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G-III and D Series

Skidders
Repair
(S.N. 586337 )

TECHNICAL MANUAL
G-III and D Series Skidders Repair
(Serial No. 586337 )
TM2111 30MAY03 (ENGLISH)

For complete service information also see:


G-III and D Series Skidders Operation and
Tests (S.N. 586337 ) . . . . . . . . . . . . . . . . . .
TM2110
TEAMMATE II 1200, 1400, and 1600 Series
Inboard Planetary Axles . . . . . . . . . . . . . . . .
CTM43
POWERTECH 4.5 L & 6.8 L Diesel Engines,
Base Engine. . . . . . . . . . . . . . . . . . . . . . . . . .
CTM104
POWERTECH 4.5 L & 6.8 L Diesel Engines,
Level 12 Electronic Fuel System with DE10
STANADYNE Pump . . . . . . . . . . . . . . . . . . .
CTM331
POWERTECH 8.1L Diesel Engines, Base
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTM86
POWERTECH 8.1 L Diesel Engines, Level 9
Electronic Fuel System With High Pressure
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . .
CTM255
Starting Motors and Alternators . . . . . . . . . .
CTM77
40 and 4000 Winches . . . . . . . . . . . . . . . . . .
CTM25
60 and 6000 Winches . . . . . . . . . . . . . . . . . .
CTM41
120 Series Hydraulic Cylinders . . . . . . . . . . TMH120A

Worldwide Construction
And Forestry Division
LITHO IN U.S.A.

Introduction
Foreword
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.

Information is organized in groups for the various


components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
testing, and repair.
Fundamental service information is available from
other sources covering basic theory of operation,
fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.

DX,TMIFC 1929SEP981/1

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Introduction

Technical Information Feedback Form


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TX,TM,FAX 1903JUL011/1

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Introduction

TM2111 (30MAY03)

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Contents
00

SECTION 00General Information


Group 01Safety Information
Group 0003Torque Values

SECTION 11Park Brake


Group 1111Active Elements
Group 1160Hydraulic System

SECTION 01Wheels
Group 0110Powered Wheels and Fastenings

SECTION 17Frame, Chassis, or Supporting


Structures
Group 1740Frame Installation
Group 1746Frame Bottom Guards

SECTION 02Axles and Suspension System


Group 0200Removal and Installation
Group 0225Input Drive Shafts and U-Joints
Group 0260Hydraulic System

01

SECTION 18Operators Station


Group 1800Removal and Installation
Group 1810Operator Enclosure
Group 1821Seat and Seat Belt
Group 1830Heating and Air Conditioning

SECTION 03Transmission
Group 0300Removal and Installation
Group 0315Controls
Group 0325Input Drive Shafts and U-Joints
Group 0350Gears, Shafts and Power Shift
Clutches
Group 0360Hydraulic System

02

03

SECTION 19Sheet Metal and Styling


Group 1910Hood or Engine Enclosure
Group 1921Grille and Grille Housing

SECTION 04Engine
Group 0400Removal and Installation

SECTION 20Safety, Convenience and


Miscellaneous
Group 2003Pressurized Water System
Group 2004Horn and Warning Devices

SECTION 05Engine Auxiliary Systems


Group 0505Cold Weather Starting Aids
Group 0510Cooling Systems
Group 0520Intake System
Group 0530External Exhaust System
Group 0560External Fuel Supply System

04

SECTION 21Main Hydraulic System


Group 2160Hydraulic System

05

SECTION 30Winch
Group 3000Removal and Installation
Group 3015Controls Linkage
Group 3025Input Drive Shafts and U-Joints
Group 3050Drive and Clutch

SECTION 06Torque Converter


Group 0600Removal and Installation
Group 0641Torque Converter Housing
Group 0651Converter Turbine, Gears, and Shaft
SECTION 07Damper Drive
Group 0752Elements

06

SECTION 32Bulldozers (Stacking & Trailbuilding


Blades)
Group 3201Blades
Group 3215Controls Linkage
Group 3260Hydraulic System

SECTION 09Steering System


Group 0930Secondary Steering
Group 0960Hydraulic System

SECTION 37Arch or Boom


Group 3740Frames

SECTION 10Service Brakes


Group 1011Active Elements
Group 1015Controls Linkage
Group 1060Hydraulic System

09
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.

10

COPYRIGHT 2003
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual

TM2111 (30MAY03)

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Contents
00

01

SECTION 38Grapple
Group 3803Grapple Mechanism
Group 3815Controls Linkage
Group 3840Frames
Group 3860Hydraulic System
SECTION 99Dealer Fabricated Tools
Group 9900Dealer Fabricated Tools

02

03

04

05

06

07

09

10

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Contents

11
INDX

17

18

19

20

21

30

32

37

38

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Contents

INDX
11

17

18

19

20

21

30

32

37

38

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00

Section 00

General Information
Contents
Page

Page

Group 01Safety Information


Skidder Safety Features . . . . . . . . . . . . . . . . . .00-01-1
Recognize Safety Information . . . . . . . . . . . . . .00-01-2
Follow Safety Instructions . . . . . . . . . . . . . . . . .00-01-2
Operate Only If Qualified. . . . . . . . . . . . . . . . . .00-01-2
Wear Protective Equipment . . . . . . . . . . . . . . . .00-01-3
Avoid Unauthorized Machine Modifications . . . .00-01-3
Inspect Machine . . . . . . . . . . . . . . . . . . . . . . . .00-01-3
Stay Clear Of Moving Parts. . . . . . . . . . . . . . . .00-01-4
Avoid High-Pressure Fluids . . . . . . . . . . . . . . . .00-01-4
Beware Of Exhaust Fumes . . . . . . . . . . . . . . . .00-01-4
Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5
Handle Starting Fluid Safely . . . . . . . . . . . . . . .00-01-5
Prevent Battery Explosions . . . . . . . . . . . . . . . .00-01-6
Handle Chemical Products Safely . . . . . . . . . . .00-01-6
Dispose of Waste Properly . . . . . . . . . . . . . . . .00-01-6
Prepare for Emergencies. . . . . . . . . . . . . . . . . .00-01-7
Use Steps And Handholds Correctly . . . . . . . . .00-01-7
Start Only From Operators Seat . . . . . . . . . . . .00-01-7
Use And Maintain Seat Belt . . . . . . . . . . . . . . .00-01-8
Prevent Unintended Machine Movement . . . . . .00-01-8
Avoid Work Site Hazards . . . . . . . . . . . . . . . . .00-01-9
Operate Machine Safely . . . . . . . . . . . . . . . . . .00-01-9
Keep Riders Off Machine . . . . . . . . . . . . . . . .00-01-10
Avoid Backover Accidents . . . . . . . . . . . . . . . .00-01-10
Avoid Machine Tip Over . . . . . . . . . . . . . . . . .00-01-11
Operating on Slopes . . . . . . . . . . . . . . . . . . . .00-01-11
Operating Or Traveling On Public Roads . . . .00-01-12
Inspect and Maintain ROPS . . . . . . . . . . . . . .00-01-12
Keep the Operator Protective Structure
(OPS) in Place. . . . . . . . . . . . . . . . . . . . . . .00-01-13
Add And Operate Attachments Safely . . . . . . .00-01-13
Park And Prepare For Service Safely . . . . . . .00-01-14
Service Cooling System Safely . . . . . . . . . . . .00-01-14
Remove Paint Before Welding or Heating . . . .00-01-15
Make Welding Repairs Safely . . . . . . . . . . . . .00-01-15
Drive Metal Pins Safely . . . . . . . . . . . . . . . . . .00-01-15
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-16

Unified Inch Bolt and Cap Screw Torque


Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-6
Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-7
Service Recommendations for 37 Flare
and 30 Cone Seat Connectors . . . . . . . . .00-0003-8
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-9
Service Recommendations For Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0003-11
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . .00-0003-12
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . .00-0003-13

Group 0003Torque Values


Hardware Torque Specifications . . . . . . . . . .00-0003-1
Keeping ROPS Installed Properly . . . . . . . . .00-0003-1
Metric Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3
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Group 01

Safety Information
00
01
1

Skidder Safety Features

1
3
4

13

13

13
7

2
10
12

5
6

11

T161851

UN20NOV02

T161851

Please remember, the operator is the key to


preventing accidents.
1. ROPS/OPS. Structures designed to help protect the
operator are certified to ISO, SAE, and OSHA.
Enclosures also deflect sun and rain.
2. Parking Brake. Is easily engaged simply by moving
the transmission control to the park position or
pushing the park brake switch. The parking brake
engages automatically whenever the engine is
stopped.
Engine Start Protection. A neutral start switch
allows the engine to start only when the
transmission is out-of-gear and the park brake is
engaged. The park brake is always engaged during
start-up.
3. Interior Rearview Mirror. Offers the operator a
view of activity behind him.
4. Front Windshield Wiper. Wiper cleans windshield
area, improving operator visibility in poor weather
conditions.

5. Bypass Start Protection. Shielding over the starter


helps prevent dangerous bypassing starting.
6. Engine Fan Guard. A secondary fan guard inside
the engine compartment helps prevent contact with
the rotating fan blades.
7. Fire Extinguisher. A fire extinguisher is provided in
the cab.
8. Operator Manual Holder. A sealed manual holder
keeps manual on machine clean and dry.
9. Steps. Wide, skid-resistant provide excellent footing
while getting in or out of the operators station.
10. Seatbelt Retractors. Seatbelt retractors help keep
belts clean and convenient to use.
11. Articulation Locking Bar. A self storing locking
bar can be positioned to prevent articulation during
servicing or transport.
12. Backup Alarm. Alerts bystanders when reverse
travel direction is selected by operator.
13. Handholds. Large conveniently placed handholds
make it easy to enter or exit the operators station.

OUO1079,0000566 1915NOV021/1

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Safety Information

Recognize Safety Information


UN28AUG00

This is the safety alert symbol. When you see this


symbol on your machine or in this manual, be alert
for the potential of personal injury.

T133555

Follow the precautions and safe operating practices


highlighted by this symbol.

1928AUG00

A signal word DANGER, WARNING, or CAUTION is


used with the safety alert symbol. DANGER identifies the
most serious hazards.

T133588

On your machine, DANGER signs are red in color,


WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.

TX03679,00016CC 1921AUG001/1

Follow Safety Instructions


UN24AUG00

Read the safety messages in this manual and on the


machine. Follow these warnings and instructions carefully.
Review them frequently.
Be sure all operators of this machine understand every
safety message. Replace operators manual and safety
labels immediately if missing or damaged.

T133556

00
01
2

TX03679,00016F9 1914MAR011/1

Operate Only If Qualified


Do not operate this machine unless you have read the
operators manual carefully and you have been
qualified by supervised training and instruction.
Familiarize yourself with the job site and your
surroundings before operating. Try all controls and

machine functions with the machine in an open area


before starting to work.
Know and observe all safety rules that may apply to
your work situation and your work site.

TX03679,00016FA 1930OCT001/1

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Safety Information
00
01
3

Wear Protective Equipment


Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.

UN23AUG88

Wear close fitting clothing and safety equipment


appropriate to the job.

TS206

Prolonged exposure to loud noise can cause impairment


or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.

TX03679,00016D0 1930OCT001/1

Avoid Unauthorized Machine Modifications


Modifications of this machine, or addition of
unapproved products or attachments, may affect
machine stability or reliability, and may create a hazard
for the operator or others near the machine.

Always contact an authorized dealer before making


machine modifications that change the intended use,
weight or balance of the machine, or that alter
machine controls, performance or reliability.

TX03679,00016B7 1930OCT001/1

Inspect Machine

T6607AQ

Keep all guards and shields in good condition and


properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.

UN18OCT88

Inspect machine carefully each day by walking around it


before starting.

TX03679,0001734 1925SEP001/1

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Safety Information

Stop engine before examining, adjusting or maintaining


any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.

T133592

Entanglements in moving parts can cause serious injury.

UN12SEP01

Stay Clear Of Moving Parts

TX03679,00016D2 1930OCT001/1

T133840

If hydraulic fluid penetrates your skin, see a doctor


immediately. Injected fluid must be removed
surgically within hours or gangrene may result.
Contact a knowledgeable medical source or the Deere &
Company Medical Department in Moline, Illinois, U.S.A.

T133509

Never search for leaks with your hands. Protect hands.


Use a piece of cardboard to find location of escaping fluid.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.

UN20SEP00

This machine uses a high-pressure hydraulic system.


Escaping fluid under pressure can penetrate the skin
causing serious injury.

UN31OCT00

Avoid High-Pressure Fluids

TX03679,00016D3 1930OCT001/1

Prevent asphyxiation. Engine exhaust fumes can cause


sickness or death.
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
outside air into the area.

UN24AUG00

Beware Of Exhaust Fumes

T133546

00
01
4

TX03679,00016D4 1914SEP001/1

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Safety Information
00
01
5

Remove Debris And Clean The Surrounding Area:


Before starting repair work, such as welding, clear the
area of any debris or flammable material.
Keep A Fire Extinguisher Available: Always keep a
multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.

T133552
UN07SEP00
T133553

Maintain Hoses and Wiring: Replace hydraulic hoses


immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.

UN07SEP00

Clean Machine Regularly: Keep trash, debris, grease


and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Store rags
and other combustible materials in a safe, fireproof
location. Use only nonflammable products for cleaning the
machine or components.

T133554

Handle Fuel Safely: Store flammable fluids away from


fire hazards. Never refuel machine while smoking or when
near sparks or flame.

UN14SEP00

Prevent Fires

TX03679,0001808 1911OCT011/1

Handle Starting Fluid Safely

To prevent accidental discharge when storing the


pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.

T145705

Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.

UN18SEP01

Starting fluid is highly flammable.

TX03679,0001807 1918SEP011/1

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Safety Information

Prevent Battery Explosions

Never check battery charge by placing a metal object


across the posts. Use a voltmeter or hydrometer.

TS204

Do not charge a frozen battery; it may explode. Warm


battery to 16C (60F).

UN23AUG88

Battery gas can explode. Keep sparks, lighted matches,


and open flame away from the top of battery.

TX03679,000174A 1914SEP001/1

If uncertain about safe handling or use of these chemical


products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS). The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.

T133580

Exposure to hazardous chemicals can cause serious


injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.

UN25AUG00

Handle Chemical Products Safely

TX03679,00016D7 1914SEP001/1

Improper disposal of waste can threaten the environment.


Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.

UN25AUG00

Dispose of Waste Properly

T133567

00
01
6

Air conditioning refrigerants can damage the atmosphere.


Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your dealer for
more information.

TX03679,0001733 1914SEP001/1

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Safety Information
00
01
7

Prepare for Emergencies


Be prepared if an emergency occurs or a fire starts.

TS291

Keep emergency numbers for doctors, ambulance service,


hospital, and fire department near your telephone.

UN23AUG88

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B 1914SEP001/1

Use extra care when mud, snow, or moisture present


slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.

T133468

Prevent falls by facing the machine when you get on and


off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.

UN30AUG00

Use Steps And Handholds Correctly

TX03679,00016F2 1914SEP001/1

Never attempt to start engine from the ground. Do not


attempt to start engine by shorting across the starter
solenoid terminals.

T133715

Avoid unexpected machine movement. Start engine only


while sitting in operators seat. Ensure all controls and
working tools are in proper position for a parked machine.

UN07SEP00

Start Only From Operators Seat

TX03679,0001799 1902MAY011/1

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Safety Information

Use And Maintain Seat Belt

T133716

1914SEP00

Use seat belt when operating machine. Remember to


fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every three years, regardless of appearance.

TX03679,00016DD 1917OCT001/1

Prevent Unintended Machine Movement

UN16OCT01

Be careful not to accidentally actuate controls. Move


transmission out of gear and lower all equipment to the
ground during work interruptions. Follow these steps
before allowing co-workers to approach the machine,
before standing up, leaving the operators seat, or exiting
the machine:

Lower equipment to the ground


Move transmission lever to park
Be sure locking sleeve engages console
Stop the engine

For machines with separate park brake switch:

ACC

OFF
ON

START

Lower equipment to the ground


Move gear selector to neutral position
Press park brake switch to on
Stop the engine

ENGINE
STARTS
"BRAKE ON"
ONLY IN
POSITION
SHIFT LEVER
IN "N" POSIT AND
ION

Always set
park brake
before leavin
g
seat.
After start up,
push to OFF
position to
release park

UN01NOV01

T146609

For machines with transmission lever park position:

brake.

T147558

00
01
8

TX03679,000180C 1911OCT011/1

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Safety Information
00
01
9

Be sure co-workers and bystanders are clear of machine


before operating. Keep co-workers a safe distance away
when skidding, because logs may kick-out unexpectedly.

T146611

Plan your operation before starting work. Check skidding


trails and landings for stumps, large rocks, drop-offs,
muddy areas and standing water. Carefully examine
overhead for trees and branches that might fall or strike
the operators station. Take precautions to avoid these
hazards.

UN22OCT01

Avoid Work Site Hazards

Use extra care if you must drive over logs or saplings that
may be dislodged or spring-up against the machine or
bystanders.
Do not operate under low-hanging electrical wires.
Contact may cause serious injury or death by
electrocution.

TX03679,000180B 1911OCT011/1

Use extra care around landings where bystanders are


more likely to be present. Do not skid logs past people
that are not a safe distance away from logs that may
swing or kick-out.

T146610

Wear the seat belt when operating this machine. Do not


operate the machine if all elements of the operator
protective structure (OPS) are not in place and in good
repair.

UN22OCT01

Operate Machine Safely

Use extra care when backing-up with logs attached. Make


sure the delimbing grate is in good repair and bystanders
are a safe distance away.
Be careful when operating in muddy or frozen conditions
because the machine may slide or tip more easily. Avoid
side slopes when possible. Drive straight up or down
slopes to reduce the possibility of tipping.

TX03679,000180A 1911OCT011/1

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Safety Information

Keep Riders Off Machine

Riders may obstruct operators view or impair his ability to


operate machine safely.

T145263

Riders are subject to injury. They may fall from machine,


be caught between machine parts, or be struck by foreign
objects.

UN06SEP01

Only allow operator on machine.

TX03679,0001800 1918SEP011/1

Before moving machine, be sure all persons are clear


of machine path. Turn around and look directly for best
visibility. Use mirror to assist in checking around machine.
Keep windows and mirror clean, adjusted, and in good
repair.
Be certain reverse warning alarm is working properly.

UN06SEP01

Avoid Backover Accidents

T145264

00
01
10

Use a signal person when backing if view is


obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.

TX03679,0001801 1931OCT011/1

TM2111 (30MAY03)

00-01-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=18

Safety Information
00
01
11

Be careful on slopes. Avoid sharp turns. Avoid stumps,


rocks and drop-offs when possible. Use extra care on soft,
uneven or frozen ground.
Do not overload. Know the capacity of the machine. Be
careful with heavy loads which may affect machine
stability.

T133716

Load and unload from trucks or trailers carefully. Be


sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.

UN06SEP01

Do not jump if the machine tips. You will be unlikely to


jump clear and the machine may crush you.

T145266

Use seat belt at all times.

1914SEP00

Avoid Machine Tip Over

T146612

UN06NOV01

Ensure solid footing. Use extra care in soft ground


conditions that may not uniformly support the wheels. Do
not operate close to banks that may cave in and cause
machine to tip or fall.

TX03679,0001802 1931OCT011/1

Select low gear speed before starting down slope. The


slope on which you can operate safely will be limited by
ground condition and the load being handled. Use service
brakes to control speed.

T145730

Avoid side slope travel whenever possible. When working


on steep slopes, travel as straight up and down as
possible to prevent machine tip over.

UN20SEP01

Operating on Slopes

TX03679,0001803 1931OCT011/1

TM2111 (30MAY03)

00-01-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=19

Safety Information

Operating Or Traveling On Public Roads

UN22MAY01

Machines that work near vehicle traffic or travel slower


than normal highway speeds must have proper lighting
and markings to assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle
(SMV) emblems, or other devices and use as required to
make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.

T141891

00
01
12

TX03679,00017C8 1914JUN011/1

Inspect and Maintain ROPS


A damaged roll-over protective structure (ROPS)
should be replaced, not reused.

To maintain the ROPS:

The protection offered by ROPS will be impaired if


ROPS is subjected to structural damage, is involved in
an overturn incident, or is in any way altered by
welding, bending, drilling, or cutting.

Replace missing hardware using correct grade


hardware.
Check hardware torque.
Check isolation mounts for damage, looseness or
wear; replace them if necessary.
Check ROPS for cracks or physical damage.

If ROPS was loosened or removed for any reason,


inspect it carefully before operating the machine again.

TX03679,000179F 1920APR011/1

TM2111 (30MAY03)

00-01-12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=20

Safety Information
00
01
13

Keep the Operator Protective Structure (OPS) in Place


It is important to keep the operator protective structure
(OPS) in place (doors, screens, windows, windshield,
etc.) to minimize hazards from whipping or intruding
objects. To maintain OPS protection, replace damaged
parts immediately.

The protection offered by OPS will be impaired if OPS


is subjected to structural damage, is involved in an
overturn incident, or is altered by welding, bending,
drilling, or cutting. Damaged OPS components should
be replaced, not reused.

Replace 3-piece hard-coated polycarbonate windshield


only with LEXAN Margard 5000 or equivalent.

Keep all bolts and attaching hardware tight.

LEXAN is a trademark of General Electric Corporation

TX,90,JC297 1931OCT011/1

Add And Operate Attachments Safely


Always verify compatibility of attachments by
contacting your authorized dealer. Adding unapproved
attachments may affect machine stability or reliability,
and may create a hazard for others near the machine.
Ensure that a qualified person is involved in
attachment installation. Add guards to machine if
operator protection is required or recommended. Verify

that all connections are secure and attachment


responds properly to controls.
Carefully read attachment manual and follow all
instructions and warnings. In an area free of
bystanders and obstructions, carefully operate
attachment to learn its characteristics and range of
motion.

TX03679,00016F0 1914SEP001/1

TM2111 (30MAY03)

00-01-13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=21

Safety Information

Park And Prepare For Service Safely

T133332

Park machine on a level surface and lower equipment


to the ground.
Engage park brake.
Stop engine and remove key.
Install frame locking bar.
Attach a Do Not Operate tag in an obvious place in
the operators station.

1914DEC01

Warn others of service work. Always park and prepare


your machine for service or repair properly.

Understand service procedures before beginning repairs.


Keep service area clean and dry. Use two people
whenever the engine must be running for service work.

TS229

Do not support machine with any hydraulically actuated


tools or attachments.
Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
Do not support machine with a single jack or other
devices that may slip out of place.

UN23AUG88

Securely support machine or attachment before working


under it.

TX03679,0001809 1918SEP011/1

Service Cooling System Safely

Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.

UN23AUG88

Explosive release of fluids from pressurized cooling


system can cause serious burns.

TS281

00
01
14

DX,RCAP 1904JUN901/1

TM2111 (30MAY03)

00-01-14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=22

Safety Information
00
01
15

Remove paint to at least 76 mm (3 in.) from area to be


heated. Wear an approved respirator when sanding or
grinding paint. If a solvent or paint stripper is used, wash
area with soap and water. Remove solvent or paint
stripper containers from work area and allow fumes to
disperse at least 15 minutes before welding or heating.

T133546

Hazardous fumes can be generated when paint is heated


by welding or using a torch. Dust from sanding or grinding
paint can also be hazardous.

UN24AUG00

Remove Paint Before Welding or Heating

Work outside or in a well-ventilated area. Dispose of


waste, paint and solvents properly.

TX03679,0001732 1906SEP001/1

Avoid welding or heating near pressurized fluid lines.


Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.

T133547

NOTE: Disable electrical power before welding. Turn off


main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and
vehicle microprocessors.

UN31AUG00

Make Welding Repairs Safely

Remove paint properly. Do not inhale paint dust or fumes.


Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.

TX03679,00016D5 1902OCT001/1

Use a soft hammer or a brass bar between hammer and


object to prevent chipping.

T133738

Always wear protective goggles or safety glasses and


other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.

UN14SEP00

Drive Metal Pins Safely

TX03679,0001745 1925SEP001/1

TM2111 (30MAY03)

00-01-15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=23

Safety Information

Safety Signs

WARNING

WARNING
PRESSURIZED TANK
Release pressure by discharging
fluid at hose end before removing
fill plug. Injury may result from
plug or cap under force. Consult
Operator's Manual before service.

T152457
Avoid crushing
DO NOT JUMP
if machine tips

USE
SEAT
BELT

Crushing injury could result.


Do not ride on machine.

T146097
WARNING
ADVERTENCIA
ADVERTISSEMENT
VORSICHT

MACHINE EQUIPPED
WITH SECONDARY
STEERING SYSTEM

WARNING

Stop machine immediately


if light or buzzer warns of
low steering pressure.
Secondary steering
system only functions
with key switch on.

To prevent shock.

M113839

always use grounded

Test secondary system


periodically. See
Operator's Manual.

3-wire extension cord.

WARNING

T146443

CAUTION
See instructions in Operator's
Manual before deactivating
park brake system:
- Secure machine against
movement
- Release brake only from
operator's station

Avoid rotating fan.


Stop engine.
Keep clear to avoid
serious injury.

T188283

WARNING
Crushing injury may result in hinge area if machine is
turned.
Make sure people are clear of machine before starting
engine or moving steering wheel.
Attach locking bar before performing service near center
of machine or transporting on a truck.

CAUTION
Pressurized refrigerant may
penetrate eyes or cause burns.
Wear goggles and protect skin.

T146436

SHIELD
EYES

FLUSH EYES
IMMECIATELY
WITH WATER
SULFURIC ACID
GET MEDICAL
CAN CAUSE
HELP FAST
BLINDNESS OR

NO
SPARKS
FLAMES
BLINDNESS OR INJURY SMOKING SEVERE BURNS
KEEP OUT OF THE REACH OF CHILDREN. DO NOT TIP. KEEP VENT CAPS TIGHT AND LEVEL.

EXPLOSIVE
GASES CAN CAUSE

CAUTION
BOOSTER CABLE INSTRUCTIONS:
1. ON A NEGATIVE GROUNDED SYSTEM,
CONNECT ENDS OF ONE CABLE TO POSITIVE(+)
TERMINAL OF EACH BATTERY.
2. CONNECT ONE END OF OTHER CABLE TO
NEGATIVE(-) TERMINAL OF THE BOOSTER
BATTERY.

T164308
Continued on next page

TM2111 (30MAY03)

00-01-16

3. CONNECT THE OTHER END OF THE CABLE,


AWAY FROM THE BATTERY, TO THE ENGINE BLOCK,
FRAME, OR SOME OTHER GOOD METALLIC GROUND.
4. REVERSE PROCEDURE WHEN
DISCONNECTING.

1924JAN03

DANGER/POISON

T164308

00
01
16

OUO1079,0000567 1915NOV021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=24

Safety Information

T164307

1924JAN03

00
01
17

OUO1079,0000567 1915NOV022/2

TM2111 (30MAY03)

00-01-17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=25

Safety Information
00
01
18

TM2111 (30MAY03)

00-01-18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=26

Group 0003

Torque Values
00
0003
1

Hardware Torque Specifications


Check cap screws and nuts to be sure they are tight. If
hardware is loose, tighten to torque shown on the
following charts unless a special torque is specified.

04T,90,K271 1908AUG911/1

Keeping ROPS Installed Properly

UN31MAR00

CAUTION: Make certain all parts are reinstalled


correctly if the roll-over protective structure
(ROPS) is loosened or removed for any reason.

T129546C

The protection offered by ROPS will be


impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or
is in any way altered by welding, bending,
drilling, or cutting. A damaged ROPS should be
replaced, not reused.
IMPORTANT: Do not over-tighten cap screws as
clevis will be deformed.

UN03APR00

Install lock nuts (A) onto cap screws (B) until full thread
engagement is achieved so nut, washers (C), and head of
cap screw are flush against each clevis.

T129547D

Tighten pin locking cap screws (D) to specification.


Keeping ROPS Installed ProperlySpecification
Pin Locking Cap ScrewTorque .................................. 130 Nm (95 lb-ft)

ALock Nut (2 used)


BCap Screw (2 used)
CWasher (As required)
DPin Locking Cap Screw (2 used)

CED,OUO1079,98 1926MAY001/1

TM2111 (30MAY03)

00-0003-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=27

Torque Values

UN07SEP99

Metric Bolt and Cap Screw Torque Values

TORQ2

00
0003
2

Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8

Class 8.8 or 9.8

Class 10.9

Class 12.9

Lubricateda
Nm(lb-ft)

Dryb
Nm(lb-ft)

Lubricateda
Nm(lb-ft)

Dryb
Nm(lb-ft)

Lubricateda
Nm(lb-ft)

Dryb
Nm(lb-ft)

Lubricateda
Nm(lb-ft)

Dryb
Nm(lb-ft)

M6

4.7 (3.5)

6 (4.4)

9 (6.6)

11.5 (8.5)

13 (9.5)

16.5 (12.2)

15.5 (11.5)

19.5 (14.5)

M8

11.5 (8.5)

14.5 (10.7)

22 (16)

28 (20.5)

32 (23.5)

40 (29.5)

37 (27.5)

47 (35)

M10

23 (17)

29 (21)

43 (32)

55 (40)

63 (46)

80 (59)

75 (55)

95 (70)

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)

Size

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)

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening


procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.

Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.

Shear bolts are designed to fail under predetermined loads. Always


replace shear bolts with identical property class.

Tighten plastic insert or crimped steel-type lock nuts to approximately


50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.

Fasteners should be replaced with the same or higher property class.


If higher property class fasteners are used, these should only be
tightened to the strength of the original.

DX,TORQ2 1901OCT991/1

TM2111 (30MAY03)

00-0003-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=28

Torque Values
00
0003
3
UN18OCT88

Additional Metric Cap Screw Torque Values

T6873AA

CAUTION: Use only metric tools on metric


hardware. Other tools may not fit properly. They
may slip and cause injury.

UN18OCT88

Check tightness of cap screws periodically. Torque values


listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.

T6873AB

Fasteners should be replaced with the same or higher


grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.

UN18OCT88

Make sure fastener threads are clean and you properly


start thread engagement. This will prevent them from
failing when tightening.

T6873AC

Tighten cap screws having lock nuts to approximately 50


percent of amount shown in chart.

Continued on next page

TM2111 (30MAY03)

00-0003-3

04T,90,M170 1929SEP991/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=29

Torque Values
00
0003
4

METRIC CAP SCREW TORQUE VALUESa


T-Bolt
Nominal
Dia
8

H-Bolt

Nm

lb-ft

29

21

Nm

lb-ft

M-Bolt
Nm

lb-ft

20

15

10

10

63

46

45

33

20

15

12

108

80

88

65

34

25

14

176

130

137

101

54

40

16

265

195

206

152

78

58

18

392

289

294

217

118

87

20

539

398

392

289

167

125

22

735

542

539

398

216

159

24

931

687

686

506

274

202

27

1372

1012

1029

759

392

289

30

1911

1410

1421

1049

539

398

33

2548

1890

1911

1410

735

542

36

3136

2314

2401

1772

931

687

Torque tolerance is 10%.

04T,90,M170 1929SEP992/2

TM2111 (30MAY03)

00-0003-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=30

Torque Values
00
0003
5

TM2111 (30MAY03)

00-0003-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=31

Torque Values

UN27SEP99

Unified Inch Bolt and Cap Screw Torque Values

TORQ1A

00
0003
6

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark)
Size
1/4

Grade 2a (No Mark)

Grade 5, 5.1 or 5.2

Grade 8 or 8.2

Lubricatedb
Nm(lb-ft)

Dryc
Nm(lb-ft)

Lubricatedb
Nm(lb-ft)

Dryc
Nm(lb-ft)

Lubricatedb
Nm(lb-ft)

Dryc
Nm(lb-ft)

Lubricatedb
Nm(lb-ft)

Dryc
Nm(lb-ft)

3.8 (2.8)

4.7 (3.5)

6 (4.4)

7.5 (5.5)

9.5 (7)

12 (9)

13.5 (10)

17 (12.5)

5/16

7.7 (5.7)

9.8 (7.2)

12 (9)

15.5 (11.5)

19.5 (14.5)

25 (18.5)

28 (20.5)

35 (26)

3/8

13.5 (10)

17.5 (13)

22 (16)

27.5 (20)

35 (26)

44 (32.5)

49 (36)

63 (46)

7/16

22 (16)

28 (20.5)

35 (26)

44 (32.5)

56 (41)

70 (52)

80 (59)

100 (74)

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)

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)

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, or fasteners with phosphate and oil coatings.

"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening


procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.

Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.

Shear bolts are designed to fail under predetermined loads. Always


replace shear bolts with identical grade.

Tighten plastic insert or crimped steel-type lock nuts to approximately


50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.

Fasteners should be replaced with the same or higher grade. If


higher grade fasteners are used, these should only be tightened to
the strength of the original.

DX,TORQ1 1901OCT991/1

TM2111 (30MAY03)

00-0003-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=32

Torque Values
00
0003
7

X9811

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

UN23AUG88

Check Oil Lines And Fittings

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 the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.
Tubing with dents may cause the oil to overheat. If you
find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified in torque
chart.
When you tighten connections, use two wrenches to
prevent bending or breaking tubing and fittings.

TX,90,DH1559 1901AUG941/1

TM2111 (30MAY03)

00-0003-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=33

Torque Values

Service Recommendations for 37 Flare and


30 Cone Seat Connectors

2. Defects in tube flare cannot be repaired.


Overtightening a defective flared fitting will not stop
leaks.
3. Align tube with fitting before attempting to start nut.

UN18OCT88

1. Inspect flare and flare seat. They must be free of dirt


or obvious defects.

T6234AC

00
0003
8

4. Lubricate male threads with hydraulic fluid or petroleum


jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on torque
chart. Do not allow hoses to twist when tightening
fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Nm

lb-ft

3/8 - 24 UNF

Thread Size

7/16 - 20 UNF

12

1/2 - 20 UNF

16

12

9/16 - 18 UNF

24

18

3/4 - 16 UNF

46

34

7/8 - 14 UNF

62

46

1-1/16 - 12 UN

102

75

1-3/16 - 12 UN

122

90

1-5/16 - 12 UN

142

105

1-5/8 - 12

190

140

1-7/8 - 12 UN

217

160

NOTE: Torque tolerance is 10%.

T82,BHMA,EL 1929SEP991/1

TM2111 (30MAY03)

00-0003-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=34

Torque Values
00
0003
9

Service Recommendations for O-Ring Boss


Fittings
Straight Fitting
UN18OCT88

1. Inspect O-ring boss seat for dirt or defects.

T6243AE

2. Lubricate O-ring with petroleum jelly. Place electrical


tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.

Continued on next page

TM2111 (30MAY03)

00-0003-9

04T,90,K66 1929SEP991/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=35

Torque Values
Angle Fitting

2. Turn fitting into threaded boss until back-up washer


contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index
(maximum of one turn).

NOTE: Do not allow hoses to twist when tightening


fittings.

UN18OCT88

1. Back-off lock nut (A) and back-up washer (B)


completely to head-end (C) of fitting.

T6520AB

00
0003
10

4. Hold fitting head-end with a wrench and tighten lock


nut and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size

Nm

lb-ft

3/8-24 UNF

7/16-20 UNF

12

1/2-20 UNF

16

12

9/16-18 UNF

24

18

3/4-16 UNF

46

34

7/8-14 UNF

62

46

1-1/16-12 UN

102

75

1-3/16-12 UN

122

90

1-5/16-12 UN

142

105

1-5/8-12 UN

190

140

1-7/8-12 UN

217

160

NOTE: Torque tolerance is 10%.

04T,90,K66 1929SEP992/2

TM2111 (30MAY03)

00-0003-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=36

Torque Values
00
0003
11

Service Recommendations For Flat Face O-Ring Seal Fittings


1. Inspect the fitting sealing surfaces and O-ring. They
must be free of dirt or defects.

fittings, use backup wrench on straight hose


couplings.

2. Lubricate O-rings and install into grove using


petroleum jelly to hold in place.

IMPORTANT: Tighten fittings to 150% of listed


torque value if indexing is necessary
or if fitting is attached to an
actuating devise.

3. Index angle fittings and tighten by hand pressing


joint together to insure O-ring remains in place.

Tighten fittings to 50% of listed


torque value if used in aluminum
housing.

4. Tighten fitting or nut to torque value shown on the


chart. Do not allow hoses to twist when tightening

FLAT FACE O-RING SEAL FITTING TORQUE*


Nominal Tube O.D.

Thread Size

Swivel Nut

Bulkhead Nut

mm

in.

in.

Nm

lb-ft

Nm

lb-ft

6.35

0.250

9/16-18

16

12

12

9.52

0.375

11/16-16

24

18

24

18

12.70

0.500

13/16-16

50

37

46

34

15.88

0.625

1-14

69

51

62

46

19.05

0.750

1 3/16-12

102

75

102

75

22.22

0.875

1 3/16-12

102

75

102

75

25.40

1.000

1 7/16-12

142

105

142

105

31.75

1.250

1 11/16-12

190

140

190

140

38.10

1.500

2-12

217

160

217

160

*Torque tolerance is +15 -20% unless otherwise specified.


Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size

Straight Hex Size

Locknut Hex Size

Inch

Inch

Inch

Straight Fitting or Locknut Toque


Nm

lb-ft

3/8-24

5/8

9/16

12

7/16-20

5/8

5/8

21

15

1/2-20

3/4

11/16

26

19

9/16-18

3/4

3/4

34

25

3/4-16

7/8

15/16

73

55

7/8-14

1 1/16

1 1/16

104

76

1 1/16-12

1 1/4

1 3/8

176

130

1 3/16-12

1 3/8

1 1/2

230

170

1 5/16-12

1 1/2

1 5/8

285

210

*Torque tolerance is +15 -20% unless otherwise specified.

04T,90,K67 1902MAR001/1

TM2111 (30MAY03)

00-0003-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=37

Torque Values

UN01MAR90

Service Recommendations for Metric Series Four Bolt Flange Fitting

T6890BB

00
0003
12

ASealing Surface

BSplit Flange

CPinched O-Ring

DSingle Piece Flange

then tighten the diagonally opposite cap screw.


Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.

1. Clean sealing surfaces (A). Inspect. Scratches


cause leaks. Roughness causes seal wear.
Out-of-flat causes seal extrusion. If defects cannot
be polished out, replace component.

DO NOT use air wrenches. DO NOT tighten one


cap screw fully before tightening the others. DO
NOT over tighten.

2. Install the correct O-ring (and backup washer if


required) into groove using petroleum jelly to hold it
in place.

TORQUE CHARTa

3. Split flange: Loosely assemble split flange (B)


halves. Make sure split is centrally located and
perpendicular to the port. Hand tighten cap screws
to hold parts in place. Do not pinch O-ring (C).

Thread

Nm

lb-ft

M6

12

4. Single piece flange (D): Place hydraulic line in


center of flange and install four cap screws. Flange
must be centrally located on port. Hand tighten cap
screws to hold flange in place. Do not pinch O-ring.

M12

95

70

M14

157

116

M16

217

160

M18

334

246

M20

421

318

5. After components are properly positioned and cap


screws are hand tightened, tighten one cap screw,

M8

30

22

M10

57

42

Tolerance 10%. The torques given are enough for the given
size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
a

Metric standard thread.

04T,90,K175 1929SEP991/1

TM2111 (30MAY03)

00-0003-12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=38

Torque Values
00
0003
13

T6890BB

UN01MAR90

Service Recommendations For Inch Series Four Bolt Flange Fittings

ASealing Surface

BSplit Flange

CPinched O-Ring

1. Clean sealing surfaces (A). Inspect. Scratches


cause leaks. Roughness causes seal wear.
Out-of-flat causes seal extrusion. If defects cannot
be polished out, replace component.
2. Install O-ring (and backup washer if required) into
groove using petroleum jelly to hold it in place.
3. Split flange: Loosely assemble split flange (B)
halves. Make sure split is centrally located and
perpendicular to port. Hand tighten cap screws to
hold parts in place. Do not pinch O-ring (C).
4. Single piece flange (D): Place hydraulic line in
center of flange and install cap screws. Flange
must be centrally located on port. Hand tighten cap
screws to hold flange in place. Do not pinch O-ring.
5. Tighten one cap screw, then tighten the diagonally
opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.

DSingle Piece Flange


TORQUE CHART
Nm

Nominal
Flange
Size
1/2

lb-ft

Cap Screw
Size
5/16-18
UNC

Min

Max

Min

Max

20

31

15

23

3/4

3/8-16 UNC

28

54

21

40

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

1/2-13 UNC

73

131

54

97

2-1/2

1/2-13 UNC

107

131

79

97

5/8-11 UNC

158

264

117

195

3-1/2

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

DO NOT use air wrenches. DO NOT tighten one


cap screw fully before tightening the others. DO
NOT over tighten.

04T,90,K174 1901AUG941/1

TM2111 (30MAY03)

00-0003-13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=39

Torque Values
00
0003
14

TM2111 (30MAY03)

00-0003-14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=40

Section 01

Wheels
Contents

01

Page

Group 0110Powered Wheels and Fastenings


Wheel Repair . . . . . . . . . . . . . . . . . . . . . . . .01-0110-1
Dual Wheel Installation . . . . . . . . . . . . . . . . .01-0110-5

TM2111 (30MAY03)

01-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

01

TM2111 (30MAY03)

01-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 0110

Powered Wheels and Fastenings


Wheel Repair
Wheel Remove and Install
CAUTION: Avoid possible injury from
unexpected machine movement. Install frame
locking bar before working in frame hinge area.
Install wheel chocks under one or more wheels
not being removed.

01
0110
1

1. Install frame locking bar.


Install wheel chocks under one or more wheels not
being removed.
CAUTION: Heavy component; use a hoist.
WheelSpecification
MachineWeight ........................................................... 998014 745 kg
(22,00032,500 lb) approximate
range
WheelWeight ............................................ 545 kg (1200 lb) approximate

2. Raise machine. Place an 18-t (20-ton) floor stand


under axle.
3. Place wheel lift under wheel. Fasten safety chain
around upper part of tire.
IMPORTANT: The rim dropping onto the cap screws
when loosened can damage the
threads. Install studs before loosening
all the cap screws to keep wheel
centered on axle flange to prevent
thread damage.
4. Remove three cap screws equally spaced around bolt
circle. Install the T45672 Studs.

Continued on next page

TM2111 (30MAY03)

01-0110-1

OUT3035,00002EB 1925NOV021/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=43

Powered Wheels and Fastenings


5. Remove cap screws and washers to remove wheel.

UN27SEP90
T7382AN

01
0110
2

IMPORTANT: Paint, rust, and dirt must be removed


from the cap screws and axle flange
threads, washers, and mating surfaces
of axle flange and rim to ensure good
contact between all surfaces. Paint,
rust, and dirt prevent good contact
between the surfaces and can result in
the wheels coming loose.
6. Clean the threads of cap screws and axle flange; and
the mating surfaces on washers, rim, and axle flange.
Apply a drop of oil to cap screw threads after cleaning
with solvent.
7. Install three studs, equally spaced, into the axle flange.
8. Install wheel.
9. Install cap screws and washers.
Tighten the cap screws just enough to hold wheel in
position. Remove the studs. Install the three remaining
cap screws.
Tighten cap screws to specification in a circular pattern
continuing past the starting point by four cap screws.
WheelSpecification
Rim-to-Axle Flange Cap Screw
Torque ......................................................................... 860 Nm (635 lb-ft)

For machines with dual wheels, apply NEVER-SEEZ


Lubricant or an equivalent to the threads of cap screws
and nuts that fasten the outer dual wheel to the inner dual
wheel. Install a washer on each cap screw and under
each nut. Tighten nuts and cap screws to the initial and
final torque using a crisscross pattern.
WheelSpecification
Inner Dual Wheel-to-Outer Dual
Wheel Cap Screw and Nut
Torque ................................................................ 407 Nm (300 lb-ft) initial
712 Nm (525 lb-ft) final

NEVER-SEEZ is a trademark of Emhart Chemical Group

TM2111 (30MAY03)

Continued on next page

01-0110-2

OUT3035,00002EB 1925NOV022/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=44

Powered Wheels and Fastenings


Tire Remove and Install
CAUTION: Explosive separation of a tire and
rim parts can cause serious injury or death.
01
0110
3

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.

UN23AUG88

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.

TS211

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.
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.
1. The tire can be removed without removing the wheel
from the machine. See the Off-The-Road Tire
Maintenance Manual to remove the tire from the wheel.
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.

Continued on next page

TM2111 (30MAY03)

01-0110-3

OUT3035,00002EB 1925NOV023/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=45

Powered Wheels and Fastenings


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. Apply soap lubricant to bead of tire and bead seat area
on rim.
6. Clear area of all persons.

OUT3035,00002EB 1925NOV024/5

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.
UN25OCT88

Check tire pressure with an accurate gauge having 6.9


kPa (0.07 bar) (1 psi) gradations.
Inflate tire to specified pressure to seat tire bead on
the rim.
WheelSpecification
Seating Tire Bead On Rim
Pressure ........................................................... 207 kPa (2.1 bar) (30 psi)
maximum

T6075AD

01
0110
4

APressure Regulating Valve


BValve Stem

8. Adjust tire pressure to recommended pressure. Use


only recommended air pressure. Pressure over this
limit can cause an explosion. See Check Tire
Pressure. (Operators Manual.)

OUT3035,00002EB 1925NOV025/5

TM2111 (30MAY03)

01-0110-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=46

Powered Wheels and Fastenings

Dual Wheel Installation


CAUTION: Heavy component; use a hoist.
WheelSpecification
Dual WheelWeight ................................... 545 kg (1200 lb) approximate

01
0110
5

1. Position outer dual wheel fange-to-flange with inner


wheel.
2. Align cap screw holes in flanges using punches if
necessary.
3. Lubricate cap screw threads with grease.
4. Insert each cap screw outward through inner washer,
inner flange and outer washer. Install nut.
5. Seat wheels to rim by tightening nuts in a criss-cross
pattern to specification.
Specification
Dual Wheel NutsInitial Torque ................................. 407 Nm (300 lb-ft)

6. Tighten nuts to final specification.


Specification
Dual Wheel NutsFinal Torque ................................. 712 Nm (525 lb-ft)

TX17994,00003BB 1908FEB031/1

TM2111 (30MAY03)

01-0110-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=47

Powered Wheels and Fastenings

01
0110
6

TM2111 (30MAY03)

01-0110-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=48

Section 02

Axles and Suspension System


Contents
Page

Group 0200Removal and Installation


Front Axle, Differential, and Oscillating
Supports . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Rear Axle and Differential . . . . . . . . . . . . . .02-0200-11
Front Axle Guard. . . . . . . . . . . . . . . . . . . . .02-0200-15

02

Group 0225Input Drive Shafts and U-Joints


Front Axle and Differential Drive Shaft . . . . .02-0225-1
Rear Axle and Differential Drive Shaft . . . . . .02-0225-4
Group 0260Hydraulic System
Differential Lock
Solenoid Valve. . . . . . . . . . . . . . . . . . . . . .02-0260-1
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . .02-0260-3
PumpCable Skidder . . . . . . . . . . . . . . . .02-0260-5
PumpGrapple Skidder . . . . . . . . . . . . . .02-0260-6
Differential Lock and Axle Hose Routing . . . .02-0260-7

TM2111 (30MAY03)

02-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

02

TM2111 (30MAY03)

02-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 0200

Removal and Installation


Front Axle, Differential, and Oscillating
Supports Remove and Install

UN13MAY98

Remove Front Axle, Differential, and Oscillating


Supports
1. Engage park brake.

T115334B

CAUTION: Avoid possible injury from


unexpected machine movement. Install frame
locking bar before working in frame hinge area.
2. Install frame locking bar.

ADrain Plugs

CAUTION: Heavy component; use a hoist.


Front Axle, Differential, and Oscillating SupportsSpecification
MachineWeight ........................................................... 998014 745 kg
(22,00032,500 lb) approximate
range

3. Raise front of machine. Place 18-t (20-ton) floor stands


under engine frame.
4. See Wheel Repair for procedure to remove and install
wheels. (Group 0110.)
5. Remove engine frame front and rear bottom guard.
6. Remove drain plugs (A) to drain oil into a container.
Dispose of used oil properly.
17.9 L (18.9 qt) approximate for 1200 Series Axle
31.2 L (33 qt) approximate for 1400 Series Axle
32 L (34 qt) approximate for 1400 Series Super
Wide Extreme Duty Axle (SWEDA)

Continued on next page

TM2111 (30MAY03)

02-0200-1

OUT3035,0000337 1922MAY031/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=51

02
0200
1

Removal and Installation

T151726

19

02
0200
2

Direct Drive Machine Shown


AFront Differential-to-Rear
Differential Line
BDifferential-to-Differential
Lock Solenoid Valve Line

CDifferential-to-Differential
Lock Pump Line
DDifferential-to-Brake Valve
Line

7. Disconnect front differential drive shaft (G). Slide


drive shaft rearward.

EDifferential-to-Differential
Lock Filter Line
FDifferential Vent

8. Disconnect lines (AE) and vent (F).

Continued on next page

TM2111 (30MAY03)

GFront Differential Drive


Shaft

02-0200-2

OUT3035,0000337 1922MAY032/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=52

Removal and Installation

CAUTION: Heavy component; use a hoist.

UN23APR91

Front Axle, Differential, and Oscillating SupportsSpecification


1200 Series AxleWeight .......................... 726 kg (1600 lb) approximate
1400 Series AxleWeight .......................... 862 kg (1900 lb) approximate
1400 Series Super Wide Extreme
Duty Axle (SWEDA)Weight.................... 1374 kg (3030 lb) approximate

T7502AI

9. Install a hydraulic lift scissors jack under axle and


differential. Support axle on each side using wooden
blocks.
Front Axle and Differential Removed

Continued on next page

TM2111 (30MAY03)

02-0200-3

OUT3035,0000337 1922MAY033/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=53

02
0200
3

Removal and Installation

T7502AH

UN29MAY91

02
0200
4

ARear Oscillating Support

BFront Oscillating Support

10. Remove cap screws (C) from front and rear


oscillating supports (A and B). Slowly lower axle
and differential.

CCap Screw (12 used)

DWasher (12 used)

to become familiar with the axle and differential


configuration. (CTM43). Go to the appropriate
repair story using the table of contents in
component technical manual.

11. Repair or replace axle and differential. See Axle


Identification before beginning repair or adjustment

OUT3035,0000337 1922MAY034/15

Disassemble and Assemble Front Axle Front


Oscillating Support

UN09APR91

1. Inspect dowels (A) for looseness, wear, or damage.


Replace if necessary.

T7502AJ

ADowel (2 used)

Continued on next page

TM2111 (30MAY03)

02-0200-4

OUT3035,0000337 1922MAY035/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=54

Removal and Installation


2. Repair or replace oscillating support (AH). See
Remove, Disassemble, and Assemble Oscillating
Support from Opposite End of Input for procedure.
(CTM43.)
AShim (as required)
BThrust Washer
CCover
DWasher (6 used)
ECap Screw (6 used)
FFront Oscillating Support
GBushing
HSeal

T7502AK

UN23APR91

02
0200
5

OUT3035,0000337 1922MAY036/15

Disassemble and Assemble Front Axle Rear


Oscillating Support

UN22APR91

1. Inspect dowels (A) for looseness, wear or damage.


Replace if necessary.

T7502CD

ADowel (2 used)

Continued on next page

TM2111 (30MAY03)

02-0200-5

OUT3035,0000337 1922MAY037/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=55

Removal and Installation


2. Repair or replace parts (B, C, and GK) as needed.
See Remove Input Oscillating Support for procedure.
(CTM43.)

T7742AF

UN08APR92

RW18724

ADFT1055 Yoke Holding Tool


BYoke
CRear Oscillating Support
GCotter Pin
HYoke
ISlotted Nut
JWasher
KO-Ring

OUT3035,0000337 1922MAY038/15

3. Repair or replace oscillating support (AG). See


Remove Input Oscillating Support for procedure.
(CTM43.)

UN23APR91

ASeal
BPipe Plug
COscillating Support
DBushing
ESnap Ring
FSeal
GThrust Washer
HDifferential

T7502AS

02
0200
6

UN07JAN91

See DFT1055 Yoke Holding Tool for instruction to


make tool for the 1200 and 1400 Series Axles with 6C
yoke. (Group 9900.)

Continued on next page

TM2111 (30MAY03)

02-0200-6

OUT3035,0000337 1922MAY039/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=56

Removal and Installation


Install Front Axle, Differential, and Oscillating
Supports
IMPORTANT: When operating in steep conditions,
add an additional 5.7 L (6 qt) of oil to
front axle.
1. Fill axle and differential with recommended oil. See
Change Front Differential Oil for procedure and
quantity. (Operators Manual.)
02
0200
7

2. Clean mounting surface on supports, dowels, and


engine frame.
Install the dowels into supports.

T7502AM

UN09APR91

AFront Oscillating Support-to-Frame Cap Screw (6


used)
BRear Oscillating Support-to-Frame Cap Screw (6
used)

OUT3035,0000337 1922MAY0310/15

3. Carefully raise axle and differential into position.

UN08MAY91

As necessary, loosen the front cover-to-oscillating


support cap screws (A) to align support cap screw
holes with holes in engine frame. Hold thrust washer in
place using a hex key wrench.

T7502EO

4. Install front and rear oscillating support-to-engine frame


cap screws and washers (A and B). Tighten cap
screws to specification.
Front Axle, Differential, and Oscillating SupportsSpecification
Oscillating Support-to-Engine
Frame Cap Screw (lubricated)
Torque ......................................................... 542 54 Nm (400 40 lb-ft)

AFront Cover-to-Oscillating Support Cap Screw


BThrust Washer

Continued on next page

TM2111 (30MAY03)

02-0200-7

OUT3035,0000337 1922MAY0311/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=57

Removal and Installation


5. Perform Adjust Axle Assembly End PlayIn Vehicle to
adjust end play to specification. Tighten three cap
screws to specification for adjustment. (CTM43.)

T7502AL

02
0200
8

UN09APR91

Front Axle, Differential, and Oscillating SupportsSpecification


Front Axle to Oscillating
SupportEnd Play ................................ 0.0760.330 mm (0.0030.013
in.)
Front Cover-to-Oscillating Support
Cap ScrewTorque .................................... 20 Nm (15 lb-ft) for end play
adjustment

6. After end play adjustment, install the three remaining


cap screws. Tighten the six cap screws to
specification.
Front Axle, Differential, and Oscillating SupportsSpecification
Front Cover-to-Oscillating Support
Cap ScrewTorque ...................................................... 100 Nm (74 lb-ft)

Continued on next page

TM2111 (30MAY03)

02-0200-8

OUT3035,0000337 1922MAY0312/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=58

Removal and Installation

T151726

UN21FEB02

02
0200
9

Direct Drive Machine Shown


AFront Differential-to-Rear
Differential Line
BDifferential-to-Differential
Lock Solenoid Valve Line

CDifferential-to-Differential
Lock Pump Line
DDifferential-to-Brake Valve
Line

EDifferential-to-Differential
Lock Filter Line
FDifferential Vent

7. Connect lines (AE). Connect lubrication lines to


oscillating support.

GFront Differential Drive


Shaft

9. Install front differential drive shaft (G).

8. Connect differential vent (F).

OUT3035,0000337 1922MAY0313/15

10. Tighten cap screws (A).

UN09APR91

Front Axle, Differential, and Oscillating SupportsSpecification


3/8 in. Cross and Bearing
Assembly-to-Yoke Cap Screw
Torque .............................................................. 5157 Nm (3842 lb-ft)
1/2 in. Cross and Bearing
Assembly-to-Yoke Cap Screw
Torque ........................................................ 127142 Nm (94105 lb-ft)

T7502AA

ACap Screw (4 used)

Continued on next page

TM2111 (30MAY03)

02-0200-9

OUT3035,0000337 1922MAY0314/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=59

Removal and Installation

Adapter Torque =
02
0200
10

Torque Wrench Length x Torque Specification


Torque Wrench Length + Adapter Length

T85624

If an adapter is fastened to the square drive of a


torque wrench, it adds to the wrench length. The real
torque then becomes greater than the force applied
when this happens. The example below can be used
to find the correct torque when an adapter is used.

UN23FEB89

11. EXAMPLE FOR FINDING ADAPTER TORQUE


SPECIFICATION:

A = Distance from the center of the square drive of


the torque wrench to the center of the handle grip.
B = Length of the adapter from the center of the
square drive of the torque wrench to the center of the
nut or cap screw. Use only the length which is parallel
to the handle.
Adapter Torque =

(A) x 163 Nm (120 lb-ft)


(A) + 88.9 mm (3.5 in.)

NOTE: If adapter is used, 90 to torque wrench does not


need conversion.
12. Install bottom guard.
Front Axle, Differential, and Oscillating SupportsSpecification
Bottom Guard-to-Engine Frame
Cap ScrewTorque .................................................... 620 Nm (457 lb-ft)

13. Install wheels. See Wheel Repair for procedure.


(Group 0110.)
14. See Service Brake Bleeding Procedure. (Group
9025-20.)

OUT3035,0000337 1922MAY0315/15

TM2111 (30MAY03)

02-0200-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=60

Removal and Installation

Rear Axle and Differential Remove and Install


Remove Rear Axle and Differential

UN27APR00

1. Engage park brake.


2. Install frame locking bar.

T130650B

CAUTION: Heavy component; use a hoist.


Rear Axle and DifferentialSpecification
MachineWeight ........................................................... 998014 745 kg
(22,00032,500 lb) approximate
range

1400 Axle Series Shown


ADrain Plug

3. Raise rear of machine. Place 18-t (20-ton) floor stands


under equipment frame.
4. Remove wheels. See Wheel Repair for procedure.
(Group 0110.)
5. Remove equipment frame bottom guard.
6. Remove drain plug (A) to drain oil. Dispose of oil
properly.
24.6 L (26 qt) approximate for 1200 Series Axle
48 L (51 qt) approximate for 1400 Series Axle
50 L (53 qt) approximate for 1400 Series Super
Wide Extreme Duty Axle (SWEDA)

Continued on next page

TM2111 (30MAY03)

02-0200-11

OUT3035,00002EE 1924SEP021/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=61

02
0200
11

Removal and Installation

T112423

UN09DEC97

02
0200
12

ARear Differential-to-Front
Differential Line
BDifferential-to-Differential
Lock Solenoid Valve Line

CRear Differential Drive


Shaft
DDifferential-to-Service
Brake Valve Line

7. Remove cap screws to disconnect rear differential


drive shaft (C).

ECap Screw (12 used)


FWasher (24 used)

8. Disconnect lines (A, B, and D).

Continued on next page

TM2111 (30MAY03)

GNut (12 used)

02-0200-12

OUT3035,00002EE 1924SEP022/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=62

Removal and Installation

CAUTION: Heavy component; use a hoist.


Rear Axle and DifferentialSpecification
1200 Series AxleWeight .......................... 726 kg (1600 lb) approximate
1400 Series AxleWeight .......................... 862 kg (1900 lb) approximate
1400 Series Super Wide Extreme
Duty Axle (SWEDA)Weight.................... 1374 kg (3030 lb) approximate

9. Install a hydraulic lift scissors jack under axle and


differential.
02
0200
13

10. Remove just enough nuts, cap screws, and washers


(A) on both sides so wooden blocks can be installed
under axle.
11. Remove remaining nuts, cap screws and washers on
both sides. Lower axle and differential.

T7502AP

UN09APR91

12. Repair or replace axle or differential. See Axle


Identification before beginning repair or adjustment to
become familiar with the axle and differential
configuration. (CTM43.) Go to the appropriate repair
story using the table of contents in component
technical manual.
Install Rear Axle and Differential
1. Fill axle and differential with recommended oil. See
Change Rear Differential Oil for procedure and
quantity. (Operators Manual.)

ACap Screw and Nut (12 used), Washer (24


used)

2. Clean mounting surface on axle housing and


equipment frame.
3. Install axle and differential to frame.

Continued on next page

TM2111 (30MAY03)

02-0200-13

OUT3035,00002EE 1924SEP023/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=63

Removal and Installation

T130651

UN01MAY00

02
0200
14

ARear Differential-to-Front
Differential Line
BDifferential-to-Differential
Lock Solenoid Valve Line

CRear Differential Drive


Shaft
DDifferential-to-Service
Brake Valve Line

IMPORTANT: The tightening sequence for cap


screws and nuts must be followed to
prevent binding which would result
in an inadequate clamping force
applied to the axle and frame joint.
4. Hold the cap screws (E) and tighten the nuts (G)
until they are snug and then again to specification
in the following sequence:

ECap Screw (12 used)


FWasher (24 used)

GNut (12 used)


HFill Plug

5. Connect drive shaft (C). Tighten cap screws to


specification.
Rear Axle and DifferentialSpecification
3/8 in. Cross and Bearing
Assembly-to-Yoke Cap
ScrewTorque .......................................... 5157 Nm (3842 lb-ft)
1/2 in. Cross and Bearing
Assembly-to-Yoke Cap
ScrewTorque .................................... 127142 Nm (94105 lb-ft)

a. two inside nuts on each side

6. Connect lines (A, B and D).

b. two middle nuts on each side

7. Check oil level. See Check Rear Differential Oil


Level for procedure. (Operators Manual.)

c. the two outside nuts on each side


8. Install bottom guard. Tighten cap screws to
specification.

Rear Axle and DifferentialSpecification


Rear Axle and
Differential-to-Equipment Frame
Nut and Cap ScrewTorque ............................... 925 Nm (680 lb-ft)

Continued on next page

TM2111 (30MAY03)

02-0200-14

OUT3035,00002EE 1924SEP024/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=64

Removal and Installation


Rear Axle and DifferentialSpecification
Bottom Guard-to-Equipment
Frame Cap ScrewTorque.................................. 620 Nm (460 lb-ft)

10. See Service Brake Bleeding Procedure. (Group


9025-20.)

9. Install wheels. See Wheel Repair for procedure.


(Group 0110.)

02
0200
15

OUT3035,00002EE 1924SEP025/5

T7502EM

UN20MAY91

Front Axle Guards Remove and Install

1Washer (4 used per guard)

2Guard (2 usedleft and


right)

3Cap Screw (2 used per


guard)

4Washer (2 used per guard)

Remove and install parts as shown.


Front Axle GuardSpecification
Axle Guard and
Housing-to-Differential Case
Cap ScrewTorque ............................................. 365 Nm (269 lb-ft)

OUT3035,00002EF 1924SEP021/1

TM2111 (30MAY03)

02-0200-15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=65

Removal and Installation

02
0200
16

TM2111 (30MAY03)

02-0200-16

G-III and D Series Skidders (S.N. 586337 )


053003

PN=66

Group 0225

Input Drive Shafts and U-Joints


Front Axle Drive Shaft Repair

T8459AN

UN16MAY95

02
0225
1

1Transmission Yoke
2Cap Screw (12 used)

3Cross and Bearing


Assembly (2 used)

4Double Universal Joint


5Cap Screw (4 used)

Hand pressure, a tap with a


soft-faced hammer or a C clamp
can be used to seat a bearing cup in
the yoke. DO NOT use the cap
screws to pull bearing cups into the
yokes.

1. Remove cap screws (2 and 5) to remove double


universal joint (4).
IMPORTANT: Yoke faces, pilots, keyways, and
bearing cup mounting face and key
must be free of foreign material,
burrs, and nicks which will prevent
the cross and bearing assembly and
yoke from becoming properly
seated.
2. Inspect parts for wear or damage. Repair or replace
as required.
IMPORTANT: Universal joints are precision
components. The fit is intended to
be tight and some compression of
seals and thrust washers is required
to seat the bearing cups in the yoke.

3. Assemble universal joint so lubrication fittings are


aligned. Bearing cup keys must engage the keyway
and bearing cups the yoke pilot.
Tighten cap screws to specification in even steps.
Front Axle and Differential Drive ShaftSpecification
3/8 in. Cross and Bearing
Assembly-to-Yoke Cap
ScrewTorque .......................................... 5157 Nm (3842 lb-ft)
1/2 in. Cross and Bearing
Assembly-to-Yoke Cap
ScrewTorque .................................... 127142 Nm (94105 lb-ft)

Continued on next page

TM2111 (30MAY03)

6Front Differential Yoke

02-0225-1

OUT3035,00002F0 1924SEP021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=67

Input Drive Shafts and U-Joints


4. Tighten lubrication fittings to specification.
Rear Axle and Differential Drive ShaftSpecification
Lubrication FittingTorque ..................... 516 Nm (48144 lb-in.)

5. See Grease Front Axle Drive Shaft U-Joints and


Transmission Output Shaft Seal for procedure to
lubricate universal joints. (Operators Manual.)

OUT3035,00002F0 1924SEP022/2

02
0225
2

TM2111 (30MAY03)

02-0225-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=68

Input Drive Shafts and U-Joints

02
0225
3

TM2111 (30MAY03)

02-0225-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=69

Input Drive Shafts and U-Joints

Rear Axle and Transmission Drive Shaft Repair

T162470

UN09DEC02

02
0225
4

Continued on next page

TM2111 (30MAY03)

02-0225-4

OUT3035,00002F1 1924SEP021/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=70

Input Drive Shafts and U-Joints


1Lock Nut
2Washer
3Yoke
4Cap Screw (8 per universal
joint)
5Snap Ring (1400 Series
Axle with 7C yokes)

6Support Bearing
7Lubrication Fitting
8Coupling Shaft
9Cross and Bearing
Assembly
10Yoke

11Cap Screw (2 used)


12Washer (4 used)
13Nut (2 used)
14Nut
15Set Screw
16Arrow

CAUTION: Avoid possible injury from


unexpected machine movement. Install
frame locking bar before working in frame
hinge area.
1. Install frame locking bar.
2. Remove shields at the articulation joint as needed
for access. Remove the equipment frame bottom
guard for access at rear axle and differential. See
Equipment Frame Bottom Guard Remove and
Install for procedure. (Group 1746.)
IMPORTANT: Yoke faces, pilots, keyways, and
bearing cup mounting face and key
must be free of foreign material,
burrs, and nicks which will prevent
the cross and bearing assembly and
yoke from becoming properly
seated.
3. Disassemble parts (121) as necessary to repair
or replace. Inspect parts for wear or damage.
Loosen the nut (14) and then the set screw (15) to
remove support bearing (6) from coupling shaft (8).
4. Install snap ring (20) into groove of transmission
yoke (21).
Install yoke on transmission output shaft. Install
special slotted nut (18).
Rear Axle and Differential Drive ShaftSpecification
Yoke-to-Transmission Output
Shaft Special Slotted Nut
Torque................................................ 271339 Nm (200250 lb-ft)
plus a maximum of 1/24 turn to
align slot with hole

NEVER-SEEZ is a trademark of Emhart Chemical Group

TM2111 (30MAY03)

17Double Universal Joint


(Telescoping Drive Shaft)
18Special Slotted Nut
19Cotter Pin
20Snap Ring
21Transmission Yoke

Install cotter pin (19). Bend legs of cotter pin against


sides of nut.
IMPORTANT: Double universal joint (telescoping
drive shaft) must be assembled with
arrow and yoke on female spline
yoke and stub yoke aligned. Yokes
not aligned will cause excessive
vibration during turns resulting in
failure of bearings.
5. Assemble double universal joint (telescoping drive
shaft) (17) so arrow and yoke on female spline
yoke and stub yoke are aligned.
Install universal joint so female spline yoke is to the
rear of machine.
6. Apply NEVER-SEEZ Lubricant to support
bearing-to-coupling shaft contact surface of support
bearing (6).
Install support bearing on coupling shaft (8) so set
screw (15) is towards the threaded end of shaft.
Tighten set screw until it contact bottom of slot in
shaft and then loosen one turn. Tighten nut (14).
Rear Axle and Differential Drive ShaftSpecification
Support Bearing-to-Coupling
Shaft Slot Set Screw
Clearance................................................ One turn out from bottom of
slot in coupling shaft.

7. For machines with 1400 series axle and 7C yokes,


install snap ring (5) into groove of coupling shaft so
opening is opposite the slot.

Continued on next page

02-0225-5

OUT3035,00002F1 1924SEP022/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=71

02
0225
5

Input Drive Shafts and U-Joints


8. Install yoke (3) so arrow (16) in keyway is aligned
with arrow on end of coupling shaft.
Install washer (2). Install lock nut (1).

02
0225
6

Rear Axle and Differential Drive ShaftSpecification


Yoke-to-Coupling Shaft
M27x1.5 Nut (Machines with
1200 Series Axle)Torque ............... 542610 Nm (400450 lb-ft)
Yoke-to-Coupling Shaft
M33x1.5 Nut (Machines with
1400 Series Axle)Torque ............... 720800 Nm (531590 lb-ft)

9. Install coupling shaft so support bearing is on the


front side of mounting plate. Install washers (12)
under the head of cap screws (11) and nuts (13).
Tighten nuts to specifications.
Rear Axle and Differential Drive ShaftSpecification
Support Bearing-to-Mounting
Plate Cap Screw and Nut
Torque................................................................... 325 Nm (240 lb-ft)

Continued on next page

TM2111 (30MAY03)

02-0225-6

OUT3035,00002F1 1924SEP023/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=72

Input Drive Shafts and U-Joints


IMPORTANT: Universal joints are precision
components. The fit is intended to be
tight and some compression of seals
and thrust washers is required to seat
the bearing cups in the yoke. Hand
pressure, a tap with a soft-faced
hammer or a C clamp can be used to
seat a bearing cup in the yoke. DO NOT
use the cap screws to pull bearing cups
into the yokes.
02
0225
7
UN07FEB96

10. Assemble universal joint so lubrication fittings are


aligned. Bearing cup keys (A) must engage the
keyways and bearing cups engage the yoke pilot (B).

Rear Axle and Differential Drive ShaftSpecification


3/8 in. Cross and Bearing
Assembly-to-Yoke Cap Screw
Torque .............................................................. 5157 Nm (3842 lb-ft)
1/2 in. Cross and Bearing
Assembly-to-Yoke Cap Screw
Torque ........................................................ 127142 Nm (94105 lb-ft)

T100216

11. Tighten cap screws to specification in even steps.

ABearing Cup Key


BYoke Pilot

12. Tighten lubrication fittings (7) and air relief valve to


specification.
Rear Axle and Differential Drive ShaftSpecification
Lubrication FittingTorque ............................ 516 Nm (48144 lb-in.)
Air Relief ValveTorque ................................ 516 Nm (48144 lb-in.)

13. See Grease Front Axle Drive Shaft U-Joints and


Transmission Output Shaft Seal for procedure to
lubricate U-joints. (Operators Manual.)

OUT3035,00002F1 1924SEP024/4

TM2111 (30MAY03)

02-0225-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=73

Input Drive Shafts and U-Joints

02
0225
8

TM2111 (30MAY03)

02-0225-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=74

Group 0260

Hydraulic System
Differential Lock Solenoid Valve Repair

UN08DEC97

1. Remove plate below left side of cab. See Power Train


Component LocationDirect Drive Machines or See
Power Train Component LocationTorque Converter
Machines for location of differential lock solenoid valve.
(Group 9020-15.)

T112425

2. Disconnect wiring connector.


3. Remove nut to remove cover and solenoid coil from
the differential lock solenoid valve (A) on the left end of
park brake and differential lock solenoid valve
manifold. Remove the valve.

ADifferential Lock Solenoid Valve

Continued on next page

TM2111 (30MAY03)

02-0260-1

OUT3035,00002F2 1924SEP021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=75

02
0260
1

Hydraulic System

T7508AE

UN09JUL91

02
0260
2

ANut
BWasher
CCover
DSolenoid

EPlate
FValve (Spool)
GO-Ring

HBackup Ring
IO-Ring
JBackup Ring

KBackup Ring
LO-Ring
MBackup Ring

4. Repair or replace parts as needed.

7. Tighten nut (A).

NOTE: The park brake solenoid valve and differential


lock solenoid valve are the same part number.

Differential Lock Solenoid ValveSpecification


Cover and Solenoid
Coil-to-Valve NutTorque........................ 6.58 Nm (5871 lb-in.)

5. Install new O-rings and backup rings (GM).

8. Connect wiring connector.

6. Tighten valve (F) to specification.

9. Install plate and cap screws.

Differential Lock Solenoid ValveSpecification


Solenoid Valve-to-Park Brake
and Differential Lock Solenoid
Valve ManifoldTorque ............................ 4754 Nm (3540 lb-ft)

IMPORTANT: Overtightening the solenoid valve


cover nut could damage the solenoid
coil. Tighten the nut to specification.

OUT3035,00002F2 1924SEP022/2

TM2111 (30MAY03)

02-0260-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=76

Hydraulic System

Differential Lock Relief Valve Remove and


Install
1. Remove plate below left side of cab.

UN23MAR01

2. Remove differential lock relief valve (1) from the front


side of park brake and differential lock solenoid valve
manifold. See Power Train Component Location
Direct Drive Machines. (Group 9020-05.) Location is
the same for torque converter machines.

T140288B

1Differential Lock Relief Valve (Pressure Sequence


Valve)

Continued on next page

TM2111 (30MAY03)

02-0260-3

OUT3035,00002F3 1925SEP021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=77

02
0260
3

UN05APR01

Hydraulic System

T140455

02
0260
4

1Spring
2Valve Body
3Spring Guide

4Ball
5O-Ring
6Spool Housing

7Backup Ring
8O-Ring

IMPORTANT: Differential lock relief valve, except


O-rings and backup rings, is
serviced as an complete assembly.
There is no adjustment procedure.

9Backup Ring
10O-Ring

5. Perform Differential Lock Pressure Test to verify


pressure setting. (Group 9020-25.)
6. Install plate.

3. Replace O-rings (5, 8, and 10) and backup rings (7


and 9)
4. Install relief valve. Tighten to specification.
Differential Lock Relief ValveSpecification
Relief Valve-to-Park Brake and
Differential Lock Solenoid Valve
ManifoldTorque ................................ 24.229.7 Nm (1822 lb-ft)

OUT3035,00002F3 1925SEP022/2

TM2111 (30MAY03)

02-0260-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=78

Hydraulic System

Differential Lock PumpCable Skidder


Remove and Install
1. See Hydraulic Cab Tilt Procedure. (Operators Manual.)
2. Disconnect lines (2 and 4). Close openings using caps
and plugs.
3. Remove fittings (5 and 6).
02
0260
5

4. Remove cap screws (1) to remove differential lock


pump (3).
UN14JUN00

5. See Replace Differential Lock Return Filter and See


Replace Differential Lock Inlet Filter to check for debris
and replace as needed. (Operators Manual.)

7. Align splines on pump shaft and drive gear and install


pump.

T131254B

6. Install new O-ring on pump.


Direct Drive Machine Shown
1Cap Screw (2 used)
2Outlet Port-to-Park Brake and Differential Lock
Solenoid Valve Manifold Line
3Differential Lock Pump
4Front Axle-to-Inlet Port Line
5Fitting
6Fitting

8. Install cap screws.


9. Install fittings.
10. Connect lines.
11. Lower the cab.

OUT3035,00002F4 1925SEP021/1

TM2111 (30MAY03)

02-0260-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=79

Hydraulic System

Differential Lock PumpGrapple Skidder


Remove and Install
Direct drive machine (differential lock pump mounted on
transmission) shown throughout. Procedures for the
torque converter machine (differential lock pump mounted
on converter) are the same except where noted.
1. See Hydraulic Cab Tilt Procedure. (Operators Manual.)

UN26MAY00

2. See Hydraulic Pump Remove and InstallDirect Drive


Machines or Hydraulic Pump Remove and Install
Torque Converter Machines. (Group 2160.)
3. Disconnect lines (2 and 5). Close openings using caps
and plugs.
4. Remove fittings (3 and 6).

T131256B

02
0260
6

5. Remove socket head cap screws (1) to remove


differential lock pump (4).

Direct Drive Machine Shown

6. See Replace Differential Return Filter and See Replace


Differential Lock Inlet Filter to check for debris and
replace as needed. (Operators Manual.)
7. Install new O-ring on pump.

1Cap Screw (2 used)


2Outlet Port-to-Park Brake and Differential Lock
Solenoid Valve Manifold Line
3Fitting
4Differential Lock Pump
5Front Axle-to-Inlet Port Line
6Fitting

8. Align splines on pump shaft and drive gear and install


pump.
9. Install cap screws.
10. Install fittings.
11. Connect line.
12. Install hydraulic oil cooler pump.
13. Lower cab.

OUT3035,00002F5 1925SEP021/1

TM2111 (30MAY03)

02-0260-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=80

Hydraulic System

Differential Lock and Axle Hose Routing

T120236

UN02MAR99

02
0260
7

Direct Drive Cable Skidder


AFront Axle-to-Service
Brake Valve Line
BPark Brake
Return-to-Transmission
Line

CTransmission-to-Park
Brake Inlet Line
DDifferential Lock Inlet Line
and Filter
EPark Brake and Differential
Lock Solenoid Valve
Manifold

FPark Brake Solenoid


Valve-to-Park Brake Line
GDifferential Lock Filter
HRear Axle

IRear Axle-to-Service Brake


Valve Line
JDifferential Lock Pump
KFront Axle

See Power Train Component LocationDirect Drive


Machines for additional hose routing. (Group 9020-15.)

Continued on next page

TM2111 (30MAY03)

02-0260-7

OUT3035,0000338 1905DEC021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=81

Hydraulic System
J
M

D
E

02
0260
8

A
F

UN05APR01

T140526

T140526

Torque Converter Grapple Skidder Shown


AFront Axle-to-Service
Brake Valve Line
BPark Brake
Return-to-Transmission
Line
CTransmission-to-Park
Brake Inlet Line

DDifferential Lock Inlet Line


and Filter
EPark Brake and Differential
Lock Solenoid Valve
Manifold

FPark Brake Solenoid


Valve-to-Park Brake Line
GDifferential Lock Filter
HRear Axle
IRear Axle-to-Service Brake
Valve Line

JDifferential Lock Pump


KFront Axle
LDifferential Vent
MTorque Converter

See Power Train Component LocationTorque


Converter Machines for additional hose routing. (Group
9020-15.)

OUT3035,0000338 1905DEC022/2

TM2111 (30MAY03)

02-0260-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=82

Section 03

Transmission
Contents
Page

Page

Group 0300Removal and Installation


Transmission Remove. . . . . . . . . . . . . . . . . .03-0300-1
Transmission Install. . . . . . . . . . . . . . . . . . .03-0300-11

First and Third Speed Clutch Packs


(Fourth Stage) Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-70
Second and Fourth Speed Clutch Packs
(Fifth Stage) Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-71
Transmission Clutch Packs
DisassembleDirect Drive Machines . . .03-0350-72
Transmission Clutch Packs AssembleDirect
Drive Machines . . . . . . . . . . . . . . . . . . . .03-0350-79
Seventh Stage (Output) ShaftDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-88
Rear Transmission Housing RepairDirect
Drive Machines . . . . . . . . . . . . . . . . . . . .03-0350-90
Front and Rear Housing AssembleDirect
Drive Machines . . . . . . . . . . . . . . . . . . . .03-0350-91
Transmission Clutch Packs and Gear
Stages RepairTorque Converter
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-94
Input Shaft (First Stage) and Sixth Stage
(Idler Gear) RepairTorque Converter
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-98
Clutch Pack RepairTorque Converter
Machines . . . . . . . . . . . . . . . . . . . . . . . . 03-0350-100
Seventh Stage (Output Gear)
RepairTorque Converter Machines . . . 03-0350-125
Rear Transmission Housing RepairTorque
Converter Machines. . . . . . . . . . . . . . . . 03-0350-127
Front and Rear Housing AssembleTorque
Converter Machines. . . . . . . . . . . . . . . . 03-0350-129

Group 0315Controls
Park Brake and Gear Shift Lever Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .03-0315-1
Group 0325Input Drive Shafts and U-Joints
Engine-to-Transmission Drive Shaft Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .03-0325-1
Group 0350Gears, Shafts and Power Shift
Clutches
Transmission Repair Procedures. . . . . . . . . .03-0350-1
Transmission Lifting and Mounting on
Repair Stand . . . . . . . . . . . . . . . . . . . . . . .03-0350-2
Winch Drive Repair . . . . . . . . . . . . . . . . . . . .03-0350-5
Park Brake Repair. . . . . . . . . . . . . . . . . . . .03-0350-11
Charge Pump Repair . . . . . . . . . . . . . . . . .03-0350-21
Transmission Suction Tube Repair . . . . . . .03-0350-29
Transmission Cover Plates to Front
Housing Remove and InstallTorque Converter
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-30
Transmission Idler Shaft Remove and
InstallTorque Converter Machines . . . .03-0350-32
Transmission Control Valve Repair . . . . . . .03-0350-34
Input Yoke Remove and Install . . . . . . . . . .03-0350-45
Front Housing Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-48
Front Housing Exploded ViewTorque
Converter Machines. . . . . . . . . . . . . . . . .03-0350-52
Front Housing RepairAll Machines . . . . . .03-0350-55
Transmission Clutch Packs and Gear
Stages Remove and InstallDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-60
Input (First Stage) and Idler (Sixth Stage)
Gear Shaft RepairDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-66
High and Low Forward (Second Stage)
Clutch Packs Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-68
High and Low Reverse (Third Stage)
Clutch Pack Exploded ViewDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-69
TM2111 (30MAY03)

Group 0360Hydraulic System


Transmission Charge Pump Remove and
InstallDirect Drive Machines . . . . . . . . . .03-0360-1
Transmission Charge Pump Remove and
InstallTorque Converter Machines . . . . .03-0360-6
Thermal Bypass Valve RepairTorque
Converter Machines. . . . . . . . . . . . . . . . . .03-0360-8

03-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

03

Contents

03

TM2111 (30MAY03)

03-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 0300

Removal and Installation


Transmission Remove
1. Install frame locking bar.

UN13APR98

2. Operate all hydraulic controls to relieve pressure in the


hydraulic system.

T113498B

3. Drain transmission. The approximate capacity of


transmission is 29.3 L (7.75 gal).
4. Raise cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
5. Remove right and left side access covers (A).
6. For direct drive machines, perform the following:

03
0300
1

a. Remove main hydraulic pump. See Hydraulic Pump


Remove and InstallDirect Drive Machines or
Hydraulic Pump Remove and InstallTorque
Converter Machines. (Group 2160.)
b. Remove two cap screws and washers (B) and move
differential lock pump aside.

UN19JUL00

c. Remove spline coupler (C).

T132624B

ASide Access Cover


BCap Screw and Washer (2 used)
CSpline Coupler

T113855D

UN13MAY98

Direct Drive (Grapple) Machines Shown

Spline CouplerDirect Drive Machine


Continued on next page

TM2111 (30MAY03)

03-0300-1

CED,OUO1032,3087 1919DEC021/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=85

Removal and Installation


7. Disconnect hydraulic hoses (A and B) from differential
lock filter housing. Close all openings with caps and
plugs.
8. Remove cap screws (D). Move bracket and filter
assembly (C) aside.
9. Disconnect vent hose (E).

UN11APR01

AFilter Inlet Hose


BFilter Outlet Hose
CBracket and Filter Assembly
DCap Screws
EVent Hose

T113499C

03
0300
2

T140921B

UN11APR01

Differential Lock FilterDirect Drive Machine

Differential Lock FilterTorque Converter Machine

Continued on next page

TM2111 (30MAY03)

03-0300-2

CED,OUO1032,3087 1919DEC022/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=86

Removal and Installation


10. Remove cap screws (B) to disconnect winch drive
shaft (A) (if equipped) from transmission.
11. Remove cap screws (C) to disconnect rear axle drive
shaft (D) from transmission.

T113503B

UN10APR98

AWinch Drive Shaft


BCap Screw (4 used)
CCap Screw (4 used)
DRear Axle Drive Shaft

Winch and Rear Axle Drive ShaftsDirect Drive Machine Shown

Continued on next page

TM2111 (30MAY03)

03-0300-3

CED,OUO1032,3087 1919DEC023/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=87

03
0300
3

Removal and Installation


12. Remove cap screw (1) and yoke (2).
13. Disconnect hydraulic hoses (CE).

T163138B

UN08JAN03

1Cap Screw
2Winch Output Shaft Yoke
CReturn Hose
DReturn Hose from Winch
EPark Brake Valve Hose

T113505B

UN13MAY98

03
0300
4

Continued on next page

TM2111 (30MAY03)

03-0300-4

CED,OUO1032,3087 1919DEC024/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=88

Removal and Installation


14. For direct drive machines, perform the following:
a. Disconnect hydraulic hose (B).
b. Remove cap screws (A and C) to remove
engine-to-transmission drive shaft.
15. For torque converter machines, remove cap screws
(A) at both ends of torque converter-to-transmission
drive shaft. Remove drive shaft.

T113506B

UN13APR98

ACap Screw (4 usedDirect Drive) (8 usedTorque


Converter)
BCharge Pump-to-Filter Hose
CCap Screw (12 used)

T113507B

UN13APR98

Drive ShaftDirect Drive Machine Shown

Drive Shaft-to-Engine Cap ScrewsDirect Drive Machine

Continued on next page

TM2111 (30MAY03)

03-0300-5

CED,OUO1032,3087 1919DEC025/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=89

03
0300
5

Removal and Installation


16. Disconnect hydraulic hoses (AE).
17. Remove cap screws (F) to disconnect drive shaft (G)
from transmission.

UN13APR98

AWinch Control Hose


BHose to Oil CoolerDirect Drive Machine
BHose to Torque ConverterTorque Converter
Machine
COutlet Hose from Filter
DPark Brake Valve Hose
EReturn Hose from Oil Cooler
FCap Screw (4 used)
GFront Axle Drive Shaft

T113509B

UN13APR98

T113508B

03
0300
6

Continued on next page

TM2111 (30MAY03)

03-0300-6

CED,OUO1032,3087 1919DEC026/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=90

Removal and Installation


18. Remove cap screws and washers (A).

T119935F

UN05APR01

ALower Transmission Mount Cap Screw and


Washers (2 of each used)

CED,OUO1032,3087 1919DEC027/13

19. For direct drive machines, perform the following:


a. Disconnect wiring harness connectors (BG).
b. Remove upper transmission mount cap screws,
nuts, and washers (H). Remove upper half of
isolator (I).
c. Remove dipstick (A).

T113511F

UN05APR01

ADipstick
BInput Speed Pickup Sensor Connector
CPark Brake Pressure On Switch Connector
DPark Brake Release Solenoid Connector
EDifferential Lock Solenoid Connector
FReverse Alarm and Fuel Sender Harness
Connector
GTransmission Harness Connector
HUpper Transmission Mount Cap Screws, Nuts, and
Washers
IIsolator (upper half)

Transmission Mounts and Wire ConnectorsDirect Drive


Machine

Continued on next page

TM2111 (30MAY03)

03-0300-7

CED,OUO1032,3087 1919DEC028/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=91

03
0300
7

Removal and Installation

T140922B

UN09APR01

03
0300
8

Transmission Mounts and Wire ConnectorsTorque Converter Machine

20. For torque converter machines, perform the following:


a. Disconnect wire connectors (AD and K).
b. Remove mounting cap screws from clamps (E and
I).

T140924B

UN05APR01

AReverse Alarm and Fuel Sender Harness


Connector
BPark Brake Release Solenoid Connector
CPark Brake Pressure On Switch Connector
DDifferential Lock Solenoid Connector
EClamp
FDipstick
GUpper Transmission Mount Cap Screws, Nuts,
and Washers
HIsolator (upper half)
IClamp
JVent Hose
KTransmission Harness Connector
LBracket
MTransmission Charge Pump Inlet Hose
NBracket

Continued on next page

TM2111 (30MAY03)

03-0300-8

CED,OUO1032,3087 1919DEC029/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=92

Removal and Installation


c. Remove mounting cap screws from brackets (L
and N).
d. Disconnect hoses (J and M).
e. Remove upper transmission mount nuts, washers,
and cap screws (G). Remove upper half of isolator
(H).
f. Remove dipstick (F).

CED,OUO1032,3087 1919DEC0210/13

21. At upper left transmission mount, remove cap screw


at location shown and install JT01748 Lifting Bracket
(A) using a cap screw 12.7 mm (1/2 in.) longer than
cap screw removed.
UN13APR98

03
0300
9

T113512B

AJT01748 Lifting Bracket

CED,OUO1032,3087 1919DEC0211/13

CAUTION: Heavy component; use a hoist.


TransmissionSpecification
TransmissionWeight................................. 590 kg (1300 lb) approximate

22. Attach D01043AA Load Positioning Sling (B) to


overhead hoist.
23. Attach one hook from load positioning sling to lifting
bracket (A).
24. Attach other hook through rear slot in upper right
transmission mount (C).
25. Adjust load positioning sling to lift right side of
transmission first. Carefully raise transmission and
remove from machine.

T113514C

UN23MAR99

AJT01748 Lifting Bracket


BD01043AA Load Positioning Sling
CUpper Right Transmission Mount

Continued on next page

TM2111 (30MAY03)

03-0300-9

CED,OUO1032,3087 1919DEC0212/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=93

Removal and Installation


26. Remove front and rear output shaft yokes. If removal
of input shaft yoke is necessary at this time, see Input
Yoke Remove and Install.. (Group 0350.)
27. Remove lower half of upper transmission isolators
(C).
28. Remove upper transmission mount supports (G).
29. Remove dipstick tube (D) and oil fill hose (E).
30. Remove wire harness (F).

T114058D

32. Remove three cap screws (A) to remove lower


transmission mount block (B).
33. Mount transmission in repair stand. See Transmission
Lifting and Mounting on Repair Stand. (Group 0350.)
TransmissionDirect Drive Shown

UN05APR01

T119924D

UN13APR99

ACap Screw (3 used)


BLower Transmission Mount Block
CUpper Transmission Isolators (lower half)
DDipstick Tube
EOil Fill Hose
FTransmission Wire Harness
GUpper Transmission Mount Supports (2 used)
HLower Transmission Mount Cap Screw
IWasher
JLarge Washer (2 used)
KIsolator (rear half)
LLower Transmission Mount Plate
MIsolator (front half)

T140870

03
0300
10

UN20JUL00

31. Remove lower transmission mount hardware (HJ).

CED,OUO1032,3087 1919DEC0213/13

TM2111 (30MAY03)

03-0300-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=94

Removal and Installation

Transmission Install
1. Install wire harness (F).
2. Install oil fill hose (E) and dipstick tube (D).
3. Install upper transmission mount supports (G). Tighten
cap screws to specification.
TransmissionSpecification
Upper Transmission Mount
Support-to-Transmission Housing
Cap ScrewTorque .................................................... 319 Nm (235 lb-ft)
UN20JUL00

4. Install lower half of upper transmission isolators (C).

T114058D

5. Install lower transmission mount block (B). Tighten cap


screws (A) to specification.
TransmissionSpecification
Lower Transmission Mount
Block-to-Transmission Housing
Cap ScrewTorque ................................. 230312 Nm (170230 lb-ft)

TransmissionDirect Drive Shown

6. Install lower transmission mount hardware (HM). Do


not tighten cap screw (H) at this time.

UN13APR99

7. Install front axle and rear axle output shaft yokes. Do


not install winch shaft yoke (if equipped) at this time.

T119924D

8. Install rear axle output shaft yoke castellated nut and


tighten to specification. If cotter pin hole does not align
with slot in castellated nut, continue turning nut until
hole aligns with slot. Install new cotter pin.
TransmissionSpecification
Rear Axle Output Shaft Yoke
Castellated NutTorque ............................................... 115 Nm (85 lb-ft)

T140870

UN05APR01

ACap Screw (3 used)


BLower Transmission Mount Block
CUpper Transmission Isolators (lower half)
DDipstick Tube
EOil Fill Hose
FTransmission Wire Harness
GUpper Transmission Mount Supports (2 used)
HLower Transmission Mount Cap Screw
IWasher
JLarge Washer (2 used)
KIsolator (rear half)
LLower Transmission Mount Plate
MIsolator (front half)

Continued on next page

TM2111 (30MAY03)

03-0300-11

CED,OUO1032,3088 1919DEC021/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=95

03
0300
11

T140871

03
0300
12

T113515D

UN05APR01

UN05APR01

Removal and Installation

CAUTION: Heavy component; use a hoist.


TransmissionSpecification
TransmissionWeight................................. 590 kg (1300 lb) approximate

UN05APR01

9. At upper left transmission mount, remove rear cap


screw (if installed) and install JT01748 Lifting Bracket
(I) using a cap screw 12.7 mm (1/2 in.) longer than the
cap screw removed.

T119935G

10. Attach one hook of D01043AA Load Positioning Sling


to lifting bracket (I) and the other hook through rear
slot in upper right transmission support (G).
11. Carefully lower transmission into machine frame until
holes in lower transmission mount plate (J) align with
holes in machine frame. Make sure washer (C) and
lower half of isolator (E) are in position between
supports (G and H) and machine frame.

AUpper Transmission Mount Cap Screw (2


used)
BWasher (2 used)
CLarge Washer (4 used)
DIsolator (upper half)
EIsolator (lower half)
FNut (2 used)
GUpper Right Transmission Support
HUpper Left Transmission Support
IJT01748 Lifting Bracket
JLower Transmission Mount Plate
KLower Transmission Mount Plate-to-Frame
Cap Screw and Washer (2 of each used)
LLower Transmission Mount Cap Screw

12. Fasten mount plate (J) to machine frame with cap


screws and washers (K). Tighten to specification.
TransmissionSpecification
Lower Transmission Mount
Plate-to-Frame Cap Screw
Torque ...................................................... 230312 Nm (170230 lb-ft)

Continued on next page

TM2111 (30MAY03)

03-0300-12

CED,OUO1032,3088 1919DEC022/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=96

Removal and Installation


13. Tighten cap screw (L) to specification.
TransmissionSpecification
Lower Transmission Mount Cap
ScrewTorque ......................................... 607743 Nm (450550 lb-ft)

14. Install upper transmission mount hardware (AD and


F). Tighten cap screw (A) and nut (F) to specification.
TransmissionSpecification
Upper Transmission Mount Cap
Screw and NutTorque ........................... 607743 Nm (450550 lb-ft)

03
0300
13
CED,OUO1032,3088 1919DEC023/11

15. For direct drive machines, perform the following:


a. Connect wire connectors (BG).
b. Install dipstick (A).

T113511G

UN05APR01

ADipstick
BInput Speed Pickup Sensor Connector
CPark Brake Pressure On Switch Connector
DPark Brake Release Solenoid Connector
EDifferential Lock Solenoid Connector
FReverse Alarm and Fuel Sender Harness
Connector
GTransmission Harness Connector

Transmission Mounts and Wire ConnectorsDirect Drive


Machine

Continued on next page

TM2111 (30MAY03)

03-0300-13

CED,OUO1032,3088 1919DEC024/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=97

Removal and Installation

T140922C

UN09APR01

03
0300
14

Transmission Mounts and Wire ConnectorsTorque Converter Machine

16. For torque converter machines, perform the following:


a. Connect hoses (H and K).
b. Install brackets (J and L).
c. Connect wire connectors (AD and I).

UN05APR01

d. Install clamps (E and G).


e. Install dipstick (F).

T140924B

AReverse Alarm and Fuel Sender Harness


Connector
BPark Brake Release Solenoid Connector
CPark Brake Pressure On Switch Connector
DDifferential Lock Solenoid Connector
EClamp
FDipstick
GClamp
HVent Hose
ITransmission Harness Connector
JBracket
KTransmission Charge Pump Inlet Hose
LBracket

Continued on next page

TM2111 (30MAY03)

03-0300-14

CED,OUO1032,3088 1919DEC025/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=98

Removal and Installation


17. Install front axle drive shaft (G) and cap screws (F).
Tighten cap screws (F) to specification.
TransmissionSpecification
Transmission-to-Front Axle Drive
Shaft universal joint Cap Screw
(3/8 in.)Torque ............................................................. 58 Nm (43 lb-ft)
Transmission-to-Front Axle Drive
Shaft universal joint Cap Screw
(1/2 in.)Torque ........................................................... 109 Nm (81 lb-ft)

18. Connect hydraulic hoses (AE).

T113508B

UN13APR98

T113509B

UN13APR98

AWinch Control Hose


BHose to Oil CoolerDirect Drive Machines
BHose to Torque ConverterTorque Converter
Machines
COutlet Hose from Filter
DPark Brake Valve Hose
EReturn Hose from Oil Cooler
FCap Screw (4 used)
GFront Axle Drive Shaft

Continued on next page

TM2111 (30MAY03)

03-0300-15

CED,OUO1032,3088 1919DEC026/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=99

03
0300
15

Removal and Installation


19. For direct drive machines, perform the following:
a. Install engine-to-transmission drive shaft with cap
screws (A and C).

T113507B

UN13APR98

b. To prevent engine flywheel from turning when


tightening drive shaft cap screws, insert timing pin
(D) through flywheel housing as shown and into
timing pin hole in flywheel.
c. Tighten drive shaft cap screws to specification.

UN13APR98

Drive Shaft-to-Damper Cap ScrewsDirect Drive Machines

d. Connect hydraulic hose (B).

T113516B

20. For torque converter machines, fasten both ends of


drive shaft with cap screws (A). Tighten cap screws to
specification.
TransmissionSpecification
Torque
Converter-to-Transmission Drive
Shaft Mounting Cap Screw
Torque ............................................................................. 58 Nm (43 lb-ft)

UN13APR98

Auniversal joint Cap Screw (4 usedDirect Drive)


(8 usedTorque Converter)
BCharge Pump-to-Filter Hose (Direct Drive
Machines)
CDrive Shaft-to-Damper Cap Screw (Direct Drive
Machines) (12 used)
DTiming Pin

T113506B

03
0300
16

TransmissionSpecification
Drive Shaft-to-Engine Damper
Cap ScrewTorque .................................................... 150 Nm (110 lb-ft)
Engine-to-Transmission Drive
Shaft universal joint Cap Screw
Torque ............................................................................. 58 Nm (43 lb-ft)

Drive Shaft and Hydraulic LineDirect Drive Machines


Continued on next page

TM2111 (30MAY03)

03-0300-16

CED,OUO1032,3088 1919DEC027/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=100

Removal and Installation


21. Connect hydraulic hoses (CE).
22. Apply thread lock and sealer (medium strength) to
cap screw (1).
23. Install yoke (2) with cap screw (1). Tighten cap screw
to specification.
TransmissionSpecification
Winch Output Shaft Yoke Cap
ScrewTorque ............................................................ 215 Nm (159 lb-ft)

1Cap Screw
2Winch Output Shaft Yoke
CReturn Hose
DReturn Hose from Winch
EPark Brake Valve Hose

T163138B

UN08JAN03

T113505B

UN13MAY98

03
0300
17

Continued on next page

TM2111 (30MAY03)

03-0300-17

CED,OUO1032,3088 1919DEC028/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=101

Removal and Installation


24. Connect rear axle drive shaft (D) to transmission with
four cap screws (C). Tighten cap screws to
specification.
TransmissionSpecification
Transmission-to-Rear Axle Drive
Shaft universal joint Cap Screw
(1/2 in.)Torque ........................................................... 109 Nm (81 lb-ft)

25. Connect winch drive shaft (A) (if equipped) to


transmission with four cap screws (B). Tighten cap
screws to specification.

AWinch Drive Shaft


BCap Screw (4 used)
CCap Screw (4 used)
DRear Axle Drive Shaft

T113503B

03
0300
18

UN10APR98

TransmissionSpecification
Transmission-to-Winch Drive
Shaft universal joint Cap Screw
(3/8 in.)Torque ............................................................. 58 Nm (43 lb-ft)

Continued on next page

TM2111 (30MAY03)

03-0300-18

CED,OUO1032,3088 1919DEC029/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=102

Removal and Installation


26. Connect vent hose (E).
27. Move bracket and filter assembly (C) into position and
install cap screws (D).
28. Install hydraulic hoses (A and B).

T113499C

UN11APR01

AFilter Inlet Hose


BFilter Outlet Hose
CBracket and Filter Assembly
DCap Screw (2 used)
EVent Hose

T140921B

UN11APR01

Differential Lock FilterDirect Drive Machines

Differential Lock FilterTorque Converter Machines

Continued on next page

TM2111 (30MAY03)

03-0300-19

CED,OUO1032,3088 1919DEC0210/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=103

03
0300
19

Removal and Installation


29. For direct drive machines, perform the following:
a. Install spline coupler (C).

UN13MAY98

b. Install differential lock pump and fasten with cap


screws (B).

T113855D

c. Install main hydraulic pump. See Hydraulic Pump


Disassemble and Assemble. (Group 2160.)
30. Install right and left side access covers (A).
31. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
32. Fill transmission with oil. See Transmission, Hydraulic
System, Park Brake, Differential, Cab Hydraulic Pump
and Winch Oil. (Operators Manual.)
33. Check transmission oil level. See Check Transmission
Oil Level. (Operators Manual.)
34. Calibrate transmission control unit. See Calibration of
Transmission Control Unit (TCU). (Group 9015-20.)

T132624B

UN19JUL00

ASide Access Cover


BCap Screw (2 used)
CSpline Coupler

UN13APR98

Direct Drive (Grapple) Machines Shown

T113498B

03
0300
20

Spline CouplerDirect Drive Machines

CED,OUO1032,3088 1919DEC0211/11

TM2111 (30MAY03)

03-0300-20

G-III and D Series Skidders (S.N. 586337 )


053003

PN=104

Group 0315

Controls
Park Brake and Gear Shift Lever Remove and
Install
NOTE: Illustrations shown are direct drive machines.
Torque converter machines are similar.
1. Remove blade control lever knob (1).
UN15JUN00

2. Remove screws (2).

T131669B

1Blade Control Lever Knob


2Screw (4 used)

03
0315
1
CED,OUO1032,3393 1901NOV021/14

3. Remove screws (1).


4. Remove housing cover (2).

T131670B

UN15JUN00

1Screw (4 used)
2Housing Cover

Direct Drive Housing Cover

CED,OUO1032,3393 1901NOV022/14

5. Disconnect wire connector (1) from Transmission


Controller Unit (TCU).

T131671B

UN15JUN00

1Wire Connector

Continued on next page

TM2111 (30MAY03)

03-0315-1

CED,OUO1032,3393 1901NOV023/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=105

Controls
6. Remove cap screws (1) and remove housing cover (2).

T131672C

UN11APR01

1Cap Screw (6 used)


2Housing Cover

03
0315
2
CED,OUO1032,3393 1901NOV024/14

7. Loosen cap screws (1), but do not remove.

T131673B

UN15JUN00

1Cap Screw (2 used)

Continued on next page

TM2111 (30MAY03)

03-0315-2

CED,OUO1032,3393 1901NOV025/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=106

Controls
8. Pull park brake and gear shift lever (1) up and toward
seat.

T131674B

UN15JUN00

1Park Brake and Gear Shift Lever

Direct Drive Park Brake and Gear Shift Lever

CED,OUO1032,3393 1901NOV026/14

9. Disconnect wire connectors (1) and remove park brake


and gear shift assembly.

T131675B

UN15JUN00

1Wire Connector (3 used)

CED,OUO1032,3393 1901NOV027/14

10. Connect wire connectors (1).

T131675B

UN15JUN00

1Wire Connector (3 used)

Continued on next page

TM2111 (30MAY03)

03-0315-3

CED,OUO1032,3393 1901NOV028/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=107

03
0315
3

Controls
11. Insert head of cap screw through large hole and slide
park brake and gear shift lever (1) into position.

UN15JUN00

1Park Brake and Gear Shift Lever

T131674B

03
0315
4

Direct Drive Park Brake and Gear Shift Lever

CED,OUO1032,3393 1901NOV029/14

12. Tighten cap screws (1).

T131673B

UN15JUN00

1Cap Screw (2 used)

Continued on next page

TM2111 (30MAY03)

03-0315-4

CED,OUO1032,3393 1901NOV0210/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=108

Controls
13. Install housing cover (2) with cap screws (1).

T131672C

UN11APR01

1Cap Screw (6 used)


2Housing Cover

03
0315
5
CED,OUO1032,3393 1901NOV0211/14

14. Connect wire connector (1) to Transmission Controller


Unit (TCU).

T131671B

UN15JUN00

1Wire Connector

CED,OUO1032,3393 1901NOV0212/14

15. Install housing cover (2).


16. Install screws (1).

T131670B

UN15JUN00

1Screw (4 used)
2Housing Cover

Direct Drive Housing Cover

Continued on next page

TM2111 (30MAY03)

03-0315-5

CED,OUO1032,3393 1901NOV0213/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=109

Controls
17. Install screws (2).
18. Install blade control lever knob (1).

T131669B

UN15JUN00

1Blade Control Lever Knob


2Screw (4 used)

03
0315
6
CED,OUO1032,3393 1901NOV0214/14

TM2111 (30MAY03)

03-0315-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=110

Group 0325

Input Drive Shafts and U-Joints


Engine-to-Transmission Drive Shaft Remove and Install

T7501BH

UN16MAY95

03
0325
1

1Universal Joint Cap Screw


3/8 in. (4 used)
2Universal Joint Cross

3Cap
4Drive Shaft

5Washer (12 used)


6Cap Screw 1/2 in. (12 used)

NOTE: Illustrations show drive shaft for direct drive


machines. For torque converter machines, a
universal joint is used at both ends of drive
shaft.
1. Remove and inspect drive shaft. Repair as
required.

7Universal Joint Cap Screw


3/8 in. (4 used)

Engine-to-Transmission Drive ShaftSpecification


Drive Shaft-to-Damper Cap
ScrewTorque ..................................................... 150 Nm (110 lb-ft)
Universal Joint Cap Screws 3/8
in.Torque ............................................................... 58 Nm (43 lb-ft)
Universal Joint Cap Screws 1/2
in.Torque ............................................................. 109 Nm (81 lb-ft)

2. Install drive shaft and tighten cap screws to


specifications.

TX,0325,WW945 1920NOV021/1

TM2111 (30MAY03)

03-0325-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=111

Input Drive Shafts and U-Joints

03
0325
2

TM2111 (30MAY03)

03-0325-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=112

Group 0350

Gears, Shafts and Power Shift Clutches


Transmission Repair Procedures

Disassembly:

Inspect control valve bores for contamination.


Inspect clutch and brake plates for facing material
condition wear to teeth and flatness of the plate.
Inspect clutch and brake separator plates for
discoloration, teeth wear, scoring and flatness.
Inspect all thrust surfaces for scoring.
Inspect all gear and spline teeth.
Inspect all gasket and sealing surfaces for damage.

Clean all parts and flush any debris from oil


passages.
Use moisture-free air to dry parts (except bearings)
and to clean out oil passages.

IMPORTANT: If the transmission has had a major


failure, replace all bearings, springs,
oil seals, O-rings, ring seals, and
gaskets.

Before beginning repair:


Drain transmission oil.
Thoroughly clean the outside of the transmission
before disassembly to reduce the possibility of
contamination.

IMPORTANT: DO NOT use solvent to clean the


clutch and brake disks; use a
lint-free cloth.

03
0350
1

Assembly:

Lightly oil all bearings after cleaning.


IMPORTANT: Spinning a bearing without
lubrication can damage the bearing.
Inspect bearings for discoloration, roughness of
rotation, and excessive wear of rollers or balls.
Inspect bushings, remove burrs and sharp edges.
Replace bushings if out-of-round, scored or
excessively worn.

Lightly oil all bearings.


Use new O-rings, seal rings, oil seals and gaskets.
Lubricate oil seals and O-rings.
Wet clutch and brake plates with clean hydraulic oil
before assembly.
Clean and prepare all gasket and sealing surfaces.

TX,03,RB546 1920FEB981/1

TM2111 (30MAY03)

03-0350-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=113

Gears, Shafts and Power Shift Clutches

Transmission Lifting and Mounting on Repair


Stand

UN23AUG88

Lifting heavy components incorrectly can cause severe


injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.

TS226

Safety Precautions

03
0350
2

CAUTION: Do not allow any part of the body to


be under the transmission while it is being
lifted or after it is suspended on the repair
stand. Do not exceed maximum capacities for
the repair stand. Use only high grade fasteners
in good condition. Personal injury could result.
The transmission repair stand should be used only by
qualified service technicians familiar with this equipment.
Use class 10.9 (SAE Grade 8) or better cap screws to
attach mounting plates to transmission.
Make sure threaded holes in adapters and transmission
are clean and not damaged.
Minimum cap screw thread engagement should be equal
to 1-1/2 times the diameter of the screw.
Do not exceed the maximum capacity rating of the stand.
Be sure transmission is solidly mounted before releasing
from lifting device.
Never permit any part of the body to be positioned under
a load being lifted or suspended. Accidental slippage may
result in personal injury.

Continued on next page

TM2111 (30MAY03)

03-0350-2

TX,03,RB555 1919DEC021/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=114

Gears, Shafts and Power Shift Clutches

CAUTION: Heavy component; use a hoist.


Transmission Lifting and Mounting on Repair StandSpecification
TransmissionWeight................................. 590 kg (1300 lb) approximate

UN09DEC97

Install lifting device into rear housing.

YZ1032

IMPORTANT: When any other stand is used, consult


the manufacturers instructions for
mounting.
1. Use D01003AA Repair Stand or equivalent.

03
0350
3
TX,03,RB555 1919DEC022/4

YZ1035

UN13FEB01

2. Install right plate of JDG1111 Mounting Plates.

Right Plate of JDG1111 Shown


Continued on next page

TM2111 (30MAY03)

03-0350-3

TX,03,RB555 1919DEC023/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=115

Gears, Shafts and Power Shift Clutches


3. Install left plate of JDG1111 Mounting Plates and
JDG1100 Transmission Mounting Adapters.

YZ1036

UN17FEB98

03
0350
4

Left Plate of JDG1111 and JDG1100 Shown

TX,03,RB555 1919DEC024/4

TM2111 (30MAY03)

03-0350-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=116

Gears, Shafts and Power Shift Clutches

Winch Drive Repair

T163170

UN16JAN03

03
0350
5

Winch Drive and Cap Screw Tightening SequenceDirect Drive Machines


AWinch Drive Cover
BCap Screw (11 used)
COil Seal
DV-Ring Seal
ECap Screw

FYoke Washer
GYoke
HDowel Pin
IDowel Pin
JBall Bearing

KOutput Shaft
LBall Bearing
MBall Bearing (2 used)
NGear
OGear

Continued on next page

TM2111 (30MAY03)

03-0350-5

PSnap Ring
QWithout Winch Drive
RO-Ring
SCover

OUO1065,0000590 1920NOV021/12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=117

Gears, Shafts and Power Shift Clutches

T163742

UN21JAN03

03
0350
6

Winch Drive and Cap Screw Tightening SequenceTorque Converter Machines

Continued on next page

TM2111 (30MAY03)

03-0350-6

OUO1065,0000590 1920NOV022/12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=118

Gears, Shafts and Power Shift Clutches


AWinch Drive Cover
BCap Screw (11 used)
COil Seal
DV-Ring Seal
EYoke

FYoke Washer
GCap Screw
HBall Bearing (2 used)
IBall Bearing
JOutput Shaft

KBall Bearing
LGear
MGear
NSnap Ring
ODowel Pin (2 used)

PSnap Ring
QWithout Winch Drive
RO-Ring
SCover

OUO1065,0000590 1920NOV023/12

1. Remove cap screw and washer (1).


2. Remove yoke (2).

UN08JAN03

3. Remove V-ring seal (3).


4. Remove seal (4).

T163169B

UN08JAN03

T163138B

1Cap Screw and Washer


2Yoke
3V-Ring Seal
4Seal

OUO1065,0000590 1920NOV024/12

5. Remove cap screws (A) from winch cover.

YZ1045

UN17FEB98

AWinch Cover Cap Screws

Continued on next page

TM2111 (30MAY03)

03-0350-7

OUO1065,0000590 1920NOV025/12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=119

03
0350
7

Gears, Shafts and Power Shift Clutches


6. Remove winch cover.
7. Remove output shaft (A).

YZ1046A

UN17FEB98

AWinch Output Shaft

OUO1065,0000590 1920NOV026/12

8. Remove idler gear (B).

YZ1048

UN17FEB98

BIdler Gear

OUO1065,0000590 1920NOV027/12

9. Remove snap ring (C).


10. Remove drive gear (D).

UN09DEC97

11. Inspect gears and replace as need.


CSnap Ring
DDrive Gear

YZ1049

03
0350
8

Continued on next page

TM2111 (30MAY03)

03-0350-8

OUO1065,0000590 1920NOV028/12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=120

Gears, Shafts and Power Shift Clutches


12. Install winch output shaft (A).
13. Install idler gear (B).

UN17FEB98

14. Install drive gear (C).


15. Install snap ring (D).

YZ1047

AWinch Output Shaft


BIdler Gear
CDrive Gear
DSnap Ring

03
0350
9
OUO1065,0000590 1920NOV029/12

16. Clean mating surfaces of housings with isopropyl


alcohol or equivalent.

UN17FEB98

IMPORTANT: Excessive amounts of gasket adhesive


may cause incorrect bearing end play,
extend cure time and cause runoff of
material. Using a small roller will help to
apply a thin, even layer of adhesive.

YZ1044D

17. Apply flexible sealant to rear housing mounting


surface, using care to apply a thin layer over the
entire surface. Excess gasket material should be
wiped from joint. Installation should occur within three
minutes of application. Allow a minimum of 30
minutes of cure time before adding oil.
18. Make sure two dowel pins are installed in rear
housing.
19. Install winch drive cover (A).
UN20MAR01

20. Install and tighten cap screws (B) in sequence shown.


Repeat sequence again to check cap screw torques.

YZ4114

Winch DriveSpecification
Winch Cover-to-Rear Housing
Torque ................................................................. 25 5 Nm (18 4 lb-ft)

AWinch Drive Cover


BCap Screw (11 Used)

Continued on next page

TM2111 (30MAY03)

03-0350-9

OUO1065,0000590 1920NOV0210/12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=121

Gears, Shafts and Power Shift Clutches


21. Install new output oil seal (A) using JDG1110 Input
Shaft Seal Installation Tool (B) and JDG1108 Clutch
Bearing Driver (C).

YZ1043

UN18FEB98

AOutput Oil Seal


BJDG1110 Input Shaft Seal Installation Tool
CJDG1108 Clutch Bearing Driver

03
0350
10
OUO1065,0000590 1920NOV0211/12

22. Install seal (4).


23. Install V-ring seal (3).

Winch DriveSpecification
Yoke Cap ScrewTorque........................................... 215 Nm (159 lb-ft)

T163138B

UN08JAN03

1Cap Screw and Washer


2Yoke
3V-Ring Seal
4Seal

T163169B

25. Install and tighten cap screw and washer (1).

UN08JAN03

24. Install yoke (2).

OUO1065,0000590 1920NOV0212/12

TM2111 (30MAY03)

03-0350-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=122

Gears, Shafts and Power Shift Clutches

Park Brake Repair


CAUTION: Cover and housing assembly is
spring loaded. Use care removing cap screws
to prevent personal injury.

UN16JAN03

IMPORTANT: Four cap screws are shorter and are


located at the recessed areas in the
housing. Remove only two cap screws
(1). These screws keep the park brake
cover and housing together.

T163607B

1. Remove yoke.
2. Remove two cap screws (1) and attach JT01748 Lifting
Brackets (2) with two 12 mm x 140 mm cap screws.
1Park Brake Cover Cap ScrewShort (4 Used)
2JT01748 Lifting Bracket (2 used)
3Park Brake Cap ScrewLong (10 Used)

3. Remove only park brake cap screws (3).

OUO1065,0000592 1921NOV021/18

CAUTION: Heavy component; use a hoist.


Park BrakeSpecification
Park BrakeWeight .......................................... 43 kg (95 lb) approximate

T163608B

UN16JAN03

4. Lift park brake assembly from rear housing.

Continued on next page

TM2111 (30MAY03)

03-0350-11

OUO1065,0000592 1921NOV022/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=123

03
0350
11

Gears, Shafts and Power Shift Clutches


5. Remove snap ring (A).
6. Remove brake hub (B).
7. Remove and discard gasket (C).

YZ4189

UN10APR01

ASnap Ring
BBrake Hub
CGasket

03
0350
12

OUO1065,0000592 1921NOV023/18

8. Remove lifting brackets (2).

UN16JAN03

CAUTION: Park brake cover is spring loaded.


Loosen each cap screw only 23 turns at a
time. Alternate between cap screws several
times until spring force has been released.

T163609B

9. Remove remaining cap screws (1).


1Cap Screws
2JT01748 Lifting Brackets (2 used)

OUO1065,0000592 1921NOV024/18

10. Remove park brake cover (1).

T163610B

UN16JAN03

1Park Brake Cover


2Park Brake Housing

Continued on next page

TM2111 (30MAY03)

03-0350-12

OUO1065,0000592 1921NOV025/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=124

Gears, Shafts and Power Shift Clutches


11. Remove Belleville spring (A).
12. Remove brake piston (B).

YZ1062A

UN13MAR01

ABelleville Spring
BBrake Piston

OUO1065,0000592 1921NOV026/18

13. Remove and discard outer piston seal (C) and inner
piston seal (D) from piston (E).

03
0350
13

YZ1063A

UN13MAR01

COuter Piston Seal


DInner Piston Seal
EPiston

OUO1065,0000592 1921NOV027/18

14. Remove separator plates (A) and clutch disks (B).


15. Inspect for wear or damage.
16. Remove and discard O-ring (C).

YZ1064A

UN13MAR01

ASeparator Plates
BClutch Disks
CO-Ring

Continued on next page

TM2111 (30MAY03)

03-0350-13

OUO1065,0000592 1921NOV028/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=125

Gears, Shafts and Power Shift Clutches

1
2

4
5
6
7

9
10

03
0350
14

11

12

17

13
12
15

T162070

1Gasket
2Brake Hub
3Retaining Ring
4Park Brake Housing
5O-Ring

12
6Clutch Disks (8 used)
7Inner Piston Seal
8Piston
9Outer Piston Seal

10Belleville Spring
11Park Brake Cover
12Cap Screw (10 used)
13Cap Screw (4 used)

13

12

T162070

13

UN25NOV02

14

16

14Oil Seal
15Grease Seal (2 used)
16Grease Fitting
17Clutch Plates (9 used)

17. Remove and discard seals (14 and 15) from cover
(11).

Continued on next page

TM2111 (30MAY03)

03-0350-14

OUO1065,0000592 1921NOV029/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=126

Gears, Shafts and Power Shift Clutches


NOTE: Use guide pins during assembly to guide the
brake housing onto the rear housing.
18. Install gasket (A) on transmission housing.
19. Install brake hub (B) in center of rear housing with
small diameter of hub down.
20. Install snap ring (C).

YZ4197

UN10APR01

YZ4196

UN10APR01

AGasket
BBrake Hub
CSnap Ring

Continued on next page

TM2111 (30MAY03)

03-0350-15

OUO1065,0000592 1921NOV0210/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=127

03
0350
15

Gears, Shafts and Power Shift Clutches


21. Install park brake housing (A) on transmission
housing.

NOTE: Lubricate O-ring to prevent damage during


assembly.
22. Lubricate and install new O-ring (B) on brake housing.

YZ4198

UN10APR01

APark Brake Housing


BO-Ring

YZ4199

UN10APR01

03
0350
16

Continued on next page

TM2111 (30MAY03)

03-0350-16

OUO1065,0000592 1921NOV0211/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=128

Gears, Shafts and Power Shift Clutches


NOTE: Clutch plate (C) must be last.
23. Starting with clutch plate (A) install alternately clutch
plates and clutch disks (A and B) into brake housing.
Must end with clutch plate (C).

YZ4200

UN24AUG01

YZ4202

UN24AUG01

AClutch Plate (9 Used)


BClutch Disk (8 Used)
CClutch Plate (Last Plate Installed)

Continued on next page

TM2111 (30MAY03)

03-0350-17

OUO1065,0000592 1921NOV0212/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=129

03
0350
17

Gears, Shafts and Power Shift Clutches


24. Lubricate and install new inner piston seal (A) and
outer piston seal (B) on piston (C).

UN24AUG01

AInner Piston Seal


BOuter Piston Seal
CPiston

YZ4201

03
0350
18

OUO1065,0000592 1921NOV0213/18

25. Install Belleville spring (A) with inner diameter of


Belleville spring contacting piston.

YZ4203

UN24AUG01

ABelleville Spring

Continued on next page

TM2111 (30MAY03)

03-0350-18

OUO1065,0000592 1921NOV0214/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=130

Gears, Shafts and Power Shift Clutches

CAUTION: Carefully lower park housing cover


watching for pinch points.

UN16JAN03

26. Install park brake cover (1) on park brake housing (2).

T163610B

1Park Brake Cover


2Park Brake Housing

OUO1065,0000592 1921NOV0215/18

IMPORTANT: Install the two cap screws in recessed


holes in park brake cover.

03
0350
19

UN16JAN03

27. Install and alternately tighten two cap screws (1) to


compress Belleville spring.
28. Remove guide pins.

T163609B

29. Attach JT01748 Lifting Brackets.


30. Position park brake housing on transmission housing.
1Cap Screws
2JT01748 Lift Brackets

OUO1065,0000592 1921NOV0216/18

31. Install and tighten all cap screws to proper


specification.

UN14JAN03

Park BrakeSpecification
Park Brake-to-Rear Housing Cap
ScrewTorque ................................................................ 87 Nm (64 lb-ft)

T163631B

32. Install JDG1519 Seal Protector.

Continued on next page

TM2111 (30MAY03)

03-0350-19

OUO1065,0000592 1921NOV0217/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=131

Gears, Shafts and Power Shift Clutches


33. Apply thread lock and sealer (medium strength) to
outside diameter of seals.
34. Apply thin layer of petroleum jelly to inner seal lip.

37. Use JDG1738 driver to install third grease seal until


flush with shoulder in park brake cover with inner seal
lip up.
03
0350
20

T163632B

36. Using JDG1737 Seal Driver install second grease


seal to bottom of seal bore in park brake cover with
inner seal lip up.

UN14JAN03

35. Use JDG1736 Seal Driver (1) to install first oil seal
until flush with shoulder in park brake cover (11).

1JDG1738 Seal Driver


2Grease Seal

OUO1065,0000592 1921NOV0218/18

TM2111 (30MAY03)

03-0350-20

G-III and D Series Skidders (S.N. 586337 )


053003

PN=132

Gears, Shafts and Power Shift Clutches

Charge Pump Repair

YZ1065

UN18FEB98

03
0350
21

AO-Ring
BBearing (2 used)
CDrive Gear

DTransmission Charge
Pump
ECap Screw (4 used)

FCap Screw
GO-Ring
HIdler Shaft

IBall Bearing (2 used)


JIdler Gear
KO-Ring

OUO1020,0001130 1922NOV021/17

1. Remove cap screws (A).


2. Loosen nut (B) to remove suction tube (C).

T115388

UN13MAY98

ACap Screws
BNut
CSuction Tube

Continued on next page

TM2111 (30MAY03)

03-0350-21

OUO1020,0001130 1922NOV022/17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=133

Gears, Shafts and Power Shift Clutches


3. If necessary, remove suction screen (2).
4. Remove and discard O-ring (1).

T163634B

UN13JAN03

1O-Ring
2Suction Screen

OUO1020,0001130 1922NOV023/17

6. Remove cap screws (B).

YZ1067

UN17DEC97

IMPORTANT: Bearing (E) and drive gear (D) are


slip-fit at the base of the charge pump
and may remain in front housing. Use
care to remove charge pump so bearing
and gear are not dropped and damaged.
7. Remove charge pump (C) from front housing.

UN17DEC97

AFlat Face Fitting


BCap Screws
CCharge Pump
DDrive Gear
EBearing

YZ1068

03
0350
22

5. Remove flat face fitting (A) if necessary. Replace both


O-rings if fitting is removed.

Continued on next page

TM2111 (30MAY03)

03-0350-22

OUO1020,0001130 1922NOV024/17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=134

Gears, Shafts and Power Shift Clutches


8. Remove drive gear (A).
ADrive Gear

YZ1090

UN17DEC97

03
0350
23

OUO1020,0001130 1922NOV025/17

9. Remove cap screw (A).

YZ1070

UN17DEC97

ACap Screw

OUO1020,0001130 1922NOV026/17

10. Install an M8 x 35 mm cap screw (B) in tapped hole.

YZ1071

UN17DEC97

BM8 x 35 mm Cap Screw

Continued on next page

TM2111 (30MAY03)

03-0350-23

OUO1020,0001130 1922NOV027/17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=135

Gears, Shafts and Power Shift Clutches


11. Use cap screw to remove idler shaft (C).

UN17DEC97

IMPORTANT: There are two O-rings (D), one at each


end of shaft. The O-ring located on the
bottom of the idler shaft may slip off at
removal of shaft.
12. Remove and discard O-rings (D).

YZ1072

13. Remove idler gear (E).


14. Replace bearings in idler gear if worn or damaged.
CIdler Shaft
DO-Rings
EIdler Gear
03
0350
24

OUO1020,0001130 1922NOV028/17

15. Install idler gear (A) into front housing.

NOTE: Lubricate O-rings to avoid damage during


assembly.
UN23DEC97

16. Install new O-rings (B) on idler shaft.


17. Install idler shaft through idler gear and housing.

YZ1150

AIdler Gear
BO-Rings

OUO1020,0001130 1922NOV029/17

18. Install an M8 x 35 mm cap screw (C) in tapped hole.


Turn shaft using cap screw to align holes in shaft and
housing.

UN21MAR01

19. Remove M8 x 35 mm cap screw (C).

YZ1071D

CM8 x 35 Cap Screw

Continued on next page

TM2111 (30MAY03)

03-0350-24

OUO1020,0001130 1922NOV0210/17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=136

Gears, Shafts and Power Shift Clutches


20. Install and tighten cap screw in idler shaft.

YZ1148

UN23DEC97

Charge Pump Specification


Idler Gear Shaft-to-Front Housing
Cap ScrewTorque ........................................................ 87 Nm (64 lb-ft)

03
0350
25
OUO1020,0001130 1922NOV0211/17

21. Install bearing (A), drive gear (B), and bearing (C).

YZ1155

UN23DEC97

ABearing
BDrive Gear
CBearing

Continued on next page

TM2111 (30MAY03)

03-0350-25

OUO1020,0001130 1922NOV0212/17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=137

Gears, Shafts and Power Shift Clutches


22. Lubricate O-ring with petroleum jelly and install in
groove in housing at (D).
23. Install charge pump.
DO-Ring

T164952B

UN04FEB03

03
0350
26

Continued on next page

TM2111 (30MAY03)

03-0350-26

OUO1020,0001130 1922NOV0213/17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=138

Gears, Shafts and Power Shift Clutches


24. Install and tighten cap screws (14) in the sequence
shown.
Charge PumpSpecification
Transmission Charge
Pump-to-Transmission Housing
Torque ............................................................................. 73 Nm (55 lb-ft)

T114002

UN16MAR98

YZ1156

UN23DEC97

1Bottom Left Cap Screw


2Top Right Cap Screw
3Bottom Right Cap Screw
4Top Left Cap Screw

Cap Screw Torque Sequence


OUO1020,0001130 1922NOV0214/17

25. Install suction screen (2) and new O-ring (1).

T163634B

UN13JAN03

1O-Ring
2Suction Screen

Continued on next page

TM2111 (30MAY03)

03-0350-27

OUO1020,0001130 1922NOV0215/17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=139

03
0350
27

Gears, Shafts and Power Shift Clutches


NOTE: Flat face fitting has two O-rings. Discard and
replace both O-rings.

YZ1067D

Charge PumpSpecification
Flat Face Fitting-to-Charge Pump
Cap ScrewTorque .................................................... 190 Nm (140 lb-ft)

UN12JAN98

26. Install flat face fitting (C) with new O-rings, if


removed.

CFlat Face Fitting

03
0350
28
OUO1020,0001130 1922NOV0216/17

27. Install suction tube (D).

Charge PumpSpecification
Suction Tube-to-Front Housing
Cap ScrewsTorque ...................................................... 25 Nm (18 lb-ft)

YZ1066D

29. Tighten suction tube nut (F).

UN08MAY98

28. Install and tighten cap screws (E).

DSuction Tube
ECap Screws
FSuction Tube Nut

OUO1020,0001130 1922NOV0217/17

TM2111 (30MAY03)

03-0350-28

G-III and D Series Skidders (S.N. 586337 )


053003

PN=140

Gears, Shafts and Power Shift Clutches

Transmission Suction Tube Repair


1. Remove cap screws (A).
2. Remove suction tube (B).
UN21MAR01

3. If necessary, remove suction screen (D).


4. Remove and discard O-ring (E).

YZ4125

5. Install suction screen (D) and new O-ring (E).


6. Install suction tube (B).
7. Install and tighten cap screws (A).

03
0350
29
UN14JAN03

Transmission Suction TubeSpecification


Suction Tube-to-Front Housing
Cap ScrewsTorque ...................................................... 25 Nm (18 lb-ft)

T163634C

ACap Screws
BSuction Tube
CSuction Tube Baffle
DSuction Screen
EO-Ring

OUO1020,0001135 1922NOV021/1

TM2111 (30MAY03)

03-0350-29

G-III and D Series Skidders (S.N. 586337 )


053003

PN=141

Gears, Shafts and Power Shift Clutches

Transmission Cover Plates to Front Housing


Remove and InstallTorque Converter
Machines

UN21MAR01

Transmission Cover Plate Remove and InstallFront


Housing (Front View)
1. Remove cap screws (A) and washers (B).

YZ4126

2. Remove cover plate (C).


3. Remove and discard O-ring (D).

UN21MAR01
YZ4127

03
0350
30

ACap Screw (4)


BWasher (4)
CCover Plate
DO-Ring

Continued on next page

TM2111 (30MAY03)

03-0350-30

OUO1020,0001136 1922NOV021/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=142

Gears, Shafts and Power Shift Clutches


1. Install new O-ring (A).
2. Install cover plate (B).
3. Install washers (C) and cap screws (D). Tighten cap
screws to proper specification.
Transmission Cover PlateSpecification
Cover Plate-to-Transmission
Housing Cap ScrewsTorque ........................................ 50 Nm (37 lb-ft)

YZ4130

UN21MAR01

YZ4129

UN21MAR01

AO-Ring
BCover Plate
CWasher (4 used)
DCap Screw (4 used)

Continued on next page

TM2111 (30MAY03)

03-0350-31

OUO1020,0001136 1922NOV022/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=143

03
0350
31

Gears, Shafts and Power Shift Clutches


Transmission Cover Plate Remove and InstallFront
Housing (Rear View)
1. Remove cap screws (A).
2. Remove cover plate (B).
3. Remove and discard O-ring (C).
UN29MAR01

1. Install O-ring (C) on cover plate (B).


2. Install cover plate to housing.

Transmission Cover Plate Specification


Cover Plate-to-Transmission
Housing Cap ScrewsTorque ........................................ 50 Nm (37 lb-ft)

ACap Screw (2 used)


BCover Plate
CO-Ring

OUO1020,0001136 1922NOV023/3

Transmission Idler Shaft Remove and


InstallTorque Converter Machines

UN06APR01

1. Remove cap screw (A).

YZ1070E

ACap Screw

OUO1020,0001137 1922NOV021/5

2. Install an M8 x 35 mm cap screw (B) in tapped hole.

UN06APR01

BM8 x 35 Cap Screw

YZ1071E

03
0350
32

YZ4178

3. Install and tighten cap screws (A).

Continued on next page

TM2111 (30MAY03)

03-0350-32

OUO1020,0001137 1922NOV022/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=144

Gears, Shafts and Power Shift Clutches


3. Use cap screw to remove idler shaft (C).
IMPORTANT: There are two O-rings (D), one at each
end of shaft. The O-ring located on the
bottom of the idler shaft may slip off at
removal of shaft.
4. Remove and discard O-rings (D).

YZ4128

UN21MAR01

CIdler Shaft
DO-Ring (2)

OUO1020,0001137 1922NOV023/5

NOTE: Lubricate O-rings to avoid damage during


assembly.
5. Install new O-rings (A) on idler shaft (B).
6. Install cap screw (C) into idler shaft.

NOTE: Cap screw helps turn the idler shaft, while


installing, to align the shaft properly in the
housing.
7. Install idler shaft (B) using cap screw to align holes in
shaft and housing.

YZ4188

UN06APR01

AO-Rings
BIdler Shaft
CCap Screw

Continued on next page

TM2111 (30MAY03)

03-0350-33

OUO1020,0001137 1922NOV024/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=145

03
0350
33

Gears, Shafts and Power Shift Clutches


8. Install and tighten cap screw in idler shaft.

YZ1148

UN23DEC97

Transmission Idler ShaftTorque Converter Machines


Specification
Idler Shaft-to-Front Housing Cap
ScrewTorque ................................................................ 87 Nm (64 lb-ft)

03
0350
34
OUO1020,0001137 1922NOV025/5

Transmission Control Valve Repair


Direct drive machine shown throughout. Procedures for
torque converter machine are the same except where
noted.

Continued on next page

TM2111 (30MAY03)

03-0350-34

OUO1020,000113A 1922NOV021/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=146

Gears, Shafts and Power Shift Clutches

YZ4135

UN22MAR01

03
0350
35

Torque Converter Machine Shown


AValve Housing
BProportional Solenoid
Torque Converter Machine
(7 used)Direct Drive
Machine (8 used)
CCooler Pressure Relief
Valve

DMain Pressure Regulator


ETemperature Sensor Direct
DriveTorque Converter
Will Have Plug
FO-Ring

GPlug (12 used)


HAuxiliary Pressure
Port-to-Transmission
IPlug (2 used)

Continued on next page

TM2111 (30MAY03)

03-0350-35

JProportional Solenoid Plug


Torque Converter Machine
OnlyDirect Drive Machine
Will Have Proportional
Solenoid (B)

OUO1020,000113A 1922NOV022/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=147

Gears, Shafts and Power Shift Clutches


1. Remove cap screws from control valve.
CAUTION: Heavy component; use a hoist.

UN17DEC97

Transmission Control Valve Specification


Control ValveWeight ................................... 27.5 kg (61 lb) approximate

2. Remove valve (A).

YZ1077

AControl Valve

OUO1020,000113A 1922NOV023/24

4. Discard gaskets and plate.

YZ1078

UN17DEC97

AGasket
BPlate
CGasket

OUO1020,000113A 1922NOV024/24

UN17DEC97

NOTE: Direct drive machines have eight proportional


solenoids in the valve housing, torque converter
machines have seven. All valves can be removed
without removing the control valve from the
transmission.
5. Remove nut (A), washer (B) and coil (C) from
proportional solenoid valve. Flange nut also used in
place of nut and washer.

YZ1079

03
0350
36

3. Remove gasket (A), plate (B) and gasket (C) from front
housing.

ANut or Flanged Nut


BWasher (Not used with Flanged Nut)
CCoil

Continued on next page

TM2111 (30MAY03)

03-0350-36

OUO1020,000113A 1922NOV025/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=148

Gears, Shafts and Power Shift Clutches


IMPORTANT: When any proportional solenoid valves
are removed or replaced, See
Calibration of Transmission Control
Unit (TCU) procedure. (Group 9015-20.)

UN17DEC97

6. Remove proportional valve (D).


7. Inspect for contamination.

YZ1080

DProportional Valve

OUO1020,000113A 1922NOV026/24

8. Remove proportional solenoid plug (1) on torque


converter machine. Direct drive machine will have a
proportional solenoid.

03
0350
37

UN13JAN03

9. Remove O-rings (2).


10. Inspect for contamination.

T163636B

1Proportional Solenoid Plug


2O-Ring (2 used)

OUO1020,000113A 1922NOV027/24

11. Remove relief valve (A).


12. Inspect for wear or contamination.

YZ1081

UN17DEC97

ACooler Pressure Relief Valve

OUO1020,000113A 1922NOV028/24

13. Remove main pressure regulator (A).


14. Inspect for wear or contamination.

YZ1082

UN17DEC97

AMain Pressure Regulator

Continued on next page

TM2111 (30MAY03)

03-0350-37

OUO1020,000113A 1922NOV029/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=149

Gears, Shafts and Power Shift Clutches


NOTE: Direct drive has temperature sensor. Torque
converter has plug.

UN17DEC97

15. Remove temperature sensor or plug (A). Direct drive


has temperature sensor. Torque converter has plug.
16. Remove O-ring (B).

YZ1083

17. Inspect for contamination.


ATemperature SensorDirect Drive Machine
BO-Ring

Temperature Sensor and O-RingDirect Drive Machine

03
0350
38
OUO1020,000113A 1922NOV0210/24

18. Remove twelve plugs (A).


19. Inspect for contamination in control valve passages.

UN17DEC97

NOTE: Apply lubricant to all O-rings prior to installing into


valve housing.
20. Install new O-ring.

YZ1084

21. Install plugs (A) and fitting into valve housing.


22. Tighten plugs (A).
Transmission Control ValveSpecification
Plug-to-Valve HousingTorque ................................... 12 Nm (106 lb-in.)

APlugs (12 used)

Continued on next page

TM2111 (30MAY03)

03-0350-38

OUO1020,000113A 1922NOV0211/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=150

Gears, Shafts and Power Shift Clutches


23. Install new O-ring (B).
24. Install temperature sensor (A). Torque converter
machine will have plug.

UN17DEC97

25. Tighten temperature sensor or plug.

YZ1083

Transmission Control ValveSpecification


Temperature Sensor or
Plug-to-Valve HousingTorque ................................... 16 Nm (142 lb-in.)

ATemperature SensorDirect Drive Machine


BO-Ring

03
0350
39
OUO1020,000113A 1922NOV0212/24

26. Install new O-rings.


27. Install and tighten main pressure regulator (A).

UN17DEC97

Transmission Control ValveSpecification


Main Regulator
Assembly-to-Valve Housing
Torque .............................................................. 3447 Nm (2535 lb-ft)

YZ1082

AMain Pressure Regulator

OUO1020,000113A 1922NOV0213/24

28. Install new O-rings (A).


29. Install and tighten relief valve.

UN17DEC97

Transmission Control ValveSpecification


Cooler Pressure Relief Valve
Assembly-to-Valve Housing
Torque .............................................................. 3447 Nm (2535 lb-ft)

YZ1081

AO-Rings

Continued on next page

TM2111 (30MAY03)

03-0350-39

OUO1020,000113A 1922NOV0214/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=151

Gears, Shafts and Power Shift Clutches


IMPORTANT: When a valve is replaced or removed,
the transmission must be calibrated.
See Calibration of Transmission Control
Unit (TCU). (Group 9015-20.)

UN24SEP96

30. Install new O-rings (AC) on proportional valve.

YZ327

AO-Ring
BO-Ring
CO-Ring

OUO1020,000113A 1922NOV0215/24

31. Install proportional valve (D) into valve housing.


32. Tighten proportional valve.

UN17DEC97

Transmission Control ValveSpecification


Proportional Valve-to-Valve
HousingTorque.............................................. 1620 Nm (1215 lb-ft)

YZ1080

DProportional Valve

OUO1020,000113A 1922NOV0216/24

33. Install coil (E) and washer (F) on proportional valve.


34. Clean threads on proportional valve and nut. Apply
cure primer.
UN12JAN98

35. Apply medium strength thread lock and sealer to nut


(G) and install on proportional valve.
ECoil
FWasher (Not used with Flange Nut)
GNut or Flange Nut

YZ1079D

03
0350
40

Continued on next page

TM2111 (30MAY03)

03-0350-40

OUO1020,000113A 1922NOV0217/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=152

Gears, Shafts and Power Shift Clutches


36. Tighten solenoid coil nut.

UN22MAR01

Transmission Control ValveSpecification


Proportional Valve
Nut-to-Proportional Solenoid
Torque .......................................................... 4.56.8 Nm (4060 lb-in.)

YZ4136

37. Repeat steps to install remaining proportional


solenoid and valve assemblies.

OUO1020,000113A 1922NOV0218/24

38. Install O-rings (2) to proportional solenoid plug.


03
0350
41

39. Install and tighten proportional solenoid plug (1).

UN13JAN03

Transmission Control ValveSpecification


Proportional Solenoid
Plug-to-Valve HousingTorque ....................... 1620 Nm (1215 lb-ft)

T163636B

1Proportional Solenoid Plug


2O-Ring

OUO1020,000113A 1922NOV0219/24

40. Install two guide bolts (A) in the front housing.

UN23DEC97

NOTE: The guide bolts help align the gaskets by holding


them in place and ease valve assembly
installation.

YZ1088

AGuide Bolts

Continued on next page

TM2111 (30MAY03)

03-0350-41

OUO1020,000113A 1922NOV0220/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=153

Gears, Shafts and Power Shift Clutches

UN23DEC97

IMPORTANT: Gaskets (B and D) and plate (C) must


be in correct order and correct side up.
Gasket (B) is cut to the shape of the
front housing. Gasket (D) is cut to the
shape of the control valve. Printed side
of gasket must be towards the control
valve.

YZ1078A

41. Put gasket (B), plate (C) and gasket (D) on front
housing using guide bolts as alignment guide.
BGasket
CPlate
DGasket

03
0350
42
OUO1020,000113A 1922NOV0221/24

42. Install control valve (A) on front housing.


43. Remove guide bolts.
44. Install and tighten cap screws (B) per numerical
sequence drawing.

YZ1087

UN23DEC97

AControl Valve
BCap Screws

Continued on next page

TM2111 (30MAY03)

03-0350-42

OUO1020,000113A 1922NOV0222/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=154

Gears, Shafts and Power Shift Clutches

T163650

UN14JAN03

03
0350
43

ACap Screw, 45 mm long


and Flat Washer (5 used)

BCap Screw, 90 mm long


and Flat Washer (9 used)

CCap Screw, 75 mm long


and Flat Washer (13 used)

Continued on next page

TM2111 (30MAY03)

03-0350-43

OUO1020,000113A 1922NOV0223/24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=155

Gears, Shafts and Power Shift Clutches


45. Tighten cap screws (AC) again in sequence
shown.
Transmission Control ValveSpecification
Control Valve-to-Front Housing
Cap ScrewsTorque ............................................... 39 Nm (29 lb-ft)

OUO1020,000113A 1922NOV0224/24

03
0350
44

TM2111 (30MAY03)

03-0350-44

G-III and D Series Skidders (S.N. 586337 )


053003

PN=156

Gears, Shafts and Power Shift Clutches

Input Yoke Remove and Install


1. Remove cap screw (A).

UN20DEC97

2. Remove washer (B).


3. Remove O-ring (C).

YZ1091

4. Remove yoke (D).


5. Remove oil seal (E).
6. Apply medium strength thread lock and sealer to
outside diameter of oil seal and petroleum jelly to
inside diameter of new oil seal (E). Install using a disk
driver.

03
0350
45

NOTE: Optimal white paste reduces spline wear.


UN20DEC97

7. Apply OPTIMOLY PASTE WHITE T on input shaft


spline before installing yoke.

YZ1092

IMPORTANT: The yoke may need to be moved up and


down until the seal lip is pointing out
over the full circumference. Seal lip of
oil seal must not be rolled when yoke is
installed.

ACap Screw
BWasher
CO-Ring
DYoke
EOil Seal

8. Install yoke (D).


9. Install O-ring (C).
10. Install washer (B).
11. Apply high strength thread lock and sealer to cap
screw (A).

OPTIMOLY PASTE WHITE T is a trademark of Optimal Lubricants, Inc.

TM2111 (30MAY03)

Continued on next page

03-0350-45

TX,03,RB605 1925NOV021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=157

Gears, Shafts and Power Shift Clutches


12. Install and tighten cap screw to specification.
Input Yoke Specification
Yoke Cap ScrewTorque........................................... 215 Nm (159 lb-ft)

UN12JAN98

ETorque Wrench

YZ1153

03
0350
46

TX,03,RB605 1925NOV022/2

TM2111 (30MAY03)

03-0350-46

G-III and D Series Skidders (S.N. 586337 )


053003

PN=158

Gears, Shafts and Power Shift Clutches

03
0350
47

TM2111 (30MAY03)

03-0350-47

G-III and D Series Skidders (S.N. 586337 )


053003

PN=159

Gears, Shafts and Power Shift Clutches

Front Housing Exploded ViewDirect Drive Machines

1
2

03
0350
48

3
4
21

5
6
8
7
14
20
13
9
10

17

18

19

16
15
11

T162133

UN11DEC02

12

T162133

Continued on next page

TM2111 (30MAY03)

03-0350-48

OUO1020,000113F 1925NOV021/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=160

Gears, Shafts and Power Shift Clutches


1Front Housing
2Cap Screw (19 used)
3O-Ring
4Flat Face Fitting
5O-Ring
6Lube Relief Valve

7Drain Valve
8Plug and O-Ring (2 used)
9O-Ring
10Plug
11Cap Screw (2 used)

12Suction Tube
13Grease Seal (2 used)
14Oil Seal
15O-Ring
16Suction Screen

Continued on next page

17Suction Tube Baffle


18Grease Fitting
19Plug
20Check Ball
21Oil Splash Guard

OUO1020,000113F 1925NOV022/4

03
0350
49

TM2111 (30MAY03)

03-0350-49

G-III and D Series Skidders (S.N. 586337 )


053003

PN=161

Gears, Shafts and Power Shift Clutches

T163654

UN14JAN03

03
0350
50

Front Housing Rear ViewDirect Drive Machines

Continued on next page

TM2111 (30MAY03)

03-0350-50

OUO1020,000113F 1925NOV023/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=162

Gears, Shafts and Power Shift Clutches


1Front Housing
2Lube Relief Valve

3Grease Seal (2 used)


4Oil Seal

5Dowel Pin (2 used)


6Bearing Cup

7Bore Sleeve (4 used)


8Bearing Cup (2 used)

OUO1020,000113F 1925NOV024/4

03
0350
51

TM2111 (30MAY03)

03-0350-51

G-III and D Series Skidders (S.N. 586337 )


053003

PN=163

Gears, Shafts and Power Shift Clutches

Front Housing Exploded ViewTorque Converter Machines

1
2
03
0350
52

3
4
5
2
10

21
23
14 24 22
13
25

20

12
19
17
16

18

15
26

T162131

UN15JAN03

11

T162131

Continued on next page

TM2111 (30MAY03)

03-0350-52

OUO1020,0001140 1925NOV021/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=164

Gears, Shafts and Power Shift Clutches


1Front Housing
2Cap Screw (19 used)
3O-Ring
4Idler Shaft
5O-Ring
6Lube Relief Valve
7O-Ring

8Cover Plate
9Washer (4 used)
10Cap Screw (4 used)
11Cap Screws (2 used)
12Plug Suction Tube
13Grease Seal (2 used)
14Oil Seal

15O-Ring
16Suction Screen
17Suction Tube Baffle
18Grease Fitting
19Plug
20Check Ball

Continued on next page

21Oil Splash Guard


22Drain Valve
23Plug (2 used)
24Fitting
25O-Ring
26Suction Tube

OUO1020,0001140 1925NOV022/3

03
0350
53

TM2111 (30MAY03)

03-0350-53

G-III and D Series Skidders (S.N. 586337 )


053003

PN=165

Gears, Shafts and Power Shift Clutches

YZ4144

UN23MAR01

03
0350
54

Rear View of Front HousingTorque Converter Machines


AFront Housing
BDowel Pin (2 used)
CBearing Cup

DBearing Cup
EBore Sleeve (4 used)

FBearing Cup
GO-Ring

HCover
ICap Screw (2 Used)

OUO1020,0001140 1925NOV023/3

TM2111 (30MAY03)

03-0350-54

G-III and D Series Skidders (S.N. 586337 )


053003

PN=166

Gears, Shafts and Power Shift Clutches

Front Housing RepairAll Machines


Direct drive machine shown throughout. Procedures for
torque converter machine are the same except where
noted.
Front Housing RemoveAll Machines
1. For direct drive machines,see Charge Pump Repair
and suction tube in this group. For torque converter
machines, see Transmission Suction Tube Repair in
this group.
2. See Transmission Control Valve Repair in this group.
03
0350
55
OUO1020,0001142 1918APR011/11

3. Install DFT1156 Transmission Housing Lifting Bracket


(B) in mounting holes. (Group 9900.)

UN14JAN03

4. Remove cap screws (C).

T163695B

BDFT1156 Transmission Housing Lifting Bracket


CCap Screws

OUO1020,0001142 1918APR012/11

CAUTION: Heavy component; use a hoist.


Front HousingAll MachinesSpecification
Front HousingWeight ................................... 94 kg (207 lb) approximate

NOTE: Slowly raise transmission front cover. Clutches


may bind and stick in cover.
UN20APR98

5. Lift front housing (A) from rear housing using proper


lifting equipment.

T114930

AFront Housing

Continued on next page

TM2111 (30MAY03)

03-0350-55

OUO1020,0001142 1918APR013/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=167

Gears, Shafts and Power Shift Clutches


Front Housing Bore Sleeves
IMPORTANT: Disassemble only if parts are damaged
and must be replaced. Sleeves are
pressed into housing.
1. Inspect bore sleeves (A).

YZ1099

UN20DEC97

ABore Sleeves

03
0350
56
OUO1020,0001142 1918APR014/11

YZ1100

UN20DEC97

2. Remove bore sleeves using a blind hole puller.

Continued on next page

TM2111 (30MAY03)

03-0350-56

OUO1020,0001142 1918APR015/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=168

Gears, Shafts and Power Shift Clutches


IMPORTANT: Install bore sleeves with the internal
chamfer (A) up (toward the inside of the
transmission case).
3. Position front housing with bearing bore side up.
UN12JAN98

4. Install JDG1109 Bushing Driver (B).

YZ1101

5. Install bore sleeves (C) until driver is against casting.


AInternal Chamfer
BJDG1109 Bushing Driver
CBore Sleeves

YZ1102

UN23DEC97

03
0350
57

Continued on next page

TM2111 (30MAY03)

03-0350-57

OUO1020,0001142 1918APR016/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=169

Gears, Shafts and Power Shift Clutches


Bearing Cups
IMPORTANT: Disassemble only if parts are damaged
and must be replaced.
UN23DEC97

1. Inspect for wear and damage.

YZ1103

2. Remove bearing cups (A) using two pry bars or


two-jaw puller.
ABearing Cups

03
0350
58
OUO1020,0001142 1918APR017/11

IMPORTANT: Use a bearing cup driver to install


bearing cup. Bearing cup must be
installed tight against shoulders.

YZ1104

UN23DEC97

3. Install new bearing cups.

OUO1020,0001142 1918APR018/11

Lube Relief Valve

NOTE: Remove only if lube relief valve is damaged or if a


failure that caused contamination occurred.
UN23DEC97

1. Position front housing with bearing bore side up.


2. Remove lube relief valve (A).

YZ1105

ALube Relief Valve

Continued on next page

TM2111 (30MAY03)

03-0350-58

OUO1020,0001142 1918APR019/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=170

Gears, Shafts and Power Shift Clutches


IMPORTANT: Use care installing lube relief valve. The
valve seat shoulder on the valve can be
damaged if too much force is applied.
3. Position front housing with bearing bore side down.

UN14JAN03

4. Install new lube relief valve (1) into lube relief valve
bore until the lube relief valve shoulder is flush with the
bore shoulder.

T163657B

1Lube Relief Valve

OUO1020,0001142 1918APR0110/11

Seventh Stage (Output Gear) Oil Seal and Grease


Seals
1. Remove two outer grease seals.
2. Remove oil seal (A).

YZ1099A

UN12JAN98

AOil Seal

OUO1020,0001142 1918APR0111/11

TM2111 (30MAY03)

03-0350-59

G-III and D Series Skidders (S.N. 586337 )


053003

PN=171

03
0350
59

Gears, Shafts and Power Shift Clutches

Transmission Clutch Packs and Gear Stages


Remove and InstallDirect Drive Machines
1. Remove transmission charge pump, input yoke, park
brake, and winch drive. See Transmission Charge
Pump Remove and InstallDirect Drive Machines,
Transmission Control Valve Repair, Input Yoke
Remove and Install, Park Brake Repair, and Winch
Drive Repair in this group.

UN18SEP97
T111308

OUO1020,00010FD 1925NOV021/11

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stage Assemblies
Specification
Seventh Stage (Output Gear)
Weight............................................................. 30.8 kg (68 lb) approximate

NOTE: Assembly must be tilted in order to be removed.

UN21JAN03

2. Use hoist and JT05548 Lifting Eyebolt (2) to remove


seventh stage output gear (3) and oil splash guard (4).
3. Remove oil splash guard (4) from seventh stage
(output gear).

T163838B

03
0350
60

AInput Shaft (First Stage)


BDirection Clutch Packs (High and Low Reverse)
(Third Stage)
CSecond and Fourth Speed Clutch Packs (Fifth
Stage)
DOutput Shaft (Seventh Stage)
ESixth Stage Gear (Idler Gear)
FFirst and Third Speed Clutch Packs (Fourth Stage)
GDirection Clutch Packs (High and Low Forward)
(Second Stage)

1JDG1101 Clutch Pack Lifting Plate


2JT05548 Metric Lifting Eyebolt
3Seventh Stage Output Gear
4Oil Splash Guard

Continued on next page

TM2111 (30MAY03)

03-0350-60

OUO1020,00010FD 1925NOV022/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=172

Gears, Shafts and Power Shift Clutches

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stage Assemblies
Specification
First Stage (Input Shaft)Weight ..................... 14 kg (30 lb) approximate

4. Remove input shaft (A) out of housing.


AInput Shaft (First Stage)

YZ1138

UN23DEC97

03
0350
61

OUO1020,00010FD 1925NOV023/11

CAUTION: Make sure JDG1101 Clutch Pack


Lifting Plate is fastened to each clutch pack to
avoid personal injury.
5. Install JDG1101 Clutch Pack Lifting Plate (B).

YZ1110

UN23DEC97

BJDG1101 Clutch Pack Lifting Plate

Continued on next page

TM2111 (30MAY03)

03-0350-61

OUO1020,00010FD 1925NOV024/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=173

Gears, Shafts and Power Shift Clutches

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stage Assemblies
Specification
Clutch Packs (SecondFifth
Stage)Weight .......................................... 157.4 kg (347 lb) approximate

6. Remove clutch packs from rear housing. Carefully set


on work bench.

YZ1111

UN23DEC97

7. Remove JDG1101 Clutch Pack Lifting Plate.

03
0350
62

OUO1020,00010FD 1925NOV025/11

CAUTION: Heavy component; use a hoist.

UN23DEC97

Transmission Clutch Packs and Gear Stage Assemblies


Specification
Sixth Stage Gear (Idler Gear)
Weight................................................................ 14 kg (30 lb) approximate

8. Remove sixth stage gear (C) from rear housing.

YZ1144

9. Clean and inspect housing and bearing cups for wear


or damage. Replace as required.
CAUTION: Heavy component; use a hoist.
CSixth Stage Gear (Idler Gear)
Transmission Clutch Packs and Gear Stage Assemblies
Specification
Sixth Stage Gear (Idler Gear)
Weight................................................................ 14 kg (30 lb) approximate

10. Install sixth stage gear (C).

Continued on next page

TM2111 (30MAY03)

03-0350-62

OUO1020,00010FD 1925NOV026/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=174

Gears, Shafts and Power Shift Clutches

CAUTION: Make sure lift plate is fastened to


clutch pack to avoid personal injury.
11. Install JDG1101 Clutch Pack Lifting Plate (B) on
clutch pack. Lock holders onto the four clutch pack
assemblies.

T115351

UN13MAY98

BJDG1101 Clutch Pack Lifting Plate

OUO1020,00010FD 1925NOV027/11

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stage Assemblies
Specification
Clutch Packs (SecondFifth
Stage)Weight .......................................... 157.4 kg (347 lb) approximate

IMPORTANT: Carefully lower clutch packs into


position to avoid damage to sixth stage
bearing

YZ1111

UN23DEC97

12. Carefully install clutch packs in rear housing.

Continued on next page

TM2111 (30MAY03)

03-0350-63

OUO1020,00010FD 1925NOV028/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=175

03
0350
63

Gears, Shafts and Power Shift Clutches


13. Remove JDG1101 Clutch Pack Lifting Plate (D).

YZ1110A

UN23DEC97

DJDG1101 Clutch Pack Lifting Plate

03
0350
64
OUO1020,00010FD 1925NOV029/11

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stage Assemblies
Specification
First Stage (Input Shaft)Weight ..................... 14 kg (30 lb) approximate

14. Install input shaft (A) to rear housing.

YZ1138

UN23DEC97

AInput Shaft (First Stage)

Continued on next page

TM2111 (30MAY03)

03-0350-64

OUO1020,00010FD 1925NOV0210/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=176

Gears, Shafts and Power Shift Clutches

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stage Assemblies
Specification
Seventh Stage (Output Gear)
Weight............................................................. 30.8 kg (68 lb) approximate

16. Use JT05548 Metric Lifting Eyebolt to install seventh


stage (output gear) with splash guard into rear
housing.

T163838B

NOTE: Seventh stage (output gear) must be tilted to


install.

UN21JAN03

15. Put oil splash guard (4) on large gear of seventh


stage (output gear).

1JDG1101 Clutch Pack Lifting Plate


2JT05548 Metric Lifting Eyebolt
3Seventh Stage (Output Gear)
4Oil Splash Guard

OUO1020,00010FD 1925NOV0211/11

TM2111 (30MAY03)

03-0350-65

G-III and D Series Skidders (S.N. 586337 )


053003

PN=177

03
0350
65

Gears, Shafts and Power Shift Clutches

Input (First Stage) and Idler (Sixth Stage)


Gear Shaft RepairDirect Drive Machines
1. Use D01048AA Puller Set to remove bearing cones (A
and B).
ABearing Cone
BBearing Cone

YZ1133

UN23DEC97

03
0350
66

Input Shaft (First Stage) Shown

Continued on next page

TM2111 (30MAY03)

03-0350-66

OUO1020,0001101 1918APR011/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=178

Gears, Shafts and Power Shift Clutches


IMPORTANT: Press only on the inner race of bearing
cone. Do not reuse bearing cones if
removed.

NOTE: Gear and shaft assemblies are serviced as an


assembly. If either the gear or shaft is damaged
or worn, entire assembly must be replaced.
2. Use JDG1105 Bearing Driver and JDG1108 Clutch
Bearing Driver (A) to install new bearing cones (B) on
both ends of shaft. Push bearing tight against shoulder
of shaft.
AJDG1108 Clutch Bearing Driver
BBearing Cone

YZ1134

UN23DEC97

03
0350
67

Input Shaft (First Stage) Shown


OUO1020,0001101 1918APR012/2

TM2111 (30MAY03)

03-0350-67

G-III and D Series Skidders (S.N. 586337 )


053003

PN=179

Gears, Shafts and Power Shift Clutches

High and Low Forward (Second Stage) Clutch Packs Exploded ViewDirect Drive
Machines

T163664

UN22JAN03

03
0350
68

1Seal Ring (3 used)


2Ball Bearing (2 used)
3Retaining Ring (2 used)
4Bearing
5Gear
6O-Ring (2 used)
7Bearing with Seal (2 used)

8Internal Snap Ring (2 used)


9Clutch Plate Retainer
10Clutch Plate (18 used)
11Clutch Separator Plate (20
used)
12Retaining Ring (2 used)

13Snap Ring Retainer (2


used)
14Clutch Return Spring (12
used)
15Lube Shut-Off Washer (2
used)

16O-Ring (2 used)
17Clutch Piston (2 used)
18Piston Outer Seal (2 used)
19Second Stage Shaft
20Gear
21Bearing

OUO1020,0001103 1926NOV021/1

TM2111 (30MAY03)

03-0350-68

G-III and D Series Skidders (S.N. 586337 )


053003

PN=180

Gears, Shafts and Power Shift Clutches

High and Low Reverse (Third Stage) Clutch Pack Exploded ViewDirect Drive Machines

T163679

UN15JAN03

03
0350
69

1Seal Ring (3 used)


2Ball Bearing (2 used)
3Retaining Ring (2 used)
4Bearing (2 used)
5Gear
6O-Ring (2 used)

7Bearing with Seal (2 used)


8Internal Snap Ring (2 used)
9Clutch Plate Retainer
10Clutch Plate (18 used)
11Clutch Separator Plate (20
used)

12Retaining Ring (2 used)


13Snap Ring Retainer (2
used)
14Clutch Return Spring (12
used)
15Lube Shut-Off Washer (2
used)

16O-Ring (2 used)
17Clutch Piston (2 used)
18Piston Outer Seal (2 used)
19Third Stage Shaft
20Gear

OUO1020,0001104 1926NOV021/1

TM2111 (30MAY03)

03-0350-69

G-III and D Series Skidders (S.N. 586337 )


053003

PN=181

Gears, Shafts and Power Shift Clutches

First and Third Speed Clutch Packs (Fourth Stage) Exploded ViewDirect Drive
Machines

T163680

UN15JAN03

03
0350
70

1Seal Ring (3 used)


2Bearing (2 used)
3Retaining Ring (2 used)
4Ball Bearing (2 used)
5Clutch Gear
6Ball Bearing (2 used)

7Snap Ring (2 used)


8Clutch Plate Retainer (2
used)
9Clutch Plate (20 used)
10Clutch Separator Plate (20
used)

11Retaining Ring (2 used)


12Snap Ring Retainer (2
used)
13Clutch Return Spring (12
used)
14Lube Shut-Off Washer (2
used)

15O-Ring (2 used)
16Clutch Piston (2 used)
17Piston Outer Seal (2 used)
18Fourth Stage Shaft
19Clutch Gear

OUO1020,0001105 1926NOV021/1

TM2111 (30MAY03)

03-0350-70

G-III and D Series Skidders (S.N. 586337 )


053003

PN=182

Gears, Shafts and Power Shift Clutches

Second and Fourth Speed Clutch Packs (Fifth Stage) Exploded ViewDirect Drive
Machines

T163681

UN15JAN03

03
0350
71

1Seal Ring (3 used)


2Bearing (2 used)
3Retaining Ring (2 used)
4Ball Bearing (2 used)
5Clutch Gear
6Ball Bearing (2 used)

7Snap Ring (2 used)


8Clutch Plate Retainer (2
used)
9Clutch Plate (20 used)
10Clutch Separator Plate (20
used)

11Retaining Ring (2 used)


12Snap Ring Retainer (2
used)
13Clutch Return Spring (12
used)
14Lube Shut-Off Washer (2
used)

15O-Ring (2 used)
16Clutch Piston (2 used)
17Piston Outer Seal (2 used)
18Fifth Stage Shaft
19Clutch Gear

OUO1020,0001106 1926NOV021/1

TM2111 (30MAY03)

03-0350-71

G-III and D Series Skidders (S.N. 586337 )


053003

PN=183

Gears, Shafts and Power Shift Clutches

Transmission Clutch Packs Disassemble


Direct Drive Machines
CAUTION: Heavy components; use a hoist.
Transmission Clutch Packs DisassembleDirect
Specification
Second Stage AssemblyWeight ................. 43.1 kg
Third Stage AssemblyWeight ..................... 40.8 kg
Fourth Stage AssemblyWeight ................... 34.5 kg
Fifth Stage AssemblyWeight ...................... 39.0 kg

Drive Machines
(95
(90
(76
(86

lb)
lb)
lb)
lb)

approximate
approximate
approximate
approximate

IMPORTANT: DO NOT mix components of individual


shaft assemblies. Keep all clutch pack
components together as a set.

NOTE: The disassembly and assembly of clutch packs


are similar. Second Stage and Fourth Stage
Clutch Packs are shown unless otherwise
indicated.

UN23DEC97

1. If necessary, JDG1106 Clutch Lifting tool can be used


to lift clutch assembly.

YZ1121

Direction Clutch Packs (High and Low Forward) (Second Stage)


Shown

OUO1020,0001107 1918APR011/15

2. Remove seal rings (A).

UN23DEC97

ASeal Rings (3 used)

YZ1122

03
0350
72

Continued on next page

TM2111 (30MAY03)

03-0350-72

OUO1020,0001107 1918APR012/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=184

Gears, Shafts and Power Shift Clutches


IMPORTANT: Use shaft protector on forcing screw
when using bearing puller.
3. Install bearing puller (B).

UN13AUG96

4. Install gear puller (A) on bearing puller.


5. Remove ball bearing (C).

YZ402

AGear Puller
BBearing Puller
CBall Bearing

03
0350
73
OUO1020,0001107 1918APR013/15

CAUTION: Wear proper eye protection when


installing or removing retaining rings.
6. Remove retaining ring (A).

YZ403

UN02NOV96

ARetaining Ring

Continued on next page

TM2111 (30MAY03)

03-0350-73

OUO1020,0001107 1918APR014/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=185

Gears, Shafts and Power Shift Clutches


IMPORTANT: Use shaft protector on forcing screw
when using bearing puller.
7. Use bearing puller to remove gear (B).
BClutch Gear

YZ404

UN12MAR97

03
0350
74

OUO1020,0001107 1918APR015/15

8. Remove ball bearing (A).

YZ849A

UN12MAR97

ABall Bearing

Continued on next page

TM2111 (30MAY03)

03-0350-74

OUO1020,0001107 1918APR016/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=186

Gears, Shafts and Power Shift Clutches


9. On direction clutch packs (high and low forward)
(second stage) and direction clutch packs (high and
low reverse) (third stage) assemblies only, remove
O-ring (A). Inspect for wear or damage.

YZ429

UN19APR97

AO-Ring

OUO1020,0001107 1918APR017/15

CAUTION: Wear proper eye protection when


removing snap ring.
10. Remove snap ring (B).

YZ407

UN25MAR97

BSnap Ring

Continued on next page

TM2111 (30MAY03)

03-0350-75

OUO1020,0001107 1918APR018/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=187

03
0350
75

Gears, Shafts and Power Shift Clutches


11. Turn shaft assembly over.

UN12MAR97

12. Remove clutch plate retainer, clutch plates and


separator plates.

YZ409

03
0350
76

OUO1020,0001107 1918APR019/15

IMPORTANT: Use shaft protector on forcing screw


when using bearing puller.
13. Install bearing puller.
14. Remove and discard bearing (A).

YZ406

UN19APR97

ABearing

Continued on next page

TM2111 (30MAY03)

03-0350-76

OUO1020,0001107 1918APR0110/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=188

Gears, Shafts and Power Shift Clutches


Remove Clutch Piston Return Spring
CAUTION: Clutch piston return springs are
under pressure.
1. Place shaft assembly on press.
2. Use JDG1103 Clutch Pack Spring Compressor (A) to
compress clutch return springs.
3. Remove retaining ring (B) from shaft groove. Inspect
for wear or damage.

UN29APR97

4. Relieve pressure on compressor tool.

YZ410

AJDG1103 Clutch Pack Spring Compressor


BRetaining Ring

OUO1020,0001107 1918APR0111/15

5. Lift out retaining ring (A), snap ring retainer (B) and
clutch return springs (C).

YZ463

UN21AUG96

ARetaining Ring
BSnap Ring Retainer
CClutch Return Springs

OUO1020,0001107 1918APR0112/15

6. Remove lube shutoff washer (D).

YZ464

UN21AUG96

DLube Shutoff Washer

Continued on next page

TM2111 (30MAY03)

03-0350-77

OUO1020,0001107 1918APR0113/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=189

03
0350
77

Gears, Shafts and Power Shift Clutches

1. Apply 69 kPa (0.7 bar) (10 psi) maximum, regulated air


pressure through oil passage to force clutch piston
from shaft assembly.
Transmission Clutch Packs DisassembleDirect Drive Machines
Specification
Maximum Regulated Air
Pressure ............................................................. 69 kPa (0.7 bar) (10 psi)

OUO1020,0001107 1918APR0114/15

2. Remove clutch piston (A).


3. Remove piston outer seal (B) and O-ring (C) from
clutch piston.

5. For complete disassembly of this shaft, repeat


disassembly steps for clutch pack assembly on
opposite end of this shaft.
AClutch Piston
BPiston Outer Seal
CO-Ring

UN20AUG96

4. Inspect for wear or damage.

YZ415

03
0350
78

YZ414

CAUTION: Prevent possible injury from


unexpected release of piston. Clear area of
bystanders. Use a protective blanket for extra
protection against the unexpected release of
piston or flying debris. Wear personal
protection equipment, including eye protection.
Use only regulated, compressed air of 69 kPa
(0.7 bar) (10 psi) maximum to remove piston.

UN20AUG96

Remove Clutch Piston

OUO1020,0001107 1918APR0115/15

TM2111 (30MAY03)

03-0350-78

G-III and D Series Skidders (S.N. 586337 )


053003

PN=190

Gears, Shafts and Power Shift Clutches

Transmission Clutch Packs Assemble


Direct Drive Machines
IMPORTANT: DO NOT mix components of individual
shaft assemblies. Keep all clutch pack
components together as a set.

UN20AUG96

Inspect inside of cylinder for sharp


edges or burrs. Use care not to damage
seals on pistons during installation.
1. Lubricate and install new O-ring (A).

YZ416

2. Lubricate and install new piston outer seal (B).


3. Install clutch piston (C) with raised center boss up.

03
0350
79

AO-Ring
BPiston Outer Seal
CClutch Piston

OUO1020,0001108 1926NOV021/14

4. Install lube shutoff washer (D).

YZ413

UN21AUG96

DLube Shutoff Washer

Continued on next page

TM2111 (30MAY03)

03-0350-79

OUO1020,0001108 1926NOV022/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=191

Gears, Shafts and Power Shift Clutches

UN20MAR97

IMPORTANT: Install clutch piston return springs as


shown for proper spring force.
5. Install clutch return springs (A) as three pairs with
outer diameters contacting for each pair.

YZ853

AClutch Return Springs

YZ417

UN14AUG96

03
0350
80

OUO1020,0001108 1926NOV023/14

IMPORTANT: Wear proper eye protection when


installing retaining rings.
6. Put snap ring retainer (B) and retaining ring (C) on
shaft.
UN19APR97

7. Compress clutch return springs using JDG1103 Clutch


Pack Spring Compressor.

YZ418

BSnap Ring Retainer


CRetaining Ring

Continued on next page

TM2111 (30MAY03)

03-0350-80

OUO1020,0001108 1926NOV024/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=192

Gears, Shafts and Power Shift Clutches

CAUTION: Wear proper eye protection when


installing retaining rings.
8. Install retaining ring (C) in groove.

UN19APR97

9. Release pressure on clutch return springs slowly. Be


sure snap ring retainer is properly positioned.

YZ410A

CRetaining Ring

03
0350
81
Continued on next page

TM2111 (30MAY03)

03-0350-81

OUO1020,0001108 1926NOV025/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=193

Gears, Shafts and Power Shift Clutches


IMPORTANT: Seal side of bearing must be toward
clutch return springs. Lubricate bearing
to prevent dry start-up of transmission.
Press only on inner race of ball bearing.
10. Install ball bearing (A), with seal side down. Install
bearing until bearing inner race contacts shoulder of
shaft.
ABall Bearing

YZ428

UN19APR97

YZ427

UN19APR97

03
0350
82

Continued on next page

TM2111 (30MAY03)

03-0350-82

OUO1020,0001108 1926NOV026/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=194

Gears, Shafts and Power Shift Clutches


IMPORTANT: For direction clutch packs (high and
low forward) (second stage) and
direction clutch packs (high and low
reverse) (third stage) ONLY, install two
clutch separator plates first.
UN12MAR97

NOTE: Clutch separator plates are steel with external


spline teeth. Clutch plates have a lining material
on the face and internal spline teeth.

YZ420

11. On direction clutch packs (high and low forward)


(second stage) and direction clutch packs (high and
low reverse) (third stage) clutch assemblies, install
two clutch separator plates (A). On first and third
speed clutch packs (fourth stage) and second and
fourth speed clutch packs (fifth stage) clutch
assemblies, install one clutch separator plate.

AClutch Separator Plates


03
0350
83

OUO1020,0001108 1926NOV027/14

12. Install one clutch plate (B) and then one clutch
separator plate. Install remaining plates alternately.

NOTE: Last plate is a clutch plate.


13. Last plate is a clutch plate.

YZ421

UN12MAR97

BClutch Plate

Continued on next page

TM2111 (30MAY03)

03-0350-83

OUO1020,0001108 1926NOV028/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=195

Gears, Shafts and Power Shift Clutches


14. Install clutch plate retainer (A).
CAUTION: Wear proper eye protection when
installing snap ring.

15. Install snap ring (D).

UN05APR01

YZ4185

AClutch Plate Retainer


BOne-Spline Tooth Missing Location
CTwo-Spline Teeth Missing Location
DSnap Ring

YZ4181

03
0350
84

UN05APR01

IMPORTANT: Second and third shaft assemblies have


three locations with two spline teeth
missing (C) and one location with one
spline tooth missing (B). Fourth and
fifth shaft assemblies have six locations
with one spline tooth missing. The
clutch plate retainer lug (A) fits in any
of the locations with one spline tooth
missing (B).

Continued on next page

TM2111 (30MAY03)

03-0350-84

OUO1020,0001108 1926NOV029/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=196

Gears, Shafts and Power Shift Clutches


IMPORTANT: Check that clutch and separator plates
do not bind.

16. Make sure piston and clutch plates are to bottom of


bore. Using a depth gauge, measure from top of
clutch pack drum to top of clutch plate retainer (A).

UN18MAY98

Using two screwdrivers, lift clutch plate retainer


against snap ring (B). Again, measure from top of
clutch pack drum to top of clutch plate retainer.

T115376

The difference of the two measurements is the clutch


plate clearance (C).
T115376

Replace clutch plates as necessary to obtain proper


clearance.

Clutch Plate Clearance


03
0350
85

AClutch Plate Retainer


BSnap Ring
CClutch Plate Clearance

Transmission Clutch Packs AssembleDirect Drive Machines


Specification
Clutch Plate (Second and Third
Stage Clutch Packs)Clearance ........ 2.314.47 mm (0.0910.176 in.)
Clutch Plate (Fourth and Fifth
Stage Clutch Packs)Clearance ........ 2.795.59 mm (0.1100.220 in.)

OUO1020,0001108 1926NOV0210/14

17. On second and third stage clutch assemblies only,


lubricate and install new O-ring (B).

YZ429A

UN19APR97

BO-Ring

Continued on next page

TM2111 (30MAY03)

03-0350-85

OUO1020,0001108 1926NOV0211/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=197

Gears, Shafts and Power Shift Clutches


IMPORTANT: Clutch plate splines must be aligned
before installing bearings on the shaft
assembly to avoid clutch plate damage.
18. Use clutch gear to align clutch plates and separator
plates.

UN12MAR97

IMPORTANT: Forcing clutch gear through clutch


plates can damage clutch plates if
plates are not properly aligned. Use
care not to damage O-ring (A).

20. Install clutch gear. O-ring (A) must fit into bore of
clutch plate retainer.
IMPORTANT: Start bearing (B) into clutch gear. DO
NOT press bearing below ring groove in
shaft. Pressing the bearing all the way
into the gear will preload the bearing.
Preloading bearing will shorten the life
of the bearing.
21. Put new bearing (B) onto clutch gear. Start bearing
into bore only.
UN20AUG96

AO-Ring
BBearing

YZ432

03
0350
86

YZ425

19. Move clutch gear clockwise; then counterclockwise,


working the clutch gear spline through the clutch and
separator plates.

Continued on next page

TM2111 (30MAY03)

03-0350-86

OUO1020,0001108 1926NOV0212/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=198

Gears, Shafts and Power Shift Clutches

23. Using a press and tool (cylinder), push slowly on


retaining ring until retaining ring fits into groove of
shaft assembly.

YZ433

IMPORTANT: Press only on retaining ring. DO NOT


preload bearing.

UN02NOV96

22. Install retaining ring (A) on shaft assembly.

Clutch gear must turn. Check for 0.25 mm (0.010 in.)


end play of gear using a dial indicator.

NOTE: Disassemble bottom half of directional clutch


assemblies following the steps outlined above.

YZ434

24. Lubricate and install ball bearing (B). Press bearing


onto shaft until bearing contacts retaining ring.

UN20AUG96

Transmission Clutch Packs AssembleDirect Drive Machines


Specification
Clutch GearEnd Play .............................................. 0.25 mm (0.010 in.)

25. Assemble opposite end of shaft by repeating steps.

YZ435

UN02NOV96

ARetaining Ring
BBall Bearing

OUO1020,0001108 1926NOV0213/14

IMPORTANT: Always use new seal rings.


26. Install three seal rings (A) into ring grooves.

YZ1122

UN23DEC97

ASeal Ring (3 used)

OUO1020,0001108 1926NOV0214/14

TM2111 (30MAY03)

03-0350-87

G-III and D Series Skidders (S.N. 586337 )


053003

PN=199

03
0350
87

Gears, Shafts and Power Shift Clutches

Seventh Stage (Output) ShaftDirect Drive


Machines
CAUTION: Use shaft protector when removing
bearing cones.
1. Use a bearing puller to remove bearing cones (A).
Discard bearing cones.
ABearing Cone

YZ1135

UN12JAN98

03
0350
88

Continued on next page

TM2111 (30MAY03)

03-0350-88

OUO1020,000110B 1926NOV021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=200

Gears, Shafts and Power Shift Clutches


IMPORTANT: Push on inner race of bearing only.
2. Install new bearing cones (A) on both ends of gear and
shaft assembly using a press and JDG1107 Bearing
Driver. Push bearing tight against shoulder of shaft.
ABearing Cones

YZ1136

UN23DEC97

03
0350
89

OUO1020,000110B 1926NOV022/2

TM2111 (30MAY03)

03-0350-89

G-III and D Series Skidders (S.N. 586337 )


053003

PN=201

Gears, Shafts and Power Shift Clutches

Rear Transmission Housing RepairDirect


Drive Machines
1. Remove and discard bearing cups (A).
2. Install new bearing cups.
ABearing Cups

YZ1142

UN23DEC97

03
0350
90

OUO1020,000110D 1926NOV021/1

TM2111 (30MAY03)

03-0350-90

G-III and D Series Skidders (S.N. 586337 )


053003

PN=202

Gears, Shafts and Power Shift Clutches

Front and Rear Housing AssembleDirect


Drive Machines
1. Attach DFT1156 Transmission Housing Lifting Bracket
to front housing (A). (Group 9900.)

UN20APR98

NOTE: Lubricate all bearings before installing front


housing.
2. Clean mounting surfaces on front and rear housings
with isopropyl alcohol or equivalent.

T114930

IMPORTANT: Excessive amounts of gasket adhesive


may cause incorrect bearing end play,
extend cure time and cause runoff of
material. Using a small roller will help to
apply a thin, even layer of adhesive.

03
0350
91

T163695B

UN14JAN03

3. Apply form-in-place gasket to rear housing mounting


surface, using care to apply a thin layer over the entire
surface. Excess gasket material should be wiped from
joint. Installation should occur within three minutes of
application. Allow a minimum of 30 minutes of cure
time before adding oil.
CAUTION: Heavy component; use a hoist.
Rear Transmission Housing RepairSpecification
Front HousingWeight ................................... 94 kg (207 lb) approximate

AFront Housing
BDFT1156 Transmission Housing Lifting
Bracket
CCap Screw (19 used)

IMPORTANT: Use guide pins during assembly to


guide the front housing onto the rear
housing. Pins will help prevent damage
to seal rings.
4. Lower front housing onto rear housing.
5. Install six cap screws evenly spaced through front
housing into rear housing snug tight.
6. Remove guide pins and install remaining cap screws
(C) snug tight.
7. Remove lifting bracket (B).

Continued on next page

TM2111 (30MAY03)

03-0350-91

OUO1065,0000593 1926NOV021/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=203

Gears, Shafts and Power Shift Clutches

T163697

UN15JAN03

03
0350
92

Cap Screw Torque Sequence

8. Tighten cap screws to specification in sequence


shown. Repeat tightening sequence a second time.
Rear Transmission Housing RepairSpecification
Front Housing-to-Rear Housing
Cap ScrewTorque ................................................. 87 Nm (64 lb-ft)

Continued on next page

TM2111 (30MAY03)

03-0350-92

OUO1065,0000593 1926NOV022/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=204

Gears, Shafts and Power Shift Clutches


9. Position front housing with bearing bore side down.
1
10. Place JDG1519 Seal Protector over shaft.
11. Apply thread lock and sealer (medium strength) to
outside diameter of oil seal (1) and grease seals (2).

13. Use JDG1736 Seal Driver to install oil seal (1) until
flush with shoulder in transmission housing.

T163701

15. Use JDG1738 Seal Driver to install second grease


seal (2) until flush with shoulder in transmission
housing.

T163700B

UN14JAN03

1Oil Seal
2Grease Seal (2 used)
3Grease Fitting
4Seal Driver
5Grease Seal

T163701

3
14. Use JDG1737 Seal Driver to install grease seal (2) to
bottom of seal bore in transmission housing.

UN21JAN03

12. Apply thin layer of petroleum jelly to inner seal lip of


oil seal (1) and grease seals (2).

OUO1065,0000593 1926NOV023/3

TM2111 (30MAY03)

03-0350-93

G-III and D Series Skidders (S.N. 586337 )


053003

PN=205

03
0350
93

Gears, Shafts and Power Shift Clutches

Transmission Clutch Packs and Gear Stages


RepairTorque Converter Machines
1. Remove transmission control valve, input yoke, park
brake, and winch drive. See Transmission Control
Valve Repair, Input Yoke Remove and Install, Park
Brake Repair and Winch Drive Repair in this group.
2. Remove transmission front housing. See Front Housing
RepairAll Machines in this group.
CAUTION: Make sure clutch pack lifting plate is
fastened to clutch packs and input shaft to
avoid personal injury.

UN04FEB03

IMPORTANT: Sixth stage bearings can contact gear


teeth during removal and installation.
Carefully lift and lower using JDG1101
Clutch Pack Lifting Plate along with
DFT1217 Transmission Input Shaft
Holder to avoid bearing damage.

T163724C

3. Attach clutch pack lifting plate (9) onto clutch stage


assemblies (14) and (7 and 8).
4. Attach transmission input shaft holder (10) to input
shaft (1) using a M8 x 38 mm cap screw. See
DFT1217 Transmission Input Shaft Holder. (Group
9900.)

UN04FEB03

1Input Shaft (First Stage)


2High and Low Reverse (Third Stage)
3Second and Fourth Speed Clutch Pack (Fifth
Stage)
4Idler Gear (Sixth Stage)
5Output Shaft and Gear (Seventh Stage)
6Oil Splash Guard
7First and Third Speed Clutch Pack (Fourth Stage)
8High and Low Forward (Second Stage)
9JDG1101 Clutch Pack Lifting Plate
10DFT1217 Input Shaft Holder

T164953B

03
0350
94

Continued on next page

TM2111 (30MAY03)

03-0350-94

OUO1020,000110F 1926NOV021/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=206

Gears, Shafts and Power Shift Clutches

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stages RepairTorque
Converter MachinesSpecification
Clutch Packs (SecondFifth
Stage) and Input ShaftTorque
Converter MachinesWeight..................... 169.7 kg (374 lb) approximate

5. Remove clutch packs and input shaft from rear


housing. Carefully set on work bench.
6. Remove clutch pack lifting plate.

03
0350
95
OUO1020,000110F 1926NOV022/5

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stages RepairTorque
Converter MachinesSpecification
Seventh Stage (Output Gear)
Weight................................................................ 28 kg (62 lb) approximate

7. Using hoist remove seventh stage (1) from housing.

UN22JAN03

8. Remove oil splash guard (3) from seventh stage.


CAUTION: Heavy component; use a hoist.

T163726B

Transmission Clutch Packs and Gear Stages RepairTorque


Converter MachinesSpecification
Sixth Stage Gear (Idler Gear)
Weight............................................................. 15.5 kg (34 lb) approximate
1Seventh Stage (Output Gear)
2Sixth Stage (Idler Gear)
3Oil Splash Guard

9. Remove sixth stage gear (2) from rear housing.


10. Clean and inspect housing and bearing cups for wear
or damage. Replace as required.

Continued on next page

TM2111 (30MAY03)

03-0350-95

OUO1020,000110F 1926NOV023/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=207

Gears, Shafts and Power Shift Clutches

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stages RepairTorque
Converter MachinesSpecification
Sixth Stage Gear (Idler Gear)
Weight............................................................. 15.5 kg (34 lb) approximate

11. Install sixth stage gear (2).

UN22JAN03

CAUTION: Heavy component; use a hoist.

03
0350
96

T163726B

Transmission Clutch Packs and Gear Stages RepairTorque


Converter MachinesSpecification
Seventh Stage (Output Gear)
Weight................................................................ 28 kg (62 lb) approximate

12. Put oil splash guard (3) on large gear of seventh


stage.
1Seventh Stage (Output Gear)
2Sixth Stage Gear (Idler Gear)
3Oil Splash Guard

13. Install seventh stage (1) into rear housing.

Continued on next page

TM2111 (30MAY03)

03-0350-96

OUO1020,000110F 1926NOV024/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=208

Gears, Shafts and Power Shift Clutches

14. Attach JDG1101 Clutch Pack Lifting Plate (9) on


clutch packs. Lock holders onto the four clutch pack
assemblies.
15. Attach DFT1217 Transmission Input Shaft Holder on
end of input shaft (1) using a M8 x 38 mm cap screw.

T164953B

IMPORTANT: Sixth stage bearings can contact gear


teeth during removal and installation.
Carefully lift and lower using JDG1101
Clutch Pack Lifting Plate along with
DFT1217 Transmission Input Shaft
Holder to avoid bearing damage.

UN04FEB03

CAUTION: Make sure clutch pack lifting plate is


fastened to clutch packs and input shaft to
avoid personal injury.

CAUTION: Heavy component; use a hoist.


Transmission Clutch Packs and Gear Stages RepairTorque
Converter MachinesSpecification
Clutch Packs (SecondFifth
Stage) and Input ShaftTorque
Converter MachinesWeight..................... 169.7 kg (374 lb) approximate

16. Carefully lift and install clutch packs in rear housing.

T163724C

1Input Shaft (First Stage)


2High and Low Reverse (Third Stage)
3Second and Fourth Speed Clutch Pack (Fifth
Stage)
4Idler Gear (Sixth Stage)
5Output Shaft and Gear (Seventh Stage)
6Oil Splash Guard
7First and Third Speed Clutch Pack (Fourth Stage)
8High and Low Forward (Second Stage)
9JDG1101 Clutch Pack Lifting Plate
10DFT1217 Input Shaft Holder

UN04FEB03

17. Remove clutch pack lifting plate.

OUO1020,000110F 1926NOV025/5

TM2111 (30MAY03)

03-0350-97

G-III and D Series Skidders (S.N. 586337 )


053003

PN=209

03
0350
97

Gears, Shafts and Power Shift Clutches

Input Shaft (First Stage) and Sixth Stage


(Idler Gear) RepairTorque Converter
Machines
1. Remove and discard bearing cones (A and B).

UN28MAR01

ABearing Cone
BBearing Cone

YZ4161

UN28MAR01

YZ4160

03
0350
98

Input Shaft (First Stage) Shown


Continued on next page

TM2111 (30MAY03)

03-0350-98

OUO1065,0000594 1927NOV021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=210

Gears, Shafts and Power Shift Clutches


IMPORTANT: Press only on the inner race of bearing
cone. Do not reuse bearing cones if
removed.

NOTE: Gear and shaft assemblies are serviced as an


assembly. If either the gear or shaft is damaged
or worn, entire assembly must be replaced.
2. Use JDG1105 Bearing Driver and JDG1108 Clutch
Bearing Driver (A) to install new bearing cones (B) on
both ends of shaft. Push bearing tight against shaft
shoulder.
AJDG1108 Clutch Bearing Driver
BBearing Cone

YZ1134

UN23DEC97

03
0350
99

Input Shaft (First Stage) Shown


OUO1065,0000594 1927NOV022/2

TM2111 (30MAY03)

03-0350-99

G-III and D Series Skidders (S.N. 586337 )


053003

PN=211

Gears, Shafts and Power Shift Clutches

Clutch Pack RepairTorque Converter Machines

YZ4152

UN26MAR01

03
0350
,100

High and Low Forward Clutch Packs (Second Stage)


ASeal Ring (3 used)
BBall Bearing (2 used)
CRetaining Ring (2 used)
DBearing (2 used)
EGear
FO-Ring (2 used)
GBearing with Seal (2 used)

HInternal Snap Ring (2 used)


IClutch Plate Retainer (2
used)
JClutch Plate (18 used)
KClutch Separator Plate (20
used)

LRetaining Ring (2 used)


MSnap Ring Retainer (2
used)
NClutch Return Spring (12
used)
OLube Shut-Off Washer (2
used)

Continued on next page

TM2111 (30MAY03)

03-0350-100

PO-Ring (2 used)
QClutch Piston (2 used)
RPiston Outer Seal (2 used)
SSecond Stage Shaft
TGear

OUO1065,0000595 1927NOV021/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=212

Gears, Shafts and Power Shift Clutches

YZ4153

UN26MAR01

03
0350
,101

High and Low Reverse Clutch Packs (Third Stage)


ASeal Ring (3 used)
BBall Bearing (2 used)
CRetaining Ring (2 used)
DBearing (2 used)
EGear
FO-Ring (2 used)
GBearing with Seal (2 used)

HInternal Snap Ring (2 used)


IClutch Plate Retainer (2
used)
JClutch Plate (18 used)
KClutch Separator Plate (20
used)

LRetaining Ring (2 used)


MSnap Ring Retainer (2
used)
NClutch Return Spring (12
used)
OLube Shut-Off Washer (2
used)

Continued on next page

TM2111 (30MAY03)

03-0350-101

PO-Ring (2 used)
QClutch Piston (2 used)
RPiston Outer Seal (2 used)
SThird Stage Shaft
TGear

OUO1065,0000595 1927NOV022/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=213

Gears, Shafts and Power Shift Clutches

YZ4154

UN26MAR01

03
0350
,102

First and Third Speed Clutch (Fourth Stage)


ASeal Ring (3 used)
BBearing (2 used)
CRetaining Ring (2 used)
DBall Bearing (2 used)
EClutch Gear
FBall Bearing (2 used)

GSnap Ring (2 used)


HClutch Plate Retainer (2
used)
IClutch Plate (20 used)
JClutch Separator Plate (20
used)

KRetaining Ring (2 used)


LSnap Ring Retainer (2
used)
MClutch Return Spring (12
used)
NLube Shut-Off Washer (2
used)

Continued on next page

TM2111 (30MAY03)

03-0350-102

OO-Ring (2 used)
PClutch Piston (2 used)
QPiston Outer Seal (2 used)
RFourth Stage Shaft
SClutch Gear

OUO1065,0000595 1927NOV023/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=214

YZ4151

UN24MAR01

Gears, Shafts and Power Shift Clutches

Second and Fourth Speed Clutch (Fifth Stage)


ASeal Ring (2 used)
BBearing (2 used)
CRetaining Ring
DBall Bearing
EClutch Gear
FBall Bearing

GSnap Ring
HClutch Plate Retainer
IClutch Plate (10 used)
JClutch Separator Plate (10
used)

KRetaining Ring
LSnap Ring Retainer
MClutch Return Spring (6
used)
NLube Shut-Off Washer

Continued on next page

TM2111 (30MAY03)

03-0350-103

OO-Ring
PClutch Piston
QPiston Outer Seal
RFifth Stage Shaft
SSnap Ring

OUO1065,0000595 1927NOV024/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=215

03
0350
,103

Gears, Shafts and Power Shift Clutches

YZ4164

UN28MAR01

AFifth Stage - Two Seal Rings


BFifth Stage - Empty Clutch Cavity

YZ4165

UN28MAR01

03
0350
,104

Continued on next page

TM2111 (30MAY03)

03-0350-104

OUO1065,0000595 1927NOV025/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=216

Gears, Shafts and Power Shift Clutches


Clutch Pack DisassembleTorque Converter
Machines
CAUTION: Heavy component; use a hoist.
Clutch PackTorque Converter MachinesSpecification
Second StageWeight ................................ 46.6 kg (103 lb) approximate
Third StageWeight .................................... 45.2 kg (100 lb) approximate
Fourth StageWeight ....................................... 35 kg (77 lb) approximate
Fifth StageWeight ....................................... 26.3 kg (58 lb) approximate

IMPORTANT: DO NOT mix components of individual


shaft assemblies. Keep all clutch pack
components together as a set.

NOTE: The disassembly and assembly of clutch packs


are similar; therefore, procedures for
disassembling and assembling clutch packs are
outlined one time. Follow these procedures when
disassembling and assembling both direction and
speed clutch packs. Second stage clutch packs
are shown, unless otherwise indicated.
UN23DEC97

03
0350
,105

YZ1121

1. If necessary, JDG1106 Clutch Lifting tool can be used


to lift clutch.

JDG1106 Clutch Lifting ToolFourth Stage


Shown

Continued on next page

TM2111 (30MAY03)

03-0350-105

OUO1065,0000595 1927NOV026/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=217

Gears, Shafts and Power Shift Clutches


NOTE: The second speed clutch pack or fifth stage
differs from the other clutch packs. It has two seal
rings (A), instead of three and one clutch pack.
One end of fifth stage shaft assembly has an
empty clutch cavity (B).

UN28MAR01

2. Remove seal rings.

YZ4164

AFifth StageTwo Seal Rings


BFifth StageEmpty Clutch Cavity

YZ4165

UN28MAR01

03
0350
,106

Continued on next page

TM2111 (30MAY03)

03-0350-106

OUO1065,0000595 1927NOV027/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=218

Gears, Shafts and Power Shift Clutches


3. Remove seal rings (A).

YZ4167

UN28MAR01

ASeal Rings (3 used)

03
0350
,107
Continued on next page

TM2111 (30MAY03)

03-0350-107

OUO1065,0000595 1927NOV028/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=219

Gears, Shafts and Power Shift Clutches


IMPORTANT: Use shaft protector when using bearing
puller.
4. Install bearing puller (B).
5. Install gear puller (A) on bearing puller.

UN28MAR01

6. Remove ball bearing (C).


CAUTION: Wear proper eye protection when
installing or removing retaining rings.

UN28MAR01

AGear Puller
BBearing Puller
CBall Bearing
DRetaining Ring

YZ4166

03
0350
,108

YZ4163

7. Remove retaining ring (D).

Continued on next page

TM2111 (30MAY03)

03-0350-108

OUO1065,0000595 1927NOV029/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=220

Gears, Shafts and Power Shift Clutches


IMPORTANT: Use shaft protector when using bearing
puller.
8. Install bearing puller.
9. Remove clutch gear (A).

YZ4168

UN28MAR01

AClutch Gear

OUO1065,0000595 1927NOV0210/38

10. Remove ball bearing (A).

YZ4169

UN28MAR01

ABall Bearing

Continued on next page

TM2111 (30MAY03)

03-0350-109

OUO1065,0000595 1927NOV0211/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=221

03
0350
,109

Gears, Shafts and Power Shift Clutches


11. On direction clutch packs (high and low forward)
(second stage) and direction clutch packs (high and
low reverse) (third stage) assemblies only, remove
O-ring (A). Inspect for wear or damage.

UN28MAR01

AO-Ring

YZ4170

03
0350
,110

OUO1065,0000595 1927NOV0212/38

CAUTION: Wear proper eye protection when


removing snap ring.
12. Remove snap ring (B).

YZ407

UN25MAR97

BSnap Ring

Continued on next page

TM2111 (30MAY03)

03-0350-110

OUO1065,0000595 1927NOV0213/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=222

Gears, Shafts and Power Shift Clutches


13. Turn shaft assembly over.

YZ409

UN12MAR97

14. Remove clutch plate retainer, clutch plates and


separator plates.

OUO1065,0000595 1927NOV0214/38

IMPORTANT: Use shaft protector when using bearing


puller.
15. Install bearing puller.
16. Remove and discard bearing (A).

YZ406

UN19APR97

ABearing

Continued on next page

TM2111 (30MAY03)

03-0350-111

OUO1065,0000595 1927NOV0215/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=223

03
0350
,111

Gears, Shafts and Power Shift Clutches


Clutch Piston Repair
CAUTION: Clutch piston return springs are
under pressure.
1. Place shaft assembly on press.
2. Use JDG1103 Clutch Pack Spring Compressor (A) to
compress clutch return springs.
3. Remove retaining ring (B) from shaft groove. Inspect
for wear or damage.

YZ410

AJDG1103 Clutch Pack Spring Compressor


BRetaining Ring

OUO1065,0000595 1927NOV0216/38

5. Lift out retaining ring (A), snap ring retainer (B) and
clutch return springs (C).

YZ463

UN21AUG96

ARetaining Ring
BSnap Ring Retainer
CClutch Return Springs

OUO1065,0000595 1927NOV0217/38

6. Remove lube shut off washer (D).

UN21AUG96

DLube Shutoff Washer

YZ464

03
0350
,112

UN29APR97

4. Relieve pressure on compressor tool.

Continued on next page

TM2111 (30MAY03)

03-0350-112

OUO1065,0000595 1927NOV0218/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=224

Gears, Shafts and Power Shift Clutches

7. Remove piston. If needed apply 69 kPa (0.7 bar) (10


psi) maximum, regulated air pressure through oil
passage to force clutch piston from shaft assembly.

UN20AUG96

Clutch PistonSpecification
Maximum Regulated Air
Pressure ............................................................. 69 kPa (0.7 bar) (10 psi)

YZ414

CAUTION: Prevent possible injury from


unexpected release of piston. Clear area of
bystanders. Use a protective blanket for extra
protection against the unexpected release of
piston or flying debris. Wear personal
protection equipment, including eye protection.
Use only regulated, compressed air of 69 kPa
(0.7 bar) (10 psi) maximum to remove piston.

03
0350
,113
OUO1065,0000595 1927NOV0219/38

8. Remove clutch piston (A).


9. Remove piston outer seal (B) and O-ring (C) from
clutch piston.
10. Inspect for wear or damage.

UN20AUG96

11. For complete disassembly of this shaft, repeat


disassembly steps for clutch pack assembly on
opposite end of this shaft.

YZ415

AClutch Piston
BPiston Outer Seal
CO-Ring

Continued on next page

TM2111 (30MAY03)

03-0350-113

OUO1065,0000595 1927NOV0220/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=225

Gears, Shafts and Power Shift Clutches


Clutch Pack Assemble Torque Converter Machines
IMPORTANT: DO NOT mix components of individual
shaft assemblies. Keep all clutch pack
components together as a set.

UN20AUG96

Inspect clutch piston bore for sharp


edges or wear. Use care not to damage
seals on pistons during installation.
1. Lubricate and install new O-ring (A).

YZ416

2. Lubricate and install new piston outer seal (B).


3. Install clutch piston (C) with raised center boss up.
AO-Ring
BPiston Outer Seal
CClutch Piston

OUO1065,0000595 1927NOV0221/38

4. Install lube shutoff washer (D).

UN21AUG96

DLube Shutoff Washer

YZ413

03
0350
,114

Continued on next page

TM2111 (30MAY03)

03-0350-114

OUO1065,0000595 1927NOV0222/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=226

Gears, Shafts and Power Shift Clutches

UN20MAR97

IMPORTANT: Install clutch piston return springs as


shown for proper spring force.
5. Install clutch return springs (A) as three pairs with
outer diameters contacting for each pair.

YZ853

AClutch Return Springs

YZ417

UN14AUG96

03
0350
,115

OUO1065,0000595 1927NOV0223/38

IMPORTANT: Wear proper eye protection when


installing retaining rings.
6. Put snap ring retainer (B) and retaining ring (C) on
shaft.
UN19APR97

7. Compress clutch return springs using JDG1103 Clutch


Pack Spring Compressor.

YZ418

BSnap Ring Retainer


CRetaining Ring

Continued on next page

TM2111 (30MAY03)

03-0350-115

OUO1065,0000595 1927NOV0224/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=227

Gears, Shafts and Power Shift Clutches

CAUTION: Wear proper eye protection when


installing retaining rings.
8. Install retaining ring (C) in groove.

UN19APR97

9. Release pressure on clutch return springs slowly. Be


sure snap ring retainer is properly positioned.

YZ410A

CRetaining Ring

03
0350
,116
OUO1065,0000595 1927NOV0225/38

IMPORTANT: For direction clutch packs (high and


low forward) (second stage) and
direction clutch packs (high and low
reverse) (third stage) ONLY, install two
clutch separator plates first.

NOTE: Clutch separator plates are steel with external


spline teeth. Clutch plates have a lining material
on the face and internal spline teeth.

YZ4182

UN05APR01

10. On direction clutch packs (high and low forward)


(second stage) and direction clutch packs (high and
low reverse) (third stage) clutch assemblies, first
install two clutch separator plates (A). On first and
third speed clutch packs (fourth stage) and second
speed clutch pack (fifth stage) clutch assemblies, first
install one clutch separator plate.
AClutch Separator Plates

Continued on next page

TM2111 (30MAY03)

03-0350-116

OUO1065,0000595 1927NOV0226/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=228

Gears, Shafts and Power Shift Clutches


11. Install one clutch plate (B).

YZ4183

UN05APR01

BClutch Plate

OUO1065,0000595 1927NOV0227/38

12. Install remaining plates alternately and end with clutch


plate.

NOTE: Last plate is a clutch plate.

YZ4186

UN05APR01

CClutch Separator Plate

Continued on next page

TM2111 (30MAY03)

03-0350-117

OUO1065,0000595 1927NOV0228/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=229

03
0350
,117

Gears, Shafts and Power Shift Clutches


IMPORTANT: Second and third shaft assemblies have
three locations with two spline teeth
missing (C) and one location with one
spline tooth missing (B). Fourth and
fifth shaft assemblies have six locations
with one spline tooth missing. The
clutch plate retainer lug (A) fits in any
of the locations with one spline tooth
missing (B).
13. Install clutch plate retainer (A).

14. Install snap ring (D).

YZ4185

IMPORTANT: Check that clutch and separator plates


do not bind.
IMPORTANT: Fifth stage assembly has one clutch
pack.
15. Check clutch plates for clearance to allow for piston
travel after assembly. Replace clutch plates as
necessary to obtain proper clearance.
Clutch Pack Assemble Torque Converter MachinesSpecification
Clutch Plate (Second and Third
Stage Clutch Packs)Clearance ........ 2.314.47 mm (0.0910.176 in.)
Clutch Plate (Fourth and Fifth
Stage Clutch Packs)Clearance ........ 2.795.59 mm (0.1100.220 in.)

UN05APR01

AClutch Plate Retainer


BOne-Spline Tooth Missing Location
CTwo-Spline Teeth Missing Location
DSnap Ring

YZ4181

03
0350
,118

UN05APR01

CAUTION: Wear proper eye protection when


installing snap ring.

Continued on next page

TM2111 (30MAY03)

03-0350-118

OUO1065,0000595 1927NOV0229/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=230

Gears, Shafts and Power Shift Clutches


IMPORTANT: Make sure clutch retainer (A) is in place
and the snap ring (B) is seated.
16. Procedure For Checking Clutch Plate Clearance
At Full Piston Travel.
a. Zero dial indicator.

UN24AUG01

CAUTION: Prevent possible injury from


unexpected release of piston. Clear area of
bystanders. Use a protective blanket for extra
protection against the unexpected release of
piston or flying debris. Wear personal
protection equipment, including eye protection.
Use only regulated compressed air.

IMPORTANT: There are two cross-drilled holes in the


seal ring end of the shaft. The hole
located between the first and second
seal ring groove (D) applies to the
bottom clutch pack and the hole located
between the second and third seal ring
groove (C) applies to the top clutch
pack. In case the wrong hole is
pressurized, make sure that the other
clutch on the shaft is either completely
built with clutch plate retainer (A) in
place and snap ring (B) seated, or that
there are no parts installed which may
be expelled by the air pressure

YZ4209

b. Position stem of a long-stem dial indicator against


clutch piston, in axial direction of shaft.

AClutch Retainer
BSnap Ring
CClutch Oil Pressure Passage
DClutch Oil Pressure Passage

Fifth stage assembly has one clutch


pack.
c. Apply regulated air pressure to piston, maximum of
620 kPa (6.20 bar) (90 psi) to appropriate hole (C
or D), depending on which clutch pack you are
checking.
d. Read the indicator. This measurement is clutch
pack clearance.

Continued on next page

TM2111 (30MAY03)

03-0350-119

OUO1065,0000595 1927NOV0230/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=231

03
0350
,119

Gears, Shafts and Power Shift Clutches


IMPORTANT: Clutch plate splines must be aligned
before installing bearings on the shaft
assembly to avoid clutch plate damage.
17. Use clutch gear to align clutch plates and separator
plates.
18. Move clutch gear clockwise, then counterclockwise,
working clutch gear spline through clutch and
separator plates. Remove clutch gear.

Continued on next page

OUO1065,0000595 1927NOV0231/38

03
0350
,120

TM2111 (30MAY03)

03-0350-120

G-III and D Series Skidders (S.N. 586337 )


053003

PN=232

Gears, Shafts and Power Shift Clutches


IMPORTANT: Seal side of bearing must be toward
clutch return springs. Lubricate bearing
to prevent dry start-up of transmission.
Press only on inner race of ball bearing.
19. Install ball bearing (A), with seal side down. Install
bearing until bearing inner race contacts shoulder of
shaft.
ABall Bearing

YZ4179

UN05APR01

YZ4180

UN05APR01

03
0350
,121

Continued on next page

TM2111 (30MAY03)

03-0350-121

OUO1065,0000595 1927NOV0232/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=233

Gears, Shafts and Power Shift Clutches


20. On second and third stage clutch assemblies only,
lubricate and install new O-ring (A).

UN28MAR01

AO-Ring

YZ4170

03
0350
,122

OUO1065,0000595 1927NOV0233/38

IMPORTANT: Forcing clutch gear through clutch


plates can damage clutch plates if
plates are not properly aligned. Use
care not to damage O-ring (B).
21. Install clutch gear (A). O-ring (B) must fit into bore of
clutch plate retainer (C).

YZ4171

UN29MAR01

AClutch Gear
BO-Ring
CClutch Plate Retainer

Continued on next page

TM2111 (30MAY03)

03-0350-122

OUO1065,0000595 1927NOV0234/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=234

Gears, Shafts and Power Shift Clutches


IMPORTANT: Start bearing (D) into clutch gear. DO
NOT press bearing below ring groove in
shaft. Pressing the bearing all the way
into the gear will preload the bearing.
Preloading bearing will shorten the life
of the bearing.
22. Put new bearing (D) onto clutch gear. Start bearing
into bore only.
23. Install retaining ring (E) on shaft assembly.

UN29MAR01

IMPORTANT: Press only on retaining ring. DO NOT


preload bearing.

YZ4172

24. Using a press and tool (cylinder) (F), push slowly on


retaining ring until retaining ring fits into groove of
shaft assembly.
Clutch gear must turn. Check for 0.25 mm (0.010 in.)
end play of gear using a dial indicator.
Clutch Pack Assemble Torque Converter MachinesSpecification
Clutch GearEnd Play .............................................. 0.25 mm (0.010 in.)

YZ4173

UN29MAR01

DBearing
ERetaining Ring
FTool

Continued on next page

TM2111 (30MAY03)

03-0350-123

OUO1065,0000595 1927NOV0235/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=235

03
0350
,123

Gears, Shafts and Power Shift Clutches


25. Lubricate and install ball bearing (G).
26. Press bearing onto shaft until bearing contacts
retaining ring.
27. Assemble opposite end of shaft by repeating these
assembly steps.
GBall Bearing

YZ4174

UN29MAR01

03
0350
,124

OUO1065,0000595 1927NOV0236/38

IMPORTANT: Always use new seal rings. The seal


rings must fit the shaft groove tightly to
avoid damage to the seal during
installation of front housing.
28. Lubricate and install three seal rings (A) into ring
grooves.

YZ4167

UN28MAR01

ASeal Rings (3 used)

Continued on next page

TM2111 (30MAY03)

03-0350-124

OUO1065,0000595 1927NOV0237/38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=236

Gears, Shafts and Power Shift Clutches


NOTE: Fifth stage assembly has two seal rings (A).
29. Lubricate and install two seal rings (A) into ring
grooves.

YZ4164

UN28MAR01

ASeal Rings (2 used)

5th Stage Seal Rings


03
0350
,125
OUO1065,0000595 1927NOV0238/38

Seventh Stage (Output Gear) RepairTorque


Converter Machines
1. Use a bearing puller to remove bearing cones (A).
Discard bearing cones.

YZ1135

UN12JAN98

ABearing Cones

Continued on next page

TM2111 (30MAY03)

03-0350-125

OUO1020,000111D 1914JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=237

Gears, Shafts and Power Shift Clutches


IMPORTANT: Push on inner race of bearing only.
2. Install bearing cones (A) on both ends of gear and
shaft assembly using a press and JDG1107 Bearing
Driver. Push bearing tight against shoulder of shaft.
ABearing Cone

YZ1136

UN23DEC97

03
0350
,126

OUO1020,000111D 1914JAN032/2

TM2111 (30MAY03)

03-0350-126

G-III and D Series Skidders (S.N. 586337 )


053003

PN=238

Gears, Shafts and Power Shift Clutches

Rear Transmission Housing RepairTorque Converter Machines

YZ4145

UN23MAR01

03
0350
,127

Rear View of Rear Housing


ARear Housing
BO-Ring (2 used)
CCylinder Speed Pickup
Sensor

DMagnetic Pickup Cover (2


used)
EWasher (4 Used)

FLock Washer (4 used)


GCap Screw (4 used)
HOutput Shaft Pickup
Sensor

Continued on next page

TM2111 (30MAY03)

03-0350-127

IIdentification Plate
JDrive Screw (2 Used)

OUO1020,0001121 1914JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=239

Gears, Shafts and Power Shift Clutches


NOTE: Disassemble only if parts are damaged and must
be replaced.
1. Inspect bearing cups for wear and damage.
2. Remove bearing cups (A).
IMPORTANT: Always use a bearing cup driver to
install bearing cups.
3. Install new bearing cups. Bearing cups must be
installed tight against housing shoulder.
ABearing Cups

YZ1142

UN23DEC97

03
0350
,128

OUO1020,0001121 1914JAN032/2

TM2111 (30MAY03)

03-0350-128

G-III and D Series Skidders (S.N. 586337 )


053003

PN=240

Gears, Shafts and Power Shift Clutches

Front and Rear Housing AssembleTorque


Converter Machines
IMPORTANT: Use guide pins during assembly to
guide the front housing onto the rear
housing. Pins will help prevent damage
to seal rings.
UN23MAR01

1. Install guide pins in rear housing.

YZ4146

2. Attach DFT1156 Transmission Housing Lifting Bracket


to front housing (A). See DFT1156 Transmission
Housing Lifting Bracket. (Group 9900.)
3. Clean mounting surfaces on front and rear housings
with isopropyl alcohol or equivalent.

03
0350
,129

4. Lubricate all bearings, bore sleeves and seal rings


before installing front housing.

T163695B

5. Apply high flex form-in-place gasket to rear housing


mounting surface. Using a small roller will help to apply
a thin, even layer of adhesive. Excess gasket material
should be wiped from joint. Installation should occur
within three minutes of application. Allow a minimum of
30 minutes of cure time before adding oil.

UN14JAN03

IMPORTANT: Excessive amounts of gasket adhesive


may cause incorrect bearing end play,
extend cure time and cause runoff of
material.

AFront Housing
BDFT1156 Transmission Housing Lifting
Bracket
CCap Screw (19 used)

CAUTION: Heavy component; use a hoist.


Front and Rear Housing AssembleSpecification
Front HousingWeight ................................... 94 kg (207 lb) approximate

6. Lower front housing onto rear housing.


7. Install six cap screws evenly spaced in front housing
snug tight.
8. Remove guide pins and install remaining cap screws
(C) snug tight.
9. Remove lifting bracket (B).

Continued on next page

TM2111 (30MAY03)

03-0350-129

OUO1020,0001122 1914JAN031/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=241

Gears, Shafts and Power Shift Clutches

T163697

UN15JAN03

03
0350
,130

10. Tighten cap screws to specification in sequence


shown. Repeat tightening sequence a second
time.

Front and Rear Housing AssembleSpecification


Front Housing-to-Rear Housing
Cap ScrewTorque ................................................. 87 Nm (64 lb-ft)

Continued on next page

TM2111 (30MAY03)

03-0350-130

OUO1020,0001122 1914JAN032/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=242

Gears, Shafts and Power Shift Clutches


11. Position JDG1519 Seal Protector over output shaft.
1
12. Apply thread lock and sealer (medium strength) to
outside diameter of oil seal (1) and grease seals (2).
2
13. Apply thin layer of petroleum jelly to inner seal lip of
oil seal (1) and grease seals (2).

15. Use JDG1737 Seal Driver to install first grease seal


(2) to bottom of seal bore in transmission housing

T163701

T163701

16. Use JDG1738 Seal Driver to install second grease


seal (2) until flush with shoulder in transmission
housing.

UN21JAN03

14. Use JDG1736 Seal Driver to install oil seal (1) until
flush with shoulder in transmission housing.

T163700B

UN14JAN03

1Oil Seal
2Grease Seal (2 used)
3Grease Fitting
4JDG1738 Seal Driver
5Grease Seal

OUO1020,0001122 1914JAN033/3

TM2111 (30MAY03)

03-0350-131

G-III and D Series Skidders (S.N. 586337 )


053003

PN=243

03
0350
,131

Gears, Shafts and Power Shift Clutches

03
0350
,132

TM2111 (30MAY03)

03-0350-132

G-III and D Series Skidders (S.N. 586337 )


053003

PN=244

Group 0360

Hydraulic System
Transmission Charge Pump Remove and
InstallDirect Drive Machines
1. Remove hydraulic pump. See Hydraulic Pump
Disassemble and Assemble. (Group 2160.)

UN19JUL00

IMPORTANT: Differential lock pump must be removed


to eliminate the potential of the
differential lock pump splined coupler
(B) dropping into the transmission
during transmission charge pump
removal.
2. Remove cap screws (A) and washers and lay
differential lock pump aside.

T132624C

3. Remove splined coupler (B).


ACap Screws
BSplined Coupler

T113855C

UN13MAY98

Grapple Machine Shown

Continued on next page

TM2111 (30MAY03)

03-0360-1

CED,OUO1032,3395 1914JAN031/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=245

03
0360
1

Hydraulic System
4. Remove cap screw (A) holding clamp and wire
harness.
5. Disconnect hydraulic hoses (B and D).

NOTE: Bearings and splined coupler are slip-fit in both


the charge pump housing and the transmission
housing. The bearings and coupler may or may
not come out with the charge pump when charge
pump is removed.

UN10APR98

T113847B

ACap Screw
BCharge Pump-to-Transmission Filter Hose
CCap Screw (4 used)
DSuction Hose

T113848B

03
0360
2

UN10APR98

6. Remove cap screws (C) to remove charge pump.

Continued on next page

TM2111 (30MAY03)

03-0360-2

CED,OUO1032,3395 1914JAN032/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=246

Hydraulic System
7. Inspect O-ring (A) in transmission pump flange for
wear or damage. Replace as required.
8. Remove bearing and splined coupler (B).
UN10APR98

9. Inspect bearings and splined coupler, replace if


necessary.

T113850B

10. Apply OPTIMOLY PASTE WHITE T to pump splines.


11. Install splined coupler on charge pump before
installing on transmission housing.
AO-Ring
BSplined Coupler

T113851B

UN10APR98

03
0360
3

OPTIMOLY PASTE WHITE T is a trademark of Optimal Lubricants, Inc.

TM2111 (30MAY03)

Continued on next page

03-0360-3

CED,OUO1032,3395 1914JAN033/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=247

Hydraulic System
12. Position charge pump on transmission case.
13. Install and tighten cap screws (C).
Transmission Charge PumpDirect Drive MachinesSpecification
Charge Pump-to-Transmission
Housing Cap ScrewTorque.......................................... 73 Nm (55 lb-ft)

14. Install suction hose (D).


IMPORTANT: Pump must be filled with oil prior to
start-up to prevent pump damage.

T113848B

16. Rotate fitting on pump 90 counterclockwise and


install hose (B).
17. Install cap screw (A) which holds clamp and wire
harness.

UN10APR98

ACap Screw
BCharge Pump-to-Transmission Filter Hose
CCap Screw (4 used)
DSuction Hose

T113847B

03
0360
4

UN10APR98

15. Rotate fitting that hose (B) connects to on pump 90


clockwise and fill pump with oil.

Continued on next page

TM2111 (30MAY03)

03-0360-4

CED,OUO1032,3395 1914JAN034/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=248

Hydraulic System
18. Install spline coupler (B).
19. Install differential lock pump and fasten with cap
screws (A).
UN13MAY98

20. Install hydraulic pump. See Hydraulic Pump


Disassemble and Assemble. (Group 2160.)

T113855C

21. Test run machine and check for leaks. See


Transmission, Hydraulic System, Park Brake,
Differential, Cab Hydraulic Pump and Winch Oil
22. Check transmission oil level. See Check Transmission
Oil Level. (Operators Manual.)
23. Calibrate transmission control unit. See Calibration of
Transmission Control Unit (TCU). (Group 9015-20.)

03
0360
5

T132624C

UN19JUL00

ACap Screws
BSpline Coupler

Grapple Machine Shown


CED,OUO1032,3395 1914JAN035/5

TM2111 (30MAY03)

03-0360-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=249

Hydraulic System

Transmission Charge Pump Remove and


InstallTorque Converter Machines
1. Remove hydraulic pump. See Hydraulic Pump
Disassemble and Assemble. (Group 2160.)

UN04APR01

2. Disconnect hoses (3 and 4).

3. Remove cap screws (2), pump (1), and splined coupler


assembly.
1Transmission Charge Pump
2Cap Screw (3 used)
3Charge Pump Outlet Hose
4Charge Pump Inlet Hose

OUO1020,00010E4 1902APR011/3

IMPORTANT: Always use NEW O-rings. Old or


damaged O-rings will leak.

UN04APR01

4. Apply petroleum jelly on new O-ring (2) and install on


charge pump flange.
5. Inspect bearings on splined coupler (1) and replace as
necessary.

T140966B

6. Install splined coupler into converter housing (3).


7. Apply OPTIMOLY PASTE WHITE T to pump splines.

UN04APR01

1Splined Coupler
2O-Ring
3Converter Housing

T140967B

03
0360
6

T140965B

NOTE: Bearings and splined coupler assembly are slip-fit


in both the pump housing and the converter
housing. The bearings and coupler may or may
not come out with the pump when pump is
removed.

OPTIMOLY PASTE WHITE T is a trademark of Optimal Lubricants, Inc.

TM2111 (30MAY03)

Continued on next page

03-0360-6

OUO1020,00010E4 1902APR012/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=250

Hydraulic System
8. Install pump (1) and cap screws (2). Tighten cap
screws to specification.
Transmission Charge PumpTorque Converter Machines
Specification
Charge Pump-to-Converter
Housing Cap ScrewTorque........................................ 100 Nm (74 lb-ft)

UN04APR01

IMPORTANT: Pump must be filled with oil prior to


start-up to prevent pump damage.

10. Install hose (3).

T140965B

9. Install hose (4). Fill pump with clean transmission oil to


bottom of side fitting. See Transmission, Hydraulic
System, Park Brake, Differential, Cab Hydraulic Pump
and Winch Oil. (Operators Manual.)

03
0360
7

1Transmission Charge Pump


2Cap Screw (3 used)
3Charge Pump Outlet Hose
4Charge Pump Inlet Hose

11. Install hydraulic pump. See Hydraulic Pump


Disassemble and Assemble. (Group 2160.)
12. Start engine and check for leaks. See Transmission,
Hydraulic System, Park Brake, Differential, Cab
Hydraulic Pump and Winch Oil. (Operators Manual.)
13. Check transmission oil level. See Check Transmission
Oil Level. (Operators Manual.)
14. Calibrate transmission control unit. See Calibration of
Transmission Control Unit (TCU). (Group 9015-20.)

OUO1020,00010E4 1902APR013/3

TM2111 (30MAY03)

03-0360-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=251

Hydraulic System

Thermal Bypass Valve RepairTorque


Converter Machines
1. Remove right engine side shields.

UN03APR01

NOTE: After disconnecting line (4) hold end of line as


high as possible and install a plug to retain as
much oil in cooler as possible.

T140853B

2. Disconnect line (4) and close open line with a plug to


retain oil in cooler.
3. Disconnect lines (13) and (7). Close all line openings
with plugs to prevent system contamination.
03
0360
8

4. Remove cap screws and washers (5) and clamp (6).

1Transmission Return Line


2Transmission Filter Relief Valve Line
3Torque Converter Out Line
4Cooler Inlet Line
5Cap Screw and Washer (2 used)
6Clamp
7Cooler Outlet Line

Continued on next page

TM2111 (30MAY03)

03-0360-8

OUO1020,00010E2 1914JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=252

Hydraulic System
NOTE: Throat opening of C-clamp or hand press must be
approximately 76 mm (3 in.) larger than valve
from end of top cover-to-end of bottom cover.
5. Using a hand press or C-clamp with sufficient throat
opening, retain top and bottom covers (2 and 7) to
valve housing (5).
6. Remove nuts (8) and carefully open hand press or
C-clamp to relieve spring (9) tension.
7. Disassemble and replace parts as necessary.
IMPORTANT: Always use NEW O-rings. Old or
damaged O-rings will leak.
03
0360
9

8. Assemble parts as shown using hand press or C-clamp


to compress spring.

UN03APR01

9. Install cap screws (1) and nuts. Tighten nuts to


specification.

T121110

Thermal Bypass ValveSpecification


Thermal Bypass Valve Housing
NutsTorque ............................................................... 12 Nm (102 lb-in.)

10. Install valve, clamp, cap screws and washers.


IMPORTANT: Always use NEW O-rings. Old or
damaged O-rings will leak.
11. Connect lines using new O-rings and tighten all hose
fittings.
12. Start engine and check for leaks.

1Cap Screw (4 used)


2Top Cover
3O-Ring
4Thermostat
5Housing
6Seal Assembly
7Bottom Cover
8Nut (4 used)
9Spring
10Repair Kit

13. Check transmission oil level. See Check Transmission


Oil Level. (Operators Manual.)
14. Install right engine side shields.

OUO1020,00010E2 1914JAN032/2

TM2111 (30MAY03)

03-0360-9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=253

Hydraulic System

03
0360
10

TM2111 (30MAY03)

03-0360-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=254

Section 04

Engine
Contents
Page

Group 0400Removal and Installation


POWERTECH 4.5 L and 6.8 L Diesel
EnginesBase EngineUse CTM104 . . .04-0400-1
POWERTECH 4.5 L & 6.8 L Diesel Engines
Level 12 Electronic Fuel System with
Stanadyne DE10 PumpUse CTM331 . . .04-0400-2
POWERTECH 8.1 L Diesel Engines
Base EngineUse CTM86 . . . . . . . . . . . .04-0400-3
POWERTECH 8.1 L Level 9 Electronic Fuel
System with High Pressure Common RailUse
CTM255. . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-4
Engine Remove and InstallDirect Drive
Machines . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-4
Engine Remove and InstallTorque
Converter Machines. . . . . . . . . . . . . . . . .04-0400-17

TM2111 (30MAY03)

04-1

04

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

04

TM2111 (30MAY03)

04-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 0400

Removal and Installation


POWERTECH 4.5 L and 6.8 L Diesel
EnginesBase EngineUse CTM104
For additional engine information, the component technical
manual (CTM) is also required.
Refer to the following in CTM104.
General Engine Operation
Lubrication System Operation
Cooling System Operation
Air Intake and Exhaust System Operation
Air Cleaner Operation
Turbocharger Operation

04
0400
1

POWERTECH is a trademark of Deere & Company

TM2111 (30MAY03)

OUO1065,0000585 1904OCT021/1

04-0400-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=257

Removal and Installation

POWERTECH 4.5 L & 6.8 L Diesel Engines


Level 12 Electronic Fuel System with
Stanadyne DE10 PumpUse CTM331
For additional engine information, the component technical
manual (CTM) is also required.
Refer to the following in CTM331.
Fuel System Operation
Fuel Supply Pump Operation
Final Fuel Filter Operation
Fuel Injection Pump Operation
Fuel Injection Nozzle Operation
Electronic Control System Terminology
04
0400
2

Electronic Control System Overview


Electronic Control System Operation
Refer to the following theory of operation in this manual
for more information.
Electronic Fuel Injection System Operation. (Group
9015-15.)

POWERTECH is a trademark of Deere & Company

TM2111 (30MAY03)

OUO1065,0000583 1904OCT021/1

04-0400-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=258

Removal and Installation

POWERTECH 8.1 L Diesel EnginesBase


EngineUse CTM86
For additional engine information, the component technical
manual (CTM) is also required.
Refer to the following in CTM86.
General Engine Operation
Lubrication System Operation
Cooling System Operation
Air Intake and Exhaust System Operation
Turbocharger Operation

04
0400
3

POWERTECH is a trademark of Deere & Company

TM2111 (30MAY03)

OUO1065,0000588 1908OCT021/1

04-0400-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=259

Removal and Installation

POWERTECH 8.1 L Level 9 Electronic Fuel


System with High Pressure Common Rail
Use CTM255
For additional engine information, the component technical
manual (CTM) is also required.
Refer to the following in CTM255.
Fuel System Operation
Primary Fuel Filter Operation
Fuel Transfer Pump Operation
Final Fuel Filter Operation
High Pressure Fuel Pump Operation
High Pressure Common Rail (HPCR) Operation
04
0400
4

Electronic Injector (EI) Operation


Electronic Control System Overview
Refer to the following theory of operation in this manual
for more information.
Electronic Fuel Injection System Operation (Group
9015-15.)

POWERTECH is a trademark of Deere & Company

OUO1065,0000587 1908OCT021/1

Engine Remove and InstallDirect Drive Machines


NOTE: 540G-III, 548G-III, 360D shown. 640G-III,
648G-III, 460D and 748G-III, 560D are similar.
1. Remove engine side shields.

2. Turn battery disconnect switch to OFF position.


3. Remove hood. See Hood Remove and Install.
(Group 1910.)

Continued on next page

TM2111 (30MAY03)

04-0400-4

OUO1017,00003A8 1910JAN031/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=260

Removal and Installation

CAUTION: Coolant may be hot. Wait until


radiator is cool to the touch before draining
coolant.

T6642EK

UN01NOV88

4. Drain coolant from radiator at radiator drain cock (2)


through drain hose (1). The approximate cooling
system capacity for 6.8 L engine is 21.5 L (22.7 qt),
8.1 L engine is 30 L (33.8 qt). Dispose of used coolant
properly.
5. Remove fan guards. See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)
6. Remove radiator overflow reservoir.

UN29OCT02

7. Remove air conditioner condenser mounting cap


screws and set condenser aside. See Air Conditioning
Condenser Remove and Install. (Group 1830.)

T160903B

8. Remove grille and grille housing. See Grille and Grille


Housing Remove and Install. (Group 1921.)
Remove radiator. See Radiator and Oil Cooler Remove
and InstallDirect Drive Machines. (Group 0510.)
9. Remove fan belt. See Fan Belt Remove and Install.
(Group 0510.)

1Drain Hose
2Radiator Drain Cock

OUO1017,00003A8 1910JAN032/15

10. Disconnect compressor clutch wire connector (3).


11. Disconnect ground wire (4).

UN29OCT02

12. Remove cap screws (5) and remove compressor and


lay on left front tire.

T160906B

3Compressor Clutch Wire Connector


4Compressor Ground Wire
5Cap Screw (4 used)

Continued on next page

TM2111 (30MAY03)

04-0400-5

OUO1017,00003A8 1910JAN033/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=261

04
0400
5

Removal and Installation


13. Disconnect connectors (6, 811, and 15).
14. Remove wire harness clamps (7 and 16) and move
harness away from engine. Cut wire ties as
necessary.
15. Disconnect fuel leak-off line (17).

UN30OCT02

16. Disconnect positive battery cable and clamp (18).


17. Disconnect negative battery cable (19) at disconnect
switch.

T160907B
UN30OCT02

540G-III, 548G-III, 360D Shown

T160908B

04
0400
6

3Air Compressor Clutch Connector


4Air Conditioner Compressor Ground Wire
6Harness-to-Manifold Air Temperature Sensor
Connector
7Wire Harness Clamp (2 used)
8Temperature Sender Wire Connector
9Fuel Temperature Sensor Connector
10Fuel Control Solenoid Connector
11Oil Pressure Sender Wire Connector
12ECU Connector
15Crankshaft Position Sensor Connector
16Wire Harness Clamp
17Fuel Leak-off Line
18Positive Battery Cable Clamp
19Negative Battery Cable

540G-III, 548G-III, 360D Shown

Continued on next page

TM2111 (30MAY03)

04-0400-6

OUO1017,00003A8 1910JAN034/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=262

T161138B

UN14JAN03

Removal and Installation

540G-III, 548G-III, 360D Shown


6Manifold Air Temperature
Sensor Connector
20Alternator Positive Wire
21Alternator Harness
Connector

22Start Aid Tubing


23Harness Clamp
24Heater Hose

25Fuel Line
26Heater Hose Clamp
27Heater Hose

18. Disconnect alternator positive wire (20) and


harness (21).

28Starter Solenoid Wires


29Starter Positive Terminal
30Starter Ground Terminal

23. Disconnect start aid tubing (22), if equipped.


24. Disconnect heater hose (24 and 27).

19. Disconnect manifold air temperature sensor


connector (6).

25. Disconnect fuel line (25).

20. Disconnect wires from starter positive terminal (29)


and ground terminal (30).

26. Raise cab.See Hydraulic Cab Tilt Procedure.


(Operators Manual.)

21. Disconnect wires (28) from starter solenoid.

27. Remove engine-to-transmission drive shaft. See


Engine-to-Transmission Drive Shaft Remove and
Install. (Group 0325.)

22. Remove clamps (23 and 26) and move harness


away from engine. Cut wire ties as necessary.

Continued on next page

TM2111 (30MAY03)

04-0400-7

OUO1017,00003A8 1910JAN035/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=263

04
0400
7

Removal and Installation


28. Disconnect cold weather disconnect lever (A), if
equipped.

T7502CV

UN20MAY91

ACold Weather Disconnect Lever

OUO1017,00003A8 1910JAN036/15

CAUTION: Use extreme caution when lifting


engine and NEVER permit any part of the body
to be positioned under an engine being lifted or
suspended.
UN11NOV97

Lift engine with longitudinal loading on lift sling


and lifting brackets only. Angular loading
greatly reduces lifting capacity of sling and
brackets.

RG7784

04
0400
8

CAUTION: Heavy component; use a hoist.


648G-III Shown
Engine Remove and InstallDirect DriveSpecification
6.8 L 6068 EngineWeight ........................ 532 kg (1172 lb) approximate
8.1 L 6081 EngineWeight ........................ 735 kg (1618 lb) approximate

AJDG23 Lifting Sling


BEngine Lifting Straps

IMPORTANT: Front and rear isolators are of different


hardness to control engine vibration.
Mark each one and install in original
position when assembling.
29. Attach JDG23 Lifting Sling (A), or other suitable sling,
to engine lifting straps (B) and overhead hoist or floor
crane.

NOTE: If engine does not have lifting straps, they can be


procured through service parts. Use of an engine
lifting sling (as shown) is the ONLY APPROVED
method for lifting engine.

Continued on next page

TM2111 (30MAY03)

04-0400-8

OUO1017,00003A8 1910JAN037/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=264

Removal and Installation

T130656

UN04MAY00

04
0400
9

1Support
2Angle
3Washer (4 used)
4Cap Screw (8 used)
5Angle

6Cap Screw (2 used)


7Washer (8 used)
8Washer (4 used)
9Isolator (2 used)

10Washer (8 used)
11Nut (4 used)
12Support (without Air
Conditioning)

NOTE: 540G-III, 548G-III, 360D models shown,


640G-III, and 648G-III, 460D, 748G-III, 560D
are similar.

13Cap Screw (2 used)


14Isolator (2 used)
15Support (with Air
Conditioning)

31. Lift engine from machine and locate on engine


stand.
32. Inspect and repair engine as necessary.

30. Remove cap screws and nuts (6, 13, and 11).

Continued on next page

TM2111 (30MAY03)

04-0400-9

OUO1017,00003A8 1910JAN038/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=265

Removal and Installation

UN20APR98

CAUTION: Use extreme caution when lifting


engine and NEVER permit any part of the body
to be positioned under an engine being lifted or
suspended.

T114906B

Lift engine with longitudinal loading on lift sling


and lifting brackets only. Angular loading
greatly reduces lifting capacity of sling and
brackets.
CAUTION: Heavy component; use a hoist.
540G-III, 548G-III, 360D Cap Screws Shown
Engine Remove and InstallDirect DriveSpecification
6.8 L 6068 EngineWeight ........................ 532 kg (1172 lb) approximate
8.1 L 6081 EngineWeight ........................ 735 kg (1618 lb) approximate

33. Install engine into engine frame with rear mounts


attached loosely to engine.
34. Install cap screws (A) for front engine mounts.

T114907B

04
0400
10

UN20APR98

NOTE: 540G-III, 548G-III, 360D shown640G-III,


648G-III, 460D, 748G-III, 560D are similar.

35. Install cap screws (B) for rear engine mounts. Do not
remove hoist from engine at this time. Tighten engine
mount-to-frame cap screws.

Right Side Shown


AFront Engine Mount Cap Screw (2 used)
BRear Engine Mount Cap Screw (2 used)

Engine Remove and InstallDirect DriveSpecification


Front and Rear Engine
Mount-to-Frame Cap Screw
Torque ......................................................................... 620 Nm (457 lb-ft)

36. Install engine-to-transmission drive shaft. See


Engine-to-Transmission Drive Shaft Remove and
Install. (Group 0325.)

Continued on next page

TM2111 (30MAY03)

04-0400-10

OUO1017,00003A8 1910JAN039/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=266

Removal and Installation

04
0400
11

TM2111 (30MAY03)

04-0400-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=267

Removal and Installation

T114876

1929APR98

04
0400
12

Continued on next page

TM2111 (30MAY03)

04-0400-12

OUO1017,00003A8 1910JAN0310/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=268

Removal and Installation


ATorsional Damper
BDimension at Top of
Damper
CDimension at Bottom of
Damper

DSix-Inch Steel Scale


EDimension at Rear of
Engine Mount (748G-III
only)

FDimension at Front of
Engine Mount (748G-III
only)

GFrame Side Rail

37. Using a six-inch steel scale (D) or depth gauge,


measure distance (B and C) at top and bottom of
torsional damper (A). Measurements for (B and C)
should be less than a 2 mm (0.08 in.) difference.

40. For 748G-III machines only: Rotate front mounts


until measurements (E and F) are less than 1.5
mm (0.06 in.) difference when measured from
frame side rail (G).

Engine Remove and InstallDirect DriveSpecification


Torsional Damper Alignment
540G-III, 548G-III, 360D,
640G-III, 648G-III, 460D
Distance ...................................................................... 2 mm (0.08 in.)

Engine Remove and InstallDirect DriveSpecification


748G-III Front Mount-to-Frame
Side RailDistance ................................ Less than 1.5 mm (0.06 in.)

41. Remove hoist from engine.

38. Raise or lower rear of engine to change


measurement.
39. Once correct measurement is achieved, tighten
mount-to-engine cap screws.
04
0400
13

Engine Remove and InstallDirect DriveSpecification


540G-III, 548G-III, 360D,
640G-III, 648G-III, 460D
Mount-to-Engine Cap Screw
Torque................................................................... 320 Nm (236 lb-ft)
748G-III 560D Mount-to-Engine
Cap ScrewTorque ............................................. 280 Nm (206 lb-ft)

OUO1017,00003A8 1910JAN0311/15

42. Connect cold weather disconnect lever (A), if


equipped.

T7502CV

UN20MAY91

ACold Weather Disconnect Lever

Continued on next page

TM2111 (30MAY03)

04-0400-13

OUO1017,00003A8 1910JAN0312/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=269

UN14JAN03

Removal and Installation

T161138B

04
0400
14

548G-III, 360D Shown


6Manifold Air Temperature
Sensor Connector
20Alternator Positive Wire
21Alternator Harness
Connector

22Start Aid Tubing


23Harness Clamp
24Heater Hose

25Fuel Line
26Heater Hose Clamp
27Heater Hose

28Starter Solenoid Wires


29Starter Positive Terminal
30Starter Ground Terminal

43. Install harness with clamps (23 and 26).

47. Connect start aid tubing (22) (if equipped).

44. Connect alternator positive wire (20) and harness


(21).

48. Connect manifold air temperature sensor


connector (6).

45. Connect starter solenoid wires (28).

49. Connect heater hose (24 and 27).

46. Connect starter positive terminal (29) and ground


terminal (30).

50. Connect fuel line (25).

Continued on next page

TM2111 (30MAY03)

04-0400-14

OUO1017,00003A8 1910JAN0313/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=270

Removal and Installation


51. Install wire harness with clamps (7 and 16).
52. Connect connectors (6, 811, and 15).
53. Connect fuel leak-off line (17).
54. Connect positive battery cable and clamp (18).

UN30OCT02

55. Connect negative battery cable (19) at disconnect


switch.

T160907B

56. Lower cab. See Hydraulic Cab Tilt Procedure.


(Operators Manual.)
3Air Compressor Clutch Connector
4Air Conditioner Compressor Ground Wire
6Harness-to-Manifold Air Temperature Sensor
Connector
7Wire Harness Clamp (2 used)
8Temperature Sender Wire Connector
9Fuel Temperature Sensor Connector
10Fuel Control Solenoid Connector
11Oil Pressure Sender Wire Connector
12ECU Connector
15Crankshaft Position Sensor Connector
16Wire Harness Clamp
17Fuel Leak-off Line
18Positive Battery Cable Clamp
19Negative Battery Cable

548G-III, 360D Shown

T160908B

UN30OCT02

04
0400
15

548G-III, 360D Shown

Continued on next page

TM2111 (30MAY03)

04-0400-15

OUO1017,00003A8 1910JAN0314/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=271

Removal and Installation


57. Connect wire connector (3).
58. Connect ground wire (4).

UN29OCT02

59. Install air conditioning compressor with cap screws


(5).

T160906B

60. Install fan belt. See Fan Belt Remove and Install.
(Group 0510.)
61. Install radiator. See Radiator and Oil Cooler Remove
and InstallDirect Drive Machines. (Group 0510.)
62. Install fan shroud. See Fan Shroud Remove and
Install. (Group 0510.)

3Compressor Clutch Wire Connector


4Compressor Ground Wire
5Cap Screw (4 used)

63. Install grille and grille housing. See Grille and Grille
Housing Remove and Install. (Group 1921.)

04
0400
16

64. Install air conditioning condenser. See Air


Conditioning Condenser Remove and Install. (Group
1830.)
65. Install fan guards. See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)
66. Install radiator overflow reservoir.
67. Add engine coolant. See Use Correct Fuels and
Lubricants. (Operators Manual.)
68. Add engine oil. See Use Correct Fuels and
Lubricants. (Operators Manual.)
69. Install hood. See Hood Remove and Install. (Group
1910.)
70. Turn battery disconnect switch to ON.
71. Test run machine. Check all fluid levels after test run.
72. Install engine side shields.

OUO1017,00003A8 1910JAN0315/15

TM2111 (30MAY03)

04-0400-16

G-III and D Series Skidders (S.N. 586337 )


053003

PN=272

Removal and Installation

Engine Remove and InstallTorque


Converter Machines
1. Remove engine side shields.
2. Turn battery disconnect switch to OFF position.
3. Remove hood. See Hood Remove and Install. (Group
1910.)

OUO1017,00003A9 1914FEB011/15

CAUTION: Coolant may be hot. Wait until


radiator is cool to the touch before draining
coolant.

T6642EK

UN01NOV88

4. Drain coolant from radiator at radiator drain cock (2)


through drain hose (1). The approximate cooling
system capacity for 6.8 L engine is 21.5 L (22.7 qt),
8.1 L engine is 30 L (33.8 qt). Dispose of used coolant
properly.
5. Remove fan guards. See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)
6. Remove radiator overflow reservoir.

UN29OCT02

7. Remove air conditioner condenser mounting cap


screws and set condenser aside.
8. Remove grille and grille housing. See Grille and Grille
Housing Remove and Install. (Group 1921.)

T160903B

9. Remove radiator.See Radiator and Oil Cooler Remove


and InstallDirect Drive Machines (Group 0510.)
10. Remove fan belt. See Fan Belt Remove and Install.
(Group 0510.)

1Drain Hose
2Radiator Drain Cock

Continued on next page

TM2111 (30MAY03)

04-0400-17

OUO1017,00003A9 1914FEB012/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=273

04
0400
17

Removal and Installation


11. Disconnect wire connector (3).
12. Disconnect ground wire (4).

UN29OCT02

13. Remove cap screws (5) and remove compressor and


lay on left front tire.

T160906B

3Compressor Clutch Wire Connector


4Compressor Ground Wire
5Cap Screw (4 used)

OUO1017,00003A9 1914FEB013/15

14. Disconnect connectors (6, 811, and 15).


15. Remove wire harness clamps (7 and 16) and move
harness away from engine. Cut wire ties as
necessary.
16. Disconnect fuel leak-off line (17).

UN30OCT02

17. Disconnect negative cables (18) and clamp (19).


18. Disconnect hose clamp (19).

T160907B

19. Disconnect starter wire connections (20).


3Air Compressor Clutch Connector
4Air Conditioner Compressor Ground Wire
6Harness-to-Manifold Air Temperature Sensor
Connector
7Wire Harness Clamp (2 used)
8Temperature Sender Wire Connector
9Fuel Temperature Sensor Connector
10Fuel Control Solenoid Connector
11Oil Pressure Sender Wire Connector
12ECU Connector
15Crankshaft Position Sensor Connector
16Wire Harness Clamp
17Fuel Leak-off Line
18Negative Cable
19Clamp
20Starter Wire Connection

UN27JAN03

Engine Left Side

T164346B

04
0400
18

Continued on next page

TM2111 (30MAY03)

04-0400-18

OUO1017,00003A9 1914FEB014/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=274

T164350B

UN27JAN03

Removal and Installation

1Manifold Air Temperature


Sensor Connector
2Alternator Wire Harness

3Charge Air Hose


4Clamp
5Heater Hose

6Fuel Lines
7Radiator Overflow
Reservoir

8Charge Air Hose


9Heater Hose
10Clamp

20. Disconnect alternator wire harness (2).

25. Disconnect start aid tubing (if equipped).

21. Connect manifold air temperature sensor


connector (1).

26. Disconnect fuel lines (6).


27. Remove charge air hoses (3 and 8).

22. Remove hose clamp (10).


28. Raise cab. See See Hydraulic Cab Tilt Procedure.
(Operators Manual.)

23. Disconnect heater hoses (5 and 9).


24. Remove clamps (4) and move harness and heater
hose away from engine. Cut wire ties as
necessary.

Continued on next page

TM2111 (30MAY03)

04-0400-19

OUO1017,00003A9 1914FEB015/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=275

04
0400
19

Removal and Installation


29. Remove flywheel access plug (1) and drive plate cap
screw access plug (2).
30. Discard drive plate cap screw access plug (2).
UN27MAR01

31. Install JDE81-1 Flywheel Turning Tool into access


hole (3).

T140270B

32. Rotate engine until drive plate cap screws can be


seen through hole.
33. Continue to rotate engine and remove eight cap
screws and washers (4).

UN27MAR01

1Flywheel Access Plug


2Drive Plate Cap Screw Access Plug
3Access Hole
4Cap Screw and Washer (8 used)

T140271B

04
0400
20

Continued on next page

TM2111 (30MAY03)

04-0400-20

OUO1017,00003A9 1914FEB016/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=276

Removal and Installation


34. Use DFT1216 Converter Housing Support to support
converter housing. (Group 9900.)
35. Turn adjusting screws (2) to tension tool and support
housing.
36. Disconnect wire connector (4) from speed sensor (5).
37. Remove cap screws (3).

T141080B

UN11APR01

110.9 M12 x 1.75 Cap Screw 30 mm Long (2 used)


2Adjusting Screw (4 used)
3Cap Screw (12 used)
4Wire Connector
5Speed Sensor

T141081B

UN11APR01

04
0400
21

Continued on next page

TM2111 (30MAY03)

04-0400-21

OUO1017,00003A9 1914FEB017/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=277

Removal and Installation

CAUTION: Use extreme caution when lifting


engine and NEVER permit any part of the body
to be positioned under an engine being lifted or
suspended.

RG7784

UN11NOV97

Lift engine with longitudinal loading on lift sling


and lifting brackets only. Angular loading
greatly reduces lifting capacity of sling and
brackets.
CAUTION: Heavy component; use a hoist.
Engine Remove and InstallTorque ConverterSpecification
6.8 L 6068 EngineWeight ........................ 532 kg (1172 lb) approximate
8.1 L 6081 EngineWeight ........................ 735 kg (1618 lb) approximate

T164367B

38. Attach JDG23 Lifting Sling, or other suitable sling, to


engine lifting straps and overhead hoist or floor crane.

NOTE: If engine does not have lifting straps, they can be


procured through service parts. Use of an engine
lifting sling (as shown) is the ONLY APPROVED
method for lifting engine.

UN27JAN03

39. Remove cap screws and nuts (1 and 2).


40. Lift engine up and slide forward away from torque
converter housing.
41. Lift engine out of frame.

T164368B

04
0400
22

UN27JAN03

IMPORTANT: Front and rear isolators are of different


hardness to control engine vibration.
Mark each one and install in original
position when assembling.

42. Repair or replace as required.


AJDG23 Lifting Sling
BEngine Lifting Straps
1Front Mount Cap Screw and Nut
2Rear Mount Cap Screw and Nut

Continued on next page

TM2111 (30MAY03)

04-0400-22

OUO1017,00003A9 1914FEB018/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=278

Removal and Installation


43. Apply anti-seize compound to outside diameter of
converter stub shaft (2) and inside diameter of pilot
sleeve (1), and to flywheel pilot bore. Install pilot
sleeve onto stub shaft.

T140746

UN30MAR01

1Pilot Sleeve
2Converter Stub Shaft

Continued on next page

OUO1017,00003A9 1914FEB019/15

04
0400
23

TM2111 (30MAY03)

04-0400-23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=279

Removal and Installation

UN27JAN03

CAUTION: Use extreme caution when lifting


engine and NEVER permit any part of the body
to be positioned under an engine being lifted or
suspended.

T164367B

Lift engine with longitudinal loading on lift sling


and lifting brackets only. Angular loading
greatly reduces lifting capacity of sling and
brackets.
CAUTION: Heavy component; use a hoist.
Engine Remove and InstallTorque ConverterSpecification
6.8 L 6068 EngineWeight ........................ 532 kg (1172 lb) approximate
8.1 L 6081 EngineWeight ........................ 735 kg (1618 lb) approximate

UN27JAN03

44. Install engine in frame.


45. If removed, install engine mount brackets.
Engine Remove and InstallTorque ConverterSpecification
640G-III, 648G-III and 460D
Mount Bracket-to-Engine Cap
ScrewTorque ............................................................ 320 Nm (236 lb-ft)

T164368B

04
0400
24

46. Install cap screws (1 and 2).

1Front Mount Cap Screw


2Rear Mount Cap Screw

47. Tighten cap screws to specifications.


Engine Remove and InstallTorque ConverterSpecification
Front Mounts-to-Frame Cap
ScrewsTorque .......................................................... 620 Nm (457 lb-ft)
Rear Mounts-to-Frame Cap
ScrewsTorque .......................................................... 712 Nm (525 lb-ft)

Continued on next page

TM2111 (30MAY03)

04-0400-24

OUO1017,00003A9 1914FEB0110/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=280

Removal and Installation


48. Apply medium strength thread lock and sealer to cap
screws (4).

UN27MAR01

49. Rotate engine and install drive plate cap screws and
washers (4). Tighten to specification.
Engine Remove and InstallTorque ConverterSpecification
Drive Plate Cap ScrewsTorque ................................... 47 Nm (35 lb-ft)

T140271B

50. Install plugs (1 and 2).

T140270B

UN27MAR01

1Flywheel Access Plug


2Drive Plate Cap Screw Access Plug
3Access Hole
4Cap Screw and Washer (8 used)

Continued on next page

TM2111 (30MAY03)

04-0400-25

OUO1017,00003A9 1914FEB0111/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=281

04
0400
25

Removal and Installation


51. Use flywheel turning tool, if necessary, to rotate
engine to aid in assembly and align the pilot sleeve
into engine flywheel.
IMPORTANT: Do not use cap screws to pull engine
and housing together. Damage to pilot
sleeve and housings could result.
UN11APR01

52. Install cap screws (3).


53. Connect wire connector (4).

T141081B

54. Loosen adjusting screws (2).


55. Remove cap screws (1) and remove DFT1216.
1Cap Screw (2 used)
2Adjusting Screw (4 used)
3Cap Screw (12 used)
4Wire Connector
5Speed Sensor

T141080B

UN11APR01

04
0400
26

Continued on next page

TM2111 (30MAY03)

04-0400-26

OUO1017,00003A9 1914FEB0112/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=282

T164350B

UN27JAN03

Removal and Installation

1Manifold Air Temperature


Sensor Connector
2Alternator Wire Harness

3Charge Air Hose


4Clamp
5Heater Hose

6Fuel Lines
7Radiator Overflow
Reservoir

8Charge Air Hose


9Heater Hose
10Clamp

56. Install clamp (10).

60. Connect heater hoses (5 and 9).

57. Connect manifold air temperature sensor


connector (1).

61. Install clamps (4).


62. Connect fuel lines (6).

58. Connect alternator wire harness (2).


63. Connect charge air hoses (3 and 8).
59. Connect start aid tubing (if equipped).

Continued on next page

TM2111 (30MAY03)

04-0400-27

OUO1017,00003A9 1914FEB0113/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=283

04
0400
27

Removal and Installation


64. Install wire harness with clamps (7 and 16).
65. Connect connectors (6, 811, and 15).
66. Connect fuel leak-off line (17).
67. Connect negative cables (18) and clamp (19).

UN30OCT02

68. Connect hose clamp (19).


69. Connect starter wire connections (20).

3Air Compressor Clutch Connector


4Air Conditioner Compressor Ground Wire
6Harness-to-Manifold Air Temperature Sensor
Connector
7Wire Harness Clamp (2 used)
8Temperature Sender Wire Connector
9Fuel Temperature Sensor Connector
10Fuel Control Solenoid Connector
11Oil Pressure Sender Wire Connector
12ECU Connector
15Crankshaft Position Sensor Connector
16Wire Harness Clamp
17Fuel Leak-off Line
18Negative Cable
19Clamp
20Starter Wire Connection

UN27JAN03

Engine Left Side

T164346B

04
0400
28

T160907B

70. Lower cab. See Hydraulic Cab Tilt Procedure.


(Operators Manual.)

Continued on next page

TM2111 (30MAY03)

04-0400-28

OUO1017,00003A9 1914FEB0114/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=284

Removal and Installation


71. Connect wire connector (3).
72. Connect ground wire (4).

UN29OCT02

73. Install air conditioning compressor with cap screws


(5).

T160906B

74. Install fan belt. See Fan Belt Remove and Install.
(Group 0510.)
75. Install radiator. See Radiator and Oil Cooler Remove
and InstallDirect Drive Machines. (Group 0510.)
76. Install fan shroud. See Fan Shroud Remove and
Install. (Group 0510.)

3Compressor Clutch Wire Connector


4Compressor Ground Wire
5Cap Screw (4 used)

77. Install grille and grille housing. See See Grille and
Grille Housing Remove and Install. (Group 0510.)
78. Install air conditioner condenser.
79. Install fan guards. See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)

04
0400
29

80. Install radiator overflow reservoir.


81. Add engine coolant. See Use Correct Fuels and
Lubricants. (Operators Manual.)
82. Add engine oil. See Use Correct Fuels and
Lubricants. (Operators Manual.)
83. Install hood. See Hood Remove and Install. (Group
1910.)
84. Turn battery disconnect switch to ON.
85. Test run machine. Check all fluid levels after test run.
86. Install engine side shields.

OUO1017,00003A9 1914FEB0115/15

TM2111 (30MAY03)

04-0400-29

G-III and D Series Skidders (S.N. 586337 )


053003

PN=285

Removal and Installation

04
0400
30

TM2111 (30MAY03)

04-0400-30

G-III and D Series Skidders (S.N. 586337 )


053003

PN=286

Section 05

Engine Auxiliary Systems


Contents
Page

Group 0505Cold Weather Starting Aids


Starting Aid Solenoid and Nozzle Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1
Engine Coolant Heater Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0505-2
Group 0510Cooling Systems
Fan Guards and Fan Blade Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1
Fan Belt Remove and Install . . . . . . . . . . . . .05-0510-2
Belt TensionerSpring Tension Check . . . . .05-0510-4
Belt Tensioner Remove and Install . . . . . . . .05-0510-5
Fan Shroud Remove and Install . . . . . . . . . .05-0510-5
Radiator and Oil Cooler Remove and
InstallDirect Drive Machines . . . . . . . . . .05-0510-7
Radiator and Oil Cooler Remove and
InstallTorque Converter Machines . . . .05-0510-11
05

Group 0520Intake System


Air Cleaner Remove and Install. . . . . . . . . . .05-0520-1
Group 0530External Exhaust System
Muffler Remove and Install540G-III,
548G-III, 640G-III, 648G-III . . . . . . . . . . . .05-0530-1
Muffler Remove and Install748G-III . . . . . .05-0530-4
Group 0560External Fuel Supply System
Fuel Tank Remove and Install540G-III,
548G-III, 640G-III. . . . . . . . . . . . . . . . . . . .05-0560-1
Fuel Tank Remove and Install648G-III,
748G-III . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-5

TM2111 (30MAY03)

05-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

05

TM2111 (30MAY03)

05-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 0505

Cold Weather Starting Aids


Starting Aid Solenoid and Nozzle Remove
and Install
1. Remove start aid tubing (A) from nozzle (F).
UN22JAN98

2. Remove nozzle from holder (B).


3. Clean or replace nozzle as required.

T112888

IMPORTANT: Nozzle must be sealed and tight in


holder to prevent engine damage from
dust. Do not overtighten or nozzle may
break.
4. If nozzle holder is removed, apply thread lock and
sealer (medium strength) to male threads of nozzle
holder.

UN15JUN00

5. Apply thread sealant to threads of nozzle.

T131708B

6. Install nozzle into holder with orifice (G) pointing up


toward center of air inlet so fluid is sprayed into
incoming air flow.
7. Connect start aid tubing (A). Tighten tube nut.
Starting Aid Solenoid and NozzleSpecification
Tube-to-Nozzle Holder Nut
Torque ........................................................................... 6.8 Nm (60 lb-in.)

05
0505
1

UN15JUN00

8. Loosen clamp (E) and lift out canister (D). The base is
part of solenoid (C); they must be removed as an
assembly.

IMPORTANT: To avoid drawing dust into engine,


always keep starting fluid canister in
position, or solenoid cap MUST be in
place when canister is not installed.
10. Install canister and tighten clamp. Install solenoid cap
when a canister is not installed.

T131707B

9. Install base and solenoid.

AStart Aid Tubing


BNozzle Holder
CSolenoid
DCanister
EClamp
FNozzle
GNozzle Orifice

CED,OUO1032,3408 1923JAN031/1

TM2111 (30MAY03)

05-0505-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=289

Cold Weather Starting Aids

Engine Coolant Heater Remove and Install

UN01NOV88

CAUTION: Coolant may be hot. Wait until


radiator is cool to the touch before draining
radiator.

T6642EK

1. Drain coolant from radiator into a container. The


approximate cooling system capacity for 6.8 L engine
is 21.5 L (22.7 qt), 8.1 L engine is 30 L (33.8 qt).
Dispose of used coolant properly.

TX,0505,JC576 1923JAN031/2

2. Remove power cord (A). Loosen nut (C) and pull


heating element (G) from block.

UN21OCT88

CAUTION: DO NOT plug coolant heater into


electrical power unless heating element is
immersed in coolant. Element could burst and
result in personal injury.

05
0505
2

3. Put heating element in cylinder block so flats on


threaded portion of element are vertical.
4. Turn element clockwise and then counterclockwise
until element contacts casting. Move element to center
position.
5. Hold element using a wrench and tighten nut (C).

T6427AO

Use a heavy-duty grounded cord to connect


coolant heater to electrical power.

APower Cord
BCap
CNut
DAdapter
EGasket
FO-Ring
GHeating Element

Engine Coolant HeaterSpecification


Heater Element NutTorque .......................................... 34 Nm (25 lb-ft)

IMPORTANT: Air must be removed from cooling


system to prevent cavitation.
6. Loosen engine coolant temperature sender in
thermostat housing or loosen plug at rear of cylinder
head to allow air to escape when filling system.
7. Fill cooling system with proper coolant.See Use
Correct Fuels and Lubricants. (Operators Manual.)
8. Tighten sender or plug when all the air has been
expelled.

TX,0505,JC576 1923JAN032/2

TM2111 (30MAY03)

05-0505-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=290

Group 0510

Cooling Systems
Fan Guards and Fan Blade Remove and
Install
1. If equipped with air conditioning, remove condenser
mounting cap screws move condenser aside.
2. Remove cap screws (1, 4, 5, and 7) to remove fan
guards.
UN27JAN03

3. Remove fan belt (3). See Fan Belt Remove and Install.
(Group 0510.)

T164387B

4. Remove fan (6), and spacer (7).


5. Install spacer.
6. Install fan with convex side of blades toward engine.

Fan Guard (648G-III, 460D Shown)

7. Install cap screws and washers and tighten to


specification.
Fan Guards and Fan BladeSpecification
Fan Blade Cap ScrewM8
Torque ............................................................................. 35 Nm (26 lb-ft)
Fan Blade Cap ScrewM10
Torque ............................................................................. 70 Nm (52 lb-ft)

UN27JAN03

8. Install left and right fan guards.


Fan Guards and Fan BladeSpecification
Fan Guard Cap ScrewTorque ..................................... 39 Nm (29 lb-ft)

T164388B

9. If equipped with air conditioning, install condenser.


Fan Guards and Fan BladeSpecification
Condenser Mounting Cap
ScrewTorque ................................................................ 73 Nm (54 lb-ft)

T162939B

UN17DEC02

1Cap Screw
2Condenser
3Left Side Fan Guard
4Cap Screw
5Cap Screw
6Right Side Fan Guard
7Cap Screw

Air Conditioning Condenser (648G-III, 460D Shown)

CED,OUO1032,3474 1923JAN031/1

TM2111 (30MAY03)

05-0510-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=291

05
0510
1

Cooling Systems

Fan Belt Remove and Install


1. Remove fan guards (6).

T164388B

UN27JAN03

5Cap Screw
6Right Side Fan Guard
7 Cap Screw

TX,05,BA2215 1917OCT021/4

2. Install a 1/2 in. drive wrench (F) into belt tensioner arm
(G) and pull wrench and arm downward to loosen fan
belt (E).

UN22JAN98

3. Remove fan belt from pulleys and lift over fan to


remove.
4. Check belt for wear or damage, replace if necessary.
EFan Belt
F1/2 in. Drive Wrench
GBelt Tensioner Arm

T112908

05
0510
2

648G-III Shown

Continued on next page

TM2111 (30MAY03)

05-0510-2

TX,05,BA2215 1917OCT022/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=292

Cooling Systems

5
4
5
4
3

6
3

T159915
240 x240

T159916

T159916

T159915

UN02OCT02

UN02OCT02

240 x240

8.1 L EngineDashed Line Indicates Machine Without Air


Conditioning

6.8 L EngineWithout Air Conditioning

5
7
4

05
0510
3

T159917

T159917
240 x240

UN02OCT02

T159918

UN02OCT02

2
2

T159918
240 x240

6.8 L EngineDirect DriveWith Air Conditioning

6.8 L EngineTorque ConverterWith Air Conditioning


1Crankshaft Pulley
2Water Pump6.8 L
Engines Only

3Tensioner
4Alternator
5Fan Pulley

6Air Conditioning
CompressorIf Equipped

7Idler6.8 L Engines with


Air Conditioning OnlyIf
Equipped

5. Install fan belt as shown. (Fan belt tension


adjustment is not necessary; belt tension is
self-adjusting.)

Continued on next page

TM2111 (30MAY03)

05-0510-3

TX,05,BA2215 1917OCT023/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=293

Cooling Systems
6. Release belt tensioner.
7. Install fan guard. Tighten to specification.

UN22JAN98

Fan BeltSpecification
Fan Guard Cap ScrewTorque ..................................... 39 Nm (29 lb-ft)

T112908

EFan Belt
F1/2 in. Drive Wrench
GBelt Tensioner Arm

648G-III Shown

TX,05,BA2215 1917OCT024/4

Belt TensionerSpring Tension Check

3. Release tension on tension arm and remove wrench.


4. Put a mark (A) on swing arm of tensioner as shown.
5. Measure 21 mm (0.83 in.) from mark (A) and put a
mark (B) on tensioner mounting base.

T112909

2. Release tension on belt using a 1/2 in. drive wrench on


tension arm. Remove belt from pulleys.

Belt TensionerSpecification
Belt Tensioner SpringDistance .................................... 21 mm (0.83 in.)

7. Record torque wrench measurement and compare with


specification. Replace tensioner as required.
Belt TensionerSpecification
Spring TensionTorque ............................ 1822 Nm (159195 lb-in.)

UN22JAN98

6. Rotate the swing arm using a torque wrench until


marks (A and B) are aligned (C).

T112910

05
0510
4

UN22JAN98

1. Remove right side fan guard.

ASwing Arm Mark


BTensioner Mark
CAligned Marks

TX,05,BA2216 1923JAN031/1

TM2111 (30MAY03)

05-0510-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=294

Cooling Systems

Belt Tensioner Remove and Install


1. Remove right side fan guard.

UN22JAN98

2. Release tension on belt using a 1/2 in. drive wrench.


3. Remove belt from pulleys.

T112911

4. Remove cap screw (A) and belt tensioner (B), leaving


spacer (C) attached to bracket.
5. Install belt tensioner onto spacer. Install and tighten
cap screw (A).
ACap Screw
BBelt Tensioner
CSpacer

Belt TensionerSpecification
Belt Tensioner Cap Screw
Torque ............................................................................. 50 Nm (37 lb-ft)

6. Install belt making sure that belt is correctly seated in


all pulley grooves.
7. Install fan guard.

TX,05,BA2217 1923JAN031/1

Fan Shroud Remove and Install

UN01NOV88

CAUTION: Coolant may be hot. Wait until


radiator is cool to the touch before draining
coolant.

T6642EK

1. Drain coolant from radiator into a container. The


approximate cooling system capacity for 6.8 L engine
is 21.5 L (22.7 qt), 8.1 L engine is 30 L (33.8 qt).
Dispose of used coolant properly.
2. Remove hood and limb risers.See Hood Remove and
Install. (Group 1910.)
3. If equipped with air conditioning, remove condenser
mounting cap screws a move condenser aside.
4. Remove fan guards. See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)
5. Remove grille and grille housing. See Grille and Grille
Housing Remove and Install. (Group 1921.)

Continued on next page

TM2111 (30MAY03)

05-0510-5

TX,05,BA2219 1923JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=295

05
0510
5

Cooling Systems
6. Disconnect upper radiator hose (1).
7. Remove fan shroud cap screws (2).
8. Remove fan blade.See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)
9. Remove fan shroud. Inspect and replace if necessary.
10. Place fan shroud in position towards engine.
11. Install fan blade. See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)

UN05JUN00

12. Install fan shroud and cap screws. Tighten to


specification.

T131357B

Fan ShroudSpecification
Fan Shroud Cap ScrewsTorque .................................. 73 Nm (54 lb-ft)

13. Connect upper radiator hose.


14. Install grille and grille housing.See Grille and Grille
Housing Remove and Install. (Group 0510.)

1Upper Radiator Hose


2Cap Screw (6 used)

15. Install fan guards. See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)
05
0510
6

16. If equipped with air conditioning, install condenser.


Fan ShroudSpecification
Condenser Mounting Cap
ScrewTorque ................................................................ 73 Nm (54 lb-ft)

17. Install hood and limb risers. See Hood Remove and
Install. (Group 1910.)
IMPORTANT: Air must be removed from cooling
system to prevent cavitation.
18. Loosen engine coolant temperature sender in
thermostat housing or loosen plug at rear of cylinder
head to allow air to escape when filling system.
19. Add engine coolant. See Use Correct Fuels and
Lubricants. (Operators Manual.)
20. Tighten sender or plug when all the air has been
expelled.

TX,05,BA2219 1923JAN032/2

TM2111 (30MAY03)

05-0510-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=296

Cooling Systems

Radiator and Oil Cooler Remove and Install


Direct Drive Machines

UN01NOV88

CAUTION: Coolant may be hot. Wait until


radiator is cool to the touch before draining
coolant.

T6642EK

1. Drain coolant from radiator at radiator drain cock (2)


through drain hose (1). The approximate cooling
system capacity for 6.8 L engine is 21.5 L (22.7 qt) 8.1
L engine is 30 L (33.8 qt). Dispose of used coolant
properly.
2. Drain coolant from engine block.

UN29OCT02

3. Remove Hood and limb risers. See Hood Remove and


Install. (Group 1910.)
4. Remove fan guards.See Fan Guards and Fan Blade
Remove and Install in this group.

T160903B

5. Remove air conditioner condenser mounting cap


screws and set condenser aside.
6. Remove radiator over flow reservoir and hose.
1Drain Hose
2Radiator Drain Cock

7. Disconnect horn wire harness.

05
0510
7

8. Remove grille housing and grille. See Grille and Grille


Housing Remove and Install. (Group 1921.)
9. Remove fan shroud cap screws and move shroud
toward engine.

Continued on next page

TM2111 (30MAY03)

05-0510-7

CED,OUO1048,416 1917OCT021/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=297

Cooling Systems
10. Using a vacuum pump to retain oil in reservoir,
disconnect hoses (27). Close all openings with caps
and plugs.

UN27JAN03

11. Disconnect lower radiator hose (1).

T160904B

1Lower Radiator Hose


2Transmission Oil Cooler Bypass
3Hydraulic Oil Cooler Bypass
4Transmission Oil Cooler Outlet
5Hydraulic Oil Cooler Outlet
6Hydraulic Oil Cooler Inlet
7Transmission Oil Cooler Inlet

CED,OUO1048,416 1917OCT022/6

12. Install grille housing-to-radiator cap screws and


washers and shroud-to-radiator cap screws and
washers. Attach lifting straps to cap screws as shown.

T7502DJ

UN16MAY91

05
0510
8

Continued on next page

TM2111 (30MAY03)

05-0510-8

CED,OUO1048,416 1917OCT023/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=298

Cooling Systems
13. Remove nuts and washers (A) from bottom radiator
mounts.
CAUTION: Heavy component; use a hoist.
UN03FEB98

Radiator and Oil CoolerSpecification


Radiator and Oil CoolerWeight .................... 95 kg (210 lb) approximate

T113167

14. Carefully remove radiator and oil coolers with hoist.


ANut and Washer (3 used)

CED,OUO1048,416 1917OCT024/6

15. Install isolators (A) in engine frame, if removed.

T7502EL

UN16MAY91

AIsolators

Continued on next page

TM2111 (30MAY03)

05-0510-9

CED,OUO1048,416 1917OCT025/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=299

05
0510
9

Cooling Systems
16. Install radiator and oil cooler.
17. Install nuts and washers (A).

UN03FEB98

18. Connect lower radiator hose and oil cooler lines.


19. Install fan shroud.

T113167

Radiator and Oil CoolerSpecification


Fan Shroud Cap ScrewsTorque .................................. 73 Nm (54 lb-ft)

20. Install grille housing and grille. See Grille and Grille
Housing Remove and Install. (Group 1921.)
ANut and Washer (3 used)

21. Connect horn wire harness.


22. Install radiator over flow reservoir and hose.
23. Install air conditioner condenser.
24. Install fan guards.See Fan Guards and Fan Blade
Remove and Install in this group.
Radiator and Oil CoolerSpecification
Fan Guard Cap ScrewTorque ..................................... 39 Nm (29 lb-ft)

05
0510
10

25. Install Hood. See Hood Remove and Install. (Group


1910.)
26. Check transmission and hydraulic oil level. See
Check Hydraulic System Oil Level. (Operators
Manual.)
IMPORTANT: Air must be removed from cooling
system to prevent cavitation.
27. Loosen engine coolant temperature sender in
thermostat housing or loosen plug at rear of cylinder
head to allow air to escape when filling system.
28. Fill radiator with proper coolant. See Use Correct
Fuels and Lubricants. (Operators Manual.) Tighten
sender or plug when all the air has been expelled.

CED,OUO1048,416 1917OCT026/6

TM2111 (30MAY03)

05-0510-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=300

Cooling Systems

Radiator and Oil Cooler Remove and Install


Torque Converter Machines

UN01NOV88

CAUTION: Coolant may be hot. Wait until


radiator is cool to the touch before draining the
coolant.

T6642EK

1. Drain coolant from Radiator.


2. Remove cap screw (1).
3. Disconnect wire leads from horn (2) and remove.
4. Remove cap screws and washers (3) and remove
shield (4).

UN05APR01

5. Remove grille and grille housing. See Grille and Grille


Housing Remove and Install. (Group 1921.)

NOTE: Seal all openings using caps and plugs.

T140864B

6. Disconnect hydraulic lines (5 and 6).


7. Remove cap screws and spacers (7).
8. Disconnect upper and lower radiator hoses (9 and 10).

05
0510
11

9. Remove cap screws and washers (8). Set shroud back


towards engine.

T164510B

UN27JAN03

1Cap Screw
2Horn
3Cap Screw and Washer (3 used)
4Shield
5Transmission Oil Cooler Out Line
6Hydraulic Oil Cooler Out Line
7Cap Screw and Spacer (2 used)
8Cap Screw and Washer (4 used)
9Upper Radiator Hose
10Lower Radiator Hose

Continued on next page

TM2111 (30MAY03)

05-0510-11

OUO1017,00003CF 1923JAN031/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=301

Cooling Systems
10. Install JT01748 lifting brackets (5) with cap screws (6)
to radiator.
CAUTION: Heavy component; use a hoist.

UN05APR01

Radiator and Oil CoolerSpecification


Radiator and Oil CoolerWeight ................ 107 kg (235 lbs) approximate

11. Attach a hoist to lifting brackets.

T140867B

12. Disconnect hydraulic hoses (1 and 2).


13. Remove cap screws and nuts (3).
14. Remove nuts (4) from studs.
15. Remove radiator and oil cooler.
16. Repair or replace as required.
IMPORTANT: Rubber isolators must be installed in
frame before radiator is set in place.

18. Connect hydraulic lines (1 and 2).

T140866B

05
0510
12

UN05APR01

17. Install radiator with cap screw and nuts (3) and nuts
(4).

1Hydraulic Oil Cooler Inlet Line


2Transmission Oil Cooler Inlet Line
3Cap Screw and Nut (2 used)
4Nut and Washer (2 used)
5JT01748 Lifting Brackets
6Cap Screw 10.9 M10 X 1.50 25 mm Long (2 used)

Continued on next page

TM2111 (30MAY03)

05-0510-12

OUO1017,00003CF 1923JAN032/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=302

Cooling Systems
19. Install cap screws and spacers (7) and cap screws
and washers (8).
20. Connect radiator hoses (9 and 10).
21. Connect hydraulic lines (5 and 6).
22. Install grille and grille housing. See Grille and Grille
Housing Remove and Install. (Group 1921.)
23. Install rubber shield (4) and cap screws and washers
(3).
24. Connect wiring leads to horn (2) and install horn with
cap screw (1).

26. Fill radiator with coolant. See Use Correct Fuels and
Lubricants. (Operators Manual.) Tighten sender or
plug when all the air has been expelled.

T164510B

25. Loosen engine coolant temperature sender in


thermostat housing or loosen plug at rear of cylinder
head to allow air to escape when filling system

UN27JAN03

IMPORTANT: Air must be removed from cooling


system to prevent cavitation.

05
0510
13

T140864B

UN05APR01

1Cap Screw
2Horn
3Cap Screw and Washer (3 used)
4Shield
5Transmission Oil Cooler Out Line
6Hydraulic Oil Cooler Out Line
7Cap Screw and Spacer (2 used)
8Cap Screw and Washer (4 used)
9Upper Radiator Hose
10Lower Radiator Hose

OUO1017,00003CF 1923JAN033/3

TM2111 (30MAY03)

05-0510-13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=303

Cooling Systems

05
0510
14

TM2111 (30MAY03)

05-0510-14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=304

Group 0520

Intake System
Air Cleaner Remove and Install

T114943

UN24APR98

05
0520
1

ACover
BAdapter
CO-Ring

DRestrictor Switch
EUnloading Valve
FHose Clamp

1. Loosen hose clamp (I) and disconnect hose (H)


from turbocharger.

GMounting Clamps
HHose
IHose Clamp

JWashers (4 used)
KCap Screws (4 used)

2. Remove cap screws (K) and remove air cleaner.

CED,OUO1032,3411 1923JAN031/1

TM2111 (30MAY03)

05-0520-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=305

Intake System

05
0520
2

TM2111 (30MAY03)

05-0520-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=306

Group 0530

External Exhaust System


Muffler Remove and Install540G-III,
548G-III, 640G-III, 648G-III
1. Disconnect battery ground cable.
TX,0530,JC591 1920JUN951/5

CAUTION: Clamps and flexible tube become hot


from exhaust. Allow parts to cool before
removing.

UN23AUG88

2. Loosen clamp (A) to remove exhaust tube.

T7502FM

UN29MAY91

TS271

AClamp

Continued on next page

TM2111 (30MAY03)

05-0530-1

TX,0530,JC591 1920JUN952/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=307

05
0530
1

External Exhaust System

CAUTION: Left riser becomes hot from exhaust.


Allow riser to cool before removal.
CAUTION: Heavy component; use a hoist.
Muffler540G-III, 548G-III, 640G-III, 648G-IIISpecification
Left Cab Riser with Muffler
Weight.............................................................. 45 kg (100 lb) approximate

T7502CM

UN02MAY91

3. Remove left riser with hoist.

Continued on next page

05
0530
2

TM2111 (30MAY03)

05-0530-2

TX,0530,JC591 1920JUN953/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=308

External Exhaust System

T120327

UN11MAR99

05
0530
3

AExhaust Pipe
BWasher (4 used)
CScrew (2 used)
DLock Nut (4 used)

EMuffler
FExhaust Pipe
GCover (2 used)
HScrew (4 used)

IWasher (4 used)
JClamp
KElbow Fitting

Continued on next page

TM2111 (30MAY03)

05-0530-3

LClamp
MU-Bolt (2 used)
NClamp (2 used)

TX,0530,JC591 1920JUN954/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=309

External Exhaust System


4. Remove and install parts as shown.

TX,0530,JC591 1920JUN955/5

Muffler Remove and Install748G-III

UN23AUG88

CAUTION: Clamps and flexible tube become hot


from exhaust. Allow parts to cool before
removing.

TS271

1. Turn battery disconnect switch to OFF position.

TX,05,RB733 1923JAN031/4

T115368

UN14MAY98

05
0530
4

ANuts (4 used)
BWashers (4 used)

CClamp (2 used)
DElbow Fitting

EExhaust Pipe

FHood Cap

2. Remove clamp (C) from elbow fitting (D) and


exhaust pipe (E).

Continued on next page

TM2111 (30MAY03)

05-0530-4

TX,05,RB733 1923JAN032/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=310

External Exhaust System

CAUTION: Left riser becomes hot from exhaust.


Allow riser to cool before removal.
CAUTION: Heavy component; use a hoist.
Muffler748G-IIISpecification
Left Cab Riser with Muffler
Weight.............................................................. 45 kg (100 lb) approximate

T7502CM

UN02MAY91

3. Remove left cab riser.

Continued on next page

TM2111 (30MAY03)

05-0530-5

TX,05,RB733 1923JAN033/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=311

05
0530
5

External Exhaust System

TP54080

UN08JUL97

05
0530
6

1Exhaust Pipe
2Elbow Fitting
3Screw (2 used)

4Muffler
5U-Bolt (4 used)
6Clamp (4 used)

7Washer (8 used)
8Lock Nut (8 used)
9Line

10Exhaust Pipe
11Cap (2 used)
12Clamp

4. Remove and install parts as shown.

TX,05,RB733 1923JAN034/4

TM2111 (30MAY03)

05-0530-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=312

Group 0560

External Fuel Supply System


Fuel Tank Remove and Install540G-III,
548G-III, 640G-III
1. Install locking bar and turn battery disconnect to OFF
position.
2. Drain fuel tank. The approximate fuel tank capacities
are: 540G-III and 640G-III159 L (42 gal), 548G-III
189 L (50 gal).
3. For 540G-III and 640G-III machines remove log arch.
See Log Arch Remove and Install. (Group 3740.) For
548G-III machines fuel tank removal, unhook arch
cylinders.

CED,OUO1032,3079 1923JAN031/6

4. Remove two cap screws (B) and remove frame locking


bar holder and guard (C).

UN23APR98

5. Disconnect fuel tank return line (D) and fuel tank


suction line (E).

T114945B

UN23APR98

T114944B

BCap Screw (2 used)


CGuard
DFuel Return Line
EFuel Suction Line

Continued on next page

TM2111 (30MAY03)

05-0560-1

CED,OUO1032,3079 1923JAN032/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=313

05
0560
1

TP63102

UN30NOV99

External Fuel Supply System

540G-III, 548G-III, 640G-III Fuel Tank


05
0560
2

1Gasket
2Fuel Sending Unit
3Screw (5 used)
4Washer (6 used)
5Cap Screw (2 used)

6Angle
7Washer (2 used)
8Cap Screw (3 used)
9Fuel Tank
10Bushing (2 used)

11Mounting Cap Screw (4


used)
12Flange Nut (2 used)
13Drain Plug
14O-Ring

15Snap Ring
16Gasket
17Filler Cap
18Strainer

6. Disconnect wiring leads from fuel sending unit (2).


7. Remove mounting cap screws (11) and cap screws
(5).

Continued on next page

TM2111 (30MAY03)

05-0560-2

CED,OUO1032,3079 1923JAN033/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=314

External Fuel Supply System

CAUTION: Heavy component; use a hoist.


8. Attach JT01748 Lifting Brackets (A) to fuel tank.
9. Attach D01043AA Load-Positioning Sling to brackets
and an overhead hoist.
10. Remove fuel tank.
11. Inspect parts. Repair or replace as necessary.

T7502FS

UN29MAY91

AJT01748 Lifting Brackets

Continued on next page

TM2111 (30MAY03)

05-0560-3

CED,OUO1032,3079 1923JAN034/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=315

05
0560
3

TP63102

UN30NOV99

External Fuel Supply System

540G-III, 548G-III, 640G-III Fuel Tank


05
0560
4

1Gasket
2Fuel Sending Unit
3Screw (5 used)
4Washer (6 used)
5Cap Screw (2 used)

6Angle
7Washer (2 used)
8Cap Screw (3 used)
9Fuel Tank
10Bushing (2 used)

11Mounting Cap Screw (4


used)
12Flange Nut (2 used)
13Drain Plug
14O-Ring

12. Attach tank as described in removal procedure


and lower into equipment frame.
13. Using a piece of wire, pull sending unit wires
through guard tube on tank.

14. Connect wiring leads to fuel sending unit (2).


15. Install mounting cap screws (11) and cap screws
(5).

Continued on next page

TM2111 (30MAY03)

15Snap Ring
16Gasket
17Filler Cap
18Strainer

05-0560-4

CED,OUO1032,3079 1923JAN035/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=316

External Fuel Supply System


16. Connect fuel tank return line (D) and fuel tank suction
line (E).

UN23APR98

17. Install two cap screws (B) to fasten frame locking bar
holder and guard (C).

T114945B

18. Fill tank with fuel. See Use Correct Fuels and
Lubricants. (Operators Manual.)

T114944B

UN23APR98

BCap Screw (2 used)


CGuard
DFuel Return Line
EFuel Suction Line

CED,OUO1032,3079 1923JAN036/6

Fuel Tank Remove and Install648G-III,


748G-III
1. Install locking bar and turn battery disconnect to OFF
position.
2. Drain fuel tank. The approximate capacities of the fuel
tanks are: 648G-III Single Function265 L (70 gal),
648G-III Dual Function227 L (60 gal), 748G-III273
L (72 gal).
3. For 648G-III and 748G-III machines equipped with dual
function grapple, remove winch. See Winch 4000
Series Remove and Install. (Group 3000.) See Winch
6000 Series Remove and Install. (Group 3000.) For
648G-III and 748G-III machines equipped with single
function grapple, remove locking bar and guard to
remove fuel tank.

Continued on next page

TM2111 (30MAY03)

05-0560-5

CED,OUO1032,3081 1923JAN031/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=317

05
0560
5

External Fuel Supply System


4. Disconnect fuel tank return line (A) and fuel tank
suction line (B).

T8473AE

UN17MAY95

AFuel Return Line


BFuel Suction Line

Continued on next page

CED,OUO1032,3081 1923JAN032/9

05
0560
6

TM2111 (30MAY03)

05-0560-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=318

TP63101

UN30NOV99

External Fuel Supply System

648G-III Single Function

TP63100

UN30NOV99

05
0560
7

648G-III Dual Function and 748G-III


1Gasket
2Fuel Sending Unit
3Screw (5 used)
4Flange Nut (2 used)
5Washer (6 used)

6Cap Screw (2 used)


7Angle
8Washer (2 used)
9Cap Screw (3 used)
10Fuel Tank

11Bushing (2 used)
12Mounting Cap Screw (4
used)
13Drain Plug
14O-Ring
Continued on next page

TM2111 (30MAY03)

05-0560-7

15Snap Ring
16Gasket
17Filler Cap
18Strainer

CED,OUO1032,3081 1923JAN033/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=319

External Fuel Supply System


5. Disconnect wiring leads from fuel sending unit (2).
6. Remove mounting cap screws (12) and cap screws
(6).
CED,OUO1032,3081 1923JAN034/9

CAUTION: Heavy component; use a hoist.


7. Attach JT01748 Lifting Brackets (A) to fuel tank. Attach
D01043AA Load-Positioning Sling to brackets and an
overhead hoist.
8. Remove fuel tank.
9. Inspect parts. Repair or replace as necessary.
AJT01748 Lifting Brackets

T7502FS

UN29MAY91

05
0560
8

Continued on next page

TM2111 (30MAY03)

05-0560-8

CED,OUO1032,3081 1923JAN035/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=320

External Fuel Supply System

CAUTION: Heavy component; use a hoist.


10. Attach JT01748 Lifting Brackets (A) to fuel tank.
Attach D01043AA Load-Positioning Sling to brackets
and an overhead hoist.
11. Lower tank into equipment frame.

T7502FS

UN29MAY91

AJT01748 Lifting Brackets

Continued on next page

TM2111 (30MAY03)

05-0560-9

CED,OUO1032,3081 1923JAN036/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=321

05
0560
9

TP63101

UN30NOV99

External Fuel Supply System

648G-III Single Function

TP63100

UN30NOV99

05
0560
10

648G-III Dual Function and 748G-III


1Gasket
2Fuel Sending Unit
3Screw (5 used)
4Flange Nut (2 used)
5Washer (6 used)

6Cap Screw (2 used)


7Angle
8Washer (2 used)
9Cap Screw (3 used)
10Fuel Tank

11Bushing (2 used)
12Mounting Cap Screw (4
used)
13Drain Plug
14O-Ring
Continued on next page

TM2111 (30MAY03)

05-0560-10

15Snap Ring
16Gasket
17Filler Cap
18Strainer

CED,OUO1032,3081 1923JAN037/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=322

External Fuel Supply System


12. Using a piece of wire, pull sending unit wires
through guard tube on tank.

14. Install mounting cap screws (12) and cap screws


(6).

13. Connect wiring leads to fuel sending unit (2).


CED,OUO1032,3081 1923JAN038/9

15. Connect fuel tank return hose (A) and fuel tank
suction hose (B).
16. Install guard and locking bar into guard holder.
17. Fill fuel tank with fuel. See Use Correct Fuels and
Lubricants. (Operators Manual.)

T8473AE

UN17MAY95

AFuel Return Line


BFuel Suction Line

CED,OUO1032,3081 1923JAN039/9

TM2111 (30MAY03)

05-0560-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=323

05
0560
11

External Fuel Supply System

05
0560
12

TM2111 (30MAY03)

05-0560-12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=324

Section 06

Torque Converter
Contents
Page

Group 0600Removal and Installation


Torque Converter Housing Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-0600-1
Group 0641Torque Converter Housing
Magnetic Speed Sensor Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-0641-1
Torque Converter Housing Disassemble . . . .06-0641-2
Torque Converter Housing Assemble . . . . .06-0641-18
Group 0651Converter Turbine, Gears, and Shaft
Torque Converter Cover, Drive Plate and
Impeller Hub Tightening Sequence . . . . . .06-0651-1
Torque Converter Drive Plate Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .06-0651-2
Torque Converter Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .06-0651-5

06

TM2111 (30MAY03)

06-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

06

TM2111 (30MAY03)

06-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 0600

Removal and Installation


Torque Converter Housing Remove and
Install
1. Remove hydraulic reservoir. See Hydraulic Reservoir
Remove and InstallDirect Drive Machines. See
Hydraulic Reservoir Remove and InstallTorque
Converter Machines. (Group 2160.)

OUO1017,00003C9 1915JAN031/14

2. Remove flywheel access plug (1) and drive plate cap


screw access plug (2).
3. Discard drive plate cap screw access plug (2).
UN27MAR01

4. Install JDE81-1 Flywheel turning tool into access hole


(3).

T140270B

5. Rotate engine until flex plate cap screws can be seen


through hole.
6. Continue to rotate engine and remove eight cap
screws (4).

T140271B

UN27MAR01

1Flywheel Access Plug


2Drive Plate Cap Screw Access Plug
3Access Hole
4Cap Screw (8 used)

Continued on next page

TM2111 (30MAY03)

06-0600-1

OUO1017,00003C9 1915JAN032/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=327

06
0600
1

Removal and Installation


NOTE: Mark or tag wire connectors for ease of assembly.
7. Disconnect wire connectors (1).

NOTE: Close all openings using caps and plugs.


8. Disconnect hydraulic line (2) from hydraulic manifold.

UN27MAR01

9. Remove clamps (3 and 4) from hydraulic reservoir


legs.
10. Lay hydraulic manifold (5) back towards rear of
machine behind torque converter housing and pumps.

T140272B

1Wire Connector (4 used)


2Hydraulic Line-to-Hydraulic Filter Manifold
3Clamp
4Clamp
5Hydraulic Manifold

OUO1017,00003C9 1915JAN033/14

11. Disconnect wire connector (1) and remove clamp (2).


Move harness away from housing towards engine.
12. Disconnect lines (3 and 4) from transmission charge
pump.
13. Remove cap screws (5) from reservoir leg (6).
UN27MAR01

14. Remove reservoir legs from both sides.


1Wire Connector
2Clamp
3Transmission Charge Pump Pressure Line
4Transmission Charge Pump Suction Line
5Cap Screw (6 used)
6Hydraulic Reservoir Leg (2 used)

T140273B

06
0600
2

Continued on next page

TM2111 (30MAY03)

06-0600-2

OUO1017,00003C9 1915JAN034/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=328

Removal and Installation


15. Remove cap screws (1).

UN27MAR01

16. Disconnect drive shaft (2) from torque converter


housing. Lay drive shaft down and towards left side
frame rail.
17. Disconnect wire connector (3).

T140274B

18. Disconnect hydraulic lines (46).

T140275B

UN27MAR01

1Cap Screw (4 used)


2Transmission Drive Shaft
3Temperature Sender Wire Connector
4Converter Out Hydraulic Line
5Converter Line-to-Sump
6Converter In Hydraulic Line

Continued on next page

TM2111 (30MAY03)

06-0600-3

OUO1017,00003C9 1915JAN035/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=329

06
0600
3

Removal and Installation


19. Remove clamp (4) from transmission charge pump.
20. Disconnect hydraulic lines (13) and (58).

T140276B

UN27MAR01

1Hydraulic Oil Cooler Pump-to-Reservoir Line


2Hydraulic Pump Outlet Line
3Hydraulic Pump Case Drain Line
4Clamp
5Differential Lock Pump Inlet Line
6Differential Lock Pump Outlet Line
7Hydraulic Oil Cooler Pump Inlet
Line-from-Reservoir
8Case Drain Line-from-Hydraulic Pump

Continued on next page

OUO1017,00003C9 1915JAN036/14

06
0600
4

TM2111 (30MAY03)

06-0600-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=330

Removal and Installation


21. Attach two JT01748 Lifting Brackets (1) to converter
housing using cap screws (2).
CAUTION: Heavy component; use a hoist.
Torque Converter HousingSpecification
Torque Converter and Torque
Converter HousingWeight ........................ 200 kg (440 lbs) approximate

22. Attach a suitable hoist to lifting brackets.

UN27MAR01

23. Remove cap screws (3) securing housing to engine.


CAUTION: Heavy component; use a hoist.

T140277B

Torque Converter HousingSpecification


Torque ConverterWeight.............................. 32 kg (70 lbs) approximate

CAUTION: Torque converter is not fastened to


housing. Housing must be kept level or slightly
tilted back during removal or torque converter
could slide off.

1JT01748 Lifting Brackets (2 used)


2Cap Screw 10.9 M12 X 1.75 30 mm Long (2
used)
3Cap Screw (12 used)

24. Slide housing towards rear of machine away from


engine.
25. Remove housing and pumps from machine.
26. Repair or replace as required.

OUO1017,00003C9 1915JAN037/14

27. Apply anti-seize lubricant to outside diameter of


converter stub shaft (2) and inside diameter of pilot
sleeve (1), and flywheel pilot bore. Install pilot sleeve
onto stub shaft.

T140746

UN30MAR01

1Pilot Sleeve
2Converter Stub Shaft

Continued on next page

TM2111 (30MAY03)

06-0600-5

OUO1017,00003C9 1915JAN038/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=331

06
0600
5

Removal and Installation


28. Attach lifting brackets (1) to housing using cap screws
(2).
CAUTION: Heavy component; use a hoist.
Torque Converter HousingSpecification
Torque Converter and Torque
Converter HousingWeight ........................ 200 kg (440 lbs) approximate

UN27MAR01

CAUTION: Torque converter is not fastened to


housing. Housing must be kept level or slightly
tilted back during installation or torque
converter could slide off.
29. Attach housing to a suitable hoist and lift into position.

T140277B

30. Use flywheel turning tool if necessary to rotate engine


to aid in assembly and align the pilot sleeve into
engine flywheel.
IMPORTANT: Do not use cap screws to pull engine
and housing together. Damage to pilot
sleeve and housings could result.

1JT01748 Lifting Brackets


2Cap Screw 10.9 M12 X 1.75 30 mm Long (2
used)
3Cap Screw (12 used)

31. Install cap screws (3).

06
0600
6

Continued on next page

TM2111 (30MAY03)

06-0600-6

OUO1017,00003C9 1915JAN039/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=332

Removal and Installation


32. Connect hydraulic lines (13) and (58).
33. Install clamp (4).

T140276B

UN27MAR01

1Hydraulic Oil Cooler Pump-to-Reservoir Line


2Hydraulic Pump Outlet Line
3Hydraulic Pump Case Drain Line
4Clamp
5Differential Lock Pump Inlet Line
6Differential Lock Pump Outlet Line
7Hydraulic Oil Cooler Pump Inlet Line From
Reservoir
8Case Drain Line from Hydraulic Pump

Continued on next page

OUO1017,00003C9 1915JAN0310/14

06
0600
7

TM2111 (30MAY03)

06-0600-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=333

Removal and Installation


34. Connect hydraulic lines (46).
35. Connect wire connector (3).
36. Install Drive shaft (2) with cap screws (1). Tighten
Cap screws to specification.

UN27MAR01

Torque Converter HousingSpecification


Transmission Drive Shaft Cap
ScrewsTorque .............................................................. 58 Nm (43 lb-ft)

T140274B

UN27MAR01

T140275B

1Cap Screw (4 used)


2Transmission Drive Shaft
3Temperature Sender Wire Connector
4Converter Out Hydraulic Line
5Converter Line-to-Sump
6Converter In Hydraulic Line

06
0600
8

OUO1017,00003C9 1915JAN0311/14

37. Install reservoir legs (6) and cap screws (5).


38. Connect hydraulic lines (3 and 4).
39. Connect wire connector (1) and install clamp (2).

T140273B

UN27MAR01

1Wire Connector
2Clamp
3Transmission Charge Outlet Suction Line
4Transmission Charge Pump Suction Line
5Cap Screw (6 used)
6Reservoir Leg (2 used)

Continued on next page

TM2111 (30MAY03)

06-0600-8

OUO1017,00003C9 1915JAN0312/14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=334

Removal and Installation


40. Lift hydraulic manifold (5) and install clamps (3 and 4)
to reservoir legs.
41. Connect hydraulic line (2).
42. Connect wire connectors (1).

T140272B

UN27MAR01

1Wire Connector (4 used)


2Hydraulic Line-to-Hydraulic Filter Manifold
3Clamp
4Clamp
5Hydraulic Manifold

OUO1017,00003C9 1915JAN0313/14

43. Apply medium strength thread lock and sealer to cap


screws (4).

45. Install plugs (1 and 2).


46. Install hydraulic reservoir. See Hydraulic Reservoir
Remove and InstallDirect Drive Machines. See
Hydraulic Reservoir Remove and InstallTorque
Converter Machines. (Group 2160.)

T140270B

UN27MAR01

1Flywheel Access Plug


2Drive Plate Cap Screw Access Plug
3Access Hole
4Cap Screw and Washer (8 used)

T140271B

Torque Converter HousingSpecification


Drive Plate Cap ScrewsTorque ................................... 47 Nm (35 lb-ft)

UN27MAR01

44. Rotate engine and install drive plate cap screws and
washers (4). Tighten to specification.

OUO1017,00003C9 1915JAN0314/14

TM2111 (30MAY03)

06-0600-9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=335

06
0600
9

Removal and Installation

06
0600
10

TM2111 (30MAY03)

06-0600-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=336

Group 0641

Torque Converter Housing


Magnetic Speed Sensor Remove and Install
1. Disconnect wiring connector.
2. Remove cap screws and washers (A).
3. Remove magnetic speed cover (B).

5. Lubricate O-ring.
6. Install new O-ring in groove on magnetic speed sensor
(C).

YZ4094A

NOTE: Install magnetic speed sensor after installing


driven gears.

UN10MAR01

4. Remove magnetic speed sensor with O-ring (C).

7. Push magnetic speed sensor into converter cover.


8. Install magnetic speed cover (B).
9. Install cap screws, lock washer and flat washers (A).

ACap Screws, Lock Washers, and Flat Washers (2


used)
BMagnetic Speed Cover
CMagnetic Speed Sensor and O-Ring

YZ4096A

Magnetic Speed SensorSpecification


Magnetic Speed Sensor Cap
ScrewTorque ............................................................... 10 Nm (89 lb-in.)

UN10MAR01

10. Tighten cap screws.

YZ01324,000006D 1928MAR011/1

TM2111 (30MAY03)

06-0641-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=337

06
0641
1

Torque Converter Housing

Torque Converter Housing Disassemble

YZ4010

UN09MAR01

06
0641
2

Component Identification of Converter


ACharge Pump
BOutput Yoke
COil In-to-Torque Converter
DDrain-to-Sump

EConverter Cover
FOil Out-to-Cooler
GAuxiliary Pump Adapter

HHydraulic Hose
ITorque Converter
JDrive Plate

Continued on next page

TM2111 (30MAY03)

06-0641-2

KMagnetic Speed Sensor


LPump Discharge Port
MPilot Sleeve

OUO1020,00010EF 1915JAN031/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=338

YZ4007

UN10MAR01

Torque Converter Housing

1Cap Screw
2Yoke Washer
3O-Ring
4Yoke
5Oil Seal
6Snap Ring
7Bearing
8Turbine Shaft
9Seal Ring
10O-Ring Plug (2 used)
11Socket Head Cap Screw (2
used)
12Cap Screw (5 used)

13Idler Shaft (2 used)


14O-Ring (2 used)
15Snap Ring Ball Bearing (4
used)
16Idler Gear (2 used)
17Oil Seal
18O-Ring (2 used)
19Converter Cover
20Sealed Bearing
21Driven Gear (2 used)
22Snap Ring Bearing
23Bearing Spacer
24Snap Ring

25O-Ring
26Hydraulic Pump Adapter
Plate
27Cap Screw (4 used)
28O-Ring
29Elbow Fitting and
O-RingsWith Orifice
30Hydraulic Hose
31Elbow Fitting and O-Rings
32Converter Housing
33O-Ring
34Stator Support Tube
35Deflector

Continued on next page

TM2111 (30MAY03)

06-0641-3

06
0641
3

36Cap Screw (7 used)


37Thrust Race
38Needle Thrust Bearing
39Input Gear
40Bearing
41O-Ring (2 used)
42Bearing (2 used)
43Washer (2 used)
44Cap Screw (2 used)
45Lock Washer (2 used)
46Magnetic Speed Cover
47Magnetic Speed Sensor
48O-Ring

OUO1020,00010EF 1915JAN032/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=339

Torque Converter Housing

CAUTION: Heavy component; use a hoist.


Torque Converter HousingSpecification
Torque Converter and Drive
PlateWeight .................................................. 32 kg (70 lbs) approximate

1. Remove torque converter (A).

YZ4097

UN10MAR01

ATorque Converter
BTorque Converter Cover

OUO1020,00010EF 1915JAN033/22

2. Remove hose (A), if not removed.

UN05MAR01

AHose
BFitting-to-Converter Housing
CFitting-to-Converter CoverAuxiliary Pump
Adapter

YZ4050

06
0641
4

3. Remove magnetic sensor, if not removed. See


Magnetic Speed Sensor Remove and Install in this
group.

Continued on next page

TM2111 (30MAY03)

06-0641-4

OUO1020,00010EF 1915JAN034/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=340

Torque Converter Housing


4. Remove parts (AD).

YZ4049

UN05MAR01

ACap Screw
BWasher
CO-Ring
DYoke

OUO1020,00010EF 1915JAN035/22

5. Remove and discard oil seal (A) from housing.

YZ4051

UN05MAR01

AOil Seal

Continued on next page

TM2111 (30MAY03)

06-0641-5

OUO1020,00010EF 1915JAN036/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=341

06
0641
5

Torque Converter Housing


6. Remove snap ring (B).

YZ4052

UN05MAR01

BSnap Ring

OUO1020,00010EF 1915JAN037/22

7. Remove turbine shaft (C) and bearing.

NOTE: Bearing will come out with shaft.


CTurbine Shaft and Bearing

YZ4054

UN05MAR01

06
0641
6

Continued on next page

TM2111 (30MAY03)

06-0641-6

OUO1020,00010EF 1915JAN038/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=342

Torque Converter Housing

CAUTION: Remove cap screw (E) last. Hold


converter housing while removing cap screw
(E). Converter housing could fall or drop
unexpectedly and cause damage to converter
housing or injury.
8. Remove plugs and O-rings (A) from converter side of
converter cover.
UN09MAR01

9. Remove socket head cap screws (B) from converter


cover.

YZ4064

10. Remove idler cap screws (C) and cap screws (D).

YZ4065

UN07MAR01

APlugs and O-Rings (2 used)


BSocket Head Cap Screws (2 used)
CCap Screws (Idler Shaft)
DCap Screws
ECap Screw

Continued on next page

TM2111 (30MAY03)

06-0641-7

OUO1020,00010EF 1915JAN039/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=343

06
0641
7

Torque Converter Housing


11. Remove cap screw (D) while holding onto converter
housing (E).
12. Remove converter housing.

YZ4055

UN07MAR01

YZ4066

UN07MAR01

DCap Screw-to-Front Cover


EConverter Housing

06
0641
8

OUO1020,00010EF 1915JAN0310/22

13. Remove O-rings (F) and input gear (G).

YZ4067

UN07MAR01

FO-Ring (2 used)
GInput Gear

Continued on next page

TM2111 (30MAY03)

06-0641-8

OUO1020,00010EF 1915JAN0311/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=344

Torque Converter Housing


14. Remove needle thrust bearing (A) and thrust race (B).
15. Remove and discard O-ring (C).
16. Remove cap screws (E) and oil deflector (F).
17. Remove stator support tube (D) from converter
housing (G).

YZ4059

UN06MAR01

YZ4058

UN06MAR01

ANeedle Thrust Bearing


BThrust Race
CO-Ring
DStator Support Tube
ECap Screws (7 used)
FOil Deflector
GConverter Housing

Continued on next page

TM2111 (30MAY03)

06-0641-9

OUO1020,00010EF 1915JAN0312/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=345

06
0641
9

Torque Converter Housing


18. Align oil passages and install stator support tube (A)
on converter housing (B).
IMPORTANT: Oil passages and oil deflector must be
in installed correctly to properly direct
oil flow. Install oil deflector (D) with
angle cut flush with outer diameter of
stator support tube (A). Check oil
deflector so tab (E) is below the surface
of thrust race shoulder of stator tube.
19. Install oil deflector (D) and tighten cap screws (C).
Torque Converter HousingSpecification
Stater Support Tube and Oil
Deflector Cap ScrewTorque ........................................ 37 Nm (27 lb-ft)

YZ4060

UN06MAR01

AStator Support Tube


BConverter Housing
CCap Screws (7 used)
DOil Deflector
EOil Deflector Tab

YZ4059A

UN06MAR01

06
0641
10

Continued on next page

TM2111 (30MAY03)

06-0641-10

OUO1020,00010EF 1915JAN0313/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=346

Torque Converter Housing


20. Apply grease to new thrust race (A) and needle thrust
bearing (B) and install on stator support tube.

NOTE: Applying grease to thrust race and needle thrust


bearing holds them in place when installing
converter housing in front cover.
21. Lubricate and install new O-ring (C).
22. Set converter housing with stator support tube aside.

YZ4058A

UN06MAR01

AThrust Race
BNeedle Thrust Bearing
CO-Ring

Continued on next page

OUO1020,00010EF 1915JAN0314/22

06
0641
11

TM2111 (30MAY03)

06-0641-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=347

Torque Converter Housing


23. Remove and discard seal ring (A).
24. Remove and discard bearing (B).

YZ4062

UN06MAR01

ASeal Ring
BBearing

YZ4061

UN06MAR01

06
0641
12

Continued on next page

TM2111 (30MAY03)

06-0641-12

OUO1020,00010EF 1915JAN0315/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=348

Torque Converter Housing


25. Press on new bearing (A), using driver (B).
IMPORTANT: Press on inner race of bearing.
26. Lubricate and install new seal ring (C).
27. Set stator shaft aside.

YZ4063

UN06MAR01

ABearing
BBearing Driver
CSeal Ring

OUO1020,00010EF 1915JAN0316/22

28. Position converter cover converter side up.

NOTE: Use cap screw (A) to pull idler shafts from front
cover bores. The shafts are a slip fit.

06
0641
13

29. Install a cap screw (A) into threaded hole in idler shaft
(B).

UN07MAR01

30. Remove idler shafts (B).


31. Remove and discard O-rings (C and D). O-rings may
stick in idler shaft housing.

YZ4068

32. Inspect idler shafts for wear or damage.


33. Remove oil seal (E) and bearing (F).
ACap Screw
BIdler Shaft (2 used)
CO-Ring (2 used)
DO-Ring (2 used)
EOil Seal
FBearing

Continued on next page

TM2111 (30MAY03)

06-0641-13

OUO1020,00010EF 1915JAN0317/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=349

Torque Converter Housing


34. Position converter cover to have pump ports and
driven gear up.
35. Remove driven gear (A) from charge pump side.

NOTE: O-ring not shown.

UN07MAR01

36. Remove O-ring located in groove of hydraulic pump


adapter plate (B).
37. Remove cap screws (C).

YZ4069

38. Remove hydraulic pump adapter plate (B) and O-ring


(D).
ADriven Gear (Charge Pump Side)
BHydraulic Pump Adapter Plate
CCap Screws (4 used)
DO-Ring

YZ4070

UN07MAR01

Driven Gear and Charge Pump Port

YZ4071

UN07MAR01

06
0641
14

Continued on next page

TM2111 (30MAY03)

06-0641-14

OUO1020,00010EF 1915JAN0318/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=350

Torque Converter Housing


39. Remove snap ring (A).
40. Remove spacer and driven gear.

YZ4072

UN08MAR01

ASnap Ring

OUO1020,00010EF 1915JAN0319/22

41. Remove bearings (C and D) from gear (B) using


puller.
42. Inspect bearings and gear and replace as necessary.

YZ4075

UN09MAR01

BDriven Gear (2 used)


CSnap Ring Bearing
DSealed Bearing

Driven GearAuxiliary Pump Side


Continued on next page

TM2111 (30MAY03)

06-0641-15

OUO1020,00010EF 1915JAN0320/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=351

06
0641
15

Torque Converter Housing


43. Remove idler gear (A) from auxiliary pump port (B).
44. Remove idler gear (C) from charge pump port (D).

YZ4076

UN09MAR01

AIdler Gear
BFront Cover Auxiliary Pump Port
CIdler Gear
DFront Cover Charge Pump Port

UN09MAR01

Idler Gear and Auxiliary Pump Port

YZ4077

06
0641
16

Idler GearCharge Pump Port

Continued on next page

TM2111 (30MAY03)

06-0641-16

OUO1020,00010EF 1915JAN0321/22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=352

Torque Converter Housing


45. Remove bearings (A) from both idler gears (B).

47. Use press to install bearing. Press on bearing outer


race until snap ring contacts outside of gear.

YZ4078

IMPORTANT: Use press to install bearings. Apply


pressure to outer race of bearing until
snap ring contacts outside of gear.

UN08MAR01

46. Inspect bearings and gears for wear or damage.

48. Turn gear over and press bearing into idler gear until
snap ring rests on outside of gear.
49. Repeat for each idler gear.

YZ4079

UN08MAR01

ABearing (2 used)
BIdler Gear

OUO1020,00010EF 1915JAN0322/22

TM2111 (30MAY03)

06-0641-17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=353

06
0641
17

Torque Converter Housing

Torque Converter Housing Assemble


IMPORTANT: Use press to install bearings. Apply
pressure to bearing inner race only.

UN14MAR98

1. Use press to install bearing (A) onto driven gear (B).


Apply pressure to bearing inner race only.
2. Turn gear over and press bearing (C) onto gear.

YZ555

IMPORTANT: Auxiliary pump port driven gear will


have one snap ring bearing (D) and one
sealed bearing (E). Install snap ring
bearing onto gear with snap ring down.
Install sealed bearing onto gear with
seal side away from driven gear.
3. Press snap ring bearing (D) onto driven gear (B) with
snap ring side toward gear.
4. Turn gear over and press sealed bearing (E) onto gear
with seal side away from gear.

YZ4075A

UN09MAR01

ABearing (Charge Pump)


BDriven Gear
CBearing (Charge Pump)
DSnap Ring Bearing (Auxiliary Pump)
ESealed Bearing (Auxiliary Pump)

Driven Gear and Snap Ring BearingAuxiliary Pump Side


06
0641
18

Continued on next page

TM2111 (30MAY03)

06-0641-18

OUO1065,000059C 1915JAN031/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=354

Torque Converter Housing


5. Position front cover with converter side up.
IMPORTANT: Make sure oil seal is flush with machine
surface of housing.

NOTE: If outside diameter of oil seal is not already


coated with a sealer, apply medium strength
thread lock.
UN08MAR01

6. Install oil seal (A).


7. Position converter cover with converter side down.

YZ4082

8. Install bearing (B) into front cover.

YZ4083

UN08MAR01

AOil Seal
BBearing

Continued on next page

TM2111 (30MAY03)

06-0641-19

OUO1065,000059C 1915JAN032/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=355

06
0641
19

Torque Converter Housing


9. Position converter cover with converter side up and
turn housing so auxiliary pump port hangs over work
table.
10. Place idler gear (A) into auxiliary pump port (B).
11. Position idler gear.
UN09MAR01

12. Turn housing so charge pump port hangs over work


table.

YZ4076

13. Install idler gear (C) into charge pump port (D).

UN09MAR01

AIdler Gear
BAuxiliary Pump Port of Converter Cover
CIdler Gear
DCharge Pump Port of Converter Cover

YZ4077

06
0641
20

Continued on next page

TM2111 (30MAY03)

06-0641-20

OUO1065,000059C 1915JAN033/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=356

Torque Converter Housing


NOTE: Hole in idler shaft must line up with bolt hole in
front cover (input housing). Use a bolt to guide the
alignment while installing.
14. Align bearing bore of idler gear (A) with input housing
shaft bore.

UN08MAR01

15. Lubricate O-ring (C) with petroleum jelly and install in


groove on idler shaft.
16. Use petroleum jelly to hold O-ring (B) to the bottom of
the idler shaft during installation.

YZ4084

ALTERNATE O-RING INSTALLATION


PROCEDURE
Position O-ring (B) at bottom of the shaft bore in input
housing.
17. Use bolt (D) to align through hole in idler shaft with
threaded hole in input cover.
18. Push idler shaft (E) through idler gear into input
housing.

UN08MAR01

19. Install the other idler shaft in same manner.

YZ4085

UN08MAR01

YZ4068A

AIdler Gear (2 used)


BO-Ring (2 used)
CO-Ring (2 used)
DBolt
EIdler Shaft (2 used)

Continued on next page

TM2111 (30MAY03)

06-0641-21

OUO1065,000059C 1915JAN034/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=357

06
0641
21

Torque Converter Housing


20. Install driven gear (A) in charge pump port of front
cover.

YZ4069

UN07MAR01

ADriven Gear

OUO1065,000059C 1915JAN035/21

21. Install driven gear with snap ring bearing up and seal
side of bearing (A) down toward torque converter
side.
ABearing (Seal Side)

YZ4086

UN08MAR01

06
0641
22

YZ4148

UN24MAR01

Snap Ring Bearing Up and Seal Side of Bearing Down Toward


Engine Side

Continued on next page

TM2111 (30MAY03)

06-0641-22

OUO1065,000059C 1915JAN036/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=358

Torque Converter Housing


22. Rotate idler gear (A) to align teeth with driven gear
(B).

YZ579

UN14MAR98

AIdler Gear
BDriven Gear

Continued on next page

OUO1065,000059C 1915JAN037/21

06
0641
23

TM2111 (30MAY03)

06-0641-23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=359

Torque Converter Housing


23. Install bearing spacer (C).
CAUTION: Wear eye protection when installing
snap rings.
24. Install snap ring (D) into groove.

YZ4088

UN08MAR01

T163729B

UN14JAN03

CBearing Spacer
DSnap Ring

06
0641
24

Continued on next page

TM2111 (30MAY03)

06-0641-24

OUO1065,000059C 1915JAN038/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=360

Torque Converter Housing


25. Lubricate and install O-ring (E) to hydraulic pump
adapter plate (F).

YZ4071A

UN08MAR01

EO-Ring
FHydraulic Pump Adapter Plate

OUO1065,000059C 1915JAN039/21

IMPORTANT: Install pump adapter plate to front cover


with screw holes (G) positioned so they
are adjacent to screw holes (H) on
housing.
26. Install hydraulic pump adapter plate.
27. Install and tighten cap screws (I).

UN08MAR01

Torque Converter HousingSpecification


Hydraulic Pump Adapter Plate
Cap ScrewsTorque ...................................................... 87 Nm (64 lb-ft)

YZ4089

GHydraulic Pump Adapter Plate Screw Holes


HFront CoverAuxiliary Pump Port Screw Holes
IHydraulic Pump Adapter Plate-to-Front Cover Cap
Screw (4 used)

Continued on next page

TM2111 (30MAY03)

06-0641-25

OUO1065,000059C 1915JAN0310/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=361

06
0641
25

Torque Converter Housing


28. Lubricate and install O-rings (A) to converter cover.
29. Install input gear (B) in housing; mesh with idler
gears.

YZ4090

UN10MAR01

AO-Ring
BInput Gear

OUO1065,000059C 1915JAN0311/21

CAUTION: Hold on to converter housing (C)


while installing cap screw (D) to prevent
component damage.

UN10MAR01

IMPORTANT: Make sure thrust race and needle thrust


bearing are aligned and in place when
installing converter housing into
converter cover.
30. Install converter housing (C) in converter cover.

YZ4055A

31. Install cap screw (D) while holding onto converter


housing. Do not tighten at this time.

UN10MAR01

CConverter Housing
DCap Screw

YZ4066A

06
0641
26

Continued on next page

TM2111 (30MAY03)

06-0641-26

OUO1065,000059C 1915JAN0312/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=362

Torque Converter Housing


32. Install and tighten cap screws (F) to idler shafts.
33. Install and tighten cap screws (E). Tighten cap screw
(D).

UN10MAR01

Torque Converter HousingSpecification


Converter Housing Cap Screw
Torque ............................................................................. 87 Nm (64 lb-ft)

34. Apply high strength thread lock to allen head cap


screws (G) and install. Tighten cap screws.

YZ4093

Torque Converter HousingSpecification


Converter Housing Allen Head
Cap ScrewTorque ........................................................ 87 Nm (64 lb-ft)

DCap Screw
ECap Screw (2 used)
FCap Screw-to-Idler Shafts (2 used)
GAllen Head Cap Screw (2 used)

OUO1065,000059C 1915JAN0313/21

35. Install and tighten plugs (H) to housing.


Torque Converter HousingSpecification
Converter Housing PlugTorque ............................... 186 Nm (137 lb-ft)
06
0641
27

YZ4064A

UN10MAR01

HPlug-to-Housing (2 used)

Continued on next page

TM2111 (30MAY03)

06-0641-27

OUO1065,000059C 1915JAN0314/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=363

Torque Converter Housing


36. Install turbine shaft (I) into converter housing.

YZ4054A

UN10MAR01

ITurbine Shaft

OUO1065,000059C 1915JAN0315/21

37. Install snap ring (J).

UN10MAR01

JSnap Ring

YZ4092

06
0641
28

OUO1065,000059C 1915JAN0316/21

38. Apply medium strength thread lock to outside


diameter of oil seal (K) and install oil seal to converter
housing.

YZ4091

UN10MAR01

KOil Seal

Continued on next page

TM2111 (30MAY03)

06-0641-28

OUO1065,000059C 1915JAN0317/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=364

Torque Converter Housing


39. Apply petroleum jelly to seal inner lip and yoke seal
surface.
40. Install yoke (D).

UN05MAR01

41. Apply high strength thread lock and sealer to cap


screw.
42. Install O-ring (C), washer (B) and cap screw (A).

YZ4049

NOTE: Install washer with number side out.


43. Tighten cap screw to specification.
Output YokeSpecification
Output Yoke Cap ScrewTorque............................... 216 Nm (160 lb-ft)

ACap Screw
BWasher
CO-Ring
DYoke

44. Install magnetic sensor. See Magnetic Speed Sensor


Remove and Install in this group.

Continued on next page

OUO1065,000059C 1915JAN0318/21

06
0641
29

TM2111 (30MAY03)

06-0641-29

G-III and D Series Skidders (S.N. 586337 )


053003

PN=365

Torque Converter Housing


45. Install fitting with orifice (C) to converter cover. (If
removed.)
46. Install fitting (B) to converter housing (if removed).
47. Install hydraulic lube hose (A) to fittings and tighten.
Torque Converter HousingSpecification
Hose Fitting-to-Converter
HousingTorque.......................................................... 12 Nm (106 lb-in.)
Hose Fitting with Orifice-to-Front
CoverPump AdapterTorque .................................. 12 Nm (106 lb-in.)
Hydraulic Lube Hose Fitting
Torque .......................................................................... 16 Nm (142 lb-in.)

YZ4050

UN05MAR01

AHydraulic Lube Hose


BElbow Fitting-to-Converter Housing
CElbow Fitting with Orifice-to-Converter Cover
Auxiliary Pump Adapter

YZ4095

UN10MAR01

06
0641
30

Continued on next page

TM2111 (30MAY03)

06-0641-30

OUO1065,000059C 1915JAN0319/21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=366

Torque Converter Housing


IMPORTANT: Seal ring ends must be hooked
together.

UN25OCT93

48. Apply petroleum jelly to seal ring (A) and install into
groove on impeller hub (B). Lock ends.

YZ4039

UN28FEB01

YZ527

ASeal Ring
BImpeller Hub

Continued on next page

OUO1065,000059C 1915JAN0320/21

06
0641
31

TM2111 (30MAY03)

06-0641-31

G-III and D Series Skidders (S.N. 586337 )


053003

PN=367

Torque Converter Housing

CAUTION: Heavy component; use a hoist.


Torque Converter Specification
Torque Converter and Drive
PlateWeight .................................................. 32 kg (70 lbs) approximate

49. Install torque converter (A) into converter cover (B).


IMPORTANT: Make sure torque converter turns freely
in clockwise rotation.
50. Install pilot sleeve (C) on torque converter. Apply
anti-seize lubricant inside diameter of pilot sleeve.

YZ4097

UN10MAR01

ATorque Converter
BConverter Cover
CPilot Sleeve

YZ4098

UN10MAR01

06
0641
32

OUO1065,000059C 1915JAN0321/21

TM2111 (30MAY03)

06-0641-32

G-III and D Series Skidders (S.N. 586337 )


053003

PN=368

Group 0651

Converter Turbine, Gears, and Shaft

YZ4057

UN06MAR01

Torque Converter Cover, Drive Plate and Impeller Hub Tightening Sequence

Torque Procedure:
All torque values listed apply to non-lubricated plain or
zinc plated cap screws which include only residual oil
of the manufacturer. Do Not Add additional lubricants
unless otherwise specified.

Torque four cap screws at zero, 180, 90 and 270


degrees, in order. This pattern is designated in graphic
using numbers 1, 2, 3 and 4.

Preliminary Torque:

Follow by a circular sequence starting at zero degrees,


which is designated as number 5 in graphic. Continue
torquing in a circular pattern, tightening each cap
screw in line back to zero degrees.

If an impact wrench is used, it must be set below the


final torque required.

1. Drive plate: apply high strength thread lock to drive


plate cap screws and tighten to specification.

Final Torque:

Torque Converter Cover, Drive Plate and Impeller Hub


Tightening SequenceSpecification
Drive Plate Ring Cap Screw
Torque....................................................................... 50 Nm (37 lb-ft)

Values listed must be obtained by a certified torque


wrench.
Torque Sequence:
Use this sequence: torque converter cover, drive plate
and impeller hub for preliminary and final torquing.

2. Torque converter cover: apply high strength thread


lock to torque converter cap screws and tighten to
specification.

Continued on next page

TM2111 (30MAY03)

06-0651-1

YZ01324,000000A 1916JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=369

06
0651
1

Converter Turbine, Gears, and Shaft


Torque Converter Cover, Drive Plate and Impeller Hub
Tightening SequenceSpecification
Torque Converter
Cover-to-Impeller Cap
ScrewsTorque ....................................................... 50 Nm (37 lb-ft)

specification.
Torque Converter Cover, Drive Plate and Impeller Hub
Tightening SequenceSpecification
Impeller-to-Hub Cap Screws
Torque.................................................................... 25 Nm (221 lb-in.)

3. Impeller hub: apply high strength thread lock to


impeller hub cap screws and tighten to

YZ01324,000000A 1916JAN032/2

Torque Converter Drive Plate Remove and


Install

YZ4011

UN27FEB01

ADrive Plate
BRing
CCap Screw (12 used)

06
0651
2

OUO1065,000059D 1916JAN031/4

CAUTION: Heavy component; use a hoist.


Torque Converter Drive PlateSpecification
Torque Converter and Drive
PlateWeight .................................................. 32 kg (70 lbs) approximate

1. Remove torque converter and place on work surface.

YZ4004

UN28FEB01

2. Drain oil through impeller hub, check for contaminants.


Dispose of oil properly.

Continued on next page

TM2111 (30MAY03)

06-0651-2

OUO1065,000059D 1916JAN032/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=370

Converter Turbine, Gears, and Shaft


3. Remove pilot sleeve (A) and cap screws (B).
4. Remove ring (C) and drive plate (D).
5. Inspect for wear or damage. Look closely at drive plate
(D) for signs of fatigue, cracks or elongated bolt holes.

YZ4013

UN27FEB01

YZ4012

UN27FEB01

APilot Sleeve
BCap Screws (12 used)
CRing
DDrive Plate

Continued on next page

TM2111 (30MAY03)

06-0651-3

OUO1065,000059D 1916JAN033/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=371

06
0651
3

Converter Turbine, Gears, and Shaft


6. Install drive plate (A) and ring (B).
7. Apply high strength thread lock to cap screws.

Torque Converter Drive PlateSpecification


Drive Plate Ring Cap Screw
Torque ............................................................................. 50 Nm (37 lb-ft)

YZ4014

9. Apply anti-seize lubricant to inside diameter of pilot


sleeve.

UN27FEB01

8. Install and tighten cap screws (C). See Torque


Converter Cover, Drive Plate and Impeller Hub
Tightening Sequence in this group.

10. Install pilot sleeve (D).

YZ4015

UN27FEB01

ADrive Plate
BRing
CCap Screw (12 used)
DPilot Sleeve

YZ4016

UN27FEB01

06
0651
4

OUO1065,000059D 1916JAN034/4

TM2111 (30MAY03)

06-0651-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=372

Converter Turbine, Gears, and Shaft

YZ4008

UN26FEB01

Torque Converter Disassemble and Assemble

ASeal Ring
BImpeller Hub
CO-Ring
DImpeller
EFlat Washer (12 used)
FCap Screws (12 used)
GThrust WasherThick

HNeedle Thrust Bearing


Large Roller
IThrust WasherThick
JRetainer Ring
KFixed Stator Hub
LStator

MRetainer Ring
NThrust WasherThin
ONeedle Thrust Bearing
Small Roller
PThrust WasherThin
QTurbine

Continued on next page

TM2111 (30MAY03)

06-0651-5

RTurbine Hub
SBearing
TO-Ring
UFront Cover
VFlat Washers (24 used)
WCap Screws (24 used)

YZ01324,0000055 1916JAN031/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=373

06
0651
5

Converter Turbine, Gears, and Shaft


1. Remove cap screws (B) and flat washers (A).
2. Thread two cap screws (D) three to four turns into front
cover to aid front cover removal.
3. Attach two JT05549 Lifting Eyebolts (C) to front cover.

UN27FEB01

IMPORTANT: Tap lightly on cap screws, with a rubber


mallet, until cover separates from the
impeller. Do not use pry bars to remove
front cover (E), damage to aluminum
impeller casting could result.

YZ4017

4. Lift front cover (E) and lightly tap cap screws (D) to
separate front cover and impeller.

YZ4018

UN27FEB01

AWasher (24 used)


BCap Screw (24 used)
CJT05549 Lifting Eyebolt (2 used)
DWasher and Cap Screw (2 used)
EFront Cover

YZ4019

UN27FEB01

06
0651
6

Continued on next page

TM2111 (30MAY03)

06-0651-6

YZ01324,0000055 1916JAN032/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=374

Converter Turbine, Gears, and Shaft


5. Remove and discard O-ring (A).

YZ4020

UN27FEB01

AO-Ring

YZ01324,0000055 1916JAN033/18

6. Remove bearing (A).


7. Remove turbine hub (B).

YZ4022

UN27FEB01

YZ4021

UN27FEB01

ABearing
BTurbine Hub

Continued on next page

TM2111 (30MAY03)

06-0651-7

YZ01324,0000055 1916JAN034/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=375

06
0651
7

Converter Turbine, Gears, and Shaft


8. Remove turbine (C) and inspect for wear or damage.

YZ4023

UN27FEB01

CTurbine

06
0651
8

Continued on next page

TM2111 (30MAY03)

06-0651-8

YZ01324,0000055 1916JAN035/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=376

Converter Turbine, Gears, and Shaft


9. Remove thrust washers (A) and needle thrust bearing
(B).
10. Remove stator (C).

YZ4025

UN27FEB01

YZ4024

UN27FEB01

AThrust WasherThin (2 used)


BNeedle Thrust BearingSmall Roller
CStator

Continued on next page

TM2111 (30MAY03)

06-0651-9

YZ01324,0000055 1916JAN036/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=377

06
0651
9

Converter Turbine, Gears, and Shaft


11. Remove retainer ring (A).
12. Remove fixed stator hub (B).
13. Turn stator (C) over.
14. Remove retainer ring (D).
15. Inspect parts for wear or damage.

YZ4026

UN27FEB01

ARetainer Ring
BFixed Stator Hub
CStator
DRetainer Ring

YZ4027

UN27FEB01

06
0651
10

Continued on next page

TM2111 (30MAY03)

06-0651-10

YZ01324,0000055 1916JAN037/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=378

Converter Turbine, Gears, and Shaft


IMPORTANT: Do not assemble stator incorrectly. The
torque converter will not work properly
and damage to converter will occur.

UN27FEB01

NOTE: In assembly process of torque converter the stator


FRONT and BACK sides will be referred to.
The stator casting is not marked; it must be
identified by characteristics of the cast vanes.

YZ4028

16. The FRONT of stator casting is identified by the


vanes being thicker. The BACK of stator casting is
identified by the vanes being thinner.

YZ4029

UN27FEB01

Front Side of Fixed Stator

Back Side of Fixed Stator

Continued on next page

TM2111 (30MAY03)

06-0651-11

YZ01324,0000055 1916JAN038/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=379

06
0651
11

Converter Turbine, Gears, and Shaft

CAUTION: Wear eye protection when installing


or removing retaining rings.
17. Position stator with back side up.
18. Install retaining ring (A) in groove.

YZ512

UN10MAR98

ARetaining Ring

Continued on next page

YZ01324,0000055 1916JAN039/18

06
0651
12

TM2111 (30MAY03)

06-0651-12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=380

Converter Turbine, Gears, and Shaft


19. Turn stator over, with thick vanes up.
IMPORTANT: Stator hub (B) must be installed with
Front side up as shown.
20. Install fixed stator hub (B) (front side up).
21. Install retaining ring (D) into groove.

YZ4031

UN28FEB01

YZ4104

UN13MAR01

BFixed Stator Hub


CStator
DRetaining Ring

Continued on next page

TM2111 (30MAY03)

06-0651-13

YZ01324,0000055 1916JAN0310/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=381

06
0651
13

Converter Turbine, Gears, and Shaft


22. Remove thrust washers (A) and needle thrust bearing
(B).
23. Remove cap screws (C) and washers (D).

YZ4033

UN28FEB01

YZ4032

UN24MAR01

AThrust WasherThick (2 used)


BNeedle Thrust BearingLarge Roller
CCap Screw (12 used)
DWasher (12 used)

06
0651
14

Continued on next page

TM2111 (30MAY03)

06-0651-14

YZ01324,0000055 1916JAN0311/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=382

Converter Turbine, Gears, and Shaft


24. Lift impeller (A) off impeller hub (B).
25. Remove O-ring (C) and seal ring (D).
26. Inspect splines, seal and bearing surfaces.

YZ4034

UN28FEB01

AImpeller
BImpeller Hub
CO-Ring
DSeal Ring

YZ4035

UN28FEB01

06
0651
15

Continued on next page

TM2111 (30MAY03)

06-0651-15

YZ01324,0000055 1916JAN0312/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=383

Converter Turbine, Gears, and Shaft


27. Lubricate O-ring (A) with petroleum jelly and install on
impeller hub (B).
28. Install impeller (C) on impeller hub (B).
29. Align holes in impeller hub (B) with holes in impeller
(C).

UN28FEB01

YZ4036

UN28FEB01

AO-Ring
BImpeller Hub
CImpeller

YZ4034A

06
0651
16

Continued on next page

TM2111 (30MAY03)

06-0651-16

YZ01324,0000055 1916JAN0313/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=384

Converter Turbine, Gears, and Shaft


30. Clean cap screws (C). Apply cure primer.
31. Apply high strength thread lock to cap screws.
32. Install cap screws (C) and washers (B) and tighten in
correct sequence to specification. See Torque
Converter Cover, Drive Plate and Impeller Hub
Tightening Sequence in this group.

UN28FEB01

Torque ConverterSpecification
Impeller-to-Hub Cap Screws
Torque .......................................................................... 25 Nm (221 lb-in.)

YZ4038

BWasher (12 used)


CCap Screw (12 used)

Continued on next page

YZ01324,0000055 1916JAN0314/18

06
0651
17

TM2111 (30MAY03)

06-0651-17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=385

Converter Turbine, Gears, and Shaft


IMPORTANT: The thrust bearing and thrust washers
used between impeller hub and stator
hub are different from set used between
stator hub and turbine. These have a
smaller outside diameter and larger
diameter needle roller with thicker
thrust washers.
UN26MAR01

33. Lubricate needle thrust bearing and thrust washers


with clean transmission fluid.

YZ4032A

IMPORTANT: Always use new thrust washers and


thrust needle bearings.
34. Install thrust washer (A).
35. Install needle thrust bearing (B).
36. Install thrust washer (C).
37. Install stator (D) with Front side up.

NOTE: If stator is installed improperly it will not turn freely


on thrust bearing.

AThrust WasherThick
BNeedle Thrust BearingLarge Roller
CThrust WasherThick
DFixed Stator
EImpeller

YZ4025A

06
0651
18

UN09MAR01

38. Rotate stator several turns to be sure it is properly


seated on thrust bearing.

Continued on next page

TM2111 (30MAY03)

06-0651-18

YZ01324,0000055 1916JAN0315/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=386

Converter Turbine, Gears, and Shaft

UN09MAR01

IMPORTANT: The thrust bearing and thrust washers


used between the stator hub and
turbine are different from set used
between impeller hub and stator hub.
These have a larger outside diameter
and smaller diameter needle roller with
thinner thrust washers.
39. Lubricate needle thrust bearing and thrust washers
with clean transmission fluid.

YZ4024A

IMPORTANT: Always use new thrust washers and


thrust needle bearings.
40. Install thrust washer (A).

AThrust WasherThin
BNeedle Thrust BearingSmall Roller
CThrust WasherThin
DImpeller

41. Install needle thrust bearing (B).


42. Install thrust washer (C).

Continued on next page

YZ01324,0000055 1916JAN0316/18

06
0651
19

TM2111 (30MAY03)

06-0651-19

G-III and D Series Skidders (S.N. 586337 )


053003

PN=387

Converter Turbine, Gears, and Shaft


43. Install turbine hub (A).
44. Install turbine (B).
45. Lubricate and install bearing (C).

NOTE: Bearing is a slip-fit bearing.

UN28FEB01

46. Rotate turbine several turns to be sure it is properly


seated on thrust bearing.

YZ4041

UN28FEB01

YZ4040

ATurbine Hub
BTurbine
CBearing

06
0651
20

Continued on next page

TM2111 (30MAY03)

06-0651-20

YZ01324,0000055 1916JAN0317/18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=388

Converter Turbine, Gears, and Shaft


47. Lubricate O-ring (A) with petroleum jelly and install.

Torque ConverterSpecification
Front Cover-to-Impeller Cap
ScrewTorque ................................................................ 50 Nm (37 lb-ft)

50. Install drive plate. See Torque Converter Drive Plate


Remove and Install in this group.

YZ4020

49. Install cap screws (D) and washers (C) and tighten in
correct sequence to specification. See Torque
Converter Cover, Drive Plate and Impeller Hub
Tightening Sequence in this group.

UN27FEB01

48. Install front cover (B). Align cap screw holes of front
cover and impeller.

YZ4017A

UN28FEB01

YZ4019A

UN28FEB01

AO-Ring
BFront Cover
CWasher (24 used)
DCap Screw (24 used)

YZ01324,0000055 1916JAN0318/18

TM2111 (30MAY03)

06-0651-21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=389

06
0651
21

Converter Turbine, Gears, and Shaft

06
0651
22

TM2111 (30MAY03)

06-0651-22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=390

Section 07

Damper Drive
Contents
Page

Group 0752Elements
Damper Remove and Install . . . . . . . . . . . . .07-0752-1
Transmission Cold Weather Disconnect
Linkage Repair . . . . . . . . . . . . . . . . . . . . .07-0752-4

07

TM2111 (30MAY03)

07-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

07

TM2111 (30MAY03)

07-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 0752

Elements
Damper Remove and Install
1. Remove engine side shields.
2. Remove drive shaft. See Input Drive Shafts and
U-Joints. (Group 0325.)
3. Remove cap screws (A) to remove cover (B).
For machines equipped with transmission disconnect.
See Transmission Cold Weather Disconnect Linkage
Repair in this group.
UN23APR98

4. Remove cap screws (C) and remove damper (D).

T114951B

ACap Screw (6 used)


BCover
CCap Screw (6 used)
DTorsional Damper
EDowel Pin (2 used) (540G-III, 548G-III, 640G-III,
648G-III)

Continued on next page

TX,07,RB804 1923JAN031/2

07
0752
1

TM2111 (30MAY03)

07-0752-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=393

Elements
5. Position damper (D) on dowel pins (E).
6. Install and tighten cap screws (C).
DamperSpecification
Flywheel-to-Flywheel Housing
Cap ScrewTorque ........................................................ 68 Nm (50 lb-ft)

7. Install cover (B). Tighten cap screws (A).

8. Install drive shaft. See Input Drive Shafts and U-Joints.


(Group 0325.)

T114951B

On machines equipped with transmission disconnect. See


Transmission Cold Weather Disconnect Linkage Repair in
this group.

UN23APR98

DamperSpecification
Flywheel Cover-to-Flywheel
Housing Cap ScrewTorque..................... 104156 Nm (78115 lb-ft)

9. Install engine side shields.


ACap Screw (6 used)
BCover
CCap Screw (6 used)
DTorsional Damper
EDowel Pin (2 used) (540G-III, 548G-III, 640G-III,
648G-III)

TX,07,RB804 1923JAN032/2

07
0752
2

TM2111 (30MAY03)

07-0752-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=394

Elements

07
0752
3

TM2111 (30MAY03)

07-0752-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=395

Elements

Transmission Cold Weather Disconnect Linkage Repair

T120461

UN23MAR99

07
0752
4

Continued on next page

TM2111 (30MAY03)

07-0752-4

TX,0752,JC612 1923JAN031/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=396

Elements
1Yoke
2Nut
3Pin
4Rod
5Spring Pin
6Washer
7Housing
8Cover
9Washer
10Cap Screw (2 used)

11Lever
12Washer (2 used)
13Cap Screw
14Pin
15Pin
16Nut
17Spring
18Plate
19Washer (4 used)
20Cap Screw (4 used)

21Bellcrank
22Washer (4 used)
23Linkage
24Cap Screw
25Cap Screw
26Pin (2 used)
27Cotter Pin (2 used)
28Link
29Ball Joint (2 used)
30Washer (6 used)

31Nut (4 used)
32Cap Screw (3 used)
33Bushing (2 used)
34Screw (2 used)
35Cotter Pin (2 used)
36Flange Nut (2 used)
37Gusset
38Grommet
39Tag
40Disconnect Linkage

1. Remove transmission drive shaft. See Input Drive


Shafts and U-Joints. (Group 0325.)

4. Tighten ball joint-to-housing nut (31) to


specification.

2. Disassemble and assemble parts as shown.

Transmission Cold Weather Disconnect LinkageSpecification


Ball Joint-to-Housing Nut
InitialTorque................................................................ Finger-tighten
Ball Joint-to-Housing Nut
FinalTorque ........................................................... 34 Nm (25 lb-ft)

NOTE: Install bushing (33) into housing (7). Press


bushing into bore until flush. Inline ream bore
ID to 15.916.0 mm (0.6260.630 in.).

5. Remove attaching parts to remove linkage (23).


3. Tighten disconnect housing-to-flywheel housing cap
screws (13 and 20) to specification.
Transmission Cold Weather Disconnect LinkageSpecification
Disconnect
Housing-to-Flywheel Housing
Cap ScrewTorque ............................................. 217 Nm (160 lb-ft)

Continued on next page

TX,0752,JC612 1923JAN032/9

07
0752
5

TM2111 (30MAY03)

07-0752-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=397

Elements

T8483AD

UN15MAY95

07
0752
6

Continued on next page

TM2111 (30MAY03)

07-0752-6

TX,0752,JC612 1923JAN033/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=398

Elements
1Cap Screw (4 used)
2Universal Joint Cross
3Stub Shaft
4Seal
5Cap Screw (6 used)
6Collar
7O-Ring
8Snap Ring
9Inner Collar

10Bushing
11Oil Seal
12Needle Bearing
13Cap Screw (12 used)
14Washer (12 used)
15Cover
16Pipe Plug (2 used)
17Thrust Bearing Race (2
used)

18Needle Thrust Bearing


19Compression Spring
20Sliding Shaft
21Bearing
22O-Ring
23Spline Hub
24Cap Screw (2 used)
25Snap Ring

26Cap
27Bearing Kit
28Disconnect Spline Kit
29Washer (6 used)
30Transmission Disconnect
31Transmission Disconnect
Kit

6. Remove cap screws (1) from stub shaft (3).

9. Remove cap (26).

7. Remove cap screws (13) and washers (14) to


remove disconnect cover (15) from damper.

10. Remove snap ring (25) to pull out stub shaft (3).
11. Remove seal (4) and collar (6) from stub shaft (3).

8. Remove cap screws (5) and washers (29) to


remove collar (6).

TX,0752,JC612 1923JAN034/9

UN11JUL91

CAUTION: Splined hub (A) is spring loaded.


Follow proper procedure to remove splined hub
and collar (B) to prevent personal injury. If
splined hub is removed improperly the spring
will pull hub up against collar.
12. Press collar (B) down.

T7502HR

ASplined Hub
BCollar

07
0752
7
TX,0752,JC612 1923JAN035/9

13. Remove snap ring (A).

T7502HO

UN11JUL91

ASnap Ring

Continued on next page

TM2111 (30MAY03)

07-0752-7

TX,0752,JC612 1923JAN036/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=399

Elements
NOTE: Hydraulic press is shown for removal. If press is
not available, a lead hammer and appropriate
drivers can be used.

T7502HP

UN11JUL91

14. Remove collar to remove sliding shaft, using a 35 mm


disk. Collar is a light press fit.

Continued on next page

TX,0752,JC612 1923JAN037/9

07
0752
8

TM2111 (30MAY03)

07-0752-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=400

Elements

CAUTION: Splined hub is spring loaded. Follow


proper removal procedure to avoid personal
injury.

UN11JUL91

15. Loosen cap screws (B) until heads are exposed.

T7502HQ

16. Install cap screws (A) in lifting holes of splined hub.


Tighten puller cap screws until hub releases.
17. Disassemble parts from cover.
18. Press seal (4) into collar (6) counterbore. Install on
stub shaft (3) with lip on ground diameter of shaft.

ACap Screw1/4 x 1 in. (2 used)


BCap Screw (2 used)

19. Install O-ring (7) on stub shaft (3).


20. Install all bushings and bearings that were removed.
21. Install sliding shaft bushing (10) to specified depth in
sliding shaft (20).
Transmission Cold Weather Disconnect LinkageSpecification
Sliding Shaft BushingDepth ................ 2.1 0.13 mm (0.08 0.005 in.)

22. Install needle bearing (12) flush with bottom of 81 mm


(3.2 in.) diameter cavity in cover (15).
23. Install cover bearing (21) to specified depth below
end surface of cover (15).
Transmission Cold Weather Disconnect LinkageSpecification
Cover BearingDepth ............................... 1717.5 mm (0.670.69 in.)

24. Install parts (1721) in cover (15) as shown.


25. Apply grease between lips of seal. Install oil seal (11)
into cover after installing sliding shaft (20).
07
0752
9

26. Install O-ring (22) into groove of spline hub (23).

Continued on next page

TM2111 (30MAY03)

07-0752-9

TX,0752,JC612 1923JAN038/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=401

Elements
27. Press collar onto sliding shaft past snap ring groove.
Install snap ring (A). Pull collar back against snap
ring.

UN11JUL91

28. Install splined hub (23) on cover (15). Tighten cap


screws (24) to specifications.

T7502HP

Transmission Cold Weather Disconnect LinkageSpecification


Splined Hub-to-Cover Cap
ScrewTorque ............................................................. 14 Nm (124 lb-in.)

29. Apply grease to splines of stub shaft (3). Install cover


with splined hub assembly onto stub shaft (3).
30. Install snap ring (25) in stub shaft groove.

UN11JUL91

31. Install washers (29) into collar (6) counterbores. Apply


thread lock and sealer (medium strength) on cap
screws (5). Install and tighten to specification. Tighten
again.

32. Apply plastic gasket into bore of cap (26) and drive
into splined hub (23).

T7502HO

Transmission Cold Weather Disconnect LinkageSpecification


Collar-to-Collar Cap Screw
InitialTorque .............................................................. 14 Nm (124 lb-in.)
Collar-to-Collar Cap Screw
FinalTorque ............................................................... 14 Nm (124 lb-in.)
ASnap Ring

33. Install and tighten cap screws (13).


Transmission Cold Weather Disconnect LinkageSpecification
Cover-to-Damper Cap Screw
Torque ........................................................................... 113 Nm (83 lb-ft)

34. Remove plug (16) and add 118.4 mL (4 oz.) hydraulic


oil in cover (15).
07
0752
10

35. Install and tighten cap screws (1).


Transmission Cold Weather Disconnect LinkageSpecification
Universal Joint-to-Stub Shaft
ScrewTorque ................................................................ 60 Nm (45 lb-ft)

36. Install parts to attach linkage (23).


37. Adjust disconnect linkage. See Cold Weather
Disconnect Linkage Adjustment. (Group 9020.)

TX,0752,JC612 1923JAN039/9

TM2111 (30MAY03)

07-0752-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=402

Section 09

Steering System
Contents
Page

Group 0930Secondary Steering


Secondary Steering Pump. . . . . . . . . . . . . . .09-0930-1
Group 0960Hydraulic System
Steering Valve. . . . . . . . . . . . . . . . . . . . . . . .09-0960-1
Steering Cylinder. . . . . . . . . . . . . . . . . . . . . .09-0960-9

09

TM2111 (30MAY03)

09-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

09

TM2111 (30MAY03)

09-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 0930

Secondary Steering
Secondary Steering Pump Remove and
Install

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

X9811

1. Remove right engine side shields.


2. Turn battery disconnect switch to OFF position.
3. Operate all hydraulic controls to release pressure in
the hydraulic system.
4. Disconnect wiring harness connectors (1) from
secondary steering pump and motor (5).
5. Disconnect lines (2 and 3) from secondary steering
pump (5). Close openings using caps and plugs.
6. Remove cap screws (4) to remove secondary steering
pump (5).

UN15JUN00

7. Inspect and replace components, as required.

T131611B

1Wiring Harness Connectors (3 used)


2Secondary Steering Pump-to-Inlet Manifold Port E
Line
3Oil Filter-to-Secondary Steering Pump Line
4Cap Screw (3 used)
5Secondary Steering Pump and Motor

Continued on next page

OUT3035,00002F6 1909DEC021/3

09
0930
1

TM2111 (30MAY03)

09-0930-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=405

Secondary Steering

T162674

UN11DEC02

09
0930
2

Secondary Steering Hydraulic System

Continued on next page

TM2111 (30MAY03)

09-0930-2

OUT3035,00002F6 1909DEC022/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=406

Secondary Steering
1Inlet Manifold B
Port-to-Steering Valve Port
P Line
2Inlet Manifold Port
D-to-Hydraulic Reservoir
Line
3Secondary Steering
Pump-to-Inlet Manifold Port
E Line
4Oil Filter-to-Secondary
Steering Pump Line
5Priority Valve Port
CF-to-Inlet Manifold Port A
Line
6Priority Valve Port T-to-Inlet
Manifold Port D Line

7Tee
8O-Ring (7 used)
9Adapter
10O-Ring (2 used)
11O-Ring (2 used)
12Adapter (2 used)
13Secondary Steering Pump
and Motor
14Plate (540G-III, 548G-III,
640G-III, 648G-III, 360D,
460D)
Plate (748G-III, 560D)
15Bracket
16Adapter
17Strap
18O-Ring

8. Install secondary steering pump and motor (13).


9. Connect hoses (3 and 4) to pump.

19O-Ring (2 used)
20O-Ring
2190 Elbow
22Cap Screw (3 used)
23Cap Screw (2 used)
24O-Ring
2590 Elbow (2 used)
26O-Ring (2 used)
27Tee
28O-Ring (3 used)
2945 Elbow
30O-Ring (2 used)
31Inlet Manifold
32Check Valve
33Pressure Switch

34Plug
35Cap Screw (2 used)
36Cap Screw
37Nut
38Not Used
39O-Ring
40Wiring Harness Connector
41Priority Valve
42Cap Screw
43Clamp
44Spacer
45Load Center Harness
46To Starter
47To Secondary Steering
Motor

12. Check hydraulic oil level in the hydraulic reservoir


before starting engine. See Check Hydraulic
System Oil Level. (Operators Manual.)

10. Connect wiring harness connectors (47) to motor.


11. Turn battery disconnect to ON position. Install
engine side shields.

OUT3035,00002F6 1909DEC023/3

09
0930
3

TM2111 (30MAY03)

09-0930-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=407

Secondary Steering

09
0930
4

TM2111 (30MAY03)

09-0930-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=408

Group 0960

Hydraulic System
Steering Valve Repair
Remove Steering Valve

UN15JUN00

1. Operate hydraulic control valves to relive pressure in


the hydraulic system.

T131633B

2. Remove cap screws (1) to remove lower console (2).


As necessary, remove the fire extinguisher and
windshield washer tank.
3. Remove the cap screw from lower end of universal
joint (4).
4. See Hydraulic Cab Tilt Procedure. (Operators Manual.)

T131635B

UN15JUN00

1Cap Screw (4 used)


2Lower Console
3Lower Steering Column
4Universal Joint

Continued on next page

OUT3035,00002F7 1926SEP021/11

09
0960
1

TM2111 (30MAY03)

09-0960-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=409

Hydraulic System

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
5. Before disconnecting the hydraulic lines (59), take
notice of the orientation of fittings and lines.

X9811

Identify lines to aid in assembly. Close openings using


caps and plugs.
6. Remove nuts and washers (9) to remove steering
valve (8). Seal may come with the valve or remain
stuck to the platform.

T162771B

UN16DEC02

5Port T-to-Return Oil Filter Line


6Priority Valve Port CF-to-Port P Line
7Port L-to-Steering Cylinders Line
8Port R-to-Steering Cylinders Line
9Port LS-to-Priority Valve Port LS Line
10Steering Valve
11Flange Nut (3 used) and Washer (6 used)

Steering ValveTorque Converter Machine

OUT3035,00002F7 1926SEP022/11

7. Take notice of position and location of rubber isolators


(13).

12Lower Steering Column


13Rubber Isolator (3 used)
14Cap Screw (4 used)
15Mounting Plate

T162768

09
0960
2

UN12DEC02

8. Remove cap screws (14) to remove mounting plate


(15) and lower steering column (12).

Continued on next page

TM2111 (30MAY03)

09-0960-2

OUT3035,00002F7 1926SEP023/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=410

T162227B

UN04DEC02

Hydraulic System

Figure 1-Steering Valve Components

Disassemble and Assemble Steering Valve

Use wooden blocks or similar material


to protect steering valve. Tighten vise
just enough to hold valve.
Overtightening can damage the valve.
1

1. Put steering valve in a vise with the gerotor end up.


Tighten just enough to hold valve.

Figure 2-Cap Screws


1Cap Screw (7 used)
2Pins (2 used)
3Anti-Cavitation Steel Balls (2 used)
4End Cap
7Spool
8Gerotor Star
9Gerotor Housing
10Plate Spacer
11Lower Steering Column
12Mounting Plate
13Housing

2. Remove the two cap screws (1, Figure 2) to remove


pins (2, Figure 1) and anti-cavitation steel balls (3).
3. Remove the remaining cap screws to remove end cap
(4), gerotor star (8), gerotor housing (9) and plate
spacer (10).
4. Hold spool (7) and reposition valve with lower steering
column (11) end up.

Continued on next page

TM2111 (30MAY03)

T162221

UN12DEC02

IMPORTANT: Perform all service on steering valve in


a clean isolated work area. Use proper
tools, cleaning material, and lubricants.

09-0960-3

09
0960
3

OUT3035,00002F7 1926SEP024/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=411

Hydraulic System
5. Remove mounting plate (12) and lower steering
column.

OUT3035,00002F7 1926SEP025/11

6. Assemble tool using a M10 x 120 mm cap screw (22)


and two nuts (28).
7. Install cap screw into housing so head engages into
input spline.
8. Hold drive spline head (20) with 20 mm socket (21).

UN04DEC02

IMPORTANT: Spring tension must be compressed


before spool (7) is removed.
9. Rotate cap screw using a wrench to compress spring
tension.

T162215B

10. Push spool (7) down out of housing (13) while spring
tension is compressed.
Figure 3-Spring Compression Tools

Be careful not to remove pin (14, Figure 6) from spool


(7) and drive spline (19, Figure 6).
11. Inspect all parts for contamination, nicks and burrs.

UN04DEC02

Spool is not serviceable. Do not disassemble spool.

T162222B

12. Replace O-rings (18, Figure 5), dust seal (24, Figure
5), backup washer (25, Figure 5) and seals (26, 27,
Figure 5).
7Spool
13Housing
20Spline Head
2120 mm Socket
22M10 x 120 mm Cap Screw
28Nuts

Figure 4-Spool Removed From Housing

09
0960
4

Continued on next page

TM2111 (30MAY03)

09-0960-4

OUT3035,00002F7 1926SEP026/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=412

Hydraulic System

18

26

25

T162216

24

UN20DEC02

27

T162216

Figure 5-Seal Placement


18O-Ring (3 used)
24Dust Seal

25Backup Washer

26Seal

27O-Ring

13. Lubricate O-rings (18 and 27) and seals (24 and
26) with TY24416 Multi-Purpose HD Lithium
Complex Grease. If petroleum jelly is used for
O-ring lubrication, use small enough amount to
avoid spreading on surfaces of other parts.

15. Install spool (7, Figure 1) by compressing spring


tension.

14. Lubricate spool with clean hydraulic oil to ease


assembly.

17. Rotate cap screw (22, Figure 4) using wrench on


nuts (28, Figure 4) to compress spring tension.

16. Hold drive spline head (20, Figure 4) with 20 mm


socket (21, Figure 4).

IMPORTANT: Make sure drive pin (14, Figure 6)


does not slip out of spool and drive
spline.

Continued on next page

OUT3035,00002F7 1926SEP027/11

09
0960
5

TM2111 (30MAY03)

09-0960-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=413

Hydraulic System
IMPORTANT: Timing of drive with respect to gerotor
star is critical.

18. Drive pin (14) must be aligned with valley (minor


diameter) of gerotor star.
19. Align pin (14), drive spline (19) and gerotor star (8) as
shown.

9
17

18

20. Install plate spacer (10).

10

21. Install gerotor star (8) and gerotor housing (9).

18

22. Install end cap (4, Figure 1).


19
23. Apply pipe sealant to bottom side of cap screw (1,
Figure 1) heads.
16
UN02DEC02

24. Install the cap screws except in the holes (1, Figure
2) for anti-cavitation steel balls (3, Figure 1) and pins
(2, Figure 1).

14

26. Install remainder cap screws.

T160389

25. Install anti-cavitation steel balls and pins.


15
Figure 6-Component Alignment

8Gerotor Star
9Gerotor Housing
10Plate Spacer
14Drive Pin
15Alignment Line
16Alignment Line
17Alignment Line
18O-Ring (3 used)
19Drive Spline

Continued on next page

OUT3035,00002F7 1926SEP028/11

09
0960
6

TM2111 (30MAY03)

09-0960-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=414

Hydraulic System
IMPORTANT: Any cap screw can be tightened first,
but the sequence shown must be
followed.
2

Steering ValveSpecification
Initial TorqueEnd
Cap-To-Housing Cap Screw
Torque ................................................................ 17 Nm (150 lb-in.) Initial
Final TorqueEnd
Cap-To-Housing Cap Screw
Torque ................................................................. 34 Nm (300 lb-in.) Final

T160436

27. Tighten cap screws to the initial specification in the


tightening sequence (17). Then tighten in sequence
to final specification.

UN17OCT02

Figure 7-Tightening Sequence


17Tightening Sequence

OUT3035,00002F7 1926SEP029/11

Install Steering Valve


1. Install lower steering column (12).

UN12DEC02

2. Install mounting plate (15) so the side with single


rubber isolator (13) is towards the port T and P corner
of steering valve.

T162768

3. Install cap screws (14). Tighten to specification.


Steering ValveSpecification
Mounting Plate and Lower
Steering Column-to-Steering
Valve Cap ScrewTorque ........................................... 26 Nm (234 lb-in.)

12Lower Steering Column


13Rubber Isolator (3 used)
14Cap Screw (4 used)
15Mounting Plate

4. Install the seal.

Continued on next page

OUT3035,00002F7 1926SEP0210/11

09
0960
7

TM2111 (30MAY03)

09-0960-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=415

Hydraulic System
5. Install one washer on each stud.

UN15JUN00

CAUTION: Cab door is heavy. Use caution when


opening cab door while cab is tilted.

T131635B

6. With the help of an assistant working through the right


cab door, install steering valve (10) so the splines of
lower steering column (3) engage splines in lower
universal joint (4) with the flat on shaft towards the cap
screw side of universal joint.
7. Install washers and flange nuts (11).
8. Install cap screw in universal joint.
9. Check that splines are engaged to specification.
Steering ValveSpecification
Lower Steering Column-to-Lower
Universal Joint Spline
EngagementDistance .................................... 19 mm (0.75 in.) minimum

10. Connect lines (59).


UN16DEC02

11. Lower the cab. Check that lines do not become


pinched as cab is lowered. Adjust the angle of elbows
and hoses as necessary.

1Cap Screw (4 used)


2Console Cover
3Lower Steering Column
4Universal Joint
5Port T-to-Return Oil Filter Line
6Priority Valve Port CF-to-Port P Line
7Port L-to-Steering Cylinders Line
8Port R-to-Steering Cylinders Line
9Port LS-to-Priority Valve Port LS Line
10Steering Valve
11Flange Nut (3 used) and Washer (6 used)

T162771B

12. Install lower console cover (2). Install cap screws (1).

T131633B

UN15JUN00

Steering ValveTorque Converter Machine

09
0960
8

OUT3035,00002F7 1926SEP0211/11

TM2111 (30MAY03)

09-0960-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=416

Hydraulic System

Steering Cylinder Remove and Install

1
3

2. Operate all controls to release hydraulic pressure.


6

3. Remove engine frame shields.

T162743

4. Disconnect lines (6 and 7) at rod and head end of


steering cylinder (5). Close openings using caps and
plugs.

4
1

T162743

1. Install frame locking bar.

UN18DEC02

CAUTION: Avoid possible injury from


unexpected machine movement. Install frame
locking bar before working in frame hinge area.

1Cap Screw (2 used)


2Lock Nut (2 used)
3Pin (2 used)
4Thrust Washer (as required)
5Steering Cylinder
6Rod End-to-Steering Valve Line
7Head End-to-Steering Valve Line

5. Remove lock nuts (2) and cap screws (1) to remove


pins (3) and thrust washer (4).
CAUTION: Heavy component; use a hoist.
Steering CylinderSpecification
540G-III, 548G-III and 360D
Steering CylinderWeight ............................. 22.7 kg (50 lb) approximate
640G-III, 648G-III, and 460D
Steering CylinderWeight ............................. 27.3 kg (60 lb) approximate
748G-III and 560D Steering
CylinderWeight ............................................... 36 kg (80 lb) approximate

6. Remove the cylinder.


7. Repair or replace cylinder.
See Disassemble Cylinder and See Assemble Cylinder
for repair procedures. (TM-H120A.)
8. Install cylinder so work ports are on the bottom, and
cap screw hole in rod end clevis is on top.
9. Install thrust washers (4) to center cylinder clevises on
the mounting plates.
10. Install the pins (3).
09
0960
9

11. Install cap screws and lock nuts. Tighten to


specifications.

Continued on next page

TM2111 (30MAY03)

09-0960-9

OUT3035,00002F8 1926SEP021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=417

Hydraulic System
Steering CylinderSpecification
Cylinder-to-Pin Cap Screw and
Lock NutTorque ........................................................... 27 Nm (20 lb-ft)

12. Connect hydraulic lines.

OUT3035,00002F8 1926SEP022/2

09
0960
10

TM2111 (30MAY03)

09-0960-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=418

Section 10

Service Brakes
Contents
Page

Group 1011Active Elements


Service Brake Lining Inspection . . . . . . . . . .10-1011-1
Group 1015Controls Linkage
Service Brake Pedal . . . . . . . . . . . . . . . . . . .10-1015-1
Group 1060Hydraulic System
Service Brake Valve . . . . . . . . . . . . . . . . . . .10-1060-1
Brake Accumulator . . . . . . . . . . . . . . . . . . . .10-1060-3

10

TM2111 (30MAY03)

10-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

10

TM2111 (30MAY03)

10-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 1011

Active Elements
Service Brake Lining Inspection

2. See External Service Brake Inspection for inspection


procedure. (Operators Manual.)
3. Replace brake disk as necessary.

T7417AO1

Remove rear cover plate for access to rear axle brake


inspection port plug (B).

UN02JAN91

1. Lower front bottom guard for access to front axle brake


inspection port plug (A).

See Disassemble and Assemble Brakes for further


inspection and replacement of brake disk. (CTM43.)

T131535B

AFront Axle Brake Inspection Port Plug (2 used)


BRear Axle Brake Inspection Port Plug (2 used)

UN08JUN00

See Axle Identification before beginning repair or


adjustment to become familiar with the axle and
differential configuration. (CTM43.)

OUT3035,0000339 1912DEC021/1

10
1011
1

TM2111 (30MAY03)

10-1011-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=421

Active Elements

10
1011
2

TM2111 (30MAY03)

10-1011-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=422

Group 1015

Controls Linkage

TP63164

UN15APR00

Service Brake Pedal Remove and Install

1Spring
2Bushing (2 used)
3Spring Pin

4Pedal
5Cap Screw (2 used)
6Nut

7Support
8Shaft

1. Remove spring pin (3).

9Cap Screw (3 used)


10Washer (3 used)

4. Perform Brake Pedal Adjustment to adjust


clearance between pedal and brake valve plunger.
(Operators Manual.)

2. Slide out shaft (8).


3. Inspect parts for wear or damage. Replace parts as
necessary.

OUT3035,000033A 1912DEC021/1

10
1015
1

TM2111 (30MAY03)

10-1015-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=423

Controls Linkage

10
1015
2

TM2111 (30MAY03)

10-1015-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=424

Group 1060

Hydraulic System
Service Brake Valve Repair
Remove and Install Service Brake Valve
1. Operate all hydraulic functions, including service
brakes, to relieve pressure in the hydraulic system.
Actuate the brake pedal 20 times at one-second
intervals to relieve oil pressure from brake
accumulator.
2. Perform Hydraulic Tilt Cab Procedure for access to
service brake valve. (Operators Manual.)

OUT3035,0000302 1914OCT021/4

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
3. Identify lines to aid in assembly.

X9811

Disconnect lines (25). Close openings using caps


and plugs.
4. Disconnect wiring connectors for the de-clutch
pressure switch (TC only) (6) and service brake
pressure switch (7).

T161600C

UN17DEC02

1Service Brake Valve


2Port BS-to-Front Axle Service Brake Pistons Line
3Port BR-to-Rear Axle Service Brake Pistons Line
4Brake Accumulator-to-Port P Line
5Port T-to-Hydraulic Reservoir Line
6De-Clutch Pressure Switch (TC Only)
7Service Brake Pressure Switch

Continued on next page

TM2111 (30MAY03)

10-1060-1

OUT3035,0000302 1914OCT022/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=425

10
1060
1

Hydraulic System

CAUTION: Cab door is heavy. Use caution when


opening cab door while cab is tilted.
5. While holding valve in place, have an assistant,
working through right cab door, remove cap screws (F)
to remove valve.
6. Repair or replace service brake valve as necessary.
7. Install fittings and pressure switch.

UN10APR98

Service Brake ValveSpecification


Fitting to HousingTorque .............................. 2739 Nm (2029 lb-ft)
Service Brake Pressure Switch to
HousingTorque.......................................................... 12 Nm (106 lb-in.)

T114341B

8. Install valve. Install and tighten cap screws.


Service Brake ValveSpecification
Cab Platform-to-Valve Cap
ScrewTorque .............................................. 2332.5 Nm (1724 lb-ft)
FCap Screw (2 used)

9. Connect the lines and wiring connectors.


10. Lower the cab. Check that lines do not become
pinched as cab is lowered. Adjust angle of elbows
and hoses as necessary.
11. Perform Brake Pedal Adjustment to adjust clearance
between pedal and brake valve plunger. (Operators
Manual.)
CAUTION: Before operating machine, the brake
bleed procedure must be done to remove air
from service brake hydraulic system.
12. See Service Brake Bleeding Procedure before
operating machine. (Group 9025-20.)

Continued on next page

OUT3035,0000302 1914OCT023/4

10
1060
2

TM2111 (30MAY03)

10-1060-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=426

Hydraulic System
Disassemble and Assemble Brake Valve

UN23APR91

IMPORTANT: Perform all service on brake valve in a


clean isolated work area. Use proper
tools, cleaning material and lubricants.
Disassemble valve for cleaning and inspection only. Only
a seal repair kit is available for service.

T7516AO

If any parts, except seals, are damaged, replace the valve


as a complete assembly.

T7516AP

UN23APR91

ABoot
BPlug
CO-Ring
DSpring
ESpool
FValve Housing
GSeal
HSpring Retainer
ISpring
JSpring Retainer
KSpring
LPlunger
MO-Ring
NPlug
OPlug
PO-Ring

OUT3035,0000302 1914OCT024/4

Brake Accumulator Remove and Install


1. Operate all hydraulic functions including brakes to
relieve pressure in the hydraulic system. Depress
brake pedal at one-second intervals approximately 20
times to relieve pressure from brake accumulator.

10
1060
3

Continued on next page

TM2111 (30MAY03)

10-1060-3

TX,10,RB679 1901NOV021/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=427

Hydraulic System
2. For direct drive machine, remove right rear engine side
shield for access to brake accumulator (1).

UN17DEC02

Perform Hydraulic Tilt Cab Procedure for access to


brake accumulator on torque converter machine.
(Operators Manual.)

T114343C

1Brake Accumulator
2Cap Screw, Lock Nut, Spacer, and Clamp (2 used)
(Direct Drive Machine)

Right Side of Direct Drive Machine

Continued on next page

TX,10,RB679 1901NOV022/4

10
1060
4

TM2111 (30MAY03)

10-1060-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=428

Hydraulic System

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
3. Identify lines before disconnecting to aid in assembly.

X9811

Disconnect tee (5) from inlet check valve fitting (4).


Disconnect line (7) from adapter (3). Use adapter in
the new accumulator. Close all openings using caps
and plugs.

NOTE: The inlet check valve fitting is serviced with the


brake accumulator.
4. For direct drive machines, remove cap screws, lock
nuts, spacers, and clamps (2) to remove accumulator
(1).
For torque converter machine, remove cap screws,
washers, and clamps to remove accumulator.

UN17DEC02

5. For direct drive machines, install accumulator so the


inlet check valve fitting is towards the center of
machine.

T114342C

For torque converter machines, install accumulator so


inlet check valve fitting is towards the cab platform.
6. Install new decal on accumulator.
1Brake Accumulator
2Cap Screw, Lock Nut, Spacer, and Clamp (2 used)
(Direct Drive Machine)
Cap Screw, Washer, and Clamp (2 used) (Torque
Converter Machine)
3Adapter
4Inlet Check Valve Fitting
5Tee
6To Grapple Rotate Solenoid Valve
7From Priority Valve (Direct Drive Machine)
From Main Hydraulic Pump (Torque Converter
Machine)
8To Service Brake Valve

T162935B

UN17DEC02

Brake AccumulatorDirect Drive Machine

Brake AccumulatorTorque Converter Machine

10
1060
5

Continued on next page

TM2111 (30MAY03)

10-1060-5

TX,10,RB679 1901NOV023/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=429

Hydraulic System

CAUTION: Before operating machine, the brake


bleed procedure must be done to remove air
from hydraulic system.
7. See Service Brake Bleeding Procedure before
operating machine. (Group 9025-20.)

TX,10,RB679 1901NOV024/4

10
1060
6

TM2111 (30MAY03)

10-1060-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=430

Section 11

Park Brake
Contents
Page

Group 1111Active Elements


Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . .11-1111-1
Group 1160Hydraulic System
Park Brake Solenoid Valve . . . . . . . . . . . . . .11-1160-1

TM2111 (30MAY03)

11-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

11

Contents

11

TM2111 (30MAY03)

11-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 1111

Active Elements
Park Brake Remove and Install
11
1111
1

CAUTION: Avoid possible injury from


unexpected machine movement.
Install frame locking bar before working in
frame hinge area.

UN02JAN03

Install wheel chocks under one or more wheels


before disconnecting drive shafts.
1. Install frame locking bar.

T162992B

2. Install wheel chocks under one or more wheels before


disconnecting drive shaft.
3. Remove shields at the articulation joint as needed for
access to park brake.

9Transmission Yoke, Nut, and Cotter Pin


12Cap Screw (10 used)
13 Cap Screw (4 used) (Recessed in Cover)
14Cover
17Housing
21Double Universal Joint (Telescoping Drive
Shaft)
22Park Brake and Differential Lock Solenoid
Valve Manifold-to-Park Brake Line

4. Disconnect line (22).


5. Remove cap screws to disconnect double universal
joint (21) from transmission yoke (9).
6. Remove cotter pin and nut to remove yoke (9).
CAUTION: The park brake contains a disk
spring under load. Four of the fourteen cap
screws are shorter and are recessed in the
cover. The four recessed cap screws hold the
cover and housing together.
Heavy component; use a hoist.
Park BrakeSpecification
Park BrakeWeight .......................................... 43 kg (95 lb) approximate

7. Remove two of the ten cap screws (12). Install guide


pins.
8. Loosen remaining cap screws (12 and 13) in even
steps to relieve spring force.

Continued on next page

TM2111 (30MAY03)

11-1111-1

OUT3035,000033B 1917DEC021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=433

Active Elements
4
11
1111
2

3
7
8

20

10
19
UN02JAN03

11
1
12

18 17 16

T162978
1Transmission Housing
2Transmission Output Shaft
3Disk (8 used)
4O-Ring
5Piston
6Disk Spring

7Oil Seal
8Grease Seal (2 used)
9Transmission Yoke, Nut,
and Cotter Pin
10Lubrication Fitting
11Separator Plate (9 used)

9. Repair or replace parts (38 and 1020) as


necessary. See Park Brake Repair for procedure.
(Group 0350.)

15

T162978

13
14

12M12 x 140 mm Cap Screw


(10 used)
13 M12 x 110 mm Cap Screw
(4 used) (Recessed In
Cover)
14Cover

15Outer Seal Ring


16Inner Seal Ring
17Housing
18Gasket
19Hub
20Snap Ring

10. Install drive shaft. See Rear Axle and Differential


Drive Shaft Repair. (Group 0225.)

OUT3035,000033B 1917DEC022/2

TM2111 (30MAY03)

11-1111-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=434

Group 1160

Hydraulic System
Park Brake Solenoid Valve Repair
11
1160
1
UN15JUN00

CAUTION: Avoid possible injury from


unexpected machine movement. Install frame
locking bar before working in frame hinge area.
1. Install frame locking bar.

T131612B

2. Remove cap screws (1) to remove guard (2) under the


left rear corner of cab. See Power Train Component
LocationDirect Drive Machines or See Power Train
Component LocationTorque Converter Machines for
location of park brake solenoid valve. (Group 9020-15.)
3. Disconnect wiring connector (3).

UN15JUN00

4. Remove nut (4) to remove cover and solenoid coil from


the valve (5) on the right end of park brake and
differential lock solenoid valve manifold. Remove the
valve.

T131614B

1Cap Screw (2 used)


2Guard
3Wiring Connector
4Nut
5Cover, Solenoid Coil, and Valve

Continued on next page

TM2111 (30MAY03)

11-1160-1

OUT3035,000033C 1918DEC021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=435

Hydraulic System

T7508AE

UN09JUL91

11
1160
2

ANut
BWasher
CCover
DSolenoid Coil

EPlate
FValve (Spool)
GO-Ring

HBackup Ring
IO-Ring
JBackup Ring

KBackup Ring
LO-Ring
MBackup Ring

5. Repair or replace parts as needed.

8. Tighten nut to specification.

NOTE: The park brake solenoid valve and differential


lock solenoid valve are the same part number.

Park Brake Solenoid ValveSpecification


Cover and Solenoid
Coil-to-Valve NutTorque........................... 58 Nm (4471 lb-in.)

6. Install new O-rings and backup rings (GM).

9. Connect wiring connector.

7. Tighten valve (F) to specification.

10. Install guard and cap screws.

Park Brake Solenoid ValveSpecification


Solenoid Valve-to-Park Brake
and Differential Lock Solenoid
Valve ManifoldTorque ............................ 4754 Nm (3540 lb-ft)

IMPORTANT: Overtightening the solenoid valve


cover nut could damage the solenoid
coil. Tighten the nut to specification.

OUT3035,000033C 1918DEC022/2

TM2111 (30MAY03)

11-1160-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=436

Section 17

Frame, Chassis, or Supporting Structures


Contents
Page

17

Group 1740Frame Installation


Welding Repair of Major Structure. . . . . . . . .17-1740-1
Engine and Equipment Frames
Separate . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-2
Lower Pivot Pin Repair . . . . . . . . . . . . . . . .17-1740-10
Upper Pivot Pin Repair . . . . . . . . . . . . . . . .17-1740-18
Group 1746Frame Bottom Guards
Bottom Guard
Engine Frame . . . . . . . . . . . . . . . . . . . . . .17-1746-1
Equipment Frame . . . . . . . . . . . . . . . . . . .17-1746-2

TM2111 (30MAY03)

17-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

17

TM2111 (30MAY03)

17-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 1740

Frame Installation
Welding Repair of Major Structure

UN23AUG88

CAUTION: Avoid potentially toxic fumes and


dust. Hazardous fumes can be generated when
paint is heated by welding, soldering, or using a
torch. Do all work outside or in a well ventilated
area. Dispose of paint and solvent properly.

TS220

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.
Remove paint before welding or heating.
IMPORTANT: Disconnect battery ground strap or turn
battery disconnect switch to "OFF".
Have only a qualified welder do this job.
Connect welder ground clamp close to
each weld area so electrical current
does not pass through any bearings.
Remove or protect all parts that can be
damaged by heat or weld splatter.
Use one of the following weld processes:
AWS-E-7018 covered electrode with shielded metal arc
welding (SMAW) process
AWS-ER-70S-3 wire electrode with gas metal arc
welding (GMAW) process
AWS-E70T-1 or E71T-1 wire electrode with flux core
arc welding (FCAW) process.
Preheat area to be repaired to allow better weld
penetration.
To repair weld metal failure, remove failed weld metal
using arc or grinding equipment. Thoroughly clean area to
be welded. Preheat structural assemblies to a minimum of
38C (100F). Preheat ground engaging tools (cutting
edges, skid shoes, and teeth shanks) to 177C (350F).

Continued on next page

TM2111 (30MAY03)

17-1740-1

TX,17,RB682 1924JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=439

17
1740
1

Frame Installation
To repair base metal failure remove enough material to
allow weld to penetrate to the bottom of crack. Preheat
structural assemblies to a minimum of 38C (100F).
Preheat ground engaging tools (cutting edges, skid shoes,
and teeth shanks) to 177C (350F).

17
1740
2

TX,17,RB682 1924JAN032/2

Engine and Equipment FramesSeparate


1. Park machine on smooth level surface and align
frames straight ahead.
UN09MAY95

2. With engine running, lower blade:

T8465AE

Single Function Grapple: Close grapple tong and


lower arch until grapple tong rests on lift table.
Dual Function Grapple: Close grapple tong, raise
arch and lower boom until grapple tong rest on lift
table.
3. Operate all hydraulic functions including brake to
release pressure in the hydraulic system. Depress
brake pedal at one second intervals 20 times to
discharge oil from accumulator.

Continued on next page

TM2111 (30MAY03)

17-1740-2

CED,OUO1032,3476 1924JAN031/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=440

Frame Installation
4. Install floor stands under grille housing and ahead of
lower pivot pin of engine frame.
5. Grapple Skidders onlyinstall chain around winch
drum and arch roller. Connect chains using a hand
winch and tighten.
6. Drain hydraulic reservoir.

17
1740
3

UN29APR98

The approximate capacity of the 540G-III and 548G-III


hydraulic reservoir is 30.3 L (8 gal). The approximate
capacity of the 640G-III, 648G-III and 748G-III
hydraulic reservoir is 41.6 L (11 gal).

T114406B

7. Raise cab. See Hydraulic Cab Tilt Procedure.


(Operators Manual.)

CED,OUO1032,3476 1924JAN032/15

8. Remove shields (AD).

T114407B

UN29APR98

ATop Engine Frame Shield


BRight Engine Frame Shield
CLeft Engine Frame Shield
DRight Equipment Frame Shield

Continued on next page

TM2111 (30MAY03)

17-1740-3

CED,OUO1032,3476 1924JAN033/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=441

Frame Installation
9. Remove shields (A and B).

UN29APR98

ALeft Equipment Frame Shield


BLeft Equipment Frame Shield

T114408B

17
1740
4

CED,OUO1032,3476 1924JAN034/15

10. Disconnect drive shafts (A and C), winch control


cable (D), and hoses (B and E).

T114409B

UN29APR98

AWinch Drive Shaft


BWinch-to-Transmission Hose
CRear Differential Drive Shaft
DWinch Control Cable
ETransmission-to-Winch Hose

CED,OUO1032,3476 1924JAN035/15

11. Disconnect wire connector (A) and move wires aside


to equipment frame.

T132859B

UN24JUL00

AReverse Alarm and Fuel Sender Wire Connector

Continued on next page

TM2111 (30MAY03)

17-1740-4

CED,OUO1032,3476 1924JAN036/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=442

Frame Installation
IMPORTANT: Identify hoses and fittings to bulkhead
before removal, hoses can be
interchanged and may cause machine
damage.
UN22APR99

12. Remove hose guide clamp.

T121221B

13. Identify hydraulic hoses (AG) and disconnect from


bulkhead (H). Close all openings with caps and plugs.
ADifferential Lock Hose
BFuel Supply Line
CFuel Return Hose
DRear Brake Hose
ERotate Hose
FBulkhead
GRotate Hose
HWinch Case Drain
IWinch Control Cable

CED,OUO1032,3476 1924JAN037/15

14. On grapple machines: Identify and disconnect four


hydraulic hoses (AD) at tee fittings. Close all
openings with caps and plugs.

T114412B

UN29APR98

AArch Cylinder Rod End Hose


BArch Cylinder Head End Hose
CGrapple Control Hose
DGrapple Control Hose

Single Function Shown

Continued on next page

TM2111 (30MAY03)

17-1740-5

CED,OUO1032,3476 1924JAN038/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=443

17
1740
5

Frame Installation
15. Remove cap screw and nut (A) and spacer (C) from
both sides.

17. Remove upper pivot pins. See Upper Pivot Pin Repair
in this group.

T132687B

18. Remove lower pivot pins. See Lower Pivot Pin Repair
in this group.
19. With the aid of an assistant, carefully roll equipment
frame back while frame is supported on a rolling floor
jack.

APin
BCap Screw and Nut (2 used)
CSpacer (as required)

20. Repair or replace as required.


21. With the aid of an assistant, carefully roll equipment
frame to engine frame to align the upper and lower
pins.
22. Install upper pivot pins. See Upper Pivot Pin Repair in
this group.
23. Install lower pivot pins. See Lower Pivot Pin Repair in
this group.
24. Install pin (A) spacers (C) (if equipped), and cap
screw and nut (B) on both sides.
25. Tighten cap screw and nut then loosen 1/2 turn.

CED,OUO1032,3476 1924JAN039/15

26. Connect hydraulic hoses (AD).

UN29APR98

AArch Cylinder Rod End Hose


BArch Cylinder Head End Hose
CGrapple Control Hose
DGrapple Control Hose

T114412B

17
1740
6

UN20JUL00

16. Place 10-ton floor jack under equipment frame behind


lower pin and raise until frame starts to move upward.

Continued on next page

TM2111 (30MAY03)

17-1740-6

CED,OUO1032,3476 1924JAN0310/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=444

Frame Installation
27. Connect hydraulic hoses (AG).

UN22APR99

28. Route and connect hoses at guide loop and install


holding clamp.

T121221B

ADifferential Lock Hose


BFuel Supply Line
CFuel Return Hose
DRear Brake Hose
ERotate Hose
FBulkhead
GRotate Hose
HWinch Case Drain
IWinch Control Cable

CED,OUO1032,3476 1924JAN0311/15

29. Connect wire harness connector (A).

T132859B

UN24JUL00

AReverse Alarm and Fuel Sender Wire Connector

Continued on next page

TM2111 (30MAY03)

17-1740-7

CED,OUO1032,3476 1924JAN0312/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=445

17
1740
7

Frame Installation
30. Connect winch hoses (B and E), winch cable (D), and
drive shafts (A and C). Tighten cap screws to
specification.

T114409B

UN29APR98

ADrive Shaft
BWinch-to-Transmission Hose
CDrive Shaft
DWinch Cable
ETransmission-to-Winch Hose

CED,OUO1032,3476 1924JAN0313/15

31. Install shields (A and B).

UN29APR98

ALeft Equipment Frame Shield


BLeft Equipment Frame Shield

T114408B

17
1740
8

Engine and Equipment FramesSpecification


Rear Drive Shaft Cap Screws
(3/8 in.)Torque ............................................................. 60 Nm (45 lb-ft)
Rear Drive Shaft Cap Screws
(1/2 in.)Torque ........................................................... 115 Nm (85 lb-ft)
Winch Drive Shaft Cap Screws
Torque ............................................................................. 60 Nm (45 lb-ft)

Continued on next page

TM2111 (30MAY03)

17-1740-8

CED,OUO1032,3476 1924JAN0314/15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=446

Frame Installation
32. Install shields (AD).
33. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
34. Fill hydraulic reservoir. See Transmission, Hydraulic
System, Park Brake, Differential, Cab Hydraulic Pump
and Winch Oil. (Operators Manual.)

17
1740
9

UN29APR98

Engine and Equipment FramesSpecification


540G-III, 548G-III Hydraulic
ReservoirCapacity ........................................ 30.3 L (8 gal) approximate
640G-III, 648G-III, 748G-III
Hydraulic ReservoirCapacity...................... 41.6 L (11 gal) approximate

35. Remove shop stand from engine frame and grille


housing.

37. Remove chain and hand winch from winch drum and
arch roller.

T114407B

36. Operate all hydraulic functions to remove any air


trapped in system.
ATop Equipment Frame Shield
BRight Engine Frame Shield
CLeft Engine Frame Shield
DRight Equipment Frame Shield

CED,OUO1032,3476 1924JAN0315/15

TM2111 (30MAY03)

17-1740-9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=447

Frame Installation

Lower Pivot Pin Repair

T130556

UN01MAY00

17
1740
10

Continued on next page

TM2111 (30MAY03)

17-1740-10

CED,OUO1048,394 1924JAN031/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=448

Frame Installation
1Upper Pivot Pin
2Cap Screw (6 used)
3Upper Quill
4Shims (as required)
5Pin Sleeve
6Seal (2 used)

7Special Washer
8Cap Screw (3 used)
9Lower Pin
10Cap Screw (3 used)
11Snap Ring (4 used)
12Bushing (2 used)

13Locking Collar
14Pin Sleeve
15Pin Retainer Guard
16Special Washer
17Cap Screw (6 used)

CAUTION: Grapple Skidders equipment must


be lowered to ground to prevent movement
of equipment frame when lower pin is
removed.

18Lube Fitting (4 used)


19Locking Collar
20Pin Sleeve
21Engine Frame
22Equipment Frame

2. Lower blade and grapple equipment to ground and


operate all hydraulic functions including brake, to
release pressure in the hydraulic system. Depress
brake pedal at one second intervals 20 times to
discharge oil from accumulator.

1. Park machine straight and install frame locking bar.

CED,OUO1048,394 1924JAN032/11

3. Remove shields (AD).

T114407B

UN29APR98

ATop Engine Frame Shield


BRight Engine Frame Shield
CLeft Engine Frame Shield
DRight Equipment Frame Shield

Continued on next page

TM2111 (30MAY03)

17-1740-11

CED,OUO1048,394 1924JAN033/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=449

17
1740
11

Frame Installation
4. Remove shield (B) and disconnect rear differential
drive shaft (A) from transmission and move to right
side.

UN29APR98

ARear Differential Drive Shaft


BShield

T114278B

17
1740
12

CED,OUO1048,394 1924JAN034/11

5. Place a 10-ton floor jack under engine and equipment


frame at hinge area.

T129738B

UN30MAR00

1Cover
2Cap Screw (6 used)

Continued on next page

TM2111 (30MAY03)

17-1740-12

CED,OUO1048,394 1924JAN035/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=450

Frame Installation

T132705

UN20JUL00

17
1740
13

6. Remove cap screws (1) from pin (2).


7. Remove special washer (3).

T132703B

UN20JUL00

8. Using a hydraulic jack, push on underside of pin (2)


and press out of engine frame (5) and equipment
frame (4).

1Cap Screw (3 used)


2Lower Pivot Pin
3Special Washer
4Equipment Frame
5Engine Frame
6Pin Sleeve
7Seal

Continued on next page

TM2111 (30MAY03)

17-1740-13

CED,OUO1048,394 1924JAN036/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=451

Frame Installation

3
17
1740
14

4
2

5
7

UN21JUL00

T132704

1
T132704

1Pin Sleeve
2Snap Ring (4 used)

3Bushing (2 used)
4Spherical Bushing

5Engine Frame
6Equipment Frame

7Seal

9. Remove upper pivot pin and separate engine and


equipment frames. See Upper Pivot Pin Repair and
see Engine and Equipment FramesSeparate and
in this group.

13. Using appropriate disk, install spherical bushing


(4) so it is centered in equipment frame (6).

10. Using a bushing driver, remove pin sleeve (1).

15. Install snap rings (2).

11. Remove snap rings (2) and drive out busings (3)
from engine frame (5).

16. Install upper pivot pin a connect engine and


equipment frames.See Upper Pivot Pin Repair and
see Engine and Equipment FramesSeparate
and in this group.

12. Remove spherical bushing (4) from equipment


frame (6) using a bushing driver.
IMPORTANT: Press only on the outer race of
spherical bushing.

14. Install bushings (3) into engine frame.

17. Install new seal (7) into pin sleeve and install pin
sleeve (1) into bushing.

Continued on next page

TM2111 (30MAY03)

17-1740-14

CED,OUO1048,394 1924JAN037/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=452

Frame Installation

T132705

UN20JUL00

17
1740
15

1Cap Screw (3 used)


2Lower Pivot Pin

3Special Washer
4Equipment Frame

5Engine Frame
6Pin Sleeve

18. Use a steel plate and floor jacks to support pin


sleeve (6) in bushing.

7Seal

23. Tighten cap screws to specification.


Lower Pivot Pin RepairSpecification
Lower Pivot Pin Cap Screws
Torque................................................................... 319 Nm (235 lb-ft)

19. Install new seal (7) in lower pivot pin (2).


20. Apply grease to pivot pin and bushings.

24. Grease pivot pins.

NOTE: Pivot pin (2) is a press fit into pin sleeve (6).
21. Install pivot pin in pin sleeve.
22. Install special washer (3) and cap screws (1).
Evenly tighten cap screws to draw pivot pin into
pin sleeve.

Continued on next page

TM2111 (30MAY03)

17-1740-15

CED,OUO1048,394 1924JAN038/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=453

Frame Installation
25. Install cover (1) and cap screws (2). Tighten cap
screws to specification.
Lower Pivot Pin RepairSpecification
Bottom Cover Cap Screws
Torque ......................................................................... 624 Nm (460 lb-ft)

T129738B

UN30MAR00

1Bottom Cover
2Cap Screw (6 used)

CED,OUO1048,394 1924JAN039/11

26. Install rear differential drive shaft (A). Install and


tighten cap screws to specification.

UN29APR98

Lower Pivot Pin RepairSpecification


Rear Drive Shaft Cap Screw 3/8
in.Torque ...................................................................... 60 Nm (45 lb-ft)
Rear Drive Shaft Cap Screw 1/2
in.Torque .................................................................... 115 Nm (85 lb-ft)

27. Install shield (B).

T114278B

17
1740
16

ARear Differential Drive Shaft


BShield

Continued on next page

TM2111 (30MAY03)

17-1740-16

CED,OUO1048,394 1924JAN0310/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=454

Frame Installation
28. Install shields (AD).
29. Remove jacks and shop stands.
ATop Engine Frame Shield
BRight Engine Frame Shield
CLeft Engine Frame Shield
DRight Equipment Frame Shield

T114407B

UN29APR98

17
1740
17

CED,OUO1048,394 1924JAN0311/11

TM2111 (30MAY03)

17-1740-17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=455

Frame Installation

Upper Pivot Pin Repair

T130556

UN01MAY00

17
1740
18

Continued on next page

TM2111 (30MAY03)

17-1740-18

CED,OUO1032,3477 1924JAN031/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=456

Frame Installation
1Upper Pivot Pin
2Cap Screw (6 used)
3Upper Quill
4Shims (as required)
5Pin Sleeve
6Seal (2 used)

7Special Washer
8Cap Screw (3 used)
9Lower Pin
10Cap Screw (3 used)
11Snap Ring (4 used)
12Bushing (2 used)

13Locking Collar
14Pin Sleeve
15Pin Retainer Guard
16Special Washer
17Cap Screw (6 used)

18Lube Fitting (4 used)


19Locking Collar
20Pin Sleeve
21Engine Frame
22Equipment Frame

1. Park machine on a level surface and install frame


locking bar.

brake pedal at one second intervals 20 times to


discharge oil from accumulator.

2. Lower blade and grapple equipment to ground and


operate all hydraulic functions, including brake, to
release pressure in hydraulic system. Depress

3. Install floor stands under grille housing and ahead


of lower pivot pin of engine frame. Support
equipment frame behind lower pin with 10-ton jack.

CED,OUO1032,3477 1924JAN032/9

4. Remove cap screws (1) and special washer (2).

T132739B

UN21JUL00

1Cap Screw (3 used)


2Special Washer

CED,OUO1032,3477 1924JAN033/9

5. Use the 17-1/2 ton hydraulic push-puller from


D01047AA 17-1/2 and 30-Ton Puller Set, to press on
bottom of upper pivot pin (1).
6. Push pin through spherical bushing (2) in engine frame
(3) and out the top of equipment frame (4).
7. Remove lower pivot pin and separate engine and
equipment frames.See Lower Pivot Pin Repair and see
Engine and Equipment FramesSeparate in this
group.

2
3
4

1
T132740
Continued on next page

TM2111 (30MAY03)

17-1740-19

T132740

UN21JUL00

1Upper Pivot Pin


2Spherical Bushing
3Engine Frame
4Equipment Frame

CED,OUO1032,3477 1924JAN034/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=457

17
1740
19

Frame Installation
8. Remove cap screws (1) and quill (2).
9. Using a bushing driver, drive out bushing (3) from the
bottom of engine frame through the top of engine
frame.

UN21JUL00

10. Install new spherical bushing (3) until it bottom in bore


of engine frame.

T132741B

11. Install quill (2) without shims. Contact with spherical


bushing must be made.
1Cap Screw (6 used)
2Quill
3Spherical Bushing

CED,OUO1032,3477 1924JAN035/9

12. Measure gap from quill to frame with a feeler gauge.


Add shims to attain 0.030.13 mm (0.0010.005 in.)
preload on spherical bushing.

T128532

UN17FEB00

Upper Pivot PinSpecification


Shim Pack Less Than Gap
Preload ................................................ 0.030.13 mm (0.0010.005 in.)

CED,OUO1032,3477 1924JAN036/9

UN17FEB00

13. Install seal in quill with sealing lip toward the quill.

T128533

17
1740
20

Continued on next page

TM2111 (30MAY03)

17-1740-20

CED,OUO1032,3477 1924JAN037/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=458

Frame Installation
14. Install required shims, quill (2) and cap screws (1).
Tighten cap screws to specification. Ball (3) must
oscillate.
Upper Pivot PinSpecification
Quill Cap ScrewTorque ........................................... 140 Nm (103 lb-ft)

T132741B

UN21JUL00

1Cap Screws (6 used)


2Quill
3Ball

Continued on next page

TM2111 (30MAY03)

17-1740-21

CED,OUO1032,3477 1924JAN038/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=459

17
1740
21

Frame Installation
1

11

9
17
1740
22

4
10

UN21JUL00

T132748

1Upper Pivot Pin


2Cap Screw (6 used)
3Quill

T132748

1 mm GAP

4Equipment Frame
5Lower Seal
6Cap Screw (3 used)

7Special Washer
8Lock Collar
9Spherical Bushing

15. Install lower seal (5) into engine frame (10) with
sealing lip facing away from spherical bushing (9).
16. Install lock collar (8) into seal.
17. Install lower pivot pin connect engine and
equipment frames. See Lower Pivot Pin Repair
and see Engine and Equipment Frames
Separate in this group.
18. Make sure that lock collar (8) stays in engine
frame.
19. Apply grease to pivot pin and install into bushing
(9).

10Engine Frame
11Upper Seal

Upper Pivot PinSpecification


Retaining Cap ScrewsInitial
Torque................................................................ 230.5 Nm (170 lb-ft)
Retaining Cap ScrewsFinal
Torque Turn .................................................................................... 90

22. Grease pivot pin.


IMPORTANT: There must be a 1.0 mm (0.039 in.)
gap between special washer (7) and
upper pivot pin (1) after cap screws
have been tightened to specification.
23. Measure gap between special washer and upper
pivot pin. Gap must be to specification.
Upper Pivot PinSpecification
Special Washer and Upper
Pivot PinGap ...................................................... 1.0 mm (0.039 in.)

20. Install special washer (7) and cap screws (6).


21. Evenly tighten cap screws to draw pin through
bushing. Tighten cap screws to specification.

CED,OUO1032,3477 1924JAN039/9

TM2111 (30MAY03)

17-1740-22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=460

Group 1746

Frame Bottom Guards


Engine Frame Bottom Guard Remove and Install

T114595

UN29APR98

17
1746
1

ARear Bottom Guard


BWasher (2 used)
CCap Screw (4 used)

DCap Screw (2 used)


EFront Bottom Guard

FCotter Pin (2 used)


GWasher (2 used)

CAUTION: Heavy component; use a hoist.


Weights may increase due to the buildup of
mud and debris.
Engine Frame Bottom GuardSpecification
Front Bottom GuardWeight ..................... 36 kg (80 lb) approximate
Rear Bottom GuardWeight...................... 25 kg (55 lb) approximate

HWasher (4 used)
ICap Screw (2 used)

The bottom guards are hinged and will swing down


to the front of machine.
2. Tighten cap screws (C, D, and I) to specifications.
Engine Frame Bottom GuardsSpecification
Front and Rear Bottom
Guard-to-Engine Frame Cap
ScrewTorque ..................................................... 620 Nm (460 lb-ft)

1. Use a service jack to hold the bottom guards (A


and E) in place while removing the cap screws (C
and I).

OUT3035,000033D 1919DEC021/1

TM2111 (30MAY03)

17-1746-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=461

Frame Bottom Guards

Equipment Frame Bottom Guard Remove and Install

T114596

UN29APR98

17
1746
2

AWasher (8 used)
BCap Screw (4 used)
CCover

DPlate (2 used)
EBottom Door
FCap Screw (2 used)

GCap Screw (4 used)


HWasher (4 used)

CAUTION: Heavy component; use a hoist.


Weights may increase due to the buildup of
mud and debris.
Equipment Frame Bottom GuardSpecification
Bottom GuardWeight............................... 27 kg (60 lb) approximate

IRear Bottom Guard


JCap Screw (4 used)

2. Tighten cap screws to specifications.


Equipment Frame Bottom GuardSpecification
Bottom Guard-to-Equipment
Frame Cap ScrewTorque.................................. 620 Nm (460 lb-ft)
Bottom Door-to-Equipment
Frame Cap ScrewsTorque .................................. 130 Nm (95 lb-ft)

1. Use a service jack to hold the bottom guard (I) in


place while removing the cap screws (G).

OUT3035,000033E 1919DEC021/1

TM2111 (30MAY03)

17-1746-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=462

Section 18

Operators Station
Contents
Page

Page

Group 1800Removal and Installation


Cab Remove and Install . . . . . . . . . . . . . . . .18-1800-1
Cab Isolators Remove and Install . . . . . . . .18-1800-16
Steering Column and Steering Wheel
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-18
Cab Tilt Hand Pump Repair . . . . . . . . . . . .18-1800-23
Cab Tilt Hand Pump Bleed Circuit. . . . . . . .18-1800-25
Cab Tilt Cylinder Remove and Install . . . . .18-1800-27

Expansion Valve Remove and Install . . . . .18-1830-33


Blower Motor Remove and Install . . . . . . . .18-1830-34
Heater Core Remove and Install . . . . . . . . .18-1830-35
Receiver Dryer Remove and Install . . . . . . .18-1830-39
Freeze Control Switch Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-40

Group 1810Operator Enclosure


Window and Window Molding Repair . . . . . .18-1810-1
Clean Windows Regularly . . . . . . . . . . . . . . .18-1810-4
Cab Door and Door Latch Repair . . . . . . . . .18-1810-6
Windshield Wiper and Washer Repair . . . . .18-1810-10
Group 1821Seat and Seat Belt
Seat Repair . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-1
Seat Belt Repair . . . . . . . . . . . . . . . . . . . . . .18-1821-9
Group 1830Heating and Air Conditioning
Proper Refrigerant Handling . . . . . . . . . . . . .18-1830-1
Air Conditioner System
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3
R134A Refrigerant Oil
Information. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6
R134A Refrigerant Recovery, Recycling and
Charging Station
Installation Procedure . . . . . . . . . . . . . . . .18-1830-8
Recover R134a Refrigerant . . . . . . . . . . . . . .18-1830-9
Evacuate R134a System . . . . . . . . . . . . . . .18-1830-10
Charge R134a System . . . . . . . . . . . . . . . .18-1830-11
Compressor Relief Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
High and Low Pressure Switches Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Air Conditioning Compressor Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-14
Air Conditioning Compressor Clutch
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-16
Air Conditioning Compressor Manifold
Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18
Air Conditioning Compressor
Disassemble, Inspect and Assemble . . . .18-1830-19
Air Conditioning Condenser Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-22
Evaporator Remove and Install . . . . . . . . . .18-1830-23
TM2111 (30MAY03)

18-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

18

Contents

18

TM2111 (30MAY03)

18-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 1800

Removal and Installation


Cab Remove and Install
Direct drive machine shown throughout. Procedures for
the torque converter machine are the same except where
noted.
Remove Cab
1. Install locking bar.
2. Operate all controls to relieve hydraulic pressure from
system. Depress brake pedal 20 times at one-second
intervals to discharge accumulator.
18
1800
1

3. Remove left-side engine shields.


4. Turn battery disconnect switch to OFF position.
5. Remove right-side engine shields.

OUO1020,00010BE 1906DEC021/23

6. On direct drive machines, close heater shut-off valve


(1).

T131341B

UN02JUN00

1Heater Shut-Off Valve

Direct Drive Machine Shown

Continued on next page

TM2111 (30MAY03)

18-1800-1

OUO1020,00010BE 1906DEC022/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=465

Removal and Installation


7. Remove shields (1 and 2) from left side of cab.
8. Remove lower cab shields from left and right side of
cab.

UN13JAN03

1Side Shield
2Side Shield

T163641B

18
1800
2

OUO1020,00010BE 1906DEC023/23

9. Raise cab. See Hydraulic Cab Tilt Procedure.


(Operators Manual.)

UN17DEC02

10. Recover refrigerant. See Recover R134a Refrigerant


in this group.

T162930B

11. Disconnect suction line (2) from compressor and


pressure line (1) from condenser. Close open lines
and fittings using caps and plugs. Remove lines from
hangers back to cab. Refrigerant lines will be
removed with cab.
Suction Line and Pressure Line (460D Shown)
1Refrigerant Pressure Line
2Refrigerant Suction Line

Continued on next page

TM2111 (30MAY03)

18-1800-2

OUO1020,00010BE 1906DEC024/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=466

Removal and Installation


12. Disconnect main electrical harness connectors (5 and
8). Remove connector (5) from mount.
13. Disconnect wire connectors (14 and 9).
14. Remove harness clamps (6).
15. Disconnect ground strap (7) from frame.
16. Remove harness from frame and set aside to be
removed with cab.

UN02JUN00

17. Disconnect transmission vent hose (10) and set aside


to be removed with cab.

T131348B

UN02JUN00

T131347B

1Grapple Rotate Solenoid Wire Connector


2Wire Connector
3Secondary Steering Harness-to-Cab Harness Wire
Connector
4Engine Harness Ground-to-Cab Harness Ground
Wire Connector
5Engine Harness-to-Cab Harness Wire Connector
6Harness Clamps (3 used)
7Ground Strap
8Transmission Harness-to-Cab Harness Wire
Connector
9Input Shaft Speed Pickup Wire Connector (Direct
Drive Machine)
10Transmission Vent Hose

OUO1020,00010BE 1906DEC025/23

NOTE: Leave nut (4) finger tight, so it can be removed


later without the use of a wrench.

UN13MAR01

18. Loosen nut (4) but DO NOT remove from cap screw
(1).

T139731B

1Cap Screw
2Shims (as needed)
3Washer (2 used)
4Nut

Continued on next page

TM2111 (30MAY03)

18-1800-3

OUO1020,00010BE 1906DEC026/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=467

18
1800
3

Removal and Installation

CAUTION: Coolant may be hot. Wait until


radiator is cool to the touch before
disconnecting heater hoses.

T6642EK

19. Disconnect heater hoses (2) from heater core hoses


(8) and connect the two heater hoses (2) together.
Allow heater core to drain. On direct drive machines
remove heater hoses from cab floor supports. On
torque converter machines remove clamps (7) and
heater hoses from cab.
20. Disconnect throttle cable (4).
21. Remove nuts and washers (1) and set steering valve
down inside engine frame.

UN13MAR01

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

T139743B

18
1800
4

UN01NOV88

NOTE: Ends of heater hoses must be above coolant level


in radiator before disconnecting to prevent coolant
loss.

Torque Converter Machine Shown


1Nuts and Washers (3 used)
2Heater Hoses (2 used)
3Brake Lines
4Throttle Cable
5Brake Valve Return Line
6Accumulator Lines
7Clamps (4 used)
8Heater Core Hoses (2 used)

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.
22. Mark brake lines (3 and 5) and accumulator line (6).
23. Disconnect lines and remove from cab floor supports.
Close all openings with caps and plugs.

Continued on next page

TM2111 (30MAY03)

18-1800-4

OUO1020,00010BE 1906DEC027/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=468

Removal and Installation

UN13JAN03

IMPORTANT: All components, hydraulic lines, and


electrical harnesses disconnected from
machine and cab must be placed in
areas that will be clear when lowering
cab. Lowering cab on top of such items
will cause damage.

T163639B

24. Lower cab. Remove cap screw (2) and disconnect


tether cable (1).
1Tether Cable
2Cap Screw

18
1800
5

OUO1020,00010BE 1906DEC028/23

25. Remove nut, cap screw (1), washers, and shims.


Move cab tilt cylinder (2) away from clevis. Note
location of shims and washers to aid in assembling.

T131351B

UN02JUN00

1Cap Screw and Nut


2Hydraulic Cab Tilt Cylinder

Continued on next page

TM2111 (30MAY03)

18-1800-5

OUO1020,00010BE 1906DEC029/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=469

Removal and Installation

T131353B

T131352B

UN02JUN00

UN27MAR01

18
1800
6

Direct Drive Machine Shown

26. Remove shields (1 and 2) from right side of cab.


27. Disconnect winch control cable (3).
28. Disconnect linkage rods (4).

UN13MAR01

NOTE: Mark pilot lines before disconnecting to aid in


assembling.
29. Disconnect pilot lines (7 and 8).

T139709B

30. Remove cap screws (6) and control valve assembly


(5) from cab.

1Shield
2Shield
3Winch Control Cable
4Linkage Rods
5Control Valve Assembly
6Cap Screws (3 used)
7Pilot Control Valve Lines (Torque Converter
Machine)
8Main Control Valve Pilot Lines (Torque Converter
Machine)

Torque Converter Machine Shown

Continued on next page

TM2111 (30MAY03)

18-1800-6

OUO1020,00010BE 1906DEC0210/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=470

Removal and Installation

CAUTION: Muffler and left riser may be hot from


exhaust. Allow riser to cool before removal.
31. Remove limb risers using a lifting strap and hoist.

T7502CM

UN02MAY91

18
1800
7

Continued on next page

TM2111 (30MAY03)

18-1800-7

OUO1020,00010BE 1906DEC0211/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=471

Removal and Installation


32. Attach lifting chains to rear lift points (1) on right and
left side of cab.

UN13MAR01

33. Install JDG909 Lifting Brackets in each limb riser


eyelet (2).
CAUTION: Heavy component; use a hoist.

34. Attach lifting chains and hoist to JDG909 Lifting


Brackets as shown.

T131354B

UN27MAR01

1Rear Lift Point


2Limb Riser Eyelet

OUO1020,00010BE 1906DEC0212/23

35. Remove nuts (1). Raise cab slightly to remove cap


screws (2). Remove washers (3) and shims (4). Note
quantity and location of washers and shims to aid in
assembling.
UN13MAR01

IMPORTANT: Carefully remove cab making sure all


hydraulic lines, harnesses, and valves
are clear as cab is lifted.
36. Remove cab.

T139720B

18
1800
8

T139764B

Operators StationSpecification
CabWeight ............................................... 875 kg (1930 lb) approximate

1Nut (2 used)
2Cap Screw (2 used)
3Washer (as needed)
4Shim (as needed)

Continued on next page

TM2111 (30MAY03)

18-1800-8

OUO1020,00010BE 1906DEC0213/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=472

Removal and Installation


Install Cab
1. Inspect and replace cab isolators if necessary. See
Cab Isolators Remove and Install in this group.

T139720B

UN13MAR01

IMPORTANT: Hydraulic lines, valves, and electric


harnesses must be clear of cab while
lowering or damage to such items may
occur.
2. Lower cab onto frame mounts, guiding hydraulic lines,
valves, and electrical harnesses into position for
hookup.

1Nut (2 used)
2Cap Screw (2 used)
3Washer (as needed)
4Shim (as needed)

IMPORTANT: Overtightening of cap screws and nuts


can cause cab clevis to deform.

18
1800
9

3. Install cap screws (2), washers (3), shims (4), and nuts
(1). Make sure nuts are fully threaded onto cap screws.
Tighten nuts until washers are snug and full thread
engagement is attained.
4. Remove lifting chains and lifting brackets from cab.

Continued on next page

TM2111 (30MAY03)

18-1800-9

OUO1020,00010BE 1906DEC0214/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=473

UN02JUN00

18
1800
10

T139709B

UN13MAR01

Removal and Installation

T131353B

Torque Converter Machine Shown

Direct Drive Machine Shown

5. Install control valve assembly (5) with cap screws (6).


6. Connect linkage rods (4).
7. Connect winch control cable (3).

UN27MAR01

8. On torque converter machines, connect pilot lines (7


and 8).

T131352B

9. Install shields (1 and 2).

1Shield
2Shield
3Winch Control Cable
4Linkage Rods
5Control Valve Assembly
6Cap Screws (3 used)
7Pilot Control Valve Lines
8Main Control Valve Pilot Lines

Continued on next page

TM2111 (30MAY03)

18-1800-10

OUO1020,00010BE 1906DEC0215/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=474

Removal and Installation


10. Position tilt cylinder (2) into cab clevis. Install cap
screw (1), washers, shims, and nut. Do not tighten
nut at this time.

T131351B

UN02JUN00

1Cap Screw
2Tilt Cylinder

OUO1020,00010BE 1906DEC0216/23

18
1800
11

11. Install tether cable (1) and cap screw (2).

T163639B

UN13JAN03

1Tether Cable
2Cap Screw

Continued on next page

TM2111 (30MAY03)

18-1800-11

OUO1020,00010BE 1906DEC0217/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=475

Removal and Installation


12. Raise cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
IMPORTANT: DO NOT overtighten tilt cylinder nut.
Overtightening of nut can cause cab
clevis to deform.

UN13MAR01

13. Tighten tilt cylinder nut until washers are snug and full
thread engagement is attained.

18
1800
12

T139743B

14. Connect brake lines (3 and 5) and accumulator lines


(6).
15. Install steering valve using nuts and washers (1).
Torque Converter Machine Shown

16. Connect throttle cable (4).

1Nuts and Washers (3 used)


2Heater Hoses (2 used)
3Brake Lines
4Throttle Cable
5Brake Valve Return Line
6Accumulator Lines (Torque Converter
Machines)
7Clamps (4 used)
8Heater Core Hoses (2 used)

17. For direct drive machines, install heater hoses (2)


through cab floor supports. For torque converter
machines, install heater hoses and clamps (7).

NOTE: Ends of heater hoses must be above coolant level


in radiator before disconnecting to prevent coolant
loss.
18. Disconnect heater hoses (2) and connect to heater
core hoses (8).

Continued on next page

TM2111 (30MAY03)

18-1800-12

OUO1020,00010BE 1906DEC0218/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=476

Removal and Installation


19. Connect transmission vent hose (10).
20. Connect ground strap (7) to frame.
21. Route wiring harness in frame and install harness
clamps (6).
22. Install main electrical connector (5) into mount and
connect main electrical connectors (5 and 8).
23. Connect wire connectors (14 and 9).

T131347B

UN02JUN00

T131348B

UN02JUN00

1Grapple Rotate Solenoid Wire Connector


2Wire Connector
3Secondary Steering Harness-to-Cab Harness Wire
Connector
4Engine Harness Ground-to-Cab Harness Ground
Wire Connector
5Engine Harness-to-Cab Harness Wire Connector
6Harness Clamp (3 used)
7Ground Strap
8Transmission Harness-to-Cab Harness Wire
Connector
9Input Shaft Speed Pickup Wire Connector
10Transmission Vent Hose

Continued on next page

TM2111 (30MAY03)

18-1800-13

OUO1020,00010BE 1906DEC0219/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=477

18
1800
13

Removal and Installation


24. Route air conditioning lines through hangers and
connect suction line (2) to compressor. Tighten to
specification.

UN17DEC02

Operators StationSpecification
Suction Line-to-Compressor
Torque ........................................................ 2428 Nm (212248 lb-in.)

T162930B

25. Connect pressure line (1) to condenser. Tighten to


specification.
Operators StationSpecification
Pressure Line-to-Condenser
Torque ........................................................ 1420 Nm (124177 lb-in.)

Suction Line and Pressure Line (460D Shown)

18
1800
14

1Refrigerant Pressure Line


2Refrigerant Suction Line

OUO1020,00010BE 1906DEC0220/23

26. Lower cab and install locking pins (2) and shims as
required. Lock pins in place with cap screws (1).
Tighten cap screws to specification.

UN02JUN00

Operators StationSpecification
Cab Pin Locking Cap Screws
Torque ............................................................................. 80 Nm (60 lb-ft)

T114910C

27. Install left and right lower cab shields.


1Cap Screws
2Locking Pins

Continued on next page

TM2111 (30MAY03)

18-1800-14

OUO1020,00010BE 1906DEC0221/23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=478

Removal and Installation


28. Install shields (1 and 2).

T163641B

UN13JAN03

1Shield
2Shield

OUO1020,00010BE 1906DEC0222/23

29. On direct drive machines, open heater shut-off valve


(1).
30. Install right-side engine shields.
UN02JUN00

31. Turn battery disconnect switch to ON.


32. Install left-side engine shields.

34. Bleed brakes. See Service Brake Bleeding Procedure.


(Group 1060.)

T131341B

33. Check and fill cooling system with proper coolant.


See Diesel Engine Coolant. (Operators Manual.)
Direct Drive Machine Shown
1Heater Shut-Off Valve

35. Adjust winch control cable. See Winch Control Cable


Remove and Install. (Group 3015.)
36. Install limb risers.

OUO1020,00010BE 1906DEC0223/23

TM2111 (30MAY03)

18-1800-15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=479

18
1800
15

Removal and Installation

Cab Isolators Remove and Install


NOTE: If cab isolators become worn or damaged, replace
isolators.
UN29APR98

Left Cab Mount Isolators

T114570B

1. Raise cab. See Hydraulic Cab Tilt Procedure.


(Operators Manual.)
2. Remove isolators from mounts.
18
1800
16

3. Apply soap on isolators to aid in installation. Install


isolators.
4. Lower cab, install pins, shims (as required), washers
and pin locking cap screws. Tighten cap screws to
specification.
Left Cab Mount IsolatorsSpecification
Cab Pin Locking Cap Screws
Torque ............................................................................. 80 Nm (60 lb-ft)

Right Cab Mount Isolators


CAUTION: Prevent unexpected machine
movement and possible injury. Install frame
locking bar before you work in frame pivot area.
1. Install frame locking bar.
2. Park machine on level ground, turn battery disconnect
switch OFF, and move shift lever to PARK.
3. Remove left engine side shields.
4. Disconnect both limb risers from top of cab.

Continued on next page

TM2111 (30MAY03)

18-1800-16

OUO1020,00010BF 1906DEC021/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=480

Removal and Installation

CAUTION: Left cab mounting pins MUST be


installed before tilting right side of cab. Tilting
cab without opposite side mounting pins
installed could cause serious personal injury.
UN29APR98

5. Open and remove lower cab shield (B).

7. Using hydraulic cab tilting jack, lift cab until weight of


cab is removed from cap screws. Remove cap screws,
washers, and shims. Note location and quantity of
washers and shims to aid in assembling.

T114970

6. Remove nuts (A).

18
1800
17

ANut (2 used)
BLower Cab Shield

OUO1020,00010BF 1906DEC022/3

8. Raise cab until mounts clear cab clevises. Support cab


using a wooden block (C) as shown.
9. Remove isolators from mounts.
UN21JUN00

10. Apply soap on new isolators to aid in installation.


Install isolators.

T131398B

11. Remove wooden block and lower cab.


IMPORTANT: Do not overtighten cap screws as
damage to clevises will result.
12. Install cap screws, washers, shims, and nuts. Use
washers and shims as required. Tighten nuts until
washers are snug against clevis.

CWooden Block

13. Install lower cab shields.


14. Connect limb risers to cab.
15. Turn battery disconnect switch to ON position.
16. Install engine side shields.
17. Remove frame locking bar.

OUO1020,00010BF 1906DEC023/3

TM2111 (30MAY03)

18-1800-17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=481

Removal and Installation

Steering Column and Steering Wheel Repair


Steering Column and Steering Wheel Remove and
Install
Direct drive machine shown throughout. Procedures for
the torque converter machine are the same except where
noted.

CED,OUO1048,396 1906DEC021/11

1. Remove fire extinguisher from bracket. Remove cap


screws (1 and 3) and bracket (2).

T131257B

UN31MAY00

1Cap Screw (2 used)


2Bracket
3Cap Screw

CED,OUO1048,396 1906DEC022/11

2. Disconnect electrical connectors (3) from windshield


washer pumps and disconnect hoses (4). Close all
openings with caps and plugs.
3. Remove cap screws (1) and remove windshield washer
tank (2).

UN31MAY00

1Cap Screws (2 used)


2Windshield Washer Tank
3Electrical Connector (2 used)
4Windshield Washer Hose (2 used)

T131258B

18
1800
18

Continued on next page

TM2111 (30MAY03)

18-1800-18

CED,OUO1048,396 1906DEC023/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=482

Removal and Installation


4. Remove screws (1) and lower dash panel (2).

T131259B

UN31MAY00

1Screws (4 used)
2Lower Dash Panel

Direct Drive Machine Shown


18
1800
19

CED,OUO1048,396 1906DEC024/11

5. Disconnect horn wire connector (2).


6. Remove cap screws (1 and 4) and slide steering
column with universal joint (3) up and off of steering
valve.

T131260B

UN31MAY00

1Cap Screw (4 used)


2Horn Wire Connector
3Universal Joint
4Cap Screw

Continued on next page

TM2111 (30MAY03)

18-1800-19

CED,OUO1048,396 1906DEC025/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=483

Removal and Installation


7. Remove cap screw (2), universal joint (1) and brackets
(3).

T131261B

UN31MAY00

1Universal Joint
2Cap Screw
3Bracket (2 used)

CED,OUO1048,396 1906DEC026/11

8. Remove steering wheel cap (1) and nut (2).

UN31MAY00

CAUTION: Spring behind steering wheel is


under tension. Remove steering wheel with
caution.

T131262B

9. Install appropriate steering wheel puller to steering


wheel and slowly remove wheel from steering column
while holding downward pressure on wheel to restrain
spring tension.
10. Install steering wheel on steering column.
11. Install steering wheel cap and nut.
12. Install brackets, universal joint and cap screw.

UN31MAY00

1Steering Wheel Cap


2Steering Wheel Nut

T131263B

18
1800
20

Continued on next page

TM2111 (30MAY03)

18-1800-20

CED,OUO1048,396 1906DEC027/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=484

Removal and Installation


13. Install cap screws (14).
14. Connect horn wire connector (2).
15. Install lower dash panel and cap screws.
16. Install windshield washer tank and cap screws.
17. Connect windshield washer pump hoses and
electrical connectors.

UN31MAY00

18. Install fire extinguisher bracket and cap screws. Install


fire extinguisher.

T131260B

1Cap Screw (4 used)


2Horn Wire Connector
3Universal Joint
4Cap Screw

CED,OUO1048,396 1906DEC028/11

Steering Column and Steering Wheel Disassemble


and Assemble

UN31MAY00

1. Remove steering wheel cap (1) and nut (2).

T131262B

CAUTION: Spring behind steering wheel is


under tension. Remove steering wheel with
caution.
2. Install puller (1) to steering wheel and slowly remove
wheel from steering column while holding downward
pressure on wheel to restrain spring tension.

T131263B

UN31MAY00

1Steering Wheel Cap


2Steering Wheel Nut

Continued on next page

TM2111 (30MAY03)

18-1800-21

CED,OUO1048,396 1906DEC029/11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=485

18
1800
21

Removal and Installation


3. Remove covers (2, 4, and 5), horn wiring lead (1) and
knob (3).

T131265B

UN31MAY00

1Horn Wiring Lead


2Cover
3Knob
4Cover
5Cover

CED,OUO1048,396 1906DEC0210/11

4. Replace parts as necessary.


5. Connect horn wiring connector to cap (7).

UN31MAY00

6. Install cap.
1Steering Column
2Disk
3Spring
4Cover
5Steering Wheel
6Nut
7Cap

T131266B

18
1800
22

CED,OUO1048,396 1906DEC0211/11

TM2111 (30MAY03)

18-1800-22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=486

Removal and Installation

Cab Tilt Hand Pump Repair


Cab Tilt Hand Pump Remove and Install

X9811

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, relieve the pressure in the
system before disconnecting or connecting
hydraulic or other lines. Tighten all connections
before applying pressure.
IMPORTANT: For satisfactory operation of the cab tilt
cylinder, it is essential that all air be
bled from the system. Therefore, any
time air is induced into the system, the
bleed procedure MUST be performed.

18
1800
23

1. Shut engine off and lower equipment to the ground.


Operate all hydraulic functions to relieve pressure.
2. Turn battery disconnect switch to OFF position.
3. Disconnect hose (2) and top hose (1). Close all
openings using caps and plugs.

UN02JUN00

4. Remove cap screws (3) and remove pump.


5. Replace or repair damaged parts.

T131385B

6. Install pump and cap screws. Tighten cap screws to


specification.
Cab Tilt Hand PumpSpecification
Hand Pump Mounting Cap
ScrewsTorque ........................................ 2226 Nm (195230 lb-in.)

1Head End Lift Hose


2Head End Retract Hose
3Cap Screw (3 used)

7. Connect hoses (1 and 2).


8. Bleed cab tilt hand pump circuit to remove air from
system. See Cab Tilt Hand Pump Bleed Circuit in this
group.
9. Fill hand pump oil reservoir.
Cab Tilt Hand PumpSpecification
Cab Tilt Hand Pump Reservoir
Capacity ........................................................ 574 mL (20 oz) approximate

10. Turn battery disconnect switch to ON position.

Continued on next page

TM2111 (30MAY03)

18-1800-23

CED,OUO1032,3379 1906DEC021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=487

Removal and Installation


Cab Tilt Hand Pump Disassemble and Assemble
IMPORTANT: For satisfactory operation of the cab tilt
cylinder, it is essential that all air be
bled from the system. Any time a
system component is changed the
bleed procedure MUST be
performed.See Cab Tilt Hand Pump
Bleed Circuit in this group.
1. Remove four cap screws from pump reservoir and
drain oil from reservoir. Check O-ring (C) and replace if
damaged.
2. Remove plastic plug (A) from bottom of pump body
with an O-ring pick.
3. Remove pump handle link (G).

UN05JUL95

4. Remove snap ring (B) from pump valve (F) and tap
assembly out of the valve body.
5. Inspect and replace damaged parts.

T8513AF

18
1800
24

6. Apply clean hydraulic oil to pump valve (F) and install


into valve body.
7. Install snap ring (B) and plastic plug (A).

APlastic Plug
BSnap Ring
CO-Ring
DSuction Screen
EFill Plug
FPump Valve
GPump Handle Link

8. Install pump handle link (G) to pump valve (F).


9. Remove and clean suction screen (D).
10. Install O-ring (C) into reservoir O-ring groove and
install reservoir to the valve body. Tighten cap
screws.
Cab Tilt Hand PumpSpecification
Reservoir-to-Valve Body Cap
ScrewsTorque ......................................... 6.611.6 Nm (4884 lb-in.)

11. Fill hand pump oil reservoir.


Cab Tilt Hand PumpSpecification
Cab Tilt Hand Pump Reservoir
Capacity ........................................................ 574 mL (20 oz) approximate

12. Oil fill plug (E) is vented; check to see if plug is clean.
Install fill plug (E).

CED,OUO1032,3379 1906DEC022/2

TM2111 (30MAY03)

18-1800-24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=488

Removal and Installation

Cab Tilt Hand Pump Bleed Circuit


CAUTION: For satisfactory operation of the cab
tilt cylinder, it is essential that all air be bled
from the system. Any time a system component
is changed the bleed procedure MUST be
performed.
1. Attach hoist and chains to cab and raise cab.

UN29APR98

2. Support cab and remove cab lift cylinder pin and cap
screw.
3. Position cylinder so that there is enough clearance to
extend and retract cylinder.

T115133B

4. Completely retract cylinder using pump.


5. Disconnect the rod end hose (B) and install plug in
hose.
6. Disconnect head end hose (A) at the base of the
hydraulic cylinder.
IMPORTANT: Keep hand pump reservoir full during
bleeding procedure to avoid air entering
circuit.
7. Fill cab tilt hand pump reservoir and maintain hydraulic
oil level.

UN29APR98

Cab Tilt Hand PumpSpecification


Cab Tilt Hand Pump Reservoir
Capacity ........................................................ 574 mL (20 oz) approximate
Cab Tilt Hand Pump Circuit
Capacity .................................................................. 2 L (2 qt) approximate

T115132B

8. Position lever (C) on pump to extend cylinder.


9. Place a container under head end hose (A) and
operate pump until all air is bled from hose. Connect
hose (A) to cylinder.
AHead End Hose
BRod End Hose
CLever

10. Place a container under cylinder rod end port.


11. Operate hand pump until cylinder is completely
extended.

Continued on next page

TM2111 (30MAY03)

18-1800-25

OUO1065,0000596 1906DEC021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=489

18
1800
25

Removal and Installation


12. Remove plug from rod end hose (B). Place a
container under hose end.
13. Position lever (C) on pump to retract cylinder.
Operate hand pump until all air is bled from line.
14. Connect hose (B) to cylinder and retract cylinder.
IMPORTANT: Overtightening of cap screw and nut
can cause cab clevis to deform.
15. Install cab tilt cylinder with pin and cap screw.
18
1800
26

16. Make sure nut is fully threaded on cap screw. Do not


overtighten cap screw.
17. Remove cab support and lower cab.

OUO1065,0000596 1906DEC022/2

TM2111 (30MAY03)

18-1800-26

G-III and D Series Skidders (S.N. 586337 )


053003

PN=490

Removal and Installation

Cab Tilt Cylinder Remove and Install

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, relieve the pressure in the
system before disconnecting or connecting
hydraulic or other lines. Tighten all connections
before applying pressure.

X9811

IMPORTANT: For satisfactory operation of cab tilt


cylinder, it is essential that all air be
bled from the system. Therefore, any
time air is induced into the system, the
bleed procedure MUST be performed.

18
1800
27

1. Raise cab. See Hydraulic Cab Tilt Procedure.


(Operators Manual.)
UN02JUN00

2. Attach hoist and chains to cab for support and aid of


removal and installation of cylinder pin and cap screw.

T131387B

3. Remove cap screw and nut (1) from cab. Retract


cylinder.
4. Remove cylinder pin (4) from engine frame.
5. Disconnect hydraulic lines (2 and 3). Remove cylinder.
6. Install new cylinder.

UN02JUN00

7. Connect hydraulic lines (2 and 3).


8. Bleed cab tilt hand pump circuit.See Cab Tilt Hand
Pump Bleed Circuit in this group.

T131386B

9. Install cylinder.
IMPORTANT: Overtightening of cap screw and nut
can cause cab clevis to deform.
10. Extend cylinder to line up cylinder rod end with cab
clevis. Install rubber bushings, washers, cap screw
and nut (1). Make sure nut is fully threaded onto cap
screw. Do not overtighten cap screw.

1Cap Screw and Nut


2Head End Retract Hydraulic Line
3Head End Lift Hydraulic Line
4Pin

11. Remove cab support and lower cab.

CED,OUO1032,3386 1909DEC021/1

TM2111 (30MAY03)

18-1800-27

G-III and D Series Skidders (S.N. 586337 )


053003

PN=491

Removal and Installation

18
1800
28

TM2111 (30MAY03)

18-1800-28

G-III and D Series Skidders (S.N. 586337 )


053003

PN=492

Group 1810

Operator Enclosure
Window and Window Molding Repair
Door Windows

UN19OCT88

1. Open locking tab (D) using JDG-128-1 Tool Assembly


(A) from JDG-128 Glass Service Set.

T6148AE

2. Loosen molding (F) around window frame (B) using


JDG-128-2 Insert Tool (E).
3. Carefully remove window frame.
4. Remove molding and inspect for damage. Replace if
necessary.

18
1810
1

UN19OCT88

5. If molding must be replaced, start molding so the joint


is on the side of window. If joint is on top or bottom of
window, water might enter into the cab.

T6148AF

CAUTION: DO NOT replace polycarbonate


windows with windows made out of glass or
plastic. The impact resistance of polycarbonate
material is recommended for forestry use.
6. Install window frame using insert tool.

Locking TabClosed Position

7. Push locking tab into groove using tool assembly.

T6148AH

UN19OCT88

T6148AG

UN19OCT88

AJDG-128-1 Tool Assembly


BWindow Frame
CCab Frame
DMolding Locking Tab
EJDG-128-2 Insert Tool
FMolding

Locking TabOpen Position

Continued on next page

TM2111 (30MAY03)

18-1810-1

CED,OUO1048,398 1910DEC021/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=493

Operator Enclosure

T137008

UN12JAN01

18
1810
2

Continued on next page

TM2111 (30MAY03)

18-1810-2

CED,OUO1048,398 1910DEC022/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=494

Operator Enclosure
1Windowpane, Rear
2Isolator (as required)
3Windowpane, Side (2 used)
4Window, Door (2 used)

5Weather-Strip (as required)


6Windowpane, Front (2
used)

7Cap Screw (79 used)


8Spacer (57 used)
9Windowpane, Front

Front, Rear, and Side Windows

10Spacer (22 used)


11Cab Door and Rear
Window Glass

screws without spacers could


damage windowpane.

1. Clean cab-to-windowpane contact area of dirt and


old weather-stripping.
CAUTION: DO NOT replace polycarbonate
windows with glass or plastic. Polycarbonate
material impact resistance is recommended
for forestry use. See story in this group for
cleaning instructions.

2. Install new weather-stripping, windowpane, spacers,


and cap screws. Tighten cap screws to
specification.
Window and Window MoldingSpecification
Windowpane Cap Screw
Torque.................................................................... 20 Nm (180 lb-in.)

IMPORTANT: Spacers must be installed before cap


screws are tightened. Tightening cap

CED,OUO1048,398 1910DEC023/3

TM2111 (30MAY03)

18-1810-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=495

18
1810
3

Operator Enclosure

Clean Windows Regularly


The windshield is a polycarbonate material which is softer
but stronger than glass. It will scratch.
IMPORTANT: DO NOT operate windshield wiper on a
dry window, or scrape windows with
sharp objects.
Before washing, flush as much loose dirt off as possible
with water. If there is a heavy concentration of tree sap,
use No. 1 or No. 3 denatured alcohol, Varsol No. 2 or
rubbing alcohol, followed by a water soluble cleaner.
18
1810
4

IMPORTANT: Some cleaning compounds may attack


the polycarbonate material, resulting in
cracks that will weaken the material.
Never use substances such as
Trichloethylene, Carbon Tetrachloride
or petroleum products.
Thoroughly rinse the windows after washing, and dry with
clean, soft towels.
To minimize scratches, and improve visibility by filling in
existing scratches, it is recommended that the windows be
waxed regularly.
IMPORTANT: If cracks or surface crazing are
observed, replace windshield.

TX,90,RR,1393 1922DEC921/1

TM2111 (30MAY03)

18-1810-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=496

Operator Enclosure

18
1810
5

TM2111 (30MAY03)

18-1810-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=497

Operator Enclosure

Cab Door and Door Latch Repair

T130709

UN04MAY00

18
1810
6

Continued on next page

TM2111 (30MAY03)

18-1810-6

OUO1065,0000597 1910DEC021/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=498

Operator Enclosure
1Ball Stud and Retainer (2
used)
2Cylinder
3Hinge (2 used)
4Cap Screw and Washer (8
used)
5Hinge (2 used)
6Strap (2 used)
7Lock Washer (2 used)
8Nut (2 used)

9Screw (4 used)
10Yoke
11Weather-Strip (as
required)
12Cover
13Cap Screw (2 used)
14Bracket
15Plate
16Lock Washer
17Cap Screw

18Latch
19Knob
20Rod
21Link (2 used)
22Striker
23Spring
24Washer
25Lock Nut
26Guard

27Lock
28Strap
29Cap Screw (4 used)
30Washer (as required)
31Bracket (2 used)
32Tape (as required)
33Seal
34Cap Screw (4 used)
35Door

Cab Door and Door LatchSpecification


Door Hinge Mounting Cap
ScrewsTorque ....................................................... 73 Nm (54 lb-ft)

Cab Door and Door Latch


1. Remove spring (23).

18
1810
7

2. Close door latch (18).


3. Adjust rod (20) so yoke (10) aligns with hole closest
to lock pivot.

Continued on next page

TM2111 (30MAY03)

18-1810-7

OUO1065,0000597 1910DEC022/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=499

Operator Enclosure

TP63077

UN02DEC99

18
1810
8

Continued on next page

TM2111 (30MAY03)

18-1810-8

OUO1065,0000597 1910DEC023/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=500

Operator Enclosure
1Right Panel
2Nut (8 used)

3Cap Screw (8 used)


4Left Panel

5Washer (8 used)

6Self-Locking Screw (8
used)

Door Panels Remove and Install


Remove and install door inner panels.

OUO1065,0000597 1910DEC024/4

18
1810
9

TM2111 (30MAY03)

18-1810-9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=501

Operator Enclosure

Windshield Wiper and Washer Repair

T130580

UN09JUN00

18
1810
10

Continued on next page

TM2111 (30MAY03)

18-1810-10

OUO1065,0000598 1910DEC021/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=502

Operator Enclosure
1Fitting
2Hose
3Tie Strap
4Wiper Motor
5Check Valve

6Cap
7Cap Screw (2 used)
8Washer (2 used)
9Grommet

10Cap Screw (2 used)


11Hose
12Bracket
13Tank

14Wiper Blade
15Wiper Arm
16Cap Screw
17Spacer

Front Windshield Wiper and Washer Remove and


Install
Disassemble and assemble.

Continued on next page

OUO1065,0000598 1910DEC022/6

18
1810
11

TM2111 (30MAY03)

18-1810-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=503

Operator Enclosure

T130581

UN01MAY00

18
1810
12

Continued on next page

TM2111 (30MAY03)

18-1810-12

OUO1065,0000598 1910DEC023/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=504

Operator Enclosure
1Wiper Blade
2Wiper Arm
3Cap Screw
4Wiper Motor

5Fuse
6Hose
7Fitting
8Spacer

9Cap
10Tank
11Check Valve
12Grommet (2 used)

13Bracket (2 used)
14Cap Screw (4 used)
15Pump (2 used)
16Tie Strap

Rear Wiper and Washer Remove and Install


Disassemble and assemble.

OUO1065,0000598 1910DEC024/6

18
1810
13

Front and Rear Windshield Wiper Adjustment

T131540B

UN27MAR01

CAUTION: Keep hands away from linkage when


the motor is in operation. DO NOT adjust park
position when the motor is in operation. Never
start a windshield wiper when the blade is
frozen to the windshield or manually stop the
blade when the wiper is operating.
1. If the blade does not park with the tip 63.5 mm (2.50
in.) (1) from the top edge of windshield, adjust the
wiper blade.

Headlight Shown Removed for Illustration Purposes


163.5 mm (2.50 in.) Measurement

Front and Rear Windshield Wiper AdjustmentSpecification


Blade-to-Top Edge of
WindshieldDistance................................................... 63.5 mm (2.50 in.)

Continued on next page

TM2111 (30MAY03)

18-1810-13

OUO1065,0000598 1910DEC025/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=505

Operator Enclosure
2. Lift wiper arm (3) away from windshield to full extended
position.
3. Lift pivot cover (1) and return wiper arm to windshield.
UN09JUN00

4. Remove retaining nut (2).

T131542B

5. Pull wiper arm from pivot shaft. Position to specification


and tighten retaining nut just until snug against wiper
arm.
6. Start motor, shut off and note the new park position.
Headlight Shown Removed for Illustration Purposes
18
1810
14

7. If blade tip still does not park 63.5 mm (2.50 in.) from
top edge of windshield, adjust by following the
procedure outlined in steps 26 until the correct park
position is obtained.

1Pivot Cover
2Retaining Nut
3Wiper Arm

8. Tighten retaining nut (2) to specification.


Front and Rear Windshield Wiper AdjustmentSpecification
Wiper Retaining Nut-to-Pivot
Torque ........................................................ 1421 Nm (124186 lb-in.)

9. Close pivot cover (1).

OUO1065,0000598 1910DEC026/6

TM2111 (30MAY03)

18-1810-14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=506

Group 1821

Seat and Seat Belt


Seat Repair
Seat Remove and Install

UN12JUN00

1. Disconnect electrical connector if equipped with air


suspension seat.

T131570B

CAUTION: Heavy component; use a hoist.


2. Remove nuts (1), both sides. Remove seat.
3. Install seat.

Continued on next page

TM2111 (30MAY03)

18
1821
1

1Nut (2 used)

4. Connect electrical connector if equipped with air


suspension seat.

18-1821-1

CED,OUO1032,3447 1923JUN001/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=507

Seat and Seat Belt

T114920

UN29APR98

18
1821
2

Continued on next page

TM2111 (30MAY03)

18-1821-2

CED,OUO1032,3447 1923JUN002/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=508

Seat and Seat Belt


1Cushion
2Cushion
3Right Plate
4Left Plate
5Arm Rest Assembly, Right
6Arm Rest Assembly, Left
7Bracket (2 used)
8Set Screw (2 used)
9Washer (2 used)

10Right Plate
11Left Plate
12Cap Screw (2 used)
13Lever
14Knob and Screw Kit
15Cap Screw
16Spring
17Latch
18Spacer

19Plate
20Cap Screw (2 used)
21Seat Belt
22Washer (4 used)
23Cap Screw (2 used)
24Washer (8 used)
25Cover
26Cap Screw (2 used)

27Spacer (2 used)
28Washer (4 used)
29Nut (4 used)
30Cap Screw (3 used)
31Lock Nut
32Spring
33Arm Rest, Right
34Arm Rest, Left

Seat Disassemble and Assemble


Disassemble and assemble.
18
1821
3

Continued on next page

TM2111 (30MAY03)

18-1821-3

CED,OUO1032,3447 1923JUN003/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=509

Seat and Seat Belt

T114921

UN29APR98

18
1821
4

1Pad
2Spring
3Shock Absorber Kit
4Shock Absorber
5Bushing (2 used)
6Bearing and Bushing Kit (2
used)
7Bushing
8Bar

9Bar
10Frame
11Bar
12Bar
13Boot
14Plug (25 used)
15Boot Suspension Kit
16Gear

17Angle
18Adjusting Knob Kit
19Adjusting Knob
20Spring Pin
21Washer
22Gear
23Plate
24Lower Tray

Continued on next page

TM2111 (30MAY03)

18-1821-4

25Upper Tray
26Guardian Suspension Kit
27Cap Screw (2 used)
28Washer (2 used)
29Belt
30Washer (2 used)
31Lock Nut (2 used)
32Belt Kit

CED,OUO1032,3447 1923JUN004/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=510

Seat and Seat Belt


Seat Base Suspension and Shock Absorber
Disassemble and Assemble

a press before disassembling so spring


force can be released slowly.

Disassemble and assemble.

1. Put base of suspension seat in a press before


removing cap screws and nuts.

CAUTION: Spring under compression is


used in base of suspension seat. Put base in

2. Slowly release press to release spring force.

Continued on next page

CED,OUO1032,3447 1923JUN005/9

18
1821
5

TM2111 (30MAY03)

18-1821-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=511

Seat and Seat Belt

T130710

UN04MAY00

18
1821
6

Continued on next page

TM2111 (30MAY03)

18-1821-6

CED,OUO1032,3447 1923JUN006/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=512

Seat and Seat Belt


1Slide Set (2 used)
2Spring (2 used)
3Snap Ring (2 used)

4Control Lever
5Spring

6Spring
7Snap Ring (4 used)

8Slide Set (2 used)


9Set Screw (4 used)

Seat Base, Seat Slide and Control Lever


Disassemble and Assemble
Disassemble and assemble.

Continued on next page

CED,OUO1032,3447 1923JUN007/9

18
1821
7

TM2111 (30MAY03)

18-1821-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=513

Seat and Seat Belt

T106768

UN31MAR97

18
1821
8

Continued on next page

TM2111 (30MAY03)

18-1821-8

CED,OUO1032,3447 1923JUN008/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=514

Seat and Seat Belt


1Tube (4 used)
2Bushing (2 used)
3Washer (2 used)
4Washer (6 used)
5Cap Screw (2 used)
6Bumper
7Washer (6 used)
8Cover
9Washer
10Shock Absorber
11Nut (5 used)
12Retainer
13Cap Screw (2 used)
14Upper Suspension
15Control Lever
16Cap Screw (3 used)

17Cap
18Shock Absorber
19Bushing (2 used)
20Washer (4 used)
21Plate (3 used)
22Roller (4 used)
23Bellows
24Bumper (2 used)
25Ring (2 used)
26Bushing (2 used)
27Nut (2 used)
28Bearing (2 used)
29Cap Screw (2 used)
30Cap Screw
31Bumper
32Tube

33Belt Tether
34Plug (22 used)
35Lower Suspension
36Retainer
37Nut (5 used)
38Cap Screw (2 used)
39Air Spring
40Fastener (5 used)
41Fastener (4 used)
42U-Clamp (2 used)
43Plate
44Compressor
45Cap Screw
46Bracket
47Fitting (2 used)

48Tube
49Cable
50Swing Arm
51Snap Ring (2 used)
52Cap Screw
53Washer (2 used)
54Lever
55Washer
56Snap Ring
57Spring
58Rivet (2 used)
59Stop (2 used)
60Retainer
61Retainer
62Bumper
18
1821
9

Seat Air Suspension Disassemble and Assemble


Disassemble and assemble.

CED,OUO1032,3447 1923JUN009/9

T8415AA

UN09FEB95

Seat Belt Repair

1. Seat belt and mounting hardware must be


inspected for wear or damage before operating the
machine. Replace the belt or mounting hardware if
worn or damaged.

2. Replace the complete seat belt assembly every


three years regardless of appearance. A date label,
to determine the age of the belt, is attached to each
belt.

Continued on next page

TM2111 (30MAY03)

18-1821-9

TX,10,DH3548 1910DEC021/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=515

Seat and Seat Belt

T114923

UN29APR98

18
1821
10

ACap Screw (2 used)

BWasher (4 used)

CSeat Belt Assembly

Two-Inch Seat Belt Disassemble and Assemble


Disassemble and assemble.

Continued on next page

TM2111 (30MAY03)

18-1821-10

TX,10,DH3548 1910DEC022/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=516

Seat and Seat Belt

T114924

UN29APR98

18
1821
11

ACap Screw (2 used)

BWasher (4 used)

Anti-Cinch Seat Belt Disassemble and Assemble


Disassemble and assemble.
Seat Belt Install
1. Install cap screw (A) with washers (B) through seat
belt and another washer (B) on right and left sides.

CSeat Belt Assembly

2. Tighten bolt until retractor is slightly snug, but


retractor can still be rotated about ten degrees in
either direction.
Seat BeltSpecification
Seat Belt Cap ScrewTorque ............ Until retractor is slightly snug,
retractor can rotate 10 either
direction

TX,10,DH3548 1910DEC023/3

TM2111 (30MAY03)

18-1821-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=517

Seat and Seat Belt

18
1821
12

TM2111 (30MAY03)

18-1821-12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=518

Group 1830

Heating and Air Conditioning


Refrigerant Cautions and Proper Handling
R134a is used in the air conditioning
system. Because it does not contain
chlorine, R134a is not detrimental to
the ozone in the atmosphere.
However, it is illegal to discharge
any refrigerant into the atmosphere.
It must be recovered using the
appropriate recovery stations.

CAUTION: DO NOT allow liquid refrigerant to


contact eyes or skin. Liquid refrigerant will
freeze eyes or skin on contact. Wear
goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO
NOT rub the area. Splash large amounts of
COOL water on affected area. Go to a
physician or hospital immediately for
treatment.

Use correct refrigerant recovery,


recycling and charging stations.
Never mix refrigerants, hoses,
fittings, components or refrigerant
oils.

DO NOT allow refrigerant to contact open


flames or very hot surfaces such as electric
welding arc, electric heating element and
lighted smoking materials.

18
1830
1

Use only John Deere approved


R134a refrigerant products. Mixing of
products not compatible will cause
system damage and contaminate
recovery, recycling and charging
station equipment. Care must be
taken to identify and use equipment,
refrigerant oil and refrigerant
designed only for R134a refrigerant
systems. Refrigerant should be
tested for type and purity before
recovery, recycling or charging of
system. JT02167A refrigerant test
instrument should be used before
any testing or repair to system is
preformed.

DO NOT heat refrigerant over 52C (125F) in


a closed container. Heated refrigerant will
develop high pressure which can burst the
container.
Keep refrigerant containers away from heat
sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container
with your bare hands. Skin may freeze to
container. Wear gloves.
If skin freezes to container, pour COOL
water over container to free the skin. Go to a
physician or hospital immediately for
treatment.
IMPORTANT: To meet government standards
relating to the use of refrigerants,

Continued on next page

TM2111 (30MAY03)

18-1830-1

TX,9031,DY5073 1904MAY011/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=519

Heating and Air Conditioning


Prism Pro Refrigerant Identification
Instrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A
To safely identify type and check purity of refrigerant
prior to recovery, recycling and recharging of A/C
systems.

TX,9031,DY5073 1904MAY012/2

18
1830
2

TM2111 (30MAY03)

18-1830-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=520

Heating and Air Conditioning

Flush and Purge Air Conditioner System


CAUTION: Liquid refrigerant will freeze eyes
or skin on contact. Wear goggles, gloves
and protective clothing. See Refrigerant
Cautions and Proper Handling in this group.

NOTE: Flushing can be performed on machine.


1. Recover refrigerant. See Recover R134a
Refrigerant in this group.

b. Connect flusher outlet hose to inlet end of


compressor discharge line using JT02102
Adapter.
c. Pour flushing solvent into suction port and
discharge port. Plug both ports in compressor
manifold, using JT02099 and JT03194 Caps.
Flush and Purge SystemSpecification
A/C Compressor Flushing
Solvent in Suction Port
Volume ....................................................................... 240 mL (8 fl oz)
A/C Compressor Flushing
Solvent in Discharge Port
Volume ....................................................................... 120 mL (4 fl oz)

Add flushing solvent to system with JT02075


Flusher and JT02098 Fitting Kit.
2. Remove and discard receiver dryer.
3. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102 Adapter.
4. Fill flusher tank with solvent and fasten all
connections. Dispose of solvent properly.
Flush and Purge SystemSpecification
Flusher TankCapacity ..................................................... 4 L (1 gal)

NOTE: Air pressure must be at minimum specification


for flushing and purging.
Flush and Purge SystemSpecification
Air PressureMinimum
Pressure................................................ 620 kPa (90 psi) (6.2 bar) for
flushing and purging

5. Connect a supply line of moisture-free compressed


air or dry nitrogen to flusher air valve.
6. Open air valve to force flushing solvent into
condenser circuit. Flusher tank is empty when hose
pulsing stops. Additional flushing cycles are
required if system is heavily contaminated with
burned oil or metal particles.

d. Turn compressor end for end and roll it side to


side.
e. Remove both plugs from manifold ports and
drain solvent from compressor.
f. Connect battery power to compressor clutch coil.
Rotate pulley at least five revolutions to move
solvent out of cylinders.
g. Invert compressor. Roll end for end and side to
side. Drain thoroughly.
h. Repeat previous two steps at least three times.
8. Divide system into two circuits:
Condenser circuit, including inlet and outlet
hoses.
Evaporator circuit, including inlet and outlet
hoses.
9. Condenser:

7. Clean compressor as follows:


a. Remove compressor and measure oil drained
from both manifold ports.

Continued on next page

TM2111 (30MAY03)

18-1830-3

TX,18,DU2461 1910DEC021/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=521

18
1830
3

Heating and Air Conditioning


IMPORTANT: DO NOT attempt to flush through
compressor or receiver dryer.
Flushing through expansion valve is
acceptable if refrigerant oil has a
normal odor and appearance.
a. Flush and Purge Condenser:

NOTE: Purging the condenser circuit takes 1012


minutes to thoroughly remove solvent.
h. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of
cardboard; continue purging until cardboard is
dry.

b. Remove and discard receiver dryer.


c. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102
Adapter.
18
1830
4

Adapter. Put nozzle in container to collect


flushing solvent.

10. See flush evaporator, if evaporator requires


flushing.

d. Fill flusher tank with solvent and fasten all


connections.
Flush and Purge SystemSpecification
Flusher TankCapacity ..................................................... 4 L (1 gal)

If system is contaminated with burned refrigerant


oil or debris, remove and bench flush evaporator.
See following steps to flush evaporator through
expansion valve, if oil appears normal.
11. Flush evaporator:

NOTE: Air pressure must be at minimum specification


for flushing and purging.
Flush and Purge SystemSpecification
Air PressurePressure ............................. 620 kPa (90 psi) (6.2 bar)
minimum for flushing and
purging

a. Remove evaporator. See Evaporator Remove


and Install in this group.
b. Force flushing solvent through evaporator inlet
with compressed air.
c. Purge system until dry.
d. Install evaporator and then go to step 13.

e. Connect a supply line of moisture-free


compressed air or dry nitrogen to flusher air
valve.

12. Flush evaporator through expansion valve:

f. Open air valve to force flushing solvent into


condenser circuit. Flusher tank is empty when
hose pulsing stops. Additional flushing cycles are
required if system is heavily contaminated with
burned oil or metal particles.
g. Attach a return hose and aerator nozzle to end
of receiver dryer inlet hose using JT03197

a. Connect flusher outlet hose to connection of


receiver dryer outlet hose using JT03188
Adapter.
b. Fill flusher tank and fasten all connections.
Flush and Purge SystemSpecification
Flusher TankCapacity ..................................................... 4 L (1 gal)

Continued on next page

TM2111 (30MAY03)

18-1830-4

TX,18,DU2461 1910DEC022/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=522

Heating and Air Conditioning


NOTE: Air pressure must be at minimum specification.
Flush and Purge SystemSpecification
Air PressurePressure ............................. 620 kPa (90 psi) (6.2 bar)
minimum for flushing and
purging

c. Connect a supply line of moisture-free


compressed air or dry nitrogen to flusher air
valve.
d. Attach a hose and aerator nozzle to
compressor inlet line using JT02101 Adapter.
Put nozzle in a container to collect solvent.

cardboard and continue purging until cardboard is


dry.
14. Install a new receiver dryer compatible with R134a
refrigerant. Fasten connections and mounting
bracket. See Receiver-Dryer Remove and Install in
this group.
15. Add required oil. See R134a Refrigerant Oil
Information in this group.
16. Install compressor and connect refrigerant lines to
manifold.
18
1830
5

17. Connect clutch coil wire and install drive belt.

NOTE: Purging evaporator circuit takes 1215


minutes to thoroughly remove solvent.
13. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of

TX,18,DU2461 1910DEC023/3

TM2111 (30MAY03)

18-1830-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=523

Heating and Air Conditioning

R134a Refrigerant Oil Information


CAUTION: All new compressors are charged
with a mixture of nitrogen, R134a refrigerant
and TY22025 (R134a) refrigerant oil. Wear
safety goggles and discharge the
compressor slowly to avoid possible injury.

18
1830
6

CAUTION: DO NOT leave system or R134a


compressor oil containers open. Refrigerant
oil easily absorbs moisture. DO NOT spill
R134a compressor oil on acrylic or ABS
plastic. This oil will deteriorate these
materials rapidly. Identify R134a oil
containers and measures to eliminate
accidental mixing of different oils.
IMPORTANT: Do not add any more oil than
required or maximum cooling will be
reduced.
A new compressor from parts depot contains 230 20
mL (7.7 0.7 fl oz) of new oil. The oil level visible
through the suction port normally is below the drive
shaft.
Normal operating oil level of a compressor removed
from operation is 3045 mL (1.01.5 fl oz). This level
cannot be seen through suction port of compressor.
Compressors can be divided into three categories
when determining correct oil charge for system.

Refrigerant Oil CapacitySpecification


New CompressorVolume ................... 230 20 mL (7.7 0.7 fl oz)
Air Conditioning System
Additional Oil Volume.......................................... 182 mL (4.0 fl oz)
Compressor Operating Oil
LevelVolume.......................................... 3045 mL (1.01.5 fl oz)

Used compressor removed from operation, oil


drained, and system flushed
Refrigerant Oil CapacitySpecification
Used Compressor and System
Flushed OilVolume ........................... 435 44 mL (14.7 1.5 fl oz)

2. When complete system was not flushed add correct


amount of oil for compressor plus amount of oil for
each component that was serviced.
New compressor or remanufactured
Refrigerant Oil CapacitySpecification
New Compressor Operating Oil
LevelVolume..................................... Drain and return 45 mL (1.5 fl
oz)

Used compressor removed from operation and oil


drained.

New compressor from parts depot


Used compressor removed from operation
Compressor internally washed with flushing solvent

Refrigerant Oil CapacitySpecification


Used Compressor Drained
OilVolume .............................................................. 45 mL (1.5 fl oz)

Determining the amount of system oil charge prior to


installation of compressor on a machine.
1. When complete system, lines, and components are
flushed add correct amount of oil as described.
New or remanufactured compressor (system
requires an additional amount of new oil)

Used compressor removed from operation


Refrigerant Oil CapacitySpecification
Used Compressor Flushed
OilVolume .............................................................. 60 mL (2.0 fl oz)

Continued on next page

TM2111 (30MAY03)

18-1830-6

TX,9031,QQ2365 1910DEC021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=524

Heating and Air Conditioning


Components listed below which have been
removed, drained and flushed, require removal of
compressor to determine correct oil charge. Use
following chart as a guide for adding oil to
components:
Refrigerant Oil CapacitySpecification
Evaporator OilVolume ......................................... 130 mL (4.4 fl oz)
Condenser OilVolume ........................................... 65 mL (2.2 fl oz)
Receiver Dryer OilVolume .................................... 30 mL (1.0 fl oz)
Flushed Compressor Oil
Volume ...................................................................... 60 mL (2.0 fl oz)
Hose OilVolume ................................ 3 mL per 30 cm (0.1 fl oz per
ft) approximate total length

If oil drained from a compressor removed from


operation is very black or amount of oil is less
than 6 mL (0.2 fl oz), perform the following and
discard oil properly:
Determine if R134a leakage was detected,
remove component and repair or replace
component.
Remove and discard receiver dryer.
Flush complete system with TY16134 Air
Conditioning Flushing Solvent.
3. If component is serviceable, pour flushing solvent in
ports and internally wash out old oil and discard oil
properly.
18
1830
7

4. Install a new receiver dryer. See Receiver-Dryer


Remove and Install in this group.

NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft)


Approximate total length equals 600 cm (20 ft).
If any section of hose is removed and flushed or
replaced, measure length of hose and use
formula 3 mL per 30 cm (0.1 fl oz per ft) to
determine correct amount of oil to be added.
Drain compressor oil into graduated container
while rotating compressor shaft and record
amount.

5. Install required amount of TY22025 Refrigerant Oil


in compressor.
6. Connect all components, evacuate and charge
system. See Evacuate R134a System and See
Charge R134a System in this group.

TX,9031,QQ2365 1910DEC022/2

TM2111 (30MAY03)

18-1830-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=525

Heating and Air Conditioning

R134a Refrigerant Recovery, Recycling and


Charging Station Installation Procedure
CAUTION: Liquid refrigerant will freeze eyes or
skin on contact. Wear goggles, gloves and
protective clothing. See Refrigerant Cautions
and Proper Handling in this group.)

UN06DEC93

CAUTION: Do not remove high pressure relief


valve (D). Air conditioning station will discharge
rapidly causing possible injury.
IMPORTANT: Use only John Deere approved
refrigerant recovery, recycling and
charging stations. DO NOT mix
refrigerant, hoses, fittings, components
or refrigerant oils.
1. Follow Refrigerant Cautions and Proper Handling
procedures in this group.
2. Close both high-side and low-side valves on refrigerant
recovery, recycling and charging station (E).

T8118AG

18
1830
8

IMPORTANT: Use only John Deere approved R134a


refrigerant products. Mixing of products
not compatible will cause system
damage and contaminate recovery,
recycling and charging station
equipment.

AHigh Pressure Hose Charge Port Cap


BRed Hose
CBlue Hose
DHigh Pressure Relief Valve
ERefrigerant Recovery, Recycling and Charging
Station

3. Remove cap from low-side charge port.


4. Connect blue hose (C) from refrigerant recovery,
recycling and charging station (E) to low-side test port.
5. Remove cap (A) from charge port on high pressure
hose and connect red hose (B).
6. Follow the manufacturers instructions when using
refrigerant recovery, recycling and charging station.

TX,9031,DU1693 1910DEC021/1

TM2111 (30MAY03)

18-1830-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=526

Heating and Air Conditioning

Recover R134a Refrigerant


CAUTION: Liquid refrigerant will freeze eyes or
skin on contact. Wear goggles, gloves and
protective clothing. See Refrigerant Cautions
and Proper Handling in this group.
CAUTION: Do not remove high pressure relief
valve. Air conditioning system will discharge
rapidly causing possible injury.
IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations. DO
NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.

18
1830
9

1. Run air conditioning system for three minutes to help in


recovery process. Turn air conditioning system off
before proceeding with recovery steps.
2. With engine OFF identify refrigerant type using
JT02167A Refrigerant Identification Instrument.
3. Connect refrigerant recovery system. See R134a
Refrigerant Recovery, Recycling and Charging Station
Installation Procedure in this group.
4. Follow manufacturers instructions when using
refrigerant recovery, recycling and charging station.

TX,9031,DU1694 1910DEC021/1

TM2111 (30MAY03)

18-1830-9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=527

Heating and Air Conditioning

Evacuate R134a System


CAUTION: Liquid refrigerant will freeze eyes
or skin on contact. Wear goggles, gloves
and protective clothing. See Refrigerant
Cautions and Proper Handling in this group.
CAUTION: Do not remove high pressure
relief valve. Air conditioning system will
discharge rapidly causing possible injury.

18
1830
10

4. Evacuate system until low-side gauge registers 98


kPa (980 mbar) (29 in. Hg) vacuum.
Air Conditioning SystemSpecification
Evacuate SystemVacuum ............... 98 kPa (980 mbar) (29 in. Hg)

If above specification vacuum cannot be obtained in 15


minutes, test the system for leaks. See Air
Conditioning System Checks. (Group 9031-25.)

1. Connect refrigerant recovery system. See R134a


Refrigerant Recovery, Recycling and Charging
Station Installation Procedure in this group.

5. When vacuum reaches above specification, close


low-side and high-side valves. Turn vacuum pump
off.

2. Open low-side and high-side valves on refrigerant


recovery, recycling and charging station.

6. If vacuum decreases more than specification in 5


minutes, there is a leak in system.

3. Follow manufacturers instructions and evacuate


system.

NOTE: Vacuum specifications listed are for sea level


conditions. Subtract 3.4 kPa (34 mbar) (1 in.
Hg) from 98 kPa (980 mbar) (29 in. Hg) for
each 300 m (1000 ft) elevation above sea
level.
Air Conditioning SystemSpecification
Evacuate SystemVacuum ................ Subtract 3.4 kPa (34 mbar) (1
in. Hg) from 98 kPa (980 mbar)
(29 in. Hg) for each 300 m
(1000 ft) elevation above sea
level

Air Conditioning SystemSpecification


Evacuate SystemVacuum .................. 3.4 kPa (34 mbar) (1 in. Hg)

7. Repair leak.
8. Evacuate system for 30 minutes after 98 kPa (980
mbar) (29 in. Hg) vacuum is reached.
9. Close low-side and high-side valves. Stop
evacuation.
10. Charge system. See Charge R134a System in this
group.

TX,1830,DT474 1910DEC021/1

TM2111 (30MAY03)

18-1830-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=528

Heating and Air Conditioning

Charge R134a System


Engine STOPPED, the pump must be capable
of pulling at least 28.6 in. Hg vacuum (sea
level). Subtract 3.4 kPa (34 mbar) (1 in. Hg)
from 98 kPa (980 mbar) (29 in. Hg) for each
300 m (1000 ft) elevation above sea level.

CAUTION: Liquid refrigerant will freeze eyes


or skin on contact. Wear goggles, gloves
and protective clothing. See Refrigerant
Cautions and Proper Handling in this group.
IMPORTANT: Use only John Deere approved
refrigerant recovery, recycling and
charging stations. DO NOT mix
refrigerant, hoses, fittings,
components or refrigerant oils.
1. Identify refrigerant type using JT02167A Refrigerant
Identification Instrument.
2. Connect R134a Refrigerant Recovery, Recycling
and Charging Station. See R134a Refrigerant
Recovery, Recycling and Charging Station
Installation Procedure in this group.
3. Evacuate system. See Evacuate R134a System in
this group.

NOTE: Before beginning to charge air conditioning


system, the following conditions must exist:

Air Conditioning SystemSpecification


Evacuate SystemVacuum ................ Subtract 3.4 kPa (34 mbar) (1
in. Hg) from 98 kPa (980 mbar)
(29 in. Hg) for each 300 m
(1000 ft) elevation above sea
level
18
1830
11

4. Follow manufacturers instructions and charge


system.
5. Add refrigerant to system.
Air Conditioning SystemSpecification
Air Conditioning System
RefrigerantRefrigerant
Quantity...................................................................... 1.93 kg (4.25 lb)

6. Check air conditioning for proper function. See


Diagnose Air Conditioning System Malfunctions.
(Group 9031-25.)

TX,18,DU2481 1910DEC021/1

TM2111 (30MAY03)

18-1830-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=529

Heating and Air Conditioning

Compressor Relief Valve Remove and Install

UN10MAY00

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

T130758B

1. Remove front left engine shield.


2. Recover refrigerant. See Recover R134a Refrigerant in
this group.
3. Slowly remove relief valve (A) from compressor
manifold.

ARelief Valve

NOTE: The relief valve is not serviceable. Replace valve


as required.
4. Install relief valve (A) and tighten to specification.
Compressor Relief ValveSpecification
Relief ValveTorque ................................. 1216 Nm (103142 lb-in.)

5. Charge the system. See Charge R134a System in this


group.
6. Install engine side shield.

CED,OUO1048,406 1910DEC021/1

High and Low Pressure Switches Remove


and Install

UN10MAY00

Direct drive machine shown throughout. Procedures for


torque converter machine are the same except where
noted.
1. Open heating and air conditioning compartment cover
located at rear of cab.

T130760B

18
1830
12

2. Remove wing nuts (A) and remove cover (B).


AWing Nut (3 used) (Torque Converter Machine
Uses Cap Screws and Washers)
BCover

Continued on next page

TM2111 (30MAY03)

18-1830-12

CED,OUO1048,407 1910DEC021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=530

Heating and Air Conditioning


IMPORTANT: Remove pressure switches using a
wrench on hex nut fitting. Damage to
switch will occur if removed by plastic
switch housing.

NOTE: Tag high and low pressure switches to aid in


installation.

UN10MAY00

The line that attaches the high pressure switch


has a valve installed to prevent discharging the air
conditioning system when switch is removed, and
the line that attaches the low pressure switch has
a valve to prevent discharging the air conditioning
system when switch is removed.

4. Test switch and replace if necessary. See Air


Conditioning Low Pressure Switch Test or see Air
Conditioning High Pressure Switch Test. (Group
9031-25.)

T130757B

3. Disconnect wiring connector (C or D) and remove


pressure switch (E or F) using a wrench on hex nut
fitting.

CWiring Connector
DWiring Connector
ELow Pressure Switch
FHigh Pressure Switch

5. Install pressure switch. Connect wiring connector to


switch connector.
6. Close and secure heating and air conditioning
compartment cover.

CED,OUO1048,407 1910DEC022/2

TM2111 (30MAY03)

18-1830-13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=531

18
1830
13

Heating and Air Conditioning

Air Conditioning Compressor Remove and


Install
1. Remove left-side engine shields.
2. Recover air conditioning refrigerant. See Recover
R134a Refrigerant in this group.

4. Remove belt (4). See Fan Belt Remove and Install.


(Group 0510.)

T162934B

18
1830
14

UN17DEC02

3. Remove fan guard (2). See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)

5. Disconnect lines (5 and 6) at compressor.


6. Disconnect electrical connector (8).
1Cap Screw
2Fan Guard
3Cap Screw (2 used)
4Belt
5Suction Line
6Pressure Line
7Ground Lead Screw
8Electrical Connector
9Cap Screw (4 used)

7. Remove screw (7) to disconnect ground lead.


8. Remove cap screws (9) to remove compressor.
9. Replace parts as necessary.
10. Install compressor using cap screws (9).
11. If removed, tighten compressor manifold cap screws
to specification.
Air Conditioning CompressorSpecification
Compressor Manifold Cap
ScrewsTorque ......................................... 2427 Nm (216240 lb-in.)

12. Install belt (4). See Fan Belt Remove and Install.
(Group 0510.)
13. Install ground lead using screw (7).
14. Connect electrical connector (8).
15. Add compressor oil. See R134a Refrigerant Oil
Information in this group.
16. Connect lines (5 and 6). Tighten to specification.
Air Conditioning CompressorSpecification
Pressure Line-to-Condenser
Torque ........................................................ 2027 Nm (177239 lb-in.)
Suction Line-to-Compressor
Torque ........................................................ 2428 Nm (212248 lb-in.)

Continued on next page

TM2111 (30MAY03)

18-1830-14

CED,OUO1032,3389 1910DEC021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=532

Heating and Air Conditioning


17. Install fan guard (2). See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)
18. Install a new receiver dryer. See Receiver-Dryer
Remove and Install in this group.
19. Evacuate and charge the system. See Evacuate
R134a System in this group. See Charge R134a
System in this group.

CED,OUO1032,3389 1910DEC022/2

18
1830
15

TM2111 (30MAY03)

18-1830-15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=533

Heating and Air Conditioning

Air Conditioning Compressor Clutch Repair

T130715

UN04MAY00

RW21157

UN24JUN92

18
1830
16

AJDG747 Hub Holding Tool


BClutch Shaft Bolt

CClutch Hub
DPulley Snap Ring

EPulley
FClutch Coil Snap Ring

Continued on next page

TM2111 (30MAY03)

18-1830-16

GClutch Coil
HShims

TX,18,RB761 1910DEC021/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=534

Heating and Air Conditioning


Air Conditioning Compressor Clutch Disassemble
and Assemble
1. Mount compressor on D01006AA Bench Mounted
Holding Fixture or see DFRW20 Compressor
Holding Fixture using two 6 in. x 1/4 in. eye bolts
with nuts as illustrated. (Group 9900.)

NOTE: The bearing in the pulley is NOT serviceable.


7. Check pulley bearing operation. Replace pulley and
bearing as required.
8. Install the clutch coil and new snap ring with flat
side of the snap ring down. Connect the clutch coil
lead wire.

2. Remove dust cover.


3. Hold the clutch hub using JDG747 Hub Holding
Tool (A) and remove the clutch shaft bolt (B).

9. Install the pulley and new snap ring with the flat
side of the snap ring down. Apply grease to the
shims (H) and install to the clutch hub.

4. Remove the clutch hub (C). Remove the shims (H)


from the clutch hub and save for installation.

10. Install clutch hub and shaft bolt and tighten to


specification.

5. Remove and discard snap ring (D). Remove the


pulley (E) using a plastic hammer or JDG220 Puller
Adapter, JDG748 Hub Puller Jaws and JDG771
Forcing Screw.

Air Conditioning Compressor ClutchSpecification


Compressor Hub Retaining
NutTorque .......................................................... 14 Nm (124 lb-in.)

18
1830
17

6. Disconnect the clutch coil lead wire. Remove and


discard the snap ring (F) and remove the clutch coil
(G).

Continued on next page

TM2111 (30MAY03)

18-1830-17

TX,18,RB761 1910DEC022/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=535

Heating and Air Conditioning


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. Correct
clearance is 0.350.65 mm (0.0140.026 in.). Add or
remove shims as required.
Air Conditioning Compressor ClutchSpecification
Air Conditioning Clutch
Hub-to-PulleyClearance ................... 0.350.65 mm (0.0140.026 in.)

RW21159

Air Conditioning Compressor ClutchSpecification


Air Conditioning Clutch Shaft
BoltTorque ............................................................... 14 Nm (124 lb-in.)

UN24JUN92

3. Tighten clutch shaft bolt to specification after correct


clearance is obtained.

TX,18,RB761 1910DEC023/3

Air Conditioning Compressor Manifold


Inspect
1. Remove cap screws (A) and the manifold (B).
2. Remove and discard seal (C). Inspect porting surfaces.
3. Lubricate and install a new seal (C).
4. Install manifold and tighten cap screws to specification.

UN24JUN92

Air Conditioning Compressor ManifoldSpecification


Manifold Through BoltTorque ................................... 26 Nm (230 lb-in.)

AManifold Cap Screw


BManifold
CManifold Seal

RW21160

18
1830
18

TX,18,RB763 1910DEC021/1

TM2111 (30MAY03)

18-1830-18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=536

Heating and Air Conditioning

Air Conditioning Compressor Disassemble, Inspect and Assemble

RW21161

UN24JUN92

18
1830
19

ARear Pins
BRear Housing
CRear Gasket
DRear Discharge Reed Valve
ERear Valve Plate
FRear Suction Reed Valve

GRear O-Ring
HFront O-Ring
IFront Suction Reed Valve
JFront Valve Plate
KFront Discharge Reed
Valve

LFront Gasket
MSnap Ring
NLip Seal
OWasher
PThrough Bolt

QFelt Holder
RFelt
SFront Housing
TFront Pins

Continued on next page

TM2111 (30MAY03)

18-1830-19

TX,18,RB764 1910DEC021/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=537

Heating and Air Conditioning


1. Clean the compressor using solvent before
disassembly. Mount compressor on holding fixture.
2. Remove clutch. See Air Conditioning Compressor
Clutch Repair in this group.
IMPORTANT: When removing front and rear housing,
be careful NOT to damage the sealing
surfaces.

RW21162

NOTE: The valve plates, reed valves, cylinders, and


cylinder housings are NOT serviceable. Some
cylinder scuffing (light scratches) is normal.
4. Inspect the valves for an even wear pattern and the
cylinders for scoring or excessive wear. Replace
compressor as required.
5. Remove the shaft seal snap ring (M). Turn the housing
over and remove the felt holder (Q) and felt (R) from
the front housing (S).
6. Remove the shaft lip seal (N) from the front housing
(S) using a small tool with 5/8 in. OD.
7. Wash all parts in clean solvent and dry before
assembly.

UN24JUN92

IMPORTANT: Lubricate O-rings, gaskets, and lip seal


using only TY22025 (R134a) refrigerant
oil during assembly. Other oils could
damage the compressor.
8. Apply R134a oil to the bore of the front housing and
install new lip seal (N) to the bottom of the bore using
a socket. Install new snap ring (M) flat side down.

RW21163

18
1830
20

UN24JUN92

3. Disassemble the compressor as illustrated and discard


the O-rings, gaskets, lip seal, snap ring, and through
bolt washers. Replace parts from service kits.

IMPORTANT: Bushing spacer (U) must be in position


before assembling the compressor.

CRear Gasket
DRear Discharge Reed Valve
ERear Valve Plate
FRear Suction Reed Valve
UBushing Spacer

9. Install pins (A) and new O-ring (G) in the rear cylinder.

Continued on next page

TM2111 (30MAY03)

18-1830-20

TX,18,RB764 1910DEC022/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=538

Heating and Air Conditioning


NOTE: The rear valve plate is marked with an R and is
installed face up.
10. Install parts (FD) over the pins on the rear cylinder.
11. Install a new gasket (C) flat side down and the rear
housing (B) on the rear cylinder. Mount the
compressor onto the holding fixture.
12. Install pins (T) and new O-ring (H) in the front
cylinder.

NOTE: The front valve plate is marked with an F and is


installed face up.

18
1830
21

13. Install parts (IK) over the pins on the front cylinder.
14. Install a new gasket (L) flat side down. Put JDG746
lip seal protector on the shaft and lubricate with
R134a oil.
15. Install the front housing (S) on the front cylinder and
remove the lip seal protectors. Install through bolts
(P) and new washers (O).
16. Partially tighten the through bolts and then tighten to
specification.
Air Conditioning CompressorSpecification
Air Conditioning Compressor
Through BoltTorque .................................................. 26 Nm (230 lb-in.)

17. Install the felt (R) and felt holder (Q) using the clutch
hub.
18. Install the pulley-clutch hub and check clearance.See
Air Conditioning Compressor Clutch Repair in this
group.

TX,18,RB764 1910DEC023/3

TM2111 (30MAY03)

18-1830-21

G-III and D Series Skidders (S.N. 586337 )


053003

PN=539

Heating and Air Conditioning

Air Conditioning Condenser Remove and


Install
1. Remove right-side and left-side engine shields.
2. Recover refrigerant. See Recover R134a Refrigerant in
this group.

UN17DEC02

NOTE: Close all openings with caps or plugs to prevent


contamination.
3. Disconnect condenser inlet line (2) and outlet line (4).
4. Remove cap screws (1 and 3) to remove condenser.
5. Inspect condenser (5) for any visible damage. Repair
or replace as necessary.
6. Install condenser (5) with cap screws (1 and 3).
Tighten cap screw to specification.
Air Conditioning CondenserSpecification
Condenser Mounting Cap
ScrewTorque ................................................................ 73 Nm (54 lb-ft)

T162939B

18
1830
22

Air Conditioning Condenser (460D Shown)


1Cap Screw (2 used)
2Condenser Inlet Line
3Cap Screw (4 used)
4Condenser Outlet Line
5Condenser

IMPORTANT: Always use new O-rings and seals.


Damaged or used O-rings and seals will
leak.
7. Connect condenser inlet line (2) and outlet line (4) and
tighten to specification.
Air Conditioning Condenser Specification
Condenser Inlet Line
ConnectionTorque..................................................... 24 Nm (212 lb-in.)
Condenser Outlet Line
ConnectionTorque..................................................... 17 Nm (150 lb-in.)

8. Evacuate and charge the system. See Evacuate


R134a System in this group. See Charge R134a
System in this group.
9. Install engine side shields.

OUO1065,000059A 1916DEC021/1

TM2111 (30MAY03)

18-1830-22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=540

Heating and Air Conditioning

Evaporator Remove and Install

UN01NOV88

Direct drive machine shown throughout. Procedures for


torque converter machine are the same except where
noted.
Evaporator Remove

T6642EK

1. Evacuate air conditioning system. See Evacuate


R134a System in this group.
2. Recover refrigerant. See Recover R134a Refrigerant in
this group.

18
1830
23

UN24MAY00

CAUTION: Coolant may be hot. Wait until


radiator is cool to the touch before draining
radiator.
3. Drain engine coolant. The approximate engine coolant
capacity is 28.4 L (30 qt).

T131190B

4. Open heating and air conditioning compartment located


at rear of cab.
5. For direct drive machines, remove thumb screw (1)
and precleaner cover (2). For torque converter
machines, release hold downs (3) and remove
precleaner cover (2) and air filter (4).

Direct Drive Machine Shown

T140039B

UN22MAR01

1Thumb Screw
2Precleaner Cover
3Hold-Downs
4Air Filter

Torque Converter Machine Shown

CED,OUO1043,140 1911DEC021/25

6. For direct drive machines, remove thumb screw (1)


and air filter (2).

T131191B

UN24MAY00

1Thumb Screw
2Air Filter

Continued on next page

TM2111 (30MAY03)

18-1830-23

CED,OUO1043,140 1911DEC022/25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=541

Heating and Air Conditioning


7. Remove freeze switch thermocouple (1) from
evaporator.

T131192B

UN24MAY00

1Freeze Switch Thermocouple

Direct Drive Machine Shown


18
1830
24

CED,OUO1043,140 1911DEC023/25

UN24MAY00

8. For direct drive machines, remove thumb screws (1)


and blower housing cover (2). For torque converter
machines, remove cap screws and washers (3) and
blower housing cover (2).

T131193B

1Thumb Screw (3 used)


2Blower Housing Cover
3Cap Screw and Washer (3 used)

T140047B

UN22MAR01

Direct Drive Machine Shown

Torque Converter Machine Shown


Continued on next page

TM2111 (30MAY03)

18-1830-24

CED,OUO1043,140 1911DEC024/25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=542

Heating and Air Conditioning


9. Disconnect wiring harness from heater valve servo
motor (1), low pressure switch connector (2), high
pressure switch connector (3), freeze switch (4), and
ground connection (5).

T131194B

UN24MAY00

1Heater Valve Servo Motor


2Low Pressure Switch Connector
3High Pressure Switch Connector
4Freeze Switch
5Ground Connection

18
1830
25

CED,OUO1043,140 1911DEC025/25

10. Disconnect coolant hoses (1) from heater core.


11. Remove cap screws (2) and move aside assembled
heater valve and heater valve servo motor (3).

T131195B

UN24MAY00

1Coolant Hose (2 used)


2Cap Screw (2 used)
3Assembled Heater Valve and Heater Valve Servo
Motor

CED,OUO1043,140 1911DEC026/25

12. Remove socket head cap screw (1).

UN24MAY00

13. Loosen tube nuts (2 and 3) and remove line and


flange assembly.

T131196B

1Socket Head Cap Screw


2Tube Nut
3Tube Nut

Continued on next page

TM2111 (30MAY03)

18-1830-25

CED,OUO1043,140 1911DEC027/25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=543

Heating and Air Conditioning


14. Remove socket head cap screws (1) and expansion
valve (2).

T131197B

UN24MAY00

1Socket Head Cap Screw (2 used)


2Expansion Valve

CED,OUO1043,140 1911DEC028/25

15. Disconnect wiring harness from blower motor


connector (1) and blower resistor (2).
16. Disconnect cooling hose (3) from blower motor (5).
17. Remove cap screws (4) and blower motor (5).

T131198B

UN24MAY00

1Blower Motor Connector


2Blower Resistor
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor

CED,OUO1043,140 1911DEC029/25

NOTE: Rotate housing 90 clockwise to remove blower


motor housing.

UN24MAY00

18. Remove cap screws (1) and blower motor housing


(2).
1Cap Screw (4 used)
2Blower Motor Housing

T131199B

18
1830
26

Continued on next page

TM2111 (30MAY03)

18-1830-26

CED,OUO1043,140 1911DEC0210/25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=544

Heating and Air Conditioning


19. Remove cap screws (1) and blower mounting plate
(2).

T131200B

UN24MAY00

1Cap Screw (6 used)


2Blower Mounting Plate

CED,OUO1043,140 1911DEC0211/25

18
1830
27

20. Remove mounting screw (1) and isolator (2) from


heater core (3).

UN24MAY00

21. Remove heater core (3).

T131201B

1Mounting Screw (2 used)


2Isolator
3Heater Core

CED,OUO1043,140 1911DEC0212/25

22. Remove freeze switch (1) and move aside.


23. Remove cap screws (2) and evaporator (3).

UN24MAY00

24. Repair or replace evaporator as required.


Evaporator Install

T131202B

1. Install evaporator (3) and cap screws (2).


2. Install freeze switch (1).
1Freeze Switch
2Cap Screw (2 used)
3Evaporator

Continued on next page

TM2111 (30MAY03)

18-1830-27

CED,OUO1043,140 1911DEC0213/25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=545

Heating and Air Conditioning


3. Install heater core (3).
4. Install mounting screws (1) and isolator (2).

T131201B

UN24MAY00

1Mounting Screw (2 used)


2Isolator
3Heater Core

CED,OUO1043,140 1911DEC0214/25

5. Install blower mounting plate (2) and cap screws (1).

T131200B

UN24MAY00

1Cap Screw (6 used)


2Blower Mounting Plate

CED,OUO1043,140 1911DEC0215/25

6. Install blower motor housing (2) and cap screws (1).

UN24MAY00

1Cap Screw (4 used)


2Blower Motor Housing

T131199B

18
1830
28

Continued on next page

TM2111 (30MAY03)

18-1830-28

CED,OUO1043,140 1911DEC0216/25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=546

Heating and Air Conditioning


7. Install blower motor (5) and cap screws (4).
8. Connect wiring harness to blower motor connector (1)
and blower resistor (2).
9. Connect cooling hose (3) to blower motor (5).

T131198B

UN24MAY00

1Blower Motor Connector


2Blower Resistor
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor

CED,OUO1043,140 1911DEC0217/25

IMPORTANT: Always use new O-rings and seals.


Used or damaged O-rings and seals will
leak.

UN24MAY00

10. Install expansion valve (2) and socket head cap


screws (1).

T131197B

1Socket Head Cap Screw (2 used)


2Expansion Valve

CED,OUO1043,140 1911DEC0218/25

11. Install line and flange assembly and socket head cap
screw (1). Fasten tube nuts (2 and 3).

T131196B

UN24MAY00

1Socket Head Cap Screw


2Tube Nut
3Tube Nut

Continued on next page

TM2111 (30MAY03)

18-1830-29

CED,OUO1043,140 1911DEC0219/25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=547

18
1830
29

Heating and Air Conditioning


12. Install assembled heater valve and heater valve servo
motor (3) and cap screws (2).
13. Connect coolant hoses (1) to heater core.

T131195B

UN24MAY00

1Coolant hose (2 used)


2Cap Screw (2 used)
3Assembled Heater Valve and Heater Valve Servo
Motor

18
1830
30

CED,OUO1043,140 1911DEC0220/25

14. Connect wiring harness to heater valve servo motor


(1), low pressure switch connector (2), high pressure
switch connector (3), freeze switch (4), and ground
connection (5).

T131194B

UN24MAY00

1Heater Valve Servo Motor


2Low Pressure Switch Connector
3High Pressure Switch Connector
4Freeze Switch
5Ground Connection

Continued on next page

TM2111 (30MAY03)

18-1830-30

CED,OUO1043,140 1911DEC0221/25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=548

Heating and Air Conditioning


15. Install blower cover (2) using cap screw and washer
(1) and thumb screws (3).

T131193B

UN24MAY00

1Thumb Screw (3 used)


2Blower Cover
3Cap Screw and Washer (3 used)

Direct Drive Machine Shown

T140047B

UN22MAR01

18
1830
31

Torque Converter Machine Shown


CED,OUO1043,140 1911DEC0222/25

16. Install freeze switch thermocouple (1) to evaporator.

T131192B

UN24MAY00

1Freeze Switch Thermocouple

Direct Drive Machine Shown

Continued on next page

TM2111 (30MAY03)

18-1830-31

CED,OUO1043,140 1911DEC0223/25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=549

Heating and Air Conditioning


17. For direct drive machines, install air filter (2) and
thumb screw (1).

T131191B

UN24MAY00

1Thumb Screw
2Air Filter

CED,OUO1043,140 1911DEC0224/25

18. For direct drive machines, install precleaner cover (2)


and thumb screw (1). For torque converter machines,
install air filter (4) and precleaner cover (2) using
hold-downs (3).
UN24MAY00

IMPORTANT: Air must be removed from cooling


system to prevent cavitation.

T131190B

NOTE: Loosen engine coolant temperature sender in


thermostat housing or loosen plug at rear of
cylinder head to allow air to escape when filling
system.
Direct Drive Machine Shown

19. Fill cooling system with proper coolant. See Diesel


Engine Coolant. (Operators Manual.)

UN22MAR01

20. Tighten sender plug when all the air has been
expelled.
21. Close heating and air conditioning compartment
cover.
22. Evacuate and charge the system. See Evacuate
R134a System in this group. See Charge R134a
System in this group.

T140039B

18
1830
32

Torque Converter Machine Shown


1Thumb Screw
2Precleaner Cover
3Hold-Down (2 used)
4Air Filter

CED,OUO1043,140 1911DEC0225/25

TM2111 (30MAY03)

18-1830-32

G-III and D Series Skidders (S.N. 586337 )


053003

PN=550

Heating and Air Conditioning

Expansion Valve Remove and Install

UN25MAY00

Direct drive machine shown throughout. Procedures for


torque converter machine are the same except where
noted.
1. Recover refrigerant. See Recover R134a Refrigerant in
this group.

T131234B

2. Open heating and air conditioning compartment cover.

NOTE: Torque converter machines use cap screws and


washers instead of thumb screws.

1Thumb Screw (3 used)


2Blower Cover

3. Remove thumb screws (1) and blower cover (2).

18
1830
33

CED,OUO1043,141 1912DEC021/3

4. Remove socket head cap screw (1) and disconnect


refrigerant lines (2 and 3) from line and flange
assembly. Remove line and flange assembly.

T131229B

UN24MAY00

1Socket Head Cap Screw


2Refrigerant Line
3Refrigerant Line

Continued on next page

TM2111 (30MAY03)

18-1830-33

CED,OUO1043,141 1912DEC022/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=551

Heating and Air Conditioning


5. Remove socket head cap screws (1) and expansion
valve (2).

UN24MAY00

IMPORTANT: Always use new O-rings and seals.


Damaged or used O-rings and seals will
leak.
6. Install expansion valve and socket head cap screws.

T131228B

7. Install line and flange assembly with socket head cap


screw.
8. Connect refrigerant lines.
1Socket Head Cap Screw (2 used)
2Expansion Valve

9. Evacuate and charge the system. See Evacuate


R134a System in this group. See Charge R134a
System in this group.
10. Install blower cover.

CED,OUO1043,141 1912DEC023/3

Blower Motor Remove and Install

UN25MAY00

Direct drive machine shown throughout. Procedures for


torque converter machine are the same except where
noted.
1. Open heating and air conditioning compartment cover.

NOTE: Torque converter machines use cap screws and


washers instead of thumb screws.

T131234B

18
1830
34

2. Remove thumb screws (1) and blower cover (2).


1Thumb Screw (3 used)
2Blower Cover

Continued on next page

TM2111 (30MAY03)

18-1830-34

CED,OUO1043,142 1912DEC021/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=552

Heating and Air Conditioning


3. Disconnect wiring harness from blower resistor (1) and
blower motor connector (2).
4. Disconnect cooling hose (3) from blower motor (5).

UN25MAY00

5. Remove cap screws (4) and blower motor (5).


6. Install blower motor (5) and cap screws (4).

T131194C

7. Connect cooling hose (3) to blower motor (5).


8. Connect wiring harness to blower resistor (1) and
blower motor connector (2).
9. Install blower cover and thumb screws.

18
1830
35

1Blower Resistor
2Blower Motor Connector
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor

10. Close heating and air conditioning compartment


cover.

CED,OUO1043,142 1912DEC022/2

Heater Core Remove and Install

UN01NOV88

Direct drive machine shown throughout. Procedures for


torque converter machine are the same except where
noted.

T6642EK

CAUTION: Coolant may be hot. Wait until


radiator is cool to the touch before draining
radiator.
1. Drain engine coolant from radiator. The approximate
coolant capacity of radiator is 28.4 L (30 qt).
2. Open heating and air conditioning compartment cover.

UN25MAY00

NOTE: Torque converter machines use cap screws and


washers instead of thumb screws.
3. Remove thumb screws (1) and blower cover (2).

T131234B

1Thumb Screw (3 used)


2Blower Cover

Continued on next page

TM2111 (30MAY03)

18-1830-35

CED,OUO1043,143 1912DEC021/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=553

Heating and Air Conditioning


4. Disconnect wiring harness from blower resistor (1) and
blower motor connector (2).
5. Disconnect cooling hose (3) from blower motor (5).

UN25MAY00

6. Remove cap screws (4) and blower motor (5).

T131194C

1Blower Resistor
2Blower Motor Connector
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor
18
1830
36

CED,OUO1043,143 1912DEC022/9

7. Remove cap screws (1) and blower housing (3).


8. Disconnect coolant hoses (2) from heater core.

T131235B

UN25MAY00

1Cap Screw (4 used)


2Coolant Hose (2 used)
3Blower Housing

CED,OUO1043,143 1912DEC023/9

9. Remove cap screws (1) and blower mounting plate (2).

T131237B

UN25MAY00

1Cap Screw (6 used)


2Blower Mounting Plate

Continued on next page

TM2111 (30MAY03)

18-1830-36

CED,OUO1043,143 1912DEC024/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=554

Heating and Air Conditioning


10. Remove isolator (2).
11. Remove mounting screws (1) and heater core (3).

UN25MAY00

12. Install heater core (3) and mounting screws (1).


13. Install isolator (2).

T131238B

1Mounting Screw (2 used)


2Isolator
3Heater Core

18
1830
37

CED,OUO1043,143 1912DEC025/9

14. Install blower mounting plate (2) and cap screws (1).

T131237B

UN25MAY00

1Cap Screw (6 used)


2Blower Mounting Plate

CED,OUO1043,143 1912DEC026/9

15. Connect coolant hoses (2) to heater core.


16. Install blower housing (3) and cap screws (1).

T131235B

UN25MAY00

1Cap Screw (4 used)


2Coolant Hose (2 used)
3Blower Housing

Continued on next page

TM2111 (30MAY03)

18-1830-37

CED,OUO1043,143 1912DEC027/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=555

Heating and Air Conditioning


17. Install blower motor (5) and cap screws (4).
18. Connect cooling hose (3) to blower motor (5).

UN25MAY00

19. Connect wiring harness to blower resistor (1) and


blower motor connector (2).

T131194C

1Blower Resistor
2Blower Motor Connector
3Cooling Hose
4Cap Screw (4 used)
5Blower Motor
18
1830
38

CED,OUO1043,143 1912DEC028/9

NOTE: Torque converter machines use cap screws and


washers instead of thumb screws.
20. Install blower cover (2) and thumb screws (1).
UN25MAY00

IMPORTANT: Air must be bled from cooling system


to prevent cavitation.

22. Fill cooling system with proper coolant. See Diesel


Engine Coolant. (Operators Manual.)

T131234B

21. Loosen engine coolant temperature sender in


thermostat housing or loosen plug at rear of cylinder
head to allow air to escape when filling system.
1Thumb Screw (3 used)
2Blower Cover

23. Tighten sender plug when all the air has been
expelled.

CED,OUO1043,143 1912DEC029/9

TM2111 (30MAY03)

18-1830-38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=556

Heating and Air Conditioning

Receiver Dryer Remove and Install


1.

UN01MAY00

2. Recover refrigerant. See Recover R134a Refrigerant in


this group.
3. Disconnect lines (A and B).

IMPORTANT: A new receiver dryer must always be


installed after purging system. DO NOT
use a flushed or used receiver-dryer.
Contamination of system can cause
component failure.

T129565D

4. Remove receiver dryer.

ALine to Condenser
BLine to Expansion Valve

18
1830
39

5. Remove plug from new receiver dryer and add 15 mL


(0.5 fl oz) of compressor oil. Install plug.
6. Install receiver dryer.
IMPORTANT: Always use new O-rings and seals.
Damaged or used O-rings and seals will
leak.
7. Put compressor oil on new O-rings. Remove plugs
from receiver dryer and immediately connect lines (A
and B).
8. Add compressor oil. See R134a Refrigerant Oil
Information in this group.
9. Evacuate and charge the system. See Evacuate
R134a System in this group. See Charge R134a
System in this group.

CED,OUO1048,410 1912DEC021/1

TM2111 (30MAY03)

18-1830-39

G-III and D Series Skidders (S.N. 586337 )


053003

PN=557

Heating and Air Conditioning

Freeze Control Switch Remove and Install


1. Open heating and air conditioning compartment located
at rear of cab.

T131190B

1Thumb Screw
2Precleaner Cover
3Hold-Downs
4Air Filter

T140039B

UN22MAR01

Direct Drive Machine Shown

Torque Converter Machine Shown


CED,OUO1032,3448 1912DEC021/9

3. For direct drive machines, remove thumb screw (1)


and air filter (2).

UN24MAY00

1Thumb Screw
2Air Filter

T131191B

18
1830
40

UN24MAY00

2. For direct drive machines, remove thumb screw (1)


and precleaner cover (2). For torque converter
machines, release hold downs (3) and remove
precleaner cover (2) and air filter (4).

Continued on next page

TM2111 (30MAY03)

18-1830-40

CED,OUO1032,3448 1912DEC022/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=558

Heating and Air Conditioning


4. Remove freeze switch thermocouple (1) from
evaporator.

T131192B

UN24MAY00

1Freeze Switch Thermocouple

Direct Drive Machine Shown


18
1830
41

CED,OUO1032,3448 1912DEC023/9

UN24MAY00

5. For direct drive machines, remove thumb screws (1)


and blower housing cover (2). For torque converter
machines, remove cap screws and washers (3) and
blower housing cover (2).

T131193B

1Thumb Screw (3 used)


2Blower Housing Cover
3Cap Screw and Washer (3 used)

T140047B

UN22MAR01

Direct Drive Machine Shown

Torque Converter Machine Shown


Continued on next page

TM2111 (30MAY03)

18-1830-41

CED,OUO1032,3448 1912DEC024/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=559

Heating and Air Conditioning


6. Disconnect connectors (1) from freeze control switch
(3).

UN15JUN00

7. Remove cap screws (2) and freeze control switch by


guiding freeze switch thermocouple (5) back through
bulkhead grommet (4).

T131706B

8. Insert freeze switch thermocouple through bulkhead


grommet.
9. Install freeze control switch and cap screws.
10. Connect wire harness connectors.
1Connector (2 used)
2Cap Screw (2 used)
3Freeze Control Switch
4Bulkhead Grommet
5Freeze Control Temperature Switch Thermocouple

CED,OUO1032,3448 1912DEC025/9

11. Install blower cover (2).

T131193B

UN24MAY00

1Thumb Screw (3 used)


2Blower Cover
3Cap Screw and Washer (3 used)

UN22MAR01

Direct Drive Machine Shown

T140047B

18
1830
42

Torque Converter Machine Shown


Continued on next page

TM2111 (30MAY03)

18-1830-42

CED,OUO1032,3448 1912DEC026/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=560

Heating and Air Conditioning


12. Install freeze switch thermocouple (1) to evaporator.

T131192B

UN24MAY00

1Freeze Switch Thermocouple

Direct Drive Machine Shown


18
1830
43

CED,OUO1032,3448 1912DEC027/9

13. For direct drive machines, install air filter (2) and
thumb screw (1).

T131191B

UN24MAY00

1Thumb Screw
2Air Filter

Continued on next page

TM2111 (30MAY03)

18-1830-43

CED,OUO1032,3448 1912DEC028/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=561

Heating and Air Conditioning


14. For direct drive machines, install precleaner cover (2)
and thumb screw (1). For torque converter machines,
install air filter (4) and precleaner cover (2) using
hold-downs (3).
UN24MAY00

15. Close heating and air conditioning compartment


cover.

T131190B

1Thumb Screw
2Precleaner Cover
3Hold-Down (2 used)
4Air Filter

Direct Drive Machine Shown

T140039B

UN22MAR01

18
1830
44

Torque Converter Machine Shown


CED,OUO1032,3448 1912DEC029/9

TM2111 (30MAY03)

18-1830-44

G-III and D Series Skidders (S.N. 586337 )


053003

PN=562

Section 19

Sheet Metal and Styling


Contents
Page

Group 1910Hood or Engine Enclosure


Hood Remove and Install . . . . . . . . . . . . . . .19-1910-1
Group 1921Grille and Grille Housing
Grille and Grille Housing Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-1921-1

19

TM2111 (30MAY03)

19-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

19

TM2111 (30MAY03)

19-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 1910

Hood or Engine Enclosure


Hood Remove and Install
Direct drive machine shown throughout. Procedures for
the torque converter machines are the same except where
noted.

CED,OUO1032,3449 1924OCT021/4

1. Remove engine side shields and turn battery


disconnect switch to OFF.
2. Loosen clamps (1 and 2).
UN30MAR01

3. Remove hold-down screws (3) from each corner of


hood.

T131581B

1Turbocharger-to-Exhaust Pipe Clamp


2Turbocharger-to-Air Cleaner Hose Clamp
3Hood Hold-Down Screw (4 used)

Continued on next page

TM2111 (30MAY03)

19-1910-1

CED,OUO1032,3449 1924OCT022/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=565

19
1910
1

Hood or Engine Enclosure


4. Loosen cap screws (2) and slide brackets away from
exhaust pipe.

UN26JUN00

5. On torque converter machines, remove oil cooler return


line clamped to underside of hood.

T131813B

CAUTION: Muffler and left limb riser become


hot from exhaust. Allow limb riser to cool
before removal.
CAUTION: Heavy component; use a hoist.
HoodSpecification
Left Limb Riser with Muffler
Weight................................................................................... 45 kg (100 lb)

6. Remove left limb riser (1) with muffler attached.


Approximate weight of left limb riser with muffler is 45
kg (100 lb).

T131580B

19
1910
2

UN30MAR01

HoodSpecification
Right Limb RiserWeight ...................................................... 32 kg (70 lb)

7. Remove right limb riser. Approximate weight of right


limb riser is 32 kg (70 lb).
1Limb Riser (2 used)
2Cap Screws (4 used)
3Hydraulic Reservoir Cap
4Cap Screw (4 used)

8. Remove hydraulic reservoir cap (3). Disconnect air


cleaner hose-to-turbocharger and air filter restriction
switch connector located at rear of air cleaner.
9. Remove cap screws (4).
CAUTION: Heavy component; use a hoist.
HoodSpecification
Hood with Air CleanerWeight ...................... 91 kg (200 lb) approximate

10. Attach JT01748 Lifting Brackets to hood. Attach lifting


chains to brackets so front of hood hangs 152203
mm (68 in.) higher than rear. Raise hood with air
cleaner attached using hoist. Lift front of hood until it
clears grille housing.
11. Slide hood forward 12.7 mm (1/2 in.) to free rear of
hood and lift hood off machine.
12. Align hood on machine.

Continued on next page

TM2111 (30MAY03)

19-1910-2

CED,OUO1032,3449 1924OCT023/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=566

Hood or Engine Enclosure


13. Lower hood until rear of hood slides over rear of
reservoir.
14. Lower hood onto grille housing and remove lifting
chains and lifting brackets.
15. Install oil reservoir cap and air cleaner cover.
16. Connect air filter restriction switch and air
cleaner-to-turbocharger hose.
17. Install air cleaner-to-turbocharger hose clamp and
tighten.
18. Install hood mounting cap screws and washers.
19. Install hood hold-down screws and washers. Install
cap screw, spacer, washer and lock nut.
19
1910
3

20. On torque converter machines, install oil cooler return


line clamped to underside of hood.
21. Install right limb riser.
22. Install left limb riser with muffler.
23. Install and tighten turbocharger-to-exhaust pipe
clamp.
IMPORTANT: Exhaust pipe brackets must not touch
exhaust pipe.
24. Slide exhaust pipe brackets toward exhaust pipe (but
not touching) and tighten cap screws.
25. Install engine side shields.

CED,OUO1032,3449 1924OCT024/4

TM2111 (30MAY03)

19-1910-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=567

Hood or Engine Enclosure

19
1910
4

TM2111 (30MAY03)

19-1910-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=568

Group 1921

Grille and Grille Housing


Grille and Grille Housing Remove and Install
Direct drive machine shown throughout. Procedure for
torque converter machine is the same except where
noted.

CED,OUO1032,3390 1924OCT021/7

1. Remove hood.See Hood Remove and Install in this


group.

UN05JUN00

2. Remove fan guards. See Fan Guards and Fan Blade


Remove and Install. (Group 0510.)
3. Attach lifting straps to grille housing with cap screws
and washers (1).

T131359B

4. Remove cap screws and washers (2).


1Cap Screw and Washer (2 used)
2Cap Screw and Washer (2 used)

CED,OUO1032,3390 1924OCT022/7

5. Remove cap screws and washers (1).

T131360B

UN05JUN00

1Cap Screw and Washer (3 used)

Continued on next page

TM2111 (30MAY03)

19-1921-1

CED,OUO1032,3390 1924OCT023/7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=569

19
1921
1

Grille and Grille Housing


6. Install cap screws and washers (2).

T131359B

UN05JUN00

1Cap Screw and Washer (2 used)


2Cap Screw and Washer (2 used)

CED,OUO1032,3390 1924OCT024/7

CAUTION: Heavy component; use a hoist.


Grille and Grille HousingSpecification
Grille Housing with GrilleWeight ..................................... 184 kg (405 lb)
UN05JUN00

7. Remove cap screws and washers (1) and nuts from


each side of grille housing.
8. Carefully lift and remove grille housing with hoist.

T131361B

19
1921
2

1Cap Screw and Washer (3 or 4 each side)

Continued on next page

TM2111 (30MAY03)

19-1921-2

CED,OUO1032,3390 1924OCT025/7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=570

Grille and Grille Housing

TP54346

UN13JAN99

19
1921
3

Grille Housing Parts (540G-III, 548G-III, 360D)


1Grille Housing
2Cover
3Cap Screw (2 used)
4Washer (2 used)

5Bushing (2 used)
6Grille
7Washer (2 used)
8Lock Nut (2 used)

9Cap Screw (2 used)


10Washer (2 used)
11Cap Screw (3 or 4 each
side)

9. Repair or replace parts as necessary.

12Flange Nut (3 or 4 each


side)
13Washer

12. Install cap screws (11), flange nuts (12), and


washers (13). Tighten flange nuts to specification.

10. Install grille housing.


Grille and Grille HousingSpecification
Grille Housing Flange Nut
Torque................................................................... 310 Nm (229 lb-ft)

11. Install and tighten cap screws (3 and 9) to


specification.
Grille and Grille HousingSpecification
Grille-to-Grille Housing Cap
ScrewTorque ....................................................... 125 Nm (92 lb-ft)

Continued on next page

TM2111 (30MAY03)

19-1921-3

CED,OUO1032,3390 1924OCT026/7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=571

Grille and Grille Housing


13. Install cap screws and washers (1). Tighten to
specification.

15. Install hood.See Hood Remove and Install in this


group.

T131360B

14. Install fan guards. See Fan Guards and Fan Blade
Remove and Install. (Group 0510.)

UN05JUN00

Grille and Grille HousingSpecification


Grille Housing Cap Screws
Torque ............................................................................. 73 Nm (54 lb-ft)

1Cap Screw and Washer (3 used)

19
1921
4

CED,OUO1032,3390 1924OCT027/7

TM2111 (30MAY03)

19-1921-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=572

Section 20

Safety, Convenience and Miscellaneous


Contents
Page

Group 2003Pressurized Water System


Pressurized Water System . . . . . . . . . . . . . .20-2003-1
Group 2004Horn and Warning Devices
Horn Remove and Install. . . . . . . . . . . . . . . .20-2004-1
Reverse Warning Alarm Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2004-1

20

TM2111 (30MAY03)

20-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

20

TM2111 (30MAY03)

20-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 2003

Pressurized Water System


Pressurized Water System

T131760

UN27JUN00

20
2003
1

1Pressure Gauge
2Relief Valve
3Fitting
4Shut-Off Valve
5Adapter (2 used)
6Hose

7Adapter
8Nozzle
9O-Ring (2 used)
10Adapter (2 used)
11Cap Screw (2 used)
12Washer (4 used)

13Elbow
14Manifold
15Nut (2 used)
16Bushing
17Hose

18Clip
19Cap Screw
20Lock Nut
21Spacer (2 used)
22Filler Plug

1. Repair or replace parts as necessary.

Continued on next page

TM2111 (30MAY03)

20-2003-1

CED,OUO1032,3450 1925JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=575

Pressurized Water System

CAUTION: Release pressure by discharging


fluid at hose and before removing fill plug.
Injury may result from plug or cap under force.
UN31MAR00

2. Move lever (A) to turn water on.


3. Squeeze water nozzle lever (D) to release water.

T129545C

4. Slowly remove plug (E).


IMPORTANT: Avoid machine water tank damage. Add
25 kg (55 lb) calcium chloride to water
tank before air temperature drops below
0C (32F).

UN04APR00

NOTE: Adding 25 kg (55 lb) calcium chloride will protect


to 29C (20F). When the temperatures are
consistently above freezing, the system should be
flushed thoroughly and refilled with water.

20
2003
2

T129560B

5. Fill tank with water.


Pressurized Water SystemSpecification
Water TankCapacity .................................. 60.6 L (16 gal) approximate

CAUTION: Plug has a vent cross hole for


release of air pressure. Do not use a substitute
plug.

ALever
BFitting
CGauge
DWater Nozzle Lever
EPlug

6. Install plug.
7. To pressurize system, connect air hose to fitting (B)
and add air. Watch gauge (C) for correct air pressure.
Pressurized Water SystemSpecification
Water TankPressure ..................................... 410 kPa (3.8 bar) (55 psi)

CAUTION: Pressurized water system. Release


pressure by discharging fluid at hose end
before removing fill plug. Injury may result from
plug removed under pressure.

CED,OUO1032,3450 1925JAN032/2

TM2111 (30MAY03)

20-2003-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=576

Group 2004

Horn and Warning Devices


Horn Remove and Install
1. Open front grille.
2. Disconnect harness leads (2 and 3) from horn (1).
Remove horn.

UN06MAR01

3. Inspect and replace as necessary.


IMPORTANT: Overtightening horn mounting nut could
cause damage to horn.

T138723B

4. If horn is removed from bracket, tighten nut to


specification.
HornSpecification
Horn Mounting NutTorque ........................................ 20 Nm (177 lb-in.)

5. Connect harness leads.

1Horn
2Harness Lead G05-BLK
3Harness Lead A01-ORG

6. Close front grill and tighten cap screws.

20
2004
1
OUO1020,00010B3 1925JAN031/1

Reverse Warning Alarm Remove and Install


1. Remove rear cover plate.
2. Disconnect harness leads (1 and 2).

UN06MAR01

3. Remove cap screw and lock nuts (3), washers (4), and
reverse warning alarm (5).
4. Install alarm and tighten lock nuts.

T138736B

5. Connect harness leads.


6. Install rear cover plate.
1Harness Leads G01-BLK
2Harness Leads M01-ORG
3Cap Screw and Lock Nut (2 used)
4Washer (4 used)
5Reverse Warning Alarm

OUO1020,00010B4 1925JAN031/1

TM2111 (30MAY03)

20-2004-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=577

Horn and Warning Devices

20
2004
2

TM2111 (30MAY03)

20-2004-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=578

Section 21

Main Hydraulic System


Contents
Page

Group 2160Hydraulic System


Hydraulic Pump Remove and InstallDirect
Drive Machines . . . . . . . . . . . . . . . . . . . . .21-2160-1
Hydraulic Pump Remove and InstallTorque
Converter Machines. . . . . . . . . . . . . . . . . .21-2160-8
Hydraulic Pump Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .21-2160-12
Priority Valve Repair . . . . . . . . . . . . . . . . . .21-2160-23
Cold Start Dump Valve Remove and Install
(If Equipped) . . . . . . . . . . . . . . . . . . . . . .21-2160-26
Hydraulic Reservoir Remove and
InstallDirect Drive Machines . . . . . . . . .21-2160-27
Hydraulic Reservoir Remove and
InstallTorque Converter Machines . . . .21-2160-35
Oil Cooler Pump Remove and Install . . . . .21-2160-41
Hydraulic Oil Cleanup Procedure Using
Portable Filter Caddy . . . . . . . . . . . . . . . .21-2160-42

21

TM2111 (30MAY03)

21-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

21

TM2111 (30MAY03)

21-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 2160

Hydraulic System
Hydraulic Pump Remove and InstallDirect
Drive Machines

T131599B

UN15JUN00

IMPORTANT: Perform Main Hydraulic Pump Leakage


TestCable Skidder, Perform Main
Hydraulic Pump Leakage TestGrapple
Skidder (Group 9025-25.) Then remove
hydraulic pump for repairs. If pump
does not pass the test, replace it, DO
NOT rebuild it.
Hydraulic Pump Remove
1Drain Hose
2Set Screw

1. Remove left and right engine side shields.


2. Operate all hydraulic control valves to release pressure
in hydraulic system.
3. Raise cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
4. Lower engine frame front bottom guard. See Engine
Frame Bottom Guard Remove and Install. (Group
1746.)
5. Route drain hose (1) outside of engine frame and
remove drain plug from hose. Put end of hose in a
container. Dispose of waste properly. Dispose of
Waste Properly. (Operators Manual.)

21
2160
1

On machines 540G-III and 548G-III, the approximate


capacity of hydraulic reservoir is 30.3 L (8 gal). On
machines 640G-III, 648G-III and 748G-III, the
approximate capacity of hydraulic reservoir is 41.6 L
(11 gal).
6. Loosen set screw (2) to open drain valve. Drain oil into
container. Dispose of waste properly.

Continued on next page

TM2111 (30MAY03)

21-2160-1

CED,OUO1032,3160 1925JAN031/8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=581

Hydraulic System
7. Support hydraulic reservoir and remove carriage bolts
and nuts (A) and cap screws and nuts (B). Remove left
side reservoir support leg (C).

T114075B

UN10APR98

ACarriage Bolt and Nut (3 used)


BCap Screw and Nut (3 used)
CReservoir Support Leg

Continued on next page

CED,OUO1032,3160 1925JAN032/8

21
2160
2

TM2111 (30MAY03)

21-2160-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=582

Hydraulic System

UN23AUG88

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

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 should reference a
knowledgeable medical source. Such
information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.
8. Remove cap screws (5) and move line (1) away from
pump.
9. Remove O-ring (8). Close all opening with caps and
plugs.

UN09JUN00

10. Disconnect hydraulic lines (24). Close all openings


with caps and plugs.

T114076C

11. Remove fitting (6) from port (7). Close all openings
with caps and plugs.
1Pump Supply Line
2Bypass Line
3Line-to-Priority Valve
4Line-to-Oil Cooler
5Cap Screw (4 used)
6Fitting
7Port
8O-Ring

T131601B

UN14JUN00

Cable Machine Shown

Grapple Machine Shown

Continued on next page

TM2111 (30MAY03)

21-2160-3

CED,OUO1032,3160 1925JAN033/8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=583

21
2160
3

Hydraulic System

CAUTION: Heavy component; use a hoist.


Hydraulic PumpDirect Drive MachinesSpecification
540G-III, 548G-III, 640G-III
Hydraulic PumpWeight ................................. 30 kg (67 lb) Approximate
648G-III, 748G-III Hydraulic
PumpWeight................................................ 54 kg (120 lb) Approximate

NOTE: Hydraulic pump has a spline coupler that couples


the pump to transmission charge pump.

UN09JUN00

12. Support pump with lifting strap. Remove cap screws


(1) to remove pump.

T114077C

1Cap Screw (2 used)

CED,OUO1032,3160 1925JAN034/8

Hydraulic Pump Install


IMPORTANT: Spline coupler must have internal snap
ring in place before installation.
1. Support pump with lifting strap. Align splines on pump
shaft with spline coupler on transmission charge pump
shaft. Install and tighten cap screws (1).

UN09JUN00

1Cap Screw (2 used)

T114077C

21
2160
4

Continued on next page

TM2111 (30MAY03)

21-2160-4

CED,OUO1032,3160 1925JAN035/8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=584

Hydraulic System
IMPORTANT: Always replace O-rings and seals.
Damaged or used O-rings will leak.
2. Install new O-ring (8)
3. Connect pump supply line (1) and install and tighten
cap screws (5) to specification.
Hydraulic PumpDirect Drive MachinesSpecification
Supply Line Mounting Cap
ScrewsTorque ............................................................ 120 Nm (89 lb-ft)

UN09JUN00

4. Connect line (3).

T114076C

1Pump Supply Line


2Bypass Line
3Line-to-Priority Valve
4Line-to-Oil Cooler
5Cap Screw (4 used)
6Fitting
7Port
8O-Ring

T131601B

UN14JUN00

Cable Machine Shown

Grapple Machine Shown

Continued on next page

TM2111 (30MAY03)

21-2160-5

CED,OUO1032,3160 1925JAN036/8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=585

21
2160
5

Hydraulic System
5. For 540G-III and 640G-III machines, connect line (4)
and elevate line above pump. Wire tie or strap in
position.
IMPORTANT: The hydraulic pump must be filled with
oil to prevent pump damage at startup.
6. Fill pump at port (7) with proper hydraulic oil.See
Transmission, Hydraulic System, Park Brake,
Differential, Cab Hydraulic Pump and Winch Oil.
(Operators Manual.)

UN09JUN00

7. Install fitting (6).


8. For 548G-III, 648G-III and 748G-III machines, connect
line (4).

T114078C

9. Connect line (2).


4Line-to-Oil Cooler

Cable Machine Shown

Continued on next page

CED,OUO1032,3160 1925JAN037/8

21
2160
6

TM2111 (30MAY03)

21-2160-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=586

Hydraulic System
10. Position reservoir support leg (C) and install carriage
bolts and nuts (A) and cap screws and nut (B) and
tighten.
11. Fill hydraulic reservoir. See Transmission, Hydraulic
System, Park Brake, Differential, Cab Hydraulic Pump
and Winch Oil. (Operators Manual.)
12. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
13. Start engine and allow to run at slow idle for several
minutes with line (D) still elevated.
14. Stop engine and check for leaks. If no leaks are
present, remove wire or tie strap from line (D).

17. Raise engine frame front bottom guard. See Engine


Frame Bottom Guard Remove and Install. (Group
1746.)
ACarriage Bolt and Nut (3 used)
BCap Screw and Nut (3 used)
CReservoir Support Leg

T114075B

16. Install engine side shields.

UN10APR98

15. Check hydraulic reservoir oil level.

21
2160
7

CED,OUO1032,3160 1925JAN038/8

TM2111 (30MAY03)

21-2160-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=587

Hydraulic System

Hydraulic Pump Remove and InstallTorque


Converter Machines

X9811

UN23AUG88

IMPORTANT: Perform Main Hydraulic Pump Leakage


TestCable Skidder, Perform Main
Hydraulic Pump Leakage TestGrapple
Skidder (Group 9025-25 Operation and
Test Manual.) Then remove hydraulic
pump for repairs. If pump does not
meet specifications, replace, DO NOT
rebuild pump.
Hydraulic Pump Remove
1. Remove left and right engine side shields.
2. Operate all hydraulic control valves to release pressure
in hydraulic system.

UN21FEB01

3. Raise cab. See Hydraulic Cab Tilt Procedure.


(Operators Manual.)

21
2160
8

T138093B

4. Drain hydraulic reservoir oil into container. The


approximate capacity of hydraulic reservoir is 41.6 L
(11 gal). Dispose of waste properly. Dispose of Waste
Properly. (Operators Manual.)
CAUTION: To avoid injury from escaping fluid
under pressure, relieve the pressure in the
system before disconnecting or connecting
hydraulic or other lines. Tighten all connections
before applying pressure.

1Pump-to-Cooler Line
2Pump-to-Priority Valve Line
3Reservoir-to-Pump Line

5. Disconnect hydraulic lines (13). Close all openings


with caps and plugs. The approximate capacity of
pump and lines is 1.9 L (0.5 gal).

Continued on next page

TM2111 (30MAY03)

21-2160-8

OUO1020,0001090 1925JAN031/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=588

Hydraulic System

CAUTION: Heavy component; use a hoist.


Hydraulic PumpTorque Converter MachinesSpecification
648G-III Hydraulic PumpWeight ................. 54 kg (120 lb) Approximate

NOTE: Hydraulic pump has a spline coupler that couples


the pump to transmission charge pump.

T138094B

UN21FEB01

6. Support pump with lifting strap and hoist. Remove cap


screws (1) and pull pump away from converter pump
drive housing.
1Cap Screw (2 used)

OUO1020,0001090 1925JAN032/5

Hydraulic Pump Install


IMPORTANT: Always replace O-rings and seals.
Damaged or used O-rings will leak.
UN21FEB01

1. Remove and install pump adaptor O-ring (1).

T138109B

2. Install pump adaptor (2).


1Pump Adaptor O-Ring
2Pump Adaptor

Continued on next page

TM2111 (30MAY03)

21-2160-9

OUO1020,0001090 1925JAN033/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=589

21
2160
9

Hydraulic System
IMPORTANT: Spline coupler must have internal snap
ring in place before installation.
3. Install spline coupler (1) (if removed).
UN21FEB01

4. Remove and install pump flange O-ring (2).

T138095B

5. Support pump with lifting strap and hoist. Align splines


on pump shaft with coupler on transmission charge
pump shaft. Install and tighten cap screws.

T138096B

UN21FEB01

1Pump Spline Coupler


2Pump Flange O-Ring

Continued on next page

OUO1020,0001090 1925JAN034/5

21
2160
10

TM2111 (30MAY03)

21-2160-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=590

Hydraulic System
6. Connect line (3) using a new O-ring. Tighten mounting
cap screws to specification.
Hydraulic PumpTorque Converter MachinesSpecification
Reservoir-to-Pump Line Mounting
Cap ScrewsTorque .................................................... 120 Nm (89 lb-ft)

UN21FEB01

IMPORTANT: The hydraulic pump must be filled with


oil to prevent pump damage at startup.

8. Connect lines (1 and 2) using a new O-ring at each


connection.
9. Fill hydraulic reservoir. See Transmission, Hydraulic
System, Park Brake, Differential, Cab Hydraulic Pump
and Winch Oil. (Operators Manual.)

T138093B

7. Fill ports for lines (1 and 2) with proper hydraulic oil.


See Transmission, Hydraulic System, Park Brake,
Differential, Cab Hydraulic Pump and Winch Oil.
(Operators Manual.)

1Pump-to-Cooler Line
2Pump-to-Priority Valve Line
3Reservoir-to-Pump Line

10. Lower cab. See Hydraulic Cab Tilt Procedure.


(Operators Manual.)
11. Start engine and allow to run at slow idle for several
minutes.
12. Stop engine and check for leaks.
21
2160
11

13. Check hydraulic reservoir oil level.


14. Install engine side shields.

OUO1020,0001090 1925JAN035/5

TM2111 (30MAY03)

21-2160-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=591

Hydraulic System

Hydraulic Pump Disassemble and Assemble

T8483AG

UN19MAY95

21
2160
12

Continued on next page

TM2111 (30MAY03)

21-2160-12

TX,2160,JC625 1925JAN031/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=592

Hydraulic System
APin (2 used)
BPiston (9 used)
CSnap Ring
DBushing
ESlipper (9 used)

FSwashplate
GBearing
HSaddle
IPin
JBearing

KSnap Ring
LOutput Shaft
MSnap Ring
NSeal
OPin (2 used)

PBearing
QRetainer
RBushing
SCap Screw (4 used)
TVelocity Fuse
TX,2160,JC625 1925JAN032/35

IMPORTANT: Use only diesel fuel to clean pump


parts. Solvents can damage internal
components.

T8483AH

UN17MAY95

IMPORTANT: Perform Main Hydraulic Pump Leakage


TestCable Skidder, Perform Main
Hydraulic Pump Leakage TestGrapple
Skidder. (Group 9025-25.) Then remove
hydraulic pump for repairs. If pump
does not pass the test, replace it. DO
NOT rebuild the pump.
1. As pump parts are removed, wash in diesel fuel and
dry using compressed air.
2. Remove velocity fuse.
3. Remove cap screws to remove pump housing cover.

21
2160
13

TX,2160,JC625 1925JAN033/35

4. Remove O-ring (A).

T7553BG

UN24JUN91

AO-Ring

Continued on next page

TM2111 (30MAY03)

21-2160-13

TX,2160,JC625 1925JAN034/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=593

Hydraulic System

T8170AC

UN31JAN94

5. Remove cylinder block.

TX,2160,JC625 1925JAN035/35

6. Remove pistons (A), retainer (B), and spring (C).

T7553AD

UN24JUN91

APistons
BRetainer
CSpring

T7553BB

UN24JUN91

21
2160
14

Components Shown Removed


TX,2160,JC625 1925JAN036/35

7. Remove snap ring (A).

T7553AE

UN24JUN91

ASnap Ring

Continued on next page

TM2111 (30MAY03)

21-2160-14

TX,2160,JC625 1925JAN037/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=594

Hydraulic System
8. Remove bushing (A).

T7553AF

UN24JUN91

ABushing

TX,2160,JC625 1925JAN038/35

9. Remove pump regulator end cover screws. Remove


two cap screws diagonally.
10. Install 5/16 in. guide pins.

T8170AD

UN31JAN94

11. Remove remaining two cap screws to remove pump


regulator.

TX,2160,JC625 1925JAN039/35

12. Remove swashplate.

T7553AH

UN24JUN91

21
2160
15

TX,2160,JC625 1925JAN0310/35

13. Remove bearings (A).

T8170AE

UN31JAN94

ABearings

Continued on next page

TM2111 (30MAY03)

21-2160-15

TX,2160,JC625 1925JAN0311/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=595

Hydraulic System
14. Remove snap ring (A).

T7553AJ

UN24JUN91

ASnap Ring

TX,2160,JC625 1925JAN0312/35

T7553AK

UN24JUN91

15. Remove bearing and output shaft.

TX,2160,JC625 1925JAN0313/35

16. Remove washer (A).

T7553AM

UN24JUN91

AWasher

TX,2160,JC625 1925JAN0314/35

17. Remove seal (A).

UN24JUN91

ASeal

T7553AL

21
2160
16

Continued on next page

TM2111 (30MAY03)

21-2160-16

TX,2160,JC625 1925JAN0315/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=596

Hydraulic System
18. Remove plug on back side of pump (not shown) with
a 1/8" hex wrench to remove spool (G).
19. Remove end cap (K).
20. Remove remaining parts.
21. Inspect spool for wear or erosion.

NOTE: If spool (G) is worn, replace parts (G and H).

T8170AF

UN31JAN94

ASpool
BSpool
CSpool
DSpring Cap
ESpring
FSpring Cap
GSpool
HCompensator Valve Housing
IServo Piston
JSpring
KEnd Cap
LAdjusting Screw

TX,2160,JC625 1925JAN0316/35

22. Inspect valve plate for scratches. If scratches can be


detected with finger nail, pump should be discarded.

T7553AS

UN24JUN91

21
2160
17

TX,2160,JC625 1925JAN0317/35

T7553AT

UN24JUN91

23. Inspect contact area around cylinder block ports for


scratches. If scratches can be detected with finger
nail, pump should be discarded.

Continued on next page

TM2111 (30MAY03)

21-2160-17

TX,2160,JC625 1925JAN0318/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=597

Hydraulic System

T7553AO

UN24JUN91

24. Inspect piston slipper for scratches. If scratches can


be detected with finger nail, pump should be
discarded.

TX,2160,JC625 1925JAN0319/35

T7553AQ

UN24JUN91

25. Inspect swashplate for scratches. If scratches can be


detected with finger nail, pump should be discarded.

TX,2160,JC625 1925JAN0320/35

26. Assemble parts (AL).

UN31JAN94

ASpool
BSpool
CSpool
DSpring Cap
ESpring
FSpring Cap
GSpool
HValve Housing
IServo Piston
JSpring
KEnd Cap
LAdjusting Screw

T8170AF

21
2160
18

Continued on next page

TM2111 (30MAY03)

21-2160-18

TX,2160,JC625 1925JAN0321/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=598

Hydraulic System

T7553AU

UN24JUN91

27. Install output shaft seal using 36 mm and 50 mm


disks and a seal driver.

TX,2160,JC625 1925JAN0322/35

28. Install washer (A).

T7553AM

UN24JUN91

AWasher

TX,2160,JC625 1925JAN0323/35

29. Install output shaft and bearing in pump housing.

T7553AK

UN24JUN91

21
2160
19

TX,2160,JC625 1925JAN0324/35

30. Install snap ring (A).

T7553AJ

UN24JUN91

ASnap Ring

Continued on next page

TM2111 (30MAY03)

21-2160-19

TX,2160,JC625 1925JAN0325/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=599

Hydraulic System
31. Lubricate bearings.
32. Install plastic bearing (A) with angled edges facing out
toward opening in housing.
UN31JAN94

33. Install steel bearing (B).

T8170AG

APlastic Bearing
BSteel Bearing

TX,2160,JC625 1925JAN0326/35

T7553AH

UN24JUN91

34. Install swashplate.

Continued on next page

TX,2160,JC625 1925JAN0327/35

21
2160
20

TM2111 (30MAY03)

21-2160-20

G-III and D Series Skidders (S.N. 586337 )


053003

PN=600

Hydraulic System
35. Install guide pins.
36. Install gasket on pump housing using grease or
petroleum jelly to hold in place.
UN31JAN94

NOTE: It is important to make sure the O-ring is centered


around the pressure passage in the gasket.

T8170AH

37. Install O-ring (A). Use grease to hold in place.


38. Loosen end cap (D) to remove spring pressure to aid
in assembly of regulator housing.

NOTE: Be sure the control pin has the long end of the
tang pointed toward the rear of the pump.
39. Install pump regulator.
UN31JAN94

40. Pin (B) must be inserted through swashplate bell


crank hole (C).

T8170AI

41. Install two cap screws (E) and tighten to specification.


Hydraulic PumpSpecification
46 cc Pump Regulator
Housing-to-Pump Housing Cap
ScrewTorque .......................................................... 11.3 Nm (100 lb-in.)

42. Remove guide pins and install remaining two cap


screws.

UN23JAN92

Hydraulic PumpSpecification
75 cc Pump Regulator
Housing-to-Pump Housing Cap
ScrewTorque .......................................................... 22.6 Nm (200 lb-in.)

T7553BH

43. Tighten pump regulator end cap-to-regulator housing


cap screws to specification.
Hydraulic PumpSpecification
End Cap-to-Regulator Housing
Cap ScrewTorque ...................................................... 2.3 Nm (20 lb-in.)

T7553BT

UN24JUN91

AO-Ring
BPin
CBell Crank Hole
DEnd Cap
ECap Screws

Continued on next page

TM2111 (30MAY03)

21-2160-21

TX,2160,JC625 1925JAN0328/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=601

21
2160
21

Hydraulic System
44. Install cylinder block bushing (A). Locating pin should
be positioned face down and at the 7 Oclock position
when looking at the pump from the regulator side.

T8170AJ

UN31JAN94

ACylinder Block Bushing

TX,2160,JC625 1925JAN0329/35

45. Install snap ring (A).

T7553AE

UN24JUN91

ASnap Ring

TX,2160,JC625 1925JAN0330/35

46. Assemble parts (AE).

T7553BE

UN24JUN91

ARetainer
BCylinder Block
CSpring
DBall Guide
EPiston (9 used)

TX,2160,JC625 1925JAN0331/35

CAUTION: Heavy component; use a hoist.

UN31JAN94

Hydraulic PumpSpecification
46 cc Hydraulic PumpWeight ....................... 30 kg (67 lb) Approximate
75 cc Hydraulic PumpWeight ..................... 54 kg (120 lb) Approximate

47. Invert the pump housing and install rotating group


assembly on output shaft. The rotating group must
seat on the swashplate. Hold the rotating group in
place and turn the pump housing to a upright position.

T8170AC

21
2160
22

Continued on next page

TM2111 (30MAY03)

21-2160-22

TX,2160,JC625 1925JAN0332/35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=602

Hydraulic System
48. Install O-ring (A).

T7553BG

UN24JUN91

AO-Ring

TX,2160,JC625 1925JAN0333/35

49. Install gasket (A).

T7553BA

UN24JUN91

AGasket

TX,2160,JC625 1925JAN0334/35

50. Install cap screws and tighten to specification.

21
2160
23

UN17MAY95

Hydraulic PumpSpecification
46 cc Pump Cover-to-Housing
Cap ScrewTorque ..................................................... 43.5 Nm (32 lb-ft)
75 cc Pump Cover-to-Housing
Cap ScrewTorque ..................................................... 70.5 Nm (52 lb-ft)

T8483AH

51. Install O-rings. Replace as required before installing


velocity fuse.

TX,2160,JC625 1925JAN0335/35

Priority Valve Repair


1. Operate all controls to relieve hydraulic pressure.
2. Remove right side engine shield.

Continued on next page

TM2111 (30MAY03)

21-2160-23

TX,21,RB636 1925JAN031/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=603

Hydraulic System

UN23AUG88

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

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 should reference a
knowledgeable medical source. Such
information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.
3. Remove hydraulic lines (AF). Close all openings with
caps and plugs. Dispose of waste properly. Dispose of
Waste Properly. (Operators Manual.)
4. Remove two cap screws (G) and remove priority valve.

UN10APR98
T114079B

21
2160
24

ALine-to-Spool Valve
BLine-to-Steering Valve
CLine-from-Hydraulic Pump
DLine-to-Accumulator (Torque Converter Machine
Line-to-Dump Valve)
ELine-to-Hydraulic Reservoir
FLine-to-Steering Valve
GCap Screw (2 used)

Direct Drive Machine Shown


Continued on next page

TM2111 (30MAY03)

21-2160-24

TX,21,RB636 1925JAN032/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=604

Hydraulic System
5. Remove parts (BJ).
6. Clean and inspect parts. Replace as necessary.

UN16JUL90

7. Assemble parts, install new O-rings.


8. Lubricate all parts with clean hydraulic oil.

T6465AR

9. Tighten spool plugs (E and I).


Priority ValveSpecification
Spool PlugTorque ................................... 54.281.4 Nm (4060 lb-ft)

10. Tighten orifices (C).


Priority ValveSpecification
Priority Valve Spool Orifices
Torque .......................................................... 7.39.7 Nm (6585 lb-in.)

11. Tighten relief valve cartridge (G).


Priority ValveSpecification
Priority Valve Relief Valve
CartridgeTorque ...................................... 33.854.3 Nm (2540 lb-ft)
Priority Valve Spring Free
LengthLength .......................................... 62 mm (2.44 in.) Approximate

AHousing
BSpool
COrifice (2 used)
DSpring
EPlug
FO-Ring
GRelief Valve Cartridge
HO-Ring
IPlug
JO-Ring

12. Position priority valve and install cap screws (G).


13. Install lines (AF).
21
2160
25

14. Install engine shield.

TX,21,RB636 1925JAN033/3

TM2111 (30MAY03)

21-2160-25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=605

Hydraulic System

Cold Start Dump Valve Remove and Install


(If Equipped)
1. Remove left and right engine side shields.
2. Operate all hydraulic control valves to release pressure
in hydraulic system.

4. Disconnect hydraulic line (1) and electrical connector


(4).

T138261B

UN27FEB01

3. Drain hydraulic reservoir into container. The


approximate capacity of hydraulic reservoir for 540G-III
and 548G-III, is 30.3 L (8 gal). On machines 640G-III,
648G-III and 748G-III, the approximate capacity of
hydraulic reservoir is 41.6 L (11 gal). Dispose of waste
properly. Dispose of Waste Properly. (Operators
Manual.)
1Priority Valve-to-Dump Valve Line
2Jam Nut
3Dump Valve
4Electrical Connector

5. Loosen jam nut (2) and remove dump valve (3).


6. Install dump valve and tighten jam nut.
7. Connect electrical connector and hydraulic line.
8. Fill hydraulic reservoir. See Transmission, Hydraulic
System, Park Brake, Differential, Cab Hydraulic Pump
and Winch Oil. (Operators Manual.)
21
2160
26

9. Start engine and allow to run at slow idle for several


minutes.
10. Stop engine and check for leaks.
11. Check hydraulic reservoir oil level.
12. Install engine side shields.

CED,OUO1032,3458 1925JAN031/1

TM2111 (30MAY03)

21-2160-26

G-III and D Series Skidders (S.N. 586337 )


053003

PN=606

Hydraulic System

Hydraulic Reservoir Remove and Install


Direct Drive Machines
1. Install frame lock bar.
2. Remove engine side shields.
3. Remove hood. See Hood Remove and Install. (Group
1910.)
4. Operate all hydraulic functions including brake to
release pressure in the hydraulic system. Depress
brake pedal at one second intervals 20 times to drain
oil from accumulator.
5. Remove plug from drain hose (1) and loosen set screw
(2) to open drain valve.
6. Drain oil into container. On machines 540G-III and
548G-III, the approximate capacity of hydraulic
reservoir is 30.3 L (8 gal). On machines 640G-III,
648G-III and 748G-III, the approximate capacity of
hydraulic reservoir is 41.6 L (11 gal). Dispose of waste
oil properly. Dispose of Waste Properly. (Operators
Manual.)

21
2160
27

Continued on next page

TM2111 (30MAY03)

21-2160-27

CED,OUO1032,3161 1925JAN031/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=607

Hydraulic System

UN23AUG88

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

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 should reference a
knowledgeable medical source. Such
information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.
7. Disconnect hydraulic lines (A, B and GI).
8. Remove cap screw and remove hose clamp (C).

UN29APR98

9. Remove cap screws (D) and remove cold start aid.


10. Remove cap screws (F) and remove valve and chain.
11. Remove cap screw (E) and remove chain.

T114063B
UN10APR98
T114064B

21
2160
28

APriority Valve Return Hydraulic Line


BBrake Return Hydraulic Line
CHose Clamp
DCap Screw (2 used)
ECap Screw
FCap Screw (2 used)
GReservoir-to-Pump Case Relief Valve
HReservoir-to-Velocity Fuse
IOil Cooler Hydraulic Line

Continued on next page

TM2111 (30MAY03)

21-2160-28

CED,OUO1032,3161 1925JAN032/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=608

Hydraulic System
12. Disconnect fitting (A) to remove dump valve (B), if
equipped.

T114065B

UN29APR98

AFitting
BDump Valve

Grapple Skidder Shown


CED,OUO1032,3161 1925JAN033/13

13. Remove cap screws (C) and move filter (D) aside.
14. Disconnect fitting (B), loosen cap screw (A) and move
filter (E) aside.
ACap Screw
BFitting
CCap Screw (3 used)
DTransmission Filter
EHydraulic Filter

T114066B

UN10APR98

21
2160
29

Continued on next page

TM2111 (30MAY03)

21-2160-29

CED,OUO1032,3161 1925JAN034/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=609

Hydraulic System
15. Remove cap screws (A) and move accumulator (B)
aside.

T114068B

UN10APR98

ACap Screws (2 used)


BAccumulator

CED,OUO1032,3161 1925JAN035/13

16. Attach hoist and chains to reservoir using JT01748


Lifting Brackets (A). Remove slack from chains.

UN10APR98

AJT01748 Lifting Brackets

T114070B

21
2160
30

Continued on next page

TM2111 (30MAY03)

21-2160-30

CED,OUO1032,3161 1925JAN036/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=610

Hydraulic System

CAUTION: Heavy component; use a hoist.


Hydraulic ReservoirDirect Drive MachinesSpecification
Hydraulic ReservoirWeight ........................... 32 kg (70 lb) Approximate

17.
Remove cap screws and lock nuts (A) from both
sides of reservoir legs. Remove reservoir.

T114071B

UN13APR98

ACap Screws and Lock Nuts

CED,OUO1032,3161 1925JAN037/13

18. Install reservoir using JT01748 Lifting Brackets (A),


chain and hoist.

21
2160
31

T114070B

UN10APR98

AJT01748 Lifting Brackets

Continued on next page

TM2111 (30MAY03)

21-2160-31

CED,OUO1032,3161 1925JAN038/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=611

Hydraulic System
19. Install reservoir legs to engine frame using cap
screws and lock nuts (A).
20. Disconnect and remove chains and hoist from
reservoir.

T114071B

UN13APR98

ACap Screws and Lock Nuts

CED,OUO1032,3161 1925JAN039/13

21. Connect accumulator (B) to reservoir leg using cap


screws (A).

UN10APR98

ACap Screw (2 used)


BAccumulator

T114068B

21
2160
32

Continued on next page

TM2111 (30MAY03)

21-2160-32

CED,OUO1032,3161 1925JAN0310/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=612

Hydraulic System
22. Connect filter (D) to reservoir using cap screws (C).
23. Connect filter (E) using cap screw (A) and fitting (B).

T114066B

UN10APR98

ACap Screw
BFitting
CCap Screws
DTransmission Filter
EHydraulic Filter

CED,OUO1032,3161 1925JAN0311/13

24. Install dump valve (B) with fitting (A) to reservoir.

21
2160
33

T114065B

UN29APR98

AFitting
BDump Valve

Continued on next page

TM2111 (30MAY03)

21-2160-33

CED,OUO1032,3161 1925JAN0312/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=613

Hydraulic System
25. Attach chain to reservoir using cap screw (E).
26. Install valve and chain using cap screw (F).
27. Install cold start aid using cap screws (D).
28. Install hose clamp (C).

31. Install hood. See Hood Remove and Install. (Group


1910.)

T114063B

30. Fill hydraulic reservoir and check oil level. See


Transmission, Hydraulic System, Park Brake,
Differential, Cab Hydraulic Pump and Winch Oil.
(Operators Manual.)

UN29APR98

29. Connect hydraulic lines (A, B and GI) to bottom of


reservoir.

32. Install engine side shields.


APriority Valve Return Line
BBrake Return Line
CHose Clamp
DCap Screw (2 used)
ECap Screw
FCap Screw
GReservoir-to-Pump Case Relief Valve
HReservoir-to-Velocity Fuse
IOil Cooler Hydraulic Line

T114064B

UN10APR98

21
2160
34

CED,OUO1032,3161 1925JAN0313/13

TM2111 (30MAY03)

21-2160-34

G-III and D Series Skidders (S.N. 586337 )


053003

PN=614

Hydraulic System

Hydraulic Reservoir Remove and Install


Torque Converter Machines
1. Install frame lock bar.
2. Remove engine side shields.
3. Remove hood. See Hood Remove and Install. (Group
1910.)
4. Operate all hydraulic functions including brake to
release pressure in the hydraulic system. Depress
brake pedal at one second intervals 20 times to drain
oil from accumulator.
5. Raise cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
6. Drain hydraulic reservoir oil into a container. The
approximate capacity of hydraulic reservoir is 41.6 L
(11 gal) Dispose of Waste Properly. (Operators
Manual.)

Continued on next page

OUO1020,0001092 1925JAN031/6

21
2160
35

TM2111 (30MAY03)

21-2160-35

G-III and D Series Skidders (S.N. 586337 )


053003

PN=615

Hydraulic System

UN23AUG88

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.

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 should reference a
knowledgeable medical source. Such
information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.
7. Disconnect hydraulic lines (15 and 9).

UN27FEB01

8. Remove clamps (6 and 8).

UN27FEB01

1Priority Valve Return Line


2Reservoir Drain Line
3Cooler Pump Outlet-to-Reservoir Line
4Cooler Pump Inlet Tee-to-Reservoir Line
5Cooler Return Line
6Clamp
7Cap Screw (2 used)
8Clamp
9Dump Valve Line

T138476B

21
2160
36

T138475B

9. Remove cap screws (7) and cold start aid bracket.

Continued on next page

TM2111 (30MAY03)

21-2160-36

OUO1020,0001092 1925JAN032/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=616

Hydraulic System
10. Disconnect electrical connectors (3 and 4).
11. Support transmission filter assembly and remove cap
screws (1), allowing filter to rest on converter housing.
12. Disconnect hydraulic lines (5 and 6) and remove tie
strap (2).
UN27FEB01

13. Loosen jam nut to remove dump valve (7) by turning


to the left.

T138477B

14. Loosen reservoir fitting (9).


15. Support hydraulic filter (10) and remove cap screw
and washer (8). Leaving hoses attached, rest filter
assembly on top of converter.

T138478B

UN27FEB01

1Cap Screw (3 used)


2Tie Strap
3Electrical Connection
4Electrical Connector
5Pilot Valve Return Line
6Main Hydraulic Pump Supply Line
7Dump Valve
8Cap Screw and Washer
9Reservoir Fitting
10Hydraulic Filter

Continued on next page

TM2111 (30MAY03)

21-2160-37

OUO1020,0001092 1925JAN033/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=617

21
2160
37

Hydraulic System
16. Remove cap screw, washer and support rod (3).
17. Remove lock nut, washer, spacer, and cap screw (2).
18. Attach hoist with lifting chain to hydraulic reservoir (5)
using JT01748 Lifting Brackets (4).

UN27FEB01

CAUTION: Heavy component; use a hoist.

T138480B

Hydraulic ReservoirTorque Converter MachinesSpecification


Hydraulic ReservoirWeight ........................... 32 kg (70 lb) Approximate

19. Remove carriage bolts (1) and carefully lift reservoir


from machine.
20. Position hydraulic reservoir in place.
21. Install and tighten carriage bolts.
22. Remove lifting brackets.

UN27FEB01

23. Install pressure reducing valve manifold and one end


of support rod.

T138481B

1Carriage Bolt (6 used)


2Lock Nut, Washer, Spacer, and Cap Screw
3Cap Screw, Washer, and Support Rod
4JT01748 Lifting Bracket (2 used)
5Hydraulic Reservoir
21
2160
38

Continued on next page

TM2111 (30MAY03)

21-2160-38

OUO1020,0001092 1925JAN034/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=618

Hydraulic System
IMPORTANT: Use NEW O-rings at all fitting
connections. Old or damaged O-rings
will leak.
24. Install hydraulic filter (10), dump valve (7), and
transmission filter.

UN27FEB01

25. Connect lines (5 and 6) and electrical connectors (3


and 4).

T138477B

UN27FEB01

T138478B

1Cap Screw (3 used)


2Tie Strap
3Electrical Connection
4Electrical Connector
5Pilot Valve Return Line
6Main Hydraulic Pump Supply Line
7Dump Valve
8Cap Screw and Washer
9Reservoir Fitting
10Hydraulic Filter

Continued on next page

TM2111 (30MAY03)

21-2160-39

OUO1020,0001092 1925JAN035/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=619

21
2160
39

Hydraulic System
26. Install cold start aid bracket and support rod.
27. Connect lines (15 and 9).
28. Install clamps (6 and 8).
29. Replace all tie straps that were removed or damaged.

T138476B

UN27FEB01

IMPORTANT: If hydraulic pump was drained, fill with


proper oil. The hydraulic pump MUST
be filled with oil to prevent pump
damage at startup.
30. Fill hydraulic reservoir to proper level. See
Transmission, Hydraulic System, Park Brake,
Differential, Cab Hydraulic Pump and Winch Oil.
(Operators Manual.)
31. Lower cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)

UN27FEB01

32. Start engine and allow to run at slow idle for several
minutes.
33. Stop engine and check for leaks.

21
2160
40

T138475B

34. Check hydraulic reservoir oil level.


35. Install hood. See Hood Remove and Install. (Group
1910.)
36. Install engine side shields.

1Priority Valve Return Line


2Reservoir Drain Line
3Cooler Pump Outlet-to-Reservoir Line
4Cooler Pump Inlet Tee-to-Reservoir Line
5Cooler Return Line
6Clamp
7Cap Screw (2 used)
8Clamp
9Dump Valve Line

OUO1020,0001092 1925JAN036/6

TM2111 (30MAY03)

21-2160-40

G-III and D Series Skidders (S.N. 586337 )


053003

PN=620

Hydraulic System

Oil Cooler Pump Remove and Install


1. Install vacuum pump or drain hydraulic reservoir.
2. Disconnect hoses (2 and 6).
3. Mark and remove hose fittings (3 and 5).
4. Remove socket head screws (1) and pump (4).
5. Install pump with new O-ring and tighten socket head
cap screws.
UN26MAY00

6. Install hose fittings as marked during disassembly.


7. Connect hydraulic hoses.

T131255B

8. Remove vacuum pump or fill hydraulic reservoir to


proper level.
Direct Drive Machine Shown

1Socket Head Screws (2 used)


2Hydraulic Hose
3Hose Fitting
4Oil Cooler Pump
5Hose Fitting
6Hydraulic Hose
7Differential Lock Pump

21
2160
41

CED,OUO1032,3433 1925JAN031/1

TM2111 (30MAY03)

21-2160-41

G-III and D Series Skidders (S.N. 586337 )


053003

PN=621

Hydraulic System

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy


machines 640G-III, 648G-III and 748G-III, the
approximate capacity of hydraulic reservoir is
41.6 L (11 gal).

1. Operate all hydraulic controls to release pressure in


the hydraulic system.
2. Remove right half of hood covering reservoir.
3. Remove cap screws to remove filler neck cover.

NOTE: For a failure that creates debris, drain oil from


reservoir. Flush reservoir.
4. Replace machine hydraulic filter.

8. Move filter caddy suction hose across bottom of


reservoir to pick up all debris. Operate filter caddy
20 minutes to circulate oil through the caddy filter.
9. Install filler neck cover and filler cap.

5. Place JT05746 Portable Filter Caddy return hose in


reservoir.

10. Start engine and run at slow idle. Retract each


cylinder. Stop engine and lower all functions by
gravity. Start engine and cycle brakes and
steering. Repeat step a minimum of 5 times.

6. Install filter caddy suction hose at bottom of


reservoir.

11. If oil bypass light comes ON, stop engine. Repeat


steps 38 once more.

7. Start filter caddy. Check that oil is flowing through


filter caddy.

12. Replace machine hydraulic filter.

NOTE: Filtering time for one exchange of reservoir oil


is 0.1 minutes X number of liters (0.3 minutes
X number of gallons). On machines 540G-III
and 548G-III, the approximate capacity of
hydraulic reservoir is 30.3 L (8 gal). On

13. Fill hydraulic reservoir to proper level. See


Transmission, Hydraulic System, Park Brake,
Differential, Cab Hydraulic Pump and Winch Oil.
(Operators Manual.)
14. Install right half of hood covering reservoir.

21
2160
42

TX,2160,UU980 1920AUG911/1

TM2111 (30MAY03)

21-2160-42

G-III and D Series Skidders (S.N. 586337 )


053003

PN=622

Section 30

Winch
Contents
Page

Group 3000Removal and Installation


Winch 4000 Series Remove and Install. . . . .30-3000-1
Winch Drum Plug 4000 Series Install . . . . . .30-3000-7
Winch 4000 Series Fasten Cable to Drum . .30-3000-7
Winch Free Spool Drag Adjustment . . . . . .30-3000-10
Winch 6000 Series Remove and Install. . . .30-3000-11
Winch 6000 Series Fasten Cable to
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-3000-14
Group 3015Controls Linkage
Winch Control Valve Linkage Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-3015-2
Group 3025Input Drive Shafts and U-Joints
Winch Drive Line Remove and Install . . . . . .30-3025-1
Winch 4000 Series Drive Shaft Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . . .30-3025-2
Group 3050Drive and Clutch
Winch 4000 Series Drive and Clutch
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-3050-1
Winch 6000 Series Drive and Clutch
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-3050-1

30

TM2111 (30MAY03)

30-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

30

TM2111 (30MAY03)

30-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 3000

Removal and Installation


Winch 4000 Series Remove and Install
Removal

X9811

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
1. Stop engine and lower all equipment to ground.
2. Operate all hydraulic functions, including brake, to
release pressure in the hydraulic system. Depress
brake pedal at one-second intervals 20 times to drain
oil from accumulator.
CAUTION: Avoid possible injury from
unexpected machine movement. Install frame
locking bar.
3. Install frame locking bar.
4. Disconnect negative battery cable.
5. Raise cab. See Hydraulic Cab Tilt Procedure.
(Operators Manual.)
6. Disconnect winch control cable yoke (C).

UN13APR98

7. Disconnect winch drive line from drive yoke (B).


8. Disconnect hydraulic lines (A and D).

T113916

9. Disconnect and remove control cable.


10. Remove winch mounting cap screws.

APressure Inlet Line


BDrive Yoke
CControl Cable Yoke
DReturn Oil Line

Continued on next page

TM2111 (30MAY03)

30-3000-1

OUO1020,000121E 1909JAN031/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=625

30
3000
1

Removal and Installation


11. Grapple machines onlyremove cap screws (A) to
remove guards.

T8474AF

UN19MAY95

ACap Screw (6 used)

OUO1020,000121E 1909JAN032/9

12. Grapple machines onlylabel and disconnect


hydraulic lines (AF).
13. Remove four fittings (H).
14. Remove fuel tank mounting cap screws and slide fuel
tank rearward as far as possible. See Fuel Tank
Remove and Install540G-III, 548G-III, 640G-III or
Fuel Tank Remove and Install648G-III, 748G-III.
(Group 0560.)

T114091C

UN23MAR99

ATo Port A Rotate Manifold


BTo Port B Rotate Manifold
CTo Arch Cylinder Head
DTo Arch Cylinder Rod End
EFrom Grapple Control Valve
FFrom Arch Control Valve
GMounting Bracket
HFittings (4 used)

Single Function Shown


30
3000
2

Continued on next page

TM2111 (30MAY03)

30-3000-2

OUO1020,000121E 1909JAN033/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=626

Removal and Installation


15. Attach lifting chains to winch as shown.
CAUTION: Heavy component; use a hoist.

UN05JUN91

Winch 4000 SeriesSpecification


WinchWeight ............................................ 545 kg (1200 lb) approximate

T7516AV

16. Remove winch.

Shown with Cable Removed

OUO1020,000121E 1909JAN034/9

NOTE: If winch is to be stored or reinstalled without


disassembly, do not drain oil.
If winch is to be disassembled, drain oil out of left
(gear side) cover drain plug. This will remove
approximately 24 L (6.25 gal) of oil, the rest of the
oil is trapped and winch will have to be
disassembled to remove it.
17. Remove plug (C) to drain oil.
18. Repair or replace winch as necessary. See 40 and
4000 Series Winches. (CTM25.)
30
3000
3

T7306AL

UN22MAY90

AReturn Line Cap


BFill Plug
CDrain Plug

Continued on next page

TM2111 (30MAY03)

30-3000-3

OUO1020,000121E 1909JAN035/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=627

Removal and Installation


Installation
1. Clean grease, dirt, oil, and paint from mounting holes.

UN05JUN91

2. Install winch.
3. Tighten mounting cap screws to specification.

T7516AV

Winch 4000 SeriesSpecification


Equipment Frame-to-Winch Cap
ScrewTorque ............................................................ 620 Nm (455 lb-ft)

4. Position fuel tank and install mounting cap screws.

Shown with Cable Removed

OUO1020,000121E 1909JAN036/9

5. Grapple machines onlyinstall four fittings (H) to


mounting bracket (G).
6. Connect hydraulic lines (AF).

UN23MAR99

ALine to Port A Rotate Manifold


BLine to Port B Rotate Manifold
CTo Line to Arch Cylinder Head
DLine to Arch Cylinder Rod End
ELine from Grapple Control Valve
FLine from Arch Control Valve
GMounting Bracket
HFittings (4 used)

T114091C

30
3000
4

Single Function Shown

Continued on next page

TM2111 (30MAY03)

30-3000-4

OUO1020,000121E 1909JAN037/9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=628

Removal and Installation


7. Grapple machines onlyposition guards and install
cap screws (A).

UN19MAY95

8. Lower cab. See Hydraulic Cab Tilt Procedure.


(Operators Manual.)

T8474AF

ACap Screw (6 used)

Continued on next page

OUO1020,000121E 1909JAN038/9

30
3000
5

TM2111 (30MAY03)

30-3000-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=629

Removal and Installation


9. Connect and adjust control cable yoke (C). See Winch
Control Cable Remove and Install. (Group 3015.)
10. Connect hydraulic lines (A and D).
11. Connect winch drive line yoke (B). Tighten cap
screws to specification.
Winch 4000 SeriesSpecification
Winch Cross-to-Yoke Cap
ScrewsTorque .............................................................. 58 Nm (43 lb-ft)

12. Fill winch with recommended oil. See Change Winch


OilIf Equipped. (Operators Manual.)
Winch 4000 SeriesSpecification
Winch OilCapacity..................................... 35.2 L (9.3 gal) approximate

13. Connect negative battery cable.

14. Operate the winch in either Power In or Free Spool


position to finish filling winch. Check transmission oil
level frequently and add oil through the transmission
dipstick. See Check Transmission Oil Level.
(Operators Manual.)
30
3000
6

T113916

NOTE: Power In position will deliver 7.89.5 L (22-1/2


gal) per minute to fill winch. Free Spool position
will take approximately 1/2 hour to fill winch.

UN13APR98

IMPORTANT: Oil capacity for winch is greater than


transmission oil capacity. Check
transmission oil level frequently while
filling to avoid transmission pump
cavitation.

APressure Oil Inlet Line


BDrive Line Yoke
CControl Cable Yoke
DReturn Oil Line

15. Operate winch and check the transmission oil level


again.
16. Install cable. See Winch 4000 Series Fasten Cable to
Drum in this group.

OUO1020,000121E 1909JAN039/9

TM2111 (30MAY03)

30-3000-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=630

Removal and Installation

Winch Drum Plug 4000 Series Install

UN22MAY90

IMPORTANT: If cable is attached in slot (A), the drum


plug (B) MUST be installed to prevent
cable from bending cable slot.
Install drum plug (B) flush in winch drum.

T7305AW

UN22MAY90

T7305AV

ACable Slot
BDrum Plug

OUO1020,0001222 1910JAN031/1

Winch 4000 Series Fasten Cable to Drum


CAUTION: Prevent possible injury from cable
wire. Wear gloves when handling cable to
protect hands. DO NOT guide cable onto winch
with your hands.

30
3000
7

Attach cable to winch drum using one of the following


methods.

Continued on next page

TM2111 (30MAY03)

30-3000-7

OUO1020,0001223 1910JAN031/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=631

Removal and Installation


Method 1:

UN03OCT90

IMPORTANT: If a ferruled cable is used, the drum


plug (B) must be installed to prevent
cable from bending cable slot.
1. Attach a ferrule or cable clamp (A) to end of cable.

T7382AH

2. Wrap cable around the drum. Slide the ferrule or cable


clamp under the cable and into slot in drum, and
secure with tab (C).
3. Perform Winch Free Spool Drag Adjustment in this
group.

NOTE: Factory free spool drag setting was done without


cable; adjust free spool drag to operators
preference when cable is added.
Ten-inch drum only has pocket method of locating
ferrule cable to drum.

UN27SEP90

ACable Clamp
BDrum Plug
CCable Tab

T7347AS

30
3000
8

Continued on next page

TM2111 (30MAY03)

30-3000-8

OUO1020,0001223 1910JAN032/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=632

Removal and Installation


Method 2:
IMPORTANT: If you unwind cable below one turn on
drum, cable will come off drum.

NOTE: To conform with certain state laws, the cable must


be attached to the drum so that it can come loose
if cable is completely unwound.
1. Remove drum plug (B).
CAUTION: Prevent possible injury from cable
wire. Wear gloves when handling cable to
protect hands. DO NOT guide cable onto winch
with your hands.
2. Thread cable up through small hole and insert cable
back down through lower hole. Pull loop into drum.
UN27SEP90

3. Perform Winch Free Spool Drag Adjustment in this


group.

T7347AS

NOTE: Factory free spool drag setting was done without


cable; adjust free spool drag to operators
preference when cable is added.

T7382AI

UN03OCT90

BDrum Plug

Continued on next page

TM2111 (30MAY03)

30-3000-9

OUO1020,0001223 1910JAN033/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=633

30
3000
9

Removal and Installation


Method 3:
1. Remove drum plug.

T7382AK

UN03OCT90

CAUTION: Prevent possible injury from cable


wire. Wear gloves when handling cable to
protect hands. DO NOT guide cable on winch
with your hands.
2. Thread cable up through small hole and wrap cable
around wedge (A). Insert cable back down through
lower hole and pull wedge into drum slot (B).
3. Perform Winch Free Spool Drag Adjustment in this
group.

UN03OCT90

NOTE: Factory free spool drag setting was done without


cable; adjust free spool drag to operators
preference when cable is added.

T7382AJ

AWedge
BDrum Slot

OUO1020,0001223 1910JAN034/4

Winch Free Spool Drag Adjustment


The winch drum drag can be adjusted to operators
preference.
UN27MAR00

1. Start engine.
2. Lower equipment to ground.

T129367C

3. Engage park brake.


4. Block wheels.
4000 Winch Shown

5. Place winch control handle in FREE SPOOL position.


6. Loosen nut (A).
7. Adjust slotted shaft (B) to desired winch drum drag.
UN10JAN95

8. Tighten nut.
ANut
BSlotted Shaft

T8390AP

30
3000
10

6000 Winch Shown


OUO1020,0001224 1910JAN031/1

TM2111 (30MAY03)

30-3000-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=634

Removal and Installation

Winch 6000 Series Remove and Install


Removal

UN23AUG88

CAUTION: Avoid possible injury from


unexpected machine movement. Install frame
locking bar.

X9811

1. Stop engine, lower all equipment to ground and install


frame locking bar.
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
2. Operate all hydraulic control valve levers to release
hydraulic pressure in the system.
3. Disconnect negative battery cable.
4. Remove cotter pin and pin (B) to disconnect yoke.
5. Remove cap screws (C) and washers to remove
mounting bracket and winch control cable.
6. Remove cap screws to disconnect winch drive line (E)
(not shown).

UN09JUL91

7. Disconnect hydraulic lines (A and D). Close all


openings using caps and plugs.

T7508AY

8. Remove drain cap and install a drain hose on fitting to


drain winch. The approximate capacity is 45.5 L (12
gal).

APressure Inlet Line


BPin
CCap Screws (2 used)
DReturn Oil Line
EDrive Line

Continued on next page

TM2111 (30MAY03)

30-3000-11

OUO1020,0001220 1910JAN031/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=635

30
3000
11

Removal and Installation

CAUTION: Heavy component; use a hoist.


Winch 6000 SeriesSpecification
WinchWeight ............................................ 680 kg (1500 lb) approximate

9. Fasten lifting chain around winch as shown and


connect chain to a hoist.
10. Remove front and rear winch mounting cap screws
through access holes in bottom of equipment frame.
11. Carefully lift winch off equipment frame.
Installation
1. Clean grease, dirt, oil, and paint from mounting holes.
2. Install winch.

UN09JUL91

3. Install front and rear mounting cap screws and tighten


to specification.

T7533AX

Winch 6000 SeriesSpecification


Winch Mounting Cap Screw
Torque ......................................................................... 620 Nm (455 lb-ft)

Continued on next page

OUO1020,0001220 1910JAN032/3

30
3000
12

TM2111 (30MAY03)

30-3000-12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=636

Removal and Installation


4. Connect hydraulic lines (A and D).
5. Connect winch drive line (E) (not shown). Install and
tighten cap screws to specification.
Winch 6000 SeriesSpecification
Winch Cross-to-Yoke Cap
ScrewTorque ................................................................ 58 Nm (43 lb-ft)

6. Install control cable mounting bracket, washers and


tighten cap screws (C).
7. Install and adjust control cable. See See Winch Control
Cable Remove and Install. (Group 3015.)Winch Control
Valve Linkage Remove and Install in this group.
8. Connect yoke to valve. Install pin (B) and cotter pin.

UN09JUL91

9. Fill winch with recommended oil. See Change Winch


OilIf Equipped. (Operators Manual.)
Winch 6000 SeriesSpecification
Winch OilCapacity...................................... 45.5 L (12 gal) approximate

IMPORTANT: Oil capacity for winch is greater than


transmission oil capacity. Check
transmission oil level frequently while
filling to avoid transmission pump
cavitation.

NOTE: Power In position will deliver 7.89.5 L (22-1/2


gal) per minute to fill winch. Free Spool position
will take approximately 1/2 hour to fill winch.

T7508AY

10. Connect negative battery cable.

APressure Inlet Line


BPin
CCap Screws (2 used)
DReturn Oil Line
EDrive Line

30
3000
13

11. Operate the winch in either Power In or Free Spool


position to fill winch. Check transmission oil levels
frequently when filling winch. See Check
Transmission Oil Level. (Operators Manual.)

OUO1020,0001220 1910JAN033/3

TM2111 (30MAY03)

30-3000-13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=637

Removal and Installation

Winch 6000 Series Fasten Cable to Drum


CAUTION: Prevent possible injury from cable
wire. Wear gloves when handling cable to
protect hands. DO NOT guide cable onto winch
with your hands.
Attach cable to winch drum using one of the following
methods.

OUO1020,0001225 1910JAN031/3

Method 1
1. Attach a ferrule (A) or cable clamp (B) to end of cable.

UN18OCT88

2. Wrap cable around the drum and slide the ferrule (A)
or cable clamp (B) under the cable and into slot in
drum.

UN07NOV88

T5843AJ

AFerrule
BCable Clamp

T5875AB

30
3000
14

Continued on next page

TM2111 (30MAY03)

30-3000-14

OUO1020,0001225 1910JAN032/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=638

Removal and Installation


Method 2
IMPORTANT: If you unwind cable below one turn on
drum, cable will come off drum.
UN07NOV88

NOTE: To conform with certain state laws, the cable must


be attached to the drum so that it can come loose
if the cable is completely unwound.

CAUTION: Prevent possible injury from cable


wire. Wear gloves when handling cable to
protect hands. DO NOT guide cable onto winch
with your hands.

T5875AC

1. Attach a ferrule or cable clamp to the end of the cable.

CCable

2. Wrap a piece of heavy wire (No. 9) or light cable (C)


around the drum and over the ferrule or cable clamps.
3. Twist or tie the heavy wire or light cable (C) to prevent
it from loosening.
4. Place the ferrule or cable clamp into the slot in the
drum.

OUO1020,0001225 1910JAN033/3

30
3000
15

TM2111 (30MAY03)

30-3000-15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=639

Removal and Installation

30
3000
16

TM2111 (30MAY03)

30-3000-16

G-III and D Series Skidders (S.N. 586337 )


053003

PN=640

Group 3015

Controls Linkage

30
3015
1

TM2111 (30MAY03)

30-3015-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=641

Controls Linkage

Winch Control Valve Linkage Remove and Install

T131308

UN01JUN00

30
3015
2

Continued on next page

TM2111 (30MAY03)

30-3015-2

OUO1020,0001226 1910JAN031/7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=642

Controls Linkage
1Pin (4000 Winch3 used)
2Yoke
3Pin (4000 Winch3 used)
4Nut
5Bracket
6Bracket
7Washer (3 used)
8Nut (3 used)
9Spacer (2 used)
10Cap Screw (2 used)
11Control Cable

12Cap Screw (2 used)


13Clamp (2 used)
14Spring
15Strap
16Strap (2 used)
17Bellcrank
18Bushing
19Bolt
20Cap Screw (2 used)
21Bushing
22Knob

23Boot
24Clip (6 used)
25Ring
26Cap Screw (2 used)
27Washer (2 used)
28Plate
29Bracket
30Strap (2 used)
31U-Bolt
32Cap Screw
33Lock Nut (2 used)

1. Remove worn or damaged parts and replace as


necessary.

34Ball Joint
35Washer (3 used)
36Nut
37Lock Nut
38Wedge
39Lever
40Ball Joint
41Nut
42Cap Screw (3 used)
43Washer (2 used)
44Label

2. Apply one drop of medium strength thread lock and


sealer to threads of ball joint (40).

OUO1020,0001226 1910JAN032/7

Winch Control Cable Remove and Install


1. Remove old cable.

UN13MAR92

2. Install new cable into cab. Install straps (30), U-bolt


(31), and lock nuts (33).
3. Install ball joint (34) six turns.

T7711AG

4. Secure the lever to the right rear of the BRAKE OFF


slot.
5. Push cable winch end IN to remove slack. Measure
from end of cable to center of mounting groove and
adjust ball joint (34) until distance (A) is to
specification.

30
3015
3

UN04APR00

Winch Control CableSpecification


End of Cable-to-Center of
Mounting GrooveDistance ....................................... 159 mm (6.250 in.)

T129676B

6. Install cable through frame and attach bracket (6),


strap (15), clamp (13), bushing (21) and cap screws
(20) on winch.
7. Install spring (14), washer (7), nut (4) and yoke (2) on
winch end of cable.

AEnd of Cable-to-Center of Mounting Groove


Distance

Continued on next page

TM2111 (30MAY03)

30-3015-3

OUO1020,0001226 1910JAN033/7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=643

Controls Linkage
IMPORTANT: Winch valve must be in FREE SPOOL
position to correctly adjust linkage.

UN06NOV90

8. Push winch valve spool IN, as far as possible, into


FREE SPOOL position.

T7402AE

9. With the 4000 winch bellcrank or 6000 winch valve


spool in free spool position, pull cable with 44.5 N (10
lb-force).
Winch Control CableSpecification
Cable Pull (Free Spool
Position)Force .......................................................... 44.5 N (10 lb-force)

On 4000 Series winch only, apply 22.2 N (5 lb-force) to


bellcrank toward cable end.
Winch Control CableSpecification
4000 Series Winch (Only)
BellcrankForce ........................................................... 22.2 N (5 lb-force)

10. Adjust the 4000 winch yoke to align with hole in


bellcrank. Adjust the 6000 winch yoke to align with
valve spool.
11. Connect the yoke to the 4000 winch bellcrank (or
6000 winch valve spool) and install pin.

Continued on next page

OUO1020,0001226 1910JAN034/7

30
3015
4

TM2111 (30MAY03)

30-3015-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=644

Controls Linkage
12. Move control lever to BRAKE ON (hold) position.
13. Slide bracket (A) so that lip contacts spring.

UN13APR98

14. Tighten bracket and control cable cap screws.

T113917

ABracket

T7402AI

UN26NOV90

4000 Series Winch

6000 Series Winch


Continued on next page

OUO1020,0001226 1910JAN035/7

30
3015
5

TM2111 (30MAY03)

30-3015-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=645

Controls Linkage

1930OCT90
T7374AZ

Winch Control CableSpecification


Control Lever-to-Stop Screw
(Free Spool Position)Distance ................... 35 mm (0.1200.160 in.)

T7374AY

16. Move control lever to FREE SPOOL position and


release lever. There must be 35 mm (0.1200.160
in.) distance between lever and stop screw.

1930OCT90

15. Run engine at slow idle.

NOTE: It is normal for engine to pull down when POWER


IN is first engaged. This valve sequencing is to
prevent winch brake from dropping load before
clutch engages.
17. Slowly move control lever to POWER IN position until
drum turns. There must be 68 mm (0.2400.320
in.) distance between lever and stop screw. Adjust as
required.
Winch Control CableSpecification
Control Lever-to-Stop Screw
(Power In Position)Distance ...................... 68 mm (0.2400.320 in.)

18. While POWER IN is engaged, release lever. Lever


must return to BRAKE ON (hold) when released from
any POWER IN position. If lever does not return,
increase return spring tension as described earlier in
this procedure.

OUO1020,0001226 1910JAN036/7

Winch Control CableSpecification


Winch Control Lever (Rearward
Pull)Force ................................................................... 22.2 N (5 lb-force)

1930OCT90
T7397AZ

20. Pull lever rearward with approximately 22.2 N (5


lb-force), then move lever to left side.

1930OCT90

19. Move winch control lever to free spool position.

T7374AY

30
3015
6

Lever must move freely through the gate and not rub
against rear of right slot or front of left slot. If lever rubs
slot gate, readjust winch cable yoke as described earlier
in this procedure.

OUO1020,0001226 1910JAN037/7

TM2111 (30MAY03)

30-3015-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=646

Group 3025

Input Drive Shafts and U-Joints


Winch Drive Line Remove and Install

UN09JUL91

CAUTION: Avoid possible injury from


unexpected machine movement. Install frame
locking bar.

T7553BY

1. Park machine in a straight position. Install frame


locking bar.
2. Remove cap screws (A) from each end of drive line.
3. Install drive line with the female yoke end (C) of
telescoping shaft toward winch.

Direct Drive Machine

4. Install cap screws (A) and tighten to specification.

UN09JUL91

Winch Drive LineSpecification


Cross-to-Yoke 3/8 in. Cap
ScrewTorque ................................................................ 58 Nm (43 lb-ft)
Flange-to-Yoke 7/16 in. Cap
ScrewTorque .............................................................. 100 Nm (75 lb-ft)

T7553BZ

5. Remove frame locking bar.


ACap Screw
BGrease Fitting
CFemale Yoke End

Direct Drive Machine

OUO1020,0001221 1910JAN031/1

30
3025
1

TM2111 (30MAY03)

30-3025-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=647

Input Drive Shafts and U-Joints

TP54250

UN02APR98

Winch 4000 Series Drive Shaft Disassemble and Assemble

Direct Drive Shaft Shown


1Universal Joint Cross (2
used)

2Lubrication Fitting
3Cap

4Washer (16 used)


5Cap Screw (16 used)

1. Disassemble parts (16).

6Drive Shaft

5. Lubricate shaft after installation on machine.

2. Inspect for excessively worn or broken parts and


replace as necessary.
3. Assemble parts.
4. Tighten joint cross-to-yoke cap screws (5).
30
3025
2

Winch 4000 Drive ShaftSpecification


Cross-to-Yoke 3/8 in. Cap
ScrewTorque ......................................................... 58 Nm (43 lb-ft)

OUO1020,0001228 1910JAN031/1

TM2111 (30MAY03)

30-3025-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=648

Group 3050

Drive and Clutch


Winch 4000 Series Drive and Clutch Repair
Repair winch drive and clutch. See Winch Drive and
Clutches. (CTM25.)
OUO1020,000122C 1914JAN031/1

Winch 6000 Series Drive and Clutch Repair


Repair winch drive and clutch. See Winch Drive and
Clutches. (CTM41)
OUO1020,000122D 1914JAN031/1

30
3050
1

TM2111 (30MAY03)

30-3050-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=649

Drive and Clutch

30
3050
2

TM2111 (30MAY03)

30-3050-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=650

Section 32

Bulldozers (Stacking & Trailbuilding Blades)


Contents
Page

Group 3201Blades
Stacking Blade Remove and Install . . . . . . . .32-3201-1
Spherical Bushing Remove and Install . . . . .32-3201-7
Group 3215Controls Linkage
Blade Control Linkage Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3215-1
Blade Control Valve Remove and Install . . . .32-3215-2
Group 3260Hydraulic System
Blade Lift Cylinder Remove and Install . . . . .32-3260-1

32

TM2111 (30MAY03)

32-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

32

TM2111 (30MAY03)

32-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 3201

Blades
Stacking Blade Remove and Install
1. Lower all equipment to the ground. Operate all control
levers to relieve pressure in the hydraulic system.
UN02JUL91

NOTE: One front wheel must be removed before stacking


blade pin can be removed.

T7502HK

2. Remove one front wheel. See Wheel Repair. (Group


0110.)
CAUTION: Heavy component; use a hoist.

Right Stacking Blade Cylinder

Stacking BladeSpecification
540G-III, 548G-III Blade
CylinderWeight ............................................ 34.4 kg (76 lb) approximate
640G-III, 648G-III Blade
CylinderWeight ............................................... 38 kg (84 lb) approximate
748G-III Blade CylinderWeight ................. 47.6 kg (105 lb) approximate

ACap Screw
BCylinder Pin
CNut

3. Attach hoist to blade cylinder using lifting straps.


4. Remove cap screws (A), nuts (C), and cylinder pins (B)
to disconnect right and left blade cylinders.

Continued on next page

OUO1020,0001213 1908JAN031/6

32
3201
1

TM2111 (30MAY03)

32-3201-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=653

T8474AG

UN22MAY95

Blades

1Cap Screw (2 used)


Cap Screw with Washer
(540G-III, 548G-III only)
2Cap (540G-III, 548G-III)
Washer (640G-III, 648G-III,
748G-III)

3Pin
4Cap Screw
5Lock Nut
6Lubrication Fitting (4 used)

CAUTION: Heavy component; use a hoist.

32
3201
2

Stacking BladeSpecification
540G-III, 548G-III Stacking
BladeWeight ...................................... 583 kg (1286 lb) approximate
640G-III, 648G-III Stacking
BladeWeight ...................................... 630 kg (1330 lb) approximate
748G-III Stacking Blade
Weight ................................................... 834 kg (1840 lb) approximate

5. Attach hoist to stacking blade using lifting straps.

7Washer (as required)


8Spherical Bushing
9Spherical Bushing
10Stacking Blade

11Washer (as required)


12Seal
13Pivot

7. Remove cap screws (1), cap (2), lock nut (5) and
cap screw (4).
8. Remove pin (3) and stacking blade (10).
9. Inspect stacking blade for cracks or damage.
10. Inspect spherical bushings in cylinder bores and
blade pivot bores for wear or damage. If a bushing
must be replaced, see Spherical Bushing Remove
and Install in this group.

6. Lower bottom guard.

Continued on next page

TM2111 (30MAY03)

32-3201-2

OUO1020,0001213 1908JAN032/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=654

Blades
11. Lift blade using a lifting strap. Center blade to install
washers between blade and engine frame as required
as pivot pin (A) is installed.

UN02JUL91

12. Replace lubrication fittings (6) if necessary, tighten to


specification.

T7502HI

Stacking BladeSpecification
Lubrication FittingsTorque ........................................... 47 Nm (35 lb-ft)

APivot Pin

Continued on next page

OUO1020,0001213 1908JAN033/6

32
3201
3

TM2111 (30MAY03)

32-3201-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=655

Blades

T8509AC

UN19JUN95

32
3201
4

540G-III, 548G-III Shown

Continued on next page

TM2111 (30MAY03)

32-3201-4

OUO1020,0001213 1908JAN034/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=656

Blades
AWasher (as required)
BShim (as required)
CEngine Frame
DPolyurethane Foam
Washer

EHardened Washer (540G-III,


548G-III only)
FCap Screw M20 x 40 mm

13. Apply medium strength thread lock and sealer to


cap screw (F).
14. Install one washer (A) on pin, then put new cap or
washer (G) on pin, and hold in place.
IMPORTANT: A minimum of 3 mm (0.120 in.) gap
(H) must be left on each side of pin
to prevent a side impact from
breaking off pin cap screws.
15. Measure gap (H) between cap and washer. Install
or remove shims (B) until specified gap is
obtained.
Stacking BladeSpecification
Cap-to-WasherGap ............................. 36 mm (0.1200.240 in.)

GBlade Pin Cap (540G-III,


548G-III)
Washer (640G-III, 648G-III,
748G-III)

H36 mm (0.1200.240 in.)


Clearance Dimension

IMPORTANT: If blade is sprung so that specified


gap cannot be obtained, the blade
must be removed and pushbeams
bent back until gap specification can
be obtained.
16. Install foam washer (D) on pin. Install cap
(540G-III, 548G-III) or washer (640G-III, 648G-III,
748G-III) (G) and washer (E).
17. Apply medium strength thread lock and sealer to
cap screw (F) and tighten to specification.
Stacking BladeSpecification
Blade Pin Cap Assembly Cap
ScrewTorque ..................................................... 495 Nm (365 lb-ft)

Continued on next page

OUO1020,0001213 1908JAN035/6

32
3201
5

TM2111 (30MAY03)

32-3201-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=657

Blades
18. Lift blade using a hoist. Install shims (D) as required
so that cylinders do not bind. Install pin (B) through
cylinder (F), shims (D) and spherical bushing (E).
19. Install cap screw (A) and nut (C) and tighten.

T7502HK

UN02JUL91

T7502HL

UN10JUL91

ACap Screw
BPin
CNut
DShim (as required)
ESpherical Bushing
FBlade Cylinder

32
3201
6

OUO1020,0001213 1908JAN036/6

TM2111 (30MAY03)

32-3201-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=658

Blades

Spherical Bushing Remove and Install


1. If bushing (A) in blade pivot bore must be replaced,
remove washer (B) using a grinder to remove weld.

T7502HJ

UN02JUL91

ABushing
BWasher

OUO1020,0001214 1908JAN031/3

2. Remove bushing (B). See DFT1099 Bushing Drivers.


(Group 9900.)

T7569AM

UN09JUL91

APipe Assembly
BSpherical Bushing
CPipe Assembly
DWasher
ENut

Continued on next page

TM2111 (30MAY03)

32-3201-7

OUO1020,0001214 1908JAN032/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=659

32
3201
7

Blades
3. Install bushing. See DFT1099 Bushing Drivers. (Group
9900.)

5. Weld new washers in place at the same location where


old ones were removed.
See Make Welding Repairs Safely, and See Remove
Paint Before Welding or Heating. (Group 9000-10.)

T7569AL

CAUTION: Have only a qualified welder do the


welding. Be sure the area near the machine is
free of debris and flammable material. Before
welding, clean all dirt and paint from weld area.
Disconnect the battery negative cable. Connect
the welder ground clamp as close as possible
to each weld area.

UN09JUL91

4. Turn nut (F) until center line (B) of bushing aligns with
center line (C) of frame.

APipe Assembly
BBushing Center Line
CFrame Center Line
DBar Stock
EWasher
FNut

OUO1020,0001214 1908JAN033/3

32
3201
8

TM2111 (30MAY03)

32-3201-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=660

Group 3215

Controls Linkage

TP35542

UN12APR95

Blade Control Linkage Remove and Install

1Shim
2Bushing (2 used)
3Knob
4Control Lever

5Boot
6Nut
7Washer
8Bushing

9Lock Nut
10Pin
11Spring Locking Pin

12Rod
13Jam Nut
14Ball Joint

4. Clean threads of pivot ball joint (14) and apply


medium strength thread lock and sealer.

1. Lower blade and relieve all hydraulic pressure.


CAUTION: Avoid possible injury from
unexpected machine movement. Install
frame locking bar before working in frame
hinge area.
2. Install frame locking bar.

5. Adjust length of rod (12) so horizontal leg of control


lever (4) is level.
6. Clean threads of lever (4) and apply medium
strength thread lock and sealer then install knob
(3).

3. Inspect and replace blade control linkage parts as


necessary.
32
3215
1

OUO1020,0001215 1908JAN031/1

TM2111 (30MAY03)

32-3215-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=661

Controls Linkage

T8487AB

UN22MAY95

Blade Control Valve Remove and Install

1Cap Screw (3 used)


2Rubber Mount (3 used)

3Blade Valve Support

4Washer (5 used)

1. Lower blade and relieve all hydraulic pressure.

3. Remove blade control valve. See Blade Control


Valve Disassemble and Assemble. (Group 3860.)

CAUTION: Avoid possible injury from


unexpected machine movement. Install
frame locking bar before working in frame
hinge area.
2. Install frame locking bar.

5Cap Screw (3 used)

4. Inspect blade control valve support and replace


parts as necessary.
5. Install blade control valve. See Blade Control Valve
Disassemble and Assemble. (Group 3860.)

32
3215
2

OUO1020,0001216 1908JAN031/1

TM2111 (30MAY03)

32-3215-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=662

Group 3260

Hydraulic System
Blade Lift Cylinder Remove and Install

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

X9811

1. Operate all hydraulic control valves to release pressure


in hydraulic system.
2. Disconnect lines (B and C).
CAUTION: Heavy component; use a hoist.

UN11JUL91

Blade Lift CylinderSpecification


CylinderWeight ............................................... 27 kg (60 lb) approximate

3. Attach hoist to blade lift cylinder using a lifting strap.

T7569AT

4. Remove cap screws (A and D).


5. Remove pins (E and F) to remove blade lift cylinder.
6. Repair or replace blade lift cylinder as required. See
Disassemble Cylinder and See Assemble Cylinder.
(TM-H120A.)
7. Install blade lift cylinder.

Wheel Removed for Illustration Purposes Only


ACap Screw
BSteering Valve-to-Steering Cylinder Rod End
Line
CSteering Valve-to-Steering Cylinder Head End
Line
DCap Screw
EPin
FPin

OUO1020,0001219 1908JAN031/1

TM2111 (30MAY03)

32-3260-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=663

32
3260
1

Hydraulic System

32
3260
2

TM2111 (30MAY03)

32-3260-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=664

Section 37

Arch or Boom
Contents
Page

Group 3740Frames
Log Arch Remove and Install . . . . . . . . . . . .37-3740-1
Horizontal Roller Remove and Install . . . . . .37-3740-1
Side Roller Remove and Install . . . . . . . . . . .37-3740-3
Roller Brackets Remove and Install. . . . . . . .37-3740-5

37

TM2111 (30MAY03)

37-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

37

TM2111 (30MAY03)

37-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 3740

Frames
Log Arch Remove and Install
CAUTION: Avoid possible injury from
unexpected machine movement. Install frame
locking bar.
1. Install frame locking bar.
2. Remove winch cable from log arch.
CAUTION: Heavy component; use a hoist.
Log ArchSpecification
Log ArchWeight ......................................... 308 kg (680 lb) approximate

3. Attach hoist to log arch using a lifting strap.


4. Remove cap screws and pins (A).
UN11JUN91

NOTE: The two rear joints are shimmed to remove side


play.

T7553BR

5. Inspect components and replace screws, if necessary.


ACap Screws and Pins

OUO1020,000121A 1909JAN031/1

Horizontal Roller Remove and Install


1. Attach hoist to horizontal roller using a lifting strap.

UN11JUN91

2. Remove cap screw (A) and grease fitting (B).

T7553BJ

ACap Screw
BGrease Fitting

Continued on next page

TM2111 (30MAY03)

37-3740-1

OUO1020,000121B 1909JAN031/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=667

37
3740
1

Frames

CAUTION: Heavy component; use a hoist.


Horizontal RollerSpecification
Horizontal RollerWeight ................................. 27 kg (60 lb) approximate

T7553BK

UN11JUN91

3. Remove pin using a brass drift.

OUO1020,000121B 1909JAN032/5

T94722

UN20OCT88

4. Remove two bushings using D01061AA Blind-Hole


Puller Set.

OUO1020,000121B 1909JAN033/5

T94723

UN20OCT88

5. Install bushing flush with surface of roller using 44 mm


disk and 52 mm disk from JT01800 Driver Set.

OUO1020,000121B 1909JAN034/5

NOTE: Roller bracket can be moved to mount roller in


different positions, for a variety of load conditions.
6. Install pin with lubrication hole down.
UN11JUN91

7. Install cap screw, nut, and grease fitting.

T7553BL

37
3740
2

OUO1020,000121B 1909JAN035/5

TM2111 (30MAY03)

37-3740-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=668

Frames

Side Roller Remove and Install

T7553BM

UN11JUN91

1. Remove cap screw and plate.

OUO1020,000121C 1909JAN031/8

2. Fasten safety chain around roller and log arch as


shown.
CAUTION: Heavy component; use a hoist.
Side RollerSpecification
Side RollerWeight .......................................... 25 kg (55 lb) approximate

T7553BN

UN11JUN91

3. Remove shaft using brass drift and disconnect chain to


remove roller.

OUO1020,000121C 1909JAN032/8

4. Remove washers.

T7553BO

UN11JUN91

37
3740
3

Continued on next page

TM2111 (30MAY03)

37-3740-3

OUO1020,000121C 1909JAN033/8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=669

Frames

T94729

UN20OCT88

5. Remove two bushings using a D01061AA Blind-Hole


Puller Set.

OUO1020,000121C 1909JAN034/8

T94730

UN20OCT88

6. Install bushings flush with bushing retainer using 28


mm disk and 37 mm disk from JT01800 Driver Set.

OUO1020,000121C 1909JAN035/8

T7553BO

UN11JUN91

7. Install washer on each end of roller.

OUO1020,000121C 1909JAN036/8

CAUTION: Heavy component; use a hoist.


Side RollerSpecification
Side RollerWeight .......................................... 25 kg (55 lb) approximate
UN11JUN91

8. Position roller on log arch.


9. Fasten safety chain around roller and log arch.
10. Install shaft.

T7553BQ

37
3740
4

Continued on next page

TM2111 (30MAY03)

37-3740-4

OUO1020,000121C 1909JAN037/8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=670

Frames
11. Install clamp and cap screw. Tighten cap screw to
specification.

T7553BM

UN11JUN91

Side RollerSpecification
Cap Screw M12Torque ............................................ 140 Nm (105 lb-ft)

OUO1020,000121C 1909JAN038/8

Roller Brackets Remove and Install


CAUTION: Heavy component; use a hoist.
Roller BracketsSpecification
Horizontal RollerWeight ................................. 27 kg (60 lb) approximate

1. Remove horizontal roller. See Horizontal Roller


Remove and Install in this group.
2. Remove side roller. See Side Roller Remove and
Install in this group.

Continued on next page

OUO1020,000121D 1909JAN031/2

37
3740
5

TM2111 (30MAY03)

37-3740-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=671

Frames
3. Remove cap screws (A) on top and bottom brackets to
remove side roller brackets.
4. Remove cap screws (B) on both sides to remove
horizontal roller brackets.

NOTE: The horizontal roller bracket can be positioned for


a variety of load conditions.

T7553BP

UN11JUN91

ACap Screws
BCap Screws

OUO1020,000121D 1909JAN032/2

37
3740
6

TM2111 (30MAY03)

37-3740-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=672

Section 38

Grapple
Contents
Page

Page

Group 3803Grapple Mechanism


Grapple Remove and Install . . . . . . . . . . . . .38-3803-1
Grapple Disassemble and Assemble . . . . . . .38-3803-2
Grapple Damper Repair . . . . . . . . . . . . . . . .38-3803-4
Grapple Damper Adjustment . . . . . . . . . . . . .38-3803-6
Damper, Yoke, and Cross Head Pins
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . .38-3803-8
Grapple Rotate Yoke Repair . . . . . . . . . . . . .38-3803-9

Control Valve Disassemble and


AssembleDual Function Grapple . . . . .38-3860-20
Dual Function Control Valve Sections
Disassemble and Assemble. . . . . . . . . . .38-3860-24
Grapple Rotate Solenoid Valve Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .38-3860-25
Grapple Rotate Solenoid Valve Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . .38-3860-26
Pilot Controller Repair (If Equipped) . . . . . .38-3860-27
Flow Divider Repair. . . . . . . . . . . . . . . . . . .38-3860-30
Rotary Manifold Remove and Install . . . . . .38-3860-34
Rotary Manifold Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .38-3860-35

Group 3815Controls Linkage


Single Function Grapple Control Linkage
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3815-1
Dual Function Grapple Control Linkage
Remove and Install . . . . . . . . . . . . . . . . . .38-3815-4
Single Lever Pilot Controller Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3815-6
Group 3840Frames
Single Function Grapple Cable Rollers
Remove and Install . . . . . . . . . . . . . . . . . .38-3840-2
Dual Function Grapple Cable Rollers Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .38-3840-4
Single Function Grapple Arch Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .38-3840-6
Dual Function Grapple Arch Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3840-10
Dual Function Grapple Boom Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3840-13
Group 3860Hydraulic System
Arch Cylinder Remove and InstallSingle
Function Grapple . . . . . . . . . . . . . . . . . . . .38-3860-1
Boom or Arch Cylinder Remove and
InstallDual Function Grapple . . . . . . . . .38-3860-3
Grapple Tong Cylinder Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3860-5
Rotate Motor Remove and Install . . . . . . . . .38-3860-7
Rotate Motor Repair . . . . . . . . . . . . . . . . . . .38-3860-8
Rotate Motor Drive Gear Remove and
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3860-13
Control Valve Remove and InstallSingle
Function Grapple . . . . . . . . . . . . . . . . . . .38-3860-14
Single Function Control Valve Sections
Disassemble and Assemble. . . . . . . . . . .38-3860-16
Control Valve Remove and InstallDual
Function Grapple . . . . . . . . . . . . . . . . . . .38-3860-18
TM2111 (30MAY03)

38-1

38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Contents

38

TM2111 (30MAY03)

38-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 3803

Grapple Mechanism
Grapple Remove and Install

GrappleSpecification
Grapple Tong CylinderWeight ..................... 80 kg (180 lb) approximate
Tong CylinderWeight ................................. 179 kg (394 lb) approximate
GrappleWeight ....................................... 1132 kg (2500 lb) approximate

X9811

1. Lower all equipment to the ground.

UN23AUG88

CAUTION: Heavy component; use a hoist.

2. Set grapple on a lift table.


CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
3. Operate hydraulic control valves to release pressure in
hydraulic system. Depress brake pedal at one second
intervals 20 times to drain oil from accumulator.

OUO1020,0001229 1910JAN031/2

4. Disconnect rotary manifold lines (C and D) at cylinder


and flow divider. Close all line openings using caps
and plugs.
5. Disconnect shock absorber cylinder (A) from rotary
yoke.
6. Remove pins (B) to remove grapple assembly.
7. Install grapple assembly and connect lines.
8. Connect shock absorber cylinder (A) to rotary yoke.

T8492AG

UN02JUN95

AShock Absorber Cylinder


BPin (2 used)
CRotary Manifold Line
DRotary Manifold Line

OUO1020,0001229 1910JAN032/2

TM2111 (30MAY03)

38-3803-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=675

38
3803
1

Grapple Mechanism

TP54274

UN16JUN98

Grapple Disassemble and Assemble

548G-III Shown
1Cap Screw (2 used)
2Washer (2 used)
3Washer (2 used)
4Pin (2 used)
5Seal (4 used)
6Flange Nut (2 used)
7Bushing (4 used)

8Lubrication Fitting (2 used)


9Cap Screw (4 used)
10Access Panel
11Washer (4 used)
12Special Washer (2 used)
13Washer (2 used)
14Bushing (2 used)

15Cap Screw (2 used)


16Washer (2 used)
17Spacer (2 used)
18Pin (2 used)
19Screw (2 used)
20Grapple Tong Cylinder Pin
(2 used)

21Grapple Tong Frame


22Access Panel
23Tong (2 used)
24Cap Screw (8 used)
25Tong Tip (2 used)

38
3803
2
Continued on next page

TM2111 (30MAY03)

38-3803-2

OUO1020,000122A 1910JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=676

Grapple Mechanism

CAUTION: The pin that attaches the cylinder


head end also attaches the opposite tong.
Cylinders should be removed one at a time
to prevent both grapple tongs from falling
out of frame.
CAUTION: Heavy component; use a hoist.
GrappleSpecification
GrappleWeight ................................ 1132 kg (2500 lb) approximate
Grapple FrameWeight ......................... 254 kg (115 lb) approximate
548G-III 8.0 Sq Ft Grapple
Tong CylinderSize ................................................ 100 mm x 50 mm
Weight ...................................................... 36.3 kg (80 lb) approximate
648G-III 10.4 Sq Ft Grapple
Tong CylinderSize ................................................ 100 mm x 50 mm
Weight ...................................................... 40.8 kg (90 lb) approximate
648G-III, 748G-III 11.7 Sq Ft
Grapple Tong CylinderSize .................................. 115 mm x 63 mm
Weight .................................................... 61.2 kg (135 lb) approximate

748G-III 14.9 Sq Ft Grapple


Tong Cylinder (180 Series)
Size .......................................................................... 125 mm x 63 mm
Weight .................................................... 83.9 kg (185 lb) approximate
548G-III 8.0 Sq Ft Grapple
TongWeight ......................................... 104 kg (230 lb) approximate
648G-III 10.4 Sq Ft Grapple
TongWeight ......................................... 147 kg (324 lb) approximate
648G-III, 748G-III 11.7 Sq Ft
Grapple TongWeight ........................... 179 kg (395 lb) approximate
748G-III 14.9 Sq Ft Grapple
TongWeight ......................................... 194 kg (428 lb) approximate

1. Disassemble parts as shown.


2. Inspect for worn or damaged parts and replace as
necessary.
3. Assemble parts.

OUO1020,000122A 1910JAN032/2

38
3803
3

TM2111 (30MAY03)

38-3803-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=677

Grapple Mechanism

UN01JUN00

Grapple Damper Repair

T131307

38
3803
4
Continued on next page

TM2111 (30MAY03)

38-3803-4

OUO1020,000122B 1910JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=678

Grapple Mechanism
1Plug (6 used)
2Spring (6 used)
3Washer (18 used)
4Snap Ring
5O-Ring
6O-Ring
7Housing
8Bushing
9O-Ring

10Plug
11Pin
12O-Ring
13Snap Ring
14Bushing
15Lubrication Fitting (6
used)
16Plate (4 used 548G-III) (6
used 648G-III, 748G-III)

CAUTION: Heavy component; use a hoist.


Grapple DamperSpecification
548G-III DamperWeight ........................ 55 kg (122 lb) approximate
648G-III, 748G-III Damper
Weight ..................................................... 105 kg (231 lb) approximate

1. Remove grapple using a suitable lifting device. See


Grapple Remove and Install in this group.

17Disk (3 used 548G-III) (5


used 648G-III, 748G-III)
18Cotter Pin
19Pin
20Pin
21Washer
22Cap Screw
23Lock Nut
24Shock Absorber Cylinder

25Washer
26Lubrication Fitting (2
used)
27Bushing (2 used)
28Grapple Damper Housing
29Pin
30Spacer
31Washer
32Cap Screw

5. Grease need not be totally removed from plates or


disks, unless obvious contamination is evident.
Wipe excess grease from plates (16) and disks (17)
and coat with fresh grease containing 35% moly.
6. Install O-rings (9) and (12), shaft (11) and snap ring
(13) into housing (28).
7. Alternately install plates (16) and disks (17)
assuring the galled steel plate is toward springs (2).

2. Remove plugs (1), washers (3) and springs (2).


3. Push housing (7) inward to remove snap ring (4).
4. Move grapple tong cylinder hoses out of the way
and use a pry bar to pry damper plates (16), disks
(17), shaft (11) and snap ring (13), out of housing
(28). Inspect for wear or damage.
IMPORTANT: The plate located next to springs (2)
will be worn or galled; this is normal.
When damper is assembled, install
this plate next to the springs.
Installing this galled plate next to a
friction element will damage the
friction element.

NOTE: Install snap ring (4) with gap located at 12


Oclock position. Snap ring helps retain grease
inside the housing.
8. Install O-rings (5) and (6), housing (7). Push
housing (7) inward to install snap ring (4) with gap
at 12 Oclock position.
9. Tighten nut (23) to specification.
Grapple DamperSpecification
Shock Cylinder NutTorque ................. Tighten to snug, back off 1/2
turn

10. Perform Grapple Damper Adjustment in this group.

NOTE: If any friction material remains on disks (17)


they are considered usable.

OUO1020,000122B 1910JAN032/2

38
3803
5

TM2111 (30MAY03)

38-3803-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=679

Grapple Mechanism

Grapple Damper Adjustment


The grapple damper limits the motion of the grapple head
when travelling empty and prevents damage to the
structural components, especially the yoke, crosshead and
pins.
Adjust the damper if the head swings to extreme heights
or hits the stops. Adjust the damper by adding or
subtracting the number of shim washers in the damper
assembly.

OUO1020,000122E 1915JAN031/3

1. Slightly loosen adjusting plugs (every other plug or all


six plugs) evenly to remove spring tension and to keep
housing from rotating.
2. Remove the three adjusting plugs (A).
3. Remove one shim washer (B) from each of the three
adjusting plugs (A) to tighten grapple damper or add
one shim washer to each plug to loosen.
4. Apply 35% moly grease to adjusting plug thread and
the inside of plugs. Tighten plugs evenly until plugs
contact shim washers.
5. Repeat steps 14 for other three plugs.
TEST CONDITIONS:

UN02FEB94

NOTE: The grapple head should be 1015 from vertical


under test conditions.

T8412AQ

Close tongs, raise the grapple arch or boom to full


height.
Lower the arch or boom slowly and bring to a
smooth stop when the tongs are approximately 300
mm (12 in.) above the ground.
AAdjusting Plugs (6 used)
BShim Washer
38
3803
6
Continued on next page

TM2111 (30MAY03)

38-3803-6

OUO1020,000122E 1915JAN032/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=680

Grapple Mechanism
When properly adjusted the grapple head will be
1015 from vertical. Measure with a magnetic base
inclinometer (C).

NOTE: If damper plates are replaced, put grease on each


plate before assembling grapple.

6. If additional tightness is required, remove shim


washers from plugs with greatest number of shim
washers. If additional looseness is required, add shim
washers to plugs with the least number of shim
washers. Repeat steps 14 until desired tightness is
achieved.

T8412AR

DO NOT add any washers to the inside


of the adjusting plugs in an attempt to
tighten the damper assembly. This will
cause the springs to become a solid
member. Damage to the outer damper
housing will result. If additional
dampening is required after all shim
washers are removed, it will be
necessary to replace the disks inside
the damper assembly. See Grapple
Damper Repair in this group.

UN02FEB94

IMPORTANT: The snap ring gap is at 12 Oclock


position to maintain the grease level in
the damper housing. During tightening
of plugs it is important to retain this
position by holding the damper housing
with a pry bar.

CInclinometer

7. To hold damper housing in place, use a pry bar


between plugs. Tighten plugs to specification.
Grapple DamperSpecification
Damper PlugTorque................................................. 184 Nm (250 lb-ft)

OUO1020,000122E 1915JAN033/3

38
3803
7

TM2111 (30MAY03)

38-3803-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=681

Grapple Mechanism

Damper, Yoke, and Cross Head Pins


Lubricate
Lubricate eight points until fresh grease escapes at joints.
UN08JUN95

IMPORTANT: If grease fitting (D) does not accept


grease, lower grapple head to the
ground and lubricate again.

T8496AD

NOTE: Using (A) as a locating point on damper, lubricate


the four fittings until grease escapes at joints.

T8499AB

UN08JUN95

ATop Locating Point


BBushing Next to Damper Assembly Grease Fitting
CDamper Head Outer Bushing Grease Fitting
DDamper Spline Grease Fitting
EBrake Plates Grease Fitting
FDamper Brake Assembly

T8412AC

UN03FEB95

Cross Section of Upper Damper Pin

Lower Pin
OUO1020,0001239 1924JAN031/1

38
3803
8

TM2111 (30MAY03)

38-3803-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=682

Grapple Mechanism

TP63038

UN07JUL99

Grapple Rotate Yoke Repair

1Bushing
2Yoke
3Spacer
4Seal
5Lower Bearing Cone

6Lower Bearing Cup


7Shim (as required)
8Shim (as required)
9Gear
10Cap Screw

11Spacer (2 used)
12Washer (2 used)
13Motor Mount Bracket
14Rotate Motor Drive Gear
15Bearing

16Grease Fitting
17Upper Bearing Cup
18Upper Bearing Cone
19Cap Screw (12 used)

38
3803
9
Continued on next page

TM2111 (30MAY03)

38-3803-9

OUO1020,000122F 1915JAN031/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=683

Grapple Mechanism

CAUTION: Heavy component; use a hoist.


Grapple Rotate YokeSpecification
YokeWeight ............................................. 30 kg (66 lb) approximate

1. Remove grapple. See Grapple Remove and Install


in this group.

3. Support yoke (2) and remove cap screws (19).


4. Remove parts (35, 79, and 17 and 18).
Replace parts as needed.
5. Install spacer (3) tight against shoulder of yoke (2).
6. Install seal (4) in spacer groove.

2. Remove rotary manifold. See Rotary Manifold


Remove and Install. (Group 3860.)

OUO1020,000122F 1915JAN032/6

UN23AUG88

CAUTION: DO NOT heat oil over 182C (360F).


Oil fumes or oil can ignite above 193C (380F).
Use a thermometer. DO NOT allow a flame or
heating element to come in direct contact with
the oil. Heat the oil in a well-ventilated area.
Plan a safe handling procedure to avoid burns.

TS227

7. Heat lower bearing cone (5) to 132C (270F). Install


bearing cone with large end toward spacer (3). Bearing
cone must be tight against spacer.
8. Install upper and lower bearing cups (6 and 17) using
a press. Bearing cups must be tight against shoulders
in housing. Apply grease to lower cup bore and outside
diameter of seal.
9. Install yoke (2) into rotate housing. Hold yoke upward
in rotate housing. Install upper bearing cone (18) on
yoke.

Continued on next page

OUO1020,000122F 1915JAN033/6

38
3803
10

TM2111 (30MAY03)

38-3803-10

G-III and D Series Skidders (S.N. 586337 )


053003

PN=684

Grapple Mechanism
10. Measure thickness (A) of gear. Use the inside hole in
two places 180 apart. Record measurement.
11. Rotate yoke so the crosshead pivot pin bore is 90 to
machine centerline and splined hole for damper pin in
yoke is to the right of the arch when viewed from the
rear.

T8320AJ

UN25MAY95

AGear Thickness

Continued on next page

OUO1020,000122F 1915JAN034/6

38
3803
11

TM2111 (30MAY03)

38-3803-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=685

Grapple Mechanism
12. Install gear so the figure "8" cutout is aligned with
machine centerline and 90 to the crosshead pivot pin
bore. Hoses from rotary manifold must not twist as
they pass through the cutout. The two 4 mm holes (B)
should be at 12:30 and 6:30 Oclock positions.
13. Install two cap screws (C) through gear 180 apart in
1 and 7 Oclock positions. Tighten cap screws to
specification. Rotate yoke back and forth 90 three
times to seat bearings. Repeat tightening cap screw
to specification, rotate yoke back and forth 90.
Repeat until cap screws remain tight.
Grapple Rotate YokeSpecification
Rotate Yoke Mounting Cap
ScrewsTorque ............................................................ 100 Nm (75 lb-ft)

UN25MAY95

14. Measure through the 4 mm holes (B) using a depth


micrometer from surface of gear to the yoke. Average
the measurements and record.

T8320AK

15. Subtract the average thickness of the gear recorded


earlier, from the surface of gear to yoke
measurement. Subtract an additional 0.58 mm (0.023
in.) to obtain shim pack dimension, for a bearing
preload of 0.560.61 mm (0.0220.024 in.). Use a
0.25 mm (0.10 in.) thick shim on top and on bottom of
shim pack.
Grapple Rotate YokeSpecification
Rotate Pivot-to-GearBearing
Preload ................................................ 0.560.61 mm (0.0220.024 in.)

16. Support yoke; remove cap screws (C) and gear.


Install shim pack and gear. Make sure gear is
indexed as explained earlier. Install cap screws (E) in
gear and tighten to specification.
Grapple Rotate YokeSpecification
Gear Cap ScrewsTorque .............................. 5481 Nm (4060 lb-ft)

UN03FEB98

17. Rotate yoke back and forth 90 three times to seat


bearings. Tighten cap screws (E) to specification.

T113103

Grapple Rotate YokeSpecification


Rotate Pivot-to-Gear Cap
ScrewsTorque .......................................................... 319 Nm (235 lb-ft)

BHoles (4 mm) (2 used)


CCap Screw (2 used)
DHoses (2 used)
ECap Screws (12 used)

38
3803
12

Continued on next page

TM2111 (30MAY03)

38-3803-12

OUO1020,000122F 1915JAN035/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=686

Grapple Mechanism
18. Pump grease into arch tube grease fitting while
rotating the yoke, until grease comes out from under
gear teeth all around gear. Apply additional grease to
gear if needed.

NOTE: Hoses (D) must be "straight" and not twist as they


pass through the gear and yoke when installing
rotary manifold.
19. Install rotary manifold with hoses (D) through gear
figure "8" cutout. Install rotate motor mount bracket.
Tighten cap screws to specification.
Grapple Rotate YokeSpecification
Rotate Motor Mount Cap
ScrewsTorque ............................................................ 130 Nm (95 lb-ft)

OUO1020,000122F 1915JAN036/6

38
3803
13

TM2111 (30MAY03)

38-3803-13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=687

Grapple Mechanism

38
3803
14

TM2111 (30MAY03)

38-3803-14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=688

Group 3815

Controls Linkage

Continued on next page

TM2111 (30MAY03)

38-3815-1

OUO1020,000123A 1924JAN031/2

TP63075

UN03MAY00

Single Function Grapple Control Linkage Repair

G-III and D Series Skidders (S.N. 586337 )


053003

PN=689

38
3815
1

Controls Linkage
1Rocker Switch
2Knob
3Nut
4Boot
5Ring
6Clip (6 used)
7Lever
8Lock Nut (2 used)
9Spring Locking Pin (2
used)

10Ball Joint (2 used)


11Nut (2 used)
12Link
13Pin (2 used)
14Sleeve
15Connector
16Eyebolt
17Nut (2 used)

18Ball Joint
19Spacer
20Screw
21Nut (3 used)
22Seal
23Label
24Washer
25Rubber Mount

CAUTION: Avoid possible injury from


unexpected machine movement. Install
frame locking bar before working in frame
hinge area.
1. Install frame locking bar.
2. Inspect and replace parts if necessary.

26Cover
27Cap Screw (4 used)
28Support
29Nut (2 used)
30Angle
31Cap Screw (2 used)
32Nut (2 used)

3. Clean threads of main pivot ball joint (18) with cure


primer and apply medium strength thread lock and
sealer.
4. Adjust length of linkage so base end of control lever
shafts are straight up and down.
5. Replace grapple rotate switch.

OUO1020,000123A 1924JAN032/2

38
3815
2

TM2111 (30MAY03)

38-3815-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=690

Controls Linkage

38
3815
3

TM2111 (30MAY03)

38-3815-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=691

Controls Linkage

UN28APR98

Dual Function Grapple Control Linkage Remove and Install

T115041

38
3815
4
Continued on next page

TM2111 (30MAY03)

38-3815-4

OUO1020,000123B 1924JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=692

Controls Linkage
ABoot
BLever
CLever
DSpacer
ELock Nut (3 used)
FBall joint
GNut (2 used)

HBall joint (3 used)


INut (3 used)
JLink (2 used)
KLink
LPin (3 used)
MSpring Locking Pin (3
used)

NNut (2 used)
OScrew (2 used)
PBushing (2 used)
QAngle Guide
RSpacer (2 used)
SWasher
TLock Nut

CAUTION: Avoid possible injury from


unexpected machine movement. Install
frame locking bar before working in frame
hinge area.
1. Install locking bar.

UInsert
VInsert
WHandle (2 used)
XSpecial Nut (2 used)
YRotate Harness Connector
ZRotate Switch

3. Clean threads of main pivot ball joint (F) and apply


medium strength thread lock and sealer.
4. Adjust length of linkage so base end of control lever
shafts are straight up and down.
5. Replace rotate switch (Z) as needed.

2. Inspect and replace parts, as necessary.

OUO1020,000123B 1924JAN032/2

38
3815
5

TM2111 (30MAY03)

38-3815-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=693

Controls Linkage

UN09OCT00

Single Lever Pilot Controller Remove and Install

T134438

38
3815
6
Continued on next page

TM2111 (30MAY03)

38-3815-6

OUO1020,0001230 1922JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=694

Controls Linkage
1Single Lever Pilot
Controller
2Boot Fastening Ring
3Cap Screw (3 used)
4Clips (6 used)
5Handle
6O-Ring
7Pilot Controller Harness
8O-Ring

9Straight Fitting (1 shown)


10O-Ring
11Console Cover
12Cap Screw (4 used)
13Clip (4 used)
14Grapple Latch Indicator
Light
15Cap Screw
16Grapple Control Valve and
Pilot Controller Support

CAUTION: Avoid possible injury from


unexpected machine movement. Install
frame locking bar before working in frame
hinge area.
1. Install frame locking bar.
2. Operate all grapple functions with key switch ON.

17Washer (8 used)
18Rubber Mount (4 used)
19Cap Screw (4 used)
20Shim
21Bushing (2 used)
22Bushing
23Washer
24Lock Nut
25Lock Nut

26Linkage Ball Joint


27Control Arm
28Boot Fastening Ring
29Boot
30Nut
31Knob
32Fitting
33O-Ring

See Hydraulic Component Location. (Group


9025-05.)
See Hydraulic Component Location. (Group
9025-05.)
See DEUTSCH Rectangular or Triangular
Connectors Replace. (Group 9015-20.)
7. Install pilot controller.
8. Connect harness (7) connectors.

3. Remove top and side console covers.

9. Operate machine to verify repair.

4. Disconnect harness (7) connectors.

10. Install console covers.

5. Disconnect pilot lines from pilot controller.


6. Remove pilot controller (1). Repair as necessary.
For additional information on hose routing and
connector repair:

OUO1020,0001230 1922JAN032/2

38
3815
7

TM2111 (30MAY03)

38-3815-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=695

Controls Linkage

38
3815
8

TM2111 (30MAY03)

38-3815-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=696

Group 3840

Frames

38
3840
1

TM2111 (30MAY03)

38-3840-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=697

Frames

UN16APR98

Single Function Grapple Cable Rollers Remove and Install

T113073

38
3840
2
Continued on next page

TM2111 (30MAY03)

38-3840-2

OUO1020,0001231 1922JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=698

Frames
AWasher (4 used)
BBushing (4 used)
CLubrication Fitting (4 used)
DVertical Roller (2 used)

EShaft (2 used)
FWasher (2 used)
GScrew (2 used)
HPlug (2 used)

IWasher (4 used)
JBushing (2 used)
KLubrication Fitting (2 used)
LShaft

CAUTION: Heavy component; use a hoist.


Single Function Grapple Cable RollersSpecification
Horizontal RollerWeight .......................... 29 kg (65 lb) approximate
Vertical RollerWeight ............................... 23 kg (50 lb) approximate

MHorizontal Roller
NStrap
OWasher (2 used)
PCap Screw (2 used)

2. Inspect bushings (B and J) and shafts (E and L) for


wear or damage.
3. Install bushings even with end surface of rollers.
4. Install rollers.

1. Remove rollers (D and M).

OUO1020,0001231 1922JAN032/2

38
3840
3

TM2111 (30MAY03)

38-3840-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=699

Frames

UN01JUN00

Dual Function Grapple Cable Rollers Remove and Install

T131310

38
3840
4
Continued on next page

TM2111 (30MAY03)

38-3840-4

OUO1020,0001232 1922JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=700

Frames
1Washer (2 used)
2Bushing (4 used)
3Lubrication Fitting (4 used)
4Vertical Roller (2 used)
5Shaft (2 used)

6Washer (2 used)
7Screw (2 used)
8Washer (as required)
9Lubrication Fitting (2 used)
10Shaft

CAUTION: Heavy component; use a hoist.


Dual Function Grapple Cable RollersSpecification
Horizontal RollerWeight .......................... 29 kg (65 lb) approximate
Vertical RollerWeight ............................... 23 kg (50 lb) approximate

11Cap Screw (2 used)


12Strap
13Cap Screw (3 used)
14Cap

15Washer (as required)


16Bushing (2 used)
17Horizontal Roller
18Washer (2 used)

2. Inspect bushings (2) and shafts (5 and 10) for wear


or damage.
3. Install bushings even with end surface of rollers.
4. Install rollers.

1. Remove rollers (4 and 17).

OUO1020,0001232 1922JAN032/2

38
3840
5

TM2111 (30MAY03)

38-3840-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=701

Frames

TP35305

UN27JAN95

Single Function Grapple Arch Remove and Install

548G-III Shown
1Arch
2Screw (6 used)
3Cover
38
3840
6

4Spherical Bushing (2 used)


5Lubrication Fitting (2 used)
6Thrust Washer (as
required)

7Pin (2 used)
8Spacer (2 used)

9Washer (2 used)
10Cap Screw (2 used)

1. Inspect boom for cracks.

Continued on next page

TM2111 (30MAY03)

38-3840-6

OUO1020,0001233 1922JAN031/4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=702

Frames
IMPORTANT: Have only a qualified welder do the
welding. Be sure the area near the
machine is free of debris and
flammable material. Before welding,
clean all dirt and paint from weld
area. Disconnect the battery ground
() cable. Connect the welder
ground clamp as close as possible
to each weld area.

2. Weld any cracks using E7018 electrodes or


equivalent. See Make Welding Repairs Safely, and
See Remove Paint Before Welding or Heating.
(Group 9000-10.)
3. Operate all hydraulic control valves to release
pressure in hydraulic system.

OUO1020,0001233 1922JAN032/4

4. Open access covers (E) on both sides of frame.

T8495AD

UN02JUN95

AArch Cylinder Pin (2 used)


BArch
CGrapple
DFrame Pin (2 used)
EAccess Door (left and right side)

Continued on next page

OUO1020,0001233 1922JAN033/4

38
3840
7

TM2111 (30MAY03)

38-3840-7

G-III and D Series Skidders (S.N. 586337 )


053003

PN=703

Frames

5. Disconnect hoses to arch. Close openings with caps


and plugs.

X9811

NOTE: If pins (D) and bushings need repair the arch can
be carefully raised enough to service these parts
without removing grapple or hoses.

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

CAUTION: Heavy component; use a hoist.


Single Function Grapple ArchSpecification
Grapple Log ArchSingle
FunctionWeight .......................................... 351 kg (773 lb) approximate
Grapple BoomSingle
FunctionWeight ........................................ 453 kg (1000 lb) approximate
Grapple Arch with Grapple
Single FunctionWeight ........................... 1483 kg (3275 lb) approximate

6. Remove grapple assembly (C) if required. See Grapple


Remove and Install. (Group 3803.)
7. Put wooden blocks under arch cylinders, remove arch
cylinder pins (A).
8. Remove grapple arch (B). Inspect pins (A and D) and
bushings. Remove bushings only if replacement is
necessary. See Spherical Bushing Remove and Install.
(Group 3201.)

OUO1020,0001233 1922JAN034/4

38
3840
8

TM2111 (30MAY03)

38-3840-8

G-III and D Series Skidders (S.N. 586337 )


053003

PN=704

Frames

38
3840
9

TM2111 (30MAY03)

38-3840-9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=705

Frames

UN01JUN00

Dual Function Grapple Arch Remove and Install

T131309

38
3840
10
Continued on next page

TM2111 (30MAY03)

38-3840-10

OUO1020,0001234 1922JAN031/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=706

Frames
1Arch
2Lubrication Fitting (2 used)
3Washer
4Pin (2 used)

5Spacer (2 used)
6Washer (as required)
7Lubrication Fitting (2 used)

8Cap Screw (2 used)


9Washer (2 used)
10Bushing (2 used)

1. Inspect boom for cracks.


IMPORTANT: Have only a qualified welder do the
welding. Be sure the area near the
machine is free of debris and
flammable material. Before welding,
clean all dirt and paint from weld
area. Disconnect the battery ground

11Pin (2 used)
12Spherical Bushing (2
used)

() cable. Connect the welder


ground clamp as close as possible
to each weld area.
2. Weld any cracks using E7018 electrodes or
equivalent. See Make Welding Repairs Safely, and
See Remove Paint Before Welding or Heating.
(Group 9000-10.)

Continued on next page

OUO1020,0001234 1922JAN032/3

38
3840
11

TM2111 (30MAY03)

38-3840-11

G-III and D Series Skidders (S.N. 586337 )


053003

PN=707

Frames
3. Operate all hydraulic control valves to release pressure
in hydraulic system.

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

X9811

NOTE: If pins (B) and bushings need repair the arch can
be carefully raised enough to service these parts
without removing boom or hoses.
4. Remove covers (H).
5. Disconnect hoses that go to boom and equipment
frame and close all openings with caps and plugs.
CAUTION: Heavy component; use a hoist.
Dual Function Grapple ArchSpecification
Grapple Log ArchDual
FunctionWeight ........................................ 465 kg (1025 lb) approximate
Grapple BoomDual Function
Weight.......................................................... 636 kg (1400 lb) approximate
Grapple Arch with GrappleDual
FunctionWeight ...................................... 1770 kg (2900 lb) approximate

6. Remove boom (F) if required. See BoomDual


Function Grapple Boom Remove and Install in this
group.
UN02JUN95

7. Put wooden blocks under arch cylinders (A), remove


arch cylinder rod end pins.

T8412AG1

8. Remove grapple arch (C). Inspect pins and bushings


(B and D). Remove bushings only if replacement is
necessary. See Spherical Bushing Remove and Install.
(Group 3201.)
AArch Cylinder (2 used)
BArch-to-Frame Pins (2 used)
CArch
DBoom-to-Arch Pins (2 used)
EBoom Cylinder (2 used)
FBoom
GGrapple
HArch Hose Cover (2 used)

38
3840
12
OUO1020,0001234 1922JAN033/3

TM2111 (30MAY03)

38-3840-12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=708

Frames

UN27JAN95

Dual Function Grapple Boom Remove and Install

TP35308

38
3840
13

Dual Function Boom


Continued on next page

TM2111 (30MAY03)

38-3840-13

OUO1020,0001235 1922JAN031/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=709

Frames
1Boom
2Cover
3Cap Screw (6 used)
4Arch Bushings (2 used)

5Arch-to-Boom Pin (2 used)


6Boom Cylinder Spherical
Bushings (2 used)

7Grease Fitting (2 used)


8Cap Screw (2 used)
9Washer (2 used)

1. Inspect boom for cracks.


IMPORTANT: Have only a qualified welder do the
welding. Be sure the area near the
machine is free of debris and
flammable material. Before welding,
clean all dirt and paint from weld
area. Disconnect the battery ground

10Spacer (2 used)
11Grease Fitting (2 used)
12Washer (as required)

() cable. Connect the welder


ground clamp as close as possible
to each weld area.
2. Weld any cracks using E7018 electrodes or
equivalent. See Make Welding Repairs Safely, and
See Remove Paint Before Welding or Heating.
(Group 9000-10.)

Continued on next page

OUO1020,0001235 1922JAN032/3

38
3840
14

TM2111 (30MAY03)

38-3840-14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=710

Frames
3. Operate all hydraulic control valves to release pressure
in hydraulic system. Remove hose covers (H), remove
and cap hoses at arch bulkhead.
CAUTION: Heavy component; use a hoist.
BoomDual Function GrappleSpecification
Grapple BoomDual Function
Weight.......................................................... 636 kg (1400 lb) approximate
Grapple Arch with GrappleDual
FunctionWeight ...................................... 1770 kg (2900 lb) approximate

4. Remove grapple (G) if required. See Grapple Rotate


Yoke Repair. (Group 3803.)
5. Connect hoist to boom using a lifting strap.
6. Remove boom cylinder (E) pins and move cylinders
back toward cab.
UN02JUN95

7. Remove boom to arch pins (D).

9. Install grapple (G) if removed. See Grapple Rotate


Yoke Repair. (Group 3803.)

T8412AG1

8. Inspect pins and bushings. Remove bushings only if


replacement is necessary. See Spherical Bushing
Remove and Install in this group.

AArch Cylinders
BArch-to-Frame Pins (2 used)
CArch
DBoom-to-Arch Pins (2 used)
EBoom Cylinder (2 used)
FBoom
GGrapple
HArch Hose Cover (2 used)

OUO1020,0001235 1922JAN033/3

38
3840
15

TM2111 (30MAY03)

38-3840-15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=711

Frames

38
3840
16

TM2111 (30MAY03)

38-3840-16

G-III and D Series Skidders (S.N. 586337 )


053003

PN=712

Group 3860

Hydraulic System
Arch Cylinder Remove and InstallSingle
Function Grapple
1. Lower grapple to the ground. Operate all control valves
to release pressure in hydraulic system.

NOTE: The cylinder rod and piston assembly can be


removed from the barrel on the machine.
Disconnect hose to rod end for piston rod
removal.
2. Remove guard cover.

Continued on next page

OUO1020,0001236 1922JAN031/2

38
3860
1

TM2111 (30MAY03)

38-3860-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=713

Hydraulic System

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

X9811

3. Disconnect lines (B and C). Close all openings with


caps and plugs.
CAUTION: Heavy component; use a hoist.

UN11JUN91

Arch CylinderSingle Function GrappleSpecification


548G-III Arch CylinderSize ........................................... 90 mm x 45 mm
Weight............................................................. 44.5 kg (98 lb) approximate
648G-III Arch CylinderSize ........................................... 90 mm x 45 mm
Weight.............................................................. 49 kg (108 lb) approximate
748G-III Arch CylinderSize ......................................... 100 mm x 56 mm
Weight.............................................................. 59 kg (130 lb) approximate

4. Connect hoist to cylinder using a lifting strap.

6. Inspect bushings for looseness, wear, or damage.


Remove bushings only if replacement is necessary.
See Spherical Bushing Remove and Install. (Group
3201.)
7. Repair cylinder as necessary. See Disassemble
Cylinder. (TM-H120A.)

T7533AP

5. Remove pins (A and D).

APin
BBoom Cylinder Head End Line
CBoom Cylinder Rod End Line
DPin

8. Install cylinder and pins (A and D).


9. Connect lines (B and C).
10. Operate cylinder through several cycles to fill it with
oil. Check hydraulic oil level. See Check Hydraulic
System Oil Level. (Operators Manual.)

OUO1020,0001236 1922JAN032/2

38
3860
2

TM2111 (30MAY03)

38-3860-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=714

Hydraulic System

Boom or Arch Cylinder Remove and Install


Dual Function Grapple

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

X9811

1. Lower grapple to the ground. Operate all control valves


to release pressure in hydraulic system.

NOTE: The cylinder rod and piston assembly can be


removed from the barrel on the machine.
Disconnect hose to rod end for piston rod
removal.
UN11JUN91

2. Disconnect hydraulic lines (F and G) from boom


cylinder or disconnect hydraulic lines (B and C) from
arch cylinder. Close all openings with caps and plugs.

T7533AN

3. Connect hoist to cylinder using lifting strap.


CAUTION: Heavy component; use a hoist.
Boom or Arch CylinderDual Function GrappleSpecification
648G-III, 748G-III Boom
CylinderSize .................................................................. 90 mm x 45 mm
Weight........................................................... 46.1 kg (102 lb) approximate
548G-III Arch CylinderSize ........................................... 90 mm x 45 mm
Weight............................................................. 44.5 kg (98 lb) approximate
648G-III Arch CylinderSize ........................................... 90 mm x 45 mm
Weight.............................................................. 49 kg (108 lb) approximate
748G-III Arch CylinderSize ......................................... 100 mm x 56 mm
Weight.............................................................. 59 kg (130 lb) approximate

4. Remove pins (E and H) for boom cylinder.


5. Remove pins (A and D) for arch cylinder.

T7533AM

UN11JUN91

APin
BValve-to-Arch Cylinder Head End Line
CValve-to-Arch Cylinder Rod End Line
DPin
EPin
FValve-to-Boom Cylinder Rod End Line
GValve-to-Boom Cylinder Head End Line
HPin

Continued on next page

TM2111 (30MAY03)

38-3860-3

OUO1020,0001237 1922JAN031/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=715

38
3860
3

Hydraulic System
6. Remove cylinder.
7. Inspect bushings for looseness, wear, or damage.
Remove bushings only if replacement is necessary.
See Spherical Bushing Remove and Install. (Group
3201.)
8. Repair cylinder as necessary. See Cylinder Repair.
(TM-H120A.)
9. Install arch cylinder and pins (A and D).
10. Connect hydraulic lines (B and C).
11. Install boom cylinder and pins (E and H).
12. Connect hydraulic lines (F and G)
13. Operate cylinder through several cycles to fill it with
oil. Check hydraulic oil level. See Check Hydraulic
System Oil Level. (Operators Manual.)

OUO1020,0001237 1922JAN032/2

38
3860
4

TM2111 (30MAY03)

38-3860-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=716

Hydraulic System

Grapple Tong Cylinder Remove and Install

UN23AUG88

CAUTION: The pin that attaches the cylinder


head end also attaches the opposite tong.
Cylinders should be removed one at a time to
prevent both grapple tongs from falling out of
frame.

X9811

1. Close grapple and lower to the ground.


2. Operate all hydraulic control valves to release pressure
in the hydraulic system.
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
3. Remove cover (C) to disconnect cylinder head end
hose. Install cap on port and hose.
4. Disconnect rod end hose at flow divider. Install cap on
port and hose.

UN05JUN95

5. Remove rod end pin (E) (other side not shown).


6. Remove cap screw (F).

T8412AE1

7. Connect hoist to cylinder using a lifting strap.

NOTE: Use a round 58 mm (2.25 in.) diameter by 300


mm (12 in.) long bar or pipe, slightly smaller in
diameter than pin, to drive pin out of cylinder and
still hold tong in place for reassembly. Removing
other cylinder rod pin aids in alignment of tong for
installation of pin.

ATong and Cylinder Head End Pin (2 used)


BGrapple Frame
CAccess Cover Head End Hose (2 used)
DGrapple Tong Cylinder (2 used)
EGrapple Rod Eye Pin (2 used)
FTong and Cylinder Pin Retaining Cap Screw (2
used)

8. Remove head end pin (A).

Continued on next page

OUO1020,0001240 1924JAN031/2

38
3860
5

TM2111 (30MAY03)

38-3860-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=717

Hydraulic System

CAUTION: Heavy component; use a hoist.


Grapple Tong CylinderSpecification
548G-III 8.0 Sq Ft Grapple Tong
CylinderSize ................................................................ 100 mm x 50 mm
Weight............................................................. 36.3 kg (80 lb) approximate
648G-III 10.4 Sq Ft Grapple Tong
CylinderSize ................................................................ 100 mm x 50 mm
Weight............................................................. 40.8 kg (90 lb) approximate
648G-III, 748G-III 11.7 Sq Ft
Grapple Tong CylinderSize......................................... 115 mm x 63 mm
Weight........................................................... 61.2 kg (135 lb) approximate
748G-III 14.9 Sq Ft Grapple Tong
Cylinder (180 Series)Size ........................................... 125 mm x 63 mm
Weight........................................................... 83.9 kg (185 lb) approximate

9. Remove cylinder and repair as necessary. See


Cylinder Repair. (TM-H120A.)

NOTE: Foam shims are located only at the cylinder rod


end.
10. Insert grapple tong cylinder into grapple frame and
install pins.
11. Connect hoses to cylinder and tighten.
12. Install cap screw (F) and washer and tighten. Install
cover (C).

OUO1020,0001240 1924JAN032/2

38
3860
6

TM2111 (30MAY03)

38-3860-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=718

Hydraulic System

Rotate Motor Remove and Install


Removal

X9811

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
1. Lower grapple to the ground.
2. Operate all hydraulic control valves to release pressure
in the hydraulic system.
3. Remove rotate motor cover from top of arch or boom.
4. Mark hoses to aid in assembly.

OUO1020,0001241 1924JAN031/3

5. Disconnect hoses (AC) and close all openings with


caps and plugs.
CAUTION: Heavy component; use a hoist.
Rotate MotorSpecification
Rotate MotorWeight ....................................... 25 kg (55 lb) approximate

6. Remove cap screws (D) to remove rotate motor.

T113099

UN03FEB98

AHose from Rotate Solenoid


BHose from Rotate Solenoid
CHose from Rotate Manifold
DCap Screw (2 used)

Continued on next page

TM2111 (30MAY03)

38-3860-7

OUO1020,0001241 1924JAN032/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=719

38
3860
7

Hydraulic System
Installation
CAUTION: Heavy component; use a hoist.
Rotate MotorSpecification
Rotate MotorWeight ....................................... 25 kg (55 lb) approximate

1. Install rotate motor on mounting plate.


2. Install cap screws (D) and tighten.
Rotate MotorSpecification
Rotate Motor Mount Cap
ScrewsTorque ......................................... 117142 Nm (86105 lb-ft)

3. Connect hoses (AC).

T113099

UN03FEB98

AHose from Rotate Solenoid


BHose from Rotate Solenoid
CHose from Rotate Manifold
DCap Screw (2 used)

OUO1020,0001241 1924JAN033/3

Rotate Motor Repair


Disassemble

UN28APR98

1. Remove screws (A) to remove crossover relief valve


housing.

T114279

AScrews (4 used)

OUO1020,0001242 1924JAN031/13

NOTE: Crossover relief valve is not a repairable item.


Disassemble only to inspect, clean and replace
O-rings and seals.

ABackup Ring (2 used)


BO-Ring
CO-Ring
DRelief Valve (2 used)

T8495AB

38
3860
8

UN02JUN95

2. Remove crossover relief valve (D). Inspect and clean.

Continued on next page

TM2111 (30MAY03)

38-3860-8

OUO1020,0001242 1924JAN032/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=720

Hydraulic System
3. Scribe a line across motor sections to aid in assembly.
4. Remove cap screws (A) to disassemble motor.

T8492AO

UN02JUN95

ACap Screw (8 used)

OUO1020,0001242 1924JAN033/13

5. Remove end cap (B) and O-ring (C).


6. Remove housing (A).

T8492AH

UN02JUN95

AMotor Housing
BEnd Cap
CO-Ring

OUO1020,0001242 1924JAN034/13

7. Remove outer ring (A) with steel balls (B).


8. Remove roller bearings (C).

T8492AI

UN02JUN95

AOuter Ring
BSteel Balls (2 used)
CRoller Bearings (8 used)

Continued on next page

OUO1020,0001242 1924JAN035/13

38
3860
9

TM2111 (30MAY03)

38-3860-9

G-III and D Series Skidders (S.N. 586337 )


053003

PN=721

Hydraulic System
9. Remove snap ring (D).
10. Remove plate (C).

UN02JUN95

11. Measure the tip clearance between roller (A) and


outer member (B). If clearance exceeds specification
replace motor.

T8492AJ

Rotate MotorSpecification
Roller and Outer Member
Clearance ................................................... 0.25 mm (0.010 in.) maximum

12. Remove outer member.

T7529AZ

UN05JUN91

ARoller Bearing (6 used)


BOuter Member
CPlate
DSnap Ring

OUO1020,0001242 1924JAN036/13

13. Remove steel rollers (C) and inner member (B).


14. Remove output shaft (D).

T8492AK

UN02JUN95

AOuter Member
BInner Member
CRoller Bearing (6 used)
DOutput Shaft

OUO1020,0001242 1924JAN037/13

15. Remove dust seal (A) and O-ring (B).

UN02JUN95

ADust Seal
BO-Ring

T8492AL

38
3860
10
Continued on next page

TM2111 (30MAY03)

38-3860-10

OUO1020,0001242 1924JAN038/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=722

Hydraulic System
Assemble

UN02JUN95

IMPORTANT: Before assembly, clean all parts with


solvent and coat with clean hydraulic
oil. Inspect parts for nicks or burrs and
repair if possible.
1. Install new O-ring (B).

T8492AL

2. Install dust seal (A) with rubber lips facing outside of


motor. Seat seal using a 26 mm socket and a press.
Coat seal with clean hydraulic oil.
ADust Seal
BO-Ring

OUO1020,0001242 1924JAN039/13

3. Check output shaft (A) for burrs. Remove burrs if


necessary.
4. Install output shaft.
5. Install inner member (G) and six roller bearings.
6. Install outer member (C) and eight roller bearings (D).
7. Install plate (F), top side up as shown.
IMPORTANT: DO NOT stretch new snap ring during
assembly or it may cause damage to
the motor.
8. Install new snap ring (E).

T8493AA

UN02JUN95

AOutput Shaft
BRoller Bearing (6 used)
COuter Member
DRoller Bearing (8 used)
ESnap Ring
FPlate (top side shown)
GInner Member

38
3860
11
Continued on next page

TM2111 (30MAY03)

38-3860-11

OUO1020,0001242 1924JAN0310/13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=723

Hydraulic System
9. Install steel balls (A) in the two 1/8 inch diameter
holes.

T8492AM

UN02JUN95

ASteel Balls (2 used)

OUO1020,0001242 1924JAN0311/13

10. Install new O-ring (D) in plate.


11. Install plate (C) using scribed line to help locate check
ball cavities over steel balls.
12. Install housing (A).
13. Install oiled cap screws (B).

T8492AN

UN02JUN95

AHousing
BCap Screw (8 used)
CPlate
DO-Ring

Continued on next page

OUO1020,0001242 1924JAN0312/13

38
3860
12

TM2111 (30MAY03)

38-3860-12

G-III and D Series Skidders (S.N. 586337 )


053003

PN=724

Hydraulic System
14. Tighten cap screws in sequence shown to initial
torque specification. Turn shaft by hand several
rotations and tighten cap screws in sequence to mid
torque specification. Turn shaft by hand several
rotations and tighten cap screws in sequence to final
torque specification.
Rotate MotorSpecification
End Cap Housing Cap Screws
Initial Torque .................................................................... 20 Nm (15 lb-ft)
Mid Torque ...................................................................... 27 Nm (20 lb-ft)
Final Torque ................................................................. 36.6 Nm (27 lb-ft)

15. Install crossover relief valves, if removed, in relief


valve housing.

UN02JUN95

16. Install crossover relief valve housing on rotate motor.


Install and tighten screws (A).

T8493AD

Rotate MotorSpecification
Crossover Relief Valve
Assembly-to-Motor Housing Cap
ScrewsTorque .............................................................. 33 Nm (24 lb-ft)

Cap Screw Tightening Sequence


ACap Screw (4 used)
OUO1020,0001242 1924JAN0313/13

Rotate Motor Drive Gear Remove and Install


CAUTION: Heavy component; use a hoist.

UN14JUN95

Rotate Motor Drive GearSpecification


Rotate MotorWeight ....................................... 25 kg (55 lb) approximate

T8495AE

1. Remove rotate motor. See Rotate Motor Remove and


Install in this group.
2. Remove bearings (A) using bearing puller set.
3. Remove drive gear. Inspect and replace if required.
ABearing (2 used)
BDrive Gear

4. Install bearings and drive gear.

OUO1020,0001243 1924JAN031/1

38
3860
13

TM2111 (30MAY03)

38-3860-13

G-III and D Series Skidders (S.N. 586337 )


053003

PN=725

Hydraulic System

Control Valve Remove and InstallSingle


Function Grapple

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

X9811

1. Operate all hydraulic control valves to release pressure


in hydraulic system.
CAUTION: Avoid possible injury from
unexpected machine movement. Install frame
locking bar.
2. Install frame locking bar.
3. Remove right side cab cover.

Continued on next page

OUO1020,0001244 1924JAN031/2

38
3860
14

TM2111 (30MAY03)

38-3860-14

G-III and D Series Skidders (S.N. 586337 )


053003

PN=726

Hydraulic System
4. Disconnect linkage (BD) if equipped. If equipped with
a single lever pilot controller, remove lines (MP).
5. Disconnect lines (EL). Put identification tags on lines
to aid assembly. Close all openings with caps and
plugs.
CAUTION: Heavy component; use a hoist.
Control ValveSingle Function GrappleSpecification
Control ValveWeight ...................................... 27 kg (60 lb) approximate

6. Remove cap screws (A) to remove valve.


7. Install orifice under line (F) with grooved side facing
out.

UN07JUN95

8. After repair, install valve and connect lines and


linkages as shown.

T134259B

UN06OCT00

Control Valve Hoses and LinkagesSingle Function Shown

T134260B

UN06OCT00

AMounting Screw (3 used)


BArch Linkage
CTong Linkage
DBlade Linkage
EInlet Line
FBlade (Head End) Line
GTong (Rod End) Line
HArch (Head End) Line
IBlade (Head End) Line
JTong (Rod End) Line
KArch (Rod End) Line
LOutlet Line
MArch Down Pilot LineFrom Pilot Controller (Port
3) (If Equipped)
NTong Close Pilot LineFrom PRV (TCP Port) (If
Equipped)
OArch Open Pilot LineFrom Pilot Controller (Port
1) (If Equipped)
PTong Open Pilot LineFrom PRV (TOP Port) (If
Equipped)

T8498AB

9. Operate function through several cycles to remove air


and fill components with oil. Check hydraulic oil level.
See Check Hydraulic System Oil Level. (Operators
Manual.)

OUO1020,0001244 1924JAN032/2

TM2111 (30MAY03)

38-3860-15

G-III and D Series Skidders (S.N. 586337 )


053003

PN=727

38
3860
15

Hydraulic System

TP35172

UN19OCT94

Single Function Control Valve Sections Disassemble and Assemble

Single Function Control Valve


1Inlet Section
2Blade Section
3Tong Section
4Arch Section

5Pipe Plug
6Outlet Housing
7Bolt (4 used)
8O-Ring

9Fitting
10O-Ring
11Fitting Plug
12O-Ring

13Orifice
14Single Function Control
Valve

Continued on next page

OUO1020,0001245 1924JAN031/2

38
3860
16

TM2111 (30MAY03)

38-3860-16

G-III and D Series Skidders (S.N. 586337 )


053003

PN=728

T8477AT

UN10MAY94

Hydraulic System

ASeal (4 used)

1. Remove tie bolts to disassemble valve, replace


seals (A) between all sections.
2. Install tie bolts and tighten to specification.
Single Function Control Valve SectionsSpecification
Control Valve Section Tie Bolt
NutsTorque............................................................ 57 Nm (42 lb-ft)

OUO1020,0001245 1924JAN032/2

38
3860
17

TM2111 (30MAY03)

38-3860-17

G-III and D Series Skidders (S.N. 586337 )


053003

PN=729

Hydraulic System

Control Valve Remove and InstallDual


Function Grapple

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

X9811

1. Operate all hydraulic control valves to release pressure


in hydraulic system.
CAUTION: Avoid possible injury from
unexpected machine movement. Install frame
locking bar before working in frame hinge area.
2. Install frame locking bar.
3. Remove right side cab cover.

Continued on next page

OUO1020,0001246 1924JAN031/2

38
3860
18

TM2111 (30MAY03)

38-3860-18

G-III and D Series Skidders (S.N. 586337 )


053003

PN=730

Hydraulic System
4. Disconnect linkage (AD) or pilot lines (machine
equipped with single lever pilot controller).
5. Disconnect lines (EN). Put identification tags on lines
to aid assembly. Close all openings with caps and
plugs.
CAUTION: Heavy component; use a hoist.
Control ValveDual Function GrappleSpecification
Control Valve (Dual Function
Grapple)Weight .............................................. 33 kg (72 lb) approximate

6. Remove cap screws (O) to remove valve.


7. Install orifice under line (E) with grooved side facing
out.

T8498AA

9. Operate function through several cycles to remove air


and fill components with oil. Check hydraulic oil level.
See Check Hydraulic System Oil Level. (Operators
Manual.)

UN07JUN95

8. After repair, install valve and connect lines and


linkages as shown.

ATong Linkage
BArch Linkage
CBoom Linkage
DBlade Linkage
EBlade (Rod End) Line
FBoom (Head End) Line
GArch (Head End) Line
HTong (Head End) Line
IInlet Line
JBlade (Head End) Line
KBoom (Rod End) Line
LArch (Rod End) Line
MTong (Rod End) Line
NOutlet Line
OCap Screw (3 used)

OUO1020,0001246 1924JAN032/2

38
3860
19

TM2111 (30MAY03)

38-3860-19

G-III and D Series Skidders (S.N. 586337 )


053003

PN=731

Hydraulic System

Control Valve Disassemble and Assemble


Dual Function Grapple
Control Valve Sections Disassemble and Assemble

X9811

UN23AUG88

NOTE: Relief valves can be removed with control valve


on machine. Valve must be removed or moved
away from machine before lift check poppets can
be removed.
CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
1. Operate all hydraulic control valves to release pressure
in hydraulic system.
2. Remove control valve. See Control Valve Remove and
InstallDual Function Grapple in this group.
3. Remove plugs (B), inspect springs (D) and lift check
poppets (E) for damage replace O-rings (C).

UN10MAY94

4. Install control valve. See Control Valve Remove and


InstallDual Function Grapple in this group.

T8477AV

ALift Check Poppets


BPlug
CO-Ring
DSpring
EPoppet

T8477AN

UN23MAY95

Single Function Shown

Lift Check
Continued on next page

OUO1020,0001238 1923JAN031/6

38
3860
20

TM2111 (30MAY03)

38-3860-20

G-III and D Series Skidders (S.N. 586337 )


053003

PN=732

Hydraulic System
Relief Valves Remove and Install
1. Remove relief valves, inspect for damage, replace
O-rings, backup rings and seals.
Relief ValveSpecification
ReliefPressure........................................... 6895 55 kPa (69 55 bar)
(1000 80 psi)

T8478AC

UN10MAY94

ANon-Adjustable Circuit Relief Valve


BAdjustable Circuit Relief Valve
CAdjustable System Relief Valve
DInlet Section
EDetent Assembly
FOutlet Section

OUO1020,0001238 1923JAN032/6

Circuit Relief and System Relief Valves Disassemble


and Assemble

UN10MAY94

NOTE: Circuit relief and system relief valve removal and


installation procedures are similar.

T8477AP

1. Inspect poppet seal (C) on adjustable circuit relief


valve or (B) on non-adjustable circuit relief valve and
spring (D) for damage.
Circuit Relief and System Relief ValvesSpecification
Circuit Relief ValveTorque ......................................... 100 Nm (75 lb-ft)
System Relief Valve Lock Nut
Torque ............................................................................. 88 Nm (65 lb-ft)

Non-Adjustable Circuit Relief Valve


AO-Ring
BPoppet
CSeal
DSpring
ERod
FShim (as required)
GBackup Ring

Replace O-rings, backup ring and seals.

38
3860
21
Continued on next page

TM2111 (30MAY03)

38-3860-21

OUO1020,0001238 1923JAN033/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=733

Hydraulic System

T8477AO

UN10MAY94

AO-Ring
BRod
CPoppet
DSpring
EAdjusting Nut
FBackup Ring

Adjustable Circuit Relief Valve

OUO1020,0001238 1923JAN034/6

Detent Valve Remove and Install


1. Inspect parts for damage. Replace as needed.

UN10MAY94

2. Apply petroleum jelly to detent balls to hold them in the


carrier.

T8477AR

3. Assemble valve. Before tightening screws, move the


control lever to detent position to center the assembly.
Tighten screws.
Detent ValveSpecification
Detent Assembly-to-Valve Cap
ScrewsTorque ........................................................... 20 Nm (175 lb-in.)

Detent Assembly
APlate
BScrews
CSpring
DSleeve
ERetainer
FDetent Balls
GCarrier
HHousing
ISpacer

Continued on next page

OUO1020,0001238 1923JAN035/6

38
3860
22

TM2111 (30MAY03)

38-3860-22

G-III and D Series Skidders (S.N. 586337 )


053003

PN=734

Hydraulic System
Spool Valves Remove and Install

NOTE: Keep spool and control valve section together as


a matched set.
1. Inspect spool for bends, scratches, or galling. Replace
packing (C).
2. Assemble valve. Before tightening screws, move the
control lever to detent position to center the assembly.
Tighten screws.
Spool ValvesSpecification
Detent Assembly-to-Valve Cap
ScrewsTorque ........................................................... 20 Nm (175 lb-in.)

T8477AS

UN10MAY94

APlate
BSpacer
CPacking
DSpool
ERetainer
FSpring Assembly
GDetent Rod

OUO1020,0001238 1923JAN036/6

38
3860
23

TM2111 (30MAY03)

38-3860-23

G-III and D Series Skidders (S.N. 586337 )


053003

PN=735

Hydraulic System

T8499BC

UN19JUN95

Dual Function Control Valve Sections Disassemble and Assemble

Dual Function Control Valve


1Inlet Section
2Blade Section
3Boom Section
4Arch Section

5Tong Section
6Outlet Housing
7Bolt (4 used)
8O-Ring

9Fitting
10O-Ring
11Fitting Plug
12O-Ring

13Pipe Plug
14Restrictor
15Dual Function Grapple
Control Valve

1. Remove tie bolts (7) to disassemble valve, replace


seals between all sections.
2. Install tie bolts and tighten nuts to specification.
Dual Function Control Valve SectionsSpecification
Control Valve Section Tie Bolt
NutsTorque............................................................ 57 Nm (42 lb-ft)

OUO1020,0001247 1924JAN031/1

38
3860
24

TM2111 (30MAY03)

38-3860-24

G-III and D Series Skidders (S.N. 586337 )


053003

PN=736

Hydraulic System

Grapple Rotate Solenoid Valve Remove and


Install

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.

X9811

1. Operate all hydraulic control valves to release pressure


in hydraulic system.
2. Disconnect lines (AD).
3. Disconnect two solenoid valve connectors.
B

5. Connect two solenoid valve connectors to transmission


harness.
6. Connect lines (AD).

T134429

7. Operate function through several cycles to remove air


and fill components with oil.
8. Check hydraulic oil level. See Check Hydraulic System
Oil Level. (Operators Manual.)

ASolenoid
BSolenoid
CSolenoid
DSolenoid

T134429

UN07OCT00

4. Remove four mounting screws and nuts to remove


valve from steering valve rotate solenoid bracket.

Valve-to-Rotate Motor Line


Valve-to-Brake Accumulator Tee
Valve-to-Rotate Motor Line
Valve-to-Reservoir Line

OUO1020,0001248 1924JAN031/1

38
3860
25

TM2111 (30MAY03)

38-3860-25

G-III and D Series Skidders (S.N. 586337 )


053003

PN=737

Hydraulic System

T8502AE

UN14JUN95

Grapple Rotate Solenoid Valve Disassemble and Assemble

AScrew (4 used)
BValve Body1

CEnd Cap (2 used)


DRing

EO-Ring (4 used)
FValve Body

GO-Ring (4 used)
HOrifice in P Port

1. Remove grapple rotate valve. See Grapple Rotate


Solenoid Valve Remove and Install in this group.

3. Disassemble parts as shown and inspect. Clean


valve.

2. Remove four screws (A) to remove valve body (B).

4. Use screw (A) to remove orifice (H) from P port.

This part is not repairable.


Continued on next page

OUO1020,0001249 1924JAN031/2

38
3860
26

TM2111 (30MAY03)

38-3860-26

G-III and D Series Skidders (S.N. 586337 )


053003

PN=738

Hydraulic System
5. Assemble solenoid valve.
6. Check operation of solenoid spools, which move
inward when they are energized. Push in on spool
using a screwdriver. Spool must move freely and not
bind.

T8502AF

UN14JUN95

7. Install grapple rotate valve. See Grapple Rotate


Solenoid Valve Remove and Install in this group.

OUO1020,0001249 1924JAN032/2

Pilot Controller Repair (If Equipped)

UN23AUG88

NOTE: The pressure reducing valve is only on machines


with the single lever pilot controller option
installed.

X9811

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
1. Operated arch, boom, and grapple functions with key
switch ON to release pressure from pilot circuits.
2. Turn key switch OFF. Disconnect all electrical
connections to valve.

38
3860
27
Continued on next page

TM2111 (30MAY03)

38-3860-27

OUO1020,000124A 1924JAN031/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=739

T134271B

UN06OCT00

T134269B

UN06OCT00

Hydraulic System

38
3860
28
Continued on next page

TM2111 (30MAY03)

38-3860-28

OUO1020,000124A 1924JAN032/3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=740

Hydraulic System
1Tong Rotate
Counterclockwise (RCC
port)To Rotary Manifold
2Arch Down Line (AR
port)From Arch Cylinder
Rod End

3Rotate Clockwise (RC


port)To Rotary Manifold
4Reduced Pressure Line (RP
port)To Pilot Controller
Port P
5Tong Open Line (TOP
port)To Bottom of Tong
Control Valve Section

3. Remove nut and chain support (6).

6Chain Support
7Pressure Line (P port)
From Accumulator
8Tank Line (T port)To
Tank

9Tong Close Line (TCP


port)To Top of Tong
Control Valve Section (TCP
port)

7. Install valve to machine. Connect all lines and


install chain support (6).

4. Remove lines (15) and (79).


8. Start machine and check for leaks.
5. Remove mounting cap screws and valve.
6. Replace valve as necessary.

OUO1020,000124A 1924JAN033/3

38
3860
29

TM2111 (30MAY03)

38-3860-29

G-III and D Series Skidders (S.N. 586337 )


053003

PN=741

Hydraulic System

Flow Divider Repair


1. Open grapple tongs and lower grapple to the ground.

X9811

UN23AUG88

CAUTION: To avoid injury from escaping fluid


under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
2. Operate all hydraulic control valves to release pressure
in hydraulic system.
3. Remove grapple frame bottom access cover.
4. Put identification tags on lines to aid assembly.
Disconnect lines (AC). Close all openings with caps
and plugs.

T113075

UN05FEB98

AFlow Divider-to-Head End Grapple Tong Cylinder


Line
BFlow Divider-to-Rotary Manifold Line
CFlow Rotate Manifold-to-Rod End Grapple Tong
Cylinder Line

Continued on next page

OUO1020,000124B 1924JAN031/6

38
3860
30

TM2111 (30MAY03)

38-3860-30

G-III and D Series Skidders (S.N. 586337 )


053003

PN=742

TP35158

UN18FEB95

Hydraulic System

1Direct Acting Crossover


Relief Valve (2 used)
2Seal Kit (2 used)

3Screw (2 used)
4Lock Nut (2 used)
5Seal Kit

6Flow Divider Valve


7Washer (2 used)

Continued on next page

TM2111 (30MAY03)

38-3860-31

8Retainer (2 used)
9Flow Divider

38
3860
31

OUO1020,000124B 1924JAN032/6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=743

Hydraulic System
5. Remove screws (3) to remove flow divider.

7. Remove flow divider valve (6).

6. Remove retainer (8) to remove relief valves (1).

OUO1020,000124B 1924JAN033/6

8. Check direct acting relief valve for wear or damage.


Replace if necessary.

UN09JUN95

9. Install new gland ring (A), backup ring (B), and O-ring
(C), as shown.

T8500AF

Flow DividerSpecification
Relief ValvePressure ............................. 6895 551 kPa (69 5.5 bar)
(1000 80 psi)
AGland Ring
BBackup Ring
CO-Ring

OUO1020,000124B 1924JAN034/6

10. Check flow divider valve for wear or damage. Replace


if necessary.

UN09JUN95

11. Install new O-rings (B and D) and backup rings (A


and C) as shown.

T8500AE

ABackup Ring (6 used)


BO-Ring (3 used)
CBackup Ring
DO-Ring

Continued on next page

OUO1020,000124B 1924JAN035/6

38
3860
32

TM2111 (30MAY03)

38-3860-32

G-III and D Series Skidders (S.N. 586337 )


053003

PN=744

Hydraulic System
12. Install flow divider valve (C) and relief valves (B).

15. Connect hydraulic lines.


16. Operate function through several cycles to remove air
and fill components with oil. Check hydraulic oil level.
See Check Hydraulic System Oil Level. (Operators
Manual.)

T8503AF

14. Install flow divider body with cap screw heads on


manifold side.

UN14JUN95

13. Install retainers (A).

17. Install bottom access cover on grapple frame.

T8503AE

UN14JUN95

ARetainer (2 used)
BDirect Acting Crossover Relief Valve (2 used)
CFlow Divider Valve

OUO1020,000124B 1924JAN036/6

38
3860
33

TM2111 (30MAY03)

38-3860-33

G-III and D Series Skidders (S.N. 586337 )


053003

PN=745

Hydraulic System

Rotary Manifold Remove and Install


1. Lower grapple to the ground.

UN23AUG88

2. Operate all hydraulic control valves to release pressure


in hydraulic system.
3. Remove top arch or boom cover.

X9811

4. Put identification tags on lines to aid assembly.


CAUTION: To avoid injury from escaping fluid
under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
5. Disconnect lines (AC) at rotary manifold. Close all
openings with caps and plugs.
6. Remove two shaft cap screws (D).
7. Remove housing cap screw (E) with washer (F) and
spacer (G).

T113097

UN03FEB98

ARotary Manifold-to-Control Valve Tong Head End


Port
BRotary Manifold-to-Control Valve Arch Rod End
Port
CRotary Manifold-to-Rotate Motor Line
DShaft Cap Screw (2 used)
EHousing Cap Screw
FWasher
GSpacer

Continued on next page

OUO1020,000124C 1924JAN031/2

38
3860
34

TM2111 (30MAY03)

38-3860-34

G-III and D Series Skidders (S.N. 586337 )


053003

PN=746

Hydraulic System
8. Remove bottom access cover on grapple frame.
9. Disconnect line (A) at flow divider.

UN03FEB98

10. Disconnect line (B) at tee.


11. Remove rotary manifold with lines (A and B).

T113088

12. Install rotary manifold with line in corresponding holes


in gear. Line port marked A connects to flow divider
and other line connects to tee.

NOTE: Lines must be straight and do not twist as they


pass through the gear and yoke when installing
rotary manifold.

ARotary Manifold Line


BRotary Manifold Line

13. Install and tighten cap screws.


Rotary ManifoldSpecification
Shaft Cap ScrewsTorque........................................... 115 Nm (85 lb-ft)
Housing Cap ScrewTorque...................................... 163 Nm (120 lb-ft)

14. Connect lines.


15. Replace top and bottom shields.

OUO1020,000124C 1924JAN032/2

Rotary Manifold Disassemble and Assemble


1. Remove rotary manifold. See Rotary Manifold Remove
and Install in this group.
UN03FEB98

2. Put identification tags on lines to aid assembly.


3. Remove lines and fittings from manifold shaft (A).

T113093

NOTE: Port A identification is stamped in manifold shaft


housing.
AManifold Shaft

38
3860
35
Continued on next page

TM2111 (30MAY03)

38-3860-35

OUO1020,000124D 1924JAN031/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=747

Hydraulic System
4. Remove snap ring (C) and manifold shaft (A).

T113090

UN03FEB98

AManifold Shaft
BHousing
CSnap Ring

T113092

UN03FEB98

OUO1020,000124D 1924JAN032/5

AManifold Housing
BO-Ring (2 used)

CWear Ring (2 used)

DO-Ring (4 used)

5. Remove manifold housing (A) seals.

EInner Expander Ring (4


used)

8. Install O-rings (B), wear rings (C) and O-rings (D),


inner expander rings (E) in sequence shown in
manifold housing (A) grooves. Seals must not be
twisted in grooves.

6. Inspect housing and shaft for wear or damage.


Replace if necessary.
7. Apply clean hydraulic oil to seals.

NOTE: Install O-ring (D) and inner expander ring (E)


as an assembly.

38
3860
36
Continued on next page

TM2111 (30MAY03)

38-3860-36

OUO1020,000124D 1924JAN033/5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=748

Hydraulic System
9. Apply petroleum jelly to seals, shaft and inside of
housing. Carefully tap shaft (A) into housing (B) using
a hammer.

UN03FEB98

10. Install snap ring (C).

T113090

AManifold Shaft
BHousing
CSnap Ring

OUO1020,000124D 1924JAN034/5

UN23AUG88

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
11. Test rotary manifold for leaks before installing on unit.

X9811

Install an ORFS plug in port (E) of manifold. Connect


a hydraulic hand operated pump to port marked "A"
(A) of rotary manifold. Operate pump to pressurize
manifold to test specification.
Rotary ManifoldSpecification
Rotary Manifold TestPort A
Pressure ................................................. 20 685 kPa (207 bar) (3000 psi)

Turn manifold shaft 10 revolutions in one minute in both


directions. Leakage must not exceed 5 drops per minute
at ports (B or D). Shaft must not bind while turning.
12. Repeat test, with plug in port (D) and applying
pressure to port marked "B" (B). Leakage must not
exceed 5 drops per minute at ports (A or E).

T8502AC

Rotary ManifoldSpecification
Rotary Manifold TestPort C
Pressure ........................................................ 1379 kPa (14 bar) (200 psi)

UN14JUN95

13. Connect hydraulic hand operated pump to port


marked "C" (C). Operate pump to pressurize manifold
to test specifications. Turn manifold shaft 10
revolutions in one minute in both directions. There
must be no external leakage.

APort Marked "A"


BPort Marked "B"
CPort Marked "C"
DPort Connected to "B"
EPort Connected to "A"
38
3860
37
OUO1020,000124D 1924JAN035/5

TM2111 (30MAY03)

38-3860-37

G-III and D Series Skidders (S.N. 586337 )


053003

PN=749

Hydraulic System

38
3860
38

TM2111 (30MAY03)

38-3860-38

G-III and D Series Skidders (S.N. 586337 )


053003

PN=750

Section 99

Dealer Fabricated Tools


Contents
Page

Group 9900Dealer Fabricated Tools


DFT1055 Yoke Holding Tool (1200 and 1400
Series Axles) . . . . . . . . . . . . . . . . . . . . . . .99-9900-1
DFT1099 Bushing Drivers . . . . . . . . . . . . . . .99-9900-2
DFT1156 Transmission Housing Lifting
Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-3
DFT1216 Converter Housing Support . . . . . .99-9900-4
DFT1217 Transmission Input Shaft
Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-5
DFRW20 Compressor Holding Fixture. . . . . .99-9900-6

TM2111 (30MAY03)

99-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

99

Contents

99

TM2111 (30MAY03)

99-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Group 9900

Dealer Fabricated Tools


DFT1055 Yoke Holding Tool (1200 and 1400 Series Axles)

R40162

UN03JAN89

99
9900
1

Yoke Holding Tool is used to hold yoke while removing


nut.

One piece of 10 x 100 x 915 mm (0.375 x 4 x 36 in.)


flat steel.

Material required:

TX,DF1055 1927NOV021/1

TM2111 (30MAY03)

99-9900-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=753

Dealer Fabricated Tools

DFT1099 Bushing Drivers

T7466AA

1911JUL91

99
9900
2

Continued on next page

TM2111 (30MAY03)

99-9900-2

TX,99,WW1176 1904AUG991/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=754

Dealer Fabricated Tools


A0.5 x 2.0 x 6.0 in. 1020 Cold
Rolled
B45 mm BushingUse 2.625
in. OD x 2.25 in. ID x 2.5 in.
B50 mm BushingUse 2.825
in. OD x 2.50 in. ID x 2.5 in.

B60 mm BushingUse 3.50


in. OD x 3.00 in. ID x 2.5 in.
B70 or 80 mm BushingUse
4.00 in. OD x 3.50 in. ID x
2.5 in.

C0.5 x 2.0 x 4.25 in. 1020


Cold Rolled
D0.5 x 8.0 Full Threaded Cap
Screw

ETack Weld With 0.5 in.


Crosshole Centered In Pipe
OD

99
9900
3

These bushing drivers are used to remove and install


spherical bushings.

TX,99,WW1176 1904AUG992/2

T113908

UN20APR98

DFT1156 Transmission Housing Lifting Bracket

TX,03,RB778 1916JAN031/1

TM2111 (30MAY03)

99-9900-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=755

Dealer Fabricated Tools

DFT1216 Converter Housing Support

T140536

UN04APR01

99
9900
4

Continued on next page

TM2111 (30MAY03)

99-9900-4

OUO1030,000054C 1910APR011/2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=756

Dealer Fabricated Tools

This tool is used to support the torque converter


housing for engine removal.
Material required:

Angle Iron (2 in. x 2 in. x 0.25 in.)


Steel Plate (6 in. x 0.50 in.)
(4) Cap Screws (7/16 x 1 1/2 in.)
(4) Cap Screws (3/8 x 1 1/2 in.)

99
9900
5

Bar Stock (1.50 in. x 0.50 in.)

OUO1030,000054C 1910APR012/2

DFT1217 Transmission Input Shaft Holder


This tool is used along with JDG1101 Clutch Pack Lifting
Plate to remove clutch packs from transmission
Material required

(57.1 mm)
2.25 in.

Steel Pipe (2.25 in ID x 2.6 in long)


Bar Stock (2.0 in x 3.0 in long .125 thick)
(66.0 mm)
2.6 in.

11/32
DRILL HOLE

(76.2 mm)
3.0 in.

T141655

T141655

1919APR01

(50.8 mm)
2.0 in.

OUO1017,00003D2 1919APR011/1

TM2111 (30MAY03)

99-9900-5

G-III and D Series Skidders (S.N. 586337 )


053003

PN=757

Dealer Fabricated Tools

DFRW20 Compressor Holding Fixture

RW13619

UN20SEP89

99
9900
6

A102 mm (4 in.)
B76 mm (3 in.)
C70 mm (2.75 in.)

D6.4 mm (0.25 in.)


E19 mm (0.75 in.)
F152 mm (6 in.)

G254 mm (10 in.)


H114 mm (4.5 in.)
I178 mm (7 in.)

JFillet Weld
KTwo Holes

Material required:

4Matching Lock Washers and Nuts

2Steel Plates (4 x 2.75 in.) and (10 x 6 in.)


2Threaded Steel Rods (0.5 x 7 in.)

Tool is used to hold air conditioning compressor during


assembly and disassembly.

TX,18,RB766 1921APR981/1

TM2111 (30MAY03)

99-9900-6

G-III and D Series Skidders (S.N. 586337 )


053003

PN=758

Index
Page

Page

A
Accumulator
Remove and install . . . . . . . . . . . . . . . . .10-1060-3
Air cleaner, remove and install . . . . . . . . . .05-0520-1
Air conditioner system
Flush. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3
Air conditioning
Charge R134a system . . . . . . . . . . . . .18-1830-11
Clutch hub clearance . . . . . . . . . . . . . .18-1830-18
Compressor clutch . . . . . . . . . . . . . . . .18-1830-16
Compressor manifold, inspect . . . . . . . .18-1830-18
Compressor relief valve remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Compressor,
disassemble/inspect/assemble. . . . . .18-1830-19
Compressor, remove and install . . . . . .18-1830-14
Condenser, remove and install . . . . . . .18-1830-22
Evacuate R134a system . . . . . . . . . . . .18-1830-10
Evaporator, remove and install . . . . . . .18-1830-23
Expansion valve, remove and install . . .18-1830-33
Freeze control switch . . . . . . . . . . . . . .18-1830-40
High pressure switch, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Low pressure switch, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12
Pressure blower motor, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-34
Receiver dryer, remove and install . . . .18-1830-39
Recover R134a refrigerant . . . . . . . . . . .18-1830-9
Refrigerant handling . . . . . . . . . . . . . . . .18-1830-1
R134A Refrigerant oil information . . . . . .18-1830-6
Air conditioning (R134A)
Station installation . . . . . . . . . . . . . . . . . .18-1830-8
Air suspension seat, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . . .18-1821-9
Alarm, reverse warning
Remove and install . . . . . . . . . . . . . . . . .20-2004-1
Anti-cinch seat belt, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-11
Arch cylinder
Remove and install . . . . . . . . . . . . . . . . .38-3860-3
Arch cylinder, single function grapple
Remove and install . . . . . . . . . . . . . . . . .38-3860-1
Arch, log
Remove and install . . . . . . . . . . . . . . . . .37-3740-1
Arch-single function grapple
Remove and install . . . . . . . . . . . . . . . . .38-3840-6
Armrest
Disassemble and assemble . . . . . . . . . .18-1821-3
Axle and differential
Front guard, remove and install. . . . . . .02-0200-15
TM2111 (30MAY03)

Front oscillating support, disassemble and


assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Hose routing . . . . . . . . . . . . . . . . . . . . . .02-0260-7
Rear oscillating support, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Rear, remove and install . . . . . . . . . . . .02-0200-11
Axle and differential drive shaft
Front, repair . . . . . . . . . . . . . . . . . . . . . .02-0225-1
Rear, repair. . . . . . . . . . . . . . . . . . . . . . .02-0225-4
Axle, differential, and oscillating supports
Front, remove and install . . . . . . . . . . . .02-0200-1

B
Bearing
Support, repair . . . . . . . . . . . . . . . . . . . .02-0225-4
Belt
Fan, remove and install. . . . . . . . . . . . . .05-0510-2
Tensioner spring tension check. . . . . . . .05-0510-4
Tensioner, automatic (spring), remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-5
Belt, seat
Anti-cinch, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . .18-1821-9
Two-inch, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-10
Blade
Control linkage, remove and install . . . . .32-3215-1
Control valve, remove and install . . . . . .32-3215-2
Lift cylinder, remove and install . . . . . . . .32-3260-1
Stacking, remove and install . . . . . . . . . .32-3201-1
Bleed procedure
Cab tilt hand pump circuit . . . . . . . . . . .18-1800-25
Boom cylinder
Remove and install . . . . . . . . . . . . . . . . .38-3860-3
Boom, dual function
Exploded view. . . . . . . . . . . . . . . . . . . .38-3840-13
Remove and install . . . . . . . . . . . . . . . .38-3840-13
Bottom guard
Engine frame, remove and install . . . . . .17-1746-1
Equipment frame, remove and install . . .17-1746-2
Brake
Park, remove and install . . . . . . . . . . . . .11-1111-1
Park, solenoid valve repair . . . . . . . . . . .11-1160-1
Brake accumulator
Remove and install . . . . . . . . . . . . . . . . .10-1060-3
Brake lining
Inspection . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1
Brake pedal
Remove and install . . . . . . . . . . . . . . . . .10-1015-1

Index-1

G-III and D Series Skidders (S.N. 586337 )


053003

PN=1

Indx
1

Index

Indx
2

Page

Page

Brake valve
Disassemble and assemble . . . . . . . . . .10-1060-3
Remove and install . . . . . . . . . . . . . . . . .10-1060-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-1
Brake, park repair. . . . . . . . . . . . . . . . . . .03-0350-11
Bushing
Spherical, remove and install . . . . . . . . .32-3201-7

Manifold, inspect . . . . . . . . . . . . . . . . . .18-1830-18


Relief valve, remove and install. . . . . . .18-1830-12
Remove and install . . . . . . . . . . . . . . . .18-1830-14
Condenser
Remove and install . . . . . . . . . . . . . . . .18-1830-22
Control linkage
Blade, remove and install . . . . . . . . . . . .32-3215-1
Dual function, remove and install . . . . . .38-3815-4
Single function, remove and install . . . . .38-3815-1
Winch, remove and install . . . . . . . . . . . .30-3015-2
Control valve
Blade, remove and install . . . . . . . . . . . .32-3215-2
Control valve sections, dual function
Disassemble and assemble . . . . . . . . .38-3860-24
Control valve sections, single function
Disassemble and assemble . . . . . . . . .38-3860-16
Control valve, transmission
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-34
Converter housing assemble . . . . . . . . . .06-0641-18
Cylinder
Arch, remove and install . . . . . . . . . . . . .38-3860-3
Blade lift, remove and install . . . . . . . . . .32-3260-1
Boom, remove and install . . . . . . . . . . . .38-3860-3
Cab tilt, hand pump circuit bleed
procedure . . . . . . . . . . . . . . . . . . . . .18-1800-25
Cab tilt, remove and install . . . . . . . . . .18-1800-27
Grapple tong, remove and install . . . . . .38-3860-5
Shock absorber, remove . . . . . . . . . . . . .38-3803-2
Steering, remove and install . . . . . . . . . .09-0960-9
Cylinder, arch single function grapple
Remove and Install . . . . . . . . . . . . . . . . .38-3860-1

C
Cab
Door latch, adjust . . . . . . . . . . . . . . . . . .18-1810-6
Door, remove and install . . . . . . . . . . . . .18-1810-6
Isolator, remove and install . . . . . . . . . .18-1800-16
Remove and install . . . . . . . . . . . . . . . . .18-1800-1
Tilt cylinder, remove and install . . . . . . .18-1800-27
Tilt hand pump circuit bleed
procedure . . . . . . . . . . . . . . . . . . . . .18-1800-25
Cable rollers, dual function
Remove and install . . . . . . . . . . . . . . . . .38-3840-4
Cable rollers, single function
Remove and install . . . . . . . . . . . . . . . . .38-3840-2
Charge pump
Remove-direct drive machines . . . . . . .03-0350-21
Charge pump, transmission
Remove and install
Torque converter machines . . . . . . . . .03-0360-6
Clutch hub clearance . . . . . . . . . . . . . . . .18-1830-18
Clutch pack
Assemble-direct drive machines . . . . . .03-0350-79
Assemble-TC mach. . . . . . . . . . . . . . . 03-0350-114
Disassemble-direct drive machines . . . .03-0350-72
Disassemble-TC mach. . . . . . . . . . . . . 03-0350-105
Fourth (first and third speed), exploded view-direct
drive machines . . . . . . . 03-0350-70, 03-0350-71
Remove-direct drive machines . . . . . . .03-0350-60
Repair-torque converter machines . . . .03-0350-94
Second (high/low forward), exploded view-direct
drive machines . . . . . . . . . . . . . . . . .03-0350-68
Third (high/low reverse), exploded view-direct drive
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-69
Clutch pack repair
Torque converter machines. . . . . . . . . 03-0350-100
Cold start dump valve
Remove and install . . . . . . . . . . . . . . . .21-2160-26
Column, steering
Disassemble and assemble . . . . . . . . .18-1800-18
Remove and install . . . . . . . . . . . . . . . .18-1800-18
Compressor
Clutch, disassemble and assemble . . . .18-1830-16
Disassemble, inspect, and assemble . .18-1830-19
TM2111 (30MAY03)

D
Damper drive
Remove and install . . . . . . . . . . . . . . . . .07-0752-1
Damper, grapple
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .38-3803-4
DFRW20 tool
Compressor holding fixture . . . . . . . . . . .99-9900-6
DFT1055 tool
Yoke holding tool . . . . . . . . . . . . . . . . . .99-9900-1
DFT1099 driver
Spherical bushings removal . . . . . . . . . .99-9900-2
DFT1216 tool
Converter housing support . . . . . . . . . . .99-9900-4
DFT1217 tool
Transmission input shaft holder . . . . . . .99-9900-5
DF1156 tool
Transmission housing lifting bracket . . . .99-9900-3

Index-2

G-III and D Series Skidders (S.N. 586337 )


053003

PN=2

Index

Page

Page

Differential and axle


Front oscillating support, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Rear oscillating support, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0200-1
Rear, remove and install . . . . . . . . . . . .02-0200-11
Differential drive shaft
Front, repair . . . . . . . . . . . . . . . . . . . . . .02-0225-1
Rear, repair. . . . . . . . . . . . . . . . . . . . . . .02-0225-4
Differential lock
Pumpcable skidder, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-5
Pumpgrapple skidder, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-6
Relief valve, remove and install. . . . . . . .02-0260-3
Solenoid valve, repair . . . . . . . . . . . . . . .02-0260-1
Differential lock and axle
Hose routing . . . . . . . . . . . . . . . . . . . . . .02-0260-7
Differential, axle, and oscillating supports
Front, remove and install . . . . . . . . . . . .02-0200-1
Door
Cab, remove and install . . . . . . . . . . . . .18-1810-6
Panel, remove and install . . . . . . . . . . . .18-1810-9
Drive and clutch repair
Winch 4000. . . . . . . . . . . . . . . . . . . . . . .30-3050-1
Winch 6000. . . . . . . . . . . . . . . . . . . . . . .30-3050-1
Drive line, winch, remove and install . . . . .30-3025-1
Drive plate
Assemble drive plate. . . . . . . . . . . . . . . .06-0651-2
Disassemble drive plate . . . . . . . . . . . . .06-0651-2
Torque converter. . . . . . . . . . . . . . . . . . .06-0651-2
Drive shaft
Engine-to-transmission, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .03-0325-1
Front axle and differential, repair. . . . . . .02-0225-1
Rear axle and differential, repair . . . . . . .02-0225-4
Winch, disassemble and assemble . . . . .30-3025-2
Dual function
Control linkage, remove and install . . . . .38-3815-4
Grapple arch, remove and install . . . . .38-3840-10
Pilot controller, remove and install . . . . .38-3815-6
Duals wheel installation . . . . . . . . . . . . . . .01-0110-5

Engine coolant heater


Remove and install . . . . . . . . . . . . . . . . .05-0505-2
Evaporator
Remove and install . . . . . . . . . . . . . . . .18-1830-23
Expansion valve, remove and install. . . . .18-1830-33

E
Engine
Remove and install-direct drive
machines . . . . . . . . . . . . . . . . . . . . . . .04-0400-4
Remove and install-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .04-0400-17
TM2111 (30MAY03)

Indx
3

F
Fabricated tools
DFRW20 compressor holding fixture. . . .99-9900-6
DFT1055 yoke holding tool . . . . . . . . . . .99-9900-1
DFT1099 bushing driver . . . . . . . . . . . . .99-9900-2
DFT1216 converter housing support . . . .99-9900-4
DFT1217 transmission input shaft
holder . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-5
DF1156 transmission housing lifting
bracket . . . . . . . . . . . . . . . . . . . . . . . .99-9900-3
Fan
Belt, remove and install. . . . . . . . . . . . . .05-0510-2
Guard, remove and install . . . . . . . . . . . .05-0510-1
Remove and install . . . . . . . . . . . . . . . . .05-0510-1
Shroud, remove and install . . . . . . . . . . .05-0510-5
First and third speed (fourth stage)
Torque converter machines. . . . . . . . . 03-0350-100
First and third speed (fourth stage assembly)
Exploded view-direct drive machines . .03-0350-70
Flow divider
Remove and install . . . . . . . . . . . . . . . .38-3860-30
Flush air conditioner system . . . . . . . . . . . .18-1830-3
Fourth stage assembly (first and third speed)
Exploded view-direct drive
machines . . . . . . . . . . . . 03-0350-70, 03-0350-71
Exploded view-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-100
Fourth stage (first and third speed)
Torque converter machines. . . . . . . . . 03-0350-100
Frame
Engine, separate. . . . . . . . . . . . . . . . . . .17-1740-2
Equipment, separate . . . . . . . . . . . . . . . .17-1740-2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1
Free spool drag adjustment . . . . . . . . . . .30-3000-10
Freeze control switch . . . . . . . . . . . . . . . .18-1830-40
Front axle, differential, and oscillating supports
Remove and install . . . . . . . . . . . . . . . . .02-0200-1
Front cover group
Remove magnetic speed sensor . . . . . . .06-0641-1
Front housing cover plates
Remove and install-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-30

Index-3

G-III and D Series Skidders (S.N. 586337 )


053003

PN=3

Index

Indx
4

Page

Page

Front housing, transmission


Assemble to rear housing-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-129
Exploded view-direct drive machines . .03-0350-48
Exploded view-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-52
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-55
Fuel tank, 540G-III, 548G-III, 640G-III
Remove . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1
Fuel tank, 648G-III, 748G-III
Remove . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-5

Grapple, dual function


Control valve disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .38-3860-20
Control valve remove and install . . . . . .38-3860-18
Grille and grille housing
Remove and install . . . . . . . . . . . . . . . . .19-1921-1
Guard
Engine frame bottom, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .17-1746-1
Equipment frame bottom, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .17-1746-2
Front axle, remove and install . . . . . . . .02-0200-15

G
Gappple arch, single function
remove and install. . . . . . . . . . . . . . . . . .38-3840-6
Gear shift lever assembly
Remove and install-direct drive
machines . . . . . . . . . . . . . . . . . . . . . . .03-0315-1
Gear, idler (sixth stage)
Torque converter machine . . . . . . . . . .03-0350-98
Gear, idler (sixth stage assembly)
Repair-direct drive machines. . . . . . . . .03-0350-66
Gear, output (seventh stage assembly)
Assemble-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-125
Disassemble-Torque converter
machines . . . . . . . . . . . . . . . . . . . . . 03-0350-125
Repair-direct drive machines. . . . . . . . .03-0350-88
Gear, winch drive
Disassemble-direct drive machines . . . . .03-0350-5
Grapple
Control valve-single function . . . . . . . . .38-3860-14
Damper adjustment. . . . . . . . . . . . . . . . .38-3803-6
Damper, repair . . . . . . . . . . . . . . . . . . . .38-3803-4
Disassemble and assemble . . . . . . . . . .38-3803-2
Rotate yoke repair . . . . . . . . . . . . . . . . .38-3803-9
Specifications . . . . . . . . . . . . . . . . . . . . .38-3803-1
Grapple and tong assembly
Remove and install . . . . . . . . . . . . . . . . .38-3803-1
Grapple arch, duel function
Remove and install . . . . . . . . . . . . . . . .38-3840-10
Grapple control linkage, dual function
Remove and install . . . . . . . . . . . . . . . . .38-3815-4
Grapple control linkage, single function
Remove and install . . . . . . . . . . . . . . . . .38-3815-1
Grapple rotate solenoid valve
Disassemble and assemble . . . . . . . . .38-3860-26
Remove and install . . . . . . . . . . . . . . . .38-3860-25
Grapple tong cylinder
Remove and install . . . . . . . . . . . . . . . . .38-3860-5
TM2111 (30MAY03)

H
Hand pump
Disassemble and assemble . . . . . . . . .18-1800-24
Remove and install . . . . . . . . . . . . . . . .18-1800-23
Heater core, remove and install . . . . . . . .18-1830-35
Heater, engine coolant
Remove and install . . . . . . . . . . . . . . . . .05-0505-2
High pressure switch, air conditioning
Remove and install . . . . . . . . . . . . . . . .18-1830-12
High/low forward (second stage)
Torque converter machines. . . . . . . . . 03-0350-100
High/low forward (second stage assembly)
Exploded view-direct drive machines . .03-0350-68
High/low reverse (third stage)
Torque converter machine . . . . . . . . . 03-0350-100
High/low reverse (third stage assembly)
Exploded view-direct drive machines . .03-0350-69
Hood, remove and install . . . . . . . . . . . . . .19-1910-1
Horizontal roller
Remove and install . . . . . . . . . . . . . . . . .37-3740-1
Horn
Remove and install . . . . . . . . . . . . . . . . .20-2004-1
Housing, front
Exploded view-direct drive machines . .03-0350-48
Exploded view-torque converter
machines . . . . . . . . . . . . . . . . . . . . . .03-0350-52
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-55
Housing, rear
Repair-direct drive machines. . . . . . . . .03-0350-90
Repair-Torque converter machines . . . 03-0350-127
Hydraulic
Fittings, 30 deg cone seat. . . . . . . . . . . .00-0003-8
Fittings, 37 deg flare . . . . . . . . . . . . . . . .00-0003-8
Pump, disassemble and inspect . . . . . .21-2160-12
Pump, remove and install
Torque converter machine . . . . . . . . . .21-2160-8

Index-4

G-III and D Series Skidders (S.N. 586337 )


053003

PN=4

Index

Page

Page

Pump, remove and install-direct drive


mach. . . . . . . . . . . . . . . . . . . . . . . . . .21-2160-1
Reservoir, remove and install . . . . . . . .21-2160-27
Torque converter machines . . . . . . . .21-2160-35
Hydraulic oil cleanup procedure . . . . . . . .21-2160-42

Metric torque values . . . .