9660 Combine

9560 STS, 9660 STS,
9760 STS and 9860 STS

Combine Repair
TECHNICAL MANUAL
9560 STS, 9660 STS, 9760 STS and
9860 STS Combine Repair
TM2181 29AUG06 (ENGLISH)
For complete service information also see:

9560 STS, 9660 STS, 9760 STS and 9860
STS Combines
Diagnosis and Tests . . . . . . . . . . . . . . . . . . . TM2182
Alternators and Starting Motors . . . . . . . . . . CTM77
POWERTECH 4.5 L & 6.8 L Diesel
Engines—Base Engines . . . . . . . . . . . . . . . . CTM104
POWERTECH 6.8 L Diesel Engine—Level 14
Diagnostics - Electronic Fuel Systems with
Denso HPCR . . . . . . . . . . . . . . . . . . . . . . . . . CTM320
POWERTECH 8.1 L Diesel Engines—Base
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM86
POWERTECH 8.1 L Engines—Level 9
Electronic Fuel Systems with Denso In-Line
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM255
POWERTECH 9.0 L Tier 3/Stage IIIA OEM
Diesel Engines—Base Engine . . . . . . . . . . . CTM400
POWERTECH 9.0 L Diesel Engine—Level 14
Diagnostics - Electronic Fuel Systems with
Denso HPCR . . . . . . . . . . . . . . . . . . . . . . . . . CTM385
POWERTECH 10.5 L and 12.5 L Diesel
Engines—Base Engine . . . . . . . . . . . . . . . . . CTM100
POWERTECH 10.5 L & 12.5 L Diesel
Engines—Operation and Diagnostics for
Deere Level 6 ECU . . . . . . . . . . . . . . . . . . . . CTM188
100 Series Hydraulic Cylinders . . . . . . . . . . TMH100A
John Deere Harvester Works
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 components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
DX,TMIFC –19–29SEP98–1/1
TM2181 (29AUG06) 60 Series STS Combine Repair

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Contents
10
SECTION 10—General Group 16—Hydraulic Valve Stack (S.N. —715300)
Group 05—Safety Group 17—Hydraulic Valve Stack (S.N. 715301—)
Group 10—Specifications Group 20—Hydraulic Cylinders
Group 15—Tune-Up and Adjustment Group 25—Motors
Group 20—Fuels and Lubricants Group 30—Accumulator
20
SECTION 20—Engine SECTION 80—Separator Shell

Group 05—Remove and Install Engine Group 05—Gull Wing Doors
Group 10—Cooling System
Group 15—Lower Engine Repair
SECTION 90—Operator Station Repair
30
Group 05—Air Conditioning System (R134a)
SECTION 30—Fuel and Air Repair Group 10—System Components
Group 05—Air Intake System Group 15—Cab
Group 10—Diesel Fuel System
SECTION 110—Feeder House Repair

SECTION 40—Electrical System 40
Group 05—Conveyor
Group 05—Batteries
Group 10—Top Shaft and Slip Clutch
Group 10—Harness and Connector Repair
Group 15—Feeder House Drives and Reverser
Group 15—Wire Harness Routing
Gear Case
Group 20—Fuses, Circuit Breakers and Relays
Group 20—CONTOUR MASTER Tilt Cylinder
Group 25—Lighting
Group 30—Operators Station Group 25—CONTOUR MASTER Tilt Frame 50
Group 35—Sensors and Switches
Group 40—Wiper SECTION 120—Separator
Group 45—Alternator Group 05—Separator Repair
Group 50—Starting Motor Group 10—Separator Drives
Group 55—Electrical Engine Control Group 15—Residue Disposal 60
Group 60—GREENSTAR Components Group 20—Conveyor Augers, Cleaning Fan And
Chaffer And Sieve Frame
SECTION 50—Power Train Repair Group 25—Tailings Elevator and Augers
Group 05—Transmission and Differential Group 30—Primary Countershaft Gear Case
Group 10—Single Reduction Final Drive—Heavy Group 35—Header Electromagnetic Clutch
70
Duty
Group 15—Hydrostatic System SECTION 130—Grain Tank and Unloading System
Group 20—Cam Lobe Motor Repair
Group 25—Tires and Wheels Group 05—Grain Tank Cross Augers
Group 10—Unloading Auger System Drives
SECTION 60—Power Steering and Brakes Group 15—Vertical Unloading Auger and Lower 80
Group 05—Steering Gear Case
Group 10—Brakes Group 20—Horizontal Unloading Auger and Gear
Case
SECTION 70—Hydraulic Repair Group 25—Clean Grain Elevator
Group 05—Hydraulic Reservoir Group 30—Grain Tank and Extensions 90
Group 10—Hydraulic Pumps
Group 15—Hydraulic Valves Continued on next page
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. 110
COPYRIGHT  2006
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2003, 2004, 2005
TM2181 (29AUG06) i 60 Series STS Combine Repair

083006
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Contents
10
SECTION 140—Engine Gear Case and Control
Valve Repair
Group 05—Engine Gear Case and Valve
SECTION 199—Dealer Fabricated Tools

20
Group 05—Dealer Fabricated Tools
30
40
50
60
70
80
90
110
TM2181 (29AUG06) ii 60 Series STS Combine Repair

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Contents
120
130
140
199
INDX
TM2181 (29AUG06) iii 60 Series STS Combine Repair

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Contents
120
130
140
199
INDX
TM2181 (29AUG06) iv 60 Series STS Combine Repair

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10
Section 10
General
Contents
Page Page
Group 05—Safety . . . . . . . . . . . . . . . . . . . . . .10-05-1 SAE Four Bolt Flange Cap Screw Torque
Values—High Pressure Applications . . . . . .10-10-36
Group 10—Specifications External Hexagon Port Plug Torque Chart . . .10-10-37
Ground Speeds (Fast Idle) Two Speed Four Prevent Hydraulic System Contamination . . . .10-10-38
Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 Check Oil Lines and Fittings . . . . . . . . . . . . . .10-10-39
Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . .10-10-2 Basic Electrical Component Handling /
Operating Speeds—9560 STS . . . . . . . . . . . . .10-10-3 Precautions For Vehicles Equipped With
Specifications—9560 STS Combine . . . . . . . . .10-10-5 Computer Controlled Systems . . . . . . . . . . .10-10-40
Dimensions—9560 STS Combine . . . . . . . . . . .10-10-7
Dimension Reference Points—9560 STS Group 15—Tune-Up and Adjustment
Combine . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-8 Tune-Up and Adjustment. . . . . . . . . . . . . . . . . .10-15-1
Operating Speeds—9660 STS, 9760 STS Care and Maintenance of Belts . . . . . . . . . . . . .10-15-2
Combines . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-9 Defective Belts . . . . . . . . . . . . . . . . . . . . . . . . .10-15-4
Specifications—9660 STS Combine . . . . . . . .10-10-11
Specifications—9760 STS Combine . . . . . . . .10-10-13 Group 20—Fuels and Lubricants
Dimensions—9660 STS, 9760 STS Handle Fuel Safely—Avoid Fires. . . . . . . . . . . .10-20-1
Combines . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-15 Handling and Storing Diesel Fuel . . . . . . . . . . .10-20-1
Dimension Reference Points—9660 STS, Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-2
9760 STS Combines . . . . . . . . . . . . . . . . . .10-10-17 Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . .10-20-3
Operating Speeds—9860 STS Combine . . . . .10-10-18 Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . . .10-20-4
Specifications—9860 STS Combine (S.N. — Testing Diesel Fuel . . . . . . . . . . . . . . . . . . . . . .10-20-4
715700) . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-20 Diesel Engine Coolant. . . . . . . . . . . . . . . . . . . .10-20-5
Specifications—9860 STS Combine (S.N. Operating in Warm Temperature Climates . . . .10-20-6
715701—) . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-22 Supplemental Coolant Additives . . . . . . . . . . . .10-20-7
Dimensions—9860 STS Combine . . . . . . . . . .10-10-24 Additional Information About Diesel
Dimension Reference Points—9860 STS Engine Coolants and Supplemental Coolant
Combine . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-25 Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-8
Metric Bolt and Screw Torque Values . . . . . . .10-10-26 Testing Diesel Engine Coolant . . . . . . . . . . . . .10-20-9
Unified Inch Bolt and Screw Torque Diesel Engine Break-In Oil . . . . . . . . . . . . . . .10-20-10
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-27 Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . .10-20-11
Sealants and Adhesives Cross-Reference Extended Diesel Engine Oil Service
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-28 Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-12
Face Seal Fittings Assembly and OILSCANand COOLSCAN . . . . . . . . . . . .10-20-12
Installation—All Pressure Applications . . . . .10-10-29 Hydrostatic Drive System, Main Hydraulic
Metric Face Seal Fitting Torque System and Main Engine Gear Case
Chart—Standard Pressure Applications . . . .10-10-30 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-13
Metric Face Seal Fitting Torque Chart—High Transmission, Final Drives, Feeder House
Pressure Applications . . . . . . . . . . . . . . . . .10-10-31 Reverser, Loading Auger, Primary
SAE Face Seal Fitting Torque Countershaft and Two-Speed Separator
Chart—Standard Pressure Applications . . . .10-10-32 Drive Gear Cases . . . . . . . . . . . . . . . . . . . .10-20-14
SAE Face Seal Fitting Torque Chart—High Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-15
Pressure Applications . . . . . . . . . . . . . . . . .10-10-33 Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-15
Four Bolt Flange Fittings Assembly and Lubricant Storage . . . . . . . . . . . . . . . . . . . . . .10-20-16
Installation—All Pressure Applications . . . . .10-10-34 Alternative and Synthetic Lubricants . . . . . . . .10-20-16
SAE Four Bolt Flange Cap Screw Torque
Values—Standard Pressure Applications . . .10-10-35 Continued on next page
TM2181 (29AUG06) 10-1 60 Series STS Combine Repair

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Contents
10
Page
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . .10-20-17

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Group 05
Safety
10
Recognize Safety Information 05
1
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.
–UN–07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT –19–29SEP98–1/1
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
–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
DX,SIGNAL –19–03MAR93–1/1
Handle Fluids Safely—Avoid Fires
When you work around fuel, do not smoke or work near

heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.
–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn

spontaneously. TS227
DX,FLAME –19–29SEP98–1/1
TM2181 (29AUG06) 10-05-1 60 Series STS Combine Repair

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Safety
10
05 Prevent Battery Explosions
2
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204
DX,SPARKS –19–03MAR93–1/1

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Safety
10
Handling Batteries Safely 05
3
CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
–UN–23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
TS204
Always remove grounded (-) battery clamp first
and replace it last.
CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 15—30
–UN–23AUG88
minutes. Get medical attention immediately.
If acid is swallowed:
TS203
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do
not exceed 2 L (2 quarts).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
AG,OUMX005,1408 –19–01MAY00–1/1

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Safety
10
05 Prepare for Emergencies
4
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
–UN–23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 –19–03MAR93–1/1
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong

enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.

3. Avoiding breathing fumes when electrolyte is added.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.
–UN–23AUG88

2. Drink large amounts of water or milk, but do not TS203
exceed 2 L (2 quarts).
DX,POISON –19–21APR93–1/1

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Safety
10
Handle Chemical Products Safely 05
5
Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical

products used with John Deere equipment.)
DX,MSDS,NA –19–03MAR93–1/1
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
X9811
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID –19–03MAR93–1/1

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Safety
10
05 Service Accumulator Systems Safely
6
Escaping fluid or gas from systems with pressurized

accumulators that are used in air conditioning, hydraulic,
and air brake systems can cause serious injury. Extreme
heat can cause the accumulator to burst, and pressurized
lines can be accidentally cut. Do not weld or use a torch
–UN–23AUG88
near a pressurized accumulator or pressurized line.
Relieve pressure from the pressurized system before

removing accumulator.
TS281
Relieve pressure from the hydraulic system before
removing accumulator. Never attempt to relieve hydraulic
system or accumulator pressure by loosening a fitting.
Accumulators cannot be repaired.
DX,WW,ACCLA2 –19–22AUG03–1/1
Wait Before Opening High-Pressure Fuel

System
High-pressure fluid remaining in fuel lines can cause

serious injury. Only technicians familiar with this type of
system should perform repairs. Before disconnecting fuel
–UN–18MAR92
lines, sensors, or any other components between the
high-pressure fuel pump and nozzles on engines with
High Pressure Common Rail (HPCR) fuel system, wait a
minimum of 15 minutes after engine is stopped.
TS1343
DX,WW,HPCR2 –19–07JAN03–1/1
Park Machine Safely
Before working on the machine:
• Lower all equipment to the ground.

• Stop the engine and remove the key.
• Disconnect the battery ground strap.
–UN–24MAY89
• Hang a "DO NOT OPERATE" tag in operator station.

TS230
DX,PARK –19–04JUN90–1/1

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Safety
10
Support Machine Properly 05
7
Always lower the attachment or implement to the ground

before you work on the machine. If the work requires that
the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
–UN–23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
TS229
Follow recommended procedures in this manual.
When implements or attachments are used with a

machine, always follow safety precautions listed in the
implement or attachment operator’s manual.
DX,LOWER –19–24FEB00–1/1
Wear Protective Clothing
Wear close fitting clothing and safety equipment

appropriate to the job.
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR –19–10SEP90–1/1
Work in Clean Area
Before starting a job:
• Clean work area and machine.

• Make sure you have all necessary tools to do your job.
–UN–18OCT88
• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN –19–04JUN90–1/1

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Safety
10
05 Service Machines Safely
8
Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
–UN–23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228
DX,LOOSE –19–04JUN90–1/1
Work In Ventilated Area
Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
–UN–23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR –19–17FEB99–1/1
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
–UN–23AUG88
TS223
DX,LIGHT –19–04JUN90–1/1
Replace Safety Signs
Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign
placement.
–UN–23AUG88
TS201
DX,SIGNS1 –19–04JUN90–1/1

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Safety
10
Use Proper Lifting Equipment 05
9
Lifting heavy components incorrectly can cause severe

injury or machine damage.
Follow recommended procedure for removal and

installation of components in the manual.
–UN–23AUG88
TS226
DX,LIFT –19–04JUN90–1/1
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
–UN–23AUG88
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed,
TS220
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1

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Safety
10
05 Avoid Heating Near Pressurized Fluid Lines
10
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can
–UN–15MAY90
accidentally burst when heat goes beyond the immediate
flame area.
TS953
DX,TORCH –19–10DEC04–1/1
Service Tires Safely
Explosive separation of a tire and rim parts can cause

serious injury or death.
Do not attempt to mount a tire unless you have the proper

equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate

the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension

hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, damaged

rims or missing lug bolts and nuts.
–UN–23AUG88
TS211
DX,RIM –19–24AUG90–1/1

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Safety
10
Avoid Harmful Asbestos Dust 05
11
Avoid breathing dust that may be generated when

handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers
–UN–23AUG88
are brake pads, brake band and lining assemblies, clutch
plates, and some gaskets. The asbestos used in these
components is usually found in a resin or sealed in some
way. Normal handling is not hazardous as long as
TS220
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for

cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator. A
special vacuum cleaner is recommended to clean
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
Keep bystanders away from the area.
DX,DUST –19–15MAR91–1/1

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Safety
10
05 Practice Safe Maintenance
12
Understand service procedure before doing work. Keep

area clean and dry.
Never lubricate, service, or adjust machine while it is

moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be

raised for service work.
Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground

cable (-) before making adjustments on electrical systems
–UN–23AUG88
or welding on machine.
On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
Construct Dealer-Made Tools Safely
Faulty or broken tools can result in serious injury. When

constructing tools, use proper, quality materials, and good
workmanship.
–UN–01JUL97
Do not weld tools unless you have the proper equipment

and experience to perform the job.
LX1016749
DX,SAFE,TOOLS –19–10OCT97–1/1

083006
PN=18
Safety
10
Use Proper Tools 05
13
Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.
Use power tools only to loosen threaded parts and

fasteners.
–UN–08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR –19–17FEB99–1/1
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.
–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN –19–03MAR93–1/1

083006
PN=19
Safety
10
05 Use Adequate Service Facilities
14
Keep the service area clean and dry. Wet or oily floors
are slippery. Wet spots can be dangerous when working
with electrical equipment.
Make sure the service area is adequately vented.
Periodically check the shop exhaust system for leakage.

Engine exhaust gas is dangerous.
Be sure all electrical outlets and tools are properly

grounded.
Use adequate light for the job at hand.
Service the machine on a level, hard-surfaced area.
Use lifting equipment and safety stands which have

adequate strength for the job being performed.
HX,1401,1005,A –19–11DEC92–1/1
Live With Safety
Before returning machine to customer, make sure

machine is functioning properly, especially the safety
systems. Install all guards and shields.
–19–07OCT88
TS231
DX,LIVE –19–25SEP92–1/1

083006
PN=20
Group 10
Specifications
10
Ground Speeds (Fast Idle) Two Speed Four 10
1
Wheel Drive
NOTE: Speeds shown are for combines equipped with

18.4 x 26 R1 rear tires. Except combines
equipped with 35.5 x 32 R2 drive tires are shown
with 28L x 26 R2 rear tires.
Speed in Km/h (mph)

Front Tire 2WD 2-Speed 4WD First Gear Second Gear Third Gear
30.5 x 32 R1 X 6.1 (3.8) 11.4 (7.1) 30.4 (19.0)
30.5 x 32 R1 Low 4.7 (2.9) 7.3 (4.6) 12.1 (7.6)
High 5.4 (3.4) 9.1 (5.7) 18.1 (11.3)
800/65R32 X 6.1 (3.8) 11.4 (7.1) 30.4 (19.0)
800/65R32 Low 4.7 (2.9) 7.3 (4.6) 12.1 (7.6)
High 5.4 (3.4) 9.1 (5.7) 18.1 (11.3)
30.5L x 32R2 X 6.3 (3.9) 11.7 (7.3) 31.2 (19.5)
30.5L x 32 R2 Low 4.8 (3.) 7.4 (4.6) 12.3 (7.7)
High 5.5 (3.4) 9.3 (5.8) 18.5 (11.6)
30.5L x 32 R3 X 5.8 (3.6) 10.8 (6.8) 28.8 (18.0)
18.4 x 38 R1 X 5.9 (3.7) 11.1 (6.9) 29.5 (18.4)
18.4 x 38 R1 Low 4.6 (2.9) 7.1 (4.4) 11.9 (7.4)
High 5.2 (3.3) 8.9 (5.6) 17.8 (11.1)
18.4 x 38 R2 X 6.1 (3.8) 11.4 (7.1) 30.4 (19.0)
18.4 x 38 R2 Low 4.7 (2.9) 7.3 (4.6) 12.2 (7.6)
High 5.4 (3.4) 9.1 (5.7) 18.3 (11.4)
20.8 x 38 R1 X 6.1 (3.8) 11.4 (7.1) 30.4 (19.0)
20.8 x 38 R1 Low 4.7 (2.9) 7.3 (4.6) 12.1 (7.6)
High 5.4 (3.4) 9.1 (5.7) 18.1 (11.3)
18.4 x 42 R1 X 6.3 (3.9) 11.8 (7.4) 31.3 (19.6)
18.4 x 42 R1 Low 4.8 (3.0) 7.4 (4.6) 12.2 (7.6)
High 5.5 (3.4) 9.3 (5.8) 18.4 (11.5)
35.5 x 32 R2 X 6.8 (4.3) 12.7 (7.9) 33.8 (21.1)
35.5 x 32 R2 Low 5.2 (3.3) 8.1 (5.1) 13.5 (8.4)
High 6 (3.8) 10.1 (6.3) 20.2 (12.6)
68 x 50-32, HF3 X 5.8 (3.6) 10.8 (6.8) 28.8 (18.0)
68 x 50-32, HF3 Low 4.5 (2.8) 7 (4.4) 11.8 (7.4)
High 5.1 (3.2) 8.7 (5.4) 17.5 (10.9)
AG,OUO6022,1688 –19–24JUL00–1/1

083006
PN=21
Specifications
10
10 Turning Radius
2
Combine Two Speed Powered
Front Tires Rear Tires Non-Powered Rear Axle
Model Rear Axle
7.4 m 7.4 m
9560 STS 30.5L-32 18.4-26 (24 ft 2 in.) (24 ft 2 in.)
9660 STS, 97560 STS 7.73 m 8.19 m
and 9860 STS 30.5L-32 18.4-26 (25 ft 3 in.) (26 ft 10 in.)
OUO6083,0000655 –19–22DEC03–1/1

083006
PN=22
Specifications
10
Operating Speeds—9560 STS 10
3
Speeds shown are average and can vary from Operating speeds specifications and design subject to
machine to machine. Speeds are rated at high idle change without notice.
with separator engaged, no load.
Engine Speed
Slow Idle (Separator Off) (6.8 L Engine) 1300 rpm
Slow Idle (Separator Off) (8.1 L Engine) 1200 rpm
Mid Speed (Separator Off) (6.8 L Engine) 1850 rpm
Mid Speed (Separator Off) (8.1 L Engine) 1680 rpm
Fast Idle (Separator Off) (6.8 L Engine) 2550 rpm
Fast Idle (Separator Off) (8.1 L Engine) 2340 rpm
Full Load Rated Speed (6.8 L Engine) 2400 rpm
Full Load Rated Speed (8.1 L Engine) 2200 rpm
Separator Drive Shaft Speed 1546 rpm
Main Countershaft Speed 1546 rpm
Single Tine Separator Speed

High Range 480 - 1300 rpm
Low Range 230 - 600 rpm
Feeder House Lower Shaft Speed

Standard Variable Speed 520 - 780 rpm
Heavy Duty Variable Speed 520 - 780 rpm
Fixed Speed 520 rpm
Fixed Speed Feeder House Drive Chain Speed

22 Tooth Fixed Speed Chain 48 rpm
38 Tooth Fixed Speed Chain (Optional) 83 rpm
Feed Accelerator Speed

Feed Accelerator 440/800 rpm
Feed Accelerator (Optional Slow Speed) 320/790 rpm
Discharge Beater Speed 849 rpm
Jackshaft Speed
Right-Hand Jackshaft, Front 532 rpm
Right-Hand Jackshaft, Rear 532 rpm
Cleaning Fan Speed

Standard Speed 500 - 1200 rpm
Special Slow Speed 300 - 600 rpm
Continued on next page OUO6083,0000DA0 –19–18JUL06–1/2

083006
PN=23
Specifications
10
10 Elevator Speed
4
Clean Grain Elevator 400 rpm
Clean Grain Loading Auger 424 rpm
Tailings Elevator, Lower Auger 405 rpm
Tailings Elevator, Upper Auger 640 rpm
Shoe Drive 297 rpm
Conveyor Augers 433 rpm
Unloading System Speed

Unloading System Countershaft 1087 rpm
Unloading Auger Gear Box, Input Shaft 450 rpm
Unloading Vertical Auger 450 rpm
Unloading Outer Auger 450 rpm
Grain Tank Horizontal Augers 420 rpm
Chopper Speed
Chopper/Discharge Beater Jackshaft 2002 rpm
Chopper (Two Speed) 1603/2500 rpm
OUO6083,0000DA0 –19–18JUL06–2/2

083006
PN=24
Specifications
10
Specifications—9560 STS Combine 10
5
NOTE: Specifications and design subject to change

without notice.
Engine
Make John Deere
Model (6.8 L Engine) 6068HH
Type six-cylinder, in line, valve-in-head, air-to-air
aftercooled diesel turbocharged
Rated Power at 2400 rpm (6.8 L Engine) 198 kW (265 hp)
Rated Power at 2200 rpm (8.1 L Engine) 198 kW (265 hp)
Power Bulge at 2300 rpm (6.8 L Engine) 212 kW (284 hp)
Power Bulge at 2100 rpm (8.1 L Engine) 212 kW (284 hp)
Power Boost 220 kW (295 hp)
Displacement (6.8 L Engine) 6.8 L (415 cu. in.)
Displacement (8.1 L Engine) 8.1L (496 cu. in.)
Firing Order 1-5-3-6-2-4
Air Cleaner Dry-type with safety element
Thermostats (two) 82° C (180° F)
Electrical System
Type 12 volt, negative ground with 200 amp
alternator
Transmission
Speeds Three Speeds
Brakes
Type Hydraulic Shoe
Feed Accelerator
Number of Wings 10
Separator Elements
Threshing Elements Corn/Small Grain 15
Tines 18
Concave
Number of Concaves 3
Number of Bars Per Concave Grain—Front 20, Mid/rear 20; Corn 25
Separating
Number of Grates 3

083006
PN=25
Specifications
10
10 Discharge Grate
6
Number of Grates 3
Discharge Beater
Number of Wings 5
Grain Tank
Capacity 7750 L (220 bu.)
Capacity (Optional) 8850 L (250 bu.)
Average Unloading rate 4650 L/min (132 bu/min)
Maximum Unloading rate 5285 L/min (150 bu/min)
Weight
Corn Combine — less header 13,053 kg (28,777 lbs)
Turning Radius
Rear Wheel Tread Width 3.3 m (10 ft. 10 in.)
Turning radius 7.4 m (24 ft. 3 in.)
Capacities
Fuel Tank 757 L (200 gal)
Cooling System w/heater (6.8 L Engine) 44 L (47 U.S. qts)
Cooling System w/heater (8.1 L Engine) 53.3 L (56 U.S. qts)
Engine Crankcase w/filter (6.8 L Engine) 32 L (34 U.S. qts)
Engine Crankcase w/filter (8.1 L Engine) 29.5 L (31 U.S. qts)
Transmission 9.6 L (10 U.S. qts)
Final Drives 8 L (8.5 U.S. qts)
Heavy Duty Feeder House Reverser Gear 2.3 L (4.75 U.S. pts)
Case w/o cooler
Case w/ cooler
Countershaft Drive Gear Case 1.2 L (2.5 U.S. pts)
Loading Auger Gear Case 3.8 L (4 U.S. qts)
Two Speed Separator Drive Gear Case 2.4 L (2.5 U.S. qts)
Engine Gear Case w/transfer 21.3 L (22.5 U.S. qts)
Hydraulic/Hydrostatic Reservoir 35 L (37 U.S. qts)
OUO6083,0000DA1 –19–18JUL06–2/2

083006
PN=26
Specifications
10
Dimensions—9560 STS Combine 10
7
NOTE: Dimension specifications subject to change

without notice.
Dimensions 9560 STS

800/70R38 R1 Front Tires and 600/65R28 R1 Rear Tires
A 8.36 m (27 ft. 4 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
9.31 m (30 ft. 5 in.) w/ 5.64 m (18 ft. 5 in.) Unload Auger
B 8.36 m (27 ft. 4 in.)
C 4.46 m (14 ft. 6 in.)
D 4.02 m (13 ft. 2 in.) w/ 7750 L (220 bu.) Extensions
4.16 m (13 ft. 6 in.) w/ 8850 L (250 bu.) Extensions
E 3.88 m (12 ft. 7 in.)
F 0.57 m (1 ft. 9 in.)
G 3.53 m (11 ft. 6 in.)
H 5.30 m (17 ft. 4 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
7.05 m (23 ft. 1 in.) w/ 6.55 m (21 ft. 5 in.) Unloading Auger
I 4.56 m (15 ft. 0 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
J 3.97 m (13 ft. 0 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
Ka 3.98 m (13 ft. 1 in.) w/ 4.80 m (15 ft. 7 in.) Unload Auger
b
L Refer to Ground Drive and Rear Axle Section
c
M Refer to Ground Drive and Rear Axle Section
• For 18.4R38*** R1 Duals and 480/80R38 (149A8) R1, • For 30.5L-32 14PR R2, subtract 82 mm (3.2 in.)
subtract 141 mm (5.6 in.) • For 30.5LR32*** R1, subtract 118 mm (4.7 in.)
• For 20.8R38** R1 Duals and 520/85R38 (155A8) R1, • For 800/65R32 (172A8) R1W, subtract 93 mm (3.7 in.)
subtract 103 mm (4.1 in.)
• For 30.5L-32 14PR R1, subtract 111 mm (4.4 in.)
a
Dimension is measured 1.22 m from grain spill point. This represents the unloading auger when centered over the grain cart.
b
See Front Tire Selection, Header Compatibility, Final Drives, Row Spacing Charts in Ground Drive and Rear Axle Section for specific
dimensions.
c
See Rear Tire Selection, Tire Spacing, and Front to Rear Tire Compatibility Charts in Ground Drive and Rear Axle Section for specific
dimensions.
OUO6083,0000DA2 –19–18JUL06–1/1

083006
PN=27
Specifications
10
10 Dimension Reference Points—9560 STS Combine
8
–UN–05APR06
H85640
OUO6083,0000D9F –19–18JUL06–1/1

083006
PN=28
Specifications
10
Operating Speeds—9660 STS, 9760 STS 10
9
Combines
Speeds shown are average and can vary from machine to

machine. Speeds are rated at high idle with separator
engaged, no load.
Operating speeds specifications and design subject to

change without notice.
Engine Speed
Slow Idle (Separator Off) 1200 rpm
Mid Speed (Separator Off) 1680 rpm
Fast Idle (Separator Off) 2340 rpm
Full Load Rated Speed 2200 rpm

Feeder House Lower Shaft Speed

Heavy Duty Variable Speed 520 - 780 rpm
High Torque Variable Speed (Optional) 520 - 780 rpm
Fixed Speed 520 rpm


Feed Accelerator (High Speed High 520/1000 rpm
Capacity)
Jackshaft Speed

083006
PN=29
Specifications
10
10 Cleaning Fan Speed
10
Elevator Speed
Shoe Drive 297 rpm

(Standard Grain Tank)
Unloading Auger Gear Box, Input Shaft (High 516 rpm
Unload Rate Grain Tank)
Unloading Gear Box, Input Shaft (Slow 460 rpm
Speed Rice) (Standard Grain Tank)
Unloading Vertical Auger (Standard Grain 450 rpm
Tank)
Unloading Vertical Auger (High Unload Rate 516 rpm
Grain Tank)
Unloading Vertical Auger (Slow Speed Rice) 460 rpm
Unloading Outer Auger (Standard Grain 450 rpm
Tank)
Unloading Outer Auger (High Unload Rate 516 rpm
Grain Tank)
Unloading Outer Auger (Slow Speed Rice) 460 rpm
Grain Tank Horizontal Augers (Standard 420 rpm
Grain Tank)
Grain Tank Horizontal Augers (High Unload 344 rpm
Rate Grain Tank)
Grain Tank Horizontal Auger (Slow Speed 305 rpm
Rice) (Standard Grain Tank)
Chopper Speed
OUO6083,0000DA3 –19–18JUL06–2/2

083006
PN=30
Specifications
10
11

without notice.
Engine
Make John Deere
Type (8.1 L Engine) six-cylinder, in line, valve-in-head, air-to-air
Type (9.0 L Engine) six-cylinder, in line, valve-in-head (four
valve), air-to-air aftercooled diesel
turbocharged
Rated Power at 2200 rpm 227 kW (305 hp)
Power Bulge at 2100 rpm 243 kW (326 hp)
Electrical System
alternator
Transmission
Speeds Three Speeds
Brakes
Type Hydraulic Shoe
Feed Accelerator
Number of Wings 10
Separator Elements
Rice Option 24
Tines 24
Concave
Separating
Number of Grates 4

083006
PN=31
Specifications
10
10 Discharge Grate
12
Number of Grates 3
Discharge Beater
Number of Wings 5
Grain Tank
Average Unloading rate (Standard Unload 4650 L/min (132 bu/min)
Rate)
Average Unloading rate (Optional High 6977 L/min (198 bu/min)
Unload Rate)
Maximum Unloading rate (Standard Unload 5285 L/min (150 bu/min)
Rate)
Maximum Unloading rate (Optional High 7612 L/min (216 bu/min)
Unload Rate)
Weight
Rice Combine — less header 14,619 kg (32,230 lbs)
Turning Radius
Capacities
Cooling System w/heater 53.3 L (56 U.S. qts)
Engine Crankcase w/filter (9.0 L Engine) 29 L (30.7 U.S. qts)
Case w/o cooler
Heavy Duty Feeder House Reverser Gear 3.5 L (7.4 pts)
Case w/ cooler
Extra Heavy Duty Feeder House Reverser 4.9 L (10.4 pts)
Gear Case w/ cooler
Two Speed Separator Drive Gear Case 4.7 L (5 U.S. qts)
OUO6083,0000DA4 –19–18JUL06–2/2

083006
PN=32
Specifications
10
13

without notice.
Engine
Make John Deere
Type (8.1 L Engine) six-cylinder, in line, valve-in-head, air-to-air
Type (9.0 L Engine) six-cylinder, in line, valve-in-head (four
valve), air-to-air aftercooled diesel
turbocharged
Electrical System
alternator
Transmission
Speeds Three Speeds
Brakes
Type Hydraulic Shoe
Feed Accelerator
Number of Wings 10
Separator Elements
Rice Option 24
Tines 24
Concave
Separating
Number of Grates 4

083006
PN=33
Specifications
10
10 Discharge Grate
14
Number of Grates 3
Discharge Beater
Number of Wings 5
Grain Tank
Average Unloading rate (High Unload Rate) 6977 L/min (198 bu/min)
Maximum Unloading rate (High Unload Rate) 7612 L/min (216 bu/min)
Weight
Rice Combine — less header 15,457 kg (34,077 lbs)
Turning Radius
Capacities
Cooling System w/heater 53.3 L (56 U.S. qts)
Engine Crankcase w/filter (9.0 L Engine) 29 L (30.7 U.S. qts)
Case w/o cooler
Extra heavy Duty Feeder House Reverser 4.9 L (10.4 pts)
Gear Case w/ cooler
Two Speed Separator Drive Gear Case 4.7 L (5 U.S. qts)
OUO6083,0000DA5 –19–18JUL06–2/2

083006
PN=34
Specifications
10
Dimensions—9660 STS, 9760 STS Combines 10
15

without notice.
Dimension 9660 STS 9660 STS and 9760 STS 9660 STS and 9760 STS
800/65R32 Front Tires 800/65R32 Front Tires 800/65R32 Front Tires
18.4x26 Rear Tires 18.4x26 Rear Tires 18.4x26 Rear Tires
Standard Auger High Unload Rate Auger High Unload Rate Power Fold Auger
A 10.47 m (34 ft. 3 in.) w/ 6.55 m (21 ft. 5 11.00 m (36 ft. 1 in.) w/ 6.86 m (22 ft. 5 11.00 m (36 ft. 1 in.) w/ 6.86 m (22 ft. 5
in.) Standard Auger in.) High Unload Rate Auger in.) High Unload Rate Power Fold Auger
B 9.12 m (29 ft. 9 in.) w/ 6.86 m (22 ft. 5
NA NA
in.) High Unload Rate Power Fold Auger
C 8.38 m (27 ft. 5 in.) 8.38 m (27 ft. 5 in.) 8.38 m (27 ft. 5 in.)
D 4.53 m (14 ft. 9 in.) 4.53 m (14 ft. 9 in.) 4.53 m (14 ft. 9 in.)
E 4.04 m (13 ft. 3 in.) 4.15 m (13 ft. 6 in.) 4.15 m (13 ft. 6 in.)
F 3.79 m (12 ft. 4 in.) 3.79 m (12 ft. 4 in.) 3.79 m (12 ft. 4 in.)
G 0.49 m (1 ft. 6 in.) 0.49 m (1 ft. 6 in.) 0.49 m (1 ft. 6 in.)
H 3.53 m (11 ft. 6 in.) 3.53 m (11 ft. 6 in.) 3.53 m (11 ft. 6 in.)
I 7.26 m (23 ft. 8 in.) w/ 6.55 m (21 ft. 5 7.66 m (25 ft. 1 in.) w/ 6.86 m (22 ft. 5 7.66 m (25 ft. 1 in.) w/ 6.86 m (22 ft. 5
J 4.95 m (16 ft. 2 in.) w/ 6.55 m (21 ft. 5 5.09 m (16 ft. 7 in.) w/ 6.86 m (22 ft. 5 5.09 m (16 ft. 7 in.) w/ 6.86 m (22 ft. 5
K 4.37 m (14 ft. 3 in.) w/ 6.55 m (21 ft. 5 4.38 m (14 ft. 4 in.) w/ 6.86 m (22 ft. 5 4.38 m (14 ft. 4 in.) w/ 6.86 m (22 ft. 5
La 4.39 m (14 ft. 4 in.) w/ 6.55 m (21 ft. 5 4.45 m (14 ft. 6 in.) w/ 6.86 m (22 ft. 5 4.45 m (14 ft. 6 in.) w/ 6.86 m (22 ft. 5
M Refer to Ground Drive and Rear Axle Refer to Ground Drive and Rear Axle Refer to Ground Drive and Rear Axle
Section b Section b Section b
a
Dimension is measured 1.22 m (4 ft.) from the spill point. This represents the unloading auger centered over the grain cart.
b
dimensions.

083006
PN=35
Specifications
10
10 Dimension 9660 STS 9660 STS and 9760 STS 9660 STS and 9760 STS
16 800/65R32 Front Tires 800/65R32 Front Tires 800/65R32 Front Tires
18.4x26 Rear Tires 18.4x26 Rear Tires 18.4x26 Rear Tires
Standard Auger High Unload Rate Auger High Unload Rate Power Fold Auger
N Refer to Ground Drive and Rear Axle Refer to Ground Drive and Rear Axle Refer to Ground Drive and Rear Axle
Section c Section c Section c
• For 18.4R42 *** R1 Duals (480/80R42), add 2 mm
(0.1 in.) • For 30.5L-32 14PR R2, add 11 mm (0.4 in.)
• For 20.8R38 ** R1 Duals (520/85R38), subtract 10 • For 30.5LR32 *** R1, subtract 25 mm (1.0 in.)
mm (0.4 in.) • For 35.5L-32 12PR R2, add 101 mm (4.0 in.)
• For 20.8R42 ** R1 Duals (520/85R42), add 39 mm • For 900/65R32 (172A8) R2, add 75 mm (3.0 in.)
(1.5 in.) • For 800/70R38 (173A8) R1W, add 93 mm (3.7 in.)
• For 20.8R42 ** R2 Duals, add 70 mm (2.8 in.) • For 76X50-32 16PR HF3, add 77 mm (3.0 in.)
c
dimensions.
OUO6083,0000DA6 –19–18JUL06–2/2

083006
PN=36
Specifications
10
Dimension Reference Points—9660 STS, 9760 STS Combines 10
17
–UN–06APR06
H85667
OUO6083,0000DA7 –19–18JUL06–1/1

083006
PN=37
Specifications
10
10 Operating Speeds—9860 STS Combine
18
Speeds shown are average and can vary from machine to

machine. Speeds are rated at high idle with separator
engaged, no load.
Engine Speed
Slow Idle (Separator Off) 1200 rpm
Mid Speed (Separator Off) 1680 rpm
Fast Idle (Separator Off) 2340 rpm
Full Load Rated Speed 2200 rpm

Feeder House Lower Shaft Sprocket Speed

Standard Variable Speed Sprocket 520 - 780 rpm
High-Capacity Variable Speed Sprocket 520 - 780 rpm
Fixed Speed Sprocket 520 rpm


Feed Accelerator (High Speed High 520/1000 rpm
Capacity)
Jackshaft Speed
Cleaning Fan Speed

Continued on next page OUO6083,0000DAB –19–18JUL06–1/2

083006
PN=38
Specifications
10
Elevator Speed 10
19
Shoe Drive 297 rpm

Unloading Vertical Auger 516 rpm
Unloading Outer Auger 516 rpm
Grain Tank Horizontal Augers 344 rpm
Chopper Speed
OUO6083,0000DAB –19–18JUL06–2/2

083006
PN=39
Specifications
10
10 Specifications—9860 STS Combine (S.N. —
20
715700)
Engine
Make John Deere
Model 6125HH
Displacement 12.5 L (765 cu. in.)
Electrical System
alternator
Transmission
Speeds Three Speeds
Brakes
Type Hydraulic Shoe
Feed Accelerator
Number of Wings 10
Separator Elements
Rice 27
Tines 24
Concave
Separating
Number of Grates 4
Discharge Grate
Number of Grates 3
Discharge Beater
Number of Wings 5
Continued on next page OUO6083,0000DAC –19–18JUL06–1/2

083006
PN=40
Specifications
10
Grain Tank 10
21
Weight
Corn Combine — less header 15,228 kg (33,577 lb)
Rice Combine — less header 15,936 kg (35,138 lb)
Turning Radius
Rear Wheel Tread Width 3.3 m (10 ft 10 in.)
Turning Radius (Non-Powered Axles) 7.73 m (25 ft 4 in.)
Turning Radius (Powered Axles) 8.19 m (26 ft 9 in.)
Capacities
Cooling System w/heater 55 L (58.1 qt)
Engine Crankcase w/filter 42 L (44.3 qt)
Transmission 9.6 L (10 qt)
Final Drives 8 L (8.5 qt)
Feeder House Reverser Standard 0.9 L (2 pt)
Feeder House Reverser High Capacity 3.5 L (7.4 pt)
w/cooler
Countershaft Drive Gear Case 1.2 L (2.5 pt)
Loading Auger Gear Case 3.8 L (4 qt)
Two Speed Separator Drive Gear Case 4.7 L (5 qt)
Engine Gear Case w/transfer 21.3 L (22.5 qt)
Hydraulic/Hydrostatic Reservoir 34 L (36 qt)
OUO6083,0000DAC –19–18JUL06–2/2

083006
PN=41
Specifications
10
10 Specifications—9860 STS Combine (S.N.
22
715701—)

without notice.
Engine
Make John Deere
Model 6125HH
Rated Power at 2200 rpm (Premium Small 313 kW (420 hp)
Grain)
Power Bulge at 2100 rpm (Premium Small 335 kW (449 hp)
Grain)
Power Boost (Premium Small Grain) 338 kW (453 hp)
Displacement 12.5 L (765 cu. in.)
Electrical System
alternator
Transmission
Speeds Three Speeds
Brakes
Type Hydraulic Shoe
Feed Accelerator
Number of Wings 10
Separator Elements
Rice Option 24
Tines 24
Concave
Continued on next page OUO6083,0000DAD –19–18JUL06–1/2

083006
PN=42
Specifications
10
Separating 10
23
Number of Grates 4
Discharge Grate
Number of Grates 3
Discharge Beater
Number of Wings 5
Grain Tank
Weight
Corn Combine — less header 15,246 kg (33,617 lb)
Rice Combine — less header 15,956 kg (35,178 lb)
Grain Combine — less header (Premium 15,291 kg (33,711 lb)
Small Grain)
Turning Radius
Turning Radius (Non-Powered Axles) 7.73 m (25 ft. 4 in.)
Turning Radius (Powered Axles) 8.19 m (26 ft. 9 in.)
Capacities
Fuel Tank 1,155 L (305 gal)
Cooling System w/heater 67.7 L (71.6 qt)
Engine Crankcase w/filter 42 L (44.3 qt)
Transmission 9.6 L (10 qt)
Final Drives 8 L (8.5 qt)
Feeder House Reverser Gear Case w/o 2.3 L (4.75 pt)
cooler
Feeder House Reverser Extra Heavy Duty 4.9 L (10.4 pt)
Gear Case w/cooler
Feeder House Reverser Extra Heavy Duty 3.6 L (7.7 pt)
Gear Case w/o cooler (Premium Small Grain)
Countershaft Drive Gear Case 1.2 L (2.5 pt)
Loading Auger Gear Case 3.8 L (4 qt)
Two Speed Separator Drive Gear Case 4.7 L (5 qt)
Engine Gear Case w/transfer 21.3 L (22.5 qt)
Hydraulic/Hydrostatic Reservoir 35 L (37 qt)
OUO6083,0000DAD –19–18JUL06–2/2

083006
PN=43
Specifications
10
10 Dimensions—9860 STS Combine
24

without notice.
Dimension 800/65R32 Front Tires 800/65R32 Front Tires

18.4x26 Rear Tires 18.4x26 Rear Tires
Standard Unload Auger Power Fold Auger
A 11.00 m (36 ft. 1 in.) w/ 6.86 m (22 ft. 5 in.) Standard Unload 11.00 m (36 ft. 1 in.) w/ 6.86 m (22 ft. 5 in.) Power Fold
Auger Auger
B 9.12 m (29 ft. 9 in.) w/ 6.86 m (22 ft. 5 in.) w/ Power Fold
NA
Auger
C 8.38 m (27 ft. 5 in.) 8.38 m (27 ft. 5 in.)
D 4.45 m (14 ft. 6 in.) 4.45 m (14 ft. 6 in.)
E 4.15 m (13 ft. 6 in.) 4.15 m (13 ft. 6 in.)
F 3.79 m (12 ft. 4 in.) 3.79 m (12 ft. 4 in.)
G 0.49 m (1 ft. 6 in.) 0.49 m (1 ft. 6 in.)
H 3.53 m (11 ft. 6 in.) 3.53 m (11 ft. 6 in.)
I 7.66 m (25 ft. 1 in.) w/ 6.86 m (22 ft. 5 in.) Standard Unload 7.66 m (25 ft. 1 in.) w/ 6.86 m (22 ft. 5 in.) Power Fold Auger
Auger
J 5.09 m (16 ft. 7 in.) w/ 6.86 m (22 ft. 5 in.) Standard Unload 5.09 m (16 ft. 7 in.) w/ 6.86 m (22 ft. 5 in.) Power Fold Auger
Auger
K 4.38 m (14 ft. 4 in.) w/ 6.86 m (22 ft. 5 in.) Standard Unload 4.38 m (14 ft. 4 in.) w/ 6.86 m (22 ft. 5 in.) Power Fold Auger
Auger
La 4.45 m (14 ft. 6 in.) w/ 6.86 m (22 ft. 5 in.) Standard Unload 4.45 m (14 ft. 6 in.) w/ 6.86 m (22 ft. 5 in.) Power Fold Auger
Auger
b b
M Refer to Ground Drive and Rear Axle Section Refer to Ground Drive and Rear Axle Section
c c
N Refer to Ground Drive and Rear Axle Section Refer to Ground Drive and Rear Axle Section
• For 18.4R42 *** R1 Duals (480/80R42), add 2 mm (0.1 in.)
• For 30.5LR32 *** R1, subtract 25 mm (1.0 in.)
• For 20.8R38 ** R1 Duals (520/85R38), subtract 10 mm (0.4 in.)
• For 35.5L-32 12PR R2, add 101 mm (4.0 in.)
• For 20.8R42 ** R1 Duals (520/85R42), add 39 mm (1.5 in.)
• For 900/65R32 (172A8) R2, add 75 mm (3.0 in.)
• For 20.8R42 ** R2 Duals, add 70 mm (2.8 in.)
• For 800/70R38 (173A8) R1W, add 93 mm (3.7 in.)
• For 76X50-32 16PR HF3, add 77 mm (3.0 in.)
• For 30.5L-32 14PR R2, add 11 mm (0.4 in.)
a
Dimension is measured 1.22 m (4 ft.) from the spill point. This represents the unloading auger centered over the grain cart.
b
dimensions.
c
dimensions.
OUO6083,0000DA9 –19–18JUL06–1/1

083006
PN=44
Specifications
10
Dimension Reference Points—9860 STS Combine 10
25
–UN–06APR06
H85667
OUO6083,0000DAA –19–18JUL06–1/1

083006
PN=45
Specifications
10
10 Metric Bolt and Screw Torque Values
26
–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
TS1670
Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size 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 Shear bolts are designed to fail under predetermined loads. Always
of the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fasteners
value or tightening procedure is given for a specific application. For with the same or higher property class. If higher property class
stainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Make
instructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start thread
crimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fasteners
shown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless different
specific application. 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 zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 –19–24APR03–1/1

083006
PN=46
Specifications
10
Unified Inch Bolt and Screw Torque Values 10
TS1671 –UN–01MAY03 27
Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c b c b c
Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricatedb Dryc
Size 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 Replace fasteners with the same or higher grade. If higher
bolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of the
tightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that you
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricate
U-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel bolts
bolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for the
bolts with identical grade. 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 zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
DX,TORQ1 –19–24APR03–1/1

083006
PN=47
Specifications
10
10 Sealants and Adhesives Cross-Reference Chart
28
U.S. Part Number Canadian Part Color Size Description LOCTITE
Number Number
Bonding
PM37513 PM38606 BLACK and 4 gm Epoxy Adhesive 445

WHITE
PM37391 PM38615 CLEAR 2 gm Gel Super Glue 454
Gasketing
PM38655 PM38625 PURPLE 50 mL Flexible Form-in-Place Gasket 515

PM37559 PM38600 BROWN 4 oz General Purpose Gasket Dressing —
PM38657 PM38628 BLUE 50 mL High-Flex Form-in-Place Gasket 17430
PM37553 — BURGUNDY 16 oz High Tack Gasket Dressing —
PM37465 PM38616 METALLIC 80 mL Ultra Blue RTV Silicone 587
BLUE
H154379 — Green — Sealant —
Priming
PM37509 PM38611 GREEN 4.5 oz Cure Primer 7649
Retaining
PM38651 PM38612 SILVER 50 mL QUICK METAL Press Fit 660

PM37485 — GREEN 36 mL Maximum Strength 680
PM38652 PM38626 GREEN 36 mL High-Temperature 620
Thread Locking and Sealing
PM37477 PM38622 BLUE 36 mL Medium Strength 242

PM37418 PM38621 BLUE 6 mL Medium Strength 242
PM38654 PM38623 RED 36 mL High Strength 271
PM37398 PM38613 WHITE 6 mL Pipe Sealant with TEFLON 592
PM37397 PM38613 WHITE 50 mL Pipe Sealant with TEFLON 592
LOCTITE is a trademark of Loctite Corp.

QUICK METAL is a trademark of Loctite Corp.
TEFLON is a trademark of Du Pont Co. OUO1073,0001CA7 –19–12AUG05–1/1

083006
PN=48
Specifications
10
Face Seal Fittings Assembly and Installation—All Pressure Applications 10
29
Face Seal O-Ring to Stud End Installation Face Seal Straight Stud End O-Ring Installation
1. Inspect the fitting surfaces. They must be free of 1. Install a thimble over the fitting threads to protect
dirt and/or defects. the O-ring from nicks.
2. Inspect the O-ring. It must be free of damage 2. Slide the O-ring over the thimble into the turned
and/or defects. down section of the fitting.
3. Lubricate O-rings and install into groove using 3. Remove thimble.

petroleum jelly to hold in place.
Fitting Installation
4. Push O-ring into groove with petroleum jelly so
O-ring is not displaced during assembly. 1. Install fitting by hand until snug.
5. Index angle fittings and tighten by hand pressing 2. Position adjustable fittings by unscrewing the fitting
joint together to insure O-ring remains in place. no more than one turn.
6. Tighten fitting or nut to torque value shown on the 3. Apply assembly torque per table.
chart per dash size stamped on the fitting. DO NOT
allow hoses to twist when tightening fittings. Assembly Torque
Face Seal Adjustable Stud End O-Ring Installation 1. Use one wrench to hold the connector body and
one wrench to tighten nut.
1. Back off lock nut (jam nut) and washer to full
exposed turned down section of the fitting. 2. For a hydraulic hose, it may be necessary to use
three wrenches to prevent twist; one on the
2. Install a thimble over the fitting threads to protect connector body, one on the nut, and one on the
the O-ring from nicks. body of the hose fitting.
3. Slide the O-ring over the thimble into the turned

down section of the fitting.
4. Remove thimble.
OUO6435,0001557 –19–29JUL04–1/1

083006
PN=49
Specifications
10
10 Metric Face Seal Fitting Torque Chart—Standard Pressure Applications
30
A B
C D
–UN–12DEC01
E
H F
F
H70406
E
A—90° Swivel Elbow and Tube C—Stud Straight and Tube Nut E—Stud End G—Swivel Nut
Nut D—Bulkhead Union and F—Tube Nut H—Lock Nut
B—90° Adjustable Stud Elbow Bulkhead Lock Nut
Metric Face Seal Fitting Torque Chart—Standard Pressure—Below 27.6 mPa (4,000 PSI), Working Pressure-27.6 MPA (4,000 PSI)
Nominal Tube OD/Hose Face Seal Tube/Hose End O-Ring Stud Ends
ID
Metric Inch Tube OD Thread Hex Tube Bulkhead Lock Thread Hex Steel or Gray Aluminum
Tube Size Size Nut/Swivel Nut Nut Torquea Size Size Iron Torquea Torquea
OD Torquea
mm Dash in. in. mm N•m lb-ft N•m lb-ft in. mm N•m lb-ft N•m lb-ft
Size
6 -4 0.250 9/16-18 17 16 12 12 9 M12 x 1.5 17 21 15.5 9 6.6
8 -5 0.312 — — — — — — — — — — — —
— — — — — — — — — M14 x 1.5 19 33 24 15 11
10 -6 0.375 11/16-16 22 24 18 24 18 M16 x 1.5 22 41 30 18 13
12 -8 0.500 13/16-16 24 50 37 46 34 M18 x 1.5 24 50 37 21 15
16 -10 0.625 1-14 30 69 51 62 46 M22 x 1.5 27 69 51 28 21
20 -12 0.750 1-3/16-12 36 102 75 102 75 M27 x 2 32 102 75 46 34
22 -14 0.875 1-3/16-12 36 102 75 102 75 M30 x 2 36 Not Established
25 -16 1.000 1-7/16-12 41 142 105 142 105 M33 x 2 41 158 116 71 52
28 — — — — — — — — M38 x 2 46 176 130 79 58
32 -20 1.25 1-11/16-12 50 190 140 190 140 M42 x 2 50 190 140 85 63
38 -24 1.50 2-12 60 217 160 217 160 M48 x 2 55 217 160 98 72
a
Tolerance is +15%, minus 20% of mean tightening torque unless otherwise specified.
OUO6435,000154D –19–29NOV01–1/1

083006
PN=50
Specifications
10
Metric Face Seal Fitting Torque Chart—High Pressure Applications 10
31
A B
C D
–UN–12DEC01
E
H F
F
H70406
E
Metric Face Seal Fitting Torque Chart—High Pressure—Above 27.6 MPA (4,000 PSI), Working Pressure-41.3 MPA (6,000 PSI)
Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends
Metric Inch Tube OD Thread Hex Tube Nut/Swivel Bulkhead Lock Thread Hex Steel or Gray Iron
Tube Size Size Nut Torquea Nut Torquea Size Size Torquea
OD
mm Dash in. in. mm N•m lb-ft N•m lb-ft in. mm N•m lb-ft
Size
6 -4 0.250 9/16-18 17 16 12 12 9 M12 x 1.5 17 35 26
8 -5 0.312 — — — — — — — — — —
— — — — — — — — — M14 x 1.5 19 45 33
10 -6 0.375 11/16-16 22 24 18 24 18 M16 x 1.5 22 55 40
12 -8 0.500 13/16-16 24 50 37 46 34 M18 x 1.5 24 70 50
16 -10 0.625 1-14 30 69 51 62 46 M22 x 1.5 27 100 75
20 -12 0.750 1-3/16-12 36 102 75 102 75 M27 x 2 32 170 125
22 -14 0.875 1-3/16-12 36 102 75 102 75 M30 x 2 36 215 160
25 -16 1.000 1-7/16-12 41 142 105 142 105 M33 x 2 41 310 225
28 — — — — — — — — M38 x 2 46 320 235
32 -20 1.25 1-11/16-12 — — — — — M42 x 2 50 330 240
38 -24 1.50 2-12 — — — — — M48 x 2 55 420 300
a
OUO6435,000154E –19–29NOV01–1/1

083006
PN=51
Specifications
10
10 SAE Face Seal Fitting Torque Chart—Standard Pressure Applications
32
A B
C D
–UN–12DEC01
E
H F
F
H70406
E
SAE Inch Face Seal Fitting Torque Chart—Standard Pressure-Below 27.6 MPA (4,000 PSI), Working Pressure-27.6 MPA (4,000 PSI)
Metric Inch Tube OD Thread Tube Nut/Swivel Nut Bulkhead Lock Nut Thread Straight Fitting or
Tube OD Size Torquea Torquea Size Lock Nut Torquea
mm Dash in. mm in. N•m lb-ft N•m lb-ft in. N•m lb-ft
Size
5 -3 0.188 4.76 — — — — — 3/8-24 8 6
6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9
8 -5 0.312 7.94 — — — — — 1/2-20 16 12
10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18
12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34
16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46
20 -12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75
22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90
25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105
32 -20 1.25 31.75 1-11/16-12 190 140 190 140 1-5/8-12 190 140
38 -24 1.50 38.10 2-12 217 160 217 160 1-7/8-12 217 160
a
OUO6435,0001546 –19–16NOV01–1/1

083006
PN=52
Specifications
10
SAE Face Seal Fitting Torque Chart—High Pressure Applications 10
33
A B
C D
–UN–12DEC01
E
H F
F
H70406
E
SAE Inch Face Seal Fitting Torque Chart—High Pressure—Above 27.6 MPA (4,000 PSI), Working Pressure-41.3 MPA (6,000 PSI)
Metric Inch Tube OD Thread Tube Nut/Swivel Nut Bulkhead Lock Nut Thread Straight Fitting or
Tube OD Size Torquea Torquea Size Lock Nut Torquea
mm Dash in. mm in. N•m lb-ft N•m lb-ft in. N•m lb-ft
Size
5 -3 0.188 3.76 — — — — — 3/8-24 — —
6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 21 15
8 -5 0.312 7.94 — — — — — 1/2-20 — —
10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 34 25
12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 73 55
16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 104 76
20 -12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 176 130
22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 230 170
25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 285 210
a
OUO6435,000154A –19–20NOV01–1/1

083006
PN=53
Specifications
10
10 Four Bolt Flange Fittings Assembly and Installation—All Pressure Applications
34
1. Inspect the sealing surfaces for nicks or scratches, With the flange centrally located on the port, hand
roughness or out-of-flat condition. Scratches cause tighten cap screws to hold it in place. Do not pinch
leaks. Roughness causes seal wear. Out-of-flat O-ring.
causes seal extrusion. If these defects cannot be
polished out, replace the component. 5. For both single piece flange and split flange, be
sure the components are properly positioned and
2. Install the correct O-ring (and back-up washer if cap screws are hand tight. Tighten one cap screw,
required) into the groove using petroleum jelly to then tighten the diagonally opposite cap screw.
hold it in place. Tighten the two remaining cap screws. Tighten all
cap screws within the specified limits shown in the
3. For split flange; loosely assemble split flange chart.
halves, being sure that the split is centrally located
and perpendicular to the port. Hand tighten cap DO NOT use air wrenches. DO NOT tighten one
screws to hold parts in place. Do not pinch O-ring. cap screw fully before tightening the others. DO
NOT overtighten.
4. For single piece flange; put hydraulic line in the
center of the flange and install four cap screws.
OUO6435,0001558 –19–17DEC01–1/1

083006
PN=54
Specifications
10
SAE Four Bolt Flange Cap Screw Torque Values—Standard Pressure Applications 10
35
–UN–30NOV01
H70423
SAE Four Bolt Flange Cap Screw Torque Values—27,600 KPA (4,000 PSI) Pressure Applications
Torque
Newton Meters Foot Pounds
a, b
Nominal Flange Size Screw Size Min Max Min Max
1/2 5/16-18 UNC 20 31 15 23
3/4 3/8-16 UNC 28 54 21 40
1 3/8-16 UNC 37 54 27 40
1-1/4 7/16-14 UNC 47 85 35 63
1-1/2 1/2-13 UNC 62 131 46 97
2 1/2-13 UNC 73 131 54 97
2-1/2 1/2-13 UNC 107 131 79 97
3 5/8-11 UNC 187 264 138 195
3-1/2 5/8-11 UNC 158 264 117 195
4 5/8-11 UNC 158 264 117 195
5 5/8-11 UNC 158 264 117 195
a
JDM A17D, SAE Grade 5 or better cap screws with plated hardware.
b
1.5.1.2 Lock washers are permissible but not recommended.
OUO6435,0001549 –19–20NOV01–1/1

083006
PN=55
Specifications
10
10 SAE Four Bolt Flange Cap Screw Torque Values—High Pressure Applications
36
–UN–30NOV01
H70423
SAE Four Bolt Flange Cap Screw Torque Values—41,400 KPA (6,000 PSI) Pressure Applications
Torque
Newton Meters Foot Pounds
a, b
Nominal Flange Size Screw Size Min Max Min Max
1/2 5/16-18 UNC 20 31 15 23
3/4 3/8-16 UNC 34 54 25 40
1 7/16-14 UNC 57 85 42 63
1-1/4 1/2-13 UNC 85 131 63 63
1-1/2 5/8-11 UNC 159 264 117 195
2 3/4-10 UNC 271 468 200 345
a
JDM A17D, SAE Grade 5 or better cap screws with plated hardware.
b
1.5.1.2 Lock washers are permissible but not recommended.
OUO6435,000154C –19–29NOV01–1/1

083006
PN=56
Specifications
10
External Hexagon Port Plug Torque Chart 10
37
Port or Stud End Thread Sizea Torque
+15%/-20%
M8 x 1 10 N•m (7.4 lb-ft)
M10 x 1 17 N•m (12.5 lb-ft)
–UN–30NOV01
M12 x 1,5 28 N•m (20.6 lb-ft)
M14 x 1,5 39 N•m (28.7 lb-ft)
M16 x 1,5 48 N•m (35.4 lb-ft)
H70356
M18 x 1,5 60 N•m (44.2 lb-ft)
M20 x 1,5 60 N•m (44.2 lb-ft)
M22 x 1,5 85 N•m (62.7 lb-ft)
M27 x 2 135 N•m (99.6 lb-ft)
M30 x 2 165 N•m (121.7 lb-ft)
M33 x 2 235 N•m (173.3 lb-ft)
M38 x 2 245 N•m (180.7 lb-ft)
M42 x 2 260 N•m (191.8 lb-ft)
M48 x 2 290 N•m (213.9 lb-ft)
M60 x 2 330 N•m (243.4 lb-ft)
a
Port to JDS-G173.1; stud end to JDS-G173.3.
OUO6435,000154B –19–20NOV01–1/1

083006
PN=57
Specifications
10
10 Prevent Hydraulic System Contamination
38
IMPORTANT: Cleanliness is very important when

working on the hydraulic system.
Prevent contamination by assembling
the cylinders, hoses, couplers, and
valves in a clean area of the shop.
Leave protective caps on the fluid

openings until ready to make the
connection. When charging the system,
use a tractor or other source that
contains clean oil, free of abrasive
materials. Keep couplers clean.
Abrasive particles, like sand or metal
fragments, can damage seals, barrels
and pistons, causing internal leakage.
NX,T9005AE –19–14NOV95–1/1

083006
PN=58
Specifications
10
Check Oil Lines and Fittings 10
39
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
–UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call Deere & Company
Medical Department in Moline, Illinois or other
knowledgeable medical source.
Check all oil lines, hoses and fittings regularly for leaks or
defects. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching machine
parts which are moving. Replace damaged parts.
AG,OUO6022,1695 –19–24JUL00–1/2
IMPORTANT: Tighten fittings as specified in torque

chart.
If necessary, use two wrenches to prevent hoses from

twisting, bending or breaking tubing and fittings. –UN–15JUN99
H58319
AG,OUO6022,1695 –19–24JUL00–2/2

083006
PN=59
Specifications
10
10 Basic Electrical Component Handling / Precautions For Vehicles Equipped With
40
Computer Controlled Systems
Electrical Precautions To Take: Why: This can cause computer system errors from
interrupting a computer program while it is running and
Never disconnect the batteries while the key switch is electrical voltage spikes that are produced can
running. Why: This can cause electrical voltage spikes damage electronic components.
that can damage electronic components.
Do not apply power or ground to any component as a
Do not connect jumper cables while the key switch is test unless specifically instructed to do so. Why:
on. Why: This can cause electrical voltage spikes that Connecting the wrong voltage to the wrong point of an
can damage electronic components. electronic system can cause electronic component
failures.
Disconnect batteries prior to recharging (if possible).
Why: Electrical loads in the combine can slow the When welding on the machine, make sure to connect
recharging process. Battery chargers can cause ground lead to the parts being welded. For maximum
electrical voltage spikes that can damage electronic protection, disconnect all electronic controller
components. connectors before welding. Why: High currents
associated with welding can damage wiring harnesses
Never jump start the machine with a voltage higher that are involved in the ground path. Welding can also
than the machine is designed to operate on. Why: This cause electrical voltage spikes that can damage
can damage electronic components. electronic components.
Do not connect or disconnect electrical connectors

while the key switch is on or the combine is running.
AG,OUO6022,1696 –19–24JUL00–1/1

083006
PN=60
Group 15
Tune-Up and Adjustment
10
Tune-Up and Adjustment 15
1
General Information Cooling System:
Before tuning up a combine engine, determine whether • Clean rotary screen, radiator core, air conditioning
a tune-up will restore operating efficiency. When there condenser and charge air cooler.
is doubt, the following preliminary tests will help • Check radiator cap.
determine if the engine can be tuned up. If the • Inspect all hoses.
condition is satisfactory, proceed with the tune-up.
Choose from the following procedures only those Cylinder Head and Valves:
necessary to restore the combine.
• Set valve clearance.
Preliminary Engine Testing
Fuel System:
Test for engine compression (minimum readings at
cranking speed). It is very important that all cylinder • Check fuel tank for water and drain off if required.
pressures be approximately alike. There should be • Check fuel tank and lines for leaks or restrictions.
less than 172 kPa (1.72 bar) (25 psi) difference • Bleed fuel system.
between cylinder pressures. • Replace fuel filter.
• Replace water separator.
Engine Tune-Up
Electrical System
Air Intake System:
• Clean and tighten battery cables and connections.
• Check system for leaks. • Check alternator belt tension.
• Check alternator output.
Exhaust System: • Check neutral safety start switch operation.
• Check safety seat switch operation.
• Check system for leaks. Check for restricted muffler • Check starter draw.
or exhaust pipe. • Check battery voltage.
• Inspect all wiring.
Crankcase Vent:
• Check for restrictions.
OUO6083,0000507 –19–26MAR03–1/1

083006
PN=61
10
15 Care and Maintenance of Belts
2
V-belts are an important part of a machine. Their care part of the machine. It is no fault of the belt or its
and maintenance is important. A V-belt transmits construction.
power by friction and a wedging action against the
sheaves. Therefore, proper belt tension and the In many cases, such failure is due to belts running too
condition of the sheave side walls are of primary loose, allowing them to "throw-out" centrifugally so
importance. they rub on parts of the machine. Proper belt tension
would prevent this from happening.
Since the power is transmitted between the belts and
the sides of the sheave, look there for signs of wear. NOTE: A slight raveling of the belt covering at the
All belts and sheaves wear with use. Normal wear can splice does not indicate premature failure. Cut
be recognized as even wear—both on the belt and the off the raveling if the cover peels at the lap.
sides of the sheave. It is the unusual signs of wear to
look for and correct. Slip Burn—This belt has been ruined by being
operated too loose. The belt slipped under load and,
When checking belts, remember that many belts when finally it grabbed, it snapped.
reported as being defective have actually been
damaged by a bad sheave, misaligned drive or some Check belt tension frequently. Turn drives over by
faulty mechanical component of the machine. hand to be sure they are free. Advise operators to
clear machines of crop before stopping to avoid over
EXAMPLES OF UNUSUAL WEAR loading drives when starting up again.
Base Cracking—Excessive cross cracking extending Gouged Edge—A gouged edge in a belt is caused by
into the rubber on the base of a belt having little or no either a damaged sheave or interference with some
side wear indicates that the belt has been run a part of a machine.
relatively short time and, therefore, must be defective.
Small cracks, which are in the cover material only, do Check the condition of the sheaves. Be sure belt does
not indicate belt failure. not rub on any part of the machine while operating.
If the side walls show substantial wear, the belt should Burn Due to Locked Drive—A burned area in a belt is
not be classified as being defective. Actually, the an indication that the drive locked, causing the belt to
cracks in the base of the belt show that it has been slip on the sheave.
exposed to weather to the extent that the inner fabric
is beginning to rot. Prevent drive from locking by checking the tension of
any chain drives in the drive train. Avoid overloading
Fabric Rupture—A fabric rupture can be caused by and plugging the machine. Never attempt to unplug a
operating a belt over badly worn sheaves, by too much machine with power without first cleaning it out.
tension which forces the belt down into the grooves, or Lubricate the machine at the specified intervals to
by foreign objects falling into the sheave groove while prevent bearing seizure.
the drive is operating.
Worn Sides—Badly worn sides of a belt result from
In cases such as this, check condition of the sheaves. long operation without enough tension. The sides will
Avoid prying belts onto sheaves. be worn and the entire circumference will be slightly
burned.
Cover Tear—A tear in the cover of a belt is caused by
the belt accidentally coming into contact with some
Continued on next page AG,OUO6022,1698 –19–24JUL00–1/2

083006
PN=62
10
Check belt tension. Also, check sheaves for incorrect 15
3
alignment.
AG,OUO6022,1698 –19–24JUL00–2/2

083006
PN=63
10
15 Defective Belts
4
Excessive Stretch—A belt that stretches excessively is Position straightedge or cord so it touches sheaves at
one that stretches beyond the tightener adjustment all points. Shafts must be parallel.
provided to take up normal belt stretch. If this condition
occurs, it will usually develop within the warranty Rotate each sheave a half revolution and note whether
period. the contact of either sheave with the straightedge is
disturbed. If so, it indicates a bent shaft or wobbling
Lumpy Belts—Lumpy belts usually occur and are more sheave.
noticeable on variable speed drives and other
high-speed belt installations. The result is excessive Belt Installation
vibration. If belts are not relieved of tension while
machine is stored, they will often cause temporary Always practice the following when installing new belts.
vibration upon start-up. Give them time to straighten
out. 1. Before installing any new belt, move the adjustable
tightener to the position where it provides the least
Internal Cord Failure—Failure of one or more of the tension when the belt is installed. In some cases, it
internal tension cords will result in the belt rolling over may be necessary to remove the tightener to install
in the sheaves. (Cords can be broken by prying a new the belt.
belt over sheaves.)
2. Examine sheaves for chips, cracks, bent side walls,
Improper Length—It is possible for belts either too long rust, corrosion or other damage.
or too short to be shipped accidentally in service parts
orders. Such belts would not pass the line run-in for 3. Check sheaves for alignment.
new machines at the factory.
4. Place the belt in the sheave groove by hand.
Belt Replacement
IMPORTANT: Never pry or force a belt onto the
Here are a few general facts to know when replacing sheave with screwdrivers, crowbars,
V-belts. wedges, etc. Damage to the belt and
drive can result.
Replace Matched Sets—Never replace just one belt of
a matched set. Never install individual belts from Belt Tension Adjustment
matched sets. Install the complete matched set only.
All belts and sheaves wear with use. For this reason,
Check Condition of Sheaves—Always check the adjustable tightener arrangements are provided in the
condition of all sheaves before replacing a belt. Check drive to maintain the proper belt tension.
the sheaves for chips, cracks, bent side walls, rust,
corrosion, etc. V-belts must have a smooth, dry More belts fail from under tension than over tension.
surface to grip in order to deliver full power. Replace To carry their full load, V-belts must be kept taut so
any sheaves that are found to be defective. they grip the full arc of contact with the sheave. Some
belts may snap in two from a crack-the-whip effect
Check Sheave Alignment—Misaligned sheaves will caused by operating the belt too loose. Loose belts
result in shortened belt life. Use a straightedge or cord slip, heat and burn, causing unnecessary wear and
to check sheave alignment. damage.

083006
PN=64
10
Belts with spring-loaded idler will frequently appear 15
CAUTION: Do not attempt to clean the belts 5
quite loose but should be tightened only as instructed
while the machine is running. Never use
in the operator’s manual.
flammable cleaning solvents.
However, V-belts should not be excessively tight.
Clean belts by wiping them with a clean cloth. Use a
When belts are too tight, bearings and sheaves heat
non-flammable cleaner or solvent to remove excessive
up, even though well lubricated. Too much tension
grease and oil. Water and a detergent soap can be
stretches and weakens belts.
used, but it is not as satisfactory as a non-flammable
cleaner.
CAUTION: Never attempt to check or adjust
belts while the machine is running. Belt Storage
Proper Belt Tension—After a new V-belt has been Proper belt storage is as important for new belts in
installed, adjust belt tension as follows: your parts department as it is for those on the
customer’s machines.
1. Apply tension as instructed in the machine
operator’s manual or until the belt appears snug. In the Shop—Store new belts as follows to keep them
Run the machine long enough for the belt to seat factory-fresh for your customers.
properly in the grooves.
1. Store belts in a clean, cool, dry atmosphere. Undue
NOTE: All new belts have an initial stretch. It will be shrinkage or deterioration may occur if belts are
necessary to adjust the tension at shorter piled on damp floors or stored near radiators.
intervals until the belt is properly seated and
the initial stretch is eliminated. 2. Keep belts away from sun and heat.
2. Stop the machine. Adjust the belt until it has the 3. Do not place belts in bins for long periods. To do so
proper tension as described in the operator’s might distort the shape of the belt.
manual or use the following “slap test”. Slap the
belt sharply with your hand. It should feel springy 4. Do not hang belts on small pegs or nails. Heavy
and alive. A dead, lifeless feel means the belt is too belts can be weakened due to distortion from such
loose and should be tightened. a practice.
3. Advise owner to check belt tension as instructed in 5. Do not break matched sets.
the operator’s manual. Under no circumstances
should a belt be allowed to operate loose. On Customer’s Machines—Pass along the following
tips to your customers about storing belts:
Belt Care
1. If a belt is not to be removed, relieve belt tension
Belt dressing is not recommended on any belt, V- or by loosening the tightener adjustment. This is
flat, at any time. Most dressings contain chemicals necessary to prevent the belt from “setting” or
which tend to soften belts. While this softening process developing unequal stresses that might lead to
actually does increase the friction between the belt and early failure.
sheave grooves, the result is only temporary.
2. If possible, remove all belts. Thoroughly clean them
Remove grease and oil as quickly as possible before as described earlier in this article. Then store them
they can penetrate deeply into the belt, causing rapid in a cool, clean, dry atmosphere.
deterioration.

083006
PN=65
10
15 3. If the belts have been removed, coat sheave 4. Protect all movable or sliding parts of variable
6
grooves with anti-rust compound or grease prior to speed drives by lubricating them thoroughly to
storage. Be sure to remove such rust preventative prevent corrosion due to moisture.
before installing the belts and starting the machine.
Sheave grooves can also be protected with a
section of discarded belt tied in place.
AG,OUO6022,1699 –19–24JUL00–3/3

083006
PN=66
Group 20
Fuels and Lubricants
10
Handle Fuel Safely—Avoid Fires 20
1
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
–UN–23AUG88
outdoors.
Prevent fires by keeping machine clean of accumulated

trash, grease, and debris. Always clean up spilled fuel.
TS202
DX,FIRE1 –19–03MAR93–1/1
Handling and Storing Diesel Fuel
When fuel is stored for an extended period or if there

CAUTION: Handle fuel carefully. Do not fill
is a slow turnover of fuel, add a fuel conditioner to
the fuel tank when engine is running.
stabilize the fuel and prevent water condensation.
Contact your fuel supplier for recommendations.
DO NOT smoke while you fill the fuel tank or
service the fuel system.
Fill the fuel tank at the end of each day’s operation to

prevent condensation and freezing during cold
weather.
OUO6075,00036E2 –19–04MAY04–1/1

083006
PN=67
10
20 Diesel Fuel
2
Consult your local fuel distributor for properties of the scar diameter of 0.45 mm as measured by ASTM
diesel fuel available in your area. D6079 or ISO 12156-1.
In general, diesel fuels are blended to satisfy the low Sulfur content:
temperature requirements of the geographical area in
which they are marketed. • Diesel fuel quality and fuel sulfur content must
comply with all existing emissions regulations for the
Diesel fuels specified to EN 590 or ASTM D975 are area in which the engine operates.
recommended. • Use of diesel fuel with sulfur content less than
0.10% (1000 ppm) is STRONGLY recommended.
Required fuel properties • Use of diesel fuel with sulfur content 0.10% (1000
ppm to 0.50% (5000 ppm) may result in REDUCED
In all cases, the fuel shall meet the following oil and filter change intervals.
properties: • BEFORE using diesel fuel with sulfur content greater
than 0.50% (5000 ppm), contact your John Deere
Cetane number of 45 minimum. Cetane number dealer.
greater than 50 is preferred, especially for • DO NOT use diesel fuel with sulfur content greater
temperatures below -20°C (-4°F) or elevations above than 1.0%.
1500 m (5000 ft).
IMPORTANT: Do not mix used diesel engine oil or
Cold Filter Plugging Point (CFPP) below the any other type of lubricating oil with
expected low temperature OR Cloud Point at least diesel fuel.
5°C (9°F) below the expected low temperature.
IMPORTANT: Improper fuel additive usage may
Fuel lubricity should pass a minimum level of 3100 cause damage on fuel injection
grams as measured by ASTM D6078 or maximum equipment of diesel engines.
DX,FUEL1 –19–17NOV05–1/1

083006
PN=68
10
Bio-Diesel Fuel 20
3
Consult your local fuel distributor for properties of the leaving deposits on injectors and in
bio-diesel fuel available in your area. the combustion chamber.
Bio-diesel fuels may be used ONLY if the bio-diesel A major environmental benefit of bio-diesel fuel is its
fuel properties meet the latest edition of ASTM D6751, ability to biodegrade. This makes proper storage and
EN 14214, or equivalent specification. handling of bio-diesel fuel especially important. Areas
of concern include:
It is recommended to purchase bio-diesel fuel blended
with B100 from a BQ-9000 Accredited Producer or a • Quality of new fuel
BQ-9000 Certified Marketer as recommended by the • Water content of the fuel
National Bio-diesel Board. • Problems due to aging of the fuel
The maximum allowable bio-diesel concentration is a Potential problems resulting from deficiencies in the
5% blend (also known as B5) in petroleum diesel fuel. above areas when using bio-diesel fuel in
It has been found that bio-diesel fuels may improve concentrations above 5% may lead to the following
lubricity in concentrations up to this 5% blend. symptoms:
When using a blend of bio-diesel fuel, the engine oil • Power loss and deterioration of performance
level must be checked daily when the air temperature • Fuel leakage
is –10°C (14°F) or lower. If oil becomes diluted with • Corrosion of fuel injection equipment
fuel, shorten oil change intervals accordingly. • Coked and/or blocked injector nozzles, resulting in
engine misfire
IMPORTANT: Raw pressed vegetable oils are NOT • Filter plugging
acceptable for use as fuel in any • Lacquering and/or seizure of internal components
concentration in John Deere • Sludge and sediments
engines. • Reduced service life of engine components
These oils do not burn completely, Consult your fuel supplier for additives to improve
and will cause engine failure by storage and performance of bio-diesel fuels.
DX,FUEL7 –19–14NOV05–1/1

083006
PN=69
10
20 Lubricity of Diesel Fuel
4
Most diesel fuels manufactured in the United States, Fuel lubricity should pass a minimum load level of
Canada, and the European Union have adequate 3100 grams as measured by ASTM D6078 or a
lubricity to ensure proper operation and durability of maximum scar diameter of 0.45 mm as measured by
fuel injection system components. However, diesel ASTM D6079 or ISO 12156-1.
fuels manufactured in some areas of the world may
lack the necessary lubricity. If fuel of low or unknown lubricity is used, add John
Deere PREMIUM DIESEL FUEL CONDITIONER (or
IMPORTANT: Make sure the diesel fuel used in equivalent) at the specified concentration.
your machine demonstrates good
lubricity characteristics.
DX,FUEL5 –19–27OCT05–1/1
Testing Diesel Fuel
DIESELSCAN is a John Deere fuel analysis program

that can be used to monitor the quality of your fuel. The
DIESELSCAN analysis verifies fuel type, cleanliness,
water content, suitability for cold weather operation, and
whether the fuel meets specifications.
Check with your John Deere dealer for availability of

DIESELSCAN kits.
DIESELSCAN is a trademark of Deere & Company DX,FUEL6 –19–14NOV05–1/1

083006
PN=70
10
Diesel Engine Coolant 20
5
The engine cooling system is filled to provide Other low silicate ethylene glycol base coolants for
year-round protection against corrosion and cylinder heavy-duty engines may also be used if they meet one
liner pitting, and winter freeze protection to -37°C of the following specifications:
(-34°F). If protection at lower temperatures is required,
consult your John Deere dealer for recommendations. • ASTM D4985 ethylene glycol base prediluted (50%)
coolant
John Deere COOL-GARD Prediluted Coolant is • ASTM D4985 ethylene glycol base coolant
preferred for service. concentrate in a 40% to 60% mixture of concentrate
with quality water
John Deere COOL-GARD Prediluted Coolant is
available in a concentration of either 50% ethylene Coolants meeting ASTM D4985 require an initial
glycol or 55% propylene glycol. charge of supplemental coolant additives, formulated
for protection of heavy duty diesel engines against
Additional recommended coolants corrosion and cylinder liner erosion and pitting. They
also require periodic replenishment of additives during
The following engine coolant is also recommended: the drain interval.
• John Deere COOL-GARD Coolant Concentrate in a Other coolants

40% to 60% mixture of concentrate with quality
water. It is possible that neither John Deere COOL-GARD nor
coolants meeting one of the coolant standards listed
John Deere COOL-GARD coolants do not require use above is available in the geographical area where
of supplemental coolant additives, except for periodic service is performed. If these coolants are unavailable,
replenishment of additives during the drain interval. use a coolant concentrate or prediluted coolant with a
quality additive package that provides cylinder liner
Other fully formulated coolants cavitation protection and protects the cooling system
metals (cast iron, aluminum alloys, and copper alloys
Other fully formulated low silicate ethylene or such as brass) from corrosion.
propylene glycol base coolants for heavy-duty engines
may be used if they meet one of the following The additive package must be part of one of the
specifications: following coolant mixtures:
• ASTM D6210 prediluted (50%) coolant • ethylene glycol or propylene glycol base prediluted
• ASTM D6210 coolant concentrate in a 40% to 60% (40% to 60%) coolant
mixture of concentrate with quality water • ethylene glycol or propylene glycol base coolant
concentrate in a 40% to 60% mixture of concentrate
Coolants meeting ASTM D6210 do not require use of with quality water
supplemental coolant additives, except for periodic
replenishment of additives during the drain interval. Water quality
Coolants requiring supplemental coolant additives
COOL-GARD is a trademark of Deere & Company Continued on next page DX,COOL3 –19–27OCT05–1/2

083006
PN=71
10
20 Water quality is important to the performance of the IMPORTANT: Do not mix ethylene glycol and
6
cooling system. Distilled, deionized, or demineralized propylene glycol base coolants.
water is recommended for mixing with ethylene glycol
and propylene glycol base engine coolant concentrate.
IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains
sealing additives.
DX,COOL3 –19–27OCT05–2/2
Operating in Warm Temperature Climates
John Deere engines are designed to operate using glycol

base engine coolants.
Always use a recommended glycol base engine coolant,

even when operating in geographical areas where freeze
protection is not required.
IMPORTANT: Water may be used as coolant in

emergency situations only.
Foaming, hot surface aluminum and

iron corrosion, scaling, and cavitation
will occur when water is used as the
coolant, even when coolant
conditioners are added.
Drain cooling system and refill with

recommended glycol base engine
coolant as soon as possible.
DX,COOL6 –19–18MAR96–1/1

083006
PN=72
10
Supplemental Coolant Additives 20
7
The concentration of coolant additives is gradually If other coolants are used, consult the coolant supplier
depleted during engine operation. For all and follow the manufacturer’s recommendation for use
recommended coolants, replenish additives between of supplemental coolant additives.
drain intervals by adding a supplemental coolant
additive every 12 months or as determined necessary The use of non-recommended supplemental coolant
by coolant testing. additives may result in additive drop-out and gelation
of the coolant.
John Deere COOLANT CONDITIONER is
recommended as a supplemental coolant additive in Add the manufacturer’s recommended concentration of
John Deere engines. supplemental coolant additive. DO NOT add more than
the recommended amount.
IMPORTANT: Do not add a supplemental coolant
additive when the cooling system is
drained and refilled with John
DeereCOOL-GARD.
COOL-GARD is a trademark of Deere & Company DX,COOL4 –19–07NOV03–1/1

083006
PN=73
10
20 Additional Information About Diesel Engine Coolants and Supplemental Coolant
8
Additives
Engine coolants are a combination of three chemical simple mixture of ethylene glycol or propylene glycol
components: ethylene glycol or propylene glycol and water will not give adequate protection.
antifreeze, inhibiting coolant additives, and quality
water. Use of supplemental coolant additives reduces
corrosion, erosion, and pitting. These chemicals
Coolant specifications reduce the number of vapor bubbles in the coolant and
help form a protective film on cylinder liner surfaces.
Some products, including John Deere COOL-GARD This film acts as a barrier against the harmful effects
Prediluted Coolant, are fully formulated coolants that of collapsing vapor bubbles.
contain all three components in their correct
concentrations. Do not add an initial charge of Avoid automotive-type coolants
supplemental coolant additives to these fully
formulated products. Never use automotive-type coolants (such as those
meeting ASTM D3306). These coolants do not contain
Coolants meeting ASTM D6210 do not require an the correct additives to protect heavy-duty diesel
initial charge of supplemental coolant additives. engines. They often contain a high concentration of
silicates and may damage the engine or cooling
Some coolant concentrates, including John Deere system.
COOL-GARD Coolant Concentrate, contain both glycol
antifreeze and inhibiting coolant additives. Mix these Water quality
products with quality water, but do not add an initial
charge of supplemental coolant additives. Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
Coolants meeting ASTM D4985 require an initial water is recommended for mixing with ethylene glycol
charge of supplemental coolant additives. and propylene glycol base engine coolant concentrate.
All water used in the cooling system should meet the
Replenish coolant additives following minimum specifications for quality:
The concentration of coolant additives is gradually Chlorides <40 mg/L

depleted during engine operation. Periodic Sulfates <100 mg/L
replenishment of inhibitors is required, even when Total dissolved solids <340 mg/L
John Deere COOL-GARD or another fully formulated Total hardness <170 mg/L
coolant is used. Follow the recommendations in this
pH 5.5 to 9.0
manual for the use of supplemental coolant additives.
Why use supplemental coolant additives? Freeze protection
Operating without proper coolant additives will result in The relative concentrations of glycol and water in the
increased corrosion, cylinder liner erosion and pitting, engine coolant determine its freeze protection limit.
and other damage to the engine and cooling system. A
COOL-GARD is a trademark of Deere & Company Continued on next page DX,COOL7 –19–19DEC03–1/2

083006
PN=74
10
Ethylene Glycol Freeze Protection Limit DO NOT use a coolant-water mixture greater than 20
9
40% -24°C (-12°F) 60% ethylene glycol or 60% propylene glycol.
50% -37°C (-34°F)
60% -52°C (-62°F)
Propylene Glycol Freeze Protection Limit
40% -21°C (-6°F)
50% -33°C (-27°F)
60% -49°C (-56°F)
DX,COOL7 –19–19DEC03–2/2
Testing Diesel Engine Coolant
Testing Diesel Engine Coolant method to check the freeze point and additive levels of
your engine coolant.
Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect Compare the results to the supplemental coolant
the engine and cooling system against freezing, additive (SCA) chart to determine the amount of
corrosion, and cylinder liner erosion and pitting. inhibiting additives in your coolant and whether more
John Deere COOLANT CONDITIONER should be
Test the coolant solution at intervals of 12 months or added.
less and whenever excessive coolant is lost through
leaks or overheating. COOLSCAN and COOLSCAN PLUS
Coolant test strips For a more thorough evaluation of your coolant,

perform a COOLSCAN or COOLSCAN PLUS analysis,
Coolant test strips are available from your John Deere where available. See your John Deere dealer for
dealer. These test strips provide a simple, effective information.
COOLSCAN is a trademark of Deere & Company

COOLSCAN PLUS is a trademark of Deere & Company DX,COOL9 –19–19DEC03–1/1

083006
PN=75
10
20 Diesel Engine Break-In Oil
10
New engines are filled at the factory with John Deere • ACEA Oil Sequence E1
ENGINE BREAK-IN OIL. During the break-in period,
add John Deere ENGINE BREAK-IN OIL as needed to After the break-in period, use John Deere PLUS-50
maintain the specified oil level. or other diesel engine oil as recommended in this
manual.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine. IMPORTANT: Do not use PLUS-50 oil or engine
oils meeting any of the following
After engine overhaul, fill the engine with John Deere during the first 100 hours of
ENGINE BREAK-IN OIL. operation of a new or rebuilt engine:
If John Deere ENGINE BREAK-IN OIL is not available, API CI-4 PLUS API CF
use a diesel engine oil meeting one of the following API CI-4 ACEA E7
API CH-4 ACEA E6
during the first 100 hours of operation: API CG-4 ACEA E5
API CF-4 ACEA E4
• API Service Classification CE API CF-2 ACEA E3
• API Service Classification CD
• API Service Classification CC These oils will not allow the engine
• ACEA Oil Sequence E2 to break-in properly.
PLUS-50 is a trademark of Deere & Company. DX,ENOIL4 –19–19DEC05–1/1

083006
PN=76
10
Diesel Engine Oil 20
11
Use oil viscosity base on the expected air temperature

range during the period between oil changes.
John Deere PLUS-50 oil is preferred.
Oil meeting one of the following specifications are also

recommended:
• ACEA Oil Sequence E7

–UN–31OCT03
Extended service intervals may apply when John Deere
PLUS-50, ACEA E7, ACEA E6, ACEA E5, or ACEA E4
engine oils are used. Consult your John Deere dealer for
more information.
TS1675
Other oils may be used if they meet one or more of the
following:
• John Deere TORQ-GARD SUPREME

• API Service Category CI-4 PLUS
• API Service Category CI-4
• API Service Category CH-4
Multi-viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply

with all existing emissions regulations for the area in
which the engine operates.
DO NOT use diesel fuel with sulfur content greater than

1.0% (10 000 ppm).
PLUS-50 is a trademark of Deere & Company

TORQ-GARD SUPREME is a trademark of Deere & Company DX,ENOIL7 –19–23NOV05–1/1

083006
PN=77
10
20 Extended Diesel Engine Oil Service Intervals
12
When John Deere PLUS-50, ACEA E5, or ACEA E4 filter, change the engine oil and filter at the normal
oils are used with the specified John Deere filter, the service interval.
service interval for engine oil and filter changes may
be increased by 50% but not to exceed a maximum of If John Deere TORQ-GARD SUPREME, API CI-4,
500 hours. API CH-4, or ACEA E3 oils are used, change the
engine oil and filter at the normal service interval.
If John Deere PLUS-50, ACEA E5, or ACEA E4 oils
are used with other than the specified John Deere
PLUS-50 is a trademark of Deere & Company

TORQ-GARD SUPREME is a trademark of Deere & Company DX,ENOIL8 –19–07NOV03–1/1
OILSCANand COOLSCAN
OILSCANand COOLSCAN are John Deere sampling

programs to help you monitor machine performance and
identify potential problems before they cause serious
damage.
–UN–15JUN89
Oil and coolant samples should be taken from each
system prior to its recommended change interval.
T6828AB
Check with your John Deere dealer for the availability of
OILSCAN and COOLSCAN kits.
–UN–18OCT88
T6829AB
OILSCAN is a registered trademark of Deere & Company.

COOLSCAN is a trademark of Deere & Company. DX,OILSCAN –19–02DEC02–1/1

083006
PN=78
10
Hydrostatic Drive System, Main Hydraulic 20
13
System and Main Engine Gear Case Oils
NOTE: The combine comes from the factory with SAE

10W oil. If you change oil, you can use any of the
oils listed below.
• SAE 10W engine oils, if they meet API Service

Classification CD or CE.
• John Deere Low Viscosity HY-GARD
Transmission/Hydraulic Oil J20 D.
HY-GARD is a trademark of Deere & Company. OUO1035,00002A7 –19–20SEP00–1/1

083006
PN=79
10
20 Transmission, Final Drives, Feeder House
14
Reverser, Loading Auger, Primary
Countershaft and Two-Speed Separator Drive
Gear Cases
Use oil viscosity based on the expected air temperature

range during the period between oil changes.
The following oils are preferred:
• John Deere GL-5 GEAR LUBRICANT

• John Deere EXTREME-GARD
Other oils may be used if they meet API Service

Classification GL-5.
Product Pkg.
Number Description Size Qty.
TY6252 80W/90 GL5 Gear Lube 5 gal 1
(35 lb pail)
–UN–14MAR96
TY6296 80W/90 GL5 Gear Lube 0.9 L (1 qt) 12
can
TY6256 85W/140 GL5 Gear Lube 5 gal 1
(35 lb pail)
TS1653
TY6345 85W/140 GL5 Gear Lube 0.9 L (1 qt) 12
can
In Canada use:
Product Pkg.
Number Description Size Qty.
TY6275 80W/90 GL5 Gear Lube 20 L pail 1
TY6276 85W/140 GL5 Gear Lube 20 L pail 1
EXTREME-GARD is a trademark of Deere & Company. OUO6083,0000AE1 –19–25JUL05–1/1

083006
PN=80
10
Grease 20
15
Use grease based on NLGI consistency numbers and the

expected air temperature range during the service interval.
The following grease is recommended:
• John Deere SD POLYUREA GREASE (TY6341)
Other greases may be used if they meet the following:
• NLGI Performance Classification GC-LB
IMPORTANT: John Deere SD POLYUREA GREASE
–UN–30JUN99
(TY6341) is the required grease for the
feeder house torque sensing cams.
Some types of grease thicken and are
TS1667
not compatible with others.
If grease fitting is missing, replace

immediately. Clean fittings thoroughly
before using grease gun.
Product Number Description

TY6341 Multi-Purpose, High-Temperature Extreme
Pressure Grease, especially effective in rolling
contact applications.
HX,AG,SF7350 –19–26OCT99–1/1
Brake Fluid
IMPORTANT: When removing reservoir cap, keep

contaminants from entering the
reservoir.
Fluid should be 6 mm (1/4 in.) from top.
Fill reservoir with SAE J1703d, DOT-3 or DOT-4 hydraulic

brake fluid.
OUO6075,000185A –19–20JUN01–1/1

083006
PN=81
10
20 Lubricant Storage
16
Your equipment can operate at top efficiency only Make certain that all containers are properly marked to
when clean lubricants are used. identify their contents.
Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual
lubricant they may contain.
Whenever possible, store lubricants and containers in
an area protected from dust, moisture, and other
contamination. Store containers on their side to avoid
water and dirt accumulation.
DX,LUBST –19–18MAR96–1/1
Alternative and Synthetic Lubricants
Conditions in certain geographical areas may require

lubricant recommendations different from those printed in
this manual.
Some John Deere brand coolants and lubricants may not

be available in your location.
Consult your John Deere dealer to obtain information and

recommendations.
Synthetic lubricants may be used if they meet the

performance requirements as shown in this manual.
The temperature limits and service intervals shown in this

manual apply to both conventional and synthetic oils.
Re-refined base stock products may be used if the

finished lubricant meets the performance requirements.
DX,ALTER –19–15JUN00–1/1

083006
PN=82
10
Mixing of Lubricants 20
17
In general, avoid mixing different brands or types of oil. Consult your John Deere dealer to obtain specific
Oil manufacturers blend additives in their oils to meet information and recommendations.
certain specifications and performance requirements.
Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricant
performance.
DX,LUBMIX –19–18MAR96–1/1

083006
PN=83
10
20
18

083006
PN=84
Section 20
Engine
Contents 20
Page
Group 05—Remove and Install Engine

Essential or Recommended Tools . . . . . . . . . . .20-05-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .20-05-3
John Deere Engine Repair . . . . . . . . . . . . . . . .20-05-4
Remove Engine—6.8 L . . . . . . . . . . . . . . . . . . .20-05-5
Install Engine—6.8 L . . . . . . . . . . . . . . . . . . . . .20-05-8
Remove Engine—8.1 L . . . . . . . . . . . . . . . . . .20-05-10
Install Engine—8.1 L . . . . . . . . . . . . . . . . . . . .20-05-12
Remove Engine—9.0 L . . . . . . . . . . . . . . . . . .20-05-14
Install Engine—9.0 L . . . . . . . . . . . . . . . . . . . .20-05-17
Remove Engine—12.5 L . . . . . . . . . . . . . . . . .20-05-19
Install Engine—12.5 L . . . . . . . . . . . . . . . . . . .20-05-23
Group 10—Cooling System

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1
Rotary Screen Drive . . . . . . . . . . . . . . . . . . . . .20-10-4
Rotary Screen Idler Arm and Sheaves . . . . . . .20-10-5
Remove and Install Upper and Lower Air
Scoops . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-6
Remove and Install Rotary Screen . . . . . . . . . .20-10-8
Adjusting Rotary Screen Knife Comb . . . . . . .20-10-11
Remove Radiator—6.8 L Engine . . . . . . . . . . .20-10-11
Install Radiator—6.8 L Engine. . . . . . . . . . . . .20-10-14
Remove Radiator—12.5 L Engine . . . . . . . . . .20-10-25
Install Radiator—12.5 L Engine . . . . . . . . . . . .20-10-28
Test Radiator . . . . . . . . . . . . . . . . . . . . . . . . .20-10-30
Test Radiator Cap . . . . . . . . . . . . . . . . . . . . . .20-10-31
Replace Thermostats . . . . . . . . . . . . . . . . . . .20-10-31
Repair or Replace Water Pump. . . . . . . . . . . .20-10-31
Group 15—Lower Engine Repair

Remove and Install Engine Oil Pan
Access Sheet. . . . . . . . . . . . . . . . . . . . . . . . .20-15-1

083006
PN=1
Contents
20

083006
PN=2
Group 05
Remove and Install Engine
Essential or Recommended Tools
NOTE: Order tools from the U.S. SERVICEGARD or RECOMMENDED TOOLS, as noted, are suggested to
European Microfiche Tool Catalogs. perform the job correctly. Some tools may be available
from local suppliers or may be fabricated.
20
ESSENTIAL TOOLS listed are required to perform the 05
job correctly and are obtainable only from 1
SERVICEGARD or European Microfiche Tool
Catalogs.
SERVICEGARD is a trademark of Deere & Company OUO6083,0000D30 –19–30MAY06–1/6
RW18149 –UN–09APR90
Lifting Sling . . . . . . . . . . . . . . . . . . . . . . . . . . JDG23
Used to remove engine.
OUO6083,0000D30 –19–30MAY06–2/6
Lifting Eye . . . . . . . . . . . . . . .JDG244-1 and JDG244-2
–UN–05JUN06
Used to attach lifting sling to 6.8 L engine.
H86019
OUO6083,0000D30 –19–30MAY06–3/6
H71259 –UN–01MAR02
Lifting Eye . . . . . . . . . . . . . . . . . . . . JD244-1 (2 used)
Continued on next page OUO6083,0000D30 –19–30MAY06–4/6

083006
PN=87
H83865 –UN–28JUN05
Lifting Eyes . . . . . . . . . . . . . JDG10040 and JDG10042
20
05
2
OUO6083,0000D30 –19–30MAY06–5/6
H71060 –UN–05FEB02
Lifting Eyes . . . . . . . . . . . . . . . R128000 and R128001
OUO6083,0000D30 –19–30MAY06–6/6

083006
PN=88
Specifications
Item Measurement Specification
Cooling System—6.8 L Engine Capacity 44 L

20
(11.6 gal) 05
3
Cooling System—8.1 L Engine with Capacity 45 L
Tier II Engine Deck (11.9 gal)
Cooling System—8.1 L Engine with Capacity 48.3 L

Tier III Engine Deck (12.75 gal)
Cooling System—9.0 L Engine Capacity 53.3 L

(14.1 gal)
Cooling System—12.5 L Engine with Capacity 55 L

Tier II Engine Deck (14.5 gal)
Cooling System—12.5 L Engine with Capacity 67.7 L

Tier III Engine Deck (17.9 gal)
Engine Oil With Filter—6.8 L Engine Capacity 32 L

(8.5 gal)
Engine Oil With Filter—8.1 L Engine Capacity 28.4 L

(7.5 gal)
Engine Oil With Filter—9.0 L Engine Capacity 29 L

(7.7 gal)
Engine Oil With Filter—12.5 L Capacity 42 L

Engine (11.1 gal)
Engine Gear Case-to-Engine Cap Torque 340 N•m

Screws (250 lb-ft)
Front Engine Mount-to-Engine Rail Torque 123 N•m

Cap Screws (90 lb-ft)
Fan-to-Fan Hub Cap Screws Torque 80 N•m

(60 lb-ft)
Variable Drive Sheave Support Jam Torque 250 N•m

Nuts (185 lb-ft)
Variable Drive Support-to-Engine Torque 350 N•m


083006
PN=89
Engine—6.8 L Engine Weight 711 kg

(1568 lb)
20
05 Engine—8.1 L Engine Weight 816 kg
4 (1800 lb)

(1987 lb)

(2657 lb)
Radiator Hose Clamps Torque 4.5 N•m

(40 lb-in)
Charge Air Cooler Tube Clamp Torque 11 N•m

(97 lb-in.)
Air Intake Hose Clamp Torque 11 N•m

(97 lb-in.)
OUO6083,0000D31 –19–30MAY06–2/2
John Deere Engine Repair
For complete repair information, the component technical

manual (CTM) is also required.
Use these component technical manuals in conjunction
–UN–06DEC96
with this combine manual.
• CTM104-4.5 L and 6.8 L Diesel Engines—Base Engine

• CTM320-6.8 L Diesel Engines Level 14 Electronic Fuel
System with Denso HPCR RW50283A
• CTM86-8.1 L Diesel Engines, Repair

• CTM255-8.1 L Diesel Engines
• CTM100-10.5 L and 12.5 L Diesel Engines, Repair
• CTM188 Level 6 John Deere Controller Operation and
Diagnostic Manual
• CMT385 9.0 L Diesel Engines Level 14 Electronic Fuel
System with Denso HPCR
OUO6083,0000D39 –19–31MAY06–1/1

083006
PN=90
Remove Engine—6.8 L
1. Turn battery disconnect switch (A) to “O” off position

(B).
20
2. Remove intake duct and air cleaner assembly. 05
–UN–06JUN05
5
3. Remove engine covers and shields as necessary.
4. Drain:
H83697
• Engine oil
Specification A—Disconnect Switch

Engine Oil With Filter—Capacity ......................................................... 32 L B—“O” Off Position
(8.5 gal)
CAUTION: Coolant may be hot. Wait until

radiator is cool before draining coolant.
• Engine cooling system
Specification
Cooling System—Capacity .................................................................. 44 L
(11.6 gal)
5. Shut off fuel supply on bottom of fuel tank.
NOTE: Cap and plug all lines and hoses.
6. Disconnect:
• Radiator and heater hoses

• Engine wiring harness
• Cold weather start aid
• Rotary screen drive belt
• Fuel supply and return lines
7. Remove:
• Muffler assembly
• Both charge air tubes

083006
PN=91
NOTE: DO NOT disconnect refrigerant lines.
• Alternator
• A/C compressor
20
05 • Upper and lower fan shroud
6 • Cooling fan, spacer, washer and sheave
OUO6083,0000D38 –19–31MAY06–2/4
8. Install lifting eyes JDG244-1 (A) and JDG244-2 (B) on

engine.
CAUTION: Use care when lifting engine and

NEVER permit any part of the body to be
positioned under a load being lifted or
–UN–30MAY06
suspended.
CAUTION: The approximate weight of the 6068
H86023
engine is 711 kg (1568 lb).
Specification
Engine—Weight .............................................................................. 711 kg A—JDG244-1 Lifting Eye
(1568 lb) B—JDG244-2 Lifting Eye
C—JDG23 Lifting Sling

083006
PN=92
10. Remove front engine mount (A) from engine rail.
11. Remove gear case-to-engine cap screws (B).
12. Carefully move engine away from gear case. Lift

20
engine out of combine. 05
–UN–30MAY06
7
13. Repair or replace as necessary.
A—Cap Screw (4 used)
H86028
B—Cap Screw (4 used)
–UN–08JUN05
H83706
OUO6083,0000D38 –19–31MAY06–4/4

083006
PN=93
Install Engine—6.8 L

20 positioned under a load being lifted or
05 suspended.
–UN–30MAY06
8

H86023
IMPORTANT: Use only a lifting sling like the JDG23
which has a spreader bar. Other types
of lifting slings could damage the A—JDG244-1 Lifting Eye
cylinder head. B—JDG244-2 Lifting Eye
C—JDG23 Lifting Sling
1. Carefully lower engine to align with engine gear case.
2. Install:
• Gear case-to-engine cap screws; tighten to

specification
Specification
Gear Case-to-Engine Cap
Screws—Torque ........................................................................... 340 N•m
(250 lb-ft)
• Front engine mount cap screws; tighten to

specification
Specification
Front Engine Mount-to-Engine
Rail Cap Screws—Torque ............................................................ 123 N•m
(90 lb-ft)
3. Remove lifting sling (C) and lifting eyes (A and B).
4. Install a/c compressor and tighten cap screws to

specification.
Specification
A/C Compressor Cap Screws—
Torque ............................................................................................ 35 N•m
(26 lb-ft)
Continued on next page OUO6083,0000D3A –19–31MAY06–1/3

083006
PN=94
NOTE: Fabricate two dowel pins, 6 mm (1/4 in.) x 180

mm (7 in.) long, to aid in aligning the fan
assembly.
5. Install fan (A), spacer (B), washer (C) and sheave (D)
20
onto hub (E) using dowel pins to aid in alignment. 05
–UN–09JUN05
9
6. Install several cap screws, remove dowel pins, install
remaining cap screws and tighten to specification.
H83707
Specification
Fan-to-Fan Hub Cap Screws—
Torque ............................................................................................ 80 N•m
(60 lb-ft)
A—Fan
B—Spacer
7. Install: C—Washer
D—Sheave
• Two piece fan shroud E—Hub
• Upper and lower radiator hoses and surge tank
hose; tighten to specification
Specification
Radiator Hose Clamps—Torque .................................................... 11 N•m
(97 lb-in.)
• Both charge air tubes: tighten to specification
Specification
Charge Air Cooler Tube
Clamps—Torque............................................................................. 11 N•m
(97 lb-in.)
• Heater hoses
• Alternator
• Fan drive and rotary screen drive belts
• Exhaust tube and muffler assembly
8. Connect:

9. Install engine covers and shields.
10. Fill:
Continued on next page OUO6083,0000D3A –19–31MAY06–2/3

083006
PN=95
• Engine with correct oil (See FUELS AND

LUBRICANTS in Section 10, Group 20.)
• Cooling system with coolant
11. Open fuel supply valve on bottom of tank.

20
05
10 12. Turn battery disconnect switch to “I” on position.
13. Follow engine break-in procedure in CTM104.
OUO6083,0000D3A –19–31MAY06–3/3
1. Disconnect battery cables. Radiator with Tier III Engine

Deck—Capacity ......................................................................... 48.2 L
(12.7 gal)
2. Remove intake duct and air cleaner assembly.
3. Remove shields as necessary.

4. Drain:
6. Disconnect:
• Engine oil
Specification • Radiator and heater hoses

Engine Oil—Capacity................................................................. 28.5 L • Engine wiring harness
(30 qt) • Cold weather start aid
7. Remove:
NOTE: Cooling capacities will vary depending on style
of engine deck. Batteries will not be located on • Exhaust tube and muffler assembly
a Tier III engine deck. • Upper and lower charge air tubes
• Starter
CAUTION: Coolant may be hot. Wait until NOTE: DO NOT disconnect refrigerant lines.
• A/C Compressor
• Engine cooling system • Alternator
• Upper and lower fan shroud, and cooling fan
Specification
Radiator with Tier II Engine
Deck—Capacity ............................................................................ 45 L
(11.9 gal)
Continued on next page OUO6083,0000A64 –19–07JUL05–1/2

083006
PN=96
8. Install JD244-1 Lifting Eyes (B).

positioned under a load being lifted or 20
suspended. 05
–UN–19APR02
11

H71700
Specification
Engine—Weight .............................................................................. 816 kg
(1800 lb) A—JDG23 Lifting Sling
B—JD244-1 Lifting Eye (2 used)
IMPORTANT: Use only a lifting sling like the JDG23,
of lifting slings could damage the
cylinder head.
9. Install JDG23 lifting sling (A) to engine. Take up slack

in lift chains before removing engine mount cap
screws.
10. Remove:
• Front engine mounts

• Dust cover-to-gear case cap screws
• Gear case-to-engine cap screws
11. Carefully move engine away from gear case. Lift

engine out of combine.
OUO6083,0000A64 –19–07JUL05–2/2

083006
PN=97

20 positioned under a load being lifted or
05 suspended.
–UN–19APR02
12

H71700
Specification
Engine—Weight ............................................................................... 816 kg
(1800 lb) A—JDG23 Lifting Sling
B—JD244-1 Lifting Eye (2 used)
2. Install:

specification
Specification
Engine Gear Case-to-Engine Cap
Screws—Torque ........................................................................... 340 N•m
(250 lb-ft)
• Front engine mounts; tighten to specification
Specification
(90 lb-ft)
NOTE: Remove lifting sling (A) and lifting eyes (B).
• Air conditioning compressor

• Cooling fan; then tighten to specification
Specification
Torque ............................................................................................ 80 N•m
(60 lb-ft)

083006
PN=98
• Upper and lower fan shroud

• Upper and lower radiator hoses; then tighten to
specification
Specification
Radiator Hose Clamps—Torque ................................................... 4.5 N•m 20
(40 lb-in) 05
13
• Upper and lower charge air tubes; then tighten to

specification
Specification
Charge Air Cooler Tube Clamp—
Torque ............................................................................................ 11 N•m
(97 lb-in.)
• Starter
• Alternator
3. Connect:

4. Install shields.
5. Install intake duct and air cleaner assembly.
6. Fill:

7. Open fuel supply valve on bottom of tank.
8. Connect battery cables.
9. Bleed fuel system. (See BLEED COMBINE FUEL

SYSTEM in Section 30, Group 10.)
10. Follow engine break-in procedures in CTM86.
OUO6083,0000A66 –19–07JUL05–2/2

083006
PN=99
1. Turn battery disconnect switch (A) to “O” off position

(B).
20
05 2. Remove intake duct and air cleaner assembly.
–UN–06JUN05
14
3. Remove engine covers and shields as necessary.
4. Drain:
H83697
• Engine oil
Specification A—Disconnect Switch

Engine Oil With Filter—Capacity ......................................................... 29 L B—“O” Off Position
(7.7 gal)

Specification
Cooling System—Capacity ............................................................... 53.3 L
(14.1 gal)
NOTE: Cap and plug all lines and hoses.
6. Disconnect:

7. Remove:
• Muffler assembly
• Upper and lower charge air tubes

083006
PN=100
• Alternator
• A/C Compressor and mounting brackets
20
• Upper and lower fan shroud 05
• Cooling fan, spacer, washer and sheave 15
OUO6083,0000D32 –19–30MAY06–2/4
8. Install JDG10040 and JDG10042 lifting eyes (A) on

engine.

positioned under a load being lifted or
–UN–08JUN05
suspended.
H83701
Specification
Engine—Weight .............................................................................. 901 kg A—Lifting Eyes
(1987 lb) B—JDG23 Lifting Sling
9. Install JDG23 lifting sling (B) to engine. Take up slack

in lift chains before removing engine mount cap
screws.

083006
PN=101
10. Remove front engine mount cap screws (A) from

engine rail.
11. Remove gear case-to-engine cap screws (B).

20
05 12. Carefully move engine away from gear case. Lift
–UN–09JUN05
16 engine out of combine.
H83705
–UN–08JUN05
H83706
OUO6083,0000D32 –19–30MAY06–4/4

083006
PN=102

suspended. 05
–UN–08JUN05
17

H83701
of lifting slings could damage the A—Lifting Eyes
cylinder head. B—JDG23 Lifting Sling
2. Install:

specification
Specification
Gear Case-to-Engine Cap
Screws—Torque ........................................................................... 340 N•m
(250 lb-ft)
• Front engine mount cap screws; tighten to

specification
Specification
(90 lb-ft)
3. Remove lifting sling (A) and lifting eyes (B).

083006
PN=103
NOTE: Fabricate two dowel pins, 6 mm (1/4 in.) x 150

mm (6 in.) long, to aid in aligning the fan
assembly.
4. Install fan (A), spacer (B), washer (C) and sheave (D)
20
05 onto hub (E) using dowel pins to aid in alignment.
–UN–09JUN05
18
5. Install several cap screws, remove dowel pins, install
remaining cap screws and tighten to specification.
H83707
Specification
Torque ............................................................................................ 80 N•m
(60 lb-ft)
A—Fan
B—Spacer
6. Install: C—Washer
D—Sheave
• Two piece fan shroud E—Hub
• Upper and lower radiator hoses; tighten to
specification
Specification
(97 lb-in.)
• Upper and lower charge air tubes: tighten to

specification
Specification
Clamps—Torque............................................................................. 11 N•m
(97 lb-in.)
• Heater hoses
• Alternator
• Fan drive and rotary screen drive belts
7. Connect:

8. Install engine covers and shields.

083006
PN=104
9. Fill:

20
05
10. Open fuel supply valve on bottom of tank. 19
11. Turn battery disconnect switch to “I” on position.
12. Follow engine break-in procedure in CTM400.
OUO6083,0000A68 –19–07JUL05–3/3
1. Disconnect batteries.
2. Remove intake duct and air cleaner assembly.
3. Remove shields as necessary.
4. Drain:
• Engine oil
Specification
Engine Oil With Filter—Capacity ......................................................... 42 L
(11.1 gal)

Specification
Cooling System with Tier II
Engine Deck—Capacity....................................................................... 55 L
(14.5 gal)
Cooling System with Tier III
Engine Deck—Capacity.................................................................... 67.7 L
(17.9 gal)

083006
PN=105
5. Shut off fuel supply valve (A) on bottom of fuel tank.
6. Remove:

20
05 • Engine wiring harness
–UN–10SEP02
20
A—Fuel Supply Valve
H73143
OUO6083,0000A69 –19–07JUL05–2/6
• Fuel supply line (A) and fuel return line (B). Cap
fittings on filter housing and plug fittings on hoses.
• Oil drain hose (C)
• Upper and lower charge air tubes
–UN–11SEP02
A—Fuel Supply Line
B—Fuel Return Line
C—Oil Drain Hose
H73149
OUO6083,0000A69 –19–07JUL05–3/6
• Rotary screen (C), engine fan (B), air conditioning

compressor/alternator (A) and drive belts
• Air conditioning compressor (E)
• Starter
–UN–21FEB01
• Alternator
• Engine fan (G), spacer (H) and fan shroud
H66412
A—Air Conditioning Compressor/Alternator Belt
B—Fan Belt
C—Rotary Screen Drive Belt
D—Cap Screw (3 used)
E—Air Conditioning Compressor
F—Cap Screw (6 used)
G—Engine Fan
H—Spacer

083006
PN=106

positioned under the load being lifted or
suspended.
20
05
–UN–03SEP02
CAUTION: The approximate weight of the 6125 21
Specification
Engine—Weight ............................................................................. 1205 kg
H73101
(2657 lb)
7. Install R128000 and R128001 lifting straps (B) using A—JDG23 Lifting Sling
M12 x 30 cap screws. Tighten to specification. B—Lifting Straps
Specification
Engine Lifting Straps Cap
Screws—Torque ........................................................................... 123 N•m
(91 lb-ft)
IMPORTANT: Use only a lifting sling like the JDG23,

of lifting slings could damage the
cylinder head.
8. Connect JDG23 Lifting Sling (A) to R128000 and

R128001 lifting straps (B).
9. Take up slack in lift chains before removing engine

mount cap screws.

083006
PN=107
10. Remove:
• Cap screws (A and B) on both sides of engine to

remove front motor mount (C)
• Cap screws (D) and swing support (E) out of the
20
05 way
• Cap screws and nuts (F)
–UN–21FEB01
22
11. Carefully move engine away from engine gear case.

Lift engine out of combine.
H66421
C—Front Motor Mount
E—Support
F—Cap Screw and Nut (4 used)
–UN–21FEB01
H66422
–UN–21FEB01
H66423
–UN–18OCT02
H73704
OUO6083,0000A69 –19–07JUL05–6/6

083006
PN=108

suspended. 05
–UN–03SEP02
23

H73101
of lifting slings could damage the A—JDG23 Lifting Sling
cylinder head. B—Lifting Straps
1. Carefully lift engine using JDG23 Lifting Sling (A) and

lifting straps (B). Lower engine to align with engine
gear case.
Specification
Engine—Weight ............................................................................. 1205 kg
(2657 lb)
Continued on next page OUO6083,0000A6A –19–07JUL05–1/4

083006
PN=109
2. Install:
• Gear case-to-engine cap screws and nuts (F);

tighten cap screws to specification
20
Specification
05
–UN–21FEB01
24
Screws—Torque ........................................................................... 340 N•m
(250 lb-ft)
H66421
• Front engine mounts (C); tighten cap screws (A and
B) to specification
Specification
(91 lb-ft)
–UN–21FEB01
• Variable drive support (E) with cap screws (D);
tighten to specification
H66422
Specification
Variable Drive Support-to-Engine
Cap Screws—Torque ................................................................... 350 N•m
(255 lb-ft)

C—Front Motor Mount
E—Variable Drive Support
F—Cap Screw and Nut (4 used)
–UN–21FEB01
H66423
–UN–18OCT02
H73704

083006
PN=110
• Air conditioning compressor (E) using cap screws

(D)
• Starter
• Alternator
• Heater hoses and clamps
20
• Lower radiator hose with clamps; tighten clamps to 05
–UN–21FEB01
specification 25
• Fan shroud
• Engine fan (G) and spacer (H); tighten cap screws
(F) to specification
H66412
Specification
Torque ............................................................................................ 80 N•m
A—Air Conditioning Compressor/Alternator Belt
(59 lb-ft)
B—Fan Belt
C—Rotary Screen Drive Belt
E—Air Conditioning Compressor
• Rotary screen drive belt (C), fan belt (B), air F—Cap Screw (6 used)
G—Engine Fan
conditioning compressor and alternator belt (A) (See H—Spacer
DRIVE BELT ROUTING in this section.)
• Engine and alternator wiring harnesses
• Upper radiator hose with clamps; tighten clamps to
specification
Specification
(106 lb-in.)

083006
PN=111
• Engine oil drain hose (C)

• Fuel return line (B), fuel supply line (A) and open
fuel shut off valve on bottom of tank
3. Connect engine wiring harness at all locations.

20
05
–UN–11SEP02
26 IMPORTANT: Insure charge air cooler tubes are free
of dirt and debris before reinstalling.
4. Install upper and lower charge air tubes with clamps.
H73149
Tighten clamps to specification.
Specification
Charge Air Cooler Tube Clamp— A—Fuel Supply Line
Torque ............................................................................................ 11 N•m B—Fuel Return Line
(97 lb-in.) C—Oil Drain Hose
5. Install air intake hose and tighten clamp to

specification.
Specification
Air Intake Hose Clamp—Torque .................................................... 11 N•m
(97 lb-in.)
6. Install:

• Engine covers and shields
• Air intake duct and air cleaner assembly
7. Fill engine with correct oil. (See FUEL AND

Specification
Engine Oil With Filter—Capacity ......................................................... 42 L
(11.1 gal)
8. Fill cooling system with coolant. (See FUEL AND

9. Connect batteries.
10. Bleed fuel system. (See procedure in Section 30,

Group 10.)
11. If engine was reconditioned, follow engine break-in

procedures in CTM100.
OUO6083,0000A6A –19–07JUL05–4/4

083006
PN=112
Group 10
Cooling System
Specifications
Radiator—6.8 L Engine Weight 56 kg

20
(123 lb) 10
1
(106 lb)

(146 lb)

(160 lb)
Radiator Hose Clamp—8.1 L Engine Torque 4.5 N•m

(40 lb-in.)
Radiator Hose Clamp—9.0 L and Torque 12 N•m

12.5 L Engines (106 lb-in.)
Air Tube Hose Clamp Torque 11 N•m

(97 lb-in.)
Charge Air Tube Clamp Torque 12 N•m

(106 lb-in.)
Engine Fan Cap Screws Torque 80 N•m

(59 lb-ft)
Coolant—6.8 L Engine Capacity 44 L

(11.6 gal)
Coolant—8.1 L Engine Capacity 53.3 L

(14.1 gal)
Coolant—9.0 L Engine Capacity 53.3 L

(14.1 gal)
Coolant—12.5 L Engine Capacity 55 L

(14.5 gal)
Radiator Test Pressure 124 kPa

(1.2 bar)
(18 psi)
Continued on next page OUO6083,0000DCF –19–21AUG06–1/2

083006
PN=113
Cooling System
Radiator Cap (9660 STS and 9760 Test Pressure 103.4 kPa
STS) (1.03 bar)
(15 psi)
20
10
2 Radiator Cap (9860 STS) Test Pressure 69 kPa
(0.7 bar)
(10 psi)
OUO6083,0000DCF –19–21AUG06–2/2

–UN–06DEC96

RW50283A
Diagnostic Manual
OUO6083,0000D39 –19–31MAY06–1/1

083006
PN=114
Cooling System
20
10
3

083006
PN=115
Cooling System
Rotary Screen Drive
1 2 3
4
20 5
10
6
4
5
8
7
1 13
24
9
25
13
26
1
15
5 27
14
6
10
13 5 28
8 29
4
16
11
18
17 19
20
12 21
22
15
23
21
19 18
38
36
14 35
34
33
–UN–24JAN06
32 30
25
37
31
H85272
Continued on next page OUO6083,0000D71 –19–21JUN06–1/2

083006
PN=116
Cooling System
1—Cap Screw 11—Shaft 20—Pin 30—Hook Bolt

2—Washer 12—Shaft Key 21—Seal 31—Spring Locking Pin
3—Sheave 13—Flanged Nut (6 used) 22—Bushing 32—Belt
4—Locking Collar (2 used) 14—Bolt 23—Arm 33—Cap Screw
5—Flange (4 used) 15—Nut 24—Nut (2 used) 34—Washer
6—Bearing (2 used) 16—Bracket (9660 STS and 25—Washer 35—Sheave
20
7—Belt 9760 STS) 26—Spring 36—Spacer
10
8—Cap Screw (6 used) 17—Cap Screw (2 used) 27—Gauge 37—Sheave
5
9—Support 18—Snap Ring (2 used) 28—Bushing (2 used) 38—Bracket (9560 STS and
10—Shaft Key 19—Washer (2 used) 29—Guide 9860 STS)
OUO6083,0000D71 –19–21JUN06–2/2
Rotary Screen Idler Arm and Sheaves
A D
E
E
E F
G I
H
J
K
L
K
P
M E
Q N
R
S O
P
–UN–01APR02
P
H71503
A—Belt F—Washer (2 used) K—Seal (2 used) P—Screw (3 used)

B—Sheave G—Bushing L—Bushing Q—Washer
C—Washer H—Bolt M—Support R— Pitman Arm
D—Bolt I—Bolt N—Spring S—Sheave
E—Flange Nut (4 used) J—Washer O—Washer (2 used)
OUO6083,0000D3C –19–31MAY06–1/1

083006
PN=117
Cooling System
Remove and Install Upper and Lower Air

Scoops
NOTE: Removal of upper and lower air scoops is not

20 necessary to remove rotary screen door.
10
6 1. Remove quick-lock pins (A).
A—Quick-Lock Pin (2 used)
–UN–18MAY05
H83504
RO33873,0000039 –19–19MAY05–1/3
2. Remove cap screws (A).
–UN–18MAY05
H83505
Continued on next page RO33873,0000039 –19–19MAY05–2/3

083006
PN=118
Cooling System
3. Remove cap screws (A). Lift upper scoop from

mounting tabs (B).
4. Install upper and lower scoops in reverse order.

20
A—Cap Screw (4 used) 10
B—Mounting Tabs (2 used) 7
–UN–18MAY05
H83507
RO33873,0000039 –19–19MAY05–3/3

083006
PN=119
Cooling System
Remove and Install Rotary Screen
20
10
8
31
3
1
4
30
2
29
8
21
28
1
20
5
26 17
27
1 6
22
24
22 16
15
14
25 23 19
7
13
18 8
9
5
12
11
10
–UN–05JUL05
H83483
Continued on next page OUO6083,0000C48 –19–24JAN06–1/5

083006
PN=120
Cooling System
1—Flange Nut 9—Air Duct 17—Screen 25—Door (2 used)

2— Cap Screw (17 used) 10—Washer (2 used) 18—Rake (2 used) 26—Clamp (4 used)
3—Support 11—Lock Nut (2 used) 19—Cap Screw (18 used) 27—Stud
4—Cap Screw 12—Brush 20—Brush 28—Washer
5—Cap Screw 13—Bushing 21—Hub 29—Wiring Lead
6—Knife 14—Hub 22—Cap Screw 30—Door
20
7—Washer 15—Washer 23—Cap Screw (2 used) 31—Seal
10
8—Cap Screw 16—Tapered Roller Bearing 24—Bracket
9
1. If equipped, remove upper and lower air scoops.

(See REMOVE AND INSTALL UPPER AND
LOWER AIR SCOOPS in Group 10.)
OUO6083,0000C48 –19–24JAN06–2/5
2. Remove rotary screen drive belt (A).
A—Drive Belt
–UN–16MAY05
H83467

083006
PN=121
Cooling System
3. Remove cap screws (A) and air duct (B).
4. Remove cap screw (C) and rotary screen.
5. Remove cap screws (D) and hub (E).

20
10
10 6. Repair or replace as necessary.
7. Install rotary screen in reverse order.

B—Air Duct
C—Cap Screw
E—Hub
–UN–06JUL05
H83916
–UN–24JAN06
H85278
OUO6083,0000C48 –19–24JAN06–4/5
8. Install rotary screen drive belt (A).
9. If equipped, install upper and lower air scoops. (See

REMOVE AND INSTALL UPPER AND LOWER AIR
SCOOPS in Group 10.)
–UN–15MAY00
A—Drive Belt
H63903
OUO6083,0000C48 –19–24JAN06–5/5

083006
PN=122
Cooling System
Adjusting Rotary Screen Knife Comb
Loosen cap screws (A) and position knife comb so rake

bar (B) passes through comb without interference.
20
–UN–18MAY04
B—Rake Bar 11
H80471
OUO6083,0000704 –19–17MAR04–1/1
Remove Radiator—6.8 L Engine

radiator is cool to the touch before draining
coolant.
–UN–01NOV88
1. Slowly open cap (A) on surge tank (B).
NOTE: The approximate coolant capacity is 44 L (11.6

gal).
T6642EK
2. Drain radiator.
3. Remove:
• Intake duct and air cleaner assembly

• Shields in obstruction of radiator
• Both charge air tubes
• Fan drive belt
–UN–01JUN06
A—Cap
B—Surge Tank
H86053
OUO6083,0000D44 –19–02JUN06–1/5
4. Remove hoses (A), cap screws (B), return hose clamp

(C) and surge tank with mounting plate (D).
A—Hose (2 used)
C—Return Hose Clamp
D—Surge Tank with Mounting Plate
–UN–01JUN06
H86060

083006
PN=123
Cooling System
5. Remove cap screws (A) and lower plate (B) to access

bottom of radiator.
6. Remove cap screw (C) from bottom of radiator.

20
10 A—Cap Screw (6 used)
–UN–28JUN05
12 B—Plate
C—Cap Screw
H83870
–UN–28JUN05
H83871

083006
PN=124
Cooling System
7. Remove radiator hoses including overflow hose.
8. Remove cap screws and washers (A) and move fan

shroud away from cooling package.
20
9. Remove cap screws and washers (B) inside cooling 10
–UN–01JUN06
package. 13
10. Remove cap screws and washers (C) from radiator in

front of engine fan.
H86067
A—Cap Screw and Washers (7 used)
B—Cap Screw and Washers (10 used)
C—Cap Screw and Washers (4 used)
–UN–30JUN05
H83877
–UN–30JUN05
H83879

083006
PN=125
Cooling System
11. Remove cap screws (A) and top plate (B).
CAUTION: Approximate weight of radiator is 56

kg (123 lb).
20
10 Specification
–UN–01JUN06
14 Radiator—Weight .............................................................................. 56 kg
(123 lb)
NOTE: Be careful not to damage radiator fins when lifting
H86068
from frame.
12. Attach proper lifting device (C) to radiator (D). Lift

straight up to remove from frame.

B—Top Plate
–UN–30JUN05
C—Lifting Device
D—Radiator
H83881
OUO6083,0000D44 –19–02JUN06–5/5
Install Radiator—6.8 L Engine

kg (123 lb).
Specification
Radiator—Weight .............................................................................. 56 kg
(123 lb)
NOTE: Be careful not to damage radiator fins when

installing.
1. Using proper lifting device, carefully lower radiator into

position. Remove lifting device.

083006
PN=126
Cooling System
NOTE: Loosely install all radiator mounting hardware.
2. Install top plate (B) using cap screws (A). Do not

tighten at this time.
20
–UN–01JUN06
B—Top Plate 15
H86068
OUO6083,0000D42 –19–02JUN06–2/5
3. Install cap screws and washers (A and B) and cap

screw (C).
4. Tighten all hardware.
A—Cap Screw and Washer (4 used)
–UN–30JUN05
B—Cap Screw and Washer (10 used)
C—Cap Screw
H83884
–UN–30JUN05
H83877
–UN–28JUN05
H83871

083006
PN=127
Cooling System
5. Install fan shroud using cap screws (A).
6. Install lower plate (B) using cap screws (C).
7. Install:
20
10
• Fan drive belt
–UN–01JUN06
16
• Both charge air tubes. Tighten clamps to
specification.
H86067
Specification
Torque ............................................................................................ 12 N•m
(106 lb-in.)
• Radiator hoses. Tighten clamps to specification.
Specification
–UN–30JUN05
Radiator Hose Clamp—Torque ...................................................... 12 N•m
(106 lb-in.)
H83886
B—Plate
C—Cap Screw (6 used)
OUO6083,0000D42 –19–02JUN06–4/5
8. Install surge tank with mounting plate (D), return hose

(C), cap screws (B) and hoses (A).
9. Close radiator drain valve.
10. Add coolant to radiator and install cap. Fill surge tank
–UN–01JUN06
to appropriate level.
Specification
Coolant—Capacity ............................................................................... 44 L
(11.6 gal)
H86060
11. Install shields, air intake duct and air cleaner

assembly. A—Hose (2 used)
C—Return Hose Clamp
D—Surge Tank with Mounting Plate
OUO6083,0000D42 –19–02JUN06–5/5

083006
PN=128
Cooling System

coolant. 20
10
–UN–01NOV88
17
1. Slowly loosen radiator cap.
NOTE: The approximate coolant capacity is 53.3 L (14.1

gal).
T6642EK
2. Drain radiator.
3. Remove:

• Radiator hoses
• Upper fan shroud
• Cooling fan
4. Install JDG19 Special Mounting Brackets and lifting

strap.

kg (106 lb).
Specification
(106 lb)

from frame.
5. Using an appropriate lifting device, apply just enough

tension to remove the slack from strap and support
radiator when the mounting bolts are removed.
6. Remove overflow hose.

083006
PN=129
Cooling System
7. Remove cap screws (A) and carefully lift radiator

straight up and out.
8. Clean and inspect radiator for damage. Repair or

replace radiator as necessary.
20
10
–UN–24APR01
18 9. Inspect seals for damage. Replace as necessary.
A—Cap Screws (7 used)
H67421
–UN–24APR01
H67422
–UN–09JUN03
H77700
OUO6083,0000D48 –19–02JUN06–2/2
1. Carefully lower radiator into position.

kg (106 lb).

installing.

083006
PN=130
Cooling System
2. Install:
• Cap screws (A)

• Overflow hose
• Cooling fan
20
10
–UN–24APR01
Specification 19
Cooling Fan Cap Screws—
Torque ............................................................................................ 80 N•m
(60 lb-ft)
H67421
• Upper fan shroud
• Radiator hoses
Specification
Radiator Hose Clamp—Torque ..................................................... 4.5 N•m
(40 lb-in.)
–UN–24APR01
• Rear charge air tube
Specification
H67422
Air Tube Hose Clamp—Torque ...................................................... 11 N•m
(97 lb-in.)
• Radiator cover shields

• Intake tube and air cleaner assembly
3. Close radiator drain valve and fill radiator with coolant.
–UN–09JUN03
Specification
Coolant—Capacity ............................................................................ 53.3 L
(14.1 gal)
H77700
OUO6083,0000D49 –19–02JUN06–2/2

083006
PN=131
Cooling System

20 coolant.
10
–UN–01NOV88
20
NOTE: The approximate coolant capacity is 53.3 L (14.1

gal).
T6642EK
2. Drain radiator.
3. Remove:

• Radiator hoses including overflow hose
• Upper charge air tube
• Fan drive belt
OUO6083,0000D47 –19–02JUN06–1/4
4. Remove cap screws (A) and lower plate (B) to access

bottom of radiator.
5. Remove cap screw (C) from bottom of radiator.
–UN–28JUN05
B—Plate
C—Cap Screw
H83870
–UN–28JUN05
H83871

083006
PN=132
Cooling System

shroud away from radiator.
7. Remove cap screws and washers (B) inside cooling

package.
20
10
–UN–01JUL05
8. Remove cap screws and washers (C) from radiator in 21
front of engine fan.
H83872
C—Cap Screw and Washer (4 used)
–UN–30JUN05
H83877
–UN–30JUN05
H83879

083006
PN=133
Cooling System

kg (146 lb).
20
10 Specification
–UN–30JUN05
22 Radiator—Weight .............................................................................. 66 kg
(146 lb)
H83880
from frame.
10. Attach proper lifting device (C) to radiator (D). Lift

straight up to remove from frame.

B—Top Plate
–UN–30JUN05
C—Lifting Device
D—Radiator
H83881
OUO6083,0000D47 –19–02JUN06–4/4

kg (146 lb).
Specification
(146 lb)

installing.
1. Using proper lifting device, carefully lower radiator into

position. Remove lifting device.

083006
PN=134
Cooling System
NOTE: Loosely install all radiator mounting hardware.

20
–UN–30JUN05
B—Top Plate 23
H83880
OUO6083,0000D43 –19–02JUN06–2/4
3. Install cap screws and washers (A and B) and cap

screw (C).
–UN–30JUN05
C—Cap Screw
H83884
–UN–30JUN05
H83877
–UN–28JUN05
H83871

083006
PN=135
Cooling System
5. Install fan shroud using cap screws (A).
6. Install lower plate (B) using cap screws (C).
7. Install:
20
10
• Fan drive belt
–UN–01JUL05
24
• Upper charge air tube. Tighten clamps to
specification.
H83872
Specification
Torque ............................................................................................ 12 N•m
(106 lb-in.)
• Radiator hoses. Tighten clamps to specification.
Specification
–UN–30JUN05
Radiator Hose Clamp—Torque ...................................................... 12 N•m
(106 lb-in.)
H83886
• Overflow hose
• Shields
• Air intake duct and air cleaner assembly A—Cap Screw and Washer (9 used)
B—Plate
8. Close radiator drain valve and fill radiator with coolant.
Specification
Coolant —9.0 L Engine—
Capacity ............................................................................................ 53.3 L
(14.1 gal)
OUO6083,0000D43 –19–02JUN06–4/4

083006
PN=136
Cooling System

coolant. 20
10
–UN–01NOV88
25
NOTE: The approximate coolant capacity is 55 L (14.5

gal).
T6642EK
Specification
Coolant—Capacity ............................................................................... 55 L
(14.5 gal)
2. Drain radiator.
3. Remove:

• Radiator hoses
• Overflow hose
• Cap screws, cooling fan and spacer

083006
PN=137
Cooling System
E
D
20
10
26
B
C
–UN–30JAN03
H74999
A—Cap Screw, Nut and C—Fan Shroud (Upper and D—Cap Screw (6 used) F—Cap Screw (4 used)
Washer (6 used) Lower) E—Cover
B—Cap Screw, Nut and
Washer (8 used)
• Cap screws, nuts, and washers (A and B) • Cap screws (D) and cover (E)
• Fan shroud (C) • Cap screws (F)

083006
PN=138
Cooling System
4. Using the appropriate lifting device, apply just

CAUTION: Approximate weight of radiator is
enough tension to remove the slack from strap and
73 kg (160 lb).
support radiator when the mounting bolts are
Specification removed.
Radiator—Weight........................................................................ 73 kg 20
(160 lb) 10
27
lifting from frame.
OUO6083,0000D45 –19–02JUN06–3/4
5. Remove cap screws (A, B and C). D

A
6. Carefully lift radiator (D) straight up and out.
7. Clean and inspect radiator for damage. Repair or

replace as necessary.

C
D—Radiator
–UN–30JAN03
B
H75000
B
OUO6083,0000D45 –19–02JUN06–4/4

083006
PN=139
Cooling System
Install Radiator—12.5 L Engine D

A

kg (160 lb).
20
10 NOTE: Be careful not to damage radiator fins when
28
installing.
1. Carefully lower radiator (D) into position.

C
Specification
(160 lb) A
–UN–30JAN03
2. Install:
B
• Cap screws and washers (A, B and C)
H75000
B
D—Radiator

083006
PN=140
Cooling System
E
D
20
10
29
B
C
–UN–30JAN03
H74999
Washer (8 used)
• Cap screws (F) • Fan shroud (C) using cap screws, nuts and
• Cover (E) and cap screws (D) washers (A and B)

083006
PN=141
Cooling System
• Overflow hose • Radiator cover shields

• Cooling fan and spacer; then tighten cap screws • Intake tube and air cleaner assembly
to specification
3. Close radiator drain valve and fill radiator with
Specification coolant.
20 Cooling Fan Cap Screws—
10 Torque...................................................................................... 80 N•m
30 Specification
(59 lb-ft)
Coolant—Capacity ........................................................................ 55 L
(14.5 gal)
• Radiator hoses and tighten clamps to

specification
Specification
Radiator Hose Clamp—Torque ............................................... 12 N•m
(106 lb-in.)
• Charge air tube and tighten clamp to specification
Specification
Charge Air Tube clamp—
Torque...................................................................................... 12 N•m
(106 lb-in.)
OUO6083,0000D46 –19–02JUN06–3/3
Test Radiator
Remove cap and visually check radiator for leaks or

damage.
Attach D05104ST tester in radiator neck. Pressurize

radiator according to specifications. Repair radiator if
–UN–15NOV88
pressure will not hold.
Specification
Radiator—Test Pressure ............................................................... 124 kPa
RW4517
(1.2 bar)
(18 psi)
AG,OUO6022,1718 –19–02JUN06–1/1

083006
PN=142
Cooling System
Test Radiator Cap
Install D05104ST tester on 9660 STS, 9760 STS and

9860 STS machines.
20
Install JDG839-2 tester on 9560 STS machines. 10
31
Pressurize cap and relief should occur close to
specifications.
Specification
–UN–29NOV88
Radiator Cap (9660 STS and
9760 STS)—Test Pressure ........................................................ 103.4 kPa
(1.03 bar)
(15 psi)
R26406N
Radiator Cap (9860 STS)—Test
Pressure .......................................................................................... 69 kPa
(0.7 bar)
(10 psi)
OUO6083,0000DCE –19–21AUG06–1/1
Replace Thermostats
To replace thermostats, refer to CTM86, CTM100,

CTM104 or CTM400.
–UN–06DEC96
RW50283A
OUO6083,000064F –19–02JUN06–1/1
Repair or Replace Water Pump
To repair or replace water pump, refer to CTM86,

CTM100, CTM104 CTM400.
–UN–06DEC96
RW50283A
OUO6083,0000A4A –19–02JUN06–1/1

083006
PN=143
Cooling System
20
10
32

083006
PN=144
Group 15
Lower Engine Repair
Remove and Install Engine Oil Pan Access
Sheet
IMPORTANT: Engine oil pan access sheet can be

reached through the upper inside rear 20
of the combine. 15
–UN–15JUN06
1
Removal of this sheet will allow access
to the engine oil pan area without
removing the engine.
H85432
1. Loosen nuts (A). Remove cap screws (B) and access
sheet (C).
2. Remove sheet (D) for access to engine oil pan.
A—Nuts (8 used)
C—Access Sheet
D—Engine Oil Pan Access Sheet
D
–UN–27FEB06
H85435
B C
OUO6083,0000C9A –19–27FEB06–1/1

083006
PN=145
Lower Engine Repair
20
15
2

083006
PN=146
Section 30
Fuel and Air Repair
Contents
Page
Group 05—Air Intake System

Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-1 30
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-2
Remove and Install Turbocharger—8.1 L
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-4
and 9.0 L Engine . . . . . . . . . . . . . . . . . . . . . .30-05-6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-9
Turbocharger Repair . . . . . . . . . . . . . . . . . . . .30-05-10
Remove and Install Charge Air Cooler—8.1 L
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-11
Remove and Install Charge Air Cooler—
6.8 L and 9.0 L Engine . . . . . . . . . . . . . . . .30-05-13
Remove and Install Charge Air Cooler—12.5
L Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-16
Cleaning the Charge Air Cooler. . . . . . . . . . . .30-05-21
Group 10—Diesel Fuel System

Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
Bleeding Fuel System 8.1 L 9660 (S.N.
—705934), 9760 (S.N. —705758) . . . . . . . . .30-10-2
Bleeding Fuel System 8.1 L Dual Filter
System 9660 (S.N. 705935—), 9760 (S.N. 705759—
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-3
Bleed Fuel System—12.5 L Engine. . . . . . . . . .30-10-7
Remove and Install Fuel Return Line
Regulator 9560 (S.N. —710250), 9660
(S.N. —710500) 9760 (S.N. —710600),
9860 (S.N. —710700) . . . . . . . . . . . . . . . . . .30-10-9
Remove and Install Fuel Tank. . . . . . . . . . . . .30-10-10
Remove and Install Fuel Tank Shut-Off
Valve and Drain Valve . . . . . . . . . . . . . . . . .30-10-12
Remove and Install Fuel Tank Strainer and
Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-14
Replace Cold Weather Starting Aid Can . . . . .30-10-15
Remove and Install Cold Weather Starting
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-15

083006
PN=1
Contents
30

083006
PN=2
Group 05
Air Intake System
Other Material
Number Name Use
TY24811 (U.S.) NEVER-SEEZ Protects parts against seizure,

corrosion, pitting, and galling.
TY24345 (U.S.) (U.S.) RTV Silicone Adhesive Sealant Used to seal out dust and debris
from the cooling package.
30
05
NEVER-SEEZ is a trademark of Emhart Chemical Group OUO6083,0000032 –19–19APR01–1/1 1

083006
PN=149
Air Intake System
Specifications
Turbocharger-to-Exhaust Manifold Torque 24 N•m

Cap Screws—8.1 L Engine (18 lb-ft)
Turbocharger-to-Exhaust Manifold Torque 40 N•m

Cap Screws—6.8 L and 9.0 L (30 lb-ft)
Engines
30
05 Turbocharger-to-Exhaust Manifold Torque 50 N•m
2
Cap Screws—12.5 L Engine (37 lb-ft)
Turbocharger Oil Return Line Torque 34 N•m

(25 lb-ft)
Hose Clamps (Intake Side) Torque 11 N•m

(97 lb-in.)
Hose Clamps (Turbo Side) Torque 11 N•m

(97 lb-in.)
Charge Air Cooler—6.8 L Engine Weight 20 kg

(44 lb)

(93 lb)

(57 lb)

(110 lb)
Engine Fan Cap Screws Torque 80 N•m

(59 lb-ft)
OUO6083,0000D4D –19–05JUN06–1/1

083006
PN=150
Air Intake System

–UN–06DEC96

RW50283A
System with Denso HPCR 30
• CTM86-8.1 L Diesel Engines, Repair 05
3
Diagnostic Manual
OUO6083,0000D39 –19–31MAY06–1/1

083006
PN=151
Air Intake System

Engine
1. Loosen clamps (A) to disconnect charge air cooler

hose (B).
–UN–29AUG05
2. Loosen clamps (C) to disconnect air intake hose (D).
3. Disconnect oil lines (E).
H84331
30 4. Loosen clamp (F) to disconnect muffler.
05
4
5. Remove four cap screws (G) and turbocharger. (See
CTM86 for turbocharger repair.) Plug and cap all A—Clamp (2 used)
B—Charge air cooler
openings to prevent contamination from entering C—Clamp (2 used)
system. D—Intake Hose
E—Oil Line (2 used)
IMPORTANT: If turbocharger oil seal has failed, all F—Clamp
intake system components must be G—Cap Screw (4 used)
cleaned and flushed, including the
charge air cooler. Any oil remaining in
the intake system may cause engine
overspeed and engine failure to occur.
(See CLEANING the CHARGE AIR
COOLER in this group.)
6. Prime (prelube) turbocharger rotating assembly prior to

installing turbocharger on engine. Prelube center
housing with clean engine oil through oil return (drain)
hole (E). Turn rotating assembly by hand to lubricate
bearings.
NOTE: Two threaded guide studs may be used to hold

turbocharger-to-exhaust manifold mounting
surface.
7. Put new gasket on turbocharger-to-exhaust manifold

mounting surface.
8. Position turbocharger against gasket in exhaust

manifold.
9. Apply TY24811 NEVER-SEEZ Compound to all

turbocharger mounting cap screws. Install cap screws
and tighten to specification.
Continued on next page OUO6083,0000B1E –19–14SEP05–1/2

083006
PN=152
Air Intake System
Specification
Turbocharger-to-Exhaust Manifold
Cap Screws (8.1 L Engine)—
Torque ............................................................................................ 24 N•m
(18 lb-ft)
10. Connect muffler and tighten clamp.
11. Connect oil return line and tighten to specification.
Specification
Turbocharger Oil Return Line— 30
Torque ............................................................................................ 34 N•m 05
(25 lb-ft) 5
12. Connect air intake hose and tighten clamps.
13. Connect charge air cooler and tighten clamps.
IMPORTANT: BEFORE STARTING an engine with a

new or repaired turbocharger, crank the
engine over (but do not start) for
several seconds to allow engine oil to
reach turbocharger bearings. DO NOT
crank engine longer than 30 seconds at
a time to avoid damaging the starting
motor.
14. Start and run engine at low idle while checking oil
inlet and air piping connections for leaks.
OUO6083,0000B1E –19–14SEP05–2/2

083006
PN=153
Air Intake System
Remove and Install Turbocharger—6.8 L and

9.0 L Engine
NOTE: Procedures for 6.8 L and 9.0 L are similar.
1. Loosen clamp (A) and remove air intake tube (B).
–UN–06JUL05
2. Loosen clamp (C) and remove exhaust pipe (D).
A—Clamp
H83899
30
B—Air Intake Tube
05
C—Clamp
6
D—Exhaust Pipe
–UN–06JUL05
H83900
Continued on next page OUO6083,0000D4C –19–05JUN06–1/4

083006
PN=154
Air Intake System
3. Loosen clamp (A) and remove boot (B).
4. Remove coolant drain line (C), coolant supply line (D)

and disconnect sensor connectors (E).
5. Remove oil supply line (F) and oil drain line (G) from
bearing housing.
–UN–06JUL05
6. Remove cap screws and washers (H) and
turbocharger. (See CTM104 or CTM400 for
H83901
turbocharger repair.) Plug and cap all openings to 30
prevent contamination from entering system. 05
7
IMPORTANT: If turbocharger oil seal has failed, all

intake system components must be
–UN–08JUL05
7. Prime (prelube) turbocharger rotating assembly prior to
H83917
installing turbocharger on engine. Prelube center
housing with clean engine oil through oil drain hole (G).
Turn rotating assembly by hand to lubricate bearings.
A—Clamp
B—Boot
C—Coolant Drain Line
turbocharger mounting cap screws. D—Coolant Supply Line
E—Connectors (2 used)
9. Position new gasket and turbocharger against exhaust F—Oil supply line
manifold. G—Oil Drain
H—Cap Screw and Washer (4 used)
10. Install cap screws (H) and tighten to specification.
Specification
Cap Screws (6.8 L and 9.0 L
Engines)—Torque........................................................................... 40 N•m
(30 lb-ft)
11. Install new gasket over cap screws and install flange
end of oil drain line to bearing housing. Tighten cap
screws to specification.
Specification
Turbocharger Oil Return Line—
Torque ............................................................................................ 34 N•m
(25 lb-ft)
Continued on next page OUO6083,0000D4C –19–05JUN06–2/4

083006
PN=155
Air Intake System
12. Install oil supply line.
13. Install coolant drain and supply lines.
14. Connect both sensor connectors.
30
05
8 OUO6083,0000D4C –19–05JUN06–3/4
15. Install air intake tube (B) and tighten clamp (A) to
specification.
Specification
Air Intake Tube Clamp—Torque .................................................... 11 N•m
(97 lb-in.)
–UN–06JUL05
16. Install exhaust pipe (D) and tighten clamp (C).

H83899
motor.
–UN–06JUL05
A—Clamp
B—Charge Air Cooler Tube
C—Clamp
H83900
D—Exhaust Pipe
OUO6083,0000D4C –19–05JUN06–4/4

083006
PN=156
Air Intake System

Engine
1. Loosen clamps (A) and disconnect boot (B) from

turbocharger.
–UN–19FEB01
2. Loosen clamps (C) and disconnect air intake hose (D).
3. Disconnect oil pressure and return lines (E and F).
H66453
4. Loosen clamp (G) and disconnect muffler. 30
05
9
5. Remove cap screws (H) and turbocharger. (See
CTM100 for turbocharger repair.) Plug and cap all
openings to prevent contamination from entering
system.
IMPORTANT: If turbocharger oil seal has failed, all

intake system components must be
–UN–19FEB01
H66454
6. Prime (prelube) turbocharger rotating assembly prior to A—Clamp (2 used)

B—Boot
installing turbocharger on engine. Prelube center C—Clamp (2 used)
housing with clean engine oil through oil pressure D—Intake Hose
fitting (F). Turn rotating assembly by hand to lubricate E—Oil Return
bearings. F—Oil Pressure
G—Clamp
H—Cap Screw (4 used)
turbocharger mounting cap screws.
8. Position new gasket and turbocharger against exhaust

manifold.
9. Install cap screws (H) and tighten to specification.
Specification
Cap Screws (12.5 L Engine)—
Torque ............................................................................................ 50 N•m
(37 lb-ft)
10. Connect muffler and tighten clamp (G).
Continued on next page OUO6083,0000A5E –19–06JUL05–1/2

083006
PN=157
Air Intake System
11. Connect oil pressure and return lines (E and F); then
tighten to specification.
Specification
Turbocharger Oil Lines—Torque .................................................... 34 N•m
(25 lb-ft)
12. Connect air intake hose (D) and tighten clamps (C).
13. Connect (B) and tighten clamps (A) to specification.

30
Specification
05
Hose Clamp (Turbocharger
10
Side)—Torque ................................................................................ 11 N•m
(97 lb-in.)

motor.
OUO6083,0000A5E –19–06JUL05–2/2
Turbocharger Repair

Use the component technical manual in conjunction with

–UN–06DEC96
this combine manual.
For turbocharger repair see CTM86, CTM100, CTM104 or

CTM400.
RW50283A
OUO6083,0000D4B –19–02JUN06–1/1

083006
PN=158
Air Intake System

Engine
1. Remove:

• Shields covering charge air cooler
• Charge air cooler tubes
• Two piece fan shroud
30
CAUTION: Approximate weight of charge air 05
cooler is 42 kg (93 lb). 11
NOTE: Be careful not to damage charge air cooler fins

and/or seals when lifting from frame.
2. Remove cap screws (A), and lift charge air cooler

straight up and out.
Specification
Charge Air Cooler—Weight ............................................................... 42 kg
(93 lb)
Continued on next page OUO6083,0000567 –19–01MAY03–1/3

083006
PN=159
Air Intake System
3. Clean and inspect charge air cooler for cracks and/or

damage.
4. Inspect seals for tears and/or cracks.
5. Repair or replace charge air cooler and seals as
–UN–08MAY01
necessary.
6. Slide charge air cooler down into position. Check to

see that all seals are in place prior to further
H67547
30 installation.
05
12
–UN–09JUN03
H77700
–UN–08MAY01
H67548

083006
PN=160
Air Intake System
7. Install:
• Cap screws (A)

• Two piece fan shroud
• Shields over charge air cooler
•
–UN–08MAY01
Intake tube and air cleaner assembly
H67547
30
05
13
–UN–09JUN03
H77700
–UN–08MAY01
H67548
OUO6083,0000567 –19–01MAY03–3/3

and 9.0 L Engine
NOTE: Procedures for 6.8 L and 9.0 L are similar.
1. Remove:

Continued on next page OUO6083,0000D4E –19–05JUN06–1/5

083006
PN=161
Air Intake System

shroud away from charge air cooler.
3. Remove cap screws and washers (B) inside cooling

package.
4. Remove cap screws and washers (C) from charge air
–UN–07JUL05
cooler in front of engine fan.
H83924
30 B—Cap Screw and Washer (10 used)
05 C—Cap Screw and Washer (4 used)
14
–UN–07JUL05
H83922
–UN–30JUN05
H83879

083006
PN=162
Air Intake System
CAUTION: Approximate weight of charge air

coolers are: 6.8 L—20 kg (44 lb) and 9.0 L—26
kg (57 lb).
–UN–30JUN05
NOTE: Be careful not to damage charge air cooler fins
when lifting from frame.
Specification
H83880
Charge Air Cooler—6.8 L 30
Engine—Weight ................................................................................. 20 kg 05
(44 lb) 15
Charge Air Cooler—9.0 L
Engine—Weight ................................................................................. 26 kg
(57 lb)
6. Attach proper lifting device (C) to charge air cooler (D).

Lift straight up to remove from frame.
–UN–07JUL05
damage. Repair or replace as necessary.
8. Install seals and carefully lower charge air cooler into
H83923
frame.

B—Top Plate
C—Lifting Device
D—Charge Air Cooler
OUO6083,0000D4E –19–05JUN06–3/5
NOTE: Loosely install all mounting hardware.


–UN–30JUN05
B—Top Plate
H83880

083006
PN=163
Air Intake System
10. Install cap screws (A and B). Tighten all hardware.
11. Install fan shroud.
12. Install charge air cooler tubes. Tighten clamps to

specification.
–UN–30JUN05
Specification
Clamps—Torque............................................................................. 11 N•m
(97 lb-in.)
H83884
30
05
16 13. Install shields, air cleaner assembly and intake tube.

–UN–07JUL05
H83922
OUO6083,0000D4E –19–05JUN06–5/5
Remove and Install Charge Air Cooler—12.5

L Engine
1. Remove:

• Overflow hose
• Engine fan and spacer

083006
PN=164
Air Intake System
E
D
30
05
17
B
C
–UN–30JAN03
H74999
Washer (8 used)
• Cap screws, nuts, and washers (A and B) • Cap screws (D) and cover (E)
• Fan shroud (C) • Cap screws (F)

083006
PN=165
Air Intake System
2. Attach suitable lifting device to cooler.

CAUTION: Approximate weight of charge air
cooler is 50 kg (110 lb).
NOTE: Be careful not to damage cooler fins when

lifting cooler from frame.
30
05
18 OUO6083,0000A61 –19–07JUL05–3/7
3. Remove cap screws and washers (A, B and C). D
A
Specification
Charge Air Cooler—Weight ............................................................... 50 kg
(110 lb)
4. Lift charge air cooler (D) straight up and out.

damage. Repair or replace as necessary. C

A
D—Charge Air Cooler
–UN–30JAN03
B
H75001
B

083006
PN=166
Air Intake System
6. Carefully lower charge air cooler (D) into frame. D
A
7. Install:
• Cap screws and washers (A, B and C). Remove

lifting device

C
D—Charge Air Cooler 30
05
19
–UN–30JAN03
B
H75001
B

083006
PN=167
Air Intake System
E
D
30
05
20
B
C
–UN–30JAN03
H74999
Washer (8 used)
• Cap screws (F) • Fan shroud (C) using cap screws, nuts and
• Cover (E) and cap screws (D) washers (A and B)

083006
PN=168
Air Intake System
• Overflow hose • Lower charge air tube and tighten clamp to

• Cooling fan and spacer; then tighten cap screws specification
to specification
Specification
Specification Charge Air Tube Clamp—
Cooling Fan Cap Screws— Torque...................................................................................... 11 N•m
Torque...................................................................................... 80 N•m (97 lb-in.)
(59 lb-ft)
• Radiator and charge air cooler cover shields

30
05
IMPORTANT: Keep charge air cooler tubes clean: 21
Ensure tubes are free of dirt and
debris before reinstalling.
• Upper charge air tube and tighten clamp to

specification
Specification
Charge Air Tube Clamp—
Torque...................................................................................... 11 N•m
(97 lb-in.)
OUO6083,0000A61 –19–07JUL05–7/7
Cleaning the Charge Air Cooler
NOTE: Replacing the charge air cooler is the best option.

This is the only way to be sure that all oil is
removed from the system. However, the charge
air cooler may be cleaned if replacement is not an
option.
1. Remove charge air cooler from combine (See

REMOVE AND INSTALL CHARGE AIR COOLER in
this group).
2. Fill cooler with a mixture of water and a grease cutting

dish soap (1 oz. soap per gallon of water).
3. Thoroughly rinse with clean water. Repeat several

times.
4. Use compressed air to completely dry charge air

cooler.
5. Reinstall charge air cooler in combine (See REMOVE

AND INSTALL CHARGE AIR COOLER in this group).
OUO6083,000050A –19–27MAR03–1/1

083006
PN=169
Air Intake System
30
05
22

083006
PN=170
Group 10
Diesel Fuel System
Other Material
Number Name Use
PM37398 (U.S.) Pipe Sealant with TEFLON Seal threads on shut off valve.
30
10
OUO6083,0000CBE –19–13MAR06–1/1 1
Specifications
Fuel Tank —9560 Capacity 757 L

(200 gal)
Fuel Tank —9660 and 9670 Capacity 945 L

(250 gal)
Fuel Tank —9860 Capacity 1155 L

(305 gal)
Fuel Tank —9560 Weight 56 kg

(124 lb)
Fuel Tank —9660 and 9760 Weight 54.4 kg

(120 lb)
Fuel Tank —9860 Weight 72 kg

(158 lb)
Shut Off Valve Hose Clamp Torque 4.5 N•m

(40 lb-in.)
Diagnostic Port Torque 14 N•m

(124 lb-in.)
OUO6083,0000CBC –19–13MAR06–1/1

083006
PN=171
Diesel Fuel System
Bleeding Fuel System 8.1 L 9660 (S.N. —

705934), 9760 (S.N. —705758)
1. Check fuel level and add diesel if necessary.
2. Place a suitable container under water separator bowl
–UN–06AUG01
(A) and momentarily open drain valve (B) to relieve
any pressure within filter and to drain any water or
contaminates, then close drain valve. This step will
prevent pressure release from the diagnostic port as it
H69578
30 is opened in Step 3.
10
2 Water Separator Drain
3. Thoroughly clean area around diagnostic port (C).
Connect JT03472 coupler and hose to diagnostic port
(C) and bleed fuel into suitable container. If coupler is
not available, loosen the diagnostic fitting to allow air
and fuel to escape.
4. Unlock and operate hand primer (D) until a steady fuel

flow free of air flows out of the diagnostic port (C).
–UN–29APR03
(Primer must be pulled up fully between pumps).
NOTE: It can take up to 350 primer strokes until fuel

flows steadily from diagnostic port (C) if the
H76232
system was emptied of fuel.
Diagnostic Port
5. Close the diagnostic port while continuing to pump the
hand primer. Tighten to specification:
Specification
Diagnostic Port—Torque ................................................................ 14 N•m
(124 lb-in.)
CAUTION: If engine has not been cranked after
–UN–29APR03
pumping the hand primer, fuel lines will be
under pressure. Wear face protection and
loosen fittings slowly in order to relieve
pressure and avoid excessive spraying of fuel.
H76233
NOTE: DO NOT attempt bleeding the high pressure lines Injection Pump
at the injector inlets on the cylinder head.
A—Water Separator bowl
B—Drain Valve
6. Completely loosen and unseat high pressure lines (E) C—Diagnostic Port
at the injection pump. Pump the hand primer (D) until D—Hand Primer
fuel free of air flows steadily from both open ports of E—High Pressure Fuel Lines
injection pump. Reattach and tighten the high pressure
lines to specification and lock the hand primer.
Continued on next page OUO6083,0000705 –19–18MAR04–1/2

083006
PN=172
Diesel Fuel System
Specification
High Pressure Fuel Lines—
Torque ............................................................................... 27 Nm (20 lb-ft)
NOTE: It can take an additional 150 primer strokes to

prime fuel to the injection pump high pressure
outlets.
7. Start engine and run 3 to 5 minutes at low idle. DO

NOT crank engine for more than 30 seconds. If engine
does not start or will not keep running, repeat Step 6.
30
10
OUO6083,0000705 –19–18MAR04–2/2 3
Bleeding Fuel System 8.1 L Dual Filter

System 9660 (S.N. 705935—), 9760 (S.N.
705759—)
CAUTION: High-pressure fluid remaining in fuel

lines can cause serious injury. Only technicians
–UN–18MAR92
familiar with this type of system should perform
repairs. Before disconnecting fuel lines,
sensors, or any other components between the
high-pressure fuel pump and nozzles on
TS1343
engines with High Pressure Common Rail
(HPCR) fuel system, wait a minimum of 15
minutes after engine is stopped.
IMPORTANT: Do not attempt to pressurize the fuel

tank with compressed air or any other
means. Fuel tank and surrounding
structural damage could result.
–UN–17OCT03
1. Close fuel supply gate valve (A).
2. Check fuel level and add clean diesel fuel if necessary.
H78645
NOTE: Greater fuel quantity in the tank will result in
easier priming.
A—Fuel Supply Valve
Continued on next page OUO6083,0000C9B –19–28FEB06–1/5

083006
PN=173
Diesel Fuel System
3. Loosen fuel filter check valve inlet fitting (A) to allow air
to pass.
4. Thoroughly clean area around precleaner bowl (B) and

remove bowl. Remove any contaminates from bowl
and screen. Inspect O-ring and reinstall bowl.
–UN–17OCT03
NOTE: Removing precleaner bowl is necessary to break
any air lock between precleaner and fuel filter inlet
check valve that may have occurred if machine
H78646
30 was run out of fuel.
10
4
5. Open fuel supply gate valve. Precleaner should
immediately fill with fuel.
A—Fuel Filter Check Valve

B—Fuel Precleaner Bowl
–UN–20OCT03
H78668
OUO6083,0000C9B –19–28FEB06–2/5
6. Tighten fuel filter check valve (A) inlet fitting.
Specification
Low Pressure Fuel Line—Torque .................................................. 27 N•m
(20 lb-ft)
–UN–17OCT03
A—Fuel Filter Check Valve
H78646

083006
PN=174
Diesel Fuel System
7. Loosen transfer pump outlet fitting (A) to allow air and

fuel to bleed.
Unlock and operate hand primer (B) until steady fuel

flow (free of air bubbles) is present out the transfer
pump outlet fitting. Primer must be pulled up fully
–UN–17OCT03
between pumps. Tighten fitting to specification.
Specification
(20 lb-ft)
H78621
30
10
NOTE: It can take up to 200 primer strokes until fuel High Pressure Pump 5
flows steadily at this point if the system was
emptied of fuel. A—Transfer Pump Outlet Fitting (Low Pressure)
B—Hand Primer
C—High Pressure Pump Inlet Fitting (Low
8. Loosen high pressure pump inlet fitting (C) on high
Pressure)
pressure pump. Operate hand primer until steady fuel D—High Pressure Pump Outlet Fitting (High
flow (free of air bubbles) is present out the high Pressure)
pressure pump inlet fitting. Primer must be pulled up E—High Pressure Pump Outlet Fitting (High
fully between pumps. Tighten fitting to specification. Pressure)
Specification
(20 lb-ft)
NOTE: It can take up to 200 additional primer strokes

until fuel flows steadily at this point if the system
was emptied of fuel.
9. Completely loosen and unseat high pressure line (D)

on high pressure pump. Operate hand primer until
steady fuel flow (free of air bubbles) is present out the
open high pressure pump fitting. Tighten the fitting to
specification.
Specification
High Pressure Pump Outlet
Fitting—Torque ............................................................................... 27 N•m
(20 lb-ft)

083006
PN=175
Diesel Fuel System
NOTE: It can take up to 150 additional primer strokes

until fuel flows steadily at this point if the system
10. Completely loosen and unseat the high pressure line

(E) on high pressure pump. Operate hand primer until
steady fuel flow (free of air bubbles) is present out the
open high pressure pump fitting. Tighten the fitting to
specification and lock the hand primer.
30 Specification
10 High Pressure Pump Outlet
6 Fitting—Torque ............................................................................... 27 N•m
(20 lb-ft)
NOTE: It can take up to 50 additional primer strokes until

fuel flows steadily at this point if the system was
emptied of fuel.
11. Start engine and run 3 to 5 minutes at low idle. DO

NOT crank engine for more than 30 seconds. If
engine does not start after three attempts or will not
keep running, repeat steps 9— 11 until the engine
starts and runs normally.
OUO6083,0000C9B –19–28FEB06–5/5

083006
PN=176
Diesel Fuel System
Bleed Fuel System—12.5 L Engine
1. Check fuel level and add diesel if necessary.
2. Place a suitable container under water separator bowl

(A) and momentarily open drain valve (B) to relieve
–UN–11DEC01
any pressure within filter and to drain any water or
contaminates, then close drain valve. This step will
prevent pressure release from the diagnostic port as it
is opened in Step 4.
H70464
30
3. Remove cover (C) and clean area around diagnostic 10
7
port.
4. Connect JT03472 coupler and hose (D) to diagnostic

port (E). Remove fuel tank cap and install other end of
hose into the fuel tank. If coupler is not available,
loosen the diagnostic port to allow air and fuel to
escape.
–UN–11DEC01
NOTE: It can take up to 350 primer strokes until fuel
flows steadily from diagnostic port if the system
H70465
5. Operate hand primer (F) until a steady fuel flow free of
air flows out of the diagnostic port. (Primer must be
released fully between pumps.)
6. Disconnect from or tighten the diagnostic port to

specifications. Reinstall fuel fill cap.
Specification
Diagnostic Port—Torque ................................................................ 14 N•m
(124 lb-in.)
A—Water Separator Bowl

B—Drain Valve
C—Diagnostic Port Cover
D—Coupler
–UN–11DEC01
E—Diagnostic Port
F—Hand Primer
H70467
Continued on next page OUO6083,000056C –19–01MAY03–1/2

083006
PN=177
Diesel Fuel System
7. Disconnect fuel return hose (A) from right-hand side of

filter header.
8. Cap off the fitting (B) on the filter base (Cap 38H1415).
9. Plug end of hose with fitting (C) to keep dirt out (Plug
–UN–12DEC01
38H1146, O-ring T77613).
10. Pump hand primer 50 times.
H70477
30
10 CAUTION: DO NOT crank for more than 30
8 seconds at a time. Let starter cool down for at
least 1 minute before cranking is resumed.
11. Crank engine for 20 seconds.
12. Repeat Steps 10 and 11 until engine starts (2-3 times

typical).
–UN–12DEC01
13. Run for 1 minute at low idle.
14. Shut engine off.
H70466
15. Remove cap and plug, and reconnect fuel hose to
filter base.
A—Return Hose
B—Fitting
C—Fitting
OUO6083,000056C –19–01MAY03–2/2

083006
PN=178
Diesel Fuel System
Remove and Install Fuel Return Line

Regulator 9560 (S.N. —710250), 9660 (S.N. —
710500) 9760 (S.N. —710600), 9860 (S.N. —
710700)
NOTE: Fuel return line regulator is installed on 8.1 L
–UN–01MAY03
engines only.
1. Remove hoses (A, B, and C).
H76279
30
2. Remove the fuel regulator (D) from fuel block (E). 10
9
A—Fuel Cooler Hose
B—Injection Pump Return Hose
C—Fuel Tank Hose
D—Fuel Regulator
E—Fuel Block
–UN–01MAY03
H76280
OUO6083,0000C9C –19–28FEB06–1/2
IMPORTANT: Fuel regulator is stamped with an arrow

to show proper direction of flow. Install
regulator with arrow pointing in
direction shown to assure proper
operation.
–UN–01MAY03
3. Install fuel regulator with arrow (D) pointing in direction
shown.
4. Install fuel hoses (A, B and C).
A—Fuel Cooler Hose H76283

B—Injection Pump Return Hose
C—Fuel Tank Hose
D—Fuel Flow
–UN–01MAY03
H76279
OUO6083,0000C9C –19–28FEB06–2/2

083006
PN=179
Diesel Fuel System
Remove and Install Fuel Tank
1. Remove:
• Rear body style panel. (See REMOVE AND

INSTALL REAR WALL PANEL in Section 80.)
• Straw chopper. (See REMOVE STRAW CHOPPER
–UN–10DEC03
in Section 120.)
2. Drain fuel tank using drain valve (A).
H79365
30
10 Specification
10 Fuel Tank —9560—Capacity ............................................................ 757 L
(200 gal)
A—Drain Valve
Fuel Tank —9660 and 9670—
Capacity ............................................................................................. 945 L
(250 gal)
Fuel Tank —9860—Capacity .......................................................... 1155 L
(305 gal)
3. Remove fuel tank access cover from engine deck.
Continued on next page OUO6083,0000CBB –19–13MAR06–1/3

083006
PN=180
Diesel Fuel System
4. Disconnect fuel sender connectors (A), return line (B),

vent hose (C) and supply hose (D).
CAUTION: The fuel tank is heavy and varies in

weight between models. Use proper lifting
device and be certain tank is adequately
–UN–30OCT02
supported prior to removing hardware.
Specification
Fuel Tank —9560—Weight ............................................................... 56 kg
H73929
(124 lb) 30
Fuel Tank —9660 and 9760— 10
Weight............................................................................................ 54.4 kg 11
(120 lb)
Fuel Tank —9860—Weight ............................................................... 72 kg
(158 lb)
5. Support fuel tank using safe lifting device.
A—Harness (2 used)
–UN–30OCT02
B—Return Line
C—Vent Hose
D—Supply Hose
H73930
–UN–11DEC03
H79408
Continued on next page OUO6083,0000CBB –19–13MAR06–2/3

083006
PN=181
Diesel Fuel System
6. Remove:
• Attaching hardware and rear support (A)

• Attaching hardware, two rear supports and actuator
support (B) as one assembly
• Attaching hardware and channel (C)
• Fuel tank
–UN–03FEB99
H51939
30 8. Install:
10
12
• Fuel tank, supports, and attaching hardware
• Straw chopper. (See INSTALL STRAW CHOPPER
in Section 120.)
• Rear body styling panel. (See REMOVE AND
INSTALL REAR WALL PANEL in Section 80.)
A—Rear Support
–UN–03FEB99
B—Actuator Support
C—Channel
H51940
OUO6083,0000CBB –19–13MAR06–3/3
Remove and Install Fuel Tank Shut-Off Valve

and Drain Valve
1. Drain fuel tank at valve (A).
Specification
–UN–22DEC03
Fuel Tank—Capacity ......................................................................... 945 L
(250 U.S. gal)
A—Fuel tank Drain Valve

H79684
OUO6083,0000CBD –19–13MAR06–1/5
2. Close fuel tank shut-off valve (A) and remove supply

hose (B).
A—Shut-Off Valve
B—Supply Hose
–UN–22DEC03
H79685
Continued on next page OUO6083,0000CBD –19–13MAR06–2/5

083006
PN=182
Diesel Fuel System
3. Loosen clamp (A) and remove valve (B or C). Repair

or replace as necessary.
4. Apply PM37398 pipe sealant with TEFLON to threads

on valve (B and C) and install into fuel tank.
–UN–22DEC03
5. Tighten clamp (A) to specification.
Specification
Fuel Tank Shut-Off Valve and
Drain Valve Clamp—Torque ......................................................... 4.5 N•m
H79686
30
40 lb-in.
10
13
A— Clamp (2 used)
B—Fuel Shut-Off Valve
C—Fuel Tank Drain Valve
OUO6083,0000CBD –19–13MAR06–3/5
6. Check condition of O-ring on shut-off valve (A) and

install supply hose (B).
A—Shut-Off Valve
B—Supply Hose
–UN–22DEC03
H79685
OUO6083,0000CBD –19–13MAR06–4/5
7. Close fuel tank drain valve (A) and fill tank. Check for
leaks.
Specification
(250 U.S. gal)
–UN–22DEC03
A—Fuel tank Drain Valve

H79684
OUO6083,0000CBD –19–13MAR06–5/5

083006
PN=183
Diesel Fuel System
Remove and Install Fuel Tank Strainer and

Breather
1. Remove cap (A) and strainer (B).
2. Inspect parts and replace as necessary.
–UN–08MAY01
3. Install strainer and cap.
4. Inspect supply hose and vent hose for cracks.
H67576
30
10
14 A—Cap
B—Strainer
–UN–19FEB01
H66490
OUO6083,0000A7C –19–13JUL05–1/2
5. Remove breather (A), located above hydraulic

reservoir, from fitting (B). Inspect and replace as
necessary.
6. Inspect vent hose (C) for cracks.
–UN–24MAY04
7. Install breather.
A—Breather
B—Fitting
C—Vent Hose H80938
OUO6083,0000A7C –19–13JUL05–2/2

083006
PN=184
Diesel Fuel System
Replace Cold Weather Starting Aid Can
CAUTION: Starting fluid is highly flammable. Do

not use fire, sparks or flames. Read the
cautionary information on the container. Protect
container against damage.
–UN–03MAY99
IMPORTANT: To avoid drawing dust into engine,
always keep a starting fluid can in
position.
H55983
30
10
NOTE: Not used on 6.8 L engines. 15
A—Canister
1. Remove safety cap and plastic spray nozzle from new
container.
2. Loosen canister (A) to remove old can.
3. Install new can and tighten canister.
OUO6083,0000D72 –19–21JUN06–1/1
Remove and Install Cold Weather Starting

Aid
NOTE: Not used on 6.8 L engines.
1. Remove parts (A—F).
2. Inspect parts for wear or damage. Replace if

necessary.
–UN–03MAY99
3. Install parts (A—F).

H55984
B—Connector
C—Injector Line
D—Can
E—Canister
F—Body

083006
PN=185
Diesel Fuel System
4. If starting aid does not operate properly, disconnect

line (A) and remove spray nozzle (B) from manifold.
5. Clean nozzle and install nozzle and line.
IMPORTANT: Be sure nozzle is secure in adapter. If
–UN–03MAY99
nozzle is loose, engine may be
damaged. However, over tightening will
break nozzle.
H55985
30
A—Injector Line
10
B—Nozzle
16
OUO6083,0000D73 –19–21JUN06–2/2

083006
PN=186
Section 40
Electrical System
Contents
Page Page
Group 05—Batteries Left-Hand Main Wiring Harness (Tier III

Prevent Battery Explosions . . . . . . . . . . . . . . . .40-05-1 Cooling Package) . . . . . . . . . . . . . . . . . . . . .40-15-7
Handling Batteries Safely . . . . . . . . . . . . . . . . .40-05-2 Right-Hand Main Wiring Harness . . . . . . . . . . .40-15-8
Prevent Damage to Electrical Systems . . . . . . .40-05-3 Right-Hand Main Wiring Harness (Tier III
Checking Electrolyte Specific Gravity . . . . . . . .40-05-4 Cooling Package) . . . . . . . . . . . . . . . . . . . . .40-15-9
Battery Replacement . . . . . . . . . . . . . . . . . . . . .40-05-5 Engine Wiring Harness . . . . . . . . . . . . . . . . . .40-15-10
Remove and Install Batteries. . . . . . . . . . . . . . .40-05-6 Engine Wiring Harness (Tier III Cooling 40
Connecting Booster Batteries . . . . . . . . . . . . . .40-05-8 Package) . . . . . . . . . . . . . . . . . . . . . . . . . . .40-15-11
Charging Batteries. . . . . . . . . . . . . . . . . . . . . . .40-05-9
Connecting Battery Cables . . . . . . . . . . . . . . .40-05-11 Group 20—Fuses, Circuit Breakers and Relays
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .40-20-1
Group 10—Harness and Connector Repair Basic Operation. . . . . . . . . . . . . . . . . . . . . . . . .40-20-2
Essential or Recommended Tools . . . . . . . . . . .40-10-1 Power Distribution Board System Basic
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-4 Description. . . . . . . . . . . . . . . . . . . . . . . . . . .40-20-3
Use Electrical Insulating Compound . . . . . . . . .40-10-5 Circuit Board Replacement . . . . . . . . . . . . . . . .40-20-3
Using High-Pressure Washers . . . . . . . . . . . . .40-10-5 Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-20-5
Electrical System Visual Inspection . . . . . . . . . .40-10-5 Power Distribution Board Relay
Basic Electrical Component Handling / Identification . . . . . . . . . . . . . . . . . . . . . . . . .40-20-6
Precautions for Vehicles Equipped with Engine Compartment Relay Panel Fuse
Computer Controlled Systems . . . . . . . . . . . .40-10-6 Identification . . . . . . . . . . . . . . . . . . . . . . . . .40-20-7
Electrical Connector / Wiring Harness Engine Compartment Relay Panel
Handling and Repair . . . . . . . . . . . . . . . . . . .40-10-7 Identification . . . . . . . . . . . . . . . . . . . . . . . . .40-20-8
Repair Procedure R-A . . . . . . . . . . . . . . . . . . . .40-10-7
Repair Procedure R-B . . . . . . . . . . . . . . . . . . .40-10-12 Group 25—Lighting
Repair Procedure R-C. . . . . . . . . . . . . . . . . . .40-10-15 Safety Rules When Replacing Halogen
Repair Procedure R-D. . . . . . . . . . . . . . . . . . .40-10-19 Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-25-1
Repair Procedure R-E . . . . . . . . . . . . . . . . . . .40-10-20 Bulb Part Numbers . . . . . . . . . . . . . . . . . . . . . .40-25-2
Repair Procedure R-F . . . . . . . . . . . . . . . . . . .40-10-23 Cab Head Light Bulb Replacement and
Repair Procedure R-G. . . . . . . . . . . . . . . . . . .40-10-25 Adjustment (S.N. —715300) . . . . . . . . . . . . .40-25-3
Repair Procedure R-I . . . . . . . . . . . . . . . . . . .40-10-27 Cab Head Light Bulb Replacement and
Repair Procedure R-J . . . . . . . . . . . . . . . . . . .40-10-28 Adjustment (S.N. 715301—) . . . . . . . . . . . . .40-25-3
Repair Procedure R-K . . . . . . . . . . . . . . . . . . .40-10-33 Remove and Install High Intensity
Repair Procedure R-M . . . . . . . . . . . . . . . . . .40-10-35 Discharge (HID-Xenon) Lights (Optional) (S.N. —
Repair Procedure R-N. . . . . . . . . . . . . . . . . . .40-10-37 715300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-25-4
Repair Procedure R-AE. . . . . . . . . . . . . . . . . .40-10-40 Remove and Install High Intensity
Discharge (HID-Xenon) Lights (Optional)
Group 15—Wire Harness Routing (S.N. 715301—). . . . . . . . . . . . . . . . . . . . . . .40-25-6
Replace Harness. . . . . . . . . . . . . . . . . . . . . . . .40-15-1 Remove and Install High Intensity
Cab Main Wiring Harness (S.N. —715300) . . . .40-15-2 Discharge (HID-Xenon) Ballasts (S.N. 715301—
Cab Main Wiring Harness (S.N. 715301—) . . . .40-15-3 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-25-8
Auxiliary Cab Main AUTOTRAC Wiring Auxiliary Field, Access Door, Grain Tank,
Harness (S.N. —715300). . . . . . . . . . . . . . . .40-15-4 Unload Auger and Work Light Bulb
Auxiliary Cab Main AUTOTRAC Wiring Replacement . . . . . . . . . . . . . . . . . . . . . . . . .40-25-9
Harness (S.N. 715301—). . . . . . . . . . . . . . . .40-15-5
Left-Hand Main Wiring Harness. . . . . . . . . . . . .40-15-6 Continued on next page

083006
PN=1
Contents
Page Page
Side Finder (Optional) Light Bulb Remove and Install Backlight Bulbs for
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .40-25-9 DIAL-A-SPEED and Active Header Control
Front Turn Signal, Tail and Side Light Bulb Switches . . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-23
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .40-25-9 Remove and Install COMMANDTOUCH
Harzard/Warning Light Bulb Replacement . . . .40-25-10 Console Membrane Switches. . . . . . . . . . . .40-30-24
Cleaning Shoe Light Bulb Replacement . . . . .40-25-10 Remove and Install COMMANDTOUCH
Turn Signal Light Bulb Replacement . . . . . . . .40-25-10 Console Circuit Board . . . . . . . . . . . . . . . . .40-30-28
Dome and Console Light Bulb Replace Neutral Safety Switch . . . . . . . . . . . .40-30-29
Replacement . . . . . . . . . . . . . . . . . . . . . . . .40-25-11 Replace Mini Harness . . . . . . . . . . . . . . . . . . .40-30-30
COMMANDTOUCH Cornerpost Monitor Light Remove and Install Multi-Function Handle . . .40-30-31
Bulb Replacement . . . . . . . . . . . . . . . . . . . .40-25-12 Remove and Install Start Switch . . . . . . . . . . .40-30-32
Warning Display Panel Light Bulb Remove and Install Starting Aid Switch. . . . . .40-30-33
Replacement . . . . . . . . . . . . . . . . . . . . . . . .40-25-13 Remove and Install Turn Signal/Side Finder
40 Light Switch . . . . . . . . . . . . . . . . . . . . . . . . .40-30-33
Group 30—Operators Station Remove and Install Horn Switch . . . . . . . . . . .40-30-34
Remove and Install Remote Mirrors
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-1
(Optional). . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-34
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-1
Remove and Install Remote Mirror Switch
Instruments and Controls Identification . . . . . . .40-30-2
(S.N. —715300) (Optional) . . . . . . . . . . . . .40-30-35
Overhead Warning Display Panel . . . . . . . . . . .40-30-3
Remove and Install Overhead Warning
(S.N. 715301—) (Optional) . . . . . . . . . . . . .40-30-36
Display Panel. . . . . . . . . . . . . . . . . . . . . . . . .40-30-4
Replace Overhead Warning Display Panel
Group 35—Sensors and Switches
Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . .40-30-5
Remove and Install Light Panel Dimmer
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-1
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-2
Remove and Install Overhead Display Rocker
Shaft Speed Sensor Locations . . . . . . . . . . . . .40-35-3
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-6 Remove and Install Ground Speed Sensor . . . .40-35-5
Remove and Install CLIMATRAK Automatic Remove And Install Low Shaft Speed
Air Conditioning/Heater Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-5
Control Switch and Fan Switch . . . . . . . . . . .40-30-7 Remove and Install STS Rotor Speed
Remove and Install Radio . . . . . . . . . . . . . . . . .40-30-7 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-6
Remove and Install Radio Speaker (S.N. Remove and Install Full Grain Tank Sensor . . .40-35-7
—715300) . . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-8 Remove and Install Tailings Sensor . . . . . . . . .40-35-7
Remove and Install Radio Speaker (S.N. Remove and Install (Shoe/Separator)
715301—) . . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-9 VISIONTRAK Sensors . . . . . . . . . . . . . . . .40-35-8
Remove and Install Radio Antenna (S.N. Remove and Install Concave Position
—715300) . . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-9 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-8
Remove and Install Radio Antenna (S.N. Remove and Install Header Height and
715301—) . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-10 CONTOUR MASTER Control Sensors. . . . . .40-35-9
Replace Cornerpost Main Circuit Board . . . . .40-30-11 Remove and Install Multi-Function Handle
Remove Header Control Module . . . . . . . . . . .40-30-15 Feed Rate Sensor . . . . . . . . . . . . . . . . . . . .40-35-10
Remove Automatic Combine Adjustment Remove and Install Hydraulic Reservoir
(ACA) Display . . . . . . . . . . . . . . . . . . . . . . .40-30-15 Temperature Sensor . . . . . . . . . . . . . . . . . .40-35-16
Remove Performance Monitor and Digital Remove and Install Hydraulic Reservoir
Tachometer Module . . . . . . . . . . . . . . . . . . .40-30-16 Temperature Sensor (Tier III Cooling
COMMANDTOUCH Console Controls . . . . . . .40-30-18 Package) . . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-16
Remove and Install COMMANDTOUCH Remove and Install Coolant Temperature
Console . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-20 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-17
Remove and Install Header and Separator Remove and Install Coolant Temperature
Engage Switches . . . . . . . . . . . . . . . . . . . . .40-30-21 Sensor (Tier III Cooling Package) . . . . . . . .40-35-19
Remove and Install DIAL-A-SPEED and
Active Header Control Switches. . . . . . . . . .40-30-22 Continued on next page

083006
PN=2
Contents
Page Page
Remove and Install Fuel Level Sensor . . . . . .40-35-21 John Deere Engine Accessories—
Remove and Install Park Brake Switch . . . . . .40-35-21 Alternator Repair—Use CTM77 . . . . . . . . . . .40-45-2
Remove and Install Air Filter Restriction Remove and Install Alternator and
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-22 Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . .40-45-3
Remove and Install Air Filter Restriction Remove and Install Voltage Regulator (185
Switch (Tier III Cooling Package). . . . . . . . .40-35-22 Amp Leece-Neville) . . . . . . . . . . . . . . . . . . . .40-45-7
Remove and Install Fuel Pressure Switch . . . .40-35-23 Remove and Install Alternator Pulley (200
Remove and Install Engine Gear Case Amp Bosch) . . . . . . . . . . . . . . . . . . . . . . . . . .40-45-8
Temperature and Pressure Switches . . . . . .40-35-23
Remove and Install Hydro Charge Group 50—Starting Motor
Pressure Switch. . . . . . . . . . . . . . . . . . . . . .40-35-24 Essential or Recommended Tools . . . . . . . . . . .40-50-1
Remove and Install Engine Oil Pressure Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .40-50-2
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-24 John Deere Starting Motor Repair—Use
Remove and Install Engine Oil Pressure CTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-50-2 40
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-25 Remove and Install Starting Motor . . . . . . . . . .40-50-2
Remove and Install Switches in the
Ground Level Switch Bank. . . . . . . . . . . . . .40-35-25 Group 55—Electrical Engine Control
Remove and Install Compressor Inlet Electronic Governor and Speed Controller
Temperature Sensor—9.0 L. . . . . . . . . . . . .40-35-26 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-55-1
Remove and Install Camshaft Position
Sensor—9.0 L . . . . . . . . . . . . . . . . . . . . . . .40-35-26 Group 60—GREENSTAR Components
Remove and Install Crankshaft Position Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .40-60-1
Sensor—9.0 L . . . . . . . . . . . . . . . . . . . . . . .40-35-27 Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .40-60-1
Remove and Install Exhaust Gas Remove and Install GREENSTAR Mass-Flow
Recirculation (EGR) Exhaust Gas Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-60-2
Temperature, Fresh Air Temperature Remove and Install GREENSTAR
and Exhaust Manifold Pressure Sensors—9.0 Moisture Sensor. . . . . . . . . . . . . . . . . . . . . . .40-60-5
L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-27 Disassemble and Assemble GREENSTAR
Remove and Install Intake Manifold Pressure Moisture Sensor. . . . . . . . . . . . . . . . . . . . . . .40-60-6
and Exhaust Gas Recirculation (EGR) Remove and Install GREENSTAR Moisture
Mixed Gas Temperature Sensor—9.0 L. . . .40-35-28 Sensor Actuator . . . . . . . . . . . . . . . . . . . . . . .40-60-7
Remove and Install Turbocharger Speed Remove and Install GREENSTAR
Sensor—9.0 L . . . . . . . . . . . . . . . . . . . . . . .40-35-28 Moisture Sensor Circuit Board . . . . . . . . . . . .40-60-9
Remove and Install Fuel Rail Pressure Remove and Replace GREENSTAR
Sensor—9.0 L . . . . . . . . . . . . . . . . . . . . . . .40-35-29 Moisture Sensor Lower Cell Assembly. . . . .40-60-11
Remove and Install Back-Up Alarm Switch . . .40-35-29 Disassemble and Assemble Position
Back-Up Alarm (S.N. —715300) . . . . . . . . . . .40-35-30 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . .40-60-24
Back-Up Alarm—9860 (S.N. 715301—) . . . . .40-35-31 Remove and Install Position Receiver . . . . . . .40-60-25
Back-Up Alarm—9560, 9660, 9760 (S.N.
715301—) . . . . . . . . . . . . . . . . . . . . . . . . . .40-35-32
Group 40—Wiper
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-1
Remove and Install Wiper Motor . . . . . . . . . . . .40-40-1
Adjust Windshield Wiper . . . . . . . . . . . . . . . . . .40-40-4
Remove and Install Windshield Washer (S.N.
—715300) . . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-6
Remove and Install Windshield Washer (S.N.
715301—) . . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-8
Group 45—Alternator
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .40-45-2

083006
PN=3
Contents
40

083006
PN=4
Group 05
Batteries
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204
AG,OUO6022,1484 –19–03MAY00–1/1
40
05
1

083006
PN=189
Batteries
Handling Batteries Safely

–UN–23AUG88
hydrometer.
TS204
CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin, eat
40
05 holes in clothing, and cause blindness if
2 splashed into eyes.

added.

the acid.
–UN–23AUG88
TS203
not exceed 2 L (2 quarts).
WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
AG,OUO6022,1735 –19–24JUL00–1/1

083006
PN=190
Batteries
Prevent Damage to Electrical Systems
To prevent damage to electrical system components,

always observe these precautions:
1. When working on electrical systems powered from the

batteries disconnect ground wire from both batteries
prior to performing repair.
2. Never disconnect the batteries with the key switch on
or the engine running.
3. Never connect jumper cables with the key switch on.
–UN–11JUL05
4. Disconnect batteries when charging them.
5. The combine should be jump started by 12 volts
ONLY.
H83378
6. Always charge the batteries with a charger set for 12
volts.
40
7. Never connect or disconnect wiring harness connectors 05
with the key switch on. 3
8. Do not apply power or ground to any component as a
test, unless instructed.
OUO6046,000207D –19–23SEP05–1/1

083006
PN=191
Batteries
Checking Electrolyte Specific Gravity

–UN–23AUG88
hydrometer.
TS204
Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in
40 clothing, and cause blindness if splashed into
05 eyes.
4

added.

the acid.
–UN–23AUG88
TS203
not exceed 1.9 L (2 quarts).
Check the specific gravity of electrolyte in each battery

cell using a battery and coolant tester such as JT05460
Battery/Coolant Tester.
–UN–10NOV88
Follow directions included with the tester.

T85402
Continued on next page OUO6083,0000640 –19–12JUN03–1/2

083006
PN=192
Batteries
A fully charged battery will have a corrected specific

gravity reading of 1.265—1.280. If the reading is below
1.225, charge the battery. Replace battery if difference
between cells is more than 0.050.
OUO6083,0000640 –19–12JUN03–2/2
Battery Replacement
Two 12-volt batteries connected in parallel provide a

12-volt electrical system.
When replacing batteries, use John Deere batteries or
–UN–19MAR02
equivalent. Both batteries must have the same rating.
40
05
H71339
5
OUO6083,000023B –19–19MAR02–1/1

083006
PN=193
Batteries
Remove and Install Batteries
CAUTION: Avoid serious injury or death from

explosions. High levels of hydrogen gas can
accumulate if the battery box is not vented
properly. Always reinstall the vent tubes (A)
–UN–07JUN05
after performing service or maintenance on the
batteries or the battery box. Verify that the
ventilation hoses are not bent or kinked.
H83517
Replacement batteries must have a ventilation
fitting suited for ventilation hose attachment.
If ventilation tubes are not attached to the

battery then the battery lid must remain off
40 whenever the machine engine is running or
05 whenever the batteries are being charged with
6
an external charger.
–UN–18AUG05
1. If equipped, turn switch (B) counterclockwise to “O” off
position (C).
2. If equipped, remove cap screws (D) and cover (E) to
H84250
access batteries.
A—Vent Tubes
B—Switch
C—“O” Off Position
D—Cap Screw (2 used
E—Cover
–UN–18AUG05
H84251
Continued on next page OUO6083,0000AF4 –19–18AUG05–1/2

083006
PN=194
Batteries
3. Disconnect negative (-) cable (B) using JT05841 clamp

spreader/cleaner or JT05840 and then disconnect
positive (+) cable (A).
NOTE: Batteries located on the right-hand side are C

equipped with vent tubes that will need to be A
removed.
4. Remove battery clamp (C) to remove batteries.
5. Clean batteries and batteries mounting area. Inspect

vent tubes for cracks. Replace as necessary.
6. Install batteries using clamp (C).
7. Connect positive (+) cable (A) and then negative (-) B

40
cable (B).
–UN–07JUN02
05
7
8. If equipped, install battery box cover and turn switch
clockwise to “I” on position.
H72429
A—Positive Cable and Terminals
B—Negative Cable and Terminals Batteries (Engine Deck Location)
C—Clamp
Batteries (Right-Hand Side Location) –UN–11JUL05

H83385
OUO6083,0000AF4 –19–18AUG05–2/2

083006
PN=195
Batteries
Connecting Booster Batteries
Cold weather starting can be easier by connecting an

additional 12-volt battery in parallel.
CAUTION: Gas given off by batteries is
–UN–09MAY05
explosive. Avoid sparks near batteries.
IMPORTANT: Never connect jumper cables with key

switch or battery disconnect switch (B)
H83397
on. Never jump-start with more than 12
volts. Batteries (Engine Deck Location)
For machines with batteries on engine deck:
40 First jumper cable must connect positive (+) post of

05 booster battery to positive (+) post of combine battery (C).
8
Second jumper cable must first be connected to negative
(-) post of booster battery and then to a good ground on
combine, away from combine batteries.
For machines with batteries on right-hand side:
First jumper cable must connect positive (+) post of
–UN–06MAY05
booster battery to positive (+) post of combine battery (C).
Second jumper cable must first be connected to negative
(-) post of booster battery and then to negative (-) post (A)
of combine battery.
H83383
A—Negative Post
Batteries (Right-Hand Side Location)
B—Switch
C—Positive Post
OUO6046,000207E –19–23SEP05–1/1

083006
PN=196
Batteries
Charging Batteries
Inspect Battery for Any Obvious Problems
• Make sure battery is clean and free of dirt and debris.

• Verify that electrolyte level is above battery plates.
• Clean any corrosion off battery posts and verify that
connections are good.
• Check battery case for any cracks or leaks.
• Verify that battery cables are in good condition.
• Test Battery using JT07347 Accuracy Plus
Battery/Charging System Tester.
Determine the Battery State of Charge
To determine the battery state of charge, the specific

40
gravity (SG) of the electrolyte will be taken with a 05
hydrometer. The hydrometer’s readings must be 9
compensated for temperature using the instructions
accompanying the hydrometer or Table 1.
Table 1
Electrolyte Temperature Fahrenheit Electrolyte Temperature Celsius Add or Subtract to Hydrometer’s SG Reading
160° 71.1° +.032
150° 65.6° +.028
140° 60.0° +.024
130° 54.4° +.020
120° 48.9° +.016
110° 43.3° +.012
100° 37.8° +.008
90° 32.2° +.004
80° 26.7° 0
70° 21.1° -.004
60° 15.6° -.008
50° 10° -.012
40° 4.4° -.016
30° -1.1° -.020
20° -6.7° -.024
10° -12.2° -.028
0° -17.8° -.032
Take a reading of each of the cells. After compensating

for temperature, average the cells of the battery and
compare them to Table 2.
Continued on next page OUO6046,000202B –19–29AUG05–1/3

083006
PN=197
Batteries
Table 2
Specific Gravity State of Charge
1.265—1.280 100%
1.225 75%
1.190 50%
1.155 25%
1.120 Discharged
If all cells should read at least 1.225 SG and show only

slight variation in readings and are within 0.050 SG of
each other, the battery is probably only discharged. If after
charging, the SG between cells varies 0.050 or more
there is likely a bad cell, replace the battery. If after
charging the SG remains virtually unchanged, the battery
is likely sulfated and may be recovered by placing on
40 charge at a slow rate, 3 or 4 amps, for 24 hours or until
05
the battery is gassing freely.
10
Recharge the Battery
Recharge the battery to 95% state of charge, a

temperature corrected specific gravity of 1.270. Follow the
battery charger manufacturers recommendations for best
results.
Battery Storage
1. Check the electrolyte level and make sure it is full for

each cell. Clean all debris and moisture off of the
battery.
2. When storing the machine for an extended period of

time it is recommended that the batteries be fully
recharged. Batteries should be fully charged before
storing the machine to extend the life of the batteries. If
the batteries state of charge drops below 80% (12.60
Volts) the batteries should be charged to 100% (12.75
Volts). If the batteries are not fully charged, battery life
may be reduced significantly.

083006
PN=198
Batteries
3. It is also recommended that the negative battery cable

be removed from battery when storing machine for
more than one month if machine is not equipped with a
disconnect switch. If machine is equipped with a
disconnect switch, it is recommended that switch be
turned counterclockwise to “O” off position. This
precautionary procedure will minimize battery
discharge.
4. Batteries should be stored in a cool dry place, if

possible. Battery discharge is largely dependant upon
temperature and will discharge much quicker at high
temperatures.
40
05
11
OUO6046,000202B –19–29AUG05–3/3
Connecting Battery Cables
CAUTION: BATTERIES ARE NEGATIVE

GROUNDED ONLY. Always connect battery
ground strap to negative (-) posts of battery.
Connect starter cable to positive (+) post of
battery. Reversed polarity in battery or
alternator connections results in permanent
damage to electrical system. Connect ground
strap to negative (-) terminal last.
–UN–11JUL05
IMPORTANT: Batteries must have same terminal
locations.
H83378
When connecting batteries:
Turn off all switches and accessories. Clean battery posts

and terminals.
Connect starter cable to positive (+) post of battery.
Connect negative (-) battery ground cable.
OUO6046,000207F –19–23SEP05–1/1

083006
PN=199
Batteries
40
05
12

083006
PN=200
Group 10
Harness and Connector Repair
ESSENTIAL TOOLS listed are required to perform the
job correctly and are obtainable only from
Catalogs.
SERVICEGARD is a trademark of Deere & Company OUO6083,0000803 –19–06OCT04–1/16
RW40022 –UN–08SEP93
Electrical Repair Tool Kit. . . . . . . . . . . . . . . . . JDG155

40
Used to repair electrical connectors. 10
1
OUO6083,0000803 –19–06OCT04–2/16
T6606AB –UN–23AUG88
DEUTSCH Electrical Repair Tool Kit . . . . . . . . JDG359
Used to remove and install DEUTSCH terminals from

connector housings.
DEUTSCH is a trademark of Deutsch Co. OUO6083,0000803 –19–06OCT04–3/16
H79330 –UN–08DEC03
Packard Crimping Tool . . . . . . . . . . . . . . . . . .JDG783
Used to crimp WEATHER PACK male and female

connectors on 14—20 gauge wires.
WEATHER PACK is a trademark of Packard Electric. OUO6083,0000803 –19–06OCT04–4/16
RW40022 –UN–08SEP93
Technician’s Electrical Repair Kit . . . . . . . . . . JT07195B
Used to repair wire connectors.
Continued on next page OUO6083,0000803 –19–06OCT04–5/16

083006
PN=201
H75562 –UN–12MAR03
1
WEATHER PACK Extractor. . . . . . . . . . . . . . . JDG364
Repair WEATHER PACK connectors.
1
Included in JT07195B Electrical Repair Kit
OUO6083,0000803 –19–06OCT04–6/16
H75563 –UN–12MAR03
Electrician’s Pliers . . . . . . . . . . . . . . . . . . . . . JDG1451

40
10 Strip insulation from wire.
2
1
Included in JDG155 Electrical Repair Tool Kit
OUO6083,0000803 –19–06OCT04–7/16
H75578 –UN–12MAR03
12—14 Gauge Extractor . . . . . . . . . . . . . . . . JDG3611
To extract contacts from DEUTSCH connector bodies.
1
Included in JDG359 DEUTSCH Electrical Repair Tool Kit
OUO6083,0000803 –19–06OCT04–8/16
H75578 –UN–12MAR03
16—18 Gauge Extractor . . . . . . . . . . . . . . . . . JDG3621
1

083006
PN=202
H75578 –UN–12MAR03
1
20 Gauge Extractor . . . . . . . . . . . . . . . . . . . .JDG363
1
OUO6083,0000803 –19–06OCT04–10/16
H75583 –UN–12MAR03
Crimper. . . . . . . . . . . . . . . . . . . . . . . . . . . .JDG3601
40
To crimp closed-barrel contacts. 10
3
1
OUO6083,0000803 –19–06OCT04–11/16
H75625 –UN–13MAR03
DEUTSCH Terminal Tool . . . . . . . . . . . . . . . JDG13831
To remove secondary lock and terminals.
1
OUO6083,0000803 –19–06OCT04–12/16
H80211 –UN–04FEB04
Crimping Pliers . . . . . . . . . . . . . . . . . . . . . . . JDG1441
To crimp contacts.
1

083006
PN=203
H75627 –UN–13MAR03
1
Terminal Extraction Tool . . . . . . . . . . . . . . . . . JDG777
To remove contacts from connector body.
1
OUO6083,0000803 –19–06OCT04–14/16
H75633 –UN–13MAR03
Terminal Extraction Tool . . . . . . . . . . . . . . . . . JDG1401

40
10 To remove contacts from connector body.
4
1
OUO6083,0000803 –19–06OCT04–15/16
–UN–09SEP03
Flexbox Terminal Repair Kit . . . . . . . . . . . . . JDG17441
Used to repair CINCH wire connectors

RXA0070456
CINCH is a trademark of Cinch Inc.
1
Includes JDG1725 Terminal Removal Tool and JDG1727 Crimping Tool
OUO6083,0000803 –19–06OCT04–16/16
Other Material
Number Name Use
TY16329 (U.S.) Electronic Contact Cleaner Used to prevent contact failure or

malfunction by dissolving and rinsing
away contaminants.
AT66865 (U.S.) Di-electric Grease Used to provide a moisture barrier

on electrical connectors.
AG,OUO6038,1684 –19–22JUL05–1/1

083006
PN=204
Use Electrical Insulating Compound
Apply AT66865 Compound directly to the terminals

between the wire seal and connector body. This provides
a moisture barrier, especially in wet and humid conditions.
OUO6090,000001A –19–18MAY01–1/1
Using High-Pressure Washers

40
IMPORTANT: Directing pressurized water at 10
electronic/electrical components or 5
connectors, bearings and hydraulic
seals, fuel injection pumps or other
–UN–18OCT88
sensitive parts and components may
cause product malfunctions. Reduce
pressure, and spray at a 45 to 90
degree angle.
T6642EJ
OUO6090,000000C –19–16MAY01–1/1
Electrical System Visual Inspection
Visual inspection of the electrical system’s wiring • Bare wires and/or shorts to ground
harnesses and components for the following items can • Loose wires and/or open circuits
significantly reduce diagnostic time: • Poor/corroded connections
• Battery condition (terminal corrosion, voltage, cold
• Mechanical damage to the wiring harness covering cranking amperage capacity, electrolyte level)
or harness itself • Alternator condition (dirty, belt tension)
• Disconnected or damaged connectors • Overheated or discolored components
KC01776,00003CE –19–19MAR01–1/1

083006
PN=205
Basic Electrical Component Handling / Precautions for Vehicles Equipped with Computer
Controlled Systems
• Never disconnect the batteries while the key switch Why: This can cause computer system errors from
is on and the engine is running. interrupting a computer program while it is running
Why: This can cause electrical voltage spikes that and electrical voltage spikes that are produced can
can damage electronic components. damage electronic components.
• Do not connect jumper cables while the key switch • Do not apply power or ground to any component as
is on. a test unless specifically instructed to do so.
Why: This can cause electrical voltage spikes that Why: Connecting the wrong voltage to the wrong
can damage electronic components. point of an electronic system can cause electronic
component failures.
• Disconnect batteries prior to recharging (if possible)
Why: Electrical loads in the machine can slow the • When welding on the machine, make sure to
40 recharging process. Battery chargers can cause connect ground lead to the parts being welded. For
10 electrical voltage spikes that can damage electronic maximum protection disconnect all electronic
6 components. controllers before welding.
Why: The high currents associated with welding can
• Never jump start the machine with a voltage higher damage wiring harnesses that are involved in the
than the machine is designed to operate on ground path. Welding can also cause electrical
Why: This can damage electronic components voltage spikes that can damage electronic
components.
• Do not connect or disconnect electrical connectors
while the key switch is on or the machine is running.
KC01776,00003CF –19–19MAR01–1/1

083006
PN=206
Electrical Connector / Wiring Harness Handling and Repair
• Electrical connectors must not be forcibly mated or by this action may not be readily visible, but may
un-mated. prevent new terminals from being properly retained
Why: The connectors have been designed to be and cause replacement of the connector body.
mated easily. If you have to use tools or excessive
force you may be doing something wrong. Prying on • When installing a new terminal on a wire make sure
or forcing connectors may cause permanent damage the proper crimping tools is used.
to the locking mechanism, contacts or both. Why: Each part of the electrical terminal is designed
for a specific purpose, failure to properly crimp the
• When working on connectors make sure you are terminal can result in future electrical or mechanical
working on the correct terminal! problems. Terminal crimping tools are available
Why: Measuring diagnostic values at the wrong through SERVICEGARD. It is important to make
connector terminal can lead to unnecessary part sure the insulation and wire crimps on each terminal
replacement. The male and female halves of an are made properly. Soldering terminals is not
electrical connector are mirror images of each other recommended. See repair procedures in the
40
and it is easy to confuse terminal locations. Look for Connector Repair Procedures Group 10
the terminal identifier info on the connector body. 7
• Soldering splices is not recommended.
• Use proper terminals for any connector repairs. Why: Any repairs to wires in the harness should not
Why: In some connectors different terminal materials allow moisture to come in contact with the actual
are used (to carry different currents). If improper copper conductor. Soldering a wire splice is not
terminals or terminal materials are used future recommended because a portion of stranded wire
electrical problems may occur from corrosion or will become solid and can cause it to break in the
current carrying capacity. future, especially if it is subject to movement. When
repairing a broken wire in a wiring harness, use
• When removing terminals from a connector body it is "Heat-Shrinkable" butt splices. Be careful not to
very important to use the proper extraction tool and place a splice in any section of the harness subject
procedure. Extraction tools are available through to motion or flexing.
SERVICEGARD.
Why: The connector body can be damaged if
terminals are just "jerked" out. The damage caused
KC01776,00003D0 –19–19MAR01–1/1
Repair Procedure R-A
Remove Contact From Connector Body
Continued on next page OUO6030,00001D7 –19–19FEB03–1/7

083006
PN=207
1. Open secondary lock (C) by gently prying locking tabs

(A) off locking studs (B).
A—Locking Tab
B—Locking Stud
C—Secondary Lock
–UN–19FEB03
H74026
40
10
8
–UN–19FEB03
H74027

083006
PN=208
2. Insert JDG364 WEATHER PACK Extractor1 (A) into

connector body socket from mating face (C) as shown
depressing locking tabs (B) and gently pull contact out
in the direction of arrow.
A—JDG364, WEATHER PACK Extractor
B—Locking Tabs
–UN–29APR03
C—Mating Face
D—Wire Entry
H74028
B
D 40
10
9
–UN–19FEB03
C
B
H74011–UN–29APR03
H74029
C D
B
–UN–19FEB03
B
H74012
WEATHER PACK is a trademark of Packard Electric
1

083006
PN=209
Install New Contact
1. Remove contact and strip wire using JDG145

Electrician’s Pliers1.
2. Insert wire (A) through seal (B) and position as shown.
–UN–19FEB03
A—Wire
B—Seal
H74030
40
10
10
1

083006
PN=210
3. Place wire and seal (A) in contact (D) as shown and

crimp both wire crimp (C) and seal crimp (B) using
JDG783 Packard Crimping Tool.
A—Wire and Seal

B—Seal Crimp
–UN–19FEB03
C—Wire Crimp
D—Contact
H74031
40
10
11
–UN–19FEB03
H74032
–UN–19FEB03
H74034
OUO6030,00001D7 –19–19FEB03–5/7
IMPORTANT: Make sure contact is fully seated and

locked.
4. Install contact in connector body in appropriate socket.

Slide contact in until locking tabs click into place.
–UN–19FEB03
H74033

083006
PN=211
NOTE: If secondary lock is difficult to close, contact may

not be properly seated or locked.
5. Close secondary lock (C) until locking tabs (B) securely

lock over locking studs (A).
–UN–19FEB03
A—Locking Stud
B—Locking Tab
C—Secondary Lock
H74035
OUO6030,00001D7 –19–19FEB03–7/7
Repair Procedure R-B

40
10 Remove Contact From Connector Body
12
1. Select correct size extractor tool for size of wire to be
removed:
• JDG361 Extractor Tool1 for 12—14 gauge wire

• JDG362 Extractor Tool1 for 16—18 gauge wire
• JDG363 Extractor Tool1 for 20 gauge wire
1

083006
PN=212
2. Start correct size extractor tool (A) over wire and slide
rearward along wire until tool tip snaps onto wire.
IMPORTANT: Do NOT twist tool when inserting in

connector.
–UN–24FEB03
3. Slide extractor tool along wire into connector body until
it is positioned over terminal contact and depressing
locking tabs (B).
H75297
4. Pull wire out of connector body using extractor tool.
Install New Contact

B
–UN–24FEB03
40
10
A—Extractor Tool 13
B—Locking Tabs
B
H75290
–UN–24FEB03
H75296
1

083006
PN=213
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.
–UN–24FEB03
4. Insert contact (D) and turn adjusting screw (C) until
contact is flush with cover (E). Tighten lock nut (B).
5. Insert wire (F) into contact (D) and crimp until handle
H75295
touches stop.
6. Release handle and remove contact.
IMPORTANT: If all wire strands are not crimped into

contact, cut off wire at contact and
40
10 repeat contact installation procedures.
14
7. Inspect contact to be certain all wires are in crimped
–UN–24FEB03
barrel.
A—Selector
B—Lock Nut
C—Adjusting Screw
H75294
D—Contact
E—Cover
F—Wire
–UN–24FEB03
H75293
–UN–24FEB03
H75292

083006
PN=214
8. Push contact straight into connector body until positive

stop is felt.
9. Pull on wire slightly to be certain contact is locked in

place.
–UN–24FEB03
H75291
OUO6030,00001D9 –19–24FEB03–4/4
Repair Procedure R-C

40
Remove Contact From Connector Body 10
15
OUO6030,00001D8 –19–20FEB03–1/6
1. Remove secondary lock from male contact body by

inserting hooked end of JDG1383 Deutsch Terminal
Tool1 in slot (A) and gently pulling lock (B) from contact
body, or from female contact body by inserting flat end
of tool between seal (C) and lock (D) and gently prying
lock from contact body.
–UN–19FEB03
A—Slot
B—Lock
C—Seal
H74116
D—Lock
–UN–19FEB03
H74117
1
Included in JDG359 Deutsch Electrical Repair Tool Kit

083006
PN=215
2. Insert JDG1383 Deutsch Terminal Tool1 into connector

body socket from mating face (C) as shown and lift
locking tab (A) and gently pull contact out through seal
(B) in direction of arrow.
Install New Contact
–UN–19FEB03
A—Locking Tab
H74118
B—Seal
C—Mating Face
40
10
16
A
–UN–19FEB03
C
H74013
–UN–19FEB03
H74119
A
–UN–06NOV02
C
H74014
1
Included in JDG359 Deutsch Electrical Repair Tool Kit
2

083006
PN=216
2. Place wire (A) in contact (D) as shown and crimp both

the wire crimp (C) and insulation crimp (B) using
JDG144 Crimping Pliers1.
A—Wire
B—Insulation Crimp
–UN–19FEB03
C—Wire Crimp
D—Contact
H74120
40
10
17
–UN–19FEB03
H74122
–UN–19FEB03
H74121
1
OUO6030,00001D8 –19–20FEB03–4/6

locked.
3. Insert contact in connector body in appropriate socket.

–UN–19FEB03
H74123

083006
PN=217
NOTE: If secondary lock is difficult to install, contact may

4. Install secondary lock (A) and push down until firmly

seated.
–UN–19FEB03
A—Secondary Lock
H74124
40
10
18
–UN–19FEB03
H74125
OUO6030,00001D8 –19–20FEB03–6/6

083006
PN=218
Repair Procedure R-D
1. Insert JDG777 Terminal Extraction Tool1 into connector

body socket from mating face (C) as shown and
–UN–26FEB03
depress locking tab (B).
2. Gently pull contact out in the direction of arrow.
H75319
Install New Contact

–UN–27FEB03
A—JDG777, Terminal Extraction Tool 40
B—Locking Tab 10
C—Mating Face C 19
B
H75303
1
2
Continued on next page OUO6030,00001DA –19–26FEB03–1/3

083006
PN=219
2. Place wire in contact as shown and crimp both wire

crimp (C) and insulation crimp (B) using JDG144
Crimping Pliers1.
A—Wire
–UN–26FEB03
C—Wire Crimp
D—Contact
H75320
40
10
20
–UN–26FEB03
H75321
1
OUO6030,00001DA –19–26FEB03–2/3

locked.

Slide contact in until locking tab clicks into place.
–UN–26FEB03
H75322
OUO6030,00001DA –19–26FEB03–3/3
Repair Procedure R-E
1. Remove secondary lock (A) by gently prying locking

tabs (B) off locking studs (C).
–UN–26FEB03
A—Secondary Lock
B—Locking Tabs
C—Locking Studs
H75324
Continued on next page OUO6030,00001DB –19–06OCT04–1/6

083006
PN=220
2. Insert JDG777 Terminal Extraction Tool1 (A) into

and depress locking tab (B) and gently pull contact out
A—JDG777, Terminal Extraction Tool
–UN–26FEB03
B—Locking Tab
C—Mating Face
H75325
B
–UN–26FEB03
40
10
21
C
H75312
1
OUO6030,00001DB –19–06OCT04–2/6
Install New Contact

–UN–26FEB03
A—Wire
B—Seal
H75326
1
Continued on next page OUO6030,00001DB –19–06OCT04–3/6

083006
PN=221
3. Place wire and seal (A) in contact (D) and crimp both
the wire crimp (C) and seal crimp (B) using JDG144
Crimping Pliers1.
A—Seal
B—Seal Crimp
–UN–26FEB03
C—Wire Crimp
D—Contact
H75327
40
10
22
–UN–26FEB03
H75328
1
OUO6030,00001DB –19–06OCT04–4/6

locked.

–UN–26FEB03
H75329
OUO6030,00001DB –19–06OCT04–5/6

5. Install secondary lock (A) by aligning with connector

body and wires and pushing down until locking tabs (B)
lock on locking studs (C).
–UN–26FEB03
A—Secondary Lock
B—Locking Tabs
C—Locking Studs
H75324
OUO6030,00001DB –19–06OCT04–6/6

083006
PN=222
Repair Procedure R-F

–UN–26FEB03
A—Secondary Lock
B—Locking Tabs
C—Locking Studs
H75333
OUO6030,00001DC –19–04FEB04–1/6

connector body socket from mating face (C) as shown 40
and depress locking tab (B) and gently pull contact out 10
in the direction of arrow. 23
–UN–27FEB03
B—Locking Tab
C—Mating Face
H75334
B
–UN–26FEB03
C
H75314
1
Continued on next page OUO6030,00001DC –19–04FEB04–2/6

083006
PN=223
Install New Contact

–UN–26FEB03
A—Wire
B—Seal
H75335
40
10
24
1
OUO6030,00001DC –19–04FEB04–3/6

A—Seal
B—Seal Crimp
–UN–26FEB03
C—Wire Crimp
D—Contact
H75336
–UN–26FEB03
H75337
1
Continued on next page OUO6030,00001DC –19–04FEB04–4/6

083006
PN=224

locked.

–UN–26FEB03
H75338
OUO6030,00001DC –19–04FEB04–5/6

not be properly seated or locked. 40
10
5. Install secondary lock (A) by aligning with connector 25
–UN–26FEB03
A—Secondary Lock
B—Locking Tabs
C—Locking Studs
H75333
OUO6030,00001DC –19–04FEB04–6/6
Repair Procedure R-G
1. Insert a “T” pin (A) or other similar device into

–UN–05MAR03
and depress locking tab (B).
2. Gently push contact out in the direction of arrow.
H75465
Install New Contact

A—”T” Pin
B—Locking Tab
C—Mating Face C
–UN–06MAR03
B
H75429
1
Continued on next page OUO6030,00001DD –19–05MAR03–1/3

083006
PN=225
2. Place wire (A) in contact (D) as shown and crimp both

wire crimp (C) and insulation crimp (B) using JDG144
Crimping Pliers1.
A—Wire
–UN–05MAR03
C—Wire Crimp
D—Contact
H75466
40
10
26
–UN–05MAR03
H75467
1
OUO6030,00001DD –19–05MAR03–2/3

locked
NOTE: Terminal will seat only one way. If terminal does

not pull into the connector body socket, check to
make sure terminal is aligned correctly.
–UN–05MAR03
3. Check to make sure locking tab on new contact is in
the outward position, then pull on wire until contact
locks in connector body socket.
H75468
OUO6030,00001DD –19–05MAR03–3/3

083006
PN=226
Repair Procedure R-I

–UN–05MAR03
and depress locking tab (B).
2. Gently push contact out in the direction of arrow.
H75460
Install New Contact

Electrician’s Pliers2
A—JDG777, Terminal Extraction Tool 40

B—Locking Tab 10
B
C—Mating Face 27
–UN–06MAR03
C
B
H75430
1
2
Continued on next page OUO6030,00001DE –19–05MAR03–1/3

083006
PN=227

Crimping Pliers1.
A—Wire
–UN–05MAR03
C—Wire Crimp
D—Contact
H75461
40
10
28
–UN–05MAR03
H75462
1
OUO6030,00001DE –19–05MAR03–2/3

locked
NOTE: Terminal will seat only one way. If terminal does

not pull into the connector body socket, check to
make sure terminal is aligned correctly.
–UN–05MAR03
3. Check to make sure locking tab on new contact is in
the outward position, then pull on wire until contact
locks in connector body socket.
H75463
OUO6030,00001DE –19–05MAR03–3/3
Repair Procedure R-J

–UN–19FEB03
A—Secondary Lock
B—Locking Tabs
C—Locking Studs
H73987
Continued on next page OUO6030,00001CD –19–01NOV02–1/6

083006
PN=228

body socket from mating face (C) as shown and
depress locking tab (A) and gently pull contact out in
the direction of arrow.
A—Locking Tab
–UN–19FEB03
B—Wire Entry
C—Mating Face
H73988
Placement of Extraction Tool Small Contact
40
–UN–01NOV02
10
29
C A
H73972
Cross Section View Small Contact
–UN–19FEB03
H73989
Placement of Extraction Tool Large Contact
–UN–01NOV02
B
H73971
Cross Section View Large Contact
1

083006
PN=229
Install New Contact

–UN–19FEB03
A—Wire
B—Seal
H73990
Large Contact Seal
40
10
30
–UN–19FEB03
H73991
1
Included in JDG155 Electrical Repair Tool Kit Small Contact Seal

083006
PN=230

A—Wire and Seal
B—Seal Crimp
C—Wire Crimp
D—Contact
–UN–19FEB03
H73992
Large Contact
40
10
31
–UN–19FEB03
H73994
–UN–19FEB03
H73993
Small Contact
–UN–19FEB03
H73995
1

083006
PN=231

locked.

–UN–19FEB03
H73996
Large Contact
40
10
32
–UN–19FEB03
H73997
Small Contact
OUO6030,00001CD –19–01NOV02–5/6

5. Install secondary lock (A) by aligning with connector

–UN–19FEB03
A—Secondary Lock
B—Locking Tabs
C—Locking Studs
H73998
OUO6030,00001CD –19–01NOV02–6/6

083006
PN=232
Repair Procedure R-K
Remove Contact from Connector Body
1. Insert JDG140 Terminal Extraction Tool1 (A) in

connector body over contact to depress locking tabs
–UN–19FEB03
(C).
2. While holding extraction tool firmly in place, depress

plunger (B) and push contact out of connector body.
H73956
Install New Contact

40
A—JDG140, Contact Extraction Tool1 10
B—Plunger 33
C—Locking Tabs
–UN–19FEB03
H73955
E
–UN–31OCT02
D C
H73953
1
2
Continued on next page OUO6030,00001CC –19–06OCT04–1/3

083006
PN=233
2. Place wire (A) in contact (D) and crimp both wire crimp
(C) and insulation crimp (B) using JDG783 PACKARD
Crimping Tool.
A—Wire
–UN–19FEB03
C—Wire Crimp
D—Contact
H73957
40
10
34
–UN–19FEB03
H73958
–UN–19FEB03
H73981
OUO6030,00001CC –19–06OCT04–2/3

locked.

–UN–19FEB03
H73982
OUO6030,00001CC –19–06OCT04–3/3

083006
PN=234
Repair Procedure R-M
1. Unlock slide type secondary lock (A) by disengaging

teeth (B) and sliding lock in direction of arrow; or door
–UN–19FEB03
type secondary lock by opening door (C).
A—Slide Type Secondary Lock

B—Teeth
H73857
C—Door Type Secondary Lock
40
10
35
–UN–19FEB03
H73858
OUO6030,00001CB –19–29OCT02–1/5

body socket from mating face (D) as shown and lift
locking tab (A) and gently pull terminal out past
secondary lock (B) in direction of arrow.
Install New Contact
–UN–19FEB03
H73879
A—Locking Tab
B—Secondary Lock
C—Wire Entry
D—Mating Face
–UN–01NOV02
H73765
1
2
Continued on next page OUO6030,00001CB –19–29OCT02–2/5

083006
PN=235
2. Place wire (A) in contact (D) and crimp both wire crimp
(C) and insulation crimp (B) using JDG144 Crimping
Pliers1.
A—Wire
–UN–19FEB03
C—Wire Crimp
D—Contact
H73921
40
10
36
–UN–19FEB03
H73922
–UN–19FEB03
H73983
Properly Crimped Contact
1
OUO6030,00001CB –19–29OCT02–3/5

locked.

Slide contact in until the lock clicks into place.
–UN–19FEB03
H73978
Continued on next page OUO6030,00001CB –19–29OCT02–4/5

083006
PN=236
NOTE: If secondary lock is difficult to engage, contact

may not be properly seated or locked.
4. Engage slide type secondary lock (A) by disengaging

teeth (B) and sliding in direction of arrow; or door type
secondary lock (C) by closing door until it locks in
–UN–19FEB03
place.
H73977
40
10
37
–UN–19FEB03
H73858
OUO6030,00001CB –19–29OCT02–5/5
Repair Procedure R-N
1. Open secondary lock doors (A) by gently prying locking

–UN–05MAR03
A—Secondary Lock Door
B—Locking Tabs
C—Locking Studs
H75453
–UN–05MAR03
H75454
Continued on next page OUO6030,00001DF –19–06MAR03–1/5

083006
PN=237

and depress locking tab (B) and gently pull contact out
Install New Contact
–UN–05MAR03
H75455
B—Locking Tab
C—Mating Face
C
40
10
38
–UN–06MAR03
B
1
H75431
2
OUO6030,00001DF –19–06MAR03–2/5

Crimping Pliers1.
A—Wire
–UN–05MAR03
C—Wire Crimp
D—Contact
H75456
–UN–05MAR03
H75457
1
Continued on next page OUO6030,00001DF –19–06MAR03–3/5

083006
PN=238

locked.

Slide contact in until locking tab clicks into place.
–UN–05MAR03
H75458
OUO6030,00001DF –19–06MAR03–4/5
NOTE: If secondary lock door is difficult to close, contact

may not be properly seated or locked. 40
10
4. Close secondary lock door (A) until locking tabs (B) are 39
securely locked over locking studs (C).
–UN–05MAR03
A—Secondary Lock Door
B—Locking Tabs
C—Locking Studs
H75454
OUO6030,00001DF –19–06MAR03–5/5

083006
PN=239
Repair Procedure R-AE
E
J
G
F
40 I
10
40
–UN–15JAN03
H
K
RXA0063965
A—Connector Locking Cam D—Connector Body G—Terminal Removal Tool I—0.6 mm Terminal
B—Cover E—Terminal Lock Opening J—1.5 mm Terminal
C—Cover Locks F—Cavity Seal Plug H—Terminal Opening K—Seal
Continued on next page OUO6083,0000D1C –19–11MAY06–1/5

083006
PN=240
1. Press tab (A) and rotate locking cam (B) 90° to

disconnect connector from flexbox.
2. Move cover locks (C) slightly outward with a small

screwdriver.
–UN–10SEP03
3. Remove cover (D) away from wires.
A—Tab
RXA0070459
B—Locking Cam
C—Cover Locks
D—Cover
40
10
41
–UN–10SEP03
RXA0070462
–UN–10SEP03
RXA0070463
OUO6083,0000D1C –19–11MAY06–2/5
4. Pull terminal lock (A) out as far as it will go, but do not
force its removal.
A—Terminal Lock
–UN–10SEP03
RXA0070464

083006
PN=241
NOTE: JDG1725 Terminal Extractor Tool has two

different sizes of pins, 0.6 for smaller 20 gauge
holes (A), and 1.5 for larger 16 and 18 gauge
holes (B).
–UN–10SEP03
5. Insert JDG1725 Terminal Extractor Tool into holes (C)
next to terminal opening (D) to unlock terminal.
6. Pull wire and terminal (E) from connector body.
RXA0070471
A—20 Gauge Holes
B—16 & 18 Gauge Holes
C—Holes
D—Terminal Hole
E—Terminal
40
10
42
–UN–10SEP03
RXA0070472
–UN–10SEP03
RXA0070473

083006
PN=242
7. Remove old terminal and strip 4.85 mm (0.191 in.) of

insulation from wire.
8. Grip JDG1727 Terminal Crimping Tool (A) securely,

and squeeze ratcheting mechanism until it bottoms out.
–UN–10SEP03
Then allow it to open completely
9. With tool in ready position (open handle), open

terminal receptacle (B).
RXA0070479
10. Insert terminal (C) into proper wire gauge window,
crimp wings facing up.
11. Close terminal receptacle (B).
12. Squeeze handle until two clicks are heard.

40
10
13. Insert stripped wire (D) into terminal. 43
–UN–10SEP03
14. Hold wire stationary and squeeze tool together until
ratchet releases.
RXA0070480
15. Remove terminated wire from tool.
16. Push terminal into connector body until fully seated.

Pull on wire slightly to ensure terminal is locked in
position.
17. Push terminal lock closed.
18. Install cover.
–UN–10SEP03
19. Install connector to controller and close connector
body locking cam.
RXA0070481
A—CINCH Terminal Crimping Tool
B—Terminal Receptacle
C—Terminal
D—Wire
OUO6083,0000D1C –19–11MAY06–5/5

083006
PN=243
40
10
44

083006
PN=244
Group 15
Wire Harness Routing
Replace Harness
IMPORTANT: Good electrical signals to instruments

and long harness life depend on
harness protection and specific points
of support. Observe the following when
replacing harnesses.
1. Tag location of harness plastic ties as ties are

removed.
2. Observe location of clamps as harness is removed.

Make sure they are in place when harness is installed.
This protects harness from damage, heat and vibration.
3. The wiring diagrams in TM2182, Section 240 give the

40
location of the electrical circuits. Use this as an aid to 15
repair. 1
4. When installing harness, keep plastic ties far enough

from connector to prevent side stress on connector.
5. Always place plastic tie where there is a protective

cover over harness.
6. Route wires in such a manner as to protect them from

heat, vibration, sharp corners, from being pinched or
insulation worn off. Use grommets or protective
covering where necessary.
OUO6083,00000D2 –19–18JUL01–1/1

083006
PN=245
Cab Main Wiring Harness (S.N. —715300)
40
15
2
–UN–06MAY04
H80804
OUO6046,0002005 –19–20JUL05–1/1

083006
PN=246
Cab Main Wiring Harness (S.N. 715301—)
40
15
3
–UN–21JUL05
H83652
RO33873,0000057 –19–20JUL05–1/1

083006
PN=247
Auxiliary Cab Main AUTOTRAC Wiring Harness (S.N. —715300)
40
15
4
–UN–07MAY04
H80805
OUO6046,0002006 –19–20JUL05–1/1

083006
PN=248
Auxiliary Cab Main AUTOTRAC Wiring Harness (S.N. 715301—)
40
15
5
–UN–15JUL05
H83984
RO33873,000005B –19–20JUL05–1/1

083006
PN=249
Left-Hand Main Wiring Harness
40
15
6
–UN–10MAY04
H80864
OUO6046,0002010 –19–26JUL05–1/1

083006
PN=250
Left-Hand Main Wiring Harness (Tier III Cooling Package)
40
15
7
–UN–20JUL05
H83650
RO33873,0000058 –19–26JUL05–1/1

083006
PN=251
Right-Hand Main Wiring Harness
40
15
8
JO
HN
DE
ER
E
–UN–10MAY04
H80865
OUO6046,0002011 –19–26JUL05–1/1

083006
PN=252
Right-Hand Main Wiring Harness (Tier III Cooling Package)
40
15
9
–UN–16JUN05
H83651
RO33873,0000059 –19–26JUL05–1/1

083006
PN=253
Engine Wiring Harness
40
15
10
–UN–10MAY04
H80866
OUO6083,0000770 –19–07MAY04–1/1

083006
PN=254
Engine Wiring Harness (Tier III Cooling Package)
40
15
11
–UN–17OCT05
H83653
RO33873,000005A –19–26JUL05–1/1

083006
PN=255
40
15
12

083006
PN=256
Group 20
Fuses, Circuit Breakers and Relays
Specifications
Large Relay Terminal Nut Torque 340 ± 60 N•cm

(30 lb-in. ± 5 lb-in.)
Small Relay Terminal Nut Torque 250 ± 50 N•cm

(22 lb-in. ± 4 lb-in.)
OUO6083,0000311 –19–09AUG02–1/1
40
20
1

083006
PN=257
Basic Operation
Primary power comes into the power distribution boards

from the Engine Compartment Relay Panel.
The power distribution boards provide protection, isolation

and control of the following power or control systems:
• Ignition Switch Power

• Turn/Brake Signal and Light Switch Power1
• Road Light Power - Cab2
• Road Light Power - Other Than Cab2
• Field Light Power2
• Rear Light Power2
• Stubble Light Power
• Engine Running Power
40
20 • Service Power
2 • Control Circuit Power
• Wiper Power
• EMIP Power (Electromagnetic Interference Protected).
Used to protect circuits against voltage spikes.
• Concave Position Adjust Control
• Fan Speed Adjust Control
IMPORTANT: Use care when mating or disconnecting

connectors so that connector halves
are kept in line during removal and
assembly. If mating surfaces are NOT
kept aligned, damage may occur to the
jack screw.
1
The power distribution board systems that deal with lighting and flashers
are discussed in TM2182 Section 240, Lighting System-Overall
Diagnostics.
2
The power distribution board systems that deal with lighting and flashers
are discussed in the lighting repair section.
OUO6083,0000C9D –19–28FEB06–1/1

083006
PN=258
Power Distribution Board System Basic

Description
The power distribution boards are located in the Central

Electronics Box (CEB), located in the compartment on the
left-hand side of the grain tank by the ladder landing, and
contain the fuses and control relays for most of the
electrical systems on the combine.
Refer to TM2182, Section 240 for systems that are

powered or controlled from the power distribution boards.
40
20
3
OUO6083,0000038 –19–23APR01–1/1
Circuit Board Replacement
NOTE: Removal is the same for all circuit boards in the

Central Electronics Box (CEB). To eliminate
damage from static electricity, keep all new
replacement boards in their protective packaging
until ready to install.
IMPORTANT: Handle a circuit board with care. Hold it

by its edges when installing. It is fragile
and expensive. Use grounding strap
during installation of circuit board.
1. Open access door and brush out any dust. Remove

cover to CEB.
OUO6083,0000039 –19–23APR01–1/4
2. Remove cap screws (A) to remove Central Electronics

Box cover.

–UN–11MAY01
H67650
Continued on next page OUO6083,0000039 –19–23APR01–2/4

083006
PN=259
NOTE: Mark locations of wiring harness connectors for

re-installation into correct position.
3. Disconnect wiring harness connectors (A) by

depressing lock release with a flat tip screw driver.
4. Loosen cap screws (B) and disconnect remaining

connectors.
5. Release latches (C). Remove Central Electronics Box

to access selected circuit board.
A—Connectors
B—Cap Screws
C—Latches
40
20
4
–UN–16APR01
H67537
OUO6083,0000039 –19–23APR01–3/4
6. Squeeze locking clips (A) on circuit board and slide

from mounting bracket.
7. Install circuit board in reverse order.
NOTE: Ensure pins to all connectors are properly seated
–UN–06APR01
prior to installation.
A—Locking Clips
H67370
OUO6083,0000039 –19–23APR01–4/4

083006
PN=260
Relays
Relays (A) carry large electrical loads and are controlled

by switches or electronics.
Relays in the central electronics box are on the power
–UN–06APR01
distribution board. Relays can be replaced.
IMPORTANT: Relays can be pulled out. They are

made with a tight fit for good contact.
H67395
To prevent damage, pull straight out.
Do not pry with a screwdriver, etc.
NOTE: Relay contacts have thick conformal coating A—Relay

applied from the supplier. It is recommended
relays be removed and installed three times to
40
remove conformal coating on contacts for proper 20
seating to connector. Ensure pins to all 5
connectors are properly seated prior to
installation.
Each relay is marked by function. All relays are

interchangeable.
OUO6083,0000645 –19–16JUN03–1/1

083006
PN=261
Power Distribution Board Relay Identification
40
20
6
–UN–06APR01
H67366
K1—Threshing Clearance K5—Fan Speed Increase K16—Right Turn Lamps K21—2 Field Lamps
Increase K6—Fan Speed Decrease K17—Driving Lamps (Export K22—Start Interlock
K2—Threshing Clearance K7—Grain Tank Cover Fold Only) K23—Delayed Power CC6
Decrease (Export Only) K18—Left Turn Lamps K24—Transmission Lockout
K3—Vane Angle Adjust Left K8—Grain Tank Cover Unfold K19—Stubble Lamps (Export Only)
(Export Only) (Export Only) K20—4 Field/Road Lamps K25—Rear Lamps
K4—Vane Angle Adjust Right K15—Beacon Lamps (Export
(Export Only) Only)
OUO6083,0000A06 –19–01JUN05–1/1

083006
PN=262
Engine Compartment Relay Panel Fuse Identification
40
20
7
–UN–11JUN04
H81164
F1—Left Control Unit 1 Power F11—Fan Speed Adjust Power F20—Unswitched Electronic F26—Fuel Pump Unswitched
F2—Control Circuit Power 1 F12—Convenience Outlet Power Power
F3—Light Power 3 Switched Power F21—Ignition Switch - Battery F27—HARVESTSMART Feed
F4—Light Power 4 F13—Unused Power Rate (Optional)
F5—Light Power 2 F14—Unused F22—Service Light Power F28—Control Circuit Power 3
F6—Service Outlet Power F15—Left Control Unit 2 Power F23—Moisture Sensor Power F40—Spare 30 Amp
F7—Pressurizer Fan Power F16—Service Lamp Power F24—Fuel Pump Switched F41—Spare 20 Amp
F8—Motor Adjust Power 1 F17—Electronic Power Power
F9—Light Power 5 F18—Light Power 1 F25—Engine Control Unit
F10—Recirculation Fan Power F19—Convenience Outlet Power
Unswitched Power
OUO6075,0003EAD –19–16MAR05–1/1

083006
PN=263
Engine Compartment Relay Panel Identification
40
20
8
–UN–11JUN04
H81165
K1—Left Control Unit 1 Power K6—Recirculation Fan Power K10—Service Lamp Power K12—Engine Control Unit
K2—Control Circuit Power 1 K7—Unused K11—Control Circuit Power 3 Power
K3—Pressurizer Fan Power K8—Convenience Outlet and HARVESTSMART K13—Fuel Pump Switched
K4—Mirror Adjust Power 1 Switched Power Feed Rate (Optional) Power
K5—Fan Speed Adjust Power K9—Electronic Power
OUO6075,0003EAE –19–16MAR05–1/1

083006
PN=264
Group 25
Lighting
Safety Rules When Replacing Halogen Bulbs
CAUTION: Halogen bulbs (A) contain gas under

pressure. Handling a bulb improperly could
cause it to shatter into flying fragments. To
avoid possible injury:
–UN–30JUN00
1. Turn off the light switch and allow the bulb
to cool before changing bulbs. Leave the
switch off until bulb change is complete.
H39474
2. Wear eye protection when changing a
halogen bulb.
3. Handle the bulb by its base. Avoid touching A—Halogen Bulb
the glass.
4. Do not drop or scratch the bulb. Keep
moisture away. 40
5. Place used bulb in the new bulb’s carton and 25
1
dispose of properly. Keep out of reach of
children.
AG,OUO6022,1785 –19–24JUL00–1/1

083006
PN=265
Lighting
Bulb Part Numbers
Location John Deere Part Number Trade (ANSI) Number

HID-Xenon Lights L150689 (S.N. —715300)
RE179974 (S.N. 715301—)
Cab Roof Lights AH211917 (S.N. —715300)
RE179326 (S.N. 715301—)
Shoe, Row Finder Lights AH162231 9006
Unloading Auger Lights AH166909 4411
Rear Red, Rear Amber, LH Front, and RH H133384 T3057
Front
Turn Signal Indicators, and Gauges AA27536 161
COMMANDTOUCHConsole Back Ground, AA27536 161
Lights
40 Dome and Console Lights 57M7173 211-2

25 Warning Display Panel and Header Float AH108380 73
2 Gauge Light
Transport/Header and Warning Lights AH164497 1156
COMMANDTOUCH Cornerpost (Left) R107890 F7:PC37
Stubble, Service Lights AH166909 GE862
Rear Discharge Lamp AH158038 GE9411
COMMANDTOUCH is a trademark of Deere & Company OUO6046,0001FEF –19–29AUG05–1/1

083006
PN=266
Lighting
Cab Head Light Bulb Replacement and

Adjustment (S.N. —715300)
CAUTION: Raise feeder house all the way up

and lower safety stop before standing on feeder
house to replace or adjust these bulbs.
–UN–30JUN00
CAUTION: Read “SAFETY RULES WHEN
REPLACING HALOGEN BULBS”.
H39475
IMPORTANT: Over tightening the screws until they
bottom out can break the head lamp.
A—Screw (3 used)
B—Head Lamp
NOTE: Center two head lamps are infra-red, others are C—Wire Lead
halogen. D—Retainer Ring 40
25
1. Unscrew three screws (A) and remove head lamp (B). 3
2. Disconnect wiring lead (C). Clean dirt from head lamp.
3. Push in and twist retainer ring (D) counterclockwise.

Bulb pulls straight out.
4. When reinstalling head lamp, adjust as follows:
Start with the two end screws first, then the bottom
screw last. Adjust the screws until all three tabs are
flush with the panel.
OUO6046,0002007 –19–20JUL05–1/1
Cab Head Light Bulb Replacement and

Adjustment (S.N. 715301—)
CAUTION: Raise feeder house and lower safety

stop before replacing or adjusting headlights.
–UN–10MAY05
1. Rotate light assembly (A) upward.
2. Disconnect wiring harness connector (B).

H83429
3. Turn bulb assembly (C) counterclockwise to remove.
4. Remove and replace bulb. A—Light Assemblies

B—Connector
5. Install bulb in reverse order and connect wiring C—Bulb Assembly
harness.
Continued on next page OUO6046,0001EAC –19–20JUL05–1/3

083006
PN=267
Lighting
NOTE: The vertical adjustment of light assemblies can be

rotated up or down in three notch positions to
achieve correct lighting angles.
6. Vertical Adjustment: Light assemblies (A) can be

rotated up or down in notches (B).
–UN–19MAY05
A—Light Assemblies
B—Notches
H83515
OUO6046,0001EAC –19–20JUL05–2/3
7. Horizontal Adjustment: To adjust light assemblies

40 (A), loosen cap screws and rotate bracket (B) until
25 notch aligns with indicator line (C).
4
B—Bracket
–UN–19MAY05
C—Indicator Line
H83516
OUO6046,0001EAC –19–20JUL05–3/3
Remove and Install High Intensity Discharge

(HID-Xenon) Lights (Optional) (S.N. —715300)

electric shock or lamp explosion. This lamp is
powered by 25,000 volts. Do not begin
–UN–06NOV02
installation of HID-Xenon lights unless the
lights are turned off, the engine is turned off,
the key is removed, and appropriate eye
protection is worn. H73136
HID-Xenon lights (A) are located in the second and fifth

hole in the cab light panel. A—HID-Xenon Lights (2 used)
Continued on next page OUO6046,0002008 –19–20JUL05–1/4

083006
PN=268
Lighting
1. Remove adjusting screws (A) and retain springs.
A—Adjusting Screws (3 used)
–UN–25MAR02
H71390
OUO6046,0002008 –19–20JUL05–2/4
IMPORTANT: To prevent equipment damage make

sure machine lights are turned off 40
before disconnecting wiring harness 25
connector (B). 5
2. Remove rubber boot (A) from light.
–UN–25MAR02
3. Disconnect ballast wiring harness connector (B) from
light by turning counterclockwise.
H71388
A—Rubber Boot
B—Ballast Wiring Harness Connector
–UN–25MAR02
H71389

083006
PN=269
Lighting
IMPORTANT: To prevent damage to ballast, assembly

must be mounted to plastic bosses
located on the cab roof. If assembly is
attached directly to metal portion of cab
or chassis the ballast will be damaged.
–UN–06NOV02
NOTE: Ballast assembly should be installed with wiring
connector pointing towards the rear of the
machine.
H73135
4. Disconnect harness connector (A) and remove cap
screws (B). Remove ballast assembly from cab.
5. Repair or replace parts as necessary. A—Harness Connector

B—Cap Screws (2 used)
6. Install ballast and light in reverse order using the
40
25 following special instructions:
6
• The initial adjustment of the light should begin with
the top surface of the adjusting screws flush with flat
surface of the fascia. Continue adjustment until
desired position is achieved.
OUO6046,0002008 –19–20JUL05–4/4

(HID-Xenon) Lights (Optional) (S.N. 715301—)

electric shock or lamp explosion. Lamps are
powered by 25,000 volts. Before working on
–UN–01FEB05
HID-Xenon lights or ballast, ensure lights are
turned off, engine is turned off, key is removed,
and appropriate eye protection is worn.
Disconnect connector at lamp and wait five H82329
minutes before working on lamp or ballast.
1. HID-Xenon lights (A) are located in the second and A—HID-Xenon Lights
fifth cab light panel holes.
Continued on next page OUO6046,0001EAD –19–14MAR06–1/5

083006
PN=270
Lighting
2. Rotate HID-Xenon light assembly (A) upward and

disconnect wiring harness (B).
A—HID-Xenon Light Assembly

B—Wiring Harness
–UN–30JUN05
H83878
OUO6046,0001EAD –19–14MAR06–2/5
3. Push in and rotate retainer (A) counterclockwise.

40
4. Push in and rotate bulb assembly (B) 25
counterclockwise. 7
5. Remove and replace bulb.
–UN–26MAY05
6. Install bulb and retainer in reverse order and connect
wiring harness.
H83611
A—Retainer
B—Bulb Assembly
OUO6046,0001EAD –19–14MAR06–3/5
NOTE: The vertical adjustment of HID-Xenon light

assemblies must be rotated to achieve correct
light angle.
7. Vertical Adjustment: Rotate light assembly (A) to first

notch (B).
–UN–20MAY05
B—First Notch
H83537
Continued on next page OUO6046,0001EAD –19–14MAR06–4/5

083006
PN=271
Lighting
8. Horizontal Adjustment: To adjust light assemblies

(A), loosen cap screws (B) and rotate light bracket (C)
towards center and tighten cap screws.
B—Cap Screws
–UN–27MAY05
C—Light Bracket
H83622
OUO6046,0001EAD –19–14MAR06–5/5

40 (HID-Xenon) Ballasts (S.N. 715301—)
25
8
electric shock or lamp explosion. Lamps are
powered by 25,000 volts. Before working on
–UN–26MAY05
HID-Xenon lights or ballast, ensure lights are
turned off, engine is turned off, key is removed,
and appropriate eye protection is worn.
Disconnect connector at lamp and wait five
H83608
minutes before working on lamp or ballast.
1. Remove cab outer roof. (See REMOVE AND INSTALL A—Connector

CAB OUTER ROOF in Section 90, Group 15.) B—Connector
C—Screw (4 used)
2. Disconnect connectors (A and B).
3. Remove screws (C) and ballast.
4. Install in reverse order of removal.
OUO6046,0001EAE –19–20JUL05–1/1

083006
PN=272
Lighting
Auxiliary Field, Access Door, Grain Tank,

Unload Auger and Work Light Bulb
Replacement
1. Remove bulb (A) from housing (B) and connector (C).
–UN–01MAY03
2. Install in reverse order.
A—Bulb
B—Housing
H76304
C—Connector
40
25
9
OUO6083,000056F –19–01MAY03–1/1
Side Finder (Optional) Light Bulb

Replacement
CAUTION: Read “SAFETY RULES WHEN

–UN–14JUN99
1. Disconnect harness lead (A) and clean dirt from light.
2. Push in and twist retaining ring (B) counterclockwise.

Bulb pulls straight out.
H58235
A—Harness Lead
B—Retaining Ring
AG,OUO6022,1790 –19–24JUL00–1/1
Front Turn Signal, Tail and Side Light Bulb

Replacement
1. Remove screws (A) and remove lens cover.
2. Remove bulb by pulling straight out of socket.

–UN–01MAR99
3. Install bulb.
A—Screws (2 used)
H51565
AG,OUO6022,1792 –19–24JUL00–1/1

083006
PN=273
Lighting
Harzard/Warning Light Bulb Replacement
1. Pry off lens cover (A).
2. Remove light bulb by pushing in and turning

counterclockwise.
–UN–12JUL01
3. Install bulb.
A—Lens Cover (2 used)
H69242
OUO6083,0000C9E –19–01MAR06–1/1
Cleaning Shoe Light Bulb Replacement

40
25
10 CAUTION: Read “SAFETY RULES WHEN
1. Disconnect harness lead (A) and clean dirt from light.
–UN–28MAY99
2. Push in and twist retainer (B) counterclockwise. Bulb
pulls straight out.
H57670
A—Harness Lead
B—Retainer Right-Hand Side Shown, Left-Hand Similar
AG,OUO6022,1794 –19–24JUL00–1/1
Turn Signal Light Bulb Replacement
1. Tilt steering column toward drivers seat.
2. Remove four screws and remove steering column

cover (A).
–UN–17APR02
3. Pull out bulb socket (B). Bulb pulls straight out.
4. Check wiring harness connections before installing

H71670
cover.
A—Steering Column Cover

B—Bulb Socket
OUO6083,000026F –19–17APR02–1/1

083006
PN=274
Lighting
Dome and Console Light Bulb Replacement
1. Remove dome or console lens cover by pressing sides

of cover.
2. Replace dome (A) or console (B) bulb.
–UN–11DEC98
3. Install lens covers by snapping in place.
A—Dome Light
H51673
B—Console Light
40
25
11
AG,OUO6022,1796 –19–24JUL00–1/1

083006
PN=275
Lighting
COMMANDTOUCH Cornerpost Monitor Light

Bulb Replacement
1. Determine which bulb is defective.
2. Disconnect wiring harness connector from back of
–UN–13NOV02
GREENSTAR Display and Mobile Processor if
equipped.
3. Remove two cap screws from back of Mobile
H74255
Processor. Remove GREENSTAR Display assembly if
equipped.
4. Remove mounting screws (A), bracket and cornerpost

monitor (B).
40
25 5. Remove defective bulb (C).
12
IMPORTANT: Always handle electronic
–UN–14NOV02
cards/components by edges to prevent
damage.
NOTE: Connector bodies are “keyed” for proper contact
H74259
mating. Be sure contacts are in proper alignment.
NOTE: If defective bulb is located under circuit board (D),

disconnect two connectors (E), carefully remove
three ribbon connectors (F) and eight screws (G).
Move circuit board for access to additional light
bulbs.
6. Remove defective bulb by turning counterclockwise.
–UN–13DEC01
7. Install bulb.
8. Install cornerpost monitor.
H70492
9. Install GREENSTAR Display assembly if previously
removed.
A—Screws (4 used)
B—COMMANDTOUCH Cornerpost Monitor
10. Install wiring harness. C—Bulb
D—Circuit Board
E—Connectors (2 used)
F—Ribbon Connectors (3 used)
G—Screws (8 used)
GREENSTAR is a trademark of Deere & Company OUO6083,00007DD –19–20MAY04–1/1

083006
PN=276
Lighting
Warning Display Panel Light Bulb

Replacement
1. Remove six screws (A) attaching warning display panel

and lower panel.
–UN–17MAR06
damage.
H85539
2. Remove screws (B) attaching circuit board to panel.
3. Remove screws (C) attaching bulb holder.
4. Remove defective bulb by pulling straight out.

40
5. Replace bulb in reverse order. 25
13
A—Screws (6 used)
–UN–17APR02
B—Screws (6 used)
C—Screws (6 used)
H71672
OUO6083,0000CC2 –19–17MAR06–1/1

083006
PN=277
Lighting
40
25
14

083006
PN=278
Group 30
Operators Station
Other Material
Number Name Use
PM38654 (U.S.) High Strength Thread Lock Eliminates vibration loosening and
prevents leaks.
OUO6083,0000AE6 –19–16AUG05–1/1
Specifications
40
Item Measurement Specification 30
1
Multi-Function Handle Shoulder Bolts Torque 6 N•m
(53 lb-in.)
Neutral Safety Switch Torque 0.9 N•m

(8.0 lb-in.)
OUO6083,000086A –19–28JUN04–1/1

083006
PN=279
Operators Station
Instruments and Controls Identification
B
C H I L
F G
M
D E J K
N
40
30
2 O
Q
S
R
B
P
T
–UN–08JUN05
X
H83627
A—Light Dimmer Switch F—Field Light Switch L—Warning Display Panel S—Steering Wheel
B—Hazard Light Switch G—Work Light Switch M—Wiper Switch T—Turn Signal Indicators
C—Road Light Switch H—CLIMATRAK Temperature N—Cornerpost U—Starting Aid Switch
D—Power Mirror Switch Control O—Gearshift Lever V—Brake Pedals
E—Mirror Heater Switch I—CLIMATRAK Power Switch P—Horn Switch W—Manual Park Brake Pedal
J—Radio Q—Multi-Function Handle X—Park Brake Disengage
K—CLIMATRAK Fan Control R—COMMANDTOUCH Console Pedal
CLIMATRAK is a trademark of Deere & Company OUO6046,0001F0D –19–31MAY05–1/1

083006
PN=280
Operators Station
Overhead Warning Display Panel
Brief Description
The warning display panel is installed in the center of the

overhead console in the cab.
The warning display panel provides both visual and

audible indication of combine operational problems and
important combine conditions.
Basic Operation
D
The warning display panel provides both visual and
audible signals.
A 40
VISUAL WARNINGS: 30
E 3
The visual warnings are divided into three levels; these
will each be described, starting with the highest priority. TAILING ELEVATOR
–UN–08JUN05
THRESHING SPEED
PRIORITY 1:
A red light will be visible on the warning display panel

indicating the problem/abnormal condition. Engine should
H83628
B C
be shut off immediately.
PRIORITY 2: A—Hydro Charge Pressure

B—Main Gear Case Pressure
A yellow light will be visible on the warning display panel C—Engine Oil Pressure
D—Parking Brake
indicating the problem/abnormal condition. This signal E—Voltage Light
indicates a condition that should be checked immediately.
You should also be aware that less than optimum
performance of the combine may occur.
PRIORITY 3:
A blue light will be visible on the warning display panel

indicating a combine condition. This signal indicates the
operator should be aware of that combine condition.
AUDIBLE WARNINGS:
On this combine, when the ignition switch is first turned

on, the following indicator lights will glow.
• Hydro charge pressure (A).

• Main gear case pressure (B).
Continued on next page OUO6046,0001F0E –19–31MAY05–1/2

083006
PN=281
Operators Station
• Engine oil pressure (C).

• Parking brake (if brake has been applied ) (D).
The buzzer will sound once due to low oil pressure.
If voltage light (E) comes on, this indicates battery voltage

is low and combine may not start.
If more than one warning is active at a time, less

important (lower priority) audible warnings will not occur.
OUO6046,0001F0E –19–31MAY05–2/2
Remove and Install Overhead Warning

40 Display Panel
30
4
1. Remove screws (A) and lower panel until suspended
by cables.
–UN–17MAR06
2. Disconnect connectors (B) from circuit board.
3. Disconnect harness from all switches and radio.
H85539
4. Disconnect antenna from radio.
5. Remove screws (C) from support cables. Remove

overhead panel.
6. Remove radio, (See REMOVE AND INSTALL RADIO

in this group), all switches and circuit board.
7. Install all switches, radio and circuit board.
–UN–10MAR99
8. Connect support cables.
9. Connect antenna and harness.
10. Lift warning display panel into place and attach with H54504
screws (A).
A—Screws (6 used)
B—Connectors (2 used)
11. Install overhead console. C—Screws (2 used)
OUO6083,0000CC3 –19–17MAR06–1/1

083006
PN=282
Operators Station
Replace Overhead Warning Display Panel

Circuit Board

damage.
–UN–17DEC98
NOTE: The warning display panel is used in several
different applications. For proper operation, the
“CAL” switches must be set to match the
H51712
application.
Set calibration switches prior to starting the

A—Circuit Board
combine. (Refer to Warning Display Panel
Diagnostics in TM2182, Section 240.)
40
NOTE: Connector bodies are “keyed” for proper contact 30
mating. Be sure contacts are in proper alignment. 5
1. Remove circuit board (A). (See WARNING DISPLAY

PANEL LIGHT BULB REPLACEMENT, in Group 25.)
2. Install circuit board in reverse order.
AG,OUO6022,1805 –19–25JUL00–1/1
Remove and Install Light Panel Dimmer

Switch
1. Remove screws (A) and lower overhead panel.
2. Disconnect connector (B).
–UN–17MAR06
3. Depress four clips and remove switch (C) and bracket
from rear of panel.
H85539
4. Remove switch from bracket.
5. Remove switch (C) from bracket.
6. Install switch.
7. Connect connector.
8. Install overhead panel.

–UN–23NOV98
A—Screws (6 used)
B—Connector
C—Switch
H51577
OUO6083,0000CC4 –19–17MAR06–1/1

083006
PN=283
Operators Station
Remove and Install Overhead Display Rocker

Switches
NOTE: Procedure for removal and installation is similar

for all switches.
–UN–10APR01
1. Remove screws (A) attaching warning display panel.
H67443
3. Depress clips on switch (C) and remove from front of
control panel.
4. Install switch.
40 5. Connect connector.
30
6 6. Install overhead panel.
–UN–23NOV98
A—Screws (6 used)
B—Connector
C—Switch
H51576
OUO6083,000004C –19–10MAY01–1/1

083006
PN=284
Operators Station
Remove and Install CLIMATRAK Automatic

Air Conditioning/Heater Temperature Control
Switch and Fan Switch
1. Remove screws (A) attaching overhead panel.
–UN–10APR01
2. Remove control knobs (B).
3. Disconnect connector (C).
H67444
4. Remove lock nut and switch (D) from rear of control
panel.
5. Install switch.
6. Connect connector. 40
30
7. Install control knobs (B). 7
–UN–23NOV98
8. Install overhead panel.
9. Calibrate overhead panel. (See QUICK CAL.

PROCEDURES in TM2182.)
H51575
A—Screws (6 used)
B—Control Knob (2 used)
C—Connector
D—Switch
OUO6083,0000254 –19–02APR02–1/1
Remove and Install Radio
1. Remove six screws and lower overhead panel. It will

hang by cables.
Continued on next page AG,OUO6022,1555 –19–03MAY00–1/2

083006
PN=285
Operators Station
2. Disconnect antenna (A) and connectors (B). Remove

cap screw (C).
3. Remove rear support bracket.
4. Push clips (D), (two per side) in and remove radio.
–UN–11DEC98
5. If the radio is still covered by warranty, return it to the
manufacturer for repair. If it is out of warranty, return it
to the manufacturer or have it repaired locally.
H51650
6. Install radio. Install cap screw (C).
7. Install rear support bracket. A—Antenna

B—Connectors (2 used)
C—Cap Screw
8. Connect connectors (B) and connect antenna (A). D—Clips (4 used)
40
30
8 9. Install overhead panel.
AG,OUO6022,1555 –19–03MAY00–2/2
Remove and Install Radio Speaker (S.N. —

715300)
1. Remove screws (A) and grille (B).
2. Remove screws holding speaker.
–UN–19SEP02
3. Disconnect wire connector.
4. Repair or replace speaker.

E51885
5. Connect wire connector.
6. Install speaker and grille (B) using screws (A). A—Screw (4 used)
B—Grille
OUO6046,0002009 –19–20JUL05–1/1

083006
PN=286
Operators Station
Remove and Install Radio Speaker (S.N.

715301—)
1. Remove headliner. (See REMOVE AND INSTALL CAB

HEADLINER in Section 90, Group 15.)
–UN–26MAY05
2. Remove screws (A) and lower speaker.
3. Disconnect connectors (B) and remove speaker.
H83612
A—Screw (4 used)
B—Connector (2 used)
40
30
9
–UN–26MAY05
H83613
OUO6046,0001EAF –19–20JUL05–1/1
Remove and Install Radio Antenna (S.N. —

715300)
1. Remove screws (A) and cover (B) from above cab

door.
–UN–19SEP02
A—Screw (6 used)
B—Cover
E51884
Continued on next page OUO6046,000200A –19–20JUL05–1/2

083006
PN=287
Operators Station
NOTE: Antenna cannot be repaired. If defective, it must

E
be replaced.
2. Remove nut (A), washer (B) and cable (C).
3. Remove antenna base (E) and seal (D) from roof. D
–UN–23SEP02
4. Install in reverse order. C
B
A—Nut
E51882
B—Lock Washer A
C—Cable
D—Seal
E—Base
40
30
10
OUO6046,000200A –19–20JUL05–2/2
Remove and Install Radio Antenna (S.N.

715301—)
1. Remove screws (A).
NOTE: Cap screw (C) is longer than cap screw (B). Note
–UN–26MAY05
locations to aid in installation.
2. Remove cap screw (B) and (C).
H83614
3. Remove communications/CB antenna (D).
A—Screw (12 used)

B—Cap Screw
C—Cap Screw
D—Communications/CB Antenna
OUO6083,0000AE8 –19–16AUG05–1/3
4. Lift up on front left-hand side of cab roof to access

antenna (A).
A—Antenna
–UN–23MAY05
H83571
Continued on next page OUO6083,0000AE8 –19–16AUG05–2/3

083006
PN=288
Operators Station
NOTE: Antenna cannot be repaired. If defective, it must

E
be replaced.
5. Remove nut (A), washer (B) and cable (C).
6. Remove antenna base (E) and seal (D) from roof. D
–UN–23SEP02
7. Install in reverse order of removal. C
B
A—Nut
E51882
B—Lock Washer A
C—Cable
D—Seal
E—Base
40
30
11
OUO6083,0000AE8 –19–16AUG05–3/3
Replace Cornerpost Main Circuit Board
IMPORTANT: Prior to removing old cornerpost, enter

diagnostics mode and record values in
CO3 addresses working backwards
from 133 through 100. These values will
–UN–18DEC03
be needed when re-programming new
cornerpost.
NOTE: Retain hardware for reinstallation of components.
H79645
1. Remove four screws (A).
A—Self-Tapping Screw (4 used)
Continued on next page OUO6083,0000463 –19–18DEC03–1/5

083006
PN=289
Operators Station
2. IF EQUIPPED WITH GREENSTAR: Disconnect wiring

harness connectors (A).
3. Remove two M10 cap screws (B) and monitor.
4. Remove four self-tapping screws (C) and monitor
–UN–13DEC99
bracket from cornerpost.
5. Pull out at bottom and pull down on cornerpost.
H62017
A—Wiring Harness Connectors
B—M10 Cap Screw (2 used)
C—Self-Tapping Screw (4 used) GREENSTAR
40
30
12
–UN–13DEC99
H62018
–UN–18DEC03
H79646

083006
PN=290
Operators Station
6. Disconnect wiring harness connectors (A). (Harness

removed for photo clarity.)
7. Disconnect ribbon connectors (B) and remove screws

(C). Remove main circuit board (D).
8. Install main circuit board (D) and retain with screws
–UN–04JAN02
(C).
9. Attach ribbon connectors (B) and wiring harness
H70523
connectors (A).
A—Wiring Harness Connector (4 used)

B—Ribbon Connector (4 used)
C—Screw (8 used)
D—Main Circuit Board 40
30
13
OUO6083,0000463 –19–18DEC03–3/5
10. Reinstall cornerpost (A) retain with four self-tapping

screws (B).
IMPORTANT: Address 125 and 129 must be entered

before address 124. After five engine
hours have been accumulated address
–UN–16FEB01
125 and 129 will be locked.
11. Enter diagnostics and select the cornerpost controller

(C03). Enter the values recorded from the old
H66428
cornerpost working down from address 133 to
address 100.
12. Perform CLIMATRAK calibration. (See CLIMATRAK A—Cornerpost

B—Self-Tapping Screw (4 used)
FAN SPEED ADJUST CALIBRATION and
CLIMATRAK TEMPERATURE SETPOINT ADJUST
CALIBRATION Procedures in the Combine Diagnosis
and Test Manual.)
13. IF EQUIPPED WITH GREENSTAR: Install cornerpost

and retain with two self-tapping screws in bottom two
holes only.

083006
PN=291
Operators Station
14. IF EQUIPPED WITH GREENSTAR: Attach mounting

bracket to cornerpost using two self-tapping screws
(C) in top two holes.
15. Attach monitor to mounting bracket using two M10

cap screws (B).
–UN–13DEC99
16. Attach wiring harness connectors (A) to monitor.
A—Wiring Harness Connectors
H62017
B—M10 Cap Screw (2 used)
C—Self-Tapping Screw (2 used)
GREENSTAR
40
30
14
–UN–13DEC99
H62018
–UN–18DEC03
H79646
OUO6083,0000463 –19–18DEC03–5/5

083006
PN=292
Operators Station
Remove Header Control Module
1. Remove cornerpost and main circuit board. (See

procedure in this group.)
2. Remove ribbon connectors (A) and screws (B) from
–UN–07JUN04
header control module (C).
3. Remove module from cornerpost.
H81089
5. Install header control module in reverse order. Tighten

screws (B) to specification. A—Ribbon Connectors (2 used)
B—Screws (4 used)
Specification C—Header Control Module
Module screws—Torque................................................................ 0.5 N•m 40
(4.5 lb-in.) 30
15
OUO6083,0000827 –19–10SEP04–1/1
Remove Automatic Combine Adjustment

(ACA) Display
1. Disconnect ribbon connectors (A) and remove screws

(B) from circuit board (C).
–UN–04JAN02
2. Remove circuit board (C) and ACA display module.
3. Install ACA display module in reverse order.
H70524
A—Ribbon Connector
B—Screw (4 used)
C—Automatic Combine Adjustment Display
OUO6083,000041C –19–28OCT02–1/1

083006
PN=293
Operators Station
Remove Performance Monitor and Digital

Tachometer Module
NOTE: Performance monitor (C) and digital tachometer

(D) are removed and installed utilizing the same
steps.
–UN–07JUN04
1. Remove cornerpost and main circuit board. (See
H81090
2. Remove ribbon connectors (A) and screws (B) from
performance monitor (C) and digital tachometer (D).
A—Ribbon Connector (2 used)
3. Remove performance monitor (C) and digital
B—Screws (4 used)
tachometer (D). C—Performance Monitor
40 D—Digital Tachometer
30 4. Repair or replace as necessary.
16
5. Install module in reverse order. Tighten screws (B) to
specification.
Specification
Module screws—Torque................................................................ 0.5 N•m
(4.5 lb-in.)
OUO6083,0000828 –19–07JUN04–1/1

083006
PN=294
Operators Station
40
30
17

083006
PN=295
Operators Station
COMMANDTOUCH Console Controls
3 4
2
7
1
9 10 11
12
8
28
40 13 14
30
18
15
16
17
18
19
20 21
–UN–08MAY03
27
22
H76771
26 23
25 24
Continued on next page OUO6083,0000C9F –19–01MAR06–1/2

083006
PN=296
Operators Station
1—Reel Fore/Aft or Reel 5—Unloading Auger Drive 13—Draper Belt Speed 23—High Speed Four Wheel
Raise/Lower or Backshaft (Swing In/Out) 14—Manual Reel Speed Drive Engage (Optional)
Speed Increase/Decrease 6—Unloading Auger Drive 15—DIAL-A-SPEED 24—Low Speed Four Wheel
or Corn Head Adjust Deck (On/Off Switch) (Optional) Drive Engage (Optional)
Plate 7—Unloading Auger Drive 16—Concave Clearance Adjust 25—Feeder House Reaction
2—Resume (Fore/Aft, Height Indicator Light 17—Cleaning Fan Speed Speed
Control, and Lateral Tilt) 8— HYDRAFLEX Control 18—Cylinder Speed 26—Automatic Function
3—Quick Stop 9—Header Engage 19—Sieve Adjust Response Rate Control
4—CONTOUR 10—Separator Engage 20—Chaffer Adjust 27—Engine Speed (Low,
MASTER/Manual Header 11—Road Transport 21—Cigar Lighter Medium and High)
Raise and Lower Disconnect Switch 22—Spreader Speed 28—Multi-Function Handle
12—Active Header Control
40
30
CONTOUR MASTER is a trademark of Deere & Company 19
HYDRAFLEX is a trademark of Deere & Company
DIAL-A-SPEED is a trademark of Deere & Company OUO6083,0000C9F –19–01MAR06–2/2

083006
PN=297
Operators Station
Remove and Install COMMANDTOUCH

Console

damage.
–UN–04MAR99
NOTE: Connector bodies are “keyed” for proper contact
mating. Be sure contacts are in proper alignment.
H54311
2. Remove nut and disconnect linkage (B).
3. Remove screw (C).

40
30 IMPORTANT: When lifting top console assembly,
20 reach back between console base and
top console assembly and pull harness
–UN–07MAY03
upwards to create enough slack to aid
in lifting top console assembly. Pulling
harness up by the top assembly can
damage harness connectors and/or
H76779
console circuit board.
4. Disconnect two connectors from wiring harness (D)

and remove console.
5. Connect harness.
IMPORTANT: When reassembling top console, reach

under base of console and pull excess
–UN–07MAY03
harness out through bottom. Make sure
top console assembly is properly
aligned with console housing while
lowering into place. Forcing console
H76780
down may cause circuit board damage.
6. Install console.
A—Screws (3 used)
B—Arm
7. Connect linkage. C—Screw
D—Wiring Harness
OUO6083,0000581 –19–07MAY03–1/1

083006
PN=298
Operators Station
Remove and Install Header and Separator

Engage Switches
1. Lift switch (A) up far enough to depress two clips on

each side and remove from socket. Switch should
hang outside socket.
–UN–05MAY03
2. Remove console. (See REMOVE AND INSTALL
COMMANDTOUCH CONSOLE in this group.)
H76700
3. Disconnect connector (B) from circuit board and
remove switch through top of console.
4. Install switch and connect connector in same position

as removed.
40
5. Install console. (See REMOVE AND INSTALL 30
COMMANDTOUCH CONSOLE in this group.) 21
–UN–07MAY03
A—Switch
B—Connector
H76782
OUO6083,000079D –19–14MAY04–1/1

083006
PN=299
Operators Station
Remove and Install DIAL-A-SPEED and

Active Header Control Switches

–UN–07MAY03
2. Remove three screws (A) and cover (B) from bottom
right-hand side of console.
3. Remove knob (C) from top of switch.
H76797
4. Remove nut and washer from top of switch.
5. Disconnect connector (D) and remove switch (E).
40 6. Install switch.
30
22 7. Install console. (See REMOVE AND INSTALL
–UN–07MAY03
A—Screws (3 used)
B—Cover
C—Knob
H76798
D—Connector
E—Switch
–UN–07MAY03
H76799
OUO6083,0000583 –19–07MAY03–1/1

083006
PN=300
Operators Station
Remove and Install Backlight Bulbs for

DIAL-A-SPEED and Active Header Control
Switches
1. Remove screws (A) and cover (B).
–UN–07MAY03
2. Remove socket (C) and bulb (D) from socket.
3. Install light bulb.
H76797
A—Screws (3 used)
B—Cover
C—Socket
D—Bulb
40
30
23
–UN–07MAY03
H76800
OUO6083,0000584 –19–07MAY03–1/1

083006
PN=301
Operators Station

Console Membrane Switches

–UN–07MAY03
2. Remove DIAL-A-SPEED and Active Header Control
knobs. (See REMOVE AND INSTALL DIAL-A-SPEED
AND ACTIVE HEADER CONTROL in this group.)
H76801
3. Remove header and separator engage switches. (See
REMOVE AND INSTALL HEADER AND SEPARATOR
SWITCHES in this group.)
4. Peel main graphic label (A) from bezel and discard.

40
30 5. Remove screws (B) and bezel (C).
24
6. Remove rubber key pad (D).
–UN–07MAY03
NOTE: Switches not used have brown plastic covers (E).
Note locations for reinstallation.
H76802
A—Main Graphic Label
B—Screw (8 used)
C—Bezel
D—Rubber Key Pad
E—Plastic Cover
–UN–07MAY03
H76809
OUO6083,0000585 –19–07MAY03–1/9
7. Remove three cap screws (A) and disconnect

multi-function handle wiring harness connector (B) from
circuit board.
8. Move multi-function handle assembly (C) to access

circuit board.
–UN–07MAY03

B—Multi-Function Handle Wiring Harness
C—Multi-Function Handle Assembly
H76810

083006
PN=302
Operators Station
9. Remove screws (A) and disconnect ribbon connectors

(B).
10. Move circuit board assembly (C) to access ground

connector.
–UN–07MAY03
A—Screw (5 used)
B—Ribbon Connectors
C—Circuit Board Assembly
H76811
OUO6083,0000585 –19–07MAY03–3/9
11. Disconnect ground connector (A).

40
30
A—Ground Connector
25
–UN–07MAY03
H76812
OUO6083,0000585 –19–07MAY03–4/9
12. Remove membrane switch (A).
13. Install new membrane switch (A) and route ribbon

harness to back of console.
A—Membrane Switch
–UN–07MAY03
H76813
OUO6083,0000585 –19–07MAY03–5/9
14. Attach ground connector (A) from membrane switch

to wiring harness connector.
A—Ground Connector
–UN–07MAY03
H76812

083006
PN=303
Operators Station
15. Reposition circuit board (C) and retain with screws

(A).
16. Attach ribbon connectors (B) to circuit board.
A—Screw (5 used)
–UN–07MAY03
B—Ribbon Connectors
C—Circuit Board Assembly
H76811
OUO6083,0000585 –19–07MAY03–7/9
NOTE: Ensure multi-function handle wiring harness is

40 correctly positioned (as shown) and retained with
30 clamp.
26
17. Reposition multi-function handle assembly (C) onto
circuit board and retain with clamp and cap screws
–UN–07MAY03
(A).
18. Attach multi-function handle wiring harness connector

(B) to circuit board connector.
H76810
B—Multi-Function Handle Wiring Harness
C—Multi-Function Handle Assembly

083006
PN=304
Operators Station
19. Install rubber key pad (D) and plastic covers (E).
20. Install bezel (C) and retain with screws (B).
21. Install new graphic label (A).
–UN–07MAY03
22. Install header and separator engage switches. (See
REMOVE AND INSTALL HEADER AND
SEPARATOR SWITCHES in this group.)
H76809
23. Install DIAL-A-SPEED and Active Header Control
Switches. (See REMOVE AND INSTALL
DIAL-A-SPEED AND ACTIVE HEADER CONTROL
SWITCHES in this group.)
24. Install console. (See REMOVE AND INSTALL

40
COMMANDTOUCH CONSOLE in this group.) 30
27
A—Graphic decal
–UN–07MAY03
B—Screw (8 used)
C—Bezel
D—Rubber Key Pad
E—Plastic Cover
H76802
–UN–07MAY03
H76801
OUO6083,0000585 –19–07MAY03–9/9

083006
PN=305
Operators Station

Console Circuit Board

cards/components by edges to help
prevent damage.
–UN–08MAY03
H76814
2. Remove cap screws (A) from multi-function handle
mounting bracket (B).
3. Disconnect multi-function control handle connector (C).
40 4. Disconnect all connectors (D) to circuit board.

30
28 5. Remove cap screws (E) and circuit board (F) from
console.
–UN–08MAY03
B—Multi-Function Handle Mounting Bracket
C—Multi-Function Handle Connector
H76817
D—Connector
E—Cap Screw (5 used)
F—Circuit Board
OUO6083,0000779 –19–22SEP04–1/2
6. Carefully install circuit board.
7. Install multi-function handle.
8. Use sequence shown when fastening circuit board to

cover. Tighten cap screws (5, 6 and 8) to specification.
–UN–16JUN03
Specification
Multi-Function Handle Pivot Cap
Screws—Torque ............................................................................ 2.7 N•m
(24 lb-in.)
H77901
9. Connect all connectors to circuit board.

Circuit Board Torque Sequence
10. Install console. (See REMOVE AND INSTALL 1—8—Cap Screw

OUO6083,0000779 –19–22SEP04–2/2

083006
PN=306
Operators Station
Replace Neutral Safety Switch

prevent damage.
–UN–18MAR04
2. Disconnect all connectors to circuit board (A).
H80473
3. Remove screws (B) to multi-function handle mounting
bracket and screws (C) and carefully remove circuit
board.
4. Remove screws (D). Disconnect connector and remove

40
switch (E). 30
29
5. Install switch. Tighten screws to specification.
–UN–18MAR04
Specification
Neutral Safety Switch—Torque ..................................................... 0.9 N•m
(8.0 lb-in.)
H80474
6. Install circuit board and multi-function handle.
7. Connect all connectors to circuit board. A—Circuit Board

B—Screw (3 used)
8. Install console. (See REMOVE AND INSTALL C—Screw (5 used)
COMMANDTOUCH CONSOLE in this group.) D—Screw (2 used)
E—Neutral Safety Switch
OUO6083,0000866 –19–28JUN04–1/1

083006
PN=307
Operators Station
Replace Mini Harness

prevent damage.
–UN–18MAR04
2. Disconnect all connectors to circuit board (A) and cigar
H80473
lighter.
3. Remove three cap screws (B) from multi-function

handle mounting bracket and screws (C) from circuit
board. Carefully remove circuit board.
40
30 4. Remove screws (D) and cover (E).
30
5. Remove sockets and bulbs (F).
–UN–18MAR04
6. Disconnect remaining connectors and remove mini
harness (G).
H80475
7. Install harness.
8. Install bulbs.
9. Install multi-function handle and circuit board.
10. Connect all connectors to circuit board.
11. Connect cigar lighter wire leads.
–UN–18MAY04
12. Install cover.
H80476
A—Circuit Board
B—Screw (3 used)
C—Screw (5 used)
D—Screw (3 used)
E—Cover
F—Sockets and Bulbs (6 used)
G—Mini Harness
OUO6083,0000708 –19–19MAR04–1/1

083006
PN=308
Operators Station
Remove and Install Multi-Function Handle

2. Disconnect connector (A) from circuit board.
–UN–08MAY03
3. Remove J-clamp (B).
4. Remove shoulder bolts (C) and spring (D) from arm
H76820
(E).
5. Remove multi-function handle (F) from top of console.

A—Connector
6. Install multi-function handle through top of console. B—J-Clamp
C—Shoulder Bolt (2 used)
D—Spring 40
7. Use LOCTITE high strength thread lock (271) and E—Arm 30
install shoulder bolts (C) and spring (D) to arm (E). F—Multi-Function Handle 31
Tighten shoulder bolts to specifications.
Specification
Multi-Function Handle Shoulder
Bolts—Torque ................................................................................... 6 N•m
(53 lb-in.)
8. Install harness correctly using J-clamp (B).
9. Connect connector (A) to circuit board.

OUO6083,0000AE7 –19–16AUG05–1/1

083006
PN=309
Operators Station
Remove and Install Start Switch
1. Remove four screws and cover (A).
2. Unplug connector (B) and single wire (E) from switch,

making certain to identify each connector for
–UN–15DEC00
installation on new switch.
3. Remove lock nut (C) and switch (D).
H65605
4. Install switch.
NOTE: A new switch will use the same key as the old
one. This key also works for the door lock.
40 A—Cover
30 B—Connector
32 C—Lock Nut
D—Switch E
E—Wire
–UN–07MAY01
C
H67861
OUO6083,0000052 –19–10MAY01–1/1

083006
PN=310
Operators Station
Remove and Install Starting Aid Switch
1. Remove cover (A).
2. Remove cap (B) and guard (C) from switch by turning

cap counterclockwise.
–UN–08MAY03
3. Pull starting aid switch (D) out through hole from inside
of housing. Switch cannot be repaired. Defective switch
must be replaced.
H76823
4. Disconnect wire lead connector (E).
6. Install switch through hole inside of housing. Place

40
guard (C) over switch (D), then thread cap (B) onto 30
switch turning clockwise to tighten. 33
–UN–04MAR99
7. Install cover.
A—Cover
B—Cap
H51672
C—Guard
D—Switch
E—Connector
OUO6083,0000301 –19–08AUG02–1/1
Remove and Install Turn Signal/Side Finder

Light Switch
See procedure in DISASSEMBLE AND ASSEMBLE

STEERING COLUMN in Section 60, Group 05.
AG,OUO6022,1575 –19–03MAY00–1/1

083006
PN=311
Operators Station
Remove and Install Horn Switch
1. Remove four screws and cover (A).
2. Remove cap (B) from switch by turning cap

counterclockwise.
–UN–08MAY03
3. Pull horn switch (C) out through hole from inside of
housing. Switch cannot be repaired. Defective switch
must be replaced.
H76823
4. Disconnect wiring lead at connector (D).
5. Install switch through hole inside of housing and

tighten cap (B) by turning clockwise.
40
30 6. Connect connector.
34
7. Install cover.
–UN–23NOV98
A—Cover
B—Cap
C—Horn Switch
H51558
D—Connector
OUO6083,00007E7 –19–21MAY04–1/1
Remove and Install Remote Mirrors

(Optional)
1. Disconnect connector (A) from mirror
2. Loosen cap screws (B).

–UN–07FEB01
3. Slide mirror off mounting post (C).
4. Inspect mirror, replace as necessary.

H66195
5. Slide mirror onto mounting post (C).
6. Tighten cap screws (B). A—Connector

C—Mounting Post
7. Connect connector (A).
OUO6083,0000648 –19–16JUN03–1/1

083006
PN=312
Operators Station

(S.N. —715300) (Optional)
A—Screw (6 used)
–UN–06FEB01
H66186
OUO6083,0000CA0 –19–01MAR06–1/3
2. Disconnect connectors (A) from switch (B).

40
3. Press in clips on sides of switch (B) and remove by 30
pushing through front of overhead panel. 35
4. Install switch (B) into overhead panel.
–UN–07FEB01
5. Connect connectors (A).
A—Connectors
H66196
B—Switch
OUO6083,0000CA0 –19–01MAR06–2/3
6. Install overhead panel and screws (A).
A—Screw (6 used)
–UN–06FEB01
H66186
OUO6083,0000CA0 –19–01MAR06–3/3

083006
PN=313
Operators Station

(S.N. 715301—) (Optional)
A—Screw (6 used)
–UN–06FEB01
H66186
OUO6083,0000CA1 –19–01MAR06–1/3
2. Disconnect connector (A) from switch (B).

40
30 3. Press in clips on sides of switch (B) and remove by
36 pushing through front of overhead panel.
4. Install switch (B) into overhead panel.
–UN–29AUG05
A—Connector
H84336
B—Switch
OUO6083,0000CA1 –19–01MAR06–2/3
6. Install overhead panel and screws (A).
A—Screw (6 used) –UN–06FEB01

H66186
OUO6083,0000CA1 –19–01MAR06–3/3

083006
PN=314
Group 35
Sensors and Switches
NOTE: Order tools from the U.S. SERVICEGARD or RECOMMENDED TOOLS, as noted, are suggested to
Catalogs.
OUO6083,0000097 –19–07JUN01–1/2
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D15032NU

40
Used to perform service work without draining reservoir. 35
1
Vacuum Pump Adapter Set . . . . . . . . . . . . . . . JT07085
–UN–01JUN01
Used with Vacuum Pump D15032NU.
H68348
OUO6083,0000097 –19–07JUN01–2/2
Other Material
Number Name Use
TY9375 (U.S.) TEFLON Pipe Sealant Seal threads to prevent escape of

liquid or gases.
PM38654 (U.S.) High Strength Threadlock Eliminates vibration loosening and

prevents leaks.
OUO6083,0000AEA –19–16AUG05–1/1

083006
PN=315
Specifications
Radiator Coolant—6.8 L Capacity 44 L

(11.6 gal)
Radiator Coolant—8.1 L and 9.0 L Capacity 48.2 L

(12.75 gal)
Radiator Coolant—12.5 L Capacity 67.7 L

(17 gal)
Shoe Sensor Ground Screw Torque 2.0 ± 0.4 N•m

(17.7 ± 3.5 lb-in.)
40
35
2
OUO6083,0000D55 –19–08JUN06–1/1

083006
PN=316
Shaft Speed Sensor Locations
40
35
3
–UN–16FEB99
H51657
Right-Hand Side
A—Spreader (if equipped) B—Discharge Beater C—Feeder House Backshaft D—STS Rotor
AG,OUO6022,1578 –19–03MAY00–1/1

083006
PN=317
Shaft Speed Sensor Locations
40
35
4
–UN–02JUN99
H51658
Left-Hand Side
A—Feed Accelerator C—Cleaning Fan E—Tailings Elevator F—Chopper (if equipped)

B—Conveyor Augers D—Clean Grain Elevator
AG,OUO6022,1579 –19–03MAY00–1/1

083006
PN=318
Remove and Install Ground Speed Sensor
1. Disconnect connector (A).
2. Loosen nut (B) and remove sensor (C) by turning

counterclockwise. Refer to TM2182 for testing sensor.
–UN–21MAY04
3. Install sensor. Turn sensor (C) clockwise until it makes
contact. Back sensor off counterclockwise 1/2 turn and
tighten nut (B).
H80929
A—Connector
B—Nut
C—Sensor
40
35
5
OUO6083,00007E6 –19–21MAY04–1/1
Remove And Install Low Shaft Speed Sensor
NOTE: The following procedure applies to feed

accelerator, conveyor auger, clean grain elevator,
chopper, spreader and discharge beater sensors.
–UN–04DEC98
1. Remove debris buildup and unplug connector (A).
2. Remove two screws (B) and sensor.
H51594
3. Remove two screws (C) and magnet. Refer to TM2182
to test the sensor.
4. Install sensor. A—Connector

B—Screws (2 used)
C—Screws (2 used)
AG,OUO6022,1580 –19–03MAY00–1/1

083006
PN=319
Remove and Install STS Rotor Speed Sensor
1. Lower feeder house to ground. Shut off engine and

remove key.
2. Remove feeder house top doors (A and B).
–UN–21JAN99
3. Remove four cap screws (C) and plate.
NOTE: The following steps also apply to removal of
H51815
cleaning fan and feeder house backshaft speed
sensors.
4. Disconnect connector (D).
5. Turn sensor (E) counterclockwise and remove. Refer to

40
35 TM2182, Section 240 to test sensor.
6
6. Install sensor. Turn sensor clockwise until it contacts
–UN–16FEB99
tone wheel (F). Back sensor off 1/2 turn
counterclockwise.
7. Connect connector (D).
H51597
A—Access Cover
B—Access Cover
C—Cap Screws (4 used)
D—Connector
E—Sensor
F—Tone Wheel
–UN–19FEB99
H51615
AG,OUO6022,1581 –19–03MAY00–1/1

083006
PN=320
Remove and Install Full Grain Tank Sensor
2. Remove attaching hardware.
–UN–12MAR99
3. Remove sensor (B).
4. Install sensor.
H54720
A—Connector
B—Sensor
40
35
7
AG,OUO6022,1582 –19–03MAY00–1/1
Remove and Install Tailings Sensor
CAUTION: Disconnect harness connectors (A)

before servicing tailings sensor(s).
NOTE: There are two sensors located on the tailings
–UN–24FEB99
elevator. Inside sensor is the master and outside
is the slave.
1. Disconnect connectors (A).
H54193
2. Remove spring (B).
A—Connectors (2 used)
3. Remove sensors (C). B—Spring
C—Sensor (2 used)
4. Install sensors.
AG,OUO6022,1583 –19–03MAY00–1/1

083006
PN=321
Remove and Install (Shoe/Separator)

VISIONTRAK Sensors
2. Remove screws (B) and remove sensor (C).
–UN–25FEB99
3. Install sensor. Tighten ground screw (B) to
specification.
H54203
Specification
Shoe Sensor Ground Screw—
Torque .................................................................................. 2.0 ± 0.4 N•m
(17.7 ± 3.5 lb-in.) A—Connector
B—Screw (4 used)
C—Sensor
40
35
8
VISIONTRAK is a trademark of Deere & Company OUO6083,0000D57 –19–08JUN06–1/1
Remove and Install Concave Position Sensor
2. Remove nut and cap screw (B) and sensor assembly

(C).
–UN–08JUN06
NOTE: Sensor is not repairable. Replace sensor if
necessary.
H86109
3. Install in reverse order and perform concave calibration
procedure. (See QUICK CAL PROCEDURES in
TM2182.)
A—Connector
B—Nut and Cap Screw
C—Sensor Assembly
OUO6083,0000D56 –19–08JUN06–1/1

083006
PN=322
Remove and Install Header Height and

CONTOUR MASTER Control Sensors
1. Remove shields (A) as necessary.
–UN–16MAR04
3. Remove screws (C), clip (D) and sensor.
A—Shield
H80445
B—Connector
C—Screw (2 used)
D—Clip
40
35
9
–UN–17MAR04
H80447
CONTOUR MASTER Lateral Tilt Sensor
–UN–17MAR04
H80446
Header Height Sensor

083006
PN=323
4. Align key (A) with notch (B) and install sensor.
5. Rotate sensor on shaft to install attaching hardware.
6. Install shields.
–UN–26FEB99
A—Key
B—Notch
H54218
40
35
10
–UN–17MAR04
H80461
OUO6083,0000700 –19–17MAR04–2/2
Remove and Install Multi-Function Handle

Feed Rate Sensor
1. Remove COMMANDTOUCH console. (See REMOVE

AND INSTALL COMMANDTOUCH CONSOLE in this
group.)
OUO6083,0000AE9 –19–16AUG05–1/16
2. Disconnect armrest wiring harnesses (A and B).
A—Wiring Harness
B—Wiring Harness
–UN–27JAN04
H80018

083006
PN=324
3. Disconnect wiring harnesses (A, B and C).
A—Wiring Harness
B—Wiring Harness
C—Wiring Harness
–UN–27JAN04
H80017
OUO6083,0000AE9 –19–16AUG05–3/16
4. Remove shoulder bolts (A) and torsion spring (B) from

multi-function control handle assembly. 40
35
11
A—Shoulder Bolts (2 used)
B—Torsion Spring
–UN–26JAN04
H80011
OUO6083,0000AE9 –19–16AUG05–4/16
5. Remove cap screws (B and D), sensor bracket (C) and

pivot bracket (A).
A—Pivot Bracket
B—Cap Screw
C—Sensor Bracket
D—Cap Screw
–UN–26JAN04
H80013
OUO6083,0000AE9 –19–16AUG05–5/16
6. Remove control handle sensor pin (A) from pivot pin

(B).
A—Sensor Pin
B—Pivot Pin
–UN–26JAN04
H79980

083006
PN=325
7. Remove cap screws and lock nuts (C) from sensor (A)
and sensor bracket (B).
A—Control Handle Sensor

B—Sensor Bracket
C—Cap Screw and Lock Nut (2 used)
–UN–02JUL04
H81217
OUO6083,0000AE9 –19–16AUG05–7/16
8. Remove shoulder bolt and lock nut (F), spring (E),

40 washer with tab (D), friction washers (C), and ground
35 speed arm (A) from pivot bracket (B). Repair or replace
12 as necessary.
A—Ground Speed Arm
–UN–09JUN04
B—Pivot Bracket
C—Friction Washers (2 used)
D—Washer with Tab
E—Spring
F—Shoulder Bolt and Lock Nut
H81143
–UN–26JAN04
H79974

083006
PN=326
9. Remove pivot pin (A) from pivot bracket (C) and

ground speed arm (B).
10. Install ground speed arm (A) through pivot bracket

(B).
11. Install friction washers (C).
–UN–26JAN04
12. Install washer with tab (D) into slot on ground speed
arm.
H79976
13. Install spring (E) onto shoulder bolt (F) and push
through hole on pivot bracket.
A—Pivot Pin
B—Ground Speed Arm
C—Pivot Bracket
40
35
13
OUO6083,0000AE9 –19–16AUG05–9/16
NOTE: Friction washers should turn freely when ground

speed arm is rotated.
14. Retain shoulder bolt (A) with lock nut (B). Tighten to
specification.
Specification
–UN–26JAN04
Pivot Bracket Lock Nut—Torque .................................................... 40 N•m
(30 lb-ft)
15. Align pivot pin (C) with ground speed arm (D) and
H79975
pivot bracket (E). Press pin into bracket until it snaps
into place.
A—Shoulder Bolt
B—Lock Nut
C—Pivot Pin
D—Ground Speed Arm
E—Pivot Bracket

083006
PN=327
IMPORTANT: Center cap screws (C) and sensor (A) in

sensor bracket (B). This is critical to
achieve correct sensor voltage
readings.
16. Center control handle sensor (A) in sensor bracket

(B) and retain with cap screws and lock nuts (C).
–UN–02JUL04
A—Control Handle Sensor
B—Sensor Bracket
H81217
40
35
14
OUO6083,0000AE9 –19–16AUG05–11/16
17. Align sensor pin (A) with slot in pivot pin (B).
A—Sensor Pin
B—Pivot Pin
–UN–26JAN04
H79980
OUO6083,0000AE9 –19–16AUG05–12/16
18. Install pivot bracket (A) and retain control handle

wiring harness with cap screw (B).
NOTE: Let sensor bracket center itself before installing

cap screws. This will help prevent the bracket
from binding.
–UN–26JAN04
19. Retain sensor bracket (C) with cap screws (D).
A—Pivot Bracket
H80013
B—Cap Screw
C—Sensor Bracket
D—Cap Screw

083006
PN=328
20. Install torsion spring (A) onto control handle.
21. Apply PM38654 Threadlock and Sealer (High

Strength) to shoulder bolts (B) and tighten to
specification.
Specification
–UN–26JAN04
Multi-Function Handle Shoulder
Bolts—Torque ................................................................................... 6 N•m
(53 lb-in.)
H80014
A—Torsion Spring
B—Shoulder Bolt (2 used)
40
35
15
OUO6083,0000AE9 –19–16AUG05–14/16
22. Connect control handle sensor wiring harness (A) to

sensor.
23. Connect feed rate armrest wiring harness (B) to

neutral switch wiring harness (C).
–UN–27JAN04
A—Wiring Harness
B—Wiring Harness
C—Wiring Harness
H80017
OUO6083,0000AE9 –19–16AUG05–15/16
24. Connect armrest circuit board wiring harness (A) and

armrest main wiring harness (B).
25. Install COMMANDTOUCH console. (See REMOVE

AND INSTALL COMMANDTOUCH CONSOLE in this
group.)
–UN–27JAN04
26. Calibrate sensor. (See TM2182, Section 240.)
A—Wiring Harness
H80018
B—Wiring Harness
OUO6083,0000AE9 –19–16AUG05–16/16

083006
PN=329
Remove and Install Hydraulic Reservoir

Temperature Sensor
1. Drain reservoir to level below sensor or use vacuum

pump D15032NU.
–UN–04DEC98
3. Remove sensor (B). Sensor cannot be repaired. If

defective, it must be replaced.
H51616
4. Install sensor (B) using new O-ring.
5. Connect connector (A). A—Connector

B—Temperature Sensor
40 6. Fill reservoir with recommended oil. (See Section 10.)

35
16
AG,OUO6022,1588 –19–03MAY00–1/1
Remove and Install Hydraulic Reservoir

Temperature Sensor (Tier III Cooling
Package)
1. Drain reservoir or use vacuum pump D15032NU.

4. Install sensor (B) using new O-ring.
–UN–14JUN05
6. Fill reservoir with recommended oil. (See Section 10.)
H83723
A—Connector
B—Temperature Sensor
RO33873,0000049 –19–25JUL05–1/1

083006
PN=330
Remove and Install Coolant Temperature

Sensor

–UN–01NOV88
coolant.
T6642EK
OUO6083,0000054 –19–25JUL05–1/3
IMPORTANT: The approximate coolant capacity is 45

L (47.6 qt). 40
35
Specification 17
Radiator Coolant—Capacity ................................................................ 45 L
(47.6 qt)
–UN–24APR01
2. Drain radiator (A) and engine block drain (B) until
coolant level has drained below coolant temperature
sensor.
H67382
3. Close radiator drain (A) and engine block drain (B).
4. Close radiator cap to prevent contamination from

entering coolant system.
A—Radiator Drain
B—Engine Block Drain
–UN–07JUN04
H81092

083006
PN=331
5. Disconnect sensor connector (A).
6. Turn sensor (B) counterclockwise using a wrench

ONLY on the hex portion of the sensor.
Sensor cannot be repaired. If defective, it must be
–UN–10MAY01
replaced.
7. Apply TY9375 pipe sealant with TEFLON to threads of

sensor. Turn sensor (B) clockwise using a wrench
H67921
8. Connect connector to sensor (A).

A—Connector
IMPORTANT: The approximate coolant capacity is 45 B—Sensor
L (47.6 qt).
40
35
18 9. Open radiator cap and fill radiator with coolant to
capacity.
Specification
Radiator Coolant—Capacity ................................................................ 45 L
(47.6 qt)
10. Close radiator cap.
OUO6083,0000054 –19–25JUL05–3/3

083006
PN=332
Remove and Install Coolant Temperature

Sensor (Tier III Cooling Package)

–UN–01NOV88
coolant.
1. Slowly loosen radiator cap or surge tank cap (A) if

equipped.
T6642EK
A—Surge Tank Cap
40
35
19
–UN–08JUN06
H86107
OUO6083,0000D54 –19–08JUN06–1/3
2. Open radiator (A) and engine block drain (B) until

coolant level has fallen below coolant temperature
sensor.
Specification
Radiator Coolant—6.8 L—
Capacity ............................................................................................... 44 L
–UN–14JUN05
(11.6 gal)
Radiator Coolant—8.1 L and 9.0
L—Capacity ...................................................................................... 48.2 L
(12.75 gal)
H83731
Capacity ............................................................................................ 67.7 L
(17 gal)
3. Close drains (A and B).
4. Install radiator cap to prevent contamination from

entering coolant system.
A—Radiator Drain
–UN–14JUN05
B—Engine Block Drain

H83732

083006
PN=333
6. Turn sensor (B) counterclockwise using a wrench

–UN–14JUN05
replaced.

sensor. Turn sensor (B) clockwise using a wrench
H83728
8. Connect connector to sensor (A).

A—Connector
9. Remove radiator cap and fill radiator with coolant to B—Sensor
capacity.
40
35
20 Specification
Capacity ............................................................................................... 44 L
(11.6 gal)
Radiator Coolant—8.1 L and 9.0
L—Capacity ...................................................................................... 48.2 L
(12.75 gal)
Capacity ............................................................................................ 67.7 L
(17 gal)
10. Install radiator cap.
OUO6083,0000D54 –19–08JUN06–3/3

083006
PN=334
Remove and Install Fuel Level Sensor
1. Clean area around fuel sensor to avoid contaminating

fuel supply when sensor is removed.
2. Remove fuel tank access door and dust cover.
–UN–10MAY01
3. Disconnect connector (A) to fuel sensor.
NOTE: Observe how float arm is positioned in relation to
H67922
fuel tank. This will simplify sensor installation.
4. Remove six screws (B), fuel sensor (C) and gasket

(D). Sensor can not be repaired. If damaged, it must A—Connector
be replaced. B—Screws (6 used)
C—Fuel Level Sensor
D—Gasket 40
5. Install fuel sensor using new gasket (D). Guide fuel 35
sender (C) through top of fuel tank with float arm 21
positioned toward center of tank. Install six screws (B).
6. Connect connector (A) to fuel sensor.
7. Install dust cover and fuel access door.
OUO6046,000200D –19–25JUL05–1/1
Remove and Install Park Brake Switch
2. Loosen retaining nut (B) and remove switch (C).
–UN–15DEC00
3. Switch cannot be repaired. Defective switch must be
replaced.
4. Install switch.
5. Connect connector. H65606
A—Connector
B—Retaining Nut
C—Switch
AG,OUO6022,1591 –19–03MAY00–1/1

083006
PN=335
Remove and Install Air Filter Restriction

Switch
2. Remove switch (B). Switch cannot be repaired and
–UN–10MAY01
must be replaced if defective.
3. Install switch (B).
H67923
A—Connector
B—Switch
40
35
22
OUO6083,0000055 –19–10MAY01–1/1
Remove and Install Air Filter Restriction

Switch (Tier III Cooling Package)
2. Remove switch (B). Switch cannot be repaired and
–UN–08JUL05
must be replaced if defective.
3. Install switch (B).
H83926
A—Connection
B—Switch
RO33873,000004C –19–25JUL05–1/1

083006
PN=336
Remove and Install Fuel Pressure Switch
1. Disconnect wiring harness connector (A).
2. Remove switch (B). Switch cannot be repaired. If

–UN–26MAY04
3. Apply TY9375 pipe sealant with TEFLON to threads
and install switch (B).
H80943
4. Connect wiring harness connector (A).
8.1 L Shown
A—Connector
B—Fuel Pressure Sensor
40
35
23
–UN–14JUN05
H83733
9.0 L Shown
OUO6046,000200E –19–25JUL05–1/1
Remove and Install Engine Gear Case

Temperature and Pressure Switches
1. Disconnect wiring harness connectors (A).
2. Remove temperature (B) and pressure (C) switches.
–UN–10MAY01
Switches cannot be repaired. If defective, they must be
replaced.
3. Install switches (B) and (C) using new O-rings.
4. Connect wiring harness connectors (A). H67924
A—Connectors
B—Temperature Switch
C—Pressure Switch
OUO6083,0000056 –19–10MAY01–1/1

083006
PN=337
Remove and Install Hydro Charge Pressure

Switch
–UN–25MAY04
3. Install switch (B) using new O-ring.
H80941
A—Connector
B—Switch
40
35
24
OUO6083,00007FF –19–25MAY04–1/1
Remove and Install Engine Oil Pressure

Switch
–UN–10MAY01

switch and install switch (B).
H67925
8.1 L Engine Oil Pressure Switch
A—Connector
B—Pressure Switch
–UN–25MAY04
H80942
12.5 L Engine Oil Pressure Switch

OUO6046,000200F –19–30AUG05–1/1

083006
PN=338
Remove and Install Engine Oil Pressure

Sensor
–UN–14JUN05

sensor and install sensor (B).
H83734
9.0 L Engine Oil Pressure Sensor
A—Connector
B—Pressure Sensor
40
35
25
OUO6046,000202E –19–30AUG05–1/1
Remove and Install Switches in the Ground

Level Switch Bank
NOTE: Removal and installation is the same for all

switches.
–UN–23NOV98
2. On face of mounting bracket, remove nut (B) from

switch.
H51556
3. Remove switch (C). Switch cannot be repaired.
Defective switch must be replaced.
4. Install switch.
A—Connector –UN–23DEC03
B—Nut
C—Switch
H79693
OUO6083,00006D9 –19–23DEC03–1/1

083006
PN=339
Remove and Install Compressor Inlet

Temperature Sensor—9.0 L
–UN–17JUN05

H83762
A—Connector
B—Sensor
40
35
26
RO33873,0000052 –19–25JUL05–1/1
Remove and Install Camshaft Position

Sensor—9.0 L


–UN–15JUN05
A—Connector
H83746
B—Sensor
RO33873,0000053 –19–25JUL05–1/1

083006
PN=340
Remove and Install Crankshaft Position

Sensor—9.0 L
1. Disconnect wiring harness connector (B).
2. Remove sensor retaining nut (A). Remove sensor.
–UN–16JUN05
replaced.
3. Install sensor. Install sensor retaining nut (A).
H83756
4. Connect wiring harness connector (B).
A—Sensor Retaining Nut

B—Connector
40
35
27
RO33873,000005C –19–25JUL05–1/1
Remove and Install Exhaust Gas

Recirculation (EGR) Exhaust Gas
Temperature, Fresh Air Temperature and
Exhaust Manifold Pressure Sensors—9.0 L
–UN–16JUN05
2. Remove sensor (B, D, or E). Sensor cannot be
repaired. If defective, it must be replaced.
H83755
sensor and install sensor (B, D, or E).
A—Connector
4. Connect wiring harness connector (A). B—Exhaust Manifold Pressure Sensor
C—EGR Valve
D—Exhaust Gas Temperature Sensor
E—Fresh Air Temperature Sensor
RO33873,0000054 –19–26JUL05–1/1

083006
PN=341
Remove and Install Intake Manifold Pressure

and Exhaust Gas Recirculation (EGR) Mixed
Gas Temperature Sensor—9.0 L
1. Disconnect wiring harness connector (A or B).
2. Remove sensor (C or D). Sensor cannot be repaired. If

–UN–15JUN05
sensor and install sensor (C or D).
4. Connect wiring harness connector (A or B).
H83748
A—Connector
40 B—Connector
35 C—EGR Mixed Gas Temperature Sensor
28 D—Intake Manifold Air Pressure Sensor
RO33873,0000055 –19–26JUL05–1/1
Remove and Install Turbocharger Speed

Sensor—9.0 L
1. Disconnect wiring harness connector.
2. Remove sensor (A). Sensor cannot be repaired. If
–UN–16JUN05

sensor and install sensor (A).
H83758
4. Connect wiring harness connector.
A—Sensor
RO33873,000005D –19–26JUL05–1/1

083006
PN=342
Remove and Install Fuel Rail Pressure

Sensor—9.0 L
–UN–17JUN05

sensor and install sensor (B).
H83772
A—Connector
B—Sensor
40
35
29
RO33873,000005E –19–26JUL05–1/1
Remove and Install Back-Up Alarm Switch
2. Loosen socket head screw (B). Remove switch (C)

from displacement control valve. Switch cannot be
repaired. If defective it must be replaced.
–UN–20JUL05
3. Install switch, tighten socket head screw and connect
wiring harness connector.
H83950
4. Adjust back-up alarm. (See procedure in Section 240
of TM2182.)
A—Connector
B—Socket Head Screw
C—Switch
OUO6083,0000ABF –19–31AUG05–1/1

083006
PN=343
Back-Up Alarm (S.N. —715300)
40
35
30
–UN–16JUN04
H81218
A—Nut (2 used) D—Bracket G—Lock Nut (2 used) I—Switch
B—Alarm E—Cap Screw (2 used) H—Bracket J—Screw (2 used)
C—Nut (2 used) F—Cap Screw (2 used)
NOTE: Alarm is located near the main engine gear

case.
OUO6083,0000A0C –19–30AUG05–1/1

083006
PN=344
Back-Up Alarm—9860 (S.N. 715301—)
D C
D
E
40
35
F 31
G
–UN–07JUN05
H
H83679
A—Bracket C—Clip E—Angle G—Cap Screw (2 used)
B—Wiring Harness D—Flange Nut (4 used) F—Alarm H—Cap Screw (2 used)
NOTE: Alarm is located on the rear panel.
OUO6083,0000A0B –19–30AUG05–1/1

083006
PN=345
Back-Up Alarm—9560, 9660, 9760 (S.N. 715301—)
B
C
D
A
40
35
32
–UN–30AUG05
H84347
G
A—Wiring Harness C—Flange Nut (2 used) E—Cap Screw (2 used) G—Cap Screw (2 used)
B—Clip D—Bracket F—Flange Nut (2 used) H—Alarm
NOTE: Alarm is located on the rear panel.
OUO6046,000202F –19–30AUG05–1/1

083006
PN=346
Group 40
Wiper
Specifications
Windshield Wiper Main Arm Lock Torque 18 N•m

Nut (159 lb-in.)
AG,OUO6022,1616 –19–03MAY00–1/1
Remove and Install Wiper Motor

40
NOTE: Make sure wipers are in the parked position 40
before starting removal procedures. 1
1. Remove cap screws (A) and sun visor (B).
–UN–30MAR00
B—Sun Visor
H63271
OUO6083,0000302 –19–08AUG02–1/8
2. Remove front headliner (A) from cab by pulling back

and down on front edge of headliner to clear tabs (B).
A—Tab (5 used)
B—Headliner
–UN–30MAR00
H63270
OUO6083,0000302 –19–08AUG02–2/8
3. Disconnect harness connector (A).
A—Harness Connector
–UN–30MAR00
H63269
Continued on next page OUO6083,0000302 –19–08AUG02–3/8

083006
PN=347
Wiper
NOTE: Wiper motor from service parts are supplied with

crank arm installed. It is not recommended to
disconnect crank arm from motor because it is
difficult to install and torque correctly.
4. Pry link (A) off ball stud on motor arm.
–UN–12JUL01
5. Remove cap screws (B) and wiper motor.
6. Inspect all parts for wear and damage, replace as
H69248
necessary.
A—Link
40
40
2
OUO6083,0000302 –19–08AUG02–4/8
7. Install motor and retain with cap screws (A).
8. Snap link (B) onto ball stud on motor arm.

B—Link
–UN–12JUL01
H69249
OUO6083,0000302 –19–08AUG02–5/8
9. Connector harness connector (A).
A—Harness Connector
–UN–30MAR00
H63269

083006
PN=348
Wiper
10. Connect front headliner (A) in cab by pulling back and

lifting up on front edge of headliner to clear tabs (B).
A—Headliner
B—Tab (5 used)
–UN–30MAR00
H63270
OUO6083,0000302 –19–08AUG02–7/8
11. Install sun visor (A) and retain with cap screws (B).
40
40
A—Sun Visor
3
–UN–30MAR00
H63276
OUO6083,0000302 –19–08AUG02–8/8

083006
PN=349
Wiper
Adjust Windshield Wiper
1. Operate wiper, mark extremes of wiper stroke with

tape on windshield near vertical center of blade holder.
2. Park wiper and shut it off. If tape markings are not
–UN–18MAY04
equally spaced from edges of windshield, adjust in
increments of 2.5 degrees (4.4 mm) [1.7 in.] at center
of blade holder by repositioning wiper arm on outer
pivot shaft.
H80385
3. To reposition wiper shaft:
a. Flex lower section of wiper arm (A) out away from A—Wiper
windshield and install a pin through small hole (B) in B—Small Hole
lower section of wiper arm near upper pivot shaft.
40
40
4 b. Remove lock nut from upper arm pivot and pry
assembly off pivot shaft.
c. Insert a 9.5 mm (3/8 in.) punch in pivot hole on front

side of arm. Drive out splined driver cone that is in
cavity on back side of arm and install it onto pivot
shaft.
d. Use marking tape as reference point and install arm

loosely on pivot shaft. Position as desired in relation
to tape before seating it on splined driver.
4. Install lock nut on pivot shaft and tighten to

specification.
Specification
Wiper Arm Lock Nut—Torque ........................................................ 18 N•m
(160 lb-in.)
5. Flex lower section of wiper arm out and remove pin

installed through lower arm below the pivot.
6. Adjust park as follows:
a. Remove front section of headliner.
b. Loosen two screws that go through slots in white

plastic cap on back of wiper motor.
Continued on next page OUO6083,00006E9 –19–03SEP04–1/2

083006
PN=350
Wiper
c. Use a wrench on hexagon stem in center of plastic

cover and slowly move plastic cover a small
amount. Try wipers. Repeat adjustment as required.
OUO6083,00006E9 –19–03SEP04–2/2
40
40
5

083006
PN=351
Wiper
Remove and Install Windshield Washer (S.N. —715300)
40
40
6
–UN–06APR00
H63360
Continued on next page OUO6046,000200B –19–20JUL05–1/2

083006
PN=352
Wiper
A—Nozzle (2 used) F—Grommet J—Cap N—Flange Nut (4 used)

B—Grommet (2 used) G—Grommet K—Filter O—Screw
C—Hose (2 used) H—Fitting L—Washer P—Grommet
D—Tee Fitting I—Hose Clamp (3 used) M—Reservoir Q—Pump
E—Hose
1. Remove washer parts as necessary. 3. Install washer parts.
2. Inspect parts. Replace as needed.
NOTE: Pump cannot be repaired. If defective, it must

be replaced.
40
40
7
OUO6046,000200B –19–20JUL05–2/2

083006
PN=353
Wiper
Remove and Install Windshield Washer (S.N. 715301—)
40
40
8
C
G
D
C H
C
B
C
N I
A J
M
–UN–01JUN05
L K
H83531
A—Nozzle (2 used) E—Grommet I—Plug L—Cap Screw (2 used)

B—Grommet (2 used) F—Grommet J—Grommet M—Reservoir
C—Hose G—Fitting K—Nut (2 used) N—Cap
D—Tee Fitting H—Pump
1. Remove washer parts as necessary. 3. Install washer parts.
2. Inspect parts. Replace as needed.
NOTE: Pump cannot be repaired. If defective, it must

be replaced.
OUO6046,0001EA7 –19–20JUL05–1/1

083006
PN=354
Group 45
Alternator
Catalogs.
SERVICEGARD is a trademark of Deere & Company OUO6083,0000A37 –19–16JUN05–1/3
Alternator Pulley Tool . . . . . . . . . . . . . . .KJD10278

40
Use to rotate alternator shaft during removal and 45
installation of pulley. 1
OUO6083,0000A37 –19–16JUN05–2/3
Strut Rod Nut Wrench . . . . . . . . . . . . . . . JDG1939
Use to remove and install hex nut while alternator

shaft is held in place by KJD10278.
OUO6083,0000A37 –19–16JUN05–3/3

083006
PN=355
Alternator
Specifications
Alternator Mounting Cap Screw Torque 71 N•m

(53 lb-ft)
95 Amp Alternator Field Nut Torque 3.2 ± 0.5 N•m

(28.3 ± lb-in.)
95 Amp Alternator Output Nut Torque 7.9 ± 0.2 N•m

(70 ± 2.0 lb-in.)
185 Amp Alternator Output Nut Torque 11 ± 1.5 N•m

(97 ± 13 lb-in.)
40
45 185 Amp Alternator Ground Nut Torque 8 ± 1 N•m
2 (71 ± 9 lb-in.)
200 Amp Alternator Field Nut Torque 3.2 ± 0.5 N•m

(28.3 ± lb-in.)
200 Amp Alternator Output Nut Torque 7.9 ± 0.2 N•m

(70 ± 2.0 lb-in.)
Alternator Pulley Nut Torque 70 N•m

(52 lb-ft)
OUO6083,0000A34 –19–16JUN05–1/1
John Deere Engine Accessories—Alternator

Repair—Use CTM77
For complete repair information the component technical


–UN–17JAN89

TS225
AG,OUO6022,1602 –19–03MAY00–1/1

083006
PN=356
Alternator
Remove and Install Alternator and Alternator

Belt
A—185 Amp Alternator

B—95 Amp Alternator
C—200 Amp Alternator
–UN–07JUL00
H64406
40
45
3
–UN–07SEP05
H84392
Continued on next page OUO6083,0000A33 –19–07SEP05–1/4

083006
PN=357
Alternator
CAUTION: Always remove grounded (-) battery

clamp first and replace last.
1. Disconnect battery ground cables (A) on earlier

machines, or if equipped, place battery disconnect
switch (B) in “O” off position (C).
–UN–23AUG88
A—Ground Cable
B—Battery Disconnect Switch
C—“O” Off Position
TS204
40
45
4
–UN–10MAY01
H67944
–UN–02JUN05
H83669

083006
PN=358
Alternator
NOTE: When replacing alternator belt, rotary screen drive

belt must be removed from engine sheave.
2. Remove:
• Alternator belt (B) using 1/2 inch drive breaker bar
–UN–26APR99
(A) in belt tensioner
• Nuts, lock washers, and wires
• Mounting hardware and alternator
• Refer to CTM77 for information on alternator repair
H55694
3. Install:
• Alternator using mounting hardware. Tighten to A—1/2 Inch Breaker Bar

specification. B—Alternator Belt
40
Specification
45
Alternator Mounting Cap Screw—
5
Torque ............................................................................................ 71 N•m
(53 lb-ft)

083006
PN=359
Alternator
• Wires, lock washers and tighten nuts (A—F) to

specification.
Specification
95 Amp Alternator Field Nut—
Torque .................................................................................. 3.2 ± 0.5 N•m
(28.3 ± lb-in.)
–UN–02JUL04
95 Amp Alternator Output Nut—
Torque .................................................................................. 7.9 ± 0.2 N•m
(70 ± 2.0 lb-in.)
185 Amp Alternator Output Nut—
Torque ................................................................................... 11 ± 1.5 N•m
H81240
(97 ± 13 lb-in.)
185 Amp Alternator Ground Nut—
Torque ........................................................................................ 8 ± 1 N•m 95 Amp Alternator
(71 ± 9 lb-in.)
200 Amp Alternator Field Nut—
Torque .................................................................................. 3.2 ± 0.5 N•m
40 (28.3 ± lb-in.)
45 200 Amp Alternator Output Nut—
6 Torque .................................................................................. 7.9 ± 0.2 N•m
(70 ± 2.0 lb-in.)
–UN–29JUN04
• Alternator belt
• Ground cable to batteries or turn on battery
H81241
disconnect switch if equipped
185 Amp Alternator

A—95 Amp Alternator Field Nut
B—95 Amp Alternator Output Nut
C—185 Amp Alternator Output Nut
D—185 Amp Alternator Ground Nut
E—200 Amp Alternator Field Nut
F—200 Amp Alternator Output Nut
–UN–07SEP05
H84391
200 Amp Alternator
OUO6083,0000A33 –19–07SEP05–4/4

083006
PN=360
Alternator
Remove and Install Voltage Regulator (185

Amp Leece-Neville)
NOTE: Alternator is removed for clarity. Regulator can be

replaced without removing alternator.
–UN–23AUG88
CAUTION: Always remove grounded (-) battery
clamp first and replace last.
1. Disconnect battery ground cables.
TS204
2. Disconnect alternator harness leads.
3. Remove attaching hardware and screen from back of

alternator.
40
45
A—Ground Cables 7
–UN–10MAY01
H67944
OUO6083,0000DB2 –19–08AUG06–1/5
4. Remove cap screws (A) and lift regulator to expose

wire terminals.

B—Regulator
–UN–08JUN00
H64097
OUO6083,0000DB2 –19–08AUG06–2/5
NOTE: Mark and identify location of regulator wires on

alternator.
5. Disconnect connectors (A—E).
A—Yellow Wire
–UN–08JUN00
B—Yellow Wire
C—Green Wire
D—Red Wire
E—Black Wire
H64098
Continued on next page OUO6083,0000DB2 –19–08AUG06–3/5

083006
PN=361
Alternator
6. Attach terminals (A—E) of the new regulator to the

alternator.
A—Yellow Wire
B—Yellow Wire
C—Green Wire
D—Red Wire
–UN–08JUN00
E—Black Wire
H64098
OUO6083,0000DB2 –19–08AUG06–4/5
7. Install regulator (B) using cap screws (A).

40
45 8. Install screen to back of alternator with attaching
8 hardware.
9. Connect alternator harness leads.
–UN–08JUN00
10. Connect battery ground cables.
H64097
B—Regulator
OUO6083,0000DB2 –19–08AUG06–5/5
Remove and Install Alternator Pulley (200

Amp Bosch)
NOTE: Alternator removed for clarity.
1. Hold alternator shaft from turning using KJD10278

–UN–16JUN05
while loosening pulley nut using JDG1939. Remove

pulley (C).

H83757
3. Install sheave and tighten nut to specification using

JDG1939 and KJD10278.
A— Tool KJD10278
B—Tool JDG1939
Specification
Alternator Pulley Nut—Torque ....................................................... 70 N•m C—Pulley
(52 lb-ft)
OUO6083,0000A35 –19–16JUN05–1/1

083006
PN=362
Group 50
Starting Motor
Catalogs.
SERVICEGARD is a trademark of Deere & Company OUO6083,0000D53 –19–07JUN06–1/4
H75768 –UN–25MAR03
Starter Wrench . . . . . . . . . . . . . . . . . . . . . . . .JDE801

40
Use to remove and install starters. 50
1
1
RECOMMENDED TOOL available through service parts catalog.
OUO6083,0000D53 –19–07JUN06–2/4
H75768 –UN–25MAR03
Starter Wrench . . . . . . . . . . . . . . . . . . . . . . JDG2046
Used to remove and install starters.
OUO6083,0000D53 –19–07JUN06–3/4
H86095 –UN–13JUN06
1
Starter Wrench . . . . . . . . . . . . . . . . . . . . . KJD10213
Used to remove and install starters.
1
OUO6083,0000D53 –19–07JUN06–4/4

083006
PN=363
Starting Motor
Specifications
Starting Motor
Cap Screws Torque 47 N•m

(35 lb-ft)
AG,OUO6022,1608 –19–03MAY00–1/1
John Deere Starting Motor Repair—Use

40 CTM77
50
2
For complete repair information the component technical
–UN–17JAN89
TS225
AG,OUO6022,1609 –19–03MAY00–1/1
Remove and Install Starting Motor
1. On machines with batteries located in engine

compartment; disconnect ground cable (-) from
batteries.
–UN–06JUN05
2. On machines with batteries located on right-hand side;
turn battery disconnect switch (A) to “O” position (B).
3. Clean area around starter.

H83697
A—Disconnect Switch
B—“O” Off Position

083006
PN=364
Starting Motor
4. Disconnect wires (A and B).
5. Remove three cap screws (C) using JDE80, JDG2046

and/or KJD10213 (depending on model) and lift out
starter.
–UN–06JUN06
6. To repair starting motor, refer to CTM77.
7. Position motor and install three cap screws (C).

Tighten to specification.
H86092
Starting Motor—Specification
Cap Screws—Torque ..................................................................... 47 N•m
(35 lb-ft)
A—Wire
B—Wires
8. Connect wires (A) and (B). C—Cap Screws (3 used)
40
9. Connect batteries if located in engine compartment. If 50
3
located on right-hand side; turn battery disconnect
switch to “I” on position.
OUO6083,0000D52 –19–06JUN06–2/2

083006
PN=365
Starting Motor
40
50
4

083006
PN=366
Group 55
Electrical Engine Control
Electronic Governor and Speed Controller
Repair
Refer to CTM255, Electronic Fuel Injection Systems, for

repair information on the electronic governor and speed
controller or CTM188 for 12.5 L engines.
–UN–17JAN89
TS225
OUO6083,0000642 –19–12JUN03–1/1
40
55
1

083006
PN=367
Electrical Engine Control
40
55
2

083006
PN=368
Group 60
GREENSTAR Components
Specifications
Mass Flow Sensor-to-Impact Plate Torque 30 N•m

Nuts (22 lb-ft)
Mass Flow Sensor-to-Transition Torque 30 N•m

Housing (22 lb-ft)
Cell Sensor Lock Nut Torque 1.4 N•m

(12 lb-in.)
Lower Cell Assembly Screws Torque .62 N•m

(6 lb-in.)
40
Casting Cover Cap Screws Torque 6 N•m 60
(53 lb-in.) 1
Actuator-to-Casting Cap Screws Torque 11 N•m

(97 lb-in.)
Plunger-to-Actuator Cap Screw Torque 11 N•m

(97 lb-in.)
Actuator Cover Cap Screws Torque 6 N•m

(53 lb-in.)
OUO6083,0000DB6 –19–09AUG06–1/1
Other Material
Number Name Use
H116160 (U.S.) Sealant To seal mating surfaces
OUO6083,0000DB3 –19–09AUG06–1/1

083006
PN=369
Remove and Install GREENSTAR Mass-Flow

Sensor
1. Release latches (A and B). Carefully lower loading

auger.
–UN–05MAY03
2. Disconnect connector (C) from wiring harness.
3. Remove two wing bolts (D) and cover.
H76686
A—Latch
B—Latch
C—Connector
D—Wing Bolt (2 used)
40
60
2
–UN–05MAY03
H76687
OUO6083,00007B5 –19–18MAY04–1/6
4. Remove nuts (A) and sensor assembly from inside of

housing.
A—Nut (2 used)
B—Sensor Assembly
–UN–05MAY03
H76688
Continued on next page OUO6083,00007B5 –19–18MAY04–2/6

083006
PN=370
5. Remove nuts (A), and mass flow sensor (C) from

impact plate (D).
A—Nut (2 used)
B—Washer
C—Mass Flow Sensor
D—Impact Plate
–UN–30MAR00
H62868
40
60
3
OUO6083,00007B5 –19–18MAY04–3/6
6. Install mass flow sensor (C) onto impact plate (D).

Tighten nuts (A) to specification.
Specification
Mass Flow Sensor-to-Impact
Plate Nuts—Torque ........................................................................ 30 N•m
(22 lb-ft)
A—Nut (2 used)
B—Washer
–UN–30MAR00
C—Mass Flow Sensor
D—Impact Plate
H62868

083006
PN=371
NOTE: Make sure clearance between inside edge of

impact plate and transition housing is equal along
entire length of impact plate.
7. Install mass flow sensor (B) into transition housing and

tighten nuts (A) to specification.
–UN–05MAY03
Specification
Mass Flow Sensor-to-Transition
Housing—Torque............................................................................ 30 N•m
(22 lb-ft)
H76688
A—Nut (2 used)
B—Sensor Assembly
40
60
4
OUO6083,00007B5 –19–18MAY04–5/6
NOTE: Make sure wiring harness rests in cover notch

before tightening wing bolts.
8. Install cover and wing bolts (D).
9. Connect connector (C).
–UN–05MAY03
10. Carefully raise loading auger and connect latches (A
and B).
H76686
A—Latch
B—Latch
C—Connector
D—Wing Bolt (2 used)
–UN–05MAY03
H76687
OUO6083,00007B5 –19–18MAY04–6/6

083006
PN=372
Remove and Install GREENSTAR Moisture

Sensor
1. Remove lock (A) and connector (B).
2. Remove cap screws and lock nuts (C) and
–UN–05MAY03
GREENSTAR moisture sensor (D).
H76254
4. Position GREENSTAR moisture sensor (D) and install
using cap screws and lock nuts (C).
5. Connect connector (B) and install lock (A).
A—Lock 40
B—Connector 60
C—Cap Screw and Lock Nut (3 used) 5
D—GREENSTAR Moisture Sensor
–UN–05MAY03
H76255
OUO6030,00000C0 –19–12JUL01–1/1

083006
PN=373
Disassemble and Assemble GREENSTAR Moisture Sensor
40
60
6
–UN–01MAY03
H76249

083006
PN=374
A—Lock Nut (6 used) G—Screw (as required M—Gasket R—Plate

B—Cap Screw (6 used) H—Actuator N—Plate S—Gasket
C—Screw I—Screw (as required) O—Circuit Board T—Plate
D—Screw (6 used) J—Plunger P—Relay (2 used) U—Moisture Sensor Module
E—Washer K—Lock Nut (as required) Q—Plate V—Plate
F—Bracket L—Angle
OUO6030,0000244 –19–30APR03–2/2

Sensor Actuator 40
60
7
1. Remove moisture sensor. (See REMOVE AND
INSTALL GREENSTAR MOISTURE SENSOR in this
group.)
OUO6083,0000DB4 –19–09AUG06–1/8
2. Remove screws (A) and plate (B).
A—Screw (6 used)
B—Plate
–UN–05MAY03
H76256
OUO6083,0000DB4 –19–09AUG06–2/8
3. Disconnect wire connectors (A and B) and harness

connector (C).
A—Wire Connector
B—Wire Connector
C—Harness Connector
–UN–05MAY03
H76257

083006
PN=375
4. Remove cap screw and washer (B).
5. Remove cap screws and lock nuts (A) and actuator (C)
by carefully pulling it from moisture sensor module.
6. Repair or replace actuator as required.
–UN–05MAY03
7. Clean gasket surface and apply a bead of H116160
Sealant to actuator.
H76258
A—Cap Screw and Lock Nut (4 used)
B—Cap Screw and Washer
C—Actuator
40
60
8
–UN–05MAY03
H76259
OUO6083,0000DB4 –19–09AUG06–4/8
8. Carefully slide actuator (C) into moisture sensor

module until fully seated.
9. Install plunger using cap screw and washer (B).

–UN–05MAY03
Specification
Plunger-to-Actuator Cap Screw—
Torque ............................................................................................ 11 N•m
(97 lb-in.)
H76258
10. Install cap screws and lock nuts (A). Tighten to
specification.
Specification
Actuator-to-Casting Cap
Screws—Torque ............................................................................. 11 N•m
(97 lb-in.)
A—Cap Screw and Lock Nut (4 used)

–UN–05MAY03
B—Cap Screw and Washer

C—Actuator
H76259

083006
PN=376
11. Connect harness connector (C) and wire connectors

(A and B).
A—Wire Connector
B—Wire Connector
–UN–05MAY03
H76257
OUO6083,0000DB4 –19–09AUG06–6/8
12. Clean gasket surface (A).

40
13. Apply a bead of H116160 Sealant to grooves (B). 60
9
A—Gasket Surface
B—Grooves
–UN–05MAY03
H76270
OUO6083,0000DB4 –19–09AUG06–7/8
14. Inspect gasket and replace as necessary.
15. Install plate (B) using screws (A).
16. Install moisture sensor. (See REMOVE AND INSTALL

GREENSTAR MOISTURE SENSOR in this group.)
–UN–05MAY03
A—Screws (6 used)
B—Plate
H76256
OUO6083,0000DB4 –19–09AUG06–8/8

Sensor Circuit Board
1. Remove moisture sensor from machine and actuator

from sensor assembly. (See REMOVE AND INSTALL
GREENSTAR MOISTURE SENSOR and
GREENSTAR MOISTURE SENSOR ACTUATOR in
this group.)
Continued on next page OUO6083,0000AEB –19–16AUG05–1/5

083006
PN=377
2. Remove relays (A).
A—Relay (2 used)
–UN–05MAY03
H76261
OUO6083,0000AEB –19–16AUG05–2/5
3. Disconnect wire connectors (A and B).

40
60 4. Remove cap screws (C) and circuit board (D). Circuit
10 board is not repairable, if failed it must be replaced.
A—Wire Connector
–UN–05MAY03
B—Wire Connector
D—Circuit Board
H76262
OUO6083,0000AEB –19–16AUG05–3/5
5. Install new circuit board (D) using cap screws (C).
6. Connect wire connectors (A and B).
A—Wire Connector
B—Wire Connector
–UN–05MAY03
D—Circuit Board
H76262
OUO6083,0000AEB –19–16AUG05–4/5
7. Install relays (A).
8. Install actuator. (See REMOVE AND INSTALL

GREENSTAR MOISTURE SENSOR ACTUATOR in
this group.)
–UN–05MAY03
9. Install moisture sensor. (See REMOVE AND INSTALL

GREENSTAR MOISTURE SENSOR in this group.)
A—Relay (2 used)
H76261
OUO6083,0000AEB –19–16AUG05–5/5

083006
PN=378
Remove and Replace GREENSTAR Moisture

Sensor Lower Cell Assembly
1. Shut OFF engine, set parking brake and remove key.
2. Remove lock (A) and connector (B).
–UN–05MAY03
3. Remove cap screws and lock nuts (C) and
GREENSTAR Moisture Sensor.
H76254
A—Lock
B—Connector
C—Cap Screw and Lock Nut (3 Used)
40
60
11
–UN–05MAY03
H76255
OUO6083,0000DB7 –19–09AUG06–1/28
5. Insert a small flat tip screwdriver between casting and

cover at silicon seal points (B) to loosen seal.
A—Cap Screws (8 Used)
–UN–18NOV03
B—Silicon Seal Points
H79147
–UN–18NOV03
H79148

083006
PN=379
6. Disconnect spade terminals (A) and eight pin

connector (B).
A—Spade Terminals (2 Used)

B—Eight Pin Connector
–UN–19NOV03
H79155
OUO6083,0000DB7 –19–09AUG06–3/28
7. Remove cap screw (A) and plunger (B).

40
60 8. Remove cap screws and nuts (C) and actuator (D).
12
A—Cap Screw
B—Plunger
–UN–18NOV03
C—Cap Screws and Lock Nuts (4 Used)
D—Actuator
H79156
–UN–18NOV03
H79157
–UN–18NOV03
H79158

083006
PN=380
9. Remove cap screws (A) from shields (B).
NOTE: Filter foam may be located under right-hand or

left-hand shield.
10. Remove and discard filter foam (C) from weep hole
(D).
–UN–27APR04
A—Cap Screws (2 Per Shield)
B—Shield (2 used)
C—Filter Foam
D—Weep Hole
H80731
40
60
13
–UN–17SEP04
H81679
Right-Hand Shield

083006
PN=381
11. Remove cap screws (A) from top casting cover (B).
12. Remove cap screws (C) from bottom casting cover.

B—Top Casting Cover
–UN–17SEP04
C—Cap Screws (8 Used)
H81683
40
60
14
–UN–17SEP04
H81684
OUO6083,0000DB7 –19–09AUG06–6/28
IMPORTANT: Pry casting cover in front first to loosen

seal. Pry rear casting cover and lift
covers off being careful not to damage
thermistor wires and cell sensor wires.
13. Insert a small flat tip screw driver between top casting
–UN–17SEP04
cover (A) and bottom casting cover (B) to loosen seal.
A—Top Casting Cover

B—Bottom Casting Cover
H81686
OUO6083,0000DB7 –19–09AUG06–7/28
NOTE: Clean crop material from cell assembly before

removing.
14. Remove and discard screws (A) from lower cell

assembly (B).
–UN–17SEP04
A—Screws
B—Lower Cell Assembly
H81687

083006
PN=382
15. Insert a small tip screw driver between lower cell

assembly (A) and bottom casting (B).
A—Lower Cell Assembly

B—Bottom Casting
–UN–20SEP04
H81690
OUO6083,0000DB7 –19–09AUG06–9/28
16. Lift lower cell assembly (A) and place on upper cell
assembly (B). 40
60
15
B—Upper Cell Assembly
–UN–20SEP04
H81691
OUO6083,0000DB7 –19–09AUG06–10/28
17. Remove nut (A) from thermistor wires (B) and cell
sensor wire (C).
18. Pull wires through opening (D) on lower cell assembly

and discard cell assembly.
–UN–20SEP04
A—Nut
B—Thermistor Wires
C—Cell Sensor Wire
D—Hole Opening
H81692

083006
PN=383
IMPORTANT: Thermistor wires need to be taped to

cell sensor wire to prevent wires from
being pinched when reassembling.
Make sure enough room is allowed so
wires slip through opening on new
lower cell assembly.
–UN–20SEP04
19. Tape thermistor wires (A) to cell sensor wire (B).
Tape approximately 50.8 mm (2 in.) starting at bottom
(C).
H81693
A—Thermistor Wires
B—Cell Sensor Wire
C—Hole Bottom
40
60
16
OUO6083,0000DB7 –19–09AUG06–12/28
20. Clean crop material from bottom of casting (A) and

around casting rim (B) where new lower cell assembly
will be placed before installing.
A—Casting Bottom
B—Casting Rim
–UN–20SEP04
H81694
OUO6083,0000DB7 –19–09AUG06–13/28
21. Install electrical wires (A) through opening (B) on new

lower cell assembly.
NOTE: Thermistor wires must be installed first, then cell

sensor wire.
–UN–20SEP04
22. Install thermistor wire (C) first and install cell sensor
wire (D) last.
23. Retain with lock nut (E) and tighten to specification.

H81695
Specification
Cell Sensor Lock Nut—Torque ..................................................... 1.4 N•m
(12 lb-in.) A—Electrical Wires
B—Hole Opening
C—Thermistor Wires
D—Cell Sensor Wire
E—Nut

083006
PN=384
24. Place electrical wires (A) in notch (B) on lower cell

assembly (C).
A—Electrical Wires
B—Notch
C—Lower Cell Assembly
–UN–20SEP04
H81696
OUO6083,0000DB7 –19–09AUG06–15/28
25. Install lower cell assembly (A) on bottom casting (B)

making sure electrical wires (C) remain in slot. 40
60
17
B—Bottom Casting
C—Electrical Wires
–UN–20SEP04
H81698
OUO6083,0000DB7 –19–09AUG06–16/28
NOTE: Make sure screws are flush with lower cell

assembly.
26. Install lower cell assembly (A) using new screws (B)
Specification
–UN–20SEP04
Lower Cell Assembly Screws—
Torque ........................................................................................... .62 N•m
(6 lb-in.)
H81699
B—Screws

083006
PN=385
27. Inspect and replace gaskets (A and B) as needed.
28. Apply two small beads of H116160 Sealant to low

spots (C) on bottom casting.
A—Gasket
–UN–22SEP04
B—Gasket
C—Low Spots
H81700
OUO6083,0000DB7 –19–09AUG06–18/28
IMPORTANT: Verify wires are not pinched between

40 cell assemblies before assembling.
60
18 29. Install upper casting cover (A) and bottom casting
cover (B) verifying electrical wires (C) are not pinched
between cell assemblies.
–UN–20SEP04
A—Upper Casting Cover
B—Bottom Casting Cover
C—Electrical Wires
H81701
OUO6083,0000DB7 –19–09AUG06–19/28
30. Verify electrical wires (A) are placed along holders

(B).
A—Electrical Wires
B—Holders
–UN–20SEP04
H81702

083006
PN=386
31. Install screws (A) on top casting cover (B) and tighten
to specification.
32. Install screws (C) on bottom casting cover (D) and

Specification
–UN–17SEP04
Casting Cover Cap Screws—
Torque .............................................................................................. 6 N•m
(53 lb-in.)
H81683
A—Screw (2 used)
B—Top Casting Cover
40
60
19
–UN–20SEP04
H81703

083006
PN=387
33. Install filter foam (C) in weep hole (D).
34. Install shields (B) using caution not to dislodge filter

foam and retain with screws (A).
A—Screw (2 per shield)

B—Shield
–UN–17SEP04
C—Filter Foam
D—Weep Hole
H81679
40
60
20
–UN–27APR04
H80731
OUO6083,0000DB7 –19–09AUG06–22/28
35. Carefully push actuator tube through seal (A) in

moisture sensor.
36. Clean gasket surface and apply a bead of H116160

Sealant to actuator.
–UN–19NOV03
A—Seal
H79162

083006
PN=388
37. Align actuator circuit board (A) before mating actuator

to casting.
A—Circuit Board
–UN–19NOV03
H79163
OUO6083,0000DB7 –19–09AUG06–24/28
38. Install previously removed cap screws and lock nuts

(A) and tighten to specification. 40
60
Specification 21
Actuator-to-Casting Cap
Screws—Torque ............................................................................. 11 N•m
(97 lb-in.)
–UN–18NOV03
39. Connect spade terminals (B) and eight pin connector
(C).
H79168
40. Install plunger (D) to end of actuator tube by aligning
square shaft of actuator with square hole in plunger.
41. Install previously removed cap screw (E) and tighten

to specification.
Specification
Plunger-to-Actuator Cap Screw—
Torque ............................................................................................ 11 N•m
(97 lb-in.)
–UN–18NOV03
A—Cap Screws and Lock nuts (4 Used)
B—Spade Terminal (2 Used)
C—Eight Pin Connector
H79169
D—Plunger
E—Cap Screw
–UN–18NOV03
H79170

083006
PN=389
NOTE: Make sure that wiring harnesses are placed in

holders (A) to prevent wires from being pinched or
getting wrapped in the actuator.
42. Apply two small beads of H116160 Sealant to the low

spots (B) in the casting.
–UN–19NOV03
A—Holders
B—Low Spots
H79165
OUO6083,0000DB7 –19–09AUG06–26/28
43. Install actuator cover using previously removed cap

40 screws (A) and tighten to specification.
60
22 Specification
Actuator Cover Cap Screws—
Torque .............................................................................................. 6 N•m
(53 lb-in.)
–UN–18NOV03
H79147
OUO6083,0000DB7 –19–09AUG06–27/28
44. Position GREENSTAR Moisture Sensor (D) and

install using cap screws and lock nuts (C).
45. Connect connector (B) and install lock (A).
A—Lock
–UN–05MAY03
B—Connector
C—Cap Screws and Lock nuts
H76254
–UN–05MAY03
H76255
OUO6083,0000DB7 –19–09AUG06–28/28

083006
PN=390
40
60
23

083006
PN=391
Disassemble and Assemble Position Receiver
40 B
60
24
D
E
G F
I
H
J
K
P
L
M
N
H
I
O
Q
–UN–03MAR04
H80393
Continued on next page OUO6083,00006EE –19–03MAR04–1/2

083006
PN=392
A—Position Receiver F—Bumper K—Spring O—Cap Screw (2 used)

B—Cover G—Quick Coupler L—Latch P—Lock Nut
C—Support H—Bushing (2 used) M—Shaft Q—Cover
D—Cap Screw (2 used) I—Nut (2 used) N—Washer (12 used) R—Cap Screw (4 used)
E—Slotted Pan Head Screw J—Washer
Refer to exploded drawing during disassembly and

assembly of position receiver.
OUO6083,00006EE –19–03MAR04–2/2
Remove and Install Position Receiver

40
1. Disconnect harness from position receiver. 60
25
2. Lift quick connect latch (A) to remove position receiver.
–UN–03MAR04
3. Inspect position receiver for damage. Replace as
required.
4. Install position receiver by aligning pins (B) with slots
H80411
(C) in position receiver mounting bracket and snapping
into place.
5. Attach harness to position receiver. A—Quick Connect Latch

B—Pin
C—Mounting Bracket Slots
OUO6083,00006EF –19–03MAR04–1/1

083006
PN=393
40
60
26

083006
PN=394
Section 50
Power Train Repair
Contents
Page Page
Group 05—Transmission and Differential Inspect Thrust Plate . . . . . . . . . . . . . . . . . . . .50-15-21

Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-1 Inspect Fixed Swashplate . . . . . . . . . . . . . . . .50-15-21
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-2 Inspect Piston Slipper . . . . . . . . . . . . . . . . . . .50-15-22
Remove and Repair Shifter Forks and Inspect Piston Retainer . . . . . . . . . . . . . . . . . .50-15-23
Shifter Cam . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-3 Inspect Cylinder Block. . . . . . . . . . . . . . . . . . .50-15-24
Install Shifter Forks and Shifter Cam. . . . . . . . .50-05-5 Inspect Bearing Plate . . . . . . . . . . . . . . . . . . .50-15-24
Remove and Install Transmission Lube Inspect Valve Plate . . . . . . . . . . . . . . . . . . . . .50-15-27
Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-7 Inspect Bearing and Race . . . . . . . . . . . . . . . .50-15-29
Remove and Install Suction Screen. . . . . . . . . .50-05-9 Inspect Servo Piston . . . . . . . . . . . . . . . . . . . .50-15-29
Remove Transmission. . . . . . . . . . . . . . . . . . .50-05-10 Inspect Drive Shaft . . . . . . . . . . . . . . . . . . . . .50-15-30
Transmission Components . . . . . . . . . . . . . . .50-05-12 Replace Cylinder Block Spring . . . . . . . . . . . .50-15-30
Transmission Recondition . . . . . . . . . . . . . . . .50-05-13 Assemble Motor . . . . . . . . . . . . . . . . . . . . . . .50-15-32
Disassemble and Repair Transmission . . . . . .50-05-14 Remove and Install Motor Valve Block 50
Assemble Transmission . . . . . . . . . . . . . . . . .50-05-22 (Manifold). . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-41
Install Transmission. . . . . . . . . . . . . . . . . . . . .50-05-26 Repair Motor Valve Block . . . . . . . . . . . . . . . .50-15-44
Remove and Install Gearshift Lever and Remove Hydrostatic Pump . . . . . . . . . . . . . . .50-15-45
Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-28 Disassemble Hydrostatic Drive Pump . . . . . . .50-15-47
Adjust Gearshift Linkage . . . . . . . . . . . . . . . . .50-05-30 Assemble Hydrostatic Drive Pump . . . . . . . . .50-15-60
Replace High-Pressure Line Center Pivot
Group 10—Single Reduction Final Drive—Heavy O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-75
Duty Disassemble and Assemble End Cover. . . . . .50-15-76
Essential Tools or Recommended Tools . . . . . .50-10-1 Repair Displacement Control Valve . . . . . . . . .50-15-77
Service Equipment and Tools . . . . . . . . . . . . . .50-10-2 Disassemble and Assemble Displacement
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-3 Control Valve with Feed Rate (Optional) . . .50-15-79
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-4 Electronic Proportional Displacement
Remove and Install Final Drive . . . . . . . . . . . . .50-10-5 Control Valve Neutral Adjustment . . . . . . . .50-15-80
Disassemble and Assemble Final Drive . . . . . .50-10-9 Install Hydrostatic Pump . . . . . . . . . . . . . . . . .50-15-84
Adjust Spindle Bearing (Preferred Method) . . .50-10-20 Remove and Install Charge Pump. . . . . . . . . .50-15-84
Adjust Spindle Bearing (Alternate Method) . . .50-10-20 Repair Charge Pump . . . . . . . . . . . . . . . . . . .50-15-86
Remove and Install Control Cable . . . . . . . . . .50-15-87
Group 15—Hydrostatic System Adjust Hydrostatic Neutral Linkage . . . . . . . . .50-15-88
Essential or Recommended Tools . . . . . . . . . . .50-15-1 Adjust Mechanical Displacement Control
Service Equipment and Tools . . . . . . . . . . . . . .50-15-2 Valve Neutral . . . . . . . . . . . . . . . . . . . . . . . .50-15-89
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-3 Start-Up Procedure After Hydrostatic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-90
Serial Number Plate . . . . . . . . . . . . . . . . . . . . .50-15-7
Clean Hydrostatic Motor and Pump. . . . . . . . . .50-15-7 Group 20—Cam Lobe Motor
Flushing the Hydrostatic System . . . . . . . . . . . .50-15-8 Essential or Recommended Tools . . . . . . . . . . .50-20-1
Remove and Install Hydrostatic Motor . . . . . . . .50-15-9 Service Equipment and Tools . . . . . . . . . . . . . .50-20-4
Disassemble Hydrostatic Motor . . . . . . . . . . . .50-15-11 Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-6
Inspect Parts . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-17 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-7
Lack of Lubrication . . . . . . . . . . . . . . . . . . . . .50-15-18 Flushing Cam Lobe Motors . . . . . . . . . . . . . . . .50-20-8
Abrasive Contamination . . . . . . . . . . . . . . . . .50-15-18 Remove Cam Lobe Motor . . . . . . . . . . . . . . . . .50-20-9
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-19 Install Cam Lobe Motor . . . . . . . . . . . . . . . . . .50-20-10
Over Speeding . . . . . . . . . . . . . . . . . . . . . . . .50-15-19
Inspect Shaft Seal . . . . . . . . . . . . . . . . . . . . . .50-15-20 Continued on next page

083006
PN=1
Contents
Page
Remove and Install Cam Lobe Motor

Control Valve . . . . . . . . . . . . . . . . . . . . . . . .50-20-11
Disassemble and Assemble Cam Lobe Motor
Control Valve . . . . . . . . . . . . . . . . . . . . . . . .50-20-14
Remove and Install Steering Yoke . . . . . . . . .50-20-16
Disassemble and Assemble Pivot Pins,
Bushings, and Seals . . . . . . . . . . . . . . . . . .50-20-23
Remove and Install Solenoid Valve and
Valve Block . . . . . . . . . . . . . . . . . . . . . . . . .50-20-26
Remove and Install Displacement Control
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-30
Remove and Install Cam and Piston
Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-33
Remove and Install Valve Stack Seals . . . . . .50-20-38
Remove and Install Axle Bearings and
Seals—Style A. . . . . . . . . . . . . . . . . . . . . . .50-20-42
Remove and Install Axle Bearings and
Seals—Style B. . . . . . . . . . . . . . . . . . . . . . .50-20-54
50
Group 25—Tires and Wheels
Service Equipment and Tools . . . . . . . . . . . . . .50-25-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .50-25-3
Service Tires Safely . . . . . . . . . . . . . . . . . . . . .50-25-3
Care and Service of Tires . . . . . . . . . . . . . . . . .50-25-4
Using Liquid Weight . . . . . . . . . . . . . . . . . . . . .50-25-6
Jacking Locations . . . . . . . . . . . . . . . . . . . . . . .50-25-7
Remove and Install Tire . . . . . . . . . . . . . . . . . .50-25-8
Drive Wheel Bolt Torque . . . . . . . . . . . . . . . . .50-25-10
Dual Wheels Bolt Torque . . . . . . . . . . . . . . . .50-25-11
Rear Wheel Bolt Torque . . . . . . . . . . . . . . . . .50-25-11
Install Axle Extension Tubes . . . . . . . . . . . . . .50-25-12
Install Dual Wheels and Truss Rod . . . . . . . . .50-25-15

083006
PN=2
Group 05
Transmission and Differential
Other Material
Number Name Use
PM38655 (U.S.) Flexible Sealant Used to seal shifter rail cap.
PM38657 (U.S.) Form-in-Place Gasket Used to seal front cover to

transmission.
TY6252 (U.S.) 80W90 GL5 GEAR LUBE Used to lubricate transmission.

Used to coat rotor and stator of
transmission lube pump during
assembly.
PM37509 (U.S.) Clean and Cure Primer Used to prime seal shims on lube
pump before applying flexible
sealant.
PM37477 (U.S.) Thread Lock and Sealer (Medium Locks and seals while preventing
242 LOCTITE (LOCTITE) Strength) parts loosening due to vibration.
TY6341 (U.S.) Multi-Purpose, SD Polyurea Grease Especially effective in rolling contact 50

applications. 05
1
PM37463 (U.S.) Form-in-Place Gasket Used to seal hydrostatic motor

mount.
AG,OUO6022,1649 –19–03AUG05–1/1

083006
PN=397
Specifications
Transmission Weight 306 kg

(675 lb)
Transmission Capacity 9.6 L

(10 qt)
Shifter Cam End Play 0.000-0.254 mm

(0.000-0.010 in.)
Transmission Cover-to-Housing Cap Torque 73 N•m

Screws (55 lb-ft)
Transmission Lube Pump Pressure 0.103 kPa

(1.0 bar)
(14.5 psi)
Transmission Lube Pump-to-Housing Torque 73 N•m

50 Cap Screws (55 lb-ft)
05
2
Input Shaft Orifice Torque 17 N•m
(12 lb-ft)
Pinion Shaft Orifice Torque 17 N•m

(12 lb-ft)
Ring Gear-to-Differential Cap Screws Torque 130 N•m

(97 lb-ft)
Differential Preload 0.076—0.254 mm

(0.003—0.010 in.)
Differential Cradles-to-Housing Cap Torque 320 N•m

Screws (235 lb-ft)
Pinion Shaft Bearing Carrier Cap Torque 2.2 N•m

Screws (For determining shim pack) (20 lb-in.)
Pinion Shaft Preload 0.127 mm

(0.005 in.)
Pinion Shaft Bearing Carrier Cap Torque 73 N•m

Screws (55 lb-ft)

083006
PN=398
Hydrostatic Motor Torque 320 N•m

Mount-to-Transmission Cap Screws (235 lb-ft)
Input Shaft Assembly Axial End Play 0.01—0.2 mm

(0.0005—0.008 in.)
Transmission Mounting Cap Screws Torque 320 N•m

(235 lb-ft)
Gearshift Linkage Distance 237 mm

(9.3 in.)
AG,OUO6022,1807 –19–25JUL00–2/2
50
Remove and Repair Shifter Forks and Shifter 05
Cam 3
NOTE: Shifter fork and/or shifter cam can be replaced

without removing transmission.
1. Drain transmission oil. Remove front cover.
Specification
Transmission—Capacity ..................................................................... 9.6 L
(10 qt)
OUO6083,00002D0 –19–14JUN02–1/3
2. Remove dowel pin (A).
A—Dowel Pin
–UN–13JAN89
H40160

083006
PN=399
3. Remove rail (A) and shifter forks (B) and (C).
CAUTION: Shifter cam compresses a heavy

spring. Use caution when removing shifter cam.
4. Inspect shifter cam to be certain grooves are free of
–UN–19AUG02
burrs and there are no flat spots. Inspect spring pins in
shifter cam. Replace any that are excessively worn or
burred. Also inspect mating shifting surfaces on shifter
rail.
H72550
There are no wear tolerances for any of the shifter
forks (B and C), rollers (D) or clips (E). Replace these A—Rail
parts if they appear damaged or worn. B—Shifter Fork
C—Shifter Fork
5. When replacing a roller (D) or pin, press pin flush with D—Rollers (2 used)
E—Clips (2 used)
roller. Roller must be able to turn freely on pin. The
usual cause for a roller pin to break is clash shifting.
6. Inspect all shift collars in the transmission for wear.

They can cause the transmission to “jump” out of gear
50
05 damaging shift forks. Incorrectly adjusted shift linkage
4 can cause excessive wear to shift collars.
OUO6083,00002D0 –19–14JUN02–3/3

083006
PN=400
Install Shifter Forks and Shifter Cam
–UN–13JUN02
50
05
5
H72548
A—Shifter Fork C—Pin (2 used) E—Rail G—Cap
B—Roller (2 used) D—Shifter Fork F—Dowel Pin H—Clip (2 used)
1. Install clips (H) on shifter fork (A). 5. Check for adequate shifter fork movement. All
gears must turn freely when transmission is turned
2. Install shifter forks (A) and (D) on shifter rail (E) and by hand.
install spring pin.
NOTE: Apply 1.6 mm (1/16 in.) bead of flexible
3. Install dowel pin (F). sealant to counterbore of housing when
installing cap (G).
4. Install rollers and pins (B) and (C). Roller must turn
freely on pin and pin must be flush with top of
roller.
Continued on next page OUO6083,00002CF –19–03AUG05–1/2

083006
PN=401
–UN–27JUN02
50
05
H72432
6
A—Cap Screw (12 used) D—Detent Ball G—O-Ring I—Spring Pin

B—Cover E—Spring Pin (2 used) H—Washer J—Arm
C—Spring F—Cam
6. Install detent ball (D). Ball must rest against spring. Specification
Install arm (J) with washer (H) and O-ring (G). Transmission Cover-to-Housing
Cap Screws—Torque .............................................................. 73 N•m
Install spring pin (I). (55 lb-ft)
7. If shifter cam (F) was removed, adjust cam and arm 9. Fill transmission with TY6252 80W90 GL5 Gear
to specified end play to obtain proper adjustment of Lube oil or approved alternate. (See FUELS AND
cam. Measure between inside edge of cam and LUBRICANTS in Section 10, Group 20.) Level must
boss on cover to check end play. be within 13 mm (1/2 in.) from bottom of fill hole.
Specification Specification
Shifter Cam—End Play.............................................. 0.000-0.254 mm Transmission—Capacity .............................................................. 9.6 L
(0.000-0.010 in.)
(10 qt)
8. Apply a continuous 1.6 mm (1/16 in.) wide bead of NOTE: If transmission is placed in rebuilt service parts
form-in-place gasket to transmission housing. Install storage, add 0.006 L (2 oz) of a commercial
cover (B) and tighten cap screws (A) to corrosion inhibitor suitable for this application.
specification.
OUO6083,00002CF –19–03AUG05–2/2

083006
PN=402
Remove and Install Transmission Lube Pump
NOTE: Use 100 psi ( 690 kPa) gauge to test lube transmission.
pump pressure. See procedure in TM2182.
Specification
This style lube pump consists of the internal Transmission Lube Pump—
Pressure............................................................................... 0.103 kPa
pump parts separate from the bearing cup and (1.0 bar)
sleeve. (14.5 psi)
If pump is not delivering specified oil pressure, it must

be repaired. Pump can be removed without removing
OUO6083,000064A –19–03AUG05–1/4
50
1. Slide oil tube (A) up and out of port in strainer and 05
insert a 1/2 in. plug into port. This will prevent 7
excessive loss of oil.
2. Remove cap screws (B) securing pump housing (C) to

transmission.
–UN–02MAR99
3. Carefully pull pump housing (C) away from assembly
to catch pump drive pin which, in most cases, will fall
from drive shaft. Be careful not to disturb shim pack.
H54294
4. Remove oil tubes from pump housing and lay complete
assembly aside. Remove rotor and stator assembly. Transmission Lube Pump
Save drive pin.
A—Oil Tube
C—Pump Housing
Continued on next page OUO6083,000064A –19–03AUG05–2/4

083006
PN=403
5. Install new parts (B), (K), (J) and (M) to ensure

satisfactory oil pressure. Be certain grooves in the new
housing (B) for oil tubes are clean before installing new
O-rings (M). A
6. Clean paint from ends of oil tubes, approximately 52 M C

mm (2 in.), and blow all paint scales from inside of D
tubes. Install oil tubes in pump housing.
E
B F
7. Press bearing cup (G) into sleeve (F) and install over G
K
bearing cone on input shaft.
J
I
8. If possible, rotate transmission shafts so that hole in M
input shaft is horizontal and insert pump drive pin. If
H
shafts cannot be rotated, use grease to hold pin in
–UN–11JUN02
place.
9. Assemble spacer (E) and washer (I) on port plate (J) L
H72430
and install on input shaft in that order.
10. Coat rotor and stator (K) with 80W90 GL5 Gear Lube
50 oil. Carefully place rotor and stator assembly into A—Screw (3 used)
05 eccentric bore and over drive pin. B—Housing
8 C—Shim
D—O-Ring
11. Position radial stop on port plate (J) to mate with slot E—Bushing
in new housing (B) at approximately 5 o’clock F—Sleeve
position. G—Bearing Cup
H—Bearing Cone
I—Washer
12. Determine proper shim pack. (See ASSEMBLE
J—Plate
TRANSMISSION in this group.) After verifying proper K—Rotor
bearing setting, install shim pack. Clean surfaces and L—Dowel Pin
prime with PM37509 Primer. Apply 1.5 mm (0.06 in.) M—O-Ring (4 used)
bead of flexible sealant to housing corner to seal
shims.
13. Coat threads of attaching bolts with PM37477 Thread

Lock and Sealer (medium strength). Tighten bolts to
specification.
Specification
Transmission Lube
Pump-to-Housing Cap Screws—
Torque ............................................................................................ 73 N•m
(55 lb-ft)
14. Force oil tubes into respective ports. Make certain the
ends of the tubes are past O-ring seals and are
against bottom of port.

083006
PN=404
15. Secure oil tube with clamp and attach lead on

sending unit.
OUO6083,000064A –19–03AUG05–4/4
Remove and Install Suction Screen
1. Push tube (E) into lube pump housing (D).
2. Remove cap screw (A), fitting (B) and screen (C).
–UN–02MAR99
3. Clean screen in solvent.
4. Install screen (C), fitting (B) and cap screw (A).
H54293
5. Pull tube (E) down into fitting (B).
A—Cap Screw
B—Fitting 50
C—Screen 05
D—Lube Pump Housing 9
E—Oil Tube
AG,OUO6022,1810 –19–25JUL00–1/1

083006
PN=405
Remove Transmission
1. Remove header from combine.
2. Fully raise feeder house and lower safety stop.
–UN–27JUN00
3. Block front drive tires.
4. Turn off engine.
H64338
5. Make sure park brake is OFF.
6. Place transmission in “NEUTRAL”.
7. Remove hydrostatic motor (A). (See procedure in

Group 15.)
8. Disconnect drive shift cable (B). Remove snap rings

(H). Slide sleeves (G) toward wheel. Remove pins (J)
–UN–26SEP97
and slide couplings (I) toward wheel.
50 9. Disconnect service brake lines (C).

05
H50243
10
10. Remove nuts (K) from mechanical park brake
balancer (L) cables.
11. Remove park brake cables from balancer (L) under

cab.
12. Disconnect all wires (D).
13. Disconnect shift cable (E) at front of transmission and
–UN–05APR99
remove shield.
14. Place a jack under the transmission.
H54933
A—Hydrostatic Motor
B—Shift Cable
C—Service Brake Line (2 used)
D—Wiring Harness
E—Shift Cable
G—Sleeve (2 used)
H—Snap Ring (2 used)
I—Coupling (2 used)
J—Pin (2 used)
K—Nut (2 used)
–UN–27JUN00
L—Balancer
M—Cap Screw (2 used)
H64339
Continued on next page OUO6083,00009C9 –19–26APR05–1/2

083006
PN=406
CAUTION: Approximate weight of transmission

is 306 kg (675 lb).
15. Remove two lower attaching cap screws (M). Raise

transmission slightly and remove two upper cap
screws (F). Remove transmission.
OUO6083,00009C9 –19–26APR05–2/2
50
05
11

083006
PN=407
Transmission Components
48
59
50
47
60
58
64
39
49
46
69
62
65
38
63
57
45
51
61
43
62
67
63
52
56
44
66
3
68
42
50
53
05
12
41
39
3
42
40
1
38
37
55
2
36
54
22
3
21
4
35
5
19
6
34
23
20
17
32
7
10
18
15
24
33
6
8
16
25
10
11
7
9
28
31
26
30
–UN–16JUL01
10
10
10
29
27
12
13
H69237
14
Heavy Duty Transmission

Continued on next page OUO6083,00000D3 –19–19JUL01–1/2

083006
PN=408
1—Housing 19—Cup 37—Input Shaft 55—Pin

2—Washer 20—Bearing 38—Key (2 used) 56—Shift Rail
3—Snap Ring (4 used) 21—Cap 39—Orifice (2 used) 57—Hydrostatic Motor Mount
4—Bearing 22—Gear 40—Gear 58—Stud (4 used)
5—Cup 23—Screen 41—Gear 59—Cap Screw (4 used)
6—O-Ring (2 used) 24—Fitting 42—Shift Collar (2 used) 60—Breather
7—Shim (as required) 25—Cap Screw 43—Snap Ring 61—Shift Fork
8—Pinion Carrier 26—Oil Tube 44—Bearing 62—Roller (2 used)
9—Cap Screw (3 used) 27—Cap Screw (12 used) 45—Cup 63—Pin (2 used)
10—O-Ring (8 used) 28—O-Ring 46—O-Ring 64—Shifter
11—Oil Tube 29—Spring Pin 47—Snap Ring 65—Yoke
12—Cap 30—Shift Arm 48—Cap 66—Cap Screw (3 used)
13—Plug 31—Washer 49—Cup 67—Cap Screw with Nut (2
14—Cap Screw (3 used) 32—Shift Cam 50—Bearing used)
15—Gear 33—Spring 51—Pinion 68—Cap Screw with Nut (2
16—Plate 34—Detent Ball 52—Gear used)
17—Washer 35—Pin (2 used) 53—Gear 69—Clip (2 used)
18—Snap Ring 36—Pin 54—Gear
OUO6083,00000D3 –19–19JUL01–2/2
50
Transmission Recondition 05
13
Transmission recondition includes the input shaft and the
pinion shaft.
Refer to shifter forks and shifter cam for removal.
Refer to transmission lube pump for its removal. Remove

oil screen.
Remove the remaining bearing carrier on the side of

transmission.
AG,OUO6022,1812 –19–25JUL00–1/1

083006
PN=409
Disassemble and Repair Transmission
50
05
–UN–05MAR99
14
H53096
Input Shaft Assembly
1—Rotor 10—Plug 19—Breather 28—Gear

2—Plate 11—Tube 20—Screw (4 used) 29—Key
3—Washer 12—Shim Pack 21—Stud (4 used) 30—Dowel Pin
4—Bushing 13—O-Ring 22—Hydrostatic Motor Mount 31—Orifice
5—Bearing 14—Tube 23—Bearing Cup 32—Input Shaft
6—Bearing Cone 15—Cap Screw 24—Bearing Cone 33—Input Shaft Kit
7—O-Ring (8 used) 16—Fitting 25—Snap Ring 34—Coupling
8—Oil Pump 17—O-Ring (2 used) 26—Shift Collar 35—Snap Ring (2 used)
9—Screw (3 used) 18—Screen 27—Gear 36—Flange Nut (4 used)
Continued on next page OUO6083,00000D4 –19–03AUG05–1/16

083006
PN=410
1. Remove shifter forks. (See procedure in this group.)
2. Remove lube pump. (See procedure in this group.)
3. Remove hydrostatic motor. (See procedure in Group

15.)
–UN–29MAR00
4. Remove input shaft assembly.
5. Press bearings off both ends of shaft.
H63009
6. Remove snap ring from shift collar end of shaft.
OUO6083,00000D4 –19–03AUG05–2/16
50
7. Press (A) off shaft and slide gear (C) and shift collar 05
(B) off shaft. 15
8. Check orifice (31) and oil passage through input shaft

for restriction. Clean thoroughly. Tighten orifice to
specification.
–UN–13JAN89
Specification
Input Shaft Orifice—Torque ........................................................... 17 N•m
(12 lb-ft)
H40168
A—Gear
B—Shift Collar
C—Gear

083006
PN=411
–UN–13JAN89
H40169
50 A—Lube Pump Drive Pin D—Gear F—Gear H—Bearing Cone
05 B—Bearing Cone E—Shift Collar G—Snap Ring I—Key
16 C—Input Shaft
9. Replace parts as necessary.

083006
PN=412
–UN–12JUL01
50
05
17
H69227
Pinion Shaft Assembly
A—Pinion Carrier G—Snap Ring (4 used) M—Gear R—Bearing Cone

B—Cap Screw (3 used) H—Washer N—Key S—Bearing Cup
C—Shim Pack I—Gear O—Orifice T—Cap
D—O-Ring J—Gear P—Pinion Shaft (Heavy Duty U—O-Ring
E—Bearing Cup K—Shift Collar Transmission) V—Snap Ring
F—Bearing Cone L—Gear Q—Pinion Shaft Kit
10. Assemble input shaft parts.
OUO6083,00000D4 –19–03AUG05–5/16
11. Remove right-hand differential bearing carrier to allow

removal of the pinion shaft.
12. Press bearings off both ends of shaft.
NOTE: Move gear end of differential toward rear of

–UN–13JAN89
transmission.
13. Remove snap rings (G) to remove gears.

H40170

083006
PN=413
14. Press gear off shaft.
15. Check orifice (O) and oil passage through pinion shaft
(P) or (Q) for restriction. Clean thoroughly. Tighten
orifice to specification.
–UN–13JAN89
Specification
Pinion Shaft Orifice—Torque.......................................................... 17 N•m
(12 lb-ft)
H40171
17. Assemble parts on shaft. Standard Duty Transmission Shown
50
05
18

083006
PN=414
G I
F
A
H B
E
D D
E C
C E
H
I F
L
G
50
M
05
W T 19
J
N V
O U
P S T
U
Q
Q
K R
R
P
–UN–18JUL01
O
S
H68494
A—Seal (2 used) G—O-Ring (2 used) M—Shim S—Needle Bearing (52 used)
B—Snap Ring (4 used) H—Bearing Cone (2 used) N—Thrust Washer (2 used) T—Washer (2 used)
C—Roller Bearing (2 used) I—Cup (2 used) O—Thrust Washer (2 used) U—Gear (2 used)
D—Drive Shaft (2 used) J—Cap Screw (14 used) P—Pinion (2 used) V—Pin
E—Cap Screw (12 used) K—Ring Gear Q—Thrust Washer (2 used) W—Spring Pin
F—Cradle (2 used) L—Housing R—Snap Ring (2 used)

083006
PN=415
18. Remove drive shafts and remove cradles.

CAUTION: Use a lifting device for heavy
components.
IMPORTANT: Do not damage plastic or aluminum

shims between transmission case
and cradles.
OUO6083,00000D4 –19–03AUG05–9/16
19. Remove snap ring (B) to remove bearing (A).
A—Bearing
B—Snap Ring
–UN–13JAN89
50
05
20
H40176
OUO6083,00000D4 –19–03AUG05–10/16
20. Remove cap screws (A) to remove ring gear (B).

B—Ring Gear
–UN–18FEB99
H54054
Heavy Duty Differential Shown

083006
PN=416
21. Remove spring pin.
–UN–13JAN89
H40177
OUO6083,00000D4 –19–03AUG05–12/16
22. Remove snap rings.
23. Remove shaft, pinion gears and bevel gears.
–UN–13JAN89
50
05
21
H40178
OUO6083,00000D4 –19–03AUG05–13/16
25. Pack all bearings with Multi-Purpose SD Polyurea

Grease. Apply a light coat of grease to housing
before pressing in bearing cups.
26. Coat thrust surfaces and bores of bevel gears and

pinion gears with oil.
–UN–13JAN89
27. Install bevel gears, pinion gears, thrust washers and
differential pins. Install snap rings. All gears must
rotate freely.
H40178

083006
PN=417
28. Install ring gear (B). Apply thread lock and sealer
(medium strength) to cap screw threads. Install cap
screws (A) and tighten to specification.
Specification
Ring Gear-to-Differential Cap
Screws—Torque ........................................................................... 130 N•m
–UN–18FEB99
(97 lb-ft)

B—Ring Gear
H54054
Heavy Duty Differential Shown
OUO6083,00000D4 –19–03AUG05–15/16
50
05 29. Install inner snap ring and press bearing cone (A) into
22 cradle. Install outer snap ring (B) and install shaft
seal. Press flush with housing. Apply Multi-Purpose
SD Polyurea Grease to seal lip.
A—Bearing
–UN–13JAN89
B—Snap Ring
H40176
OUO6083,00000D4 –19–03AUG05–16/16
Assemble Transmission

components.
1. Install differential (A) in transmission housing. Use a 2

–UN–18FEB99
x 4 in. block (B) to position differential.
A—Differential
B—Block
H54055
Heavy Duty Transmission Shown
Continued on next page AG,OUO6022,1814 –19–03AUG05–1/5

083006
PN=418
NOTE: Move the gear end of differential toward rear of

transmission to allow installation of pinion
assembly.
2. Install pinion assembly. Be sure pinion shaft gear (B)

meshes with differential gear (A).
–UN–18FEB99
3. If old shims (behind cradle) were not damaged, they
may be used. Otherwise, assemble a new pack. Start
with several shims to ensure end play.
H54056
4. Install cradles.
Heavy Duty Transmission Shown
5. Check differential preload. Add or remove shims as
A—Differential Gear
needed. Apply Thread Lock and Sealer (medium B—Pinion Shaft Gear
strength) to cap screw threads. Tighten to specification.
Specification
Differential—Preload...................................................... 0.076—0.254 mm
(0.003—0.010 in.)
Differential Cradles-to-Housing
(235 lb-ft) 50
05
23
AG,OUO6022,1814 –19–03AUG05–2/5
6. Install bearing cup, cap, O-ring and retaining ring (A—

D).
A—Bearing Cup
B—Cap
C—O-Ring A
B
–UN–07JUN02
D—Retaining Ring
C
D
H72433

083006
PN=419
IMPORTANT: The following procedure must be B

followed when determining required C
shim pack for the pinion shaft. This D
A
prevents false endplay readings caused E
by retaining ring.
–UN–07JUN02
7. Install bearing carrier (B). Leave O-ring (D) off at this
time.
8. Evenly tighten cap screws to specification.
H72434
Specification
Pinion Shaft Bearing Carrier Cap
Screws (For determining shim A—Cap Screw (3 used)
pack)—Torque ............................................................................... 2.2 N•m B—Bearing Carrier
(20 lb-in.) C—Shim (as required)
D—O-Ring
9. Rotate pinion shaft at least two complete revolutions. E—Bearing Cup
Again evenly tighten cap screws to specification.
Specification
50 Screws (For determining shim
05 pack)—Torque ............................................................................... 2.2 N•m
24 (20 lb-in.)
10. Measure gap between bearing carrier (B) and housing

at two places exactly 180° apart. Install shim pack (C)
equal to average of these two readings. This shim
pack will provide specified preload.
Specification
Pinion Shaft—Preload ................................................................ 0.127 mm
(0.005 in.)
11. Install O-ring on carrier and install shim pack and

carrier.
12. Apply Thread Lock and Sealer (medium strength) to

cap screw threads. Install cap screws and tighten to
specification.
Specification
Screws—Torque ............................................................................. 73 N•m
(55 lb-ft)
13. Install input shaft assembly in transmission.

083006
PN=420
14. Apply form-in-place gasket to face of hydrostatic

motor mount. Install on transmission. Tighten cap
Specification
Hydrostatic Motor
Mount-to-Transmission Cap
Screws—Torque ........................................................................... 320 N•m
(235 lb-ft)
15. Install lube pump. (See procedure in this group.)
16. Adjust lube pump shim pack to provide specified axial

end play of input shaft assembly.
Specification
Input Shaft Assembly—Axial End
Play ....................................................................................... 0.01—0.2 mm
(0.0005—0.008 in.)
17. Install hydrostatic motor. (See procedure in Group

20.)
50
05
25
AG,OUO6022,1814 –19–03AUG05–5/5

083006
PN=421
Install Transmission

components.
Raise feeder house and lower safety stop.
–UN–05APR99
1. Use jack to position transmission. Install cap screws
(F) and tighten to specification.
H54932
Specification
Transmission Mounting Cap
Screws—Torque ........................................................................... 320 N•m
(235 lb-ft)
2. Fill transmission with 9.6 L (10 qt) of GL-5 80-90W

Gear Lube. (See FUELS AND LUBRICANTS in
Section 10, Group 20.) Level must be within 13 mm
(1/2 in.) from bottom of fill plug.
–UN–26SEP97
3. Connect service brake lines (C). Bleed air from service
50 brake system. (See procedure in Section 60.)
05
H50243
26 4. Connect wires (D).
5. Slide couplers (I) onto shaft and install pins (J).
6. Slide sleeves (G) over couplers (I) and secure with

snap rings (H).
7. Install hydrostatic motor (A). (See procedure in Group

15.)
–UN–05APR99
8. Install shift cable (E).
9. Adjust gearshift linkage. (See ADJUST GEARSHIFT
H54933
LINKAGE in this group.)
10. Install park brake cables in balancer (L).

A—Hydrostatic Motor
B—Drive Shaft (2 used)
11. Install nuts (K) on park brake cables. C—Service Brake Line (2 used)
D—Wiring Harness
12. Adjust park brake. (See procedure in Section 60.) E—Shift Cable
G—Sleeve (2 used)
H—Snap Ring (2 used)
I—Coupling (2 used)
J—Pin (2 used)
K—Nut (2 used)
L—Balancer
AG,OUO6022,1815 –19–25JUL00–1/1

083006
PN=422
50
05
27

083006
PN=423
Remove and Install Gearshift Lever and Linkage
X E
F
50
05 U
28 G
U P
H
O
F
F
I G
P I
N
O N M
M
G L
K
R
–UN–24SEP02
S
H73330
Continued on next page OUO6083,00003BA –19–23SEP02–1/2

083006
PN=424
A—Knob G—Clamp M—Cap Screw S— Cap Screw

B—Shifter Rod H—Nut N—Clamp T—Cap Screw
C—Label I—Ball Joint O—Cable U—Washer
D—Cap Screw J—Bracket P—Isolator V—Housing
E—Bearing K—Round Head Bolt Q—Bracket W—Seal
F—Cap Screw L—Nut R—Nut X—Boot
1. Remove knob (A). 4. Install parts as needed. Install knob (A).
2. Remove parts as needed. 5. Adjust gearshift linkage. (See procedure in this

group.)
3. Inspect and replace parts as necessary.
OUO6083,00003BA –19–23SEP02–2/2
50
05
29

083006
PN=425
Adjust Gearshift Linkage
1. Shift transmission into second gear. Gearshift lever

should be leaning slightly forward.
2. From under cab, loosen nut (B). Remove and adjust
–UN–20MAY02
ball joint (A) to specified dimension (C). Do not adjust
clamp (D).
Specification
Gearshift Linkage—Distance ......................................................... 237 mm
H72264
(9.3 in.)
3. At transmission, remove ball joint (G) from shift arm

(E). Shift arm should be straight down.
4. Loosen nut (F) and adjust ball joint (G) until stud on
ball joint aligns with hole in shift arm (E). Reinstall ball
joint (G) to shift arm (E).
–UN–02MAR99
5. Check for specified dimension (H). Do not adjust clamp
(I).
50
05
30 Specification
H54292
Gearshift Linkage—Distance ......................................................... 237 mm
(9.3 in.)
A—Ball Joint
B—Nut
C—Dimension
D—Clamp
E—Shift Arm
F—Nut
G—Ball Joint
H—Dimension
I—Clamp
OUO6083,00002A4 –19–20MAY02–1/1

083006
PN=426
Group 10
Single Reduction Final Drive—Heavy Duty
Essential Tools or Recommended Tools
Catalogs.
AG,OUO6022,1818 –19–25JUL00–1/6
Service Jack . . . . . . . . . . . . . . . . . . . . . . JT07056A
Used to remove and install final drives.
–UN–14SEP89
50
10
1
H40598
AG,OUO6022,1818 –19–25JUL00–2/6
Final Drive Adapter . . . . . . . . . . . . . . . . . . . JT05874
Use with JT07056A Service Jack to remove and install

final drives.
–UN–05SEP89
H40599
AG,OUO6022,1818 –19–25JUL00–3/6
Final Drive Spindle Nut Socket. . . . . . . . . . . . .JDG665
Used to remove and install spindle nut.

–UN–23APR94
H46365

083006
PN=427
Final Drive Repair Kit—Standard Duty . . . . . . . .JDG690
Used in conjunction with JDG1296 to repair final drive.
–UN–23FEB92
H44021
AG,OUO6022,1818 –19–25JUL00–5/6
Final Drive Repair Kit—Heavy Duty. . . . . . . . . JDG1296
Used to repair final drive.
50
–UN–12APR99
10
2
H55333
AG,OUO6022,1818 –19–25JUL00–6/6
Service Equipment and Tools
NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.
AG,OUO6022,1819 –19–25JUL00–1/5
12-Ton Support Stand . . . . . . . . . . . . . . . . . . JT02043
Used to support front axle for final drive removal.

083006
PN=428
Bushing, Bearing, and Seal Driver Set
Used to remove and install bushings, bearings, and seals.
AG,OUO6022,1819 –19–25JUL00–3/5
17-1/2 and 30-Ton Puller Set
Used to remove bearings and seals.
AG,OUO6022,1819 –19–25JUL00–4/5
Dial Indicator
Used to check pinion gear shaft preload/end play.
AG,OUO6022,1819 –19–25JUL00–5/5
50
Other Material 10
3
Number Name Use
TY6341 (U.S.) Multi-Purpose, SD Polyurea Grease Especially effective in rolling contact

applications.
TY6252 (U.S.) 80W90 GL5 GEAR LUBE Used to service final drives.
PM37463 (U.S.) Form-in-Place Gasket Used to seal inner and outer

housing.
PM38655 (U.S.) Flexible Sealant Used to seal final drive end cap and
final drive pinion cap.
AG,OUO6022,1820 –19–03AUG05–1/1

083006
PN=429
Specifications
Front Tire and Wheel Approximate Weight (without ballast) 400 kg

(882 lb)
Final Drive Capacity 8L

(8.5 qt)
Final Drive Weight 233 kg

(514 lb)
Final Drive Mounting Cap Screws Oiled Torque 620 ± 186 N•m
(457 ± 137 lb-ft)
Tire and Wheel Weight 400 kg

(882 lb)
Front Wheel Bolts Torque 200 N•m + 1/4 turn

(150 lb-ft) + 1/4 turn
50
10 Inner Housing-to-Outer Housing Cap Torque 320 N•m
4
Screws (235 lb-ft)
Bearing Cap-to-Outer Housing Cap Torque (Preload Measurement) 12 N•m

Screws (106 lb-in.)
Pinion Gear Shaft Preload 0.1 mm

(0.004 in.)
Pinion Gear Shaft End Play 0.05 mm

(0.002 in.)
Bearing Cap-to-Outer Housing Cap Torque 73 N•m

Screws (55 lb-ft)
Spindle Bearing Adjustment Deflection 0.30—0.36 mm

(Preferred Method) (0.012—0.014 in.)
Spindle Bearing Adjustment Torque 375 N•m

(Alternate Method) (275 lb-ft)
OUO6083,00005EF –19–28MAY03–1/1

083006
PN=430
Remove and Install Final Drive
CAUTION: Grain tank must be empty and

header removed.
1. Loosen wheel bolts one turn. Do not remove at this

time.
CAUTION: Block up front axle before removing
–UN–05APR99
wheels.
CAUTION: Jack must have a minimum rating of

5443 kg (6 ton).
H55107
2. Raise combine using jack (A) positioned in jacking
pocket (B). Jacking pockets are located on either side A—Jack
of combine near the feeder house lift cylinder B—Jacking Pocket
attachment points.
3. Block up front axle or install JT02043 12-Ton Support

50
Stand. 10
5
4. Support tire and wheel; then remove wheel bolts, front
tire and wheel.
Specification
Front Tire and Wheel—
Approximate Weight (without
ballast) ............................................................................................. 400 kg
(882 lb)
Continued on next page OUO6083,00005EE –19–28MAY03–1/7

083006
PN=431
5. Pry out spiral snap ring (A) and slide sleeve (B)
inward.
6. Drive out pin (C) and drive coupler (D) inward.
7. Drain final drive.
–UN–31MAR99
Specification
Final Drive—Capacity ............................................................................ 8 L
(8.5 qt)
H55108
A—Spiral Snap Ring
B—Sleeve
C—Pin
D—Coupler
OUO6083,00005EE –19–28MAY03–2/7
50
10 CAUTION: The approximate weight of final drive
6
is 233 kg (514 lb).
Specification
Final Drive—Weight......................................................................... 233 kg
(514 lb)
8. Use JT07056A Service Jack (C) with JT05874 Final

Drive Adapter (B) to remove final drive (A).
–UN–31MAR99
A—Final Drive
B—Final Drive Adapter
C—Service Jack
H55109

083006
PN=432
10. If dowel pins do not come out with final drive, remove
from axle and install in housing.
11. Remove and repair final drive as necessary. (See

DISASSEMBLE AND ASSEMBLE FINAL DRIVE in
–UN–29JAN02
this group.)
12. Install axle spacers if necessary. See
H71010
SPECIFICATIONS in this group for bolt torques.
Front Side
–UN–29JAN02
50
10
7
H71009
Rear Side
OUO6083,00005EE –19–28MAY03–4/7
CAUTION: The approximate weight of final drive

is 233 kg (514 lb).
13. Use JT07056A Service Jack (C) with JT05874 Final

Drive Adapter (B) to install final drive (A).
A—Final Drive
B—Final Drive Adapter
C—Service Jack
–UN–31MAR99
H55109

083006
PN=433
14. Lubricate threads of cap screws (A) with grease or oil.
15. Install cap screws and tighten to specifications.
Specification
Final Drive Mounting Cap
Screws—Oiled Torque ....................................................... 620 ± 186 N•m
–UN–29JAN02
(457 ± 137 lb-ft)
16. Apply Multi-Purpose SD Polyurea grease to drive

shaft splines and coupler.
H71010
A—Cap Screws (6 used) Front Side
–UN–29JAN02
50
10
8
H71009
Rear Side
OUO6083,00005EE –19–28MAY03–6/7
17. Drive coupler (D) toward final drive and drive in pin
(C) flush with coupler.
18. Slide sleeve (B) on and install spiral snap ring (A).
19. Fill final drive with 8 L (8.5 qt) of 80W90 GL5 Gear
–UN–31MAR99
Lube. (See FUELS AND LUBRICANTS in Section 10,
Group 20.)
CAUTION: The approximate weight of tire and H55108

wheel is 400 kg (882 lb) (without liquid ballast).
Specification
Tire and Wheel—Weight ................................................................. 400 kg A—Spiral Snap Ring
(882 lb) B—Sleeve
C—Pin
D—Coupler
20. Install wheel. Tighten bolts to specification.
Specification
Front Wheel Bolts—Torque ......................................... 200 N•m + 1/4 turn
(150 lb-ft) + 1/4 turn
OUO6083,00005EE –19–28MAY03–7/7

083006
PN=434
Disassemble and Assemble Final Drive
13 14 19
25 18
26 20
11 21
27
28 22
29 23
10 24
12
17
16
15
30 8 9
6
32
31
5
1
4
–UN–02APR02
7 3
50
2
10
9
N60012
1—Axle 9—Fitting (2 used) 17—Bearing Cup 25—Pinion Gear
2—Oil Seal 10—Line 18—Bearing Cone 26—Bearing Cone
3—Oil Seal Cup 11—Dowel Pin (2 used) 19—Dust Cap 27—Bearing Cup
4—Bearing Cone 12—Ring Gear 20—Retaining Ring 28—Shim (as required)
5—Bearing Cup 13—Inner Housing 21—Key 29—Cap
6—Seal 14—Plug 22—Nut 30—Cap Screw (4 used)
7—Grease Fitting 15—Snap Ring 23—Bearing Cup 31—Cap Screw (12 used)
8—Outer Housing 16—Spacer 24—Bearing Cone 32—Seal
1. Stand final drive on axle flange.

CAUTION: The approximate weight of final
drive is 233 kg (514 lb). Always use
appropriate lifting device to avoid injury or
death.
Specification
Final Drive—Weight .................................................................. 233 kg
(514 lb)

083006
PN=435
2. Pry off cap (A). Remove retaining ring (D) and key (B).
3. Remove nut (C) using JDG665 Final Drive Spindle Nut

Socket (E).
A—Cap
–UN–04AUG05
B—Key
C—Nut
D—Retaining Ring
E—Socket
H84172
–UN–23FEB92
50
10
10
H44022
OUO6083,000064B –19–04AUG05–2/22
4. Install adapter JDG690-3 (A) from JDG690 Final Drive

Repair Kit to shaft end.
5. Remove cap screws holding outer housing to inner

housing.
–UN–08APR02
A—Adapter
H71548

083006
PN=436
NOTE: Earlier made JDG690-1 Puller Adapter Plates may

need to be modified for servicing heavy duty final
drives. Mounting holes will need to be enlarged to
25 mm (1 in.).
6. Attach JDG690-1 Adapter Plate (A) from JDG690 Final
–UN–08APR02
Drive Repair Kit to inner housing (B), using 102 mm (4
in.) cap screws (C) and 57 mm (2-1/4 in.) spacers (D).
A—JDG690-1 Adapter Plate
H71547
B—Inner Housing
D—Spacer (4 used)
OUO6083,000064B –19–04AUG05–4/22
50
7. Attach D1047AA 17-1/2 and 30 ton puller set (A) to 10
plate. 11
8. Install lifting device to cross strap (B) of puller set.
9. Thread puller screw (C) into JDG690-3 adapter (D) on
–UN–08APR02
axle shaft.
10. Separate inner housing using 17-1/2 and 30 ton puller

set.
H71549
CAUTION: Ring gear and outer housing are
heavy and can cause serious injury. Use two A—17-1/2 and 30 Ton Puller Set
persons or lifting device to remove parts. B—Cross Strap
C—Puller Screw
IMPORTANT: Lift ring gear using two blocks of wood, D—JDG690-3 Adapter
while removing inner housing from
outer housing.
11. Remove inner housing from outer housing using hoist.
12. Remove bearing cone and spacer.
13. Clean gasket material from housings. Run a wire

through vent/fill plug to be sure it is open.

083006
PN=437
14. Inspect bearing cup (A). If replacement is necessary,

drive bearing cup from inner housing.
A—Bearing Cup
–UN–15MAR89
H40230
OUO6083,000064B –19–04AUG05–6/22
15. Apply a light coat of TY6341 Multi-Purpose SD

Polyurea grease to inner housing bore.
16. Install bearing cup into bore of inner housing.
–UN–15MAR89
50
10
12
H40231
OUO6083,000064B –19–04AUG05–7/22
17. Remove pinion gear and bearing cup (A).
18. Remove seal from pinion shaft bore.
A—Bearing Cup
–UN–15MAR89
H40232
OUO6083,000064B –19–04AUG05–8/22
19. Inspect bearing cup (A). If replacement is necessary,

drive bearing cup from pinion shaft bore.

Polyurea Grease to pinion shaft bore. Drive in bearing
cup.
–UN–15MAR89
A—Bearing Cup
H40233

083006
PN=438
21. Install seal (A) flush with housing.
22. Inspect and replace pinion shaft bearings as

necessary. Go to Step 27, if replacement is not
necessary.
–UN–15MAR89
A—Seal
H40234
OUO6083,000064B –19–04AUG05–10/22
23. Remove bearing (B) from pinion shaft, using

JDG1296-3 Block Bearing Remover (A) from
JDG1296 Final Drive Repair Kit, and a puller.
24. Pack bearings with TY6341 Multi-Purpose SD

Polyurea Grease (or equivalent).
–UN–23FEB92
50
A—Block Bearing Remover 10
B—Bearing (2 used) 13
H44026
OUO6083,000064B –19–04AUG05–11/22
25. Install bearings (A) on pinion shaft using JDG1296-6

driver from JDG1296 Final Drive Repair Kit.
26. Install pinion shaft and bearing cup in inner housing.
A—Bearing (2 used)
–UN–15MAR89
H40236

083006
PN=439
CAUTION: Ring gear and outer housing are

heavy and can cause serious injury or death to
you or others if it falls. Use two persons or
lifting device to remove parts.
27. Remove beveled spacer (A).
–UN–08APR02
28. Lift ring gear (B) off axle shaft.
29. Remove outer housing (C) from axle shaft.
H71559
30. Turn outer housing over.
A—Beveled Spacer
B—Ring Gear
C—Outer Housing
OUO6083,000064B –19–04AUG05–13/22
50
10 31. Remove bearing cup (A) and inner seal.
14
Polyurea Grease to bore of outer housing.
A—Bearing Cup
–UN–15MAR89
H40247
OUO6083,000064B –19–04AUG05–14/22
33. Coat oil seal lip with TY6341 Multi-Purpose SD

Polyurea Grease.
34. Install oil seal (A) with lip to inside of housing. Drive
seal until fully seated against housing bore.
–UN–15MAR89
35. Press bearing cup into housing.
36. Press oil seal cup (B) into housing, until flange is
seated against housing.
H40246
37. Press dowel pins into finished flanged surface until

exposed length is to specification.
A—Oil Seal
Specification B—Seal Cup
Dowel Pin—Exposed Length........................................................... 20 mm
(13/16 in.)

083006
PN=440
38. Remove V-ring seal (A), bearing cone (B), and seal
(C) from axle using puller from JDG1296 Final Drive
Repair Kit and D1047AA 17-1/2 and 30 ton puller set.
NOTE: Long puller legs (D) must be used.
–UN–23FEB92
39. Apply Multi-Purpose SD Polyurea Grease to seal lips.
A—V-Ring Seal
B—Bearing Cone
H44027
C—Seal
D—Long Puller Leg (2 used)
OUO6083,000064B –19–04AUG05–16/22
50
IMPORTANT: Metal edge of seal (C) must face toward 10
outer housing when placed over axle. 15
40. Install seal (C) using JDG1296-2 driver (A) and

JDG1296-5 (B) from JDG1296 Final Drive Repair Kit
and D1047AA 17-1/2 and 30 ton puller set.
–UN–23FEB92
A—JDG1296-2 Driver
B—JDG1296-5 Driver
C—Seal
H44028

083006
PN=441
NOTE: Pack all bearing cones with TY6341 Multi-Purpose

SD Polyurea Grease before assembly.
41. Thread puller screw (D) into JDG690-3 Adapter (C)

on axle shaft. Install bearing cone (B) on axle using
JDG1296-2 driver (A) from JDG1296 Final Drive
Repair Kit and D1047AA 17-1/2 and 30 ton puller set.
42. Install V-ring seal next to bearing cone. V-lip must be

pointed away from bearing cone.
43. Install snap ring inside ring gear.
A—JDG1296-2 Driver
B—Bearing Cone
C—JDG690-3 Adapter
D—Puller Screw
–UN–12JAN93
50
10
16
H44029
OUO6083,000064B –19–04AUG05–18/22
44. Set axle on flat surface, shaft up.
45. Install outer housing (C) on axle.
46. Place wood blocks on outer housing.
–UN–08APR02
47. Install ring gear (B) on axle, snap ring side up.
48. Install spacer (A) with chamfered or beveled edge

toward bearing.
H71559
49. Apply a 1.5 mm (0.06 in.) continuous bead of

PM37463 Form-In-Place Gasket around flange of
outer housing. A—Beveled Spacer
B—Ring Gear
C—Outer Housing
50. Install inner housing on outer housing. Tighten cap
Specification
Inner Housing-to-Outer Housing
(235 lb-ft)
51. Install inner bearing. Seat into bearing cup.

083006
PN=442
52. Install nut (A). Tighten nut until SNUG using JDG665
socket (E). Do not overtighten bearings. (See
ADJUST SPINDLE BEARING in this group.) A
C
B
A—Nut
B—Key
C—Cap
D—Retaining Ring
E—Socket
–UN–06JUN02
H72435
50
10
17
–UN–23FEB92
H44022

083006
PN=443
IMPORTANT: Install plastic shims against each C

housing cast surface. B
A
D
53. Install shim pack (C). If old shims have not been
damaged, they may be used. If damaged, assemble a
new pack as follows:
–UN–27FEB02
• 0.13 mm (0.005 in.) - Plastic - 2 used
• 0.25 mm (0.010 in.) - Steel - 1 used
• 0.50 mm (0.020 in.) - Steel - 1 used
H71258
54. Attach bearing cap (B) with entire shim pack to
housing (D). Tighten cap screws (A) to specification.
Specification B—Bearing Cap
Bearing Cap-to-Outer Housing C—Shim (as required)
Cap Screws—Torque (Preload D—Housing
Measurement)................................................................................. 12 N•m
(106 lb-in.)
50
10
18

083006
PN=444
55. Adjust pinion gear end play using the following

special instructions:
• Measure and record pinion gear shaft end play with

dial indicator.
• Remove bearing cap and add or remove shims as
–UN–15MAR89
needed to achieve specification.
Specification
Pinion Gear Shaft—End Play .......................................... -0.1— +0.05 mm
(-0.004— +0.002 in.)
H40308
• Remove cap and apply 1.5 mm (0.06 in.) bead of
PM38655 Flexible Sealant to lip of cap and install.
• Tighten cap screws to specification.
Specification
Bearing Cap-to-Outer Housing
Cap Screws—Final Torque ............................................................ 73 N•m
(55 lb-ft)
50
10
19
56. Apply TY6341 Multi-Purpose SD Polyurea Grease at

lubrication fitting until grease leaks out around seal.
NOTE: If final drive is to be placed in service parts

storage, add 29.6 mL (1 oz.) of a commercially
available corrosion inhibitor suitable for this
application.
OUO6083,000064B –19–04AUG05–22/22

083006
PN=445
Adjust Spindle Bearing (Preferred Method)
1. Rotate final drive assembly two revolutions to seat

lower bearing.
2. Install flat bar (B) across mounting flange.
–UN–06JUL89
3. Install dial indicator (A) on bar and with indicator on
axle (D). Set dial at zero.
H41196
4. Tighten nut (C) until specified housing deflection is
observed.
Specification A—Dial Indicator

Spindle Bearing Adjustment B—Flat Bar
(Preferred Method)—Deflection......................................... 0.30—0.36 mm C—Nut
(0.012—0.014 in.) D—Axle
5. Advance nut to next locking position and install key

and retainer.
6. Apply a bead of flexible sealant to lip of cap and install

50
cap.
10
20
AG,OUO6435,630 –19–03AUG05–1/1
Adjust Spindle Bearing (Alternate Method)
1. Rotate final drive assembly two revolutions to seat

bearings.
2. Tighten nut (A) to specification.
–UN–29MAR00
Specification
Spindle Bearing Adjustment
(Alternate Method)—Torque ......................................................... 375 N•m
(275 lb-ft)
H63013
3. Advance nut to next locking position and install key

and retainer.
A—Nut
4. Apply a bead of flexible sealant to lip of cap and install

cap.
OUO6435,0001714 –19–03AUG05–1/1

083006
PN=446
Group 15
Hydrostatic System
Catalogs.
OUO6083,00009CF –19–03AUG05–1/4
Hydrostatic Transmission Tool Kit . . . . . . . . . . .JDG630
–UN–30APR99
Used to repair hydrostatic pump and motor.
H55899
50
15
1
OUO6083,00009CF –19–03AUG05–2/4
H40188 –UN–12JAN89
Snap Ring Pliers . . . . . . . . . . . . . . . . . . . . . JDG1141
Used to remove and install internal snap rings.
1
RECOMMENDED TOOL
OUO6083,00009CF –19–03AUG05–3/4
Shaft Seal Installer Set. . . . . . . . . . . . . . . . . JDG1503
Used to install hydrostatic pump and motor input shaft

seals
–UN–30JAN03
H74997
OUO6083,00009CF –19–03AUG05–4/4

083006
PN=447
Hydrostatic System

OUO6083,0000572 –19–06MAY03–1/10
Portable Filter Caddy . . . . . . . . . . . . . . . . . . . JT05746
Used to flush hydraulic/hydrostatic system.
–UN–01JUN01
50
15
2
H68347
OUO6083,0000572 –19–06MAY03–2/10
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D15032NU
Used to perform service work without draining reservoir.
–UN–01JUN01
H68348
OUO6083,0000572 –19–06MAY03–3/10
SAE Dial Indicator . . . . . . . . . . . . . . . . . . . D17526C1
Used to measure shaft end play.
OUO6083,0000572 –19–06MAY03–4/10
Metric Dial Indicator . . . . . . . . . . . . . . . . . . D17527C1
Used to measure shaft end play.

083006
PN=448
Hydrostatic System
Slide Hammer . . . . . . . . . . . . . . . . . . . . . D01399AA
Used to remove pump trunnions.
OUO6083,0000572 –19–06MAY03–6/10
Micrometer. . . . . . . . . . . . . . . . . . . . . . . . D17511C1
Used to measure piston slipper flange and slipper retainer

flange thickness.
OUO6083,0000572 –19–06MAY03–7/10
Spring Scale
Used to check swashplate movement.
OUO6083,0000572 –19–06MAY03–8/10
50
Depth Micrometer 15
3
Checking zero angle of swashplate.
OUO6083,0000572 –19–06MAY03–9/10
Magnetic Base . . . . . . . . . . . . . . . . . . . . . D17525C1
Used to hold dial indicator.
OUO6083,0000572 –19–06MAY03–10/10
Other Material
Number Name Use
TY22000 (U.S.) HY-GARD Hydraulic Oil Used to service/flush

hydraulic/hydrostatic systems and
pre-lube parts during assembly.
242 LOCTITE (LOCTITE) Strength) parts loosening due to vibration.
3M #1606 (U.S.) Electrical Contact Cleaner Use to clean parts.
SCOTCH is a registered trademark of the 3M Company. AG,OUO6022,1828 –19–03AUG05–1/1

083006
PN=449
Hydrostatic System
Specifications
Hydraulic/Hydrostatic Reservoir Approximate Capacity 34 L

(36 qt)
Hydrostatic Motor-to-Transmission Torque 115 N•m

Mount Cap Screws (85 lb-ft)
Fixed Clearance of Assembly Clearance 0.20 mm

(0.008 in.)
Swashplate Connecting Cap Screws Torque 22—26 N•m

(16—19 lb-ft)
Swashplate Mounting Cap Screws Torque 27—33 N•m

(20—24 lb-ft)
Swashplate Preload Breakaway Force 9—22 N

(2—5 lb)
50
15 End Cover-To-Hydrostatic Motor Cap Torque 85 N•m
4
Screws (63 lb-ft)
Motor Shaft End Play 0.05—0.18 mm

(0.002—0.007 in.)
Valve Block-to-Hydrostatic Motor Torque 38 N•m

Hydrostatic Motor Valve Block
High Pressure Relief Valve Torque 100 N•m

(75 lb-ft)
Low Pressure Control Valve Torque 165 N•m

(125 lb-ft)
Shuttle Valve Hex Plugs Torque 92—111 N•m

(68—82 lb-ft)
Shoulder Bolt-to-Servo Piston Cap Torque 22—26 N•m

Screw (192—228 lb-in.)

083006
PN=450
Hydrostatic System
Hydrostatic Drive Pump Cover Plugs
Plug (A) Torque 81 N•m

(60 lb-ft)
Plug (B) Torque 12 N•m

(9 lb-ft)
Plugs (C) Torque 7 N•m

(5 lb-ft)
Plug (D) Torque 12 N•m

(9 lb-ft)
Rotating Group Fixed Clearance 0.20 mm

(0.008 in.)
Swashplate Retaining Strap Cap Torque 24.0 N•m

Screws (17.5 lb-ft) 50
15
5
Pump Trunnion Cap Screws Torque 60 N•m
(44 lb-ft)
Swashplate Zero Angle Maximum Allowable Difference 0.12 mm

(0.005 in.)
Maximum Allowable Rock 0.03 mm
(0.010 in.)
Pump Mounting Flange Cap Screws Torque 60 N•m

(44 lb-ft)
End Cover-to-Drive Pump Cap Torque 85 N•m

Screws (63 lb-ft)
Pump Drive Shaft End Play 0.05—0.18 mm

(0.002—0.007 in.)
Valve Plate-to-End Cover Cap Torque 85 N•m

Screws (63 lb-ft)
Charge Pump-to-End Cover Cap Torque 27—33 N•m

Screws (20—24 lb-ft)
Control Valve-to-Pump Cap Screws Torque 22 N•m

(16 lb-ft)

083006
PN=451
Hydrostatic System
Drive Pump End Cover
Spring Box (A) Torque 81 N•m

(60 lb-ft)
Plug (E) Torque 12 N•m

(9 lb-ft)
Plug (F) Torque 7 N•m

(5 lb-ft)
Plug (G) Torque 7 N•m

(5 lb-ft)
Plug (I) Torque 12 N•m

(9 lb-ft)
Control Valve-to-Pump Cap Screws Torque 22—26 N•m

50 (264—312 lb-in.)
15
6
Hydrostatic Pump-to-Engine Gear Torque 130 ± 50 N•m
Case Cap Screws (96 ± 36 lb-ft)
Charge Pump Low Pressure Relief Torque 108 N•m

Valve (80 lb-ft)
Charge Pump Cover-to-Pump Torque 27—33 N•m

Housing Cap Screws (20—24 lb-ft)
Hydrostatic Motor Weight 40 kg

(90 lb)
Main Hydraulic Pump Weight 68 kg

(160 lb)
Half Clamp Cap Screw Torque 72 N•m

(53 lb-ft)
OUO6083,0000574 –19–06MAY03–3/3

083006
PN=452
Hydrostatic System
Serial Number Plate
A serial number plate is on the pump and motor.
List the entire serial number in all correspondence. This

number provides the factory with valuable information
when communicating with the manufacturer concerning
service. It also allows warranty claims to be matched with
–UN–01DEC98
returned units.
Be certain to include the entire serial number on the

return tag with the unit.
H41401
NOTE: First two digits of (A) indicate type of hydrostatic
system: A—Displacement (cu. in./rev.) as 0033 = 3.3 CIR
B—Type of Product: as
• 46 = Standard Duty 21, 23 = Variable Displacement Pump
• 64 = Heavy duty 31, 33 = Fixed Displacement Motor
41 = Variable Displacement Motor
C—Specific Unit Configuration
D—Month of Manufacture
E—Year of Manufacture
F—Specific Serial Number of Unit 50
15
7
OUO6083,00002C8 –19–11JUN02–1/1
Clean Hydrostatic Motor and Pump
IMPORTANT: Always use clean tools and keep open

surfaces free of dirt and foreign matter.
Cleanliness is essential when servicing
the hydrostatic system.
Clean outside of motor thoroughly. Either steam clean or

wash with solvent. Clean surrounding area so dirt will not
get into system when hoses and line are disconnected.
AG,OUO6022,1831 –19–25JUL00–1/1

083006
PN=453
Hydrostatic System
Flushing the Hydrostatic System
NOTE: If the original failure occurred in the hydraulic or

reel drive area, the hydrostatic system has inlet
filtration which protects all components and lines
EXCEPT the charge pump. Flush the charge
pump (steps 6 and 7), but the remaining steps are
not necessary.
1. Remove hydrostatic units. The hydro units cannot be

flushed. These units must be disassembled and
cleaned, or rebuilt units ordered.
2. Remove reservoir and clean thoroughly.
3. Remove and discard the filter element.
4. The cooler cannot be thoroughly cleaned. With inlet

filtration to the hydrostatic pump, this is not a concern.
5. Remove the charge pump.

50
15 6. Using hoses supplied with the Portable Filter Caddy
8
JT05746, and proper hose fittings, connect from outlet
port of the Portable Filter Caddy to the inlet port of the
charge pump. Connect hose from the outlet port of the
charge pump to drum of flushing oil.
7. Activate the Portable Filter Caddy and slowly rotate the

charge pump shaft by hand while flushing.
8. Flush all hoses and lines thoroughly.
OUO6083,0000305 –19–09AUG02–1/1

083006
PN=454
Hydrostatic System
Remove and Install Hydrostatic Motor

–UN–23AUG88
fluids.
X9811
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
IMPORTANT: When disconnecting a line, hose, or

transfer tube from a hydrostatic
50
component, always mark end and port 15
from which it was removed so that it 9
can be connected to proper port when
reassembling.
Also, when disconnecting a line, hose,

or transfer tube from a component,
always plug them to keep dirt out of
system. Use a plastic plug or plastic
bag - never a cloth. Cloth contains lint
which can damage hydrostatic system.
High pressure hoses have clamp-type

bolted fittings with O-rings. When this
type of fitting is disassembled, inner
surfaces must be cleaned thoroughly
and new O-rings installed. This is to
insure a tight seal and reduce
possibility of leakage.
1. Fully lower header and reel to ground and continue

depressing switch for 5 seconds to relieve hydraulic
system pressure. Shut off engine and remove key.
Continued on next page OUO6083,000064C –19–16JUN03–1/3

083006
PN=455
Hydrostatic System
2. Install D15032NU vacuum pump on reservoir using

JT07085 adapter set or drain reservoir.
Specification
Hydraulic/Hydrostatic Reservoir—
Approximate Capacity ......................................................................... 34 L
(36 qt)
OUO6083,000064C –19–16JUN03–2/3
3. Disconnect hoses (A). Plug lines or cover with plastic

bags.
CAUTION: The approximate weight of motor is

40 kg (90 lb).
–UN–06APR99
50 4. Remove four cap screws (B) and pull motor away from
15 transmission mount.
10
5. Repair motor as necessary.
H55157
6. Attach motor to mount with cap screws (B). Tighten to
specification. A—Hoses (3 used)
Specification
Hydrostatic
Motor-to-Transmission Mount Cap
Screws—Torque .......................................................................... 115 N•m
(85 lb-ft)
7. Replace O-rings in hoses (A). Connect hoses to motor.
8. Check oil levels. Start engine and bleed system. (See

OUO6083,000064C –19–16JUN03–3/3

083006
PN=456
Hydrostatic System
Disassemble Hydrostatic Motor
1. Set motor on a sleeve, or wooden support at least 50

mm (2 in.) high.
IMPORTANT: Do not drop valve block on motor end
–UN–10FEB99
cover while removing.
2. Remove cap screws (A) that hold valve block (B) to

motor (C).
H52972
3. Remove valve block.

B—Valve Block
C—Motor
OUO6083,0000790 –19–12MAY04–1/10
50
NOTE: Clean dirt out of seal area using a spray lubricant 15
or solvent prior to disassembly. Do not use cloth 11
or brush.
4. Remove snap ring (A) using JDG114 Snap Ring Pliers,

or equivalent.
–UN–01JUN01
A—Snap Ring
H68382
OUO6083,0000790 –19–12MAY04–2/10
5. Use a center punch or ice pick to make a small hole in

the side of seal (B). Be careful not to damage bearing
or sealing surfaces.
6. Remove stationary seal (B) using sheet metal screw

(A).
–UN–01JUN01
A—Sheet Metal Screw

B—Seal
H68383

083006
PN=457
Hydrostatic System
7. Internal parts are spring loaded. To avoid internal

damage, remove six of eight cap screws (A) securing
end cover (B) to motor housing, leaving two opposite A
cap screws tight. Gradually and evenly remove those
two cap screws. End cover should raise. If not,
carefully tap end cover from housing. B
8. Carefully remove end cover (B), gasket (C) and two

end cover dowel pins (G). If valve plate (F) is stuck to C
end cover, hold in place and remove with cover. Avoid
dropping parts.
D
NOTE: Pump valve plates (F) are all unidirectional
(clockwise) with two metering slots (I). Motor valve E
plates (H) are bidirectional with four metering slots
F
(I). PUMP AND MOTOR VALVE PLATES ARE
NOT INTERCHANGEABLE.
9. Remove bearing cup (E) from end cover (B). Use a

slight twisting motion. Bearing cup is a slip fit in end G
cover.
50
15 10. Remove shims (D) from end cover. Do not misplace
12
shims as they are used to adjust end play of motor
output shaft.
IMPORTANT: Handle bearing and valve plates with

extreme care. Plates are lapped to
extremely close tolerances for flatness.
–UN–01JUL02
11. If valve plate is not removed with end cover, insert a
small screwdriver in oil drain slots of valve plate.
Carefully pry valve plate away from bearing plate.
H72436
12. Insert a small screwdriver in oil drain slot of bearing
plate. Carefully lift plate from cylinder barrel. Wrap
both parts separately in clean paper.
F H
B—End Cover
C—Gasket
D—Shims
E—Bearing Cup
F—Pump Valve Plate
–UN–07JUN02
G—Dowel Pin (2 used)

H—Motor Valve Plate
I—Metering Slots
I
H72437

083006
PN=458
Hydrostatic System
13. Position two small blocks, thicker than the length of

output shaft, under motor flange. Protect cylinder
barrel with a clean cloth or paper before pulling
bearing.
14. Use low clearance puller from JDG630 Hydrostatic

Transmission Tool Kit to remove end cover bearing
cone.
15. Lay motor on its side. Remove two hex head cap
screws retaining swashplate in housing.
16. Remove and discard washers from cap screws.

Replace with NEW washers.
–UN–07JUN02
17. Push output shaft assembly inward to dislodge
swashplate from housing.
18. Carefully remove cylinder barrel assembly and output
H72438
shaft from housing.
50
15
13
OUO6083,0000790 –19–12MAY04–5/10
19. Position cylinder barrel and output shaft assembly (A) A

as shown.
20. Remove output shaft.
A—Output Shaft Assembly
–UN–18JUN02
H72439

083006
PN=459
Hydrostatic System
IMPORTANT: Caution must be used when replacing

the motor output shaft bearing.
Bearings are pressed to a dimension
NOT to the shoulder on the shaft.
NOTE: Use dimensions in table to construct the special II A .001

stop limit tool (made of steel).
21. When output shaft bearing cone must be replaced,

use a press to remove cone from shaft. A
C
D
A
–UN–18JUN02
1.50/1.70 B
X
H72440
5.00/6.00 Dia.
A B C D
50 ± 0.025 mm (0.001 in.)
15 169.7 mm 33.0/ 33.5 mm 57.2/59.7 mm 76.2 mm
14 (6.682 in.) (1.30/1.32 in.) (2.20/2.30 in.) (3.0 in.)
22. Use a special stop limit tool (see table) when

installing NEW cone on shaft.

083006
PN=460
Hydrostatic System
23. Use bearing puller or punch to remove shaft bearing

cup from housing.
24. Position cylinder barrel and swashplate with

swashplate facing downward.
–UN–11JUN02
50
15
15
H72441
OUO6083,0000790 –19–12MAY04–8/10
25. Remove cap screws (A) from retaining strap (B) and
spacers (C) on one side of swashplate.
26. Loosening cap screws on other retaining strap will

make it easier to remove cylinder barrel from
swashplate.

B—Retaining Strap
C—Spacer (2 used)
–UN–24AUG00
H44039

083006
PN=461
Hydrostatic System
27. Carefully position cylinder barrel (B) and swashplate

(A) with swashplate upward. Lift swashplate slightly, A
slide over to disengage from retaining strap (C) and
remove.
28. Remove cap screws (D), retaining strap (C), spacers

(E) and thrust plate (G) from swashplate (A). G
29. Disassemble cylinder barrel assembly (B). Place on

clean protective surface for inspection and cleaning. F
A—Swashplate
B—Cylinder Barrel
C—Retainer E
E—Spacer (2 used) C
F—Piston Assembly
G—Thrust Plate D
–UN–12JUN02
50
15
16
H72443
OUO6083,0000790 –19–12MAY04–10/10

083006
PN=462
Hydrostatic System
Inspect Parts
NOTE: Some internal parts of the motor and pump are Excessive fluid temperature may also cause this
similar in appearance and function; others condition by increasing the lubricating film loss
have the same part number. between rotating mating parts.
Most part failures are identifiable by inspecting the part (Smeared) This condition is usually indicated by the
and comparing it to the following information to presence of bronze embedded in or across finished
determine the suspected cause of failure. mating surfaces. Smearing is usually caused by a lack
of or improper lubrication or possible abrasive
(Worn) This condition is usually indicated by a smooth contamination suspended in the fluid. Excessive fluid
but definite wear pattern in or across finished surfaces. temperature may also cause this condition by the
A worn condition is usually caused by a lack of lubricating fluid film loss between rotating mating parts.
lubrication or very fine abrasive contamination
suspended in the fluid. (Galled) This condition is usually indicated by the
presence of material that has been removed from one
(Scored) This condition is usually indicated by fine surface, normally by friction, and sometimes adhered
scratch marks in or across finished surfaces. Scoring to its mating component surface. Galling usually is
usually is caused by a lack of or improper lubrication caused by a lack of or improper lubrication. Excessive
or possible abrasive contamination suspended in the fluid temperature may also cause this condition by
fluid. increasing the lubricating fluid loss between rotating
mating parts. 50
(Scratched) This condition is usually indicated by small 15
17
scratches in or across finished surfaces. It is usually (Eroded) This condition is usually indicated by erosion
caused by abrasive contamination suspended in the (pitted appearance) or removal of material from
fluid. finished surfaces. Eroding is usually caused by
cavitation or voids in the fluid.
(Grooved) This condition is usually indicated by
grooves cut in or across finished surfaces. Grooves (Rolled) This condition is usually indicated by the
are usually caused by a lack of lubrication or large extreme outer edge of the finished surface being
particle contamination suspended in the fluid. deformed or rolled over. Rolled usually is caused by a
lack of lubrication to the edges of these finished
(Discoloration) This condition is usually indicated by a surfaces when subjected to over speeding or block lift
noticeable change in color on the finished surfaces. conditions.
Discoloring usually is caused by a lack of or improper
lubrication.
AG,OUO6022,1835 –19–25JUL00–1/1

083006
PN=463
Hydrostatic System
Lack of Lubrication
The following terminology will be used for determining Without the proper oil film, rotating metal-to-metal
probable causes of system and/or part failure. surfaces create friction and excessive temperatures
that usually cause premature part failures.
Lack of lubrication is probably the most common, yet
misinterpreted terminology associated with failure Depending on the severity of the oil film loss and
analysis of system and/or part failures. It usually is a friction, rotating critical surfaces will become severely
result of condition(s) that create an insufficient oil film worn, smeared, galled or noticeably discolored.
required to lubricate rotating part surfaces.
AG,OUO6022,1836 –19–25JUL00–1/1
Abrasive Contamination
Abrasive contamination is probably the second most A lack of lubrication may also be created by abrasive
common, yet identifiable terminology. contamination that creates excessive leakage
passages between critical rotating surfaces.
This condition usually is system-related by the
introduction of abrasive foreign particles that damage Depending on the size and amount of abrasive
50
the critical surface areas as they pass through the contamination passing through or contacting parts, the
15
18 system. rotating surfaces will become worn, scored, scratched
or grooved.
These abrasive particles usually are larger than the
lubricating oil film thickness required to lubricate part
surfaces.
AG,OUO6022,1837 –19–25JUL00–1/1

083006
PN=464
Hydrostatic System
Cavitation
Cavitation is sometimes confused with the lack of system cooling, high pressure oil passing over relief
lubrication which usually is the result of, but not the valves and excessive closed loop leakage. Excessive
cause of cavitation. oil temperatures usually will decrease the fluid
viscosity or lubrication oil film thickness required to
This condition usually is created by the presence of air lubricate rotating surfaces.
suspended in the oil.
Depending on the condition or severity of oil
Excessive amounts of air in the oil will not provide an temperature, rotating surfaces usually will become
adequate film required to properly lubricate. scored, smeared, galled or discolored.
Partial or total restriction of the pump inlet will also The most common cause of improper lubrication is
create cavitation. created by chemical contaminants present in the
hydraulic fluid, such as water. Water not only creates
Depending on the severity of cavitation, rotating improper lubrication to rotating surfaces, but also
surfaces will become eroded, scored, smeared or creates undesirable chemical changes to the oil and
galled. mating surfaces.
Excessive oil temperature is sometimes the result or Depending on the severity of the improper lubrication
lack of lubrication, but not necessarily the direct cause. used, component parts usually will become discolored,
This condition usually is system-created by improper scored, smeared, or galled. 50
15
19
AG,OUO6022,1838 –19–25JUL00–1/1
Over Speeding
Over speeding is sometimes associated with the lack This small area usually is located on the outer edge of
of lubrication, which usually is the result of, but not rotating parts, and because of the excessive loading
necessarily the direct cause of over speeding. subject to this area, the lubrication is removed also.
Depending on the severity of over speeding that
Hydrostatic transmissions by design, are subject to creates this excessive loading and loss of lubrication to
operate within certain speed limitations. When units rotating parts, a rolled, scored, smeared or galled
are operated above their design limitations, certain condition will occur.
parts separate or tip, creating excessive loading to
small areas of these parts.
AG,OUO6022,1839 –19–25JUL00–1/1

083006
PN=465
Hydrostatic System
Inspect Shaft Seal
The shaft seal assembly is a pressure-type mechanical

seal that consists of two mating parts, a bronze rotating
half and a steel stationary half.
–UN–22SEP88
To properly seal the shaft, the fine lapped sealing surface
located on each seal half must be smooth, flat, and free of
all nicks, burrs, and scratches.
N36987
The scoring across the sealing surfaces indicates the seal
was subject to abrasive contamination.
AG,OUO6022,1840 –19–25JUL00–1/3
50
15 The scoring marks across the sealing surface indicate that
20 it was subject to abrasive contamination.
–UN–20JAN89
H50349
AG,OUO6022,1840 –19–25JUL00–2/3
The smearing around the center of the sealing surface

indicates it was subject to a lack of/or insufficient
lubrication. This condition usually is a result of insufficient
oil film to properly lubricate rotating part mating surfaces.
The discoloration on this bronze seal half indicates the

–UN–20JAN89
possibility of excessive oil temperatures.
Water not only creates an improper lubrication condition,

but will also cause undesirable chemical changes to the
H50350
oil. This chemical change to the oil will cause the bronze
parts to discolor or turn dark.
AG,OUO6022,1840 –19–25JUL00–3/3

083006
PN=466
Hydrostatic System
Inspect Thrust Plate
Smearing on the thrust plate surface indicates it was

subjected to a lack of/or insufficient lubrication. This
condition usually is a result of insufficient oil film required
to properly lubricate rotating part surfaces.
This thrust plate may be reused by installing it with the

smeared side toward the swashplate, only if the thrust
plate is not damaged in any way. The other finished side
must be smooth, flat and free of any nicks, burrs, and
scratches.
AG,OUO6022,1841 –19–25JUL00–1/3
50
The scoring marks on this thrust plate indicate it was 15
subjected to abrasive contamination. This contamination 21
may have been suspended in the oil.
–UN–20JAN89
H50352
AG,OUO6022,1841 –19–25JUL00–2/3
The discoloration on this thrust plate indicates it was

subjected to extremely high temperature. This condition is
a result of very high oil temperature.
This thrust plate should not be reversed and reused

because the excessive temperature created bends.
–UN–20JAN89
H50353
AG,OUO6022,1841 –19–25JUL00–3/3
Inspect Fixed Swashplate
Scoring on the fixed swashplate indicates it was subjected

to abrasive contamination.
AG,OUO6022,1842 –19–25JUL00–1/1

083006
PN=467
Hydrostatic System
Inspect Piston Slipper
The small scratch marks across this slipper face indicates

that it was subjected to some very fine abrasive.
–UN–20JAN89
H50355
AG,OUO6022,1843 –19–25JUL00–1/4
The scoring on this piston slipper face indicates it was

subjected to abrasive contamination. A small particle of
contamination is embedded into the balance land of this
piston slipper.
–UN–20JAN89
50
15
22
H50356
AG,OUO6022,1843 –19–25JUL00–2/4
The galling around the underside of this slipper indicates it

was subjected to an over speeding condition.
Over speeding usually causes the piston slipper to tip and

scrape against the edge of its mating part, creating
galling.
–UN–20JAN89
H50357
AG,OUO6022,1843 –19–25JUL00–3/4
The smearing across this slipper indicates it was

subjected to a severe lack of or insufficient lubrication.
–UN–20JAN89
H50358
AG,OUO6022,1843 –19–25JUL00–4/4

083006
PN=468
Hydrostatic System
Inspect Piston Retainer
The scoring around the nine holes and center hole

indicates it was subjected to a fine abrasive
contamination.
–UN–20JAN89
H50359
AG,OUO6022,1844 –19–25JUL00–1/4
The scoring around the nine holes indicates it was

subjected to fine abrasive contamination.
The galling on the center hole usually is created by a lack

of lubrication.
–UN–20JAN89
50
15
23
H50360
AG,OUO6022,1844 –19–25JUL00–2/4
The slight scoring around the nine piston slipper holes

indicates it was subjected to a fine abrasive.
The galling on the center hole usually is created by a lack

of lubrication.
–UN–20JAN89
H50361
AG,OUO6022,1844 –19–25JUL00–3/4
The discoloration on this retainer indicates it was

subjected to possible improper lubrication or excessive
heat.
–UN–20JAN89
H50362
AG,OUO6022,1844 –19–25JUL00–4/4

083006
PN=469
Hydrostatic System
Inspect Cylinder Block
The scoring in these cylinder barrel bushings indicates it

was subjected to abrasive contamination. This
contamination between the cylinder bushing and pistons
caused two of the bushings to be pulled out of the
–UN–20JAN89
cylinder barrel.
H50365
AG,OUO6022,1845 –19–25JUL00–1/1
Inspect Bearing Plate
The grooving between the port or kidneys on this bearing

plate indicates it was subjected to particle contamination.
–UN–20JAN89
50
15
24
H50366
AG,OUO6022,1846 –19–25JUL00–1/12
The discoloration between the port or kidneys indicates it

was possibly subjected to an improper oil. This condition
most likely was caused by water in the system. Water
under pressure tends to discolor bronze parts.
–UN–20JAN89
H50367
AG,OUO6022,1846 –19–25JUL00–2/12
The discoloration and grooving between the port or

kidneys indicates it was not only subjected to improper
fluid but also to particle contamination.
–UN–20JAN89
H50368

083006
PN=470
Hydrostatic System
The smearing on the balance lands and slight erosion

between the port or kidneys indicates it was subjected to
a lack of or improper lubrication or possibly cavitation.
–UN–20JAN89
H50369
AG,OUO6022,1846 –19–25JUL00–4/12
The corrosion appearance on the back side of the plate

indicates possible cavitation. This condition usually is the
result of the bearing plate being separated or pulled off its
mating part in a fluttering motion.
–UN–20JAN89
50
15
25
H50370
AG,OUO6022,1846 –19–25JUL00–5/12
The smearing on the balance lands, inner bearing support

area and erosion of the leading edge of the port or
kidneys indicates it was subjected to a lack of or improper
lubrication or cavitation.
–UN–20JAN89
H50371
AG,OUO6022,1846 –19–25JUL00–6/12
The corrosion appearance on the back side of the plate

indicates possible extended cavitation.
–UN–20JAN89
H50372

083006
PN=471
Hydrostatic System
The erosion noted between the port or kidneys indicates it

was subjected to cavitation.
–UN–20JAN89
H50373
AG,OUO6022,1846 –19–25JUL00–8/12
The erosion on the leading edges and grooves between

the port or kidneys indicates it was subjected to cavitation
and particle contamination.
–UN–20JAN89
50
15
26
H50374
AG,OUO6022,1846 –19–25JUL00–9/12
The erosion on the leading edges and in between the port

or kidneys indicates it was subjected to extended
cavitation. The smearing on the inner and outer balance
lands indicates a possible lack of or insufficient lubrication.
–UN–20JAN89
H50375
AG,OUO6022,1846 –19–25JUL00–10/12
The smearing across the entire face of this bearing plate

indicates it was subjected to a lack of or insufficient
lubrication.
–UN–20JAN89
H50376

083006
PN=472
Hydrostatic System
The severe discoloration noted on this bearing plate

indicates it was subjected to a very high oil temperature.
–UN–20JAN89
H50377
AG,OUO6022,1846 –19–25JUL00–12/12
Inspect Valve Plate
The smearing on both the inner plate and outer balance

lands indicates it was subjected to a lack of or insufficient
lubrication.
–UN–20JAN89
50
15
27
H50378
AG,OUO6022,1847 –19–25JUL00–1/8
The heavier score marks between the port or kidneys and

lighter score marks noted on the balance lands and
bearing support areas indicate the valve plate was
subjected to abrasive contaminants.
–UN–20JAN89
H50379
AG,OUO6022,1847 –19–25JUL00–2/8
The scoring marks on the balance lands and bearing

support area indicate the valve plate was subjected to
abrasive contamination. Also noticeable, is some
smearing between the port or kidneys and inner bearing
support area indicating a possible lack of or improper
lubrication.
–UN–20JAN89
H50380

083006
PN=473
Hydrostatic System
The scoring on the balance lands and inner part of the

bearing support area indicates abrasive contamination.
Also noticeable is some smearing between the port or
kidneys and extreme outer edge of the bearing support,
which indicates possible over speeding. Over speeding
usually causes the rotating parts to tip and contact only
–UN–20JAN89
their outer edges rather than across the entire surface.
When tipped, excessive loading to small contact areas
occurs.
H50381
AG,OUO6022,1847 –19–25JUL00–4/8
The smearing on the bearing support area indicates the

valve plate was subjected to a lack of and possibly
improper lubrication. Close inspection shows cracks
across this area, likely created by friction, probably as a
result of the loss of lubricating oil film required to properly
lubricate mating part surfaces. Also shown is some very
–UN–20JAN89
heavy scoring between the port or kidneys caused by
50
particle abrasive contamination suspended in the system
15
28 oil.
H50382
AG,OUO6022,1847 –19–25JUL00–5/8
The discoloration between the balance indicates it was

subjected to high fluid temperature or possibly a complete
loss of lubrication.
–UN–20JAN89
H50383
AG,OUO6022,1847 –19–25JUL00–6/8
The discoloration of this valve plate indicates it was

subjected to a high oil temperature or improper fluid.
–UN–20JAN89
H50384

083006
PN=474
Hydrostatic System
The discoloration of this valve plate indicates it was

subjected to excessive oil temperature. The scoring
across the plate surface indicates a possible lack of or
improper lubrication.
–UN–20JAN89
H50385
AG,OUO6022,1847 –19–25JUL00–8/8
Inspect Bearing and Race
The discoloration indicates excessive system

temperatures.
–UN–10FEB89
50
15
29
H50386
AG,OUO6022,1848 –19–25JUL00–1/2
The grooves across this trunnion bearing race indicates it

was subjected to an improper bearing preloading. This
condition is the result of the insufficient preload, allowing
the trunnion to move back and forth during operation.
–UN–20JAN89
H50387
AG,OUO6022,1848 –19–25JUL00–2/2
Inspect Servo Piston
The scratches on this servo piston indicate it was

subjected to abrasive contamination.
–UN–20JAN89
H50388

083006
PN=475
Hydrostatic System
The scoring inside the threaded end on this servo sleeve

indicates it was subjected to abrasive contamination or
lack of lubrication.
–UN–20JAN89
H50389
AG,OUO6022,1849 –19–25JUL00–2/2
Inspect Drive Shaft
This broken shaft end indicates a severe side loading or

misalignment.
–UN–20JAN89
50
15
30
H50390
AG,OUO6022,1850 –19–25JUL00–1/1
Replace Cylinder Block Spring
1. Press outer retaining ring (A) down to compress spring

(C).
2. Remove spiral retaining ring (B).
–UN–29SEP88
3. Remove retaining ring, spring, and beveled inner
retainer (D).
4. Replace spring and reinstall parts. N36010
5. Install beveled inner retainer (D) with beveled side

toward splined end of block. A—Outer Retaining Ring
B—Spiral Retaining Ring
C—Spring
6. Install outer retaining ring (A) with shoulder towards D—Inner Retainer (Beveled)
open end of block.
7. Compress spring and outer retaining ring, then install

spiral retaining ring.
AG,OUO6022,1851 –19–25JUL00–1/1

083006
PN=476
Hydrostatic System
50
15
31

083006
PN=477
Hydrostatic System
Assemble Motor
2
3
4
1 5
6
8
9
10 11
22
6 9
21 13
10
20 19
18 12
50
19 17
15
32
19
28 19
29 18 1
17
16
28 1
27
29
26 15
14
25 1
31
30
32
33 24
35
34 23
–UN–01JUN01
H68386
Hydrostatic Motor

083006
PN=478
Hydrostatic System
1—Dowel Pin (5 used) 10—O-Ring (2 used) 19—Spacer (4 used) 27—Motor Housing

2—Gasket 11—Valve Block 20—Slipper Retainer Plate 28—Cap Screw (2 used)
3—Bearing 12—Cap Screw (4 used) 21—Piston and Slipper 29—Washer (2 used)
4—Shim (as required) 13—Cap Screw (2 used) Assembly (9 used) 30—Dowel Pin
5—End Cover 14—Valve Plate 22—Thrust Plate 31—Socket Pipe Plug
6—Lifting Strap (2 used) 15—Bearing Plate 23—Swashplate 32—I.D. Tag and Screws
7—Cap Screw (6 used) 16—Cylinder Barrel 24—Drive Shaft 33—Drain Plug and O-Ring
8—Square Cut Seal 17—Cap Screw (4 used) 25—Retaining Ring 34—Stationary Seal
9—Back Up Washer (2 used) 18—Retaining Strap (2 used) 26—Output Shaft Bearing 35—Retaining Ring
1. Assemble motor using exploded view for parts grit paper, files, or grinders on finished surfaces.
reference. Install new O-rings and gaskets. Apply Replace gaskets and O-rings.
petroleum jelly to O-rings and finished surfaces.
Apply clean hydraulic oil to parts as specified. 3. Lubricate O-rings with petroleum jelly for retention
during assembly. Lubricate bearings and finished
2. Clean parts in clean solvent. Dry with compressed part surfaces with clean hydraulic fluid.
air. Replace all damaged parts. Do not use coarse
OUO6083,0000307 –19–03AUG05–2/14
50
4. Lubricate and install piston slippers assembly (A) in 15
cylinder barrel (B). Lubricate brass slipper faces with 33
clean hydraulic fluid. A
A—Piston Slipper Assembly

B—Cylinder Barrel
–UN–12JUN02
H72444

083006
PN=479
Hydrostatic System
5. Check fixed clearance of assembly:
Measure height of spacer (A). Spacers are critical and

can not be adjusted.
Measure thickness of piston slipper flange (C) and

slipper retainer plate (B). Subtract this measurement
from spacer measurement (A) to get fixed clearance of
–UN–31MAY01
assembly.
Fixed clearance must not exceed specification. If more,

replace worn parts, i.e., piston slipper assemblies,
H67750
thrust plate, retaining strap, and slipper retainer plate.
Specification
Fixed Clearance of Assembly— A—Spacer Height
Clearance ..................................................................................... 0.20 mm B—Retainer Plate
(0.008 in.) C—Slipper Flange
D—Piston Slipper
Fixed clearance = A - (C + B)
50
15
34

083006
PN=480
Hydrostatic System
IMPORTANT: Thread Lock and Sealer must contact A

only those parts intended before
assembly. Apply non-petroleum base
solvent with cloth to wipe excess from
swashplate.
B
6. Apply one or two drops of Thread Lock and Sealer C

(medium strength) in first or second thread down in
E
each of four holes in swashplate (D).
7. Lubricate and install thrust plate (E).
8. Align cap screw holes. Install spacers (C), retaining D

strap (B) and cap screws (A) on one side of
–UN–12JUN02
swashplate (D). Do not tighten cap screws at this time.
9. Put cylinder barrel assembly on clean, flat surface with

piston slippers pointing up.
H72445
10. Carefully install swashplate on cylinder barrel by
slightly lifting side without retaining strap. Slide
swashplate over to engage installed retaining strap 50
B—Retainer (2 used)
around piston retainer. 15
C—Spacer (4 used)
35
D—Swashplate
E—Thrust Plate

083006
PN=481
Hydrostatic System
11. Carefully position cylinder barrel and swashplate with A

swashplate in down position. Install remaining
spacers (C), retainer (B), and cap screws (A). Tighten
all four cap screws to specification.
Specification
Swashplate Connecting Cap C B
Screws—Torque ...................................................................... 22—26 N•m
(16—19 lb-ft)
–UN–10JUL02
NOTE: If a feeler gauge is used, make certain gauge is
inserted between retaining strap and slipper
retainer plate ONLY. Slipper faces could be
damaged if gauge is inserted between piston
H72446
slipper and thrust plate.
12. Position cylinder barrel and swashplate so cylinder A—Cap Screw (2 used)
barrel face is on a clean, flat surface. B—Retainer
C—Spacer
13. Lubricate and install output shaft in cylinder barrel.
50
15
36
OUO6083,0000307 –19–03AUG05–6/14
14. Install two headless 5/16 X 6 in. cap screws (A) in

swashplate to guide swashplate into pocket in A
housing. Make certain to align dowel pin in housing
with notch in swashplate.
15. Carefully slide housing over output shaft, swashplate

and cylinder barrel assemblies.
A—Headless Cap Screw

–UN–14JUN01
H67749

083006
PN=482
Hydrostatic System
16. Hold cylinder barrel assembly in position in housing.

Position motor on its side and remove headless cap
screws (A).
C
17. Install swashplate cap screws (B) with new special B
washers (C). Tighten cap screws to specification. A
Specification
Swashplate Mounting Cap
Screws—Torque ...................................................................... 27—33 N•m
(20—24 lb-ft)
–UN–13JUN02
A—Headless Cap Screw (2 used)
C—Washer (2 used)
H72447
OUO6083,0000307 –19–03AUG05–8/14
50
18. Set motor on block with shaft down, being careful not 15
to bump shaft and cause it to move up out of ball 37
guide.
19. Use a press or bearing driver to install end cover

bearing cone on output shaft. Bearing cone must seat
against shoulder of output shaft.
20. Install two dowel pins and gasket on end cover.
–UN–10JUN02
H72448

083006
PN=483
Hydrostatic System
21. Lubricate and install shims (B) and bearing cup (A)
into cover (C).
22. Check output shaft end play by installing end cover

without installing valve or bearing plates. This
removes cylinder barrels spring tension against output
shaft.
A
23. Install cap screws in end cover and evenly tighten to
specification. B
Specification
Cover-to-Pump Cap Screws—
Torque ............................................................................................ 85 N•m
(63 lb-ft)
24. Support motor assembly on end cover. Tap output

shaft inward.
C
A—Bearing Cup
B—Shims
–UN–10JUN02
C—Cover
50
15
38
H72449
OUO6083,0000307 –19–03AUG05–10/14
25. Install dial indicator (A) on mounting flange (B) with

gauge on output shaft end. Use pliers (C) to grip
output shaft as low as possible.
26. Pry upward to determine shaft end play. End play

must be within specification. Adjust as necessary by
adding or removing shims under bearing cup in end
cover.
–UN–10MAR99
Specification
Motor Shaft—End Play ...................................................... 0.05—0.18 mm
(0.002—0.007 in.)
27. Generously coat with petroleum jelly; then install

H44047
bearing plate (brass) on cylinder barrel.
A—Dial Indicator
B—Mounting Flange
C—Pliers

083006
PN=484
Hydrostatic System
28. Install end cover gasket (A) on motor.
29. Coat valve plate (B) (side towards cover) with

petroleum jelly and set on end cover (C). Align dowel
pin (D) in end cover with slot in plate.
30. While holding valve plate inside end cover, align

scribe marks and install end cover.
31. Install cap screws in end cover. Slowly and evenly

tighten. Torque cap screws to specification. B
Specification D
End Cover-to-Hydrostatic Motor
A
(63 lb-ft)
32. Torque screws in a star pattern; then torque each

screw a second time to compensate for gasket
compression set.
IMPORTANT: Do not use solvent from parts cleaning

50
–UN–08MAY01
tank. This solvent may be contaminated C
15
and defeat the purpose of cleaning 39
shaft area.
H67752
33. Clean shaft area with a spray cleaner, such as an
electrical contact cleaner (SCOTCH 3M #1606) or
clean solvent in a spray bottle.
A—Gasket
B—Valve Plate
C—End Cover
D—Dowel Pin (2 used)
OUO6083,0000307 –19–03AUG05–12/14
CAUTION: During installation of seal use care

not to damage the seal or the sealing surface.
34. Grease surface of seal (A) which contacts shaft.
NOTE: Closed face of seal should face closed end of

–UN–10APR01
seal protector.
35. Press the new seal onto JDG1503-2 Seal Protector

(B).
H67020
A—Seal, Lip
B—Protector, Seal

083006
PN=485
Hydrostatic System
36. Install JDG1503-2 Seal Protector (A) over input shaft.
37. Install JDG1503-1 Lip Seal Installer (B) over

JDG1503-2 Seal Protector.
38. Using a rubber mallet. Drive seal in until surfaces (C)
–UN–10OCT01
and (D) touch.
39. Using JDG114 Snap Ring Pliers, install snap ring,

BEVELED EDGE OUT. Make sure snap ring is fully
E50674
expanded in its groove. Avoid damaging finished
surfaces.
40. Rotate shaft being careful not to damage splines. If

shaft binds, check end play and correct.
A—Protector, Seal
B—Driver, Seal
C—Surface
–UN–05OCT01
D—Surface
50
15
40
E50634
OUO6083,0000307 –19–03AUG05–14/14

083006
PN=486
Hydrostatic System
Remove and Install Motor Valve Block

(Manifold)

–UN–23AUG88
X9811
fluids.

1. Fully lower header and reel to ground and continue to 50

depress switch for 5 seconds to relieve hydraulic 15
system pressure. Shut off engine and remove key. 41

083006
PN=487
Hydrostatic System
IMPORTANT: Clean outside of motor thoroughly.

Either steam clean or wash with
solvent. Also clean surrounding area so
dirt will not get into system. If internal
work is to be performed, keep work
bench, tools and equipment clean.
When disconnecting a line, hose or

component, always mark end and port
from which it was removed so that it
reassembling.

always plug them and component to
keep dirt out of system. Use a plastic
plug or plastic bag - never a cloth.
Cloth contains lint which can damage
hydrostatic system.
50
15 High pressure hoses have clamp-type
42
possibility of leakage.
2. Scribe a line between valve block and motor to assist

in proper reassembly.

083006
PN=488
Hydrostatic System
3. Remove four cap screws (A) to remove valve block (B)

from motor (C). It is not necessary to remove motor to
service valve block. Place a container under valve
block to catch any oil that drains when block is
removed. Do not save drained oil.
–UN–23APR99
4. Plug holes in end cap of motor with plastic plugs to
minimize oil loss.
5. Cover motor end cap with plastic to keep dirt out of
H55204
motor.
6. Repair valve block as necessary.

7. Attach valve block (B) to motor (C) with four cap B—Valve Block (Manifold)
C—Motor
screws (A). Tighten cap screws to specification.
Specification
Valve Block-to-Hydrostatic Motor
(28 lb-ft)
50
8. Check oil level. Start engine and bleed system. (See
15
procedure in this group.) 43
AG,OUO6022,1853 –19–25JUL00–3/3

083006
PN=489
Hydrostatic System
Repair Motor Valve Block
50
15
44
–UN–03MAY00
H63624
1—Plug (2 used) 7—Spool 12—O-Ring (3 used) 17—Plug (3 used)
2—O-Ring (2 used) 8—Washer (2 used) 13—Ring (4 used) 18—O-Ring (3 used)
3—Spring (2 used) 9—O-Ring (2 used) 14—O-Ring (3 used) 19—Cap Screw (4 used)
4—Valve (2 used) 10—Seal 15—Valve (2 used) 20—Valve
5—O-Ring 11—Charge Pressure Relief 16—Block
6—Ring Valve
1. Remove outer hex plugs (1) to remove shuttle valve 4. Clean all parts in solvent and dry thoroughly.
spool (7) and components from both sides of valve
block. 5. Check parts for excessive wear and scoring.
Replace if necessary. If a high pressure relief valve
2. Remove low pressure control valve (11). or low pressure control valve are defective, the
complete valve must be replaced. Individual parts
3. Remove high pressure relief valves (15) from both are NOT available.
sides of valve block. Wrench only on hex section
next to block body. 6. Install new O-rings on hex plugs and valves.

083006
PN=490
Hydrostatic System
7. Install high pressure relief valves and low pressure 8. Install shuttle valve components. Tighten hex plugs
control valve in valve block. Tighten valves to to specification.
specification.
Specification
Specification Shuttle Valve Hex Plugs—
High Pressure Relief Valve— Torque............................................................................. 92—111 N•m
Torque.................................................................................... 100 N•m (68—82 lb-ft)
(75 lb-ft)
Low Pressure Control Valve—
Torque.................................................................................... 165 N•m
(125 lb-ft)
AG,OUO6022,1854 –19–25JUL00–2/2
Remove Hydrostatic Pump

–UN–23AUG88
all connections before applying pressure. 50
Search for leaks with a piece of cardboard. 15
Protect hands and body from high pressure 45
fluids.
X9811
Company Medical Department in Moline, or
other knowledgeable medical source.
1. Clean pump and surrounding area thoroughly.
2. Fully lower header and reel to ground and continue to

depress switch for 5 seconds to relieve hydraulic
Continued on next page OUO6083,000009A –19–12JUN01–1/3

083006
PN=491
Hydrostatic System
IMPORTANT: When disconnecting a line, hose, or

component, always mark end and port
from which it was removed so that it
reassembling.

always plug them and component to
keep dirt out of system. Use a plastic
plug or plastic bag - never a cloth.
Cloth contains lint which can damage
hydrostatic system.
High pressure hoses have clamp-type

50 possibility of leakage.
15
46
3. Install D15032NU vacuum pump on reservoir using
JT07085 adapter set. If pump is not available, drain
reservoir.
Specification
Reservoir—Approximate Capacity ...................................................... 34 L
(36 qt)
Continued on next page OUO6083,000009A –19–12JUN01–2/3

083006
PN=492
Hydrostatic System
4. Disconnect lines to main hydraulic pump (A) and

charge pump (B). Remove these items as one unit.
Plug or cover lines.
5. Disconnect lines and control cable to hydrostatic pump

(C).
6. Put a nylon strap or chain around pump.
CAUTION: Approximate weight of the pump
–UN–26APR99
assembly is 68 kg (160 lb).
7. Remove cap screws (D) and remove pump.
H55765
A—Main Hydraulic Pump
B—Charge Pump
C—Hydrostatic Pump
50
15
47
OUO6083,000009A –19–12JUN01–3/3
Disassemble Hydrostatic Drive Pump
1. Clean pump and drain oil.
2. Use JDG114 Snap Ring Pliers to remove snap ring

(A).
–UN–01MAY01
A—Snap Ring
H67016
OUO6083,000085E –19–03AUG05–1/21
3. Use a center punch and/or ice pick to make a small

hole in the side of seal (B). Careful not to damage
bearing behind seal.
4. Remove stationary seal (B) using sheet metal screw

(A).
–UN–11APR01
A—Sheet Metal Screw

B—Stationary Seal
H67017
Continued on next page OUO6083,000085E –19–03AUG05–2/21

083006
PN=493
Hydrostatic System
5. Remove six cap screws (A) that hold control valve (B)
to pump.

B—Control Valve
–UN–06APR01
H67074
OUO6083,000085E –19–03AUG05–3/21
50
15 6. Lift valve (B) away from pump and disengage linkage
48 (B) and (C).
7. Remove gasket (A).
8. Set pump on wooden blocks.
–UN–10APR01
A—Gasket
B—Linkage, Swashplate
C—Linkage, Control Valve
H67086
D—Control Valve

083006
PN=494
Hydrostatic System
9. Remove four cap screws (A). Do not remove two cap

screws (B) as they hold charge pump together.
Remove charge pump. DO NOT pry charge pump to
loosen. Tap with soft mallet.
10. Remove gasket (D) and dowel pins (C).
–UN–06APR01
C—Dowel Pin (2 used)
H67075
D—Gasket
–UN–11APR01
50
15
49
H67117
OUO6083,000085E –19–03AUG05–5/21
11. Inspect check valves (B). If oil is visible in bores, they

are functioning properly. If no oil, valve may be
leaking and should be replaced.
A
If a valve has to be replaced, replace both valves to

provide uniform operation.
12. Remove the two check valves. Insert a screwdriver

(C) through high pressure port of end cover to
remove check valves (B), or a tool (A) may be made B
from stiff wire to remove valves. Insert hook inside
valve cross hole, then pull from end cover.
A—Tool
B—Check Valve (2 used)
C—Screw Driver
C
–UN–14JUN02
H72450

083006
PN=495
Hydrostatic System
50
15
50
–UN–14JUN02
H72451

083006
PN=496
Hydrostatic System
A—Cap Screw (8 used) D—Bearing Cup F—Valve Plate H—Cover

B—Gasket E—Dowel Pin G—Bearing Plate I—Dowel Pin (2 used)
C—Shim (as required)
IMPORTANT: Internal parts are spring loaded. 16. Remove cap screws and end cover (H). Turn end
Damage to pump may occur if end cover over and set it on a clean cloth.
cover is removed incorrectly. Use
care when handling parts. These IMPORTANT: Valve plate (F) may lift away with
parts are machined to EXTREMELY end cover. Do not drop valve plate.
close tolerances.
17. Remove valve plate (F) and dowel pin (E).
13. Remove six of eight cap screws (A). Leave two
cap screws opposite each other. 18. Remove bearing cup (D). Cup is a slip fit. Remove
shims (C).
14. Loosen remaining two cap screws one or two
turns. The cover (H) should rise. If not, tap cover 19. Remove bearing plate (G) and gasket (B).
with a soft mallet to break gasket seal.
20. Remove two dowel pins (I).
15. Loosen two cap screws slowly and evenly until
spring tension is relieved.
50
15
51
OUO6083,000085E –19–03AUG05–8/21
21. Remove screws (A) and retainers (B) from sleeve.
IMPORTANT: DO NOT interchange parts. Mark parts

and housing clearly using a scribe to
help prevent re-installing sleeves and
pistons in the wrong configuration.
–UN–11APR01
22. Scribe marks (C) on each sleeve. (Make a horizontal
mark where sleeve and housing meet; then make a
vertical line starting on sleeve and ending on housing.
H67080
These marks will identify mounting depth of sleeves
during assembly.
A—Screw (6 used)
B—Retainer (2 used)
C—Marks
–UN–14JUN01
H67079

083006
PN=497
Hydrostatic System
23. Install a self-manufactured retaining strap (A) to pump

housing to help prevent block from falling out during
removal of trunnions.
A—Strap
–UN–12APR01
H67477
OUO6083,000085E –19–03AUG05–10/21
24. Carefully remove sleeves (A) from pistons (D).
25. Remove O-rings (B) and (C).
26. Position pump with control valve mount up.
50 A—Sleeve
15 B—O-Ring (2 used)
52 C—O-Ring (2 used)
D—Piston (2 used)
–UN–10APR01
H67171
OUO6083,000085E –19–03AUG05–11/21
27. Remove twelve cap screws and mounting flange (A).

Tap with soft mallet if necessary to break loose.
28. Remove gasket (B) and pins (C).
29. Remove bearing cup (D) and shims. Be careful not to

damage shims.
30. Inspect bearing cup and replace if necessary.

–UN–11APR01
A—Mounting Flange
B—Gasket
C—Pin (2 used)
D—Bearing Cup
H67078

083006
PN=498
Hydrostatic System
31. Remove retaining rings (A) from pins (B) connecting

pistons (C) to swashplate. Slide pins out through case
drain holes (D), and remove pistons.
A—Retaining Ring (2 used)

B—Pin (2 used)
–UN–12APR01
C—Piston (2 used)
D—Drain Hole
H67458
–UN–11APR01
50
15
53
H67459

083006
PN=499
Hydrostatic System
C
B
D
E
50
–UN–10JUN02
15
54
H72452
A—Cap Screw (6 used) C—Shim (as required) D—Trunnion (2 used) E—Bearing Cone (2 used)
B—O-Ring (2 used)
32. Mark pump housing and trunnions (D) so they will in a trunnion (use a 7/16—14 screw). Remove
be installed in the same position. trunnions (D) and shims (C).
33. Remove cap screws (A). 35. Remove O-rings (B).
IMPORTANT: Keep shims with each trunnion. They 36. Remove bearing cones (E) if damaged. Bearings
must be installed on same trunnion. are a press fit.
The shims pre-load the bearings.
37. Carefully remove swashplate, cylinder barrel, and
34. Trunnions fit tight. Use slide hammer to loosen shaft through mounting flange end of housing.
trunnions. Screw slide hammer into threaded hole

083006
PN=500
Hydrostatic System
38. Remove bearing cone from shaft using a special low

clearance bearing puller (A) and spacer (B). Spacer
prevents slotted end of shaft from spreading.
39. Remove shaft and bearing assembly from swashplate

and cylinder barrel making certain that cylinder barrel
and pistons remain together.
A—Bearing Puller
B—Spacer
50
–UN–25JUN02
15
55
H72453
B
OUO6083,000085E –19–03AUG05–15/21
40. Remove bearing cone (B) from shaft if damaged. A

Bearing is a press fit. B
IMPORTANT: DO NOT damage sealing area (A)

between bearing journal and keyway.
This area is extremely critical.
41. Press bearing cone on shaft using JDG630

Hydrostatic Transmission Tool Kit. Position of bearing
cone on shaft is IMPORTANT.
–UN–02JUL02
A—Sealing Area
B—Bearing Cone
H72454

083006
PN=501
Hydrostatic System
42. Set swashplate (F) and cylinder barrel (D) assembly A

on one of the trunnions making it easier to remove
retaining strap cap screws (A). Remove one retaining
strap (B) and loosen the other.
B
IMPORTANT: Keep cylinder barrel and pistons
together.
C
C
43. Position swashplate and cylinder barrel so barrel is on
the bottom. Remove swashplate by lifting it slightly
D
and sliding it over to disengage retaining strap.
44. Remove retaining strap and thrust plate from

swashplate.
45. Remove trunnion bearing cups (E) if damaged. Use a

long punch to remove the old bearing cups; then
carefully press new bearing cups into swashplate.
–UN–01JUL02
B—Retaining Strap (2 used)
50 C—Spacer (4 used)
15 D—Cylinder Barrel F E
H72455
56 E—Bearing Cup (2 used)
F—Swashplate
OUO6083,000085E –19–03AUG05–17/21
IMPORTANT: For reassembly, identify pistons,

sleeves, housing, and swashplate
link-ups with a letter, number, color,
etc.
NOTE: Disassemble servo piston assemblies only if

–UN–12APR01
replacement parts are required.
46. Remove retaining clips (A) and pins (B) connecting

link (C) to piston (D).
H67307
A—Clip (8 used)
B—Pin (4 used)
C—Link (2 used)
D—Servo Piston (2 used)

083006
PN=502
Hydrostatic System
CAUTION: Retain spring load when

disassembling servo piston.
47. Compress spring retainer and springs.
–UN–06APR01
48. Carefully and gradually loosen shoulder bolt (C) and
remove from piston (D).
49. Remove retainer (B) and springs (A).
H67303
50. Install springs (A) and spring retainer (B) in piston
(D).
A—Springs
B—Retainer
51. Compress spring assembly.
C—Shoulder Bolt
D—Piston
52. Apply thread lock and sealer (medium strength) to
shoulder bolt (C), then install. Tighten to specification.
Specification
Shoulder Bolt-to-Servo Piston
Cap Screw—Torque ................................................................ 22—26 N•m
(192—228 lb-in.) 50
15
57
OUO6083,000085E –19–03AUG05–19/21
53. If spring (C) appears damaged or contaminated,

press retaining ring (A) down to compress spring.
54. Remove outer retaining ring (B).
55. Remove retaining ring, spring and beveled inner
–UN–29SEP88
retainer (D).
56. Wash parts with clean solvent and replace spring.
N36010
57. Install beveled inner retainer (D) with beveled side
toward splined end of block.
58. Install outer retainer (A) with shoulder toward open A—Retaining Ring
B—Outer Retaining Ring
end of block. C—Spring
D—Inner Retainer
59. Compress spring and outer retainer, then install
retaining ring.

083006
PN=503
Hydrostatic System
C
D
G
I
H
G
B
G J
M
K
N
F
E
–UN–17JUN02
A
H72456
50
15
58
A—Holder D—Plug (Includes O-Ring) H—Needle Roller L—Valve Spool
B—Plug (Includes O-Ring) E—O-Ring I—Needle Roller M—Washer
C—Plug (Includes O-Ring) (2 F—Shim Kit J—Cover N—Compression Spring
used) G—O-Ring (4 used) K—Orifice
60. After end cover has been removed, flush end IMPORTANT: Do not flatten and reuse orifices.
cover internal passages and wash parts with clean
solvent. Blow parts dry with compressed air. 66. Stake orifice in six places with center punch
making certain orifice is properly seated after
61. Inspect parts and replace if worn or damaged. staking.
62. Inspect orifice and, if plugged after flushing, 67. Reassemble end cover. Install NEW O-rings and
replace it. tighten plugs and holder to specifications.
63. To remove plugged orifice, strike it in the center Hydrostatic Drive Pump Cover Plugs—Specification
with center punch. This will curl the orifice so it Plug (A)—Torque ..................................................................... 81 N•m
(60 lb-ft)
can be removed. Plug (B)—Torque ..................................................................... 12 N•m
(9 lb-ft)
64. Install NEW orifice of the same size. Plugs (C)—Torque ..................................................................... 7 N•m
(5 lb-ft)
NOTE: Orifice size is stamped on orifice in Plug (D)—Torque..................................................................... 12 N•m
(9 lb-ft)
thousandths of an inch; example: 57 = 0.057
in.
65. Place orifice in orifice pocket so size is visible.
OUO6083,000085E –19–03AUG05–21/21

083006
PN=504
Hydrostatic System
50
15
59

083006
PN=505
Hydrostatic System
Assemble Hydrostatic Drive Pump
1 2
4
5
6
2
3 7
8 13
14
12
15
10 8
42
33
43 9
11
8 41 8
50 40 44
15
60 45
16
8 24
17
18
19
20
21 30
8 22 31 32
39 25 23
38 8
37 33
18 34
27
17
28
21 8
20 26 23 29
19
22 36 13
35 14
–UN–08JUN04
15
16
H81134
Continued on next page OUO6083,000085D –19–03AUG05–1/24

083006
PN=506
Hydrostatic System
1—Swashplate Assembly 13—O-Ring (3 used) 24—Pump Housing 36—End Cover

2—Retaining Ring (8 used) 14—O-Ring (2 used) 25—Plug and O-Ring 37—Seal
3—Pin (4 used) 15—Servo Sleeve (2 used) 26—Plug and O-Ring 38—Snap Ring
4—Thrust Plate 16—Servo Piston Assembly (2 27—End Cover Bearing 39—O-Ring
5—Piston and Slipper used) 28—Shaft Shims (as required) 40—Mounting Flange Bolt (12
Assembly 17—Trunnion Bolt (6 used) 29—End Cover Gasket used)
6—Slipper Retaining Plate 18—Trunnion Assembly (2 30—Check Valve Assembly (2 41—Bearing Kit (as required)
7—Cylinder Barrel used) used) 42—Mounting Flange
8—Dowel Pin (9 used) 19—Bearing (as required) 31—O-Ring (2 used) Assembly
9—Bearing Plate 20—O-Ring (2 used) 32—Back-Up Ring (2 used) 43—Bearing Cup
10—Retaining Strap and Bolts 21—Trunnion Shims (as 33—Spring Strap (2 used) 44—Mounting Flange Gasket
(2 used) required) 34—End Cover Bolt (6 used) 45—Drive Shaft Assembly
11—Rotating Group 22—Cap Screw (6 used) 35—End Cover Bolt (2 used)
12—Valve Plate 23—Servo Sleeve Retainer (2
used)
1. Wash pump body and parts with clean solvent. Dry • Valve Plate (12)
with compressed air. Keep parts clean. • Ball Guide
• Bearings (19)
NOTE: Refer to “Inspect Parts”, which follows • Internal Splines of Cylinder Barrel (7)
hydrostatic drive motor disassembly procedure,
for examples of parts damage and probable Replace parts as necessary.
causes.
NOTE: If bearing plate (9) is scored, eroded or
50
2. Inspect middle land of slippers on pistons (5, smeared, replace it. 15
exploded view) for nicks and scratches. 61
4. Assemble pump using exploded view. Install
3. Inspect the following for wear or damage: gaskets. Apply petroleum jelly to finished surfaces.
Apply clean hydraulic oil to parts when specified in
• Races in Swashplate (1) following instructions.
• Bearing Plate (9)

083006
PN=507
Hydrostatic System
5. Install slipper retainer plate and piston slippers in A

H
cylinder barrel.
G
6. Check fixed clearance of unit. Measure height of

B
retaining strap spacer with a micrometer or calipers.
–UN–01JUL02
Measure thickness of both piston slipper flange and C
F
slipper retainer plate (B) and (C). Subtracting this
measurement from spacer (F) measurement gives E D
H72457
fixed clearance of unit. Fixed clearance must not
exceed specification. If fixed clearance exceeds
specification, replace worn parts, as required. A—Piston
B—Slipper Retainer Plate
Specification C—Piston Slipper
Rotating Group—Fixed Clearance ............................................... 0.20 mm D—Thrust Plate
(0.008 in.) E—Swashplate
F—Spacer
Fixed Clearance = Spacer height - (slipper flange + G—Retaining Strap
H—Cap screw
retainer plate)
50
15
62
OUO6083,000085D –19–03AUG05–3/24
7. Apply thread lock and sealer (high strength) in first or

second thread down, in each of four holes (A) in
swashplate.
8. Install thrust plate (B). Install spacers (C), retaining

strap (D), and cap screws (E) on one retaining strap.
–UN–10APR01
Do not tighten cap screws.
9. Put cylinder barrel assembly on clean flat surface with

piston slippers up. Carefully install swashplate on
cylinder barrel by slightly lifting side without retaining H67176
strap. Slide swashplate over to engage installed

retaining strap around piston retainer.
A—Hole (4 used)
B—Thrust Plate
C—Spacer (2 used)
D—Retainer
–UN–10APR01
H67177

083006
PN=508
Hydrostatic System
10. Carefully reposition cylinder barrel and swashplate

with swashplate in down position. Install remaining
spacers (A), retainer (B) and cap screws (C) in
swashplate. Tighten cap screws to specification.
Specification
Swashplate Retaining Strap Cap
–UN–10APR01
Screws—Torque .......................................................................... 24.0 N•m
(17.5 lb-ft)
A—Spacer (2 used)
H67178
B—Retainer
OUO6083,000085D –19–03AUG05–5/24
50
11. Slide shaft and bearing assembly through swashplate 15
and cylinder barrel. 63
12. Carefully install swashplate, cylinder barrel and shaft

in pump housing. Be sure feedback linkage is by
control valve mount.
–UN–10APR01
H67172

083006
PN=509
Hydrostatic System
IMPORTANT: Do not let cylinder barrel slide off

pistons.
13. Lubricate and install new O-rings (A) on trunnions (B).
IMPORTANT: Trunnion shims on each side of pump
–UN–10APR01
should be of equal thickness. Maximum
allowable difference between sides is
0.3 mm (0.010 in.).
H67173
14. Install shims (C) and trunnions in original position.
Tighten cap screws (D) to specification.
Specification
Pump Trunnion Cap Screws—
Torque ............................................................................................ 60 N•m
(44 lb-ft)
15. Remove shaft and bearing assembly from

swashplate.
–UN–10APR01
50 A—O-Ring (2 used)
15 B—Trunnion (2 used)
64 C—Trunnion Shims
H67183

083006
PN=510
Hydrostatic System
16. Check movement of swashplate by attaching spring

scale (A) to control link (B). If more than specification
is required to move swashplate, disassemble and add
more shims.
Specification
Swashplate Preload—Breakaway
Force.............................................................................................. 9—22 N
(2—5 lb)
A—Spring Scale
B—Control Link
–UN–04MAR99
H54325
50
15
65
OUO6083,000085D –19–03AUG05–8/24
IMPORTANT: Do not let cylinder barrel slide off

pistons.
17. Install servo piston (A) into pump housing and align
servo link to swashplate.
–UN–10APR01
18. Install pin (B) through case drain holes (C) and apply
retaining rings (D). Repeat procedure for second
servo piston.
H67180
19. Cover pistons with CLEAN hydraulic oil.
20. Position pump so it is sitting on mounting flange

surface.
A—Servo Piston
B—Pin
C—Case Drain Hole
D—Retaining Ring (2 used)
–UN–10APR01
H67174

083006
PN=511
Hydrostatic System
21. Lubricate and install new O-rings (B) and (C) on

sleeves (A).
22. Install each sleeve in its original position, start by

lifting one piston (D) and tilting swashplate to
maximum angle.
23. Carefully fit sleeve over piston. Lower sleeve and

piston into pump housing until threads meet. Screw in
sleeve until scribe marks line up. Repeat procedure
–UN–10APR01
for second sleeve.
A—Sleeve
B—O-Ring
H67171
C—O-Ring
D—Piston
OUO6083,000085D –19–03AUG05–10/24
50
15 IMPORTANT: Zeroing swashplate insures that springs
66 on pistons will return swashplate to
neutral when control lever is centered.
24. Check zero angle of swashplate (B).
25. Place parallel bars (A) across end cover gasket

surface and measure depth to swashplate on each
side of cylinder barrel using a depth micrometer (C).
Specification
A
Swashplate Zero Angle—
Maximum Allowable Difference .................................................... 0.12 mm C
(0.005 in.)
Maximum Allowable Rock ............................................................ 0.03 mm
(0.010 in.)
26. Screw servo sleeves in or out to adjust swashplate

zero angle. –UN–02JUL02
A—Parallel Bar
B—Swashplate
C—Depth Micrometer
B
H72458

083006
PN=512
Hydrostatic System
27. Install retainer (A) and cap screws (B).
28. Take a punch and dent retainer (A) at slot (C).
NOTE: DO NOT let cylinder barrel slide off pump.
–UN–10APR01
29. Position pump so control valve mount is on top.
30. Carefully slide shaft and bearing assembly into pump.
H67179
A—Retainer
C—Slot
OUO6083,000085D –19–03AUG05–12/24
50
31. Install dowels (A) in pump housing. 15
67
32. Install new gasket (B). Hold in place with petroleum
jelly.
33. Lubricate bearing (C) with clean hydraulic fluid.
34. Install mounting flange (D). Tighten cap screws to

specification.
–UN–10APR01
Specification
Pump Mounting Flange Cap
Screws—Torque ............................................................................. 60 N•m
(44 lb-ft)
H67298
A—Dowel
B—Gasket
C—Bearing
D—Mounting Flange

083006
PN=513
Hydrostatic System
35. Turn pump over so shaft is vertical and mounting

flange is down.
36. Support pump shaft and use a bearing driver to install

end cover bearing cone. Be sure bearing cone is
seated against shoulder of shaft.
37. Remove shaft support.
–UN–25JUN02
50
15
68
H72459

083006
PN=514
Hydrostatic System
38. Install dowel pins (D) in holes in pump housing.
39. Install new gasket. A
B
40. Check shaft end play before installing bearing and
valve plates.
–UN–01JUL02
Be sure shims (B) and bearing cup (A) are in end
cover (C).
C
41. Install end cover. Tighten cap screws alternately to
H72460
specifications. D
Specification A—Bearing Cup

End Cover-to-Drive Pump Cap B—Shim (as required)
Screws—Torque ............................................................................. 85 N•m C—End Cover
(63 lb-ft) D—Dowel (2 used)
42. Turn pump over so mounting flange and shaft are up.
Place a wood block under end cover so pump weight
is not on servo sleeves.
50
43. Remove pump from blocks.
15
69
44. Using a rubber mallet, tap end of shaft to seat
bearings.
OUO6083,000085D –19–03AUG05–15/24
45. Using D17525C1 Magnetic Base (B) and D17526C1

Dial Indicator, measure total shaft end play. Grip shaft
(D) with pliers (C), pry shaft out for total end play. If
not within specifications remove cover and reshim A
D
behind end cover bearing cup.
C
Specification
Pump Drive Shaft—End Play ............................................ 0.05—0.18 mm
(0.002—0.007 in.)
–UN–19JUN02
A—End Play
B—D17525C1 Magnetic Base
C—Pliers
H72461
D—Shaft

083006
PN=515
Hydrostatic System
46. Turn pump back over and remove end cover.
47. Install dowel pins (A) in holes in cylinder barrel face.
48. Place bearing plate (B) on cylinder barrel and engage

holes (C) with previously installed dowel pins (A).
–UN–10APR01
A—Dowel (2 used)
B—Bearing Plate
C—Engagement Hole (2 used)
H67294
–UN–10APR01
50
15
70
H67293
OUO6083,000085D –19–03AUG05–17/24
49. Install dowel pins (A) and gasket (B).
50. Liberally lubricate bronze surface of bearing plate with

clean hydraulic fluid.
51. Place valve plate (C) on bearing plate.
–UN–10APR01
A—Dowel Pins (2 used)
B—Gasket
C—Valve Plate
H67292

083006
PN=516
Hydrostatic System
52. Install end cover (A) and start cap screws (B).
53. Align dowel pin (C) in end cover with engagement

hole (D) in valve plate.
54. Tighten cap screws evenly so cylinder barrel spring

preload is taken up gradually. Tighten cap screws to
specification.
Specification
Valve Plate-to-End Cover Cap
–UN–10APR01
Screws—Torque ............................................................................. 85 N•m
(63 lb-ft)
A—End Cover
H67295
C—Dowel Pin
D—Engagement Hole
50
15
71
–UN–10APR01
H67182
OUO6083,000085D –19–03AUG05–19/24
55. Lubricate and install new O-ring and back-up ring (A)
on check valves. Back-up ring must be installed on
charge pump side.
56. Install check valves. Push valves down until tops are
flush with surface (C) of end cover.
–UN–10APR01
A—Back-up Ring
B—Check Valve
C—Surface
H67184

083006
PN=517
Hydrostatic System
57. Install dowel pins (A) in end cover.
58. Install new gasket (B).
59. Rotate charge pump shaft so tang and dowel pin

holes line up with pump. Install charge pump (C).
–UN–10APR01
IMPORTANT: Be sure to use the correct torque when
tightening charge pump mount cap
screws. Using a higher torque reduces
H67300
the internal clearance of the pump
which can result in pump failure.
60. Install cap screws (D) and tighten alternately to

specification.
Specification
Charge Pump-to-End Cover Cap
Screws—Torque ...................................................................... 27—33 N•m
(20—24 lb-ft)
–UN–10APR01
61. Position pump so control valve mount is on top.
50
15
72 A—Dowel Pin (2 used)
H67365
B—Gasket
C—Charge Pump

083006
PN=518
Hydrostatic System
62. Install new control valve gasket (A).
IMPORTANT: Be sure linkage points toward end

cover.
63. Connect linkage (B) and (C) and place control valve
–UN–10APR01
(D) on pump.
64. Install cap screws (E). Tighten finger tight.
H67348
65. Move control lever back and forth. It should move
freely in both directions and self-center. If not, check
linkage.
66. Tighten cap screws to specification.
Specification
Control Valve-to-Pump Cap
Screws—Torque ............................................................................. 22 N•m
(16 lb-ft)
67. Place pump on its side. Do not set pump on control

50
lever arm.
15
73
A—Gasket
B—Linkage
–UN–10APR01
C—Linkage
D—Control Valve
H67357
OUO6083,000085D –19–03AUG05–22/24
68. Grease surface of seal (A) which contacts shaft.
NOTE: Closed face of seal should face closed end of

seal protector.
69. Press the new seal onto JDG1503-2 Seal Protector

–UN–10APR01
(B).
A—Seal, Lip
B—Protector, Seal
H67020

083006
PN=519
Hydrostatic System
70. Install JDG1503-2 Seal Protector (A) over input shaft.
71. Install JDG1503-1 Lip Seal Installer (B) over

JDG1503-2 Seal Protector.
72. Using a rubber mallet. Drive seal in until surfaces (C)
–UN–10APR01
and (D) touch.
73. Using JDG114 Snap Ring Pliers, install snap ring,

BEVELED EDGE OUT. Make sure snap ring is fully
H67019
expanded in its groove. Avoid damaging finished
surfaces.
74. Rotate shaft being careful not to damage splines. If

shaft binds, check end play and correct.
A—Protector, Seal
B—Driver, Seal
C—Surface
–UN–10APR01
D—Surface
50
15
74
H67015
OUO6083,000085D –19–03AUG05–24/24

083006
PN=520
Hydrostatic System
Replace High-Pressure Line Center Pivot O-Rings
–UN–31MAY01
H67753
A—Clamp (4 used) B—O-Ring (2 used) 50
15
When a high-pressure line is removed from the 4. Coat new O-rings with clean hydrostatic oil and 75
machine, replace center pivot O-ring as follows: install.
1. Remove clamps (A) from high-pressure line 5. Assemble high pressure hoses. Tighten half clamp
couplings. cap screws to specification.
2. Remove O-rings (B) from center coupling of both Specification

Half Clamp Cap Screw—
high-pressure lines.
Torque...................................................................................... 72 N•m
(53 lb-ft)
3. Clean coupler joint surfaces before assembly.
OUO6083,000020A –19–06MAR02–1/1

083006
PN=521
Hydrostatic System
Disassemble and Assemble End Cover
–UN–31MAY01
H67754
A—Spring Box E—Plug H—Pin K—Spool
B—O-Ring F—Plug I—Plug L—Shim (as required)
50 C—Spring G—Plug J—Pin M—Control Orifice
15 D—Spacer
76
1. Remove parts (A—L). 6. Assemble parts (A—L).
2. Flush end cover passages and parts with clean Drive Pump End Cover—Specification
Spring Box (A)—Torque .......................................................... 81 N•m
solvent. Dry parts with compressed air.
(60 lb-ft)
Plug (E)—Torque ..................................................................... 12 N•m
3. Replace worn or damaged parts. (9 lb-ft)
Plug (F)—Torque ....................................................................... 7 N•m
4. Inspect control orifice (M). Replace if plugged. (5 lb-ft)
Plug (G)—Torque ...................................................................... 7 N•m
Remove by striking in center with a punch.
(5 lb-ft)
Plug (I)—Torque ...................................................................... 12 N•m
5. Install new orifice of same size. Size is stamped on (9 lb-ft)
orifice in thousandths of an inch. Example; 57 =
0.057 in. Install orifice so size is visible. Stake in six
places.
OUO6083,000020B –19–06MAR02–1/1

083006
PN=522
Hydrostatic System
Repair Displacement Control Valve
1
26
27
25
2
23
24
3 8
22
12 4
19
11 5
6
7
21 20
13 9
14 50
10 15
15 77
–UN–08JUN04
18
17
H81115
16
1—Cap Screw (2 used) 8—Repair Kit 15—Snap Ring (2 used) 22—Washer

2—Housing 9—O-Ring 16—Control Link 23—Link
3—Spool 10—Adjusting Screw 17—Connector 24—O-Ring
4—Washer 11—Bolt 18—Spring Pin 25—Shaft
5—Spring 12—Set Screw 19—O-Ring (2 used) 26—Cap Screw (4 used)
6—Retainer 13—Gasket 20—Plug (2 used) 27—Seal
7—Cap Screw 14—Link 21—Nut
Valve may be removed from pump without removing 5. Scribe two lines on adjusting screw (10) to indicate
pump from combine. Disconnect control linkage. setting.
1. Remove cap screws (1 and 26) to loosen valve. 6. Loosen set screw and remove adjusting screw (10)
and spool (3).
2. Unhook link (16) from control link.
7. Clean all parts in solvent and dry thoroughly.
3. Discard drained oil and cover opening in pump Replace all worn or damaged parts and install new
housing to keep dirt out. O-rings.
4. Unhook link (14) from connector (17), loosen set 8. Insert spool kit (8) into housing. Screw centering
screw (12), remove spring pin (18) and pull shaft spring adjusting screw (10) until scribe marks align.
(25) out of valve. Tighten set screw.
Continued on next page OUO6083,0000CBA –19–09MAR06–1/2

083006
PN=523
Hydrostatic System
9. If new spool, spring or adjusting screw is installed, 12. Hook link (16) into control link. Make sure control
turn adjusting screw into housing until just link is pointing toward end cover of housing or unit
contacting spring. DO NOT compress spring. will not function properly.
10. Install pivot shaft, new sealing washer and O-ring. 13. Tighten attaching cap screws to specification.
Tighten set screw (12) and install pin (18) and
connect link (14) in connector (17). Specification
Control Valve-to-Pump Cap
Screws—Torque ............................................................... 22—26 N•m
11. Check spool (3) for end play by moving it back (264—312 lb-in.)
and forth. If there is end play, tighten adjusting
screw (10) until it touches spring. Exert a slight
back and forth force on spool while adjusting
screw. DO NOT compress spring beyond its
installed length.
OUO6083,0000CBA –19–09MAR06–2/2
50
15
78

083006
PN=524
Hydrostatic System
Disassemble and Assemble Displacement

Control Valve with Feed Rate (Optional)
3
2
10
6 11
7 4
8 12
5 13 50
15
79
6
2
7
14 25
9 15
16
17
18
15 19
14 20
26
16
13 27
1
17
12 18 28
11 13
19
20
16
21
29
10 22
30
23
24
–UN–27JAN06
H85185
Continued on next page OUO6083,0000CB9 –19–09MAR06–1/2

083006
PN=525
Hydrostatic System
1—Cap Screw (3 used) 8—Sensor 16—O-Ring (3 used) 24—Gasket

2—Cap Screw (2 used) 9—O-Ring 17—Fitting (2 used) 25—Connector
3—Cap Screw (1 used) 10—Retainer (2 used) 18—O-Ring (2 used) 26—Nut
4—Connector 11—O-Ring (2 used) 19—Adapter (2 used) 27—Coil
5—Wire Harness 12—Solenoid Valve (2 used) 20—O-Ring (2 used) 28—Solenoid Valve
6—Socket Head Cap Screw (2 13—O-Ring (2 used) 21—Screen (2 used) 29—Sensor
used) 14—Coil (2 used) 22—O-Ring 30—Connector
7—Washer (2 used) 15—Rubber Washer (2 used) 23—Socket Head Screen
IMPORTANT: Solenoid coils (14) are numbered 3. Tighten socket head screen (23) to specification.
and must be installed on correct
side of valve. Specification
Socket Head Screen—Torque................................... 38 N•m ± 4 N•m
(28 lb-ft ± 35 lb-in.)
1. Disassemble parts (1-30).
OUO6083,0000CB9 –19–09MAR06–2/2
50
15
Electronic Proportional Displacement Control
80 Valve Neutral Adjustment
CAUTION: Avoid machine movement! Place

transmission in neutral and move multifunction
control handle gently forward to verify machine
–UN–15DEC04
is in neutral. Apply parking brake and block
wheels. Leave transmission in neutral for entire
procedure to avoid machine movement.
H82196
1. Turn engine OFF.
2. Disconnect connector (A) from displacement control A—Displacement Control Valve Connector
valve (B). B—Displacement Control Valve
C—Servo Neutral Valve
3. Remove servo neutral valve (C) from displacement
control valve (B).
Continued on next page OUO6083,00009C8 –19–03AUG05–1/6

083006
PN=526
Hydrostatic System
4. Install diagnostic receptacles (M14 X 1.5 M ORB -

JT05480) or plugs (M14 X 1.5 M ORB - JT05485) into
servo pressure ports (A and B).
A—Reverse servo port

B—Forward servo port
–UN–15DEC04
H82197
OUO6083,00009C8 –19–03AUG05–2/6
5. Remove plug from charge pressure port (A) on

hydrostatic pump.
6. Install diagnostic receptacle (7/16-20 M ORB -

JT03442) into charge pressure port (A).
–UN–22SEP04
7. Install a 3447 kPa (500 psi) gauge to diagnostic
50
receptacle. A quality liquid filled analog gauge is
15
recommended. 81
H81736
A—Plug

083006
PN=527
Hydrostatic System
8. Loosen lock nut (A) with a wrench by holding neutral

adjust screw (C) with a screwdriver.
NOTE: The neutral adjust screw is not threaded into the

displacement control valve. The neutral adjust
screw rotates on a large sleeve with an o-ring
–UN–02APR04
inside the displacement control valve. The sleeve
prevents the screw from falling out, and the o-ring
prevents case pressure oil from leaking out of the
valve. It turns freely in either direction. It is not
H80557
necessary to turn the neutral screw more than
one revolution in either direction.
A—Lock Nut
CAUTION: Make sure transmission is placed in B—Displacement Control Valve
neutral. C—Neutral Adjust Screw
9. Start combine with parking brake engaged and

transmission in neutral. Run engine at low idle.
CAUTION: Do not stand on rear tire to check

50 pump pressure settings.
15
82
10. While observing the pressure gauge, rotate the
neutral adjust screw clockwise approximately 1/4 to
1/2 a turn, then back counterclockwise to obtain the
highest pressure reading (typically 1862 kPa [270
psi]). Pressure will vary slightly depending on the
machine. Center the neutral adjust screw at the point
where the pressure is highest.
NOTE: There will only be a 69 kPa (10 psi) difference

between the lowest reading and highest reading
because there is minimal load against the
hydrostatic drive with the transmission in neutral.
Neutral is used for safety purposes.

083006
PN=528
Hydrostatic System
11. With the pressure set, hold neutral adjust screw (C)
on pump (B) and tighten lock nut (A) to specification.
Do not let the neutral adjust screw turn while
tightening the lock nut. Recheck the gauge reading to
make sure it remained at the highest pressure.
–UN–02APR04
Specification
Lock Nut—Torque .......................................................................... 14 N•m
(10 lb-ft)
H80557
A—Lock Nut
B—Displacement Control Valve
C—Neutral Adjust Screw
OUO6083,00009C8 –19–03AUG05–5/6
50
12. Reconnect connector (A) to displacement control 15
valve (B). 83
NOTE: When started, combine should not “creep” if

displacement control valve was adjusted correctly.
13. Start combine, place transmission in gear and release
–UN–15DEC04
parking brake.
14. Push multifunction control handle slowly forward and

slowly rearward to see if machine operates normally.
H82196
15. If machine functions properly, remove gauge and
diagnostic receptacle and replace plug. A—Displacement Control Valve Connector
B—Displacement Control Valve
C—Servo Neutral Valve
OUO6083,00009C8 –19–03AUG05–6/6

083006
PN=529
Hydrostatic System
Install Hydrostatic Pump
CAUTION: Approximate weight of pump

1. Attach pump-to-engine gear case with cap screws (D).

Specification
Hydrostatic Pump-to-Engine Gear
Case Cap Screws—Torque.................................................. 130 ± 50 N•m
–UN–26APR99
(96 ± 36 lb-ft)
2. Connect lines and cable to pump (C). Use new

O-rings. Connect lines to pumps (A) and (B).
H55765
3. Check oil level. Start engine and bleed system. (See
procedure in this group.) A—Main Hydraulic Pump
B—Charge Pump
C—Hydrostatic Pump
50
15
84
AG,OUO6022,1861 –19–25JUL00–1/1
Remove and Install Charge Pump

–UN–23AUG88
fluids. X9811



083006
PN=530
Hydrostatic System
2. Remove main pump (A).
3. Disconnect harness connector and line to filter head

(B), and line to pump (C).
4. Remove pump (D).
–UN–26APR99
5. Repair pump as needed.
6. Install pump (D).
H55766
7. Connect harness connector and line to filter head (B),
and line to pump (C).
A—Main Pump
8. Install main pump (A). B—Filter Head
C—Line to Charge Pump
D—Charge Pump
AG,OUO6022,1862 –19–25JUL00–2/2
50
15
85

083006
PN=531
Hydrostatic System
Repair Charge Pump
1 4
5
2 3 6
12
7 11
31
24
30 9
13 14
29
8
9 16
28 10
17
20
15
25 24 27 10
26 21
23
18
24
–UN–17JUN04
50 22
15 19
86
H81225
21
1—Gasket 9—Pin (2 used) 17—Snap Ring 25—Filter

2—Shaft 10—O-Ring (2 used) 18—Oil Pump 26—Plug
3—Pin 11—Spring 19—Ball Bearing 27—Socket Head Cap Screw
4—Relief Valve 12—Plug 20—Cover 28—Filter Base
5—O-Ring 13—Poppet 21—Cap Screw (2 used) 29—Coupler
6—O-Ring 14—O-Ring 22—O-Ring 30—Cover
7—Housing 15—Spacer 23—Pressure Sensor 31—Pin
8—Needle Bearing 16—Snap Ring 24—O-Ring (3 used)
1. Scribe a line across pump sections. 7. Tighten low pressure relief valve (5) to specification.
2. Remove cap screws (12) and (13). Specification

Charge Pump Low Pressure
Relief Valve—Torque............................................................. 108 N•m
3. Inspect rotor assembly (14), shaft (1) and body (6) (80 lb-ft)
for excessive wear or scoring. Replace if
necessary. 8. Tighten cap screws (12) and (13) to specification.
4. Remove and clean low pressure relief valve (5). Specification

Charge Pump Cover-to-Pump
5. Install new O-rings and packings. Housing Cap Screws—Torque ......................................... 27—33 N•m
(20—24 lb-ft)
6. Assemble pump, aligning scribe marks.
OUO6083,0000864 –19–17JUN04–1/1

083006
PN=532
Hydrostatic System
Remove and Install Control Cable
1. Remove cable (A) from hydrostatic pump control lever

(B).
2. Remove instructional seat in cab.
–UN–26APR99
3. Remove cable clamp (C) on cab floor behind heater
blower motor.
H55768
4. Remove nut (D) from cable ball joint to multifunction
control handle (E).
5. Tie a rope to end of cable before removing assembly

from machine to aid in the installation.
6. Install cable assembly in cab first.
7. Attach cable ball joint to multifunction control handle

(E) with nut (D).
NOTE: Grind a point on an M6 x 30 cap screw to aid in 50

locating the holes in cab floor for cable clamp. 15
87
8. Install cable clamp (C) on cab floor.
9. Install instructional seat.
10. Route cable and secure with clamps to sidesheet.
11. Move multifunction control handle (E) through full

range of forward and reverse.
–UN–28NOV01
NOTE: If handle will not move through full range, adjust
cable ball joint at cab end.
H70377
12. Move hydro pump control lever (B) side to side by
hand. Control lever is spring loaded and will return to
neutral position by itself. A—Cable
B—Hydrostatic Pump Control Lever
NOTE: Do not move control lever to attach ball joint. C—Cable Clamp
D—Nut
Adjust ball joint on threaded cable to install. E—Multifunction Control Handle
13. Attach rear cable ball joint (A) to inside hole of control
lever (B).
Continued on next page OUO6083,00009CA –19–26APR05–1/2

083006
PN=533
Hydrostatic System
14. Start engine with multifunction control handle in

neutral. Combine should not “creep”. If it does, adjust
cable ball joint at hydro pump.
OUO6083,00009CA –19–26APR05–2/2
Adjust Hydrostatic Neutral Linkage
1. Shut off engine.
2. Place multifunction control handle in neutral.
–UN–26APR99
3. Remove ball joint (A) from arm (B).
CAUTION: The gearshift must be in neutral so

the combine will not move.
H55768
4. Place gearshift in neutral. Start engine and run for 15
seconds. Shut off engine and remove key. Operating A—Ball Joint
50 engine with linkage disconnected will cause hydrostatic B—Arm
15 unit to come to neutral.
88
5. Do not move arm (B) on hydrostatic unit. Cable must
not be connected to pump arm.
6. Push cable forward (all the way in) to remove

backlash.
7. Align ball joint with hole in arm by adjusting bulkhead

fitting on cable at cable support. If further adjustment is
needed, adjust at rear ball joint. Do not bottom out ball
joint. Keep a minimum of three turns for later
adjustment.
8. Turn ball joint in three full turns when ball joint stud
aligns with hole in arm and cable is pushed all the way
in.
9. Pull cable out so it aligns with hole in arm. Secure in

place.
OUO6083,00008E5 –19–02FEB05–1/1

083006
PN=534
Hydrostatic System
Adjust Mechanical Displacement Control

Valve Neutral
CAUTION: Place transmission in neutral, apply

parking brake, turn engine off and remove key.
–UN–22SEP04
1. Disconnect cable ball joint (A) from lever (B) on
displacement control valve.
2. Inspect lever to shaft connection and make sure parts
H81734
are securely connected. Worn splines on either part
will require replacement. Verify nut (C) holding lever to
shaft is secure.
3. Loosen set screw (D).
4. Use pliers to turn adjusting screw (E) out one full turn.
5. Turn adjusting screw (E) in slowly while moving lever

(B) back and forth. Continue turning adjusting screw
until free play at lever is eliminated. Turning the 50
adjusting screw in too far will add free play. 15
–UN–23SEP04
89
NOTE: Ball joint may have to be adjusted after procedure
is completed. Loosen jam nut on cable and turn
ball joint either direction so it fits into lever without
H81740
moving lever. Tighten jam nut.
6. Tighten set screw (D) and reattach cable ball joint (A) A—Ball Joint
to lever (B). B—Lever
C—Nut
D—Set Screw
E—Adjusting Screw
OUO6083,0000A0A –19–23AUG06–1/1

083006
PN=535
Hydrostatic System
Start-Up Procedure After Hydrostatic System

Repair
1. Fill system with John Deere HY-GARD transmission

and hydraulic oil and leave cap off reservoir.
2. Disconnect multi-pin connector to injectors on end of

cylinder head.
3. Crank engine, with starting motor, several times for 15

seconds at one minute intervals. This starts oil flowing
into hydrostatic pump.
4. Reconnect multi-pin connector to injectors.
CAUTION: To avoid injury or death to others,

keep all bystanders away from machine while
performing start-up procedure. Machine may
move unexpectedly.
50 5. Place transmission in neutral and engage parking

15 brake.
90
6. Start engine and run at slow idle speed for 5 minutes
to bleed air from system.
7. Move hydro lever slightly forward out of neutral. After

30 seconds, return hydro lever to neutral position.
8. Move hydro lever slightly into reverse travel. After 30

seconds, return to neutral.
9. Repeat steps 7 and 8 using slightly more stroke than

previous until maximum forward and reverse travel is
reached.
10. Release parking brake.
11. Increase engine speed to full throttle.
12. Shift transmission to second gear and run machine in

forward and reverse several times to check drive
system.
13. Check for system leaks, fill reservoir with oil and
install cap.

083006
PN=536
Hydrostatic System
14. Clear A00 codes on cornerpost. (See DIAGNOSTIC

TROUBLE CODES in Machine Operators Manual.)
OUO6435,00016C1 –19–01APR02–2/2
50
15
91

083006
PN=537
Hydrostatic System
50
15
92

083006
PN=538
Group 20
Cam Lobe Motor
NOTE: Order tools from U.S. SERVICEGARD or RECOMMENDED TOOLS, as noted, are suggested to
Catalogs.
OUO6083,0000887 –19–09SEP05–1/13
Weatherpack Terminal Extractor (blue handle) . . JDG776
Used to extract wire terminals from connector.
–UN–04JUN01
50
20
1
H68294
OUO6083,0000887 –19–09SEP05–2/13
Block, Bearing Remover . . . . . . . . . . . . . . . . JDG690-7
Used to remove spindle from cam lobe motor.
–UN–09AUG02
H72969
OUO6083,0000887 –19–09SEP05–3/13
Bearing Puller Attachment. . . . . . . . . . . . . . D01243AA
Used to remove spindle bearing and seal from cam lobe

motor.
–UN–09AUG02
H72969
Continued on next page OUO6083,0000887 –19–09SEP05–4/13

083006
PN=539
Cam Lobe Motor
17-1/2 Ton Push-Puller (Hydraulic) . . . . . . . . D01219AA
Used to remove spindle bearing and seal from cam lobe

motor.
–UN–09AUG02
H72970
OUO6083,0000887 –19–09SEP05–5/13
30 Ton Push-Puller (Hydraulic) . . . . . . . . . . D01246AA
–UN–09AUG02
50
20
2
H72970
OUO6083,0000887 –19–09SEP05–6/13
Bushing Driver . . . . . . . . . . . . . . . . . . . . . . JDG1376
Used to install inner pivot bushing on cam lobe motor.

–UN–30MAY01
H68298

083006
PN=540
Cam Lobe Motor
Slide Hammer Adapter . . . . . . . . . . . . . . . . . JDG1377
Used to remove tapered wedges from cam.
Pilot Bearing Puller . . . . . . . . . . . . . . . . . . D01209AA
–UN–30MAY01
Used with JDG1377 to remove tapered wedges from cam.
H68299
–UN–30MAY01
50
20
H68300
3
OUO6083,0000887 –19–09SEP05–8/13
Bearing Installer . . . . . . . . . . . . . . . . . . . . . JDG1378
Used to install outer spindle bearing race.
–UN–30MAY01
H68301
OUO6083,0000887 –19–09SEP05–9/13
Bearing Installer . . . . . . . . . . . . . . . . . . . . . JDG1379
Used to install inner spindle bearing race.

–UN–30MAY01
H68302

083006
PN=541
Cam Lobe Motor
Seal Installer . . . . . . . . . . . . . . . . . . . . . . . JDG1380
Used to install inner spindle seals.
–UN–30MAY01
H68303
OUO6083,0000887 –19–09SEP05–11/13
Seal/Bearing Installer . . . . . . . . . . . . . . . . . . JDG1381
Used to install outer spindle seal and bearing.
–UN–30MAY01
50
20
4
H68304
OUO6083,0000887 –19–09SEP05–12/13
Split Ring Service Tool1 . . . . . . . . . . . . . . . . . DFHXT1
Used to preload inner spindle bearing enough to remove

and install split ring.
1
See Section 199 for instructions to fabricate tool.
OUO6083,0000887 –19–09SEP05–13/13


083006
PN=542
Cam Lobe Motor
Portable Filter Caddy . . . . . . . . . . . . . . . . . . . JT05746
Used to flush cam lobe motors
–UN–01JUN01
H68347
OUO6083,000030B –19–09AUG02–2/4
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D15032NU
–UN–01JUN01
50
20
5
H68348
OUO6083,000030B –19–09AUG02–3/4
Handle, Bushing Driver. . . . . . . . . . . . . . . . . . JDG537
Used with JDG1376 to install inner pivot bushing.
OUO6083,000030B –19–09AUG02–4/4

083006
PN=543
Cam Lobe Motor
Other Material
Number Name Use
TY22000 (U.S.) HY-GARD Hydraulic Oil Used to service/flush

hydraulic/hydrostatic system.
TY6341 (U.S.) Multi-Purpose SD Polyurea Grease Used to lube pivot bushings, seals,
O-rings and pack bearings during
assembly.
PM38655 (U.S.) Flexible Form-In-Place Gasket Used to seal yoke to sealing rings.
515 LOCTITE (LOCTITE)
PM37391 (U.S.) Gel Super Glue Used to retain pivot thrust bushing to
454 LOCTITE (LOCTITE) motor housing.
PM37421 (U.S.) High Strength Thread Lock Use to retain cap screws and seal
271 LOCTITE (LOCTITE) housing.
50
20
6
OUO6083,0000357 –19–04AUG05–1/1

083006
PN=544
Cam Lobe Motor
Specifications
Hydraulic Reservoir Capacity 34 L

(36 qt)
Cam Lobe Motor-to-Axle Cap Screws Torque 560 N•m

(413 lb-ft)
Steering Cylinder and Tie Rod Torque 150 N•m

Slotted Nuts (111 lb-ft)
Wheel Bolts, Powered Rear Axles Torque 200 N•m plus an additional 1/4 turn
(M20 Bolt) (150 lb-ft) plus an additional 1/4 turn
Sealing Ring Cap Screws Torque 10 N•m

(89 lb-in.)
Pivot Pin Cap Screws Torque 70 N•m

(50 lb-ft)
50
Solenoid Valve Torque 27 N•m 20
7
(20 lb-ft)
Nut Torque 3 N•m

(27 lb-in.)
Solenoid Valve Block Cap Screw Torque 15 N•m

(133 lb-in.)
Displacement Control Valve Plug Torque 280 N•m

(200 lb-ft)
Hex Head Socket Cap Screws Torque 355 N•m

(260 lb-ft)
Specified Torque (B) Rolling Drag Torque 37 N•m

(27 lb-ft)
2-Speed Cam Lobe Motor Weight 195 kg

(425 lb)
Yoke Weight 33 kg
(73 lb)
Spindle Assembly Weight 41 kg

(90 lb)
OUO6083,000030C –19–09AUG02–1/1

083006
PN=545
Cam Lobe Motor
Flushing Cam Lobe Motors
1. Disassemble, clean and flush 4-wheel drive control

valve and tee block.
2. Disconnect and flush all hoses associated with 4-wheel

drive system.
3. Connect hose from oil transfer unit to bottom port of

cam lobe motor. Plug charge pressure port. Connect
and route hose from return port to drum of flushing oil.
4. Activate transfer unit and flush cam lobe motor for 30

minutes, rotating wheel occasionally.
5. Repeat procedure on opposite cam lobe motor.
6. Assemble all components, hoses and lines.
50
20
8
AG,OUO6022,1873 –19–25JUL00–1/1

083006
PN=546
Cam Lobe Motor
Remove Cam Lobe Motor
1. Raise combine and block rear axle. Remove rear

wheel. (See procedure in Group 25.)
2. Disconnect connector (D).
–UN–23AUG88
3. Remove cotter pin and slotted nut (A). Disconnect tie
rod.
X9811
fluids.
–UN–26APR99
50
surgically removed within a few hours or 20
H55790
gangrene may result. Doctors unfamiliar with 9

5. Install D15032NU Vacuum Pump to reservoir using
–UN–08JUN00
JT07085 adapter set or drain reservoir.
Specification
Hydraulic Reservoir—Capacity............................................................ 34 L
H64172
(36 qt)
6. Clean outside of cam lobe motor. Disconnect three

A—Slotted Nut
hoses (B) from motor. Plug all open ports. B—Hose (3 used)
D—Connector
CAUTION: Approximate weight of cam lobe
motor is 195 kg (425 lb).
7. Support motor with a suitable hoist. Remove four cap

screws (C) attaching yoke to rear axle.
OUO6083,0000798 –19–12MAY04–1/1

083006
PN=547
Cam Lobe Motor
Install Cam Lobe Motor

motor is 195 kg (425 lb).
1. Position motor on rear axle.
–UN–08JUN00
2. Install motor on axle using cap screws (C). Tighten to
specification.
H64172
Specification
Cam Lobe Motor-to-Axle Cap
Screws—Torque ........................................................................... 678 N•m
(500 lb-ft) A—Slotted Nut
B—Hoses (3 used)
3. Connect hoses (B) to motor. C—Cap Screw (4 used)
D—Connector
4. Connect tie rod. Install slotted nut (A) and tighten to

specification. Tighten further, if necessary, to install
cotter pin.
50 Specification
20 Tie Rod End Slotted Nuts—
10 Torque .......................................................................................... 150 N•m
(111 lb-ft)
5. Connect connector (D).
6. Fill reservoir.
Specification
(36 qt)
OUO6083,0000799 –19–12MAY04–1/1

083006
PN=548
Cam Lobe Motor
Remove and Install Cam Lobe Motor Control

Valve

–UN–23AUG88
X9811
fluids.

1. Fully lower header and reel to ground and continue to 50

system pressure. Shut off engine and remove key. 11
AG,OUO6022,1876 –19–25JUL00–1/4
2. Clean all dirt from around cam lobe motor control valve
(A).
A—Control Valve
–UN–26APR99
H55799

083006
PN=549
Cam Lobe Motor
NOTE: Marking hoses and valve ports prior to

disconnecting hydraulic lines will make
reassembly easier and help prevent incorrect
hose connections.
3. Disconnect lines (A—F).
–UN–26APR99
4. Disconnect harness connector (G) from valve solenoid.
5. Remove three cap screws (H) and valve.
H55800
6. Repair or replace valve as necessary.
A—Hydraulic Line
B—Hydraulic Line
C—Hydraulic Line
D—Hydraulic Line
E—Hydraulic Line (2 used)
F—Hydraulic Line (2 used)
G—Connector
–UN–03AUG00
50
20
12
H64523
AG,OUO6022,1876 –19–25JUL00–3/4
7. Install valve using three cap screws (H).
8. Connect lines (A—F).
9. Connect electrical connector (G) to valve solenoid.
–UN–26APR99
10. Be sure hoses do not rub on wheel rim by steering
combine full left to full right. Also be sure hose does
not kink or collapse when turning full left or full right.
11. Operate 4-wheel drive functions; then shut off engine, H55800
check for leaks and top off hydraulic reservoir.
A—Hydraulic Line
B—Hydraulic Line
C—Hydraulic Line
D—Hydraulic Line
E—Hydraulic Line (2 used)
F—Hydraulic Line (2 used)
G—Electrical Connector
–UN–03AUG00

H64523
AG,OUO6022,1876 –19–25JUL00–4/4

083006
PN=550
Cam Lobe Motor
50
20
13

083006
PN=551
Cam Lobe Motor
Disassemble and Assemble Cam Lobe Motor Control Valve
1
3
2 4
5
11
B
2
A 14 15 19
7
16
D
8 C 20
9
12
10
12 19 13
50
20 13 17
14 19
16
20
11 19
17
18 18
–UN–13JUL05
H83930
1—Plug 7—Solenoid Valve 12—O-Ring (2 used) 17—Fitting (2 used)
2—O-Ring (2 used) 8—Coil 13—Plug (2 used) 18—O-Ring (2 used)
3—Plug 9—Nut 14—Elbow Fitting 19—O-Ring (4 used)
4—O-Ring 10—Plug 15—O-Ring 20—O-Ring (2 used)
5—Spring 11—Cap Screw and Nut (2 16—Fitting (2 used)
6—Control Valve used)
1. Disassemble parts (1—20). 3. Install parts (1—20).
OUO6083,0000A7A –19–13JUL05–1/1

083006
PN=552
Cam Lobe Motor
50
20
15

083006
PN=553
Cam Lobe Motor
Remove and Install Steering Yoke
50
20
16
–UN–06JUL00
H64387

083006
PN=554
Cam Lobe Motor
A—Sealing Ring (2 used) D—Tube H—Socket Head Cap Screw (5 J—Lower Pivot
B—Socket Head Cap Screw (8 E—Tube used) K—Socket Head Cap Screw (4
used) F—O-Ring (2 used) I—O-Ring used)
C—O-Ring (2 used) G—Upper Pivot
AG,OUO6022,1878 –19–04AUG05–2/14
NOTE: Tag or mark wires to simplify reassembly.
1. Use wire connector tool JDG776 Weatherpack

Extractor (blue handle) and release pins out of
solenoid wiring harness connector.
–UN–31MAY00
2. Remove solenoid harness from yoke.
H63946
AG,OUO6022,1878 –19–04AUG05–3/14
50
3. Remove cap screws (A). 20
17
NOTE: When removing pivot pins from yoke, a vacuum is
created causing pins to be hard to completely
remove. Removal of lubrication fittings will vent
this area and aid in removal of pivot pins.
–UN–17MAY00
4. Thread two of previously removed cap screws into
threaded holes (B) to pull pivots from yoke.
H63934
A—Socket Head Cap Screw (9 used)
B—Threaded Hole (2 used)
–UN–17MAY00
H63932

083006
PN=555
Cam Lobe Motor
CAUTION: Approximate weight of yoke (A) is 33

kg (73 lb). Use proper lifting device to avoid
injury.
5. Support yoke (A) with suitable lifting device.
–UN–17MAY00
NOTE: Upper and lower pivots use different length cap
screws. Upper pivot uses longer screws.
6. Remove cap screws (B).
H63937
A—Yoke Upper Pivot
B—Socket Head Cap Screw (8 used)
–UN–22MAY00
50
20
18
H63933
Lower Pivot
AG,OUO6022,1878 –19–04AUG05–5/14
7. Carefully remove yoke from cam lobe motor.
–UN–23MAY00
H63949

083006
PN=556
Cam Lobe Motor
8. Gently pry sealing rings (A) off motor.
9. Inspect pivots, seals and bushings for damage and/or

wear.
10. Apply TY6341 Multi-Purpose SD Polyurea Grease to
–UN–23MAY00
both upper and lower pivot bushings and seals.
11. Install sealing rings.
H63950
A—Sealing Ring (2 used)
AG,OUO6022,1878 –19–04AUG05–7/14
50
12. Apply PM38655 Flexible Form-In-Place Gasket to 20
mating surfaces of sealing rings (A) and yoke. 19
A—Sealing Ring (2 used)
–UN–31MAY00
H64055

083006
PN=557
Cam Lobe Motor
NOTE: Use longer cap screws on top pivot.
13. Install yoke (A) over sealing rings and install cap
screws (B). Tighten to specification.
Specification
Sealing Ring Cap Screws—
–UN–22MAY00
Torque ............................................................................................ 10 N•m
(89 lb-in.)
A—Yoke
H63936
–UN–17MAY00
50
20
20
H63937
Upper Pivot
Lower Pivot –UN–22MAY00

H63933
AG,OUO6022,1878 –19–04AUG05–9/14
14. Remove tubes (A) and (B).
A—Tube
B—Tube
–UN–29MAR00
H63150

083006
PN=558
Cam Lobe Motor
NOTE: O-rings (A) are not a serviceable item. If wear

and/or damage is evident, tube replacement is
necessary.
15. Inspect O-rings (A). Replace tubes as necessary.
–UN–29MAR00
A—O-Ring (4 used)
H63156
AG,OUO6022,1878 –19–04AUG05–11/14
16. Remove and discard O-ring (A).
17. Install new O-ring.
A—O-Ring
–UN–29MAR00
50
20
21
H63153
AG,OUO6022,1878 –19–04AUG05–12/14
18. Lube O-rings with clean hydraulic oil and install tubes
into pivot.
19. Lightly coat both upper and lower pivot pins with
TY6341 Multi-Purpose SD Polyurea Grease.
–UN–23MAY00
H63948

083006
PN=559
Cam Lobe Motor
20. Install pivot pins (A) into yoke and motor and retain
with cap screws (B).
21. Tighten cap screws to specification.
Specification
Pivot Pin Cap Screws—Torque...................................................... 70 N•m
–UN–23MAY00
(50 lb-ft)
22. Install solenoid harness through yoke and install wires

into wire connector.
H63975
A—Pivot Pin (2 used)
–UN–23MAY00
50
20
22
H63976
AG,OUO6022,1878 –19–04AUG05–14/14

083006
PN=560
Cam Lobe Motor
Disassemble and Assemble Pivot Pins, Bushings, and Seals
50
20
23
–UN–06JUL00
H64389
A—Motor Housing B—Seal (2 used) C—Bushing (2 used) D—Bushing (2 used)
1. Remove steering yoke. (See procedure in this

group.)

083006
PN=561
Cam Lobe Motor
CAUTION: Be careful not to damage bushing

bores when removing bushings.
NOTE: Bushing (A) is retained to motor housing with

super glue.
–UN–31MAY00
2. Remove bushings (A) and (B) and seal (C).
A—Bushing (2 used)
B—Bushing (2 used)
H64053
C—Seal (2 used)
AG,OUO6022,1879 –19–04AUG05–2/6
50
20 3. Align grease hole (A) in bushing with grease hole (B)
24 in motor.
A—Grease Hole
B—Grease Hole
–UN–27JUN00
H64331
AG,OUO6022,1879 –19–04AUG05–3/6
4. Use JDG1376 Bushing Driver (B) and JDG537 Handle

to install bushing (A).
A—Bushing
B—JDG1376 Bushing Driver
–UN–27JUN00
H64330

083006
PN=562
Cam Lobe Motor
5. Apply PM37391 Gel Super Glue to back side of pivot

thrust bushing. Install bushing.
–UN–29MAR00
H63155
AG,OUO6022,1879 –19–04AUG05–5/6
6. Apply PM37391 Gel Super Glue to back side of pivot

seal. Install seal.
A—Seal
–UN–27JUN00
50
20
25
H64332
AG,OUO6022,1879 –19–04AUG05–6/6

083006
PN=563
Cam Lobe Motor
Remove and Install Solenoid Valve and Valve Block
F D
C
A
E
–UN–06MAR02
50
H71269
20
26
A—Motor Housing C—Solenoid Valve Block E—Plug F—Solenoid Valve Assembly

B—O-Ring (4 used) D—Socket Head Cap Screw (4
used)
OUO6083,00002B0 –19–22MAY02–1/11
1. Use JDG776 Weatherpack Extractor (Narrow

Metripack) tool and release pins out of solenoid wiring
harness connector.
2. Observe harness routing; then remove solenoid

harness from yoke.
–UN–31MAY00
H63946

083006
PN=564
Cam Lobe Motor
3. Remove cap screws (A) and cover (B).

B—Cover
–UN–31MAY00
H63939
OUO6083,00002B0 –19–22MAY02–3/11
NOTE: There are four small O-rings between valve block

and motor.
4. Remove cap screws (A) and solenoid valve block (B).
5. Remove and discard O-rings.
–UN–31MAY00
50
A—Socket Head Cap Screw (4 used) 20
B—Solenoid Valve Block 27
H63940
OUO6083,00002B0 –19–22MAY02–4/11
6. Remove nut (A) and coil (B) from valve block (C).
A—Nut
B—Coil
C—Valve Block
–UN–17MAY00
H63942

083006
PN=565
Cam Lobe Motor
7. Remove solenoid valve (A) from valve block (B).
8. Inspect for wear and damage, replace parts as

needed.
9. Inspect valve block for dirt and debris, clean as
–UN–17MAY00
needed.
10. Replace seals on solenoid valve and coat with clean

hydraulic oil.
H63941
A—Solenoid Valve
B—Valve Block
OUO6083,00002B0 –19–22MAY02–6/11
50
20 11. Install valve and tighten to specification.
28
Specification
Solenoid Valve—Torque................................................................. 27 N•m
(20 lb-ft)
–UN–23MAY00
H63979
OUO6083,00002B0 –19–22MAY02–7/11
12. Install coil and tighten nut to specification.
Specification
Nut—Torque ..................................................................................... 3 N•m
(27 lb-in.)
–UN–23MAY00
H63982

083006
PN=566
Cam Lobe Motor
13. Coat new O-rings (A) with TY6341 Multi-Purpose SD

Polyurea Grease.
A—O-Ring (4 used)
–UN–23MAY00
H63944
OUO6083,00002B0 –19–22MAY02–9/11
14. Install solenoid valve assembly. Tighten cap screws

(A) to specification.
Specification
Solenoid Valve Block Cap
Screw—Torque ............................................................................... 15 N•m
(133 lb-in.)
–UN–23MAY00
50
A—Socket Head Cap Screw (4 used) 20
29
H63983
OUO6083,00002B0 –19–22MAY02–10/11
15. Install cover (A) using cap screws (B).
16. Route solenoid wires through yoke and install wire

connector.
A—Cover
–UN–23MAY00
B—Socket Head Cap Screw
H63984
OUO6083,00002B0 –19–22MAY02–11/11

083006
PN=567
Cam Lobe Motor
Remove and Install Displacement Control Valve
F
E
D
C
–UN–06MAR02
50
H71270
20
30
A—Motor Housing C—Spring E—Snap Ring F—Plug

B—Spool D—Washer
1. Remove solenoid valve block. (See procedure in

this group.)
OUO6083,00002B1 –19–22MAY02–1/7
2. Remove and discard O-rings (A).
A—O-Ring (4 used)
–UN–23MAY00
H63944

083006
PN=568
Cam Lobe Motor
3. Remove plug (A).
A—Plug
–UN–17MAY00
H63943
OUO6083,00002B1 –19–22MAY02–3/7
4. Remove spool (A), washer (B) and spring (C).
A—Spool
B—Washer
C—Spring
–UN–23MAY00
50
20
31
H63945
OUO6083,00002B1 –19–22MAY02–4/7
5. Inspect for wear or damage. Replace parts as needed.
–UN–23MAY00
H63978
OUO6083,00002B1 –19–22MAY02–5/7
6. Coat spool, washer and spring with clean hydraulic oil.
7. Reassemble spool assembly as shown and install.

–UN–23MAY00
H63980

083006
PN=569
Cam Lobe Motor
8. Replace seal on plug (A).
9. Install plug (A) and tighten to specification.
Specification
Displacement Control Valve
Plug—Torque................................................................................ 280 N•m
–UN–23MAY00
(200 lb-ft)
10. Coat new O-rings (B) with TY6341 Multi-Purpose SD

Polyurea Grease.
H63981
11. Install solenoid valve and flange assembly. (See
A—Plug
B—O-Ring (4 used)
OUO6083,00002B1 –19–22MAY02–7/7
50
20
32

083006
PN=570
Cam Lobe Motor
Remove and Install Cam and Piston Carrier
50
20
33
–UN–07JUL00
H64390
A—Motor Housing E—Seal H—Valve Stack K—O-Ring
B—Seat F—Seal I—Spring (9 used) L—Cam
C—Wedge G—Seal J—Piston Carrier M—O-Ring
D—Seal
1. Remove yoke. (See procedure in this group.)
OUO6083,000030D –19–04AUG05–1/12

–UN–29MAR00
H63148

083006
PN=571
Cam Lobe Motor

motor is 195 kg (425 lb). Use proper lifting
device to avoid injury.
4. Position motor assembly as shown.
5. Scribe a line (A) across spindle, cam and valve block.
CAUTION: Approximate weight of spindle
–UN–29MAR00
6. Remove cap screws (B) and lift spindle assembly (C)

from cam.
H63154
A—Scribe Line
B—Hex Head Socket Cap Screw (4 used)
C—Spindle Assembly
50
20
34
OUO6083,000030D –19–04AUG05–3/12
7. Lift piston carrier (A) from cam.
A—Piston Carrier
–UN–29MAR00
H63166

083006
PN=572
Cam Lobe Motor
NOTE: There are tapered wedges in two of cam holes.
8. Screw JDG1377 Slide Hammer Adapter (A) into

tapered wedge and use D01209AA Pilot Bearing Puller
(B) to remove tapered wedges.
9. Strike both sides of cam at dowel pins with a lead or

brass hammer.
IMPORTANT: Be careful not to damage sealing

surfaces of cam and valve block.
–UN–31MAY00
10. Pry cam loose from outer cover using screwdrivers
between cam and valve block. Pry evenly since dowel
pin breakage is possible. Lift straight up and off dowel
pins.
H64054
A—JDG1377 Slide Hammer Adapter
B—D01209AA Pilot Bearing Puller
50
20
35
OUO6083,000030D –19–04AUG05–5/12
11. Inspect cam lobes (A) for pitting, scratches or nicks.
12. Pour clean hydraulic oil on inside cam surfaces.
A—Lobe Surface
–UN–23MAY00
H63986
OUO6083,000030D –19–04AUG05–6/12
13. Fill O-ring groove with TY6341 Multi-Purpose SD

Polyurea Grease and install O-ring (A).
A—O-Ring
–UN–23MAY00
H63985

083006
PN=573
Cam Lobe Motor
IMPORTANT: Make sure scribe mark on cam aligns

with mark on valve block, incorrect
orientation of holes may result in
machine damage.
14. Align scribe on cam to scribe on valve block and
–UN–23MAY00
install cam onto dowel pins.
15. Install dowel pin wedges into cam holes where dowel
pins exist.
H63989
16. Using a hammer and brass punch, lightly drive
wedges into dowel pins.
A—Scribe Line
B—Scribe Line
OUO6083,000030D –19–04AUG05–8/12
50
20 IMPORTANT: Before installing piston carrier, be
36 certain valve stack tabs are aligned with
notches in valve block.
Be certain that oil passages in piston

carrier mate up with valve stack.
–UN–29MAR00
17. Carefully lower piston carrier into cam.
H63233
OUO6083,000030D –19–04AUG05–9/12

Polyurea Grease and install O-ring.
A—O-Ring
–UN–29MAR00
H63234

083006
PN=574
Cam Lobe Motor

19. Apply PM37421 to threads of cap screws (A).
20. Tilt cam lobe motor enough to install short cap screws
(A).
21. Using a suitable lifting device, carefully lower spindle

assembly (B) onto cam lobe motor while aligning both
–UN–29MAR00
spindle shaft with piston carrier and scribed line on
spindle housing to scribe line on cam (C).
NOTE: Be certain O-ring is still seated in its groove in
H63235
spindle housing before pulling two units together.
22. Tighten cap screws (A) until two units are pulled A—Socket Head Cap Screws (4 used)
together. B—Scribe Mark
50
20
37
OUO6083,000030D –19–04AUG05–11/12
23. Apply PM37421 to threads of remaining six cap

screws (A).
24. Install remaining six cap screws (A) and tighten to

specification.
–UN–17MAY00
Specification
Hex Head Socket Cap Screws—
Torque .......................................................................................... 355 N•m
(260 lb-ft)
H63236
A—Socket Head Cap Screws (10 used)
OUO6083,000030D –19–04AUG05–12/12

083006
PN=575
Cam Lobe Motor
Remove and Install Valve Stack Seals
50
20
38
–UN–07JUL00
H64390
A—Motor Housing E—Seal H—Valve Stack K—O-Ring
B—Seat F—Seal I—Spring (9 used) L—Cam
C—Wedge G—Seal J—Piston Carrier M—O-Ring
D—Seal
2. Remove cam and piston carrier. (See procedure in

this group.)
Continued on next page OUO6083,0000A7D –19–13JUL05–1/8

083006
PN=576
Cam Lobe Motor
4. Notice and record tab alignment to valve block (B).
NOTE: There are nine springs under valve stack, retain

springs with valve stack.
–UN–29MAR00
5. Lift valve stack (C) from valve block.
A—O-Ring
H63152
B—Tab
C—Valve Stack
OUO6083,0000A7D –19–13JUL05–2/8
50
6. Remove springs (A) from valve stack. 20
39
A—Spring (9 used)
–UN–29MAR00
H63158
OUO6083,0000A7D –19–13JUL05–3/8
7. Remove and discard seals (A).
A—Seal (4 used)
–UN–29MAR00
H63213

083006
PN=577
Cam Lobe Motor
8. Remove and discard back-up O-rings (A).
A—Back-Up O-Ring (4 used)
–UN–29MAR00
H63212
OUO6083,0000A7D –19–13JUL05–5/8
NOTE: Avoid excessive bending or twisting of seals

during installation.
9. Lubricate seal grooves.
10. Install new back-up O-rings and seals.
–UN–29MAR00
50
20
40
H63209
–UN–29MAR00
H63210
OUO6083,0000A7D –19–13JUL05–6/8
11. Fill spring holes with TY6341 Multi-Purpose SD

Polyurea Grease and insert springs (A).
A—Spring (9 used)
–UN–29MAR00
H63158

083006
PN=578
Cam Lobe Motor
NOTE: Make sure valve stack tabs (B) align with notches
in valve block.
12. Apply a thin coat of TY6341 Multi-Purpose SD

Polyurea Grease to valve block seals and install valve
stack.
–UN–29MAR00
H63231
14. Install cam and piston carrier. (See procedure in this
group.)
15. Install yoke. (See procedure in this group.) A—O-Ring

B—Timing Tab (2 used)
OUO6083,0000A7D –19–13JUL05–8/8
50
20
41

083006
PN=579
Cam Lobe Motor
Remove and Install Axle Bearings and Seals—Style A
A
B
C
E
F
H G
50
20
–UN–20MAY04
42
N66201
A—Split Ring D—Seal Housing G—Seal J—Deflector
B—Thrust Ring E—Seal H—Spindle Housing K—Lip Seal
C—Bearing F—Seal Housing I—Bearing L—Spindle
OUO6046,000204A –19–13SEP05–1/27

–UN–29MAR00
H63148
Continued on next page OUO6046,000204A –19–13SEP05–2/27

083006
PN=580
Cam Lobe Motor

device to prevent injury.
5. Scribe a line (A) across the spindle, cam, and valve

block to ensure proper reassembly.
–UN–29MAR00
H63154
from cam.
A—Scribed Line
B—Socket Head Cap Screws (4 used)
50
20
43
OUO6046,000204A –19–13SEP05–3/27
A—O-Ring
–UN–29MAR00
H63161
OUO6046,000204A –19–13SEP05–4/27
8. Remove thrust ring (A).
A—Thrust Ring
–UN–21MAY04
N66210

083006
PN=581
Cam Lobe Motor
NOTE: A press with the minimum capacity of 27,000 kg

(30 tons) is required.
9. Mount spindle assembly into press as shown.
10. Align notch in DFHXT1 Split Ring Service Tool1 with
–UN–21MAY04
split ring ends.
11. Apply pressure onto inner race of bearing cone until

split ring (A) can be removed from groove.
N66211
A—Split Ring
1
See Section 199 for instructions to fabricate tool
OUO6046,000204A –19–13SEP05–6/27
50
20 12. Press spindle from housing using JDG690-7 Block,
44 Bearing Remover (A) and D01246AA 30-Ton
Push-Puller (Hydraulic) (B) as shown.
A—JDG690-7
B—D01246AA
–UN–29MAR00
H63171
OUO6046,000204A –19–13SEP05–7/27
13. Cut lip seal under bearing and remove using a

screwdriver.
14. Use D01243AA Bearing Puller Attachment and

D01219AA 17-1/2 Ton Push-Puller (Hydraulic) to
remove bearing (A) from spindle.
A—Bearing
–UN–21MAY04
N66212

083006
PN=582
Cam Lobe Motor
15. Remove deflector (A) from spindle (B) using a puller.
A—Deflector
B—Spindle
–UN–21MAY04
N66213
OUO6046,000204A –19–13SEP05–9/27
16. Using a brass punch and hammer, remove both inner

and outer spindle bearing cups from spindle housing.
17. Clean and inspect all parts, replace as needed.
–UN–30MAY00
50
20
45
H64050
OUO6046,000204A –19–13SEP05–10/27
18. Use JDG1381 Seal/Bearing Installer (B) to remove

spindle housing seals (A).
A—Seal (2 used)
B—JDG1381 Seal / Bearing Installer
–UN–30MAY00
H64051
OUO6046,000204A –19–13SEP05–11/27
19. Remove seal (A), seal and back-up O-ring (B) from
inner spindle seal supports.
A—Seal
B—Seal and Back-up O-Ring
–UN–30MAY00
H64052

083006
PN=583
Cam Lobe Motor
NOTE: Avoid excessive bending or twisting of neoprene

seal.
20. Lubricate seal grooves using TY6341 Multi-Purpose

SD Polyurea Grease.
–UN–29MAR00
21. Install new back-up O-ring and seal in seal support.
H63218
OUO6046,000204A –19–13SEP05–13/27
22. Apply PM37421 Thread Lock and Sealer (high

strength) to outer rim of seal support.
–UN–29MAR00
50
20
46
H63220
OUO6046,000204A –19–13SEP05–14/27
23. Press outer seal (A) into place using JDG1380 Seal
Installer (B).
A—Seal
B—JDG1380 Seal Installer
–UN–30MAY00
H64047
–UN–01JUN00
H64046

083006
PN=584
Cam Lobe Motor
24. Install inner seal (A) and press into place using
JDG1380 Seal Installer.
A—Seal
–UN–30MAY00
H64048
–UN–01JUN00
50
20
47
H64046
OUO6046,000204A –19–13SEP05–16/27
25. Install outer spindle bearing cup (A) using JDG1378

Bearing Installer (B).
A—Bearing Race
B—JDG1378 Bearing Installer
–UN–31MAY00
H63991
OUO6046,000204A –19–13SEP05–17/27
26. Install inner bearing cup (A) using JDG1379 Bearing

Installer (B).
A—Bearing Race
–UN–31MAY00
H64045

083006
PN=585
Cam Lobe Motor
27. Install deflector (A) onto spindle (B).
A—Deflector
B—Spindle
–UN–21MAY04
N66214
OUO6046,000204A –19–13SEP05–19/27
28. Pack bearing (A) with TY6341 Multi-Purpose SD

Polyurea Grease and install into housing.
29. Install lip seal (B) using appropriate size seal installer
(C).
–UN–21MAY04
30. Coat seals with TY6341 Multi-Purpose SD Polyurea
50
Grease; then lower spindle housing onto spindle.
20
48
A—Bearing
N66215
B—Lip Seal
C—Seal Installer
–UN–21MAY04
N66216

083006
PN=586
Cam Lobe Motor
31. Install inner spindle bearing using JDG690-7 Block,

Bearing Remover (A) and D01246AA 30 Ton
Push-Puller (Hydraulic) (B).
A—JDG690-7 Block, Bearing Remover

B—D01246AA 30 Ton Push-Puller (Hydraulic)
–UN–20AUG02
H73010
50
20
49

083006
PN=587
Cam Lobe Motor

32. Using split rings (A) from repair kit with lowest
thickness, install in groove of shaft (B).
–UN–21MAY04
33. Apply pressure onto inner race of bearing cone using
a press and DFHXT1 Split Ring Service Tool1 with
split ring ends.
N66217
34. Measure clearance (C) between split rings (A) and
groove mating surface (D).
35. Remove pressure from press.
36. Remove split rings.
37. Determine correct thickness of split ring needed:

Thickness of correct split ring to be used is equal to
–UN–21MAY04
clearance (C) + thickness of split ring (A) used in step
32.
50
20 38. Choose the split ring from the repair kit whose
50
N66218
thickness is closest to the value determined in step
37 and install.
39. Apply pressure to inner race of bearing using a press.
40. When installed, ensure split ring gap (E) is equal on

each side of shaft.
A—Split Ring
–UN–21MAY04
B—Shaft
C—Clearance
D—Mating Surface
E—Gap
N66220
1

083006
PN=588
Cam Lobe Motor
41. Install thrust ring (A).
A—Thrust Ring
–UN–21MAY04
N66221
50
20
51

083006
PN=589
Cam Lobe Motor
42. Adjust spindle rolling drag torque using the following

method:
NOTE: The length of the torque wrench used (offset) will

have to be measured so that an actual torque
value is achieved. Use the following formula to
determine what torque value should be seen on
the wrench when the offset is factored in. Use
meters as the unit of measurement.
–UN–13JUL00
EXAMPLE:
The torque wrench being used has a length (C) of
H63221
500 mm (0.5 m).
The distance (D) from spindle center to bolt hole

center is 140 mm (0.14 m).
The torque wrench (A) should read 39.0 N•m when

specified torque is achieved.
50 • Rotate spindle in spindle housing a minimum of five

20
–UN–03AUG00
revolutions.
52
• Install M12 cap screw into one of the perimeter
spindle housing holes as shown.
• Measure length of torque wrench (C).
• Measure distance (D) from center of spindle to
H64150
center of previously installed cap screw.
• Prevent spindle from turning.
A—Specified Torque with Offset Factored
NOTE: A direct reading or “beam” type torque wrench is B—Specified Torque (50 N•m)
C—Length of Wrench
required for accurate readings. D—Distance from Spindle Center to Bolt Hole
Center
• Use torque wrench to turn spindle housing, record
amount of torque needed to rotate spindle housing
(A) and compare to specification.
Specification
Specified Torque (B)—Rolling
Drag Torque ................................................................................... 50 N•m
(37 lb-ft)
• Add or remove shims to obtain specified torque.

083006
PN=590
Cam Lobe Motor

A—O-Ring
–UN–29MAR00
H63161
OUO6046,000204A –19–13SEP05–25/27

44. Align splines on spindle within piston carrier; then

lower spindle housing making certain alignment marks
(A) on housing are correct.
50
45. Lower spindle housing onto cam and install cap 20
screws (B). 53
–UN–29MAR00
NOTE: Be certain that the O-ring is still seated in its
groove in the spindle housing before pulling the
two units together.
H63154
46. Tighten cap screws evenly on both sides of housing
until all sections are pulled together.
A—Scribed Line
OUO6046,000204A –19–13SEP05–26/27
47. Install the remaining six cap screws (A) and tighten to
specification.
Specification
Socket Head Cap Screw—Torque ............................................... 355 N•m
(260 lb-ft)
–UN–17MAY00
48. Install yoke. (See procedure in this group.)

H63236
OUO6046,000204A –19–13SEP05–27/27

083006
PN=591
Cam Lobe Motor
Remove and Install Axle Bearings and Seals—Style B
A
B
C
D
E
50
20
–UN–06SEP05
54
H84359
A—Split Ring D—Seal F—Bearing H—Lip Seal
B—Thrust Ring E—Seal Housing G—Deflector I—Spindle
C—Bearing
OUO6046,000204C –19–13SEP05–1/23

–UN–29MAR00
H63148
Continued on next page OUO6046,000204C –19–13SEP05–2/23

083006
PN=592
Cam Lobe Motor

device to prevent injury.
5. Scribe a line (A) across the spindle, cam, and valve

block to ensure proper reassembly.
–UN–29MAR00
H63154
from cam.
A—Scribed Line
B—Socket Head Cap Screws (4 used)
50
20
55
OUO6046,000204C –19–13SEP05–3/23
A—O-Ring
–UN–29MAR00
H63161
OUO6046,000204C –19–13SEP05–4/23
8. Remove thrust ring (A).
A—Thrust Ring
–UN–21MAY04
N66210

083006
PN=593
Cam Lobe Motor

9. Mount spindle assembly into press as shown.
10. Align notch in DFHXT1 Split Ring Service Tool1 with
–UN–21MAY04
split ring ends.
11. Apply pressure onto inner race of bearing cone until

split ring (A) can be removed from groove.
N66211
A—Split Ring
1
OUO6046,000204C –19–13SEP05–6/23
50
20 12. Press spindle from housing using JDG690-7 Block,
56 Bearing Remover (A) and D01246AA 30-Ton
Push-Puller (Hydraulic) (B) as shown.
A—JDG690-7
B—D01246AA
–UN–29MAR00
H63171
OUO6046,000204C –19–13SEP05–7/23
13. Cut lip seal under bearing and remove using a

screwdriver.
14. Use D01243AA Bearing Puller Attachment and

D01219AA 17-1/2 Ton Push-Puller (Hydraulic) to
remove bearing (A) from spindle.
A—Bearing
–UN–21MAY04
N66212

083006
PN=594
Cam Lobe Motor
15. Remove deflector (A) from spindle (B) using a puller.
A—Deflector
B—Spindle
–UN–21MAY04
N66213
OUO6046,000204C –19–13SEP05–9/23
16. Using a brass punch and hammer, remove both inner

and outer spindle bearing cups from spindle housing.
17. Clean and inspect all parts, replace as needed.
–UN–30MAY00
50
20
57
H64050
OUO6046,000204C –19–13SEP05–10/23
18. Use JDG1381 Seal/Bearing Installer (B) to remove

spindle housing seal (A).
A—Seal
B—JDG1381 Seal/Bearing Installer
–UN–30MAY00
H64051

083006
PN=595
Cam Lobe Motor
19. Press seal (A) into place using JDG1380 Seal

Installer (B).
A—Seal
–UN–30MAY00
H64047
–UN–01JUN00
50
20
58
H64046
OUO6046,000204C –19–13SEP05–12/23
20. Install outer spindle bearing cup (A) using JDG1378

Bearing Installer (B).
A—Bearing Race
–UN–31MAY00
H63991
OUO6046,000204C –19–13SEP05–13/23
21. Install inner bearing cup (A) using JDG1379 Bearing

Installer (B).
A—Bearing Race
–UN–31MAY00
H64045

083006
PN=596
Cam Lobe Motor
22. Install deflector (A) onto spindle (B).
A—Deflector
B—Spindle
–UN–21MAY04
N66214
OUO6046,000204C –19–13SEP05–15/23
23. Pack bearing (A) with TY6341 Multi-Purpose SD

Polyurea Grease and install into housing.
24. Install lip seal (B) using appropriate size seal installer
(C).
–UN–21MAY04
25. Coat seals with TY6341 Multi-Purpose SD Polyurea
50
Grease; then lower spindle housing onto spindle.
20
59
A—Bearing
N66215
B—Lip Seal
C—Seal Installer
–UN–21MAY04
N66216

083006
PN=597
Cam Lobe Motor
26. Install inner spindle bearing using JDG690-7 Block,

Bearing Remover (A) and D01246AA 30 Ton
Push-Puller (Hydraulic) (B).
A—JDG690-7 Block, Bearing Remover

B—D01246AA 30 Ton Push-Puller (Hydraulic)
–UN–20AUG02
H73010
50
20
60

083006
PN=598
Cam Lobe Motor

27. Using split rings (A) from repair kit with lowest
thickness, install in groove of shaft (B).
–UN–21MAY04
28. Apply pressure onto inner race of bearing cone using
a press and DFHXT1 Split Ring Service Tool1 with
split ring ends.
N66217
29. Measure clearance (C) between split rings (A) and
groove mating surface (D).
30. Remove pressure from press.
31. Remove split rings.
32. Determine correct thickness of split ring needed:

Thickness of correct split ring to be used is equal to
–UN–21MAY04
clearance (C) + thickness of split ring (A) used in step
32.
50
33. Choose the split ring from the repair kit whose 20
61
N66218
thickness is closest to the value determined in step
37 and install.
34. Apply pressure to inner race of bearing using a press.
35. When installed, ensure split ring gap (E) is equal on

each side of shaft.
A—Split Ring
–UN–21MAY04
B—Shaft
C—Clearance
D—Mating Surface
E—Gap
N66220
1

083006
PN=599
Cam Lobe Motor
36. Install thrust ring (A).
A—Thrust Ring
–UN–21MAY04
N66221
50
20
62

083006
PN=600
Cam Lobe Motor
37. Adjust spindle rolling drag torque using the following

method:
NOTE: The length of the torque wrench used (offset) will

have to be measured so that an actual torque
value is achieved. Use the following formula to
determine what torque value should be seen on
the wrench when the offset is factored in. Use
meters as the unit of measurement.
–UN–13JUL00
EXAMPLE:
The torque wrench being used has a length (C) of
H63221
500 mm (0.5 m).
The distance (D) from spindle center to bolt hole

center is 140 mm (0.14 m).
The torque wrench (A) should read 39.0 N•m when

specified torque is achieved.
• Rotate spindle in spindle housing a minimum of five 50

20
–UN–03AUG00
revolutions.
63
• Install M12 cap screw into one of the perimeter
spindle housing holes as shown.
• Measure length of torque wrench (C).
• Measure distance (D) from center of spindle to
H64150
center of previously installed cap screw.
• Prevent spindle from turning.
A—Specified Torque with Offset Factored
NOTE: A direct reading or “beam” type torque wrench is B—Specified Torque (50 N•m)
C—Length of Wrench
required for accurate readings. D—Distance from Spindle Center to Bolt Hole
Center
• Use torque wrench to turn spindle housing, record
amount of torque needed to rotate spindle housing
(A) and compare to specification.
Specification
Specified Torque (B)—Rolling
Drag Torque ................................................................................... 50 N•m
(37 lb-ft)
• Add or remove shims to obtain specified torque.

083006
PN=601
Cam Lobe Motor

A—O-Ring
–UN–29MAR00
H63161
OUO6046,000204C –19–13SEP05–21/23

39. Align splines on spindle within piston carrier; then

lower spindle housing making certain alignment marks
(A) on housing are correct.
50
20 40. Lower spindle housing onto cam and install cap
64 screws (B).
–UN–29MAR00
NOTE: Be certain that the O-ring is still seated in its
groove in the spindle housing before pulling the
two units together.
H63154
41. Tighten cap screws evenly on both sides of housing
until all sections are pulled together.
A—Scribed Line
OUO6046,000204C –19–13SEP05–22/23
42. Install the remaining six cap screws (A) and tighten to
specification.
Specification
Socket Head Cap Screw—Torque ............................................... 355 N•m
(260 lb-ft)
–UN–17MAY00
43. Install yoke. (See procedure in this group.)

H63236
OUO6046,000204C –19–13SEP05–23/23

083006
PN=602
Group 25
Tires and Wheels
NOTE: Order tools from the U.S. SERVICEGARD or

European Microfiche Tool Catalogs.
ESSENTIAL TOOLS listed are required to perform the job

correctly and are obtainable only from SERVICEGARD or
RECOMMENDED TOOLS, as noted, are suggested to

perform the job correctly. Some tools may be available
OUO6083,00004C1 –19–29JAN03–1/4
50
M20 X 1.5 Metric Tap . . . . . . . . . . . . . . . . . JDG6741 25
1
Used to restore threads in lug bolt holes in final drive
hubs.
–UN–01JUN01
H68350
1
RECOMMENDED TOOL avaialbe through service parts catalog.
OUO6083,00004C1 –19–29JAN03–2/4
Service Jack . . . . . . . . . . . . . . . . . . . . . . JT07056A
Used with D05079ST to remove and install rear wheel

weights.
–UN–14SEP89
H40598

083006
PN=603
Tires and Wheels
H41133 –UN–07SEP89
Wheel Weight Adapter . . . . . . . . . . . . . . . . D05079ST
Used with JT07056A to remove and install rear wheel

weights.
Final Drive Adapter . . . . . . . . . . . . . . . . . . . . JT05874
Use with JT07056A to remove and install final drives.
–UN–05SEP89
H40599
OUO6083,00004C1 –19–29JAN03–4/4
50
25
2
AG,OUO6435,685 –19–03MAY00–1/2
4 to 1 Torque Multiplier . . . . . . . . . . . . . . . . .ST05706
Used to torque drive wheel mounting bolts.
AG,OUO6435,685 –19–03MAY00–2/2

083006
PN=604
Tires and Wheels
Specifications
Drive Wheel Bolts Torque 200 N•m plus an additional 1/4 turn
(150 lb-ft) plus an additional 1/4 turn
Dual Wheel Bolt Torque 200 N•m plus an additional 1/4 turn
(150 lb-ft) plus an additional 1/4 turn
Rear Wheel Bolts (Non Powered Torque 315 N•m

Axles) (M16 Bolt) (232 lb-ft)
Rear Wheel Bolts (Powered Axles) Torque 200 N•m plus an additional 1/4 turn
(M20 Bolt) (150 lb-ft) plus an additional 1/4 turn
Rear Wheel Weight (Outside) Weight 65 kg

(143 lb)
Rear Wheel Weight (Inside) Weight 46 kg

(101 lb)
50
25
3
OUO6435,0001756 –19–01MAY02–1/1
Service Tires Safely
CAUTION: Explosive separation of a tire and

rim parts can cause serious injury or death.
Only attempt to mount a tire if 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.
When inflating tires, use a clip-on chuck and

extension hose long enough to allow you to
stand to one side and NOT in front of or over
the tire assembly. Use a safety cage if available.
Inspect tires and wheels daily. Do not operate

with low pressure, cuts, bubbles, damaged rims
or missing lug bolts and nuts.
–UN–23AUG88
TS211
AG,OUO6435,688 –19–03MAY00–1/1

083006
PN=605
Tires and Wheels
Care and Service of Tires
Check tires daily for damage or noticeably low pressure.
At least every 100 hours of operation, check tire pressure.

If tires contain liquid ballast, use a special air-water gauge
and measure with valve stem at bottom.
A small puncture in a tubeless tire can be temporarily

repaired without dismounting the tire, thus avoiding down
time during a busy season.
Protect tires from exposure to sunlight, petroleum

products, and chemicals.
Drive carefully. Try to avoid rocks and sharp objects.
–UN–15DEC00
50
H65609
25
4
Continued on next page OUO6083,00005F0 –19–28MAY03–1/2

083006
PN=606
Tires and Wheels
IMPORTANT: A permanent repair should be made as

soon as possible to prevent further tire
damage.
Tire Size Ply Rating Air Pressure

kPa (bar) (psi)
Drive Tires
18.4R-38 (Radial) two stars 205 (2.0) (30)
18.4R-42 (Radial) three stars 250 (2.5) (36)
24.5-32 12 220 (2.1) (32)
30.5L-32 12 180 (1.8) (26)
30.5L-32 14 195 (1.9) (28)
35.5L-32 12 180 (1.8) (26)
30.5LR-32 three stars 250 (2.5) (36)
76 x 50-32 16 103 (1.0) (15)
800/65R-32 172A8 275 (2.8) (40)
800/70R-38 173A8 205 (2.0) (30)
900/65R-32 172A8 205 (2.0) (30) 50
25
Steering Tires
5
14.9-24 8 195 (1.8) (26)
16.9-26 two stars 205 (2.0) (30)
18.4-26 6 140 (1.4) (20)
18.4-30 10 235 (2.3) (34)
28L-26 10, 12 103 (1.0) (15)
a
18.4-26 two stars 235 (2.3) (34)
600/65R-28 147A8 205 (2.1) (30)
a
France only
NOTE: Tire pressures listed in preceding table may be

higher than the tire pressures shown on the side
of the tires.
OUO6083,00005F0 –19–28MAY03–2/2

083006
PN=607
Tires and Wheels
Using Liquid Weight
CAUTION: Installing liquid weight (ballast)

requires special equipment and training.
IMPORTANT: Cover rim completely with solution to
–UN–09JAN01
avoid corrosion, but NEVER fill any tire
more than 90 per cent full. More
solution would leave too little air space
to absorb shocks. Damage to tire could
H65625
occur.
A solution of water and calcium chloride provides safe,

economical ballast. Used properly, it will not damage tires,
tubes or rims.
Use calcium chloride to prevent water from freezing. A

mixture of 1.6 kg (3-1/2 lb) of calcium chloride per 3.8 L (1
gal) will not freeze solid above -45°C (-50°F).
NOTE: Use of alcohol as liquid ballast is not

50
25 recommended. Calcium chloride solution is
6 heavier and more economical.
Fill tubeless tires at least to valve level (minimum 75 per

cent full). Less solution would expose part of rim, possibly
causing corrosion. Tube-type tires may be filled to any
level below 90 per cent.
AG,OUO6435,690 –19–03MAY00–1/1

083006
PN=608
Tires and Wheels
Jacking Locations
CAUTION: Always empty grain tank before

jacking up the combine.
Do not jack combine at any other location than those with
–UN–05JAN01
a jack pocket.
H65709
–UN–05JAN01
50
25
7
H65710
AG,OUO6435,695 –19–03MAY00–1/1

083006
PN=609
Tires and Wheels
Remove and Install Tire
CAUTION: Explosive separation of a tire and

rim parts can cause serious injury or death.
Always maintain the correct tire pressure. DO

NOT inflate tires above the recommended
pressure.
Inspect tires and wheels daily. DO NOT operate

with low pressure, cuts, bubbles, damaged
rims, or missing lug bolts and nuts.
Carefully inspect any tire and rim assembly that

has been run flat or severely under inflated
before reinflating the tire. Damage to the rim
and tire may have developed. Call your
authorized dealer or a qualified repair service to
inspect the rim and tire assembly and make
necessary repairs.
–UN–23AUG88
50
25 When inflating tires, use a clip-on chuck and
8 extension hose long enough to allow you to
stand to one side and NOT in front of or over
TS211
the tire assembly. Use a safety cage if available.
NEVER cut or weld on an inflated tire or rim

assembly. Heat from welding could cause an
increase in pressure and may result in tire
explosion.
Do not attempt to mount a tire if you do not

have the proper equipment and experience to
perform the job. Have it done by your
authorized dealer or a qualified repair service.
Check tire pressure with an accurate gauge having 6.9

kPa (0.07 bar) (1 psi) graduations.
1. The tire can be removed without removing the wheel

from the machine. See the John Deere Off-The-Road
Tire Maintenance Manual to remove the tire from the
wheel.
Continued on next page OUO6435,00017B9 –19–09SEP05–1/3

083006
PN=610
Tires and Wheels
2. Always completely deflate the tire by removing valve

core from valve before attempting any demounting
operation. Check the valve stem by running a probe
through it to make sure the valve stem is not plugged.
3. To prevent slipping of the rim under load, the inside

and outside of rim must be free of paint, rust, oil,
grease, dirt or other foreign material before installation.
4. Install valve stem in rim base and tighten valve core

housing finger tight.
CAUTION: Serious bodily injury can occur from

explosion when mounting and inflating tires if
safe procedures are not followed.
5. Before mounting tire on rim, add soap lubricant to bead

of tire.
6. Clear the area of all persons.

50
25
9
OUO6435,00017B9 –19–09SEP05–2/3
7. Turn tire so valve stem (B) is pointing down. Use a

pressure regulating valve (A) with clip-on chuck and
extension hose long enough to allow you to stand to
one side and NOT in front of tire while inflating.
8. Use only recommended air pressure. Pressure over
–UN–25OCT88
this limit can cause an explosion.
A—Regulating Valve
B—Valve Stem
T6075AD
OUO6435,00017B9 –19–09SEP05–3/3

083006
PN=611
Tires and Wheels
Drive Wheel Bolt Torque
IMPORTANT: Wheel bolts must be clean and free of

lube before installing. Torque value is D
for clean, dry bolt. Lubricating reduces A C E
–UN–12JUN02
B
friction and overloads the bolts.
NOTE: Use JDG674 M20 x 1.5 Metric Tap to restore F

threads in lug bolt holes in final drive hubs if
H72242
necessary.
1. Each time a drive wheel is repositioned or replaced, A—Wheel Bolt

torque wheel bolts to specification without using a B—30 mm Socket (3/4 in. Drive)
torque multiplier. Tighten bolts in a criss/cross pattern. C—4 to 1 Multiplier (1000 lb-ft capacity) (1/2 in.
Input Drive, 3/4 in. Output Drive)
Specification D—3/4 in. Drive x 18 in. Long Extension
Drive Wheel Bolts—Torque ...................... 200 N•m plus an additional 1/4 E—Torque Wrench
F—Wheel
turn
(150 lb-ft) plus an additional 1/4
turn
2. Use a 4 to 1 torque multiplier and turn bolt head 1/4

50 turn (ratchet or torque wrench will make a full turn).
25
Pull multiplier handle against inside of wheel when
10
tightening.
OUO6435,000178C –19–17MAY02–1/1

083006
PN=612
Tires and Wheels
Dual Wheels Bolt Torque B E G

A C F
D
IMPORTANT: Wheel bolts must be clean and free of
lube before installing. Torque value is
–UN–16MAY02
for clean, dry bolt. Lubricating reduces
friction and overloads the bolts.
H
1. Each time a dual wheel is repositioned or replaced,
H72243
torque wheel bolts to 200 N•m (150 lb-ft) without using
a torque multiplier. Tighten bolts in a criss/cross
pattern. A—Wheel Bolt
B—Bolt Spacer
2. Use a 4 to 1 torque multiplier and turn bolt head 1/4 C—30 mm Socket (3/4 in. Drive)
turn (ratchet or torque wrench will make a full turn). D—3/4 in. x 16 in. Extension
E—4 to 1 Multiplier
Pull multiplier handle against inside of wheel when
F—1/2 in. x 10 in. Extension
tightening. G—Torque Wrench
H—Outside Dual Wheel
Specification
Dual Wheel Bolt—Torque ........................ 200 N•m plus an additional 1/4
turn
turn
50
25
11
OUO6435,000178B –19–17MAY02–1/1
Rear Wheel Bolt Torque
Each time a rear wheel is replaced, torque wheel bolts to

specification. Then, re-torque wheel bolts after one hour of
operation.
–UN–15DEC00
Specification
Rear Wheel Bolts (Non Powered
Axles) (M16 Bolt)—Torque ........................................................... 315 N•m
(232 lb-ft)
Rear Wheel Bolts (Powered
H65610
Axles) (M20 Bolt)—Torque ....................... 200 N•m plus an additional 1/4
turn
turn
NOTE: Mount rear tires with the offset “in” and valve
stems to the outside.
AG,OUO6022,1895 –19–12JAN01–1/1

083006
PN=613
Tires and Wheels
Install Axle Extension Tubes
50
25
–UN–18FEB97
12
H48031
A—Dowel Pins C—Truss Rod Hole E—Spacers F—Flange Nuts
B—Extension Tube D—Cap Screws
NOTE: It is recommended to position spacer (E) on 3. Attach tube using six cap screws (D) with spacers
nut side. (E) and flange nuts (F) to the outside of extension
tube (as shown).
1. Apply NEVER-SEEZ to dowel pins (A) and axle
housing holes and install locating dowel pins in axle
housing holes.
2. Position axle extension tube (B) on pins with truss

rod hole (C) down and to the inside (to axle
housing).
Continued on next page OUO6083,00004BF –19–29JAN03–1/5

083006
PN=614
Tires and Wheels
IMPORTANT: Cap screw threads must be oiled prior

to installation to assure that the correct
torque is applied. All final drive torques
shown are for oiled threads.
4. Torque top two flange nuts (A) on axle side (B) of
–UN–28JAN03
extension tube (C) to specification.
Specification
Axle Extension Tube Top Flange
Nuts—Oiled Torque ..................................................... 455 N•m (340 lb-ft)
H74943
to installation to assure that the correct A—Top Flange Nut (2 used)
torque is applied. All final drive torques B—Axle Side
shown are for oiled threads. C—Extension Tube
D—Bottom Flange Nut (4 used)
5. Torque bottom four flange nuts (D) to specification.
Specification
Axle Extension Tube Bottom
Flange Nuts—Oiled Torque......................................... 790 N•m (580 lb-ft)
50
25
13
OUO6083,00004BF –19–29JAN03–2/5
6. Position final drive (A) to tube end mounting position

using Service Jack JT07056A (B) and Final Drive
Adapter JT05874 (C).
A—Final Drive
B—Final Drive Adapter JT05874
C—Service Jack JT07056A
–UN–26SEP97
H50245
Continued on next page OUO6083,00004BF –19–29JAN03–3/5

083006
PN=615
Tires and Wheels

to installation to assure that the correct
torque is applied. All final drive torques
shown are for oiled threads.
NOTE: Use previously removed hardware to reinstall final
–UN–28JAN03
drive.
7. Attach final drive to drive extension tube using six

previously removed M24 x 80 cap screws (A and B)
H74945
with 18 mm spacers. Torque cap screws (A and B) to
specifications.
Specification A—Top Cap Screw (2 used)

Axle Extension Tube Top Cap B—Bottom Cap Screw (4 used)
Screws—Oiled Torque ................................................ 455 N•m (340 lb-ft)
Axle Extension Tube Bottom Cap
Screws—Oiled Torque ................................................ 790 N•m (580 lb-ft)
50
25
14
OUO6083,00004BF –19–29JAN03–4/5
8. Install spiral snap ring (B) and sleeve (C) on extension

shaft (A).
9. Attach extension shaft to input shaft using splined

coupler (D) and pin.
–UN–28AUG96
10. Slide sleeve over coupler and retain with spiral snap
ring.
11. Attach inner end of drive shaft using existing parts (E)
(coupler, pin, sleeve, and spiral snap ring). H48034
A—Extension Shaft
B—Spiral Snap Ring
C—Sleeve
D—Splined Coupler
E—Existing Parts
OUO6083,00004BF –19–29JAN03–5/5

083006
PN=616
Tires and Wheels
Install Dual Wheels and Truss Rod
50
25
–UN–29AUG96
15
H48025
A—Pilot Stud B—Spacer Ring C—Wheel Bolts
Torque values specified in the

CAUTION: Wheels are heavy (approximately
following procedures are for clean,
340 kg (750 lb) without liquid ballast) and
dry, wheel bolts. Lubricating oil
difficult to handle due to extreme offset of
reduces friction and thread bite to
tire and rim. When handling wheels, off
overload bolts.
centered weight can suddenly shift making
wheel handling awkward and the wheel
Due to countersunk design of spacer
difficult to control. To avoid personal injury,
ring, inner wheel bolts can be
two service technicians are needed to
checked and torqued when outer
control wheel handling.
wheel is removed.
NOTE: Use of pilot stud H138607 is strongly
2. Position inner wheel on studs with bottom end of
recommended to help guide wheels in
tire cleats to the front and down.
mounting position.
3. Attach wheel with spacer (B) and eight wheel bolts
1. Install pilot studs (A) in top and bottom holes of
(C). Wheel bolts head fit inside of larger unthreaded
drive hub. Stud threads must bottom out in hole so
holes.
inner end is flush with inside of hub.
4. Remove pilot studs and replace with spacers and
IMPORTANT: Wheel bolts MUST be clean and
wheel bolts.
oil-free when installing and torquing.

083006
PN=617
Tires and Wheels
5. Initial Wheel Bolt Torque: Using tightening sequence

shown, torque wheel bolts to specifications using
criss/cross pattern to evenly pull wheel tight to hub.
Specification
Wheel Bolt—Torque .................................................................... 200 N•m
–UN–28AUG96
(150 lb-ft)
H48028
Bolt Tightening Sequence
OUO6083,0000D75 –19–05JUL06–2/8
50
25 IMPORTANT: Final wheel bolt torque is extremely
16 high and cannot be reached using
common hand tools and torque wrench.
A Four-to-One Torque Multiplier is
required to meet final wheel bolt torque
specifications. To achieve high torque
results, final torquing must be done
with tires on the ground and with
multiplier handle against inside of rim.
6. Final Bolt Torque: Position tools (A—C) as shown, with

Torque Multiplier handle against inside of rim.
7. Turn all BOLT HEADS an additional 1/4 turn, past

initial torque. Due to 4-to-1 torque multiplier, torque
wrench will make a full turn while bolt head makes a
1/4 turn.
8. Repeat steps on opposite side of machine.

–UN–29AUG96
A—30 mm Socket (3/4 in. Drive)

B—4 to 1 Torque Multiplier
C—Torque or Ratchet Wrench
H48035

083006
PN=618
Tires and Wheels
50
25
–UN–05JUL06
17
H86295
A—Pilot Stud B—Spacers C—Wheel Bolts
IMPORTANT: Wheel bolts MUST be clean and

CAUTION: Dual wheels are heavy
oil-free when installing and torquing.
(approximately 340 kg (750 lb) without liquid
Torque values specified in the
ballast) and difficult to handle due to
following procedures are for clean,
extreme offset of tire and rim. When
dry, wheel bolts. Lubricating oil
handling wheels, off centered weight can
reduces friction and thread bite to
suddenly shift making wheel handling
overload bolts.
awkward and the wheel difficult to control.
To avoid personal injury, two service
Due to countersunk design of spacer
technicians are needed to control wheel
ring, inner wheel bolts can be
handling.
checked and torqued when outer
wheel is removed.
NOTE: Use of pilot stud H138607 is strongly
recommended to help guide wheels in
10. Position outer wheel on studs with bottom end of
mounting position.
tire cleats to front and down.
9. Install pilot studs (A) in top and bottom holes of
11. Attach wheel with spacers (B) and wheel bolts (C).
drive hub. Stud threads must bottom out in hole so
inner end is flush with inside of hub.

083006
PN=619
Tires and Wheels
12. Remove pilot studs and replace with final wheel

bolts and spacers.
OUO6083,0000D75 –19–05JUL06–5/8
13. Initial Wheel Bolt Torque: Using tightening sequence

shown, torque wheel bolts to specification using
criss/cross pattern to evenly pull wheel tight to hub.
Specification
Wheel Bolt—Torque .................................................................... 200 N•m
–UN–28AUG96
(150 lb-ft)
14. Repeat steps 9—13 on opposite side of machine.
H48028
Bolt Tightening Sequence
50
25
18

083006
PN=620
Tires and Wheels
NOTE: With wheels installed and still off ground install

truss rod between extension tubes.
15. Slide truss rod (A) through frame plate(s) and install
cupped washer (B) and nut (C).
–UN–12DEC96
16. Hand-tighten nuts on both ends so rod is centered
between plates, with equal number of threads
exposed on both ends.
H48820
17. Install outer nuts (D) on both ends.
IMPORTANT: Torque on outer nuts Only. Torquing on

inner nuts will pre-tension truss rod and
can bend mounting flange plates.
18. With both wheels off the ground, torque outer nuts to
specification.
–UN–12DEC96
Specification
Nut—Torque ................................................................................ 600 N•m
(450 ft-lb)
50
25
19. With truss rod nuts torqued, blocking can be removed
H48821
19
and combine lowered to the ground.
A—Truss Rod
B—Cupped Washer
C—Nut
D—Outer Nut

083006
PN=621
Tires and Wheels
IMPORTANT: Final wheel bolt torque is extremely

high and cannot be reached using
common hand tools and torque wrench.
A Four-to-One Torque Multiplier is
required to meet final wheel bolt torque
specifications. To achieve high torque
results, final torquing must be done
with tires on the ground and with
multiplier handle against inside of rim.
20. Final Bolt Torque: Position tools (A—E) as shown,

with Torque Multiplier handle against inside of rim.
21. Turn all BOLT HEADS an additional 1/4 turn, past

initial torque. Due to 4-to-1 torque multiplier, torque
wrench will make a full turn while bolt head makes a
1/4 turn.
22. Check tire pressure and inflate as necessary. Refer to

Operator’s Manual for tire inflation pressure.
–UN–29AUG96
50
A—30 mm Socket (3/4 in. Drive)
25
B—3/4 x 16 In. Extension
20
C—4 to 1 Torque Multiplier
H48036
D—1/2 to 10 In. Extension
E—Torque or Ratchet Wrench
OUO6083,0000D75 –19–05JUL06–8/8

083006
PN=622
Section 60
Power Steering and Brakes
Contents
Page Page
Group 05—Steering Install Brake Drum. . . . . . . . . . . . . . . . . . . . . .60-10-11

Essential or Recommended Tools . . . . . . . . . . .60-05-1 Remove and Install Master Cylinder . . . . . . . .60-10-11
Service Equipment and Tools . . . . . . . . . . . . . .60-05-2 Disassemble and Assemble Master
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-3 Cylinder (Double Bleed Screw) . . . . . . . . . .60-10-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-4 Brake Fluid Reservoir . . . . . . . . . . . . . . . . . . .60-10-13
Steering Pump Repair . . . . . . . . . . . . . . . . . . . .60-05-5 Adjusting Master Cylinder . . . . . . . . . . . . . . . .60-10-14
Remove Steering Valve. . . . . . . . . . . . . . . . . . .60-05-6 Bleeding Brake System—Double Bleed
Steering Valve. . . . . . . . . . . . . . . . . . . . . . . . . .60-05-7 Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-15
Disassemble Steering Valve . . . . . . . . . . . . . . .60-05-8 Remove and Install Slave Cylinders . . . . . . . .60-10-20
Assemble Steering Valve . . . . . . . . . . . . . . . .60-05-11 Disassemble and Assemble Slave Cylinder. . .60-10-21
Install Steering Valve . . . . . . . . . . . . . . . . . . .60-05-15 Disassemble and Assemble Brake Pedals . . .60-10-22
Electro-Hydraulic Steering Valve and Disassemble and Assemble Parking Brake
Flowmeter—Exploded View . . . . . . . . . . . . .60-05-18 Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-28
Remove and Install Flow Meter . . . . . . . . . . . .60-05-19 Adjust Park Brake Pedal . . . . . . . . . . . . . . . . .60-10-36
AUTOTRAC Assisted Steering Flowmeter—
Exploded View. . . . . . . . . . . . . . . . . . . . . . .60-05-20
Steering Column Components. . . . . . . . . . . . .60-05-21
Disassemble And Assemble Steering 60
Column . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-22
Replace Telescoping Shaft Bearings. . . . . . . .60-05-26
Remove and Install Steering Cylinder . . . . . . .60-05-27
Disassemble And Assemble Steering
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-31
Toe-In Adjustment . . . . . . . . . . . . . . . . . . . . . .60-05-32
Remove and Install Steering Tie Rod Joint . . .60-05-32
Remove And Install Tie Rod End . . . . . . . . . .60-05-33
Remove And Install Rear Spindle Assembly
Non-Powered. . . . . . . . . . . . . . . . . . . . . . . .60-05-34
Disassemble and Assemble Rear Spindle
Assembly—Non-Powered . . . . . . . . . . . . . .60-05-36
Remove and Install Rear Axle Pivot
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-44
Rear Axle Adjustment . . . . . . . . . . . . . . . . . . .60-05-47
Group 10—Brakes
Service Equipment and Tools . . . . . . . . . . . . . .60-10-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-2
Deglazing Brake Linings . . . . . . . . . . . . . . . . . .60-10-3
Remove Brake Drum. . . . . . . . . . . . . . . . . . . . .60-10-3
Remove Brake Shoe
Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-5
Repair Brakes
Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-6
Assemble Brakes
Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . .60-10-10

083006
PN=1
Contents
60

083006
PN=2
Group 05
Steering
Catalogs.
OUO6083,0000CB7 –19–09MAR06–1/5
Spanner Wrench . . . . . . . . . . . . . . . . . . . . . .JDG347
Used to remove lock rings on steering cylinder.
–UN–08MAY03
H76714
OUO6083,0000CB7 –19–09MAR06–2/5
60
H85286 –UN–26JAN06 05
1
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . JDG102921
To be used with JDG347 Spanner Wrench
1
OUO6083,0000CB7 –19–09MAR06–3/5
H40188 –UN–12JAN89
Snap Ring Pliers . . . . . . . . . . . . . . . . . . . . . JDG1141
Used to remove and install internal snap rings.
1
RECOMMENDED TOOL avaialbe through service parts catalog.

083006
PN=625
Steering
Spindle Repair Kit . . . . . . . . . . . . . . . . . . . . JDG1307
Used to remove and install bearing and seal.
OUO6083,0000CB7 –19–09MAR06–5/5

AG,OUO6022,1900 –19–25JUL00–1/4
12 Ton Support Stand . . . . . . . . . . . . . . . . . . JT02043
Used to support rear axle.
60
–UN–11JUN97
05
2
RW25751
AG,OUO6022,1900 –19–25JUL00–2/4
17-1/2 and 30 Ton Puller Set. . . . . . . . . . . . D01047AA
Used to remove and install outer bearing of rear spindle.
AG,OUO6022,1900 –19–25JUL00–3/4
Bushing, Bearing and Seal Driver Kit. . . . . . . D01044AA
Used to install rear spindle bushings and seals.
AG,OUO6022,1900 –19–25JUL00–4/4

083006
PN=626
Steering
Other Material
Number Name Use

applications.
AG,OUO6022,1901 –19–25JUL00–1/1
60
05
3

083006
PN=627
Steering
Specifications
Steering Valve Cap Screws
First sequence Torque 11 to 17 N•m

(100 to 150 lb-in.)
Final sequence Torque 25 to 31 N•m

(225 to 275 lb-in.)
Front of Steering Wheels Toe-in 13 mm

(1/2 in.)
Tie Rod Joint Clamp Bolt Torque 70 ± 18 N•m

(52 ± 13 lb-ft)
Steering Tie Rod End Nut Torque 200 N•m

(150 lb-ft)
Rear Spindle Assembly Approximate Weight 80 kg

(176 lb)
Rear Spindle-to-Axle Cap Screws Torque 646 ± 97 N•m

(475 ± 71 lb-ft)
60
05
4 Spindle Pin-to-Yoke Cap Screws Torque 70 N•m
(52 lb-ft)
Rear Spindle Nut Torque 100 N•m

(74 lb-ft)
Steering Column Couplings Clearance 2.5 ± 0.5 mm

(0.10 ± 0.02 in.)
Steering Column Upper Coupling Torque 28 ± 2.8 N•m

Clamp Bolt (21 ± 2 lb-ft)
Steering Column Bearing Nut Torque 40 ± 4 N•m

(29 ± 3 lb-ft)
Steering Wheel Nut Torque 47 N•m

(35 lb-ft)
Bushing Retaining Plate Cap Screws Torque 35 ± 9 N•m

(26 ± 7 lb-ft)

083006
PN=628
Steering
Bushing Bracket Center Cap Screw Torque 207 ± 52 N•m

(153 ± 38 lb-ft)
Bushing Bracket-to-Chassis Cap Torque 207 ± 52 N•m

Screws (153 ± 38 lb-ft)
OUO6083,0000517 –19–31MAR03–2/2
Steering Pump Repair
For steering pump (A) procedures see (Section 70, Group

10).
A—Steering Pump
–UN–17AUG06
H86465
OUO6083,0000DC6 –19–17AUG06–1/1
60
05
5

083006
PN=629
Steering
Remove Steering Valve

–UN–23AUG88
fluids.
X9811
–UN–19JUL05
NOTE: Procedures are similar for machines equipped
with AUTOTRAC assisted steering.
H84015
system pressure. Shut off engine and close
accumulator shut-off valve. A—Oil Line-to-Steering Cylinder
60 B—Oil Line Return-to-Filter
05 C—Oil Line-to-Steering Cylinder
2. Disconnect oil lines (A—D).
6 D—Oil Supply Line-From-Pump
3. Plug and cap all openings. F—Steering Valve
4. Remove cap screws (E) to remove steering valve (F)

and plate.
OUO6083,0000AB0 –19–19JUL05–1/2
5. Remove coupler (D).
6. Remove cap screws (B).
7. Remove support (A) from steering valve (C).

–UN–20APR89
A—Support
C—Steering Valve
D—Coupler
H40577
OUO6083,0000AB0 –19–19JUL05–2/2

083006
PN=630
Steering
Steering Valve
3
1
22
22 22
5 23
3
6 23 23
24
7
11
9
10
8
60
05
7
12 17
13
18
14
15 19 20
16
21
–UN–14MAR02
H71311
1—End Cap Screw (7 used) 7—Spool 13—Needle Bearing 19—Seal

2—End Cap 8—Sleeve 14—Bearing 20—Housing
3—O-Ring (3 used) 9—Springs (4 used) 15—Seal 21—Screw (4 used)
4—Rotator 10—Pin 16—Seal 22—Check Ball
5—Drive 11—Control Housing 17—Bushing 23—Pin
6—Spacer 12—Bearing 18—Snap Ring 24—Insert
NOTE: Only seal repair kit items (3, 15, 16 and 19)
are available for service.
OUO6435,0001669 –19–14MAR02–1/1

083006
PN=631
Steering
Disassemble Steering Valve
IMPORTANT: Perform all service work on steering

valve in clean area. Use proper tools,
cleaning material and lubricants.
–UN–26MAY99
NOTE: Only a seal repair kit is available for service.
1. Remove screws (A) to remove front housing (B).
H57564
A—Screw (4 used)
B—Front Housing
AG,OUO6022,1908 –19–25JUL00–1/11
2. Remove snap ring (A).
A—Snap Ring
60
–UN–26MAY99
05
8
H57565
AG,OUO6022,1908 –19–25JUL00–2/11
3. Remove seal gland bushing assembly.
–UN–26MAY99
H57566

083006
PN=632
Steering
4. Remove O-ring (A).
A—O-Ring
–UN–26MAY99
H57567
AG,OUO6022,1908 –19–25JUL00–4/11
5. Remove oil seal.
–UN–24OCT88
T87425
AG,OUO6022,1908 –19–25JUL00–5/11
60
05
9
6. Remove O-ring.
–UN–26MAY99
H57568
AG,OUO6022,1908 –19–25JUL00–6/11
7. Remove races (A) and thrust bearing (B).
A—Races (2 used)
B—Bearing
–UN–14APR99
H55447

083006
PN=633
Steering
8. Remove cap screws to remove gerotor assembly.
–UN–26MAY99
H57569
AG,OUO6022,1908 –19–25JUL00–8/11
9. Remove O-rings (A).
A—O-Ring (3 used)
–UN–26MAY99
H57570
AG,OUO6022,1908 –19–25JUL00–9/11
60
05
10
IMPORTANT: If it is necessary to remove spool and
sleeve assembly from housing for
cleaning, be careful to prevent these
parts from binding. Tolerances in this
area are very close and when
replacement is necessary the steering
–UN–24OCT88
valve must be ordered as an assembly.
10. To prevent binding, turn spool and sleeve assembly

as it is removed from housing. Do not disassemble
spool and sleeve assembly. T87428

083006
PN=634
Steering
11. Remove and inspect (A—C).
A—Screw Insert
B—Rod
C—Ball
–UN–26MAY99
H57571
AG,OUO6022,1908 –19–25JUL00–11/11
Assemble Steering Valve
1. Install (A—C).
2. Thoroughly clean all parts. Apply clean hydraulic oil to

all internal parts.
–UN–26MAY99
3. Use a steering valve seal repair kit when assembling
steering valve.
H57571
4. To prevent binding, turn spool and sleeve assembly as
it is installed.
60
05
A—Screw Insert
11
B—Rod
C—Ball
–UN–24OCT88
T87428
AG,OUO6022,1909 –19–25JUL00–1/12
IMPORTANT: For correct operation, the drive shaft

must be installed into gerotor star so
groove is in alignment with one of the
roots of gerotor star teeth.
5. Install gerotor star (A) on drive shaft so root of tooth is

–UN–24OCT88
in alignment with groove in the end of drive shaft (B).
A—Gerotor Star
B—Drive Shaft
T5835AG

083006
PN=635
Steering
6. Install O-rings (D).
7. Install drive shaft (A) and spacer (B). Slot (C) must
engage pin in spool and sleeve assembly.
A—Drive Shaft
–UN–26MAY99
B—Spacer
C—Slot
D—O-Ring (2 used)
H57572
AG,OUO6022,1909 –19–25JUL00–3/12
8. Install O-ring (C) on gerotor ring (A).
9. Install gerotor ring and spacer (B).
A—Gerotor Ring
B—Spacer
–UN–26MAY99
C—O-Ring (2 used)
D—End Cap
H57573
AG,OUO6022,1909 –19–25JUL00–4/12
60
05
12
10. Install end cap.
11. Clean and dry cap screws before installing.
IMPORTANT: Any cap screw can be tightened first,

but the sequence shown must be
–UN–22OCT98
followed.
12. Install and tighten the cap screws to specified torque

using sequence (1 through 7) shown:
RW25138A
Steering Valve Cap Screws—Specification
First sequence—Torque ........................................................ 11 to 17 N•m
(100 to 150 lb-in.)
Final sequence—Torque ....................................................... 25 to 31 N•m
(225 to 275 lb-in.)

083006
PN=636
Steering
13. Install races (A) and thrust bearing (B).
A—Races (2 used)
B—Bearing
–UN–14APR99
H55447
AG,OUO6022,1909 –19–25JUL00–6/12
14. Install O-ring.
–UN–26MAY99
H57568
AG,OUO6022,1909 –19–25JUL00–7/12
60
05
13
15. Install oil seal with lip of seal opposite bottom of bore
using 30 mm and 24 mm disks.
Push oil seal to the bottom of bore.
Apply petroleum jelly to lip of seal.
–UN–24OCT88
T87433
AG,OUO6022,1909 –19–25JUL00–8/12
16. Install O-ring (A). Apply petroleum jelly to seal.
A—O-Ring
–UN–26MAY99
H57567

083006
PN=637
Steering
17. Install seal gland bushing assembly.
–UN–26MAY99
H57566
AG,OUO6022,1909 –19–25JUL00–10/12
18. Install snap ring (B) into steering valve (A).
A—Steering Valve
B—Snap Ring
–UN–14APR99
H55450
AG,OUO6022,1909 –19–25JUL00–11/12
60
05
14
19. Install housing (B) using screws (A).
A—Screws (4 used)
B—Housing
–UN–26MAY99
H57564
AG,OUO6022,1909 –19–25JUL00–12/12

083006
PN=638
Steering
Install Steering Valve
NOTE: Procedures are similar for machines equipped

with AUTOTRAC assisted steering.
1. Attach support (A) to steering valve (C) with cap
–UN–20APR89
screws (B). Tighten cap screws.
2. Slide coupler (D) on valve shaft.
H40577
A—Support
C—Steering Valve
D—Coupler
OUO6083,0000AB1 –19–19JUL05–1/3
NOTE: Get help from a second service technician to align

valve shaft.
3. Align coupling and install valve.
4. With 2.5 mm clearance between couplings, tighten set 60
–UN–26MAY99
screw on lower coupler. 05
15
H57590
Continued on next page OUO6083,0000AB1 –19–19JUL05–2/3

083006
PN=639
Steering
5. Install steering valve (F) to cab floor using cap screws

(E).
6. Connect oil lines (A—D).
7. Start engine and operate at slow idle for 3 minutes

without using any hydraulic functions or steering.
–UN–19JUL05
8. Build pressure intermittently for 3 minutes by turning
steering wheel.
H84015
9. Increase engine speed to fast idle and build pressure
intermittently for 3 minutes. Shut off engine and
visually check the valve for leaks. Repair leaks as
necessary.
A—Oil Line-to-Steering Cylinder

B—Oil Line Return-to-Filter
C—Oil Line-to-Steering Cylinder
D—Oil Supply Line-From-Pump
F—Steering Valve
OUO6083,0000AB1 –19–19JUL05–3/3
60
05
16

083006
PN=640
Steering
60
05
17

083006
PN=641
Steering
Electro-Hydraulic Steering Valve and Flowmeter—Exploded View
C
B
T B
E
S
F
60 R
05
18
G
H
B
G A
G
I
Q
J
P
O
K
–UN–11MAY04
B L
N
G
H80884
Continued on next page OUO6083,000079B –19–13MAY04–1/2

083006
PN=642
Steering
A—Hose F—Fitting K—O-Ring P—O-Ring

B—O-Ring G—O-Ring L—Plug Q—Fitting
C—Fitting H—Fitting M—Fitting R—Valve
D—Adapter I—Fitting N—O-Ring S—Cap Screw
E—Nut J— O-Ring O—Plug T—Washer
OUO6083,000079B –19–13MAY04–2/2
Remove and Install Flow Meter
1. Disconnect wire harness from connector (A).
2. Remove hydraulic fittings (B).
–UN–24MAR04
3. Remove cap screws (C) and flow meter. Repair or
H80493
A—Connector
B—Hydraulic Fitting (2 used)
OUO6083,0000711 –19–24MAR04–1/1
60
05
19

083006
PN=643
Steering
AUTOTRAC Assisted Steering Flowmeter—Exploded View
D
C
E
B
–UN–11MAY04
H
60
05 F
20
H80883
G
A—Solenoid Valve D—Sensor G—Socket Head Cap Screw (4 H—Socket Head Cap Screw (2
B—Relief Valve E—O-Ring used) used)
C—O-Ring (4 used) F—Washer (4 used)
OUO6083,0000787 –19–11MAY04–1/1

083006
PN=644
Steering
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
–UN–12MAY04
27 60
05
21
28 27
30
H80889
29
1—Cap 11—Snap Ring 21—Universal Joint with Shaft 29—Splined Coupling

2—O-Ring 12—Rod 22—Cap Screw (2 used) 30—Set Screw
3—Cap Screw 13—Snap Ring (2 used) 23—Flange Nut (2 used) 31—Shaft Key
4—Knob 14—Ball Bearing (2 used) 24—Bearing 32—Spring Pin
5—Nut 15—Washer 25—Spring Pin 33—Steering Control Unit
6—Nut 16—Steering Wheel Shaft 26—Coupling 34—Cap Screw (4 used)
7—Steering Wheel 17—O-Ring 27—Clamp Bolt and Special 35—Lock Washer (4 used)
8—Snap Ring 18—Steering Wheel Shaft Nut 36—Bracket
9—Switch 19—Washer 28—Isolator 37—Pillow Block
10—Connector 20—Housing
OUO6083,0000788 –19–12MAY04–1/1

083006
PN=645
Steering
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
–UN–09JUL01
screwdriver. Inspect O-ring and replace if
required.
H67658
2. Turn knob (A) counterclockwise to remove.
A—Knob
B—Cap
OUO6083,000086D –19–28JUN04–1/9
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
60 mallet.
05
–UN–23APR01
22
A—Washer
B—Nut
H67659
OUO6083,000086D –19–28JUN04–2/9
A—Snap Ring
–UN–23APR01
H67660
Continued on next page OUO6083,000086D –19–28JUN04–3/9

083006
PN=646
Steering
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)
–UN–23APR01
H67661
OUO6083,000086D –19–28JUN04–4/9
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
60
05
23
–UN–24MAY99
H57381
OUO6083,000086D –19–28JUN04–5/9
9. Remove screws (A) from both sides of housing and

remove lower cover.
A—Screws (2 used per side)

–UN–24MAY99
H57395

083006
PN=647
Steering
10. Remove spring pin (A) and cap screws (B).
11. Remove clamp (C).
12. Remove telescoping shaft assembly.
–UN–24MAY99
A—Spring Pin
B—Cap Screw
C—Clamp
H57399
60
05
24

083006
PN=648
Steering
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.
–UN–24MAY99
17. Install lower coupling half and tighten set screw.
18. Install bearing and upper coupling half on U-joint with
H57405
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)
–UN–24MAY99
20. Tilt steering column to lowest position.
21. Slide upper coupling half down universal joint with 60
H57506
shaft until specified clearance is obtained between 05
jaws of upper coupling and hub of lower coupling. 25
Specification A—Bolt
Steering Column Couplings— B—Nuts
Clearance .............................................................................. 2.5 ± 0.5 mm C—U-Joint with Shaft
(0.100 ± 0.020 in.) D—Isolator
E—Set Screw
F—Coupling
22. Tighten nut on upper coupling clamp bolt to
specification.
Specification
Steering Column Upper Coupling
Clamp Bolt—Torque .............................................................. 28 ± 2.8 N•m
(21 ± 2 lb-ft)
NOTE: Be sure to route turn signal switch connector

between housing and telescoping shaft before
tightening telescoping shaft clamp.
23. Tighten steering wheel nut to specification and bend

up tabs on retaining washer.

083006
PN=649
Steering
Specification
Steering Wheel Nut—Torque ......................................................... 47 N•m
(35 lb-ft)
24. After assembly, be sure steering shaft turns freely.
25. Connect battery ground cable.
OUO6083,000086D –19–28JUN04–9/9
Replace Telescoping Shaft Bearings
1. Remove telescoping shaft assembly. (See

DISASSEMBLE STEERING COLUMN in this group.)
AG,OUO6022,1912 –19–25JUL00–1/4
A—Snap Ring
60
–UN–24MAY99
05
26
H57404
AG,OUO6022,1912 –19–25JUL00–2/4
3. Separate three sections of shaft and remove key (A),

spring washer (B) and bearing (C).
A—Key
B—Washer
C—Bearing
–UN–24MAY99
H57421

083006
PN=650
Steering
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.
–UN–24MAY99
7. Assemble and install telescoping shaft. (See
DISASSEMBLE AND ASSEMBLE STEERING
COLUMN in this group.)
H57425
A—Snap Ring
B—Bearing
C—Washer
AG,OUO6022,1912 –19–25JUL00–4/4
Remove and Install Steering Cylinder

60
–UN–23AUG88
05
all connections before applying pressure. 27
fluids.
X9811
1. Fully lower header and reel and continue to depress

switch for 5 seconds to relieve hydraulic system
pressure. Shut off engine and remove key.

083006
PN=651
Steering
2. Disconnect hoses (A) and remove fittings (B) from both

ends of steering cylinder.
A—Hose (2 used)
B—Fitting (2 used)
–UN–25JAN99
H51819
OUO6083,0000CB8 –19–09MAR06–2/8
3. Remove cotter pin (A) and nut (B).
4. Disconnect tie rod end (C) from steering spindle or

cam lobe motor (if equipped).
A—Cotter Pin
–UN–26JAN99
B—Nut
C—Tie Rod End
H51824
OUO6083,0000CB8 –19–09MAR06–3/8
60
05
28
IMPORTANT: Left- and right-hand tie rods must be
installed on same side of machine as
removed.
5. Identify tie rods.
6. Remove tie rod (A) from cylinder rod (B) on both ends
–UN–25JAN99
of steering cylinder.
A—Tie Rod
H51820
B—Steering Cylinder Rod

083006
PN=652
Steering
7. Pry up on rubber plug (A) to remove end of lock ring

from slot.
A—Plug
–UN–25JAN99
H51821
OUO6083,0000CB8 –19–09MAR06–5/8
8. Install JDG10292 adapter and JDG347 Spanner

Wrench (A). Turn cylinder to remove lock ring (B).
A—JDG347
B—Lock Ring
–UN–26JAN99
H51822
OUO6083,0000CB8 –19–09MAR06–6/8
60
05
29
9. Remove cylinder. Repair or replace cylinder as
necessary.
10. Install cylinder in axle housing.
–UN–26JAN99
H51823

083006
PN=653
Steering
NOTE: Cylinder ports must align with openings in axle

housing after lock ring is installed. Check for
proper alignment before installing lock ring.
11. Install end of lock ring through slot in axle and into
slot in cylinder. Rotate cylinder using JDG347
–UN–11MAY99
Spanner Wrench until lock ring is pulled completely
around groove. Push rubber plug on end of lock ring
into slot to seat.
H56022
A—JDG347
B—Lock Ring
OUO6083,0000CB8 –19–09MAR06–8/8
60
05
30

083006
PN=654
Steering
Disassemble And Assemble Steering Cylinder
A
F B
C
D
E
E I
D
C
J
B
A
G
60
H
05
G 31
–UN–03APR03
H75798
A—Seal (2 used) D—Back-Up Washer (2 used) G—Back-Up Washer (2 used) I—Lock Ring (2 used)
B—Seal (2 used) E—O-Ring (2 used) H—Seal J—Barrel
C—Rod Guide (2 used) F—Piston and Rod Assembly
Disassemble cylinder. Inspect parts and replace as

necessary. Install new O-rings, seals and lock rings.
OUO6083,0000519 –19–03APR03–1/1

083006
PN=655
Steering
Toe-In Adjustment
With steering wheels straight ahead, loosen nut on clamp

bolt (A) on both sides of steering cylinder. Turn both tie
rod joints (B) equally until front of wheels toe-in to
specification.
–UN–11MAY99
Specification
Front of Steering Wheels—Toe-in................................................... 13 mm
(1/2 in.)
H56052
Tighten nuts on clamp bolts to specification.
Specification
Tie Rod Joint Clamp Bolt— A—Tie Rod Joint
Torque .................................................................................... 70 ± 18 N•m B—Tie Rod
(52 ± 13 lb-ft)
AG,OUO6022,1915 –19–25JUL00–1/1
Remove and Install Steering Tie Rod Joint
1. Disconnect joint from cylinder rod using wrench flat (A)

to hold cylinder rod, and turning joint at wrench flat (B).
60
A—Wrench Flat, Cylinder Rod
–UN–11MAY99
05
B—Wrench Flat, Joint
32
H57044
OUO6083,00007B8 –19–18MAY04–1/2
2. Loosen clamp bolt (A).
3. Remove joint by turning at wrench flat (B).
4. Install joint, check toe-in, (See TOE-IN ADJUSTMENT

in this group) and tighten clamp bolt to specification.
–UN–11MAY99
Specification
Tie Rod Joint Clamp Bolt—
Torque .................................................................................... 70 ± 18 N•m
(52 ± 13 lb-ft)
H57045
A—Clamp Bolt
B—Wrench Flat, Joint
OUO6083,00007B8 –19–18MAY04–2/2

083006
PN=656
Steering
Remove And Install Tie Rod End
1. Remove cotter pin and nut (A).
2. Separate tie rod end from steering spindle assembly.
–UN–06OCT04
3. Remove lock nuts, spacers and cap screws (B) to
remove tie rod end.
4. Install tie rod end, spacers cap screws and lock nuts.
H81794
5. Position tie rod end to steering spindle assembly and
install nut. Tighten to specification and install cotter pin.
Tighten nut to next slot, if necessary, to install cotter A—Nut
B—Cap Screw
pin.
Specification
Steering Tie Rod End Nut—
Torque .......................................................................................... 200 N•m
(150 lb-ft)
6. Check toe-in (See TOE-IN ADJUSTMENT in this

group).
OUO6083,00009C5 –19–25APR05–1/1
60
05
33

083006
PN=657
Steering
Remove and Install Rear Spindle Assembly—

Non-Powered
1. Apply parking brakes.
2. Raise rear axle and position support stand.
–UN–11MAY99
3. Remove rear wheel. (See procedure in Section 50,
Group 25.)
H57004
4. Remove cotter pin and nut (A) to disconnect tie rod.
5. Attach a safe lifting device to spindle assembly.
Specification
Rear Spindle Assembly—
Approximate Weight .......................................................................... 80 kg
(176 lb)
6. Remove cap screws (B) from spindle assembly (C).
–UN–06OCT04
8. Position rear spindle assembly to axle.
H81795
9. Install five cap screws (B) and tighten to specification.
Remove lifting device. A—Nut
60 B—Cap Screw (5 used)
05 Specification C—Spindle Assembly
34 Rear Spindle-to-Axle Cap
Screws—Torque ........................................................................... 646 N•m
(475 lb-ft)
10. Position tie rod to spindle assembly and install nut

(A). Tighten nut to specification and install cotter pin.
Tighten nut to next slot, if necessary, to install cotter
pin.
Specification
Steering Tie Rod End Nut—
Torque .......................................................................................... 200 N•m
(150 lb-ft)
11. Install rear wheel. (See procedure in Section 50,

Group 25.)
12. Raise rear axle and remove support stand.
OUO6083,00009C6 –19–26APR05–1/1

083006
PN=658
Steering
60
05
35

083006
PN=659
Steering
Disassemble and Assemble Rear Spindle Assembly—Non-Powered
26
1
19
18
3
6
17
4
8
23 5
22 10
11
12
14 13
60 15
05 16 7
20 9
36
8
24
17
21
18
19
25
–UN–15MAR04
22
23
H80432
Continued on next page OUO6083,00007A4 –19–17MAY04–1/13

083006
PN=660
Steering
1—Shaft 9—Bearing Cone 17—Bushing (2 used) 22—Pin (2 used)

2—Seal 10—Bearing Cup 18—Seal (2 used) 23—Cap Screw (6 used)
3—Bearing Cup 11—Washer 19—Washer (2 used) 24—Washer (5 used)
4—Oil Cup 12—Lock Nut 20—Yoke; 9660 STS (S.N. 25—Dowel Pin (2 used)
5—Bearing Cone 13—Key 706391—), 9760 STS (S.N. 26—Yoke; 9660 STS (S.N. —
6—Lubrication Fitting 14—Retaining Ring 705898—), 9860 STS (S.N. 706390), 9760 STS (S.N. —
7—Housing 15—Plug 705798—) 705897), 9860 STS (S.N. —
8—Lubrication Fitting (2 used) 16—Snap Ring 21—Cap Screw (5 used) 705797)
1. Apply parking brakes. 4. Remove rear wheel. (See procedure in Section 50,
Group 25.)
2. Raise rear axle and position support stand.
3. Disconnect tie rod end from spindle assembly. (See

REMOVE AND INSTALL TIE ROD END in this
group.)
OUO6083,00007A4 –19–17MAY04–2/13
5. Remove snap ring (A) using JDG114 Snap Ring Pliers.
NOTE: Reassembly will require a new plug (B). Install

new bearing cups in spindle housing if bearing
cones are replaced.
60
–UN–06MAY04
6. Remove plug (B) by punching a hole in center and 05
37
prying out with pry bar.
A—Snap Ring
H80854
B—Plug

083006
PN=661
Steering
7. Remove retaining ring (C), key (B), nut (A), spindle and
inner bearing.
8. Clean and inspect all parts. Replace as necessary.
A—Nut
–UN–26MAR03
B—Key
C—Retaining Ring
H75788
Spindle Nut
60
05
38

083006
PN=662
Steering
9. Install JDG1301-1 Threaded Adapter (A) from

JDG1301 Spindle Repair Kit on spindle (B).
10. Remove seal (C) and bearing cone (D) from spindle
(B) using D01047AA 17-1/2 and 30 Ton Puller Set.
–UN–19APR99
A—Adapter
B—Spindle
C—Seal
D—Bearing Cone
E—17-1/2 and 30 Ton Puller
H55547
60
05
39
–UN–19APR99
H55548

083006
PN=663
Steering
11. Install seal (A) and bearing (B) using bearing installer
(C) and JDG1301-1 Threaded Adapter (D) from
JDG1301 Spindle Repair Kit and 17-1/2 and 30 ton
puller set (D).
A—Seal
B—Bearing Cone
C—Bearing Installer
D—Adapter
E—17-1/2 and 30 Ton Puller Set
–UN–19APR99
H55549
OUO6083,00007A4 –19–17MAY04–6/13
60
05
40
12. Remove cap screws (A) and pins (B) to remove
housing (C) and washers (D) from yoke (E). Inspect
grease seals and bushings and replace as necessary.

B—Pin (2 used)
–UN–17MAR99
C—Housing
D—Washer
E—Yoke
H54791

083006
PN=664
Steering
13. Remove seal (A) by prying up with a screwdriver.
14. Inspect bushing for wear.
15. Remove bushing from bore by peeling the bushing

starting at seam (B).
–UN–23MAR99
A—Seal
B—Bushing Seam
H54871
–UN–23MAR99
H54872
OUO6083,00007A4 –19–17MAY04–8/13
60
05
41
16. Install bushing (A) using 2-1/2 in. disk from
D01044AA Bushing, Bearing and Seal Driver Set.
17. Install seal (B) using 2-9/16 in. disk from D01044AA
Bushing, Bearing and Seal Driver Set.
–UN–23MAR99
A—Bushing
B—Seal
H54873
–UN–23MAR99
H54874

083006
PN=665
Steering
NOTE: Remove lubrication fittings from housing and coat

bushings and pins with Multi-purpose SD Polyurea
Grease prior to installation of pins (B). This will
allow air to escape as pins are installed. Replace
lubrication fittings after pins are installed.
–UN–17MAR99
18. Install housing (C), washers (D) and pins (B) on yoke
(E). Install cap screws (A) and tighten to
specification.
H54791
Specification
Spindle Pin-to-Yoke Cap
Screws—Torque ..................................................................... 70 ± 18 N•m
(52 ± 13 lb-ft)
B—Pin (2 used)
C—Housing
D—Washer
E—Yoke
OUO6083,00007A4 –19–17MAY04–10/13
19. Install spindle, inner bearing, washer and nut (A).

Tighten nut to specification.
Specification
Rear Spindle Nut—Torque .................... 100 N•m ± 25 N•m; then back off
10°
60
(74 lb-ft ± 18 lb-ft; then back off
–UN–26MAR03
05
10°)
42
20. Rotate spindle one revolution and retighten nut (A) to

specification. Loosen nut (A) 10°.
H75788
21. If key (B) cannot be installed, loosen nut until first set
of slots align with slots in shaft. Install key (B) and Spindle Nut
retaining ring (C). A—Nut
B—Key
C—Retaining Ring
OUO6083,00007A4 –19–17MAY04–11/13
22. Install new plug (B) using an appropriate driver. Install

snap ring (A) using JDG114 snap ring pliers.
A—Snap Ring
B—Plug
–UN–06MAY04
H80854

083006
PN=666
Steering
23. Lubricate fitting (A) using 840 cc of Multi-purpose SD

Polyurea Grease or until grease is visible at wiper
seal interface (B).
24. Lubricate fittings (C) using Multi-Purpose SD Polyurea

Grease until pressure builds up. Grease should be
–UN–23MAR99
visible at washer interface (D) after 2—5 minutes.
25. Install tie rod end to spindle assembly. (See

REMOVE AND INSTALL TIE ROD END in this
H54875
group.)
26. Install rear wheel. (See procedure in Section 50,

Group 25.)
27. Raise axle and remove support stand.
A—Lubrication Fitting
B—Wiper Seal Interface
–UN–06MAY04
C—Lubrication Fittings
D—Washer Interface
H80856
OUO6083,00007A4 –19–17MAY04–13/13
60
05
43

083006
PN=667
Steering
Remove and Install Rear Axle Pivot Bushings
D
H
F E O
G
I
B
G L
E
C J
P
–UN–20DEC04
M
N
K
G
H82195
60
05
44
A—Cap Screw (4 used) G—Bushing (3 used) M—Washer (5 used) P—Extension; 9660 STS (S.N.
B—Washer (4 used) H—Plate N—Cap Screw (5 used) 706391—), 9760 STS (S.N.
C—Nut (4 used) I—Axle O—Extension; 9660 STS 705898—), 9860 STS (S.N.
D—Cap Screw J—Nut (S.N. —706390), 9760 STS 705798—)
E—Washer (2 used) K—Plate (S.N. —705897), 9860 STS
F—Bracket (2 used) L—Nut (5 used) (S.N. —705797)
1. Apply parking brake.
2. Raise rear axle and position support stands under

chassis.
OUO6083,00009CC –19–26APR05–1/7
3. Remove four cap screws and spacers (A) from plate

(B).
A—Cap Screws with Spacers (4 used)

B—Plate
–UN–23MAY01
H68260
Continued on next page OUO6083,00009CC –19–26APR05–2/7

083006
PN=668
Steering
4. Remove four cap screws (A) from brackets (B).
5. Move axle back to access front bushing.

B—Brackets (2 used)
–UN–23MAY01
H68261
OUO6083,00009CC –19–26APR05–3/7
6. Remove cap screw (A) from center of front and rear

brackets (B).
7. Remove and replace parts as necessary.
A—Cap Screw
–UN–23MAY01
H68262
OUO6083,00009CC –19–26APR05–4/7
60
05
45
8. Move axle back into position and install four cap
screws and spacers (A) in plate (B) and tighten to
specification.
Specification
Bushing Retaining Plate Cap
Screws—Torque ............................................................................. 35 N•m
–UN–23MAY01
(26 lb-ft)

B—Plate
H68260
Continued on next page OUO6083,00009CC –19–26APR05–5/7

083006
PN=669
Steering
9. Install cap screw (A) through center of brackets (B)

and tighten to specifications.
Specification
Bushing Bracket Center Cap
Screw—Torque ............................................................................. 207 N•m
(153 lb-ft)
–UN–23MAY01
A—Cap Screw
B—Bracket (2 used)
H68262
OUO6083,00009CC –19–26APR05–6/7
10. Attach brackets (B) to chassis using four cap screws

(A) and tighten to specification.
Specification
Bushing Bracket to Chassis Cap
Screws—Torque ........................................................................... 207 N•m
(153 lb-ft)
–UN–23MAY01
11. Raise axle and remove support stand.
H68261
60
05
46
OUO6083,00009CC –19–26APR05–7/7

083006
PN=670
Steering
Rear Axle Adjustment
The axle is adjustable to let the rear tires track the drive
tires.
CAUTION: When changing axle widths, the rear
–UN–11JUN99
frame of combine must be raised and blocked
properly.
Jack up one end of the axle (A). Remove bolts (B) and tie
H57477
rod bolts (C).
If combine is equipped with 4-wheel drive, loosen hose

clamp (D) and hose tie strap (E). Pull enough hose
through clamp to be able to reposition axle. Tighten clamp
and tie strap after moving axle.
To prevent hose failure, be certain there is adequate hose

length for maximum wheel pivot and axle oscillation.
–UN–11JUN99
Refer to the charts in the combine operators manual for
correct positions and axle widths. Tie rod holes will go in
or out the same amount of holes and align correctly.
H57478
A drift may be needed to align axle holes and start bolts
(B).
60
Torque cap screws (B and C) to specification. 05
47
Specification
Axle Cap Screws (B)—Torque ...................................................... 620 n•m
(460 lb-ft)
Tie Rod Cap Screws (C)—Torque ............................................... 130 N•m
–UN–13JUL00
(95 lb-ft)
Repeat steps on other side. H64190
Retorque first side to specification; then retorque second

side to specification.
A—Axle
IMPORTANT: This sequence must be followed B—Bolts
because of “relaxing” of the bolts C—Tie Rod Bolts
D—Hose Clamp
tension.
E—Hose Tie Strap
OUO6083,0000312 –19–14AUG02–1/1

083006
PN=671
Steering
60
05
48

083006
PN=672
Group 10
Brakes

OUO6083,0000656 –19–19JUN03–1/2
Brake Shoe Adjustment Tool . . . . . . . . . . . . . . JDG699
–UN–17JUN03
Used to set service brake shoe clearance.
H77905
OUO6083,0000656 –19–19JUN03–2/2
60
10
1
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium Locks and seals while preventing
TY9473 (Canadian) Strength) parts loosening due to vibration.

applications.
SAE J1703D or DOT 3 (U.S.) Hydraulic Brake Fluid Used to service brakes.
AG,OUO6022,1921 –19–25JUL00–1/1

083006
PN=673
Brakes
Specifications
Shoe Lining Minimum Thickness 0.8 mm above rivets at thinnest

point.
(0.031 in.) above rivets at thinnest
point.
Brake Drum Maximum Turn Down 1.52 mm from diameter or 0.76 mm

on each side.
(0.060 in.) from diameter or (0.030
in.) on each side.
Maximum Out of Round 0.15 mm
(0.006 in.)
Brake Drum Maximum Scoring 0.25 mm

(0.010 in.)
Brake Drum Maximum Bellmouth 0.25 mm

(0.010 in.)
Brake Drum Maximum Surface Variance 0.13 mm

(0.005 in.)
Brake Anchor Bolt Torque 45 N•m

(33 lb-ft)
60
10
2 Brake Backing Plate-to-Transmission Torque 620 N•m
Bolts (460 lb-ft)
Master Cylinder-to-Piston (New) Maximum Bore Clearance 0.15 mm

(0.006 in.)
Master and Slave Cylinder Bleed Torque 7.3—9.0 N•m

Screws (65—80 lb-in.)
Slave Cylinder-to-Backing Plate Cap Torque 27 N•m

Screws (20 lb-ft)
Slave Cylinder-to-Piston (New) Maximum Bore Clearance 0.15 mm

(0.006 in.)
Service Brake Shoe-to-Drum Clearance 0.76 mm less than brake drum

(0.030 in.less than brake drum)
OUO6083,0000651 –19–17JUN03–1/1

083006
PN=674
Brakes
Deglazing Brake Linings
When a loss of braking power is noticed, or when the park

brake will not hold, deglaze the brake linings as follows:
1. Lock pedals together, start engine and put
–UN–17MAR06
transmission in first gear.
2. Drive combine forward at fast idle and at full hydro

lever travel.
H85537
3. Apply brakes firmly for 60 to 75 m (200 to 250 ft).
Engine speed should drop about 200 rpm.
4. Bring combine to a stop, shut off engine and allow

brakes to cool for 15 minutes.
5. After brakes have cooled, start engine and drive

combine forward, in first gear, repeatedly applying the
brakes to actuate the automatic adjusters.
6. From a stop, the foot brakes should hold the combine

in first gear. The park brake should hold the combine
in third gear.
If, after deglazing the brake linings, the brakes still do not
work properly, further service work is required.
60
10
3
OUO6083,0000CC0 –19–17MAR06–1/1
Remove Brake Drum

stop.
Engine must be off and key removed.

–UN–17MAR06
1. Lift safety stop (A) off latch and lower it down onto
cylinder rod.
H85538
A—Safety Stop
Continued on next page OUO6083,0000CC1 –19–17MAR06–1/2

083006
PN=675
Brakes
2. Remove snap ring (F) to slide coupling (E) from sleeve

(C).
3. Remove pin (B) from sleeve (C). (Repeat at other end

of drive shaft).
–UN–06SEP89
4. Remove drive shaft (D) from brake drum (A).
5. Remove brake drum.
H40510
6. Pry plug out of inspection hole in backing plate.
Disconnect parking brake cable at equalizer bar.
Disconnect brake line. Remove five cap screws that
secure brake assembly to transmission. Lower
assembly to the ground.
A—Brake Drum
B—Pin
C—Sleeve
D—Drive Shaft
E—Coupling
F—Snap Ring
OUO6083,0000CC1 –19–17MAR06–2/2
60
10
4

083006
PN=676
Brakes
Remove Brake Shoe
1. Remove brake drum. (See procedure in this group.)
IMPORTANT: Keep hands clean when handling brake

shoes. Do not permit oil or grease to
come in contact with linings.
NOTE: Only remove anchor bolt (D) if it is necessary to

repair park brake mechanism.
2. Remove spring (O) and pawl (N).
3. Remove springs (Q) and (R).
4. Remove screws (H) and retainer (G) to remove brake

shoes (A).
–UN–15FEB99
A—Brake Shoe (2 used)
B—Cable
C—Cam
H53035
D—Anchor Bolt
E—Park Brake Lever
F—Slave Cylinder
G—Retainer (2 used)
H—Screw (2 used)
I—Washer (5 used)
J—Cap Screw (5 used)
K—Cable 60
L—Pivot Wheel 10
M—Adjuster Bolt 5
N—Pawl
O—Spring
P—Spring
Q—Spring
R—Spring
OUO6083,00009C4 –19–25APR05–1/1

083006
PN=677
Brakes
Repair Brakes
60
10
6
–UN–02MAR99
H53038

083006
PN=678
Brakes
1—Snap Ring 10—Screw (2 used) 19—Pivot Wheel 26—Guide (2 used)

2—Washer 11—Spring 20—Adjusting Bolt 27—Backing Plate
3—Cam 12—Cover 21—Drum (2 used) 28—Dust Seal
4—Park Brake Lever 13—Pin 22—Snap Ring (2 used) 29—Cable (To Pedal)
5—Spring 14—Cable 23—Shoes 30—Fluid Line
6—Anchor Bolt 15—Guide 24—Brake/Transmission Cap 31—Screw (6 used)
7—Park Brake Kit 16—Spring Screw, M20 x 50 (5 used) 32—Washer (6 used)
8—Spring 17—Pawl 25—Washer, 13/16 x 1 1/2 in.
9—Retainer (2 used) 18—Adjuster Kit (5 used)
1. Clean backing plate (27). Be sure shoe support 6. Brake shoes (23) must not be distorted, cracked or
points are smooth and free of rough edges. have broken welds.
2. Attach dust seal (28) to backing plate (27) with 7. Check slave cylinder by pulling back edge of dust
screws (31) and washers (32). boot. There should be no brake fluid inside the
boot. If inside of boot is wet, repair cylinder as
3. Clean pivot wheel (19) threads and check for thread described in this group.
damage. The adjusting bolt (20) must turn freely on
the screw. 8. Each brake drum (21) that does not meet turn down
specifications must be replaced.
4. Check springs (5), (8), (11) and (16) and other
parts for loss of tension and damage. Replace Specification
Brake Drum—Maximum Turn
weak springs and any damaged or worn parts.
Down .................................................. 1.52 mm from diameter or 0.76
mm on each side.
5. Shoe linings must not be glazed, soiled with grease (0.060 in.) from diameter or
or brake fluid or otherwise damaged. Insure that (0.030 in.) on each side.
linings are within specification. Maximum Out of Round ........................................................ 0.15 mm
(0.006 in.)
Specification 60
Shoe Lining—Minimum 10
Thickness .......................................... 0.8 mm above rivets at thinnest 7
point.
(0.031 in.) above rivets at
thinnest point.

083006
PN=679
Brakes
9. Re-bore or replace brake drum if the contact surface

has scoring (A) deeper than specification. The best
method of checking scoring depth is to mount the
brake drum on a lathe.
Specification
–UN–15NOV02
Brake Drum—Maximum Scoring .................................................. 0.25 mm
(0.010 in.)
10. Re-bore or replace brake drum if the inside diameter

of the drum at the open end exceeds the inside
H74246
diameter at the closed end by more than the specified
limit (B). Measure diameters with a micrometer.
A—Scored Drum
Specification B—Bellmouthed Drum
Brake Drum—Maximum
Bellmouth ...................................................................................... 0.25 mm
(0.010 in.)
OUO6083,00009C3 –19–25APR05–3/5
60
10
8
11. Re-bore or replace the drum if the surface variance
exceeds specification. Measure this with a
straightedge and narrow feeler gauge.
Specification
Brake Drum—Maximum Surface
Variance........................................................................................ 0.13 mm
–UN–15NOV02
(0.005 in.)
A—Convex Drum
B—Concave Drum H74247

083006
PN=680
Brakes
12. Re-bore or replace the drum if hard or chill spots (A)

cause noticeable effects of pedal pulsations or brake
roughness. B
A
13. Re-bore or replace the drum if heat checks (B) are

plainly visible or can be felt with a fingernail.
–UN–02AUG05
A—Hard or Chill Spots
B—Heat Checks
H74248
OUO6083,00009C3 –19–25APR05–5/5
60
10
9

083006
PN=681
Brakes
Assemble Brakes
1. Apply a small amount of Multi-Purpose SD Polyurea

Grease to cam mechanism (C) behind the anchor bolt
(D). Be certain parts work freely, but do not
over-lubricate. Also apply a small amount of this
grease to the dimples on the backing plate on which
the brake shoes (A) ride.
2. Install parts (A—R).
3. Tighten anchor bolt (D) to specification.
Specification
Brake Anchor Bolt—Torque ........................................................... 45 N•m
(33 lb-ft)
4. Tighten bolts (J) to specification.
–UN–15FEB99
Specification
Brake Backing
Plate-to-Transmission Bolts—
H53035
Torque .......................................................................................... 620 N•m
(460 lb-ft)
5. Install brake drum. A—Brake Shoe (2 used)

B—Cable
6. Check brake shoe-to-drum clearance by rotating brake C—Cam
60 drums back-and-forth. D—Anchor Bolt
10 E—Park Brake Lever
10 F—Slave Cylinder
A slight drag should be felt. G—Retainer (2 used)
H—Screw (2 used)
If no drag or excess drag is felt, remove brake drum. I—Washer (5 used)
J—Bolt (5 used)
K—Cable
7. Using JDG699 Brake Shoe Adjustment Tool, check
L—Pivot Wheel
shoe-to-drum clearance. M—Adjuster Bolt
N—Pawl
8. Compare to brake shoe OD and adjust accordingly O—Spring
using star adjusting wheel. Set brake shoes to P—Spring
Q—Spring
specification.
R—Spring
Specification
Service Brake Shoe-to-Drum—
Clearance .................................................. 0.76 mm less than brake drum
(0.030 in.less than brake drum)
OUO6083,0000870 –19–28JUN04–1/1

083006
PN=682
Brakes
Install Brake Drum
Install parts (A—F).
A—Brake Drum
B—Pin
–UN–06SEP89
C—Sleeve
D—Drive Shaft
E—Coupling
F—Snap Ring
H40510
AG,OUO6022,1931 –19–25JUL00–1/1
Remove and Install Master Cylinder
1. Clean all around master cylinder (A).
2. Disconnect and cap lines going to cylinder.
3. Disconnect yokes (B).
4. Remove cap screws (C) to remove cylinder.
–UN–04APR00
5. Make repairs as necessary.
6. Install master cylinder using cap screws (C). 60
H63398
10
7. Connect yokes (B). 11
8. Connect lines to cylinder. A—Master Cylinder

B—Yokes
9. Bleed brake system. (See procedure in this group.)
AG,OUO6022,1932 –19–25JUL00–1/1

083006
PN=683
Brakes
Disassemble and Assemble Master Cylinder (Double Bleed Screw)
60
10
12
–UN–03MAY00
H63638
1—Connector 9—Housing 16—Plug (2 used) 23—Piston (2 used)

2—O-Ring (2 used) 10—Spring (2 used) 17—Screw (2 used) 24—Quad Seal (2 used)
3—Valve (2 used) 11—O-Ring (2 used) 18—Retainer (2 used) 25—Piston (2 used)
4—Spring (2 used) 12—Bearing (2 used) 19—Spring (2 used) 26—Bleed Screw (2 used)
5—Ball (2 used) 13—Poppet (2 used) 20—Retainer (2 used) 27—Quad Ring Seal (2 used)
6—Valve Seat (2 used) 14—Spring (2 used) 21—Oil Cup (2 used) 28—Boot (2 used)
7—Seal (2 used) 15—O-Ring (2 used) 22—Retainer (2 used) 29—Retainer (2 used)
8—Complete Valve (2 used)
Continued on next page OUO6083,00005F9 –19–26FEB04–1/2

083006
PN=684
Brakes
1. Wash all parts in clean denatured alcohol. Do not IMPORTANT: Honing of the cylinder wall is not
use kerosene, gasoline or petroleum base cleaners. recommended. If the condition of the
Allow to air dry before coating and assembly. wall would indicate honing, replace
the cylinder.
NOTE: Before cleaning internal parts, wash hands
with soap and water. Hands must be clean. Do 3. Install repair kits as needed. Swollen or damaged
not use gasoline or petroleum base fluids to rubber parts can indicate that the wrong brake fluid
clean hands. is in the system. If this is the case, drain all fluid,
refill and bleed system.
2. Clean cylinder bore and inspect for corrosion,
scratches and burrs. Check clearance between new 4. Coat parts with clean brake fluid when assembling
piston and cylinder bore with feeler gauge. If cylinder. Be careful not to cut or tear rubber parts.
clearance exceeds specification the cylinder must
be replaced. 5. Add fluid and bleed cylinder. (See procedure in this
group.)
Specification
Master Cylinder-to-Piston
(New)—Maximum Bore
Clearance.............................................................................. 0.15 mm
(0.006 in.)
OUO6083,00005F9 –19–26FEB04–2/2
60
10
13
Brake Fluid Reservoir
Check fluid through cap (A). Be careful to keep dirt out of

system.
Fluid should be 6 mm (1/4 in.) from top.
–UN–08MAY03
Use SAE J1703D or DOT-3 hydraulic brake fluid.
Keep fluid off painted surfaces.
A—Cap H76824
OUO6083,000058A –19–08MAY03–1/1

083006
PN=685
Brakes
Adjusting Master Cylinder
Follow this procedure only if parts in the brake system

have been replaced or if excessive free play between the
pedal and the master cylinder is noticed.
Loosen nut (A). Slide boot (B) off master cylinder and
onto push-rod (C) to expose inside of cylinder.
IMPORTANT: Outer edge of piston must be touching
–UN–04APR00
snap ring in the cylinder. Clean all dirt
from between cylinder and snap ring.
Screw push-rod (C) in or out of yoke (D) until push-rod
H63399
just contacts piston in the cylinder (E), then turn push-rod
1/4 turn away from piston.
IMPORTANT: Use your fingers to adjust each A—Lock Nut

push-rod. Do not move piston away B—Rubber Boot
C—Push Rod
from snap ring. D—Yoke
E—Master Cylinder
Hold push-rod carefully in place when tightening lock nut
(A). Slide rubber boot back on cylinder.
Repeat for the other cylinder.
60
10
14
AG,OUO6022,1935 –19–25JUL00–1/1

083006
PN=686
Brakes
Bleeding Brake System—Double Bleed

Screw
CAUTION: Park combine on a flat, level surface

and place blocks in front of and behind drive
tires.
1. Disengage park brake.
2. Remove drive shafts. (See procedure in Section 50,

Group 05, Remove Transmission.)
3. Check brake shoe-to-drum clearance by rotating brake

drums. If slight drag is felt, proceed to brake bleeding
procedure.
4. If no drag, or excess drag is felt, remove brake drums.
5. Check brake shoe to drum clearance using JDG699

brake setting gauge.
6. Compare to brake shoe OD and adjust as needed

using adjusting wheel. Set brake shoes to specification.
If brakes are too tight, hold self-adjusting arm off
adjusting wheel, and back off adjusting wheel.
Specification 60
Service Brake Shoe-to-Drum— 10
Clearance .................................................. 0.76 mm less than brake drum 15
(0.030 in. less than brake drum)
7. Install brake drums and proceed to brake bleeding.
NOTE: Two persons are required to bleed brakes, one to

pump brakes and fill reservoir, and the other to
bleed the brakes.
Use only clean TY15975 or DOT 3 brake fluid.
Keep brake fluid off painted surfaces.
8. Check brake system for leaks and loose fittings. Brake

system must be free of leaks and all connections must
be tight. Check bleed screws on master and slave
cylinders and make sure they are tight.
Continued on next page OUO6083,00003C0 –19–09SEP05–1/6

083006
PN=687
Brakes
9. Check fluid in brake reservoir and fill as needed during

bleeding. Loosen, but do not remove reservoir cap to
avoid creating a vacuum during bleeding. Prevent dirt
from entering reservoir.
OUO6083,00003C0 –19–09SEP05–2/6
10. Install a piece of clean 5 mm (3/16 in.) ID clear plastic

tubing, approximately 915 mm (36 in.) long, to
right-hand master cylinder bleed screw (A). Route
hose up so bleed screw is at lowest point and place
hose end in a suitable container.
11. Loosen right-hand master cylinder bleed screw 1/4

turn.
–UN–04APR00
12. Add brake fluid to remote reservoir and watch fluid
flow through plastic tubing until there is a clear flow of
fluid with no air bubbles.
H63400
13. Close right-hand master cylinder bleed screw.
14. Lock brake pedals together.

A—Bleed Screw
15. With clear tubing still installed, loosen right-hand
master cylinder bleed screw 1/4 turn.
60
10 16. Slowly depress both brake pedals to floor, tighten
16 bleed screw and slowly release pedals. Repeat until
there is a clear flow of fluid with no air bubbles.
17. Close right-hand master cylinder bleed screw.

083006
PN=688
Brakes
18. Install tubing on left-hand slave cylinder bleed screw

(B). Route hose up so bleed screw is at lowest point
and place hose end in suitable container.
19. Loosen left-hand slave cylinder bleed screw 1/4 turn.
–UN–16FEB99
20. With pedals still locked together, slowly depress to
floor, tighten bleed screw, and slowly release pedals.
Repeat until there is a clear flow of fluid with no air
bubbles.
H53024
NOTE: If system is partially filled before bleed procedure
was started, a steady, clear flow of fluid may
appear for several initial strokes. If air is located in A—Right-Hand Slave Cylinder Bleed Screw
or near master cylinder, it will take several strokes B—Left-Hand Slave Cylinder Bleed Screw
to move air through lines and out bleed screw.
21. Close left-hand slave cylinder bleed screw.
22. Unlock brake pedals.
23. Install tubing on right-hand slave cylinder bleed screw

(A). Route hose up so bleed screw is at lowest point
and place hose end in a suitable container.
24. Slowly depress right-hand brake pedals to floor,

tighten bleed screw and slowly release brake pedal.
60
Repeat until there is clear flow of fluid with no air 10
bubbles. 17
25. Close right-hand slave cylinder bleed screw.
26. Lock brake pedals together.

083006
PN=689
Brakes
27. Install tubing to left-hand master cylinder bleed screw

(A). Route hose up so bleed screw is at lowest point
and place hose end in a suitable container.
28. Loosen left-hand master cylinder bleed screw 1/4

turn.
–UN–27OCT04
29. With brake pedals locked together, slowly depress to
floor, tighten bleed screw and slowly release pedals.
Repeat until there is a clear flow of fluid with no air
H81910
bubbles.
30. Tighten left-hand master cylinder bleed screw.

A—Bleed Screw, Left-Hand
31. Fill brake fluid reservoir to proper level and tighten
cap.
32. Unlock brake pedals.

60
10
18

083006
PN=690
Brakes
33. Install tubing on right-hand master cylinder bleed

screw (A). Route hose up so bleed screw is at lowest
point and place hose end in a suitable container.
34. Loosen right-hand master cylinder bleed screw 1/4

turn.
NOTE: By rapidly depressing pedal, an internal relief

valve is opened which allows that passage to be
–UN–04APR00
bled.
35. With a firm, rapid motion, depress right-hand brake

pedal to maximum possible stroke and hold
H63400
momentarily. Tighten bleed screw and slowly release
pedal. Repeat until no more air bubbles appear and
fluid flow stops.
A—Right-Hand Bleed Screw
36. With tubing still on right-hand master cylinder bleed
screw, loosen bleed screw 1/4 turn.
37. With a firm, rapid motion, depress left-hand brake

pedal to maximum possible stroke and hold
momentarily. Tighten bleed screw and slowly release
pedal. Repeat until no more air bubbles appear and
fluid flow stops.
38. Tighten all bleed screws to specification.

60
10
Specification 19
Master and Slave Cylinder Bleed
Screws—Torque .................................................................... 7.3—9.0 N•m
(65—80 lb-in.)
39. Check entire brake system for leaks and check each
pedal for firm, solid feel.
40. Check reservoir for proper fluid level.
41. Install drive shafts and engage park brake system.
42. Road test.
OUO6083,00003C0 –19–09SEP05–6/6

083006
PN=691
Brakes
Remove and Install Slave Cylinders
1. Remove brake drum. (See procedure in this group.)
2. Disconnect and cap line (D) to slave cylinder (A).
–UN–16FEB99
3. Remove five cap screws that secure brake assembly to
transmission. Lower assembly to the ground.
IMPORTANT: Keep hands clean when handling brake
H53062
shoes. Do not permit oil or grease to
come in contact with linings.
Heavy Duty Brake System Shown
4. Disassemble brakes. (See procedure in this group.)
A—Slave Cylinder
B—Bleed Screw
5. Remove cap screws (C) to remove slave cylinder. C—Cap Screw (2 used)
D—Brake Line
6. Inspect parts. Replace as necessary.
7. Install parts. Tighten cap screws (C) to specification.
Specification
Slave Cylinder-to-Backing Plate
(20 lb-ft)
8. Add fluid and bleed slave cylinders. (See procedure in

60 this group.)
10
20
AG,OUO6022,1937 –19–25JUL00–1/1

083006
PN=692
Brakes
Disassemble and Assemble Slave Cylinder
1. Disassemble parts (A—G) to disassemble cylinder.
2. Wash all parts in clean denatured alcohol. Do not use

kerosene, gasoline or petroleum base cleaners. Allow
–UN–06SEP89
to air dry before coating and reassembly.
NOTE: Before cleaning internal parts, wash hands with

soap and water. Hands must be clean. Do not use
H40513
gasoline or petroleum base fluids to clean hands.
3. Clean cylinder bore and inspect for corrosion,

scratches and burrs. Check clearance between new A—Link (2 used)
B—Boot (2 used)
piston and cylinder bore with a feeler gauge. If
C—Piston (2 used)
clearance exceeds specification the cylinder must be D—Boot (2 used)
replaced. E—Housing
F—Oil Cup (2 used)
Specification G—Spring
Slave Cylinder-to-Piston (New)—
Maximum Bore Clearance ............................................................ 0.15 mm
(0.006 in.)
IMPORTANT: Honing of the cylinder wall is not

recommended. If the condition of the
wall would indicate honing, replace the
cylinder.
60
4. Install repair kits as needed. Swollen or damaged 10
rubber parts can indicate that the wrong brake fluid is 21
in the system. If this is the case, drain all fluid, refill
and bleed system.
5. Coat parts with clean brake fluid when assembling

cylinder. Be careful not to cut or tear rubber parts.
AG,OUO6022,1938 –19–19OCT04–1/1

083006
PN=693
Brakes
Disassemble and Assemble Brake Pedals
–UN–12MAY00
H63415
60
10
22
A—Master Cylinder F—Cotter Pin (2 used) K—Isolator (2 used) P—Spring (2 used)
B—Support (2 used) G—Pin (2 used) L—Strap Q—Pad (2 used)
C—Cap Screw (4 used) H—Washer (2 used) M—Spring R—Shaft
D—Push Rod (2 used) I—Yoke (2 used) N—Spring Pin S—Shaft
E—Nut (2 used) J—Pedal (2 used) O—Bushing (4 used)
1. Lower feeder house to ground. 2. Shut off engine and remove key.
OUO6083,000058B –19–08MAY03–1/16
3. Pull floor mat (A) away from pedals.
A—Mat
–UN–15MAY01
H68013

083006
PN=694
Brakes
4. Remove screws (A) and floor plate (B).
A—Cap Screw
B—Plate
–UN–15MAY01
H68007
OUO6083,000058B –19–08MAY03–3/16
5. Loosen cap screws (A) and remove lower cab panel.
–UN–08MAY03
H76826
OUO6083,000058B –19–08MAY03–4/16
60
10
23
NOTE: It is not necessary to disconnect lines from master
cylinder to service brake pedals.
6. Remove cap screws (A) on both sides.
7. Loosen cap screw (B) on both sides.
–UN–04APR00
H63402
OUO6083,000058B –19–08MAY03–5/16
8. Disconnect springs (A) from pedals.
A—Springs
–UN–04APR00
H63406

083006
PN=695
Brakes
9. Remove cotter key, washer and pin (A).
A—Pin
–UN–04APR00
H63416
OUO6083,000058B –19–08MAY03–7/16
10. Remove cap screw (A) on both sides.
A—Cap Screw
–UN–04APR00
H63408
OUO6083,000058B –19–08MAY03–8/16
60
10
24
NOTE: It is not necessary to remove cap screws from
support on both sides to remove pedals.
11. Remove cap screws (A) from support.
–UN–04APR00
H63407

083006
PN=696
Brakes
12. Remove bushing (A) and pedal(s) (B) from shaft on

both sides.
13. Lift pedal(s) (B) through hole in cab floor to remove.
14. Inspect bushings, shaft and pedals. Replace as
–UN–13APR00
necessary.
15. Install pedal(s) through cab floor.
H63421
16. Install bushings and pedal(s) to shaft.
A—Bushing
B—Pedal
OUO6083,000058B –19–08MAY03–10/16
17. Install pedal assembly to holes in supports and install

cap screws (A).
60
10
–UN–04APR00
25
H63407
OUO6083,000058B –19–08MAY03–11/16
18. Install springs (A).
A—Springs
–UN–04APR00
H63406

083006
PN=697
Brakes
19. Install cap screws (A) and (B) on both sides.

–UN–04APR00
H63402
OUO6083,000058B –19–08MAY03–13/16
20. Install pin (A), washers and cotter pin through yoke
and pedal.
A—Pin (2 used)
–UN–04APR00
H63416
OUO6083,000058B –19–08MAY03–14/16
60
10
26
21. Install lower cab panel and tighten cap screws (A).
–UN–08MAY03
H76826
OUO6083,000058B –19–08MAY03–15/16
22. Install floor plate (B) with cap screws (A).
23. Install floor mat.
24. Adjust master cylinder push rods. (See ADJUST

MASTER CYLINDER in this group.)
–UN–15MAY01
A—Cap Screw
B—Plate
H68007
OUO6083,000058B –19–08MAY03–16/16

083006
PN=698
Brakes
60
10
27

083006
PN=699
Brakes
Disassemble and Assemble Parking Brake Pedal
60
10
28
–UN–12MAY00
H63732

083006
PN=700
Brakes
1—Isolator 10—Switch 19—Bolt 28—Link (2 used)

2—Arm 11—Screw (3 used) 20—Bolt 29—Link (2 used)
3—Spring Pin 12—Pin 21—Plate 30—Clevis
4—Spring Pin 13—Plate 22—Screw (2 used) 31—Spring
5—Frame 14—Washer 23—Pin 32—Bushing (2 used)
6—Bushing (2 used) 15—Spring 24—Cotter Pin (5 used) 33—Screw (5 used)
7—Pedal 16—Hook 25—Pin 34—Seal
8—Ratchet 17—Screw (2 used) 26—Pin (3 used) 35—Washer (2 used)
9—Pawl 18—Spring 27—Balancer (2 used) 36—Lock Nut (2 used)
1. Lower feeder house to ground. 2. Shut off engine and remove key.
OUO6083,000058C –19–08MAY03–2/17
3. Pull back floor mat (A).
A—Floor Mat
–UN–10JUN99
H57558
OUO6083,000058C –19–08MAY03–3/17
60
10
29
4. Remove screws (A) and loosen cap screw (B) to
remove floor plate.
A—Screws (2 used)
B—Cap Screw
–UN–07JUN99
H57987
OUO6083,000058C –19–08MAY03–4/17
5. Loosen cap screws (A) and remove lower cab panel.

–UN–08MAY03
H76826

083006
PN=701
Brakes
6. Disconnect wiring connector (A).
A—Connector
–UN–08JUN99
H57992
OUO6083,000058C –19–08MAY03–6/17
7. Remove cotter pin and pin (A) from pedal.
A—Pin
–UN–09JUN99
H58190
60
10
30

083006
PN=702
Brakes
–UN–07JUN99
H57800
60
A—Nuts (2 used) C—Spring Pin E—Cap Screw (2 used) G—Cap Screw (2 used) 10
B—Springs (2 used) D—Shoulder Bolt F—Shoulder Bolt 31
8. Loosen lock nuts (A) to relieve tension on 11. Remove shoulder bolts (D) and (F) from pawl.
balancers.
12. Remove cap screws from supports to cab floor.
9. Disconnect springs (B).
13. Remove cap screws (E) and (G) and supports.
10. Remove spring pin (C), hook and washer from
release lever.

083006
PN=703
Brakes
–UN–09JUN99
H58156
60
10 A—Spring B—Pedal C—Spring Pin D—Lever
32
14. Disconnect spring (A) from pedal and support. 16. Remove spring pin (C).
15. Remove pedal (B) from support and down through 17. Slide release lever (D) through support to remove.
cab floor. Replace worn or damaged parts as necessary.
OUO6083,000058C –19–08MAY03–9/17
18. Inspect bushing (A) on both sides, and ratchet (B).

Replace as necessary.
NOTE: If replacing bushings, apply a thin coat of light oil

on bushing prior to installation. This will aid
breaking in the bushing and provide for a longer
service life.
–UN–08JUN99
NOTE: If replacing ratchet, apply Thread Lock and

Sealer. This will prevent screws from loosening
H57988
during normal use and vibration.
A—Bushing (2 used)
B—Ratchet

083006
PN=704
Brakes
–UN–09JUN99
H58156
60
A—Spring B—Pedal C—Spring Pin D—Lever 10
33
19. Install brake release lever (D) and spring pin (C). 21. Install spring (A) to support and pedal.
20. Install pedal (B) up through cab floor and insert

pin into support.

083006
PN=705
Brakes
–UN–07JUN99
H57800
60
10 A—Nuts (2 used) C—Spring Pin E—Cap Screw (2 used) G—Cap Screw (2 used)
34 B—Springs (2 used) D—Shoulder Bolt F—Shoulder Bolt
22. Install supports and cap screws (E) and (G). 25. Install washer, hook and spring pin (C) to brake
release pedal.
23. Install cap screws through supports and into cab
floor. 26. Connect springs (B).
24. Install pawl and shoulder bolts (D) and (F).
OUO6083,000058C –19–08MAY03–12/17
27. Install pin (A) and cotter pin to pedal.
28. Adjust park brake cables. (See ADJUST PARK

BRAKE PEDAL in this group.)
A—Pin
–UN–09JUN99
H58190

083006
PN=706
Brakes
29. Connect wiring connector (A).
A—Connector
–UN–08JUN99
H57992
OUO6083,000058C –19–08MAY03–14/17
30. Install lower cab panel and tighten cap screws (A).
–UN–08MAY03
H76826
OUO6083,000058C –19–08MAY03–15/17
60
10
35
31. Install floor plate and screws (A).
32. Tighten cap screw (B).
A—Screw (2 used)
B—Cap Screw
–UN–07JUN99
H57987
OUO6083,000058C –19–08MAY03–16/17
33. Install floor mat (A).
A—Floor Mat
–UN–10JUN99
H57558
OUO6083,000058C –19–08MAY03–17/17

083006
PN=707
Brakes
Adjust Park Brake Pedal
1. Inspect park brake actuator mechanism under cab floor

for interference and wear.
2. Measure threaded cable ends (A) sticking out of
–UN–02JUN99
balancer bar (B). 17 mm (11/16 in.) to 19 mm (3/4 in.)
should be sticking out past balancer bar (B).
3. Push park brake pedal down and count number of
H57102
tooth clicks. Pedal should go to fifth click.
4. If pedal goes past fifth click, tighten cable nuts (A) 1

mm and test. A—Threaded Cable Ends
B—Balancer Bar
5. If pedal cannot reach fifth click, loosen cable nuts 1
mm and retest.
AG,OUO6022,1941 –19–25JUL00–1/1
60
10
36

083006
PN=708
Section 70
Hydraulic Repair
Contents
Page Page
Group 05—Hydraulic Reservoir Electro-Hydraulic Feeder House Reverser

Essential or Recommended Tools . . . . . . . . . . .70-05-1 Valve—Exploded View. . . . . . . . . . . . . . . . . .70-15-5
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .70-05-1 Remove Straw Spreader Flow Control Valve. . .70-15-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .70-05-2 Disassemble and Assemble Straw
Remove and Install Reservoir (S.N. — Spreader Flow Control Valve . . . . . . . . . . . . .70-15-7
715300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-05-2 Install Straw Spreader Flow Control Valve . . . .70-15-8
Remove and Install Reservoir (S.N. Remove Reel/Belt Speed Flow Control
715301—) . . . . . . . . . . . . . . . . . . . . . . . . . . .70-05-4 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-15-8
Flushing the Hydraulic System . . . . . . . . . . . . .70-05-7 Repair Reel/Belt Speed Flow Control Valve . . .70-15-9
Flushing the Reel/Belt Pickup Drive System . . .70-05-8 Install Reel/Belt Speed Flow Control Valve . . .70-15-10
Start-Up Procedure After Hydrostatic System Remove and Install Header Height Control
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-05-9 Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-15-11
Remove and Install Accumulator Shut-off
Group 10—Hydraulic Pumps Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-15-12
Essential or Recommended Tools . . . . . . . . . . .70-10-1 Feeder House Multi-Coupler Valve
Service Equipment and Tools . . . . . . . . . . . . . .70-10-1 Identification . . . . . . . . . . . . . . . . . . . . . . . .70-15-12
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-2 Disassemble, Inspect and Assemble Feeder
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-3 House Multi-Coupler . . . . . . . . . . . . . . . . . .70-15-13
Remove Triple Main Hydraulic Pump . . . . . . . .70-10-4
Marking Triple Main Hydraulic Pump . . . . . . . . .70-10-5 Group 16—Hydraulic Valve Stack (S.N. —715300)
Disassembling Triple Main Hydraulic Pump. . . .70-10-5 Service Equipment and Tools . . . . . . . . . . . . . .70-16-1
Replace Seal. . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .70-16-1
Triple Main Hydraulic Pump—Exploded Remove and Install Hydraulic Valve Stack . . . .70-16-2
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-8 Disassemble and Assemble Hydraulic 70
Assembling Triple Main Hydraulic Pump . . . . . .70-10-9 Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . .70-16-4
Install Triple Main Hydraulic Pump . . . . . . . . .70-10-10 Solenoid Control Relief Valve Module . . . . . . . .70-16-6
Reel/Belt Pickup and Straw Spreader Two-Way Reel Lift and Variable Speed
Pump—Exploded View . . . . . . . . . . . . . . . .70-10-11 Feeder House Valve Module . . . . . . . . . . . . .70-16-7
Remove and Install Reel/Belt Pickup Threshing Speed Valve Module. . . . . . . . . . . . .70-16-8
Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . .70-10-12 Auger Swing Valve Module . . . . . . . . . . . . . . . .70-16-9
Disassemble and Assemble Reel/Belt Pickup Reel Fore/Aft Valve Module . . . . . . . . . . . . . .70-16-10
Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . .70-10-15 CONTOUR MASTER (Header Tilt) Valve
Remove Straw Spreader Pump . . . . . . . . . . . .70-10-19 Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-16-11
Install Straw Spreader Pump. . . . . . . . . . . . . .70-10-20 Hydraulic Solenoid Control Valve Leakage
Disassemble Reel/Belt Pickup Straw Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-16-12
Spreader Pump . . . . . . . . . . . . . . . . . . . . . .70-10-21 Replacing Pilot Solenoid Assemblies. . . . . . . .70-16-15
Assemble Reel/Belt Pickup and Straw Replacing Pilot Sleeve O-Rings. . . . . . . . . . . .70-16-16
Spreader Pump . . . . . . . . . . . . . . . . . . . . . .70-10-23
Group 17—Hydraulic Valve Stack (S.N. 715301—)
Group 15—Hydraulic Valves Service Equipment and Tools . . . . . . . . . . . . . .70-17-1
Service Equipment and Tools . . . . . . . . . . . . . .70-15-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .70-17-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .70-15-1 Valve Stack Identification . . . . . . . . . . . . . . . . .70-17-3
Electro-Hydraulic Feeder House Reverser Remove and Install Hydraulic Valve Stack
Valve—General Information . . . . . . . . . . . . . .70-15-2 (HIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-17-4
Electro-Hydraulic Feeder House Reverser
Valve and Hoses—Exploded View . . . . . . . . .70-15-4 Continued on next page

083006
PN=1
Contents
Page
Disassemble and Assemble Hydraulic Valve

Stack (HIC) . . . . . . . . . . . . . . . . . . . . . . . . . .70-17-6
Group 20—Hydraulic Cylinders

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-1
Remove and Install Header Lift Cylinder . . . . . .70-20-1
Disassemble and Assemble Header Lift
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-2
Remove and Install Unloading Auger Swing
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-5
Unloading Auger Swing Cylinder Exploded
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-6
Adjust Unloading Auger Swing Cylinder . . . . . .70-20-7
Remove and Install Unloading Auger Drive
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-8
Group 25—Motors
Remove and Install Straw Spreader Motor . . . .70-25-1
Remove and Install Wide Spread
Tailboard Motors . . . . . . . . . . . . . . . . . . . . . .70-25-4
Group 30—Accumulator
Accumulator (General Information) . . . . . . . . . .70-30-1
Checking Header Float System Accumulator. . .70-30-2
Accumulator Precharge Pressure . . . . . . . . . . .70-30-3
70

083006
PN=2
Group 05
Hydraulic Reservoir
SERVICEGARD or European Microfiche Tool
Catalogs.
SERVICEGARD is a trademark of Deere & Company OUO6083,000008C –19–30MAY01–1/2
Portable Filter Caddy . . . . . . . . . . . . . . . . . . JT05746
Used to flush hydraulic/hydrostatic system.
–UN–17MAY95
RW25352
OUO6083,000008C –19–30MAY01–2/2
Other Material
Number Name Use

70
TY22000 (U.S.) HY-GARD Transmission and Used to fill hydraulic reservoir. 05
Hydraulic Oil 1
HY-GARD is a trademark of Deere & Company AG,OUO6022,1943 –19–25JUL00–1/1

083006
PN=711
Hydraulic Reservoir
Specifications

(36 qt)
Hydraulic Reservoir Approximate Weight 18 kg

(40 lb)
Hydraulic Reservoir Pressure Test Pressure 35 kPa

(0.34 bar)
(5 psi)
AG,OUO6022,1944 –19–25JUL00–1/1
Remove and Install Reservoir (S.N. —715300)

–UN–23AUG88
fluids.
X9811
70
05 If an accident occurs, see a doctor immediately.
2

2. Loosen reservoir cap.
Continued on next page OUO6083,0000AEF –19–17AUG05–1/3

083006
PN=712
Hydraulic Reservoir
3. Remove drain cap (A) to drain hydraulic oil. Discard oil.
Specification
(36 qt)
4. Install and tighten drain cap (A).
–UN–03MAY99
A—Cap
H55826
OUO6083,0000AEF –19–17AUG05–2/3
5. Remove parts (B—J). Cap lines and hoses.
6. Remove hydraulic reservoir (A).
Specification
Hydraulic Reservoir—
(40 lb)
NOTE: Leaking may be caused by cracks in sight lens. If

cracked, replace sight lens with retrofit lens
assembly AE41319. Install retrofit lens assembly
in reservoir using pipe sealant to avoid leakage.
7. Plug reservoir openings and pressure test at 35 kPa

(0.34 bar) (5 psi) while submerged in water. Repair
leaks by soldering.
Specification
70
Hydraulic Reservoir Pressure
05
Test—Pressure ................................................................................ 35 kPa
3
(0.34 bar)
–UN–20MAR89
(5 psi)
8. Install reservoir.
H40355
9. Install parts (B—J).
10. Fill reservoir with clean hydraulic oil. (See FUELS

A—Hydraulic Reservoir
AND LUBRICANTS in Section 10, Group 20 for
B—Reservoir Cap
recommended oil.) C—Cap Screw (4 used)
D—Temperature Sensor
Specification E—Oil Line-to-Hydraulic Filter
Hydraulic Reservoir—Capacity............................................................ 34 L F—Oil Line-to-Main Hydraulic Pump
(36 qt) G—Oil Line-from-Main Hydraulic Pump
H—Oil Line (Powered Rear Wheel Solenoid Valve
Return)
I—Oil Line-to-Oil Cooler
J—Filter Screen
OUO6083,0000AEF –19–17AUG05–3/3

083006
PN=713
Hydraulic Reservoir
Remove and Install Reservoir (S.N. 715301—)

–UN–23AUG88
fluids.
X9811

2. Loosen reservoir cap.
70
05
Continued on next page OUO6083,0000CA2 –19–06MAR06–1/4
4

083006
PN=714
Hydraulic Reservoir
3. Remove cap (A) to partially drain hydraulic oil.
Specification
(37 qt)
4. Remove plug (B), or if equipped, chaff spreader
–UN–14JUN05
suction hose, to drain remaining oil from reservoir.
Discard oil.
5. Install and tighten cap (A) and plug (B).
H83720
A—Cap
B—Plug
–UN–24AUG05
H84303
OUO6083,0000CA2 –19–06MAR06–2/4
6. Remove hoses (B—I). Cap lines and hoses.
B
A—Cap A
B—Hydraulic Reservoir 70
C—Main Cooler Return 05
D—Main Hydraulic Return 5
E—Chaff Spreader Return
F—Feeder House Reverser Valve Return
G—Chaff Spreader Suction
H—Propulsion Suction
I—Main Hydraulic Suction
J—Fluid Level Sight Glass
K—Mounting Flange K
C
J
D
E
–UN–20JUL05
G
I F
H
H83712

083006
PN=715
Hydraulic Reservoir
7. Remove cap screws (A). Remove hydraulic reservoir.
Specification
(45 lb)
NOTE: Leaking may be caused by cracks in indicator

lens. Replace as needed.
8. Plug reservoir openings and pressure test at 27.5 kPa

(0.27 bar) (4 psi) while submerged in water. Repair
leaks by soldering.
Specification
Hydraulic Reservoir Pressure A
Test—Pressure ............................................................................. 27.5 kPa
(0.27 bar)
(4 psi)
–UN–20JUL05
9. Install reservoir in reverse order.
10. Fill reservoir with clean hydraulic oil. (See FUELS
H83713
AND LUBRICANTS in Section 10, Group 20 for
recommended oil.)
Specification A—Cap Screws (6 used)

(37 qt)
70
05
OUO6083,0000CA2 –19–06MAR06–4/4
6

083006
PN=716
Hydraulic Reservoir
Flushing the Hydraulic System

–UN–23AUG88
fluids.
X9811
IMPORTANT: Flushing as soon as possible after a

failure is recommended so debris does
not have a chance to travel throughout
the system.
NOTE: The information below concentrates on those

areas where there is continuous oil flow.
NOTE: Information on flushing four wheel drive cam lobe

motor can be found in Section 50, Groups 25 and
30.

70
pressure. Shut off engine and remove key. 7
2. Remove the solenoid control valve. The valve cannot

be flushed. Disassemble and clean the valve.
3. Remove the main hydraulic pump.
4. Using the hoses supplied with the oil transfer unit, and
the proper hose fittings, connect a hose from the outlet
port of the transfer unit to the inlet port on the main
hydraulic pump. Connect another hose from the outlet
of the hydraulic pump to a drum of flushing oil.

083006
PN=717
Hydraulic Reservoir
5. Activate the transfer unit and slowly rotate the

hydraulic pump shaft, by hand, while flushing.
6. Flush all hoses and lines thoroughly. Flush out quick

couplers at the feeder house.
AG,OUO6022,1946 –19–25JUL00–2/2
Flushing the Reel/Belt Pickup Drive System
IMPORTANT: Flushing as soon as possible after a

failure is recommended so debris does
not have a chance to travel throughout
the system.
NOTE: The information below concentrates on those

areas where there is continuous oil flow.
NOTE: Information on flushing four wheel drive cam lobe

motor can be found in Section 50, Groups, 25 and
30.
1. Remove the control valve. The control valve cannot be

flushed. Disassemble and clean the valve.
2. Remove the reel/belt pickup pump.

70
05
8 3. Using the hoses supplied with the JT05746 Filter
Caddy, and the proper hose fittings, connect a hose
from the outlet port of the Filter Caddy to the inlet port
of the pickup pump. Connect another hose from the
outlet port of the pump to a drum of flushing oil.
4. Activate the filter caddy and slowly rotate the pump

shaft, by hand, while flushing.
5. Remove the motor on the header. The motor cannot

be flushed. Disassemble and clean the motor.
6. Flush all hoses and lines thoroughly on the combine

and header. Flush out the quick couplers at the feeder
house.
AG,OUO6022,1947 –19–25JUL00–1/1

083006
PN=718
Hydraulic Reservoir
Start-Up Procedure After Hydrostatic System

Repair
1. Fill system with John Deere HY-GARD transmission

and hydraulic oil and leave cap off reservoir.
2. Disconnect multi-pin connector to injectors on the end

of cylinder head.
3. Crank engine, with starting motor, several times for 15

seconds at one minute intervals. This starts oil flowing
into the hydrostatic pump.
4. Reconnect multi-pin connector to injectors.
CAUTION: To avoid injury or death to others,

keep all bystanders away from machine while
performing start-up procedure. Machine may
move unexpectedly.
5. Place transmission in neutral and engage parking

brake.
6. Start engine and run at slow idle speed for 5 minutes

to bleed air from system.
7. Move hydro lever slightly forward out of neutral. After

30 seconds, return hydro lever to neutral position.
8. Move hydro lever slightly into reverse travel. After 30

seconds, return to neutral.
70
9. Repeat steps 7 and 8 until maximum forward and 05
reverse travel is reached. 9
10. Release parking brake.
11. Increase engine speed to full throttle.
12. Shift transmission to second gear and run machine in

forward and reverse several times to check the drive
system.
13. Check for system leaks, fill reservoir with oil and
install cap.

083006
PN=719
Hydraulic Reservoir
14. Clear AOO codes on cornerpost. (See DIAGNOSTIC

TROUBLE CODES in Machine Operators Manual.)
OUO6083,0000288 –19–01MAY02–2/2
70
05
10

083006
PN=720
Group 10
Hydraulic Pumps
SERVICEGARD or European Microfiche Tool
Catalogs.
SERVICEGARD is a trademark of Deere & Company OUO6083,0000D50 –19–06JUN06–1/2
Snap Ring Pliers. . . . . . . . . . . . . . . . . . . JDG1141
Used to remove internal snap rings.
1
OUO6083,0000D50 –19–06JUN06–2/2

U.S. SERVICEGARD Catalog or from the 70
European Microfiche Tool Catalog (MTC). Some 10
tools may be available from a local supplier. 1
SERVICEGARD is a trademark of Deere & Company OUO6083,0000577 –19–06MAY03–1/3
Seal, bushing and bearing driver set . . . . . . D01072AA
Used to install seals.

083006
PN=721
Hydraulic Pumps
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D15032NU
–UN–01JUN01
H68348
OUO6083,0000577 –19–06MAY03–3/3
Other Material
Number Name Use
TY22000 (U.S.) HY-GARD Transmission and Used to lubricate parts during

Hydraulic Oil assembly.
TY6341 (U.S.) Multi-Purpose, SD Polyurea Grease Used to lubricate parts during

assembly.
70
10
AG,OUO6022,1951 –19–25JUL00–1/1
2

083006
PN=722
Hydraulic Pumps
Specifications
Main Hydraulic Pump Front-to-Rear Torque 35 N•m

Section Cap Screws (26 lb-ft)
Main Hydraulic Pump Mounting Cap Torque 75 N•m

Screws (55 lb-ft)
Hydraulic Reservoir Approximate Capacity 35 L

(37 qt)
Straw Spreader Pump Adapter Torque 38 N•m

Flange Nut (28 lb-ft)
Triple Pump Assembly Cap Screws Torque 35 N•m

(26 lb-ft)
Reel/Belt Pickup and Straw Spreader Torque 35 N•m

Pump Cap Screws (26 lb-ft)
Reel/Belt Pickup Pump Bearing Approximate Capacity 133 mL

Cavity (4–1/2 oz.)
Drive Pump Nut Torque 38 N•m

(28 lb-ft)
70
10
OUO6083,0000B17 –19–24AUG05–1/1
3

083006
PN=723
Hydraulic Pumps
Remove Triple Main Hydraulic Pump

penetrate the skin, causing serious injury.
–UN–23AUG88
all connections before applying pressure. Use a
piece of cardboard to search for leaks. Protect
hands and body from high pressure fluids.
X9811
If injured by escaping fluid, see a doctor
immediately. Any fluid injected into the skin
must be surgically removed within a few hours
or gangrene may result. Doctors unfamiliar with

depressing switch for 5 to 10 seconds to relieve
hydraulic system pressure. Stop engine.
2. Connect D15032NU Vacuum Pump to reservoir. This

will allow removing the pump without draining the
reservoir. If vacuum pump is not available, drain
reservoir. Approximate capacity is 35 L (37 qt).
70
10
OUO6083,0000DC7 –19–17AUG06–1/2
4
3. Disconnect five oil lines (A) from triple pump (B).
4. Remove two cap screws (C) and pump.
A—Oil Line (5 used)

B—Pump
–UN–01DEC04

H82109
OUO6083,0000DC7 –19–17AUG06–2/2

083006
PN=724
Hydraulic Pumps
Marking Triple Main Hydraulic Pump
IMPORTANT: Mark all pump parts prior to removal to

ensure correct reinstallation.
–UN–18JAN05
H82270
OUO6083,0000DC8 –19–17AUG06–1/1
Disassembling Triple Main Hydraulic Pump
NOTE: Eight cap screws hold together the hydraulic

pump which consists of three pump units.
1. Remove cap screws (A and C ) from pump assembly

(B).
–UN–18JAN05
B—Pump Assembly
H82271
70
10
–UN–18JAN05
5
H82273
OUO6083,0000DC9 –19–17AUG06–1/2
2. Disassemble parts of pump (A) which need to be

repaired.
A—Pump
–UN–18JAN05
H82272
OUO6083,0000DC9 –19–17AUG06–2/2

083006
PN=725
Hydraulic Pumps
Replace Seal
1. Press out seal (A) and washer, taking care not to

damage seal seat surface.
2. When installing seal ring, make sure sealing lip faces

toward the inside.
–UN–18JAN05
A—Seal
H82274
OUO6083,000089B –19–18JAN05–1/1
70
10
6

083006
PN=726
Hydraulic Pumps
70
10
7

083006
PN=727
Hydraulic Pumps
Triple Main Hydraulic Pump—Exploded View
70
10
8
–UN–19JAN05
H82269
Continued on next page OUO6083,0000DCA –19–17AUG06–1/2

083006
PN=728
Hydraulic Pumps
1—Cap Screw (8 used) 9—Housing 16—Housing 23—Gear

2—Seal (2 used) 10—Gear 17—Cover 24—O-Ring
3—Washer (3 used) 11—Gear 18—Diagnostic Receptacle 25—Seal
4—Plate 12—Shaft Key (2 used) 19—O-Ring 26—Snap Ring
5—Gasket (3 used) 13—Shaft 20—Plate 27—Cap Screw (8 used)
6—Plate (3 used) 14—Housing 21—Housing 28—Cap Screw (4 used)
7—Dowel Pin (12 used) 15—Housing 22—Gear 29—Washer (4 used)
8—O-Ring (6 used)
OUO6083,0000DCA –19–17AUG06–2/2
Assembling Triple Main Hydraulic Pump
1. Use new gaskets.
2. Coat all moving parts with clean hydraulic oil before

assembling.
–UN–18JAN05
3. Assemble hydraulic pump, noting marks made before
disassembly.
H82275
4. Install cap screws with washers (A) into pump cavity
(B).
5. Install cap screws (C) into pump housing (D). Tighten A—Cap Screw with Washers (4 used)
all cap screws to specification. B—Pump Cavity
D—Pump Housing
Specification
Triple Pump Assembly Cap
Screws—Torque ............................................................................. 35 N•m 70
(26 lb-ft) 10
9
OUO6083,0000DCB –19–17AUG06–1/2
6. Install cap screws (A) and tighten.

–UN–18JAN05
H82276
OUO6083,0000DCB –19–17AUG06–2/2

083006
PN=729
Hydraulic Pumps
Install Triple Main Hydraulic Pump
1. Install pump (A) and tighten cap screws (B) to

specification.
Specification
Main Hydraulic Pump Mounting
–UN–01DEC04
(55 lb-ft)
2. Connect oil lines (C).
H82099
3. Perform start-up procedure. (See START-UP
PROCEDURE AFTER HYDROSTATIC SYSTEM
A—Pump
REPAIR in this section.) B—Cap Screw (2 used)
C—Oil Line (5 used)
OUO6083,0000DCC –19–17AUG06–1/1
70
10
10

083006
PN=730
Hydraulic Pumps
Reel/Belt Pickup and Straw Spreader Pump—Exploded View
M
J L
I
N
H
J
G
F K
E J
D
C
B
70
A
10
11
–UN–19JUL06
K
H86347
A—Cap Screw (8 used) E—Front Plate I—Diaphragm M—Drive Gear

B—Snap Ring F—Seal J—Dowel Pin (4 used) N—Idler Gear
C—Seal G—Gasket K—O-Ring (2 used) O—Body
D—Washer H—Gasket L—Key P—Back Plate
OUO6083,0000DAE –19–19JUL06–1/1

083006
PN=731
Hydraulic Pumps
Remove and Install Reel/Belt Pickup Pump

Drive

–UN–23AUG88
X9811
fluids.


system pressure. Stop engine and remove key.
2. Install D15032NU Vacuum Pump on reservoir to allow

removing pump drive without draining reservoir. If
pump is not available, drain reservoir. Approximate
capacity is 34 L (36 qt).
70
10
OUO6083,0000579 –19–06MAY03–1/6
12
3. Loosen nuts (A) and remove belt (B) from sheave.
4. Disconnect hydraulic hose and line (C). Cap hydraulic

hose and line to prevent contamination.
A—Nuts (2 used)
–UN–28JAN99
B—Belt
C—Hydraulic Hose and Line
H51889

083006
PN=732
Hydraulic Pumps
CAUTION: Move and support idler sheave to

obtain clearance during pump removal and
installation.
5. Remove nut, vibration washer, washer and screw from

strap (A).
–UN–28JAN99
6. Remove mounting screws and washers (B).
7. Remove pump assembly.
H51892
A—Strap
OUO6083,0000579 –19–06MAY03–3/6
8. Remove pump (C) from drive assembly (B) using

D01251AA Puller from 17-1/2 and 30 Ton Puller Set.
Pump shaft is tapered and uses a woodruff key.
A—Puller
B—Drive Assembly
–UN–22MAY02
C—Pump
H72283
70
10
OUO6083,0000579 –19–06MAY03–4/6
13
9. Remove round head bolt and strap (A).
10. Remove fittings (B).
11. Replace mount and inner and outer bearings if

necessary. Fill cavity with TY6341 Multi-Purpose SD
–UN–01FEB99
Polyurea Grease.
Specification
Reel/Belt Pickup Pump Bearing
Cavity—Approximate Capacity ....................................................... 133 mL
H51914
(4–1/2 oz.)
12. Install drive pump.

A—Strap
B—Fitting (2 used)

083006
PN=733
Hydraulic Pumps
13. Install nut (A). Tighten to specification.
Specification
Drive Pump Nut—Torque ............................................................... 38 N•m
(28 lb-ft)
14. Install belt and tighten nuts on belt tensioner until
–UN–01FEB99
washer aligns with tip of gauge.
A—Nut
H51895
OUO6083,0000579 –19–06MAY03–6/6
70
10
14

083006
PN=734
Hydraulic Pumps
Disassemble and Assemble Reel/Belt Pickup Pump Drive
70
10
15
–UN–28MAR00
H63142

083006
PN=735
Hydraulic Pumps
1—Plug 7—Flange Nut 11—Adapter 16—Lock Nut (2 used)

2—Snap Ring 8a—Sheave (Standard 12—O-Ring 17—O-Ring
3—Ball Bearing Capacity) 13—Line 18—Elbow Fitting
4—Hub 8b—Sheave (Hi Capacity) 14—Strap 19—O-Ring
5—Lubrication Fitting 9—Shaft Key 15—Bolt (2 used) 20—Hydraulic Hose
6—Ball Bearing 10—O-Ring
1. Remove reel/belt pickup pump from drive assembly.

(See REMOVE AND INSTALL REEL/BELT PICKUP
PUMP DRIVE in this group.)
OUO6083,0000265 –19–12APR02–2/9
2. Remove snap ring from drive sheave shaft.
3. Remove hub (B) from sheave shaft (A) using

D01047AA 17-1/2 and 30 Ton Puller Set. Bearings are
a press fit on shaft.
–UN–29AUG89
A—Hub
B—Sheave Shaft
H41246
OUO6083,0000265 –19–12APR02–3/9
4. Remove bearing (B) from hub (A). Bearing is held in

place with thread lock and sealer (medium strength).
70 A—Hub
10 B—Bearing
16
–UN–29AUG89
H41247
OUO6083,0000265 –19–12APR02–4/9
5. Remove bearing (A) from sheave (B) using D01047AA

17-1/2 and 30 ton puller set.
A—Bearing
B—Sheave
–UN–29AUG89
H41249

083006
PN=736
Hydraulic Pumps
6. Coat OD of bearing with thread lock and sealer

(medium strength). Install bearing (B) on sheave (A)
with seal toward sheave. Bearing is a press fit.
A—Sheave
B—Bearing
–UN–29AUG89
H41250
OUO6083,0000265 –19–12APR02–6/9
7. Install hub (A) on sheave (B). Pack Multi-Purpose SD

Polyurea Grease into cavity between hub sheave. Do
not get grease on hub or sheave area where bearing
will be pressed in.
A—Hub
–UN–29AUG89
B—Sheave
H41251
OUO6083,0000265 –19–12APR02–7/9
8. Coat OD of bearing (A) with thread lock and sealer

(medium strength). Press bearing onto sheave shaft
past snap ring groove. Seal on bearing should face
away from grease. 70
10
17
A—Bearing
–UN–29AUG89
B—Hub
H41248

083006
PN=737
Hydraulic Pumps
9. Install snap ring (D).
10. Install pump (C) with key on drive assembly (B) using
nut (A). Tighten nut to specification.
Specification
Reel/Belt Pump-to-Drive
–UN–29AUG89
Assembly Mounting Nut—Torque .................................................. 38 N•m
(28 lb-ft)
11. Install plug into hub.
H41252
12. Pump Multi-Purpose SD Polyurea Grease into lube
fitting on hub until grease is seen purging through one
A—Nut
of the two bearings. B—Drive Assembly
C—Pump
Specification D—Snap Ring
Reel/Belt Pickup Pump Bearing
Cavity—Approximate Capacity ....................................................... 133 mL
(4–1/2 oz.)
OUO6083,0000265 –19–12APR02–9/9
70
10
18

083006
PN=738
Hydraulic Pumps
Remove Straw Spreader Pump

penetrate the skin causing serious injury.
–UN–23AUG88
X9811
fluids.

this type of injury should reference a
knowledgeable medical source. Such
information is available from Deere & Company
Medical Department in Moline, Illinois, or other

2. Install D15032NU Vacuum Pump on reservoir. This will

allow removal of hydraulic components without draining
the reservoir. If vacuum pump is not available, drain
reservoir.
70
Specification
10
19
(36 qt)
OUO6083,0000D51 –19–06JUN06–1/4
3. Remove hoses (A) from pump. Cap all lines and

openings.
4. Remove cap screws and nuts (B) to remove cover (C).
A—Hose (2 used)
–UN–30APR02

C—Cover
H71978

083006
PN=739
Hydraulic Pumps
5. Remove cap screws (A), hub (B) and pump (C).

B—Hub
C—Pump
–UN–30APR02
H71982
OUO6083,0000D51 –19–06JUN06–3/4
6. Remove nut (A) to remove hub (B).
7. Remove cap screws and nuts (E) to remove bracket

(C) from pump (D).
A—Nut
–UN–05MAR99
B—Hub
C—Bracket
D—Pump
E—Cap Screw and Nut (2 used)
H54363
OUO6083,0000D51 –19–06JUN06–4/4
Install Straw Spreader Pump
1. Install plate (C) to pump (D) using cap screws and nuts
70 (E).
10
20 2. Install hub (B) to pump (D) using nut (A). Tighten nut
–UN–05MAR99
to specification.
Specification
Chaff Spreader Pump Adapter
Flange Nut—Torque ....................................................................... 38 N•m
H54363
(28 lb-ft)
A—Nut
B—Hub
C—Bracket
D—Pump

083006
PN=740
Hydraulic Pumps
3. Install pump (C) and hub (B) using cap screws (A).

B—Hub
C—Pump
–UN–30APR02
H71982
OUO6083,0000283 –19–30APR02–2/3
4. Install cover (C) using cap screws (B).
5. Connect hoses (A).
6. Check oil level in reservoir.
–UN–30APR02
7. Start engine and operate at slow idle for three minutes.
8. Increase engine speed to fast idle and operate function

for three minutes.
H71978
9. Check pump for leaks and recheck oil level in
reservoir.
A—Hose (2 used)
C—Cover
70
10
OUO6083,0000283 –19–30APR02–3/3
21
Disassemble Reel/Belt Pickup Straw

Spreader Pump
1. Scribe a line across front plate, body and back plate

for proper reassembly of pump. –UN–20MAR89
H40172

083006
PN=741
Hydraulic Pumps
A—Snap Ring
–UN–02FEB89
H40156
OUO6083,0000266 –19–12APR02–2/5
3. Remove eight cap screws (A).
–UN–02FEB89
H40157
OUO6083,0000266 –19–12APR02–3/5
70
10
22
–UN–20MAR89
H40159
A—Back Plate E—Idler Gear I—Cap Screw (8 used) M—Seal

B—O-Ring (2 used) F—Key J—Snap Ring N—Drive Gear
C—Body G—Diaphragm K—Seal O—Bushing (2 used)
D—Dowel Pin (4 used) H—Front Plate L—Gasket
4. Remove parts (A—N).
5. Inspect parts for wear or damage. Replace parts if

necessary.

083006
PN=742
Hydraulic Pumps
IMPORTANT: Inspect seal. Do not remove seal unless

replacement is necessary as seal will be
damaged when removing. Use care to
prevent damage to front plate when
removing seal.
–UN–21AUG89
6. Remove washer (B) and seal (C) from front plate (A).
A—Plate
B—Washer
H40343
C—Seal
OUO6083,0000266 –19–12APR02–5/5
Assemble Reel/Belt Pickup and Straw

Spreader Pump
1. Install washer (C) and seal (D) into front plate (A)
using 27505 Driver (B).
–UN–21AUG89
A—Front Plate
B—27505 Driver
C—Washer
D—Seal
H40345
70
10
23

083006
PN=743
Hydraulic Pumps
–UN–20MAR89
H40159
A—Back Plate E—Idler Gear I—Cap Screw (8 used) M—Seal
B—O-Ring (2 used) F—Key J—Snap Ring N—Drive Gear
C—Body G—Diaphragm K—Seal O—Bushing (2 used)
D—Dowel Pin (4 used) H—Front Plate L—Gasket
IMPORTANT: Diaphragm (G) must be placed with NOTE: Install seal (K) with recess towards body (C).
bronze face toward idler gear (E) and
drive gear (N).
2. Install parts (A—N). Lubricate parts with a thin film

of clean hydraulic oil.
OUO6083,0000267 –19–12APR02–2/4
3. Align scribe marks, install and tighten eight cap screws

(A) to specification.
Specification
70
Reel/Belt Pickup and Chaff
10
Spreader Pump Cap Screws—
24
Torque ........................................................................................... 35 N•m
–UN–02FEB89
(26 lb-ft)
H40158
OUO6083,0000267 –19–12APR02–3/4
4. Install snap ring (A).
A—Snap Ring
–UN–02FEB89
H40156
OUO6083,0000267 –19–12APR02–4/4

083006
PN=744
Group 15
Hydraulic Valves

OUO6083,000057B –19–06MAY03–1/2
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D15032NU
–UN–01JUN01
H68348
OUO6083,000057B –19–06MAY03–2/2
Specifications

70
Hydraulic Reservoir Capacity 34 L 15
(36 qt) 1
Multi-Coupler Valve Torque 92 N•m

(68 lb-ft)
OUO6046,0001FFE –19–18JUL05–1/1

083006
PN=745
Hydraulic Valves
Electro-Hydraulic Feeder House Reverser

Valve—General Information
The feeder house reverser is electronically actuated by

pulling the header engagement switch rearward. Switching
direction of the gear case can only be done after the drum
–UN–04JUN03
comes to a complete stop. The valve, located on the
left-hand side beneath the main hydraulic pump, receives
its hydraulic oil pressure from the charge pump. When the
valve coil is energized, hydraulic pressure moves a piston
H77636
in the reverser gear case to reverse direction of the feeder
house. Excess oil is returned to the main hydraulic
reservoir.
A—Electro-Hydraulic Feeder House Reverser
Valve
OUO6083,000060C –19–04JUN03–1/1
70
15
2

083006
PN=746
Hydraulic Valves
70
15
3

083006
PN=747
Hydraulic Valves
Electro-Hydraulic Feeder House Reverser Valve and Hoses—Exploded View
D C
M
Q
Q
P B
P E
N
H R
O
C
B A
B
C
C N
C
70 N
15
4 B
K I
J
L C
N
F B
–UN–29MAY03
H77498
Continued on next page OUO6083,000060B –19–04JUN03–1/2

083006
PN=748
Hydraulic Valves
A—Round Head Bolt (2 used) F—O-Ring (2 used) K—Hydraulic Hose O—Hydraulic Hose
B—O-Ring (5 used) G—Hydraulic Hose L—Tee Fitting P—Clip (2 used)
C—O-Ring (6 used) H—Adapter M—Clamp Q—Flange Nut (2 used)
D—Tee Fitting I—O-Ring N—Adapter (4 used) R—Control Valve
E—Elbow Fitting J—Flange Nut (2 used)
OUO6083,000060B –19–04JUN03–2/2
Electro-Hydraulic Feeder House Reverser Valve—Exploded View
F G B
E
H
D
H
A
–UN–29MAY03
F
H
H77497
70
15
5
A—Housing C—Valve E—Nut G—Adapter
B—Seal Kit D—Electric Coil F—Adapter H—O-Ring
OUO6083,00006AE –19–04DEC03–1/1

083006
PN=749
Hydraulic Valves
Remove Straw Spreader Flow Control Valve

penetrate the skin causing serious injury.
–UN–23AUG88
X9811
fluids.

this type of injury can contact Deere &


reservoir.
Specification
70 (36 qt)
15
6
OUO6083,000057D –19–06MAY03–1/3
3. Disconnect harness from electric actuator motor (B).
4. Loosen bolt through coupler (C) and remove motor.
5. Disconnect hydraulic hoses (A) from valve.

–UN–22MAR01
A—Hydraulic Hoses
B—Actuator Motor
C—Coupler
H66977
Continued on next page OUO6083,000057D –19–06MAY03–2/3

083006
PN=750
Hydraulic Valves
6. Remove two cap screws with lock nuts and valve

assembly (A) from bracket.
A—Valve Assembly
–UN–03DEC98
H51587
OUO6083,000057D –19–06MAY03–3/3
Disassemble and Assemble Straw Spreader Flow Control Valve
C
A
D
F
G
V H
I
U
T J
S K
R
Q L 70
15
7
–UN–26MAR03
N
O
P
H75740
A—Groove Pin G—Solid Shim M—Spring S—Plug

B—Stem H—Solid Shim N—Shim T—O-Ring
C—Back-up Ring I—Back-up Ring O—O-Ring U—Hydraulic Quick Connect
D—O-Ring J—O-Ring P—Plug Coupler
E—Plug K—O-Ring Q—Spool V—Cover
F—Solid Shim L—Housing R—O-Ring
1. Disassemble parts (A—U). 3. Assemble parts (A—U). Always install new O-rings
and back-up rings.
2. Inspect parts for wear or damage. Replace as
necessary.
OUO6083,000050D –19–28MAR03–1/1

083006
PN=751
Hydraulic Valves
Install Straw Spreader Flow Control Valve
1. Attach valve assembly (A) to bracket using two cap

screws and lock nuts.
A—Valve Assembly
–UN–03DEC98
H51587
OUO6083,0000025 –19–22MAR01–1/2
2. Install motor and coupler (C) on valve.
3. Connect harness to motor (B).
4. Install hydraulic hoses (A) to valve.
–UN–22MAR01
A—Hydraulic Hoses
B—Control Actuator Motor
C—Coupler
H66977
OUO6083,0000025 –19–22MAR01–2/2
Remove Reel/Belt Speed Flow Control Valve

70 depress switch for 5 to 10 seconds to relieve hydraulic
15 system pressure. Shut off engine.
8
–UN–03MAY99
2. Disconnect wiring harness (A) from electric actuator
motor.
3. Loosen bolt through coupler (D) and remove motor.

H55857
4. Install D15032NU vacuum pump on reservoir. This will

allow removing the valve without draining reservoir.
A—Wiring Harness
5. Disconnect and plug four oil lines (B) from valve. B—Oil Lines (4 used)
D—Coupler
6. Remove cap screws (C) and valve.
OUO6083,00005EC –19–27MAY03–1/1

083006
PN=752
Hydraulic Valves
Repair Reel/Belt Speed Flow Control Valve
C
A
D
F
G
V H
I
U
T J
S K
R
Q L
–UN–26MAR03
N
O
P
H75740
A—Groove Pin G—Solid Shim M—Spring S—Plug
B—Stem H—Solid Shim N—Shim T—O-Ring
C—Back-up Ring I—Back-up Ring O—O-Ring U—Hydraulic Quick Connect
D—O-Ring J—O-Ring P—Plug Coupler
E—Valve Body K—O-Ring Q—Spool V—Cover 70
F—Solid Shim L—Housing R—O-Ring 15
9
Refer to the exploded view to disassemble valve and outlet port with solvent and compressed air.
install repair kit. (Refer to diagram in Reel/Belt Speed System
Theory of Operation in TM2182.) Lubricate all
NOTE: Clean valve with solvent before assembling parts with SAE 10W oil during assembly.
with repair kit. Clean screened passage in
OUO6083,000050C –19–28MAR03–1/1

083006
PN=753
Hydraulic Valves
Install Reel/Belt Speed Flow Control Valve
1. Install valve to bracket and install cap screws (C).
2. Connect four oil lines (B) to valve.
–UN–03MAY99
IMPORTANT: When installing motor be sure to rotate
spool all the way closed and run the
motor to full slow. Then install the
coupler.
H55857
3. Install motor and coupler (D) on valve.
4. Connect wiring harness (A) to motor. A—Wiring Harness

B—Oil Lines (4 used)
D—Coupler
OUO6083,00005ED –19–27MAY03–1/1
70
15
10

083006
PN=754
Hydraulic Valves
Remove and Install Header Height Control

Valve

–UN–23AUG88
X9811
fluids.

–UN–12FEB01
1. Start engine and lower header or feeder house to the

ground. Hold switch for 5 to 10 seconds to relieve
H66320
hydraulic system pressure. Shut-off engine.
NOTE: Cap and plug all openings to avoid hydraulic

system contamination. A—Connectors
B—Hydraulic Hoses
2. Disconnect electrical connectors (A).
3. Remove hydraulic hoses (B).
4. Remove cap screws (C) and remove valve. 70

15
5. Install valve using new O-rings. 11
OUO6083,00003FD –19–14OCT02–1/1

083006
PN=755
Hydraulic Valves
Remove and Install Accumulator Shut-off

Valve

depress switch for 5 to 10 seconds to relieve hydraulic
pressure. Shut-off engine.
–UN–18OCT05
2. Disconnect power connector and pressure sensor (A).
3. Disconnect header height control valve (C) and
H83977
hydraulic line (D) from shut-off valve.
4. Disconnect accumulator from shut-off valve.

A—Connectors
5. Remove cap screws (B) and remove shut-off valve. C—Header Height Control Valve
Repair or replace as necessary. D—Hydraulic Hose
6. Install valve using new O-rings.
7. Start engine and operate header lift system. Lower

header completely to the ground and shut-off engine.
Visually check for leaks.
OUO6046,0001FFA –19–14JUL05–1/1
Feeder House Multi-Coupler Valve

Identification
70 A—Reel Drive Pressure

15 B—Reel Drive Return
12 C—Electrical Connector Cavity
D—Reel Fore/Aft Retract
–UN–05FEB02
E—Reel Fore/Aft Extend
F—Reel Lift
H71037
OUO6435,00015F6 –19–04FEB02–1/1

083006
PN=756
Hydraulic Valves
Disassemble, Inspect and Assemble Feeder

House Multi-Coupler

–UN–23AUG88
X9811
fluids.

While valve repair is illustrated as a bench top procedure,

valve can be repaired on the machine, provided they (and
surrounding areas) are thoroughly cleaned and all
openings are capped or plugged to prevent internal
contamination.
70
15
OUO6083,00007BB –19–18MAY04–1/7
13
1. Clean all dirt and debris from multi-coupler.
CAUTION: Wear safety equipment suitable to

the job.
2. Have an assistant start engine and operate header

–UN–20FEB02
functions. Wearing appropriate safety equipment,

inspect valves for leakage at (A, B and C).

H71050
depress switch for 5 to 10 seconds to relieve hydraulic

system pressure.
A—Inner Groove
B—Center Groove
C—Outer Groove
Continued on next page OUO6083,00007BB –19–18MAY04–2/7

083006
PN=757
Hydraulic Valves
IMPORTANT: Be careful not to scratch inner sleeve

when depressing center ring. If
scratches are found on inner sleeve,
complete valve replacement is
necessary.
–UN–06FEB02
NOTE: Tool Tip: Wrap a piece of black tape around the
end of a drift punch to depress center ring.
4. If leakage is determined to be coming from the inner or
H71035
center groove, use a blunt instrument and depress
center ring (A). Clean around inner and outer mating
surfaces using TY6350 Multi-Purpose Spray Lubricant
while moving ring in and out several times. A—Center Ring
OUO6083,00007BB –19–18MAY04–3/7
5. If leakage is determined to be coming from the outer

ring. Remove valve using AH2018081 Spanner Wrench
(A).
A—Spanner Wrench
–UN–05FEB02
H71036
70 1
Available through service parts.
15
14

083006
PN=758
Hydraulic Valves
6. Inspect O-rings (A) for wear or damage. Replace as

necessary.
NOTE: If wear or damage is evident on back-up ring (B),

complete valve replacement is needed.
–UN–20FEB02
7. Inspect back-up ring (B) for wear or damage.
A—O-Ring
B—Back-Up Ring
H71051
Reel Drive Pressure, Return and Reel Lift
–UN–07FEB02
H71034
Reel Fore/Aft Extend and Retract
OUO6083,00007BB –19–18MAY04–5/7
8. Inspect O-ring (A) for wear or damage. Replace as

necessary.
A—O-Ring 70
15
15
–UN–05FEB02
H71038
Reel Drive Pressure, Return and Reel Lift

083006
PN=759
Hydraulic Valves
9. Clean valve bore (A) of all dirt and oil.
10. Lightly coat valve O-rings and back-up ring with clean
oil or grease. Install valve and tighten to specification.
Specification
Multi-Coupler Valve—Torque ......................................................... 92 N•m
–UN–07FEB02
(68 lb-ft)
A—Valve Bore
H71033
OUO6083,00007BB –19–18MAY04–7/7
70
15
16

083006
PN=760
Group 16
Hydraulic Valve Stack (S.N. —715300)

OUO6083,000057B –19–06MAY03–1/2
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D15032NU
–UN–01JUN01
H68348
OUO6083,000057B –19–06MAY03–2/2
Specifications

70
Hydraulic Reservoir Approximate Capacity 34 L 16
(36 qt) 1
Hydraulic Valve Stack Tie Bolts Torque 11 N•m

(97 lb-in.)
Solenoid-to-Valve (Except No. 4, 5 Torque 14 N•m

and 6) (125 lb-in.)
Solenoid Number 4, 5 and 6 Torque 11 N•m

(97 lb-in.)
OUO6046,0002001 –19–18JUL05–1/1

083006
PN=761
Remove and Install Hydraulic Valve Stack

–UN–23AUG88
fluids.
X9811
CAUTION: “Cracking” hydraulic hose fittings to

lower header will result in an instantaneous
dropping of the header and expulsion of the
sealing O-ring in the fitting.

70
16
2

083006
PN=762

allow removing the valve without draining the reservoir.
If vacuum pump is not available, drain reservoir.
Specification
–UN–27MAY03
(36 qt)
NOTE: DO NOT leave vacuum pump running for

extended period of time. Remove component and
H77444
cap lines. Extended use may burn up vacuum
pump.
A—Mounting Cap Screw (4 used)
3. Disconnect oil lines (C). B—Wire Harness Connector (3 used)
C—Oil Lines
4. Disconnect wiring harnesses (B).
5. Remove four mounting cap screws (A) and remove

valve downward from bracket and clear of lines.
6. Any work to the valve should be done in a clean area

away from dust and dirt. Repair as necessary.
7. Install valve and tighten four mounting cap screws (A).
8. Connect oil lines (C).
9. Connect wiring harnesses (B).
10. Fill reservoir.
Specification
Hydraulic Reservoir— 70
Approximate Capacity ......................................................................... 34 L 16
(36 qt) 3
OUO6083,000057C –19–06MAY03–2/2

083006
PN=763
Disassemble and Assemble Hydraulic Valve Stack
70
16
4
–UN–18MAR02
H71262
Continued on next page OUO6083,00005E7 –19–06JUL05–1/2

083006
PN=764
1—Nut (6 used) 8—Seal (8 used) 13—Valve (Reel Lift) 19—Nut (10 used)
2—Lock Washer (6 used) 9—Valve (Reel Fore/Aft) 14—Valve (Threshing Speed) 20—Connector (2 used)
3—Tie Bolt (3 used) 10—Valve (Unload Auger 15—Cover 21—Cap Screw (8 used)
4—Bracket (2 used) Swing) 16—Seal (2 used) 22—O-Ring
5—Seal (2 used) 11—Coil 17—Valve (Unload Relief) 23—Diagnostic Receptacle
6—Orifice (6 used) 12—Pin Contact 18—Connector Plate (2 used) 24—Dust Cover
7—Valve (CONTOUR MASTER)
NOTE: Two types of coil (11) are used. A 13 ohm coil 5. Pry modules apart carefully. Tag each coil
used on modules (17, 10, 9 and 7) has white removed. To make sure it is installed on the correct
wires. A 4 ohm coil used on modules (13 and post of the new module, work on one module at a
14) has black wires. time.
1. Remove four sheet metal nuts (19) and lift away 6. Refer to the exploded views when disassembling
both connector plates (18). Install sheet metal nuts the various modules. Work on only the module(s)
on posts to keep coils from falling off. that require service.
2. Clean chaff from under connector, taking care not 7. Lift valve up and on mounting. Attach to plate with
to get contamination in all oil ports. four bolts.
3. If repairing, but not replacing a faulty module, it is 8. Connect all lines and wiring harness.
easier to leave the stack intact. Do not remove tie
bolts (3). 9. Remove vacuum pump or fill reservoir. (See FUELS
AND LUBRICANTS, Section 10.) Start engine,
4. To replace complete modules, remove long tie bolts cycle functions and check for leaks.
(3). One is longer than the other two.
10. Replenish oil to proper level.
Torque tie bolts to specification at installation.
Specification
Hydraulic Valve Stack Tie
Bolts—Torque .......................................................................... 11 N•m
(97 lb-in.)
70
16
5
OUO6083,00005E7 –19–06JUL05–2/2

083006
PN=765
Solenoid Control Relief Valve Module
–UN–29OCT02
H73728
1—Sheet Metal Nut 9—Guide 17—O-Ring 25—Coupler
2—Cover 10—Orifice 18—Pipe Plug 26—Cover
3—Coil 11—O-Ring 19—O-Ring 27—Relief Valve
4—Sleeve 12—O-Ring 20—Drain Plug 28—Seal
70
5—Washer 13—Housing 21—Seal (2 used) 29—O-Ring
16
6—Armature 14—O-Ring 22—O-Ring 30—O-Ring
6
7—Poppet 15—Poppet 23—Fitting 31—Seal
8—Spring 16—Spring 24—O-Ring
OUO6083,0000441 –19–29OCT02–1/1

083006
PN=766
Two-Way Reel Lift and Variable Speed Feeder House Valve Module
3
4
8
5
1
6
9
8
10
7 9
11 4
10 2
11
5
12 6
3
12
7
13
70
–UN–20MAY03
16
7
16 17
14
H77134
15
1—Sheet Metal Nut 6—Spring 10—Orifice 14—O-Ring

2—Cover 7—Poppet 11—O-Ring 15—Fitting
3—Coil 8—Armature 12—O-Ring 16—Seal
4—Sleeve 9—Solenoid 13—Housing 17—Orifice
5—Washer
OUO6083,00005C7 –19–20MAY03–1/1

083006
PN=767
Threshing Speed Valve Module
23 8
4 2
9
10
11
5
12
6 3
13 7
21
22 14
15
16
17
70 18
–UN–20MAY03
16
19
8
20
H77135
1—Sheet Metal Nut 7—Poppet 13—Housing 19—O-Ring

2—Cover 8—Armature 14—O-Ring 20—Plug
3—Coil 9—Solenoid 15—Fitting 21—Seal
4—Sleeve 10—Orifice 16—Poppet 22—Orifice
5—Washer 11—O-Ring 17—Spring 23—Guide
6—Spring 12—O-Ring 18—Shim 24—Seal Kit
OUO6083,00005C8 –19–20MAY03–1/1

083006
PN=768
Auger Swing Valve Module
–UN–28MAR00
70
16
H63139
9
1—Sheet Metal Nut 7—Poppet 13—Housing 19—Spring (2 used)

2—Cover 8—Armature 14—Washer (2 used) 20—O-Ring (2 used)
3—Coil 9—Solenoid 15—Spring (2 used) 21—Cap (2 used)
4—Sleeve 10—Orifice 16—O-Ring (2 used) 22—Valve, Complete
5—Washer 11—O-Ring 17—Plug (2 used) 23—Tube
6—Spring 12—O-Ring 18—Check (2 used)
AG,OUO6022,1974 –19–10JAN01–1/1

083006
PN=769
Reel Fore/Aft Valve Module
8
1
9
2
10 4
11
5
12
17
6
16
3
15 7
14
21
13
20
19
18
14
15
22 16
17
23
–UN–08JUN04
21
18
19
H81133
20
70
16
10 1—Sheet Metal Nut 7—Poppet 13—Housing 19—Spring (2 used)
2—Cover 8—Armature 14—Washer (2 used) 20—O-Ring (2 used)
3—Coil 9—Solenoid 15—Spring (2 used) 21—Cap (2 used)
4—Sleeve 10—Orifice 16—O-Ring (2 used) 22—Tube
5—Washer 11—O-Ring 17—Pipe Plug (2 used) 23—Plug
6—Spring 12—O-Ring 18—Check (2 used)
OUO6083,0000835 –19–08JUN04–1/1

083006
PN=770
CONTOUR MASTER (Header Tilt) Valve Module
–UN–28MAR00
70
16
H63138
11
1—Sheet Metal Nut 8—Armature 14—Washer (2 used) 20—O-Ring (2 used)

2—Cover 9—Solenoid 15—Spring (2 used) 21—Cap (2 used)
3—Coil 10—Orifice 16—O-Ring (2 used) 22—Valve, Complete
4—Sleeve 11—O-Ring 17—Pipe Plug (2 used) 23—Orifice (2 used)
5—Washer 12—O-Ring 18—Check (2 used) 24—Tube
6—Spring 13—Housing 19—Spring (2 used) 25—Plug
7—Poppet
AG,OUO6022,1976 –19–10JAN01–1/1

083006
PN=771
Hydraulic Solenoid Control Valve Leakage

Repair
Use the following procedure when repairing valves that

are leaking externally. Observing valve in a dusty
environment can indicate which part of valve is suspect.
–UN–23AUG88
Make this check before starting the procedure.

X9811
disconnecting hydraulic hoses. Tighten all
connections before applying pressure. Search
for leaks with a piece of cardboard. Protect
hands and body from pressure fluids.

“Cracking” hydraulic hose fittings to lower

header will result in an instantaneous dropping
of the header and expulsion of the sealing
O-ring in the fitting.

70 pressure. Shut off engine and remove key.
16
12 2. Clean area around valve and remove coils one at a
time identifying its location for later reassembly. It is
very important that the valve be clean and free of oil
before proceeding.
3. Reinstall coil No. 1 ONLY.
4. From the cab, with the engine at low idle, pulse the
reel raise button several times. The reel will NOT raise
as coil No. 2 is not attached to valve. However, the
relief valve will be activated and seepage should occur
at the problem areas. With the coils off and valve
initially dry, an accurate leak point can be located.

083006
PN=772
5. Shut off engine and look at the valve to locate where

leaks have occurred and what parts need to be
replaced.
6. Potential leak points are listed below:
• Upper or lower threaded connection on pilot sleeve

assembly.
• Leaking where pilot sleeve assembly threads into
casting.
• Leaking between modules. Oil will typically come
from tie rod bolt holes. (Plug or thru tubes between
affected modules MUST be replaced - See Parts
Catalog for proper part numbers.)
70
16
13

083006
PN=773
7. Leak points (A and B) can be repaired without

removing valve from combine. Valve should be
removed from combine for repair of leak points (C).
Repair of leak points (A and B) should be made first.
Leak point (C) is often misdiagnosed as a result of
excessive leakage at (B).
A—Leak Point
B—Leak Point
C—Leak Point
C
B
A
–UN–18MAR02
H71318
–UN–13JUN94
70
16
H46546
14
OUO6083,0000239 –19–15MAR02–3/3

083006
PN=774
Replacing Pilot Solenoid Assemblies
1. Use a 5/8 in. open end wrench to remove solenoid (A)

including all internal parts and put aside.
NOTE: Leave the orifice (B) (pressed in the cast iron

valve body) in place.
2. Remove solenoid assembly CAREFULLY from repair
–UN–13JUN94
kit. Loosely hold finger over bottom of solenoid
assembly to make sure that parts remain in place.
IMPORTANT: Replace the correct coil on the
H46547
solenoid.
3. Replace valves by aligning NEW solenoid over the

orifice and threading in place. Torque solenoid to
specification except solenoid number 4, 5 and 6. These
functions have a plastic seat and are torqued to a
lower specification. 13 12
Specification 11 10
Solenoid-to-Valve (Except No. 4,
5 and 6)—Torque ........................................................................... 14 N•m
(125 lb-in.) 9 8
Specification 5 4
Solenoid Number 4, 5 and 6—
Torque ............................................................................................ 11 N•m
–UN–08FEB01
(97 lb-in.) 6
NOTE: Repeat this procedure if changing more than one 1

solenoid.
HXC65968
70
4. Install coil cover and bracket. 16
15
5. Install nuts. A—Solenoid
B—Orifice
NOTE: Install coils slightly angled to allow connector to
nest between coils. After coils and bulkhead are
installed on the valve, make a functional check of
all hydraulic functions to make sure that no pins
have been dislodged from the connections and
that all coils are on the correct posts.
OUO6083,00005EB –19–27MAY03–1/1

083006
PN=775
Replacing Pilot Sleeve O-Rings
NOTE: Leave the orifice (B) (pressed into the cast iron
valve body) in place. Machined into the inside of
the cavity is a black O-ring (C). Remove this
O-ring. A thin sharp tool works well as a pick
when removing O-ring.
1. Install NEW O-ring into the cavity.
–UN–19AUG94
NOTE: Work the O-ring below the thread with your finger;
then use a thin, blunt instrument to guide the
O-ring into the groove. Make sure that the NEW
H46550
O-ring is not cut, nicked or damaged during the
installation. Make sure that the O-ring is
completely seated (all the way around). Be careful
not to scratch orifice (B) during procedure.
IMPORTANT: Replace the correct coil on the

solenoid.
2. Replace valves by aligning solenoid over the orifice
–UN–13JUN94
and threading in place. Torque solenoid to specification
except solenoid number 4, 5 and 6. These functions
have a plastic seat and are torqued to a lower
specification.
H46549
Specification
Solenoid-to-Valve (Except No. 4,
5 and 6)—Torque ........................................................................... 14 N•m
(125 lb-in.)
Specification
70 Solenoid Number 4, 5 and 6— 13 12
16 Torque ............................................................................................ 11 N•m
16 (97 lb-in.)
11 10
NOTE: Repeat this procedure if changing more than one

9 8
O-ring.
5 4
3. Install coil cover and bracket.
–UN–08FEB01
4. Install nuts. 6
1
A—Solenoid
B—Orifice
HXC65968
C—O-Ring
Continued on next page OUO6083,00005EA –19–27MAY03–1/2

083006
PN=776
NOTE: Install coils slightly angled to allow connector to

nest between coils. After coils and bulkhead are
installed on the valve, make a functional check of
all hydraulic functions to make sure that no pins
have been dislodged from the connections and
that all coils are on the correct posts.
OUO6083,00005EA –19–27MAY03–2/2
70
16
17

083006
PN=777
70
16
18

083006
PN=778
Group 17
Hydraulic Valve Stack (S.N. 715301—)

OUO6083,000057B –19–06MAY03–1/2
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D15032NU
–UN–01JUN01
H68348
OUO6083,000057B –19–06MAY03–2/2
70
17
1

083006
PN=779
Specifications
Hydraulic Reservoir Approximate Capacity 34 L

(36 qt)
Cartridge Valves (18, 33, and 26) Torque 27—34 N•m

(20—25 lb-ft)
Cartridge Valves (5) Torque 41—47 N•m

(30—35 lb-ft)
Orifice (12) Torque 3.4 N•m

(30 lb-in.)
Orifice (10 and 36) Torque 11 N•m

(96 lb-in.)
Orifice (37) Torque 4.5 N•m

(40 lb-in.)
Orifice (38) Torque 8 N•m

(72 lb-in.)
Fittings (8) Torque 31 N•m

(23 lb-ft)
Fittings (15) Torque 88 N•m

(65 lb-ft)
Fittings (32) Torque 13.5 N•m

70 (120 lb-in.)
17
2
Plugs (13) Torque 9.5—13.5 N•m
(84—120 lb-in.)
Plugs (34) Torque 19—24 N•m

(168—216 lb-in.)
Relief Valves Torque 27—34 N•m

(20—25 lb-ft)
Check Valves Torque 27 N•m

(20 lb-ft)
Diagnostic Receptacle Torque 13.5 N•m

(120 lb-in.)

083006
PN=780
Coil Nuts Torque 5—8 N•m

(48—72 lb-in.)
Socket Head Cap Screws Torque 13.5 N•m

(120 lb-in.)
OUO6046,0002002 –19–18JUL05–2/2
Valve Stack Identification

F
Function Coils Magnetized
Reel Raise (Header Speed F and D
Increase)
Reel Lower (Header Speed E
R T V
Decrease)
A E
Threshing Speed Increase A and D
D S U W
Threshing Speed Decrease A
–UN–08MAR05
Unloading Auger Extend S and D
Unloading Auger Retract R and D
Reel Fore/Aft Extend (Deck U and D A
Plates Open)
H82531
Reel Fore/Aft Retract (Deck T and D
Plates Close)
CONTOUR MASTER Extend (Tilt W and D A—Valve Stack Diagnostic Receptacle (B1)
Right)
CONTOUR MASTER Retract (Tilt V and D 70
Left) 17
3
OUO6046,0002004 –19–19JUL05–1/1

083006
PN=781
Remove and Install Hydraulic Valve Stack

(HIC)

–UN–23AUG88
X9811
fluids.

CAUTION: “Cracking” hydraulic hose fittings to

lower header will result in an instantaneous
dropping of the header and expulsion of the
sealing O-ring in the fitting.


allow removing the valve without draining the reservoir.
70 If vacuum pump is not available, drain reservoir.
17
4
Specification
(36 qt)
NOTE: DO NOT leave vacuum pump running for

extended period of time. Remove component and
cap lines. Extended use may burn up vacuum
pump.
Continued on next page OUO6083,0000DC5 –19–17AUG06–1/2

083006
PN=782
3. Disconnect oil lines (A).
4. Disconnect connectors (C and D).
5. Remove mounting cap screws (B) and remove valve

downward from bracket and clear of lines.
–UN–10JUN05
6. Any work to the valve should be done in a clean area
away from dust and dirt. Repair as necessary.
H83711
7. Install valve and tighten mounting cap screws (B).
8. Connect oil lines (A).

A—Oil Lines
9. Connect connectors (C and D). B—Cap Screw (2 used)
C—Connector
D—Pressure Sensor Connector
10. Fill reservoir.
Specification
(36 qt)
OUO6083,0000DC5 –19–17AUG06–2/2
70
17
5

083006
PN=783
Disassemble and Assemble Hydraulic Valve Stack (HIC)
6
3
7
4 8
10
5
2
1 32
16
15
11
13
12 14
37 36 38
17
13
36
70
17
6
18
35
11
34 33
31
21
39
20
23 19
22
26 30
–UN–21AUG06
4 28
29
27
25
24
H86468
Continued on next page OUO6083,0000DCD –19–18AUG06–1/3

083006
PN=784
1—Relief Valve 9—O-Ring (6 function, 7 used; 18—Cartridge Valve 29—Washer

2—Relief Valve 5 function, 6 used) 19—Nut 30—Bracket
3—Nut (6 function, 8 used; 5 10—Orifice (0.91 mm, 0.036 in.) 20—Cover 31—Connector
function, 6 used) 11—Check Valve (6 function, 6 21—Coil 32—Fitting (6 function only)
4—Coil (6 function, 9 used; 5 used; 5 function, 4 used) 22—Dust Cap 33—Cartridge Valve
function, 7 used) 12—Orifice (6 function only) 23—Diagnostic Fitting 34—Plug
5—Cartridge Valve (6 function, (0.66 mm, 0.026 in.) 24—Nut 35—O-Ring
7 used; 5 function, 5 used) 13—Plug (6 function, 29 used; 25—Socket Head Cap Screw (2 36—Orifice (2 used) (0.43 mm,
6—Disk (6 function, 7 used; 5 5 function, 26 used) used) 0.017 in.)
function, 6 used) 14—O-Ring (2 used) 26—Cartridge Valve 37—Orifice (0.43 mm, 0.017 in.)
7—O-Ring (6 function, 7 used; 15—Fitting (2 used) 27—Nut 38—Orifice (0.99 mm, 0.039 in.)
5 function, 6 used) 16—O-Ring (2 used) 28—Lock Washer (2 used) 39—O-Ring
8—Fitting (6 function, 7 used; 17—Cap Screw (2 used)
5 function, 6 used)
IMPORTANT: Work in clean area. Cleanliness is 8. Install orifices and tighten to specification.
extremely important when repairing
hydraulic valves. Specification
Orifice (12)—Torque ............................................................... 3.4 N•m
(30 lb-in.)
1. Remove socket head cap screws (25), bracket (30), Orifice (10 and 36)—Torque.................................................... 11 N•m
and harness connector (31). (96 lb-in.)
Orifice (37)—Torque ............................................................... 4.5 N•m
2. Remove nuts (3, 19, and 27), coils (4 and 21), and (40 lb-in.)
Orifice (38)—Torque .................................................................. 8 N•m
cartridge valves (5, 18, 33, and 26).
(72 lb-in.)
3. Inspect cartridge valves for scoring or damage.

9. Tighten fittings to specifications.
4. Replace O-rings and back-up rings any time Specification
cartridge valves are removed. Fittings (8)—Torque ................................................................. 31 N•m
(23 lb-ft)
5. Dip cartridge valves in clean hydraulic oil to Fittings (15)—Torque ............................................................... 88 N•m
(65 lb-ft)
lubricate O-rings and install in valve body. Torque
Fittings (32)—Torque ............................................................ 13.5 N•m
cartridge valves to specification. (120 lb-in.)
Specification
Cartridge Valves (18, 33, and
10. Tighten plugs to specification. 70
17
26)—Torque ...................................................................... 27—34 N•m
Specification 7
(20—25 lb-ft)
Cartridge Valves (5)—Torque........................................... 41—47 N•m Plugs (13)—Torque ...................................................... 9.5—13.5 N•m
(30—35 lb-ft) (84—120 lb-in.)
Plugs (34)—Torque .......................................................... 19—24 N•m
(168—216 lb-in.)
NOTE: Tapping plugs, fittings, and orifices with a
hammer may help aid in removal.
11. Install relief valves and tighten to specification.
6. Remove plugs (13 and 34), relief valves (1 and 2), Specification
fittings (8, 15, and 32) and orifices (10, 12, 36, 37, Relief Valves—Torque ...................................................... 27—34 N•m
and 38). (20—25 lb-ft)
7. Inspect all parts for wear or damage and replace as 12. Remove check valves (11). Inspect for wear or
necessary. damage and replace as necessary.
Continued on next page OUO6083,0000DCD –19–18AUG06–2/3

083006
PN=785
13. Install check valves and tighten to specification. 16. Install coils and tighten nuts to specification.
Specification Specification
Check Valves—Torque ............................................................ 27 N•m Coil Nuts—Torque ................................................................ 5—8 N•m
(20 lb-ft) (48—72 lb-in.)
14. Remove diagnostic fittings (23). Inspect for wear 17. Install bracket (30) and socket head cap screws
of damage and replace as necessary. (25). Tighten socket head cap screws to
specification.
15. Install diagnostic fitting and tighten to specification.
Specification
Specification Socket Head Cap Screws—
Diagnostic Receptacle—Torque ........................................... 13.5 N•m Torque................................................................................... 13.5 N•m
(120 lb-in.) (120 lb-in.)
OUO6083,0000DCD –19–18AUG06–3/3
70
17
8

083006
PN=786
Group 20
Hydraulic Cylinders
Specifications
Unloading Auger Swing Cylinder Torque 100—125 N•m

Piston (75—90 lb-ft)
AG,OUO6022,1671 –19–14JUL00–1/1
Remove and Install Header Lift Cylinder
CAUTION: To avoid personal injury or damage

to the combine, remove header from feeder
house before removing lift cylinder.
1. Place a suitable stand under front of feeder house.
2. Start engine and lower feeder house onto stand.

Engage parking brake and shut-off engine.
Continued on next page OUO6083,00007BC –19–18MAY04–1/2
70
20
1

083006
PN=787
Hydraulic Cylinders

penetrate the skin, causing serious injury.
all connections before applying pressure. Use a
piece of cardboard to search for leaks. Protect
–UN–23AUG88
hands and body from high pressure fluids.

X9811
3. Disconnect oil line (A).
4. Remove pins (B) to remove cylinder.
–UN–20FEB01
NOTE: Cylinder safety stop will come off with left-hand
cylinder.
H66493
5. Repair as required.
6. Install cylinder with pins (B).
7. Connect oil line (A).
8. Start engine, raise feeder house and remove stand.
–UN–11DEC03
70 A—Line
20 B—Pin (2 used)
2
H79395
OUO6083,00007BC –19–18MAY04–2/2
Disassemble and Assemble Header Lift

Cylinder
1. Remove paint and rust from rod with fine emery cloth.
Wash cylinder and dry.

083006
PN=788
Hydraulic Cylinders
2. Remove fitting from port on lift cylinder. Slide piston

until snap ring can be seen through port (A). Use a
screwdriver (B) to slide snap ring into groove, then
remove piston.
A—Port
B—Screwdriver
–UN–14APR00
H63611
70
20
3

083006
PN=789
Hydraulic Cylinders
J
L
M
K
O A O
B
C
D
E
F
G
H
–UN–05JUL01
I
H68999
A—Rod E—Seal U-Cup I—Hydraulic Cylinder Barrel M—Snap Ring
B—Snap Ring F—Back-up Ring J—Cotter Pin N—Stop
C—Seal G—Buffer Seal K—Pin O—Spacer (2 used)
D—Wear Ring H—Wear Ring L—Bushing
3. Remove seal kit (B—H). 5. Install seal kit (H—B).
70 4. Check hydraulic cylinder rod and barrel for wear

20 and damage. Replace as necessary.
4
OUO6083,00000D7 –19–19JUL01–3/3

083006
PN=790
Hydraulic Cylinders
Remove and Install Unloading Auger Swing

Cylinder
1. Swing auger all the way in (retracted).
2. Shut off engine.
–UN–23AUG88
X9811
fluids.

–UN–11FEB05
H82442
3. Disconnect and cap hoses (A).

A—Hydraulic Hose (2 used)
B—Pin (2 used)
4. Remove pins (B).
C—Cylinder
5. Remove cylinder (C).
6. Inspect parts and repair as necessary.

70
7. Install cylinder (C) and pins (B). 20
5
8. Connect hoses.
OUO6083,000091E –19–11FEB05–1/1

083006
PN=791
Hydraulic Cylinders
Unloading Auger Swing Cylinder Exploded View
J
I
H
G
F
E
L
D M
C N
B
O
A
P
70 R
20 S
6
U
–UN–20MAY03
H77255
Continued on next page OUO6083,00005CB –19–20MAY03–1/2

083006
PN=792
Hydraulic Cylinders
A—Tie Rod End G—Snap Ring L—O-Ring Q—Rod

B—Nut H—Seal M—Seal R—Cap
C—Seal I—Washer N—Ring S—Orifice
D—Snap Ring J—O-Ring O—Piston T—Barrel
E—Seal K—Guide P—Seal U—Nut
F—O-Ring
For cylinder repairs (See TMH100A).
OUO6083,00005CB –19–20MAY03–2/2
Adjust Unloading Auger Swing Cylinder
1. Swing unloading auger to storage or transport position.

Keep pivoting cradle pinned (A).
2. Measure distance (B) between back edge of cradle
–UN–28APR03
support bracket (C) and tubular structure of grain tank
frame.
NOTE: Cradle support bracket must be square with grain
H76212
tank frame.
3. Loosen but do not remove cap screws (D). Adjust to

specification and tighten cap screws. A—Pin
B—Measured Distance
Specification C—Cradle Support Bracket
Back Face of Cradle Support D—Cap Screw (3 used)
Bracket to Tank Structure—
Distance ......................................................................................... 111 mm 70
(4.37 in.) 20
7
4. For machines with High Unload Rate, perform the
following;
OUO6083,0000BB6 –19–18OCT05–1/3
Measure distance from unloading auger edge (A) to

tubular structure on grain tank frame (B).
A—Unloading Auger Edge

B—Grain Tank Frame
–UN–27MAY04
H80949
Continued on next page OUO6083,0000BB6 –19–18OCT05–2/3

083006
PN=793
Hydraulic Cylinders
5. If gap is incorrect, loosen jam nut (A), remove cap

screw, plate and pin (B).
6. Manually move auger to specification.
Specification
Unloading Auger Edge to Grain
–UN–11FEB05
Tank Structure—Distance ............................................................... 73 mm
(2.88 in.)
7. Turn eyebolt (C) in or out of cylinder.
H82441
8. Install pin (B), plate and cap screw. Tighten jam nut
(A).
A—Jam Nut
B—Pin
C—Eyebolt
OUO6083,0000BB6 –19–18OCT05–3/3

Cylinder

–UN–23AUG88
X9811
70 fluids.
20
8


083006
PN=794
Hydraulic Cylinders
NOTE: Gull wing door removed for clarity.
2. Disconnect hoses (A) from drive cylinder (B).
3. Remove cotter pin, washer and pin (C).
4. Remove E-ring and washer from idler pivot (D).
–UN–21JAN99
Remove idler pivot and drive cylinder as an assembly.
A—Hydraulic Hoses
H51800
B—Drive Cylinder
C—Pin
D—Idler Pivot
OUO6083,0000316 –19–14AUG02–2/3
5. Remove cotter pin, washer, and pin (A).
6. Remove two hydraulic fittings (C).
7. Install unloading auger drive cylinder (B) in reverse

order.
A—Pin
B—Drive Cylinder
–UN–21JAN99
C—Hydraulic Fitting (2 used)
70
20
9
H51801
OUO6083,0000316 –19–14AUG02–3/3

083006
PN=795
Hydraulic Cylinders
70
20
10

083006
PN=796
Group 25
Motors
Remove and Install Straw Spreader Motor

–UN–23AUG88
fluids.
X9811
–UN–26FEB99
NOTE: Procedure is similar for BOTH motors.
1. Remove quick-lock pin (B) and disk (A).
H54212
A—Disk
B—Quick-Lock Pin
70
25
AG,OUO6022,1995 –19–25JUL00–1/7
1
2. Remove cap screws (A) and shield (B).
3. Remove sensor and actuator (left-hand spreader shaft

only).
A—Cap Screw
B—Shield
–UN–04MAY99
H55888

083006
PN=797
Motors
4. Remove round head bolts (A) retaining bearing.
A—Round Head Bolt (3 used)
–UN–03MAY99
H55895
AG,OUO6022,1995 –19–25JUL00–3/7
5. Remove cap screws (A) and support (B).

B—Support
–UN–03MAY99
H55897
AG,OUO6022,1995 –19–25JUL00–4/7
6. Loosen cap screws (A), remove shaft (C) and coupler

(B).

25 B—Coupler
2 C—Shaft
–UN–03MAY99
H55898
AG,OUO6022,1995 –19–25JUL00–5/7
7. Disconnect hydraulic hose (A). Disconnect hose from

coupler (B) and plug openings.
A—Hydraulic Hose
B—Quick Coupler
–UN–03MAY99
H55904

083006
PN=798
Motors
8. Remove cap screws (A) and motor.
9. Position motor and install cap screws.
10. Connect hydraulic hoses.
–UN–17MAY99
11. Install coupler and shaft.
12. Install bearing support and cap screws.
H55905
13. Position bearing flanges and install round head bolts.
14. Install sensor, actuator and shield.

15. Slide disk on shaft and install quick-lock pin.
AG,OUO6022,1995 –19–25JUL00–7/7
70
25
3

083006
PN=799
Motors
Remove and Install Wide Spread Tailboard

Motors

–UN–23AUG88
X9811
fluids.

–UN–15JUN05
NOTE: Procedure is similar for BOTH motors.
H83737
1. Remove lock nuts (A), cap screws (B), round head
bolts (C) and cover (D).
2. Remove cap screw and nut (E) and disk assembly (F).
A—Lock Nut (3 used)

C—Round Head Bolt (4 used)
D—Cover
E—Cap Screw and Nut
–UN–15JUN05
70 F—Disk Assembly
25
4
H83738
Continued on next page OUO6083,0000D9B –19–17JUL06–1/2

083006
PN=800
Motors
3. Remove hydraulic hoses (A) from motor.
4. Remove cap screws (B), plate (C) and motor (D).
5. Replace as necessary.
6. Install in reverse order using new O-rings on hydraulic
–UN–17JUL06
fittings.
A—Hydraulic Hoses
H86335
C—Plate
D—Hydraulic Motor
–UN–15JUN05
H83744
OUO6083,0000D9B –19–17JUL06–2/2
70
25
5

083006
PN=801
Motors
70
25
6

083006
PN=802
Group 30
Accumulator



OUO6083,00006A3 –19–18NOV03–1/4
Nitrogen Accumulator Service Kit . . . . . . . . . . . JT03515
Checking charge pressure on accumulator.
OUO6083,00006A3 –19–18NOV03–2/4
Gas Cock . . . . . . . . . . . . . . . . . . . . . . . . . . JT01735
To be used with JT03515

70
30
OUO6083,00006A3 –19–18NOV03–3/4
1
High Pressure Hose Assembly . . . . . . . . . . . . . JT05563
To be used with JT03515
OUO6083,00006A3 –19–18NOV03–4/4
Accumulator (General Information)
The accumulator is connected to the header lift system

between the lift cylinders and the solenoid control valve. It
suspends the header over uneven ground by compressing
nitrogen gas with a diaphragm in the accumulator tank.
–UN–18NOV03
The accumulator has a volume of 0.7 L (0.18 U.S. gal.).

Gas pressure is dependent on header size, lift cylinder
diameter and feeder house type.
H79152
OUO6083,00006A1 –19–18NOV03–1/1

083006
PN=803
Accumulator
Checking Header Float System Accumulator
NOTE: Before connecting service kit JT03515 to

accumulator, slightly loosen accumulator hex head
cap screw. This will avoid damage to the testing
device when accumulator is opened.
–UN–18NOV03
1. Relieve pressure in hydraulic hose to header lift
cylinders by actuating switch for lowering header.
H79153
IMPORTANT: Be sure all valves are closed before
installing testing device. If checking
pressure only, DO NOT install nitrogen
charge hose. This could give false A—Accumulator
reading on pressure gauge. B—Service Kit JT03515
2. For checking accumulator (A), install service kit

JT03515 (B) to accumulator.
OUO6083,00009CD –19–26APR05–1/3
NOTE: High pressure hose JT05563 and gas cock

JT01735 will be needed to hook service kit
JT03515 to nitrogen tank if charging is required.
70
30 3. Use a ratchet (A) to open accumulator valve (B).
2 Accumulator charging pressure is indicated by the
–UN–18NOV03
pressure gauge (C). If charging pressure is too low, the
accumulator must be charged with nitrogen.
A—Ratchet
H79154
B—Accumulator Valve
C—Gauge
Continued on next page OUO6083,00009CD –19–26APR05–2/3

083006
PN=804
Accumulator
4. The accumulator may be charged by opening the gas

cocks (A). If the accumulator is not connected to an
external nitrogen source, (under pressure) pressure is
reduced by opening knurled screw (B).
5. Adjust charging pressure according to the table in this
–UN–18NOV03
group.
A—Gas Cock (2 used)

B—Knurled Screw
H79166
OUO6083,00009CD –19–26APR05–3/3
Accumulator Precharge Pressure
NOTE: Refer to the following chart to determine if

precharge needs to be changed. The factory
precharge setting is 6895 kPa (1000 psi).
Header Model Header Weight 63 mm Lift Cylinders 70 mm Lift Cylinders

618 1691 kg (3730 lb) 6000 kPa (870 psi) N/A
620 1818 kg (4010 lb) 8000 kPa (1160 psi) N/A
622 1945 kg (4290 lb) 8000 kPa (1160 psi) N/A
625 2135 kg (4710 lb) 9000 kPa (1305 psi) 6000 kPa (870 psi)
900D 925D 2400 kg (5393 lb) 12000 kPa (1740 psi) 10000 kPa (1450 psi) 70
930D 2600 kg (5733 lb) 30
936D 3000 kg (6615) 3
OUO6083,00005D6 –19–21MAY03–1/1

083006
PN=805
Accumulator
70
30
4

083006
PN=806
Section 80
Separator Shell
Contents
Page
Group 05—Gull Wing Doors

Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .80-05-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .80-05-1
Remove and Install Gull Wing Doors. . . . . . . . .80-05-2
Remove and Install Rear Wall Panel. . . . . . . . .80-05-2
Remove and Install Rear Access Door . . . . . . .80-05-3
Composite Panel Repair . . . . . . . . . . . . . . . . . .80-05-5
Align Gull Wing Doors . . . . . . . . . . . . . . . . . . . .80-05-7
Remove and Install Engine Platform Ladder . . .80-05-9
80

083006
PN=1
Contents
80

083006
PN=2
Group 05
Gull Wing Doors
Other Material
Number Name Use
PM37513 (U.S.) Epoxy Adhesive Used to repair pulled out studs in

composite style panels.
OUO6083,0000BB8 –19–18OCT05–1/1
Specifications
Right-Hand Gull Wing Door Weight 37 kg

(82 lb)
Left-Hand Front Gull Wing Door Weight 35 kg

(78 lb)
Left-Hand Rear Gull Wing Door Weight 33 kg

(73 lb)
Rear Wall Panel Weight 30 kg

(66 lb)
OUO6083,0000C40 –19–23JAN06–1/1
80
05
1

083006
PN=809
Gull Wing Doors
Remove and Install Gull Wing Doors
CAUTION: Cylinder contents under pressure.

Do not take apart, puncture, apply heat or fire.
1. Disconnect wiring harness (E) and remove cylinder (D)
–UN–01JUL02
at both ends of gull wing panel (C).
CAUTION: Gull wing doors are heavy. To help
H72753
avoid personal injury use two or more persons
to remove gull wing door(s).
NOTE: Do not remove cap screws (B) from saddle A—Cap Screw (4 used)
bracket. B—Cap Screw (4 used)
C—Gull Wing Panel
D—Cylinder
2. Remove cap screws (A) and nuts at both ends of gull E—Connector
wing panel.
3. Remove gull wing panel.
4. Repair or replace parts as necessary.
5. Position gull wing panel (C) on hinge bracket.
6. Align holes on hinge bracket and retain using cap

screws (A) and nuts at both ends.
7. Close gull wing panels and check alignment. (See

ALIGN GULL WING DOORS in this group.)
80
05
2
OUO6083,00002EC –19–01JUL02–1/1
Remove and Install Rear Wall Panel
1. Open rear left-hand gull wing door and right-hand side

access door.
Continued on next page OUO6083,0000C3F –19–23JAN06–1/2

083006
PN=810
Gull Wing Doors
2. Turn socket (A) counterclockwise and remove from

light housings on rear panel.
3. Remove cap screws (B) from bracket (C) attached to

rear panel.
–UN–20JAN06
CAUTION: Approximate weight of rear panel is
30 kg (66 lb).
H85259
CAUTION: If equipped, rear access door must
be held and strap reattached to upright to
prevent door from falling and being damaged.
4. Attach proper lifting device (D) to brackets (E).
5. Remove cap screws (F) from brackets (G).
6. Repair or replace rear panel as needed.
–UN–20JAN06
7. Install rear panel in reverse order.
A—Socket (4 used)
H85260
C—Bracket
D—Lifting Device
E—Bracket
G—Bracket (4 used)
–UN–23JAN06
H85261
80
05
3
OUO6083,0000C3F –19–23JAN06–2/2
Remove and Install Rear Access Door
1. Open right-hand side access door.
Continued on next page OUO6083,00000AE –19–26JUN01–1/2

083006
PN=811
Gull Wing Doors
2. Turn socket (A) counterclockwise and remove from

right-hand turn signal light housing on rear access
door.
3. Disconnect connector (B) from service light switch (C).
–UN–25FEB00
4. With rear access door closed, remove nut (D) and cap
screw.
IMPORTANT: Have an assistant hold onto door prior
H62818
to removing cap screws and nuts. Door
will be damaged if allowed to fall.
5. Remove two nuts (E), cap screws and lift rear access
door from hinges.
6. Install rear access door.
7. Install light socket.
–UN–25FEB00
8. Connect connector (B).
A—Socket
B—Connector
H62819
C—Service Light Switch
D—Nut
E—Nut (2 used)
–UN–25JUN01
H68969
80
05
4
–UN–25FEB00
H62821
OUO6083,00000AE –19–26JUN01–2/2

083006
PN=812
Gull Wing Doors
Composite Panel Repair
CAUTION: Read and understand safety and

handling instructions provided by the
manufacturer of repair materials to help avoid
personal injury.
NOTE: For more information on fiberglass repair refer to

the following manuals:
FOS 5904—Fiberglass Fundamentals of Service

Manual; recommended guide of fiberglass and
other thermoset parts.
FOS 6501—Plastic Repair Fundamentals of

Service Manual; recommended guide for repair of
thermoplastic parts.
The following procedures cover repair of specific damage

types. Procedures listed are general guidelines for repair
of fiberglass reinforced plastic (composite) panels. Always
follow manufacturer’s instructions when applying repair
material.
OUO6083,0000AAF –19–19JUL05–1/7
Pulled Out Stud

80
1. Remove nuts and bracket from damaged area.
05
5
2. Clean loose debris from boss (A) using compressed
air.
–UN–14APR99
3. Clean debris from stud threads.
A—Boss
H54946
Continued on next page OUO6083,0000AAF –19–19JUL05–2/7

083006
PN=813
Gull Wing Doors
4. Apply PM37513 Epoxy Adhesive to boss (A) and

threads of stud (B).
5. Insert stud into boss until flange on stud contacts boss.

Follow manufacturer’s instructions and allow adequate
drying time.
–UN–14APR99
A—Boss
B—Stud
H54953
OUO6083,0000AAF –19–19JUL05–3/7
Ribs Cracked Or Broken Out Stud
1. Remove all loose material and debris from damaged

area (A).
2. Remove composite material from threads of stud (B).
–UN–14APR99
A—Damaged Area
B—Stud
H54958
OUO6083,0000AAF –19–19JUL05–4/7
3. Cut pieces of fiberglass cloth (A) from fiberglass repair

kit1, large enough to extend past damaged area.
A—Fiberglass Cloth
–UN–14APR99
80
05 H54966
6 1
Available from local supplier
OUO6083,0000AAF –19–19JUL05–5/7
4. Mix repair material and apply to both sides of damaged

area, extending out the length of repair cloth and also
into boss (B).
5. Embed cloth (A) in repair material.

–UN–14APR99
A—Repair Cloth
B—Boss
H54988
Continued on next page OUO6083,0000AAF –19–19JUL05–6/7

083006
PN=814
Gull Wing Doors
6. Insert stud (A) into repair material in boss, until stud

flange contacts boss. Installing two nuts on stud will
help to thread stud into boss.
NOTE: If bracket was removed to make repair, use

bracket as a template to align stud while material
–UN–14APR99
is soft.
7. Allow first application to harden; then apply second

application of repair material to area and work until
H54989
smooth.
A—Stud
OUO6083,0000AAF –19–19JUL05–7/7
Align Gull Wing Doors
1. Open gull wing door.
2. Loosen nut (A) on clamp (B) on both sides for

horizontal adjustment.
–UN–24MAY99
A—Nut
B—Clamp
H57441
OUO6083,0000C3E –19–20JAN06–1/4
3. Loosen cap screws (A) and nuts (B) on both sides for
vertical and lateral adjustment.
80
05
B—Nut (4 used) –UN–24MAY99
H57442
Continued on next page OUO6083,0000C3E –19–20JAN06–2/4

083006
PN=815
Gull Wing Doors
4. Adjust so decals (A) align and door opens freely.
A—Decal
–UN–04JUN99
H57598
OUO6083,0000C3E –19–20JAN06–3/4
6. Loosen nuts (A) and align door latch.
7. Tighten nuts (A) and close gull wing door.
A—Nuts
–UN–11JAN06
H85214
–UN–11JAN06
H85215
80
05
8
OUO6083,0000C3E –19–20JAN06–4/4

083006
PN=816
Gull Wing Doors
Remove and Install Engine Platform Ladder
1. Remove round head bolts (A) from transport warning

light mounting bracket.
A—Round Head Bolts (4 used)
–UN–18MAY05
H83502
RO33873,0000035 –19–19MAY05–1/2
2. Rotate ladder (B) to right-hand side as shown and pull

straight out.
3. Install ladder and reattach transport warning light (A).
A—Transport Warning Light

B—Ladder
–UN–18MAY05
H83501
80
05
9
RO33873,0000035 –19–19MAY05–2/2

083006
PN=817
Gull Wing Doors
80
05
10

083006
PN=818
Section 90
Operator Station Repair
Contents
Page Page
Group 05—Air Conditioning System (R134a) Replace Heater Control Valve . . . . . . . . . . . . . .90-10-8
Essential or Recommended Tools . . . . . . . . . . .90-05-1 Remove and Install Temperature Control
Service Equipment and Tools . . . . . . . . . . . . . .90-05-3 Door Actuator . . . . . . . . . . . . . . . . . . . . . . . .90-10-9
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-4 Remove and Install Heater Core . . . . . . . . . . .90-10-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-5 Remove Condenser . . . . . . . . . . . . . . . . . . . .90-10-11
Service Parts Kits . . . . . . . . . . . . . . . . . . . . . . .90-05-6 Remove Condenser—Tier III Cooling
Hose and Tubing O-Ring Connection Package . . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-12
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-6 Repair Condenser . . . . . . . . . . . . . . . . . . . . . .90-10-14
Discharge and Recovery of Air Conditioning Install Condenser . . . . . . . . . . . . . . . . . . . . . .90-10-14
Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-7 Install Condenser—Tier III Cooling
Remove and Install Compressor . . . . . . . . . . . .90-05-8 Package . . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-16
Test Volumetric Efficiency . . . . . . . . . . . . . . . .90-05-10 Replace Evaporator—Style A . . . . . . . . . . . . .90-10-19
Leak Testing Air Conditioning System Replace Evaporator—Style B . . . . . . . . . . . . .90-10-20
With Dye . . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-12 Replace Expansion Valve . . . . . . . . . . . . . . . .90-10-21
Test Shaft Seal Leakage . . . . . . . . . . . . . . . . .90-05-15 Remove and Install Evaporator Temperature
Disassemble and Assemble Compressor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-22
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-16 Replace Low Pressure Switch . . . . . . . . . . . . .90-10-22
Check Clutch Hub Clearance . . . . . . . . . . . . .90-05-17 Replace High Pressure Switch . . . . . . . . . . . .90-10-23
Inspect Compressor Manifold . . . . . . . . . . . . .90-05-17 Replace Air Temperature Sensors . . . . . . . . .90-10-23
Disassemble, Inspect, and Assemble
Compressor . . . . . . . . . . . . . . . . . . . . . . . . .90-05-18
Remove and Install Compressor Relief Group 15—Cab
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-20 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-1
System Information . . . . . . . . . . . . . . . . . . . . .90-05-22 Remove and Install Cab Windshield—
Flush Air Conditioning System . . . . . . . . . . . .90-05-24 Style A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-2
Purge Air Conditioning System . . . . . . . . . . . .90-05-26 Remove and Install Cab Windshield—
Evacuate Air Conditioning System . . . . . . . . .90-05-27 Style B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-6
Compressor Oil Information. . . . . . . . . . . . . . .90-05-29 Remove Cab . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-10
Determine Correct Oil Charge . . . . . . . . . . . . .90-05-30 Install Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-18
Check Refrigerant Oil Charge . . . . . . . . . . . . .90-05-31 Replace Rear Window. . . . . . . . . . . . . . . . . . .90-15-25
Charge Air Conditioning System . . . . . . . . . . .90-05-32 Remove and Install Cab Roof—Style A. . . . . .90-15-26
Remove and Install Cab Outer Roof—
Group 10—System Components Style B. . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-28
Essential or Recommended Tools . . . . . . . . . . .90-10-1 Remove and Install Cab Inner Roof—Style
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-29 90
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-2 Remove and Install Cab Headliner—Style
Air Conditioning System With Precleaner B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-33
(General Information). . . . . . . . . . . . . . . . . . .90-10-3 Remove and Install Operator’s Seat . . . . . . . .90-15-33
Remove and Install Receiver/Dryer . . . . . . . . . .90-10-4 Remove and Install Armrest Control
Remove and Install Blower Motor—Style A . . . .90-10-5 Pivot—Style A . . . . . . . . . . . . . . . . . . . . . . .90-15-37
Remove and Install Blower Motor—Style B . . . .90-10-6 Remove and Install Armrest Control
Remove and Install Recirculator Fan Pivot—Style B . . . . . . . . . . . . . . . . . . . . . . .90-15-39
Motor Driver—Style A . . . . . . . . . . . . . . . . . .90-10-6 Disassemble and Assemble Armrest
Remove and Install Recirculator Fan Control Pivot . . . . . . . . . . . . . . . . . . . . . . . .90-15-40
Motor Driver—Style B . . . . . . . . . . . . . . . . . .90-10-7
Remove and Install Recirculator Motor . . . . . . .90-10-7 Continued on next page

083006
PN=1
Contents
Page
Remove and Install Operator Presence

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-42
Operator Seat—Exploded View . . . . . . . . . . . .90-15-44
Operator Seat Air Suspension Assembly—
Exploded View. . . . . . . . . . . . . . . . . . . . . . .90-15-46
Disassemble and Assemble Operator Seat
Air Suspension Assembly . . . . . . . . . . . . . .90-15-47
Remove and Install Cab Door . . . . . . . . . . . . .90-15-51
Disassemble and Assemble Cab Door . . . . . .90-15-52
Cab Door Latch Striker . . . . . . . . . . . . . . . . . .90-15-54
90

083006
PN=2
Group 05
Air Conditioning System (R134a)
Catalogs.
AG,OUO6045,51 –19–25JUL00–1/12
HFC134A Recovery/Recycling Station . . . . . . . JT020501
Servicing air conditioning system using R134a refrigerant.
–UN–17AUG92
RW21613
1
Used with JT02046 Charging Station. JT02047 Recovery, Recycling,
and Charging Station can be substituted for JT02046 and JT02050.
AG,OUO6045,51 –19–25JUL00–2/12
RW40022 –UN–08SEP93
Air Conditioning R12/R134a Fitting Kit . . . . . . . JT02098
Connect flushing, purging and pressure equipment.
AG,OUO6045,51 –19–25JUL00–3/12
Manifold with Gauges. . . . . . . . . . . . . . . . . . . JT02051
Check A/C system pressure.
–UN–22JUN94
90
05
1
RW25172
AG,OUO6045,51 –19–25JUL00–4/12
RW25567 –UN–06SEP96
Electronic Leak Detector . . . . . . . . . . . . . . . . JT02081
Checking A/C system for leaks.

083006
PN=821
RW19932 –UN–19MAY92
Air Conditioning Compressor Clutch Spanner . . .JDG747
Used to remove and install compressor clutch.
AG,OUO6045,51 –19–25JUL00–6/12
RW40022 –UN–08SEP93
Pulley Remover . . . . . . . . . . . . . . . . . . . . D05277ST
Remove compressor pulley.
AG,OUO6045,51 –19–25JUL00–7/12
RW19935 –UN–19MAY92
Hub Puller Jaws . . . . . . . . . . . . . . . . . . . . . .JDG748
Removing compressor pulley—(Used with D05277ST

Puller and JDG771 Hub Protector.)
AG,OUO6045,51 –19–25JUL00–8/12
RW21598 –UN–17AUG92
Hub Protector . . . . . . . . . . . . . . . . . . . . . . . .JDG771
Used to protect end of shaft when removing hub.
AG,OUO6045,51 –19–25JUL00–9/12
RW40022 –UN–08SEP93
Compressor Seal and Clutch Repair Kit . . . . . . .JDG215
Remove and install air conditioning seal and clutch

components on air conditioning compressor.
AG,OUO6045,51 –19–25JUL00–10/12
RW19943 –UN–19MAY92
Compressor Seal Protector . . . . . . . . . . . . . . .JDG746
Install seal on compressor.
AG,OUO6045,51 –19–25JUL00–11/12
90 HFC134A Charging Station . . . . . . . . . . . . . . JT020461

05
2
–UN–17AUG92
1
Used with JT02050 Recovery and Recycling Station. JT02047
RW21595
Recovery, Recycling and Charging Station can be substituted for

JT02046 and JT02050.
AG,OUO6045,51 –19–25JUL00–12/12

083006
PN=822

OUO6083,00002D6 –19–19JUN02–1/5
Dial Indicator, Metric Scale . . . . . . . . . . . . . D17527C1
Used to check pulley-to-clutch hub clearance.
OUO6083,00002D6 –19–19JUN02–2/5
Dial Indicator, English Scale . . . . . . . . . . . . D17526C1
Used to check pulley-to-clutch hub clearance.
OUO6083,00002D6 –19–19JUN02–3/5
Magnetic Base with Adjustable Arms. . . . . . . D17525C1
Used to hold dial indicator during use.
OUO6083,00002D6 –19–19JUN02–4/5
Compressor Holding Fixture . . . . . . . . . . . . . DFRW20
Used to hold compressor during disassembly and

assembly.
OUO6083,00002D6 –19–19JUN02–5/5
90
05
3

083006
PN=823
Other Material
Number Name Use
TY22101-12 oz (U.S.) R134a Compressor Oil Lubricate the system.
TY25601-1 gal (U.S.) Air conditioning flushing solvent Used to flush air conditioning
system.
TY15949-12 oz (U.S.) Refrigerant 134A Used to charge the system
TY15951-30 lb (U.S.) Refrigerant 134A Used to charge the system
OUO6083,0000590 –19–14JUN05–1/1
90
05
4

083006
PN=824
Specifications
Evacuating System Required Vacuum at Sea Level 94.4 kPa

(0.9 bar)
(28.6 in. Hg)
Refrigerant R134a Capacity 1.8—2.1 kg

(4—4.5 lb)
Compressor Oil Charge 255 mL

(8.5 fl oz)
Discharge Pressure at 2000 rpm 690—2590 kPa
(6.9—25.9 bar)
(100—375 psi)
Suction Pressure at 2000 rpm 7—200 kPa
(0.07—2.0 bar)
(1—30 psi)
Clutch Hub Cap Screw Torque 14 N•m

(124 lb-in.)
Hub-to-Pulley Clearance 0.35—0.65 mm

(0.014—0.026 in.)
Clutch Coil Current Draw at 12 volts 20°C (68°F) 2.6 amps

Resistance at 20°C (68°F) (3.5—4.0 ohms)
Compressor Manifold Cap Screws Torque 26 N•m

(19 lb-ft)
Compressor Through Bolts Torque 26 N•m

(19 lb-ft)
Compressor Relief Valve Opening Pressure 3450—4140 kPa

(34.5—41.4 bar)
(500—600 psi)
Torque 12—16 N•m
(9—12 lb-ft)
Compressor Suction Line Torque 34—42 N•m

(25—31 lb-ft)
90
Compressor Discharge Line Torque 32—40 N•m 05
5
(24—29 lb-ft)
OUO6083,0000591 –19–08MAY03–1/1

083006
PN=825
Service Parts Kits
The following kits are available through your parts • Compressor Clutch Hub And Pulley Kit
catalog: • Compressor Clutch Coil Kit
• Compressor Hardware Kit
• Compressor Shaft Seal Kit
RX15009010,3 –19–25JUL00–1/1
Hose and Tubing O-Ring Connection Torques

Metal Tube Outside Diameter Thread and Fitting Size Torque
N•m (lb-ft)
1/4 7/16 14-20 (10-15)
3/8 5/8 14-20 (10-15)
1/2 3/4 33-39 (24-29)
5/8 7/8 35-42 (26-31)
3/4 1-1/16 41-47 (30-35)
RX14339005,4 –19–25JUL00–1/1
90
05
6

083006
PN=826
Discharge and Recovery of Air Conditioning

Refrigerant
Operate the air conditioning system for 10 minutes with

engine at 2000 rpm if the compressor is operable. Set
temperature control for maximum cooling and blower
switch at high. This allows the refrigerant oil to be
circulated through the system and indicates the quantity of
oil in the compressor.
Stop the engine and use the following procedure to

discharge the system.
1. Connect JT02050 R134a Refrigerant Recovery and

Recycling Station to a JT02046 HFC134a Refrigerant
Charging Station.
NOTE: Used with JT02046 Charging Station. JT02047

Recovery, Recycling, and Charging Station can be
substituted for JT02046 and JT02050.
OUO6083,00009D0 –19–27APR05–1/2
2. Connect low-side hose (blue) from the charging station

to suction fitting (A). Connect high-side hose (red) to
the discharge fitting (B).
3. Follow the manufacturer’s instructions and discharge

the system. Cap the fittings to prevent contamination
–UN–08NOV04
from entering the system.
A—Suction Fitting
B—Discharge Fitting
H81947
OUO6083,00009D0 –19–27APR05–2/2
90
05
7

083006
PN=827
Remove and Install Compressor
NOTE: Procedure shown for 9.0 L engines, procedure for

12.5 L and 8.1 L engines are similar.
1. Discharge air conditioning system. (See DISCHARGE
–UN–02JUN05
AND RECOVERY OF AIR CONDITIONING
REFRIGERANT, in this group.)
2. Remove belt (A) from the compressor pulley.
H83644
3. Disconnect clutch coil wire (B) and ground wire (E).
IMPORTANT: Corrosion sometimes develops between

the hose fittings and the compressor
manifolds causing disassembly difficult
or impossible without damaging
manifold port threads. Leave hoses
attached to the manifold to aid
–UN–13JUN05
disassembly and assembly.
4. Remove cap screws (C) and discharge manifold (D)

from the compressor. Cap all lines and fittings to
H83645
prevent contamination.
5. Remove cap screws (F and G), bracket (H) and

compressor. A—Belt
B—Clutch Coil Wire
6. Flush the complete system if compressor failed D—Manifold
internally due to damaged parts or seizure. (See E—Ground Wire
FLUSH AIR CONDITIONING SYSTEM, in this group.) F—Cap Screw (4 used)
G—Cap Screw (2 used)
7. Determine correct compressor oil charge. (See H—Bracket
OUO6046,0001F0F –19–13JUN05–1/3
90 NOTE: Alignment spring pins (A) must be in the front two

05 holes of the mounting bracket. If spring pins are
8
not in place, misalignment can occur causing
premature belt failure.
8. Check that spring pins (A) are in place in mounting

–UN–13JUN05
bracket.
A—Spring Pin (2 used)

H83730
Continued on next page OUO6046,0001F0F –19–13JUN05–2/3

083006
PN=828
9. Install compressor, bracket (H) and cap screws (G).
10. Install cap screws (F).
11. Install manifold (D) and retain with cap screws (C).
–UN–02JUN05
12. Connect clutch coil wire (B) and ground wire (E).
13. Install belt (A).
H83644
14. Evacuate and charge system. (See procedures in this
group.)
IMPORTANT: If NEW compressor clutch was

installed, turn compressor on and off
(engine running) in 1-second intervals
for 5 seconds (cycle five times in 5
seconds). This will burnish clutch and
hub drive surfaces.
–UN–13JUN05
A—Belt
B—Clutch Coil Wire
H83645
D—Manifold
E—Ground Wire
G—Cap Screw
H—Bracket
OUO6046,0001F0F –19–13JUN05–3/3
90
05
9

083006
PN=829
Test Volumetric Efficiency
1. Drain oil from compressor and record amount.
2. Remove front cover from compressor pulley and rotate

drive shaft 30 revolutions using a speed wrench and
10 mm socket.
3. Drain remaining oil from compressor and record

amount.
NOTE: If no oil was removed, add two ounces of R134a

refrigerant oil in suction port. Slowly roll
compressor in each direction at least two times.
Repeat Steps 1—3.
4. Secure compressor in a vise with ports upward.
5. Install JT020991 Adapter in suction port with JT031941

Cap.
–UN–20AUG98
6. Connect suction hose coupler of gauge set to suction
test port (A) on manifold.
RW40028A
7. Close gauge set suction side valve and open valve on
suction hose coupler.
8. Rotate compressor drive shaft with speed wrench to A—Suction Test Port
obtain peak vacuum on low side gauge. Check for
even suction (no pulsing) while turning wrench at a
slow rate to maintain peak vacuum (25 in. Hg.
minimum).
9. Stop rotating shaft and check leak-down time.

Compressor should hold peak vacuum for a minimum
of three seconds. If compressor does not hold for three
seconds, inspect compressor valve plates and cylinder
walls for damage.
10. Open suction port of compressor to atmosphere.
90
05
10
1
Included in JT02098 Air Conditioning Fitting Kit

083006
PN=830
11. Connect gauge set suction hose to discharge port (A)

using JT021001 Adapter and JT021081 Hose.
12. Close gauge set suction side valve.
13. Rotate drive shaft no faster than two turns per second
for six turns.
14. Record pressure after six complete turns. Pressure

should be 380 kPa (3.8 bar) (55 psi) minimum.
NOTE: Pressure normally leaks down when rotation

stops.
15. Continue to rotate compressor at a uniform speed to

obtain peak pressure. Compression pressure should
increase smoothly and should not vary more than 34
kPa (0.34 bar) (5 psi) at peak pressure. Bleed off
pressure and repeat Steps 13, 14 and 15 four times.
–UN–20AUG98
NOTE: Pressure varying more than 34 kPa (0.34 bar) (5
psi) indicates a leaking reed-valve or piston seal.
Inspect compressor valve plates and cylinder
walls for damage. Repair compressor.
RW40029A
16. Leak test compressor. (See TEST SHAFT SEAL
LEAKAGE, this group.)
A—Discharge Port
1
AG,OUO6030,137 –19–25JUL00–2/2
90
05
11

083006
PN=831
Leak Testing Air Conditioning System With

Dye
CAUTION: Always wear safety glasses when

working with refrigerants. Contact with
refrigerant can cause serious injury.
IMPORTANT: Use only approved dye in John Deere

systems, other dyes may not have
compatible oil for R134a systems. DO
NOT allow dye to come into contact
with vehicle painted surfaces. Wipe off
immediately in case of spillage.
Test for presence of dye in system:
NOTE: If dye has been installed in the system, the

receiver-dryer should be tagged with a sticker
from the correct kit.
Perform an operational check to be sure that air

conditioning system is functioning properly to circulate
dye.
Run combine with air conditioning on for 15 minutes to

circulate refrigerant and dye.
NOTE: combine should be parked out of direct sunlight

for best results.
CAUTION: This lamp is made for intermittent

use ONLY. DO NOT hold lamp switch on for
more than 5 minutes at one time. DO NOT touch
lens end of light when hot. NEVER look directly
into light or expose skin. DO NOT operate light
with cracked lens or broken housing. Always
wear JT02178-4 Enhancer Glasses when using
light.
Put on JT02178-4 Enhancer Glasses before using light.
With combine running shine JT02178-1 UV Lamp at sight

90 glass (if available) of receiver-dryer. If dye is present glass
05
should be bright yellow.
12
Continued on next page OUO6083,00009D1 –19–27APR05–1/3

083006
PN=832
Check For Leaks in System
Perform an operational check to be sure that air

conditioning system is functioning properly to circulate
dye.
Remove low pressure (Blue) hose from either JT02045

Recovery/Recycling, and Charging Station or JT02051
Manifold with Gauges and install JT02178-5 R134a Dye
Injector. Reinstall low-side hose to outlet of JT02178-5
R134a Dye Injector. Purge air from low-side hose and dye
injector to remove air and impurities.
Turn off combine before testing components.
Put on JT02178-4 Enhancer Glasses before using light.
Shine JT02178-1 UV Lamp on components to test for

leaks. Leaks are indicated by a yellow tint on components
where dye has left system.
Clean area of leak using TY27507 Fluorescent Dye

Cleaner and recheck to confirm leak is still present.
Add Dye To System
IMPORTANT: At least 1/2 lb of refrigerant must pass

through JT02178-5 R134a Dye Injector
when injecting dye.
Do an operational check on system before trying to inject

dye.
If combine is at full charge or unknown, recover at least

1/2 lb of refrigerant before attempting to inject dye.
Run combine with air conditioning on for 15 minutes to

circulate refrigerant and dye.
Close both valves on JT02178-5 R134a Dye Injector and

carefully remove cap. Add one TY27506 bottle of pre
measured dye into injector and close cap tightly.
90
05
13

083006
PN=833
NOTE: If dye has been installed in the system, the

receiver-dryer should be tagged with a sticker
from the correct kit.
Open the dye injector outlet side valve first, and then
open the inlet valve. Recharging refrigerant will carry dye
into system.
OUO6083,00009D1 –19–27APR05–3/3
90
05
14

083006
PN=834
Test Shaft Seal Leakage
1. Remove front plate from compressor pulley.
2. Remove clutch hub and screw.
IMPORTANT: Do not lose inner clutch hub shims.
3. Install JT020991 Adapter in suction port and JT021001

in discharge port. Cap discharge port adapter using
JT031941.
4. Connect gauge set and/or container of R134a

refrigerant to suction port (A) of compressor.
–UN–19DEC97
5. Open valves to pressurize compressor.
IMPORTANT: Do not exceed range of low pressure

gauge.
RW41334A
6. Check the following for leaks using leak detector
JT02081 or 50-50 mixture of soap and water:
A—Suction Port
• Shaft seal
• Manifold seal
• Housing seals at front, rear and midsection of
compressor body
• Relief valve
• Suction coupler Schrader valve
Leakage should not exist. Repair compressor if

required, and repeat test.
7. Assemble compressor and add required oil. (See

DETERMINE CORRECT OIL CHARGE, in this group.)
90
05
15
1
AG,OUO6030,138 –19–25JUL00–1/1

083006
PN=835
Disassemble and Assemble Compressor

Clutch
1. Mount compressor on DFRW20 Compressor Holding

Fixture using two 6 in. x 1/4 in. eyebolts with nuts as
illustrated.
2. Remove dust cover.
3. Hold the clutch hub using JDG747 Compressor Clutch

Spanner (A) and remove the clutch hub cap screw (B).
4. Remove clutch hub (C).
–UN–24JUN92
5. Remove shims (H) from clutch hub and save for
installation.
6. Remove and discard snap ring (D).
RW21157
7. Remove pulley (E) using a plastic hammer or
D05277ST Puller, JDG748 Jaws, and JDG771 Hub
Protector.
8. Disconnect the clutch coil lead wire.

F
9. Remove and discard snap ring (F) using D05327ST 1 D
Retaining Ring Plier, and remove clutch coil (G).
–UN–04JAN01
NOTE: The bearing in the pulley is not serviceable. H
G
10. Check pulley bearing operation. Replace pulley and
bearing as required. B E
H65447
C
11. Install the clutch coil (G) and new snap ring (F) with
flat side down. Connect clutch coil lead wire. A—JDG747 Compressor Clutch Spanner
B—Clutch Hub Cap Screw
12. Install pulley (E) and new snap ring (D) with flat side C—Clutch Hub
of snap ring down. Apply grease to shims (H) and D—Pulley Snap Ring
E—Pulley
install to the clutch hub (C).
F—Clutch Coil Snap Ring
G—Clutch Coil
13. Install clutch hub cap screw (B) and tighten to H—Shim
specification. Install dust cover.
90 Specification
05 Clutch Hub Cap Screw—Torque ................................................... 14 N•m
16 (124 lb-in.)
1
Included in JDG215
AG,OUO6030,108 –19–25JUL00–1/1

083006
PN=836
Check Clutch Hub Clearance
NOTE: The clutch coil is NOT polarity sensitive.
1. Check pulley-to-clutch hub clearance using a dial

indicator. Mount the gauge to the pulley as illustrated
and connect a set of jumper wires from the compressor
to a 12V battery.
2. Rotate the pulley and check clearance in three equally

spaced locations around the clutch hub. Add or remove
shims as required to adjust clearance to specification.
Specification
Hub-to-Pulley—Clearance ................................................ 0.35—0.65 mm
(0.014—0.026 in.)
3. Tighten clutch hub cap screw to specification after

correct clearance is obtained.
Specification
–UN–24JUN92
Clutch Hub Cap Screw—Torque .................................................... 14 N•m
(124 lb-in.)
RW21159
AG,OUO6030,109 –19–25JUL00–1/1
Inspect Compressor Manifold
1. Remove cap screws (A) and manifold (B).
2. Remove and discard seal (C).
3. Inspect porting surfaces.
4. Lubricate and install a new seal (C).
5. Install manifold (B) using cap screws (A) and tighten to

specification.
Specification
–UN–12AUG98
Compressor Manifold Cap

Screws—Torque ............................................................................. 26 N•m 90
(19 lb-ft) 05
17
RW21160A
A—Manifold Cap Screw

B—Manifold
C—Manifold Seal
AG,OUO6045,1138 –19–25JUL00–1/1

083006
PN=837
Disassemble, Inspect, and Assemble Compressor
–UN–07APR00
H63259
A—Rear Pin (2 used) G—Rear O-Ring L—Front Gasket Q—Felt Holder
B—Rear Housing H—Front O-Ring M—Snap Ring R—Felt
C—Rear Gasket I—Front Suction Reed Valve N—Lip Seal S—Front Housing
D—Rear Discharge Reed Valve J—Front Valve Plate O—Washer T—Front Pins
E—Rear Valve Plate K—Front Discharge Reed P—Through Bolt
F—Rear Suction Reed Valve Valve
1. Clean the compressor using solvent before 3. Inspect the valves for an even wear pattern and the
disassembly. Mount compressor on holding fixture cylinders for scoring or excessive wear. Replace
and remove clutch. (See DISASSEMBLE AND compressor as required.
ASSEMBLE COMPRESSOR CLUTCH, in this
group.) 4. Remove the shaft seal snap ring (M). Turn the
housing over and remove the felt holder (Q) and felt
IMPORTANT: When removing front and rear (R) from the front housing (S).
housing, be careful NOT to damage
the sealing surfaces. 5. Remove the shaft lip seal (N) from the front housing
(S) using a small tool with 5/8 in. OD.
2. Disassemble the compressor as illustrated and
discard the O-rings, gaskets, lip seal, snap ring, 6. Wash all parts in clean solvent and dry using
and through bolt washers. Replace with new parts moisture-free compressed air before assembly.
90 from service kits.
05
18 NOTE: The valve plates, reed valves, cylinders and
cylinder housing are NOT serviceable. Some
cylinder scuffing (light scratches) is normal.

083006
PN=838
–UN–24JUN92
–UN–24JUN92
RW21162
RW21163
IMPORTANT: Lubricate O-rings, gaskets and lip 11. Install pins (T) and new O-ring (H) in the front
seal using only TY22101 (R134a) cylinder.
compressor oil during assembly.
Other oils could damage the NOTE: The front valve plate is marked with an “F” and
compressor. is installed face up.
7. Apply R134a oil to the bore of the front housing and 12. Install parts (I—K) over the pins on the front
install new lip seal (N) to the bottom of the bore cylinder.
using a socket. Install new snap ring (M) flat side
down. 13. Install a new gasket (L) flat side down. Put
JDG746 lip seal protector on the shaft and
IMPORTANT: Bushing spacer (U) must be in lubricate with R134a oil.
position before assembling the
compressor. 14. Install front housing (S) on the front cylinder and
remove the lip seal protector. Install through bolts
8. Install pins (A) and new O-ring (G) in the rear (P) and new washers (O).
cylinder.
15. Partially tighten through bolts and then tighten to
NOTE: The rear valve plate is marked with an “R” and specification.
is installed face up.
Specification
9. Install parts (F—D) over the pins on the rear Compressor Through Bolts—
Torque...................................................................................... 26 N•m
cylinder. (19 lb-ft)
90
05
19
10. Install a new gasket (C) flat side down and the 16. Install felt (R) and felt holder (Q) using the clutch
rear housing (B) on the rear cylinder. Mount the hub.
compressor onto the holding fixture.

083006
PN=839
17. Install the pulley-clutch hub and check clearance.

(See DISASSEMBLE AND ASSEMBLE
COMPRESSOR CLUTCH, in this group.)
AG,OUO6030,111 –19–25JUL00–3/3
Remove and Install Compressor Relief Valve
CAUTION: High pressure may exist at the

discharge fitting. If this pressure is released too
rapidly, there may be considerable discharge of
refrigerant and oil.
1. Discharge the system. (See DISCHARGE AND

RECOVERY OF AIR CONDITIONING REFRIGERANT,
in this group.)
OUO6083,0000258 –19–02APR02–1/4
2. Remove cap screws (A) and deflector (B).

B—Fan Blast Deflector
–UN–14DEC01
H70493
OUO6083,0000258 –19–02APR02–2/4
3. Slowly remove relief valve (A) from compressor. Clean,

inspect and replace as required.
4. Install relief valve (A) and tighten to specification.
Specification
Compressor Relief Valve—
–UN–03JUN99
Torque ..................................................................................... 12—16 N•m

90 (9—12 lb-ft)
05
20
A—Relief Valve
H57813

083006
PN=840
5. Install deflector (B) using cap screws (A).
6. Charge the system. (See CHARGE AIR

CONDITIONING SYSTEM in this group.)
–UN–14DEC01
B—Fan Blast Deflector
H70493
OUO6083,0000258 –19–02APR02–4/4
90
05
21

083006
PN=841
System Information
FLUSHING: • Recover all used solvents with appropriate flushing

equipment.
Flushing the system or a component is a cleaning • Purge the air conditioning system with compressed
process using a liquid solvent to remove oil and debris. air for the recommended amount of time specified in
the flushing procedure.
When to flush the air conditioning system:
IMPORTANT: Failure to use a recommended final
• The compressor has an internal failure flushing solvent after using a parts
• No oil remains in used compressor cleaning solvent for the primary
• Oil drained from compressor appears or smells flush will cause the refrigerant oil to
overheated become diluted and compressor life
• System was contaminated with a mixture of will be shortened.
refrigerant oils
• System was left open to the atmosphere long
enough for dirt, moisture or debris to enter the NOTE: Failure to properly purge the system will dilute
tubing or components the solvent.
• System has an internal blockage
Use 0.47 liter (1 pint) of clean solvent for flushing a
The R134a system on a John Deere Combine requires serviceable compressor that will be reinstalled on a
a two step process as follows: machine.
PRIMARY FLUSH: PURGING:
IMPORTANT: Use only fresh solvent for the Purging the system or a component is a cleaning
primary flush. process using a gas to force liquid from the system.
Purging alone will not remove refrigerant oil from the
Automotive parts cleaning solvent used according to system.
applicable guidelines can be utilized for a system
primary flush. When to purge an air conditioning system:
IMPORTANT: Do Not Use diesel fuel, gasoline, fuel • After flushing system with solvent, to prevent oil
oil, water, alcohol or any cleaning dilution
fluids formulated for dissolving oil, • System was contaminated with nitrogen or two
grease and antifreeze. refrigerants
• System was left open to atmosphere and flushing
FINAL FLUSH: could not be performed
• Installation of new lines, condenser or evaporator
• Use 1.9 liters (1/2 gal.) TY25601 Flushing Solvent or was required
equivalent.
• Review applicable MSDS data for hazard EVACUATING:
identification rating.
90 • Separate the air conditioning system into two circuits Evacuating the system is a process to remove air and
05 and follow the flushing procedure listed in this group. moisture from the system, by creating a vacuum.
22

083006
PN=842
SOLVENTS FINAL flush with TY25601 Air Conditioning

System Flush is performed. Parts tank
The following solvent is recommended for flushing air solvents will not evaporate below 60° C (140°
conditioning systems. Use only solvents with an F). Therefore TY25601 Air Conditioning
equivalent MSDS. System Flush must be used for the final flush
since the evaporation temperature is much
TY25601 Air Conditioning System Flush lower and is easily removed when evacuating
the system.
NOTE: New solvent used in parts cleaning tanks can
be used for the PRIMARY flush, providing a
AG,OUO6030,140 –19–25JUL00–2/2
90
05
23

083006
PN=843
Flush Air Conditioning System
Add flushing solvent to system with JT02075 Air • Condenser, including inlet and outlet hoses.
Conditioning Flusher and JT02098 Air Conditioning (Steps 6 through 13)
Fitting Kit. • Evaporator, including inlet and outlet hoses.
(Steps 14 through 30)
1. Discharge system. (See DISCHARGE AND
RECOVERY OF AIR CONDITIONING Flush/Purge Condenser:
REFRIGERANT, in this group.)
IMPORTANT: DO NOT attempt to flush through
NOTE: If compressor is being replaced, go to step 4. compressor or receiver-dryer.
Flushing through expansion valve or
2. Remove compressor and measure oil drained from orifice tube is acceptable if
both manifold ports. refrigerant oil has a normal odor and
appearance.
3. Clean compressor as follows:
6. Connect flusher outlet hose to inlet connection of
a. Pour 240 mL (8 fl oz) of TY25601 Air compressor discharge line using JT021021 Adapter
Conditioning System Flush into suction port and to flush condenser.
120 mL (4 fl oz) into discharge port. Plug both
ports in compressor manifold, using JT020991 7. Attach a return hose and aerator nozzle to
and JT021001 with JT031941 Caps. receiver-dryer inlet line using JT031971 Adapter. Put
nozzle in container to collect flushing solvent.
b. Turn compressor end for end and roll
compressor side to side. NOTE: New solvent used in the parts cleaning tank
can be used, providing a final flush with
c. Remove both plugs from manifold ports and ACC-U-FLUSH II TY25601 Air Conditioning
drain solvent from compressor. System Flush is performed. Parts tank
solvents will not evaporate at temperatures
d. Connect battery power to compressor clutch coil. below 60° C (140° F). Therefore,
Rotate pulley at least five revolutions to move ACC-U-FLUSH II TY25601 is necessary for
solvent out of cylinders. the final flush because it evaporates at 30° C
(85° F) and is easily removed when evacuating
e. Invert compressor, roll to all sides, and drain the system.
thoroughly.
8. Fill flusher tank with 4 L (1 gal) of solvent and
f. Let compressor sit inverted for three to five fasten all connections.
minutes.
NOTE: Air pressure must be at least 620 kPa (6.2
g. Repeat previous two steps at least three times. bar) (90 psi) for flushing and purging.
4. Remove and discard receiver-dryer. 9. Connect a supply line of moisture-free compressed

air or dry nitrogen to flusher air valve.
90 5. Flushing can be performed on combine. Divide
05 system into two circuits:
24
1
Continued on next page OUO6083,00006A8 –19–02DEC03–1/3

083006
PN=844
10. Open air valve to force flushing solvent into 21. Reinstall expansion valve.
condenser circuit. Flusher tank is empty when
hose pulsing stops. Additional flushing cycles are Final Flush
required if system is heavily contaminated with
burned oil or metal particles. 22. Final flush uses the same procedure as primary
flush for condenser and evaporator, except for
11. Continue forcing air through system to purge out solvent used.
solvent. Purging the condenser circuit takes 10—
12 minutes to thoroughly remove solvent. a. Add 1.9 L (0.5 gal) of ACC-U-FLUSH II
flushing solvent (TY25601) to the flusher tank.
12. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of IMPORTANT: ACC-U-FLUSH II flushing solvent
cardboard; continue purging until cardboard is dry. (TY25601) evaporates at 85° F, to
keep losses at a minimum, keep
13. Solvent from condenser can be used to flush container lids on at all times when
evaporator if solvent is not contaminated with not in use.
burnt oil or metal particles. Used solvent should be
put in shop parts cleaner. b. Connect a supply line of moisture-free air or
dry nitrogen to the flusher valve.
Flush/Purge Evaporator:
NOTE: Air pressure must be at least 490 kPa (4.9
14. Flush evaporator through expansion valve if oil bar) (70 psi) but not more than 620 kPa (6.2
appears normal. bar) (90 psi) maximum for final flushing and
purging.
15. Connect flusher outlet hose to compressor suction
line using JT021011 Adapter. c. Open the air valve to force flushing solvent into
the condenser or evaporator circuit. Flusher is
16. Attach a hose and aerator nozzle to receiver-dryer empty when hose pulsing stops. Reuse the
outlet line using JT031881 Adapter. Put nozzle in same solvent to do both circuits.
container to collect flushing solvent.
NOTE: Only one final flushing cycle is necessary,
17. Repeat Steps 8, 9 and 10 to flush evaporator. providing that another solvent was used prior
to the Final Flush.
18. Purging the evaporator circuit takes 12—15
minutes to thoroughly remove solvent. d. After flushing the circuits with ACC-U-FLUSH II
flushing solvent (TY25601), continue to purge
19. If system is contaminated with burned refrigerant with shop air through the flushing equipment.
oil or debris, remove expansion valve to flush
evaporator. e. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of
20. Disconnect hose from aeration nozzle to check cardboard; continue purging until cardboard is
circuit for solvent. Hold hose close to a piece of dry.
cardboard; continue purging until cardboard is dry.
90
05
25
ACC-U-FLUSH II is a trademark of Microcare Company
1
Continued on next page OUO6083,00006A8 –19–02DEC03–2/3

083006
PN=845
f. After flushing both circuits, put used ACC-U-FLUSH 23. Install a new receiver-dryer compatible with R134a
II in a separate, clean container and cap refrigerant. Fasten connections and mounting
immediately. brackets.
NOTE: Identify the container as ACC-U-FLUSH II 24. Add required oil. (See DETERMINE CORRECT
flushing solvent (TY25601). This solvent can OIL CHARGE, in this group.)
be used to flush additional machines. When
the solvent has an excessive amount of 25. Install compressor, and connect refrigerant lines to
dilution from the parts solvent used for the manifold.
primary flush, properly dispose of the solvent
in compliance with local and state regulations. 26. Connect clutch coil wire, and install drive belt.
g. Cap the system hoses or lines immediately after 27. Purge system. (See PURGE AIR CONDITIONING
removal of test equipment to prevent moisture from SYSTEM, in this group.)
entering the system.
OUO6083,00006A8 –19–02DEC03–3/3
Purge Air Conditioning System
IMPORTANT: Air compressors used for purging

systems require a water separator.
Purging without a separator adds
moisture, creating hydrofluoric acid
when combined with refrigerant oil.
Acid is corrosive to metal tubing.
1. Connect dry nitrogen hose to gauge manifold center

hose.
2. Connect gauge manifold suction hose to compressor

suction port, and open valves.
3. Connect gauge manifold discharge hose to compressor

discharge port, and open valve. Disconnect discharge
hose from gauge manifold to allow purging nitrogen to
atmosphere.
4. Open nitrogen tank valve and adjust regulator to 275

kPa (2.75 bar) (40 psi). Purge system for two minutes.
90
05 Disconnect nitrogen supply.
26
5. Evacuate system. (See EVACUATE AIR
CONDITIONING SYSTEM, in this group.)
AG,OUO6030,142 –19–25JUL00–1/1

083006
PN=846
Evacuate Air Conditioning System
IMPORTANT: DO NOT run compressor (E) while

evacuating system.
Use only R134a Recovery and

Recycling Stations JT020501 or vacuum
pump (D) when servicing a system
charged with R134a.
Air conditioning system must be

recovered, flushed and purged prior to
evacuating.
1. Connect low-side hose (blue) (A) from the manifold

gauge set to low-side service port.
2. Connect high-side hose (red) (B) to the high-side port.
3. Attach center charging hose (yellow) (C) to vacuum

pump or to recovery and recycling station. Open
–UN–16APR97
vacuum pump exhaust port.
NOTE: Pump must be capable of pulling at least 28.6 in.

Hg. vacuum (sea level).
TYK337
4. Start vacuum pump or recovery and recycling station.
(See station’s operator’s manual for instructions.)
5. Open both low and high pressure manifold gauge

valves.
6. Evacuate system until low-side gauge registers 28.6 in.

Hg. vacuum or as close as possible for a minimum of
–UN–08NOV04
30 minutes.
H81947
A—Low Side
B—High Side
C—Charging Hose
D—Vacuum Pump 90
E—Compressor 05
27
1

083006
PN=847
NOTE: The “perfect” vacuum may not be achievable.
Vacuum specifications listed are for sea level

conditions. Deduct 1 in. Hg. from 28.6 in. Hg. for
each 300 m (1000 ft) elevation above sea level.
7. If 28.6 in. Hg. (as close as possible) vacuum can not

be reached in 30 minutes, or if the low pressure gauge
needle moves toward the atmospheric pressure side
(gauge pressure 0), test system for leaks and correct
(go to step 11).
8. When a vacuum of 28.6 in. Hg. (as close as possible)

is reached, close low-side and high-side valves. Turn
vacuum pump off.
9. If the vacuum does not decrease more than 1 in. Hg.

in 5 minutes, the system is ready to be charged.
NOTE: If the vacuum decreases more than 1 in. Hg. in 5

minutes the system has a leak. Go to step 11.
10. Charge the system.
11. If a leak is present, add 0.5 kg (1 lb) of R134a to

system and use leak detector to locate leak. Correct
any leaks.
12. Remove refrigerant.
13. Start vacuum pump, open both high-side and low-side

valves and evacuate system for at least 30 minutes
after 28.6 in. Hg. vacuum is reached.
14. Close both high-side and low-side valves and stop

vacuum pump.
15. If the vacuum does not decrease more than 1 in. Hg.
in 5 minutes, the system is ready to be charged.
NOTE: If the system decreases more than 1 in. Hg. in 5

minutes, repeat steps 11 through 15 until all leaks
are corrected.
90
05 16. Charge the system.
28
OUO6083,00009D2 –19–27APR05–2/2

083006
PN=848
Compressor Oil Information
Typically 21 mL (0.7 fl oz) of oil covers internal

CAUTION: All new compressors are charged
surfaces of the compressor exposed to refrigerant gas
with a mixture of nitrogen, R134a refrigerant
and cannot be drained.
and TY22101 (R134a) compressor oil. Wear
safety goggles.
When 230 mL (7.7 fl oz) is installed in a dry
compressor the oil level will be above the drive shaft.
A new compressor from parts depot contains 230 mL
(7.7 fl oz) of new oil. The oil level visible through the
The normal operating oil level of a compressor
suction port, normally is below the drive shaft. The
removed from operation is 30 mL (1.0 fl oz). This level
amount of oil that cannot be drained is 81 mL (2.7 fl
cannot be seen through the suction port of the
oz). Approximately 60 mL (2.0 fl oz) will have seeped
compressor.
into the cylinders during shipping and storage.
AG,OUO6022,1364 –19–02MAR00–1/1
90
05
29

083006
PN=849
Determine Correct Oil Charge
Compressors can be divided into three categories 9560 STS, 9660 STS, 9760 STS and 9860 with Tier II Cooling
when determining the correct oil charge for the system. Package
A/C System Hose Lengths
• New compressor from parts depot Hose Routing Length Approximate
• Used compressor removed from operation Oil Needed
• Compressor internally washed with flushing solvent Compressor-to- 2240 mm 0.73 fl oz
Condenser (7.3 ft)
Determining the amount of system oil charge prior to Condensers- 7000 mm 2.3 fl oz
installation of compressor on a combine. receiver/dryer (23.0 ft)
Receiver/dryer-to- 912 mm 0.3 fl oz
1. When the complete system, lines, and components evaporator (3.0 ft)
were flushed add the correct amount of oil as Evaporator-to- 910 mm 0.3 fl oz
shown in the tables that follow. compressor (3.0 ft) 1.85 fl oz
5650 mm
(18.5 ft)
2. If the complete system was not flushed add the
correct amount of oil for the compressor plus
amount of oil for each component that was NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft).
serviced. Approximate total length equals 1,671 cm
(54.8 ft).
• New compressor from parts depot, drain and
9660 STS , 9760 STS and 9860 STS with Tier III Cooling
return 50 mL (1.7 fl oz) of oil to the compressor. Package
• Used compressor removed from operation and oil
A/C System Hose Lengths
drained, add 45 mL (1.5 fl oz) of new oil.
• Used compressor removed from operation, oil Hose Routing Length Approximate
Oil Needed
drained and flushed add 50 mL (1.7 fl oz) of new
oil. Compressor-to- 3550 mm 1.17 fl oz
Condenser (11.7 ft)
Condensers- 7000 mm 2.3 fl oz
NOTE: Components listed below that have been
receiver/dryer (23.0 ft)
removed, drained, or flushed, require the
Receiver/dryer-to- 912 mm 0.3 fl oz
removal of the compressor to determine the
evaporator (3.0 ft)
correct oil charge. Use the following chart as a
Evaporator-to- 910 mm 0.3 fl oz
guide for adding oil to components:
compressor (3.0 ft) 2.1 fl oz
6450 mm
Evaporator 40 mL (1.4 fl oz) (21 ft)
Condenser 40 mL (1.4 fl oz)
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft). Approximate
Receiver-Dryer 10 mL (0.35 fl oz) total length equals 1,882 cm (61.7 ft).
Compressor 50 mL (1.7 fl oz)
90
05
30
Continued on next page OUO6046,0001F10 –19–14JUN05–1/2

083006
PN=850
If any section of hose is removed and flushed or IMPORTANT: DO NOT leave the system or R134a
replaced, use the table to determine the correct compressor oil containers open.
amount of oil to be added. This oil easily absorbs moisture.
Keep R134a compressor oil away
If any component is removed because of damage, from acrylic or ABS plastics. Identify
and/or leakage is evident, remove compressor and to eliminate accidental mixing of
determine amount of oil needed to bring system to full different oils.
charge. (See CHECK REFRIGERANT OIL CHARGE in
this group.)
OUO6046,0001F10 –19–14JUN05–2/2
Check Refrigerant Oil Charge
Remove compressor if a R134a leak was detected and 3. Flush complete system with air conditioning flushing
repair. (See REMOVE COMPRESSOR, in this group.) solvent.
Drain oil from compressor and record amount. 4. Perform a Volumetric efficiency test on compressor
to determine serviceable condition. If compressor is
NOTE: Drain oil and save if this is a new compressor. serviceable, pour flushing solvent in manifold ports
and internally wash out old oil.
If oil drained from a compressor is very black or
amount of oil is less than 6 mL (0.2 fl oz), perform the 5. Install a new receiver-drier.
following:
6. Install 260 mL (8.8 fl oz) of TY22101 compressor oil
1. Remove and discard receiver-dryer. in compressor.
2. Remove, clean, and bench test expansion valve, 7. Connect all components, evacuate and charge
but do not disassemble valve. system.
OUO6083,000068B –19–03SEP03–1/1
90
05
31

083006
PN=851
Charge Air Conditioning System
1. Evacuate the system. (See EVACUATE AIR IMPORTANT: Before beginning to charge air
CONDITIONING SYSTEM in this group.) conditioning system, the following
conditions must exist:
IMPORTANT: Use only R134a Refrigerant
Recovery, Recycling and Charging • Engine stopped
Stations. Eliminate mixing R134a • System holding a vacuum of at
equipment, refrigerant, and least 28.6 in. Hg (less 1 in. from
refrigerant oils with R12 systems to 28.6 for each 300 m [1000 ft]
prevent compressor damage. elevation)
2. Use a JT02046 HFC134a Refrigerant Charging 4. Follow the manufacturer’s instructions and charge
Station to charge the system. the system.
NOTE: Used with JT02050 Recovery and Recycling 5. Add R134a refrigerant until system is charged with
Station. JT02047 Recovery, Recycling and 1.81—2.0 kg (4—4.5 lb).
Charging Station can be substituted for
JT02046 and JT02050. 6. Check ambient temperature, cab temperature and
system pressures. (See diagnostic sequence in
3. Connect low-side hose (blue) from the charging unit TM2182, Section 290.)
to suction hose fitting on the compressor. Connect
high-side hose (red) to the pressure hose fitting on
the condenser.
OUO6083,00009D3 –19–27APR05–1/1
90
05
32

083006
PN=852
Group 10
System Components
ESSENTIAL TOOLS listed are required to perform the RECOMMENDED TOOLS, as noted, are suggested to
job correctly and are obtainable only from perform the job correctly. Some tools may be available
SERVICEGARD or European Microfiche Tool from local suppliers or may be fabricated.
Catalogs.
HX,90,CH11 –19–25JUL00–1/2
HFC134A Recovery/Recycling Station . . . . . . . JT020501
–UN–17AUG92
RW21613
1
HX,90,CH11 –19–25JUL00–2/2
Other Material
Number Name Use
TY15949-12 oz (U.S.) Refrigerant R134a Purge and charge system. Total

system charge is 8.8—9.9 kg (4—4.5
lb).
TY22101-12 oz (U.S.) 525 Viscosity Compressor Oil Replace oil lost during condenser
removal and repair, approximately 30
mL (1.0 fl oz).
90
10
1
HX,90,CH12 –19–25JUL00–1/1

083006
PN=853
System Components
Specifications
Connecting Pipe-to-Expansion Valve Torque 23 ± 3 N•m

Socket Head Cap Screw (17 ± 2 lb-ft)
Expansion Valve Socket Head Cap Torque 7 N•m

Screws (62 lb-in.)
OUO6083,0000D62 –19–13JUN06–1/1
90
10
2

083006
PN=854
System Components
Air Conditioning System With Precleaner

(General Information)
A
H
B
C
–UN–08JAN01
D
H39194
A—Hole C—Pressurizer Fan E—Fresh Air Filter G—Recirculator Blower
B—Air Duct D—Precleaner F—Recirculating Filter H—Cab Through Ducts
Air is drawn into the cab through holes (A). This dirty with air from inside the cab, being drawn into the
air flows down air duct (B) and into the pressurizer fan evaporator compartment through the recirculating filter
(C). The air is then pushed through the precleaner (D) (F). It then passes through the evaporator and heater
where the majority of dirt and a small amount of air is core.
discharged out through the cab floor. Be certain this
opening is open. Treated air (heated or cooled) is now drawn into the
recirculator blower (G) and discharged into the cab
This cleaned air then passes through fresh air filter (E) through ducts (H).
into the evaporator compartment. The air is now mixed
90
10
3
HX1401,9010,A –19–25JUL00–1/1

083006
PN=855
System Components
Remove and Install Receiver/Dryer
1. Recover refrigerant from the system. (See procedure in

Group 05.)
2. Disconnect lines (A). Plug lines to keep dirt out.
–UN–07JUN05
3. Loosen clamps (B) and remove receiver/dryer.
IMPORTANT: Replace receiver/dryer as often as
H83698
required to prevent moisture from
contaminating the system. Always
install a new receiver/dryer when the
system is opened up for service, or A—Line (2 used)
when the compressor shaft seal leaks. B—Clamp (2 used)
Be sure to keep the new receiver/dryer
capped until installing. Install
receiver/dryer last.
4. Install new receiver/dryer and clamps (B).
5. Connect lines (A).
6. Check and add compressor oil. (See COMPRESSOR

OIL INFORMATION in Group 05.)
7. Evacuate and charge the system. (See procedures in

Group 05.)
OUO6046,0001F52 –19–07JUN05–1/1
90
10
4

083006
PN=856
System Components
Remove and Install Blower Motor—Style A
1. Remove eight screws and lift out instructional seat and

cover.
–UN–18MAY04
3. Disconnect wire (B) and remove cover (C).
4. Remove motor (D).
H80423
NOTE: Motor cannot be repaired, it must be replaced.
5. Replace a cracked fan. Note direction of fan fins and

remove fan from old motor and install on new motor.
6. Install motor (D) and cover (C) using cap screws (A).
7. Connect wire (B).
–UN–18MAY04
8. Install instructional seat and cover using eight screws.
H80424
B—Connector
C—Cover
D—Motor
OUO6083,0000D69 –19–14JUN06–1/1
90
10
5

083006
PN=857
System Components
Remove and Install Blower Motor—Style B

Blower motor and fan are a balanced set and will
be removed and installed as one unit.
–UN–12JUN06
cover.
H86110
3. Remove cap screws (B) and cap screws with washers
(C).
4. Remove blower motor assembly (D). Replace as

necessary.
–UN–12JUN06
A—Connector
C—Cap Screw with Washer (2 used)
D—Blower Motor Assembly
H86111
OUO6083,0000D6A –19–14JUN06–1/1
Remove and Install Recirculator Fan Motor

Driver—Style A

cover.
–UN–20APR99
2. Disconnect wires (A and B).
3. Remove screws (C) and module (D).
H55582
5. Install module (D) using screws (C).

A—Connector
B—Connector
90 6. Connect wires (A and B). C—Screw (3 used)
10 D—Module
6 7. Install instructional seat and cover using eight screws.
OUO6083,0000D6F –19–15JUN06–1/1

083006
PN=858
System Components
Remove and Install Recirculator Fan Motor

Driver—Style B

cover.
–UN–14JUN06
3. Remove cap screw (B).
H86131
4. Push in on locking tabs (C) and remove driver (D) from
housing.
5. Install in reverse order. A—Connector

B—Cap Screw
C—Locking Tab (2 used)
D—Driver
OUO6083,0000D70 –19–15JUN06–1/1
Remove and Install Recirculator Motor

Blower motor and fan are a balanced set and will
be removed and installed as one unit.
–UN–12JUN06
cover.
H86113
3. Remove cap screws (B) and recirculator motor
assembly (C).
A—Connector
4. Replace as necessary.
C—Recirculator Motor Assembly
OUO6083,0000D6B –19–14JUN06–1/1
90
10
7

083006
PN=859
System Components
Replace Heater Control Valve

radiator is cool to the touch before replacing
heater control valve.
–UN–01NOV88
1. Remove eight screws and remove instructional seat
and cover.
2. Disconnect harness (A).
T6642EK
3. Remove cap screws (B) and servo actuator (C).
4. Remove screw (D) and adapter (E).
5. Remove flange nuts (F).
6. Remove cap screws (H) and mounting plate (G).
–UN–29MAY03
7. Clamp off inlet and outlet hoses (I).
NOTE: Some coolant may be present when heater hoses

are disconnected.
H77506
8. Disconnect hoses and remove control valve (J).
9. Connect inlet and outlet hoses (I) to new control valve

(J) and remove clamps.
10. Attach mounting plate (G) to control valve (J) with cap
screws (H) and install using flange nuts (F).
–UN–20APR99
11. Install adapter (E) using screw (D).
12. Install servo actuator (C) using cap screws (B).
H55592
13. Connect harness (A).
A—Harness
C—Servo Actuator
D—Screw
E—Adapter
F—Flange Nut (2 used)
90 G—Mounting Plate
10 H—Cap Screw (2 used)
8 I—Hose (2 used)
–UN–20APR99
J—Control Valve
H55607

083006
PN=860
System Components
14. Run engine, check coolant level and watch for leaks.
Add coolant as necessary.
15. Install instructional seat and cover using eight screws.

OUO6083,0000D60 –19–13JUN06–2/2
Remove and Install Temperature Control

Door Actuator

and cover.
–UN–14JUN06
3. Remove cap screws (B) and actuator (C).
H86132
NOTE: Manually move door to check for obstructions
before reinstalling actuator.
4. Install actuator in reverse order. A—Connector

C—Actuator
OUO6083,0000D6E –19–14JUN06–1/1
90
10
9

083006
PN=861
System Components
Remove and Install Heater Core

radiator is cool to the touch before removing
heater core.
–UN–01NOV88
and cover.
2. Clamp off inlet and outlet hoses.
T6642EK
3. Remove cap screws (A) and clamps (B and C).
NOTE: Some coolant may be present when heater hoses

are disconnected.
4. Remove clamps (D) and hoses from heater core.
5. Carefully lift heater core (E) from housing.
–UN–14JUN06
6. Install new seals on new heater core at same location
as previously removed unit.
H86128
7. Install heater core in reverse order.

B—Clamp
C—Clamp
D—Clamp (2 used)
E—Heater Core
OUO6083,0000D6C –19–14JUN06–1/1
90
10
10

083006
PN=862
System Components
Remove Condenser
1. Recover refrigerant from system. (See DISCHARGE

REFRIGERANT in group 05.)
–UN–13MAY00
2. Open rotary screen door.
NOTE: Cap and plug all lines and fittings to prevent

system contamination.
H63893
3. Disconnect lines (A).
4. Loosen cap screw (B) and remove spacer washers.
5. Tighten cap screw (B) with it aligned in pivot hole.
A—Line (2 used)
B—Cap Screw
–UN–13MAY00
H63898
HX,1401,9010,BA –19–25JUL00–1/3
6. Install nut (A) on cap screw and tighten nut until lower
pivot (B) is clear of lower frame.
7. Tie the other end of cooler assembly to the top

channel of cooling package housing.
–UN–13MAY00
A—Nut
B—Lower Pivot
H63894
90
10
11
–UN–13MAY00
H63899
Continued on next page HX,1401,9010,BA –19–25JUL00–2/3

083006
PN=863
System Components
8. Remove cap screws (A) and condenser.
–UN–13MAY00
H63892
HX,1401,9010,BA –19–25JUL00–3/3
Remove Condenser—Tier III Cooling Package
1. Recover refrigerant from system. (See DISCHARGE

REFRIGERANT in group 05.)
–UN–03JUN05
2. Open rotary screen door.
NOTE: Cap and plug all lines and fittings to prevent

system contamination.
H83687
3. Disconnect lines (A).
A—Line (2 used)
90
10
12

083006
PN=864
System Components
4. Remove cap screws (A), rubber stop (C) and brackets

(B).

C—Rubber Stop
–UN–03JUN05
H83688
–UN–03JUN05
H83689
–UN–03JUN05
H83690
OUO6046,0001F11 –19–14JUN05–2/3
5. Loosen cap screws (A) and push bracket (B) upward to 90

release pin (C). 10
13
6. Lift oil cooler off of condenser and support oil cooler.
7. Remove condenser.
–UN–03JUN05

B—Bracket
C—Pin
H83692
OUO6046,0001F11 –19–14JUN05–3/3

083006
PN=865
System Components
Repair Condenser
1. If contamination appears in the condenser, flush 5. Connect refrigerant supply to the Schrader-type
entire system. valve.
2. Inspect condenser. Fins must be straight and clean. 6. Open refrigerant container valve and test condenser
for leaks with a leak detector. If the condenser
3. Cap outlet and install a Schrader-type service valve leaks, replace it.
in inlet.
7. Plug or cap openings until ready to install.
4. Place refrigerant container in a pail of water heated
to a maximum of 125°F (51.5°C), which gives a
pressure of 12 bar (170 psi).
1401,9010,I –19–25JUL00–1/1
Install Condenser
1. Position condenser and install cap screws (A).
–UN–13MAY00
H63892
90
10
14

083006
PN=866
System Components
2. Align lower pivot (B) with lower frame and remove nut
(A).
A—Nut
B—Pivot
–UN–13MAY00
H63894
–UN–13MAY00
H63899
OUO6083,0000317 –19–14AUG02–2/3
3. Loosen cap screw (B) and install spacer washer

previously removed and retighten cap screw.
4. If the condenser was repaired or replaced with a new

one, pour 30 mL (1.0 fl oz) of oil into condenser. If
there were any major leaks in the system, (See
–UN–13MAY00
DETERMINE CORRECT OIL CHARGE in Group 05.)
NOTE: Install new O-rings on A/C lines anytime they are

removed.
5. Connect and tighten lines (A). (See HOSE AND H63893

TUBING O-RING CONNECTION TORQUES in Group
05.)
90
6. Evacuate and charge the system. (See procedures in 10
Group 05.) 15
7. Perform the operational test.

–UN–13MAY00
A—Line (2 used)
B—Cap Screw
H63898
OUO6083,0000317 –19–14AUG02–3/3

083006
PN=867
System Components
Install Condenser—Tier III Cooling Package
1. Position condenser and lower oil cooler onto

condenser.
2. Lower bracket (B) onto pin (C). Make sure pin is
–UN–03JUN05
secure in bracket and tighten cap screws (A).

B—Bracket
H83692
C—Pin
90
10
16

083006
PN=868
System Components
3. Install brackets (B), cap screws (A), and rubber stop

(C).

C—Rubber Stop
–UN–03JUN05
H83688
–UN–03JUN05
H83689
–UN–03JUN05
H83690
90
10
17

083006
PN=869
System Components
4. If condenser was repaired or replaced with a new one,

pour 30 mL (1.0 fl oz) of oil into condenser. If there
were any major leaks in the system, (See DETERMINE
CORRECT OIL CHARGE IN Group 05).
NOTE: Install new O-rings on A/C lines anytime they are

removed.
–UN–03JUN05
5. Connect and tighten lines (A). (See HOSE AND
TUBING O-RING CONNECTION TORQUES in Group
H83687
05.)
6. Evacuate and charge the system. (See procedures in

Group 05.) A—Line (2 used)
7. Perform the operational tests.
OUO6046,0001F12 –19–14JUN05–3/3
90
10
18

083006
PN=870
System Components
Replace Evaporator—Style A
IMPORTANT: Water build up in evaporator case may

be caused by a plugged drain hose.
Clean weep valve and drain hose as
needed.
1. Install gauge and recover refrigerant from system. (See

DISCHARGE AND RECOVERY OF AIR
CONDITIONING REFRIGERANT in Group 05.)

and cover.
–UN–02JUL02
3. Disconnect harnesses (A).
H72755
4. Remove cap screws (B) and cover (C).
5. Disconnect harnesses (D and E).
6. Disconnect lines (F) and heater hoses (G).
7. Remove evaporator (H).
8. Install new evaporator (H).
–UN–02JUL02
9. Connect heater hoses (G) and lines (F).
10. Connect harnesses (D and E).
H72756
11. Install cover (C) using cap screws (B).
12. Install connectors (A). A—Wire Harness (2 used)

C—Cover
13. Charge system and check for leaks. (See procedure D—Harness
in Group 05.) E—Harness
F—Lines
14. Install instructional seat and cover. Attach using eight G—Heater Hose (2 used)
screws. H—Evaporator
90
10
19
OUO6083,0000D5F –19–13JUN06–1/1

083006
PN=871
System Components
Replace Evaporator—Style B
IMPORTANT: Water build up in evaporator case may

be caused by a plugged drain hose.
Clean weep valve and drain hose as
needed.
–UN–13JUN06
H86118
and cover.
5. Remove socket head cap screw (D) and separate
–UN–13JUN06
connecting pipe from expansion valve.
6. Lift evaporator (E) from housing.
H86119
7. Install new seals on new evaporator at same location
as previously removed unit.
8. Install new evaporator into housing. A—Connector

C—Cover
9. Install new sealwashers on connecting pipe. D—Socket Head Cap Screw
E—Evaporator
10. Attach connecting pipe to expansion valve using new
socket head cap screw (D) and tighten to
specification.
Specification
Connecting Pipe-to-Expansion
Valve Socket Head Cap Screw—
Torque ...................................................................................... 23 ± 3 N•m
(17 ± 2 lb-ft)
11. Install cover (C) using cap screws (B). Connect

connector (A).
12. Charge system and check for leaks. (See procedure

90 in Group 05.)
10
20
13. Install instructional seat and cover.
OUO6083,0000D65 –19–14JUN06–1/1

083006
PN=872
System Components
Replace Expansion Valve

–UN–13JUN06
and cover.
3. Remove socket head cap screw (A) and connecting
H86126
pipe (B).
4. Remove socket head cap screws (C) and expansion

Valve (D) from evaporator.
IMPORTANT: Use new sealwashers when installing

expansion valve.
5. Install expansion valve (D) to evaporator using new
–UN–13JUN06
sealwashers. Tighten socket head cap screws (C) to
specification.
Specification
Expansion Valve-to-Evaporator
H86127
Socket Head Cap Screws—
Torque .............................................................................................. 7 N•m
(62 lb-in.)
A—Socket Head Cap Screw
B—Connecting Pipe
6. Install connecting pipe (B) to expansion valve using C—Socket Head Cap Screw (2 used)
new sealwashers. Tighten socket head cap screw (A) D—Expansion Valve
to specification.
Specification
Connecting Pipe-to-Expansion
Valve Socket Head Cap Screw—
Torque ...................................................................................... 23 ± 3 N•m
(17 ± 2 lb-ft)
7. Charge system and check for leaks. (See procedure in

Group 05.)
8. Install instructional seat and cover.
90
10
21
OUO6083,0000D6D –19–14JUN06–1/1

083006
PN=873
System Components
Remove and Install Evaporator Temperature

Sensor

and cover.
2. Disconnect harnesses (A).
4. Disconnect harness (D).
–UN–02JUL02
5. Remove temperature sensor (E) from evaporator.
6. Install temperature sensor (E) and connect harness

(D).
H72755
7. Install cover (C) attach with cap screws (B).
8. Connect harnesses (A).
9. Install instructional seat and cover. Attach using eight

screws.
A—Harness (2 used)
–UN–02JUL02
C—Cover
D—Harness
E—Evaporator Temperature Sensor
H72757
OUO6083,00002F0 –19–02JUL02–1/1
Replace Low Pressure Switch

–UN–22APR99

90
10 3. Remove low pressure switch (B).
22
H55674
4. Install low pressure switch (B).

A—Harness
B—Low Pressure Switch
6. Charge system. (See procedure in Group 05.)
AG,OUO6030,131 –19–25JUL00–1/1

083006
PN=874
System Components
Replace High Pressure Switch

–UN–03JUN99
3. Remove high pressure switch (B).
H57820
4. Install high pressure switch (B).

A—Connector
6. Charge system. (See procedure in Group 05.) B—High Pressure Switch
AG,OUO6030,132 –19–25JUL00–1/1
Replace Air Temperature Sensors

cover.
2. Remove harness (A) and remove inlet air temperature

sensor (B) from rubber grommet (C).
3. Install new sensor in rubber grommet (C) and connect

harness (A).
4. Disconnect harness (D) and remove cab air

temperature sensor (E) from mounting bracket (F).
5. Install new sensor in mounting bracket (F) and connect

harness (D).
–UN–02JUL02
6. Disconnect harness (G) and remove outlet air
temperature sensor (H) from rubber grommet (I). H72713
7. Install new sensor in rubber grommet (I) and connect

harness (G).
90
A—Harness 10
8. Install instructional seat and cover and attach using B—Inlet Air Temperature Sensor 23
eight screws. C—Rubber Grommet
D—Harness
E—Cab Air Temperature Sensor
F—Mounting Bracket
G—Harness
H—Outlet Air Temperature Sensor
I—Rubber Grommet
OUO6083,00002F1 –19–02JUL02–1/1

083006
PN=875
System Components
90
10
24

083006
PN=876
Group 15
Cab
Specifications
Windshield Clamps Approximate Spacing 600 mm

(24 in.)
Seat Mounting Nuts Torque 15 N•m

(133 lb-in.)
Door Latch Striker Bolt Torque 80 N•m

(60 lb-ft)
Radiator Capacity 45 L
(47.6 qt)
Cab Weight 578 kg

(1275 lb)
Operator’s Seat Weight 29 kg

(65 lb)
OUO6083,00002D3 –19–14JUN02–1/1
90
15
1

083006
PN=877
Cab
Remove and Install Cab Windshield—Style A
Do not attempt to install a replacement windshield unless

you are qualified in glass replacement.
The original factory adhesive used to bond the windshield
–UN–29JUN99
in place is a urethane type. When installing this glass, use
an adhesive method that is compatible with urethane
adhesive. These types of adhesive ARE NOT available
from John Deere.
H58556
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 the
cure time. However, if it is necessary to operate the
combine, for the first 48 hours use caution to avoid bumps
and shock loads, such as when crossing a border, etc.
1. Raise feeder house all the way up and lower safety

stop. The feeder house will be used as a work
platform.
OUO6046,0001F6C –19–14JUN05–1/7
NOTE: Make sure wipers are in the parked position

before starting removal procedures.

–UN–30MAR00
B—Sun Visor
90
15
2
H63271
Continued on next page OUO6046,0001F6C –19–14JUN05–2/7

083006
PN=878
Cab

A—Tab (5 used)
B—Headliner
–UN–30MAR00
H63270
OUO6046,0001F6C –19–14JUN05–3/7
4. Remove wiper blades (A) and wiper motor mounting

(B).
5. From inside cab, remove wiper motor.
6. Remove upper panel screws (C). Pull out panel and
–UN–29JUN99
disconnect headlights by disconnecting harness
connector from light bulb.
7. Disconnect windshield washer hoses, if equipped, and
H58555
remove upper panel.
A—Wiper Blades
B—Wiper Motor Mounting
C—Screw (12 used)
OUO6046,0001F6C –19–14JUN05–4/7
8. Remove cap screws (A) and lower cab panel.
–UN–08MAY03
90
15
3
H76826

083006
PN=879
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.
9. 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.
10. Apply a thin coat of adhesive to area (A) on both
–UN–10OCT88
clamps (B) provided.
11. Slip clamps (B) on windshield as specified (C).
H40068
Specification
Windshield Clamps—Approximate
Spacing .......................................................................................... 600 mm
(24 in.) A—Area for Adhesive
B—Clamp
C—Clamp Placement
12. Bend leg (D) up on both clamps. D—Clamp Leg
90
15
4

083006
PN=880
Cab
IMPORTANT: Edges of glass on both sides must not

contact cab frame.
13. 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).
A E
14. Tighten two clamps attached to cab floor (C).
15. Use nonmetallic shims (D) to hold glass in place.
16. Bend leg (E) up on both clamps to secure glass.
17. Tape sides of glass with duct tape to hold glass in

position.
18. Install all parts.
19. Remove tape after 48 hours.
–UN–29MAY01
A—Bracket
B—Head Panel
C—Clamp Screw
D
H67759
D—Shims C
E—Clamp Leg
OUO6046,0001F6C –19–14JUN05–7/7
90
15
5

083006
PN=881
Cab
Remove and Install Cab Windshield—Style B
Do not attempt to install a replacement windshield unless

The original factory adhesive used to bond the windshield
–UN–07JUN05
in place is a urethane type. When installing this glass, use
an adhesive method that is compatible with urethane
from John Deere.
H83632
Curing time of this type adhesive depends on weather

cure time. However, if it is necessary to operate the
1. Raise feeder house all the way up and lower safety

stop. The feeder house will be used as a work
platform.
OUO6046,0001EA8 –19–10AUG05–1/12
NOTE: Make sure wipers are in the parked position

before starting removal procedures.

–UN–30MAR00
B—Sun Visor
90
15
6
H63271
Continued on next page OUO6046,0001EA8 –19–10AUG05–2/12

083006
PN=882
Cab

4. Remove headliner. (See procedure in this group.)
A—Tab (5 used)
–UN–30MAR00
B—Headliner
H63270
OUO6046,0001EA8 –19–10AUG05–3/12
5. Remove nuts (A and B) and wiper arm (C).
A—Nut
B—Nut
C—Wiper Arm
–UN–23MAY05
H83549
OUO6046,0001EA8 –19–10AUG05–4/12
6. Remove cap screws (A) and grab handle (B).

B—Grab Handle
–UN–23MAY05
H83552
OUO6046,0001EA8 –19–10AUG05–5/12
7. Remove boot (A), nut (B) and plate (C). 90

15
7
A—Boot
B—Nut
C—Plate
–UN–23MAY05
H83553

083006
PN=883
Cab
9. Push wiper motor assembly (A) towards roof and

remove wiper motor assembly.
A—Wiper Motor Assembly
–UN–23MAY05
B—Connector
H83554
OUO6046,0001EA8 –19–10AUG05–7/12
10. Remove cap screws (A) and lower cab panel.
–UN–08MAY03
H76826
OUO6046,0001EA8 –19–10AUG05–8/12
11. Remove front and rear inner roof mounts (A and B).
A—Front Inner Roof Mount (2 used)

B—Rear Inner Roof Mount (2 used)
–UN–23MAY05
H83557
Front Cab Mount
90
15
8
–UN–23MAY05
H83558
Rear Cab Mount


083006
PN=884
Cab
12. 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
–UN–23MAY05
H83561
OUO6046,0001EA8 –19–10AUG05–10/12
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.
13. 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.
14. Apply a thin coat of adhesive to area (A) on both
–UN–10OCT88
clamps (B) provided.
15. Slip clamps (B) on windshield as specified (C).
H40068
Specification
Windshield Clamps—Approximate
Spacing .......................................................................................... 600 mm
(24 in.) A—Area for Adhesive
B—Clamp
C—Clamp Placement
16. Bend leg (D) up on both clamps. D—Clamp Leg
90
15
9

083006
PN=885
Cab
IMPORTANT: Edges of glass on both sides must not

contact cab frame.
17. 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).
A E
18. Tighten two clamps attached to cab floor (C).
19. Use nonmetallic shims (D) to hold glass in place.
20. Bend leg (E) up on both clamps to secure glass.
21. Tape sides of glass with duct tape to hold glass in

position.
22. Install all parts.
23. Remove tape after 48 hours.
–UN–29MAY01
A—Bracket
B—Head Panel
C—Clamp Screw
D
H67759
D—Shims C
E—Clamp Leg
OUO6046,0001EA8 –19–10AUG05–12/12
Remove Cab
1. Discharge air conditioning refrigerant. (See procedure

in Group 05.)
NOTE: Cap all lines to prevent system contamination

–UN–07JUN05
90 2. Disconnect lines (A).

15
10 3. Remove cap screw (B) and clamp (C).
H83699
A—Line (2 used)
B—Cap Screw
C—Clamp
Continued on next page OUO6046,0001F53 –19–10AUG05–1/15

083006
PN=886
Cab

coolant.
4. Drain radiator. (See Section 10, Group 10 for

capacities.)
–UN–01NOV88
T6642EK
OUO6046,0001F53 –19–10AUG05–2/15
5. Disconnect heater hoses at clamps (A) and drain any

remaining coolant into a suitable container.
6. Disconnect harness connectors (B).
7. Remove cap screws (C) and clamp (D) under cab wall
–UN–07JUN05
plate.
A—Heater Hose Clamp

B—Harness Connectors
H83700
D—Clamp
–UN–29JUN99
H58561
90
15
11

083006
PN=887
Cab
8. Loosen cap screws (A) and remove cab fascia (B).
–UN–01JUL99
H58557
OUO6046,0001F53 –19–10AUG05–4/15
9. Remove wiring harness from clamps (A).
10. Disconnect harness connector (B).
A—Clamp (4 used)
B—Left-Hand Main Harness-To-Steering Column
–UN–01JUL05
Harness Connector
H83887
–UN–01JUL05
90
15
H83888
12

083006
PN=888
Cab
11. Disconnect three lines (A) at brake valve. Cap and

plug all lines and fittings to prevent system
contamination.
A—Brake Line (3 used)
–UN–16JUN99
H58337
OUO6046,0001F53 –19–10AUG05–6/15
12. Remove clamps (A) from brake lines.
13. Disconnect tube (B).
A—Clamp (3 used)
B—Evaporator Drain Tube
–UN–29JUN99
H58544
–UN–29JUN99
90
15
H58545
13

083006
PN=889
Cab
14. Remove nuts and washers (A) that attach park brake
cables to balancer assembly.
15. Remove cotter pin (B) and pin (C).
16. Remove left-hand balancer and cables from balancer
–UN–14APR00
assembly.
A—Nut and Washer (2 used)

B—Cotter Pin
H63641
C—Pin
OUO6046,0001F53 –19–10AUG05–8/15
17. Disconnect ground strap (A).
A—Ground Strap
–UN–09MAY03
H76853
OUO6046,0001F53 –19–10AUG05–9/15
NOTE: Mark hoses and valves before disconnecting. This

will ensure proper reassembly.
18. Disconnect hoses (A) at steering valve. Cap and plug

all hoses and fittings to prevent system
contamination.
90 A—Steering Valve Hose (4 used)

15 B—Reverser Control Cable
14
–UN–16JUN99
H58339

083006
PN=890
Cab
19. Disconnect gear shift control cable.
20. Remove cap screws (A) (two on each side).
–UN–09JAN02
H70768
–UN–16JUN99
H58343
OUO6046,0001F53 –19–10AUG05–11/15
21. Disconnect tube (A), located near upper left-hand rear

of cab.
A—Windshield Washer Tube
–UN–29JUN99
H58552
90
15
15

083006
PN=891
Cab
22. Disconnect ball joint (A) at hydro pump, if equipped.
23. Remove jam nut (B) and clamps (C), if equipped.
A—Ball Joint
B—Jam Nut
C—Clamp (4 used)
–UN–29JUN99
H58546
–UN–30JUN99
H58547
–UN–30JUN99
H58548
90
15
16

083006
PN=892
Cab
CAUTION: The approximate weight of cab is 578

kg (1275 lb).
Specification
Cab—Weight ................................................................................... 578 kg
(1275 lb)
–UN–20MAR89
24. Attach lifting brackets at rear of cab (A) and cab roof
(B) on both sides. Attach hoist to brackets.
H40452
IMPORTANT: Door hinge will contact the side grab
handle and break if cab door is not
securely latched prior to removing cab.
A—Rear of Cab
B—Cab Roof
25. Be certain cab door is firmly latched.
OUO6046,0001F53 –19–10AUG05–14/15
26. Enter grain tank, remove cap screws (B) and covers
(A).
27. Remove cap screws (C).
28. Slowly raise cab. Have an assistant watch to be sure
–UN–16JUN99
hydro cable, if equipped, is free to move with cab and
that no lines, harnesses or cables are damaged while
cab is removed.
H58335
29. Inspect all parts. Repair or replace as necessary.
A—Cover (2 used)
–UN–16JUN99
90
15
H58340
17
OUO6046,0001F53 –19–10AUG05–15/15

083006
PN=893
Cab
Install Cab
CAUTION: The approximate weight of cab is 578

kg (1275 lb).
Specification
Cab—Weight ................................................................................... 578 kg
(1275 lb)
IMPORTANT: Door hinge will contact the side grab

handle and break if cab door is not
securely latched prior to installing cab.
1. With hoist, carefully lower cab into position while

routing hydro cable, if equipped. Be sure no lines,
harnesses or cables are damaged while lowering cab.
OUO6046,0001F54 –19–10AUG05–1/13
2. Enter grain tank and install two cap screws (C).
3. Position covers (A) and install cap screws (B).
A—Cover (2 used)
B—Cap Screw
–UN–16JUN99
H58340
–UN–16JUN99
90
15
H58335
18

083006
PN=894
Cab
4. Install cap screws (A), (two on each side).
5. Connect gear shift cable.
–UN–09JAN02
H70768
–UN–16JUN99
H58343
90
15
19

083006
PN=895
Cab
6. If equipped, route hydro control cable and install

clamps (C), jam nut (B) and ball joint (A).
A—Ball Joint
B—Jam Nut
C—Clamp (4 used)
–UN–30JUN99
H58547
–UN–30JUN99
H58548
–UN–29JUN99
H58546
90
15
20

083006
PN=896
Cab
7. Connect steering valve hoses (A) to steering valve.
8. Connect feeder house reverser control cable (B).
A—Steering Valve Hose (4 used)

B—Reverser Control Cable
–UN–16JUN99
H58339
OUO6046,0001F54 –19–10AUG05–5/13
9. Align park brake cable balancer with bracket and install

pin (C) and cotter pin (B).
10. Install nuts and washers (A) and adjust park brake.
(See ADJUST PARK BRAKE PEDAL in Section 60,
Group 10.)
–UN–16JUN99
A—Nut and Washer (2 used)
B—Cotter Pin
C—Pin
H58338
OUO6046,0001F54 –19–10AUG05–6/13
11. Connect ground strap (A).
A—Ground Strap
–UN–09MAY03
90
15
21
H76853

083006
PN=897
Cab
IMPORTANT: Brake lines use O-ring seal fittings.

When replacing fitting O-rings, use
white TEFLON O-rings that will not be
damaged by brake fluid.
12. Connect three oil lines (A) to brake valve.
A—Brake Line (3 used)
–UN–16JUN99
H58337
OUO6046,0001F54 –19–10AUG05–8/13
13. Install clamps (A) and tube (B).
A—Clamp (3 used)
B—Evaporator Drain Tube
–UN–29JUN99
H58545
–UN–29JUN99
90
15
H58544
22

083006
PN=898
Cab
14. Connect harness connectors (B).
15. Connect heater hoses (A).
A—Heater Hose (2 used)

B—Harness Connectors
–UN–07JUN05
H83700
OUO6046,0001F54 –19–10AUG05–10/13
16. Position harness in clamps (A) and install clamp (D)

and cap screws (C).
17. Connect steering column connector (B).
A—Clamp (4 used)
–UN–01JUL05
B—Left-Hand Main Harness-To-Steering Column
Harness Connector
D—Clamp
H83887
–UN–01JUL05
H83888
90
15
23
–UN–29JUN99
H58561

083006
PN=899
Cab
18. Position cab fascia (B) and tighten cap screws (A).

B—Panel
–UN–01JUL99
H58557
OUO6046,0001F54 –19–10AUG05–12/13
19. Connect lines (A).
20. Install clamp (C) and cap screw (B).
21. Charge air conditioning system. (See procedure in

Group 05.)
–UN–07JUN05
22. Fill radiator with recommended coolant. (See FUELS
and LUBRICANTS in Section 10, Group 20.)
Approximate capacity is 45 L (47.6 qt).
H83699
23. Bleed brake system. (See BLEEDING BRAKE
SYSTEM—DOUBLE BLEED SCREW in Section 60,
Group 10.) A—Line (2 used)
B—Cap Screw
C—Clamp
24. Adjust hydro control cable, if equipped. (See ADJUST
HYDROSTATIC NEUTRAL LINKAGE in Section 50,
Group 15.)
90
15
24
OUO6046,0001F54 –19–10AUG05–13/13

083006
PN=900
Cab
Replace Rear Window
Do not attempt to install replacement window (A) unless

The original factory adhesive used to bond the window in

place is a urethane type. When installing this glass, use
an adhesive method that is compatible with urethane A
from John Deere.
–UN–07DEC01
H70389
Curing time of this type adhesive is dependent on weather
cure time. However, if it is necessary to operate the A—Replacement Window
OUO6083,0000211 –19–06MAR02–1/1
90
15
25

083006
PN=901
Cab
Remove and Install Cab Roof—Style A
1. Remove screws that attach sunvisor to cab roof (if

equipped).
2. Push up and pull back on forward edge of front
–UN–26SEP97
headliner (A) to release from clips. Remove headliner.
3. Remove rear window trim.
H50258
4. Remove coat hook.
NOTE: The rear headliner has one mounting screw that is A—Front Headliner
hidden underneath the cab door weather-strip B—Overhead Control Panel
seal. C—Rear Headliner
D—Dome Light
5. Push up on back edge of rear headliner (C) to release, E—Speaker (2 used)
F—Screw (6 used)
and pull rear headliner back to remove.
6. Remove screws (F) and lower overhead control panel

(B).
7. Disconnect the following:
• Radio Antenna Coupler

• Radio Connector
• Wiper Motor Connector
• VISIONTRAK Console Connector
• Warning Display Panel Connectors
• Wiper Switch Connector
• Light Switch Connectors
• Panel Lights Dimmer Connector
• Auxiliary Field Lights Switch Connector
8. Remove speakers (E) on both sides of cab.
9. Disassemble and remove dome light (D) so that

harness can be pulled out.
90
15
26
Continued on next page OUO6046,0001F6D –19–14JUN05–1/3

083006
PN=902
Cab
NOTE: It may be necessary to remove the grain tank A

window to gain access to cab exterior aft trim B
panel hardware. C
P
10. Remove screws (F) and covers (G), (H) and (I). D
E
11. Remove cap screws (L) and bonding cables (M) to
remove overhead control panel.
12. Remove cap screws (J) and overhead control panel

mount frame (K). N
E
13. Remove nuts (O) to loosen roof (P).
F O
14. Remove cap screws (B) and replace with eyebolts
(A). G
M L
L
15. Partially remove staples that secure headliner at K
dome light mount area. Pull dome light wiring harness F
to right-hand side of cable.
–UN–29MAY01
H
16. Connect lifting device to eyebolts (A) and remove roof J
(P).
H67758
17. Inspect parts. Repair or replace as necessary. F
F I
18. Install roof (P). Remove eyebolts (A) and replace with
cap screws (B). Tighten nuts (O). A—Eyebolt (2 used)
C—Washer (2 used)
19. Insert dome light wiring harness into headliner until D—Seal Washer (2 used)
harness connectors are accessible at dome light E—Antenna
mount area. Install headliner in cab roof. F—Screw (27 used)
G—Cover
H—Cover (2 used)
20. Install parts (B—N) as shown
I—Cover
J—Cap Screw (4 used)
K—Overhead Control Panel Mount Frame
L—Cap Screw (4 used)
M—Bonding Cable (2 used)
N—Cover
O—Nut (4 used)
P—Roof
90
15
27
Continued on next page OUO6046,0001F6D –19–14JUN05–2/3

083006
PN=903
Cab
21. Install speakers (E) on both sides of cab.
22. Assemble and install dome light (D).
23. Connect the following:
–UN–26SEP97
• Radio Antenna Connector
• Radio Connector
• Wiper Motor Connector
• VISIONTRAK Console Connector
H50258
• Warning Display Panel Connectors
• Wiper Switch Connector
• Light Switch Connectors
A—Front Headliner
• Panel Lights Dimmer Connector B—Overhead Control Panel
• Auxiliary Field Lights Switch Connector C—Rear Headliner
D—Dome Light
24. Install rear headliner (C). E—Speaker (2 used)
F—Screw (6 used)
25. Install coat hook.
26. Install rear window trim.
27. Position overhead control panel (B) into headliner and

install screws (F).
28. Install front headliner (A).
29. Install sun visor (if equipped).
OUO6046,0001F6D –19–14JUN05–3/3
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.
–UN–26MAY05
90 2. Remove cap screws (B and C).

15
28 3. Remove communications/CB antenna (D).
H83614
A—Screw (12 used)

B—Cap Screw
C—Cap Screw
D—Communications/CB Antenna
Continued on next page OUO6046,0001EA9 –19–30JUN05–1/2

083006
PN=904
Cab
4. Lift up on front left-hand side of cab roof to access

antenna (A). Disconnect antenna.
5. Remove cab outer roof.
–UN–23MAY05
IMPORTANT: Inspect seal along cab outer roof for
defects. Replace as needed.
H83571
A—Antenna
OUO6046,0001EA9 –19–30JUN05–2/2
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.)
–UN–23MAY05
3. Remove nuts (A and B) and wiper arm (C).
A—Nut
B—Nut
H83549
C—Wiper Arm
OUO6046,0001EAA –19–31AUG05–1/8
4. Remove cap screws (A) and grab handle (B). 90

15
29
B—Grab Handle
–UN–23MAY05
H83552
Continued on next page OUO6046,0001EAA –19–31AUG05–2/8

083006
PN=905
Cab
5. Remove boot (A), nut (B) and plate (C).
A—Boot
B—Nut
C—Plate
–UN–23MAY05
H83553
OUO6046,0001EAA –19–31AUG05–3/8
7. Push wiper motor assembly (A) towards roof and

remove wiper motor assembly.
A—Wiper Motor Assembly
–UN–23MAY05
B—Connector
H83554
OUO6046,0001EAA –19–31AUG05–4/8
8. Remove covers (A) and disconnect speaker wires.
9. Route speaker wires through access hole (B) and into

cab.
A—Cover (2 used)
–UN–24MAY05
B—Access Hole
H83580
90
15
30
–UN–24MAY05
H83581

083006
PN=906
Cab
10. Remove clips (A) from cab roof.
A—Clip (3 used)
–UN–24MAY05
H83582
OUO6046,0001EAA –19–31AUG05–6/8
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
–UN–24MAY05
disconnected.
11. Remove screws and connector (A) from front of cab

roof.
H83585
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.
–UN–24MAY05
15. Disconnect connectors (D) from ballast.
16. Route main harness on top of cab through access

hole (C) and into cab.
H83586
17. Remove screw (E) and communications/CB radio
antenna cable.
A—Connector
B—Light Grommet (4 used) 90
C—Access Hole 15
D—Connector (2 used) 31
E—Screw
F—Antenna Wire
G—Cap Screw

083006
PN=907
Cab
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
–UN–23MAY05
is 31 kg (69 lb).
Specification
Inner Cab Roof—Weight ................................................................... 31 kg
H83557
(69 lb)
20. Remove inner cab roof from combine. Front Cab Mount
21. Repair or replace inner cab roof as necessary.
22. If replacing cab roof, perform the following steps:
• Remove speakers. (See procedure in Section 40,

Group 30.)
–UN–26MAY05
• Remove cab lights. (See procedure in Section 40,
Group 25.)
• Remove ballast. (See procedure in Section 40,
Group 25.)
H83596
A—Front Cab Mount (2 used)
B—Rear Cab Mount (2 used)
C—Washer Hose
OUO6046,0001EAA –19–31AUG05–8/8
90
15
32

083006
PN=908
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
–UN–01JUN05
headliner (E) to release from clips. Remove front
headliner.
3. Remove rear window trim.
H83575
4. Remove coat hook.
5. Move door weatherstrip to access screw (C) and A—Overhead Control Panel
remove screw. B—Sound Resonator Cover (2 used)
C—Screw
D—Dome Light
NOTE: Overhead panel and dome light harnesses do not E—Front Headliner
need to be disconnected in order to remove F—Location
headliner. G—Clip (4 used)
6. Lower overhead control panel (A) and dome light (D).
7. Remove sound resonator covers (B).
8. Using a putty knife, move headliner away from cab

frame to release headliner from clips (G) at locations
(F) and lower headliner.
9. Move overhead control panel and dome light through

holes in headliner and remove headliner.
OUO6046,0001EAB –19–30JUN05–1/1
Remove and Install Operator’s Seat 90

15
33
1. Open compartment lid (B) on armrest control panel (A).
A—Armrest Control Panel

B—Compartment Lid
–UN–02APR01
H67021
Continued on next page OUO6046,0001FF0 –19–30JUN05–1/11

083006
PN=909
Cab
–UN–09MAY03
H76848
OUO6046,0001FF0 –19–30JUN05–2/11
3. Disconnect hydrostatic control cable (A), if equipped.
4. Lift off control panel armrest.
A—Hydrostatic Control Cable
–UN–02APR01
H67022
OUO6046,0001FF0 –19–30JUN05–3/11
5. Disconnect cable (A) from bracket, if equipped.
–UN–07JUN99
H57418
OUO6046,0001FF0 –19–30JUN05–4/11
90 6. Disconnect harness connectors (A).

15
34
A—Electrical Connector (2 used)
–UN–02APR01
H67023

083006
PN=910
Cab
CAUTION: Approximate weight of operator’s

seat is 57 kg (125 lb).
7. Remove four nuts (A) and seat assembly.
8. Repair or replace seat as necessary. (See repair
–UN–02APR01
procedures in this group.)
A—Nut (4 used)
H67024
–UN–02APR01
H67025
OUO6046,0001FF0 –19–30JUN05–6/11
CAUTION: Approximate weight of operator’s

seat is 57 kg (125 lb).
9. Install seat assembly using four nuts (A).
–UN–02APR01
A—Nut (4 used)
H67024
90
15
35
–UN–02APR01
H67025

083006
PN=911
Cab
10. Connect harness connectors (A).
A—Electrical Connector (2 used)
–UN–02APR01
H67023
OUO6046,0001FF0 –19–30JUN05–8/11
11. Connect hydrostatic control cable (A), if equipped.
12. Position control panel armrest.
–UN–07JUN99
H57418
OUO6046,0001FF0 –19–30JUN05–9/11
13. Connect hydrostatic control cable (A), if equipped.
–UN–02APR01
H67022
OUO6046,0001FF0 –19–30JUN05–10/11
90 14. Attach control panel armrest using cap screws (A).

15
36
–UN–09MAY03
H76848
OUO6046,0001FF0 –19–30JUN05–11/11

083006
PN=912
Cab
Remove and Install Armrest Control Pivot—

Style A
1. Remove cap screws and washers (A).
2. Disconnect hydrostatic control cable (B) and remove
–UN–07JUN99
from bracket (C).
3. Lift off control panel armrest.
H57414
B—Hydrostatic Control Cable
C—Bracket
–UN–04OCT02
H73548
OUO6083,0000CA4 –19–07MAR06–1/3
4. Loosen support nuts (A) and remove armrest control

pivot (B).
5. Disassemble and repair as required. (See

DISASSEMBLE AND ASSEMBLE ARMREST
CONTROL PIVOT in this group.)
–UN–04OCT02
6. Install armrest control pivot (B) and tighten support
nuts (A).
H73549
A—Support Nuts
B—Armrest Control Pivot
90
15
37

083006
PN=913
Cab
7. Install control panel armrest using cap screws and

washers (A).
8. Connect hydrostatic control cable (B) and secure in

bracket (C).
–UN–07JUN99
B—Hydrostatic Control Cable
C—Bracket
H57414
–UN–04OCT02
H73548
OUO6083,0000CA4 –19–07MAR06–3/3
90
15
38

083006
PN=914
Cab
Remove and Install Armrest Control Pivot—

Style B
1. Remove cap screws and washers (A).
2. Disconnect hydrostatic control cable (B).
–UN–07JUN99
3. Loosen nut (C) on support and remove control cable.
4. Loosen knob (D) and lower support to access socket
H57414
head screws (E).
A—Cap Screw and washer (4 used)

B—Control Cable
C—Nut
–UN–18MAY04
D—Adjusting Knob
E—Socket Head Screw (2 used)
H80469
–UN–18MAY04
H80470
OUO6083,0000CA5 –19–07MAR06–1/1
90
15
39

083006
PN=915
Cab
Disassemble and Assemble Armrest Control Pivot
A
B
C E
D
G
S
J
R
K
I
N
M
L
–UN–04OCT02
P
H73557
A—Snap Ring F—Shaft (2 used) K—Cap Screw (2 used) P—Support Nut (2 used)
B—Knob G—Bushing (as required) L—Locking Pawl Q—Socket Head Screw (2
C—Snap Ring H—Belt M—Screw used)
D—Spring I—Sprocket (2 used) N—Bushing R—Driver
E—Housing J—Washer (2 used) O—Bolt (2 used) S—Flange Nut
90
15
40

083006
PN=916
Cab
1. Remove snap ring (A), knob (B) and spring (C).
2. Remove locking pawl (D).
A—Snap Ring
B—Knob
–UN–04OCT02
C—Spring
D—Locking Pawl
H73553
–UN–04OCT02
H73554
OUO6083,0000CA6 –19–07MAR06–2/4
3. Remove snap ring (A) and driver (B).
4. Remove cap screws and washers (C) and cap screw,

nut and bushing (D).
5. Remove belt (E) and sprockets (F).
–UN–04OCT02
6. Inspect all parts and replace as necessary.
A—Snap Ring
H73555
B—Driver
C—Cap Screw and Washer (2 used)
D—Cap Screw, Nut and Bushing
E—Belt
F—Sprocket (2 used)
90
15
41
–UN–04OCT02
H73556

083006
PN=917
Cab
NOTE: Belt sprockets must be timed during assembly to

ensure proper operation.
7. Assemble in the reverse order of disassembly using

the following special instruction:
• Time sprockets during belt installation by aligning
–UN–04OCT02
socket head screws (A) with access holes (B).
• Complete assembly and check for proper operation.
H73568
A—Socket Head Screw (2 used)
B—Access Hole (2 used)
OUO6083,0000CA6 –19–07MAR06–4/4
Remove and Install Operator Presence

Switch
1. Disconnect electrical connector (A), located below

right-hand armrest.
–UN–30OCT02
A—Connector
H73866
OUO6083,0000452 –19–31OCT02–1/4
2. Remove screws (A) and lift out seat cushion (B).
A—Screw (3 used)
B—Cushion
–UN–30OCT02
90
15
42
H73867

083006
PN=918
Cab
3. Remove switch plate assembly (A) and pull switch

harness through seat frame.
4. Repair or replace switch plate as needed.
5. Install switch plate assembly and route switch harness

through seat frame.
–UN–03JUL02
A—Switch Plate Assembly
H72741
OUO6083,0000452 –19–31OCT02–3/4
6. Reinstall seat and connect wire harness (A).
7. To test the switch after installation, sit in the seat, turn

the key to the RUN position, engage separator and
header switches on. Overhead panel lights will come
on for low shaft speed. Raise up off of seat. In five
–UN–30OCT02
seconds the overhead lights will go off if the switch is
working correctly.
A—Wire Harness
H73866
OUO6083,0000452 –19–31OCT02–4/4
90
15
43

083006
PN=919
Cab
Operator Seat—Exploded View
B
C
F E
90 I
15
44
J
–UN–26JUN01
H68823
Continued on next page OUO6083,000009F –19–30JUN05–1/2

083006
PN=920
Cab
A—Back Cushion D—Reed Switch G—Support J—Base

B—Seat Cushion E—Actuator H—Seat Belt Latch K—Spring
C—Armrest F—Plate I—Seat Belt L—Spring
OUO6083,000009F –19–30JUN05–2/2
90
15
45

083006
PN=921
Cab
Operator Seat Air Suspension Assembly—Exploded View
K
Q H
L
J G
I F
90
15 D
46 B
–UN–26JUN01
A
H68824

083006
PN=922
Cab
A—Lower Housing F—Air Spring J—Height Adjustment Control N—Plate

B—Air Compressor G—Scissor Assembly K—Upper Housing O—Cover
C—Air Line H—Shock Absorber L—Isolator Release P—Shock Absorber
D—Wire Harness I—Rail (2 used) M—Firmness Control Q—Weight Indicator
E—Boot
OUO6083,0000212 –19–06MAR02–2/2
Disassemble and Assemble Operator Seat

Air Suspension Assembly
1. Remove operators seat. (See procedure in this group.)
2. Remove adjusting rails.
–UN–03JUL02
3. Remove rubber boot and plastic covers (A and B).
NOTE: Place two wooden blocks (C) approximately 115
H72740
mm (4-1/2 in.) long into U-rails of frame as shown.
A—Plastic Cover
B—Plastic Cover
C—Wooden Blocks (2 used)
–UN–08NOV02
H74159
Continued on next page OUO6083,00007C2 –19–18MAY04–1/6
90
15
47

083006
PN=923
Cab
4. Remove snap ring (A) and remove horizontal shock

absorber (B).
NOTE: Note cable and air line routing and location of

cable ties to aid in reassembly.
5. Disconnect Bowden cable (C) at shock absorber (E)

and loosen cable clamps.
6. Remove snap rings (D) from bearing pins and remove

shock absorber.
–UN–03JUL02
A—Snap Ring
B—Horizontal Shock Absorber
C—Bowden Cable
D—Snap Rings
E—Shock Absorber
H72739
90
15
48

083006
PN=924
Cab
7. Remove screw (A) from horizontal adjusting handle (B)

and disconnect handle with linkage.
8. Drill out rivets (C) of emergency stops (D) and remove

stops from frame (E).
–UN–08NOV02
9. Disconnect indicator (J), slide frame to recess and
remove.
10. Remove cap screws (F) and horizontal spring
H74158
assembly (G).
11. Disconnect spring (H) and remove snap ring (K) from
bearing pin. Remove locking lever (I).
A—Screw
B—Adjusting Handle
C—Rivets (2 used)
D—Emergency Stop (2 used)
E—Frame
–UN–03JUL02
G—Horizontal Spring Assembly
H—Spring
I—Locking Lever
H72759
J—Indicator
K—Snap Ring
OUO6083,00007C2 –19–18MAY04–3/6
12. Remove three screws (A) from weight and height

adjuster. Disconnect air line (B) and remove support
(C).
A—Screw (3 used)
B—Air Line
–UN–08NOV02
C—Support
90
15
49
H74162

083006
PN=925
Cab
13. Loosen hose clamp and pull hose off compressor.
14. Remove cap screws (A and B) of air spring (C) and

remove air spring.
15. Remove nuts (D) and bearing brackets (E).
–UN–08JUL02
16. Remove seat rocker (F).
A—Cap Screw
H72761
B—Cap Screw
C—Air Spring
D—Nut (2 used)
E—Bearing Bracket (2 used)
F—Seat Rocker
–UN–03JUL02
H72758
OUO6083,00007C2 –19–18MAY04–5/6
17. Remove cap screw (A) from compressor (B).

Disconnect hose (C) and connector. Remove
compressor.
18. Assemble in reverse order.
–UN–08JUL02
A—Cap Screw
B—Compressor
C—Hose
H72760
OUO6083,00007C2 –19–18MAY04–6/6
90
15
50

083006
PN=926
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).
–UN–01OCT02
2. Remove cab door.
3. Repair or replace cab door as necessary.
H73474
4. Install cab door using hinge pins (B) and snap rings
(A).
A—Snap Ring
B—Hinge Pin
–UN–01OCT02
H73475
OUO6030,00001BC –19–16FEB06–1/1
90
15
51

083006
PN=927
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
90
15
52
28
–UN–02OCT02
25
26
H73479
Continued on next page OUO6030,00001BD –19–16FEB06–1/2

083006
PN=928
Cab
1—Strap Nut 10—Nut (2 used) 20—Bushing 29—Lock Washer (4 used)

2—Spring Washer (2 used) 11—Washer (2 used) 21—Washer 30—Screw (4 used)
3—Striker 12—Screw (2 used) 22—Cap 31—Lock Nut (2 used)
4—Socket Head Screw (2 13—Bracket 23—Screw 32—Washer (2 used)
used) 14—Spacer 24—Pin (2 used) 33—Washer
5—Screw 15—Door 25—Hinge (2 used) 34—Screw
6—Cover 16—Bushing 26—Snap Ring (2 used) 35—Isolator
7—Latch 17—Gasket 27—Bushing 36—Washer
8—Bearing 18—Handle 28—Washer (8 used) 37—Lock Nut
9—Tube 19—Gasket
Disassemble and assemble door as required to make

repairs.
OUO6030,00001BD –19–16FEB06–2/2
90
15
53

083006
PN=929
Cab
Cab Door Latch Striker
C
B
D
–UN–02OCT02
H73480
A—Socket Head Screw (2 B—Striker Plate C—Spring Washer (2 used) D—Strap Nut
used)
NOTE: Make sure washers (C) are not lost when 5. Check proper operation of door latch from inside
removing striker plate (B). and outside cab. Make further adjustments as
required.
1. Remove socket head screws (A), striker plate (B),
spring washers (C) and strap nut (D). 6. Tighten socket head screws (A) to specification.
2. Inspect parts for wear. Replace parts as required. Specification

Striker Plate Socket Head
Screws—Torque ...................................................................... 72 N•m
3. Install striker plate (B) and washers (C), with cup (53 lb-ft)
side toward cab frame, using socket head screws
(A). Do not tighten at this time.
90
15
4. Check alignment of striker plate with door latch
54
assembly. Loosen striker plate and realign as
required.
OUO6083,0000439 –19–16FEB06–1/1

083006
PN=930
Section 110
Feeder House Repair
Contents
Page Page
Group 05—Conveyor Backshaft Speed Sensor . . . . . . . . . . . . . . . .110-15-22

Other Material . . . . . . . . . . . . . . . . . . . . . . . . .110-05-1 Remove, Repair and Install Variable Drive
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .110-05-1 Sheaves and Cams—Style A. . . . . . . . . . .110-15-23
Remove and Install Feeder House . . . . . . . . .110-05-2 Repair Variable Drive Sheaves and
Feeder House Conveyor Chain—Adjust . . . . .110-05-4 Cams—Style B . . . . . . . . . . . . . . . . . . . . .110-15-28
Remove and Install Conveyor Chain . . . . . . . .110-05-5 Remove and Install Variable Drive
Measure Conveyor Chain Wear . . . . . . . . . . .110-05-8 Sheaves and Cams—Style B. . . . . . . . . . .110-15-36
Removing Conveyor Chain Link . . . . . . . . . . .110-05-8 Remove and Install Fixed Drive Sheave . . . .110-15-37
Replace Conveyor Chain Slats . . . . . . . . . . . .110-05-9 Remove and Install Reverser Gear Case . . .110-15-38
Replace Conveyor Chain Wear Strips . . . . . .110-05-10 Feeder House Reverser Gear Case—
Adjust Drum Height . . . . . . . . . . . . . . . . . . . .110-05-13 Exploded View. . . . . . . . . . . . . . . . . . . . . .110-15-42
Remove and Install Conveyor Drum . . . . . . .110-05-13 Disassemble and Assemble Feeder
Remove And Install Sub-Floor Assembly. . . .110-05-17 House Reverser Gear Case. . . . . . . . . . . .110-15-43
Remove and Install Front Wear Plates . . . . .110-05-18 Disassemble and Assemble Reverser
Single Point Latching Level Land— Gear Case Oil Pump . . . . . . . . . . . . . . . . .110-15-56
Exploded View. . . . . . . . . . . . . . . . . . . . . .110-05-20 Remove and Install Reverser Shift Piston . . .110-15-61
Remove and Install Feed Plate . . . . . . . . . . .110-05-21 Remove and Install Lower Shaft . . . . . . . . . .110-15-64
Adjust Feed Plate Assembly . . . . . . . . . . . . .110-05-22 Remove and Install Oil Cooler. . . . . . . . . . . .110-15-65
Feed Plate Support—Exploded View . . . . . .110-05-24 Remove and Install Backshaft . . . . . . . . . . . .110-15-68
Disassemble and Assemble Fixed Speed
Group 10—Top Shaft and Slip Clutch Drive Tightener . . . . . . . . . . . . . . . . . . . . .110-15-70
Essential or Recommended Tools . . . . . . . . . .110-10-1 Disassemble/Assemble Conveyor Drive
Other Material . . . . . . . . . . . . . . . . . . . . . . . . .110-10-1 Chain/Tightener/Guides . . . . . . . . . . . . . . .110-15-72
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .110-10-2 Feeder House Variable Speed Belt—
Remove Top Shaft Slip Clutch (9660, 9760 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .110-15-73
and 9860) . . . . . . . . . . . . . . . . . . . . . . . . . .110-10-2 Replace Variable Speed Feeder House
Disassemble and Assemble Top Shaft Slip Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110-15-76
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110-10-4 Replace and Adjust Fixed Speed Feeder
Install Top Shaft Slip Clutch (9660 STS, House Belt. . . . . . . . . . . . . . . . . . . . . . . . .110-15-79
9760 STS and 9860 STS) . . . . . . . . . . . . . .110-10-8
Remove and Install Top Shaft Slip Clutch Group 20—CONTOUR MASTER Tilt Cylinder
(9560 STS) . . . . . . . . . . . . . . . . . . . . . . . . .110-10-8 CONTOUR MASTER Tilt Cylinder Hoses and
Remove and Install Top Shaft Supports . . . .110-10-11 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . .110-20-1
Disassemble and Assemble Top Shaft . . . . .110-10-15 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . .110-20-2
Remove and Install CONTOUR MASTER Tilt
Group 15—Feeder House Drives and Reverser Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . .110-20-3
Gear Case
Essential or Recommended Tools . . . . . . . . . .110-15-1 Group 25—CONTOUR MASTER Tilt Frame
Other Material . . . . . . . . . . . . . . . . . . . . . . . . .110-15-2 Other Material . . . . . . . . . . . . . . . . . . . . . . . . .110-25-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .110-15-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . .110-25-1 110
Remove and Install Variable Drive Tilt Frame and Beam (S.N. —720100) . . . . . .110-25-2
Countershaft . . . . . . . . . . . . . . . . . . . . . . . .110-15-6 Tilt Frame and Beam (S.N. 720101—) . . . . . .110-25-4
Disassemble and Assemble Upper Variable Remove and Install Tilt Frame . . . . . . . . . . . .110-25-5
Drive Countershaft . . . . . . . . . . . . . . . . . . .110-15-14 Remove and Install Tilt Beam . . . . . . . . . . . . .110-25-7
Disassemble and Assemble Standard
Capacity Fixed Speed Countershaft. . . . . .110-15-21 Continued on next page

083006
PN=1
Contents
Page
Adjust Single Point Latching . . . . . . . . . . . . .110-25-10

Lateral Tilt Beam with Single Point
Latching—Exploded View (S.N. —
715300) . . . . . . . . . . . . . . . . . . . . . . . . . . .110-25-12
Lateral Tilt Beam with Single Point
Latching—Exploded View (S.N. 715301—
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110-25-13
Adjust Fore-Aft Turnbuckles . . . . . . . . . . . . .110-25-14
Remove Fore-Aft Tilt Frame . . . . . . . . . . . . .110-25-14
Install Fore-Aft Tilt Frame . . . . . . . . . . . . . . .110-25-17
110

083006
PN=2
Group 05
Conveyor
Other Material
Number Name Use
AG,OUO6435,883 –19–25JUL00–1/1
Specifications
Feeder House Pivot Casting Cap Torque 620 N•m

Screws (457 lb-ft)
Drum Adjusting Nut Torque 140 N•m

(103 lb-ft)
Feeder House Drum Shield Cap Torque 73 N•m

Screws (54 lb-ft)
Conveyor Chain Capnuts Torque 25 N•m

(18 lb-ft)
Conveyor Chain Slat Hardware Torque 25 N•m

(18 lb-ft)
Conveyor Drum Housing Cap Torque 120 N•m

Screws (87 lb-ft)
Main Floor Cap Screws Torque 120 N•m

(87 lb-ft)
Conveyor Drum Weight 36 kg

(80 lb)
OUO6083,0000DBA –19–10AUG06–1/1
110
05
1

083006
PN=933
Conveyor
Remove and Install Feeder House

stop. Engine must be off and key removed.
1. Lower feeder house safety stop onto lift cylinder.
2. Remove:
• Feeder house shields

• Hose clamps on both sides
• Hoses from CONTOUR MASTER cylinder (if
equipped)
• Feeder house drive belt from electric clutch and reel
pump
• Multi-coupler hose cover on top of feeder house
• Multi-coupler upper supporting bracket
• Upper rear seal assembly
3. Disconnect:
• Wiring harnesses
• Hydraulic hose from reverser. Cap hose
• Parking brake cables from connector bracket
• Header height sensor linkage
• Multi-coupler from lower bracket
4. Pull multi-coupler and hose assembly back to chassis.
5. Raise feeder house and lift safety stop.
6. Lower feeder house to ground and continue to depress

header lower switch for five seconds to relieve high
pressure oil at hydraulic valve stack.
7. Set parking brake, shut off engine and remove key.

110
05
2

083006
PN=934
Conveyor
CAUTION: High pressure can exist at any

hydraulic connection. Avoid injury from high
pressure leaks by relieving system pressure
before disconnecting any hydraulic lines,
fittings or connections.
–UN–09MAY03
CAUTION: Weight of feeder house can vary
depending on model and drive configuration,
but is extremely heavy. Avoid injury by using
H76854
safe lifting device.
8. Disconnect and cap lift cylinder hose (A) on both sides.

A—Hose (2 used)
9. Remove rear cylinder pin (B) on both sides. B—Pin (2 used)
C—Feed Plate
10. Drop feed plate (C). E—Pivot Casting
11. Attach lifting device to feeder house.
12. Remove cap screw (D) from pivot casting retainers on

both sides.
13. Slowly back combine away.
14. Inspect feeder house components. Repair or replace

as required.
15. Install feeder house in reverse order using the

following special instructions:
• Apply T43512 Thread Lock and Sealer (Medium

Strength) to pivot casting cap screw threads. Install
cap screws and tighten to specification.
Specification
Feeder House Pivot Casting Cap
Screws—Torque ........................................................................... 620 N•m
(457 lb-ft)
OUO6083,0000616 –19–05JUN03–2/2
110
05
3

083006
PN=935
Conveyor
Feeder House Conveyor Chain—Adjust
1. Open left- and right-hand front feeder house shields.
2. Set conveyor drum “float” to grain position (See

ADJUST DRUM HEIGHT in this group).
–UN–11JUN03
3. Loosen nut (A) on both sides of feeder house.
IMPORTANT: Do not over tighten chain to make
H76855
center strands as tight as outer strands.
Center strands normally sag more
because of weight of slats and upward
force from crop material.
4. Adjust eyebolt (B) with adjustment nuts (C) on both

sides of feeder house until left- and right-hand side
outer chains contact runner at the center of inspection
door (D).
5. Tighten nuts (C) on eyebolt (B). Tighten nuts (A) to

specification.
Specification
Drum Adjusting Nut—Torque ....................................................... 140 N•m
(103 lb-ft)
–UN–11APR00
a. Check tension on both sides every 100 hours.
Adjust when outside strands touch front of runner
channel (E). Adjust no tighter than runner contact
H62782
(F) at center for inspection door.
b. Do not over tighten chain to make center strands as A—Nut (2 used)

tight as outer strands. Center strands normally sag B—Eyebolt (2 used)
more because of weight of slats and upward force C—Adjustment Nut (4 used)
D—Inspection Door
from crop material.
E—Runner Channel
F—Runner Contact
c. Bent eyebolts indicate excessive chain tension or
slug feeding.
d. Out-of-round sprockets or drum and bent shafts can

cause chain tension to be uneven, too tight, or too
loose.
e. Shaft and bearing failure are often caused by

excessive chain tension.
110
05
4
Continued on next page OUO6083,0000DBB –19–11AUG06–1/2

083006
PN=936
Conveyor
f. When adjusting eyebolt can go no further and the

chain needs more tension, remove a half link. (See
REMOVING CONVEYOR CHAIN LINK in this
group).
6. Close shields.
OUO6083,0000DBB –19–11AUG06–2/2
Remove and Install Conveyor Chain
1. Swing front side shields open.
2. Loosen cap screw (B) and nuts (A) on both sides to

relieve tension on conveyor chain.
–UN–09MAY03
A —Nut (4 used)
H76856
OUO6083,0000D85 –19–11JUL06–1/7
3. If equipped, remove cap screws (A) from top and

closure shields (C).
4. Remove cap screws (B), washers, spacers and nuts.
5. Rotate conveyor to gain access to connecting link.
–UN–09MAY03
C—Shields
H76857
OUO6083,0000D85 –19–11JUL06–2/7
6. Machines equipped with “S” hooks:
Remove “S” hooks (A) to remove connecting links.
A—“S” Hooks
110
–UN–28JUN99
05
5
H58526

083006
PN=937
Conveyor
7. Machines equipped with capnuts:
Remove capnuts (A), connecting link plate (B) and

threaded connecting link (C).
8. Pull conveyor out of feeder house.
–UN–10JUL06
9. Inspect chain and slats. Repair or replace as
necessary. (See MEASURE CONVEYOR CHAIN
WEAR and REPLACE CONVEYOR CHAIN SLATS in
H86317
this group.)
NOTE: Be sure angle leg of slat is on trailing edge.

A—Capnut (2 used)
10. Pull conveyor into feeder house using a rope. B—Connecting Link Plate
C—Threaded Connecting Link
OUO6083,0000D85 –19–11JUL06–4/7
IMPORTANT: When shortening conveyor chain,

remove an offset link from each strand
using a chain breaker. Connector link
can be reused to connect chain.
–UN–28JUN99
Connect chain ends with connector links and new “S”
hooks (A). On outside chains, install connector links
so hooks are toward inside edge of feeder house to
H58526
prevent pins from striking drum ring.
A—“S” Hooks
110
05
6

083006
PN=938
Conveyor
Connect chain ends with threaded connecting link (A),

connecting link plate (B) and capnuts (C). On outside
chains, install threaded links with capnuts on inside.
Tighten capnuts to specification.
–UN–10JUL06
Specification
Conveyor Chain Capnuts—
Torque ............................................................................................ 25 N•m
(18 lb-ft)
H86317
A—Capnut (2 used)
B—Connecting Link Plate
OUO6083,0000D85 –19–11JUL06–6/7
13. If equipped, install closure shields (C) using cap

screws (A).
14. Install cap screws (B), washers, spacers and nuts.
15. Adjust conveyor chain tension. (See ADJUST
–UN–09MAY03
CONVEYOR CHAIN in this group.)
16. Close front side shields.
H76857
C—Shields
OUO6083,0000D85 –19–11JUL06–7/7
110
05
7

083006
PN=939
Conveyor
Measure Conveyor Chain Wear
1. Stretch chain assembly out on a smooth surface.
2. Measure from center of holes in end links.
3. Divide length by number of links to get average pitch

length.
New chain pitch length 41 mm (1-5/8 in.)
A chain worn more than 4 percent may jump drive

sprocket teeth or cause sprocket wear.
4. Do not replace worn chain unless average pitch is at

least 43 mm (1-11/16 in.) (3.4 percent wear) or if one
chain strand is more than 36 mm (1-13/32 in.) longer
than adjacent strand.
AG,OUO6037,21 –19–25JUL00–1/1
Removing Conveyor Chain Link
NOTE: Part numbers can change. Be sure to check parts

catalog before ordering parts.
1. Make first adjustment when sidesheet slots limit chain

tensioning. Remove offset links (A) for initial chain
adjustment.
2. Remove offset links (B) for second adjustment. When

adjustment is all used up from the second adjustment,
the chain is worn out and should be replaced.
NOTE: When replacing chain links always check

sprockets for wear.
A—Offset Link
B—Offset Link
–UN–07JAN02
110
05
8
H70736
OUO6083,00002CC –19–12JUN02–1/1

083006
PN=940
Conveyor
Replace Conveyor Chain Slats
1. Raise feeder house and lower safety stop (A). Set

parking brake, shut off engine and remove key.
A—Safety Stop
–UN–12MAY03
H76859
OUO6083,0000D8D –19–12JUL06–1/2
2. Rotate feeder house drive belt to access damaged slat.
3. Riveted slats:
Grind off rivet heads (A) on each end of slat (B) and
remove slat. Remove the rest of the rivet in the
–UN–19AUG02
conveyor chain with a punch and hammer.
Install slat in the same direction as previous and retain

with cap screws and lock nuts (C). Tighten to
H72999
specification.
4. Bolted slats:
Remove cap screws and lock nuts (D) on each end of

slat. Remove slat.
5. Install slat in the same direction as previous and retain

with cap screws and lock nuts (D). Tighten to
–UN–19AUG02
specification.
Specification
Conveyor Chain Slat Hardware—
Torque ............................................................................................ 25 N•m
H73000
(18 lb-ft)
NOTE: This is the same hardware used on tough material

handling option chain.
A—Rivet (4 used per slat)

B—Slat
C—Cap Screw and Lock Nut (4 used per slat)
D—Cap Screw and Lock Nut (4 used per slat)
–UN–13JUL05
110
05
H83961
OUO6083,0000D8D –19–12JUL06–2/2

083006
PN=941
Conveyor
Replace Conveyor Chain Wear Strips
1. Lower feeder house to ground.
OUO6083,000063B –19–11JUN03–1/9
2. Remove top door (A).
A—Top Door
–UN–09MAY03
H76858
OUO6083,000063B –19–11JUN03–2/9
3. Block conveyor slat (A) up on both sides to provide

clearance between chain and wear strip (B).
A—Slat
B—Wear Strip
–UN–12MAY99
H57135
–UN–14APR00
H63609

110
05
10

083006
PN=942
Conveyor
4. Raise feeder house and lower safety stop (A).
5. Shut off engine and remove key.
6. Drop feed plate.
–UN–12MAY03
A—Safety Stop
H76859
OUO6083,000063B –19–11JUN03–4/9
7. Remove feed plate support (A), cap screws (B) and

seal from feeder house floor.
8. Remove conveyor chain wear strips:
A—Support
–UN–12MAY99
H57136
OUO6083,000063B –19–11JUN03–5/9
a. Remove socket head cap screw and washer (A).
b. Push up and slide strip towards rear of machine to

remove.
c. Install new wear strip.
–UN–14APR00
d. Install washer and socket head cap screw.
e. Repeat steps (a—d) for remaining wear strips.
A—Socket Head Cap Screw H63608

110
05
11

083006
PN=943
Conveyor
9. Install seal, cap screws (B) and feed plate support (A)
to feeder house floor.
10. Raise feed plate.
11. Raise safety stop and lower feeder house.
–UN–12MAY99
A—Support
H57136
OUO6083,000063B –19–11JUN03–7/9
12. Remove block from slat (A) on both sides.
A—Slat
–UN–12MAY99
H57135
OUO6083,000063B –19–11JUN03–8/9
13. Install feeder house top door (A).
A—Top Door
–UN–09MAY03
H76858
OUO6083,000063B –19–11JUN03–9/9
110
05
12

083006
PN=944
Conveyor
Adjust Drum Height
Float cams are located on both sides of feeder house.
To set float:
–UN–14FEB05
1. For large grain, rotate handle (B) until pin (A) engages
with notch (C).
2. For small grain, rotate handle (B) until pin (A) engages
H82375
in existing position.
A—Pin
B—Handle
C—Notch
OUO6083,000090F –19–07FEB05–1/1
Remove and Install Conveyor Drum
NOTE: It is not necessary to remove feeder house to

service drum.
1. If equipped, remove cap screws (A).
–UN–02DEC03
2. Remove cap screws (B), washers, spacers, nuts and
shields (C).
H79239
B—Cap Screw, Washer, Spacer, Nut (2 used)
C—Shield (3 used)
OUO6083,0000D88 –19–11JUL06–1/6
3. Loosen nuts (A) and cap screws (B) on both sides of

feeder house to relieve tension on conveyor chain.
A—Nut (4 used)
110
–UN–09MAY03
05
13
H76856

083006
PN=945
Conveyor
Rotate conveyor chain to remove “S” hooks (A) and

connecting link (B).
A—“S” Hook
–UN–02DEC03
B—Connecting Link
H79243
OUO6083,0000D88 –19–11JUL06–3/6
Remove capnuts (A), connecting link plate (B) and

threaded connecting link (C).
A—Capnut (2 used)
–UN–10JUL06
B—Connecting Link Plate
H86317
110
05
14

083006
PN=946
Conveyor
S
K
D
B
A I
U
J L
–UN–01FEB06
R
T
E
P
H
F Q
H85328
G N O
A—Lock Nut (2 used) H—Washer (2 used) N—Arm (2 used) (Later S—Cap Screw (8 used) (Later
B—Washer (2 used) I—Bushing (2 used) Models) Models)
C—Handle (2 used) J—Arm (2 used) (Earlier O—Pin (2 used) (Later Models) T—Bearing with Housing (2
D—Jam Nut (4 used) Models) P—Cotter Pin (2 used) (Later used) (Later Models)
E—Eyebolt (2 used) K—Flange Nut (2 used) Models) U—Drum (Later Models)
F—Cap Screw (2 used) L—Bearing (2 used) Q—Shaft (Later Models)
G—Flange Nut (2 used) M—Drum R—Bearing Cap (2 used)
(Later Models)
12. Heat bearing to over 300° to loosen LOCTITE.

CAUTION: The approximate weight of
Remove bearing (L) using slide hammer puller
conveyor drum on earlier model machines is
D01209AA.
36 kg (80 lb) and 50 kg (110 lb) on later
model machines.
Drum arms can slide out of drum heads on
14. Apply 609 LOCTITE to bearing and press into
earlier machines.
drum.
6. Remove nuts (K) on both sides of feeder house.
15. Install shaft (Q), if equipped, and arms into drum
and drum assembly into feeder house.
7. Remove cap screws (F), bushing (I) and washers
(H).
16. Attach with previously removed hardware.
8. Remove drum assembly (M) from feeder house.
17. Connect conveyor chain using new “S” hooks. If
equipped with capnuts, torque to specifications.
9. Remove arm (J), if equipped, on both sides.
Specification
10. Remove cotter pin (P) and pin (O) from arm (N), if Conveyor Chain Capnuts—
equipped, on both sides. Torque...................................................................................... 25 N•m
(18 lb-ft)
110
11. Remove shaft (Q), if equipped, from drum. 05
15

083006
PN=947
Conveyor
18. Install shields (C) in reverse order using cap screws

(A and B). Tighten cap screws (B) to specification.
Specification
Feeder House Drum Shield Cap
Screws—Torque ............................................................................. 73 N•m
(54 lb-ft)
–UN–02DEC03
19. Adjust conveyor tension. (See ADJUST FEEDER
CONVEYOR CHAIN in this group.)
H79239
B—Cap Screw, Washer, Spacer, Nut (2 used)
C—Shield (3 used)
OUO6083,0000D88 –19–11JUL06–6/6
110
05
16

083006
PN=948
Conveyor
Remove And Install Sub-Floor Assembly
F
I
B
B
A C
–UN–16JUL01
G E H
ZX25142
A—Mid-Floor Assembly D—Cap Screw (8 used) F—Cap Screw (6 used) H—Flange Nut (12 used)
B—Round Head Bolt (2 used) E—Sub Floor G—Flange Nut (6 used) I—Cap Screw (12 used)
C—Flange Nut (10 used) 110
05
17
1. Remove shields from both sides of feeder house. 2. Raise feeder house. Lower safety stop.

083006
PN=949
Conveyor
NOTE: Raising the conveyor drum (large grain 5. Remove sub-floor assembly.
position) aids removal of the sub floor by lifting
the conveyor chain off the floor. 6. Inspect feeder house floor for wear and/or damage,
3. Raise conveyor drum.
7. Install sub-floor in reverse order.
4. Remove cap screws (F) and (I) from both sides of
feeder house. 8. Put conveyor drum in desired position.
OUO6435,0001416 –19–23JUL01–2/2
Remove and Install Front Wear Plates
1. Remove platform, raise feeder house and lower safety

stop (A).
A—Safety Stop
–UN–12MAY03
H76859
OUO6083,0000D86 –19–11JUL06–1/6
2. Remove closure plates (A) if equipped.
A—Plates
–UN–12MAY03
H76866
OUO6083,0000D86 –19–11JUL06–2/6
3. Remove tilt beam. (See REMOVE AND INSTALL TILT

BEAM in Group 25.)
4. Remove round head bolts.
110 A—Tilt Beam

–UN–12MAY03
05 B—Round Head Bolt (6 used)

18
H76867

083006
PN=950
Conveyor
5. Loosen all cap screws (A) from front seam of floor and
sealing angle. Adjust fore/aft frame for clearance if
needed. (See ADJUST FORE-AFT TURNBUCKLES in
Group 25.)
6. Remove fore/aft frame wear plate, sealing angle and
–UN–10MAY99
fixed frame wear plate. Replace as needed.
7. Tighten cap screws (A) to specification.
H56035
Specification
Feeder House Main Floor Cap
Screws—Torque ........................................................................... 120 N•m
Bottom of Feeder House Shown
(87 lb-ft)
A—Cap Screw
8. Return fore/aft frame to original position (if required).
(See ADJUST FORE-AFT TURNBUCKLES in Group
25.)
OUO6083,0000D86 –19–11JUL06–4/6
9. Install cap screws (B) in wear plate and attach to floor.
10. Install tilt beam (A). (See REMOVE AND INSTALL

TILT BEAM in Group 25.)
A—Tilt Beam
–UN–12MAY03
B—Round Head Bolts (6 used)
H76867
OUO6083,0000D86 –19–11JUL06–5/6
11. Install closure plates (A) if equipped.
A—Plates
110
–UN–12MAY03
05
19
H76866
OUO6083,0000D86 –19–11JUL06–6/6

083006
PN=951
Conveyor
Single Point Latching Level Land—Exploded View
D
E
F
G
C
H
J
K I W
T
V
L
U B
R
S
D
N
M A
O
–UN–08JUN04
P G
L
K
H81110
Q
A—Pin (2 used) G—Cap Screw (2 used) M—Clip S—Cap Screw

B—Spring (2 used) H—Angle N—Flange Nut T—Cotter Pin
C—Grommet I—Washer O—Cable U—Washer
D—Spacer (2 used) J—Pivot P—Grommet V—Washer
E—Washer K—Nut (4 used) Q—Flange Nut W—Latch
F—Washer L—Nut (2 used) R—Bracket
OUO6083,0000886 –19–12JUL04–1/1
110
05
20

083006
PN=952
Conveyor
Remove and Install Feed Plate
CAUTION: When working under the feeder

house always place the hydraulic cylinder
safety stop in the safety position to prevent
feeder house from lowering.
–UN–21SEP89
1. Raise feeder house and lower safety stop (A) onto
hydraulic cylinder rod.
TS696
2. Shut off engine, set park brake and remove key.
A—Safety Stop
–UN–12MAY03
H76859
OUO6083,0000AB7 –19–21JUL05–1/3
3. Loosen nuts (A) on left- and right-hand sides.
4. Move lever (B) down and remove feed plate hinge

assembly (C).
A—Nut (4 used)
B—Lever
C—Feed Plate Hinge Assembly
–UN–06NOV00
H65225

110
05
21

083006
PN=953
Conveyor
5. Remove pin (B) and separate feed plate (A) from hinge
plate (C). A
6. Repair or replace as necessary. B
–UN–21JUL05
8. Adjust feed plate if needed. (See procedure in this
group.)
C
H83996
A—Feed Plate
B—Pin
C—Hinge Plate
OUO6083,0000AB7 –19–21JUL05–3/3
Adjust Feed Plate Assembly
CAUTION: When working under the feeder

house always place the hydraulic cylinder
–UN–21SEP89
TS696
A—Safety Stop
–UN–12MAY03
H76859

110
05
22

083006
PN=954
Conveyor
IMPORTANT: Grain leakage could occur if feed plate

(A) is not properly sealed.
3. Loosen nuts (B) on both sides.
4. Turn eccentric (C).
–UN–17MAY99
5. Tighten nut (B) holding eccentric.
6. Tighten remaining cap screws.
H52762
7. Close feed plate door (A) and check seal.
8. Repeat Steps (3—7) as required to obtain a good seal. A—Feed Plate Door
B—Nut (4 used)
C—Eccentric
OUO6083,0000AB8 –19–19JUL05–2/2
110
05
23

083006
PN=955
Conveyor
Feed Plate Support—Exploded View
–UN–02APR02
H71512
A—Cap Screw E—Washer (4 used) I—Lock Nut (3 used) M—Support
B—Cotter Pin (2 used) F—Strap (2 used) J—Handle N—Arm (2 used)
C—Washer (2 used) G—Sleeve K—Lock Nut (4 used) O—Round Head Bolt (2 used)
D—Cap Screw (2 used) H—Bushing L—Cam (2 used) P—Hound Head Bolt (2 used)

CAUTION: Engine must be turned off and
key removed.
4. Install parts (A—P).
1. Raise feeder house and lower safety stop.
110 2. Remove parts (A—P).

05
24
OUO6083,00002AD –19–22MAY02–1/1

083006
PN=956
Group 10
Top Shaft and Slip Clutch



AG,OUO6037,80 –19–19JUL05–1/2
Slip Clutch Cam Compressor. . . . . . . . . . . . . JDG5801
Used to service feeder house top shaft slip clutch.
–UN–06JAN92
E36375
1
RECOMMENDED TOOL
AG,OUO6037,80 –19–19JUL05–2/2
Other Material
Number Name Use

applications.
AG,OUO6037,79 –19–25JUL00–1/1
110
10
1

083006
PN=957
Specifications
Top Shaft Sprocket Set Screws Torque 50 N•m

(37 lb-ft)
Slip Clutch Outer Springs Free Length 23 mm

(59/64 in.)
Slip Clutch Inner Springs Free Length 21 mm

(53/64 in.)
Top Shaft Support Nuts and Bolts Torque 520 N•m

(383 lb-ft)
Top Shaft Slip Clutch Slip Torque 1050 ± 105 N•m

High Capacity Drive (775 ± 77 lb-ft)
Top Shaft Slip Clutch Slip Torque 900 ± 90 N•m

Standard Capacity (664 ± 66 lb-ft)
Top Shaft Bearing Cap Screws Torque 122 N•m

(90 lb-ft)
Top Shaft Castle Nut Torque 353 N•m

High Capacity Drive (260 lb-ft)
Top Shaft Hex Nut and Lock Nut Torque 353 N•m
Standard Capacity Drive (260 lb-ft)
Conveyor Drive Support Weight 270 kg

(595 lb)
Conveyor Chain Connecting Link Torque 25 N•m

Capnuts (18 lb-ft)
OUO6083,0000D8F –19–12JUL06–1/1
Remove Top Shaft Slip Clutch (9660, 9760

and 9860)
1. Remove feeder house side shields.

Continued on next page OUO6083,000082C –19–07JUN04–1/4
110
10
2

083006
PN=958
2. Remove cap screws (A), washers and clutch cover (B).
A—Cap Screw
B—Cover
–UN–07JUN04
H81093
OUO6083,000082C –19–07JUN04–2/4
3. Loosen nut (A) to relieve chain tension.
4. Remove chain from clutch sprocket.
A—Nut
–UN–18JUN01
ZX25148
OUO6083,000082C –19–07JUN04–3/4
5. Remove cotter pin (A), castle nut (B) and washer (C)
on high capacity drive.
6. Remove two nuts and washer for standard capacity

drive.
–UN–07JUN04
7. Remove clutch assembly (D) from feeder house.
8. Repair or replace as necessary. (See DISASSEMBLE

AND ASSEMBLE TOP SHAFT SLIP CLUTCH in this
H81094
group.)
A—Cotter Pin
B—Castle Nut
C—Washer
D—Clutch
OUO6083,000082C –19–07JUN04–4/4
110
10
3

083006
PN=959
Disassemble and Assemble Top Shaft Slip

Clutch
NOTE: Procedures shown are for high capacity drive slip

clutch. Standard capacity procedures are similar.
1. Remove clutch from feeder house. (See REMOVE

TOP SHAFT SLIP CLUTCH in this group.)
OUO6083,000082D –19–07JUN04–1/8
2. Remove cap screws (A) to separate clutch and

sprocket.
–UN–21APR99
H55579
–UN–07JUN04
H81095
OUO6083,000082D –19–07JUN04–2/8
CAUTION: Due to stored spring energy, this

clutch must be disassembled and assembled
using JDG580 Slip Clutch Cam Compressor.
3. Remove snap ring (A) and thrust washer (B).

110
–UN–07JUN04
10
4 A—Snap Ring
B—Thrust Washer
H81096

083006
PN=960
4. Slide clutch (A) on JDG580 Slip Clutch Cam

Compressor (B).
5. Press hub (C), springs, cams and plastic seal into

JDG580 (B).
–UN–07JUN04
A—Clutch
B—JDG580
C—Hub
H81097
–UN–23APR99
H55655
110
10
5

083006
PN=961
6. Slowly remove clutch assembly (A) from JDG580.
7. Inspect hub (B) and cams (E). Replace as necessary.
8. Inspect all springs (C) and (D). Measure free length

and replace as necessary.
–UN–19NOV02
Specification
Clutch Outer Springs—Free
Length .............................................................................................. 23 mm
(59/64 in.)
H74323
Clutch Inner Springs—Free
Length .............................................................................................. 21 mm
(53/64 in.)
NOTE: Additional inner springs may be used to achieve

proper slip torque.
Specification
Top Shaft Slip Clutch
High Capacity Drive—Slip Torque ................................... 1050 ± 105 N•m
–UN–19NOV02
(775 ± 77 lb-ft)
Top Shaft Slip Clutch
Standard Capacity—Slip Torque .......................................... 900 ± 90 N•m
(664 ± 66 lb-ft)
H74324
9. Assemble inner and outer springs, cams and hub.
A—Clutch Assembly
B—Hub
C—Outer Spring (32 used)
D—Inner Spring (25 used)
E—Cam (32 used)
OUO6083,000082D –19–07JUN04–5/8
10. Install hub assembly (A) into JDG580 Slip Clutch

Cam Compressor (B).
11. Press hub (A) into housing (C) and remove

compressor (B).
–UN–23APR99
A—Hub
B—JDG580
C—Housing
H55676

110
10
6

083006
PN=962
12. Install plastic seal (A) into groove (B).
13. Install thrust ring (C) and snap ring (D).
14. Lubricate with Multi-Purpose SD Polyurea Grease

through fitting.
–UN–23APR99
A—Seal
B—Groove
C—Thrust Ring
H55677
D—Snap Ring
OUO6083,000082D –19–07JUN04–7/8
15. Install sprocket with cap screws (A).
16. Install clutch assembly to feeder house. (See

INSTALL TOP SHAFT SLIP CLUTCH in this group.)
–UN–07JUN04
H81095
OUO6083,000082D –19–07JUN04–8/8
110
10
7

083006
PN=963
Install Top Shaft Slip Clutch (9660 STS, 9760

STS and 9860 STS)
1. Install clutch assembly (D), washer (C) and castle nut

(B) for high capacity drive. Tighten nut to specification.
–UN–07JUN04
Specification
Top Shaft Castle Nut
High Capacity Drive—Torque....................................................... 353 N•m
(260 lb-ft)
H81094
2. Install cotter pin (A).
3. For standard capacity drive, install hex nut and lock A—Cotter Pin
nut. Tighten to specification. B—Castle Nut
C—Washer
Specification D—Clutch
Top Shaft Hex Nut and Lock Nut
Standard Capacity Drive—Torque ............................................... 353 N•m
(260 lb-ft)
OUO6083,000082B –19–07JUN04–1/2
4. Install chain over sprocket.
5. Adjust chain tension and tighten idler sprocket nut (A).
6. Install clutch cover and shields.
–UN–18JUN01
A—Nut
ZX25148
OUO6083,000082B –19–07JUN04–2/2
Remove and Install Top Shaft Slip Clutch

(9560 STS)
1. Remove feeder house side shields.

Continued on next page OUO6083,00007CE –19–19MAY04–1/8
110
10
8

083006
PN=964
2. Remove cap screws (A), washers and clutch cover (B).
A—Cap Screw
B—Cover
–UN–21APR99
H55561
OUO6083,00007CE –19–19MAY04–2/8
CAUTION: Spring (E) under cover (D) is under

tension. Remove cover carefully.
3. Loosen nut (A) to relieve conveyor drive chain tension.
4. Remove chain (B) from clutch sprocket.
–UN–21APR99
5. Remove nuts (C) and slowly remove cover (D).
6. Remove spring (E) and jaw (F).
H55562
A—Nut
B—Chain
C—Nuts (4 used)
D—Cover
E—Spring
F—Jaw
–UN–07MAY99
H56067
OUO6083,00007CE –19–19MAY04–3/8
7. Remove lock nut (A), flange nut (B), washer (C) and
spacer (D).
A—Lock Nut
B—Flange Nut
C—Washer
110
–UN–07MAY99
D—Spacer
10
9
H56064

083006
PN=965
8. Remove hub (D), washer (C), sprocket (A) and key (B)
from shaft.
9. Repair and/or replace as necessary.
A—Sprocket
–UN–07MAY99
B—Key
C—Washer
D—Hub
H56065
OUO6083,00007CE –19–19MAY04–5/8
NOTE: Install round head bolts through sprocket before

installing sprocket.
10. Install key (B), sprocket (A), washer (C) and hub (D)
on shaft.
–UN–07MAY99
A—Sprocket
B—Key
C—Washer
D—Hub
H56065
OUO6083,00007CE –19–19MAY04–6/8
11. Install spacer (D), washer (C), and flange nut (B).
Tighten flange nut to specification.
Specification
Slip Clutch Flange Nut—Torque .................................................. 353 N•m
(260 lb-ft)
–UN–07MAY99
12. Install lock nut (A). Tighten to specification.
Specification
Slip Clutch Lock Nut—Torque ...................................................... 350 N•m
(258 lb-ft) H56064
NOTE: If excessive clutch slippage has occurred, a

washer can be installed to increase spring tension A—Lock Nut
by 16 percent. B—Flange Nut
C—Washer
D—Spacer

110
10
10

083006
PN=966
13. Install jaw (F) and spring (E).
14. Apply T43512 Thread Lock and Sealer (medium

strength) to threads of bolts used to hold cover.
15. Install cover (D) and attach using nuts (C).
–UN–07MAY99
16. Install chain (B) and adjust tension using idler
sprocket. Tighten nut (A).
H56067
A—Nut
B—Chain
C—Nut (4 used)
D—Cover
E—Spring
F—Jaw
–UN–07MAY99
H56062
OUO6083,00007CE –19–19MAY04–8/8
Remove and Install Top Shaft Supports
CAUTION: Lower variable sheave is under

spring tension; if belt is removed, sheave will
snap back to a closed position.
–UN–16AUG05
1. Adjust variable drive to slow speed to close sheaves
(A).
H84227
3. Remove feeder house shields on both sides.
A—Sheaves
4. Remove belt (B). (See REPLACE VARIABLE SPEED B—Belt
FEEDER HOUSE BELT in Group 15.)
5. Remove feeder house from combine. (See REMOVE

AND INSTALL FEEDER HOUSE in Group 05.)
110
10
11

083006
PN=967
6. Loosen nuts (A) and cap screws (B) on left- and

right-hand side to relieve conveyor chain tension.
A—Nuts (4 used)
–UN–09MAY03
H76856
OUO6083,0000D92 –19–13JUL06–2/9
7. Loosen nut (A) to relieve conveyor drive chain tension.
A—Nut
–UN–21APR99
H55562
OUO6083,0000D92 –19–13JUL06–3/9
CAUTION: Weight of countershaft assembly can

vary depending on model, but is heavy. Use a
lifting device to avoid personal injury.
8. Remove nuts (A), bracket and nuts (B) to remove

countershaft assembly.
–UN–21APR99
A—Nuts (2 used)
B—Nuts (3 used)
H55633
110
10
12

083006
PN=968
CAUTION: The approximate weight of the

conveyor drive support is 270 kg (595 lb).
Specification
Conveyor Drive Support—Weight ................................................... 270 kg
(595 lb)
–UN–20MAR89
9. Remove ”S” hooks (A), or capnuts if equipped, and
chain links to separate chains.
H40433
10. Remove top shaft and slip clutch. (See procedures in
this group.)
11. Install lifting device to conveyor drive support (D) on

both sides.
12. Remove nuts and cap screws (B) to remove strippers

(C).
–UN–21MAY99
A—“S” Hooks
C—Stripper (2 used)
D—Support (2 used)
H57368
OUO6083,0000D92 –19–13JUL06–5/9
13. Remove cap screws and nuts (A) and nuts (B) from
support (C) on both sides.
14. Slowly remove support assembly and inspect. Repair

or replace as required.
–UN–20MAR89
components.
15. Install conveyor drive assembly.
H40436
16. Install conveyor top shaft and slip clutch. (See
procedure in this group.) A—Cap Screws and Nuts (6 used)
B—Nuts
17. Install cap screws and nuts (A) and nuts (B) to C—Drive Support
support (C) on both sides. Tighten cap screws and
nuts (A) to specification.
Specification
Top Shaft Support Nuts and
Bolts—Torque ............................................................................... 520 N•m 110
(383 lb-ft) 10
13

083006
PN=969
18. Install strippers (C) using cap screws (B) and nuts.
19. Remove lifting device from supports (D).
20. Attach conveyor chain ends using connecting links

and “S” hooks (A), or capnuts if equipped. On outside
–UN–21MAY99
chains, install connector links so “S” hooks, or
capnuts if equipped, are on inside of chain to prevent
from striking shoulder of drum ring. Tighten to
specification.
H57368
Specification
Conveyor Chain Connecting Link
Capnuts—Torque ........................................................................... 25 N•m
(18 lb-ft)
A—“S” Hooks
C—Stripper (2 used)
D—Support (2 used)
–UN–20MAR89
H40433
OUO6083,0000D92 –19–13JUL06–7/9
21. Install countershaft using nuts (B).
22. Install bracket with nuts (A).
A—Nuts (2 used)
B—Nuts (3 used)
–UN–21APR99
H55633
110
10
14

083006
PN=970
23. Adjust conveyor drive chain tension and tighten nut

(A).
24. Adjust conveyor chain tension. (See ADJUST

CONVEYOR CHAIN in Group 05.)
–UN–21APR99
25. Install feeder house to combine. (See REMOVE AND
INSTALL FEEDER HOUSE in Group 05.)
26. Install feeder house drive belt and adjust tension.
H55562
(See procedures in Group 15.)
27. Install feeder house side shields.
A—Nut
OUO6083,0000D92 –19–13JUL06–9/9
Disassemble and Assemble Top Shaft

F
1. Start engine and lower feeder house to the ground. A
Shut off engine and remove key. G J
E
A—Spacer B
B—Ball Bearing C G
C—Housing (2 used) J
E—Chain Sprocket
F—Shaft Key
J
G—Shaft
H—Bracket/Stripper C
I—Tube
J—Set Screw D E B
D
H
–UN–15JUN01
I
H68715

110
10
15

083006
PN=971
2. Remove feeder house top door (A) and access door

(B).
3. Remove shields on both sides of feeder house.
A—Top Door
–UN–14APR99
B—Access Door
H55437
OUO6083,0000D93 –19–13JUL06–2/19
4. Loosen cap screws (B) and nuts (A) on both sides to

relieve conveyor chain tension.
5. Rotate conveyor chain so connecting links are over top

shaft.
–UN–09MAY03
A—Nut (4 used)
H76856
OUO6083,0000D93 –19–13JUL06–3/19
6. Remove “S” hooks (A), or capnuts if equipped, and

connecting links on outside strands to separate chains.
7. Secure chain halves to feeder house to prevent

conveyor from sliding down.
–UN–20MAR89
8. Remove “S” hooks, or capnuts if equipped, from middle
strand.
9. Lay upper half of chain on top of feeder house and tie

off using a piece of rope. H40433
10. Tie lower half of chain to underside of feeder house.
A—“S” Hooks

110
10
16

083006
PN=972
11. Remove cap screws (A), washers and clutch cover

(B).
A—Cap Screw
B—Cover
–UN–21APR99
H55561
OUO6083,0000D93 –19–13JUL06–5/19
12. Loosen nut (A) to relieve conveyor drive chain

tension. Remove chain from clutch sprocket.
A—Nut
–UN–21APR99
H55562
OUO6083,0000D93 –19–13JUL06–6/19
13. Remove cotter pin (A), castle nut (B) and washer (C)
from high capacity drive slip clutch (shown).
14. Remove two nuts and washer from standard drive slip
clutch.
15. Remove clutch assembly (D) from feeder house.
–UN–10JAN02
16. Remove two outer top shaft strippers.
H70783
A—Cotter Pin
B—Castle Nut
C—Washer
D—Clutch

110
10
17

083006
PN=973
–UN–29APR99
H55867
A—Set Screws B—Sprockets C—Cap Screw
NOTE: Center sprocket does not need to be loosened 20. Pull left-hand bearing housing away from side of
if teeth are not worn or shaft is not replaced. feeder house. Move left-hand end of shaft down.
17. Loosen set screws (A) in all sprockets.

CAUTION: Lower safety stop.
18. Drive outside sprockets (B) inward away from the
21. Start engine, raise feeder house, and lower safety
bearings approximately 25 mm (1 in.).
stop (A). Set parking brake, shut off engine and
remove key.
19. Remove three cap screws (C) from left-hand
bearing housing.
22. Lower feed plate under feeder house.
NOTE: Right- and left-hand sides are determined by
23. Pull shaft out of right-hand bearing housing.
facing in the direction of forward travel.
OUO6083,0000D93 –19–13JUL06–8/19
NOTE: When reversing sprockets worn on one side only,

the right- and left-hand sprockets change places
and the inner sprocket is reversed.
24. Remove bearing housing (A) and sprocket (B) from

both ends from shaft (C). Keep sprockets in order.
–UN–23OCT97
25. Inspect shaft and sprockets for excessive wear.

H50599
A—Bearing Housing
B—Sprocket
C—Shaft
110
10
18

083006
PN=974
26. Tap down on one side of bearing (A) until bearing is

vertical in housing (C).
27. Rotate bearing to cut-out (B) in housing. Remove

bearing.
–UN–16JUN92
29. Install bearing (A) through cut-out (B).
H44700
A—Bearing
B—Cut-Out
C—Housing
OUO6083,0000D93 –19–13JUL06–10/19
IMPORTANT: Be sure teeth of all sprockets are

aligned.
30. Slide sprockets (B) and left-hand bearing housing (A)

onto shaft (C).
–UN–23OCT97
A—Bearing Housing
B—Sprocket
C—Shaft
H50599
110
10
19

083006
PN=975
31. Install right-hand end of shaft (F) into right-hand

bearing from under feeder house.
32. Position left-hand end of shaft and bearing housing

(A) through slot (C) in upper shaft support.
–UN–10OCT97
33. Raise safety stop and lower feeder house.
IMPORTANT: Be sure sprocket bores are aligned with

screw indents, both sides.
H50510
34. Install cap screws (B) in left-hand side bearing
housing.
A—Bearing Housing
B—Cap Screw
35. Tighten cap screws (B) to specification. C—Slot
D—Sprocket
Specification E—Screw
Top Shaft Bearing Cap Screw— F—Shaft
Torque .......................................................................................... 122 N•m G—Stripper
(90 lb-ft)
OUO6083,0000D93 –19–13JUL06–12/19
B B A
–UN–15SEP05
H84241
A—Dimension B—Dimension
36. Position center of right sprocket teeth (A) 56 mm 38. Tighten set screws to specification.
(2-1/4 in.) from right-hand bearing housing.
Specification
37. Position remaining sprockets (B) to following Top Shaft Sprocket Set
Screws—Torque ..................................................................... 50 N•m
dimensions: (37 lb-ft)
110
10 • 9560 STS — 468 mm (18 1/2 in.)
20 • 9660 STS, 9760 STS, and 9860 STS — 603
mm (23 3/4 in.)

083006
PN=976
39. Install clutch assembly (D), washer (C) and castle nut
(B) on high capacity drive (shown) or two nuts and
washer on standard clutch. Tighten nuts to
specification.
Specification
Top Shaft Castle Nut
–UN–10JAN02
High Capacity Drive—Torque....................................................... 353 N•m
(260 lb-ft)
Top Shaft Hex Nut and Lock Nut
Standard Capacity Drive—Torque ............................................... 353 N•m
H70783
(260 lb-ft)
40. Install cotter pin (A).

A—Cotter Pin
B—Castle Nut
C—Washer
D—Clutch
OUO6083,0000D93 –19–13JUL06–14/19
41. Install conveyor drive chain and adjust tension using

idler sprocket. Tighten nut (A).
A—Nut
–UN–18JUN01
ZX25148
OUO6083,0000D93 –19–13JUL06–15/19
42. Install top shaft strippers (A). Adjust each stripper

within 3 mm (1/8 in.) of shaft.
A—Strippers
–UN–18JUL01
H69329

110
10
21

083006
PN=977
43. Connect conveyor chains using “S” hooks (A), or

capnuts if equipped. Be certain “S” hooks, or capnuts
if equipped, are on inside of chain so they will not hit
strippers. Tighten to specification.
Specification
–UN–20MAR89
Conveyor Chain Connecting Link
Capnuts—Torque ........................................................................... 25 N•m
(18 lb-ft)
H40433
A—“S” Hooks
OUO6083,0000D93 –19–13JUL06–17/19
44. Adjust conveyor chains using nuts (A) and cap

screws (B). (See ADJUST FEEDER CONVEYOR
CHAIN in Group 05.)
A—Nut (4 used)
–UN–09MAY03
H76856
OUO6083,0000D93 –19–13JUL06–18/19
45. Install doors (A and B).
46. Install slip clutch cover and shields.
A—Top Door
B—Access Door
–UN–14APR99
H55437
OUO6083,0000D93 –19–13JUL06–19/19
110
10
22

083006
PN=978
Group 15
Feeder House Drives and Reverser Gear Case



OUO6046,0002029 –19–29AUG05–1/2
70 mm Socket . . . . . . . . . . . . . . . . . . . . . JDG10050
Used to remove feeder house drive nut.
OUO6046,0002029 –19–29AUG05–2/2
110
15
1

083006
PN=979
Other Material
Number Name Use
TY6252-5 gal (U.S.) 80W90 GL-5 Gear Lubricant Used in reverser gear case.
TY6385-1 gal (U.S.)

applications.
PM37509 (U.S.) Clean and Cure Primer Used to clean surfaces and speed
drying time of retaining compound.
PM37485 (U.S.) Retaining Compound Maximum Strength , Mounting of

Cylindrical Parts.
TY16135 (U.S.) RTV Silicone Adhesive Sealant Used to seal parts during assembly.
TY24811 (U.S.) NEVER-SEEZ Protects metal parts against seizure,

corrosion, pitting and galling.
TY9370 (U.S.) Thread Lock and Sealer Locks and seals while preventing
parts loosening due to vibration.
PM37477 (U.S.) Medium Strength Thread Lock Used to retain lock collar on bearing
242 LOCTITE (U.S.)
OUO6083,0000D8A –19–12JUL06–1/1
110
15
2

083006
PN=980
Specifications
Variable Drive Sheave Weight 43 kg

(95 lb)
Countershaft Piston Torque 200 N•m

(150 lb-ft)
Standard Variable Drive Sheave Gap 25 mm

(31/32 in.)
Heavy Duty Variable Drive Sheave Gap 31 mm

(1-7/32 in.)
High Torque Variable Drive Sheave Gap 37 mm

(1-29/64 in.)
Countershaft Strap Bolt Torque 185 N•m

(135 lb-ft)
Countershaft Strap Round Head Torque 54 N•m

Bolts (40 lb-ft)
Countershaft Hub-to-Housing Cap Torque 35 N•m

Screws (26 lb-ft)
Variable Sheave Set Screw Torque 11 N•m

(97 lb-in.)
Cam-Spacer Cap Screws Torque 73 N•m

(55 lb-ft)
Spring Retainer Cap Screws Torque 73 N•m

(55 lb-ft)
Drive Sheave Nut Torque 320 N•m

(236 lb-ft)
Outer Sheave-to-Inner Cam Cap Torque 37 N•m

Screws (27 lb-ft)
Socket Head Cap Screws Torque 130 N•m

(96 lb-ft)
Lock Plate Cap Screws Torque 37 N•m

(27 lb-ft)
110
15
3
Continued on next page OUO6083,0000DBD –19–14AUG06–1/2

083006
PN=981
Variable Sheave Nut Torque 328 N•m

(242 lb-ft)
Reverser Gear Case Mounting Cap Torque 170 N•m

Screws (125 lb-ft)
Extra Heavy Duty Reverser Gear Capacity 4.9 L

Case (5.2 qt)
Heavy Duty Reverser Gear Case Capacity 3.5 L

(3.7 qt)
Standard Reverser Gear Case Capacity 2.3 L

(2.4 qt)
Reverser Piston Seal Cap Screw Torque 30 N•m

(22 lb-ft)
Reverser Gear Case Planetary Cap Torque 73 N•m

Screws (54 lb-ft)
Quill Cap Screws Torque 50 N•m

(37 lb-ft)
Reverser Gear Case Oil Pump Cap Torque 28 N•m

Screws (20 lb-ft)
Fitting Cap Screw Torque 48 N•m

(35 lb-ft)
Reverser Piston Seal Cap Screw Torque 30 N•m

(22 lb-ft)
Idler Pulley-to-Arm Cap Screw Torque 125 N•m

(92 lb-ft)
Conveyor Drive Chain Idler Bolt Torque 130 N•m

(97 lb-ft)
OUO6083,0000DBD –19–14AUG06–2/2
110
15
4

083006
PN=982
110
15
5

083006
PN=983
Remove and Install Variable Drive Countershaft
1
25
2
4 7
3
5
6
11
11
10
15
9 12
13
14
16
17
20
23
22
21
24 18
19
–UN–05JUN03
110
15
6
H77637
Continued on next page OUO6083,0000DBF –19–14AUG06–1/19

083006
PN=984
1—Support 8—Seal 14—Boot 20—Seal

2—O-Ring 9—Sheave 15—Tie Band 21—Piston
3—Cap Screw (6 used) 10—Bearing 16—Washer 22—Seal
4—Bearing 11—Lubrication Fitting (2 17—Strap 23—Barrel
5—Hub used) 18—Cap Screw 24—Cylinder
6—Sheave 12—Washer (as required) 19—Round Head Bolt and 25—Cap Screw and Nut (3
7—Belt 13—Washer (as required) Flange Nut (3 used) used)
OUO6083,0000DBF –19–14AUG06–2/19
2. Run feeder house to close lower variable sheave.
3. Set parking brake. Shut off engine and remove key.
–UN–17MAR06
A—Safety Stop
H85538
OUO6083,0000DBF –19–14AUG06–3/19
4. Loosen cap screw and nut (A). Slide belt idler sheave
(B) down to release tension on drive belt.
A—Cap Screw and Nut

B—Sheave
–UN–23MAR06
H85607
OUO6083,0000DBF –19–14AUG06–4/19
NOTE: Cap all openings to prevent system contamination

and fluid loss.
5. Disconnect hydraulic hose (A) from multi-coupler.
A—Hydraulic Hose 110

–UN–26AUG05
15
7
H84326

083006
PN=985
6. Loosen nuts (A) and remove drive belt (B).
A—Nut (2 used)
B—Belt
–UN–14AUG06
H86456
OUO6083,0000DBF –19–14AUG06–6/19
7. Remove nuts (A) and bracket (B).
8. Loosen nuts (C) and move upper sheave assembly

forward.
A—Nuts (2 used)
–UN–27JUL05
B—Bracket
C—Nuts (3 used)
H84136
OUO6083,0000DBF –19–14AUG06–7/19
9. Remove cap screw (A).
10. Loosen nut (B) and remove nut and cap screw (C).
11. Remove three round head bolts (D).
–UN–06JUN03
A—Cap Screw
B—Lock Nut
C—Cap Screw
D—Round Head Bolt (3 used)
H77676
OUO6083,0000DBF –19–14AUG06–8/19
12. Remove variable drive belt (A).
13. Cut wire tie (B) and remove boot and washers from
sheave to access piston.
110 A—Variable Drive Belt

–UN–14AUG06
15 B—Wire Tie
8
H86460

083006
PN=986
CAUTION: Approximate weight of sheaves is 43

kg (95 lb).
Specification
Variable Drive Sheave—Weight ........................................................ 43 kg
(95 lb)
–UN–20MAR89
14. Remove piston (A) by turning counterclockwise.
15. Remove sheaves from countershaft.
H40395
A—Piston
B—Barrel
OUO6083,0000DBF –19–14AUG06–10/19
16. Inspect countershaft (A) for wear or damage. Replace

O-ring (D) and countershaft if necessary.
17. If countershaft needs replaced, remove three nuts (C)

and countershaft.
18. Install countershaft (A) using nuts (C).
19. Install O-ring (D) to countershaft. Apply TY6341
–UN–21APR00
Multi-Purpose SD Polyurea Grease to O-ring.
20. Inspect inner sheave hub for any defects. Remove

defects with emery paper if necessary. Apply
H63688
TY24811 NEVER-SEEZ to the sheave hub prior to
assembly.
A—Countershaft
B—Slot (3 used)
C—Nut (3 used)
D—O-Ring
–UN–21APR00
H63689
110
15
9

083006
PN=987
21. Coat outer sheave lugs (A) with TY6341

Multi-Purpose SD Polyurea Grease.
22. Fill lug cavities (B) on the inner sheave between each
set of two lugs (C) with TY6341 Multi-Purpose SD
Polyurea Grease.
–UN–22SEP05
CAUTION: Approximate weight of sheaves is 43
kg (95 lb).
H84551
Specification
Variable Drive Sheave—Weight ........................................................ 43 kg
(95 lb)
NOTE: Apply TY24811 NEVER-SEEZ lubricant to thread

and tapered portion of piston.
23. Install upper variable drive sheave.
–UN–22SEP05
A—Lug (2 used)
B—Cavity (2 used)
C—Lug (4 used)
H84552
OUO6083,0000DBF –19–14AUG06–12/19
24. Install piston (A) by turning clockwise. Tighten to

specification.
Specification
Countershaft Piston—Torque ....................................................... 200 N•m
(150 lb-ft)
–UN–20MAR89
A—Piston
B—Barrel
H40395
110
15
10

083006
PN=988
C B
–UN–13SEP05
H84433
E D
A—Lubrication Fitting (2 used) C—Sheave Gap D—Large Shims (As Required) E—Small Shims (As Required)
B—Seal
25. Pump 20 pumps each of TY6341 Multi-Purpose 28. For high torque variable drive, open sheaves until
SD Polyurea Grease at lubrication fittings (A). there is a 37 mm (1-29/64 in.) gap between
sheave halves at (C).
26. For standard variable drive, open sheaves until
there is a 25 mm (31/32 in.) gap between sheave Specification
High Torque Variable Drive
halves at (C).
Sheave—Gap ........................................................................... 37 mm
(1-29/64 in.)
Specification
Standard Variable Drive
Sheave—Gap ........................................................................... 25 mm NOTE: Adding large shims (D) will decrease sheave
(31/32 in.) gap. Adding small shims (E) will increase
sheave gap.
27. For heavy duty drive, open sheaves until there is a
31 mm (1-7/32 in.) gap between sheave halves at 29. Install shims (D) or (E) as required.
(C).
Specification
Heavy Duty Variable Drive
Sheave—Gap ........................................................................... 31 mm
(1-7/32 in.)
110
15
11

083006
PN=989
30. Install flat washer against shims and install rubber

boot over washer.
31. Use wire tie (D) to attach boot to sheave assembly.
32. Install drive belt (C).
–UN–21APR00
33. Install variable drive belt (A).
A—Variable Drive Belt
H63687
B—Lock Nut (2 used)
C—Feeder House Drive Belt
D—Wire Tie
E—Variable Drive Sheave
OUO6083,0000DBF –19–14AUG06–15/19
34. Install strap and rod using round head bolts (D).
Leave round head bolts loose at this time.
35. Install cap screw (A) and tighten to specification.
Specification
Countershaft Strap Bolt—Torque ................................................. 185 N•m
–UN–06JUN03
(135 lb-ft)
36. Attach rod to bracket with nut and cap screw (C).
H77676
A—Cap Screw
B—Lock Nut
C—Cap Screw
OUO6083,0000DBF –19–14AUG06–16/19
37. Install hydraulic hose (A) with new O-ring.
A—Hydraulic Hose
110
–UN–26AUG05
15
12
H84326

083006
PN=990
–UN–13SEP05
H84440
Top View
NOTE: Check alignment of upper countershaft sheaves

(C). Make sure sheaves are running parallel to
feeder house sidesheet. Parallel alignment of
countershaft sheaves may be adjusted by
loosening three round head bolts (F) and using
nuts (A) on bolt (E).
–UN–13SEP05
38. Using nuts (A), turn bolt (E) to move outer strap (B)
forward or rearward to align sheaves (C) parallel to
feeder house sidesheet (D).
H84444
39. Tighten round head bolts (F) to specification.
Specification A—Nut (2 used)

Countershaft Strap Round Head B—Outer Strap
Bolts—Torque ................................................................................ 54 N•m C—Sheave (2 used)
(40 lb-ft) D—Sidesheet
E—Cap Screw
F—Round Head Bolts (3 used)
40. Check sheave gap of variable speed reverser gear
case and adjust if necessary. (See ADJUST
VARIABLE SPEED FEEDER HOUSE BELT in this
group.)
OUO6083,0000DBF –19–14AUG06–18/19
NOTE: Strap removed for clarity.
41. Adjust tension on feeder house drive belt (A) by

tightening nuts (B) until washer aligns with gauge.
A—Feeder House Drive Belt 110

–UN–21APR00
B—Nut (2 used) 15
13
H63695
OUO6083,0000DBF –19–14AUG06–19/19

083006
PN=991
Disassemble and Assemble Upper Variable

Drive Countershaft
1. Remove upper variable drive sheave assembly. (See

DISASSEMBLE AND ASSEMBLE UPPER VARIABLE
DRIVE COUNTERSHAFT in this group.)
OUO6083,0000A79 –19–13JUL05–1/14
2. Remove hydraulic hose (A) from barrel.
3. Remove O-ring from hydraulic hose fitting.
4. Remove outer seal and back-up ring (B) from barrel.
–UN–28APR00
5. Remove barrel from sheave assembly.
6. Turn barrel over and remove inner seal and back-up

ring (C).
H63752
A—Hydraulic Hose
B—Outer Seal and Back-Up Ring
C—Inner Seal and Back-Up Ring
–UN–28APR00
H63753

110
15
14

083006
PN=992
7. Remove cap screws and hub (A).
A—Hub
–UN–24JUN99
H58487
OUO6083,0000A79 –19–13JUL05–3/14
8. Press bearing out of hub.
–UN–20MAR89
H40398
OUO6083,0000A79 –19–13JUL05–4/14
9. Press bearing out of sheave.
–UN–20MAR89
H40399
Standard Capacity Sheave Shown

110
15
15

083006
PN=993
10. Turn sheave over and remove seal (A).
11. Clean and inspect all parts. Replace as necessary.
12. Inspect orifice screen in fitting for dirt. Clean as

necessary.
–UN–01AUG00
A—Seal
H64561
OUO6083,0000A79 –19–13JUL05–6/14
NOTE: Feeder house height sensor linkage and bracket

not shown.
13. Inspect countershaft (A) for wear or damage. Replace

assembly if necessary.
–UN–21FEB00
14. Install new O-ring (B) to countershaft. Apply TY6341
Multi-Purpose SD Polyurea Grease to O-ring (B).
A—Countershaft
H62762
B—O-Ring
OUO6083,0000A79 –19–13JUL05–7/14
IMPORTANT: Install new seal with opening towards

inside.
15. Install new seal (A) in sheave.
A—Seal
–UN–01AUG00
H64561

110
15
16

083006
PN=994
16. Press bearing (A) in hub (B) until bearing bottoms.
A—Bearing
B—Hub
–UN–24JUN99
H58489
OUO6083,0000A79 –19–13JUL05–9/14
17. Press bearing (A) in sheave assembly (B) until

bearing bottoms.
A—Bearing
B—Sheave
–UN–20MAR89
H40402
OUO6083,0000A79 –19–13JUL05–10/14
18. Apply TY16135 RTV silicone sealant to mating

surface of hub (A).
19. Install hub. Tighten cap screws to specification.
Specification
Countershaft Hub-to-Housing Cap
–UN–24JUN99
Screws—Torque ............................................................................. 35 N•m
(26 lb-ft)
20. Apply TY6341 Multi-Purpose SD Polyurea Grease to
H58487
hub and barrel surfaces.
21. Install sheaves.

A—Hub

110
15
17

083006
PN=995
NOTE: Procedure for installing inner and outer seals are

similar.
22. Install back-up ring (A) first, followed by seal (B) with
O-ring (C) toward pressure using the following
instructions:
IMPORTANT: Use a blunt tool to install back-up ring

and seal making sure no damage
occurs to back-up ring, seal or seal
groove. B B A
A
• Shape back-up ring (A) into kidney shape and
–UN–30NOV04
install into seal groove first
A—Back-Up Ring
B—Seal C
H81959
C—O-Ring C
–UN–06JUL05
H83903
–UN–12JUL05
H83953

110
15
18

083006
PN=996
• Use a blunt tool to work back-up ring (A) into inner

seal groove
• Shape seal (B) into kidney shape and install under
back-up ring (A)
• Using a blunt tool (C), work seal (B) into inner
groove from bottom making sure that O-ring is
toward pressure
–UN–12JUL05
A—Back-Up Ring
B—Seal
H83954
C—Blunt Tool
–UN–13JUL05
H83955
–UN–13JUL05
H83956
110
15
19

083006
PN=997
• Shape back-up ring (A) into kidney shape and

install into outer seal groove first
• Shape seal (B) into kidney shape and install under
back-up ring (A)
• Fold seal (B) down
• Using a blunt tool (C), work seal (B) into outer
groove from bottom making sure that O-ring is
–UN–13JUL05
toward pressure
23. Install new O-ring on hydraulic hose fitting.
H83958
24. Install hydraulic hose to barrel.
25. Install piston.
26. Install upper variable drive sheave assembly. (See

REMOVE AND INSTALL VARIABLE DRIVE
COUNTERSHAFT in this group.)
A—Back-Up Ring
–UN–06JUL05
B—Seal
C—Blunt Tool
H83904
–UN–12JUL05
H83925
–UN–06JUL05
110
H83905
15
20
OUO6083,0000A79 –19–13JUL05–14/14

083006
PN=998
Disassemble and Assemble Standard Capacity Fixed Speed Countershaft
–UN–29APR99
H55788
A—Screw D—Bearing G—Bearing J—Strap

B—Screw E—Snap Ring (2 used) H—Lock Collar K—Scraper
C—Shaft F—Sheave I—Screw L—Belt
110
15
21
AG,OUO6030,178 –19–25JUL00–1/1

083006
PN=999
Backshaft Speed Sensor
–UN–08MAY02
H72138
A—Connector E—Wiring Harness I—Wheel L—Sensor

B—Flange Nut F—Clip (3 used) J—Bracket M—Connector
C—Clip (3 used) G—Bolt (2 used) K—Clip N—Screw (2 used)
110 D—Hose H—Nut (2 used)
15
22
OUO6083,00002A6 –19–20MAY02–1/1

083006
PN=1000
Remove, Repair and Install Variable Drive Sheaves and Cams—Style A
D
F
B
G
H
C
I
J
K L
N
O
P
Q
R
S
T
–UN–24MAY02
V
H72148
A—Sheave F—Belt M—Cam S—Spacer
B—Set Screw (2 used, G—Lubrication Fitting (2 used) N—Gasket T—Cap Screw and Lock
Standard only) H—Sheave O—Seal Washer (6 used)
C—Ball (standard only) I—Snap Ring P—Compression Spring U—Retainer
D—Pin (1 on Standard Duty, 2 J—Retainer Q—Plug V—Screw (3 used)
on Heavy Duty) K—Seal R—Cam
E—Snap Ring L—Shaft Key (2 used on
Heavy Duty)
Continued on next page OUO6083,0000DBC –19–11AUG06–1/9

110
15
23

083006
PN=1001
1. Run feeder house to slow speed.
3. Remove left-hand feeder house shields.
–UN–14MAY02
4. Loosen idler and remove belt.
CAUTION: Spring is compressed. Remove cap

screws slowly.
H72176
5. Remove cap screws (A), retainer (B) and spring (C).
B—Retainer
C—Spring
OUO6083,0000DBC –19–11AUG06–2/9
7. Remove spacer (B), cam (C) and sheave (D).

B—Spacer
–UN–14MAY02
C—Cam
D—Sheave
H72180
OUO6083,0000DBC –19–11AUG06–3/9
8. Remove two set screws (B) and ball on standard

reverser.
9. Remove spring pins (A).
• 1 pin used on Standard Duty

• 2 pins used on Heavy Duty
–UN–29JUL04
NOTE: Inner sheave is installed using maximum strength

retaining compound. It may be necessary to heat
H81423
sheave hub to allow separation from input shaft.
10. Remove sheave (D).

110 A—Spring Pin
15 B—Set Screw (2 used)
24 C—Sheave

083006
PN=1002
11. Remove keys (A) from shaft.
12. Inspect all parts for burrs or irregularities, and repair

13. Apply PM37509 Clean and Cure Primer, and then
–UN–04MAY99
PM37485 Retaining Compound (Maximum Strength)
to front portion of input shaft and keyways.
14. Install keys (A).
H55912
A—Keys
OUO6083,0000DBC –19–11AUG06–5/9
NOTE: Inspect inner sheave hub for burrs or

irregularities. Remove burrs with emery cloth.
15. Apply PM37509 Cure Primer to shaft and sheave

bore. Apply 5 mm (3/16 in.) wide bead of PM37485
Retaining Compound (Maximum Strength) (A) 360
degrees around the shaft at dimension (B) from face
–UN–29JUL04
of reverser (C). Also apply a bead to inside bore of
sheave at dimension (B) from sheave face (D).
H81424
A—Retaining Compound
B—20 mm (3/4 in.)
C—Face of Reverser
D—Sheave Face
–UN–11AUG06
H86453

110
15
25

083006
PN=1003
16. Install sheave (C).
17. Install spring pin (A).
18. Standard Duty Only: Install ball and one set screw
(B). Tighten set screw until ball bottoms in groove.
Apply Thread Lock and Sealer (medium strength) to
–UN–29JUL04
second set screw and install. Tighten set screw to
specification.
H81423
Specification
Variable Sheave Set Screw—
Torque ........................................................................................... 11 N•m
(97 lb-in.)
A—Spring Pin
B—Set Screw (2 used)
IMPORTANT: If a new seal is installed in outer C—Sheave
sheave, install flush with large lip facing
in.
19. Apply thin coat of TY6341 Multi-Purpose SD Polyurea

Grease to ID of outer sheave. Install sheave.
20. Apply a thin coat of PM37509 Clean and Cure Primer

and PM37485 Retaining Compound (Maximum
Strength) to ID of cam half of seal and to keyway of
cam.
OUO6083,0000DBC –19–11AUG06–7/9
21. Apply NEVER-SEEZ to OD of inner sheave hub and

ID of cam (A).
22. Install cam (A) and spacer (B).
23. Install cap screws (C). Tighten to specification.

–UN–14MAY02
Specification
Cam-Spacer Cap Screws—
Torque ............................................................................................ 73 N•m
(55 lb-ft)
H72174

110 B—Spacer
15 C—Cam
26 D—Sheave

083006
PN=1004
24. Install spring (C), retainer (B) and cap screws (A).
Specification
Spring Retainer Cap Screws—
Torque ............................................................................................ 73 N•m
(55 lb-ft)
–UN–14MAY02
25. With variable sheaves open, pump a total of 15 cc
(0.5 oz) TY6341 Multi-Purpose SD Polyurea Grease
into each lubrication fittings in outer sheave.
H72176
26. Adjust belt tension. (See procedure in this group.)
B—Retainer
C—Spring
OUO6083,0000DBC –19–11AUG06–9/9
110
15
27

083006
PN=1005
Repair Variable Drive Sheaves and Cams—Style B
–UN–11JUL05
H83859
A—Sheave G—Cam M—Spring Q—Plate
B—Washer H—Belt N—Plate R—Lock Plate
C—Retaining Ring I—Sheave O—Socket Head Cap Screw (3 S—Socket Head Cap Screw (3
D—Seal J—Retaining Ring used) used)
E—Cap Screw (8 used) K—Seal P—Nut T—Cap Screw (2 used)
F—O-Ring L—Cam
Continued on next page OUO6083,0000A80 –19–26AUG05–1/15

110
15
28

083006
PN=1006
–UN–28JUN05
4. Remove cap screws (A) and lock plate (B).

B—Lock Plate
H83848
OUO6083,0000A80 –19–26AUG05–2/15
CAUTION: Spring is compressed. Remove cap

screws slowly and evenly. If spring retainer
plate (B) backs off more than distance (D) then
inspect rivets (C) for damage. If damage has
occurred, torque sensing unit must be placed in
a press to disassemble.
–UN–08JUL05
NOTE: Scribe a line on retainer plate and sheaves to
help aid in reassembly. Parts are timed and only
go together one way.
H83760
5. Loosen socket head cap screws (A) evenly until
tension is relieved from socket head cap screws. If
tension is not relieved before distance (D) occurs,
torque sensing unit must be removed and
disassembled in a press. (See REMOVE AND
INSTALL VARIABLE DRIVE SHEAVE ASSEMBLY in
this group for removal procedure.)
–UN–28JUN05
6. Remove socket head cap screws (A) and plate (B).

B—Plate
H83849
C—Rivet (3 used)
D—Distance (7.6 cm) (3 in.)

110
15
29

083006
PN=1007
7. Remove socket head cap screws (A) evenly, retainer

(B), spring (C), and sheave (D).

B—Retainer
C—Spring
D—Sheave
–UN–28JUN05
H83852
–UN–28JUN05
H83850
OUO6083,0000A80 –19–26AUG05–4/15
8. Remove cap screws (A) and inner cam (B).
9. Turn sheave over and remove outer cam (C).

B—Inner Cam
–UN–05JUL05
C—Outer Cam
H83895
–UN–05JUL05
110
15
30
H83896

083006
PN=1008
10. Remove retaining ring (A) and seal (B) from outer
sheave. A B
A—Retaining Ring
B—Seal
–UN–05JUL05
H83866
OUO6083,0000A80 –19–26AUG05–6/15
11. Remove O-ring (A), retaining ring (C) and seal (B).
A—O-Ring A
B—Seal
C—Retaining Ring
B
C
–UN–05JUL05
H83867
110
15
31

083006
PN=1009
12. Remove nut (A) using JDG10050 70 mm socket.

Remove inner sheave (B).
13. Inspect all parts for burrs or irregularities and repair or

14. Apply anti-seize compound to face (D) and 6 mm (1/4
–UN–08JUL05
in.) of I.D. and O.D. (C) of nut (A).
NOTE: Use an old yoke and a pry bar on right-hand side
H83897
of feeder house to hold shaft while tightening
drive nut.
15. Install inner sheave and nut (A). Tighten nut to

specification using JDG10050 70 mm socket.
Specification
Drive Sheave Nut—Torque .......................................................... 320 N•m
(236 lb-ft)
–UN–26AUG05
A—Nut
B—Inner Sheave
C—I.D. and O.D. of Nut
D—Face of Nut
H84327
OUO6083,0000A80 –19–26AUG05–8/15
16. Apply a small amount of lubrication to O-ring (A) and

install.
A
17. Install seal (B) and retaining ring (C).
B
A—O-Ring C
–UN–05JUL05
B—Seal
C—Retaining Ring
H83867

110
15
32

083006
PN=1010
18. Apply anti-seize lubricant to lobes of inner cam. Install

inner cam (B) and cap screws (A). Tighten cap
Specification
Outer Sheave-to-Inner Cam Cap
Screws—Torque ............................................................................. 37 N•m
–UN–05JUL05
(27 lb-ft)
19. Install outer cam (C).
H83895
B—Inner Cam
C—Outer Cam
–UN–05JUL05
H83896
OUO6083,0000A80 –19–26AUG05–10/15
IMPORTANT: Outer cam (D) must be installed in outer

sheave (C) before installing seal. C
A B
20. Install seal (B) and retaining ring (A).
A—Retaining Ring
B—Seal
C—Outer Sheave
D—Outer Cam D
–UN–05JUL05
110
15
33
H83898

083006
PN=1011
NOTE: Position lubrication fittings on outer sheave 180°

from vent (E).
21. Install sheave (D), spring (C), retainer (B), and socket
head cap screws (A). Tighten socket head cap
screws evenly to specification.
–UN–28JUN05
Specification
Torque .......................................................................................... 130 N•m
(96 lb-ft)
H83852
B—Retainer
C—Spring
D—Sheave
E—Vent
–UN–28JUN05
H83850
–UN–08JUL05
H83927
110
15
34

083006
PN=1012
22. Install plate (B) and socket head cap screws (A).
Tighten socket head cap screws evenly to
specification.
Specification
Torque .......................................................................................... 130 N•m
–UN–08JUL05
(96 lb-ft)

B—Plate
H83760
OUO6083,0000A80 –19–26AUG05–13/15
23. Install lock plate (B) and cap screw (A). Rotate lock
plate clockwise and tighten cap screws to
specification.
Specification
Lock Plate Cap Screws—Torque ................................................... 37 N•m
(27 lb-ft)
–UN–28JUN05
24. Install belt and adjust.
H83848
B—Lock Plate
OUO6083,0000A80 –19–26AUG05–14/15
25. Pump a total of 100 cc (3.4 oz) of TY6341

Multi-Purpose SD Polyurea Grease in lubrication
fitting (A), and 10 cc (0.4 oz) in lubrication fitting (B) .
A—Lubrication Fitting
B—Lubrication Fitting 110
–UN–08JUL05
15
35
H83928
OUO6083,0000A80 –19–26AUG05–15/15

083006
PN=1013
Remove and Install Variable Drive Sheaves

and Cams—Style B
–UN–28JUN05
4. Remove feeder house belt. (See REPLACE VARIABLE
H83848
SPEED FEEDER HOUSE BELT in this group.)
5. Remove cap screws (A) and lock plate (B).

B—Lock Plate
OUO6083,0000AE3 –19–29AUG05–1/3
6. Remove nut (A) using JDG10050 70 mm socket.
7. Repair or replace as needed. (See procedure in this

group.)
8. Apply anti-seize compound to face (B) and 6 mm (1/4

in.) of I.D. and O.D. (C) of nut (A).
–UN–26JUL05
NOTE: Use an old yoke and a pry bar on right-hand side
of feeder house to hold shaft while tightening
H83863
drive nut.
9. Install feeder house drive assembly on shaft and

tighten nut to specification using JDG10050 70 mm
socket.
Specification
Variable Sheave Nut—Torque ..................................................... 328 N•m
(242 lb-ft)
–UN–29AUG05
A—Nut
B—Face of Nut
C—I.D. and O.D. of Nut
H84329

110
15
36

083006
PN=1014
10. Install lock plate (B) and cap screws (A). Rotate lock
plate clockwise against nut before tightening cap
screws. Tighten cap screws to specification.
Specification
Lock Plate Cap Screws—Torque ................................................... 37 N•m
(27 lb-ft)
–UN–28JUN05
B—Lock Plate
H83848
OUO6083,0000AE3 –19–29AUG05–3/3
Remove and Install Fixed Drive Sheave
Style (A) Drive Sheave
1. Remove belt (A).
–UN–29AUG05
2. Remove cap screw (B) and nut.
3. Remove sheave (C).
H84332
4. Install in reverse order of removal using the following
special instruction:
Tighten cap screw to specification. A—Belt

B—Cap Screw
Specification C—Sheave
Fixed Drive Sheave Cap Screw—
Torque ............................................................................................ 70 N•m
(52 lb-ft)
110
15
37

083006
PN=1015
Style (B) Drive Sheave
1. Remove belt (A).
2. Remove cap screws (B) and retainer (C).
–UN–29AUG05
3. Remove nut (D) using JDG10050 70 mm socket.
4. Remove sheave (E).
H84328
5. Install sheave in reverse order of removal using the
• Apply anti-seize compound to face (F) and 6 mm

(1/4 in.) of I.D. and O.D. (G) of nut (D).
• Tighten nut to specification using JDG10050 70 mm
socket.
Specification
Fixed Drive Sheave Nut—Torque ................................................ 328 N•m
–UN–29AUG05
(242 lb-ft)
A—Belt
H84333
C—Retainer
D—Nut
E—Sheave
F—Face of Nut
G—I.D. and O.D. of Nut
OUO6046,0002027 –19–29AUG05–2/2
Remove and Install Reverser Gear Case
1. Remove feeder house side shields on both sides.
2. Raise feeder house and lower safety stop.
3. Drain oil from reverser gear case.
4. Relieve belt tension and remove belt from sheave.

110
15
38

083006
PN=1016
5. Disconnect oil line (A) from feeder house reverser gear

case.
A—Oil Line
–UN–20JUN01
ZX25182
110
15
39

083006
PN=1017
NOTE: If servicing internal parts of gear case, it may be

easier to remove drive sheave(s) while reverser
gear case is mounted on feeder house.
6. Remove cap screws (A), washers and bushings.
–UN–20JUN01
7. Remove gear case from feeder house.
8. Install feeder house reverser in reverse order using the

ZX25183
• Tighten mounting cap screws to specification.
Specification A—Cap Screw (3 used)

Reverser Gear Case Mounting
(125 lb-ft)
IMPORTANT: Feeder house must be in raised

position to check oil level in gear case.
Gear cases with oil coolers must be run
two minutes after filling to fill cooler
lines. Check oil again after running.
9. Install plug using new O-ring. Fill gear case to mark on

dipstick with 80W90 GL-5 Gear Lubricant.
Specification
Extra Heavy Duty Reverser Gear
Case—Capacity .................................................................................. 4.9 L
(5.2 qt)
Heavy Duty Reverser Gear
Case—Capacity .................................................................................. 3.5 L
(3.7 qt)
Standard Reverser Gear Case—
Capacity .............................................................................................. 2.3 L
(2.4 qt)
OUO6083,0000622 –19–11JUL05–3/3
110
15
40

083006
PN=1018
110
15
41

083006
PN=1019
Feeder House Reverser Gear Case—Exploded View
3 17 18
11
19
4
5
1 9 12 13
2 10
14
6
7
15
27
28
16
20 23
21 24
22
25
30
31 26
33
34
29 35
32
37
59
38
40 36 39
41
42
43
48
44 45 58
60
53 46 47
110
–UN–26AUG05
51
15 56
42
57
54 49
H84324
50
55 52

083006
PN=1020
1—Cap Screw (3 used) 17—Cap Screw (4 used) 33—Thrust Washer (6 used) 49—Key (2 used) (Style A
2—Lock Washer (3 used) 18—Cover 34—Needle Roller (174 used) only)
3—Retaining Cap 19—O-Ring 35—Washer (3 used) 50—Sheave (Style A only)
4—Spring 20—Plug 36—Cover 51—Cap Screw (Style A only)
5—Cap Screw 21—O-Ring (2 used) 37—Pin (3 used) 52—Nut (Style A only)
6—Lock Washer 22—Plug 38—Spacer (3 used) 53—Sheave (Style B only)
7—Piston 23—Snap Ring 39—Ball (3 used) 54—Washer (Style B only)
8—Cap Screw (6 used) 24—Bearing 40—Bearing 55—Nut Style B only)
9—O-Ring (2 used) 25—Snap Ring 41—Input Gear (Style A only) 56—Retainer (Style B only)
10—Fitting 26—Shaft 42—Bearing 57—Cap Screw (2 used) (Style
11—Dip Stick 27—Washer 43—Seal B only)
12—Tube 28—Shift Fork 44—Bearing 58—Sheave Assembly (Style
13—Plug 29—Gear 45—Snap Ring A)
14—O-Ring 30—Shift Collar 46—Quill 59—Input Gear (Style B only)
15—Seal 31—Gear 47—Cap Screw (6 used) 60—Sheave Assembly (Style
16—Cap Screw 32—Gear (3 used) 48—Seal B)
OUO6046,0002047 –19–31AUG05–2/2
Disassemble and Assemble Feeder House

Reverser Gear Case
1. Remove sheave.
2. Remove plug on bottom of gear case and drain oil.
CAUTION: Approximate weight of reverser gear

case is 68 kg (150 lb). Use a suitable lifting
device to remove gear case.
–UN–24APR01
3. Remove gear case from feeder house using a suitable
lifting device. (See REMOVE REVERSER GEAR
CASE in this group.)
H67588
4. Remove cap screws (A) and quill (B).

B—Quill
Continued on next page OUO6083,0000623 –19–07JAN04–1/22

110
15
43

083006
PN=1021
5. Remove spacers (A).
A—Spacer (3 used)
–UN–24APR01
H67589
OUO6083,0000623 –19–07JAN04–2/22
6. Remove six cap screws (A) and separate planetary

assembly from housing.
–UN–24APR01
H67590
110
15
44

083006
PN=1022
7. Remove snap ring (A) and press shaft (B) out of

bearing.
8. Remove bearing from housing using a punch.
9. Remove snap ring (C) from bearing.
A—Snap Ring
B—Shaft
C—Snap Ring
–UN–25APR01
H67687
–UN–25APR01
H67688
–UN–25APR01
H67689

110
15
45

083006
PN=1023
10. Turn pinions (B) so numbers point straight out.

Pinions are numbered one, two and three in a
counterclockwise direction. Place a mark (A) on
housing at each pinion for alignment during assembly.
11. Remove gear (C).
A—Mark (3 used)
B—Pinion (3 used)
C—Gear
–UN–24APR01
H67593
OUO6083,0000623 –19–07JAN04–5/22
IMPORTANT: Needle rollers will fall out when pin is

removed from planetary gear. Be certain
that carrier is placed on a clean surface
to help prevent loss of needle rollers.
12. Drive pin out far enough to remove ball (A).
A—Ball
–UN–25APR01
H67664
–UN–25APR01
H67666
110
15
46

083006
PN=1024
13. Remove pin (D) and pinion gear assembly from

carrier.
14. Remove thrust washers (B), needle rollers (A) and

washer (C). Inspect parts and replace as necessary.
A—Needle Roller (174 used)
–UN–25APR01
B—Thrust Washer (6 used)
C—Washer (3 used)
D—Pin (3 used)
H67665
OUO6083,0000623 –19–07JAN04–7/22
15. Remove ring gear (A).
A—Ring Gear
–UN–24APR01
H67592
110
15
47

083006
PN=1025
16. Remove cap screws (A) evenly and incrementally to

relieve spring pressure.
17. Remove retainer cap (B), spring (C) and cap screw
(D).

B—Retainer Cap
C—Spring
D—Cap Screw
–UN–25APR01
H67591
–UN–25APR01
H67668
–UN–25APR01
H67680

110
15
48

083006
PN=1026
18. Remove piston (A).
19. Remove shift collar (B) and fork (C).
A—Piston
B—Collar
C—Fork
–UN–25APR01
H67678
–UN–25APR01
H67679
110
15
49

083006
PN=1027
20. Remove snap ring (C) and shaft (B) from housing (A).
21. Inspect seal (D) and replace as necessary.
22. Install shaft (B) into bore of housing (A). Install snap
ring (C).
A—Housing
B—Shaft
C—Snap Ring
–UN–25APR01
D—Seal
H67594
–UN–01MAY01
H67737
OUO6083,0000623 –19–07JAN04–11/22
IMPORTANT: Install collar with tabs facing outward.
23. Install fork (A) to collar (B); then install in housing.
A—Fork
B—Collar
–UN–25APR01
H67681

110
15
50

083006
PN=1028
IMPORTANT: Always install new feeder house piston B

seal kit even if not replacing any other
parts.
A
24. Install new feeder house piston seal kit using the
following special instructions: C
–UN–06JAN04
Lubricate seal (B) on piston (A) using clean hydraulic
oil; then install squarely into bore of housing with
thrust washer (C) and lock washer (D) being careful D
H79694
not to damage seal. Raised center facing outward.
A—Piston
B—Seal
C—Thrust Washer
D—Lock Washer
110
15
51

083006
PN=1029
25. Use cap screw (D) to pull piston assembly into

housing and tighten to specification.
Specification
Reverser Piston Seal Cap
Screw—Torque ............................................................................... 30 N•m
(22 lb-ft)
–UN–25APR01
26. Install spring (C) and retainer cap (B) using cap
screws (A).
H67680
B—Retainer Cap
C—Spring
D—Cap Screw
–UN–25APR01
H67668
–UN–25APR01
H67591

110
15
52

083006
PN=1030
27. Install ring gear (A).
A—Ring Gear
–UN–24APR01
H67592
OUO6083,0000623 –19–07JAN04–15/22
28. Install washer (C) to ID of pinion gear.
29. Apply a layer of TY6341 Multi-Purpose, SD Polyurea

Grease to ID of gear to help hold needle rollers in
place.
30. Install needle rollers (A) to ID of gear.
–UN–25APR01
31. Place a thin layer of TY6341 Multi-Purpose, SD
Polyurea Grease to one side of each thrust washer
(B) to hold in place while installing pinion assembly to
carrier.
H67665
NOTE: Install pinions consecutively (one, two and three)
in a counterclockwise direction.
32. Install pinion gear assembly to carrier.
33. Inspect needle rollers (A) to be certain they are

seated against ID of gear before attempting to install
pin (D).
–UN–25APR01
A—Needle Roller (174 used)

B—Thrust Washer (6 used)
C—Washer (3 used)
H67667
D—Pin (3 used)
110
15
53

083006
PN=1031
34. Install ball (A) to pin and align with hole in carrier;
then drive pin until fully seated.
A—Ball
–UN–25APR01
H67666
OUO6083,0000623 –19–07JAN04–17/22
NOTE: Snap ring (C) is used to seat the bearing at a

specified depth. Install snap ring to bearing before
driving bearing into bore of housing.
35. Install snap ring (C) to new bearing.
–UN–25APR01
36. Install bearing in bore of carrier housing.
37. Install shaft (B) and snap ring (A).
H67689
A—Snap Ring
B—Shaft
C—Snap Ring
–UN–25APR01
H67687

110
15
54

083006
PN=1032
38. Line up numbers on pinions (B) with marks (A) made

on cover during disassembly. Install gear (C).
IMPORTANT: If gears are not correctly installed and

timed, gear case may not turn freely
causing it to overheat.
39. Clean mating surfaces of housing and carrier. Apply a

bead of TY16135 Clear RTV Silicone Adhesive
Sealant on flange toward the inside of the six tapped
holes.
–UN–24APR01
A—Mark
B—Pinion (3 used)
C—Gear
H67593
OUO6083,0000623 –19–07JAN04–19/22
40. Install planetary carrier assembly into gear case

housing.
41. Install cap screws (A) and tighten to specification.
Specification
Reverser Gear Case Planetary
(54 lb-ft)
–UN–24APR01
H67590
110
15
55

083006
PN=1033
NOTE: Apply a small amount of Multi-Purpose SD

Polyurea Grease to spacers during assembly to
hold in place.
42. Install spacers (A).
43. Clean mating surfaces of carrier and quill.
44. Apply a bead of TY16135 Clear RTV Silicone

Adhesive Sealant to outside edge of lubrication
–UN–24APR01
groove and outside of quill.
A—Spacer (3 used)
H67589
OUO6083,0000623 –19–07JAN04–21/22
45. Install quill (B) and cap screws (A). Tighten to

specification.
Specification
Quill Cap Screws—Torque ............................................................. 50 N•m
(37 lb-ft)
46. Install gear case. (See INSTALL REVERSER GEAR

CASE in this group.)
–UN–24APR01
B—Quill
H67588
OUO6083,0000623 –19–07JAN04–22/22
Disassemble and Assemble Reverser Gear

Case Oil Pump
1. Remove plug from bottom of gear case and drain oil.
110 2. Remove reverser gear case. (See REMOVE

15 REVERSER GEAR CASE in this group.)
56

083006
PN=1034
3. Slide oil tube (A) out of fitting (B).
4. Remove fitting (B) and inspect O-rings (C). Replace as

necessary.
A—Tube
–UN–10MAY99
B—Fitting
C—O-Rings
H56000
–UN–10MAY99
H56004
OUO6083,0000CA8 –19–07MAR06–2/9

B—Cover
–UN–03MAY02
H72055
110
15
57

083006
PN=1035
6. Remove rotor assembly (A—E) and pin (F).
7. Remove O-ring (G) from pump housing.
8. Inspect and replace as necessary.
–UN–10MAY99
A—Rotor (Inner)
B—Rotor (Outer)
C—Plate
D—Washer
E—Spacer
H56001
F—Pin
G—O-Ring
–UN–10MAY99
H56002
OUO6083,0000CA8 –19–07MAR06–4/9
9. Remove carrier (A) and gear assembly (B).
A—Carrier
B—Gear Assembly
–UN–10MAY99
H56003
OUO6083,0000CA8 –19–07MAR06–5/9
10. Inspect gear (A), bearings (B) and carrier (C).

11. Install gear assembly and carrier into pump housing.
110 A—Gear
–UN–10MAY99
15 B—Bearings
58 C—Carrier
H56014

083006
PN=1036
12. Install O-ring (G) into groove in housing.
13. Install pin (F) in shaft.
14. Install spacer (E), washer (D) and plate (C) in

housing.
–UN–10MAY99
15. Install inner and outer rotors (A and B) into plate (C).
NOTE: Be certain that slot in inner rotor (A) engages pin
H56002
(F) to ensure proper pump operation.
A—Rotor (Inner)
B—Rotor (Outer)
C—Plate
D—Washer
E—Spacer
F—Pin
G—O-Ring
–UN–10MAY99
H56001
OUO6083,0000CA8 –19–07MAR06–7/9
16. Install housing cover (B) and cap screws (A). Tighten
to specification.
Specification
Reverser Gear Case Oil Pump
(20 lb-ft)
–UN–03MAY02
B—Cover
H72055
110
15
59

083006
PN=1037
17. Install fitting (B) and insert oil tube (A). Tighten cap
screw (C) to specification.
Specification
Fitting Cap Screw—Torque ............................................................ 48 N•m
(35 lb-ft)
–UN–23JUN99
18. Install gear case to machine. (See INSTALL
REVERSER GEAR CASE in this group.)
IMPORTANT: Feeder house must be in the raised
H58473
position to check oil level in gear case.
19. Fill gear case to mark on dipstick with 80W90 GL-5 A—Tube
Gear Lubricant. B—Fitting
C—Cap Screw
Specification
Case—Capacity .................................................................................. 4.9 L
(5.2 qt)
Case—Capacity .................................................................................. 3.5 L
(3.7 qt)
Standard Reverser Gear Case—
Capacity .............................................................................................. 2.3 L
(2.4 qt)
OUO6083,0000CA8 –19–07MAR06–9/9
110
15
60

083006
PN=1038
Remove and Install Reverser Shift Piston
1. Remove cap screws (A) evenly and incrementally to

relieve spring pressure.
2. Remove retainer cap (B), spring (C) and cap screw

(D).

B—Retainer Cap
–UN–25APR01
C—Spring
D—Cap Screw
H67591
–UN–25APR01
H67668
–UN–25APR01
H67680
Continued on next page OUO6083,00006DA –19–05JAN04–1/4

110
15
61

083006
PN=1039
3. Remove and discard piston (A).
A—Piston
–UN–25APR01
H67678
OUO6083,00006DA –19–05JAN04–2/4
4. Install new feeder house piston seal kit using the B

A
Lubricate seal (B) on piston (A) using clean hydraulic
oil; then install squarely into bore of housing with thrust
washer (C) and lock washer (D) being careful not to C
damage seal. Raised center facing outward.
–UN–06JAN04
A—Piston
B—Seal D
H79694
C—Thrust Washer
D—Lock Washer
Continued on next page OUO6083,00006DA –19–05JAN04–3/4
110
15
62

083006
PN=1040
5. Use cap screw (D) to pull piston assembly into housing

Specification
Reverser Piston Seal Cap
Screw—Torque ............................................................................... 30 N•m
(22 lb-ft)
–UN–25APR01
6. Install spring (C) and retainer cap (B) using cap screws
(A).
H67680
B—Retainer Cap
C—Spring
D—Cap Screw
–UN–25APR01
H67668
–UN–25APR01
H67591
OUO6083,00006DA –19–05JAN04–4/4
110
15
63

083006
PN=1041
Remove and Install Lower Shaft
1. Loosen chain tensioner (A) and remove chain (B) from

lower shaft.
2. Disconnect speed sensor (C).
–UN–14DEC04
3. Loosen tone wheel (D) and slide out on shaft.
4. Remove nuts (E) and sensor bracket (F).
H82186
5. Slide lower shaft (G) out from reverser (H) and out of
feeder house.
7. Install shaft into feeder house and into reverser.
8. Install bearing and sensor bracket using round head
–UN–14DEC04
bolts and nuts. Connect sensor.
A—Chain Tensioner
B—Chain
H82187
C—Speed Sensor
D—Tone Wheel
E—Nuts (3 used)
F—Sensor Bracket
G—Lower Shaft
H—Reverser
–UN–14DEC04
H82188
110
15
64

083006
PN=1042
9. If shaft or bearing has been replaced, pull lower shaft

(A) to right-hand side of machine so shoulder is tight
against bearing (B).
10. Install lock collar (C) on bearing (D) using PM37477

medium strength thread lock. Set lock collar in
–UN–14DEC04
clockwise rotation. Tighten set screw.
11. Install tone wheel over sensor and tighten.
H82189
12. Install chain on lower shaft and tighten tensioner.
A—Lower Shaft
B—Bearing
C—Lock Collar
D—Bearing
–UN–14DEC04
H82190
OUO6083,0000CA9 –19–07MAR06–2/2
Remove and Install Oil Cooler
NOTE: Harvesting high yielding or high moisture corn The feeder house reverser gear case oil cooler system
at fast speeds with 8 or 12 row corn heads, includes an external fin oil cooler mounted under the
where feeder house front shaft loads can be feeder house.
high, may cause excessive heat buildup in the
reverser gear case oil. The optional feeder Pressure oil is routed to the oil cooler where it is
house oil cooler keeps oil cool to improve convection cooled before passing along to the reverser
reverser gear case service life. gear case. The pump sends hot oil from the gear case
and routes the oil through the oil cooler.
If overheating exists, raise feeder house and check for
proper oil level in the reverser gear case. Add 80W90 1. Remove left-hand side feeder house shields.
GL-5 Gear Lubricant as required.
Continued on next page OUO6083,00005AE –19–11JUL05–1/5

110
15
65

083006
PN=1043
3. Drain oil from reverser gear case.
4. Remove hose clamps.
–UN–12MAY03
A—Safety Stop
H76859
OUO6083,00005AE –19–11JUL05–2/5
5. Disconnect hoses (A) from reverser case.
6. Plug fittings and cap hose ends to help avoid

contamination of system.
A—Hoses
–UN–12MAY03
H76889
OUO6083,00005AE –19–11JUL05–3/5
7. Remove cap screws (A) and nuts from oil cooler

hangers.
8. Remove oil cooler from underside of feeder house.
9. Inspect hoses, fittings and oil cooler. Repair or replace
–UN–13MAY03
as necessary.
10. Slide oil cooler under feeder house and install cap
screws (A) and nuts.
H76907
Continued on next page OUO6083,00005AE –19–11JUL05–4/5

110
15
66

083006
PN=1044
11. Connect hoses (A) to reverser gear case.
12. Install hose clamps.
IMPORTANT: Feeder house must be in the raised

position to check oil level.
–UN–12MAY03
Specification
Case—Capacity .................................................................................. 4.9 L
(5.2 qt)
H76889
Case—Capacity .................................................................................. 3.5 L
(3.7 qt)
A—Hoses
13. Fill reverser gear case to mark on dipstick with
TY6252 80W90 GL-5 Gear Lubricant.
14. Install feeder house shields.
OUO6083,00005AE –19–11JUL05–5/5
110
15
67

083006
PN=1045
Remove and Install Backshaft
1. Loosen chain tensioner (A).
2. Remove chain (B) from backshaft.
3. Disconnect speed sensor (C).
4. Remove cap screws (D).
–UN–24JUL01
5. Slide backshaft (E) from reverser (F) and out of feeder
house.
ZX25289
A—Chain Tensioner
B—Chain
C—Speed Sensor
E—Backshaft
F—Reverser
–UN–13MAY03
H76904
OUO6083,00005AD –19–13MAY03–1/1
110
15
68

083006
PN=1046
110
15
69

083006
PN=1047
Disassemble and Assemble Fixed Speed Drive Tightener
11
5
6 1
1 3
12
7
6 13
25
25
9
10
2
3
24
22 13
11
4
8
23
21 14
20
15
16
–UN–05JUN03
110
15
70 17
18
H77641
19

083006
PN=1048
1—Bolt (2 used) 8—Pivot 14—Nut (2 used) 20—Bolt

2—Arm 9—Washer 15—Washer 21—Bracket
3—Spacer (2 used) 10—Lock Nut 16—Spring 22—Flange Nut (2 used)
4—Bolt 11—Idler (2 used) 17—Gauge 23—Reinforcement
5—Washer 12—Belt 18—Washer 24—Round Head Bolt
6—Washer (2 used) 13—Flange Nut (2 used) 19—Washer (2 used) 25—Bushing (2 used)
7—Bushing
1. Disassemble parts (1—28) as needed. Specification

Idler Pulley-to-Arm Cap
Screw—Torque ...................................................................... 125 N•m
2. Inspect all parts. Replace as necessary. If bushings (92 lb-ft)
in idlers (11) are worn, complete idler must be
replaced. 4. Tighten spring (16) until end of spring is aligned
with end of gauge (17).
3. Assemble parts (1—28). Tighten bolts (1) to
specification.
OUO6083,0000612 –19–05JUN03–2/2
110
15
71

083006
PN=1049
Disassemble and Assemble Conveyor Drive Chain, Tightener and Guides
E
D
F
A
K J
A R
P
K J
R
B
I
N L
O
N
–UN–17JUN02
O H
110
15
H72559
72 Q
Continued on next page OUO6083,00000A1 –19–15JUN01–1/2

083006
PN=1050
A—Lock Nut (4 used) F—Chain K—Sprocket (2 used) P—Guide

B—Support G—Bracket L—Cap Screw Q—Sprocket
C—Plate (2 used) H—Flange Nut (4 used) M—Round Head Bolt R—Washer
D—Bracket I— Round Head Bolt N—Washer S—Guide
E—Round Head Bolt (4 used) J—Spacer (2 used) O—Nut (2 used) T—Support
1. Disassemble parts (A—T) as needed. Specification

Conveyor Drive Chain Idler
Bolt—Torque .......................................................................... 130 N•m
2. Inspect all parts. Replace as necessary. If (97 lb-ft)
bushing(s) in sprocket(s) (K) is worn, complete
sprocket must be replaced.
3. Assemble parts (A—T). Tighten cap screw (L) to

specification.
OUO6083,00000A1 –19–15JUN01–2/2
Feeder House Variable Speed Belt—

Adjustment
NOTE: Minor adjustments can be made to the feeder

house variable speed belt by raising idler. If a 3
mm (1/8 in.) gap cannot be reached by raising
–UN–26JUL05
idler, proceed to next.
1. Start engine, engage separator and move switch to

fast idle. Adjust feeder house drive belt to slow
H84134
front shaft speed.
2. Disengage separator, stop engine and remove key.

A—Rubber Boot
B—Bracket
3. Look under rubber boot (A) to verify if upper sheaves
are fully open. At low speed position, outer sheave half
bulb will be against bracket (B).
4. Remove feeder house shields.

110
15
73

083006
PN=1051
5. Loosen nut (A) to adjust idler (B) to lower position.
A—Nut
B—Idler
–UN–26JUL05
H84135
OUO6046,0002019 –19–01AUG05–2/9
6. Remove and retain nuts (A) and bracket (B).
7. Loosen nuts (C) to allow upper sheave assembly to

move.
A—Nuts (2 Used)
–UN–27JUL05
B—Bracket
C—Nuts (3 Used)
H84136
OUO6046,0002019 –19–01AUG05–3/9
NOTE: Nut (C) may be moved and jammed against nut

(A). Together these nuts can be used to turn
tensioner bolt.
8. Loosen nut (A) away from bracket (B) until a 3 mm

(1/8 in.) gap exists between either side of bracket.
–UN–26JUL05
9. Tighten nut (C) against nut (A).
A—Nut
H84138
B—Bracket
C—Nut

110
15
74

083006
PN=1052
IMPORTANT: Rotate belt while adjusting sheave gap.

Failure to rotate belt while adjusting
sheave gap will result in belt damage.
A gap between sheave halves is

important so sheave halves can grip
belt when in slow speed position.
–UN–26JUL05
Cutting platform drive shaft speed must
be at slow speed.
H84139
10. Turn nut (A) to adjust bolt (B).
11. Move upper variable sheave assembly with bolt until

a 3 mm (1/8 in.) gap exists between lower sheave
halves or upper sheave assembly reaches end of
slots.
A—Nut
B—Bolt
–UN–26JUL05
C—Gap, 3 mm (1/8 in.)
H84140
OUO6046,0002019 –19–01AUG05–5/9
12. Tighten nut (A) first and then nut (B).
A—Nut
B—Nut
–UN–26JUL05
H84141
OUO6046,0002019 –19–01AUG05–6/9
13. Tighten nuts (C) and install bracket (B) and retain
with nuts (A).
A—Nuts (2 Used)
B—Bracket
C—Nuts (3 Used)
110
–UN–27JUL05
15
75
H84136

083006
PN=1053
IMPORTANT: DO NOT Stand on belt while pushing up

on idler to set gap.
14. Raise idler (A) until idler touches belt.
15. Raise belt an additional 25 mm (1 in.) and tighten nut

(B).
–UN–26JUL05
A—Idler
B—Nut
H84142
OUO6046,0002019 –19–01AUG05–8/9
16. Tighten adjusting nut (A) until washer aligns with end
of gauge to adjust reel drive belt (B).
17. Install feeder house shields.
A—Nut
–UN–18JUL05
B—Belt
H83967
OUO6046,0002019 –19–01AUG05–9/9
Replace Variable Speed Feeder House Belt
CAUTION: Lower variable sheave is under

spring tension; if belt is removed, it will snap
back to a closed position.
1. Run feeder house to close lower variable sheave.
3. Lower safety stop and remove left-hand feeder house

shields.

110
15
76

083006
PN=1054
4. Remove shields (A).
5. Loosen idler nut (B) to relieve belt tension.
A—Shields
B—Nut
–UN–28JUL05
H84156
OUO6083,0000D8B –19–12JUL06–2/7
6. Loosen nuts (A) to relieve tension on reel drive belt

(B).
A—Nut
B—Belt
–UN–18JUL05
H83967
OUO6083,0000D8B –19–12JUL06–3/7
7. Remove and retain nuts (A) and bracket (B).
8. Loosen nuts (C) to allow upper sheave assembly to

move.
A—Nuts (2 Used)
–UN–27JUL05
B—Bracket
C—Nuts (3 Used)
H84136
110
15
77

083006
PN=1055
NOTE: Nut (C) may be moved and jammed against nut

(A). Together these nuts can be used to turn
tensioner bolt.
9. Loosen nut (A) away from bracket (B) until a 3 mm

(1/8 in.) gap exists between either side of bracket.
–UN–28JUL05
10. Tighten nut (C) against nut (A).
NOTE: Threading the bolt into the tensioner allows the
H84161
sheave to move forward to remove the belt.
11. Use nut (A) to screw threaded bolt into tensioner (D).
A—Nut
B—Bracket
C—Nut
D—Tensioner
OUO6083,0000D8B –19–12JUL06–5/7
12. Remove cap screw and nut (A) to swing bracket (B)
out of way.
13. Remove belt (C) from sheaves.
A—Cap Screw and Nut
–UN–28JUL05
B—Bracket
C—Belt
H84157
OUO6083,0000D8B –19–12JUL06–6/7
NOTE: If total belt failure has occurred, it may be

necessary to bleed hydraulic fluid from upper
variable cylinder to install new belt.
14. If total belt failure has occurred and upper variable

sheave is in closed position (high speed), loosen
–UN–26AUG05
fitting (A) and bleed hydraulic oil from cylinder to open

sheave.
15. Install new belt on upper sheave and roll onto

H84326
reverser sheave. Adjust tension. (See Feeder HOUSE

VARIABLE SPEED BELT—ADJUSTMENT in this
group).
110 A—Fitting
15
78 16. Install bracket and feeder house shields previously
removed.
OUO6083,0000D8B –19–12JUL06–7/7

083006
PN=1056
Replace and Adjust Fixed Speed Feeder House Belt
–UN–21MAY02
H72276
A—Nuts B—Belt C—Washer D—Gauge
1. Remove shields. 5. Tighten nuts until washer (C) aligns with end of
gauge (D).
2. Loosen nuts (A) to release tension on idlers.
6. Install shields.
3. Remove belt (B).
4. Install new belt.
OUO6083,00002A7 –19–21MAY02–1/1
110
15
79

083006
PN=1057
110
15
80

083006
PN=1058
Group 20
CONTOUR MASTER Tilt Cylinder
CONTOUR MASTER
Tilt Cylinder Hoses and Fittings
L D
I
E C
F J B
G K
H
D
C
E
–UN–05JUN03
A
H77648
A
A—Hose, Hydraulic (2 used) D—Spacer, 21/64 x 1-15/32 x G—Fitting, Straight J—Fitting, Straight
B—Screw (2 used) 7/64 in. H—O-Ring, 4-FSF K—O-Ring, 6-FSF
C—Washer, 0.364 x 0.540 x 1/4 E—Pin, 0.746 x 2-3/4 in. I—O-Ring, 6-SAE L—Cylinder, Hydraulic
in. F—O-Ring, 4-SAE
OUO6083,0000624 –19–06JUN03–1/1
110
20
1

083006
PN=1059
Tilt Cylinder
H
G
F
E
D
C
B
I O
–UN–05DEC03
N
M
K L
H79295
J
A—Rod E—Ring, Back-Up I—Ring, Wear M—Piston

B—O-Ring F—Guide, Rod J—Washer N—Screw, Cap, 5/8 x 2 in.
C—Ring, Snap G—Seal K—O-Ring O—Barrel
D—Seal H—Ring, Snap L—Ring, Piston
OUO6083,000083F –19–11JUN04–1/1
110
20
2

083006
PN=1060
Remove and Install CONTOUR MASTER Tilt

Cylinder
CAUTION: Remove header before attempting to

remove cylinder.
–UN–05JUN03
1. Start combine, tilt frame to left-hand side to retract
cylinder. Shut off engine and remove key.
2. Clean area around cylinder to prevent contamination of
H77654
hydraulic system when hydraulic hoses are
disconnected from cylinder.
A—Cap Screw
3. Remove cap screw (A), washer, bracket and spacer. B—Hoses
C—Cap Screw
D—Pins
CAUTION: Tilt frame will tilt with very little effort E—Cylinder
when hydraulic hoses are disconnected.
4. Disconnect hoses from cylinder (E). Plug hoses (B)

and cap cylinder fittings.
5. Remove cap screw (C), spacer and washer.
6. Remove pins (D).
7. Level tilt frame by hand to provide clearance to remove

cylinder.
8. Remove cylinder (E).
Continued on next page OUO6083,00007F8 –19–25MAY04–1/2
110
20
3

083006
PN=1061
10. Attach hoses (B) to cylinder (E).
NOTE: Larger diameter hose connects to cylinder rod end

port.
11. Attach cylinder to feeder house frame and rod end to
–UN–05JUN03
tilt frame.
12. Install pins (D).
H77654
13. Install spacer, washer and cap screw (C).
14. Install spacer, bracket, washer and cap screw (A).

A—Cap Screw
NOTE: Advise customer to clean the tilt cylinder area B—Hoses
C—Cap Screw
regularly to avoid compaction of foreign material D—Pins
which can limit tilt travel. Clean more often in wet E—Cylinder
or freezing conditions.
OUO6083,00007F8 –19–25MAY04–2/2
110
20
4

083006
PN=1062
Group 25
CONTOUR MASTER Tilt Frame
Other Material
Number Name Use
PM37418 (U.S.) Thread Lock and Sealer (Medium Keep cap screws from loosening.
PM38621 (Canadian) Strength)
OUO6083,0000B23 –19–29AUG05–1/1
Specifications
Tilt Frame Weight 100 kg

(220 lb)
Tilt Frame Cap Screws Torque 315 N•m

(230 lb-ft)
Tilt Frame Shield Cap Screws Torque 130 N•m

(95 lb-ft)
Tilt Beam Pivot Cap Screw Torque 610 N•m

(450 lb-ft)
Fore/Aft Tilt Frame Mounting Nuts Torque 215 N•m

(159 lb-ft)
Torque Plate Cap Screw Torque 130 N•m

(96 lb-ft)
OUO6083,0000D26 –19–22MAY06–1/1
110
25
1

083006
PN=1063
Tilt Frame and Beam

(S.N. —720100)
15
14
16
2
17
1
3
19 18 4
20 5
6
7
8
9
10
11
12
13 39
21
22
24 23
31
25
30
26
27
28
29
33 32
110
–UN–13MAY03
37
25 38
2 35
H76899
36
34
Continued on next page OUO6083,0000D1D –19–17MAY06–1/2

083006
PN=1064
1—Pin (4 used) 11—Washer (2 used) 21—Washer (2 used) 31—Wear Pad (2 used)

2—Cotter Pin (4 used) 12—Spacer (2 used) 22—Flange Nut (2 used) 32—Tilt Frame
3—Rear Eyebolt (2 used) 13—Washer (2 used) 23—Tilt Beam 33—Cap Screw (5 used)
4—Turnbuckle (2 used) 14—Cap Screw (2 used) 24—Bushing 34—Cap Screw (8 used)
5—Jam Nut (2 used) 15—Flange Nut 25—Pin 35—Closure Plate, Left-Hand
6—Front Eyebolt (2 used) 16—Bracket 26—Round Head Bolt (6 used) 36—Cap Screw (2 used)
7—Flange Nut (4 used) 17—Cap Screw (2 used) 27—Pivot Plate 37—Enclosure
8—Washer (4 used) 18—Round Head Bolt (4 used) 28—Nut (6 used) 38—Closure Plate, Right-Hand
9—Round Head Bolt (2 used) 19—Cap Screw (2 used) 29—Cap Screw 39—Single Point Latching
10—Cap Screw (2 used) 20—Washer (2 used) 30—Pop Rivet (12 used) Assembly
OUO6083,0000D1D –19–17MAY06–2/2
110
25
3

083006
PN=1065
Tilt Frame and Beam

(S.N. 720101—)
1
2
6
4
3
7
9
10
8
11
5
13
12
14
42
15
21
16
22
23
24 18 19
37 17
25
20
33
34 28 26
27
35 29 17
16
30
38 39 33
40 41 31
34
–UN–13FEB06
36
110 32
H85370
25 37
4
Continued on next page OUO6083,0000D1E –19–17MAY06–1/2

083006
PN=1066
1—Cable 12—Wear Plate (Left- and 22—Cap Screw (8 used) 33—Rivet (8 used)
2—Pipe Right-Hand Sides) 23—Strap (2 used) 34—Pad (2 used)
3—Seal 13—Bracket 24—Cap Screw (4 used) 35—Tilt Beam
4—Strap 14—Round Head Bolt (4 used) 25—Spacer 36—Cap Screw (8 used)
5—Cap Screw (8 used) 15—Quick Lock Pin (2 used) 26—Cap Screw 37—Shim (2 used)
6—Isolator 16—Flange Nut (8 used) 27—Plate 38—Deflector
7—Cap Screw 17—Washer (4 used) 28—Frame 39—Spacer
8—Clamp 18—Flange Nut 29—Round Head Bolt (2 used) 40—Cap Screw
9—Wear Plate (2 used) 19—Cap Screw (2 used) 30—Washer (2 used) 41—Strap (2 used)
10—O-Ring (4 used) 20—Strap 31—Plate (2 used) 42—Frame
11—Flange Nut (4 used) 21—Seal (2 used) 32—Cap Screw (8 used)
OUO6083,0000D1E –19–17MAY06–2/2
Remove and Install Tilt Frame
1. Level tilt frame.
2. Remove quick lock pin (A), tube (B) and seal (C).
–UN–17MAY06
3. Remove cap screw (D) and pin (E) from tilt cylinder
(F).
A—Quick Lock Pin
H85946
B—Tube
C—Seal
D—Cap Screw
E—Pin
F—Tilt Cylinder
–UN–17MAY06
H85944
110
25
5

083006
PN=1067
NOTE: It may be necessary to heat cap screws due to

the use of thread lock sealer adhesive.
4. Remove cap screws (A) from lower left- and right-hand

corners of tilt frame.
–UN–17MAY06
CAUTION: Approximate weight of frame is 100
kg (220 lb).
Specification
H85943
Tilt Frame—Weight.......................................................................... 100 kg
(220 lb)
5. Remove tilt frame (B) using proper lifting device.

B—Tilt Frame
–UN–17MAY06
H85945
OUO6083,0000D21 –19–18MAY06–2/4
NOTE: Wear pads (A) can be held in place to frame by

using O-rings (B) as retainers on wear pad posts.
7. Install wear pad (A) on both sides of feeder house.
A—Wear Pad
–UN–18MAY06
B—O-Ring
H85955
110
25
6

083006
PN=1068
IMPORTANT: Be sure mating surfaces of frame (A)

and tilt beam (B) are clean and free of
dirt, oil or foreign material.
8. Install tilt frame (A) to feeder house.
–UN–18MAY06
NOTE: Be sure all cap screws have proper torque.
9. Apply T43512 Thread Lock and Sealer to cap screws

(C) and install in both sides. Torque cap screws to
H85960
specification.
Specification
Tilt Frame Cap Screw—Torque ................................................... 315 N•m
(230 lb-ft)
10. Install pin (D) at rod end of tilt cylinder (E).
11. Install cap screw (F) for tilt sensor cable.
–UN–18MAY06
A—Frame
B—Tilt Beam
D—Pin
H85962
E—Tilt Cylinder
F—Cap Screw
OUO6083,0000D21 –19–18MAY06–4/4
Remove and Install Tilt Beam
IMPORTANT: DO NOT actuate latch pins if header is

still attached and on the ground. Shear
pin (A) on multi-coupler handle will
break to prevent damage to cable
–UN–19OCT05
mechanism. (Replacement shear pins

(B) are located on multi-coupler
bracket.)
H84781
1. Level tilt frame.
A—Shear Pin 110

B—Spare Shear Pins (3 used) 25
7

083006
PN=1069
2. Remove cap screw (A) from tilt angle sensor mounting

bracket.
3. Remove pin (B) from rod end of tilt cylinder (C).
4. Remove tilt frame. (See procedure in this group.)
–UN–18MAY06
A—Cap Screw
B—Pin
C—Tilt Cylinder
H85963
OUO6083,0000D91 –19–13JUL06–2/6
CAUTION: Approximate weight of tilt beam is 58

kg (128 lb).
Specification
Tilt Beam—Weight............................................................................. 58 kg
(128 lb)
–UN–13JUL06
5. Remove cap screw (A) from latching cable (B).
6. Attach proper lifting device to tilt beam (C).
H85984
A—Cap Screw
B—Latching Cable
C—Tilt Beam
–UN–13JUL06
H85985
110
25
8

083006
PN=1070
7. Remove cap screw (A) and block (B) from latching

cable.
8. Remove nut (C) from cap screw (D) from rear of tilt
beam.
–UN–19MAY06
9. Remove cap screws (E) and pivot pin retainer plate
(F).
10. Remove cap screw (D) from pivot pin (J).
H85967
NOTE: Pivot pin (J) is threaded for a M24 cap screw to
be used as a puller.
A—Cap Screw
11. Remove pivot pin (J) from rear of tilt beam. B—Block
C—Nut
D—Cap Screw
12. Remove latching cable out front of feeder house E—Cap Screw (2 used)
before lowering tilt beam. F—Retainer Plate
13. Repair or replace as necessary. H—Spacer (2 used)
I—Washer (2 used)
J—Pivot Pin
OUO6083,0000D91 –19–13JUL06–4/6
CAUTION: Approximate weight of tilt beam is 58

kg (128 lb).
14. Install tilt beam (A) to feeder house using proper

lifting device.
–UN–23MAY06
15. Feed latching cable through back side of tilt beam.
Install cap screw (B) to latching cable (C).
H85983
A—Tilt Beam
B—Cap Screw
C—Latching Cable –UN–13JUL06
110
25
9
H85984

083006
PN=1071
16. Install pivot pin (J) through rear of tilt beam.
17. Install retainer plate (F) with cap screws (E).
18. Install cap screw (D) through front of feeder house

with nut (C) to back side. Tighten to specification.
–UN–19MAY06
Specification
Tilt Beam Pivot Cap Screw—
Torque ......................................................................................... 610 N•m
(450 lb-ft)
H85967
19. Install block (B) and cap screw (A).
A—Cap Screw
20. Install cap screw (G), spacer (H) and washer (I) on B—Block
both sides. C—Nut
D—Cap Screw
21. Install tilt frame. (See REMOVE AND INSTALL TILT E—Cap Screw (2 used)
F—Retainer Plate
FRAME in this group.)
H—Spacer (2 used)
I—Washer (2 used)
J—Pivot Pin
OUO6083,0000D91 –19–13JUL06–6/6
Adjust Single Point Latching
IMPORTANT: Verify handle is against stop on

multi-coupler. Failure to do so could
result in inaccurate pin dimensions
which could allow header to fall off
–UN–24OCT05
during harvesting or in transportation.
NOTE: Adjustment should only be made to cable at

multi-coupler handle.
H84801
1. Move multi-coupler handle (A) against stop (B).
NOTE: Moving cable “up” in bracket pulls pin in farther.
Moving cable “down” in bracket pushes pin farther

out.
2. Loosen jam nuts (C).

–UN–24OCT05
110
25 A—Handle
10 B—Stop
C—Jam Nuts (2 used)
H84802
Continued on next page OUO6083,0000BE3 –19–24OCT05–1/3

083006
PN=1072
3. Adjust cable in bracket as needed for left-hand pin to

meet specification (A).
Specification
Feeder House Pin (Retracted)—
Distance .......................................................................................... ± 2 mm
(0.08 in.)
–UN–10DEC03
4. Hold bottom jam nut and tighten top jam nut.
H79344
A—Specification
A
OUO6083,0000BE3 –19–24OCT05–2/3
IMPORTANT: Verify handle is against stop on

multi-coupler. Failure to do so could
result in inaccurate pin dimensions
which could allow header to fall off
during harvesting or in transportation.
–UN–23JUN04
5. Fully lower multi-coupler handle (A) and verify pins (B)
(both sides) are set to specification. Readjust as
needed.
H81287
Specification
Feeder House Pins (Extended)—
Distance ................................................................................. 45 — 52 mm
(1-3/4 in. — 2 in.)
A—Handle
B—Pins (2 used)
–UN–23JUN04
H81288
OUO6083,0000BE3 –19–24OCT05–3/3
110
25
11

083006
PN=1073
Lateral Tilt Beam with Single Point Latching—Exploded View (S.N. —715300)
C
A
E
D
B
F L
G J
M
I N
H K
O
F D
–UN–12MAY03
I
H
C
H76892
A—Tilt Beam E—Plate I—Washer (2 used) M—Yoke Pin
B—Spring F—Cotter Pin (2 used) J—Spacer (2 used) N—Cable Mounting Bracket
C—Latch Pin (2 used) G—Cap Screw (2 used) K—Linkage O—Linkage
D—Washer (2 used) H—Cap Screw (2 used) L—Yoke
During assembly, apply PM37418 Thread Lock and

Sealer to cap screws (G and H).
OUO6083,0000B24 –19–29AUG05–1/1
110
25
12

083006
PN=1074
Lateral Tilt Beam with Single Point Latching—Exploded View (S.N. 715301—)
H I
F
E N
D
C
O
G
P
H
K G
J K
L M J
B
–UN–30AUG05
E
D
C
H84322
A—Tilt Beam E—Spacer (2 used) I—Linkage M—Cable
B—Latch Pin (2 used) F—Linkage J—Cap Screw (2 used) N—Block
C—Cap Screw (2 used) G—Washer (2 used) K—Washer (2 used) O—Socket Head Cap Screw
D—Washer (2 used) H—Cotter Pin (2 used) L—Cap Screw P—Linkage
During assembly, apply PM37418 Thread Lock and

Sealer to cap screws (C and J).
OUO6083,0000D58 –19–08JUN06–1/1
110
25
13

083006
PN=1075
Adjust Fore-Aft Turnbuckles
1. Loosen nuts (A) and cap screws (B) on both sides of

feeder house.
2. Loosen jam nut (C) and turn turnbuckle (D) on each
–UN–23MAY06
side of feeder house until desired angle is reached.
3. Tighten jam nuts (C).
H85987
4. Torque nuts (A) and cap screws (B) to specification.
Specification
Fore/Aft Tilt Frame Mounting
Nuts—Torque ............................................................................... 215 N•m
(159 lb-ft)
A—Nut (6 used)
C—Jam Nut (2 used)
–UN–23MAY06
D—Turnbuckle (2 used)
H85988
OUO6083,0000D28 –19–23MAY06–1/1
Remove Fore-Aft Tilt Frame
1. Remove tilt frame (A). (See procedure in this group.)
A—Tilt Frame
–UN–23MAY06
H85994
110
25
14

083006
PN=1076
2. Remove cap screws (A) along with torque plates (B

and C) from feeder house.
B
B—Torque Plate, Top (2 used)
C—Torque Plate, Bottom (2 used)
–UN–23FEB01
A
H66556
–UN–23FEB01
H66557
OUO6083,0000D2D –19–24MAY06–2/6
3. Remove cap screws (A) and plastic seals (B) on both

sides.

B—Seal (2 used)
110
–UN–17AUG05
25
15
H84230

083006
PN=1077
4. Remove nuts, washers and round head bolts (A) on

both sides.
–UN–23MAY06
H85991
OUO6083,0000D2D –19–24MAY06–4/6
5. Remove self-tapping cap screws (A) and strap (B).
6. Loosen jam nut (C) and rotate turnbuckle (D) until

frame is tilted to its extreme forward position.
7. Remove spring locking pin (E) and pin.
–UN–23MAY06
A—Self-Tapping Cap Screw (5 used)
B—Strap
C—Nut (2 used)
H85989
D—Turnbuckle (2 used)
E—Spring Locking Pin (2 used)
–UN–23MAY06
H85990
OUO6083,0000D2D –19–24MAY06–5/6
8. Attach suitable lifting device to frame; apply tension to

lifting device.
9. Remove pivot point cap screw (A) on both sides.
10. Remove frame using lifting device.

110
–UN–23MAY06
25
16 11. Make repairs as necessary.

H85992
OUO6083,0000D2D –19–24MAY06–6/6

083006
PN=1078
Install Fore-Aft Tilt Frame
1. Position tilt frame to front of feeder house using lifting

device. Floor sealing angle must lay on top of fixed
frame wear plate.
–UN–23MAY06
2. Install pivot point cap screw (A) on both sides.
H85992
OUO6083,0000D2B –19–23MAY06–1/8
CAUTION: Frame can suddenly rotate

downward creating a pinch point. Avoid
personal injury and be certain that turnbuckles
are connected before attempting to install lower
adjusting bolts.
–UN–23MAY06
3. Connect turnbuckle (B) using pin and spring locking pin
(C) on both sides.
4. Loosen jam nut (A); then tighten turnbuckle (B) to tilt
H85995
frame upwards far enough to install lower round head
bolts.
A—Nut (2 used)
B—Turnbuckle (2 used)
C—Spring Locking Pin (2 used)
OUO6083,0000D2B –19–23MAY06–2/8
5. Install plastic seals (B) and retain using cap screws (A)
on both sides.

B—Seal (2 used) –UN–17AUG05
H84230
Continued on next page OUO6083,0000D2B –19–23MAY06–3/8

110
25
17

083006
PN=1079
6. Install round head bolts (A), washers and nuts to both

sides. Do not tighten at this time.
–UN–23MAY06
H85991
OUO6083,0000D2B –19–23MAY06–4/8
7. Install seal and strap (B) using self-tapping cap screws

(A).
8. Adjust turnbuckles (C) to obtain desired tilt: then

tighten jam nut (D).
–UN–23MAY06
A—Self-Tapping Cap Screw (5 used)
B—Strap
C—Turnbuckle (2 used)
D—Nut (2 used)
H85989
–UN–23MAY06
H85996
110
25
18

083006
PN=1080
9. Install torque plates (B) and (C) using cap screws (A)
B
Specification
Torque Plate Cap Screw—Torque ............................................... 130 N•m
(96 lb-ft)
B
B—Torque Plate, Top (2 used)
C—Torque Plate, Bottom (2 used)
–UN–23FEB01
A
H66556
–UN–23FEB01
H66557
OUO6083,0000D2B –19–23MAY06–6/8
10. Tighten nuts (A) and cap screw (B) on both sides of
feeder house to specification.
Specification
Fore/Aft Tilt Frame Mounting
Nuts—Torque ............................................................................... 215 N•m
(159 lb-ft) 110
–UN–23MAY06
25
19
A—Nuts (6 used)
H85987

083006
PN=1081
11. Install tilt frame (A). (See procedure in this group.)
A—Tilt Frame
–UN–23MAY06
H85994
OUO6083,0000D2B –19–23MAY06–8/8
110
25
20

083006
PN=1082
Section 120
Separator 120
Contents
Page Page
Group 05—Separator Repair Threshing Bar And Separator Tine

Essential or Recommended Tools . . . . . . . . . .120-05-1 Location (Rice) (S.N. —715300) . . . . . . . .120-05-94
Other Material . . . . . . . . . . . . . . . . . . . . . . . . .120-05-3 Threshing Element and Separator Tine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .120-05-4 Location (15 Element Configuration) . . . . .120-05-96
Remove And Install Feed Accelerator And Threshing Element and Separator Tine
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-6 Location (24 Element Dense Pack
Remove and Install Feed Accelerator Configuration) . . . . . . . . . . . . . . . . . . . . . .120-05-98
Wear Strips . . . . . . . . . . . . . . . . . . . . . . . .120-05-13 Remove And Replace RIVNUT Threaded
Remove And Install Separator Top Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-99
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-14 Remove And Install STS Rotor Feed
Remove and Install Separator Rails . . . . . . .120-05-19 Flights . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-100
Remove And Install STS Rotor Front Static Balance STS Rotor . . . . . . . . . . . . . .120-05-102
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-27 Aligning Rotor Drive Bulkhead. . . . . . . . . . .120-05-105
Remove and Install Stone Trap Door . . . . . .120-05-31
Remove and Install STS Rotor . . . . . . . . . . .120-05-32 Group 10—Separator Drives
Replace Rear Bulkhead (Rotor Drive Gear Essential or Recommended Tools . . . . . . . . . .120-10-1
Case Support) . . . . . . . . . . . . . . . . . . . . . .120-05-36 Specifications . . . . . . . . . . . . . . . . . . . . . . . . .120-10-2
Remove and Install STS Rotor Torque Remove and Install Right-Hand Front
Sensing—Driven . . . . . . . . . . . . . . . . . . . .120-05-37 Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .120-10-3
Disassemble and Assemble STS Rotor Remove and Install Right-Hand Rear
Torque Sensing—Driven . . . . . . . . . . . . . .120-05-41 Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .120-10-5
Remove and Install STS Rotor Drive Gear Remove and Install Primary Countershaft
Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-50 Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-10-9
Disassemble and Assemble STS Rotor Drive Remove and Install Primary Countershaft . . .120-10-11
Gear Case . . . . . . . . . . . . . . . . . . . . . . . . .120-05-54 Remove and Install Primary Drive Shafts . . .120-10-14
Remove And Install Discharge Beater Grate Replace Drive Shaft Carrier Bearing . . . . . . .120-10-19
Section . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-59
Remove And Install Discharge Beater Group 15—Residue Disposal
Grate Frame . . . . . . . . . . . . . . . . . . . . . . .120-05-63 Service Equipment and Tools . . . . . . . . . . . . .120-15-1
Remove And Install Discharge Beater . . . . . .120-05-65 Other Material . . . . . . . . . . . . . . . . . . . . . . . . .120-15-1
Remove and Install Discharge Beater Specifications . . . . . . . . . . . . . . . . . . . . . . . . .120-15-2
Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . .120-05-71 Straw Chopper Rotor (Fine Cut) . . . . . . . . . . .120-15-3
Remove and Install Discharge Beater Straw Chopper Rotor (Extra Fine Cut). . . . . . .120-15-4
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-72 Straw Chopper Housing . . . . . . . . . . . . . . . . .120-15-6
Remove And Install Separator Grates . . . . . .120-05-75 Remove Straw Chopper . . . . . . . . . . . . . . . . .120-15-7
Remove and Install Concave Sections . . . . .120-05-76 Remove and Install Chopper Raise/Lower
Adjust Concave Level . . . . . . . . . . . . . . . . . .120-05-83 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-10
Remove and Install Concave Adjusting Install Straw Chopper . . . . . . . . . . . . . . . . . .120-15-14
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-88 Chopper Blades Replacement and
Remove And Install Concave Adjusting Configuration—9560 . . . . . . . . . . . . . . . . .120-15-16
Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-05-88 Remove and Replace Straw Chopper Blades
Repair Separator Rotor Shell . . . . . . . . . . . .120-05-89 (Fine Cut) . . . . . . . . . . . . . . . . . . . . . . . . .120-15-18
Remove And Install Threshing Elements Remove and Replace Straw Chopper
And Tines . . . . . . . . . . . . . . . . . . . . . . . . .120-05-90 Blades (Extra Fine Cut) . . . . . . . . . . . . . . .120-15-19
Threshing Bar And Separator Tine Location
(S.N. —715300). . . . . . . . . . . . . . . . . . . . .120-05-92 Continued on next page

083006
PN=1
Contents
Page Page
120
Replace Knife Blades (S.N. —715300) . . . . .120-15-22 Remove and Install Shake Pan . . . . . . . . . . .120-20-47
Replace Knife Blades (S.N. 715301—) . . . . .120-15-23 Remove and Install Shoe Pitman Arms . . . . .120-20-49
Remove and Install Easy Adjust Knife
Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-24 Group 25—Tailings Elevator and Augers
Remove and Install Crop Diverter . . . . . . . . .120-15-25 Specifications . . . . . . . . . . . . . . . . . . . . . . . . .120-25-1
Replace Left-Hand Chopper Rotor Remove Lower Tailings Auger . . . . . . . . . . . .120-25-1
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-28 Install Lower Tailings Auger . . . . . . . . . . . . . .120-25-4
Replace Right-Hand Chopper Rotor Remove Upper Tailings Auger . . . . . . . . . . . .120-25-8
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-32 Install Upper Tailings Auger . . . . . . . . . . . . . .120-25-9
Remove Straw Chopper Drive Jackshaft . . . .120-15-32 Remove Tailings Elevator . . . . . . . . . . . . . . .120-25-12
Install Straw Chopper Drive Jackshaft . . . . . .120-15-35 Install Tailings Elevator . . . . . . . . . . . . . . . . .120-25-19
Powered Tailboard—Exploded View . . . . . . .120-15-38
Remove and Install Powered Tailboard Group 30—Primary Countershaft Gear Case
Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-39 Essential or Recommended Tools . . . . . . . . . .120-30-1
Remove Straw Spreader . . . . . . . . . . . . . . . .120-15-41 Other Material . . . . . . . . . . . . . . . . . . . . . . . . .120-30-1
Disassemble and Assemble Straw Specifications . . . . . . . . . . . . . . . . . . . . . . . . .120-30-2
Spreader . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-44 Remove and Install Primary Countershaft
Install Straw Spreader . . . . . . . . . . . . . . . . . .120-15-48 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . .120-30-3
Disassemble and Assemble Primary
Group 20—Conveyor Augers, Cleaning Fan And Countershaft Gear Case . . . . . . . . . . . . . . .120-30-6
Chaffer And Sieve Frame
Other Material . . . . . . . . . . . . . . . . . . . . . . . . .120-20-1 Group 35—Header Electromagnetic Clutch
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .120-20-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . .120-35-1
Remove and Install Conveyor Auger Drive Remove Header Electromagnetic Clutch . . . . .120-35-1
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-20-3 Header Electromagnetic Clutch—Exploded
Remove and Install Conveyor Augers . . . . . . .120-20-6 View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-35-3
Remove and Install Conveyor Auger Install Header Electromagnetic Clutch . . . . . . .120-35-3
Trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-20-8
Remove and Install Conveyor Auger Slip
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-20-10
Remove and Install Cleaning Fan Sheave
and Bearing . . . . . . . . . . . . . . . . . . . . . . . .120-20-10
Fan Drive Speed Control. . . . . . . . . . . . . . . .120-20-16
Remove Cleaning Fan Drive . . . . . . . . . . . . .120-20-17
Disassemble and Assemble Cleaning Fan
Drive Jackshaft . . . . . . . . . . . . . . . . . . . . .120-20-20
Install Cleaning Fan Drive . . . . . . . . . . . . . . .120-20-21
Adjust Fan Speed Actuator . . . . . . . . . . . . . .120-20-23
Remove And Install Cleaning Fan . . . . . . . . .120-20-23
Remove and Install Cleaning Fan Blade
Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-20-29
Remove And Install Chaffer . . . . . . . . . . . . .120-20-30
Remove And Install Chaffer With Remote
Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-20-34
Remove And Install Sieve . . . . . . . . . . . . . . .120-20-35
Remove And Install Sieve With Remote
Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-20-37
Remove and Install Remote Shoe
Actuator Motor . . . . . . . . . . . . . . . . . . . . . .120-20-38
Remove and Install Front Chaffer
Element . . . . . . . . . . . . . . . . . . . . . . . . . . .120-20-40
Remove And Install Chaffer Frame . . . . . . . .120-20-42
Remove And Install Sieve Frame . . . . . . . . .120-20-44

083006
PN=2
Group 05
Separator Repair
NOTE: Order tools from the U.S. SERVICEGARD or RECOMMENDED TOOLS, as noted, are suggested to 120
05
European Microfiche Tool Catalogs. perform the job correctly. Some tools may be available 1
Catalogs.
OUO6083,0000AE4 –19–28APR06–1/9
Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG1268
Used to remove feed accelerator drive sheave.
–UN–04JUN01
H68321
OUO6083,0000AE4 –19–28APR06–2/9
Tine Separator Scoop Kit . . . . . . . . . . . . . . JDG10001
Used to remove STS Rotor assembly.
–UN–15JUL04
H81351
Continued on next page OUO6083,0000AE4 –19–28APR06–3/9

083006
PN=1085
Separator Repair
STS Rotor Drive Gear Case Bearing Driver . . . JDG13081
120 Used to install bearings on gear case shaft.

05
2
–UN–04JUN01
H68323
1
Recommended Tool available through service parts catalog.
OUO6083,0000AE4 –19–28APR06–4/9
Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . D01205AA1
Used to remove discharge beater drive hub.
1
OUO6083,0000AE4 –19–28APR06–5/9
Slave Cup Kit . . . . . . . . . . . . . . . . . . . . . . . JDG1269
Used to establish rotor drive gear case end play for final
preload setting.
–UN–25MAR02
H71403
OUO6083,0000AE4 –19–28APR06–6/9
RIVNUT Installation Tool . . . . . . . . . . . . . . JDG1316
Used to install RIVNUT threaded inserts.

–UN–04JUN01
H68325
RIVNUT is a trademark of Bollhoff. Continued on next page OUO6083,0000AE4 –19–28APR06–7/9

083006
PN=1086
Separator Repair
Compression Tool . . . . . . . . . . . . . . . . . . . . JDG1267
Remove and apply spring tension to torque sensing 120

05
sheave. 3
–UN–25MAR02
H71404
OUO6083,0000AE4 –19–28APR06–8/9
STS Combine Clearance Gauge . . . . . . . . . AH2049331
Used to inspect wear on threshing elements, tines and

concaves.
1
OUO6083,0000AE4 –19–28APR06–9/9
Other Material
Number Name Use
PT 569 (U.S.) NEVER-SEEZ Protects parts against extreme heat,

seizure, corrosion, rust and pitting.
TY6382-1 gal (U.S.) 80W/90 GL5 Gear Lube Lubricate STS Rotor drive gear case.
TY6252-5 gal (U.S.)
PM37521 (U.S.) Clear RTV Silicone Adhesive Sealant Sealing STS Rotor drive gear case
mating surfaces.
TY6341-14 oz (U.S.) Multi-Purpose, SD Polyurea Grease Especially effective in rolling contact

applications.
AN102562-14 oz (U.S.) Special Purpose Corn Head Grease Used to lubricate cam cavity of
torque sensing—driven.
AG,OUO1026,83 –19–28JUL05–1/1

083006
PN=1087
Separator Repair
Specifications
120 Item Measurement Specification
05
4
End of Feed Accelerator Length 140 mm
Shaft-to-Sidesheet (5-1/2 in.)
Feed Accelerator Sheave Nut Torque 308 N•m

(227 lb-ft)
Feed Accelerator Wing-to Hub Cap Torque 70 N•m

Screws (52 lb-ft)
Feed Accelerator Hub Clamp Cap Torque 70 N•m

Screws (52 lb-ft)
Tough Straw/Rice Feed Accelerator Torque 90 N•m

Wear Strip Round Head Bolts (66 lb-ft)
Standard Feed Accelerator Wear Torque 70 N•m

Strip Round Head Bolts (52 lb-ft)
Rear Top Cover Weight 55 kg

(121 lb)
Middle Top Cover Weight 56 kg

(124 lb)
Front Top Cover Weight 22 kg

(49 lb)
Tire and Wheel Weight 400 kg

(882 lb)
Front Wheel Bolts Torque 200 N•m + 1/4 turn

(150 lb-ft) + 1/4 turn
STS Rotor Front Bearing Housing Torque 250 N•m

Flange Nuts (184 lb-ft)
STS Rotor (Grain) Weight 429 kg

(947 lb)
STS Rotor (Rice) Weight 519 kg

(1143 lb)
STS Rotor Drive Coupler Cap Torque 240 N•m

Screws (177 lb-ft)

083006
PN=1088
Separator Repair
STS Rotor Torque Sensing—Driven; Weight 65 kg 120

05
Standard Duty (143 lb) 5
STS Rotor Torque Sensing—Driven; Weight 76 kg

Heavy Duty (168 lb)
Torque Sensing—Driven Sheave Capacity 40 cc

Lubrication Fitting
STS Rotor Torque Sensing—Driven, Torque 308 N•m

Locknut (227 lb-ft)
STS Rotor Driven Sheaves Gap 8.0 mm

(0.315 in.)
Torque Sensing Sheave-To-Hub Cap Torque 123 N•m

Screws (90 lb-ft)
Torque Sensing Sheave Cam Cavity Capacity 2.1 L

(70 oz)
Torque Sensing Sheave Cover Cap Torque 70 N•m

Screws (50 lb-ft)
STS Rotor Drive Gear Case Weight 76 kg

(168 lb)
Torque Sensing—Driven Gear Case; Weight 141 kg

Standard Duty (310 lb)
Torque Sensing—Driven Gear Case; Weight 153 kg

Heavy Duty (337 lb)
STS Rotor Drive Gear Case Capacity 4.7 L

(5.0 qt)
STS Rotor Drive Gear Torque 207 N•m

Case-to-Bulkhead Cap Screws (153 lb-ft)
STS Rotor Drive Gear Case Cover Torque 50 N•m

Input and Output Shaft (ONLY With End Play 0.05—0.15 mm

Slave Cups in Cover) (0.002—0.006 in.)

083006
PN=1089
Separator Repair
120 Input and Output Shaft Preload 0.05—0.15 mm

05
6
(0.002—0.006 in.)
Discharge Beater Sheave Cap Torque 70 N•m

Screws (52 lb-ft)
Discharge Beater Wing Hardware Torque 70 N•m

(52 lb-ft)
Assembled Grate Sections Weight 31 kg

(69 lb)
Threshing Bar Cap Screws Torque 90 N•m

(66 lb-ft)
Separator Tine Cap Screws Torque 90 N•m

(66 lb-ft)
Feed Flight Section Bolts Torque 140 N•m

(103 lb-ft)
OUO6083,0000DC2 –19–15AUG06–3/3
Remove And Install Feed Accelerator And

Shaft
NOTE: Feeder house does NOT need to be removed to

service feed accelerator.
–UN–21JAN99
CAUTION: To prevent an accidental start, lower
feeder house, shut off engine and remove key
from key switch.
H51815
1. Lower feeder house completely.
2. Remove both feeder house top doors (A and B). A—Top Door
B—Top Door
3. Remove right-hand front tire.

083006
PN=1090
Separator Repair
NOTE: It is not necessary to remove wear strips when

removing accelerator wings from standard feed
accelerator. 120
05
7
4. Standard Feed Accelerator Only:
–UN–30AUG05
Remove cap screws (A) and wings (B) from
accelerator hubs.
A—Cap Screws
H84348
B—Wing
Standard Feed Accelerator
OUO6083,0000DC3 –19–15AUG06–2/16
5. Tough Straw/Rice Feed Accelerator Only:
Remove round head bolts (A) and wear strips (B).
Remove cap screws (C) and wings (D) from

accelerator hubs.
–UN–15DEC03
A—Round Head Bolt
B—Wear Strip
C—Cap Screw
H79440
D—Wing
Tough Straw/Rice Feed Accelerator
OUO6083,0000DC3 –19–15AUG06–3/16
6. Clean ends of shaft enough to allow outer hubs to slide

to center.
7. Loosen shaft clamps (A) on end hubs and slide hubs

toward center of shaft. Remove keys from shaft.
–UN–20JAN99
A—Clamp
H51811

083006
PN=1091
Separator Repair
8. Loosen nut (A).
120 9. Use arm (B) to relieve belt tension. Remove belt from
05
8
sheave.
A—Nut
B—Belt Idler Arm
–UN–20JAN99
H51812
Feed Accelerator Drive Sheave
OUO6083,0000DC3 –19–15AUG06–5/16
10. Loosen nut and break sheave (A) loose from shaft
using JDG1268 Puller (B). Remove puller, nut, and
sheave.
A—Sheave
B—JDG1268 Puller
–UN–29JAN99
H51663
OUO6083,0000DC3 –19–15AUG06–6/16
11. Loosen set screw and remove locking collar (A).
12. Remove flanged housing with bearing (B).
A—Locking Collar
B—Bearing
–UN–13DEC01
H70488

083006
PN=1092
Separator Repair
13. Remove sensor (A), actuator (B) and locking collar

(C) from left-hand end of shaft.
120
05
14. Move shaft to right-hand side until hubs can be 9
removed.
15. Remove hubs and shaft.
–UN–20JAN99
16. Clean shaft with emery cloth and file to remove nicks
and burrs.
H51814
A—Sensor
B—Actuator
C—Locking Collar
OUO6083,0000DC3 –19–15AUG06–8/16
17. Install shaft from right-hand side until enough shaft is

inserted to install hubs. Install hubs in reverse order
as removed and insert shaft into left-hand bearing
assembly.
18. Align shaft and hub keyways; then install key (A) into
clamping hubs at each end of shaft.
–UN–21JAN99
A—Hub Key
H51817
Right-Hand Side Shown
OUO6083,0000DC3 –19–15AUG06–9/16
19. Install right-hand flanged bearing assembly (B) and

position locking collar (A) but do not tighten.
A—Locking Collar
B—Bearing Assembly
–UN–13DEC01
H70488

083006
PN=1093
Separator Repair
20. Measure from sidesheet to end of shaft and position

shaft at specified dimension. Tighten locking collar in
120 direction of shaft rotation. Tighten set screw.
05
10
Specification
End of Feed Accelerator
Shaft-to-Sidesheet—Length .......................................................... 140 mm
–UN–13DEC01
(5-1/2 in.)
H70489
OUO6083,0000DC3 –19–15AUG06–11/16
21. Install key, drive sheave, washer and nut (A). Tighten
nut to specification.
Specification
Feed Accelerator Sheave Nut—
Torque .......................................................................................... 308 N•m
(227 lb-ft)
22. Position drive belt on sheave and tension belt using

arm (B).
–UN–20JAN99
A—Nut
B—Belt Idler Arm
H51812

083006
PN=1094
Separator Repair
23. Standard Feed Accelerator Only:
Install two wings. Ensure that wear strips (A) alternate 120
05
on adjoining wings. 11
24. Center hubs between sidesheets and tighten clamps

on end hubs to specification.
–UN–21JAN99
25. Install remaining wings leaving hardware finger tight
until all wings are installed. Tighten hardware to
H51818
specification.
Specification Standard Feed Accelerator

Feed Accelerator Wing-to Hub
Cap Screws—Torque ..................................................................... 70 N•m A—Wear Strips
(52 lb-ft)
Feed Accelerator Hub Clamp Cap
Screws—Torque ............................................................................. 70 N•m
(52 lb-ft)

083006
PN=1095
Separator Repair
26. Tough Straw/Rice Feed Accelerator Only:
120 Install wing with access holes (A) inline with hub
05
12
clamping cap screws (B).
27. Install remaining wings and wear strips leaving
–UN–15DEC03
hardware finger tight.
28. Tighten all wear strip round head bolts (C) prior to
wing cap screws (D). Tighten all hardware to
H79441
specification.
Specification Tough Straw/Rice Feed Accelerator

Tough Straw/Rice Feed
Accelerator Wear Strip Round A—Access Hole (2 used)
Head Bolts—Torque ....................................................................... 90 N•m B—Cap Screw (2 used)
(66 lb-ft) C—Round Head Bolt (60 used)
Feed Accelerator Wing-to Hub D—Cap Screw (50 used)
(52 lb-ft)
29. Center accelerator between sidesheets and tighten

hub clamps to specification.
Specification
Feed Accelerator Hub Clamp Cap
Screws—Torque ............................................................................. 70 N•m
(52 lb-ft)
OUO6083,0000DC3 –19–15AUG06–14/16
30. Install locking collar (C) and tighten in direction of

shaft rotation. Tighten set screw.
31. Install actuator (B) and sensor (A).
32. Install right-hand tire.

–UN–20JAN99
A—Sensor
B—Actuator
C—Locking Collar
H51814

083006
PN=1096
Separator Repair
33. Install feeder house top doors (A and B).
120
A—Top Door 05
B—Top Door 13
–UN–21JAN99
H51815
OUO6083,0000DC3 –19–15AUG06–16/16
Remove and Install Feed Accelerator Wear

Strips

from key switch.
NOTE: Feeder house does NOT need to be removed to

service feed accelerator.
This feed accelerator is not balanced at the factory nor

does it have to be balanced in the field. However, it is
critical that all of the wear strips or wings are equal in
weight, as you would find the hammers on a straw
chopper rotor.
If any of the strips are missing or if they are worn to the

point of reducing the height of the strip, then replace all of
them (30 standard, 60 rice).
OUO6083,0000DC1 –19–15AUG06–1/3
2. Remove both feeder house top doors (A and B).
A—Top Door
B—Top Door
–UN–21JAN99
H51815

083006
PN=1097
Separator Repair
3. Remove round head bolt (A) from wear strip (B).

120
05
14
4. Install wear strip (B) using round head bolt (A). Tighten
to specification.
–UN–30AUG05
Specification
Standard Feed Accelerator Wear
Strip Round Head Bolts—Torque .................................................. 70 N•m
(52 lb-ft)
Tough Straw/Rice Feed
H84351
Accelerator Wear Strip Round
Head Bolts—Torque ....................................................................... 90 N•m
(66 lb-ft) Standard Wear Strip
A—Round Head Bolt

B—Wear Strip
–UN–16DEC03
H79472
Tough Straw/Rice Wear Strip
OUO6083,0000DC1 –19–15AUG06–3/3
Remove And Install Separator Top Covers
1. Open gull wing doors and remove inspection covers

(A) from both sides.
2. Remove sheet metal filler plates (B) from right- and
–UN–04FEB02
left-hand sides of separator.
3. Remove separator grates (C) to access separator tines

and/or seal cap screws. (See REMOVE AND INSTALL
SEPARATOR GRATES in this group.) H70739
A—Inspection Covers
B—Dust Cover
C—Grates
–UN–07JAN02
H70738

083006
PN=1098
Separator Repair
4. Remove clamp (A), four cap screws (B), and air

deflector (C).
120
05
A—Clamp 15
C—Air Deflector
–UN–07MAY01
H67375
OUO6083,0000A84 –19–14JUL05–2/13
5. In engine compartment, remove cap screws (A) and

step (B).

B—Step
–UN–07MAY01
H67378
OUO6083,0000A84 –19–14JUL05–3/13
6. Remove tube (A) and hose (B).
7. Remove shield (C) and channel (D).
A—Tube
B—Hose
–UN–17MAY01
C—Shield
D—Channel
H68093

083006
PN=1099
Separator Repair
8. Remove clamps (A), (B), cap screws (C) and muffler

(D).
120
05
16 A—Clamp
B—Clamp
D—Muffler
–UN–04JAN01
H65672
OUO6083,0000A84 –19–14JUL05–5/13
9. Remove cap screws and seal (A) between middle and

rear top covers.
A—Seal
–UN–08FEB99
H51829
OUO6083,0000A84 –19–14JUL05–6/13
CAUTION: The approximate weight of rear top

cover is 55 kg (121 lb). Use three people in the
removal of the top covers.
Specification
Rear Top Cover—Weight .................................................................. 55 kg
–UN–07JAN02
(121 lb)
10. Remove cap screws from rear top cover (A). With the
aid of others, remove cover out through engine
H70740
compartment.
A—Rear Cover

083006
PN=1100
Separator Repair
12. Remove hood (C). 120

05
17
13. Remove seal from between front and middle top
covers.
–UN–04JAN01
A—Top Door
B—Top Door
C—Hood
H65696
OUO6083,0000A84 –19–14JUL05–8/13
CAUTION: Approximate weight of front top

Specification
Front Top Cover—Weight ................................................................. 22 kg
–UN–01DEC04
(49 lb)
14. Remove cap screws (A) and front top cover (B). With
the aid of others, remove cover out front of combine.
H82078
A—Cap Screw
B—Front Top Cover
OUO6083,0000A84 –19–14JUL05–9/13
NOTE: Center concave is removed to gain access to the

tailings auger flange.
15. Remove spring locking pin and two-piece retainer (A)

from center concave. –UN–13MAY03
A—Concave Retainer
H76917

083006
PN=1101
Separator Repair
16. Remove cap screws (A) and center concave (B).
120
18 B—Concave
–UN–08FEB99
H51837
OUO6083,0000A84 –19–14JUL05–11/13
17. Loosen clamp and slide boot (A) away from upper
tailings auger flange.
18. Remove cap screws (B) and separate flange from

middle top cover.
–UN–11JUN03
A—Boot
H77756
OUO6083,0000A84 –19–14JUL05–12/13
CAUTION: Approximate weight of middle top

Specification
Middle Top Cover—Weight ............................................................... 56 kg
–UN–04JAN01
(124 lb)
19. Remove front seal (A) and cap screws (B) from
middle top cover (C). With the aid of others, remove
cover out through engine compartment. H65694
20. Inspect all parts for wear or damage. Replace as Left-Hand Side Shown
necessary.
A—Front Seal
B—Cap Screw
21. Reinstall top covers in reverse order of disassembly. C—Middle Top Cover
OUO6083,0000A84 –19–14JUL05–13/13

083006
PN=1102
Separator Repair
Remove and Install Separator Rails
NOTE: Front tires are removed from machine for better 120
05
access. 19
NOTE: If both rails are worn or damaged, it is

recommended to replace both at the same time.
CAUTION: Grain tank must be empty and

header removed.
–UN–05APR99
H55107
from key switch.
1. Lower feeder house.

A—Jack
2. Loosen wheel bolts one turn. Do not remove at this B—Jacking Pocket
time.
CAUTION: Block up front axle before removing

wheels.
CAUTION: Jack must have a minimum rating of

5443 kg (6 ton).
3. Raise combine using jack (A) positioned in jacking

pocket (B). Jacking pockets are located on either side
of combine near the feeder house lift cylinder
attachment points.
4. Block up front axle or install JT02043 12-Ton Support

Stand.
5. Support tire and wheel and remove wheel bolts and

front tire and wheel.
Specification
Tire and Wheel— Weight ................................................................ 400 kg
(882 lb)
6. Remove right- and left-hand shields.

083006
PN=1103
Separator Repair
120
05 A—Top Door
20 B—Top Door
–UN–21JAN99
H51815
OUO6083,0000875 –19–28JUN04–2/12
8. Disconnect hose clamps (A) and remove plastic hood

(B).
9. Remove hood support plate (C) from brackets (D).
10. Remove separator inspection covers. (See REMOVE

AND INSTALL SEPARATOR TOP COVERS in this
–UN–17JUL01
group.)
11. Remove separator grates. (See REMOVE AND
H69321
INSTALL SEPARATOR GRATES in this group.)
12. Remove center concave section. (See REMOVE and

INSTALL CONCAVE SECTIONS in this group.) A—Clamp (2 used)
B—Hood
C—Plate
13. Remove separator top covers. (See REMOVE AND D—Bracket (2 used)
INSTALL SEPARATOR TOP COVERS in this group.)

083006
PN=1104
Separator Repair
14. Left-hand side:
Remove bolts (A—E) from separator rail. 120

05
A—Cap Screw and Nut (4 used) 21
B—Cap Screw and Nut (2 used)
C—Cap Screw and Nut (2 used)
D—Cap Screw and Nut (3 used)
–UN–07JAN02
H70742
–UN–13DEC00
H65565
–UN–13DEC00
H65566
–UN–13DEC00
H65567

083006
PN=1105
Separator Repair
15. Right-hand side:
120 Remove cap screws (A—D) from separator rail.

05
22
16. Remove cap screws (G).
17. After rail is removed, remove cap screws (E) and
–UN–07JAN02
bracket (F) and install onto new right-hand rail.
A—Cap Screw and Nut (4 used)
H70741
F—Bracket
G—Cap Screw and Nut (2 used)
–UN–18DEC00
H65628
–UN–18DEC00
H65629
–UN–18DEC00
H65630

083006
PN=1106
Separator Repair
NOTE: Once hardware is removed, separator rail will

need to be raised approximately 100 mm (4 in.) at
front of combine to clear front bulkhead. 120
05
23
18. Using an assistant, guide left-hand separator rail (A)
out front of combine.
19. Guide right-hand rail out front of combine using a
–UN–15DEC00
similar method.
A—Separator Rail
H65616
OUO6083,0000875 –19–28JUN04–6/12
20. Remove round head bolts (A), cast plate (B), and
concave stop bolts (C) from left-hand rail and install
onto new rail.
A—Round Head Bolts (5 used)

B—Cast Plate
–UN–13DEC00
C—Concave Stop Bolts
H65568
–UN–18DEC00
H65624

083006
PN=1107
Separator Repair
21. Install separator rail(s) (A) through front of combine.
120
05 A—Separator Rail (Right-Hand)
24
–UN–15MAR02
H71320
Right-Hand Shown

083006
PN=1108
Separator Repair
22. Left-hand side:
Install bolts (A—E) in separator rail. 120

05
–UN–07JAN02
H70742
–UN–13DEC00
H65565
–UN–13DEC00
H65566
–UN–13DEC00
H65567

083006
PN=1109
Separator Repair
23. Right-hand side:
120 Install bolts (A—E) in separator rail.

05
26
24. Install separator top covers. (See REMOVE AND
INSTALL SEPARATOR TOP COVERS in this group.)
–UN–07JAN02
25. Install center concave section. (See REMOVE and
INSTALL CONCAVE SECTIONS in this group.)
H70741
26. Install separator grates. (See REMOVE AND
27. Adjust concave level. (See ADJUST CONCAVE

LEVEL in this group.)
28. Install separator inspection covers. (See REMOVE

AND INSTALL SEPARATOR TOP COVERS in this
group.)
–UN–18DEC00
H65628
–UN–18DEC00
H65636
–UN–18DEC00
H65637

083006
PN=1110
Separator Repair
29. Install plastic hood (B) and connect hose clamps (A).
30. Install hood support plate (C). 120

05
27
A—Clamp (2 used)
B—Hood
–UN–17JUL01
C—Plate
D—Bracket (2 used)
H69321
OUO6083,0000875 –19–28JUN04–11/12
31. Install both feeder house top doors (A and B).
CAUTION: The approximate weight of tire and

wheel is 400 kg (882 lb) (without liquid ballast).
Specification
–UN–21JAN99
Tire and Wheel—Weight ................................................................. 400 kg
(882 lb)
32. Install wheels. Tighten bolts to specification.
H51815
Specification
Front Wheel Bolts—Torque ......................................... 200 N•m + 1/4 turn
(150 lb-ft) + 1/4 turn
A—Top Door
B—Top Door
OUO6083,0000875 –19–28JUN04–12/12
Remove And Install STS Rotor Front Bearing
A—Top Door
B—Top Door
–UN–21JAN99
H51815

083006
PN=1111
Separator Repair
2. Remove all separator inspection covers (A) on both

sides of machine.
120
05
28
3. Close concave.
A—Inspection Cover (10 used)
–UN–11MAR02
H71280
OUO6083,0000876 –19–28JUN04–2/9
4. Remove spring locking pin and two-piece retainer (A)

from center concave.
A—Concave Retainer
–UN–13MAY03
H76917
OUO6083,0000876 –19–28JUN04–3/9
5. Remove cap screws (A) and center concave (B).

B—Concave
–UN–08FEB99
H51837

083006
PN=1112
Separator Repair
6. Open concave and install support block (A) between

concave and rotor.
120
05
7. Close concave until block contacts rotor. This will 29
support rotor when bearing is removed.
–UN–08FEB99
8. Position additional block (B) across separator rails
between front concave and threshing element (C). This
will prevent forward movement of rotor when servicing
front bearing.
H51838
A—Block
B—Block
C—Threshing Element
–UN–08FEB99
H51839
OUO6083,0000876 –19–28JUN04–5/9
9. Remove plastic hood (A) and plate (B).
A—Hood
B—Plate
–UN–08FEB99
H51840
Feeder House Removed For Clarity

083006
PN=1113
Separator Repair
10. Remove shield (A).
120 11. Disconnect lubrication line (B) from sidesheet.

05
30
12. Disconnect sensor (C).
–UN–08FEB99
13. Remove bracket (D) and sensor.
14. Loosen set screw and remove tone wheel (E).
H51841
A—Shield
B—Lubrication Line
C—Sensor
D—Bracket
E—Tone Wheel
OUO6083,0000876 –19–28JUN04–7/9
15. Loosen set screw and remove locking collar (A) by

turning clockwise.
16. Remove nuts and bearing housing (B).
A—Locking Collar
–UN–08FEB99
B—Bearing Housing
H51968
OUO6083,0000876 –19–28JUN04–8/9
17. Turn bearing (A) to remove from housing (B).
18. Inspect all parts for wear or damage. Replace as

necessary.
19. Install flanged bearing assembly. Tighten nuts to

–UN–27JUL89
specification.
Specification
STS Rotor Front Bearing Housing
Flange Nuts—Torque ................................................................... 250 N•m
H41174
(184 lb-ft)
20. Install locking collar and tighten in direction of shaft

A—Bearing
rotation (counterclockwise viewed from front). Tighten B—Housing
set screw.
OUO6083,0000876 –19–28JUN04–9/9

083006
PN=1114
Separator Repair
Remove and Install Stone Trap Door

120
CAUTION: When working under the feeder 05
house always place the hydraulic cylinder 31
–UN–21SEP89
TS696
A—Safety Stop
–UN–12MAY03
H76859
OUO6083,0000DC0 –19–15AUG06–1/5
3. Earlier models:
a. Move lever (A) upward to open stone trap.
A—Lever
–UN–06FEB04
H80233
OUO6083,0000DC0 –19–15AUG06–2/5
b. Remove cotter pins (B) and pins (C).
c. Remove stone trap door (A).
A—Stone Trap Door

B—Cotter Pin (2 used)
–UN–18JUL05
C—Pin (2 used)
H84001

083006
PN=1115
Separator Repair
4. Later models:
120 a. Move lever (A) upward to open stone trap.

05
32
A—Lever
–UN–05JUL06
H86270
OUO6083,0000DC0 –19–15AUG06–4/5
b. Remove cotter pins (A) on both sides.
Remove cap screws and nuts (B) from both sides.
Pull hinge pins (C) out of sidesheets on both sides

and remove stone trap door.
–UN–05JUL06
H86272
A—Cotter Pin (2 used)
B—Cap Screw and Lock Nut (2 used)
C—Hinge Pin (2 used)
D—Stone Trap Door
OUO6083,0000DC0 –19–15AUG06–5/5
Remove and Install STS Rotor
1. Remove feeder house. (See REMOVE FEEDER

HOUSE in Section 110, Group 05.)
2. Remove feed plate (A). (See REMOVE AND INSTALL

–UN–12FEB99
FEED PLATE in Section 110, Group 05.)
3. Remove feed accelerator and shaft. (See REMOVE

AND INSTALL FEED ACCELERATOR AND SHAFT in
H51976
this group.)
A—Feed Plate
Continued on next page OUO6083,0000ABE –19–28JUL05–1/10

083006
PN=1116
Separator Repair
4. Remove separator inspection covers (A) from both

sides of combine.
120
05
5. Remove separator grates. (See REMOVE AND 33
6. Remove separator tines. (See REMOVE AND
–UN–07JAN02
INSTALL SEPARATOR TINES in this group.)
7. Open concave.
H70744
A—Covers
OUO6083,0000ABE –19–28JUL05–2/10
8. Disconnect hose clamps (A) and remove plastic hood

(B).
9. Remove hood support plate (C).
10. Remove support plate brackets (D).
–UN–17JUL01
A—Clamp (2 used)
B—Hood
C—Plate
H69321
D—Bracket (2 used)
OUO6083,0000ABE –19–28JUL05–3/10
11. Remove support (A) from both sidesheets.
A—Support
–UN–12FEB99
H51971

083006
PN=1117
Separator Repair
120
05 A—Shield
34
–UN–23JAN02
H70993
OUO6083,0000ABE –19–28JUL05–5/10
13. Disconnect sensor connector (A). Pull harness back

through hole in bearing support.
14. Disconnect two lubrication lines (B) from sidesheet.
15. Remove sensor bracket (C).
–UN–23JAN02
16. Loosen set screw and remove tone wheel (D).
A—Connector
H70994
B—Lubrication Lines
C—Bracket
D—Tone Wheel
OUO6083,0000ABE –19–28JUL05–6/10
17. Remove cap screws (A) and feed accelerator drive

belt idler arm and pivot assembly (B).

B—Idler Arm and Pivot
–UN–12FEB99
H51974

083006
PN=1118
Separator Repair
18. Rotate rotor so feed flights (A) are parallel with

bearing support (B) as shown. C A A C
B 120
05
19. Attach JDG10001 Tine Separator Scoop (D) with 35
forklift to bearing support plate using pins (C).
CAUTION: Approximate weight of STS grain

rotor is 429 kg (947 lb). Approximate weight of
STS rice rotor is 519 kg (1143 lb). Use
JDG10001 Tine Separator Scoop and John
Deere 480 forklift or unit of equal capacity.
–UN–22JAN02
Specification D
STS Rotor (Grain)—Weight............................................................. 429 kg
(947 lb)
H70756
STS Rotor (Rice)—Weight .............................................................. 519 kg
(1143 lb)
20. Remove cap screws attaching front bearing support A—Rotor Feed Flights
B—Support
(B).
C—Pins
D—JDG10001 Tine Separator Scoop
OUO6083,0000ABE –19–28JUL05–8/10
21. Carefully remove rotor assembly by slowly driving

forklift in reverse while lowering forks.
–UN–12FEB99
H51975

083006
PN=1119
Separator Repair
22. Prior to installing STS Rotor, apply TY24811

NEVER-SEEZ lubricant to output shaft splines (A) of
120 STS Rotor drive gear case.
05
36
23. Inspect drive coupler (B) isolator bushings. Replace
coupler if necessary. Tighten coupler cap screws to
–UN–12FEB99
specification.
Specification
STS Rotor Drive Coupler Cap
Screws—Torque ........................................................................... 240 N•m
H51977
(177 lb-ft)
STS Rotor Drive Output Shaft

24. Position rotor assembly and align splines of output
shaft with splines of STS Rotor drive coupler.
NOTE: Be sure to place rotor drive gear case in gear.

Rotate the rotor drive sheaves to aid in lining up
of shafts.
25. Install front bearing support cap screws. Remove
–UN–12FEB99
JDG10001 Tine Separator Scoop and forklift.
26. Finish installing in reverse order.
H51978
A—Output Shaft Splines
B—Drive Coupler STS Rotor Drive Coupler
OUO6083,0000ABE –19–28JUL05–10/10
Replace Rear Bulkhead (Rotor Drive Gear

Case Support)
If replacement is necessary, call Harvester DTAC for

information on alignment of support. Special tools are
required to align gear case support (A) to front STS rotor
–UN–14APR00
bearing support.
A—Gear Case Support

H63631
AG,OUO6022,1348 –19–25JUL00–1/1

083006
PN=1120
Separator Repair
Remove and Install STS Rotor Torque

Sensing—Driven
120
05
1. With separator engaged and running, set STS Rotor 37
drive in low speed position so driven sheaves on gear
case are closed.
CAUTION: To prevent accidental starting, shut

off engine and remove key.
2. Shift STS Rotor drive gear case to neutral position.
Continued on next page OUO6083,00007EE –19–28JUL05–1/5

083006
PN=1121
Separator Repair
3. Loosen cap screws (A), draw bolt (B) and fully rotate
gear case to left-hand side of machine using draw bolt.
120
05
38
4. Remove drive belt (C).
CAUTION: Approximate weight of STS Rotor
–UN–08JAN99
torque sensing—driven (standard duty) is 65 kg
(143 lb), heavy duty is 76 kg (168 lb). Use
proper lifting device.
H51755
Specification
STS Rotor Torque Sensing—
Standard Duty Driven—Weight ......................................................... 65 kg
(143 lb)
Heavy Duty Driven—Weight.............................................................. 76 kg
(168 lb)
5. Remove plug (D), O-ring, lock nut (E) and washer.
–UN–30APR99
6. Remove torque sensing—driven from gear case.
NOTE: Prior to installation, check sheave on torque

sensing—driven for specified amount of grease.
H55597
Prior to installation, check cam cavity of torque
sensing—driven for specified amount
(Approximately 5 tubes) of corn head grease.
7. Apply NEVER-SEEZ lubricant on splines (G) of STS

Rotor drive gear case input shaft.
Specification
–UN–28APR99
Torque Sensing—Driven Sheave
Lubrication Fitting—Capacity............................................................. 40 cc
Specification
Torque Sensing—Driven Cam
H51756
Cavity—Capacity ................................................................... 2.1 L (70 oz)
8. Position STS Rotor torque sensing—driven on input

A—Cap Screw (4)
shaft. B—Draw Bolt
C—Belt
D—Plug
E—Lock Nut
F—Shoulder
G—Splines

083006
PN=1122
Separator Repair
IMPORTANT: A new lock nut (E) must be used to

install torque sensing assembly. Failure
to do so may result in machine damage. 120
05
39
9. Install washer, new lock nut, O-ring and plug (D).
Specification
Driven, Locknut—Torque.............................................................. 308 N•m
(227 lb-ft)
NOTE: Gear case must be rotated as far to the left-hand

side as travel permits. This will make belt
installation easier.
10. Install drive belt (C).
OUO6083,00007EE –19–28JUL05–3/5
11. Tighten draw bolt until specified sheave gap (A) is

achieved.
Specification
STS Rotor Driven Sheaves—Gap.................................................. 8.0 mm
(0.315 in.)
–UN–10MAY99
NOTE: Operate separator and recheck sheaves for
specified gap.
H56068
A—Sheave Gap

083006
PN=1123
Separator Repair
NOTE: There is no recommended service interval for

grease cavity. It should be refilled only if drive has
120 been disassembled and has been rebuilt. TY6341
05
40
grease should be used in all other 200 hour
grease fittings in this drive, as shown in operators
manual.
–UN–14DEC00
12. Check torque sensing—driven sheave for proper
grease level as follows:
H65591
Start engine and run rotor speed to maximum.
• Shut off engine and remove key.
• Remove plug (A).
• Grease level should be approximately 2 inches A—Plug
below bottom of hole.
• Use corn head grease to bring grease up to this
level if necessary.
OUO6083,00007EE –19–28JUL05–5/5

083006
PN=1124
Separator Repair
Disassemble and Assemble STS Rotor

Torque Sensing—Driven
120
05
1. Remove STS Rotor torque sensing—driven. (See 41
A—Valve
B—Plug
C—O-Ring
D—Nut
E—Washer
G—Cover
H—Snap Ring
I—Cam
J—Thrust Washer (2 used)
K—Spring
L—O-Ring (2 used)
M—Cam Ring
N—Seal
O—Snap Ring (2 used on earlier machines)
–UN–24APR00
P—Bushing (2 used on earlier machines)
Q—Sheave
R—Lubrication Fitting
S—Lubrication Fitting
T—Snap Ring
H63658
U—Sheave
V—Hub
W—Cap Screw (6 used)
OUO6083,0000A04 –19–15JUN06–1/13
2. Remove plug (A) and O-ring.
3. Remove six cap screws (B), and cover (C).
A—Plug
B—Cap Screw (6 Used)
C—Cover
–UN–24APR00
H63704

083006
PN=1125
Separator Repair
CAUTION: Spring under cam is compressed. To

120 avoid injury, use ONLY recommended spring
05 compressor to release spring tension.
42
Use wrench to prevent movement of nut (A)
while turning nut (B).
4. Install JDG1267 Compression Tool and compress

spring until snap ring (C) can be removed.
–UN–12MAY99
5. Remove snap ring (C).
6. Loosen nuts (B) equally until spring is no longer

compressed. Remove JDG1267 Compression Tool.
H54844
A—Nut (2 used)
B—Nut (2 used)
C—Snap Ring
–UN–26MAR99
H54845

083006
PN=1126
Separator Repair
7. Remove cam (I), thrust washers (J) and spring (K).
8. Remove cam ring (M). 120

05
43
9. Remove O-rings (L) from both sides of cam ring (M).
A—Valve
B—Plug
C—O-Ring
D—Nut
E—Washer
G—Cover
H—Snap Ring
I—Cam
K—Spring
L—O-Ring (2 Used)
M—Cam Ring
N—Seal
Q—Sheave
–UN–24APR00
T—Snap Ring
U—Sheave
H63658
V—Hub
–UN–24APR00
H63698

083006
PN=1127
Separator Repair
120
05
44
–UN–24APR00
H63657
A—Sheave C—Snap Ring D—Bushing (2 used on earlier E—Snap Ring (2 used on
B—Seal machines) earlier machines)
NOTE: Seals (B) are press fit. 11. Remove snap rings (E) and bushings (D) from
sheave (A).
10. Remove snap ring (C), and seals (B).

083006
PN=1128
Separator Repair
12. Remove six cap screws (A) and sheave (B) from hub
(C).
120
05
13. Clean and inspect parts. Replace as necessary. 45
A—Cap Screw
B—Sheave
C—Hub
–UN–26MAR99
H54846
OUO6083,0000A04 –19–15JUN06–6/13
14. Attach sheave (B) to hub (C) using six cap screws
(A). Tighten cap screws to specification.
Specification
Torque Sensing Sheave-To-Hub
(90 lb-ft)
A—Cap Screw
B—Sheave
–UN–26MAR99
C—Hub
H54846

083006
PN=1129
Separator Repair
120
05
46
–UN–24APR00
H63657
A—Sheave C—Snap Ring D—Bushing (2 used on earlier E—Snap Ring (2 used on
B—Seal machines) earlier machines)
15. Apply TY6341 Multi-Purpose SD Polyurea Grease 16. Install snap rings (E) into sheave (A).
to bushings (D) and install into sheave (A).

083006
PN=1130
Separator Repair
NOTE: Seals (B) are press fit.
IMPORTANT: Install top seal (A) with steel backing IN. 120
05
Install bottom seal with (B) steel 47
backing OUT.
–UN–24APR00
17. Coat seals (A and B) with TY6341 Multi-Purpose SD
Polyurea Grease and press into sheave.
18. Install snap ring (C).
H63700
A—Seal
B—Seal
C—Snap Ring
–UN–24APR00
H63699
–UN–24APR00
H63701

083006
PN=1131
Separator Repair
19. Slide assembled sheave (Q) over hub shaft (V) until it
contacts sheave (U).
120
05
48
20. Install O-rings (L) on cam ring (M).
21. Install cam ring (M) onto sheave (Q).
22. Install spring (K), thrust washers (J) and cam (I).
A—Valve
B—Plug
C—O-Ring
D—Nut
E—Washer
G—Cover
H—Snap Ring
I—Cam
K—Spring
L—O-Ring
–UN–24APR00
M—Cam Ring
N—Seal
Q—Sheave
H63658
T—Snap Ring
U—Sheave
V—Hub

083006
PN=1132
Separator Repair
CAUTION: To avoid injury, use ONLY

recommended spring compressor to apply 120
spring tension. 05
49
IMPORTANT: Use wrench to prevent movement of nut
(A) while turning nut (B).
23. Install JDG1267 Compression Tool and compress

spring until snap ring (C) can be installed.
–UN–12MAY99
24. Install snap ring.
25. Remove compression tool.
H54844
A—Nut
B—Nut
C—Snap Ring
–UN–26MAR99
H54845
OUO6083,0000A04 –19–15JUN06–11/13
26. Fill cavity (A) with corn head grease (approximately 5

tubes).
Specification
Torque Sensing Sheave Cam
Cavity—Capacity ................................................................................ 2.1 L
(70 oz)
–UN–12MAY99
A—Cavity
H55008

083006
PN=1133
Separator Repair
NOTE: Ensure cover is fully seated in groove.
120 27. Install six cap screws (B), cover (C) and O-ring.
05
50
Tighten cap screws to specification.
Specification
Torque Sensing Sheave Cover
(50 lb-ft)
28. Install plug (A) and O-ring.
29. Install STS Rotor torque sensing—driven. (See
–UN–24APR00
A—Plug
H63704
C—Cover
OUO6083,0000A04 –19–15JUN06–13/13
Remove and Install STS Rotor Drive Gear

Case
1. With separator engaged and running, set separator

drive in low speed position so driven sheaves on gear
case are closed.
CAUTION: To prevent accidental starting shut

off engine and remove key.
2. Shift STS Rotor drive gear case to the neutral position.
Continued on next page OUO6083,00007EC –19–28JUL05–1/4

083006
PN=1134
Separator Repair
3. Remove spring locking pin and washer to disconnect

linkage (A) from gear case shifting arm.
120
05
4. Loosen cap screws (C). 51
5. Loosen jam nuts on draw bolt (B).
–UN–27APR00
6. Remove spring locking pin, washers, pin (E) and draw
bolt. Fully rotate gear case to left-hand side of
machine.
H63748
7. Remove drive belt (D) and cap screws (C).
CAUTION: Approximate weight of STS rotor

torque sensing—driven (standard duty) is 65 kg
(143 lb), heavy duty is 76 kg (168 lb).
Approximate weight of STS rotor drive gear
case is 76 kg (168 lb). Approximate combined
weight of torque sensing—driven (standard
–UN–27APR00
duty) and gear case is 141 kg (310 lb).
Approximate combined weight of torque
sensing—driven (heavy duty) and gear case is
153 kg (337 lb). Use proper lifting device.
H63746
Specification
Driven (Standard Duty)—Weight ....................................................... 65 kg
(143 lb)
Driven (Heavy Duty)—Weight ........................................................... 76 kg
(168 lb)
STS Rotor Drive Gear Case—
Weight................................................................................................ 76 kg
–UN–27APR00
(168 lb)
Torque Sensing—Driven
(Standard Duty) and Gear
Case—Weight.................................................................................. 141 kg
(310 lb)
H63749
Torque Sensing—Driven (Heavy
Duty) and Gear Case—Weight ....................................................... 153 kg
(337 lb)
A—Shift Linkage
8. Remove gear case and torque sensing—driven as an B—Draw Bolt
assembly. C—Cap Screw (4 Used)
D—Belt
E—Pin
9. Separate torque sensing—driven from gear case. (See
REMOVE AND INSTALL STS ROTOR TORQUE
SENSING—DRIVEN in this group.)

083006
PN=1135
Separator Repair
10. If gear case is to be replaced, drain oil, remove drain

valve and install on new gear case.
120
05
52
11. Fill gear case with 80W/90 GL5 Gear Lube to knurled
part of dipstick.
Specification
Capacity .............................................................................................. 4.7 L
(5.0 qt)
12. Install torque sensing—driven to gear case. (See

REMOVE AND INSTALL STS ROTOR TORQUE
SENSING—DRIVEN in this group.)
13. Install gear case and torque sensing—driven as an

assembly.

083006
PN=1136
Separator Repair
14. Install cap screws (C) finger tight. Install drive belt
(D).
120
05
15. Install draw bolt (B), pin (E), two washers and spring 53
locking pin. Tighten draw bolt until specified sheave
gap is achieved.
–UN–27APR00
Specification
STS Rotor Driven Sheaves—Gap...................................................... 8mm
(0.315 in.)
H63748
16. Tighten cap screws (C) to specifications.
Specification
STS Rotor Drive Gear
Case-to-Bulkhead Cap Screws—
Torque .......................................................................................... 207 N•m
(153 lb-ft)
17. Attach linkage (A), washer and spring locking pin to

shifting arm.
–UN–27APR00
18. Attach drain hose to hose clamps.
NOTE: Operate separator and recheck sheaves for
H63746
specified gap.
A—Shift Linkage
B—Draw Bolt
C—Cap Screw (4 Used)
D—Drive Belt
E—Pin
F—Sheave Gap
–UN–27APR00
H63749
–UN–27APR00
H63751
OUO6083,00007EC –19–28JUL05–4/4

083006
PN=1137
Separator Repair
Disassemble and Assemble STS Rotor Drive

Gear Case
120
05
54 CAUTION: Approximate weight of gear case is
76 kg (168 lb).
Specification
Weight................................................................................................ 76 kg
(168 lb)
1. Remove gear case from machine. (See REMOVE AND

INSTALL STS ROTOR DRIVE GEAR CASE in this
group.)
2. Drain gear case oil (if not drained before removal) and
remove drain hose.
OUO6083,00007EB –19–28JUL05–1/10
3. Remove dipstick (A).
A—Dipstick
–UN–31MAR99
H54965
OUO6083,00007EB –19–28JUL05–2/10
4. Remove plug (A), spring (B) and pin (C) from cover
(D).
A—Plug
B—Spring
C—Pin
–UN–29MAR99
D—Cover
H54964
Continued on next page OUO6083,00007EB –19–28JUL05–3/10

083006
PN=1138
Separator Repair
5. Remove cap screws (A) from gear case.
6. Remove cover. 120

05
55
–UN–29MAR99
H54885
OUO6083,00007EB –19–28JUL05–4/10
7. Remove output gear shaft assembly (A), shift fork (B)

and input shaft (C).
A—Output Gear Assembly

B—Shift Fork
C—Input Shaft
–UN–29MAR99
H54959

083006
PN=1139
Separator Repair
NOTE: Low gear and high gear assemblies are similar.
120 8. Remove bearing cones using a press.

05
56
9. Inspect the following and clean or replace as
–UN–31MAR99
necessary:
• Output shaft (high and low side)

– Gear teeth
H55044
– Thrust washers
– Needle bearings
– Spacers Low Gear Assembly Shown
– Shaft A—Bearing Cone (2 used)
– Shift collar B—Outer Thrust Washer (2 used)
• Input shaft C—Low Speed Gear
– Gear teeth D—Needle Bearing (2 used)
– Shaft E—Spacer (2 used)
F—Inner Thrust Washer (2 used)
• Housing G—Shift Collar
– Bearing cups H—Shaft
– Oil seals I—High Speed Gear
– Snap rings
10. Remove snap rings and oil seals.
IMPORTANT: Be certain to install outer thrust

washers with tapered holes toward gear
side to provide proper lubrication to
needle bearings.
11. Install in following order:
• Output gear assembly (high and low side)

– Shift collar
– Inner thrust washer
– Needle bearing
– Spacer
– Needle bearing
– Gear
– Outer thrust washer
– Bearing cone
12. Press on bearing cones using JDG1308 Bearing
Driver or equivalent.

083006
PN=1140
Separator Repair
13. Use a bearing puller to remove bearing cups (A) in

housing.
120
05
IMPORTANT: Do not force slave cups into housing. 57
Smooth any rough edges using an
emery cloth or a file, so cups fit loosely.
–UN–29MAR99
NOTE: Input and output slave cups differ slightly in size.
Use JDG1269-1 for input shaft and JDG1269-2 for
output shaft.
H54960
14. Install JDG1269 slave cups in input cover.
A—Bearing Cups (4 used)
OUO6083,00007EB –19–28JUL05–7/10
15. Install input shaft (A).
16. Install output shaft assembly (B) without shift fork.
17. Install cover and cap screws without sealant. Tighten

cap screws to specification.
–UN–29MAR99
Specification
STS Rotor Drive Gear Case
Cover Cap Screws—Torque .......................................................... 50 N•m
(37 lb-ft)
H54961
A—Input Shaft
B—Output Shaft Assembly
–UN–29MAR99
H54962

083006
PN=1141
Separator Repair
18. Measure input and output shaft end play using a dial
indicator (A).
120
05
58
19. Remove cover and install shim(s) as necessary to
achieve specified end play.
–UN–29MAR99
NOTE: Using slave cups to achieve specified end play
will set proper preload. Slave cups are 0.20 mm
narrower than the bearing cups. Shim sizes
available for the input shaft are 0.100, 0.200, and
H54963
0.500 mm. Shim sizes available for the output
shaft are 0.127, 0.178, and 0.508 mm.
Input Side Shown
Specification
Input and Output Shaft (ONLY A—Dial Indicator
With Slave Cups in Cover)—End
Play .................................................................................... 0.05—0.15 mm
(0.002—0.006 in.)
Input and Output Shaft—Preload ...................................... 0.05—0.15 mm
(0.002—0.006 in.)
20. Remove cap screws and cover.
21. Replace slave cups with bearing cups to obtain

specified preload.
22. Install shift fork to output gear assembly.
23. Clean cover and housing mating surfaces and apply

PM37521 RTV Sealant.
24. Install cover and tighten cap screws to specification.
Specification
STS Rotor Drive Gear Case
Cover Cap Screws—Torque .......................................................... 50 N•m
(37 lb-ft)

083006
PN=1142
Separator Repair
25. Install pin (C), spring (B) and plug (A).
26. Coat oil seal lips with TY6341 Multi-Purpose SD 120

05
Polyurea Grease before installation. 59
27. Install oil seals and snap rings.
–UN–29MAR99
28. Install oil drain hose.
29. Install gear case. (See REMOVE AND INSTALL STS
H54964
ROTOR DRIVE GEAR CASE in this group.)
30. Fill gear case to mark on dipstick with TY6382 gear

lube. A—Plug
B—Spring
Specification C—Pin
STS Rotor Drive Gear Case— D—Housing
Capacity .............................................................................................. 4.7 L
(5 qt)
OUO6083,00007EB –19–28JUL05–10/10
Remove And Install Discharge Beater Grate

Section
CAUTION: Shut off engine and remove key to

help avoid accidental starting and personal
injury.
–UN–15FEB99
1. Remove separator shields and inspection covers (A)
on both sides as required.
A—Inspection Cover H51956

Right-Hand Side
Continued on next page OUO6046,0001FF6 –19–28JUL05–1/9

083006
PN=1143
Separator Repair
2. Remove front nuts and cap screws (A) of grate section

to be replaced.
120
05
60 A—Front Cap Screw
–UN–17MAR99
H54179
Frame Removed For Clarity
OUO6046,0001FF6 –19–28JUL05–2/9
3. Loosen sidesheet cap screws (A) on front of discharge

beater grate frame.
4. Remove rear sidesheet cap screws (B) from frame.
A—Cap Screw
–UN–13JUL05
B—Cap Screw
H83960
Right-Hand Side
–UN–14JUL05
H83975
Left-Hand Side

083006
PN=1144
Separator Repair
5. Raise frame (A) and support with block (B).
120
A—Frame 05
B—Block 61
–UN–24FEB99
H54178
OUO6046,0001FF6 –19–28JUL05–4/9
6. Remove rear nuts and cap screws (A) of grate section.
A—Rear Cap Screw
–UN–24FEB99
H54180
OUO6046,0001FF6 –19–28JUL05–5/9
7. Remove grate (B) through the bottom toward rear of

machine.
8. Install grate under frame (A) as removed.
A—Beater Grate Frame

–UN–15FEB99
B—Beater Grate
H51959

083006
PN=1145
Separator Repair
9. Install rear cap screws (B) loosely.
120 10. Install front cap screws (A).

05
62
–UN–15FEB99
A—Nut and Cap Screw
B—Nut and Cap Screw
H51960
OUO6046,0001FF6 –19–28JUL05–7/9
12. Remove block and install rear frame cap screws (B)
and nuts.
13. Tighten nuts and cap screws (A and B).
A—Front Cap Screw
–UN–13JUL05
B—Rear Cap Screw
H83960
Right-Hand Side
–UN–14JUL05
H83975
Left-Hand Side

083006
PN=1146
Separator Repair
14. Install inspection covers (A) and shields on both

sides.
120
05
A—Inspection Cover 63
–UN–15FEB99
H51956
OUO6046,0001FF6 –19–28JUL05–9/9
Remove And Install Discharge Beater Grate

Frame

injury.
–UN–15FEB99
1. Remove shields and separator inspection covers (A)
on both sides.
H51956
A—Inspection Cover
Right-Hand Side
OUO6046,0001FF7 –19–29JUL05–1/7
2. Remove cap screws (A) and air chutes (B) from both
sides.

B—Air Chute (2 used) –UN–07MAY02
H72105

083006
PN=1147
Separator Repair
3. Remove inspection door (A).
120
05 A—Inspection Door
64
–UN–13JUL01
H69277
OUO6046,0001FF7 –19–29JUL05–3/7
4. Remove front and rear cap screws (A and B) on both

sides.
5. Remove discharge beater grate frame through rear of

machine. Repair or replace as necessary.
6. Install discharge beater grate frame through rear of
–UN–13JUL05
machine.
7. Install front and rear cap screws (A and B) on both
H83960
sides.
Right-Hand Side
A—Front Cap Screw
B—Rear Cap Screw
–UN–14JUL05
H83975
Left-Hand Side
OUO6046,0001FF7 –19–29JUL05–4/7
8. Install inspection door (A).
A—Inspection Door
–UN–13JUL01
H69277

083006
PN=1148
Separator Repair
9. Install air chutes (B) with cap screws (A) on both sides.
120
A—Cap Screws (5 used) 05
B—Air Chute (2 used) 65
–UN–13JUL05
H83959
OUO6046,0001FF7 –19–29JUL05–6/7
10. Install inspection covers (A) and shields.
A—Inspection Cover
–UN–15FEB99
H51956
Right-Hand Side
OUO6046,0001FF7 –19–29JUL05–7/7
Remove And Install Discharge Beater
NOTE: Wear strips do not need to be removed to remove

beater wings.
1. Remove beater wings (A).

–UN–09FEB99
A—Beater Wing
H51919
Continued on next page OUO6083,0000D7C –19–07JUL06–1/18

083006
PN=1149
Separator Repair
2. Loosen shaft clamps (A) on both sides.
120 3. Clean shaft (B) with emery cloth.

05
66
A—Shaft Clamp
B—Shaft
–UN–02FEB99
H51924
OUO6083,0000D7C –19–07JUL06–2/18
4. Slide shaft clamps (A) on end hubs toward center of

shaft.
5. Remove hub key (B) from both ends of shaft.
A—Shaft Clamp
–UN–02FEB99
B—Hub Key (2 used)
H51925
Right-Hand Side
OUO6083,0000D7C –19–07JUL06–3/18
6. Remove sensor (A) and actuator (B) from right-hand

side.
A—Sensor
B—Actuator
–UN–02FEB99
H51926

083006
PN=1150
Separator Repair
7. Loosen set screw (A) and remove locking collar (B).
120
A—Set Screw 05
B—Locking Collar 67
–UN–02FEB99
H51936
OUO6083,0000D7C –19–07JUL06–5/18
A—Shield
–UN–04FEB99
H51927
OUO6083,0000D7C –19–07JUL06–6/18
9. Loosen nuts (A) to relieve belt tension (B).
10. Remove belt from beater pulley.
A—Idler Tension Spring

B—Belt
–UN–02FEB99
H51928
OUO6083,0000D7C –19–07JUL06–7/18
11. Remove cap screws (A) and outer sheave (B).
12. Disconnect lubrication line (C) from sidesheet.

B—Outer Sheave
–UN–02FEB99
C—Lubrication Line
H51929

083006
PN=1151
Separator Repair
13. Remove nuts (A) from left-hand bearing flange (B).
120
05 A—Nut (3 used)
68 B—Bearing Flange Plate
–UN–02FEB99
H51934
OUO6083,0000D7C –19–07JUL06–9/18
14. Pull shaft (A) out left-hand side until hubs can be
removed.
15. Remove hubs and shaft.
16. Clean shaft with emery cloth and file to remove nicks
–UN–02FEB99
and burrs.
17. Install shaft from left-hand side until enough shaft is

inserted to install hubs. Install hubs in reverse order
H51935
as removed and insert shaft into right-hand bearing
assembly.
A—Shaft
OUO6083,0000D7C –19–07JUL06–10/18
18. Install keys (B) and slide clamping hubs (A) toward
each end of shaft.
NOTE: Do not tighten shaft clamps at this time.
A—Shaft Clamp
–UN–02FEB99
B—Hub Key (2 used)

H51925
Right-Hand Side

083006
PN=1152
Separator Repair
19. Install left-hand bearing flange (B).
120
A—Nut (3 used) 05
B—Bearing Flange 69
–UN–02FEB99
H51934
OUO6083,0000D7C –19–07JUL06–12/18
20. Connect lubrication line (C) to sidesheet.
21. Install outer sheave (B) with cap screws (A). Tighten
Specification
Discharge Beater Sheave Cap
–UN–02FEB99
Screws—Torque ............................................................................. 70 N•m
(52 lb-ft)
H51929
B—Outer Sheave
C—Lubrication Line
OUO6083,0000D7C –19–07JUL06–13/18
22. Install belt (B) and tighten nuts (A) until washer aligns
with gauge.
A—Idler Tension Spring

B—Belt –UN–02FEB99
H51928

083006
PN=1153
Separator Repair
23. Install beater wings. Ensure that wear strips (A) are
installed in same direction as removed.
120
05
70
24. Rotate or replace damaged wear strips (A) by
removing lock nuts (B).
–UN–02FEB99
25. Center beater between sidesheets and tighten clamps
on end hubs. Ensure keys remain in proper position.
26. Tighten hardware to specification.
H51937
Specification
Discharge Beater Wing
Hardware—Torque ......................................................................... 80 N•m
A—Wear Strip
(59 lb-ft)
OUO6083,0000D7C –19–07JUL06–15/18
27. Install locking collar (B) and tighten set screw (A).
A—Set Screw
B—Locking Collar
–UN–02FEB99
H51936
OUO6083,0000D7C –19–07JUL06–16/18
28. Install sensor (A) and actuator (B).
A—Sensor
B—Actuator
–UN–02FEB99
H51926

083006
PN=1154
Separator Repair
29. Install shield (A).
120
A—Shield 05
71
–UN–04FEB99
H51927
OUO6083,0000D7C –19–07JUL06–18/18
Remove and Install Discharge Beater Drive

Hub
1. Remove discharge beater drive shield and belt.

OUO6083,0000327 –19–15AUG02–1/3
2. Remove cap screws (A) from sheave (B).

B—Sheave
–UN–16JUL01
H69312
OUO6083,0000327 –19–15AUG02–2/3
3. Remove nut and washer from shaft.
4. Remove hub (A) from shaft using puller D01205AA

2-jaw puller or equivalent.
5. Inspect and replace parts as necessary.

–UN–16JUL01
6. Reinstall hub on shaft with key and tighten retaining

H69313
Specification
Discharge Beater Drive Hub
Nut—Torque ................................................................................. 308 N•m
(227 lb-ft)
A—Hub
7. Reinstall sheave, drive belt and shield.
OUO6083,0000327 –19–15AUG02–3/3

083006
PN=1155
Separator Repair
Remove and Install Discharge Beater

Housing
120
05
72 1. Park machine on a flat level surface, engage park
brake, shut off engine and remove key.
–UN–18JUN03
NOTE: Retain all hardware for installation of new part
unless otherwise noted.
H77907
on both sides of machine.
A—Covers
OUO6083,0000A3A –19–27JUN05–1/9
NOTE: Assembled separator grates can be removed from

machine without disassembly if necessary. For
ease of removal, remove center separator grate
assembly first.
CAUTION: Assembled grate sections are heavy.
–UN–09DEC04
Approximate weight of assembled grate
sections is 31 kg (69 lb).
Specification
H82157
Assembled Grate Sections—
Weight................................................................................................ 31 kg
(69 lb)
A—Cap Screws and Nuts (8 used)
3. Remove cap screws nuts (A) on both sides of machine B—Separator Grates
from rear two separator grates (B). C—Sensor Harness
D—Cap Screws (2 used)
E—Bracket
4. Disconnect sensor harness (C) and remove nuts, cap
screws (D) and sensor bracket (E).
Continued on next page OUO6083,0000A3A –19–27JUN05–2/9

083006
PN=1156
Separator Repair
5. Remove cap screws (A) and separator seals (B) on

both sides of machine.
120
05
A—Cap Screws (4 used) 73
B—Separator Seal (2 used)
–UN–09DEC04
H82158
OUO6083,0000A3A –19–27JUN05–3/9
6. Loosen nuts (A and B) on each side of machine.
A—Nuts (4 used)
B—Nuts (4 used)
–UN–09DEC04
H82159
OUO6083,0000A3A –19–27JUN05–4/9
7. Remove cap screws (A) from both sides of machine.
8. Remove cap screws (B) and shims (C) from both sides
of machine.
9. Rotate housing around STS rotor and remove through
–UN–09DEC04
left-hand side of machine.
H82169
NOTE: Do not tighten hardware at this time.
11. Rotate discharge housing through left-hand side of

machine into separator area and slide rearward. A—Cap Screw (8 used)
C—Shim (2 used)
12. Route wiring harness through bracket.

083006
PN=1157
Separator Repair
13. Install cap screws (B) and shim (C) on both sides of
machine.
120
05
74
14. Install cap screws (A) on both sides of machine.
Tighten all hardware.
–UN–09DEC04
C—Shim (2 used)
H82169
OUO6083,0000A3A –19–27JUN05–6/9
15. Install separator seals (B) using cap screws (A).

B—Separator Seal (2 used)
–UN–09DEC04
H82158
OUO6083,0000A3A –19–27JUN05–7/9
CAUTION: Assembled grate sections are heavy.

Approximate weight of assembled grate
sections is 31 kg (69 lb).
Specification
–UN–09DEC04
Weight................................................................................................ 31 kg
(69 lb)
16. Install sensor bracket (E) and retain with cap screws
(D). H82157
17. Connect sensor harness (C) to sensor.

A—Cap Screws and Nuts (8 used)
18. Install separator grates (B) using cap screws and nuts B—Separator Grates
(A). C—Sensor Harness
E—Bracket

083006
PN=1158
Separator Repair
19. Reinstall separator inspection covers (A) and shields

on both sides of machine.
120
05
A—Covers 75
–UN–18JUN03
H77907
OUO6083,0000A3A –19–27JUN05–9/9
Remove And Install Separator Grates
NOTE: Assembled separator grates can be removed from

the combine without disassembly if necessary. For
ease of removal, center grate assembly should be
removed first. Approximate weight of assembled
grate sections is 31 kg (69 lb). The following
–UN–07JAN02
procedure should be followed when replacing
damaged grate sections.
H70745
Specification
Weight................................................................................................ 31 kg
(69 lb)
A—Covers

from both sides of machine.
OUO6083,000021A –19–08MAR02–1/2
2. Remove upper cap screws (A) and lower cap screws

(B) to remove individual grate sections.
3. Remaining sections can be removed using same

procedure.
4. Install grate sections and tighten cap screws.

–UN–07JAN02
A—Cap Screw
B—Cap Screw
H70748
OUO6083,000021A –19–08MAR02–2/2

083006
PN=1159
Separator Repair
Remove and Install Concave Sections

120 NOTE: For ease of removal, close concave completely.
05
76
1. Move handle (A) to shift rotor gear case to neutral
position (B).
–UN–12APR00
A—Rotor Drive Gear Case Handle
B—Neutral Position
H63544
OUO6083,0000877 –19–28JUN04–1/21
2. Remove spring clip and open side shield (A).
3. Remove spring clips and remove shields (B) and (C).
A—Shield
B—Shield
–UN–12APR00
C—Shield
H63545
–UN–12APR00
H63546
OUO6083,0000877 –19–28JUN04–2/21
4. Remove separator inspection covers (A).
5. Inspect wear on concave sections using AH204933

STS Combine Clearance Gauge.
A—Separator Cover
–UN–08JAN02
H70754

083006
PN=1160
Separator Repair
NOTE: Removing separator grate provides access for

rotating rotor for maximum concave to threshing
element clearance. 120
05
77
6. Remove cap screws (A) and separator grate (B).
–UN–07JAN02
B—Separator Grate
H70749
OUO6083,0000877 –19–28JUN04–4/21
7. Loosen cap screws (A) and remove left-hand sheet

metal diverter (B).

B—Diverter
–UN–12APR00
H63543
OUO6083,0000877 –19–28JUN04–5/21
8. Place a piece of cardboard (A) or poly over conveyor

augers. This provides protection for the augers and
allows a smooth surface to remove the concaves.
A—Cardboard
–UN–12APR00
H63541

083006
PN=1161
Separator Repair
9. Remove spring clips and shields (A).
120
05 A—Shields
78
–UN–12APR00
H63539
OUO6083,0000877 –19–28JUN04–7/21
10. Remove spring clips and front two separator covers

(A) on right-hand side of combine.
A—Separator Cover
–UN–12APR00
H63538
OUO6083,0000877 –19–28JUN04–8/21
11. Remove spring lock pin and two-piece retainer (A)

from each concave section.
A— Two-Piece Retainer
–UN–13MAY03
H76917

083006
PN=1162
Separator Repair
12. Loosen 12 cap screws (A).
13. Fully open concave. This will allow the weight of the 120
05
concaves to rest on the conveyor auger bed. 79
–UN–14APR00
H63582
OUO6083,0000877 –19–28JUN04–10/21
14. Remove 12 cap screws (A).
15. Remove cotter pins, pins (B) and “Z” bar (C).
16. Rotate rotor so there is a gap in the threshing bar

pattern at the middle concave.
–UN–14APR00
17. Remove middle concave section.
18. Slide rear concave to the middle position and remove.
H63583
19. Remove front concave.
20. Install concaves in reverse order. A—Cap Screw (12 used)

B—Pin (2 used)
C—“Z” Bar
OUO6083,0000877 –19–28JUN04–11/21
21. Install two-piece retainer (A) on concave sections.
A—Two-Piece Retainer
–UN–13MAY03
H76917

083006
PN=1163
Separator Repair
22. Position “Z” bar (C) over end of concaves and install
12 cap screws, but do not tighten.
120
05
80
23. Install pins (B).
24. Fully close concave.
–UN–14APR00
B—Pin (2 used)
C—“Z” Bar
H63583
OUO6083,0000877 –19–28JUN04–13/21
25. Be sure the ends of concaves fit snug into “Z” bar;
then tighten top row of cap screws (A) first.
26. Tighten bottom row of cap screws last.
27. Adjust concave level. (See ADJUST CONCAVE
–UN–16FEB99
LEVEL in this group.)
H51980
OUO6083,0000877 –19–28JUN04–14/21
28. Install separator covers (A).
NOTE: Be sure that all separator covers are under door

clip (sheet metal with notches welded to rail).
A—Separator Cover (2 used)
–UN–12APR00
H63538

083006
PN=1164
Separator Repair
29. Install shields (A).
120
A—Shields 05
81
–UN–12APR00
H63539
OUO6083,0000877 –19–28JUN04–16/21
30. Install separator grate (B) and retain with cap screws
(A).

B—Separator Grate
–UN–07JAN02
H70749
OUO6083,0000877 –19–28JUN04–17/21
31. Remove cardboard (A) or poly from conveyor augers.
A—Cardboard
–UN–12APR00
H63541

083006
PN=1165
Separator Repair
32. Install diverter (B) to original position and tighten cap

screws (A).
120
05
B—Diverter
–UN–12APR00
H63543
OUO6083,0000877 –19–28JUN04–19/21
33. Install separator inspection covers (A).
A—Separator Cover
–UN–08JAN02
H70754
OUO6083,0000877 –19–28JUN04–20/21
34. Install shields (B) and (C).
35. Close side shield (A).
36. Place rotor drive gear case in desired speed range.
–UN–12APR00
A—Shield
B—Shield
C—Shield
H63545
–UN–12APR00
H63546
OUO6083,0000877 –19–28JUN04–21/21

083006
PN=1166
Separator Repair
Adjust Concave Level
1. Remove spring clip and open side shield (A). 120

05
83
2. Remove spring clips and remove shields (B) and (C).
–UN–12APR00
A—Shield
B—Shield
C—Shield
H63545
–UN–12APR00
H63546
OUO6083,00009FA –19–28JUL05–1/10
3. Remove separator inspection covers (A).
A—Separator Covers
–UN–08JAN02
H70754
OUO6083,00009FA –19–28JUL05–2/10
NOTE: Removing separator grate provides access for

rotating rotor.
4. Remove cap screws (A) and separator grate (B).

–UN–07JAN02
B—Separator Grate
H70749
Continued on next page OUO6083,00009FA –19–28JUL05–3/10

083006
PN=1167
Separator Repair
5. Back off stop bolt (A and B).
120
05 A—Stop Bolt
84 B—Stop Bolt
–UN–15MAY00
H63912
–UN–15MAY00
H63911
OUO6083,00009FA –19–28JUL05–4/10
6. Loosen jam nuts (A) and back off nuts (B) five turns
each.
A—Bottom Nut (2 used)

B—Top Nut (2 used)
–UN–16FEB99
H51982

083006
PN=1168
Separator Repair
7. Adjust concave all the way upward using switch in cab

until the worm gear (B) and sector gear (A) are
bottomed out in the upward position. 120
05
85
A—Sector Gear
B—Worm Gear
–UN–07JAN02
H70751
OUO6083,00009FA –19–28JUL05–6/10
8. Shift STS Rotor drive gear case shift handle (A) to

neutral position (B).
A—Shift Handle
B—Neutral Position
–UN–12APR00
H63544

083006
PN=1169
Separator Repair
9. Adjust front eyebolt top nut (A) slowly until elements

“tick” concave while rotor is rotating. Back off three
120 complete turns.
05
86
10. Adjust rear eyebolt top nut (C) slowly until elements
“tick” concave while rotor is rotating. Back off three
complete turns.
11. Adjust front eyebolt top nut (A) down slowly until
–UN–22NOV00
elements “tick” concave. Back off slowly until “tick”
stops. As soon as “tick” has stopped back off one
complete turn and tighten top jam nut.
H65419
12. Adjust rear eyebolt top nut (C) down slowly until
elements “tick” concave. Back off slowly until “tick”
stops. As soon as “tick” has stopped back off one
complete turn and tighten top jam nut. A—Front Eyebolt Top Nut
B—Front Eyebolt Bottom Jam Nut
C—Rear Eyebolt Top Nut
13. Tighten bottom front concave adjustment nut. Hold D—Rear Eyebolt Bottom Jam Nut
front eyebolt top nut (A) with open end wrench and
tighten front eyebolt bottom jam nut (B).
14. Tighten bottom rear concave adjustment nut. Hold

rear eyebolt top nut (C) with open end wrench and
tighten rear eyebolt bottom jam nut (D).

083006
PN=1170
Separator Repair
15. Adjust front and rear concave stop bolt (A) by

tightening bottom nut (B) until head of bolt (C) is snug
against concave. Tighten top nut (D) while holding 120
05
bottom nut (B) with open end wrench. 87
A—Stop Bolt (2 used)
–UN–22NOV00
B—Jam Nut
C—Head of Bolt
D—Jam Nut
H65421
Front Stop Bolt
–UN–22NOV00
H65420
Rear Stop Bolt
OUO6083,00009FA –19–28JUL05–9/10
16. Install separator grate (B) and retain with cap screws
(A).
17. Shift STS Rotor drive gear case shift handle to

desired position.
–UN–30OCT02
18. Install separator inspection covers and shields.
19. Calibrate concave position in cab. (See CONCAVE

SENSOR ZERO CALIBRATION in Combine
H73877
Operators Manual.)

B—Separator Grate
OUO6083,00009FA –19–28JUL05–10/10

083006
PN=1171
Separator Repair
Remove and Install Concave Adjusting Motor

120 1. Disconnect harness lead connector at motor.
05
88
2. Remove screws (A), motor and spacer (B).
–UN–09DEC04
3. Remove spring pin (C) and sector gear (D).
4. Remove worm gear (E).
H82148
NOTE: Concave adjusting motor is not repairable.
Replace if necessary.
5. Inspect parts and replace as necessary. A—Screw (3 used)

B—Spacer
C—Spring Pin
6. Install worm gear, sector gear, spacer and motor. D—Sector Gear
E—Worm Gear
OUO6083,00009FB –19–16MAY05–1/1
Remove And Install Concave Adjusting Tube
1. Remove shields and separator inspection covers (A).
A—Covers
–UN–08JAN02
H70754
OUO6083,00009FC –19–16MAY05–1/4
2. Disconnect harness connector from concave position

sensor (A).
3. Remove cap screw (B).
4. Remove sensor and bracket as an assembly.

–UN–23FEB99
A—Sensor
B—Cap Screw
H54150
Concave Position Sensor
Continued on next page OUO6083,00009FC –19–16MAY05–2/4

083006
PN=1172
Separator Repair
5. Support concave with block.
6. Remove spring pin (A) and sector gear. 120

05
89
A—Spring Pin
–UN–10DEC04
H82152
OUO6083,00009FC –19–16MAY05–3/4
7. Remove cotter pin (A) and pin (B) from both concave
eyebolts.
8. Slide tube toward front of machine to remove end from

adjusting motor support; then slide toward rear to
remove from machine.
–UN–23FEB99
9. Install concave adjusting tube in reverse order.
10. Calibrate concave position in cab. (See CONCAVE
H54153
SENSOR ZERO CALIBRATION in Combine
Operators Manual.)
A—Cotter Pin
B—Pin
OUO6083,00009FC –19–16MAY05–4/4
Repair Separator Rotor Shell
1. To repair a crack or tear in the rotor shell, heat the

damaged area then straighten and flatten the metal.
2. Weld the crack full and grind the weld smooth.
3. If there is a RIVNUT in the repaired area, see

REMOVE AND INSTALL RIVNUT THREADED
INSERTS in this group.
NOTE: If the damaged area is too severe to be repaired,

then the rotor shell will have to be replaced.
OUO6083,0000878 –19–28JUN04–1/1

083006
PN=1173
Separator Repair
Remove And Install Threshing Elements And

Tines
120
05
90 IMPORTANT: STS Rotor is a balanced assembly. Bars
and tines must be replaced in sets of
three to maintain balance. Replacement
kits are available through service parts
and include new cap screws with
pre-applied LOCTITE 204. Always use
new cap screws and do not retighten
after initial installation. Tines or bars
that become loose may result in
machine damage.
IMPORTANT: If tines or bars need to be removed for

other than replacement, mark location
on tine(s)/bar(s) and rotor, prior to
removal. Install in same location as
removed to maintain balance. Always
use new cap screws.
IMPORTANT: Make sure to clean out tailings and

front cross auger if tine replacement is
due to broken or damage tines. Failure
to do so before initial start-up may
allow broken tines to recirculate and
cause tine damage to reoccur.
1. Remove separator grates or concave sections as

needed to access STS Rotor. (See procedure in this
group.)
2. Inspect wear on threshing elements and separator

tines using AH204933 STS Combine Clearance
Gauge.

083006
PN=1174
Separator Repair
3. Remove cap screws (A) and threshing bar or tine.
120
A—Cap Screws 05
91
–UN–18FEB99
H54005
Threshing Bar
–UN–18FEB99
H54007
Separator Tine
OUO6083,0000559 –19–28JUL05–2/3
4. Inspect RIVNUT threaded inserts (A). Replace if

damaged. (See REMOVE AND REPLACE RIVNUT
THREADED INSERTS in this group.)
5. If one bar or tine needs replaced, replace all in the

group. Example: If bar 2 needs to be replaced, replace
–UN–18FEB99
bars 1 and 3 also.
6. Use THRESHING BAR AND SEPARATOR TINE

LOCATION diagram for identifying bars and tines.
7. Tighten cap screws to specification. H54006
Specification A—Threaded Insert

Threshing Bar Cap Screws—
Torque ............................................................................................ 90 N•m
(66 lb-ft)
Separator Tine Cap Screws—
Torque ............................................................................................ 90 N•m
(66 lb-ft)
OUO6083,0000559 –19–28JUL05–3/3

083006
PN=1175
Separator Repair
Threshing Bar And Separator Tine Location (S.N. —715300)

120
05
92
–UN–17FEB99
H51671
Continued on next page OUO6083,0000AFA –19–18AUG05–1/2

083006
PN=1176
Separator Repair
Threshing Bar Groups

Group 1 Bars 1, 2, 3
120
Group 2 Bars 4, 5, 6
05
Group 3 Bars 7, 8, 9 93
Group 4 Bars 10, 11, 12
Group 5 Bars 13, 14, 15
Separator Tine Groups

Group 1 Tines 1, 2, 5
OUO6083,0000AFA –19–18AUG05–2/2

083006
PN=1177
Separator Repair
Threshing Bar And Separator Tine Location (Rice) (S.N. —715300)

120
05
94
–UN–16JAN01
H65798
Continued on next page OUO6083,0000AFB –19–18AUG05–1/2

083006
PN=1178
Separator Repair
Threshing Bar Groups Separator Tine Groups

Group 1 Bars 1, 2, 3 Group 1 Tines 1, 2, 5
120
05
Group 3 Bars 5, 7, 9 Group 3 Tines 8, 9, 11 95
Group 7 Bars 17, 19 ,21 Group 7 Tines 19, 22, 23
Group 9 Bars 23, 25, 27
OUO6083,0000AFB –19–18AUG05–2/2

083006
PN=1179
Separator Repair
Threshing Element and Separator Tine Location (15 Element Configuration)

120
05
96
13
6 12 18 23
1 7 1 8 14 20
4
10
14
3 10 16 22
2
5 8 11 24
5 17
11
15
4 7 13 19
3
6 9
2 9 15 21
12
–UN–02FEB06
H85332
Continued on next page OUO6083,0000D7E –19–07JUL06–1/2

083006
PN=1180
Separator Repair
IMPORTANT: Make sure to clean out tailings and Threshing Element Groups (15 Element Configuration)
front cross auger if tine replacement Group 1 Elements 1, 2, 3
is due to broken or damage tines. 120
Group 2 Elements 4, 5, 6
05
Failure to do so before initial Group 3 Elements 7, 8, 9 97
start-up may allow broken tines to
recirculate and cause tine damage to
reoccur.
Separator Tine Groups

OUO6083,0000D7E –19–07JUL06–2/2

083006
PN=1181
Separator Repair
Threshing Element and Separator Tine Location (24 Element Dense Pack Configuration)
120
05
98 7 19 6 12 18 23
1
4 13
8 20
1 8 14 20
14
2
9 21 3 10 16 22
5
15
10 22 11 24
5 17
3 16
11 23 2 7 13 19
6
17
12 24 9 15
4 21
–UN–17SEP04
18
H81668
Threshing Element Groups (24 Element Dense Pack Separator Tine Groups
Configuration) Group 1 Tines 1, 4, 5
Group 1 Elements 1, 2, 3 Group 2 Tines 2, 3, 6
Group 3 Elements 7, 9, 11 Group 4 Tines 7, 10,12
OUO6083,0000AFD –19–18AUG05–1/1

083006
PN=1182
Separator Repair
Remove And Replace RIVNUT Threaded

Inserts
120
05
1. Remove threshing elements or separator tines as 99
needed. (See REMOVE AND INSTALL THRESHING
ELEMENTS AND TINES in this group.)
–UN–18FEB99
2. Remove insert head (A) using a chisel.
A—Insert Head
H54023
OUO6083,0000AF5 –19–18AUG05–1/5
3. Screw head end (A) of insert onto pull-up stud (B) of

JDG1316 RIVNUT Installation Tool, until all threads of
insert are engaged with stud.
A—Insert Head
B—Pull-Up Stud
–UN–18FEB99
H54038
OUO6083,0000AF5 –19–18AUG05–2/5
4. Rotate anvil (A) until tight against head of insert (B).
A—Anvil
B—Insert
–UN–18FEB99
H54044
Continued on next page OUO6083,0000AF5 –19–18AUG05–3/5

083006
PN=1183
Separator Repair
5. Position insert in hole with head tight to metal.
120 6. Hold socket head stationary with wrench (A). Rotate

05
,100
hex nut (B) clockwise until firm resistance is felt
(approximately four turns).
–UN–18FEB99
A—Wrench
B—Hex Nut
H54045
OUO6083,0000AF5 –19–18AUG05–4/5
7. Shoulder of fastener will collapse and hold insert tight

to metal. (See illustration.)
8. Break hex nut loose with counterclockwise movement

and remove both wrenches.
–UN–18FEB99
9. Remove tool by turning entire tool counterclockwise.
A—Insert (Not Installed)

B—Insert (Installed)
H54072
OUO6083,0000AF5 –19–18AUG05–5/5
Remove And Install STS Rotor Feed Flights

from key switch.
–UN–21JAN99

H51815
A—Top Door
B—Top Door
Continued on next page OUO6083,0000D7D –19–07JUL06–1/3

083006
PN=1184
Separator Repair
3. Disconnect clamps (A) and remove plastic hood (B).
4. Remove plate (C) from bracket (D). 120

05
,101
NOTE: Concave sections need to be removed to access
bolts on rear flight section only.
–UN–17JUL01
5. Remove front two concave sections, if required. (See
REMOVE AND INSTALL CONCAVE SECTIONS in this
group.)
H69321
A—Clamp
B—Hood
C—Plate
D—Bracket
OUO6083,0000D7D –19–07JUL06–2/3
IMPORTANT: STS Rotor is a balanced assembly.

Flight sections are available as sets
from service parts. Front or rear
sections must be replaced in sets of
three to maintain balance.
–UN–05APR99
6. Remove bolts (A and B) to remove front flight section.
7. Remove bolts (C) to remove rear flight section.
H55061
8. Install flight section and tighten mounting bolts to
specification.
Specification
Feed Flight Section Bolts—
Torque .......................................................................................... 140 N•m
(103 lb-ft)
A—Bolts
B—Bolts –UN–05APR99
C—Bolts
H55062
OUO6083,0000D7D –19–07JUL06–3/3

083006
PN=1185
Separator Repair
Static Balance STS Rotor

120
05 CAUTION: Make sure all parts removed to
,102 access rotor are reinstalled before operating
separator to help avoid personal injury or
machine damage caused by contact with
–UN–06APR99
spinning rotor.

Start engine and engage separator ONLY, to verify
H55168
rotor imbalance.
Threshing Bar Cavity
NOTE: If imbalance condition exists with rotor drive in
neutral, imbalance is NOT in rotor assembly. A—Cavity
Inspect other separator components (feed
accelerator, discharge beater, etc.) for damaged
or missing parts.
2. If imbalance is determined to be in rotor assembly,

inspect rotor, feed flights, threshing bars and separator
tines for damaged or missing parts. Repair as
necessary; then shift STS Rotor drive gear case to
high, start engine and engage separator.
3. If imbalance persists, clean all debris and crop residue

from all threshing bar cavities (A); then start engine
and engage separator. Check to see if imbalance
persists.
NOTE: If imbalance persists after performing the previous

steps, it will be necessary to perform the following
steps to static balance STS Rotor assembly.
4. Start engine and engage separator. Operate separator

for approximately 20 minutes at 800 rpm to warm oil in
STS Rotor drive gear case, and grease in front rotor
bearing.

083006
PN=1186
Separator Repair
5. Remove feeder house top doors, plastic hood and

support plate to access STS Rotor feed flights. (See
REMOVE AND INSTALL STS ROTOR FEED 120
05
FLIGHTS in this group.) ,103
6. Loosen nuts on belt tensioners (A) and remove belts
–UN–13MAY03
from primary countershaft sheave (B). Tie belts back to
avoid interference with countershaft sheave.
A—Belt Tensioner
H76923
B—Sheave
OUO6083,00005B5 –19–13MAY03–2/5
8. Spin rotor several times by hand from top of feeder

house. As rotor slows, “heavy” side should stop
consistently on the bottom.
9. When rotor stops, and there is a balance weight

location on top side of rotor (12 o’clock position), add
one weight (A) from balance kit to STS Rotor feed
flights. Spin rotor to check for balance.
–UN–12APR99
A—Balance Weight
H55188
STS Rotor Front View

083006
PN=1187
Separator Repair
10. When rotor stops and 12 o’clock position is directly

between two weight locations, look at position 180°
120 opposite to see if there is an existing weight (A). If so,
05
,104
remove weight and spin rotor to check for balance.
A—Existing Weight
–UN–12APR99
H55189
OUO6083,00005B5 –19–13MAY03–4/5
11. If no weight is found, add one weight (A) to both

locations on either side of 12 o’clock position (B).
Spin rotor to check for balance.
12. Repeat procedure until balance is achieved.
If imbalance is still present, STS Rotor may need to

be dynamically balanced.
A—Balance Weights
B—Weight Location at 12 o’clock
–UN–13APR99
H55190
OUO6083,00005B5 –19–13MAY03–5/5

083006
PN=1188
Separator Repair
Aligning Rotor Drive Bulkhead
1. (Both Sides): Loosen cap screws (A and B). 120

05
,105
A—Cap Screw (4 Per Side)
B—Cap Screw (4 Per Side)
–UN–22JAN02
H70945
OUO6435,00015E0 –19–22JAN02–1/7
2. Install laser tool (A) onto rotor drive output shaft and
retain by tightening screws (B).
A—Laser Tool
B—Retaining Screws
–UN–11NOV99
H61797
OUO6435,00015E0 –19–22JAN02–2/7
3. Remove bearing housing from front rotor support plate.
4. Install front rotor support plate back on machine and

retain with one cap screw (A) on each side.
A—Cap Screws
–UN–11NOV99
H61801
Continued on next page OUO6435,00015E0 –19–22JAN02–3/7

083006
PN=1189
Separator Repair
5. Using a compass, draw a 25 mm (1 in.) circle in the

center of a piece of a paper.
120
05
,106
6. Align circle (A) in the center of bearing opening (B) and
retain with tape.
–UN–22JAN02
A—Circle
B—Bearing Opening
H70952
OUO6435,00015E0 –19–22JAN02–4/7
7. Move toggle switch (A) to turn laser tool on.
A—Toggle Switch
–UN–29OCT02
H73846
OUO6435,00015E0 –19–22JAN02–5/7
8. Turn rotor gear case input shaft (A) while observing

laser on front rotor support.
9. Align bulkhead so that the laser stays in the drawn

circle through the complete rotation.
–UN–30OCT02
A—Rotor Gear case Input Shaft
H73905
–UN–22JAN02
H70951
Continued on next page OUO6435,00015E0 –19–22JAN02–6/7

083006
PN=1190
Separator Repair
10. (Both Sides): Tighten cap screws (A and B).
NOTE: Once bulkhead screws are tight, make sure laser 120
05
is still in alignment. ,107
A—Cap Screw (4 Per Side)

B—Cap Screw (4 Per Side)
–UN–22JAN02
H70945
OUO6435,00015E0 –19–22JAN02–7/7

083006
PN=1191
Separator Repair
120
05
,108

083006
PN=1192
Group 10
Separator Drives
10
Catalogs.
OUO6083,0000087 –19–28JUL05–1/6
Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG12681
Used to remove primary countershaft sheave.
–UN–04JUN01
H68321
1
Recommended Tool
OUO6083,0000087 –19–28JUL05–2/6
Bearing Puller Attachment. . . . . . . . . . . . . . D01218AA
Used to remove carrier bearing from drive shaft.
OUO6083,0000087 –19–28JUL05–3/6
Push-Puller . . . . . . . . . . . . . . . . . . . . . . . D01290AA
Used to remove carrier bearing from drive shaft.
OUO6083,0000087 –19–28JUL05–4/6
Drive Shaft Seal Installer . . . . . . . . . . . . . . . JDG131-1
Used to install large metal cup seal on drive shaft.
OUO6083,0000087 –19–28JUL05–5/6
Drive Shaft Bearing Installer . . . . . . . . . . . . . JDG131-2
Used to install drive shaft bearing.
OUO6083,0000087 –19–28JUL05–6/6

083006
PN=1193
Separator Drives
Specifications
10
2
Right-Hand Front Jackshaft Support Torque 70 N•m
Right-Hand Front Jackshaft Steel Torque 70 N•m

Sheave-to-Cast Sheave Cap Screws (52 lb-ft)
Inside Hub—Rear Jackshaft Position 16.75 mm

Assembly (0.66 in.)
Inside Hub Nut—Rear Jackshaft Torque 70 N•m

Assembly (52 lb-ft)
Outside Hub Nut—Rear Jackshaft Torque 70 N•m

Assembly (52 lb-ft)
Slip Clutch Mounting Nut— Torque 250 N•m

Right-Hand Rear Jackshaft (184 lb-ft)
12-Point Cap Screws—Drive Shaft Torque 40 N•m

Universal Joint (30 lb-ft)
Cap Screws and Flanged Lock Torque 40 N•m

Nuts—Top Drive Shaft Shield (30 lb-ft)
Carrier Bearing Cap Screws and Torque 140 N•m

Flanged Lock Nuts (103 lb-ft)
Primary Countershaft Retaining Nut Torque 328 N•m

(242 lb-ft)
Sheave and Jackshaft Assembly Weight 31 kg

(67 lb)
Primary Countershaft Weight 37 kg

(81 lb)
OUO6083,000032B –19–15AUG02–1/1

083006
PN=1194
Separator Drives
Remove and Install Right-Hand Front

Jackshaft
120
10
NOTE: Gull wing doors removed for clarity. 3
1. Relieve belt tension by loosening nuts (A) and remove
–UN–16FEB99
primary belts from sheave.
2. Remove six cap screws, spacers (B) and sheave.
H53085
3. Relieve belt tension and remove secondary belt (C).
4. Relieve belt tension and remove feed accelerator belt

(D) from jackshaft sheave.
CAUTION: Approximate weight of sheave and

jackshaft assembly is 31 kg (67 lb).
Specification
–UN–16FEB99
Sheave and Jackshaft
Assembly—Weight ............................................................................ 31 kg
(67 lb)
H51845
5. Remove nuts and mounting cap screws (E) from
sidesheet. Remove jackshaft and support assembly.
A—Belt Tension Adjuster

C—Secondary Belt
D—Feed Accelerator Belt
–UN–21JAN99
H51846

083006
PN=1195
Separator Drives
120 7. Loosen set screw and turn locking collar (B) clockwise
10
4
to remove.
8. Remove sheave from jackshaft (C).
–UN–21JAN99
9. Press bearings from bore if necessary.
10. Assemble sheave to jackshaft.
H51847
11. Tighten locking collar in counterclockwise direction
and tighten set screw.
A—Snap Ring
12. Tighten jackshaft support cap screws to specification. B—Locking Collar
C—Jackshaft
Specification
Right-Hand Front Jackshaft
Support Cap Screws—Torque ....................................................... 70 N•m
(52 lb-ft)
13. Install large sheave to cast sheave using six cap

screws. Tighten cap screws to specification.
Specification
Right-Hand Front Jackshaft Steel
Sheave-to-Cast Sheave Cap
Screws—Torque ............................................................................. 70 N•m
(52 lb-ft)
OUO6083,0000027 –19–26MAR01–2/3
14. Install belts and tighten nuts (A) until washer on

spring aligns with gauge.
A—Nut (2 used)
–UN–16FEB99
H53085
OUO6083,0000027 –19–26MAR01–3/3

083006
PN=1196
Separator Drives
Remove and Install Right-Hand Rear

Jackshaft
120
10
1. Loosen nuts (A) and remove tailings auger drive belt 5
(B).
–UN–24FEB99
2. Remove nut (C), slip clutch and sheave assembly (D).
Remove woodruff key from shaft.
3. Loosen nuts (E) and remove clean grain drive belt (F).
H54158
4. Loosen cap screw (G) and nut from hub.
5. Remove sheave (H) and woodruff key from shaft.

A—Nuts
B—Tailings Auger Drive Belt
C—Nut
D—Slip Clutch Assembly
E—Belt Tension Adjuster
F—Clean Grain Belt
–UN–24FEB99
G—Cap Screw
H—Sheave
H54159
–UN–24FEB99
H54160
–UN–25APR00
H63697
Continued on next page OUO6083,00002CD –19–13JUN02–1/5

083006
PN=1197
Separator Drives
6. Loosen nut (A) and remove belt (B).
120 7. Remove attaching hardware from support (C) and

10
6
remove jackshaft and support.
8. Loosen cap screw (D). Remove sheave and woodruff
–UN–24FEB99
key.
9. Loosen set screw and remove locking collar (E) by

turning in opposite direction of shaft rotation.
H54161
10. Remove nuts and cap screws (F). Remove flangettes
(G) and outside bearing.
11. Loosen set screw and remove locking collar (H) by

12. Remove nuts (I) and cap screws. Remove flangettes

(J) and inside bearing.
–UN–24FEB99
13. Remove jackshaft (K).
A—Belt Tension Adjuster
B—Elevator Jackshaft Drive Belt
H54162
C—Support
D—Cap Screw
E—Locking Collar
G—Flangettes
H—Locking Collar
I—Nut (3 used)
J—Flangettes
K—Jackshaft
–UN–24FEB99
H54163
–UN–24FEB99
H54170

083006
PN=1198
Separator Drives
14. Install inside and outside bearings (A) in support (B).

Do not tighten locking collars at this time.
120
10
A—Bearings 7
B—Support
–UN–26FEB99
H54234

083006
PN=1199
Separator Drives
120
10
8
C 16.75 mm (0.66 in.)
E D
–UN–21JUN01
H68332
A—Sheave and Hub Assembly C—Sheave D—Nut E—Clearance
B—Nut
15. Install sheave and hub assembly (A) on shaft. 16. Tighten nut (B) on hub to specifications.
Position sheave and hub assembly on shaft until Specification

face of hub is 16.75 mm (0.66 in.) from end of Inside Hub Nut—Rear
Jackshaft Assembly—Torque .................................................. 70 N•m
shaft. (52 lb-ft)
Specification
Inside Hub—Rear Jackshaft 17. Slide shaft inside support assembly until inside
Assembly—Position ............................................................. 16.75 mm hub is against inside bearing.
(0.66 in.)

083006
PN=1200
Separator Drives
18. Tighten inside and outside locking collars in 21. Install slip clutch. Check to see visible gap at
direction of shaft rotation. Tighten set screw. location (E) exist between slip clutch and sheave
(C). Tighten mounting nut to specifications. 120
10
19. Install support. 9
Specification
20. Install sheave (C) and tighten hub nut (D) to Slip Clutch Mounting Nut—
Right-Hand Rear Jackshaft—
specifications. Torque.................................................................................... 250 N•m
(184 lb-ft)
Specification
Outside Hub Nut—Rear
Jackshaft Assembly—Torque .................................................. 70 N•m 22. Install belts and tighten nuts until washer on idler
(52 lb-ft) adjustment spring aligns with gauge.
OUO6083,00002CD –19–13JUN02–5/5
Remove and Install Primary Countershaft

Bearing
NOTE: Gull wing doors removed for clarity.
1. Turn nuts (A) to relieve belt tension. Remove belts (B)
–UN–04JUN04
from countershaft sheave.
2. Loosen nut (C) and install puller JDG1268 (D).
H81081
3. Loosen sheave (E). Remove nut, sheave, and woodruff
key.
A—Nuts
B—Belts
C—Nut
D—Puller JDG1268
E—Sheave
–UN–04JUN04
H81082
Continued on next page OUO6083,000087D –19–28JUL05–1/4

083006
PN=1201
Separator Drives
4. Use the following procedures for machines

equipped with separate bearing and flangette
120 housings:
10
10
• Remove locking collar (A)
• Remove nuts and round head bolts (B)
• Remove outside flangette (C) and bearing. Repair or
–UN–22JAN99
replace as necessary
• Install bearing and outside flangette (C)
• Install round head bolts (B) and nuts
• Install locking collar (A) and tighten in direction of
H51798
shaft rotation. Tighten set screw
A—Locking Collar
C—Outside Flangette
OUO6083,000087D –19–28JUL05–2/4

equipped with one piece bearing and pillow block
housing:

• Remove cap screws (B) and bearing (C). Replace as
necessary
–UN–01JUL04
• Install bearing (C) using cap screws (B)
• Install locking collar (A) and tighten in direction of
shaft rotation. Tighten set screw
H81233
IMPORTANT: Always use a new retaining nut when
installing sheave to help prevent
machine damage caused by loose nut.
6. Install woodruff key, sheave (D), and new nut (E).

Tighten nut to specifications.
Specification
Primary Countershaft Retaining
–UN–01JUL04
Nut—Torque ................................................................................. 328 N•m

(242 lb-ft)
A—Locking Collar
H81328

C—Bearing
D—Sheave
E—Nut

083006
PN=1202
Separator Drives
7. Install belts and tighten nuts on each idler tension

spring until washer (B) aligns with gauge (A).
120
10
A—Gauge 11
B—Washer
–UN–15FEB99
H51799
OUO6083,000087D –19–28JUL05–4/4
NOTE: Gull wing doors removed for clarity.
1. Remove header electromagnetic clutch. (See REMOVE

HEADER ELECTROMAGNETIC CLUTCH in this
section.)
OUO6083,000087E –19–06JUL04–1/5
2. Relieve belt tensioners (A) and remove belts (B) from

sheave.
3. Loosen nut (C) and install JDG1268 puller (D).
4. Loosen sheave (E). Remove nut, sheave, and woodruff
–UN–04JUN04
key.
A—Tensioner (2 used)
B—Belts
H81081
C—Nut
D—Puller
E—Sheave
–UN–04JUN04
H81082
Continued on next page OUO6083,000087E –19–06JUL04–2/5

083006
PN=1203
Separator Drives
CAUTION: Approximate weight of primary

120 countershaft is 37 kg (81 lb).
10
12 Specification
Primary Countershaft—Weight .......................................................... 37 kg
(81 lb)
–UN–22JAN99
equipped with separate bearing and flangette
housings:
H51798
• Remove nuts and round head bolts (B)
• Remove outside flangette (C) and bearing A—Locking Collar
• Remove primary countershaft from right-hand side of B—Round Head Bolts (4 used)
C—Outside Flangette
combine
• Remove bearing and inside flangette from primary
countershaft. Repair or replace as necessary
• Position inside flangette and bearing on primary
countershaft
• Install countershaft from right-hand side of combine
• Install outside flangette (C)
• Install round head bolts (B), and nuts

083006
PN=1204
Separator Drives

equipped with one piece bearing and pillow block
housing: 120
10
13
• Remove cap screws (B) and bearing (C)
• Remove primary countershaft from right-hand side of
–UN–01JUL04
combine
• Install primary countershaft from right-hand side of
combine
• Install bearing (C) using cap screws (B)
H81233
• Install locking collar and tighten in direction of shaft
rotation. Tighten set screw
7. Install header electromagnetic clutch. (See INSTALL

HEADER ELECTROMAGNETIC CLUTCH in this
section.)
NOTE: Prior to tightening electromagnetic clutch retaining

nut, fill gear case splined cavity with TY6341
–UN–01JUL04
Multi-Purpose SD Polyurea Grease through
lubrication fitting on output shaft.
H81328
8. Install locking collar (A). Tighten collar in direction of
rotation and tighten set screw.
IMPORTANT: Always use a new retaining nut when A—Locking Collar

installing sheave to help prevent
C—Bearing
machine damage caused by loose nut. D—Sheave
E—Nut
9. Install woodruff key, sheave (D), and new nut (E).
Specification
Primary Countershaft Retaining
Nut—Torque ................................................................................. 328 N•m
(242 lb-ft)

083006
PN=1205
Separator Drives
10. Install belts and tighten nuts on each idler tension

spring until washer (B) aligns with tip of gauge (A).
120
10
14 A—Gauge
B—Washer
–UN–15FEB99
H51799
OUO6083,000087E –19–06JUL04–5/5
Remove and Install Primary Drive Shafts
The primary countershaft gear case is driven by two

sections of drive shaft. The two sections are of unequal
length and are supported by a rubber mounted carrier
bearing where front and rear sections join.
–UN–17FEB00
2. Remove cap screws and flanged lock nuts (F) and top
H62734
drive shaft shield (E).
3. Remove 12-point cap screws (B) and discard. Top View From Front of Engine Compartment
4. Remove universal joint retaining clamps (C) from yoke

on splined shaft coming from engine transfer case (D).
NOTE: Before removing drive shaft from combine, apply

tape to universal joint bearing caps to help
prevent dislodging bearing caps and losing needle
–UN–25APR00
bearings.
A—Rear Drive Shaft

B—12-Point Cap Screw (4 used)
C—Clamp (2 used) H63703
D—Engine Transfer Gear Case
E—Shield Top Drive Shaft Universal Joint
F—Cap Screw and Flanged Lock Nut (3 used)
Continued on next page OUO6083,000032C –19–15AUG02–1/6

083006
PN=1206
Separator Drives
5. Remove cap screws and flanged lock nuts (C) from

carrier bearing (B).
120
10
6. Loosen packing nut (E) on yoke (D). 15
7. Slide packing nut (E) and packing (F) away from yoke
–UN–17FEB00
(D).
8. Separate rear drive shaft (A) and attached carrier

bearing (B) from front drive shaft (G) and yoke (D).
H62720
9. Remove rear drive shaft (A).
Carrier Bearing Viewed From Below

B—Carrier Bearing
C—Cap Screw and Flanged Lock Nut
D—Yoke
E—Packing Nut
F—Packing
G—Front Drive Shaft
–UN–17FEB00
H62721

083006
PN=1207
Separator Drives
10. Remove 12-point cap screws (B) and discard.
120 11. Remove universal joint retaining clamps (C) from

10
16
yoke on splined shaft coming from primary
countershaft gear case (D).
–UN–17FEB00
NOTE: Before removing drive shaft from combine, apply
tape to universal joint bearing caps to help
prevent dislodging bearing caps and losing needle
bearings.
H62733
12. Remove front drive shaft (A).
13. Install bottom drive shaft (A) by sliding drive shaft into A—Front Drive Shaft
approximate position. B—12-Point Cap Screw
C—Clamp
D—Primary Countershaft Gear Case
14. Remove tape from universal joint bearing caps and
insert front drive shaft (A) universal joint into yoke on
splined shaft of primary countershaft gear case (D).
IMPORTANT: Do not reuse 12-point cap screws (B).

Discard and replace, using new 12-point
cap screws during installation.
15. Install new 12-point cap screws (B) and universal joint
retaining clamps (C) on yoke of splined shaft coming
from primary countershaft gear case (D).
16. Tighten 12-point cap screws to specification.
Specification
12-Point Cap Screws—Drive
Shaft Universal Joint—Torque ....................................................... 40 N•m
(30 lb-ft)

083006
PN=1208
Separator Drives
NOTE: Before installing top drive shaft (A), apply tape to

universal joint bearing caps to help prevent
dislodging bearing caps and losing needle 120
10
bearings. 17
17. Insert front drive shaft (A) into yoke (D) of front drive
–UN–17FEB00
shaft (G).
18. Slide packing (F) down splined shaft and tighten

packing nut (E) on yoke (D).
H62721
A—Front Drive Shaft
B—Carrier Bearing Carrier Bearing Viewed From Below
D—Yoke
E—Packing Nut
F—Packing
G—Front Drive Shaft

083006
PN=1209
Separator Drives
19. Remove tape from universal joint bearing caps and

insert front drive shaft (A) universal joint into yoke on
120 splined shaft of engine transfer gear case (D).
10
18
IMPORTANT: Do not reuse 12-point cap screws (B).
Discard and replace, using new 12-point
–UN–25APR00
cap screws during installation.
20. Install new 12-point cap screws (B) and universal joint
retaining clamps (C) on yoke of splined shaft from
H63703
engine transfer gear case (D).
21. Tighten 12-point cap screws to specification. Top Drive Shaft Universal Joint
Specification
12-Point Cap Screws—Drive
Shaft Universal Joint—Torque ....................................................... 40 N•m
(30 lb-ft)
22. Install front drive shaft shield (E) and tighten cap
screws and flanged lock nuts (F) to specification.
–UN–17FEB00
Specification
Cap Screws and Flanged Lock
Nuts—Top Drive Shaft Shield—
H62734
Torque ............................................................................................ 40 N•m
(30 lb-ft)
Top View From Front of Engine Compartment
A—Front Drive Shaft

B—12-Point Cap Screw (4 used)
C—Clamp (2 used)
D—Engine Transfer Gear Case
E—Shield
F—Cap Screw and Flanged Lock Nut (3 used)

083006
PN=1210
Separator Drives
23. Mount carrier bearing (B) with cap screws and

flanged lock nuts (C) and tighten to specification.
120
Specification 10
Carrier Bearing Cap Screws and 19
Flanged Lock Nuts—Torque ........................................................ 140 N•m
(103 lb-ft)
–UN–17FEB00
B—Carrier Bearing
C—Cap Screw and Flanged Lock Nut
H62720
D—Splined Yoke
OUO6083,000032C –19–15AUG02–6/6
Replace Drive Shaft Carrier Bearing
The carrier bearing is replaced as a complete kit. The kit

consists of two metal cup seals and a rubber mounted
bearing and bracket assembly. Removal of press fitted
carrier bearing will be assisted by first removing metal
–UN–17FEB00
bracket and rubber mount surrounding ball bearing. A
bearing removal tool can then be easily inserted between
ball bearing and larger metal cup seal.
H62735
1. Remove outer metal bracket and rubber insert from
carrier bearing assembly.
2. Insert D01218AA bearing pulling attachment (D) A—Drive Shaft

B—Bearing
between large metal cup seal and bearing (B).
C—D01290AA Puller
D—D01218AA Bearing Pulling Attachment
3. Attach D01218AA bearing pulling attachment (D) to
D01290AA puller (C) with 24 cm (9-1/2 in.) legs and
remove bearing.
4. Remove large metal cup seal from drive shaft (A) by

tapping off with a hammer.

083006
PN=1211
Separator Drives
5. Press new large metal cup seal (D) on drive shaft. (C)
with drive shaft seal installer tool JDG131-1 (B) in
120 hydraulic press (A).
10
20
NOTE: It is not necessary to disassemble rubber
mounted carrier bearing assembly prior to
–UN–17FEB00
pressing on drive shaft.
6. Remove JDG131-1 drive shaft seal installer (B) and

insert JDG131-2 drive shaft bearing installer adapter
H62737
(E) into it.
7. Slide carrier bearing (F) over splined end of drive shaft Bearing and Seal Installation Tools
(C).
8. Slide small metal cup seal (G) over splined end of

drive shaft (C).
9. Slide assembled tools JDG131-1 (B) and JDG131-2

(E) over splined end of drive shaft (C). Press carrier
–UN–17FEB00
bearing (F) and small metal cup seal (G) into position
with hydraulic press (A).
A—Press
H62736
B—JDG131-1 Drive Shaft Seal Installer
C—Drive Shaft
D—Large Metal Cup Seal Pressing Large Metal Cup Seal On Drive Shaft
E—JDG131-2 Drive Shaft Bearing Installer Adapter
F—Carrier Bearing
G—Small Metal Cup Seal
–UN–18FEB00
H62759
Pressing Carrier Bearing and Small Metal Cup Seal.
AG,OUO1075,1945 –19–25JUL00–2/2

083006
PN=1212
Group 15
Residue Disposal
NOTE: Order tools according to information given in the 120

15
U.S. SERVICEGARD Catalog or from the 1
AG,OUO1026,230 –19–25JUL00–1/2
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . D15032NU
–UN–01JUN01
H68348
AG,OUO1026,230 –19–25JUL00–2/2
Other Material
Number Name Use
PM38654 (U.S.) Thread Lock and Sealer (High Used to take up play between
Strength) jackshaft shaft and jackshaft bearing.
OUO6083,0000DD1 –19–23AUG06–1/1

083006
PN=1213
Residue Disposal
Specifications
15
2
Actuator Mounting Bracket Cap Torque 140 N•m
Screws (105 lb-ft)
Chopper Blades Lock Nut Torque 60 N•m

(44 lb-ft)
Straw Chopper Jackshaft Distance 76.5 mm

Bearing-to-End Of Shaft (3.0 in.)
Straw Chopper Drive Jackshaft Torque 308 N•m

Inside Flange Nut (227 lb-ft)
Straw Chopper Drive Jackshaft Torque 308 N•m

Outside Flange Nut (227 lb-ft)
Straw Chopper Jackshaft Mounting Torque 300 N•m


(36 qt)
Powered Tailboard Blade Cap Screw Torque 22 N•m

(16 lb-ft)
Straw Spreader Motor Cap Clearance 3 mm

Screws-to-Coupler (0.12 in.)
OUO6083,0000B54 –19–15SEP05–1/1

083006
PN=1214
Residue Disposal
Straw Chopper Rotor (Fine Cut)

120
15
F 3
C G
D
E
C
B
–UN–17JUN02
H
A
H72552
A—Rotor D—Left-Hand Paddle Blade (24 F—Right-Hand Paddle Blade G—Lock Nut (34 used)
B—Cap Screw (34 used) used) (24 used) H—Straight Blade (20 used)
C—Washer (68 used) E—Bushing (68 used)
OUO6083,00009E5 –19–10MAY05–1/1

083006
PN=1215
Residue Disposal
Straw Chopper Rotor (Extra Fine Cut)

120
15
4
–UN–23AUG05
H84275
A—Rotor D—Blade (30 used) G—Blade (30 used) I—Blade (60 used)
B—Cap Screw (60 used) E—Bushing (4 used) H—Lock Nut (60 used) J—Outer Bushing (116 used)
C—Washer (4 used) F—Inner Bushing (116 used)
OUO6083,0000B03 –19–23AUG05–1/1

083006
PN=1216
Residue Disposal
120
15
5

083006
PN=1217
Residue Disposal
Straw Chopper Housing

120
15
6
1 5
6
2 10
7
2
4
9
12 8
3
13
11
14
43 42
44
41
15
30 16
39 40 17
38
21
37
36 35
33 19
34 18
46
22
10
32
20
8 31 47
9 23
45
32
27 24
28 25
29 26
47
48
46
49
53
50
51
–UN–23AUG05
49
49 54
H84284
52
Continued on next page OUO6083,0000B04 –19–23AUG05–1/2

083006
PN=1218
Residue Disposal
1—Top Sheet 14—Round Head Bolt (8 used) 29—Cap screw 44—Left Side Pivot Bracket
2—Actuator Bracket (2 used) 15—Floor 30—Left Sidesheet 45—Lift Arm
3—Controller Bar (Extra Fine 16—Nut 31—Plate (2 used) 46—Washer (2 used) 120
Cut Only) 17—Quick Lock Pin 32—Magnet 47—Pin (2 used) 15
4—Cap Screw 18—Retaining Rod 33—Clip 48—Adjuster 7
5—Right Side Pivot Bracket 19—Clip 34—Bracket 49—Grip (3 used)
Assembly 20—Cap Screw 35—Sensor 50—Label
6—Cover 21—Knife Channel 36—Spring 51—Lift Arm
7—Washer 22—Nut 37—Washer 52—End Plate
8—Spacer (2 used) (Extra Fine 23—Support 38—Pin 53—Cross Rod
Cut Only) 24—Cap Screw 39—Latch 54—9560 STS (S.N. 715301—),
9—Bearing (2 used) 25—Nut 40—Stud 9660 STS (S.N. 715401—),
10—Locking Collar (2 used) 26—Stationary Knife (59 used) 41—Bracket 9760 STS (S.N. 715501—),
11—Flange Nut 27—Bushing (2 used) 42—Cap Screw 9860 STS (S.N. 716501—)
12—Cap Screw (8 used) 28—Washer (2 used) 43—Nut
13—Deflector (2 used) (Extra
Fine Cut Only)
OUO6083,0000B04 –19–23AUG05–2/2
Remove Straw Chopper
1. Remove cap screws and lock nuts (B and C) and

tailboard assembly (A).
A—Tailboard Assembly
–UN–25APR02
B—Cap Screw and Lock Nut (2 used)
H71837
OUO6083,0000B05 –19–23AUG05–1/7
2. Raise straw chopper until lockout pins latch and

access door (A) is clear. Depress pin (B) and lower
door. Lower straw chopper back down.
A—Access Door
B—Pin
–UN–25APR02
H71838

083006
PN=1219
Residue Disposal
3. Release latch (A) and lift shield (B) to remove from

pins (C).
120
15
8 A—Latch
B—Shield
C—Pins
–UN–25APR02
H71839
OUO6083,0000B05 –19–23AUG05–3/7
4. Remove pin (A) and lift shield (B) from bracket (C).
A—Pin
B—Shield
C—Bracket
–UN–19MAR02
H71327
OUO6083,0000B05 –19–23AUG05–4/7
5. Disconnect sensor (A).
A—Sensor
–UN–19APR99
H55178

083006
PN=1220
Residue Disposal
6. Loosen idler tensioner (A), remove straw chopper drive

belt (B) and lower chopper.
120
15
CAUTION: Use a hoist or other safe lifting 9
device to support straw chopper assembly.
–UN–19MAR02
7. Support straw chopper assembly using safe lifting
device.
H71330
A—Idler Tensioner
B—Straw Chopper Drive Belt
OUO6083,0000B05 –19–23AUG05–6/7
8. Remove cap screw (A) from actuator at rod end.
9. Remove cap screws (B) on both sides and remove

straw chopper.
A—Cap Screw
–UN–28MAY03
H77495
–UN–25APR02
H71840
OUO6083,0000B05 –19–23AUG05–7/7

083006
PN=1221
Residue Disposal
Remove and Install Chopper Raise/Lower

Actuator
120
15
10 NOTE: Fuel tank does not have to be drained and
tailboard assembly does not have to be lowered
to remove actuator on machines (S.N. 715301—).
–UN–23AUG05
1. Release latch pins (A) and lower door (B).
2. Lower chopper into the chop position.
H84285
A—Latch Pin (2 used)
B—Door
OUO6083,0000CAC –19–07MAR06–1/12
3. Drain fuel tank at valve (A).
Specification
(250 gal)
–UN–08MAY01
A—Drain Valve
H67618
OUO6083,0000CAC –19–07MAR06–2/12
4. Remove cap screws (A) from arms (B) and lower

tailboard assembly.

B—Arm (2 used)
–UN–19MAR02
H71329
Continued on next page OUO6083,0000CAC –19–07MAR06–3/12

083006
PN=1222
Residue Disposal
NOTE: The use of a second person is needed to help

remove hardware on seal (B).
120
15
5. Remove cap screws and nuts (A) and seal (B). 11
6. Remove cap screw (E).
–UN–15APR02
7. Disconnect harness connector (C) and remove harness
from clamps (D).
H71643
B—Seal
D—Clamp (3 used)
E—Cap Screw
OUO6083,0000CAC –19–07MAR06–4/12
8. Remove cap screws (A) and actuator mounting bracket

(B).

B—Actuator Mounting Bracket
–UN–25JAN00
H62352
OUO6083,0000CAC –19–07MAR06–5/12
9. Remove cap screw and nut (B) and actuator from

bracket (A).
A—Actuator Mounting Bracket

B—Cap Screw and Nut –UN–22APR99
H55659

083006
PN=1223
Residue Disposal
10. Install new actuator (B) in bracket (C) using cap

screw and nut (A).
120
15
12 A—Cap Screw and Nut
B—Actuator
C—Mounting Bracket
–UN–25JAN00
H62353
OUO6083,0000CAC –19–07MAR06–7/12
11. Position mounting bracket (B) and install cap screws

(A). Tighten cap screws to specification.
Specification
Actuator Mounting Bracket Cap
Screws—Torque ........................................................................... 140 N•m
(103 lb-ft)
–UN–25JAN00
B—Actuator Mounting Bracket
H62352
OUO6083,0000CAC –19–07MAR06–8/12
NOTE: Use of a second person is needed to help install

hardware on seal (B).
12. Install seal (B) using cap screws and nuts (A).
13. Install harness in clamps (D) and connect harness

connector (C).
–UN–25JAN00
14. Install cap screw (E).
H62351
B—Seal
D—Clamp (3 used)
E—Cap Screw

083006
PN=1224
Residue Disposal
15. Position tailboard arms (B) and install cap screws and
nuts (A).
120
15
B—Arm (2 used)
–UN–19MAR02
H71329
OUO6083,0000CAC –19–07MAR06–10/12
16. Raise chopper far enough to position door (B) using

latch pins (A).
A—Latch Pin (2 used)

B—Door
–UN–23AUG05
H84285
OUO6083,0000CAC –19–07MAR06–11/12
17. Close drain valve (A).
18. Fill fuel tank with recommended fuel. (See FUEL AND
LUBRICANTS in Section 10.)
A—Drain Valve
–UN–08MAY01
H67618
OUO6083,0000CAC –19–07MAR06–12/12

083006
PN=1225
Residue Disposal
Install Straw Chopper

120
15 CAUTION: Use a hoist or other safe lifting
14 device to support straw chopper assembly.
1. Position straw chopper and install cap screws (B) on
–UN–25APR02
both sides of straw chopper.
2. Install cap screw (A) in actuator at rod end.
H71840
A—Cap Screw
–UN–28MAY03
H77495
OUO6083,0000B07 –19–23AUG05–1/7
3. Install straw chopper drive belt (B) and tighten idler

tensioner (A).
A—Idler Tensioner
–UN–19MAR02
H71330
OUO6083,0000B07 –19–23AUG05–2/7
4. Connect sensor (A).
A—Sensor
–UN–19APR99
H55178

083006
PN=1226
Residue Disposal
5. Install shield (B) on bracket (C) and retain with pin (A).
120
A—Pin 15
B—Shield 15
C—Bracket
–UN–19MAR02
H71327
OUO6083,0000B07 –19–23AUG05–4/7
6. Install shield (B) onto pins (C) and lock latch (A).
A—Latch
B—Shield
C—Pins
–UN–25APR02
H71839
OUO6083,0000B07 –19–23AUG05–5/7
7. Raise straw chopper until lockout pins latch and allow

clearance for raising access door (A). Raise lower door
until pin (B) engages as shown. Lower straw chopper
back down.
A—Access Door
–UN–25APR02
B—Pin
H71838
OUO6083,0000B07 –19–23AUG05–6/7
8. Install tailboard assembly (A) by installing cap screws

and lock nuts (B) and cap screws and lock nuts (C).
A—Tailboard Assembly
B—Cap Screw and Lock nut (2 used)
C—Cap Screw and Lock nut (2 used)
–UN–25APR02
H71837
OUO6083,0000B07 –19–23AUG05–7/7

083006
PN=1227
Residue Disposal
Chopper Blades Replacement and

Configuration—9560
120
15
16 CAUTION: Shut OFF engine, set parking brake
and remove key. Before performing service or
maintenance on raised chopper, use lift
–UN–27APR05
actuator to snap lock-out pins into place.
NOTE: Rotor shown illustrates blade replacement for

paddle blades. Always maintain original factory
H83239
provided blade pattern.
1. Remove lock nut (A), cap screw (B), washers (C) and A—Lock Nut
bushings (D). B—Cap Screw
C—Washers
NOTE: If removing blades or bushings for inspection D—Bushings
purposes, be certain to reinstall blades on SAME
support from which they were removed. This must
be done to maintain balance. It is a good practice
to individually mark each blade before removal.
2. Inspect bushings (D) while replacing blades. Replace

worn bushings. See your John Deere dealer for
replacement parts.
Continued on next page OUO6083,0000CD6 –19–24MAR06–1/2

083006
PN=1228
Residue Disposal
IMPORTANT: Chopper balance MUST be maintained.

Replace BOTH blades on single support
and BOTH blades on opposite support 120
15
(180°). Also, replace the four blades at 17
the other end of the rotor, at the same
axial distance from the balance ring.
–UN–27APR05
Eight blades MUST be installed to
replace one broken blade, or all the
blades can be replaced at one time.
H83239
This MUST be done to keep vibration to
a minimum.
Example: If paddle blade (E) is broken,

replace paddle blades (E—L).
3. Replace blade and install cap screw (B), washer (C),

bushing (D) and lock nut (A). Tighten nut to
specification.
–UN–27APR05
Specification
Chopper Blades Lock Nut—
Torque ............................................................................................ 60 N•m
(44 lb-ft)
H83240
IMPORTANT: Verify clearance between rotor blades
and stationary knives, by rotating rotor
A—Lock Nut
by hand, before running chopper. B—Cap Screw
C—Washers
D—Bushings
E—L—Paddle Blade
OUO6083,0000CD6 –19–24MAR06–2/2

083006
PN=1229
Residue Disposal
Remove and Replace Straw Chopper Blades C

B D A
(Fine Cut)
120
15
18 NOTE: Rotor shown illustrates blade replacement
examples for both paddle and straight blades.
Always maintain original factory blade pattern.
1. Remove lock nut (A), cap screw (B), washer (C) and
bushing (D).
NOTE: If removing blades or bushings for inspection

purposes, be certain to reinstall on SAME support E F G H
from which they were removed. This must be
done to maintain balance. It is a good practice to
individually mark each blade before removal.
2. Inspect blade bushings (D) while replacing blades.

Replace worn bushings.
IMPORTANT: Chopper MUST be maintained. Replace

BOTH blades on single support and I J K L
BOTH blades on opposite support
(180°). Also, replace the four blades at M N O P
the other end of the rotor, at the same
axial distance from the balance ring.
Eight blades MUST be installed to

replace one broken blade, or all the
–UN–12FEB02
blades can replaced at one time. This
MUST be done to keep vibration to a
minimum.
H71019
Q R S T
For example: If paddle blade (E) is
broken, replace paddle blades (E—L). If Straw Chopper Blades
straight blade (M) is broken, replace
straight blades (M—T). A—Lock Nut
B—Cap Screw
C—Washer
3. Replace blade and install cap screw (B), washer (C), D—Bushing
bushing (D) and lock nut (A). Tighten nut to E—L—Paddle Blade
specification. M—T—Straight Blade
Specification
Chopper Blade Lock Nut—Torque ................................................. 60 N•m
(44 lb-ft)
Continued on next page OUO6083,00009E8 –19–10MAY05–1/2

083006
PN=1230
Residue Disposal
IMPORTANT: Damage could occur if proper clearance

between rotor blades and stationary
knives are not met. 120
15
19
4. Rotate rotor by hand to check clearance between rotor
blades and stationary knives.
OUO6083,00009E8 –19–10MAY05–2/2
Remove and Replace Straw Chopper Blades F A

(Extra Fine Cut)
E
D
CAUTION: Shut OFF engine, set parking brake C
and remove key. Before performing service or B
maintenance on raised chopper, use lift
–UN–05OCT04
actuator to snap lock-out pins into place.
NOTE: Rotor shown illustrates blade replacement

examples for both paddle and straight blades.
H81774
Always maintain original factory provided blade
pattern.
A—Lock Nut
Outer Most Blade Removal: B—Cap Screw
C—Washer
NOTE: If removing blades or bushings for inspection D—Bushing
E—Bushing
purposes, be certain to reinstall blades on SAME F—Bushing
support from which they were removed. This must
Remove lock nut (A), cap screw (B), washer (C), and
bushings (D), (E) and (F).
Inspect, and if needed, replace blade bushings (D), (E),

and (F) while replacing blades.
Continued on next page OUO6083,0000CAD –19–07JUL06–1/5

083006
PN=1231
Residue Disposal
Inner Blade Removal: A

C
120 NOTE: If removing blades or bushings for inspection D
15
20
purposes, be certain to reinstall blades on SAME D
support from which they were removed. This must C
–UN–05OCT04
Remove lock nut (A), cap screw (B), bushings (C and D).
B
H81775
Inspect, and if needed, replace blade bushings (C and D)
while replacing blades.
A—Lock Nut
B—Cap Screw
C—Bushings
D—Bushings
OUO6083,0000CAD –19–07JUL06–2/5
Blade Configuration:
A B C D
IMPORTANT: Chopper balance MUST be maintained.

Replace BOTH blades on single support
and BOTH blades on opposite support
(180 degrees). Also, replace the four
–UN–10NOV03
blades at the opposite end of the rotor,
at the same axial distance from the
balance ring. Eight blades MUST be
installed to replace one broken blade,
H78905
or all the blades can be replaced at one E F G H
time. This MUST be done to keep
vibration to a minimum.
I J K L
If paddle blade (A) is broken, replaces paddle blades (A—
H).
If straight blade (I) is broken, replace straight blades (I—

P).
–UN–10NOV03
A—H—Paddle Blades
I—P—Straight Blades
H78904
M N O P
Continued on next page OUO6083,0000CAD –19–07JUL06–3/5

083006
PN=1232
Residue Disposal
Outer Most Blade Installation: F A
Replace blade and install cap screw (B), washer (C), E 120
D 15
bushings (D), (E), (F), and lock nut (A). Tighten nuts to 21
specification. C
B
–UN–05OCT04
Specification
Chopper Blade Lock Nuts—
Torque ............................................................................................ 60 N•m
(44 lb-ft)
H81774
A—Lock Nut
B—Cap Screw
C—Washer
D—Bushing
E—Bushing
F—Bushing
OUO6083,0000CAD –19–07JUL06–4/5
Inner Blade Installation: A

C
Replace blade and install cap screw (B), bushings (C), D
(D), and lock nut (A). Tighten nuts to specification. D
C
Specification
Chopper Blade Lock Nuts—
–UN–05OCT04
Torque ............................................................................................ 60 N•m
(44 lb-ft)
B
A—Lock Nut
H81775
B—Cap Screw
C—Bushings
D—Bushings
OUO6083,0000CAD –19–07JUL06–5/5

083006
PN=1233
Residue Disposal
Replace Knife Blades (S.N. —715300)

120
15 CAUTION: Engine must be off and key removed.
22
1. Loosen right- and left-hand cap screws (A) and lower
knife assembly to position shown. Tighten right- and
–UN–28MAY03
left-hand cap screws (A).
2. Loosen lock nuts (B).
H77500
CAUTION: Knife sections are sharp.
3. Remove pin (C) and slide retaining rod (D) out either A—Cap Screw (2 used)
side. B—Lock Nut (8 used)
C—Pin
D—Retaining Rod
4. Turn knives over for additional usage, or replace
knives if worn on both sides.
OUO6083,0000B09 –19–23AUG05–1/2
5. Push retaining rod (D) back into position.
6. Install pin (C) as shown.
7. Tighten lock nuts (B).
–UN–28MAY03
8. Loosen right- and left-hand cap screws (A) and
position knife assembly to desired position. Tighten
right- and left-hand cap screws (A).
H77500
C—Pin
D—Retaining Rod
OUO6083,0000B09 –19–23AUG05–2/2

083006
PN=1234
Residue Disposal
Replace Knife Blades (S.N. 715301—)

120
CAUTION: Engine must be off and key removed. 15
23
1. Remove knife bank. (See REMOVE AND INSTALL
EASY ADJUST KNIFE BANK in this group.)
–UN–23AUG05
2. Remove pin (A).
3. Loosen cap screws (B) and remove retaining rod (C).
H84296
4. Turn knives over for additional usage, or replace
knives if worn on both sides. A—Pin
5. Install in reverse order. C—Retaining Rod
OUO6083,0000B19 –19–12JAN06–1/1

083006
PN=1235
Residue Disposal
Remove and Install Easy Adjust Knife Bank

120
15 CAUTION: Engine must be off and key removed.
24
1. Remove wing nut (A) from left- hand side of chopper
housing.
–UN–11MAY05
2. Support knife bank assembly and remove spring pin
(B), washer (C), arm and rod assembly (D) and
spacers (E).
H83453
CAUTION: Knife blades are sharp.
3. Remove knife assembly from chopper housing. Repair

4. Install knife assembly in reverse order.
–UN–11MAY05
A—Wing Nut
B—Spring Pin
C—Washer
D—Arm and Rod Assembly
E—Spacer (2 used)
H83454
–UN–12MAY05
H83460
OUO6083,00009EB –19–12MAY05–1/1

083006
PN=1236
Residue Disposal
Remove and Install Crop Diverter
1. Raise straw chopper until lockout pins latch and 120

15
access door (A) is clear. Depress pins (B), one on 25
each side, and lower door.
–UN–25APR02
NOTE: The use of a second person is needed to support
crop diverter while removing hardware.
2. Position crop diverter in corn position.
H71838
A—Access Door
B—Pin (2 used)
Continued on next page OUO6083,0000B0B –19–23AUG05–1/3

083006
PN=1237
Residue Disposal
CAUTION: Crop diverter will drop when

120 removing spacer (C).
15
26 3. Remove:
• Chopper drive shield
–UN–23AUG05
• Cap screw, washer (A) and handle (B) from
right-hand side of machine
• Cap screw, washer (A) and spacer (C) from left-hand
side of machine
H84299
• Crop diverter (D) from cleaning shoe access area

B—Handle
C—Spacer
D—Crop Diverter
–UN–25APR02
H71852
–UN–01OCT02
H73470
Continued on next page OUO6083,0000B0B –19–23AUG05–2/3

083006
PN=1238
Residue Disposal
4. Install:
• Crop diverter (D) 120

15
• Spacer (C), cap screw and washer (A) on left-hand 27
side of machine
• Handle (B), cap screw and washer (A) on right-hand
–UN–23AUG05
side of machine. Tighten all hardware.
• Chopper drive shield
H84299
B—Handle
C—Spacer
D—Crop Diverter
–UN–25APR02
H71852
–UN–01OCT02
H73470
OUO6083,0000B0B –19–23AUG05–3/3

083006
PN=1239
Residue Disposal
Replace Left-Hand Chopper Rotor Bearing

120 IMPORTANT: Damage to chopper components can
15
28
occur if blade-to-knife clearance is not
maintained. Replace only one rotor
bearing at a time to avoid changing
existing alignment.
1. Park machine on a flat level surface, set parking brake,

shut off engine and remove key.
2. Remove shields (A) on left-hand side of straw chopper.
–UN–12JUL02
3. Release tension from chopper belt.
4. Remove belt from chopper rotor sheave and set aside.
H72822
5. Raise chopper to access bearing hardware.
6. Remove cap screw and nut (B).
7. Remove chopper rotor sheave (C) and key.
A—Shields
B—Cap Screw And Nut
–UN–11JUL02
C—Chopper Rotor Sheave
H72803
Continued on next page OUO6083,0000B0D –19–13JAN06–1/4

083006
PN=1240
Residue Disposal
NOTE: For ease in disassembly, remove paint from

chopper rotor shaft using abrasive cloth before
attempting to remove remaining components. 120
15
29
9. Loosen top two flange nuts (B).
–UN–11JUL02
10. Remove sensor bracket (C).
H72805
11. Loosen sensor collar screws (D) and remove collars.
12. If equipped, loosen socket head screw (E) and

remove sleeve (F).
A—Connector
B—Flange Cap Screws
C—Sensor Bracket
D—Sensor Collar Screws
E—Socket Head Screw
–UN–04FEB05
F—Sleeve
H82372
–UN–25AUG05
H84300

083006
PN=1241
Residue Disposal
13. Loosen lock collar set screw (A).
120 14. Rotate lock collar clockwise (direction of arrow) to

15
30
unlock it from the bearing assembly.
15. Remove and discard lock collar.
–UN–11JUL02
IMPORTANT: When removing bearing assembly, use
a bearing puller to avoid possible
damage to rotor shaft.
H72813
16. Remove and discard four flanged lock nuts (B) and
bearing assembly (C).
A—Lock Collar Set Screw
NOTE: There is a thin sheet metal spacer between the B—Flanged Lock Nuts
C—Bearing Assembly
bearing housing and chopper sidesheet on the
extra fine cut chopper. This will be required for
assembly.

083006
PN=1242
Residue Disposal
IMPORTANT: For extra fine cut chopper, install sheet

metal spacer between chopper
sidesheet and bearing housing with 120
15
opening pointing downward. Install 31
bearing housing with grease fitting to
match same downward location.
–UN–11JUL02
17. Loosely install replacement bearing assembly using
new locking flange nuts.
H72814
18. Align new bearing assembly with paint outline of
removed bearing assembly. Tighten two flanged lock
nuts (A).
19. Install sensor bracket and tighten top two flanged lock
nuts.
20. Align new lock collar with bearing.
–UN–04FEB05
21. Rotate lock collar counterclockwise (direction of
arrow) to lock it against bearing.
22. Tighten set screw (B).
H82371
23. If equipped, push inner sensor sleeve against bearing
lock collar and tighten set screw.
24. Install sensor and tighten two screws.
25. Measure gap (C) between sensor and sensor collar.

Adjust sensor to specification as necessary.
–UN–24AUG05
Specification
Between Sensor And Sensor
Collar—Gap ....................................................................................... 2 mm
(1/8 in.)
H84301
26. Install chopper shaft sheave.
27. Verify belt alignment between chopper shaft sheave

A—Flanged Lock Nuts
and jackshaft sheave. B—Set Screw
C—Sensor Gap
28. Install sheave (D). Tighten cap screw and nut (E). D—Sheave
E—Cap Screw and Nut
29. Pump three pumps of John Deere SD Polyurea
Multi-Purpose grease into bearing assembly.
30. Install belts and shields.
OUO6083,0000B0D –19–13JAN06–4/4

083006
PN=1243
Residue Disposal
Replace Right-Hand Chopper Rotor Bearing

120 NOTE: Extra fine cut chopper bearing cover retained
15
32
using two nuts, and no washers.
1. Remove four nuts (A), cover (B), and four washers
–UN–09JUL02
behind cover.
NOTE: Extra fine cut chopper uses a thin sheet metal

spacer behind bearing. Save for reassembly.
H72780
2. Remove and discard lock collar (C) and bearing
assembly (D) using the same procedure as on
left-hand side.
IMPORTANT: For extra fine cut chopper, install sheet

metal spacer between chopper
sidesheet and bearing housing with
opening pointing downward. Install
–UN–11JUL02
bearing housing so grease fitting
matches same downward location.
3. Install replacement bearing assembly and lock collar
H72816
using the same procedure as on left-hand side. (For
right-hand side, reverse rotational directions for lock
collar.) A—Nuts (4 Used)
B—Cover
4. Install washers, cover and nuts. C—Lock Collar
D—Bearing Assembly
OUO6083,00009ED –19–28JUL05–1/1
Remove Straw Chopper Drive Jackshaft
1. Remove shields (A).
A—Shields
–UN–19MAR02
H71328
Continued on next page OUO6083,0000DD3 –19–23AUG06–1/8

083006
PN=1244
Residue Disposal
2. Loosen idler (A) and remove straw chopper drive belt

(B).
120
15
A—Idler 33
B—Straw chopper Drive Belt
–UN–19MAR02
H71330
OUO6083,0000DD3 –19–23AUG06–2/8
CAUTION: Use hoist or other safe lifting device

to support jackshaft assembly.
3. Loosen nuts (A) to relieve belt tension.
4. Remove pin (B) and disconnect tensioner rod.
–UN–03JUN99
5. Loosen two cap screws (C).
6. Remove belts (D and E).
H55237
7. Remove two cap screws (C) and lower straw chopper
drive jackshaft. A—Nut (2 used)
B— Pin
D—Belt
E—Belt
OUO6083,0000DD3 –19–23AUG06–3/8
8. Remove flange nut, washer and key (A).
A—Flange Nut, Washer and Key
–UN–19APR99
H55472

083006
PN=1245
Residue Disposal
9. Remove sheave (A) using a puller (B).
120
15 A—Sheave
34 B—Puller
–UN–19APR99
H55473
OUO6083,0000DD3 –19–23AUG06–5/8
NOTE: May be necessary to apply heat to remove

bearings from jackshaft.
10. Remove locking collar (A), bearing (B) and arm (C).
A—Locking Collar
–UN–19APR99
B—Bearing
C—Arm
H55474
OUO6083,0000DD3 –19–23AUG06–6/8
11. Remove flange nut (A), washer and key.
12. Remove sheave (B).
A—Flange Nut
B—Sheave
–UN–19APR99
H55476

083006
PN=1246
Residue Disposal
NOTE: May be necessary to apply heat to remove

bearings from jackshaft.
120
15
13. Remove locking collar (B) and bearing (A). 35
14. Clean and inspect all parts. Replace parts as

necessary.
–UN–21JUL99
A—Bearing
B—Locking Collar
H58661
OUO6083,0000DD3 –19–23AUG06–8/8
Install Straw Chopper Drive Jackshaft
NOTE: Apply PM38654 Thread Lock and Sealer (High

Strength) between jackshaft bearings and
jackshaft during reassembly.
–UN–24MAY04
1. Position bearing (B) at specified dimension (A).
Specification
Straw Chopper Jackshaft
Bearing-to-End Of Shaft—
H80937
Distance ........................................................................................ 76.5 mm
(3.0 in.)
2. Install lock collar (C) on bearing and tighten in

clockwise direction.
3. Install shaft with bearing into arm (D).
4. Install bearing (E) and locking collar (F). Tighten
–UN–21JUL99
locking collar in clockwise direction.
A—Dimension
B—Bearing
H58660
C—Locking Collar
D—Arm
E—Bearing
F—Locking Collar

083006
PN=1247
Residue Disposal
5. Install key, sheave (B), washer and flange nut (A).

Tighten flange nut to specification.
120
15 Specification
36 Straw Chopper Drive Jackshaft
Inside Flange Nut—Torque .......................................................... 308 N•m
(227 lb-ft)
–UN–21JUL99
A—Nut
B—Sheave
H58668
OUO6083,0000DD2 –19–23AUG06–2/6
6. Install sheave (B).
7. Install flange nut, washer and key (A). Tighten flange

Specification
–UN–20APR99
Straw Chopper Drive Jackshaft
Outside Flange Nut—Torque ....................................................... 308 N•m
(227 lb-ft)
H55472A
A—Flange Nut, Washer and Key
B—Sheave
OUO6083,0000DD2 –19–23AUG06–3/6
8. Raise straw chopper jackshaft drive and install two cap

screws (C) finger tight.
9. Install belts (D and E).
10. Tighten two cap screws (C) to specification.

–UN–03JUN99
Specification
Straw Chopper Jackshaft
Mounting Cap Screws—Torque ................................................... 300 N•m
(221 lb-ft)
H55237
11. Connect tensioner rod and install pin (B).

A—Nut (2 used)
12. Tighten nuts (A) until washer aligns with gauge. B—Cotter Pin
D—Belt
E—Belt

083006
PN=1248
Residue Disposal
13. Install straw chopper drive belt (B) and tighten belt
with idler (A).
120
15
A—Idler 37
–UN–19MAR02
H71330
OUO6083,0000DD2 –19–23AUG06–5/6
14. Install shields (A).
A—Shields
–UN–19MAR02
H71328
OUO6083,0000DD2 –19–23AUG06–6/6

083006
PN=1249
Residue Disposal
Powered Tailboard—Exploded View

120
15
38
2 14 15
1
17
16
18
3 19
4
20
5
11
9
21
19
6
10
22
10
10
23
24
25
10 13
11
9
8 9
29 39 12
27
30 28
31
34
32
33 26
–UN–23AUG05
38 36
35
H83630
37
Continued on next page OUO6083,0000B0E –19–24AUG05–1/2

083006
PN=1250
Residue Disposal
1—Cover 11—Round Head Bolt 21—Bushing (2 used) 31—Shroud

2—Cap Screw 12—Cap Screw (4 used) 22—Plate (2 used) 32—Shroud
3—Round Head Bolt 13—Cap Screw (2 used) 23—Bracket 33—Air Deflector (12 used) 120
4—Cap Screw 14—Lock Nut (2 used) 24—Cap Screw 34—Disk (2 used) 15
5—Clamp 15—Bushing (2 used) 25—Cap Screw 35—Cap Screw 39
6—Tailboard 16—Support (2 used) 26—Tube (2 used) 36—Blade (12 used)
7—Flange Nut 17—Cap Screw (2 used) 27—Hub (2 used) 37—Washer
8—Cap Screw 18—Cap Screw (2 used) 28—Disk (2 used) 38—Lock Nut
9—Plate (2 used) 19—Lock Nut (4 used) 29—Cap Screw 39—Plug (4 used)
10—Lock Nut (6 used) 20—Support (2 used) 30—Washer
OUO6083,0000B0E –19–24AUG05–2/2
Remove and Install Powered Tailboard

Blades
IMPORTANT: Disk assemblies are left-and right-hand

side. Mark disk assemblies before
removing to assure correct
–UN–10FEB05
reinstallation.
1. Remove lock nut (A) and cap screw (B) from spreader
disks. Remove disk assemblies.
H82425
A—Lock Nut
B—Cap Screw

083006
PN=1251
Residue Disposal
IMPORTANT: When replacing worn or damaged

blades, make sure to replace blades on
120 opposite sides of the disk at the same
15
40
time. This will maintain disk rotational
balance.
NOTE: Blades are oriented in alternating hole patterns to
–UN–14JUN05
obtain an optimum material spread. Reinstall
blades back in same set of holes as previously
removed.
H83736
2. Remove lock nuts and washers (A) and blade (B).
3. Replace blades as needed. Tighten hardware to A—Lock Nut and Washer (3 used)
specification. B—Blade
Specification
Powered Tailboard Blade Cap
Screw—Torque ............................................................................... 22 N•m
(16 lb-ft)
OUO6083,0000A2A –19–14JUN05–2/2

083006
PN=1252
Residue Disposal
Remove Straw Spreader

120
CAUTION: Escaping fluid under pressure can 15
penetrate the skin causing serious injury. 41
–UN–23AUG88
X9811
fluids.


accumulator shut-off valve.

reservoir.
Specification
(36 qt)
OUO6083,0000B55 –19–15SEP05–1/6
3. Remove limit curtain (D).
4. Remove cap screws (B and C) and shield assembly

(A).
A—Shield Assembly
–UN–29MAY03
B—Cap Screw with Flanged Nut (4 used)

C—Cap Screw
D—Limit Curtain
H77503

083006
PN=1253
Residue Disposal
5. Disconnect hydraulic hoses (A) from quick couplers.
120
15 A—Hose (2 used)
42
–UN–27APR99
H55802
OUO6083,0000B55 –19–15SEP05–3/6
6. Disconnect quick-lock pin (A), pull pin (B) and move

support (C) forward.
A—Quick-Lock Pin
B—Pin
C—Support
–UN–15SEP05
H84480
OUO6083,0000B55 –19–15SEP05–4/6
7. Disconnect sensor (A).
A—Sensor
–UN–27APR99
H55804

083006
PN=1254
Residue Disposal
CAUTION: Lifting heavy components incorrectly

can cause severe injury or machine damage. 120
Follow recommended procedure for installation 15
of components. 43
8. Position a forklift or other suitable lifting device under
–UN–23AUG88
spreader (A) and remove eight M10 x 25 flange screws
(B) and flange nuts.
A—Straw Spreader
TS226
B—Flange Screw (8 used)
–UN–24FEB99
H51598
OUO6083,0000B55 –19–15SEP05–6/6

083006
PN=1255
Residue Disposal
Disassemble and Assemble Straw Spreader

120
15
44
–UN–08JUL99
H57524B

083006
PN=1256
Residue Disposal
1— Flange Nut (8 used) 6—Bracket Assembly (2 used) 9—Bushing (2 used) 12—Deflector Panel
2— Flange Nut (10 used) 7—Left-Hand Bracket 10—Left-Hand Gas Spring 13—Main Support
3—Cap Screw (8 used) Assembly Bracket 14—Gas Spring (2 used) 120
4—Cap Screw (2 used) 8—Right-Hand Bracket 11—Right-Hand Gas Spring 15
5—Cap Screw (6 used) Assembly Bracket 45
OUO6083,0000B53 –19–15SEP05–2/6
S B
V
C
A
U
D
B
G
E C
B
F
W
I H
J R
H
K
M
H
L Q
M I O
–UN–17JUL01
L
M P H69282
A—Cotter Pin G—Pin M—Lock Nut S—Panel

B—Screw H—Bolt N—Plate T—Limit Curtain
C—Flange Nut I—Screw O—Hub U—Flange Nut
D—Tube J—Blade P—Lubrication Fitting V—Screw
E—Washer K—Reinforcement Q—Reinforcement W—Shroud
F—Spring L—Washer R—Crop Divider

083006
PN=1257
Residue Disposal
A
120 C
15 B
46
F
B
J K
M L
N
O
P
Q
R –UN–30MAY02
U
H72379
A—Motor G—Shaft L—Hub Q—Bracket

B—Key (2 used) H—Round Head Bolt (3 used) M—Screw (2 used) R—Switch
C—Support I—Bearing N—Actuator S—Pan Head Screw (2 used)
D—Cap Screw (4 used) J—Flange (2 used) O—Locking Collar T—Shield
E—Cap Screw (2 used) K—Round Head Bolt (2 used) P—Magnet U—Flange Nut (5 used)
F—Coupling
Assemble using the following special instructions: • Shaft on motor (A) must touch shaft (G)

083006
PN=1258
Residue Disposal
• Set clearance between coupling (F) and cap screws • Tighten locking collar (O) on left-hand shaft
(D) to specification counterclockwise
• Tighten locking collar (O) on right-hand shaft 120
Specification 15
clockwise 47
Straw Spreader Motor Cap • Install actuator (N), magnet (P), bracket (Q) and
Screws-to-Coupler—Clearance .................................................. 3 mm
(0.12 in.) switch (R) on left-hand shaft
OUO6083,0000B53 –19–15SEP05–5/6
F
H
F
A E D
–UN–24AUG05
C
B
D
H84302
A—Support C—Cap Screw (2 used) E—Flange Nut (2 used) G—Flange Nut (4 used)
B—Spreader Hoop D—Washer (2 used) F—Cap Screw (4 used) H—Support
OUO6083,0000B53 –19–15SEP05–6/6

083006
PN=1259
Residue Disposal
Install Straw Spreader

120
15 CAUTION: Lifting heavy components incorrectly
48 can cause sever injury or machine damage.
Follow recommended procedure for installation
of components.
–UN–23AUG88
1. Using a forklift or other suitable lifting device, position
straw spreader (A) and attach to combine using cap
screws (B) and flanged nuts.
TS226
A—Straw Spreader
–UN–24FEB99
H51598
OUO6083,0000B56 –19–15SEP05–1/5
2. Connect sensor (A).
A—Sensor
–UN–27APR99
H55804
OUO6083,0000B56 –19–15SEP05–2/5
3. Align support (A) and install pin (B). Retain using

quick-lock pin.
4. Tighten nut (C).
A—Support
–UN–18JUL05
B—Pin
C—Nut
H84008

083006
PN=1260
Residue Disposal
5. Route hydraulic hoses (A) through hose clamp to straw

spreader and connect quick couplers.
120
15
A—Hose (2 used) 49
–UN–27APR99
H55802
OUO6083,0000B56 –19–15SEP05–4/5
6. Attach shield assembly (A) using cap screws and

flanged nuts (B), and cap screw (C).
7. Install limit curtain (D).
A—Shield Assembly
–UN–29MAY03
B—Cap Screw And Flanged Nuts (4 used)
C—Cap Screw
D—Limit Curtain
H77503
OUO6083,0000B56 –19–15SEP05–5/5

083006
PN=1261
Residue Disposal
120
15
50

083006
PN=1262
Group 20
Conveyor Augers, Cleaning Fan And Chaffer And Sieve Frame
Other Material
Number Name Use 120

20
1
PM37477 (U.S.) Thread Lock and Sealer (Medium Fan speed actuator threads.
Strength)
PM38654 (U.S.) Thread Lock and Sealer (High Retain bevel gears-to-conveyor
Strength) auger drive shaft.
OUO6083,0000DD4 –19–23AUG06–1/1

083006
PN=1263
Specifications
20
2
Conveyor Auger Drive Shaft Bevel Backlash 0.75 mm
Gears (1/32 in.)
Conveyor Shaft-to-Sidesheet Distance 220 ± 3 mm

(8 3/4 ± 1/8 in.)
Conveyor Auger Sheave Mounting Torque 250 N•m

Nut (185 lb-ft)
Conveyor Auger Gear-to-Locking Distance 3 mm

Collar (1/8 in.)
Cleaning Fan Outer Sheave Set Torque 55 N•m

Screws (40 lb-ft)
Cleaning Fan Drive Jackshaft Nuts Torque 123 N•m

(90 lb-ft)
Cleaning Fan Drive Jackshaft Cap Torque 70 N•m

Screw (52 lb-ft)
Cleaning Fan Drive Inner Sheave Torque 70 N•m

End of Cleaning Fan Shaft-to-Fan Distance 383 mm

Wheel (15 in.)
Front Chaffer Cap Screws Torque 70 N•m

(52 lb-ft)
Front Chaffer Finger Cap Screws Torque 20 N•m

(15 lb-ft)
Chaffer Frame Weight 120 kg

(265 lb)
Front Swinger Arms Torque 320 N•m

(235 lb-ft)
Rear Swinger Arms Torque 130 N•m

(95 lb-ft)
Sieve Retaining Bolts Torque 100 N•m

(74 lb-ft)

083006
PN=1264
Chaffer Retaining Bolts Torque 100 N•m 120

20
(74 lb-ft) 3
Shoe Pitman Arm Bearing Race Distance 127 mm

(5 in.)
Pitman Arm Hub Cap Screws Torque 320 N•m

(236 lb-ft)
Shear Plate Weight 29 kg

(65 lb)
Sieve Frame Weight 83 kg

(183 lb)
OUO6083,0000DD5 –19–23AUG06–2/2
Remove and Install Conveyor Auger Drive

Shaft
CAUTION: Block wheels to prevent personal

injury from machine movement.
–UN–14FEB99
1. Remove right-hand wheel(s). (See TIRES AND
WHEELS in Section 50.)
2. Loosen nuts (A) to relieve belt tension. Remove belt
H52984
(B) from sheave (D).
3. Remove nut (C) and sheave (D). Remove woodruff

key.
4. Loosen set screw and remove locking collar (E) by

5. Remove nuts and cap screws (F). Remove outside –UN–14FEB99
flangette and bearing.
6. Remove conveyor auger speed sensor. (See

procedure in Section 40, Group 35.)
H52985
A—Nuts (2 used)
B—Belt
C—Nut
D—Sheave
E—Locking Collar
Continued on next page OUO6083,0000DDA –19–25AUG06–1/6

083006
PN=1265
7. Loosen set screw and remove locking collar (A) by

120
20
4
8. Remove nuts and cap screws (B). Remove bracket
and outside flangette. Move inside flangette away from
sidesheet and remove bearing.
–UN–14FEB99
A—Locking Collar
H52989
OUO6083,0000DDA –19–25AUG06–2/6
NOTE: May be necessary to apply heat to bevel gears to

release from shaft.
9. Loosen four clamps (A) on bevel gears (B) and slide to

side. Remove four woodruff keys.
–UN–22MAY01
10. Loosen set screw and remove locking collar (D) by
IMPORTANT: Note direction of bevel gears prior to
H67005
shaft removal. Gears are right- and
left-hand and must be installed
correctly.
A—Clamp (4 used)
B—Bevel Gears
11. Remove shaft (C) out right-hand side of combine.
C—Shaft
D—Locking Collar
12. Install shaft (C).
OUO6083,0000DDA –19–25AUG06–3/6
13. Position end of shaft from sidesheet to dimension (A).
Specification
Conveyor Shaft-to-Sidesheet—
Distance ................................................................................... 220 ± 3 mm
(8 3/4 ± 1/8 in.)
–UN–23AUG06
14. Tighten locking collars in direction of shaft rotation.

Tighten set screws.
15. Apply PM38654 Thread Locker (High Strength) to

H86485
gear through key slot and spin gear on shaft for full
coverage.
A—Dimension
16. Install four woodruff keys.
Continued on next page OUO6083,0000DDA –19–25AUG06–4/6

083006
PN=1266
17. Adjust gear backlash to specification as follows:
a. Align gears (B) until fully meshed. 120

20
5
b. Back clamp (A) off 0.75 mm (1/32 in.) and tighten
clamp.
–UN–25AUG06
c. Push drive gears against clamps so thread lock
compound sets up with the correct backlash.
H86494
Specification
Conveyor Auger Drive Shaft
Bevel Gears—Backlash................................................................ 0.75 mm
(1/32 in.)
A—Clamp
B—Bevel Gear
18. Install conveyor auger speed sensor. (See procedure

in Section 40, Group 25.)
OUO6083,0000DDA –19–25AUG06–5/6
19. Install sheave. Tighten nut (A) to specification.
Specification
Conveyor Auger Sheave
Mounting Nut—Torque ................................................................. 250 N•m
(185 lb-ft)
–UN–14FEB99
20. Install belt. Tighten nuts on idler tension spring until
washer aligns with gauge.
21. Install right-hand side wheel(s). (See TIRES AND
H53015
WHEELS in Section 50.)
A—Nut
OUO6083,0000DDA –19–25AUG06–6/6

083006
PN=1267
Remove and Install Conveyor Augers

120
20 CAUTION: Block wheels to prevent personal
6 injury from machine movement.
1. Earlier Models:
OUO6083,0000DD9 –19–25AUG06–1/5
Remove transmission-to-final drive shaft for access to

front auger bevel gears.
NOTE: Procedure to remove any conveyor auger is

similar. May be necessary to apply heat to bevel
gears to release from shaft.
–UN–14FEB99
2. Drive spring pin (A) out of gear.
3. Loosen set screw and remove locking collar (B) by
H52975
4. Remove locking collar (C) and cap screws (D).
5. Remove auger (E) toward rear of combine.
A—Spring Pin
–UN–25JAN06
B—Set Screw
C—Locking Collar
E—Auger
H85284

083006
PN=1268
IMPORTANT: Install augers in proper location or

damage to machine may occur.
120
20
7. Install auger from rear of combine. 7
8. Install gear onto auger shaft. Apply PM38654 Thread
–UN–23AUG06
Lock (High Strength) into unaligned spring pin hole.
Spin gear on shaft for full coverage.
9. Install spring pin and set gap (A) to specification.
H86486
Specification
Conveyor Auger Gear-to-Locking
Collar—Distance ................................................................................ 3 mm
A—Gap
(1/8 in.)
10. Tighten locking collars in direction of auger rotation.
OUO6083,0000DD9 –19–25AUG06–3/5
11. Adjust gear backlash to specification as follows:
Specification
(1/32 in.)
–UN–14FEB99
a. Loosen clamp (A) and remove drive (B) gear from
key.
b. Clean area on shaft (C) where thread locker
H52994
compound will be applied.
c. Apply PM38654 Thread Locker and Sealer (High

A—Clamp (4 used)
Strength) to gear through key slot and spin gear B—Bevel Gears
on shaft for full coverage. C—Shaft
d. Align gears (B) until fully meshed.
e. Back clamp (A) off 0.75 mm (1/32 in.) from gear

and tighten clamp.
f. Push drive gears against clamps so thread lock


083006
PN=1269
12. Later Models:
120 Remove cap screws (A) from bulkhead (B).

20
8
13. Remove cap screws (C) from support (D).
–UN–24AUG06
14. Remove auger (E) toward rear of combine. Repair or
H86491
16. Check gear specifications as stated earlier in this
procedure.

B—Bulkhead
D—Support
E—Auger
–UN–25AUG06
H86492
OUO6083,0000DD9 –19–25AUG06–5/5
Remove and Install Conveyor Auger Trough
1. Remove straw chopper. (See REMOVE AND INSTALL

STRAW CHOPPER in this section.)
2. Remove shake pan. (See REMOVE AND INSTALL

SHAKE PAN in this group.)
–UN–25JAN06
3. Remove chaffer element. (See REMOVE AND
INSTALL CHAFFER in this group.)
H85285
4. Remove pre chaffer element. (See REMOVE AND

INSTALL FRONT CHAFFER in this group.)
A—Locking Collar (4 used)
5. Remove metal seal above rear of cleaning fan. (Not B—Cap Screw (4 used)
C—Support
illustrated.) D—Cap Screw (12 used)
6. Remove locking collars (A), cap screws (B) and auger

support (C).
7. Remove cap screws (D).
8. Tie augers to concave.

083006
PN=1270
9. Remove nuts and cap screws (A) from channel

assembly.
120
20
10. Remove trough through rear of combine. 9
11. Install trough in reverse order.
–UN–25JAN06
A—Nut and Cap Screw (16 used)
H85292
OUO6083,0000DD8 –19–23AUG06–2/3
12. Adjust bevel gear backlash to specification.
Specification
(1/32 in.)
–UN–14FEB99
a. Loosen clamp (A) and remove drive (B) gear from
key.
b. Clean shaft area where thread locker compound
H52994
will be applied.
c. Apply PM38654 Thread Locker and Sealer (High

A—Clamp (4 used)
Strength) to gear through key slot and spin gear B—Bevel Gears
on shaft for full coverage. C—Shaft
d. Align gears (B) until fully meshed.
e. Back clamp (A) off 0.75 mm (1/32 in.) from gear

and tighten clamp.
f. Push drive gears against clamps so thread lock

13. Install front chaffer element. (See REMOVE AND

INSTALL FRONT CHAFFER in this group.)
14. Install chaffer element. (See REMOVE AND INSTALL

CHAFFER in this group.)
15. Install shake pan. (See REMOVE AND INSTALL

SHAKE PAN in this group.)
16. Install straw chopper if equipped. (See REMOVE

AND INSTALL STRAW CHOPPER in this section.)
OUO6083,0000DD8 –19–23AUG06–3/3

083006
PN=1271
Remove and Install Conveyor Auger Slip

Clutch
120
20
10 NOTE: It is not necessary to remove slip clutch for
service.
–UN–15FEB99
1. Remove four nuts (A), washers, springs, spacers and
cap screws.
2. Remove retainer (B).
H53052
3. Remove slip clutch (C).
4. Install slip clutch.
5. Tighten nuts (A) until washers set firmly against

spacers.
A—Nut (4 used)
–UN–15FEB99
B—Retainer
C—Slip Clutch
H53053
OUO6083,0000332 –19–15AUG02–1/1
Remove and Install Cleaning Fan Sheave and

Bearing
NOTE: Fan speed actuator shaft has left-hand threads.
1. Relieve belt tension by operating the cleaning fan
–UN–07JUN99
speed switch to the slow position. Loosen nuts (A) and
move to outer end of shaft if more slack is required to
remove belt.
H57958
IMPORTANT: Do not turn gear by hand with motor
installed. To avoid damage to assembly,
remove cap screws (B) and drive motor
A—Nut (2 used)
or connect an outside 12-volt power
source to motor if power is not
available through switch.

083006
PN=1272
2. Remove belt (A) from sheave (B).
120
A—Belt 20
B—Sheave 11
–UN–24AUG05
H84304
OUO6046,0002024 –19–26AUG05–2/9
3. Remove cap screw and washer (A).
NOTE: Loosen cap screws evenly to relieve spring

tension.
4. Remove cap screws (B), nuts, springs (C) and
–UN–24AUG05
spacers.
5. Remove outer half of sheave (D) using a puller.
H84305
6. Remove key (E) and inner half of sheave (F).
A—Cap Screw and Washer

C—Spring (4 used)
D—Sheave
E—Key
F—Sheave
–UN–24AUG05
H84306
–UN–24AUG05
H84307

083006
PN=1273
7. Remove washer (A).
120
20 A—Washer
12
–UN–24AUG05
H84309
OUO6046,0002024 –19–26AUG05–4/9
8. Inspect seals (A) in inner half of sheave. Replace as

necessary.
A—Seal (2 used)
–UN–10JAN02
H70797
–UN–10JAN02
H70798

083006
PN=1274
NOTE: Rubber sleeve on cleaning fan shaft is for

production purposes only. It is not necessary to
reinstall during assembly. 120
20
13
9. Loosen set screw (A) and remove locking collar (B).
–UN–24AUG05
10. Remove nuts (C), round head bolts and flange plate
(D).
11. Remove bearing and inner flange from shaft. Replace
H84310
as necessary.
12. Inspect shaft and remove any nicks or burrs using

emery cloth or file. A—Set Screw
B—Lock Collar
C—Nut (4 used)
13. Install inner flange and bearing. D—Flange
14. Install outer flange (D), round head bolts and nuts
(C).
15. Install lock collar (B) and tighten set screw (A).
OUO6046,0002024 –19–26AUG05–6/9
16. Install washer (A).
A—Washer
–UN–24AUG05
H84309

083006
PN=1275
17. Install inner half of sheave (F) and key (E)
120 18. Install outer half of sheave (D).

20
14
19. Tighten cap screw and washer (A) to specification.
–UN–24AUG05
Specification
Cleaning Fan Outer Sheave Cap
Screw—Torque ............................................................................. 140 N•m
(105 lb-ft)
H84307
IMPORTANT: Be certain to position springs in cast
pockets to obtain proper tension.
20. Install cap screws (B), spacers and springs (C).
21. Install nuts and tighten until washer is seated against

spacers inside of springs.
A—Set Screw (2 used)
–UN–24AUG05
C—Spring (4 used)
D—Sheave
E—Key
H84306
F—Sheave
–UN–24AUG05
H84305

083006
PN=1276
NOTE: Do not roll belt onto sheave by turning shaft with

wrench on cap screw (C). This will over torque
cap screw (C). 120
20
15
22. Install belt (A) to sheave (B).
–UN–25AUG05
23. Start machine and engage separator. Adjust cleaning
fan to desired speed.
A—Belt
H84313
B—Sheave
C—Cap Screw
OUO6046,0002024 –19–26AUG05–9/9

083006
PN=1277
Fan Drive Speed Control

120
20
16
C
C
D
A
I
J
K
H
M N
–UN–25FEB04
H80356
Continued on next page AG,OUO6435,1000 –19–20FEB04–1/2

083006
PN=1278
A—Shaft E—Pin I—Snap Ring L—Nut (3 used)

B—Nut (4 used) F—Cotter Pin J—Washer M—Bearing
C—Bushing (2 used) G—Support K—Washer N—Cap Screw (3 used) 120
D—Trunnion H—Bushing 20
17
AG,OUO6435,1000 –19–20FEB04–2/2
Remove Cleaning Fan Drive
1. Open right-hand side gull wing door.
AG,OUO6037,100 –19–28JUL05–1/8
NOTE: Fan speed actuator shaft has left-hand threads.
2. Relieve belt tension by operating the cleaning fan

speed switch to the slow position. Loosen nuts (A) and
move to outer end of shaft if more slack is required to
remove belt.
–UN–07JUN99
IMPORTANT: Do not turn gear by hand with motor
installed. To avoid damage to assembly,
remove cap screws (B) and drive motor
H57958
or connect an outside 12-volt power
source to motor if power is not
available through switch.
A—Nut (2 used)
AG,OUO6037,100 –19–28JUL05–2/8
3. Remove nut (A), cap screw (B) and bushing from

support.
4. Remove belt from drive sheave.
A—Nut
–UN–08JUN99
B—Cap Screw
H58009

083006
PN=1279
5. Disconnect wiring connector (A).
120 6. Remove cotter pin (B) and pin (C) from support.
20
18
A—Connector
B—Cotter Pin
–UN–08JUN99
C—Pin
H58008
AG,OUO6037,100 –19–28JUL05–4/8
7. Loosen nuts on spring to relieve belt tension. Remove

belt (B) from drive sheave.
A—Nuts (2 used)
B—Belt
–UN–08JUN99
H58010
AG,OUO6037,100 –19–28JUL05–5/8
8. Remove cap screw (A), washer (B) and outer half of

sheave (C).
9. Inspect bearing (D). Replace as necessary.
A—Cap Screw
–UN–09JUN99
B—Washer
C—Sheave
D—Bearing
H58011
AG,OUO6037,100 –19–28JUL05–6/8
10. Remove cap screws (A) and inner half of sheave (B).

B—Sheave
–UN–08JUN99
H58013

083006
PN=1280
11. Remove nuts (A), cap screws, and cap screw (B).
Remove jackshaft assembly.
120
20
12. Inspect shaft and remove any nicks or burrs using an 19
emery cloth or file.
–UN–08JUN99
13. Inspect bearings. Replace as necessary. (See
DISASSEMBLE AND ASSEMBLE CLEANING FAN
DRIVE JACKSHAFT in this group.)
H58012
A—Nuts
B—Cap Screw
AG,OUO6037,100 –19–28JUL05–8/8

083006
PN=1281
Disassemble and Assemble Cleaning Fan Drive Jackshaft

120
20
20
–UN–08JUN99
H58014
A—Snap Ring C—Snap Ring E—Bearing F—Shaft
B—Bearing D—Support
1. Remove snap ring (A) and bearing (B). 5. Press bearing (E) on shaft (F) and install in support
(D).
2. Remove shaft (F) from support (D).
6. Inspect snap ring (C) and be certain it is seated in
3. Press bearing (E) off of shaft. groove.
4. Inspect shaft and remove any nicks or burrs using 7. Install bearing (B) and snap ring (A).
an emery cloth or file.
AG,OUO6037,101 –19–25JUL00–1/1

083006
PN=1282
Install Cleaning Fan Drive
1. Install jackshaft assembly using cap screws, nuts (A) 120

20
and cap screw (B). Tighten nuts and cap screws to 21
specification.
Specification
–UN–08JUN99
Cleaning Fan Drive Jackshaft
Nuts—Torque ............................................................................... 123 N•m
(90 lb-ft)
Cleaning Fan Drive Jackshaft
H58012
Cap Screw—Torque ....................................................................... 70 N•m
(50 lb-ft)
A—Nuts
B—Cap Screw
AG,OUO6037,102 –19–25JUL00–1/7
2. Install inner half of sheave (B) using cap screws (A).

Specification
Cleaning Fan Drive Inner Sheave
(52 lb-ft)
–UN–08JUN99
B—Sheave
H58013
AG,OUO6037,102 –19–25JUL00–2/7
3. Install outer half of sheave (C), washer (B) and cap

screw (A).
A—Cap Screw
B—Washer
C—Sheave
–UN–09JUN99
H58189

083006
PN=1283
4. Install drive belt (B) to sheave and tighten nuts (A) until
120
20
22
5. Install fan belt to sheave.
A—Nuts (2 used)
–UN–08JUN99
B—Belt
H58010
AG,OUO6037,102 –19–25JUL00–4/7
6. Install pin (C) and cotter pin (B).
7. Connect wiring connector (A).
A—Connector
B—Cotter Pin
–UN–08JUN99
C—Pin
H58008
AG,OUO6037,102 –19–25JUL00–5/7
8. Install bushing, cap screw (B) and nut (A).
A—Nut
B—Cap Screw
–UN–08JUN99
H58009
AG,OUO6037,102 –19–25JUL00–6/7
IMPORTANT: If nuts (A) were moved during service, it

is necessary to adjust actuator. (See
ADJUST FAN SPEED ACTUATOR in this
group.)
A—Nut (2 used)
–UN–09JUN99
H58172
AG,OUO6037,102 –19–25JUL00–7/7

083006
PN=1284
Adjust Fan Speed Actuator
1. Start combine and set cleaning fan speed to mid speed 120
20
to gain clearance to inside set of nuts. Shut off 23
combine.
–UN–23FEB04
2. Loosen nuts (A) and turn both nuts toward speed A
D
actuator. B
C
3. Start combine and set fan speed to 1600 rpm. Shut off
H80327
combine.
4. Apply PM37477 Thread Lock and Sealer (medium

strength) on threads next to spacer (B) where nuts (D) A—Nut (2 used)
B—Spacer (2 used)
will be located. Tighten nuts so spacer (B) is tight
C—Trunnion
against trunnion (C). Start combine and lower cleaning D—Nut (2 used)
fan speed to gain clearance to nuts. Shut off combine.
Tighten nuts to specification.
Specification
Fan Speed Actuator Nuts—
Torque ............................................................................................ 24 N•m
(18 lb-ft)
OUO6083,0000CB2 –19–08MAR06–1/1
Remove And Install Cleaning Fan
1. Adjust cleaning fan to low speed position.
NOTE: Depending upon tire and wheel configuration, it

may be necessary to remove front right-hand
–UN–13MAY03
tire(s) and wheel(s) to remove fan shaft.
2. Remove body shields as necessary.
H76929
CAUTION: The approximate weight of shear
plate is 29 kg (65 lb).
Specification
B—Recessed Cap Screw (12 used)
Shear Plate—Weight ......................................................................... 29 kg
C—Shear Plate
(65 lb)
3. Support shear plate.
4. Remove cap screws (A), recessed cap screws (B) and

cleaning fan shear plate (C).

083006
PN=1285
120
20 A—Belt
24 B—Sheave
–UN–24AUG05
H84304
OUO6046,0002025 –19–26AUG05–2/16
6. Loosen shaft clamps (A) on both sides.
A—Shaft Clamp (2 used)
–UN–24AUG05
H84308
OUO6046,0002025 –19–26AUG05–3/16
7. Remove locking collar (A).
8. Disconnect sensor connector (B).
A—Locking Collar
B—Sensor Connector
–UN–24AUG05
H84311

083006
PN=1286
9. Loosen set screw (A) in tone wheel (B).
120
A—Set Screw 20
B—Tone Wheel 25
–UN–18FEB99
H54053
OUO6046,0002025 –19–26AUG05–5/16
10. Remove cap screws and nuts (A) from support

bracket on right-hand side.
11. Slide shaft and sheave assembly out right-hand side.

Hubs and blade assembly will remain in machine.
–UN–25AUG05
H84312
OUO6046,0002025 –19–26AUG05–6/16
12. Remove nuts (A).
13. Remove cap screws (B) from fan housing (C) on both
sides.
A—Nut (4 used)
–UN–25AUG05
C—Fan Housing
H84320

083006
PN=1287
14. Remove nuts (A) and vanes (B).
120 IMPORTANT: Note fan blade direction prior to

20
26
removal for correct installation.
15. Push fan housing (C) toward front of machine.
–UN–25AUG05
16. Remove fan (D) through bottom opening.
17. Inspect parts and repair or replace as necessary.
H84321
18. Install fan through bottom opening.
19. Install scroll vanes and nuts. A—Nut (2 used)

B—Scroll Vane (2 used)
C—Fan Housing
D—Cleaning Fan
OUO6046,0002025 –19–26AUG05–8/16
20. Install cap screws (B) to fan housing sheet (C) on

both sides.
21. Install nuts (A).
22. Slide shaft through fan hubs into left-hand side
–UN–25AUG05
bearing assembly.
A—Nut (4 used)
H84320
C—Fan Housing
OUO6046,0002025 –19–26AUG05–9/16
23. Install cap screws and nuts (A) in support bracket.

–UN–25AUG05
H84312

083006
PN=1288
24. Set distance (A) to specification.
Specification 120
End of Cleaning Fan Shaft-to-Fan 20
Wheel—Distance ........................................................................... 383 mm 27
(15 in.)
–UN–22FEB99
25. Center fan between sidesheets.
NOTE: Clamps must be installed with the nut and clamp

finger trailing the direction of rotation.
H54078
NOTE: Position clamps 180 degrees apart to aid
balancing.
A—Distance
OUO6046,0002025 –19–26AUG05–11/16
26. Install shaft clamps (A).
27. Tighten clamps (A) until legs contact each other.
A—Shaft Clamp (2 used)
–UN–24AUG05
H84308
OUO6046,0002025 –19–26AUG05–12/16
28. Install lock collar (A) and connect sensor connector

(B).
A—Lock Collar
B—Sensor Connector
–UN–24AUG05
H84311

083006
PN=1289
29. Align tone wheel (B) with sensor and tighten set
screw (A).
120
20
28 A—Set Screw
B—Tone Wheel
–UN–18FEB99
H54053
OUO6046,0002025 –19–26AUG05–14/16

cap screw (C).
–UN–25AUG05
A—Belt
B—Sheave
C—Cap Screw
H84313
OUO6046,0002025 –19–26AUG05–15/16
31. Install shear plate (C) using recessed cap screws (B)
and cap screws (A).
32. Install all shields previously removed.
–UN–13MAY03
C—Shear Plate
H76929
OUO6046,0002025 –19–26AUG05–16/16

083006
PN=1290
Remove and Install Cleaning Fan Blade

Inserts
120
20
1. Remove body shields as necessary. 29
CAUTION: The approximate weight of shear
–UN–13MAY03
plate is 29 kg (65 lb).
Specification
Shear Plate—Weight ......................................................................... 29 kg
H76929
(65 lb)
2. Support shear plate.

3. Remove cap screws (A), recessed cap screws (B) and C—Shear Plate
cleaning fan shear plate (C).
OUO6046,000202A –19–29AUG05–1/5
A—Belt
B—Sheave
–UN–24AUG05
H84304
OUO6046,000202A –19–29AUG05–2/5
5. Rotate cleaning fan so blade insert (C) can be

accessed from under machine, as shown.
6. Remove vanes (A).
7. Release clips (B) from blade insert (C).

–UN–29AUG05
8. Remove and replace blade insert.
9. Install vanes (A).

H84325
A—Vane (2 used)
B—Clip (5 used)
C—Blade Insert

083006
PN=1291

120 cap screw (C).
20
30
–UN–25AUG05
A—Belt
B—Sheave
C—Cap Screw
H84313
OUO6046,000202A –19–29AUG05–4/5
11. Install shear plate (C) using recessed cap screws (B)
and cap screws (A).
12. Install all shields previously removed.
–UN–13MAY03
C—Shear Plate
H76929
OUO6046,000202A –19–29AUG05–5/5
Remove And Install Chaffer

injury.
–UN–13JUL05
NOTE: It is not necessary to remove straw chopper (if
equipped) to remove chaffer. Chopper must be in
fully raised position.
H83959
1. If equipped with a straw chopper, remove cap screws
(A) and air chutes (B) from both sides.
B—Air Chute (Right- and Left-Hand)

083006
PN=1292
2. Raise spreader (if equipped) and remove pins (B).
3. Remove spreader disks (A). 120

20
31
A—Disk (2 used)
B—Quick-Lock Pin (2 used)
–UN–19FEB99
H54063
OUO6046,0001FF8 –19–28JUL05–2/9
4. Loosen gauge adjustment screw (A) in chaffer element

(B).
A—Adjustment Screw
B—Chaffer Element
–UN–17MAR99
H51987
OUO6046,0001FF8 –19–28JUL05–3/9
5. Slide chaffer opening gauge (A) inside chaffer element.
A—Chaffer Opening Gauge
–UN–07MAY02
H72109

083006
PN=1293
6. Remove chaffer retaining bolts (A) and springs from

both sides.
120
20
32
7. Remove chaffer element out rear of machine.
8. Inspect grain seals on chaffer element.
–UN–08APR99
10. Install chaffer element in rear of machine.
H51988
11. Install chaffer retaining bolt assembly (A) on both
sides. Tighten to specifications.
A—Chaffer Retaining Bolt Assembly (2 used)
Specification
Chaffer Retaining Bolts—Torque ................................................. 100 N•m
(74 lb-ft)
OUO6046,0001FF8 –19–28JUL05–5/9
12. Slide opening gauge (A) through sidesheet.
13. Calibrate opening gauge to proper dimension.
a. Crank chaffer to full open position.
–UN–07MAY02
A—Chaffer Opening Gauge
H72109

083006
PN=1294
b. Close slowly until average opening measures

approximately 8 mm with combine clearance
gauge (A). 120
20
33
c. Slide opening gauge (B) to read 8 mm at
sidesheet (C).
–UN–17FEB99
A—Combine Clearance Gauge
B—Opening Gauge
C—Sidesheet
H54012
–UN–16JAN01
H65811
OUO6046,0001FF8 –19–28JUL05–7/9
d. Tighten gauge adjustment screw (A) in chaffer

element (B).
A—Adjustment Screw
B—Chaffer Element
–UN–17MAR99
H51987
OUO6046,0001FF8 –19–28JUL05–8/9
14. If equipped with a straw chopper, install air chutes (B)

with cap screws (A) on both sides.
15. Install spreader disks and lower straw spreader.

–UN–13JUL05

H83959
OUO6046,0001FF8 –19–28JUL05–9/9

083006
PN=1295
Remove And Install Chaffer With Remote

Shoe
120
20
34 CAUTION: Shut off engine and remove key to
–UN–08OCT01
injury.
NOTE: It is not necessary to remove straw chopper (if

equipped) to remove chaffer. Chopper must be in
ZX25337
fully raised position.
1. Disconnect wire connector (A) from chaffer (B).

A—Connector
B—Chaffer
OUO6046,0002026 –19–25AUG05–1/3

B—Cover
–UN–25AUG05
H84314

083006
PN=1296
3. Remove chaffer retaining bolts (A) and springs from

both sides.
120
20
4. Remove chaffer element (B) out rear of machine. 35
5. Inspect grain seals on chaffer element.
–UN–08OCT01
7. Install chaffer element in rear of machine.
ZX25338
8. Install new chaffer retaining bolt assembly (A) on both
sides. Tighten to specifications.
A—Chaffer Retaining Bolt Assembly (2 used)
Specification B—Chaffer
Chaffer Retaining Bolts—Torque ................................................. 100 N•m
(74 lb-ft)
9. Reattach wire connector and install cover.
10. Check accuracy of opening with in-cab readout on

cornerpost. Recalibrate if necessary (See Operators
Manual).
OUO6046,0002026 –19–25AUG05–3/3
Remove And Install Sieve

help prevent accidental starting and personal
injury.
1. Remove chaffer. (See REMOVE AND INSTALL

2. Loosen gauge adjustment screw in sieve element.
NOTE: Sieve opening gauge, set screw and retainer bolts

are similar to chaffer.

083006
PN=1297
3. Slide sieve opening gauge (A) inside sieve element.
120 4. Remove retaining bolts on both sides.

20
36
5. Remove sieve out rear of machine.
–UN–07MAY02
6. Inspect grain seals on sieve element.
H72110
8. Install sieve in rear of machine.
A—Sieve Opening Gauge
OUO6083,000006B –19–17MAY01–2/5
9. Install sieve retaining bolts (A) with additional 10 mm

block (B) between star washer and spring. Tighten to
specification.
Specification
Sieve Retaining Bolts—Torque .................................................... 100 N•m
(74 lb-ft)
–UN–01AUG00
10. Slide sieve opening gauge (A) through sidesheet.
11. Calibrate gauge to proper dimension.
H64554
a. Crank sieve to full open position.
A—Sieve Retaining Bolt (2 used)
B—10 mm Block
OUO6083,000006B –19–17MAY01–3/5
b. Close slowly until average opening measures

approximately 8 mm with combine clearance
gauge (A).
A—Combine Clearance Gauge

–UN–17FEB99
H54012

083006
PN=1298
c. Slide opening gauge (A) to read 8 mm mark at

sidesheet (B).
120
20
d. Tighten gauge adjustment screw in sieve element. 37
12. Install chaffer. (See REMOVE AND INSTALL

–UN–09JAN01
A—Opening Gauge
B—Sidesheet
H65776
OUO6083,000006B –19–17MAY01–5/5
Remove And Install Sieve With Remote Shoe

injury.
1. Remove chaffer. (See REMOVE AND INSTALL

OUO6083,00005BC –19–28JUL05–1/4
2. Disconnect wire connector (A) from sieve (B).
3. Remove actuator cover.
A—Wire Connector
B—Sieve
–UN–08OCT01
ZX25339
Continued on next page OUO6083,00005BC –19–28JUL05–2/4

083006
PN=1299
4. Remove sieve retaining bolts (A) and 10 mm block (B)

on both sides.
120
20
38
5. Remove sieve out rear of machine.
–UN–08OCT01
7. Install sieve in rear of machine.
A—Spring Retaining Hardware Assembly
ZX25341
B—10 mm Block
OUO6083,00005BC –19–28JUL05–3/4
8. Install sieve retaining bolts (A) with additional 10 mm

block (B) between star washer and spring. Tighten to
specification.
Specification
Sieve Retaining Bolts—Torque .................................................... 100 N•m
(74 lb-ft)
–UN–08OCT01
9. Reattach wiring harness and install cover.
10. Check accuracy of opening with in-cab readout on
ZX25341
cornerpost. Recalibrate if necessary (See Operators
Manual).
A—Spring Retaining Hardware Assembly
11. Install chaffer. (See REMOVE AND INSTALL B—10 mm Block
OUO6083,00005BC –19–28JUL05–4/4
Remove and Install Remote Shoe Actuator

Motor
NOTE: Element does not have to be completely removed

from machine to service actuator.
1. Remove element to be repaired (See procedures in

this group).

083006
PN=1300
2. Disconnect wire harness (A).
3. Remove lock nut (B) from adjustment bar (C). 120

20
39
A—Wire Harness
B—Lock Nut
–UN–15MAY03
C—Adjusting Bar
H77022
OUO6083,00005C6 –19–15MAY03–2/4
4. Remove cap screws (A) and actuator (B) from element

(C).
NOTE: Actuator is not serviceable. Replace if necessary.
5. Install actuator (B) on element (C) with cap screws (A).
–UN–15MAY03
B—Actuator
C—Element
H77023
OUO6083,00005C6 –19–15MAY03–3/4
6. Hold adjustment bar (C) to prevent binding with

element while installing lock nut (B). Tighten to
specification.
Specification
Actuator Lock Nut—Torque ............................................................ 18 N•m
(159 lb-in.)
–UN–15MAY03
7. Connect wire harness to actuator (A).
8. Install element (See procedures in this group).
H77022
9. Recalibrate position on cornerpost (See TM2182 for
procedure). A—Wire Harness
B—Lock Nut
C—Adjusting Bar
OUO6083,00005C6 –19–15MAY03–4/4

083006
PN=1301
Remove and Install Front Chaffer Element

120
20 CAUTION: Shut off engine and remove key to
40 help prevent accidental starting and personal
injury.
–UN–13JUL05
IMPORTANT: Close and cover rear chaffer element to
prevent possible damage during front
chaffer removal and installation.
H83959
1. Remove cap screws (A) air chutes (B) on both sides.


083006
PN=1302
120
20
A 41
–UN–18JUN03
H77906
A—Cap Screw (2 used) B—Front Chaffer Element
2. Remove cap screws (A). 6. Install front chaffer element (B) through rear of
machine.
3. Remove front chaffer element (B) through rear of
machine. 7. Install cap screws (A) and tighten to specification.
4. Inspect all front chaffer element seals and fingers. Specification

Front Chaffer Cap Screws—
Repair or replace as necessary.
Torque.................................................................................... 140 N•m
(105 lb-ft)
5. Install fingers (if previously removed) and tighten
Specification
Front Chaffer Finger Cap
Screws—Torque ...................................................................... 20 N•m
(15 lb-ft)

083006
PN=1303
8. Install air chutes (B) using cap screws (A).
120
20 A—Cap Screws (5 used)
42 B—Air Chutes (Right- and Left-Hand)
–UN–13JUL05
H83959
OUO6046,0001FF9 –19–14JUL05–3/3
Remove And Install Chaffer Frame

injury.
1. Remove:
• Straw chopper if equipped (See REMOVE STRAW

CHOPPER in this section.)
• Loss monitor sensor brackets
• Chaffer element (See REMOVE AND INSTALL
• Front chaffer element (See REMOVE AND INSTALL
FRONT CHAFFER in this group.)
• Sieve element (See REMOVE AND INSTALL SIEVE
in this group.)

083006
PN=1304
2. Remove nuts from chaffer frame swinger arms (A).
120
CAUTION: The approximate weight of chaffer 20
frame is 120 kg (265 lb). 43
Specification
–UN–07JAN04
Chaffer Frame—Weight................................................................... 120 kg
(265 lb)
3. Remove cap screws (B) on both sides.
H79642
NOTE: It may be necessary to cover holes in sidesheet to
prevent swinger arms from interfering with
removal of chaffer and sieve frames.
4. Remove chaffer frame from machine.
5. Inspect all grain seals on chaffer frame.
–UN–15FEB99
7. Install:
• Chaffer frame with cap screws (B) and nuts on both
H53017
sides, but do not tighten at this time
• Sieve element (See REMOVE AND INSTALL SIEVE
in this group.) A—Chaffer Swinger Arms
• Front chaffer element (See REMOVE AND INSTALL B—Cap Screw (4 used)
FRONT CHAFFER in this group.)
• Chaffer element (See REMOVE AND INSTALL
• Loss monitor sensor brackets
8. Rotate separator by hand until shoe swinger arms are

at midpoint of stroke.

083006
PN=1305
120
20
44
A
B
B
A
–UN–05FEB02
B
H70894
A—140 N•m (105 lb-ft) B—350 N•m (258 lb-ft)
9. Tighten swinger arm hardware (A and B) to B—Torque (In Mid Stroke) .................................................... 350 N•m
specification. (258 lb-ft)
Swinger Arms—Specification 10. Install straw chopper if equipped. (See INSTALL

A—Torque (In Mid Stroke) .................................................... 140 N•m STRAW CHOPPER in this section.)
(105 lb-ft)
OUO6083,0000334 –19–23DEC03–3/3
Remove And Install Sieve Frame

injury.
1. Remove chaffer frame. (See REMOVE AND INSTALL

CHAFFER FRAME in this group.)
CAUTION: The approximate weight of sieve

frame is 83 kg (183 lb).
Specification
Sieve Frame—Weight ....................................................................... 83 kg
(183 lb)
Continued on next page OUO6083,00001BB –19–23DEC03–1/3

083006
PN=1306
2. Remove nuts and cap screws from swinger arms (A)

on both sides.
120
20
NOTE: It may be necessary to cover swinger arm holes 45
in sidesheet to keep swinger arms from interfering
with removal of chaffer and sieve frames.
–UN–18DEC03
3. Remove sieve frame.
4. Inspect grain seals on sieve frame.
H79643
6. Install sieve frame. A—Swinger Arms
7. Install cap screws and nuts on swinger arms (A) but do

not tighten at this time.
8. Rotate separator by hand until swinger arms are in

midpoint of stroke.
Continued on next page OUO6083,00001BB –19–23DEC03–2/3

083006
PN=1307
120
20
46
A
B
B
A
–UN–05FEB02
B
H70894
A—140 N•m (105 lb-ft) B—350 N•m (258 lb-ft)
9. Tighten swinger arm hardware to specification. 10. Install chaffer frame. (See REMOVE AND
INSTALL CHAFFER FRAME in this group.)
Swinger Arms—Specification
A—Torque.............................................................................. 140 N•m
(105 lb-ft)
B—Torque.............................................................................. 350 N•m
(258 lb-ft)
OUO6083,00001BB –19–23DEC03–3/3

083006
PN=1308
Remove and Install Shake Pan
1. Remove: 120
20
47
• Separator inspection covers (A) from both sides
• Nuts (B) and hydraulic line shield (C)
•
–UN–08MAY02
Cap screws (D) and air chutes (E)
• Inspection door (F)
A—Separator Inspection Cover
H72139
B—Flanged Nut (3 used)
C—Shield
E—Air Chute (Right- and Left-Hand)
F—Inspection Door
–UN–13JUL05
H83957
–UN–08MAY02
H72143

083006
PN=1309
2. Remove nuts (A) from front and rear swinger arms (B)
on both sides.
120
20
48
NOTE: Be certain front of shake pan is raised enough to
allow clearance over inspection lights.
–UN–15FEB99
CAUTION: The approximate weight of shake
pan is 54 kg (119 lb).
3. Slide shake pan out rear of machine.
H51993
5. Install:
• Shake pan in rear of machine
A—Nut (4 used)
B—Swinger Arm
–UN–20DEC04
H82205

083006
PN=1310
• Cap screws and nuts (A) in front and rear swinger

arms (B) on both sides, but do not tighten at this
time 120
20
49
6. Rotate separator by hand until swinger arms are at
midpoint of stroke.
–UN–15FEB99
7. Tighten all hardware to specification.
Specification
Front Swinger Arms—Torque....................................................... 320 N•m
H51993
(235 lb-ft)
Rear Swinger Arms—Torque ....................................................... 130 N•m
(95 lb-ft)
8. Install:
• Air chutes
• Inspection door
• Hydraulic line shield
–UN–20DEC04
• Inspection covers
A—Nuts (4 used)
B—Swinger Arm
H82205
OUO6046,0001FF5 –19–13JUL05–3/3
Remove and Install Shoe Pitman Arms
1. Loosen belt idler and remove belt from sheave.
2. Remove cap screws (A), and sheave (B). –UN–07JUL00

B—Sheave
H64400
Continued on next page OUO6083,00009C1 –19–29JUL05–1/13

083006
PN=1311
3. Remove cap screw (D) and hub (C).
120 IMPORTANT: Note the order that flanged housings

20
50
with eccentric cams are removed for
proper assembly.
–UN–25APR05
Install eccentric cams and housings in
same order as removed, or machine
damage may occur.
H83198
4. Remove nuts and bolts (A), and flanged housing (B).
A—Nuts and Bolts

B—Flanged Housing
C—Hub
D—Cap Screw
OUO6083,00009C1 –19–29JUL05–2/13
5. Remove cap screws and nuts (A), and flanged housing

(B).
6. Remove shaft key.
–UN–07JUL00
B—Flanged Housing
H64402
OUO6083,00009C1 –19–29JUL05–3/13
7. Remove locking collar (A), and flanged housing with

bearing (B) from shaft (C).
NOTE: Parts removal is similar on other side of unit.
A—Locking Collar
–UN–07JUL00
B—Bearing
C—Shaft
H64404

083006
PN=1312
120
A—Snap Ring 20
51
–UN–08AUG89
H41257
OUO6083,00009C1 –19–29JUL05–5/13
9. Remove eccentric (A). Eccentric is a press fit.
A—Eccentric
–UN–08AUG89
H41258
OUO6083,00009C1 –19–29JUL05–6/13
10. Remove nuts and bolts (A) to separate flanged

housing halves (B). Remove bearing (C).
11. Assemble bearing (C) in flanged housing halves (B).

Install bolts and nuts (A).
–UN–08AUG89
A—Nuts and Bolts
B—Housing halves
C—Bearing
H41259
OUO6083,00009C1 –19–29JUL05–7/13
IMPORTANT: Install cams and housings in same

order as removed, or machine damage
may occur.
12. Install eccentric (A) in flanged housing bearing.

Eccentric is a press fit.
–UN–08AUG89
A—Eccentric
H41260

083006
PN=1313
13. Install snap ring (A).
120
20 A—Snap Ring
52
–UN–08AUG89
H41257
OUO6083,00009C1 –19–29JUL05–9/13
14. Install shaft (A), and flanged housing (B) with bearing
(C).
15. Adjust shaft as specified from locking collar (D) to end

of shaft. Tighten lock collar.
Specification
–UN–07JUL00
Shoe Pitman Arm Bearing
Race—Distance ............................................................................. 127 mm
(5 in.)
H64403
16. Install shaft key.
A—Shaft
B—Flanged Housing
C—Bearing
D—Lock Collar
OUO6083,00009C1 –19–29JUL05–10/13
17. Install flanged housing (B) using cap screws and nuts
(A).

B—Flanged Housing
–UN–07JUL00
H64402

083006
PN=1314
18. Install flanged housing (B) using cap screws and nuts
(A).
120
20
19. Install hub (C). Tighten cap screw (D) to specification. 53
Specification
Pitman Arm Hub Cap Screw—
–UN–25APR05
Torque .......................................................................................... 320 N•m
(236 lb-ft)
H83198
B—Flanged Housing
C—Hub
D—Cap Screw
OUO6083,00009C1 –19–29JUL05–12/13
20. Install sheave (B) using cap screws (A).

B—Sheave
–UN–07JUL00
H64400
OUO6083,00009C1 –19–29JUL05–13/13

083006
PN=1315
120
20
54

083006
PN=1316
Group 25
Tailings Elevator and Augers
Specifications

25
1
Tailings Elevator Weight 82 kg
(180 lb)
Upper Tailings Elevator Sheave Cap Torque 70 N•m

Screws (51 lb-ft)
AG,OUO1026,219 –19–25JUL00–1/1
Remove Lower Tailings Auger
1. Remove bearing cover (A).
A—Cover
–UN–03MAR99
A43172
OUO6083,0000337 –19–28JUL05–1/9
2. Loosen nuts (A) and back nut (B) off to relieve chain
tension.
A—Nut (5 used)
B—Nut –UN–03MAR99
A43173A

083006
PN=1317
3. Remove tension bracket (A).
120 4. Remove locking collar (B).

25
2
A—Bracket
B—Locking Collar
–UN–03MAR99
A43173
OUO6083,0000337 –19–28JUL05–3/9
5. Remove bearing (A) and plate (B).
A—Bearing
B—Plate
–UN–03MAR99
A43174
OUO6083,0000337 –19–28JUL05–4/9
NOTE: Round head bolts can fall inside left-hand

sidesheet if not retained.
6. Remove shaft speed sensor assembly (A) located on

left-hand side of lower auger shaft.
–UN–03MAR99
A—Shaft Speed Sensor

A43175

083006
PN=1318
NOTE: It is not necessary to remove bearing, bracket or

inside flangette to remove lower auger. It may be
easier to install auger if these parts are removed. 120
25
3
7. Remove sensor bracket (D), locking collar (C), outside
flangette (A) and bearing (B) (optional).
–UN–03MAR99
A—Flangette
B—Bearing
C—Locking Collar
D—Sensor Bracket
A43309
OUO6083,0000337 –19–28JUL05–6/9
8. Remove inside flangette (A) and cover plate (B).
A—Flangette
B—Cover Plate
–UN–03MAR99
A43308
OUO6083,0000337 –19–28JUL05–7/9
9. Remove connecting link (B) to separate paddle chain

(A) at lower sprocket (C).
10. Remove sprocket (C).
A—Paddle Chain
–UN–03MAR99
B—Connecting Link
C—Sprocket
A43184

083006
PN=1319
11. Rotate auger out slot in left-hand sidesheet.
120
25
4
–UN–24FEB99
A43177
Auger Removal
OUO6083,0000337 –19–28JUL05–9/9
Install Lower Tailings Auger
1. Rotate auger through slot in left-hand sidesheet.
–UN–24FEB99
A43177A
Auger Installation
OUO6083,0000338 –19–23DEC03–1/9
2. Install sprocket (C).
3. Connect paddle chain (A) at lower sprocket (C) using

connecting link (B).
A—Paddle Chain
–UN–03MAR99
B—Connecting Link
C—Sprocket
A43184

083006
PN=1320
NOTE: For ease of installation, use nuts to hold bolts in

place during assembly.
120
25
4. Install cover plate (B) and inside flangette (A). 5
A—Flangette
B—Cover Plate
–UN–03MAR99
A43308
OUO6083,0000338 –19–23DEC03–3/9
5. Install bearings (B), outside flangette (A) and locking

collar (C). Tighten locking collar and tighten set screw.
6. Install sensor bracket (D).
A—Flangette
B—Bearing
C—Locking Collar
–UN–03MAR99
D—Sensor Bracket
A43309
OUO6083,0000338 –19–23DEC03–4/9
7. Install shaft speed sensor assembly (A).

–UN–03MAR99
A43175

083006
PN=1321
8. Install plate (B) and bearing (A).
120
25 A—Bearing
6 B—Plate
–UN–03MAR99
A43174
OUO6083,0000338 –19–23DEC03–6/9
9. Install locking collar (B) and tighten. Tighten set screw.
10. Install tension bracket (A).
A—Tension Bracket
B—Locking Collar
–UN–03MAR99
A43173

083006
PN=1322
11. Apply tension to paddle chain using nut (B). Tighten

nuts (A).
120
25
Paddle chain is adjusted properly when lower end of 7
chain can be slid across the sprocket. If chain can be
pulled a maximum of 6 mm (1/4 in.) away from
sprocket, adjust chain.
A—Nut (5 used)
–UN–03MAR99
B—Nut
A43173A
OUO6083,0000338 –19–23DEC03–8/9
12. Install bearing cover (A).
A—Cover
–UN–03MAR99
A43172
OUO6083,0000338 –19–23DEC03–9/9

083006
PN=1323
Remove Upper Tailings Auger

120 1. Relieve chain tension by loosening cap screw on
25
8
tension block behind sheave (A).
2. Remove chain (C) by removing connecting link (B).
–UN–14MAY03
A—Sheave
B—Connecting Link
C—Chain
H76972
–UN–03MAR99
A43171
OUO6083,00005BF –19–14MAY03–1/4
NOTE: If necessary, access can be gained into auger

trough through access door.
3. Remove locking collar (A), flangettes (B), bearing (C)

and outer bearing bracket (D).
A—Locking Collar
B—Flangette (2 used)
C—Bearing
–UN–03MAR99
D—Outer Bearing Bracket

A43310
Continued on next page OUO6083,00005BF –19–14MAY03–2/4

083006
PN=1324
4. Remove round head bolts and nuts (A) from flangettes.
120
A—Round Head Bolt and Nut (3 used) 25
9
–UN–03MAR99
A43311
OUO6083,00005BF –19–14MAY03–3/4
5. Rotate auger clockwise out through slot to remove.
–UN–25FEB99
A43312
OUO6083,00005BF –19–14MAY03–4/4
Install Upper Tailings Auger
1. Rotate auger counterclockwise to install.
–UN–25FEB99
A43312A

083006
PN=1325
2. Install round head bolts and nuts (A) to flangettes.
120
25 A—Round Head Bolt and Nut (3 used)
10
–UN–03MAR99
A43311
OUO6083,00005C0 –19–14MAY03–2/4
3. Install outer bearing bracket (D), bearing (C), flangettes

(B) and locking collar (A). Tighten locking collar and
tighten set screw.
A—Locking Collar
C—Bearing
D—Outer Bearing Bracket
–UN–03MAR99
A43310

083006
PN=1326
4. Connect chain (C) using connecting link (B).
5. Apply tension to chain and tighten cap screw on 120

25
tension block behind sheave (A). 11
A—Sheave
–UN–14MAY03
B—Connecting Link
C—Chain
H76972
–UN–03MAR99
A43171
OUO6083,00005C0 –19–14MAY03–4/4

083006
PN=1327
Remove Tailings Elevator

120 1. Loosen nuts (A) to relieve belt tension.
25
12
2. Remove belt (B).
–UN–03MAR99
A—Nut (2 used)
B—Belt
A43154A
–UN–14MAY03
H76973
OUO6083,00005C1 –19–14MAY03–1/17
3. Remove four cap screws and nuts (A) and tension

bracket assembly (B).

B—Tension Bracket Assembly
–UN–14MAY03
H76974
OUO6083,00005C1 –19–14MAY03–2/17
4. Remove four cap screws and nuts (A) from upper

auger trough (B).

B—Auger Trough
–UN–14MAY03
H76975

083006
PN=1328
5. Remove sheave (A).
6. Relieve chain tension by loosening cap screw on 120

25
tension block (E) under sheave. 13
7. Remove chain (C) by removing connecting link (B).
–UN–14MAY03
8. Remove sprocket (D) and tension block (E).
A—Sheave
H76972
B—Connecting Link
C—Chain
D—Sprocket
E—Tension Block
–UN–03MAR99
A43171
–UN–14MAY03
H76978

083006
PN=1329
9. Remove bearing cover (A).
120
25 A—Cover
14
–UN–03MAR99
A43172
OUO6083,00005C1 –19–14MAY03–5/17
10. Loosen nuts (A) and back nut (B) off to relieve paddle
chain tension.
A—Nut (5 used)
B—Nut
–UN–03MAR99
A43173A
OUO6083,00005C1 –19–14MAY03–6/17
11. Remove paddle chain (A) by removing connecting link

(B).
A—Paddle Chain
B—Connecting Link
–UN–03MAR99
A43183

083006
PN=1330
12. Remove tension bracket (A).
13. Remove locking collar (B). 120

25
15
A—Tension Bracket
B—Locking Collar
–UN–03MAR99
A43173
OUO6083,00005C1 –19–14MAY03–8/17
14. Remove bearing (A) and plate (B).
A—Bearing
B—Plate
–UN–03MAR99
A43174
OUO6083,00005C1 –19–14MAY03–9/17
NOTE: Round head bolts can fall inside left-hand

sidesheet if not retained.
15. Remove shaft speed sensor assembly (A) from lower

auger shaft.
–UN–03MAR99

A43175

083006
PN=1331
NOTE: It is not necessary to remove bearing, bracket or

inside flangette to remove lower auger. It may be
120 easier to install auger if these parts are removed.
25
16
16. Remove sensor bracket (D), locking collar (C),
outside flangette (A) and bearing (B) (optional).
–UN–03MAR99
A—Flangette
B—Bearing
C—Locking Collar
D—Sensor Bracket
A43309
OUO6083,00005C1 –19–14MAY03–11/17
17. Remove inside flangette (A) and cover plate (B).
A—Flangette
B—Cover Plate
–UN–03MAR99
A43308

083006
PN=1332
18. Rotate auger out left-hand side of combine until auger

is out of tailings elevator.
120
25
17
–UN–24FEB99
A43177
Auger Removal
–UN–29JAN99
A43178
Auger Clears Tailings Elevator
OUO6083,00005C1 –19–14MAY03–13/17
CAUTION: Disconnect harness connectors on

sensors (A) before removing or servicing them.
19. Disconnect harness connectors and remove tailings

monitor sensors (A) if equipped.
–UN–03MAR99
20. Attach lifting device to elevator.
A—Tailings Monitor Sensor

A43182

083006
PN=1333
CAUTION: The approximate weight of elevator

120 is 82 kg (180 lb).
25
18 Specification
Tailings Elevator—Weight ................................................................. 82 kg
(180 lb)
21. Remove cap screws (A) and nuts (B) attaching lower
tailings elevator.
–UN–03MAR99
22. Lower tailings elevator enough to allow clearance to
remove upper tailings elevator shaft.
A43179
B—Nut (2 used)
OUO6083,00005C1 –19–14MAY03–15/17
23. Remove locking collars (A) from front and rear of

upper tailings elevator shaft.
24. Remove flangettes (B), round head bolts (C) and nuts
from front and rear of upper tailings elevator shaft.
–UN–14MAY03
25. Push shaft out the rear side of tailings elevator.

H76979
C—Round Head Bolt and Nut (3 used)

083006
PN=1334

is 82 kg (180 lb). 120
25
Specification 19
(180 lb)
–UN–26FEB99
NOTE: It may be necessary to raise and block right-hand
side of rear axle to allow clearance for tailings
elevator to slide under axle.
A43319
26. Lower tailings elevator under rear axle and pull out
from rear of combine.
OUO6083,00005C1 –19–14MAY03–17/17
Install Tailings Elevator

is 82 kg (180 lb).
Specification
–UN–24FEB99
(180 lb)
NOTE: It may be necessary to raise and block right-hand
A43301
side of rear axle to allow clearance for elevator to
slide under axle.
Elevator Position for Shaft Installation
1. Pull tailings elevator from under rear axle and position
as shown to install upper tailings elevator shaft.
IMPORTANT: Ensure rear end of shaft is 21 mm from

end of bearing end face.
2. Install shaft from rear side of tailings elevator ensuring

that rear end of shaft is 21 mm from end of bearing
end face.

083006
PN=1335
3. Attach flangettes (B), round head bolts (C) and nuts on

front and rear of upper tailings elevator shaft.
120
25
20
4. Install locking collars (A) on front and rear of upper
tailings elevator shaft.
–UN–14MAY03
5. Install sprocket (D) and tension block (E).

H76979
C—Round Head Bolt and Nut (3 used)
D—Sprocket
E—Tension Block
–UN–14MAY03
H76978
OUO6083,00005C2 –19–14MAY03–2/17
6. Position elevator and install cap screws (A) and nuts

(B).

B—Nut (2 used)
–UN–03MAR99
A43179

083006
PN=1336
7. Install cap screws and nuts (A) on upper auger trough

(B).
120
25
B—Auger Trough
–UN–14MAY03
H76975
OUO6083,00005C2 –19–14MAY03–4/17
8. Install tailings monitor sensors (A), if equipped.

Connect harness connectors.
A—Tailings Monitor Sensor
–UN–03MAR99
A43182
OUO6083,00005C2 –19–14MAY03–5/17
9. Rotate auger clockwise through slot in sidesheet.
–UN–24FEB99
A43177A

083006
PN=1337
NOTE: For ease of installation, use nuts to hold bolts in

place during assembly.
120
25
22
10. Install cover plate (B) and inside flangette (A).
A—Flangette
B—Cover Plate
–UN–03MAR99
A43308
OUO6083,00005C2 –19–14MAY03–7/17
11. Install bearings (B), outside flangette (A) and locking

collar (C) if previously removed. Tighten set screw on
locking collar.
12. Install sensor bracket (D).
A—Flangette
–UN–03MAR99
B—Bearing
C—Locking Collar
D—Sensor Bracket
A43309
OUO6083,00005C2 –19–14MAY03–8/17
13. Install shaft speed sensor assembly (A).

–UN–03MAR99
A43175

083006
PN=1338
14. Install plate (B) and bearing (A).
120
A—Bearing 25
B—Plate 23
–UN–03MAR99
A43174
OUO6083,00005C2 –19–14MAY03–10/17
15. Install locking collar (B).
16. Install tension bracket (A).
A—Tension Bracket
B—Locking Collar
–UN–03MAR99
A43173
OUO6083,00005C2 –19–14MAY03–11/17
17. Install paddle chain (A) by attaching connecting link

(B).
A—Paddle Chain
B—Connecting Link
–UN–03MAR99
A43183

083006
PN=1339
18. Adjust paddle chain tension using nut (B). Tighten

nuts (A).
120
25
24
Paddle chain is adjusted properly when lower end of
chain can be slid across the sprocket. If chain can be
pulled a maximum of 6 mm (1/4 in.) away from
sprocket, adjust chain.
A—Nut (5 used)
–UN–03MAR99
B—Nut
A43173A
OUO6083,00005C2 –19–14MAY03–13/17
A—Cover
–UN–03MAR99
A43172

083006
PN=1340
20. Install chain (A) by attaching connecting link (B).
21. Adjust chain tension and tighten cap screw on tension 120
25
block. 25
22. Install sheave (C). Tighten cap screws to
–UN–14MAY03
specification.
Specification
Upper Tailings Elevator Sheave
H76972
(51 lb-ft)
A—Chain
B—Connecting Link
C—Sheave
–UN–03MAR99
A43171
OUO6083,00005C2 –19–14MAY03–15/17
23. Install four cap screws and nuts (B) to attach tension
bracket assembly (A).
A—Tension Bracket Assembly

B—Nut (4 used) –UN–14MAY03
H76974

083006
PN=1341
24. Install belt (B).
120 25. Tighten nuts (A) until washer aligns with end of gauge
25
26
(C).
A—Nut (2 used)
–UN–03MAR99
B—Belt
C—Gauge
A43154
–UN–14MAY03
H76973
OUO6083,00005C2 –19–14MAY03–17/17

083006
PN=1342
Group 30
Primary Countershaft Gear Case
30
Catalogs.
AG,OUO6022,310 –19–25JUL00–1/2
Spanner Wrench. . . . . . . . . . . . . . . . . . . . JDG685
Remove input shaft yoke.
AG,OUO6022,310 –19–25JUL00–2/2
Other Material
Number Name Use

applications.
PM38621 (Canadian) Strength) parts loosening due to vibration.
AG,OUO1026,215 –19–28JUL05–1/1

083006
PN=1343
Specifications
30
2
Primary Countershaft Gear Case Torque 123 N•m
Mounting Cap Screws (91 lb-ft)
Primary Countershaft Input Shaft Torque 40 N•m

U-Joint Cap Screws (29 lb-ft)

Housing Cap Screws (54 lb-ft)
Primary Countershaft Gear Case End Play 0.22—0.32 mm + 1/4 turn

Input Shaft (0.008—0.012 in.) + 1/4 turn

Input Housing Cap Screws (54 lb-ft)
Primary Countershaft Gear Case Weight 54 kg

(119 lb)
Primary Countershaft Gear Case Capacity 1.2 L

(2.5 pt)
OUO6083,000033E –19–15AUG02–1/1

083006
PN=1344

Gear Case
120
30
1. Remove header electromagnetic clutch. (See REMOVE 3
HEADER ELECTROMAGNETIC CLUTCH in Group 35
of this section.)
–UN–21JAN99
2. Disconnect drive shaft from U-joint by removing screws
(A), and straps (B), on U-joint.
H51781
3. Wrap end of drive shaft with tape to protect bearings.
4. Move drive shaft to rear to provide clearance.
5. Remove dipstick and dipstick tube.
IMPORTANT: Support drive shaft after it is

disconnected to prevent possible
damage to U-joint bearings for the
–UN–21JAN99
following step.
6. Remove mounting cap screws (C), washers, bushings,

retainers and spacers.
H51782
CAUTION: Approximate weight of gear case is
54 kg (119 lb). A—Cap Screw (4 used)
B—Strap (2 used)
Specification C—Cap Screw (2 used)
Primary Countershaft Gear D—Gear Case
Case—Weight.................................................................................... 54 kg E—Retainer (2 used)
(119 lb)
7. Remove gear case (D), washers, retainers (E) and

bushings.
8. Position washers, retainers (E), bushings and spacers.

Install gear case (D) and cap screws (C). Tighten cap
Specification
Mounting Cap Screws—Torque ................................................... 123 N•m
(91 lb-ft)
9. Remove tape from end of drive shaft.
10. Connect drive shaft to U-joint using straps (B) and

screws (A). Tighten screws to specifications.
Continued on next page OUO6083,00001C4 –19–05FEB02–1/2

083006
PN=1345
Specification
Primary Countershaft Input Shaft
120 U-Joint Cap Screws—Torque......................................................... 40 N•m
30 (29 lb-ft)
4
11. Install dipstick tube. Fill gear case with GL-5 80W/90
Gear Lubricant and install dipstick.
Specification
Primary Countershaft Gear
Case—Capacity ................................................................................. 1.2 L
(2.5 pt)
12. Install header electromagnetic clutch. (See INSTALL

HEADER ELECTROMAGNETIC CLUTCH in Group
35 of this section.)
Prior to tightening clutch retaining nut, fill gear case

splined cavity with TY6341 Multi-Purpose SD
Polyurea Grease through lubrication fitting on output
shaft.
OUO6083,00001C4 –19–05FEB02–2/2

083006
PN=1346
120
30
5

083006
PN=1347
Disassemble and Assemble Primary Countershaft Gear Case

120
30
6
–UN–10DEC01
H70394

083006
PN=1348
1—O-Ring 10—O-Ring 19—Gear (41-tooth) 28—Lock Washer

2—Adapter 11—Shim (as required) 20—Screw (11 used) 29—Yoke
3—Dipstick Tube 12—Housing 21—Screw 30—O-Ring 120
4—Dipstick 13—Screw (11 used) 22—Housing 31—Retainer 30
5—Screw (4 used) 14—Seal 23—Bearing Cup 32—Bearing Cup 7
6—Cover 15—Lubrication Fitting 24—Bearing Cone 33—Bearing Cone
7—Gear Case 16—Bearing Cone 25—Seal 34—Fitting
8—Bearing Cone 17—Bearing Cup 26—Nut 35—Threaded Nipple
9—Bearing Cup 18—Shim (as required) 27—Lock Washer 36—Seal
OUO6083,000033D –19–28JUL05–2/19
1. Remove lubrication fitting from shaft.
CAUTION: The approximate weight of gear case

in 54 kg (119 lb).
Specification
–UN–18MAR99
Primary Countershaft Gear
Case—Weight.................................................................................... 54 kg
(119 lb)
NOTE: Gears are a matched set and must be replaced
H54833
as a set.
2. Bend tab of lock washer (B) out of nut. Use spanner A—Housing
wrench JDG685 to remove nut. Pull off yoke (C). B—Nut and Lock Washer
C—Yoke
3. Remove cap screws (D), cap screw (E), and housing E—Cap Screw
(A). F—Shim (as required)
4. Remove O-ring next to shim pack.
5. Remove shim pack (F). Do not damage shims so they

can be used in assembly. Keep shims separate from
shims that will be removed from output housing.
Remove gear from input housing. Remove bearing
cone as gear is being removed.

083006
PN=1349
6. Remove bearing cup (A) using a bearing puller.
120
30 A—Bearing Cup
8
–UN–25JUL89
H40559
OUO6083,000033D –19–28JUL05–4/19
7. Remove retainer (A).
A—Retainer
–UN–25JUL89
H40560
OUO6083,000033D –19–28JUL05–5/19
8. Remove seal (A) and bearing cup (B).
A—Seal
B—Bearing Cup
–UN–12MAR99
H54754
OUO6083,000033D –19–28JUL05–6/19
9. Remove bearing cone (A) from input gear. Bearing is a

press fit.
A—Bearing Cone
–UN–25JUL89
H40566

083006
PN=1350
10. Remove six cap screws (B) and housing (A).
120
A—Housing 30
B—Cap Screw (6 used) 9
–UN–25JUL89
H40569
OUO6083,000033D –19–28JUL05–8/19
11. Remove bearing cup (A) and seal (B).
12. Remove O-ring next to shim pack.
13. Remove shim pack (C). Do not damage shims so

they can be used in assembly. Keep shim pack (C)
–UN–25JUL89
separate from shim pack removed from input housing.
A—Bearing Cup
B—Seal
H40570
C—Shim Pack
OUO6083,000033D –19–28JUL05–9/19
14. Remove bearing cone (A) from output gear. Bearing

is a press fit. Remove bearing cone from gear end of
output gear shaft.
A—Seal –UN–25JUL89
H40572

083006
PN=1351
15. Remove seal (A) from gear case.
120 16. Remove bearing cup from left-hand output bore of

30
10
gear case.
17. Remove shims from behind bearing cup.
–UN–25JUL89
Check following shim packs if following parts are
H40574
replaced:
• Left-hand output shims,

– Output gear A—Seal
– Gear Case
• Right-hand output shims,
– Output gear
– Gear case
– Output bearing sets
– Output housing
• Input housing shims,
– Output gear
– Gear case
– All bearing sets
– Output housing
– Input retainer and snap ring
– Input housing
– Yoke
19. Install seal (A) flush with gear case face, with spring
loaded lip toward bearing.
OUO6083,000033D –19–28JUL05–11/19
20. Install bearing cone (A) on output gear so it seats

against shoulder. Bearing is a press fit. Install bearing
cone on output gear shaft and seat against gear.
A—Bearing Cone
–UN–25JUL89
H40573

083006
PN=1352
21. To determine left-hand output shim pack (B):
a. Add dimension etched on back of output gear (D), 120

30
93.5 nominal, to dimension stamped on gear case 11
(A), 98 nominal.
–UN–17MAR99
b. Subtract dimension etched on output gear shaft,
164.5 nominal, from above total and also subtract
25.45 mm (1.002 in.).
H54755
NOTE: Subtract 164.5 if there is no dimension etched on
the output gear.
c. Select shim pack equal to calculated dimension ± A—Gear Case

0.05 mm (0.002 in.). B—Shim (as required)
C—Bearing Cup
D—Output Gear
22. Install parts in gear case in following order: Shim
pack (B), bearing cup (C) and output gear (D).
OUO6083,000033D –19–28JUL05–13/19
23. Install bearing cup (A) and seal (B).
24. Install shim pack (C) and O-ring.
NOTE: If shim pack was damaged during disassembly,

measure shim pack thickness and replace with
new shims. Do not use more than one plastic
–UN–25JUL89
shim.
To determine right-hand output shim pack (C),
H40570
install right-hand output housing and use a shim
pack thickness that will preload bearings 0.03—
0.13 mm (0.001—0.005 in.).
A—Bearing Cup
B—Seal
C—Output Shim Pack

083006
PN=1353
25. Install housing (A) on gear case. Install cap screws

(B) and tighten to specifications.
120
30 Specification
12 Primary Countershaft Gear Case
Housing Cap Screws—Torque ....................................................... 73 N•m
(54 lb-ft)
–UN–25JUL89
A—Housing
H40569
OUO6083,000033D –19–28JUL05–15/19
26. Install bearing cone (A) on input gear. Bearing must

rest on shoulder of shaft. Bearing is a press fit.
Record backlash stamped on heel of input gear to be
used when determining input housing shims.
A—Bearing Cone
–UN–25JUL89
H40567
OUO6083,000033D –19–28JUL05–16/19
27. Install retainer (B) and bearing cup (A) in housing (C).
A—Bearing Cup
B—Retainer
C—Housing
–UN–25JUL89
H41190
OUO6083,000033D –19–28JUL05–17/19
28. Install bearing cup (B) and slide gear in housing.

Install bearing cone (C) and seal (D) in housing (A).
Install seal with spring-loaded lip toward bearing.
Press flush in housing (A).
A—Housing
–UN–25JUL89
B—Bearing Cup
C—Bearing Cone
D—Seal
H41188

083006
PN=1354
29. Install yoke (C). Install washer (end washer with

concave outward). Apply PM37418 Thread Lock and
Sealer (medium strength) to gear shaft threads. 120
30
Tighten nut with JDG685 wrench to get 0.22—0.32 13
mm (0.008—0.012 in.) end play and tighten an
additional 90° (1/4 turn). Bend one tab of washer to
–UN–18MAR99
lock in place.
Specification
Input Shaft—End Play ....................................... 0.22—0.32 mm + 1/4 turn
H54833
(0.008—0.012 in.) + 1/4 turn
NOTE: If shim pack was damaged during disassembly,

A—Housing
measure shim pack thickness and replace with B—Nut and Lock Washer
new shims. Do not use more than one plastic C—Yoke
shim. D—Cap Screw (5 used)
E—Cap Screw
30. Install housing (A), O-ring and shim (F) on gear case. F—Shim (as required)
Determine input housing shim pack (F) by using

backlash 0.13—0.28 mm (0.005—0.011 in.) recorded
earlier from heel of input gear. Select shims to
provide backlash (dimension on heel of gear) +0.1,
-0.0 mm (+0.004, -0.0 in.) at tightest condition of gear
mesh.
31. Install and tighten cap screws (D and E) to

specification.
Specification
Input Housing Cap Screws—
Torque ............................................................................................ 73 N•m
(54 lb-ft)
OUO6083,000033D –19–28JUL05–19/19

083006
PN=1355
120
30
14

083006
PN=1356
Group 35
Header Electromagnetic Clutch
Specifications

35
1
Header Electromagnetic Clutch Torque 123 N•m
Sheave Cap Screws (90 lb-ft)
Electromagnetic Clutch Retaining Nut Torque 328 N•m

(242 lb-ft)
Magnetic Clutch Flange Cap Screws Torque 100 N•m

(74 lb-ft)
Brush Module-to-Powershaft Torque 33 N•m

(24 lb-ft)
Electromagnetic Clutch Assembly Weight 28.6 kg

(63 lb)
OUO6083,0000340 –19–16AUG02–1/1
Remove Header Electromagnetic Clutch
1. Loosen nuts (B) to release tension on idler.
NOTE: If only brush module is being replaced, disconnect

two connectors located on brush module.
–UN–01JUL99
2. Remove two screws (C) attaching wire leads.
3. Disconnect connector (D). Remove strap and bracket
H58618
(E).
4. Rotate brush module (F) counterclockwise and remove.
5. Remove belt (A) from clutch sheave.
A—Belt
B—Nut (2 used)
C—Screw (2 used)
–UN–21APR00
D—Connector
E—Bracket
F—Brush Module
H63695

083006
PN=1357
6. Remove nut (A) and washer (B) from shaft (C).
120
35 CAUTION: Approximate weight of
2 electromagnetic clutch assembly is 28.6 kg (63
lb).
–UN–21JAN99
Specification
Electromagnetic Clutch
Assembly—Weight ......................................................................... 28.6 kg
(63 lb)
H51775
7. Remove clutch assembly (D).
8. Remove woodruff key from shaft (C). A—Nut

B—Washer
C—Primary Countershaft
D—Clutch and Sheave Assembly
OUO6083,0000341 –19–16AUG02–2/3
9. Remove cap screws (A) and sheave from clutch.
A— Cap Screw (4 used)
–UN–21JAN99
H51777
OUO6083,0000341 –19–16AUG02–3/3

083006
PN=1358
Header Electromagnetic Clutch—Exploded View

120
35
3
M
B L
N
C
K
A D J
I
F
O
–UN–03JUN04
H
H81041
A—Cap Screw E—Carbon Brush Holder I—Lock Nut M—Sheave
B—Bracket F—Fitting Plug J—Washer N—Cap Screw (4 used)
C—Strap G—Wiring Harness K—Key, Woodruff O—Belt
D—Flange Nut H—Nut L—Clutch
OUO6083,0000820 –19–03JUN04–1/1
Install Header Electromagnetic Clutch
1. Install sheave to clutch using cap screws (A). Tighten

Specification
–UN–21JAN99
Sheave Cap Screws—Torque ...................................................... 123 N•m

(90 lb-ft)

H51777
Continued on next page OUO6083,000033F –19–16AUG02–1/3

083006
PN=1359
CAUTION: Approximate weight of

120 electromagnetic clutch assembly is 28.6 kg (63
35 lb).
4
Specification
Electromagnetic Clutch
–UN–21JAN99
Assembly—Weight ......................................................................... 28.6 kg
(63 lb)
2. Install woodruff key on shaft (C). Install

electromagnetic clutch assembly (D) on shaft.
H51775
IMPORTANT: A new retaining nut (A) is required to
install clutch and sheave assembly to A—Nut
help prevent machine damage caused B—Washer
by loose nut. C—Primary Countershaft
D—Electromagnetic Clutch and Sheave Assembly
3. Install washer (B) and a new nut (A) to primary

countershaft (C).
Specification
Electromagnetic Clutch Retaining
Nut—Torque ................................................................................. 328 N•m
(242 lb-ft)
Continued on next page OUO6083,000033F –19–16AUG02–2/3

083006
PN=1360
4. Install brush module (A) on countershaft by turning

clockwise and tighten to specification.
120
Specification 35
Brush Module-to-Powershaft— 5
Torque ............................................................................................ 33 N•m
(24 lb-ft)
–UN–10MAY99
5. Install screws (B) through wire leads and into clutch
assembly.
H51779
6. Install safety strap and bracket (C).
7. Connect harness connector (D).
8. Install belt (E) and tighten nuts (F) until washer (G) on
idler spring aligns with tip of gauge (H).
9. Start engine, engage separator at low idle.
–UN–21JAN99
10. Engage front end electric clutch. Check cornerpost
display to make sure feeder house is running.
11. Disengage front end electric clutch. Check cornerpost
H51780
display to make sure feeder house stops.
12. Disengage separator clutch and shut engine off.

A—Brush Module
B—Screw (2 used)
C—Bracket
D—Connector
E—Belt
F—Nuts (2 used)
G—Washer
H—Gauge
OUO6083,000033F –19–16AUG02–3/3

083006
PN=1361
120
35
6

083006
PN=1362
Section 130
Grain Tank and Unloading System Repair
Contents
Page Page 130
Group 05—Grain Tank Cross Augers Folding Horizontal Auger—Exploded View . .130-20-14
Remove Grain Tank Cross Augers (Regular Folding Horizontal Auger Pivot—Exploded
Unload Rate) . . . . . . . . . . . . . . . . . . . . . . . .130-05-1 View . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-16
Install Grain Tank Cross Augers (Regular Remove and Install Folding Auger
Unload Rate) . . . . . . . . . . . . . . . . . . . . . . . .130-05-4 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-17
Remove Grain Tank Cross Augers (High Remove and Install Outer Folding Auger
Unload Rate) . . . . . . . . . . . . . . . . . . . . . . . .130-05-7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-17
Install Grain Tank Cross Augers (High Unload Remove and Install Folding Auger Rings. . . .130-20-18
Rate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130-05-10 Remove Rear Horizontal Folding Auger . . . .130-20-19
Remove Front Horizontal Folding Auger . . . .130-20-19
Group 10—Unloading Auger System Drives Install Front Horizontal Folding Auger . . . . . .130-20-22
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .130-10-1 Install Rear Horizontal Folding Auger . . . . . .130-20-23
Remove and Install Unloading Auger Drive Remove Horizontal Auger Gear Case . . . . . .130-20-24
Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130-10-1 Disassemble And Assemble Horizontal
Remove and Install Unloading Auger Drive Unloading Auger Gear Case . . . . . . . . . . .130-20-25
Countershaft—Style A . . . . . . . . . . . . . . . . .130-10-2 Install Horizontal Auger Gear Case . . . . . . . .130-20-28
Remove and Install Unloading Auger Drive Remove Horizontal Unloading Auger
Countershaft—Style B . . . . . . . . . . . . . . . . .130-10-4 Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-29
Install Horizontal Unloading Auger Tube . . . .130-20-30
Group 15—Vertical Unloading Auger and Lower Unloading Auger Elbow—Exploded View . . .130-20-32
Gear Case Remove Horizontal Auger Elbow. . . . . . . . . .130-20-34
Essential or Recommended Tools . . . . . . . . . .130-15-1 Install Horizontal Auger Elbow. . . . . . . . . . . .130-20-36
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .130-15-2 Remove Unloading Auger Charge
Remove Vertical Auger Lower Gear Case Housing . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-38
and Vertical Auger . . . . . . . . . . . . . . . . . . . .130-15-3 Install Unloading Auger Charge Housing . . . .130-20-41
Disassemble and Assemble Vertical Auger
Group 25—Clean Grain Elevator
Lower Gear Case . . . . . . . . . . . . . . . . . . . .130-15-6
Other Material . . . . . . . . . . . . . . . . . . . . . . . . .130-25-1
Install Vertical Auger and Vertical Auger
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .130-25-1
Lower Gear Case . . . . . . . . . . . . . . . . . . .130-15-12
Adjust Clean Grain Elevator Chain . . . . . . . . .130-25-2
Remove Clean Grain Elevator . . . . . . . . . . . . .130-25-2
Group 20—Horizontal Unloading Auger and Gear Install Clean Grain Elevator. . . . . . . . . . . . . . .130-25-7
Case Remove and Install Clean Grain Elevator
Essential or Recommended Tools . . . . . . . . . .130-20-1 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . .130-25-12
Other Material . . . . . . . . . . . . . . . . . . . . . . . . .130-20-2 Disassemble and Assemble Clean Grain
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .130-20-3 Elevator Gear Case . . . . . . . . . . . . . . . . . .130-25-14
Inspection of Horizontal Unloading Auger . . . .130-20-4 Remove And Install Clean Grain Loading
Horizontal Unloading Auger—Regular Auger. . . . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-18
Unload Rate . . . . . . . . . . . . . . . . . . . . . . . .130-20-5 Replace Clean Grain Loading Auger
Horizontal Unloading Auger—High Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-19
Unload Rate . . . . . . . . . . . . . . . . . . . . . . . .130-20-6 Remove And Install Lower Clean Grain
Remove and Install Unloading Auger Grain Auger. . . . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-20
Saver Door . . . . . . . . . . . . . . . . . . . . . . . . .130-20-7
Remove Horizontal Auger . . . . . . . . . . . . . . . .130-20-7 Group 30—Grain Tank and Extensions
Install Horizontal Auger . . . . . . . . . . . . . . . . . .130-20-8 Grain Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .130-30-2
Folding Horizontal Auger Housing—
Exploded View. . . . . . . . . . . . . . . . . . . . . .130-20-12 Continued on next page

083006
PN=1
Contents
Page
Grain Tank Extensions . . . . . . . . . . . . . . . . . .130-30-5
130

083006
PN=2
Group 05
Grain Tank Cross Augers
Remove Grain Tank Cross Augers (Regular
Unload Rate)
NOTE: Use the following steps to remove either (A) or (B)

grain tank cross augers.
–UN–06MAY05
1. Remove right-hand gull wing door. (See REMOVE
AND INSTALL GULL WING DOORS in Section 80, 130
Group 05.) 05
1
H83377
2. Loosen chain tensioner (C) and remove drive chain
(D).
A—Front Auger
B—Rear Auger
C—Chain Tensioner
D—Drive Chain
OUO6083,0000AC5 –19–21JUL05–1/6
NOTE: Note location and number of washers behind snap

ring. Install washers upon assembly to correctly
align sprockets.
3. Remove snap ring and washers (A). Loosen set

screws and remove sprocket (B).
–UN–26APR99
A—Snap Ring
B—Sprocket
H55798
OUO6083,0000AC5 –19–21JUL05–2/6
4. Remove key (A) and locking collar (B).
A—Key
B—Locking Collar
–UN–26MAR99
H54956
Continued on next page OUO6083,0000AC5 –19–21JUL05–3/6

083006
PN=1365
5. Remove locking collar (A) from right-hand side of

auger shaft.
A—Locking Collar
–UN–26MAR99
130
05
2
H54968
OUO6083,0000AC5 –19–21JUL05–4/6
6. Remove nuts (B) and (C). Remove bearing support

plates (A).
A—Plates
B—Nut
C—Nut
–UN–26MAR99
H54957
–UN–26MAR99
H54967
–UN–26MAR99
H54986

083006
PN=1366
CAUTION: The approximate weight of each

auger is:
Cross Auger Weights

kg (lb)
Regular Duty Regular
–UN–26MAR99
Unload Rate Front 25 (55)
Auger 130
05
3
Unload Rate Rear 25 (55)
H54987
Auger
Heavy Duty Regular
Auger
Heavy Duty Regular
Auger
IMPORTANT: Front and rear augers are different. DO

NOT INTERCHANGE.
7. Remove auger by pulling straight out.
OUO6083,0000AC5 –19–21JUL05–6/6

083006
PN=1367
Install Grain Tank Cross Augers (Regular

Unload Rate)
NOTE: Loosen left-hand bearing and flangettes for easier

installation.
–UN–26MAR99
130
05
auger is:
4
Cross Auger Weights
H54987
kg (lb)
Regular Duty Regular Auger Inserted—Right-Hand Side
Auger
Auger
Heavy Duty Regular
Auger
–UN–26MAR99
Heavy Duty Regular
Auger
H54990
NOT INTERCHANGE.
1. Install augers from right-hand side by pushing straight

in until left-hand end of auger shaft is inserted through
bearing.
2. Clean off old seal and caulking from bearing support

plates and apply new seal and caulking.

083006
PN=1368
NOTE: Leave right-hand bearing and flangettes loose for

easier installation.
3. Install cover (A) by pushing onto auger shaft. Install

nuts (B) and (C).
4. Slide augers fully to right-hand side. Tighten bearing

and flangettes and install locking collar. Tighten set 130
screw. 05
–UN–26MAR99
5
A—Cover
B—Nut
C—Nut
H54986A
–UN–26APR99
H55767
OUO6083,0000AC6 –19–21JUL05–2/5
5. Tighten flangette cap screws on left-hand side. Install

woodruff key (A) and locking collar (B) to left-hand end
of auger shaft. Tighten locking collar and set screw.
A—Key
B—Lock Collar
–UN–26MAR99
H54956

083006
PN=1369
6. Install sprocket (A and B). Do not tighten set screws at

this time.
7. Use straight edge and align sprockets (A and B) with

sprocket (C). Tighten set screws.
–UN–06MAY05
8. Position washers on shaft and install snap ring (D). No
130 space should exist between washers and snap ring.
05
6
A—Cross Auger Sprocket
H83379
B—Cross Auger Sprocket
C—Cross Auger Drive Sprocket
D—Snap Ring Sprockets in Alignment
–UN–26APR99
H54955
OUO6083,0000AC6 –19–21JUL05–4/5
9. Install drive chain (A) and tighten nuts on chain

tensioner (B) until washer aligns with gauge.
10. Install right-hand gull wing door. (See REMOVE AND

INSTALL GULL WING DOORS in Section 80, Group
05.)
–UN–06MAY05
A—Drive Chain
B—Chain Tensioner
H83380
OUO6083,0000AC6 –19–21JUL05–5/5

083006
PN=1370
Remove Grain Tank Cross Augers (High

Unload Rate)
NOTE: Use the following steps to remove either (A or B)

grain tank cross augers.
–UN–06MAY05
1. Disconnect one end of gas cylinders from left-hand gull
wing door. Lift and support door high enough to 130
remove augers from grain tank. 05
7
H83381
NOTE: Note location and number of washers behind snap
ring. Install washers upon assembly to correctly
align sprockets.
2. Loosen chain tensioner (D) and remove drive chain

(C).
3. Remove snap ring (E) and washers. Loosen set

screws and remove drive sprocket (F).
–UN–06MAY05
A—Front Auger
B—Rear Auger
C—Drive Chain
H83382
D—Chain Tensioner
E—Snap Ring
F—Drive Sprocket
OUO6083,0000AC7 –19–21JUL05–1/5
4. Remove key (A) and locking collar (B).
A—Key
B—Locking Collar
–UN–28APR05
H83263

083006
PN=1371
5. Remove locking collar (A) from right-hand side of

auger shaft.
A—Locking Collar
–UN–28APR05
130
05
8
H83265
OUO6083,0000AC7 –19–21JUL05–3/5
6. Remove nuts (A, D, and E), cap screw (B), and cover
plate (C).
A—Nut (5 used)
B—Cap Screw
C—Cover Plate
–UN–28APR05
D—Nut (3 used)
E—Nut (2 used)
H83264

083006
PN=1372
NOTE: Rotate auger manually to allow clearance during

removal.
Remove auger shield in grain tank to allow rear

auger to be tilted during removal.
–UN–02MAY05
auger is: 130
05
9
Cross Auger Weights
H83266
kg (lb)
Regular Duty High
A—Auger
Auger
B—Bearing
Regular Duty High C—Bearing Flangette (2 used)
Auger
Heavy Duty High
Auger
Heavy Duty High
Auger

NOT INTERCHANGE.
7. Remove auger (A) by pulling out at a downward angle.

Remove flangettes (C) and inspect bearing (B).
Replace if necessary.
OUO6083,0000AC7 –19–21JUL05–5/5

083006
PN=1373
Install Grain Tank Cross Augers (High

Unload Rate)
NOTE: Loosen right-hand bearing and flangettes for

–UN–02MAY05
130
05
auger is:
10
Cross Auger Weights
H83266
kg (lb)
Regular Duty High
Unload Rate Front 36 (80) A—Auger
Auger B—Bearing
Regular Duty High C—Flangettes (2 used)
Auger
Heavy Duty High
Auger
Heavy Duty High
Auger

NOT INTERCHANGE.
1. Install augers from left-hand side by pushing in at an

upward angle until left-hand end of auger shaft clears
door. Push straight in until right-hand end of auger is
inserted through bearing.
OUO6083,0000AC8 –19–21JUL05–1/7
2. Clean off old caulking from bearing support plates and

apply new caulking to caulk areas (A).
A—Caulk Areas
–UN–02MAY05
H83305

083006
PN=1374
3. Install cover plate (C) by pushing onto auger shaft.
NOTE: Leave left-hand bearing and flangettes loose for

4. Install bearing and flangettes to cover plate using cap
–UN–28APR05
screws and nuts (D).
130
5. Install nuts (A and E) and cap screw (B). 05
11
H83264
6. Tighten nuts (D).
A—Nut (5 used)
B—Cap Screw
C—Cover Plate
D—Nut (3 used)
E—Nut (2 used)
OUO6083,0000AC8 –19–21JUL05–3/7
7. Slide auger fully to right-hand side. Install locking collar

(B) and woodruff key (A). Tighten set screw on locking
collar.
A—Woodruff Key Set Screw

B—Locking Collar
–UN–28APR05
H83263
OUO6083,0000AC8 –19–21JUL05–4/7
8. Tighten flangettes and install locking collar (A). Tighten

set screw on locking collar.
A—Locking Collar
–UN–28APR05
H83265

083006
PN=1375
9. Install sprocket (A and B). Do not tighten set screws at

this time.
10. Use straight edge and align sprockets (A and B) with

sprocket (C). Tighten set screws.
–UN–06MAY05
11. Position washers on shaft and install snap ring (D).
130 No space should exist between washers and snap
05 ring.
12
H83386
A—Front Auger Sprocket
B—Rear Auger Sprocket
C—Cross Auger Drive Sprocket
D—Snap Ring
–UN–28APR05
H83277
OUO6083,0000AC8 –19–21JUL05–6/7
12. Install drive chain (A) and tighten nuts on chain

tensioner (B) until washer aligns with gauge.
13. Connect gas cylinder to left-hand gull wing door.
A—Drive Chain
–UN–06MAY05
B—Chain Tensioner
H83384
OUO6083,0000AC8 –19–21JUL05–7/7

083006
PN=1376
Group 10
Unloading Auger System Drives
Specifications
Sidesheet-to-End of Shaft Distance 196 mm

(7.7 in.)
Shear Bolt Torque 25 N•m 130

(18 lb-ft) 10
1
OUO6046,0002003 –19–18JUL05–1/1

Belt
2. Loosen nuts (A) and remove chain.
–UN–03JUN03
3. Remove nuts, and cap screws (B).
4. Separate two piece belt trap (C) and remove.
H77608
5. Remove belts (D).
6. Install belts.
7. Install two piece belt trap.
8. Install chain and adjust tensioner until washer aligns

with gauge.
–UN–09APR99
A—Nuts (2 used)
C—Belt Trap
H55311
D—Belts (2 used)
OUO6083,0000CB6 –19–09MAR06–1/1

083006
PN=1377

Countershaft—Style A
1. Remove chain and drive belts. (See procedure in this

group.)
–UN–09APR99
130
10 3. Loosen two jam nuts and set screws (B).
2
H55317
4. Remove gear (C) and woodruff key.
5. Loosen two lock nuts and set screws (D).
NOTE: Note location of spare shear bolts (L).
6. Remove nut, shear bolt (E), outside countershaft hub

(F) and woodruff key.
–UN–09APR99
7. Loosen set screw and turn locking collar (G) in
opposite direction of shaft rotation to remove.
8. Remove nuts and cap screws from flangettes. Remove
H55319
bearing (H).
9. Loosen set screw and turn locking collar (I) in opposite

direction of shaft rotation.
10. Remove nuts, cap screws from flangette and bearing

(J).
11. Remove hardware attaching sheave to inside
–UN–06JUN01
countershaft hub (K).
12. Slide shaft toward outside of combine. Tilt sheave to

remove from shaft. Remove hub and bushing.
H68562
13. Remove spacer, flangettes, bearing (J) and shaft as
an assembly.
A—Snap Ring
B—Set Screw (2 used)
14. Remove spacer, flangettes, and bearing (J) from C—Gear
shaft. D—Set Screw (2 used)
E—Shear Bolt
F—Outside Hub
G—Locking Collar
H—Bearing
I—Locking Collar
J—Bearing
K— Inside Hub
L—Shear Bolts
Continued on next page OUO6046,0001FEA –19–12JUL05–1/2

083006
PN=1378
NOTE: Measurement (A) from end of shaft to face of

locking collar is 190.5 mm (7.5 in.).
15. Install bearing, flangettes, locking collar and spacer

on shaft.
–UN–09APR99
16. Install shaft and sheave (B).
130
17. Install belts. 10
3
H55340
with gauge (C).
A—Measurement
B—Sheave
C—Gauge
–UN–09APR99
H55341
–UN–09APR99
H55342
OUO6046,0001FEA –19–12JUL05–2/2

083006
PN=1379

Countershaft—Style B
1. Remove chain and drive belts (A). (See procedure in

this group.)
–UN–29JUN05
2. Remove snap ring (B), shims, and washer (C).
130
10 3. Remove shear bolt (E) and sprocket assembly (D).
4
H83806
4. Loosen set screw and turn locking collar (G) in
opposite direction of shaft rotation to remove.
5. Remove nuts and cap screws from flangettes. Remove

bearing (H).
6. Loosen set screw and turn locking collar (I) in opposite

direction of shaft rotation.
–UN–28JUN05
7. Remove nuts, cap screws from flangette and bearing
(J).
8. Remove cap screws (F).
H83869
9. Slide shaft toward outside of combine. Tilt sheave to
remove from shaft. Remove hub.
10. Remove flangettes, bearing (J) and shaft as an

assembly.
11. Remove spacer, flangettes, and bearing (J) from

shaft.
–UN–28JUN05
A—Drive Belts
B—Snap Ring
C—Special Washer
H83868
D—Sprocket Assembly
E—Shear Bolt
G—Locking Collar
H—Bearing
I—Locking Collar
J—Bearing
K—Shear Bolts
Continued on next page OUO6046,0001FEB –19–18JUL05–1/2

083006
PN=1380
12. Install bearing and flangettes.
13. Install shaft in support assembly.
14. Position shaft to specification. Measurement should

be taken from sidesheet (A) to end of shaft.
–UN–18JUL05
Specification
130
Sidesheet-to-End of Shaft—
10
Distance ......................................................................................... 196 mm
5
(7.7 in.)
H84003
15. Install and tighten inside and outside locking collars in
direction of shaft rotation. Tighten set screws.
16. Install sheave and hub assembly against outside lock

collar. Make sure key is still in keyway.
17. Install sprocket assembly by inserting hub inside cast

drive hub. Install shear bolt and tighten to
–UN–11JUL05
specification.
Specification
Shear Bolt—Torque ........................................................................ 25 N•m
H83937
(18 lb-ft)
18. Install special washer on shaft with tab in cut out.

A—Sidesheet
19. Install shims that were removed during disassembly B—Gauge
and install snap ring.
20. Install belts.

with gauge (B).
OUO6046,0001FEB –19–18JUL05–2/2

083006
PN=1381
130
10
6

083006
PN=1382
Group 15
Vertical Unloading Auger and Lower Gear Case
SERVICEGARD or European Microfiche Tool 130
Catalogs. 15
1
AG,OUO6022,310CONV1 –19–25JUL00–1/4
Service Jack . . . . . . . . . . . . . . . . . . . . . . JT07056A
Used to remove and install vertical auger lower gear case.
–UN–14SEP89
H40598
AG,OUO6022,310CONV1 –19–25JUL00–2/4
Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . D05071ST
–UN–27JUL89
H41163
AG,OUO6022,310CONV1 –19–25JUL00–3/4
Auger Gear Case Remover/Installer Bracket . . . JT05877

–UN–05SEP89
H41091
AG,OUO6022,310CONV1 –19–25JUL00–4/4

083006
PN=1383
Specifications
Output Shaft Gear Retaining Cap Torque 270 N•m

Screw (200 lb-ft)
130 Quill Cap Screws Torque 68 N•m

15 (50 lb-ft)
2
Input Shaft Cap Screw Torque 290 N•m
(214 lb-ft)
Vertical Auger Lower Gear Case Backlash 0.15—0.51 mm

Bevel Gear (0.006—0.020 in.)
Vertical Auger Lower Gear Case Weight 37 kg

(82 lb)
High Unload Rate Charge Housing Torque 130 N•m

Filler Plate (96 lb-ft)
OUO6083,0000610 –19–05JUN03–1/1

083006
PN=1384
Remove Vertical Auger Lower Gear Case and

Vertical Auger
1. Swing auger to unload position. Shut off engine and

remove key.
–UN–25JAN05
2. Remove cover from horizontal auger inspection hole
(A). 130
15
NOTE: Observe position of horizontal and vertical auger 3
H82301
flight (C) for proper installation.
A—Horizontal Auger Inspection Hole

B—Horizontal Auger
C—End of Auger Flight
D—Vertical Auger
–UN–22MAY03
H77333

083006
PN=1385
3. Loosen nuts (A) and remove chain.
4. Remove attaching hardware and chain guard (B).
5. Remove drive sprocket (C).
–UN–03JUN03
6. Remove cap screws (D) and shield (E).
130
15 7. Remove shield (F).
4
H77609
A—Nuts
B—Chain Guard
C—Drive Sprocket
E—Shield
F—Shield
–UN–21JUL00
H64482
–UN–21JUL00
H64483

083006
PN=1386

is 37 kg (82 lb).
Specification
Vertical Auger Lower Gear
Case—Weight.................................................................................... 37 kg
(82 lb)
–UN–21JUL00
130
8. Attach JT07056A Service Jack with D05071ST 15
Pedestal and JT05877 Auger Gear Case 5
Remover/Installer Bracket (A) to gear case (B).
H64484
Regular Unload Rate Shown
auger is:
Vertical Auger Weights

kg (lb)
Regular Duty High
Unload Rate Vertical 30 (66)
Auger
–UN–21JUL00
Heavy Duty High
Auger
H64485
Auger
Heavy Duty Regular
Unload rate Vertical 30 (65)
Auger
9. Remove attaching hardware (C). Lower service jack

and remove vertical auger and gear case from charge
housing (D).
–UN–05JUN03
NOTE: On high unload rate systems, remove cap screws
(E) and plate (F) before lowering vertical auger
and gear case.
H77640
10. Remove vertical auger from gear case.
High Unload Rate Shown
11. Repair or replace vertical auger as necessary.
A—Auger Remover/Installer Bracket
12. Check the vertical flighting on the lower portion of the B—Gear Case
vertical auger. If the flighting is worn back from the C—Bolts (10 used)
D—Charge Housing
OD more than 25 mm (1 in.), or the end of the E—Cap Screw (16 used)
flighting is damaged, consider rebuilding the flighting F—Plate
or replacing the auger.
OUO6083,0000AC9 –19–21JUL05–3/3

083006
PN=1387
Disassemble and Assemble Vertical Auger Lower Gear Case
130
15
6
–UN–17MAY00
H63889
Continued on next page OUO6083,000022A –19–12MAR02–1/15

083006
PN=1388
1—Shaft 10—Cap Screw (3 used) 17—Washer 24—Seal

2—Key (2 used) 11—Washer (2 used) 18—Lock Nut 25—Cover
3—Seal 12—Cap Screw (2 used) 19—Lube Fitting 26—Seal
4—Snap Ring (2 used) 13—Shim-0.25 mm (0.010 in.); 20—Shaft 27—Cover
5—Bearing (2 used) Shim-0.51 mm (0.020 in.) 21—Sprocket, 46 Tooth 28—Washer (5 used)
6—Spring (2 used) 22—Key 29—Wing Screw (5 used)
7—Bushing 14—Gear (2 used) 23—Cap Screw with Flange 30—Cap Screw with Flange
8—Bearing (2 used) 15—Case Nut Nut (9 used)
9—Quill 16—Shim
130
15
7
OUO6083,000022A –19–12MAR02–2/15

is 37 kg (82 lb).
Specification
Case—Weight.................................................................................... 37 kg
(82 lb)
1. Remove cap screw and washer (C).
2. Remove quill (B), guard (D) and shims (A).
A—Shim (2 used)
B—Quill
C—Cap screw
D—Guard
–UN–01SEP89
H41080
OUO6083,000022A –19–12MAR02–3/15
3. Remove bearing (A) from quill (B). Bearing is a press

fit.
A—Bearing
B—Quill
–UN–01SEP89
H41081

083006
PN=1389
4. Use a soft-faced mallet to free gear, shaft (A) and

bearing from case.
A—Shaft
–UN–01SEP89
130
15
8
H41082
OUO6083,000022A –19–12MAR02–5/15
5. Remove bearing (D).
6. Remove gear (C) with shaft.
7. Remove nut and washer (B).
8. Remove gear (A).
A—Gear
B—Nut and Washer
C—Gear
D—Bearing
–UN–01SEP89
H41083
OUO6083,000022A –19–12MAR02–6/15
9. Remove key (B) and shim (A).
A—Shim
B—Woodruff Key
–UN–01SEP89
H41084

083006
PN=1390
10. Push shaft (B) out.
11. Remove seal (A).
A—Seal
B—Shaft
–UN–01SEP89
130
15
9
H41085
OUO6083,000022A –19–12MAR02–8/15
12. Install bearing (A) in quill (B). Bearing is a press fit.
A—Bearing
B—Quill
–UN–01SEP89
H41086
OUO6083,000022A –19–12MAR02–9/15
13. Install seal (A) in case.
14. Install shaft (B).
A—Seal
B—Shaft
–UN–01SEP89
H41085
OUO6083,000022A –19–12MAR02–10/15
15. Install shim (A) and key (B).
A—Shim
B—Key
–UN–01SEP89
H41084

083006
PN=1391
16. Install gear (A).
17. Install washer and nut (B). Tighten nut to

specifications.
Specification
Output Shaft Gear Retaining
–UN–01SEP89
Nut—Torque ................................................................................ 270 N•m
130 (200 lb-ft)
15
10
18. Position shaft and gear (C).
H41087
A—Gear
B—Nut
C—Gear
OUO6083,000022A –19–12MAR02–12/15
19. Install shims (B), quill (C), guard (A) and cap screws
(D). Tighten cap screws to specification.
Specification
Quill Cap Screws—Torque ............................................................. 68 N•m
(50 lb-ft)
20. Install shaft and gear (E).
21. Install washer and cap screw (F). Tighten cap screw
to specification.
Specification
Input Shaft Cap Screw—Torque .................................................. 290 N•m
(214 lb-ft)
A—Guard
B—Shim (2 used)
C—Quill
E—Shaft and Gear
F—Cap Screw
–UN–01SEP89
H41088

083006
PN=1392
22. Install bearing (A). Bearing is a press fit.
A—Bearing
–UN–01SEP89
130
15
11
H41089
OUO6083,000022A –19–12MAR02–14/15
23. Check gear backlash specification using a dial

indicator.
Specification
Vertical Auger Lower Gear Case
Bevel Gear—Backlash ...................................................... 0.15—0.51 mm
(0.006—0.020 in.)
Adjust with shims (A) as necessary.
A—Shims
–UN–01SEP89
H41090
OUO6083,000022A –19–12MAR02–15/15

083006
PN=1393
Install Vertical Auger and Vertical Auger

Lower Gear Case

auger is:
–UN–29MAR99
Vertical Auger Weights
130
kg (lb)
15
12 Regular Duty High
H55084
Auger
Heavy Duty High Regular Unload Rate Shown
Auger A—Remover/Installer Bracket
Regular Duty Regular B—Gear Case
Auger
Heavy Duty Regular
Unload rate Vertical 30 (65)
Auger

is 37.4 kg (82 lb).
Specification
Case—Weight.................................................................................... 37 kg
(82 lb)
1. Attach JT07056A Service Jack with D05071ST

Pedestal and JT05877 Auger Gear Case
Remover/Installer Bracket (A) to gear case (B). Install
vertical auger on gear case.
2. Raise service jack until vertical auger is almost

engaged with horizontal gear case.
Continued on next page OUO6083,0000ACA –19–21JUL05–1/5

083006
PN=1394
IMPORTANT: Time vertical and horizontal augers or

severe damage will result.
NOTE: Observe location of horizontal and vertical auger

flighting (C).
3. Time vertical auger (A) with horizontal auger (B) at 90

degrees angle as shown. View augers through the 130
access panel located on the horizontal auger tube near 15
the elbow. 13
A—Vertical Auger
C—End of Auger Flighting
–UN–03APR03
H75801
OUO6083,0000ACA –19–21JUL05–2/5
4. Install gear case (A) and attaching hardware (B).
NOTE: For high unload rate systems, install plate (D)

using cap screws (E). Tighten to specification.
Specification
High Unload Rate Charge
–UN–31MAR99
Housing
Filler Plate Cap Screws—Torque ................................................. 130 N•m
(96 lb-ft)
H55087
5. Remove service jack (C).
A—Gear Case
B—Nuts ( 10 used)
C—Service Jack
D—Plate
–UN–05JUN03
H77644
High Unload Rate Shown

Continued on next page OUO6083,0000ACA –19–21JUL05–3/5

083006
PN=1395
6. Install chain guard (B).
7. Install sprocket (C) and drive chain.
8. Install shield (E) with cap screws (D).
–UN–03JUN03
9. Tighten nuts on tensioner until washer aligns with end
130 of gauge (A).
15
14
A—Gauge
H77609
B—Chain Guard
C—Sprocket
E—Shield
–UN–21JUL00
H64482
OUO6083,0000ACA –19–21JUL05–4/5
10. Install cover over inspection hole (A).
A—Inspection Hole
–UN–25JAN05
H82301
OUO6083,0000ACA –19–21JUL05–5/5

083006
PN=1396
Group 20
Horizontal Unloading Auger and Gear Case
from local suppliers or may be fabricated
SERVICEGARD or European Microfiche Tool 130
Catalogs. 20
1
OUO6083,0000630 –19–09JUN03–1/2
Auger Straightening Tool . . . . . . . . . . . . . . . JT05885
For removing dents and dings in horizontal and cannon

auger tubes.
–UN–11MAY94
H46405
OUO6083,0000630 –19–09JUN03–2/2

083006
PN=1397
Other Material
Number Name Use
N2710021 (U.S.) Sealant, Green Seal charge housing to grain tank.

130 applications.
20
2 T43512 (U.S.) Thread Lock and Sealer (Medium Locks and seals while preventing
1
Available through service parts
OUO6083,0000ACB –19–21JUL05–1/1

083006
PN=1398
Specifications
Unloading Auger Gear Case Sleeve Torque 37 N•m

Screws (27 lb-ft)
Unloading Auger Gear Case Gear Backlash 0.15—0.35 mm 130

(0.006—0.014 in.) 20
3
Charge Housing Weight 37 kg
(82 lb)
Regular Unload Rate Weight 181 kg

Horizontal Unloading Auger and (400 lb)
Tube
High Unload Rate Weight 240 kg

Horizontal Unloading Auger and (529 lb)
Tube
Regular Unload Rate Weight 163 kg

Horizontal Auger Elbow (359 lb)
High Unload Rate Weight 219 kg

Horizontal Auger Elbow (483 lb)
High Unload Rate Auger Weight 27 kg

Pivot Support (60 lb)
High Unload Rate Torque 320 N•m ± 64 N•m

Pivot Support Cap Screws (236 lb-ft ± 47 lb-ft)
Regular Unload Rate Charge Weight 40 kg

Housing (88 lb)
High Unload Rate Charge Housing Weight 78 kg

(172 lb)
OUO6083,0000AD0 –19–21JUL05–1/1

083006
PN=1399
Inspection of Horizontal Unloading Auger
1. Remove the intermediate inspection access on the

unloading auger.
2. Check the union area between the two piece unloading
–UN–31MAR99
auger.
130
20 3. The timing of the two piece unloading auger is critical.
4 These two pieces must be timed 180 degrees from one
H55158
another. If not, grain will be restricted in the short
segment of the horizontal unloading auger and cause
back pressure in the vertical auger charge housing and
grain tank cross augers. A—Short Auger
B—Long Auger
OUO6083,0000AD5 –19–21JUL05–1/1

083006
PN=1400
Horizontal Unloading Auger—Regular Unload Rate
130
20
5
A
B
C
D
E
F
H
G
D
E I
F R
T
J
P
Q
K
G S
–UN–23MAY03
O L
N
M
H77335
Horizontal Unloading Auger
A—Bushing G—Flange Nut (4 used) L—Torsion Spring Q—Flange Nut

B—Coupling H—Gudgeon M—Door R—Cap Screw (3 used)
C—Auger I—Auger N—Pin S—Cap Screw
D—Round Head Bolt (4 used) J—Washer (as required) O—Seal T—Washer
E—Housing K—Cap Screw with Flanged P—Bracket
F—Ball Bearing Nut
(as required)
OUO6083,00005DE –19–22MAY03–1/1

083006
PN=1401
Horizontal Unloading Auger—High Unload Rate
130
20
6
A
B
C
D E
F
H
G
D E
I
F R
T
J
P
Q
K
G S
–UN–23MAY03
O L
N
M
H77338
High Unload Rate Horizontal Unloading Auger
A—Bushing G—Flange Nut (8 used) L—Torsion Spring Q—Flange Nut

B—Coupling H—Gudgeon M—Door R—Cap Screw (3 used)
C—Auger I—Auger N—Pin S—Cap Screw
D—Round Head Bolt (8 used) J—Washer (as required) O—Seal T—Washer
E—Housing K—Cap Screw with Flanged P—Bracket
F—Ball Bearing Nut
(as required)
OUO6083,00005E6 –19–23MAY03–1/1

083006
PN=1402
Remove and Install Unloading Auger Grain

Saver Door
1. Loosen nuts (A) to remove unloading auger boot.
2. Remove nuts (B).
–UN–05JUN03
3. Remove cap screws (C) from grain saver door 130
assembly (D). 20
7
H77355
5. Crimp both ends of grain saver door assembly to retain

pin (E).
A—Nut (8 used)
B—Nut (4 Used)
–UN–25JAN05
D—Grain Saver Door
E—Pin
H82300
OUO6083,0000A87 –19–15JUL05–1/1
Remove Horizontal Auger
1. Loosen nuts (A) to remove boot.
2. Remove grain saver door. (See REMOVE AND

INSTALL GRAIN SAVER DOOR in this group.)
–UN–05JUN03
3. Remove cap screws (B and C), washer (D) and
support (E).
H77355
A—Nuts (8 used)
C—Cap Screw
D—Washer
E—Support
–UN–22MAY03
H77363
High Unload Rate Bearing Support Shown


083006
PN=1403
4. Remove inspection covers (A).
NOTE: Note location of horizontal and vertical auger

flighting through elbow inspection hole before
removing auger.
5. Remove round head bolts (B) from carrier bearing
–UN–25JAN05
130 support and tube.
20
8 6. Remove auger through horizontal tube.
H82302
A—Inspection Holes
B—Round Head Bolt (2 used)
–UN–25JAN05
H82303
OUO6083,0000CB4 –19–08MAR06–2/2
Install Horizontal Auger
IMPORTANT: Time vertical auger with horizontal

auger or severe damage will result.
1. Position auger in tube using a hoist.

083006
PN=1404

degree angle (C).
3. Rotate augers by hand to ensure proper timing.
4. Install carrier bearing support using round head bolts

(D).
130
5. Time front and rear horizontal augers. (See 20
INSPECTION OF HORIZONTAL UNLOADING AUGER 9
in this group.)
6. Install inspection covers.
A—Vertical Auger
–UN–03APR03
H75801
–UN–25JAN05
H82304

083006
PN=1405
7. Install support (E) using cap screws (B and C) and

washer (D).
8. Install grain saver door. (See REMOVE AND INSTALL

GRAIN SAVER DOOR in this group.)
–UN–22MAY03
9. Install boot and tighten nuts (A).
130
20 A—Nuts (8 used)
10 B—Cap Screw and Nut (4 used)
H77363
C—Cap Screw
D—Washer
E—Support High Unload Rate Bearing Support Shown
–UN–05JUN03
H77355
OUO6083,0000CB5 –19–08MAR06–3/3

083006
PN=1406
130
20
11

083006
PN=1407
Folding Horizontal Auger Housing—Exploded View
2 4
1 3
5
6
130
20
12
8
16 9
14
3
17
10 11
18
19 22
15
11
20 23 24
21
13 12
9 1
13 23 4 9
12 25
26
27
28
29 30
31
35
32
36
–UN–24JAN05
33
H82288
34

083006
PN=1408
1—Cap Screw (17 used) 11—Bushing (2 used) 20—Shim 28—Push Nut (9 used)
2—Lock Nut (13 used) 12—Pin (2 used) 21—Seal 29—Round Head Bolt (9 used)
3—Clamp 13—Spring Pin (2 used) 22—Casting 30—Strip (2 used)
4—Nut (8 used) 14—Socket Head Cap Screw 23—Washer (12 used) 31—Cap Screw (8 used)
5—Door (10 used) 24—Socket Head Cap Screw (5 32—Washer (8 used)
6—Isolator 15—Washer (10 used) used) 33—Strip
7—Housing 16—Cap Screw 25—Washer (4 used) 34—Flange Nut (8 used)
8—Cap Screw (8 used) 17—Pin 26—Boot 35—Spacer (4 used)
9—Flange Nut (12 used) 18—Washer 27—Housing 36—Cover
10—Casting 19—Spring Pin 130
20
13
OUO6083,0000A88 –19–15JUL05–2/2

083006
PN=1409
Folding Horizontal Auger—Exploded View
130
20
14
15
6
7
8
4 9
5 11
10
12
13
14
16
17
13
18
15
19 22
21
20 24
12
25
23 26
27
–UN–25JAN05
28
H82291

083006
PN=1410
1—Auger 8—Coupler 15—Wave Washer (2 used) 22—Bracket

2—Spacer 9—Spring Pin 16—Auger 23—Washer (6 used)
3—Housing 10—Guide 17—Cap Screw (4 used) 24—Flange Nut (6 used)
4—Flange Nut (4 used) 11—Support 18—Housing 25—Seal
5—Cap Screw (4 used) 12—Flange Nut (7 used) 19—Washer 26—Door
6—Bearing (2 used) 13—Washer (7 used) 20—Cap Screw 27—Spring
7—Spring 14—Cap Screw (3 used) 21—Cap Screw (6 used) 28—Pin
130
20
15
OUO6083,0000A89 –19–15JUL05–2/2

083006
PN=1411
Folding Horizontal Auger Pivot—Exploded View
130
20
16 1
2
3
4
4
5
4
7
3
4
6 8
6 4
3
10
18
11
17 12
–UN–21JAN05
13
11
14
H82289
15 16

083006
PN=1412
1—Spring Pin (2 used) 6—Bushing (4 used) 11—Bracket 15—Sensor

2—Pin (2 used) 7—Pin 12—Screw (2 used) 16—Nut (2 used)
3—Snap Ring (3 used) 8—Spring Pin 13—Bracket 17—Pin fastener
4—Washer (5 used) 9—Link 14—Lock Washer (2 used) 18—Pin
5—Plate 10—Cap Screw
OUO6083,0000A8A –19–15JUL05–2/2
Remove and Install Folding Auger Actuator 130

20
17
CAUTION: Park machine on level ground before
removing folding auger actuator. Outer auger
will move freely with actuator removed.
–UN–15OCT04
1. Disconnect wiring harness from actuator.
2. Remove spring pins and pins (A). Remove actuator

motor.
H81520
A—Spring Pins and Pins (2 used)
OUO6083,0000ACF –19–21JUL05–1/1
Remove and Install Outer Folding Auger

Assembly
CAUTION: Use proper lifting device to remove

and install folding auger assembly.
–UN–02FEB05
1. Attach auger assembly to proper lifting device.
2. Remove folding auger actuator. (See REMOVE AND

INSTALL FOLDING AUGER ACTUATOR in this
H82356
group.)
3. Disconnect connector (A) from position sensor. A—Connector

4. Remove cap screws (B) and brackets (C) with position C—Bracket (2 used)
sensor.
Continued on next page OUO6083,0000A8C –19–15JUL05–1/2

083006
PN=1413
5. Remove E-clips (A), washers (B) and plates (C and D).
6. Remove cap screw (E) and pivot pin (F).
–UN–02FEB05
130
20 A—E-Clip (2 used)
18 B—Washer (2 used)
H82357
C—Plate
D—Plate
E—Cap Screw
F—Pivot Pin
–UN–02FEB05
H82358
OUO6083,0000A8C –19–15JUL05–2/2
Remove and Install Folding Auger Rings
NOTE: Procedure is similar between mating parts.
1. Remove folding auger assembly. (See REMOVE AND

INSTALL FOLDING AUGER ASSEMBLY in this
–UN–02FEB05
group.)
2. Remove cap screws and nuts (A), socket head cap

screws and nuts (B) and ring (C).
H82359
4. Install ring using N271002 sealant between ring and A—Cap Screw and Nut (4 used)
housing. B—Socket Head Cap Screw and Nut (5 used)
C—Ring
5. Install previously removed hardware and tighten to

specification.
Specification
Folding Auger Ring Cap
Screws—Torque ........................................................................... 110 N•m
(81 lb-ft)
OUO6083,0000A8D –19–15JUL05–1/1

083006
PN=1414
Remove Rear Horizontal Folding Auger

auger from housing.
1. Loosen nuts (A) to remove boot.
–UN–05JUN03
2. Remove grain saver door. (See REMOVE AND 130
20
INSTALL GRAIN SAVER DOOR in this group.) 19
H77355
3. Remove cap screws (B and C), washer (D) and
support (E).
4. Remove auger from housing using proper lifting device.
A—Nuts (8 used)
B—Cap Screw and nut (4 used)
C—Cap Screw
D—Washer
–UN–22MAY03
E—Support
H77363
OUO6083,0000AD6 –19–21JUL05–1/1
Remove Front Horizontal Folding Auger

auger from housing.
1. Position folding auger in transport position.
–UN–28JAN05
2. Remove spring pin (A), guide (B), coupler (C) and
spring (D).
H82322
3. Remove cap screws and nuts (E) and support (F).
4. Remove auger through horizontal tube using proper

lifting device.
A—Spring Pin
B—Guide
C—Coupler
D—Spring
–UN–31JAN05
E—Nuts (4 used)
F—Support
H82323
Continued on next page OUO6083,0000A8F –19–15JUL05–1/2

083006
PN=1415
5. Remove covers from inspection holes (A).

removing auger.
–UN–25JAN05
130 support and tube.
20
20 7. Remove bearing support through inspection hole.
H82302
lifting device.
9. Repair or replace as needed.
A—Inspection Hole (2 used)

–UN–25JAN05
H82303
OUO6083,0000A8F –19–15JUL05–2/2
Remove Front Horizontal Folding Auger

auger from housing.
1. Position folding auger in transport position.
–UN–28JAN05
2. Remove spring pin (A), guide (B), coupler (C) and
spring (D).
H82322
3. Remove cap screws and nuts (E) and support (F).

lifting device.
A—Spring Pin
B—Guide
C—Coupler
D—Spring
–UN–31JAN05
E—Nuts (4 used)
F—Support
H82323
Continued on next page OUO6083,0000AD7 –19–21JUL05–1/2

083006
PN=1416
5. Remove covers from inspection holes (A).

removing auger.
–UN–25JAN05
support and tube. 130
20
7. Remove bearing support through inspection hole. 21
H82302
lifting device.
A—Inspection Hole (2 used)

–UN–25JAN05
H82303
OUO6083,0000AD7 –19–21JUL05–2/2

083006
PN=1417
Install Front Horizontal Folding Auger
CAUTION: Use proper lifting device to install

augers in housing.
IMPORTANT: Time vertical auger with horizontal

auger or severe damage will result.
130
20
22
1. Position front auger in tube.

degree angle (C).
3. Rotate augers by hand to ensure proper timing.
–UN–03APR03
4. Install carrier bearing support using round head bolts
(D).
5. Install rear auger using proper lifting device.
H75801
6. Time front and rear horizontal augers. (See
INSPECTION OF HORIZONTAL UNLOADING AUGER
in this group.)
7. Install inspection covers.
A—Vertical Auger
–UN–25JAN05
D—Round Head Bolts (4 used)
H82304

083006
PN=1418
8. Install support (F) using cap screws and nuts (E).
IMPORTANT: Install coupler (D) so drive tooth is 180°

from flight edge of auger.
9. Apply TY25797 graphite lubricant to hex shaft.
–UN–28JAN05
10. Install spring (D), coupler (C), guide (B) and spring 130
pin (A). 20
23
H82322
A—Spring Pin
B—Guide
C—Coupler
D—Spring
E—Nuts (4 used)
F—Support
–UN–31JAN05
H82323
OUO6083,0000AD8 –19–21JUL05–2/2
Install Rear Horizontal Folding Auger
CAUTION: Use proper lifting device to install

auger.
1. Position auger in tube.
–UN–22MAY03
2. Install support (E) using cap screws (B and C) and
washer (D).
H77363
3. Install grain saver door. (See REMOVE AND INSTALL
UNLOADING AUGER GRAIN SAVER DOOR in this
group.)
4. Install boot and tighten nuts (A).
A—Nuts (8 used)
B—Cap Screw and nut (4 used)
C—Cap Screw
–UN–05JUN03
D—Washer
E—Support
H77355
OUO6083,0000AD9 –19–21JUL05–1/1

083006
PN=1419
Remove Horizontal Auger Gear Case

remove key.
NOTE: Auger can be pushed to rear of tube without

separating front and rear auger sections. This will
130 eliminate the need to time auger flighting upon
20 assembly.
24
2. Slide horizontal auger out of tube enough to access
gear case. Do not separate. (See REMOVE
HORIZONTAL AUGER in this group.)
OUO6083,00005E1 –19–22MAY03–1/2
3. Remove attaching hardware (A) and grease cap (B).
4. Remove attaching hardware (C) and access cap (D).
5. Remove gear case through inspection hole.
–UN–31MAR99
NOTE: If ring (E) needs replaced, remove round head

bolts (F) and lubrication lines (G).
H55090
A—Attaching Hardware
B—Grease Cap
C—Attaching Hardware
D—Access Cap
E—Ring
F—Round Head Bolts
G—Lubrication Line
–UN–05APR99
H55091
OUO6083,00005E1 –19–22MAY03–2/2

083006
PN=1420
Disassemble And Assemble Horizontal Unloading Auger Gear Case
B
H
F
A I
130
20
E G 25
D
C
B J
C M
K G
–UN–15JUL05
H
H83992
J
A—Seal (2 used) E—Gear Case H—O-Ring (2 used) K—Spacer

B—Lock Washer (2 used) F—Cap Screw (4 used) I—Housing (2 used) L—Lubrication Cap Screw
C—Bearing (2 used) G—Shim (2 used) J—Cap Screw (6 used) M—Lubrication Fitting
D—Pinion Shaft (2 used)
Continued on next page OUO6083,0000ADA –19–21JUL05–1/5

083006
PN=1421
1. Remove six cap screws (A).
2. Remove two sleeves (B).

B—Sleeve (2 used)
130
20
26
–UN–26MAR99
H54785
OUO6083,0000ADA –19–21JUL05–2/5
3. Disassemble parts (A—M). F
4. Clean and inspect parts. Replace as necessary.

D E
C
5. Lubricate gears and bearings using Multi-Purpose SD B
Polyurea Grease. A
D
6. Assemble parts (A—M).
C
L
A—Seal (2 used) B M
B—Lock Washer (2 used)
C—Bearing (2 used)
G A
D—Pinion Shaft (2 used) H
E—Gear Case
F—Cap Screw (4 used) I G
G—Shim (2 used) K J
H—O-Ring (2 used) H
I—Housing (2 used)
J—Cap Screw (6 used) I
–UN–24JAN05
K—Spacer
L—Lubrication Cap Screw
M—Lubrication Fitting
J
H82294
Continued on next page OUO6083,0000ADA –19–21JUL05–3/5

083006
PN=1422
7. Install two sleeves (B).
8. Apply T43512 Thread Lock and Sealer (Medium

Strength) to cap screws (A). Install cap screws and
Specification
Unloading Auger Gear Case
Sleeve Screws—Torque ................................................................. 37 N•m 130
(27 lb-ft) 20
27
A—Cap Screw
B—Sleeve
–UN–26MAR99
H54785
OUO6083,0000ADA –19–21JUL05–4/5
9. Check gears for specified backlash. Add or remove

shims as necessary to obtain specified backlash.
Specification
Unloading Auger Gear Case
Gear—Backlash................................................................. 0.15—0.35 mm
(0.006—0.014 in.)
–UN–26MAR99
H54787
OUO6083,0000ADA –19–21JUL05–5/5

083006
PN=1423
Install Horizontal Auger Gear Case
1. Position gear case in elbow.
2. Install access cap (A) and attaching hardware (B).
–UN–31MAR99
3. Install grease cap (C) and attaching hardware (D).
130
20 4. Slide horizontal auger into position. Time horizontal
28 auger to vertical auger. (See INSTALL VERTICAL
H55141
AUGER AND VERTICAL AUGER LOWER GEAR
CASE in this section.)
5. Finish installing horizontal auger. (See INSTALL

HORIZONTAL AUGER in this group.)
A—Access Cap
B—Attaching Hardware
C—Grease Cap
–UN–31MAR99
D—Attaching Hardware
H55142
OUO6083,00005E2 –19–22MAY03–1/1

083006
PN=1424
Remove Horizontal Unloading Auger Tube
CAUTION: The approximate weight of regular

unload rate auger and tube is 181 kg (400 lb).
High unload rate auger and tube is 240 kg (529
lb).
–UN–22MAR99
Specification 130
Regular Unload Rate 20
Horizontal Unloading Auger and 29
H54878
Tube—Weight .................................................................................. 181 kg
(400 lb)
High Unload Rate
Horizontal Unloading Auger and
Tube—Weight .................................................................................. 240 kg A—Cap Screw (11 used)
(529 lb)
1. Remove horizontal unloading auger. (See procedure in

this group.)
2. Attach hoist to auger tube.
3. Disconnect wiring harness at elbow.
4. Remove cap screws (A) from top seam of auger tube.
5. Remove tube.
OUO6083,0000614 –19–05JUN03–1/1

083006
PN=1425
Install Horizontal Unloading Auger Tube
CAUTION: The approximate weight of regular

unload rate auger and tube is 181 kg (400 lb).
High unload rate auger and tube is 240 kg (529
lb).
–UN–22MAR99
130 Specification
20 Regular Unload Rate
30 Horizontal Unloading Auger and
H54878
Tube—Weight .................................................................................. 181 kg
(400 lb)
High Unload Rate
Horizontal Unloading Auger and
Tube—Weight .................................................................................. 240 kg A—Cap Screw (11 used)
(529 lb)
1. Install auger tube on elbow with hoist.
2. Install cap screws (A) through top seam of auger tube.
3. Connect wiring harness at elbow.
4. Install horizontal unloading auger. (See procedure in

this group.)
OUO6083,0000606 –19–04JUN03–1/1

083006
PN=1426
130
20
31

083006
PN=1427
Unloading Auger Elbow—Exploded View
4 6
3 7
5
130
20 2
32 13
9
10
11 12
8
1
14
15
17
16
18
21
19
21
20 25
22
25
–UN–07OCT02
23 23
24
23 23
H73547
Continued on next page OUO6083,000022B –19–12MAR02–1/2

083006
PN=1428
1—Housing 8—Door 15—Cap Screw (4 used) 20—Ring

2—Bushing (2 used) 9—Cap Screw (4 used) 16—Hose 21—Hose (2 used)
3—Washer 10—Support 17—Pin 22—Hose
4—Cap Screw with Nut 11—Nut 18—Spring Pin 23—Nut
5—Strap 12—Cap Screw 19—Round Head Bolt with 24—Cap Screw (12 used)
6—Nut (4 used) 13—Seal Flange Nut (12 used) 25—Sector (3 used)
7—Washer (4 used) 14—Support
130
20
33
OUO6083,000022B –19–12MAR02–2/2

083006
PN=1429
Remove Horizontal Auger Elbow
CAUTION: Approximate weight of regular

unload rate horizontal auger elbow is 163 kg
(359 lb). High unload rate horizontal auger
elbow is 219 kg (483 lb).
–UN–25JAN05
130 Specification
34 Horizontal Auger Elbow—Weight .................................................... 163 kg
H82309
(359 lb)
High Unload Rate
Horizontal Auger Elbow—Weight .................................................... 219 kg
(483 lb)
1. Remove horizontal auger and tube. (See procedures in

this group.)

remove key.
–UN–25JAN05
3. Support auger (A) using proper lifting device.
4. Remove cap screw (B), retainer (C) and pin (D). Move
H82307
hydraulic cylinder.
5. Remove nuts (E) and pull lubrication hoses through

grain tank until free.
6. Remove cap screws (F) and sectors (G) from bottom

of ring.
A—Auger
B—Cap Screw
–UN–26JAN05
C—Retainer
D—Pin
E—Nuts (5 used)
F—Cap Screws (12 used)
G—Sector (3 used)
H82308
–UN–26JAN05
H82310

083006
PN=1430
7. For regular unload rate: Remove attaching hardware

and pivot cap (A) from inside grain tank.
CAUTION: Approximate weight of support is 27

kg (60 lb).
–UN–24MAR99
Specification
High Unload Rate Auger 130
Pivot Support—Weight ...................................................................... 27 kg 20
60 lb) 35
H54931
8. For high unload rate, remove the following:
Regular Unload Rate
• Bottom cap screws (C) under grain tank from
support (E)
• Cap screws (D) from support (E) in grain tank
• Cap screws (F) and pivot cap (G) from inside grain
tank
9. Remove elbow.
–UN–04JUN03
10. Replace bushing (B) as needed.
A—Pivot Cap (Regular Unload Rate)
B—Bushing (2 halves)
H77621
E—Support High Unload Rate Support
G—Pivot Cap (High Unload Rate)
–UN–04JUN03
H77617
High Unload Rate Support
–UN–21JUN01
H68915
OUO6083,0000AD1 –19–21JUL05–2/2

083006
PN=1431
Install Horizontal Auger Elbow

unload rate horizontal auger elbow is 163 kg
(359 lb). High unload rate horizontal auger
elbow is 219 kg (483 lb).
–UN–24MAR99
130 Specification
36 Horizontal Auger Elbow—Weight .................................................... 163 kg
H54931
(359 lb)
High Unload Rate
Horizontal Auger Elbow—Weight .................................................... 219 kg
Regular Unload Rate
(483 lb)
1. Position elbow to charge housing using a hoist.
2. Time vertical auger with horizontal auger. (See

INSTALL HORIZONTAL AUGER in this group.)
3. For regular unload rate: Install pivot cap (A) from inside
–UN–04JUN03
grain tank and tighten hardware.
4. For high unload rate, install the following:
H77617
• Pivot cap (G) with cap screws (F) leaving hardware
loose
• Support (E) using cap screws (C and D) leaving
hardware loose
5. Install cap screws (B) and three sectors to bottom of

ring.
6. Tighten cap screws (F) on pivot cap (G).
–UN–04JUN03
7. Tighten cap screws (C and D) on support (E) to
specification.
H77621
A—Pivot Cap (Regular Unload Rate)
E—Support
G—Pivot Cap (High Unload Rate)
–UN–26JAN05
H82311

083006
PN=1432
Specification
High Unload Rate
Pivot Support Cap Screws—
Torque .......................................................................... 320 N•m ± 64 N•m
(236 lb-ft ± 47 lb-ft)
OUO6083,0000AD2 –19–21JUL05–2/3
8. Move hydraulic swing cylinder into position and install 130

pivot pin (A), retainer (B) and cap screw (C). 20
37
9. Route lubrication hoses and install nuts (D).
10. Install horizontal auger and tube. (See INSTALL

HORIZONTAL AUGER AND INSPECTION OF
–UN–27JAN05
HORIZONTAL UNLOADING AUGER in this group.)
11. Apply Multi-Purpose SD Polyurea Grease to mating
H82312
surfaces of charge housing and elbow.
A—Pin
B—Retainer
C—Cap Screw
D—Nut (5 used)
–UN–26JAN05
H82313
OUO6083,0000AD2 –19–21JUL05–3/3

083006
PN=1433
Remove Unloading Auger Charge Housing
NOTE: Once the charge housing has been deformed, do

not attempt to weld or force it back to its original
design. The system, by deforming this metal, has
naturally relieved this area to accept the load of
–UN–26MAR99
material.
130
20 1. Remove horizontal unloading auger. (See procedure in
38 this group.)
H54997
2. Remove unloading auger elbow. (See procedure in this
group.) Regular Unload Rate
3. Remove vertical auger lower gear case and vertical

auger. (See REMOVE VERTICAL AUGER LOWER
GEAR CASE AND VERTICAL AUGER in Group 15.)
4. Remove grain tank cross augers and covers. (See

REMOVE GRAIN TANK CROSS AUGERS in Group
–UN–26MAR99
05.)
5. Remove cap screws (A) and plate (B).
H54998
6. Remove attaching hardware and plates (C and D).
Regular Unload Rate
7. Remove plates (E and F) on high unload rate.
8. Remove nuts (G) from regular unload rate housing.

B—Plate
C—Plate
D—Plate
E—Plate
–UN–04JUN03
F—Plate
G—Nuts (25 used)
H77629
High Unload Rate
–UN–04JUN03
H77630

083006
PN=1434
9. Remove nuts (A) from high unload rate housing.
A—Nuts (48 used)
–UN–27JAN05
130
20
39
H82317
High Unload Rate Charge Housing
–UN–27JAN05
H82318
High Unload Rate Housing

083006
PN=1435
10. Remove wire harness, attaching hardware and

sidesheet (A).

unload rate charge housing is 40 kg (88 lb).
High unload rate is 78 kg (172 lb).
–UN–26MAR99
130 Specification
20 Regular Unload Rate Charge
40 Housing—Weight ............................................................................... 40 kg
H55000
(88 lb)
housing—Weight ............................................................................... 78 kg
(172 lb)
11. Remove housing using proper lifting device.
NOTE: If ring (B) needs replaced, remove round head

bolts (C) and ring. Procedure is similar for high
unload rate system.
–UN–05APR99
A—Sidesheet
B—Ring
C—Round Head Bolt (12 used)
H55171
Regular Unload Rate Charge Housing
OUO6083,0000AD3 –19–21JUL05–3/3

083006
PN=1436
Install Unloading Auger Charge Housing

unload rate charge housing is 40 kg (88 lb).
High unload rate is 78 kg (172 lb).
–UN–26MAR99
Specification
Regular Unload Rate Charge 130
Housing—Weight ............................................................................... 40 kg 20
(88 lb) 41
H55010
housing—Weight ............................................................................... 78 kg
(172 lb)
Regular Unload Rate Charge Housing
1. Apply N271002 Charge Housing Seal to all seams of

charge housing. Install housing using proper lifting
device. Tighten nuts (A).
2. Install attaching hardware, sidesheet (B) and wire

harness.
–UN–27JAN05
3. Install grain tank cross augers and covers. (See
INSTALL GRAIN TANK CROSS AUGERS in Group
05.)
H82317
4. Install attaching hardware and plates (C and D).
A—Nut (25 used on RUR, 48 used on HUR) High Unload Rate Charge Housing
B—Sidesheet
C—Plate
D—Plate
–UN–26MAR99
H55011
–UN–26MAR99
H55003
Regular Unload Rate
Continued on next page OUO6083,0000ACC –19–21JUL05–1/2

083006
PN=1437
5. Install plate (A) with cap screws (B).
6. For high unload rate systems, install plates (C and D).
7. Install vertical auger and vertical auger gear case. (See

INSTALL VERTICAL AUGER AND VERTICAL AUGER
GEAR CASE in Group 15.)
–UN–28JAN05
130
20 8. Install horizontal auger elbow. (See INSTALL
42 HORIZONTAL AUGER ELBOW in this group.)
H82320
9. Install horizontal unloading auger. (See INSTALL
HORIZONTAL AUGER in this group.) Regular unload Rate
A—Plate
C—Plate
D—Plate
–UN–28JAN05
H82321
High Unload Rate Charge Housing
OUO6083,0000ACC –19–21JUL05–2/2

083006
PN=1438
Group 25
Clean Grain Elevator
Other Material
Number Name Use

applications.
TY6382 (U.S.) GL-5 Gear Lubricant Used to lubricate clean grain elevator 130
gear case. 25
1
H154379 (U.S.) Sealant Used to seal mating surfaces and
seams in grain tank floor.
OUO6083,000029B –19–15MAY02–1/1
Specifications
Lock Nut, Input Shaft and Output Torque 125 N•m

Shaft (92 lb-ft)
Nut, Auger Drive Torque 350 N•m

(255 lb-ft)
Clean Grain Elevator Gear Case Capacity 3.8 L

(4 qt)
Clean Grain Loading Auger Weight 23 kg

(51 lb)
AG,OUO6022,315 –19–25JUL00–1/1

083006
PN=1439
Adjust Clean Grain Elevator Chain
1. Remove nuts and bearing cover.
2. Loosen nuts (A) on bearing mount plate.
–UN–07APR99
3. Loosen nuts (B) and (C) on adjusting bolt.
130
25 4. Turn nut (C) to adjust chain tension. Turning nut
2 counterclockwise loosens the chain, and turning nut
H55238
clockwise tightens the chain.
NOTE: Paddle chain is adjusted properly when lower end

of chain can be slid across the sprocket. If chain A—Nut (4 used)
can be pulled 6 mm (1/4 in.) maximum, away from B—Nut
C—Nut
sprocket, adjust chain. After a period of use, it
may be necessary to remove a half link to adjust
the elevator chain correctly.
5. Tighten nuts (A), (B) and (C).
AG,OUO1026,36 –19–25JUL00–1/1
Remove Clean Grain Elevator
1. Remove right-hand gull wing door.
2. Loosen nuts (A) to relieve belt tension.
–UN–22MAY03
3. Remove belt from sheaves and idler.
A—Nut (2 used)
H77331
OUO6083,0000AD4 –19–21JUL05–1/16
4. Remove upper drives cover (A).
5. Remove cross auger cover (B).
A—Upper Drive Cover

B—Cross Auger Cover
–UN–23DEC03
H79692

083006
PN=1440
6. Remove cap screws (A), round head bolts (B) and

cover (C).

C—Cover
–UN–20JUN02
130
25
3
H72620
OUO6083,0000AD4 –19–21JUL05–3/16
7. Remove belt from upper drive sheaves.
8. Remove cap screws (A) from top of elevator.
9. Remove cap screws (B) from left-hand side and cap

screws on right-hand side of elevator.
10. Remove cap screws from seals (C—F).

B—Cap Screws
C—Rear Seal
D—Left-Hand Seal
E—Front Seal
F—Right-Hand Seal
–UN–19MAR99
H54326
OUO6083,0000AD4 –19–21JUL05–4/16
NOTE: Front seal (A) can be removed by using

self-locking pliers attached to seal as illustrated.
Right-hand seal does not need to be removed to
remove elevator.
11. Remove rear, left-hand and front seals.

–UN–19MAR99
A—Front Seal
H54349

083006
PN=1441
12. Disconnect harness lead connector at clean grain

auger sensor.
13. Remove sensor (A) and actuator (B) from left-hand

side of clean grain auger.
–UN–19MAR99
A—Sensor
130 B—Actuator
25
4
H54350
OUO6083,0000AD4 –19–21JUL05–6/16
15. Remove nuts (B), sensor bracket and outside

flangette.
16. Remove nuts (C).
–UN–01JUN99
A—Locking Collar
B—Nuts
C—Nuts
H54764
OUO6083,0000AD4 –19–21JUL05–7/16
17. Open cleanout door and remove cotter pin (A) and
pin from paddle chain connecting link.
A—Cotter Pin
–UN–19MAR99
H54769
OUO6083,0000AD4 –19–21JUL05–8/16
18. Remove nuts and bearing cover (A).
A—Bearing Cover
–UN–19MAR99
H54765

083006
PN=1442
20. Remove nuts (B).
21. Loosen or remove nuts on screw (C) as needed to

remove outer bearing plate and adjusting plate (D).
–UN–01JUN99
A—Locking Collar 130
B—Nut (4 used) 25
C—Adjusting Screw 5
H54770
D—Plate
OUO6083,0000AD4 –19–21JUL05–10/16
22. Remove bearing (A) and inner bearing plate (B).
A—Bearing
B—Plate
–UN–01JUN99
H54771
OUO6083,0000AD4 –19–21JUL05–11/16
23. Slide auger to left-hand side far enough to remove

spacer (A) and sprocket (B).
A—Spacer
B—Sprocket –UN–19MAR99
H54775

083006
PN=1443
24. Remove bearing (A), inside flangette and plate.
A—Bearing
–UN–01JUN99
130
25
6
H54776
OUO6083,0000AD4 –19–21JUL05–13/16
NOTE: Lower auger does not need to be removed from

machine, just enough to allow elevator removal.
NOTE: If paddle chain is removed with elevator body, be

sure to attach ends of chain together to prevent
chain from falling.
–UN–01JUN99
H54777
OUO6083,0000AD4 –19–21JUL05–14/16
26. Remove cap screws attaching lower auger tube (A) to

sidesheet.
A—Tube
–UN–19MAR99
H54780

083006
PN=1444
CAUTION: Clean grain elevator is heavy and

awkward. Use a safe lifting device to help
prevent personal injury.
27. Attach lifting device to elevator.
–UN–21MAY03
28. Remove cap screws (A) from front of elevator.
130
25
29. Remove cap screws (B) and bracket. 7
H77327
30. Carefully lower elevator out of combine.

–UN–21MAY03
H77326
OUO6083,0000AD4 –19–21JUL05–16/16
Install Clean Grain Elevator
NOTE: It may be easier to install elevator if hardware is

not tightened until all hardware is installed.
1. Position elevator in combine and install cap screws in
–UN–19MAR99
through lower auger tube (A) into sidesheet.
A—Lower Auger Tube
H54780
OUO6083,00005D8 –19–21MAY03–1/14
2. Route belt around upper and lower drive sheaves

using decal (A) on elevator as a guide.
3. Install bracket to rear jackshaft support and elevator

body.
–UN–21MAY03
A—Decal
H77330

083006
PN=1445
4. Install cap screws attaching elevator (A) to upper clean

grain auger gear case housing (B).
A—Elevator
B—Housing
130
25
8
–UN–19MAR99
H54831
OUO6083,00005D8 –19–21MAY03–3/14
5. Turn lower auger in far enough to install paddle chain

sprocket. (See next step.)
–UN–01JUN99
H54857
OUO6083,00005D8 –19–21MAY03–4/14
6. Install key (A).
7. Install sprocket (B) tight against shoulder on auger

shaft.
8. Install spacer (C) tight against sprocket.

–UN–19MAR99
A—Key
B—Sprocket
C—Spacer
H54860

083006
PN=1446
9. Install inside bearing flange and bearing (A), making

sure bearing is tight against spacer (B).
A—Bearing
B—Spacer
–UN–19MAR99
130
25
9
H54861
OUO6083,00005D8 –19–21MAY03–6/14
10. Install outer bearing flange (A) and adjusting plate (B)
using four round head bolts. Nuts should be snug but
not tightened.
11. Install locking collar (C) and tighten. Tighten set

screw.
12. Connect paddle chain using connecting link, pin and

cotter pin.
–UN–19MAR99
A—Flange
B—Plate
C—Locking Collar
H54862
OUO6083,00005D8 –19–21MAY03–7/14
13. Position plate, inner flangette and bearing (A) on

auger.
A—Bearing
–UN–01JUN99
H54776

083006
PN=1447
14. Install outer flangette, plate and sensor bracket using

round head bolts (C) and (B).
15. Install locking collar (A) and tighten. Tighten set

screw.
–UN–01JUN99
A—Locking Collar
130 B—Round Head Bolts
25 C—Round Head Bolts
10
H54764
OUO6083,00005D8 –19–21MAY03–9/14
16. Install actuator (B) and sensor (A). Connect harness

connector to sensor.
A—Sensor
B—Actuator
–UN–19MAR99
H54350
OUO6083,00005D8 –19–21MAY03–10/14
NOTE: Apply H154379 Sealant to seal mating surfaces

and seams to help prevent grain leakage.
17. Install seal plates (A—C) and cap screws. Install seal
(A) first, seal (B) next and seal (C) last. Tighten all
hardware including those previously left finger tight.
18. Make sure drive belt is routed correctly; then install

clean grain loading auger drive sheave cover, cross
auger cover and upper drive cover.
A—Front Seal
B—Left-Hand Seal
C—Rear Seal
–UN–19MAR99
H54863

083006
PN=1448
19. Tighten nuts (A) until washer aligns with gauge.
A—Nut (2 used)
–UN–22MAY03
130
25
11
H77331
OUO6083,00005D8 –19–21MAY03–12/14
20. Turn nut (A) to adjust chain tension. Turning nut

clockwise tightens chain, and turning nut
counterclockwise loosens chain.

of chain can be slid across the sprocket. If chain
can be pulled 6 mm (1/4 in.) maximum, away from
–UN–19MAR99
the chain correctly.
21. Install nut (B) and tighten.
H54876
22. Tighten nuts (C).
A—Nut
B—Nut
C—Nut
D—Nut
OUO6083,00005D8 –19–21MAY03–13/14
A—Cover
–UN–19MAR99
H54765
OUO6083,00005D8 –19–21MAY03–14/14

083006
PN=1449
Remove and Install Clean Grain Elevator

Gear Case
1. Remove rear cross auger cover.

OUO6083,0000806 –19–26MAY04–1/3
130 2. Remove cap screws (A), round head bolts (B) and
25 cover (C).
12

C—Cover
–UN–23DEC03
H79692

083006
PN=1450
3. Loosen nuts (A) to relieve belt tension. Remove belt

from sheave (C).
4. Disconnect latches and move upper folding auger to

open position. Remove cap screws, plate and upper
folding auger.
–UN–22MAY03
5. Remove nut (B), sheave (C) and woodruff key. 130
25
6. Remove cap screws (D) and gear case (E) from top of 13
H77331
housing.
7. Repair or replace gear case as necessary. (See

DISASSEMBLE AND ASSEMBLE CLEAN GRAIN
ELEVATOR GEAR CASE.)
8. Install gear case.
9. Install upper folding auger, plate and cap screws.
–UN–26MAY04
10. Install belt. Tighten nuts on idler tension spring until
H80944
A—Nuts (2 used)
B—Nut
C—Sheave
E—Gear Case
–UN–21MAY03
H77328
OUO6083,0000806 –19–26MAY04–3/3

083006
PN=1451
Disassemble and Assemble Clean Grain Elevator Gear Case
130
25
14
–UN–16MAR01
H66724
A—Cap Screw (11 used) F—Bearing Assembly K—Ball Bearing P—Dipstick
B—Cover G—Key (2 used) L—Bushing Q—Gear Case
C—Lock Nut (2 used) H—Shaft M—Ball Bearing R—Seal
D—Washer (2 used) I—Gear N—Shaft S—Seal
E—Gear J—Snap Ring O—O-Ring T—Key
1. Drain gear case. The approximate capacity is 3.8 L

(4 qt).
Specification
Clean Grain Elevator Gear
Case—Capacity ........................................................................... 3.8 L
(4 qt)
Continued on next page OUO6083,00002AC –19–22MAY02–1/8

083006
PN=1452
2. Remove nut (A) to remove auger drive (B).
3. Remove cover (C).
4. Clean cover and case mating surfaces.
–UN–05SEP89
A—Nut
B—Auger Drive 130
C—Cover 25
15
H41326
OUO6083,00002AC –19–22MAY02–2/8
5. Remove lock nuts and washers (B).
6. Press out shaft or shafts needing repair from gears (A).
A—Gear (2 used)
B—Washer (2 used)
–UN–05SEP89
H40333
OUO6083,00002AC –19–22MAY02–3/8
7. Remove output shaft components (A—H). A

C
8. Replace parts as necessary. D
F
A—Lock Nut G
B I
B—Washer
C—Bearing Cone
E J I
D—Bearing Cup
E—Spacer
F—Snap Ring
–UN–28MAR01
G—Bearing Cup H
H—Bearing Cone
I—Key
J—Shaft
K—Seal
H66798

083006
PN=1453
9. Remove input shaft components (A—F). A B
C
D
A—Snap Ring
B—Ball Bearing E
–UN–14FEB01
C—Bushing
D—Ball Bearing
130
E—Shaft
25
F—Key
16
G—Key
H66296
G
F

083006
PN=1454
130
25
17
–UN–16MAR01
H66723
A—Cap Screw (11 used) F—Bearing K—Seal O—Ball Bearing
B—Cover G—Key (2 used) L—Input Shaft P—Snap Ring
C—Lock Nut (2 used) H—Output Shaft M—Ball Bearing Q—Bevel Gear
D—Washer (2 used) I—Gear Case Housing N—Bushing R—Key
E—Gear J—Seal
11. Drive ball bearing (M) over threaded end of input 15. Install snap ring (P) in gear case housing (I)
shaft (L) and seat against shoulder. against ball bearing (O).
12. Install input shaft (L) with bearing (M) through 16. Install key (G) in keyway of input shaft (L).
large opening of gear case housing (I) and into
long quill side of housing. 17. Slide bevel gear (Q) over threaded end of input
shaft (L) and key with heel of gear first.
NOTE: End of shaft with keyway should extend out of
quill and housing. 18. Slide washers (D) over threaded end of input shaft
(L) and against hub of gear (Q).
13. Slide bushing (N) over shaft and against bearing
(M). 19. Install lock nut (C) on input shaft (L) or output
shaft (H) against washer (D). Torque to
14. Drive ball bearing (O) over threaded end of input specifications.
shaft (L) and seat against bushing (N).

083006
PN=1455
Specification 22. Apply Form-in-Place Gasket to gear case housing

Lock Nut, Input Shaft and (I) and cover (B) mating surfaces. Apply all around
Output Shaft—Torque........................................................... 125 N•m
(92 lb-ft) cap screw holes.
20. Install seal (J) in short quill side of gear case 23. Install cover (B) on gear case housing with cap
housing (I). Pack seal cavity with Multi-Purpose screws (A).
SD Polyurea Grease. Press into housing until
130 outer diameter is flush with housing.
25
18
21. Install seal (K), with spring loaded lip to the inside
until outer edge of seal is flush with housing.
OUO6083,00002AC –19–22MAY02–7/8
24. Install cover (C).
25. Install auger drive (B) using nut (A). Torque nut to
specifications.
Specification
Nut, Auger Drive—Torque ............................................................ 350 N•m
–UN–05SEP89
(255 lb-ft)
26. Fill gear case with TY6382, GL-5 Gear Lubricant.
H41326
Specification
Clean Grain Elevator Gear
Case—Capacity .................................................................................. 3.8 L
(4 qt)
OUO6083,00002AC –19–22MAY02–8/8
Remove And Install Clean Grain Loading

Auger
1. Remove quick-lock pin and sample trough (A).
2. Remove four nuts and shield (B).

–UN–22MAR99
A—Trough
B—Shield
H54882
Continued on next page AG,OUO1026,40 –19–27FEB06–1/2

083006
PN=1456
3. Remove four round head bolts and nuts (A).
4. Remove cap screw (B) and washer.
5. Remove spacer (C).
–UN–22MAR99
6. Remove bearing and support as an assembly.
130
25
CAUTION: The approximate weight of auger is 19
23 kg (51 lb).
H54883
Specification
Clean Grain Loading Auger—
Weight................................................................................................ 23 kg
(51 lb)
7. Remove auger from housing.
8. Install auger in housing.
–UN–22MAR99
9. Turn auger to engage with gear case drive.
10. Install spacer, bearing and support assembly, washer

and cap screw.
H54884
11. Install shield and sample trough.
A—Bolts And Nuts
B—Cap Screw
C—Spacer
AG,OUO1026,40 –19–27FEB06–2/2
Replace Clean Grain Loading Auger Bearing
NOTE: Shield on auger housing does not need to be

removed to remove bearing.
1. Remove round head bolts and nuts (A).

–UN–22MAR99
2. Remove cap screw (B) and washer.
3. Remove bearing, flangettes and spacer.

H54886
4. Install bearing, flangettes, spacer and hardware.
A—Nuts
B—Cap Screw
AG,OUO1026,42 –19–25JUL00–1/1

083006
PN=1457
Remove And Install Lower Clean Grain Auger
1. Disconnect harness lead connector at clean grain

auger sensor.
2. Remove sensor (A) and actuator (B) from left-hand
–UN–19MAR99
side of clean grain auger.
130
25 A—Sensor
20 B—Actuator
H54350
AG,OUO1026,43 –19–25JUL00–1/18
4. Remove nuts (B), sensor bracket and outside flangette.
5. Remove nuts (C).
–UN–01JUN99
A—Locking Collar
B—Nuts
C—Nuts
H54764
AG,OUO1026,43 –19–25JUL00–2/18
6. Open cleanout door and remove cotter pin (A) and pin
from paddle chain connecting link.
–UN–19MAR99
H54769
AG,OUO1026,43 –19–25JUL00–3/18
7. Remove nuts and bearing cover (A).

–UN–19MAR99
H54765

083006
PN=1458
9. Remove nuts (B).
10. Loosen or remove nuts on screw (C) as needed to

remove outer bearing flange and adjusting plate (D).
–UN–01JUN99
A—Locking Collar 130
B—Nut (4 used) 25
C—Adjusting Screw 21
H54770
D—Plate
AG,OUO1026,43 –19–25JUL00–5/18
11. Remove bearing (A) and inner bearing flange (B).
A—Bearing
B—Flange
–UN–01JUN99
H54771
AG,OUO1026,43 –19–25JUL00–6/18
12. Slide auger to left-hand side far enough to remove

spacer (A) and sprocket (B).
A—Spacer
B—Sprocket –UN–19MAR99
H54775

083006
PN=1459
13. Remove bearing (A), inside flangette and plate.
A—Bearing
–UN–01JUN99
130
25
22
H54776
AG,OUO1026,43 –19–25JUL00–8/18
–UN–01JUN99
H54777
AG,OUO1026,43 –19–25JUL00–9/18
15. Turn lower auger in far enough to install paddle chain

sprocket. (See next step.)
–UN–01JUN99
H54857
AG,OUO1026,43 –19–25JUL00–10/18
16. Install key (A).
17. Install sprocket (B) tight against shoulder on auger

shaft.
18. Install spacer (C) tight against sprocket.

–UN–19MAR99
A—Key
B—Sprocket
C—Spacer
H54860

083006
PN=1460
19. Install inside bearing flange and bearing (A), making

sure bearing is tight against spacer (B).
A—Bearing
B—Spacer
–UN–19MAR99
130
25
23
H54861
AG,OUO1026,43 –19–25JUL00–12/18
20. Install outer bearing flange (A) and adjusting plate (B)
using four round head bolts. Nuts should be snug but
not tightened.
21. Install locking collar (C) and tighten. Tighten set

screw.
22. Connect paddle chain using connecting, pin and

cotter pin.
–UN–19MAR99
A—Flange
B—Plate
C—Locking Collar
H54862
AG,OUO1026,43 –19–25JUL00–13/18
23. Position plate, inner flangette and bearing (A) on

auger.
A—Bearing
–UN–01JUN99
H54776

083006
PN=1461
24. Install outer flangette, plate and sensor bracket using

round head bolts (C) and (B).
25. Install locking collar (A) and tighten. Tighten set

screw.
–UN–01JUN99
A—Locking Collar
130 B—Round Head Bolts
25 C—Round Head Bolts
24
H54764
AG,OUO1026,43 –19–25JUL00–15/18
26. Install actuator (B) and sensor (A). Connect harness

connector to sensor.
A—Actuator
B—Sensor
–UN–19MAR99
H54350
AG,OUO1026,43 –19–25JUL00–16/18
27. Turn nut (A) to adjust chain tension. Turning nut

clockwise tightens chain, and turning nut
counterclockwise loosens chain.

of chain can be slid across the sprocket. If chain
can be pulled 6 mm (1/4 in.) maximum, away from
–UN–19MAR99
the chain correctly.
28. Install nut (B) and tighten.

H54876
29. Tighten nuts (C).
A—Nut
B—Nut
C—Nut
D—Nut

083006
PN=1462
A—Cover
–UN–19MAR99
130
25
25
H54765
AG,OUO1026,43 –19–25JUL00–18/18

083006
PN=1463
130
25
26

083006
PN=1464
Group 30
Grain Tank and Extensions
130
30
1

083006
PN=1465
Grain Tank
B
A
130
30
2
C
D
V
U E F
T
S
H
J
K
R
N
Q
–UN–04JUN03
K
O
H77610
High Unload Rate


083006
PN=1466
A—Clevis (2 used) G—Plate M—Support R—Isolator

B—Channel H—Grommet N—Bracket S—Door
C—Cover I—Bracket O—Shield T—Tank
D—Panel J—Cover P—Door U—Plate
E—Clamp K—Clamp (2 used) Q—Bracket V—Cover
F—Cover L—Cover
130
30
3

083006
PN=1467
130
30
4
–UN–13APR99
H55344
Regular Unload Rate
A—Panel C—Strip (2 used) E—Cover G—Top, Tank

B—Bracket (2 used) D—Cover F—Cover H—Door
OUO6083,0000604 –19–04JUN03–3/3

083006
PN=1468
Grain Tank Extensions
130
30
5
–UN–23MAY03
H77377
High Unload Rate
A—Panel, Rear Corner (2 C—Panel, Rear F—Window H—Panel, Front

used) D—Panel, Left-Hand Side G—Panel, Front Corner (2 I—Panel, Right-Hand Side
B—Strip (8 used) E—Isolator used)

083006
PN=1469
130
30
6
–UN–13APR99
H55345
Regular Unload Rate
A—Panel, Corner Extension F—Adapter Left-Hand Rear K—Plate Adapter O—Plate Adapter
B—Plate Adapter Extension L—Panel, Front and Rear P—Panel, Side Extension
C—Panel, Front and Rear G—Plate Adapter Extension Q—Plate Adapter
Extension H—Panel, Side Extension M—Plate Adapter R—Adapter Right-Hand Rear
D—Plate Adapter I—Plate Adapter N—Panel, Corner Extension Extension
E—Panel, Corner Extension J—Panel, Corner Extension

083006
PN=1470
130
30
7
–UN–28JUL99
H58649
9560 STS and 9660 STS
A—Panel D—Holder (4 used) F—Panel H—Holder

B—Holder (3 used) E—Panel G—Panel I—Panel
C—Panel
OUO6083,00005E5 –19–23MAY03–3/3

083006
PN=1471
130
30
8

083006
PN=1472
Section 140
Engine Gear Case and Control Valve Repair
Contents
Page
Group 05—Engine Gear Case and Valve

Essential or Recommended Tools . . . . . . . . . .140-05-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . .140-05-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .140-05-5
General Information. . . . . . . . . . . . . . . . . . . . .140-05-8 140
Remove and Install Engine Gear Case . . . . . .140-05-9
Engine Gear Case Specifications . . . . . . . . .140-05-16
Remove and Install STS Rotor Variable
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140-05-17
Disassemble and Assemble STS Rotor
Variable Drive . . . . . . . . . . . . . . . . . . . . . .140-05-20
Remove and Install STS Rotor Variable
Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . .140-05-26
Remove and Install Transfer Gear Case . . . .140-05-28
Disassemble and Assemble Transfer Gear
Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140-05-32
Disassemble and Assemble Separator Drive
Wet Clutch. . . . . . . . . . . . . . . . . . . . . . . . .140-05-36
Disassemble and Assemble Hydrostatic
Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . .140-05-46
Set Gear Position . . . . . . . . . . . . . . . . . . . . .140-05-47
Preload Bearings. . . . . . . . . . . . . . . . . . . . . .140-05-49
Disassemble and Assemble Straw
Chopper/Unloading System . . . . . . . . . . . .140-05-50
Set Separator Gear Position . . . . . . . . . . . . .140-05-54
Preload Bearings. . . . . . . . . . . . . . . . . . . . . .140-05-55
Disassemble and Assemble Separator
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140-05-56
Preload Separator Drive Bearings . . . . . . . . .140-05-59
Set Separator Drive Gear Backlash. . . . . . . .140-05-60
Disassemble and Assemble Hydrostatic
Pump Drive . . . . . . . . . . . . . . . . . . . . . . . .140-05-61
Preload Hydrostatic Pump Drive Bearings. . .140-05-63
Set Hydrostatic Pump Drive Gear
Backlash . . . . . . . . . . . . . . . . . . . . . . . . . .140-05-64
Disassemble and Assemble Oil Screen. . . . .140-05-65
Disassemble and Assemble Oil Trough. . . . .140-05-65
Disassemble and Assemble Dipstick
Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140-05-66
Remove and Install Filter. . . . . . . . . . . . . . . .140-05-66
Remove and Install Pressure Regulating
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140-05-67
Disassemble and Assemble Pressure
Regulating Valve . . . . . . . . . . . . . . . . . . . .140-05-68

083006
PN=1
Contents
140

083006
PN=2
Group 05
Engine Gear Case and Valve
Catalogs.
OUO6083,0000B52 –19–25JAN06–1/10
140
05
Engine Repair Stand . . . . . . . . . . . . . . . . . D05223ST 1
Used to service main engine gear case.
–UN–16AUG05
H84150
OUO6083,0000B52 –19–25JAN06–2/10
Main Engine Gear case Support Bracket . . . . . . JT07334
To be used with D05223ST Engine Repair Stand
–UN–16AUG05
H84151
OUO6083,0000B52 –19–25JAN06–3/10
Rear Engine Support Bracket . . . . . . . . . . . . JDG1297
Support engine during remove and install procedures.

–UN–01JUN01
H68345
Continued on next page OUO6083,0000B52 –19–25JAN06–4/10

083006
PN=1475
Clutch Pack Lifting Tool . . . . . . . . . . . . . . . . JDG12941
Remove wet clutch assembly from gear case.
–UN–01JUN01
H68346
1
OUO6083,0000B52 –19–25JAN06–5/10
140
05
2 Spring Washer Compressor. . . . . . . . . . . . . . . JDT24A
Compresses spring type washers.
–UN–03OCT02
H73522
OUO6083,0000B52 –19–25JAN06–6/10
T6557CI –UN–01NOV88
1
Air Test Plug . . . . . . . . . . . . . . . . . . . . . . . JDG185
Used to release clutch from piston.
1
Continued on next page OUO6083,0000B52 –19–25JAN06–7/10

083006
PN=1476
H84133 –UN–27JUL05
Combine Main Engine PTO Gear Case Seal

Installer . . . . . . . . . . . . . . . . . . . . . . . . . . JDG10028
Install input shaft seal into main engine PTO gear case.
OUO6083,0000B52 –19–25JAN06–8/10
140
05
Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . JDG12681 3
Remove sheaves from combine.
–UN–04JUN01
H68321
1
OUO6083,0000B52 –19–25JAN06–9/10
Spanner Wrench . . . . . . . . . . . . . . . . . . . . . .JDG666
Remove and install wet clutch lock nuts.
–UN–20MAR02
H71345
OUO6083,0000B52 –19–25JAN06–10/10

083006
PN=1477
Other Material
Number Name Use
TY22068 (U.S.) TORQ-GARD SAE 10W Lubricate gear case components.
PM37521 (U.S.) RTV Silicone Adhesive Sealant Used to seal mating surfaces of seal
plate and engine gear case.
PM38654 (U.S.) Thread Lock and Sealer Used to prevent dipstick tube from
loosening.

140 applications.
05
4
PM37397 (U.S.) Pipe Sealant Used to prevent cap screws from
loosening.
TY24811 (U.S.) NEVER-SEEZ Coat STS rotor drive shaft.
AG,OUO6022,385 –19–05AUG05–1/1

083006
PN=1478
Specifications
Engine Gear Case-to-Engine Cap Torque 340 N•m

Screws (250 lb-ft)
Engine Gear Case-to-Frame Cap Torque 123 ± 31 N•m

Engine Gear Case Plate Cap Screws Torque 25 N•m

(221 lb-in.)
Hydrostatic Pump-to-Gear Case Cap Torque 130 ± 30 N•m 140

05
Screws (96 ± 22 lb-ft) 5
Variable Speed Drive-to-Transfer Torque 84 ± 21 N•m

Gear Case Cap Screws (62 ± 15 lb-ft)
Transfer Gear Case
Case-to-Engine Gear Case Cap Torque 84 ± 21 N•m

Screws (62 ± 15 lb-ft )
Hex Flange Bolt and Nut Torque 215 ± 43 N•m

(159 ± 32 lb-ft)
Output Shaft Bearings Preload 0.03—0.13 mm

(0.001—0.005 in.)
Output Cover Cap Screws Torque 50 ± 10 N•m

(37 ± 7 lb-ft)
Engine Gear Case Wet Clutch
Clutch Hub Cap Screws Torque 75 N•m

(55 lb-ft)
Clutch-to-Gear Case Cap Screws Torque 50 N•m

(40 lb-ft)
Seal Plate Cap Screws Torque 15 N•m

(144 lb-in.)
Straw Chopper Drive Sheave Cap Torque 90 N•m

Screws (65 lb-ft)
Continued on next page OUO6083,000022E –19–12MAR02–1/3

083006
PN=1479
Unloader Shaft Nut Torque 340 N•m

(250 lb-ft)
Bearing Housing-to-Gear Case Cap Torque 50 N•m

Screws (40 lb-ft)
Separator Drive-to-Gear Case Cap Torque 50 ± 10 N•m

Separator Drive End Play 0.33 to 0.43 mm

(0.010 to 0.020 in.)
140 + 1/4 turn to preload
05
6
Separator Drive Outer Lock Nut Torque 70 N•m
(52 lb-ft)
Separator Drive Assembly Rolling Drag Torque 28 N•cm

(40 oz-in.)
Hydrostatic Pump Drive Gear End Play 0.33 to 0.43 mm

(0.010 to 0.020 in.)
+ 1/4 turn to preload
Hydrostatic Pump Drive Outer Nut Torque 70 N•m

(52 lb-ft)
Hydrostatic Drive Pump Rolling Drag Torque 28 N•cm

(40 oz-in.)
Hydrostatic Pump Drive-to-Gear Torque 50 N•m

Case Cap Screws (40 lb-ft)
Engine Gear Case Oil Screen Cover Torque 25 N•m

Cap Screws (216 lb-in.)
Oil Trough Cover Cap Screws Torque 25 ± 5 N•m

(221 ± 44 lb-in.)
Engine Gear Case Capacity 21.3 L

(22.5 qt)
Pressure Regulating Valve Solenoid Torque 25 N•m

Cartridge (216 lb-in.)
Pressure Regulating Valve Cap Torque 25 N•m

Screws (216 lb-in.)
Continued on next page OUO6083,000022E –19–12MAR02–2/3

083006
PN=1480
STS Rotor Variable Drive Sheave Torque 123 ± 31 N•m

Cap Screws (91 ± 23 lb-ft)
STS Rotor Variable Drive Sheave Gap 45.3 mm

(1.78 in.)
STS Rotor Drive Cylinder Cap Torque 70 N•m

Screws (52 lb-ft)
STS Rotor Variable Sheave Lock Nut Torque 207 ± 52 N•m

(153 ± 38 lb-ft)
140
05
Pump Assembly Weight 77 kg 7
(150 lb)
Engine Gear Case Weight 264 kg

(582 lb)
Standard Duty Variable Speed Drive Weight 93 kg

(205 lb)
Heavy Duty Variable Speed Drive Weight 96 kg

(212 lb)
Clutch Pack Weight 49 kg

(108 lb)
Separator Drive Weight 28 kg

(62 lb)
OUO6083,000022E –19–12MAR02–3/3

083006
PN=1481
General Information
The inner seal (A) can be replaced without draining the

gear case oil. (See REMOVE AND INSTALL ENGINE
GEAR CASE in this group.)
–UN–27MAY99
Repair can be done on any one area without
disassembling entire gear case. Only for complete
disassembly is it necessary to remove gear case.
H57504
A—Inner Seal
140
05
8
AG,OUO6022,364 –19–25JUL00–1/2
Read the information in TM2182, Section 275, on how the

gear case and its valve operate.
Familiarize yourself with the exploded views of the gear

case before starting repair work.
–UN–19MAY99
H57366
AG,OUO6022,364 –19–25JUL00–2/2

083006
PN=1482
Remove and Install Engine Gear Case

–UN–23AUG88
fluids.
X9811
Any fluid injected into the skin must be 140
gangrene may result. Doctors unfamiliar with 9
–UN–23APR99
1. Swing unloading auger to unload position.
H55609
system pressure. Shut off engine. Remove key.
3. Install JDG1297 Rear Engine Support Bracket (F).
5. Remove variable speed drive assembly. (See

REMOVE AND INSTALL STS ROTOR VARIABLE
DRIVE in this section.)
–UN–23APR99
6. Remove oil plug (A) and drain gear case.
H55660
7. Remove attaching hardware and auger drive belt trap.
Remove auger drive belt (B).
8. Remove attaching hardware and straw chopper drive A—Oil Plug

belt shield (C). B—Auger Drive Belt
C—Shield
D—Nut (2 used)
9. Loosen nuts (D) to relieve belt tension and remove E—Chopper Drive Belt (Upper)
straw chopper upper drive belt (E). F—JDG1297 Rear Engine Support Bracket

083006
PN=1483
10. Remove attaching hardware and shield (A).
11. Disconnect (B) hydrostatic control cable from lever.

Remove attaching hardware (C) and move bracket
and cable out of the way.
–UN–23APR99
12. Disconnect hydraulic hose (D) and cap to prevent
contamination. Remove attaching hardware from
cylinder support bracket and move cylinder (E) and
bracket out of the way.
H55610
13. Remove hydraulic hoses from support (F). Remove
support.
140
05
10 A—Bracket
B—Linkage
D—Hydraulic Hose, Unloading System Drive Cylinder
E—Unloading System Drive Cylinder
F—Support
–UN–23APR99
H55611
–UN–23APR99
H55612

083006
PN=1484
14. Remove cap screw and hose clamp from bracket (A).
15. Disconnect connectors (B).
A—Bracket
B—Connector (4 used)
–UN–23APR99
H55614
140
05
11
–UN–23APR99
H55613

083006
PN=1485
16. Disconnect four hydraulic hoses (A). Cap or plug all

openings.
17. Remove starting aid line (B).
18. Remove solenoid (C).
–UN–23APR99
A—Hydraulic Hose (4 used)
B—Ether Line
C—Solenoid
H55620
140
05
12
–UN–23APR99
H55621
–UN–23APR99
H55627

083006
PN=1486
CAUTION: Approximate weight of pump

Specification
Pump Assembly—Weight .................................................................. 77 kg
(150 lb)
NOTE: It is not necessary to disconnect hydraulic lines

and hoses to pumps.
–UN–02JUN99
19. Attach lifting device (A) to pump assembly.
H57764
140
05
21. Remove hydrostatic pump (B), charge pump (D) and 13
main hydraulic pump (E) as an assembly.
NOTE: Plate is mounted between engine and gear case

using two cap screws per side. Cap screws must
be removed or flywheel may damage plate during
gear case removal.
–UN–23APR99
22. Remove cap screws (F).
CAUTION: Approximate weight of gear case is
H55653
264 kg (582 lb).
Specification
Engine Gear Case—Weight ............................................................ 264 kg
(582 lb)
23. Attach lifting device to gear case. Remove four cap

screws (G).
24. Remove cap screws (H) and gear case.
–UN–23APR99
25. Repair or replace gear case as necessary.
26. Use D05223ST engine stand and JT07334 support
H55675
bracket to aid in repair of gear case
A—Lifting Device
B—Hydrostatic Pump
D—Charge Pump
E—Main Hydraulic Pump
–UN–23APR99
H55721

083006
PN=1487
NOTE: Turn outer unloading sheave to align spline on

gear case with engine flywheel.
27. Apply new RTV sealant to entire gear case flange (A).
Install dowel pins on engine. Align dowel pins on
engine with gear case. Install cap screws (B). Tighten
–UN–24JUN99
cap screws to specifications.
Specification
Screws—Torque ........................................................................... 340 N•m
H55717
(250 lb-ft)
140
28. Install seal plate cap screws (C). Tighten to
05 specifications.
14
Specification
Engine Gear Case Plate Cap
Screws—Torque ............................................................................. 25 N•m
(221 lb-in.)
–UN–23APR99
29. Install gear case to frame cap screws (D). Tighten to
specifications.
Specification
H55718
Engine Gear Case-to-Frame Cap
Screws—Torque ................................................................... 123 ± 31 N•m
(91 ± 23 lb-ft)
A—Gear Case Flange

B—Engine Gear Case-to-Engine Cap Screw (4 used)
C—Plate Cap Screw (4 used)
D—Engine Gear Case-to-Frame Cap Screw (4 used)
–UN–23APR99
H55719
–UN–23APR99
H55722

083006
PN=1488
30. Install hydrostatic pump, charge pump and main

hydraulic pump as an assembly. Tighten cap screws
(D) to specifications.
Specification
Hydrostatic Pump-to-Gear Case
Cap Screws—Torque ........................................................... 130 ± 30 N•m
–UN–12MAY00
(96 ± 22 lb-ft)
31. Install solenoid.
H63891
32. Connect starting aid line.
33. Connect four hydraulic hoses (B). 140

05
34. Connect harness connectors. 15
35. Install hose clamp to bracket by drive shaft.
36. Install support and position hoses inside support.
–UN–23APR99
37. Install unloading auger drive cylinder, idler arm and
bracket.
H55739
38. Install bracket and hydro cable to linkage.
39. Install bracket (C).
40. Install chopper drive belt and cover.
41. Install auger drive belt, belt trap and adjust idler
tension spring until washer aligns with gauge.
–UN–23APR99
42. Install variable speed drive assembly. (See REMOVE
AND INSTALL TRANSFER GEAR CASE in this
section.)
H55740
44. Remove rear engine support.
45. Fill gear case to capacity. (See FUELS AND

LUBRICANTS Section 10.)
B—Hydraulic Hose (4 used)
C—Bracket
–UN–23APR99
H55753

083006
PN=1489
Specification
Engine Gear Case—Capacity .......................................................... 21.3 L
(22.5 qt)
OUO6083,0000B20 –19–29AUG05–8/8
Engine Gear Case Specifications
24
140
05
16
20 23
19 21
22
18
17 8
16 13 12
–UN–04JUN02
15
14 6 4
11
5
10 2
3
H72403
9 7
1—Power From Engine 8—Power to Pumps 13—Shims-Gear Position 19—Shims-Gear Backlash

2—15 N•m (144 lb-in.) 9—0.38 mm (0.015 in.) end 14—50 N•m (40 lb-ft) 20—50 N•m (40 lb-ft)
3—50 N•m (40 lb-ft) play + 1/4 turn to preload 15—75 N•m (55 lb-ft) 21—Separator Drive
4—Wet Clutch Disk 10—50 N•m (40 lb-ft) 16—Straw Chopper Drive 22—Shims-Preload Bearings
5—75 N•m (55 lb-ft) 11—Shims-Gear Backlash 17—Unloading Drive 23—Wet Clutch Plates
6—50 N•m (40 lb-ft) 12—Shims-Gear Position 18—340 N•m (250 lb-ft) 24—340 N•m (250 lb-ft)
7—70 N•m (50 lb-ft) with zero
end play
OUO6083,00005CC –19–20MAY03–1/1

083006
PN=1490
Remove and Install STS Rotor Variable Drive
1. With separator engaged and running, set STS Rotor

Drive in low speed position so drive sheaves on gear
case are open.
3. Disconnect battery ground cable. (See Remove and

Install Batteries, Section 40, Group 15.)
NOTE: Gull wing door can be removed to aid in service

of variable drive, although it is not necessary.
140
05
4. Raise left-hand rear gull wing door. 17

083006
PN=1491
CAUTION: High pressure can exist at any

hydraulic connection. Avoid injury from
high-pressure leaks by relieving system
pressure before disconnecting any hydraulic
lines, fittings or connections.
–UN–19APR99
5. Remove oil plug (A) and drain transfer gear case.
Approximate capacity is 2.8 (3 qt).
6. Remove drive belt (B). (See REMOVE AND INSTALL
H55522
STS ROTOR TORQUE SENSING—DRIVEN in Section
120, Group 05.)
140
05 7. Disconnect oil lines (C).
18
8. Loosen nuts (D).
9. Remove cotter pin and pin (E) to disconnect support

from housing.
–UN–24MAY99
CAUTION: Approximate weight of standard duty
variable speed drive is 93 kg (205 lb).
H57374
Approximate weight of heavy duty variable
speed drive is 96 kg (212 lb).
Specification A—Plug
Standard Duty Variable Speed B—Belt
Drive—Weight.................................................................................... 93 kg C—Oil Line (2 used)
(205 lb) D—Lock Nut (2 used)
Heavy Duty Variable Speed E—Pin
Drive—Weight.................................................................................... 96 kg F—Cap Screw (12 used)
(212 lb)
10. Attach lifting device to variable speed drive.
11. Remove cap screws (F) and variable speed drive.
12. Inspect and repair or replace as necessary. (See

DISASSEMBLE AND ASSEMBLE STS ROTOR
VARIABLE DRIVE in this group.)
13. Install new O-ring seal.

083006
PN=1492
14. Position variable drive to transfer gear case and

install cap screws (F) to housing. Apply pipe sealant
to two M12 x 35 cap screws that install in holes (G) to
prevent oil leakage. Tighten cap screws to
specifications.
–UN–19APR99
Specification
Variable Speed Drive Cap
Screws—Torque ...................................................................... 84 N•m ±21
(62 lb-ft ± 15)
H55522
15. Install pin (E) and cotter pin.
16. Tighten lock nuts (D). 140

05
17. Connect oil lines (C). 19
18. Install drive belt (B). (See REMOVE AND INSTALL

STS ROTOR TORQUE SENSING—DRIVEN in
Section 120.)
–UN–24MAY99
19. Connect battery ground cable. (See REMOVE AND
INSTALL BATTERIES in Section 40 Group 15.)
H57374
20. Install oil plug (A) and fill engine gear case to full
level on dipstick. (See FUELS AND LUBRICANTS
Section 10.)
A—Plug
B—Belt
D—Lock Nut (2 used)
E—Pin
–UN–04APR00
G—Hole (2 used)
H63188
OUO6083,0000A01 –19–05AUG05–3/3

083006
PN=1493
Disassemble and Assemble STS Rotor Variable Drive
17
140 12
05
20
16
11 15
10 14
9 13
4 8
2
6 32
4
3
1
24
31
25
23 30
22
26
29
28
21 27
20
19
18
–UN–22AUG06
H86480

083006
PN=1494
1—Fitting 9—Seal 17—Sheave 25—Adapter

2—Lock Nut 10—Bushing 18—Washer 26—O-Ring
3—Washer 11—Plug 19—Hub 27—Cap Screw (10 used)
4—O-Ring (2 used) 12—Sheave 20—Seal 28—Housing
5—Cap Screw (6 used) 13—Lubrication Fitting 21—Seal 29—O-Ring
6—Cylinder 14—Seal 22—Relief Valve 30—Bearing
7—Spacer 15—O-Ring 23—Cap Screw (6 used) 31—Snap Ring
8—Snap Ring 16—Snap Ring 24—O-Ring 32—Shaft
OUO6083,0000DD0 –19–22AUG06–2/17
140
05
21
CAUTION: When retaining nut (A) is removed,
inner and outer sheave halves can slide off of
shaft. To avoid injury, be certain to retain
sheave halves prior to removing retaining nut.
NOTE: On machines with Standard Duty Variable Drive it
–UN–03JUN04
is not necessary to remove variable drive
assembly from transfer gear case to service inner
and outer sheave halves. Assembly must be
removed on machines with Heavy Duty Variable
H81059
Drive.
1. Remove union fitting (A), lock nut (B) and washer (C).
A—Fitting
B—Lock Nut
C—Washer
–UN–19MAY99
H57230
OUO6083,0000DD0 –19–22AUG06–3/17
2. Remove cap screws (A), cylinder assembly (B) and

spacer (C).

B—Cylinder Assembly
C—Spacer
–UN–20MAY99
H57231

083006
PN=1495
3. Remove piston (A) from barrel (B).
A—Piston
B—Housing
–UN–19MAY99
H57232
OUO6083,0000DD0 –19–22AUG06–5/17
140
05
22 4. Remove O-rings (A), back-up washers (B) and seal
(C). Replace as necessary.
5. Clean and inspect all parts. Remove any nicks and

burrs.
–UN–19MAY99
6. Replace O-rings (A), back-up washers (B) and seal
(C).
7. Install piston in barrel.
H57233
A—O-Ring (2 used)
B—Back-up Washer
C—Seal
–UN–20MAY99
H57234
OUO6083,0000DD0 –19–22AUG06–6/17
8. Remove plug (A) to relieve suction between sheave

halves.
9. Remove outer half of sheave (B).
A—Plug
–UN–19MAY99
B—Sheave
H57291

083006
PN=1496
10. Remove snap ring (A) and seal (B).
11. Clean and inspect ID of sheave half. Remove any

nicks or burrs.
A—Snap Ring
–UN–19MAY99
B—Seal
H57235
OUO6083,0000DD0 –19–22AUG06–8/17
140
05
12. Remove O-ring (A). 23
13. Peel the bushing starting at seam (C) to remove if

necessary.
14. Install bushing (B).
–UN–19MAY99
15. Install O-ring (A) and snap ring (D).
A—O-Ring
H57236
B—Bushing
C—Seam
D—Snap Ring
D
A
–UN–06JUL01
H69110
–UN–23JUN99
H58328

083006
PN=1497
16. Remove washer (A) and inner half of sheave (B).
A—Washer
B—Inner Sheave
–UN–19MAY99
H57237
OUO6083,0000DD0 –19–22AUG06–10/17
140
05
24 17. Inspect and replace seal (A) as necessary. Install seal
(A) with thin, flexible lip against the face of seal (B).
A—Seal
B—Seal
–UN–22AUG06
H86481
OUO6083,0000DD0 –19–22AUG06–11/17
18. Remove cap screws (A) and inspect hub (B). Replace
as necessary.
19. Install hub (B) and cap screws (A). Tighten cap
Specification
–UN–25JUN99
STS Rotor Variable Drive Sheave
Cap Screws—Torque ........................................................... 123 ± 31 N•m
(91 ± 23 lb-ft)
H57238
B—Hub

083006
PN=1498
20. Install inner half of sheave (B) and washer (A).
A—Washer
B—Inner Sheave
–UN–19MAY99
H57237
OUO6083,0000DD0 –19–22AUG06–13/17
140
05
21. Install outer half of sheave (B) and plug (A). 25
A—Plug
B—Sheave
–UN–19MAY99
H57291
OUO6083,0000DD0 –19–22AUG06–14/17
22. Install spacer (C) as required to achieve proper

sheave gap.
Specification
STS Rotor Variable Drive
Sheave—Gap ............................................................................... 45.3 mm
(1.78 in.)
–UN–20MAY99
23. Install cylinder assembly (B) and cap screws (A).
H57231
Specification
STS Rotor Drive Cylinder Cap
Screws—Torque ............................................................................. 70 N•m
(52 lb-ft) A—Cap Screw (6 used)
B—Cylinder Assembly
C—Spacer

083006
PN=1499
24. Install washer (C) and lock nut (B). Tighten lock nut to
specification.
Specification
STS Rotor Variable Sheave Lock
Nut—Torque ......................................................................... 207 ± 52 N•m
(153 ± 38 lb-ft)
–UN–19MAY99
25. Install union fitting (A).
Install sheave assembly. (See REMOVE AND
H57230
INSTALL STS ROTOR VARIABLE DRIVE in this
group.)
140 A—Fitting
05 B—Lock Nut
26 C—Washer
OUO6083,0000DD0 –19–22AUG06–16/17
26. Pump 40 shots of TY6341 Multi-Purpose SD Polyurea

Grease into grease fitting (A). Then switch grease
fitting (A) with plug (B) and pump 175 shots of the
same grease into grease fitting. Switch grease fitting
and plug back to the original position.
–UN–18JAN01
A—Grease Zerk
B—Plug
H65844
OUO6083,0000DD0 –19–22AUG06–17/17
Remove and Install STS Rotor Variable Drive

Shaft
1. Remove variable drive. (See REMOVE AND INSTALL

STS ROTOR VARIABLE DRIVE in this group.)
2. Disassemble variable drive sheave. (See

DISASSEMBLE AND ASSEMBLE STS ROTOR
VARIABLE DRIVE in this group.)
Continued on next page OUO6083,00009FF –19–31MAY05–1/4

083006
PN=1500
3. Remove snap ring (A) and shaft (B) from housing.
A—Snap Ring
B—Shaft
–UN–19MAY99
140
H57239
05
27
OUO6083,00009FF –19–31MAY05–2/4
4. Inspect shaft, O-ring (A) and bearing (B). Replace as

necessary.
A—O-Ring
B—Bearing
–UN–19MAY99
H57240
OUO6083,00009FF –19–31MAY05–3/4
5. Install shaft (B) and snap ring (A) into housing.
6. Assemble variable drive sheave. (See DISASSEMBLE

AND ASSEMBLE STS ROTOR VARIABLE DRIVE in
this group.)
7. Install variable drive to transfer gear case. (See

REMOVE AND INSTALL STS ROTOR VARIABLE
DRIVE in this group.)
–UN–19MAY99
A—Snap Ring
B—Shaft
H57239
OUO6083,00009FF –19–31MAY05–4/4

083006
PN=1501
Remove and Install Transfer Gear Case

–UN–23AUG88
fluids.
X9811
140 Any fluid injected into the skin must be
05 surgically removed within a few hours or
28 gangrene may result. Doctors unfamiliar with
–UN–19APR99
H55522
accumulator shut-off valve. Remove key.
3. Remove oil plug (A) and drain transfer gear case.
4. Remove drive belt (B). (See REMOVE AND INSTALL

STS ROTOR TORQUE SENSING—DRIVEN in Section
120, Group 05.)
–UN–19APR99
5. Disconnect oil hoses (C).
6. Loosen lock nuts (D).
H55523
7. Remove cotter pin and pin (E) to disconnect from
housing.
A—Oil Plug
B—Drive Belt
D—Lock Nuts (2 used)
E—Pin
F—Cap Screws (12 used)
–UN–19APR99
H55524

083006
PN=1502

Specification
Standard Duty Variable Speed
Drive—Weight.................................................................................... 93 kg
(205 lb)
Heavy Duty Variable Speed
Drive—Weight.................................................................................... 96 kg
(212 lb)
8. Attach lifting device to variable speed drive. 140

05
9. Remove cap screws (F) and variable speed drive. 29
CAUTION: Transfer gear case weighs

approximately 65 kg (143 lb).
10. Attach lifting device to transfer case.
OUO6083,0000A00 –19–05AUG05–2/5
11. Disconnect hydraulic hose (A).
12. Disconnect drive shaft (B).
13. Remove cap screws (C) and transfer gear case.
–UN–19APR99
A—Hydraulic Hose
B—Drive Shaft
H55526
–UN–19APR99
H55525

083006
PN=1503
CAUTION: Transfer gear case weighs

NOTE: Grease O-ring and beveled area of transfer case

prior to installation. Tighten each cap screw
evenly so O-ring will not be damaged.
–UN–23JUN99
14. Position transfer case and install cap screws (A).
H55538
Specification
Transfer Case to Engine Gear
Case Cap Screws—Torque.................................................... 84 ± 21 N•m
140 (62 ± 15 lb-ft)
05
30
15. Install oil plug.
16. Connect drive shaft.
–UN–19APR99
H55539
Specification
Standard Duty Variable Speed
Drive—Weight.................................................................................... 93 kg A—Cap Screw (13 used)
(205 lb) B—Cap Screw (12 used)
Heavy Duty Variable Speed C—Hole (2 used)
Drive—Weight.................................................................................... 96 kg
(212 lb)
17. Install variable speed driver. Apply pipe sealant to two

M12 x 35 cap screws that install in holes (C), to
prevent oil leakage.Tighten cap screws (B) to
specifications.
Specification
Variable Speed Drive-to-Transfer
Gear Case Cap Screws—Torque .......................................... 84 ± 21 N•m
(62 ± 15 lb-ft)
18. Install support.
19. Install oil hoses.
20. Install drive belt. (See REMOVE AND INSTALL STS

ROTOR TORQUE SENSING— DRIVEN in Section
120, Group 05.)

083006
PN=1504
22. Fill gear case with SAE 10W oil to capacity.
Specification
(22.5 qt)
23. Check oil level on engine gear case dipstick.
OUO6083,0000A00 –19–05AUG05–5/5
140
05
31

083006
PN=1505
Disassemble and Assemble Transfer Gear Case
4
22 23
3
21
140
16
05 2 17
32
20 18
13 19
18
17
14
16
1 15
9 12
10
11
10
9
24
–UN–08JAN02
25
26
H70531
1—Oil Seal 9—Bearing Cup 16—Preset Bearing Matched 20—Helical Gear, 58T
2—Cap Screw (10 used) 10—Bearing Cone Set Left-Hand
3—Cover Plate 11—Helical Gear, 49T 17—Preset Bearing Matched 21—Barrel
4—Shim Plastic 0.08 mm (2 Right-Hand Set 22—O-Ring
used) 12—Orifice 18—Preset Bearing Matched 23—Nut
5—Shim Steel 0.13 mm 13—Oil Plug Set 24—Oil Plug
6—Shim Steel 0.25 mm 14—Housing 19—Preset Bearing Matched 25—Washer
7—Shim Steel 0.50 mm 15—O-Ring Set 26—Hex Flange Bolt
8—O-Ring

083006
PN=1506
1. Remove nut (A) and cap screw.
2. Remove cap screws (B), seal, O-ring, shims and cover

(C).
3. Remove gear (D).
–UN–19APR99
4. Remove barrel assembly (E) and center gear. Inspect
for worn or damaged parts. Replace parts if necessary.
H51718
A—Nut
C—Cover
D—Gear 140
E—Barrel Assembly 05
33
–UN–19APR99
H55001
–UN–19APR99
H55546

083006
PN=1507
5. Install center gear and press barrel assembly (A) into

housing.
6. Install gear (B).
7. Install hex flange bolt and nut (C). Tighten nut to
–UN–19APR99
specification.
Specification
Transfer Gear Case Hex Flange
Bolt and Nut—Torque........................................................... 215 ± 43 N•m
H55551
(159 ± 32 lb-ft)
140
8. Apply PM37397 Pipe Sealant with TEFLON to cap
05 screws (D).
34
9. Establish preload of bearing by adjusting shim pack to
output drive cover.
Specification
–UN–19APR99
Transfer Gear Case Output Shaft
Bearings—Preload............................................................. 0.03—0.13 mm
(0.001—0.005 in.)
10. Install seal, O-ring, shims and cover (E). Tighten cap
H55552
screws (D) to specification.
Specification
Transfer Gear Case Output Cover
Cap Screws—Torque ............................................................. 50 ± 10 N•m
(37 ± 7 lb-ft)
A—Barrel Assembly
B—Gear
–UN–19APR99
C—Nut
E—Cover
H55553
OUO6083,00001F4 –19–05AUG05–3/3

083006
PN=1508
140
05
35

083006
PN=1509
Disassemble and Assemble Separator Drive Wet Clutch
2
3
4
3
2
1
1 12
1
1 11
12
140
05 11
36 12
11
12
11
37
10
9 37
22
7 22
6 21
5
5
5 39
5
20
16
8 18 19
17 35
36
38 33 34
15
15 32
15 29 31
15
15
14 24
13
23
30
–UN–09JUL01
28
27 26
H69124
25

083006
PN=1510
1—Shim 10—Hub 20—Shaft 30—Bolt, M10 x 35 (6 used)

2—Roller Bearing Cup (2 used) 11—Clutch Disk 21—Drum 31—Ball Bearing
3—Roller Bearing Cone (2 12—Clutch Plate 22—Sealing Ring (2 used) 32—Snap Ring
used) 13—Snap Ring 23—Thrust Washer 33—Gasket
4—Gear 14—Retainer 24—Gasket 34—Seal
5—Shim 15—Spring Washer 25—Seat 35—Seal Plate
6—Housing 16—Centering Washer 26—Ball 36—Bolt, M6 x 25 (8 used)
7—Bolt, M10 x 35 (6 used) 17—Piston 27—Pin 37—Fiber Washer (2 used)
8—Bolt, M10 x 30 (6 used) 18—Seal 28—Plug 38—Seal
9—Hub 19—Snap Ring 29—Housing 39—Snap Ring
OUO6083,0000B21 –19–29AUG05–2/19
140
05
37
CAUTION: Weight of clutch pack is
Specification
Clutch Pack—Weight......................................................................... 49 kg
(108 lb)
1. Remove cap screws (A), seal plate (B) and gasket.
–UN–26MAR99
NOTE: Tapped holes (D) are used for clutch pack
removal.
H55017
B—Seal Plate and Gasket
D—Tapped Hole (3 used)

083006
PN=1511
3. Install JDG1294 Clutch Pack Lifting Tool (A) in three

tapped holes and remove clutch pack (B).
A—JDG1294 Clutch Pack Lifting Tool

B—Clutch Pack
–UN–26MAR99
140
H55013
05
38
OUO6083,0000B21 –19–29AUG05–4/19
4. Remove cap screws (A) and hub (B).
A—Bolts (6 used)
B—Hub
–UN–13MAY99
H57175
OUO6083,0000B21 –19–29AUG05–5/19
5. Remove hub (A).
IMPORTANT: Clutch disks and plates must be

installed in the same order as removed.
NOTE: The fiber washers (D) are bonded to the hub. If

–UN–13MAY99
the washers are loose, then replace hub.
NOTE: 9660 STS has three clutch disks and clutch

plates, and four spring washers.
H51695
6. Remove clutch disks (B) and clutch plates (C).
7. Inspect parts for wear or damage. Replace parts as A—Hub

necessary. B—Clutch Disks (4 used)
C—Clutch Plates (4 used)
D—Fiber Washer (2 used)

083006
PN=1512
8. Remove snap ring (A). Turn hub over to remove shaft

(B) and centering washer (C).
A—Snap Ring
B—Shaft
C—Centering Washer
–UN–03MAY99
140
H51696
05
39
–UN–29MAR99
H55034
–UN–14MAY99
H57182

083006
PN=1513
10. Press clutch drum (B) out of housing (C).
A—Snap Ring
B—Drum
–UN–14MAY99
C—Housing
H57185
140
05
40
–UN–14MAY99
H57186
OUO6083,0000B21 –19–29AUG05–8/19
11. Inspect seal rings (A) and thrust washer (B) for nicks,
cracks or broken pieces. Replace damage or worn
parts as necessary.
A—Seal Rings
B—Thrust Washer
–UN–12DEC88
H40151
OUO6083,0000B21 –19–29AUG05–9/19
12. Install JDT24A Spring Washer Compressor (A).

Tighten compressor just enough to remove snap ring
(B) and retainer (C). Slowly release compressor and
remove spring washers.
A—JDT24A Spring Washer Compressor

–UN–03JUN02
B—Snap Ring
C—Retainer
H72394

083006
PN=1514
13. Apply compressed air to hole (A) located over boss

(C) to release piston (B).
NOTE: JDG185 Air Test Plug can be used to release

clutch piston from housing.
–UN–03JUN99
A—Air Hole
B—Piston
C—Boss
H57293
OUO6083,0000B21 –19–29AUG05–11/19
140
05
14. Remove seals (A) and (B). 41
15. Inspect parts for wear or damage. Replace parts as

necessary.
16. Coat parts with clean hydraulic oil.
17. Install seals (A) and (B).
18. Install piston.
A—Outer Seal
B—Inner Seal
C—Piston
D—Clutch Drum
E—Spring Washer (5 used)
–UN–03JUN99
F—Retainer
G—Snap Ring
H57300
OUO6083,0000B21 –19–29AUG05–12/19
19. Use JDT24A Spring Washer Compressor and install

retainer (C) and snap ring (B).
A—JDT24A Spring Washer Compressor

B—Snap Ring
C—Retainer
–UN–03JUN02
H72394

083006
PN=1515
20. Install thrust washer (B) and seal rings (A).
A—Seal Rings
B—Thrust Washer
–UN–12DEC88
H40151
OUO6083,0000B21 –19–29AUG05–14/19
140
05
42 21. Install clutch drum in housing. Install bearing and
snap ring (A).
A—Snap Ring
–UN–14MAY99
H57185

083006
PN=1516
22. Install centering washer (C) on shaft (B). Turn hub

over and install shaft and snap ring (A).
A—Snap Ring
B—Shaft
C—Centering Washer
–UN–03MAY99
140
H51696
05
43
–UN–29MAR99
H55034
–UN–14MAY99
H57182

083006
PN=1517
IMPORTANT: Clutch disks and plates must be

installed in the same order as removed.
23. Install clutch disk (B) and plates (C).
NOTE: Rotate hub to align with disk.
–UN–24JUN99
24. Install hub (A).
A—Hub
H58495
B—Clutch Disks (4 used)
C—Clutch Plates (4 used)
140
05
44
OUO6083,0000B21 –19–29AUG05–17/19
25. Install hub (B) and cap screws (A). Tighten cap
Specification
Clutch Hub Cap Screws—Torque ................................................. 75 N•m
(55 lb-ft)
–UN–13MAY99
26. Install clutch in gear case. Tighten cap screws to
specification.
Specification
H57175
Clutch-to-Gear Case Cap
Screws—Torque ............................................................................. 50 N•m
(40 lb-ft)
A—Bolts (6 used)
B—Hub

083006
PN=1518
27. Install JDG10028 Combine Main Engine PTO Gear

caseSeal Installer on shaft.
28. Install seal (B) in seal plate.
IMPORTANT: DO NOT use grease or lubricate seal lip

to install seal plate. Assemble seal plate
–UN–27JUL05
with seal lip dry.
29. Install gasket (C) and seal plate over JDG10028 seal
H84143
installer and tighten cap screws (D) to specification.
Specification
Seal Plate Cap Screws—Torque ................................................... 15 N•m 140
(144 lb-in.) 05
45
A—JDG10028 Combine Main Engine PTO Gear case

Seal Installer
B—Seal
C—Gasket
–UN–27JUL05
H84144
–UN–27JUL05
H84145
OUO6083,0000B21 –19–29AUG05–19/19

083006
PN=1519
Disassemble and Assemble Hydrostatic Gear Set
140
05
46
–UN–03JUN02
A
H72385
B
A—Cap Screw (6 used) B—Gear
1. Remove separator drive wet clutch. (See procedure 5. Replace parts as necessary.
in this group.)
NOTE: Only when installing new gears or bearing,
2. Remove six cap screws (A). Remove housing and shim and adjust them in the following order:
shims.
• Set gear position to mating gear with shims.
3. Remove gear assembly (B). • Preload primary bearings with shims.
• Preload second (mating gear) bearings with
4. Inspect gear teeth for wear and bearings for adjusting nut.
roughness. • Set gear backlash with shims.
IMPORTANT: Gears are available only as a

matched set. Replace as a matched
set.
OUO6083,00002BD –19–31MAY02–1/1

083006
PN=1520
Set Gear Position

C
Adjust setting with shims (A). Use metric dimension on

gear (B), gear tube (C) and housing (D) to determine shim
pack. Shims available are:
• 0.08 mm (0.003 in.)

• 0.13 mm (0.005 in.)
• 0.25 mm (0.010 in.)
• 0.50 mm (0.020 in.)
–UN–30MAY02
Never use more than one plastic shim in a shim pack.
A
Example: 140
B 05
47
H72335
Dimension on housing 109.50 mm (4.31 in.)
Plus dimension on gear 80.00 mm (3.15 in.)
Result 189.50 mm (7.46 in.)
Minus gear tube dimension 166.00 mm (6.54 in.) A
Result 23.50 mm (0.93 in.)
Minus bearing width (same 22.15 mm (0.87 in.)
always)
Required shim pack 1.35 mm (0.053 in.)
NOTE: Convert mm (metric) to inches by dividing by 25.4.
NOTE: If dimension is not stamped on housing, use

109.50 mm (4.31 in.) to determine shim pack. If
dimension is not stamped on gear, use 80.00 mm
(3.15 in.) to determine shim pack. If dimension is
not stamped on gear tube, use 166.00 mm (6.54
in.) to determine shim pack.
DE18569 Separator Gear Set Information (Engine Gear
–UN–08JAN02
Case)
On the heel of the 37 tooth gear is a dimension within a

range of 72.5 +/- 0.25 mm. Subtract from this number the
H70532
dimension stamped on the gear case housing, and
subtract the bearing width of 24.12 mm. The resulting
number is the thickness of shim pack for the bearing race.
A—Shims
B—Gear
C—Gear Tube
D—Housing
–UN–03JUN02
H72396
Continued on next page OUO6083,00002C0 –19–04JUN02–1/2

083006
PN=1521
On the heel of the 56 tooth gear is a number for the

average backlash. Use a shim that gives a backlash at
least as much as the etched number, to 0.1 mm above
the etched number. DO NOT use a backlash less than the
etched number. If the etched number is not on the gear
then use a backlash of 0.15—0.25 mm.
NOTE: Other markings on the gear set are identifications

to insure a matched set is maintained during
production.
DE19182 Hydrostatic Gear Set Information (Engine

Gear Case)
140
05
48
On the heel of the 34 tooth gear is a dimension within a
range of 80.0 +/- 0.25 mm. Add the dimension stamped
on the gear case housing to the dimension on the 34
tooth gear, and subtract the dimension on the side of the
tube that is within a range of 166.0 +/- 0.26 mm. Subtract
the bearing width of 22.15 mm. The resulting number is
the thickness of shim pack for the bearing race.
On the end of the 23 tooth gear (end opposite the gear

teeth) is a number for the average backlash. Use a shim
that gives a backlash at least as much as the etched
number, to 0.1 mm above the etched number. DO NOT
use a backlash less than the etched number. If the etched
number is not on the gear then use a backlash of 0.15—
0.25 mm.
NOTE: Other markings on the gear set are identifications

to insure a matched set is maintained during
production.
OUO6083,00002C0 –19–04JUN02–2/2

083006
PN=1522
Preload Bearings
1. Install enough shims between bearing housing and

gear case to provide end play.
Shims available are:
–UN–08NOV89
• 0.08 mm (0.003 in.)
• 0.13 mm (0.005 in.)
• 0.25 mm (0.010 in.)
•
H41404
0.50 mm (0.020 in.)
2. Tighten cap screws to 50 N•m (40 lb-ft) before

checking end play with a dial indicator. Total thickness 140
05
of shims to be removed is end play measurement plus 49
0.03 to 0.13 mm (0.001 to 0.005 in.) to obtain desired
preload.
Example:
–UN–19MAY99
End play Measurement 0.17 mm (0.007 in.)
Desired Preload 0.08 mm (0.003 in.)
Shim Size to Remove 0.25 mm (0.010 in.)
H57347
3. Install remaining shims on pilot diameter of bearing
housing. Tighten cap screws to specification.
Engine Gear Case Wet Clutch—Specification

Clutch-to-Gear Case Cap
Screws—Torque ............................................................................. 50 N•m
(40 lb-ft)
AG,OUO6022,371 –19–25JUL00–1/1

083006
PN=1523
Disassemble and Assemble Straw Chopper/Unloading System
140
05
50
–UN–16JUN99
H57349

083006
PN=1524
1—Bearing Cone 10—Trough 19—Bearing 28—Cap Screw (6 used)

2—Bearing Cup 11—Lock Nut (2 used) 20—Sheave 29—Cap Screw (2 used)
3—Shim (as required) 12—Gear 21—Lubrication Fitting 30—Shaft
4—Snap Ring 13—Key 22—Nut (2 used) 31—Key
5—Shaft 14—Bearing Cone 23—Hub 32—Flange
6—Bushing 15—Bearing Cup 24—Seal 33—Cap Screw (4 used)
7—Case 16—Seal 25—Housing 34—Sheave
8—Cap Screw (8 used) 17—O-Ring 26—O-Ring 35—Washer
9—Cover 18—Shim (as required) 27—Plug 36—Nut
NOTE: It is not necessary to remove gear case. 1. Remove three belts on end of gear case.
OUO6083,00002C1 –19–04JUN02–2/7
140
05
2. Remove nut (A) and washer (B). 51
A—Nylon Nut
B—Washer
–UN–27MAY99
H57517
OUO6083,00002C1 –19–04JUN02–3/7
3. Remove sheave (A) using puller (B). Remove key.
A—Sheave
B—Puller
–UN–19MAY99
H57350
OUO6083,00002C1 –19–04JUN02–4/7
4. Remove four cap screws (A).
5. Remove sheave (B) and flange (D).
6. Remove shaft (C) with bearing.

–UN–19MAY99

B—Sheave
C—Shaft
D—Flange
H57353

083006
PN=1525
7. Inspect bearing for damage. If replacement is

necessary, press off bearing and press on new
bearing.
–UN–02JUN99
H57815
140
05
52

083006
PN=1526
8. Remove two cap screws (B).
9. Remove hub (C) to replace seal (A).
10. Remove six cap screws (D).
–UN–21MAY99
11. Remove bearing housing (E) with seal, shim pack and
O-ring assembly.
12. Remove gear shaft with bearing.
H57383
13. Inspect gear teeth for wear and bearings for
roughness.
140
05
IMPORTANT: Gears are available only as a matched 53
set. Replace as a matched set.
–UN–21MAY99
NOTE: Only when assembling new gears or bearings,
shim and adjust them in the following order:
• Set gear position to mating gear with shims.

• Preload primary bearings with shims.
H57384
• Preload second (mating gear) bearings with
adjusting nut.
• Set gear backlash with shims. A—Seal
C—Hub
When replacing seal (A), make certain to tape D—Cap Screw (6 used)
gear keyway to prevent damage to seal. E—Housing
15. Install chopper drive sheave. Tighten cap screws to

specification.
Specification
Straw Chopper Drive Sheave Cap
Screws—Torque ............................................................................. 90 N•m
(65 lb-ft)
16. Install unloader sheave and new nylon nut on shaft.

Specification
Unloader Shaft Nut—Torque ........................................................ 340 N•m
(250 lb-ft)
OUO6083,00002C1 –19–04JUN02–7/7

083006
PN=1527
Set Separator Gear Position
–UN–02JUN99
140
05
54
H57426
Adjust setting with shims (A). Use metric dimensions on
gear (B) and housing (C) to determine shim pack. Shims
available are:
• 0.08 mm (0.003 in.)

• 0.13 mm (0.005 in.)
B
• 0.25 mm (0.010 in.)
• 0.50 mm (0.020 in.)
Never use more than one plastic shim in a shim pack.
Example:
Dimension on gear 72.31 mm

Minus dimension on housing 46.76 mm
–UN–11APR02
Result 25.55 mm
Minus bearing width (always the 24.12 mm
same)
Required shim pack: 1.43 mm (0.056 in.) A
H71543
NOTE: Convert mm (metric) to inches by dividing by 25.4. C
NOTE: If dimension is not stamped on housing, use

47.00 mm to determine shim pack. If dimension is
not stamped on gear, use 72.50 mm to determine
shim pack.
A—Shims
B—Gear
–UN–04APR02
C—Housing
H71544
OUO6083,000025F –19–04APR02–1/1

083006
PN=1528
Preload Bearings
140
05
55
–UN–28MAY99
H57427
1. Install enough shims (A) between bearing housing (B)
and gear case to provide end play.
• 0.08 mm (0.003 in.)

•
–UN–21MAY99
0.13 mm (0.005 in.)
• 0.25 mm (0.010 in.)
• 0.50 mm (0.020 in.)
H57396
2. Tighten cap screws (C) to specification before checking
end play with a dial indicator.
Specification A—Shim
Bearing Housing-to-Gear Case B—Bearing Housing
Cap Screws—Torque .................................................................... 50 N•m C—Cap Screw
(40 lb-ft)
Total thickness of shims to be removed is end play

measurement plus 0.03 to 0.13 mm (0.001 to 0.005 in.) to
obtain desired preload.
Example:
Endplay Measurement 0.17 mm (0.007 in.)

Desired Preload 0.08 mm (0.003 in.)
Shim Size to Remove 0.25 mm (0.010 in.)

083006
PN=1529
3. Install remaining shims (A) and O-ring (D) on pilot

diameter of bearing housing. Tighten cap screws to
specification.
Specification
Bearing Housing-to-Gear Case
Cap Screws—Torque .................................................................... 50 N•m
(40 lb-ft)
AG,OUO6022,374 –19–25JUL00–2/2
140
05
56 Disassemble and Assemble Separator Drive
C
B
A
J E
K
B
J C
I D
F
H
–UN–08JAN02
G
H70533
A—Gear D—O-Ring (2 used) G—Cap Screw, M10 x 35 (7 I—Keyed Washer

B—Bearing Cone (2 used) E—Shim (as required) used) J—Lock Nut (2 used)
C—Bearing Cup (2 used) F—Housing H—Gear K—Lock Washer
NOTE: The gear case does not have to be removed 1. Remove transfer case. (See REMOVE AND
from the combine to service separator drive. INSTALL TRANSFER GEAR CASE in this group.)

083006
PN=1530
CAUTION: Approximate weight of separator

drive is 28 kg (62 lb).
Specification
Separator Drive—Weight................................................................... 28 kg
(62 lb)
–UN–21MAY99
2. Remove cap screws (A) and bearing housing (B).
H57429
B—Housing
140
05
57

083006
PN=1531
3. Pry out tangs (A) on lock washer.
4. Remove lock nut (B) using JDG666 Spanner Wrench.
5. Remove lock washer, lock nut, keyed washer and gear

(C).
–UN–21MAY99
6. Remove gear (D) from housing (E).
7. Inspect housing, O-rings, bearing cups, bearings and
H57433
gear. Replace parts as necessary.
8. Install gear (D) in housing.

140
05
58
9. Install gear (C). Set preload on separator drive
bearings. (See PRELOAD SEPARATOR DRIVE
BEARINGS in this group.)
10. Install separator drive in gear case. Tighten cap
–UN–21MAY99
Specification
Separator Drive-to-Gear Case
Cap Screws—Torque ............................................................. 50 ± 10 N•m
H57448
(37 ± 7 lb-ft)

B—Housing
C—Gear
D—Gear
E—Housing
–UN–21MAY99
H57449
OUO6083,0000230 –19–12MAR02–3/3

083006
PN=1532
Preload Separator Drive Bearings
1. Assemble keyed washer over hub of spiral bevel gear

and next to gear.
2. Screw inner lock nut (A) onto spiral bevel gear hub
–UN–21MAY99
with chamfered side against keyed washer. Use
JDG666 Spanner Wrench and tighten lock nut to
specification for bearing end play (B).
H57503
Specification
Separator Drive—End Play ............................................ 0.33 to 0.43 mm
(0.010 to 0.020 in.)
140
05
3. Rap each end of gear lightly with soft hammer and 59
rotate gear at least five revolutions before taking end
play or rolling torque measurements. Tighten nut 90
degrees (1/4 turn).
–UN–27MAY99
4. Assemble lock washer over hub of spiral bevel gear
with concave side outward. If no washer tab aligns with
a slot in nut, tighten nut to nearest slot alignment.
H57536
5. Use JDG666 Spanner Wrench and install outer lock
nut (C) with chamfered side against lock washer.
6. With nut snug against washer, bend one tab to washer

into a slot of inner nut. Tighten outer nut to
specification.
Specification
Separator Drive Outer Lock Nut—
–UN–21MAY99
Torque ............................................................................................ 70 N•m
(52 lb-ft)
Rolling torque must not exceed specification.
H57505
Specification
Separator Drive Assembly—
Rolling Drag Torque ..................................................................... 28 N•cm
(40 oz-in.) A—Inner Lock Nut
B—Rolling Drag torque
If rolling torque is too high, remove outer nut and lock

washer and back off inner nut 45 degrees (1/8 turn).
Repeat installation and adjustment.
Final assembly must provide zero end play and less than
28 N•cm (40 oz-in.) rolling torque.

083006
PN=1533
7. Bend one tab of lock washer into slot of outer nut.
AG,OUO6022,376 –19–05AUG05–2/2
Set Separator Drive Gear Backlash
NOTE: Do not use more than one plastic shim.
1. Select shims to provide backlash (dimension on heel of

larger gear +0.1 to -0.0 mm (+0.004 to -0.0 in.) at
140
–UN–27MAY99
05
tightest condition of gear mesh.
60
2. Install shims and O-ring on pilot diameter of bearing
H57537
Specification
Separator Drive-to-Gear Case
(40 lb-ft)
• 0.08 mm (0.003 in.)

• 0.13 mm (0.005 in.)
• 0.25 mm (0.010 in.)
• 0.50 mm (0.020 in.)
AG,OUO6022,377 –19–25JUL00–1/1

083006
PN=1534
Disassemble and Assemble Hydrostatic Pump Drive
140
05
61
M F
E B
C
D
K
L
–UN–08JAN01
J
I
G
G
H65454
H
A—Gear E—O-Ring H—Lock Washer K—Cap Screw (5 used)

B—Bearing Cone F—Oil Cup I—Lock Washer L—Bearing Cup
C—Bearing Cup G—Lock Nut (2 used) J—Bearing Cone M—Housing
D—Shim (as required)
1. Remove hydrostatic pump. (See procedure in this NOTE: It is not necessary to remove gear case to
group.) remove pump drive.
AG,OUO6022,378 –19–12JAN01–1/3
2. Remove five cap screws (A) and remove gear

assembly (B).

B—Gear Assembly
–UN–10MAY99
H57031
Continued on next page AG,OUO6022,378 –19–12JAN01–2/3

083006
PN=1535
3. Remove lock nut using JDG666 spanner wrench.
4. Remove gear from housing.
5. Inspect parts. Repair as necessary.
–UN–19MAY99
H57356
AG,OUO6022,378 –19–12JAN01–3/3
140
05
62

083006
PN=1536
Preload Hydrostatic Pump Drive Bearings
1. Assemble keyed washer over hub of spiral bevel gear

and next to bearing cone.
2. Screw lock nut using JDG666 Spanner Wrench onto

spiral bevel gear hub with chamfered side against
keyed washer. Tighten nut to specification to provide
end play in bearing.
Specification
Hydrostatic Pump Drive Gear—
End Play ......................................................................... 0.33 to 0.43 mm
(0.010 to 0.020 in.)
140
05
63
3. Rap each end of gear lightly with soft hammer and
rotate gear at least five revolutions before taking end
play or rolling torque measurements. Tighten nut 90
degrees (1/4 turn).
4. Assemble lock washer over hub of spiral bevel gear

with concave side outward. If no washer tab aligns with
a slot in nut, tighten nut to nearest slot alignment.
5. Install lock nut using JDG666 Spanner Wrench with

chamfered side against lock washer.
6. With nut snug against washer, bend one tab of washer

into a slot of inner nut. Tighten outer nut to
specification.
Specification
Hydrostatic Pump Drive Outer
Nut—Torque ................................................................................... 70 N•m
(52 lb-ft)
Rolling torque must not exceed specification.
Specification
Hydrostatic Drive Pump—Rolling
Drag Torque ................................................................................. 28 N•cm
(40 oz-in.)
If rolling torque is too high, remove outer nut and lock

washer and back off inner nut 45 degrees (1/8 turn).
Repeat installation and adjustment.
Final assembly must provide zero end play and less than
28 N•cm (40 oz-in.) rolling torque.

083006
PN=1537
7. Bend one tab to lock washer into slot of outer nut.
AG,OUO6022,379 –19–25JUL00–2/2
Set Hydrostatic Pump Drive Gear Backlash
NOTE: Do not use more than one plastic shim.
1. Select shims to provide backlash (dimension on end of

smaller gear to +0.1 to -0.0 mm (+0.004 to -0.0 in.) at
140
–UN–27MAY99
05
tightest condition of gear mesh.
64
2. Install shims and O-ring on pilot diameter of bearing
H57543
Specification
Hydrostatic Pump Drive-to-Gear
Case Cap Screws—Torque........................................................... 50 N•m
(40 lb-ft)
• 0.08 mm (0.003 in.)

• 0.13 mm (0.005 in.)
• 0.25 mm (0.010 in.)
• 0.50 mm (0.020 in.)
AG,OUO6022,380 –19–25JUL00–1/1

083006
PN=1538
Disassemble and Assemble Oil Screen
NOTE: Whenever gears, shafts, or bearings have been

replaced, clean oil screen.
1. Remove cover (A) with gasket.
–UN–10MAY99
2. Clean oil screen (B).
3. Thoroughly clean sump area (C).
H56076
4. Install oil screen. Be sure closed end of screen fits in
recess on opposite side. Pilot (D) must be DOWN to
position screen low in sump. Tighten cover bolts to A—Cover 140
B—Oil Screen 05
specification. 65
C—Reservoir
D—Pilot
Specification
Engine Gear Case Oil Screen
Cover Cap Screws—Torque ......................................................... 25 N•m
(216 lb-in.)
AG,OUO6022,381 –19–25JUL00–1/1
Disassemble and Assemble Oil Trough
1. Remove oil trough (A) with cover (B).
IMPORTANT: Correct lock nuts must be used on cap

screws (C). Standard nuts may come
–UN–10MAY99
loose, fall into gear case and cause
damage.
IMPORTANT: Be certain trough is attached to cover
H56041
as shown or oil will not be delivered to
bearings.
2. Replace if damaged. A—Oil Trough

B—Surface
C—Cover
3. Apply a thin bead of sealant all around surface (D). D—Surface
4. Install oil trough. Tighten cap screws to specification.
Specification
Oil Trough Cover Cap Screws—
Torque ...................................................................................... 25 ± 5 N•m
(221 ± 44 lb-in.)
AG,OUO6022,298 –19–05AUG05–1/1

083006
PN=1539
Disassemble and Assemble Dipstick Tube
NOTE: Remove dipstick tube only if damaged.
1. Remove dipstick tube (A). Tube is a tight fit.
–UN–10MAY99
2. Apply a coat of thread lock and sealer in bore (B).
3. Drive in tube until it seats.
H57024
A—Dipstick Tube
B—Bore
140
05
66
AG,OUO6022,297 –19–05AUG05–1/1
Remove and Install Filter
1. Turn filter (A) counter clockwise and remove.
2. Install filter (A).
–UN–04FEB02
3. Fill gear case with SAE 10W oil. Fill to capacity.
Specification
(22.5 qt)
H68195
4. Check oil level after engaging drives.
A—Filter
OUO6083,0000075 –19–21MAY01–1/1

083006
PN=1540
Remove and Install Pressure Regulating

Valve

–UN–23AUG88
X9811
fluids.
If an accident occurs, see a doctor immediately. 140

Any fluid injected into the skin must be 05
–UN–25JUN99

H56026
accumulator. Remove key.
2. Disconnect lines (A—F).
3. Disconnect wires leads (G—J).
4. Remove cap screws (K) and remove valve.
–UN–25JUN99
5. Inspect for wear or damage. Replace as necessary.
NOTE: Do not use sealer on gasket.
H56027
6. Install valve. Tighten cap screws to specification.
Specification
Pressure Regulating Valve Cap A—Hydraulic Hose
Screws—Torque ............................................................................ 25 N•m B—Hydraulic Hose
(216 lb-in.) C—Hydraulic Hose
D—Hydraulic Hose
7. Connect wires (G—J). E—Hydraulic Hose
F—Hydraulic Hose
G—Connector
8. Connect lines (A—F). H—Connector
I—Connector
J—Connector
K—Cap Screws (7 used)
AG,OUO6022,294 –19–25JUL00–1/1

083006
PN=1541
Disassemble and Assemble Pressure Regulating Valve
140
05
68
–UN–29JUN99
H56037

083006
PN=1542
1—Plug 10—O-Ring 19—Valve Housing 27—Spring

2—O-Ring 11—Test Gauge Fitting 20—Gasket 28—Solenoid (2 used)
3—Spring 12—Dust Cap 21—Cap Screw (4 used) 29—O-Ring
4—O-Ring 13—Plug 22—Cover 30—Adapter
5—Valve (3 used) 14—Adapter 23—Gasket 31—Adapter
6—Spring 15—Oil Pressure Sender 24—Accumulator Piston 32—Spring
7—Plug 16—O-Ring 25—Washer 33—Shim
8—Cap Screw (7 used) 17—O-Ring 26—Spring 34—Fitting
9—Wet Clutch Oil Temperature 18—Tee
Sender
1. Refer to the exploded view for disassembly and 4. Insert cross drilled holes on valves (5) into housing
assembly. first.
2. Wash parts in solvent and dry thoroughly. 5. Replace same quantity of shims (33) that were 140
removed. They are pre-set at the factory. However, 05
3. Remove small nicks and burrs with emery cloth. if valve housing (19) is replaced, install original 69
Replace parts as needed. Repair kits are not shims and check regulated pressure. Add shims as
available. necessary. Each shim will increase the pressure by
approximately 10 psi.
NOTE: O-rings are used on all spools except spool in
port “R”. Do not use an O-ring on spool in port 6. Temperature sender (9) goes into port “TI”.
“R”. Pressure sender (15) goes into port “PI”.

083006
PN=1543
140
05
70
–UN–24JUN99
H57022
A—Separator Solenoid B—Unloading System
Solenoid
7. The two solenoids are identical; (A) engages the 8. Do not use a sealer on gaskets (20) and (23).
separator and (B) engages the unloading system. Tighten the seven cap screws to specification.
Refer to the exploded view for repair. Tighten large
hex when installing solenoid cartridge to Specification
specification. Pressure Regulating Valve Cap
Screws—Torque ...................................................................... 25 N•m
(216 lb-in.)
Specification
Pressure Regulating Valve
Solenoid Cartridge—Torque .................................................... 25 N•m
(216 lb-in.)

083006
PN=1544
L M
J
N
I
140
G H 05
71
E
D
C
–UN–22JAN01
B
A
H65821
Valve Solenoid
A—Back-up Ring E—Snap Ring I—Plunger L—guide

B—O-Ring F—Spool J—Spring M—Nut
C—Back-up Ring G—Spring Pin K—O-Ring N—Coil
D—O-Ring H—O-Ring
OUO6083,00005C3 –19–14MAY03–4/4

083006
PN=1545
140
05
72

083006
PN=1546
Section 199
Dealer Fabricated Tools
Contents
Page
Group 05—Dealer Fabricated Tools

DFRW20—Compressor Holding Fixture . . . . .199-05-1
DFHXT1—Split Ring Tool . . . . . . . . . . . . . . . .199-05-1
199

083006
PN=1
Contents
199

083006
PN=2
Group 05
DFRW20—Compressor Holding Fixture
199
05
–UN–20SEP89
1
RW13619
A—102 mm (4 in.) D—6.4 mm (0.25 in.) G—254 mm (10 in.) J—Weld
B—76 mm (3 in.) E—19 mm (0.75 in.) H—114 mm (4.5 in.) K—Two Holes
C—70 mm (2.75 in.) F—152 mm (6 in.) I—178 mm (7 in.)
Material Required: • 4—Matching Lock Washers and Nuts
• 2—Steel Plates (4 x 2.75 in.) and (10 x 6 in.) Tool is used to hold air conditioner compressor during
• 2—Threaded Steel Rods (0.5 x 7 in.) disassembly and assembly.
RX,DFRW20 –19–25JUL00–1/1
DFHXT1—Split Ring Tool
This tool is used to service split ring retainer in cam lobe

motor housing.
Continued on next page OUO1073,0001D3E –19–15JUL04–1/2

083006
PN=1549
B C E
D
H
199 F
05 G
2
–UN–14JUL04
N66626
A—65 ± 2 mm (2.559 ± 0.079 B—65 ± 10 mm (2.559 ± 0.394 E—105 ± 10 mm (4.134 ± 0.394 G—53 ± 2 mm (2.087 ± 0.079
in.) in.)1 in.) in.)
C—96 ± 1 mm (3.78 ± 0.039 in.) F—33 ± 2 mm (1.299 ± 0.079 H—55 mm (2.165 in.)
D—125 ± 5 mm (4.921 ± 0.197) in.) Maximum2
Material Required: • 125 mm (4.921 in.) RD JDM A0 1045F CD QL-2

Steel
IMPORTANT: Steel must be 1045F CD QL-2 or

harder.
NOTE: OD of tool must be a minimum of 125 mm

(4.921 in), but may be larger.
1
65 mm (2.559 in.) is the MAXIMUM OD allowed to maintain proper
sidewall thickness. OD may be made smaller than 65 mm (2.559
in.). Diameter should match press cylinder diameter to aid in
centering tool over bearing.
2
55 mm (2.165 in.) is the MAXIMUM depth of top bore to maintain
proper thickness. Top bore depth may be less than 55 mm (2.165)
but must be a MINIMUM of 5 mm (0.197 in.) deep.
OUO1073,0001D3E –19–15JUL04–2/2

083006
PN=1550
Index
Page Page
A Style B . . . . . . . . . . . . . . . . . . . . . . . . .90-10-7
Recirculator motor
Abrasive contamination Remove and install . . . . . . . . . . . . . . . . .90-10-7
Hydrostatic system . . . . . . . . . . . . . . . . . .50-15-18 Service equipment and tools . . . . . . . . . . . .90-05-3
Accumulator Service parts kits . . . . . . . . . . . . . . . . . . . .90-05-6
Checking header float system . . . . . . . . . . .70-30-2 Specifications . . . . . . . . . . . . . . . . . . . . . . .90-05-5
Essential or recommended tools . . . . . . . . .70-30-1 System information . . . . . . . . . . . . . . . . . .90-05-22
General information. . . . . . . . . . . . . . . . . . .70-30-1 Test shaft seal leakage . . . . . . . . . . . . . . .90-05-15
Repair shut-off Valve Test volumetric efficiency . . . . . . . . . . . . .90-05-10
Remove and install . . . . . . . . . . . . . . . .70-15-12 Air conditioning system (R134a)
Accumulator shut-off valve Essential or recommended tools . . . . . . . . .90-05-1
Remove and install . . . . . . . . . . . . . . . . . .70-15-12 Air conditioning system with precleaner
Actuator General information. . . . . . . . . . . . . . . . . . .90-10-3
Fan speed Air conditioning systems
Adjust . . . . . . . . . . . . . . . . . . . . . . . . .120-20-23 Temperature control door actuator
Folding auger Remove and install . . . . . . . . . . . . . . . . .90-10-9
Remove and install . . . . . . . . . . . . . . .130-20-17 Air cooler
Adhesives and sealants . . . . . . . . . . . . . . . .10-10-28 Remove and install
AHC pump 12.5 L . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-16
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-9 8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-11
Disassemble . . . . . . . . . . . . . . . . . . . . . . . .70-10-5 Air filter
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-10 Restriction switch
Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-5 Remove and install . . . . . . . . . . . . . . . .40-35-22
Indx
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-4 Air intake system 1
Air conditioning system Other materials . . . . . . . . . . . . . . . . . . . . . .30-05-1
Blower motor Remove and install turbocharger
Remove and install 12.5 L . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-9
Style A . . . . . . . . . . . . . . . . . . . . . . . . .90-10-5 8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-4
Style B . . . . . . . . . . . . . . . . . . . . . . . . .90-10-6 Specifications . . . . . . . . . . . . . . . . . . . . . . .30-05-2
Charge . . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-32 Turbocharger repair . . . . . . . . . . . . . . . . .30-05-10
Check refrigerant oil charge . . . . . . . . . . .90-05-31 Air temperature sensors
Clutch hub clearance, check . . . . . . . . . . .90-05-17 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-23
Compressor clutch, disassemble and Alternator
assemble . . . . . . . . . . . . . . . . . . . . . . . .90-05-16 Pulley
Compressor holding fixture Remove and install . . . . . . . . . . . . . . . . .40-45-8
DFRW20 air conditioning system. . . . . .199-05-1 Remove and install . . . . . . . . . . . . . . . . . . .40-45-3
Compressor manifold, inspect . . . . . . . . . .90-05-17 Specification . . . . . . . . . . . . . . . . . . . . . . . .40-45-2
Compressor oil information . . . . . . . . . . . .90-05-29 Alternator belt
Compressor relief valve, remove and Remove and installl. . . . . . . . . . . . . . . . . . .40-45-3
install. . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-20 Alternator repair
Compressor, disassemble, inspect and Engine accessories . . . . . . . . . . . . . . . . . . .40-45-2
assemble . . . . . . . . . . . . . . . . . . . . . . . .90-05-18 Antenna
Compressor, remove and install . . . . . . . . .90-05-8 Remove and install . . . . . . . . . . . . . . . . . . .40-30-9
Correct oil charge . . . . . . . . . . . . . . . . . . .90-05-30 Armrest control pivot
Discharge/recover refrigerant . . . . . . . . . . .90-05-7 Disassemble and assemble . . . . . . . . . . .90-15-40
Evacuate. . . . . . . . . . . . . . . . . . . . . . . . . .90-05-27 Armrest control pivot -style A
Flush. . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-24 Remove and install . . . . . . . . . . . . . . . . . .90-15-37
Hose and tubing connection torques . . . . . .90-05-6 Armrest control pivot -style B . . . . . . . . . . . .90-15-39
Other material . . . . . . . . . . . . . . . . . . . . . . .90-05-4 Auger
Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-26 Clean grain loading
Recirculator fan motor driver Remove and install . . . . . . . . . . . . . . .130-25-18
Remove and install Folding auger rings
Style A . . . . . . . . . . . . . . . . . . . . . . . . .90-10-6 Remove and install . . . . . . . . . . . . . . .130-20-18
TM2181 (29AUG06) Index-1 60 Series STS Combine Repair

083006
PN=1
Index
Page Page
Folding horizontal auger Switch

Exploded view . . . . . . . . . . . . . . . . . . .130-20-14 Remove and install . . . . . . . . . . . . . . . .40-35-29
Folding horizontal auger pivot 9560, 9660, 9760 (S.N. 715301-) . . . . . . .40-35-32
Exploded view . . . . . . . . . . . . . . . . . . .130-20-16 9860 (S.N. 715301-) . . . . . . . . . . . . . . . . .40-35-31
Front horizontal unloading Basic electrical component handling
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-22 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-40
Front Horizontal unloading Batteries
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-19 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . .40-05-9
Front horizontal unloading Connecting booster batteries. . . . . . . . . . . .40-05-8
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-20 Connecting cables . . . . . . . . . . . . . . . . . .40-05-11
Horizontal unloading Electrical system safety. . . . . . . . . . . . . . . .40-05-3
Elbow Electrolyte specific gravity
Install . . . . . . . . . . . . . . . . . . . . . . . .130-20-36 Check . . . . . . . . . . . . . . . . . . . . . . . . . . .40-05-4
Remove . . . . . . . . . . . . . . . . . . . . . .130-20-34 Prevent battery explosions . . . . . . . . . . . . .40-05-1
Gear case Remove and install . . . . . . . . . . . . . . . . . . .40-05-6
Install . . . . . . . . . . . . . . . . . . . . . . . .130-20-28 Battery
Remove . . . . . . . . . . . . . . . . . . . . . .130-20-24 Replacement. . . . . . . . . . . . . . . . . . . . . . . .40-05-5
High unload rate . . . . . . . . . . . . . . . . . .130-20-6 Bearing
Install. . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-8 Primary countershaft
Regular unload rate . . . . . . . . . . . . . . . .130-20-5 Remove and install . . . . . . . . . . . . . . . .120-10-9
Remove. . . . . . . . . . . . . . . . . . . . . . . . .130-20-7 STS Rotor
Tube Remove and install . . . . . . . . . . . . . . .120-05-27
Install . . . . . . . . . . . . . . . . . . . . . . . .130-20-30 Bearing and race
Indx
2 Remove . . . . . . . . . . . . . . . . . . . . . .130-20-29 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-29
Outer folding auger assembly Bearing plate
Remove and install . . . . . . . . . . . . . . .130-20-17 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-24
Rear horizontal folding Bearings
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-23 Hydrostatic gear set, preload . . . . . . . . .140-05-49
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-19 Belt
Auger drive countershaft Unloading auger drive
Install . . . . . . . . . . . . . . . . . . . .130-10-2, 130-10-4 Remove and install . . . . . . . . . . . . . . . .130-10-1
Remove . . . . . . . . . . . . . . . . . .130-10-2, 130-10-4 Belt replacement
Auger swing valve module . . . . . . . . . . . . . . .70-16-9 Clean grain elevator
Automatic combine adjustment display Remove. . . . . . . . . . . . . . . . . . . . . . . . .130-25-2
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-15 Clean grain elvator
Auxiliary cab main AUTOTRAC wiring Install. . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-7
harness. . . . . . . . . . . . . . . . . . . . .40-15-4, 40-15-5 Belts
Auxiliary field lights Adjusting
Bulb part numbers . . . . . . . . . . . . . . . . . . .40-25-2 Feeder house variable speed . . . . . . .110-15-73
Axle bearings and seals Blade inserts
Remove and install . . . . . . . . . .50-20-42, 50-20-54 Cleaning fan
Axle extension tubes Remove and install . . . . . . . . . . . . . . .120-20-29
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-25-12 Blower motor
Remove and install
Style A. . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-5
Style B. . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-6
Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-15
B Brake fluid reservoir . . . . . . . . . . . . . . . . . . .60-10-13
Brakes
Back ground lights, arm rest lights Assemble . . . . . . . . . . . . . . . . . . . . . . . . .60-10-10
Bulb part numbers . . . . . . . . . . . . . . . . . . .40-25-2 Bleeding (double-bleed screw) . . . . . . . . .60-10-15
Back-up alarm Brake pedals, assemble . . . . . . . . . . . . . .60-10-22
(S.N. -715300) . . . . . . . . . . . . . . . . . . . . .40-35-30 Brake pedals, disassemble . . . . . . . . . . . .60-10-22

083006
PN=2
Index
Page Page
Deglazing linings. . . . . . . . . . . . . . . . . . . . .60-10-3 Operator’s seat

Drum installation . . . . . . . . . . . . . . . . . . . .60-10-11 Remove and install . . . . . . . . . . . . . . . .90-15-33
Drum removal . . . . . . . . . . . . . . . . . . . . . . .60-10-3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-10
Fluid reservoir . . . . . . . . . . . . . . . . . . . . . .60-10-13 Cab door
Master cylinder installation . . . . . . . . . . . .60-10-11 Disassemble and assemble . . . . . . . . . . .90-15-52
Master cylinder removal . . . . . . . . . . . . . .60-10-11 Latch striker
Master cylinder, assemble. . . . . . . . . . . . .60-10-12 Remove and install . . . . . . . . . . . . . . . .90-15-54
Master cylinder, disassemble . . . . . . . . . .60-10-12 Remove and install . . . . . . . . . . . . . . . . . .90-15-51
Other material . . . . . . . . . . . . . . . . . . . . . . .60-10-1 Cab inner roof
Parking pedal, assemble . . . . . . . . . . . . . .60-10-28 Remove and install
Parking pedal, disassemble . . . . . . . . . . .60-10-28 Style B. . . . . . . . . . . . . . . . . . . . . . . . . .90-15-29
Remove brake shoe . . . . . . . . . . . . . . . . . .60-10-5 Cab roof
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-6 Remove and install
Service equipment and tools . . . . . . . . . . . .60-10-1 Style A. . . . . . . . . . . . . . . . . . . . . . . . . .90-15-26
Slave cylinder, assemble . . . . . . . . . . . . .60-10-21 Style B. . . . . . . . . . . . . . . . . . . . . . . . . .90-15-28
Slave cylinder, disassemble . . . . . . . . . . .60-10-21 Cab, and (optional ) side finder lights
Slave cylinder, install . . . . . . . . . . . . . . . .60-10-20 Bulb part number . . . . . . . . . . . . . . . . . . . .40-25-2
Slave cylinder, remove . . . . . . . . . . . . . . .60-10-20 Cam and piston carrier
Specifications . . . . . . . . . . . . . . . . . . . . . . .60-10-2 Remove and install . . . . . . . . . . . . . . . . . .50-20-33
Break-in engine oil . . . . . . . . . . . . . . . . . . . .10-20-10 Cam lobe motor
Bulb Control valve, disassemble and
Cleaning shoe light assemble . . . . . . . . . . . . . . . . . . . . . . . .50-20-14
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-10 Control valve, remove and install . . . . . . .50-20-11 Indx
COMMANDTOUCH cornerpost monitor Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-10 3
Replacement . . . . . . . . . . . . . . . . . . . . .40-25-12 Other materials . . . . . . . . . . . . . . . . . . . . . .50-20-6
Dial-A-Speed Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-9
Active header control Service equipment and tools . . . . . . . . . . . .50-20-4
Remove and install . . . . . . . . . . . . . .40-30-23 Specifications . . . . . . . . . . . . . . . . . . . . . . .50-20-7
Front turn signal Camshaft Position
Tail light Sensor
Replacement . . . . . . . . . . . . . . . . . . . .40-25-9 Remove and install
Hazard/warning light 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-26
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-10 Care and maintenance of belts
Maximum tilt indicator Tune-up and adjustment . . . . . . . . . . . . . . .10-15-2
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-10 Carrier bearing
Part numbers . . . . . . . . . . . . . . . . . . . . . . .40-25-2 Primary drive shaft
Side light Replace . . . . . . . . . . . . . . . . . . . . . . . .120-10-19
Replacement . . . . . . . . . . . . . . . . . . . . . .40-25-9 Cavitation
Turn signal Hydrostatic system . . . . . . . . . . . . . . . . . .50-15-19
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-10 Central control box
Warning display panel Relay location . . . . . . . . . . . . . . . . . . . . . . .40-20-5
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-13 Central Electronics Box (CEB)
Bulkhead Circuit board
Rotor drive Replacement . . . . . . . . . . . . . . . . . . . . . .40-20-3
Alignment . . . . . . . . . . . . . . . . . . . . .120-05-105 Chaffer
Chaffer frame
Remove and install . . . . . . . . . . . . . . .120-20-42
Opening gauge calibration . . . . . . . . . . .120-20-30
With remote shoe . . . . . . . . . . . . . . . .120-20-34
C Remove and install . . . . . . . .120-20-30, 120-20-34
Chain
Cab Clean grain elevator
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-18 Adjustment . . . . . . . . . . . . . . . . . . . . . .130-25-2

083006
PN=3
Index
Page Page
Charge air cooler Drive

Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-21 Install. . . . . . . . . . . . . . . . . . . . . . . . . .120-20-21
Remove and install Remove. . . . . . . . . . . . . . . . . . . . . . . .120-20-17
12.5 L . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-16 Drive jackshaft
6.8 L and 9.0 L . . . . . . . . . . . . . . . . . . .30-05-13 Disassemble and assemble . . . . . . . . .120-20-20
8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-11 Remove and install . . . . . . . . . . . . . . . . .120-20-23
Charge housing Speed control . . . . . . . . . . . . . . . . . . . . .120-20-16
Unloading auger Cleaning fan bearing
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-41 Remove and install . . . . . . . . . . . . . . . . .120-20-10
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-38 Cleaning fan sheave
Charge pump Remove and install . . . . . . . . . . . . . . . . .120-20-10
Remove and install . . . . . . . . . . . . . . . . . .50-15-84 CLIMATRAK
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-86 Switch
Check oil lines and fittings Air conditioning control
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-39 Remove and install . . . . . . . . . . . . . . .40-30-7
Chopper Heater control
Rotor bearing (left-hand) Remove and install . . . . . . . . . . . . . . .40-30-7
Replace . . . . . . . . . . . . . . . . . . . . . . . .120-15-28 Clutch
Rotor bearing (right-hand) Electromagnetic
Replace . . . . . . . . . . . . . . . . . . . . . . . .120-15-32 Header
Chopper raise/lower actuator Exploded view . . . . . . . . . . . . . . . . . .120-35-3
Remove and install . . . . . . . . . . . . . . . . .120-15-10 Header
Circuit board Remove and install . . . . . . . . . . . . . . . .120-35-1
Indx
4
COMMANDTOUCH console Clutch, slip
Remove and install . . . . . . . . . . . . . . . .40-30-28
Conveyor auger
Warning display panel
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-5
Cold weather starting aid
Clean grain auger, lower
Remove and install . . . . . . . . . . . . . . . . . .30-10-15
Remove and install . . . . . . . . . . . . . . . . .130-25-20
Replace can . . . . . . . . . . . . . . . . . . . . . . .30-10-15
Clean grain elevator
COMMANDTOUCH console
Chain
Backlight bulb
Adjustment . . . . . . . . . . . . . . . . . . . . . .130-25-2
Active header control
Gear case . . . . . . . . . . . . . . . . . . . . . . . .130-25-14
Remove and install . . . . . . . . . . . . . .40-30-23
Dial-A-Speed
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-7
Other material . . . . . . . . . . . . . . . . . . . . . .130-25-1 Remove and install . . . . . . . . . . . . . .40-30-23
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-2 Circuit board
Specifications . . . . . . . . . . . . . . . . . . . . . .130-25-1 Remove and install . . . . . . . . . . . . . . . .40-30-28
Top access doors Console controls . . . . . . . . . . . . . . . . . . . .40-30-18
Install. . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-7 Multi-function handle
Remove. . . . . . . . . . . . . . . . . . . . . . . . .130-25-2 Remove and install . . . . . . . . . . . . . . . .40-30-31
Clean grain elevator belt replacement Remove and install . . . . . . . . . . . . . . . . . .40-30-20
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-7 Switches
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-2 ACTIVE HEADER CONTROL
Clean grain loading auger Remove and install . . . . . . . . . . . . . .40-30-22
Bearing DIAL-A-SPEED
Replace . . . . . . . . . . . . . . . . . . . . . . . .130-25-19 Remove and install . . . . . . . . . . . . . .40-30-22
Remove and install . . . . . . . . . . . . . . . . .130-25-18 Composite style panels
Cleaning fan Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-05-5
Actuator Pulled out stud . . . . . . . . . . . . . . . . . . . .80-05-5
Adjust . . . . . . . . . . . . . . . . . . . . . . . . .120-20-23 Ribs cracked . . . . . . . . . . . . . . . . . . . . . .80-05-6
Blade inserts Compressor holding fixture
Remove and install . . . . . . . . . . . . . . .120-20-29 DFRW20 air conditioning system . . . . . . .199-05-1

083006
PN=4
Index
Page Page
Concave Remove and install . . . . . . . . . . . . . . . .110-25-5

Adjusting motor Tilt frame and beam (s.n. --720100) . . . . .110-25-2
Remove and install . . . . . . . . . . . . . . .120-05-88 Tilt frame and beam (s.n. 720101--) . . . . .110-25-4
Adjusting tube CONTOUR MASTER (header tilt) valve
Remove and install . . . . . . . . . . . . . . .120-05-88 module . . . . . . . . . . . . . . . . . . . . . . . . . . .70-16-11
Level Control cable
Adjust . . . . . . . . . . . . . . . . . . . . . . . . .120-05-83 Hydrostatic pump . . . . . . . . . . . . . . . . . . .50-15-87
Remove and install . . . . . . . . . . . . . . . . .120-05-76 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-88
Concave position sensor Controls and instruments
Remove and install . . . . . . . . . . . . . . . . . . .40-35-8 Identification . . . . . . . . . . . . . . . . . . . . . . . .40-30-2
Condenser Conveyor
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-14 Chain
Tier III cooling package . . . . . . . . . . . . .90-10-16 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .110-05-4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-11 Measure chain wear . . . . . . . . . . . . . . .110-05-8
Tier III cooling package . . . . . . . . . . . . .90-10-12 Remove and install . . . . . . . . . . . . . . . .110-05-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-14 Chain link
Connector repair Remove. . . . . . . . . . . . . . . . . . . . . . . . .110-05-8
Other material . . . . . . . . . . . . . . . . . . . . . . .40-10-4 Drive chain tightener and guides
R-A repair procedure . . . . . . . . . . . . . . . . .40-10-7 Disassemble and assemble . . . . . . . . .110-15-72
R-AE repair procedure . . . . . . . . . . . . . . .40-10-40 Drum
R-B repair procedure . . . . . . . . . . . . . . . .40-10-12 Adjust height . . . . . . . . . . . . . . . . . . . .110-05-13
R-C repair procedure . . . . . . . . . . . . . . . .40-10-15 Remove and install . . . . . . . . . . . . . . .110-05-13
R-D repair procedure . . . . . . . . . . . . . . . .40-10-19 Wear plate Indx
R-E repair procedure . . . . . . . . . . . . . . . .40-10-20 Install. . . . . . . . . . . . . . . . . . . . . . . . . .110-05-18 5
R-F repair procedure. . . . . . . . . . . . . . . . .40-10-23 Wear strips
R-G repair procedure . . . . . . . . . . . . . . . .40-10-25 Replace . . . . . . . . . . . . . . . . . . . . . . . .110-05-10
R-I repair procedure . . . . . . . . . . . . . . . . .40-10-27 Conveyor auger
R-J repair procedure . . . . . . . . . . . . . . . . .40-10-28 Drive shaft
R-K repair procedure . . . . . . . . . . . . . . . .40-10-33 Remove and install . . . . . . . . . . . . . . . .120-20-3
R-M repair procedure . . . . . . . . . . . . . . . .40-10-35 Remove and install . . . . . . . . . . . . . . . . . .120-20-6
R-N repair procedure . . . . . . . . . . . . . . . .40-10-37 Slip clutch
Connectors Remove and install . . . . . . . . . . . . . . .120-20-10
Handling and repair. . . . . . . . . . . . . . . . . . .40-10-7 Trough
Console Remove and install . . . . . . . . . . . . . . . .120-20-8
COMMANDTOUCH Conveyor chain slat
Remove and install . . . . . . . . . . . . . . . .40-30-20 Feeder house
Overhead Remove. . . . . . . . . . . . . . . . . . . . . . . . .110-05-9
Remove and install . . . . . . . . . . . . . . . . .40-30-4 Coolant
Console light Additional information . . . . . . . . . . . . . . . . .10-20-8
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .40-25-11 Diesel engine . . . . . . . . . . . . . . . . . . . . . . .10-20-5
Console membrane switch Supplemental additives . . . . . . . . . . . . . . . .10-20-7
Remove and install . . . . . . . . . . . . . . . . . .40-30-24 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-9
CONTOUR MASTER Warm temperature climates . . . . . . . . . . . .10-20-6
Fore/aft tilt frame Coolant temperature
Remove. . . . . . . . . . . . . . . . . . . . . . . .110-25-14 Sensor
Fore/aft turnbuckles Remove and install . . . . . . . .40-35-17, 40-35-19
Adjust . . . . . . . . . . . . . . . . . . . . . . . . .110-25-14 Cooling system
Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . .110-20-2 Install radiator
Remove. . . . . . . . . . . . . . . . . . . . . . . . .110-20-3 12.5 L . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-28
Tilt cylinder fittings . . . . . . . . . . . . . . . . . .110-20-1 8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-18
Tilt cylinder hoses . . . . . . . . . . . . . . . . . . .110-20-1 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-22
Tilt frame John Deere engine repair . . . . . . 20-05-4, 20-10-2,
Install. . . . . . . . . . . . . . . . . . . . . . . . . .110-25-17 30-05-3

083006
PN=5
Index
Page Page
Remove radiator Cylinder block

12.5 L . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-25 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-24
6.8 L . . . . . . . . . . . . . . . . . . .20-10-11, 20-10-14 Cylinder, master
8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-17 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-14
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-20
Replace thermostats . . . . . . . . . . . . . . . . .20-10-31
Rotary screen
Remove and install . . . . . . . . . . . . . . . . .20-10-8 D
Rotary screen drive. . . . . . . . . . . . . . . . . . .20-10-4
Rotary screen knife comb Defective belts
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-11 Tune-up and adjustment . . . . . . . . . . . . . . .10-15-4
Specifications . . . . . . . . . . . . . . . . . . . . . . .20-10-1 Diesel fuel . . . . . . . . . . . . . . . . . . . .10-20-2, 10-20-3
Test radiator . . . . . . . . . . . . . . . . . . . . . . .20-10-30 Diesel fuel system
Test radiator cap. . . . . . . . . . . . . . . . . . . .20-10-31 Fuel tank shut-off valve and drain valve
Water pump Remove and install . . . . . . . . . . . . . . . .30-10-12
Repair or replace. . . . . . . . . . . . . . . . . .20-10-31 Remove and install fuel line regulator . . . . .30-10-9
Cornerpost Remove and install fuel tank . . . . . . . . . . .30-10-10
Remove digital tachometer module . . . . . .40-30-16 Diesel fuel systems
Remove header control module . . . . . . . .40-30-15 Other materials . . . . . . . . . . . . . . . . . . . . . .30-10-1
Remove performance monitor . . . . . . . . . .40-30-16 Specifications . . . . . . . . . . . . . . . . . . . . . . .30-10-1
Cornerpost lights Digital tachometer module
Bulb part numbers . . . . . . . . . . . . . . . . . . .40-25-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-16
Cornerpost main circuit board Dimension reference points . . . . . . . . . . . . .10-10-17
Indx
6 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-11 9560 combine . . . . . . . . . . . . . . . . . . . . . . .10-10-8
9860 STS combine . . . . . . . . . . . . . . . . . .10-10-25
Cover
Dimensions
Separator top
9560 combine . . . . . . . . . . . . . . . . . . . . . . .10-10-7
9660 STS, 9760 STS combines . . . . . . . .10-10-15
Crankshaft Position
9860 STS combine . . . . . . . . . . . . . . . . . .10-10-24
Sensor
Dipstick tube
Remove and install
Disassemble and assemble . . . . . . . . . .140-05-66
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-27
Discharge beater
Crop diverter
Discharge beater grate frame
Cross auger countershaft hub
Install . . . . . . . . . . . . . . . . . . . .130-10-2, 130-10-4 Wings
Remove . . . . . . . . . . . . . . . . . .130-10-2, 130-10-4 Remove and install . . . . . . . . . . . . . . .120-05-65
Cross auger countershaft shear bolt Discharge beater drive hub
Install . . . . . . . . . . . . . . . . . . . .130-10-2, 130-10-4 Remove and install . . . . . . . . . . . . . . . . .120-05-71
Remove . . . . . . . . . . . . . . . . . .130-10-2, 130-10-4 Discharge beater grate
Cross augers Grate section
Install . . . . . . . . . . . . . . . . . . .130-05-4, 130-05-10 Remove and install . . . . . . . . . . . . . . .120-05-59
Remove . . . . . . . . . . . . . . . . . .130-05-1, 130-05-7 Discharge beater housing
Cylinder Remove and install . . . . . . . . . . . . . . . . .120-05-72
Steering Displacement control valve
Disassemble and reassemble . . . . . . . .60-05-31 Remove and install . . . . . . . . . . . . . . . . . .50-20-30
Unloading auger drive Dome and console lights
Remove and install . . . . . . . . . . . . . . . . .70-20-8 Bulb part numbers . . . . . . . . . . . . . . . . . . .40-25-2
Unloading auger swing Dome light
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-7 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .40-25-11
Remove and install . . . . . . . . . . . . . . . . .70-20-5 Drive cylinder
Unloading auger swing cylinder Unloading auger
Exploded view . . . . . . . . . . . . . . . . . . . . .70-20-6 Remove and install . . . . . . . . . . . . . . . . .70-20-8

083006
PN=6
Index
Page Page
Drive pump Cornerpost main circuit board

Reel/belt Replace . . . . . . . . . . . . . . . . . . . . . . .40-30-11
Remove and install . . . . . . . . . . . . . . . .70-10-12 Header and separator engage switch
Drive pump, assemble . . . . . . . . . . . . . . . . .50-15-60 Remove and install . . . . . . . . . . . . . .40-30-21
Drive pump, disassemble . . . . . . . . . . . . . . .50-15-47 Mini harness
Drive shaft Replace . . . . . . . . . . . . . . . . . . . . . . .40-30-30
Carrier bearing Neutral safety switch
Replace . . . . . . . . . . . . . . . . . . . . . . . .120-10-19 Replace . . . . . . . . . . . . . . . . . . . . . . .40-30-29
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-30 Power distribution board
Primary countershaft gear case . . . . . . .120-10-19 Basic description . . . . . . . . . . . . . . . . . . .40-20-3
Remove and install . . . . . . . . . . . . . . .120-10-14 Radio
Remove and install . . . . . . . . . . . . . . . . .120-10-14 Antenna, remove and install . . . . . . . . . .40-30-9
Drive wheel Sensors and switches
Bolt torque CONTOUR MASTER control sensor
Dual wheel . . . . . . . . . . . . . . . . . . . . . .50-25-11 Remove and install . . . . . . . . . . . . . . .40-35-9
Single wheel . . . . . . . . . . . . . . . . . . . . .50-25-10 GREENSTAR mass-flow sensor
Drives Remove and install . . . . . . . . . . . . . . .40-60-2
Powered rear wheel assist Ground speed
Flushing. . . . . . . . . . . . . . . . . . . . . . . . . .50-20-8 Remove and install . . . . . . . . . . . . . . .40-35-5
Straw chopper Position receiver
Jackshaft, remove . . . . . . . . . . . . . . . .120-15-32 Disassemble and assemble . . . . . . . .40-60-24
Dual wheels Remove and install . . . . . . . . . . . . . .40-60-25
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-25-15 Wiper Indx
Dual wheels and truss rod Windshield wiper 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-25-15 Adjust. . . . . . . . . . . . . . . . . . . . . . . . . .40-40-4
Wiper motor
Wiring harness
E Auxiliary cab main AUTOTRAC wiring
harness . . . . . . . . . . . . . . . . .40-15-4, 40-15-5
Elbow Electrolyte specific gravity
Horizontal unloading auger Checking. . . . . . . . . . . . . . . . . . . . . . . . . . .40-05-4
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-36 Electromagnetic clutch
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-34 Header
Unloading auger Exploded view . . . . . . . . . . . . . . . . . . . .120-35-3
Remove and install . . . . . . . . . . . . . . .130-20-32 Electronic displacement control valve
Electrical Neutral adjustment . . . . . . . . . . . . . . . . . .50-15-80
Batteries Electronic governor and speed controller
Prevent damage to electrical systems . . .40-05-3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-55-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .40-05-1 Elevator
Component handling precautions . . . . . . . .40-10-6 Clean grain
Visual inspection . . . . . . . . . . . . . . . . . . . . .40-10-5 Install. . . . . . . . . . . . . . . . . . . . . . . . . . .130-25-7
Electrical system Remove. . . . . . . . . . . . . . . . . . . . . . . . .130-25-2
Batteries Tailings
Changing batteries . . . . . . . . . . . . . . . . .40-05-9 Install. . . . . . . . . . . . . . . . . . . . . . . . . .120-25-19
Circuit board replacement . . . . . . . . . . . . . .40-20-3 Remove. . . . . . . . . . . . . . . . . . . . . . . .120-25-12
Fuses, circuit breakers and relays Engine
Basic operation . . . . . . . . . . . . . . . . . . . .40-20-2 Gear case
Operators station Remove and install . . . . . . . . . . . . . . . .140-05-9
Automatic combine adjustment display Install
Remove . . . . . . . . . . . . . . . . . . . . . . .40-30-15 12.5 L . . . . . . . . . . . . . . . . . . . . . . . . . .20-05-23
COMMANDTOUCH console membrane switches 6.8 L . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-05-8
Remove and install . . . . . . . . . . . . . .40-30-24 8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . .20-05-12

083006
PN=7
Index
Page Page
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . . . .20-05-17 Engine oil pan access sheet

Remove Remove and install . . . . . . . . . . . . . . . . . . .20-15-1
12.5 L . . . . . . . . . . . . . . . . . . . . . . . . . .20-05-19 Engine oil pressure
8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . .20-05-10 Sensor
9.0 L . . . . . . . . . . . . . . . . . . . .20-05-5, 20-05-14 Remove and install . . . . . . . . . . . . . . . .40-35-25
Engine compartment relay panel Switch
Fuse identification . . . . . . . . . . . . . . . . . . . .40-20-7 Remove and install . . . . . . . . . . . . . . . .40-35-24
Relay identification . . . . . . . . . . . . . . . . . . .40-20-8 Essential or recommended tools
Engine gear case Accumulator . . . . . . . . . . . . . . . . . . . . . . . .70-30-1
Chopper/unloading system drive Air conditiong system components . . . . . . .90-10-1
Disassemble and assemble . . . . . . . . .140-05-50 Air conditioning system (R134a) . . . . . . . . .90-05-1
Dipstick tube Engine gear case and valve . . . . . . . . . . .140-05-1
Disassemble and assemble . . . . . . . . .140-05-66 Feeder house drives and reverser gear
General informatiion . . . . . . . . . . . . . . . . .140-05-8 case . . . . . . . . . . . . . . . . . . . . . . . . . . .110-15-1
Hydrostatic gear set Final drives . . . . . . . . . . . . . . . . . . . . . . . . .50-10-1
Disassemble and assemble . . . . . . . . .140-05-46 Harness and connector repair . . . 40-10-1, 40-45-1,
Preload bearings . . . . . . . . . . . . . . . . .140-05-49 40-50-1
Set gear position . . . . . . . . . . . . . . . . .140-05-47 Horizontal unloading auger and gear
Hydrostatic pump drive case . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-1
Disassemble and assemble . . . . . . . . .140-05-61 Hydraulic pump . . . . . . . . . . . . . . . . . . . . . .70-10-1
Preload bearings . . . . . . . . . . . . . . . . .140-05-63 Hydraulic reservoir . . . . . . . . . . . . . . . . . . .70-05-1
Hydrostatic pump drive gear Hydrostatic system . . . . . . . . . . . . . . . . . . .50-15-1
Set backlash . . . . . . . . . . . . . . . . . . . .140-05-64 Primary countershaft gear case . . . . . . . .120-30-1
Indx
8
Oil filter Remove and install engine . . . . . . . . . . . . .20-05-1
Sensors and Switches. . . . . . . . . . . . . . . . .40-35-1
Oil screen
Separator drives . . . . . . . . . . . . . . . . . . . .120-10-1
Disassemble and assemble . . . . . . . . .140-05-65
Separator repair . . . . . . . . . . . . . . . . . . . .120-05-1
Oil trough
Single reduction final drive . . . . . . . . . . . . .50-20-1
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-1
Pressure regulating valve
Tires and wheels. . . . . . . . . . . . . . . . . . . . .50-25-1
Top shaft and slip clutch . . . . . . . . . . . . . .110-10-1
Vertical unloading auger and lower gear
case . . . . . . . . . . . . . . . . . . . . . . . . . . .130-15-1
Separator drive
Evaporator
Preload bearings . . . . . . . . . . . . . . . . .140-05-59 Replace
Set gear backlash . . . . . . . . . . . . . . . .140-05-60 Style A. . . . . . . . . . . . . . . . . . . . . . . . . .90-10-19
Separator drive wet clutch Style B. . . . . . . . . . . . . . . . . . . . . . . . . .90-10-20
Disassemble and assemble . . . . . . . . .140-05-36 Evaporator temperature sensor
Separator gear Remove and install . . . . . . . . . . . . . . . . . .90-10-22
Preload bearings . . . . . . . . . . . . . . . . .140-05-55 Exhaust gas recirculation
Set separator gear position . . . . . . . . . . .140-05-54 Sensors
Specifications . . . . . . . . . . . . . . . . . . . . .140-05-16 Remove and install
Transfer gear case 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-27
Disassemble and assemble . . . . . . . . .140-05-32 Exhaust gas recirculation (EGR) mixed gas
Engine gear case and valve temperature sensor
Essential or recommended tools . . . . . . . .140-05-1 Sensor
Other material . . . . . . . . . . . . . . . . . . . . . .140-05-4 Remove and install
Specifications . . . . . . . . . . . . . . . . . . . . . .140-05-5 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-28
Engine oil Exhaust manifold pressure
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-10 Sensors
Engine Oil Remove and install
Extended Service Intervals . . . . . . . . . . . .10-20-12 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-27

083006
PN=8
Index
Page Page
Expansion valve Inspect. . . . . . . . . . . . . . . . . . . . . . . . . .70-15-13

Replace . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-21 Oil cooler
Other material
Drives and reverser gear case. . . . . . . .110-15-2
F Tilt frame . . . . . . . . . . . . . . . . . . . . . . . .110-25-1
Feed accelerator Reverser gear case. . . . . . . . . . . . . . . . .110-15-42
Shaft Disassemble and assemble . . . . . . . . .110-15-43
Remove. . . . . . . . . . . . . . . . . . . . . . . . .120-05-6 Oil pump
Wear strips Disassemble and assemble . . . . . . .110-15-56
Remove and install . . . . . . . . . . . . . . .120-05-13 Remove and install . . . . . . . . . . . . . . .110-15-38
Feed flights Reverser shift piston
Remove and install . . . . . . . . . . . . . . . .120-05-100 Remove and install . . . . . . . . . . . . . . .110-15-61
Feeder house Reverser valve
Adjust variable speed belt . . . . . . . . . . . .110-15-73 Exploded view . . . . . . . . . . . . . . . . . . . . .70-15-5
Backshaft speed sensor . . . . . . . . . . . . .110-15-22 General information . . . . . . . . . . . . . . . . .70-15-2
Belt Reverser valve and hoses
Fixed speed Exploded view . . . . . . . . . . . . . . . . . . . . .70-15-4
Replace . . . . . . . . . . . . . . . . . . . . . .110-15-79 Single point latching
Variable speed Level land
Replace . . . . . . . . . . . . . . . . . . . . . .110-15-76 Exploded View . . . . . . . . . . . . . . . . .110-05-20
Conveyor Specifications Indx
Wear plate Top shaft and slip clutch . . . . . . . . . . . .110-10-2 9
Install . . . . . . . . . . . . . . . . . . . . . . . .110-05-18 Sub-floor assembly
Conveyor chain Remove and install . . . . . . . . . . . . . . .110-05-17
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .110-05-4 Top shaft
Measure wear . . . . . . . . . . . . . . . . . . . .110-05-8 Disassemble and assemble . . . . . . . . .110-10-15
Remove and install . . . . . . . . . . . . . . . .110-05-5 Top shaft slip clutch
Conveyor chain link Disassemble and assemble . . . . . . . . . .110-10-4
Remove. . . . . . . . . . . . . . . . . . . . . . . . .110-05-8 Top shaft slip clutch (9660 STS, 9760 STS and
Conveyor chain slat 9860 STS)
Remove. . . . . . . . . . . . . . . . . . . . . . . . .110-05-9 Install. . . . . . . . . . . . . . . . . . . . . . . . . . .110-10-8
Conveyor drum Top shaft slip clutch (9660, 9760 and 9860)
Remove and install . . . . . . . . . . . . . . .110-05-13 Remove. . . . . . . . . . . . . . . . . . . . . . . . .110-10-2
Conveyor wear strips Top shaft supports
Replace . . . . . . . . . . . . . . . . . . . . . . . .110-05-10 Remove and install . . . . . . . . . . . . . . .110-10-11
Countershaft Variable drive countershaft
Fixed speed Disassemble and assemble . . . . . . . . .110-15-14
Disassemble and assemble . . . . . . .110-15-21 Variable drive sheaves
Drum Cams
Adjust . . . . . . . . . . . . . . . . . . . . . . . . .110-05-13 Remove and install . . . .110-15-23, 110-15-36
Feed plate support Repair . . . . . . . . . . . . . . . . . . . . . . .110-15-28
Exploded View. . . . . . . . . . . . . . . . . . .110-05-24 Feeder house backshaft
Fixed drive sheave Remove and install . . . . . . . . . . . . . . . . .110-15-68
Remove and install . . . . . . . . . . . . . . .110-15-37 Feeder house drives and reverser gear case
Fixed speed Essential or recommended tools . . . . . . . .110-15-1
Drive tightener Specifications . . . . . . . . . . . . . . . . . . . . . .110-15-3
Disassemble and assemble . . . . . . .110-15-70 Feeder house repair
Lower shaft CONTOUR MASTER fore-aft tilt frame
Remove and install . . . . . . . . . . . . . . .110-15-64 Remove. . . . . . . . . . . . . . . . . . . . . . . .110-25-14
Multi-coupler CONTOUR MASTER fore/aft turnbuckles
Disassemble and assemble . . . . . . . . . .70-15-13 Adjust . . . . . . . . . . . . . . . . . . . . . . . . .110-25-14

083006
PN=9
Index
Page Page
CONTOUR MASTER tilt beam Folding auger rings

Remove and install . . . . . . . . . . . . . . . .110-25-7 Remove and install . . . . . . . . . . . . . . . . .130-20-18
CONTOUR MASTER tilt frame Folding horizontal auger
Install. . . . . . . . . . . . . . . . . . . . . . . . . .110-25-17 Auger
Conveyor Exploded view . . . . . . . . . . . . . . . . . . .130-20-14
Conveyor chain slat Housing
Removing. . . . . . . . . . . . . . . . . . . . . .110-05-9 Exploded view . . . . . . . . . . . . . . . . . . .130-20-12
Drum height Pivot
Adjust. . . . . . . . . . . . . . . . . . . . . . . .110-05-13 Exploded view . . . . . . . . . . . . . . . . . . .130-20-16
Feeder house drives and reverser gear case Fresh air temperature
Fixed drive sheave Sensors
Remove and install . . . . . . . . . . . . .110-15-37 Remove and install
Lower shaft 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-27
Remove and install . . . . . . . . . . . . .110-15-64 Front chaffer element
Reverser gear case Element remove and install . . . . . . . . . . .120-20-40
Remove and install . . . . . . . . . . . . .110-15-38 Front horizontal unloading auger
Reverser gear case oil pump Install . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-22
Disassemble and assemble . . . . . . .110-15-56 Front Horizontal unloading auger
Variable drive sheaves and cams Remove . . . . . . . . . . . . . . . . . . . . . . . . .130-20-19
Remove and install . . . .110-15-23, 110-15-36 Front horizontal unloading auger
Repair . . . . . . . . . . . . . . . . . . . . . . .110-15-28 Remove . . . . . . . . . . . . . . . . . . . . . . . . .130-20-20
Tilt Frame Fuel
Remove and install . . . . . . . . . . . . . . . .110-25-5 Bleeding fuel system
Indx
10 Tilt frame and beam (s.n. --720100) . . . . .110-25-2 Dual filter
9660 (S.N. 705935--), 9760 (S.N.
Tilt frame and beam (s.n. 720101--) . . . . .110-25-4
705759) . . . . . . . . . . . . . . . . . . . . . .30-10-3
Top shaft slip clutch (9560 STS)
Diesel . . . . . . . . . . . . . . . . . . . . . .10-20-2, 10-20-3
Handling and storing . . . . . . . . . . . . . . . . . .10-20-1
Feeder house/conveyor
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-4
Other material . . . . . . . . . . . . . . . . . . . . . .110-05-1
Fuel pressure
Specifications . . . . . . . . . . . . . . . . . . . . . .110-05-1
Switch
Final drive
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-9
Fuel rail pressure
Disassemble . . . . . . . . . . . . . . . . . . . . . . . .50-10-9
Sensor
Remove and install . . . . . . . . . . . . . . . . . . .50-10-5
Single reduction Fuel return line regulator
Adjust spindle bearing (alternate Remove and install . . . . . . . . . . . . . . . . . . .30-10-9
method) . . . . . . . . . . . . . . . . . . . . . . .50-10-20 Fuel sender
Adjust spindle bearing (preferred Remove and install . . . . . . . . . . . . . . . . . .40-35-21
method) . . . . . . . . . . . . . . . . . . . . . . .50-10-20 Fuel system
Final drives Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-7
Specifications . . . . . . . . . . . . . . . . . . . . . . .50-10-4 8.1 L
Fixed swashplate 9660 (S.N.-705934), 9760 (S.N.
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-21 -705758) . . . . . . . . . . . . . . . . . . . . . .30-10-2
Flow control valve Fuel tank
Reel/belt pickup Install strainer and breather . . . . . . . . . . .30-10-14
Install. . . . . . . . . . . . . . . . . . . . . . . . . . .70-15-10 Remove and install . . . . . . . . . . . . . . . . . .30-10-10
Remove. . . . . . . . . . . . . . . . . . . . . . . . . .70-15-8 Sender
Flushing Remove and install . . . . . . . . . . . . . . . .40-35-21
Reel/belt pickup drive system . . . . . . . . . . .70-05-8 Fuel tank shut-off valve and drain valve
Folding auger Remove and install . . . . . . . . . . . . . . . . . .30-10-12
Actuator Fuel tank strainer and breather
Remove and install . . . . . . . . . . . . . . .130-20-17 Remove and install . . . . . . . . . . . . . . . . . .30-10-14

083006
PN=10
Index
Page Page
Full grain tank Moisture sensor

Sensor Actuator
Remove and install . . . . . . . . . . . . . . . . .40-35-7 Remove and install . . . . . . . . . . . . . . .40-60-7
Fuses, circuit breakers and relays Circuit board
Specifications . . . . . . . . . . . . . . . . . . . . . . .40-20-1 Remove and install . . . . . . . . . . . . . . .40-60-9
Disassemble and assemble . . . . . . . . . . .40-60-6
Lower cell assembly
Remove and replace . . . . . . . . . . . . .40-60-11
G Remove and install . . . . . . . . . . . . . . . . .40-60-5
GREENSTAR components
Gauges and monitors Other material . . . . . . . . . . . . . . . . . . . . . . .40-60-1
Low shaft speed sensor Specifications . . . . . . . . . . . . . . . . . . . . . . .40-60-1
Remove and install . . . . . . . . . .40-35-3, 40-35-4 Ground speed (fast idle)
Gear case Two speed four wheel drive
Clean grain elevator . . . . . . . . . . . . . . . .130-25-14 Specification . . . . . . . . . . . . . . . . . . . . . .10-10-1
Remove and install . . . . . . . . . . . . . . .130-25-12 Ground speed sensor
Horizontal unloading auger Remove and install . . . . . . . . . . . . . . . . . . .40-35-5
Disassemble and assemble . . . . . . . . .130-20-25 Gull wing doors
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-28 Align . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-05-7
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-24 Other material . . . . . . . . . . . . . . . . . . . . . . .80-05-1
Primary countershaft Remove and install . . . . . . . . . . . . . . . . . . .80-05-2
Disassemble and assemble . . . . . . . . . .120-30-6 Specifications . . . . . . . . . . . . . . . . . . . . . . .80-05-1
Remove and install . . . . . . . . . . . . . . . .120-30-3 Indx
11
Rotor
Transfer H
Assemble . . . . . . . . . . . . . . . . . . . . . .140-05-32
Gear case oils . . . . . . . . . . . . . . . . . . . . . . .10-20-13
Halogen bulbs
Gearshift lever and linkage
Safety rules. . . . . . . . . . . . . . . . . . . . . . . . .40-25-1
Handling batteries safely
Gearshift linkage
Safety . . . . . . . . . . . . . . . . . . . . . .10-05-3, 40-05-2
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-30
Harness
Grain saver door
Unloading auger Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .40-15-1
Remove and install . . . . . . . . . . . . . . . .130-20-7 Header
Grain tank Electromagnetic clutch
Cross augers, install . . . . . . . .130-05-4, 130-05-10 Exploded view . . . . . . . . . . . . . . . . . . . .120-35-3
Cross augers, remove. . . . . . . .130-05-1, 130-05-7 Install. . . . . . . . . . . . . . . . . . . . . . . . . . .120-35-3
Exploded view Removal . . . . . . . . . . . . . . . . . . . . . . . .120-35-1
High unload rate . . . . . . . . . . . . . . . . . .130-30-2 Header and separator switches
Regular unload rate . . . . . . . . . . . . . . . .130-30-2 Remove and install . . . . . . . . . . . . . . . . . .40-30-21
Extensions Header electromagnetic clutch
High unload rate . . . . . . . . . . . . . . . . . .130-30-5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-35-3
Regular unload rate . . . . . . . . . . . . . . . .130-30-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . .120-35-1
9560 STS and 9650 STS . . . . . . . . . . .130-30-5 Header height control valve
Grates Remove and install . . . . . . . . . . . . . . . . . .70-15-11
Separator, remove and install . . . . . . . . .120-05-75 Header height sensor
Grease Remove and install . . . . . . . . . . . . . . . . . . .40-35-9
Extreme pressure and multipurpose . . . . .10-20-15 Header Lift Cylinder
GREENSTAR Remove and install . . . . . . . . . . . . . . . . . . .70-20-1
Mass-Flow sensor Header magnetic clutch
Remove and install . . . . . . . . . . . . . . . . .40-60-2 Specifications . . . . . . . . . . . . . . . . . . . . . .120-35-1

083006
PN=11
Index
Page Page
Headliner Hydraulic Pump

Remove and install Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-10
Style B. . . . . . . . . . . . . . . . . . . . . . . . . .90-15-33 Hydraulic pump
Heater control valve Other material . . . . . . . . . . . . . . . . . . . . . . .70-10-2
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-8 Reel/belt
Heater core Straw spreader
Remove and install . . . . . . . . . . . . . . . . . .90-10-10 Exploded view . . . . . . . . . . . . . . . . . .70-10-11
HID-Xenon lighting Seal
Remove and install ballast . . . . . .40-25-4, 40-25-6 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-6
Remove and install light . . . . . . . .40-25-4, 40-25-6 Service equipment and tools . . . . . . . . . . . .70-10-1
High pressure switch Specifications . . . . . . . . . . . . . . . . . . . . . . .70-10-3
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-23 Hydraulic pumps
High unload rate Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-5
Horizontal unload auger . . . . . . . . . . . . . .130-20-6 Triple main
High-presure line center pivot o-rings Remove. . . . . . . . . . . . . . . . . . . . . . . . . .70-10-4
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-75 Hydraulic repair
Horizontal unloading auger Hydraulic reservoir
Elbow Hydraulic system
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-36 Flushing . . . . . . . . . . . . . . . . . . . . . . . .70-05-7
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-34 Reel/belt pickup and straw spreader pump
Gear case Assemble . . . . . . . . . . . . . . . . . . . . . .70-10-23
Disassemble and assemble . . . . . . . . .130-20-25 Reel/belt pickup drive system
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-28 Flushing . . . . . . . . . . . . . . . . . . . . . . . .70-05-8
Indx
12
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-24 Hydraulic valves
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-4 Auger swing valve module
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-8 Identification. . . . . . . . . . . . . . . . . . . . .70-16-9
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-7 CONTOUR MASTER (header tilt) valve module
Tube Identification. . . . . . . . . . . . . . . . . . . .70-16-11
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-30 Electro-hydraulic feeder house reverser valve
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-29 Exploded view . . . . . . . . . . . .70-15-4, 70-15-5
Horizontal unloading auger and gear case Hydraulic solenoid control valve
Essential or recommended tools . . . . . . . .130-20-1 Leakage repair . . . . . . . . . . . . . . . . . .70-16-12
Other material . . . . . . . . . . . . . . . . . . . . . .130-20-2 Pilot sleeve o-rings
Horn Replacing. . . . . . . . . . . . . . . . . . . . . .70-16-16
Switch Pilot solenoid assemblies
Remove and install . . . . . . . . . . . . . . . .40-30-34 Replacing. . . . . . . . . . . . . . . . . . . . . .70-16-15
Housing Reel fore/aft valve module
Folding horizontal auger Identification. . . . . . . . . . . . . . . . . . . .70-16-10
Exploded view . . . . . . . . . . . . . . . . . . .130-20-12 Threshing speed valve module
Hub Identification. . . . . . . . . . . . . . . . . . . . .70-16-8
Cross auger countershaft Two way reel lift and variable speed feeder
Install. . . . . . . . . . . . . . . . . . .130-10-2, 130-10-4 house valve module
Remove. . . . . . . . . . . . . . . . .130-10-2, 130-10-4 Identification. . . . . . . . . . . . . . . . . . . . .70-16-7
Hydraulic cylinder Hydraulic reservoir
Header lift Essential or recommended tools . . . . . . . . .70-05-1
Disassemble and reassemble . . . . . . . . .70-20-2 Other material . . . . . . . . . . . . . . . . . . . . . . .70-05-1
Remove and install . . . . . . . . . . . . . . . . .70-20-1 Remove and install
Hydraulic cylinders (S.N. 715301--) . . . . . . . . . . . . . . . . . . . .70-05-4
Specifications . . . . . . . . . . . . . . . . . . . . . . .70-20-1 (S.N.--715300). . . . . . . . . . . . . . . . . . . . .70-05-2
Hydraulic pump Specifications . . . . . . . . . . . . . . . . . . . . . . .70-05-2
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-9 Temperature sensor
Disassemble . . . . . . . . . . . . . . . . . . . . . . . .70-10-5 Remove and install . . . . . . . . . . . . . . . .40-35-16
Essential or recommended tools . . . . . . . . .70-10-1 Tier III cooling pacakge . . . . . . . . . . .40-35-16

083006
PN=12
Index
Page Page
Hydraulic solenoid control valve Hydrostatic motor

Leakage repair . . . . . . . . . . . . . . . . . . . . .70-16-12 Disassemble . . . . . . . . . . . . . . . . . . . . .50-15-11
Hydraulic system Serial number plate. . . . . . . . . . . . . . . . . . .50-15-7
Flush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-05-7 Start-up procedure . . . . . . . . . . . . . . . . . .50-15-90
Hydraulic valve stack Hydrostatic system repair
Disassemble and assemble . . . . . . . . . . . .70-16-4 Start-up procedure . . . . . . . . . . . . . . . . . . .70-05-9
Remove and install . . . . . . . . . . . .70-16-2, 70-17-4
Solenoid control valve module
Identification . . . . . . . . . . . . . . . . . . . . . .70-16-6 I
Hydraulic valves
Service equipment and tools . . . . 70-15-1, 70-16-1, Inserts
70-17-1 Threaded RIVNUT
Hydro charge pressure Remove and replace . . . . . . . . . . . . . .120-05-99
Switch Instruments and controls
Remove and install . . . . . . . . . . . . . . . .40-35-24 Identification . . . . . . . . . . . . . . . . . . . . . . . .40-30-2
Hydrostatic gear set Intake manifold pressure sensor
Disassemble and assemble . . . . . . . . . .140-05-46 Sensor
Preload bearings. . . . . . . . . . . . . . . . . . .140-05-49 Remove and install
Set gear positiion . . . . . . . . . . . . . . . . . .140-05-47 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-28
Hydrostatic motor
Assemble . . . . . . . . . . . . . . . . . . . . . . . . .50-15-32
Cylinder block spring, replace . . . . . . . . . .50-15-30
Disassemble . . . . . . . . . . . . . . . . . . . . . . .50-15-11 J Indx
13
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-17
Jacking
Locations . . . . . . . . . . . . . . . . . . . . . . . . . .50-25-7
Valve block, repair . . . . . . . . . . . . . . . . . .50-15-44
Jackshaft
Hydrostatic motor and pump
Straw chopper
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-7
Install. . . . . . . . . . . . . . . . . . . . . . . . . .120-15-35
Hydrostatic pump
Remove. . . . . . . . . . . . . . . . . . . . . . . .120-15-32
Assemble . . . . . . . . . . . . . . . . . . . . . . . . .50-15-60
John Deere engine repair
Disassemble . . . . . . . . . . . . . . . . . . . . . . .50-15-47
Cooling system . . . . . . . .20-05-4, 20-10-2, 30-05-3
Displacement control valve
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-77
Displacement valve with feed rate
Exploded view . . . . . . . . . . . . . . . . . . . .50-15-79 K
Electronic displacement control valve
Neutral adjustment . . . . . . . . . . . . . . . .50-15-80 Knife bank
End cover, assemble . . . . . . . . . . . . . . . .50-15-76 Easy adjust
End cover, disassemble . . . . . . . . . . . . . .50-15-76 Remove and install . . . . . . . . . . . . . . .120-15-24
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-84
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-45
Hydrostatic pump drive L
Hydrostatic pump drive bearings Lack of lubrication
Preload . . . . . . . . . . . . . . . . . . . . . . . . . .140-05-63 Hydrostatic system . . . . . . . . . . . . . . . . . .50-15-18
Hydrostatic pump drive gear Lateral tilt sensor
Set backlash . . . . . . . . . . . . . . . . . . . . . .140-05-64 Remove and install . . . . . . . . . . . . . . . . . . .40-35-9
Hydrostatic system Leak testing air conditioning system
Control cable With dye . . . . . . . . . . . . . . . . . . . . . . . . . .90-05-12
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-88 Lift cylinder
Remove and install . . . . . . . . . . . . . . . .50-15-87 Header
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-8 Disassemble and assemble . . . . . . . . . . .70-20-2

083006
PN=13
Index
Page Page
Light M
Access door work light, bulb
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .40-25-9 Master cylinder
Auxiliary field work light, bulb Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-14
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .40-25-9 Disassemble and assemble . . . . . . . . . . .60-10-12
Backlight bulb Remove and install . . . . . . . . . . . . . . . . . .60-10-11
Active header control Mechanical displacement control valve
Remove and install . . . . . . . . . . . . . .40-30-23 Neutral, adjust. . . . . . . . . . . . . . . . . . . . . .50-15-89
Dial-A-Speed Mini harness
Remove and install . . . . . . . . . . . . . .40-30-23 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-30
Cleaning shoe Mirror
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-10 Switch
COMMANDTOUCH cornerpost light bulb Remove and install . . . . . . . .40-30-35, 40-30-36
Replacement . . . . . . . . . . . . . . . . . . . . .40-25-12 Mirrors
Console Remove and install . . . . . . . . . . . . . . . . . .40-30-34
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-11 Mixing lubricants. . . . . . . . . . . . . . . . . . . . . .10-20-17
Dome Module
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-11 Remove header control. . . . . . . . . . . . . . .40-30-15
Front turn signal Motor
Tail Concave adjust
Replacement . . . . . . . . . . . . . . . . . . . .40-25-9 Remove and install . . . . . . . . . . . . . . .120-05-88
Hazard/warning, bulb Motor valve block (manifold)
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-10 Remove and install . . . . . . . . . . . . . . . . . .50-15-41
Indx
14
Side finder (optional) light bulb Multi-coupler
replacement. . . . . . . . . . . . . . . . . . . . . . .40-25-9 Feeder house
Side light Disassemble and assemble . . . . . . . . . .70-15-13
Replacement . . . . . . . . . . . . . . . . . . . . . .40-25-9 Inspect. . . . . . . . . . . . . . . . . . . . . . . . . .70-15-13
Warning display panel bulb Valve identification. . . . . . . . . . . . . . . . .70-15-12
Replace . . . . . . . . . . . . . . . . . . . . . . . . .40-25-13 Multi-function handle
Light panel dimmer Feed rate sensor
Switch Remove and install . . . . . . . . . . . . . . . .40-35-10
Remove and install . . . . . . . . . . . . . . . . .40-30-5 Remove and install . . . . . . . . . . . . . . . . . .40-30-31
Light, (Infra Red)
Cab head light bulb replacement and
adjustment. . . . . . . . . . . . . . . . . . . . . . . .40-25-3
N
Low pressure switch
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-22
Neutral safety switch
Low shaft speed sensor
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-29
Lower cell assembly
GREENSTAR moisture sensor
Remove and replace . . . . . . . . . . . . . . .40-60-11 O
Lower engine repair
Remove and install engine oil pan access Oil screen
sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-15-1 Disassemble and asssemble. . . . . . . . . .140-05-65
Lower gear case Oil trough
Vertical auger Disassemble and assemble . . . . . . . . . .140-05-65
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-15-12 Operating speeds
Remove. . . . . . . . . . . . . . . . . . . . . . . . .130-15-3 9560 combine . . . . . . . . . . . . . . . . . . . . . . .10-10-3
Lubricant 9660 STS, 9670 STS . . . . . . . . . . . . . . . . .10-10-9
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-17 9860 Combine . . . . . . . . . . . . . . . . . . . . .10-10-18
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-16 Operators seat
Lubricity of diesel fuel. . . . . . . . . . . . . . . . . . .10-20-4 Air suspension exploded view . . . . . . . . . .90-15-46

083006
PN=14
Index
Page Page
Operator’s seat Park brake pedal

Exploded view. . . . . . . . . . . . . . . . . . . . . .90-15-44 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-36
Operators seat Performance monitor
Presence switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-16
Remove and install . . . . . . . . . . . . . . . .90-15-42 Pilot sleeve assembly
Operator’s seat Replacing . . . . . . . . . . . . . . . . . . . . . . . . .70-16-15
Remove and install . . . . . . . . . . . . . . . . . .90-15-33 Pilot sleeve o-ring
Operators station Replacing . . . . . . . . . . . . . . . . . . . . . . . . .70-16-16
Other material . . . . . . . . . . . . . . . . . . . . . . .40-30-1 Piston retainer
Specifications . . . . . . . . . . . . . . . . . . . . . . .40-30-1 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-23
Other material Piston slipper
Air conditioning system . . . . . . . . .90-05-4, 90-10-1 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-22
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1 Pittman arms
Clean grain elevator . . . . . . . . . . . . . . . . .130-25-1 Remove and install . . . . . . . . . . . . . . . . .120-20-49
Connector repair . . . . . . . . . . . . . . . . . . . . .40-10-4 Pivot Axle Bushing
Engine gear case and valve . . . . . . . . . . .140-05-4 Remove and install . . . . . . . . . . . . . . . . . .60-05-44
Feeder house Pivot pins, bushings, and seals
Drives and reverser gear case. . . . . . . .110-15-2 Disassemble and assemble . . . . . . . . . . .50-20-23
Tilt frame . . . . . . . . . . . . . . . . . . . . . . . .110-25-1 Position receiver
Feeder house/conveyor. . . . . . . . . . . . . . .110-05-1 C-band
Final drives . . . . . . . . . . . . . . . . . . . . . . . . .50-10-3 Disassemble and assemble . . . . . . . . . .40-60-24
Gull wing doors . . . . . . . . . . . . . . . . . . . . . .80-05-1 Remove and install . . . . . . . . . . . . . . . .40-60-25
Horizontal unloading auger and gear L-band Indx
case . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-2 15
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . .70-10-2 Remove and install . . . . . . . . . . . . . . . .40-60-25
Hydraulic reservoir . . . . . . . . . . . . . . . . . . .70-05-1 Position sensor
Hydrostatic system . . . . . . . . . . . . . . . . . . .50-15-3 Concave
Operators station . . . . . . . . . . . . . . . . . . . .40-30-1 Remove and install . . . . . . . . . . . . . . . . .40-35-8
Primary countershaft gear case . . . . . . . .120-30-1 Power distribution board
Sensors and switches . . . . . . . . . . . . . . . . .40-35-1 Basic description. . . . . . . . . . . . . . . . . . . . .40-20-3
Separator repair . . . . . . . . . . . . . . . . . . . .120-05-3 Relay identification . . . . . . . . . . . . . . . . . . .40-20-6
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-3 Power steering and brakes
Top shaft and slip clutch . . . . . . . . . . . . . .110-10-1 Brakes
Transmission and differential. . . . . . . . . . . .50-05-1 Double bleed screw
Other materials Bleeding brake system. . . . . . . . . . . .60-10-15
Air intake system . . . . . . . . . . . . . . . . . . . .30-05-1 Steering
Cam lobe motor . . . . . . . . . . . . . . . . . . . . .50-20-6 AUTOTRAC assisted steering flowmeter
Diesel fuel systems . . . . . . . . . . . . . . . . . . .30-10-1 Exploded view . . . . . . . . . . . . . . . . . .60-05-20
Outer folding auger assembly Electro-hydraulic steering valve and flowmeter
Remove and install . . . . . . . . . . . . . . . . .130-20-17 Exploded view . . . . . . . . . . . . . . . . . .60-05-18
Over speeding Steering column
Hydrostatic system . . . . . . . . . . . . . . . . . .50-15-19 Componets. . . . . . . . . . . . . . . . . . . . .60-05-21
Overhead console Steering valve
Remove and install . . . . . . . . . . . . . . . . . . .40-30-4 Install . . . . . . . . . . . . . . . . . . . . . . . . .60-05-15
Remove . . . . . . . . . . . . . . . . . . . . . . . .60-05-6
Power train repair
Cam lobe motor
P Axle bearings and seals
Remove and install . . . . . .50-20-42, 50-20-54
Park brake Disassemble and assemble
Switch Pivot pins, bushings, and
Remove and install . . . . . . . . . . . . . . . .40-35-21 seals--2-speed . . . . . . . . . . . . . . . .50-20-23

083006
PN=15
Index
Page Page
Four wheel drive cam lobe motor 8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-18

Flushing . . . . . . . . . . . . . . . . . . . . . . . .50-20-8 Remove
Remove and install 12.5 L . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-25
Cam and piston carrier--2-two 6.8 L . . . . . . . . . . . . . . . . . . .20-10-11, 20-10-14
speed . . . . . . . . . . . . . . . . . . . . . . .50-20-33 8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-17
Displacement control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-30
valve--2-speed . . . . . . . . . . . . . . . .50-20-30 Radiator cap
Solenoid valve and valve block . . . . .50-20-26 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-31
Steering yoke . . . . . . . . . . . . . . . . . . .50-20-16 Radio
Valve stack seals--2-two speed . . . . .50-20-38 Antenna, remove and install . . . . . . . . . . . .40-30-9
Hydrostatic system
Charge pump. . . . . . . . . . . . . . . . . . . . .50-15-86
Radio speaker
Hydrostatic motor
Removal and installation . . . . . . . . . . . . . . .40-30-8
Disassemble . . . . . . . . . . . . . . . . . . .50-15-11
Rear access door
Transmission and differential
Gearshift lever and linkage Remove and install . . . . . . . . . . . . . . . . . . .80-05-3
Remove and install . . . . . . . . . . . . . .50-05-28 Rear axle adjustment . . . . . . . . . . . . . . . . . .60-05-47
Precautions for vehicles equipped with computer Rear discharge lamp
controlled systems Bulb part number . . . . . . . . . . . . . . . . . . . .40-25-2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-40 Rear horizontal folding auger
Pressure regulating valve Install . . . . . . . . . . . . . . . . . . . . . . . . . . .130-20-23
Disassemble and assemble . . . . . . . . . .140-05-68 Rear horizontal Folding Auger
Remove and install . . . . . . . . . . . . . . . . .140-05-67 Remove . . . . . . . . . . . . . . . . . . . . . . . . .130-20-19
Indx Prevent hydraulic system contamination Rear spindle assembly
16 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-38 Non-powered heavy duty
Primary countershaft Disassemble and assemble . . . . . . . . . .60-05-36
Remove and install . . . . . . . . . . . . . . . . .120-10-11 Rear spindle assembly-non powered
Right-hand bearing Remove and install . . . . . . . . . . . . . . . . . .60-05-34
Remove and install . . . . . . . . . . . . . . . .120-10-9 Rear wall panel
Primary countershaft bearing Remove and install . . . . . . . . . . . . . . . . . . .80-05-2
Remove and install . . . . . . . . . . . . . . . . . .120-10-9 Rear wheel
Primary countershaft gear case Bolt torque . . . . . . . . . . . . . . . . . . . . . . . .50-25-11
Disassemble and assembly. . . . . . . . . . . .120-30-6 Rear window
Drive shaft . . . . . . . . . . . . . .120-10-14, 120-10-19 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-25
Essential or recommended tools . . . . . . . .120-30-1
Receiver/dryer
Other material . . . . . . . . . . . . . . . . . . . . . .120-30-1
Recirculator fan motor driver
Specifications . . . . . . . . . . . . . . . . . . . . . .120-30-2
Primary drive shaft Remove and install
Carrier bearing Style A. . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-6
Replace . . . . . . . . . . . . . . . . . . . . . . . .120-10-19 Style B. . . . . . . . . . . . . . . . . . . . . . . . . . .90-10-7
Remove and install . . . . . . . . . . . . . . . . .120-10-14 Recirculator motor
Pump Remove and install . . . . . . . . . . . . . . . . . . .90-10-7
Reel/belt Reel fore/aft valve module . . . . . . . . . . . . . .70-16-10
Straw spreader Reel/belt pickup
Exploded view . . . . . . . . . . . . . . . . . .70-10-11 Flow control valve
Reel/belt pickup Install. . . . . . . . . . . . . . . . . . . . . . . . . . .70-15-10
Remove and install . . . . . . . . . . . . . . . .70-10-12 Remove. . . . . . . . . . . . . . . . . . . . . . . . . .70-15-8
Reel/belt pickup drive
Disassemble and assemble . . . . . . . . . . .70-10-15
R
Reel/belt pickup pump
Radiator Assemble . . . . . . . . . . . . . . . . . . . . . . . . .70-10-23
Install Reel/belt pickup pump drive
12.5 L . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-28 Remove and install . . . . . . . . . . . . . . . . . .70-10-12

083006
PN=16
Index
Page Page
Reel/belt speed flow control valve S

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-15-9
Relay identification Safety
Power distribution board . . . . . . . . . . . . . . .40-20-6 Basic electrical component handling . . . . .10-10-40
Relay location Check oil lines and fittings . . . . . . . . . . . .10-10-39
Power distribution board . . . . . . . . . . . . . . .40-20-5 Handling batteries safely . . . . . . . .10-05-3, 40-05-2
Remote shoe actuator motor Precautions for vehicles equipped with computer
Remove and install . . . . . . . . . . . . . . . . .120-20-38 controlled systems. . . . . . . . . . . . . . . . .10-10-40
Remove and install Prevent hydraulic system
Chopper raise/lower actuator . . . . . . . . .120-15-10 contamination . . . . . . . . . . . . . . . . . . . .10-10-38
GREENSTAR moisture sensor Use adequate service facilities . . . . . . . . .10-05-14
Actuator. . . . . . . . . . . . . . . . . . . . . . . . . .40-60-7 Seat air suspension assembly
Circuit board . . . . . . . . . . . . . . . . . . . . . .40-60-9 Disassemble and assemble . . . . . . . . . . .90-15-47
Residue disposal Sensor
Service equipment and tools . . . . . . . . . . .120-15-1 Camshaft Position
Retainer Remove and install
Concave . . . . . . . . . . . . . . . . . . . . . . . . .120-05-76 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-26
Reverser gear case Chopper
Disassemble and assemble . . . . . . . . . .110-15-43 Remove and install . . . . . . . . . . . . . . . . .40-35-4
Exploded view. . . . . . . . . . . . . . . . . . . . .110-15-42 Coolant temperature
Reverser shift piston Remove and install . . . . . . . . . . . . . . . .40-35-17
Feeder house Tier III cooling package . . . . . . . . . . .40-35-19
Remove and install . . . . . . . . . . . . . . .110-15-61 Crankshaft Position Indx
Reverser valve Remove and install 17
Feeder house 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-27

Discharge beater
Exploded view . . . . . . . . . . . . . . . . . . . . .70-15-5
General information . . . . . . . . . . . . . . . . .70-15-2
Engine oil pressure
Right-hand front jackshaft
Exhaust gas recirculation mixed gas temperature
Right-hand rear jackshaft
sensor
Remove and install
Rotary screen
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-28
Idler arm and sheaves . . . . . . . . . . . . . . . .20-10-5
Feeder house backshaft
Remove and install . . . . . . . . . .40-35-3, 40-35-6
Rotary screen drive
Fuel rail pressure
Cooling system . . . . . . . . . . . . . . . . . . . . . .20-10-4 Remove and install . . . . . . . . . . . . . . . .40-35-29
Rotary screen knife comb Full grain tank
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-11 Remove and install . . . . . . . . . . . . . . . . .40-35-7
Rotor Hydraulic reservoir temperature
Feed flights Remove and install . . . . . . . . . . . . . . . .40-35-16
Remove and install . . . . . . . . . . . . . .120-05-100 Intake manifold pressure sensor
Gear case Remove and install
Remove and install . . . . . . . . . . . . . . .120-05-50 9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-28
Remove and install . . . . . . . . . . . . . . . . .120-05-32 Low shaft speed
Torque sensing--driven Remove and install . . .40-35-3, 40-35-4, 40-35-5
Disassemble and assemble . . . . . . . . .120-05-41 Moisture
Remove and install . . . . . . . . . . . . . . .120-05-37 Disassemble and assemble . . . . . . . . . . .40-60-6
Rotor drive Remove and install . . . . . . . . . . . . . . . . .40-60-5
Separator STS Rotor speed
Replace . . . . . . . . . . . . . . . . . . . . . . . .120-05-36 Remove and install . . . . . . . . . . . . . . . . .40-35-6
Rotor drive bulkhead Tailings
Aligning. . . . . . . . . . . . . . . . . . . . . . . . .120-05-105 Remove and install . . . . . . . . . . . . . . . . .40-35-7

083006
PN=17
Index
Page Page
Turbocharger Compressor Inlet Shoe supply augers, cleaning fan and chaffer and
Remove and install sieve frame
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-26 Fan speed actuator
Turbocharger speed Adjust. . . . . . . . . . . . . . . . . . . . . . . .120-20-23
Remove and install Shoe pittman arms
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-28 Remove and install . . . . . . . . . . . . .120-20-49
VISIONTRAK Threshing bars
Separator Remove and install . . . . . . . . . . . . . . .120-05-90
Remove and install . . . . . . . . . . . . . . .40-35-8 Threshing element location drawing
Sensors 15 element configuration . . . . . . . . . . .120-05-96
Exhaust gas recirculation 24 element dense pack
Remove and install configuration . . . . . . . . . . . . . . . . . .120-05-98
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-27 Tine location drawing
Exhaust manifold pressure 15 element configuration . . . . . . . . . . .120-05-96
Remove and install 24 element dense pack
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-27 configuration . . . . . . . . . . . . . . . . . .120-05-98
Fresh air temperature Tines
Remove and install Remove and install . . . . . . . . . . . . . . .120-05-90
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-27 Top covers
Sensors and switches Remove and install . . . . . . . . . . . . . . .120-05-14
Other material . . . . . . . . . . . . . . . . . . . . . . .40-35-1 Repair . . . . . . . . . . . . . . . . . . . . . . . . .120-05-89
Specifications . . . . . . . . . . . . . . . . . . . . . . .40-35-2 Separator drive
Separator Disassemble and assemble . . . . . . . . . .140-05-56
Indx
18 Balance Rotor . . . . . . . . . . . . . . . . . . . .120-05-102 Wet clutch
Cleaning fan
Separator drives
Drive
Essential or recommended tools . . . . . . . .120-10-1
Install . . . . . . . . . . . . . . . . . . . . . . . .120-20-21
Right-hand front jackshaft
Remove . . . . . . . . . . . . . . . . . . . . . .120-20-17
Drive jackshaft
Right-hand rear jackshaft
Disassemble and assemble . . . . . . .120-20-20
Conveyor auger
Specifications . . . . . . . . . . . . . . . . . . . . . .120-10-2
Separator gear
Conveyor auger drive shaft
Preload bearings. . . . . . . . . . . . . . . . . . .140-05-55
Separator rail
Conveyor auger slip clutch Remove and install . . . . . . . . . . . . . . . . .120-05-19
Remove and install . . . . . . . . . . . . . . .120-20-10 Separator repair
Conveyor auger trough Essential or recommended tools . . . . . . . .120-05-1
Remove and install . . . . . . . . . . . . . . . .120-20-8 Other material . . . . . . . . . . . . . . . . . . . . . .120-05-3
Feed flights Specifications . . . . . . . . . . . . . . . . . . . . . .120-05-4
Remove and install . . . . . . . . . . . . . .120-05-100 Separator shell
Grates Gull wing doors
Remove and install . . . . . . . . . . . . . . .120-05-75 Align . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-05-7
Preload drive bearings . . . . . . . . . . . . . .140-05-59 Remove and install . . . . . . . . . . . . . . . . .80-05-2
Rail Separator tine
Remove and install . . . . . . . . . . . . . . .120-05-19 Location drawing
Rotor drive (S.N.--715300). . . . . . . . . . . . . . . . . . .120-05-92
Replace . . . . . . . . . . . . . . . . . . . . . . . .120-05-36 15 element configuration . . . . . . . . . . .120-05-96
Sensor 24 element dense pack
VISIONTRAK configuration . . . . . . . . . . . . . . . . . .120-05-98
Remove and install . . . . . . . . . . . . . . .40-35-8 Separator tine (rice)
Set drive gear backlash . . . . . . . . . . . . .140-05-60 Location drawing (rice)
Set gear position. . . . . . . . . . . . . . . . . . .140-05-54 (S.N.--715300). . . . . . . . . . . . . . . . . . .120-05-94

083006
PN=18
Index
Page Page
Service equipment and tools Solenoid valve and valve block

Air conditioning system (R134a) . . . . . . . . .90-05-3 Remove and install . . . . . . . . . . . . . . . . . .50-20-26
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1 Specific gravity, electrolyte . . . . . . . . . . . . . . .40-05-4
Cam lobe motor . . . . . . . . . . . . . . . . . . . . .50-20-4 Specifications
Final drives . . . . . . . . . . . . . . . . . . . . . . . . .50-10-2 Air conditioning system . . . . . . . . .90-05-5, 90-10-2
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . .70-10-1 Air intake system . . . . . . . . . . . . . . . . . . . .30-05-2
Hydraulic valves . . . . . . .70-15-1, 70-16-1, 70-17-1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .40-45-2
Hydrostatic system . . . . . . . . . . . . . . . . . . .50-15-2 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-2
Residue disposal. . . . . . . . . . . . . . . . . . . .120-15-1 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-1
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-2 Cam lobe motor . . . . . . . . . . . . . . . . . . . . .50-20-7
Tires and wheels. . . . . . . . . . . . . . . . . . . . .50-25-2 Chaffer and sieve frame . . . . . . . . . . . . . .120-20-2
Service Internals Clean grain elevator . . . . . . . . . . . . . . . . .130-25-1
Extended Diesel Engine Oil . . . . . . . . . . .10-20-12 Cleaning fan . . . . . . . . . . . . . . . . . . . . . . .120-20-2
Servo piston Combine dimensions. . . . . . . . . . . . . . . . .10-10-17
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-29 Conveyor augers. . . . . . . . . . . . . . . . . . . .120-20-2
Set drive gear backlash Cooling system . . . . . . . . . . . . . . . . . . . . . .20-10-1
Separator . . . . . . . . . . . . . . . . . . . . . . . .140-05-60 Diesel fuel systems . . . . . . . . . . . . . . . . . . .30-10-1
Shaft Engine gear case . . . . . . . . . . . . . . . . . .140-05-16
Feed accelerator Engine gear case and valve . . . . . . . . . . .140-05-5
Remove. . . . . . . . . . . . . . . . . . . . . . . . .120-05-6 Feeder house
Shaft seal Tilt frame . . . . . . . . . . . . . . . . . . . . . . . .110-25-1
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-20 Top shaft and slip clutch . . . . . . . . . . . .110-10-2
Shake pan Feeder house drives and reverser gear Indx
Remove and install . . . . . . . . . . . . . . . . .120-20-47 case . . . . . . . . . . . . . . . . . . . . . . . . . . .110-15-3 19
Shear bolt Feeder house/conveyor. . . . . . . . . . . . . . .110-05-1
Cross auger countershaft Final drives . . . . . . . . . . . . . . . . . . . . . . . . .50-10-4
Install. . . . . . . . . . . . . . . . . . .130-10-2, 130-10-4 Fuses, circuit breakers and relays. . . . . . . .40-20-1
Remove. . . . . . . . . . . . . . . . .130-10-2, 130-10-4 Ground speed (fast idle)
Shifter cam Two speed four wheel drive. . . . . . . . . . .10-10-1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-05-5 Gull wing doors . . . . . . . . . . . . . . . . . . . . . .80-05-1
Remove and install . . . . . . . . . . . . . . . . . . .50-05-3 Header electromagnetic clutch . . . . . . . . .120-35-1
Shifter forks Hydraulic cylinders . . . . . . . . . . . . . . . . . . .70-20-1
Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-05-5 Hydraulic pump . . . . . . . . . . . . . . . . . . . . . .70-10-3
Remove and install . . . . . . . . . . . . . . . . . . .50-05-3 Hydraulic reservoir . . . . . . . . . . . . . . . . . . .70-05-2
Shoe pittman arms Hydraulic valves . . . . . . . . . . . . . . . . . . . . .70-15-1
Remove and install . . . . . . . . . . . . . . . . .120-20-49 Hydrostatic system . . . . . . . . . . . . . . . . . . .50-15-4
Side finder Operators station . . . . . . . . . . . . . . . . . . . .40-30-1
Switch Primary countershaft gear case . . . . . . . .120-30-2
Remove and install . . . . . . . . . . . . . . . .40-30-33 Remove and install engine . . . . . . . . . . . . .20-05-3
Sieve Sensors and switches . . . . . . . . . . . . . . . . .40-35-2
Remove and install Separator drives . . . . . . . . . . . . . . . . . . . .120-10-2
Opening gauge calibration . . . . . . . . . .120-20-35 Separator repair . . . . . . . . . . . . . . . . . . . .120-05-4
With remote shoe. . . . . . . . . . . . . . .120-20-37 Starting motor . . . . . . . . . . . . . . . . . . . . . . .40-50-2
Sieve frame Steering . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-4
Remove and install . . . . . . . . . . . . . . .120-20-44 Tailings elevator and augers . . . . . . . . . . .120-25-1
Single point latching Tires and wheels. . . . . . . . . . . . . . . . . . . . .50-25-3
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .110-25-10 Transmission and differential. . . . . . . . . . . .50-05-2
Exploded view (S.N. --715300) . . . . . . . .110-25-12 Turning radius. . . . . . . . . . . . . . . . . . . . . . .10-10-2
Exploded view (S.N. 715301--) . . . . . . . .110-25-13 Unloading auger system drives . . . . . . . . .130-10-1
Single reduction final drive Valve stack . . . . . . . . . . . . . . . . . . . . . . . . .70-16-1
Essential or recommended tools . . . . . . . . .50-20-1 Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-1
Solenoid control relief valve module 9560 combine . . . . . . . . . . . . . . . . . . . . . . .10-10-5
Identification . . . . . . . . . . . . . . . . . . . . . . . .70-16-6 9660 STS combine . . . . . . . . . . . . . . . . . .10-10-11

083006
PN=19
Index
Page Page
9760 STS combine . . . . . . . . . . . . . . . . . .10-10-13 Steering pump

9860 STS Combine (S.N. --715700) . . . . .10-10-20 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-9
9860 STS Combine (S.N. 715701--) . . . . .10-10-22 Disassemble . . . . . . . . . . . . . . . . . . . . . . . .70-10-5
Speed control Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-10
Fan drive. . . . . . . . . . . . . . . . . . . . . . . . .120-20-16 Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-5
Spindle bearing (alternate method) Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-4
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-20 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-5
Spindle bearing (preferred method) Steering tie rods
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-20 Remove and install . . . . . . . . . . . . . . . . . .60-05-32
Split ring tool Steering valve
DFHXT1 Assemble . . . . . . . . . . . . . . . . . . . . . . . . .60-05-11
Cam lobe motor. . . . . . . . . . . . . . . . . . .199-05-1 Disassemble . . . . . . . . . . . . . . . . . . . . . . . .60-05-8
STARFIRE Exploded view. . . . . . . . . . . . . . . . . . . . . . .60-05-7
Position receiver Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-15
Disassemble and assemble . . . . . . . . . .40-60-24 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .60-05-6
Remove and install . . . . . . . . . . . . . . . .40-60-25 Steering valve and flowmeter
Start switch Electro-hydraulic
Remove and install . . . . . . . . . . . . . . . . . .40-30-32 Exploded view . . . . . . . . . . . . . . . . . . . .60-05-18
Start-up procedure Steering yoke
Hydrostatic system repair . . . . . .50-15-90, 70-05-9 Remove and install . . . . . . . . . . . . . . . . . .50-20-16
Starting aid Stone trap door
Cold weather Remove and install . . . . . . . . . . . . . . . . .120-05-31
Remove and install . . . . . . . . . . . . . . . .30-10-15 Storing fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-1
Indx
20 Switch Storing lubricants . . . . . . . . . . . . . . . . . . . . .10-20-16
Straw chopper
Blades replacement and configutation
Starting motor
9560 . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-16
Straw Chopper
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-50-2
Blades, remove
Steering
Extra fine cut . . . . . . . . . . . . . . . . . . . .120-15-19
AUTOTRAC assisted steering flowmeter
Straw chopper
Exploded view . . . . . . . . . . . . . . . . . . . .60-05-20
Blades, remove
Essential or recommended tools . . . . . . . . .60-05-1
FIne cut . . . . . . . . . . . . . . . . . . . . . . . .120-15-18
Flow meter
Blades, replace
Extra fine cut . . . . . . . . . . . . . . . . . . . .120-15-19
Other material . . . . . . . . . . . . . . . . . . . . . . .60-05-3 Fine cut . . . . . . . . . . . . . . . . . . . . . . . .120-15-18
Rods, installation. . . . . . . . . . . . . . . . . . . .60-05-32 Drive jackshaft, install . . . . . . . . . . . . . . .120-15-35
Rods, remove . . . . . . . . . . . . . . . . . . . . . .60-05-32 Drive jackshaft, remove. . . . . . . . . . . . . .120-15-32
Service equipment and tools . . . . . . . . . . . .60-05-2 Housing . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-6
Specifications . . . . . . . . . . . . . . . . . . . . . . .60-05-4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-14
Steering valve Knives, replace . . . . . . . . . . . 120-15-22, 120-15-23
Exploded view . . . . . . . . . . . . . . . . . . . . .60-05-7 Remove . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-7
Tie rod end Straw Chopper
Remove and install . . . . . . . . . . . . . . . .60-05-33 Rotor
Steering column Extra fine cut . . . . . . . . . . . . . . . . . . . . .120-15-4
Assemble . . . . . . . . . . . . . . . . . . . . . . . . .60-05-22 Straw chopper
Components . . . . . . . . . . . . . . . . . . . . . . .60-05-21 Rotor
Disassemble . . . . . . . . . . . . . . . . . . . . . . .60-05-22 Fine cut . . . . . . . . . . . . . . . . . . . . . . . . .120-15-3
Telescoping shaft bearings Straw spreader
Replace . . . . . . . . . . . . . . . . . . . . . . . . .60-05-26 Disassemble and assemble . . . . . . . . . .120-15-44
Steering cylinder Flow control valve
Disassemble and assemble . . . . . . . . . . .60-05-31 Disassemble and reassemble . . . . . . . . .70-15-7
Remove and install . . . . . . . . . . . . . . . . . .60-05-27 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .70-15-8

083006
PN=20
Index
Page Page
Remove. . . . . . . . . . . . . . . . . . . . . . . . . .70-15-6 Fuel pressure

Install . . . . . . . . . . . . . . . . . . . . . . . . . . .120-15-48 Remove and install . . . . . . . . . . . . . . . .40-35-23
Pump, install . . . . . . . . . . . . . . . . . . . . . . .70-10-20 Horn
Pump, remove . . . . . . . . . . . . . . . . . . . . .70-10-19 Remove and install . . . . . . . . . . . . . . . .40-30-34
Remove . . . . . . . . . . . . . . . . . . . . . . . . .120-15-41 Hydro charge pressure
Straw spreader motor Remove and install . . . . . . . . . . . . . . . .40-35-24
Remove and install . . . . . . . . . . . . . . . . . . .70-25-1 Light
Straw spreader pump Hazard
Assemble . . . . . . . . . . . . . . . . . . . . . . . . .70-10-23 Remove and install . . . . . . . . . . . . . . .40-30-6
Dissassemble . . . . . . . . . . . . . . . . . . . . . .70-10-21 Light panel dimmer
STS Rotor Remove and install . . . . . . . . . . . . . . . . .40-30-5
Front bearing Park brake
Remove and install . . . . . . . . . . . . . . .120-05-27 Remove and install . . . . . . . . . . . . . . . .40-35-21
Static balance . . . . . . . . . . . . . . . . . . . .120-05-102 Power mirror
Variable drive Remove and install . . . . . . . .40-30-35, 40-30-36
Disassemble and assemble . . . . . . . . .140-05-20 Service light
Variable drive shaft Shoe light
STS Rotor drive gear case Sieve adjust
Disassemble and assemble . . . . . . . . . .120-05-54 Remove and install . . . . . . . . . . . . . . . .40-35-25
Sub-floor assembly Start
Remove and install . . . . . . . . . . . . . . . . .110-05-17 Remove and install . . . . . . . . . . . . . . . .40-30-32 Indx
Suction screen Starting aid 21
Remove and install . . . . . . . . . . . . . . . . . . .50-05-9 Remove and install . . . . . . . . . . . . . . . .40-30-33
Switch Turn signal
Air restriction Remove and install . . . . . . . .40-30-33, 60-05-22
Tier III cooling package . . . . . . . . . . .40-35-22
Back-up alarm
Remove and install . . . . . . . . . . . . . . . .40-35-29 T
Chaffer adjust
Remove and install . . . . . . . . . . . . . . . .40-35-25 Tailboard
Chopper raise/lower Powered
Remove and install . . . . . . . . . . . . . . . .40-35-25 Blades
Cleaning shoe light Remove and install . . . . . . . . . . . . .120-15-39
Remove and install . . . . . . . . . . . . . . . .40-35-25 Exploded view . . . . . . . . . . . . . . . . . . .120-15-38
CLIMATRAK Tailboard motor
Air conditioning control Remove and install . . . . . . . . . . . . . . . . . . .70-25-4
Remove and install . . . . . . . . . . . . . . .40-30-7 Tailing elevator and augers
Heater control Specifications . . . . . . . . . . . . . . . . . . . . . .120-25-1
Remove and install . . . . . . . . . . . . . . .40-30-7 Tailings
ClimaTrak Sensor
Remove and install . . . . . . . . . . . . . . . . .40-30-6 Remove and install . . . . . . . . . . . . . . . . .40-35-7
Engine gear case pressure Tailings auger
Remove and install . . . . . . . . . . . . . . . .40-35-23 Lower, remove . . . . . . . . . . . . . . . . . . . . .120-25-1
Engine gear case temperature Upper, install. . . . . . . . . . . . . . . . . . . . . . .120-25-9
Remove and install . . . . . . . . . . . . . . . .40-35-23 Upper, remove . . . . . . . . . . . . . . . . . . . . .120-25-8
Engine oil pressure Tailings auger, lower
Remove and install . . . . . . . . . . . . . . . .40-35-24 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .120-25-4
Field Tailings elevator
Work Install . . . . . . . . . . . . . . . . . . . . . . . . . . .120-25-19
Remove and install . . . . . . . . . . . . . . .40-30-6 Remove . . . . . . . . . . . . . . . . . . . . . . . . .120-25-12

083006
PN=21
Index
Page Page
Temperature control door actuator Face seal fittings

Remove and install . . . . . . . . . . . . . . . . . . .90-10-9 Metric
Thermostats High pressure . . . . . . . . . . . . . . . . . .10-10-31
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-31 Standard pressure . . . . . . . . . . . . . . .10-10-30
Threshing bars SAE
Location drawing High pressure . . . . . . . . . . . . . . . . . .10-10-33
(S.N.--715300). . . . . . . . . . . . . . . . . . .120-05-92 Standard pressure . . . . . . . . . . . . . . .10-10-32
Remove and install . . . . . . . . . . . . . . . . .120-05-90 Four bolt flange
Threshing bars (rice) SAE
Location drawing (rice) High pressure . . . . . . . . . . . . . . . . . .10-10-36
(S.N.--715300). . . . . . . . . . . . . . . . . . .120-05-94 Standard pressure . . . . . . . . . . . . . . .10-10-35
Threshing element Torque sensing--driven
Location drawing Disassemble and assemble . . . . . . . . . .120-05-41
15 element configuration . . . . . . . . . . .120-05-96 Remove and install . . . . . . . . . . . . . . . . .120-05-37
24 element dense pack Transfer gear case
configuration . . . . . . . . . . . . . . . . . .120-05-98 Assemble . . . . . . . . . . . . . . . . . . . . . . . .140-05-32
Threshing speed valve module . . . . . . . . . . . .70-16-8 Disassemble . . . . . . . . . . . . . . . . . . . . . .140-05-32
Tie rod end Install . . . . . . . . . . . . . . . . . . . . . . . . . . .140-05-28
Remove and install . . . . . . . . . . . . . . . . . .60-05-33 Remove . . . . . . . . . . . . . . . . . . . . . . . . .140-05-28
Tilt cylinder Transmission
CONTOUR MASTER . . . . . . . .110-20-1, 110-20-2 Assemble . . . . . . . . . . . . . . . . . . . . . . . . .50-05-22
Remove. . . . . . . . . . . . . . . . . . . . . . . . .110-20-3 Disassemble and repair . . . . . . . . . . . . . .50-05-14
Indx Tines Exploded view. . . . . . . . . . . . . . . . . . . . . .50-05-12
22 Remove and install . . . . . . . . . . . . . . . . .120-05-90 Gearshift lever and linkage
Tire Remove and install . . . . . . . . . . . . . . . .50-05-28
Care and service. . . . . . . . . . . . . . . . . . . . .50-25-4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-26
Remove and install . . . . . . . . . . . . . . . . . . .50-25-8 Lube pump
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-25-3 Remove and install . . . . . . . . . . . . . . . . .50-05-7
Using liquid weight . . . . . . . . . . . . . . . . . . .50-25-6 Recondition. . . . . . . . . . . . . . . . . . . . . . . .50-05-13
Tires and wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-10
Essential or recommended tools . . . . . . . . .50-25-1 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-14
Service equipment and tools . . . . . . . . . . . .50-25-2 Shifter forks and cam
Specification . . . . . . . . . . . . . . . . . . . . . . . .50-25-3 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .50-05-5
Toe-in adjustment. . . . . . . . . . . . . . . . . . . . .60-05-32 Remove and repair . . . . . . . . . . . . . . . . .50-05-3
Top cover Suction screen
Remove and install . . . . . . . . . . . . . . . . .120-05-14 Remove and install . . . . . . . . . . . . . . . . .50-05-9
Top covers Transmission and differential
Separator Other material . . . . . . . . . . . . . . . . . . . . . . .50-05-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . .120-05-89 Specifications . . . . . . . . . . . . . . . . . . . . . . .50-05-2
Top shaft Transport/header and warning lights
Disassemble and assemble . . . . . . . . . .110-10-15 Bulb part numbers . . . . . . . . . . . . . . . . . . .40-25-2
Top shaft and slip clutch Triple main hydraulic pump
Essential or recommended tools . . . . . . . .110-10-1 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-9
Other material . . . . . . . . . . . . . . . . . . . . . .110-10-1 Disassemble . . . . . . . . . . . . . . . . . . . . . . . .70-10-5
Top shaft slip clutch Exploded view. . . . . . . . . . . . . . . . . . . . . . .70-10-8
Disassemble and assemble . . . . . . . . . . .110-10-4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .110-10-8 Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .110-10-2 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-4
Top shaft supports Truss rod
Remove and install . . . . . . . . . . . . . . . . .110-10-11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-25-15
Torque chart Trust plate
External hexagon plug . . . . . . . . . . . . . . .10-10-37 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-21

083006
PN=22
Index
Page Page
Tube Elbow
Horizontal unloading auger Remove and install . . . . . . . . . . . . . . .130-20-32
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-30 Grain saver door
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-29 Remove and install . . . . . . . . . . . . . . . .130-20-7
Tune-up and adjustment Unloading auger swing cylinder
Care and maintenance of belts . . . . . . . . . .10-15-2 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-7
Defective belts . . . . . . . . . . . . . . . . . . . . . .10-15-4 Exploded view. . . . . . . . . . . . . . . . . . . . . . .70-20-6
Tune-up and adjustment . . . . . . . . . . . . . . .10-15-1 Remove and install . . . . . . . . . . . . . . . . . . .70-20-5
Turbocharger Unloading auger system drives
Remove and install Specifications . . . . . . . . . . . . . . . . . . . . . .130-10-1
12.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-9 Unloading auger, grain tank lights
8.1 L . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-05-4 Bulb part numbers . . . . . . . . . . . . . . . . . . .40-25-2
Remove and install turbocharger Use adquate service facilities
6.8 L and 9.0 L . . . . . . . . . . . . . . . . . . . .30-05-6 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-05-14
Turbocharger Compressor Inlet
Sensor
Remove and install V
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-26 Valve
Turbocharger repair Pressure regulating
Air intake system . . . . . . . . . . . . . . . . . . .30-05-10 Disassemble and assemble . . . . . . . . .140-05-68
Turbocharger speed Remove and install . . . . . . . . . . . . . . .140-05-67
Sensor Valve plate
Remove and install Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . .50-15-27 Indx
9.0 L . . . . . . . . . . . . . . . . . . . . . . . . .40-35-28 23
Valve stack
Turn signal Specifications . . . . . . . . . . . . . . . . . . . . . . .70-16-1
Switch Valve stack seals
Remove and install . . . . . . . . . . . . . . . .40-30-33 Remove and install . . . . . . . . . . . . . . . . . .50-20-38
Turn signal indicators and gauge lights Variable drive
Bulb part numbers . . . . . . . . . . . . . . . . . . .40-25-2 STS Rotor
Turn signal switch Disassemble and assemble . . . . . . . . .140-05-20
Remove and install . . . . . . . . . . . . . . . . . .60-05-22 Remove and install . . . . . . . . . . . . . . .140-05-17
Turn signals, tail and flasher lights Variable drive countershaft
Bulb parts numbers. . . . . . . . . . . . . . . . . . .40-25-2 Remove and install . . . . . . . . . . . . . . . . . .110-15-6
Turning radius Variable speed feeder house valve
Specifications . . . . . . . . . . . . . . . . . . . . . . .10-10-2 module . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-16-7
Two piece Vertical auger
Horizontal unloading auger Install . . . . . . . . . . . . . . . . . . . . . . . . . . .130-15-12
Regular unload rate . . . . . . . . . . . . . . . .130-20-5 Lower gear case
Two way reel lift valve module . . . . . . . . . . . .70-16-7 Assemble . . . . . . . . . . . . . . . . . . . . . . .130-15-6
Disassemble . . . . . . . . . . . . . . . . . . . . .130-15-6
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-15-12
Remove. . . . . . . . . . . . . . . . . . . . . . . . .130-15-3
U Remove . . . . . . . . . . . . . . . . . . . . . . . . . .130-15-3
Vertical unloading auger and lower gear case
Unloading auger Essential or recommended tools . . . . . . . .130-15-1
Charge housing Voltage regulator (185 amp)
Install. . . . . . . . . . . . . . . . . . . . . . . . . .130-20-41 Remove and install . . . . . . . . . . . . . . . . . . .40-45-7
Remove. . . . . . . . . . . . . . . . . . . . . . . .130-20-38
Drive belt W
Drive cylinder Warning display panel
Remove and install . . . . . . . . . . . . . . . . .70-20-8 basic operation . . . . . . . . . . . . . . . . . . . . . .40-30-3

083006
PN=23
Index
Page
Circuit board
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-5
Description . . . . . . . . . . . . . . . . . . . . . . . . .40-30-3
Warning display panel and header float gauge lights
Bulb part numbers . . . . . . . . . . . . . . . . . . .40-25-2
Warning panel
Switch
ClimaTrak
Field
Hazard
Remve and install . . . . . . . . . . . . . . . .40-30-6
Light
Work
Water pump, repair or replace . . . . . . . . . . .20-10-31
Wear strips
Feed accelerator
Wet clutch
Indx
24
Separator drive
Wheels
Steering toe-in adjustment . . . . . . . . . . . .60-05-32
Windshield washer
Remove and install . . . . . . . . . . . .40-40-6, 40-40-8
Windshield wiper
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-40-4
Windshield, cab
Remove and install
Style A. . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-2
Style B. . . . . . . . . . . . . . . . . . . . . . . . . . .90-15-6
Wiper
Specifications . . . . . . . . . . . . . . . . . . . . . . .40-40-1
Wiper motor
Wiring harness
Routing
Cab, main . . . . . . . . . . . . . . . . .40-15-2, 40-15-3
Engine . . . . . . . . . . . . . . . . . .40-15-10, 40-15-11
Left-hand main . . . . . . . . . . . . .40-15-6, 40-15-7
Right-hand main . . . . . . . . . . . .40-15-8, 40-15-9

083006
PN=24

9660 Combine

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Available Formats

9660 Combine

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Available Formats

9560 STS, 9660 STS,

9760 STS and 9860 STS

For complete service information also see:

TM2181 (29AUG06) 60 Series STS Combine Repair

SECTION 20—Engine SECTION 80—Separator Shell

SECTION 110—Feeder House Repair

All information, illustrations and specifications in this manual are based on

TM2181 (29AUG06) i 60 Series STS Combine Repair

SECTION 199—Dealer Fabricated Tools

TM2181 (29AUG06) ii 60 Series STS Combine Repair

TM2181 (29AUG06) iii 60 Series STS Combine Repair

TM2181 (29AUG06) iv 60 Series STS Combine Repair

TM2181 (29AUG06) 10-1 60 Series STS Combine Repair

Mixing of Lubricants . . . . . . . . . . . . . . . . . . . .10-20-17

TM2181 (29AUG06) 10-2 60 Series STS Combine Repair

This is a safety-alert symbol. When you see this symbol

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is

DANGER or WARNING safety signs are located near

Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near

Store flammable fluids away from fire hazards. Do not

Do not store oily rags; they can ignite and burn

TM2181 (29AUG06) 10-05-1 60 Series STS Combine Repair

Keep sparks, lighted matches, and open flame away from

Never check battery charge by placing a metal object

TM2181 (29AUG06) 10-05-2 60 Series STS Combine Repair

CAUTION: Battery gas can explode. Keep

CAUTION: Sulfuric acid in battery electrolyte is

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

WARNING: Battery posts, terminals, and related

TM2181 (29AUG06) 10-05-3 60 Series STS Combine Repair

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

1. Flush your skin with water.

1. Do not induce vomiting.

TM2181 (29AUG06) 10-05-4 60 Series STS Combine Repair

Direct exposure to hazardous chemicals can cause

(See your John Deere dealer for MSDS’s on chemical

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin

Avoid the hazard by relieving pressure before

Search for leaks with a piece of cardboard. Protect hands

If an accident occurs, see a doctor immediately. Any fluid

TM2181 (29AUG06) 10-05-5 60 Series STS Combine Repair

Escaping fluid or gas from systems with pressurized

Relieve pressure from the pressurized system before

Accumulators cannot be repaired.

Wait Before Opening High-Pressure Fuel

High-pressure fluid remaining in fuel lines can cause

Park Machine Safely