear case Capacity
2.2 L
(2.3 qt)
Go to Section_121:Group_20
ZX08994,00002C1-19-20050125
1575
Install Module Drive Gear Case
Install Module Drive Gear Case
1.
H58818-UN: Gear Case Mounting
LEGEND:
A - Cap Screw (8 used)
Install spacers and U-joint drive assemblies on gear cases before installing.
2. Position gear case assembly to tine separator module drive couplers and install bushings, washers and
cap screws (A) and tighten to specification.
Item
Measurement Specification
Gear Case Cap Screws Torque
130 N˙m
(96 lb-ft)
3.
H55543-UN: Gear Case Mounting
LEGEND:
A - Cap Screw (6 used)
B - Channel
C - Harness Connector for Speed Monitoring System
D - U-Joint Flange
Install channel (B).
4. Connect harness (C).
5. Position U-joint flanges (D) and install cap screws (A). Tighten cap screws to specification.
1576
Install Module Drive Gear Case
Item
Measurement Specification
Module Gear Case U-Joint Flange Cap Screws Torque
100 N˙m
(74 lb-ft)
6.
H58794-UN: Drive Assembly
LEGEND:
A - Cap Screw (3 used)
B - U-Joint
Align U-joint assembly (B) and install cap screws (A). Tighten cap screws to specification.
Item
Measurement Specification
Module Gear Case U-Joint Cap Screws Torque
100 N˙m
(74 lb-ft)
Go to Section_121:Group_20
AG,OUO6045,111-19-20030206
1577
Shaker Pan Exploded View
Shaker Pan Exploded View
H58998-UN: Shaker Pan Exploded View
LEGEND:
A - Nut (5 used)
B - Arm (2 used)
C - Screw (10 used)
D - Screw (2 used)
E - Sheet
F - Washer (7 used)
G - Flange Nut (7 used)
H - Screw (7 used)
I - Seal
J - Nut (4 used)
K - Screw (2 used)
L - Arm
M - Grain Pan
N - Nut (10 used)
1578
Shaker Pan Exploded View
O - Lock Nut (10 used)
P - Retainer (2 used)
Q - Sheet
Go to Section_121:Group_25
HX,120,SD71-19-20030206
1579
Shaker Pan Exploded View
Shaker Pan Exploded View
H58998-UN: Shaker Pan Exploded View
LEGEND:
A - Nut (5 used)
B - Arm (2 used)
C - Screw (10 used)
D - Screw (2 used)
E - Sheet
F - Washer (7 used)
G - Flange Nut (7 used)
H - Screw (7 used)
I - Seal
J - Nut (4 used)
K - Screw (2 used)
L - Arm
M - Grain Pan
N - Nut (10 used)
1580
Shaker Pan Exploded View
O - Lock Nut (10 used)
P - Retainer (2 used)
Q - Sheet
Go to Section_121:Group_25
HX,120,SD71-19-20030206
1581
Remove and Install Straw Chopper
Remove and Install Straw Chopper
1.
ZX1034898-UN: Straw Chopper Tensioner
LEGEND:
A - Lock Nut
B - Adjusting Nut
C - Washer
D - Gauge
Relieve belt tension.
2.
ZX1034899-UN: Chopper Belt
ZX1034900-UN: Sensor
LEGEND:
E - Belt
F - Sensor Connector
Remove drive belt (E).
1582
Remove and Install Straw Chopper
3. Disconnect sensor connector (F).
4.
ZX1034918-UN: Intermediate Panel
Remove intermediate panel (A).
CAUTION:
5.
Straw chute is heavy. Two persons are required to remove it.
ZX1034920-UN: Straw Chute
ZX1034921-UN: Rod
LEGEND:
C - Spring Pin
D - Rod
1583
Remove and Install Straw Chopper
E - Straw Chute
Remove spring pin (C) and pull rod (D) to the left to unhook and remove straw chute (E).
6.
ZX1034919-UN: Tailboard
Loosen screw (B) on left and right side and remove chopper tailboard (F).
7.
CAUTION:
The approximate weight of straw chopper is 160 kg (350 lb).
ZX1034922-UN: Straw Chopper
Attach suitable lifting device to chopper.
Loosen screws (G) and lower straw chopper to the ground.
Go to Section_121:Group_30
ZX08994,00002CA-19-20050128
1584
Remove and Install Straw Chopper
Remove and Install Straw Chopper
1.
ZX1034898-UN: Straw Chopper Tensioner
LEGEND:
A - Lock Nut
B - Adjusting Nut
C - Washer
D - Gauge
Relieve belt tension.
2.
ZX1034899-UN: Chopper Belt
ZX1034900-UN: Sensor
LEGEND:
E - Belt
F - Sensor Connector
Remove drive belt (E).
1585
Remove and Install Straw Chopper
3. Disconnect sensor connector (F).
4.
ZX1034918-UN: Intermediate Panel
Remove intermediate panel (A).
CAUTION:
5.
Straw chute is heavy. Two persons are required to remove it.
ZX1034920-UN: Straw Chute
ZX1034921-UN: Rod
LEGEND:
C - Spring Pin
D - Rod
1586
Remove and Install Straw Chopper
E - Straw Chute
Remove spring pin (C) and pull rod (D) to the left to unhook and remove straw chute (E).
6.
ZX1034919-UN: Tailboard
Loosen screw (B) on left and right side and remove chopper tailboard (F).
7.
CAUTION:
The approximate weight of straw chopper is 160 kg (350 lb).
ZX1034922-UN: Straw Chopper
Attach suitable lifting device to chopper.
Loosen screws (G) and lower straw chopper to the ground.
Go to Section_121:Group_30
ZX08994,00002CA-19-20050128
1587
Chopper and Blades
Chopper and Blades
ZX1034915-UN: Chopper Rotor
LEGEND:
A - Chopper Rotor
B - Blades
C - Washers
D - Bushings
E - Screw
Go to Section_121:Group_30
ZX08994,00002F0CONV1-19-20050323
1588
Remove and Install Rotor Bearings
Remove and Install Rotor Bearings
ZX25187-UN: Rotor Bearings
LEGEND:
A - Guard
B - Felt Seal
C - Bearing Support
D - Clamping Ring
E - Bearing
F - Lock Washer
G - Slotted Nut
H - Bearing Cap
1. Remove bearing cap (H) and felt seal (B).
2. Loosen slotted nut (G) and clamping ring (D).
3. Remove bearing support (C) with bearing (E).
4. Inspect bearing (E) and replace, if necessary.
5. Install in reverse order.
1589
Remove and Install Rotor Bearings
Go to Section_121:Group_30
OUO6089,0000050CONV1-19-20010629
1590
Chopper Housing and Knife Bank
Chopper Housing and Knife Bank
ZX1034916-UN: Straw Chopper
LEGEND:
A - Straw Chopper Housing
B - Knife Sections
C - Intermediate Panel
D - Cover
E - Flap
F - Console
Go to Section_121:Group_30
ZX08994,00002CB-19-20050204
1591
Replace Knife Sections
Replace Knife Sections
ZX25268-UN: Chopper Blades
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (6 used)
C - Shield
CAUTION:
Engine must be off and key removed.
1. Remove right and left cap screw (A) and pull frame rearward.
2. Remove hardware on left side and pull frame out.
3.
CAUTION:
Knife sections are sharp.
Remove cap screw (B) and shield (C).
Go to Section_121:Group_30
OUO6435,000167B-19-20020321
1592
Remove and Install Straw Chopper Idler Assembly
Remove and Install Straw Chopper Idler Assembly
ZX25178-UN: Chopper Idler Assembly
LEGEND:
1 - Flange Nut
2 - Idler
3 - Screw
4 - Cap Screw
5 - Pin
6 - Pivot
7 - Gauge
8 - Spring
9 - Washer
10 - Nut (2 used)
11 - Cap Screw
12 - Washer
13 - Snap Ring
14 - Washer
15 - Flange Nut
16 - Pulley
17 - Belt
18 - Bushing
19 - Seal
20 - Arm
1593
Remove and Install Straw Chopper Idler Assembly
1.
ZX25174-UN: Rear Drive
LEGEND:
A - Nuts (2 used)
B - Belt
Loosen nuts (A).
2. Remove belt (B).
3.
H51887-UN: Front Drive
LEGEND:
A - Snap Ring
B - Idler Assembly
Remove snap ring (A) and chopper idler assembly (B).
4. Inspect all parts. Replace parts as necessary.
5.
1594
Remove and Install Straw Chopper Idler Assembly
H40481-UN: Housing
LEGEND:
A - Seals
B - Bushings
Install new bushings (B) flush with edge of chamfer in housing. Bushings are a press fit.
6. Install seals (A) with lips facing out. Seals are a press fit.
7. Apply TY6341 Multipurpose SD Polyurea Grease to inner circumference of bushings and between
bushings.
8. Install in reverse order.
Go to Section_121:Group_30
OUO6089,000001ECONV1-19-20010618
1595
Table of Contents
Section 122: Separator - T Series
Group 01: Common Separator Components
Common Separator Components
Group 10: Separator Components and Separator Drive
Separator Components
Separator Drive
Group 30: Straw Walker Drive
Remove Straw Walker Drive
Disassemble and Assemble Straw Walker Gearcase
Install Straw Walker Drive
Group 60: Remove and Install Beater Grate
Remove Beater Grate
Install Beater Grate
Group 65: Remove and Install Beater
Remove and Install Beater
Remove Speed Sensor (Left Side)
Remove Locking Collar
Remove Beater Pulley (Right Side)
Remove Hub and Speed Sensor (Right Side)
Disassemble Beater
Remove Bearing
Remove Shaft
Install Beater
Group 70: Remove and Install Separator Rotor
Remove and Install Separator Rotor
Measure Distance from Pulley to Sidewall
Remove Pulley (Left Side)
Remove Pulley (Right Side)
Remove Hub
Remove Finger Bars and Retaining Plates
Loosen Segment Clamping Screws
Remove Bearings
1596
Table of Contents
Install Separator Rotor
Group 75: Remove and Install Separator Grate
Remove and Install Separator Grate
Remove Finger Bars of Separator Rotor
Remove Separator Grate Inserts
Position Separator Grate
Lift Out Separator Grate
Install and Adjust Separator Grate
Group 80: Remove and Install Overshot Beater
Remove and Install Overshot Beater
Remove Pulley
Remove Gearcase
Disassemble Overshot Beater
Remove Locking Collar (Right Side)
Install Overshot Beater
Group 85: Remove and Install Stripper Roll
Remove and Install Stripper
Remove Pulley
Remove Locking Collar (Right Side)
Remove stripper from the front
Stripper Roll, Exploded View
Install Stripper
1597
Common Separator Components
Common Separator Components
The following separator components are almost identical with those of the W series:
Cylinder drives
Straw walkers
Walker return pan
Front and rear crankshaft
Walker drive and gearcase
Straw chopper and chaff spreader
Shoe supply augers, cleaning fan, chaffer and sieve frame
Tailings elevator and auger
Primary countershaft gear case
Header electromagnetic clutch
For repair instructions, see Section 120 (Separator - W Series).
Go to Section_122:Group_01
ZX09263,00027C4-19-20080303
1598
Common Separator Components
Common Separator Components
The following separator components are almost identical with those of the W series:
Cylinder drives
Straw walkers
Walker return pan
Front and rear crankshaft
Walker drive and gearcase
Straw chopper and chaff spreader
Shoe supply augers, cleaning fan, chaffer and sieve frame
Tailings elevator and auger
Primary countershaft gear case
Header electromagnetic clutch
For repair instructions, see Section 120 (Separator - W Series).
Go to Section_122:Group_01
ZX09263,00027C4-19-20080303
1599
Separator Components
Separator Components
ZX1041278-UN: Separator Components
LEGEND:
A - Threshing Cylinder
B - Stripper
C - Overshot Beater
D - Separator Rotor
E - Concave
F - Beater Cover (Bottom)
G - Separator Grate
H - Beater Grate
I - Beater Grate Adjusting Lever
J - Separator Grate Adjusting Lever
K - Beater
L - Straw Walkers
M - Curtain
N - Walker Return Pan
O - Cleaning Shoe
P - Precleaner
Q - Feeding Auger
Go to Section_122:Group_10
ZX08798,000065E-19-20080219
1600
Separator Components
Separator Components
ZX1041278-UN: Separator Components
LEGEND:
A - Threshing Cylinder
B - Stripper
C - Overshot Beater
D - Separator Rotor
E - Concave
F - Beater Cover (Bottom)
G - Separator Grate
H - Beater Grate
I - Beater Grate Adjusting Lever
J - Separator Grate Adjusting Lever
K - Beater
L - Straw Walkers
M - Curtain
N - Walker Return Pan
O - Cleaning Shoe
P - Precleaner
Q - Feeding Auger
Go to Section_122:Group_10
ZX08798,000065E-19-20080219
1601
Separator Drive
Separator Drive
ZX1041277-UN: Separator Drive
LEGEND:
A - Threshing Cylinder
B - Stripper
C - Overshot Beater
D - Separator Rotor
E - Beater
F - Beater Drive (gearcase)
G - Straw Walker Drive (gearcase)
H - Drive Shaft (PTO transmission)
I - Bevel Gear Drive
Go to Section_122:Group_10
ZX08798,000065F-19-20080130
1602
Remove Straw Walker Drive
Remove Straw Walker Drive
NOTE:
The straw walker gear case is lubricated for life and is not vented. Gear case is lubricated with
corn head grease. If disassembled for repair, repack using 414 mL (14 oz.) of AN102562 Corn
Head Grease.
ZX1041521-UN: Straw Walker Drive
LEGEND:
A - Straw Walker Drive
Remove cap screws (A) (3 used). Remove guard (B).
ZX1041525-UN: Guard, Straw Walker Housing
LEGEND:
A - Cap Screws (3 used)
B - Guard
1603
Remove Straw Walker Drive
ZX1041526-UN: Belt Tensioner, Straw Walker Gearcase
LEGEND:
A - Hex. Nut
B - Belt Tensioner
C - V-Belt
D - Pulley
Loosen hex. nut (A) and slacken belt tensioner (B). Remove V-belt (C) from pulley (D).
Loosen clamping screw (A) at pulley and remove pulley (B).
ZX1041524-UN: Pulley, Straw Walker Gearcase
LEGEND:
A - Clamping Screw
B - Pulley
Remove cap screw (A) from bracket (B).
ZX1041523-UN: Bracket, Straw Walker Gearcase
LEGEND:
A - Cap Screw
B - Bracket
Remove attaching screw (A) from drive shaft and remove straw walker gearcase (B) from walker drive shaft (C).
1604
Remove Straw Walker Drive
ZX1041522-UN: Attaching screw, straw walker gearcase
LEGEND:
A - Attaching Screw
B - Walker Gearcase
ZX1041520-UN: Walker drive shaft
LEGEND:
C - Walker Drive Shaft
Go to Section_122:Group_30
ZX08798,000066B-19-20080226
1605
Remove Straw Walker Drive
Remove Straw Walker Drive
NOTE:
The straw walker gear case is lubricated for life and is not vented. Gear case is lubricated with
corn head grease. If disassembled for repair, repack using 414 mL (14 oz.) of AN102562 Corn
Head Grease.
ZX1041521-UN: Straw Walker Drive
LEGEND:
A - Straw Walker Drive
Remove cap screws (A) (3 used). Remove guard (B).
ZX1041525-UN: Guard, Straw Walker Housing
LEGEND:
A - Cap Screws (3 used)
B - Guard
1606
Remove Straw Walker Drive
ZX1041526-UN: Belt Tensioner, Straw Walker Gearcase
LEGEND:
A - Hex. Nut
B - Belt Tensioner
C - V-Belt
D - Pulley
Loosen hex. nut (A) and slacken belt tensioner (B). Remove V-belt (C) from pulley (D).
Loosen clamping screw (A) at pulley and remove pulley (B).
ZX1041524-UN: Pulley, Straw Walker Gearcase
LEGEND:
A - Clamping Screw
B - Pulley
Remove cap screw (A) from bracket (B).
ZX1041523-UN: Bracket, Straw Walker Gearcase
LEGEND:
A - Cap Screw
B - Bracket
Remove attaching screw (A) from drive shaft and remove straw walker gearcase (B) from walker drive shaft (C).
1607
Remove Straw Walker Drive
ZX1041522-UN: Attaching screw, straw walker gearcase
LEGEND:
A - Attaching Screw
B - Walker Gearcase
ZX1041520-UN: Walker drive shaft
LEGEND:
C - Walker Drive Shaft
Go to Section_122:Group_30
ZX08798,000066B-19-20080226
1608
Disassemble and Assemble Straw Walker Gearcase
Disassemble and Assemble Straw Walker Gearcase
NOTE:
See Disassemble and Assemble Straw Walker Gearcase in Section 120, Group 15.
Go to Section_122:Group_30
ZX08798,000066C-19-20080221
1609
Install Straw Walker Drive
Install Straw Walker Drive
For installation of straw walker drive, reverse removal procedure.
Go to Section_122:Group_30
ZX08798,000066E-19-20080226
1610
Remove Beater Grate
Remove Beater Grate
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
CAUTION:
Place a thick tarpaulin, plywood or cardboard on the straw walkers. This is necessary to
avoid injuries when repairing beater and beater grate (some of the work must be
performed lying down).
Open the straw hood door (access via rear platform).
ZX1041327-UN: Straw hood door
ZX1041328-UN: Beater grate, eyebolt (center)
LEGEND:
A - Eyebolt (center)
Cover the straw walkers as described above and enter the machine.
Loosen three eyebolts (left, center, right) on the beater.
1611
Remove Beater Grate
ZX1041329-UN: Beater grate, eyebolt (left)
LEGEND:
A - Eyebolt (left)
Remove nuts on both sides.
Lift out the beater grate over the straw walkers.
Go to Section_122:Group_60
ZX08798,0000663-19-20080206
1612
Remove Beater Grate
Remove Beater Grate
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
CAUTION:
Place a thick tarpaulin, plywood or cardboard on the straw walkers. This is necessary to
avoid injuries when repairing beater and beater grate (some of the work must be
performed lying down).
Open the straw hood door (access via rear platform).
ZX1041327-UN: Straw hood door
ZX1041328-UN: Beater grate, eyebolt (center)
LEGEND:
A - Eyebolt (center)
Cover the straw walkers as described above and enter the machine.
Loosen three eyebolts (left, center, right) on the beater.
1613
Remove Beater Grate
ZX1041329-UN: Beater grate, eyebolt (left)
LEGEND:
A - Eyebolt (left)
Remove nuts on both sides.
Lift out the beater grate over the straw walkers.
Go to Section_122:Group_60
ZX08798,0000663-19-20080206
1614
Install Beater Grate
Install Beater Grate
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
CAUTION:
Place a thick tarpaulin, plywood or cardboard on the straw walkers. This is necessary to
avoid injuries when repairing beater and beater grate (some of the work must be
performed lying down).
For installation, follow removal procedure in reverse order.
1. Move beater grate into the machine over the straw walkers.
2. Move beater to correct position and attach to support using nuts (A).
ZX1041329-UN: Beater grate, nut
LEGEND:
A - Nut
Go to Section_122:Group_60
ZX08798,0000664-19-20080214
1615
Remove and Install Beater
Remove and Install Beater
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
CAUTION:
Place a thick tarpaulin, plywood or cardboard on the straw walkers. This is necessary to
avoid injuries when repairing beater (some of the work must be performed lying down).
NOTE:
For better access to the beater, removal of center straw walkers is recommended, but this is not
absolutely necessary.
Go to Section_122:Group_65
ZX61739,00002F0-19-20080211
1616
Remove and Install Beater
Remove and Install Beater
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
CAUTION:
Place a thick tarpaulin, plywood or cardboard on the straw walkers. This is necessary to
avoid injuries when repairing beater (some of the work must be performed lying down).
NOTE:
For better access to the beater, removal of center straw walkers is recommended, but this is not
absolutely necessary.
Go to Section_122:Group_65
ZX61739,00002F0-19-20080211
1617
Remove Speed Sensor (Left Side)
Remove Speed Sensor (Left Side)
ZX1041644-UN: Remove speed sensor
LEGEND:
A - Sensor Wheel
B - Sensor
C - Hose Clamp
Remove sensor wheel (A), speed sensor (B) and hose clamp (C).
Go to Section_122:Group_65
ZX61739,00002E7-19-20080227
1618
Remove Locking Collar
Remove Locking Collar
ZX1041645-UN: Remove Locking Collar
LEGEND:
A - Locking Collar
B - Nut
Z - Distance
Measure distance (Z) from shaft end to sidewall and remove locking collar (A).
Item
Measurement Specification
Bearing shell nut (B) Torque
80 N•m
(59 lb-ft)
Go to Section_122:Group_65
ZX61739,00002EA-19-20080228
1619
Remove Beater Pulley (Right Side)
Remove Beater Pulley (Right Side)
ZX1041646-UN: Remove Pulley
LEGEND:
A - Belt
B - Screws (3 used)
C - Pulley
Remove belt (A) from pulley (C). Remove screws (B) (3 used) and pulley (C).
Item
Measurement Specification
Pulley Screw (B) Torque
73 N•m
(54 lb-ft)
Go to Section_122:Group_65
ZX61739,00002EB-19-20080222
1620
Remove Hub and Speed Sensor (Right Side)
Remove Hub and Speed Sensor (Right Side)
ZX1041647-UN: Remove hub and speed sensor
LEGEND:
A - Clamping Screw
B - Hub
C - Speed Sensor
D - Locking Collar
X - Distance
Measure distance (X) from hub (B) to sidewall. Loosen clamping screw (A) and remove hub (B) and speed sensor
(C).
Item
Measurement Specification
Clamping screw (A) Torque
73 N•m
(54 lb-ft)
Go to Section_122:Group_65
ZX61739,00002EC-19-20080221
1621
Disassemble Beater
Disassemble Beater
ZX1041280-UN: Stripper
LEGEND:
A - Stripper
Remove beater stripper (A).
ZX1041287-UN: Beater filler plates
LEGEND:
A - Clamping Screw
B - Key
C1 - Cap Screw
C2 - Cap Screw
D - Screw
E - Beater Filler Plates
F - Shaft
G - Segment
After removing beater filler plates (E), loosen clamping screws (A) (both sides of beater) and remove key (B).
Instructions for beater assembly
1622
Disassemble Beater
ZX1041653-UN: Assemble beater
LEGEND:
A - Clamping Screw
B - Key
C1 - Cap Screw
C2 - Cap Screw
E - Beater Filler Plates
F - Shaft
G - Segments
To ensure true running of the beater, always install beater filler plates (E) in pairs (1 and 1, 3 and 3). First tighten
cap screws (C1), then tighten cap screws (C2). When four of the eight beater filler plates (E) are installed, center
the beater between the sidewalls and tighten clamping screws (A). Afterwards install the remaining beater filler
plates and tighten screws (C1) and (C2).
Item
Measurement Specification
Screws (C1 and C2), beater filler plates Torque
50 N•m
(37 lb-ft)
Segment clamping screw (A)
87 N•m
(64 lb-ft)
Torque
IMPORTANT:
Beater filler plates must not touch the strippers. Adjust if needed.
NOTE:
The beater does not require balance weights and will not require balancing.
Go to Section_122:Group_65
ZX61739,00002E9-19-20080229
1623
Remove Bearing
Remove Bearing
ZX1041648-UN: Remove Bearing
LEGEND:
B - Nut (4 used)
D - Locking Collar
Remove locking collar (D) and nuts (B).
Item
Measurement Specification Number Name
Bearing Torque
shell
nut (B)
80 N•m
(59 lb-ft)
PT507
(U.S.)
Use
Multi-Purpose Grease (Lithium- Grease all bearing surfaces
Saponified)
and seals.
Go to Section_122:Group_65
ZX61739,00002ED-19-20080130
1624
Remove Shaft
Remove Shaft
ZX1041649-UN: Remove Shaft
ZX1041650-UN: Segments
LEGEND:
A - Shaft
B - Segments
Pull out shaft (A) from the right side. A second person is required to remove segments (B) from shaft (A).
Go to Section_122:Group_65
ZX61739,00002EE-19-20080212
1625
Install Beater
Install Beater
For installation reverse removal procedure.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Slide the shaft into machine from the right side.
Slide the segments on the shaft and insert the keys.
Install bearings on both sides.
Adjust distance (Z) from shaft end to sidewall and install the locking collar.
Re-install and adjust the speed sensor (left side)
Install the locking collar on right side.
Install speed sensor, adjust hub to obtain specified distance (X) to sidewall and tighten.
Install the pulley.
Install two pairs of beater filler plates and center the beater between the sidewalls. Check beater for true
running.
10. Tighten the clamping screws.
11. Install and tighten remaining beater filler plates.
12. Put on the belt and tension it.
Go to Section_122:Group_65
ZX61739,00002EF-19-20080220
1626
Remove and Install Separator Rotor
Remove and Install Separator Rotor
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
For removal of the separator rotor, beater grate and beater have to be removed first. For better access, it is
recommended to remove the straw walkers.
On combines with six walkers, the tailings elevator has to be removed.
1. Remove straw walkers, see Section 120, Group 15.
2. Remove beater grate, see Section 122, Group 60.
3. Remove beater, see Section 122, Group 65.
4. Remove tailings elevator, see Section 120, Group 30.
Go to Section_122:Group_70
ZX08798,000064A-19-20080227
1627
Remove and Install Separator Rotor
Remove and Install Separator Rotor
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
For removal of the separator rotor, beater grate and beater have to be removed first. For better access, it is
recommended to remove the straw walkers.
On combines with six walkers, the tailings elevator has to be removed.
1. Remove straw walkers, see Section 120, Group 15.
2. Remove beater grate, see Section 122, Group 60.
3. Remove beater, see Section 122, Group 65.
4. Remove tailings elevator, see Section 120, Group 30.
Go to Section_122:Group_70
ZX08798,000064A-19-20080227
1628
Measure Distance from Pulley to Sidewall
Measure Distance from Pulley to Sidewall
ZX1041270-UN: Determine distance from pulley to sidewall
LEGEND:
A - Belt
B - Tensioner Arm
C - Clamping Screw
D - Service Opening
Y - Distance from Pulley to Sidewall
Slacken V-belt (A) by means of tensioner arm (B) and remove the belt from the pulley. Measure distance (Y) from
pulley to sidewall.
Go to Section_122:Group_70
ZX61739,00002DE-19-20080222
1629
Remove Pulley (Left Side)
Remove Pulley (Left Side)
Loosen clamping screw (A) of pulley (B) and remove pulley.
Measure distance (X) from shaft end to sidewall.
ZX1041338-UN: Pulley, left
ZX1041269-UN: Distance
LEGEND:
A - Clamping Screw
B - Pulley
X - Distance
Item
Measurement Specification
Clamping screw (A) Torque
120 N•m (88.5 lb-ft)
Pulley
20 kg (44 lb)
Weight
Go to Section_122:Group_70
ZX61739,00002D7-19-20080222
1630
Remove Pulley (Right Side)
Remove Pulley (Right Side)
First loosen screws (B) (3 used) on the right side, then remove belts (C) and (D). Remove screws (B) (3 used)
and pulley (A).
ZX1041271-UN: Remove Pulley
LEGEND:
A - Pulley
B - Screws (3 used)
C - Belt
D - Belt
Go to Section_122:Group_70
ZX61739,00002D9-19-20080228
1631
Remove Hub
Remove Hub
Measure distance (Z) from hub to sidewall and then remove hub (B).
ZX1041272-UN: Remove hub
LEGEND:
A - Clamping Screw
B - Hub
Z - Distance
Item
Measurement Specification
Clamping screw (A) Torque
73 N•m (54 lb-ft)
Go to Section_122:Group_70
ZX61739,00002DF-19-20080220
1632
Remove Finger Bars and Retaining Plates
Remove Finger Bars and Retaining Plates
IMPORTANT:
Weigh retaining plates (B) to avoid imbalance. Always replace retaining plates (B) in pairs.
IMPORTANT:
If no separator rotor components are replaced, mark finger bars (C) and retaining plates (B) before removal to
make sure that each of these components is re-installed at its original location.
Remove screws (A1) and (A2). Remove finger bars (C) and retaining plates (B).
ZX1041652-UN: Mark retaining plates
ZX1041341-UN: Separator Rotor
ZX1041276-UN: Service Opening
LEGEND:
A1 - Screw
A2 - Screw
B - Retaining Plates
1633
Remove Finger Bars and Retaining Plates
C - Finger Bars
D - Service Opening
E - Segment
F - Screw
Instructions for separator rotor assembly
ZX1041975-UN: Install retaining plates
ZX1041652-UN: Mark retaining plates
LEGEND:
A1 - Screw
A2 - Screw
B - Retaining Plates
C - Finger Bars
D - Service Opening
E - Segment
F - Screw
To ensure true running of the separator rotor (no imbalance), assemble the rotor as follows:
1. Install retaining plates (B) so that marks (1-8) on plates are aligned with marks on segments (E).
2. After installing retaining plates 1 and 5 or 3 and 7, center the separator rotor between the sidewalls and
tighten the clamping screws. Install remaining retaining plates (B).
3. Re-install finger bars (C) paying attention to the marks, but do not tighten screws (F).
4. Begin with retaining plate 1. First tighten screws (A1) in crosswise fashion, then tighten screws (A2).
5. Continue with retaining plate 5. First tighten screws (A1) in crosswise fashion, then tighten screws (A2).
Continue with retaining plate pair 3 and 7. Tighten the remaining retaining plate pairs using the same
procedure.
6. Insert finger bars (C) all the way and align laterally. Tighten screws (F).
NOTE:
1634
Remove Finger Bars and Retaining Plates
When installing finger bars (C), note the offset position of the fingers.
Item
Measurement Specification
Screws of finger bars (C) and retaining plates (B) Torque
73 N•m (54 lb-ft)
Clamping screws
130 N•m (96 lb-ft)
Torque
Go to Section_122:Group_70
ZX61739,00002DA-19-20080229
1635
Loosen Segment Clamping Screws
Loosen Segment Clamping Screws
Remove clamping screws (A) of segments (B) and key (C).
ZX1041275-UN: Segment
LEGEND:
A - Clamping Screw
B - Segment
C - Key
Item
Measurement Specification
Clamping screws Torque
130 N•m (96 lb-ft)
Go to Section_122:Group_70
ZX61739,00002DB-19-20080228
1636
Remove Bearings
Remove Bearings
Remove both bearings and bearing shells (C).
ZX1041273-UN: Bearing, Left
ZX1041274-UN: Bearing, Right
LEGEND:
A - Screw
B - Locking Collar
C - Bearing Shell
Pull out shaft (A) from the side. A second person is required to remove the segments from the shaft.
Item
Measurement Specification
Screws (A) Torque
80 N•m (59 lb-ft)
Go to Section_122:Group_70
ZX61739,00002DC-19-20080222
1637
Install Separator Rotor
Install Separator Rotor
1. Slide the drive shaft into machine from the right side. A second person is required for sliding the
segments on the shaft and aligning them.
2. Re-adjust the drive shaft to distance (X).
3. Install and secure bearing locking collars.
4. Install four of the eight retaining plates and center separator rotor between sidewalls. When installing the
retaining plates, pay attention to the marks (to avoid imbalance).
5. Tighten segment clamping screws. Install remaining retaining plates and finger bars. Tighten retaining
plate and finger bar screws.
6. Install left drive pulley and align (dimension Y). Tighten the clamping screw.
7. Install V-belt and tension it using the tensioner.
8. Install hub, align (dimension Z) and tighten clamping screw.
9. Install pulley and tighten screws.
10. Put on the V-belt and tension it.
Go to Section_122:Group_70
ZX08798,0000651-19-20080222
1638
Remove and Install Separator Grate
Remove and Install Separator Grate
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
For removal of separator grate, the following preliminary work is necessary:
1. Remove walker return pan, see Section 120, Group 15.
2. Remove beater grate, see Section 122, Group 60.
3. Remove beater, see Section 122, Group 65.
ZX1041658-UN: Remove straw walkers
LEGEND:
A - Tensioner Strap
B - Straw Walkers
For removal of separator grate, it is not necessary to remove the straw walkers (B) completely. Retract the straw
walkers as far as possible and secure using a tensioner strap (A).
Go to Section_122:Group_75
ZX61739,00002E0-19-20080218
1639
Remove and Install Separator Grate
Remove and Install Separator Grate
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
For removal of separator grate, the following preliminary work is necessary:
1. Remove walker return pan, see Section 120, Group 15.
2. Remove beater grate, see Section 122, Group 60.
3. Remove beater, see Section 122, Group 65.
ZX1041658-UN: Remove straw walkers
LEGEND:
A - Tensioner Strap
B - Straw Walkers
For removal of separator grate, it is not necessary to remove the straw walkers (B) completely. Retract the straw
walkers as far as possible and secure using a tensioner strap (A).
Go to Section_122:Group_75
ZX61739,00002E0-19-20080218
1640
Remove Finger Bars of Separator Rotor
Remove Finger Bars of Separator Rotor
IMPORTANT:
Mark the position of finger bars (A) to allow re-installation at the original position (to avoid imbalance).
NOTE:
For removal of separator grate, it is not necessary to remove the separator rotor (B) completely.
ZX1041279-UN: Remove Finger Bars of Separator Rotor
LEGEND:
A - Finger Bars
B - Separator Rotor
C - Screws
Remove screws (C) of separator rotor (B) and take out finger bars (A) from the side.
Item
Measurement Specification
Screw (C) of finger bar Torque
73 N•m (54 lb-ft)
Go to Section_122:Group_75
ZX61739,00002E2-19-20080221
1641
Remove Separator Grate Inserts
Remove Separator Grate Inserts
ZX1041654-UN: Remove inserts
LEGEND:
A - Screw
B - Inserts
For easier handling of the separator grate, the rear inserts (B) should be removed.
Go to Section_122:Group_75
ZX61739,00002F1-19-20080213
1642
Position Separator Grate
Position Separator Grate
ZX1041286-UN: Grate adjustment
ZX1041281-UN: Position separator grate, right side
LEGEND:
A - Separator Grate
B - Wooden Block
C - Screw (2 used, second screw not illustrated)
D - Cotter Pin
E - Pin
F - Adjusting Lever
Move separator grate (A) to the closed position and support on both sides using wooden blocks (B). Use adjusting
lever (F) to place separator grate (A) on wooden block (B). Remove screws (C, 2 used), cotter pin (D) and pin (E).
Go to Section_122:Group_75
ZX61739,00002E4-19-20080124
1643
Lift Out Separator Grate
Lift Out Separator Grate
ZX1041657-UN: Wooden wedge
ZX1041284-UN: Rails
ZX1041283-UN: Loosen Separator Grate, Left
ZX1041282-UN: Loosen Separator Grate, Right
1644
Lift Out Separator Grate
ZX1041659-UN: Lift Out Separator Grate
LEGEND:
A - Screw
B - Rails (self-manufactured)
C - Swing Arms
D - Separator Grate
E - Wooden Wedge
When removing separator grate (D), make sure that swing arms (C) are flush with sidewall. Remove screw (A)
(both sides). Now separator grate (D) can be pulled out using two self-manufactured rails (B).
Item
Measurement Specification
Screw (A)
Torque
285 N•m (210 lb-ft)
Weight of separator grate without inserts Weight
90 kg (198 lb)
Weight of separator grate with inserts
160 kg (352 lb)
Weight
Go to Section_122:Group_75
ZX61739,00002E5-19-20080222
1645
Install and Adjust Separator Grate
Install and Adjust Separator Grate
ZX1041285-UN: Adjust the Separator Grate
LEGEND:
A - Separator Grate Inserts
B - Separator Grate Adjusting Screws
C - Separator Rotor Finger Bar
X - Distance
For installation reverse removal procedure.
After installing the separator grate, make sure to check distance (X) between inserts (A) and finger bar (C).
Measure distance (X) between the fifth row of inserts (A) (from the front) and finger bar (C). If necessary, correct
the distance using adjusting screws (B).
Item
Measurement Specification
Distance (X), finger bars to inserts with separator grate open
Gap
50 mm (1.96 in.)
Distance (X), finger bars to inserts with separator grate closed Gap
30 mm (1.18 in.)
Go to Section_122:Group_75
ZX61739,00002E6-19-20080222
1646
Remove and Install Overshot Beater
Remove and Install Overshot Beater
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
For removal of overshot beater, the following preliminary work is necessary:
1.
2.
3.
4.
5.
Remove tailings elevator, see Section 120, Group 30.
Remove intermediate cylinder drive, see Section 120, Group 10.
Remove beater grate, see Section 122, Group 60.
Remove beater, see Section 122, Group 65.
Remove separator rotor, see Section 122, Group 70.
Go to Section_122:Group_80
ZX61739,00002F2-19-20080222
1647
Remove and Install Overshot Beater
Remove and Install Overshot Beater
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
For removal of overshot beater, the following preliminary work is necessary:
1.
2.
3.
4.
5.
Remove tailings elevator, see Section 120, Group 30.
Remove intermediate cylinder drive, see Section 120, Group 10.
Remove beater grate, see Section 122, Group 60.
Remove beater, see Section 122, Group 65.
Remove separator rotor, see Section 122, Group 70.
Go to Section_122:Group_80
ZX61739,00002F2-19-20080222
1648
Remove Pulley
Remove Pulley
ZX1041661-UN: Distance
ZX1041660-UN: Remove Pulley
LEGEND:
A - Pulley
B - Belt
C - Clamping Screw
X - Distance
Measure distance (X) from pulley (A) to sidewall. Loosen clamping screw (C) and remove pulley (A).
Item
Measurement Specification
Pulley
Weight
Clamping screw (C ) Torque
30 kg (66 lb)
130 N•m (96 lb-ft)
Go to Section_122:Group_80
ZX61739,00002F3-19-20080219
1649
Remove Gearcase
Remove Gearcase
ZX1041662-UN: Remove Gearcase
ZX1041663-UN: Distance
LEGEND:
A - Screw (8 used)
B - Gearcase
Y - Distance
Remove screws (A) and lift off gearcase (B). Measure distance (Y) from shaft end to sidewall.
Item
Measurement Specification
Gearcase Weight
30 kg (66 lb)
Screw (A) Torque
130 N•m (96 lb-ft)
Go to Section_122:Group_80
ZX61739,00002F4-19-20080222
1650
Disassemble Overshot Beater
Disassemble Overshot Beater
ZX1041972-UN: Disassemble Overshot Beater
ZX1041971-UN: Loosen Clamping Screw
LEGEND:
A1 - Cap Screw
A2 - Cap Screw
B - Screw
C - Overshot Beater Filler Plates
D - Segment
E - Key
F - Clamping Screw
Remove screws (A1, A2 and B) of overshot beater filler plates (C). Remove the filler plates. Loosen clamping
screw (F) and remove key (E).
Instructions for overshot beater assembly
ZX1041970-UN: Overshot Beater
1651
Disassemble Overshot Beater
To ensure true running of the overshot beater, always install beater filler plates (C) in pairs (1 and 1, 3 and 3).
First tighten cap screws (A1), then tighten cap screws (A2). When four of the eight overshot beater filler plates (C)
are installed, center the beater between the sidewalls and tighten clamping screws (F). Afterwards install the
remaining overshot beater filler plates (C) and tighten screws (A1) and (A2).
Item
Measurement Specification
Screws (A1, A2 and B) Torque
73 N•m (54 lb-ft)
Clamping screw (F)
87 N•m (64 lb-ft)
Torque
Go to Section_122:Group_80
ZX61739,00002F7-19-20080218
1652
Remove Locking Collar (Right Side)
Remove Locking Collar (Right Side)
ZX1041969-UN: Loosen bearing
LEGEND:
A - Overshot Beater Bearing
B - Stripper Bearing
C - Locking Collar of Overshot Beater
D - Locking Collar of Stripper
E - Nut
F - Nut
Remove locking collar (D) and pull out the shaft from the left side. A second person is required to remove the
segments from the shaft inside the machine.
Go to Section_122:Group_80
ZX61739,00002F6-19-20080222
1653
Install Overshot Beater
Install Overshot Beater
For installation reverse removal procedure.
1.
2.
3.
4.
5.
6.
7.
8.
Insert the shaft into the machine from the left side.
Slide the segments on the shaft and insert the keys.
Install the right bearing.
Adjust distance (Y) from shaft end to sidewall.
Install the locking collar on right side.
Install gearcase.
Adjust the pulley to obtain distance (X) between pulley and sidewall and tighten.
Install two pairs of overshot beater filler plates (1 and 1, 3 and 3) and center the overshot beater
between the sidewalls. Check overshot beater for true running.
9. Tighten the clamping screws.
10. Install and tighten remaining pairs of overshot beater filler plates.
11. Put on the belt and tension it.
Go to Section_122:Group_80
ZX61739,00002F8-19-20080222
1654
Remove and Install Stripper
Remove and Install Stripper
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
For removal of stripper, the following preliminary work is necessary:
1. Remove feeder house, see Section 110, Group 05.
2. Remove threshing cylinder, see Section 120, Group 05.
NOTE:
If separator rotor and overshot beater have already been removed, the stripper can be removed
from the rear if desired.
Go to Section_122:Group_85
ZX61739,00002F9-19-20080222
1655
Remove and Install Stripper
Remove and Install Stripper
CAUTION:
To prevent accidental starting of the engine, disconnect battery ground cable, remove key
from switch and install a DO NOT OPERATE tag in operator's cab.
For removal of stripper, the following preliminary work is necessary:
1. Remove feeder house, see Section 110, Group 05.
2. Remove threshing cylinder, see Section 120, Group 05.
NOTE:
If separator rotor and overshot beater have already been removed, the stripper can be removed
from the rear if desired.
Go to Section_122:Group_85
ZX61739,00002F9-19-20080222
1656
Remove Pulley
Remove Pulley
ZX1041973-UN: Remove Pulley
ZX1041974-UN: Remove Bearing
LEGEND:
A - Pulley
B - Belt
C - Clamping Screws
D - Key
E - Locking Collar
F - Nut
X - Distance (X) from Pulley to Sidewall
Y - Distance (Y) from Shaft End to Sidewall
Measure distance (X) from pulley to sidewall.
Loosen clamping screws (C) and remove belt (B). Remove pulley (A) and nuts (F).
Measure distance (Y) from shaft end to sidewall.
Go to Section_122:Group_85
ZX61739,00002FC-19-20080227
1657
Remove Locking Collar (Right Side)
Remove Locking Collar (Right Side)
ZX1041969-UN: Loosen bearing
LEGEND:
A - Overshot Beater Bearing
B - Stripper Bearing
C - Locking Collar of Overshot Beater
D - Locking Collar of Stripper
E - Nut
F - Nut
Remove locking collar (D) of stripper and pull out the stripper shaft from the left side.
Go to Section_122:Group_85
ZX61739,00002FD-19-20080221
1658
Remove stripper from the front
Remove stripper from the front
ZX1041980-UN: Remove stripper from the front
LEGEND:
B - Stripper Roll
Remove strippers and stripper roll (B).
Remove stripper from the rear
ZX1041977-UN: Remove stripper
ZX1041978-UN: Remove stripper from the rear
LEGEND:
A - Stripper
B - Stripper Roll
Remove strippers (A) and stripper roll (B).
1659
Remove stripper from the front
Go to Section_122:Group_85
ZX61739,0000300-19-20080221
1660
Stripper Roll, Exploded View
Stripper Roll, Exploded View
H59141-UN: Stripper Roll, Exploded View
LEGEND:
A - Stripper (2 used)
B - Screw (3 used)
C - Belt
D - Set Screw (2 used)
E - Lock Nut (2 used)
F - Pulley
G - Set Screw
H - Locking Collar
1661
Stripper Roll, Exploded View
I - Flange
J - Bearing (2 used)
K - Flange (2 used)
L - Screw (3 used)
M - Stripper Roll
N - Key
O - Shaft
P - Flange
Q - Lubrication Hose
R - Lubrication Fitting
Go to Section_122:Group_85
ZX61739,00002FE-19-20080222
1662
Install Stripper
Install Stripper
For installation reverse removal procedure.
1.
2.
3.
4.
5.
Install the bearing on right side.
Insert the shaft from the left side.
Install the bearing on the left side and adjust the shaft to obtain distance (Y).
Install the locking collars and adjust the pulley to obtain dimension (X).
Reinstall strippers.
Go to Section_122:Group_85
ZX61739,00002FF-19-20080218
1663
Table of Contents
Section 130: Grain Tank and Unloading System
Group 05: Grain Tank Cross Augers
Remove and Install Grain Tank Cross Augers
Group 10: Unloading Auger System Drives
Specifications
Replace Unloading Auger Drive Belts
Remove and Install Cross Auger Countershaft Hub and Shear Bolt
Remove Unloading Auger Drive Countershaft
Install Unloading Auger Drive Countershaft
Align Unloading Auger Drive
Adjust Unloading Auger Drive Cylinder
Replace Unloading Auger Grain Saver Door
Group 15: Vertical Auger and Lower Gear Case
Essential and Recommended Special Tools
Specifications
Remove Vertical Auger Lower Gear Case And Vertical Auger
Disassemble and Assemble Vertical Auger Lower Gear Case
Install Vertical Auger and Vertical Auger Lower Gear Case
Group 20: Horizontal Auger and Gear Case
Essential and Recommended Special Tools
Other Material
Specifications
Inspection of Horizontal Unloading Auger
17 ft. (5.18 m) and 20 ft. (6.1 m) Augers - Two-Piece
Remove Horizontal Auger
Install Horizontal Auger
Remove Horizontal Auger Gear Case
Disassemble And Assemble Horizontal Unloading Auger Gear Case
Install Horizontal Auger Gear Case
Remove Horizontal Unloading Auger Tube
Unloading Auger Elbow, Exploded View
Remove Horizontal Unloading Auger Elbow
1664
Table of Contents
Install Horizontal Unloading Auger Elbow
Remove Unloading Auger Charge Housing
Group 25: Clean Grain Elevator and Loading Auger Gear Case
Other Material
Specifications
Adjust Clean Grain Elevator Chain
Replace Clean Grain Elevator Belt
Clean Grain Loading Auger, Exploded View
Replace Clean Grain Loading Auger Bearing
Remove Clean Grain Loading Auger Assembly
Remove and Install Clean Grain Elevator Gear Case
Disassemble and Assemble Clean Grain Elevator Gear Case
Remove Clean Grain Elevator
Group 30: Grain Tank and Extensions
Grain Tank Base
Grain Tank
Grain Tank Covers - 8,000 and 9,000 Liters
Grain Tank Cover Seals - 8,000 and 9,000 Liters
Grain Tank Cover Supports - 8,000 and 9,000 Liters
Grain Tank Cover Cylinders - 8,000 and 9,000 Liters
Grain Tank Cover Actuator - 8,000 and 9,000 Liters
Grain Tank, General View - 11,000 Liters
Grain Tank Covers - 11,000 Liters
Grain Tank Lift Cylinders and Linkage - 11,000 Liters
1665
Remove and Install Grain Tank Cross Augers
Remove and Install Grain Tank Cross Augers
H64480-UN: Grain Tank Cross Augers
LEGEND:
1 - Set Screw and Nut (4 used)
2 - Set Screw (4 used)
3 - Locking Collar (4 used)
4 - Key (2 used)
5 - Front Auger
6 - Rear Auger
7 - Cover (2 used)
8 - Flanged Housing (4 used)
9 - Ball Bearing (2 used)
10 - Reinforcement (2 used)
11 - Screw and Flange Nut (8 used)
12 - Screw and Flange Nut (3 used)
13 - Screw and Nut (4 used)
14 - Screw and Flange Nut (4 used)
15 - Sprocket, 49 Teeth
16 - Sprocket, 49 Teeth
17 - Washer (As Required)
18 - Snap Ring (2 used)
19 - Chain
1.
NOTE:
Remove gas cylinders from right gull wing door. Lift and support door high enough to
remove augers from grain tank.
1666
Remove and Install Grain Tank Cross Augers
ZX25279-UN: Remove Chain
LEGEND:
A - Nuts
B - Chain
C - Set Screw (2 used)
D - Sprocket
Loosen nuts (A) to release chain tension.
2. Remove chain (B).
3. Remove snap ring and washers from end of shaft.
4. Loosen two nuts and set screws (C) to remove sprocket (D).
5.
H41354-UN: Bearing Removal
LEGEND:
A - Locking Collar
B - Nut (3 used)
C - Bearing
Remove locking collar (A).
6. Remove three nuts (B), flanged housing and bearing (C).
1667
Remove and Install Grain Tank Cross Augers
7.
ZX25278-UN: Remove Right Bearing
LEGEND:
A - Nut (8 used)
B - Cover
C - Flanged Housing with Bearing
D - Locking Collar
E - Nut (3 used)
Remove locking collar (D) from right end.
8. Remove three nuts (E) to remove flanged housing with bearing (C).
9. Remove eight nuts (A) to remove cover (B).
10.
CAUTION:
The approximate weight of each auger is 25 kg (55 lb).
IMPORTANT:
Front and rear augers are different. Do not interchange.
H41356-UN: Front Auger Shown
LEGEND:
A - Auger
Remove augers (A) from right side of combine.
11. Repair or replace augers as necessary.
12. Install augers (A) from right side of machine.
1668
Remove and Install Grain Tank Cross Augers
13.
ZX25278-UN: Install Right Bearing
LEGEND:
A - Nut (8 used)
B - Cover
C - Flanged Housing with Bearing
D - Locking Collar
E - Nut (3 used)
Install cover (B) using eight nuts (A).
14. Install flanged housing with bearing (C) using three nuts (E).
15. Install locking collar (D).
16.
H41354-UN: Install Bearing
LEGEND:
A - Locking Collar
B - Nut (3 used)
C - Bearing
Install flanged housing with bearing (C) using three nuts (B).
17. DO NOT install locking collar (A) at this time.
1669
Remove and Install Grain Tank Cross Augers
18.
ZX25279-UN: Chain Installation
LEGEND:
A - Nuts
B - Chain
C - Set Screws
D - Sprocket
Install sprocket (D).
19. Install washers and snap ring.
20. Pull sprocket (D) tight against washers and snap ring.
21. Tighten set screws (C).
22. Push auger assembly to right of combine until sprocket (D) is against bearing race.
23. Install locking collar on right end of auger.
24. Install chain (B) and tighten chain with nuts (A).
25.
H67900-UN: Chain Tensioner
LEGEND:
A - Nut
B - Washer
C - Gauge
D - Lock Nut
Tighten nut (A) until washer (B) aligns with end of gauge (C). Tighten lock nut (D).
1670
Remove and Install Grain Tank Cross Augers
Go to Section_130:Group_05
OUO6435,00013E8-19-20010622
1671
Remove and Install Grain Tank Cross Augers
Remove and Install Grain Tank Cross Augers
H64480-UN: Grain Tank Cross Augers
LEGEND:
1 - Set Screw and Nut (4 used)
2 - Set Screw (4 used)
3 - Locking Collar (4 used)
4 - Key (2 used)
5 - Front Auger
6 - Rear Auger
7 - Cover (2 used)
8 - Flanged Housing (4 used)
9 - Ball Bearing (2 used)
10 - Reinforcement (2 used)
11 - Screw and Flange Nut (8 used)
12 - Screw and Flange Nut (3 used)
13 - Screw and Nut (4 used)
14 - Screw and Flange Nut (4 used)
15 - Sprocket, 49 Teeth
16 - Sprocket, 49 Teeth
17 - Washer (As Required)
18 - Snap Ring (2 used)
19 - Chain
1.
NOTE:
Remove gas cylinders from right gull wing door. Lift and support door high enough to
remove augers from grain tank.
1672
Remove and Install Grain Tank Cross Augers
ZX25279-UN: Remove Chain
LEGEND:
A - Nuts
B - Chain
C - Set Screw (2 used)
D - Sprocket
Loosen nuts (A) to release chain tension.
2. Remove chain (B).
3. Remove snap ring and washers from end of shaft.
4. Loosen two nuts and set screws (C) to remove sprocket (D).
5.
H41354-UN: Bearing Removal
LEGEND:
A - Locking Collar
B - Nut (3 used)
C - Bearing
Remove locking collar (A).
6. Remove three nuts (B), flanged housing and bearing (C).
1673
Remove and Install Grain Tank Cross Augers
7.
ZX25278-UN: Remove Right Bearing
LEGEND:
A - Nut (8 used)
B - Cover
C - Flanged Housing with Bearing
D - Locking Collar
E - Nut (3 used)
Remove locking collar (D) from right end.
8. Remove three nuts (E) to remove flanged housing with bearing (C).
9. Remove eight nuts (A) to remove cover (B).
10.
CAUTION:
The approximate weight of each auger is 25 kg (55 lb).
IMPORTANT:
Front and rear augers are different. Do not interchange.
H41356-UN: Front Auger Shown
LEGEND:
A - Auger
Remove augers (A) from right side of combine.
11. Repair or replace augers as necessary.
12. Install augers (A) from right side of machine.
1674
Remove and Install Grain Tank Cross Augers
13.
ZX25278-UN: Install Right Bearing
LEGEND:
A - Nut (8 used)
B - Cover
C - Flanged Housing with Bearing
D - Locking Collar
E - Nut (3 used)
Install cover (B) using eight nuts (A).
14. Install flanged housing with bearing (C) using three nuts (E).
15. Install locking collar (D).
16.
H41354-UN: Install Bearing
LEGEND:
A - Locking Collar
B - Nut (3 used)
C - Bearing
Install flanged housing with bearing (C) using three nuts (B).
17. DO NOT install locking collar (A) at this time.
1675
Remove and Install Grain Tank Cross Augers
18.
ZX25279-UN: Chain Installation
LEGEND:
A - Nuts
B - Chain
C - Set Screws
D - Sprocket
Install sprocket (D).
19. Install washers and snap ring.
20. Pull sprocket (D) tight against washers and snap ring.
21. Tighten set screws (C).
22. Push auger assembly to right of combine until sprocket (D) is against bearing race.
23. Install locking collar on right end of auger.
24. Install chain (B) and tighten chain with nuts (A).
25.
H67900-UN: Chain Tensioner
LEGEND:
A - Nut
B - Washer
C - Gauge
D - Lock Nut
Tighten nut (A) until washer (B) aligns with end of gauge (C). Tighten lock nut (D).
1676
Remove and Install Grain Tank Cross Augers
Go to Section_130:Group_05
OUO6435,00013E8-19-20010622
1677
Specifications
Specifications
Item
Measurement Specification
Unloading Auger Drive Sprocket Set Screw
Torque
48 N˙m
(35 lb-ft)
Unloading Auger Drive Countershaft Lock Nut
Torque
24 N˙m
(15 lb-ft)
Unloading Auger Drive Countershaft Retaining Nut Torque
300 N˙m
(220 lb-ft)
Unloading Auger Drive Countershaft Shear Bolt
25 N˙m
(18 lb-ft)
Torque
Go to Section_130:Group_10
OUO6435,000142E-19-20010725
1678
Specifications
Specifications
Item
Measurement Specification
Unloading Auger Drive Sprocket Set Screw
Torque
48 N˙m
(35 lb-ft)
Unloading Auger Drive Countershaft Lock Nut
Torque
24 N˙m
(15 lb-ft)
Unloading Auger Drive Countershaft Retaining Nut Torque
300 N˙m
(220 lb-ft)
Unloading Auger Drive Countershaft Shear Bolt
25 N˙m
(18 lb-ft)
Torque
Go to Section_130:Group_10
OUO6435,000142E-19-20010725
1679
Replace Unloading Auger Drive Belts
Replace Unloading Auger Drive Belts
H67902-UN: Belt Trap
H67906-UN: Belt
LEGEND:
A - Cap Screw (4 used)
B - Trap
C - Belt Trap
D - Belt (2 used)
CAUTION:
Shut off engine and remove key.
Be certain drive is disengaged.
Remove cap screws (A) and trap (B).
Loosen belt trap (C). Remove belts (D).
IMPORTANT:
Always replace both belts as a matched set to ensure equal wear.
Adjust belt trap (C).
Install trap (B).
1680
Replace Unloading Auger Drive Belts
If the unloading auger drive will not shut off (disengage) as the new belts stretch, adjust the drive cylinder (see
Adjust Unloading Auger Drive Cylinder in this group).
Go to Section_130:Group_10
OUO6030,0000091-19-20010523
1681
Remove and Install Cross Auger Countershaft Hub and Shear Bolt
Remove and Install Cross Auger Countershaft Hub and Shear Bolt
H55906-UN: Countershaft and Shear Bolt
LEGEND:
A - Belt
B - Nut
C - Washer
D - Shear Hub
E - Shear Bolt
F - Sheave
G - Hub and Bushing
H - Cap Screw (6 used)
1. If hub (D) is frozen to shaft, remove shear bolt (E).
2. Turn unloading system sheave by hand without turning augers. If augers turn, hubs (D) and (G) need to
be loosened.
3. Install shear bolt (E).
Go to Section_130:Group_10
AG,OUO6435,1026-19-20000503
1682
Remove Unloading Auger Drive Countershaft
Remove Unloading Auger Drive Countershaft
H55302-UN: Unloading Auger Drive Countershaft.
LEGEND:
A - Belt (2 used)
B - Nut
C - Washer
D - Shear Hub
E - Shear Bolt
F - Sheave (2 used)
G - Hub and Bushing
H - Cap Screw
I - Locking Collar (2 used)
J - Shaft
K - Woodruff Key (2 used)
L - Bearing (2 used)
M - Flangettes (4 used)
N - Cap Screw (6 used)
1683
Remove Unloading Auger Drive Countershaft
O - Washer
P - Sprocket
Q - Set Screw
R - Snap Ring
S - Arm
1. Remove drive belts (A) (see Replace Unloading Auger Drive Belts in this group).
2. Remove nut (B) and washer (C).
3. Remove sheave assembly (D - H) from shaft (J).
4. Loosen drive chain tensioner sprocket and remove chain from sprocket (P).
5. Remove snap ring (R), loosen set screw (Q) and remove sprocket (P).
6. Remove woodruff keys (K) from ends of shaft.
7. Loosen set screws and locking collars (I) and remove shaft (J) from bearings.
8. Remove cap screws (N) from bearing flangettes (M).
9. Remove bearings (L).
10. Inspect all parts.
11. Replace as necessary.
Go to Section_130:Group_10
AG,OUO6435,1027-19-20000503
1684
Install Unloading Auger Drive Countershaft
Install Unloading Auger Drive Countershaft
H55302-UN: Unloading Auger Drive Countershaft
LEGEND:
A - Belt (2 used)
B - Nut
C - Washer
D - Shear Hub
E - Shear Bolt
F - Sheave (2 used)
G - Hub and Bushing
H - Cap Screws and Nuts
I - Locking Collar (2 used)
J - Shaft
K - Woodruff Key (2 used)
L - Bearing (2 used)
M - Flangettes (4 used)
N - Cap Screw (6 used)
1685
Install Unloading Auger Drive Countershaft
O - Washer
P - Sprocket
Q - Set Screw
R - Snap Ring
S - Arm
1. Install bearings (L) and flangettes (M) to arm (S) using cap screws and nuts (N). Lock collar ring of
bearings to outside of arm (S). DO NOT TIGHTEN NUTS (N).
2. Install shaft (J) through bearings (L) with tapered end towards inside of arm (S).
3. Tighten nuts (N).
4. Locate shaft (J) 127.5 mm (5 in.) from inner race of right bearing to threaded end of shaft.
5. Install set screws and locking collars (I) and set in counterclockwise direction.
6. Install washer (O) on left end of shaft against locking collar (I).
7. Install woodruff key (K) in left end of shaft (J).
8. Install sprocket (P) on left end of shaft (J). Hub must face away from bearing.
9. Install set screw (Q) with lock nut. Torque set screw to specification.
Item
Measurement Specification
Unloading Auger Drive Sprocket Set Screw Torque
48 N˙m
(35 lb-ft)
10. Tighten lock nut to specification.
Item
Measurement Specification
Unloading Auger Drive Countershaft Lock Nut Torque
24 N˙m
(15 lb-ft)
11. Install snap ring (R) on left end of shaft.
12. Install woodruff key (K) in right end of shaft taper.
13. Install hub and bushing (G) in sheave (F).
14. Install cap screws (H) through sheave (F) and hub (G).
15. Install nuts and tighten.
16. Install sheave (F) and hub assembly (G) on shaft (J).
17. Install shear hub (D) on tapered end of shaft (J).
18. Install washer (C) and retaining nut (B) on shaft (J). Tighten retaining nut to specification.
Item
Measurement Specification
Unloading Auger Drive Countershaft Retaining Nut Torque
1686
300 N˙m
(220 lb-ft)
Install Unloading Auger Drive Countershaft
19. Install shear bolt (E) through shear hub (D) and hub (G). Tighten to specification.
Item
Measurement Specification
Unloading Auger Drive Countershaft Shear Bolt Torque
25 N˙m
(18 lb-ft)
20. Install drive chain on sprocket (P).
21. Tighten idler sprocket until washer aligns with spring gauge.
22. Tighten lock nut.
Go to Section_130:Group_10
AG,OUO6435,1028-19-20000503
1687
Align Unloading Auger Drive
Align Unloading Auger Drive
H54254-19: Unloading Auger Drive
LEGEND:
A - Nuts
B - Eyebolt Adjusting Nuts
C - Screws
CAUTION:
Shut off engine and remove key.
1. Remove cap screws securing bottom belt trap and remove trap.
2. Loosen nuts (A) on eyebolts behind pivot of unloading auger drive arm.
3. Adjust the two eyebolts equally using nuts (B) until center of groove in bottom sheave is aligned with
center of groove in top sheave.
4. Tighten nuts (B).
1688
Align Unloading Auger Drive
5. Bottom sheave must be parallel both up and down and front to back with top sheave.
6. If there is a difference between the top and bottom you will need to twist the arm. Adjust either the top or
bottom eyebolt using nuts (B). This adjustment twists the top or bottom of the arm depending on which
nut is turned.
7. When the sheaves are aligned and parallel, tighten nuts (A).
8. Check to make sure that top belt trap is not putting outer shield into a side loaded position. If it is, it must
be straightened so the two sides are parallel and perpendicular with the top.
9. Be certain that top belt trap is bolted to the inner side of the casing using screws (C).
Go to Section_130:Group_10
AG,OUO6435,1029-19-20000503
1689
Adjust Unloading Auger Drive Cylinder
Adjust Unloading Auger Drive Cylinder
H39472-UN: Unloading Auger Drive Cylinder
LEGEND:
A - Tape
B - Nut
C - Cap Screw (2 used)
D - Slide Stop
If the unloading auger drive will not shut off (disengage), or if the belts jump off as they stretch from use, the
cylinder rod stop may need adjustment. A belt that has stretched can cause the drive not to shut off. The belt
rotating around the belt trap can fold over and make contact with the upper sheave.
To adjust the stop:
CAUTION:
1.
Shut off engine and remove key.
Mark present stop position on rod with tape (A).
2. Loosen nut (B) to relieve spring tension.
3. Loosen cap screws (C) and slide stop (D) 13 mm (1/2 in.) toward cylinder.
4. Tighten cap screws (C).
5. Tighten nut (B) to its original position.
NOTE:
When installing new belts, adjust stop to its original position (stop positioned against barrel of
cylinder with rod fully retracted).
Go to Section_130:Group_10
AG,OUO6435,1030-19-20000503
1690
Replace Unloading Auger Grain Saver Door
Replace Unloading Auger Grain Saver Door
H67464-UN: Grain Saver Door
H63714-UN: Grain Saver Door
LEGEND:
A - Screw (2 used)
B - Nut (2 used)
C - Spring (2 used)
D - Grain Saver Door
1. Remove screw (A) and washer from each side of unloading auger tube.
2. Remove springs (C) if necessary.
3. Remove nut (B) and carriage bolt from door assembly.
4. Remove grain saver door assembly (D).
Go to Section_130:Group_10
OUO6435,00013E1-19-20010619
1691
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
To remove and install various components.
H40598-UN: Service Jack
Pedestal.......D05071ST
To remove and install various components.
H41163-UN: Pedestal
Auger Gear Case Remover/Installer
Bracket.......JT05877
To remove and install vertical auger gear case.
H41091-UN: Auger Gear Case Remover/Installer
Bracket
1692
Essential and Recommended Special Tools
Go to Section_130:Group_15
ZX09263,000274D-19-20080201
1693
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Service Jack.......D05070ST
To remove and install various components.
H40598-UN: Service Jack
Pedestal.......D05071ST
To remove and install various components.
H41163-UN: Pedestal
Auger Gear Case Remover/Installer
Bracket.......JT05877
To remove and install vertical auger gear case.
H41091-UN: Auger Gear Case Remover/Installer
Bracket
1694
Essential and Recommended Special Tools
Go to Section_130:Group_15
ZX09263,000274D-19-20080201
1695
Specifications
Specifications
Item
Measurement Specification
Output Shaft Gear Retaining Cap Screw
Torque
270 N˙m
(200 lb-ft)
Bearing Quill Screws
Torque
68 N˙m
(50 lb-ft)
Input Shaft Cap Screw
Torque
290 N˙m
(214 lb-ft)
Vertical Auger Lower Gear Case Bevel Gear Backlash Backlash
0.15—0.51 mm
(0.006—0.020 in.)
Go to Section_130:Group_15
OUO6037,0001497-19-20010821
1696
Remove Vertical Auger Lower Gear Case And Vertical Auger
Remove Vertical Auger Lower Gear Case And Vertical Auger
1.
H67907-UN: Guard
LEGEND:
A - Cap Screw (2 used)
B - Guard
Remove tailings elevator, see Section 120, Group 30.
2. Remove cap screws (A) and guard (B).
3.
H68308-UN: Idler
LEGEND:
A - Nut (2 used)
B - Drive Chain
Loosen nuts (A) and remove drive chain (B).
1697
Remove Vertical Auger Lower Gear Case And Vertical Auger
4.
H65775-UN: Shield
LEGEND:
A - Nut and Washer
B - Sprocket
C - Wing Screw (5 used)
D - Shield (2 used)
E - Cap Screw (3 used)
F - Shield
G - Cap Screws
Remove nut and washer (A), sprocket (B), wing screws (C) and shields (D).
5. Remove cap screws (E), shield (F) and cap screws (G).
6.
CAUTION:
The approximate weight of gear case is 45 kg (100 lb).
1698
Remove Vertical Auger Lower Gear Case And Vertical Auger
H67892-UN: Vertical Auger Gear Case
LEGEND:
A - Gear Case
B - Remover/installer Bracket
C - Cap Screw (10 used)
Attach D05070ST Service Jack with D05071ST Pedestal and JT05877 Auger Gear Case
Remover/Installer Bracket (B) to gear case (A).
7. Remove cap screws (C).
1699
Remove Vertical Auger Lower Gear Case And Vertical Auger
8.
H67893-UN: Gear Case
LEGEND:
A - Auger
B - Gear Case
C - Chain
Lower gear case (B) slightly.
9. Support auger (A) with chain or strap (C) to keep it from dropping.
10. Remove gear case.
11. Repair or replace gear case as necessary.
12. Replace vertical auger (A) as necessary.
1700
Remove Vertical Auger Lower Gear Case And Vertical Auger
13. Check the flighting on the lower portion of the vertical auger. If the flighting is worn back from the OD
more than 25 mm (1 in.), or the end of the flighting is damaged, consider rebuilding the flighting or
replacing the auger.
Go to Section_130:Group_15
OUO6030,0000089-19-20010522
1701
Disassemble and Assemble Vertical Auger Lower Gear Case
Disassemble and Assemble Vertical Auger Lower Gear Case
H63889-UN: Vertical Auger Lower Gear Case
LEGEND:
1 - Shaft
2 - Key (2 used)
3 - Seal
4 - Snap Ring (2 used)
5 - Bearing (2 used)
6 - Spring
7 - Bushing
8 - Bearing (2 used)
1702
Disassemble and Assemble Vertical Auger Lower Gear Case
9 - Quill
10 - Cap Screw (3 used)
11 - Washer (2 used)
12 - Cap Screw (2 used)
13 - Shim-0.25 mm (0.010 in.); Shim-0.51 mm (0.020 in.) (2 used)
14 - Gear (2 used)
15 - Case
16 - Shim
17 - Washer
18 - Lock Nut
19 - Lubrication Fitting
20 - Shaft
21 - Sprocket, 46 Teeth
22 - Key
23 - Cap Screw with Flange Nut
24 - Gasket
25 - Cover
26 - Gasket
27 - Cover
28 - Washer (5 used)
29 - Wing Screw (5 used)
30 - Cap Screw and Flange Nut (8 used)
1.
CAUTION:
Weight of gear case is approximately 37 kg (82 lb).
Item
Measurement Specification
Vertical Auger Lower Gear Case Weight
1703
37 kg
(82 lb)
Disassemble and Assemble Vertical Auger Lower Gear Case
H41080-UN: Vertical Auger Gear Case
LEGEND:
A - Shim (2 used)
B - Quill
C - Cap Screw
D - Guard
Remove cap screw and washer (C).
2. Remove quill (B), guard (D) and shims (A).
3.
H41081-UN: Vertical Auger Gear Case
LEGEND:
A - Bearing
B - Quill
Remove bearing (A) from quill (B). Bearing is a press fit.
4.
H41082-UN: Vertical Auger Gear Case
LEGEND:
A - Shaft
Use a soft-faced mallet to free gear, shaft (A) and bearing from case.
1704
Disassemble and Assemble Vertical Auger Lower Gear Case
5.
H41083-UN: Vertical Auger Lower Gear Case
LEGEND:
A - Gear
B - Nut and Washer
C - Gear
D - Bearing
Remove bearing (D).
6. Remove gear (C) with shaft.
7. Remove nut and washer (B).
8. Remove gear (A).
9.
H41084-UN: Vertical Auger Lower Gear Case
LEGEND:
A - Shim
B - Woodruff Key
Remove key (B) and shim (A).
1705
Disassemble and Assemble Vertical Auger Lower Gear Case
10.
H41085-UN: Vertical Auger Lower Gear Case
LEGEND:
A - Seal
B - Shaft
Push shaft (B) out.
11. Remove seal (A).
12.
H41086-UN: Vertical Auger Lower Gear Case
LEGEND:
A - Bearing
B - Quill
Install bearing (A) in quill (B). Bearing is a press fit.
13.
H41085-UN: Vertical Auger Lower Gear Case
LEGEND:
A - Seal
B - Shaft
Install seal (A) in case.
14. Install shaft (B).
1706
Disassemble and Assemble Vertical Auger Lower Gear Case
15.
H41084-UN: Vertical Auger Lower Gear Case
LEGEND:
A - Shim
B - Key
Install shim (A) and key (B).
16.
H41087-UN: Vertical Auger Lower Gear Case
LEGEND:
A - Gear
B - Nut
C - Gear
Install gear (A).
17. Install washer and nut (B). Tighten nut to specification.
Item
Measurement Specification
Output Shaft Gear Retaining Cap Screw Torque
18. Position shaft and gear (C).
1707
270 N˙m
(200 lb-ft)
Disassemble and Assemble Vertical Auger Lower Gear Case
19.
H41088-UN: Vertical Auger Lower Gear Case
LEGEND:
A - Guard
B - Shim (2 used)
C - Quill
D - Cap Screw (3 used)
E - Shaft and Gear
F - Cap Screw
Install shims (B), quill (C), guard (A) and cap screws (D). Tighten cap screws to specification.
Item
Measurement Specification
Bearing Quill Screws Torque
68 N˙m
(50 lb-ft)
20. Install shaft and gear (E).
21. Install washer and cap screw (F). Tighten screw to specified torque.
Item
Measurement Specification
Input Shaft Cap Screw Torque
290 N˙m
(214 lb-ft)
22.
H41089-UN: Vertical Auger Lower Gear Case
LEGEND:
1708
Disassemble and Assemble Vertical Auger Lower Gear Case
A - Bearing
Install bearing (A). Bearing is a press fit.
23.
H41090-UN: Vertical Auger Lower Gear Case
LEGEND:
A - Shims
Check for gear backlash using dial indicator.
Item
Measurement Specification
Vertical Auger Lower Gear Case Bevel Gear Backlash Backlash
0.15—0.51 mm
(0.006—0.020 in.)
Adjust with shims (A) as necessary.
Go to Section_130:Group_15
AG,OUO6022,284-19-20030206
1709
Install Vertical Auger and Vertical Auger Lower Gear Case
Install Vertical Auger and Vertical Auger Lower Gear Case
1.
H67894-UN: Vertical Auger
LEGEND:
A - Auger
B - Chain
Install auger (A) into housing and hold in place with chain (B) while installing vertical auger lower gear
case.
1710
Install Vertical Auger and Vertical Auger Lower Gear Case
2.
H67893-UN: Vertical Auger Gear Case
LEGEND:
A - Auger
B - Gear Case
C - Chain
Position gear case (B) under auger (A).
3. Raise gear case and remove chain (C).
1711
Install Vertical Auger and Vertical Auger Lower Gear Case
4.
H67465-UN: Inspection Hole
LEGEND:
A - Inspection Hole
Remove cover from horizontal auger inspection hole (A).
5. IMPORTANT:
Time vertical and horizontal augers or severe damage will result.
H47980-UN: Vertical and Horizontal Augers
LEGEND:
A - Vertical Auger
B - Horizontal Auger
1712
Install Vertical Auger and Vertical Auger Lower Gear Case
C - End of Auger Flighting
Time vertical auger (A) with horizontal auger (B) at 90 degree angles as shown. View augers through
the inspection hole located on the horizontal auger tube near the unloading auger gear case.
6.
H67465-UN: Inspection Hole
LEGEND:
A - Inspection Hole
Install cover on inspection hole (A).
7.
1713
Install Vertical Auger and Vertical Auger Lower Gear Case
H67892-UN: Install Gear Case
LEGEND:
A - Gear Case
B - Remover/installer Bracket
C - Cap Screw (10 used)
Install gear case (A) using cap screws (C).
8. Remove service jack, pedestal and remover/installer bracket (B).
9.
H67903-UN: Gear Case
LEGEND:
A - Nut and Washer
B - Sprocket
C - Wing Screw (5 used)
D - Shield (2 used)
E - Cap Screws (3 used)
F - Shield
G - Cap Screws
Install shield (F) using cap screws (E).
10. Install shields (D) using wing screws (C).
11. Install sprocket (B) using nut and washer (A).
12.
1714
Install Vertical Auger and Vertical Auger Lower Gear Case
H67900-UN: Idler
LEGEND:
A - Nut
B - Washer
C - Gauge
D - Lock Nut
Tighten nut (A) until washer (B) aligns with end of gauge (C). Tighten lock nut (D).
13.
H67907-UN: Shield
LEGEND:
A - Cap Screw (2 used)
B - Guard
Install guard (B) and screws (A).
14. Install tailings elevator, see Section 120, Group 30.
Go to Section_130:Group_15
OUO6045,000012D-19-20010507
1715
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Auger Straightening Tool.......JT05885
For removing dents in horizontal auger tube.
H46405-UN: Auger Straightening Tool
Go to Section_130:Group_20
ZX09263,000274E-19-20080201
1716
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Auger Straightening Tool.......JT05885
For removing dents in horizontal auger tube.
H46405-UN: Auger Straightening Tool
Go to Section_130:Group_20
ZX09263,000274E-19-20080201
1717
Other Material
Other Material
Number
Name
Use
T43512 (U.S.)
TY9473 (Canadian)
242 LOCTITE ™
(LOCTITE®)
Thread Lock and Sealer (medium
strength)
To retain unloading auger gear case sleeve
screws.
Go to Section_130:Group_20
OUO6435,000142A-19-20021120
1718
Specifications
Specifications
Item
Measurement Specification
Unloading Auger Gear Case Sleeve Screws Torque
37 N˙m
(27 lb-ft)
Unloading Auger Gear Case Gear
0.15—0.35 mm
(0.059—0.138 in.)
Backlash
Go to Section_130:Group_20
OUO6435,0001429-19-20010725
1719
Inspection of Horizontal Unloading Auger
Inspection of Horizontal Unloading Auger
H47981-UN: Unloading Auger Orientation
LEGEND:
A - Short Auger
B - Long Auger
C - Flighting Ends
1. Remove the center inspection cover on the unloading auger.
2. Check the union area between the two-piece unloading auger.
3. The timing of the two-piece unloading auger is critical. These two pieces must be timed 180 degrees
from one another. If not, grain flow will be restricted in the short segment of the horizontal unloading
auger, causing back pressure in the vertical auger charge housing and grain tank cross augers.
Go to Section_130:Group_20
1401,DV578-19-19960905
1720
17 ft. (5.18 m) and 20 ft. (6.1 m) Augers - Two-Piece
17 ft. (5.18 m) and 20 ft. (6.1 m) Augers - Two-Piece
H63890-UN: Horizontal Unloading Auger
LEGEND:
A - Bushing
B - Coupling
C - Auger
D - Ball Bearing
E - Housing
F - Screw with Flange Nut (2 used)
G - Gudgeon
H - Washer (as required)
1721
17 ft. (5.18 m) and 20 ft. (6.1 m) Augers - Two-Piece
I - Strip (as required)
J - Screw with Nut (as required)
K - Auger
L - Set Screw
M - Locking Collar
N - Screw and Nut (3 used)
O - Flange Housing (2 used)
P - Ball Bearing
Q - Cap
R - Screw and Flange Nut (5 used)
S - Spring
T - Door
U - Screw
V - Flange Nut
Go to Section_130:Group_20
OUO6435,00013E7-19-20010622
1722
Remove Horizontal Auger
Remove Horizontal Auger
H54867-UN: Auger
H54868-UN: Auger Tube
LEGEND:
A - Spout
B - Cap Screw (6 used)
C - Auger
D - Locking Collar
E - Carriage Bolt (3 used)
1. Remove attaching hardware and spout (A).
2. Remove cap screws (B).
3. Remove carriage bolts (E).
4. Remove end cap and auger (C) from horizontal tube.
5. Loosen set screw and turn locking collar (D) in direction of shaft rotation.
6. Remove end cap from auger.
1723
Remove Horizontal Auger
7.
H67466-UN: Cover
H67467-UN: Inspection Hole
LEGEND:
A - Cover
B - Inspection Hole
C - Carriage Bolt (2 used)
Remove cover (A) from inspection hole (B).
8. Remove carriage bolts (C).
9. Remove auger through horizontal tube.
Go to Section_130:Group_20
AG,OUO6435,1042-19-20000503
1724
Install Horizontal Auger
Install Horizontal Auger
1. IMPORTANT:
Time vertical auger with horizontal auger or severe damage will result.
H67465-UN: Inspection Hole
LEGEND:
A - Inspection Hole
Install auger in horizontal auger tube.
2. Remove cover from horizontal auger inspection hole (A).
3. IMPORTANT:
Time vertical auger with horizontal auger or severe damage will result.
1725
Install Horizontal Auger
H47980-UN: Timing Augers
LEGEND:
A - Vertical Auger
B - Horizontal Auger
C - End of Auger Flighting
Time vertical auger (A) with horizontal auger (B) at 90 degree angles.
4.
H67465-UN: Inspection Hole
LEGEND:
A - Inspection Hole
Install cover on horizontal auger inspection hole (A).
1726
Install Horizontal Auger
5.
H41101-UN: Auger Hardware
LEGEND:
A - Cap Screw and Nut (5 used)
B - Cap
C - Spout
D - Bearing and Housing
E - Cap Screw and Nut (3 used)
F - Locking Collar
Install cap (B) using cap screws and nuts (A).
6. Install flanged bearing housings with bearing (D) using cap screws and nuts (E).
7. Install locking collar (F).
8. Install spout (C).
9.
H67466-UN: Door
1727
Install Horizontal Auger
H67467-UN: Inspection Hole
LEGEND:
A - Door
B - Inspection Hole
C - Carriage Bolt (2 used)
Install carriage bolts (C).
10. Install door (A) on inspection hole (B).
Go to Section_130:Group_20
OUO6030,000008B-19-20010522
1728
Remove Horizontal Auger Gear Case
Remove Horizontal Auger Gear Case
1.
H67438-UN: Plate
LEGEND:
A - Cap Screw (4 used)
B - Plate
Remove horizontal auger. See Remove Horizontal Auger in this group.
2.
NOTE:
Support sheet removed for clarity.
Remove cap screws (A) and plate (B).
3.
H41345-UN: Gear Case Cap Screws
LEGEND:
A - Cap Screw (4 used)
Remove cap screws (A).
1729
Remove Horizontal Auger Gear Case
4.
H56013-UN: Horizontal Auger Gear Case
LEGEND:
A - Horizontal Auger Gear Case
Pull gear case (A) up from vertical auger and remove gear case.
5. Repair gear case as necessary.
Go to Section_130:Group_20
OUO6045,000012F-19-20010507
1730
Disassemble And Assemble Horizontal Unloading Auger Gear Case
Disassemble And Assemble Horizontal Unloading Auger Gear Case
H58645-UN: Unloading Auger Gear Case - Exploded View
LEGEND:
A - Gear (2 used)
B - Bearing Cone (4 used)
C - Bearing Cup (4 used)
D - Shim (2 used)
E - O-Ring (2 used)
F - Snap Ring (2 used)
G - Sleeve (2 used)
H - Snap Ring (2 used)
I - Seal Ring (2 used)
J - Ring Clamp (2 used)
K - Screw
L - Elbow, 90°
1731
Disassemble And Assemble Horizontal Unloading Auger Gear Case
1.
H54785-UN: Auger Gear Case
LEGEND:
A - Cap Screw (6 used)
B - Sleeve (2 used)
Remove six cap screws (A).
2. Remove two sleeves (B).
1732
Disassemble And Assemble Horizontal Unloading Auger Gear Case
3.
H54786-UN: Auger Gear Case
LEGEND:
A - Gear (2 used)
B - Bearing Cone (4 used)
C - Bearing Cup (4 used)
D - Shim (2 used)
E - O-Ring (2 used)
F - Sleeve (2 used)
G - Snap Ring (2 used)
H - Snap Ring (2 used)
I - Seal Ring (2 used)
J - Ring Clamp (2 used)
Disassemble parts (A - J).
4.
NOTE:
Parts (B), (C), (I) and (J) are a press fit.
Clean and inspect parts. Replace as necessary.
5. Assemble parts (A - J).
1733
Disassemble And Assemble Horizontal Unloading Auger Gear Case
6.
H54785-UN: Auger Gear Case
LEGEND:
A - Cap Screw
B - Sleeve
Install two sleeves (B).
7. Apply T43512 Thread Lock and Sealer (Medium Strength) to cap screws (A). Install cap screws and
tighten to specification.
Item
Measurement Specification
Unloading Auger Gear Case Sleeve Screws Torque
1734
37 N˙m
(27 lb-ft)
Disassemble And Assemble Horizontal Unloading Auger Gear Case
8.
H54787-UN: Backlash
Check gears for specified backlash. Add or remove shims to obtain specified value.
Item
Measurement Specification
Unloading Auger Gear Case Gear Backlash
0.15—0.35 mm
(0.059—0.138 in.)
Go to Section_130:Group_20
AG,OUO6023,29-19-20021120
1735
Install Horizontal Auger Gear Case
Install Horizontal Auger Gear Case
1.
H56013-UN: Horizontal Auger Gear Case
LEGEND:
A - Horizontal Auger Gear Case
Install gear case (A) on vertical auger.
2.
H41345-UN: Gear Case Cap Screws
LEGEND:
A - Cap Screw (4 used)
Install cap screws (A).
3.
NOTE:
Support sheet removed for clarity.
H67438-UN: Plate
LEGEND:
1736
Install Horizontal Auger Gear Case
A - Cap Screw (4 used)
B - Plate
Install plate (B) and cap screws (A).
4. Install horizontal unloading auger (see procedure in this group).
Go to Section_130:Group_20
OUO6045,0000130-19-20010507
1737
Remove Horizontal Unloading Auger Tube
Remove Horizontal Unloading Auger Tube
1.
H67469-UN: Auger Tube
Remove horizontal unloading auger. See Remove Horizontal Auger in this group.
2.
CAUTION:
Approximate weight of auger is 181 kg (400 lb).
Attach hoist to auger tube.
3. Disconnect wiring harness at elbow.
4. Remove cap screws from top seam of auger tube.
5. Remove tube.
Go to Section_130:Group_20
AG,OUO6435,1047-19-20000503
1738
Unloading Auger Elbow, Exploded View
Unloading Auger Elbow, Exploded View
H67403-UN: Unloading Auger Elbow, Exploded View
LEGEND:
1 - Housing
2 - Bushing Halves
3 - Washer
4 - Screw
5 - Strap
6 - Wing Nut (4 used)
7 - Washer (4 used)
8 - Door
1739
Unloading Auger Elbow, Exploded View
9 - Screw
10 - Support
11 - Nut
12 - Screw
13 - Weather Strip
14 - Support
15 - Cap Screw
16 - Lubrication Hose
17 - Pin
18 - Cotter Pin
19 - Stop Screw
20 - Auger Base
21 - Lubrication Hoses
22 - Lubrication Hose
23 - Nut
24 - Screw
25 - Sector Plates
Go to Section_130:Group_20
OUO6435,0001402-19-20010717
1740
Remove Horizontal Unloading Auger Elbow
Remove Horizontal Unloading Auger Elbow
1. Remove horizontal auger and tube (see Remove Horizontal Auger and Remove Horizontal Unloading
Auger Tube in this group).
2. Remove left grain tank cover (see procedure in this section).
3.
H67402-UN: Speed Pickup Casting
LEGEND:
A - Hub
B - Cap Screw (6 used)
Remove cap screws (B) and hub (A).
4.
H67432-UN: Bushings
LEGEND:
A - Bushing Half (2 used)
Remove bushing halves (A) from pivot.
1741
Remove Horizontal Unloading Auger Elbow
5.
H67407-UN: Wiring Harness
LEGEND:
A - Connector
B - Wiring Harness
Disconnect harness connector (A) and remove harness (B) from clamps.
6.
H67409-UN: Support
LEGEND:
A - Cap Screw (7 used)
B - Support
Remove cap screws (A) and support (B).
7.
H67410-UN: Trim
1742
Remove Horizontal Unloading Auger Elbow
H67411-UN: Trim
H67412-UN: Trim
LEGEND:
A - Cap Screw (5 used)
B - Bracket
C - Trim
D - Cap Screw (2 used)
Remove cap screws (A) and (D), bracket (B) and trim (C).
8.
H67414-UN: Brace
1743
Remove Horizontal Unloading Auger Elbow
H67415-UN: Brace
LEGEND:
A - Cap Screw (15 used)
B - Support Sheet
Remove cap screws (A) and support sheet (B).
9.
CAUTION:
Approximate weight of elbow is 162 kg (356 lb).
Attach hoist to elbow.
10.
H67427-UN: Lubrication Lines
LEGEND:
A - Lubrication Line (4 used)
Disconnect lubrication lines (A).
1744
Remove Horizontal Unloading Auger Elbow
11.
H67431-UN: Support
LEGEND:
A - Pin
B - Spring Locking Pin
C - Sector Plate (3 used)
D - Cap Screw (12 used)
E - Unloading Auger Elbow
Remove spring locking pin (B) and pin (A).
12. Remove cap screws (D) and sector plates (C).
13. Remove elbow (E).
14. Repair or replace elbow as needed.
Go to Section_130:Group_20
OUO6435,00013EC-19-20010702
1745
Install Horizontal Unloading Auger Elbow
Install Horizontal Unloading Auger Elbow
CAUTION:
Approximate weight of elbow is 162 kg (356 lb).
1. Grease mating surfaces of charge housing and elbow.
2. Lower elbow to charge housing with hoist.
3.
H67431-UN: Elbow
LEGEND:
A - Pin
B - Spring Locking Pin
C - Sector Plate (3 used)
D - Cap Screw (12 used)
E - Unloading Auger Elbow
Install sector plates (C) and cap screws (D).
4. Attach elbow (E) to cylinder using pin (A) and spring locking pin (B).
5.
H67427-UN: Lubrication Lines
LEGEND:
A - Lubrication Line (4 used)
1746
Install Horizontal Unloading Auger Elbow
Connect lubrication lines (A).
6.
H67414-UN: Brace
H67415-UN: Brace
LEGEND:
A - Cap Screw (15 used)
B - Support Sheet
Install support sheet (B) using cap screws (A).
7.
H67410-UN: Trim
1747
Install Horizontal Unloading Auger Elbow
H67411-UN: Trim
H67412-UN: Trim
LEGEND:
A - Cap Screw (5 used)
B - Bracket
C - Trim
D - Cap Screw (2 used)
Install trim (C) using cap screws (A) and (D) and bracket (B).
8.
H67409-UN: Support
LEGEND:
A - Cap Screw (7 used)
B - Support
Install support (B) using cap screws (A).
1748
Install Horizontal Unloading Auger Elbow
9.
H67407-UN: Wiring Harness
LEGEND:
A - Connector
B - Wiring Harness
Position wiring harness (B) in clamps and connect connector (A).
10.
H67432-UN: Bushings
LEGEND:
A - Bushing Half (2 used)
Position bushing halves (A) on pivot.
11.
NOTE:
Do not dislodge bushing halves when installing hub (A).
H67402-UN: Speed Pickup Casting
1749
Install Horizontal Unloading Auger Elbow
LEGEND:
A - Hub
B - Cap Screw (6 used)
Position hub (A) over bushing halves and install cap screws (B).
12. Install left grain tank cover (see procedure in this section).
13. Install unloading auger tube (see Install Horizontal Unloading Auger Tube in this group).
14. Install unloading auger (see Install Horizontal Auger in this group).
Go to Section_130:Group_20
OUO6435,00013EB-19-20010702
1750
Remove Unloading Auger Charge Housing
Remove Unloading Auger Charge Housing
NOTE:
Once the charge housing has been deformed, do not attempt to weld or force it back to its
original design. The system, by deforming this metal, has naturally relieved this area to accept the
load of material.
1. Remove unloading auger (see Remove Horizontal Auger and Remove Horizontal Unloading Auger Tube
in this group).
2. Remove unloading auger elbow (see Remove Horizontal Unloading Auger Elbow in this group).
3. Remove vertical auger lower gear case and vertical auger (see procedures in Group 15).
4. Remove grain tank cross augers (see procedure in Group 05).
5.
H67914-UN: Plate
LEGEND:
A - Cap Screw (16 used)
B - Support Plate
Remove cap screws (A) and support plate (B).
1751
Remove Unloading Auger Charge Housing
6.
H67913-UN: Charge Housing
LEGEND:
A - Cap Screw (30 used)
B - Charge Housing
Remove cap screws (A) to remove charge housing (B).
7.
CAUTION:
The approximate weight of charge housing is 43 kg (95 lb).
1752
Remove Unloading Auger Charge Housing
H41075-UN: Remove Charge Housing
LEGEND:
A - Charge Housing
Remove charge housing (A).
8. Repair or replace parts as necessary.
Go to Section_130:Group_20
OUO6435,00013ED-19-20010702
1753
Other Material
Other Material
Number
Name
Use
TY6341 (U.S.)
Multipurpose SD Polyurea Grease
Especially effective in rolling contact
applications.
TY16135 (U.S.)
NA (Canadian)
58730 LOCTITE ™
(LOCTITE®)
ULTRA BLUE ™ RTV Silicone Form-InPlace Gasket
To seal parts during assembly.
TY6382 (U.S.)
GL-5 Gear Lubricant
To lubricate clean grain elevator gear
case.
Go to Section_130:Group_25
OUO6435,0001426-19-20021120
1754
Other Material
Other Material
Number
Name
Use
TY6341 (U.S.)
Multipurpose SD Polyurea Grease
Especially effective in rolling contact
applications.
TY16135 (U.S.)
NA (Canadian)
58730 LOCTITE ™
(LOCTITE®)
ULTRA BLUE ™ RTV Silicone Form-InPlace Gasket
To seal parts during assembly.
TY6382 (U.S.)
GL-5 Gear Lubricant
To lubricate clean grain elevator gear
case.
Go to Section_130:Group_25
OUO6435,0001426-19-20021120
1755
Specifications
Specifications
Item
Measurement Specification
Clean Grain Elevator Gear Case
Capacity
Lock Nut, Input Shaft and Output Shaft Torque
3.8 L
(4 qt)
125 N˙m
(92 lb-ft)
Go to Section_130:Group_25
OUO6435,0001425-19-20010725
1756
Adjust Clean Grain Elevator Chain
Adjust Clean Grain Elevator Chain
1.
H55856-UN: Adjust Clean Grain Elevator Chain
LEGEND:
A - Nut (4 used)
B - Nut
C - Nut
Release latch and open lower door.
2. Loosen four nuts (A) on bearing mounting plate.
3. Use nuts (B) and (C) to adjust chain.
4. Use nut (B) to loosen chain. Use nut (C) to tighten chain.
NOTE:
Elevator chain is properly adjusted when the lower end of the chain can be slid across
the sprocket. When the chain loosens up to 6 mm (1/4 in.) away from the sprocket,
readjust chain. After a period of use, it may be necessary to remove a half link to adjust
the elevator chain correctly.
5. Tighten nuts (A), (B) and (C).
Go to Section_130:Group_25
AG,OUO6435,1057-19-20000503
1757
Replace Clean Grain Elevator Belt
Replace Clean Grain Elevator Belt
1.
H57726-UN: Belt Tightener
LEGEND:
A - Nut (2 used)
B - Belt
Remove shields.
2. Loosen nuts (A) to relieve tension on belt (B).
3.
H55838-UN: Shield
LEGEND:
A - Cap Screw (8 used)
B - Door
C - Cap Screw (2 used)
D - Door
Remove cap screws (A) and door (B).
4. Remove cap screws (C) and door (D).
1758
Replace Clean Grain Elevator Belt
5.
H58403-UN: Belt
LEGEND:
B - Belt
Remove belt (B).
6.
H57726-UN: Belt Tightener
LEGEND:
A - Nut (2 used)
B - Belt
Install new belt (B) using routing diagram on elevator.
7. Tighten nuts (A) until gauge aligns with washer.
8. Install shields.
Go to Section_130:Group_25
AG,OUO6435,1058-19-20000503
1759
Clean Grain Loading Auger, Exploded View
Clean Grain Loading Auger, Exploded View
ZX25214-UN: Loading Auger Assembly
LEGEND:
A - Cap Screw
B - Washer
C - Nut (2 used)
D - Bearing Flange (2 used)
E - Bearing
F - Shim
G - Spacer
H - Carriage Bolt (2 used)
I - Nut (4 used)
J - Carriage Bolt (4 used)
K - Auger Tube
L - Auger
Go to Section_130:Group_25
OUO6435,0001401-19-20010717
1760
Replace Clean Grain Loading Auger Bearing
Replace Clean Grain Loading Auger Bearing
1.
NOTE:
Shield on auger housing does not need to be removed to remove bearing.
IMPORTANT:
Install bearing assembly on top of support. If bearing is between support and auger, the gear case may
fail.
Remove carriage bolts and nuts (A).
H54886-UN: Loading Auger Bearing
LEGEND:
A - Nuts
B - Cap Screw
2. Remove cap screw (B) and washer.
3. Remove bearing, flangettes and spacer.
4. Install spacer, bearing, flangettes and hardware.
Go to Section_130:Group_25
AG,OUO6435,1062-19-20000503
1761
Remove Clean Grain Loading Auger Assembly
Remove Clean Grain Loading Auger Assembly
1.
CAUTION:
Auger assembly is heavy. Use suitable lifting equipment to avoid personal injury.
ZX25191-UN: Lift Cylinder
LEGEND:
A - Cap Screw
B - Assist Cylinder
C - Cap Screw
D - Lift Cylinder
Attach a suitable lifting device to auger.
2. Perform the following steps on machines equipped with 10,000 liter grain tank extensions:
1. Disconnect all grain tank cover linkage from loading auger.
2. Remove nut, cap screw (C) and disconnect lift cylinder (D).
3. Remove nut, cap screw (A) and disconnect assist cylinder (B).
3.
H66323-UN: Auger Mounting
LEGEND:
A - Nut
1762
Remove Clean Grain Loading Auger Assembly
B - Cap Screw (2 used)
Lower auger and remove nut (A) and cap screw from universal joint.
4. Remove cap screws (B) attaching auger to transition housing.
5. Remove auger.
6. Repair or replace parts as necessary.
Go to Section_130:Group_25
OUO6435,0001467-19-20010817
1763
Remove and Install Clean Grain Elevator Gear Case
Remove and Install Clean Grain Elevator Gear Case
1.
H54386-UN: Clean Grain Elevator Idler, Tension Spring
LEGEND:
A - Nut (2 used)
Loosen nuts (A) to relieve belt tension on upper drives.
2. Remove clean grain loading auger (see Remove Clean Grain Loading Auger Assembly in this group).
3.
H66310-UN: Sheave Nut
H66311-UN: Removal of Sheave Using Puller
1764
Remove and Install Clean Grain Elevator Gear Case
H66312-UN: Gear Case Cap Screws
LEGEND:
A - Belt
B - Nut
C - Cap Screw (4 used)
Remove belt (A) and nut (B) from sheave.
4. Remove sheave using a suitable puller.
5. Remove cap screws (C) and gear case.
6. Inspect gear case. Repair or replace parts as necessary. See Disassemble and Assemble Clean Grain
Elevator Gear Case in this group.
7. Install in reverse order.
8. Install belt. Tighten nuts on idler tension spring until washer aligns with gauge.
Go to Section_130:Group_25
OUO6435,00013E2-19-20010620
1765
Disassemble and Assemble Clean Grain Elevator Gear Case
Disassemble and Assemble Clean Grain Elevator Gear Case
H66298-UN: Clean Grain Elevator Gear Case
LEGEND:
A - Screw and Washer (11 used)
B - Cover
C - Lock Nut (2 used)
D - Washer (2 used)
E - Gear
F - Bearing Assembly
G - Key (2 used)
H - Output Shaft
I - Gear Case
J - Seal
K - Seal
L - Input Shaft
M - Ball Bearing
N - Bushing
O - Ball Bearing
P - Snap Ring
Q - Bevel Gear
R - Key
1. Drain gear case. The approximate capacity is 3.8 L (4 qt).
Item
Measurement Specification
Clean Grain Elevator Gear Case Capacity
3.8 L
(4 qt)
1766
Disassemble and Assemble Clean Grain Elevator Gear Case
2.
H66294-UN: Clean Grain Elevator Gear Case
H66675-UN: Clean Grain Elevator Gear Case
LEGEND:
A - Cover (2 used)
Remove covers (A).
3. Clean covers and case mating surfaces.
4.
H40333-UN: Clean Grain Elevator Gear Case
LEGEND:
A - Gear (2 used)
B - Washer (2 used)
1767
Disassemble and Assemble Clean Grain Elevator Gear Case
Remove lock nuts and washers (B).
5. Press out shaft or shafts needing repair from gears (A).
6.
H66343-UN: Output Shaft
LEGEND:
A - Lock Nut
B - Washer
C - Bearing Cone
D - Bearing Cup
E - Spacer
F - Snap Ring
G - Bearing Cup
H - Bearing Cone
I - Key
J - Shaft
K - Seal
Remove output shaft components (A - K).
7. Replace parts as necessary.
1768
Disassemble and Assemble Clean Grain Elevator Gear Case
8.
H66296-UN: Input Shaft
LEGEND:
A - Snap Ring
B - Ball Bearing
C - Bushing
D - Ball Bearing
E - Shaft
F - Key
G - Key
Remove input shaft components (A - G).
9. Replace parts as necessary.
1769
Disassemble and Assemble Clean Grain Elevator Gear Case
10.
H66297-UN: Clean Grain Elevator Gear Case
LEGEND:
A - Screw and Washer (11 used)
B - Cover
C - Lock Nut (2 used)
D - Washer (2 used)
E - Gear
F - Bearing Assembly
G - Key (2 used)
H - Output Shaft
I - Gear Case
J - Seal
K - Seal
L - Input Shaft
M - Ball Bearing
N - Bushing
O - Ball Bearing
P - Snap Ring
Q - Bevel Gear
R - Key
Drive ball bearing (M) over threaded end of input shaft (L) and seat against shoulder.
11. Install input shaft (L) with bearing (M) through large opening of gear case (I) and into long quill side of
case.
NOTE:
End of shaft with keyway should extend out of quill and case.
12. Slide bushing (N) over shaft and against bearing (M).
1770
Disassemble and Assemble Clean Grain Elevator Gear Case
12. Slide bushing (N) over shaft and against bearing (M).
13. Drive ball bearing (O) over threaded end of input shaft (L) and seat against bushing (N).
14. Install snap ring (P) in gear case (I) against ball bearing (O).
15. Install key (G) in keyway of input shaft (L).
16. Slide bevel gear (Q) over threaded end of input shaft (L) and key with heel of gear first.
17. Slide washers (D) over threaded end of input shaft (L) and against hub of gear (Q).
18. Install lock nut (C) on input shaft (L) or output shaft (H) against washer (D). Tighten nut to specification.
Item
Measurement Specification
Lock Nut, Input Shaft and Output Shaft Torque
125 N˙m
(92 lb-ft)
19. Install seal (J) in short quill side of gear case (I). Pack seal cavity with Multi-Purpose SD Polyurea
Grease. Press seal into case until outer edge is flush with case.
20. Install seal (K) with spring-loaded lip to the inside until outer edge of seal is flush with case.
21. Apply TY16135 Ultra Blue RTV Silicone Form-In-Place Gasket to gear case (I) and cover (B) mating
surfaces. Apply all around cap screw holes.
22. Install cover on gear case with eleven cap screws and washers (A).
23.
H66294-UN: Clean Grain Elevator Gear Case
LEGEND:
A - Cover
Install cover (A).
24. Fill gear case with TY6382, GL-5 Gear Lubricant.
1771
Disassemble and Assemble Clean Grain Elevator Gear Case
Item
Measurement Specification
Clean Grain Elevator Gear Case Capacity
3.8 L
(4 qt)
Go to Section_130:Group_25
OUO6435,0001392-19-20021120
1772
Remove Clean Grain Elevator
Remove Clean Grain Elevator
1.
H57734-UN: Wiring Harness
LEGEND:
A - Harness Connector
B - Moisture Sensor
C - Clamp
Disconnect harness connector (A).
2. Remove harness clamp (C).
3. Remove moisture sensor (B).
4.
H57726-UN: Elevator Belt Tensioner
LEGEND:
A - Nuts
B - Belt
Loosen nuts (A) to relieve belt tension.
5. Remove belt (B) from sheaves and idler.
1773
Remove Clean Grain Elevator
6.
ZX25203-UN: Access Doors
LEGEND:
A - Cap Screw (11 used)
B - Door
C - Cap Screw (2 used)
D - Access Cover
Remove cap screws (A) and door (B).
7. Remove cap screws (C) and access cover (D).
8. Remove belt.
9. Remove loading auger (see procedure in this group).
10.
H58723-UN: Baffle
LEGEND:
A - Baffle
Remove baffle (A).
1774
Remove Clean Grain Elevator
11.
ZX25264-UN: Transition Housing
LEGEND:
A - Cap Screw (9 used)
Remove cap screws (A).
1775
Remove Clean Grain Elevator
12.
H58726-UN: Transition Housing
LEGEND:
A - Cap Screw (4 used)
B - Support
C - Mass Flow Sensor Harness Connection
D - Transition Housing
Remove cap screws (A) and support (B).
13. Disconnect mass flow sensor connector (C), if equipped.
CAUTION:
14.
Approximate weight of transition housing is 49 kg (108 lb).
Remove transition housing (D).
15.
H58682-UN: Elevator Seals
LEGEND:
A - Seal
B - Seal
Remove floor seals (A) and (B).
1776
Remove Clean Grain Elevator
16.
H57729-UN: Clean Grain Auger Sensor
LEGEND:
A - Sensor
B - Actuator
Disconnect harness at sensor (A).
17. Remove sensor and actuator (B).
18.
H57728-UN: Clean Grain Auger Locking Collar
LEGEND:
A - Locking Collar
B - Nut (3 used)
C - Cap Screws
Loosen set screw and remove locking collar (A).
19. Remove nuts (B), sensor bracket and outside flangette.
20. Remove cap screws (C).
1777
Remove Clean Grain Elevator
21.
H54769-UN: Paddle Chain Master Link
LEGEND:
A - Cotter Pin
Open cleanout door and remove cotter pin (A) and pin from paddle chain master link.
22. Remove paddle chain.
23.
H57739-UN: Bearing Cover
LEGEND:
A - Cover
Remove nuts and bearing cover (A).
24. Loosen set screw and remove locking collar (A).
H57741-UN: Locking Collar
LEGEND:
1778
Remove Clean Grain Elevator
A - Locking Collar
B - Nut (4 used)
C - Adjusting Screw
D - Plate
25. Remove nuts (B).
26. Loosen nuts on screw (C).
27. Remove outer bearing plate and adjusting plate (D).
28.
H57740-UN: Bearing And Plate
LEGEND:
A - Bearing
B - Plate
Remove bearing (A) and inner bearing plate (B).
29.
H54775-UN: Sprocket And Spacer
LEGEND:
A - Spacer
B - Sprocket
Slide auger to the left and remove sprocket (B) and spacer (A).
1779
Remove Clean Grain Elevator
30.
H57727-UN: Bearing
LEGEND:
A - Bearing
Remove bearing (A), inside flangette and plate.
31.
NOTE:
Lower auger does not need to be removed from machine, just enough to allow elevator
removal.
NOTE:
If paddle chain is removed with elevator body, be sure to attach ends of chain together
to prevent chain from falling.
Rotate auger out slot in left sidesheet.
H57742-UN: Remove Auger
1780
Remove Clean Grain Elevator
32.
H57738-UN: Brace
H57733-UN: Hinge Pins
LEGEND:
A - Brace
B - Hinge Pins
C - Cover
Remove brace (A), hinge pins (B) and cover (C).
33.
H57732-UN: Cap Screws
LEGEND:
A - Cap Screw (5 used)
Remove cap screws (A) and shields.
1781
Remove Clean Grain Elevator
34.
H57725-UN: Lower Auger Tube
LEGEND:
A - Tube
B - Cap Screw (8 used)
Remove cap screws (B) attaching lower auger tube (A) to sidesheet.
35.
H58683-UN: Lower Boot
LEGEND:
A - Cap Screw (8 used)
B - Boot
Remove cap screws (A) and boot (B).
36.
CAUTION:
Clean grain elevator is heavy and awkward to handle. Use suitable lifting
equipment to avoid personal injury.
Elevator weighs 83 kg (183 lb).
Attach lifting device to elevator.
1782
Remove Clean Grain Elevator
37.
H58447-UN: Rear Seal Mounting
H58448-UN: Rear Seal Mounting
LEGEND:
A - Cap Screw (2 used)
B - Cap Screw (7 used)
C - Sheave (2 used)
Remove cap screws (A) and sheaves (C).
38. Remove cap screws (B).
39. Carefully lower elevator out of combine.
Go to Section_130:Group_25
OUO6435,0001400-19-20010717
1783
Grain Tank Base
Grain Tank Base
ZX25229-UN: Grain Tank Base
LEGEND:
1 - Bracket
2 - Wing Nut
3 - Cover
4 - Housing
5 - Seal (as required)
6 - Dust Shield
7 - Flange Nut (4 used)
8 - Cap Screw and Flange Nut (8 used)
1784
Grain Tank Base
9 - Bracket
10 - Bracket
11 - Screw (2 used)
12 - Deflector
13 - Bracket
14 - Cap Screw and Flange Nut (5 used)
15 - Channel
16 - Plate (4 used)
17 - Cap Screw and Flange Nut (37 used)
18 - Bracket
19 - Bracket
20 - Cap Screw and Flange Nut (6 used)
21 - Spring Pin (4 used)
22 - Pin (4 used)
23 - Curtain (2 used)
24 - Bracket
25 - Hose Support
26 - Hose Support
27 - Support
28 - Mount (2 used)
29 - Bracket (2 used)
30 - Channel
31 - Screw (12 used)
32 - Nut
33 - Screw
34 - Housing
35 - Cap Screw, Washer, and Flange Nut (5 used)
36 - Tank
37 - Screw (5 used)
38 - Lock Washer (5 used)
39 - Screw (5 used)
40 - Washer (5 used)
41 - Support
42 - Support
43 - Plate
44 - Spring Pin (2 used)
45 - Pin
46 - Deflector
47 - Screws (4 used)
48 - Bushing (4 used)
49 - Washer (4 used)
50 - Flange Nut (4 used)
51 - Bracket
Go to Section_130:Group_30
OUO6435,00013FF-19-20010716
1785
Grain Tank Base
Grain Tank Base
ZX25229-UN: Grain Tank Base
LEGEND:
1 - Bracket
2 - Wing Nut
3 - Cover
4 - Housing
5 - Seal (as required)
6 - Dust Shield
7 - Flange Nut (4 used)
8 - Cap Screw and Flange Nut (8 used)
1786
Grain Tank Base
9 - Bracket
10 - Bracket
11 - Screw (2 used)
12 - Deflector
13 - Bracket
14 - Cap Screw and Flange Nut (5 used)
15 - Channel
16 - Plate (4 used)
17 - Cap Screw and Flange Nut (37 used)
18 - Bracket
19 - Bracket
20 - Cap Screw and Flange Nut (6 used)
21 - Spring Pin (4 used)
22 - Pin (4 used)
23 - Curtain (2 used)
24 - Bracket
25 - Hose Support
26 - Hose Support
27 - Support
28 - Mount (2 used)
29 - Bracket (2 used)
30 - Channel
31 - Screw (12 used)
32 - Nut
33 - Screw
34 - Housing
35 - Cap Screw, Washer, and Flange Nut (5 used)
36 - Tank
37 - Screw (5 used)
38 - Lock Washer (5 used)
39 - Screw (5 used)
40 - Washer (5 used)
41 - Support
42 - Support
43 - Plate
44 - Spring Pin (2 used)
45 - Pin
46 - Deflector
47 - Screws (4 used)
48 - Bushing (4 used)
49 - Washer (4 used)
50 - Flange Nut (4 used)
51 - Bracket
Go to Section_130:Group_30
OUO6435,00013FF-19-20010716
1787
Grain Tank
Grain Tank
ZX25320-UN: Grain Tank
LEGEND:
1 - Bracket
2 - Cap Screw (2 used)
3 - Panel
4 - Cap Screw (6 used)
5 - Tank
6 - Cap Screw (2 used)
7 - Access Ladder
8 - Cap Screw (2 used)
9 - Cap Screw and Flange Nut (7 used)
10 - Cap Screw and Flange Nut (13 used)
11 - Nut (2 used)
12 - Cap Screw (4 used)
13 - Bracket (2 used)
14 - Gasket (2 used)
15 - Screws (4 used)
16 - Screw and Nut (2 used)
17 - Hinge (2 used)
1788
Grain Tank
18 - Bushing (2 used)
19 - Door
20 - Rivet (2 used)
21 - Latch
22 - Knob
23 - Weather Strip (as required)
24 - Flange Nut (4 used)
25 - Washer (2 used)
26 - Lock Nut (2 used)
27 - Cap Screw (4 used)
28 - Nut (4 used)
29 - Washer (4 used)
30 - Bracket (2 used)
31 - Washer (2 used)
32 - Cap Screw (2 used)
33 - Plate
34 - Plate
35 - Cap Screw (4 used)
36 - Bushing (4 used)
37 - Latch (2 used)
38 - Wing Nut (2 used)
39 - Window Pane
Inspect grain tank parts. Repair or replace parts as necessary.
Go to Section_130:Group_30
OUO6435,0001431-19-20010725
1789
Grain Tank Covers - 8,000 and 9,000 Liters
Grain Tank Covers - 8,000 and 9,000 Liters
ZX25275-UN: Grain tank covers
LEGEND:
1 - Cover
2 - Cover
3 - Hinge
4 - Cap Screw
5 - Flange Nut
6 - Handle
7 - Lock Nut
8 - Hinge
1790
Grain Tank Covers - 8,000 and 9,000 Liters
9 - Cap Screw
10 - Cap Screw
11 - Lock Nut
12 - Tube
Go to Section_130:Group_30
OUO6435,0001406-19-20010718
1791
Grain Tank Cover Seals - 8,000 and 9,000 Liters
Grain Tank Cover Seals - 8,000 and 9,000 Liters
ZX25276-UN: Grain Tank Cover Seals
LEGEND:
1 - Cover
2 - Cover
3 - Reinforcement
4 - Bracket
5 - Cap Screw
6 - Flange Nut
7 - Seal
8 - Rivet
1792
Grain Tank Cover Seals - 8,000 and 9,000 Liters
9 - Seal
10 - Reinforcement
11 - Seal
12 - Seal
13 - Cap Screw
14 - Flange Nut
Go to Section_130:Group_30
OUO6435,0001408-19-20010718
1793
Grain Tank Cover Supports - 8,000 and 9,000 Liters
Grain Tank Cover Supports - 8,000 and 9,000 Liters
ZX25272-UN: Grain Tank Support
LEGEND:
1 - Rod
2 - Guide
3 - Guide
4 - Spring
5 - Gas Assist Cylinder
6 - Cap Screw
7 - Nut
8 - Cap Screw
1794
Grain Tank Cover Supports - 8,000 and 9,000 Liters
9 - Cap Screw
10 - Cap Screw
11 - Washer
12 - Nut
13 - Bracket
14 - Bushing
15 - Flange Nut
16 - Flange Nut
17 - Washer
18 - Cap Screw
19 - Support
Go to Section_130:Group_30
OUO6435,0001403-19-20010718
1795
Grain Tank Cover Cylinders - 8,000 and 9,000 Liters
Grain Tank Cover Cylinders - 8,000 and 9,000 Liters
ZX25273-UN: Grain Tank Cylinders
LEGEND:
1 - Gas Assist Cylinder
2 - Cap Screw
3 - Lock Nut
4 - Cap Screw
5 - Flange Nut
6 - Holder
7 - Cap Screw
1796
Grain Tank Cover Cylinders - 8,000 and 9,000 Liters
Go to Section_130:Group_30
OUO6435,0001404-19-20010718
1797
Grain Tank Cover Actuator - 8,000 and 9,000 Liters
Grain Tank Cover Actuator - 8,000 and 9,000 Liters
ZX25274-UN: Grain Tank Actuator
LEGEND:
1 - Lift Motor
2 - Holder
3 - Bushing
4 - Bushing
5 - Cap Screw
6 - Lock Nut
7 - Cap Screw
8 - Flange Nut
1798
Grain Tank Cover Actuator - 8,000 and 9,000 Liters
Go to Section_130:Group_30
OUO6435,0001405-19-20010718
1799
Grain Tank, General View - 11,000 Liters
Grain Tank, General View - 11,000 Liters
ZX25223-UN: Grain Tank
Go to Section_130:Group_30
OUO6435,0001413-19-20010720
1800
Grain Tank Covers - 11,000 Liters
Grain Tank Covers - 11,000 Liters
ZX25277-UN: Grain Tank Covers
LEGEND:
1 - Access Ladder
2 - Cap Screw
3 - Beam
4 - Cap Screw
5 - Nut
6 - Cap Screw
7 - Lock Nut
8 - Frame
1801
Grain Tank Covers - 11,000 Liters
9 - Bracket
10 - Flange Nut
11 - Cap Screw
12 - Bracket
13 - Cover
14 - Cover
15 - Cover
16 - Cover
17 - Panel
18 - Channel
19 - Channel
20 - Cap Screw
21 - Lock Washer
22 - Cap Screw
23 - Cap Screw
24 - Nut
25 - Screw
26 - Strap
27 - Strap
28 - Strap
29 - Strap
30 - Brace
31 - Washer
32 - Cap Screw
33 - Lock Nut
34 - Cap Screw
35 - Cap Screw
36 - Brace
37 - Connecting Rod
38 - Spacer
39 - Cap Screw
40 - Cap Screw
41 - Bushing
42 - Washer
43 - Connecting Rod
44 - Pin
45 - Spring Locking Pin
46 - Connecting Rod
47 - Bushing
Go to Section_130:Group_30
OUO6435,000140A-19-20010718
1802
Grain Tank Lift Cylinders and Linkage - 11,000 Liters
Grain Tank Lift Cylinders and Linkage - 11,000 Liters
ZX25281-UN: Grain Tank Lift Cylinders and Linkage
LEGEND:
1 - Deflector
2 - Cradle
3 - Cap Screw (10 used)
4 - Tube
5 - Nut (4 used)
6 - Bracket
7 - Cap Screw (4 used)
8 - Bushing (8 used)
9 - Nut (4 used)
10 - Connecting Rod (2 used)
1803
Grain Tank Lift Cylinders and Linkage - 11,000 Liters
11 - Flange Nut (2 used)
12 - Lock Nut (2 used)
13 - Rod End (2 used)
14 - Brace (2 used)
15 - Nut (4 used)
16 - Washer (4 used)
17 - Cap Screw (4 used)
18 - Lift Cylinder
19 - Nut (2 used)
20 - Cap Screw (2 used)
21 - Assist Cylinder
22 - Spring
23 - Assist Cylinder
24 - Cap Screw (2 used)
25 - Bushing (2 used)
26 - Washer (2 used)
27 - Springs (2 used)
28 - Spacer (2 used)
Adjust rod ends (13) until side canvases are taut when covers are in the full open position.
Go to Section_130:Group_30
OUO6435,0001409-19-20010718
1804
Table of Contents
Section 140: Engine Gear Case and Control Valve, Repair
Group 05: Engine Gear Case and Valve
Essential and Recommended Special Tools
Other Material
Specifications
General Information
Remove and Install Engine Gear Case
Engine Gear Case Specifications
Disassemble and Assemble Separator Drive Wet Clutch
Disassemble and Assemble Hydrostatic Gear Set
Set Gear Position
Preload Bearings
Disassemble and Assemble Straw Chopper/Unloading System
Set Separator Drive Gear Position
Preload Bearings
Disassemble and Assemble Separator Drive
Preload Separator Drive Bearings
Set Separator Drive Gear Backlash
Disassemble and Assemble Hydrostatic Pump Drive
Preload Hydrostatic Pump Drive Bearings
Set Hydrostatic Pump Drive Gear Backlash
Disassemble and Assemble Oil Screen
Disassemble and Assemble Oil Trough
Disassemble and Assemble Dipstick Tube
Remove and Install Filter
Remove and Install Pressure Regulating Valve
Disassemble and Assemble Pressure Regulating Valve
1805
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Rear Engine Support Bracket.......JDG1297
Support engine during removal of main engine gear
case.
H68345-UN: JDG1297
Clutch Pack Lifting Tool.......JDG1294
Remove wet clutch assembly from gear case.
H68346-UN: JDG1294
Spring Washer Compressor.......JDT24A
Compresses spring-type washers.
H40102-UN: Spring Washer Compressor
1806
Essential and Recommended Special Tools
Air Test Plug.......JDG185
Used to release clutch from piston.
T6557CI-UN: Air Test Plug
Puller.......JDG1268
Remove sheaves from combine
H68321-UN: JDG1268
Spanner Wrench.......JDG666
Remove and install wet clutch lock nuts.
H40101-UN: Spanner Wrench
Go to Section_140:Group_05
ZX09263,000274F-19-20080201
1807
Essential and Recommended Special Tools
Essential and Recommended Special Tools
NOTE:
Order tools from the U.S. SERVICEGARD ™ catalog or via the European spare parts channel.
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable from the U.S.
SERVICEGARD ™ catalog or via the European spare parts channel.
RECOMMENDED TOOLS , as noted, are suggested to perform the job correctly. Some tools may be available
from local suppliers or may be fabricated
Rear Engine Support Bracket.......JDG1297
Support engine during removal of main engine gear
case.
H68345-UN: JDG1297
Clutch Pack Lifting Tool.......JDG1294
Remove wet clutch assembly from gear case.
H68346-UN: JDG1294
Spring Washer Compressor.......JDT24A
Compresses spring-type washers.
H40102-UN: Spring Washer Compressor
1808
Essential and Recommended Special Tools
Air Test Plug.......JDG185
Used to release clutch from piston.
T6557CI-UN: Air Test Plug
Puller.......JDG1268
Remove sheaves from combine
H68321-UN: JDG1268
Spanner Wrench.......JDG666
Remove and install wet clutch lock nuts.
H40101-UN: Spanner Wrench
Go to Section_140:Group_05
ZX09263,000274F-19-20080201
1809
Other Material
Other Material
Number
Name
Use
TY22068
(U.S.)
Torq-Gard ™ SAE 10W
Lubricate gear case components
T43513
(U.S.)
Thread Lock and Sealer (High
Strength)
Prevent dipstick tube from loosening.
TY24345
(U.S.)
RTV Silicone Adhesive Sealant
To seal mating surfaces.
For seal plate on engine gear case.
TY6341
(U.S.)
Multipurpose SD Polyurea
Grease
Applied where shock loads and sliding contacts are continuously
encountered.
Go to Section_140:Group_05
AG,OUO6435,1071-19-20021120
1810
Specifications
Specifications
Item
Measurement
Specification
Engine Gear Case-to-Engine Cap Screws
Torque
340 N˙m
(250 lb-ft)
Engine Gear Case-to-Frame Cap Screws
Torque
123 ± 31 N˙m
(91 ± 23 lb-ft)
Engine Gear Case Plate Cap Screws
Torque
25 N˙m
(221 lb-in.)
Hydrostatic Pump-to-Gear Case Cap Screws
Torque
130 ± 30 N˙m
(96 ± 22 lb-ft)
Clutch Hub Cap Screws
Torque
75 N˙m
(55 lb-ft)
Clutch-to-Gear Case Cap Screws
Torque
50 N˙m
(40 lb-ft)
Seal Plate Cap Screws
Torque
15 N˙m
(144 lb-in.)
Straw Chopper Drive Sheave Cap Screws
Torque
90 N˙m
(65 lb-ft)
Unloading System Drive Shaft Nut
Torque
340 N˙m
(250 lb-ft)
Bearing Housing-to-Gear Case Cap Screws
Torque
50 N˙m
(40 lb-ft)
Separator Drive-to-Gear Case Cap Screws
Torque
50 ± 10 N˙m
(37 ± 7 lb-ft)
Separator Drive
Axial Play
0.33 to 0.43 mm
(0.012 to 0.016 in.)
+ 1/4 turn to preload
Separator Drive Outer Lock Nut
Torque
70 N˙m
(52 lb-ft)
Separator Drive Assembly
Rolling Drag Torque 28 N˙cm
(40 oz-in.)
Hydrostatic Pump Drive Gear
Axial Play
0.33 to 0.43 mm
(0.012 to 0.016 in.)
+ 1/4 turn to preload
Hydrostatic Pump Drive Outer Nut
Torque
70 N˙m
(52 lb-ft)
Hydrostatic Pump Drive
Rolling Drag Torque 28 N˙cm
(40 oz-in.)
Engine Gear Case Wet Clutch
Hydrostatic Pump Drive-to-Gear Case Cap Screws Torque
50 N˙m
(40 lb-ft)
Engine Gear Case Oil Screen Cover Cap Screws
Torque
25 N˙m
(216 lb-in.)
Oil Trough Cover Cap Screws
Torque
25 ± 5 N˙m
(221 ± 44 lb-in.)
Engine Gear Case
Capacity
16 L
(17 qt)
Pressure Regulating Valve Solenoid Cartridge
Torque
25 N˙m
(216 lb-in.)
Pressure Regulating Valve Cap Screws
Torque
25 N˙m
(216 lb-in.)
1811
Specifications
Item
Measurement
Specification
Pump
Weight
77 kg
(150 lb)
Go to Section_140:Group_05
OUO6089,0000078-19-20010730
1812
General Information
General Information
H57504-UN: Inner Seal of Wet Clutch
LEGEND:
A - Inner Seal
The inner seal (A) can be replaced without draining the gear case oil (see Remove and Install Engine Gear Case
in this group).
Repair can be done on any one area without disassembling entire gear case. Only for complete disassembly is it
necessary to remove gear case.
H58317-UN: Engine Gear Case
Read the information in the Diagnosis and Tests manual, Section 270, on how the gear case and its valves
operate.
Familiarize yourself with the exploded views of the gear case before starting repair work.
Go to Section_140:Group_05
OUO6089,0000079-19-20010730
1813
Remove and Install Engine Gear Case
Remove and Install Engine Gear Case
1.
H68230-UN: Panel
LEGEND:
A - Panel
B - Muffler
Remove left gull wing doors (see Remove and Install Gull Wing Doors in Section 80, Group 05).
2. Swing out unloading auger. Remove panel (A) and muffler (B).
3. Fully lower header and reel and continue to press switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine. Remove key.
4.
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other
lines. Tighten all connections before applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin
must be surgically removed within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a knowledgeable medical
source. Such information is available from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
1814
Remove and Install Engine Gear Case
ZX25197-UN: Remove Hose
ZX25195-UN: Remove Hose
LEGEND:
A - Plug
B - Belt Trap
C - Belts
D - Hose
E - Cap Screws (2 used)
F - Nut
G - Linkage
Remove plug (A) to drain oil from gear case.
5. Remove belt trap (B).
6. Remove belts (C).
1815
Remove and Install Engine Gear Case
7. Remove cap screws (E), nut (F) and linkage (G).
8. Remove hose (D).
9.
H58627-UN: Engine Gear Case
LEGEND:
A - Hose
B - Hose
C - Hose
D - Hose
E - Wire
F - Wire
G - Wire
H - Wire
Disconnect hoses (A) to (D).
NOTE:
Plug and cap all openings to avoid contamination and make certain to identify ALL
hoses and wires for correct reassembly.
10. Disconnect wires (E) to (H).
NOTE:
It is not necessary to remove filter-to-valve hoses.
11.
CAUTION:
1816
Remove and Install Engine Gear Case
Approximate weight of pump assembly is 77 kg (150 lb).
NOTE:
It is not necessary to disconnect lines and hoses to pumps.
H44351-UN: Pump Assembly
LEGEND:
A - Lifting Device
B - Hydrostatic Pump
C - Cap Screw (4 used)
D - Charge Pump
E - Main Hydraulic Pump
Attach lifting device (A) to pump assembly.
12. Remove four cap screws (C).
13. Remove hydrostatic pump (B), charge pump (D) and main hydraulic pump (E) as an assembly.
14.
ZX25196-UN: Drive Shaft Shield
LEGEND:
A - Nuts
B - Bracket
C - Shield
1817
Remove and Install Engine Gear Case
Remove nuts (A), bracket (B) and shield (C).
15.
H44365-UN: Separator Drive Shaft
LEGEND:
A - Separator Drive Shaft
Disconnect separator drive shaft (A) at front of grain tank. Use tape to keep needle bearings in place.
16.
H58631-UN: Separator Drive Shaft
LEGEND:
A - Splines
Slide complete separator drive shaft off splines (A).
17.
CAUTION:
The approximate weight of gear case is 190 kg (425 lb).
1818
Remove and Install Engine Gear Case
H58628-UN: Engine Gear Case
H58322-UN: Engine Gear Case
H68343-UN: JDG1297
LEGEND:
A - Lifting Device
B - Cap Screw (4 used)
C - Cap Screw (8 used)
D - RTV Silicone Adhesive Sealant
E - JDG1297 Rear Engine Support Bracket
Install JDG1297 Rear Engine Support Bracket.
18. Attach lifting device (A). Remove dust cover.
19. Remove cap screws (B) and (C) and remove gear case.
20. Inspect parts. Repair or replace parts as necessary.
21.
NOTE:
Turn outer unloading system sheave to align splines on gear case with engine flywheel.
Apply new RTV Silicone Adhesive Sealant (D) to gear case flange. Install dowel pins on engine.
22. Align dowel pins on engine with gear case and install gear case. Tighten cap screws (B) to specification.
Item
Measurement Specification
Engine Gear Case-to-Frame Cap Screws Torque
1819
123 ± 31 N˙m
(91 ± 23 lb-ft)
Remove and Install Engine Gear Case
Tighten cap screws (C) to specified torque.
Item
Measurement Specification
Engine Gear Case-to-Engine Cap Screws Torque
340 N˙m
(250 lb-ft)
Engine Gear Case Plate Cap Screws
25 N˙m
(221 lb-in.)
Torque
23.
H58631-UN: Separator Drive Shaft
LEGEND:
A - Splines
Install separator drive shaft on splines (A).
24.
H44365-UN: Drive Shaft
LEGEND:
A - Drive Shaft
Connect drive shaft (A) at front of grain tank.
25. Install drive shaft shield.
1820
Remove and Install Engine Gear Case
26.
H44351-UN: Pump Assembly
LEGEND:
A - Lifting Device
B - Hydrostatic Pump
C - Cap Screw (4 used)
D - Charge Pump
E - Main Hydraulic Pump
Install hydrostatic pump (B), charge pump (D) and main hydraulic pump (E).
27. Tighten cap screws (C) to specified torque.
Item
Measurement Specification
Hydrostatic Pump-to-Gear Case Cap Screws Torque
Remove lifting device (A).
28.
H58627-UN: Engine Gear Case
LEGEND:
A - Hose
B - Hose
C - Hose
D - Hose
1821
130 ± 30 N˙m
(96 ± 22 lb-ft)
Remove and Install Engine Gear Case
E - Wire
F - Wire
G - Wire
H - Wire
Connect wires (E) to (H).
29. Connect hoses (A) to (D).
30.
ZX25197-UN: Install Hose
ZX25196-UN: Gear Case Linkage
LEGEND:
A - Plug
B - Belt Trap
C - Belts
D - Hose
E - Cap Screws
F - Nut
G - Linkage
Install hose (D).
31. Install linkage (G) using nut (F) and cap screws (E).
32. Install belts (C) and belt trap (B). To adjust belt tension, refer to the Operator's Manual.
33. Tighten plug (A).
34. Fill gear case with specified amount of oil (see Fuel, Lubricants and Coolant in Section 10).
1822
Remove and Install Engine Gear Case
Item
Measurement Specification
Engine Gear Case Capacity
16 L
(17 qt)
35. Install muffler and side panel.
36. Check for leaks.
37. Install gull wing doors (see Remove and Install Gull Wing Doors in Section 80, Group 05).
Go to Section_140:Group_05
OUO6089,000003E-19-20010621
1823
Engine Gear Case Specifications
Engine Gear Case Specifications
H69111-UN: Gear Case
LEGEND:
1 - Power from Engine
2 - 15 N˙m (144 lb-in.)
3 - 50 N˙m (40 lb-ft)
4 - Wet Clutch Disk (3 used)
5 - 75 N˙m (55 lb-ft)
6 - 50 N˙m (40 lb-ft)
7 - 70 N˙m (50 lb-ft) with zero axial play
8 - Power to Pumps
9 - 0.38 mm (0.015 in.) axial play + 1/4 turn to preload
10 - 50 N˙m (40 lb-ft)
11 - Shims - Backlash
12 - Shims - Gear Position
13 - Shims - Gear Position
14 - 50 N˙m (40 lb-ft)
15 - 75 N˙m (55 lb-ft)
16 - Straw Chopper Drive
17 - Unloading Drive
18 - 340 N˙m (250 lb-ft)
19 - Shims - Backlash
20 - 50 N˙m (40 lb-ft)
1824
Engine Gear Case Specifications
21 - Separator Drive
22 - Shims - Preload Bearings
23 - Wet Clutch Plate (3 used)
24 - 340 N˙m (250 lb-ft)
Go to Section_140:Group_05
OUO6089,0000066-19-20010709
1825
Disassemble and Assemble Separator Drive Wet Clutch
Disassemble and Assemble Separator Drive Wet Clutch
H69109-UN: Wet Clutch
LEGEND:
1 - Shim
2 - Roller Bearing Cup (2 used)
3 - Roller Bearing Cone (2 used)
4 - Gear
5 - Shim
6 - Housing
7 - Screw (6 used)
8 - Screw (6 used)
1826
Disassemble and Assemble Separator Drive Wet Clutch
9 - Hub
10 - Hub
11 - Clutch Disk (3 used)
12 - Clutch Plate (3 used)
13 - Snap Ring
14 - Retainer
15 - Spring Washer (4 used)
16 - Centering Washer
17 - Piston
18 - Seal
19 - Snap Ring
20 - Shaft
21 - Drum
22 - Seal Ring (2 used)
23 - Thrust Washer
24 - Seal
25 - Seat
26 - Ball
27 - Pin
28 - Plug
29 - Housing
30 - Screw (6 used)
31 - Ball Bearing
32 - Snap Ring
33 - Gasket
34 - Seal
35 - Seal Plate
36 - Screw (8 used)
37 - Fiber Washer (2 used)
38 - Seal
39 - Snap Ring
1.
CAUTION:
Weight of clutch pack is approximately 49 kg (108 lb).
1827
Disassemble and Assemble Separator Drive Wet Clutch
H55017-UN: Clutch
LEGEND:
A - Cap Screw (8 used)
B - Seal Plate and Gasket
C - Cap Screw (6 used)
D - Tapped Hole (3 used)
Remove cap screws (A), seal plate (B) and gasket.
2.
NOTE:
Tapped holes (D) are used for clutch pack removal.
Remove cap screws (C).
3. Install JDG1294 Clutch Pack Lifting Tool (A) in three tapped holes and remove clutch pack (B).
H55013-UN: Special Tool
LEGEND:
A - Clutch Pack Lifting Tool JDG1294
B - Clutch
1828
Disassemble and Assemble Separator Drive Wet Clutch
4.
H57175-UN: Wet Clutch Hub
LEGEND:
A - Screw (6 used)
B - Hub
Remove cap screws (A) and hub (B).
5.
H51695-UN: Clutch Disks and Plates
LEGEND:
A - Hub
B - Clutch Disk (3 used)
C - Clutch Plate (3 used)
D - Fiber Washer (2 used)
Remove hub (A).
NOTE:
The fiber washers are bonded to the hub. If washers are loose, replace hub.
6. IMPORTANT:
Clutch disks and plates must be installed in the same order as removed.
Remove clutch disks (B) and clutch plates (C).
7. Inspect parts for wear or damage. Replace as necessary.
8. Remove snap ring (A). Turn hub over to remove shaft (B) and centering washer (C).
1829
Disassemble and Assemble Separator Drive Wet Clutch
H51696-UN: Remove Snap Ring
H55034-UN: Shaft
H57182-UN: Shaft
LEGEND:
A - Snap Ring
B - Shaft
C - Centering Washer
9. Remove snap ring (A).
1830
Disassemble and Assemble Separator Drive Wet Clutch
H57185-UN: Wet Clutch
H57186-UN: Wet Clutch, Hub and Drum
LEGEND:
A - Snap Ring
B - Drum
C - Housing
10. Press clutch drum (B) out of housing (C).
11.
H40151-UN: Seal Rings
LEGEND:
A - Seal Rings
B - Thrust Washer
Inspect seal rings (A) and thrust washer (B) for nicks, cracks or broken pieces. Replace worn or
damaged parts as needed.
1831
Disassemble and Assemble Separator Drive Wet Clutch
12.
H40115-UN: Spring Washer Compressor
LEGEND:
A - Spring Washer Compressor JDT24A
B - Snap Ring
C - Retainer
Install JDT24A Spring Washer Compressor (A). Tighten compressor just enough to remove snap ring (B)
and retainer (C). Slowly release compressor and remove spring washers.
13.
H40116-UN: Wet Clutch Spring Washers
LEGEND:
A - Air Hole
B - Piston
C - Boss
Apply compressed air to hole (A) located over boss (C) to release piston (B).
NOTE:
JDG185 Air Test Plug can be used to release clutch piston from housing.
1832
Disassemble and Assemble Separator Drive Wet Clutch
14.
H44369-UN: Wet Clutch Spring Washers
LEGEND:
A - Outer Seal
B - Inner Seal
C - Piston
D - Clutch Drum
E - Spring Washer (5 used)
F - Retainer
G - Snap Ring
Remove seals (A) and (B).
15. Inspect parts for wear or damage. Replace parts as necessary.
16. Coat parts with clean hydraulic oil.
17. Install seals (A) and (B).
18. Install the piston.
19. Use JDT24A Spring Washer Compressor and install retainer (C) and snap ring (B).
H40115-UN: Spring Washer Compressor
LEGEND:
A - Spring Washer Compressor JDT24A
B - Snap Ring
C - Retainer
1833
Disassemble and Assemble Separator Drive Wet Clutch
20. Install thrust washer (B) and seal rings (A).
H40151-UN: Seal Rings
LEGEND:
A - Seal Rings
B - Thrust Washer
21. Install clutch drum in housing. Install bearing and snap ring (A).
H57185-UN: Wet Clutch
LEGEND:
A - Snap Ring
22. Install centering washer (C) on shaft (B). Turn hub over and install shaft and snap ring (A).
H51696-UN: Remove Snap Ring
1834
Disassemble and Assemble Separator Drive Wet Clutch
H55034-UN: Shaft
H57182-UN: Shaft
LEGEND:
A - Snap Ring
B - Shaft
C - Centering Washer
23. IMPORTANT:
Clutch disks and plates must be installed in the same order as removed.
Install clutch disks (B) and plates (C).
H51695-UN: Clutch Disks and Plates
LEGEND:
A - Hub
1835
Disassemble and Assemble Separator Drive Wet Clutch
B - Clutch Disk (3 used)
C - Clutch Plate (3 used)
D - Fiber Washer (2 used)
24.
NOTE:
Rotate hub to align with disk.
Install hub (A).
25.
H57175-UN: Wet Clutch Hub
LEGEND:
A - Screw (6 used)
B - Hub
Install hub (B) and cap screws (A). Tighten cap screws to specification.
Item
Measurement Specification
Engine Gear Case Wet Clutch
Clutch Hub Cap Screws Torque
75 N˙m
(55 lb-ft)
26. Install clutch in gear case. Tighten cap screws to specification.
Item
Measurement Specification
Engine Gear Case Wet Clutch
Clutch-to-Gear Case Cap Screws Torque
50 N˙m
(40 lb-ft)
27. IMPORTANT:
Apply TY6341 grease to lubricate seal lip.
Install gasket and seal plate. Tighten cap screws to specification.
Item
Measurement Specification
Engine Gear Case Wet Clutch
Seal Plate Cap Screws Torque
15 N˙m
(144 lb-in.)
1836
Disassemble and Assemble Separator Drive Wet Clutch
Go to Section_140:Group_05
OUO6089,000003F-19-20010622
1837
Disassemble and Assemble Hydrostatic Gear Set
Disassemble and Assemble Hydrostatic Gear Set
H58309-UN: Hydrostatic Gear Set
LEGEND:
A - Cap Screw (6 used)
B - Gear
1. Remove separator drive wet clutch. (See procedure in this group.)
2. Remove six cap screws (A) and remove housing and shims.
3. Remove gear assembly (B).
4. Inspect gear teeth for wear and bearings for roughness.
5. IMPORTANT:
Gears are available only as a matched set. Replace as a matched set.
Replace parts as necessary.
NOTE:
Only when installing new gears or bearings, shim and adjust them in the following order:
Set gear position to mating gear with shims.
Preload primary bearings with shims.
Preload secondary (mating gear) bearings with adjusting nut.
Set gear backlash with shims.
1838
Disassemble and Assemble Hydrostatic Gear Set
Go to Section_140:Group_05
AG,OUO6435,1077-19-20000503
1839
Set Gear Position
Set Gear Position
H58460-UN: Engine Gear Case
1840
Set Gear Position
H57344-UN: Shims
H40144-UN: Dimension Stamped on Gear Case
LEGEND:
A - Shims
B - Gear
C - Gear Tube
D - Case
Adjust with shims (A). Use metric dimension on gear (B), gear tube (C) and case (D) to determine shim pack.
Shims are available in the following sizes:
0.08 mm (0.003 in.)
0.13 mm (0.005 in.)
0.25 mm (0.010 in.)
0.50 mm (0.020 in.)
Never use more than one plastic shim in a shim pack.
Example:
-: Set Gear Position
Dimension on case
109.50 mm (4.31 in.)
Plus dimension on gear
80.00 mm (3.15 in.)
Result
189.50 mm (7.46 in.)
Minus gear tube dimension
166.00 mm (6.54 in.)
Result
23.50 mm (0.93 in.)
Minus bearing width (always the same) 22.15 mm (0.87 in.)
Required shim pack
1.35 mm (0.07 in.)
NOTE:
If dimension is not stamped on case, use 109.50 mm (4.31 in.) to determine shim pack. If
dimension is not stamped on gear, use 80.00 mm (3.150 in.) to determine shim pack. If dimension
is not stamped on gear tube, use 166.00 mm (6.540 in.) to determine shim pack.
Information on DE18718 Separator Drive Gear Set (Engine Gear Case)
On the heel of the 37-tooth gear is a dimension within a range of 72.5 ± 0.25 mm. Subtract from this number the
dimension stamped on the gear case, and subtract the bearing width of 24.12 mm. The result gives the thickness
of the shim pack for the bearing race.
On the heel of the 56-tooth gear is a number for the average backlash. Use a shim that gives a backlash at least
1841
Set Gear Position
as much as the etched number, to 0.1 mm above the etched number. DO NOT use a backlash less than the
etched number. If the etched number is not on the gear, then use a backlash of 0.15 - 0.25 mm.
NOTE:
Other markings on the gear set are identifications to ensure a matched set is maintained during
production.
Information on DE19182 Hydrostatic Gear Set (Engine Gear Case)
On the heel of the 34-tooth gear is a dimension within a range of 80.0 ± 0.25 mm. Add the dimension stamped on
the gear case to the dimension on the 34-tooth gear, and subtract the dimension on the side of the tube that is
within a range of 166.0 ± 0.26 mm. Subtract the bearing width of 22.15 mm. The result gives the thickness of the
shim pack for the bearing race.
On the end of the 23-tooth gear (end opposite the gear teeth) is a number for the average backlash. Use a shim
that gives a backlash at least as much as the etched number, to 0.1 mm above the etched number. DO NOT use
a backlash less than the etched number. If the etched number is not on the gear, then use a backlash of 0.15 0.25 mm.
NOTE:
Other markings on the gear set are identifications to ensure a matched set is maintained during
production.
Go to Section_140:Group_05
OUO6435,0001903-19-20100423
1842
Preload Bearings
Preload Bearings
H57427-UN: Bearing Preload
H57396-UN: Unloading System, Dial Indicator
1. Install enough shims (A) between bearing housing (B) and gear case to provide axial play.
Shims are available in the following sizes:
0.08 mm (0.003 in.)
0.13 mm (0.005 in.)
0.25 mm (0.010 in.)
0.50 mm (0.020 in.)
2. Tighten cap screws (C) to specified torque. Measure axial play with a dial indicator.
Item
Measurement Specification
Bearing Housing-to-Gear Case Cap Screws Torque
50 N˙m
(40 lb-ft)
Total thickness of shims to be removed is axial play measurement plus 0.03 to 0.13 mm (0.001 to 0.005
1843
Preload Bearings
in.) to obtain desired preload.
Example:
-: Axial Play
Axial Play Measurement 0.17 mm (0.007 in.)
Desired Preload
0.08 mm (0.003 in.)
Shim Size to Remove
0.25 mm (0.010 in.)
3. Install remaining shims (A) and O-ring (D) on pilot diameter of bearing housing. Tighten cap screws to
specification.
Item
Measurement Specification
Bearing Housing-to-Gear Case Cap Screws Torque
50 N˙m
(40 lb-ft)
Go to Section_140:Group_05
OUO6435,0001938CONV2-19-20021011
1844
Disassemble and Assemble Straw Chopper/Unloading System
Disassemble and Assemble Straw Chopper/Unloading System
H58325-UN: Straw Chopper/Unloading System
LEGEND:
1 - Bearing Cone
2 - Bearing Cup
3 - Shim (as required)
4 - Snap Ring
5 - Shaft
6 - Bushing
7 - Case
8 - Cap Screw (8 used)
1845
Disassemble and Assemble Straw Chopper/Unloading System
9 - Cover
10 - Trough
11 - Lock Nut (2 used)
12 - Gear
13 - Key
14 - Bearing Cone
15 - Bearing Cup
16 - Seal
17 - O-Ring
18 - Shim (as required)
19 - Bearing
20 - Sheave
21 - Lubrication Fitting
22 - Nut (2 used)
23 - Hub
24 - Seal
25 - Housing
26 - O-Ring
27 - Plug
28 - Cap Screw (6 used)
29 - Cap Screw (2 used)
30 - Shaft
31 - Key
32 - Flange
33 - Cap Screw (4 used)
34 - Sheave
35 - Washer
36 - Nut
1.
NOTE:
It is not necessary to remove gear case.
Remove three belts on end of gear case.
2. Remove channel at sheaves for easier access.
1846
Disassemble and Assemble Straw Chopper/Unloading System
3.
H58329-UN: Sheave, Unloading Drive
LEGEND:
A - Nylon Nut
B - Washer
Remove nut (A) and washer (B).
4.
H58330-UN: Sheave, Unloading Drive
LEGEND:
A - Sheave
B - Puller
Remove sheave (A) and key using puller (B).
5.
H58331-UN: Chopper Drive Sheave
LEGEND:
A - Cap Screw (4 used)
B - Sheave
1847
Disassemble and Assemble Straw Chopper/Unloading System
C - Shaft
D - Flange
Remove four cap screws (A).
6. Remove sheave (B) and flange (D).
7. Remove shaft (C) with bearing.
8.
H57815-UN: Bearing
Inspect bearing for damage. If replacement is necessary, press off bearing and press on new bearing.
9.
H57383-UN: Unloading System, Hub
LEGEND:
A - Seal
B - Cap Screw (2 used)
1848
Disassemble and Assemble Straw Chopper/Unloading System
C - Hub
D - Cap Screw (6 used)
E - Housing
Remove two cap screws (B).
10. Remove hub (C) to replace seal (A).
11. Remove six cap screws (D).
12. Remove bearing housing (E) with seal, shim pack and O-ring assembly.
13. Remove gear shaft with bearing.
14. Inspect gear teeth for wear and bearings for roughness.
15. IMPORTANT:
Gears are available only as a matched set. Replace gears as a matched set.
Replace parts as necessary.
NOTE:
Only when installing new gears or bearings, shim and adjust them in the following order:
Set gear position to mating gear with shims.
Preload primary bearings with shims.
Preload secondary (mating gear) bearings with adjusting nut.
Set gear backlash with shims.
When replacing seal (A), make certain to tape gear keyway to prevent damage to seal.
16. Install chopper drive sheave. Tighten cap screws to specification.
Item
Measurement Specification
Straw Chopper Drive Sheave Cap Screws Torque
90 N˙m
(65 lb-ft)
17. Install unloading system drive sheave and a new nylon nut on shaft. Tighten nut to specification.
Item
Measurement Specification
Unloading System Drive Shaft Nut Torque
340 N˙m
(250 lb-ft)
Go to Section_140:Group_05
OUO6089,0000040-19-20010622
1849
Set Separator Drive Gear Position
Set Separator Drive Gear Position
H57426-UN: Unloading System
H58308-UN: Separator, Gear Case
1850
Set Separator Drive Gear Position
H40123-UN: Gear
LEGEND:
A - Shims
B - Gear
C - Case
Adjust with shims (A). Use metric dimensions on gear (B) and case (C) to determine shim pack. Shims are
available in the following sizes:
0.08 mm (0.003 in.)
0.13 mm (0.005 in.)
0.25 mm (0.010 in.)
0.50 mm (0.020 in.)
Never use more than one plastic shim in a shim pack.
Example:
-: Set Gear Position
Dimension on gear
72.31 mm (2.846 in.)
Minus dimension on case
46.76 mm (1.840 in.)
Result
25.55 mm (1.00 in.)
Minus bearing width (always the same) 24.12 mm (0.949 in.)
Required shim pack
1.43 mm (0.056 in.)
NOTE:
If dimension is not stamped on case, use 47.00 mm to determine shim pack. If dimension is not
stamped on gear, use 72.50 mm to determine shim pack.
Go to Section_140:Group_05
OUO6089,000005A-19-20021119
1851
Preload Bearings
Preload Bearings
H57427-UN: Bearing Preload
H57396-UN: Unloading System, Dial Indicator
1. Install enough shims (A) between bearing housing (B) and gear case to provide axial play.
Shims are available in the following sizes:
0.08 mm (0.003 in.)
0.13 mm (0.005 in.)
0.25 mm (0.010 in.)
0.50 mm (0.020 in.)
2. Tighten cap screws (C) to specified torque. Measure axial play with a dial indicator.
Item
Measurement Specification
Bearing Housing-to-Gear Case Cap Screws Torque
50 N˙m
(40 lb-ft)
Total thickness of shims to be removed is axial play measurement plus 0.03 to 0.13 mm (0.001 to 0.005
1852
Preload Bearings
in.) to obtain desired preload.
Example:
-: Axial Play
Axial Play Measurement 0.17 mm (0.007 in.)
Desired Preload
0.08 mm (0.003 in.)
Shim Size to Remove
0.25 mm (0.010 in.)
3. Install remaining shims (A) and O-ring (D) on pilot diameter of bearing housing. Tighten cap screws to
specification.
Item
Measurement Specification
Bearing Housing-to-Gear Case Cap Screws Torque
50 N˙m
(40 lb-ft)
Go to Section_140:Group_05
OUO6435,0001938CONV1-19-20021011
1853
Disassemble and Assemble Separator Drive
Disassemble and Assemble Separator Drive
H58333-UN: Separator Drive
LEGEND:
A - Gear
B - Bearing Cone
C - Bearing Cup
D - O-Ring
E - Shim (as required)
F - Cap Screw (7 used)
G - Clip
H - Clamp
I - Housing
J - Bearing Cup
K - Bearing Cone
L - Washer
M - Bearing
N - Lock Washer
O - Gasket
P - Seal
Q - Housing
R - Cap Screw (8 used)
1.
NOTE:
The gear case does not have to be removed from the combine to service separator
drive.
1854
Disassemble and Assemble Separator Drive
H44365-UN: Drive Shaft
LEGEND:
A - Drive Shaft
Disconnect separator drive shaft (A) at front of grain tank. Use tape to keep needle bearings in place.
2.
H58631-UN: Drive Shaft
LEGEND:
A - Splines
Slide complete drive shaft off splines (A).
3.
H58629-UN: Separator Drive
LEGEND:
A - Cap Screw (8 used)
B - Plate
Remove cap screws (A) and remove plate (B) with seal.
1855
Disassemble and Assemble Separator Drive
4.
H58630-UN: Separator Drive
LEGEND:
A - Cap Screw (7 used)
B - Housing
Remove cap screws (A) and lift out bearing housing (B) with shaft.
5.
H40130-UN: Separator Drive
LEGEND:
A - Tangs
Pry out tangs (A).
6. Remove lock nut (B) using JDG666 Spanner Wrench. Remove lock washer, lock nut and washer.
7. Remove gear assembly from case.
8. Inspect case, O-rings, bearing cups, bearings and gear. Replace parts as necessary.
9. Install gear in case. Set preload on separator drive bearings (see Preload Separator Drive Bearings in
this group).
10. Install separator drive in gear case. Tighten cap screws to specification.
Item
Measurement Specification
Separator Drive-to-Gear Case Cap Screws Torque
1856
50 ± 10 N˙m
(37 ± 7 lb-ft)
Disassemble and Assemble Separator Drive
Go to Section_140:Group_05
AG,OUO6435,1083-19-20000503
1857
Preload Separator Drive Bearings
Preload Separator Drive Bearings
H41403-UN: