Technical Manual 3520 and 3522 Sugar Cane Harvester Repair

DCG
3520 and 3522 Sugar Cane

Harvester Repair Manual
TECHNICAL MANUAL
3520 and 3522 Sugar Cane
Harvester Repair
TM100419 27OCT11 (ENGLISH)
For complete service information also see:
3520 and 3522 Sugar Cane Harvester

Diagnostic Technical Manual ............................. TM100519
PowerTech Plus 9.0 L Tier 3/Stage IIIA OEM
Diesel Engines — Base Engine.......................... CTM400
PowerTech Plus 9.0L Diesel Engines — Level
14 Electronic Fuel System With Denso HPCR .. CTM385
TM100419
John Deere Thibodaux

LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for use. beginning of each group are summary listings of all
Live with safety: Read the safety messages in the applicable essential tools, service equipment and tools,
introduction of this manual and the cautions presented other materials needed to do the job, service parts kits,
throughout the text of the manual. specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
This is the safety-alert symbol. When you see this machines. They are on-the-job guides containing only the
symbol on the machine or in this manual, be alert to the vital information needed for diagnosis, analysis, testing,
potential for personal injury. and repair.
Technical manuals are divided in two parts: repair and Fundamental service information is available from other
operation and tests. Repair sections tell how to repair sources covering basic theory of operation, fundamentals
the components. Operation and tests sections help you of troubleshooting, general maintenance, and basic type
identify the majority of routine failures quickly. of failures and their causes.
RW67285,0000B0A -19-22OCT01-1/1
TM100419 (27OCT11) 3520 and 3522 Sugar Cane Harvester Repair

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Contents
Section 10—General Group 30B—Collector, Crop Divider, Feedroller and
Group 05—Safety Elevator Motor
Group 10—Specifications Group 30C—Topper and Secondary Extractor Motor
Group 15—General Capacities Group 30D—Basecutter and Primary Extractor Motors
Group 20—Torque Specifications Group 30E—Secondary Extractor Hood Rotate Motor
Group 25—Fluid Recommendations Group 30F—Cooling Package/Oil Cooler Motor
Group 30—General Information Group 30G—Variable Displacement Ground Drive
Group 35—Service Points Motor (Wheel)
Group 30H—Fixed Displacement Motor (Track)
Section 20—Engine Group 30I—Chopper Motor
Group 05—Pump Drive Gear Box Group 40A—Rear Feed Roller Valve
Group 40B—Steering Priority Valve (Wheel)
Group 40C—Steering Valve
Section 30—Feed Roller System
Group 05—Knockdown Roller
Group 10—Buttlifter Roller (B1) Section 80—Topper System
Group 15—Bottom Feed Roller Group 05—Collector, Crop Divider, Feed Roller and
Group 20—Top Feed Roller Elevator Motor
Section 40—Electrical Section 90—Operator’s Station

Group 10—Electrical Harness and Connectors Group 05—Cab
Section 50—Hydrostatic System Section 100—Crop Divider System

Group 05—Planetary Final Drive Bonfiglioli Group 05—Crop Divider
Group 10—Planetary Final Drive Iberica
Group 15—Track Section 110—Basecutter System
Group 20—Wheel Group 05—Basecutter Gearbox
Group 10—Basecutter Lift Cylinder Accumulators
Section 60—Steering System
Group 05—Steering Column (Type A) Section 120—Chopper System
Group 10—Steering Column (Type B) Group 05—Chopper Box
Group 15—Steering Wheel Position Input Assembly
(Autotrac Ready Track Machines) Section 130—Cleaning System
Group 20—Relief Valve Group 05—Primary Extractor
Section 70—Main Hydraulic System Section 140—Elevator System

Group 10A—Multiple Gear Pump Group 05—Elevator Systems Installation
Group 10B—Piston Pump
Group 20A—Steering Cylinder
Group 20B—Crop Divider Cylinder
Group 20C—Crop Divider Tilt Cylinder
Group 20D—Topper Cylinder
Group 20E—Basecutter Cylinder
Group 20F—Elevator Cylinders
Group 20G—Height Indicator Cylinder
Group 20H—Cab Tilt Cylinder
Group 20I—Knockdown Tilt and Crop Divider Tilt
Cylinder
Group 30A—Fixed Displacement Motor
Original Instructions. All information, illustrations and specifications in this

manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2011
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ® Manual
TM100419 (27OCT11) i 3520 and 3522 Sugar Cane Harvester Repair

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Contents
TM100419 (27OCT11) ii 3520 and 3522 Sugar Cane Harvester Repair

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Section 10
General
Contents
Page Page
Group 05—Safety
Safety and You .............................................. 10-05-1 Group 10—Specifications
Operation Safety............................................ 10-05-1 Specifications — John Deere 6090
Safety instructions ......................................... 10-05-2 Engine PowerTech™ ................................. 10-10-1
Service Safety ............................................... 10-05-3 Preliminary Service Intervals ......................... 10-10-1
Safety in Your Service Area........................... 10-05-4 Common Wear Parts ..................................... 10-10-1
Safety when Cleaning or Storing ................... 10-05-4
Safety Nevers ................................................ 10-05-5 Group 15—General Capacities
Seat Safety Shut-off ...................................... 10-05-5 Harvester Capacities ..................................... 10-15-1
Tilting the Cab ............................................... 10-05-6 Tire Inflation Pressure ................................... 10-15-1
Recognize Safety Information ....................... 10-05-6
Understand Signal Words.............................. 10-05-7 Group 20—Torque Specifications
Follow Safety Instructions.............................. 10-05-7 Torque Specifications .................................... 10-20-1
Protect Bystanders ....................................... 10-05-8 Torque for Grade 2 NC Weld
Use Handles and Steps................................. 10-05-8 Studs ......................................................... 10-20-1
Avoid Exhaust Fumes.................................... 10-05-9 Metric Bolt and Screw Torque
Wear Protective Clothing............................... 10-05-9 Values ........................................................ 10-20-2
Handle Fuel Safely — Avoid Fires................ 10-05-10 Unified Inch Bolt and Screw Torque
Safely Service Accumulator......................... 10-05-10 Values ........................................................ 10-20-3
Accumulator Safety ..................................... 10-05-11 Suggested Torque Values and
Safely Service Cooling System ................... 10-05-11 Clamp Loads for Grades 2, 5, &
Prepare for Emergencies............................. 10-05-12 8 Bolts........................................................ 10-20-4
Use Safety Lights and Devices.................... 10-05-12 Suggested Torque Values For
Use Cylinder Safety Stops........................... 10-05-13 Grades 5.6, 8.8, 10.9, 12.9 Zinc
Safe Transport of Harvester ........................ 10-05-13 Plated Bolts ............................................... 10-20-4
Avoid High-Pressure Fluids ......................... 10-05-14 Grade or Property Class Head
Use Caution on Hillsides ............................. 10-05-14 Marking for SI Bolts ................................... 10-20-5
Stopping and Parking .................................. 10-05-15 Conversion Factors ....................................... 10-20-5
Service Tires Safely..................................... 10-05-15 Straight O-Ring Boss Fittings ........................ 10-20-5
Tire Inflation................................................. 10-05-16 Angled O-Ring Boss Fittings ......................... 10-20-5
Avoid Electrical Power Lines ....................... 10-05-16 SAE 37° (JIC) ................................................ 10-20-6
Keep Hands Away From Knives.................. 10-05-17 Metric............................................................. 10-20-6
Avoid Contact With Moving Parts ................ 10-05-17 BSPP (Port Connection Only) ....................... 10-20-6
Dispose of Waste Properly .......................... 10-05-18 ORS............................................................... 10-20-7
Fire Prevention ............................................ 10-05-18 Straight Thread O-Ring Boss ........................ 10-20-7
Safety Recommendations ........................... 10-05-19 37° Flare Cone Fittings.................................. 10-20-7
Avoid Serious Injury..................................... 10-05-19 Hex Flats Recommended
Hazardous Area........................................... 10-05-20 Rotation ..................................................... 10-20-8
Stay Clear of Chopper Area ........................ 10-05-21 Four Bolt Flange Fittings ............................... 10-20-8
Rotating Chopper Drum............................... 10-05-22 SAE Bolt Torque Chart .................................. 10-20-9
Avoid Hazardous Area................................. 10-05-23
Avoid Electrical Power Lines ....................... 10-05-24 Group 25—Fluid Recommendations
Safe Service Practice .................................. 10-05-25 John Deere Engine Coolant
Prevent Fires ............................................... 10-05-26 Requirements ............................................ 10-25-1
Training Seat ............................................... 10-05-27 John Deere Prediluted
Avoid Personal Injury and Damage Antifreeze/Summer Coolant ...................... 10-25-1
to the Machine ......................................... 10-05-28 Heavy Duty Diesel Engine
Keep Hands Away ....................................... 10-05-29 Coolant ...................................................... 10-25-1
Keep Away From Rotating Knives................ 10-05-30 John Deere Antifreeze/Summer
Avoid Injury.................................................. 10-05-31 Coolant Concentrate.................................. 10-25-2
Preventing Machine Runaway..................... 10-05-32 John Deere Antifreeze/Summer
Exhaust System Warning ............................ 10-05-33 Coolant ...................................................... 10-25-2
Continued on next page
TM100419 (27OCT11) 10-1 3520 and 3522 Sugar Cane Harvester Repair
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Contents
Page
Hydraulic Fluid (World) .................................. 10-25-2

Diesel Fuel..................................................... 10-25-2
Engine Break-In Oil (John Deere).................. 10-25-3
Diesel Engine Oil ........................................... 10-25-3
Gear Oil — Pump Drive, Chopper
Box, and Basecutter .................................. 10-25-3
Gear Oil — Final Drive .................................. 10-25-3
Grease........................................................... 10-25-3
Group 30—General Information

Conversions................................................... 10-30-1
Length Measure............................................. 10-30-1
Metric 1SI Measurements .............................. 10-30-1
Metric to English ............................................ 10-30-1
English to Metric ............................................ 10-30-1
Multiplication Factors..................................... 10-30-2
Temperature Conversion Chart ..................... 10-30-2
Recommended Supplies ............................... 10-30-3
Hydraulic Gauge Kit....................................... 10-30-6
Harvester Specialty Tools and Part
Numbers .................................................... 10-30-8
Group 35—Service Points

Harvester Component Locations ................... 10-35-1
Harvester Service Point
Locations ................................................... 10-35-2
Harvester Grease Point
Locations ................................................... 10-35-3
Grease Point Locations ................................. 10-35-4
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Group 05
Safety
Safety and You Therefore, the warnings we provide are not all inclusive.
If a procedure, tool, or work method not specifically
We at John Deere are very concerned for your safety recommended by John Deere is used, you must satisfy
when you are operating or servicing your harvester. With yourself that it is safe for you and others and also that
this in mind, you should read and study the following the machine will not be damaged or made unsafe by the
section. Hopefully you will take every precaution seriously procedures you choose.
and use good "old-fashioned" common sense before
attempting to use or service your harvester.
Of course, John Deere cannot anticipate every possible
circumstance that might involve a potential hazard.
T803324,0000623 -19-15OCT07-1/1
Operation Safety
The following is a list of safe operation procedures that
you should practice at all times:
1. Be sure to read the operator's manual and all safety
precautions before starting the harvester.
2. Dress for the job. Any loose clothing, jewelry
(especially rings), belts, or scarves will present a
definite safety hazard.
3. When either stopping or starting the machine, make
sure the area is clear of personnel.
4. Before leaving the machine unattended, lower all
implements to the lowest position.
CM989999001 —UN—06JAN00
5. Do Not allow riders or any passenger on the machine
when it is in operation.
6. Keep a fully charged fire extinguisher on or near the
operator's station. It must be easily accessible when
needed. Know how to operate it.
7. Keep a fully stocked first aid kit on the operator's
station. Know basic first aid.
8. Keep the operation area free of all loose objects such
as tools, lunch kits, soft drink cans, etc. 13. Maintain your John Deere equipment as if your life
depends on it—It does! Improper lubrication and
9. Never allow an open flame within 3.05 M (10 feet) of maintenance can be dangerous and could result in
the harvester. injury or death.
10. Be sure that all shields, guards, and safety equipment 14. Before climbing on machine, ensure that no one else
are in their proper place and in good condition. is working in or on machine.
11. This is the safety alert symbol. When you see this 15. Ensure that all operators are taught to blow the horn
symbol, be alert to the possibility of personal injury. several times and wait a few seconds before starting
Carefully read any message following this symbol. the machine.
12. Use step and grab handles when mounting or 16. Ensure that all persons anywhere near the machine
dismounting the harvester. Clean all mud or debris know that when the horn blows, the machine is about
from steps, walkways, and work areas. Always face to be started and to move away as soon possible.
the equipment when using its steps or ladder.
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TM100419 (27OCT11) 10-05-1 3520 and 3522 Sugar Cane Harvester Repair
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Safety
Safety instructions
CQ280450 —19—04JUL08
Before operating, keep the machine in proper condition to
safeguard against hazards.
GB52027,0000607 -19-04JUL08-1/1
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Safety
Service Safety
When a service person or mechanic is unfamiliar with
all systems on this harvester, extra caution should be
used when performing service work. A good working
knowledge of the system and its components is important
for removal or disassembly. The following is a list of basic
precautions that should always be observed.
1. Make sure that you read and understand all warning
plates and decals before lubricating or performing
other maintenance.
2. Always wear protective glasses and footwear when
working. In particular, wear safety glasses when
pounding on any part of the machine or attachments
CM989999038 —UN—07JAN00
with a hammer. Use protective clothing when welding.
Do Not wear any loose fitting or torn clothing. Remove
all rings from fingers before working on equipment.
3. Before starting work on the machine, disconnect
battery and hang this DO NOT START sign in the
operator's station.
IMPORTANT: Before climbing on machine, ensure
that no one is working in or on it.
Ensure that all operators blow the horn several cannot roll. Do Not work on any machine that is
times before starting the machine. supported only by lift jacks or a hoist.
Ensure that any persons near the machine 5. Relieve all pressure in air, oil, or water systems before
know that when the horn blows, the machine any lines, fittings, or related parts are disconnected
is about to be started, and to move away or removed. Always make sure that all raised
as soon as possible. components and implements are correctly blocked.
Be alert for possible pressure when disconnecting any
Use the following Lock-Out Tag-Out Procedure: device from a system that utilizes pressure.
a. Parking Procedure
CAUTION: Liquid escaping from a very small
1. Lower topper onto safety stop. hole can be almost invisible. Use wood
2. Lower basecutter onto safety stops. or cardboard, instead of your hand, when
3. Lower crop dividers. searching for suspected leaks.
4. Lower elevator.
6. Escaping fluid under pressure can have sufficient force
NOTE: In the event that topper and/or basecutter safety
to penetrate the skin. Therefore, before disconnecting
stops are not functioning properly, a 2" x 2" x
any lines, be sure all pressure in the system is relieved.
1/4" angle iron by the length required may be
Before applying pressure, make sure all lines, fittings,
used as a temporary safety stop.
and connections are tight and undamaged.
b. Stop engine, remove ignition key, disengage and 7. If you are injured by escaping fluid under pressure,
remove electrical system master disconnect switch; see a doctor at once. A serious infection or reaction
remove negative battery cables from battery, install may result if proper medical attention is not received
lock out device and tag. Also tag steering wheel immediately.
or track control.
NOTE: Any fluid injected into the skin must be surgically
c. Before beginning any hydraulic repairs you must removed within a few hours or gangrene may
first relieve pressure from the hydraulic tank. result. Further information is available from
Deere & Company Medical Department in
NOTE: In the event repairs need to be made to the
Moline, Illinois. 1-800-822-8262
basecutter lift and/or topper lift, the hydraulic
pressure should be relieved by lowering the
8. Lower all implements to the ground prior to working
basecutter and/or topper.
on the machine. If this cannot be done, make sure
the implement is properly blocked to prevent it from
4. If at all possible, make all repairs with the machine
dropping unexpectedly.
parked on level ground. Block the machine so it
Continued on next page T803324,0000625 -19-25SEP07-1/2
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Safety
9. To avoid back injuries, use a hoist when lifting starting any repairs. If a guard or shield must be
components that weigh over 23 kg (50 lb). When using removed to perform repair work, use extra caution
a hoist, make sure all hooks are correctly positioned. while working.
10. To avoid burns, be alert for hot parts located on the 15. Take precautions to prevent damage to wiring during
machine after it has stopped. Be particularly careful of removal. After reinstalling the wiring, double check to
hot fluids in lines, tubes, and components. make sure it is was not damaged during removal or
installation. Ensure that the wiring does not touch any
11. Be careful when removing cover plates. Gradually hot, sharp, or moving parts after it is installed.
loosen the last two bolts or nuts located at the opposite
ends of the cover or device. Carefully pry the cover 16. Ensure that all protective devices and guards are
loose to relieve any spring or other tension before properly installed and are functioning correctly before
removing it completely. starting any repairs. If a guard or shield must be
removed to perform repair work, use extra caution
12. Be careful when removing filler caps, breathers, or while working.
plugs on the machine. Hold a rag over the cap or plug
to prevent being sprayed or splashed by fluids under 17. Do Not operate the harvester if any rotating part is
pressure. damaged or contacts any other part during operation.
Any high-speed rotating component that has been
13. Always use tools that are in good condition. Before damaged or altered must be checked for balance
performing any service, make sure you know how to before operation.
use the proper tools.
18. Avoid working on equipment with the engine running.
14. Replace all fasteners with the same SAE or metric If it is absolutely necessary to make checks with the
grade. Never substitute a softer part where a engine running, always use two men: one to operate
hardened part is used, conversely never substitute a the controls and the other to work where the operator
harder part where a softer part is used. can see him. The hydrostatic transmission must be
in neutral, the braking system set, and all pertinent
Ensure that all protective devices and guards are safety locks set.
properly installed and are functioning correctly before
T803324,0000625 -19-25SEP07-2/2
Safety in Your Service Area 3. Be sure that all electrical outlets and tools are properly
To maintain proper safety procedure in the service area, grounded.
the following should be observed: 4. Use adequate lighting for the job.
1. Keep the service area clean and dry. Wet or oily floors 5. Be prepared if an accident or fire should occur. Know
are slippery and wet spots can be dangerous. where the first aid kit and fire extinguishers are
2. Make sure the service area is adequately ventilated. located. Know how to use both of them.
Periodically check the shop exhaust system for
leakage.
T803324,0000626 -19-13APR05-1/1
Safety when Cleaning or Storing 3. Avoid a possible fire hazard. Keep the radiator, oil
coder and engine closure screens free of foreign
CAUTION: Engine exhaust gas is dangerous. material.
4. Keep all equipment free of dirt and oil. In bad weather
The following practices should be observed whenever you beware of snow, ice, and mud on ladders, steps, and
clean or store your equipment: in the operator's station.
5. When preparing the engine for storage, remember that
1. Always stop the engine before cleaning the harvester. inhibitors are volatile and therefore, dangerous. Seal
2. Keep the operator's station clean. Do Not use it for a and tape openings after adding the inhibitor. Keep the
storage area. Keep in mind that this harvester has inhibitor container tightly closed when not in use.
a tilting cab.
T803324,0000627 -19-13APR05-1/1
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Safety
Safety Nevers 5. Never allow sparks or flames near the batteries. This
includes smoking near the batteries.
The following is a list of practices that you should Never 6. Never check fuel, battery electrolyte, or coolant levels
use: with an open flame nearby.
1. Never smoke while refueling or handling flammable 7. Never use an open flame to look for leaks anywhere
materials. on the equipment.
2. Never refuel the engine while it is running. Use care 8. Never use an open flame as a light anywhere on or
during refueling when the engine is hot. near the equipment.
3. Never use open pans of gasoline or diesel fuel for 9. Never adjust the fuel system while the machine is in
cleaning parts. A good commercial, nonflammable motion.
solvent is preferred.
4. Never check the charging battery by placing metal
objects across the posts. Provide adequate ventilation
when charging batteries.
T803324,0000628 -19-13APR05-1/1
Seat Safety Shut-off
The operator must be seated and the reset switch activated stop. To restart harvesting functions, the operator must CM023500020 —UN—07FEB05
to start harvesting functions. If the operator leaves the return to the seated position and cycle the reset switch.
seat for more than five seconds, harvesting functions will
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Safety
Tilting the Cab

The entire cab tilts forward, providing access to the engine
for maintenance and repair by a qualified technician. The
cab pivots at the front, raised by a single hydraulic cylinder.
Make sure all bystanders are clear of the machine. (See
the cab tilting procedure in the Service Section.)
CM023500037 —UN—07FEB05
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Recognize Safety Information

This is a safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe operating
practices.
CM989999002 —UN—06JAN00
T803324,000062B -19-13APR05-1/1
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Safety
Understand Signal Words

A signal word — DANGER, WARNING, or CAUTION —
is used with the safety-alert symbol. DANGER identifies
the most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
CM053510164 —19—21JUL05
T803324,000062C -19-13APR05-1/1
Follow Safety Instructions

Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
CM989999004 —UN—06JAN00
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Safety
Protect Bystanders
Be sure everyone is clear of the harvester before starting
the engine or moving the steering wheel.
CM989999005 —UN—06JAN00
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Use Handles and Steps

Clean off mud, grease, and any crop residue that may
have accumulated on the steps and operator's platform of
your harvester. Remember that chains and tools carried
on the platform may interfere with pedal operation or
cause a fall from the harvester. Remove them.
CM989999006 —UN—06JAN00
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Safety
Avoid Exhaust Fumes

Never run engine in a closed building. Make sure service
area is adequately ventilated.
Avoid inhaling exhaust gases produced by a running
engine. Exhaust gases, particularly carbon monoxide,
may build up. Carbon monoxide is colorless, odorless,
and potentially lethal.
CM989999008 —UN—06JAN00
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Wear Protective Clothing

Wear close fitting clothing and safety equipment
appropriate to the job.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
CM989999014 —UN—06JAN00
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Safety
Handle Fuel Safely — Avoid Fires

Handle fuel with care: it is highly flammable. Do not refuel
the machine while smoking or when near open flame or
sparks.
Always stop engine before refueling machine. Fill fuel
tank outdoors.
Prevent fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up spilled fuel.
CM989999010 —UN—06JAN00
T803324,0000634 -19-13APR05-1/1
Safely Service Accumulator

Accumulators contain gas and oil under pressure. To
avoid injury from escaping fluid, relieve all pressure
from accumulator before disconnecting topper or track
accumulator.
The accumulator is charged with dry nitrogen to at least
a pressure of 5170 kPa (51.7 Bar) (750 PSI). If it needs
recharging, have the job done only by a qualified service
person and only with dry nitrogen.
CM989999011 —UN—06JAN00
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Safety
Accumulator Safety
CQ280445 —19—04JUL08
Avoid pressurized fluid escaping from accumulator.
Consult technical manual for service procedures.
GB52027,00005FE -19-04JUL08-1/1
Safely Service Cooling System

Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Remove filler cap when cool enough to
touch with bare hand. To relieve pressure, slowly loosen
cap to first stop, and then remove completely.
CM989999012 —UN—06JAN00
T803324,0000636 -19-13APR05-1/1
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Safety
Prepare for Emergencies

Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
CM989999013 —UN—06JAN00
T803324,0000637 -19-13APR05-1/1
Use Safety Lights and Devices

When transporting your machine on a road or highway,
whether it is at night or during the day, use the necessary
safety lights. Check local government regulations.
Keep safety items in good condition. Replace missing or
damaged items.
CM989999015 —UN—06JAN00
T803324,0000638 -19-13APR05-1/1
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Safety
Use Cylinder Safety Stops

When working under the harvester, always raise the
machine all the way up. Apply stops to the lift cylinders
and lower harvester onto the stops. If a hose should bust,
the harvester will remain raised.
CM989999016 —UN—06JAN00
T803324,0000639 -19-13APR05-1/1
Safe Transport of Harvester

Before driving harvester on public roads, raise the topper.
It must not, however, obstruct the operator's view of the
road.
CQ280276 —UN—27FEB08
GB52027,0000572 -19-23OCT08-1/1
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Safety
Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin
causing serious injury.
Relieve pressure before removing hydraulic lines or any
other lines. Tighten all connections before applying
pressure. Keep hands and body away from pinholes and
nozzles that eject fluids under high pressure. Use a piece
of cardboard to search for leaks.
If Any fluid is injected into the skin, it must be surgically
removed within a few hours by a doctor familiar with this
type of injury or gangrene may result.
CM989999018 —UN—06JAN00
T803324,000063C -19-13APR05-1/1
Use Caution on Hillsides

Avoid holes, ditches, and obstructions that may cause the
harvester to tip, especially on hillsides.
Never drive near the edge of a gully or steep embankment
because it may cave in.
Be especially careful when using single wheels. The
danger of an overturn increases greatly with narrow tread,
2032 mm (80") or less, and with high speed.
For hillside operation, always use front and rear dual
wheels. Avoid sharp, uphill turns.
CM989999019 —UN—06JAN00
Keep hydraulic oil level at upper level when operating on
hillsides. Low oil level might result in loss of steering.
If this should happen, hold harvester with brakes, shift
to NEUTRAL, apply park brake, stop engine, and add
hydraulic oil to proper level.
Before operating on extremely steep slopes, fill hydraulic
system beyond overfull sight glass 4 to 8 L (1 to 2 gal).
This is particularly important when using large hydraulic
cylinders, due to the volume of oil used to extend them.
T803324,000063D -19-13APR05-1/1
102711
PN=20
Safety
Stopping and Parking

Your ability to stop your harvester and park it safely is just
as important as being able to get it underway safely.
harvester up-sets, collisions, runaway tractors, and
people being crushed under machines can happen when
operators ignore safety.
To avoid these accidents, take these precautions:
• Signal before stopping, turning, or slowing down on
highways.
• Pull over to right-hand shoulder of highway before
stopping, if possible.
CM989999020 —UN—06JAN00
• Slow down before braking.
• Pump brakes when stopping on slippery surfaces like
ice, snow, mud, or loose gravel.
• Shift to park or set parking brake.
• Turn off all electrical switches and remove key
T803324,000063E -19-25SEP07-1/1
Service Tires Safely

Explosive separation of a tire and rim can cause serious
injury or death.
Do not attempt to mount a tire unless you have the proper
equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
CM989999022 —UN—06JAN00
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, damaged
rims, or missing lug bolts and nuts.
T803324,000063F -19-13APR05-1/1
102711
PN=21
Safety
Tire Inflation
CQ289523 —19—05SEP11
Proper tire inflation is essential for safety. Use
recommended tire pressures.
GB52027,0000520 -19-21SEP11-1/1
Avoid Electrical Power Lines

Put the topper and elevator in transport position before
driving on public roads.
Secure radio aerial in its transport position before driving
on public roads, it may come into contact with low-hanging
electrical cables. This would result in the operator
suffering a severe electrical shock. CM989999024 —UN—06JAN00
T803324,0000640 -19-13APR05-1/1
102711
PN=22
Safety
Keep Hands Away From Knives

Never attempt to clear obstructions in cutting areas unless
engine is shut off and key removed. Everyone must be
clear of the harvester before starting the engine.
CM989999025 —UN—06JAN00
T803324,0000641 -19-13APR05-1/1
Avoid Contact With Moving Parts

Keep hands, feet, and clothing away from power driven
parts. Never clean, lubricate, or adjust machine when it
is running.
CM989999026 —UN—06JAN00
T803324,0000642 -19-13APR05-1/1
102711
PN=23
Safety
Dispose of Waste Properly

Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Inquire about the proper way to recycle or dispose of
CM989999029 —UN—06JAN00
waste from your local environmental or recycling center.
T803324,0000643 -19-13APR05-1/1
Fire Prevention
1. Machines should be cleaned of debris at least daily,
particularly around engine, exhaust, and driveline
components.
2. Machines should be inspected at least daily for
potential fire hazards at electrical, exhaust, driveline,
fuel, hydraulic, and brake systems. Repairs should be
made immediately.
3. Operating personnel must be instructed on what to do
when a fire starts, how to use the fire extinguisher,
and must follow such instructions. Operators should
be required to demonstrate an ability to use fire
suppression equipment.
CM989999028 —UN—10NOV00
4. Hydraulic leaks, accumulation of grease, fuel, and oil
(including spillage) should be eliminated immediately.
5. The radiator and the engine cooling system should
be cleaned and serviced daily to maintain moderate
engine temperatures.
6. Any portable extinguisher or fire suppression system
carried on the machine that has been previously used
should be recharged or replaced before the machine
resumes operation.
7. Prior to welding or brazing on any part of the machine,
the part and the surrounding area should be cleaned 8. Smoking, open flames, etc., should not be permitted
and a fire extinguisher should be made readily around any machine during fueling operations and/or
available. when the fuel system is open to the atmosphere.
T803324,0000644 -19-13APR05-1/1
102711
PN=24
Safety
Safety Recommendations
1. Always read and completely understand safety,
operator, and maintenance manuals before operating
or servicing any piece of equipment.
2. Always use eye protection when working on or around
equipment.
3. Escaping fluid under pressure can penetrate the skin
and cause serious injury.
4. Use a safe material rather than bare hands to check
for leaks.
5. Relieve pressure to hydraulic tank before working on
or around the harvester, especially when working on
hydraulic components.
CM989999027 —UN—06JAN00
6. Clean up all oil after service or repairs are done.
7. Be prepared for emergencies. Keep a fire extinguisher
and first aid kit nearby.
T803324,0000645 -19-13APR05-1/1
Avoid Serious Injury
CQ280440 —19—04JUL08
Only allow the operator on the machine. Keep riders off. Riders also obstruct the operator's view resulting in the
Riders on machine are subject to injury such as being machine being operated in an unsafe manner.
struck by foreign objects and being thrown off the machine.
GB52027,00005F9 -19-23FEB10-1/1
102711
PN=25
Safety
Hazardous Area
CQ285260 —19—23FEB10
Hazardous area - Stay clear of rotating knives, which precaution to prevent accidents. Keep away from machine
may be overhead or close to ground level. Take every when engine is running.
GB52027,00005FA -19-23FEB10-1/1
102711
PN=26
Safety
Stay Clear of Chopper Area
CM063510065 —UN—27FEB06
Decal reads, WARNING - Avoid serious injury from
movement of chopper knives or basecutter knives. CAUTION: Rotating basecutter discs will cause
Basecutter knives rotate when chopper drums are turning. chopper knives to rotate. Avoid serious injury
Chopper knives rotate when basecutter legs are turning. by keeping chopper area clear of personnel
Clear areas before performing service or maintenance. while changing basecutter blades.
T803324,00008A7 -19-24OCT05-1/1
102711
PN=27
Safety
Rotating Chopper Drum
CM063510065 —UN—27FEB06
Decal reads, WARNING - Avoid serious injury from
movement of chopper knives or basecutter knives. CAUTION: Rotating chopper drum will cause
Basecutter knives rotate when chopper drums are turning. basecutter blades to rotate. Avoid serious injury
Chopper knives rotate when basecutter legs are turning. by keeping basecutter blade area free from
Clear areas before performing service or maintenance. personnel while changing chopper blades.
T803324,00008A8 -19-24OCT05-1/1
102711
PN=28
Safety
Avoid Hazardous Area
CQ280446 —19—04JUL08
Avoid crushing and/or pinching of hands on support cable.
GB52027,00005FF -19-04JUL08-1/1
102711
PN=29
Safety
Avoid Electrical Power Lines
CQ280442 —19—04JUL08
To avoid injury or death, keep sufficient distance away on the machine that could potentially come into contact
from electrical power lines. Always be aware of any part with power lines.
GB52027,00005FB -19-04JUL08-1/1
102711
PN=30
Safety
Safe Service Practice
CQ280443 —19—04JUL08
Secure lifting cylinders with locking devices prior to
performing any maintenance on the machine.
GB52027,00005FC -19-04JUL08-1/1
102711
PN=31
Safety
Prevent Fires
CQ280444 —19—04JUL08
Keep machine clear of trash, debris, and oil. Maintain all
fire extinguishers in proper working order.
GB52027,00005FD -19-04JUL08-1/1
102711
PN=32
Safety
Training Seat
CQ280448 —19—04JUL08
The instruction seat is only for training and diagnostic
problems. Keep riders off machine. Always use seat belt
when operating the machine.
GB52027,0000600 -19-04JUL08-1/1
102711
PN=33
Safety
Avoid Personal Injury and Damage to the Machine
CQ280455 —19—04JUL08
Follow the cab tilt procedure.
GB52027,0000601 -19-04JUL08-1/1
102711
PN=34
Safety
Keep Hands Away
CQ280447 —19—04JUL08
Keep hands away from fans, drive belts and other
components while engine is running.
GB52027,0000602 -19-04JUL08-1/1
102711
PN=35
Safety
Keep Away From Rotating Knives
CQ280453 —19—04JUL08
Avoid serious injury by keeping away from rotating knives
at the front of the machine.
GB52027,0000604 -19-04JUL08-1/1
102711
PN=36
Safety
Avoid Injury
CQ280449 —19—04JUL08
Avoid body crush area at the rear mainframe of the
machine.
GB52027,0000606 -19-04JUL08-1/1
102711
PN=37
Safety
Preventing Machine Runaway
CQ280451 —19—04JUL08
Start machine from operator's seat only.
GB52027,0000608 -19-04JUL08-1/1
102711
PN=38
Safety
Exhaust System Warning
CQ280139 —19—28MAR08
Stay clear of hot surfaces to prevent severe burns.
GB52027,000051F -19-29JAN08-1/1
102711
PN=39
Safety
102711
PN=40
Group 10
Specifications
Specifications — John Deere 6090 Engine
PowerTech™
Measurement Specifications
Type John Deere 6090H, 9.0 L
Quantity of Cylinders 6
Model 609HT803 Tier III
609HT804 Non EGR Tier II
Power 337 HP to 2100 RPM
375 HP to 2100 RPM
Air Intake Turbocharger and air-to-air
aftercooled
Oil Capacity Maximum Load 29.5 L (7.8 U.S.
gal)
Coolant capacity 69.6 Liters (18.4 U.S. gal)
Primary Fuel Filter Spin On/Spin Off Type Element
Final Fuel Filter Spin On/Spin Off Element
Tension (Electrical System) 12 Volt Battery (2 used)
PowerTech is a registered trademark of the Deere & Company

GB52027,0000550 -19-26MAR09-1/1
Preliminary Service Intervals 1. Change the engine oil and filter.

After the first 100 hours of operation, or after rebuilding 2. Change all fuel filters.
your engine, do the following:
NOTE: Refer to the Maintenance Section for
1. Change the engine oil and filter. complete service intervals.
2. Change all fuel filters.
Every 250 hours of operation thereafter, do the following:
OUO6083,000073A -19-26APR04-1/1
Common Wear Parts

Oil Filter — RE509672
Pre Fuel Element — RE522687
Belt (Crank Shaft) — R135604
Final Fuel Element — RE522688
OUO6083,00004F0 -19-18MAR03-1/1
102711
PN=41
Specifications
102711
PN=42
Group 15
General Capacities
Harvester Capacities
Approximate capacity
Component 3520 3522
Fuel Tank—Diesel 568 L (150 U.S. gal) 568 L (150 U.S. gal)
Hydraulic Oil Tank—SAE 10W30 super high 397 L (105 US Gal) World 397 L (105 US Gal) World
performance, heavy duty diesel engine oil
Radiator Coolant—50% Clean Water and 50% 69.6 L (16.5 U.S. gal) 69.6 L (16.5 U.S. gal)
Ethylene Glycol
Final Drive of Track— 85W/140 oil or 4.2 L (1.1 U.S. gal) 4.2 L (1.1 U.S. gal)
80W/140 Synthetic oil
Final Drive of Wheel—85W/140 oil or 4.2 L (1.1 U.S. gal) 4.2 L (1.1 U.S. gal)
80W/140 Synthetic oil
Chopper Gearbox— 85W/140 oil 11.01 L (2.9 U.S. gal) 11.01 L (2.9 U.S. gal)
Basecutter Gearbox — 85W/140 oil Dry 8.97 L (2.37 U.S. gal) Dry 13.5 L (3.5 U.S. gal)
Pump Drive Gearbox— 85W/140 oil 7.1 L (1.87 U.S. gal) 7.1 L (1.87 U.S. gal)
John Deere 6090 Engine—SAE 15W40 oil 29.5 L (7.8 U.S. gal) 29.5 L (7.8 U.S. gal)
Air Conditioner R134A refrigerant 3.4 kg (7.5 lb) 3.4 kg (7.5 lb)
R134A compressor oil 118 ml (4.oz) 118 ml (4.oz)
Approximate Weight of Combine 19050 kg (42000 lb) 19780 kg (43600 lb)
GB52027,000080F -19-23APR09-1/1
Tire Inflation Pressure

Tire Size Calibration Pressure
psi bar kPa
14-17.5 10 PLY FIR. 60 4.1 415
Front
14-17.5 14 PLY GAL. 80 5.5 550
23.5 R25 28 MICH L2 50 3.4 345
Rear
23.5-25 20 GALAXY 54 3.7 370
GB52027,000083A -19-21SEP11-1/1
102711
PN=43
General Capacities
102711
PN=44
Group 20
Torque Specifications
Location Torque Adhesive
Feed Roller Motor Mounting Bolts and Nuts 110 Nm (80 Lb-Ft) Araldite
Top Feed Roller Pin Mountine Studs 35 Nm (24 Lb-Ft) Araldite
Bottom Feed Roller Mounting Studs 80 Nm (60 Lb-Ft) Araldite
Basecutter Mounting Bolts 250 Nm (180 Lb-Ft) Araldite
Basecutter Disk Mounting Bolts 110 Nm (80 Lb-Ft)
Chopper Box Inspection Cover Bolts 25 Nm (20 Lb-Ft)
Chopper Box Cover Bolts 110 Nm (80 Lb-Ft) Loctite 242
Chopper—Lower Gear Mounting Bolts 300 Nm (225 Lb-Ft)
Chopper Flywheel Nut 373 Nm (275 Lb-Ft)
Final Drive Mounting Bolts 475 Nm (390 Lb-Ft Loctite 271
Final Drive Motors 373 Nm (275 Lb-Ft) Loctite 271
Rear Wheel Bolts 380 Nm (280 Lb-Ft) Anti-Seize
Front Wheel Bolts 230 Nm (170 Lb-Ft) Anti-Seize
Track-Guides 237 Nm (175 Lb-Ft) Loctite 271
Track-Top Idler Roller 122 Nm 90 Lb-Ft) Loctite 271
Track-Rear Axle Inner Nut 815 Nm (600 Lb-Ft)
Track-Rear Axle Outer Nut (Bolts) 50 Nm (35 Lb-Ft) Loctite 242
Track-Rear Axle Mounting Bolts 380 Nm (280 Lb-Ft) Araldite
Track-Shoe 407 Nm (300 Lb-Ft) Loctite 271
Track-Rollers 339 Nm (250 Lb-Ft) Loctite 271
Track-Sprockets 271 Nm (200 Lb-Ft) L&S Loctite 271
529 Nm (390 Lb-Ft) BNA Loctite 271
Track-Segments Sprockets 271 Nm (200 Lb-Ft) Loctite 271
Engine Mounting Bolt 380 Nm (280 Lb-Ft)
Scroll Bottom Bearing Flange 110 Nm (80 Lb-Ft) Araldite
Scroll Motor Mounting Bolts 110 Nm (80 Lb-Ft) Araldite
Scroll Motor Mount Assembly Bolts 110 Nm (80 Lb-Ft) Loctite 271
All Motor Spline Adapter Hubs 35 Nm (25 Lb-Ft) Araldite
All Spline Hubs (Grade 8) 110 Nm (80 Lb-Ft Araldite
Primary and Secondary Extractor Assemblies 110 Nm (80 Lb-Ft) Loctite 271
Primary Extractor (Motor In Can) 552 Nm (400 Lb-Ft) Dry
Swing Table Nuts
Top Nut of Swing Table Pin 460 Nm (300 Lb-Ft) Loctite 271
Bottom Nut of Swing Table Pin 815 Nm (600 Lb-Ft)
AG,T803584,239 -19-18FEB08-1/1
Torque for Grade 2 NC Weld Studs 3/8" Weld Studs — 32 N·m (25 Lb-Ft)
1/2" Weld Studs — 80 N·m (60 Lb-Ft)
1/4" Weld Studs — 8 N·m (6 Lb-Ft)
T803584,000002D -19-19MAR01-1/1
102711
PN=45
Metric Bolt and Screw Torque Values

TS1670 —UN—01MAY03
4.8 8.8 9.8 10.9 12.9 12.9
4.8 8.8 9.8 10.9 12.9 12.9
Bolt or Screw Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N·m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength of Shear bolts are designed to fail under predetermined loads. Always
the bolt or screw. DO NOT use these values if a different torque value or replace shear bolts with identical property class. Replace fasteners with
tightening procedure is given for a specific application. For stainless steel the same or higher property class. If higher property class fasteners are
fasteners or for nuts on U-bolts, see the tightening instructions for the used, tighten these to the strength of the original. Make sure fastener
specific application. Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement. When
by turning the nut to the dry torque shown in the chart, unless different possible, lubricate plain or zinc plated fasteners other than lock nuts,
instructions are given for the specific application. wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ2 -19-12JAN11-1/1
102711
PN=46
Unified Inch Bolt and Screw Torque Values

TS1671 —UN—01MAY03
Bolt or Screw SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N·m lb.-ft. N·m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N·m lb.-ft. N·m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N·m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt Replace fasteners with the same or higher grade. If higher
or screw. DO NOT use these values if a different torque value or tightening grade fasteners are used, tighten these to the strength of the
procedure is given for a specific application. For plastic insert or crimped steel original. Make sure fastener threads are clean and that you
type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the properly start thread engagement. When possible, lubricate
tightening instructions for the specific application. Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts, wheel bolts
under predetermined loads. Always replace shear bolts with identical grade. or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ1 -19-12JAN11-1/1
102711
PN=47
Suggested Torque Values and Clamp Loads

for Grades 2, 5, & 8 Bolts
Nominal Thread Stress SAE Grade Capscrews SAE Grade 5 Capscrews SAE Grade 8 Capscrews
Diameter and Area (Sq-In)
TPI (inches)
Clamp Load Tightening Clamp Load Tightening Clamp Load Tightening
60-90% Proof Torque (Ft-Lb) 60-90% Proof Torque (Ft-Lb) 60-90% Proof Torque (Ft-Lb)
(Pounds) (Pounds) (Pounds)
1/4-20 0.0318 1049-1574 4-7 1622-2433 7-10 2290-3434 10-4
1/4-28 0.0364 1201.1802 5-8 1856-2785 8-12 2621-3931 11.16
5/16-18 0.0524 1729-2594 9-14 2672-4009 14-21 3773-5659 20-29
5/16-24 0.0580 1914-2871 10-15 2958-4437 15-23 4176-6264 22-33
3/8-16 0.0775 2558-3868 16-24 3953-5929 25-37 5580-8370 35-52
3/8-24 0.0878 2897-4346 18-27 4478-6717 28-42 6322-9482 40-59
7/16-14 0.1063 3508-5262 26-38 5421-8132 40-59 7654-11480 56-84
7/16-20 0.1187 3917-5876 29-43 6054-9081 44-66 8546-12820 62-93
1/2-13 0.1419 4683-7024 39-59 7237-10855 60-90 10217-15325 85-128
1/2-20 0.1599 5277-7915 44-66 8155-12232 68-102 11513-17269 96-144
9/16-12 0.1820 6006-9009 56-84 9282-13923 87-131 13104-19656 123-184
9/16-18 0.2030 6699-10049 63-94 10353-15530 97-146 14616-21924 137-206
5/8-11 0.2260 7458-11187 78-117 11526-17289 120-180 16272-24408 170-254
5/8-18 0.2560 8448-12672 88-132 13056-19584 136-204 18432-27648 192-288
3/4-10 0.3340 11022-16533 138-207 17034-25551 213-319 24048-36072 301-451
3/4-16 0.3730 12309-18464 154-231 19023-28535 238-357 26856-40284 336-504
7/8-9 0.4620 15246-22869 222-334 23562-35343 344-515 33264-46896 485-728
7/8-14 0.5090 16797-25196 245-367 25959-38939 379-568 36648-54972 534-802
1-8 0.6060 19998-29997 333-500 30906-46359 515-773 43632-65448 727-1091
1-14 0.6790 22407-33611 373-560 34629-51944 577-866 48888-73332 815-1222
1 1/8-7 0.7630 25179-37769 472-708 33877-50816 635-953 54936-82404 1030-1545
1 1/8-12 0.8560 28248-42372 530-794 38006-57010 713-1069 61632-92448 1156-1733
1 1/4-7 0.9690 31977-47966 666-999 43024-64535 896-1344 69768-104652 1454-2180
1 1/4-12 1.0730 35409-53114 738-1107 47641-71462 993-1489 77256-115884 1610-2414
AG,T803584,242 -19-13JUN00-1/1
Suggested Torque Values For Grades 5.6,

8.8, 10.9, 12.9 Zinc Plated Bolts
Grade 5.6 Fine Grade 8.8 Fine Grade 10.9 Fine Grade 12.9 Fine
Nominal Diameter N·m ft.-Ib. N·m ft.-Ib. N·m ft.-Ib. N·m ft.-Ib.
M8 x 1 N/A N/A 25 18 35 25 42 30
M10 x 1.25 N/A N/A 49 36 68 50 82 60
M12 x 1.25 N/A N/A 88 64 125 92 150 110
M14 x 1.5 N/A N/A 140 103 195 143 235 173
M16 x 1.5 N/A N/A 210 154 295 217 350 258
M18 x 1.5 N/A N/A 305 224 425 313 510 376
M20 x 1.5 N/A N/A 425 313 600 442 720 531
M22 x 1.5 N/A N/A 570 420 800 590 960 708
M24 x 2 N/A N/A 720 531 1000 737 1200 885
AG,T803584,241 -19-13JUN00-1/1
102711
PN=48
Grade or Property Class Head Marking for

SI Bolts
SAE Grade Diameter Tensile Strength SI Class Diameter Tensile Strength
5 1/4" 105,000 PSI 8.8 Up to 16 MM 800 MP A
5 1 1-1/2" 120,000 PSI 8.8 17 to 36 MM 830 MP A
5 1/4" 1-1/2" 150,000 PSI 10.9 Up to 36 MM 1040 MP A
AG,T803584,243 -19-13JUN00-1/1
Conversion Factors
Torque In N·m x 0.737 = Torque In Lb-Ft
Torque In Lb-Ft x 1.356 = Torque In N·m
CM002500256 —UN—08JUN00
Torque In Lb-Ft x 12 = Torque In Lb-In
AG,T803584,244 -19-13JUN00-1/1
Straight O-Ring Boss Fittings

1. Inspect the o-ring boss seat of fitting for dirt or defects.
2. Lubricate the o-ring with o-ring lube or petroleum jelly.
3. Place tape (preferably electrical tape) over the threads
CM992600057 —UN—12JAN00
to protect the o-ring.
4. Slide the o-ring over the tape and into the o-ring
groove of fitting.
5. Tighten fitting until the hex bottoms out.
AG,T803584,245 -19-14JUN00-1/1
Angled O-Ring Boss Fittings

1. Back off the locknut and backup washer completely to
the “head-end” of the fitting.
2. Screw the fitting into the threaded boss until the CM992600058 —UN—12JAN00
backup washer contacts the face of the boss.

3. Turn the fitting “head-end” counterclockwise to the
proper index (a maximum of one turn).
4. Hold the fitting “head-end” with a wrench and tighten
the locknut until the backup washer bottoms out. Be
careful when installing fittings. Do Not twist hoses
when tightening.
AG,T803584,246 -19-14JUN00-1/1
102711
PN=49
SAE 37° (JIC)

A torque wrench should be used to assure proper fitting
assembly of these connections.
Swivel Nut Torque
Dash Size Thread Size Lb-Ft Newton Meters
7
-04 /16-20 11-12 15-16
7
-05 /16-20 15-16 20-22
9
-06 /16-18 18-20 24-28
3
-08 /4-16 38-42 52-58
7
-10 /8-14 57-62 77-85
-12 15/16-12 79-87 108-119
-16 15/16-12 108-113 148-154
-20 15/8-12 127-133 173-182
-24 17/8-12 158-167 216-227
-32 21/2-12 245-258 334-352
AG,T803584,242 -19-13JUN00-1/1
Metric
Straight Adapter or Locknut Torque
Thread Size (mm) Lb-Ft Newton Meters
M10 x 1 13-15 18-20
M12 x 1.5 15-19 20-25
M14 x 1.5 19-23 25-30
M16 x 1.5 33-40 45-55
M18 x 1.5 37-44 50-60
M20 x 1.5 52-66 70-90
M22 x 1.5 55-70 75-95
M26 x 1.5 81-96 110-130
M27 x 2 96-111 130-150
M33 x 2 162-184 220-250
M42 x 2 170-192 230-260
M48 x 2 258-347 350-470
T803324,00008AA -19-25OCT05-1/1
BSPP (Port Connection Only)

Straight Adapter or Locknut Torque
Thread Size (mm) Lb-Ft Newton Meters
G1/8-28 13-15 18-20
G1/4-19 19-23 25-30
3
G /8-19 33-40 45-55
G1/2-14 55-70 75-95
G3/4-14 103-118 140-160
G1-11 162-184 220-250
G11/4-11 170-192 230-260
G11/2-11 258-347 350-470
T803324,00008AA -19-25OCT05-1/1
102711
PN=50
ORS
Swivel Nut Torque
Dash Size Thread Size (Inches) Lb-Ft Newton Meters
9
-04 /16-18 10-12 14-16
11
-06 /16-16 18-20 24-27
13
-08 /16-16 32-35 43-47
-10 1-14 46-50 62-68
-12 13/16-12 65-70 88-95
-16 17/16-12 92-100 125-136
-20 111/16-12 125-140 170-190
-24 2-12 150-165 204-224
T803324,00008A9 -19-24OCT05-1/1
Straight Thread O-Ring Boss

Low Pressure with 37° (SAEJ514)
Jam Nut or Straight Fitting Torque
Dash Size Thread Size (Inches) Lb-Ft Newton Meters
3
-03 /8-24 8-9 12-13
7
-04 /16-20 13-15 18-20
1
-05 /2-20 14-15 19-21
9
-06 /16-18 23-24 32-33
3
-08 /4-16 40-43 55-57
7
-10 /8-14 43-48 59-64
-12 11/16-12 68-75 93-101
-14 13/16-12 83-90 113-122
-16 15/16-12 112-123 152-166
-20 15/8-12 146-161 198-218
-24 17/8-12 154-170 209-230
-32 21/2-12 218-240 296-325
T803324,00008A9 -19-24OCT05-1/1
37° Flare Cone Fittings

1. Inspect flare and flare seat. They both must be free
of dirt or obvious defects.
2. Defects in tube flare cannot be repaired.
CM992600059 —UN—12JAN00
Overtightening a defective flared fitting will not stop
leaks.
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or
petroleum jelly.
5. Index angle fittings and tighten by hand.
6. After fittings are hand tightened, mark the male and
female sides. Rotate the male fitting according to the
chart on the following page.
AG,T803584,247 -19-14JUN00-1/1
102711
PN=51
Hex Flats Recommended Rotation

Dash Size 37° Flared Tube 37° Machined Fitting
Seat
Ferrule and Nut Fittings and Hoses
CM992600060 —UN—12JAN00
-4 2 1/4-2 3/4 1 1/2-1 3/4
-6 2 1/4-2 3/4 1-1 1/2
-8 2 1/4-2 3/4 1 1/4-1 3/4
-12 2-2 1/2 1-1 1/2
-16 2 1/4-2 3/4 3/4-1
-20 1 1/4-1 3/4 1/2-3/4
AG,T803584,248 -19-14JUN00-1/1
Four Bolt Flange Fittings

1. Clean sealing surfaces (A) and inspect. Scratches
cause leaks. Roughness causes seal wear and
unlevelness causes seal extrusion; therefore, if
defects cannot be polished out, replace component.
2. Install the correct o-ring (and backup washer if
required) into groove using petroleum jelly to hold it
in place.
3. Split flange (B): Loosely assemble split flange halves.
Make sure split is centrally located and perpendicular
to port. Hand-tighten bolts to hold parts in place. Do
not pinch o-ring (C).
CM992600061 —UN—12JAN00
4. One piece flange (D): Place hydraulic line in center of
flange and install four bolts. Flange must be centrally
located on port. Hand-tighten bolts to hold flange in
place. Do not pinch o-rings.
5. After components are properly positioned and bolts
are hand tightened, tighten one bolt, then tighten the
diagonally opposite bolt. Tighten the two remaining
bolts. Tighten all bolts as specified in the chart below.
6. Do Not use air wrenches. Do Not Tighten one bolt
fully before tightening the others. Do Not over tighten.
AG,T803584,249 -19-14JUN00-1/1
102711
PN=52
SAE Bolt Torque Chart

Flange Size Bolt Size UNC (Min) LB-Ft (Max) (Min) N·m (Max)
1/2" 5/16-18 (15) — (23) (20) — (30)
3/4" 3/8-16 (21) — (40) (28) — (55)
1" 3/8-16 (27) — (40) (37) — (55)
1-1/4" 7/16-14 (35) — (63) (47) — (85)
1-1/2" 1/2-13 (46) — (97) (62) — (130)
2" 1/2-13 (55) — (97) (73) — (130)
2-1/2" 1/2-13 (80) — (97) (105) — (130)
3" 5/8-11 (115) — (195) (160) — (265)
3-1/2" 5/8-11 (115) — (195) (160) — (265)
4" 5/8-11 (115) — (195) (160) — (265)
5" 5/8-11 (115) — (195) (160) — (265)
AG,T803584,251 -19-14JUN00-1/1
102711
PN=53
102711
PN=54
Group 25
Fluid Recommendations
John Deere Engine Coolant Requirements The following engine coolant is preferred for service:
Contact your engine distributor or servicing dealer to 1. John Deere Prediluted Antifreeze/Summer Coolant
determine what the cooling system of this engine is filled
with and the winter freeze protection level. 2. John Deere Cool-Gard, where available.
Solutions of antifreeze and supplemental coolant The following engine coolant is also recommended: John
additives must be used year-round for freeze protection, Deere Antifreeze/Summer Coolant Concentrate in a 40 to
boil-over protection, and to provide a stable, noncorrosive 60 percent mixture of concentrate with quality water.
environment for seals, hoses, and metal engine parts.
T803324,000073B -19-30JUN05-1/1
John Deere Prediluted Antifreeze/Summer supplemental coolant additives (SCAs). It is ready to use;
Coolant no mixing is required.
This product contains all the necessary ingredients John Deere Prediluted Antifreeze/Summer Coolant
that make up the proper coolant solution, chemically permits extended service life to 5000 hours or 60 months
pure water, ethylene glycol (low silicate antifreeze), and of operation.
T803324,000073C -19-30JUN05-1/1
Heavy Duty Diesel Engine Coolant

The engine cooling system is filled to provide year-round
protection against corrosion and cylinder liner pitting, and
• Is formulated with a quality nitrite-free additive package.
winter freeze protection to -37°C (-34°F). If protection at
• Provides cylinder liner cavitation protection according to
either the John Deere Cavitation Test Method or a fleet
lower temperatures is required, consult your John Deere study run at or above 60% load capacity
dealer for recommendations.
• Protects the cooling system metals (cast iron, aluminum
The following engine coolants are preferred: alloys, and copper alloys such as brass) from corrosion
• John Deere COOL-GARD™ II Premix The additive package must be part of one of the following
• John Deere COOL-GARD II PG Premix coolant mixtures:
Use John Deere COOL-GARD II PG Premix when a • ethylene glycol or propylene glycol base prediluted
non-toxic coolant formulation is required. (40—60%) heavy duty coolant
• ethylene glycol or propylene glycol base heavy
Additional Recommended Coolants duty coolant concentrate in a 40—60% mixture of
concentrate with quality water
The following engine coolant is also recommended:
Water Quality
• John Deere COOL-GARD II Concentrate in a 40–60%
mixture of concentrate with quality water. Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
John Deere COOL-GARD II Premix, COOL-GARD II PG
water is recommended for mixing with ethylene glycol and
Premix, and COOL-GARD II Concentrate coolants do not
propylene glycol base engine coolant concentrate.
require use of supplemental coolant additives.
IMPORTANT: Do not use cooling system sealing
Other Coolants additives or antifreeze that contains
John Deere COOL-GARD II and COOL-GARD II PG sealing additives.
coolants might not be available in the geographical area Do not mix ethylene glycol and propylene
where service is performed. glycol base coolants.
If these coolants are unavailable, use a coolant Do not use coolants that contain nitrites.
concentrate or prediluted coolant intended for use with
heavy duty diesel engines and with a minimum of the
following chemical and physical properties:
COOL-GARD is a trademark of Deere & Company

DX,COOL3 -19-14APR11-1/1
102711
PN=55
John Deere Antifreeze/Summer Coolant lowest freeze protection temperature desired according
Concentrate to the following table:
% Concentrate Freeze Protection Limit
This product contains ethylene glycol (low silicate
antifreeze) and supplemental coolant additives (SCA’s). 40 -24°C (-12°F)
It Must Be mixed with quality water, as described later in 50 -37°C (-34°F)
this section, before adding to the engine cooling system. 60 -52°C (-62°F)
The proportion of water to be used depends upon the
T803324,000073E -19-30JUN05-1/1
John Deere Antifreeze/Summer Coolant

Concentrate permits extended service life to 5000 hours
or 60 months of operation.
T803324,000073F -19-30JUN05-1/1
Hydraulic Fluid (World)
CM053510043 —19—10MAR05
The hydraulics fluid is SAE 10W30, super high Engine oil may be used provided it meets one of
performance, heavy duty diesel engine oil. the following: API Service CF-4/SH, MIL-L-2140C,
MIL-L-2140CD, OR MIL-L-2140B.
Optional Hydraulic Fluid: Rykon® Oil AW ISO 68
AG,T803324,150 -19-23JUL99-1/1
Diesel Fuel be periodically drained.) A fuel conditioner to prevent

water condensation must be added if fuel is stored for
For fuel specifications, refer to Engine Manual. After an extended period of time.
buying good quality, clean fuel from a reputable supplier,
proper storage is extremely important. The fuel must be To avoid condensation in the harvester fuel tank, fill at
stored in clean storage and transfer tanks. (The water the end of each day's operation. Capacity is 568 L (150
and sediments from the bottom of the storage tanks must gallons).
AG,T803324,152 -19-19SEP07-1/1
102711
PN=56
Engine Break-In Oil (John Deere) of a new or rebuilt engine. These oils will not
allow the engine to break-in properly.
New engines are filled at the factory with John Deere
ENGINE BREAK-IN OIL. During the break-in period, If John Deere Engine Break-In Oil is not available, use a
add John Deere ENGINE BREAK-IN OIL as needed diesel oil meeting one of the following during the first 100
to maintain the specified oil level. The engine oil part hours of operation.
number is TY22041.
IMPORTANT: Do not use John Deere PLUS-50 oil
• API Service Classification CE
or engine oils meeting API CG-4, API CF-4,
• ACEA Specification E1
ACEA E3, ACEA E2, or CCMC D5 performance
• CCMC Specification D4
levels during the first 100 hours of operation After the break-in period, use John Deere Plus-50 or other
diesel oil as recommended in this manual.
AG,T803324,154 -19-19SEP07-1/1
Diesel Engine Oil Other oils may be used if they meet one or more of the
Use oil viscosity based on the expected air temperature following:
range during the period between oil changes. • John Deere Uni-Gard
• API Service Classification CG-4
The following oil is preferred: • API Service Classification CF-4
• John Deere Plus-50 • ACEA Specifications E3
If John Deere Plus-50 engine oil and a John Deere oil • ACEA Specification E2
filter are used, the service interval for oil and filter changes • CCMC Specification D5
may be extended by 50%. • CCMC Specification D4
The following oil is also recommended: Multi-viscosity diesel engine oils are preferred.
• John Deere Torq-Gard Supreme If diesel fuel with sulfur content greater than 0.5% is used,
reduce the service interval by 50%.
AG,T803324,155 -19-27FEB06-1/1
Gear Oil — Pump Drive, Chopper Box, and

Basecutter
Use a 85W140 multigrade oil that meets extreme pressure
(EP) gear lubricant specification MIL-L-2105C or API
classification GL-5.
AG,T803324,157 -19-23JUL99-1/1
Gear Oil — Final Drive API GL5, using a SAE 85W/140 mineral or synthetic oil
type.
The recommended oil type should have EP (Extreme
Pressure) characteristics according to MIL-L-2105C and
BL04947,0000362 -19-22SEP11-1/1
Grease
Use a SAE multipurpose grease containing 3 to 5%
molybdenum disulfide and having extreme pressure (EP)
performance.
AG,T803324,159 -19-23JUL99-1/1
102711
PN=57
102711
PN=58
Group 30
General Information
Conversions You may find frequent use for the fraction-decimal-
The following pages contain information that will be useful millimeter conversion chart on this page, especially when
to you as you work with non-metric fasteners. you have to cut or restore threads.
Item Measurement Specification
1 Gross or Long Ton Weight 2,240 Lb

1 Net or Short Ton Weight 2,000 Lb
1 Cubic Foot of Water Weight 62.5 Lb
1 Gallon of Water Weight 8.3 Lb
T803324,0000749 -19-30JUN05-1/1
Length Measure • 1 Station = 100 Feet

• 1 Mile = 8 Furlongs • 1 Chain = 4 Rods
• 1 Mile = 80 Chains • 1 Chain = 22 Yards
• 1 Mile = 320 Rods • 1 Chain = 66 Feet
• 1 Mile = 1,760 Yards • 1 Chain = 100 Links
• 1 Mile = 5,280 Feet • 1 Rod = 5.5 Yards
• 1 Furlong = 10 Chains • 1 Rod = 16.5 Feet
• 1 Furlong = 220 Yards • 1 Yard = 3 Feet
• 1 Station = 6.06 Rods • 1 Yard = 36 Inches
• 1 Station = 33.3 Yards • 1 Foot = 12 Inches
T803324,000074A -19-30JUN05-1/1
Metric 1SI Measurements fit metric fasteners. Consult tool manufacturer literature to
determine these sizes.
The use of metric measurements and metric fasteners
has greatly increased in recent years. You’ll encounter Although there are metric equivalents for all English
them even more frequently as they are gradually adopted measurements (length, weight, volume, and so on), the
in the United States. Furthermore, many foreignmade only ones you are likely to deal with in your work with
products have become commonplace. These are usually fasteners are linear (length) measurements. The tables
manufactured to metric measurements. For instance, the which follow are provided to help you compare metric to
fasteners used in foreign-built cars and tractors are made English measurements, or to make conversions when you
to metrics and many require metric wrenches to remove are required to do so.
and install them. In some cases, inch-size wrenches will
1
SI stands for System D'Unites (International System of Units).
In English, the term is abbreviated to “SI”, and is called the
“International System of Measurements.”
T803324,000074B -19-30JUN05-1/1
Metric to English • 1 Meter = 39.37 Inches

• 1 Millimeter = 0.03937 Inches • 1 Meter = 3.2808 Feet
• 1 Centimeter = 0.3937 Inches • 1 Meter = 1.0936 Yards
T803324,000074D -19-30JUN05-1/1
English to Metric • 1 Foot = 30.48 Centimeters (cm)

• 1 Foot = 0.3048 Meter (M)
• 1 Inch = 25.4 Millimeters (mm) • 1 Yard = 91.44 Centimeters (cm)
• 1 Inch = 2.4 Centimeters (cm) • 1 Yard = 0.9144 Meter (M)
• 1 Foot = 304.8 Millimeters (mm)
T803324,000074D -19-30JUN05-1/1
102711
PN=59
General Information
Multiplication Factors
When you know ....................
Multiply To Find
Millimeters 0.04 Inches
Centimeters 0.39 Inches
Meters 3.28 Feet
Meters 1.09 Yards
Newton-Meters 0.737 Foot-Pounds
Liters 1.057 Quarts
Liters 0.2642 Gallons
Liters 2.10 Pints
Inches 2.54 Centimeters
Feet 30.5 Centimeters
Yards 0.91 Meters
Foot-Pounds 1.356 Newton-Meters
PSI 14.63 Bar
*Approximate
T803324,000074E -19-30JUN05-1/1
Temperature Conversion Chart

To convert Celsius to Fahrenheit, multiply by 1.8 and add
When temperatures are given in Celsius (formerly 32.
Centigrade) (C) or Fahrenheit (F), use the chart below to
quickly convert from one to the other. • F° = (C° x 1.8) + 32)
Celsius Fahrenheit To convert Fahrenheit to Celsius, subtract 32 and divide
0° 32° by 1.8.
30° 86° • C° = (F° -32) ÷ 1.8)
100° 212°
T803324,000074F -19-28SEP07-1/1
102711
PN=60
General Information
Recommended Supplies
John Deere offers the following list of supplies for our
customers' convenience. Keep in mind that some of these
products are not readily obtainable in all countries.
Number Name Use
0841303194 (U.S.) Loctite Primer-N 1
Recommended as a surface
preparative, use before any type of
Loctite application. This part number
is for a 6 oz spray can.
0840008762 (U.S.) Loctite PST Recommended for use on all types

of threads to prevent leakage at the
joint. This is for use on hydraulic,
air or water lines. This part number
is for a 50 ml bottle.
0841304201 (U.S.) Loctite 242 Recommended for use on parts that

will be removed again. This is for
the prevention of parts loosening
during normal operation. The part
can still be removed by a mechanic
without too much difficulty. This part
number is for a 50 ml bottle.
0841303179 (U.S.) Loctite 271 Recommended for use when repairing

a cylinder. This is specifically used
for the internal bolt that holds the
head in place. This part number
is for a 50 ml bottle.
0841322669 (U.S.) Loctite 620 Recommended for use when installing

high temperature cylindrical parts.
This part number is for a 250 ml bottle.

parts with a press fit.. This part
number is for a 50 ml bottle.

a part that will never be removed again.
This can only be removed by burning.
0430024221 (U.S.) Silicone Sealant (RTV) Recommended as a general sealant.

This can, in many instances, replaces
older gasket materials. This part
number is for a 4.7 oz tube.
0390032007 (U.S.) Plastic Gasket Recommended as a general sealant.

It hardens in the assembled joint
to form a tough, thin gasket that
resists lubricants and chemicals.
Metal-to-metal contact of flanges
provides an excellent bond. Joint is
locked against vibration loosening.
Operating limit is 300° F (150° C).
Continued on next page T803324,0000751 -19-30JUN05-1/3
102711
PN=61
General Information
Number Name Use

0841305658 (U.S.) Antiseize Compound Recommended for use on all types
of threads to prevent galling. This
part number is for a 16 ounce
can with a brush top.
0840021386 (U.S.) Teflon Thread Tape Recommended for use on all types
of threads to prevent leakage at the
joint. This is for use on hydraulic,
air or water lines.. This part number
is for a ½ inch x 50 feet roll.
0840008762 (U.S.) Teflon Thread Paste Recommended for use on all types
of threads to prevent leakage at
the joint. It has the same uses as
Teflon thread tape. The use of either
of the two forms is strictly a matter
of personal preference. This part
number is for a 1.69 ounce tube.
0841304202 (U.S.) O-Ring Lube Recommended for the ease of

installing o-rings, seals and gaskets.
This holds them in place and also
protects them from damage during
installation. This part number is
for a 2 oz. tube.
0910041171 (U.S.) Dry Spline Lube Recommended for the lubrication of

the splines in pumps and motors. This
will prolong the service life of parts that
are subjected to high torques. This
part number is for a 2.8 ounce tube.
0841340040 (U.S.) Araldite Adhesive Kit Recommended as a locking element

for mating parts with the tendency
to loosen during operation. It is also
used for special isolation purposes
during construction and repair. This
part number includes Reusable
Gun P/N 0841306707, Cartridge
P/N 0841306708, and Nozzle-Mix
P/N 0841306709.
0841307790 (U.S.) Araldite Cartridge This is a preloaded cartridge of

Araldite resin and hardener. It
is included in the above Araldite
Adhesive Kit P/N 0841340040. This
cannot be used without the applicator
Gun P/N 0841306707. This part
number is for a 50 ml cartridge.
0841306709 (U.S.) Araldite Nozzle Nozzle to attach to the above

Araldite Cartridge P/N 0841307790
for mixing Araldite.
Continued on next page T803324,0000751 -19-30JUN05-2/3
102711
PN=62
General Information
Number Name Use

0491310039 (U.S.) O-Ring Kit This is an assortment of all the o-rings
used on the boss o-ring hydraulic
fittings. These fittings are used on
your equipment where it is necessary
to seal a joint. It is recommended
that a supply of these o-rings be
kept on hand. The kit contains 5 of
size 24; 10 of size 4, 6, 10, and 20;
and 20 of size 8 and 16.
0561310037 (U.S.) Cap and Plug Kit This is an assortment of plastic caps
and plugs used to cap-off or plug hoses
and components during service or
repairs. The kit contains 40 of size 04,
06 and 12 in both caps and plugs; 50
of size 16 in both caps and plugs; and
60 of size 08 in both caps and plugs.
0841346779 (U.S.) Wrench Set Angled This is a heavy duty, open-ended,

offset wrench set. It is recommended
for removing hydraulic hoses and
fittings located in tight places. The
set has 2”, 1-7/8”, 1-5/8”, 1-1/2”
and a 1-3/8” wrench.
0841346780 (U.S.) Wrench Set Angled This set contains angled, open-end
wrenches in fourteen of the most
popular sizes. From 3/8” to
1-1/8”, in increments of 1/16” and
a 1-1/4” wrench.
0631341478 (U.S.) Electrical Grease This is a heavy duty water proof and
corrosion proof electrical grease. It is
recommended that whenever a wire is
repaired that is should be filled with
this grease before connection. This
part number is for a 1 oz. bottle.
0601305130 (U.S.) Flow Tester 75 GPM Kit This is a 75 GPM in-line hydraulic
flow tester.
0840317083 (U.S.) Hose Kit This is for the flow meter 0601305130.
0840322463 (U.S.) Flow Meter This is a 125 GPM flow meter kit
with adapter fittings.
0910041171 (U.S.) Optimoly White Paste This is an anti-seize lubricant

that prevents seizing, galling,
and excessive wear of various
harvester components.
1
All Loctite® adhesives have a one year shelf life; therefore, John Deere
recommends that you do not order more than can be used in a year's time.
T803324,0000751 -19-30JUN05-3/3
102711
PN=63
General Information
Hydraulic Gauge Kit
CM053510143 —UN—24MAR08
Continued on next page T803324,0000752 -19-20MAR08-1/2
102711
PN=64
General Information
A—Test Fittings 9— Hose 18— Fitting 27— Allen Wrench

1— Pressure Gauge 10— Manifold Test Kit 19— Fitting 28— Allen Wrench
2— Pressure Gauge 11— BK-Link Chain 20— Fitting 29— Fitting
3— Pressure Gauge 12— S-Hook 21— Fitting 30— Fitting
4— Comp Gauge 13— Eye Bolt 22— Nut 31— Fitting
5— Fitting 14— Fitting 23— N/A 32— Assy-Test Tee
6— Fitting 15— Fitting 24— Tool Box 33— Assy-Test Tee
7— Fitting 16— Fitting 25— Combination Wrench
8— Female Coupling 17— Fitting 26— Allen Wrench
T803324,0000752 -19-20MAR08-2/2
102711
PN=65
General Information
Harvester Specialty Tools and Part Numbers

Ground Drive
Number Name Use

1190315364 (U.S.) Tool - Track Recoil Spring
0841329348 (U.S.) Tool - Shaft Bullet 1”
0290289270 (U.S.) Tool - Axle Nut
0841331949 (U.S.) Tool - Sprocket Wear Gauge
0841338384 (U.S.) Tool - Roller Lube Nozzle
0290244461 (U.S.) Tool - Bushing Installer
0290244683 (U.S.) Tool - Sleeve
0290244684 (U.S.) Tool - Seal Installer
Final Drive
Number Name Use

CB01439350 (U.S.) Torque Multiplier Tool
CB01422548 and CB01422546 (U.S.) Parking Brake Spring Compressor
JDG1451 (U.S.) Parking Brake Spring Compressor
JDG1787 (U.S.) Safety Plate
JDG1782 (U.S.) Torque Multiplier
JDG1786 (U.S.) Bearing Race Installer
OTC1154 (U.S.) Puller
Basecutter
Number Name Use

1190290188 (U.S.) Tool - Basecutter Leg-Timing
1190323529 (U.S.) Puller Kit - Basecutter Bearing
1191374512 (U.S.) Leg & Seal Alignment Tool
CB01407093 (U.S.) Basecutter Leg Bearing Race Installer
CB01444383 (U.S.) Tool - Basecutter Seal Adapter
CB11422828 (U.S.) Tool - Basecutter Leg Blocking

Assembly
CB11444166 (U.S.) Basecutter Stand
Continued on next page BL04947,000038C -19-26OCT11-1/2
102711
PN=66
General Information
Number Name Use

CB11444448 (U.S.) Tool - Basecutter Leg Bearing Installer
Chopper
Number Name Use

CB01444732 (U.S.) Tool - Flywheel Seal
CB01444779 (U.S.) Tool - Chopper Box Freeze Plug
CB21443671 (U.S.) Motor Lift Tool
CB11444588 (U.S.) Flywheel Lifter
Feed Rollers
Number Name Use

0290244355 (U.S.) Tool - Wiper Roll Bearing
0290244341 (U.S.) Tool - Front End Alignment
0841306323 (U.S.) Tool - Seal Installer
CB01444277 (U.S.) CRS - Tool - Freezer Plug - Feed Roller
Elevator
Number Name Use

0290227533 (U.S.) Tool - Swing Table Bearing
CB01445982 (U.S.) Tool - Swing Table Upper Bushing

Installer
CB01445983 (U.S.) Tool - Swing Table Lower Bushing

Installer
1190289732 (U.S.) Balancer - Extractor Fan Secondary
Basecutter Cylinder
Number Name Use

CB11446203 (U.S.) Basecutter Cylinder Trunnion
Seal Installer
CB11446242 (U.S.) Front Wheel Hub Cap Installer
CB11446249 (U.S.) Basecutter Cylinder Trunnion

Cap Installer
BL04947,000038C -19-26OCT11-2/2
102711
PN=67
General Information
102711
PN=68
Group 35
Service Points
Harvester Component Locations
CM063510046 —UN—24MAR08
1— Secondary Extractor 7— Engine Compartment 13— Basecutter 19— Chopper Flywheel
2— Elevator 8— Cab 14— Buttlifter Roller 20— Cart Guard
3— Primary Extractor 9— Topper 15— Feed Rollers 21— Bin Flap
4— Lift Lug 10— Crop Dividers/Scrolls 16— Chopper Box
5— Lights (3 areas) 11— Binding Hole (Transporting) 17— Tow Loops
6— Air Intake Screen 12— Power Knockdown Roller (2) 18— Basket
AG,T803584,107 -19-05JUN00-1/1
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PN=69
Service Points
Harvester Service Point Locations
CM063510047 —UN—24MAR08
1— Secondary Extractor Fan 7— Hydraulic Filters (Right Side) 13— Fuel/Water Separator Filter 19— Hydraulic Oil Tank (Right
2— Primary Extractor Fan 8— Fuel Tank (Left Side) 14— Topper Blades Side)
3— Primary Extractor Hood 9— Fresh Air AC Filter (Left 15— Engine Oil Filter (Left Side) 20— Chopper Gearbox (Right
4— Engine Air Filters (Left Side) Outside of Cab) 16— Pump Drive Oil Level (Right Side) & Bearings (Left Side)
5— Oil Cooler AC Condenser 10— Recirculation AC Filter Side) 21— Final Drive (Both Sides)
6— Radiator (Behind Training Seat) 17— Engine Oil Dipstick (Left 22— Swing Table
11— Fuses And Relays (Remove Side) 23— Elevator Chain Adjustment
Training Seat Back Cushion) 18— Basecutter Gearbox Sight
12— Windshield Wiper Fluid (Left Gauge (Right Side)
Side)
AG,T803584,108 -19-05JUN00-1/1
102711
PN=70
Service Points
Harvester Grease Point Locations
CM063510048 —UN—24MAR08
1— Secondary Extractor 6— Scroll Bearings — 2 Fittings 11— Feed Roller Bearing — 9 16— Chopper Curtain Agitator —
Mounting Bearing — 1 Fitting 7— Crop Divider Cylinders / Fittings 1 Fitting
2— Secondary Extractor Hood Mounting Pins— 10 Fittings 12— Feed Roller Cradle Pins — 17— Elevator Cable Support
Ring — 2 Fittings 8— Track-Rod & Butt End of 10 Fittings Sheave — 2 Fittings
3— Primary Extractor Hood Ring Cylinders — 4 Fittings 13— Chopper Rollers — 2 Fittings 18— Headshaft Flange Mounted
— 5 Fittings 9— Wheel Struts — 10 Fittings 14— Tail Shaft Bearings — 2 Bearings — 2 Fittings
4— Topper Upper & Lower 10— Wheel Steering Cylinder Fittings
Mounting Pins — 4 Fittings Pins — 4 Fittings 15— Swing Table — 9 Fittings
5— Topper Lift Cylinder Rod and
Butt End — 2 Fittings
AG,T803584,109 -19-05JUN00-1/1
102711
PN=71
Service Points
Grease Point Locations 1. (2) Fittings — one on each side of hood ring
For the following lubrication points use SAE multipurpose 2. (1) Fitting — fan mount, rotate fan by hand while
grease with extreme pressure (EP) performance and greasing.
containing 3 to 5 % molybdenum disulfide. Clean fittings All of the following locations contain SEALED Bearings.
before greasing. If grease fitting is missing, replace Only pump 3 SHOTS every 250 hours. Overlubrication
immediately. will blow out seals, causing premature failure. Use a hand
Topper — 6 Fittings (25 Hours) pump grease gun.
Crop Divider Scrolls — 2/4 Fittings (250 Hours)
1. (2) Fittings — upper and lower pins at topper.
2. (2) Fittings — upper and lower pins at cab. Only pump 3 shots with hand pump every 250 hours.
3. (2) Fittings — rod and butt end of cylinder.
1. (2) Fittings — base of scrolls accessible through hole.
Crop Divider Assemblies — 10/18 Fittings (25 Hours) 2. (2) Fittings — base of optional outer scrolls.
1. (2) Fittings — butt end of cylinders. RH Feed Rollers — 4 Fittings (250 Hours)
2. (4) Fittings — both pins on top adjustable hinges
3. (4) Fittings — both pins on bottom hinges. Only pump 3 shots with hand pump every 250 hours.
4. (8) Fittings — Optional - rod and butt end of tilt crop
divider cylinders 1. (2) Fittings — second and fourth top rollers from the
front.
Wheel Steering Cylinders — 4 Fittings (25 Hours) 2. (2) Fittings — third and fifth bottom rollers from the
front.
1. (4) Fittings — rod and butt end of each cylinder
LH Feed Rollers — 5 Fittings (250 Hours)
Wheel Front Lift Cylinders — 12 Fittings (25 Hours)
Only pump 3 shots with hand pump every 250 hours.
1. (8) Fittings — rod and butt end of each cylinder.
2. (2) Fittings — one on each bottom of each cylinder. 1. (3) Fittings — first, third and fifth top rollers before
3. (2) Fittings — one on each height indicator assembly. chopper.
2. (2) Fittings — second and fourth bottom rollers before
Track Front Lift Cylinders — 4 Fittings (25 Hours) chopper.
1. (4) Fittings — rod and butt end of each cylinder. Chopper Shaft Bearings — 2 Fittings (250 Hours)
Feed Roller Cradle Pins — 10 Fittings (25 Hours) Only pump 3 shots with hand pump every 250 hours.
Primary Extractor — 7 Fittings (25 Hours) 1. (2) Fittings — each chopper bearing has (1) fitting.
Chopper Curtain Agitator — 1 Fitting (250 Hours)
1. (5) Fittings — on hood ring..
2. (2) Fittings — one on each elevator cable support Only pump 3 shots with hand pump every 250 hours.
sheave.
1. (1) Fitting — chopper curtain agitator bearing.
Elevator Swing Table — 9 Fittings (25 Hours)
Elevator — 4 Fittings (250 Hours)
1. (4) Fittings — swing cylinder trunnion mount.
2. (2) Fittings — swing cylinder rod ends. Only pump 3 shots with hand pump every 250 hours.
3. (2) Fittings — swing table mounting pin (fitting located
on base of pin). 1. (2) Fittings — headshaft flange mounted bearings on
4. (1) Fitting—top plate of swing table. top of elevator.
2. (2) Fittings — tail shaft mounting bearings on bottom
Secondary Extractor — 3 Fittings (25 Hours) of elevator.
AG,T803584,110 -19-05JUN00-1/1
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PN=72
Section 20
Engine
Contents
Page
Group 05—Pump Drive Gear Box

Pump Drive Removal..................................... 20-05-1
Disassembly .................................................. 20-05-3
Clean and Inspect.......................................... 20-05-9
Assembly ..................................................... 20-05-10
102711
PN=1
Contents
102711
PN=2
Group 05
Pump Drive Gear Box
Pump Drive Removal
CM002500287 —UN—26SEP07
1— Housing 7— O-ring 13— Shaft 19— Fitting

2— Ball Bearing 8— Adapter Plate 14— Bearing 20— Pipe Bushing
3— Spur Gear 9— Socket Head Screw 15— Housing 21— Tube
4— Spline Coupling 10— Ball Bearing 16— Seal 22— Pipe Plug
5— Adapter Plate 11— Gear 17— Pipe Plug 23— Pipe Plug
6— Bolt 12— Bearing 18— Cap Screw
Continued on next page BL04947,000034B -19-15SEP11-1/6
102711
PN=75
Pump Drive Gear Box
1. Drain the hydraulic tank and pump drive.

3. Disconnect the electrical harness from the pumps.
2. Disconnect, label and cap all suction and pressure
lines to the pumps. DO NOT disconnect the engine 4. To prevent contamination, make sure all hydraulic
drain line. lines and ports are capped or plugged.
BL04947,000034B -19-15SEP11-2/6
5. Loosen the four bolts (B) located on each side of the

engine flywheel housing. It is not necessary to fully
remove these bolts (B).
6. To remove the load from the rear engine mounts,
CM073510558 —UN—03MAR08
slightly lift the engine and pump drive. Block
underneath the engine flywheel housing.
7. Support the pump drive and pumps as a single unit.
BL04947,000034B -19-15SEP11-3/6
8. Remove the twelve bolts from the flywheel housing,

located on the rear of the pump drive.
CM073510559 —UN—24MAR08
BL04947,000034B -19-15SEP11-4/6
9. Remove the four bolts (B), located on each side of the

pump drive, that are securing the rear engine mount.
10. Carefully slide the pump drive backward, away from
the engine. The coupling and drive shaft may stay
CM073510558 —UN—03MAR08
with either the engine or the pump drive.
Continued on next page BL04947,000034B -19-15SEP11-5/6
102711
PN=76
Pump Drive Gear Box
11. Inspect the pump drive and the drive shaft seal (16)
for damage. Discard and replace at assembly.
CM073510560 —UN—03MAR08
BL04947,000034B -19-15SEP11-6/6
Disassembly
1. Position the pump drive with the hydraulic adapter
plates (5 & 8) facing upward.
CM073510563 —UN—24MAR08
T803324,0000756 -19-05OCT07-1/9
2. Remove bolts (6 & 9) and adapter plates from pump

drive housing (1).
CM073510564 —UN—24MAR08
Continued on next page T803324,0000756 -19-05OCT07-2/9
102711
PN=77
Pump Drive Gear Box
3. Remove gears (3), splined adapters (4) and bearings

(2) from the pump drive housing. This can be done by
hand, since the bearings are slip-fitted to the housing
and pump adapter bores.
CM073510565 —UN—27SEP07
CM073510566 —UN—03MAR08
102711
PN=78
Pump Drive Gear Box
4. Bearings are press-fit to the gear hubs. It may be

necessary to tip the gear slightly, in order to clear the
pinion gear bearing pocket.
CM073510567 —UN—03MAR08
CM073510568 —UN—03MAR08
T803324,0000756 -19-05OCT07-4/9
5. After all gears and their bearings have been removed,

remove the breather parts (19, 20 & 21).
CM073510569 —UN—24MAR08
102711
PN=79
Pump Drive Gear Box
6. Turn the gear box over so that adapter housing (15)

is facing upward. Remove eight bolts (18) and lift the
adapter housing from the pump drive housing.
CM073510570 —UN—03MAR08
CM073510571 —UN—03MAR08
102711
PN=80
Pump Drive Gear Box
7. Remove pinion gear (11) and bearings (10 & 12).
CM073510572 —UN—24MAR08
CM073510573 —UN—27SEP07
102711
PN=81
Pump Drive Gear Box
8. Remove bearings (2, 10 & 12) from the hubs of gears

(3 & 11) using a gear puller or arbor press.
CM073510574 —UN—24MAR08
CM073510575 —UN—03MAR08
102711
PN=82
Pump Drive Gear Box
9. Remove oil seal (16) by driving outward or pulling

outward, toward the engine side of the adapter
housing (15).
CM073510576 —UN—24MAR08
CM073510577 —UN—03MAR08
T803324,0000756 -19-05OCT07-9/9
Clean and Inspect

3. Clean the old Loctite out of all bolt hole threads.
John Deere recommends the use of new seals when
reassembling. Refer to your parts manual for replacement 4. Check around the splines and chamfered area of the
parts and proper kit numbers. shaft for burrs, nicks, or sharp edges that can damage
the seals when reassembling.
1. Clean and inspect all parts for wear or damage. Check
all mating surfaces. 5. Prior to installation, lubricate all seals with O-ring lube
(0841304202) or equivalent.
2. Replace all necessary parts. Bolts should not be
reused.
T803324,0000756 -19-05JUL05-1/1
102711
PN=83
Pump Drive Gear Box
Assembly
1. For assembly, reverse steps 1 through 5 in
disassembly.
2. Install new bolts (6, 9 & 18) using Loctite® 262
(084130179), into adapter housing (15) and adapter
plates (5 & 8).
3. Torque all bolts to 271 (200 lb-ft).
CM073510578 —UN—24MAR08
BL04947,0000349 -19-09SEP11-1/6
4. Replace oil seal (16). Lubricate and install the oil seal
towards the engine side of adapter housing (15). The
rubber lip of the oil seal must point toward the inside
of the pump drive as shown.
CM073510579 —UN—03MAR08
CM073510580 —UN—03MAR08
Continued on next page BL04947,0000349 -19-09SEP11-2/6
102711
PN=84
Pump Drive Gear Box
5. John Deere recommends that the oil seal (16) be

replaced whenever a repair is made to the pump drive.
CM073510581 —UN—06MAR08
BL04947,0000349 -19-09SEP11-3/6
6. Inspect the eight bolts, located in the center of the

drive coupling, for damage. Replace, if necessary. Be
sure the spline, located in the center of the rubber
coupling, is fully bottomed on the shaft spline. Torque
bolts to 50 N·m (37 lb-ft).
CM073510561 —UN—24MAR08
BL04947,0000349 -19-09SEP11-4/6
7. Install the pump drive shaft (13) into the pump drive
housing. Be careful not to damage the seal (16).
8. Install the pump drive onto the flywheel housing by
meshing the rubber coupling spline with the aluminum
CM073510562 —UN—24MAR08
ring bolted to the engine flywheel. The pilot, located
on the pump drive shaft, must go into the support
bearing, located in the center of the flywheel.
102711
PN=85
Pump Drive Gear Box
9. After get the flywheel housing and the pump drive

aligned bolt them using the bolts (C).
CQ285071 —UN—29DEC09
BL04947,0000349 -19-09SEP11-6/6
102711
PN=86
Section 30
Feed Roller System
Contents
Page
Group 05—Knockdown Roller

Knockdown Roller.......................................... 30-05-1
Knockdown Roller Removal .......................... 30-05-2
Disassembly .................................................. 30-05-2
Assembly ....................................................... 30-05-2
Group 10—Buttlifter Roller (B1)

Buttlifter Roller (B1) ....................................... 30-10-1
Buttlifter Roller Repair ................................... 30-10-2
Assembly ....................................................... 30-10-2
Group 15—Bottom Feed Roller

Bottom Feed Roller (B2, B3, B4,
B5) ............................................................. 30-15-1
Bottom Feed Roller Repair (B2,
B3, B4, B5) ................................................ 30-15-2
Assembly ....................................................... 30-15-2
Group 20—Top Feed Roller

Top Floating Feed Roller (T1, T2,
T3, T4, T5)................................................. 30-20-1
Top Floating Feed Roller Repair.................... 30-20-2
Assembly ....................................................... 30-20-2
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PN=1
Contents
102711
PN=2
Group 05
Knockdown Roller
Knockdown Roller
CM053510275 —UN—17AUG05
Flush with edge (A). Bolt Placement Detail (B).

1— Knockdown Roller 6— Hex Bolt 11— Hex Bolt 16— Lock Washer
2— Lock Washer 7— Hub Spline 12— Lock Nut 17— Lock Nut
3— Lock Washer 8— Spacer 13— Hex Nut 18— Expansion Plug
4— Hub Spline Adapter 9— Motor Mount Assembly 14— Squiggly Paddle Plate
5— Hex Bolt 10— Roller Guard 15— Hex Bolt
T803324,000081F -19-17AUG05-1/1
102711
PN=89
Knockdown Roller
Knockdown Roller Removal 3. Remove the nuts (13) and lock washers (3) that
1. Label all the hoses going to the two knockdown secure the motor mount assembly (9).
motors. Disconnect the hoses ensuring that all fittings 4. Support the roller (1) and remove both motor mount
and hoses are capped and plugged. assemblies (9) along with the motors.
2. Remove the bolts (11) and nuts (12) that secure the 5. The knockdown roller can now be removed.
roller guards. Remove the roller guards.
T803324,0000820 -19-17AUG05-1/1
Disassembly 2. Remove hex bolts (15) and locknuts (17); this will
NOTE: Disassembly is possible once the finned roller allow you to remove the squiggly paddle plates.
is out of the harvester frame.
3. Remove the motor from housing (9).
1. Remove bolts (6) and (3) from both spline hubs (7). 4. Remove hex head bolts (5) and lock washers (2) from
The spline hubs can now be removed. the two motors; this will allow the hub spline adapter
(4) to be removed from the motors.
T803324,0000821 -19-27SEP07-1/1
Clean and Inspect 3. Inspect the motor for leakage at the seals and gaskets.
1. Clean all parts and inspect for wear or damage. Repair 4. Clean the remaining Araldite (this should have
or replace as necessary. crystallized after application of heat) from all internal
2. Pay particular attention to the splines of hub adapter and external threads and splines. Inspect, then repair
(4) and spline hub (7). If these are damaged, John or replace as necessary.
Deere recommends that both parts be replaced
together for maximum efficiency.
T803324,0000822 -19-17AUG05-1/1
Assembly 7. Apply Araldite when installing bolts (6) and washers

1. Assembly is the reverse of disassembly. (3). Torque bolts to 70 to 79 N·m (52 to 58 lb-ft).
2. Apply Araldite to all fasteners before installation. 8. Position the finned roller in its proper location and
install the complete motor mount assembly, along with
3. Apply Araldite to internal splines only; do not apply to the motor.
splines of adapter.
9. Align roller with motor and install fasteners (13 & 3) to
4. Install fasteners (5 & 2) to secure adapter (4) to motor. secure the housing assembly to the harvester side
Torque bolts (5) 32 to 35 N·m (24 to 26 lb-ft. walls. Torque the nuts to 81 N·m (60 lb-ft).
5. Install motors into their mounting assemblies (9). 10. Install guard assembly (10) to the side wall. Apply
Araldite to the fastener and torque to 24 N·m (18 lb-ft).
6. Install bolts, washers and nuts. Torque bolts to 103 to
119 N·m (76 to 84 lb-ft). 11. Reconnect hoses.
T803324,0000823 -19-17AUG05-1/1
102711
PN=90
Group 10
Buttlifter Roller (B1)
CM053510276 —UN—22AUG05
Continued on next page T803324,0000824 -19-17AUG05-1/2
102711
PN=91
1— External Bearing Cradle 10— Hex Bolt 19— Zerk 28— Rubber Stop
2— Lock Washer 11— Cart Sphere Bearing 20— Spacer Sheet 29— Set Screw
3— Hex Nut 12— Zerk 21— External Roller Shaft 30— Socket Bolt
4— Splined Hub Adapter 13— Wave Bar Plate 22— Motor Mount 31— Hex Nut
5— Lock Washer 14— Hex Nut 23— Feed Roller Bearing Mount 32— Lock Washer
6— Hex Bolt 15— Roller Pin 24— Hex Bolt 33— Zerk
7— Bolt 16— External Bearing Cradle 25— Feed Roller Cast Stop 34— Expansion Plug
8— Splined Hub 17— Roller 26— Stop Spacer 35— Zerk
9— Hex Bolt 18— Zerk 27— Lock Nut
T803324,0000824 -19-17AUG05-2/2
Buttlifter Roller Repair 6. Remove the motor housings; this will leave the roller
1. Label, remove, and cap hydraulic hoses and fittings. suspended on the supports. The roller can now be
lowered to the ground.
2. Remove four nuts (3) and washers (2) which are
holding motor mount assembly (22) to the frame. 7. Heat the bolt (6) and separate adapter (4) to soften
the Araldite.
NOTE: Heat may need to be used.
8. Remove the bolt and washers (6 & 5), then the splined
3. Pull the housing outward until adapter hub (4) is clear hub adapter (4) from adapter.
of hub (8) and roller rests on mount (22). This can
9. Remove nut and washer and use a hex head (Allen)
be done by using two 1/2 inch NC bolts to jack the
wrench, loosen bolt holding the motor to mount (22);
housing from the frame.
there is a slot located in the housing for this purpose.
4. Support the roller and remove the motor housing from
10. Remove motor from housing.
one side.
5. Repeat step 3 and 4 for opposite side.
T803324,0000825 -19-03OCT07-1/1
Clean and Inspect 3. Clean remaining Araldite (this should have crystallized
1. Clean all parts and inspect for wear or damage; after application from heat) from all internal and
replace as necessary. external threads and splines. Inspect, repair, or
replace as necessary.
2. Pay particular attention to the splines of hub adapter
(4) and hub (8). If these are damaged, John Deere
recommends that both parts be replaced together for
maximum efficiency.
T803324,0000826 -19-22AUG05-1/1
Assembly 3. Apply Araldite and torque bolt (3, 24) to 109 N·m (80
1. Assembly is the reverse of disassembly. lb-ft).
NOTE: Do not apply Araldite to the splines of the 4. Apply Araldite and torque bolt (6) to 32 N·m (24 lb-ft).
adapter. The Araldite will travel backward to the 5. The maximum out-of-alignment to the side wall is 5 mm
motor seal if is applied to the adapter. (0.197 inch). The end float of the rollers is between
the two motors, is a maximum of 7 mm (0.275 inch).
2. Apply Araldite to the internal splines of hub (4) only.
T803324,0000827 -19-03OCT07-1/1
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Group 15
Bottom Feed Roller
Bottom Feed Roller (B2, B3, B4, B5)
CM053510277 —UN—22AUG05
102711
PN=93
Bottom Feed Roller
T803324,0000828 -19-22AUG05-2/2
Bottom Feed Roller Repair (B2, B3, B4, B5) Loosen Allen set screws in bearing (11). Remove
bearing assembly from roller. Remove bolts (9) and
1. Label, remove and cap hydraulic hoses and fittings. washers (2) from external shaft (21). Remove external
2. Remove four nuts (3) and washers (2) holding motor shaft (21). Remove the motor housing (22) on the
mount assembly (22) to the frame.1 opposite end; this will leave the roller suspended on the
supports. The roller can now be lowered to the ground.
NOTE: Heat may need to be used.
6. Remove fasteners (5 & 6) securing adapter (4) to the
3. Pull the housing outward until hub adapter (4) is clear motor.
of hub (8) and roller rests on mount (22). This can 7. Using a hex head (Allen) wrench, loosen bolts holding
be done by using two 1/2 inch bolts NC to jack hub the motor mount (22). There is a slot located in the
from the frame. housing for this purpose.
4. On the opposite side of the roller, remove four nuts (3) 8. Remove the motor from the housing.
and washers (2) from bearing flange (23).
5. Support the roller and remove the last nut (3) and
washer (2) located on the bearing housing (23).
1
All fasteners have been installed using Araldite. They must be heated
to soften the fixative before they can be removed.
T803324,0000829 -19-03OCT07-1/1
Clean and Inspect 3. Clean remaining Araldite (this should have crystallized
1. Clean all parts and inspect for wear or damage; after application of heat) from all internal and external
replace as necessary. threads and splines. Inspect, repair, or replace as
necessary.
2. Pay particular attention to the splines of hub adapter
(4) and hub (8). If these are damaged, John Deere
recommends that both parts be replaced together for
maximum efficiency.
T803324,000082A -19-22AUG05-1/1
Assembly The Araldite will travel backward to the motor seal if

it is applied.
The maximum out-of-alignment to the side wall is 5 mm
(0.197 inch). The end float of the rollers, between the two 3. Apply Araldite and torque nut (3) and bolt (9, 24) to
motors, is a maximum of 7 mm (0.275 inch). 109 N·m (80 lb-ft).
1. Assembly is the reverse of disassembly. 4. Apply Araldite and torque bolt (6) to 32 N·m (24 lb-ft).
2. Apply Araldite to the internal splines of hub (4) only;
do not apply Araldite to the splines of the adapter.
T803324,000082B -19-03OCT07-1/1
102711
PN=94
Group 20
Top Feed Roller
Top Floating Feed Roller (T1, T2, T3, T4, T5)
CM053510278 —UN—22AUG05
Continued on next page T803324,000082C -19-22AUG05-1/2
102711
PN=95
Top Feed Roller
T803324,000082C -19-22AUG05-2/2
Top Floating Feed Roller Repair 5. Remove three nuts (14), and washers (5) from each
1. If necessary, remove the bottom roller that will provide pivot pin (15). These are located on both ends of the
better access to the top. roller.
2. Label, remove and cap hydraulic hoses and fittings. 6. With the weight of the roller still supported, remove
both pivot pins (15). This will allow the roller to be
3. Remove bolt (24) and washer (2) that are securing lowered to the ground through space provided when
motor mount (22). Support the weight of the roller and the appropriate bottom roller was removed.
remove the mount (22). This can be done using two
1/2 inch NC bolts to jack the mount from the frame.1 7. Remove fasteners (6 & 5) which are securing adapter
(4) to the motor.
4. On the opposite side of the roller, remove four bolts
(9) and washers (2) from bearing flange (23). Loosen 8. Remove the motor from the motor mount assembly.
Allen set screws in bearing (11). Remove bearing
assembly from roller. Remove bolts (9) and washers
(2) from external shaft (21). Remove external shaft.1
1
All fasteners have been installed using Araldite. They must be heated
to soften the fixative before they can be removed.
T803324,000082D -19-03OCT07-1/1
Clean and Inspect 3. Inspect bearing (11) and flange (23) for wear or
1. Clean all parts and inspect for wear or damage; damage.
replace as necessary. 4. Clean the remaining Araldite (this should have
2. Pay particular attention to the splines of hub adapter crystallized after application of heat) from all internal
(4) and hub (8). If these are damaged, John Deere and external threads and splines. Inspect, repair or
recommends that both parts be replaced together for replace as necessary.
maximum efficiency.
T803324,000082E -19-03OCT07-1/1
Assembly Araldite will travel backward to the motor seal if it is

applied.
The maximum out-of-alignment to the side wall is 5 mm
(0.197 inch). The end float of the rollers, between the two 4. Apply Araldite and torque bolts (9, 10, 24) to 109 N·m
motors, is a maximum of 7 mm (0.275 inch). (80 lb-ft).
1. Assembly is the reverse of disassembly. 5. Apply Araldite and torque bolt (6) to 32 N·m (36 lb-ft).
2. Check the floating roller stop; this prevents the motor 6. Apply Araldite and torque nuts (14) to 68 N·m (36 lb-ft).
mount from hammering the side wall.
3. Apply Araldite to the internal splines of hub only. Do
not apply Araldite to the splines of the adapter. The
T803324,000082F -19-03OCT07-1/1
102711
PN=96
Section 40
Electrical
Contents
Page
Group 10—Electrical Harness and Connectors

Electrical Tool Repair Kit................................ 40-10-1
Connector Identification................................. 40-10-1
Electrical Connector Handling ....................... 40-10-2
Replace Weather Pack
Connector .................................................. 40-10-3
Install Weather Pack Contact ........................ 40-10-4
Remove Connector Body from
Blade Terminals ......................................... 40-10-5
Replace Deutsch Style
Connectors ................................................ 40-10-5
Install Deutsch Contact.................................. 40-10-7
Replace (Pull Type) Metri-Pack
Connectors ................................................ 40-10-8
Replace (Push Type) Metric-Pack
Connectors ................................................ 40-10-9
Harness Repair — Splice Broken
or Cut Wire .............................................. 40-10-11
Harness Repair — Splice
Connector ................................................ 40-10-13
102711
PN=1
Contents
102711
PN=2
Group 10
Electrical Harness and Connectors
Electrical Tool Repair Kit
CM073510470 —UN—21SEP07
1— CB01482732 - Tool Box 3— CB11478746 - Electrical 5— CB11478747 - Electrical 7— CB11478728 - Electrical
2— CB11478749 - Electrical Service Kit Weatherpack Service Kit Miscellaneous Service Kit Tier II Engine
Service Kit Deutsch Removal 4— CB11478745 - Electrical 6— CB11478743 - Electrical Terminals and Connectors
Tools and Locks Service Kit Load Center Service Kit Deutsch Terminals
and Connectors
The CB11478722 Service Repair Kit contains tools and

components needed to make repairs to the various
electrical connectors.
T803324,0001067 -19-21SEP07-1/1
Connector Identification
1. Weather Pack Connects
a. Pin housing (A) has a female body with pins inside.
b. Socket housing (B) has a male body with locking
tabs and a socket inside.
A34689 —UN—10OCT88
102711
PN=99
2. Metric-Pack Connectors
a. Socket housing (A) has a male body with locking
tab and socket inside.
b. Pin Housing (B) has a female body with pin inside.
3. Deutsch Connector
a. Plastic connector. Housing contains pins and
A40805 —UN—16DEC96
sockets.
H55916 —UN—30APR99
T803324,0001068 -19-21SEP07-2/2
Electrical Connector Handling When removing terminals from connectors, it is very

Electrical connectors must not be forcibly mated or important to use the correct extraction tool and gently
unmated. All are designed to be mated easily. If you have remove the terminal. The connector body can be damaged
to use tools, you may be doing something wrong. Prying if terminals are just “jerked” out of it. The damage caused
or forcing connectors may cause permanent damage to will prevent the new terminal from staying in the connector,
the locking mechanism, contacts or both. making replacement of the connector body necessary.
When working on connectors, make sure you are working When installing a new terminal on a wire, make sure the
on the correct terminal. Remember that male and female insulation crimp and wire crimp are both made properly.
halves are mirror images of each other. Look for the Each part of the terminal crimp is designed for a specific
terminal number on the connector body. The connection purpose. Failure to properly crimp the wire contact area
of improper electrical circuits can cause unusual electrical can result in poor or no electrical contact. Failure to crimp
symptoms. the insulation support properly can result in problems
getting the terminal into the connector body, thus causing
When an electrical connector is repaired, it is important premature failure.
that the proper terminals are used. In some of these
connectors, different terminals are used to carry different
currents. If contacts of different materials are mated,
corrosion may develop that could affect performance.
T803324,0001069 -19-21SEP07-1/1
102711
PN=100
Replace Weather Pack Connector

1. Open connector body.
2. Insert the proper extraction tool over the terminal
contact in the connector body.
TS0128 —UN—23AUG88
T803324,000106A -19-21SEP07-1/3
NOTE: If terminal cannot be removed, insert wire

or nail through extractor tool handle and push
terminal contact from the connector.
IMPORTANT: Carefully spread contact lances to

assure good retention in connector body.
TS0129 —UN—23AUG88
NOTE: Connector bodies are “keyed” for proper contact
mating. Be sure contacts are in proper alignment.
3. Hold the extractor tool fully seated and pull the wire
from the connector body.
T803324,000106A -19-21SEP07-2/3
4. Push contact into new connector body until fully seated.

5. Pull on the wire slightly to be certain contact is locked
in place.
6. Transfer remaining wires to correct terminals in new
connector.
TS0130 —UN—23AUG88
7. Close connector body.
T803324,000106A -19-21SEP07-3/3
102711
PN=101
Install Weather Pack Contact

NOTE: Cable seals are color coded for three sizes of wire:
• Green — 18 to 20 gauge wire
• Gray — 14 to 16 gauge wire
• Blue — 10 to 12 gauge wire
TS0136 —UN—23AUG88
1. Slip correct size cable seal on wire.
NOTE: Contacts have numbered identification
for two sizes of wire:
• #15 for 14 to 16 gauge wire
• #19 for 18 to 20 gauge wire
2. Strip insulation from wire to expose 6 mm (1/4 in.) and
align cable seal with edge on insulation.
T803324,000106B -19-21SEP07-1/4
3. Put proper size contact on wire and crimp in place

with a “W” type crimp.
IMPORTANT: Proper contact installation for sleeve
(A) and pin (B) is shown.
4. Secure the cable seal to contact, as shown in the
TS1623 —UN—02NOV94
previous photo.
5. Install Weather Pack contact body.
T803324,000106B -19-21SEP07-2/4
6. Push contact (A) into Weather Pack connector body

(B) until fully seated.
7. Pull on the wire slightly to be certain the contacts are
locked in place.
N42124HI —UN—27APR92
Continued on next page T803324,000106B -19-21SEP07-3/4
102711
PN=102
8. Close connector body wire clips (C).
CM073510471 —UN—21SEP07
T803324,000106B -19-21SEP07-4/4
Remove Connector Body from Blade

Terminals
1. Depress locking tang (A) on terminal, using a small
screw driver. Slide connector body off.
2. Be sure to bend locking tang back to its original
RW4218 —UN—23AUG88
position (B) before installing connector body.
T803324,000106C -19-21SEP07-1/1
Replace Deutsch Style Connectors

NOTE: The following extractors may be found in
Electrical Service Kit CB11478722.
1. Select the correct size extractor tool for size wire to
TS0124 —UN—23AUG88
be removed:
• JDG361 Extractor Tool for 12 to 14 gauge wire.
2. Start correct size extractor tool over wire at the handle
(A).
Continued on next page T803324,000106D -19-24SEP07-1/5
102711
PN=103
NOTE: Do not twist tool when inserting in connector.
3. Slide the extractor tool rearward along the wire until

tool tip (A) snaps into the wire.
TS0125 —UN—23AUG88
T803324,000106D -19-24SEP07-2/5
4. Slide extractor tool along the wire into the connector

body until it is positioned over terminal contact.
TS120 —UN—23AUG88
T803324,000106D -19-24SEP07-3/5
5. Pull wire with extractor tool out of the connector body.
TS0126 —UN—23AUG88
102711
PN=104
IMPORTANT: Install contact in proper location

using correct size grommet.
6. To install the wire, push contact straight into connector

body until positive stop is felt.
7. Pull on the wire slightly to be certain contact is locked
in place.
8. Transfer remaining wire to correct terminals in new
connector.
T803324,000106D -19-24SEP07-5/5
Install Deutsch Contact

NOTE: JDG360 crimper may be found in JDG359
Deutsch Electrical Tool Kit.
1. Strip 6 mm (1/4 in.) insulation from wire.

2. Adjust selector (A) on JDG360 Crimper for correct
wire size.
3. Loosen lock nut (B) and turn adjusting screw (C) in
until it stops.
T803324,000106E -19-24SEP07-1/4
IMPORTANT: Select proper size contact “sleeve”

or “pin” to fit connector body.
4. Insert contact (A) and turn adjusting screw (D) until

contact is flush with the cover (B).
IMPORTANT: Contact must remain centered between
TS0134 —UN—23AUG88
indenters while crimping.
5. Tighten lock nut (C).
Continued on next page T803324,000106E -19-24SEP07-2/4
102711
PN=105
6. Insert wire into contact and crimp until handle touches

stop.
7. Release handle and remove contact.
T803324,000106E -19-24SEP07-3/4
IMPORTANT: If all wire strands are not crimped into

contact, cut off wire at contact and repeat
contact installation procedures.
NOTE: Readjust crimping tool for each crimp-

ing procedure.
TS0135 —UN—23AUG88
8. Inspect contact to be certain all wires are in crimped
barrel.
T803324,000106E -19-24SEP07-4/4
Replace (Pull Type) Metri-Pack Connectors

1. Disconnect Metri-Pack connector (A).
RW16933 —UN—26APR89
Continued on next page T803324,000106F -19-21SEP07-1/3
102711
PN=106
NOTE: Use JDG777 Terminal Extraction Tool or “T”

pin to remove terminals.
2. Insert a “T” pin (B) 6.4 mm (1/4 in.) into connector

body socket (C).
RW16934 —UN—26APR89
T803324,000106F -19-21SEP07-2/3
3. Angle “T” pin so pin tip slides close to plastic socket

edge pushing terminal locking tab (D) inward.
4. Remove “T” pin and push terminal (E) out of socket.
5. Remove terminal, cut, strip and crimp wire through
connector.
RW16935 —UN—26APR89
NOTE: Terminal will seat only one way. If terminal does
not pull into connector body socket, check to
make sure terminal is aligned correctly.
6. Check to make sure locking tab on new terminal is in

outward position, then pull on wire until terminal locks
in connector body socket.
T803324,000106F -19-21SEP07-3/3
Replace (Push Type) Metric-Pack Connectors

1. Disconnect Metri-Pack connector. Remove any tie
bands or tape.
CM073510472 —UN—21SEP07
102711
PN=107
2. Remove connector (A) and mark wire colors for

identification.
3. Identify wire color locations with connector terminal
letters.
CM073510473 —UN—21SEP07
T803324,0001070 -19-21SEP07-2/5
NOTE: Use JDG776 Extraction Tool with 56, 280 and

630 series Metri-Pack terminals. Use JDG777
Extraction Tool with Metri-Pack terminals.
4. Insert JDG776 or JDG777 Terminal Extraction Tool (B)
CM073510474 —UN—21SEP07
into connector body socket (C) pushing the terminal
locking tab inward.
T803324,0001070 -19-21SEP07-3/5
5. Remove extraction tool and pull terminal (D) out of

socket.
CM073510475 —UN—21SEP07
102711
PN=108
6. Replace terminal. Make sure locking tab (E) on new

terminal is in outward position.
7. Push terminal into connector body socket until terminal
locks.
CM073510476 —UN—21SEP07
T803324,0001070 -19-21SEP07-5/5
Harness Repair — Splice Broken or Cut Wire

NOTE: When the wire length is critical and there is no
extra length of wire to twist ends together and a
splice connector is not available, do the following.
CM073510477 —UN—21SEP07
1. Strip 7 mm (3/8 in.) of insulation from both ends of the
wires to be spliced (A) and (B). Slide a piece of shrink
wrap (long enough to cover spliced area) onto wire (A).
2. Remove a single strand of wire, 101 mm (4 in.) long
from a piece of scrap 16 or 18 gauge wire.
T803324,0001071 -19-21SEP07-1/7
3. Wrap the single strand of wire (D) 1-1/2 turns around

the middle (E) of one stripped end.
CM073510478 —UN—21SEP07
102711
PN=109
4. Bend one strand (F) of stripped end over the single

strand of wire (D) wrapped around the middle of
stripped end. This will hold single strand of wire (D)
in place.
CM073510479 —UN—21SEP07
T803324,0001071 -19-21SEP07-3/7
5. Place the end (G) to be spliced over the first stripped

end (H) and wrap a single strand of wire (I) around the
second stripped end two times.
CM073510480 —UN—21SEP07
T803324,0001071 -19-21SEP07-4/7
6. Bend of strand (J) of the second stripped end (G)

over the single strand of wire (I) wrapped around the
stripped ends. This will hold the second stripped end
in place.
CM073510481 —UN—21SEP07
102711
PN=110
7. Finish wrapping both ends of the single strand of wire

(I) tightly around the splice.
8. Solder the splice.
CM073510482 —UN—21SEP07
T803324,0001071 -19-21SEP07-6/7
9. Center the shrink wrap (C) over the splice and use a
heat gun or hair dryer to heat the shrink wrap forming
a good seal.
CM073510483 —UN—21SEP07
T803324,0001071 -19-21SEP07-7/7
Harness Repair — Splice Connector

1. Strip 7 mm (3/8”) of insulation from both ends of wires
to be spliced (A). Slide shrink wrap (C) on wire (A) and
away from area to be spliced. The shrink wrap should
CM073510484 —UN—21SEP07
be long enough to cover the splicing area.
102711
PN=111
2. Install connector (B) to both ends of stripped wire (A)

and crimp connector.
3. Solder both ends of the connector.
CM073510485 —UN—21SEP07
T803324,0001072 -19-24SEP07-2/3
4. Center the shrink wrap (C) over the splice and use a
heat gun or hair dryer to heat the shrink wrap forming
a good seal.
CM073510486 —UN—21SEP07
T803324,0001072 -19-24SEP07-3/3
102711
PN=112
Section 50
Hydrostatic System
Contents
Page Page
Group 05—Planetary Final Drive Bonfiglioli Carrier Roller Wear Chart - Outside
BNA Final Drive ............................................. 50-05-1 Brazil........................................................ 50-15-14
Disassembly .................................................. 50-05-1 Carrier Roller Wear Chart - In
Reassembly................................................. 50-05-11 Brazil........................................................ 50-15-15
Assembly ..................................................... 50-05-12 Track Roller Wear Chart - Outside
Instructions to properly assemble Brazil........................................................ 50-15-15
the lifetime seal........................................ 50-05-13 Track Roller Wear Chart - In Brazil................ 50-15-15
Final Assembly ............................................ 50-05-14 Rolling Undercarriage.................................. 50-15-16
Idler Tread Wear Measurement................... 50-15-16
Group 10—Planetary Final Drive Iberica Swapping Idlers ........................................... 50-15-16
Essential or Recommended Tools.................. 50-10-1 Check Idler Flange Wear............................. 50-15-16
Service Equipment and Tools ........................ 50-10-2 Flange Top Wear ......................................... 50-15-16
Specifications ................................................ 50-10-3 Flange Side Wear........................................ 50-15-16
Planetary Hub—Exploded View .................... 50-10-4 Idlers Percentage Wear Chart -
Disassemble Planetary Hub .......................... 50-10-5 Outside Brazil .......................................... 50-15-17
Assemble Planetary Hub ............................. 50-10-12 Idlers Percentage Wear Chart - In
Brazil........................................................ 50-15-17
Group 15—Track Track Shoe Problems .................................. 50-15-18
Track Assembly ............................................. 50-15-1
Track Alignment............................................. 50-15-2 Group 20—Wheel
Roller Lubrication........................................... 50-15-2 Wheel Assembly............................................ 50-20-1
Idler Lubrication ............................................. 50-15-3 Remove and Replace Front Wheel
Track Shoe Tightening................................... 50-15-3 Bearings .................................................... 50-20-2
Track Shoe Inspection Torque....................... 50-15-3 Remove Rear Wheel Assembly..................... 50-20-2
Sprocket Tightening....................................... 50-15-3 Remove and Mount Tire onto
Rear Axle Maintenance ................................. 50-15-3 Wheel Assembly........................................ 50-20-3
Track Adjustment........................................... 50-15-4 Install Wheel Assembly ................................. 50-20-3
Track Recoil Spring Repair............................ 50-15-4
Recoil Spring Adjustment .............................. 50-15-5
Link Rail Wear ............................................... 50-15-5
Link Wear Chart - Outside Brazil ................... 50-15-6
Link Wear Chart - In Brazil ............................ 50-15-7
Sealed Track Bushings & Pins ...................... 50-15-7
Track Bushing Allowable Wear
Chart - Outside Brazil ................................ 50-15-8
Track Bushing Allowable Wear
Chart - In Brazil.......................................... 50-15-9
Internal Pitch Wear ...................................... 50-15-10
Internal Pitch Wear Chart - Outside
Brazil........................................................ 50-15-10
Internal Pitch Wear Chart - In
Brazil........................................................ 50-15-11
Track Rollers ............................................... 50-15-11
Track Roller Lubrication............................... 50-15-11
Seal Assembly............................................. 50-15-12
Specifications .............................................. 50-15-12
Carrier Roller ............................................... 50-15-12
Carrier Roller Lubrication............................. 50-15-12
Carrier Roller Assembly............................... 50-15-13
Sprocket Wear Patterns .............................. 50-15-13
Rolling Undercarriage.................................. 50-15-14
Roller Wear Diagnosis................................. 50-15-14
How to Measure Roller Wear ...................... 50-15-14
102711
PN=1
Contents
102711
PN=2
Group 05
Planetary Final Drive Bonfiglioli
BNA Final Drive
CM073510487 —UN—25SEP07
1— Bolt 9— 1st Stage Sun Gear 19— O-ring Seal 27— O-ring Seal
2— Seal 11— 1st Reduction 20— Flanged Hub 28— Brake Piston
3— Plug 12— Spacer 21— Spacer Ring 29— Spring
4— Plug 13— 2nd Reduction 22— Brake Shaft 30— Spring Retainer Disc
5— Seal 14— Spacer 23— Brake Disc Unit 31— Circlip
6— End Cover 16— Nut 24— Brake Disc Unit 32— O-ring Seal
7— O-ring Seal 17— Gearbox Housing 25— Spacer Ring 33— Bolt
8— Line Up Pin 18— 1st Half Seal and 2nd Half 26— O-ring Seal
Seal
T803324,0001074 -19-25SEP07-1/1
Disassembly
1. Remove the final drive from the harvester. Thoroughly
clean the exterior of the final drive.
CM073510489 —UN—03MAR08
2. Install special tool CB01422548 and CB01422546 on
the flanged hub.
3. Turn the bolt until it contrasts the force of the internal
springs.
102711
PN=115
4. Using proper snap ring pliers, remove the circlip (31)

and the special tool.
CM073510490 —UN—03MAR08
T803324,0001075 -19-03MAR08-2/27
5. Remove the spring retainer disc (30).
CM073510491 —UN—03MAR08
T803324,0001075 -19-03MAR08-3/27
6. Remove the springs (29) from the brake piston (28).
CM073510492 —UN—03MAR08
102711
PN=116
7. Insert an inside puller into the hole of the brake shaft;

expand the lower end of the puller into the internal
release of the brake shaft (22) and remove it and the
brake piston (28).
CM073510493 —UN—03MAR08
CM073510494 —UN—24MAR08
T803324,0001075 -19-03MAR08-5/27
8. Insert an inside puller into the hole of the brake shaft

(22); expand the lower end of the puller into the internal
release of the brake shaft and remove the spacer (12).
CM073510495 —UN—03MAR08
CM073510496 —UN—24MAR08
102711
PN=117
9. Remove the O-ring seal (27) from the flanged hub (20).
CM073510497 —UN—03MAR08
T803324,0001075 -19-03MAR08-7/27
10. Remove spacer ring (25).
CM073510498 —UN—03MAR08
T803324,0001075 -19-03MAR08-8/27
11. Remove the O-ring seal (26) from the spacer (25).
CM073510499 —UN—03MAR08
102711
PN=118
12. Remove the brake disc unit (23 - 24).
CM073510500 —UN—03MAR08
T803324,0001075 -19-03MAR08-10/27
13. Remove the spacer ring (21) from the flanged hub (20).
CM073510501 —UN—03MAR08
T803324,0001075 -19-03MAR08-11/27
14. Unscrew the socket head screws (1) from the end
cover (6).
CM073510502 —UN—03MAR08
102711
PN=119
15. Remove end cover (6).
CM073510503 —UN—03MAR08
T803324,0001075 -19-03MAR08-13/27
16. Remove O-ring seal (7) from cover (6).
CM073510504 —UN—03MAR08
102711
PN=120
17. Remove the 1st reduction (11) from gearbox housing

(17).
CM073510505 —UN—03MAR08
CM073510506 —UN—24MAR08
T803324,0001075 -19-03MAR08-15/27
NOTE: This operation should be done only when it is

necessary to replace the sun gear.
18. Remove the 1st stage sun gear (9) from the 1st
reduction (11).
CM073510507 —UN—03MAR08
102711
PN=121
19. Using snap ring pliers, remove the four circlips (15)
from the four planet assemblies of the 2nd reduction
(13).
CM073510508 —UN—03MAR08
T803324,0001075 -19-03MAR08-17/27
20. Using a puller, remove the four planet assemblies of

the second reduction (13).
CM073510509 —UN—03MAR08
T803324,0001075 -19-03MAR08-18/27
21. Remove the four spacers (14).
CM073510510 —UN—03MAR08
102711
PN=122
22. Using a multiplier, loosen the nut (16).
CM073510511 —UN—03MAR08
T803324,0001075 -19-03MAR08-20/27
23. Remove the nut (16).
CM073510512 —UN—03MAR08
T803324,0001075 -19-03MAR08-21/27
24. Using a press, remove the flanged hub (20) from the
gearbox housing (17).
CM073510513 —UN—03MAR08
102711
PN=123
25. Using a puller, turn the bolts until the bearing inner
ring comes out.
CM073510514 —UN—03MAR08
T803324,0001075 -19-03MAR08-23/27
NOTE: In case of oil leakages, it might be necessary

to check and eventually replace the lifetime seal,
which means both the steel rings and O-rings.
26. Remove the first half seal (18).
CM073510515 —UN—03MAR08
T803324,0001075 -19-03MAR08-24/27
27. Using a flat head screwdriver, remove the second half

seal (18).
CM073510516 —UN—03MAR08
102711
PN=124
28. Remove the bearing inner ring from gearbox housing

(17).
CM073510517 —UN—03MAR08
T803324,0001075 -19-03MAR08-26/27
29. Remove the bearing balls from the gearbox housing

(17).
30. The gearbox disassembly ends with the above
operation. All parts are now available for the
CM073510518 —UN—03MAR08
necessary inspection.
T803324,0001075 -19-03MAR08-27/27
Reassembly seats and having buttered some grease on the seats

themselves and on the O-rings
When proceeding with the gearbox reassembly, it is 3. Always replace all components that seem to be
necessary to follow the rules listed below. damaged or have excessive wear, with original spare
1. In case of damaged gears, for example a planet, do not parts.
replace the single gear, but the whole reduction stage.
2. Always replace the O-ring and seal rings of the part
to be reassembled after having carefully cleaned the
T803324,0001076 -19-25SEP07-1/1
102711
PN=125
Assembly
1. Fit the lower ball row (d) in the gearbox housing (17),
holding the inner raceway (c) with spacers (a) and (b).
CM073510519 —UN—03MAR08
T803324,0001077 -19-25SEP07-1/2
2. Remove spacer (b). Drop the lower ball row (e).

Assemble the inner raceway (f).
CM073510520 —UN—03MAR08
T803324,0001077 -19-25SEP07-2/2
102711
PN=126
Instructions to properly assemble the

lifetime seal
CM073510521 —UN—03MAR08
1. Carefully clean the seats #1 and #2 using, if necessary, substances. The metal ring surfaces must be perfectly
metal brushes or solvent (surfaces in contact with clean and dry.
O-ring #3 must be perfectly clean and dry).
3. Carefully clean the lapped surface #4 of the metal
2. Make sure that the sealing surfaces #4 of the metal ring #5 and remove the dust or finger prints. Then
rings #5 are free from scratches, dings or foreign lubricate them with a thin oil film, taking care not to oil
other components.
T803324,0001078 -19-03MAR08-1/5
4. Assemble the half seal (18) on the tool.
CM073510523 —UN—03MAR08
T803324,0001078 -19-03MAR08-2/5
5. Assemble the half seal (18) on the gearbox housing

(17).
CM073510524 —UN—03MAR08
102711
PN=127
6. Using the same tool, install the other half seal (18)
onto the flanged hub (20).
CM073510525 —UN—03MAR08
T803324,0001078 -19-03MAR08-4/5
7. Clean the metallic faces of the seal (18) and lube with
a thin oil film.
CM073510526 —UN—03MAR08
T803324,0001078 -19-03MAR08-5/5
Final Assembly
1. Support the gearbox housing (17) by using the spacers
(a) as shown in previous sketch. Lower the flanged
hub (20) inside the gearbox (17).
CM073510527 —UN—03MAR08
102711
PN=128
2. Place the flanged hub (2) inside the gearbox housing

(17). By using a press and stopper, push the flanged
hub (20) against the shoulder of the gearbox housing
(17) until assembly of the unit is complete.
CM073510528 —UN—03MAR08
T803324,0001079 -19-03MAR08-2/31
3. Install nut (16).
CM073510529 —UN—03MAR08
T803324,0001079 -19-03MAR08-3/31
4. Using a multiplier, tighten the ring nut to 6248.974 N·m

(4609 lb-ft).
CM073510530 —UN—03MAR08
102711
PN=129
5. Stake the ring nut (16) near two seats at 180 degrees
of the flanged hub (20).
CM073510531 —UN—03MAR08
T803324,0001079 -19-03MAR08-5/31
6. Staking detail.
CM073510532 —UN—03MAR08
102711
PN=130
7. Install the spacers (14) on the pins of the flanged hub

(20).
CM073510533 —UN—03MAR08
CQ280021 —UN—27JUN07
T803324,0001079 -19-03MAR08-7/31
8. Place the planet gears (13) on the pins of the flanged

hub (20), checking that the groove is toward the end
cover.
CM073510534 —UN—03MAR08
102711
PN=131
9. Using a rubber hammer and stopper, push the planet

gears (13) against the flanged hub (20) shoulder.
CM073510535 —UN—03MAR08
T803324,0001079 -19-03MAR08-9/31
10. Install the circlips (15) in the flanged hub seats (20).
CM073510536 —UN—03MAR08
T803324,0001079 -19-03MAR08-10/31
11. Install the first reduction assembly (11).
CM073510537 —UN—03MAR08
102711
PN=132
12. Using a rubber hammer, install the sun gear (9).
CM073510538 —UN—03MAR08
T803324,0001079 -19-03MAR08-12/31
13. Install the O-ring (7) into the seat in the cover.
CM073510539 —UN—03MAR08
T803324,0001079 -19-03MAR08-13/31
14. Install cover (6).
CM073510540 —UN—03MAR08
102711
PN=133
15. Fix the cover (6) to the gearbox housing (17) by using
bolts (1). Torque the bolts to 25 N·m (18 lb-ft).
CM073510541 —UN—03MAR08
T803324,0001079 -19-03MAR08-15/31
16. Turn the gearbox upside down and install the spacer
(21).
CM073510542 —UN—03MAR08
T803324,0001079 -19-03MAR08-16/31
17. Using a rubber hammer, tap the spacer (12) against

the shoulder inside the brake shaft (22).
CM073510543 —UN—03MAR08
102711
PN=134
18. Install the brake shaft (22).
CM073510544 —UN—03MAR08
T803324,0001079 -19-03MAR08-18/31
19. Install the brake disc package in the following order:

First, insert one sintered bronze disc with external
teeth (23).
CM073510545 —UN—03MAR08
T803324,0001079 -19-03MAR08-19/31
20. Insert an internal toothed steel disc (24). Repeat the

operation until all six sintered bronze discs and five
steel discs have been installed.
CM073510546 —UN—03MAR08
102711
PN=135
21. Lubricate the seal seat inside the flanged hub (20)
with oil and install the O-ring (27).
CM073510547 —UN—03MAR08
T803324,0001079 -19-03MAR08-21/31
22. Install the O-ring (26) into the brake spacer inner seat
(25).
CM073510548 —UN—03MAR08
102711
PN=136
23. Install the brake spacer (25) inside the flanged hub
(20).
CM073510549 —UN—03MAR08
CQ280020 —UN—27JUN07
T803324,0001079 -19-03MAR08-23/31
NOTE: Lubricate the seats already fitted.
24. Install the 2nd O-ring seal (27) into its seat in the
flanged hub (20).
CM073510550 —UN—03MAR08
102711
PN=137
25. Insert the brake piston (28) into the flanged hub (20),
being careful not to damage the seals already fitted.
CM073510551 —UN—03MAR08
T803324,0001079 -19-03MAR08-25/31
26. Install the springs (29) in their seats in the brake

piston (28).
CM073510552 —UN—03MAR08
T803324,0001079 -19-03MAR08-26/31
27. Install the spring retainer disc (30).
CM073510553 —UN—03MAR08
102711
PN=138
28. Install the special tool on the flanged hub (20) and turn
the bolt until it contrasts the force of the spring (29).
CM073510554 —UN—03MAR08
T803324,0001079 -19-03MAR08-28/31
29. Install the circlip (6) and remove the special tool.
CM073510555 —UN—03MAR08
T803324,0001079 -19-03MAR08-29/31
30. Install the plug (4) into the filler hole and torque the
CM073510556 —UN—03MAR08
102711
PN=139
31. Install the plug (3) into the level hole and torque the
CM073510557 —UN—03MAR08
T803324,0001079 -19-03MAR08-31/31
102711
PN=140
Group 10
Planetary Final Drive Iberica
Essential or Recommended Tools RECOMMENDED TOOLS, as noted, are suggested to
NOTE: Order tools from the U.S. SERVICEGARD™ perform the job correctly. Some tools may be available
or European Microfiche Tool Catalogs. from local suppliers or may be fabricated.
ESSENTIAL TOOLS listed are required to perform the job

correctly and are obtainable only from SERVICEGARD or
European Microfiche Tool Catalogs.
SERVICEGARD is a trademark of Deere & Company
BL04947,000038B -19-26OCT11-1/6
Parking Brake Spring Compressor ..................... JDG1451

Used to compress planetary hub brake piston.
N64174 —UN—03OCT03
BL04947,000038B -19-26OCT11-2/6
Safety Plate ........................................................ JDG1787

Used to retain flanged hub to main housing during
assembly of planetary hub.
N64178 —UN—03OCT03
Continued on next page BL04947,000038B -19-26OCT11-3/6
102711
PN=141
Torque Multiplier ................................................. JDG1782

Used to loosen and install ring nut in planetary hub.
N64173 —UN—03OCT03
BL04947,000038B -19-26OCT11-4/6
Bearing Race Installer ........................................ JDG1786

Used to install bearing race in planetary hub.
N64175 —UN—03OCT03
BL04947,000038B -19-26OCT11-5/6
Installer, Seal ...................................................... JDG1785

Used to install seal.
CQ291369 —UN—27OCT11
BL04947,000038B -19-26OCT11-6/6
Service Equipment and Tools European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.
NOTE: Order tools according to information given in
the U.S. SERVICEGARD™ Catalog or from the
SERVICEGARD is a trademark of Deere & Company

Continued on next page RG53986,0001114 -19-25OCT10-1/2
102711
PN=142
Puller .................................................................. OTC1154

Used to remove planetary hub planet gear.
RG53986,0001114 -19-25OCT10-2/2
Specifications
Planetary Hub Seals StandOut Height Variation Level +/- 1 mm

(+/- 0.04 in.)
Planetary Hub Ring Nut Torque (Torque Multiplier Input) 100 N·m +/- 10 N·m
(74 lb.-ft. +/- 7 lb.-ft.)
Planetary Hub Ring Nut Torque (Torque Multiplier Output) 3078 N·m +/- 308 N·m
(2278 lb.-ft. +/- 215 lb.-ft.)
Cover Cap Screws Torque 145 N·m
(107 lb.-ft.)
Mounting Flange-to-Drive Coupler Depth 111,4—112,2 mm
(4.386—4.425 in.)
BL04947,000034C -19-19SEP11-1/1
102711
PN=143
Planetary Hub—Exploded View
10 15
10
7 9 14
13
11
12
8
11
9
7
9 10
6
21
1
22
22
3
2 20 21
19
5 3 28
4 2
18
17
29
16 28
29
28
29
28
29
28
29
28
25
24 11 27
36
24
35
23
34
26 33
N89787 —UN—27OCT10
32
25
31
24
30
24
23
Continued on next page BL04947,000034D -19-19SEP11-1/2
102711
PN=144
1— Socket Head Cap Screw (18 10— Spur Gear (3 used) 19— Hub 28— Steel Disk (6 used)
used) 11— Bronze Bushing (3 used) 20— Wheel Studs (12 used) 29— Fiber Disk (5 used)
2— Plug (2 used) 12— Sun Gear 21— O-Ring (2 used) 30— O-Ring
3— O-Ring (2 used) 13— Snap Ring 22— Mechanical Face Seal (2 31— Piston
4— Plug 14— Planet Pinion Gear used) 32— Inner Spring (12 used)
5— O-Ring 15— Sun Gear 23— Snap Ring (4 used) 33— Outer Spring (12 used)
6— Cover 16— Lock Nut 24— Secondary Gear (4 used) 34— O-Ring
7— O-Ring (2 used) 17— Spacer 25— Spacer (4 used) 35— Spring Retainer
8— Ring Gear 18— Bearing 26— Housing 36— Snap Ring
9— Snap Ring 27— Coupler
Cap screws (1), cover (6), O-ring (7) and sun gear (12)
removed for tow procedure. (See Emergency Tow
Procedure in Section 50, Group 05.)
BL04947,000034D -19-19SEP11-2/2
Disassemble Planetary Hub

1. Remove hydrostatic drive motor. (See Remove and
Install Hydrostatic Drive Motor in Section 50, Group
05.).
2. Remove planetary hub from machine. (See Remove
N64115 —UN—02OCT03
Planetary Hub in Section 50, Group 05).
3. Before disassembly, clean planetary hub thoroughly.
NOTE: Refer to exploded view when disassembling
and assembling planetary hub.
4. Place hub on a clean workbench, with hydrostatic

drive motor mounting flange facing upward.
1
A—Disk C—Snap Ring
5. Install disk (A), bar (B), and forcing screw from B—Bar
1
JDG1451 Park Brake Spring Compressor. Tighten

forcing screw to compress brake assembly and
remove snap ring (C).
6. Slowly remove screw to release spring tension.
Remove tool.
1
Included in JDG1451 Parking Brake Spring Compressor
Continued on next page BL04947,000034F -19-19SEP11-1/16
102711
PN=145
7. Remove spring retainer (A) and springs (B).
A—Retainer B—Spring (12 inner and 12

outer used)
N64116 —UN—02OCT03
N89860 —UN—01NOV10
BL04947,000034F -19-19SEP11-2/16
8. Remove brake shaft (A) and piston (B) using an inside

puller.
A—Brake Shaft B—Brake Piston
N89861 —UN—01NOV10
102711
PN=146
9. Remove O-ring (A).

10. Remove brake disks (B) and separator plates.
A—O-Ring B—Brake Disk (6 steel and 5

fiber used)
N89758 —UN—22OCT10
BL04947,000034F -19-19SEP11-4/16
11. Turn planetary hub over and remove socket head cap
screws (A) and end cover (B).
A—Socket Head Cap Screw (18 B—Cover

used)
N89759 —UN—22OCT10
BL04947,000034F -19-19SEP11-5/16
NOTE: First stage reduction assembly is available

only as an assembly. Individual components
are not serviceable.
12. Remove first stage sun gear (A).

13. Remove first stage reduction assembly (B).
A—First Stage Sun Gear B—First Stage Reduction

Assembly
N89760 —UN—27OCT10
102711
PN=147
14. Remove snap rings (A) from second reduction

assembly planet gears.
A—Snap Ring (4 used)
N64128 —UN—02OCT03
BL04947,000034F -19-19SEP11-7/16
15. Remove second reduction assembly planet gears (A)

using OTC1154 puller or equivalent.
A—Second Reduction Planet

Gear (4 used)
N64129 —UN—02OCT03
BL04947,000034F -19-19SEP11-8/16
16. Remove spacers (A) from planet gear pedestals.
A—Spacer (4 used)
N64130 —UN—02OCT03
102711
PN=148
17. Remove ring gear (A) from hub (B).

18. Remove spacer ring (C) from hub (B).
A—Ring Gear C—Spacer Ring

B—Hub
N89761 —UN—26OCT10
N89762 —UN—22OCT10
102711
PN=149
19. Remove lock nut (B) as described in the following

steps.
a. Using an electric drill and a small drill bit (A), drill a
hole starting in stake mark (C) as shown.
b. Drill two additional holes (D) as shown.
N70774 —UN—16AUG05
IMPORTANT: Do not drill into spindle threads
when enlarging holes.
c. Use next size drill bit and enlarge drilled holes.

d. Repeat Sub-step c until material between holes is
removed.
A—Electric Drill C—Stake Mark

B—Lock Nut D—Holes
N70773 —UN—16AUG05
N70757 —UN—12AUG05
BL04947,000034F -19-19SEP11-11/16
e. Using a cold chisel (A) in drilled area, split lock nut.

f. Repeat Sub-steps a—d on opposite stake point.
g. Remove two halves of the lock nut (A).
A—Cold Chisel
N70758 —UN—11AUG05
102711
PN=150
20. Position hub assembly in press, and press flanged

hub (B) from hub housing (A).
A—Hub Housing B—Flanged Hub
N89765 —UN—27OCT10
BL04947,000034F -19-19SEP11-13/16
21. Remove first half-seal assembly (A).
A—Half-Seal Assembly
N64143 —UN—02OCT03
BL04947,000034F -19-19SEP11-14/16
22. Remove second half-seal assembly (A) by prying

lightly with a small prybar.
A—Half-Seal Assembly
N64138 —UN—02OCT03
102711
PN=151
23. Position hub assembly in press, and press bearing

(A) from hub housing (B).
24. Inspect all parts, replace as necessary.
A—Bearing B—Hub Housing
N89786 —UN—26OCT10
BL04947,000034F -19-19SEP11-16/16
Assemble Planetary Hub

Before assembling hub, read and follow these guidelines
to ensure proper operation and to avoid premature
component failure.
Inspect all parts for excessive wear and damage and
N70948 —UN—26AUG05
replace as necessary.
In case of damaged gears, for example a planet, do not
replace the single gear, but the whole reduction stage.
Always replace all O-rings and seals if the threaded ring
nut is removed.
Threaded ring nut cannot be reused, always install a new
threaded ring nut. A—Lock Nut B—Spindle
The unit must be cleaned as thoroughly as possible.
Remove all dirt and debris to prevent planetary hub failure.
Assemble unit on a bench in a clean work area free of IMPORTANT: If the lock nut can only be turned
dust and dirt. on a few threads and it is started correctly,
torque multiplier can be used to turn nut
1. Before beginning assembly procedure, do the on and off several times.
following:
c. Screw the new lock nut (A) onto spindle (B) by
a. Clean threads of spindle to remove any thread lock hand. The lock nut must turn on by hand for correct
material. assembly.
b. Inspect threads of spindle. Repair any damaged d. Remove nut.
threads using a thread file.
e. Clean spindle and the lock nut in clean solvent
IMPORTANT: Threaded lock nut can easily be to remove any foreign material. Blow dry using
cross threaded. Ensure that nut is started compressed air.
correctly. If nut cannot be started correctly,
or will not thread on at least two threads by f. Repeat Sub-step c to ensure the lock nut threads all
hand once started, replace nut. of the way onto spindle by hand.
102711
PN=152
A B
F F
C C
E E
N54714 —UN—11AUG00
D D
A—Seat C—ORing (2 used) E—Half Seal (2 used)

B—Seat D—Sealing Surfaces F— Half Seal Surfaces
2. Before installing the half seals, do the following: rest of the half seals. Any Moly on the surfaces that
contact O-rings (C) MUST be cleaned and dried
a. Carefully clean surfaces (A, B and F), if necessary, before installing the half seals.
metal brushes or solvent can be used. Surfaces in On half seals that are reused, a thin film of oil on
contact with O-rings (C) MUST be perfectly clean sealing surfaces during assembly will be sufficient.
and dry.
3. Seal rings, O-rings, and housings must be clean and
b. Make sure that sealing surfaces (D) of the half seals free of any oil film, dust, or other foreign matter. Use
are free from scratches, nicks or foreign substances, a solvent that evaporates quickly, leaves no residue,
metal ring surfaces MUST be perfectly clean and dry. and is compatible with the rubber O-rings. (Follow all
c. Carefully clean the seal surface (D) of half seals to safety guidelines for use of the solvent.) Seal ring and
remove dust and fingerprints. If new seals are used, housing should be wiped clean. Use a solvent-soaked
lubricate with Moly from the tube that is supplied cloth or paper towel that are lint free.
with the seal, taking care not to get any Moly on the
102711
PN=153
4. After all components have been wiped clean, O-rings

should be installed on seal rings so that they rest in
the radius of the seal ring. Insure that the O-rings are
not twisted, by inspecting the mold line on the outside
N55266 —UN—05OCT00
diameter of the O-ring for true tracking around the seal
rings. Twisted O-rings (D) will cause nonuniform face
load that can result in leakage. If a twist is apparent,
it can be eliminated by gently pulling a section of the
O-ring (B) away from the seal ring (A) and letting it
“snap” back. Repeating this in several places around
the ring will eliminate any twist in the O-ring.
A—Seal Ring D—Twisted O-Ring C

B—O-Ring E—Incorrect O-Ring Seating
C—Correct O-Ring Seating
N75869 —UN—24APR07
E
BL04947,0000350 -19-19SEP11-3/27
5. Position flanged hub (B) on a press and install bearing

(A).
A—Flanged Hub B—Bearing
N89855 —UN—29OCT10
102711
PN=154
6. Assemble first half-seal by installing O-ring (A) on

steel ring (B).
7. Install half-seal assembly onto JDG1785 Metal Face
Seal Installer Ring (C).
A—O-Ring C—JDG1785 Metal Face Seal
N64144 —UN—02OCT03
B—Steel Ring Installer Ring
N64145 —UN—02OCT03
BL04947,0000350 -19-19SEP11-5/27
8. Install halfseal assembly on hub housing until installer

ring (A) bottoms out on housing. Remove installer ring.
A—JDG1785 Metal Face Seal

Installer Ring
N64147 —UN—02OCT03
102711
PN=155
NOTE: Seal standout height will vary, however it is

important that the seal is evenly installed and
N75873 —UN—24APR07
A A
does not exceed specified variation around
entire circumference.
9. Remove the installation tool. Using a dial indicator,

check seal standout height (A) at several places
around the circumference of the ring. If the seal does
not meet specification, inspect the O-ring for twists
or obvious deformities. If seal is not in specification,
remove repeat Steps 9—12 until seal is installed to A—Stand-Out Height
specification. Dimension
Specification
Planetary Hub
Seals—StandOut Height
Variation........................................................................... Level +/- 1 mm
(+/- 0.04 in.)
BL04947,0000350 -19-19SEP11-7/27
10. Assemble second half-seal by installing O-ring (A) on

steel ring (B).
11. Install half-seal assembly onto JDG1785 Metal Face
Seal Installer Ring (C).
A—O-Ring C—JDG1785 Metal Face Seal
N64144 —UN—02OCT03
B—Steel Ring Installer Ring
N64145 —UN—02OCT03
102711
PN=156
12. Install halfseal assembly onto flanged hub until installer

ring (A) bottoms out on hub. Remove installer ring.
13. Check seal standout height.
A—JDG1785 Metal Face Seal

Installer Ring
N64146 —UN—02OCT03
BL04947,0000350 -19-19SEP11-9/27
14. Lightly lubricate surface of steel ring (A) with clean oil.
A—Steel Ring
N64148 —UN—02OCT03
BL04947,0000350 -19-19SEP11-10/27
15. Lightly lubricate lapped surface of steel ring with clean

oil before assembly of hub.
16. Use JDG1786 Bearing Race Installer (A), press
flanged hub (B) onto hub housing (C).
17. Press flanged hub until it contacts hub housing
shoulder.
A—JDG1786 Bearing Race C—Hub Housing

Installer
N89856 —UN—29OCT10
B—Flanged Hub
102711
PN=157
18. Install JDG1787 Safety Plate (A) and cap screws in

the bottom flange and on the sugar cane harvester
use a wheel or sprocket bolt. Install nut over hub stud.
N89857 —UN—29OCT10
BL04947,0000350 -19-19SEP11-12/27
19. Install lock nut (B).

20. Align dowel pins in JDG1782 Torque Multiplier (C) with
holes (A) in lock nut (B).
IMPORTANT: Output of torque multiplier turns in
opposite direction of input. Tighten lock nut by
N89763 —UN—22OCT10
turning input of multiplier counterclockwise.
NOTE: Torque wrench should be set for 150 N·m +/-

15 N·m (111 lb.-ft. +/- 11 lb.-ft.).
21. Tighten lock nut to specification using torque multiplier

(C).
Specification
Planetary Hub Ring
Nut—Torque (Torque
Multiplier Input)..........................................................150 N·m +/- 15 N·m
(111 lb.-ft.) +/- 11 lb.-ft.
Specification
Planetary Hub Ring
Nut—Torque (Torque
Multiplier Output)...................................................3078 N·m +/- 308 N·m
N89764 —UN—28OCT10
(2278 lb.-ft. +/- 215 lb.-ft.)
22. Remove JDG1782 torque multiplier (C) and JDG1787

Safety Plate (D).
A—Hole C—JDG1782 Torque Multiplier

B—Lock Nut D—JDG1787 Safety Plate
102711
PN=158
23. Stake lock nut near two seats (A), 180° apart.
A—Seats
N64157 —UN—02OCT03
N64158 —UN—02OCT03
BL04947,0000350 -19-19SEP11-14/27
NOTE: Align holes on ring gear and hub.
24. Install spacer ring (B).

25. Install new Orings onto ring gear (A) and install onto
hub (B).
N89761 —UN—26OCT10
A—Ring Gear C—Spacer Ring
B—Hub
N89762 —UN—22OCT10
102711
PN=159
26. Install spacers (A), as shown, with bevel facing down.
A—Spacers
N64159 —UN—02OCT03
BL04947,0000350 -19-19SEP11-16/27
27. Position second reduction assembly planet gears ( A)

with radiused edge of inner bearing race (B) facing
down. Install using appropriate sized driver and rubber
mallet.
A—Planet Gear (4 used) B—Inner Bearing Race
N64160 —UN—02OCT03
102711
PN=160
28. Install snap rings (A).
A—Snap Ring (4 used)
N64128 —UN—02OCT03
BL04947,0000350 -19-19SEP11-18/27
29. Install first reduction assembly (B).

30. Install sun gear (A).
A—First Stage Sun Gear B—First Stage Reduction

Assembly
N89760 —UN—27OCT10
102711
PN=161
31. Install end cover (B).

32. Install end cover and sockethead cap screws (A).
Tighten to specification.
Specification
Cover Cap
Screws—Torque..........................................................................145 N·m
(107 lb.-ft.)
A—Socket-Head Cap Screw (18 B—Cover
N89759 —UN—22OCT10
used)
BL04947,0000350 -19-19SEP11-20/27
33. Install the plugs (A) with torque 50 N·m (37 lb.-ft.).
A—Plugs
CQ291340 —UN—24OCT11
BL04947,0000350 -19-19SEP11-21/27
34. Turn hub over and install brake shaft (A).

35. Alternately install steel and fiber brake disks (B),
starting with steel disk.
A—Brake Shaft B—Brake Shaft

N64161 —UN—02OCT03
102711
PN=162
36. Install O-ring (A).

37. Install O-ring (C) onto piston (B).
A—O-Ring C—O-Ring
B—Piston
N89858 —UN—29OCT10
N89859 —UN—01NOV10
BL04947,0000350 -19-19SEP11-23/27
38. Install brake piston (A) and springs (B).
A—Brake Piston B—Spring (12 inner and 12

outer used)
N89862 —UN—01NOV10
102711
PN=163
39. Install spring retainer (A).
A—Spring Retainer
N64116 —UN—02OCT03
BL04947,0000350 -19-19SEP11-25/27
40. Install disk (A), bar (B), and forcing screw from
JDG1451 Parking Brake Spring Compressor. Tighten
forcing screw to compress brake assembly and install
snap ring (C).
41. Slowly remove screw to release spring tension.
Remove tool.
N64115 —UN—02OCT03
1
A—Disk C—Snap Ring
1
B—Bar
1
Included in JDG1451 Parking Brake Spring Compressor
BL04947,0000350 -19-19SEP11-26/27
42. Using a depth gauge, measure distance from mounting

flange to brake shaft. If measurement is not within
specification, final drive must be disassembled.
Specification
Mounting FlangetoDrive
Coupler—Depth............................................................ 111,4—112,2 mm
N64182 —UN—07OCT03
(4.386—4.425 in.)
43. Perform brake check:

a. Using auxiliary hydraulic power source to brake
port, pressurize brakes to 27.6 bar (400 psi).
b. Brakes must hold pressure for 3 minutes. If brakes
do not hold pressure, gear case has not been
assembled correctly, or seals are damaged. Repair A—Mounting Flange B—Brake Shaft
as required.
IMPORTANT: When filling planetary hub see Drain
and Fill Planetary Hub in Section 50, group 44. Install hydrostatic drive motor. (See Remove and
05 for proper filling procedure. Install Hydrostati Drive Motor in Section 50, Group
00.)
Overfilling of planetary hub can cause
premature bearing failure and over heating.
BL04947,0000350 -19-19SEP11-27/27
102711
PN=164
Group 15
Track
Track Assembly
CM002500182 —UN—24MAR08
1— Idler Assy-Front 4— Bushing 7— Roller Assy-Track
2— Spring Assy-Recoil 5— Pin 8— Sprocket Assy
3— Rail Assy-Link 6— Roller Assy-Carrier 9— Track Shoe
T803324,0000792 -19-27JUL05-1/1
102711
PN=165
Track
Track Alignment
CM053510242 —UN—27JUL05
A—Sprocket C—Track Shoe E—Rear Axle Cover G—Track Roller
B—Carrier Roller D—Idler F— Hydraulic Track Adjuster
One of the most important factors to check for obtaining a A simple field test to check the load distribution is to walk
good service life is correct track alignment. All the rollers the machine on a hard surface for about 1 km (5/8 mile).
should be central to a line from the sprocket tooth center Check the rollers for correct oil level prior to this test. Feel
to the front idler center. each roller with your hand and note the temperature of
Another vital check is that all bottom track rollers are level. each one. Any rollers that feel hotter than others would
Misalignment from wear, bearing failure, or a distortion in indicate that they are carrying more than their share of
track frame causes uneven distribution of the uncorrected the load.
uneven load distribution. A new bottom roller should
never be used along with worn ones.
T803324,0000793 -19-27JUL05-1/1
Roller Lubrication 2. Remove the shaft plug and screw in the lubrication
The track, carrier and idler rollers are filled with a SAE 30 fitting.
engine oil, which has a red dye additive. This allows for 3. Attach a lubrication gun nozzle and pump oil in until it
easy detection of leakage, if a leak occurs. A periodic comes out from around the 1fitting.
visual inspection should be made for signs of leakage.
Since these are “lifetime” rollers, it is not normally 4. This indicates correct level. Quickly remove the nozzle
necessary to refill them until the shells are due for and refit the plug.
replacement. However, in cane harvester applications, the
lubrication level should be checked on an annual basis. An alternative way to lubricate is to place the machine on
an angle away from the filler plug at approximately 20°. Oil
To check, use the following procedure: can then be fed in with an oil can or gun. Allow time for the
oil to travel down the shaft and out into the bearing areas.
1. Position the harvester on level ground.
1
If oil flowing from around the fitting is dirty or mixed with water,
keep filling until flowing oil is absolutely clean.
T803324,0000794 -19-04OCT07-1/1
102711
PN=166
Track
Idler Lubrication nozzle (P/N 0841338384) filling through the hole in the
idler shell body. Oil to be used is a SAE 30 or SAE 40.
The idler is filled with SAE 30 engine oil, which has a red The quantity of lubricant necessary is just a little less than
dye additive for leak detection. If lubricant is required, the full capacity, which is approximately 9.8 cc (0.34 oz).
position the plug at 15°. Remove the plug. Lubrication Reinstall the plug and tighten.
can be added by means of a low pressure pump with a
T803324,0000795 -19-27JUL05-1/1
Track Shoe Tightening permanent deformation occurs, this deformation ensures

that the bolts maximum clamping force is used.
The following is the proper procedure for torquing the
track hardware. The initial torque draws the parts together 1. Lubricate the bolt threads.
tightly, an additional 1/3 turn gives the bolt a stretch for
good retention. Stretching stresses the bolt until some 2. Install bolts and nuts with the rounded side of the nut
against the face of the chain link. Torque bolts to 407
N·m (300 lb-ft).
T803324,0000796 -19-04OCT07-1/1
Track Shoe Inspection Torque 3. Tighten bolt until the two marks align.
Inspection procedure for loose bolts should be as follows: 4. Read the torque at this point. If the torque is below
1. Mark bolt head and the adjacent surface of the track 400 N·m (300 lb-ft), loosen all four bolts and retighten
shoe. by the torque-turn method. If the torque is higher, it is
acceptable.
2. Loosen bolt approximately 1/8 of a turn (45°).
T803324,0000797 -19-19SEP07-1/1
Sprocket Tightening 2. Torque segment nuts to 278 N·m (205 lb-ft). Torque
disc bolts to 529 N·m (390 lb-ft).
1. Apply Loctite® 271 to the bolts.
NOTE: Make sure the threads are free of oil. Do not use
air tools to install them. Clean bolts and holes in
final drive to ensure they are free from grease.
T803324,0000798 -19-19SEP07-1/1
Rear Axle Maintenance the outer nut by hand, then loosen until the three bolt
holes in each nut line up. Torque the outer nut locking
Every 250 hours of operation service the rear axle. bolts to 50 N·m (35 lb-ft). Pack bearings with grease.
Remove rear axle cover. Torque the inner nut to 815 N·m Coat the inner cavity walls with grease. Be sure to use
(600 lb-ft) using specialty tool (P/N 0290289270). Tighten silicone to properly seal when putting the cover back on.
T803324,0000799 -19-19SEP07-1/1
102711
PN=167
Track
Track Adjustment
CM992500057 —UN—24MAR08
For correct track adjustment, use the following procedure. 2. Proper track tension is achieved when the distance
The track adjustment procedure should be performed between the track chain and track frame (C) is
under the same conditions in which the machine is used. approximately 1-1/4” to 1-1/2”.
Packing must be removed from the track, if packing
conditions exist on the job. 3. When the track chain is too tight, loosen the relief
valve (D) until grease escapes (compressing the track
1. Move the harvester forward a distance of twice its adjuster.)
length. Allow the harvester to come to a complete
stop when one of the track pins (A) is centered on the 4. When the track chain is too loose, add grease to
carrier roller (B). the relief valve (D) until the proper measurement is
reached.
T803324,000079A -19-27JUL05-1/1
Track Recoil Spring Repair

Although the recoil spring is serviceable, it does not
normally need to be serviced. A special Track Recoil
Spring Tool (1190315364) is needed to disassemble unit.
CM002500186 —UN—24MAR08
To service, do the following:
1. Remove the pin located in the nut. A pressure exerted
on flange (2) that is greater than 36,500 N·m (27,500
lb-ft) is necessary to remove the nut without causing
any damage.
2. Disassemble the parts in order to repair or change
seals.
3. Rubber seals and all contact surfaces must be clean
and dry at assembly. Put a thin layer of oil on the 1— Nut 5— Seal
surfaces of the metal seals. 2— Flange 6— Seal
3— Cylinder 7— Piston
4. To assemble, compress spring (4) and measure from 4— Spring
the outside of flange (2) to the outside of piston (7) a
length of 390 mm (15.359”).
5. Tighten nut (1) until both pin holes, located on cylinder
(3) and the nut are aligned. Insert the pin into the
holes and relieve the pressure placed on the flange.
T803324,000079D -19-19SEP07-1/1
102711
PN=168
Track
Recoil Spring Adjustment Make sure the vent holes are clean before the
tension is released on the track. Watch the
The recoil springs are normally in compression. They are cylinder to see that it moves.
held between brackets and stops on the track roller frames.
Normally, the force of the springs is not against the tracks. If rocks or debris get between the track and the rollers,
The force against the track for the correct setting of track idlers or sprocket, the recoil rod will move toward the rear
curve is controlled by the mechanism for track adjustment. of the machine. The movement of the recoil rod tightens
Track adjustment is made by the hydraulic mechanism for the track. Since the grease in the cavity cannot be put in
track adjustment. Pressurized grease is sent to a cavity compression, the piston and bolt move toward the rear of
through a fill valve. This moves the recoil rod and the the machine. The bolt pushes the pilot toward the rear of
front idler toward the front of the machine. The movement the machine. The pilot pushes on the spring, this puts
of the recoil rod and front idler tightens the track. The the spring in a compressed state. The movement of the
tension on the track is released by a relief valve. pilot and the compression of the spring prevents too much
tension on the track.
NOTE: Never visually inspect the vent holes or valves
to see if grease or oil is coming out of them. Nut (1) is used to keep the recoil spring in compression.
Recoil Spring Compressed Length 390 mm (15.359 Inches)

Fill and Relief Valves Torque 28-42 N·m (20-30 lb-ft)
Fork/Bracket 1Bolts Torque 230 N·m (170 lb-ft)
Shaft Diameter 60.00-59.954 mm (2.362-2.360 Inches)
Between Shaft & Bushing Max. Clearance 0.386 mm (0.015 Inches)
Shaft Max. Permissible Bend 0.00
1
Use Loctite® 271 (0841303179)
T803324,000079E -19-04OCT07-1/1
Link Rail Wear measurement is outside of the links at the end of the track
pin. Position the depth gauge as close to the end of the
Link Rail Measurement pin as possible, making sure link and shoe surfaces are
The only measurable wear position on the link is rail (top) clean. Ensure the gauge is flat against the link rails and
wear. It is measured with a broad base depth gauge from perpendicular to the shoe surface. Measure to the closest
the rail surface to the track shoe plate. This dimension 0.25 mm (0.01").
is the rail height. The correct location for track link
T803324,000079F -19-29JUL05-1/1
102711
PN=169
Track
Link Wear Chart - Outside Brazil

96mm Link Wear Chart
mm in. % Worn
96 3.78 0
95.1 3.74 10
94.4 3.72 20
93.6 3.68 30
92.9 3.66 40
92.2 3.63 50
91.5 3.6 60
90.8 3.58 70
90 3.54 80
89.3 3.52 90
88.6 3.49 100
NOTE: Specifications applicable for both “standard”

and “sealed & lube” chain types.

mm in. % Worn
101.3 3.99 0
100.5 3.96 10
99.7 3.93 20
98.9 3.89 30
98.1 3.86 40
97.3 3.83 50
96.5 3.8 60
95.7 3.77 70
94.9 3.74 80
94.1 3.71 90
93.3 3.67 100
92.3 3.63 110
91.3 3.59 120
NOTE: Specifications applicable only for “sealed

& lube” chain types.
BL04947,0000355 -19-21SEP11-1/1
102711
PN=170
Track
Link Wear Chart - In Brazil

mm in. % Worn
96.00 3.78 0
95.40 3.76 10
94.70 3.73 20
94.00 3.70 30
93.20 3.67 40
92.40 3.64 50
91.50 3.60 60
90.60 3.57 70
89.70 3.53 80
88.60 3.49 90
87.50 3.45 100
86.40 3.40 110
85.30 3.36 120

BL04947,0000356 -19-21SEP11-1/1
Sealed Track Bushings & Pins

Bushing and Pin Wear
Since the successful turn-ability and total life of sealed
CM002500187 —UN—22MAY00
track pins and bushings is a function of both internal
and external wear, interpretation of external bushing
wear alone will not accurately determine if and when to
make the turn. However, the type and degree of external
bushing wear is a good indicator of abnormal problems.
Wear Measurement
A small caliper must be used to measure the wear at
the minimum diameter of the bushing, regardless of the
position with respect to vertical and forward or reverse.
This is because the sealed track bushing must have Wear charts for sealed track bushings have the built-in
sufficient strength to resist cracking after the turn. This effect of approximately double the expected wear rate
remaining strength is largely affected by wear before the after the bushing case depth is worn through. The chart
turn. The sealed track bushing receives most of its load in has a faster, yet expected wear rate (approximately three
the later part of its wear life, at the same position where times), after a significant amount of internal wear. The
maximum wear occurs. chart further accelerates wear, due to greater interference
loads and relative motion, between the bushing and the
Wear Limits — Service and Destruction sprocket.
Wear limits for sealed track bushings are determined not The percentage worn charts translate direct component
only on the basis of remaining strength before and after measurements into the percent worn. All percent worn
the turn, but also upon the external wear in later hours. figures shown are based on the percent of time used. This
The “high impact” allowable wear to the service point is allows the charts to be used to directly calculate or project
3.1 mm (0.12"). The “low impact” allowable wear to the the total potential time, or remaining life, until the service
service point is 4.8 mm (0.19"). Destruction or break limit is reached. In most cases, service limit projections
through, is expected to occur within 20% of any additional made from less than 30% worn cannot be considered
hours if the condition continues to exist. Wear limits should accurate. However, such projections can be used to
always be chosen on the basis of the degree of expected determine the subsequent dates for remeasuring wear.
impact, not on the basis of abrasiveness or desired life.
T803324,00007A2 -19-04OCT07-1/1
102711
PN=171
Track
Track Bushing Allowable Wear Chart -

Outside Brazil
Sealed & Lube Track Bushing Outer Diameter Allowable Wear Chart
mm in. % Worn
56.80 2.24 0
56.25 2.22 10
55.70 2.19 20
55.15 2.17 30
54.45 2.14 40
53.85 2.12 50
52.70 2.08 60
51.60 2.03 70
50.30 1.98 80
48.95 1.93 90
47.85 1.88 100
46.55 1.83 110
45.15 1.78 120
Standard Track Bushing Outer Diameter Allowable Wear Chart

mm in. % Worn
53.90 2.12 0
53.50 2.11 10
53.35 2.10 20
52.90 2.08 30
52.70 2.07 40
52.40 2.06 50
51.90 2.04 60
51.50 2.03 70
50.65 2.00 80
49.60 1.95 90
48.60 1.91 100
47.75 1.88 110
46.90 1.85 120
BL04947,0000357 -19-21SEP11-1/1
102711
PN=172
Track
Track Bushing Allowable Wear Chart - In

Brazil
Sealed & Lube Track Bushing Outer Diameter Allowable Wear Chart
mm in. % Worn
57.00 2.24 0
56.40 2.22 10
56.10 2.21 20
55.60 2.19 30
55.20 2.17 40
54.80 2.16 50
54.30 2.14 60
53.80 2.12 70
53.20 2.09 80
52.60 2.07 90
52.00 2.05 100
Standard Track Bushing Outer Diameter Allowable Wear Chart

mm in. % Worn
53.80 2.12 0
53.40 2.10 10
53.10 2.09 20
52.60 2.07 30
52.20 2.06 40
51.80 2.04 50
51.30 2.02 60
50.80 2.00 70
50.20 1.98 80
49.60 1.95 90
49.00 1.93 100
48.40 1.91 110
47.70 1.88 120
BL04947,0000358 -19-21SEP11-1/1
102711
PN=173
Track
CM002500188 —UN—22MAY00
Internal Pitch Wear
Measurement Technique
Sealed track internal wear is measured by determining the
pitch's extended length over four adjacent sections with a
measuring tape calibrated in 5 mm (0.02”) increments.
1. Stretch the track and tape tightly and straight to obtain
an accurate measurement. 2. Track snakiness damages other components, which
shortens their total life potential and rebuildability.
2. Locate the calibrated side of the tape along an
imaginary line which connects the pin centers. 3. There is a tendency of users to overtighten tracks to
compensate for the snakiness of an excessive pitch
3. Take the reading from one side of a pin to the same side extended track. This, in effect, acts upon bushings,
of the fifth pin away (which includes 4 track sections). sprockets, and other components.
4. The hook located on the tape end should not be 4. When the forward drive side external wear is critical,
used. The mark at an even increment of inches or there is a loss of strength to the internal bushing walls.
millimeters should be placed at the 5th pin, leaving the This contributes to bushings cracking on the forward
end of the tape free to measure the fractional part of drive side, before the pins are turned. There is also a
the total length. loss of wall strength of the forward drive side after turn,
5. This measurement should be taken at least three when the rear drive side external wear was critical
sections away from any one-piece type master link before the turn.
joint. It should be repeated at least twice, over different
Allowable Wear
sections of the track, on both sides of the machine.
The internal wear is affected by the impact conditions.
Detrimental Effects of Excessive Pinch
When low impact conditions exist, the bushing and pin
1. Counter-bore depth and elongation wear accelerates wear can extend beyond 100 percent.
wear rates and prevents adequate resealing after the
turn. It also shortens after turn or replacement, pin
and bushing life.
BL04947,0000359 -19-22SEP11-1/1
Internal Pitch Wear Chart - Outside Brazil

mm in. % Worn
686.00 27.01 0
687.00 27.05 10
688.50 27.11 20
689.50 27.15 30
691.00 27.20 40
692.00 27.24 50
693.50 27.30 60
694.50 27.34 70
696.00 27.40 80
697.00 27.44 90
698.50 27.50 100
701.00 27.60 110
703.50 27.70 120

BL04947,000035A -19-22SEP11-1/1
102711
PN=174
Track
Internal Pitch Wear Chart - In Brazil

mm in. % Worn
684.40 26.94 0
685.70 27.00 10
987.20 38.87 20
688.70 27.11 30
690.30 27.18 40
692.00 27.24 50
693.70 27.31 60
695.70 27.39 70
697.70 27.47 80
699.90 27.56 90
702.20 27.65 100
704.50 27.74 110
706.90 27.83 120

BL04947,000035B -19-22SEP11-1/1
Track Rollers
The track rollers are fastened to the track roller frames.
The track rollers are in contact with the inside surfaces
of the track links. Flanges on the track rollers prevent
CM002500189 —UN—24MAR08
movement of the track from side to side. The inside
surfaces of the track links cause an equal distribution of
the weight of the harvester along the track.
The flange, located at the center of shaft, and bearings
(3) carry the side load from the roller. The amount of
side movement, or end clearance, of the shaft cannot be
adjusted.
The track rollers have floating metal seals (6) at both ends
of shaft (5).
Each track roller frame holds eight double flanged track
rollers.
T803324,00007A6 -19-29JUL05-1/1
Track Roller Lubrication

If lubricant is added, when the roller is removed from the
machine, shaft must be in a horizontal position. The slot
located in the end, where the nozzle is installed, must
CM002500190 —UN—24MAR08
be pointing downward.
The lubricant is sent into center passage (5) through the
nozzle. The lubricant fills tank (4) in the rollers. When the
tanks are full, the pressure of the oil causes the air and
extra lubricant to exit through the relief threads located
on the nozzle.
When the lubricant is bubble free, remove the nozzle and
install the plug.
T803324,00007A7 -19-29JUL05-1/1
102711
PN=175
Track
Seal Assembly 2. Apply a thin layer of oil on the surfaces of all contacting
1. Rubber toric seals, and all surfaces in contact with metal seals just before installation.
them, must be clean and dry at assembly. 3. Apply lubricant on all other seals at assembly.
T803324,00007A8 -19-29JUL05-1/1
Specifications
Roller End Clearance 0.40-0.61 mm (0.016-0.024 Inches)

Roller End Maximum Permissible Clearance 1.27 mm (0.050 Inches)
Roller Diameter 54.46 - 54.66 mm (2.144 - 2.152 Inches)
Lubrication Plug Torque 150 - 190 N·m (110-140 lb-ft)
Roller Bolts Torque 339 N·m to Frame (175 lb-ft) with
Loctite® 271
T803324,00007A9 -19-04OCT07-1/1
Carrier Roller
The track carrier roller must be aligned with the sprocket
The track carrier rollers give support to the track between and the front idler. The alignment is done by the
the sprocket and the front idler. The shaft of the track movement of the roller shaft inside of the support bracket.
carrier roller is clamped to a support bracket. The support The carrier roller turns on two tapered roller bearings.
bracket is fastened to the track roller frame.
T803324,00007AA -19-29JUL05-1/1
Carrier Roller Lubrication

If lubricant is added with the roller removed from the
machine, the shaft must be in a horizontal position.
CM002500191 —UN—24MAR08
Lubricant is sent through the nozzle and into the center
of end cover (4). The lubricant fills the cavity between
the shaft (1) and the roller. When the cavity is full, the
pressure of the oil causes the air and extra lubricant to
exit through the relief threads located in the nozzle.
When the lubricant is bubble free, remove the nozzle and
install the plug. Torque the plug to 150-190 N·m (110-
140 lb-ft).
1— Shaft 4— End Cover

2— Metal Seal 5— Plug
3— Bearings
T803324,00007AB -19-04OCT07-1/1
102711
PN=176
Track
Carrier Roller Assembly 4. Apply lubricant to all other seals at assembly.

1. Assemble the shaft flush with the back of the bracket. 5. Assemble the ground face of the plate to the end of
Make an adjustment, if necessary, for track alignment. the shaft and bearing.
2. Rubber toric seals and all surfaces in contact with 6. Before installation, apply lubricant to the inside of the
them must be clean and dry at assembly. collar assembly.
3. Just before installation, apply a thin layer of oil on the
surfaces of all contacting metal seals.
Two bolts Torque with 271 Loctite® 38-52 N·m (90 lb-ft)
T803324,00007AC -19-04OCT07-1/1
Sprocket Wear Patterns

Sprocket Replacement
The wear, as illustrated, is caused by dirt packing in
CM002500192 —19—14AUG00
the sprocket teeth or around the bushing, temporarily
increasing the sprocket pitch. Normally this condition only
occurs when sprocket, pins, and bushings are new. The
problem is relieved after some internal wear has taken
place, because the sprocket pitch has changed very little,
if at all. There is no need to replace the sprocket.
Use sprocket wear gauge 0841331949 to measure wear.
Its function is to indicate whether there is sufficient wear
material left, in the sprocket tooth, to provide structural life
to match the expected remaining life, that will be used
with it, following a bushing turn or replacement.
Use the gauge on or near bushing turn or replacement
time only (bushing turned or replaced at 90-110
CM002500193 —19—31JUL00
percentage worn).
The gauge is designed to ignore the sprocket tooth tip
conditions. It determines the ratio of root tooth wear
compared to tooth side wear. The wear on the tooth
sides is the determining factor in reusability, for structural
purposes.
The gauge should be placed, into one or more teeth, with
the point at the root aimed at the center of the sprocket.
wear life as already provided by the bushing sides that
If the point of the gauge touches the tooth root, the ran against it.
sprocket tooth does not have enough wear material
left to support the back side of the turned bushing that The past and projected sprocket life should be thought of in
caused the wear already present on the sprocket. It will terms of the bushing (sides) life it has or will be expected to
not support the wear life of the replacement bushing, provide, not in terms of actual hours on the sprocket itself.
assuming its expected wear life potential is equal to the
wear life obtained on the bushing that caused the wear It would be best not to reuse sprocket with turned (or
already present on the sprocket. replaced) bushings.
If the two side tips touch and the root tip does not touch,
then the segment can be expected to provide as much
Continued on next page T803324,00007AD -19-29JUL05-1/2
102711
PN=177
Track
Tip Gouged
This is caused by a snaky track and/or interference
with the inner link sides. If the gouging is limited to
either the inner or outer sprocket, the cause is probably
CM002500194 —UN—23MAY00
misalignment of the sprocket and/or the roller frame. This
will make the rebuilding of links questionable and it will
shorten the sprocket life.
To remedy this, if caused by worn guiding guards, replace
the wear strip. If caused by misalignment, realign the
roller frame and/or the sprocket.
T803324,00007AD -19-29JUL05-2/2
Rolling Undercarriage Wear occurs in two major places: contact with the link
The rolling undercarriage is composed of three parts: the rails causes roller thread wear and side-hill operation
track rollers, the carrier rollers and the idler assembly. causes roller flange wear.
T803324,00007AF -19-29JUL05-1/1
Roller Wear Diagnosis the roller questionable. To remedy this, install or maintain
the track guiding guards, realign the roller frame, adjust
Thread wear is caused by normal usage, and will cause the track to reduce snakiness, or rebuild the rollers.
the roller flange to hit the pin boss of the links. To remedy
this, rebuild before the flange hits the pin boss. Threads worn off center is caused by roller misalignment
and side-hill operation. It reduces link life and renders
Flange wear is caused by side-hill operation, carrier roller rebuilding as questionable. To remedy this,
misalignment, snaky track, or the flange striking the link realign or rebuild the carrier roller .
pin boss. It will reduce the link life, and make rebuilding
T803324,00007B0 -19-04OCT07-1/1
How to Measure Roller Wear the diameter measurement. Compare the worn diameter
to the “Percentage Worn Chart” to determine the roller
Using large calipers, gauge the diameter of the roller assembly’s wear.
thread. Place the calipers against a steel ruler to find
T803324,00007B1 -19-29JUL05-1/1
Carrier Roller Wear Chart - Outside Brazil

mm in. % Worn
149.00 5.87 0
148.90 5.86 10
148.70 5.85 20
147.60 5.81 30
146.40 5.76 40
145.20 5.72 50
144.10 5.67 60
142.90 5.63 70
141.80 5.58 80
140.00 5.51 90
138.20 5.44 100
136.40 5.37 110
134.50 5.30 120
BL04947,000035C -19-22SEP11-1/1
102711
PN=178
Track
Carrier Roller Wear Chart - In Brazil

mm in. % Worn
150.00 5.91 0
149.20 5.87 10
148.20 5.84 20
147.10 5.79 30
145.90 5.74 40
144.70 5.70 50
143.40 5.65 60
141.90 5.59 70
140.40 5.53 80
138.70 5.46 90
137.00 5.39 100
135.30 5.33 110
133.60 5.26 120
BL04947,000035D -19-22SEP11-1/1
Track Roller Wear Chart - Outside Brazil

mm in. % Worn
203.00 7.99 0
201.60 7.94 10
200.20 7.88 20
198.80 7.83 30
197.40 7.77 40
195.80 7.71 50
194.40 7.65 60
193.00 7.60 70
191.50 7.54 80
190.00 7.48 90
187.50 7.38 100
185.20 7.29 110
183.00 7.21 120
BL04947,000035E -19-22SEP11-1/1
Track Roller Wear Chart - In Brazil

mm in. % Worn
203.00 7.99 0
202.00 7.95 10
201.00 7.91 20
199.90 7.87 30
198.70 7.82 40
197.50 7.78 50
196.20 7.72 60
194.70 7.67 70
193.30 7.61 80
191.70 7.55 90
190.00 7.48 100
188.30 7.41 110
186.60 7.35 120
BL04947,000035F -19-22SEP11-1/1
102711
PN=179
Track
Rolling Undercarriage clearance, when the parts are new. For example, if the
clearance is 17.2 mm (0.69"), the roller radius wear is
Flange to Boss Measurement 3.8 mm (0.15") and the link wear is 4.6 mm (0.18"): Pin
If the track roller guards make the pin-boss-to-roller flange Boss Clearance
measurement difficult to obtain, you can acquire it by = 17.55 mm - (3.8 + 4.6)
subtracting the link wear plus the roller wear, from the = 17.5 mm - 8.4 mm
= 9.1 mm
T803324,00007B5 -19-19SEP07-1/1
Idler Tread Wear Measurement

Tread wear is the only measurable wear location on the
idler. Tread wear is determined by measuring, with a
broad based depth gauge, from the idler center flange to
CM002500195 —UN—23MAY00
the tread surface. The depth gauge should be positioned
so that the ruler is aimed, as closely as possible, toward
the center of the idler. The ruler’s base should be flat
on the center flange and parallel to the idler shaft. The
greatest error in measuring idler wear is caused by any
wear located on top of the center flange; this alters the
reference point. Abrasive packing conditions usually
cause the greatest amount of center flange wear. If this
wear is suspected, some attempt to compensate should be
made when the reading is taken. Remember, idler tread
wear occurs and decreases as center flange wear occurs.
T803324,00007B6 -19-04OCT07-1/1
Swapping Idlers most worn to least worn is greater than 1.5 to 1 and the
average percentage worn is less than 60%.
In order to balance wear, idlers can be swapped from
one side to the other. Swapping is best when the ratio of
T803324,00007B7 -19-04OCT07-1/1
Check Idler Flange Wear Excessive wear on both sides may indicate that the
Examine the idler flanges for excessive wear. Wear on wear strips or shims are worn out. The problem may be
just one side may mean the idler is off center. Correct corrected by adding shims. But new wear strips may be
with a shim adjustment. needed. Another possible cause of this type of wear is
that the roller frame could be out of alignment or if there is
continuous side-hill operation.
T803324,00007B8 -19-29JUL05-1/1
Flange Top Wear This can reduce the wear measurement distance and the
resulting measurement’s accuracy.
This is commonly caused by mud and debris packing
around the idler which causes abrasive action to the idler To remedy, clean the packed material away from the area
top flange. It is also caused by the links jumping out of behind the idler and correct the problem causing the link
thread and running on the center flange. If the track is too to jump track. Top flange wear is not normally critical, but
loose or snaky, the chances of link damage is increased. if wear is extreme, rebuild.
T803324,00007B9 -19-29JUL05-1/1
Flange Side Wear To remedy, install or maintain the track guiding guards,
This is caused by side-hill operation or misalignment. This realign the idler and roller frame or rebuild the idler.
reduces link life and makes idler rebuilding questionable.
T803324,00007BA -19-04OCT07-1/1
102711
PN=180
Track
Idlers Percentage Wear Chart - Outside Brazil

mm in. % Worn
17.00 0.67 0
17.30 0.68 10
17.70 0.71 20
18.10 0.73 30
18.50 0.74 40
18.90 0.76 50
19.40 0.78 60
19.80 0.80 70
20.30 0.83 80
21.10 0.87 90
22.10 0.92 100
23.30 0.92 110
24.50 0.96 120
BL04947,0000360 -19-22SEP11-1/1
Idlers Percentage Wear Chart - In Brazil

mm in. % Worn
17.00 0.67 0
17.40 0.69 10
17.80 0.70 20
18.20 0.72 30
18.70 0.74 40
19.10 0.75 50
19.60 0.77 60
20.20 0.80 70
20.80 0.82 80
21.40 0.84 90
22.00 0.87 100
22.70 0.89 110
23.50 0.93 120
BL04947,0000361 -19-22SEP11-1/1
102711
PN=181
Track
CM002500196 —UN—23MAY00
Track Shoe Problems
Grouser Wear Measurement
Grouser height wear is measured with a broad based
depth gauge. Set the base across two adjacent grousers
and use the gauge to measure down to the plate. The
position of the depth gauge should be 1/3 of the way in from
the outer edge of the shoe; this eliminates a problem in
measuring in cases of uneven outer-to-inner grouser wear.
The depth gauge should be perpendicular to the plate in
order to get the most accurate reading. Measurements
CM002500197 —UN—23MAY00
should be made to the closest 0.01" (0.25 mm).
Wear Limits — Service & Destruction
Wear limits for all shoes are based on three criteria, in the
following order:
1. Remaining beam or bending resistance strength for
the standard width shoe.
2. Remaining grouser base available for regrousering
purposes.
3. Remaining traction-penetration ability of the shoe to
prevent traction losses.
Depending on the nature of the shoe and its expected
use, both high and low impact wear limits have been
established.
As the degree of impact increases, a shoe is more subject
to bending. Shoes may require re-grousering before the
high impact wear limit is reached to help avoid bending.
The shoe grouser base is generally less evenly worn,
thus reducing its re-grouseability. The shoe will need
more penetration to grip a hard surface and it may require
re-grousering before the wear limit is reached.
The service point is represented by 100% worn. The
destruction point is represented by 120% worn, meaning
destruction will be reached in 20% more hours than it
takes to reach the service limit of 100%. Destruction is
the complete loss of grouser and/or if the shoe bends or
breaks.
Grouser Wear
This is caused by sliding contact with the surface
underfoot. It can be accelerated by weight, horsepower,
speed, impact, abrasiveness, terrain, and all operating
variables that cause nonproductive slippage, turning or
sliding. This causes a loss of traction, bending strength
and the re-grouserability when wear limits are reached
or exceeded.
To remedy this, reduce or eliminate controllable accelerator
variables, particularly slippage and unnecessary turning.
Continued on next page T803324,00007BC -19-04OCT07-1/5
102711
PN=182
Track
Plate Wear and Leading/Training Edge Wear

This is caused by sliding contact with the surface
underfoot. It can be accelerated by weight, horsepower,
speed, impact, abrasiveness, terrain, and all operating
CM053510243 —UN—24MAR08
variables that cause non-production slippage, turning or
sliding. This causes a loss of bending strength and may
prevent the re-grousered life to reach the wear limit, even
if the grouser is in good condition.
To remedy this, reduce or eliminate controllable accelerator
variables, particularly slippage and unnecessary turning.
T803324,00007BC -19-04OCT07-2/5
Bolt Hole Wallowing Out

This is caused by the loss of clamping between shoe and
link or loose bolts. It is accelerated by having too much
turning resistance, resulting from a too high grouser or
CM002500199 —UN—23MAY00
inadequately tightened hardware. It will cause loose
shoes and loss of service life and rebuildability.
To remedy, properly torque hardware and check after the
first 100 hours of operation, and check periodically at 50
to 100 hours of operation thereafter.
T803324,00007BC -19-04OCT07-3/5
Self-Locking Track Nut

The self-locking track nut is installed with the rounded
corners against the link. The chamfered edge is away from
the link. Prolong track life by keeping track hardware tight.
CM002500200 —UN—23MAY00
Bolts Torque 400 N·m (300 lb-ft)

Continued on next page T803324,00007BC -19-04OCT07-4/5
102711
PN=183
Track
Sprocket Chain Roller Alignment
CM053510244 —UN—29JUL05
Sprocket Chain Roller Alignment —
Segment Sprocket: 2.19 inches
Solid Sprocket: 2.25
T803324,00007BC -19-04OCT07-5/5
102711
PN=184
Group 20
Wheel
Wheel Assembly
CM002500247 —UN—26MAR08
1— Hub Cap 4— Washer 7— Hub Assy 10— Oil Seal

2— Cotter Pin 5— Cone Bearing 8— Cup Bearing
3— Nut 6— Cup Bearing 9— Cone Bearing
T803324,00007BD -19-29JUL05-1/1
102711
PN=185
Wheel
Remove and Replace Front Wheel Bearings 8. Drive new bearing cups (6 and 8) into wheel hub (7)
1. Block up front of harvester. tightly against hub shoulders.
2. Remove hub cap (1), cotter pin (2) and retaining nut 9. Pack bearing cones (5 and 9) with grease. Install in
(3) from spindle. hub.
3. Remove wheel and hub, with bearings, from spindle. 10. Carefully install oil seal (10) on hub (7).
4. Remove bearings (5 and 9) and inspect. 11. Assemble wheel hub (7) and bearing cones (5 and 9)
on spindle. Pull into position with spindle nut (3).
5. Inspect bearing cups (6 and 8).
12. Adjust wheel bearings by tightening spindle nut to
6. Inspect oil seal (10) for leakage, cracks, or brittleness. 47 N·m (35 lb-ft), then back off spindle nut minimum
amount required to insert cotter pin in spindle.
7. When changing bearing cups (6 and 8), position punch
in cut-out hub: drive out bearing cups and oil seal (10).
T803324,00007BE -19-29JUL05-1/1
Remove Rear Wheel Assembly 1. Loosen wheel bolts or nuts before lifting the unit off
Suggested Tools the ground.
1. 20 ton service jack 2. Raise the axle housing using a 20 ton capacity service
jack.
2. 20 ton floor stand
3. Put a 20 ton floor stand under the axle housing.
3. Heavy duty wheel lift
4. Put wheel lift under the wheel. Fasten a safety chain
4. Lug torque wrench around the upper portion of the tire.
5. Air hose and pressure gauge. 5. Remove three evenly spaced bolts and install threaded
dowels in their place. Remove the retaining bolts and
CAUTION: The wheel assembly weighs pull the wheel assembly away from the unit.
approximately 1000 pounds, without fluid (in
some applications tires may be filled with
fluid). Use suitable equipment when handling
these heavy wheels to avoid injury.
T803324,00007BF -19-29JUL05-1/1
102711
PN=186
Wheel
Remove and Mount Tire onto Wheel

Assembly
CAUTION: Explosive separation of a tire from a

wheel can cause serious injury or death.
1. Before attempting any demounting operation, always

completely deflate the tire. For tires with fluid, rotate
the valve stem to the 12 o'clock position.
2. If the tire is flat, check for a plugged valve stem by
running a wire through it. Inspect parts for wear or
damage; replace if necessary.
CM19989999022 —UN—02NOV99
3. Make sure all parts are clean and free of dirt, paint, rust,
oil, grease or other foreign material before assembly.
4. Install the valve stem into the rim base.
5. Apply soap to the bead of the tire and mount the tire
on the rim.
6. Clear area of personnel.
CAUTION: Possible overinflation may cause the

tire to explode; this may cause personal injury or side flanges of the tire slide outward against the rim.
death. When inflating tires, use a clip-on chuck Adjust the tire pressure.
and an extension hose long enough to allow you 8. Install the valve stem cap.
to stand to one side. Do Not stand in front of, or
over the tire. Use a safety cage if one is available.
7. Connect the pressure regulating valve to the valve

stem and stand to one side. Inflate the tire until the
T803324,00007C0 -19-25SEP07-1/1
Install Wheel Assembly

NOTE: Clean bolts and holes in final drive to ensure
1. Clean and inspect all fastening hardware before they are free from grease.
installation. Replace as necessary.
3. Torque to 231 N·m (170 lb-ft) Front.
2. Install wheel using a wheel lift. Guide the wheel over
three threaded dowels. Install three nuts. Apply 4. Torque to 529 N·m (390 lb-ft) Rear.
Loctite®271 to the remaining 1bolts. (Install these
bolts without air tools.) Remove the dowels and install 5. Remove the shop stands and lower all equipment to
the first three bolts. Apply Loctite to the three bolts the ground. Check the air pressure.
and reinstall.
Front Skidder Tire 17.5 x 14-10 ply Pressure 65 PSI (450 KAP)
Rear Tire 23.5 25-20 ply Pressure 50 PSI (345 KAP)
Loctite is a trademark of Henkel Corporation
1
Start lugnuts by hand to prevent thread damage.
T803324,00007C1 -19-29JUL05-1/1
102711
PN=187
Wheel
102711
PN=188
Section 60
Steering System
Contents
Page
Group 05—Steering Column (Type A)

Steering Column Breakdown......................... 60-05-1
Group 10—Steering Column (Type B)

Steering Column Components ...................... 60-10-1
Disassemble And Assemble
Steering Column........................................ 60-10-2
Replace Telescoping Shaft
Bearings .................................................... 60-10-6
Group 15—Steering Wheel Position Input

Assembly (Autotrac Ready
Track Machines)
Specifications ................................................ 60-15-1
Repair Steering Wheel Position
Input Assembly (Autotrac Ready
Track Machines) ........................................ 60-15-1
Group 20—Relief Valve

Relief Valve Adjustment................................. 60-20-1
Steering Linkage............................................ 60-20-2
Check Front Axle Toe-In ................................ 60-20-3
Adjust Front Axle Toe-In ................................ 60-20-4
102711
PN=1
Contents
102711
PN=2
Group 05
Steering Column (Type A)
Steering Column Breakdown
CQ282628 —UN—24MAR09
A—Handle C—Cover E—Steering Column Tube

B—Cover D—Shaft
Repair as needed following the Steering Column

Breakdown
BL04947,0000351 -19-16SEP11-1/1
102711
PN=191
Steering Column (Type A)
102711
PN=192
Group 10
Steering Column (Type B)
Steering Column Components
1
20
12
2
13 14
4
14 33
13
5
15 34
6 21
35
16
36
32
31
22 37
7 17
8 24
18
25
9
23
26
10 19
11
H80889 —UN—12MAY04
27
28 27
29 30
1— Cap 11— Snap Ring 21— Universal Joint with Shaft 31— Shaft Key
2— O-Ring 12— Rod 22— Cap Screw (2 used) 32— Spring Pin
3— Cap Screw 13— Snap Ring (2 used) 23— Flange Nut (2 used) 33— Steering Control Unit
4— Knob 14— Ball Bearing (2 used) 24— Bearing 34— Cap Screw (4 used)
5— Nut 15— Washer 25— Spring Pin 35— Lock Washer (4 used)
6— Nut 16— Steering Wheel Shaft 26— Coupling 36— Bracket
7— Steering Wheel 17— O-Ring 27— Clamp Bolt and Special Nut 37— Pillow Block
8— Snap Ring 18— Steering Wheel Shaft 28— Isolator
9— Switch 19— Washer 29— Splined Coupling
10— Connector 20— Housing 30— Set Screw
OUO6083,0000788 -19-12MAY04-1/1
102711
PN=193
Disassemble And Assemble Steering Column

1. Disconnect battery ground cable.
NOTE: It is not necessary to remove cap (B) from knob
unless it fits loosely or needs replaced. If cap is
loose, remove by carefully prying upward using a
screwdriver. Inspect O-ring and replace if required.
H67658 —UN—09JUL01
2. Turn knob (A) counterclockwise to remove.
A—Knob B—Cap
OUO6083,000086D -19-28JUN04-1/8
3. Bend down tabs on retaining washer (A). Remove nut

(B).
4. Pull steering wheel off of shaft. If steering wheel does
not come off easily, tap lightly upward using a rubber
mallet.
H67659 —UN—23APR01
A—Washer B—Nut
OUO6083,000086D -19-28JUN04-2/8
5. Remove snap ring (A).
A—Snap Ring
H67660 —UN—23APR01
Continued on next page OUO6083,000086D -19-28JUN04-3/8
102711
PN=194
6. Remove screws (A) from both sides of housing and

remove top cover. Leave harness connected and set
cover aside.
A—Screws (2 used per side)
H67661 —UN—23APR01
OUO6083,000086D -19-28JUN04-4/8
7. Disconnect turn signal switch from harness connector

(A).
8. Loosen cap screws (B) enough to allow connector to
fit between housing and steering column. Remove
turn signal switch.
A—Connector B—Cap Screw
H57381 —UN—24MAY99
102711
PN=195
9. Remove screws (A) from both sides of housing and

remove lower cover.
A—Screws (2 used per side)
H57395 —UN—24MAY99
OUO6083,000086D -19-28JUN04-6/8
10. Remove spring pin (A) and cap screws (B).

11. Remove clamp (C).
12. Remove telescoping shaft assembly.
A—Spring Pin C—Clamp
H57399 —UN—24MAY99
B—Cap Screw
102711
PN=196
13. Remove coupling clamp bolt (A) and bearing retaining

nuts (B) to remove U-joint and shaft assembly (C).
14. Remove isolator (D).
15. Loosen set screw (E) to remove lower coupling half (F).
16. Clean and inspect all parts. Replace worn or damaged
parts as needed.
17. Install lower coupling half and tighten set screw.
18. Install bearing and upper coupling half on U-joint with
H57405 —UN—24MAY99
shaft. Leave clamping bolt loose.
19. Position isolator and install U-joint and shaft assembly.
Tighten nuts on bearing cap screws to specification.
Specification
Steering Column Bearing
Nut—Torque........................................................................... 40 ± 4 N·m
(29 ± 3 lb-ft)
20. Tilt steering column to lowest position.

21. Slide upper coupling half down universal joint with
shaft until specified clearance is obtained between
jaws of upper coupling and hub of lower coupling.
H57506 —UN—24MAY99
Specification
Steering Column
Couplings—Clearance........................................................ 2.5 ± 0.5 mm
(0.100 ± 0.020 in.)
22. Tighten nut on upper coupling clamp bolt to

specification.
Specification
A—Bolt D—Isolator
Steering Column B—Nuts E—Set Screw
Upper Coupling Clamp C—U-Joint with Shaft F— Coupling
Bolt—Torque.........................................................................28 ± 2.8 N·m
(21 ± 2 lb-ft)
NOTE: Be sure to route turn signal switch connector Specification

between housing and telescoping shaft before Steering Wheel
tightening telescoping shaft clamp. Nut—Torque..................................................................................47 N·m
(35 lb-ft)
23. Tighten steering wheel nut to specification and bend
24. After assembly, be sure steering shaft turns freely.
up tabs on retaining washer.
25. Connect battery ground cable.
OUO6083,000086D -19-28JUN04-8/8
102711
PN=197
Replace Telescoping Shaft Bearings

1. Remove telescoping shaft assembly. (See
DISASSEMBLE STEERING COLUMN in this group.)
2. Remove snap ring (A).
H57404 —UN—24MAY99
A—Snap Ring
AG,OUO6022,1912 -19-25JUL00-1/3
3. Separate three sections of shaft and remove key (A),

spring washer (B) and bearing (C).
A—Key C—Bearing
B—Washer
H57421 —UN—24MAY99
AG,OUO6022,1912 -19-25JUL00-2/3
4. Remove snap ring (A) and bearing (B).

5. Remove spring washer (C).
6. Clean and inspect all parts for wear or damage.
Replace parts as needed.
7. Assemble and install telescoping shaft. (See
H57425 —UN—24MAY99
DISASSEMBLE AND ASSEMBLE STEERING
COLUMN in this group.)
A—Snap Ring C—Washer

B—Bearing
AG,OUO6022,1912 -19-25JUL00-3/3
102711
PN=198
Group 15
Steering Wheel Position Input Assembly (Autotrac Ready Track Machines)
Specifications
Steering Input Assembly Cap Screws Torque 40 N·m

(30 lb-ft)
OUOD010,0000076 -19-28APR06-1/1
Repair Steering Wheel Position Input

Assembly (Autotrac Ready Track Machines)
1. Remove three special screws (A) and cover from
sensor assembly.
NOTE: Sensor assembly (B) is serviced as a unit.
RW25641 —UN—26FEB97
2. Disconnect the three electrical connectors.
3. Replace sensor assembly as required.
4. Connect electrical connectors to sensor assembly.
a. Connect three electrical connectors from wiring
harness to sensor assembly making sure all three
sensors are connected correctly (top sensor to top
sensor connector, etc). A—Cap Screw D—Rod
B—Sensor Assembly E—Slot
b. Turn key switch to ON position (do not start the C—Key Slot
harvester).
c. Align notches of three sensors so three connectors
are 120 degrees apart. 5. Install sensor assembly to body, aligning center shaft
with key slot (C). Install rod (D) between slots (E).
d. Access PSC address 007 and turn shaft of three
sensors until reading is 2.2—2.8 volts. 6. Install cover.
e. Access PSC address 008. Voltage should be 7. Install steering wheel position input assembly on the
2.2—2.8 volts. Harvester.
f. Access PSC address 009. Voltage should be 8. Perform calibration procedure. (See Operation and
2.2—2.8 volts. Test TM).
g. Install sensor assembly on steering wheel position
input assembly with all three notches matching with
alignment pin.
BL04947,0000352 -19-16SEP11-1/1
102711
PN=199
Steering Wheel Position Input Assembly (Autotrac Ready Track Machines)
102711
PN=200
Group 20
Relief Valve
Relief Valve Adjustment inward will increase the pressure and outward will
decrease the pressure.
1. To adjust the pressure, remove the tank port fitting and
install a 7/32 inch Allen wrench into the port. Screwing 2. The relief should be set to 172 bar (2500 PSI).
T803324,00007E0 -19-19SEP07-1/1
102711
PN=201
Relief Valve
Steering Linkage
CM053510260 —UN—26MAR08
Continued on next page T803324,00007E6 -19-16FEB06-1/2
102711
PN=202
Relief Valve
1— Zerk 8— Trunnion Assy 15— Grease Press Cap 22— Nut

2— Zerk 9— Bolt 16— Steering Cylinder 23— Cylinder Extension
3— Cotter Pin 10— Ball Bushing 17— Washer 24— Nut-SL
4— Washer 11— Front Strut Assy (RH) 18— Bushing 25— Cotter Pin
5— Triple Lip Seal 12— Front Wheel Hub 19— Ball Joint 26— Ball Joint
6— Snap Ring 13— Nut-UT 20— Nut-SL
7— Bearing 14— Nut-SL 21— Cotter Pin
T803324,00007E6 -19-16FEB06-2/2
Check Front Axle Toe-In

1. Position wheels for straight ahead travel.
2. Mark center (A) of each tire at front and rear, on
centerline (B).
3. Measure from mark-to-mark on rear of each tire.
Record measurement for rear spacing dimension (C).
4. Measure from mark-to-mark on front of each tire.
Record measurement for front spacing dimension (D).
5. Subtract front spacing from rear spacing to obtain
toe-in dimension. Dimension (D) should be as
specified, less than dimension (C).
Specification
Front Axle Toe-
In—Clearance...................................................................6.35 mm (1/4”)
If dimensions are not within specified range, see Adjusting

Front Axle Toe-In in this section.
A—Center of Tire C—Rear Spacing Definition

B—Centerline D—Front Spacing Dimension
N42173UX —UN—15JAN97
T803324,00007E9 -19-16FEB06-1/1
102711
PN=203
Relief Valve
Adjust Front Axle Toe-In
CM053510261 —UN—09AUG05
Continued on next page T803324,00007EA -19-27SEP07-1/3
102711
PN=204
Relief Valve
1. Level the harvester and position both front wheels

straight. This can be checked by obtaining the same
measurement from the front (B) and rear (A) centerline
of the tire to the side wall (D) of the harvester.
CM053510262 —UN—09AUG05
C—Center Line of Tire D—Side Wall
CM053510263 —UN—09AUG05
Front Tire
Continued on next page T803324,00007EA -19-27SEP07-2/3
102711
PN=205
Relief Valve
CM053510261 —UN—09AUG05
2. Disconnect the two hydraulic hoses (A) going to the 5. Tighten the nut (B) and reconnect the hoses (A).
steering cylinder.
6. Repeat the same procedure to the other front wheel.
3. Loosen nut (B).
4. Turn the complete cylinder assembly (C) clockwise
until you've moved the front of the tire 1/8” inward.
T803324,00007EA -19-27SEP07-3/3
102711
PN=206
Section 70
Main Hydraulic System
Contents
Page Page
Group 10A—Multiple Gear Pump

Multiple Gear Pump Repair .........................70-10A-1 Group 20F—Elevator Cylinders
Repair Precautions ......................................70-10A-2 Repair Elevator Swing Cylinder................... 70-20F-1
Bushing Removal Tool.................................70-10A-2 Elevator Swing Cylinder
Seal Removal Tool.......................................70-10A-3 Disassembly ............................................ 70-20F-2
Bushing Installation Tool..............................70-10A-3 Assemble Elevator Swing
Special Steel Sleeve....................................70-10A-3 Cylinder ................................................... 70-20F-5
Seal Installation Tool....................................70-10A-3 Repair Elevator Lift Cylinder...................... 70-20F-10
Multiple Gear Pump Repair Elevator Lift Cylinder
Procedure ................................................70-10A-3 Disassembly .......................................... 70-20F-11
Clean and Inspect...................................... 70-10A-11 Clean and Inspect...................................... 70-20F-13
Assembly ...................................................70-10A-13 Piston Seal Installation .............................. 70-20F-14
Start-Up Procedure....................................70-10A-26 Elevator Lift Cylinder Assembly................. 70-20F-14
Recommended Test Procedure .................70-10A-26
Group 20G—Height Indicator Cylinder
Group 10B—Piston Pump Repair Height Indicator Cylinder................. 70-20G-1
Piston Pump Repair.....................................70-10B-1
Suggested Tools and Supplies ....................70-10B-2 Group 20H—Cab Tilt Cylinder
General Repair Instructions.........................70-10B-2 Repair Cab Tilt Cylinder ............................. 70-20H-1
Orifice Check Valve Replacement................70-10B-2
Charge Pressure Relief Valve Group 20I—Knockdown Tilt and Crop
Replacement ...........................................70-10B-3 Divider Tilt Cylinder
Shaft Seal Replacement..............................70-10B-3 Repair Knockdown Tilt and Crop
Multifunction Valve Cartridge Divider Tilt Cylinder (Optional).................. 70-20I-1
Replacement (2 per pump)......................70-10B-5
Charge Pump Disassembly .........................70-10B-6 Group 30A—Fixed Displacement Motor
Fixed Displacement Motor...........................70-30A-1
Group 20A—Steering Cylinder Seal Replacement .......................................70-30A-1
Repair Steering Cylinder ............................70-20A-1 Disassembly ................................................70-30A-2
Clean and Inspect........................................70-30A-2
Group 20B—Crop Divider Cylinder Assembly .....................................................70-30A-2
Repair Crop Divider Lift Cylinder .................70-20B-1
Group 30B—Collector, Crop Divider,
Group 20C—Crop Divider Tilt Cylinder Feedroller and Elevator Motor
Repair Crop Divider Tilt Cylinder ................ 70-20C-1 Repair Collector, Crop Divider,
Tilt Cylinder Disassembly ........................... 70-20C-1 Feedroller and Elevator Motor .................70-30B-1
Cleaning and Inspection ............................. 70-20C-3 Suggested Tools ..........................................70-30B-2
Tilt Cylinder Assembly ................................ 70-20C-4 Disassembly ................................................70-30B-3
Testing ........................................................ 70-20C-5 Clean and Inspect........................................70-30B-9
Assembly ...................................................70-30B-10
Group 20D—Topper Cylinder
Repair Topper Cylinder............................... 70-20D-1 Group 30C—Topper and Secondary
Extractor Motor
Group 20E—Basecutter Cylinder Repair Topper and Secondary
Repair Basecutter Lift Cylinder Extractor Motor ....................................... 70-30C-1
(Wheel) ....................................................70-20E-1 Gear Motor Repair...................................... 70-30C-2
Suggested Tools ..........................................70-20E-3 Suggested Tools ......................................... 70-30C-2
Clean and Inspect........................................70-20E-3 Repair Precautions ..................................... 70-30C-2
Basecutter Lift Cylinder Disassembly ............................................... 70-30C-3
Reassembly.............................................70-20E-3 Clean and Inspect....................................... 70-30C-7
Assembly .................................................. 70-30C-10
Start-up Procedure ................................... 70-30C-14
102711
PN=1
Contents
Page Page
Recommended Test Procedure ................ 70-30C-15 Removing the Distributor .............................. 70-30I-3
Removing the Motor Cover........................... 70-30I-4
Group 30D—Basecutter and Primary Removing the Rear Retaining
Extractor Motors Ring .......................................................... 70-30I-4
Repair Basecutter and Primary Removing the Cylinders ............................... 70-30I-4
Extractor Motors ..................................... 70-30D-1 Removing the Shaft ...................................... 70-30I-5
Required Tools............................................ 70-30D-2 Removing the Shaft Bearings....................... 70-30I-5
Disassembly ............................................... 70-30D-2 Motor Assembly Procedures ........................ 70-30I-6
Assembly .................................................. 70-30D-10 Bearing Assembly......................................... 70-30I-6
Shaft Assembly............................................. 70-30I-6
Group 30E—Secondary Extractor Hood Cylinder Assembly........................................ 70-30I-8
Rotate Motor Distributor Cover Assembly .......................... 70-30I-9
Repair Secondary Extractor Hood Rotary Valve Subassembly........................... 70-30I-9
Rotate Motor............................................70-30E-1 Distributor Cover Subassembly .................. 70-30I-10
Required Tools.............................................70-30E-2 Rotary Group Assembly ............................. 70-30I-11
Disassembly ................................................70-30E-2 Distributor Cover Assembly ........................ 70-30I-12
Assembly ...................................................70-30E-10
Group 40A—Rear Feed Roller Valve
Group 30F—Cooling Package/Oil Cooler Motor Valve Assembly ...........................................70-40A-1
Repair Cooling Package/Oil Cooler Suggested Tools ..........................................70-40A-1
Motor ....................................................... 70-30F-1 External Relief Settings ...............................70-40A-2
Clean and Inspect........................................ 70-30F-4 Valve Overhaul ............................................70-40A-2
Assembly ..................................................... 70-30F-4 Valve Bank Disassembly .............................70-40A-3
Valve Assembly Procedure..........................70-40A-3
Group 30G—Variable Displacement Ground
Drive Motor (Wheel) Group 40B—Steering Priority Valve (Wheel)
Repair Variable Displacement Repair Steering Priority Valve
Ground Drive Motor (Wheel) .................. 70-30G-1 (Wheel) ....................................................70-40B-1
About Servicing the Motor .......................... 70-30G-2
Shaft Seal Disassembly.............................. 70-30G-3 Group 40C—Steering Valve
Inspection ................................................... 70-30G-4 Repair Steering Valve................................. 70-40C-1
Assembly .................................................... 70-30G-4 Disassembly/Reassembly .......................... 70-40C-2
Cartridge Disassembly ............................... 70-30G-6 Requirements ............................................. 70-40C-2
Housing Disassembly ................................. 70-30G-9 Reassembly Requirements ........................ 70-40C-2
Housing Assembly.....................................70-30G-11 Troubleshooting.......................................... 70-40C-6
Reconditioning and Replacement
of Shaft Assembly................................. 70-30G-15
Piston Ring Reconditioning and
Replacement ........................................ 70-30G-16
Reconditioning and Replacement
of Bearing Plate, Valve Segment
and Cylinder Block................................ 70-30G-17
Group 30H—Fixed Displacement Motor (Track)

Repair Fixed Displacement Motor
(Track) .................................................... 70-30H-1
Fixed Displacement Motor
(Track) .................................................... 70-30H-2
Cartridge Assembly .................................... 70-30H-2
Synchronizing Shaft Assembly ................... 70-30H-4
Cylinder Block Assembly ............................ 70-30H-7
Bearing Plate and Valve Segment
Assembly ...............................................70-30H-11
End Cap to Main Housing
Assembly .............................................. 70-30H-13
Group 30I—Chopper Motor

Repair Chopper Motor .................................. 70-30I-1
Motor Strip Down & Assembly
Tools ......................................................... 70-30I-2
Motor Disassembly Procedures.................... 70-30I-2
102711
PN=2
Group 10A
Multiple Gear Pump
Multiple Gear Pump Repair
CM073510081 —UN—20AUG07
Continued on next page T803324,00009FF -19-17SEP07-1/2
TM100419 (27OCT11) 70-10A-1 3520 and 3522 Sugar Cane Harvester Repair
102711
PN=209
Multiple Gear Pump
1— Seal 11— Housing 21— Gear 31— Housing

2— Cover 12— Shaft 22— Housing 32— Housing
3— Plug 13— Gear 23— Washer 33— Shaft
4— Bushing 14— Housing 24— Stud 34— Seal
5— Seal 15— Housing 25— Shaft 35— Nut
6— Plate 16— Housing 26— Plate 36— Gear Case
7— Gear 17— Washer 27— Seal 37— Gear
8— Seal 18— Bolt 28— Seal 38— Gear Case
9— Dowel Pin 19— Nut 29— Dowel Pin
10— Gear Housing 20— Gear 30— Bushing
These service instructions will familiarize you with multiple 4. Bushing Removal Tool (0841329345)
pumps, their component parts, the relative position of
each part, proper methods for assembly or disassembly 5. Clean lintless cloths
of the units, and care and use of these pumps. This will
give you the best performance and a longer working life. 6. Deburring tool (an old file with cutting teeth ground off)
To facilitate the repair of these pumps, and before any work 7. Machinist's Hammer
is done, we suggest you first read all of the repair steps. 8. Soft Hammer
The first requirement for good maintenance of hydraulic 9. Permatex form-a-gasket number C2 non-hardening
equipment is cleanliness. Make sure you perform all sealant or equivalent
repair work in a clean area.
10. Medium grit carborundum stone
The repair graphics show a double pump, but they are
also applicable to the triple pump. 11. Seal Removal Tool
It is important to air blast all parts and wipe them with a 12. Snap Ring Pliers
clean, lintless cloth before assembly.
13. Prick Punch
Use caution in gripping all parts in the vise to avoid
damaging machined surfaces. 14. Bushing Installation Tool
A pump must be driven in the direction of rotation for 15. Scale (1/32 Inch or 1/64 Inch graduations)
which it is was built, otherwise the pressure will blow the 16. Small screwdriver
shaft seal.
17. Torque Wrench
Check all replacement parts before installation to be
certain they were not damaged in shipment. 18. Vise with 6 in. minimum open spread
Suggested Tools 19. Seal Installation Tool (0840249684)
1. Arbor Press 20. Special Steel Sleeve (0290244683)
2. 1-1/2 In. diameter steel ball. 21. Awl
3. Bearing Puller
T803324,00009FF -19-17SEP07-2/2
Repair Precautions 3. All gears are closely matched; therefore; they must be
1. If it is necessary to pry off sections, take extreme care kept as sets when removed from the pump. Handle
not to mar or damage machined surfaces. Excessive with care to avoid damage to the journals or teeth.
force while prying can result in misalignment and may Avoid touching gear journals.
seriously damage parts. 4. Never hammer bushings into bores, use an arbor
2. If parts are difficult to install during assembly, tap press.
gently with a soft hammer. Never use a metal hammer.
T803324,0000A00 -19-06AUG07-1/1
Bushing Removal Tool

The bushing in the double and triple pumps should be
removed from their bores by using bushing removal tool
(0841329345).
T803324,0000A01 -19-20AUG07-1/1
102711
PN=210
Multiple Gear Pump
Seal Removal Tool

The seal removal tool can be easily made from an old
screwdriver. Heat the tip and bend to 90°. Grind the tip
to fit the notch behind the shaft seal.
T803324,0000A02 -19-06AUG07-1/1
Bushing Installation Tool

To install the bushings, use bushing installation tool
(0290244461).
T803324,0000A03 -19-20AUG07-1/1
Special Steel Sleeve

The special steel sleeve (0290244683) is used to insert
the drive shaft through the lip seal without damage.
T803324,0000A04 -19-20AUG07-1/1
Seal Installation Tool

The seal installation tool (0290244684) is used to install
the lip seal into the housing.
T803324,0000A05 -19-20AUG07-1/1
Multiple Gear Pump Repair Procedure

1. Place the pump in a vise with the drive shaft facing
downward. Match mark all sections to be sure to align
these marks when assembling.
CM073510082 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-1/21
2. Use a socket wrench to remove four hex nuts (19),

washer (17), stud bolts (18), hex nuts (35), stud bolts
(24) and washers (23).
CM073510083 —UN—06MAR08
Continued on next page T803324,0000FA7 -19-17SEP07-2/21
102711
PN=211
Multiple Gear Pump
3. Lift off port end cover (16). If prying is necessary, be

careful not to damage the machine surfaces. Dowel
pins (29) will remain in either the port end cover (16),
or gear housing (31). Keep all gear sets together;
they are matched sets. Remove thrust plate (26) from
CM073510084 —UN—06MAR08
gear housing (31).
T803324,0000FA7 -19-17SEP07-3/21
4. Lift gear housing (31) from housing (22). If prying is

necessary, take care not to damage machine surfaces.
CM073510085 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-4/21
5. Remove the two gears (20) from housing (22). Label

and keep this gear set together because they are a
matched set.
CM073510086 —UN—06MAR08
102711
PN=212
Multiple Gear Pump
6. Carefully lift or pry housing (22) from gear housing

(32). Dowel pins (29) will remain in either housing (22)
or gear housing (32). Do not remove them.
CM073510087 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-6/21
7. Remove connecting shaft (33). Remove thrust plate

(26). Remove gear set (21). Keep these gears
together; they are a matched set. Be careful not to
damage the machined surfaces of the gears.
CM073510088 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-7/21
8. Carefully lift or pry gear housing (32) from housing

(14). Dowel pins (9) will remain in either gear housing
(32) or housing (14). Do not remove them.
CM073510089 —UN—06MAR08
102711
PN=213
Multiple Gear Pump
9. Remove thrust plate (26). Remove connector shaft

(25).
CM073510090 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-9/21
10. Remove housing (14) from gear housing (36). Dowel

pins (9) will remain in either housing (14) or gear
housing (36). Do not remove them.
CM073510091 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-10/21
11. Remove thrust plate (6) and gear set (37) from gear
housing (36).
CM073510092 —UN—06MAR08
102711
PN=214
Multiple Gear Pump
12. Remove gear housing (36) from housing (15). Dowel

pins (9) will remain in gear housing (36) or housing
(15). Do not remove them.
CM073510093 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-12/21
13. Remove thrust plate (6) and connector shaft (12) from
housing (15).
CM073510094 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-13/21

pins (9) will remain in housing (15) or gear housing
CM073510095 —UN—06MAR08
102711
PN=215
Multiple Gear Pump
15. Remove thrust plate (6) and gear set (13) from gear
housing (10).
CM073510096 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-15/21
16. Remove gear housing (10) from housing (11). Dowel

pins (9) will remain in gear housing (10) or housing
CM073510097 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-16/21
17. Remove thrust plate (6) and connector shaft (12) from
housing (11).
CM073510098 —UN—06MAR08
102711
PN=216
Multiple Gear Pump

pins (9) will remain in either housing (11) or gear
housing (38). Do not remove them.
CM073510099 —UN—06MAR08
T803324,0000FA7 -19-17SEP07-18/21
19. Remove thrust plate (6), gear housing (38), gear

assembly (7) and remaining thrust plate (6) from cover
(2).
CM073510100 —UN—06MAR08
102711
PN=217
Multiple Gear Pump
CM073510101 —UN—06MAR08
20. Using a bushing puller, remove all bushings (30) and
(4) from their respective housings. Inspect all bushings
for scoring or discoloration. Replace, if necessary.
T803324,0000FA7 -19-17SEP07-20/21
21. Place front cover (2) in a vise with the mounting facing
downward. Remove lip seal (1) by inserting a seal
removing tool into the notch between the lip seal and
the front cover. Tap the seal out of the cover and
discard.
CM073510102 —UN—06MAR08
22. Remove and discard all rubber and polymer O-rings
and seals.
T803324,0000FA7 -19-17SEP07-21/21
102711
PN=218
Multiple Gear Pump
Clean and Inspect

Clean and inspect all parts for wear or damage. Replace
if necessary. See John Deere Parts Manual for the correct
part numbers to order. Notice that all gear assemblies are
a matched set and cannot be ordered separately.
T5921AH —UN—25OCT88
Replace gear housings if either has wear in excess of
0.13 mm (0.005 in) cutout. Use the following method to
determine cutout:
Place a straight edge across the bore. If you can slip a
0.13 mm (0.005 in) feeler gauge under the straight edge
in the cutout area, replace the gear housing.
1. Pressure pushes the gears against the housing on the
low pressure side. As the hubs and bushings wear, the of the outer tooth diameter will require replacement.
cutout becomes more pronounced. Excessive cutout Nicking, grooving, or fretting of teeth surfaces will also
in a short period of time indicates excessive pressure necessitate replacement.
or oil contamination. If the relief valve settings are
within prescribed limits, check for shock pressures or 4. Drive shaft (7) should be replaced if any wear is
tampering. Check an oil sample and the tank itself for detectable, by touch, in the seal area or at the drive
contamination. coupling. The maximum allowable wear is 0.05 mm
(0.002 in). Wear in the shaft seal area indicates
2. Where cutout is moderate, 0.13 mm (0.005 in) or oil contamination. Wear or damage to splines will
less, the gear housing is in good condition and may necessitate replacement.
be reused.
3. Gears which exhibit any scoring on the gear hub
should be replaced. Any scoring, grooving, or burring
T803324,00009FB -19-18SEP07-1/6
5. Thrust plates (6) seal the gear sections at the sides of

the gears. Wear here will allow internal slippage and
oil bypass within the pump. A maximum of 0.05 mm
(0.002 in) wear is allowable. Replace thrust plates if
they are scored, eroded or pitted.
CM073510103 —UN—06MAR08
6. Check the center of the thrust plates (6) where the
gears mesh. Erosion here indicates oil contamination.
Pitted thrust plates indicate cavitation or oil aeration.
Discolored thrust plates indicate overheating, probably
due to insufficient oil.
Continued on next page T803324,00009FB -19-18SEP07-2/6
102711
PN=219
Multiple Gear Pump
7. Dowel pins (9) must be replaced if either the dowel or

dowel hole is damaged. If there is damage, the dowel
or machined housing or both must be replaced. If more
than reasonable force is required to seat dowel pins the
cause may be poorly deburred or dirty parts, cocking
CM073510104 —UN—06MAR08
of the dowel pin in the hole, or improper pin to hole fit.
T803324,00009FB -19-18SEP07-3/6
8. Bushings (4) and (30) must be replaced if gears are

replaced. Bushings should fit into the bore with a
heavy press fit.
CM073510105 —UN—06MAR08
T803324,00009FB -19-18SEP07-4/6
9. All sealing parts: lip seal (1), channel seals (5), and
square seals (8) and (28) must be replaced. See
John Deere Parts Catalog for complete seal kit part
numbers.
CM073510106 —UN—06MAR08
Continued on next page T803324,00009FB -19-18SEP07-5/6
102711
PN=220
Multiple Gear Pump
10. Examine check assembly (3) located in front cover

(2). Ensure that it is in the proper position and tightly
seated.
CM073510107 —UN—06MAR08
T803324,00009FB -19-18SEP07-6/6
Assembly
1. Rub a medium grit carborundum stone over the
machined surfaces. If bushings (4) or (3) were
removed or a new section is used, debur the bores with
CM073510108 —UN—06MAR08
a fine emery cloth. Wash in a solvent, blow dry with air
and wipe with a clean lintless cloth before assembly.
2. Place front cover (2), mounting face downward, in a
vise.
3. Any bushings (4) or (30) removed from front cover (2),
housing (11), housing (15), housing (14), housing (22)
and housing (16) should be assembled in the drive
bores (bores in which the gear shafts and connector
shafts pass through) with the bushing groove facing
toward the top of the pump (12 o’clock). Assemble the 5. Repeat step 1.
bushings in the drive bores (bores which do not house
the connector shafts) with the bushing groove facing 6. After installing the bushings in all housings, ensure
toward the bottom of the pump (6 o’clock). that the dowel pins are in place in any new housing.
Examine all dowel pins and before inserting, make
4. Bushings should be pressed into the bores, one at certain the hole is clean and free from burrs. Gently
a time using installation tool (0290244461) and an start pin (9) straight into the hole and tap lightly with
arbor press. Be sure the grooves are positioned, as a soft hammer.
specified in step 3. Bushings must be pressed into the
bores flush with the housing face. Be sure to support
the housings so they are square and level.
T803324,00009FC -19-18SEP07-1/33
7. Before inserting a new lip seal (1) into front cover (2),
coat the outer edge and its recess with non hardening
gasket sealant. With the mental side of the lip facing
upward and the spring facing toward the gear, press it
into the mounting flange side of the front cover with an
CM073510109 —UN—06MAR08
arbor press and seal installer (0290244684). Be careful

not to damage the lip of the seal. Press inward until
flush with the recess and wipe off any excess sealant.
Continued on next page T803324,00009FC -19-18SEP07-2/33
102711
PN=221
Multiple Gear Pump
CM073510110 —UN—06MAR08
8. Lubricate O-rings (8) with O-ring lube (0841304202)
and install into the grooves, located on both sides, of
all gear housings.
T803324,00009FC -19-18SEP07-3/33
9. Position gear housing (38) over the front cover (2)

and dowel pin (9). Tap it with a soft hammer until it
rests tightly against the cover. Be sure that the large
rounded area is located on the inlet side.
CM073510111 —UN—24MAR08
T803324,00009FC -19-18SEP07-4/33
10. Install channel seal (5) into the grooves located in

thrust plate (6). The flat side of the seal must face
away from the thrust plate.
CM073510112 —UN—06MAR08
102711
PN=222
Multiple Gear Pump
11. Carefully slip the thrust plate (6) through gear housing
(38) and into place onto the shaft end cover (2). The
channel seal (5) from step 10 should face shaft end
cover (2). The relief groove, located in the thrust plate
(6) should face the outlet side of the pump.
CM073510113 —UN—06MAR08
T803324,00009FC -19-18SEP07-6/33
12. Slide the driven gear from set (7), through the housing
and into the bushing (4) located in the front cover (2).
Coat steel sleeve tool (0290244683) with grease.
Lightly grease drive shaft from set (7) and place inside
CM073510114 —UN—06MAR08
sleeve tool. Slide both the sleeve tool and drive shaft
through the end cover (2) with a twisting motion until
the integral gear rests against the thrust plate (6).
Avoid damaging lip seal (1). Remove the sleeve tool
and squirt system oil over the gears.
CM073510115 —UN—06MAR08
102711
PN=223
Multiple Gear Pump
13. Slip thrust plate (6) with seals over gear journals and
into housing bore. The flat side of the seal should face
upward with the relief groove facing the outlet side.
CM073510116 —UN—06MAR08
T803324,00009FC -19-18SEP07-8/33
14. Position housing (11) over gear housing (38) so

bushing (6) in housing (11) receives the journals of
drive and driven gears (7). Be sure to line up the
dowel holes over the dowel pins. When the parts are
parallel, squeeze them together or alternately tap over
CM073510117 —UN—06MAR08
each dowel until the parts are together.
102711
PN=224
Multiple Gear Pump
15. Insert connecting shaft (12) into the splines of the

drive gear, from set (7).
Position and place gear housing (10) over housing
(11) and dowel pin. Tap it with a soft hammer until it
CM073510118 —UN—06MAR08
rests tightly against the cover. Be careful not to pinch
the seal. Be sure the large round area is located on
the inlet side.
CM073510119 —UN—06MAR08
T803324,00009FC -19-18SEP07-10/33
16. Place thrust plate (6) in gear housing (10) as instructed

in Step 11.
Insert gear assembly (13) into bushings located in
housing (11). Make certain gears are in contact with
CM073510120 —UN—06MAR08
the face of the thrust plate (6).
CM073510121 —UN—06MAR08
102711
PN=225
Multiple Gear Pump
17. Slip thrust plate (6) with seal over gear journal (13)
and into gear housing (10).
CM073510122 —UN—06MAR08
T803324,00009FC -19-18SEP07-12/33
18. Position housing (15) over gear housing (10) so the

bushings receive the journals of the drive and driven
gears (13). Be sure to line up the dowel holes over
the dowel pins. When the parts are parallel, squeeze
them together or alternately tap over each dowel until
CM073510123 —UN—06MAR08
the parts are seated together.
T803324,00009FC -19-18SEP07-13/33

CM073510124 —UN—06MAR08
102711
PN=226
Multiple Gear Pump
20. Position and place gear housing (36) over housing

rests tightly against the housing (15). Be careful not to
pinch the seal. Be sure the large round area is located
on the inlet side.
CM073510125 —UN—06MAR08
T803324,00009FC -19-18SEP07-15/33
21. Place thrust plate (6) in gear housing (36) as instructed

in Step 11.
CM073510126 —UN—06MAR08
T803324,00009FC -19-18SEP07-16/33
22. Insert gear assembly (37) into bushings located in

CM073510127 —UN—06MAR08
102711
PN=227
Multiple Gear Pump
CM073510128 —UN—06MAR08
T803324,00009FC -19-18SEP07-18/33

CM073510129 —UN—06MAR08
T803324,00009FC -19-18SEP07-19/33

CM073510130 —UN—06MAR08
102711
PN=228
Multiple Gear Pump
CM073510131 —UN—06MAR08
26. Replace the four hex nuts (19), washer (17) and studs 27. After the fastener are tight and there is no internal
(18). Thread the four studs (18), washer (17) and hex binding, cross torque the nuts (19) to 272 N·m (250
nut (19) into the front cover (2) and cross tighten. lb-ft).
Rotate the drive shaft with a wrench to make certain
there is no binding in the pump.
102711
PN=229
Multiple Gear Pump

on the inlet side.
CM073510132 —UN—06MAR08
T803324,00009FC -19-18SEP07-22/33
29. Place thrust plate (26) in gear housing (32) as

instructed in Step 11.
CM073510133 —UN—06MAR08
T803324,00009FC -19-18SEP07-23/33

CM073510134 —UN—06MAR08
102711
PN=230
Multiple Gear Pump
CM073510135 —UN—06MAR08
T803324,00009FC -19-18SEP07-25/33

CM073510136 —UN—06MAR08
T803324,00009FC -19-18SEP07-26/33

CM073510137 —UN—06MAR08
102711
PN=231
Multiple Gear Pump

on the inlet side.
CM073510138 —UN—06MAR08
T803324,00009FC -19-18SEP07-28/33
35. Place thrust plate (26) in gear housing (31) as

instructed in Step 11.
CM073510139 —UN—06MAR08
T803324,00009FC -19-18SEP07-29/33

CM073510140 —UN—06MAR08
102711
PN=232
Multiple Gear Pump
CM073510141 —UN—06MAR08
T803324,00009FC -19-18SEP07-31/33
38. Place end cover (16) over the gear journals (20). Align
the dowel pins with the holes in the mating housing.
Be careful not to pinch the seal. Tap the end cover
lightly in the center to engage the dowel pins and to
move the parts together in a final seat.
CM073510142 —UN—06MAR08
T803324,00009FC -19-18SEP07-32/33
39. Replace the four hex nuts (35), washers (23) and studs
(24). Thread the four studs, washers and nuts into
housing and cross tighten. Rotate the drive shaft with a
wrench to make certain there is no binding in the pump.
CM073510143 —UN—06MAR08
40. After all fasteners are tight and there is no internal
binding, cross torque nuts (35) to 272 N·m (250 lb-ft).
T803324,00009FC -19-18SEP07-33/33
102711
PN=233
Multiple Gear Pump
Start-Up Procedure 3. After connecting the hoses and mounting the rebuilt
1. Before installing a new or rebuilt pump, back of pump, operate the pump at least two minutes at no
the main relief valve until the spring tension on load and at low RPM (400 minimum). During this
the adjusting screw is relieved. This will avoid the break-in period, the unit should run free and not
possibility of immediate damage to the replacement develop an excessive amount of heat. If the pump
pump, in the event the relief valve setting has been operates properly, speed and pressure can then be
increased beyond recommended operating pressure, increased to normal operating settings.
prior to removing the old unit. 4. Set the main relief valve to its proper setting while
2. Before connecting any hoses to the pump, fill all ports the pump is running at maximum operating speed for
with clean system oil to provide initial lubrication. the engine.
T803324,0000FA8 -19-17SEP07-1/1
Recommended Test Procedure

8. Delivery should run close to rated performance figures
1. Be sure there is an adequate supply of system oil for which are averaged from testing several pumps. A
the pump, at least one liter (0.26 gallon) of oil for each 5% lower reading may be used as a rate minimum if
L/min (GPM) of pump capacity. new or relatively new parts have been used. When
rebuilding the pump with parts from the original pump
2. If only one section of the tandem pump is being tested, (which, while worn, appear satisfactory for use) a 10%
make sure that all other sections, not being tested to 15% lower reading should be used, depending upon
are adequately supplied with oil. If any of the other the performance expected from the equipment. One's
sections run dry, or if plugs are left in the ports, serious own experience will prove the best guide here.
or permanent damage will result.
9. Many service representatives measure the outlet at
3. The oil should be a good quality hydraulic oil rated at normal operating speed and at zero pressure, then
150 SSU at 38° C (100° F) with the oil temperature again at 69 bar (1000 PSI) (or the operating pressure
held at 46° to 52° C (115° to 125° F). of the equipment) and allow a volume decrease
4. The suction line must be of adequate size with no approximating the list below. It is a suggested
more than 17 kpa (5 inches) of mercury vacuum reference only which makes allowance for reused
adjacent to the pump inlet. As a rule, the feed line parts. At test speeds other than 1800 RPM, L/min
must provide a feed flow velocity not in excess of 2.4 (GPM) delivery will vary almost proportionately, but
meters per second (8 feet per second). the same (drop off) figures should be used.
100 PSI 1000 PSI 2000 PSI 3000 PSI
5. Feeding hot oil into a cold pump may cause the pump
to seize. Jog the pump by momentarily starting the 10 — 30 GPM 1-1/2 — 3 GPM 2 — 3-1/2 GPM 2-1/2 — 4 GPM
driving engine to gradually equalize pump and oil 30 — 50 GPM 2 — 3 GPM 2-1/2 — 4 GPM 3 — 4-1/2 GPM
temperatures. 50 — 70 GPM 2-1/2 — 3-1/2 3 — 5 GPM 3-1/2 — 5-1/2
GPM GPM
6. Run the pump at least two minutes at no load and
moderate speed (not over 1500 RPM). If the pump 6.9 Bar 69 Bar 138 Bar 207 Bar
becomes excessively hot, shut down immediately and 38 — 113.6 L 5.7 — 11.4 L 7.6 — 13 L 9.5 — 15 L
locate the problem. 113.6 — 189 L 7.6 — 11.4 L 9.5 — 15.1 L 11.4 — 17 L
7. Gradually increase pressure on the pump in 34 bar 189 — 265 L 9.5 — 13.2 L 11.4 — 18.9 L 13.2 — 20.8 L
(500 PSI) increments until desired test pressure has
been reached. This should take about five minutes.
T803324,0000FA9 -19-18SEP07-1/1
102711
PN=234
Group 10B
Piston Pump
Piston Pump Repair
CM073510144 —UN—23AUG07
Continued on next page T803324,0000FAA -19-06SEP07-1/2
TM100419 (27OCT11) 70-10B-1 3520 and 3522 Sugar Cane Harvester Repair
102711
PN=235
Piston Pump
1— Pressure Relief Valve 11— O-ring 21— Lever 31— Kit

2— Cylindrical Roller Bearing 12— Control 22— Round Retainer 32— O-ring
3— Pin 13— O-ring 23— Shim 33— O-ring
4— Plug 14— Coupling 24— Gasket Kit 34— O-ring
5— Plug 15— Valve 25— Nut 35— Piston
6— Plug 16— O-ring 26— O-ring 36— O-ring
7— Filter 17— Link 27— Bolt 37— Ring
8— Plate 18— Dowel Pin 28— Pressure Relief Valve 38— Sway Block
9— Swash Plate 19— Spring 29— Spring 39— Orifice
10— Cylinder Block 20— Cover 30— O-ring
T803324,0000FAA -19-06SEP07-2/2
Suggested Tools and Supplies • 5 mm Allen wrench

• Large flat screwdriver
• 1-1/16” wrench • Continuity Tester
• 1-1/8” wrenches (2) • (2) Pressure Gauges - 50 bar (600 PSI)
• 1-1/4” wrench • (2) Pressure Gauges - 700 bar (10,000 PSI)
• 10 mm wrench • O-ring lube
• 13 mm wrench
• 4 mm Allen wrench
T803324,0000FAC -19-06SEP07-1/1
General Repair Instructions

Protect all exposed sealing surfaces and open cavities
Cleanliness is a primary means of insuring satisfactory from damage and foreign material.
service life, on either new or repaired pumps. Cleaning
parts with a clean solvent wash and air drying is sufficient. John Deere recommends that all gaskets and O-rings be
The internal components must be kept free of foreign replaced when making a repair. All gasket sealing surfaces
materials and chemicals. must be cleaned prior to installation. Lightly lubricate all
O-rings with O-ring lube (0841304202) prior to assembly.
T803324,0000FAD -19-06SEP07-1/1
Orifice Check Valve Replacement

1. Thoroughly clean external surfaces prior to removal of
the old displacement control.
CM002500137 —UN—07MAR08
2. Using a 5 mm hex (Allen) wrench, remove the six bolts
and lift control from the pump housing.
3. Protect exposed surfaces and cavities on the pump
housing from damage and foreign material.
4. The orifice check valve is located at the surface of the
pump housing face, in control assembly (4). Remove
spring retainer (1) and spring (2) from the valve cavity
and then remove orifice check valve (3).
5. Install a new orifice check valve in the cavity. Install 1— Spring Retainer 3— Orifice Check Valve
the spring and spring retainer to hold the orifice check 2— Spring 4— Control Assembly
valve in position.
6. Install the control on the pump as described above.
T803324,000075B -19-17SEP07-1/1
102711
PN=236
Piston Pump
Charge Pressure Relief Valve Replacement

1. Before removing the screw adjustable relief valve
plug, mark the plug, locknut, and housing so as to
approximately maintain the original adjustment when
CM053510146 —UN—07MAR08
assembling.
2. Remove the screw adjustable charge relief valve plug.
Loosen the locknut with a 1-1/16” wrench and unscrew
the plug with a large screwdriver.
3. Remove the spring and the relief valve poppet.
4. Inspect the poppet and mating seat in the end cap for
damage or foreign material.
5. Install the poppet and spring. A—Alignment Marks
6. Install an O-ring on the plug assembly.
7. Install the plug and torque to 68 N·m (50 lb-ft).
9. Check the charge pressure and adjust, if necessary.
8. Install the plug with its locknut, aligning the marks
made at disassembly, and torque the locknut 52 N·m
(38 lb-ft).
T803324,000075C -19-06SEP07-1/1
Shaft Seal Replacement

NOTE: Refer to pump breakdown in the beginning
of this section.
CM073510148 —UN—07MAR08
1. Using a 5 mm hex (Allen ) wrench, remove bolts (69),
which hold the retainer plate (68).
T803324,0000FAF -19-19SEP07-1/6
2. The seal carrier (65) should move out of the bore by

approximately 6 mm (1/4”) an outward spring force
on the shaft will tend to overcome the fiction from the
O-ring on the retainer plate’s outer diameter. If the
seal carrier does not move from its bore upon removal
of the bolts, pry it from its bore and/or lightly tap the CM073510149 —UN—07MAR08
shaft end with a soft mallet. Do Not remove the shaft

(62). After the seal carrier is removed, the shaft is free
and can fall out of the pump.
Continued on next page T803324,0000FAF -19-19SEP07-2/6
102711
PN=237
Piston Pump
3. Place the seal carrier (65) and seal in an arbor press

and remove the old seal (66).
CM073510150 —UN—07MAR08
T803324,0000FAF -19-19SEP07-3/6
4. Inspect the seal carrier (65), seal (66) and O-ring (67)
for any damage. Discard seals after inspection and
replace seal carrier (65) if necessary.
5. Using an arbor press, install a new seal in the seal
CM073510151 —UN—07MAR08
carrier. Use caution; do not damage the seal.
6. Inspect the sealing area on the shaft (62) for rust,
wear or contamination.
7. Wrap the splined end of shaft (62) with either plastic
film or tape to prevent damage to the seal’s sealing
lip during installation.
8. Prior to assembly, lubricate the outer diameter of the
seal carrier (65) and the inner diameter of the seal
with O-ring lube or petroleum jelly.
T803324,0000FAF -19-19SEP07-4/6
9. Install the seal carrier (65) and seal over the shaft and
into the seal carrier cavity.
CM073510152 —UN—07MAR08
Continued on next page T803324,0000FAF -19-19SEP07-5/6
102711
PN=238
Piston Pump
10. Install the retainer plate (68) and bolts (69) and torque
the bolts to 9.5 N·m (7 lb-ft).
CM073510153 —UN—07MAR08
T803324,0000FAF -19-19SEP07-6/6
Multifunction Valve Cartridge Replacement

(2 per pump)
1. Use a 1-1/4” wrench to remove the valve cartridge (28).
CM073510154 —UN—07MAR08
T803324,0000FB0 -19-06SEP07-1/2
2. Inspect the cartridge for damage and discard seals (30)

and (61). Replace the seals and any damaged parts.
3. Install the cartridge into the multifunction valve cavity
and torque to 89 N·m (66 lb-ft).
CM073510155 —UN—23AUG07
T803324,0000FB0 -19-06SEP07-2/2
102711
PN=239
Piston Pump
Charge Pump Disassembly

1. Remove four bolts (15) holding auxiliary mounting pad
(13) to end cap (1). Remove the auxiliary mounting
pad.
2. Using a 10 mm wrench, remove six bolts (11) holding
charge pump cover retainer (10).
3. Remove charge pump cover (9), bushing (8), shaft (4),
the gerotor (6), the pin (5) and the key (3).
NOTE: Note location of pin(s).
4. Inspect the valve plate gerotor assembly, the shaft
CM002500139 —UN—17MAY00
spline and bearings for abnormal wear, damage or
foreign material. Replace, if necessary.
T803324,000075F -19-19SEP07-1/1
102711
PN=240
Group 20A
Steering Cylinder
Repair Steering Cylinder
CM073510003 —UN—26MAR08
1— Ball Joint Tie Rod 5— Backup Seal 9— O-ring 13— Nut

2— Seal 6— O-ring 10— Piston 14— Barrel
3— Square Wire Wrap 7— End Cap 11— Seal 15— Jam Nut
4— Seal 8— Rod 12— Wear Ring 16— Ball Joint
Continued on next page T803324,0000A11 -19-13AUG07-1/11
102711
PN=241
Steering Cylinder
1. Remove the cylinder from the harvester.

T803324,0000A11 -19-13AUG07-2/11
2. Loosen cap screw (A) and remove tie rod end (B).
A—Cap Screw B—Tie Rod End
N61178 —UN—06NOV02
T803324,0000A11 -19-13AUG07-3/11
3. Using a suitable spanner wrench, turn the end cap (B)

counterclockwise to force the square wrap wire (A) out
of the cylinder. Continue to turn the end cap until the
square wrap wire comes completely out of the barrel.
4. Pull the rod with end cap and piston out of the barrel.
N61179 —UN—06NOV02
A—Square Wrap Wire B—End Cap
T803324,0000A11 -19-13AUG07-4/11
CM073510004 —UN—03AUG07
A—Rod C—Piston E—End Cap

B—O-ring D—Lock Nut
5. Remove lock nut (D), piston (C), O-ring (B) and end
cap (E) from rod (A).
102711
PN=242
Steering Cylinder
6. Remove wiper seal (B) and O-ring with back-up ring

from end cap.
N61182 —UN—06NOV02
T803324,0000A11 -19-13AUG07-6/11
7. Remove T-seal (C) and wear ring (D) from piston.
N61185 —UN—06NOV02
T803324,0000A11 -19-13AUG07-7/11
8. Inspect cylinder barrel (A) for wear or damage and

replace as needed.
9. Replace all seals and O-rings.
10. Install the end cap to the rod.
11. Position the O-ring and piston on the rod.
N61186 —UN—06NOV02
12. Apply a bead of T43513 Thread Lock and Sealer (High
Strength) to threads of piston end of the cylinder rod.
102711
PN=243
Steering Cylinder
13. Tighten piston retaining nut (A) to specifications.

Specification
Piston Retaining
Nut—Torque.............................................176 - 196 N·m (130 - 145 lb-ft)
14. Screw the female ball joint end onto the cylinder rod
until threads are fully engaged.
N61187 —UN—06NOV02
15. Install the cylinder onto the harvester and bleed the
steering system.
16. Check the toe end.
T803324,0000A11 -19-13AUG07-9/11
a. Level the harvester and position both wheels

straight. This can be checked by obtaining the
same measurement from the front (B) and rear
(A) centerline of the tire to the side wall (D) of the
harvester.
CM073510005 —UN—03AUG07
102711
PN=244
Steering Cylinder
CM053510261 —UN—09AUG05
b. Disconnect the two hydraulic hoses (A) going to the e. Tighten the nut (B) and reconnect the hoses (A).
steering cylinder.
f. Repeat the same procedure to the other front wheel.
c. Loosen nut (B).
d. Turn the complete cylinder assembly (C) clockwise
until you have moved the front of the tire 1/8” inward.
T803324,0000A11 -19-13AUG07-11/11
102711
PN=245
Steering Cylinder
102711
PN=246
Group 20B
Crop Divider Cylinder
Repair Crop Divider Lift Cylinder
CM073510006 —UN—26MAR08
1— Cylinder Rod 5— Nut 9— Seal 13— Seal

2— Barrel 6— Thrust Washer 10— O-ring 14— Wear Ring
3— Piston 7— Grease Fitting 11— O-ring 15— Seal
4— Cylinder Head 8— Bushing 12— O-ring 16— Seal
Continued on next page T803324,0000A12 -19-06SEP07-1/10
102711
PN=247

CAUTION: Before removing the cylinder from the
harvester for repair, relieve the hydraulic pressure.
T803324,0000A12 -19-06SEP07-2/10
2. Using a suitable spanner wrench, turn the cylinder

head (4) counterclockwise until the threads on the head
separates from the internal threads in the barrel (2).
2— Barrel 4— Cylinder Head
CM073510007 —UN—19MAR08
T803324,0000A12 -19-06SEP07-3/10
3. Pull on the rod (1) with head (4), piston (3), washer (6)
and nut (5) from the barrel (2).
4. Remove nut (5), washer (6), head (3) and head (4)
from the rod (1). Inspect these components for wear
CM073510008 —UN—19MAR08
or damage. Replace if necessary.
T803324,0000A12 -19-06SEP07-4/10
5. Inspect the inside of the cylinder barrel (2) for wear or

damage and replace as needed.
CM073510009 —UN—19MAR08
102711
PN=248
6. Replace the seals and lightly coat the new seals with
clean filtered oil. Oil on the seal will ease assembly
and prevent seal damage.
CM073510010 —UN—19MAR08
T803324,0000A12 -19-06SEP07-6/10
7. Carefully push the head (4) onto the rod (1). A soft
mallet may be used to gently tap the head onto the
rod. Take care not to damage the internal seals.
CM073510011 —UN—19MAR08
T803324,0000A12 -19-06SEP07-7/10
NOTE: Loctite will not be fully cured for 24 hours.
8. Install the piston (3) onto the rod (1). Apply Loctite 271
to the threads on the rod. Install the thrust washer (6)
and nut (5) to the rod (1). Tighten the nut by hand until
CM073510012 —UN—19MAR08
finger tight, then torque to 176- 196 N·m (130 – 145

lb-ft). Allow the Loctite to fully cure before applying
oil pressure.
102711
PN=249
9. Apply a film of oil to the inside of the barrel (2) near

the opening to ease the assembly. Line up the barrel
(2) and the rod (1) centerlines and push the rod (1)
assembly into the barrel (2). Be careful not to damage
the seal.
CM073510013 —UN—19MAR08
T803324,0000A12 -19-06SEP07-9/10
10. Push the head (4) into the tube until it stops. Push
the rod assembly fully into the barrel to assure the
cylinder is fully retracted.
11. Using a suitable spanner, tighten the head into the
CM073510014 —UN—19MAR08
barrel.
NOTE: Be sure to start with the cylinder in the retracted
position and extend the cylinder first to prevent
fluid dieseling with large volume of air on the
retract side of the cylinder. Make sure the cylinder
cycles freely in both directions.
12. Test the cylinder once assembly is complete.

• All cylinder testing should be conducted with oil of
minimum level of cleanliness of ISO 18/15. • Open the butt end port on the cylinder. Pressurize
• Cycle the cylinder at 200 PSI two or three times to the rod end of the cylinder. Watch for fluid running
fill it with oil and remove any trapped air. out of the butt end port. If the fluid continues to
• Change test stand pressure to 2500 PSI. stream out for more than a few seconds, the piston
• Fully extend the cylinder and pressurize to full seal was damaged during assembly and will need
pressure for 60 seconds. Check for external leaks. to be replaced.
T803324,0000A12 -19-06SEP07-10/10
102711
PN=250
Group 20C
Crop Divider Tilt Cylinder
Repair Crop Divider Tilt Cylinder
CM073510651 —UN—15OCT07
1— Tube 7— Spherical Roller Bearing 13— O-ring 19— Back-Up Ring
2— Hydraulic Cylinder Rod 8— Lubrication Fitting 14— Back-Up Ring 20— O-ring
3— Cylinder Head 9— Bushing 15— O-ring 21— Wear Ring
4— Piston 10— Ring 16— Wear Ring
5— Nut 11— Seal 17— Back-Up Ring
6— Washer 12— Seal 18— O-ring
T803324,000107F -19-15OCT07-1/1
Tilt Cylinder Disassembly

NOTE: All disassembly and reassembly of hydraulic
components should be done in a clean, well lit
environment. Any contamination can seriously
CM073510652 —UN—15OCT07
deteriorate seals and component life of not
only the hydraulic cylinder, but also the other
hydraulic system components.
1. Remove all dirt and grease from the cylinder.

Especially take care to clean the ports, cylinder rod
and near the head end of the tube.
2. Orient the cylinder with the ports down to drain the
oil from the cylinder.
3. Secure the cylinder in a vise or other acceptable
holding device. Use care not to damage the tube.
Clamp the end mount if possible.
TM100419 (27OCT11) 70-20C-1 3520 and 3522 Sugar Cane Harvester Repair
102711
PN=251
4. Using an adjustable face pin spanner wrench, unscrew

the cylinder head (3)
CM073510653 —UN—19MAR08
T803324,0001080 -19-15OCT07-2/6
IMPORTANT: Protect the finish on the rod at all times.

Damage to the surface of the rod can cause
premature seal failure. Do not use pneumatic or
hydraulic pressure to remove rod assembly.
CM073510654 —UN—19MAR08
5. Slide the rod assembly from the cylinder using care
not to damage the outside of the rod (2) or the cylinder
piston (4). Dragging the piston (4) across the threads
on the inside of the tube (1) will score the piston (4).
T803324,0001080 -19-15OCT07-3/6
6. Fasten rod (2) end mount in a vise and use a padded

support below the rod to prevent damage to the rod.
CM073510655 —UN—19MAR08
102711
PN=252
7. Remove the locknut (5) that is retaining the piston (4).

It may be necessary to apply heat to break the sealant
bound between the bolt and rod (2). Wipe off any
hydraulic oil. The heat should be applied uniformly
to a temperature of 300° to 400° F. Take care not to
CM073510656 —UN—19MAR08
overheat the parts or the parts may become distorted
or damaged. The sealant often leaves a white powdery
residue on the threads, which must be removed by
brushing with a soft wire brush prior to reassembly.
T803324,0001080 -19-15OCT07-5/6
8. Slide the piston (4) and cylinder head (3) off the rod
(2). Note the orientation of all seals before removing
and discarding all seals. Take care when removing
the seals to not scratch the grooves. DO NOT
attempt to salvage used cylinder seals. Always use
CM073510657 —UN—19MAR08
a new, complete seal kit when rebuilding hydraulic
components.
T803324,0001080 -19-15OCT07-6/6
Cleaning and Inspection

1. Inspect all load bearing welds for signs of fatigue or
cracks. Replace weldments where necessary.
CM073510658 —UN—19MAR08
2. Thoroughly clean all components. All contaminates
must be removed to assure proper operation of the
cylinder.
3. Inspect the cylinder head (3) and piston (4) for damage.
4. Replace all seals with a new seal kit. Care should be
taken not to damage seals during assembly of seals.
Do not over stretch seals, wipers or O-rings. After
installing the seals, verify that they are not twisted in
their grooves.
5. Inspect tube barrel (1) bore for scratches or scoring. 6. Inspect cylinder rod for scratches or dents. If large
Small tube scratches may be removed with a honing scratches or dents are found, the rod should be
stone or emery cloth of very fine grit. Large scratches replaced. Clean rod after repair with a clean, filtered
or scoring should not be repaired and the tube should solvent.
be replaced. Clean the tube after repair with clean,
filtered solvent.
T803324,0001081 -19-15OCT07-1/1
102711
PN=253
Tilt Cylinder Assembly

1. Coat the outside of the piston (4) and both the inside
and outside of the cylinder head (3) with a thin layer of
clean filtered hydraulic oil. Oil on the seal surface will
CM073510658 —UN—19MAR08
ease assembly and prevent seal damage.
T803324,0001082 -19-15OCT07-1/5
2. Carefully push the cylinder head (3) onto the rod (2).
A soft mallet may be used to gently tab the cylinder
head (3) onto the rod (2). Take care not to damage
internal cylinder head seals.
CM073510659 —UN—19MAR08
T803324,0001082 -19-15OCT07-2/5
3. Install the piston (4) onto the rod (2). Apply Loctite
271 thread locker to the rod threads. Install washer
(6) and locknut (5) onto rod (2) and torque to 338.9 -
372.8 N·m (250-275 lb-ft) allow thread locker to fully
cure before applying oil pressure.
CM073510660 —UN—19MAR08
102711
PN=254
4. Apply a ring of oil to the inside of the tube (1) near the
opening to ease assembly. Line up the tube (1) and
rod (2) centerlines and push rod assembly into tube
(1). Be careful not to damage the piston seals on the
tube threads.
CM073510661 —UN—19MAR08
T803324,0001082 -19-15OCT07-4/5
5. Push the cylinder head (3) into the tube (1). Using
an adjustable face pin spanner wrench, screw the
cylinder head (3) into the tube and torque to 338.9 -
406.7 N·m (250-300 lb-ft)
CM073510662 —UN—19MAR08
T803324,0001082 -19-15OCT07-5/5
Testing 5. Fully retract cylinder and pressurize to full pressure for

1. All cylinder testing should be conducted with oil of sixty seconds. Wipe the cylinder head seal. Check
minimum level of cleanliness of ISO 18/15. for external leakage.
2. Cycle cylinder at 200 PSI two or three times to fill it 6. Open the base end port. Fully pressurize the rod end
with oil and remove any trapped air. of the cylinder. Watch for fluid running out of the base
end port. If the fluid continues to stream out for more
IMPORTANT: Be sure to start with the cylinder in the than a few seconds, the piston seal was damaged
retract position and extend the cylinder first, during assembly and will need to be replaced.
to prevent fluid dieseling with large volume of
air on the retract side of the cylinder. 7. Plug cylinder ports to prevent contamination.
3. Change test stand pressure to 2500 PSI.

4. Fully extend cylinder and pressurize to full pressure
for sixty seconds. Check for external leakage.
T803324,0001083 -19-15OCT07-1/1
102711
PN=255
102711
PN=256
Group 20D
Topper Cylinder
Repair Topper Cylinder
CM073510015 —UN—03AUG07
1— Hydraulic Cylinder Kit 3— Wear Ring 5— Seal 7— Hydraulic Cylinder Barrel
2— Snap Ring 4— Seal 6— Seal 8— Hydraulic Cylinder Rod
1. Remove the cylinder from the harvester. 2. Remove any paint and rust from the rod with fine
emery cloth.
TM100419 (27OCT11) 70-20D-1 3520 and 3522 Sugar Cane Harvester Repair
102711
PN=257
Topper Cylinder
3. Remove the fitting from the port (A) on the cylinder.

Slide the piston rod until the snap ring (C) can be seen
through port (A). Use a screwdriver (B) to slide the
snap ring (C) into the groove (D), and then remove the
piston rod from the barrel.
A—Port C—Snap Ring (2)

B—Screwdriver D—Groove
H63611 —UN—14APR00
CM073510016 —UN—03AUG07
T803324,0000A13 -19-06SEP07-2/4
4. Once the rod is removed from the barrel, remove and

replace the snap ring and seals.
5. Coat the seals with light oil and insert the piston rod
assembly into the barrel, taking extra precaution not to
CM073510017 —UN—19MAR08
damage the seals during assembly.
2— Snap Ring 5— Seal

3— Wear Ring 6— Seal
4— Seal
102711
PN=258
Topper Cylinder
6. Slide the rod into the cylinder until the snap ring can
be seen through port (A). Use a screwdriver to slide
the new snap ring from out of the groove to its original
position.
7. Check the cylinder for leaks.
A—Port C—Snap Ring (2)

B—Screwdriver D—Groove
H63611 —UN—14APR00
CM073510016 —UN—03AUG07
T803324,0000A13 -19-06SEP07-4/4
102711
PN=259
Topper Cylinder
102711
PN=260
Group 20E
Basecutter Cylinder
Repair Basecutter Lift Cylinder (Wheel)
CM11475579A1 —UN—06MAR08
1— Hydraulic Cylinder Barrel 6— Hydraulic Cylinder Rod 11— Bolt 16— Seal
2— Nut 7— Stop 12— V-Ring Seal 17— O-ring
3— Washer 8— Hydraulic Cylinder Cap 13— Back-Up Ring 18— Fitting
4— Seal 9— Ring 14— O-ring 19— O-ring
5— Piston 10— Washer 15— Wear Ring
TM100419 (27OCT11) 70-20E-1 3520 and 3522 Sugar Cane Harvester Repair
102711
PN=261
Basecutter Cylinder
CAUTION: Before removing cylinder for repair, 3. Place the cylinder in a vise and tighten securely. DO
block up machine and relieve all system pressure. NOT over tighten, since it is possible to distort the
cylinder barrel enough to cause damage.
2. A clean cylinder is easier to work on; therefore, plug
the cylinder ports and clean the exterior with solvent
or pressurized spray.
T803324,0000A14 -19-17SEP07-2/5
4. Remove the four bolts (11) and washers (10) from the
cap (8) and barrel assembly (1).
NOTE: Residual oil on the retract side of the piston may be
forced out of the retract port when the rod is pulled
CM073510018 —UN—19MAR08
from the barrel. It is a good idea to point the port
away from oneself and to cover it loosely with a cloth.
5. Very carefully, pull the rod assembly (6) along with

cylinder cap (8) and piston (5), from the cylinder barrel
(1).
T803324,0000A14 -19-17SEP07-3/5
6. Piston (5) is retained by nut (2). Remove the nut; it

may be necessary to apply heat in order to remove the
nut, since Loctite was used during installation.
CM073510020 —UN—19MAR08
T803324,0000A14 -19-17SEP07-4/5
7. Remove piston (5), stop tube (7) and cylinder cap (8)
with gentle blows from a plastic or hard rubber hammer.
CM073510021 —UN—19MAR08
T803324,0000A14 -19-17SEP07-5/5
102711
PN=262
Basecutter Cylinder
Suggested Tools
4. Loctite 271 — 0841303174
1. Vise
5. Anti-seize Compound — 0841305658
2. Spanner Wrench — 0840030555
3. Non-Flammable Solvent
T803324,0000842 -19-14SEP07-1/1
Clean and Inspect the edges of seal grooves to check for dents and burrs.
These may be repaired with light filing and polishing.
CAUTION: Do Not use a flammable solvent to clean 4. Clean all cylinder parts thoroughly with solvent before
cylinder parts. An explosion may occur inside repacking and reassembly. Inspect the barrel with
the cylinder, at the moment of pressurization, a flashlight for scratches or extreme wear. Light
if just a tiny drop of any flammable solvent is scratches can be removed with 600 grit sandpaper
trapped inside of a confined cylinder area. dampened in oil. Other barrel defects will require
replacement for optimum seal life. Check ports for
1. Examine all seals for abnormal wear. Note any accumulations of heavy dirt deposits.
abnormal wear and keep seals for possible evaluation
by cylinder troubleshooter. DO NOT REUSE SEALS. 5. Clean the rod assembly and examine surfaces
for dents or scratches. Examine the pin bore for
2. If possible, note how the old seals are installed in their wear. Replace bushing, if necessary. Clean threads
grooves. Make a sketch if necessary. Improperly thoroughly. Use a wire brush and Loctite Primer-N
oriented seals will leak immediately. (0841303194) to clean the male threads. Clean
3. Remove old seals by using soft metal tools to avoid threads of nut (6) and inspect for damage. Check the
damaging the sealing surfaces of the cylinder cap (8) fit of nut on male rod threads by screwing nut (6) on by
and piston (5). Inspect the piston and cylinder cap for hand for full engagement.
wear and damage. Carefully run your finger around
T803324,0000A15 -19-06SEP07-1/1
Basecutter Lift Cylinder Reassembly

1. Ensure parts are thoroughly clean before repacking
and reassembly.
CM073510022 —UN—19MAR08
2. Check that all seals widths, lengths and diameters
are the same as the old ones. Use cylinder assembly
drawings or disassembly notes as a guide to orient
new seals into their proper grooves.
3. Coat all seals with a thin coat of hydraulic oil or O-ring
lube (0841304202) before installing them into their
grooves. Use soft metal tools to stretch and install
seals. Tools must not have sharp edges or burrs.
4. Install wiper seal (4) into the eye end of the cylinder
cap (8). If required, use a small rubber or plastic
hammer to seat the seal.
102711
PN=263
Basecutter Cylinder
5. Install U-cup seal (12) with the flat part towards the
butt end of the cylinder, into cylinder cap (8). If
required, use a small rubber hammer to seat the seal.
CM073510023 —UN—19MAR08
T803324,0000A16 -19-06SEP07-2/14
6. Install back-up ring (13) on the cylinder cap (8).
CM073510024 —UN—19MAR08
T803324,0000A16 -19-06SEP07-3/14
7. Install O-ring (14) on cylinder cap (8). Apply a light

coat of O-ring lube (084134202) to help the installation.
CM073510025 —UN—19MAR08
102711
PN=264
Basecutter Cylinder
8. Install wear ring (15) onto the eye of the piston (5).
CM073510026 —UN—19MAR08
T803324,0000A16 -19-06SEP07-5/14
9. Install expander ring (9) onto piston (5).
CM073510027 —UN—19MAR08
T803324,0000A16 -19-06SEP07-6/14
10. Install seal (16) on the butt end of piston (5). Apply a
light coat of O-ring lube to aid installation.
CM073510028 —UN—19MAR08
102711
PN=265
Basecutter Cylinder
11. Install O-ring (19) into the inner groove of piston (5).
CM073510029 —UN—19MAR08
T803324,0000A16 -19-06SEP07-8/14
12. Place the rod eye in a vise. Lubricate rod (6) lead - in
chamfer, as well as the inside of the cylinder cap (8).
Align the cylinder cap (8) on the rod and tap it onto the
rod with a rubber or plastic hammer. Make sure the
cylinder cap slides easily up and down on the rod. (6).
CM073510030 —UN—19MAR08
T803324,0000A16 -19-06SEP07-9/14
13. Slide stop tube (7) onto rod (6).
CM073510031 —UN—19MAR08
102711
PN=266
Basecutter Cylinder
14. Slide piston (5) onto rod (6)
CM073510032 —UN—19MAR08
T803324,0000A16 -19-06SEP07-11/14
15. Install washer (3) over the threaded end of the rod.
16. Wipe any excess oil from the rod threads. Apply
Loctite Primer - N (0841303194) to the external
threads of the rod.
CM073510033 —UN—19MAR08
T803324,0000A16 -19-06SEP07-12/14
17. Install the nut (2) and tighten.

18. Install rod assembly into barrel. Rod assembly must
be installed straight within the barrel. Special care
must be taken not to damage piston seals.
CM073510034 —UN—19MAR08
102711
PN=267
Basecutter Cylinder
19. Install four bolts (11) and washers (10) through

cylinder cap (8) and into barrel assembly (1). Torque
to 156 N·m (115 lb-ft).
20. Install the cylinder on the harvester.
CM073510035 —UN—19MAR08
T803324,0000A16 -19-06SEP07-14/14
102711
PN=268
Group 20F
Elevator Cylinders
Repair Elevator Swing Cylinder
CM073510036 —UN—26MAR08
TM100419 (27OCT11) 70-20F-1 3520 and 3522 Sugar Cane Harvester Repair
102711
PN=269
Elevator Cylinders
1— Hydraulic Cylinder Cap 7— Lubricating Fitting 13— O-ring 19— Seal

2— Ring 8— Nut 14— Back-Up Ring 20— Ring
3— O-ring 9— Ring 15— Seal 21— Nut
4— Hydraulic Cylinder Barrel 10— Piston 16— Seal 22— Hydraulic Cylinder Rod
5— Bushing 11— Wear Ring 17— Hydraulic Cylinder Rod
6— Bushing 12— Seal Guide
18— Wear Ring
T803324,0000A17 -19-06SEP07-2/2
Elevator Swing Cylinder Disassembly
CAUTION: Secure the elevator swing table

before removal of the cylinder.
CM073510037 —UN—19MAR08
1. Extend the rod to remove oil or air between the rod
assembly and the rod guide. An excessive amount of
trapped oil or air will force the seals to expand, making
disassembly difficult.
2. Extend rod assembly (22) until piston (10) is
approximately 25.4 mm (1 in.) from the rod guide (17).
T803324,0000A18 -19-06SEP07-1/11
3. Mark rod guide (17) and nut (21) to aid in later

assembly.
CM073510038 —UN—19MAR08
T803324,0000A18 -19-06SEP07-2/11
4. Remove nut (21) using an adjustable spanner wrench

or a blunt chisel and hammer. If the nut and rod guide
should turn as an assembly, put the cylinder in a
vise. Be sure the vise jaws contact the cylinder barrel
behind the nut and over the rod guide area. Tighten
the vise just enough to hold the rod guide.
T6119AL —UN—19OCT88
102711
PN=270
Elevator Cylinders
NOTE: Filler rings (used for disassembly only) are

installed between the spanner nut (21) and rod
guide (17) to aid in disassembly.
5. Move rod guide rearward, using a wooden dowel or

brass drift, just enough to remove the snap ring (A).
T6119AM —UN—12APR91
Remove snap ring by tipping snap ring inward, always
push the side opposite the gap in the ring. Use care
not to damage rod guide threads or seal.
T803324,0000A18 -19-06SEP07-4/11
NOTE: Rod piston assembly removed for clarity

of photograph
6. Install filler ring in snap ring groove.
T6119AN —UN—19OCT88
T803324,0000A18 -19-06SEP07-5/11
7. Remove rod and piston assembly.
T6223AA1 —UN—11APR90
102711
PN=271
Elevator Cylinders
8. Remove wear ring (11) and cap seals (12) from the
piston (10).
CM073510039 —UN—19MAR08
T803324,0000A18 -19-06SEP07-7/11
9. Inspect the snap ring groove inside the opening of the

barrel. If necessary, clean the groove of nicks or burrs.
T6119AO —UN—19OCT88
T803324,0000A18 -19-06SEP07-8/11
10. Remove rod guide (17) from rod (22).
CM073510040 —UN—19MAR08
102711
PN=272
Elevator Cylinders
11. Remove O-ring (13), back-up ring (14), seal (15), seal
(16), wear ring (18) and seal (19) from rod guide (17).
CM073510041 —UN—19MAR08
T803324,0000A18 -19-06SEP07-10/11
12. Remove cap (1) and remove seal (2) and seal (3).
CM073510042 —UN—19MAR08
T803324,0000A18 -19-06SEP07-11/11
Assemble Elevator Swing Cylinder

Use a cylinder repair kit when assembling repairable
cylinders. Before assembling, apply clean hydraulic oil to
all internal parts.
1. Install wiper seal (19). Push seal to the bottom of the
T6122AA —UN—19OCT88
bore.
102711
PN=273
Elevator Cylinders
2. Install O-rings (13) and (14) to the exterior groove of

the cylinder rod guide (17).
CM073510043 —UN—07AUG07
T803324,0000A19 -19-06SEP07-2/10
3. Install wear ring (18) and seals (16) and (15) into the
grooves in the interior of cylinder rod guide (17).
CM073510044 —UN—07AUG07
102711
PN=274
Elevator Cylinders
4. Install nut (21), snap ring (20), and rod guide assembly
(17) onto cylinder rod.
CM073510045 —UN—19MAR08
T803324,0000A19 -19-06SEP07-4/10
5. Install seals (2) and (3) onto cylinder end cap (1).
Install cylinder end cap into barrel (4) and torque to
375 N·m (275 lb-ft).
CM073510042 —UN—19MAR08
T803324,0000A19 -19-06SEP07-5/10
6. Install the remaining seals on the piston (10).
T6122AF —UN—19OCT88
102711
PN=275
Elevator Cylinders
7. Install piston (10) and nut (8) onto the cylinder rod (22)
and torque the nut to 400 N·m (295 lb-ft).
T6172BP —UN—19OCT88
T803324,0000A19 -19-06SEP07-7/10
8. Apply lubrication on the seals of the piston and the

chamfer of the barrel.
T803324,0000A19 -19-06SEP07-8/10
9. Carefully push the piston (10) and rod guide (17) into
the barrel. Care must be taken to keep the piston and
rod guide together. Push the rod guide (17) into the
barrel just enough to install snap ring (20). Install snap
ring (20).
T6133AE —UN—27OCT88
102711
PN=276
Elevator Cylinders
10. Pull the rod guide (17) against the snap ring (20).
Place the filler ring between the rod guide (17) and
spanner nut (21). Clean the spanner nut (21) and rod
guide threads using clean and curer primer. Apply
thread lock and sealer (medium strength) to threads.
11. Install the spanner nut (21) and tighten nut until the
T6119AR —UN—27OCT88
rod guide and nut marks, made before disassembly,
align. Ensure the nut is tight.
T803324,0000A19 -19-06SEP07-10/10
102711
PN=277
Elevator Cylinders
Repair Elevator Lift Cylinder
CM11472724A4 —UN—14FEB07
1— Cylinder Tube Assembly 5— Expander Ring 9— O-ring 13— Wiper

2— Lock Nut 6— Piston 10— Buffer Seal 14— Locking Collar
3— Wear Ring 7— O-ring 11— Head 15— Cylinder Rod Assembly
4— Seal 8— Set Screw 12— U-Cup Seal
T803324,0000A1A -19-06SEP07-1/1
102711
PN=278
Elevator Cylinders
Elevator Lift Cylinder Disassembly
CAUTION: Secure the elevator and swing table

before removal of the cylinder.
CM073510046 —UN—19MAR08
1. Remove the cylinder from the harvester and drain as
much oil as possible from the cylinder. Plug the fittings
on the hoses and cap the fittings on the cylinder.
2. A clean cylinder is easier to work on. Clean the
exterior with solvent or a pressurized spray.
3. Place the cylinder in a vise and tighten securely.
4. A set screw (8) is used to prevent the cap or gland
(14) from backing off, or out of the cylinder barrel. shoulder of the part, for removal by a specialized
Back the set screw out of its hole two or three turns wrench. If the wrench is not available, a pipe wrench
to unlock the cap or gland. Failure to loosen the set or chain wrench, of appropriate size, can be used to
screw will make disassembly difficult and may even turn the part counterclockwise. Sometimes it may be
cause irreparable damage to the barrel threads. necessary to tap on the outer diameter of the cap with
5. Caps or glands are retained by right – hand threads. a hammer to loosen it.
Spanner wrench holes are drilled into the face, or
T803324,0000A1B -19-06SEP07-1/4
6. Unscrew the cap (14) until it is free of any thread

engagement of the barrel (1).
7. Remove the caps or plugs that were installed on the
cylinder barrel ports.
CM073510047 —UN—19MAR08
Continued on next page T803324,0000A1B -19-06SEP07-2/4
102711
PN=279
Elevator Cylinders
CM073510048 —UN—19MAR08
8. Grab the end of the rod (15), by hand or put a pin point the port away from oneself and to cover with a
through the rod end and pull the rod and internal parts cloth.
out of the barrel. Residual oil on the retract side of the
piston (6) may be forced out of the retract port when 9. Using a socket wrench, remove the lock nut (2) that
the rod is pulled from the barrel (1). It is a good idea to retains the piston (6).
Continued on next page T803324,0000A1B -19-06SEP07-3/4
102711
PN=280
Elevator Cylinders
10. Remove the piston (6) and the cylinder head (11) from
the rod (15), with gentle blows from a dead- blow
hammer.
11. Examine the seals for normal wear. If found, make
CM073510049 —UN—19MAR08
notes as to the location of wear and keep the old seals
for possible evaluation by a cylinder troubleshooter.
12. Note how old seals are installed in their grooves; make
a sketch if necessary. Improper orientated seals will
leak immediately.
13. Remove the old seals. Use soft metal tools to avoid
damaging the sealing surfaces of the cylinder head
(11) or piston (6).
14. Clean all cylinder parts thoroughly with solvent, before Replace the bushing, if necessary. Clean all female
repacking and reassembly. Inspect the barrel, with threads thoroughly, using a wire brush and Loctite
a flashlight for scratches or extreme wear. Light Primer-N (0841303194). The rod locknut should be
scratches can be removed with 600 grit, oil wetted hard to turn on the rod thread, replace the nut if no
sandpaper. Other barrel defects shall necessitate resistance is felt.
replacement for optimum seal life. Check ports for
accumulations of heavy dirt deposits. 17. Inspect the piston and cylinder head for wear and
damage. Carefully run your finger around the edges of
15. Check the critical barrel mouth, lead – in chamfer for all seal grooves to check for dents and burrs. These
burrs. File and sand smooth. may be repaired with light filing and polishing.
16. Clean the rod assembly and examine the surface for
scratches or dents. Examine the pin bore for wear.
T803324,0000A1B -19-06SEP07-4/4
Clean and Inspect 3. Apply a thin coat of system oil, or other similar lubricate
1. Before repacking and reassembly, clean all parts to all seals before installing them into their grooves.
thoroughly. Use soft metal tools to stretch and install seals. Tools
must not have sharp edges or burrs.
2. Compare new seals with old. Check that all new
seal widths, lengths and diameters are the same as 4. All cylinder head seals may be installed by hand,
the old ones. Use the cylinder assembly drawing, or although some specialized tools are available which
disassembly notes, to guide the proper orientation of make the task easier. Double check seal orientations.
new seals into their grooves.
T803324,0000A1C -19-06SEP07-1/1
102711
PN=281
Elevator Cylinders
Piston Seal Installation

1. The piston (6) has two nylon wear rings (3) and bronze
filled Teflon piston ring (5) with an O-ring loader (4).
Begin installation by stretching the O-ring (4) into the
CM073510050 —UN—19MAR08
center groove.
2. Carefully stretch the piston ring (5) onto the first
groove of the piston, keeping the stretching tool
between the ring and the piston. Then carefully walk
the seal over and into the groove, while turning the
piston in your hand. The piston seal is not very flexible
at room temperature; its installation is facilitated by
heating the ring to approximately 93° C (200° F) in
hot water or hot oil bath.
3. After installing the ring (5), it will slowly shrink back to generous lead–in taper). Allow the piston to stay in
size if it has not been overstretched. It can be re-sized the tube for thirty seconds.
by pressing the piston through a sizing tube (a short 4. Snap the nylon wear rings (3) on last.
piece of tubing of the cylinder bore size with a long
T803324,0000A1D -19-14SEP07-1/1
Elevator Lift Cylinder Assembly

1. Place the rod eye into a vise and support the rod
horizontally. Lubricate the rod lead on chamfer, as well
as the cylinder head (11) inner diameter. Install the
CM073510051 —UN—19MAR08
locking collar on the rod, then align the cylinder head
(11) on the rod (15) and bump it onto the rod with a
dead blow hammer.
T803324,0000A1E -19-06SEP07-1/6
2. Locate the piston (6) on the rod.

3. Apply a drop or two of oil to the turndown threads.
Thread the locknut (2) onto the rod threads until a
resistance is felt. Tighten the nut fully with a socket
wrench and torque to 339- 373 N·m (250 – 275 lb-ft). CM073510052 —UN—19MAR08
Check the torque with a torque wrench.
Continued on next page T803324,0000A1E -19-06SEP07-2/6
102711
PN=282
Elevator Cylinders
CM073510053 —UN—19MAR08
4. Place the clean cylinder barrel into a vise. Generously outer diameter and its seals (3), (4), (5) and to the
apply system oil to the barrel’s inner diameter, cylinder head’s outer diameter, O-ring (9) and back-up
especially the lead chamfer. Apply oil to the piston’s ring (10).
T803324,0000A1E -19-06SEP07-3/6
CM073510054 —UN—19MAR08
5. Clamp the barrel assembly (1) vertically or horizontally line and carefully strike the end of the rod eye to drive
in a vise. Align the rod center line with the barrel center the rod into the barrel, at least 12 inches (305 mm).
Continued on next page T803324,0000A1E -19-06SEP07-4/6
102711
PN=283
Elevator Cylinders
CM073510055 —UN—19MAR08
6. Tap the cylinder head into place, taking care not to cut 8. The locking collar for the lift cylinder has coarse ACME
the O-ring or back-up ring. threads and must have extra locking torque applied.
7. Brush anti-seize onto the barrel’s threads. Screw the Strike the spanner wrench approximately five times
locking collar (14) onto the barrel threads, until snug. with a 10 lb. shop hammer. The locking collar needs
Use a spanner wrench to fully tighten the cap (14) only 542 N·m (400 lb-ft) of torque. Use a spanner
against the cylinder head (11). wrench, chain wrench or pipe wrench to torque.
T803324,0000A1E -19-06SEP07-5/6
9. Apply Loctite – PST (0840008762) to the caps set

screw (8) and torque to appropriate value.
10. Assembled cylinders should have the ports plugged
for storage or during transportation to keep out
CM073510046 —UN—19MAR08
contamination.
11. Allow 30 minutes before applying hydraulic pressure
to the cylinder. This allows time for the Loctite to cure.
12. If a hydraulic test stand is available, it is wise to test
the repaired cylinder hydraulically before installing it
on the harvester. Check for external leaks and internal
bypassing. Stroke the cylinder several times at low
pressure to expel any trapped air.
T803324,0000A1E -19-06SEP07-6/6
102711
PN=284
Group 20G
Height Indicator Cylinder
Repair Height Indicator Cylinder
CM073510056 —UN—26MAR08
1— O-ring 2— Seal
1. The basecutter height indicator cylinder is a very their groove in the cylinder barrel, taking care not to
simple cylinder with very few replacement parts. mark or scar the sealing area.
2. Remove the cylinder from the harvester and clean 5. Using a flashlight, inspect the seal grooves for scars
thoroughly. or visual damages.
3. Pull outward on the cylinder rod and it will come 6. Wipe the rod clean and check for scars and pings.
completely out of the barrel. This cylinder has no
fastening device to hold the rod in the barrel.
4. Once the rod has been removed, using a soft tool
instrument remove the seal (2) and O-ring (1) from
T803324,0000A1F -19-14SEP07-1/3
7. Once all the cylinder components have been cleaned,

install O-ring (1) in its proper groove in the barrel. CM073510057 —UN—19MAR08
Continued on next page T803324,0000A1F -19-14SEP07-2/3
TM100419 (27OCT11) 70-20G-1 3520 and 3522 Sugar Cane Harvester Repair
102711
PN=285
Height Indicator Cylinder
8. Install seal (2) in its proper location in the barrel.

9. Lubricate the rod with clean filtered hydraulic oil and
align the center line of the rod with the center line of
the barrel.
CM073510058 —UN—19MAR08
10. Carefully insert the rod into the barrel. Light taps may
be required to get the rod to fully enter.
T803324,0000A1F -19-14SEP07-3/3
102711
PN=286
Group 20H
Cab Tilt Cylinder
Repair Cab Tilt Cylinder
IMPORTANT: Extend rod to remove oil or air between
rod piston and rod guide. Excessive amounts
of trapped oil or air will expand seals and
CM073510059 —UN—19MAR08
make disassembly more difficult.
Clamping cylinder in vise at the middle or
rod end of barrel may damage the barrel.
Clamp only at the cylinder base end unless
otherwise instructed.

2. Clean outside surface of cylinder and dry to prevent
dirt and debris from entering the cylinder barrel (2).
1— Check Valve 10— Seal
3. Open both ports on the cylinder barrel and drain all 2— Cylinder Barrel 11— O-ring
oil from inside the barrel. 3— Bushing 12— Seal
4— Cylinder Rod 13— O-ring
5— Internal Snap Ring 14— Wear Ring
6— External Snap Ring 15— Back-up Ring
7— Cylinder Head 16— O-ring
8— Piston 17— Seal
9— Bolt
T803324,0000A21 -19-17SEP07-1/23
CM073510060 —UN—24MAR08
4. Extend rod (4) fully.

TM100419 (27OCT11) 70-20H-1 3520 and 3522 Sugar Cane Harvester Repair
102711
PN=287
Cab Tilt Cylinder
5. Remove external snap ring (A) using snap ring pliers.
HCD1115 —UN—23JUL03
T803324,0000A21 -19-17SEP07-3/23
CM073510061 —UN—09AUG07
6. Install groove filler in the internal snap ring groove in
the barrel. It is provided in the cylinder barrel or barrel
seal kit.
T803324,0000A21 -19-17SEP07-4/23
7. Remove the rod (4) from the barrel (2).

8. Remove the filler ring from the snap ring groove. It is
not necessary for assembly.
9. Inspect the snap ring groove. If necessary, clean
CM073510062 —UN—19MAR08
groove and inside of barrel. Remove any nicks, burrs
or rust.
102711
PN=288
Cab Tilt Cylinder
10. Remove bolt (9) to remove the piston (7) and cylinder
head (8)
CM073510063 —UN—19MAR08
T803324,0000A21 -19-17SEP07-6/23
11. Remove seal (10) and O-ring (11) from piston (8).
CM073510064 —UN—19MAR08
T803324,0000A21 -19-17SEP07-7/23
IMPORTANT: To prevent damage of cap seal during

assembly, the lands on piston must be clean
and free of nicks or burrs.
12. Inspect the piston lands. If necessary, clean the lands

and remove nicks or burrs that can cut the seal.
102711
PN=289
Cab Tilt Cylinder
NOTE: When removing seals from the cylinder head,

do not damage, mark or scar any surface
that will contact the seal.
13. Remove the cylinder head (7).
CM073510065 —UN—19MAR08
T803324,0000A21 -19-17SEP07-9/23
14. Remove seal (12), O-ring (13), wear ring (14), back-up
ring (15), O-ring (16), and seal (17) from cylinder head
(7).
CM073510066 —UN—19MAR08
T803324,0000A21 -19-17SEP07-10/23
IMPORTANT: All parts must be thoroughly cleaned

and dried prior to reuse.
NOTE: Use a cylinder repair kit(s) when assembling

cylinder. Before assembly, apply a light film of
CM073510067 —UN—19MAR08
clean hydraulic oil to all sealing parts.
15. Install internal seals (12), (14) and (17) into the
cylinder head (7).
102711
PN=290
Cab Tilt Cylinder
16. Install O-ring (13), back-up ring (15) and O-ring (16)
onto the exterior of cylinder head (7).
CM073510068 —UN—19MAR08
T803324,0000A21 -19-17SEP07-12/23
17. Install seal expander O-ring (11) into its groove on the
piston.
NOTE: The cap seal (10) can be made more pliable
by warming it with your hands or put it in hot
CM073510069 —UN—10AUG07
water for approximately 5 minutes.
Once started, install the cap seal (10) as quickly
as possible to keep the amount of time that the
seal is stretched to a minimum.
18. Push the seal onto the piston.
T803324,0000A21 -19-17SEP07-13/23
19. Install a plastic tie wrap around the cap seal (10) with
the smooth side against the seal.
20. Pull the cap seal (10) across the land into position over
the seal expander O-ring (11) using the plastic tie wrap.
CM073510070 —UN—10AUG07
102711
PN=291
Cab Tilt Cylinder
21. Assemble external snap ring (5), internal snap ring

(6), cylinder head (7) and piston assembly (8) onto
rod, as shown.
22. Apply a light coat of T43513 Thread Lock Sealer (High
CM073510071 —UN—10AUG07
Strength) to the male threads on bolt (9). Tighten to
torque specification using the following directions.
T803324,0000A21 -19-17SEP07-15/23
23. Put tape around a socket. Make marks on the tape

to divide that socket in 1/12's. The marks will be 30
degrees apart. These will serve as a handy visual
reference for determining “Degrees Beyond Snug
Torque.”
T6149AG —UN—19OCT88
T803324,0000A21 -19-17SEP07-16/23
24. Tape a piece of wire (A) on rod (B), over the piston
(C), pointing to one of the marks on the socket.
102711
PN=292
Cab Tilt Cylinder
25. Turn the bolt (9) beyond the snug torque, the number
of degrees specified in the appropriate table.
HCD1129 —19—24JUL03
CAP SCREW TORQUE SPECIFICATIONS
Thread Diameter x Pitch Snug Torque Degrees Beyond Snug Torque
1 in. — 14 UNF2A 200 N·m (147 lb-ft) 90°
M30 x 3.5 225 N·m (166 lb-ft) 90°
M30 x 2.0 225 N·m (166 lb-ft) 90°
M30 x 2.0 250 N·m (184 lb-ft) 90°
26. Apply a light film of clean hydraulic oil on seals and

chamfer of the barrel.
T803324,0000A21 -19-17SEP07-18/23
IMPORTANT: To prevent seal damage, the barrel,

piston and rod must be in alignment
during installation.
27. Carefully push piston (A) and cylinder head (B) into
the barrel.
102711
PN=293
Cab Tilt Cylinder
NOTE: There are two types of internal snap ring

installation. In Type 1, the snap ring is
installed separately. In Type 2, the snap ring
is installed with the rod guide.
28. Install Rod Assembly - Type 1
Push cylinder head into the barrel just enough to
install snap ring (A).
29. Install the snap ring. The snap ring must be seated in
the barrel groove. Pull on the rod until the cylinder
head is against the snap ring.
30. Install Rod Assembly - Type 2
Install the snap ring in the deep beveled groove on the
cylinder head.
T803324,0000A21 -19-17SEP07-20/23
31. Compress the internal snap ring in the groove with a

hose clamp (B) or ring compressor until it is almost
flush with the surface of rod guide (C) and the hose
clamp can still slide on the rod.
Insert the rod assembly with piston and cylinder head
(C) into the barrel until the internal snap ring starts
HCD1071 —UN—19NOV01
in the barrel.
32. Remove hose clamp (B) and push the cylinder head
in until the internal snap ring snaps into the groove.
Use care not to push the head further than necessary
to prevent any O-rings from being cut on the port hole
or groove.
33. Pull the rod assembly outward to seat the cylinder
head (C) against the internal snap ring. A—Chamfer C—Rod Guide
B—Hose Clamp
T803324,0000A21 -19-17SEP07-21/23
34. External Flat Snap Ring Assembly

Install external flat snap ring (A) using a snap ring
pliers. HCD1109 —UN—08JUL03
102711
PN=294
Cab Tilt Cylinder
35. External Round Snap Ring Assembly

Install external round snap ring (A) using snap ring
pliers.
36. Check the repaired cylinder for leaks and install it in
its proper location.
T803324,0000A21 -19-17SEP07-23/23
102711
PN=295
Cab Tilt Cylinder
102711
PN=296
Group 20I
Knockdown Tilt and Crop Divider Tilt Cylinder
Repair Knockdown Tilt and Crop Divider Tilt Cylinder (Optional)
CM073510072 —UN—26MAR08
1— Tube 7— Spherical Roller Bearing 13— O-ring 19— Back-up Ring

2— Hydraulic Cylinder Rod 8— Lubrication Fitting 14— Back-up Ring 20— O-ring
3— Cylinder Head 9— Bushing 15— O-ring 21— Wear Ring
4— Piston 10— Ring 16— Wear Ring
5— Nut 11— Seal 17— Back-up Ring
6— Washer 12— Seal 18— O-ring
TM100419 (27OCT11) 70-20I-1 3520 and 3522 Sugar Cane Harvester Repair
102711
PN=297
1. Remove the cylinder from the harvester and clean 3. Drain as much oil from the cylinder as possible, before
thoroughly. beginning disassembly.
2. Place the cylinder in a vise with the fitting ports facing
down and secure firmly.
T803324,0000A22 -19-06SEP07-2/9
4. Pull on rod (2) until it has reached the end of the

stroke; this will also assist in draining the oil and air
from the cylinder.
CM073510073 —UN—19MAR08
T803324,0000A22 -19-06SEP07-3/9
5. Using a suitable spanner wrench, turn the cylinder

head (3) counterclockwise until the threads on the head
separates from the internal threads in the barrel (1).
CM073510074 —UN—19MAR08
T803324,0000A22 -19-06SEP07-4/9
6. Remove the complete rod assembly from the barrel (1).

CM073510075 —UN—10AUG07
102711
PN=298
7. Remove the locknut (5), washer (6), piston (4) and

cylinder head (3) from rod (2).
8. Remove the old seals. Clean the cylinder components
thoroughly and inspect the piston, cylinder head and
CM073510076 —UN—19MAR08
barrel damage.
9. Replace the seals and any other necessary
components in their proper orientation.
T803324,0000A22 -19-06SEP07-6/9
10. Lubricate the interior seals of cylinder head (3) with

clean oil and install the head onto rod (2) ensuring not
to damage the interior seals.
CM073510077 —UN—19MAR08
T803324,0000A22 -19-06SEP07-7/9
11. Install piston (4), and washer (6) onto rod (2).
12. Apply Loctite 271 onto the internal threads of nut
(5) and install it on rod (2). Using a suitable torque
wrench, torque nut (5) to 393 - 420 N·m (290-310 lb-ft).
CM073510078 —UN—19MAR08
13. Lubricate the exterior seals on cylinder head (3),
piston (4) and barrel (1) chamfer area with clean oil.
102711
PN=299
14. Insert the complete rod assembly into barrel (1),

ensuring not to damage the seals during entry. Light
taps on the rod end may be necessary to establish
entry.
CM073510080 —UN—10AUG07
15. Screw the cylinder head (3) into barrel (1) and torque
to 338-406 N·m (250-300 lb-ft).
16. Test repaired cylinder for leaks and install to its original
location.
T803324,0000A22 -19-06SEP07-9/9
102711
PN=300
Group 30A
Fixed Displacement Motor perform all repair work in a clean area. It is important to
air blast all parts and wipe them with a clean, lintless cloth
These service instructions will familiarize you with the before assembly.
fixed displacement motor’s relative position of each part,
proper methods for assembly or disassembly of the units Use caution in gripping all parts before installation, to
and care and use of this motor. This will give you the best be certain they were not damaged in shipment. Change
performance and a longer working life. all seals, O-rings, and gaskets whenever the motor is
repaired. Close all parts of the hydraulic components with
To facilitate the repair of this motor, and before any work is cap and plugs, when a repair is being done.
done, we suggest that you first read all of the repair steps.
Fill up hydraulic components with clean system oil before
The first requirement for good maintenance of any start up.
hydraulic equipment is cleanliness. Make sure you
T803324,0000A06 -19-14SEP07-1/1
Seal Replacement
1. Tape the shaft splines and remove the circlip and pry
off the cover.
2. Inspect the cover, shaft seal located in the cover and
the drive shaft.
3. Remove the old shaft seal from the cover.
4. Press in the shaft seal ring, to the correct position,
with a suitable sleeve.
5. If the shaft is deeply grooved, insert a shim behind the
seal to reposition the seal on the shaft.
CM053510252 —UN—24MAR08
6. Install a new and greased O-ring, ensure it is a snug
fit. Grease the shaft seal and install the cover.
7. Install the circlip using a punch.
8. Using a punch, make sure that the circlip is well seated
by tapping on one end of the circlip.
9. Mark the position of the cover plate. Remove the bolts
that retain the cover plate assembly.
A—Seal C—Grooves
B—Shim
CM053510253 —UN—24MAR08
102711
PN=301
10. Twist the port plate on the locating pin and lift off the
cover plate assembly. Note the position of the locating
pin to the valve plate.
11. Inspect the O-ring groove and the valve plate. Lightly
grease a new O-ring and install into valve plate groove.
CM053510254 —UN—16AUG05
12. Remove the motor flushing valve bolts from the cover
plate assembly and remove the valve.
13. Remove O-rings and install new lightly greased
O-rings.
14. Install the motor flushing valve onto the cover plate
assembly. Install the bolts and torque to 10 N·m (7.4
lb-ft).
15. Install the cover plate to its original position. Install the
bolts and torque to 86 N·m (63.4 lb-ft)
T803324,0000A07 -19-17SEP07-2/2
Disassembly 4. Remove the circlip and front cover.

1. Tape the splines on the shaft and mark the position of 5. Remove the shims.
the cover plate assembly.
6. Using a puller, remove the rotary group as a complete
2. Remove the bolts from the cover plate. Remove the unit.
cover plate and the control plate.
7. Remove the rotary group's retaining plate. The bolts
3. Carefully remove the cylinder. Do not damage it in are held by Loctite.
any way.
T803324,0000A08 -19-23AUG07-1/1
Clean and Inspect scratches and unevenness. It should have a minimum

hardness of 700 HV10.
1. Inspect the drive shaft for corrosion or erosion.
Check for damage to the splines and traces of wear 4. Check for damage or wear where the bearings fit into
scratches. Make sure that bearing cups are free from the housing.
2. Inspect the piston, center pin, and retaining plate for 5. If pistons are changed, they should only be replaced
scratches, wear and pitting. as a complete set. When changing other components,
recalibration is required.
3. Inspect the cylinder bores for scratches and wear.
Check the cylinder block and control plate for cracks, 6. The cylinder block and control plate must be replaced
as a set.
T803324,0000A09 -19-23AUG07-1/1
Assembly 6. Make sure that a new shaft seal has been installed.
1. Insert the center pin with retaining ring. Correctly fit 7. Heat the housing to 80° C (176° F) and install it over
the retaining plate. the rotating group, until the housing stops.
2. Apply Loctite 242 (08413042010) sparingly to bolt only. 8. Turn the motor over and install the shims.
3. Heavily grease and install the spring pad and Belleville 9. If the shaft is deeply grooved, insert a shim behind
washers as shown. Make sure all parts are installed in the seal.
their correct position.
10. Install a new O-ring, ensure it is a snug fit. Grease the
4. Install the pistons in their bores. O-ring and lips of the shaft seal and install the cover.
5. Press the pistons firmly into the cups while holding the 11. Install the circlip using a punch and make sure that it
cylinder block in a central position. Swivel the cylinder is well seated.
block to maximize the angle.
T803324,0000A0A -19-14SEP07-1/1
102711
PN=302
Group 30B
Collector, Crop Divider, Feedroller and Elevator Motor
Repair Collector, Crop Divider, Feedroller and Elevator Motor
CM073510156 —UN—26MAR08
Continued on next page T803324,0000FC4 -19-06SEP07-1/2
102711
PN=303
1— Seal 7— Seal 13— Valve 19— Housing

2— Housing 8— Wear Plate 14— Balance Ring 20— Bolt
3— Seal 9— Drive Shaft 15— Outer Face Seal 21— Plug
4— Seal 10— Geroler 16— Inner Face Seal
5— Seal 11— Valve Drive 17— Pin
6— Shaft 12— Valve Plate 18— Spring
T803324,0000FC4 -19-06SEP07-2/2
Suggested Tools • Breaker bar — 300-450 mm (12-16 in.)

NOTE: The following tools are not necessary
• Socket — 9/16 in.
for disassembly and assembly, but are
• Small Screwdriver — 50-200 x 6.5 mm (6-8 x 1/4 in.)
extremely helpful.
• 3/16 hex Allen Wrench
• Press
• Torque Wrench — 58 N·m (50 lb-ft
CM073510157 —UN—28AUG07
• Alignment studs (2) Char-Lynn drawings are being used with permission from
• Seal Installer Tool — 0841306323 Eaton Corporation.
NOTE: A different bearing housing is used for the collector
motor, but the other parts are the same as the Crop
Divider, Feedroller and Elevator motors. The same
assembly and disassembly procedures apply.
T803324,0000FC5 -19-06SEP07-1/1
102711
PN=304
Disassembly
Cleanliness is extremely important when repairing a
hydraulic motor. Always work in a clean area. Before
disconnecting the lines, clean the port area of the motor
thoroughly. Use a wire brush to remove foreign material
and debris from exterior joints of the motor. Check the
shaft, keyway or splines and remove all nicks, burrs, and
sharp edges that might damage the shaft seals when
installing the retainer on the shaft and bearing assembly.
Before starting disassembly procedures, drain oil from
inside of motor.1
1. Place the motor in a vise with the output shaft facing
CM073510158 —UN—28AUG07
down. Clamp across the mounting flange of the motor
not the housing. Excessive clamping pressure will
cause distortion. When clamping, use some protective
device on the vise, such as special soft jaws, pieces of
hard rubber or wood. Mark the sections for alignment.
NOTE: Although not all drawings show the motor in
a vise, we recommend that you keep the motor
in a vise during disassembly and reassembly.
Follow the clamping procedures explained
throughout the manual.
1
John Deere recommends that you keep the motor in a
vise during disassembly.
T803324,0000FC7 -19-14SEP07-1/19
2. Remove four bolts (20) from the motor.
CM073510159 —UN—19MAR08
102711
PN=305
3. Lift housing (19) straight upward. If done carefully,

pins (17), springs (18) face seals (15 and 16); balance
ring (14) and valve (13) will remain on the valve plate
(12) for easier removal.
CM073510160 —UN—28AUG07
T803324,0000FC7 -19-14SEP07-3/19
4. Carefully remove O-ring (3) and case drain plug (21)

from housing (19).
CM073510161 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-4/19
5. Remove two balance ring springs (18) and pins (17)

from balance ring assembly (14).
CM073510162 —UN—19MAR08
102711
PN=306
6. Remove balance ring (14) from valve (13).
CM073510163 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-6/19
7. Remove inner and outer face seals (15 and 16) from
the balance ring (14).
CM073510164 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-7/19
8. Lift off valve (13) from valve plate (12)
CM073510165 —UN—19MAR08
102711
PN=307
9. Remove valve plate (12).
CM073510166 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-9/19
10. Remove O-ring (3) from valve plate (12).
CM073510167 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-10/19
11. Remove valve drive (11).
CM073510168 —UN—19MAR08
102711
PN=308
12. Remove geroler (10). Retain the rollers located in the

outer geroler ring, if loose.
CM073510169 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-12/19
13. Remove drive shaft (9).
CM073510170 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-13/19
14. Remove O-ring (3) from wear plate (8).
CM073510171 —UN—19MAR08
102711
PN=309
15. Remove wear plate.
CM073510172 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-15/19
16. Remove shaft seal (7) from the wear plate (8).
CM073510173 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-16/19
17. Remove O-ring (3) from bearing housing (2).
CM073510174 —UN—19MAR08
102711
PN=310
NOTE: Individual parts of the shaft and bearing

assembly are not sold separately and must be
replaced as a complete unit.
18. Remove shaft and bearing assembly (6) from housing
CM073510175 —UN—19MAR08
(2). It may be necessary to use a press for removal. If
the motor has a key, remove the key before removing
the shaft assembly.
T803324,0000FC7 -19-14SEP07-18/19
19. Use a small screwdriver to remove shaft seal (5),

backup washer (4) and dust seal (1). Do not damage
the bore of the housing.
CM073510176 —UN—19MAR08
T803324,0000FC7 -19-14SEP07-19/19
Clean and Inspect 4. Check around the keyway or splines and chamfered
1. Check all mating surfaces and replace any parts that area of the shaft for burrs, nicks or sharp edges that
have scratches or burrs that could cause leakage. can damage the seals when reassembling the bearing
housing.
2. Clean all metal parts in clean solvent and blow dry with
air. Do not wipe parts with cloth or paper towel. Lint 5. Prior to installation, lubricate all seals with O-ring lube
or other material could get into the hydraulic system (0841304202) or equivalent.
and cause damage.
6. John Deere recommends the use of new seals when
3. Do not use a course grit paper, or try to file or grind reassembling the motor. Refer to the John Deere
motor parts. Parts Manual for replacement parts and kit numbers.
T803324,0000FC8 -19-06SEP07-1/1
102711
PN=311
Assembly
CM073510177 —UN—19MAR08
1. Use a press to install seal (1) into the outer bore of is not available, use a plastic or rubber hammer, being
housing (2). The seal lip must face outward. If a press careful not to damage or cock the seal in the bore.
T803324,0000FC9 -19-14SEP07-1/23
CM073510178 —UN—19MAR08
2. Place seal (5) onto installation tool (0841306323).
Press the seal into the seal bore located in the housing.
T803324,0000FC9 -19-14SEP07-2/23
3. Clamp housing (2) in a vise, across the mounting

flange, with the output shaft end facing down.
CM073510179 —UN—19MAR08
102711
PN=312
CM073510180 —UN—19MAR08
4. Place a protective sleeve or tape over the shaft (6); it may be necessary to use a press to do this. Do
splines. Grease the inside diameter of seal (1) and not cut or distort the seals.
shaft seal (5). Install the shaft and bearing assembly
102711
PN=313
CM073510181 —UN—19MAR08
5. Apply lubricate to O-ring (3) and install into housing (2)
T803324,0000FC9 -19-14SEP07-5/23
6. Alignment studs (A) are very helpful in the assembly

of this motor. (See the tool list for fabrication
dimensions.) Install the two studs, diagonally opposed
to each other, in housing (2).
CM073510182 —UN—19MAR08
102711
PN=314
7. Install shaft seal (7) into wear plate (8). Do not distort
the seal.
CM073510183 —UN—19MAR08
CM073510184 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-7/23
8. Install wear plate (8).
CM073510172 —UN—19MAR08
102711
PN=315
9. Apply a light film of lubricate on O-ring (3) and install

in wear plate.
CM073510171 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-9/23
10. Install drive shaft (9) into output shaft (6).
CM073510170 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-10/23
11. Align the notches (B) located on the outside of geroler

(10), with the notches located on the wear plate (8).
Install the geroler against the wear plate. Be sure to
retain the rollers in the outer ring, if loose.
CM073510185 —UN—19MAR08
102711
PN=316
12. Install valve drive (11) into the geroler (10). Installation
at this point involves three steps for timing the motor.
Timing determines the direction of rotation of the
output shaft.
CM073510186 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-12/23
a. Timing Step 1 — Locate the largest open pocket

(C) in the geroler (10). Mark the location of this
pocket on the outside edge of the geroler.
Apply a light coat of lubricate to O-ring (3) and
install into groove of valve plate (12).
CM073510187 —UN—19MAR08
Align the notch (B) located on the outside of the
valve plate (12) with the notch (B) located on the
geroler (10).
CM073510188 —UN—19MAR08
CM073510189 —UN—19MAR08
102711
PN=317
b. Timing Step 2 — Locate the slot opening (C) in the

valve plate (12) which is in line with the largest open
pocket (C) of the geroler (10).
CM073510190 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-14/23
c. Timing Step 3 — Locate any one of the valve (13)

side openings and align this opening with an open
valve plate (12) slot that is aligned with the largest
open pocket of the geroler (10). Install the valve
(13) by rotating it clockwise until the splined teeth
CM073510191 —UN—19MAR08
engage (1/2 splined tooth maximum). This provides
the proper rotation when pressurized.
D—Alignment Reference Only
T803324,0000FC9 -19-14SEP07-15/23
13. Install two pins (17) and springs (18) into holes located
in the bore of housing (19).
CM073510192 —UN—19MAR08
102711
PN=318
14. Apply a light film of lubricate to O-ring (3) and install

in housing (19).
CM073510193 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-17/23
15. Apply lubricate to inner and outer face seals (15 & 16)
and install on balance ring (14). Install the face seals
in the positions, as shown, or the motor will not operate
properly. DO NOT force or bend the face seals. Any
damage to these seals will affect motor operation.
CM073510164 —UN—19MAR08
CM073510194 —UN—19MAR08
102711
PN=319
16. Align the pin notches located in balance ring (14) with
pins (17), located in the bore of the valve housing.
Install the balance ring assembly into the valve
housing (19).
CM073510195 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-19/23
17. Insert your finger through the port of the valve housing
(19). Apply pressure to the side of the balance ring
(14) assembly. Hold the ring into position until valve
housing (19) is in place against valve plate (12).
18. After installing valve housing (19) on valve plate (12),
check for proper alignment. Push downward on valve
housing (19). You should feel a slight spring action.
A—Alignment Studs
CM073510196 —UN—24MAR08
102711
PN=320
19. Install and finger tighten two bolts (20) opposite the
alignment studs. Remove the alignment studs and
install the remaining bolts. Cross torque all four bolts
to 50 N·m or (38 lb-ft).
CM073510197 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-21/23
20. Install a new O-ring or case drain plug (21) and then
install the plug into valve housing (19). Torque to 6
N·m (4 lb-ft).
CM073510198 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-22/23
21. After assembling the motor, press the seal guard (4)
onto the shaft with a tool that will provide an even push
over the seal. This tool must bottom out against the
housing (2) and provide a 4.5 mm (.177 inch) stop (D)
for the seal guard.
CM073510199 —UN—19MAR08
T803324,0000FC9 -19-14SEP07-23/23
102711
PN=321
102711
PN=322
Group 30C
Topper and Secondary Extractor Motor
Repair Topper and Secondary Extractor Motor
CM073510200 —UN—29AUG07
Continued on next page T803324,0000FCA -19-06SEP07-1/2
102711
PN=323
1— Snap Ring 7— Lip Seal 13— Side Seal 19— Gear Housing
2— Shaft 8— Shaft End Cover 14— End Seal 20— Port End Cover
3— Ball Bearing 9— Pipe Plug 15— Thrustplate 21— Washer
4— Spacer 10— Check Assy 16— Square Seal 22— Bolt
5— Retaining Ring 11— Bushing Kit 17— Dowel Pin
6— Seal Retainer 12— Backup Seal 18— Gear Set
T803324,0000FCA -19-06SEP07-2/2
Gear Motor Repair a clean area. The repair graphics show a single section
motor, but is also applicable to the double section motor. It
These service instructions will familiarize you with gear is important to air burst all parts and wipe them clean with
motors: their component parts, the relative position of a lint free cloth before assembly. Use caution in gripping
each part, proper methods for assembly or disassembly of all parts in the vise to avoid damaging machined surfaces.
units, care and use of these motors. This will give you the A motor must be driven in the direction of rotation for
best performance and a longer working life. To facilitate which it was built; otherwise, pressure will blow the shaft
the repair of these motors and before any work is done, we seal. Check all replacement parts before installation to be
suggest that you first read all of the repair steps. The first certain they were not damaged in shipment.
requirement for good maintenance of hydraulic equipment
is cleanliness. Make sure you perform all repair work in
T803324,0000FCB -19-06SEP07-1/1
Suggested Tools • Medium grit carborundum stone

• Arbor Press • Seal removal tool
• 1-1/2 inch diameter steel ball • System oil and grease
• Bearing Puller • Snap Ring Pliers
• Bushing Removal Tool (0841329345) • Prick Punch
• Clean lint free cloth • Bushing Installation Tool (0290244461)
• Deburring tool (an old file with cutting teeth ground off) • Scale (1/32 inch or 1/16 inch graduations)
• Machinist Hammer • Small screwdriver
• Soft Hammer • Torque Wrench
• Permatex Form-A-Gasket number C2 non-hardening • Vise with 15 cm (6 in.) minimum open spread
sealant or equivalent
• Seal Installation Tool Awl
T803324,0000FCC -19-06SEP07-1/1
Repair Precautions
3. All gears are closely matched; therefore, they must be
1. If it is necessary to pry off sections, take extreme care kept together as sets when removed from the motor.
not to mar or damage machine surfaces. Excessive Handle with care to avoid damage to the journals or
force while prying can result in misalignment and may teeth. Avoid touching gear journals.
seriously damage parts.
4. Never hammer bushings into bores; use an arbor
2. If parts are difficult to fit during assembly, tap gently press.
with a soft hammer. Never use a metal hammer.
T803324,0000FCD -19-28SEP07-1/1
102711
PN=324
Disassembly
1. Place the motor in a vise with the drive shaft pointing
downward. Match-mark all sections; be sure to align
CM073510201 —UN—29AUG07
T803324,0000FCE -19-14SEP07-1/14
2. Use a socket wrench to remove four bolts (22) and

washer (21).
CM073510202 —UN—19MAR08
T803324,0000FCE -19-14SEP07-2/14

careful not to damage the machined surfaces. Dowel
pins (17), if used, will remain in either port end cover
(20), or gear housing (19). Do Not remove them.
CM073510203 —UN—19MAR08
Continued on next page T803324,0000FCE -19-14SEP07-3/14
102711
PN=325
4. Remove thrust plate (15).
CM073510204 —UN—19MAR08
T803324,0000FCE -19-14SEP07-4/14
5. Carefully remove gear assembly (18). Avoid tapping

the gear teeth together or against other hard surfaces.
Keep these gears together; they are a matched set.
CM073510205 —UN—19MAR08
T803324,0000FCE -19-14SEP07-5/14
6. Lift gear housing (19) from front cover (8). If prying

is necessary, take care not to damage machined
surfaces.
CM073510206 —UN—19MAR08
102711
PN=326
7. Remove thrust plate (15).
CM073510207 —UN—19MAR08
T803324,0000FCE -19-14SEP07-7/14
CM073510208 —UN—19MAR08
8. Inspect all bushings (11) for scoring or discoloration
and replace if necessary. Use a bushing removal tool
to remove.
T803324,0000FCE -19-14SEP07-8/14
9. Place the front cover (8) in a vise with the mounting

face pointing upward. Remove the snap ring (1) using
a pair of snap ring pliers.
CM073510209 —UN—19MAR08
102711
PN=327
10. Remove shaft assembly (2) by lifting up on the shaft

end.
CM073510210 —UN—19MAR08
T803324,0000FCE -19-14SEP07-10/14
11. Remove seal retainer (6).
CM073510211 —UN—19MAR08
T803324,0000FCE -19-14SEP07-11/14
12. Remove seal (7) from housing (8).
CM073510212 —UN—19MAR08
102711
PN=328
13. Remove retainer ring (5) from shaft (2).
CM073510213 —UN—19MAR08
T803324,0000FCE -19-14SEP07-13/14
14. Remove spacer (4) and bearing (3) from shaft (2).
CM073510214 —UN—19MAR08
T803324,0000FCE -19-14SEP07-14/14
Clean and Inspect

1. Clean and inspect all parts for wear or damage.
Replace if necessary. See John Deere Parts Manual
for part numbers to order. Notice that all gear
assemblies are a matched set and cannot be ordered
separately.
2. Replace gear housing (19), if it has wear in excess
of 0.13 mm (0.005 inch) cut out. Use the following
method to determine the cut out.
a. Place a straight – edge across the bore. If you can
insert a 0.13 mm (0.005 inch) feeler gauge under
the straight-edge in the cut-out area, replace the
gear housing.
valve settings are within prescribed limits, check for
b. Pressure pushes the gears against the housing on shock pressures or tampering. Take an oil sample
the low pressure side. As the hubs and bushings and check the tank itself for contamination.
wear, the cutout becomes more pronounced.
Excessive cutout in a short period of time indicates c. Where cutout is moderate, 0.13 mm (0.005 in.) or
excessive pressure or oil contamination. If the relief less, the gear housing is good and may be reused.
Continued on next page T803324,0000FCF -19-14SEP07-1/8
102711
PN=329
3. Gears (18) which exhibit any scoring on gear hub

should be replaced. Any scoring, grooving or burring
of outer tooth diameter will require their replacement.
Nicking, grooving or fretting of teeth surfaces will also
necessitate replacement.
CM073510215 —UN—19MAR08
T803324,0000FCF -19-14SEP07-2/8
4. Drive shaft (2) should be replaced if any wear is

detectable, by touch in the seal area or at the drive
coupling. The maximum allowable wear is 0.05 mm
(0.002 inch). Wear in the shaft seal area indicates
oil contamination. Wear or damage to splines will
CM073510216 —UN—19MAR08
necessitate replacement.
T803324,0000FCF -19-14SEP07-3/8
5. Thrust plates (15) seal the gear sections at the sides

of the gear. Wear here will allow internal slippage and
oil will bypass within the pump. A maximum of 0.05
mm (0.002 inch) wear is allowable. Replace thrust
plates if they are scored, eroded or pitted.
CM073510217 —UN—19MAR08
6. Check the center of the thrust plates where the gears
mesh; erosion here indicates oil contamination.
102711
PN=330
CM073510218 —UN—19MAR08
7. Dowel pins (17) must be replaced if either the dowel seat the dowels, the cause may be poorly deburred or
pin or dowel hole is damaged. If there is damage, dirty parts; cocking of dowel in the hole; or improper
either the dowel or machined housing, or both must be pin-to-hole fit.
replaced. If more than reasonable force is required to
T803324,0000FCF -19-14SEP07-5/8
CM073510219 —UN—19MAR08
8. Bushings (11) must be replaced if gears are replaced.
Bushings should fit into bore with a heavy press fit.
T803324,0000FCF -19-14SEP07-6/8
CM073510220 —UN—19MAR08
9. All sealing parts, lip seal (7), square channel seals

(16) must be replaced. See John Deere Parts Manual
for complete seal kit part number.
102711
PN=331
10. Examine check assembly (10) located in front housing

(8). Ensure that it is in the proper position and tightly
seated.
CM073510221 —UN—19MAR08
T803324,0000FCF -19-14SEP07-8/8
Assembly
1. Rub a medium grit carborundum stone over machined
surfaces. If bushings were removed or a new section
is used, debur bores with a fine emery cloth. Wash in
CM073510222 —UN—19MAR08
a solvent, blow dry with air and wipe with a clean lint
free cloth before assembly.
2. Grip shaft end cover (8) in a vise with mounting face
down. Examine check valves (10) to be sure they are
tightly in place. Replacement is necessary only if parts
are damaged. Remove with a screwdriver.
3. If the check valves are being replaced, screw in the
new parts tightly. Stake plug with a prick punch at
both ends of screwdriver slot and around edges. Peen
edge of hole 0.794 to 1.588 mm (1/32 to 1/16 inch) pressing them into the bearing bore with an arbor
with a 38.1 mm (1- 1/2 inch ) diameter steel ball. press.
4. If any bearings have been removed from the shaft

end cover or port end cover, replace the bearings by
T803324,0000FD0 -19-28SEP07-1/13
5. Before inserting a new lip seal (7) in the shaft cover

(8), coat the outer edge of the seal and its bore with
non-hardening gasket sealant. With the metal side of
the lip seal up, press it into the mounting flange side
of the shaft end cover (8) with an arbor press and a CM073510212 —UN—19MAR08
piece of 38.1 X 50.8 mm (1-3/4 X 2 inch ) round bar.

Make sure the lip seal is fully seated in the bore. Wipe
off excess sealant.
6. Check all thrust plates (15) for wear. Replace if
necessary.
Continued on next page T803324,0000FD0 -19-28SEP07-2/13
102711
PN=332
7. Position shaft end cover (8) so that the mounting

surface is up.
CM073510223 —UN—19MAR08
T803324,0000FD0 -19-28SEP07-3/13
8. Install bearing (3), spacer (4) retainer ring (5) and seal
retainer (6) on the shaft (2).
CM073510224 —UN—19MAR08
T803324,0000FD0 -19-28SEP07-4/13
9. Install shaft assembly in shaft end cover (8) from the

mounting surface side.
CM073510225 —UN—19MAR08
102711
PN=333
10. Install snap ring (1) over the shaft end cover to retain
shaft (2).
CM073510209 —UN—19MAR08
T803324,0000FD0 -19-28SEP07-6/13
11. Grip the shaft end cover (8) in a vise with the mounting
face down.
CM073510226 —UN—19MAR08
T803324,0000FD0 -19-28SEP07-7/13
CM073510227 —UN—19MAR08
12. Grease new seals (16) and insert them into the with a soft hammer until it rests tightly against the shaft
grooves in both sides of the gear housing (19). Place end cover (8). Be careful not to pinch the seal.
the gear housing (19) on shaft end cover (8) and tap
102711
PN=334
13. Assemble the channel seals (12), (13) and (14) into
the grooves in the thrust plates (15) with the flat side of
the seals facing away from the thrust plate. Slide the
thrust plate assembly through the gear housing (19)
and bottom out on shaft end cover (8) with smooth
CM073510228 —UN—19MAR08
side of thrust plate (15) facing gears.
T803324,0000FD0 -19-28SEP07-9/13
14. Install the gear sets (18) with the one with the internal
splines going on the shaft (2).
CM073510229 —UN—19MAR08
T803324,0000FD0 -19-28SEP07-10/13
15. Assemble the channel seals (12), (13) and (14) into
the grooves in the thrust plates (15) with the flat side
of the seals facing away from the thrust plate. Slide
the thrust plate (15) with the smooth side of the thrust
plate facing the gears into the gear housing (19).
CM073510230 —UN—19MAR08
102711
PN=335
16. Place the port end cover (20) over the gear journals
and tap lightly against the gear housing (19). Be
careful not to pinch the seal (16).
CM073510231 —UN—19MAR08
T803324,0000FD0 -19-28SEP07-12/13
17. Thread the four bolts (22) with washers (21) into the
shaft end cover (8) and tighten alternately or cross
corner. Rotate the drive shaft with a wrench to make
certain there is no binding in the motor.
CM073510232 —UN—19MAR08
18. After the fasteners are tight and there is not internal
binding, torque the diagonally opposite bolts (22) to
272 N·m (200 lb-ft).
T803324,0000FD0 -19-28SEP07-13/13
Start-up Procedure and at low RPM (400 minimum). During this break-in
period, the unit should run free and not develop an
1. Before connecting any hoses to the motor, fill all ports excessive amount of heat. If the motor operates
with clean system oil to provide initial lubrication. properly, speed and pressure can then be increased
2. After mounting the motor and connecting the hoses, to normal operating settings.
operate the motor at least two minutes at no load
T803324,0000FD1 -19-06SEP07-1/1
102711
PN=336
Recommended Test Procedure becomes excessively hot, shut down immediately and
locate the problem’s source.
1. Be sure there is an adequate supply of system oil for
the pump, at least one gallon of oil for each GPM of 6. Delivery should run close to rated performance figures
motor capacity. which are averaged from testing several motor. A
5% lower reading may be used as a rated minimum
2. The oil should be a good quality hydraulic oil rated at if new, or relatively new parts have been used. When
150 SSU at 38° C (100° F) with the oil temperature rebuilding the motor with parts from the original motor,
held at 46-52° C (115-125° F). which, while worn, appear satisfactory for reuse, a
3. The suction line must be of adequate size with no 10% or 15% lower reading should be used, depending
more than 17 kPa (5 inches) of mercury vacuum upon the performance expected from the equipment.
adjacent to the pump inlet. As a rule, the feed line One’s own experience will prove the best guide here.
must provide a feed flow velocity not in excess of 2.4 7. It is recommended to measure the output at normal
meters per second (8 feet per second). operating speed and at zero pressure, then again
4. Feeding hot oil into a cold motor may cause the motor at 69 bar (1000 PSI) (or the operating pressure
to seize. Jog the pump by momentarily starting the of the equipment) and allow a volume decrease
driving engine to gradually equalize motor and oil approximating the listing below. It is a suggested
temperatures. reference only that makes allowance for reused parts.
At test speeds other than 1800 RPM, L/Min (GPM)
5. Run the motor at least two minutes at no load and delivery will vary almost proportionately, but the same
moderate speed (not over 1500 RPM). If the motor (drop-off) figures should be used.
GPM Drop Off at 100 PSI 1000 PSI 1500 PSI 2000 PSI 2500 PSI
GPM Delivery at 1800 5 - 14 2-3 21/2 - 3 1/2 3-4 31/2 - 4 1/2
RPM 15 - 25 21/2 - 31/2 3-4 31/2 - 5 4 - 51/2
26 - 50 3-4 4-5 4-6 41/2 - 61/2
L/Min Drop Off at 6.9 Bar 69 Bar 103 Bar 138 Bar 172 Bar
L/Min Delivery at 1800 19 - 53 L 7.6 - 11.4 L 9.5 - 13.2 L 11.4 - 15.1 L 13.2 - 17 L
RPM 53.8 - 94.6 L 9.5 - 13.2 L 11.4 - 15.1 L 11.4 - 18.9 L 15.1 - 20.8 L
98 - 189 L 11.4 - 15.1 L 15.1 - 18.9 L 15.1 - 22.7 L 17 - 24.6 L
After completing testing procedures, the motor is ready Again, it must be remembered that to prevent seizure, hot
for installation and immediate operation on the harvester. oil must not be fed into a cold motor.
T803324,0000FD2 -19-28SEP07-1/1
102711
PN=337
102711
PN=338
Group 30D
Basecutter and Primary Extractor Motors
Repair Basecutter and Primary Extractor Motors
CM073510233 —UN—05SEP07
102711
PN=339
1— Motor Drive Shaft 8— Seal Ring 15— Port Plate 22— Spacer
2— End Cover 9— O-ring 16— Shim Assembly 23— Retaining Ring
3— Valve 10— Back-Up Ring 17— Bearing Race (Outer) 24— Fitting
4— Housing 11— Fitting 18— Bearing Race (Inner) 25— Sealing Flat Washer
5— Bolt 12— Bearing Cup 19— Rotary Group 26— Relief Valve
6— Bolt 13— Gasket 20— Cap Screw
7— Bolt 14— Dowel 21— Shaft Seal
T803324,0000FD3 -19-05SEP07-2/2
Required Tools • Pliers

• Punch
• Hammer
extremely helpful.
• Bearing Press or Driver
• Light Petroleum Jelly
• Cleaning Solvent
• Retaining Ring Pliers • Small Screwdriver (1/8 in. Blade)
• Breaker Bar or Ratchet • Clean Lint Free Rags
• 1-3/8 in. Hex Wrench • Bearing Cone Driver
• 9/16 in. Socket • Headless 5/16 in. Cap Screw — 5 -6 in. long (2 required)
• 5/8 in. Socket • Low Clearance Bearing Puller
• Torque Wrench (200 lb-ft) • Limit Stop for Bearing Cone Installation
• 1/4 in. Hex Bit Socket
• 1/4 in. Hex Key Char-Lynn drawings are being used with permission from
• Loctite No. 271 Eaton Corporation.
T803324,0000FD4 -19-06SEP07-1/1
CM073510234 —UN—05SEP07
Disassembly
NOTE: Thoroughly clean the exterior of the motor before
disassembly. Make sure all open ports are sealed.
1. Using a pair of retaining ring pliers, remove retaining

ring (23).
T803324,0000FD5 -19-14SEP07-1/23
CM073510235 —UN—05SEP07
2. Use a punch and hammer to punch a hole in the shaft
seal.
102711
PN=340
CM073510236 —UN—05SEP07 CM073510237 —UN—05SEP07

3. Install a 3 inch sheet metal screw with the point
blunted in to the punched hole just far enough to pull
the shaft seal out of the pocket.
T803324,0000FD5 -19-14SEP07-3/23
CM073510238 —UN—05SEP07
4. Carefully, insert the blade of a flat screwdriver behind
the seal and pry out the seal taking care not to damage
the output drive shaft.
T803324,0000FD5 -19-14SEP07-4/23
5. Position the motor on its mounting flange as shown.

Loosen all the relief valves (26) and plugs (24) in the
valve block (3). Remove the four bolts (7) that hold
the valve block to the motor. Then remove the valve
block (3).
CM073510239 —UN—19MAR08
CM073510240 —UN—19MAR08
102711
PN=341
6. Remove O-rings (9) and back-up rings (10) from the

mounting face of valve block (3).
CM073510241 —UN—19MAR08
T803324,0000FD5 -19-14SEP07-6/23
NOTE: The high pressure relief valves have two white

back-up rings and one O-ring in the lower groove.
The settings on these valves are preset at the factory.
7. Using a 1-3/8 in. hex wrench, remove the two high
CM073510242 —UN—19MAR08
pressure relief valves (26) from valve block (3).
T803324,0000FD5 -19-14SEP07-7/23
8. Remove the two plug fittings (24) from valve block (3).
CM073510243 —UN—19MAR08
102711
PN=342
CAUTION: Internal parts are spring loaded.

To avoid internal part damage, remove
six bolts leaving two bolts opposite each
other tight. Gradually and evenly remove
CM073510244 —UN—19MAR08
the two remaining bolts.
9. Remove the two hex head bolts (5) and six hex head
bolts (6).
T803324,0000FD5 -19-14SEP07-9/23
CAUTION: Remove any parts (port plate, bearing

cup or shims) that may have stuck to the end
cover. Be careful not to drop any.
CM073510245 —UN—19MAR08
10. Carefully remove end cover (2), gasket (13) and the
two dowel pins (14).
T803324,0000FD5 -19-14SEP07-10/23
11. Remove rear bearing race (18) from rear cover (2),
using a slight twisting motion. This bearing race is slip
fit into end cover (2).
CM073510246 —UN—19MAR08
102711
PN=343
12. Remove and retain rear bearing shims (16) from

rear cover (2). These shims are used to adjust shaft
bearing end play of the motor output shaft.
13. If gasket (13) and dowel pins (14) did not come off
CM073510247 —UN—19MAR08
with end cover (2), remove them from housing (4) at
this time.
T803324,0000FD5 -19-14SEP07-12/23
IMPORTANT: Handle the bearing plate and valve

plates with extreme care. They are lapped to
extremely close tolerances for flatness.
14. Remove port plate (A), bearing plate (B) and pins from
CM073510248 —UN—19MAR08
the cylinder barrel (C). If using a small screw driver to
pry the bearing plate (B) from the cylinder barrel (C),
make sure bearing plate and barrel surfaces are not
scratched or damaged.
T803324,0000FD5 -19-14SEP07-13/23
NOTE: Low clearance bearing puller is recommended

for removal of end cover bearing. The bearing
puller pulls against bearing rollers, not against
inner cup. It is designed to prevent bearing cone
and cylinder barrel face from being damaged when
CM073510249 —UN—19MAR08
bearing is removed. Low clearance between the
end cover bearing and cylinder barrel makes it
difficult to use any other bearing puller.
15. Install bearing puller and remove bearing from output

shaft.
102711
PN=344
16. Carefully reposition motor on its side. Using a 1/4 in.

hex bit socket, remove the two cap screws (20) and
washers (25) that hold the swash plate in the housing
(4).
CM073510250 —UN—19MAR08
T803324,0000FD5 -19-14SEP07-15/23
17. Remove and discard sealing washer (25) from cap

screws (20). Replace with new sealing washers.
CM073510251 —UN—19MAR08
T803324,0000FD5 -19-14SEP07-16/23
18. Push inward on shaft assembly (1) to dislodge the

swashplate (D) from its pocket in housing (4).
CM073510252 —UN—19MAR08
102711
PN=345
19. Carefully remove the output shaft/cylinder barrel

assembly from housing.
CM073510253 —UN—05SEP07
T803324,0000FD5 -19-14SEP07-18/23
20. Position the shaft/cylinder barrel subassembly with

the shaft facing up. Carefully lift out the output drive
shaft subassembly.
CM073510254 —UN—05SEP07
T803324,0000FD5 -19-14SEP07-19/23
IMPORTANT: When removing or installing bearing

cone, do not damage the shaft sealing area
(stepped area between the bearing journal
and output drive shaft splines). This area is
critical for sealing the shaft seal.
CM073510255 —UN—05SEP07
21. When the bearing must be replaced, use a press to
remove the bearing from the shaft assembly.
22. You must use special stop limit tool when installing a
new cone bearing.
102711
PN=346
23. If the bearing cup (12) needs replacing, carefully

remove the cup using a hammer and drift punch (E).
CM073510256 —UN—19MAR08
T803324,0000FD5 -19-14SEP07-21/23
24. Reposition the cylinder barrel/swashplate with the

swashplate (D) on the bottom. Using a 1/4 in. hex
key, remove the cap screws (F) from the retaining
strap (G) on one side of the swashplate (D) . Loosen
the cap screw (F) on the other retainer strap (G) to
CM073510257 —UN—19MAR08
make it easier to remove cylinder barrel (C) from the
swashplate (D).
T803324,0000FD5 -19-14SEP07-22/23
25. Carefully reposition the cylinder barrel/swashplate

(D) with the swashplate facing up. Remove the
swashplate by lifting slightly and sliding it over to
disengage from the retainer strap (G).
CM073510258 —UN—19MAR08
26. Remove cap screws, retaining strap, spacer and thrust
plate from swashplate.
27. Disassemble cylinder barrel subassembly. Place it on
a clean protective surface for inspection and cleaning.
T803324,0000FD5 -19-14SEP07-23/23
102711
PN=347
Assembly
IMPORTANT: Before reassembly, clean all parts and
assemblies in clean solvent and blow them
dry with compressed air. Inspect and replace
CM073510259 —UN—19MAR08
all scratched or damaged parts. Do not use
coarse grit paper, files or grinders on any
finished surfaces. Replace all gaskets and
O-rings. Lubricate O-rings with petroleum jelly
for retention during reassembly. Freely lubricate
all bearings and finished part surfaces with
clean hydraulic fluid. This will provide required
start-up lubrication for moving parts.
1. Lubricate and install shoe retainer plate (H) and

piston shoes (I) in cylinder barrel (C) assembly. After height of retaining strap spacer with a micrometer or
installation, freely lubricate brass shoe faces with vernier caliper. There are two fixed spacer heights
clean hydraulic fluid. – one for the 33, 39, 46 units and one for the 54, 64
units. Spacers are critical to the unit design and may
2. Before assembling the motor any further, you must not be interchanged.
check the fixed clearance of motor. Measure the
T803324,0000FD6 -19-17SEP07-1/24
3. Measure the combined thickness of the piston shoe

and shoe retainer plate. Subtract this measurement
from the spacer height to arrive at the fixed clearance
of unit.
CM073510260 —UN—19MAR08
NOTE: An alternative method of checking fixed clearance
is with the use of a feeler gauge. If using this
method, make sure gauge is inserted between
retaining strap and shoe retainer plate only. Piston
shoe faces could be damaged if gauge is inserted
between piston shoe and thrust plate.
4. Fixed clearance must not exceed .008 inches (.20

mm). If fixed clearance exceeds .009 inches (.22 mm),
replace worn parts, (i.e. piston shoe subassemblies,
thrust plate, retaining strap and/or retainer plate). 1— Spacer 5— Shoe Retainer Plate
2— Retaining Strap 6— Piston Shoes
3— Cap Screw 7— Thrust Plate
4— Piston 8— Swashplate
T803324,0000FD6 -19-17SEP07-2/24
5. Apply one or two drops of Loctite 271 in the first

or second thread, in each of the four holes in the
swashplate.
CM073510261 —UN—19MAR08
102711
PN=348
6. Lightly lubricate and install thrust plate (7), aligning the

cap screw holes. Install spacers (1), retaining straps
(2) and cap screws (3) on one side of the swashplate.
DO NOT tighten cap screws at this time.
CM073510262 —UN—19MAR08
T803324,0000FD6 -19-17SEP07-4/24
CAUTION: Loctite parts must contact only those

surfaces intended for assembly. Wipe excess
Loctite from swashplate with non-petroleum
base solvent applied to a cloth. Do not apply
Loctite to threads more than 15 minutes before
CM073510263 —UN—19MAR08
installing cap screws. If Loctite stands for
more than 15 minutes, repeat the application.
If repeating the application, it is not necessary
to remove previously applied Loctite.
7. Place the cylinder barrel (C) subassembly on a clean,

flat surface with the piston shoes facing up. Carefully
install the swashplate onto the barrel by slightly
lifting the side without the retaining strap. Slide the
swashplate over to engage installed strap around
piston retainer.
T803324,0000FD6 -19-17SEP07-5/24
8. Carefully reposition cylinder barrel/swashplate with

the swashplate down. Install the remaining spacer,
retaining strap and cap screw. Tighten all four cap
screws 22 to 26 N·m (16 - 19 lb-ft).
CM073510264 —UN—05SEP07
102711
PN=349
CM073510265 —UN—05SEP07
9. Carefully reposition cylinder barrel/swashplate with
cylinder barrel face on a clean flat surface. Lubricate
and install the output drive shaft subassembly into the
cylinder barrel subassembly.
T803324,0000FD6 -19-17SEP07-7/24
10. Install two headless 5/16 inch cap screws, five to six
inches long into the swashplate to use as guides.
Aligning the pin in the housing with the notch in the
swashplate, carefully slide the housing over the output
drive shaft/swashplate/cylinder barrel subassembly.
CM073510266 —UN—05SEP07
T803324,0000FD6 -19-17SEP07-8/24
11. Holding the cylinder barrel subassembly carefully in

position in the housing, reposition the motor on its
side. Remove the headless cap screws that were
used as guides.
CM073510267 —UN—05SEP07
102711
PN=350
12. Install new sealing washers on the two swashplate cap

screws. Install the cap screws into the swashplate.
Tighten to 27 to 33 N·m (20 to 24 lb-ft).
CM073510268 —UN—05SEP07
T803324,0000FD6 -19-17SEP07-10/24
13. Carefully reposition and support the motor on its

mounting flange. Support the output shaft in a slightly
raised position. Using a press or bearing cone driver
(Z), install the end cover bearing cone (17) onto the
output shaft (1). The bearing cone must seat against
CM073510269 —UN—19MAR08
the shoulder of the output shaft.
T803324,0000FD6 -19-17SEP07-11/24
14. Install two dowel pins (14) and gasket (13) on end
cover (2).
CM073510270 —UN—19MAR08
102711
PN=351
15. Lubricate and install bearing shims (16) and bearing

cup (18) into end cover (2).
CM073510271 —UN—19MAR08
T803324,0000FD6 -19-17SEP07-13/24
16. You must check the end play of the output drive
shaft subassembly. Install the end cover (2) without
installing either valve (3) or bearing plates (15). This
eliminates spring tension against the output shaft.
17. Install cap screws into the end cover (2), slowly and
CM073510272 —UN—05SEP07
evenly tighten them. On models 33 / 39 / 46 torque
the cap screws to 53 N·m (39 lb-ft) on models 54 / 64
torque to 85 N·m (63 lb-ft).
T803324,0000FD6 -19-17SEP07-14/24
18. Place and support the motor assembly on the end

cover (2). Gently tap the output shaft (1) inward with a
hammer. Install a magnetic base indicator (A) on the
mounting flange with the gauge on the output shaft
end. Using a pair of pliers to grip the output shaft as
CM073510273 —UN—05SEP07
low as possible, pry upward to determine the shaft end
play. The indicator must read .002 to .007 inches (.05
to .17 mm) shaft end play. If the end play is incorrect,
adjust by adding or removing shims under the bearing
cup (18) located in the end cover (2).
102711
PN=352
NOTE: There are two types of shaft seals. Depending

on the date of manufacture, either type seal may
have been used. A unit MUST be serviced with
the same type of seal as was originally installed.
The seals are not interchangeable.
CM073510274 —UN—05SEP07
19. After adjusting the end play, reposition the motor on
its mounting flange and remove the end cover (2).
Install two dowel pins into the face of the cylinder
barrel subassembly. Freely lubricate the bearing plate
with dowel pins and install it on to the cylinder barrel
subassembly.
T803324,0000FD6 -19-17SEP07-16/24
20. Lubricate the O-ring seal of the stationary seal

subassembly, and then install the seal.
CM073510275 —UN—19MAR08
T803324,0000FD6 -19-17SEP07-17/24
21. Install spacer (22) in to housing (4), then using a snap

ring pliers install retainer ring (23).
CM073510276 —UN—19MAR08
102711
PN=353
22. Install valve plate dowel pin in the face of the end
cover. Using petroleum jelly, lightly coat the side of the
valve plate (15) that will be facing the end cover (2).
The jelly will assist in holding the valve plate during
assembly. Install valve plate (15) over bearing cup
CM073510277 —UN—19MAR08
(18), aligning it with the dowel pins.
T803324,0000FD6 -19-17SEP07-19/24
23. Holding the valve plate (15) firmly in position, install

the end cover (2) on housing (4).
24. Install the cap screws (5) and (6) into end cover (2).
Tighten them slowly and evenly. Torque the cap screws
CM073510278 —UN—19MAR08
in a star pattern. Model 33 /39 /46 should be torqued
to 53 N·m (39 lb-ft). Models 54 /64 should be torqued
to 85 N·m (63 lb-ft). Torque each cap screw a second
time to compensate for gasket compression set.
T803324,0000FD6 -19-17SEP07-20/24
25. Install O-rings and back-up rings on valve block (3).
CM073510279 —UN—19MAR08
102711
PN=354
NOTE: Be careful not to damage the O-rings and back-up

rings. Use petroleum jelly to hold O-rings and
back-up rings in place during block installation.
26. The high pressure ports require an O-ring (A) and
CM073510280 —UN—19MAR08
back-up ring (B) . The O-ring (A) comes on first, then
the back-up ring (B). The curved side of the ring goes
towards the O-ring.
T803324,0000FD6 -19-17SEP07-22/24
27. Position the valve block (3) on end cover (2). Install
four hex bolts (7). Torque bolts to 38 N·m (28 lb-ft).
CM073510281 —UN—19MAR08
T803324,0000FD6 -19-17SEP07-23/24
28. Install the gauge port plugs (24) and torque to 22 N·m
(16 lb-ft). Install the two high pressure relief valves
and torque to 34 N·m (25 lb-ft).
CM073510282 —UN—19MAR08
T803324,0000FD6 -19-17SEP07-24/24
102711
PN=355
102711
PN=356
Group 30E
Secondary Extractor Hood Rotate Motor
Repair Secondary Extractor Hood Rotate Motor
CM073510283 —UN—12SEP07
1— Bolt 6— Commutator Plate 11— Key 16— Seal

2— Cover 7— Manifold 12— Shaft 17— Washer
3— Seal 8— Rotor 13— Bearing 18— Housing
4— Seal Ring 9— Plate 14— Thrust Washer 19— Bearing
5— Commutator Ring 10— Link 15— Bearing 20— Seal
T803324,0001027 -19-11SEP07-1/1
102711
PN=357
Required Tools • Masking Tape

• Breaker Bar
• Torque Wrench — lb-ft (N·m)
extremely helpful.
• Sockets: 1/2 or 9/16 in. thin wall
• Allen Sockets: 3/16 and 3/8 in.
• Adjustable Crescent Wrench
• Clean, petroleum-based solvent • SAE 10W40 SE or SF oil
• Emery paper • Special Bearing Mandrel
• Vise with soft jaw • Feeler Gauge .005 in. (.13 mm)
• Air pressure source • Blind Hole Bearing Puller
• Arbor Press • Corrosion Resistant Grease
• Screw Driver
T803324,0001028 -19-11SEP07-1/1
Disassembly
1. Place the motor in a soft jaw vise, with the shaft
pointing down and the vise jaws clamping firmly on
the sides of the housing mounting flange. Scribe
CM073510284 —UN—26MAR08
an alignment mark down the housing to facilitate
reassembly orientation where required.
T803324,0001029 -19-17SEP07-1/20
2. Remove the six bolts (1), using the appropriate socket.
CM073510285 —UN—26MAR08
102711
PN=358
3. Inspect the bolts for damaged threads, or sealing rings

under the bolt head. Replace damaged bolts.
CM073510286 —UN—26MAR08
T803324,0001029 -19-17SEP07-3/20
4. Remove the end cover (2) and O-ring seal (4). Discard
the O-ring.
CM073510287 —UN—12SEP07
T803324,0001029 -19-17SEP07-4/20
5. Thoroughly wash end cover (2) in proper solvent and

blow dry. Inspect the end cover for cracks and the
bolt head recess for good bolt head sealing surfaces.
Replace end cover as necessary.
CM073510288 —UN—26MAR08
102711
PN=359
NOTE: A polished pattern (not scratches) on the

cover from rotation of the commutator ring (5) is
normal. Discoloration would indicate excess fluid
temperature, thermal shock, or excess speed and
requires system investigation for cause and close
CM073510289 —UN—26MAR08
inspection of the end cover and rotor set.
6. Remove commutator plate (6). Inspect the plate for

cracks or burrs.
T803324,0001029 -19-17SEP07-6/20
7. Remove commutator ring (5) and seal ring (3).

Remove the seal ring from the commutator ring, using
an air hose to blow air into the ring groove until the
seal ring is lifted out. Once the seal ring is removed,
discard it. Inspect the commutator ring for cracks,
CM073510290 —UN—26MAR08
burrs, wear or scoring. If any of these conditions exist,
replace the commutator plate (6) and commutator ring
(5) as a matched set.
CM073510291 —UN—26MAR08
102711
PN=360
NOTE: The manifold is constructed of plates bonded

together to form an integral component not subject
to further disassembly for service. Compare
configuration of both sides of the manifold
to ensure that same surface is reassembled
CM073510292 —UN—26MAR08
against the rotor set.
8. Remove manifold (7) and inspect for cracks and

surface scoring. Replace the manifold if any of these
conditions exist. A polished pattern on the ground
surface from commutator ring or rotor rotation is
normal. Remove and discard the sealing rings (4) that
are on both sides of the manifold.
T803324,0001029 -19-17SEP07-8/20
9. Remove rotor (8) and wear plate (9) together to retain

the rotor set in its assembled form, maintaining the
same rotor vane to stator contact surfaces.
CM073510293 —UN—26MAR08
T803324,0001029 -19-17SEP07-9/20
NOTE: The rotor set (8) components may become

disassembled during service procedures.
Marking the surface of the rotor and stator that
is facing up, with itching ink or grease pencil
before removal for the motor will ensure correct
CM073510294 —UN—26MAR08
assembly of rotor into stator and rotor set into
motor. Marking all rotor components and mating
splined components for exact repositioning at
assembly will ensure maximum wear life and
performance of rotor set and motor.
10. Drive link (10) may come away from the coupling shaft
(12) with the rotor set and wear plate. You may have
to shift the rotor set on the wear plate to work the drive
link out of the rotor and wear plate. Inspect the rotor
set in its assembled form for nicks and scoring on set. Inspect the wear plate for cracks and scoring.
any surface. Also, check for broken or worn splines. Discard seal ring (4) that is between the rotor set and
If the rotor set components require replacement, the wear plate.
complete rotor set must be replaced as it is a matched
102711
PN=361
11. Place rotor set (8) and wear plate (9) on a flat surface
and center rotor in the stator such that two rotor lobes
(180 degrees apart) and a roller vane centerline are
on the same stator centerline. Check the rotor lobe
to the roller vane clearance with a feeler gage at this
CM073510295 —UN—26MAR08
common centerline. If there is more than .005 inches
(0.13 mm) of clearance, replace the rotor set.
T803324,0001029 -19-17SEP07-11/20
12. Remove drive link (10) from coupling shaft (12) if it

was not removed with the rotor set and wear plate.
Inspect the drive link for cracks, worn or damaged
splines. No perceptible lash (play) should be noted
between mating spline parts. Remove and discard
CM073510296 —UN—26MAR08
seal ring (4) from housing (18).
T803324,0001029 -19-17SEP07-12/20
13. Check exposed portion of coupling shaft (12) to be

sure you have removed all signs of rust and corrosion
which might prevent its withdrawal through the seal
and bearing. Crocus cloth or fine emery paper may be
used. Remove the key (11) at this time.
CM073510297 —UN—26MAR08
102711
PN=362
NOTE: Minor shaft wear in the seal area is permissible. If

wear exceeds .020 inches (0.51 mm) diametrically,
replace coupling shaft.
NOTE: A slight “polish” is permissible in the shaft
CM073510298 —UN—26MAR08
bearing area. Anything more would require
coupling shaft replacement.
14. Remove coupling shaft (12), by pushing on the output

end of the shaft. Inspect coupling shaft bearing and
seal surface for spalling, nicks, grooves, severe wear
or corrosion and discoloration. Inspect for damaged or
worn internal and external splines or keyway. Replace
the coupling shaft if any of these conditions exist.
15. Remove and discard seal (4) from housing (18).
CM073510299 —UN—26MAR08
T803324,0001029 -19-17SEP07-14/20
16. Remove thrust bearing (15) and thrust washer (14).

Inspect for wear, corrosion and a full complement of
retained rollers.
CM073510300 —UN—26MAR08
102711
PN=363
17. Remove seal (16) and back up washer (17) from

housing (18). Discard both items.
CM073510301 —UN—26MAR08
T803324,0001029 -19-17SEP07-16/20
18. Remove housing (18) from the vise, invert it and

remove and discard seal (20). A blind hole bearing
or seal puller is required.
CM073510302 —UN—26MAR08
T803324,0001029 -19-17SEP07-17/20
19. Inspect housing (18) assembly for cracks, the

machined surfaces for nicks, burrs and corrosion.
Remove burrs that can be removed without changing
dimensional characteristics. Inspect tapped holes for
thread damage. If the housing is defective in these
CM073510303 —UN—26MAR08
areas, discard the housing assembly.
102711
PN=364
NOTE: The depth or location of bearings/bushing (13) in

relation to the housing wear plate surface and the
depth or location of bearing/bushing (19) in relation
to the beginning of bearings/bushing counter bore
should be measured and noted before removing the
CM073510304 —UN—26MAR08
bearings/bushings. This will facilitate the correct
reassembly of new bearings/bushings.
20. If the housing (18) assembly has passed inspection to

this point, inspect the housing bearing/bushings (19)
and (13) and if they are captured in the housing cavity
the thrust washer (14) and thrust bearing (15). The
bearing rollers must be firmly retained in the bearing
cages, but must rotate and orbit freely. All rollers
and thrust washers must be free of corrosion. If the
housing has passed inspection the disassembly of the
motor is completed.
T803324,0001029 -19-17SEP07-19/20
21. If the bearings, bushing or thrust washers must

be replaced use a suitable size bearing puller to
remove bearing/bushing (19) and (13) from housing
(18) without damaging the housing. Remove thrust
washers (14) and thrust bearing (15) if they were
CM073510306 —UN—26MAR08
previously retained in the housing by bearing (13).
CM073510307 —UN—26MAR08
T803324,0001029 -19-17SEP07-20/20
102711
PN=365
Assembly
Replace all seals and seal rings with new ones each
time you reassemble the motor. Lubricate all seals and
seal rings with SAE 10W40 oil or clean grease before
CM073510308 —UN—26MAR08
assembly. Wash all parts in clean petroleum based
solvent before assembly. Blow them dry with compressed
air. Remove any paint chips from mating surfaces of
the end cover, commutator set, manifold set, wear plate
housing and from ports and sealing areas.
CAUTION: Since they are flammable, be extremely

careful when using solvent. Even a small
explosion or fire could cause injury or death.
CAUTION: Wear eye protection and be sure

to comply with OSHA or other maximum
air pressure requirements.
CM073510309 —UN—26MAR08
NOTE: Bearing mandrel must be pressed against the
lettering end of the bearing shell. Take care that
the housing bore is square with the press base and
the bearing/bushing is not cocked when pressing
a bearing/bushing into the housing.
NOTE: If the bearing mandrel specified is not available

and alternate methods are used to press in
bearing/bushing (13) and (19), the bearing/bushing
bearing/bushing (19) with clean corrosion resistant
depth specified must be achieved to insure
grease recommended in the material section. Press
adequate bearing support and correct relationship
the new bearing/bushing into the counter bore at
to adjacent components when assembled.
the mounting flange end of the housing, using the
appropriate size bearing mandrel which will control the
IMPORTANT: Because bearing/bushings (13) and
bearing/bushing depth .151 - .161 inches (3.84 – 4.09
(19) have press fit into the housing, they
mm) from the end of the bearing counter bore.
must be discarded when removed. They
must never be reused.
1. If the housing (18) bearing components were removed

for replacement, thoroughly coat and pack a new outer
T803324,000102A -19-20MAR08-1/20
2. The inner housing bearing/bushing (13) can now be

pressed into its counter bore in housing (18) flush to
.03 inch (.76 mm) below the housing wear plate contact
face. Use the opposite end of the bearing mandrel that
was used to press in the outer bearing/bushing (19).
CM073510310 —UN—26MAR08
Continued on next page T803324,000102A -19-20MAR08-2/20
102711
PN=366
3. Press a new dirt and water seal (20) into the housing
(18) outer bearing counter bore. The dirt and water
seal (20) must be pressed in until its flange is flush
against the housing.
CM073510311 —UN—26MAR08
CM073510312 —UN—26MAR08
T803324,000102A -19-20MAR08-3/20
4. Place housing (18) assembly into a soft jawed vise

with the coupling shaft bore down, clamping against
the mounting flange.
CM073510313 —UN—26MAR08
102711
PN=367
5. Assemble a new back up washer (17) and new seal

(16) with the seal lip facing toward the inside motor.
Now, install them into their respective counter bores
in housing (18).
Continued on next page CM073510314 —UN—26MAR08

CM073510315 —UN—11SEP07
T803324,000102A -19-20MAR08-5/20
102711
PN=368
6. Assemble thrust washer (14) then thrust bearing (15).
CM073510316 —UN—26MAR08
CM073510317 —UN—11SEP07
T803324,000102A -19-20MAR08-6/20
7. Apply masking tape around the splines or keyway

shaft (12) to prevent damage to the seal.
CM073510318 —UN—26MAR08
102711
PN=369
IMPORTANT: The outer bearing (19) is not

lubricated by the system’s hydraulic fluid.
Be sure it is thoroughly packed with the
recommended grease.
CM073510319 —UN—26MAR08
NOTE: A 102 tube is included in each seal kit.
NOTE: The coupling shaft (12) will be flush or

just below the housing wear plate surface
when properly seated.
8. Be sure that a generous amount of clean corrosion

resistant grease has been applied to the lower (outer)
housing bearing/bushing (19). Install the coupling
shaft (12) into housing (18) seating against the thrust
bearing (15) in the housing.
T803324,000102A -19-20MAR08-8/20
NOTE: One or two alignment studs screwed finger

tight into housing (18) bolt holes, approximately
180 degrees apart, will facilitate the assembly
and alignment of components as required in
the following procedures.
CM073510320 —UN—26MAR08
9. Apply a small amount of grease to a new seal ring (4)
and insert it into the housing (18) seal ring groove.
T803324,000102A -19-20MAR08-9/20
NOTE: Use any alignment marks put on the coupling

shaft and drive link before disassembly to assemble
the drive link splines in their original position in
the mating coupling shaft spline.
CM073510321 —UN—26MAR08
10. Install drive link (10) the long splined end down into the
coupling shaft (12) and engage the drive link splines
into mesh with the coupling shaft splines.
102711
PN=370
11. Assemble wear plate (9) over the drive link (10) and
alignment stubs onto the housing (18).
CM073510322 —UN—26MAR08
T803324,000102A -19-20MAR08-11/20
12. Apply a small amount of clean grease to a new seal

ring (4) and assemble it into the seal ring groove on
the wear plate side of the rotor set.
CM073510323 —UN—26MAR08
T803324,000102A -19-20MAR08-12/20
NOTE: It may be necessary to turn one alignment stud

out of the housing (18) temporarily to assemble
rotor set (8) or manifold (7) over the drive link.
NOTE: The rotor set counter bore side must be down
CM073510324 —UN—26MAR08
against wear plate for drive link clearance and
to maintain the original rotor – drive link spline
contact. A rotor set without a counter bore and
that was not etched before assembly can be
reinstalled using the drive link spline pattern on
the rotor splines if apparent, to determine which
side was down. The rotor set seal ring groove
faces toward the wear plate (9).
13. Install and assemble rotor set (8) onto wear plate (9)
with rotor counter bore and seal ring down and the
splines into mesh with the drive link splines.
102711
PN=371
NOTE: The manifold (7) is made up of several plates

bonded together permanently to form an integral
component. The manifold surface that must contact
the rotor set has its series of irregular shaped
cavities on the largest circumference or circle around
CM073510325 —UN—26MAR08
the inside diameter. The polished impression left on
the manifold by the rotor set is another indication
of which surface must contact the rotor set.
14. Apply clean grease to a new seal ring (4) and

assemble it in the seal ring groove in the rotor set
contact side of manifold (7).
T803324,000102A -19-20MAR08-14/20
15. Assemble the manifold (7) over the alignment studs

and drive link (10) and onto rotor set. Be sure the
correct manifold surface is against the rotor set.
CM073510326 —UN—26MAR08
T803324,000102A -19-20MAR08-15/20
16. Apply grease to a new seal ring (4) and insert it in the
seal ring groove exposed on the manifold.
CM073510327 —UN—26MAR08
102711
PN=372
17. Assemble the commutator plate (6) over alignment

studs onto the manifold.
CM073510328 —UN—26MAR08
T803324,000102A -19-20MAR08-17/20
18. Assemble a new seal ring (3) flat side up, into
commutator ring (5) and assemble commutator ring
over the end of drive link (10) onto manifold (7) with
seal ring side up.
CQ280284 —UN—19MAR08
CM073510329 —UN—26MAR08
102711
PN=373
19. Assemble a new seal ring (4) into end cover (2) and
assemble end cover over the alignment studs and
onto the commutator set.
CQ280283 —UN—19MAR08
CM073510330 —UN—26MAR08
102711
PN=374
20. Assemble the bolts (1) and screw in finger tight.

Remove and replace the two alignment studs with
bolts after the other bolts are in place. Alternately and
progressively tighten the bolts to pull the end cover
and other components into place with the final torque
of 22- 26 lb-ft (30-35 N·m).
CQ280285 —UN—20MAR08
CM073510331 —UN—26MAR08
CQ280282 —UN—19MAR08
CM073510332 —UN—26MAR08
T803324,000102A -19-20MAR08-20/20
102711
PN=375
102711
PN=376
Group 30F
Cooling Package/Oil Cooler Motor
Repair Cooling Package/Oil Cooler Motor
CM073510333 —UN—11SEP07
1— Housing 6— Key 11— Seal 16— Spacer

2— Cover 7— Dowel Pin 12— Seal 17— Check Valve
3— Housing 8— Thrust Plate 13— Seal 18— Washer
4— Shaft 9— Snap Ring 14— Seal 19— Washer
5— Bolt 10— Seal 15— Spacer 20— Nut
102711
PN=377
1. Place the motor in a vise with the drive shaft pointing

downward. Match-mark all sections; be sure to align
CM073510334 —UN—11SEP07
T803324,000102B -19-18SEP07-2/7

washer (18).
CM073510335 —UN—19MAR08
T803324,000102B -19-18SEP07-3/7

careful not to damage the machined surfaces. Dowel
pins (7), if used, will remain in either port end cover
(2), or gear housing (3). Do Not remove them.
CM073510336 —UN—19MAR08
102711
PN=378
4. Remove thrust plate (8), gear housing (3), gear

assembly (4) and remaining thrust plate (8) from cover
(1).
CM073510337 —UN—19MAR08
T803324,000102B -19-18SEP07-5/7
5. Place the front cover (1) in a vise with the mounting

face pointing upward. Remove the snap ring (9) using
a pair of snap ring pliers.
CM073510338 —UN—19MAR08
T803324,000102B -19-18SEP07-6/7
6. Remove the two spacers (16 & 15) and seal (13) from
front cover (1).
CM073510339 —UN—19MAR08
T803324,000102B -19-18SEP07-7/7
102711
PN=379
Clean and Inspect

4. Dowel pins (7) must be replaced if either the dowel
1. Clean and inspect all parts for wear or damage, pin or dowel hole is damaged. If there is damage,
replace if necessary. See John Deere Parts Manual either the dowel or machined housing, or both must be
for part numbers to order. replaced. If more than reasonable force is required to
seat the dowels, the cause may be poorly deburred or
2. Replace thrust plates (8) if they are scored, eroded dirty parts; cocking of dowel in the hole; or improper
or pitted. pin-to-hole fit.
3. Check the center of the thrust plates where the gears 5. All sealing parts must be replaced. See John Deere
mesh; erosion here indicates oil contamination. Parts Manual for complete seal kit part number.
T803324,000102C -19-14SEP07-1/1
Assembly
1. Grip shaft end cover (1) in a vise with mounting face
down. Examine check valve (17) to be sure they are
tightly in place. Replacement is necessary only if parts
CM073510340 —UN—19MAR08
are damaged. Remove with a screwdriver.
2. If the check valves are being replaced, screw in the
new parts tightly. Stake plug with a prick punch at
both ends of screwdriver slot and around edges. Peen
edge of hole 0.794 to 1.588 mm (1/32 to 1/16 inch)
with a 38.1 mm (1- 1/2 inch) diameter steel ball.
T803324,000102D -19-14SEP07-1/10
3. Before inserting a new lip seal (13) in the shaft cover

(1), coat the outer edge of the seal and its bore with
the lip seal up, press it into the mounting flange side of
the shaft end cover (1). Make sure the lip seal is fully
CM073510341 —UN—19MAR08
seated in the bore. Wipe off excess sealant.
102711
PN=380
4. Install both spacers (15) (16) into housing (1). Once

they are seated, install snap ring (9) using a pair of
snap ring pliers.
CM073510342 —UN—19MAR08
T803324,000102D -19-14SEP07-3/10
CM073510343 —UN—19MAR08
5. Grease new seals (14) and insert them into the with a soft hammer until it rests tightly against the shaft
grooves in both sides of the gear housing (3). Place end cover (1). Be careful not to pinch the seal.
the gear housing (3) on shaft end cover (1) and tap
T803324,000102D -19-14SEP07-4/10
6. Install seals (10), (11) and (12) into the grooves

located in thrust plate (8).
CM073510344 —UN—19MAR08
102711
PN=381
7. Carefully slip the thrust plate (8) through gear housing

(3) and into place onto the shaft end cover (1).
CM073510345 —UN—19MAR08
T803324,000102D -19-14SEP07-6/10
8. Lightly grease drive shaft, from set (4) and slide drive
shaft (4) through the end cover (1) with a twisting
motion until the integral gear rests against the thrust
plate (8). Avoid damaging lip seal (13).
CM073510346 —UN—19MAR08
T803324,000102D -19-14SEP07-7/10
9. Once shaft assembly (4) is seated against thrust plate

(8) located in the housing, install the other thrust plate
(8) over the journals of shaft assembly (4).
CM073510347 —UN—19MAR08
102711
PN=382
10. Place end cover (2) over the gear journals (4). Align
the dowel pins with the holes in the mating housing.
Be careful not to pinch the seal, tap the end cover
lightly in the center to engage the dowel pins and to
move the parts together in a final seat.
CM073510348 —UN—19MAR08
T803324,000102D -19-14SEP07-9/10
11. Install new washers (18) and bolts (5). Torque to

specification.
CM073510349 —UN—19MAR08
T803324,000102D -19-14SEP07-10/10
102711
PN=383
102711
PN=384
Group 30G
Variable Displacement Ground Drive Motor (Wheel)
Repair Variable Displacement Ground Drive Motor (Wheel)
CM002500259 —UN—12JUL00
102711
PN=385
1— Ring-Distance 21— Valve-Segment 41— Bolt 61— Plug

2— Ring Kit-Piston 22— Gasket-End Cap 42— O-ring 62— Bolt
3— Shaft Assembly 23— Pin 43— Cover-Piston 63— Filter-Screen
4— O-ring 24— Housing 44— Bolt 64— O-ring
5— O-ring 25— Ring-Seal 45— Plug 65— Orifice
6— Housing-Bearing 26— Lever-Feedback 46— O-ring 66— Nut-Seal
7— Ring-Retaining 27— Bolt 47— O-ring 67— Cap
8— O-ring 28— Bolt 48— Plug 68— Plug
9— Seal-Lip 29— Piston-Servo 49— O-ring 69— O-ring
10— Carrier-Seal 30— Nut-Seal Lock 50— Spring 70— Bolt
11— Bolt 31— Bolt 51— Guide-Spring 71— Plug
12— O-ring 32— O-ring 52— Piston 72— Orifice
13— Housing-Motor 33— Bolt 53— Guide-Spring 73— Spool
14— Shaft-Synch 34— Nut 54— Spring 74— Plug
15— Roller 35— O-ring 55— Seat-Spring 75— Relief-Charge
16— Pin-Support 36— O-ring 56— Spring 76— Spring
17— Block-Cylinder 37— Bolt 57— Seat-Spring 77— Poppet
18— Bearing 38— Bolt 58— Bushing Assy
19— Pin 39— Plug 59— O-ring
20— Plate-Bearing 40— O-ring 60— Ring
T803324,000102E -19-14SEP07-2/2
About Servicing the Motor

These service instructions will familiarize you with the
fixed displacement motor's relative position of each part,
proper methods for assembly or disassembly of the units
and care and use of this motor. This will give you the best
performance and a longer working life.
To facilitate the repair of this motor, and before any work
is done, we suggest you first read all of the repair steps.
The first requirement for good maintenance of any
hydraulic equipment is cleanliness. Make sure you
perform all repair work in a clean area. It is important to
air blast all parts and wipe them with a clean, lintless cloth
CM002500263 —UN—12JUL00
before assembly.
Use caution to avoid damaging machined surfaces when
clamping parts in a vise.
Check all replacement parts before installation to be
certain they were not damaged in shipment. Change
all seals, O-rings, and gaskets whenever the motor is
repaired. Close all openings with cap and plugs, when
a repair is done.
Fill the motor with clean system oil before start-up.
T803324,0000765 -19-14SEP07-1/1
102711
PN=386
Shaft Seal Disassembly

NOTE: Lip type seals are used on the motor. These
seals can be replaced without major disassembly
of the unit. However, replacement of the shaft seal
CM073510350 —UN—19MAR08
requires removal of the motor from the final drive.
1. Remove the seal carrier retaining ring (7) from the

bearing housing (6).
T803324,000102F -19-12SEP07-1/4
2. Carefully pull the seal carrier (10) from the housing

(6). Care must be taken to prevent damage to the
housing bore or shaft.
CM073510351 —UN—19MAR08
T803324,000102F -19-12SEP07-2/4
3. Remove O-ring (8) from housing (6).
CM073510352 —UN—19MAR08
102711
PN=387
4. Remove seal (9) from the carrier (10). Once removed,

the seal is not reusable.
CM073510353 —UN—19MAR08
T803324,000102F -19-12SEP07-4/4
Inspection
1. Inspect the carrier and the new seal for any damage
or nicks.
2. Inspect the seals on the shaft for rust, wear or
CM073510354 —UN—12SEP07
contamination.
T803324,0001031 -19-12SEP07-1/1
Assembly
1. Install the carrier O-ring (8) into the groove in the
housing (6). Prior to assembly, lubricate the carrier
O-ring as well as the interior surface of the seal with
CM073510355 —UN—19MAR08
petroleum jelly.
2. Protect the seal lip from damage during installation
by wrapping the splines or key end of the shaft with
plastic film or by using a seal installation tool.
102711
PN=388
NOTE: The outside of the seal may be lightly coated

with a sealant prior to installation. This will aid
in preventing leaks caused by damage to the
seal bore in the seal carrier.
CM073510356 —UN—19MAR08
3. Install the carrier assembly (10) and (9) over the shaft
(3) and into the bore of housing (6). Take care not to
damage the O-ring or seal during installation.
T803324,0001032 -19-14SEP07-2/3
4. Install the seal carrier retainer ring (7) and O-ring (12).
CM073510357 —UN—19MAR08
T803324,0001032 -19-14SEP07-3/3
102711
PN=389
Cartridge Disassembly
CM073510358 —UN—12SEP07
1— Distance Spacer Ring 4— O-ring 6— Bearing Housing 11— Bolts

3— Shaft Assembly 5— O-ring 7— Retaining Ring 13— Motor Housing
102711
PN=390
1. Remove the following items, (12), (7), (10), (9) and (8)
from shaft assembly (3).
CM073510359 —UN—19MAR08
T803324,0001033 -19-12SEP07-2/8
2. Remove the screws (11).
CM073510360 —UN—19MAR08
T803324,0001033 -19-12SEP07-3/8
3. Separate bearing housing (6) from main housing (13).
CM073510361 —UN—19MAR08
102711
PN=391
4. Remove O-rings (4) and (5).
CM073510362 —UN—19MAR08
T803324,0001033 -19-12SEP07-5/8
5. Remove spacer ring (1).
CM073510363 —UN—19MAR08
T803324,0001033 -19-12SEP07-6/8
6. Press shaft assembly (3) out of bearing housing (6),

taking care not to damage the shaft, piston sockets
and speed sensor ring (if installed).
CM073510364 —UN—19MAR08
102711
PN=392
7. The inner ring (7) for the shaft seal carrier may be
removed from the bearing housing (6) at this time.
CM073510365 —UN—19MAR08
T803324,0001033 -19-12SEP07-8/8
Housing Disassembly
CM073510366 —UN—19MAR08
24— End Cover Housing 26— Feed Back Lever 28— Lock Screw 61— Plug
25— Seal Ring 27— Cone Point Set Screw 29— Servo Piston
102711
PN=393
1. Remove end cap plug (61) from end cap (24).
CM073510367 —UN—19MAR08
T803324,0001034 -19-12SEP07-2/5
2. Remove lock screw (28) and cone set screw (27).
CM073510368 —UN—19MAR08
T803324,0001034 -19-12SEP07-3/5
3. Remove feedback lever (26) through the port in end

cap housing (24).
CM073510369 —UN—19MAR08
102711
PN=394
CM073510370 —UN—19MAR08
4. Remove servo piston (29) from end cap (24). Inspect 5. Inspect servo piston bore in end cap (24) for damage
seal ring (25) for damage or wear. Remove seal ring or wear.
(25) from servo piston (29) if replacement is required.
T803324,0001034 -19-12SEP07-5/5
Housing Assembly
1. Carefully install seal ring (25) on servo piston (29),
lubricate with hydraulic oil.
CM073510371 —UN—19MAR08
102711
PN=395
2. Install servo piston (29) into housing (24). The end of

the servo piston with the seal ring is located opposite
the multifunction block/control mounting surface of the
end cap housing (24).
CM073510372 —UN—19MAR08
T803324,0001035 -19-12SEP07-2/6
3. Install feedback lever (26) into the servo piston (29)

through the port in end cap housing (24).
CM073510373 —UN—19MAR08
102711
PN=396
CM073510374 —UN—19MAR08
4. The off set of feedback lever (26) must be located so that its point enters the groove (A) in the feedback
away from the multifunction block control of the end lever. Do not tighten the set screw at this time.
cap housing (24). Install the cone point set screw (27)
T803324,0001035 -19-12SEP07-4/6
5. Install and torque the end cap housing plug (61).

NOTE: A 1.06” (26.9 mm) diameter rod with the
end machined perpendicular to its axis may
be inserted through the valve sleeve bore in
CM073510367 —UN—19MAR08
the end cap housing to align the fork while
tightening the cone point set screw.
6. Torque the cone point set screw (27) to 5 N·m (44 lb-ft).
102711
PN=397
CM073510375 —UN—19MAR08
7. After torquing the cone point set screw, install and
torque the lock screw (28) to 0.62 N·m (14 lb-ft).
T803324,0001035 -19-12SEP07-6/6
102711
PN=398
Reconditioning and Replacement of Shaft Assembly
CM053510150 —UN—21JUL05
A—Speed Sensor Ring C—Synchronizing Shaft Insert E—Bearing G—Seal Area
B—Piston Assemblies D—Bearing F— Bearing Retaining Nut H—Spring Seat
There is an optional magnetic speed sensor ring (A) that is NOTE: If the bearing adjustments for used bearings are
pressed into a machined surface of the output shaft flange. incorrect or if used bearings must be replaced, a
NOTE: Do not damage the magnetic speed sensor ring. complete shaft assembly including pistons and
new bearings must be installed.
Check the seal area of the shaft (G) and the output splines
for damage or wear. Inspect the synchronizing shaft Check the piston assemblies (B) for damage and wear. It
insert (C) and the spring seat (H) for wear. The internal is normal for the piston balls to be tight in their sockets.
spring must not be damaged. These parts are retained The piston sockets are retained in the output shaft by an
by three hardened steel pins pressed into blind holes in interference press fit.
the synchronizing shaft insert (C), and are not individually NOTE: If a piston(s) must be replaced, this entire
serviceable. assembly, including pistons and new bearings,
Inspect shaft bearings (D and E) for wear and roughness. must be installed.
Check that the bearing retaining nut (F) is firmly staked
to the output shaft, and that no noticeable looseness is The replacement output shaft assembly includes pistons
present in the bearings (D and E). and bearings.
T803324,0000768 -19-16FEB06-1/1
102711
PN=399
Piston Ring Reconditioning and Replacement
CM053510151 —UN—21JUL05
A—Radial identification mark B—The spherical surface of the
located on this side of piston piston ring must conform to
ring. the spherical shape of the
piston.
A small pair of retaining ring pliers may facilitate the A radial identification mark provided on the outer side of
removal of the piston rings from the pistons. the piston rings must NOT overlap each other.
Install new piston rings onto the pistons.
NOTE: When installing new spherical piston rings,
make sure the spherical surface conforms to
the shape of the piston!
T803324,000076A -19-14SEP07-1/1
102711
PN=400
Reconditioning and Replacement of Bearing Plate, Valve Segment and Cylinder Block
CM073510376 —UN—12SEP07
17— Cylinder Block 20— Bearing Plate 21— Valve Segment
T803324,0001037 -19-12SEP07-1/6
CM073510377 —UN—12SEP07
1. Inspect the running (bronze) surface of the bearing
plate (20) for damage and excessive wear. The
sealing surfaces must be free from scratches and
nicks. The locating pinholes must not be worn.
T803324,0001037 -19-12SEP07-2/6
2. Inspect the valve segment (21) for damage or wear on

the sealing surfaces. Inspect the spindle (B) for wear.
CM073510378 —UN—12SEP07
102711
PN=401
3. Check the spindle in the valve segment (21) by

measuring distance (A). If the dimension is not within
1.28” (32.6 mm) to 1.29” (32.8 mm), it indicates that
the spindle has moved in the valve segment and the
assembly must be replaced.
CM073510379 —UN—12SEP07
T803324,0001037 -19-12SEP07-4/6
4. Inspect the cylinder block assembly (17) for wear or

damage. The bearing plate (20) must be free from
scratches or nicks and the holes for the bearing plate
locating pins must not be worn. The races for the
synchronizing shaft rollers must not be worn. If the
CM073510380 —UN—12SEP07
cylinder block (17) requires replacement, remove the
bearing using a suitable puller.
T803324,0001037 -19-12SEP07-5/6
5. Press the new bearing (D) into the cylinder block using
a suitable press pin. Press the bearing (D) into the
cylinder block until it is located the proper distance
below the plate surface. Distance (B) should be 1.101”
(27.97 mm) and distance (C) should be 0.45” + 0.01”
CM073510381 —UN—12SEP07
(11.75 + 0.25 mm).
T803324,0001037 -19-12SEP07-6/6
102711
PN=402
Group 30H
Fixed Displacement Motor (Track)
Repair Fixed Displacement Motor (Track)
CM073510382 —UN—14SEP07
102711
PN=403
1— Ring 18— Plug 35— O-ring 52— Piston

2— Housing 19— Plug 36— Piston 53— Guide
3— Cover 20— Spring 37— Bolt 54— Spring
4— O-ring 21— Poppet 38— Bolt 55— Round Retainer
5— O-ring 22— Gasket 39— Fitting 56— Spring
6— Gasket 23— Pin 40— O-ring 57— Round Retainer
7— Snap Ring 24— Housing 41— Socket Head Screw 58— Ring
8— O-ring 25— Ring 42— O-ring 59— O-ring
9— Seal 26— Lever 43— Housing 60— Bushing
10— Seal 27— Bolt 44— Bolt 61— Plug
11— Bolt 28— Bolt 45— Plug 62— Bolt
12— O-ring 29— O-ring 46— O-ring 63— Filter
13— O-ring 30— Lock Nut 47— O-ring 64— O-ring
14— Bolt 31— Nut 48— Plug 65— Orifice
15— Plug 32— O-ring 49— O-ring 66— Nut
16— Orifice 33— Rod 50— Spring 67— Cover
17— Spool 34— Nut 51— Spring 68— Plug
T803324,0001038 -19-14SEP07-2/2
Fixed Displacement Motor (Track) air blast all parts and wipe them clean with a lint free cloth
before assembly.
These service instructions will familiarize you with the
fixed displacement motor’s relative position of each part, Use caution to avoid damaging machined surfaces when
proper methods for assembly or disassembly of the units clamping parts in a vise.
and care and use of this motor. This will give you the best
performance and a longer working life. Check all replacement parts before installation to be
certain they were not damaged in shipment. Change
To facilitate the repair of this motor, and before any work is all seals, O-rings and gaskets whenever the motor is
done, we suggest that you first read all of the repair steps. repaired. Close all openings with caps and plugs, when a
repair is being done.
The first requirement for good maintenance of any
hydraulic equipment is cleanliness. Make sure you Fill the motor with clean system oil before start up.
perform all repair work in a clean area. It is important to
T803324,0001039 -19-14SEP07-1/1
Cartridge Assembly
A—Inner Retaining Ring E—O-ring
B—Bearing Housing F— O-ring
C—Spacer Ring G—Shaft Assembly
D—Main Housing H—Bolt
CM073510383 —UN—19MAR08
Continued on next page T803324,000103A -19-13SEP07-1/4
102711
PN=404
IMPORTANT: Do not damage the piston sockets

or shaft seal surfaces.
1. The inner retainer ring (A) for the shaft seal carrier
may be installed in the bearing housing (B).
CM073510384 —UN—19MAR08
T803324,000103A -19-13SEP07-2/4
2. Install spacer ring (C). The end of the spacer with

the larger diameter is installed next to the inner shaft
bearing cup.
CM073510385 —UN—19MAR08
T803324,000103A -19-13SEP07-3/4
CM073510386 —UN—13SEP07
3. Install O-ring (E and F) and then install main housing

(D). Install and torque bolts (H) to 32 N·m (24 lb-ft).
T803324,000103A -19-13SEP07-4/4
102711
PN=405
Synchronizing Shaft Assembly
CM073510387 —UN—13SEP07
A—Cylinder Block B—Synchronizing Shaft Support C—Synchronizing Shaft Rollers D—Synchronizing Shaft
Pin
102711
PN=406
1. Install the first synchronizing shaft support pin (B) into

the recess in the cylinder block and retain with grease.
CM073510388 —UN—19MAR08
T803324,000103B -19-13SEP07-2/6
2. Install the synchronizing shaft roller (C) on the journals

of the synchronizing shaft (D) and retain with grease.
CM073510389 —UN—19MAR08
T803324,000103B -19-13SEP07-3/6
3. The recess (X) of each roller (C) must be positioned

to face the center line of the synchronizing shaft (D).
Position each roller (C) with its outside edge flush with
the end of the synchronizing shaft (D) journals.
CM073510390 —UN—19MAR08
102711
PN=407
4. Install the second synchronizing shaft support pin (B)

into the motor shaft assembly and retain with grease.
CM073510391 —UN—19MAR08
T803324,000103B -19-13SEP07-5/6
5. Install the synchronizing shaft (D) and rollers (C) into

the motor shaft (2). The cylinder block end of the shaft
(1) is larger than the motor shaft end.
6. The roller (C) must enter the races in the motor shaft
insert, and the recess in the end of the synchronizing
shaft must engage the support pin (B).
7. Tip and rotate the synchronizing shaft in all directions
to check binding. The synchronizing shaft rollers must
move freely in the races in the motor shaft insert.
CM073510392 —UN—24MAR08
T803324,000103B -19-13SEP07-6/6
102711
PN=408
Cylinder Block Assembly
CM053510157 —UN—19MAR08
A—Position of Motor Shaft prior C—Pistons and cylinder block E—Synchronizing Shaft Rollers G—Synchronizing Shaft Support
to installing the cylinder block bores F— Synchronizing Shaft Pin
B—Cylinder Block D—Pistons
T803324,000103C -19-17SEP07-1/8
1. Position the motor as shown (A) in the illustration. Tip

the three pistons (2) closet to the minimum angle stop
out, toward the housing.
CM073510393 —UN—19MAR08
Continued on next page T803324,000103C -19-17SEP07-2/8
102711
PN=409
2. Lubricate the pistons and cylinder block bores (C) with

hydraulic oil.
CM073510394 —UN—19MAR08
T803324,000103C -19-17SEP07-3/8
3. With the synchronizing shaft (F) supported in the

motor shaft, install the cylinder block (B) and its
synchronizing shaft support pin (G) onto the piston (D)
and synchronizing shaft (F).
CM073510395 —UN—19MAR08
102711
PN=410
4. The cylinder block (B) must be positioned so the

synchronizing shaft rollers (E) will enter their races in
the block, while each piston enters its corresponding
bore in the block.
CM073510396 —UN—19MAR08
CM073510397 —UN—19MAR08
T803324,000103C -19-17SEP07-5/8
5. A brass rod may be inserted through the cylinder

kidneys to guide the piston into position. Start with
the six pistons closest to the lowest part of the end
cap mounting surface.
CM073510398 —UN—13SEP07
102711
PN=411
6. After the six pistons enter their bores, tilt the cylinder
block (B) so the shaft synchronizing shaft rollers (E)
enter their races in the cylinder block (B) and the
support pins (G) enter the recess of the synchronizing
shaft (F).
CM073510399 —UN—19MAR08
T803324,000103C -19-17SEP07-7/8
7. Lift the cylinder block (B) slightly and guide the

remaining three pistons into their bores.
NOTE: If the cylinder block (B) is properly installed,
there will be very little rotational free-play between
the block and the motor shaft.
CM073510400 —UN—13SEP07
8. After the last piston is in position, check the position
of the rollers (E) closest to the minimum angle stop.
Maintain an inward force on the cylinder block (B) and
carefully push it toward the highest part of the end cap
mounting surface and check that all synchronizing
shaft rollers (E) are in place.
T803324,000103C -19-17SEP07-8/8
102711
PN=412
Bearing Plate and Valve Segment Assembly
CM073510401 —UN—13SEP07
A—Bearing Plate Locating Pins C—End Cap Aligning Pin E—Valve Segment
B—Bearing Plate D—Gasket F— End Cover
T803324,000103D -19-13SEP07-1/5
1. Locate the bearing plate locating pins (A) into the

cylinder block. The longer end of each shouldered pin
is installed into the block.
CM073510402 —UN—19MAR08
102711
PN=413
2. Install the bearing plate (B) on the cylinder block, with

the steel side facing toward the block. Lubricate the
bronze side of the plate with clean filtered hydraulic oil.
CM073510403 —UN—19MAR08
T803324,000103D -19-13SEP07-3/5
3. Install the end cap alignment pins (C) and gasket (D).
Carefully locate the cylinder block in the approximate
center of the housing opening.
CM073510404 —UN—19MAR08
T803324,000103D -19-13SEP07-4/5
4. Install the valve segment (E) into the end cap so the
segment spindle engages the setting lug in the servo
piston and retain with heavy grease. The hole in the
end of the segment should be installed opposite the
minimum displacement adjustment screw. Locate the
CM073510405 —UN—19MAR08
valve segment and servo piston in the approximate
center of their travel.
T803324,000103D -19-13SEP07-5/5
102711
PN=414
End Cap to Main Housing Assembly

A—End Cap Assembly with C—Screws
Valve Segment
B—Screws
CM073510406 —UN—19MAR08
T803324,000103E -19-14SEP07-1/4
NOTE: Do not allow the piston or synchronizing shaft

rollers to fall out of position.
1. Install end cap assembly with valve segment (A).

The segment spindle must engage the bearing in the
CM073510407 —UN—19MAR08
cylinder block.
T803324,000103E -19-14SEP07-2/4
2. Install the screws (B and C) retaining the end cap

assembly to the motor. The screws must be installed
in their proper locations to ensure adequate thread
engagement. The internal spring (in the motor shaft)
should hold the end cap away from the housing a
CM073510408 —UN—19MAR08
short distance.
102711
PN=415
3. Tighten screws by hand in a double X pattern while

rotating the motor shaft to ensure proper positioning of
the synchronizing shaft rollers.
4. When the end cap is in position, torque the screws in
double X pattern to 78 N·m (58 lb-ft).
CM073510409 —UN—13SEP07
5. Rotate the motor and check for play between the
shaft and cylinder block. Any play indicates that the
synchronizing shaft rollers are not installed correctly.
Recheck the end cap screw torque.
6. Reinstall the minimum angle servo cover, control
springs (if used), 4 way valve spool and sleeve (if
used) and control and multifunction block (if used).
T803324,000103E -19-14SEP07-4/4
102711
PN=416
Group 30I
Chopper Motor
Repair Chopper Motor
CM073510410 —UN—17SEP07
102711
PN=417
Chopper Motor
1— Ring 9— Housing 17— Pin 25— Disk

2— Ring 10— Seal 18— Bolt 26— Bushing
3— O-ring 11— O-ring 19— Bolt 27— Cover
4— Seal 12— Seal 20— O-ring 28— Ring
5— Cover 13— Shaft 21— O-ring 29— Seal
6— O-ring 14— Clip 22— O-ring 30— O-ring
7— Cylinder 15— Bearing 23— Seal 31— Rotary Valve Sleeve
8— Piston 16— Pin 24— Dowel Pin 32— Shaft Key
T803324,000103F -19-17SEP07-2/2
Motor Strip Down & Assembly Tools
CM073510411 —UN—17SEP07
1— Jacking Plate 2— Extractor Jacks 3— Lever A—Bolt Circle
T803324,0001040 -19-17SEP07-1/1
Motor Disassembly Procedures Drain the motor casing oil. In order to be able to
NOTE: On assembly at the factory one of the distributor re-assemble the distributor in the same position it is
closing bolts is lead sealed. The number on advisable to mark the alignment of the distributor ports
the seal is a factory reference number and with respect to the drain – line holes. To help with fault
should not be removed. The guarantee, where diagnosis it is advisable to mark also the position of the
applicable, on motors returned for repairs is motor cover with respect to the motor body and, after step
only valid if this seal is intact. 3, the position of each of the cylinders with respect to the
motor body.
Preliminary Steps
T803324,0001041 -19-17SEP07-1/1
102711
PN=418
Chopper Motor
Removing the Distributor

1. Remove the 5 closing bolts (18) of the distributor. Lift
off the distributor cover (27) and the distributor rotary
valve sleeve (31).
CM073510412 —UN—19MAR08
CM073510413 —UN—19MAR08
T803324,0001042 -19-17SEP07-1/2
2. Take out the distributor drive pin (17) and the

distributor centering bushing (26).
CM073510414 —UN—19MAR08
CM073510415 —UN—19MAR08
T803324,0001042 -19-17SEP07-2/2
102711
PN=419
Chopper Motor
Removing the Motor Cover

Remove motor cover closing bolts (19). With an
appropriate jacking plate, using the distributor bolt holes
and levering on the shaft through the distributor drive
CM073510416 —UN—19MAR08
pin hole, lift off the motor cover (5). Remove the motor
cover/body seals (20) and locating pins (16).
CM073510417 —UN—19MAR08
T803324,0001050 -19-18SEP07-1/1
Removing the Rear Retaining Ring

Using appropriate snap ring pliers, remove the retaining
clip (14).
CM073510418 —UN—19MAR08
T803324,0001051 -19-17SEP07-1/1
Removing the Cylinders

Rotate the shaft so that the piston (8) of the cylinder (7)
to be removed is fully extended. Hook a finger under the
piston and lift it up, tapping the cylinder trunnion with a
CM073510419 —UN—19MAR08
rubber hammer to loosen the piston from the shaft. Lift

out the cylinder and piston. The piston may be extracted
for inspection of seals and working surfaces.
T803324,0001052 -19-19SEP07-1/1
102711
PN=420
Chopper Motor
Removing the Shaft

1. It is advisable to place a protective covering over the
spline of the shaft (tape), before extraction to avoid
damaging the shaft seal.
CM073510420 —UN—19MAR08
2. Motors with roller bearings, lift the shaft (13) out.
Motors with ball bearings, remove the shaft (13) by
tapping on the end of the shaft with a rubber hammer.
CM073510421 —UN—19MAR08
T803324,0001053 -19-17SEP07-1/1
Removing the Shaft Bearings

If it is necessary to replace the shaft bearings (15), the
bearing races can be removed from the shaft or from
the motor cover or body using appropriate extractor
CM073510422 —UN—19MAR08
jacks. If the bearings do not need to be replaced it is
recommended that the bearing races are not removed
from the motor cover or body.
T803324,0001054 -19-17SEP07-1/1
102711
PN=421
Chopper Motor
Motor Assembly Procedures

Shaft Seal
CM073510423 —UN—19MAR08
Ensure that the shaft seal (12) in the motor body (9) has
not been damaged. Replace if necessary.
T803324,0001055 -19-17SEP07-1/1
Bearing Assembly
IMPORTANT: Roller Bearings — To avoid the
possibility of axial shocks the outer bearing race
should be placed in the motor cover or body and
CM073510424 —UN—19MAR08
the inner race should be assembled to the shaft.
IMPORTANT: Ball bearings — These should be

inserted in the motor body or cover (and
not assembled to the shaft).
To avoid the possibility of damage to the bearing seat

in the motor cover (5) or the motor body (9) caused by
edges on the external diameter of the bearing race the
motor body or cover should be heated to a temperature of
80° C (176° F) before inserting the bearing. Alternatively in the area of the corner fillets, that may have remained
smooth down any edges, even slight ones and especially after the machining processes.
T803324,0001056 -19-19SEP07-1/1
Shaft Assembly
1. Replace the shaft retaining ring, spring and C clip to
the rear side of the piston support ring.
CM073510425 —UN—19MAR08
102711
PN=422
Chopper Motor
2. Dislodge the C clip from the front side of the piston

support ring.
CM073510426 —UN—19MAR08
T803324,0001057 -19-17SEP07-2/3
3. Insert the shaft (13) in the bearing seat of the motor

cover (5), in the case of ball bearings using a rubber
hammer to tap it home.
CM073510427 —UN—19MAR08
CM073510428 —UN—19MAR08
T803324,0001057 -19-17SEP07-3/3
102711
PN=423
Chopper Motor
Cylinder Assembly
1. Insert O-ring (11) and plastic slipper seal (10) in the
cylinder (7). Insert O-ring (3), plastic ring seal (2),
steel ring (1) and shaped insert (4) into the cylinder
CM073510429 —UN—19MAR08
trunnions. Insert the pistons (8) in the cylinder.
CM073510419 —UN—19MAR08
T803324,0001058 -19-19SEP07-1/3
2. Place the long cylinder trunnion containing the seal into

the motor cover. Slide the piston out onto the piston
support ring and place the lip of the piston foot between
the piston retaining ring and the piston support ring.
CM073510430 —UN—19MAR08
3. Using an appropriate lever ensure that the piston foot
comes into full contact with the piston support ring. It
may be necessary to lift the cylinder and shaft out of
their seats a little to facilitate the operation. Repeat
for all five cylinders.
102711
PN=424
Chopper Motor
4. Position the front retaining ring and spring over the

piston feet and insert C clip. By tapping lightly with a
rubber hammer on the cylinder trunnions and shaft
end ensure that the shafts are properly seated.
CM073510431 —UN—19MAR08
T803324,0001058 -19-19SEP07-3/3
Distributor Cover Assembly

IMPORTANT: To avoid seriously damaging the
motor, do not attempt to place a distributor
cover pre-assembled with rotary valve and
CM073510436 —UN—19MAR08
disc directly onto the motor cover. The
external components of the distributor must be
assembled separately from the distributor cover.
IMPORTANT: Ensure that no objects fall into

cylinder feed holes in the motor. If this
happens it will be necessary to dismantle
the motor to remove the object.
Incorrect
T803324,000105A -19-17SEP07-1/1
Rotary Valve Subassembly
CM073510437 —UN—17SEP07
1. Insert the O-ring and plastic slipper with the concave

side on the O-ring side in the seat in the top side of
the distributor rotary.
102711
PN=425
Chopper Motor
2. The plastic seal should be assembled by first placing

the positioning lug in its seat. For versions with the
steel ring; first place the O-ring, then the plastic seal
(without lug) and the steel ring.
CM073510438 —UN—19MAR08
T803324,000105B -19-17SEP07-2/2
Distributor Cover Subassembly

1. Insert the distributor/motor cover O-ring in the seat in
the bottom of the distributor cover.
CM073510439 —UN—19MAR08
T803324,000105C -19-17SEP07-1/2
CM073510440 —UN—19MAR08
2. For distributors with the bronze disc; insert the O-ring

and plastic slipper with the chamfer on the side of the
bottom of the distributor.
T803324,000105C -19-17SEP07-2/2
102711
PN=426
Chopper Motor
Rotary Group Assembly

NOTE: Ensure that no objects fall into the cover. If
this happens it will be necessary to dismantle
the motor to remove the object.
CM073510441 —UN—19MAR08
1. Insert distributor drive pin in the shaft through the
central hole in the motor cover.
T803324,000105D -19-17SEP07-1/5
2. Insert the locating pins in their holes in the motor cover.
CM073510442 —UN—19MAR08
T803324,000105D -19-17SEP07-2/5
3. Place the disc on the cover, positioning it with the

locating pins. Motors without the disc do not have the
locating pins. The disc must sit flush with the motor
cover. It does not have to be pressed on and the five
oil feed holes must line up with the holes in the motor
CM073510443 —UN—19MAR08
cover. Once positioned it must be not be able to rotate
or to move laterally.
102711
PN=427
Chopper Motor
4. Insert the centering bushing in the disc.
CM073510444 —UN—19MAR08
T803324,000105D -19-17SEP07-4/5
5. Position the distributor rotary on the disc with the side

containing the seals on top and with the three radial
holes to the left of the reference cylinder and the three
axial holes to the right.
CM073510445 —UN—19MAR08
T803324,000105D -19-17SEP07-5/5
Distributor Cover Assembly

1. Place the distributor cover over the rotary, aligning the
bolt holes in the distributor cover and the motor cover.
CM073510446 —UN—19MAR08
102711
PN=428
Chopper Motor
2. The distributor can be placed in any of five positions.

Screw in and tighten the five bolts.
CM073510447 —UN—19MAR08
T803324,000105E -19-17SEP07-2/2
102711
PN=429
Chopper Motor
102711
PN=430
Group 40A
Rear Feed Roller Valve
Valve Assembly
CM053510246 —UN—29JUL05
1— Valve Assembly 8— O-ring 15— Outlet Section 22— Retainer
2— Bolt 9— Relief Valve 16— O-ring 23— O-ring
3— Flange 10— Cap 17— Tie Rod 24— O-ring
4— Tube 11— Bolt 18— Hex Nut 25— SAE Plug
5— Bolt 12— Spool 19— Tie Rod 26— Plug
6— Washer 13— Inlet Section Assembly 20— Hex Nut 27— O-ring
7— Spring 14— Body 21— Relief Cartridge Valve
T803324,0000A0B -19-23AUG07-1/1
Suggested Tools 4. 1/4” Allen Wrench

1. 11/16” Wrench 5. Loctite 271
2. 3/4” Wrench
6. O-ring Lube
3. Torque Wrench
T803324,0000A0C -19-23AUG07-1/1
102711
PN=431
External Relief Settings

1. The inlet section (13) of the valve has an adjustable
relief (21) which is set at 179 bar (2750 ± 100 PSI).
CM073510448 —UN—19MAR08
T803324,0000A0D -19-18SEP07-1/2
2. The main relief and port reliefs are adjusted by

loosening the locking jamnut (A) with a 1 1/8 inch
wrench. Using a 1/4 inch Allen wrench, screw inward
to increase pressure and outward to decrease. After
adjusting, tighten the locking jamnut (A).
CM073510449 —UN—19MAR08
A—Locking Jam Nut
T803324,0000A0D -19-18SEP07-2/2
Valve Overhaul Remove the valve bank from the equipment and
Valves are often used in hazardous environments, disconnect all hoses, fittings, control handles, and linkage
therefore care should be taken to frequently inspect the connectors that might be attached to the valve. Plug all
product for damage due to improper use, corrosion, or ports and thoroughly clean the valve bank's exterior.
normal wear. Repairs should be made immediately, if NOTE: All repair work must be performed in a clean area.
needed.
Always refer to the owner's manual for the proper
procedure to remove the valve from the machine.
T803324,0000A0E -19-18SEP07-1/1
102711
PN=432
Valve Bank Disassembly 2. Then mark the port boss closest to the back cap on
NOTE: Mark the valve bank. each work section with a “B” (for back cap end).
3. Next mark the port boss closest to the spool clevis on
This step is the most critical step in the disassembly each work section with an “A” (for spool end).
procedure. It should be followed very closely to ensure
that the valve bank is properly reassembled after repairs 4. Lastly, if relief valves must be removed from the valve
have been made. bank, they should be marked with the number of
the casting and port to which they belong. Inlet and
1. Take a waterproof, quick-drying marker and mark each mid-inlet relief valves are marked with their casting
casting with a sequential number. Start by marking number only.
the inlet casting as #1 and finish by marking the outlet
with the highest number.
CM073510450 —UN—19MAR08
5. Remove the three (3) tie bolts that hold the bank
together and separate the sections.
T803324,0000A0F -19-18SEP07-1/1
Valve Assembly Procedure

1. Layout valve components on a clean, flat working
surface. The inlet section will include an O-ring.
CM073510451 —UN—19MAR08
102711
PN=433
2. The spool section (14) will include an O-ring (16) and

possibly a load check poppet and load check spring.
CM073510452 —UN—19MAR08
T803324,0000A10 -19-23AUG07-2/7
3. Tools required for basic valve assembly include a 3/4

in. and 11/16 in. open or box end wrench and a torque
wrench with thin wall sockets.
CM073510453 —UN—19MAR08
T803324,0000A10 -19-23AUG07-3/7
4. Assemble tie rod nuts to one end of each tie rod with
one or two threads showing. Insert the tie rods through
the rod holes in the inlet section (13). Ensure that the
large tie rod (17) passes through the top hole of the
section. Lay the inlet section on its end with the tie rod
CM073510454 —UN—19MAR08
up and place O-ring (6) into its position.
102711
PN=434
5. Place the first spool section (14) with the O-ring side
up onto inlet section (13). Position the O-ring (16) and
insert the load check poppet (nose down) and spring
(behind poppet) into load check cavity as shown.
Repeat this procedure for each spool section; the
CM073510455 —UN—19MAR08
load checks are compressed by the following sections
during assembly.
T803324,0000A10 -19-23AUG07-5/7
6. Position the end section (15) on the last section as

shown and hand tighten tie rod nuts. The end section
in this picture is a “turn around” section without ports.
Universal outlet/power beyond section and power
beyond and closed center sections are also used as
CM073510456 —UN—19MAR08
end sections. These end sections do not have O-ring
grooves.
T803324,0000A10 -19-23AUG07-6/7
7. Position the valve assembly with the mounting pads

of the end sections on a flat surface. To obtain proper
alignment of the end section relative to the spool
sections apply downward pressure to the end section;
snug tie rod nuts to about 10 lb-ft.
CM053510250 —UN—19MAR08
8. Torque the two 11/16 nuts to 48 ± 5 lb-ft; finally torque
the 3/4 in. nut to 74 ± 8 lb-ft. Check for proper spool
movement.
9. Install auxiliary valves and plugs and torque to proper
specifications.
NOTE: The load check and spring may be omitted from
assembly in certain circuit conditions.
T803324,0000A10 -19-23AUG07-7/7
102711
PN=435
102711
PN=436
Group 40B
Steering Priority Valve (Wheel)
Repair Steering Priority Valve (Wheel)
CM073510457 —UN—18SEP07
1— Adjusting Screw 4— Ball Holder 7— O-ring 10— Housing

2— Cover 5— Ball 8— Screen 11— O-ring
3— Spring 6— Relief Valve 9— Seat 12— O-ring
102711
PN=437
1. Remove relief valve (6) from housing (10).
CM073510458 —UN—18SEP07
T803324,000105F -19-18SEP07-2/11
2. Inspect the ball (5) seating on the ball holder (4).
CM073510459 —UN—18SEP07
102711
PN=438
3. Inspect the O-ring (7); discard after inspection.
CM073510460 —UN—18SEP07
T803324,000105F -19-18SEP07-4/11
4. Inspect seat (9), screen (8) and ring (7) for damage. If
damaged, replace the relief.
CM073510461 —UN—18SEP07
102711
PN=439
5. Remove adjusting screw (1) from relief valve (6).

Be careful, since there is a small amount of spring
pressure exerted on the adjusting screw (1).
CM073510462 —UN—18SEP07
T803324,000105F -19-18SEP07-6/11
6. Remove cover (2), spring (3), ball holder (4) and ball
(5). Inspect for damage; replace the entire relief valve
(6) if necessary.
CM073510463 —UN—18SEP07
102711
PN=440
7. Inspect ball seat (9) for scratches or debris. Remove

any debris; replace entire valve (6) if damaged.
CM073510464 —UN—18SEP07
T803324,000105F -19-18SEP07-8/11
8. Install ball (5), ball holder (4), spring (3) and cover (2)
into relief valve (6).
CM073510463 —UN—18SEP07
T803324,000105F -19-18SEP07-9/11
CM073510465 —UN—18SEP07
9. Install adjusting screw (1) into relief valve (6).
102711
PN=441
10. Install seat (9), screen (8) and O-ring (7) into housing
(10).
11. Set relief to 172 bar (2500 PSI).
CM073510466 —UN—18SEP07
T803324,000105F -19-18SEP07-11/11
102711
PN=442
Group 40C
Steering Valve
Repair Steering Valve
CM053510256 —UN—08AUG05
1— Cap Screw 5— Spacer Plate 9— Centering Pin 13— Bearing Race

2— End Cap 6— Drive 10— Spring Spacer 14— Needle Thrust Bearing
3— O-ring 7— Housing Valve 11— Centering Spring 15— Seal
4— Gerotor 8— Sleeve Spool 12— Retainer Spring 16— Dust Seal
T803324,0001061 -19-19SEP07-1/1
102711
PN=443
Steering Valve
Disassembly/Reassembly that retains these parts should be removed first.

Safely retain these parts and remember to reinstall
Cleanliness is extremely important when repairing a these parts last after reassembly.
steering control unit. Work in a clean area. Before
disconnecting lines, clean port area of unit thoroughly. 1. Clamp unit in a vise, meter end up. Clamp lightly on
Use a wire brush to remove foreign material and debris the edges of port face sides. Use protective material
from around exterior joints of the unit. on vise jaws. Housing distortion could result if jaws
Although not all drawings show the unit in a vise, we are over tightened.
recommend that you keep the unit in a vise during 2. Carefully disassemble the steering control unit in the
disassembly and reassembly. Follow the clamp vertical position. If it is not kept vertical, the pin that
procedures. links the sleeve, spool and drive could possibly slip
NOTE: Notice placement of check ball and roll pin and dead bolt; it will lock these parts in the housing
(manual steering check valve), the cap screw before it is completely out.
T803324,0001062 -19-19SEP07-1/1
Requirements section are lubricated with petroleum jelly for assembly

purposes, the amount of petroleum jelly used should be
Assure that all parts are free from rust, other contaminants, minimal to avoid spreading jelly on the surfaces that form
nicks and burrs at time of reassembly. the interfaces between end cap and gerotor ring and
Lubricate O-ring seals with mobilith SCH220 high between gerotor ring and spacer plate.
temperature grease. If the O-ring seals used in meter
T803324,0001063 -19-19SEP07-1/1
Reassembly Requirements
1. Sealing lips/surfaces of the shaft seal should be
protected against deforming, cutting or abrasion
during installation. Sealing surface area of the shaft
CM073510467 —UN—19MAR08
must be free from scratches, dents and other defects
detrimental to seal performance and life.
2. Spool must rotate smoothly inside the sleeve with less
than 0.111 N·m (1 lb-in) torque (finger force) when
both parts are lubricated with system oil.
3. Installation of spring spacers (10) and springs (11).
Hold spring retainer (12) at an angle as shown.
102711
PN=444
Steering Valve
CM073510468 —UN—19MAR08
4. Insert spring spacers (10) and springs (11) one at a then position spring retainer (12) correctly over all
time in sequence noted by reference numbers 2-9 (A these parts. Adjust alignment of spring parts with a
— Standard Torque), 2-8 (B — Medium Torque), small screwdriver.
102711
PN=445
Steering Valve
CM073510469 —UN—20SEP07
1— Gerotor Meter Star Valley 2— Drive Marked Parallel with Pin 3— Pin Location Reference Align
Align with Mark on Drive A, B, and C
Spline
5. Timing of drive with respect to the gerotor star is

critical. The pin slot in drive must be aligned with the
valley of the gerotor star contour.
102711
PN=446
Steering Valve
NOTE: Seven cap screws for meter section should be

torqued evenly with less than 5 percent variation.
Tightening torque variation 31-37 N·m (275-325
lb-in) to satisfy travel limit slip rate and input
torque requirements is permissible.
6. Torque all cap screws to 11-17 N·m (100-150 lb-in.)

evenly, then to final torque in sequence shown to 31 -
37 N·m (275 - 325 lb-in).
7. When the input drive at spline is rotated, gerotor star
shall rotate smoothly with less than 60 percent of
torque as specified after reassembly and tightening
of the seven cap screws to final torque level in the
CM053510258 —UN—08AUG05
previous step. Complete assembly should rotate
smoothly with less input torque than the valves
specified in the final test specification when warmed to
60 – 66°C (140 – 150°F).
8. Housing meter (gerotor) end, spacer plate, gerotor ring
and end cap shall form pressure tight (zero leakage)
at 275 bar (4000 PSI) interfaces after reassembly and
tightening of the seven cap screws.
T803324,0001064 -19-19SEP07-4/4
102711
PN=447
Steering Valve
Troubleshooting steering control valve is not the cause of most problems.

The following is a list of steering problems and their
Most steering problems can be corrected if the problem possible cause along with suggested corrections.
is properly defined. The entire steering system should be
evaluated before removing any components. Usually the
Symptom Problem Solution
Slow Steering, Hard Steering or Worn or Malfunctioning Pump Repair or replace pump.
Loss of Power Assist
Leaking or kinked supply line for load Trace the hose and tighten fittings or
sensor. replace hose.
Malfunctioning priority valve. Check for sticking spring or spool.
Check system pressure at the steering

valve inlet for proper setting. If
necessary, replace the priority valve
relief cartridge.
Wander - The tendency to deviate Air in system due to low oil level, Check the system and add system
from Operator directed course cavitating pump, loose fittings, kinked fluid.
hose, etc.
Worn mechanical linkage. Repair or replace.
Binding of linkage or cylinder rod. Repair or replace.
Loose cylinder piston. Repair or replace.
Severe wear in steering valve. Repair or replace.
Drift - The tendency to deviate from Worn or damaged steering linkage. Repair or replace linkage and align
Non-Operator directed course: front end.
Slip - When a slow movement of Leakage of cylinder piston seals. Replace piston seals.
steering wheel fails to cause any
movement of steered wheels:
Erratic Steering Air in system due to low oil level, Check system and add system fluid.
cavitating pump, loose fittings, kinked
hose, etc.
Loose cylinder piston. Repair or replace cylinder.
Thermal shock damage.1 Repair or replace steering valve.
Spongy or Soft Steering Air in system due to low oil level, Check system for the above and add
cavitating pump, loose fittings, kinked system fluid to correct.
hose, etc.
Air in hydraulic system. (Most likely Bleed air from system.
air is trapped in cylinders or lines.)
Low oil level. Add oil and check for leaks.
Free Wheeling, (Steering Wheel Steering column upper shaft is loose Tighten steering wheel nut, repair or
turns freely with no feeling of or damaged. replace column.
pressure and no action on steered
wheels.)
Lower splines of column may be Repair or replace column.
disengaged or broken.
102711
PN=448
Steering Valve
Symptom Problem Solution
Steering valve gerotor is low on Starting engine will usually cure this
oil. (This can happen on start-up, problem.
after repair, or after long periods of
non-use.)
No flow to steering unit caused by low Add oil and check for leaks or ruptured
oil. hose.
Internal steering valve damaged due Repair or replace the valve.

to thermal shock.
1
Thermal shock is a condition caused when the hydraulic system is operated for some time without turning the steering wheel.
This may cause the oil in the hydraulic system to be hot and the steering valve may relatively cool (more than a 10° C (50° F)
temperature differential.) When the steering wheel is turned quickly the result is a temporary seizure and possible damage to
internal parts of the steering valve. This seizure may be followed by total free wheeling.
T803324,0001066 -19-19SEP07-2/2
102711
PN=449
Steering Valve
102711
PN=450
Section 80
Topper System
Contents
Page
Group 05—Collector, Crop Divider, Feed

Roller and Elevator Motor
Collector, Crop Divider, Feed Roller
and Elevator Motor .................................... 80-05-1
Suggested Tools ............................................ 80-05-2
Collector Motor .............................................. 80-05-2
Disassembly .................................................. 80-05-2
Assembly ....................................................... 80-05-4
Topper Repair ................................................ 80-05-5
Collector Drum and Motor
Removal .................................................... 80-05-5
Topper Assembly Removal............................ 80-05-6
Drum and Topper Assembly .......................... 80-05-6
Shredder Topper............................................ 80-05-7
Shredder Topper Repair ................................ 80-05-8
Collector Drum and Motor
Removal .................................................... 80-05-8
Topper Assembly Removal............................ 80-05-8
Drum and Topper Assembly .......................... 80-05-9
Scroll Cylinder ............................................. 80-05-10
Suggested Tools .......................................... 80-05-11
Disassembly ................................................ 80-05-11
Clean and Inspect........................................ 80-05-11
Assembly ..................................................... 80-05-12
Topper Lift.................................................... 80-05-12
Disassemble and Assemble Topper
Lift Cylinder.............................................. 80-05-13
Gear Motor .................................................. 80-05-14
Gear Motor Repair....................................... 80-05-15
Suggested Tools .......................................... 80-05-15
Repair Precautions ...................................... 80-05-15
Disassembly ................................................ 80-05-16
Assembly ..................................................... 80-05-17
Start-up Procedure ...................................... 80-05-17
Recommended Test Procedure ................... 80-05-18
102711
PN=1
Contents
102711
PN=2
Group 05
Collector, Crop Divider, Feed Roller and Elevator Motor
CM053510264 —UN—10AUG05
Continued on next page T803324,00007EB -19-10AUG05-1/2
102711
PN=453
1— Dust Seal 7— Shaft Face Seal 13— Valve 19— Housing

2— Bearing Housing 8— Wear Plate 14— Balance Ring 20— O-Ring
3— O-Ring 9— Drive Shaft 15— Outer Face Seal 21— Plug Assy
4— Backup Ring 10— Geroler 16— Inner Face Seal 22— Bolt
5— Shaft Seal 11— Valve Drive 17— Pin
6— Shaft Assy 12— Valve Plate 18— Spring
T803324,00007EB -19-10AUG05-2/2
Suggested Tools
6. Press
1. Torque Wrench - 57 Nm (50 lb-ft) capacity
7. 2 Alignment Studs - 200 x 9.5 mm diameter with
2. Breaker Bar - 300-450 mm (12-16 In) 3/8-24 UNF Threads 25 mm long (3/8-24 x 8 In UNF
- with 1 inch of threads)
3. Socket - 9/16 In
8. Seal Installation Tool - (0841306323)
4. Small Screwdriver - 50-200x6.5 mm (6-8 x 1/4 In) Blade
5. 3/16 Hex Allen Wrench
T803324,00007EC -19-10AUG05-1/1
Collector Motor
A different bearing housing is used, but the other parts are
the same as the other motors. The same assembly and
disassembly procedures apply.
T803324,00007ED -19-10AUG05-1/1
Disassembly
Cleanliness is extremely important when repairing a
hydraulic motor, always work in a clean area. Before
disconnecting the lines, clean the port area of the motor
thoroughly. Use a wire brush to remove foreign material
and debris from exterior joints of the motor. Check the
shaft, keyway or splines and remove all nicks, burrs, and
sharp edges that might damage the shaft seals when
installing the retainer on the shaft and bearing assembly.
Before starting disassembly procedures, drain oil from
inside of motor1.
1. Place the motor in a vise with the output shaft facing
CM002500096 —UN—23MAY00
downward. Clamp across the mounting flange of the
motor, not the housing. Excessive clamping pressure
on the housing will cause distortion. When clamping,
use a protective device on the vise, such as special
soft jaws, pieces of hard rubber or wood. Mark
sections for alignment.
2. Remove four bolts (22) from the motor.
1
John Deere recommends that you keep the motor in
the vise during disassembly.
Continued on next page T803324,00007EE -19-10AUG05-1/2
102711
PN=454
3. Lift housing assembly (19) straight upward. If done

carefully, pins (17), springs (18), face seals (15 & 16),
balance ring (14) and valve (13) will remain on valve
plate (12) for easier removal.
4. Carefully remove O-ring (3) and case drain plug
assembly (21) from housing (19).
5. Remove two balance ring springs (18) and pins (17)
from the balance ring assembly (14).
6. Remove balance ring assembly (14).
7. Remove inner and outer face seals (15 & 16) from the
balance ring.
CM002500097 —UN—23MAY00
8. Lift off valve (13).
9. Remove valve plate (12).
10. Remove O-ring (3) from valve plate.
11. Remove valve drive (11).
12. Remove geroler (10). Retain the rollers located in the
outer geroler ring, if loose.
13. Remove drive (9). the motor has a key, remove the key before removing
the shaft assembly.
14. Remove O-ring (3) from wear plate (8).
19. Use a small screwdriver to remove shaft seal (5),
15. Remove wear plate (8). backup washer (4) and dust seal (1). Do not damage
16. Remove shaft seal (7) from wear plate. the bore of the housing.
17. Remove O-ring (3) from bearing housing (2).

18. Remove shaft and bearing assembly (6) from housing
(2).1 It may be necessary to use a press for removal. If
1
Individual parts of the shaft and bearing assembly are not sold
separately and must be replace as a complete unit.
T803324,00007EE -19-10AUG05-2/2
Clean and Inspect 5. Check around the keyway or splines and chamfered
1. Check all mating surfaces. area of the shaft for burrs, nicks or sharp edges that
can damage the seals when reassembling the bearing
2. Replace any parts that have scratches or burrs that housing.
could cause leakage.
6. Lubricate all seals, prior to installation, with O-ring
3. Clean all metal parts in clean solvent and blow dry with lube (0841304202) or equivalent.
air. Do not wipe parts with a cloth or paper towel, lint
or other materials could get into the hydraulic system 7. John Deere recommends the use of new seals when
and cause damage. reassembling the motor. Refer to John Deere parts
manual for replacement parts and kit numbers.
4. Do not use a coarse grit, or try to file or grind motor
parts.
T803324,00007EF -19-10AUG05-1/1
102711
PN=455
Assembly
1. Use a press to install dust seal (1) into the outer bore
of bearing housing (2). The seal lip must face outward.
If a press is not available, use a plastic or rubber
hammer, being careful not to damage or cock the seal
in the bore.
2. Place backup washer (4) into the seal bore. Place
shaft seal (5) onto installation tool (0841306323).
Press the seal into the seal bore located in the housing.
3. Clamp housing (2) in the vise, across the mounting
flange, with the output shaft end facing downward.
CM053510265 —UN—15AUG05
4. Place a protective sleeve or tape over the shaft
splines. Grease the inside diameter of dust and shaft
seals (1 & 5). Install the shaft and bearing assembly,
it may be necessary to use a press to do this. Do not
cut or distort the shaft seal.1
5. Apply lubricant to O-ring (3) and install into the bearing
housing.
6. Alignment studs are very helpful in the assembly of this
motor. (See the tool list for fabrication dimensions.) A—Largest Open Pocket F— Valve Drive
Install the two studs, diagonally opposed to each B—Case Drain Hole G—Geroler
other, in the bearing housing. C—One of Six Ports Open to H—Pressure Relief Hole
the outside I— Case Drain Hole
7. Install shaft face seal (7) into wear plate (8), as shown. D—Valve J— Heavy Line is to trace
Do not distort seal. E—Valve Plate alignment through parts
8. Install wear plate (8)

9. Apply a light film of lubricant on O-ring (3) and install 15. Align the notch located on the outside of the valve
in wear plate. plate with the notch located on the geroler.
10. Install drive (9) into output shaft. 16. Timing Step 2 - Locate the slot opening in the valve
plate which is in line with the largest open pocket of
11. Align the notch, located on the outside of geroler (10),
the geroler.
with the notch located on the wear plate. Install the
geroler against the wear plate. Be sure to retain the 17. Timing Step 3 - Locate any one of the valve side
rollers in the outer ring, if loose. openings and align this opening with an open valve
plate slot that is aligned with the largest open pocket of
12. Install valve drive (11, F) into the geroler (G).
the geroler. Install the valve by rotating it clockwise until
Installation at this point involves 3 steps for timing the
the spline teeth engage (1/2 spline tooth maximum).
motor. Timing determines the direction of rotation of
This provides the proper rotation when pressurized.
the output shaft.
18. Install two pins (17) and springs (18) into the holes
13. Timing Step 1 - Locate the largest open pocket in the
located in the bore of housing (19).
geroler. Mark the location of this pocket on the outside
edge of the geroler. 19. Apply a light film of lubricant to O-ring (3) and install
in the valve housing.
14. Apply a light film of lubricant to O-ring (3) and install
into the groove of valve plate (12, E).
1
Damage to shaft seal will cause external leakage.
Continued on next page T803324,00007F0 -19-10AUG05-1/2
102711
PN=456
20. Apply lubricant to inner and outer face seals (15 & 16)
and install on balance ring (14, N). Install the face
seals in the positions, as shown, or the motor will not
operate properly. Do not force or bend the face seals.
Any damage to these seals will affect motor operation.
CM053510266 —UN—16AUG05
21. Align the pin notches, located in the balance ring with
pins (17), located in the bore of the valve housing.
Install the balance ring assembly into the valve
housing.
22. Insert your finger through the port of the housing
and apply pressure to the side of the balance ring
assembly. Hold the ring in position, until the valve
housing is in place, against the valve plate.
23. After installing the valve housing on the valve plate, K—Pin Notch M—Outer Seal
L— Inner Seal N—Balance Ring
check for proper alignment. Push downward on the
valve housing. You should get a slight spring action.
24. Install and finger tighten two bolts (22) opposite 25. Install O-ring (20) onto case drain plug (21) and then
alignment studs. Remove the alignment studs and install the plug into the valve housing. Torque to 6 Nm
install the remaining bolts. Cross-torque all four bolts (4 lb-ft).
to 50 Nm (38 lb-ft).
T803324,00007F0 -19-10AUG05-2/2
Topper Repair Care should be taken to ensure all bolts and nuts are
The topper consists of a sturdy frame that has two secure at all times to minimize damage to the rotary and
collector drum assemblies. These are individually driven fixed components.
by wheel motors. Care must be taken to ensure the gathering drum is
The eight blade topping disc is mounted between the balanced to prevent vibration.
collector drums.
The topping disc is driven by a gear motor.
T803324,00007F1 -19-16AUG05-1/1
Collector Drum and Motor Removal 1. Remove bolts that hold the collector to the hub.
CAUTION: To prevent possible injury, remove 2. Remove cotter pin from nut.
the topper blades from the disc before
disassembling or remove the complete topper 3. Remove nut from motor shaft.
assembly from the harvester. 4. Remove hub mounted on hub shaft.
5. Label, remove and cap hydraulic hoses and fittings.
CAUTION: Collectors are heavy. Lifting heavy
components incorrectly can cause severe 6. Mark the motor's position on topper frame.
injury or machine damage.
7. Remove the collector motors from topper frame.
T803324,00007F2 -19-16AUG05-1/1
102711
PN=457
Topper Assembly Removal 3. Remove the splined hub from the topper motor shaft.
CAUTION: To prevent possible injury, remove 4. Label, remove and cap hydraulic hoses and fittings.
the topper blades from the disc before 5. Remove the topper motor from topper frame.
disassembling or remove the complete topper
assembly from the harvester. NOTE: It may be necessary to apply heat to
remove nut, because araldite or loctite was
1. Remove topper segment blades. used during assembly.
2. Remove the topper disc and drum (9) together.
T803324,00007F3 -19-16AUG05-1/1
Clean and Inspect 3. Make sure all keyways and splines are not worn out.
1. Clean all parts with a nonflammable solvent and air dry. 4. Clean Araldite and Loctite from all threads and inspect
2. Inspect all parts for damage and ensure that all for damage.
the components are in good condition. Replace as 5. Check motor seals for leakage; replace as necessary.
necessary.
T803324,00007F4 -19-16AUG05-1/1
Drum and Topper Assembly 6. Heat the collector drum hub to 300° F (149° C).
1. Install the collector drum motor, ensuring that the RH 7. Install the collector drum on the motor.
is on the right side and the LH is on the left. Torque
mounting bolts and nuts to 108 Nm (80 lb-ft). 8. Apply Araldite to the motor shaft and tighten the nut
2. Install the topper motor and apply Araldite to the motor
studs. Install nuts and washers and torque to 108 Nm 9. Install pin and bend the pin tabs to lock.
(80 lb-ft).
10. Install the hub cab.
3. Install the drum assembly and toppers disc.
11. Connect all hoses and fittings.
4. Install twelve bolts and washers to mount with topper
disc with Loctite 242 (0841304201) and torque to 47 12. Install blades with bolts and nuts. Torque to 35 Nm
Nm (35 lb-ft). (26 lb-ft).
5. Remove pin and the nut located on the collector motor.

T803324,00007F5 -19-16AUG05-1/1
102711
PN=458
Shredder Topper
CM053510267 —UN—16AUG05
Continued on next page T803324,00007F6 -19-16AUG05-1/2
102711
PN=459
1— Shredder Frame Assembly 15— Lock Nut 29— Shear Bar Plate 43— N/A
2— Shredder Drum Cover 16— Snap Ring 30— Bolt 44— RMT-Elab Seal Frame
3— Lock Nut 17— Support Washer 31— Throat Plate LH Sheet (Position at final assembly
4— Cotter Pin 18— Bearing Hub 32— Throat Palte RH Sheet with drum in place.)
5— Shredder Topper Cover 19— Bearing 33— N/A 45— Topper Blade Shim
6— Expansion Plug 20— Extractor Fan Adapter 34— Bolt 46— Shredder Topper Cover
7— Bolt 21— Topper Drum Assembly 35— Motor Mount Assembly 47— Rubber Grommet
8— Lock Washer 22— Bolt 36— N/A 48— Grommet
9— Washer 23— Segment Blade 37— N/A 49— RMT-Guard
10— HB Bolt 24— Nut 38— Lock Washer 50— Shredder Topper Belt
11— Bolt 25— Bolt 39— Gathering Disc Plate 51— Shredder Topper Belt Mount
12— HD Washer 26— Lock Washer 40— Gathering Hub Plate 52— Bolt
13— Shredder Topper Shield 27— Topper Baseplate Assembly 41— Drum Stop (Shipping Only) 53— Lock Nut
14— Bolt 28— Shear Bar Plate 42— N/A
T803324,00007F6 -19-16AUG05-2/2
Shredder Topper Repair Care must be taken to ensure the gathering disc and topper
The topper consists of a sturdy frame which has two drum assembly is balanced in order to prevent vibration.
gathering disc assemblies. These are individually driven
by wheel motors. CAUTION: To prevent possible injury, remove
The twenty-eight bladed topping drum which is driven by
disassembling or remove the complete topper
a gear motor, mounts between the gathering disc.
assembly from the harvester.
Care should be taken to ensure all bolts and nuts are
secure at all times to minimize damage to the rotary and
fixed components.
T803324,00007F7 -19-16AUG05-1/1
Collector Drum and Motor Removal

5. Install then nut back on the motor shaft to protect the
1. Remove cotter pin (4) and the motor retaining nut. threads and secure the key.
2. Remove the gathering discs (39 & 40) from the topper 6. Mark the motor LH and RH for reassembly.
assembly.
3. Label, remove and cap all hydraulic hoses and fittings. CAUTION: To prevent possible injury, remove
4. Remove four bolts and nuts securing the motor and disassembling or remove the complete topper
remove. assembly from the harvester.
T803324,00007F8 -19-16AUG05-1/1
Topper Assembly Removal 6. Remove the two bolts and washers that secure the
1. Remove bolts (22), nuts (24), and segment blades (23). motor to the frame (1) and hub assembly (18). It may
be necessary to apply heat to remove bolts, because
2. Remove drum cover (2), baseplate assembly (27), and Araldite and Loctite was used during assembly.
throat sheets (31 & 32).
7. Remove six bolts (34) and washers (26) holding
3. Remove six bolts (25) and washers (26). Remove bearing hub assembly (18).
drum assembly (21).
8. Remove snap-ring (16) and washer (17) to separate
4. Remove covers (5 & 46) to gain access to motor (33) hub (18) and adapter (20). Remove bearings (19)
and hydraulic hoses and fittings. from hub assembly (18).
5. Label and cap all hydraulic hoses and fittings.
T803324,00007F9 -19-16AUG05-1/1
102711
PN=460
Clean and Inspect

4. Clean Araldite and Loctite from all threads and inspect
1. Clean all parts with a nonflammable solvent and air dry. for damage.
2. Inspect all parts for damage and ensure that all 5. Check all assemblies for structural damage.
the components are in good condition. Replace as
necessary. 6. Check motor seals for leakage; replace as necessary.
3. Make sure that all keyways and splines are not worn
out.
T803324,00007FA -19-16AUG05-1/1
Drum and Topper Assembly

9. Install fixed blades (23) with bolts (22), shims (45) and
1. Install bearings (19) in hub assembly (18) with bearing nuts (24). Torque to 35 nm (26 lb-ft).
seals towards inside of housing (seals down). Pack
bearings with grease. 10. Install motor mount assemblies using bolts and nuts.
2. Place bearing hub assembly (18) onto extractor 11. Install collector drum motors ensuring that the LH is
adapter (20). Spin hub assembly (18) to check on the left side and the RH is on the right side. Torque
freedom of movement. bolts and nuts to 108 Nm (80 lb-ft).
3. Install bearing hub assembly (18) into frame assembly 12. Remove pins (4) and nut located on the collector motor.
(1). Install six bolts (34) and washers (26) with Loctite 13. Heat the collector drums (39 & 40) to 149°C (300°F) to
242 (0841304201) and torque to 108 Nm (80 lb-ft). clean off old araldite.
4. Install the topper motor (33) into the frame (1). Install 14. Install the collector drums (39 & 40) on the motors.
two bolts (42) and washers (26) with Loctite 242
(0841304201) and torque to 108 Nm (80 Lb-Ft). 15. Apply araldite to the motor shafts and tighten the nut
5. Install all hoses and fittings.
16. Install pin (4) and bend the pin tabs to lock.
6. Place drum assembly (21) onto adapter (20). Install
six bolts (25) and washers (26) with loctite 242 17. Install throat plates (31 & 32) and shear bar plates (28
(0841304201) and torque bolts to 108 Nm (80 & 29) using bolts (14 & 11) and nuts (3 & 15). Do Not
lb-ft). Turn drum to check clearance and freedom of Tighten Bolts At This Time.
movement.
18. Install side shields (13) with bolts (14) and nuts (15).
7. Install drum cover (2) with six bolts (7), lock washers
19. Tighten all bolts and nuts on lower drum assembly.
(8) and flat washers (9).
20. Install segment blades (23) on topper drum assembly
8. Bolt baseplate assembly (27) to fixed legs on frame
(21). Turn drum to check for clearance and freedom of
(1) using bolts (14) and nuts (15). Do Not Tighten
movement.
Bolts At This Time.
T803324,00007FB -19-16AUG05-1/1
102711
PN=461
Scroll Cylinder
CM053510269 —UN—17AUG05
1— Tube Assembly 6— Head 11— U-Cup Seal 16— Expander Ring

2— N/A 7— Locking Collar 12— Backup Ring 17— Wear Ring
3— Bolt 8— Bolt 13— O-Ring
4— Hard Washer 9— Rod Assembly 14— Buffer Seal
5— Piston 10— Wiper 15— Seal
NOTE: Use Loctite 271 on threads of item 3. Continued on next page T803324,00007FC -19-17AUG05-1/2
102711
PN=462
NOTE: Use Anti-seize on threads of item 7.

T803324,00007FC -19-17AUG05-2/2
Suggested Tools • Scroll Lift Cylinder—0610053967

• Topper Lift Cylinder—0610053968
• Vise • Tube Seal Kit—0610053972
• Spanner Wrench—0840030555 • Loctite 271—0841303179
• 7/32 In Hex (Allen) Wrench (included in wrench set • Antiseize Compound—0841305658
0840021409)
• Loctite Primer-N—0841303194
• Non-Flammable Solvent
• Rod Seal Kits
T803324,00007FD -19-17AUG05-1/1
Disassembly 3. Very carefully pull rod assembly (9) along with locking
collar (7), head (6) and piston (5) from tube assembly
CAUTION: Before removing cylinder for repair, (1)†.
relieve all system pressure.
4. Remove bolt (3) and washer (4). It may be necessary
1. Loosen setscrew (8) in locking collar (7). to apply heat in order to remove the bolt, since it was
installed with Loctite.
2. Using spanner wrench (0840030555), loosen locking
collar (7) on cylinder tube assembly (1). 5. Remove piston (5), head (6), and collar (7) from rod
assembly (9).
T803324,00007FE -19-17AUG05-1/1
Clean and Inspect 3. Using a wire brush, remove the cured Loctite from the
threads of the bolt.
CAUTION: Do Not use a flammable solvent to clean
cylinder parts. An explosion may occur inside 4. Clean and inspect threads of the locking collar.
the cylinder, at the moment of pressurization, 5. Inspect the rod for scratches or nicks. Check the
if just a tiny drop of any flammable solvent is inside of the tube assembly for scratches or scoring.
trapped inside of a confined cylinder area. Replace if necessary.
1. All parts must be thoroughly cleaned, and kept clean 6. Remove and discard all seals and o-rings. John Deere
during inspection and assembly. Use a nonflammable recommends all seals and o-rings be replaced at
solvent to clean and compressed air to dry. If using assembly.
air, make sure it is filtered to remove all contamination
and water. 7. Inspect, both internally and externally, the head and
piston for scoring or excessive wear. Replace if
2. Remove the cured Loctite from the internal threads of necessary.
the cylinder rod. Run a tap into the rod end.
T803324,00007FF -19-17AUG05-1/1
102711
PN=463
Assembly 5. Wipe any excess oil from the rod end. Apply Loctite
1. Install new seals (10 through 14) on head (6). Primer-N (0841303194) to the internal threads of rod
(9). Slip piston (5) onto rod. Install flatwasher (4) onto
2. Install new seals (15, 16, & 17) on piston (5). bolt (3) and apply Loctite 271 (0841303179) to bolt
threads.
3. Clamp the lug end of rod assembly (9) into a vise and
slip on locking collar (7). 6. Immediately install bolt (3) into rod (9) and tighten
to 200 Lb-Ft (270 Nm). The rod assembly must be
4. Apply clean oil to the inner diameter of head (6) and
installed straight within the tube. Special care must be
slip onto rod assembly (9).
taken not to damage the piston seal.
NOTE: When buffer seal (11) engages the rod chamber
7. Position collar (7) onto tube (1) and tighten until cap
end, extra force may be needed to move head (6).
no longer rotates. Torque setscrew (8) to 25 Lb-Ft
Ensure the head is straight and centered with the
(34 Nm).
rod, and gently tap with a rubber hammer until the
head slides on to the rod. Make sure that the head 8. Plug all ports and wait 24 hours before putting oil in
slides easily upward and downward on the rod1. cylinder.
1
Galling may occur if the head is not straight on the rod.
T803324,0000800 -19-17AUG05-1/1
Topper Lift
CM053510271 —UN—17AUG05
1— Hydraulic Cylinder 4— Wear Ring 7— Seal

2— Rod 5— Seal 8— Hydraulic Cylinder Kit
3— Hydraulic Cylinder Barrel 6— Seal 9— Snap Ring
T803324,0000801 -19-17AUG05-1/1
102711
PN=464
Disassemble and Assemble Topper Lift

Cylinder
1. Remove paint and rust from rod with fine emery cloth.
Wash cylinder and dry.
2. Remove fitting from port on lift cylinder. Slide piston
until snap ring can be seen through port (A). Use a
screwdriver (B) to slide snap ring into groove, the
remove piston.
H63611 —UN—14APR00
A—Port B—Screwdriver
T803324,0000802 -19-17AUG05-1/2
CM053510270 —UN—17AUG05
A—Rod D—Wear Ring G—Buffer Seal

B—Snap Ring E—U-Cup Seal H—Wear Ringe
C—Seal F— Backup Ring I— Hydraulic Cylinder Barrel
3. Remove seal kit (B-H). 4. Check hydraulic cylinder rod and barrel for wear and
damage. Replace as necessary.
T803324,0000802 -19-17AUG05-2/2
102711
PN=465
Gear Motor
CM002500294 —UN—14JUL00
1— Snap Ring 7— Lip Seal 13— Side Seal 19— Gear Housing
2— Shaft 8— Shaft End Cover 14— End Seal 20— Port End Cover
3— Ball Bearing 9— Pipe Plug 15— Thrustplate 21— Washer
4— Spacer 10— Check Assy 16— Square Seal 22— Bolt
5— Retaining Ring 11— Bushing Kit 17— Dowel Pin
6— Seal Retainer 12— Backup Seal 18— Gear Set
T803324,0000803 -19-17AUG05-1/1
102711
PN=466
Gear Motor Repair repair work in a clean area. The repair graphics show a
single section motor but is also applicable to the double
These service instructions will familiarize you with gear section motor. It is important to air blast all parts and
motors: their component parts, the relative position of wipe them with a clean, lintless cloth before assembly.
each part proper methods for assembly or disassembly of Use caution in gripping all parts in the vise to avoid
the units and care and use of these motors. This will give damaging machines surfaces. A motor must be driven in
you the best performance and a longer working life. To the direction of rotation for which is was built; otherwise,
facilitate the repair of these motor, and before any work is pressure will blow the shaft seal. Check all replacement
done, we suggest that you first read all of the repair steps. parts, before installation, to be certain they were not
The first requirement for good maintenance of hydraulic damaged in shipment.
equipment is cleanliness. Make sure you perform all
T803324,0000804 -19-17AUG05-1/1
Suggested Tools • Medium Grit Carborundum Stone

• Seal Removal Tool
• Arbor Press • System Oil and Grease
• 1-1/2 Inch Diameter Steel Ball • Snap Ring Pliers
• Bearing Puller • Prick Punch
• Bushing Removal Tool (0841329345) • Bushing Installation Tool
• Clean Lintless Cloths • Scale (1/32 Inch or 1/64 Inch Graduations)
• Deburring Tools (An old file with cutting teeth ground off) • Small Screwdriver
• Machinist's Hammer • Torque Wrench
• Soft Hammer • Vise with 15 cm (6”) Minimum Open Spread
• Permatex Form-A-Gasket Number C2 Non-Hardening • Seal Installation Tool
Sealant or Equivalent
• Awl
T803324,0000805 -19-17AUG05-1/1
Repair Precautions 3. All gears are closely matched, therefore they must be
1. If it is necessary to pry off sections, take extreme care kept together, as sets, when removed from the pump.
not to mar or damage machined surfaces. Excessive Handle with care to avoid damage to the journals or
force while prying can result in misalignment and may teeth. Avoid touching gear journals.
seriously damage parts.
4. Never hammer bushings into bores, use an arbor
2. If parts are difficult to fit during assembly, tap gently press.
with a soft hammer, never use a metal hammer.
T803324,0000806 -19-17AUG05-1/4
Bushing Removal Tool....................................0841329345 The bushing in the double and triple pumps should be
removed from their bores by using this tool.
T803324,0000806 -19-17AUG05-2/4
Seal Removal Tool........................................................N/A

The seal removal tool can easily be made from an old
screwdriver. Heat the tip and bend to 90°. Grind off
the tip to fit the notch behind the shaft seal.
T803324,0000806 -19-17AUG05-3/4
Bushing Installation Tool.................................0290244461 To install the bushings.

T803324,0000806 -19-17AUG05-4/4
102711
PN=467
Disassembly
7. Remove thrustplate (15).
1. Place the motor in a vise1 with the drive shaft pointing
downward. Match-mark all sections, be sure to align 8. Inspect all bushing for scoring or discoloration and
these marks when assembling. replace if necessary. Use bearing puller to remove
bearing.
washers (21). 9. Place front cover (8) in a vise with the mounting face
pointing upward. Remove the snap ring (1) with snap
3. Lift off port end cover (20). If prying is necessary, be ring pliers.
careful not to damage the machines surfaces. Dowel
pins, if used, will remain in either port end cover, or 10. Remove shaft assembly (2) by lifting up on the shaft
gear housing (19 ). Do Not remove them. end.
4. Remove thrust plate (15). 11. Remove seal retainer (6).
5. Carefully remove gear assembly (18). Avoid tapping 12. Remove seal (7) from housing (8).
the gear teeth together or against other hard surfaces. 13. Remove retaining ring (5) from shaft (2).
Keep these gears together, they are a matched set.
14. Remove spacer (4) and bearing (3) from the shaft (2).
6. Lift gear housing (19) from front cover (8). If prying
is necessary, take care not to damage machined
surfaces.
1
Do Not grip on or near any machined surfaces during as-
sembly or disassembly.
T803324,0000808 -19-17AUG05-1/1
Clean and Inspect coupling. The maximum allowable wear is 0.05 mm

(0.002 inch) . Wear in the shaft seal area indicates
1. Clean and inspect all parts for wear of damage, oil contamination. Wear or damage to splines will
replace if necessary. See John Deere Parts Manual for necessitate replacement.
part numbers to order. Notice that all gear assemblies
are a matched set and cannot be ordered separately. 5. Thrust Plates (15) seal the gear sections at the sides
of the gears. Wear here will allow internal slippage
2. Replace the gear housing (19), if either has wear in and oil will bypass within the pump. A maximum of
excess of 0.13 mm (0.005 inch) cut-out. Use the 0.05 mm (0.002 inch) wear is allowable. Replace
following method to determine cut-out: thrust plates if they are scored, eroded or pitted.
1. Place a straight-edge across bore. If you can slip 6. Check the center of the thrust plates where the gears
a 0.13 mm (0.005 inch) feeler gauge under the mesh, erosion here indicates oil contamination.
straight-edge in the cut-out area, replace the gear Pitted thrust plates indicate cavitation or oil aeration.
housing. Discolored thrust plates indicate overheating, probably
2. Pressure pushes the gears against the housing on due to insufficient oil.
the low pressure side. As the hubs and bushings
wear, the cut-out be comes more pronounced. 7. Dowel pins (17) must be replaced if either the dowel
Excessive cut-out in a short period of time indicates or dowel hole is damaged. If there is damage, either
excessive pressure or oil contamination. If the relief the dowel or machined housing, or both, must be
valve settings are within prescribed limits, check for replaced. If more than reasonable force is required
shock pressures or tampering. Take an oil sample to seat dowels, the cause may be poorly deburred or
and check it, and the tank, for contamination. dirty parts; cocking of dowel in the hole; or improper
3. Where cut-out is moderate, 0.13 mm (0.005 inch) pin-to-hole fit.
or less, the gear housing is in good condition and
may be reused. 8. Bushings (11) must be replaced if gears are replaced.
Bushings should fit into bore with a heavy press fit.
3. Gears (18) which exhibit any scoring on gear hub,
should be replaced. Any scoring, grooving, or burring 9. All sealing parts, lip seal (7), square seals channel
of outer tooth diameter will require their replacement. seal (16) must be replaced. See John Deere Parts
Nicking, grooving, or fretting of teeth surfaces will also Manual for complete seal kit parts numbers.
necessitate replacement. 10. Examine check assembly (10) located in front housing.
4. Drive shaft (2) should be replaced if any wear is Ensure that it is in the proper position and tightly
detectable, by touch, in the seal area or at the drive seated.
T803324,0000809 -19-17AUG05-1/1
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PN=468
Assembly 10. Install shaft assembly in shaft end cover plate (8) from
1. Rub a medium grit carborundum stone over machined the mounting surface side.
surfaces. If bushings were removed or a new section 11. Install snap ring (1) over the shaft end cover to retain
is used, debur bores with a fine emery cloth. Wash shaft (2).
in a solvent, blow dry with air and wipe with a clean
lintless cloth before assembly. 12. Grip the shaft end cover (8) in a vise with the mounting
face down.
2. Grip shaft end cover (8) in vise with mounting face
down. Examine check valves (10) to be sure they are 13. Grease the new seals (16) and insert them into the
tightly in place. Replacement is necessary only if parts grooves in both sides of the gear housing (19). Place
are damaged. Remove with screwdriver. the gear housing (19) on shaft end cover (8) and tap it
with a soft hammer until is rests tightly against the shaft
3. If check valves are being replaced, screw in new parts end cover (8). Be careful not to pinch the gasket seal.
tightly. Stake plug with prick punch at both ends of
screwdriver slot and around edges. Peen edge of hold 14. Assemble the channel seals (12, 13, & 14) into the
0.794 to 1.588 mm (1/32 to 1/16 inch) with a 38.1 mm grooves in the thrust plates (15) with the flat side
(1-1/2 inch) diameter steel ball. of seals (12, 13, & 14) facing away from the thrust
plate (15). Slide the thrust plate (15) through the gear
NOTE: Assembly steps 4, 5, 6, 8 and 10 apply to housing (19) and bottom out on shaft end cover (8).
shaft end cover and port end cover. Smooth side of thrust plate (15) facing gears.
4. If ring seals are being replaced, insert into bottom of 15. Install the gear sets (18) with the one with the internal
drive gear bearing bore. The notch in the ring seal spline going on the shaft (2).
Must Be Visible. This is a check to be certain the
notched side in next to the bearing. 16. Assemble the channel seals (12, 13, & 14) into the
grooves in the thrust plates (15) with the flat side of
5. If any bearing have been removed from the shaft seals (12, 13, & 14) facing away from the thrust plate
end cover or port end cover. Replace the bearings (15). Slide the thrust plate (15) with smooth side of
by pressing them into the bearing bore with an arbor thrust plate (15) facing gears into the gear housing (19).
press.
17. Place the port end cover (20) over the gear journals
6. Before inserting a new lip seal (7) in the shaft cover and tap tightly against the gear housing (19). Be
(8), coat the outer edge of the seal and its bore with careful not to pinch the gasket seal (16).
the lip seal up, press it into the mounting flange side 18. Thread the four bolts (22) with washers (21) into
of the shaft end cover (8) with an arbor press and a the shaft end cover (8) and tighten alternately or
piece of 38.1 x 50.8 mm (1-3/4 x 2 inch) round bar. cross-corner. Rotate the drive shaft with a wrench to
Make sure the lip seal is fully seated in the bore. Wipe make certain there is no binding in the motor.
off excess sealant. 19. After the fasteners are tight and there is not internal
7. Check all thrust plates for wear. Replace if necessary. binding, torque the diagonally opposite bolts (22) to
200 Lb.Ft (272 Nm).
8. Position shaft end cover so that the mounting surface
is up.
9. Install bearing (3), spacer (4) retaining ring (5), and
spacer (6) on the shaft (2).
T803324,000080A -19-17AUG05-1/1
Start-up Procedure minutes at no load and at low RPM (400 minimum).

During this break-in period, the unit should run free
1. Before connecting any lines to the motor, fill all ports and not develop an excessive amount of heat. If the
with clean system oil to provide initial lubrication. motor operates properly, speed and pressure can then
2. After connecting the lines and mounting the be increased to normal operating settings.
replacement motor, operate the motor at least two
T803324,000080B -19-17AUG05-1/1
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PN=469
Recommended Test Procedure GPM 100 PSI 1000 PSI 1500 PSI 2000 PSI 2500 PSI
Drop Off
1. Be sure there is an adequate supply of system oil for at
the pump, at least one gallon of oil for each GPM of GPM 5 - 14 2-3 21/2 - 3 3-4 31/2 - 4
motor capacity. Delivery 1/2 1/2
at 1800 15 - 25 21/2 - 3-4 31/2 - 5 4 - 51/2
2. The oil should be a good quality hydraulic oil rated at RPM 31/2
150 SSU at 38°C (100°F) with the oil temperature held
at 46-52°C (115-125°F). 26 - 50 3-4 4-5 4-6 41/2 -
61/2
3. The suction line must be of adequate size with no
more than 17 kPa (5 inches) of mercury vacuum L/Min 6.9 Bar 69 Bar 103 Bar 138 Bar 172 Bar
Drop Off
adjacent to the pump inlet. As a rule, the feed line at
must provide a feed flow velocity not in excess of 2.4
L/Min 19 - 53 L 7.6 - 11.4 9.5 - 13.2 11.4 - 15.L 13.2 - 17 L
meters per second (8 feet per second). Delivery L L
at 1800
4. Feeding hot oil into a cold motor may cause the motor RPM
53.8 - 9.5 - 13.2 11.4 - 15. 11.4 - 18.9 15.1 -
to seize. Jog the pump by momentarily starting the 94.6 L L L L 20.8 L
driving engine to gradually equalize motor and oil 98 - 189 L 11.4 - 15.1 15.1 - 15.1 - 17 - 24.6 L
temperatures. L 18.9 L 22.7 L
7. It is recommended to measure the output at normal
5. Run the motor at least two minutes at no load and operating speed and at zero pressure, then again
moderate speed (not over 1500 RPM). If the motor at 69 bar (1000 PSI) (or the operating pressure
becomes excessively hot, shut down immediately and of the equipment) and allow a volume decrease
locate the problem’s source. approximating the listing below. It is a suggested
6. Delivery should run close to rated performance figures reference only which makes allowance for reused
which are averaged from testing several motor. A 5% parts. At test speeds other than 1800 RPM, L/Min
lower reading may be used as a rated minimum if (GPM) delivery will vary almost proportionately, but
new, or relatively new, parts have been used. When the same (drop-off) figures should be used.
rebuilding the motor with parts from the original motor, After completing testing procedures, the motor is ready
which, while worn, appear satisfactory for reuse, a for installation and immediate operation on the harvester.
10% or 15% lower reading should be used, depending Again, it must be remembered that to prevent seizure, hot
upon the performance expected from the equipment. oil must not be fed into a cold motor.
One’s own experience will prove the best guide here.
T803324,000080C -19-17AUG05-1/1
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Section 90
Operator’s Station
Contents
Page
Group 05—Cab
Other Material................................................ 90-05-1
Remove and Install Cab
Windshield—Style B .................................. 90-05-1
Remove and Install Cab Outer
Roof—Style B ............................................ 90-05-6
Remove and Install Cab Inner
Roof—Style B ............................................ 90-05-6
Remove and Install Cab
Headliner—Style B .................................. 90-05-10
Remove and Install Instructional
Seat ......................................................... 90-05-10
Remove and Install Cab Door ..................... 90-05-12
Disassemble and Assemble Cab
Door......................................................... 90-05-14
Cab Door Latch Striker ................................ 90-05-15
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Contents
102711
PN=2
Group 05
Cab
Other Material
Number Name Use
AR54749 (U.S.) Liquid Soap Apply to Molding
T803324,0000757 -19-16FEB06-1/1
Remove and Install Cab Windshield—Style B

Do not attempt to install a replacement windshield unless
you are qualified in glass replacement.
The original factory adhesive used to bond the windshield
in place is a urethane type. When installing this glass,
H83632 —UN—07JUN05
use an adhesive method that is compatible with urethane
adhesive. These types of adhesive ARE NOT available
from John Deere.
Refer to the manufacturer's adhesive/primer label and the
SAFETY DATA SHEET for safety precautions.
Curing time of this type adhesive depends on weather
conditions (heat and humidity). After installing this glass,
it is preferred that the combine not be operated during harvester, for the first 48 hours use caution to avoid bumps
the cure time. However, if it is necessary to operate the and shock loads, such as when crossing a border, etc.
OUO6046,0001EA8 -19-23MAR06-1/12
NOTE: Make sure wipers are in the parked position

before starting removal procedures.
1. Remove cap screws (A) and sun visor (B).
A—Cap Screw (3 used) B—Sun Visor
H63271 —UN—30MAR00
OUO6046,0001EA8 -19-23MAR06-2/12
2. Remove front headliner (A) from cab by pulling back

and down on front edge of headliner to clear tabs (B).
3. Remove headliner. (See procedure in this group.)
A—Tab (5 used) B—Headliner

H63270 —UN—30MAR00
Continued on next page OUO6046,0001EA8 -19-23MAR06-3/12
102711
PN=473
Cab
4. Remove nuts (A and B) and wiper arm (C).
A—Nut C—Wiper Arm

B—Nut
H83549 —UN—23MAY05
OUO6046,0001EA8 -19-23MAR06-4/12
5. Remove cap screws (A) and grab handle (B).
A—Cap Screw (3 used) B—Grab Handle
H83552 —UN—23MAY05
OUO6046,0001EA8 -19-23MAR06-5/12
6. Remove boot (A), nut (B) and plate (C).
A—Boot C—Plate
B—Nut
H83553 —UN—23MAY05
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PN=474
Cab
7. Disconnect connector (B).

8. Push wiper motor assembly (A) towards roof and
remove wiper motor assembly.
A—Wiper Motor Assembly B—Connector
H83554 —UN—23MAY05
OUO6046,0001EA8 -19-23MAR06-7/12
9. Remove cap screws (A) and lower cab panel.
A—Cap Screw (3 used)
H76826 —UN—08MAY03
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PN=475
Cab
10. Remove front and rear inner roof mounts (A and B).
A—Front Inner Roof Mount (2 B—Rear Inner Roof Mount (2

used) used)
H83557 —UN—23MAY05
Front Cab Mount
H83558 —UN—23MAY05
Rear Cab Mount
OUO6046,0001EA8 -19-23MAR06-9/12
11. Lift inner cab roof (A) up enough to gain access to

windshield and support front of inner cab roof with
blocks (B).
A—Inner Cab Roof B—Blocks
H83561 —UN—23MAY05
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PN=476
Cab
NOTE: The H128392 clips in the windshield kit will be

required for the purpose of installing and securing the
windshield during adhesive cure time of 2.5 hours.
12. Completely remove all of old windshield glass. Also

remove the two old clamps from head panel (two new
clamps (B) are supplied with the glass). Try to leave
a layer of the old adhesive on the frame. However, if
you remove all of the old adhesive, leaving bare metal,
use the correct primer to ensure a good bond between
metal and adhesive.
13. Apply a thin coat of adhesive to area (A) on both
clamps (B) provided.
H40068 —UN—10OCT88
14. Slip clamps (B) on windshield as specified (C).
Specification
Windshield
Clamps—Approximate
Spacing....................................................................................... 600 mm
(24 in.)
15. Bend leg (D) up on both clamps.

A—Area for Adhesive C—Clamp Placement
B—Clamp D—Clamp Leg
OUO6046,0001EA8 -19-23MAR06-11/12
IMPORTANT: Edges of glass on both sides must

not contact cab frame.
16. Apply adhesive to cab frame and position new glass B

by pushing it up until the two new brackets (A) contact
the head panel (B).
17. Tighten two clamps attached to cab floor (C).
A E
18. Use nonmetallic shims (D) to hold glass in place.
19. Bend leg (E) up on both clamps to secure glass.
20. Tape sides of glass with duct tape to hold glass in
position.
21. Install all parts.
22. Remove tape after 48 hours.
A—Bracket D—Shims
B—Head Panel E—Clamp Leg
C—Clamp Screw
H67759 —UN—29MAY01
D C
OUO6046,0001EA8 -19-23MAR06-12/12
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PN=477
Cab
Remove and Install Cab Outer Roof—Style B

1. Remove screws (A) and washers.
NOTE: Cap screw (C) is longer than cap screw (B).
Note locations to aid in installation.
H83614 —UN—26MAY05
2. Remove cap screws (B and C).
3. Remove communications/CB antenna (D).
A—Screw (12 used) C—Cap Screw

B—Cap Screw D—Communications/CB
Antenna
OUO6046,0001EA9 -19-16FEB06-1/2
4. Lift up on front left-hand side of cab roof to access

antenna (A). Disconnect antenna.
5. Remove cab outer roof.
6. Repair or replace as necessary.
IMPORTANT: Inspect seal along cab outer roof for
H83571 —UN—23MAY05
defects. Replace as needed.
7. Install in reverse order of removal.
A—Antenna
OUO6046,0001EA9 -19-16FEB06-2/2
Remove and Install Cab Inner Roof—Style B

1. Remove cab outer roof. (See procedure in this group.)
2. Remove cab headliner. (See procedure in this group.)
3. Remove nuts (A and B) and wiper arm (C).
H83549 —UN—23MAY05
A—Nut C—Wiper Arm
B—Nut
Continued on next page OUO6046,0001EAA -19-16FEB06-1/8
102711
PN=478
Cab
4. Remove cap screws (A) and grab handle (B).
A—Cap Screw (3 used) B—Grab Handle
H83552 —UN—23MAY05
OUO6046,0001EAA -19-16FEB06-2/8
5. Remove boot (A), nut (B) and plate (C).
A—Boot C—Plate
B—Nut
H83553 —UN—23MAY05
OUO6046,0001EAA -19-16FEB06-3/8
6. Disconnect connector (B).

7. Push wiper motor assembly (A) towards roof and
remove wiper motor assembly.
A—Wiper Motor Assembly B—Connector
H83554 —UN—23MAY05
102711
PN=479
Cab
8. Remove covers (A) and disconnect speaker wires.

9. Route speaker wires through access hole (B) and into
cab.
A—Cover (2 used) B—Access Hole
H83580 —UN—24MAY05
H83581 —UN—24MAY05
OUO6046,0001EAA -19-16FEB06-5/8
10. Remove clips (A) from cab roof.
A—Clip (3 used)
H83582 —UN—24MAY05
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PN=480
Cab
CAUTION: HID-Xenon lamps are powered

by 25,000 volts. Do not begin removal of
HID-Xenon lights or ballast unless the lights are
turned off, the engine is turned off, the key is
removed, appropriate eye protection is worn and
connectors to HID-Xenon lights are disconnected.
H83585 —UN—24MAY05
11. Remove screws and connector (A) from front of cab
roof.
12. Disconnect light connectors. Remove light grommets
(B) and pull harness and connectors up through roof.
13. Remove cap screw (G) and clamp.
14. Remove grommet and push antenna wire (F) into cab.
15. Disconnect connectors (D) from ballast.
16. Route main harness on top of cab through access
hole (C) and into cab.
H83586 —UN—24MAY05
17. Remove screw (E) and communications/CB radio
antenna cable.
A—Connector E—Screw
B—Light Grommet (4 used) F— Antenna Wire
C—Access Hole G—Cap Screw
D—Connector (2 used)
OUO6046,0001EAA -19-16FEB06-7/8
18. Remove front and rear cab mounts (A and B).

19. Disconnect washer hose from tee in front of cab and
remove washer hose (C) from cab roof.
CAUTION: Approximate weight of inner cab

roof is 31 kg (69 lb).
H83557 —UN—23MAY05
Specification
Inner Cab Roof—Weight.................................................................. 31 kg
(69 lb)
20. Remove inner cab roof from combine.

21. Repair or replace inner cab roof as necessary. Front Cab Mount
22. If replacing cab roof, perform the following steps:

• Remove speakers. (See procedure in Section 40,
Group 30.)
• Remove cab lights. (See procedure in Section 40,
Group 25.)
•
H83596 —UN—26MAY05
Remove ballast. (See procedure in Section 40,

Group 25.)
A—Front Cab Mount (2 used) C—Washer Hose

B—Rear Cab Mount (2 used)
OUO6046,0001EAA -19-16FEB06-8/8
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PN=481
Cab
Remove and Install Cab Headliner—Style B

1. Remove screws that attach sunvisor to cab roof (if
equipped).
2. Push up and pull back on forward edge of front
headliner (E) to release from clips. Remove front
H83575 —UN—01JUN05
headliner.
3. Remove rear window trim.
4. Remove coat hook.
5. Move door weatherstrip to access screw (C) and
remove screw.
NOTE: Overhead panel and dome light harnesses
do not need to be disconnected in order A—Overhead Control Panel E—Front Headliner
B—Sound Resonator Cover (2 F— Location
to remove headliner. used) G—Clip (4 used)
C—Screw
6. Lower overhead control panel (A) and dome light (D). D—Dome Light
7. Remove sound resonator covers (B).

8. Using a putty knife, move headliner away from cab 9. Move overhead control panel and dome light through
frame to release headliner from clips (G) at locations holes in headliner and remove headliner.
(F) and lower headliner.
OUO6046,0001EAB -19-16FEB06-1/1
Remove and Install Instructional Seat

1. Pull up and remove storage bin (A).
2. Pull up on knob (B) and remove upper portion
instructional seat (C).
N56385 —UN—22MAR01
A—Storage Bin C—Instructional Seat
B—Knob
OUO6083,000073E -19-23MAR06-1/4
NOTE: Screws (B) around load center do not

need to be removed.
3. Remove screws (A) and pull instructional seat (C)

forward slightly.
N56386 —UN—29MAR01
A—Screws (8 used) C—Instructional Seat

B—Screws (4 used)
Continued on next page OUO6083,000073E -19-23MAR06-2/4
102711
PN=482
Cab
4. Remove nuts (A) and set load center (B) and mounting
bracket aside.
5. Remove instructional seat from cab.
6. Inspect instructional seat, replace as necessary.
7. Install load center (B), mounting bracket, and nuts (A)
N56383 —UN—29MAR01
to back of instructional seat.
8. Carefully slide the instructional seat (C) into position
and install screws (A).
A—Screws (8 used) C—Instructional Seat

B—Screws (4 used)
N56386 —UN—29MAR01
OUO6083,000073E -19-23MAR06-3/4
9. Lift up on knob (B) and install upper portion of

instructional seat (C).
10. Install storage bin (A).
N56385 —UN—22MAR01
OUO6083,000073E -19-23MAR06-4/4
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PN=483
Cab
Remove and Install Cab Door

CAUTION: Support cab door prior to removing
hinge pins. Door may shatter if dropped.
1. Remove snap rings (A) and hinge pins (B).
H73474 —UN—01OCT02
2. Remove cab door.
3. Repair or replace cab door as necessary.
4. Install cab door using hinge pins (B) and snap rings (A).
A—Snap Ring B—Hinge Pin
H73475 —UN—01OCT02
OUO6030,00001BC -19-16FEB06-1/1
102711
PN=484
Cab
102711
PN=485
Cab
Disassemble and Assemble Cab Door
5 6
1
7
4 2
8 3
12
9
10
15
11
37
13
34 14
32 33
31
36
35
10
11
16
17
19
20
18
21
22
30
27
29
23
28
24
28
H73479 —UN—02OCT02
25
26
Continued on next page OUO6030,00001BD -19-16FEB06-1/2
102711
PN=486
Cab
1— Strap Nut 11— Washer (2 used) 21— Washer 31— Lock Nut (2 used)
2— Spring Washer (2 used) 12— Screw (2 used) 22— Cap 32— Washer (2 used)
3— Striker 13— Bracket 23— Screw 33— Washer
4— Socket Head Screw (2 used) 14— Spacer 24— Pin (2 used) 34— Screw
5— Screw 15— Door 25— Hinge (2 used) 35— Isolator
6— Cover 16— Bushing 26— Snap Ring (2 used) 36— Washer
7— Latch 17— Gasket 27— Bushing 37— Lock Nut
8— Bearing 18— Handle 28— Washer (8 used)
9— Tube 19— Gasket 29— Lock Washer (4 used)
10— Nut (2 used) 20— Bushing 30— Screw (4 used)
Disassemble and assemble door as required to make

repairs.
OUO6030,00001BD -19-16FEB06-2/2
Cab Door Latch Striker
C
B
D
H73480 —UN—02OCT02
A—Socket Head Screw (2 used) B—Striker Plate C—Spring Washer (2 used) D—Strap Nut
NOTE: Make sure washers (C) are not lost when 5. Check proper operation of door latch from inside and
removing striker plate (B). outside cab. Make further adjustments as required.
1. Remove socket head screws (A), striker plate (B), 6. Tighten socket head screws (A) to specification.
spring washers (C) and strap nut (D).
Specification
2. Inspect parts for wear. Replace parts as required. Striker Plate Socket Head
Screws—Torque............................................................................72 N·m
3. Install striker plate (B) and washers (C), with cup side (53 lb-ft)
toward cab frame, using socket head screws (A). Do
not tighten at this time.
4. Check alignment of striker plate with door latch
assembly. Loosen striker plate and realign as required.
OUO6083,0000439 -19-16FEB06-1/1
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PN=487
Cab
102711
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Section 100
Crop Divider System
Contents
Page
Group 05—Crop Divider

Crop Divider................................................. 100-05-1
Crop Divider Removal ................................. 100-05-2
Disassembly ................................................ 100-05-2
Assembly ..................................................... 100-05-2
Crop Divider Shoe Assembly....................... 100-05-2
Crop Divider Shoe Removal ........................ 100-05-2
Gauge Wheel............................................... 100-05-3
102711
PN=1
Contents
102711
PN=2
Group 05
Crop Divider
Crop Divider
CM053510274 —UN—17AUG05
1— Adjust Linkage Upper 3— Bushing 5— Fl. Washer 7— Bolt

Assembly 4— Zerk 6— Lock Washer
2— Adjust Linkage Upper
Assembly
T803324,0000818 -19-17AUG05-1/1
102711
PN=491
Crop Divider
Crop Divider Removal

It may not be necessary to remove the crop divider from
NOTE: See Parts Manual for complete crop the harvester. If there is no structural or wear damage,
divider breakdowns. repair can be performed while it is on the harvester. To
carry out work on the crop divider structures, they must be
removed from the harvester chassis.
T803324,0000819 -19-27SEP07-1/1
Disassembly 4. Label, remove and cap all hoses and fittings located
1. Label, remove and cap all hoses and fittings. on the motor.
2. Disconnect floating shoe assembly from the main 5. Remove fasteners and remove motor mount along
frame at the chain adjustment end and remove with the motor splined adapter hub.
fasteners from the pivot point. 6. Splined hub adapter is Araldited to the motor shaft and
3. Remove retaining fasteners from pivot pins and retained by single bolt. To remove, loosen the center
remove the pins. This frees the crop divider assembly bolt and apply a puller to the drive spline.1
from the harvester for disassembly.
1
It may be necessary to apply heat to soften Araldite for removal.
T803324,000081A -19-27SEP07-1/1
Clean and Inspect 3. Check the motor seal for leakage. Replace as
1. If the bearing is damaged or worn, replace. See John necessary.
Deere Parts Manual for replacement part numbers. 4. Check structural parts for wear or damage. Repair
2. Check the condition of mating splines and shafts. or replace as necessary.
Repair or replace as necessary.
T803324,000081B -19-17AUG05-1/1
Assembly 3. If male drive spline is removed from the drive motor,

1. Assembly is the reverse of disassembly. Araldite must be used to affix splines.
2. The scroll adjustment is 3 mm (1/8 inch) up and down

movement in the splines.
T803324,000081C -19-17AUG05-1/1
Crop Divider Shoe Assembly the basecutters. The shoe assemblies are secured to the
crop divider with a bolt, and supported by an adjustment
Due to differing crop conditions and types of cultivation, chain at the rear.
crop divider shoe assemblies are used to direct cane into
T803324,000081D -19-17AUG05-1/1
Crop Divider Shoe Removal 2. Raise the harvester until the main frame clears the
1. Lower the harvester to the ground; disconnect the crop divider shoe assembly and remove.
support chain and remove the bolt.
T803324,000081E -19-17AUG05-1/1
102711
PN=492
Crop Divider
Gauge Wheel
CQ282584 —UN—11FEB09
1— Nut 8— Nut 15— Cap Screw 22— Bushing

2— Washer 9— Bearing 16— Lock Washer 23— Lock Nut
3— Stand 10— Roller Race 17— Nut 24— Axle
4— Bolt 11— Bearing 18— Dust Cap 25— Tire and Wheel
5— Seal Kit 12— Roller Race 19— Slotted Nut
6— Bolt 13— Washer 20— Cotter Pin
7— Hub 14— Fitting 21— Cap Screw
Continued on next page GB52027,000087A -19-12FEB09-1/2
102711
PN=493
Crop Divider
Assemble gauge wheel as ilustrated.

IMPORTANT: Apply John Deere SD POLYUREA
IMPORTANT: Install nut (N) and tighten until heavy Grease or an equivalent SAE multipurpose-type
drag is felt on hub as it is rotated. Back grease to the fittings (J).
nut (N) off one castelation. Insert cotter
pin and bend it over spindle.
GB52027,000087A -19-12FEB09-2/2
102711
PN=494
Section 110
Basecutter System
Contents
Page
Group 05—Basecutter Gearbox

Basecutter Gearbox - 3520 ......................... 110-05-1
Basecutter Gearbox - 3522 ......................... 110-05-3
Basecutter Box Assembly............................ 110-05-4
Group 10—Basecutter Lift Cylinder Accumulators

Accumulators Calibration............................. 110-10-1
102711
PN=1
Contents
102711
PN=2
Group 05
Basecutter Gearbox
Basecutter Gearbox - 3520
CM073510663 —UN—15OCT07
Continued on next page GB52027,0000860 -19-21JAN09-1/2
102711
PN=497
Basecutter Gearbox
1— Basecutter Shaft Assembly 11— Basecutter Leg Washer (2) 21— Bolt (30) 31— Snap-Ring (2)
(2) 12— Slotted Fine Thread Nut (2) 22— Hub Cap Gasket (3) 32— O-ring
2— Basecutter Seal Adapter (2) 13— Bolt (2) 23— Cap (3) 33— Shield Mount (2)
3— Single Lip (Top) Seal (2) 14— Lock Nut (2) 24— Bolt (18) 34— Magnetic Plug (3)
4— Seal (Bottom) (2) 15— Bearing (4) 25— Fitting 35— Sight Gauge
5— Basecutter Box Assembly 16— Basecutter Pinion Gear 26— Kickers (8) 36— V-Ring Seal (2)
6— Bolt (4) 17— Basecutter Idler Gear 27— Lock Nuts (16) 37— Zerk (2)
7— Cone Bearing (4) 18— Dowel Pin (3) 28— Bolt (16) 38— Check Valve (5 pound) (2)
8— Flat Washer (4) 19— Basecutter Cover Gasket 29— Flat Washer (16)
9— Bearing Cup (4) 20— Basecutter Cover 30— Lock Washer (30)
10— Basecutter Leg Gear (2)
GB52027,0000860 -19-21JAN09-2/2
102711
PN=498
Basecutter Gearbox
Basecutter Gearbox - 3522

21
33
30
33
18
31
23
22
20
12
11
10
17
16
15
7
9
3
34
5 37
38
35
34
7
36
4
CQ282569 —UN—11DEC08
102711
PN=499
Basecutter Gearbox
1— Basecutter Shaft Assembly 11— Basecutter Leg Washer (2) 21— Bolt (30) 31— Snap-Ring (2)
(2) 12— Slotted Fine Thread Nut (2) 22— Hub Cap Gasket (3) 32— O-ring
2— Basecutter Seal Adapter (2) 13— Bolt (2) 23— Cap (3) 33— Shield Mount (2)
3— Single Lip (Top) Seal (2) 14— Lock Nut (2) 24— Bolt (18) 34— Magnetic Plug (3)
4— Seal (Bottom) (2) 15— Bearing (4) 25— Fitting 35— Sight Gauge
5— Basecutter Box Assembly 16— Basecutter Pinion Gear 26— Kickers (8) 36— V-Ring Seal (2)
6— Bolt (4) 17— Basecutter Idler Gear 27— Lock Nuts (16) 37— Zerk (2)
7— Cone Bearing (4) 18— Dowel Pin (3) 28— Bolt (16) 38— Check Valve (5 pound) (2)
8— Flat Washer (4) 19— Basecutter Cover Gasket 29— Flat Washer (16)
9— Bearing Cup (4) 20— Basecutter Cover 30— Lock Washer (30)
10— Basecutter Leg Gear (2)
GB52027,0000861 -19-21JAN09-2/2
Basecutter Box Assembly

1. Check basecutter shaft (1) where seal carrier (2) fits
for smooth clean surface.
CQ280263 —UN—27FEB08
CM073510664 —UN—03MAR08
102711
PN=500
Basecutter Gearbox
NOTE: Blow box out with air pressure all during assembly.
2. Clean basecutter box (5) with hot water. Blow out with
air pressure and wipe clean.
CM073510665 —UN—03MAR08
GB52027,0000855 -19-20JAN09-2/31
3. Wrap Teflon Thread Tape on plug (34) and install it in

the box (5). Apply Teflon Thread Paste to sight glass
(35) and install it into the box.
CM073510666 —UN—03MAR08
GB52027,0000855 -19-20JAN09-3/31
4. Place shaft bearing cups (9) in freezer for at least 30

minutes.
CM073510667 —UN—03MAR08
102711
PN=501
Basecutter Gearbox
5. Install seal carrier (2) on shaft (1) with Loctite 640

(green).
CM073510668 —UN—03MAR08
CM073510664 —UN—03MAR08
102711
PN=502
Basecutter Gearbox
6. Install pinion bearing (15) and idler bearing (15) in box

(5) with Loctite 640 (green).
CM073510669 —UN—03MAR08
3520
15
CQ282574 —UN—20JAN09
3522
CM073510670 —UN—03MAR08
102711
PN=503
Basecutter Gearbox
7. Install V-ring seal (36) on top of seal carriers (2).

Insure the thick lip of the V seal is against the seal
carrier.
NOTE: Put a small bead of Loctite 640 around the
lower outer edge of bearing. Let dry for 4 to
CQ280264 —UN—27FEB08
6 hours before adding oil.
CM073510671 —UN—03MAR08
GB52027,0000855 -19-20JAN09-7/31
8. Heat bearing cones (7) in oven for 15 minutes.
CM073510672 —UN—03MAR08
102711
PN=504
Basecutter Gearbox
NOTE: Wear welding gloves when handling bearings.
9. Install bearing cones (7) onto shaft (1). Make sure

bearing cone (7) is fully seated on shaft.
CM073510673 —UN—03MAR08
102711
PN=505
Basecutter Gearbox
10. Install the top single lip seals (3) into gearbox (5).
Insure the seal is installed before installing bearing
cup (9). The grease port should be visible once the
seal is fully seated.
CQ280265 —UN—27FEB08
CM073510674 —UN—03MAR08
CM073510675 —UN—03MAR08
CM073510676 —UN—03MAR08
102711
PN=506
Basecutter Gearbox
11. Remove bearing cup (9) from the freezer.
CM073510677 —UN—03MAR08
GB52027,0000855 -19-20JAN09-11/31
12. Install the cold shaft bearing cups (9) in box (5). Use
Loctite 640 (green) and fully seat the bearing cup on
the step.
CQ280266 —UN—27FEB08
CM073510678 —UN—03MAR08
102711
PN=507
Basecutter Gearbox
13. Rotate the gearbox (5) where the legs of the gearbox
are facing upward.
CM073510679 —UN—03MAR08
GB52027,0000855 -19-20JAN09-13/31
14. Install the cold shaft bearing cups (9) in box (5). Use
Loctite 640 (green) and fully seat the bearing cup on
the step.
CM073510680 —UN—03MAR08
GB52027,0000855 -19-20JAN09-14/31
15. Install bottom seal (4) into gearbox (5).
CM073510681 —UN—03MAR08
102711
PN=508
Basecutter Gearbox
16. Insure the bottom seal (4) is fully seated.

17. Rotate the gearbox (5) again where the box legs are
facing downward.
CM073510682 —UN—03MAR08
GB52027,0000855 -19-20JAN09-16/31
18. Install the shaft assembly (1) into gearbox (5).
CM073510683 —UN—15OCT07
CM073510684 —UN—03MAR08
102711
PN=509
Basecutter Gearbox
19. Clean shaft area before installing bearing. Install top

(hot) bearing cone (7). Tap bearing cone on inner race
lightly to seat in cup (9).
CM073510685 —UN—03MAR08
CM073510686 —UN—03MAR08
102711
PN=510
Basecutter Gearbox
20. Install gear (10), washer (11) and nut (12) on to shaft
(1).
CM073510687 —UN—03MAR08
CQ280267 —UN—27FEB08
CM073510688 —UN—03MAR08
102711
PN=511
Basecutter Gearbox
NOTE: Secure shaft (1) to stand before torquing nut

(12). Torque nut (12) to 149.1 N·m (110 lb-ft). Turn
the shaft (1) several times to seat the bearings
and check to torque again. Tighten to line up
hole in shaft (1) with the slot in the nut (12).
CM073510689 —UN—03MAR08
Install bolt (13) with lock nut (14).
CQ280268 —UN—27FEB08
CM073510690 —UN—03MAR08
GB52027,0000855 -19-20JAN09-20/31
NOTE: Install the timing bar after installing the second

gear (10) on second shaft (1).
21. Install the second shaft the same as the first.

CM073510691 —UN—03MAR08
102711
PN=512
Basecutter Gearbox
22. Install pinion (16) and idler gear (17) with bearing (15)
in box (5).
CM073510692 —UN—03MAR08
3520
15
17
16
CQ282576 —UN—21JAN09
3522
CM073510693 —UN—03MAR08
102711
PN=513
Basecutter Gearbox
23. Apply Teflon Tape to both plugs (34). Install one plug in
the top port of each gearbox leg and torque until tight.
CM073510694 —UN—03MAR08
CQ280274 —UN—27FEB08
CM073510695 —UN—03MAR08
102711
PN=514
Basecutter Gearbox
24. Apply liquid Teflon to both grease zerks (37) and install
one in each bottom port on the gearbox leg.
CM073510696 —UN—03MAR08
CQ280270 —UN—27FEB08
GB52027,0000855 -19-20JAN09-24/31
25. Apply liquid Teflon to the two 5 PSI check valves (38).
Install one valve in each of the center ports on the
gearbox legs. Ensure that the center portion of the
check valve moves in and out freely.
NOTE: Use SAE multi-purpose extreme pressure
CQ280275 —UN—27FEB08
performance grease containing 3 to 5%
molybdenum disulfide to fill the grease cavities. This
is the same recommended grease used to grease
all the other grease locations on the harvester
NOTE: Once the harvester begins working, it is

recommended that you check the capacity
every 100 hours. This is accomplished by
pumping fresh grease into the zerk until it
comes out of the check valve.
26. Begin pumping grease into zerk (37). Continue this

procedure until grease begins coming out of the 5 psi
CM073510697 —UN—03MAR08
check valve (38). This action tells you that the grease
cavity is full. Once this is accomplished, repeat the
same procedure to the other leg. Check for grease
leaking out of items (37 and 34). If grease is escaping
from these items, they may require more torque.
102711
PN=515
Basecutter Gearbox
27. Glue gasket (19) to cover (20) with hitack adhesive.
CM073510698 —UN—03MAR08
GB52027,0000855 -19-20JAN09-26/31
28. Install cover (20) to box (5) and install the dowel pins
(18).
CM073510699 —UN—03MAR08
GB52027,0000855 -19-20JAN09-27/31
NOTE: Start from the middle of the cover and

work your way outward.
29. Install the two shield mounts (33) to box (5) with bolts
(21) and lock washers (30). Use Loctite 242 (blue) on
CM073510700 —UN—03MAR08
all the bolts and torque to 47.4 N·m (35 lb-ft).
102711
PN=516
Basecutter Gearbox
30. Install both snap rings (31), one for the pinion gear
and the other for the idler gear.
CM073510701 —UN—03MAR08
GB52027,0000855 -19-20JAN09-29/31
31. Install cover (23) and gasket (22) on shafts (1) and
idler (17) using bolts (24) with Loctite 242 (blue) and
torque to 13.5 N·m (10 lb-ft).
CM073510702 —UN—03MAR08
CQ280271 —UN—27FEB08
102711
PN=517
Basecutter Gearbox
32. Install the basecutter motor using bolts (6) and

washers (8). Use Loctite 242 (blue) and torque to
119.3 N·m (88 lb-ft).
33. Fill the box with 85W140 gear oil and check for leaks.
CM073510703 —UN—16OCT07
GB52027,0000855 -19-20JAN09-31/31
102711
PN=518
Group 10
Basecutter Lift Cylinder Accumulators
Accumulators Calibration
1. Hold the accumulator in a bench.
CQ286046 —UN—17SEP10
BL04947,0000353 -19-16SEP11-1/21
2. Tighten the fitting.
CQ286047 —UN—17SEP10
BL04947,0000353 -19-16SEP11-2/21
3. Loose the allen nut.
CQ286048 —UN—17SEP10
102711
PN=519
4. Position the allen wrench into the special tool

JTO35152 as illustrated.
CQ286049 —UN—17SEP10
BL04947,0000353 -19-16SEP11-4/21
5. Put the special tool JTO35152 allen wrench in the

accumulator screw.
CQ286051 —UN—23SEP10
BL04947,0000353 -19-16SEP11-5/21
6. Mount the special tool JTO35152 in the accumulator.
CQ286052 —UN—17SEP10
102711
PN=520
CQ286053 —UN—17SEP10
BL04947,0000353 -19-16SEP11-7/21
CQ286054 —UN—01OCT10
BL04947,0000353 -19-16SEP11-8/21
9. Position the cylinder hose tightening it slightly to not

damage the valve.
CQ286055 —UN—17SEP10
102711
PN=521
10. Open the valve.
CQ286056 —UN—04OCT10
BL04947,0000353 -19-16SEP11-10/21
11. Open the valve.
CQ286057 —UN—17SEP10
BL04947,0000353 -19-16SEP11-11/21
12. Open the cylinder.
CQ286058 —UN—17SEP10
102711
PN=522
13. Set the pressure to 375 PSI.
CQ286059 —UN—17SEP10
BL04947,0000353 -19-16SEP11-13/21
14. Tightening the screw slightly.
CQ286060 —UN—04OCT10
BL04947,0000353 -19-16SEP11-14/21
15. Close the valve.
CQ286061 —UN—17SEP10
102711
PN=523
16. Close the valve.
CQ286062 —UN—17SEP10
BL04947,0000353 -19-16SEP11-16/21
17. Remove the cylinder hose.
CQ286063 —UN—17SEP10
BL04947,0000353 -19-16SEP11-17/21
18. Open the relieve valve.
CQ286064 —UN—17SEP10
102711
PN=524
19. Hold the allen wrench and remove the special tool
JTO35152 from the accumulator.
CQ286065 —UN—17SEP10
BL04947,0000353 -19-16SEP11-19/21
20. Remove the allen wrench to finish the special tool

JTO35152 removal.
CQ286066 —UN—17SEP10
BL04947,0000353 -19-16SEP11-20/21
21. Tighten the allen nut using an allen wrench.
CQ286067 —UN—17SEP10
BL04947,0000353 -19-16SEP11-21/21
102711
PN=525
102711
PN=526
Section 120
Chopper System
Contents
Page
Group 05—Chopper Box

Chopper Box Assembly ............................... 120-05-1
Removal ...................................................... 120-05-2
Chopper Gearbox Pre-Assembly
and Installation ........................................ 120-05-9
Install Top and Bottom Drum ..................... 120-05-13
Final Assembly of Chopper Box ................ 120-05-19
Clean and Close the Box........................... 120-05-23
Differential Chopper Blade and
Kicker Installation .................................. 120-05-26
Chopper System........................................ 120-05-27
Differential Chopper Timing ....................... 120-05-27
Installing Blades and Kickers..................... 120-05-28
Differential Chopper Timing and
Adjustments........................................... 120-05-29
Field Setting of Slip Clutch ........................ 120-05-29
Chopper Deflector Shield
Adjustment............................................. 120-05-30
Chopper Bearing Installation ..................... 120-05-31
102711
PN=1
Contents
102711
PN=2
Group 05
Chopper Box
Chopper Box Assembly
CM053510283 —UN—23AUG05
A — Install gear (41) with side marked “X” away from motor.
102711
PN=529
Chopper Box
1— Chopper Box Assembly 15— Washer 29— Access Cover Gasket 43— Washer
2— Bolt 16— Bolt 30— Access Cover Gasket 44— Bolt
3— Bearing Hub 17— Bearing Race 31— Bearing Holder Gasket 45— Chopper Adjustment Lever
4— Main Gear Adapter 18— Pinion Shaft 32— Chopper Motor O-ring 46— Pin Adjustment
5— Expansion Plug 19— Spherical Bearing 33— Fitting 47— Hex Bolt
6— Hex Bolt 20— Bearing Holder 34— O-ring 48— Chopper Box Backing Plate
7— Seal Housing Bearing 21— Lock Washer 35— Chopper Box Cover 49— Retainer Plate
8— Bolt 22— Hex Bolt Assembly 50— Washer
9— Dowel Pin 23— Seal 36— Breather 51— Bolt
10— Spherical Roller Bearing 24— Chopper Clutch 37— Chopper Box Top Cover 52— Sight Gauge
11— Bearing Keeper Ring 25— Flywheel Assembly 53— Duocone
12— Bolt 26— O-ring 38— Access Cover Plate 54— Hex Bolt
13— Duocone Seal 27— Drain Magnetic Plug 39— Bolt 55— Hex Bolt
14— Gear 28— Chopper Box Cover Gasket 40— Bolt 56— Washer
41— Gear
42— N/A
T803324,0000846 -19-02OCT07-2/2
Removal
1. Drain oil from chopper box.
CM073510582 —UN—10OCT07
T803324,0000847 -19-09OCT07-1/18
CAUTION: Be very careful. Blades are sharp.
2. Remove chopper blades and blade retainers from

chopper shafts.
CM073510583 —UN—10OCT07
3. Secure a large rope or chain to hand rail above

chopper motor. Secure the chopper motor with a large
rope or chain. Be careful not to damage hoses.
102711
PN=530
Chopper Box
CAUTION: Be very careful. Motor is heavy.
4. Remove chopper motor from chopper box.
CM073510584 —UN—10OCT07
T803324,0000847 -19-09OCT07-3/18
CM073510585 —UN—10OCT07
5. Remove flywheel hub cap, nut, washers, clutch

pressure plate, metal locking disc, friction disc,
flywheel and splined hub.
102711
PN=531
Chopper Box
6. Remove bolts (40 and 44) from large front cover (35).
CM073510586 —UN—10OCT07
T803324,0000847 -19-09OCT07-5/18
CAUTION: Dowel pins are holding cover to box.

Pry out cover. Be careful; cover is heavy.
7. Remove chopper adjustment lever (45).
CM073510587 —UN—03MAR08
T803324,0000847 -19-09OCT07-6/18
8. Remove timing gears (14).
CM073510588 —UN—03MAR08
102711
PN=532
Chopper Box
NOTE: Where Araldite has been used, the application

of heat will assist dismantling.
9. Remove bearings on opposite side of chopper box.
CM073510589 —UN—10OCT07
T803324,0000847 -19-09OCT07-8/18
10. Remove bearing shaft hubs.
CM073510590 —UN—03MAR08
T803324,0000847 -19-09OCT07-9/18
11. Install chopper shaft hanger tool into the bottom

bearing adapter (a) and chopper shaft.
12. Unbolt bearing adapters (a).
CM073510591 —UN—03MAR08
102711
PN=533
Chopper Box
NOTE: Where Araldite has been used, the application

of heat will assist dismantling.
13. Remove shield ring halves from inside choppers.
CM073510592 —UN—03MAR08
T803324,0000847 -19-09OCT07-11/18
14. Remove main gear adapter (4).

15. Remove bottom chopper shaft from machine.
16. Repeat steps 11-15 for top shaft removal.
CM073510593 —UN—03MAR08
T803324,0000847 -19-09OCT07-12/18
17. Remove bearing keeper rings (11).
CM073510594 —UN—24MAR08
102711
PN=534
Chopper Box
18. Remove bearing (10) and bearing hub (3).
CM073510595 —UN—24MAR08
T803324,0000847 -19-09OCT07-14/18
CAUTION: Be very careful; these parts

are oily and heavy.
19. Remove bearing holder (20).
CM073510596 —UN—24MAR08
T803324,0000847 -19-09OCT07-15/18
20. Remove pinion shaft assembly (18).
CM073510597 —UN—24MAR08
102711
PN=535
Chopper Box
21. Remove bearing seal (13) and housing (7).

22. Secure box (1) for removal.
CM073510598 —UN—24MAR08
T803324,0000847 -19-09OCT07-17/18
CAUTION: Be very careful; these parts

are oily and heavy.
23. Remove box backing plates (48).

NOTE: Gear backlash is 6 to 12 thousand.
24. Remove box (1) from frame.
CM073510599 —UN—24MAR08
T803324,0000847 -19-09OCT07-18/18
102711
PN=536
Chopper Box
Chopper Gearbox Pre-Assembly and (SUP1405706). Blow out with air pressure and wipe
Installation clean.
1. Clean chopper gearbox (1). Wash with hot

water pressure washer and rinse with Geoguard
Continued on next page T803324,0000848 -19-27FEB08-1/8
102711
PN=537
Chopper Box
CM073510600 —UN—03MAR08
CQ280272 —UN—27FEB08
CM073510601 —UN—03MAR08
CQ280273 —UN—27FEB08
CM073510602 —UN—03MAR08
102711
PN=538
Chopper Box
T803324,0000848 -19-27FEB08-3/8
NOTE: Install the oil filler groove to top of box.
3. Install expansion plug (5) in bearing hub (3) that

bearings fit on.
CM073510603 —UN—03MAR08
T803324,0000848 -19-27FEB08-4/8
4. Press bearing (10) on bearing hub (3).
CM073510604 —UN—03MAR08
T803324,0000848 -19-27FEB08-5/8
5. Press bearing assembly (10 and 3) in bearing seal

housing (7) in box (1).
CM073510605 —UN—03MAR08
102711
PN=539
Chopper Box
NOTE: Block up box (1) before pressure in bearing

assembly (10 & 3).
6. Install bearing keeper ring (11). Torque bolts (12) to

48.8 N·m (36 lb-ft) with Loctite 271 (red).
CM073510606 —UN—03MAR08
CM073510607 —UN—03MAR08
CM073510608 —UN—03MAR08
T803324,0000848 -19-27FEB08-7/8
7. Hang chopper box (1) and install on frame.

CM073510609 —UN—03MAR08
T803324,0000848 -19-27FEB08-8/8
102711
PN=540
Chopper Box
8. Install inner box backing plates (48). Apply Araldite to

bolts (2) and torque to 237.2 N·m (175 lb-ft).
CM073510610 —UN—03MAR08
T803324,0000848 -19-27FEB08-9/8
Install Top and Bottom Drum

NOTE: Always start with top shaft first.
1. Install Duocone seal plate (53) to top chopper shaft
CM073510611 —UN—03MAR08
(57). Apply Araldite to bolts and torque to 119.3 N·m
(88 lb-ft).
T803324,0000849 -19-23AUG05-1/18
2. Lightly sand with mild sandpaper bearing seal housing

(7) in chopper box and Duocone seal plate (53) on
chopper shaft. Clean both parts with degreaser.
CM073510612 —UN—03MAR08
102711
PN=541
Chopper Box
3. Remove half of seal from wrapping (one O-ring and

one retainer). Pour alcohol on O-ring and retainer to
clean. Install O-ring and retainer into seal installer
(2221352540).
CM073510613 —UN—03MAR08
CM073510614 —UN—03MAR08
T803324,0000849 -19-23AUG05-3/18
a. Place seal with installer into box on bearing seal

housing (7).
b. Tap installer lightly onto bearing seal housing (7)
to seat seal.
CM073510615 —UN—03MAR08
4. Remove the other half of seal from wrapping. Pour
alcohol on O-ring and retainer into seal installer
(2221352540).
102711
PN=542
Chopper Box
a. Place seal with installer onto Duocone seal plate

(53) on chopper shaft (57).
b. Tap installer lightly onto Duocone seal plate (53)
to seat seal.
CM073510616 —UN—03MAR08
T803324,0000849 -19-23AUG05-5/18
5. Install O-ring (26) on bearing hub (3) in box (1). Lightly

lubricate O-ring.
CM073510617 —UN—03MAR08
T803324,0000849 -19-23AUG05-6/18
6. Lightly oil the seal retainer surfaces of both halves of

seal.
CM073510618 —UN—03MAR08
102711
PN=543
Chopper Box
7. Install line up pins (three long bolts with heads

removed into Duocone seal plate (53) on shaft (57).
CM073510619 —UN—03MAR08
T803324,0000849 -19-23AUG05-8/18
8. Install bearing adapter on chopper shaft hanger, then

slide hanger into chopper shaft (57) from opposite
side of seal.
CM073510620 —UN—03MAR08
T803324,0000849 -19-23AUG05-9/18
9. Install shaft (57) in frame with line up pins going

through bearing hub (3).
CM073510621 —UN—03MAR08
102711
PN=544
Chopper Box
10. Install gear adapter (4) onto line up pins and bearing
hub (3).
CM073510622 —UN—03MAR08
T803324,0000849 -19-23AUG05-11/18
11. Install bolts (6) with flat washers (43) in the other nine
holes of gear adapter (4). Tighten bolts slowly to pull
chopper shaft (57), bearing hub (3) and gear adapter
(4) together. Remove line up pins and replace with
bolts (6) and washers (43). Coat all bolts with Loctite
CM073510623 —UN—03MAR08
271 (Red) and torque to 119.3 N·m (88 lb-ft).
T803324,0000849 -19-23AUG05-12/18
12. Install bearing adapter to frame wall (A) with two

piece shield ring plate (6) on inside wall. Apply Araldite
on bolts (8) with flats (10) and torque to 119.3 N·m (88
lb-ft). Remove chopper shaft hanger tool.
CM073510624 —UN—10OCT07
102711
PN=545
Chopper Box
13. Drive expansion plugs (5) in bearing shaft hub (3)

opposite bolt flange side.
CM073510625 —UN—03MAR08
T803324,0000849 -19-23AUG05-14/18
14. Install bearing shaft hub (B) in chopper shaft end.

Apply Loctite 271 (Red) to bolts (9), washers (10) and
torque bolts to 119.3 N·m (88 lb-ft).
15. Apply Anti-seize on bearing shaft hub (3) opposite bolt
CM073510626 —UN—03MAR08
flange side.
T803324,0000849 -19-23AUG05-15/18
16. Install bearing (4) with grease zerk on bottom. Apply

Araldite Loctite 271 (Red) to bolts. Install bolts and
washers (12) and torque to 379.6 N·m (280 lb-ft).
CM073510627 —UN—03MAR08
102711
PN=546
Chopper Box
17. Install locking collar on bearing. Apply Loctite 271

(Red) on set screws and tighten.
CM073510628 —UN—03MAR08
T803324,0000849 -19-23AUG05-17/18
NOTE: Shaft assembly should turn freely.
18. Install blades and kickers on top shaft.

19. Install bottom shaft same as top shaft.
CM073510629 —UN—03MAR08
T803324,0000849 -19-23AUG05-18/18
Final Assembly of Chopper Box

1. Assemble bearings (17 & 19) onto pinion shaft (18).
Heat race of bearing (17) to install on pinion shaft.
Place assembly into freezer to cool.
CM073510630 —UN—24MAR08
Continued on next page T803324,000084A -19-23AUG05-1/10
102711
PN=547
Chopper Box
2. Install gear (14) on lower chopper shaft adapter (4).

Coat bolts (16) with Araldite. Install bolts (16) and
washers (15) into round holes in gear (14). Torque
CM073510631 —UN—03MAR08
T803324,000084A -19-23AUG05-2/10
3. Install gear (14) on top chopper shaft adapter (4).

Start all bolts (16) then turn gear all the way counter
clockwise until bolts hit end of slot in gear or as close
as possible. Torque bolts to 427 N·m (315 lb-ft.
CM073510632 —UN—03MAR08
T803324,000084A -19-23AUG05-3/10
4. Install pin (46) into top gear (14). Line up chopper

adjustment lever (45) slot with two holes in main gear
adapter (4). Install bolts (47) in slot as near to the end
of the slot or as close as possible. Torque bolts (47) to
427 N·m (315 lb-ft).
CM073510633 —UN—03MAR08
102711
PN=548
Chopper Box
5. Glue gaskets (29 & 30) to covers (37 & 38). Install
covers (37 & 38) to chopper box cover (35). Install
bolts (39) with Loctite 242 (Blue) and torque to 48.8
N·m (36 lb-ft).
CM073510634 —UN—24MAR08
T803324,000084A -19-23AUG05-5/10
6. Remove pinion shaft assembly from freezer. Install

assembly in chopper box.
CM073510597 —UN—24MAR08
102711
PN=549
Chopper Box
7. Glue gasket (31) to bearing holder (20) after installing

seal (23). Install bearing holder (20) onto chopper
box with bolts (22) and lock washers (21). Coat bolts
(22) with Loctite 242 (Blue) and torque to 108.4 N·m
(80 lb-ft).
CM073510635 —UN—24MAR08
CM073510636 —UN—24MAR08
T803324,000084A -19-23AUG05-7/10
NOTE: Install gear with X; mark away from motor.
8. Install gear (41) onto chopper motor.
CM073510637 —UN—24MAR08
102711
PN=550
Chopper Box
9. Apply Araldite on bolt (51). Install bolt (51), washer

(50) and retainer plate (49) to end of the motor shaft.
Install O-ring (32) on motor. Apply a light coat of oil
on O-ring (32).
CM073510638 —UN—24MAR08
T803324,000084A -19-23AUG05-9/10
10. Install motor into chopper box with bolts (54 & 55) and
washers (56). Apply Loctite 271 (Red).
CM073510639 —UN—24MAR08
T803324,000084A -19-23AUG05-10/10
Clean and Close the Box

1. Clean box out by wiping and blowing out with air
pressure.
CM073510640 —UN—24MAR08
2. Glue large gasket (28) to large cover (35)
Continued on next page T803324,000107A -19-10OCT07-1/5
102711
PN=551
Chopper Box
3. Apply Loctite 272 to chopper box cover bolts (44) and

install cover (35) to chopper box (1).
4. Torque bolts to 110 N·m (80 lb-ft).
5. Fill to proper level.
CM073510641 —UN—24MAR08
T803324,000107A -19-10OCT07-2/5
6. Install access cover gasket (29 and 30) to chopper

box cover (37 and 38) with Loctite Quick Stick Gasket
Dressing.
CM073510642 —UN—24MAR08
T803324,000107A -19-10OCT07-3/5
7. Install covers (37 and 38) with bolts (39).

8. Torque bolts to 35 N·m (26 lb-ft).
CM073510643 —UN—24MAR08
Continued on next page T803324,000107A -19-10OCT07-4/5
102711
PN=552
Chopper Box
9. Install Teflon tape on magnetic drain plug (27) and

install.
CM073510644 —UN—24MAR08
T803324,000107A -19-10OCT07-5/5
102711
PN=553
Chopper Box
Differential Chopper Blade and Kicker Installation
CM073510704 —UN—23OCT07
View from Gear Box Side
Continued on next page T803324,000084B -19-23AUG05-1/2
102711
PN=554
Chopper Box
1— Top Differential Chopper 5— Rubber Chopper Kicker 9— Washer 13— Bolt

Drum 6— Chopper Blade Clamping Bar 10— Bolt
2— Bottom Differential Chopper 7— Chopper Blade 11— Lock Nut
Drum 8— Bolt 12— Bolt
3— Washer
4— Kicker Chopper Keeper
A — Gear Box Side C — Cane Flow

B — Bearing Side
T803324,000084B -19-23AUG05-2/2
Chopper System
The chopper system cuts clean, even billets by slicing
the cane between two opposing blades and delivering
them to the elevator. This system is the most important
in controlling quality cane samples. Wash chopper
mechanism periodically to avoid bacteria growth.
Lubrication is very important since the chopper system is
both high speed and high impact.
CM053510285 —UN—23AUG05
Cane Flow
T803324,000084D -19-23OCT07-1/1
Differential Chopper Timing

Differential chop does not lend itself to continual retiming
in order to prolong the blade life.
1. Rather than attempting to re-time chopper when
CM053510286 —UN—23AUG05
blades begin to wear, the top or bottom blades should
be extended out and re-clamped.
2. Worn blades can be re-sharpened by machining them.
3. A spacer should be added to bring the size of the
blade back to specification.
4. Alternately, the blades should be changed.
Cane Flow
5. Blades need to have full blade contact, but not to
gouge or hit hard.
NOTE: Differential chop does not lend itself to
John Deere’s differential chop has been designed not continual retiming in order to prolong blade
only to extend blade life, but to improve and maintain life or maintain billet quality.
billet quality.
A close study of this illustration shows the action of the NOTE: Blades need to have full contact blade to
blades to resemble scissors. The trouble encountered by blade, but not to gouge or hit hard.
excessive retarding of the top blade should be apparent
from this diagram.
T803324,000084E -19-23OCT07-1/1
102711
PN=555
Chopper Box
Installing Blades and Kickers

1. Apply Anti-seize on bolts (8).
CM073510705 —UN—24MAR08
T803324,0001086 -19-23OCT07-1/4
2. Install clamping bar (6) with bolts (8) and washers

(9) loosely.
CM073510706 —UN—24MAR08
T803324,0001086 -19-23OCT07-2/4
NOTE: Make sure the blade is seated on the inside

ledge before tightening bolts.
3. Install blade (7) in top slot of shaft between clamping

bar (6) and shaft with the slanting slide to you. Torque
CM073510707 —UN—24MAR08
bolts (8) to 298.2 N·m (220 lb-ft).
102711
PN=556
Chopper Box
4. Install kickers (5) in between blades. Torque bolts (10)

and nuts (11) to 155.9 N·m (115 lb-ft).
CM073510708 —UN—24MAR08
T803324,0001086 -19-23OCT07-4/4
Differential Chopper Timing and Adjustments

NOTE: Difference in differential chop is size of chopper
drums, blade placement and timing.
1. Chopper drums: Top chopper drum is larger than

bottom drum. It measures 16 inches, blade tip to blade
tip. The bottom drum measures 15 inches blade tip to
blade tip. The top chopper drum is always installed
first in machine.
2. Blade Replacement
NOTE: See illustration of cane flow for chopper
blade replacement.
CM053510285 —UN—23AUG05
3. Timing Blades.
NOTE: Differential chop does not lend itself to
continual retiming in order to prolong blade
life or maintain billet quality.
This action of the blades is to resemble scissors cutting.

Cane Flow
NOTE: Blades need to have full contact, blade to
blade, but not to gouge or hit hard.
T803324,000084C -19-02OCT07-1/1
Field Setting of Slip Clutch make a mark on the chopper fly wheel and cover. Cut
approximately two to three hundred feet of cane. Check
It is important to keep the chopper slip clutch set properly. how much the flywheel moved from the mark. Proper
The setting may change depending on crop yields. adjustment will allow the fly wheel to slip no more than 1/8
Heavier yields require the clutch to be tightened, lighter turn. Tighten the nut at the proper setting.
yields require loosening of the fly wheel nut. To do so,
T803324,0000852 -19-23AUG05-1/1
102711
PN=557
Chopper Box
Chopper Deflector Shield Adjustment

1. The chopper deflector shield is a three position metal
shield used to deflect the billets from coming out of
the chopper system.
2. The purpose of this shield is to direct the cane billets
to different heights in the primary extractor chamber,
which allows for increased control of cane quality
and/or loss.
3. THICK BARREL CANE: When cutting thick barrel
cane, adjust the deflector to the highest position. This
position will deflect the billets to a height closest to the
primary extractor fan, which will aid in the cleaning
CM073510709 —UN—23OCT07
process.
4. MEDIUM BARREL CANE: When cutting medium
barrel cane, adjust the shield to the medium position.
This position will deflect the billets to a lower position,
which will aid the cleaning process and prevent billets
from being sucked through the primary extractor
blades.
5. THIN BARREL CANE: When cutting then barrel cane,
adjust the shield to the lowest position. This position and prevent the light billets from being sucked through
will deflect the billets to the lowest position in the the primary extractor blades.
cleaning chamber, which will aid the cleaning process
T803324,0001087 -19-23OCT07-1/3
CM073510710 —UN—23OCT07
6. To adjust the deflector shield, pull the right and left
spring pins.
102711
PN=558
Chopper Box
7. Position the shield to the desired position and install

the spring pin.
CM073510711 —UN—23OCT07
T803324,0001087 -19-23OCT07-3/3
Chopper Bearing Installation

1. Apply NEVER-SEEZ® to the shaft (A).
CQ286089 —UN—05OCT10
NEVER-SEEZ é uma marca comercial da "Bostik Findley, Inc."
BL04947,0000354 -19-16SEP11-1/11
2. Back all four set screws (B) on bearing out with

supplied allen wrench.
CQ286090 —UN—05OCT10
102711
PN=559
Chopper Box
3. Slide bearing over shaft.
CQ286091 —UN—05OCT10
BL04947,0000354 -19-16SEP11-3/11
4. Screw eye bolt/sling attachment into shaft.
CQ286092 —UN—05OCT10
BL04947,0000354 -19-16SEP11-4/11
5. Attach sling (C) to jib crane, use crane to line up the

bearing on the shaft.
CQ286093 —UN—05OCT10
102711
PN=560
Chopper Box
6. Push bearing into place by hand.
CQ286094 —UN—05OCT10
BL04947,0000354 -19-16SEP11-6/11
7. Stab bolts and washers (D).
CQ286095 —UN—05OCT10
BL04947,0000354 -19-16SEP11-7/11
8. Tighten bolts with impact.
CQ286096 —UN—05OCT10
102711
PN=561
Chopper Box
9. Apply Loctite® 271 to set screws.
CQ286098 —UN—05OCT10
Loctite is a trademark of Henkel Corporation
BL04947,0000354 -19-16SEP11-9/11
10. Tighten the four mounting screws located on the

MOUNTING SIDE collar a total of 1/2 turn by
alternately tightening in two increments 1/4 turn and
1/4 turn to prevent cocking of the inner ring and
sleeve, which can result in the bearing eventually
working its way loose on the shaft.
CQ286099 —UN—05OCT10
A—Mounting Side
BL04947,0000354 -19-16SEP11-10/11
11. Use supplied allen wrench and torque indicator to

torque the set screws (allen wrench should bend past
tip of indicator).
F— Torque indicator
CQ286100 —UN—05OCT10
BL04947,0000354 -19-16SEP11-11/11
102711
PN=562
Section 130
Cleaning System
Contents
Page
Group 05—Primary Extractor

Primary Extractor Fan Blades...................... 130-05-1
Installing the Hub to the Motor
Shaft ........................................................ 130-05-1
Installing Fan Blades, Doubler
Plates and Backing Plates....................... 130-05-2
Safety Start-Up ............................................ 130-05-4
102711
PN=1
Contents
102711
PN=2
Group 05
Primary Extractor
Primary Extractor Fan Blades
7— Cap Screw 21— Tube
9— Cap Screw 24— Hub
10— Lock Nut 25— Blade
11— Washer 26— Doubler Plate
15— Washer 27— Retainer
16— Nut 29— Bolt
17— Cotter Pin 32— Washer
19— Lock Washer
CM073510645 —UN—15OCT07
T803324,000086A -19-24AUG05-1/1
Installing the Hub to the Motor Shaft

NOTE: Use the proper lock-out tag-out procedure
before working on machine. Never remove the
complete fan assembly from the motor shaft.
Always remove the blades and doubler plates
before removing the blade hub.
1. Remove shaft nut (16) and cotter key (17) from the
motor shaft.
2. Remove any tape that may be holding the cotter key
in place.
3. Clean the shaft and apply one “dab” of grease to
CM073510646 —UN—15OCT07
keyway.
NOTE: Washers may be needed to adjust the height
of the nut where as the motor shaft pin hole is
at least half the height of the nut.
4. Reinstall key to keyway.

5. Line up keyways on shaft and hub, then install hub on
shaft (larger opening hub). Press firmly against the
hub upward to ensure that the hub has topper out on
shaft shoulder. 7. Do not back off nut (16) to install the cotter pin (17).
Tighten if needed, then install cotter pin.
6. Install and torque motor shaft nut (16) to 542 N·m (400
lb-ft).
T803324,000107C -19-15OCT07-1/1
102711
PN=565
Primary Extractor
CM073510647 —UN—15OCT07
Installing Fan Blades, Doubler Plates and
Backing Plates
IMPORTANT: Always install blades and doubler
plates from a factory set.
NOTE: Doubler plates do not need to be changed

every time blades are changed. Change
doubler plates only as needed.
1. Start two bolts (7) only to penetrate hub (24).

T803324,000107D -19-15OCT07-1/4
2. Insert one fan blade (25) and doubler plate (26)

between hub (24) and base retainer (27). Do this
between the previous two temporary bolts. (Retaining
plate (27) should be on bottom of blade with curvature
up.) Start two bolts through base retainer plate, blade
and doubler plate to penetrate hub by 19 mm (3/4”).
3. Repeat step 2 at 180° from the first blade.
4. Remove the first two temporary bolts from step 1.
5. Repeat step 2 for the two remaining blades.
CM073510648 —UN—15OCT07
Continued on next page T803324,000107D -19-15OCT07-2/4
102711
PN=566
Primary Extractor
6. Install the remaining eight bolts (7) with Loctite 271

(red) and hardened flat washer (15). Start bolts to
penetrate hub by 19 mm (3/4”).
7. Remove the bolts without Loctite from step 2 through
step 5 and reinstall the remaining eight bolts (7) with
Loctite 271 (red) and hardened flat washer (15). Start
bolts to penetrate hub by 19 mm (3/4”).
CM073510649 —UN—15OCT07
T803324,000107D -19-15OCT07-3/4
8. Start four carriage bolts (29) on doubler plates and

blades. Use flat washers (11) and vibration resistant
nuts (5) with Loctite 271 (red).
9. Torque the sixteen hub bolts in an even fashion to 169
N·m (125 lb-ft).
10. Torque the four carriage bolts to 135.6 10 N·m (100
lb-ft).
CM073510650 —UN—15OCT07
T803324,000107D -19-15OCT07-4/4
102711
PN=567
Primary Extractor
Safety Start-Up 4. Slowly increase fan speed at a rate of 100 RPMs

1. Be sure all personnel and tools have evacuated the per 1/2 minute until full speed has been achieved.
area. If any vibration was observed from the fan, STOP
the machine immediately and follow proper Lock-Out
2. Follow proper Lock-Out Tag-Out procedure for starting Tag-Out procedures before investigating any possible
up the machine problem.
3. Start fan at 100 to 200 RPMs to check for vibration. (Be 5. If no vibration was observed, proceed with normal and
sure no personnel are within 300 feet of the machine.) safe machine operation.
T803324,000107E -19-15OCT07-1/1
102711
PN=568
Section 140
Elevator System
Contents
Page
Group 05—Elevator Systems Installation

Elevator Floor and Wearstrips
Installation ............................................... 140-05-1
Elevator Extension....................................... 140-05-3
Elevator Group ............................................ 140-05-4
Chain Adjustment ........................................ 140-05-4
Changing Chain and Sprockets................... 140-05-4
Chain Removal on Repair ........................... 140-05-5
Elevator Sprocket and Chain....................... 140-05-6
Elevator Swing Table ................................... 140-05-8
Standard Elevator...................................... 140-05-10
Elevator Extensions................................... 140-05-11
102711
PN=1
Contents
102711
PN=2
Group 05
Elevator Systems Installation
Elevator Floor and Wearstrips Installation
CM053510309 —UN—21SEP05
1— Tail End Wearstrip 5— Middle Middle Wearstrip 9— Middle Left Hand Floor 13— Lock Nut
2— Lower Middle Wearstrip 6— Middle Bottom Wearstrip Assembly 14— Floor Bottom Retainer
3— Lower Bottom Wearstrip 7— Rolled Wearstrip 10— Middle Right Hand Floor
4— Middle Top Wearstrip 8— Bottom Corner Floor Assembly
Assembly 11— Bolt
12— Washer
102711
PN=571
1. Install items 1-7.

2. Install items 8-10.
T803324,000088B -19-21SEP05-2/2
102711
PN=572
Elevator Extension
CM053510310 —UN—21SEP05
102711
PN=573
1— Elevator Frame — 12 in. Left 11— Wearstrip — Bottom 21— Bolt 31— Elevator Cover Plate
Hand Top Extension 12— Hi Ridge Slat Assembly 22— Washer 32— Flex Trim
2— Elevator Frame — 12 in. Right 13— Sheet — Wild Cart Guard 23— Nut 33— Bolt
Hand Top Extension 14— Sheet — Cart Guard Clip 24— Bolt 34— Bolt
3— Elevator Frame — 12 in. Right 15— Elevator Chain 25— Washer 35— Direct Drive Mount
Hand Bottom Extension 16— Connecting Link 26— Nut Assembly
4— Elevator Frame — 12 in. Left 17— Inner Link 27— Bolt 36— Direct Drive Mount
Hand Bottom Extension 18— Bolt 28— Hose Clamp Assembly
5— N/A 19— Nut 29— Bolt 37— Washer
6— Floor Assembly — 12 in. 20— Bolt 30— Bolt
Extension Right Hand
7— Floor Assembly — 12 in.
Extension Left Hand
8— Sheet — Top Brace 12 in.
Extension
9— Wearstrip — Top 12 in.
Extension
10— Wearstrip — Middle
1. Install items 1 and 2.

4. Install item 10.
5. Install item 9.
3. Install item 11.
T803324,000088C -19-21SEP05-2/2
Elevator Group The elevator is made up of twin lengths of roller type

The elevator has a high clearance to minimize the chain, connected by slats, which are bolted to the chain
damage caused by various cane collection containers that links. The conveyor is driven by orbital motors, mounted
come into contact with the underside of the elevator. The on both sides, and it is fully reversible to clear blockages.
elevator is adjustable in height; this is controlled from the To maintain correct chain tension, the drive shaft grease
cab by two hydraulic cylinders supporting the elevator. cylinders are mounted in order to allow chain adjustment.
This allows the elevator to be lowered for traveling in areas The chains are driven by two sprockets that are bolted to
of overhead obstructions, and to minimize the height of the motors. The idler shaft sprockets are held in place by
platforms required to work on the secondary extractor. a machined shaft, bearings, and retaining nuts. There
The elevator swings through 180°. are replaceable wearstrips bolted to the elevator chain
runners. When these have excessive wear, they should
be replaced along with all retaining bolts.
T803324,000088D -19-20SEP07-1/1
Chain Adjustment 3. Measure the chain at the open section located on the
1. To adjust the elevator chain, loosen the eight bolts bottom of the elevator. The correct tension is 25 mm
securing the frame assembly adjustment at the side (1 inch) of play, on the tightest chain.
near the motors and the three bolts securing the 4. The wearstrips are replaceable and should be
adjustable elevator floor in the center. replaced along with all mounting bolts when they have
2. Adjust the grease cylinders to the correct chain excessive wear.
tension. Adjust both grease cylinders equally and
measure to ensure the sprockets are parallel.
T803324,000088E -19-20SEP07-1/1
Changing Chain and Sprockets 2. Separate (break) both chains and remove them from
If either the elevator chains or sprockets need changing, the elevator.
John Deere recommends that both are changed at the 3. Remove the two bolts securing each hydraulic motor
same time. A worn part mated to a new one will not to the bearing carrier assembly. Pull out the motors
operate at its optimal capacity. and store on the floor, inside of the elevator.
1. Loosen and remove the bolts and slats from the chain
assembly.
T803324,000088F -19-20SEP07-1/1
102711
PN=574
Chain Removal on Repair

3. To rejoin the chain, the same link can be reused.
1. Locate the position where the chain is to be broken, Replace the link pins with 2 - 1/4 inch x 3/8 inch bolts
and grind the peened edge of both pins located in and 2-3/8 inch nuts. Place them through the link to
the link. locate the link's side plate.
2. Remove the side plate from the link and remove that
link from the two ends of the chain.
T803324,0000890 -19-20SEP07-1/1
102711
PN=575
Elevator Sprocket and Chain
CM053510311 —UN—30SEP05
102711
PN=576
1— Tailshaft 14— Sprocket 27— Washer 40— Lock Nut

2— Tailshaft Mount 15— Sprocket Spindle 28— Elevator Chain 41— Bolt
3— Sprocket Chain Adjuster 16— Lower Lift Link Spacer 29— Inner Link 42— Bolt
4— N/A 17— Ball Bearing 30— Connecting Link 43— Bolt
5— N/A 18— Snap Ring 31— Bolt 44— FMS - Floor Retainer
6— Direct Drive Adjuster 19— Retaining Ring 32— Nut 45— RMT- Spacer
7— N/A 20— Bearing 33— Bolt 46— Bolt
8— Floor Support 21— Special Set Screw 34— Washer 47— Washer
9— Elevator Chain Assembly 22— Bearing Out Retainer 35— Washer 48— Lock Washer
10— Slat Assembly 23— Zerk 36— Lock Nut 49— Nut
11— Sprocket Hub 24— Bearing In Retainer 37— Bolt 50— Nut
12— Sprocket 25— O-ring 38— Bolt 51— Washer
13— Sprocket 26— Lock Nut 39— Bolt
A - In Seat Right Side B - In Seat Left Side

T803324,0000891 -19-20SEP07-2/2
102711
PN=577
Elevator Swing Table
CM053510312 —UN—30SEP05
102711
PN=578
1— Lock Nut 12— Lock Nut 23— Sheave Pin Assembly 34— Washer
2— Bolt 13— Washer 24— RMT - Spacer 35— Bolt
3— RMT- Spacer Swing 14— Zerk 25— Elevator Sheave Cable 36— Sheave Pin Cylinder
4— Washer 15— Washer 26— Elevator Sheave Assembly
5— Swing Table Assembly 16— Lower Table Washer 27— Bolt 37— KLIK Pin
6— Trunnion Pin 17— Upper Table Washer 28— N/A 38— Washer
7— Table Pin 18— Zerk 29— Washer 39— Elevator Block Plate
8— Cylinder Pin 19— Bolt 30— Lock Nut 40— Bolt
9— Ball Bushing 20— Lock Washer 31— Cylinder Pin 41— Washer
10— Bolt 21— Bushing 32— Spacer 42— Lubricant
11— Swing Table Pin Assembly 22— Elevator Sheave Assembly 33— Washer 43— Modified Bolt
Item (A) is welded to Item (5). bearings and is controlled by two opposing cylinders,
which are pin attached. The two cylinders operate in
Fill gaps (B) with shims, items (13 and 16). opposition and turn the table through 180°. The two pivot
The elevator swing table is mounted to the main frame by pins secure the swing table to the main frame with nylon
two pins (7 and 11). The table pivots on two spherical locknuts on each pin.
T803324,0000892 -19-20SEP07-2/2
102711
PN=579
Standard Elevator
CM053510314 —UN—03OCT05
1— Upper Top Wearstrip 6— Bolt 11— Bolt 16— Lock Washer

2— Upper Mid Wearstrip 7— Washer 12— Bolt 17— Wiper Belt
3— Upper Bottom Wearstrip 8— Lock Nut 13— Direct Drive Mount Assy R 18— Bolt
4— Upper Left Hand Floor Assy 9— Cart Guard Sheet 14— Direct Drive Mount Assy L 19— Backing Plate
5— Upper Right Hand Floor Assy 10— Cart Guard Clip 15— Bolt
Continued on next page T803324,00008A1 -19-03OCT05-1/2
102711
PN=580
A - The last set of studs on this end do not require nuts

2. Install items 4 & 5.
and washers until installation of drive components.
1. Install items 1, 2 & 3.
T803324,00008A1 -19-03OCT05-2/2
Elevator Extensions
See parts catalog for installation of 12 inch or 24 inch
elevator extensions.
T803324,00008A2 -19-03OCT05-1/1
102711
PN=581
102711
PN=582
Index
Page Page
A Component
Locations............................................................ 10-35-1
Accumulator......................................................... 10-05-10 Conversion
Antifreeze .............................................................. 10-25-2 Temperature....................................................... 10-30-2
Axle Conversions........................................................... 10-30-1
Front.....................................................60-20-3, 60-20-4 Coolant ....................................................10-25-1, 10-25-2
Maintenance ...................................................... 50-15-3 Diesel engine ..................................................... 10-25-1
Cooling System ................................................... 10-05-11
Crop Divider........................................................... 80-05-1
B Clean and Inspect ............................................ 100-05-2
Disassembly..................................................... 100-05-2
Bearings ................................................................ 50-20-2
Removal........................................................... 100-05-2
Bolt and screw torque values
Shoe Assembly ................................................ 100-05-2
Metric ................................................................. 10-20-2
Crop Divider System............................................ 100-05-1
Unified inch ........................................................ 10-20-3
Buttlifter.............................................................. 30-10-1
Bottom Feed Roller................................................ 30-15-1
Cubo planetário
Repair ................................................................ 30-15-2
Montagem ........................................................ 50-10-12
Break-In Oil............................................................ 10-25-3
Cylinder Safety Stops .......................................... 10-05-13
Bushing................................................................70-10A-2
Bushings and Pins................................................. 50-15-7
Buttlifter D
Roller.................................................................. 30-10-2
Buttlifter Roller ....................................................... 30-10-1 Diesel..................................................................... 10-25-2
Engine Oil .......................................................... 10-25-3
Differential Chopper Timing ............................... 120-05-29
C Directional Valve..................................................70-40A-1
Disassemble Planetary Hub
Cab
Disassemble ...................................................... 50-10-5
Tilting ................................................................. 10-05-6
Drum.................................................................. 120-05-13
Cab door
Drum and Topper................................................... 80-05-9
Disassemble and assemble ............................. 90-05-14
Drum and Topper Assembly .................................. 80-05-6
Latch striker
Remove and install....................................... 90-05-15
Remove and install .......................................... 90-05-12 E
Cab inner roof
Remove and install Elevator
Style B ............................................................ 90-05-6 Motor.................................................................. 80-05-1
Cab roof Sprocket Tightening ........................................... 50-15-3
Remove and install Elevator System
Style B ............................................................ 90-05-6 Chain Adjustment............................................. 140-05-4
Carrier Roller .......................................50-15-12, 50-15-13 Chain and Sprockets........................................ 140-05-4
Lubrication ....................................................... 50-15-12 Elevator Floor................................................... 140-05-1
Wear ................................................50-15-14, 50-15-15 Extension ......................................................... 140-05-3
Charge Pressure Relief .......................................70-10B-3 Standard ........................................................ 140-05-10
Charge Pump ......................................................70-10B-6 Swing Table...................................................... 140-05-8
Chopper Blade................................................... 120-05-26 Wearstrips........................................................ 140-05-1
Chopper Box........................................................ 120-05-1 Engine
Final Assembly............................................... 120-05-19 Break-In Oil ........................................................ 10-25-3
Preassembly .................................................... 120-05-9 Oil....................................................................... 10-25-3
Remove............................................................ 120-05-2 Pump Drive Removal ......................................... 20-05-1
Chopper System.................................................. 120-05-1 Essential or recommended tools
Clamp Loads Planetary hub..................................................... 50-10-1
Bolts ................................................................... 10-20-4 Exhaust.................................................................. 10-05-9
Cleaning or storing ................................................ 10-05-4 External Relief .....................................................70-40A-2
Cleaning System
Fan Assembly .................................................. 130-05-1 F
Collector ................................................................ 80-05-1
Collector Drum.........................................80-05-5, 80-05-8 Feed Roller ............................................................ 80-05-1
Collector Motor ...................................................... 80-05-2
TM100419 (27OCT11) Index-1 3520 and 3522 Sugar Cane Harvester Repair
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Feed Roller System

Bottom Feed Roller ............................................ 30-15-1 K
Knockdown Roller .............................................. 30-05-1
Top Floating Feed Roller.................................... 30-20-1 Knives
Final Drive Safety............................................................... 10-05-17
Gear Oil.............................................................. 10-25-3 Knockdown Roller.................................................. 30-05-1
Fire Prevention .................................................... 10-05-18 Removal............................................................. 30-05-2
Fixed Displacement Motor...................................70-30A-1
Flange.................................................................. 50-15-16 L
Fittings ............................................................... 10-20-8
Side Wear ........................................................ 50-15-16 Link Rail Wear ....................................................... 50-15-5
Top Wear.......................................................... 50-15-16 Links ...................................................................... 50-15-6
Fluid Lubrication
Coolant............................................................... 10-25-1 Carrier Roller.................................................... 50-15-12
Diesel Fuel ......................................................... 10-25-2 Idler .................................................................... 50-15-3
Engine Break-In Oil............................................ 10-25-3 Track Rollers.................................................... 50-15-11
Engine Coolant .................................................. 10-25-1
Final Drive Gear Oil ........................................... 10-25-3 M
Gear Oil.............................................................. 10-25-3
Fluids Metric bolt and screw torque values ...................... 10-20-2
High Pressure .................................................. 10-05-14 Metric Conversion.................................................. 10-30-1
Four bolt Mulitple Gear Pump
Flange fittings..................................................... 10-20-8 Repair ..............................................................70-10A-1
Fuel...................................................................... 10-05-10
O
G
O-ring
Gear Motor .......................................................... 80-05-14 Fittings ............................................................... 10-20-5
Repair .............................................................. 80-05-15 O-ring fittings
Gear Oil ................................................................. 10-25-3 Angled o-ring boss fittings.................................. 10-20-5
Grease................................................................... 10-25-3 Operation
Grease Point Locations ......................................... 10-35-4 Safety................................................................. 10-05-1
Grease Points........................................................ 10-35-3 Orifice Check Valve .............................................70-10B-2
H P
Handles ................................................................. 10-05-8 Parking ................................................................ 10-05-15
Hardware torque values Piston Ring ....................................................... 70-30G-16
Metric ................................................................. 10-20-2 Pitch..................................................................... 50-15-10
Unified inch ........................................................ 10-20-3 Planetary Hub
Harvester Repair ................................................................ 50-10-4
Component Locations ........................................ 10-35-1 Power steering and brakes
Headliner Steering
Remove and install Steering column
Style B .......................................................... 90-05-10 Componets ................................................. 60-10-1
Hydraulic Pump Drive............................................................ 20-05-1
Fluid ................................................................... 10-25-2
Hydraulic Gauge Kit............................................... 10-30-6
R
I Rear Wheel............................................................ 50-20-2
Recoil Spring Adjustment ...................................... 50-15-5
Idler Recoil Spring Repair.............................................. 50-15-4
Lubrication ......................................................... 50-15-3 Relief Valve............................................................ 60-20-1
Idler Tread Wear.................................................. 50-15-16 Adjustment ......................................................... 60-20-1
Idlers....................................................50-15-16, 50-15-17 Roller Lubrication................................................... 50-15-2
Instructional Seat................................................. 90-05-10 Roller Wear..........................................50-15-14, 50-15-15
Rolling Undercarriage.......................................... 50-15-14
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Page Page
Switch
S Turn signal
Remove and install......................................... 60-10-2
Safety
Cleaning T
Storing ............................................................ 10-05-4
Cylinder Safety Stops ...................................... 10-05-13 Temperature
Fire Prevention................................................. 10-05-18 Conversion......................................................... 10-30-2
Handling fuel .................................................... 10-05-10 Tilting
High pressure fluids ......................................... 10-05-14 Cab .................................................................... 10-05-6
Knives .............................................................. 10-05-17 Timing
Lights and devices ........................................... 10-05-12 Differential Chopper ....................................... 120-05-29
Preparation ...................................................... 10-05-12 Tires
Protective clothing.............................................. 10-05-9 Service ............................................................. 10-05-15
Recognize safety symbols ................................. 10-05-6 Tools
Recommendations ........................................... 10-05-19 Bushing Installation..........................................70-10A-3
Seat Shut-off ...................................................... 10-05-5 Bushing Removal.............................................70-10A-2
Service .................................................10-05-3, 10-05-4 Seal..................................................................70-10A-3
Transport.......................................................... 10-05-13 Seal Installation................................................70-10A-3
Understand signal words ................................... 10-05-7 Special Steel Sleeve ........................................70-10A-3
Scroll Cylinder ..................................................... 80-05-10 Top Floating Feed Roller ....................................... 30-20-1
Seal Topper Lift............................................................ 80-05-12
Assembly ......................................................... 50-15-12 Cylinder............................................................ 80-05-13
Replacement....................................................70-30A-1 Topper System
Seat ..................................................................... 90-05-10 Assembly .............................................80-05-6, 80-05-8
Service Clean and Inspect .............................................. 80-05-6
Grease Point Locations...................................... 10-35-3 Collector Drum ................................................... 80-05-5
Intervals ............................................................. 10-10-1 Drum and Topper Assembly............................... 80-05-6
Service Points .................................................... 10-35-2 Repair ................................................................ 80-05-5
Tires ................................................................. 10-05-15 Shredder Topper ................................................ 80-05-7
Service Area .......................................................... 10-05-4 Topper Lift ........................................................ 80-05-12
Service equipment and tools Torque
Planetary hubs ................................................... 50-10-2 Bolts ................................................................... 10-20-4
Shaft Assembly................................................. 70-30G-15 Conversion Factors............................................ 10-20-5
Shredder Topper.................................................... 80-05-7 Grade 2 NC Weld Studs .................................... 10-20-1
Repair ................................................................ 80-05-8 SAE Bolt............................................................. 10-20-9
Slip Clutch Zinc Plated Bolts ................................................ 10-20-4
Field Setting ................................................... 120-05-29 Torque charts
Specifications Metric ................................................................. 10-20-2
Torque ................................................................ 10-20-1 Unified inch ........................................................ 10-20-3
Sprocket Track
Wear Patterns .................................................. 50-15-13 Adjustment ......................................................... 50-15-4
Sprocket Tightening............................................... 50-15-3 Alignment ........................................................... 50-15-2
Steering Assembly ........................................................... 50-15-1
Linkage .............................................................. 60-20-2 Bushings and Pins ............................................. 50-15-7
Troubleshooting ...............................................70-40C-6 Link Rail Wear.................................................... 50-15-5
Valve ................................................................70-40C-1 Links................................................................... 50-15-6
Steering column Recoil Spring Adjustment................................... 50-15-5
Assemble ........................................................... 60-10-2 Recoil Spring Repair .......................................... 50-15-4
Components....................................................... 60-10-1 Roller................................................................ 50-15-15
Disassemble ...................................................... 60-10-2 Roller Lubrication ............................................... 50-15-2
Telescoping shaft bearings Roller Wear ...................................................... 50-15-14
Replace .......................................................... 60-10-6 Rollers.............................................................. 50-15-11
Steps ..................................................................... 10-05-8 Shoe Problems ................................................ 50-15-18
Stopping .............................................................. 10-05-15 Track Shoe ............................................................ 50-15-3
Straight Inspection Torque............................................... 50-15-3
O-ring fittings...................................................... 10-20-5 Tightening .......................................................... 50-15-3
Swing Table ......................................................... 140-05-8 Troubleshooting
Steering............................................................70-40C-6
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Page Page
Turn signal switch

Remove and install ............................................ 60-10-2 W
U Waste disposal .................................................... 10-05-18
Wear
Undercarriage......................................50-15-14, 50-15-16 Carrier Roller....................................50-15-14, 50-15-15
Unified inch bolt and screw torque Wheel
values .................................................................. 10-20-3 Assembly ........................................................... 50-20-1
Bearings............................................................. 50-20-2
V Install.................................................................. 50-20-3
Rear ................................................................... 50-20-2
Valve Remove and Mount Tire .................................... 50-20-3
Assembly .........................................................70-40A-3 Windshield, cab
Bank Disassembly ...........................................70-40A-3 Remove and install
Charge Pressure Relief....................................70-10B-3 Style B ............................................................ 90-05-1
Directional ........................................................70-40A-1 (World)
Orifice Check Valve..........................................70-10B-2 Hydraulic fluid .................................................... 10-25-2
Overhaul ..........................................................70-40A-2
102711
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Index
102711
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Index
102711
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Technical Manual 3520 and 3522 Sugar Cane Harvester Repair

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3520 and 3522 Sugar Cane

For complete service information also see:

3520 and 3522 Sugar Cane Harvester

John Deere Thibodaux

TM100419 (27OCT11) 3520 and 3522 Sugar Cane Harvester Repair

Section 40—Electrical Section 90—Operator’s Station

Section 50—Hydrostatic System Section 100—Crop Divider System

Section 70—Main Hydraulic System Section 140—Elevator System

Original Instructions. All information, illustrations and specifications in this

TM100419 (27OCT11) i 3520 and 3522 Sugar Cane Harvester Repair

TM100419 (27OCT11) ii 3520 and 3522 Sugar Cane Harvester Repair

Continued on next page

Hydraulic Fluid (World) .................................. 10-25-2

Group 30—General Information

Group 35—Service Points

Seat Safety Shut-off

Tilting the Cab

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Use Handles and Steps

Avoid Exhaust Fumes

Wear Protective Clothing

Handle Fuel Safely — Avoid Fires

Safely Service Accumulator

Safely Service Cooling System

Prepare for Emergencies

Use Safety Lights and Devices

Use Cylinder Safety Stops

Safe Transport of Harvester

Avoid High-Pressure Fluids

Use Caution on Hillsides

Stopping and Parking

Service Tires Safely

Avoid Electrical Power Lines

Keep Hands Away From Knives

Avoid Contact With Moving Parts

Dispose of Waste Properly

Avoid Serious Injury

Stay Clear of Chopper Area

Rotating Chopper Drum

Avoid Hazardous Area

Avoid Electrical Power Lines

Safe Service Practice

Avoid Personal Injury and Damage to the Machine

Keep Hands Away

Keep Away From Rotating Knives

Preventing Machine Runaway

Exhaust System Warning

PowerTech is a registered trademark of the Deere & Company

Preliminary Service Intervals 1. Change the engine oil and filter.

Common Wear Parts

Tire Inflation Pressure

Metric Bolt and Screw Torque Values

4.8 8.8 9.8 10.9 12.9 12.9

4.8 8.8 9.8 10.9 12.9 12.9

Unified Inch Bolt and Screw Torque Values

Suggested Torque Values and Clamp Loads

Suggested Torque Values For Grades 5.6,

Grade or Property Class Head Marking for

Straight O-Ring Boss Fittings

Angled O-Ring Boss Fittings