160D Repair

160DLCExcavator

Repair

TECHNICAL MANUAL160DLC Excavator Repair

TM10091 11JAN08 (ENGLISH)

For complete service information also see:

160DLC Excavator Operation and Tests . . . TM10088160DLC Excavator Operator’s Manual . . . . . OMT226911POWERTECH 4.5L/6.8L POWERTECH E6.8L Diesel Engines—Base Engine . . . . . . . CTM104POWERTECH E 6.8L DieselEngines—Level 16 Electronic Fuel Systemwith Denso HPCR . . . . . . . . . . . . . . . . . . . . . CTM502Alternators and Starter Motors. . . . . . . . . . . CTM77Undercarriage Appraisal Manual . . . . . . . . . SP326Super Caddy Oil Cleanup Procedure . . . . . . CTM310

Worldwide ConstructionAnd Forestry Division

LITHO IN U.S.A

Introduction

DX,TMIFC –19–29SEP98–1/1

Foreword

This manual is written for an experienced technician.Essential tools required in performing certain servicework are identified in this manual and arerecommended for use.

Live with safety: Read the safety messages in theintroduction of this manual and the cautions presentedthroughout the text of the manual.

This is the safety-alert symbol. When you see thissymbol on the machine or in this manual, be alert tothe potential for personal injury.

Technical manuals are divided in two parts: repair andoperation and tests. Repair sections tell how to repairthe components. Operation and tests sections help youidentify the majority of routine failures quickly.

Information is organized in groups for the variouscomponents requiring service instruction. At thebeginning of each group are summary listings of allapplicable 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 specificmachines. They are on-the-job guides containing onlythe vital information needed for diagnosis, analysis,testing, and repair.

Fundamental service information is available fromother sources covering basic theory of operation,fundamentals of troubleshooting, general maintenance,and basic type of failures and their causes.

TM10091 (11JAN08) 160DLC Excavator Repair011108

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Introduction

TX,TM,FAX –19–03JUL01–1/1

Technical Information Feedback Form

We need your help to continually improve our technicalpublications. Please copy this page and FAX or mail yourcomments, ideas and improvements.

SEND TO: John Deere Dubuque WorksP.O. Box 538Attn: Publications Supervisor, Dept. 303Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

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Introduction


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Contents00

SECTION 00—General InformationGroup 01—SafetyGroup 0003—Torque Values

SECTION 01—Tracks01Group 0130—Track System

SECTION 02—Axles, Differentials and SuspensionSystems

Group 0250—Axle Shaft, Bearings, and ReductionGears

Group 0260—Hydraulic System

SECTION 04—EngineGroup 0400—Removal and Installation

02

SECTION 05—Engine Auxiliary SystemGroup 0510—Cooling SystemGroup 0520—Intake SystemGroup 0560—External Fuel Supply System

SECTION 07—Dampener Drive (Flex Coupling)Group 0752—Elements

SECTION 17—Frame or Supporting StructureGroup 1740—Frame InstallationGroup 1749—Chassis Weights

04

SECTION 18—Operator’s StationGroup 1800—Removal and InstallationGroup 1810—Operator EnclosureGroup 1821—Seat and Seat BeltGroup 1830—Heating and Air Conditioning

SECTION 33—ExcavatorGroup 3302—BucketsGroup 3340—FramesGroup 3360—Hydraulic System

05

SECTION 43—Swing or Pivoting SystemGroup 4350—Mechanical Drive ElementsGroup 4360—Hydraulic System

SECTION 99—Dealer Fabricated ToolsGroup 9900—Dealer Fabricated Tools

All information, illustrations and specifications in this manual are based onthe latest information available at the time of publication. The right isreserved to make changes at any time without notice.

07

COPYRIGHT 2008DEERE & COMPANY

Moline, IllinoisAll rights reserved

A John Deere ILLUSTRUCTION ManualPrevious EditionsCopyright 2007

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TM10091 (11JAN08) i 160DLC Excavator Repair011108

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TM10091 (11JAN08) ii 160DLC Excavator Repair011108

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TM10091 (11JAN08) iii 160DLC Excavator Repair011108

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TM10091 (11JAN08) iv 160DLC Excavator Repair011108

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00

Section 00General Information

Contents

Page

Group 01—Safety . . . . . . . . . . . . . . . . . . . . . .00-01-1

Group 0003—Torque ValuesTorque Value

Metric Bolt and Cap Screw . . . . . . . . . . . .00-0003-1Additional Metric Cap Screw Torque

Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2Torque Value

Unified Inch Bolt and Cap Screw . . . . . . . .00-0003-4Service Recommendations for 37° Flare

and 30° Cone Seat Connectors . . . . . . . . .00-0003-5Service Recommendations for O-Ring

Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6Service Recommendation

O-Ring Boss Fittings In AluminumHousing—Excavators . . . . . . . . . . . . . . .00-0003-8

Service Recommendations For FlaredConnections—Straight or TaperedThreads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10

Service Recommendations For Flat FaceO-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0003-11

Service RecommendationO-Ring Face Seal Fittings with SAE

Inch Hex Nut and Stud End for HighPressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-12

O-Ring Face Seal Fittings with MetricHex Nut and Stud End for StandardPressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-14

O-Ring Face Seal Fittings with MetricHex Nut and Stud End for HighPressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-16

Service Recommendations for MetricSeries Four Bolt Flange Fitting . . . . . . . .00-0003-18

Service Recommendations For InchSeries Four Bolt Flange Fittings. . . . . . . .00-0003-19

Service RecommendationInch Series Four Bolt Flange For High

Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-20

TM10091 (11JAN08) 00-1 160DLC Excavator Repair011108

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Contents

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Group 01Safety

00011

TX03679,00016CC –19–03JAN07–1/1

Recognize Safety Information

T13

3555

–UN

–28A

UG

00T

1335

88–1

9–28

AU

G00

This is the safety alert symbol. When this symbol isnoticed on the machine or in this manual, be alert forthe potential of personal injury.

Follow the precautions and safe operating practiceshighlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — isused with the safety alert symbol. DANGER identifies themost serious hazards.

On the machine, DANGER signs are red in color,WARNING signs are orange, and CAUTION signs areyellow. DANGER and WARNING signs are located nearspecific hazards. General precautions are on CAUTIONlabels.

TX03679,00016F9 –19–03JAN07–1/1

Follow Safety Instructions

T13

3556

–UN

–24A

UG

00

Read the safety messages in this manual and on themachine. Follow these warnings and instructions carefully.Review them frequently.

Be sure all operators of this machine understand everysafety message. Replace operator’s manual and safetylabels immediately if missing or damaged.

TX03679,00016FA –19–08JAN08–1/1

Operate Only If Qualified

Do not operate this machine unless the operator’smanual has been read carefully, and you have beenqualified by supervised training and instruction.

Operator should be familiar with the job site andsurroundings before operating. Try all controls and

machine functions with the machine in an open areabefore starting to work.

Know and observe all safety rules that may apply toevery work situation and work site.

TM10091 (11JAN08) 00-01-1 160DLC Excavator Repair011108

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Safety

0001

2

TX03679,00016D0 –19–03JAN07–1/1

Wear Protective Equipment

TS

206

–UN

–23A

UG

88

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

Wear close fitting clothing and safety equipmentappropriate to the job.

Prolonged exposure to loud noise can cause impairmentor loss of hearing. Wear suitable hearing protection suchas earmuffs or earplugs to protect against objectionable oruncomfortable loud noises.

AM40430,00000A9 –19–17JUL07–1/1

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine JohnDeere replacement parts to ensure machineperformance. Never substitute genuine John Deereparts with alternate parts not intended for theapplication as these can create hazardous situations orhazardous performance. Non-John Deere Parts, or anydamage or failures resulting from their use are notcovered by any John Deere warranty.

Modifications of this machine, or addition ofunapproved products or attachments, may affect

machine stability or reliability, and may create a hazardfor the operator or others near the machine. Theinstaller of any modification which may affect theelectronic controls of this machine is responsible forestablishing that the modification does not adverselyaffect the machine or its performance.

Always contact an authorized dealer before makingmachine modifications that change the intended use,weight or balance of the machine, or that altermachine controls, performance or reliability.


PN=10

Safety

00013

TX03679,00016CE –19–03JAN07–1/1

Add Cab Guarding for Special Uses

T13

3733

–UN

–15S

EP

00

Special work situations or machine attachments maycreate an environment with falling or flying objects.Working near an overhead bank, doing demolition work,using a hydraulic hammer, or working in a wooded area,for example, may require added guarding to protect theoperator.

FOPS (falling object protective structures) and specialscreens or guarding should be installed when falling orflying objects may enter or damage the machine. Contactyour authorized dealer for information on devices intendedto provide protection in special work situations.

TX03679,0001734 –19–03JAN07–1/1

Inspect Machine

T66

07A

Q–U

N–1

8OC

T88

Inspect machine carefully each day by walking around itbefore starting.

Keep all guards and shields in good condition andproperly installed. Fix damage and replace worn or brokenparts immediately. Pay special attention to hydraulichoses and electrical wiring.

TX03679,00016D2 –19–03JAN07–1/1

Stay Clear of Moving Parts

T13

3592

–UN

–12S

EP

01Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintainingany part of machine with moving parts.

Keep guards and shields in place. Replace any guard orshield that has been removed for access as soon asservice or repair is complete.


PN=11

Safety

0001

4

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Fluids

X98

11–U

N–2

3AU

G88

Escaping fluid under pressure can penetrate the skincausing serious injury.

Avoid the hazard by relieving pressure beforedisconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

Search for leaks with a piece of cardboard. Protect handsand body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluidinjected into the skin must be surgically removed within afew hours or gangrene may result. Doctors unfamiliar withthis type of injury should reference a knowledgeablemedical source. Such information is available from Deere& Company Medical Department in Moline, Illinois, U.S.A.

TX03679,00016D3 –19–01OCT07–1/1

Avoid High-Pressure Oils

T13

3509

–UN

–17M

AR

06T

1338

40–U

N–2

0SE

P00

This machine uses a high-pressure hydraulic system.Escaping oil under pressure can penetrate the skincausing serious injury.

Never search for leaks with your hands. Protect hands.Use a piece of cardboard to find location of escaping oil.Stop engine and relieve pressure before disconnectinglines or working on hydraulic system.

If hydraulic oil penetrates your skin, see a doctorimmediately. Injected oil must be removed surgicallywithin hours or gangrene may result. Contact aknowledgeable medical source or the Deere & CompanyMedical Department in Moline, Illinois, U.S.A.


PN=12

Safety

00015

TX03679,00016D4 –19–03JAN07–1/1

Beware of Exhaust Fumes

T13

3546

–UN

–24A

UG

00

Prevent asphyxiation. Engine exhaust fumes can causesickness or death.

If you must operate in a building, provide adequateventilation. Use an exhaust pipe extension to remove theexhaust fumes or open doors and windows to bringoutside air into the area.

TX03679,00016F5 –19–08MAR07–1/1

Prevent Fires

T13

3552

–UN

–14S

EP

00T

1335

53–U

N–0

7SE

P00

T13

3554

–UN

–07S

EP

00

Handle Fuel Safely: Store flammable fluids away fromfire hazards. Never refuel machine while smoking or whennear sparks or flame.

Clean Machine Regularly: Keep trash, debris, greaseand oil from accumulating in engine compartment, aroundfuel lines, hydraulic lines and electrical wiring. Never storeoily rags or flammable materials inside a machinecompartment.

Maintain Hoses and Wiring: Replace hydraulic hosesimmediately if they begin to leak, and clean up any oilspills. Examine electrical wiring and connectors frequentlyfor damage.

Keep A Fire Extinguisher Available: Always keep amultipurpose fire extinguisher on or near the machine.Know how to use extinguisher properly.

TX03679,000174A –19–03JAN07–1/1

Prevent Battery Explosions

TS

204

–UN

–23A

UG

88

Battery gas can explode. Keep sparks, lighted matches,and open flame away from the top of battery.

Never check battery charge by placing a metal objectacross the posts. Use a voltmeter or hydrometer.

Do not charge a frozen battery; it may explode. Warmbattery to 16°C (60°F).


PN=13

Safety

0001

6

TX03679,00016D7 –19–08JAN08–1/1

Handle Chemical Products Safely

T13

3580

–UN

–25A

UG

00

Exposure to hazardous chemicals can cause seriousinjury. Under certain conditions, lubricants, coolants,paints and adhesives used with this machine may behazardous.

If uncertain about safe handling or use of these chemicalproducts, contact your authorized John Deere dealer for aMaterial Safety Data Sheet (MSDS) or go to internetwebsite http://www.jdmsds.com. The MSDS describesphysical and health hazards, safe use procedures, andemergency response techniques for chemical substances.Follow MSDS recommendations to handle chemicalproducts safely.

TX03679,0001733 –19–03JAN07–1/1

Dispose of Waste Properly

T13

3567

–UN

–25A

UG

00

Improper disposal of waste can threaten the environment.Fuel, oils, coolants, filters and batteries used with thismachine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or intoany water source.

Air conditioning refrigerants can damage the atmosphere.Government regulations may require using a certifiedservice center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact yourlocal environmental or recycling center or your authorizeddealer for more information.

TX03679,000174B –19–03JAN07–1/1

Prepare for Emergencies

TS

291

–UN

–23A

UG

88

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,hospital, and fire department near your telephone.


PN=14

Safety

00017

TX03679,00016F2 –19–25JAN07–1/1

Use Steps and Handholds Correctly

T13

3468

–UN

–30A

UG

00

Prevent falls by facing the machine when you get on andoff. Maintain 3-point contact with steps and handrails.Never use machine controls as handholds.

Use extra care when mud, snow, or moisture presentslippery conditions. Keep steps clean and free of greaseor oil. Never jump when exiting machine. Never mount ordismount a moving machine.

TX03679,0001799 –19–03JAN07–1/1

Start Only From Operator’s Seat

T13

3715

–UN

–07S

EP

00Avoid unexpected machine movement. Start engine onlywhile sitting in operator’s seat. Ensure all controls andworking tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do notattempt to start engine by shorting across the startersolenoid terminals.

TX03679,00016DD –19–10JAN07–1/1

Use and Maintain Seat Belt

T13

3716

–19–

14S

EP

00Use seat belt when operating machine. Remember tofasten seat belt when loading and unloading from trucksand during other uses.

Examine seat belt frequently. Be sure webbing is not cutor torn. Replace seat belt immediately if any part isdamaged or does not function properly.

The complete seat belt assembly should be replacedevery three years, regardless of appearance.


PN=15

Safety

0001

8

DW90712,00002BF –19–26OCT06–1/1

Prevent Unintended Machine Movement

T21

6779

–UN

–22N

OV

05

Be careful not to accidentally actuate control levers whenco-workers are present. Pull pilot control shutoff lever tolocked position during work interruptions. Pull pilot controlshutoff lever to locked position and stop engine beforeallowing anyone to approach machine.

Always lower work equipment to the ground and pull pilotcontrol shutoff lever to locked position before standing upor leaving the operator’s seat. Stop engine before exiting.


PN=16

Safety

00019

TX03679,0001748 –19–13DEC07–1/1

Avoid Work Site Hazards

T13

4986

–UN

–31O

CT

00T

1336

50–U

N–2

7SE

P00

T13

3549

–UN

–24A

UG

00

Avoid contact with gas lines, buried cables and waterlines. Call utility line location services to identify allunderground utilities before you dig.

Prepare work site properly. Avoid operating nearstructures or objects that could fall onto the machine.Clear away debris that could move unexpectedly if runover.

Avoid boom or arm contact with overhead obstaclesor overhead electrical lines. Never move any part ofmachine or load closer than 3 m (10 ft) plus twice the lineinsulator length to overhead wires.

Keep bystanders clear at all times. Use barricades or asignal person to keep vehicles and pedestrians away. Usea signal person if moving machine in congested areas orwhere visibility is restricted. Always keep signal person inview. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient tosupport machine. When working close to an excavation,position travel motors away from the hole.

Reduce machine speed when operating with tool on ornear ground when obstacles may be hidden (e.g., duringsnow removal or clearing mud, dirt, etc). At high speeds,hitting obstacles (rocks, uneven concrete or manholes)can cause a sudden stop. Always wear your seat belt.

TX03679,0001726 –19–03JAN07–1/1

Keep Riders Off Machine

T72

73A

H–U

N–0

8JU

N90

Only allow operator on machine.

Riders are subject to injury. They may fall from machine,be caught between machine parts, or be struck by foreignobjects.

Riders may obstruct operator’s view or impair his ability tooperate machine safely.


PN=17

Safety

000110

TX03679,00016F3 –19–03JAN07–1/1

Avoid Backover Accidents

T13

3548

–UN

–24A

UG

00

Before moving machine, be sure all persons are clearof both travel and swing paths. Turn around and lookdirectly for best visibility. Use mirrors to assist in checkingall around machine. Keep windows and mirrors clean,adjusted, and in good repair.

Be certain travel alarm is working properly.

Use a signal person when backing if view isobstructed or when in close quarters. Keep signalperson in view at all times. Use prearranged hand signalsto communicate.

TX03679,00016DF –19–03JAN07–1/1

Avoid Machine Tip Over

T13

3716

–19–

14S

EP

00T

1335

45–U

N–1

5SE

P00

T13

3803

–UN

–27S

EP

00

Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely tojump clear and the machine may crush you.

Load and unload from trucks or trailers carefully. Besure truck is wide enough and on a firm level surface. Useloading ramps and attach them properly to truck bed.Avoid trucks with steel beds because tracks slip moreeasily on steel.

Be careful on slopes. Use extra care on soft, rocky orfrozen ground. Machine may slip sideways in theseconditions. When traveling up or down slopes, keep thebucket on uphill side and just above ground level.

Be careful with heavy loads. Using oversize buckets orlifting heavy objects reduces machine stability. Extendinga heavy load or swinging it over side of undercarriagemay cause machine to tip.

Ensure solid footing. Use extra care when operatingnear banks or excavations that may cave-in and causemachine to tip or fall.


PN=18

Safety

000111

TX03679,00016E1 –19–24SEP07–1/1

Use Special Care When Lifting Objects

T13

3839

–UN

–27S

EP

00

Never use this machine to lift people.

Never lift a load above another person. Keep bystandersclear of all areas where a load might fall if it breaks free.Do not leave the seat when there is a raised load.

Do not exceed lift capacity limits posted on machine andin this manual. Extending heavy loads too far or swingingover undercarriage side may cause machine to tip over.

Use proper rigging to attach and stabilize loads. Be sureslings or chains have adequate capacity and are in goodcondition. Use tether lines to guide loads and prearrangedhand signals to communicate with coworkers.

TX03679,00016F0 –19–12FEB07–1/1

Add and Operate Attachments Safely

Always verify compatibility of attachments by contactingyour authorized dealer. Adding unapproved attachmentsmay affect machine stability or reliability and may create ahazard for others near the machine.

Ensure that a qualified person is involved in attachmentinstallation. Add guards to machine if operator protectionis required or recommended. Verify that all connectionsare secure and attachment responds properly to controls.

Carefully read attachment manual and follow allinstructions and warnings. In an area free of bystandersand obstructions, carefully operate attachment to learn itscharacteristics and range of motion.


PN=19

Safety

000112

TX03679,00016E9 –19–03JAN07–1/1

Park and Prepare for Service Safely

T13

3332

–19–

14D

EC

01T

S22

9–U

N–2

3AU

G88

Warn others of service work. Always park and prepareyour machine for service or repair properly.

• Park machine on a level surface and lower equipmentand attachments to the ground.

• Place pilot shutoff lever in “lock” position. Stop engineand remove key.

• Attach a “Do Not Operate” tag in an obvious place inthe operator’s station.

Securely support machine or attachment before workingunder it.

• Do not support machine with boom, arm, or otherhydraulically actuated attachments.

• Do not support machine with cinder blocks or woodenpieces that may crumble or crush.

• Do not support machine with a single jack or otherdevices that may slip out of place.

Understand service procedures before beginning repairs.Keep service area clean and dry. Use two peoplewhenever the engine must be running for service work.

DX,RCAP –19–04JUN90–1/1

Service Cooling System SafelyT

S28

1–U

N–2

3AU

G88

Explosive release of fluids from pressurized coolingsystem can cause serious burns.

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


PN=20

Safety

000113

DX,PAINT –19–24JUL02–1/1

Remove Paint Before Welding or Heating

TS

220

–UN

–23A

UG

88

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heatedby welding, soldering, or using a torch.

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from areato be affected by heating. If paint cannot be removed,wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust.Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper withsoap and water before welding. Remove solvent orpaint stripper containers and other flammable materialfrom area. Allow fumes to disperse at least 15 minutesbefore welding or heating.

Do not use a chlorinated solvent in areas where weldingwill take place.

Do all work in an area that is well ventilated to carry toxicfumes and dust away.

Dispose of paint and solvent properly.


PN=21

Safety

000114

TX03679,00016D5 –19–12SEP07–1/1

Make Welding Repairs Safely

T13

3547

–UN

–31A

UG

00

IMPORTANT: Disable electrical power before welding.Turn off main battery switch ordisconnect positive battery cable.Separate harness connectors to engineand vehicle microprocessors.

Avoid welding or heating near pressurized fluid lines.Flammable spray may result and cause severe burns ifpressurized lines fail as a result of heating. Do not let heatgo beyond work area to nearby pressurized lines.

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 protectionand protective equipment when welding.

TX03679,0001745 –19–17JUL07–1/1

Drive Metal Pins Safely

T13

3738

–UN

–14S

EP

00Always wear protective goggles or safety glasses andother protective equipment before striking hardened parts.Hammering hardened metal parts such as pins andbucket teeth may dislodge chips at high velocity.

Use a soft hammer or a brass bar between hammer andobject to prevent chipping.


PN=22

Group 0003Torque Values

0000031

OUT3035,TORQUE2 –19–22MAR06–1/1

Metric Bolt and Cap Screw Torque Values

TO

RQ

2–U

N–0

7SE

P99

Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings

METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Thread Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb

Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (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)

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)a "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.b "Dry" means plain or zinc plated without any lubrication.

Fasteners should be replaced with the same or higher property class.CAUTION: Use only metric tools on metric hardware. If higher property class fasteners are used, these should only beOther tools may not fit properly. Tool may slip and tightened to the strength of the original.cause injury.

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

DO NOT use these values if a different torque value or tightening tightening.procedure is given for a specific application. Torque values listed arefor general use only. Check tightness of fasteners periodically. 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,Shear bolts are designed to fail under predetermined loads. Always not to the bolt head. Tighten toothed or serrated-type lock nuts to thereplace shear bolts with identical property class. full torque value.


PN=23

Torque Values

000003

2

04T,90,M170 –19–29SEP99–1/2

Additional Metric Cap Screw Torque Values

T68

73A

A–U

N–1

8OC

T88

T68

73A

B–U

N–1

8OC

T88

T68

73A

C–U

N–1

8OC

T88

CAUTION: Use only metric tools on metrichardware. Other tools may not fit properly. Theymay slip and cause injury.

Check tightness of cap screws periodically. Torque valueslisted are for general use only. Do not use these values ifa different torque value or tightening procedure is listedfor a specific application.

Shear bolts are designed to fail under predeterminedloads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or highergrade. If higher grade fasteners are used, these shouldonly be tightened to the strength of the original.

Make sure fastener threads are clean and you properlystart thread engagement. This will prevent them fromfailing when tightening.

Tighten cap screws having lock nuts to approximately 50percent of amount shown in chart.

Continued on next page


PN=24

Torque Values

0000033

04T,90,M170 –19–29SEP99–2/2

METRIC CAP SCREW TORQUE VALUESa

T-Bolt H-Bolt M-Bolt

NominalDia N•m lb-ft N•m lb-ft N•m lb-ft

8 29 21 20 15 10 7

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 687aTorque tolerance is ±10%.


PN=25

Torque Values

000003

4

OUT3035,TORQUE1 –19–14JAN04–1/1

Unified Inch Bolt and Cap Screw Torque Values

TO

RQ

1A–U

N–2

7SE

P99

Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified

Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2

Thread Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc

Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)

1/4 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)

1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)

1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)

1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)

1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)

1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)a Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,and for all other types of bolts and screws of any length.b "Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.c "Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly startprocedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing whenfor general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximatelyreplace shear bolts with identical grade. 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 theFasteners should be replaced with the same or higher grade. If full torque value.higher grade fasteners are used, these should only be tightened tothe strength of the original.


PN=26

Torque Values

0000035

T82,BHMA,EL –19–29SEP99–1/1

Service Recommendations for 37° Flare and30° Cone Seat Connectors

T62

34A

C–U

N–1

8OC

T88

1. Inspect flare and flare seat. They must be free of dirtor obvious defects.

2. Defects in tube flare cannot be repaired.Overtightening a defective flared fitting will not stopleaks.

3. Align tube with fitting before attempting to start nut.

4. Lubricate male threads with hydraulic fluid or petroleumjelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on torquechart. Do not allow hoses to twist when tighteningfittings.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft

3/8 - 24 UNF 8 6

7/16 - 20 UNF 12 9

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%.


PN=27

Torque Values

000003

6

04T,90,K66 –19–29SEP99–1/2

Service Recommendations for O-Ring BossFittings

T62

43A

E–U

N–1

8OC

T88

Straight Fitting

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

2. Lubricate O-ring with petroleum jelly. Place electricaltape over threads to protect O-ring. Slide O-ring overtape and into O-ring groove of fitting. Remove tape.

3. Tighten fitting to torque value shown on chart.



PN=28

Torque Values

0000037

04T,90,K66 –19–29SEP99–2/2

T65

20A

B–U

N–1

8OC

T88

Angle Fitting

1. Back-off lock nut (A) and back-up washer (B)completely to head-end (C) of fitting.

2. Turn fitting into threaded boss until back-up washercontacts face of boss.

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

NOTE: Do not allow hoses to twist when tighteningfittings.

4. Hold fitting head-end with a wrench and tighten locknutand back-up washer to proper torque value.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft

3/8-24 UNF 8 6

7/16-20 UNF 12 9

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%.


PN=29

Torque Values

000003

8

OUT3035,0000353 –19–14JAN04–1/2

O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators

T19

6315

–UN

–17N

OV

03

O-Ring Boss Straight and Adjustable Fittings

1—Straight Fitting 3—Stud End 5—Hex Nut 6—Backup Washer2—O-Ring 4—Adjustable Fitting

O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUDEND NUT WITH METRIC THREAD IN ALUMINUM HOUSINGTORQUE VALUES—Tolerance is ± 10% unless otherwise

specified

Thread Size Hex Nut Sizemm mm N•m (lb-ft)

M12 x 1.5 17 39 (29)

M14 x 1.5 19 39 (29)

M16 x 1.5 22 55 (41)

M22 x 1.5 27 75 (55)

M27 x 2 32 110 (81)

M30 x 2 36 141 (104)

M33 x 2 41 165 (122)

M38 x 2 46 165 (122)

M42 x 2 50 275 (203)



PN=30

Torque Values

0000039

OUT3035,0000353 –19–14JAN04–2/2

O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUDEND NUT WITH INCH THREAD IN ALUMINUM HOUSINGTORQUE VALUES—Tolerance is ± 10% unless otherwise

specified

Thread Sizein. N•m (lb-ft)

1/8 —

1/4 28 (20)

3/8 39 (29)

1/2 75 (55)

3/4 126 (93)

1 165 (122)

1-1/8 —

1-1/4 259 (191)

1-3/8 —

1-1/2 330 (243)

1-3/4 —

2 —

O-RING BOSS PLUG STUD END WITH INCH THREAD INALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10%

unless otherwise specified

Thread Sizein. N•m (lb-ft)

1/8 7.8 (5.80)

1/4 11.8 (8.70)

3/8 23 (17)

1/2 39 (29)

3/4 55 (41)

1 86 (64)

1-1/4 126 (93)

1-1/2 157 (116)

2 204 (150)

1. Inspect fitting and O-ring boss sealing surfaces andthe O-ring. They must be free of dirt, scratches,nicks, or burrs. O-ring must be free of dirt, cuts,cracks, swelling or flatten condition.

2. Back the stud end hex nut (5) off as far as possible.Push backup washer (6) towards the nut to fullyexpose the turn down section of stud end. Washermust fit turned down section and not be too loose

3. Wrap electrical tape over threads to protect O-ring.Slide O-ring over the tape into turned down section.Remove tape. Apply hydraulic oil to the threads ofstud end, turned down section, and O-ring.

4. Turn fitting into the boss by hand until face of nut orbackup washer squeezes O-ring into the seat andcontacts face of boss. Loosen an adjustable fittingno more than one turn for alignment.

5. Tighten straight fitting or hex nut to the torque valuegiven. Hold body of adjustable fitting using asecond wrench when tightening hex nut.


PN=31

Torque Values

000003

10

04T,90,M171 –19–28JAN92–1/1

Service Recommendations For FlaredConnections—Straight or Tapered Threads

T68

73A

E–U

N–1

8OC

T88

Straight Thread

T68

73A

D–U

N–1

8OC

T88

Tapered Thread

1. Inspect flare and flare seat. They must be free of dirtor obvious defects.

2. Defects in the tube flare cannot be repaired.Overtightening a defective flared fitting will not stopleaks.

3. Align the tube with the fitting before attempting to startthe nut.

4. Lubricate the male threads with hydraulic fluid orpetroleum jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tighteningfittings.

TORQUE CHART a

Straight Thread b Tapered Thread

ThreadSize N•m lb-ft N•m lb-ft

1/8 15 11

1/4 20 15 45 33

3/8 29 21 69 51

1/2 49 36 93 69

3/4 69 51 176 130

1 157 116 343 253

1-1/2 196 145 539 398

2 255 188 588 434aTorque tolerance is ±10%.bWith seat face.

NOTE: If female thread is cast iron (control valves, brakevalves motors, etc.), torque must be reducedapproximately 10%.


PN=32

Torque Values

00000311

04T,90,K67 –19–02MAR00–1/1

Service Recommendations For Flat Face O-Ring Seal Fittings

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

2. Lubricate O-rings and install into grove usingpetroleum jelly to hold in place.

3. Index angle fittings and tighten by hand pressingjoint together to insure O-ring remains in place.

4. Tighten fitting or nut to torque value shown on thechart. Do not allow hoses to twist when tightening

fittings, use backup wrench on straight hosecouplings.

IMPORTANT: Tighten fittings to 150% of listedtorque value if indexing is necessaryor if fitting is attached to anactuating devise.

Tighten fittings to 50% of listedtorque value if used in aluminumhousing.

FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut

mm in. in. N•m lb-ft N•m lb-ft

6.35 0.250 9/16-18 16 12 12 9

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 Straight Fitting or Locknut Toque

Inch Inch Inch N•m lb-ft

3/8-24 5/8 9/16 12 9

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.


PN=33

Torque Values

000003

12

OUT3035,0000420 –19–14JAN04–1/2

O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High PressureService Recommendations

E

A BDC

EFH

G

F

H70

406

–UN

–12D

EC

01

A—90° Swivel Elbow and Tube C—Stud Straight and Tube Nut E—Stud End G—Swivel NutNut D—Bulkhead Union and Nut F—Tube Nut H—Hex Nut

B—90° Adjustable Stud Elbow

O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified

Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut

Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size TorqueOD

mm Dash Size mm (in.) in. in. N•m (lb-ft) in. N•m (lb-ft)

5 -3 4.78 (0.188) — — — — —

6 -4 6.35 (0.250) 9/16-18 11/16 24 (18) 13/16 32 (24)

8 -5 7.92 (0.312) — — — — —

10 -6 9.53 (0.375) 11/16-16 13/16 37 (27) 1 42 (31)

12 -8 12.70 (0.500) 13/16-16 15/16 75 (55) 1-1/8 93 (69)

16 -10 15.88 (0.625) 1-14 1-1/8 103 (76) 1-5/16 118 (87)

20 -12 19.05 (0.750) 1-3/16-12 1-3/8 152 (112) 1-1/2 175 (129)

22 -14 22.23 (0.875) 1-3/16-12 — 152 (112) — 175 (129)

25 -16 25.40 (1.000) 1-7/16-12 1-5/8 214 (158) 1-3/4 247 (182)

32 -20 31.75 (1.250) 1-11/16-12 1-7/8 286 (211) 2 328 (242)

38 -24 38.10 (1.500) 2-12 2-1/4 326 (240) 2-3/8 374 (276)



PN=34

Torque Values

00000313

OUT3035,0000420 –19–14JAN04–2/2

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified

Thread Size Straight Hex Sizea Adjustable Nut Hex Size Steel or Gray Iron Torque

in. in. in. N•m (lb-ft)

3/8-24 5/8 9/16 18 (13)

7/16-20 5/8 5/8 24 (18)

1/2-20 3/4 11/16 30 (22)

9/16-18 3/4 3/4 37 (27)

3/4-16 7/8 15/16 75 (55)

7/8-14 1-1/16 1-1/16 103 (76)

1-1/16-12 1-1/4 1-3/8 177 (131)

1-3/16-12 1-3/8 1-1/2 231 (170)

1-5/16-12 1-1/2 1-5/8 270 (199)

1-5/8-12 1-3/4 1-7/8 286 (211)

1-7/8-12 2-1/8 2-1/8 326 (240)a Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces andthe O-rings. They must be free of dirt, scratches,nicks, and burrs. O-ring must be free of dirt, cuts,cracks, swelling or flatten condition.

2. Back the stud end hex nut off as far as possible.Push backup washer towards the nut to fullyexpose the turn down section. Washer must fitturned down section and not be too loose

3. Lubricate O-rings using a thin film of clean hydraulicoil or as needed, petroleum jelly to hold O-ring inplace.

Install O-ring into groove making sure it is seated atthe bottom. Excess petroleum jelly will preventseating of O-ring and cause it to pop out.

To protect an O-ring from threads, wrap electricaltape over the threads. Slide O-ring over the tapeinto the turned down section. Remove the tape.

4. Turn fitting into the boss by hand until face of nut orwasher squeezes the O-ring into the seat andcontacts face of boss. Loosen adjustable fittings nomore than one turn for alignment.

Hold connections together while tightening nut toensure O-ring remains in place.

5. Tighten fitting or nut to torque value shown. Use asecond wrench to hold the fitting in position or tokeep hose from twisting while tightening nut.


PN=35

Torque Values

000003

14

OUT3035,0000366 –19–14JAN04–1/2

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard PressureService Recommendations

1 2 3 4

6

7

10

11

8

98 11

10

6

10

5

811

T196337 T19

6337

–UN

–18N

OV

03

1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove3—Stud Straight 6—Tube Nut 9—Hex Nut

O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa(275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified



mm Dash Size mm (in.) in. mm N•m (lb-ft) mm N•m (lb-ft)

4 -2 3.18 (0.125) — — — — —

5 -3 4.78 (0.188) — — — — —

6 -4 6.35 (0.250) 9/16-18 17 16 (12) 22 32 (24)

8 -5 7.92 (0.312) — — — — —

10 -6 9.53 (0.375) 11/16-16 22 24 (18) 27 42 (31)

12 -8 12.70 (0.500) 13/16-16 24 50 (37) 30 93 (69)

16 -10 15.88 (0.625 1-14 30 69 (51) 36 118 (87)

20 -12 19.05 (0.750) 1-3/16-12 36 102 (75) 41 175 (129)

22 -14 22.23 (0.875) 1-3/16-12 36 102 (75) 41 175 (129)

25 -16 25.40 (1.000) 1-7/16-12 41 142 (105) 46 247 (182)

28 — — — — — — —

32 -20 31.75 (1.250) 1-11/16-12 50 190 (140) 50 328 (242)

38 -24 38.10 (1.500) 2-12 60 217 (160) 60 374 (276)

50 -32 50.80 (2.000) — — — — —



PN=36

Torque Values

00000315

OUT3035,0000366 –19–14JAN04–2/2

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified

Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Steel or Gray Iron Torque Aluminum or BrassSize Torque

mm. mm mm N•m (lb-ft) N•m (lb-ft)

M8 x 1 12 12 8 (6) 5 (4)

M10 x 1 14 14 15 (11) 10 (7)

M12 x 1.5 17 17 25 (18) 17 (12)

M14 x 1.5 19 19 40 (30) 27 (20)

M16 x 1.5 22 22 45 (33) 30 (22)

M18 x 1.5 24 24 50 (37) 33 (25)

M22 x 1.5 27 27 69 (51) 46 (34)

M27 x 2 32 32 100 (74) 67 (49)

M30 x 2 36 36 130 (96) 87 (64)

M33 x 2 41 41 160 (118) 107 (79)

M38 x 2 46 46 176 (130) 117 (87)

M42 x 2 50 50 210 (155) 140 (103)

M48 x 2 55 55 260 (192) 173 (128)

M60 x 2 65 65 315 (232) 210 (155)a Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.b Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.










PN=37

Torque Values

000003

16

OUT3035,0000421 –19–14JAN04–1/2

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure ServiceRecommendations

1 2 3 4

6

7

10

11

8

98 11

10

6

10

5

811

T196337 T19

6337

–UN

–18N

OV

03

1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove3—Stud Straight 6—Tube Nut 9—Hex Nut

O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified



mm Dash Size mm (in.) in. mm N•m (lb-ft) mm N•m (lb-ft)

4 -2 3.18 (0.125) — — — — —

5 -3 4.78 (0.188) — — — — —

6 -4 6.35 (0.250) 9/16-18 17 24 (18) 22 32 (24)

8 -5 7.92 (0.312) — — — — —

10 -6 9.53 (0.375) 11/16-16 22 37 (27) 27 42 (31)

12 -8 12.70 (0.500) 13/16-16 24 75 (55) 30 93 (69)

16 -10 15.88 (0.625) 1-14 30 103 (76) 36 118 (87)

20 -12 19.05 (0.750) 1-3/16-12 36 152 (112) 41 175 (129)

22 -14 22.23 (0.875) 1-3/16-12 36 152 (112) 41 175 (129)

25 -16 25.40 (1.000) 1-7/16-12 41 214 (158) 46 247 (182)

28 — — — — — — —

32 -20 31.75 (1.250) 1-11/16-12 — 286 (211) 50 328 (242)

38 -24 38.10 (1.500) 2-12 — 326 (240) 60 374 (276)



PN=38

Torque Values

00000317

OUT3035,0000421 –19–14JAN04–2/2

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600KPA (275.8 BAR) (4,000 PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified

Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Size Steel or Gray Iron Torque

mm. mm mm N•m (lb-ft)

M8 x 1 12 12 8 (6)

M10 x 1 14 14 15 (11)

M12 x 1.5 17 17 35 (26)

M14 x 1.5 19 19 45 (33)

M16 x 1.5 22 22 55 (41)

M18 x 1.5 24 24 70 (52)

M22 x 1.5 27 27 100 (74)

M27 x 2 32 32 170 (125)

M30 x 2 36 36 215 159)

M33 x 2 41 41 260 (192)

M38 x 2 46 46 320 (236)

M42 x 2 50 50 360 (266)

M48 x 2 55 55 420 (310)a Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.b Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.










PN=39

Torque Values

000003

18

04T,90,K175 –19–29SEP99–1/1

Service Recommendations for Metric Series Four Bolt Flange Fitting

T68

90B

B–U

N–0

1MA

R90

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

2. Install the correct O-ring (and backup washer ifrequired) into groove using petroleum jelly to hold itin place.

3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to the port. Hand tighten cap screwsto hold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line incenter of flange and install four cap screws. Flangemust be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.

5. After components are properly positioned and capscrews are hand tightened, tighten one cap screw,

then tighten the diagonally opposite cap screw.Tighten two remaining cap screws. Tighten all capscrews as specified in the chart below.

DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.

TORQUE CHARTa

Threadb N•m lb-ft

M6 12 9

M8 30 22

M10 57 42

M12 95 70

M14 157 116

M16 217 160

M18 334 246

M20 421 318aTolerance ± 10%. The torques given are enough for the givensize connection with the recommended working pressure.Increasing cap screw torque beyond these amounts will result inflange and cap screw bending and connection failures.bMetric standard thread.


PN=40

Torque Values

00000319

04T,90,K174 –19–01AUG94–1/1

Service Recommendations For Inch Series Four Bolt Flange Fittings

T68

90B

B–U

N–0

1MA

R90


1. Clean sealing surfaces (A). Inspect. Scratchescause leaks. Roughness causes seal wear.Out-of-flat causes seal extrusion. If defects cannotbe polished out, replace component.

2. Install O-ring (and backup washer if required) intogroove using petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to port. Hand tighten cap screws tohold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line incenter of flange and install cap screws. Flangemust be centrally located on port. Hand tighten capscrews to hold flange in place. Do not pinch O-ring.

5. Tighten one cap screw, then tighten the diagonallyopposite cap screw. Tighten two remaining capscrews. Tighten all cap screws as specified in thechart below.

DO NOT use air wrenches. DO NOT tighten onecap screw fully before tightening the others. DONOT over tighten.

TORQUE CHART

N•m lb-ft

Nominal Cap ScrewFlange Size

Size Min Max Min Max

1/2 5/16-18 20 31 15 23UNC

3/4 3/8-16 UNC 28 54 21 40

1 3/8-16 UNC 37 54 27 40

1-1/4 7/16-14 47 85 35 63UNC

1-1/2 1/2-13 UNC 62 131 46 97

2 1/2-13 UNC 73 131 54 97

2-1/2 1/2-13 UNC 107 131 79 97

3 5/8-11 UNC 158 264 117 195

3-1/2 5/8-11 UNC 158 264 117 195

4 5/8-11 UNC 158 264 117 195

5 5/8-11 UNC 158 264 117 195


PN=41

Torque Values

000003

20

OUT3035,0000422 –19–14JAN04–1/1

Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations

T68

90B

B–U

N–0

1MA

R90


INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa(414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES—

Tolerance is ± 10% unless otherwise specified

Nominal Cap Screw Sizea Min—Max TorqueFlange Size

in. in. N•m (lb-ft)b

1/2 5/16-18 UNC 20—31 (15—23)

3/4 3/8-16 UNC 34—54 (25—40)

1 7/16-14 UNC 57—85 (42—63)

1-1/4 1/2-13 UNC 85—131 (63—97)

1-1/2 5/8-11 UNC 159—264 (117—195)

2 3/4-10 UNC 271—468 (200—345)a JDM A17D, SAE Grade 5 or better cap screws with platedhardware.Lock washers are permissible but not recommended.b Minimum torques given are enough for the given size connectionwith the recommended working pressure. Torques can beincreased to the maximum shown for each cap screw size ifdesired. Increasing cap screw torque beyond the maximum willresult in flange and cap screw bending and connection failures.

1. Clean sealing surfaces (A). Inspect. Scratches,nicks, and burrs cause leaks. Roughness causesO-ring wear. Out-of-flat causes O-ring extrusion. Ifimperfection cannot be polished out, replacecomponent.

2. Install the O-ring (and backup ring, if used) intogroove. Use petroleum jelly to hold it in place.

IMPORTANT: DO NOT use air wrenches. DO NOTtighten one cap screw fully beforetightening the others. DO NOT overtighten.

3. Split flange: Loosely assemble split flange (B)halves. Make sure split is centrally located andperpendicular to port. Hand tighten cap screws tohold flange halves and line in place. Do not pinchO-ring (C).

Single piece flange (D): Make sure flange iscentrally located on port and line is centered inflange. Install the cap screws. Hand tighten capscrews to hold flange and line in place. Do notpinch O-ring.

4. Tighten one cap screw and then the diagonallyopposite cap screw. Tighten the two remaining capscrews. Tighten cap screws within the specifiedtorque values.


PN=42

Section 01Tracks

Contents 01

Page

Group 0130—Track SystemTrack Roller Remove and Install . . . . . . . . . .01-0130-1Track Roller Disassemble and Assemble . . .01-0130-3Track Roller Pressure Test . . . . . . . . . . . . . .01-0130-5Track Carrier Roller Remove and Install . . . .01-0130-6Metal Face Seals Repair . . . . . . . . . . . . . . . .01-0130-8Track Shoe Remove and Install . . . . . . . . .01-0130-11Track Chain Remove and Install . . . . . . . . .01-0130-11Track Chain Disassemble and Assemble . .01-0130-16Track Chain Repair . . . . . . . . . . . . . . . . . . .01-0130-17Sprocket Remove and Install. . . . . . . . . . . .01-0130-19Front Idler Remove and Install . . . . . . . . . .01-0130-20Front Idler Disassemble and Assemble . . . .01-0130-21Track Adjuster and Recoil Spring Remove

and Install . . . . . . . . . . . . . . . . . . . . . . . .01-0130-23Track Adjuster and Recoil Spring

Disassemble and Assemble. . . . . . . . . . .01-0130-25Track Adjuster Cylinder Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-30


PN=1

Contents

01


PN=2

Group 0130Track System

0101301

OUO6046,00022F1 –19–03APR07–1/3

Track Roller Remove and Install

1. Swing upperstructure 90° and lower bucket to raisetrack off ground. Keep angle between boom and arm90—110° and position round side of bucket on ground.

CAUTION: Prevent possible injury fromunexpected machine movement. Position shopstands under frame to support machine whileremoving lower track roller.

SpecificationMachine—Weight (Approximate) 18 151 kg................................................

39 980 lb

2. Put shop stands under machine.

OUO6046,00022F1 –19–03APR07–2/3

T73

96D

Z–U

N–2

8NO

V90

A—Grease FittingB—ValveC—Bleed Hole

CAUTION: Prevent possible injury from highpressure grease. Do not remove grease fitting(A) from valve (B).

3. Loosen valve (B) one to two turns to release greasethrough bleed hole (C).



PN=45

Track System

010130

2

OUO6046,00022F1 –19–03APR07–3/3

T65

85T

N–U

N–2

5OC

T88

A—Cap Screw (4 used)B—Track Roller

CAUTION: Heavy component; use appropriatelifting device.

SpecificationTrack Roller—Weight 35 kg........................................................................

77 lb

4. Attach appropriate lifting device to track roller (B).Remove cap screws (A) and track roller (B).

5. Measure track roller tread diameter. See 160DLCTrack Roller Tread Diameter. (SP326 UndercarriageAppraisal Manual.)

6. Repair or replace parts as necessary. See Track RollerDisassemble and Assemble. (Group 0130.)

7. Install track roller and tighten cap screws tospecification.

SpecificationRoller-to-Frame Cap Screw—Torque 460 N•m..........................................................................................

340 lb-ft

8. If equipped, install track roller guard and tighten capscrews to specification.

SpecificationTrack Roller Guard Cap Screw—Torque 460 N•m..........................................................................................

340 lb-ft

9. Tighten valve on track adjuster to specification.

SpecificationTrack Adjuster Valve—Torque 88 N•m.......................................................

65 lb-ft

10. Check and adjust track sag. See Check and AdjustTrack Sag. (Operator’s Manual.)


PN=46

Track System

0101303

OUO6046,00022F2 –19–19APR07–1/2

Track Roller Disassemble and Assemble

T83

10A

H–U

N–2

1SE

P94

A—Plug (2 used) C—Pin (2 used) E—Metal Face Seal (2 used) G—RollerB—Bracket (2 used) D—O-Ring (2 used) F—Bushing (2 used) H—Axle

1. Remove plug (A) and drain oil.

2. Remove pin (C).

3. Remove bracket (B) using a bearing pullerattachment and adapters from puller set.

IMPORTANT: Metal face seals can be reused ifthey are not worn or damaged. Aused seal must be kept together as aset because of wear patterns on sealring face.

4. Remove metal face seal (E) from roller and bracket.Keep seal rings together as a matched set with sealring faces together to protect surfaces.

5. Inspect metal face seals. See Metal Face SealsRepair. (Group 0130.)

6. Remove axle (H) from roller.

NOTE: Only remove bushings if replacement isnecessary.

7. Remove bushings (F) using a 2-jaw puller andadapters from puller set.

8. Replace parts as necessary.

Apply a thin film of oil to bushings (F) and install.

IMPORTANT: O-rings and seat surfaces forO-rings must be clean, dry, and oilfree so O-rings do not slip whenroller is turning.

9. Thoroughly clean O-rings and seat surfaces inbrackets (B) and in seal rings using volatile,non-petroleum base solvent and lint-free tissues.

10. Install seals (E) in brackets (B) and in roller (G).Apply equal pressure with fingers at four equallyspaced points on seal face. Seal must “pop” downinto place so O-ring is tight against seal bore. Avolatile, non-petroleum base solvent or talcumpowder may be used as a lubricant.


PN=47


Track System

010130

4

OUO6046,00022F2 –19–19APR07–2/2

11. Wipe finger prints and foreign material off seal ringface using clean oil and lint-free tissues. Apply athin film of oil to each seal ring face.

12. Install axle (H) to bracket (B).

13. Install roller (G) onto axle (H).

14. Install opposite side bracket (B) on rollerassembly.

15. Apply TY24811NEVER-SEEZ anti-seize lubricantor equivalent to pins (C). Install pins (C) even withflat surface of brackets (B).

16. Fill roller to specification.

SpecificationLower Track Roller—Capacity 260 mL.................................................

8.8 oz

17. Apply PM37509 Cure Primer and PM37398 PipeSealant to threads of plug. Install and tighten plug.

SpecificationPlug—Torque 30 N•m...........................................................................

22 lb-ft

NEVER-SEEZ is a trademark of Bostik Findley, Inc.


PN=48

Track System

0101305

OUO6046,00022F3 –19–19APR07–1/1

Track Roller Pressure Test

T10

9691

B–U

N–0

2JU

N97

A—Plug, Barbed Adapter and ConnectorB—JT03001 Tee Fitting 7/16-20 M 37° x 7/16-20 F

37° SW x 7/16-20 M 37°C—Hose (2 used)D—Pressure GaugeE—Needle ValveF—Air Pressure Regulator

1. Hold shaft and turn shell of roller several turns to seatmetal face seals.

2. Remove the drain plug.

NOTE: Plug, barbed adapter, and connector (A) are fromleak detector kit D05361ST.

3. Install parts (A—F).

4. Tighten plug. Slowly pressurize oil cavity to testpressure specification.

SpecificationTrack Roller Oil Cavity—Pressure 110 ± 28 kPa.......................................

16 ± 4 psi

5. Close valve. Wait for 30 seconds. Check for oil leaksor pressure decrease.

6. If leakage, disassemble roller and replace parts asnecessary. See Track Roller Disassemble andAssemble. (Group 0130.)

7. Apply PM37509 Cure Primer and PM37398 PipeSealant to threads of plug. Install and tighten plug tospecification.

SpecificationPlug—Torque 30 N•m..................................................................................

22 lb-ft


PN=49

Track System

010130

6

OUO6046,00022F4 –19–05MAR07–1/3

Track Carrier Roller Remove and Install

T73

96D

Z–U

N–2

8NO

V90




OUO6046,00022F4 –19–05MAR07–2/3

TX

1006

136A

–UN

–07A

PR

06

1—Track Frame2—Carrier Roller3—Track Chain4—Wood Block

2. Raise track chain (3), using a jack, enough to permitcarrier roller (2) removal.

CAUTION: Prevent accidental lowering of trackby securely supporting track before attemptingservice procedure.

3. Install wooden block (4) between track chain (3) andtrack frame (1).



PN=50

Track System

0101307

OUO6046,00022F4 –19–05MAR07–3/3

TX

1018

018A

–UN

–26J

AN

07

1—Cap Screw (4 used)2—Carrier Roller

4. Remove cap screws (1) and carrier roller (2).

5. Measure track carrier roller tread diameter. See160DLC Carrier Roller Tread Diameter. (SP326Undercarriage Appraisal Manual.)

IMPORTANT: Carrier roller replaced as assemblyonly.

6. Replace carrier roller as necessary.

SpecificationCarrier Roller—Weight 21 kg......................................................................

46 lb

7. Install carrier roller and cap screws (1).

8. Tighten carrier roller cap screws (1) to specification.

SpecificationCarrier Roller-to-Frame CapScrew—Torque 270 N•m.............................................................................

200 lb-ft

9. Remove wooden blocks and jack.

10. Tighten valve on track adjuster to specification.


65 lb-ft



PN=51

Track System

010130

8

OUO6046,00022F5 –19–05MAR07–1/4

Metal Face Seals Repair

T85

079

–UN

–24A

UG

93

A—Seal RingB—Worn Area (Shaded Area)C—Seal Ring FaceD—Outer Half of Seal Ring FaceE—Sealing Area (Dark Line)

Inspect Metal Face Seals

IMPORTANT: If seals are to be reused, keep sealrings together as a matched set withseal ring faces together. Insert a pieceof cardboard to protect surfaces.

1. Inspect for the following conditions to determine ifseals can be reused:

a. The narrow, highly polished sealing area (E) mustbe in the outer half of seal ring face (D).

b. Sealing area must be uniform and concentric withthe ID and OD of seal ring (A).

c. Sealing area must not be chipped, nicked, orscratched.

OUO6046,00022F5 –19–05MAR07–2/4

T85

080

–UN

–05D

EC

96

A—Seal RingB—Worn area (Shaded Area)C—Inner Half of Seal Ring FaceD—Sealing Area (Dark Line)

2. Illustration shows examples of worn seal rings (A).

I—Sealing area (D) is in inner half of seal ring face (C).

II—Sealing area (D) not concentric with ID and OD ofseal ring.


PN=52


Track System

0101309

OUO6046,00022F5 –19–05MAR07–3/4

T82

840

–UN

–23F

EB

89

A—Seal Face

3. Clean reusable seals by removing all foreign materialfrom seal rings, except seal face (A), using a scraperor a stiff bristled fiber brush.

4. Wash seal rings and O-rings using a volatile,non-petroleum base solvent to remove all oil.Thoroughly dry parts using a lint-free tissue.



PN=53

Track System

010130

10

OUO6046,00022F5 –19–05MAR07–4/4

TX

1018

110

–UN

–26J

AN

07T

X10

1811

2–U

N–2

6JA

N07

A—O-RingB—Mating FaceC—Ring SurfaceD—DistanceE—Distance

Assemble Metal Face Seals

IMPORTANT: If incorrectly assembled, oil leakage ordamage will occur.

1. Check that the O-ring (A) is not twisted and that it isinstalled correctly on seal ring.

2. After installing seal, check that seal ring surface (C) isparallel with seal mating face (B) by measuringdistances (D) and (E), as shown. If these distancesdiffer, correct O-ring seating.


PN=54

Track System

01013011

OUO6046,00022F6 –19–05MAR07–1/1

Track Shoe Remove and Install

T67

94A

M–U

N–2

3FE

B89

T63

52A

H–U

N–2

3FE

B89

A—Rounded EdgeB—Chamfered Edge

1. Measure grouser height. See 160DLC Three BarGrouser Height. (SP326 Undercarriage AppraisalManual.)

2. Apply a light coat of oil to cap screw threads and installshoe.

3. Install all track shoe nuts with rounded corners (A)against the link and chamfered edges (B) away fromthe link. Be sure nut is properly positioned in the linkso there is full contact between the nut and the link.

4. Tighten cap screws in pattern shown.

SpecificationShoe-to-Link Cap Screw—Torque 804 N•m...............................................

593 lb-ft

OUO6046,00022F7 –19–03APR07–1/4

Track Chain Remove and Install

1. Swing upperstructure to side. Lower boom to raisetrack off the ground.

Keep the angle between boom and arm at 90—110°with the round side of bucket on the ground.

CAUTION: Prevent possible injury fromunexpected machine movement. Put blocks orshop stands under machine frame to supportmachine while measuring track sag.

SpecificationMachine—Weight 18 151 kg.......................................................................

39 980 lb

2. Place blocks or shop stands under the machine tosupport machine.


PN=55


Track System

010130

12

OUO6046,00022F7 –19–03APR07–2/4

T73

96D

Z–U

N–2

8NO

V90






PN=56

Track System

01013013

OUO6046,00022F7 –19–03APR07–3/4

T14

3215

B–U

N–2

0JU

L01

1—Bushing (2 used)2—Master Pin3—Dimple

NOTE: Master pin (2) and master link are identified bylarge dimple (3) and snap ring on master pin.

4. Move track chain so master pin (2) is over front idler orsprocket.

5. Remove track shoe on each side of master pin. SeeTrack Shoe Remove and Install. (Group 0130.)

6. If removing chain at idler, put wooden blocks in front ofidler and under chain so chain does not fall whenmaster pin is removed.

7. Remove snap ring.

IMPORTANT: Master pin can be removed in only onedirection.

8. Remove master pin using a 50-Ton Master Pin PusherInstaller.

9. If chain was disconnected at idler, slowly operate travellever in reverse direction to remove chain from top oftrack frame.


SpecificationTracks—Weight 1180 kg.............................................................................

2602 lb

10. Remove track chain.

11. Measure track chain link, bushing, and pitch. (SeeSP326 Undercarriage Appraisal Manual.)


13. Position track chain so section on ground has pinboss on links toward rear of machine.

14. Install end of chain on sprocket and slowly turnsprocket in forward direction to pull chain across topof frame to front idler.

15. Remove stand and lower machine.


PN=57


Track System

010130

14

OUO6046,00022F7 –19–03APR07–4/4

IMPORTANT: Master pin can be installed in only onedirection.

16. Pull ends of chain together. Install master pin using50-Ton Master Pin Pusher Installer.

IMPORTANT: Replace snap ring with new one.

17. Install snap ring.

18. Install track shoe. See Track Shoe Remove andInstall. (Group 0130.)

19. Tighten valve in track adjuster to specification.


65 lb-ft



PN=58

Track System

01013015


PN=59

Track System

010130

16

OUO6046,00022F8 –19–03APR07–1/2

Track Chain Disassemble and Assemble

T16

2713

–UN

–15J

AN

03


PN=60


Track System

01013017

OUO6046,00022F8 –19–03APR07–2/2

1—Track Link (42 used) 7—Master Pin 12—Nut (172 used) 16—Master Bushing2—Master Track Link 8—Spacer (2 used) 13—Shoe (43 used) 17—Track Chain Without3—Pin (42 used) 9—Snap Ring 14—Track Link (42 used) Shoes5—Seal (84 used) 10—Cap Screw (172 used) 15—Bushing (42 used)

1. Measure track components (1—17). See 160DLCStandard Bushing Outer Diameter. (SP326Undercarriage Appraisal Manual.)

2. Turn pins (3 and 7) and bushings (15 and 16) asrequired.

3. Clean any dust or rust from surfaces of track linkpin bores, counterbores, and ends of bushings.

4. Apply grease to counterbore in track links, theseals, and ends of bushings.

5. For each joint, fill clearance between pin OD andbushing ID with grease.

6. Install seal (5) so tapered side is toward bushing.

OUO6046,00022F9 –19–05MAR07–1/4

Track Chain Repair

T58

21A

G–U

N–2

6OC

T88

A—Cut LocationsB—Broken Link

1. Remove track shoes from each side of broken linkassembly. See Track Shoe Remove and Install. (Group0130.)

IMPORTANT: When making cuts using cutting torch,be careful not to cut or gouge goodparts.

2. Cut links, bushing, and pin at points (A) to removebroken link (B).

OUO6046,00022F9 –19–05MAR07–2/4

T58

21A

H–U

N–2

6OC

T88

A—Bushing

3. Grind ends of bushing (A) even with links to make itinto a master bushing.


PN=61


Track System

010130

18

OUO6046,00022F9 –19–05MAR07–3/4

T58

21A

I–U

N–2

6OC

T88

A—Pin StubB—Hammer

4. Burn holes through center of pin stubs (A).

5. Hold a heavy hammer (B) against link while pin stub isbeing driven out.

OUO6046,00022F9 –19–05MAR07–4/4

T58

21A

J–U

N–2

4MA

Y89

A—Master PinB—SpacerC—Right LinkD—Master BushingE—Left Link

6. Install links (C and E) on master bushing (D). Checkcap screw hole spacing using a track shoe.

7. Instal spacers (B) into counterbore of links.

8. Install link assembly. Install master pins (A).

9. Install track shoes. See Track Shoe Remove andInstall. (Group 0130.)


PN=62

Track System

01013019

OUO6046,00022FA –19–19APR07–1/1

Sprocket Remove and Install

T14

5912

B–U

N–0

1FE

B02

1—Cap Screw (16 used)

IMPORTANT: Sprocket must be replaced when thetooth tips become excessively rounded,worn, or chipped to prevent excessivewear to chain. If machine is driven inone direction a majority of the time,wear will be on one side of teeth. Toextend service life, change sprocketsfrom one side of machine to the other.

1. Disconnect track chain. See Track Chain Remove andInstall. (Group 0130.)

2. Lift side of machine so sprocket teeth clear chain.


SpecificationSprocket—Weight (approximate) 46 kg......................................................

100 lb

3. Remove cap screws (1) and sprocket.

4. Apply PM37509 Cure Primer and PM37421 ThreadLock and Sealer (High Strength) to threads of capscrews (B).

5. Install sprocket and tighten cap screws (1).

SpecificationSprocket-to-Travel Gearbox CapScrew—Torque 500 N•m.............................................................................

369 lb-ft

6. Lower machine.

7. Install track chain. See Track Chain Remove andInstall. (Group 0130.)


PN=63

Track System

010130

20

OUO6046,00022FB –19–05MAR07–1/1

Front Idler Remove and Install

T68

76B

U–U

N–2

5OC

T88

A—Front Idler

1. Disconnect track chain. See See Track Chain Removeand Install. (Group 0130.)

2. Slide front idler (A) forward, using pry bar.


SpecificationFront Idle—Weight 119 kg...........................................................................

260 lb

3. Attach appropriate lifting device to front idler andremove from frame.

4. Measure front idler wear. See Front Idler FlangeHeight. (SP326 Undercarriage Appraisal Manual.)

5. Repair or replace idler as necessary. See Front IdlerDisassemble and Assemble. (Group 0130.)

6. Install front idler.

7. Connect track chain. See Track Chain Remove andInstall. (Group 0130.)


PN=64

Track System

01013021

OUO6046,00022FC –19–19APR07–1/2

Front Idler Disassemble and Assemble

T115165

A

A

E

E

H

B

BC

D

D

JI

GF

F G

T11

5165

–UN

–21A

PR

06

A—Pin (2 used) D—Drain Plug (2 used) G—O-Ring (2 used) I—YokeB—Bushing (2 used) E—Bracket (2 used) H—Axle J—Cap Screw (4 used)C—Idler F—Metal Face Seal (2 used)

1. Remove cap screws (J) and yoke (I).

2. Remove drain plug (D) and drain oil.

IMPORTANT: Metal face seals (F) can be reused ifthey are not worn or damaged. Aused seal must be kept together as aset because of wear patterns on sealring face.

IMPORTANT: Put matching marks on brackets (E)and axle (H).

3. Remove pins (A), brackets (E), O-rings (G) andmetal face seals (F).

4. Inspect metal face seals (F). See Metal Face SealsRepair. (Group 0130.) Keep seal rings together as

a matched set with seal ring faces together toprotect surfaces.

5. Remove axle (H). Inspect axle (H) and bushings (B)for scoring or excessive wear.

NOTE: Remove bushings (B) only if replacement isnecessary.

6. Remove bushing (B) using a 2-jaw puller andadapters from 17-1/2 and 30-ton puller set.

7. Apply a thin film of oil to new bushings (B). Installbushings (B) so flange is tight against shoulder ofidler (C).


PN=65


Track System

010130

22

OUO6046,00022FC –19–19APR07–2/2

8. Apply a thin layer of anti-seize lubricant orequivalent to end of axle (H) and to bore inbrackets (E).

IMPORTANT: Seat surfaces for O-rings must beclean, dry, and oil free so O-rings donot slip when idler is turning.

9. Thoroughly clean seat surfaces in idler (C),brackets (E), and seal rings using volatile,non-petroleum base solvent and lint-free tissues.

NOTE: A volatile, non-petroleum base solvent ortalcum powder may be used as a lubricant.

10. Install metal face seal (F) in bracket (E). Applyequal pressure with fingers at four equally spacedpoints on seal face. Seal must "pop" down intoplace so O-ring is tight against seal bore.

11. Wipe finger prints and foreign material off seal ringface using clean oil and lint-free tissues. Apply athin film of oil to each seal face.

NOTE: Repeat steps 12 and 13 for installing oppositeside metal face seal (F) and bracket (E) inidler.

12. Install axle (H) into idler.

13. Install O-rings (G) on axle.

14. Install brackets (E) onto axle (H).

15. Apply anti-seize lubricant or equivalent to pins (A).Install pins.

16. Add oil through plug holes on bearing brackets (E)to specification.

SpecificationFront Idler Oil—Capacity 265 mL.........................................................

8.96 oz

17. Apply PM37509 Cure Primer to threads of drainplug (D).

18. Apply PM37418 Thread Lock and Sealer (MediumStrength) to threads of plug.

19. Install and tighten plug (D) to specification.

SpecificationFront Idler Plug—Torque 30 N•m.........................................................

22 lb-ft

20. Install yoke (I). Tighten cap screws (J) tospecification.

SpecificationYoke-to-Bracket Cap Screw—Torque 206 N•m....................................................................................

150 lb-ft


PN=66

Track System

01013023

OUO6046,00022FD –19–10APR07–1/2

Track Adjuster and Recoil Spring Removeand Install

1. Remove track chain. See Track Chain Remove andInstall. (Group 0130.)

2. Remove front idler. See Front Idler Remove and Install.(Group 0130.)

CAUTION: Spring or rod may break if droppedwhile handling, transporting or disassembling.Nicks or weld craters in spring and rodassembly can cause stress concentrationresulting in a weak spot. Weak spots may resultin immediate or eventual failure creating a riskof personal injury. Put a heavy protectivecovering around spring assembly whenhandling, transporting, or disassembling trackadjuster.

A compression tool must be used fordisassembly and assembly because of theextreme preload on spring.



PN=67

Track System

010130

24

OUO6046,00022FD –19–10APR07–2/2

T65

57C

X–U

N–2

5OC

T88

A—Track Adjuster

3. Slide track adjuster (A) forward, using a pry bar.


SpecificationTrack Adjuster Cylinder andRecoil Spring—Weight 125 kg....................................................................

280 lb

4. Attach appropriate lifting device to track adjuster andremove from frame.

5. Repair or replace parts as necessary. See TrackAdjuster and Recoil Spring Disassemble andAssemble. (Group 0130.)

6. Install front idler. See Front Idler Remove and Install.(Group 0130.)

7. Install track chain. See Track Chain Remove andInstall. (Group 0130.)


PN=68

Track System

01013025

OUO6046,00022FE –19–05MAR07–1/5

Track Adjuster and Recoil SpringDisassemble and Assemble

T65

57D

Y–U

N–2

5OC

T88

A—ST4920 Track Recoil Spring Disassembly andAssembly Tool

B—NutC—Top Plate

CAUTION: Spring or rod may break if droppedwhile handling, transporting or disassembling.Nicks or weld craters in spring and rodassembly can cause stress concentrationresulting in a weak spot. Weak spots may resultin immediate or eventual failure creating a riskof personal injury. Put a heavy protectivecovering around spring assembly whenhandling, transporting, or disassembling trackadjuster.



SpecificationTrack Recoil Spring Disassemblyand Assembly Tool—Weight 225 kg...........................................................

496 lb

1. Place an 18-t (20-ton) jack on bottom of ST4920 TrackRecoil Spring Disassembly and Assembly Tool (A).Remove nuts (B) and top plate (C). See ST4920 TrackRecoil Spring Disassembly and Assembly Tool. (Group9900.)

NOTE: It is not necessary to remove the recoil spring toreplace wear ring and U-ring packing on piston.To replace O-ring in the cylinder, remove recoilspring and rod.

2. Remove nuts (B). Remove top plate (C).



PN=69

Track System

010130

26

OUO6046,00022FE –19–05MAR07–2/5

T77

20A

F–U

N–2

8AP

R92

A—Lifting StrapB—Track AdjusterC—DFT1110 Spacer


SpecificationTrack Adjuster Cylinder andRecoil Spring—Weight 125 kg....................................................................

280 lb

3. Connect appropriate lifting device to track adjuster (B)using a lifting strap (A).

4. Put track adjuster in assembly tool with cylinder end onDFT1110 Spacer (C). See DFT1110 Spacer. (Group9900.)

5. Remove lifting strap.



PN=70

Track System

01013027

OUO6046,00022FE –19–05MAR07–3/5

T77

20A

G–U

N–2

8AP

R92A—Top Plate

B—Nut (8 used)C—ValveD—NutE—Special PlugF—DFT1087 Track Recoil Spring Disassembly and

Assembly Guard Tool

6. Install DFT1087 Track Recoil Spring Disassembly andAssembly Guard Tool (F). See DFT1087 Track RecoilSpring Disassembly and Assembly Guard Tool. (Group9900.)

7. Install plate top (A) and nuts (B) with smallest openingto allow access to nut (D).

8. Extend jack ram to provide enough travel to releasespring to the approximate free length.

SpecificationRecoil Spring—Free Length 606 mm..........................................................

23.9 in.

9. Tighten nuts (B) so top plate (A) is tight againstretainer plate.

10. Remove valve (C) and special plug (E).



PN=71

Track System

010130

28

OUO6046,00022FE –19–05MAR07–4/5

T77

20A

H–U

N–2

8AP

R92

A—Top PlateB—Nut (8 used)D—NutF—DFT1087 Track Recoil Spring Disassembly and

Assembly Guard Tool

11. Raise upper half of guard tool (F). Tighten T-handles.

12. Operate jack to compress spring just enough so nut(D) can be removed.

13. Lower jack ram to release spring force.

14. Repair or replace parts as necessary. See TrackAdjuster Cylinder Disassemble and Assemble. (Group0130.)

15. Put track adjuster cylinder in assembly tool withcylinder end on spacer.

16. Install spacer on rod.

17. Install spring using appropriate lifting device and liftingstrap.

SpecificationRecoil Spring—Weight 65 kg......................................................................

145 lb

18. Install retainer plate.

19. Install guard tool.

20. Install top plate. Install nuts.

21. Raise upper half of guard tool. Tighten T-handles.

22. Operate jack to compress spring to the compressedlength.

SpecificationRecoil Spring—CompressedLength 490 mm............................................................................................

19.3 in.

23. Install nut (D) so hole is aligned with hole in rod.Install special plug.

24. Tighten special plug to specification.

SpecificationSpecial Plug—Torque 15 N•m.....................................................................

133 lb-in.


PN=72


Track System

01013029

OUO6046,00022FE –19–05MAR07–5/5

25. Tighten valve.

SpecificationTrack Adjuster and Recoil SpringValve—Torque 88 N•m................................................................................

65 lb-ft


PN=73

Track System

010130

30

OUO6046,00022FF –19–05MAR07–1/2

Track Adjuster Cylinder Disassemble and Assemble

TX

1004

754

–UN

–17M

AR

06

1—Holder 4—U-Ring 7—Spring 10—Plug2—Piston Rod 5—Cylinder 8—Spacer 11—Nut3—Dust Seal 6—Rod 9—Washer 12—Grease Valve

CAUTION: Spring or rod may break ifdropped while handling, transporting ordisassembling. Nicks or weld craters inspring and rod assembly can cause stressconcentration resulting in a weak spot. Weakspots can result in immediate or eventualfailure of spring or rod creating a risk ofpersonal injury. Put a heavy protectivecovering around spring assembly whenhandling, transporting, or disassembling.


NOTE: It is not necessary to remove the recoil springto replace dust seal (3) and U-ring packing (4).It is necessary to remove the recoil spring toreplace rod (6).

1. Remove piston rod (2) from cylinder (5).

2. Remove holder (1) from piston rod (2) using apress.

IMPORTANT: Do not damage dust seal (3) andU-ring (4).

3. Remove dust seal (3) and U-ring (4) from cylinder(5).

4. Remove recoil spring if necessary. See TrackAdjuster and Recoil Spring Remove and Install.(Group 0130.)

5. Remove rod (6) from cylinder (5).

6. Repair or replace parts as necessary.

7. Install rod (6) into cylinder (5).


PN=74


Track System

01013031

OUO6046,00022FF –19–05MAR07–2/2

8. Install spring (7), spacer (8), washer (9), plug (10),nut (11), and grease valve (12). See Track Adjusterand Recoil Spring Disassemble and Assemble.(Group 0130.)

9. Apply grease to inner surfaces of U-ring (4) anddust seal (3)

NOTE: Install U-ring (4) with lip towards inside ofcylinder (5).

10. Install U-ring (4) and dust seal (3) into cylinder (5).

11. Press holder (1) into piston rod (2).

12. Install piston rod (2) assembly into cylinder (5).


PN=75

Track System

010130

32


PN=76

Section 02Axles, Differentials and Suspension Systems

Contents

Page

Group 0250—Axle Shaft, Bearings, and ReductionGears 02

Travel Gearbox Remove and Install . . . . . . .02-0250-1Travel Gearbox Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-4

Group 0260—Hydraulic SystemTravel Motor and Park Brake Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-2Travel Motor and Park Brake Disassemble

and Assemble . . . . . . . . . . . . . . . . . . . . .02-0260-10Counterbalance Valve Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-13Crossover Relief Valve Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-15Make-Up Check Valve Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-17Travel Speed Change Valve Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-19Travel Motor and Park Brake Start-Up

Procedure . . . . . . . . . . . . . . . . . . . . . . . .02-0260-21


PN=1

Contents

02


PN=2

Group 0250Axle Shaft, Bearings, and Reduction Gears

0202501

OUO6046,0002300 –19–16APR07–1/3

Travel Gearbox Remove and Install

TX

1020

196A

–UN

–07M

AR

07

1—Pressure Release Button2—Hydraulic Oil Tank Cover

1. Disconnect track chain. See Track Chain Repair.(Group 0130.)

2. Remove sprocket. See Sprocket Remove and Install.(Group 0130.)

CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure release button (1).

3. Push pressure release button (1).

4. Remove cover from track frame.

5. Drain oil from travel gearbox. The approximatecapacity of travel gearbox is 6.8 L (1.8 gal).

6. Drain oil from hydraulic oil tank or pull vacuum inhydraulic oil tank using vacuum pump. See ApplyVacuum to Hydraulic Oil Tank. (Group 3360.) Theapproximate capacity of hydraulic oil tank is 120.4 L(31.8 gal).

7. Tag and disconnect lines. Close all open lines andfittings using caps and plugs.



PN=79

Axle Shaft, Bearings, and Reduction Gears

020250

2

OUO6046,0002300 –19–16APR07–2/3

T14

2702

B–U

N–1

5JU

N01

1—Cap Screw (14 used)


8. Attach JDG909 Lifting Bracket to gearbox as shown.

SpecificationTravel Gearbox and MotorAssembly—Approximate Weight 325 kg.....................................................

717 lb

NOTE: Make alignment marks between travel gearboxand undercarriage to aid in installation.

9. Remove cap screws (1). Remove travel gearbox andmotor assembly.

10. Repair or replace parts as necessary. See TravelGearbox Disassemble and Assemble. (Group 0250.)

NOTE: Align marks made during removal.

11. Install travel gearbox and motor assembly. Tightencap screws (1).

SpecificationTravel Gearbox-to-Frame CapScrew—Torque 630 N•m.............................................................................

465 lb-ft

12. Connect lines. See Travel Hydraulic System LineConnection. (Group 9025-15.)

13. Fill travel gearbox with oil. See Check Travel GearboxOil Level. (Operator’s Manual.)

14. Do Travel Motor and Park Brake Start-Up Procedure.(Group 0260.)

15. Install cover. Tighten cap screws to specification.

SpecificationTravel Gearbox Cover CapScrews—Torque 140 N•m...........................................................................

103 lb-ft

16. Install sprocket. See Sprocket Remove and Install.(Group 0130.)

17. Connect track chain. See Track Chain Remove andInstall. (Group 0130.)


PN=80



OUO6046,0002300 –19–16APR07–3/3


0202503


PN=81


020250

4

OUO6046,0002301 –19–19APR07–1/7

Travel Gearbox Disassemble and Assemble

TX

1021

556

–UN

–03A

PR

07


PN=82



0202505

OUO6046,0002301 –19–19APR07–2/7

0—Hydraulic Motor and 11—Needle Bearing (6 used) 24—Washer 35—Needle Bearing (3 used)Gearbox Assembly 12—Third Planetary Pinion 25—Planetary Gear (3 used) 36—Plate (6 used)

1—Hydraulic Motor Carrier 26—Needle Bearing (3 used) 37—Spacer (3 used)2—Seal (2 used) 13—Planetary Gear (3 used) 27—Plate (6 used) 38—Spring Pin (3 used)3—Tapered Roller Bearing (2 15—Plate (6 used) 28—Pin Fastener (3 used) 39—Shaft

used) 16—Pin Fastener (3 used) 29—Pin Fastener (3 used) 41—Cover4—Drum 17—Spring Pin (3 used) 30—Second Sun Gear 42—Pin5—Chain Sprocket 18—Third Sun Gear 32—First Planetary Pinion 43—Cap Screw (16 used)6—Cap Screw (16 used) 20—Ring Gear Carrier 44—Fitting Plug (3 used)7—Lock Washer (16 used) 21—Cap Screw (20 used) 33—Spacer —O-Ring9—Bearing Nut 23—Second Planetary Pinion 34—Planetary Gear (3 used)10—Pin Fastener Carrier

1. Remove cap screws (43) and cover (41).

2. Remove shaft (39) and first planetary pinion carrier(32).

3. Remove second sun gear (30) and secondplanetary pinion carrier (23) from ring gear (20).

CAUTION: Heavy component; useappropriate lifting device.

SpecificationRing Gear—ApproximateWeight 40 kg.........................................................................................

88 lb

4. Install JT01748 Lifting Brackets to ring gear (20).Remove cap screws (21) and ring gear from drum(4).


SpecificationThird Planetary Pinion Carrier—Approximate Weight 40 kg...................................................................

88 lb

5. Remove third sun gear (13) and third planetarypinion carrier (12).



PN=83


020250

6

OUO6046,0002301 –19–19APR07–3/7

TX

1018

574

–UN

–14F

EB

07

9—Bearing Nut47—DFT1109 Holding Bar48—DF1036A Travel Gearbox Nut Wrench

6. Remove bearing nut (9) from travel motor (1) usingDFT1109 Holding Bar (47) and DFT1036A TravelGearbox Nut Wrench (48). See DFT1109 Holding Bar.See DFT1036A Travel Gearbox Nut Wrench. (Group9900.)


SpecificationDrum—Approximate Weight 54 kg..............................................................

120 lb

7. Remove drum (4) using JT01748 Lifting Brackets.

NOTE: Disassembly of first, second, and third planetarypinion carriers are similar. Repeat procedure asrequired.

8. Remove spring pins, pins, thrust plates, needlebearings, and planetary gears.

Clean and inspect parts, replace as necessary. Oilparts with gear oil prior to assembly.

IMPORTANT: Metal face seals can be reused if theyare not worn or damaged. A used sealmust be kept together as a set becauseof wear patterns on seal ring face.

9. Remove metal face seal (2). See Metal Face SealsRepair. (Group 0130.)


NOTE: Further disassembly is not necessary unlessbearing replacement is required. Bearing will bedestroyed during removal, replace with newbearing.

11. Inspect bearing (3) and race inside drum (4).



PN=84


0202507

OUO6046,0002301 –19–19APR07–4/7

CAUTION: DO NOT heat oil over 182°C (260°F).Oil fumes or oil can ignite above 193°C (380°F).Use a thermometer. DO NOT allow a flame orheating element to come in direct contact withthe oil. Heat the oil in a well-ventilated area.Plan a safe handling procedure to avoid burns.

12. Heat inner bearing cone. Install cone tight againstshoulder.

SpecificationBearing Cone—Temperature 50—70°C....................................................

122—158°F

13. Install drum (4).

IMPORTANT: Metal face seal O-rings and seatsurfaces for O-rings must be clean, dry,and oil free so O-ring does not slip.

14. Thoroughly clean metal face seal O-rings and seatsurfaces in travel motor ring gear, drum, and seal ringusing volatile, non-petroleum base solvent andlint-free tissues.

NOTE: A volatile, non-petroleum base solvent or talcumpowder can be used as a lubricant. Solvent mustnot damage the O-ring or leave an oil residue.

15. Install O-ring and metal face seal on travel motor ringgear and drum. Apply equal pressure with fingers atfour equally spaced points on seal face. Seal must“pop” down into place so O-ring is tight against sealbore and seal ring is installed squarely.

16. Clean seal ring face. Apply a thin film of clean oil.

17. Install drum (4) onto hydraulic motor (1).

18. Apply a thin coat of multi-purpose grease to threadsof bearing nut (9). Install bearing nut with machinedsurface towards bearing.

19. Tighten bearing nut (9) using DFT1109 Holding Barand DFT1036A Travel Gearbox Nut Wrench. SeeDFT1109 Holding Bar. See DFT1036A TravelGearbox Nut Wrench. (Group 9900.) Seat bearings.


PN=85



020250

8 OUO6046,0002301 –19–19APR07–5/7

SpecificationBearing Nut—Torque 800 N•m....................................................................

590 lb-ft

20. To seat bearings, tap on drum using a plastichammer. Then turn drum four-tofive times to theright and left to seat the bearings.

Repeat steps to ensure bearings are seated properly.

OUO6046,0002301 –19–19APR07–6/7

TX1004312

9

10

39

TX

1004

312

–UN

–14M

AR

06

TX1004313

4612

TX

1004

313

–UN

–14M

AR

06

9—Bearing Nut10—Dowel Pin12—Third Planetary Pinion Carrier39—Travel Motor46—Hole

21. Ensure center of dowel pin (10) is aligned with centerof spline on travel motor (39). If centers are notaligned tighten bearing nut (9) until dowel pin centeraligns with center of the next spline.

NOTE: Assembly of first, second, and third planetarypinion carrier assemblies is similar. Repeatprocedure as required.

22. Install needle bearings (11) into planetary gears (13).

IMPORTANT: There is an identification groove on oneside of third planetary gears (16). Besure that this marked side faces thehole for the spring pin.

23. Install thrust plates (15) and planetary gears (13) intothird planetary pinion carrier (12).

24. Install pins (16).



PN=86


0202509

OUO6046,0002301 –19–19APR07–7/7

45

TX1004310 16

TX

1004

310

–UN

–14M

AR

06

16—Pin45—Slit

25. Install spring pins (17) with slit (45) toward end ofpins (16).

26. Assemble second and first planetary pinion carrierassemblies.

27. Install third planetary pinion carrier so dowel pin (10)enters hole (46) on third planetary pinion carrier (12).

28. Apply PM38656 Rigid Form-in-Place gasket to flangesurface on ring gear.

29. Install ring gear (20) onto drum (4).

30. Install and tighten cap screws (21).

SpecificationRing Gear-to-Drum Cap Screw—Torque 270 N•m..........................................................................................

199 lb-ft

31. Install second and first planetary pinion carriers, sungears, and shaft.

32. Apply PM38656 Form-in-Place gasket to flangesurface on cover (41).

33. Install cover on ring gear (20).

34. Apply PM37418 Thread Lock and Sealer (mediumstrength) to thread of cap screws (43). Install andtighten cap screws.

SpecificationCover-to-Ring Gear Cap Screw—Torque 110 N•m..........................................................................................

83 lb-ft


PN=87


020250

10


PN=88

Group 0260Hydraulic System

0202601


PN=89

Hydraulic System

020260

2

FS41334,0000172 –19–10APR07–1/7

Travel Motor and Park Brake Remove and Install

TX

1000

629

–UN

–28N

OV

05


PN=90


Hydraulic System

0202603

FS41334,0000172 –19–10APR07–2/7

0—Travel Motor and Gearbox 10—Pin Fastener 23—Second Planetary Pinion 33—SpacerAssembly 11—Needle Bearing (6 used) Carrier 34—Planetary Gear (3 used)

1—Travel Motor 12—Third Planetary Pinion 24—Washer 35—Needle Bearing (3 used)2—Seal (2 used) Carrier 25—Planetary Gear (3 used) 36—Plate (6 used)3—Tapered Roller Bearing (2 13—Planetary Gear (3 used) 26—Needle Bearing (3 used) 37—Spacer (3 used)

used) 15—Plate (6 used) 27—Plate (6 used) 38—Spring Pin (3 used)4—Drum 16—Pin Fastener (6 used) 28—Pin Fastener (3 used) 39—Shaft5—Chain Sprocket 17—Spring Pin (3 used) 29—Pin Fastener (3 used) 41—Cover6—Cap Screw (20 used) 18—Third Sun Gear 30—Second Sun Gear 42—Pin7—Lock Washer (20 used) 20—Ring Gear 32—First Planetary Pinion 43—Cap Screw (12 used)9—Bearing Nut 21—Cap Screw (28 used) Gear 44—Fitting Plug (3 used)

IMPORTANT: Travel motor housing will bedamaged if removal is attemptedwhile travel gearbox is on machine.Travel motor housing is an integralpart of travel gearbox and retained inplace by bearing nut (9).

This procedure is written to showremoval and installation of the travelgearbox from the travel motor. Thisis the recommended repairprocedure for performing majorrepairs to travel motor or park brake.

NOTE: Travel motor and park brake internalcomponents can be replaced with care whilemotor is on machine.

1. Remove travel motor and gearbox assembly frommachine. See Travel Gearbox Remove and Install.(Group 0250.)

CAUTION: Heavy component; use anappropriate lifting device.

IMPORTANT: Weight of travel motor and gearboxassembly can damage motor valveplate. Block travel motor andgearbox assembly so that the motorcover does not carry full weight oftravel motor and gearbox assembly.

2. Position travel motor and gearbox assemblysecurely in a vertical position with the motor valveplate end down.

SpecificationTravel Motor and Gearbox—Weight 310 kg.......................................................................................

685 lb

3. Make alignment marks between cover (41), ringgear (20), and drum (4).

4. Remove cap screws (43) and cover (41).

5. Remove shaft (39) and first stage planetary pinioncarrier (32) from ring gear (20).

6. Remove second stage sun gear (30), second stageplanetary pinion carrier (23), and third stage sungear (18) from ring gear (20).


7. Install JT01748 lifting brackets to ring gear (20).Remove cap screws (21) and ring gear (20) fromdrum (4).

SpecificationRing Gear Approximate—Weight 64 kg.........................................................................................

140 lb


PN=91


Hydraulic System

020260

4 FS41334,0000172 –19–10APR07–3/7


SpecificationThird Stage Planetary PinionCarrier Approximate—Weight 40 kg.....................................................

88 lb

8. Remove third stage planetary pinion carrier (12).



PN=92

Hydraulic System

0202605

FS41334,0000172 –19–10APR07–4/7

TX

1018

574

–UN

–14F

EB

07

9—Bearing Nut47—DFT1109 Holding Bar48—DFT1036A Travel Gearbox Nut Wrench

9. Remove bearing nut (9) using holding bar (47) andtravel gearbox nut wrench (48). See DFT1109 HoldingBar and See DFT1036A Travel Gearbox Nut Wrench.(Group 9900.)


SpecificationDrum Approximate—Weight 59 kg..............................................................

130 lb

10. Remove drum (4) from travel motor housing usingJT01748 lifting brackets.

IMPORTANT: Metal face seals can be reused if theyare not worn or damaged. A used sealmust be kept together as a set becauseof wear patterns on seal ring surface.

11. Remove metal face seal (2). See Metal Face SealsRepair. (Group 0130.)

12. Repair or replace parts as necessary. See TravelMotor and Park Brake Disassemble and Assemble.(Group 0260.)

13. Clean and oil parts with gear oil prior to assembly.

NOTE: Further disassembly is not necessary unlessbearing replacement is required. Bearing will bedestroyed during removal, replace with a newbearing.

14. Inspect bearings (3) and races inside housing.




PN=93

Hydraulic System

020260

6

FS41334,0000172 –19–10APR07–5/7

CAUTION: DO NOT heat oil over 182 °C (260 °F).Oil fumes or oil can ignite above 193°C (380 °F).Use thermometer to measure. Do Not allow aflame or heating element to come in contactwith the oil. Heat in a well ventilated area. Plana safe handling procedure to avoid burns.

SpecificationBearing Cone—Temperature 50—70 °C....................................................

122—158 °F

16. Heat inner bearing cone. Install cone tight againstshoulder.

IMPORTANT: Metal face seal O-rings and seatsurfaces for O-rings must be clean, dry,and oil free so O-ring does not slip.

17. Thoroughly clean metal face seal O-rings and seatsurfaces in travel motor housing, drum, and seal ring.Use volatile, non-petroleum based solvent andlint-free tissues.

NOTE: A volatile, non-petroleum based solvent or talcumpowder can be used as a lubricant. Solvent mustnot damage the O-ring or leave an oil residue.

18. Install O-ring and metal face seal on travel motorhousing and drum. Apply equal pressure with fingersat four, equally spaced points on seal face.

Seal most “pop” down into place so O-ring is tightagainst seal bore and seal ring is installed squarely.

19. Clean ring seal face. Apply a thin film of clean oil.

20. Install drum (4) onto travel motor. Make sure thatroller bearings are fully installed by checking to seethat clearance between motor and drum is equal.



PN=94

Hydraulic System

0202607

FS41334,0000172 –19–10APR07–6/7

IMPORTANT: Install bearing nut with stepped surfacetowards bearing.

21. Apply a thin coat of multi-purpose grease to bearingnut (9). Tighten bearing nut using tools DFT1109 andDFT1036A to specification. See DFT1109 Holding Barand See DFT1036A Travel Gearbox Nut Wrench.(Group 9900.)


590 lb-ft

22. To seat bearings, tap around face of drum with aplastic hammer. Then, rotate drum 4 to 5 times ineach direction. Retighten to specification.

NOTE: If dowel pin does not engage with spline ofhousing, tighten bearing nut (9) until dowel pincenter aligns with center of next spline.

23. Ensure center of dowel pin (10) is aligned with centerof spline on travel motor. If centers are not aligned,tighten bearing nut (9) until dowel pin center alignswith center of next spline.

24. Install planetary gears (13) in third stage planetarypinion carrier (12), if removed.



PN=95

Hydraulic System

020260

8

FS41334,0000172 –19–10APR07–7/7

45

TX1004310 16

TX

1004

310

–UN

–14M

AR

06

Spring Pin Installation

16—Pin45—Slit

25. Install spring pinions with slit (45) toward end of pin(16).

26. Install third stage planetary pinion carrier (12) andthird stage sun gear (18).

27. Apply PM38627 Rigid Form-in-Place gasket to flangesurface on ring gear (20) and install ring gear.

28. Apply PM37421 Thread Lock and Sealer (highstrength) to cap screws (21). Tighten to specification.

SpecificationRing Gear-to-Drum Cap Screw—Torque 265 N•m..........................................................................................

195 lb-ft

29. Install second stage planetary pinion carrier (23),washer (24), sun gear (30), first stage planetarypinion carrier (32), washer (33), and shaft (39).

30. Apply PM38656 Rigid Form-in-Place to flange surfaceof ring gear cover (41).

31. Apply PM37418 Thread Lock and Sealer (mediumstrength) to threads of cap screws (43). Tighten tospecification.

SpecificationCover-to-Ring Gear Cap Screw—Torque 110 N•m..........................................................................................

83 lb-ft

32. Install travel motor and gearbox assembly. See TravelGearbox Remove and Install. (Group 0250.)


PN=96

Hydraulic System

0202609


PN=97

Hydraulic System

020260

10

FS41334,0000152 –19–08MAR07–1/3

Travel Motor and Park Brake Disassemble and Assemble

TX

1000

643

–UN

–01D

EC

05


PN=98


Hydraulic System

02026011

FS41334,0000152 –19–08MAR07–2/3

0—Hydraulic Motor 10—Roller Bearing 22—Plate (4 used) 31—O-Ring (2 used)0A—Housing 14—Piston (9 used) 23—Plate (4 used) 32—Travel Motor Cover1—Seal 16—Retainer 25—Piston 33—Needle Bearing3—Piston 17—Bushing 26—O-Ring 37—Dowel Pin (2 used)7—Shaft 18—Swash Plate 28—O-Ring 39—Valve Plate8—Snap Ring 19—Spring (6 used) 29—Spring 40—Bolt (9 used)9—Pin (2 used) 21—Rotor 30—O-Ring


SpecificationTravel Motor—ApproximateWeight 91 kg.........................................................................................

200 lb

IMPORTANT: Use care when removing travelmotor cover (32), valve plate iseasily damaged.

1. Remove travel motor cover (32), and plate (39).

IMPORTANT: Remove needle bearing (33) only ifreplacement is necessary. Do notreuse needle bearing as it may havebeen damaged during removal.

2. Remove needle bearing (33) as required.

3. Remove disc spring (29). Inspect part for wear ordamage.

SpecificationDisc Spring—Height 7.0—6.9 mm.......................................................

0.276—0.272 in.

4. Apply 100—300 kPa (14—43 psi) air pressure tobrake release passage to remove brake piston (25).

5. Remove friction plates (22) and plates (23).

6. Inspect parts for wear or damage.

SpecificationFriction Plate—Height 2.75—2.70 mm.................................................

0.108—0.106 in.

Plate—Height 1.80—1.75 mm..............................................................0.071—0.069 in.

IMPORTANT: Pistons must be installed into thesame bores because of wearpatterns. Mark location of pistonswith respect to bores to aid inassembly.

7. Remove parts (21, 19, 17, 16, and 14).

8. Remove parts (7, 10, 8, and 1) through motor sideof housing (0A).



SpecificationTravel Motor Housing—Weight 50 kg..................................................

110 lb

10. Apply multi-purpose grease to lip of seal (1) andapply PM38627 Rigid Form-in-Place Gasket toouter surface of seal.

11. Install parts (7, 10, 8, and 1) using D01044AABushing, Bearing and Seal Driver Set.


PN=99


Hydraulic System

020260

12

FS41334,0000152 –19–08MAR07–3/3

16

17

TX

1004

978

–UN

–23M

AR

06

17—Bushing16—Retainer

12. Lubricate parts (21, 19, 17, 16, 14, and 18) withhydraulic oil and install. Ensure that pistons (14) areinstalled in their original bores. Install bushing (17)and retainer (16) as shown.

13. Install parts (29, 28, 25, 26, 22, and 23).

14. Install needle bearing (33) into travel motor cover(32).

NOTE: Apply petroleum jelly to mating surface of valveplate to adhere it to travel motor cover duringassembly.

15. Install pins (37) then valve plate (39).

16. Assemble travel motor cover to housing (0A).

17. Install cap screws (40) and tighten.

SpecificationTravel Motor Cover-to-TravelMotor Housing Cap Screw—Torque 300 N•m..........................................................................................

220 lb-ft


PN=100

Hydraulic System

02026013

FS41334,0000151 –19–13APR07–1/3

Counterbalance Valve Remove and Install

TX

1020

196A

–UN

–07M

AR

07

1—Pressure Relief Button2—Hydraulic Oil Tank Cover

CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. Relieve pressure by pushingpressure relief button (1).

1. Push pressure relief button (1).


3. Disconnect battery ground (negative) cable.




PN=101

Hydraulic System

020260

14

FS41334,0000151 –19–13APR07–2/3

TX

1020

307A

–UN

–07M

AR

07

TX

1020

308

–UN

–09M

AR

07

1—Travel Motor Cover2—Spool (2 used)3—Spring (2 used)4—O-Ring (2 used)5—Plug (2 used)6—Valve Spool

NOTE: Valves may be removed with travel motor inmachine.

5. Remove counterbalance valve plugs (5) from travelmotor cover (1).

6. Remove spring (3) and spool (2) from travel motorusing a magnet.

7. Remove valve spool (6) from travel motor using amagnet.

8. Repair or replace parts as needed. Apply a film ofclean hydraulic oil to parts before assembly.

9. Install valve spool (6) halfway into cover (1).

10. Instal spools (2), Springs (3), and plugs (5) on eachside of valve spool (6). Tighten by hand.

11. Tighten counterbalance valve plug (5) on each side tospecification.

SpecificationCounterbalance Valve Plug—Torque 450 N•m..........................................................................................

332 lb-ft

12. Fill hydraulic oil tank. See Check Hydraulic Tank OilLevel. (Operator’s Manual.)

IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting engine.Procedure must be performed whenevera new pump is installed or oil has beendrained from the pump or hydraulic oiltank.

13. Fill pump housing with oil. See Pump 1 and 2Start-Up Procedure. (Group 3360.)

14. Connect battery ground (negative) cable.

15. Perform travel motor start-up procedure. See TravelMotor and Park Brake Start-Up Procedure. (Group3360.)

16. Install cover to track frame and torque tospecification.


PN=102


Hydraulic System

FS41334,0000151 –19–13APR07–3/3

SpecificationTrack Frame Cover—Torque 50 N•m.........................................................

37 lb-ft

02026015

FS41334,0000159 –19–13APR07–1/4

Crossover Relief Valve Remove and Install

TX

1020

196A

–UN

–07M

AR

07







FS41334,0000159 –19–13APR07–2/4

TX

1020

327A

–UN

–07M

AR

07

1—Travel Motor Cover2—Plug (2 used)


5. Remove crossover relief valves (10) from travel motorcover (1).

Crossover relief valves retain make-up check valve andspring. For correct reinstallation; See Make-Up CheckValve Remove and Install. (Group 0260.)


PN=103


Hydraulic System

020260

16

FS41334,0000159 –19–13APR07–3/4

TX

1020

309

–UN

–09M

AR

07

1—Travel Motor Cover 5—Valve (2 used) 8—Piston (2 used) 11—O-Ring (2 used)2—Sleeve (2 used) 6—Guide (2 used) 9—Back-Up Ring (4 used) 12—Packing (2 used)3—O-Ring (2 used) 7—Spring (2 used) 10—Plug (2 used) 13—Shim (2 used)4—Back-Up Ring (4 used)

IMPORTANT: Disassembly of crossover reliefvalve will alter the set pressure.Adjust after repairs are made.

6. Disassemble crossover relief valves.


8. Assemble crossover relief valves.

9. Install relief valves (10) and tighten to specification.

SpecificationRelief Valve—Torque 450 N•m.............................................................

332 lb-ft

10. Fill hydraulic oil tank. See Check Hydraulic TankOil Level. (Operator’s Manual.)

IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before startingengine. Procedure must beperformed whenever a new pump isinstalled or oil has been drainedfrom the pump or hydraulic oil tank.



13. Perform travel motor start-up procedure. SeeTravel Motor and Park Brake Start-Up Procedure.(Group 0260.)


PN=104


Hydraulic System

02026017FS41334,0000159 –19–13APR07–4/4

14. Install cover to track frame.

SpecificationTrack Frame Cover—Torque 50 N•m...................................................

37 lb-ft

15. Perform crossover relief valve test and adjustment.See Travel Motor Crossover Relief Valve Test andAdjustment. (9025-25.)

FS41334,0000158 –19–13APR07–1/2

Make-Up Check Valve Remove and Install

TX

1020

196A

–UN

–07M

AR

07









PN=105

Hydraulic System

020260

18

FS41334,0000158 –19–13APR07–2/2

TX

1020

327A

–UN

–07M

AR

07T

X10

2091

0A–U

N–2

3MA

R07

1—Travel Motor Cover2—Relief Valve (2 used)3—Spring (2 used)4—Check Valve (2 used)


5. Remove relief valves (2) from travel motor cover (1).

6. Remove springs (3) and check valves (4) from travelmotor using a magnet.


8. Install Springs (3) to check valves (4). Install checkvalves into travel motor cover (1).

9. Install relief valves (2) and tighten to specification.

SpecificationRelief Valve—Torque 450 N•m...................................................................

332 lb-ft








37 lb-ft


PN=106

Hydraulic System

02026019

FS41334,0000157 –19–13APR07–1/2

Travel Speed Change Valve Remove andInstall

TX

1020

196A

–UN

–07M

AR

07









PN=107

Hydraulic System

020260

20

FS41334,0000157 –19–13APR07–2/2

TX

1019

101A

–UN

–19M

AR

07T

X10

2026

3A–U

N–0

6MA

R07

1—Line2—Valve Spool3—Spring4—Fitting Plug


5. Remove fitting plug (4) from travel motor cover.

6. Remove compression spring (3) and valve spool (2)from travel motor cover using a magnet.


8. Install valve spool (2) into cover with shoulder facingspring.

9. Install spring (3) and fitting plug (4). Tighten tospecification.

SpecificationFitting Plug—Torque 35 N•m......................................................................

26 lb-ft








37 lb-ft

15. Perform travel speed solenoid valve test and adjust.Travel Speed Solenoid Valve Test and Adjustment.(Group 9025-25.)


PN=108

Hydraulic System

02026021

FS41334,0000150 –19–08MAR07–1/1

Travel Motor and Park Brake Start-UpProcedure

TX

1018

694A

–UN

–19M

AR

07

1—Travel Motor Drain Line

IMPORTANT: Travel motor will be damaged if notfilled with oil before operating travelfunction. Procedure must be performedwhenever a new travel motor isinstalled or oil has been drained fromthe motor.

1. Disconnect drain line (1).

2. Fill motor with hydraulic oil until oil reaches top of drainport.

NOTE: Use a funnel with suitable diameter neck to allowair to escape while filling.

3. Connect drain line (1).


PN=109

Hydraulic System

020260

22


PN=110

Section 04Engine

Contents

Page

Group 0400—Removal and InstallationEngine Remove and Install . . . . . . . . . . . . . .04-0400-1

04


PN=1

Contents

04


PN=2

Group 0400Removal and Installation

TJ15698,0000181 –19–11APR07–1/18

Engine Remove and Install


0404001

TJ15698,0000181 –19–11APR07–2/18

TS

281

–UN

–23A

UG

88

CAUTION: Explosive release of fluids frompressurized cooling system can cause seriousburns.

Shut off engine. Remove filler cap when cool totouch. Slowly loosen filler cap to first stop torelieve pressure, then remove.

2. Drain coolant from radiator. Approximate capacity is 19L (5 gal).

TJ15698,0000181 –19–11APR07–3/18

TX

1020

196A

–UN

–07M

AR

07




4. Pull a vacuum in hydraulic oil tank using a vacuumpump, or drain tank. Approximate oil capacity is 120.4L (31.8 gal). See Apply Vacuum to Hydraulic Oil Tank.(Group 3360.)

5. Close fuel supply valve on bottom of fuel tank.

6. Remove engine cover, muffler cover, and control valvecover.



PN=113

Removal and Installation

040400

2

TJ15698,0000181 –19–11APR07–4/18

TX

1021

007A

–UN

–29M

AR

07

1—Upper Intercooler Tube2—Upper Radiator Hose3—Coolant Surge Tank

7. Remove coolant surge tank (3). See Coolant SurgeTank Remove and Install. (Group 0510.)

8. Remove upper intercooler tube (1), upper radiator hose(2), and lower radiator hose.

TJ15698,0000181 –19–11APR07–5/18

TX

1020

192A

–UN

–05A

PR

07

1—Cap Screw (4 used)2—Final Fuel Filter3—Primary Fuel Filter

9. Remove cap screws (1) and set fuel filters (2 and 3)aside.

TJ15698,0000181 –19–11APR07–6/18

TX

1020

874A

–UN

–22M

AR

07

1—Shield2—Cap Screws (6 used)3—Water Drain

10. Remove water drain (3), cap screws (2), and mufflershield (1).



PN=114


0404003

TJ15698,0000181 –19–11APR07–7/18

TX

1020

754A

–UN

–29M

AR

07

1—Muffler2—Cap Screw (4 used)3—Bracket

CAUTION: Exhaust parts may be hot. Avoidburns by waiting until the parts are cool to thetouch before working on them.

11. Disconnect exhaust pipe from turbocharger.

12. Support pump 1 and 2. Remove cap screws (2) andbracket (3) with muffler (1). Reinstall cap screws.

TJ15698,0000181 –19–11APR07–8/18

TX

1021

000A

–UN

–29M

AR

07

1—Engine Control Unit2—Electrical Connector (2 used)3—Cover4—Bracket5—Air Intake Tube6—Fan Drive Pump Supply Hose7—Alternator

13. Remove air intake tube (5) and bracket (4).

14. Disconnect electrical connectors (2) and removeengine control unit (1).

15. Disconnect electrical connector and wires fromalternator (7).

16. Disconnect fan drive pump supply hose (6) and linefrom pump and engine mount.

17. Close all open hoses and fittings using caps andplugs.

18. Remove cover (3).



PN=115


TJ15698,0000181 –19–11APR07–9/18

TX

1021

004A

–UN

–29M

AR

07

040400

4

1—Electrical Connector (2 used)

19. Disconnect connectors (1).

TJ15698,0000181 –19–11APR07–10/18

TX

1021

001A

–UN

–29M

AR

07

1—Compressor Mounting Bracket2—Fuel Hose (2 used)3—Lower Intercooler Tube

NOTE: It is not necessary to discharge the airconditioning system.

20. Disconnect air conditioner compressor mountingbracket (1) from engine. Fasten compressor andbracket so it will not interfere with engine removal.

21. Disconnect fuel hoses (2) and close all open fittingsand hoses using caps and plugs.

22. Remove lower intercooler tube (3).

TJ15698,0000181 –19–11APR07–11/18

TX

1021

005A

–UN

–29M

AR

07

1—Starter2—Fuel Hose (2 used)

23. Tag and disconnect fuel hoses (2). Close all openfittings and hoses using caps and plugs.

24. Disconnect wires from starter (1).



PN=116


TJ15698,0000181 –19–11APR07–12/18

TX

1021

006A

–UN

–29M

AR

07

0404005

1—Fan Drive Pump Outlet Hose2—Heater Hose (2 used)3—Engine Oil Filter Hose (2 used)

25. Tag and disconnect heater hoses (2), hose (1), andoil filter hoses (3).


TJ15698,0000181 –19–11APR07–13/18

TX

1021

205A

–UN

–02A

PR

07

1—Eyebolt (2 used)2—Lifting Bracket

27. Install JT05550 Lifting Eyebolt (1) and JDG19 LiftingBracket (2) in housing of pump 1 and 2.

TJ15698,0000181 –19–11APR07–14/18

TX

1021

141A

–UN

–29M

AR

07

1—DFT1119 Pump Support2—Lever Block


28. Install DFT1119 Pump Support (1) on machine asshown. See DFT1119 Pump Support. (Group 9900.)

SpecificationPump 1 and 2—Weight 190 kg..................................................................

419 lb

29. Attach pump support to machine using C-clamps toprevent movement.

30. Support pump 1 and 2 using DFT1119 Pump Support(1) and a lever block (2). Attach lever block toeyebolts and lifting bracket installed in pump housingusing suitable lifting sling.


PN=117



040400

6

TJ15698,0000181 –19–11APR07–15/18

TX

1021

109A

–UN

–29M

AR

07

1—Lifting Sling2—Lifting Eye (2 used)

31. Install lifting eyes (2) and lifting sling (1).


SpecificationEngine—Approximate Weight 491 kg........................................................

1083 lb

33. Remove cap screws securing pump 1 and 2 and drivegearbox to engine flywheel housing.



PN=118


0404007

TJ15698,0000181 –19–11APR07–16/18

TX

1021

106A

–UN

–29M

AR

07

Counterweight Side

TX

1021

107A

–UN

–29M

AR

07

Swing Gearbox Side

TX

1021

108A

–UN

–29M

AR

07Bottom Side

1—Cap Screw (14 used)2—Nut (4 used)

34. Remove cap screws (1) and nuts (2).

35. Raise engine slightly. Move engine away from pump1 and 2 and drive gearbox. Lift and remove enginewhen disengaged from hydraulic pump drive coupling.



SpecificationEngine—Approximate Weight 491 kg........................................................

1083 lb

37. Align hydraulic pump and drive gearbox to engine andinstall engine. Install cap screws (1), washers, andnuts (2). Tighten cap screws and nuts to specification.

SpecificationEngine Mount Cap Screw—Torque 110 N•m..........................................................................................

81 lb-ft

SpecificationEngine Isolator Nut—Torque 400 N•m........................................................

295 lb-ft

38. Install pump housing cap screws. Tighten cap screwsto specification.

SpecificationPump 1 and 2Housing-to-Flywheel Housing CapScrew—Torque 65 N•m...............................................................................

48 lb-ft

39. Remove lifting sling and lifting eyes from engine.

40. Connect engine oil filter hoses.

41. Connect heater hoses.

42. Connect hoses to fan drive pump. See Fan DrivePump Remove and Install. (Group 3360.)

43. Connect fuel hoses to fuel transfer pump.

44. Install cover.


PN=119



040400

8

TJ15698,0000181 –19–11APR07–17/18

45. Install engine control unit and connect harnessconnectors.

46. Connect starter and alternator wires.

47. Install air conditioning compressor and mountingbracket to engine.

48. Install compressor belt. Inspect and adjustcompressor belt tension. See Check and Adjust A/CBelt. (Operator’s Manual.)

49. Connect fuel hoses to fuel injection pump.

50. Install muffler and bracket. Tighten muffler bracketcap screws to specification.

SpecificationPump 1 and 2Housing-to-Flywheel Housing CapScrew—Torque 65 N•m...............................................................................

48 lb-ft

51. Remove lifting bracket, lifting eyebolt, and pumpsupport from pump 1 and 2.

52. Install covers surrounding muffler.

53. Connect air intake tube.

54. Connect upper and lower radiator hoses. SeeRadiator Remove and Install. (Group 0510.)

55. Install intercooler tubes. See Intercooler Remove andInstall. (Group 0510.)

56. Install fuel filters.

57. Install top covers over control valve and muffler.

58. Open fuel supply valve on bottom of fuel tank.

59. Fill engine with clean engine oil. See Diesel EngineOil. (Operator’s Manual.)

60. Fill cooling system. See Cooling System Fill andDeaeration Procedure. (Operator’s Manual.)


PN=120



0404009

TJ15698,0000181 –19–11APR07–18/18

61. Fill and check hydraulic oil level. Approximate oilcapacity is 120.4 L (31.8 gal).

IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting. Proceduremust be performed to fill pump housingwhenever oil has been drained from thepump or hydraulic oil tank.

62. If hydraulic oil tank was drained, perform pumpstart-up procedure. See Pump 1 and 2 Start-UpProcedure. (Group 3360.)

63. Bleed fuel system. See Bleed Fuel System.(Operator’s Manual.)


PN=121


040400

10


PN=122

Section 05Engine Auxiliary SystemContents

Page

Group 0510—Cooling SystemRadiator Remove and Install . . . . . . . . . . . . .05-0510-1Hydraulic Oil Cooler Remove and Install . . . .05-0510-4Intercooler Remove and Install . . . . . . . . . . .05-0510-6Fuel Cooler Remove and Install . . . . . . . . .05-0510-11Cooling Package Remove and Install . . . . .05-0510-11Fan, Fan Guard, and Fan Shroud Remove

and Install . . . . . . . . . . . . . . . . . . . . . . . .05-0510-19Coolant Surge Tank Remove and Install . . .05-0510-24

Group 0520—Intake SystemAir Cleaner Remove and Install. . . . . . . . . . .05-0520-1

05Group 0560—External Fuel Supply SystemFuel Tank Remove and Install. . . . . . . . . . . .05-0560-1Primary Fuel Filter (Water Separator)

Remove and Install . . . . . . . . . . . . . . . . . .05-0560-3Final Fuel Filter Remove and Install . . . . . . .05-0560-4


PN=1

Contents

05


PN=2

Group 0510Cooling System

LD30992,0000598 –19–18APR07–1/7

Radiator Remove and Install

1. Remove batteries. See Battery Remove and Install.(Group 9015-20).

0505101

LD30992,0000598 –19–18APR07–2/7

TS

281

–UN

–23A

UG

88

CAUTION: Prevent possible injury from hotspraying water. DO NOT remove surge tank capunless engine is cool. Then remove cap slowly.

2. Remove surge tank filler cap to relieve pressure.

3. Open drain valve and drain coolant into suitablecontainer.

SpecificationCooling System—Capacity 19.0 L...............................................................

5.0 gal

4. Remove coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)

5. Remove fan and fan shroud. See Fan, Fan Guard, andFan Shroud Remove and Install. (Group 0510.)

LD30992,0000598 –19–18APR07–3/7

TX

1020

785A

–UN

–23M

AR

07

1—Cap Screw (4 used)2—Condenser3—Connector

NOTE: It is not necessary to discharge air conditioningsystem.

6. Disconnect wiring harness connector (3) fromreceiver-dryer.

7. Remove any clamps attaching air conditioning lines toframe or panels.

IMPORTANT: Use caution when repositioningcondenser to avoid damagingcondenser fins.

8. Remove cap screws (1). Lay condenser (2) aside andsecure in place.


PN=125


Cooling System

LD30992,0000598 –19–18APR07–4/7

TX

1020

784A

–UN

–23M

AR

07

050510

2

1—Cap Screw (4 used)2—Fan Drive Motor Assembly

9. Support fan drive motor assembly (2). Remove capscrews (1) and fan drive motor assembly (2).

LD30992,0000598 –19–18APR07–5/7

TX

1020

802A

–UN

–19M

AR

07

1—Lower Radiator Hose2—Cap Screw

10. Loosen clamp and disconnect lower radiator hose (1).

11. Remove cap screw (2).



PN=126

Cooling System

0505103

LD30992,0000598 –19–18APR07–6/7

TX

1020

803A

–UN

–19M

AR

07

1—Radiator2—Cap Screw (16 used)

CAUTION: Heavy component; use a hoist.

SpecificationRadiator—Weight 27 kg..............................................................................

60 lb

12. Attach suitable lifting device to radiator (1).

13. Remove cap screws (2), washers, and nuts attachingradiator to intercooler and hydraulic oil cooler.

14. Remove radiator. Repair or replace as necessary.

15. Ensure all foam seals are in place and install radiator.Tighten cap screws to specification.

SpecificationRadiator-to-Hydraulic Oil CoolerCap Screws—Torque 37 N•m.....................................................................

27 lb-ftRadiator-to-Intercooler CapScrews—Torque 37 N•m.............................................................................

27 lb-ftRadiator-to-Frame Lower CapScrew—Torque 55 N•m...............................................................................

41 lb-ft

16. Connect lower radiator hose.

17. Install fan drive motor assembly. Tighten cap screwsto specification.

SpecificationFan Drive Motor Assembly CapScrews—Torque 73 N•m.............................................................................

54 lb-ft

18. Install condenser assembly.

19. Connect wiring harness connector to receiver-dryer.

20. Install fan and fan shroud. See Fan, Fan Guard, andFan Shroud Remove and Install. (Group 0510.)

21. Install coolant surge tank. See Coolant Surge TankRemove and Install. (Group 0510.)

22. Install batteries. See Battery Remove and Install.(Group 9015-20).


PN=127


Cooling System

LD30992,0000598 –19–18APR07–7/7


LD30992,0000599 –19–18APR07–1/6

Hydraulic Oil Cooler Remove and Install

1. Remove radiator. See Radiator Remove and Install.(Group 0510.)

050510

4

LD30992,0000599 –19–18APR07–2/6

TX

1020

824A

–UN

–23M

AR

07

1—Cap Screw2—Cap Screws3—Fuel Cooler

2. Remove cap screw (1) from upper mounting bracket.

IMPORTANT: Use caution when repositioning fuelcooler to avoid damaging fuel coolerfins.

3. Remove cap screws (2). Lay fuel cooler (3) andmounting bracket aside and secure in place.

LD30992,0000599 –19–18APR07–3/6

TX

1020

827A

–UN

–23M

AR

07

1—Hydraulic Hose2—Cover

4. Drain hydraulic oil tank. Approximate oil capacity is120.4 L (31.8 gal).

5. Remove cap screws from cover (2) to gain furtheraccess to fitting on lower oil cooler hydraulic hose (1).

6. Disconnect lower oil cooler hydraulic hose (1). Applycaps and plugs to close all openings.


PN=128


Cooling System

LD30992,0000599 –19–18APR07–4/6

TX

1020

826A

–UN

–23M

AR

07

0505105

1—Hydraulic Oil Cooler-to-Frame Lower Cap Screw2—Mounting Bracket-to-Frame Cap Screws


SpecificationHydraulic Oil Cooler—Weight 42 kg............................................................

92 lb

7. Attach suitable lifting device to hydraulic oil cooler.

8. Remove cap screws (1) and (2).

LD30992,0000599 –19–18APR07–5/6

TX

1020

828A

–UN

–23M

AR

07

1—Hydraulic Oil Cooler

9. Move hydraulic oil cooler (1) toward rear of machineuntil hydraulic fitting in lower port clears access hole inside panel.

10. Remove hydraulic oil cooler.



PN=129

Cooling System

050510

6

LD30992,0000599 –19–18APR07–6/6

2

1

43

65

TX

1021

207

–UN

–27M

AR

07

1—Hydraulic Oil Cooler2—Mounting Bracket3—Washer (8 used)4—Cap Screw (8 used)5—Nut (8 used)6—Washer (8 used)

11. Remove washers (3 and 6), nuts (5), cap screws (4),and mounting bracket (2) from hydraulic oil cooler (1).

12. Install mounting bracket onto new hydraulic oil cooler.

13. Install hydraulic oil cooler. Tighten cap screw tospecification.

SpecificationHydraulic Oil Cooler-to-FrameLower Cap Screw—Torque 55 N•m............................................................

41 lb-ft

14. Connect lower hydraulic hose.

15. Install fuel cooler and mounting bracket.

16. Install upper mounting bracket cap screw.

17. Install radiator. See Radiator Remove and Install.(Group 0510.)

18. Fill and check hydraulic oil level. See 160DLC Drainand Refill Capacities. (Operator’s Manual.)


19. Perform pump start-up procedure. See Pump 1 and 2Start-Up Procedure. (Group 3360.)

LD30992,000059A –19–10APR07–1/9

Intercooler Remove and Install





PN=130


Cooling System

LD30992,000059A –19–10APR07–2/9

TX

1020

785A

–UN

–23M

AR

07







0505107

LD30992,000059A –19–10APR07–3/9

TX

1020

786A

–UN

–23M

AR

07

1—Mounting Bracket2—Cap Screws

7. Remove cap screws (2) and condenser mountingbracket (1).

LD30992,000059A –19–10APR07–4/9

TX

1020

787A

–UN

–23M

AR

071—Cap Screw

8. Remove cap screw (1) from upper mounting uppermounting bracket.



PN=131

Cooling System

LD30992,000059A –19–10APR07–5/9

TX

1020

784A

–UN

–23M

AR

07

050510

8



LD30992,000059A –19–10APR07–6/9

TX

1020

788A

–UN

–23M

AR

07

1—Mounting Bracket-to-Frame Cap Screws2—Intercooler-to-Frame Lower Cap Screw3—Lower Intercooler Tube

10. Remove cap screws (1) and (2) from bottom ofintercooler.

11. Loosen clamps and disconnect lower intercooler tube(3).

LD30992,000059A –19–10APR07–7/9

TX

1020

789A

–UN

–23M

AR

07

1—Intercooler2—Cap Screw (8 used)


SpecificationIntercooler—Weight 27 kg...........................................................................

60 lb

12. Attach suitable lifting device to intercooler (1).

13. Remove cap screws (2), washers, and nuts from eachside of intercooler.

14. Remove intercooler.



PN=132

Cooling System

LD30992,000059A –19–10APR07–8/9

TX

1020

790A

–UN

–23M

AR

07

0505109

1—Mounting Bracket2—Intercooler

15. Remove cap screws and mounting bracket (1) fromintercooler (2).

16. Install mounting bracket onto new intercooler. Tightencap screws to specification.

SpecificationMounting Bracket-to-IntercoolerCap Screws—Torque 37 N•m.....................................................................

27 lb-ft



PN=133

Cooling System

050510

10

LD30992,000059A –19–10APR07–9/9

TX

1020

791A

–UN

–23M

AR

07

1—Wiring Harness

IMPORTANT: Ensure wiring harness (1) is securedbehind foam and mounting bracketbefore fully lower intercooler.

17. Ensure all foam seals are in place and installintercooler. Tighten cap screws to specification.

SpecificationIntercooler-to-Radiator CapScrews—Torque 37 N•m.............................................................................

27 lb-ftIntercooler-to-Frame Lower CapScrew—Torque 55 N•m...............................................................................

41 lb-ft

18. Install upper mounting bracket cap screw.


SpecificationFan Drive Motor Assembly CapScrews—Torque 73 N•m.............................................................................

54 lb-ft

20. Install condenser assembly.






PN=134

Cooling System

OUO1073,0002101 –19–13MAR07–1/1

Fuel Cooler Remove and Install

TX

1019

245A

–UN

–15F

EB

07

05051011

1—Fuel Return Hose2—Fuel Cooler3—Cap Screws (4 used)4—Fuel Supply Hose

1. Tag and disconnect fuel hoses (1 and 4).

2. Remove cap screws (3) and fuel cooler (2).

3. Repair or replace as necessary.

4. Install cooler and connect hoses.

5. Install air filter assembly.

LD30992,000059C –19–18APR07–1/16

Cooling Package Remove and Install

TX

1020

196A

–UN

–07M

AR

07


CAUTION: High pressure release of oil frompressurized system can cause serious burns orpenetrating injury. The hydraulic tank ispressurized. Relieve pressure by pushingpressure release button (1).




PN=135

Cooling System

050510

12

LD30992,000059C –19–18APR07–2/16

TS

281

–UN

–23A

UG

88



3. Open drain valve and drain coolant into suitablecontainer.

SpecificationCooling System—Capacity 19.0 L...............................................................

5.0 gal



6. Remove access panels on bottom of machine.

LD30992,000059C –19–18APR07–3/16

TX

1021

548A

–UN

–03A

PR

07T

X10

2154

9A–U

N–0

3AP

R07

1—Hood Support Rod2—Cap Screws3—Hood

7. Raise engine hood.

8. Remove retaining pin and disconnect hood support rod(1).


SpecificationEngine Hood—Weight 36 kg.......................................................................

80 lb

9. Attach appropriate lifting device to hood.

10. Remove cap screws (2) and hood (3).


PN=136


Cooling System

LD30992,000059C –19–18APR07–4/16

TX

1021

073A

–UN

–02A

PR

07

05051013

1—Intercooler Tube2—Radiator Hose3—Hydraulic Hose4—Hydraulic Hose5—Cover6—Cover

11. Loosen clamps and disconnect upper intercooler tube(1) and upper radiator hose (2).

12. Drain hydraulic oil tank. Approximate oil capacity is120.4 L (31.8 gal).

13. Disconnect hydraulic hoses (3 and 4) to hydraulic oilcooler. Apply caps and plugs to close all openings.

14. Remove covers (5 and 6).

LD30992,000059C –19–18APR07–5/16

TX

1020

785A

–UN

–23M

AR

07







LD30992,000059C –19–18APR07–6/16

TX

1020

786A

–UN

–23M

AR

07

1—Mounting Bracket2—Cap Screws

18. Remove cap screws (2) and condenser mountingbracket (1).


PN=137


Cooling System

LD30992,000059C –19–18APR07–7/16

TX

1020

787A

–UN

–23M

AR

07

050510

14

1—Cap Screw


LD30992,000059C –19–18APR07–8/16

TX

1021

622A

–UN

–05A

PR

07

1—Cap Screw2—Cap Screws3—Fuel Cooler


IMPORTANT: Use caution when repositioning fuelcooler to avoid damaging fuel coolerfins.

21. Remove cap screws (2). Lay fuel cooler (3) andmounting bracket aside and secure in place.



PN=138

Cooling System

05051015

LD30992,000059C –19–18APR07–9/16

TX

1021

074A

–UN

–02A

PR

07

1—Air Filter Assembly2—Fan Drive Control Valve3—Panel4—Cold Weather Starting Aid

22. Remove cap screws attaching air filter assembly (1)to panel (3). Secure air filter to side panel behind rearof cab.

23. Disconnect wiring harness connectors from fan drivecontrol valve (2).

NOTE: Hydraulic hoses do not need to be disconnectedfrom fan control valve.

24. Remove cap screws attaching fan control valve (2) topanel (3). Lay fan control valve on floor panel.

25. Disconnect hose from cold weather starting aid (4).

26. Disconnect wiring harness connector from coldweather starting aid.

27. Remove any clamps attaching wiring harness to panel(3).

28. Remove mounting cap screws from panel. Lift panel(3) and remove.

LD30992,000059C –19–18APR07–10/16

TX

1021

075A

–UN

–02A

PR

07

1—Cap Screw (4 used)2—Hydraulic Hose

29. Remove cap screws (1) and disconnect lower oilcooler hydraulic hose (2). Apply caps and plugs toclose all openings.

LD30992,000059C –19–18APR07–11/16

TX

1020

211A

–UN

–07M

AR

07

1—Cap Screws

30. Remove cap screws (1) and cover.


PN=139


Cooling System

050510

16

LD30992,000059C –19–18APR07–12/16

TX

1020

687A

–UN

–22M

AR

07T

X10

2068

8A–U

N–2

2MA

R07

1—Hydraulic Hose (to Fan Drive Motor)2—Cap Screw

31. Disconnect fan drive motor hydraulic hose (1) fromhydraulic oil tank. Apply caps and plugs to close allopenings.

32. Remove cap screw (2) and hose clamp.

33. Route hydraulic hose back through opening in side offan shroud.

LD30992,000059C –19–18APR07–13/16

TX

1020

690A

–UN

–22M

AR

07

1—Hydraulic Hose2—Hydraulic Hose

34. Tag and disconnect hydraulic hoses (1 and 2). Applycaps and plugs to close all openings.

35. Route hoses through opening in side of fan shroud.



PN=140

Cooling System

LD30992,000059C –19–18APR07–14/16

TX

1021

077A

–UN

–02A

PR

07

05051017

1—Cooling Package


SpecificationCooling Package—ApproximateWeight 126 kg..............................................................................................

278 lb

IMPORTANT: Do not use lifting eyes on individualcooling package components(intercooler, radiator, and hydraulic oilcooler) to lift entire cooling package.

36. Attach suitable lifting device to cooling package (1).



PN=141

Cooling System

050510

18

LD30992,000059C –19–18APR07–15/16

TX

1021

076A

–UN

–02A

PR

07

1—Cap Screws2—Intercooler Tube3—Cap Screw4—Cap Screw5—Cap Screw6—Radiator Hose

37. Disconnect lower intercooler tube (2) and lowerradiator hose (6).

38. Remove cap screws (3—5) from cooling packagecomponents.

39. Remove cap screws (1) and cooling package.

40. Replace components as necessary.

41. Install cooling package. Tighten cap screws (3—5) tospecification.

SpecificationIntercooler-to-Frame Lower CapScrew—Torque 55 N•m...............................................................................

41 lb-ftRadiator-to-Frame Lower CapScrew—Torque 55 N•m...............................................................................

41 lb-ftHydraulic Oil Cooler-to-FrameLower Cap Screw—Torque 55 N•m............................................................

41 lb-ft

42. Connect upper and lower intercooler tubes.

43. Connect upper and lower radiator hoses.

44. Connect upper and lower hydraulic oil cooler hoses.

45. Install panel, air filter assembly, fan drive controlvalve, and cold weather starting aid.

46. Route and connect fan drive motor hydraulic hoses.

47. Connect wiring harness connectors to cold weatherstarting aid.

48. Connect cold weather starting aid hose.

49. Connect wiring harness connectors to fan drivecontrol valve.

50. Install air conditioning condenser and fuel cooler.


52. Install cooling package upper mounting bracket capscrews.


PN=142


Cooling System

05051019

LD30992,000059C –19–18APR07–16/16

53. Install covers.

54. Install hood.





58. Perform pump start-up procedure. See Pump 1 and 2Start-Up Procedure. (Group 3360.)

OUO1073,0002103 –19–10APR07–1/9

Fan, Fan Guard, and Fan Shroud Removeand Install

Remove and Install Fan and Fan Guard


OUO1073,0002103 –19–10APR07–2/9

TX

1020

695A

–UN

–22M

AR

07

1—Cap Screw (4 used)2—Fan Guard

2. Remove cap screws (1) and fan guard (2).


PN=143


Cooling System

050510

20

OUO1073,0002103 –19–10APR07–3/9

TX

1021

215A

–UN

–27M

AR

07

1—Fan2—Cap Screw (6 used)

3. Loosen clamps and remove upper radiator hose.

4. Remove cap screws (2), washers, and fan (1).

5. Install fan, washers, and cap screws. Tighten capscrews to specification.

SpecificationFan Cap Screws—Torque 37 N•m..............................................................

27 lb-ft

6. Install upper radiator hose.

7. Install fan guard and cap screws. Tighten cap screwsto specification.

SpecificationFan Guard Cap Screws—Torque 37 N•m..................................................

27 lb-ft


Remove and Install Fan Shroud

OUO1073,0002103 –19–10APR07–4/9

TX

1020

196A

–UN

–07M

AR






PN=144

Cooling System

05051021

OUO1073,0002103 –19–10APR07–5/9

TX

1021

548A

–UN

–03A

PR

07T

X10

2154

9A–U

N–0

3AP

R07

1—Hood Support Rod2—Cap Screws3—Hood

2. Raise engine hood.

3. Remove retaining pin and disconnect hood support rod(1).


SpecificationEngine Hood—Weight 36 kg.......................................................................

80 lb

4. Attach appropriate lifting device to hood.

5. Remove cap screws (2) and hood (3).

6. Remove fan and fan guard.

7. Remove access covers on bottom of machine.

8. Pull a vacuum in hydraulic oil tank using a vacuumpump. See Apply Vacuum to Hydraulic Oil Tank.(Group 3360.)

OUO1073,0002103 –19–10APR07–6/9

TX

1020

211A

–UN

–07M

AR

07

1—Cap Screws

9. Remove cap screws (1) and cover.



PN=145

Cooling System

050510

22

OUO1073,0002103 –19–10APR07–7/9

TX

1020

687A

–UN

–22M

AR

07T

X10

2068

8A–U

N–2

2MA

R07

1—Hydraulic Hose (to Fan Drive Motor)2—Cap Screw

10. Disconnect fan drive motor hydraulic hose (1) fromhydraulic oil tank. Apply caps and plugs to close allopenings.

11. Remove cap screw (2) and hose clamp.

12. Route hydraulic hose back through opening in side offan shroud.

OUO1073,0002103 –19–10APR07–8/9

TX

1020

690A

–UN

–22M

AR

07

1—Hydraulic Hose2—Hydraulic Hose

13. Tag and disconnect fan drive motor hydraulic hoses(1 and 2). Apply caps and plugs to close all openings.

14. Route hoses through opening in side of fan shroud.



PN=146

Cooling System

05051023

OUO1073,0002103 –19–10APR07–9/9

TX

1020

691A

–UN

–27M

AR

07

1—Cap Screw (8 used)2—Fan Shroud3—Hydraulic Hose4—Hydraulic Hose5—Fan Drive Motor Shaft6—Upper Intercooler Tube

15. Loosen clamps and remove upper intercooler tube(6).

16. Disconnect hydraulic oil cooler hoses (3 and 4). Applycaps and plugs to close all openings.

NOTE: Lower shroud cap screws can be accessed byremoving access panel on bottom ofupperstructure.

17. Remove cap screws (1) and washers from fan shroud(2).

IMPORTANT: To prevent damage to fan shroud, usean additional technician to help guideshroud past fan drive motor shaft (5)from below.

18. Lift fan shroud up, tilt toward left-hand side ofmachine, and remove.

19. Install fan shroud, washers, and cap screws. Tightencap screws to specification.

SpecificationFan Shroud Cap Screws—Torque 37 N•m.................................................

27 lb-ft

20. Connect hydraulic oil cooler hoses.

21. Install upper intercooler cooler tube.

22. Route hydraulic hoses back through opening in fanshroud and connect.

23. Install access covers.

24. Install fan and fan guard.

25. Install upper radiator hose.

26. Install hood.


28. Check hydraulic oil level. Fill as necessary. See160DLC Drain and Refill Capacities. (Operator’sManual.)


PN=147

Cooling System

OUO1073,0002102 –19–18APR07–1/2

Coolant Surge Tank Remove and Install

TS

281

–UN

–23A

UG

88



050510

24

OUO1073,0002102 –19–18APR07–2/2

TX

1020

677A

–UN

–22M

AR

07

1—Hose (to Engine)2—Hose3—Hose (to Radiator)4—Cap Screw (4 used)5—Hose6—Coolant Surge Tank

2. Drain coolant until level is below surge tank.

3. Loosen hose clamps and disconnect hoses (1, 2, and3).

4. Remove cap screws (4) from coolant surge tank (5).Reposition coolant surge tank to access lower hose(5).

5. Loosen hose clamp and disconnect lower hose (6).

6. Remove coolant surge tank. Replace as necessary.

7. Install coolant surge tank and cap screws.

8. Connect hoses and tighten clamps.



PN=148

Group 0520Intake System

0505201

LD30992,00005A0 –19–04APR07–1/1

Air Cleaner Remove and Install

TX

1021

229

–UN

–04A

PR

07

1—Cap Screw (4 used) 8—Hose 15—Intake Air Temperature 21—Nut2—Washer (4 used) 9—Hose Clamp Sensor 22—Air Cleaner Dust Valve3—Brackets 10—Mounting Bracket 16—Hose Clamp 23—Air Filter Housing4—Air Filter Restriction Switch 11—Washer (3 used) 17—Hose 24—Safety Element5—Intake Tube 12—Cap Screw (3 used) 18—Hose Clamp 25—Primary Air Cleaner6—Mounting Bracket 13—Cap Screw (4 used) 19—Cap Screw Element7—Hose Clamp 14—Washer (4 used) 20—Screen


PN=149

Intake System

050520

2


PN=150

Group 0560External Fuel Supply System

0505601

TJ15698,000012F –19–11APR07–1/4

Fuel Tank Remove and Install

TX

1020

209A

–UN

–07M

AR

07

1—Cover2—Step3—Handrail4—Toolbox

1. Drain fuel from tank. Approximate capacity is 320 L (85gal).

NOTE: Two cap screws for panel (1) are located intoolbox (4).


2. Disconnect and remove wiring harness from inside oftoolbox.

3. Remove step (2), cover (1), handrail (3), and toolbox(4).

SpecificationToolbox—Weight 33 kg...............................................................................

72 lb

TJ15698,000012F –19–11APR07–2/4

TX

1020

212A

–UN

–07M

AR

07

1—Cap Screw (3 used)2—Panel Latch Bracket

4. Remove cap screws (1) and bracket (2).

5. Remove control valve cover.



PN=151

External Fuel Supply System

050560

2

TJ15698,000012F –19–11APR07–3/4

TX

1020

200A

–UN

–07M

AR

07T

X10

2019

7A–U

N–0

7MA

R07

1—Cap Screws (4 used)2—Fuel Return Hose3—Clamp4—Electrical Connector

6. Disconnect electrical connector (4) and return hose (2).

7. Disconnect fuel supply hose from bottom of tank.


8. Remove cap screws (1) and fuel tank.

SpecificationFuel Tank—Weight 97 kg approximate without fuel....................................

214 lb approximate without fuel


10. Install fuel tank and tighten mounting cap screws tospecification.

SpecificationFuel Tank Mounting CapScrews—Torque 270 N•m...........................................................................

199 lb-ft

11. Connect fuel supply hose, return hose, and electricalconnector.

12. Install control valve cover and side panel latchbracket.



PN=152


0505603

TJ15698,000012F –19–11APR07–4/4

TX

1020

209A

–UN

–07M

AR

07


13. Install handrail (3), toolbox (4), cover (1), and step(2).

14. Fill tank with fuel.

15. Bleed fuel system. See Bleed Fuel System.(Operator’s Manual.)

TJ15698,000012D –19–11APR07–1/1

Primary Fuel Filter (Water Separator) Removeand Install

TX

1020

198A

–UN

–07M

AR

07

1—Cap Screw (2 used)2—Fuel Hose

1. Loosen drain valve on bottom of filter and drain fuelinto a container.

2. Disconnect electrical connector from bottom of filter.

3. Tag and disconnect fuel hoses (2).

4. Remove cap screws (1) and primary fuel filterassembly.

5. Install primary fuel filter assembly and tighten capscrews.

6. Connect fuel hoses and electrical connector.

7. Bleed fuel system. See Bleed Fuel System. (Operator’sManual.)


PN=153


TJ15698,000012E –19–11APR07–1/1

Final Fuel Filter Remove and Install

TX

1020

210A

–UN

–07M

AR

07

1—Cap Screw (2 used)2—Fuel Hose3—Electrical Connector

1. Loosen drain valve on bottom of filter and drain fuelinto a container.

2. Disconnect electrical connector (3).

3. Tag and disconnect fuel hoses (2).

4. Remove cap screws (1) and final fuel filter assembly.

5. Install final fuel filter assembly and tighten cap screws.

6. Connect fuel hoses and electrical connector.

7. Bleed fuel system. See Bleed Fuel System. (Operator’sManual.)

050560

4


PN=154

Section 07Dampener Drive (Flex Coupling)

Contents

Page

Group 0752—ElementsDampener Drive (Flex Coupling) Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1

07


PN=1

Contents

07


PN=2

Group 0752Elements

0707521

FS41334,0000145 –19–10APR07–1/3

Dampener Drive (Flex Coupling) Remove andInstall

TX

1019

969

–UN

–02M

AR

07

1—Hub2—Set Screw (2 used)3—Flex Coupling4—Cap Screw (4 used)5—Insert (4 used)6—Guide Pins (4 used)7—Cap Screw (4 used)8—Insert (4 used)

1. Remove engine or hydraulic pump. See EngineRemove and Install. (Group 0400.) or See Pump 1 and2 Remove and Install. (Group 3360.)

NOTE: Flex coupling may come off with pump or stay onengine flywheel.

2. Remove parts (1—8).

3. Inspect and replace parts as necessary.

IMPORTANT: Do not use steel hammer to installguide pins (2). Use only rubber orplastic mallet.

4. If guide pins in engine flywheel are damaged, removeand replace pins. Use new pins and install intoflywheel using a plastic or rubber mallet.

5. Install each insert so index hole is aligned with guidepin, installed in previous step.

FS41334,0000145 –19–10APR07–2/3

TX

1019

893A

–UN

–19M

AR

07

1—Engine Flywheel2—Insert (4 used)3—Cap Screw (4 used)4—Flex Coupling

6. Apply PM37418 Thread Lock and Sealer (MediumStrength) to cap screws (3). Tighten to specification.

SpecificationFlex Coupling-to-Flywheel CapScrew—Torque 137 N•m.............................................................................

101 lb-ft

7. Install flex coupling (4) onto flywheel inserts (2) asshown.


PN=157


Elements

070752

2

FS41334,0000145 –19–10APR07–3/3

TX

1019

891A

–UN

–19M

AR

07

1—Hydraulic Pump Housing2—Insert (4 used)3—Set Screw (2 used)4—Cap Screw (4 used)5—Hub6—Pump Shaft

8. Clean face of hydraulic pump housing (1).

9. Apply PM37418 Thread Lock and Sealer (MediumStrength) to threads of cap screws (4).

10. Install inserts (2) onto hub (5) using cap screws (4)and tighten to specification.

SpecificationPump Insert Cap Screws—Torque 137 N•m..........................................................................................

101 lb-ft

CAUTION: Install hub assembly so face is flushwith end of pump shaft. It cannot rub or hitpump housing or shaft oil seal when rotated.

11. Install hub (5) onto splines of pump shaft (6). Positionhub so face is flush with pump shaft end. Spacebetween hub and pump housing is approximately 2mm (0.08 in.).

12. Apply PM37418 Thread Lock and Sealer (MediumStrength) to set screws (3).

13. Tighten set screws (3) to specification.

SpecificationHub-to-Pump Shaft Set Screw—Torque 108 N•m..........................................................................................

80 lb-ft

14. Install engine or hydraulic pump. See Engine Removeand Install. (Group 0400.) or See Pump 1 and 2Remove and Install. (Group 3360.)


PN=158

Section 17Frame or Supporting Structure

Contents

Page

Group 1740—Frame InstallationWelding On Machine. . . . . . . . . . . . . . . . . . .17-1740-1Welding Repair of Major Structure. . . . . . . . .17-1740-3

Group 1749—Chassis WeightsCounterweight Remove and Install . . . . . . . .17-1749-1

17


PN=1

Contents

17


PN=2

Group 1740Frame Installation

OUO1073,0002105 –19–09APR07–1/4

Welding On Machine

IMPORTANT: Electrical current traveling from thewelder through the machine electricalsystem may damage the machineelectrical system, including battery,engine control unit (ECU), informationcontroller (ICF) and main controller(MCF). Disconnect battery cables andECU, ICF and MCF electrical connectorsbefore welding on the machine.

Before welding on the machine, follow the steps listedbelow to protect the machine electrical system.

1717401OUO1073,0002105 –19–09APR07–2/4

TX

1003

378A

–UN

–07F

EB

06

1—Electrical Connectors2—Main Controller (MCF)

1. Disconnect battery ground and positive cables.

2. Remove rear console cover behind seat. See RearCover Remove and Install. (9015-20.)

3. Disconnect electrical connectors (1) from MCF (2). SeeCab Harness (W1) Component Location (9015-10.)

OUO1073,0002105 –19–09APR07–3/4

TX

1003

380A

–UN

–01M

AR

061—Electrical Connector (2 used)2—Information Controller (ICF)

4. Disconnect electrical connectors (1) from ICF (2). SeeCab Harness (W1) Component Location. (9015-10.)



PN=161

Frame Installation

OUO1073,0002105 –19–09APR07–4/4

TX

1021

721A

–UN

–10A

PR

07

1—Engine Control Unit (ECU)2—Electrical Connectors

NOTE: Engine Control Unit (ECU) is located in the enginecompartment.

6. Disconnect electrical connectors (2) from enginecontrol unit (ECU) (1). See Engine Interface Harness(W5) Component Location. (9015-10.)

171740

2


PN=162

Frame Installation

1717403

OUO1073,0002106 –19–28MAR07–1/1

Welding Repair of Major Structure

CAUTION: Avoid potentially toxic fumes anddust. Hazardous fumes can be generatedwhen paint is heated by welding, soldering,or using a torch. Do all work outside or in awell ventilated area. Dispose of paint andsolvent properly.

If you sand or grind paint, avoid breathingthe dust. Wear an approved respirator. If youuse solvent or paint stripper, removestripper with soap and water before welding.Remove solvent or paint stripper containersand other flammable material from area.Allow fumes to disperse at least 15 minutesbefore welding or heating.

1. Remove paint before welding or heating.

IMPORTANT: Disconnect battery ground strap andpositive cables. Also disconnect thewiring harness connectors to themain controller (MCF), informationcontroller (ICF) and engine controlunit (ECU). See Welding on Machine.(Group 1740.)

Have only a qualified welder do thisjob. Connect welder ground clampclose to each weld area so electricalcurrent does not pass through anybearings. Remove or protect all partsthat can be damaged by heat or weldsplatter.

2. Use one of the following weld processes:

• AWS-E-7018 covered electrode with shieldedmetal arc welding (SMAW) process.

• AWS-ER-70S-3 wire electrode with gas metal arcwelding (GMAW) process.

• AWS-E70T-1 or E71T-1 wire electrode with fluxcore arc welding (FCAW) process.

Welding Repair of Major Structure—SpecificationWeld Metal—Tensile Strength 482.6 mPa (70,000 psi).......................Yield Strength 413.7 mPa (60,000 psi)................................................Elongation 22%.....................................................................................

IMPORTANT: Area to be repaired must bepreheated to allow better weldpenetration.

3. To repair weld metal failure, remove failed weldmetal using arc or grinding equipment. Thoroughlyclean area to be welded. Preheat structuralassemblies to a minimum of 38°C (100°F). Preheatground engaging tools (cutting edges, skid shoes,and teeth shanks) to 177°C (350°F).

To repair base metal failure remove enoughmaterial to allow weld to penetrate to the bottom ofcrack. Preheat structural assemblies to a minimumof 38°C (100°F). Preheat ground engaging tools(cutting edges, skid shoes, and teeth shanks) to177°C (350°F).

Welding Repair of Major Structure—SpecificationStructural Assemblies—PreheatTemperature 38°C (100°F)...................................................................Ground Engaging Tools—Preheat Temperature 177°C (350°F)....................................................


PN=163

Frame Installation

171740

4


PN=164

Group 1749Chassis Weights

1717491

TJ15698,0000144 –19–29MAR07–1/1

Counterweight Remove and Install

T14

3043

–UN

–20J

UL0

1T

1430

44–U

N–0

3SE

P02

T14

3045

–UN

–20J

UL0

1

1—Plastic Cap (2 used)2—Lifting Device3—Spreader Bar4—Cap Screw and Washer (4 used)

1. Park machine on level ground.

2. Remove two plastic caps (1) from top of counterweight.


The lifting capacity of a lifting eyeboltdecreases as the lift angle increases fromvertical. A spreader bar should be used toobtain, as close as possible, a vertical lift fromeyebolts.

SpecificationCounterweight—Weight 3310 kg.................................................................

7299 lb

3. Connect counterweight to an appropriate lifting device(2) using a spreader bar (3).

4. Remove cap screws and washers (4).

5. Remove counterweight.


7. Install counterweight onto machine using appropriatelifting device.

8. Install cap screws and washers (4). Tighten tospecification.

SpecificationFrame-to-Counterweight CapScrew—Torque 1150 N•m...........................................................................

830 lb-ft


PN=165

Chassis Weights

171749

2


PN=166

Section 18Operator’s Station

Contents

Page

Group 1800—Removal and InstallationCab Remove and Install . . . . . . . . . . . . . . . .18-1800-1

Group 1810—Operator EnclosureSliding Windows Remove and Install. . . . . . .18-1810-1Windowpanes Remove and Install . . . . . . . .18-1810-2Windowpanes Dimensions . . . . . . . . . . . . . .18-1810-3

Group 1821—Seat and Seat BeltSeat Remove and Install . . . . . . . . . . . . . . . .18-1821-1Seat Belt Remove and Install . . . . . . . . . . . .18-1821-2Mechanical Suspension Seat Disassemble

and Assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-3Air Suspension Seat Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-4Left and Right Console Covers Remove

and Install . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-5

Group 1830—Heating and Air ConditioningRefrigerant Cautions and Proper

Handling . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1Flush and Purge Air Conditioner System. . . .18-1830-3R134a Refrigerant Oil Information . . . . . . . . .18-1830-6R134a Refrigerant Recovery/Recycling

and Charging Station InstallationProcedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7

Recover R134a Refrigerant . . . . . . . . . . . . . .18-1830-8Evacuate R134a System. . . . . . . . . . . . . . . .18-1830-9Charge R134a System . . . . . . . . . . . . . . . .18-1830-10

18Compressor Remove and Install . . . . . . . . .18-1830-11Condenser Remove and Install . . . . . . . . . .18-1830-11Heater and Air Conditioner Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13Receiver-Dryer Remove and Install . . . . . . .18-1830-17


PN=1

Contents

18


PN=2

Group 1800Removal and Installation

OUO1073,0002100 –19–03APR07–1/17

Cab Remove and Install

1. Disconnect battery ground (-) cable.

OUO1073,0002100 –19–03APR07–2/17

TX

1020

462A

–UN

–16M

AR

07

1—Door

2. Remove door (1).

OUO1073,0002100 –19–03APR07–3/17

TX

1020

458A

–UN

–16M

AR

07

1818001

1—Cover


OUO1073,0002100 –19–03APR07–4/17

TX

1020

459A

–UN

–16M

AR

07

1—Hose Clamp

4. Loosen hose clamp (1).



PN=169


OUO1073,0002100 –19–03APR07–5/17

TX

1020

460A

–UN

–16M

AR

07

1—Air Filter Assembly2—Windshield Washer Reservoir3—Hose4—Diagnostic Connector5—Cap Screw (4 used)

5. Disconnect hose (3) from windshield washer reservoir(2).

6. Disconnect wiring harness from windshield washerreservoir (2).

7. Lift windshield washer reservoir (2) off of mountingbracket and remove.

8. Remove cap screws attaching diagnostic connector (4)to air filter assembly mounting bracket. Lay connectoraside.

9. Remove cap screws (5) and air filter assembly (1).Close air tube openings.

OUO1073,0002100 –19–03APR07–6/17

TX

1020

461A

–UN

–16M

AR

07

181800

2

1—Panel2—Panel

NOTE: Lower mounting hardware for panel (1) can beaccessed by removing access panels on bottomof machine.

10. Remove panels (1 and 2) to access rear of cab.

OUO1073,0002100 –19–03APR07–7/17

TX

1020

388A

–UN

–19M

AR

07

1—Connector2—Connector3—Connector4—Connector5—Ground

11. Disconnect cab wiring harness connectors (1—4).

12. Disconnect ground wires (5) from frame.

13. Remove seat. See Seat Remove and Install. (Group1821.)

14. Remove cab floor mat.


PN=170



OUO1073,0002100 –19–03APR07–8/17

TX

1020

391

–UN

–16M

AR

07

1—Bracket2—Cap Screw (3 used)3—Cab Frame4—Seat Mount

15. Remove cap screws (2) and bracket (1) from cabframe (3) and seat mount (4).

OUO1073,0002100 –19–03APR07–9/17

TX

1020

272A

–UN

–08M

AR

07

1818003

1—Cover2—Screws3—Cap Screws4—Panel

16. Remove cover (1) from rear panel.

17. Remove screws (2) and cap screws (3) from rearpanel (4).

18. Pull rear panel forward. Disconnect wiring harnessfrom lighter and power outlet and remove panel.

OUO1073,0002100 –19–03APR07–10/17

TX

1020

347A

–UN

–08M

AR

07

1—Screw2—Panel3—Air Duct

19. Remove screws (1), panel (2), and air duct (3).



PN=171


OUO1073,0002100 –19–03APR07–11/17

TX

1020

275A

–UN

–08M

AR

07

1—Inlet Duct2—Cap Screw

20. Remove cap screws (2), mounting bracket, and freshair inlet duct (1).

181800

4

OUO1073,0002100 –19–03APR07–12/17

TX

1020

387A

–UN

–19M

AR

07T

X10

2039

4A–U

N–1

9MA

R07

1—Cap Screw2—Cab Wiring Harness3—Cap Screw4—Bracket5—Cap Screws

21. Remove cap screw (1) behind 12 volt powerconverter.

22. Remove cap screw (3), cap screws (5) and bracket(4).

23. Disconnect cab wiring harness (2) from left and rightconsoles and air conditioning module. See CabHarness (W1) Component Location . (Group9015-10).

24. Remove any clamps or tie bands securing cabharness to floor or consoles.

OUO1073,0002100 –19–03APR07–13/17

TX

1021

236A

–UN

–27M

AR

07

1—Monitor Controller2—Cup Holder3—Panel

25. Remove monitor controller (1). See Monitor ControllerRemove and Install. (Group 9015-20.)

26. Remove cup holder (2) and panel (3).


PN=172



OUO1073,0002100 –19–03APR07–14/17

TX

1020

389A

–UN

–19M

AR

07

Rear Anchor Bolt

TX

1020

390A

–UN

–19M

AR

07

Front Anchor Bolt

1818005

1—Ground Wire2—Anchor Bolt

27. Remove access covers from bottom of cab.

28. Remove anchor bolts (1), spacers, and washers.

29. Remove cap screw and disconnect ground (1) fromframe.

OUO1073,0002100 –19–03APR07–15/17

21 2

1

3

45

63

4

57

8

3

46

TX

1020

393

–UN

–19M

AR

07

1—Lock Nut (4 used)2—Washer (4 used)3—Socket Head Cap Screw (4 used)4—Washer (4 used)5—Cap Screw (6 used)6—Washer (6 used)7—Socket Head Cap Screw8—Washer

30. Remove socket head cap screws (3 and 7), capscrews (5), and isolator lock nuts (1) to separate cabframe from floor. Discard lock nuts.



PN=173


181800

6

OUO1073,0002100 –19–03APR07–16/17

TX

1003

209A

–UN

–14M

AR

06

1—Lifting Brackets


SpecificationCab—Weight 380 kg...................................................................................

838 lb

31. Use lifting straps and connect appropriate liftingdevice to lifting brackets (1) on roof of cab.

IMPORTANT: Before lifting cab, ensure all wiringharness connectors and ducts havebeen disconnected.

32. Remove cab.


IMPORTANT: Ensure all wiring harnesses and othercomponents are out of the way beforeinstalling cab.

34. Install cab. Tighten cab mounting hardware tospecification.

SpecificationCab-to-Floor Socket Head CapScrews—Torque 50 N•m.............................................................................

37 lb-ft

SpecificationCab-to-Floor Cap Screws—Torque 50 N•m............................................................................................

37 lb-ft

SpecificationCab Isolator Lock Nuts—Torque 210 N•m..................................................

155 lb-ft

SpecificationCab Anchor Bolts—Torque 550 N•m..........................................................

406 lb-ft

35. Install access covers on bottom of cab. Tighten capscrews to specification.

SpecificationCab Access Cover Cap Screws—Torque 50 N•m............................................................................................

37 lb-ft


PN=174



OUO1073,0002100 –19–03APR07–17/17

36. Connect cab wiring harness connectors. See CabHarness (W1) Component Location . (Group9015-10).

37. Connect ducts to heater and air conditioning module.

38. Install monitor controller. See Monitor ControllerRemove and Install. (Group 9015-20.)

39. Install seat. See Seat Remove and Install. (Group1821.)

40. Install panels behind cab.


42. Install windshield washer reservoir and connect hose.

43. Install diagnostic connector to air filter assemblymounting bracket.

44. Install door.

1818007


PN=175


181800

8


PN=176

Group 1810Operator Enclosure

RO33873,0000A5E –19–03APR07–1/1

Sliding Windows Remove and Install

T14

0968

–UN

–30A

PR

01

1—Window Frame2—Bottom Spacer (4 used)3—Molding4—Adhesive

1. Remove molding (3) from inside of window.

2. Use putty knife to cut adhesive (4) between cab flangeand window frame (1).

IMPORTANT: Work carefully to avoid damaging frameand windowpane. Two technicians arerequired during window removal; one topush window out of cab, and one toprevent window from falling.

3. Carefully remove window frame from cab.

4. Lift frame slightly at top-center to remove and installwindowpanes.

5. Apply PM37391 Instant Gel Adhesive to cab flange.

6. Install windows and frame with spacers (2) at thebottom.

7. Using water as lubricant, push window frame tightagainst cab flange.

8. Install molding (3) around window and cab flange.

1818101


PN=177

Operator Enclosure

181810

2

RO33873,0000A5F –19–03APR07–1/1

Windowpanes Remove and Install

The adhesive used to secure windowpanes is a urethaneadhesive used on automobile windshields. Urethaneadhesive manufactured by Henkel Corporation orequivalent is recommended. DO NOT use any other typeof adhesive. It is recommended that an auto glass dealerinstall windowpanes.

IMPORTANT: Windowpanes must include anultraviolet barrier around edge toprevent adhesive deterioration.Windowpanes ordered through JohnDeere Parts include ultraviolet barrier. Ifwindowpane is purchased throughglass dealer, the dealer mustincorporate ultraviolet barrier on theglass. DO NOT paint border of glass.

If auto glass dealer does not install windowpanes,proceed as follows:

1. Remove windowpane frame from cab.

2. Scrape any broken glass off existing adhesive. DONOT remove adhesive from window frame or cab.

IMPORTANT: Adhesive will not bond to bare metal.

3. If existing adhesive is removed and paint is scraped,paint window frame. Paint must fully cure beforeinstalling windowpane.

4. Trim existing adhesive to form a smooth surface.

IMPORTANT: Follow manufacturer’s instructions forusing adhesive.

5. Apply 6 mm (1/4 in.) bead of adhesive over existingadhesive.

6. Position windowpane in cab frame. Use hand pressureto force windowpane down until edges are even withmetal frame.

7. Secure windowpane with duct tape until adhesivecures. Allow adhesive to cure for 24 hours beforeoperating machine.


PN=178

Operator Enclosure

1818103

OUO1073,0002108 –19–17APR07–1/5

Windowpanes Dimensions

TX

1021

276

–UN

–04A

PR

07

Cab Door Glass


PN=179


Operator Enclosure

181810

4

OUO1073,0002108 –19–17APR07–2/5

TX

1018

573

–UN

–23F

EB

07

Cab Right-Hand Glass


PN=180


Operator Enclosure

1818105

OUO1073,0002108 –19–17APR07–3/5

TX

1021

275

–UN

–04A

PR

07

Cab Rear and Left-Hand Rear Glass


PN=181


Operator Enclosure

181810

6

OUO1073,0002108 –19–17APR07–4/5

TX

1018

570

–UN

–23F

EB

07

Cab Front Glass


PN=182


Operator Enclosure

OUO1073,0002108 –19–17APR07–5/5

1—Black Ceramic Coating 2—Black Ceramic CoatingRange Surface

NOTE: Dimensions shown are in millimeters.

1818107


PN=183

Operator Enclosure

181810

8


PN=184

Group 1821Seat and Seat Belt

1818211

OUO1073,00020FF –19–17APR07–1/1

Seat Remove and Install

TX

1020

303A

–UN

–08M

AR

07T

X10

2030

4A–U

N–0

8MA

R07

1—Cap Screw2—Socket Head Cap Screw3—Cap Screws4—Stop5—Socket Head Cap Screws

1. Slide seat forward.

2. Remove cap screws (1), lock washers, and lower seatbelts from each side of seat.

3. Remove socket head cap screws (2) from rear of seat.

4. Slide seat rearward.

5. Remove socket head cap screws (5) from front of seat.


SpecificationSeat—Weight 40 kg....................................................................................

90 lb

6. Remove seat through front window using lifting strapand hoist.


8. Install seat.

9. Tighten seat mounting hardware to specification.

SpecificationSeat Mount Socket Head CapScrews—Torque 20 N•m.............................................................................

177 lb-in.

10. Install lower seat belt, lock washer and cap screw oneach side of seat. Tighten cap screw to specification.

SpecificationLower Seat Belt Mount CapScrews—Torque 50 N•m.............................................................................

37 lb-ft


PN=185

Seat and Seat Belt

OUO1073,00020E8 –19–10APR07–1/1

Seat Belt Remove and Install

TX

1018

443A

–UN

–09F

EB

07T

1889

88B

–UN

–26M

AR

0318

18212

1—Lower Seat Belt2—Cap Screw3—Upper Seat Belt4—Cap Screw

1. Slide seat forward. Remove cap screw (2), lock washerand lower seat belt (1) from each side of seat.

2. Remove cap screw (4) and upper seat belt (3) fromeach side of seat.


4. Install seat belts and cap screws (4).

5. Install lower seat belt to lower mount on each side ofseat using cap screw (4), lock washer and cap screw.Tighten cap screw to specification.

SpecificationLower Seat Belt Mount CapScrews—Torque 50 N•m.............................................................................

37 lb-ft


PN=186

Seat and Seat Belt

1818213

RO33873,0000A6B –19–16MAR06–1/1

Mechanical Suspension Seat Disassemble and Assemble

TX

1004

008

–UN

–21F

EB

06

0—Seat Assembly 6—Frame 12—Adjuster 17—Cover2—Cushion Cover 7—Cable 13—Lever 20—Bushing3—Support 8—Stand 14—Seat Suspension 21—Link4—Cushion 10—Spring 15—Seat Slide Track Kit 24—Seat Kit5—Pad 11—Torsional Damper 16—Handle 25—Head Restraint


PN=187

Seat and Seat Belt

181821

4

RO33873,0000A6C –19–16MAR06–1/1

Air Suspension Seat Disassemble and Assemble

TX

1004

009

–UN

–21F

EB

06

0—Seat Assembly 8—Handle 16—Compressor 22—Seat Suspension2—Cushion Cover 9—Stand 17—Lever 23—Seat Suspension Boot Kit3—Pad 10—Spring 18—Torsional Damper 24—Seat Adjustment Cable Kit4—Cushion 11—Seat Slide Track Kit 19—Air Spring Seat Kit 25—Wiring Lead5—Pad 14—Lever Kit 20—Valve 26—Head Restraint6—Frame 15—Bearing Kit 21—Kit 27—Heater7—Cable


PN=188

Seat and Seat Belt

LD30992,00004F1 –19–28MAR07–1/3

Left and Right Console Covers Remove andInstall

TX

1018

700A

–UN

–08F

EB

07

1—Pilot Control Shutoff Lever2—Cap Screws and Washers (8 used)

1. Remove pilot control shutoff lever (1).

2. Remove cap screws (2) from pilot control boot.


1818215


PN=189

Seat and Seat Belt

181821

6

LD30992,00004F1 –19–28MAR07–2/3

TX

1000

801

–UN

–15D

EC

05


PN=190


Seat and Seat Belt

LD30992,00004F1 –19–28MAR07–3/3

0—Cover 9—Cap Screw, Washer, and 18—Cover 26—Cover4—Screw (4 used) Lock Washer 19—Cap Screw, Washer, and 27—Cap Screw, Washer, and5—Cap Screw, Washer, and 11—Cover Lock Washer (3 used) Lock Washer (4 used)

Lock Washer 12—Cap Screw, Washer, and 22—Cover 28—Cap (2 used)7—Cover Lock Washer 23—Cap Screw, Washer, and 30—Label8—Cap Screw, Washer, and 15—Cover Lock Washer (2 used) 31—Label

Lock Washer (2 used) 16—Screw (4 used) 24—Cap Screw, Washer, andLock Washer

3. Remove:

• Caps (28)• Screws (4 and 16)• Cap Screws (5, 8, 9, 12, 19, 23, 24, and 27)• Covers (0, 7, 11, 15, 18, 22, and 26)


5. Install covers, cap screws, screws, and caps.

6. Install pilot control shutoff lever and pilot controlboot cap screws.

1818217


PN=191

Seat and Seat Belt

181821

8


PN=192

Group 1830Heating and Air Conditioning

1818301

TX,9031,DY5073 –19–21JUL06–1/2

Refrigerant Cautions and Proper Handling

CAUTION: DO NOT allow liquid refrigerant tocontact eyes or skin. Liquid refrigerant willfreeze eyes or skin on contact. Weargoggles, gloves and protective clothing.

If liquid refrigerant contacts eyes or skin, DONOT rub the area. Splash large amounts ofCOOL water on affected area. Go to aphysician or hospital immediately fortreatment.

DO NOT allow refrigerant to contact openflames or very hot surfaces such as electricwelding arc, electric heating element andlighted smoking materials.

DO NOT heat refrigerant over 52°C (125°F) ina closed container. Heated refrigerant willdevelop high pressure which can burst thecontainer.

Keep refrigerant containers away from heatsources. Store refrigerant in a cool place.

DO NOT handle damp refrigerant containerwith your bare hands. Skin may freeze tocontainer. Wear gloves.

If skin freezes to container, pour COOLwater over container to free the skin. Go to aphysician or hospital immediately fortreatment.

IMPORTANT: To meet government standardsrelating to the use of refrigerants,

R134a is used in the air conditioningsystem. Because it does not containchlorine, R134a is not detrimental tothe ozone in the atmosphere.However, it is illegal to dischargeany refrigerant into the atmosphere.It must be recovered using theappropriate recovery stations.

Use correct refrigerant recovery,recycling and charging stations.Never mix refrigerants, hoses,fittings, components or refrigerantoils.

Use only John Deere approvedR134a refrigerant products. Mixing ofproducts not compatible will causesystem damage and contaminaterecovery, recycling and chargingstation equipment. Care must betaken to identify and use equipment,refrigerant oil and refrigerantdesigned only for R134a refrigerantsystems. Refrigerant should betested for type and purity beforerecovery, recycling or charging ofsystem. JT02167A refrigerant testinstrument should be used beforeany testing or repair to system ispreformed.



PN=193

Heating and Air Conditioning

TX,9031,DY5073 –19–21JUL06–2/2

Prism Pro Refrigerant IdentificationInstrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A

To safely identify type and check purity of refrigerantprior to recovery, recycling and recharging of A/Csystems.

181830

2


PN=194


1818303

OUO1073,00020F4 –19–10APR07–1/3

Flush and Purge Air Conditioner System

CAUTION: Liquid refrigerant will freeze eyesor skin on contact. Wear goggles, glovesand protective clothing.

See Refrigerant Cautions and ProperHandling. (Group 1830.)

NOTE: Flushing can be performed on machine.

1. Recover refrigerant from system. See RecoverR134a Refrigerant. (Group 1830.)

Add flushing solvent to system with JT02075Flusher and JT02098 Flusher Fitting Kit.

2. Remove and discard receiver/dryer.

3. Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102 Adapter.

4. Fill flusher tank with solvent and fasten allconnections. Dispose of solvent properly.

SpecificationFlusher Tank—Capacity 4 L.................................................................

1 gal

NOTE: Air pressure must be at least at specificationfor flushing and purging.

SpecificationAir Pressure—MinimumPressure 620 kPa for flushing and

purging........................................................

90 psi for flushing and purging6.2 bar for flushing and purging

5. Connect supply line of moisture-free compressedair or dry nitrogen to flusher air valve.

6. Open air valve to force flushing solvent intocondenser circuit. Flusher tank is empty when hosepulsing stops. Additional flushing cycles arerequired if system is heavily contaminated withburned oil or metal particles.

7. Clean compressor as follows:

a. Remove compressor and measure oil drainedfrom both manifold ports.

b. Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102Adapter.

c. Pour flushing solvent into suction port anddischarge port. Plug both ports in compressormanifold, using JT02099 and JT03194 Caps.

SpecificationFlushing Solvent in SuctionPort—Volume 240 mL...........................................................................

8 fl ozFlushing Solvent in DischargePort—Volume 120 mL...........................................................................

4 fl oz

d. Turn compressor end for end and roll it side toside.

e. Remove both plugs from manifold ports anddrain solvent from compressor.

f. Connect battery power to compressor clutch coil.Rotate pulley at least five revolutions to movesolvent out of cylinders.

g. Invert compressor. Roll end for end and side toside. Drain thoroughly.

h. Repeat previous two steps at least three times.

8. Divide system into two circuits:

• Condenser circuit, including inlet and outlethoses.

• Evaporator circuit, including inlet and outlethoses.

9. Condenser:


PN=195



181830

4

OUO1073,00020F4 –19–10APR07–2/3

IMPORTANT: DO NOT attempt to flush throughcompressor or receiver/dryer.Flushing through expansion valve isacceptable if refrigerant oil has anormal odor and appearance.

a. Flush/Purge Condenser:

b. Remove and discard receiver/dryer.

c. Connect flusher outlet hose to inlet end ofcompressor discharge line using JT02102Adapter.

d. Fill flusher tank with solvent and fasten allconnections.


1 gal

NOTE: Air pressure must be at least to specificationfor flushing and purging.

SpecificationAir Pressure—MinimumPressure 620 kPa for flushing and

purging.........................................................

90 psi for flushing and purging.6.2 bar for flushing and

purging.

e. Connect supply line of moisture-free compressedair or dry nitrogen to flusher air valve.

f. Open air valve to force flushing solvent intocondenser circuit. Flusher tank is empty whenhose pulsing stops. Additional flushing cycles arerequired if system is heavily contaminated withburned oil or metal particles.

g. Attach return hose and aerator nozzle to end ofreceiver/dryer inlet hose using JT03197 Adapter.

Put nozzle in container to collect flushingsolvent.

NOTE: Purging the condenser circuit takes 10—12minutes to thoroughly remove solvent.

h. Disconnect hose from aeration nozzle to checkcircuit for solvent. Hold hose close to piece ofcardboard; continue purging until cardboard isdry.

10. See flush evaporator, if evaporator requiresflushing.

If system is contaminated with burned refrigerantoil or debris, remove and bench flush evaporator.See following steps to flush evaporator throughexpansion valve, if oil appears normal.

11. Flush evaporator:

a. Remove evaporator and expansion valve. SeeHeater and Air Conditioner Remove and Install.(Group 1830.)

b. Force flushing solvent through evaporator inletwith compressed air.

c. Purge system until dry.

d. Install evaporator and then go to step 13.

12. Flush evaporator through expansion valve:

a. Connect flusher outlet hose to connection ofreceiver/dryer outlet hose using JT03188adapter.

b. Fill flusher tank and fasten all connections.


1 gal


PN=196



OUO1073,00020F4 –19–10APR07–3/3

NOTE: Air pressure must be at least to specificationfor flushing and purging.

SpecificationAir Pressure—MinimumPressure 620 kpa for flushing and

purging.........................................................

90 psi for flushing and purging.6.2 bar for flushing and

purging.

c. Connect supply line of moisture-freecompressed air or dry nitrogen to flusher airvalve.

d. Attach hose and aerator nozzle to compressorinlet line using JT02101 adapter. Put nozzle incontainer to collect solvent.

NOTE: Purging evaporator circuit takes 12—15minutes to thoroughly remove solvent.

13. Disconnect hose from aeration nozzle to checkcircuit for solvent. Hold hose close to piece ofcardboard and continue purging until cardboard isdry.

14. Install new receiver/dryer compatible with R134arefrigerant. Fasten connections and mountingbracket. See Receiver-Dryer Remove and Install.(Group 1830.)

15. Add required oil. See R134a Refrigerant OilInformation. (Group 1830.)

16. Install compressor and connect refrigerant lines tomanifold.

17. Connect clutch coil wire and install drive belt.

1818305


PN=197


181830

6

OUO1073,00020F5 –19–04APR07–1/1

R134a Refrigerant Oil Information

CAUTION: All new compressors are chargedwith a mixture of nitrogen, R134a refrigerantand TY22025 (R134a) refrigerant oil. Wearsafety goggles and discharge thecompressor slowly to avoid possible injury.

IMPORTANT: Do not add any more oil thanrequired or maximum cooling will bereduced.

DO NOT leave system or R134acompressor oil containers open.Refrigerant oil easily absorbsmoisture. DO NOT spill R134acompressor oil on acrylic or ABSplastic. This oil will deteriorate thesematerials rapidly. Identify R134a oilcontainers and measures toeliminate accidental mixing ofdifferent oils.

New compressor from parts depot contains new oil. Oillevel visible through suction port normally is belowdrive shaft.

Normal operating oil level of compressor removed fromoperation cannot be seen through suction port ofcompressor.

Compressors can be divided into three categorieswhen determining correct oil charge for system.

• New compressor from parts depot• Used compressor removed from operation• Compressor internally washed with flushing solvent

Determine amount of system oil charge prior toinstallation of compressor on machine.

When complete system, lines, and components areflushed add correct amount of oil as described.

SpecificationOil—Volume 180 mL.............................................................................

6.09 fl ozR134a—Weight 950 ± 50 g...................................................................

2.09 ± 0.1 lb

If any section of hose is removed and flushed orreplaced, measure length of hose and use formula 3mL per 30 cm (0.1 fl oz per ft ) to determine correctamount of oil to be added.

Drain compressor oil into graduated container whilerotating compressor shaft and record amount.

If oil drained from compressor removed from operationis very black or amount of oil is less than 6 mL (0.2 floz), perform the following and discard oil properly:

❒ Determine if R134a leakage was detected, removecomponent and repair or replace component.

❒ Remove and discard receiver/dryer.❒ Flush complete system with TY16134 Air

Conditioning Flushing Solvent.

If component is serviceable, pour flushing solvent inports and internally wash out old oil and discard oilproperly.

Install new receiver-dryer.See Receiver-Dryer Removeand Install. (Group 1830.)

Install required amount of TY22025 Refrigerant Oil incompressor.

Connect all components. Evacuate and charge system.See Evacuate R134a System and See Charge R134aSystem. (Group 1830.)


PN=198


1818307

OUO1073,00020F6 –19–05MAR07–1/1

R134a Refrigerant Recovery/Recycling andCharging Station Installation Procedure

T81

18A

G–U

N–0

6DE

C93

A—High Pressure Hose Charge Port CapB—Red HoseC—Blue HoseD—High Pressure Relief ValveE—Refrigerant Recovery/Recycling and Charging

Station

CAUTION: Liquid refrigerant will freeze eyes orskin on contact. Wear goggles, gloves andprotective clothing.

See Refrigerant Cautions and Proper Handling.(Group 1830.)

IMPORTANT: Use only John Deere approved R134arefrigerant products. Mixing of productsnot compatible will cause systemdamage and contaminate recovery,recycling and charging stationequipment.

CAUTION: Do not remove high pressure reliefvalve (D). Air conditioning station will dischargerapidly causing possible injury.

IMPORTANT: Use only John Deere approvedrefrigerant recovery/recycling andcharging stations. DO NOT mixrefrigerant, hoses, fittings, componentsor refrigerant oils.

1. Follow procedures. See Refrigerant Cautions andProper Handling. (Group 1830.)

2. Close both high-side and low-side valves on refrigerantrecovery/recycling and charging station (E).

3. Remove cap from low-side charge port.

4. Connect blue hose (C) from refrigerantrecovery/recycling and charging station (E) to low-sidetest port.

5. Remove cap (A) from charge port on high pressurehose and connect red hose (B).

6. Follow the manufacturers’ instructions when usingrefrigerant recovery/recycling and charging station.


PN=199


181830

8

OUO1073,00020F7 –19–05MAR07–1/1

Recover R134a Refrigerant

CAUTION: Liquid refrigerant will freeze eyes orskin on contact. Wear goggles, gloves andprotective clothing.

See Refrigerant Cautions and Proper Handling.(Group 1830.)

CAUTION: Do not remove high pressure reliefvalve. Air conditioning system will dischargerapidly causing possible injury.

IMPORTANT: Use correct refrigerantrecovery/recycling and chargingstations. DO NOT mix refrigerant,hoses, fittings, components orrefrigerant oils.

1. Run air conditioning system for three minutes to help inrecovery process. Turn air conditioning system offbefore proceeding with recovery steps.

2. With engine OFF identify refrigerant type usingJT02167A Refrigerant Identification Instrument.

3. Connect refrigerant recovery system. See R134aRefrigerant Recovery/Recycling and Charging StationInstallation Procedure. (Group 1830.)

4. Follow manufacturers’ instructions when usingrefrigerant recovery/recycling and charging station.


PN=200


1818309

OUO1073,00020F8 –19–05MAR07–1/1

Evacuate R134a System



Do not remove high pressure relief valve. Airconditioning system will discharge rapidlycausing possible injury.

1. Connect refrigerant recovery system. See R134aRefrigerant Recovery/Recycling and ChargingStation Installation Procedure. (Group 1830.)

2. Open low-side and high-side valves on refrigerantrecovery/recycling and charging station.

3. Follow manufacturers’ instructions and evacuatesystem.

NOTE: Vacuum specifications listed are for sea levelconditions. Subtract 3.4 kPa (34 mbar) (1 in.Hg) from 98 kPa (980 mbar) (29 in. Hg) foreach 300 m (1000 ft) elevation above sealevel.

SpecificationEvacuate System—Vacuum Subtract 3.4 kPa from 98 kPa

for each 300 m elevation abovesea level

................

Subtract 34 mbar from 980mbar for each 300 m elevation

above seal levelSubtract 1 in. Hg from 29 in.Hg for each 1000 ft elevation

above sea level

4. Evacuate system until low-side gauge registers 98kPa (980 mbar) (29 in. Hg) vacuum.

SpecificationEvacuate System—Vacuum 98 kPa.....................................................

980 kPa29 in. Hg

If above specification vacuum cannot be obtained in 15minutes, test the system for leaks. See RefrigerantLeak Test. (Group 9031-25.)

5. When vacuum reaches above specification, closelow-side and high-side valves. Turn vacuum pumpoff.

6. If vacuum decreases more than specification in 5minutes, there is a leak in system.

SpecificationEvacuate System—Vacuum 3.4 kPa....................................................

34 mbar1 in. Hg

7. Repair leak.

8. Evacuate system for 30 minutes after 98 kPa (980mbar) (29 in. Hg) vacuum is reached.

9. Close low-side and high-side valves. Stopevacuation.

10. Charge system. See Charge R134a System.(Group 1830.)


PN=201


181830

10

OUO1073,00020F9 –19–27MAR07–1/1

Charge R134a System



IMPORTANT: Use only John Deere approvedrefrigerant recovery/recycling andcharging stations. DO NOT mixrefrigerant, hoses, fittings,components or refrigerant oils.

1. Identify refrigerant type using JT02167A RefrigerantIdentification Instrument.

2. Connect R134a Refrigerant Recovery/Recyclingand Charging Station. See R134a RefrigerantRecovery/Recycling and Charging StationInstallation Procedure. (Group 1830.)

3. Evacuate system. See Evacuate R134a System .(Group 1830.)

NOTE: Before beginning to charge air conditioningsystem, the following conditions must exist:Engine STOPPED, the pump must be capableof 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 each300 m (1000 ft) elevation above sea level.

SpecificationEvacuate System—Vacuum Subtract 3.4 kPa from 98 kPa

for each 300 m elevation abovesea level

................

Subtract 34 mbar from 980mbar for each 300 m elevation

above seal levelSubtract 1 in. Hg from 29 in.Hg for each 1000 ft elevation

above sea level

4. Follow manufacturer’s instructions and chargesystem.

5. Add refrigerant to system.

SpecificationAir Conditioning SystemRefrigerant—RefrigerantQuantity .95 kg......................................................................................

2.09 lb

6. Check air conditioning for proper function. SeeDiagnose Air Conditioning System Malfunctions.(Group 9031-15.)


PN=202


18183011

OUO1073,00020FA –19–03APR07–1/1

Compressor Remove and Install

TX

1020

173A

–UN

–07M

AR

07

1—Cap Screws2—Low Pressure Line3—High Pressure Line4—Connector5—Cap Screw (4 used)6—Compressor7—Belt

1. Recover refrigerant from system. See See RecoverR134a Refrigerant. (Group 1830.)

2. Remove compressor drive belt (7).

3. Disconnect wiring harness connector (4).

4. Remove cap screws (1) and disconnect low pressureline (2) and high pressure line (3). Close all open linesand fittings using caps and plugs.

5. Remove cap screws (5) and compressor (6).

6. Install compressor. Tighten cap screws to specification.

SpecificationAir Conditioning Compressor CapScrew—Torque 30 N•m...............................................................................

22 lb-ft

7. Connect harness connector.

8. Connect high and low pressure lines. Install andtighten cap screws (1).

SpecificationPressure Line Cap Screw—Torque 28 N•m............................................................................................

21 lb-ft

9. Install compressor belt. Inspect and adjust compressorbelt tension. See See Check and Adjust A/C Belt.(Operator’s Manual.)

10. Evacuate and charge system. See Evacuate R134aSystem and See Charge R134a System. (Group1830.)

OUO1073,00020FB –19–27MAR07–1/2

Condenser Remove and Install

1. Recover refrigerant from system. See Recover R134aRefrigerant. (Group 1830.)


PN=203



181830

12

OUO1073,00020FB –19–27MAR07–2/2

TX

1020

174A

–UN

–07M

AR

07

1—Condenser2—High Pressure Liquid Input Line3—Electrical Connector4—High Pressure Gas Input Line5—High Pressure Gas Output Line6—Receiver-Dryer7—Cap Screw8—Bracket9—Cap Screws (4 used)


3. Remove cap screws and disconnect high pressureliquid input line (2) and high pressure liquid output line(5) from receiver-dryer (6).

4. Loosen cap screw (7) and remove receiver-dryer (6)from bracket.

5. Remove cap screw and disconnect high pressure gasinput line (4) from condenser (1).

6. Remove cap screws (9) and condenser (1).

7. Remove cap screws and receiver-dryer mountingbracket (8) from condenser.

8. Install condenser.

9. Connect high pressure gas input line (4) to condenser.Tighten cap screw to specification.

SpecificationHigh Pressure Gas Input LineCap Screw—Torque 23 N•m.......................................................................

17 lb-ft

10. Install receiver-dryer.

11. Connect high-pressure output line and high pressureinput line cap screw to receiver-dryer. Tighten capscrews to specification.

SpecificationReceiver-Dryer Input and OutputLine Cap Screws—Torque 5 N•m...............................................................

44 lb-in.




PN=204


OUO1073,00020FE –19–13APR07–1/8

Heater and Air Conditioner Remove andInstall



OUO1073,00020FE –19–13APR07–2/8

TX

1020

272A

–UN

–08M

AR

07

18183013

1—Cover2—Screws3—Cap Screws4—Panel

3. Remove cover (1) from rear panel.

4. Remove screws (2) and cap screws (3) from rear panel(4).

5. Pull rear panel forward. Disconnect wiring harnessfrom lighter and power outlet and remove panel.

OUO1073,00020FE –19–13APR07–3/8

TX

1020

273A

–UN

–08M

AR

07

1—Air Duct2—Bracket3—Monitor Warning Alarm4—Mounting Bracket5—Cover

6. Remove screws and air duct (1).

7. Remove screws and bracket (2).

8. Remove monitor warning alarm (3) from mountingbracket (4).

9. Remove screws and mounting bracket (4).



PN=205



OUO1073,00020FE –19–13APR07–4/8

TX

1020

274A

–UN

–08M

AR

07

1—Cap Screws2—Relay Block3—12 Volt Power Converter4—Cap Screw5—Cap Screws6—Information Controller (ICF)7—Panel8—Cab Wiring Harness

11. Remove screws attaching relay block (2) to panel (7).

NOTE: Panel (7) may be removed with power converterand information controller installed on panel.

12. Disconnect 12 volt power converter (3) andinformation controller (ICF) (6) from cab wiringharness.

13. Remove clamps and hold-downs attaching cab wiringharness (8) to panel (7).

14. Remove cap screws (1 and 5).

15. Disconnect cab wiring harness (8) from and rightconsole, security alarm, and ground locations onpanel (7). See Cab Harness (W1) ComponentLocation . (Group 9015-10.)

16. Lift cab wiring harness (8). Slide out panel (7) andremove.

181830

14

OUO1073,00020FE –19–13APR07–5/8

TX

1020

275A

–UN

–08M

AR

07

1—Inlet Duct2—Cap Screw

17. Remove cap screws (2) and fresh air inlet duct (1).



PN=206


OUO1073,00020FE –19–13APR07–6/8

TX

1020

276A

–UN

–08M

AR

07

1—Screw2—Panel3—Air Duct4—Mounting Bracket

18. Remove screws (1), panel (2), and air duct (3).

19. Remove cap screws and mounting bracket (4).


18183015


PN=207


181830

16

OUO1073,00020FE –19–13APR07–7/8

TX

1020

277A

–UN

–08M

AR

07

1—Air Conditioner2—Air Duct3—Engine Coolant Hoses4—Air Conditioner Refrigerant Lines5—Air Duct6—Cap Screw (6 used)7—Screws

20. Clamp off engine coolant hoses (3). Disconnectengine coolant hoses from air conditioner (1). Plugengine coolant lines to minimize coolant loss.

21. Remove air conditioner refrigerant lines (4) from airconditioner (1).

22. Disconnect wiring harness from air conditioner (1).

23. Remove screws (7) and air duct (5).

24. Remove cap screws (6). Separate air conditioner (1)from air duct (2) and remove.


26. Install air conditioner and cap screws.

27. Connect wiring harness.

28. Connect air ducts.

29. Connect engine coolant hoses and refrigerant lines.

30. Install mounting bracket, rear panel, and air duct.

31. Install fresh air inlet duct.

32. Install rear panel and cap screws.

33. Connect cab wiring harness. See Cab Harness (W1)Component Location . (Group 9015-10.)

34. Attach wiring harness to panel using clamps andhold-downs.

35. Install air duct, mounting brackets, and monitorwarning alarm.

36. Connect wiring harness to lighter and power outletand install rear panel.

37. Install seat. See Seat Remove and Install (Group1821.)



PN=208



OUO1073,00020FE –19–13APR07–8/8

39. Check engine coolant level. Add coolant asnecessary. See Cooling System Fill and DeaerationProcedure. (Operator’s Manual.)

18183017

OUO1073,00020FC –19–05MAR07–1/1

Receiver-Dryer Remove and Install

TX

1018

622A

–UN

–22F

EB

07

1—Electrical Connector2—High Pressure Liquid Input Line3—Cap Screws4—High Pressure Liquid Output Line5—Cap Screw6—Receiver-Dryer



3. Remove cap screws (3) and disconnect high pressureliquid input line (2) and high pressure liquid output line(4).

4. Loosen cap screw (5) and remove receiver-dryer (6)from bracket.

5. Install receiver-dryer.

6. Tighten high-pressure output line cap screw and highpressure input line cap screw.

SpecificationReceiver-Dryer Input and OutputLine Cap Screws—Torque 5 N•m...............................................................

44 lb-in

7. Connect electrical connector.

8. Evacuate and charge system. See Evacuate R134aSystem and See Charge R134a System. (Group 1830.)


PN=209


181830

18


PN=210

Section 33Excavator

Contents

Page Page

Group 3302—Buckets Pilot Valve (Left and Right) Remove andBucket Remove and Install . . . . . . . . . . . . . .33-3302-1 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-47Bucket Pin-Up Data. . . . . . . . . . . . . . . . . . . .33-3302-2 Pilot Valve (Left and Right) Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-50Group 3340—FramesTravel Pilot Valve Remove and Install . . . . .33-3360-52Bucket Links Remove and Install . . . . . . . . .33-3340-1Travel Pilot Valve Disassemble andArm Remove and Install . . . . . . . . . . . . . . . .33-3340-3

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-54Boom Remove and Install . . . . . . . . . . . . . . .33-3340-6Pilot Signal Manifold Remove and Install. . .33-3360-56Inspect Pins, Bushings and Bosses—FrontPilot Signal Manifold Disassemble andAttachment . . . . . . . . . . . . . . . . . . . . . . .33-3340-11

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-58Bushings and Seal Remove and Install . . . .33-3340-14Control Valve Remove and Install . . . . . . . .33-3360-61Control Valve (5-Spool) Disassemble andGroup 3360—Hydraulic System

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63Apply Vacuum to Hydraulic Oil Tank . . . . . . .33-3360-1Control Valve (4-Spool) Disassemble andHydraulic Oil Cleanup Procedure Using

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-71Portable Filter Caddy . . . . . . . . . . . . . . . . .33-3360-3Hydraulic Oil Tank Remove and Install . . . .33-3360-76Pump 1 and 2 Remove and Install . . . . . . . .33-3360-4Hydraulic Oil Tank Disassemble andPump 1 and 2 Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-80Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-10Restriction Valve Remove and Install . . . . .33-3360-81Pump 1 and 2 Inspection . . . . . . . . . . . . . .33-3360-22Hydraulic Oil Cooler Bypass Valve RemovePump 1 and 2 Start-Up Procedure . . . . . . .33-3360-25

and Install . . . . . . . . . . . . . . . . . . . . . . . .33-3360-83Pump 1 and 2 Regulator Remove andBoom Cylinder Remove and Install . . . . . . .33-3360-85Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-26Boom Cylinder Disassemble andPump 1 and 2 Regulator Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-89Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-28Arm Cylinder Remove and Install . . . . . . . .33-3360-91Pilot Pump Remove and Install . . . . . . . . . .33-3360-30Arm Cylinder Disassemble andPilot Pump Disassemble and Assemble . . .33-3360-32

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-96Pilot Pump Drive Shaft Remove andBucket Cylinder Remove and Install . . . . . .33-3360-99Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-34Bucket Cylinder Disassemble andPilot Pressure Regulating Valve and Filter

Assemble. . . . . . . . . . . . . . . . . . . . . . . .33-3360-103Remove and Install . . . . . . . . . . . . . . . . .33-3360-35Hydraulic Cylinder Bleed Procedure . . . . .33-3360-106Pilot Pressure Regulating Valve and Filter

Disassemble and Assemble. . . . . . . . . . .33-3360-36Pilot Shutoff Solenoid Valve Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3633Pilot Shutoff Solenoid Valve Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-38Fan Drive Pump Remove and Install . . . . . .33-3360-39Fan Drive Motor Remove and Install . . . . . .33-3360-40Fan Drive Control Valve Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-43Solenoid Valve Manifold Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-44Solenoid Valve Remove and Install—Power

Dig (SG), Travel Speed (SI), BoomMode (SC), and Boom Flow Rate(SF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-46


PN=1

Contents

33


PN=2

Group 3302Buckets

3333021

TJ15698,0000128 –19–11APR07–1/1

Bucket Remove and Install

5

4

53

81

2

3

7

3

6

4

32

1

T142450

T14

2450

–UN

–24J

UL0

1

1—Bushing (2 used) 3—O-Ring (4 used) 5—Pin (2 used) 7—Pin2—Seal (2 used) 4—Ring (2 used) 6—Pin 8—Bucket


SpecificationBucket—Weight 1018 kg approximate.................................................

2245 lb approximate

1. Position bucket (8) on level surface.

2. Remove parts (4, 5, 6, and 7).

3. Remove bucket.


5. Align pin bores and install pins (6 and 7).

6. Adjust bucket to arm joint. See Adjusting Bucket toArm Joint. (Operator’s Manual.)


PN=213

Buckets

TJ15698,0000183 –19–29MAR07–1/2

Bucket Pin-Up Data

Section A Section B

87

17

9 14

1312

11

10 1615

1

65

3

4

2

A

B

TX1003797

TX

1003

797

–UN

–07M

AR

06

333302

2



PN=214

Buckets

3333023

TJ15698,0000183 –19–29MAR07–2/2

IMPORTANT: If the front attachment of a previousmodel machine is used, use thegrease intervals for previous modelmachine.

Item

1 370 mm14.6 in.

2 10 mm0.4 in.

3 540 mm21.2 in.

4 520 mm20.4 in.

5 400 mm15.7 in.

6 1430 mm56.3 in.

7 433 mm17 in.

8 326 mm12.8 in.

9 80 mm3.2 in.

10 400 mm15.7 in.

11 31 mm1.2 in.

12 433 mm17 in.

13 307 mm12.1 in.

14 80 mm3.1 in.

15 0°

16 0°

17 449 mm17.7 in.


PN=215

Buckets

333302

4


PN=216

Group 3340Frames

3333401

TJ15698,0000129 –19–13APR07–1/2

Bucket Links Remove and Install

TX

1020

202

–UN

–04A

PR

07

1—Nut (4 used) 6—Thrust Plate (4 used) 9—Center Link (2 used) 14—O-Ring (2 used)2—Cap Screw (2 used) 7—Bucket Cylinder Rod 10—Right Side Link 15—Pin3—Thrust Plate (2 used) End-to-Side and Center 11—Left Side Link 16—Ring4—Dust Seal (2 used) Links Pin 12—Side Links-to-Arm Pin5—Bushing (2 used) 8—Wood Block 13—Bucket-to-Center Links

Pin

NOTE: Removal of bucket is not necessary forremoval of bucket links.

1. Connect hoist to center links (9) using lifting strap.Put wood block (8) between bucket cylinder andarm to hold cylinder up when cylinder pin (7) isremoved.


As cylinder pin (7) is removed, lower links (10 and11) to ground.

3. Remove ring (16) and pin (15).

4. Remove pins (12 and 13) and remove side andcenter links.



PN=217

Frames

333340

2

TJ15698,0000129 –19–13APR07–2/2

TX

1020

201

–UN

–07M

AR

07

1—Dust Seal (6 used) 3—Center Link 5—Dust Seal (2 used) 7—Spacer2—Bushing (4 used) 4—Lubrication Fitting (2 used) 6—Bushing (2 used)

5. Inspect bushings (2 and 6) and dust seals (1 and5). See Inspect Pins, Bushings and Bosses—FrontAttachment. (Group 3340.)


7. Before installing pins, align pin bores to preventdamage to dust seal when pins are installed.

8. Tighten nuts against each other allowing capscrews to be free to turn in hole.

9. Apply multi-purpose grease to all pivot joints. SeeTrack Adjuster, Working Tool Pivot, Swing Bearing,And Swing Bearing Gear Grease. (Operator’sManual.)


PN=218

Frames

TJ15698,000012A –19–11APR07–1/7

Arm Remove and Install

1. Remove bucket. See Bucket Remove and Install.(Group 3302.)

2. Retract arm cylinder.

3. Put floor stand under end of boom, so load is onboom, not on arm cylinder. Extend arm cylinder justenough to put end of arm on ground.

TJ15698,000012A –19–11APR07–2/7

TX

1020

196A

–UN

–07M

AR

07

3333403




TJ15698,000012A –19–11APR07–3/7

X98

11–U

N–2

3AU

G88

CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

5. Loosen bucket cylinder hydraulic hoses to release anyresidual pressure.

NOTE: Remove bucket cylinder and linkage only ifnecessary to repair arm.

7. Remove bucket links and bucket cylinder. See BucketLinks Remove and Install (Group 3340.) See BucketCylinder Remove and Install. (Group 3360.)


PN=219


Frames

TJ15698,000012A –19–11APR07–4/7

T66

26JC

–UN

–31O

CT

88

Arm With Bucket Cylinder

CAUTION: Heavy component; use appropriatelifting device. Weight of boom, arm and bucketassembly and components will vary dependingon machine configuration.

SpecificationBoom, Arm and BucketAssembly—Approximate Weight 2900 kg...................................................

6395 lbBucket Cylinder—Weight 120 kg.................................................................

265 lbArm Cylinder—Weight 205 kg.....................................................................

452 lb

8. Attach appropriate lifting device to arm.

333340

4

TJ15698,000012A –19–11APR07–5/7

TX

1003

794A

–UN

–19A

PR

06

1—Nut (2 used)2—Pin3—Cap Screw4—Arm5—Arm Cylinder

9. Put wooden block between arm cylinder (5) and boomto hold cylinder up when cylinder pin (2) is removed.

10. Remove nuts (1), cap screw (3) and pin (2).



PN=220

Frames

TJ15698,000012A –19–11APR07–6/7

TX

1003

793A

–UN

–15M

AR

06

1—Cap Screw2—Pin3—Hydraulic Hose

11. Tag and disconnect hydraulic hoses (3). Close allopen lines and fittings using caps and plugs.

12. Remove cap screw (1) and boom-to-arm pin (2).

13. Remove arm and lower to floor.

14. Inspect bushings and dust seals. See Inspect Pins,Bushings and Bosses—Front Attachment. (Group3340.)

15. Repair or replace parts as necessary. See Bushingsand Seal Remove and Install. (Group 3340.)


3333405


PN=221

Frames

TJ15698,000012A –19–11APR07–7/7

4

5

6

4

1

3

2

T14

2652

–UN

–27S

EP

01

710

11

12

13 12

89

T14

2653

–UN

–24J

UL0

1

333340

6

1—Nut (2 used)2—Stopper3—Cap Screw4—Thrust Plate (2 used)5—Thrust Plate6—Cylinder Pin7—Cap Screw8—Washer9—Plate10—Block11—Pin12—Thrust Plate (2 used)13—Thrust Plate

16. Install thrust plates (4 and 12) equally on each side ofarm to get minimal amount of clearance betweenboom and arm.

17. Install boom-to-arm pin (11), block (10), plate (9),washer (8) and cap screw (7).

18. Connect arm cylinder by inserting cylinder pin (6), capscrew (3) and nuts (1).

19. Connect hoses. See Hydraulic System LineConnections. (Group 9025-15.)

20. Apply multi-purpose grease to all lubrication fittings.

21. Install bucket. See Bucket Remove and Install.(Group 3302.)

TJ15698,000012C –19–11APR07–1/10

Boom Remove and Install

1. Remove bucket and arm. See Bucket Remove andInstall (Group 3302.) See Arm Remove and Install.(Group 3340.)

2. Lower boom to ground.

3. Disconnect wiring harness.


PN=222


Frames

TJ15698,000012C –19–11APR07–2/10

TX

1020

196A

–UN

–07M

AR

07




3333407

TJ15698,000012C –19–11APR07–3/10

X98

11–U

N–2

3AU

G88

TX

1003

795A

–UN

–09M

AR

06

1—Hydraulic Hoses (4 used)

CAUTION: To avoid injury from escaping fluidunder pressure, stop engine and relieve thepressure in the system before disconnecting orconnecting hydraulic or other lines. Tighten allconnections before applying pressure.

5. Slowly loosen hydraulic hoses (1) to relieve anyresidual pressure; then disconnect hoses. Close allopen lines and fittings using caps and plugs.

6. Remove arm cylinder only if necessary to repair boom.See Arm Cylinder Remove and Install. (Group 3360.)



PN=223

Frames

TJ15698,000012C –19–11APR07–4/10

T10

5828

–UN

–30D

EC

96

F—Boom Cylinder (2 used)


SpecificationBoom Cylinder—Weight 155 kg..................................................................

342 lb

7. Attach appropriate lifting device to boom cylinder (F)using lifting strap.

TJ15698,000012C –19–11APR07–5/10

TX

1003

796A

–UN

–17F

EB

06

333340

8

1—Cap Screw (2 used)2—Lubrication Hoses (2 used)3—Retainer (2 used)

8. Disconnect lubrication hoses (2), nuts, cap screws (1),and retainers (3).

TJ15698,000012C –19–11APR07–6/10

T14

2979

–UN

–24J

UL0

1

1—Nut (4 used)2—Retainer (2 used)3—Cap Screw (2 used)4—Boom Cylinder Rod End-to-Boom Pin5—Thrust Plate (4 used)6—Boom Cylinder (2 used)

9. Push boom cylinder-to-boom pin (4) into boom.

10. Lower boom cylinder (6) onto floor stand. Repeatprocedure for second boom cylinder.


PN=224


Frames

TJ15698,000012C –19–11APR07–7/10

T66

26JW

–UN

–31O

CT

88

CAUTION: Heavy component; use appropriatelifting device. Weight of boom, arm, and bucketassembly and components will vary dependingon machine configuration.

SpecificationBoom, Arm and BucketAssembly—Approximate Weight 2900 kg...................................................

6395 lbBucket Cylinder—Weight 120 kg.................................................................

265 lbArm Cylinder—Weight 205 kg.....................................................................

452 lb

11. Attach appropriate lifting device to boom. Useprotective covering to prevent damage to pin if chainis used.

IMPORTANT: Arm end of boom is heavy end with armcylinder installed. Frame end is heavyend when arm cylinder is removed.

3333409

TJ15698,000012C –19–11APR07–8/10

TX

1020

209A

–UN

–07M

AR

07



NOTE: Two cap screws for cover (1) are located intoolbox (4).

12. Remove step (2), cover (1), and toolbox (4).

SpecificationToolbox—Weight 33 kg...............................................................................

72 lb

Disconnect and remove wiring harness from inside oftoolbox.


PN=225


Frames

TJ15698,000012C –19–11APR07–9/10

TX

1003

791A

–UN

–19A

PR

06

1—Cap Screw2—Spacer3—Boom-to-Frame Pin

13. Remove cap screw (1), washer, and spacer (2).

14. Insert bar between plate of boom-to-frame pin (3) andbracket. Pull plate out.

15. Remove boom-to-frame pin (3). Remove washers.

16. Remove boom.

17. Inspect bushings and dust seals. See Inspect Pins,Bushings and Bosses—Front Attachment. (Group3340.)

18. Repair or replace parts as necessary. See Bushingsand Seal Remove and Install. (Group 3340.)

19. Install washers equally on each side of boom to getminimal amount of clearance between boom andframe.

20. Install boom. Tighten boom-to-frame cap screw (1).

SpecificationBoom-to-Frame Cap Screw—Torque 392 N•m..........................................................................................

290 lb-ft

21. Install toolbox, cover, and step.

333340

10



PN=226

Frames

TJ15698,000012C –19–11APR07–10/10

TX

1003

796A

–UN

–17F

EB

06

1—Cap Screw (2 used)2—Lubrication Lines (2 used)3—Retainer (2 used)

22. Connect rod end of boom cylinders. Install thrustplates equally on each side to get minimum amountof clearance between boom and cylinder rod end.

23. Install retainers (3) and cap screws (1).

24. Tighten nuts against each other allowing cap screw(1) to be free to turn in hole.

SpecificationBoom Cylinder Rod End-to-BoomPin Retainer Nut—Torque 550 N•m (tighten nut against nut).....................

405 lb-ft (tighten nut against nut)

25. Connect lubrication hoses (2).

26. Connect hydraulic hoses. See Hydraulic System LineConnections. (Group 9025-15.)

27. Apply multi-purpose grease to all pivot joints. SeeTrack Adjuster, Working Tool Pivot, Swing Bearing,and Swing Bearing Gear Grease. (Operator’sManual.)

33334011

TJ15698,0000184 –19–29MAR07–1/3

Inspect Pins, Bushings and Bosses—FrontAttachment

TX1004442

2

13

6 5 7

8 10

4

119

TX

1004

442

–UN

–06M

AR

06

1—Boom-to-Frame Joint2—Boom Cylinder Head End-to-Frame Joint3—Boom Cylinder Rod End-to-Boom Joint4—Boom-to-Arm Joint5—Arm Cylinder Rod End-to-Arm Joint6—Arm Cylinder Head End-to-Boom Joint7—Bucket Cylinder Head End-to-Arm Joint8—Bucket Cylinder Rod End-to-Side and Bucket

Links Joint9—Side Links-to-Arm Joint10—Bucket Link-to-Bucket Joint11—Bucket-to-Arm Joint



PN=227

Frames

333340

12

TJ15698,0000184 –19–29MAR07–2/3

Pins, Bushings, and Bosses

Item Standard Allowable Limit Remedy

1 Pin 80 mm 79.0 mm Replace3.15 in. 3.11 in.

Boss (Main Frame) 80 mm 81.5 mm Replace3.15 in. 3.21 in.

Bushing 80 mm 81.5 mm Replace3.15 in. 3.21 in.


Boss (Main Frame) 80 mm 81.5 mm Replace3.15 in. 3.21 in.

Bushing (Boom Cylinder) 80 mm 81.5 mm Replace3.15 in. 3.21 in.


Bushing (Boom Cylinder) 80 mm 81.5 mm Replace3.15 in. 3.21 in.

Boss (Boom) 80 mm 81.5 mm Replace3.15 in. 3.21 in.



Bushing (Arm) 80 mm 81.5 mm Replace3.15 in. 3.21 in.


Boss (Arm) 71 mm 72.5 mm Replace2.80 in. 2.85 in.

Bushing (Arm Cylinder) 71 mm 72.5 mm Replace2.80 in. 2.85 in.



Bushing (Arm Cylinder) 71 mm 72.5 mm Replace2.80 in. 2.85 in.



Bushing (Bucket Cylinder) 65 mm 66.5 mm Replace2.56 in. 2.62 in.



PN=228


Frames

TJ15698,0000184 –19–29MAR07–3/3

Pins, Bushings, and Bosses

Item Standard Allowable Limit Remedy

Boss (Link B) 71 mm 72.5 mm Replace2.80 in. 2.85 in.

Bushing (Link A) 71 mm 72.5 mm Replace2.80 in. 2.85 in.

Bushing (Bucket Cylinder) 71 mm 72.5 mm Replace2.80 in. 2.85 in.





Boss (Bucket) 80 mm 79.0 mm Replace3.15 in. 3.11 in.

Bushing (Link A) 80 mm 81.5 mm Replace3.15 in. 3.21 in.




33334013


PN=229

Frames

TJ15698,000012B –19–05MAR07–1/1

Bushings and Seal Remove and Install

T95

237

–UN

–01N

OV

88T

6641

CW

–UN

–31O

CT

88

333340

14

A—Hydraulic RamB1—Pipe—Minimum ID to Clear Bushing ODB2—Pipe—Maximum ODB3—Pipe—Length of BushingC—BushingD—DisksE—Bushing Stop (Disk)F—Pilot (Disk)G—Ram Stop (Disk)H—Thickness of Dust Seal

IMPORTANT: Only install bushings using press asshown. Bushings will be damaged ifinstalled with driver.

NOTE: Bushing can also be removed by welding three tofive weld beads on the inside of bushing. Bushingwill shrink enough to permit removal using ahammer.

1. Remove bushings (C) and dust seals using bushing,bearing, and seal driver set.

2. Install bushings with lubrication hole aligned withlubrication passage in pivot.

3. Install bushing to a depth equal to thickness of dustseal (H).

4. Install dust seals with lip toward outside of component.


PN=230


FS41334,000014E –19–05MAR07–1/3

Apply Vacuum to Hydraulic Oil Tank

Applying vacuum to hydraulic oil tank eliminates the needto drain tank prior to servicing of hydraulic systemcomponents.

FS41334,000014E –19–05MAR07–2/3

TX

1020

196A

–UN

–07M

AR

07

3333601






PN=231

Hydraulic System

FS41334,000014E –19–05MAR07–3/3

TX

1000

587A

–UN

–17N

OV

05T

X10

0332

9A–U

N–0

6FE

B06

333360

2

3—Cap Screws (4 used)

2. Use 5 mm hex wrench to remove cap screws (3) andcover.

3. Assemble fittings and hydraulic oil tank adapter fromD15032NU Vacuum Pump Kit, and JT07085A VacuumPump Set. Install in hydraulic tank opening as shown.Refer to pump instructions for operating information.


PN=232

Hydraulic System

3333603

FS41334,000014D –19–10APR07–1/1

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

SPECIFICATIONS

Hydraulic Oil Tank Capacity 120 L approximate31.8 gal approximate

Hydraulic Oil Tank Filtering 11 minutes approximateTime

Hydraulic System Capacity 220 L approximate58 gal approximate

Hydraulic System Filtering Time 35 minutes approximate

SERVICE EQUIPMENT AND TOOLS

JDG1724A Super Caddy

JT05679 Hose 3.7 m (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 MNPT Ends (2 used)

JTO5751A Suction Wand

JTO5750A Discharge Wand

1. Install new return filter elements.

NOTE: For a failure that creates a lot of debris,remove access cover from hydraulic tank.Drain hydraulic tank. Connect filter caddysuction line to drain port. Add a minimum of 19L (5 gal) of oil to reservoir. Operate filter caddyand wash out the hydraulic tank.

IMPORTANT: The minimum ID for a connector is13 mm (1/2 in.) to prevent cavitationof filter caddy pump.

2. Put filter caddy suction and discharge wands intohydraulic tank filler hole so ends are as far apart aspossible to obtain a thorough cleaning of oil.

3. Start the filter caddy. Check to be sure oil is flowingthrough the filters.

Operate filter caddy until all the oil in hydraulic tankhas been circulated through the filter a minimum offour times.

SpecificationHydraulic Oil Tank—Capacity 120 L approximate................................

31.8 gal approximateHydraulic Oil Tank—FilteringTime 11 minutes approximate...............................................................

NOTE: Filtering time for hydraulic tank is 0.089 minutex number of liters (0.33 minutes x number ofgallons).

4. Leave filter caddy operating for the next step.

5. Start the engine and run it at fast idle.

IMPORTANT: For the most effective results,cleaning procedure must start withthe smallest capacity circuit thenproceed to the next larger capacitycircuit.

6. Starting with the smallest capacity circuit, operateeach function through a complete cycle.

Repeat procedure until the total system capacityhas circulated through filter caddy seven times.Each function must go through a minimum of threecomplete cycles for a thorough cleaning of oil.

SpecificationHydraulic System—Capacity 220 L approximate.................................

58 gal approximateHydraulic System—FilteringTime 35 minutes approximate...............................................................

NOTE: Filtering time for complete hydraulic system is0.158 minute x number of liters (0.6 minute xnumber of gallons). Filtering time for machineswith auxiliary hydraulic functions must beincreased because system capacity is larger.

7. Stop the engine. Remove the filter caddy.

8. Install new return filter elements.

9. Check hydraulic oil level. See Check HydraulicTank Oil Level. (Operator’s Manual.)


PN=233

Hydraulic System

FS41334,000014C –19–13APR07–1/13

Pump 1 and 2 Remove and Install

TX

1020

196A

–UN

–07M

AR

07




2. Drain hydraulic oil tank. Approximate capacity is 120.4L (31.8 gal).

3. Drain pump drive gearbox. Approximate oil capacity is0.9 L (1.0 qt).

4. Remove hydraulic compartment cover and mufflercover.

333360

4

FS41334,000014C –19–13APR07–2/13

TX

1020

192A

–UN

–05A

PR

07

1—Cap Screws (4 used)2—Final Fuel Filter3—Primary Fuel Filter

5. Remove cap screws (1) and set fuel filters (2 and 3)aside. Protect against damage to hoses and filters.

FS41334,000014C –19–13APR07–3/13

TX

1020

366A

–UN

–19M

AR

07

1—Oil Filter Assembly2—Cap Screw (2 used)

6. Remove cap screws (2) and set engine oil filterassembly (1) aside. Protect against damage to hosesand filter.


PN=234


Hydraulic System

FS41334,000014C –19–13APR07–4/13

TX

1020

874A

–UN

–22M

AR

07

1—Shield2—Cap Screws (6 used)3—Water Drain

7. Remove cap screws (2), water drain (3), and mufflershield (1).

CAUTION: Exhaust parts may be hot. Avoidburns by waiting until the parts are cool to thetouch before working on them.

8. Support muffler using appropriate lifting device.

FS41334,000014C –19–13APR07–5/13

TX

1020

749A

–UN

–19M

AR

07

3333605

1—Clamp2—Tube3—Muffler

9. Loosen clamp (1) and move onto muffler tube (2).

FS41334,000014C –19–13APR07–6/13

TX

1020

923A

–UN

–23M

AR

07

1—Muffler2—U-Bolt Nut (8 used)3—Support

10. Remove nuts (2) and U-bolts from muffler support (3).

11. Remove muffler (1).

12. Disconnect electrical connectors.

13. Disconnect lines.


PN=235


Hydraulic System

FS41334,000014C –19–13APR07–7/13

TX

1020

397

–UN

–12M

AR

07

1—Lift Point (3 used)


SpecificationHydraulic Pump and DriveGearbox—Approximate Weight 168 kg.......................................................

370 lb

14. Install JT05550 Lifting Eyebolt and JDG19 LiftingBracket to pump (1). Connect an appropriate liftingdevice to eyebolt and lifting bracket using liftingstraps.


333360

6


PN=236

Hydraulic System

3333607

FS41334,000014C –19–13APR07–8/13

TX

1020

354

–UN

–09M

AR

07

1—Hydraulic Pump Drive Gearbox2—Bracket3—Support4—Cap Screw (8 used)

15. Remove cap screws (4), muffler support (3), and hosebracket (2) from hydraulic pump gearbox (1).

16. Pull pump assembly (1) away from flywheel housingto disengage damper drive (flex coupler).

17. Remove hydraulic pump and drive gearbox frommachine.


IMPORTANT: Align flex coupler on drive gearbox withmating part on engine flywheel.

19. Align damper drive and install pump assembly toflywheel housing.

20. Install muffler support (3), hose bracket (2), and pumpassembly with cap screws (1). Tighten tospecification.

SpecificationPump Drive Gearbox-to-FlywheelHousing Cap Screw—Torque 65 N•m.........................................................

48 lb-ft

21. Connect lines. See Pump 1, Pump 2, and Pilot PumpLine Identification. (Group 9025-15.)

22. Connect electrical connectors. See Pump Harness(W8) Component Location. (Group 9015-10.)

23. Install split flange and tighten cap screws.

SpecificationSplit Flange 8 mm Cap Screw—Torque 50 N•m............................................................................................

37 lb-ftSplit Flange 10 mm Cap Screw—Torque 90 N•m............................................................................................

67 lb-ft

24. Apply pipe sealant to pump drive gearbox pipe plugthreads, if removed.


PN=237


Hydraulic System

FS41334,000014C –19–13APR07–9/13

TX

1020

923A

–UN

–23M

AR

07

1—Muffler2—U-Bolt Nut (8 used)3—Support

25. Install muffler (1) to support using U-bolts and nuts(2). Hand tighten for next step.

FS41334,000014C –19–13APR07–10/13

TX

1020

749A

–UN

–19M

AR

07

333360

8

1—Clamp2—Tube3—Muffler

NOTE: Clamp torque is 8.5 N•m (75 lb-in.) with maximumtorque of 20 N•m (177 lb-in.).

26. Install clamp (1) and tighten.

27. Tighten muffler U-bolt nuts to specification.

SpecificationMuffler U-Bolt Nut—Torque 50 N•m............................................................

37 lb-ft

FS41334,000014C –19–13APR07–11/13

TX

1020

874A

–UN

–22M

AR

07

1—Shield2—Cap Screw (6 used)3—Water Drain

28. Install muffler shield (1) using cap screws (2).

29. Install and route water drain (3) down through mufflershield.



PN=238

Hydraulic System

FS41334,000014C –19–13APR07–12/13

TX

1020

366A

–UN

–19M

AR

07

1—Engine Oil Filter2—Cap Screw (2 used)

30. Install engine oil filter (1) assembly using cap screws(2).

3333609

FS41334,000014C –19–13APR07–13/13

TX

1020

192A

–UN

–05A

PR

07


31. Install fuel filters (2 and 3) using cap screws (1).

32. Install muffler cover and hydraulic compartment cover.


IMPORTANT: Hydraulic pump and drive gearbox willbe damaged if not filled with oil beforestarting engine. Start-up proceduremust be performed whenever a newpump or gearbox is installed or oil hasbeen drained from the pump, gearboxor hydraulic oil tank.

34. Fill pump housing and pump drive gearbox with oil.See Pump 1 and 2 Start-Up Procedure. (Group3360.)

35. Check pump regulator adjustments.

For minimum flow:

• See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)

For maximum flow:

• See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)


PN=239

Hydraulic System

333360

10

FS41334,000015A –19–13APR07–1/13

Pump 1 and 2 Disassemble and Assemble

7 8 9

10

11

6

12

5

13

4

13

14

1516

1718

19 2021

22 23

24

2322

2125

1826

1716

15

2728

2930

2827

3132

1

23

33

37

3635

3456

5554

57

58

44

35

3840

41

42

5153 52

5150

49

48

4746

45

39

43

32

20

T142373

T14

2373

–UN

–20J

UL0

1


PN=240


Hydraulic System

FS41334,000015A –19–13APR07–2/13

1—Pump Housing 16—Roller Bearing (2 used) 29—O-Ring 43—Drain Plug2—Lock Washer (6 used) 17—Ring (2 used) 30—Special Fitting 44—O-Ring3—Cap Screw (6 used) 18—Roller Bearing (2 used) 31—Spring Pin (2 used) 45—Cap Screw (2 used)4—Spring Pin (4 used) 19—Hydraulic Pump 1 (Front) 32—Oil Seal (2 used) 46—Lock Washer (2 used)5—O-Ring (10 used) Drive Shaft 33—Snap Ring (2 used) 47—Washer (2 used)6—O-Ring (2 used) 20—Pin (2 used) 34—Fill Plug 48—Pilot Pump7—Cap Screw (4 used) 21—Center Shaft (2 used) 35—Snap Ring (2 used) 49—Snap Ring8—Hydraulic Pump 1 (Front) 22—Spring (2 used) 36—Hydraulic Pump 1 Driven 50—Snap Ring

Regulator 23—Piston (14 used) Gear 51—Ball Bearing9—Cap Screw (2 used) 24—Cylinder Block (Rotor) 37—Gasket 52—Pilot Pump Drive Gear10—Cap Screw (2 used) (2 used) 38—Cap Screw (2 used) 53—Pilot Pump Drive Shaft11—Cap Screw (2 used) 25—Hydraulic Pump 2 (Rear) 39—Hydraulic Pump 2 Drive 54—Snap Ring12—Hydraulic Pump 2 (Rear) Drive Shaft Gear 55—Oil Seal

Regulator 26—Hydraulic Pump 2 Spacer 40—Dipstick 56—Pump Drive Gearbox13—O-Ring (4 used) Ring 41—Dipstick Tube 57—Set Screw (2 used)14—O-Ring (6 used) 27—O-Ring (2 used) 42—Gasket 58—Dampener Drive Coupling15—Bearing Nut (2 used) 28—Plug (2 used)


33336011


PN=241

Hydraulic System

333360

12

FS41334,000015A –19–13APR07–3/13

82

82

59

60

61

60

6660

81

80

79

77

78

76

69

67

68

70

71

72

73

74

71

75

6263

6563

6260

6263

6463

62

60

66

59

6061

60

T142375

T14

2375

–UN

–20J

UL0

1

59—Dowel Pin 65—Hydraulic Pump 2 Valve 71—O-Ring (4 used) 77—Servo Piston (2 used)60—Snap Ring (12 used) Plate 72—Cap Screw (8 used) 78—Pin (2 used)61—Dowel Pin (2 used) 66—Dowel Pin (4 used) 73—Cover (2 used) 79—O-Ring (2 used)62—Lever (4 used) 67—Back-Up Ring 74—O-Ring (2 used) 80—Stop (2 used)63—Dowel Pin (4 used) 68—O-Ring 75—Cap Screw (12 used) 81—Cap Screw (8 used)64—Hydraulic Pump 1 Valve 69—Spring Pin (2 used) 76—Set Screw (2 used) 82—Feedback Link (2 used)

Plate 70—Cylinder Head (Cover)

1. Remove plug (43) from pump gearbox. Drain gearoil. Approximate oil capacity is 0.9 L (1.0 qt).


PN=242


Hydraulic System

FS41334,000015A –19–13APR07–4/13


SpecificationHydraulic Pump Housing andGearbox—Approximate Weight 168 kg................................................

370 lb

2. Loosen set screws (57) and remove dampenerdrive coupling (58).

3. Remove pilot pump (48). For repair: See PilotPump Disassemble and Assemble. (Group 3360.)


SpecificationPump Housing Assembly—Approximate Weight 105 kg.................................................................

230 lb

4. Remove cap screws (3) and lock washers (2) toremove pump housing (1) from pump drive gearbox(56).

5. Remove parts (49-53). For removal of pilot pumpdrive shaft: See Pilot Pump Drive Shaft Removeand Install. (Group 3360.)


33336013


PN=243

Hydraulic System

333360

14

FS41334,000015A –19–13APR07–5/13

TX

1018

511A

–UN

–07F

EB

07

35—Snap Ring (2 used)36—Driven Gear39—Drive Gear83—Driven Gear-to-Drive Gear Timing Mark84—Pump 2 (Rear) Drive Shaft-to-Drive Gear

Timing Mark85—Pump 1 (Front) Drive Shaft-to-Driven Gear

Timing Mark

NOTE: The gears are not interchangeable. To aid inreassembly, make timing marks on drive shafts at(84) and (85), and mark (83) on drive gear (39)and driven gear (36).

6. Make timing marks on pump gears to aid inreassembly.

7. Measure amount of backlash between gears, usingspecification, to determine limit of use.

SpecificationPump Drive and Driven Gear—Backlash 0.68 mm (0.027 in.) nominal........................................................

1.50 mm (0.059 in.) limit of use

8. Remove snap rings (35) and remove gears (36 and39).

9. Remove pump regulators (8 and 12). For repair: SeePump 1 and 2 Regulator Disassemble and Assemble.(Group 3360.)


SpecificationCylinder Head—ApproximateWeight 30 kg................................................................................................

66 lb

IMPORTANT: Valve plates (64 and 65) are connectedto the feedback linkage and mustremain on the cylinder blocks (24).Valve plates and end of cylinder blockshave highly machined surfaces and canbe damaged.

10. Remove cap screws (75) and carefully removecylinder head (70).

11. Remove servo pistons (77) only if replacement isnecessary.

Disassemble servo piston using following procedure:

• Heat set screw (76) to loosen thread lock andsealer. (Medium strength thread lock used.)


PN=244


Hydraulic System

FS41334,000015A –19–13APR07–6/13

• Remove set screw. (Use a 6 mm hex key wrench.)• Remove pin (78).

IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)(65) valve plates are notinterchangeable. Take notice of thelocation and position of ports in plate.The inlet port in valve plate is locatedtowards the center and top of pumphousing.

12. Remove hydraulic pump 1 (64) and hydraulic pump 2(65) valve plates. Protect machined surfaces of platesfrom damage.

13. Remove special fittings (30) before removinghydraulic pump 1 (19) and hydraulic pump 2 (25)drive shafts.

14. Remove hydraulic pump 2 spacer ring (26) from bore.

15. Remove bearing nut (15) using JDG769 SpannerWrench.

16. Remove roller bearings (16 and 18) from pump 1 (19)and pump 2 (25) drive shafts using a knife edgepuller and a press.

17. Clean and inspect parts. Repair or replace parts asnecessary. See Pump 1 and 2 Inspection. (Group3360.)

18. Assemble hydraulic pump in reverse order, using thefollowing information.

33336015



PN=245

Hydraulic System

FS41334,000015A –19–13APR07–7/13

TX

1018

493

–UN

–07F

EB

07T

X10

1849

4–U

N–0

7FE

B07

333360

16

15—Bearing Nut16—Roller Bearing17—Spacer Ring18—Roller Bearing19—Pump 1 (Front) Drive Shaft25—Pump 2 (Rear) Drive Shaft

CAUTION: DO NOT heat oil over 182°C (360°F).Oil fumes or oil can ignite above 193°C (380°F).Use a thermometer. Do not allow a flame orheating element to come in direct contact withthe oil. Heat the oil in a well-ventilated area.Plan a safe handling procedure to avoid burns.

19. Heat roller bearings (16 and 18).

SpecificationRoller Bearing Heat—Temperature 50—80°C................................................................................

122—176°F

20. Apply oil to bearing. Push roller bearing (18) on driveshaft so inner race is tight against shoulder.

21. Install spacer ring (17) and roller bearing (16).

22. Apply oil to threads of bearing nut (15).

23. Tighten bearing nut using JDG769 Spanner Wrench.

SpecificationPump Drive Shaft Bearing Nut—Rolling Drag Torque 1.96 ± 0.49 N•m.........................................................

17 ± 4 lb-in.

FS41334,000015A –19–13APR07–8/13

TX

1018

495A

–UN

–07F

EB

07

26—Spacer Ring

24. Install hydraulic pump 2 spacer ring (26) into housingbore.


PN=246


Hydraulic System

FS41334,000015A –19–13APR07–9/13

TX

1018

496A

–UN

–07F

EB

07

19—Drive Shaft25—Drive Shaft30—Special Fitting (2 used)

25. To help installation of drive shafts (19 and 25), heatpump housing using a heat gun such as the JT07010Two Temperature Heat Gun.

SpecificationHydraulic Pump Housing Heat—Temperature 50—80°C................................................................................

122—176°F

26. Apply a film of oil to outer race of bearings. Install thedrive shafts.

NOTE: Allow housing to cool to the touch, to safelyhandle after drive shaft installation.

27. Install and tighten special fittings (30).

SpecificationSpecial Plug-to-Hydraulic PumpHousing Special Fitting—Torque 34 N•m....................................................

25 lb-ft

28. Apply multi-purpose grease to lips of oil seals (32).Install oil seals with lip (spring side) toward inside ofhousing. Install snap rings (33).

33336017



PN=247

Hydraulic System

333360

18

FS41334,000015A –19–13APR07–10/13

TX

1018

511A

–UN

–07F

EB

07T

X10

1849

7–U

N–0

7FE

B07

19—Pump 1 (Front) Drive Shaft25—Pump 2 (Rear) Drive Shaft35—Snap Ring (2 used)36—Driven Gear39—Drive Gear83—Driven Gear-to-Drive Gear Timing Mark84—Pump 2 (Rear) Drive Shaft-to-Drive Gear

Timing Mark85—Pump 1 (Front) Drive Shaft-to-Driven Gear

Timing Mark86—JDG1054 Aligning Bar (Pump Timing Tool)87—Socket88—Socket89—Socket Alignment Dowel90—Socket Alignment Dowel91—M8-1.25 Cap Screw (2 used)

29. Install drive (39) and driven (36) gears usingprocedure:

For original parts;

• Install drive (39) and driven (36) gears on shafts sotiming marks (83, 84, and 85) are aligned. Installsnap rings (35).

For new parts;

• Install the JDG1054 Aligning Bar on the socket (87and 88) end of drive shafts.

• Install aligning bar so end marked “Long ShaftSide” is to pump 2 (rear) drive shaft (25). Turnshafts so socket alignment dowels (89 and 90)engage a socket in drive shafts. The socket forpump 1 (front) drive shaft is slightly below thecenter-line of socket for pump 2 (rear) drive shaftwhen shafts are timed correctly.

• Install cap screws (91) to hold bar in position.• From the spline end of shafts, turn shafts to the left

to remove any play between socket alignmentdowels and sockets.

• Install gear on pump 2 (rear) drive shaft. Install thesnap ring.

• Install gear on pump 1 (front) drive shaft. Asnecessary, turn shaft slightly or turn gear to anotherposition so teeth on gears engage. Install snap ring.

30. Apply oil to center shaft (21), pistons (23), andcylinder blocks (24). Use petroleum jelly to hold pin(20) in hole in center shaft.

31. Install cylinder block so pin engages slot in cylinderblock.

32. Apply thread lock and sealer (medium strength) tothreads of dowel pins (63). Tighten dowel pins intopump 1 (front) (64) and pump 2 (rear) (65) valveplates.

SpecificationDowel Pin-to-Pump 1 (Front) andPump 2 (Rear) Valve Plate—Torque 9.8 N•m...........................................................................................

86 lb-in.


PN=248


Hydraulic System

33336019

FS41334,000015A –19–13APR07–11/13

IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)(65) valve plates are notinterchangeable. The inlet port in valveplate is located toward the center andtop of pump housing.

33. Install valve plates using procedure:

• Apply oil to valve plates.• Install valve plates so inlet port is toward the center

and top of pump housing.• Connect levers (62) for feedback linkage to valve

plates.

34. Install servo pistons (77) and pins (78). If set screwwas removed, install using procedure:

• Apply thread lock and sealer (medium strength) tothreads of set screw (76).

• Tighten set screw (76) using a 6 mm hex keywrench.

SpecificationServo Piston-to-Pin Set Screw—Torque 34 N•m............................................................................................

25 lb-ft

35. Tighten cap screws (72 and 81) for stop (80) andcover (73) to specification.

SpecificationStop and Cover-to-Cylinder HeadCap Screw—Torque 19.5 N•m....................................................................

180 lb-in.

CAUTION: Heavy component; user anappropriate lifting device.

36. Install cylinder head (70) checking to be sure thatpins engage middle hole in valves plates.

SpecificationCylinder Head—ApproximateWeight 30 kg................................................................................................

66 lb


PN=249


Hydraulic System

333360

20

FS41334,000015A –19–13APR07–12/13

Tighten cap screws (75) to specification.

SpecificationCylinder Head-to-Hydraulic PumpHousing Cap Screw—Torque 108 N•m.......................................................

80 lb-ft

37. Install regulators:

• Remove air bleed plugs from pump regulators (8and 12).

• Install regulators, making sure groove in remotecontrol sleeve and load sleeve engage dowel pin(61) in feedback link (82). Check, through hole, thatgroove in sleeves engage dowel pin.

• Reinstall air bleed plugs to avoid contamination tohydraulic pump during installation.

• Tighten cap screws to specification.

SpecificationRegulator-to-Hydraulic PumpHousing Cap Screw—Torque 49 N•m.........................................................

36 lb-ft

38. Install and tighten pump pressure sensors tospecification.

SpecificationPump PressureSensor-to-Hydraulic PumpHousing—Torque 98 N•m............................................................................

72 lb-ft

39. Install parts (49-53). For installation of pilot pumpdrive shaft: See Pilot Pump Drive Shaft Remove andInstall. (Group 3360.)


SpecificationHydraulic Pump HousingAssembly—Approximate Weight 105 kg.....................................................

230 lb

40. Install pump housing assembly (1) to gearbox (56).


PN=250


Hydraulic System

33336021

FS41334,000015A –19–13APR07–13/13


SpecificationHydraulic PumpHousing-to-Gearbox Housing CapScrew—Torque 147 N•m.............................................................................

109 lb-ft

41. Apply rigid form-in-place gasket to mounting surfacefor pilot pump (48).


SpecificationPilot Pump-to-Gearbox CapScrew—Torque 49 N•m...............................................................................

36 lb-ft

42. Apply multi-purpose grease to lips of oil seal (55).Install oil seal with lip (spring side) toward inside ofhousing.

CAUTION: Install damper drive coupling hub soface is flush with end of pump shaft. It cannotrub or hit gearbox housing or shaft oil sealwhen rotated.

43. Install damper drive coupling (58) onto splines ofpump shaft (25). Position so hub face is flush withpump shaft end. Space between coupling andgearbox housing (56) is approximately 2 mm (0.08in.).

44. Apply thread lock and sealer (medium strength) tothreads of set screws (57).

Tighten set screws (57) to specification. For assemblyof dampener drive: See Dampener Drive (FlexCoupling) Remove and Install. (Group 0752.)

SpecificationDampener Drive Hub-to-Pump 2(Rear) Drive Shaft Set Screw—Torque 108 N•m..........................................................................................

80 lb-ft

45. Fill pump and pump drive gearbox with oil. See Pump1 and 2 Start-Up Procedure. (Group 3360.)


PN=251

Hydraulic System

FS41334,000014A –19–11APR07–1/6

Pump 1 and 2 Inspection

T10

5725

–UN

–09J

AN

97

A—Oil Seal Contact SurfaceB—Oil Seal Contact SurfaceC—Pump 2 (Rear) Drive ShaftD—Oil Seal Contact SurfaceE—Pump 1 (Front) Drive Shaft

1. Measure diameter of oil seal contact surfaces (A, B,and D) on pump 1 (front) (E) and pump 2 (rear) (C)drive shafts.

SpecificationPump 2 (Rear) Drive Shaft OilSeal Contact Surface (A)—OD 45 mm nominal.........................................

1.77 in. nominal44.8 mm limit of use

1.76 in. limit of usePump 2 (Rear) Drive Shaft OilSeal Contact Surface (B)—OD 55 mm nominal.........................................


2.16 in. limit of usePump 1 (Front) Drive Shaft OilSeal Contact Surface—OD 55 mm nominal...............................................


2.16 in. limit of use

333360

22

FS41334,000014A –19–11APR07–2/6

T10

5726

–UN

–09J

AN

97

F—Piston Connecting RodG—Rear Drive ShaftH—Play

2. Measure play (H) between piston connecting rod (F)and socket in front and rear drive shafts (G).

SpecificationPiston-to-Drive Shaft Socket—Play 0.058 mm nominal...............................................................................

0.0023 in. nominal0.400 mm limit of use0.0157 in. limit of use



PN=252

Hydraulic System

FS41334,000014A –19–11APR07–3/6

T65

57E

M–U

N–1

8OC

T88

T65

57E

N–U

N–1

8OC

T88

3. Measure ID of cylinder block piston bore. Measure ODof piston. Subtract the OD from the ID for clearance.

SpecificationCylinder Block Bore-to-Piston—Clearance 0.043 mm nominal.....................................................................


FS41334,000014A –19–11APR07–4/6

T65

57E

K–U

N–1

8OC

T88

4. Clamp the connecting rod end of a piston in a vise withsoft-jaw faces. Measure play between connecting rodand piston.

SpecificationPiston-to-Connecting Rod—Play 0.150 mm nominal..................................


33336023



PN=253

Hydraulic System

FS41334,000014A –19–11APR07–5/6

T10

5727

–UN

–19D

EC

96

333360

24

A—Cylinder HeadB—IDC—ODD—Servo Piston

5. Measure OD (C) of small and large end of servo piston(D). Measure ID (B) of small and large end of bore incylinder head (A). Subtract the OD from the ID forclearances.

SpecificationServo Piston-to-Cylinder HeadBore—Clearance 0.079 mm nominal..........................................................


FS41334,000014A –19–11APR07–6/6

T10

5729

–UN

–09J

AN

97

A—Valve PlateB—Piston PinC—ODD—ID

6. Measure OD (C) of servo piston pin (B). Measure ID(D) of bore in valve plate (A). Subtract the OD from theID for the clearance.

SpecificationServo Piston Pin-to-Valve PlateBore—Clearance 0.051 mm nominal..........................................................



PN=254

Hydraulic System

33336025

FS41334,0000149 –19–10APR07–1/1

Pump 1 and 2 Start-Up Procedure

TX

1020

193A

–UN

–06M

AR

07T

1450

92–U

N–3

1AU

G01

TX

1020

374A

–UN

–19M

AR

071—Dipstick2—Fill Plug3—Air Bleed Plug (2 used)

IMPORTANT: Hydraulic pump and drive gearbox willbe damaged if not filled with oil beforestarting engine. Procedure must beperformed whenever a new pump orgearbox is installed or oil has beendrained from the pump, gearbox orhydraulic oil tank.

Procedure is to ensure the pumps andgearbox are filled with oil and air is bledfrom suction side of pumps to preventcavitation.

1. Fill pump drive gearbox with oil through fill plug (2) solevel is above “H” mark on dipstick (1). See PumpGearbox Oil. (Operator’s Manual.)

2. Remove air bleed plugs (3) from the top of pumpregulators to allow housing to fill with oil from thehydraulic oil tank and to let air escape.

3. When pump housing is full of oil, install plugs.

4. As necessary, add oil to hydraulic oil tank until it isbetween marks on sight glass. See Hydraulic Oil.(Operator’s Manual.) Tighten tank cap. Tighten ventplug.

5. Start engine and run at slow idle. Slowly raise boom tofull height and then lower to pressurize hydraulic oiltank.

6. Purge air from the hydraulic system by slowlyoperating each function through three cycles. Air inpilot circuits are purged automatically.


PN=255

Hydraulic System

FS41334,0000148 –19–13APR07–1/2

Pump 1 and 2 Regulator Remove and Install

TX

1020

196A

–UN

–07M

AR

07


NOTE: Pump 1 (front) and pump 2 (rear) regulators aresimilar in design. Removal of pump 2 (rear)regulator is shown.



2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) Hydraulic oil tankcapacity is approximately 120.4 L (31.8 gal).

3. Disconnect lines.


333360

26



PN=256

Hydraulic System

FS41334,0000148 –19–13APR07–2/2

TX

1003

224A

–UN

–06F

EB

06

1—Cap Screw (8 used)2—Hydraulic Pump Regulator (2 used)

5. Remove cap screws (1) and regulator (2).


7. Install regulators making sure groove in remote controlsleeve and load sleeve engage dowel pin in feedbacklink. Check through hole that groove in sleeves engagedowel pin.

8. Tighten cap screws (1) to specification.

SpecificationPump 1 (Front) and Pump 2(Rear) Regulator-to-PumpHousing Cap Screw—Torque 49 N•m.........................................................

36 lb-ft


10. Connect electrical connectors. See Pump Harness(W8) Component Location. (Group 9015-10.)



33336027


PN=257

Hydraulic System

333360

28

FS41334,0000147 –19–10APR07–1/2

Pump 1 and 2 Regulator Disassemble and Assemble

T14

2272

B–U

N–1

6FE

B07

Pump 2 (Rear) Regulator Shown

1—Cap Screw (4 used) 8—O-Ring (3 used) 15—Spring (2 used) 22—Piston2—Nut 9—Load Adjusting Screw 16—Remote Control Spool 23—Load Piston3—Nut (2 used) (Stop) 17—Remote Control Sleeve 24—Cylinder4—Minimum Flow Adjusting 10—Regulator Body 18—O-Ring 25—Load Sleeve

Screw 11—Cap Screw (4 used) 19—Backup Ring 26—Load Spool5—Cover 12—End Plate 20—O-Ring 27—Inner Spring6—Nut (2 used) 13—Flow Adjusting Cartridge 21—Cylinder7—Load Adjusting Cartridge 14—Maximum Flow Adjusting

Screw (Stop)

NOTE: Pump 1 (front) and pump 2 (rear) regulatorsare similar. Pump 2 (rear) regulator is shown.

IMPORTANT: Removal of adjusting screws (4, 9and 14) and cartridges (7 and 13)from end plate (12) and cover (5) willrequire the adjustment of pumpregulators. Only remove parts fromend plate and cover if replacement isnecessary.

1. Remove end plate (12) and cover (5) with adjustingscrews and cartridges installed.


3. Tighten cap screws (1 and 11).

SpecificationPump 1 (Front) and Pump 2(Rear) End Plate andCover-to-Housing Cap Screw—Torque 19.8 N•m...................................................................................

180 lb-in.


PN=258


Hydraulic System

33336029

FS41334,0000147 –19–10APR07–2/2

T10

5706

–UN

–09J

AN

97

2—Load Sleeve 13—Load Adjusting Screw 24—Maximum Flow Adjusting 34—Nut3—Load Spool (Stop) Screw (Stop) 35—End Plate5—Cylinder 15—Spring 27—Remote Control Sleeve 36—Cover6—Load Piston 16—Nut (2 used) 28—Remote Control Spool 37—Cap Screw (8 used)12—Load Adjusting Cartridge 17—Nut (2 used) 29—Minimum Flow Adjusting 47—Outer Spring

(Stop) 20—Piston Screw 48—Inner Spring—Flow Adjusting Cartridge 21—Cylinder

(Stop)

4. Tighten cap screws.

5. Tighten air bleed plug.

SpecificationPump 1 (Front) and Pump 2(Rear) Air BleedPlug-to-Housing—Torque 78 N•m........................................................

58 lb-ft

IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before startingengine. Procedure must beperformed whenever a new pump isinstalled or oil has been drainedfrom the pump or hydraulic oil tank.


7. Check pump regulator adjustments.

For minimum flow:

• See Pump Regulator Test and Adjustment—Minimum Flow. (Group 9025-25.)

For maximum flow:

• See Pump Regulator Test and Adjustment—Maximum Flow. (Group 9025-25.)


PN=259

Hydraulic System

FS41334,0000146 –19–10APR07–1/3

Pilot Pump Remove and Install

TX

1020

196A

–UN

–07M

AR

07




2. Drain pump drive gearbox. Approximate oil capacity is0.9 L (1.0 qt).

3. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) and See 160DLCDrain and Refill Capacities. (Operator’s Manual.)

FS41334,0000146 –19–10APR07–2/3

TX

1020

192A

–UN

–05A

PR

07

333360

30


4. Remove cap screws (1) and set fuel filters (2 and 3)aside. Protect against damage to hoses and filters.



PN=260

Hydraulic System

FS41334,0000146 –19–10APR07–3/3

TX

1020

294A

–UN

–19M

AR

07

1—Pilot Pump2—Cap Screw (2 used)3—Adapter (2 used)4—Pump Drive Gearbox

5. Tag and disconnect lines and hoses. Close all openlines and fittings using caps and plugs.

6. Remove adapters (3).

7. Remove cap screws (2) and pilot pump (1) fromgearbox (4).


9. Apply T43514 Rigid Form-In-Place Gasket to mountingsurface for pilot pump.


SpecificationPilot Pump-to-Pump DriveGearbox Cap Screw—Torque 49 N•m........................................................

36 lb-ft

11. Install adapters (3) and O-ring.


13. Fill pump drive gearbox so level is above “H” mark ondipstick. See Change Pump Drive Gearbox Oil.(Operator’s Manual.)

33336031


PN=261

Hydraulic System

333360

32

TJ15698,0000113 –19–11APR07–1/3

Pilot Pump Disassemble and Assemble

TX

1000

393

–UN

–16N

OV

05


PN=262


Hydraulic System

TJ15698,0000113 –19–11APR07–2/3

0—Pilot Pump 6—Seal (2 used) 13—Driven Gear 26—Bushing1—Housing 7—End Cover 14—Drive Gear 27—Bushing2—Flange 9—Backup Retainer (2 used) 15—Washer (4 used) 28—Pin (4 used)3—Oil Seal 10—Key (2 used) 16—Cap Screw (4 used) 30—Seal Kit5—Snap Ring 12—O-Ring (2 used)

TJ15698,0000113 –19–11APR07–3/3

T76

85IX

–UN

–13M

AY

92

A—Drive GearB—Keys (2 used)C—Driven GearD—Bushing

IMPORTANT: Be careful not to lose keys (B).

1. Check bushings (D). If inside diameter and surfacetoward gear are rough or worn, replace pump.

2. Check gears (A and C) and housing. If gear teeth,shaft, and inside of housing is rough or worn, replacepump.

IMPORTANT: Apply clean hydraulic oil to all parts.Pump failure can result if pump isassembled dry.

3. Apply clean hydraulic oil to all parts.

4. Apply multi-purpose grease to lip of oil seal. Install oilseal with lip (spring side) towards inside of housing.


SpecificationCover-to-Flange Cap Screw—Torque 41 N•m............................................................................................

30 lb-ft

6. Check pilot pressure setting. See See Pilot PressureRegulating Valve Test and Adjustment. (Group9025-25.)

33336033


PN=263

Hydraulic System

FS41334,000014F –19–02MAR07–1/1

Pilot Pump Drive Shaft Remove and Install

T10

5640

–UN

–12D

EC

96T

1056

57–U

N–1

2DE

C96

T14

2290

–UN

–20J

UL0

1

333360

34

1—Pump Drive Gearbox Case3—Pilot Pump Drive Gear4—Pilot Pump Drive Shaft5—Ball Bearing (2 used)6—Snap Ring7—Snap Ring

1. Remove snap rings (6 and 7).

2. Remove pilot pump drive shaft (4) and outer ballbearing (5) using a blind-hole puller or an internalpuller. Ball bearings are a press fit on drive shaft andin housing.

3. Remove pilot pump drive gear (3) through opening forhydraulic pump.

4. Repair or replace as needed.

5. Assemble in reverse order.


PN=264

Hydraulic System

TJ15698,0000138 –19–11APR07–1/2

Pilot Pressure Regulating Valve and FilterRemove and Install

TX

1020

196A

–UN

–07M

AR

07




33336035

TJ15698,0000138 –19–11APR07–2/2

TX

1020

241A

–UN

–07M

AR

07

1—Hydraulic Hose2—Pilot Pressure Regulating Valve3—Filter4—Cap Screw (2 used)

2. Tag and disconnect hoses (1).

3. Close all open hoses and fittings using caps and plugs.

4. Remove cap screws (4) and remove pilot pressureregulating valve (2) and filter (3).


6. Install cap screws (4).

SpecificationFilter Head-to-Support CapScrew—Torque 49 N•m...............................................................................

36 lb-ft

7. Replace pilot filter element (3).

SpecificationPilot Filter ElementHousing-to-Filter Head—Torque 25 N•m...................................................

220 lb-in.

8. Connect hoses. See Hydraulic System LineConnections. (Group 9025-15.)

9. Check pilot pressure setting. See Pilot PressureRegulating Valve Test and Adjustment. (Group9025-25.)


PN=265

Hydraulic System

TJ15698,0000139 –19–06MAR07–1/1

Pilot Pressure Regulating Valve and FilterDisassemble and Assemble

1

23

45

6

TX

1003

402

–UN

–07F

EB

06

1—Pilot Pressure Regulating Valve Housing2—Poppet3—Shim (as required)4—Spring5—O-Ring6—Plug

1. Remove plug (6) with O-ring (5).


3. Inspect, clean and replace parts as necessary.

4. Check that poppet (2) slides smoothly in pilot pressureregulating valve housing.

5. Tighten plug (6).

SpecificationPlug-to-housing—Torque 49 N•m................................................................

36 lb-ft

333360

36

TJ15698,0000130 –19–18APR07–1/3

Pilot Shutoff Solenoid Valve Remove andInstall

1. Turn upperstructure 90° to tracks.

TJ15698,0000130 –19–18APR07–2/3

TX

1020

196A

–UN

–07M

AR

07






PN=266

Hydraulic System

TJ15698,0000130 –19–18APR07–3/3

TX

1003

407A

–UN

–07F

EB

06T

X10

0340

6A–U

N–0

7FE

B06

33336037

1—Cap Screw (2 used)2—Connector

3. Tag and disconnect hoses and lines. Close all openlines and fittings using caps and plugs.

4. Disconnect solenoid connector (2).

5. Remove cap screws (1) and valve.


7. Install valve. Tighten cap screws.

SpecificationPilot Shutoff ValveHousing-to-Cab Platform CapScrew—Torque 49 N•m...............................................................................

36 lb-ft

8. Connect lines. See Pilot Shutoff Solenoid ValveOperation. (Group 9025-05.)


PN=267

Hydraulic System

333360

38

TJ15698,0000114 –19–18APR07–1/2

Pilot Shutoff Solenoid Valve Disassemble and Assemble

TX

1000

413

–UN

–16N

OV

05


PN=268


Hydraulic System

TJ15698,0000114 –19–18APR07–2/2

1—Spring 5—Screen 9—Screw (2 used) 12—O-Ring (2 used)2—Plate 6—Solenoid 10—Screw (2 used) 13—Valve, Pilot Shutoff3—Housing 8—Plug (2 used) 11—O-Ring Solenoid4—Spool

1. Clamp housing (3) in a vise.

2. Scribe a line on housing (3) and solenoid (6).

3. Remove screws (9), solenoid (6), and O-ring (11).

4. Remove plug (8), O-ring (12), spring (1), and spool(4), from housing.

5. Remove screen (5).

6. Clean and inspect all parts. Replace worn ordamaged parts as necessary. Use new O-ringswhen assembling.

7. Install spool (4), spring (1), plug (8), and O-ring(12). Tighten plug to specification.

SpecificationShutoff Solenoid Valve HousingPlug—Torque 28 N•m...........................................................................

246 lb-in.

8. Install screen (5).

9. Install O-ring (11) to solenoid (6).

10. Align scribe marks and install solenoid (6) tohousing (3), using screws (9). Tighten screws tospecification.

SpecificationSolenoid-to-Housing Screws—Torque 4 N•m........................................................................................

36 lb-in.

33336039

OUO6046,0002328 –19–10APR07–1/2

Fan Drive Pump Remove and Install

TX

1020

196A

–UN

–07M

AR

07




2. Pull a vacuum in hydraulic oil tank using a vacuumpump, or drain tank. See Apply Vacuum to HydraulicOil Tank. (Group 3360.) Approximate capacity ofhydraulic oil tank it 120.4 L (31.8 gal).



PN=269

Hydraulic System

OUO6046,0002328 –19–10APR07–2/2

TX

1020

830A

–UN

–23M

AR

07T

X10

2082

9A–U

N–2

3MA

R07

1—Cold Weather Starting Aid Line2—Inlet Hose3—Outlet Hose4—Cap Screws (2 used)

3. Disconnect cold weather starting aid line (1).

4. Loosen clamp and disconnect inlet hose (2).

5. Disconnect outlet hose (3). Close all open lines andfittings using caps and plugs.

6. Remove cap screws (4), washers, pump (3), andgasket.

7. If installing new pump, remove fittings and top capscrew from existing pump and install onto new pumpusing new O-rings on fittings.

8. Install pump and new gasket.


10. Connect inlet and outlet hoses.

11. Tighten fittings and clamp.


333360

40

OUO6046,0002327 –19–04APR07–1/3

Fan Drive Motor Remove and Install





PN=270

Hydraulic System

OUO6046,0002327 –19–04APR07–2/3

TX

1020

784A

–UN

–23M

AR

07




33336041


PN=271

Hydraulic System

333360

42

OUO6046,0002327 –19–04APR07–3/3

TX

1021

112A

–UN

–30M

AR

07

1—Hub2—Lock Nut3—Cap Screws4—Hydraulic Hose5—Fan Drive Motor6—Hydraulic Hose7—Hydraulic Hose

4. Disconnect hydraulic hoses (4, 6, and 7).

5. Remove lock nut (2) and washer. Discard lock nut.

6. Remove hub (1) from motor shaft using suitable puller.

7. Remove cap screws (3), nuts, washers, and fan drivemotor (5).

8. Replace motor as necessary.

9. Install motor into mounting bracket.

10. Install cap screws, washers, and nuts. Tighten capscrews to specification.

SpecificationFan Drive Motor-to-MountingBracket Cap Screws—Torque 73 N•m........................................................

54 lb-ft

11. Install hub on fan shaft.

12. Install washer and new lock nut onto fan shaft.Tighten lock nut to specification.

SpecificationFan Motor Shaft Lock Nut—Torque 50 N•m............................................................................................

37 lb-ft

13. Connect hydraulic hoses.


SpecificationFan Drive MotorAssembly-to-Cooling PackageCap Screws—Torque 73 N•m.....................................................................

54 lb-ft




PN=272

Hydraulic System

OUO1073,0002104 –19–18APR07–1/2

Fan Drive Control Valve Remove and Install

TX

1020

196A

–UN

–07M

AR

07




2. Pull a vacuum in hydraulic oil tank using a vacuumpump. See Apply Vacuum to Hydraulic Oil Tank.(Group 3360.)

33336043

OUO1073,0002104 –19–18APR07–2/2

TX

1021

223A

–UN

–27M

AR

07

1—Connectors2—Cap Screw (2 used)3—Fan Drive Control Valve

NOTE: Reversing control valve shown, standard valvesimilar.

3. Disconnect wiring harness connectors (1).

4. Tag and disconnect hydraulic hoses. Close all openlines and fittings using caps and plugs.

5. Remove cap screws (2) and fan drive control valve (3).

6. Install valve and cap screws.

7. Connect hydraulic hoses. See Fan Drive SystemComponent Location. (Group 9025-15.)

8. Connect wiring harness connectors.



PN=273

Hydraulic System

TJ15698,0000131 –19–11APR07–1/2

Solenoid Valve Manifold Remove and Install

TX

1020

196A

–UN

–07M

AR

07




2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) Approximate oilcapacity is 120.4 L (31.8 gal).


333360

44


PN=274

Hydraulic System

TJ15698,0000131 –19–11APR07–2/2

TX

1020

239A

–UN

–07M

AR

07

1—Solenoid Valve Manifold2—Cap Screws (2 used)

3. Tag and disconnect electrical connectors.

4. Tag and disconnect hoses and lines.

5. Close all open lines, hoses, and fittings using caps andplugs.

6. Remove cap screws (2) and solenoid valve manifold(1).


8. Install manifold and tighten cap screws to specification.

SpecificationSolenoid Valve Manifold CapScrews—Torque 50 N•m.............................................................................

37 lb-ft

9. Connect hoses and lines.

10. Connect electrical connectors.

11. Fill hydraulic oil tank. Approximate oil capacity is120.4 L (31.8 gal).


12. Perform pump 1 and 2 start-up procedure. See Pump1 and 2 Start-Up Procedure. (Group 3360.)

33336045


PN=275

Hydraulic System

TJ15698,0000132 –19–11APR07–1/2

Solenoid Valve Remove and Install—PowerDig (SG), Travel Speed (SI), Boom Mode(SC), and Boom Flow Rate (SF)

TX

1020

196A

–UN

–07M

AR

07




333360

46

TJ15698,0000132 –19–11APR07–2/2

TX

1020

240A

–UN

–07M

AR

07

1—Cap Screw (8 used)2—Solenoid Valve Coil (4 used)3—Electrical Connector (4 used)


3. Remove cap screws (1) and remove solenoid valve coil(2). Be careful not to lose spring and O-ring.

4. Keep parts for each individual solenoid valve together.

5. Install solenoid valve coil (2) with O-ring and spring.

6. Tighten cap screws (1).

SpecificationSolenoid Valve Coil-to-ManifoldCap Screws—Torque 6 N•m.......................................................................

53 lb-in.

7. Connect electrical connectors (3).

8. Check pressure setting of solenoid valves. See PowerDigging Solenoid Valve Test and Adjustment. SeeTravel Speed Solenoid Valve Test and Adjustment.See Arm Regenerative Solenoid Valve Test andAdjustment. See Dig Regenerative Solenoid Valve Testand Adjustment. (Group 9025-25.)


PN=276

Hydraulic System

TJ15698,0000133 –19–11APR07–1/3

Pilot Valve (Left and Right) Remove andInstall

TX

1020

196A

–UN

–07M

AR

07





3. Remove console covers. See Left and Right ConsoleCovers Remove and Install. (Group 1821.)


33336047


PN=277

Hydraulic System

333360

48

TJ15698,0000133 –19–11APR07–2/3

TX

1018

524

–UN

–05F

EB

071—Handle (2 used) 5—Boot (2 used) 8—Cap Screw and Washer (6 10—Cap Screw (2 used)2—Tie Band (2 used) 6—Washer (8 used) used) 11—Washer (2 used)3—Nut (4 used) 7—Tie Band (2 used) 9—Spring Pin (2 used) 12—Pilot Valve (2 used)4—Shaft (2 used)

4. Disconnect wiring harness and remove handles (1).Handles are threaded onto shaft (4).

5. Remove cap screws (8 and 10) and remove pilotvalves (12) from console.

6. Tag and disconnect hoses. Close all open hosesand fittings using caps and plugs.


8. Connect hoses. See Pilot Control Valve-to-PilotSignal Manifold Component Location—ExcavatorPattern. (Group 9025-15.)

NOTE: Position cap screw (10) with spring pin (9), inlower left hole of left pilot valve, and lowerright hole of right pilot valve.

9. Install pilot valves (12) and tighten cap screws (8and 10).


PN=278


Hydraulic System

TJ15698,0000133 –19–11APR07–3/3

SpecificationPilot Valve-to-Console CapScrew—Torque 20 N•m........................................................................

177 lb-in.

10. After pilot valve is installed, check operation of allfunctions. See Control Lever Pattern Operation.(Operator’s Manual.)

11. Install console covers. See Left and Right ConsoleCovers Remove and Install. (Group 1821.)

12. Install seat. See Seat Remove and Install. (Group1821.)

33336049


PN=279

Hydraulic System

333360

50

TJ15698,0000116 –19–03APR07–1/3

Pilot Valve (Left and Right) Disassemble and Assemble

TX

1000

262

–UN

–16N

OV

05


PN=280


Hydraulic System

33336051

TJ15698,0000116 –19–03APR07–2/3

0—Housing and Spools 11—Snap Ring (4 used) 21—Plate 27—O-Ring3—Shim (4 used) 14—Pusher B (2 used) 22—Universal Joint 28—Snap Ring4—Spacer (4 used) 15—Pusher A (2 used) 23—Cam 33—Return Spring (2 used)6—Balance Spring (2 used) 17—Sleeve (4 used) 24—Coupling 34—Return Spring (2 used)8—Balance Spring (2 used) 19—O-Ring (4 used) 26—Plug 35—Pilot Valve10—Guide (4 used)

IMPORTANT: The housing and spools (0) arereplaced as an assembly becausethe spools are select fitted to boresin housing.

Some parts from ports 1 and 3 aredifferent than parts from ports 2 and4. Parts for each port must be kepttogether and installed into the sameport from which it was removed. Theport numbers are stamped on thehousing.

Remove universal joint (22) only ifnecessary.

Note port location and quantity ofshims (3) when removing. Samenumber of shims must be used wheninstalling.

1. Remove:

• Coupling (24)• Cam (23)• Universal Joint (22)• Plate (21)

NOTE: Sleeves (17) cannot be disassembled. Do notattempt to remove oil seal from sleeve.

2. Remove sleeves (17).

3. Remove:

• Pusher (14 and 15)• Snap Ring (11)• Guide (10)• Spring (6 and 8)• Spring (33 and 34)• Shim (3)

• Spacer (4)• Spools (0)• Snap Ring (28)• O-Ring (27)• Plug (26)


5. Install O-ring (27) onto plug (26).

6. Install plug (26) and snap ring (28).

IMPORTANT: Components are select fit to bores.Install components in the same borethat they were removed from.

7. Install spools (0).

IMPORTANT: Ports 1 and 3 use short balancesprings. Ports 2 and 4 use longbalance springs.

8. Install spacers (4), shims (3), and balance springs(6 and 8).

IMPORTANT: Ports 1 and 3 use short returnsprings. Ports 2 and 4 use longreturn springs.

9. Install return springs (33 and 34).

10. Install guides (10) with protrusion facing upward.

11. Install snap rings (11).

IMPORTANT: Ports 1 and 3 use pushers with 1outer groove. Ports 2 and 4 usepushers with 2 outer grooves.

12. Install pushers A (15) and pushers B (14).


PN=281


Hydraulic System

TJ15698,0000116 –19–03APR07–3/3

13. Apply TY6341 Multi-Purpose SD Polyurea Greaseto ball at ends of pushers A and pushers B.

14. Apply TY6341 Multi-Purpose SD Polyurea Greaseto joint of universal joint (22) and to inner surfaceof sleeve (17) seals.

15. Install O-rings (19) and sleeves (17).

16. Apply LOCTITE 262 Threadlocker (high strength)to threads of universal joint (22).

IMPORTANT: Align cap screw hole in plate (21)with cap screw hole in housing (0).

17. Install plate (21) and universal joint (22). Tightenuniversal joint.

SpecificationUniversal Joint—Torque 24.5 N•m.......................................................

217 lb-in.

18. Install cam (23) on universal joint (22). Adjustclearance between pushers A (15) and pushers B(14) and cam.

SpecificationCam-to-Pusher A and PusherB—Clearance 0—0.20 mm...................................................................

0—0.008 in.

19. Hold cam (23) and tighten coupling (24).

SpecificationCoupling-to-Cam and UniversalJoint—Torque 69 N•m..........................................................................

51 lb-ft

LOCTITE is a trademark of Henkel Corporation

333360

52

TJ15698,0000134 –19–11APR07–1/2

Travel Pilot Valve Remove and Install

TX

1020

196A

–UN

–07M

AR

07






PN=282

Hydraulic System

TJ15698,0000134 –19–11APR07–2/2

TX

1003

510A

–UN

–16F

EB

06

1—Cap Screw (4 used)2—Cap Screw (2 used)3—Travel Pilot Valve

2. Tag and disconnect hoses underneath of cab.

3. Close all open hoses and fittings using caps and plugs.

4. Remove cap screws (1) and remove pedals and levers.

5. Remove cap screws (2) and remove travel pilot valve(3).



SpecificationValve-to-Cab Platform CapScrew—Torque 50 N•m...............................................................................

37 lb-ft


SpecificationTravel Pedal-to-Lever CapScrew—Torque 50 N•m...............................................................................

37 lb-ft

9. Connect hoses. See Travel Hydraulic System LineConnection. (Group 9025-15.)

10. After travel pilot valve is installed, check the operationof all functions to be sure they operate correctly.

33336053


PN=283

Hydraulic System

333360

54

TJ15698,0000117 –19–16FEB07–1/3

Travel Pilot Valve Disassemble and Assemble

1

235

34

33

32

3031

26

27 2829

10

14

19

20

21

22 23

24

25

13

12

11

9

8

7

6 54

3

18

17

1516

TX

1018

305

–UN

–31J

AN

07

1—Cap Screw (2 used) 10—Holder 19—Spool (4 used) 28—Cap Screw (4 used)2—Cover 11—Oil Seal (4 used) 20—Spring (4 used) 29—Lock Washer (4 used)3—Pin (2 used) 12—O-Ring (4 used) 21—Spacer (4 used) 30—Spring Pin (2 used)4—O-Ring (2 used) 13—Bushing (4 used) 22—Shim (As required) 31—Spring Pin (2 used)5—O-Ring (2 used) 14—Casing 23—Balance Spring (4 used) 32—Bushing (4 used)6—Dampener (2 used) 15—O-Ring 24—Spring Guide (4 used) 33—Cam (2 used)7—Rubber Seat (2 used) 16—Plug 25—Pusher (4 used) 34—Spring Pin (2 used)8—Cap Screw (2 used) 17—Plug 26—Bracket (2 used) 35—Spring Pin (2 used)9—Lock Washer (2 used) 18—O-Ring 27—Spring Pin (2 used)


PN=284


Hydraulic System

33336055

TJ15698,0000117 –19–16FEB07–2/3

IMPORTANT: The casing (14) and spools (19) arereplaced as an assembly becausethe spools are select fitted to boresin housing.

Parts for each port must be kepttogether and installed into the sameport from which it was removed. Theport numbers are stamped on thehousing.

Note port location and quantity ofshims (22) when removing. Samenumber of shims must be used wheninstalling.

1. Remove parts from casing. Remember to keepparts removed from each port together. Identifyeach group of parts by port numbers stamped oncasing.

NOTE: Spring pins (30 and 31) are stepped and canonly be removed from one direction.

Remove spring pin (27) and bushings (32) onlyif necessary.


NOTE: Use same number of shims (22) as wereremoved.

3. Install spools (19), springs (20), spacers (21), shims(22) and balance springs (23) into casing (14).

4. Install spring guides (24) with stepped end facingdown.

5. Apply multi-purpose grease to the end of eachpusher (25) and to oil seals (11).

IMPORTANT: Note direction of insertion for springpins (34 and 35).

6. Assemble cam (33) in holder (10) with spring pins(34 and 35), and pin (3). Install spring pins with slits90° apart.

7. Lock pins (34 and 35) in position by displacing thebore above spring pin using a punch and hammer.

8. Install holder (10) to casing (14) with cap screws(8), lock washers (9) and tighten.

SpecificationHolder-to-Casing Cap Screw—Torque 49 N•m......................................................................................

36 lb-ft

9. Apply multi-purpose grease to O-rings (4 and 5)and install on pin (3).

10. Position rubber seat (7) and dampener (6) on pin(3) with lever facing upward.

11. Install cap screws (28), lock washers (29) andtighten.

SpecificationDampener-to-Holder CapScrew—Torque 7 N•m..........................................................................

62 lb-in.

IMPORTANT: Note direction of insertion for springpins (30 and 31).

Spring pins must be positioned withslits 90° apart.

Align brackets with marks madeduring disassembly.

12. Install brackets (26) and spring pins (30 and 31).

13. Lock pins (30 and 31) in position by displacing thebore above spring pin using a punch and hammer.

14. Install cover (2) and cap screws (1) and tighten.

SpecificationCover-to-Holder Cap Screw—Torque 5 N•m........................................................................................

44.3 lb-in.

15. Apply multi-purpose grease to spring pin (27).


PN=285


Hydraulic System

TJ15698,0000117 –19–16FEB07–3/3

16. Install O-ring (18) and plug (17). Tighten plug tospecification.


89 lb-in.

17. Install O-ring (15) and plug (16). Tighten plug tospecification.


177 lb-in.

TJ15698,0000135 –19–11APR07–1/2

Pilot Signal Manifold Remove and Install

TX

1020

196A

–UN

–07M

AR

07




2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) Approximate oilcapacity is 120.4 L (31.8 gal).

333360

56



PN=286

Hydraulic System

TJ15698,0000135 –19–11APR07–2/2

TX

1021

445A

–UN

–02A

PR

07

1—Pilot Signal Manifold2—Bracket3—Cap Screw (4 used)

3. Tag and disconnect hoses and lines.

4. Close all open lines, hoses, and fittings using caps andplugs.


6. Remove cap screws (3).


8. Position manifold (1) on bracket (2) and tighten capscrews (3).

SpecificationPilot Signal Manifold-to-BracketCap Screw—Torque 50 N•m.......................................................................

37 lb-ft

9. Connect electrical connectors. See System FunctionalSchematic, Component Location, and Wiring DiagramMaster Legend. (Group 9015-10.)

10. Connect hoses and lines. See PilotControllers-to-Pilot Signal Manifold ComponentLocation—Excavator Pattern. See Pilot SignalManifold-to-Control Valve Line Connection. (Group9025-15.)


33336057


PN=287

Hydraulic System

333360

58

TJ15698,0000118 –19–16FEB07–1/3

Pilot Signal Manifold Disassemble and Assemble

14

13

15

1619

20

1617

19

18

2012

11

1

23

5

4

6 7

22

23

24

21 14

8

9

10

20 14

25

2619

2716

15

28

17

29

19

1716

15

17

A

B

C

D

T143485

T14

3485

–UN

–17J

UL0

1


PN=288


Hydraulic System

TJ15698,0000118 –19–16FEB07–2/3

1—Cap Screw (10 used) 9—Gasket 16—O-Ring (7 used) 23—Valve2—Body 10—Body 17—Spring (4 used) 24—O-Ring3—Gasket 11—Name Plate 18—Spring 25—Spring4—Body 12—Screw (4 used) 19—Spring Seat (7 used) 26—Spool5—Gasket 13—Plate 20—Spool (6 used) 27—Spring6—Body 14—Cap Screw (11 used) 21—Plate 28—Spring7—Gasket 15—Plug (7 used) 22—O-Ring 29—Plate8—Body


33336059


PN=289

Hydraulic System

333360

60

TJ15698,0000118 –19–16FEB07–3/3

A B

C D

30 32

31

32

31

30

3130

T143486

T14

3486

–UN

–17J

UL0

1

30—Filter (17 used) 31—Shuttle Valve (21 used) 32—Spring (4 used)


PN=290

Hydraulic System

OUO6046,000231D –19–10APR07–1/3

Control Valve Remove and Install

TX

1020

196A

–UN

–07M

AR

07




2. Pull a vacuum in hydraulic oil tank using a vacuumpump, or drain tank. See Apply Vacuum to HydraulicOil Tank. (Group 3360.) See 160DLC Drain and RefillCapacities. (Operator’s Manual.)

OUO6046,000231D –19–10APR07–2/3

TX

1020

604A

–UN

–23M

AR

07

33336061

1—Cap Screws2—Pilot Signal Manifold

3. Tag and disconnect hydraulic lines and hoses. Closeall open lines and fittings using caps and plugs.


5. Remove cap screws (1) and washers. Place pilotsignal manifold (2) with bracket to side.

6. Attach an appropriate lifting device to control valveusing lifting straps.



PN=291

Hydraulic System

333360

62

OUO6046,000231D –19–10APR07–3/3

2

2

1

51

3

4

3

TX

1003

909

–UN

–20F

EB

06

1—Cap Screw (4 used)2—Washer (4 used)3—Spacer (4 used)4—Front Mounting Bracket5—Rear Mounting Bracket


SpecificationControl Valve—ApproximateWeight 220 kg..............................................................................................

485 lb

7. Remove cap screws (1), washers (2), and spacers (3).Remove control valve.


9. Install in reverse order.


SpecificationMounting Bracket-to-ControlValve Cap Screw—Torque 270 N•m...........................................................

200 lb-ft

11. Install pilot signal manifold with bracket. Tighten capscrews to specification.

SpecificationPilot Signal ManifoldBracket-to-Control Valve CapScrew—Torque 140 N•m.............................................................................

103 lb-ft

12. Connect hydraulic hoses and lines. See HydraulicSystem Line Connections. (Group 9025-15.)

13. Connect electrical connectors.

14. Check hydraulic tank oil level. See Check HydraulicTank Oil Level. (Operator’s Manual.)

15. Do Pump 1 and 2 Start-Up Procedure. (Group 3360.)


PN=292

Hydraulic System

33336063

OUO6046,000231E –19–16APR07–1/8

Control Valve (5-Spool) Disassemble and Assemble

TX

1004

777

–UN

–26A

PR

06

Control Valve End Caps 5-Spool Side


PN=293


Hydraulic System

333360

64

OUO6046,000231E –19–16APR07–2/8

TX

1004

778

–UN

–25A

PR

06


PN=294


Hydraulic System

33336065

OUO6046,000231E –19–16APR07–3/8

1—Housing 33—Spring 68—Poppet 100—O-Ring2—O-Ring 34—Piston 69—Poppet 104—Body3—Plug 35—O-Ring 70—Plug 105—Auxiliary Flow Combiner4—Poppet 36—Plug 71—O-Ring Check Valve5—Spring 37—Poppet 72—Flange 106—Main Relief Valve6—O-Ring (3 used) 38—Spring 73—Spring Isolation Check Valve7—Flange 39—O-Ring 74—Poppet 107—Arm Reduced Leakage8—Cap Screw (22 Used) 40—Spacer 75—Flange (2 Used) Valve9—O-Ring (4 Used) 41—Left Travel Spool 76—Poppet (2 Used) 108—Left Travel Spool10—Plug (4 Used) 42—Spring Seat (10 Used) 77—Auxiliary Flow Rate Spool 109—Auxiliary Spool11—Poppet 43—Spring (5 Used) 78—Spring 110—Boom II Spool12—Spring (2 Used) 44—Bolt (5 Used) 79—Plug 111—Arm I Spool13—O-Ring (5 Used) 45—Auxiliary Spool 80—Spring 112—Swing Spool14—O-Ring 46—Boom 2 Spool 81—Poppet 113—Check Valve15—Backup Ring 47—Arm 1 Spool 82—Poppet 114—Auxiliary Flow Rate16—Plug 48—Spring Seat (2 Used) 83—Poppet Control Valve17—Main Relief and Power 49—Spring 84—Cover (2 Used) 115—Auxiliary Flow Combiner

Digging Valve 50—Swing Spool 85—O-Ring (2 Used) Valve Check Valve18—O-Ring 51—O-Ring (10 Used) 86—Poppet 116—Lift Check (Left Travel19—Arm Out Circuit Relief and 52—Cap Screw (16 Used) 87—Plug Power Passage Check

Anticavitation Valve (2 53—O-Ring 88—O-Ring Valve)Used) 54—Plug 89—Spring 117—Dig Regenerative Check

20—O-Ring (5 Used) 55—Cap 90—Poppet Valve21—O-Ring 56—Plug (2 Used) 91—Socket Bolt (4 Used) 118—Auxiliary Flow Combiner22—Spring 57—O-Ring (2 Used) 92—Cap (2 Used) Valve23—Seat 58—Cap Screw (8 Used) 93—Spring Seat (2 Used) 119—Dig Regenerative Valve24—Poppet 59—Arm 1 Flow Rate Spool 94—Spring 120—Arm Reduced Leakage25—Backup Ring 60—Spring 95—Auxiliary Flow Combiner Valve26—O-Ring 61—Spring Seat (2 Used) Spool 121—Lift Check (Boom 227—O-Ring 62—O-Ring (2 Used) 96—Spring Power Passage)28—Backup Ring 63—Plug (2 Used) 97—Dig Regenerative Spool 122—Arm 1 Flow Rate Control29—Sleeve 64—Sleeve (2 Used) 98—Cap (4 Used) Valve30—Spool 65—Spring (2 Used) 99—Arm In Circuit Relief and 123—Lift Check (Swing Neutral31—O-Ring 66—Plug Anticavitation Valve Passage)32—Body 67—Spring

1. Remove cap screws (52) and bottom pilot caps(98).

2. Remove cap screws (52) and top pilot cap (55).

3. Spool—5 Spool (108—112):

IMPORTANT: The spool (108—112) are select fittedto bores in housing and are adifferent design for each function.Spools must be installed into thesame bores from which they wereremoved for proper operation ofmachine.

NOTE: Hold spool in a vise by the spool end betweenwooden blocks.

a. Remove spools (108—112).

b. Disassemble control valve spools.

c. Inspect control valve spools for wear anddamage.

d. Replace parts as necessary.

e. Assemble in reverse order.


PN=295


Hydraulic System

333360

66

OUO6046,000231E –19–16APR07–4/8

f. Tighten cap screws (44) to specification.

SpecificationCap Screw-to-Control ValveSpool—Torque 15 N•m.........................................................................

132 lb-in.

NOTE: Apply clean hydraulic oil to spools beforeinstallation.

g. Install spools (108—112) into housing (1) whilerotating them slowly.

h. After installing spools into housing, push themby hand to confirm smoothness.

4. Dig Regenerative Valve (119):

a. Remove cap screws (91) and parts (92, 6, 93,96 and 97).

b. Inspect parts for wear and damage.

c. Replace parts as necessary.

d. Assemble in reverse order.

e. Tighten cap screws (91) to specification.

SpecificationDig RegenerativeValve-to-Housing Cap Screw—Torque 11 N•m......................................................................................

84 lb-in.

5. Lift Check (Left Travel Neutral Passage) (116):

a. Remove plug (10) O-ring (9), spring (38) andpoppet (86).


c. Replace parts as necessary


e. Install plug (10) and tighten to specification.

SpecificationLeft Travel NeutralPassage-to-Housing Lift CheckPlug—Torque 76 N•m...........................................................................

56 lb-ft

6. Auxiliary Flow Combiner Valve Check Valve(115):

a. Remove parts (8, 7, 6, 5 and 83).


c. Assemble in reverse order.

d. Install flange (7) and tighten cap screws (8) tospecification.

SpecificationAuxiliary Flow Combiner ValveCheck Valve-to-Housing CapScrew—Torque 61 N•m........................................................................

46 lb-ft

7. Arm Reduced Leakage Valve (120):

a. Remove cap screws (8) and flange (72).

b. Remove spring (73) and poppet (74).

c. Inspect parts for wear and damage.



f. Install flange (72) and tighten cap screws (8).

SpecificationArm Reduced LeakageValve-to-Housing Cap Screw—Torque 61 N•m......................................................................................

46 lb-ft


PN=296


Hydraulic System

33336067

OUO6046,000231E –19–16APR07–5/8

8. Lift Check (Boom 2 Power Passage) (121):

a. Remove cap screws (8) and flanges (75).

b. Remove O-ring (13), spring (12) and poppet(76).




f. Install flanges (75) and tighten cap screws (8) tospecification.

SpecificationPower Passage-to-HousingCap Screw—Torque 61 N•m................................................................

46 lb-ft

9. Lift Check (Swing Neutral Passage) (123):

a. Remove cap screws (8) and flanges (75).

b. Remove O-ring (13), spring (12) and poppet(76).




f. Install flanges (75) and tighten cap screws (8) tospecification.

SpecificationNeutral Passage-to-HousingCap Screw—Torque 61 N•m................................................................

46 lb-ft

10. Auxiliary Flow Rate Control Valve (114) andArm I Flow Rate Control Valve (122):

a. Remove cap screws (58) and housing (104).

b. Loosen plugs (56 and 63) from bodies (104).

c. Remove O-rings (20 and 13).

d. Remove plugs (63), spring seats (61), springs(60 and 78) and spools (59 and 77).

e. Remove plugs (56).

f. Remove sleeves (64), springs (65), plugs (66and 79), springs (67 and 80) and poppets (68,69, 81, and 82) from housing (1).

g. Inspect parts for wear and damage.

h. Replace parts as necessary.

i. Assemble in reverse order.

j. Install housing (104) and tighten cap screws(58) to specification.

SpecificationFlow Rate ValveHousing-to-Housing CapScrew—Torque 61 N•m........................................................................

46 lb-ft

k. Tighten plug (63) to specification.

SpecificationFlow Rate Valve HousingPlug—Torque 98 N•m...........................................................................

72 lb-ft

11. Arm Reduced Leakage Valve (107):

a. Remove plug (36).

b. Remove cap screws (8) and body (32).

c. Remove parts (33—35).

d. Remove parts (22—31).

e. Inspects parts for wear and damage.


PN=297


Hydraulic System

OUO6046,000231E –19–16APR07–6/8

f. Replace parts as necessary.

g. Assemble in reverse order.

h. Apply petroleum jelly to valve seat (23) andspring (22) to hold in place.

IMPORTANT: Install spool (30) with the hole sidetowards poppet (24) to ensureproper operation of valve.

i. Install plug (36) loosely.

j. Tighten cap screws (8) to specification.

SpecificationArm Reduced Leakage ValveBody-to-Housing Cap Screw—Torque 62 N•m......................................................................................

46 lb-ft

k. Tighten plug (36) to specification.

SpecificationPlug-to-Arm Reduced LeakageValve—Torque 108 N•m.......................................................................

80 lb-ft


333360

68


PN=298

Hydraulic System

33336069

OUO6046,000231E –19–16APR07–7/8

17

TX1005220

A

B

F

K

M

O

C

D

E

G

H

I

J

L

N

PQ

TX

1005

220

–UN

–24M

AR

06

A—First Adjusting PlugB—O-RingC—PistonD—NutE—Second Adjusting PlugF—O-RingG—Pilot Poppet SpringH—Pilot PoppetI—NutJ—CartridgeK—O-RingL—Pilot Poppet SeatM—Backup RingN—O-RingO—Main Poppet SpringP—Main PoppetQ—Main Poppet Seat

12. Main Relief and Power Digging Valve (17)

NOTE: Disassemble valve for cleaning and inspectiononly. Valve is serviced as an assembly.

a. Disassemble parts (A—Q).


c. If any part of valve is damaged, replace valve asan assembly.

d. Tighten nuts (D and I) to specification.

Main Relief Valve—SpecificationMain Relief Valve 27 mm Nut(D)—Torque 64 N•m....................................................................................

47 lb-ftMain Relief Valve 32 mm Nut(I)—Torque 83 N•m.....................................................................................

61 lb-ft

e. Tighten valve cartridge (J) to specification.

SpecificationMain Relief ValveCartridge-to-Housing—Torque 83 N•m.......................................................

61 lb-ft

f. Check and adjust pressure setting for system reliefvalve and power boost. See Main Relief and PowerDigging Valve Test and Adjustment. (Group9025-25.)

13. Install top pilot cap (55) and tighten cap screws (52)to specification.

SpecificationTop Pilot Cap-to-Housing CapScrew—Torque 42 N•m...............................................................................

32 lb-ft

14. Install bottom pilot caps (98) and tighten cap screws(52).


PN=299


Hydraulic System

OUO6046,000231E –19–16APR07–8/8

SpecificationBottom Pilot Caps-to-HousingCap Screw—Torque 42 N•m......................................................................

32 lb-ft

333360

70


PN=300

Hydraulic System

33336071

OUO6046,000231F –19–19APR07–1/6

Control Valve (4-Spool) Disassemble and Assemble

TX

1004

704

–UN

–16M

AR

06

4-Spool Control Valve


PN=301


Hydraulic System

333360

72

OUO6046,000231F –19–19APR07–2/6

TX

1004

708

–UN

–16M

AR

06

Control Valve End Caps (4-Spool Side)


PN=302


Hydraulic System

33336073

OUO6046,000231F –19–19APR07–3/6

1—Housing 34—Piston 72—Spring 106—Spring2—Poppet 35—O-Ring 73—Travel Flow Combiner 107—Flange3—Spring (2 used) 36—Plug Spool 108—Poppet4—O-Ring (3 used) 37—Right Travel Spool 74—Circuit Relief and 109—Poppet5—Flange 38—Spring Seat (8 used) Anticavitation Valve (2 110—Spring6—Cap Screw (13 used) 39—Spring (4 used) Used) 111—Plug7—O-Ring (3 used) 40—Body 75—Poppet 112—Poppet8—Plug (3 used) 41—Cap Screw (4 used) 76—Spring 113—Spring9—O-Ring (5 used) 42—Plug 77—O-Ring (5 Used) 114—Plug (3 Used)10—Plug (3 used) 43—Backup Ring (2 used) 78—O-Ring (2 Used) 115—O-Ring (3 Used)11—Poppet 44—O-Ring 79—O-Ring 116—Spring Seat (3 Used)12—Spring 45—Spring 80—Manual Boom Lower 117—Spring13—O-Ring (3 used) 46—Poppet Screw 118—Arm 2 Flow Rate Spool14—O-Ring 47—Bucket Spool 81—O-Ring 119—Plug (3 Used)15—Poppet 48—Plug 82—Plug 120—O-Ring (3 Used)16—Flange 49—Poppet 83—Poppet 121—Spring17—Main Relief Valve Isolation 50—Boom 1 Spool 84—Poppet 122—Arm 2 Flow Rate Spool

Check Valve 51—Arm 2 Spool 85—Spring 123—Body18—Right Travel and Bucket 52—Spring Seat (2 used) 86—Plug 124—Arm 2 Flow Rate Spool

Combined Function Check 53—Spring 87—Spring (3 Used) 125—SpringValve 54—Arm Regenerative Spool 88—Sleeve 126—O-Ring

19—O-Ring (2 used) 55—O-Ring 89—Plug 127—Plug20—Circuit Relief and 56—Backup Ring 90—O-Ring 128—Boom Reduced Leakage

Anticavitation Valve (2 57—Arm Regenerative Spool 91—Body Valveused) 58—Spring 92—Bucket Flow Rate Spool 129—By-Pass Shut-Off Valve

21—Spring 59—O-Ring (8 Used) 93—Spring 130—Right Travel Spool22—Washer 60—O-Ring 94—Spring Seat 131—Bucket Spool23—Poppet 61—Plug 95—O-Ring 132—Boom 1 Spool24—Backup Ring 62—Top Pilot Cap 96—Plug 133—Arm 2 Spool25—O-Ring 63—Cap Screw (14 Used) 97—Cap Screw (12 Used) 134—Arm Regenerative Valve26—O-Ring 64—Bottom Pilot Cap 98—Poppet 135—Travel Flow Combiner27—Arm Regenerative Circuit 65—O-Ring 99—Poppet Valve

Check Valve 66—Plug 100—Spring 136—Boom Reduced Leakage28—Backup Ring 67—Cap (3 Used) 101—Plug Valve29—Sleeve 68—Cap Screw (2 Used) 102—O-Ring 137—Bucket Flow Rate30—Spool 69—Cap 103—Cap Control Valve31—O-Ring 70—Cap Screw 104—Cap Screw (4 Used) 138—Arm 2 Flow Rate Control32—Body 71—Spring Seat (2 Used) 105—By-Pass Shut-Off Spool Valve33—Spring

1. Remove cap screws (63), top pilot cap (62) andO-rings (59) from housing (1).

2. Remove cap screws (63) and bottom pilot caps (67)from housing (1).

3. Spool—4 Spool (130—133):

NOTE: When disassembling spools (131, and 132),heat plugs (46, 48, and 49) to 200—300 °C(392—482 °F) to melt thread lock and sealer.

IMPORTANT: The spools (130—133) are select fitto bores in housing and are adifferent design for each function.Spools must be installed into samebores from which they were removedfor proper operation of machine.

a. Remove spools (130—133).


PN=303


Hydraulic System

333360

74

OUO6046,000231F –19–19APR07–4/6

NOTE: Hold the spool in a vise by the spool end,using wooden blocks.

b. Remove cap screws (41) and spools.

c. Heat plugs (46, 48, and 49) with heat gun tomelt thread lock and sealer and remove plugs.

d. Inspect parts for wear and damage.

e. Replace parts as necessary.

f. For right travel spool (130) and arm 2 spool(133); install and tighten cap screws (41) tospecification.


11 lb-ft

g. For bucket and boom 1 spool (131 and 132):

Apply thread lock and sealer (high strength) toplugs (46, 48, and 49).

h. Install plugs (46, 48, and 49) onto spool (131and 132) and tighten to specification.

SpecificationPlugs-to-Control Valve Spool—Torque 15 N•m......................................................................................

11 lb-ft

i. Install cap screw (41) into spool and tighten tospecification.


11 lb-ft

NOTE: Apply hydraulic oil to spools before installation.

j. Install spools (130—133) into housing (1) whilerotating them slowly.

IMPORTANT: After installing spool (130—133) intohousing (1), push them by hand toconfirm smoothness.

4. Travel Flow Combiner Valve (135):

a. Remove cap screws (68) and cap (69).

b. Remove parts (4,70—72).




f. Tighten cap screw (70) to specification.

SpecificationCap Screw-to-Flow CombinerValve Spool—Torque 11 N•m...............................................................

7 lb-ft

g. Install spool (73), cap (69) and tighten capscrews (68) to specification.

SpecificationCap-to-Housing Cap Screw—Torque 10 N•m......................................................................................

7 lb-ft

5. Arm Regenerative Valve (134):

a. Remove parts (4, 54—58).


c. Replace parts as necessary.



PN=304


Hydraulic System

33336075

OUO6046,000231F –19–19APR07–5/6

e. Install parts (4, 54—58).

6. Arm 2 Flow Rate Control Valve (138):

a. Remove cap screws (97) and body (123).

b. Remove O-rings (77, 13) and poppet (15).

c. Remove plugs (114), spring seats (116), springs(117, 121, 125) and spools (118, 122, 124).

d. Remove plugs (119) and (127).

e. Remove spring (113) and poppet (112).

f. Remove springs (87) and poppets (98, 108).Remove plugs (101, 111), springs (100, 110) andpoppets (99, 109) from poppets (98, 108).

g. Inspect parts for wear and damage.

h. Replace parts as necessary.

i. Install in reverse order and loosely install plugs.

j. Install body (123) to housing (1) using capscrews (97). Tighten to specification.

SpecificationArm 2 Flow Rate Control ValveBody-to-Housing Cap Screw—Torque 61 N•m......................................................................................

45 lb-ft

7. Boom Reduced Leakage Valve (128):

a. Remove plug (36).

b. Remove parts (33—35).

c. Remove cap screws (6) and body (32).

d. Remove parts (21—31).

e. Inspect parts for wear and damage.

f. Replace parts as necessary.

g. Apply petroleum jelly to washer (22) and spring(21) to hold them in place.

h. Install spool (30), with hole side towards poppet(23).

i. Install parts (33—35).

j. Loosely install plug (36).

k. Install and tighten cap screws (6) tospecification.

SpecificationBoom Reduced Leakage ValveBody-to-Housing Cap Screw—Torque 62 N•m......................................................................................

46 lb-ft

l. Tighten plug (36) to specification.

SpecificationBoom Reduced LeakageValve-to-Body Plug—Torque 108 N•m.................................................

80 lb-ft

8. Bucket Flow Rate Valve (137):

a. Remove cap screws (97), housing (91), andO-ring (13).

b. Remove parts (89, 90, 92—96)).

c. Remove (83—88) from housing (1).

d. Inspect parts for wear and damage.

e. Replace parts as necessary.

f. Assemble in reverse order.

g. Install housing (91) and tighten cap screws (97)to specification.


PN=305


Hydraulic System

OUO6046,000231F –19–19APR07–6/6

SpecificationBucket Flow Rate ValveHousing-to-Housing CapScrew—Torque 61 N•m........................................................................

46 lb-ft

h. Tighten plug (96) to specification.

SpecificationFlow Rate Valve HousingPlug—Torque 98 N•m...........................................................................

72 lb-ft

9. Boom Reduced Leakage Valve (136):

a. Remove cap screws (6), housing (40), andO-rings (13).

b. Remove parts (75—78).




f. Install housing (40) and tighten cap screws (6) tospecification.

SpecificationBoom Reduced LeakageValve-to-Housing Cap Screw—Torque 61 N•m......................................................................................

46 lb-ft

10. By-Pass Shut-Off Valve (129):

a. Remove cap screws (6), flange (107) andO-ring (4) from housing (1).

b. Remove spring (106) and spool (105).



e. Install O-ring (4) and parts (105—107); thentighten cap screws (6) to specification.

SpecificationBy-Pass Shut-OffValve-to-Housing Cap Screw—Torque 61 N•m......................................................................................

46 lb-ft

11. Install top pilot cap (62) and tighten cap screws(63) to specification.

SpecificationTop Pilot Cap-to-Housing CapScrew—Torque 42 N•m........................................................................

32 lb-ft

12. Install bottom pilot caps (64 and 67) and tightencap screws (63) to specification.

SpecificationBottom Pilot Cap-to-HousingCap Screw—Torque 42 N•m................................................................

32 lb-ft

333360

76

TJ15698,000013A –19–11APR07–1/5

Hydraulic Oil Tank Remove and Install

TX

1020

196A

–UN

–07M

AR

07




PN=306


Hydraulic System

TJ15698,000013A –19–11APR07–2/5

TX

1020

325A

–UN

–09M

AR

07

33336077

1—Engine Cover2—Control Valve Cover

2. Remove covers (1 and 2).


TJ15698,000013A –19–11APR07–3/5

TX

1020

242A

–UN

–07M

AR

07

1—Cap Screw2—Return Line (2 used)3—Hydraulic Hose (4 used)

4. Tag and disconnect hoses (3) and lines (2).

5. Close all open lines and fittings using caps and plugs.

6. Remove cap screw (1).



PN=307

Hydraulic System

333360

78

TJ15698,000013A –19–11APR07–4/5

TX

1020

243A

–UN

–07M

AR

07

1—Engine Oil Filter Housing2—Panel Latch Bracket3—Pilot Pressure Regulating Valve and Filter

Housing4—Clamps (4 used)5—Cap Screws (4 used)6—Electrical Connector7—Hydraulic Hose

7. Remove bracket (2).


9. Remove bottom cover and disconnect pump supplyhose.

10. Tag and disconnect hoses (7).


12. Remove clamps (4) and filter housings (1 and 3) fromtank and support.

13. Remove cap screws (5).


SpecificationHydraulic Oil Tank—Weight 102 kg approximate.......................................

225 lb approximate

14. Remove hydraulic oil tank using a hoist and liftingstraps.

15. Remove tank components. See Hydraulic Oil TankDisassemble and Assemble. (Group 3360.)


17. Install tank components. See Hydraulic Oil TankDisassemble and Assemble. (Group 3360.)

18. Install hydraulic oil tank.

19. Tighten tank mounting cap screws to specification.

SpecificationHydraulic Oil Tank-to-Frame CapScrew—Torque 400 N•m.............................................................................

295 lb-ft



PN=308

Hydraulic System

TJ15698,000013A –19–11APR07–5/5

TX

1020

243A

–UN

–07M

AR

07

1—Engine Oil Filter Housing2—Panel Latch Bracket3—Pilot Pressure Regulating Valve and Filter

Housing4—Clamps (4 used)5—Cap Screws (4 used)6—Electrical Connector7—Hydraulic Hose

20. Connect return lines and hoses.

21. Connect electrical connector (6).

22. Install filter housings (1 and 3), hoses (7), clamps (4),and bracket (2).

23. Install covers.

24. Fill hydraulic oil tank. Approximate capacity is 120.4 L(31.8 gal).


25. Perform pump 1 and 2 start-up procedure. See Pump1 and 2 Start-Up Procedure. (Group 3360.)

33336079


PN=309

Hydraulic System

333360

80

TJ15698,0000137 –19–30MAR07–1/2

Hydraulic Oil Tank Disassemble and Assemble

TX

1020

244

–UN

–07M

AR

07


PN=310


Hydraulic System

TJ15698,0000137 –19–30MAR07–2/2

1—Hydraulic Oil Tank 7A—Housing 13—Washers 21—Elbow Fitting and O-Ring3—O-Ring 7B—Filter Element 14—Hydraulic Oil Temperature 22—Filter Element4—Cap Screw (6 used) 7C—Cover Sensor 23—Cover5—Spring 7D—Nut 15—Gasket 31—Washer (4 used )6—Cover Assembly 7E—Cap 16—Suction Strainer and Rod 32—Cap Screw (4 used)6A—Bracket 8—Packing 16A—Rod 33—Filter Element6B—Cover 9—O-Ring 16B—Suction Strainer 33A—Sealing Ring6C—Cap Screw 10—Screw (4 used) 17—Plug and O-Ring (4 used) 33B—Valve6D—Washer 11—Cap Screw (6 used) 18—Plug and O-Ring 33C—O-Ring6E—Washer 12—Sight Glass 20—Adapter Fitting and 33D—Filter Element7—Filter 12A—Cap Screws O-Ring (3 used)

1. Tighten cap screws (4 and 11).

SpecificationCovers-to-Hydraulic Oil TankCap Screws—Torque 49 N•m..............................................................

36 lb-ft

2. Adjust the length of rod on suction strainer (16).

SpecificationSuction Strainer Rod (Top ofRod-to-Bottom of Strainer)—Length 869 mm....................................................................................

34.2 in

3. Tighten nuts on suction strainer rod.

SpecificationSuction Strainer Rod Nuts—Torque 17 N•m......................................................................................

153 lb-in.

33336081

TJ15698,0000143 –19–11APR07–1/3

Restriction Valve Remove and Install

TX

1020

196A

–UN

–07M

AR

07




2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain tank. See Apply Vacuum to HydraulicOil Tank. (Group 3360.) Approximate oil capacity is120.4 L (31.8 gal).



PN=311

Hydraulic System

333360

82

TJ15698,0000143 –19–11APR07–2/3

TX

1020

324

–UN

–09M

AR

07


PN=312


Hydraulic System

TJ15698,0000143 –19–11APR07–3/3

1—Cap Screw (4 used) 5—Washer 9—Washer (2 used) 12—O-Ring2—Flange (2 used) 6—Clamp 10—Bracket 13—Restriction Valve3—Oil Cooler Hose 7—Coupling 11—Return Line 14—Snap Ring4—Cap Screw 8—Cap Screw (2 used)

3. Remove clamp (6).

4. Disconnect hose (3) from line (11).

5. Remove snap ring (14) and restriction valve (13).


7. Install restriction valve (13) and snap ring (14).

8. Connect hose (3) to line (11).

SpecificationHydraulic Oil Tank Return LineCoupling Cap Screw—Torque 90 N•m.................................................

66 lb-ft


IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before starting.Procedure must be performed to fillpump housing whenever oil hasbeen drained from the pump orhydraulic oil tank.

10. Perform pump 1 and 2 start-up procedure. SeePump 1 and 2 Start-Up Procedure. (Group 3360.)

33336083

TJ15698,0000136 –19–11APR07–1/2

Hydraulic Oil Cooler Bypass Valve Removeand Install

TX

1020

196A

–UN

–07M

AR

07




2. Pull a vacuum in hydraulic oil tank using a vacuumpump or drain tank. See Apply Vacuum to HydraulicOil Tank. (Group 3360.) Approximate oil capacity is120.4 L (31.8 gal).



PN=313

Hydraulic System

333360

84

TJ15698,0000136 –19–11APR07–2/2

1 2

3

4

65

7

TX

1004

061

–UN

–09M

AR

06

1—Control Valve 3—Oil Cooler Bypass Valve 5—Hydraulic Return Line 7—Hydraulic Oil Tank2—O-Ring 4—Socket Head Cap Screws 6—Coupling

3. Loosen cap screws and nuts on coupling (6).

4. Remove socket head cap screws (4) and hydraulicreturn line (5).

5. Remove oil cooler bypass valve (3) and O-ring (2)from control valve (1). Repair or replace asnecessary.

6. Install oil cooler bypass valve (3) and O-ring (2).

7. Install hydraulic line (5).

8. Install socket head cap screws (4). Tighten tospecification.

SpecificationReturn Line Flange-to-ControlValve Socket Head CapScrews—Torque 50 N•m......................................................................

37 lb-ft

9. Tighten nuts on coupling.

SpecificationControl Valve-to-Hydraulic OilTank Return Line CouplingNuts—Torque 11 N•m...........................................................................

97 lb-in.


IMPORTANT: Hydraulic pump will be damaged ifnot filled with oil before starting.Procedure must be performed to fillpump housing whenever oil hasbeen drained from the pump orhydraulic oil tank.

11. Perform pump 1 and 2 start-up procedure. SeePump 1 and 2 Start-Up Procedure. (Group 3360.)


PN=314

Hydraulic System

OUO6046,0002320 –19–18APR07–1/6

Boom Cylinder Remove and Install

T10

6031

–UN

–10J

AN

97

NOTE: Procedure is the same for both boom cylinders.

1. Park machine on firm, level surface.

2. Retract arm and bucket cylinders and lower bucket toground.

OUO6046,0002320 –19–18APR07–2/6

TX

1020

196A

–UN

–07M

AR

07




4. Loosen boom cylinder hydraulic lines at frame end ofboom to release any residual pressure.

5. Disconnect lines. Close all open lines and fittings usingcaps and plugs.

6. Disconnect lubrication line at rod end of cylinder.

33336085

OUO6046,0002320 –19–18APR07–3/6

TX

1006

808

–UN

–21A

PR

06

1—Boom Cylinder


SpecificationBoom Cylinder—Weight 155 kg..................................................................

342 lb

7. Attach appropriate lifting device to boom cylinder (1)using lifting strap.


PN=315


Hydraulic System

OUO6046,0002320 –19–18APR07–4/6

T14

2979

–UN

–24J

UL0

1

1—Nut (2 used)2—Retainer3—Cap Screw4—Boom Cylinder-to-Boom Pin5—Shim (2 used)6—Boom Cylinder

8. Remove parts (1—3, and 5).

9. Push pin (4) into boom.

10. Lower boom cylinder (6) on floor stand.


333360

86


PN=316

Hydraulic System

33336087

OUO6046,0002320 –19–18APR07–5/6

9

107 7

6

11

11

8 8

T14

3048

–UN

–02A

UG

01

6—Boom Cylinder7—Hydraulic Lines8—Shim (as required)9—Cap Screw (2 used)10—Boom Cylinder-to-Frame Pin (2 used)11—Nut (4 used)

11. Disconnect hydraulic lines (7) from head end of boomcylinder (6). Close all open lines and fitting using capsand plugs.

12. Mark location of shims (8) to aid in assembly.

13. Remove parts (8—11) and remove boom cylinder (6).


15. Install shims equally on each side of cylinder headend to get the minimum amount of clearance in joint.

16. Align pin bores so shims are not damaged as pin (10)is installed.

17. Connect boom cylinder head end to frame.

18. Tighten nuts (11) against each other allowing capscrews (9) to be free to turn in hole.

SpecificationBoom Cylinder-to-Frame PinRetainer Nut—Torque 270 N•m (tighten nut against nut)...........................


19. Connect lines. See Hydraulic System LineConnections. (Group 9025-15.)

20. Tighten boom cylinder hoses.

SpecificationBoom Cylinder Hose Fitting—36mm—Torque 175 N•m.............................................................................

130 lb-ft

SpecificationBoom Cylinder Hose Fitting—41mm—Torque 205 N•m.............................................................................

150 lb-ft



PN=317

Hydraulic System

333360

88

OUO6046,0002320 –19–18APR07–6/6

IMPORTANT: Trapped air suddenly compressed in acylinder is heated and ignites the oilused for assembly causing cap seal andring damage. Start with cylinder rodretracted and the rod end filled withclean oil. Connect the cylinder head endand lines. Operate function to slowlyextend rod. Procedure will eliminatemost of the air and reduce thepossibility of damage.

21. Start engine.

22. Slowly extend boom cylinder (6) to align pin bores soshims (5) are not damaged as pin (4) is installed.

23. Install shims to get the minimum amount of clearancebetween boom and boom cylinder rod end.

24. Connect boom cylinder rod end to boom.

25. Tighten nuts (1) against each other allowing capscrew (3) to be free to turn in hole.

SpecificationBoom Cylinder-to-Frame PinRetainer Nut—Torque 550 N•m (tighten nut against nut)...........................


26. Connect lubrication line.

SpecificationBoom Cylinder Pivot LubricationLine—Torque 25 N•m..................................................................................

18 lb-ft

27. Lubricate all pivot joints. See Track Adjuster, WorkingTool Pivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)

28. Bleed air from cylinder. See Hydraulic Cylinder BleedProcedure. (Group 3360.)

29. Check hydraulic oil level. See Check Hydraulic TankOil Level. (Operator’s Manual.)


PN=318

Hydraulic System

33336089

OUO6046,0002321 –19–05APR07–1/3

Boom Cylinder Disassemble and Assemble

TX

1004

546

–UN

–14M

AR

06

22

18141514

1010

1321

16 17

TX1004547

12 4

5

6

9 113 8 20

712 13

19

TX

1004

547

–UN

–14M

AR

06

1—Rod 7—Cylinder Head 13—Slide Ring (2 used) 18—Set Screw2—Dust Wiper 8—Bushing 14—Wear Ring (2 used) 19—Ball3—Backup Ring 9—Snap Ring 15—Backup Ring (2 used) 20—Piston Nut4—U-Ring 10—Backup Ring 16—O-Ring 21—Cushion Bearing5—Buffer Ring 11—O-Ring 17—Seal Ring 22—Cushion Seal6—Cap Screw (12 used) 12—Barrel


SpecificationBoom Cylinder—ApproximateWeight 155 kg.......................................................................................

342 lb

1. Fasten head end of cylinder to JT30043 CylinderService Stand.

2. Pull rod out so piston nut is against cylinder head.

3. Connect rod to appropriate lifting device using alifting strap.

4. Remove cap screws (6) from cylinder head (7).

5. Remove rod, cylinder head and piston nut frombarrel (12).


PN=319


Hydraulic System

333360

90

OUO6046,0002321 –19–05APR07–2/3

6. Install rod eye in sliding housing and install housingin JT30043 Cylinder Service Stand.

7. Make an alignment mark on piston nut (20) and rod(1).

8. Remove staked material from set screw (18) holeusing a small air grinder or a drill and bit.

9. Remove set screw (18) and steel ball (19).

IMPORTANT: To avoid damaging tapped hole forset screw, cap screw in ST3243 HexPiston Nut Wrench must betightened against a side of nutwithout tapped hole.

To avoid gouging side of nut, installa piece of steel flat stock betweennut and cap screw.

10. Install ST3243 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (20)without tapped hole.

11. Install a piece of steel flat stock between pistonnut and cap screw. Tighten cap screw of pistonnut wrench.

12. Remove piston nut (20) using JT30043 CylinderService Stand.

SpecificationBoom Cylinder Piston Nut—Torque 4000 N•m..................................................................................

2950 lb-ft

IMPORTANT: Note direction of oil groove incushion bearing (21) and notch incushion seal (22) for installation.

13. Remove cushion bearing (21) and cushion seal(22) from rod (1).

14. Remove components (13—17) from piston nut(20).

15. Remove cylinder head (7) from rod (1).

IMPORTANT: Note direction of dust wiper (2) andU-ring (4) for installation.

16. Remove components (2—5) and (9—11) fromcylinder head (7).

17. Remove bushing (8) using ST8019.

18. Inspect dust seals and bushings in rod (1) andbarrel (12) for wear or damage. Repair or replaceparts as necessary. See Inspect Pins, Bushingsand Bosses—Front Attachment. (Group 3340.)

19. Check for rod curvature on V-blocks using dialindicator.

SpecificationBoom Rod—Curvature 0.5 mm per 1 m..............................................

0.020 in. per 3.25 ft


21. Install bushing (8) into cylinder head (7) usingST8019. Press to bottom of bore.

22. Install snap ring (9).

23. Install backup ring (10) and O-ring (11).

24. Install buffer ring (5).

25. Install U-ring (4) with lip towards bushing (8).

26. Install backup ring (3).

27. Install dust wiper (2) using ST8019 with liptowards outside of cylinder.

28. Install assembled cylinder head (7) on rod (1)using ST8019.

29. Install O-ring (16) and seal ring (17) to piston nut(20) using ST2962 Installer. Adjust seal ring (17)using ST2205 Adjustment Tool.

30. Install backup rings (15) on each side of seal ring.


PN=320


Hydraulic System

OUO6046,0002321 –19–05APR07–3/3

31. Install wear rings (14) and slide rings (13) topiston nut (20).

IMPORTANT: Install cushion seal (22) so thatnotch is towards piston.

32. Install cushion seal (22).

IMPORTANT: Note direction of oil groove incushion bearing (21) duringinstallation.

33. Install cushion bearing (21).

34. Align marks made during disassembly and installpiston nut (20).



35. Install ST3243 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (20)

without tapped hole. Install a piece of steel flatstock between nut and cap screw. Tighten capscrew of piston nut wrench. Tighten piston nut (20)to specification using JT30043 Cylinder ServiceStand.

SpecificationBoom Cylinder Piston Nut—Torque 4000 N•m..................................................................................

2950 lb-ft

36. Install steel ball (19) and set screw (18).

37. Stake set screw (18) in two places 90° fromprevious stake marks.

38. Apply clean oil to piston nut and seals. Attachappropriate lifting device to rod using a liftingstrap. Carefully install piston nut, rod and cylinderhead into barrel.

39. Install cylinder head cap screws (6). Tighten tospecification.

SpecificationBoom Cylinder Head-to-BarrelCap Screw—Torque 267 N•m..............................................................

197 lb-ft

33336091

OUO6046,0002322 –19–05APR07–1/6

Arm Cylinder Remove and Install

T10

6031

–UN

–10J

AN

97


2. Retract arm and bucket cylinders and lower bucket toground.



PN=321

Hydraulic System

OUO6046,0002322 –19–05APR07–2/6

TX

1020

196A

–UN

–07M

AR

07




4. Loosen arm cylinder hydraulic lines at frame end ofboom to release any residual pressure.


OUO6046,0002322 –19–05APR07–3/6

T14

3063

–UN

–02A

UG

01

1—Arm Cylinder2—Boom3—Wood Block

6. Insert wood block (3) between arm cylinder (1) andboom (2).


SpecificationArm Cylinder—Weight 205 kg....................................................................

452 lb

7. Attach arm cylinder to appropriate lifting device usinglifting straps.

333360

92



PN=322

Hydraulic System

OUO6046,0002322 –19–05APR07–4/6

T14

3064

–UN

–02A

UG

01

1—Nut (2 used)2—Cap Screw3—Shim (as required)4—Arm Cylinder-to-Arm Pin

8. Remove parts (1 and 2).

NOTE: Note location of shims (3) to aid in assembly.

9. Push pin (4) out and remove shims.

10. Disconnect lubrication line.


33336093


PN=323

Hydraulic System

333360

94

OUO6046,0002322 –19–05APR07–5/6

T14

3065

–UN

–02A

UG

01

1—Nut (2 used)2—Cap Screw3—Shim (as required)4—Arm Cylinder-to-Boom Pin


NOTE: Note location of shims (3) to aid in assembly.

12. Push pin (4) out and remove shims.

13. Remove arm cylinder


15. Install shims equally on each side of cylinder to getminimum amount of clearance in joint. There must besome clearance in the joint.

16. Align pin bores so shims are not damaged as pin (4)is installed.


SpecificationArm Cylinder Pivot LubricationLine—Torque 25 N•m..................................................................................

18 lb-ft

18. Connect arm cylinder head end to boom.


SpecificationArm Cylinder-to-Boom PinRetainer Nut—Torque 550 N•m (tighten nut against nut)...........................



20. Slowly extend arm cylinder to align pin bores soshims are not damaged as pin is installed.

21. Connect arm cylinder rod end to arm.


PN=324


Hydraulic System

OUO6046,0002322 –19–05APR07–6/6


SpecificationArm Cylinder-to-Arm Pin RetainerNut—Torque 550 N•m (tighten nut against nut)..........................................



SpecificationArm Cylinder Pivot LubricationLine—Torque 25 N•m..................................................................................

18 lb-ft

24. Tighten arm cylinder hoses.

SpecificationArm Cylinder Hose Fitting—36mm—Torque 175 N•m.............................................................................

130 lb-ft

SpecificationArm Cylinder Hose Fitting—41mm—Torque 205 N•m.............................................................................

150 lb-ft




33336095


PN=325

Hydraulic System

333360

96

OUO6046,000232A –19–09APR07–1/3

Arm Cylinder Disassemble and Assemble

TX

1004

548

–UN

–14M

AR

06

26 24

22181918

1010

1725

23 1621TX1004549

12 4

5

6

9 113 8 20

14

718

17

13

15

TX

1004

549

–UN

–14M

AR

06

1—Rod 8—Bushing 15—Cushion Seal 21—Seal Ring2—Dust Wiper 9—Snap Ring 16—Snap Ring 22—Set Screw3—Backup Ring 10—Backup Ring 17—Slide Ring (2 used) 23—Ball4—U-Ring 11—O-Ring 18—Wear Ring (2 used) 24—Piston Nut5—Buffer Ring 12—Barrel 19—Backup Ring (2 used) 25—Cushion Bearing6—Cap Screw (12 used) 13—Stopper (2 used) 20—O-Ring 26—Cushion Seal7—Cylinder Head 14—Cushion Bearing


SpecificationArm Cylinder—ApproximateWeight 205 kg......................................................................................

452 lb







PN=326


Hydraulic System

33336097

OUO6046,000232A –19–09APR07–2/3


6. Remove stopper (13), cushion bearing (14), cushionseal (15), and snap ring (16).








12. Install a piece of steel flat stock between nut andcap screw. Tighten cap screw of piston nutwrench.


SpecificationArm Cylinder Piston Nut—Torque 5150 N•m..................................................................................

3799 lb-ft


14. Remove cushion bearing (25) and cushion seal(26) from rod (1).






19. Inspect dust seals and bushings in rod (1) andbarrel (12) for wear or damage. Repair or replaceparts as necessary. See Inspect Pins, Bushingsand Bosses—Front Attachment. (Group 3340.)


SpecificationArm Cylinder Rod—Curvature 0.5 mm per 1 m...................................

0.020 in. per 3.25 ft










PN=327


Hydraulic System

333360

98

OUO6046,000232A –19–09APR07–3/3




32. Install slide rings (17) and wear rings (18) topiston nut (24).


33. Install cushion seal (26).


34. Install cushion bearing (25).




36. Install ST3245 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (24)

without tapped hole. Install a piece of steel flatstock between nut and cap screw. Tighten capscrew of piston nut wrench. Tighten piston nut (24)to specification using JT30043 Cylinder ServiceStand.

SpecificationArm Cylinder Piston Nut—Torque 5150 N•m..................................................................................

3799 lb-ft




39. Install snap ring (16) and cushion seal (15).


40. Install cushion bearing (14) and stopper (13).



SpecificationArm Cylinder Head-to-BarrelCap Screw—Torque 267 N•m..............................................................

197 lb-ft


PN=328

Hydraulic System

OUO6046,000232B –19–09APR07–1/5

Bucket Cylinder Remove and Install

T10

6031

–UN

–10J

AN

97T

X10

0680

7–U

N–2

1AP

R06

33336099

1—Bucket Cylinder2—End of Arm3—Wood Block


2. Retract arm cylinder and bucket cylinder (1) and lowerbucket to ground. Position end of arm (2) on woodblock (3).

OUO6046,000232B –19–09APR07–2/5

TX

1020

196A

–UN

–07M

AR

07






PN=329

Hydraulic System

OUO6046,000232B –19–09APR07–3/5

T14

3075

–UN

–02A

UG

01

1—Side and Center Links-to-Bucket Cylinder Pin2—Cap Screw3—Shim (as required)4—Bucket Cylinder Rod End-to-Bucket Section

Top Port Line5—Wood Block6—Nut (2 used)7—Side Link


5. Connect center link to appropriate lifting device usinglifting strap.

6. Put wood block (5) between bucket cylinder and arm tohold cylinder up when pin (1) is removed.


NOTE: Mark location of shims (3) to aid in assembly.

8. Push pin (1) out and remove shims (3).


333360,100


PN=330

Hydraulic System

333360,101

OUO6046,000232B –19–09APR07–4/5

2

1

3

5

4

6

T14

3076

–UN

–02A

UG

01

1—Bucket Cylinder Rod End Hose2—Bucket Cylinder3—Nut (2 used)4—Shim (as required)5—Cap Screw6—Bucket Cylinder-to-Arm Pin


SpecificationBucket Cylinder—Weight 120 kg................................................................

265 lb

9. Disconnect bucket cylinder rod end hose (1).

10. Connect bucket cylinder (2) to appropriate liftingdevice using lifting strap.


NOTE: Mark location of shims (4) to aid in assembly.

12. Push pin (6) out and remove shims (4).

13. Remove bucket cylinder.

14. Repair or replace parts as necessary. See BucketCylinder Disassemble and Assemble. (Group 3360.)

15. Install shims equally on each side of bucket cylinderhead end to get minimum amount of clearance injoint.

16. Align pin bores so shims are not damaged as pin isinstalled.

17. Connect bucket cylinder head end to arm.


SpecificationBucket Cylinder-to-Arm PinRetainer Nut—Torque 270 N•m (tighten nut against nut)...........................



20. Tighten bucket cylinder hoses.

SpecificationBucket Cylinder Hose—Torque 175 N•m....................................................

130 lb-ft


PN=331


Hydraulic System

333360,102

OUO6046,000232B –19–09APR07–5/5


21. Start engine.

22. Slowly extend bucket cylinder to align pin bores soshims are not damaged as pin is installed.

23. Install shims equally on each side of cylinder rod endand side links to get minimum amount of clearance injoint.

24. Connect bucket cylinder head end to arm.

25. Tighten nuts against each other allowing cap screw tobe free to turn in hole.

SpecificationBucket Cylinder-to-Pin RetainerNut—Torque 550 N•m (tighten nut against nut)..........................................






PN=332

Hydraulic System

333360,103

OUO6046,000232C –19–09APR07–1/3

Bucket Cylinder Disassemble and Assemble

TX100455014 17 16 15 13

1 4 5

96

2 37

8 1011

12

13 20 15

1819 14

TX

1004

550

–UN

–09M

AR

06

TX1004551

1

16 17

2 4 5

3 8 9 10

12

11

13 14 14 13 20

18

19

15

76

TX

1004

551

–UN

–09M

AR

06

1—Rod 6—Cap Screw (12 used) 11—O-Ring 16—O-Ring2—Dust Wiper 7—Cylinder Head 12—Barrel 17—Seal Ring3—Backup Ring 8—Bushing 13—Slide Ring (2 used) 18—Set Screw4—U-Ring 9—Snap Ring 14—Wear Ring (2 used) 19—Ball5—Buffer Ring 10—Backup Ring 15—Backup Ring (2 used) 20—Piston Nut


SpecificationBucket Cylinder—ApproximateWeight 120 kg......................................................................................

265 lb










PN=333


Hydraulic System

333360,104

OUO6046,000232C –19–09APR07–2/3





11. Install a piece of steel flat stock between nut andcap screw. Tighten cap screw of piston nutwrench.


SpecificationBucket Cylinder Piston Nut—Torque 4280 N•m..................................................................................

3157 lb-ft






17. Inspect dust seals and bushings in rod (1) andbarrel (12) for wear or damage. Repair or replace

parts as necessary. See Inspect Pins, Bushingsand Bosses—Front Attachment. (Group 3340.)


SpecificationBucket Cylinder Rod—Curvature 0.5 mm per 1 m...................................................................

0.020 in. per 3.25 ft












30. Install slide rings (13) and wear rings (14) topiston nut (20).



PN=334


Hydraulic System

OUO6046,000232C –19–09APR07–3/3



32. Install ST3242 Hex Piston Nut Wrench so capscrew is tightened against side of piston nut (20)without tapped hole. Install a piece of steel flatstock between nut and cap screw. Tighten capscrew of piston nut wrench. Tighten piston nut (20)to specification using JT30043 Cylinder ServiceStand.

SpecificationBucket Cylinder Piston Nut—Torque 4280 N•m..................................................................................

3157 lb-ft

.





SpecificationBucket Cylinder Head-to-BarrelCap Screw—Torque 267 N•m..............................................................

197 lb-ft

333360,105


PN=335

Hydraulic System

OUO6046,000232D –19–05APR07–1/1

Hydraulic Cylinder Bleed Procedure


NOTE: Bleed air at initial start-up, whenever major repairsor maintenance (oil change) is done on hydraulicsystem, or when machine has been in storage fora period of time.

1. Run engine at slow idle.

2. Slowly operate function to move cylinder to the mosthorizontal position possible.

3. Slowly extend and retract cylinder several times toapproximately 100 mm (4 in.) from end of stroke.

4. Operate cylinder several times to full stroke.


333360,106


PN=336

Section 43Swing or Pivoting System

Contents

Page

Group 4350—Mechanical Drive ElementsSwing Gearbox Remove and Install . . . . . . .43-4350-1Swing Gearbox Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-4Swing Gearbox Start-Up Procedure . . . . . .43-4350-11Upperstructure Remove And Install . . . . . . .43-4350-11Swing Bearing Remove and Install . . . . . . .43-4350-14Swing Bearing Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .43-4350-16Swing Bearing Upper Seal Install . . . . . . . .43-4350-19Swing Bearing Lower Seal Install . . . . . . . .43-4350-20

Group 4360—Hydraulic SystemCenter Joint Remove and Install . . . . . . . . . .43-4360-1Center Joint Disassemble and Assemble . . .43-4360-4Center Joint Air Test . . . . . . . . . . . . . . . . . . .43-4360-5Swing Motor and Park Brake Remove and

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-6Swing Motor and Park Brake

Disassemble . . . . . . . . . . . . . . . . . . . . . .43-4360-10Swing Motor and Park Brake Inspection . . .43-4360-12Swing Motor and Park Brake Assemble . . .43-4360-14Swing Motor and Park Brake Start-Up

Procedure . . . . . . . . . . . . . . . . . . . . . . . .43-4360-16Crossover Relief Valve and Make-Up

Check Valve Remove and Install . . . . . . .43-4360-17Make-Up Check Valve Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .43-4360-18Swing Park Brake Release Valve Remove

and Install . . . . . . . . . . . . . . . . . . . . . . . .43-4360-19

43


PN=1

Contents

43


PN=2

Group 4350Mechanical Drive Elements

TJ15698,000013B –19–11APR07–1/3

Swing Gearbox Remove and Install

TX

1020

196A

–UN

–07M

AR

07




2. Pull vacuum in hydraulic oil tank using vacuum pumpor drain hydraulic oil tank. See Apply Vacuum toHydraulic Oil Tank. (Group 3360.) The approximatecapacity of hydraulic oil tank is 120.4 L (31.8 gal).


4343501


PN=339

Mechanical Drive Elements

434350

2

TJ15698,000013B –19–11APR07–2/3

TX

1003

159A

–UN

–02F

EB

06

1—Cap Screw and Washer (14 used)2—Electrical Connector

3. Tag and disconnect lines from swing motor. Close allopen lines and fittings using caps and plugs.


NOTE: Swing motor may be removed by itself or withswing gearbox. See Swing Motor and Park BrakeRemove and Install. (Group 4360.)

Mark swing gearbox housing to machineupperstructure to aid in installation.

4. Install JT01748 Lifting Brackets and connect toappropriate lifting device.

SpecificationSwing Motor, Brake, andGearbox—Weight 218 kg............................................................................

481 lb


6. Remove cap screws and washers (1).

7. Remove swing gearbox and motor.

8. Repair or replace parts as necessary. See SwingGearbox Disassemble and Assemble. (Group 4350.)

9. Apply PM38656 Thread Lock and Sealer (HighStrength) to mating surfaces of swing gearbox housingand upperstructure.

10. Install swing gearbox and motor.


SpecificationSwing Gearbox-to-UpperstructureCap Screw—Torque 500 N•m.....................................................................

369 lb-ft




PN=340



TJ15698,000013B –19–11APR07–3/3

14. See Swing Gearbox Start-Up Procedure. (Group4350.) See Swing Motor and Park Brake Start-UpProcedure. (Group 4360.)

15. If hydraulic oil tank was drained, fill hydraulic oil tank.Approximate oil capacity is 120.4 L (31.8 gal).



4343503


PN=341


434350

4

TJ15698,0000119 –19–11APR07–1/8

Swing Gearbox Disassemble and Assemble

TX

1018

815

–UN

–09F

EB

07


PN=342



4343505

TJ15698,0000119 –19–11APR07–2/8

0—Swing Gearbox 9—Plate 17—Spring Pin (3 used) 27—Needle Bearing (3 used)1—Shaft 10—Cap Screw 18—Second Stage Sun Gear 28—Thrust Plate (3 used)2—Sleeve 11—Second Planetary Pinion 20—Ring Gear Housing 29—Spring Pin (3 used)3—O-Ring Carrier 21—Cap Screw (12 used) 30—Snap Ring4—Roller Bearing 12—Washer 23—First Planetary Pinion 31—First Stage Sun Gear5—Seal 13—Pin (2 used) Carrier 33—Line6—Housing 14—Planetary Gear (3 used) 24—Thrust Plate 34—Fitting Plug (2 used)7—Roller Bearing 15—Needle Bearing (6 used) 25—Pin (3 used) 36—Fitting Plug8—Bearing Nut 16—Thrust Plate (3 used) 26—Planetary Gear (3 used)

1. Make alignment marks between swing motor, ringgear housing (20) and housing (6) to aid inassembly.

2. Remove swing motor. See Swing Motor and ParkBrake Remove and Install. (Group 4360.)


SpecificationSwing Motor—Weight 48 kg.................................................................

105 lb

3. Remove first planetary pinion carrier assembly(23-29) from ring gear housing (20).

NOTE: First stage sun gear (31) may be removedseparately or along with carrier.


SpecificationRing Gear—Weight 23 kg.....................................................................

50 lb

4. Remove cap screws (21) and ring gear housing(20).

5. Remove second planetary pinion carrier assembly(11-18).

NOTE: Second stage sun gear (18) may be removedseparately or with carrier.

6. Disassemble first planetary pinion carrier (23)assembly.

IMPORTANT: Hole for spring pin (29) located onfirst planetary pinion carrier (23) isnot a through hole.

7. Tap spring pin (29) into pin (25) until it reaches thecenter of pin (25).

8. Remove pin (25), planetary gear (26), needlebearing (27), and thrust plate (28) from first planetpinion carrier (23).

9. Inspect needle bearing (27) for wear.

10. Remove thrust plate (24) from carrier.

IMPORTANT: Damaging the surface of pin (25) cancause bearing failure, use care whenhandling pin.

11. Using wood blocks, clamp pin (25) in vise. Tapspring pin (29) out of pin.

12. Disassemble second planetary pinion carrier (11)assembly as in Steps 7-11.

13. Remove cap screws (10) and lock plate (9) frombearing nut (8).


PN=343



TJ15698,0000119 –19–11APR07–3/8

8

TX

1004

267

–UN

–01M

AR

06

8—Bearing Nut

14. Remove bearing nut (8) from shaft (1) using DFT1220Swing Gearbox Nut Spanner Wrench. See DFT1220Swing Gearbox Nut Spanner Wrench. (Group 9900.)


SpecificationHousing Assembly—Weight 106 kg............................................................

234 lb

15. Install eyebolts into bolt hole on housing (6). Useappropriate lifting device and position housingassembly (6) onto press.

TJ15698,0000119 –19–11APR07–4/8

1

6

TX

1004

268

–UN

–01M

AR

06

1—Shaft6—Housing

NOTE: Bearing and sleeve are pressed onto shaft.

16. Using press, push upper end of shaft (1) and removefrom housing (6). Inner race of roller bearing (4) andsleeve (2) are removed with shaft (1).


434350

6


PN=344


4343507

TJ15698,0000119 –19–11APR07–5/8

TX1004269

2

1

4

TX

1004

269

–UN

–19A

PR

06

1—Shaft2—Sleeve4—Roller Bearing

17. Inspect shaft (1), roller bearing (4), and sleeve (2).

18. If disassembly is necessary, use press and knife edgebearing puller to push upper end of shaft (1) andremove inner race of roller bearing (4) and sleeve (2).

19. Remove O-ring (3) from sleeve (2).

20. Insert a round bar into oil passage in housing (6). Tapand remove outer race of roller bearing (4).

21. Remove oil seal (5) from housing (6).

NOTE: Oil seal (5) can not be reused.

22. Remove outer race of roller bearing (7) from housing(6) using brass drift and hammer.


24. Install O-ring (3) in sleeve (2).

25. Install sleeve (2) and inner race of roller bearing (4) toshaft (1) using press and a piece of pipe.

26. Install outer race of roller bearing (4) into housing (6).

27. Apply PM38656 Thread Lock and Sealer (HighStrength) to OD of oil seal (5).

28. Install oil seal (5) so lip (spring side) is toward bottomof bore. Push seal to bottom of bore.

29. Apply grease to ID of oil seal (5).

30. Apply grease to outer surface of sleeve (2) on shaft(1).


SpecificationHousing Assembly—Weight 65 kg..............................................................

143 lb

31. Install eyebolts into bolt holes in housing (6).

32. Using appropriate lifting device, slowly lift housing (6)assembly onto shaft (1).


PN=345



434350

8

TJ15698,0000119 –19–11APR07–6/8

IMPORTANT: Align carefully so as not to damage oilseal (5) lip.

33. Install inner race of roller bearing (7) onto shaft (1).

34. Tap inner race of roller bearing (7) until upper end ofinner race reaches two threads for bearing nut (8) onshaft (1).

35. Hand tighten bearing nut (8) to shaft (1) to retainshaft assembly.

36. Install eyebolts into ring gear housing (20) and liftonto housing (6).

37. Remove bearing nut (8) from shaft (1).

38. Press on inner race of roller bearing (7).

39. Apply film of grease on threaded surface of bearingnut (8). Install bearing nut (8) on shaft (1) withstepped side of bearing nut (8) towards roller bearing(7).

40. Tighten bearing nut (8) to specification. Use DFT1220Swing Gearbox Nut Spanner Wrench. See DFT1220Swing Gearbox Nut Spanner Wrench. (Group 9900.)


360 lb-ft

41. Install lock plate (9) to bearing nut (8) with capscrews (10). Tighten to specification.

SpecificationLock Plate-to-Bearing Nut CapScrews—Torque 50 N•m.............................................................................

37 lb-ft

42. If lock plate (9) does not engage with splines of shaft(1), tighten bearing nut until lock plate engages.

43. Assemble planetary gears (14), needle bearings (15),and thrust plates (16).

44. Position gear assemblies (14, 15, 16) into secondplanetary pinion carrier (11).


PN=346



TJ15698,0000119 –19–11APR07–7/8

45. Align holes in pins (13) and planetary carrier (11).


4343509


PN=347


434350

10

TJ15698,0000119 –19–11APR07–8/8

TX1004270

38

13

TX

1004

270

–UN

–19A

PR

06

13—Pin (2 used)38—Slit

46. Install spring pins (17) with slit (38) of spring pinstowards end of pins (13).

NOTE: Procedure for assembly of first and secondplanetary pinion carrier assemblies is identical.

47. Assemble first planetary pinion carrier (23) assemblyfollowing Step 43 through 46.

48. Align the spline of shaft (1) and install the secondplanetary carrier assembly (11).

49. Install thrust plate (12) with oil grooves towardssecond planet pinion carrier (11).

50. Install second stage sun gear (18) into secondplanetary pinion carrier (11) assembly with smallerdiameter of second stage sun gear upward.

51. Apply PM38656 Thread Lock and Sealer (HighStrength) to ring gear housing (20) mounting surfaceof housing (6).

52. Align mating marks and install ring gear housing (20)to housing (6).

53. Apply PM37418 Thread Lock and Sealer (MediumStrength) to cap screws (21). Tighten cap screws (21)to specification.

SpecificationRing Gear Housing-to-HousingCap Screw—Torque 210 N•m.....................................................................

155 lb-ft

54. Align spline of second stage sun gear (18) and installfirst planetary pinion carrier (23) assembly.

55. Install first stage sun gear (31) into first planetarypinion carrier (23) assembly with stepped side of sungear down.

56. Install swing motor. See Swing Motor and Park BrakeRemove and Install. (Group 4360.)


PN=348


TJ15698,000013C –19–11APR07–1/1

Swing Gearbox Start-Up Procedure

TX

1001

071A

–UN

–02D

EC

05

1—Dipstick2—Fill Cap

IMPORTANT: Swing gearbox will be damaged if notfilled with oil before operating swingfunction. Procedure must be performedwhenever a new swing gearbox isinstalled or oil has been drained fromthe gearbox.

1. Check that drain line plug is installed.

2. Remove fill cap (2) and add oil. See Swing Gearboxand Travel Gearbox Oils. (Operator’s Manual.)

3. Install fill cap. Check oil level on dipstick (1).

43435011

TJ15698,000017F –19–11APR07–1/4

Upperstructure Remove And Install

TX

1020

196A

–UN

–07M

AR

07


1. Clean machine thoroughly.

2. Disconnect negative battery cables.




5. Remove cab. See Cab Remove and Install. (Group1800.)

6. Remove counterweight. See Counterweight Removeand Install. (Group 1749.)

7. Remove boom. See Boom Remove and Install. (Group3340.)

8. Disconnect center joint hydraulic hoses and removestop. See Center Joint Remove and Install. (Group4360.)


PN=349



TJ15698,000017F –19–11APR07–2/4

T18

8539

–UN

–17M

AR

03T

1885

40–U

N–1

7MA

R03


SpecificationUpperstructure—Weight 4500 kg approximate...........................................

9923 lb approximate

9. Attach chains to counterweight support beams andboom bracket.

IMPORTANT: Make sure chains do not touch engine.

43TJ15698,000017F –19–11APR07–3/4

T10

5961

–UN

–20D

EC

96

Swing Bearing

435012

A—Swing BearingB—Cap Screw (36 used)

10. Put matching marks on the upperstructure and outerrace of the swing bearing to aid in installation. Loosenand remove cap screws (B).



PN=350


43435013

TJ15698,000017F –19–11APR07–4/4

T18

8541

–UN

–17M

AR

03

11. Lift upperstructure from undercarriage using hoist.



SpecificationUpperstructure—Weight 4500 kg approximate...........................................

9923 lb approximate

13. Install upperstructure to undercarriage.

14. Align mark on the outer race of swing bearing withmark on upperstructure. Install DFT1144 Guide Pinsto help align holes in swing bearing with holes inupperstructure. See DFT1144 Guide Pin. (Group9900.)

15. Install cap screws (B).

16. Remove chains from upperstructure and tighten capscrews (B).

SpecificationSwing Bearing-to-UpperstructureCap Screws—Torque 510 N•m...................................................................

380 lb-ft

17. Connect center joint hydraulic hoses and install stop.See Center Joint Remove and Install. (Group 4360.)

18. Install boom. See Boom Remove and Install. (Group3340.)

19. Install counterweight. See Counterweight Removeand Install. (Group 1749.)

20. Install cab. See Cab Remove and Install. (Group1800.)

IMPORTANT: Hydraulic pump will be damaged if notfilled with oil before starting engine.Start-up procedure must be performedwhenever a new pump is installed or oilhas been drained from the pump orhydraulic oil tank.



PN=351


TJ15698,0000125 –19–11APR07–1/2

Swing Bearing Remove and Install

T77

64A

B–U

N–0

7MA

Y92

C—JT01748 Lifting BracketsD—Cap Screw and Lock Washer

1. Remove upperstructure. See Upperstructure Removeand Install. (Group 4350.)


SpecificationSwing Bearing—Weight 210 kg...................................................................

463 lb

2. Connect swing bearing to appropriate lifting deviceusing lifting brackets (C) such as JT01748 LiftingBrackets.

3. Remove cap screws and lock washers (D) and removeswing bearing.

4. Check and replace swing bearing upper and lowerseals if necessary. See Swing Bearing Upper SealInstall. (Group 4350.) See Swing Bearing Lower SealInstall. (Group 4350.)

5. Replace steel balls and ball supports as necessary.


7. Clean mating surfaces of swing bearing,upperstructure, and undercarriage.

434350

14



PN=352


TJ15698,0000125 –19–11APR07–2/2

T59

25A

A–U

N–1

1AP

R90

A—ToothB—Loading Plug

IMPORTANT: The tooth marked with the letter “G” or“S” or equivalent is the starting andstopping point for the hardeningprocess. The tooth and the bearingloading plug must be installed on theright side of the machine so the use ofthat part of the swing bearing isminimized.

8. Install swing bearing on undercarriage so tooth (A)marked “G” or “S” or equivalent and bearing loadingplug (B) is to right side of machine.

9. Install cap screws and lock washers and tighten.

SpecificationUndercarriage-to-Swing BearingCap Screw—Torque 510 N•m.....................................................................

376 lb-ft

10. Apply multi-purpose grease to swing bearing teethand pinion shaft. See Track Adjuster, Working ToolPivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)

11. Install upperstructure. See Upperstructure Removeand Install. (Group 4350.)

43435015


PN=353


434350

16

TJ15698,000011A –19–11APR07–1/5

Swing Bearing Disassemble and Assemble

TX

1000

479

–UN

–25J

AN

06


PN=354



TJ15698,000011A –19–11APR07–2/5

0—Outer Race 2—Steel Ball (121 used) 8—Lower Seal 10—Spacer (121 used)1—Inner Race 5—Lubrication Fitting (2 used) 9—Upper Seal 11—Swing Bearing

1. Check swing bearing upper seal (9) and lower seal(8). If damaged, replace. See Swing Bearing Upper

Seal Install. (Group 4350.) See Swing BearingLower Seal Install. (Group 4350.)

TJ15698,000011A –19–11APR07–3/5

T68

76F

I–U

N–0

7MA

Y92

43435017

A—Tack WeldB—Taper PinC—Loading Plug

2. Grind tack weld (A) off top of taper pin (B).

3. Drive taper pin out from bottom side of bearing.

4. Remove loading plug (C) using an M8-1.25 cap screw.



PN=355


TJ15698,000011A –19–11APR07–4/5

T68

76F

K–U

N–0

7MA

Y92

T77

63A

B–U

N–0

7MA

Y92

434350

18

A—Spacer (121 used)B—Steel Ball (121 used)

5. Remove steel balls (A) and spacers (B).

6. Turn inner race to remove remaining steel balls andspacers.

7. Lift outer race off inner race.


9. Install spacers (B) and steel balls (A). Turn inner raceas needed to install spacers and steel balls.

TJ15698,000011A –19–11APR07–5/5

T68

76F

I–U

N–0

7MA

Y92

A—Tack WeldB—Taper PinC—Loading Plug

10. Install loading plug (C).

11. Install taper pin (B) even with top of swing bearing.

12. Tack weld pin (A) to swing bearing.

13. Add multi-purpose grease to swing bearing throughlubrication fittings. See Track Adjuster, Working ToolPivot, Swing Bearing, and Swing Bearing GearGrease. (Operator’s Manual.)


PN=356


TJ15698,0000123 –19–11APR07–1/1

Swing Bearing Upper Seal Install

T59

25A

M–U

N–1

1AP

R90

A—Seal


2. Remove old seal (A).

3. Scrape old adhesive from seal groove. Thoroughlyclean seal groove and new seal using PM37509 CurePrimer.

4. Apply PM37391 Gel Super Glue sparingly to sealgroove.

5. Install seal with lip against inner bearing race. Startabout 76 mm (3 in.) from end of seal using bluntinstrument to force seal into groove. Push seal indirection of portion already installed to avoid stretchingseal.

6. Before bringing ends of seal together, cut off excesslength.

7. Apply PM37391 Gel Super Glue to both ends of seal.Push ends into seal groove making sure they cometogether.

IMPORTANT: To avoid pulling seal out of groove,adhesive must cure for at least 24hours before using swing function.

8. Install upperstructure. See Upperstructure Remove andInstall. (Group 4350.)

43435019


PN=357


TJ15698,0000124 –19–18APR07–1/1

Swing Bearing Lower Seal Install

T59

36B

A–U

N–1

7MA

Y89

A—SealB—Seal Groove


NOTE: Part of swing bearing shown cut away to showlower seal in groove.

2. Remove old seal (A).

3. Scrape old adhesive from seal groove (B). Thoroughlyclean seal groove and new seal using PM37509 CurePrimer.

4. Apply PM37391 Gel Super Glue sparingly to sealgroove.

5. Install seal with seal lip against outer race. Start about76 mm (3 in.) from end of seal using blunt instrumentto force seal into groove. Push seal in direction ofportion already installed to avoid stretching seal.

6. Before bringing ends of seal together, cut off excesslength.

7. Apply PM37391 Gel Super Glue to both ends of seal.Push ends into seal groove making sure they cometogether.

IMPORTANT: To avoid pulling seal out of groove,adhesive must cure for at least 24hours before using swing function.

8. Install upperstructure. See Upperstructure Remove andInstall. (Group 4350.)

434350

20


PN=358


FS41334,0000144 –19–13APR07–1/4

Center Joint Remove and Install

TX

1020

196A

–UN

–07M

AR

07





3. Apply vacuum to hydraulic tank or drain hydraulic tank.See Apply Vacuum to Hydraulic Oil Tank. (Group3360). The approximate capacity of hydraulic oil tank is120.4 L (31.8 gal).

FS41334,0000144 –19–13APR07–2/4

TX

1020

553A

–UN

–19M

AR

07

4343601

1—Bracket2—Cap Screw (2 used)3—Hydraulic Line (4 used)4—Small Hydraulic Line (2 used)

4. Tag and disconnect upper hydraulic lines (3). Close allopen lines and fittings using caps and plugs.

5. Remove cap screws (2) and bracket (1).

6. Disconnect small hydraulic lines (4). Close all openlines and fittings using caps and plugs.



PN=359

Hydraulic System

43FS41334,0000144 –19–13APR07–3/4

T76

85JC

–UN

–27A

PR

92

7. Attach the center joint to an appropriate lifting deviceusing a lifting strap. See Center Joint (Rotary Manifold)Lifting Tool (2 used). See (Group 9900.)

8. Tag and disconnect lower hydraulic lines. Close allopen lines and fittings using caps and plugs.


SpecificationCenter Joint—Weight 27 kg........................................................................

60 lb

9. Remove four cap screws and lower center joint.

10. Replace parts as necessary. See Center JointDisassemble and Assemble. (Group 4360.)

11. Install center joint. Tighten four cap screws tospecifications.

SpecificationCenter Joint-to-Frame CapScrew—Torque 90 N•m...............................................................................

66 lb-ft

12. Install stop bracket. Tighten cap screws.

SpecificationStop Bracket-to-Frame CapScrew—Torque 140 N•m.............................................................................

103 lb-ft

13. Connect upper and lower hydraulic lines.



43602



PN=360

Hydraulic System

FS41334,0000144 –19–13APR07–4/4



4343603


PN=361

Hydraulic System

434360

4

FS41334,0000143 –19–02MAR07–1/2

Center Joint Disassemble and Assemble

TX

1018

875

–UN

–12F

EB

07

1—Plug (Ball)2—Spindle3—Dust Seal4—O-Ring5—Bushing6—Oil Seal (6 used)7—Housing8—Ring9—Snap Ring10—O-Ring11—Cover12—Cap Screw (4 used)


SpecificationCenter Joint—Weight 27 kg........................................................................

60 lb

1. Make alignment marks on spindle assembly (2),housing (7) and cover (11) to aid in assembly.

2. Remove cover (11), snap ring (9), and ring (8).

3. Install puller to housing (7) using cap screws (12).Carefully remove spindle assembly (2) from housing(7).

4. Remove plug (1) from spindle assembly and cleanport.

NOTE: Bushing (5) can be removed using built-up weld at4 places on its inner diameter, then quenchingbushing to shrink. Cover seal surfaces to protectfrom weld spatter.

5. Remove dust seal (3), bushing (5), and oil seals (6).

6. Inspect and repair or replace parts as necessary.

7. Install bushing (5) into housing (7) using a press.Lubricate bushing with grease or molybdenumdisulfide.


PN=362


Hydraulic System

FS41334,0000143 –19–02MAR07–2/2

IMPORTANT: Install dust seal (3) with lip side towardhousing (7).

8. Install dust seal (3) onto spindle (2).

9. Install O-ring (4) and oil seals (6) into housing (7).

IMPORTANT: Install spindle assembly (2) slowly intohousing (7) so oil seals (6) are notdamaged.

10. Lubricate spindle assembly (2) with hydraulic oil andinstall into housing (7). Align reference marks madeduring disassembly.

IMPORTANT: Install ring (8) with chamfered sidefacing spindle assembly (2).

11. Install parts (8—12), aligning reference marks madeduring disassembly.


SpecificationCover-to-Housing Cap Screw—Torque 49 N•m............................................................................................

36 lb-ft

13. Install plug (1).

4343605

FS41334,0000142 –19–02MAR07–1/1

Center Joint Air Test

T65

57JB

–UN

–01N

OV

88

1. Install a plug in one port of a selected passage.

2. Apply shop air pressure, using JDG185 Air Test Plug,to the other port in that passage.

3. Listen for air leaks at other ports on either side ofcenter joint.

4. Repeat test for other passages.

5. Repair or replace if leaks are found. See Center JointDisassemble and Assemble. (Group 4360.)


PN=363

Hydraulic System

TJ15698,000013D –19–11APR07–1/3

Swing Motor and Park Brake Remove andInstall

TX

1020

196A

–UN

–07M

AR

07




2. Apply vacuum to hydraulic tank or drain hydraulic tank.See Apply Vacuum to Hydraulic Tank. (Group 3360).The approximate capacity of hydraulic oil tank is 120.4L (31.8 gal).


434360

6


PN=364

Hydraulic System

43TJ15698,000013D –19–11APR07–2/3

TX

1003

156A

–UN

–19A

PR

06

1—Electrical Connector2—Hydraulic Line3—Main Hydraulic Line4—Hydraulic Line5—Cap Screw (8 used)6—Swing Dampener Valve Hydraulic Lines

3. Tag and disconnect hydraulic lines (2, 3, 4, and 6).

4. Close all open lines and fittings using caps and plugs.



SpecificationSwing Motor and Park Brake—Weight 48 kg................................................................................................

105 lb

6. Remove cap screws (5) to remove swing motor andpark brake.

7. Repair or replace parts as necessary. See SwingMotor and Park Brake Disassemble. (Group 4360.)

8. Install swing motor and park brake.


SpecificationSwing Motor-to-Ring Gear CapScrew—Torque 90 N•m...............................................................................

67 lb-ft



12. See Swing Motor and Park Brake Start-Up Procedure.(Group 4360.)

13. Check oil level in hydraulic oil tank. See CheckHydraulic Tank Oil Level. (Operator’s Manual). Add oilif necessary. See Hydraulic Oil. (Operator’s Manual).

43607



PN=365

Hydraulic System

TJ15698,000013D –19–11APR07–3/3



434360

8


PN=366

Hydraulic System

4343609


PN=367

Hydraulic System

434360

10

TJ15698,000011B –19–16FEB07–1/2

Swing Motor and Park Brake Disassemble

TX

1000

252

–UN

–28N

OV

05


PN=368


Hydraulic System

43436011

TJ15698,000011B –19–16FEB07–2/2

0—Hydraulic Motor 14—Shoe Plate 43—Fitting Plug (2 used) 76—O-Ring1—Piston (9 used) 15—Valve Plate 44—Make-Up Check Valve 77—O-Ring5—Crossover Relief Valve (2 20—Swing Motor Cover Plug (2 used) 78—Spring (24 used)

used) 30—Housing 45—O-Ring 79—Friction Plates (3 used)8—Piston 35—Poppet (2 used) 47—O-Ring (2 used) 81—Pipe Plug (2 used)10—Shaft 36—Spring (2 used) 48—O-Ring (2 used) 85—Seal Kit11—Cylinder Block 40—Cap Screw (4 used) 49—Seal 87—Spring12—Retainer 41—Roller Bearing 70—Brake Piston 88—Ball13—Plate 42—Roller Bearing 73—Plates (4 used) 89—Packing

IMPORTANT: Do not disassemble crossover reliefvalve (5).

1. Remove crossover relief valves (5) from swingmotor cover (20).

2. Remove make-up check valve plugs (44).

3. Remove springs (36) and poppets (35).


SpecificationSwing Motor and Park Brake—Weight 48 kg.........................................................................................

105 lb

CAUTION: Swing motor housing and swingmotor cover is under spring pressure.Remove cap screws evenly to release springforce.

4. Mark alignment of swing motor housing (30) andswing motor cover (20) assembly. Loosen capscrews (40).

IMPORTANT: Do not remove roller bearing (42)unless necessary.

IMPORTANT: Valve plate (15) has a polishedsurface. Valve plate may remain onswing motor cover (20) or stay withcylinder block (11). Valve plate maybe damaged if dropped. Hold valveplate during disassembly.

5. Remove valve plate (15) from cylinder block (11).

6. Remove O-ring (45).

7. Remove springs (78).

8. Remove brake piston (70).

9. Remove O-rings (76, 77) from housing (30).

10. Remove parts (1, 13 and 12) from shaft (10).

11. Remove plates (73) and friction plates (79).

IMPORTANT: Do not damage sliding surface ofshoe plate (14).

12. Remove shoe plate (14).

13. Remove shaft (10) from housing (30) using aplastic hammer.

14. Push out oil seal (49) and remove outer race ofroller bearing (41) from housing (30).

15. Remove inner race of roller bearing (41) fromshaft (10) using a press.

NOTE: Filter and orifice are mounted inside of piston(8). Unless clogged or deformed, do notdisassemble. Do so only when absolutelyneeded. If internal parts need to be replaced,replace piston (8) as an assembly.

16. Remove swing park brake release valve piston (8),packing (89), spring (87), and ball (88).

NOTE: Use seal kit (85) to replace seals and O-rings.



PN=369

Hydraulic System

TJ15698,000011C –19–29MAR07–1/4

Swing Motor and Park Brake Inspection

T14

2067

–UN

–22J

UN

01

1. Measure clearance between outer diameter of pistonand inner bore of cylinder.

SpecificationPiston-to-Cylinder—Clearance 0.027 mm new...........................................

0.001 in. new0.052 mm maximum used0.0020 in. maximum used

434360

12

TJ15698,000011C –19–29MAR07–2/4

T14

2069

–UN

–22J

UN

01

2. Measure clearance between piston and slipper.

SpecificationPiston-to-Slipper—Clearance 0.0 mm new.................................................

0.0 in. new0.3 mm maximum used

0.0117 in. maximum used


PN=370


Hydraulic System

TJ15698,000011C –19–29MAR07–3/4

T14

2072

–UN

–22J

UN

01

Slipper Thickness

3. Measure thickness of slipper.

SpecificationSlipper—Thickness 5.5 mm new.................................................................

0.214 in. new5.3 mm minimum

0.207 in. minimum

TJ15698,000011C –19–29MAR07–4/4

T14

2073

–UN

–22J

UN

01

Friction Plate Thickness

4. Measure thickness of friction plate.

SpecificationFriction Plate—Thickness 2.0 mm new.......................................................

0.078 in. new1.8 mm minimum

0.070 in. minimum

43436013


PN=371

Hydraulic System

434360

14

TJ15698,000011D –19–16FEB07–1/3

Swing Motor and Park Brake Assemble

TX

1000

252

–UN

–28N

OV

05

Swing Motor and Park Brake


PN=372


Hydraulic System

43436015

TJ15698,000011D –19–16FEB07–2/3

0—Hydraulic Motor 14—Shoe Plate 43—Fitting Plug (2 used) 76—O-Ring1—Piston (9 used) 15—Valve Plate 44—Make-Up Check Valve 77—O-Ring5—Crossover Relief Valve (2 20—Swing Motor Cover Plug (2 used) 78—Spring (24 used)

used) 30—Housing 45—O-Ring 79—Friction Plate (3 used)8—Piston 35—Poppet (2 used) 47—O-Ring (2 used) 81—Pipe Plug (2 used)10—Shaft 36—Spring (2 used) 48—O-Ring (2 used) 85—Seal Kit11—Cylinder Block 40—Cap Screw (4 used) 49—Seal 87—Spring12—Retainer 41—Roller Bearing 70—Brake Piston 88—Ball13—Plate 42—Roller Bearing 73—Plate (4 used) 89—Packing

1. Install ball (88), spring (87), packing (89), andpiston (8) into housing (30).

IMPORTANT: Install inner race of roller bearing(41) with flange facing step side ofshaft (10).

2. Install inner race of roller bearing (41) onto shaft(10) using a press.

3. Install oil seal (49) to housing (30).

4. Install outer race of roller bearing (41) to housing(30).

IMPORTANT: Wind tape onto spline end of shaft(10) to prevent damage to oil seal(49).

5. Install shaft (10) into housing (30).

6. Install shoe plate (14) to housing (30) withchamfered surface toward housing.

7. Align notches on plate (13) and retainer (12). Installpistons (1).

8. Install retainer (12) and plate (13) to pistons (1) withnotches facing shoe plate (14).

9. Apply hydraulic oil into piston holes in cylinder block(11).

10. Insert piston (1) assembly into cylinder block (11).

11. Install cylinder block (11) assembly to shaft (10).

IMPORTANT: There are four notches on outer sideof plates (73) and four notches on

spline teeth side of friction plates(79).

IMPORTANT: Align each notch when installing.

12. Alternately install plates (73) and friction plates(79) to housing (30).

13. Install O-rings (76, 77) to housing (30).

14. Align mating marks and install brake piston (70).

15. Install springs (78) to brake piston (70).

NOTE: Do step 15 only if bearing (42) was removed.

16. Install roller bearing (42) into swing motor cover(20) using plastic hammer.

17. Install O-ring (45) to swing motor cover (20).

18. Install valve plate (15) to swing motor cover (20)with notch in port facing toward cylinder block(11).

19. Apply grease to valve plate (15) to help retain toswing motor cover (20).

20. Apply grease to roller bearing (42) ID to easeshaft (10) installation.

21. Align mating marks on swing motor cover (20) andhousing (30). Install cap screws (40) and tighten tospecification.

SpecificationSwing Motor Cover-to-HousingCap Screw—Torque 431 N•m..............................................................

318 lb-ft


PN=373


Hydraulic System

TJ15698,000011D –19–16FEB07–3/3

22. Install poppets (35) and spring (36). Tightenmake-up check valve plug (44) with O-ring (48)attached.

SpecificationMake-Up Check Valve Plug—Torque 334 N•m....................................................................................

246 lb-ft

23. Install crossover relief valves (5) into swing motorcover (20).

SpecificationCrossover Relief Valve—Torque 177 N•m....................................................................................

131 lb-ft

TJ15698,000013E –19–11APR07–1/1

Swing Motor and Park Brake Start-UpProcedure

TX

1003

231A

–UN

–02F

EB

06

1—Hydraulic Line

IMPORTANT: Swing motor will be damaged if notfilled with oil before operating swingfunction. Start-up procedure must beperformed whenever a new swing motoris installed or oil has been drained fromthe motor.

NOTE: Procedure is to ensure swing motor is filled withoil.

1. Disconnect swing motor hydraulic line (1).

2. Fill motor through port until oil reaches level of port.See Hydraulic Oil. (Operator’s Manual.)

NOTE: Air must be allowed to escape from the swingmotor while filling.

3. Connect hydraulic line (1).

434360

16


PN=374

Hydraulic System

TJ15698,000013F –19–11APR07–1/3

Crossover Relief Valve and Make-Up Check Valve Remove and Install

4

31

2

T139645

T13

9645

–UN

–30A

PR

01

1—Make-Up Check Valve 2—Make-Up Check Valve 3—Crossover Relief Valve 4—Crossover Relief Valve

43436017

TJ15698,000013F –19–11APR07–2/3

TX

1003

161A

–UN

–02F

EB

06

1—Crossover Relief Valve (2 used)

Remove and Install Crossover Relief Valve

1. Remove crossover relief valves (1).

2. Replace crossover relief valves (1) as necessary.

3. Install crossover relief valves (1). Tighten tospecification.

SpecificationCrossover Relief Valve—Torque 177 N•m..................................................

130 lb-ft

4. Check crossover relief valve pressure setting. SeeSwing Motor Crossover Relief Valve Test andAdjustment. (Group 9025-25.)


PN=375


Hydraulic System

TJ15698,000013F –19–11APR07–3/3

TX

1003

232A

–UN

–02F

EB

06

1—Make-Up Check Valve (2 used)

Remove and Install Make-Up Check Valve

1. Remove make-up check valves (1).

2. Repair or replace parts as necessary. See Make-UpCheck Valve Disassemble and Assemble. (Group4360.)

3. Install make-up check valves (1). Tighten tospecification.

SpecificationMake-Up Check Valve—Torque 334 N•m...................................................

245 lb-ft

TJ15698,0000140 –19–11APR07–1/2

Make-Up Check Valve Disassemble andAssemble

TX

1003

721A

–UN

–16F

EB

06

1—Make-Up Check Valve (2 used)

1. Remove make-up check valves (1). See CrossoverRelief Valve and Make-Up Check Valve Remove andInstall. (Group 4360.)


434360

18


PN=376

Hydraulic System

TJ15698,0000140 –19–11APR07–2/2

TX

1003

722

–UN

–16F

EB

06

43436019

1—Make-Up Check Valve Plug (2 used)2—O-Ring (2 used)3—Spring (2 used)4—Poppet (2 used)5—Cap Screw (4 used)6—Swing Motor Top Plate7—O-Ring

2. Examine O-rings (2), springs (3), and poppets (4) forwear and damage.


4. Install O-rings (2), springs (3), poppets (4), andmake-up check valve plugs (1).

5. Tighten make-up check valve plugs (1) to specification.See Crossover Relief Valve and Make-Up Check ValveRemove and Install. (Group 4360.)

TJ15698,0000120 –19–11APR07–1/1

Swing Park Brake Release Valve Removeand Install

NOTE: Swing park brake release valve is internallylocated in swing motor. See Swing Motor andPark Brake Disassemble. See Swing Motor andPark Brake Assemble. (Group 4360.)


PN=377

Hydraulic System

434360

20


PN=378

Section 9999Dealer Fabricated Tools

Contents

Page

Group 9900—Dealer Fabricated ToolsDF1063 Lift Bracket . . . . . . . . . . . . . . . . . . .99-9900-1ST4920 Track Recoil Spring Disassembly

and Assembly Tool . . . . . . . . . . . . . . . . . .99-9900-3DFT1087 Track Recoil Spring

Disassembly and Assembly Guard Tool. . .99-9900-7DFT1110 Spacer. . . . . . . . . . . . . . . . . . . . . .99-9900-8DFT1130 Adapter . . . . . . . . . . . . . . . . . . . . .99-9900-9DFT1036A Travel Gearbox Nut Wrench . . .99-9900-10DF1038 Torque Adapter . . . . . . . . . . . . . . .99-9900-11DFT1109 Holding Bar . . . . . . . . . . . . . . . . .99-9900-12Center Joint (Rotary Manifold) Lifting

Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-13DFT1144 Guide Pin . . . . . . . . . . . . . . . . . .99-9900-13DFT1119 Pump Support . . . . . . . . . . . . . . .99-9900-14DFT1220 Swing Gearbox Nut Spanner

Wrench . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-16


PN=1

Contents

99


PN=2

Group 9900Dealer Fabricated Tools

9999001

TJ15698,0000106 –19–16FEB07–1/2

DF1063 Lift Bracket

T83

18A

C–U

N–2

0SE

P94

Tool is the same as used on other machines. Only the liftbracket of the tool is used for this machine with adapterDFT1130.

Lift Bracket is used to remove and install travel motor.

Material required:

• 38.1 mm x 76.2 mm x .48 mm (1-1/2 in. x 3 in. x 3/16in.) Square Tube

• 1.3 mm (1/2 in.) 1020 Steel Plate• 1 mm x 38.1 mm (3/8 in. x 1-1/2 in.) Cap Screw with

Nut (4 used)



PN=381

Dealer Fabricated Tools

999900

2

TJ15698,0000106 –19–16FEB07–2/2

T72

47B

W–1

9–25

AP

R90


PN=382


9999003

TJ15698,0000107 –19–13APR07–1/4

ST4920 Track Recoil Spring Disassembly andAssembly Tool

T65

85U

Y–U

N–2

4MA

R98

A—Nut (12 used)B—Stud (4 used)C—HolderD—Eyebolt (2 used)E—Supporting PlateF—Base PlateG—Base (4 used)H—Cap Screw (4 used)I—Lock Washer (8 used)

NOTE: It is recommended that DFT1087 Track RecoilSpring Disassembly and Assembly Guard Tool beused with track recoil spring disassembly andassembly tool. See DFT1087 Track Recoil SpringDisassembly and Assembly Guard Tool. (Group9900.)

Dimensions given are metric.

Tool is the same as used on other machines except theholder (C). For each track adjuster use the holder with thecorrect size hole for the nut on that track adjuster.

Track Recoil Spring Disassembly and Assembly Tool(compression tool) is used with hydraulic jack to compressrecoil spring in track adjuster repair.

Material required:

• 1020 HR Steel for Holder (C), Supporting Plate (E),Base Plate (F), and Base (G).

• “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A),and Cap Screws (H).

• “F” Grade (SAE Grade 8) for Studs (B).

Print Numbers:

• A-ST4050 Nut• B-ST4045 Bolt• C-ST4035 Holder (Plate)• C-ST4036 Holder (Plate)• C-ST4037 Holder (Plate)• D-ST4047 Eyebolt• E-ST4040 Supporting Base• F-ST4042 Base Plate• G-ST4041 Base• H-ST4046 Cap Screw• I-ST4049 Lock Washer



PN=383


999900

4

TJ15698,0000107 –19–13APR07–2/4

T70

29C

I–U

N–0

6JU

L89



PN=384


9999005

TJ15698,0000107 –19–13APR07–3/4

T70

29C

H–U

N–0

6JU

L89


PN=385



999900

6

TJ15698,0000107 –19–13APR07–4/4

T70

29C

G–U

N–0

6JU

L89


PN=386


9999007

TJ15698,0000108 –19–13APR07–1/1

DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

T71

62A

F–U

N–1

7OC

T89

A—3/16 in. 1020 CR Steel Plate C—1/2 in. Nut (2 used) D—1/2 x 2 in. Cap Screw (2 E—1/2 x 3 in. Steel RoundB—9/16 in. Hole (2 places) used) Stock (2 used)

Track Disassembly and Assembly Guard Tool is usedwith ST4920 Track Recoil Spring Disassembly andAssembly Tool. See ST4920 Track Recoil SpringDisassembly and Assembly Tool. (Group 9900.)

Material required:

• 3/16 in. 1020 CR Steel Plate (A)• 9/16 in. Hole (2 places) (B)• 1/2 in. Nut (2 used) (C)• 1/2 x 2 in. Cap Screw (D) (2 used)• 1/2 x 3 in. Steel Round Stock (E) (2 used)


PN=387


999900

8

TJ15698,0000109 –19–13APR07–1/1

DFT1110 Spacer

T77

08A

C–U

N–2

3FE

B92

Spacer is used with ST4920 Track Recoil SpringDisassembly and Assembly Tool. Spacer is installedon the bottom plate so force is applied to spring flangeon cylinder and not to the piston. See ST4920 TrackRecoil Spring Disassembly and Assembly Tool. (Group9900.)

Cut the ends of spacer so they are parallel to eachother.

Material Required:

• 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) HeavyWall Steel Pipe


PN=388


9999009

TJ15698,000010A –19–16FEB07–1/1

DFT1130 Adapter

T83

19B

N–U

N–2

0SE

P94

A—Adapter Plate B—Tube C—Stop Plate

Adapter is used with DF1063 Lift Bracket to removeand install travel motor.

Material required:

• 1.3 mm (1/2 in.) 1020 Steel Plate (A)• 38.1 mm x 38.1 mm x .48 mm (1-1/2 in. x 1-1/2 in. x

3/16 in.) Square Tube (B)• .6 mm (1/4 in.) 1020 Steel Plate (C)


PN=389


999900

10

TJ15698,000010B –19–13APR07–1/1

DFT1036A Travel Gearbox Nut Wrench

T76

81F

Z–U

N–2

8FE

B92

Travel Gearbox Nut Wrench is used to remove andinstall the hub-to-housing nut in the travel gearbox.

Material required:

• 16 mm (5/8 in.) Flat Bar Stock• M24 (1 in.) Nut• M10-1.5 x 60 mm Cap Screw (2 used)• M10-1.5 Nut (2 used)


PN=390


99990011

TJ15698,000010C –19–13APR07–1/1

DF1038 Torque Adapter

T65

57C

H–U

N–2

5OC

T95

Torque Adapter is used to check rolling drag torque onrotor drive shaft.

Material required:

• 17 mm (0.125 in.) hex head driver


PN=391


999900

12

TJ15698,000010D –19–11APR07–1/1

DFT1109 Holding Bar

T76

90A

A–U

N–2

7FE

B92

Holding Bar is used with the DF1036A Travel GearboxNut Wrench as a guide when loosening thehub-to-housing nut in the travel gearbox. SeeDF1036A Travel Gearbox Nut Wrench. (Group 9900.)

Material required:

• 16 mm (5/8 in.) Flat Bar Stock


PN=392


99990013

TJ15698,000010E –19–13APR07–1/1

Center Joint (Rotary Manifold) Lifting Tool

T66

41D

O–U

N–2

4OC

T88

A—Threads

Tool is used to remove and install center joint.

Drill and tap disk in fitting cap to M8-1.25 mm threads (A).

Material required:

• 38H1416 Cap (—12)• M8-1.25 Lifting Eyebolt such as JT05548 Metric Lifting

Eyebolt

TJ15698,000010F –19–13APR07–1/1

DFT1144 Guide Pin

T66

41E

K–U

N–2

4OC

T88

A—230 mm (9 in.)B—100 mm (4 in.)

Guide pin is used to align cap screw holes in swingbearing and upperstructure.

Remove threads for a distance (B) and then grind a taperon same end.

Material Required:

• M20-2.5 x 230 mm (9 in.) Threaded Rod


PN=393


999900

14

TJ15698,0000110 –19–30APR07–1/1

DFT1119 Pump Support

TX1022920

610 mm(24 in.)

76.2 x 76.2 x 6.35 mm(3 x 3 x 0.250 in.)

88.9 x 88.9 x 6.35 mm(3.5 x 3.5 x 0.250 in.)

63.5 x 63.5 x 6.35 mm(2.5 x 2.5 x 0.250 in.)

38 mm (1.5 in.)

104.8 mm (4.125 in.)165 mm (6.5 in.)376 mm (14.8 in.)

233 mm (9.2 in.)

335 mm (13.2 in.)

76 mm (3 in.)152 mm (6 in.)229 mm (9 in.)305 mm (12 in.)380 mm (15 in.)457 mm (18 in.)533 mm (21 in.)610 mm (24 in.)

1524 mm(60 in.)

38 mm(1.5 in.)

9.5 mm(0.375 in.)

9.5 mm(0.375 in.)

Ø12 mm(0.472 in.)5 Places

9.5 mm(0.375 in.)

Ø11 mm(0.438 in.)

457 mm(18 in.)

76 mm(3 in.)114 mm(4.5 in.)

9.5 mm(0.375 in.)

19 mm(0.750 in.)

13 mm(0.5 in.)

13 mm(0.5 in.)

Ø38 mm(1.5 in.)

76 mm(3 in.)

89 mm(3.5 in.)102 mm(4 in.)

Ø11 mm(0.438 in.)12 PLACES76 mm

(3 in.)

TX

1022

920

–UN

–11J

AN

08

Pump support is used with a hand hoist to support apump(s) when an engine is removed.

Two end stands are needed.

Drill the holes through the square steel tubing so theyare centered.

Material required:

• C3 x 5 Steel Channel

• 88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 in.) SquareSteel Tubing

• 76.2 x 76.2 x 6.35 mm (3 x 3 x 0.250 in.) SquareSteel Tubing

• 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.) SquareSteel Tubing

• 19 mm (3/4 in.) Flat Bar Stock• M10 x 89 mm or 3/8 x 3-1/2 in. D Grade (SAE

Grade 5) Cap Screw (2 used)• M10 or 3/8 in. D Grade (SAE Grade 5) Nut (2 used)


PN=394


99990015


PN=395


999900

16

TJ15698,0000111 –19–16FEB07–1/2

DFT1220 Swing Gearbox Nut Spanner Wrench

T14

3704

–UN

–17J

UL0

1


PN=396



99990017

TJ15698,0000111 –19–16FEB07–2/2

1—Weld (4 Places)

Material required:

• 159.4 x 82.5 mm (6.275 x 3.25 in.) Steel Tubing

• 159.4 x 38.1 x 6.35 mm (6.65 x 1.5 x .25 in.)


PN=397


999900

18


PN=398

IndexPage Page

A Boom flow rate solenoid valveRemove and install . . . . . . . . . . . . . . . .33-3360-46

Boom mode solenoid valveAir cleanerRemove and install . . . . . . . . . . . . . . . .33-3360-46Remove and install . . . . . . . . . . . . . . . . .05-0520-1

Boom pins and bushingsAir conditionerInspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Condenser, remove and install . . . . . . .18-1830-11

IndxBoom, arm, and bucket bushings and bossesReceiver-dryer, remove and install . . . .18-1830-171Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Air conditioner and heater

Boom, arm, and bucket pinsRemove and install . . . . . . . . . . . . . . . .18-1830-13Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11Air conditioner system

BrakeFlush and purge . . . . . . . . . . . . . . . . . . .18-1830-3Swing park, inspection . . . . . . . . . . . . .43-4360-12Refrigerant cautions and properSwing park, remove and install . . . . . . . .43-4360-6handling. . . . . . . . . . . . . . . . . . . . . . . .18-1830-1

Air conditioning Brake, park and travel motorCharge R134a system . . . . . . . . . . . . .18-1830-10 Disassemble and assemble . . . . . . . . .02-0260-10Compressor, remove and install . . . . . .18-1830-11 Remove and install . . . . . . . . . . . . . . . . .02-0260-2Evacuate R134a system . . . . . . . . . . . . .18-1830-9 BucketRecover R134a refrigerant . . . . . . . . . . .18-1830-8 Remove and install . . . . . . . . . . . . . . . . .33-3302-1R134a refrigerant oil information . . . . . . .18-1830-6 Bucket cylinderR134a station installation . . . . . . . . . . . .18-1830-7 Bleed procedure . . . . . . . . . . . . . . . . .33-3360-106

Arm Disassemble and assemble . . . . . . . .33-3360-103Remove and install . . . . . . . . . . . . . . . . .33-3340-3 Inspect pins and bushings. . . . . . . . . . .33-3340-11

Arm cylinder Remove and install . . . . . . . . . . . . . . . .33-3360-99Bleed procedure . . . . . . . . . . . . . . . . .33-3360-106 Bucket linksDisassemble and assemble . . . . . . . . .33-3360-96 Remove and install . . . . . . . . . . . . . . . . .33-3340-1Inspect pins and bushings. . . . . . . . . . .33-3340-11 Bucket pinsRemove and install . . . . . . . . . . . . . . . .33-3360-91 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11

Arm pins and bushings BushingsInspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . .33-3340-14

AttachmentsAdding safely . . . . . . . . . . . . . . . . . . . . . .00-01-11Operating safely . . . . . . . . . . . . . . . . . . . .00-01-11

C

CabBRemove and install . . . . . . . . . . . . . . . . .18-1800-1

Cab guarding . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3Backover accidentsCenter jointAvoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10

Air test . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-5Battery explosionsDisassemble and assemble . . . . . . . . . .43-4360-4Prevent . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5Remove and install . . . . . . . . . . . . . . . . .43-4360-1Bearing

Check valve, make-upSwing, disassemble and assemble . . . .43-4350-16Remove and install . . . . . . . . . . . . . . . .02-0260-17Swing, remove and install . . . . . . . . . . .43-4350-14

Chemical productsBleed procedureHandling . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-6Hydraulic cylinder . . . . . . . . . . . . . . . .33-3360-106

Condenser, air conditionerBoomRemove and install . . . . . . . . . . . . . . . .18-1830-11Remove and install . . . . . . . . . . . . . . . . .33-3340-6

Console coversBoom cylinderRemove and install . . . . . . . . . . . . . . . . .18-1821-5Bleed procedure . . . . . . . . . . . . . . . . .33-3360-106

Control valveDissassemble and assemble. . . . . . . . .33-3360-89Arm reduced leakage valve. . . . . . . . . .33-3360-63Inspect pins and bushings. . . . . . . . . . .33-3340-11

Remove and install . . . . . . . . . . . . . . . .33-3360-85 Arm regenerative valve . . . . . . . . . . . . .33-3360-71

TM10091 (11JAN08) Index-1 160DLC Excavator Repair011108

PN=1

Index

Page Page

Auxiliary flow combiner valve check Dvalve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63

Dampener driveAuxiliary flow rate valve . . . . . . . . . . . .33-3360-63Remove and install . . . . . . . . . . . . . . . . .07-0752-1Auxiliary function flow combiner

Dealer fabricated toolsvalve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63Center joint lifting tool . . . . . . . . . . . . . .99-9900-13Boom reduced leakage valve . . . . . . . .33-3360-71DFT1036A travel gearbox nutBucket flow rate valve . . . . . . . . . . . . . .33-3360-71

wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10Bypass shut-off valve . . . . . . . . . . . . . .33-3360-71DFT1087 track recoil spring disassembly and

Indx2

Lift check and orifice (left travel powerassembly guard tool . . . . . . . . . . . . . .99-9900-7

passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-63 DFT1109 holding bar . . . . . . . . . . . . . .99-9900-12Lift check (arm I power passage) . . . . .33-3360-63 DFT1110 spacer . . . . . . . . . . . . . . . . . . .99-9900-8Lift check (boom II power passage) . . .33-3360-63 DFT1119 pump support . . . . . . . . . . . .99-9900-14Lift check (left travel neutral DFT1130 adapter . . . . . . . . . . . . . . . . . .99-9900-9

passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-63 DFT1144 guide pin . . . . . . . . . . . . . . . .99-9900-13Lift check (swing neutral passage) . . . .33-3360-63 DFT1220 swing gearbox nut spannerRemove and install . . . . . . . . . . . . . . . .33-3360-61 wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-16Spool assemblies (4-spool) . . . . . . . . . .33-3360-71 DF1038 torque adapter . . . . . . . . . . . . .99-9900-11Spool assemblies (5 spool) . . . . . . . . . .33-3360-63 DF1063 lift bracket . . . . . . . . . . . . . . . . .99-9900-1

ST4920 track recoil spring disassembly andSystem relief and power boost valve. . .33-3360-63assembly tool . . . . . . . . . . . . . . . . . . .99-9900-3Travel function flow combiner valve . . .33-3360-71

Drive gearbox4-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-71Start-up procedure . . . . . . . . . . . . . . . .33-3360-255-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63

Drive shaft, pilot pumpCooling packageRemove and install . . . . . . . . . . . . . . . .33-3360-34Remove and install . . . . . . . . . . . . . . . .05-0510-11

Driving metal pins. . . . . . . . . . . . . . . . . . . . .00-01-14Cooling systemFan drive motor, remove and install . . .33-3360-40Fan drive pump, remove and install . . .33-3360-39

EFan guard, remove and install. . . . . . . .05-0510-19Fan shroud, remove and install . . . . . . .05-0510-19

Emergency preparation . . . . . . . . . . . . . . . . .00-01-6Fan, remove and install. . . . . . . . . . . . .05-0510-19EngineRadiator, remove and install . . . . . . . . . .05-0510-1

Remove and install . . . . . . . . . . . . . . . . .04-0400-1Surge tank, remove and install . . . . . . .05-0510-24Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . .00-01-5Counterbalance valve, travel motorExplosionRemove and install . . . . . . . . . . . . . . . .02-0260-13

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5Counterweight

Remove and install . . . . . . . . . . . . . . . . .17-1749-1Coupling, flex

FRemove and install . . . . . . . . . . . . . . . . .07-0752-1Crossover relief valve

FanRemove and install . . . . . . . . . . . . . . . .43-4360-17Remove and install . . . . . . . . . . . . . . . .05-0510-19Crossover relief valve, travel motor

Fan drive control valveRemove and install . . . . . . . . . . . . . . . .02-0260-15Remove and install . . . . . . . . . . . . . . . .33-3360-43

Cylinder Fan drive motorArm, disassemble and assemble. . . . . .33-3360-96 Remove and install . . . . . . . . . . . . . . . .33-3360-40Arm, remove and install . . . . . . . . . . . .33-3360-91 Fan drive pumpBleed procedure . . . . . . . . . . . . . . . . .33-3360-106 Remove and install . . . . . . . . . . . . . . . .33-3360-39Boom, disassemble and assemble . . . .33-3360-89 Fan guardBoom, remove and install . . . . . . . . . . .33-3360-85 Remove and install . . . . . . . . . . . . . . . .05-0510-19Bucket, disassemble and asemble . . .33-3360-103 Fan shroud

Remove and install . . . . . . . . . . . . . . . .05-0510-19Bucket, remove and install . . . . . . . . . .33-3360-99


PN=2

Index

Page Page

Filter, pilot Remove and install . . . . . . . . . . . . . . . . .33-3360-4Start-up procedure . . . . . . . . . . . . . . . .33-3360-25Remove and install . . . . . . . . . . . . . . . .33-3360-35

Fire prevention . . . . . . . . . . . . . . . . . . . . . . . .00-01-5 Hydraulic pump regulatorDisassemble and assemble . . . . . . . . .33-3360-28Flex coupling

Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Remove and install . . . . . . . . . . . . . . . .33-3360-26Front idler

IndxDisassemble and assemble . . . . . . . . .01-0130-213Remove and install . . . . . . . . . . . . . . . .01-0130-20

IFuel coolerRemove and install . . . . . . . . . . . . . . . .05-0510-11

Inch bolt and cap screwFuel filterTorque value. . . . . . . . . . . . . . . . . . . . . .00-0003-4Final, remove and install . . . . . . . . . . . . .05-0560-4

Inch series four bolt flange fittingPrimary, remove and install. . . . . . . . . . .05-0560-3Service recommendation, torque value for highFuel tank

pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20Remove and install . . . . . . . . . . . . . . . . .05-0560-1Inspect machine . . . . . . . . . . . . . . . . . . . . . . .00-01-3Inspection

Hydraulic pump. . . . . . . . . . . . . . . . . . .33-3360-22G Intercooler

Remove and install . . . . . . . . . . . . . . . . .05-0510-6Gearbox, travel

Disassemble and assemble . . . . . . . . . .02-0250-4Remove and install . . . . . . . . . . . . . . . . .02-0250-1

L

Lifting objectsH Special care . . . . . . . . . . . . . . . . . . . . . . .00-01-11

Handhold use . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7Hazards

MAvoiding . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-9Heater and air conditioner

Remove and install . . . . . . . . . . . . . . . .18-1830-13 Machine inspection. . . . . . . . . . . . . . . . . . . . .00-01-3Machine modificationsHigh-pressure oils

Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-4 Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-2Machine movementHydraulic

Fittings, 30° cone seat. . . . . . . . . . .00-0003-5 Unintended . . . . . . . . . . . . . . . . . . . . . . . . .00-01-8Machine tip overFittings, 37° flare . . . . . . . . . . . . . . .00-0003-5

Hydraulic cylinder Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10Make-up check valveBleed procedure . . . . . . . . . . . . . . . . .33-3360-106

Hydraulic fitting Disassemble and assemble . . . . . . . . .43-4360-18Remove and install . . . . . . 02-0260-17, 43-4360-17Flared connections . . . . . . . . . . . . . . . .00-0003-10

Hydraulic oil Manifold, pilot signalRemove and install . . . . . . . . . . . . . . . .33-3360-56Cleanup procedure using portable filter

caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3 Metal face sealsRepair . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8Hydraulic oil cooler

Remove and install . . . . . . . . . . . . . . . . .05-0510-4 Metal pins. . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-14Metric bolt and cap screwHydraulic oil tank

Apply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1 Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-1MotorDisassemble and assemble . . . . . . . . .33-3360-80

Remove and install . . . . . . . . . . . . . . . .33-3360-76 Swing, assemble. . . . . . . . . . . . . . . . . .43-4360-14Swing, disassemble . . . . . . . . . . . . . . .43-4360-10Hydraulic pump

Disassemble and assemble . . . . . . . . .33-3360-10 Swing, inspection . . . . . . . . . . . . . . . . .43-4360-12Swing, remove and install . . . . . . . . . . . .43-4360-6Inspection . . . . . . . . . . . . . . . . . . . . . . .33-3360-22


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Index

Page Page

Motor, travel and park brake Pilot signal manifoldRemove and install . . . . . . . . . . . . . . . .33-3360-56Disassemble and assemble . . . . . . . . .02-0260-10

Remove and install . . . . . . . . . . . . . . . . .02-0260-2 Pilot valve, travelDisassemble and assemble . . . . . . . . .33-3360-54Moving parts

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3 Remove and install . . . . . . . . . . . . . . . .33-3360-52Portable filter caddyServicing. . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3

Hydraulic oil cleanup procedure . . . . . . .33-3360-3Power dig solenoid valve

Remove and install . . . . . . . . . . . . . . . .33-3360-46

Indx4

OPressure test . . . . . . . . . . . . . . . . . . . . . . .01-0130-5Protective equipment . . . . . . . . . . . . . . . . . . .00-01-2

O-ring boss fitting in aluminum housing—excavatorsPump regulator, hydraulic

Torque value, serviceDisassemble and assemble . . . . . . . . .33-3360-28

recommendation . . . . . . . . . . . . . . . . .00-0003-8Remove and install . . . . . . . . . . . . . . . .33-3360-26

O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6Pump, hydraulic

O-ring face seal fittingDisassemble and assemble . . . . . . . . .33-3360-10

Inch hex nut and stud end for high pressure torqueRemove and install . . . . . . . . . . . . . . . . .33-3360-4

values . . . . . . . . . . . . . . . . . . . . . . . .00-0003-12Pump, pilot

Metric hex nut and stud end for high pressureDisassemble and assemble . . . . . . . . .33-3360-32

torque values. . . . . . . . . . . . . . . . . . .00-0003-16Remove and install . . . . . . . . . . . . . . . .33-3360-30

Metric hex nut and stud end for standard pressuretorque values. . . . . . . . . . . . . . . . . . .00-0003-14

Oil coolerRBypass valve, remove and install . . . . .33-3360-83

Oil informationRadiator

R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6Remove and install . . . . . . . . . . . . . . . . .05-0510-1

Operation qualification . . . . . . . . . . . . . . . . . .00-01-1Receiver-dryer

Remove and install . . . . . . . . . . . . . . . .18-1830-17Refrigerant

P Cautions and proper handling . . . . . . . . .18-1830-1Recover R134a, air conditioning . . . . . . .18-1830-8

Park brake Refrigerant oil informationSwing, disassemble . . . . . . . . . . . . . . .43-4360-10 R134a. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6Swing, inspection . . . . . . . . . . . . . . . . .43-4360-12 Refrigerant recovery/recycling and chargingSwing, remove and install . . . . . . . . . . . .43-4360-6 Charging station installationSwing, start-up procedure . . . . . . . . . . .43-4360-16 procedure . . . . . . . . . . . . . . . . . . . . . .18-1830-7

Park brake and travel motor Regulator, hydraulic pumpDisassemble and assemble . . . . . . . . .02-0260-10 Disassemble and assemble . . . . . . . . .33-3360-28Remove and install . . . . . . . . . . . . . . . . .02-0260-2 Remove and install . . . . . . . . . . . . . . . .33-3360-26

Pilot control shut-off lever . . . . . . . . . . . . . . . .00-01-8 Relief valve, crossover, travel motorPilot filter Remove and install . . . . . . . . . . . . . . . .02-0260-15

Remove and install . . . . . . . . . . . . . . . .33-3360-35 Riding machine. . . . . . . . . . . . . . . . . . . . . . . .00-01-9Pilot filter and pilot pressure regulating valve R134a refrigerant recovery . . . . . . . . . . . . .18-1830-8

Remove and install . . . . . . . . . . . . . . . .33-3360-35 R134a refrigerant recovery and charging stationPilot pressure regulating valve and filter Installation procedure . . . . . . . . . . . . . . .18-1830-7

Remove and install . . . . . . . . . . . . . . . .33-3360-35 R134a system charge. . . . . . . . . . . . . . . .18-1830-10Pilot pump R134a system evacuate . . . . . . . . . . . . . . .18-1830-9

Disassemble and assemble . . . . . . . . .33-3360-32Drive shaft, remove and install . . . . . . .33-3360-34Remove and install . . . . . . . . . . . . . . . .33-3360-30 S

Pilot shutoff solenoid valveDisassemble and assemble . . . . . . . . .33-3360-38 Safety

Operator’s seat . . . . . . . . . . . . . . . . . . . . . .00-01-7Remove and install . . . . . . . . . . . . . . . .33-3360-36


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Index

Page Page

Welding repairs . . . . . . . . . . . . . . . . . . . . .00-01-14 Lower seal install . . . . . . . . . . . . . . . . .43-4350-20Remove and install . . . . . . . . . . . . . . . .43-4350-14Safety equipment . . . . . . . . . . . . . . . . . . . . . .00-01-2

Safety information Upper seal, install . . . . . . . . . . . . . . . . .43-4350-19Swing gearboxRecognizing . . . . . . . . . . . . . . . . . . . . . . . .00-01-1

Safety instructions . . . . . . . . . . . . . . . . . . . . .00-01-1 Disassemble and assemble . . . . . . . . . .43-4350-4Safety symbols . . . . . . . . . . . . . . . . . . . . . . . .00-01-1 Remove and install . . . . . . . . . . . . . . . . .43-4350-1

IndxSeal, Start-up procedure . . . . . . . . . . . . . . . .43-4350-115Swing bearing lower, install. . . . . . . . . .43-4350-20 Swing motor

Swing bearing upper, install . . . . . . . . .43-4350-19 Assemble . . . . . . . . . . . . . . . . . . . . . . .43-4360-14Disassemble . . . . . . . . . . . . . . . . . . . . .43-4360-10Seals

Remove and install . . . . . . . . . . . . . . . .33-3340-14 Inspection . . . . . . . . . . . . . . . . . . . . . . .43-4360-12Remove and install . . . . . . . . . . . . . . . . .43-4360-6Seals, metal face

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Start-up procedure . . . . . . . . . . . . . . . .43-4360-16Swing park brake release valveSeat

Air suspension, disassemble and Remove and install . . . . . . . . . . . . . . . .43-4360-19assemble. . . . . . . . . . . . . . . . . . . . . . .18-1821-4

Mechanical suspension, disassemble andassemble. . . . . . . . . . . . . . . . . . . . . . .18-1821-3

TRemove and install . . . . . . . . . . . . . . . . .18-1821-1Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7

Remove and install . . . . . . . . . . . . . . . . .18-1821-2 Tank, hydraulic oilApply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1Service recommendation

Inch series four bolt flange fitting for high Tip overAvoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20

O-ring boss fitting in aluminum housing— Torque valueFlared connections . . . . . . . . . . . . . . . .00-0003-10excavators . . . . . . . . . . . . . . . . . . . . . .00-0003-8

O-ring face seal fittings with inch hex nut and Flat face O-ring seal fitting . . . . . . . . . .00-0003-11Inch SAE four bolt flange fitting. . . . . . .00-0003-19stud end for high pressure. . . . . . . . .00-0003-12

O-ring face seal fittings with metric hex nut and Inch series four bolt flange fitting for highpressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20stud end for high pressure. . . . . . . . .00-0003-16

O-ring face seal fittings with metric hex nut and Metric bolt and cap screw . . . . . . . . . . . .00-0003-1Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-2stud end for standard pressure . . . . .00-0003-14

Servicing machine safely . . . . . . . . . . . . . . .00-01-12 Metric four bolt flange fitting . . . . . . . . .00-0003-18O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6Shutoff solenoid valve, pilot

Remove and install . . . . . . . . . . . . . . . .33-3360-36 O-ring boss fitting in aluminum housing—excavators . . . . . . . . . . . . . . . . . . . . . .00-0003-8Sliding window

Remove and install . . . . . . . . . . . . . . . . .18-1810-1 O-ring face seal fittings with inch hex nut andstud end for high pressure. . . . . . . . .00-0003-12Solenoid valve

Boom flow rate, remove and install . . . .33-3360-46 O-ring face seal fittings with metric hex nut andstud end for high pressure. . . . . . . . .00-0003-16Boom mode, remove and install . . . . . .33-3360-46

Power dig, remove and install . . . . . . . .33-3360-46 O-ring face seal fittings with metric hex nut andstud end for standard pressure . . . . .00-0003-14Travel speed, remove and install . . . . .33-3360-46

Sprocket Unified inch bolt and cap screw . . . . . . .00-0003-430° cone seat hydraulic fittings . . . .00-0003-5Remove and install . . . . . . . . . . . . . . . .01-0130-19

Start-up procedure 37° flare hydraulic fittings . . . . . . . .00-0003-5Track adjusterDrive gearbox . . . . . . . . . . . . . . . . . . . .33-3360-25

Hydraulic pump. . . . . . . . . . . . . . . . . . .33-3360-25 Recoil spring, disassemble andassemble. . . . . . . . . . . . . . . . . . . . . .01-0130-25Travel motor and park brake . . . . . . . . .02-0260-21

Steps use . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7 Recoil spring, remove and install . . . . .01-0130-23Track adjuster cylinderSurge tank

Remove and install . . . . . . . . . . . . . . . .05-0510-24 Disassemble and assemble . . . . . . . . .01-0130-30Track carrier rollerSwing bearing

Disassemble and assemble . . . . . . . . .43-4350-16 Remove and install . . . . . . . . . . . . . . . . .01-0130-6


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Index

Page Page

Track chain Remove and install . . . . . . . . . . . . . . . .33-3360-52Valve, travel speed changeDisassemble and assemble . . . . . . . . .01-0130-16

Remove and install . . . . . . . . . . . . . . . .01-0130-11 Remove and install . . . . . . . . . . . . . . . .02-0260-19Repair . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-17

Track roller . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-5Disassemble and assemble . . . . . . . . . .01-0130-3 WRemove and install . . . . . . . . . . . . . . . . .01-0130-1

Track shoeWaste disposal . . . . . . . . . . . . . . . . . . . . . . . .00-01-6

Remove and install . . . . . . . . . . . . . . . .01-0130-11

Indx6

Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3Travel gearbox

Welding precautions . . . . . . . . . . . . . . . . . .17-1740-1Disassemble and assemble . . . . . . . . . .02-0250-4

Window, slidingRemove and install . . . . . . . . . . . . . . . . .02-0250-1

Remove and install . . . . . . . . . . . . . . . . .18-1810-1Travel motor and park brake

WindowpanesDisassemble and assemble . . . . . . . . .02-0260-10

Dimensions . . . . . . . . . . . . . . . . . . . . . . .18-1810-3Remove and install . . . . . . . . . . . . . . . . .02-0260-2

Remove and install . . . . . . . . . . . . . . . . .18-1810-2Start-up procedure . . . . . . . . . . . . . . . .02-0260-21

Work site hazardsTravel motor, counterbalance valve

Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-9Remove and install . . . . . . . . . . . . . . . .02-0260-13

Travel pilot valveDisassemble and assemble . . . . . . . . .33-3360-54Remove and install . . . . . . . . . . . . . . . .33-3360-52

Travel speed change valveRemove and install . . . . . . . . . . . . . . . .02-0260-19

Travel speed solenoid valveRemove and install . . . . . . . . . . . . . . . .33-3360-46

U

UpperstructureRemove and install . . . . . . . . . . . . . . . .43-4350-11

V

ValveCrossover relief, remove and install . . .43-4360-17Make-up check, disassemble . . . . . . . .43-4360-18Make-up check, remove and install . . . .43-4360-17Pilot pressure regulating, disassemble and

assemble. . . . . . . . . . . . . . . . . . . . . .33-3360-36Swing park brake release, remove and

install . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-19Valve, control

Remove and install . . . . . . . . . . . . . . . .33-3360-61Valve, pilot pressure regulating

Remove and install . . . . . . . . . . . . . . . .33-3360-35Valve, pilot shutoff solenoid

Disassemble and assemble . . . . . . . . .33-3360-38Remove and install . . . . . . . . . . . . . . . .33-3360-36

Valve, travel pilotDisassemble and assemble . . . . . . . . .33-3360-54


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160D Repair

Documents

Transcript of 160D Repair