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John Deere 8320RT, 8345RT, & 8370RT Tractors Repair Technical Manual TM119319 – PDF DOWNLOAD
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John Deere 8320RT, 8345RT, & 8370RT Tractors Repair Technical Manual TM119319 – PDF DOWNLOAD
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Description
John Deere 8320RT, 8345RT, & 8370RT Tractors Repair Technical Manual TM119319 – PDF DOWNLOAD
FILE DETAILS:
John Deere 8320RT, 8345RT, & 8370RT Tractors Repair Technical Manual TM119319 – PDF DOWNLOAD
Language : English
Pages : 1180
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 8320RT, 8345RT, & 8370RT Tractors Repair Technical Manual TM119319 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential and recommended tools required in performing certain service work are identified in this manual.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are used to provide service information. The Repair Technical Manual tells how to repair the components. The Operation and Test Technical Manual helps you quickly identify the majority of routine failures.
- 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 and recommended tools, other material needed to do the job, service part 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.
TABLE OF CONTENTS:
John Deere 8320RT, 8345RT, & 8370RT Tractors Repair Technical Manual TM119319 – PDF DOWNLOAD
Contents................................................................................................................ 3 General Information................................................................................................. 6 Safety.......................................................................................................... 7 Recognize Safety Information................................................................................ 7 Understand Signal Words..................................................................................... 7 Follow Safety Instructions.................................................................................. 7 Wear Protective Clothing.................................................................................... 8 Handle Starting Fluid Safely................................................................................ 8 In Case of Fire............................................................................................. 8 Avoid Static Electricity Risk When Refueling................................................................ 9 Service Machines Safely..................................................................................... 9 Stay Clear of Rotating Drivelines........................................................................... 9 Handle Fluids Safely—Avoid Fires............................................................................ 10 Prevent Battery Explosions.................................................................................. 10 Prepare for Emergencies..................................................................................... 10 Remove Paint Before Welding or Heating...................................................................... 11 Avoid Heating Near Pressurized Fluid Lines.................................................................. 11 Avoid Hot Exhaust........................................................................................... 11 Clean Exhaust Filter Safely................................................................................. 12 Prevent Acid Burns.......................................................................................... 13 Handle Agricultural Chemicals Safely........................................................................ 14 Clean Vehicle of Hazardous Pesticides....................................................................... 14 Handling Batteries Safely................................................................................... 15 Avoid Harmful Asbestos Dust................................................................................. 16 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 16 Avoid High-Pressure Fluids.................................................................................. 17 Wait Before Opening High-Pressure Fuel System............................................................... 17 Service Accumulator Systems Safely.......................................................................... 17 Protect Against High Pressure Spray......................................................................... 18 Service Cooling System Safely............................................................................... 18 Prevent Machine Runaway..................................................................................... 18 Keep ROPS Installed Properly................................................................................ 19 Use Seat Belt Properly...................................................................................... 19 Park Machine Safely......................................................................................... 19 Support Machine Properly.................................................................................... 20 Work in Clean Area.......................................................................................... 20 Work In Ventilated Area..................................................................................... 20 Illuminate Work Area Safely................................................................................. 21 Use Proper Lifting Equipment................................................................................ 21 Instructional Seat.......................................................................................... 21 Passenger Seat.............................................................................................. 22 Use Steps and Handholds Correctly........................................................................... 22 Transport Tractor Safely.................................................................................... 22 Practice Safe Maintenance................................................................................... 23 Use Proper Tools............................................................................................ 23 Construct Dealer-Made Tools Safely.......................................................................... 24 Replace Safety Signs........................................................................................ 24 Install All Guards.......................................................................................... 24 Live With Safety............................................................................................ 25 General References.............................................................................................. 27 List of References.......................................................................................... 27 Trademarks.................................................................................................. 28 Sealants and Adhesives Cross-Reference Chart................................................................ 30 Metric Bolt and Screw Torque Values......................................................................... 32 Unified Inch Bolt and Screw Torque Values................................................................... 33 Face Seal Fittings Assembly and Installation—All Pressure Applications...................................... 34 Metric Face Seal And O-ring Stud End Fitting Torque Chart—Standard Pressures................................ 35 Metric Face Seal and O-ring Stud End Fitting Torque Chart—High Pressure Applications........................ 36 SAE Face Seal and O-ring Stud End Fitting Torque Chart—Standard Pressures................................... 37 SAE Face Seal and O-ring Stud End Fitting Torque Chart—High Pressure Applications........................... 38 Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications............................... 39 SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications................................. 39 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications..................................... 40 External Hexagon Port Plug Torque Chart..................................................................... 40 Prevent Hydraulic System Contamination...................................................................... 41 Check Oil Lines and Fittings................................................................................ 41 Basic Electrical Component Handling / Precautions For Vehicles Equipped With Computer Controlled Systems.... 42 Identify Zinc-Flake Coated Fasteners........................................................................ 42 Use Torque Wrench Adapter................................................................................... 43 Servicing and Connecting Snap to Connect STC™ Fittings...................................................... 44 Use Special Wrench.......................................................................................... 44 Install Hydraulic Fittings.................................................................................. 45 Glossary of Terms........................................................................................... 46 Aftertreatment Indicators Overview.......................................................................... 49 Changing Diesel Exhaust Fluid (DEF) Dosing Unit Filter...................................................... 50 Cleaning Diesel Exhaust Fluid (DEF) Tank.................................................................... 51 Engine.............................................................................................................. 53 Component Removal and Installation.............................................................................. 55 List of References.......................................................................................... 55 Essential, Recommended, and Fabricated Tools 20—00.......................................................... 55 Other Material 20—00........................................................................................ 55 Specifications 20—00........................................................................................ 56 Remove Engine............................................................................................... 56 Install Engine.............................................................................................. 62 Remove Front Frame.......................................................................................... 66 Install Front Frame......................................................................................... 67 Engine Repair................................................................................................... 73 List of References.......................................................................................... 73 Essential, Recommended, and Fabricated Tools 20—05.......................................................... 73 Other Material 20—05........................................................................................ 73 Specifications 20—05........................................................................................ 73 Replace Torsional Damper.................................................................................... 74 Engine Repair—Use CTM....................................................................................... 75 Remove and Install Timing Gear Cover........................................................................ 76 Fuel, Air Intake, Exhaust, and Cooling.............................................................................. 79 Diesel Fuel System.............................................................................................. 81 List of References.......................................................................................... 81 Specifications 30—05........................................................................................ 81 Remove and Install Left-Hand Fuel Tank...................................................................... 82 Remove and Install Right-Hand Fuel Tank..................................................................... 86 Remove Center Fuel Tank..................................................................................... 91 Replace Fuel Filter, Fuel Pump, and Bleed Fuel System....................................................... 96 Air Intake System............................................................................................... 97 List of References.......................................................................................... 97 Specifications 30—10........................................................................................ 97 Air Intake Pipe Connections................................................................................. 98 Remove and Install Air Cleaner Pipe......................................................................... 99 Remove and Install Aspirator Pipe........................................................................... 101 Remove and Install Charge Air Cooler Pipes.................................................................. 102 Auxiliary Drive System.......................................................................................... 109 List of References.......................................................................................... 109 Essential, Recommended, and Fabricated Tools 30—15.......................................................... 109 Specifications 30—15........................................................................................ 109 Auxiliary Drive Belt Routing................................................................................ 110 Belt Tensioner Location..................................................................................... 110 Inspect Belt Tensioner...................................................................................... 111 Replace Idler Pulleys and Belt Tensioner.................................................................... 112 Remove and Install Vari-Cool™ Fan Belt ..................................................................... 113 Replace Auxiliary Drive Pulley.............................................................................. 116 Replace Auxiliary Drive Shaft Seal.......................................................................... 118 Radiator and Coolers............................................................................................ 119 List of References.......................................................................................... 119 Essential, Recommended, and Fabricated Tools 30—20.......................................................... 119 Other Material 30—20........................................................................................ 119 Specifications 30—20........................................................................................ 120 Draining, Flushing, and Refilling Cooling System............................................................ 122 Test Radiator and Deaeration Tank........................................................................... 127 Test Radiator Cap........................................................................................... 127 Remove and Install Radiator................................................................................. 128 Check and Fill Vari-Cool™ Fan Sheaves....................................................................... 131 Remove and Install Vari-Cool™ Drive Assembly................................................................ 134 Remove and Install Vari-Cool™ Fan Driven Assembly........................................................... 135 Repair Vari-Cool™ Fan Drive Assembly ....................................................................... 137 Repair Vari-Cool™ Fan Driven Assembly....................................................................... 172 Remove and Install Vari-Cool™ Control Valve................................................................. 191 Repair Vari-Cool™ Control Valve............................................................................. 191 Remove and Install Air Conditioning Condenser............................................................... 192 Remove and Install Fuel Cooler—Hydraulic Oil Cooler......................................................... 192 Leak Test Hydraulic Oil Cooler.............................................................................. 193 Exhaust System.................................................................................................. 195 List of References.......................................................................................... 195 Other Material 30—25........................................................................................ 195 Specifications 30—25........................................................................................ 196 Service Exhaust System...................................................................................... 198 Replace NOx Sensor.......................................................................................... 233 Remove and Install DEF Tank................................................................................. 239 Replace Header Assembly..................................................................................... 241 Replace DEF Dosing Unit..................................................................................... 244 Replace DEF Dosing Injector................................................................................. 245 Electrical.......................................................................................................... 249 Connectors...................................................................................................... 251 List of References.......................................................................................... 251 Essential, Recommended, and Fabricated Tools 40—05.......................................................... 251 Other Material 40—05........................................................................................ 251 Use Electrical Insulating Compound.......................................................................... 252 Using High-Pressure Washers................................................................................. 252 Installation of Repair Wire Assembly (RWA).................................................................. 252 Repair AMP™ Connector....................................................................................... 257 Repair AMPSEAL 16™ Connectors............................................................................... 258 Bosch™ Connectors........................................................................................... 261 Remove Connector Body from Blade Terminals.................................................................. 262 CINCH™ Control Unit Connectors.............................................................................. 263 Exploded View—CINCH™ FlexBox Connectors..................................................................... 270 CINCH™ FlexBox Connectors................................................................................... 271 Repair CPC™ Blade Type Connectors........................................................................... 274 Repair CPC™, Large Mate-N-Loc™, and Metrimate™ Pin Type Connectors.......................................... 274 Repair DEUTSCH™ Connectors.................................................................................. 275 Repair DEUTSCH™ Implement Connectors........................................................................ 277 Repair ITT Connector........................................................................................ 280 Repair Small Mate-N-Loc™ Socket Connector................................................................... 282 Repair Small Mate-N-Loc™ Pin Connector...................................................................... 283 Repair (Pull Type) Metri-Pack™ Connectors................................................................... 284 Repair (Push Type) Metri-Pack™ Connectors................................................................... 285 Repair Molex™ Control Unit Connectors....................................................................... 287 Repair Molex™ Connector..................................................................................... 291 Repair SUMITOMO™ Connectors................................................................................. 292 Repair Tyco™ Fuel Injector Connector........................................................................ 294 Repair WEATHER PACK™ Connector.............................................................................. 295 Repair YAZAKI™ Connectors................................................................................... 297 Charging Circuit................................................................................................ 299 List of References.......................................................................................... 299 Specifications 40—10........................................................................................ 299 Repair Alternator—Use CTM................................................................................... 299 Disconnect Electrical Circuit............................................................................... 299 Replace Alternator.......................................................................................... 300 Replace Alternator and Battery Fuse......................................................................... 301 Starting Circuit................................................................................................ 303 List of References.......................................................................................... 303 Essential, Recommended, and Fabricated Tools 40—15.......................................................... 303 Specifications 40—15........................................................................................ 303 Repair Starter—Use CTM...................................................................................... 303 Remove and Install Starter Motor............................................................................ 304 Replace Master Fuse......................................................................................... 304 Replace Starter Circuit Relay............................................................................... 305 Relays, Fuses, Solenoids, and Switches.......................................................................... 307 List of References.......................................................................................... 307 Essential, Recommended, and Fabricated Tools 40—20.......................................................... 307 Other Material 40—20........................................................................................ 307 Specifications 40—20........................................................................................ 308 General Repair Procedures 40—20............................................................................. 310 Replace Hydraulic Backup Pump Fuse.......................................................................... 311 Replace Hydraulic Backup Pump Relay......................................................................... 312 Replace Start Aid Solenoid.................................................................................. 312 Replace Sensors e23™ Transmission........................................................................... 313 Replace Solenoids e23™ Transmission......................................................................... 314 Replace Park Supply Solenoid (e23™)......................................................................... 314 Replace Park Sump Block Solenoid (e23™)..................................................................... 315 Replace Range Clutch R1 and R2 Solenoids (e23™)............................................................. 315 Replace Oil Cooler Bypass Solenoid (e23™)................................................................... 316 Replace Lube Prioritization Valve Solenoid (e23™)........................................................... 316 Replace Sensors and Solenoids PST Transmission.............................................................. 316 Replace Electrohydraulic Shift Valve Solenoids (PST)........................................................ 317 Replace Park Brake Release Solenoid (PST)................................................................... 317 Replace Sensors IVT™ Transmission........................................................................... 318 Replace Solenoids IVT™ Transmission......................................................................... 318 Replace Clutch Enable Solenoid (IVT™)....................................................................... 319 Replace Park Supply Solenoid (IVT™)......................................................................... 319 Replace Park Sump Block Solenoid (IVT™)..................................................................... 319 Replace Hydro Clutch Unit Solenoid (IVT™)................................................................... 320 Replace Ring Unit Hydro Control Solenoid (IVT™)............................................................. 320 Replace Loop Flush Cut Off Solenoid (IVT™).................................................................. 320 Replace PTO Solenoid........................................................................................ 321 Replace Engine Oil Pressure Switch.......................................................................... 321 Replace Cab Door Light Switch............................................................................... 322 Replace Starting Aid Switch................................................................................. 322 Replace Ignition Switch..................................................................................... 327 Replace Key Immobilizer..................................................................................... 331 Replace Seat Raise-Lower Switch............................................................................. 335 Replace Heated Seat Switch.................................................................................. 337 Replace Operator Presence Seat Switch....................................................................... 339 Replace Brake Light Switch.................................................................................. 339 Replace Hydraulic Oil Filter Restriction Switch............................................................. 340 Replace Hydraulic Clean-Oil Level Switch.................................................................... 340 Replace Ethernet Switch..................................................................................... 341 Replace Battery Disconnect Switch........................................................................... 341 Replace External Hitch Raise-Lower Switches................................................................. 342 Replace Air Conditioning Dual Pressure Sensor............................................................... 342 Replace Air Conditioning Temperature Sensor................................................................. 342 Replace Air Conditioning Motor Speed Control................................................................ 343 Monitoring System............................................................................................... 345 List of References.......................................................................................... 345 Essential, Recommended, and Fabricated Tools 40—25.......................................................... 345 Other Material 40—25........................................................................................ 345 Specifications 40—25........................................................................................ 346 General Information 40—25................................................................................... 347 Control Units Identification................................................................................ 347 Replace Control Units....................................................................................... 349 Replace Navigation Bar...................................................................................... 350 Replace Engine Coolant Temperature Sensor................................................................... 350 Replace Engine Coolant Level Sensor......................................................................... 351 Replace Engine Coolant Loss Sensor.......................................................................... 351 Replace Engine Crank Speed Sensor........................................................................... 352 Replace Fuel Level Sensor................................................................................... 352 Replace Track Position Sensor............................................................................... 353 Replace Steering Column Module.............................................................................. 353 Replace Primary Transmission Speed Sensor................................................................... 356 Replace Secondary Transmission Speed Sensor................................................................. 356 Replace PTO Speed Sensor.................................................................................... 357 Replace Radar Sensor........................................................................................ 357 Replace Hydro Charge Pressure Sensor........................................................................ 358 Replace Hydro Loop Override 1 Solenoid...................................................................... 358 Replace Hydro Loop Override 2 Solenoid...................................................................... 359 Replace Left Hydro Pressure Sensor.......................................................................... 359 Replace Right Hydro Pressure Sensor......................................................................... 360 Replace Steering Charge Pressure Switch..................................................................... 360 Replace Hitch Position Sensor............................................................................... 361 Replace Draft Sensing Sensor................................................................................ 362 Replace CommandCenter™ Processor............................................................................ 363 CommandARM™..................................................................................................... 365 List of References.......................................................................................... 365 Specifications 40—30........................................................................................ 365 Armrest Test Procedures..................................................................................... 365 Remove and Install CommandARM™ Assembly..................................................................... 365 Replace Armrest Interface Control Unit (AIC)................................................................ 366 Replace Throttle Control Module............................................................................. 367 Replace Transmission Control Lever Module................................................................... 367 Replace SCV Control Lever Module............................................................................ 368 Replace Rear Hitch Control Lever and SCV I Control Lever Module............................................. 368 Replace Hitch Controls Module............................................................................... 369 Replace Rear PTO Switch..................................................................................... 370 Replace Secondary Brake Switch.............................................................................. 370 Replace Cab Controls Module................................................................................. 371 Replace SCV Lock Module..................................................................................... 371 Implement and Accessory Connectors.............................................................................. 373 List of References.......................................................................................... 373 Replace Seven-Terminal Outlet Socket........................................................................ 373 Replace GreenStar™ Terminal Connector....................................................................... 374 Replace Auxiliary Power Strip............................................................................... 374 Replace Three-Pin Accessory Outlet.......................................................................... 375 Replace Three-Pin Accessory Outlet—Storage Box.............................................................. 376 Convenience and Accessory....................................................................................... 377 List of References.......................................................................................... 377 Specifications 40—40........................................................................................ 377 Replace Wiper Motors........................................................................................ 378 Replace Circulation Blower Motor............................................................................ 379 Replace HVAC Pressurizer Blower Motor....................................................................... 380 Replace Air Flow Mode Motor................................................................................. 381 Replace Windshield Washer Pumps............................................................................. 384 Remove Radio and Speakers................................................................................... 384 Replace Refrigerator........................................................................................ 386 Replace Refrigerator Tray................................................................................... 387 Replace Refrigerator Top Cover.............................................................................. 387 Replace Refrigerator Door................................................................................... 388 Replace Refrigerator Thermostat............................................................................. 389 Replace Refrigerator Module................................................................................. 393 Infinitely Variable Transmission (IVT™)............................................................................. 398 Component Removal and Installation.............................................................................. 399 List of References.......................................................................................... 399 Essential, Recommended, and Fabricated Tools 50A—00......................................................... 399 Other Material 50A—00....................................................................................... 399 Specifications 50A—00....................................................................................... 400 Remove Transmission—IVT™.................................................................................... 400 Install Transmission—IVT™................................................................................... 414 Remove and Install Scavenge Pump—IVT™....................................................................... 426 In Tractor Repair............................................................................................... 431 List of References.......................................................................................... 431 Essential, Recommended, and Fabricated Tools 50A—05......................................................... 431 Other Material 50A—05....................................................................................... 431 Specifications 50A—05....................................................................................... 431 Replace Input Shaft Front Seal—IVT™......................................................................... 432 Replace Auxiliary Drive Shaft Seal—IVT™..................................................................... 434 Synchronizer/Shift Assembly Repair—In Chassis—IVT™.......................................................... 435 Service Hydrostatic Jumper Tubes—IVT™....................................................................... 442 Transmission Repair............................................................................................. 447 List of References.......................................................................................... 447 Essential, Recommended, and Fabricated Tools 50A—10......................................................... 447 Other Material 50A—10....................................................................................... 448 Specifications 50A—10....................................................................................... 449 General Repair Procedures 50A—10............................................................................ 451 Hydrostatic Module Replacement—IVT™......................................................................... 453 Install Transmission Onto Repair Stand—IVT™................................................................. 454 Disassemble Transmission—IVT™............................................................................... 454 Exploded View—Valve Manifold—IVT™........................................................................... 468 Repair Valve Manifold—IVT™.................................................................................. 469 Repair Synchronizer—IVT™.................................................................................... 470 Cross Sectional View—C1-C2 Shift Assembly—IVT™.............................................................. 473 Repair C1-C2 Shift Assembly—IVT™............................................................................ 474 Repair Accumulator—IVT™..................................................................................... 477 Exploded View—Hydrostatic Module Assembly—IVT™.............................................................. 478 Multi-Function Valves—IVT™.................................................................................. 478 Test Multi-Function Valves—IVT™............................................................................. 479 Hydrostatic Module Loop Flush Valve—IVT™.................................................................... 479 Repair Hydrostatic Module Assembly—IVT™..................................................................... 480 Exploded View—Reverse Brake—IVT™............................................................................ 484 Repair Reverse Brake Housing—IVT™........................................................................... 485 Cross Sectional View—High-Low Clutch Assembly—IVT™.......................................................... 487 Repair High-Low Clutch Assembly—IVT™........................................................................ 488 Cross Sectional View—Planetary Input Assembly—IVT™.......................................................... 495 Repair Planetary Input—IVT™................................................................................. 496 Exploded View—Planetary Assembly—IVT™....................................................................... 498 Repair Planetary Assembly—IVT™.............................................................................. 499 Cross Sectional View—Park Brake—IVT™........................................................................ 507 Repair Park Brake—IVT™...................................................................................... 508 Repair Bearing Carrier Assembly—IVT™........................................................................ 510 Repair Scavenge Pump—IVT™................................................................................... 511 Assemble Transmission........................................................................................... 517 List of References.......................................................................................... 517 Essential, Recommended, and Dealer Fabricated Tools 50A—15.................................................. 517 Other Material 50A—15....................................................................................... 517 Specifications 50A—15....................................................................................... 518 Install Bearing Cups—IVT™................................................................................... 519 Install CU Idler—IVT™....................................................................................... 520 Install Planetary Input Gears—IVT™.......................................................................... 520 Install Synchronizer—IVT™................................................................................... 523 Install PTO Drive Gear—IVT™................................................................................. 524 Install Front Cover—IVT™.................................................................................... 525 Install Bearing Cover—IVT™.................................................................................. 529 Install Planetary Ring Gear and RU Idler—IVT™............................................................... 530 Install Hydrostatic Assembly—IVT™........................................................................... 532 Install Planetary Assembly—IVT™............................................................................. 534 Install Reverse Brake and High-Low Clutch Assembly—IVT™..................................................... 535 Install Transmission Output Shaft—IVT™...................................................................... 540 Install Rear Cover—IVT™..................................................................................... 541 Install Manifold—IVT™....................................................................................... 543 Install Scavenge Pump—IVT™.................................................................................. 545 Adjust Bearings—IVT™........................................................................................ 546 Install Auxiliary Drive Shaft—IVT™.......................................................................... 548 Clutch Element Leak Check—IVT™.............................................................................. 550 e23™ Transmission (e23™)............................................................................................ 553 Component Removal and Installation.............................................................................. 555 List of References.......................................................................................... 555 Essential, Recommended, and Fabricated Tools 50B—00......................................................... 555 Other Material 50B—00....................................................................................... 555 Specifications 50B—00....................................................................................... 556 Remove Transmission—e23™.................................................................................... 556 Install Transmission—e23™................................................................................... 570 In Tractor Repair............................................................................................... 583 List of References.......................................................................................... 583 Essential, Recommended, and Fabricated Tools 50B—05......................................................... 583 Other Material 50B—05....................................................................................... 583 Specifications 50B—05....................................................................................... 583 Replace Auxiliary Drive Shaft Seal—e23™..................................................................... 584 Replace Input Shaft Front Seal—e23™......................................................................... 587 Replace Rear PTO Drive Shaft Seal—e23™...................................................................... 588 Replace Output Shaft Seal—e23™.............................................................................. 589 Transmission Repair............................................................................................. 591 List of References.......................................................................................... 591 Essential, Recommended, and Fabricated Tools 50B—10......................................................... 591 Other Material 50B—10....................................................................................... 592 Specifications 50B—10....................................................................................... 593 General Repair Procedures 50B—10............................................................................ 596 Install Transmission Onto Repair Stand—e23™................................................................. 597 Disassemble Transmission—e23™............................................................................... 597 Repair Upper Manifold Valves—e23™........................................................................... 602 Repair Lower Manifold Valves—e23™........................................................................... 603 Cleaning Procedures—Manifold, Rear Cover, and Valves—e23™................................................... 608 Repair Auxiliary Drive—e23™................................................................................. 609 Repair Park Brake—e23™...................................................................................... 616 Repair Rear Cover—e23™...................................................................................... 620 Repair Scavenge Pump—e23™................................................................................... 623 Clutch Backing Plate Orientation—e23™....................................................................... 626 Cross Sectional View—9 Disk Cast Clutch Pack—e23™........................................................... 626 Repair 9 Disk Cast Clutch Pack—e23™......................................................................... 627 Cross Sectional View—12 Disk Clutch Pack—e23™............................................................... 634 Repair 12 Disk Clutch Pack—e23™............................................................................. 634 6 Disk Clutch Pack Identification—e23™...................................................................... 639 Cross Sectional View—6 Disk Clutch Pack—e23™................................................................ 640 Repair 6 Disk Clutch Pack—e23™.............................................................................. 640 Cross Sectional View—Output Shaft Assembly—e23™............................................................. 646 Repair Output Shaft Assembly—e23™........................................................................... 648 Cross Sectional View—B Countershaft Assembly—e23™........................................................... 661 Repair B Countershaft Assembly—e23™......................................................................... 662 Cross Sectional View—C Countershaft Assembly—e23™........................................................... 676 Repair C Countershaft Assembly—e23™......................................................................... 677 Cross Sectional View—Input Shaft Assembly—e23™.............................................................. 692 Repair Input Shaft Assembly—e23™............................................................................ 693 Exploded View—Rear PTO Drive Shaft Assembly—e23™............................................................ 705 Repair Rear PTO Shaft Assembly—e23™......................................................................... 706 Inspect Clutch Disks—e23™................................................................................... 711 Assemble Transmission........................................................................................... 713 List of References.......................................................................................... 713 Essential, Recommended, and Fabricated Tools 50B—15......................................................... 713 Other Material 50B—15....................................................................................... 713 Specifications 50B—15....................................................................................... 713 Install Transmission Shaft Assemblies—e23™.................................................................. 714 Install Rear Cover—e23™..................................................................................... 717 Install Auxiliary Drive—e23™................................................................................ 721 Remove and Install Upper Manifold—e23™...................................................................... 722 Remove and Install Lower Manifold—e23™...................................................................... 724 Drive Train......................................................................................................... 728 Component Removal and Installation.............................................................................. 729 List of References.......................................................................................... 729 Essential, Recommended, and Fabricated Tools 50C—00......................................................... 729 Other Material 50C—00....................................................................................... 729 Specifications 50C—00....................................................................................... 729 Remove Rear Axle Assembly................................................................................... 730 Install Rear Axle Assembly.................................................................................. 734 Remove Final Drive Assembly................................................................................. 737 Install Final Drive Assembly................................................................................ 740 Rear Axle Assembly.............................................................................................. 743 List of References.......................................................................................... 743 Essential, Recommended and Fabricated Tools 50C—05.......................................................... 743 Other Material 50C—05....................................................................................... 743 Specifications 50C—05....................................................................................... 744 General Repair Procedures 50C—05............................................................................ 745 Remove Input Gears.......................................................................................... 746 Disassemble and Assemble Input Shaft/Gear Assembly.......................................................... 748 Disassemble and Assemble Steering Pump Drive Gear........................................................... 749 Disassemble and Assemble Integrated Hydraulic Pump Drive Gear............................................... 749 Disassemble and Assemble Idler Gear......................................................................... 749 Install Input Gears......................................................................................... 750 Adjust Input Shaft Bearing Preload.......................................................................... 752 Remove and Install Pump Drive Housing....................................................................... 757 Cross-Sectional View—Spiral Bevel Pinion Shaft.............................................................. 759 Disassemble and Recondition Spiral Bevel Pinion Shaft....................................................... 759 Assemble and Install Spiral Bevel Pinion Shaft.............................................................. 762 Cross-Sectional View—Spiral Bevel Ring Gear Assembly........................................................ 767 Remove and Recondition Spiral Bevel Ring Gear Assembly...................................................... 768 Install Spiral Bevel Ring Gear Assembly..................................................................... 772 Side Quill Adjustment Information........................................................................... 773 Adjust Carrier Assembly Bearing Preload..................................................................... 773 Adjust Spiral Bevel Ring Gear Backlash...................................................................... 775 Steering Gears.................................................................................................. 779 List of References.......................................................................................... 779 Essential, Recommended, and Fabricated Tools 50C—10......................................................... 779 Other Material 50C—10....................................................................................... 779 Specifications 50C—10....................................................................................... 779 Remove Steering Planetary, Ring Gear, and Sun Gear.......................................................... 780 Recondition Steering Planetary.............................................................................. 781 Install Steering Planetary, Ring Gear, and Sun Gear......................................................... 782 Remove, Recondition, and Install Steering Idler Gears....................................................... 783 Remove, Recondition, and Install Steering Motor Output Gear................................................. 784 Remove, Recondition, and Install Cross Shaft Gear Assembly.................................................. 786 Final Drives.................................................................................................... 793 List of References.......................................................................................... 793 Essential, Recommended, and Fabricated Tools 50C—15......................................................... 793 Other Material 50C—15....................................................................................... 793 Specifications 50C—15....................................................................................... 793 Disassemble Axle Assembly................................................................................... 794 Assemble Axle Assembly and Determine Shim Pack.............................................................. 803 Preload Shim Pack Example and Worksheet—Final Drives........................................................ 815 Remove, Recondition, Assemble Brakes........................................................................ 816 PTO............................................................................................................. 823 List of References.......................................................................................... 823 Essential, Recommended, and Fabricated Tools 50C—20......................................................... 823 Other Material 50C—20....................................................................................... 823 Specifications 50C—20....................................................................................... 824 Cross-Sectional View—PTO Clutch Assembly.................................................................... 825 Remove PTO Clutch........................................................................................... 826 Recondition PTO Clutch...................................................................................... 830 Install PTO Clutch.......................................................................................... 834 Remove and Install PTO Output Housing Assembly.............................................................. 839 Cross-Sectional View—PTO Output Housing Assembly............................................................ 840 Recondition PTO Output Housing.............................................................................. 840 Mid-Frame Drive Shafts.......................................................................................... 845 List of References.......................................................................................... 845 Other Material 50C—25....................................................................................... 845 Specifications 50C—25....................................................................................... 845 Cross-Sectional View—Mid-Frame Drive Shafts................................................................. 846 Remove and Install Drive Shafts............................................................................. 846 Brakes.............................................................................................................. 855 Service Brakes.................................................................................................. 857 List of References.......................................................................................... 857 Essential, Recommended, and Fabricated Tools 60A—05......................................................... 857 Specifications 60A—05....................................................................................... 858 General Repair Procedures 60A—05............................................................................ 859 Remove and Install Brake Rod................................................................................ 860 Remove and Install Brake Valve.............................................................................. 861 Repair Brake Valve.......................................................................................... 863 Remove and Install Priority and Load Sense Manifold......................................................... 870 Repair Priority and Load Sense Manifold..................................................................... 871 Remove and Install Secondary Brake and Steering Control Manifold............................................ 873 Repair Secondary Brake and Steering Control Manifold........................................................ 873 Remove and Install Primary and Secondary Brake Manifold..................................................... 875 Remove and Install Backup Pump.............................................................................. 875 Remove and Install Park Pump Off Manifold................................................................... 876 Repair Park Pump Off Manifold............................................................................... 876 Bleed Brakes................................................................................................ 878 Check Brakes................................................................................................ 879 Manually Release Park Brake—IVT™............................................................................ 880 Manually Release Park Brake—e23™............................................................................ 882 Hydraulic Trailer Brakes........................................................................................ 885 List of References.......................................................................................... 885 Specifications 60A—10....................................................................................... 885 Hydraulic Trailer Brake System.............................................................................. 885 Remove and Install Hydraulic Trailer Brake Valve............................................................ 887 Steering............................................................................................................ 889 Steering Column................................................................................................. 891 List of References.......................................................................................... 891 Other Material 60B—05....................................................................................... 891 Specifications 60B—05....................................................................................... 891 Remove and Install Control Support.......................................................................... 892 Repair Clutch and Brake Pedals.............................................................................. 893 Repair Steering Column...................................................................................... 896 Remove and Install Steering Wheel Position Input Assembly................................................... 901 Repair Steering Wheel Position Input Assembly............................................................... 907 Steering Valves................................................................................................. 909 List of References.......................................................................................... 909 Specifications 60B—10....................................................................................... 909 Remove and Install Loop Override Valve...................................................................... 909 Repair Loop Override Valve.................................................................................. 911 Steering Pump................................................................................................... 913 List of References.......................................................................................... 913 Essential, Recommended, and Fabricated Tools 60B—15......................................................... 913 Specifications 60B—15....................................................................................... 913 Remove and Install Steering Pump............................................................................ 913 Disassemble, Inspect, Assemble Displacement Control Valve................................................... 915 Replace Input Shaft Seal.................................................................................... 917 Service Multi-Funtion Valves and Relief Valves.............................................................. 917 Steering Motor.................................................................................................. 919 List of References.......................................................................................... 919 Specifications 60B—20....................................................................................... 919 Remove and Install Steering Motor........................................................................... 920 Repair Steering Motor....................................................................................... 921 Hydraulics.......................................................................................................... 923 Component Removal and Installation.............................................................................. 925 List of References.......................................................................................... 925 Essential, Recommended, and Fabricated Tools 70—00.......................................................... 925 Specifications 70—00........................................................................................ 926 Remove and Install Integrated Hydraulic Pump................................................................ 927 Remove and Install Transmission Pump........................................................................ 934 Remove and Install Hitch-SCV Valve Stack.................................................................... 938 Remove and Install Hitch Frame.............................................................................. 940 Hydraulic System................................................................................................ 945 List of References.......................................................................................... 945 Essential, Recommended, and Fabricated Tools 70—05.......................................................... 945 Specifications 70-05........................................................................................ 945 General Repair Procedures 70—05............................................................................. 945 Install Hydraulic Fittings 70—05............................................................................ 946 Drain Hydraulic System...................................................................................... 946 Fill Hydraulic System....................................................................................... 948 Hydraulic Fixed Displacement Pump Repair.................................................................... 950 Integrated Hydraulic Pump....................................................................................... 953 List of References.......................................................................................... 953 Essential, Recommended, and Fabricated Tools 70—10.......................................................... 953 Specifications 70—10........................................................................................ 953 Remove and Install Hydraulic Compensator Valve.............................................................. 953 Repair Hydraulic Compensator Valve.......................................................................... 955 Repair Hydraulic Pump....................................................................................... 956 Hitch Valve, Selective Control Valves, and Couplers............................................................. 959 List of References.......................................................................................... 959 Essential, Recommended, and Fabricated Tools 70—15.......................................................... 959 Specifications 70—15........................................................................................ 960 Disassemble and Assemble Hitch-SCV Valve Stack.............................................................. 961 Service Pressure Compensator................................................................................ 964 Service Pressure Compensating Check Valve................................................................... 965 Service Solenoid Pilot Valve................................................................................ 967 Service Spool Centering Spring Assembly..................................................................... 968 Service Electronic Control Unit............................................................................. 973 Test Surge Relief Valve..................................................................................... 974 Service Surge Relief Valve.................................................................................. 975 Service Shuttle Valve....................................................................................... 976 Remove and Install Coupler Housing.......................................................................... 979 Repair Couplers............................................................................................. 980 Remove and Install Motor Return............................................................................. 982 Remove and Install Motor Return with Power Beyond........................................................... 983 Rear Hitch...................................................................................................... 985 List of References.......................................................................................... 985 Essential, Recommended, and Fabricated Tools 70—20.......................................................... 985 Other Material 70—20........................................................................................ 985 Specifications 70—20........................................................................................ 985 Remove and Install Lift Cylinder............................................................................ 986 Disassemble, Inspect, and Assemble Lift Cylinder............................................................ 987 Replace Rockshaft Bushings.................................................................................. 987 Repair Draft Sensing........................................................................................ 989 Miscellaneous....................................................................................................... 995 Hood and Side Panels............................................................................................ 997 List of References.......................................................................................... 997 Essential, Recommended, and Fabricated Tools 80A—05......................................................... 997 Specifications 80A—05....................................................................................... 997 Position Hood Forward....................................................................................... 998 Optional Forward Hood Position.............................................................................. 998 Remove and Install Hood..................................................................................... 999 Remove and Install Grille and Headlight Assembly............................................................1000 Remove and Install Hood Side Panels.........................................................................1001 Remove and Install Hood Screens.............................................................................1002 Remove and Install Hood Latch...............................................................................1003 Platform Step Assembly..........................................................................................1005 List of References..........................................................................................1005 Specifications 80A—10.......................................................................................1005 Remove and Install Platform Step Assembly...................................................................1005 Track Frame and Components..........................................................................................1011 Track...........................................................................................................1013 List of References..........................................................................................1013 Essential, Recommended, and Fabricated Tools 80B—05.........................................................1013 Specifications 80B—05.......................................................................................1013 Install Support Stands......................................................................................1014 Track Tensioning and De-tensioning..........................................................................1016 Remove and Install Track....................................................................................1019 Check Track Alignment.......................................................................................1020 Adjust Track Alignment......................................................................................1020 Drive Wheel And Walking Beam Settings.......................................................................1022 Adjust Track Tread Settings.................................................................................1023 Tension Cylinder and Accumulator................................................................................1027 List of References..........................................................................................1027 Essential, Recommended and Fabricated Tools 80B—10..........................................................1027 Other Material 80B—10.......................................................................................1027 Specifications 80B—10.......................................................................................1027 Remove and Install Track Tension Cylinder...................................................................1028 Cross-Sectional View—Track Tension Cylinder.................................................................1029 Disassemble, Inspect, and Assemble Track Tension Cylinder...................................................1029 Remove and Install Tension Accumulator......................................................................1031 Charge Tension Accumulator..................................................................................1032 Track Frame.....................................................................................................1033 List of References..........................................................................................1033 Essential, Recommended, and Fabricated Tools 80B—15.........................................................1033 Other Material 80B—15.......................................................................................1033 Specifications 80B—15.......................................................................................1034 Remove and Install Track Frame..............................................................................1035 Replace Walking Beam-to-Track Frame Bushing.................................................................1036 Remove and Install Tension Link and Alignment Lever.........................................................1037 Replace Alignment Lever Bushings............................................................................1042 Replace Tension Link Pivot Bushings.........................................................................1042 Repair Front Idler Hubs.....................................................................................1046 Repair Mid-Roller Assembly..................................................................................1052 Remove and Install Drive Hub................................................................................1057 Repair Drive Hub............................................................................................1060 Track Suspension................................................................................................1069 List of References..........................................................................................1069 Essential, Recommended, and Fabricated Tools 80B—20.........................................................1069 Other Material 80B—20.......................................................................................1069 Specifications 80B—20.......................................................................................1070 Replace Rubber Walking Beam Bumpers.........................................................................1071 Replace Shock Absorber......................................................................................1072 Replace Air Spring..........................................................................................1073 Replace Air Compressor......................................................................................1076 Remove and Install Walking Beam.............................................................................1078 Replace Swing Arm Bushings..................................................................................1080 Replace Walking Beam Pivot Bushing and Isolator Bushing.....................................................1081 Inflate Track Air Suspension System.........................................................................1083 Cab and Open Operator’s Station.....................................................................................1085 Component Removal and Installation..............................................................................1087 List of References..........................................................................................1087 Essential, Recommended, and Fabricated Tools 90—00..........................................................1087 Other Material 90—00........................................................................................1087 Specifications 90—00........................................................................................1087 Remove Cab..................................................................................................1088 Install Cab.................................................................................................1094 Repair Cab..................................................................................................1098 Remove Inner Roof...........................................................................................1099 Install Inner Roof..........................................................................................1106 Remove and Install Left Hand Armrest........................................................................1112 Heating, Ventilating, and Air Conditioning (HVAC)...............................................................1115 List of References..........................................................................................1115 Essential, Recommended, and Fabricated Tools 90—05..........................................................1115 Other Material 90—05........................................................................................1115 Specifications 90—05........................................................................................1116 Repair Air Conditioning System—Use CTM......................................................................1116 Hose and Tubing O-ring Connection Torques...................................................................1117 Discharge Air Conditioning System...........................................................................1117 Flushing, Purging, and Evacuating Information...............................................................1118 Purge Air Conditioning System...............................................................................1119 Evacuate Air Conditioning System............................................................................1119 Charge Air Conditioning System..............................................................................1120 Refrigerant Oil Information.................................................................................1120 Check Compressor Oil Charge.................................................................................1121 Determine Correct Refrigerant Oil Charge....................................................................1122 Add Refrigerant Oil to System...............................................................................1123 Add Refrigerant Oil to Pressurized System...................................................................1124 Remove and Install Compressor...............................................................................1125 Replace Receiver-Dryer......................................................................................1127 Remove and Install Compressor Relief Valve..................................................................1127 Remove and Install Expansion Valve..........................................................................1128 Remove HVAC Module..........................................................................................1128 Install HVAC Module.........................................................................................1130 Remove and Install Heater Control Valve.....................................................................1132 ComfortCommand™ Seat............................................................................................1133 List of References..........................................................................................1133 Essential, Recommended, and Fabricated Tools 90—10..........................................................1133 Other Material 90—10........................................................................................1133 Specifications 90—10........................................................................................1133 Remove and Install Seat—ComfortCommand™.....................................................................1134 Repair Seat Air System—ComfortCommand™......................................................................1134 Repair Seat Suspension—ComfortCommand™......................................................................1136 Repair Seat Back—ComfortCommand™............................................................................1140 Repair Seat Control Knobs—ComfortCommand™...................................................................1142 Cab Door and Windshield.........................................................................................1145 List of References..........................................................................................1145 Specifications 90—15........................................................................................1145 Repair Cab Door Latch.......................................................................................1146 Cab Door Adjustment—Step 1..................................................................................1148 Cab Door Adjustment—Step 2..................................................................................1148 Cab Door Adjustment—Step 3..................................................................................1149 Cab Door Adjustment—Step 4..................................................................................1150 Preparing Windshield Glass or Side Window For Replacement...................................................1151 Dealer Tools........................................................................................................1153 Dealer Fabricated Tools.........................................................................................1155 Fabricated Tools............................................................................................1155 List of References..........................................................................................1155 DFRW2—Needle Valve Test Hose Assembly.......................................................................1156 DFRW7—Differential Lifting Tool.............................................................................1157 DFRW63 - DFRW64 - DFRW65 - DFRW66 - DFRW81—Tap-Out Harnesses................................................1158 DFRW89—Transmission Shaft and Clutch Holding Fixture........................................................1160 DFRW90—Transmission Support Plate...........................................................................1162 DFRW91—Guide Pins...........................................................................................1163 DFRW97—Transmission Countershaft Rotation Screw.............................................................1163 DFRW117—Transmission-Hydraulic Flusher......................................................................1164 DFRW123—Steering Motor Bypass Hose..........................................................................1166 DFRW136—STEERING PUMP REMOVAL TOOL..........................................................................1167 DFRW144—European Narrow Rear Axle Lift Tool.................................................................1168 DFRW168—Park Brake Solenoid Harness.........................................................................1169 DFRW210—Hole Drilled in JT07201.............................................................................1170 DFRW211—Transmission Support Plate..........................................................................1171 DFRW212—Leak Test Assembly..................................................................................1172 DFRW213—Hydraulic Trailer Brake Test / Bleed Assembly.......................................................1174 DFRW220—Clutch Cover Removal Plate..........................................................................1175 DFRW231—Guide Pins..........................................................................................1176 DFRW233—Support Bar.........................................................................................1177 DFRW234—Hood Support Rod....................................................................................1178 Page Number............................................................................................................. 3 Section 10.......................................................................................................... 6 Group 05A....................................................................................................... 7 Group 05B....................................................................................................... 27 Section 20.......................................................................................................... 53 Group 00........................................................................................................ 55 Group 05........................................................................................................ 73 Section 30.......................................................................................................... 79 Group 05........................................................................................................ 81 Group 10........................................................................................................ 97 Group 15........................................................................................................ 109 Group 20........................................................................................................ 119 Group 25........................................................................................................ 195 Section 40.......................................................................................................... 249 Group 05........................................................................................................ 251 Group 10........................................................................................................ 299 Group 15........................................................................................................ 303 Group 20........................................................................................................ 307 Group 25........................................................................................................ 345 Group 30........................................................................................................ 365 Group 35........................................................................................................ 373 Group 40........................................................................................................ 377 Section 50A......................................................................................................... 398 Group 00........................................................................................................ 399 Group 05........................................................................................................ 431 Group 10........................................................................................................ 447 Group 15........................................................................................................ 517 Section 50B......................................................................................................... 553 Group 00........................................................................................................ 555 Group 05........................................................................................................ 583 Group 10........................................................................................................ 591 Group 15........................................................................................................ 713 Section 50C......................................................................................................... 728 Group 00........................................................................................................ 729 Group 05........................................................................................................ 743 Group 10........................................................................................................ 779 Group 15........................................................................................................ 793 Group 20........................................................................................................ 823 Group 25........................................................................................................ 845 Section 60A......................................................................................................... 855 Group 05........................................................................................................ 857 Group 10........................................................................................................ 885 Section 60B......................................................................................................... 889 Group 05........................................................................................................ 891 Group 10........................................................................................................ 909 Group 15........................................................................................................ 913 Group 20........................................................................................................ 919 Section 70.......................................................................................................... 923 Group 00........................................................................................................ 925 Group 05........................................................................................................ 945 Group 10........................................................................................................ 953 Group 15........................................................................................................ 959 Group 20........................................................................................................ 985 Section 80A......................................................................................................... 995 Group 05........................................................................................................ 997 Group 10........................................................................................................1005 Section 80B.........................................................................................................1011 Group 05........................................................................................................1013 Group 10........................................................................................................1027 Group 15........................................................................................................1033 Group 20........................................................................................................1069 Section 90..........................................................................................................1085 Group 00........................................................................................................1087 Group 05........................................................................................................1115 Group 10........................................................................................................1133 Group 15........................................................................................................1145 Section 300.........................................................................................................1153 Group 05........................................................................................................1155
S.S 22/02/2025
