Axles and Suspension Systems John Deere 410E II, 460E II Truck Service Manual
410E-II and 460E-II
Articulated Dump Truck Repair
PIN: 1DW410E_ _ _D708125—
PIN: 1DW460E_ _ _D708125—
REPAIR TECHNICAL MANUAL
410E-II and 460E-II Articulated Dump Truck
TM14453X019
13OCT21 (ENGLISH)
For complette service information also see:
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410E-IIand460E-IIArticulatedDumpTruckOperationand Test
Hydraulic Cylinders
6135 Diesel Engine — Level 32 ECU
Connectors Repair
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CTM115319
TM14452X019
CTM120519
CTM119919
CTM704219
TM143019
SP458VOL2
CTM10090X19
Foreword
Thismanualiswrittenforanexperiencedtechnician.Essential toolsrequiredinperformingcertainserviceworkareidentifiedin this manual and are recommended for use.
Informationisorganizedingroupsforthevariouscomponents requiringserviceinstruction.Atthebeginningofeachgroupare summarylistingsofallapplicableessentialtools,service equipmentandtools,othermaterialsneededtodothejob,service parts kits, specifications, wear tolerances, and torque values. Technicalmanualsareconciseguidesforspecificmachines.They areon-the-jobguidescontainingonlythevitalinformationneeded for diagnosis, analysis, testing, and repair Fundamentalserviceinformationisavailablefromothersources coveringbasictheoryofoperation,fundamentalsof troubleshooting,generalmaintenance,andbasictypeoffailures and their causes.
MM16284,00026ED-19-20210914
IMPORTANT:
Useonlysupportingmanualsdesignatedforeachspecific machine.Ifincorrectmanualischosen,improperservicemay occur.Verifyproductidentificationnumber(PIN)when choosing the correct manual.
Whennecessary,productidentificationnumbersarelistedonthe frontcoversofthemanuals.Thesenumbersareusedtoidentify the correct supporting manual for the machine.
IMPORTANT:Avoidenginedamage.Thisinformation applies only to machines with F or L engine.
NOTE:Thisinformationappliesonlytomachineswith F or L engine.
For machines equipped with C or D engine.
System Functional Schematic—F and L Engine
2-17 Character PIN
Theproductidentificationnumber(PIN)plate(1)islocatedonthe leftsideofequipmentframeunderoperator′sstation.Eachmachine has a 17-character PIN (2) shown on PIN plate.
ThePINidentifiestheproducingfactory,machinemodelnumber, machineoption,yearofmanufacture,engineemissionlevel,and machine serial number.
ThefollowingisanexampleforamachinethatmeetsFinalTier4 and Stage IV emission levels:
(1—3)WorldCode: Identifieslocationwhere machine is manufactured.
1T0 World Code (manufacturing location)
1DW Davenport Works
1T8.............. Thibodaux Works
1T0.............. Dubuque Works
(4—8)MachineModelIdentifier: Identifiesmodel number
410E
460E
NOTE:
Machine Model Identifier
Machine Model Identifier
Characters7—8identifyseriesandmajormachine configurationoptions.Thesecharacterswillchange from one machine to another
EffectiveJune2006allmachinessoldintheEuropeanUnion mustcomplywiththemachinerydirective2006/42/ECandany amendments.Eachmachinemeetingtheserequirementsmust beartheconformitymarkCE.Inaddition,eachmachinemustbe accompaniedwithaDeclarationofConformitybythemachine manufacturer.Thisdeclarationmustbekeptwiththemachineatall timesanddoesnotdeclareconformitytonationalroadregulations. EffectiveFebruary15,2013,allmachinessoldintheEurasian Economic UnionmustcomplywiththeTechnicalRegulationsof theEurasianEconomicUnionTRTS010/2011‘OnSafetyof MachineryandEquipment.”Eachmachinemeetingthese requirements must bear the EAC marking (3).
NOTE:
Thismachinemayneedcountryapprovalfortravelonpublic roadsinEuropeassomeEuropeancountriesrequirespecial equipment and approvals.
ProductIdentificationNumber(PIN),CEMark,EACMarking, and EU Flex Label Locations
Themachineisidentifiedbytheproductidentificationnumber(PIN) thatisstampedonaserialnumberplate.ThePINplate(1)and,if required,theCEmark(2),EACmarking,andEUflexlabel(4)are located on the machine as indicated in the machine image.
Ifthismachinewascertified(homologated)tothe requirementsoftheEurasianEconomicUnion,therewillbe an EAC marking affixed in the indicated area.
Sound and Vibration Specifications
Model 410E-II 460E-II
Operator sound pressure and exterior sound power levels are (North America):
Cab 71 dB(A) and 112 dB(A) or less 72 dB(A) and 113 dB(A) or less
Operator sound pressure and exterior sound power levels are (Eurasian Economic Union):
Cab 76 dB(A) and 112 dB(A) or less 76 dB(A) and 113 dB(A) or less
NOTE:
Factors affecting listed values include operator performance, machine age, the condition of window and door seals, the use of accessories, environment, and any machine movement.
NOTE:
Sound levels were obtained using the test method specified per ISO 6396 or ISO 18564 for interior noise and ISO 6395 or ISO 18564 for exterior noise.
Data acquisition system precision with a 2% technical uncertainty
Eurasian Economic Union
Operator vibration are for properly maintained machines operating on a flat, dirt area that is free of large objects such as trees and rocks.
Recognize Safety Information
T133555-UN:
Whole body vibration levels were obtained using the test method specified per GOST 31191.1.
Model 410E-II 460E-II
Whole Body 0.46 m/s2or less 0.46 m/s2or less
Hand Arm 5 m/s2or less 5 m/s2or less
NOTE:
Factors affecting listed values include operator performance, machine age, the condition of window and door seals, the use of accessories, environment, and any machine movement.
Data acquisition system precision with a 2% technical uncertainty
European Union
Operator vibration are for properly maintained machines operating on a flat, dirt area that is free of large objects such as trees and rocks.
Vibration levels were obtained using the test method specified per ISO 2631-1, ISO 5349 or ISO TR 25398 where applicable.
Model 410E-II 460E-II
Whole Body 0.85 m/s2or less 0.85 m/s2or less
Hand Arm 5 m/s2or less 5 m/s2or less
NOTE:
Factors affecting listed values include operator performance, machine age, the condition of window and door seals, the use of accessories, environment, and any machine movement.
Data acquisition system precision with a 2% technical uncertainty
GW86913,0000486-19-20200728
T133588-19: Safety Alert Symbols
Thisisthesafetyalertsymbol.Whenyouseethissymbolon yourmachineorinthismanual,bealertforthepotentialof personal injury
Followtheprecautionsandsafeoperatingpracticeshighlightedby this symbol.
Onyourmachine,DANGERsignsareredincolor,WARNING signsareorange,andCAUTIONsignsareyellow.DANGERand WARNINGsignsarelocatednearspecifichazards.General precautions are on CAUTION labels.
Learnhowtooperatethemachineandhowtousecontrols properly. Do not let anyone operate without instruction.
Keepyourmachineinproperworkingcondition.Unauthorized modificationstothemachinecouldimpairthefunctionorsafetyand affect machine life.
Ifyoudonotunderstandanypartofthismanualandneed assistance, contact your John Deere dealer.
TX,FOLLOW-19-20110120
Operatorshouldbefamiliarwiththejobsiteandsurroundings beforeoperating.Tryallcontrolsandmachinefunctionswiththe machine in an open area before starting to work.
Knowandobserveallsafetyrulesthatmayapplytoeverywork situation and work site.
TX,QUALIFIED-19-20110118
TS206-UN: Protective Clothing
Guardagainstinjuryfromflyingpiecesormetalordebris;wear goggles or safety glasses.
Therearemanyvariablesthataffectthesoundlevelrange, includingmachineconfiguration,conditionandmaintenancelevel ofthemachine,groundsurface,operatingenvironmental,duty cycles, ambient noise, and attachments.
Exposure to loud noise can cause impairment or loss of hearing. Alwayswearhearingprotection. Wearasuitablehearing protectivedevicesuchasearmuffsorearplugstoprotectagainst objectionable or uncomfortable loud noises.
DX,NOISE-19-20171003
AvoidUnauthorizedMachine Modifications
JohnDeererecommendsusingonlygenuineJohnDeere replacementpartstoensuremachineperformance.Never substitutegenuineJohnDeerepartswithalternatepartsnot intendedfortheapplicationasthesecancreatehazardous situationsorhazardousperformance.Non-JohnDeereparts,or anydamageormalfunctionsresultingfromtheiruse,arenot covered by any John Deere warranty
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Modificationstothismachineoradditionofunapprovedproducts orattachmentsmayaffectmachinestabilityorreliabilityandmay createahazardfortheoperatororothersnearthemachine.The installerofanymodificationthatmayaffecttheelectroniccontrols ofthismachineisresponsibleforestablishingthatthemodification does not adversely affect the machine or its performance.
Searchforleakswithapieceofcardboard.Protecthandsandbody from high-pressure fluids.
Ifanaccidentoccurs,seeadoctorimmediately.Anyfluidinjected intotheskinmustbesurgicallyremovedwithinafewhoursor gangrenemayresult.Doctorsunfamiliarwiththistypeofinjury shouldreferenceaknowledgeablemedicalsource.Such informationisavailablefromDeere&CompanyMedical Department in Moline, Illinois, U.S.A.
TX,FLUID-19-20200608
X9811-UN: High Pressure
Avoid High-Pressure Oils
T133840-UN: Avoid High-Pressure Oils
Thismachineusesahigh-pressurehydraulicsystem.Escapingoil under pressure can penetrate the skin causing serious injury Neversearchforleakswithyourhands. Protecthands.Usea pieceofcardboardtofindlocationofescapingoil.Stopengineand relievepressurebeforedisconnectinglinesorworkingonhydraulic system.
Engineexhaustfumescancausesicknessordeath.Ifitis necessarytorunanengineinanenclosedarea,removethe exhaust fumes from the area with an exhaust pipe extension. Ifyoudonothaveanexhaustpipeextension,openthedoorsand get outside air into the area.
DX,AIR-19-19990217
RG21992-UN: Static Discharge (Fuel Nozzle)
TheremovalofsulfurandothercompoundsinUltra-LowSulfur Diesel(ULSD)fueldecreasesitsconductivityandincreasesits ability to store a static charge. Refineriesmayhavetreatedthefuelwithastaticdissipating additive.However,therearemanyfactorsthatcanreducethe effectiveness of the additive over time.
T133509-UN: Avoid High Pressure Oils
StaticchargescanbuildupinULSDfuelwhileitisflowingthrough fueldeliverysystems.Staticelectricitydischargewhencombustible vapors are present could result in a fire or explosion. Therefore,itisimportanttoensurethattheentiresystemusedto refuelyourmachine(fuelsupplytank,transferpump,transferhose,
Manyoperationscreateflammabledebrissuchasmulching, shredding,recycling,andagriculturalapplications.Operatingin suchenvironmentsmayrequirefrequentcleaningofthemachine andattachments.Frequencyofcleaningwillvarydependingona number of factors, including operating conditions and weather
TX,HIGH,DEBRIS,APP-19-20200224
HandleFluidsSafely: Allfuels,mostlubricants,andsomecoolant mixturesareflammable.Storeflammablefluidsawayfromfire hazards.Neverrefuelmachinewhilesmokingorwhennearsparks or flame.
MaintainHoses,Tubes,andWiring: Replacehosesandtubes immediatelyiftheybegintoleak.Cleanupanyoilspills.Examine electrical wiring and connectors frequently for damage.
BeAwareoftheOperatingEnvironment: Airbornedebrismay contain sparks or embers. Do not operate near any flame.
Lithium-Ion Battery Safety:
•Toreducetheriskoffireorburns,donotattempttoopen, disassemble,orservicethedisplayunit.Servicingofthisunitis tobeperformedonlybyanauthorizeddealer.Therearenouserserviceablepartsinsidethedisplayunit.Accessingtheinsideofthe equipment will void the warranty
Directexposuretohazardouschemicalscancauseseriousinjury PotentiallyhazardouschemicalsusedwithJohnDeereequipment include such items as lubricants, coolants, paints, and adhesives. AMaterialSafetyDataSheet(MSDS)providesspecificdetails onchemicalproducts:physicalandhealthhazards,safety procedures, and emergency response techniques.
Follow instructions for specialized components. Releasestoredenergybyloweringsuspended machineelements,relaxingsprings,disconnecting thebatteryorotherelectricalpower,andreleasing pressureinhydrauliccomponents,accumulators,and other similar systems.
TS1356-UN: Store Safely
Starting fluid is highly flammable. Keepallsparksandflameawaywhenusingit.Keepstartingfluid away from batteries and cables.
Serviceanddisposeofairconditioningsystems appropriately.Governmentregulationsmayrequirea certifiedservicecentertorecoverandrecycleair conditioningrefrigerantswhichcoulddamagethe atmosphere if allowed to escape.
Evaluaterecyclingoptionsfortires,metal,plastic, glass,rubber,andelectroniccomponentswhichmay be recyclable, in part or completely.
Contactyourlocalenvironmentalorrecyclingcenter, oryourJohnDeeredealerforinformationonthe proper way to recycle or dispose of waste.
DX,DRAIN-19-20150601
Prepare for Emergencies
Clean Debris from Machine
Add Cab Guarding for Special Uses
Specialworksituationsormachineattachmentscouldcreatean environmentwithfallingorflyingobjects.Workingnearan overheadbank,demolitionwork,usingahydraulichammeror winch,workinginaforestryapplicationorwoodedarea,orworking inawastemanagementapplication,forexample,couldrequire added guarding to protect the operator.
Use Steps and Handholds Correctly
TS291-UN: First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy
Keepemergencynumbersfordoctors,ambulanceservice, hospital, and fire department near your telephone.
DX,FIRE2-19-19930303
T6669AG-UN: Clean
Debris From Machine
Keepenginecompartment,radiator,batteries,hydrauliclines, exhaustcomponents,fueltank,andoperator′sstationcleanand free of debris.
Clean any oil spills or fuel spills on machine surfaces. Temperatureinenginecompartmentcouldgoupimmediatelyafter engineisstopped.BEONGUARDFORFIRESDURINGTHIS PERIOD.
AdditionallevelIIFOPS(fallingobjectprotectivestructure),forestry protectionpackages,andspecialscreensorguardingshouldbe installedwhenfallingorflyingobjectscouldenterordamagethe machine.Arearscreenshouldalwaysbeusedwithawinchto protectagainstasnappingcable.Beforeoperatinginanyspecial workenvironments,followtheoperatorprotection recommendationsofthemanufacturerofanyspecialized attachmentorequipment.ContactyourauthorizedJohnDeere dealer for information on protective guarding.
TX,CABGUARD-19-20130212
T133468-UN: Use Handholds And Steps
Preventfallsbyfacingthemachinewhenyougetonandoff. Maintain3-pointcontactwithstepsandhandrails.Neveruse machine controls as handholds.
Avoidunexpectedmachinemovement.Startengineonlywhile sittinginoperator′sseat.Ensurethatallcontrolsandworkingtools are in proper position for a parked machine.
Neverattempttostartenginefromtheground.Donotattemptto start engine by shorting across the starter solenoid terminals.
CAUTION: Preventpersonalinjury.Checkconditionofseatbeltand mountinghardwarebeforeoperatingmachine.Replaceif worn,frayed,ordamaged. Replaceseatbeltatleastevery3 years, regardless of condition.
TX,SEAT,BELT-19-20200727
H124189-UN: Safety Graphic
Anoverheatedseatheatercancauseaburninjuryordamageto theseat.Toreducetheriskofburns,usecautionwhenusingthe seatheaterforextendedperiodsoftime,especiallyiftheoperator cannotfeeltemperaturechangeorpaintotheskin.Donotplace objectsontheseat,suchasablanket,cushion,cover,orsimilar item, which can cause the seat heater to overheat.
Ensuredumpbodyisloweredduringworkinterruptions.Push neutralselectionswitch(3)toengageneutralgear,pushparkbrake switch(2)toengageparkbrake,andpushenginestopswitch(1) to stop engine before allowing anyone to approach the machine. Followthesesameprecautionsbeforestandingup,leavingthe operator’s seat, or exiting the machine.
GW86913,0000487-19-20201210
TX1286211-UN: 811 Call Before You Dig
Beforedigging,checklocalrequirementsandcallutilityline locationservicestoidentifyandmarkallundergroundutilities indiggingareabeforestartingwork.Avoidcontactwithgas lines, buried cables and water lines.
Prepareworksiteproperly. Avoidoperatingnearstructuresor objectsthatcouldfallontothemachine.Clearawaydebristhat could move unexpectedly if run over
Avoidboomorattachmentcontactwithoverheadobstaclesor overheadelectricallines. Nevermovemachinecloserthan3m (10 ft) plus twice the line insulator length to overhead wires. Keepbystandersclearatalltimes. Keepbystandersawayfrom raisedbooms,attachments,andunsupportedloads.Avoid swingingorraisingbooms,attachments,orloadsoverornear personnel.Usebarricadesorasignalpersontokeepvehicles andpedestriansaway.Useasignalpersonifmovingmachinein congestedareasorwherevisibilityisrestricted.Alwayskeepsignal person in view. Coordinate hand signals before starting machine. Operateonlyonsolidfooting withstrengthsufficienttosupport machine.Beespeciallyalertworkingnearembankmentsor excavations.
Avoidworkingunderover-hangingembankmentsor stockpiles that could collapse under or on machine.
Powerlinescarryingmorethan50000voltsrequireasafety distanceof10ft(3m)plus1/2in(13mm)foreachadditional 1000 volts above the 50 000 volt level.
Approachwithcautionareaswhereoverhangingtelephoneor electricpowerlinesarepresent.Seriousinjuryordeathby electrocutioncanresultifthemachineoranyofitsattachmentsare not kept a safe distance from high-voltage electric power lines. Maintainadistanceof10ft(3m)betweenthemachine,boom, stick, and any power line carrying up to 50 000 volts or less. Ifstate/province,local,orjobsiteregulationsrequireevengreater safetydistancesthanstatedabove,adherestrictlytothese regulations for personal protection.
TX,AVOID,POWER,LINES-19-20200508
T143354-UN: Keep Riders Off Machine
Always use seat belt.
Only allow operator on machine.
Theinstructionalseat,ifequipped,isusedtoaccommodate trainers,personsthatneedtoobservemachineoperation,andfor coworkers to provide further operational instructions.
Beforemovingthemachine,ensurethatallpersonsareclear ofthemachinepath. Usemirrorsandcameras,ifequipped,to assistincheckingallaround.Keepwindows,mirrorsandlenses clean, adjusted, and in good repair.
Verify reverse/travel warning alarm is working properly Useasignalpersonwhenbackingifviewisobstructedor wheninclosequarters. Keepsignalpersoninviewatalltimes. Use prearranged hand signals to communicate.
Rearvisibilityaidsmayhavelimitationsduetomaintenance practices, environmental conditions, and operating range.
TX,BACKOVER1-19-20200508
AvoidMachineTipOverandMachine Damage
Operating on Slopes
Operating or Traveling On Public Roads
Inspect and Maintain ROPS
Adamagedrolloverprotectivestructure(ROPS)shouldbe replaced, not reused.
TheprotectionofferedbyROPScouldbeimpairedifROPSis subjectedtostructuraldamage,isinvolvedinanoverturnincident, or is in any way altered by welding, bending, drilling, or cutting.
T144185-UN: Avoid Machine Tip Over
Use seat belt at all times.
Donotjumpifthemachinetips. Operatorisunlikelytojump clear and may be crushed by machine.
Useextracarewhenbin(dumpbody)israised. Machine stabilityisgreatlyreducedwhenbin(dumpbody)israised.Drive slowly. Avoid sharp turns and uneven ground.
Becarefulonslopesandsoft,rocky,orfrozenground. Traction andstabilityarereducedbyslopesandadverseterrain.Avoidpiles ofdirtandbanksorexcavationsthatmaycaveinandcausethe machine to tip or fall.
Donotoverloadthemachine. Oversizeloadsreducemachine stability,increasetireflex,anderodetravelsurfaces.Braking capability and brake life are also reduced.
Ifmachinetips,carefullyinspectbrakeandhydrauliclines, electrical wiring, and machine structure before operating.
GW86913,000048C-19-20200421
T143361-UN: Operating on Slopes
Avoid side slope travel whenever possible. Checkservicebrakeconditionfrequentlywhenoperatingon slopes.
Selectlowgearspeedbeforestartingdownslope.Themaximum slopethatisbeingoperatedonislimitedbygroundconditions along with the load being handled.
Usethetransmissionretarderandservicebrakestocontrolspeed. Suddenbrakeapplicationwithaloadedbin(dumpbody)could cause loss of machine control.
GW86913,0000496-19-20200421
T141891-UN: Operating or Traveling On Public Roads
Machinesthatworknearvehicletrafficortravelslowerthannormal highwayspeedsmusthaveproperlightingandmarkingstoassure they are visible to other drivers.
Installadditionallights,beaconlights,slowmovingvehicle(SMV) emblems,orotherdevicesanduseasrequiredtomakethe machinevisibleandidentifyitasaworkmachine.Checkstateand localregulationstoassurecompliance.Keepthesedevicesclean and in working condition.
TX,ROADS-19-20110120
IfROPSwasloosenedorremovedforanyreason,inspectit carefully before operating the machine again.
To maintain the ROPS:
Replacemissinghardwareusingcorrectgrade hardware.
Check hardware torque.
T133716-19: Use Seat Belt
TX,ROPS-19-20110120
Checkisolationmountsfordamage,looseness,or wear; replace them if necessary.
Check ROPS for cracks or physical damage.
Travel Safely
Prevent Acid Burns
Add and Operate Attachments Safely
Alwaysverifycompatibilityofattachmentsbycontactingyour authorizeddealer.Addingunapprovedattachmentscouldaffect machinestabilityorreliabilityandcouldcreateahazardforothers near the machine.
Whenworkingonsteepslopes,travelasstraightupanddownas possible to prevent roll over DO NOT PARK ON A HILLSIDE OR AN INCLINE. Always park the machine on level ground. Know the location of bystanders before moving the machine. Alwayskeepthereverse/travelwarningalarminworkingcondition. Thealarmwarnsbystanderswhenthemachinestartstomovein reverse.
Useasignalpersonwhenmovingthemachineincongestedareas. Coordinate hand signals before starting the machine.
TX,TRAVEL,SAFE1-19-20200508
TS203-UN: Acid Burns
Sulfuricacidinbatteryelectrolyteispoisonous.Itisstrongenough toburnskin,eatholesinclothing,andcauseblindnessifsplashed into eyes.
Avoid the hazard by:
Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. Use proper jump start procedure.
If you spill acid on yourself:
Flush your skin with water
Apply baking soda or lime to help neutralize the acid. Flushyoureyeswithwaterfor15—30minutes.Get medical attention immediately.
If acid is swallowed:
Do not induce vomiting.
Drinklargeamountsofwaterormilk,butdonotexceed 2 L (2 quarts).
Get medical attention immediately
DX,POISON-19-19930421
recommended.Verifythatallconnectionsaresecureand attachment responds properly to controls.
Warnothersofservicework. Alwaysparkandprepareyour machine for service or repair properly
Park machine on a level surface.
Lowerbin(dumpbody)unlessraisedpositionis required for service.
Engage park brake. Stop engine.
Attacha‘DoNotOperate”taginanobviousplacein the operator′s station.
Installservicelockbarifbin(dumpbody)orcabis raised for service.
Installservicelocksifbin(dumpbody)orcabisraised for service.
Securely support machine before working under it.
Installwheelchockstoensurethatmachinecannotmove backward or forward during service.
Understandserviceproceduresbeforebeginningrepairs.Keep serviceareacleananddry.Usetwopeoplewhenevertheengine must be running for service work.
Whenperformingabove-groundmaintenance,useappropriate supportdevicessuchasladders,lifts,orplatforms.Ifequipped,use themachineanchoragepointsandapprovedfallarrestharnesses and lanyards.
TX,PARK,ADT-19-20200923
TS228-UN: Service Machines Safely
Tielonghairbehindhead.Donotwearanecktie,scarf,loose clothing,ornecklacewhenworkingnearmachinetoolsormoving parts. If these items were to get caught, severe injury could result. Removeringsandotherjewelrytopreventelectricalshortsand entanglement in moving parts.
TX,SERV,SAFE-19-20200508
TS281-UN: Cooling System
Explosivereleaseoffluidsfrompressurizedcoolingsystemcan cause serious burns.
Donotserviceradiatorthroughtheradiatorcap.Onlyfillthrough thesurgetankfillercap.Shutoffengine.Onlyremovesurgetank fillercapwhencoolenoughtotouchwithbarehands.Slowly loosen cap to relieve pressure before removing completely.
TX,SURGE-19-20110119
T133332-19: Do Not Operate Tag
Service Accumulator Systems Safely
Remove Paint Before Welding or Heating
TS220-UN: Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardousfumescanbegeneratedwhenpaintisheatedby welding, soldering, or using a torch.
Relievepressurefromthehydraulicsystembeforeremoving accumulator.Neverattempttorelievehydraulicsystemor accumulator pressure by loosening a fitting.
Accumulators cannot be repaired.
Remove paint before heating:
Removepaintaminimumof100mm(4in.)from areatobeaffectedbyheating.Ifpaintcannotbe removed,wearanapprovedrespiratorbeforeheating or welding.
Ifyousandorgrindpaint,avoidbreathingthedust. Wear an approved respirator
Ifyouusesolventorpaintstripper,removestripper withsoapandwaterbeforewelding.Removesolvent orpaintstrippercontainersandotherflammable materialfromarea.Allowfumestodisperseatleast 15 minutes before welding or heating.
Doallworkinanareathatiswellventilatedtocarrytoxicfumes and dust away
Dispose of paint and solvent properly
DX,PAINT-19-20020724
Donotweldorapplyheatonanypartofareservoirortankthat hascontainedoilorfuel.Heatfromweldingandcuttingcancause oil,fuel,orcleaningsolutiontocreategaseswhichareexplosive, flammable, or toxic.
Avoidweldingorheatingnearpressurizedfluidlines.Flammable spraymayresultandcausesevereburnsifpressurizedlines malfunctionasaresultofheating.Donotletheatgobeyondwork area to nearby pressurized lines.
Removepaintproperly.Donotinhalepaintdustorfumes.Usea qualifiedweldingtechnicianforstructuralrepairs.Makesurethere isgoodventilation.Weareyeprotectionandprotectiveequipment when welding.
TX,WELD,SAFE-19-20200508
Drive Metal Pins Safely
Service Tires Safely
Use Proper Lifting Equipment
T133738-UN: Hardened Metal Parts
Alwayswearprotectivegogglesorsafetyglassesandother protectiveequipmentbeforestrikinghardenedparts.Hammering hardenedmetalpartssuchaspinsandbucketteethcoulddislodge chips at high velocity
Explosiveseparationofatireandrimpartscancauseserious injury or death.
Donotattempttomountatireunlessyouhavetheproper equipment and experience to perform the job.
Alwaysmaintainthecorrecttirepressure.Donotinflatethetires abovetherecommendedpressure.Neverweldorheatawheel andtireassembly.Theheatcancauseanincreaseinairpressure resultinginatireexplosion.Weldingcanstructurallyweakenor deform the wheel.
Wheninflatingtires,useaclip-onchuckandextensionhoselong enoughtoallowyoutostandtoonesideandNOTinfrontofor over the tire assembly. Use a safety cage if available.
Checkwheelsforlowpressure,cuts,bubbles,damagedrimsor missing lug bolts and nuts.
DX,RIM-19-19900824
TS226-UN: Proper Lifting Equipment
Liftingheavycomponentsorattachmentsincorrectlycancause injury or machine damage.
Followrecommendedprocedureforremovalandinstallationof components or attachments.
TX,LIFT,EQUIP-19-20200508
Torque Values
Metric Bolt and Cap Screw Torque Values
TORQ2-UN: Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings
4.8
Bolt or Screw Size
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
8.8 or 9.8
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
10.9
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
12.9
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
The nominal torque values listed are for general use only with the assumed wrenching accuracy of 20%, such as a manual torque wrench.
DO NOT use these values if a different torque value or tightening procedure is given for a specific application.
For lock nuts, stainless steel fasteners, or nuts on U-bolts, see the tightening instructions for the specific application.
CAUTION:
Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Avoid injury. Use only metric tools on metric hardware. Other tools may not fit properly, causing tool to slip resulting in injury
Make sure that fastener threads are clean. Apply a thin coat of Hy-Gard™ or equivalent oil under the head and on the threads of the fastener, as shown in the following image.
Bolt or Screw Size
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Torque Values
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Be conservative with the amount of oil to reduce the potential for hydraulic lockup in blind holes because of excessive oil. Properly start thread engagement.
TS1741-UN: Lubricant Locations
Hy-Gard is a trademark of Deere & Company
OUT3035,TORQUE2-19-20200220
Additional Metric Cap Screw Torque Values
T6873AB-UN: H-Bolt
T6873AA-UN: T-Bolt
T6873AC-UN: M-Bolt
CAUTION:
Useonlymetrictoolsonmetrichardware.Othertoolsmaynot fit properly. They may slip and cause injury
Checktightnessofcapscrewsperiodically.Torquevalueslistedareforgeneraluseonly.Donotusethesevaluesifadifferenttorque 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. Fastenersshouldbereplacedwiththesameorhighergrade.Ifhighergradefastenersareused,theseshouldonlybetightenedtothe strength of the original. Makesurefastenerthreadsarecleanandthatthethreadengagementisproperlystarted.Thiswillpreventfastenersfromfailingwhen tightening.
Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.
METRIC CAP SCREW TORQUE VALUES [Torque tolerance is ±10%.]
Torque Values
Unified Inch Bolt and Cap Screw Torque Values
TORQ1A-UN: Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings
SAE Grade 1 [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.]
Bolt or Screw
Size
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
SAE Grade 2 [Grade 2 applies for hex cap screws (not hex bolts) up to 6 in (152 mm) long.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
The nominal torque values listed are for general use only with the assumed wrenching accuracy of 20%, such as a manual torque wrench.
DO NOT use these values if a different torque value or tightening procedure is given for a specific application.
For lock nuts, stainless steel fasteners, or nuts on U-bolts, see the tightening instructions for the specific application.
Make sure that fastener threads are clean.
Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Apply a thin coat of Hy-Gard™ or equivalent oil under the head and on the threads of the fastener, as shown in the following image.
Be conservative with the amount of oil to reduce the potential for hydraulic lockup in blind holes because of excessive oil.
Properly start thread engagement.
SAE Grade 5, 5.1 or 5.2
SAE Grade 8 or 8.2
Bolt or Screw Size
SAE Grade 1 [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.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Torque Values
SAE Grade 2 [Grade 2 applies for hex cap screws (not hex bolts) up to 6 in (152 mm) long.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
Hex Head [Hex head column values are valid for ISO 4014 and ISO 4017 hex head, ISO 4162 hex socket head, and ISO 4032 hex nuts.]
Flange Head [Hex flange column values are valid for ASME B18.2.3.9M, ISO 4161, or EN 1665 hex flange products.]
TS1741-UN: Lubricant Locations
Hy-Gard is a trademark of Deere & Company
Identifying Zinc-Flake Coated Fasteners
RXA0073812-UN: Fastener Identification
LEGEND:
A-Standard Cap Screws
B-Zinc-plated Cap Screw
C-Zinc-Flake Cap Screw (20 mm and larger)
OUT3035,TORQUE1-19-20200220
Standard cap screws (A) have a reflective silver color
Zinc plated cap screws (B) have a reflective gold color
Zinc-Flake Coated cap screws (C) have a dull silver color
OURX985,0000024-19-20051103
ServiceRecommendationsfor37°Flare and 30° Cone Seat Connectors
