200clc, 230clc, and 270clc Repair Tm1931

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200CLC 230CLC and 270CLC Excavator Repair
TECHNICAL MANUAL 200CLC, 230CLC, and 270CLC Excavator Repair

TM1931 09JAN04 (ENGLISH)
For complete service information also see: 200CLC, 230CLC, and 270CLC Excavator Operation and Tests . . . . . . . . . . . . . . . . . . . POWERTECH 4.5 L & 6.8 L (4045 and 6068) Diesel Engines, Base Engine . . . . . . . . . . . . POWERTECH 4.5 L & 6.8 L (4045 and 6068) Diesel Engines, Level 4 Electronic Fuel Systems with Bosch VP44 Pump . . . . . . . . . Alternators and Starting Motors . . . . . . . . . . Undercarriage Appraisal Manual . . . . . . . . . TM1930 CTM104
CTM170 CTM77 SP326
Worldwide Construction And Forestry Division

LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
DX,TMIFC 1929SEP981/1
TM1931 (09JAN04)
200CLC, 230CLC & 270CLC Excavator Repair

010904
PN=2
Introduction
Technical Information Feedback Form

We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.
SEND TO: John Deere Dubuque Works P.O. Box 538 Attn: Publications Supervisor, Dept. 303 Dubuque, IA 52004-0538 563-589-5800
FAX NUMBER:
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Company Name: Technician Name: Address: Phone: Fax No.: Dealer Acct. No.: THANK YOU!
TX,TM,FAX 1919JUN001/1
TM1931 (09JAN04)

010904
PN=3
Introduction
TM1931 (09JAN04)

010904
PN=4
Contents
00
SECTION 00General Information Group 0001Safety Group 0003Torque Values SECTION 01Tracks Group 0130Track System SECTION 02Axles and Suspension Systems (Propel) Group 0250Axle Shaft, Bearings, and Reduction Gears Group 0260Hydraulic System SECTION 04Engine Group 0400Removal and Installation SECTION 05Engine Auxiliary System Group 0510Cooling System Group 0520Intake System Group 0560External Fuel Supply System SECTION 07Dampener Drive (Flex Coupling) Group 0752Elements SECTION 17Frame or Supporting Structure Group 1740Frame Installation Group 1749Chassis Weights SECTION 18Operators Station Group 1800Removal and Installation Group 1810Operator Enclosure Group 1821Seat and Seat Belt Group 1830Heating and Air Conditioning SECTION 33Excavator Group 3302Buckets Group 3340Frames Group 3360Hydraulic System SECTION 43Swing or Pivoting System Group 4350Mechanical Drive Elements Group 4360Hydraulic System SECTION 99Dealer Fabricated Tools Group 9900Dealer Fabricated Tools
33 04 01
02
05
07
17
18
All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
COPYRIGHT 2004 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 2001
43
TM1931 (09JAN04)

010904
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Contents
00
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02
04
05
07
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TM1931 (09JAN04)
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INDX
TM1931 (09JAN04)
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00
Section 00
General Information
Contents
Page
Group 0001Safety . . . . . . . . . . . . . . . . . .00-0001-1 Group 0003Torque Values Unified Inch Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1 Metric Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2 Additional Metric Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3 Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-5 Service Recommendations for O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6 Service Recommendations for Flat Face O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-8 Service Recommendations for 37 Flare and 30 Cone Seat Connectors . . . . . . . . .00-0003-9 Service Recommendations For Flared ConnectionsStraight or Tapered Threads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10 Service Recommendations For Inch Series Four Bolt Flange Fittings. . . . . . . .00-0003-11 Service Recommendations for Metric Series Four Bolt Flange Fitting . . . . . . . .00-0003-12
TM1931 (09JAN04)
00-1

010904
PN=1
Contents
00
TM1931 (09JAN04)
00-2

010904
PN=2
Group 0001
Safety
Recognize Safety Information
UN28AUG00
00 0001 1
This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word DANGER, WARNING, or CAUTION is used with the safety alert symbol. DANGER identifies the most serious hazards. On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
TX03679,00016CC 1921AUG001/1
Follow Safety Instructions

UN24AUG00
Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Be sure all operators of this machine understand every safety message. Replace operators manual and safety labels immediately if missing or damaged.
TX03679,00016F9 1928AUG001/1
Operate Only If Qualified

Do not operate this machine unless you have read the operators manual carefully and you have been qualified by supervised training and instruction. Familiarize yourself with the job site and your surroundings before operating. Try all controls and machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to your work situation and your work site.
TX03679,00016FA 1930OCT001/1
TM1931 (09JAN04)
00-0001-1

010904
PN=9
T133556
T133588
1928AUG00
T133555
Safety
00 0001 2
Wear Protective Equipment

Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
TX03679,00016D0 1930OCT001/1
Avoid Unauthorized Machine Modifications

Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.
TX03679,00016B7 1930OCT001/1
Add Cab Guarding For Special Uses

Special work situations or machine attachments may create 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 the operator. FOPS (falling object protective structures) and special screens or guarding should be installed when falling or flying objects may enter or damage the machine. Contact your authorized dealer for information on devices intended to provide protection in special work situations.
UN15SEP00
TX03679,00016CE 1930OCT001/1
TM1931 (09JAN04)
00-0001-2

010904
PN=10
T133733
TS206
UN23AUG88
Safety
Inspect Machine
Inspect machine carefully each day by walking around it before starting.
UN18OCT88
00 0001 3
Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.
TX03679,0001734 1925SEP001/1
Stay Clear Of Moving Parts

Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.
UN12SEP01
TX03679,00016D2 1930OCT001/1
Avoid High-Pressure Fluids

This machine uses a high-pressure hydraulic system. Escaping fluid under pressure can penetrate the skin causing serious injury. Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping fluid. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system. If hydraulic fluid penetrates your skin, see a doctor immediately. Injected fluid must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.
TX03679,00016D3 1930OCT001/1
TM1931 (09JAN04)
00-0001-3

010904
PN=11
T133840
UN20SEP00
T133509
UN31OCT00
T133592
T6607AQ
Safety
00 0001 4
Beware Of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.
TX03679,00016D4 1914SEP001/1
Prevent Fires
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines and electrical wiring. Never store oily rags or flammable materials inside a machine compartment. Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage. Keep A Fire Extinguisher Available: Always keep a multi-purpose fire extinguisher on or near the machine. Know how to use extinguisher properly.
UN14SEP00
TX03679,00016F5 1925SEP001/1
Prevent Battery Explosions

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 object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16C (60F).
TX03679,000174A 1914SEP001/1
TM1931 (09JAN04)
00-0001-4

010904
PN=12
TS204
UN23AUG88
T133554
UN07SEP00
T133553
UN07SEP00
T133552
T133546
UN24AUG00
Safety
Handle Chemical Products Safely

UN25AUG00
00 0001 5
Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous. If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS). The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely.
TX03679,00016D7 1914SEP001/1
Dispose Of Waste Properly

UN25AUG00
Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly. Never pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants. If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for more information.
TX03679,0001733 1914SEP001/1
Prepare For Emergencies

Be prepared if an emergency occurs or a fire starts. Keep a first aid kit and fire extinguisher handy.
UN23AUG88
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
TX03679,000174B 1914SEP001/1
TM1931 (09JAN04)
00-0001-5

010904
PN=13
TS291
T133567
T133580
Safety
00 0001 6
Use Steps And Handholds Correctly

UN30AUG00
Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds. Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.
TX03679,00016F2 1914SEP001/1
Start Only From Operators Seat

Avoid unexpected machine movement. Start engine only while sitting in operators seat. Ensure all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.
UN07SEP00
TX03679,0001799 1902MAY011/1
Use And Maintain Seat Belt

1914SEP00
Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly. The complete seat belt assembly should be replaced every three years, regardless of appearance.
TX03679,00016DD 1917OCT001/1
TM1931 (09JAN04)
00-0001-6

010904
PN=14
T133716
T133715
T133468
Safety
Prevent Unintended Machine Movement

Be careful not to accidentally actuate control levers when co-workers are present. Pull pilot control shut-off lever to locked position during work interruptions. Pull pilot control shut-off lever to locked position and stop engine before allowing anyone to approach machine. Always lower work equipment to the ground and pull pilot control shut-off lever to locked position before standing up or leaving the operators seat. Stop engine before exiting.
UN20SEP00
00 0001 7
TX03679,0001746 1930OCT001/1
Avoid Work Site Hazards

Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before you dig. Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or arm contact with overhead obstacles or overhead electrical lines. Never move any part of machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires. Keep bystanders clear at all times. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Operate only on solid footing with strength sufficient to support machine. When working close to an excavation, position propel motors away from the hole.
TX03679,0001748 1930OCT001/1
TM1931 (09JAN04)
00-0001-7

010904
PN=15
T133549
UN24AUG00
T133650
UN27SEP00
T134986
UN31OCT00
T133863
Safety
00 0001 8
Keep Riders Off Machine

Only allow operator on machine. Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operators view or impair his ability to operate machine safely.
TX03679,0001726 1914SEP001/1
Avoid Backover Accidents

Before moving machine, be sure all persons are clear of both travel and swing paths. Turn around and look directly for best visibility. Use mirrors to assist in checking all 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 is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.
TX03679,00016F3 1914SEP001/1
TM1931 (09JAN04)
00-0001-8

010904
PN=16
T133548
UN24AUG00
T7273AH
UN08JUN90
Safety
Avoid Machine Tip Over

1914SEP00
00 0001 9
Use seat belt at all times. Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you. Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps. Properly attach ramps to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel. Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these conditions. When traveling up or down slopes, keep the bucket on uphill side and just above ground level. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy load or swinging it over side of undercarriage may cause machine to tip. Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or fall.
TX03679,00016DF 1912APR011/1
Use Special Care When Lifting Objects

UN27SEP00
Never use this machine to lift people. Never lift a load above another person. Keep bystanders clear 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 and in this manual. Extending heavy loads too far or swinging over undercarriage side may cause machine to tip over. Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good condition. Use tether lines to guide loads and prearranged hand signals to communicate with co-workers.
TX03679,00016E1 1902OCT001/1
TM1931 (09JAN04)
00-0001-9

010904
PN=17
T133839
T133803
UN27SEP00
T133545
UN15SEP00
T133716
Safety
00 0001 10
Add And Operate Attachments Safely

Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability, and may create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. Verify that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.
TX03679,00016F0 1914SEP001/1
Park And Prepare For Service Safely

Warn others of service work. Always park and prepare your machine for service or repair properly. Park machine on a level surface and lower equipment to the ground. Place pilot control shut-off lever in lock position. Stop engine and remove key. Attach a Do Not Operate tag in an obvious place in the operators station. Securely support machine or equipment before working under it. Do not support machine with boom, arm, or other hydraulically actuated attachments. Do not support machine with cinder blocks or wooden pieces that may crumble or crush. Do not support machine with a single jack or other devices that may slip out of place. Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.
1914DEC01
TX03679,00016E9 1912APR011/1
TM1931 (09JAN04)
00-0001-10

010904
PN=18
TS229
UN23AUG88
T133332
Safety
Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
00 0001 11
DX,RCAP 1904JUN901/1
Remove Paint Before Welding or Heating

Hazardous fumes can be generated when paint is heated by welding or using a torch. Dust from sanding or grinding paint can also be hazardous. Remove paint to at least 76 mm (3 in.) from area to be heated. Wear an approved respirator when sanding or grinding paint. If a solvent or paint stripper is used, wash area with soap and water. Remove solvent or paint stripper containers from work area and allow fumes to disperse at least 15 minutes before welding or heating. Work outside or in a well-ventilated area. Dispose of waste, paint and solvents properly.
TX03679,0001732 1906SEP001/1
Make Welding Repairs Safely

UN31AUG00
NOTE: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors.
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.
TX03679,00016D5 1902OCT001/1
TM1931 (09JAN04)
00-0001-11

010904
PN=19
T133547
T133546
UN24AUG00
TS281
UN23AUG88
Safety
00 0001 12
Drive Metal Pins Safely

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.
UN14SEP00
TX03679,0001745 1925SEP001/1
TM1931 (09JAN04)
00-0001-12

010904
PN=20
T133738
Safety
Safety Signs
00 0001 13
TX14740,0001D0E 1909APR011/1
TM1931 (09JAN04)
00-0001-13

010904
PN=21
T141213
1917APR01
Safety
00 0001 14
TM1931 (09JAN04)
00-0001-14

010904
PN=22
Group 0003
Torque Values
Unified Inch Bolt and Cap Screw Torque Values
00 0003 1
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark) Size 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
a
Grade 2a (No Mark) Lubricatedb Nm(lb-ft) 6 (4.4) 12 (9) 22 (16) 35 (26) 53 (39) 76 (56) 105 (77) 190 (140) 190 (140) 285 (210) 400 (300) 570 (420) 750 (550) 990 (730) Dryc Nm(lb-ft) 7.5 (5.5) 15.5 (11.5) 27.5 (20) 44 (32.5) 67 (49) 95 (70) 135 (100) 240 (175) 240 (175) 360 (265) 510 (375) 725 (535) 950 (700) 1250 (930)
Grade 5, 5.1 or 5.2 Lubricatedb Nm(lb-ft) 9.5 (7) 19.5 (14.5) 35 (26) 56 (41) 85 (63) 125 (92) 170 (125) 300 (220) 490 (360) 730 (540) 910 (670) 1280 (945) 1700 (1250) 2250 (1650) Dryc Nm(lb-ft) 12 (9) 25 (18.5) 44 (32.5) 70 (52) 110 (80) 155 (115) 215 (160) 380 (280) 615 (455) 920 (680) 1150 (850) 1630 (1200) 2140 (1580) 2850 (2100)
Grade 8 or 8.2 Lubricatedb Nm(lb-ft) 13.5 (10) 28 (20.5) 49 (36) 80 (59) 120 (88) 175 (130) 240 (175) 425 (315) 690 (510) 1030 (760) 1450 (1075) 2050 (1500) 2700 (2000) 3600 (2650) Dryc Nm(lb-ft) 17 (12.5) 35 (26) 63 (46) 100 (74) 155 (115) 220 (165) 305 (225) 540 (400) 870 (640) 1300 (960) 1850 (1350) 2600 (1920) 3400 (2500) 4550 (3350)
Lubricatedb Nm(lb-ft) 3.8 (2.8) 7.7 (5.7) 13.5 (10) 22 (16) 34 (25) 48 (35.5) 67 (49) 120 (88) 190 (140) 285 (210) 400 (300) 570 (420) 750 (550) 990 (730)
Dryc Nm(lb-ft) 4.7 (3.5) 9.8 (7.2) 17.5 (13) 28 (20.5) 42 (31) 60 (45) 85 (63) 150 (110) 240 (175) 360 (265) 510 (375) 725 (535) 950 (700) 1250 (930)
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 c
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. "Dry" means plain or zinc plated without any lubrication.
Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.
DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.
DX,TORQ1 1901OCT991/1
TM1931 (09JAN04)
00-0003-1

010904
PN=23
TORQ1A
UN27SEP99
Torque Values
00 0003 2
Metric Bolt and Cap Screw Torque Values
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8 Size M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36
a b
Class 8.8 or 9.8 Lubricateda Nm(lb-ft) 9 (6.6) 22 (16) 43 (32) 75 (55) 120 (88) 190 (140) 265 (195) 375 (275) 510 (375) 650 (480) 950 (700) 1290 (950) 1750 (1300) 2250 (1650) Dryb Nm(lb-ft) 11.5 (8.5) 28 (20.5) 55 (40) 95 (70) 150 (110) 240 (175) 330 (245) 475 (350) 650 (480) 820 (600) 1200 (885) 1630 (1200) 2200 (1625) 2850 (2100)
Class 10.9 Lubricateda Nm(lb-ft) 13 (9.5) 32 (23.5) 63 (46) 110 (80) 175 (130) 275 (200) 375 (275) 530 (390) 725 (535) 920 (680) 1350 (1000) 1850 (1350) 2500 (1850) 3200 (2350) Dryb Nm(lb-ft) 16.5 (12.2) 40 (29.5) 80 (59) 140 (105) 220 (165) 350 (255) 475 (350) 675 (500) 920 (680) 1150 (850) 1700 (1250) 2300 (1700) 3150 (2325) 4050 (3000)
Class 12.9 Lubricateda Nm(lb-ft) 15.5 (11.5) 37 (27.5) 75 (55) 130 (95) 205 (150) 320 (235) 440 (325) 625 (460) 850 (625) 1080 (800) 1580 (1160) 2140 (1580) 2900 (2150) 3750 (2770) Dryb Nm(lb-ft) 19.5 (14.5) 47 (35) 95 (70) 165 (120) 260 (190) 400 (300) 560 (410) 790 (580) 1080 (800) 1350 (1000) 2000 (1475) 2700 (2000) 3700 (2730) 4750 (3500)
Lubricateda Nm(lb-ft) 4.7 (3.5) 11.5 (8.5) 23 (17) 40 (29.5) 63 (46) 100 (74) 135 (100) 190 (140) 265 (195) 330 (245) 490 (360) 660 (490) 900 (665) 1150 (850)
Dryb Nm(lb-ft) 6 (4.4) 14.5 (10.7) 29 (21) 50 (37) 80 (59) 125 (92) 170 (125) 245 (180) 330 (245) 425 (315) 625 (460) 850 (625) 1150 (850) 1450 (1075)
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. "Dry" means plain or zinc plated without any lubrication.
Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.
DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.
Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.
DX,TORQ2 1901OCT991/1
TM1931 (09JAN04)
00-0003-2

010904
PN=24
TORQ2
UN07SEP99
Torque Values
Additional Metric Cap Screw Torque Values

CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when tightening. Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.
UN18OCT88
00 0003 3
Continued on next page
04T,90,M170 1929SEP991/2
TM1931 (09JAN04)
00-0003-3

010904
PN=25
T6873AC
UN18OCT88
T6873AB
UN18OCT88
T6873AA
Torque Values
00 0003 4 Nominal Dia 8 10 12 14 16 18 20 22 24 27 30 33 36
a
METRIC CAP SCREW TORQUE VALUESa T-Bolt Nm 29 63 108 176 265 392 539 735 931 1372 1911 2548 3136 46 80 130 195 289 398 542 687 1012 1410 1890 2314 lb-ft 21 H-Bolt Nm 20 45 88 137 206 294 392 539 686 1029 1421 1911 2401 lb-ft 15 33 65 101 152 217 289 398 506 759 1049 1410 1772 M-Bolt Nm 10 20 34 54 78 118 167 216 274 392 539 735 931 7 15 25 40 58 87 125 159 202 289 398 542 687 lb-ft
Torque tolerance is 10%.
04T,90,M170 1929SEP992/2
TM1931 (09JAN04)
00-0003-4

010904
PN=26
Torque Values
Check Oil Lines And Fittings

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately. Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings.
00 0003 5
TX,90,DH1559 1901AUG941/1
TM1931 (09JAN04)
00-0003-5

010904
PN=27
X9811
UN23AUG88
Torque Values
00 0003 6
Service Recommendations for O-Ring Boss Fittings

Straight Fitting
UN18OCT88
1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart.
04T,90,K66 1929SEP991/2
TM1931 (09JAN04)
00-0003-6

010904
PN=28
T6243AE
Torque Values
Angle Fitting 1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.
UN18OCT88
00 0003 7
2. Turn fitting into threaded boss until back-up washer contacts face of boss. 3. Turn fitting head-end counterclockwise to proper index (maximum of one turn).
NOTE: Do not allow hoses to twist when tightening fittings.

4. Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size 3/8-24 UNF 7/16-20 UNF 1/2-20 UNF 9/16-18 UNF 3/4-16 UNF 7/8-14 UNF 1-1/16-12 UN 1-3/16-12 UN 1-5/16-12 UN 1-5/8-12 UN 1-7/8-12 UN Nm 8 12 16 24 46 62 102 122 142 190 217 lb-ft 6 9 12 18 34 46 75 90 105 140 160
NOTE: Torque tolerance is 10%.
04T,90,K66 1929SEP992/2
TM1931 (09JAN04)
00-0003-7

010904
PN=29
T6520AB
Torque Values
00 0003 8
Service Recommendations for Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring. It must be free of damage or defects. 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place. 4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly. 5. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 6. Tighten fitting or nut to torque value shown on the chart per dash size stamped on the fitting. Do not allow hoses to twist when tightening fittings.
FLAT FACE O-RING SEAL FITTING TORQUE Nominal Tube O.D. mm 6.35 9.52 12.70 15.88 19.05 22.22 25.40 31.75 38.10 0.250 0.375 0.500 0.625 0.750 0.875 1.000 1.250 1.500 in. -4 -6 -8 -10 -12 -14 -16 -20 -24 Dash Size Nm Thread Size in. lb-ft 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 3/16-12 1 7/16-12 1 11/16-12 2-12 16 24 50 69 102 102 142 190 217 Nm 12 18 37 51 75 75 105 140 160 Swivel Nut lb-ft 5.0 9.0 17.0 17.0 17.0 17.0 17.0 17.0 17.0 3.5 6.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 Bulkhead Nut
UN18OCT88
NOTE: Torque tolerance is +15 -20%.
04T,90,K67 1929SEP991/1
TM1931 (09JAN04)
00-0003-8

010904
PN=30
T6243AD
Torque Values
Service Recommendations for 37 Flare and 30 Cone Seat Connectors

1. Inspect flare and flare seat. They must be free of dirt or obvious defects. 2. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align tube with fitting before attempting to start nut. 4. Lubricate male threads with hydraulic fluid or petroleum jelly. 5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size 3/8 - 24 UNF 7/16 - 20 UNF 1/2 - 20 UNF 9/16 - 18 UNF 3/4 - 16 UNF 7/8 - 14 UNF 1-1/16 - 12 UN 1-3/16 - 12 UN 1-5/16 - 12 UN 1-5/8 - 12 1-7/8 - 12 UN Nm 8 12 16 24 46 62 102 122 142 190 217 lb-ft 6 9 12 18 34 46 75 90 105 140 160
UN18OCT88
00 0003 9
NOTE: Torque tolerance is 10%.
T82,BHMA,EL 1929SEP991/1
TM1931 (09JAN04)
00-0003-9

010904
PN=31
T6234AC
Torque Values
00 0003 10
Service Recommendations For Flared ConnectionsStraight or Tapered Threads

1. Inspect flare and flare seat. They must be free of dirt or obvious defects. 2. Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align the tube with the fitting before attempting to start the nut.
Straight Thread
UN18OCT88
4. Lubricate the male threads with hydraulic fluid or petroleum jelly. 5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings.
TORQUE CHART Straight Thread Thread Size 1/8 1/4 3/8 1/2 3/4 1 1-1/2 2
a b b a
Tapered Thread Nm lb-ft
Nm 15 20 29 49 69 157 196 255
lb-ft 11 15 21 36 51 116 145 188
Tapered Thread
45 69 93 176 343 539 588
33 51 69 130 253 398 434
Torque tolerance is 10%. With seat face.
NOTE: If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced approximately 10%.
04T,90,M171 1928JAN921/1
TM1931 (09JAN04)
00-0003-10

010904
PN=32
T6873AD
UN18OCT88
T6873AE
Torque Values
Service Recommendations For Inch Series Four Bolt Flange Fittings
00 0003 11
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange TORQUE CHART Nm lb-ft
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
Nominal Flange Size 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5
Cap Screw Size Min 5/16-18 UNC 3/8-16 UNC 3/8-16 UNC 7/16-14 UNC 1/2-13 UNC 1/2-13 UNC 1/2-13 UNC 5/8-11 UNC 5/8-11 UNC 5/8-11 UNC 5/8-11 UNC 20 28 37 47 62 73 107 158 158 158 158 Max 31 54 54 85 131 131 131 264 264 264 264 Min 15 21 27 35 46 54 79 117 117 117 117 Max 23 40 40 63 97 97 97 195 195 195 195
04T,90,K174 1901AUG941/1
TM1931 (09JAN04)
00-0003-11

010904
PN=33
T6890BB
UN01MAR90
Torque Values
00 0003 12
Service Recommendations for Metric Series Four Bolt Flange Fitting
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw,
a
then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
TORQUE CHARTa Thread M6 M8 M10 M12 M14 M16 M18 M20
b
Nm 12 30 57 95 157 217 334 421
lb-ft 9 22 42 70 116 160 246 318
Tolerance 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures.
b
Metric standard thread.
04T,90,K175 1929SEP991/1
TM1931 (09JAN04)
00-0003-12

010904
PN=34
T6890BB
UN01MAR90
Section 01
Tracks
Contents
Page 01
Group 0130Track System Track Roller, Front Idler, and Carrier Roller Oil . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-1 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-1 Track Carrier Roller. . . . . . . . . . . . . . . . . . . .01-0130-5 Metal Face Seals Repair . . . . . . . . . . . . . . . .01-0130-8 Track Shoe . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-9 Track Chain. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-10 Broken Track Chain Part Repair . . . . . . . . .01-0130-13 Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-14 Front Idler . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-16 Track Adjuster and Recoil Spring . . . . . . . .01-0130-19 Track Adjuster Cylinder . . . . . . . . . . . . . . . .01-0130-25
TM1931 (09JAN04)
01-1

010904
PN=1
Contents
01
TM1931 (09JAN04)
01-2

010904
PN=2
Group 0130
Track System
Track Roller, Front Idler, and Carrier Roller Oil
Use SAE 30 oil meeting API Service GL-5 (MIL-L-2105E).
TX,45,DH5142 1906NOV011/1
01 0130 1
Track Roller Repair

Remove and Install Track Roller 1. Swing upperstructure 90 and lower bucket to raise track off ground. Keep angle between boom and arm 90110 and position round side of bucket on ground. CAUTION: Prevent possible injury from unexpected machine movement. Put shop stands under frame to support machine while removing lower track roller.
Track RollerSpecification Machine (200CLC)Weight.................................... 20 298 kg (44,750 lb) approximate Machine (230CLC)Weight.................................... 23 773 kg (52,410 lb) approximate Machine (270CLC)Weight.................................... 26 082 kg (57,500 lb) approximate
2. Place shop stands under machine.
OUOE049,0000063 1919NOV011/6
CAUTION: Prevent possible injury from high pressure grease. Do not remove grease fitting (A) from valve (B). 3. Loosen valve (B) one to two turns to release grease through bleed hole (C).
AGrease Fitting BValve CBleed Hole
OUOE049,0000063 1919NOV012/6
TM1931 (09JAN04)
01-0130-1

010904
PN=37
T7396DZ
UN28NOV90
Track System
CAUTION: Heavy component; use a hoist.

Track RollerSpecification Track Roller (200CLC and 230CLC)Weight.............................................. 35 kg (77 lb) approximate Track Roller (270CLC)Weight...................... 54 kg (120 lb) approximate
4. Attach hoist to track roller (B). Remove cap screws (A) and track roller (B). 5. Measure track roller tread diameter. See 200CLC Track Roller Tread Diameter, 230CLC Track Roller Tread Diameter, or 270CLC Track Roller Tread Diameter. (SP326 Undercarriage Appraisal Manual.) 6. Repair or replace parts as necessary. 7. Tighten cap screws.
Track RollerSpecification Roller-to-Frame Cap Screw (200CLC and 230CLC)Torque................................. 460 Nm (340 lb-ft) Roller-to-Frame Cap Screw (270CLC)Torque ...................................................... 670 Nm (490 lb-ft)
ACap Screw (4 used) BTrack Roller
8. If applicable, install rock guard and tighten cap screws.

Track RollerSpecification Rock Guard Cap Screw (200CLC and 230CLC)Torque ................................................ 460 Nm (340 lb-ft) Rock Guard Cap Screw (270CLC)Torque ...................................................... 670 Nm (490 lb-ft)
9. Check and Adjust Track Sag. (Operators Manual.)
OUOE049,0000063 1919NOV013/6
TM1931 (09JAN04)
01-0130-2

010904
PN=38
T6585TN
UN25OCT88
01 0130 2
Track System
01 0130 3
APlug (2 used) BBracket (2 used)
CPin (2 used) DO-Ring (2 used)
EMetal Face Seal (2 used) FBushing (2 used)
GRoller HAxle
Disassemble and Assemble Track Roller 1. Remove plug (A) and drain oil. 2. Remove pin (C). 3. Remove bracket (B) using a bearing puller attachment and adapters from puller set. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face. 4. Remove metal face seal (E) from roller and bracket. Keep seal rings together as a matched set with seal ring faces together to protect surfaces. 5. Inspect metal face seals. See Metal Face Seals Repair. (See procedure in this group.) For seals that will be reused, put a piece of cardboard between seal rings to protect seal face. 6. Remove axle (H) from roller.
NOTE: Only remove bushing if replacement is necessary.

7. Remove bushing (F) using a 2 jaw puller and adapters 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 for O-rings must be clean, dry, and oil free so O-rings do not slip when roller is turning. 9. Thoroughly clean O-rings and seat surfaces in brackets (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 equally spaced points on seal face. Seal must pop down into place so O-ring is tight against seal bore. A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant.
OUOE049,0000063 1919NOV014/6
TM1931 (09JAN04)
01-0130-3

010904
PN=39
T8310AH
UN21SEP94
Track System
11. Wipe finger prints and foreign material off seal ring face using clean oil and lint-free tissues. Apply a thin film of oil to each seal ring face.
01 0130 4
15. Fill roller with 260 mL (8.8 oz) of oil. 16. Apply cure primer and pipe sealant to threads of plug. Install and tighten plug.
Track RollerSpecification PlugTorque ......................................................... 20 Nm (177 lb-in.)
12. Apply a thin layer of NEVER-SEEZ anti-seize lubricant or an equivalent to pin (C). Install pin even with flat surface of bracket. 13. Install axle to bracket. 14. Apply NEVER-SEEZ anti-seize lubricant or equivalent to pin (C). Install pin even with flat surface of bracket.
NEVER-SEEZ is a trademark of Emhart Chemical Group.
OUOE049,0000063 1919NOV015/6
Test Track Roller for Oil Leakage 1. Hold the shaft and turn shell several turns to seat metal face seals.
UN02JUN97
2. Remove the plug. 3. Install parts (AF). Plug, barbed adapter and connector are from a leak detector kit such as the D05361ST Rubber Stopper/Leak Detector Kit. 4. Holding plug so it is not pushed out, slowly pressurize oil cavity using air.
Track RollerSpecification Oil Cavity Air TestPressure ................ 110 18 kPa (1.1 0.3 bar) (16 4 psi) APlug, Barbed Adapter and Connector BJT03001 Tee Fitting 7/16-20 M 37 x 7/16-20 F 37 SW x 7/16-20 M 37 CHose (2 used) DPressure Gauge ESnubber (Needle) Valve FAir Pressure Regulator
5. Close valve and wait for a minimum of 30 seconds. Check for oil leakage. Check gauge to see if air pressure has decreased. 6. If there is leakage, disassemble roller and replace parts as necessary. 7. Apply cure primer and pipe sealant to threads. Install plug.
OUOE049,0000063 1919NOV016/6
TM1931 (09JAN04)
01-0130-4

010904
PN=40
T109691B
Track System
Track Carrier Roller Repair

Remove and Install Track Carrier Roller CAUTION: Prevent possible injury from high pressure grease. Do not remove grease fitting (A) from valve (B). 1. Loosen valve (B) one to two turns to release grease through bleed hole (C). 2. Raise track link, using a jack, enough to permit carrier roller removal. CAUTION: Prevent accidental lowering of track by securely supporting track before attempting service procedure. 3. Install wooden blocks between track link and frame.
01 0130 5
OUOE049,0000064 1919NOV011/4
4. Remove cap screws (B) and carrier roller (A). 5. Measure track carrier roller tread diameter. See 200CLC Carrier Roller Tread Diameter, 230CLC Carrier Roller Tread Diameter, or 270CLC Carrier Roller Tread Diameter. (SP326 Undercarriage Appraisal Manual.) 6. Repair or replace parts as necessary. 7. Install carrier roller and tighten cap screws (B).
Track Carrier RollerSpecification Roller-to-Frame Cap Screw Torque ......................................................................... 270 Nm (200 lb-ft)
ACarrier Roller BCap Screw
8. Check and Adjust Track Sag. (Operators Manual.)
OUOE049,0000064 1919NOV012/4
TM1931 (09JAN04)
01-0130-5

010904
PN=41
T6557DK
UN25OCT88
T7396DZ
UN28NOV90
Track System
01 0130 6
APlug BCover
CCap Screw (2 used) DThrust Washer
EBushing FRoller
GMetal Face Seal HSupport
Disassemble and Assemble Track Carrier Roller 1. Remove plug (A) and drain oil. 2. Remove cap screws (C) through oil plug drain hole. 3. Remove roller (F) from support (H).
IMPORTANT: Replace entire roller assembly if bushing (E) and shaft surfaces are damaged. Bushing (E) is no longer serviceable because cover (B) cannot be removed. 4. Inspect bushing (E) and shaft on support (H).
Continued on next page OUOE049,0000064 1919NOV013/4
TM1931 (09JAN04)
01-0130-6

010904
PN=42
T114725
UN30APR98
Track System
IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face. 5. Remove metal face seal (G). 6. Inspect metal face seal. See Metal Face Seals Repair. (See procedure in this group.) For seals that will be reused, put a piece of cardboard between seal rings to protect seal face. 7. Replace parts as necessary. IMPORTANT: O-rings may slip when roller is turning if O-rings and seat surfaces are not clean, dry and oil free. 8. Thoroughly clean the O-rings and seat surfaces in roller, support, and seal bushings using a volatile, non-petroleum base solvent and lint-free tissue. 9. Install O-ring on seal rings.
A volatile, non-petroleum base solvent or talcum power may be used as a lubricant.

10. Install one half of metal face seal into support (H). 11. Apply a thin coat of oil to the metal faces on each half of the seal. 12. Install the other half of metal face seal on the half already in place in support (H). 13. Install roller (F) over shaft on support (H) being sure to keep cap screws (C) in alignment with holes on shaft. 14. Tighten cap screws (C).
Track Carrier RollerSpecification Thrust Washer-to-Support Shaft Cap ScrewTorque ................................................. 64 Nm (47 lb-ft) 01 0130 7
15. For 200CLC and 230CLC, fill carrier roller with 70 mL (0.018 gal) of clean oil through plug (A) hole. For 270CLC, fill carrier roller with 75 mL (0.020 gal) of oil. 16. Apply cure primer and pipe sealant to threads of plug. Install plug.
NOTE: Current carrier roller metal face seals use a tapered fit. There is no longer the pop into place fit previously used.
OUOE049,0000064 1919NOV014/4
TM1931 (09JAN04)
01-0130-7

010904
PN=43
Track System
Metal Face Seals Repair

Inspect Metal Face Seals
01 0130 8
1. Inspect for the following conditions to determine if seals can be reused: a. The narrow, highly polished sealing area (E) must be in the outer half of seal ring face (D). b. Sealing area must be uniform and concentric with the ID and OD of seal ring (A). c. Sealing area must not be chipped, nicked, or scratched.
ASeal Ring BWorn Area (Shaded Area) CSeal Ring Face DOuter Half of Seal Ring Face ESealing Area (Dark Line)
T47,0130,5939HQ 1919NOV011/3
2. Illustration shows examples of worn seal rings (A). ISealing area (D) is in inner half of seal ring face (C). IISealing area (D) not concentric with ID and OD of seal ring.
ASeal Ring BWorn area (Shaded Area) CInner Half of Seal Ring Face DSealing Area (Dark Line)
T47,0130,5939HQ 1919NOV012/3
TM1931 (09JAN04)
01-0130-8

010904
T85080
UN05DEC96
PN=44
T85079
UN24AUG93
Track System
3. Clean reusable seals by removing all foreign material from seal rings, except seal face (A), using a scraper or 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. Apply a thin film of oil to seal ring face. Put face of seal rings together and hold using tape.
ASeal Face 01 0130 9
T47,0130,5939HQ 1919NOV013/3
Track Shoe Repair

Remove and Install Track Shoe 1. Measure grouser height. See 200CLC Three Bar Grouser Height, 230CLC Three Bar Grouser Height, or 270CLC Three Bar Grouser Height 800 mm (31.5 in.) Width. (SP326 Undercarriage Appraisal Manual.) 2. Apply a light coat of oil to cap screw threads and install shoe. 3. Install all track shoe nuts with rounded corners (A) against the link and chamfered edges (B) away from the link. Be sure nut is properly positioned in the link so there is full contact between the nut and the link. 4. Tighten cap screws in pattern shown.
Track ShoeSpecification Shoe-to-Link Cap Screw (18 mm) (200CLC)Torque Turn.............................. 210 21 Nm (155 16 lb-ft) plus 1/2 (180) turn Track ShoeSpecification Shoe-to-Link Cap Screw (20, 22 mm) (230CLC and 270CLC) Torque Turn ................................................... 298 Nm (220 lb-ft) plus 1/2 (180) turn
UN23FEB89
ARounded Edge BChamfered Edge
TX,01,SB384 1919SEP001/1
TM1931 (09JAN04)
01-0130-9

010904
PN=45
T6352AH
T6794AM
UN23FEB89
T82840
UN23FEB89
Track System
Track Chain Repair

Remove and Install Track Chain
01 0130 10
1. Swing upperstructure to side. Lower boom to raise track off the ground. Keep the angle between boom and arm at 90110 with the round side of bucket on the ground. CAUTION: Prevent possible injury from unexpected machine movement. Put blocks or shop stands under machine frame to support machine while measuring track sag.
Track ChainSpecification Machine (200CLC)Weight.................................... 20 298 kg (44,750 lb) approximate Machine (230CLC)Weight.................................... 23 773 kg (52,410 lb) approximate Machine (270CLC)Weight.................................... 26 082 kg (57,500 lb) approximate
2. Place blocks or shop stands under the machine to support machine.
OUOE049,0000065 1920JUN011/5
CAUTION: Prevent possible injury from high pressure grease. Do not remove grease fitting (A) from valve (B). 3. Loosen valve (B) one to two turns to release grease through bleed hole (C).
OUOE049,0000065 1920JUN012/5
TM1931 (09JAN04)
01-0130-10

010904
PN=46
T7396DZ
UN28NOV90
Track System NOTE: The master pin (2) can be identified by the large dimple (3) on the pins end.
4. Move track chain so master pin (2) is over front idler or sprocket. 5. Remove the track shoe on each side of master pin. 6. If removing chain at idler, put wooden blocks in front of idler and under chain so chain does not fall when master pin is removed. 7. Remove master pin using a 50-Ton Master Pin Pusher Installer. Remove bushings (1). CAUTION: Heavy component; use a hoist.
Track ChainSpecification Tracks with 800 mm (32 in.) Shoes (200CLC)Weight ......................... 1293 kg (2850 lb) approximate Tracks with 800 mm (32 in.) Shoes (230CLC)Weight ......................... 1395 kg (3075 lb) approximate Tracks with 800 mm (32 in.) Shoes (270CLC)Weight ......................... 1814 kg (4000 lb) approximate 1Bushing (2 used) 2Master Pin 3Dimple
01 0130 11
8. Remove track chain. 9. Measure track chain link, bushing, and pitch. (See SP326 Undercarriage Appraisal Manual.) 10. Replace parts as necessary. 11. Position track chain so section on ground has pin boss on links toward rear of machine. 12. Install end of chain on sprocket and slowly turn sprocket in forward direction to pull chain across top of frame to front idler. 13. Pull ends of chain together. Install bushings and master pin (2) using 50-Ton Master Pin Pusher Installer. 14. Install track shoe. See Track Shoe Repair. (See procedure in this group.) 15. Check and Adjust Track Sag. (Operators Manual.)
OUOE049,0000065 1920JUN013/5
TM1931 (09JAN04)
01-0130-11

010904
PN=47
T143215B
UN20JUL01
Track System
01 0130 12
ATrack Link (49 used) BMaster Track Link CMaster Pin
DSnap Ring EMaster Bushing FSpacer (2 used)
GTrack Link (48 used) HSeal (96 used) IBushing (48 used)
JShoe (49 used) KPin (48 used)
Disassemble and Assemble Track Chain 1. Measure track components (AK). See Track Chain. (SP326 Undercarriage Appraisal Manual.)
OUOE049,0000065 1920JUN014/5
TM1931 (09JAN04)
01-0130-12

010904
PN=48
T117027
UN09SEP98
Track System NOTE: Wear on pins and bushings does not extend over the entire surface. Turning pins and bushing is determined by the amount of wear.
2. Turn pins (C and K) and bushings (E and I) as required. 3. Clean any dust or rust from the surfaces of track link pin bores and counterbores and the ends of bushings. 4. Apply grease to the counterbore in track links, the seals, and the ends of bushings. 5. For each joint, fill the clearance between the pin OD and bushing ID with grease. 6. Install seal (H) so tapered side (L) is toward bushing.
01 0130 13
OUOE049,0000065 1920JUN015/5
Broken Track Chain Part Repair

Disassemble and Assemble Track Chain to Replace Broken Part
UN26OCT88
1. Remove track shoes from each side of broken link assembly. See Track Shoe Repair. (See procedure in this group.) IMPORTANT: When making cuts using cutting torch, be careful not to cut or gouge good parts. 2. Cut links, bushing, and pin at points (A) to remove broken link (B).
ACut Locations BBroken Link
OUOE003,0000008 1928OCT011/4
3. Grind the ends of bushing (A) even with links to make it into a master bushing.
ABushing
UN26OCT88
OUOE003,0000008 1928OCT012/4
TM1931 (09JAN04)
01-0130-13

010904
PN=49
T5821AH
T5821AG
Track System
4. Burn holes through center of pin stubs (A). 5. Hold a heavy hammer (B) against the link while pin stub is being driven out.
UN26OCT88
01 0130 14
APin Stub BHammer
OUOE003,0000008 1928OCT013/4
6. Install links (C and E) on master bushing (D). Check cap screw hole spacing using a track shoe. 7. Instal spacers (B) into counterbore of links.
UN24MAY89
8. Install link assembly. Install master pins (A). 9. Install track shoes. See Track Shoe Repair. (See procedure in this group.)
AMaster Pin BSpacer CRight Link DMaster Bushing ELeft Link
OUOE003,0000008 1928OCT014/4
Sprocket Repair
Remove and Install Sprocket
OUOE003,0000009 1909NOV011/2
TM1931 (09JAN04)
01-0130-14

010904
PN=50
T5821AJ
T5821AI
Track System
IMPORTANT: Sprocket must be replaced when the tooth tips become excessively rounded, worn, or chipped to prevent excessive wear to chain. If machine is driven in one direction a majority of the time, wear will be on one side of teeth. To extend service life, change sprockets from one side of machine to the other. 1. Disconnect track chain. See Track Chain Repair. (See procedure in this group.) 2. Lift side of machine so sprocket teeth clear chain. CAUTION: Heavy component; use a hoist.
SprocketSpecification Sprocket (200CLC and 230CLC)Weight............................................ 46 kg (101 lb) approximate Sprocket (270CLC)Weight ........................... 70 kg (150 lb) approximate
01 0130 15
1Cap Screw (16 used)
3. Remove cap screws (1) and sprocket. 4. Apply cure primer and thread lock and sealer (high strength) to threads of cap screws (B). 5. Install sprocket and tighten cap screws (1).
SprocketSpecification Sprocket-to-Propel Gearbox Cap ScrewTorque ............................................................ 490 Nm (360 lb-ft)
6. Lower machine. 7. Install track chain. See Track Chain Repair. (See procedure in this group.)
OUOE003,0000009 1909NOV012/2
TM1931 (09JAN04)
01-0130-15

010904
PN=51
T143369B
UN20JUL01
Track System
Front Idler Repair

Remove and Install Front Idler
01 0130 16
2. Slide front idler (A) forward, using pry bar. CAUTION: Heavy component; use a hoist.
Front IdlerSpecification Front Idler (200CLC and 230CLC)Weight.......................................... 100 kg (240 lb) approximate Front Idler (270CLC)Weight....................... 160 kg (350 lb) approximate
AFront Idler
3. Attach front idler to hoist and remove from frame. 4. Measure front idler wear. See Front Idler Flange Height. (SP326 Undercarriage Appraisal Manual.) 5. Repair or replace idler as necessary. 6. Install front idler. 7. Connect track chain. See Track Chain Repair. (See procedure in this group.)
TX,01,SB395 1915NOV011/4
TM1931 (09JAN04)
01-0130-16

010904
PN=52
T6876BU
UN25OCT88
1. Disconnect track chain. See Track Chain Repair. (See procedure in this group.)
Track System
01 0130 17
APin (2 used) BBushing (2 used) CIdler
DPlug (2 used) EBracket (Bearing) (2 used) FMetal Face Seal (2 used)
GO-Ring (2 used) HAxle
IYoke JCap Screw (4 used)
Disassemble and Assemble Front Idler 1. Remove cap screws (J) and yoke (I). 2. Remove drain plug (D) and drain oil. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face. 3. Remove pins (A), brackets (E), O-rings (G) and metal face seals (F). 4. Inspect metal face seals. See Metal Face Seals Repair. (See procedure in this group.) Keep seal rings together as a matched set with seal ring faces together to protect surfaces.
5. Remove axle (H). Inspect axle and bushing for scoring or excessive wear.
NOTE: Remove bushings only if replacement is necessary.

6. Remove bushing using a 2-jaw puller and adapters from 17-1/2 and 30-ton puller set. 7. Replace parts as necessary. 8. Apply a thin film of oil to bushings (B). Install bushings so flange is tight against shoulder of idler. 9. Install O-rings (G) on axle. 10. Apply a thin layer of NEVER-SEEZ anti-seize lubricant or equivalent to end of axle from O-ring to end of axle and to bore in bracket (E).
TX,01,SB395 1915NOV012/4
TM1931 (09JAN04)
01-0130-17

010904
PN=53
T8312AA
UN21SEP94
Track System
11. Install axle into bracket. 12. Apply NEVER-SEEZ anti-seize lubricant or equivalent to pin (A). Install pin.
01 0130 18
16. Wipe finger prints and foreign material off seal ring face using clean oil and lint-free tissues. Apply a thin film of oil to each seal face. 17. For 200CLC and 230CLC, fill front idler with 265 mL (8.96 oz) of oil. For 270CLC, fill front idler with 300 mL (10.14 oz) of oil. 18. Install axle (H) into idler. 19. Apply cure primer to threads of drain plug (D). 20. Apply thread lock and sealer (medium strength) to threads of plug. Install and tighten plug. 21. Install yoke (I). Tighten cap screws (J).
Front IdlerSpecification Yoke-to-Bracket Cap Screw Torque................................................................... 210 Nm (156 lb-ft)
IMPORTANT: Metal face seal O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-rings do not slip when idler is turning. 13. Thoroughly clean the metal face seal (F) O-rings and seat surfaces in idler, brackets, and seal rings using volatile, non-petroleum base solvent and lint-free tissues. 14. Install metal face seal O-ring on seal rings.
NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant.
15. Install metal face seals (F) in bracket and idler. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must "pop" down into place so O-ring is tight against seal bore.
TX,01,SB395 1915NOV013/4
TM1931 (09JAN04)
01-0130-18

010904
PN=54
Track System
Test Front Idler for Oil Leakage 1. Turn the shaft several turns to seat metal face seals. 2. Remove the plug (G). 3. Install parts (AF) as shown. Plug barbed adapter, and connector are from a leak detector kit such as the D05361ST Rubber Stopper/Leak Detector Kit. 4. Holding plug so it is not pushed out, slowly pressurize oil cavity using air.
Front IdlerSpecification Oil Cavity Air TestPressure ................ 110 28 kPa (1.1 0.3 bar) (16 4 psi) 01 0130 19
5. Close valve and wait for a minimum of 30 seconds to check for oil leakage. Check gauge to see if air pressure has decreased. 6. If there is external leakage, disassemble idler and replace parts as necessary. 7. Check oil level in idler. If the oil level is down and there is no external leakage, check for a leak from oil cavity to interior of idler wheel. 8. Apply cure primer to threads of plug. 9. Apply thread lock and sealer (medium strength) to threads of plug. Install and tighten plug.
APlug, Adapter and Connector BConnector 1/8 M NPT x 7/16-20 M 37 CHose DPressure Gauge ESnubber (Needle) Valve FAir Pressure Regulator GDrain Plug
UN13JUN97
TX,01,SB395 1915NOV014/4
Track Adjuster and Recoil Spring Repair

Remove and Install Track Adjuster and Recoil Spring 1. Remove track chain. See Track Chain Repair. (See procedure in this group.) 2. Remove front idler. See Front Idler Repair. (See procedure in this group.)
OUOE003,000000A 1909NOV011/6
TM1931 (09JAN04)
01-0130-19

010904
PN=55
T109791B
Track System
A compression tool must be used for disassembly and assembly because of the extreme preload on spring. 3. Slide track adjuster (A) forward, using a pry bar. CAUTION: Heavy component; use a hoist.
Track Adjuster and Recoil SpringSpecification Track Adjuster Cylinder and Recoil Spring (200CLC and 230CLC)Weight.......................................... 129 kg (280 lb) approximate Track Adjuster Cylinder and Recoil Spring (270CLC)Weight.................. 180 kg (400 lb) approximate
ATrack Adjuster
4. Attach track adjuster to hoist and remove from frame. 5. Repair or replace parts as necessary. 6. Install front idler. See Front Idler Repair. (See procedure in this group.) 7. Install track chain. See Track Chain Repair. (See procedure in this group.)
OUOE003,000000A 1909NOV012/6
TM1931 (09JAN04)
01-0130-20

010904
PN=56
T6557CX
UN25OCT88
01 0130 20
CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots may result in immediate or eventual failure creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling track adjuster.
Track System
Disassemble and Assemble Track Adjuster and Recoil Spring CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots may result in immediate or eventual failure creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling track adjuster. A compression tool must be used for disassembly and assembly because of the extreme preload on spring. CAUTION: Heavy component; use a hoist.
Track Adjuster and Recoil SpringSpecification Track Recoil Spring Disassembly and Assembly ToolWeight ......................... 225 kg (496 lb) approximate
UN25OCT88
01 0130 21
1. Place an 18-t (20-ton) jack on bottom of ST4920 Track Recoil Spring Disassembly and Assembly Tool (A). Remove nuts (B) and top plate (C). (Group 9900.)
NOTE: It is not necessary to remove the recoil spring to replace wear ring and U-ring packing on piston. To replace O-ring in the cylinder, remove recoil spring and rod.
2. Remove nuts (B). Remove top plate (C).
AST4920 Track Recoil Spring Disassembly and Assembly Tool BNut CTop Plate
OUOE003,000000A 1909NOV013/6
TM1931 (09JAN04)
01-0130-21

010904
PN=57
T6557DY
Track System

Track Adjuster and Recoil SpringSpecification Track Adjuster Cylinder and Recoil Spring (200CLC and 230CLC)Weight.......................................... 129 kg (280 lb) approximate Track Adjuster Cylinder and Recoil Spring (270CLC)Weight.................. 180 kg (400 lb) approximate
01 0130 22
3. Connect track adjuster (B) to a hoist using a lifting strap (A). 4. Put track adjuster in assembly tool with cylinder end on DFT1110 Spacer (C). (Group 9900.) 5. Remove lifting strap.
ALifting Strap BTrack Adjuster CDFT1110 Spacer
UN28APR92
OUOE003,000000A 1909NOV014/6
TM1931 (09JAN04)
01-0130-22

010904
PN=58
T7720AF
Track System
6. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool (F). (Group 9900.) 7. Install plate top (A) and nuts (B) with smallest opening to allow access to nut (D). 8. Extend jack ram to provide enough travel to release spring to the approximate free length.
Track Adjuster and Recoil SpringSpecification Recoil Spring (200CLC and 230CLC)Free Length .......................... 626 mm (24.64 in.) approximate Recoil Spring (270CLC)Free Length ..................................................... 679 mm (26.73 in.) approximate
01 0130 23
9. Tighten nuts (B) so plate is tight against retainer plate. 10. Remove valve (C) and special plug (E).
ATop Plate BNut (8 used) CValve DNut ESpecial Plug FDFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
OUOE003,000000A 1909NOV015/6
TM1931 (09JAN04)
01-0130-23

010904
PN=59
T7720AG
UN28APR92
Track System
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.
01 0130 24
13. Lower jack ram to release spring force. 14. Repair or replace parts as necessary. 15. If disassembly of track adjuster cylinder is necessary, seeTrack Adjuster Cylinder Repair. (See procedure in this group.) 16. Put track adjuster cylinder in assembly tool with cylinder end on spacer. 17. Install spacer on rod. 18. Install spring using a hoist and lifting strap. 19. Install retainer plate. 20. Install guard tool. 21. Install top plate. Install nuts. 22. Raise upper half of guard tool. Tighten T-handles. 23. Operate jack to compress spring to the compressed length.
Track Adjuster and Recoil SpringSpecification Recoil Spring (200CLC and 230CLC)Compressed Length .................................. 521 mm (20.51 in.) Recoil Spring (270CLC) Compressed Length .................................................... 557 mm (21.92 in.) ATop Plate BNut (8 used) DNut FDFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
UN28APR92
24. Install nut (D) so hole is aligned with hole in rod. Install special plug. 25. Tighten valve.
Track Adjuster and Recoil SpringSpecification ValveTorque ................................................................. 88 Nm (65 lb-ft)
OUOE003,000000A 1909NOV016/6
TM1931 (09JAN04)
01-0130-24

010904
PN=60
T7720AH
Track System
Track Adjuster Cylinder Repair

Disassemble and Assemble Track Adjuster Cylinder CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots can result in immediate or eventual failure of spring or rod creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling. A compression tool must be used for disassembly and assembly because of the extreme preload on spring.
01 0130 25
NOTE: It is not necessary to remove the recoil spring to replace wear ring (4) and U-ring packing (5). It is necessary to remove the recoil spring to replace O-ring (8).
1. Remove recoil spring if necessary. See Track Adjuster and Recoil Spring Repair. (See procedure in this group.)
TX,01,SB407 1925JUN011/2
TM1931 (09JAN04)
01-0130-25

010904
PN=61
Track System
2. If necessary, remove rod (7) from cylinder (9) using a press. 1 3. Repair or replace parts as necessary.
01 0130 26
2 3
4. Apply multi-purpose grease to U-ring packing (5), wear ring (4) and O-ring (8). Fill grooves inside flange (2) with grease. 5. Install U-ring packing (5) with lip towards inside of cylinder. 6. Tighten cap screws (1).
Track Adjuster CylinderSpecification Flange-to-Cylinder Cap Screw Torque ............................................................................. 50 Nm (37 lb-ft)
5 6
7 8
T143380
TX,01,SB407 1925JUN012/2
TM1931 (09JAN04)
01-0130-26

010904
PN=62
T143380
1Cap Screw (3 used) 2Flange 3Piston Rod 4Wear Ring 5U-Ring 6Retaining Ring 7Rod 8O-Ring 9Cylinder
9
UN20JUL01
Section 02
Axles and Suspension Systems (Propel)

Contents
Page
Group 0250Axle Shaft, Bearings, and Reduction Gears Propel Gearbox . . . . . . . . . . . . . . . . . . . . . . .02-0250-1 Group 0260Hydraulic System Propel Motor . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Start-Up Procedure . . . . . . . . . . . . . . . . .02-0260-22 Rotary Manifold . . . . . . . . . . . . . . . . . . . . . .02-0260-22
02
TM1931 (09JAN04)
02-1

010904
PN=1
Contents
02
TM1931 (09JAN04)
02-2

010904
PN=2
Group 0250
Axle Shaft, Bearings, and Reduction Gears

Propel Gearbox Repair
Remove and Install Propel Gearbox 1. Disconnect track chain. See Track Chain Repair. (Group 0130.) 2. Remove sprocket. See Sprocket Repair. (Group 0130.) CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. 3. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 4. Disconnect hydraulic lines.
02 0250 1
OUOE049,0001000 1919NOV011/14
TM1931 (09JAN04)
02-0250-1

010904
PN=65

5. Attach JDG909 Lifting Bracket to gearbox as shown. CAUTION: Heavy component; use a hoist.
Propel GearboxSpecification Propel Gearbox (200CLC) Weight............................................................ 310 kg (680 lb) approximate Propel Gearbox (230CLC) Weight............................................................ 322 kg (710 lb) approximate Propel Gearbox (270CLC) Weight.......................................................... 480 kg (1060 lb) approximate 02 0250 2
NOTE: Make alignment marks between propel gearbox and undercarriage to aid in installation.
6. Remove cap screws (1). Remove propel gearbox and propel motor. 7. Repair or replace parts as necessary.
UN15JUN01
NOTE: Align marks made during removal.

8. Install gearbox. Tighten cap screws (1).
Propel GearboxSpecification Gearbox-to-Frame Cap Screw Torque ......................................................................... 630 Nm (460 lb-ft)
200CLC Machine Shown

1Cap Screw (14 used)200CLC and 230CLC Cap Screw (17 used)270CLC
9. Connect lines. See Propel System Component Location. (Group 9025-15.) 10. Fill propel gearbox with oil. See Check Propel Gearbox Oil Level. (Operators Manual.) 11. Do Propel Motor Start-Up Procedure. (Group 0260.)
OUOE049,0001000 1919NOV012/14
TM1931 (09JAN04)
02-0250-2

010904
PN=66
T142702B
02 0250 3
TM1931 (09JAN04)
02-0250-3

010904
PN=67
14 13 7
02 0250 4
15
6 3 5 4 3 9 8 2 1 10
12 11 9 16
17
18 20 21 22 20 23 24 25 26 27 26 25 28 29 30 32 33 19
30
31
UN15JUN01
T142270
OUOE049,0001000 1919NOV013/14
TM1931 (09JAN04)
02-0250-4

010904
PN=68
T142270

1Third Planet Carrier 2Third Planet Sun Gear 3Thrust Plate (6 used) 4Second Planet Gear (3 used) 5Needle Bearing (3 used) 6Pin (3 used) 7Spring Pin (3 used) 8Second Planet Carrier 9Spacer (2 used) 10Second Planet Sun Gear 11First Planet Carrier 12Shaft 13Ring Gear 14Thrust Pad 15Cap Screw (12 used) 16Cover 17Cap Screw (24 used) 18Spring Pin (3 used) 19Pin (3 used) 20Thrust Plate (6 used) 21Needle Bearing (3 used) 22First Planet Gear (3 used) 23Spring Pin (3 used) 24Pin (3 used) 25Thrust Plate (6 used) 26Needle Bearing (6 used) 27Third Planet Gear 28Propel Motor 29Metal Face Seal 30Bearing (2 used) 31Drum 32Bearing Nut 33Dowel Pin
Disassemble and Assemble Propel Gearbox 200CLC and 230CLC 1. Remove cap screws (15) and cover (16). 2. Remove shaft (12) and first planet carrier (11). 3. Remove second planet sun gear (10) and second planet carrier (8). CAUTION: Heavy component; use a hoist.
Propel GearboxSpecification Ring Gear (200CLC and 230CLC)Weight ....................................... 41 kg (90 lb) approximate
5. Remove third planet sun gear (2) and third planet carrier (1).
NOTE: Disassembly of first, second, and third planet carriers are similar. Repeat procedure as required.
6. Remove spring pins, pins, thrust plates, needle bearings, and planetary gears. Clean and inspect parts, replace as necessary. Oil parts with gear oil prior to assembly.
02 0250 5
4. Install JT01748 Lifting Brackets to ring gear (13). Remove cap screws (17) and ring gear. CAUTION: Heavy component; use a hoist.
Propel GearboxSpecification Third Planet Carrier (200CLC and 230CLC)Weight................................ 39 kg (85 lb) approximate
OUOE049,0001000 1919NOV014/14
7. Install spring pins with slit (1) toward end of pin. 8. Install third planet gear (27) in third planet carrier (1) with marked side towards hole for spring.
1Slit
UN22JUN01
OUOE049,0001000 1919NOV015/14
TM1931 (09JAN04)
02-0250-5

010904
PN=69
T142429

9. Remove bearing nut (32) from propel motor (28) using DF1036A Propel Gearbox Nut Wrench (35) and DFT1109 Holding Bar (34). Fasten holding bar to ring gear. (Group 9900.) CAUTION: Heavy component; use a hoist.
Propel GearboxSpecification Drum (200CLC and 230CLC) Weight................................................................ 44 kg (97 lb) approximate
10. Remove drum (31) using JT01748 Lifting Brackets. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face. 11. Remove metal face seal (29). See Metal Face Seals Repair. (Group 0130.)
32Bearing Nut 34DFT1109 Holding Bar 35 DF1036A Propel Gearbox Nut Wrench
NOTE: Further disassembly is not necessary unless bearing replacement is required. Bearing will be destroyed during removal, replace with new bearing.
12. Inspect bearing (30) and race inside housing (31). 13. Replace parts as necessary. CAUTION: DO NOT heat oil over 182C (260F). Oil fumes or oil can ignite above 193C (380F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 14. Heat inner bearing cone. Install cone tight against shoulder.
Propel GearboxSpecification Bearing Cone (200CLC and 230CLC)Temperature ....................................... 5070C (122158F)
OUOE049,0001000 1919NOV016/14
TM1931 (09JAN04)
02-0250-6

010904
PN=70
T142380
UN15JUN01
02 0250 6

IMPORTANT: Metal face seal O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-ring does not slip. 15. Thoroughly clean metal face seal O-rings and seat surfaces in propel motor housing, drum, and seal ring using volatile, non-petroleum base solvent and lint-free tissues.
NOTE: A volatile, non-petroleum base solvent or talcum powder can be used as a lubricant. Solvent must not damage the O-ring or leave an oil residue.
16. Install O-ring and metal face seal on propel motor housing and drum. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must pop down into place so O-ring is tight against seal bore and seal ring is installed squarely. 17. Clean seal ring face. Apply a thin film of clean oil. 18. Apply a thin coat of multi-purpose grease to threads of bearing nut (32). Install bearing nut with machined surface towards bearing. 19. Tighten bearing nut using DF1036A Propel Gearbox Nut Wrench and DFT1109 Holding Bar. Fasten holding bar to ring gear. (Group 9900.) Seat bearings.
Propel GearboxSpecification Bearing Nut (200CLC and 230CLC)Torque .................................... 790 Nm (580 lb-ft) then tap on drum using a plastic hammer, turn drum 45 turns to the right and left to seat the bearings.
02 0250 7
20. Repeat steps to ensure bearings are seated.
OUOE049,0001000 1919NOV017/14
TM1931 (09JAN04)
02-0250-7

010904
PN=71

21. Ensure center of dowel pin (33) is aligned with center of spline on propel motor shaft. If centers are not aligned tighten bearing nut until dowel pin center aligns with center of the next spline. 22. Install third planet carrier so dowel pin (33) enters hole (35) on third planet carrier. 23. Apply rigid from-in-place gasket to flange surface on ring gear. 24. Apply thread lock and sealer (high strength) to cap screws (17). Tighten cap screws.
Propel GearboxSpecification Ring Gear-to-Drum Cap Screw (200CLC and 230CLC)Torque................................. 265 Nm (195 lb-ft)
UN15JUN01
02 0250 8
25. Install second and first planet carriers, sun gears and shaft. 26. Apply rigid from-in-place gasket to flange surface on cover. 27. Apply thread lock and sealer (medium strength) to thread of cap screws (15). Tighten cap screws.
Propel GearboxSpecification Cover-to-Ring Gear Cap Screw (200CLC and 230CLC)Torque................................... 110 Nm (83 lb-ft)
35
28Propel Motor 32Bearing Nut 33Dowel Pin 35Hole
OUOE049,0001000 1919NOV018/14
TM1931 (09JAN04)
02-0250-8

010904
PN=72
T142944
UN15JUN01
T142422
02 0250 9
TM1931 (09JAN04)
02-0250-9

010904
PN=73
02 0250 10
OUOE049,0001000 1919NOV019/14
TM1931 (09JAN04)
02-0250-10

010904
PN=74
T109286
UN25APR97

00Propel Motor 02Propel Gearbox Housing 03Seal 05Drum 06Sprocket 07Lock Washer (20 used) 08Cap Screw (20 used) 09Roller Bearing (2 used) 10Nut 11Lock Plate 12Cap Screw (2 used) 14Third Planet Carrier 15Third Planet Gear (3 used) 17Thrust Washer (6 used) 18Pin (3 used) 19Spring Pin (3 used) 20Third Planet Sun Gear 21Needle Bearing (6 used) 23Ring Gear 25Cap Screw (24 used) 27Second Planet Carrier 28Thrust Washer (2 used) 29Second Planet Sun Gear (3 used) 30Needle Bearing (3 used) 31Thrust Washer (6 used) 32Pin (3 used) 33Spring Pin (3 used) 34Second Planet Sun Gear 35Thrust Washer 36First Planet Carrier 37First Planet Gear (3 used) 38Needle Bearing (3 used) 39Thrust Washer (6 used) 40Pin (3 used) 41Spring Pin (3 used) 42Propel Shaft 44Cover 45Pin 46Roller Bearing 47Snap Ring 48Cap Screw and Lock Washer (12 used) 49Plug (3 used) 51O-Ring 52Cap Screw (4 used) 53Lock Washer (4 used) 55Name Plate 56Cap Screw (2 used) 02 0250 11
Disassemble and Assemble Propel Gearbox 270CLC 1. Make alignment marks between cover (44), ring gear (23) and drum (05). 2. Remove cap screws and lock washers (48) and cover (44). 3. Remove shaft (42) and first planet carrier (36). 4. Remove second planet sun gear (34) and second planet carrier (27). CAUTION: Heavy component; use a hoist.
Propel GearboxSpecification Ring Gear (270CLC)Weight .................. 55 kg (120 lb) approximate

Propel GearboxSpecification Third Planet Carrier (270CLC)Weight.................................... 52 kg (120 lb) approximate
6. Remove third planet sun gear (20) and third planet carrier (14).
NOTE: Disassembly of first, second, and third planet carriers are similar. Repeat procedure as required.
7. Remove spring pins, pins, thrust plates, needle bearings, and planetary gears. Clean and inspect parts, replace as necessary. Oil parts with gear oil prior to assembly.
5. Install JT01748 Lifting Brackets to ring gear (23). Remove cap screws (25) and ring gear.
OUOE049,0001000 1919NOV0110/14
IMPORTANT: There is a mark on one side of third planet gear (15). Be sure that this marked side faces the hole for the spring pin.
UN22JUN01
8. Install spring pins with slit (1) toward end of pin. 9. Remove cap screws (12) and lock plate (11).
1Slit
OUOE049,0001000 1919NOV0111/14
TM1931 (09JAN04)
02-0250-11

010904
PN=75
T142429

10. Remove bearing nut (10) using DF1036A Propel Gearbox Nut Wrench (35) and DFT1109 Holding Bar (34). Fasten holding bar to ring gear. (Group 9900.) CAUTION: Heavy component; use a hoist.
Propel GearboxSpecification Drum (270CLC)Weight ................................ 65 kg (140 lb) approximate
11. Remove drum (05) using JT01748 Lifting Brackets. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face. 12. Remove metal face seal (03). See Metal Face Seals Repair. (Group 0130.)
UN15JUN01
02 0250 12
NOTE: Further disassembly is not necessary unless bearing replacement is required. Bearing will be destroyed during removal, replace with new bearing.
13. Inspect bearings (09) and races inside housing. 14. Replace parts as necessary. CAUTION: DO NOT heat oil over 182C (260F). Oil fumes or oil can ignite above 193C (380F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 15. Heat inner bearing cone. Install cone tight against shoulder.
Propel GearboxSpecification Bearing Cone (270CLC) Temperature ......................................................... 5070C (122158F)
OUOE049,0001000 1919NOV0112/14
TM1931 (09JAN04)
02-0250-12

010904
PN=76
T142380

IMPORTANT: Metal face seal O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-ring does not slip. 16. Thoroughly clean metal face seal O-rings and seat surfaces in propel motor housing, drum, and seal ring using volatile, non-petroleum base solvent and lint-free tissues.
NOTE: A volatile, non-petroleum base solvent or talcum powder can be used as a lubricant. Solvent must not damage the O-ring or leave an oil residue.
17. Install O-ring and metal face seal on propel motor housing and drum. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must pop down into place so O-ring is tight against seal bore and seal ring is installed squarely. 18. Clean seal ring face. Apply a thin film of clean oil. IMPORTANT: Install bearing nut with stepped surface towards bearing. 19. Apply a thin coat of multi-purpose grease to bearing nut. Tighten bearing nut using DF1036A Propel Gearbox Nut Wrench and DFT1109 Holding Bar. Fasten holding bar to ring gear. (Group 9900.)
Propel GearboxSpecification Bearing Nut (270CLC)Torque .............. 790 Nm (580 lb-ft) Then tap on drum using a plastic hammer. Then turn drum four-to-five times to the right and left to seat the bearings.
02 0250 13
20. To seat bearings, tap on drum using a plastic hammer. Then turn drum three times to the right and left to seat the bearings. Repeat steps to ensure bearings are seated properly.
OUOE049,0001000 1919NOV0113/14
TM1931 (09JAN04)
02-0250-13

010904
PN=77
Axle Shaft, Bearings, and Reduction Gears NOTE: If lock plate (11) will not engage with spline of housing tighten bearing nut until lock plate engages.
21. Install lock plate (11). Apply thread lock and sealer (high strength) to threads of cap screws (12). Tighten cap screws.
Propel GearboxSpecification Lock Plate-to-Bearing Nut Cap Screw (270CLC)Torque ............................................... 88 Nm (65 lb-ft)
02 0250 14
22. Apply rigid from-in-place gasket to flange surface on ring gear. Apply thread lock and sealer (high strength) to cap screws (25). Tighten cap screws.
Propel GearboxSpecification Ring Gear-to-Drum Cap Screw (270CLC)Torque ...................................................... 265 Nm (195 lb-ft)
23. Install second and first planet carriers, sun gears and shaft. 24. Apply rigid from-in-place gasket to flange surface on cover. Apply thread lock and sealer (medium strength) to thread of cap screws (48). Tighten cap screws.
Propel GearboxSpecification Cover-to-Ring Gear Cap Screw (270CLC)Torque ........................................................ 110 Nm (83 lb-ft)
OUOE049,0001000 1919NOV0114/14
TM1931 (09JAN04)
02-0250-14

010904
PN=78
Group 0260
Hydraulic System
Propel Motor Repair
Remove and Install Propel Motor200CLC and 230CLC
NOTE: Propel motor is an integral part of propel gearbox.

If removal is required. See Propel Gearbox Repair. (Group 0250.) Remove and Install Propel Motor270CLC CAUTION: Prevent possible injury from unexpected machine movement. Block both tracks when removing propel motors. When propel motors are removed, machine has no brakes and can move. The machine will roll free on a slope or while being towed. 1. Block tracks. 2. Drain oil from propel gearbox. Approximate capacity is 6.0 L (6.5 qt). CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 3. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 4. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 270CLC Drain and Refill Capacities. (Operators Manual.)
02 0260 1
ouoe049,0001010 1919NOV011/26
TM1931 (09JAN04)
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010904
PN=79
Hydraulic System
5. Disconnect lines. CAUTION: Heavy component; use a hoist.
Propel MotorSpecification Propel Motor Cover (270CLC) Weight.............................................................. 90 kg (200 lb) approximate
02 0260 2
6. Loosen cap screws and lock washers (1). 7. Connect propel motor and park brake to a hoist using lifting straps or chains and DF1063 Lift Bracket and DFT1130 Adapter. (Group 9900.) 8. Remove cap screws (1) and remove propel motor, park brake and remove O-ring. 9. Replace parts as necessary. 10. Install O-ring. Install propel motor and park brake. 11. Install and tighten cap screws (1).
Propel MotorSpecification Propel Motor Cover-to-Propel Gearbox Cap Screw (270CLC) Torque ......................................................................... 265 Nm (195 lb-ft)
12. Connect lines. See Propel System Component Location. (Group 9025-15.) 13. Fill propel gearbox with oil. See Check Propel Gearbox Oil Level. (Operators Manual.) 14. Do Propel Motor Start-Up Procedure. (See procedure in this group.)
Right Side Shown

1Cap Screw and Lock Washer (4 used)
ouoe049,0001010 1919NOV012/26
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010904
PN=80
T8318AC
UN20SEP94
T147509B
UN19NOV01
NOTE: Cap screws (1) used to hold propel motor and park brake to propel gearbox have heads longer than those holding propel motor cover to housing.
Hydraulic System
7 8 6 5 9 4 2 6 1 3 17 16 15 14 13 12 11 29 10 28 27 26 25 24 23 22
UN20JUL01
02 0260 3
18 20 21 29 19
30
30
T142484
1Shaft 2Retaining Ring (2 used) 3Roller Bearing 4Oil Seal 5O-Ring 6O-Ring (3 used) 7Brake Release Passage 8Speed Change Passage (2 used)
9Housing 10Pin (2 used) 11Valve Plate 12Rotor 13Spring (6 used) 14Bushing 15Retainer 16Piston (9 used)
17Swash Plate 18Pin 19Plate 20Ball (2 used) 21Piston (2 used) 22Cap Screw (9 used) 23Propel Motor Cover
24Needle Bearing 25Disc Spring 26O-Ring 27Brake Piston 28O-Ring 29Friction Plate (4 used) 30Plate (4 used)
ouoe049,0001010 1919NOV013/26
TM1931 (09JAN04)
02-0260-3

010904
PN=81
T142484
Hydraulic System
Disassemble and Assemble Propel Motor200CLC and 230CLC 1. If required, remove propel gearbox. See Propel Gearbox Repair. (Group 0250.) CAUTION: Heavy component; use a hoist.
Propel MotorSpecification Propel Motor (200CLC and 230CLC)Weight ..................................... 92 kg (203 lb) approximate
6. Remove friction plates (29) and plates (30). 7. Inspect parts for wear or damage.
Propel MotorSpecification Friction Plate (200CLC and 230CLC)Height................................ 2.752.70 mm (0.1080.106 in.) Plate (200CLC and 230CLC) Height.................................................. 1.801.75 mm (0.0710.069 in.)
02 0260 4
IMPORTANT: Use care when removing propel motor cover (23), valve plate (11) is easily damaged. 2. Remove propel motor cover (23), and valve plate (11). IMPORTANT: Remove needle bearing (24) only if replacement is necessary. Do not re-use needle bearing as it may have been damaged during removal. 3. Remove needle bearing (24) as required. 4. Remove disc spring (25). Inspect part for wear or damage.
Propel MotorSpecification Disc Spring (200CLC and 230CLC)Height.............................. 7.06.9 mm (0.2760.272 in.)
IMPORTANT: Pistons must be installed into the same bores because of wear patterns. Mark location of pistons with respect to bores to aid in assembly. 8. Remove parts (1218). 9. Remove parts (14) through motor side of housing (9). 10. Replace parts as necessary. 11. Apply multi-purpose grease to lip of seal (4) and apply rigid form-in-place gasket to outer surface of seal. 12. Install parts (14) using D01044AA Bushing, Bearing and Seal Driver Set.
5. Apply 100300 kPa (1443 psi) air pressure to brake release passage (7) to remove brake piston (27).
ouoe049,0001010 1919NOV014/26
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02-0260-4

010904
PN=82
Hydraulic System
13. Lubricate parts (1218) with hydraulic oil and install. Insure that pistons (16) are installed in their original bores. Install bushing (14) and retainer (15) as shown. 14. Install parts (2530). 14 15. Install needle bearing (24) into propel motor cover (23).
15
NOTE: Apply petroleum jelly to mating surface of valve plate to adhere it to propel motor cover during assembly.
16. Install pins (10) then valve plate (11). 17. Assemble propel motor cover (23) to housing (9). 18. Install cap screws (22) and tighten.
Propel MotorSpecification Propel Motor Cover-to-Propel Motor Housing Cap Screw (200CLC and 230CLC)Torque................................. 300 Nm (225 lb-ft)
T142996
UN20JUL01
02 0260 5
14Bushing 15Retainer
ouoe049,0001010 1919NOV015/26
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010904
PN=83
Hydraulic System
18 17 8
02 0260 6
16 13 12 11 9 10 14 15
6 6 5 4 3 2 1 7 7 31 32 33 28 34 30 36 29 37 27 19 25 26 38 28
35
20
21
39 22 23 24
UN01NOV01
42
T146684
40
41
Propel Motor and Park Brake Components270CLC
ouoe049,0001010 1919NOV016/26
TM1931 (09JAN04)
02-0260-6

010904
PN=84
T146684
Hydraulic System
1O-Ring 2Disk Spring 3Brake Piston 4O-Ring 5O-Ring 6Plate (5 used) 7Friction Plate (4 used) 8Spacer 9Motor Drive Shaft 10Roller Bearing 11Spacer 12Roller Bearing 13Nut 14Propel Motor Housing 15O-Ring 16Brake Releasing Oil Passage 17Lip Seal 18Snap Ring 19Cap Screw (4 used) 20Cover 21O-Ring 22Piston Seal 23Piston Seal 24Servo Piston 25Cap Screw (4 used) 26O-Ring 27Plug 28Pivot Plug (2 used) 29Shoulder Bolt 30Link 31Pin 32Center Shaft 33Spring 34Piston (7 used) 35Rotor 36Bushing 37Valve Plate 38Plate 39Pin (2 used) 40Propel Motor Cover 41Plug 42O-Ring
Disassemble and Assemble Propel Motor270CLC IMPORTANT: Valve plate and pistons have machined surfaces. Do not let valve plate and pistons drop. 1. Remove propel motor cover (40) from propel motor housing (14). Make sure valve plate in valve housing is not damaged. IMPORTANT: Pistons must be installed into the same bores because of wear pattern. 2. Mark pistons and bores in rotor (35) so pistons are installed into same bores during assembly. 3. Remove parts (32, 33, and 35).
5. Apply 100300 kPa (1443 psi) air pressure to brake release passage (16) to remove brake piston (3). 6. Remove brake parts (38).
02 0260 7
NOTE: If parts are not within specification, replace parts.

7. Inspect brake parts for wear or damage.
Propel MotorSpecification Disk Spring (270CLC)Height......... 7.27.6 mm (0.2830.300 in.) Friction Plate (270CLC) Thickness ............................................ 3.253.30 mm (0.1280.130 in.) Plate (270CLC)Thickness ............... 1.751.80 mm (0.0690.071 in.)
NOTE: Remove pin (31) only if necessary.

4. Remove pistons (34).
8. Remove parts (17 and 18).
NOTE: Remove piston evenly from bore. Do not scratch or damage piston or bore.
ouoe049,0001010 1919NOV017/26
TM1931 (09JAN04)
02-0260-7

010904
PN=85
Hydraulic System
9. Remove nut (B) using JDG911 Spanner Wrench. 10. Use a puller and a press to remove parts (CE) from shaft (A).
AMotor Drive Shaft BNut CRoller Bearing DSpacer ERoller Bearing 02 0260 8
UN11OCT94
ouoe049,0001010 1919NOV018/26
IMPORTANT: Valve plate and slide plate have machined surfaces. Do not let plates drop. 11. Remove parts (AD).
ACover BPlug and O-Ring CShoulder Bolt DValve Plate and Link Assembly
ouoe049,0001010 1919NOV019/26
TM1931 (09JAN04)
02-0260-8

010904
PN=86
T8321AF
UN20SEP94
T8320AE
Hydraulic System
12. Disassemble servo piston parts (AE) if necessary.
APlug BO-Ring CSpool DSpring EPiston Ring (2 used)
T7685IE
UN27APR92
ouoe049,0001010 1919NOV0110/26
02 0260 9
13. Inspect bushing (B) and replace if necessary. IMPORTANT: Thread lock and sealer (high strength) is used on pivot plugs (A).
UN20SEP94
NOTE: Remove pivot plugs (A) only if necessary to remove valve plate (C).
14. Replace parts as necessary.
APivot Plug BBushing CValve Plate
ouoe049,0001010 1919NOV0111/26
NOTE: If removed install bushing (B) with chamfered side of bushing facing inside of valve plate (C).
15. Install bushing (B) using disk drivers, until bushing is even with valve plate (C). 16. If removed, apply thread lock and sealer (high strength) to threads of pivot plugs (A). IMPORTANT: DO NOT allow thread lock and sealer on smooth portion of pivot plugs. 17. Install valve plate and pivot plugs (A) in link. Tighten pivot plugs.
Propel MotorSpecification Pivot Plug (270CLC)Torque......................................... 49 Nm (36 lb-ft)
UN20SEP94
APivot Plug (2 used) BBushing CValve Plate
ouoe049,0001010 1919NOV0112/26
TM1931 (09JAN04)
02-0260-9

010904
PN=87
T8321AH
T8321AH
Hydraulic System
IMPORTANT: Piston seals are brittle. Use care not to chip, crack or break seals. 18. Assemble servo piston parts (AE).
APlug BO-Ring CSpool DSpring EPiston Ring (2 used) 02 0260 10
UN27APR92
ouoe049,0001010 1919NOV0113/26
19. Apply clean oil to all internal parts. 20. Install parts (D and E). IMPORTANT: Valve plate and slide plate have machined surfaces. Use care not damage or scratch machined surfaces. 21. Apply petroleum jelly to both sides of plate (B). 22. Install parts (AC). Align link assembly with servo piston.
AValve Plate and Link Assembly BPlate CPin (2 used) DServo Piston EPiston Seal (2 used)
UN20SEP94
ouoe049,0001010 1919NOV0114/26
TM1931 (09JAN04)
02-0260-10

010904
PN=88
T8321AG
T7685IE
Hydraulic System
23. Install shoulder bolt (C) through link assembly (D) at end of servo piston. Install plug and O-Ring . Tighten shoulder bolt (C) and plug (B).
Propel MotorSpecification Shoulder Bolt (270CLC)Torque ................................... 49 Nm (36 lb-ft)
24. Install O-ring and cover (A). Tighten cover cap screws.
Propel MotorSpecification Servo Piston Cover Cap Screw (270CLC)Torque .......................................................... 88 Nm (65 lb-ft) 02 0260 11
UN20SEP94
ACover BPlug and O-Ring CShoulder Bolt DValve Plate and Link Assembly
ouoe049,0001010 1919NOV0115/26
TM1931 (09JAN04)
02-0260-11

010904
PN=89
T8321AF
Hydraulic System
25. Heat bearing cones (C and E).

02 0260 12 Propel MotorSpecification Bearing Cone (270CLC) Temperature ......................................................... 5070C (122158F)
26. Install parts (CE) on motor drive shaft (A). Install race and spacer with spacer notches towards larger bearing. 27. Apply clean oil to threads of nut (B). Install nut with thin shoulder away from bearing.
AMotor Drive Shaft BNut CRoller Bearing DSpacer ERoller Bearing
UN11OCT94
ouoe049,0001010 1919NOV0116/26
TM1931 (09JAN04)
02-0260-12

010904
PN=90
T8320AE
TS227
UN23AUG88
CAUTION: DO NOT heat oil over 182C (360F). Oil fumes or oil can ignite above 193C (380F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns.
Hydraulic System
02 0260 13
UN26SEP94
T8320AO
ANut
BDF1038 Torque Adapter
CJDG911 Spanner Wrench
28. Tighten nut (A) using JDG911 Spanner Wrench (C) until rolling drag torque is to specification.
Propel MotorSpecification Motor Drive Shaft (270CLC) Rolling Drag Torque .............................. 3.04.0 Nm (2735 lb-in.)
29. Check rolling drag torque using DF1038 Torque Adapter (B). (Group 9900.) 30. Stake nut in one place on the thin shoulder.
ouoe049,0001010 1919NOV0117/26
TM1931 (09JAN04)
02-0260-13

010904
PN=91
T8320AP
UN11OCT94
Hydraulic System
31. Apply rigid form-in-place gasket to outer diameter of oil seal (B). 32. Install seal with spring side into bore first. Use a disk driver to push seal to bottom of bore. 33. Apply multi-purpose grease to seal lips. 34. Install snap ring (A).
02 0260 14
UN20SEP94
NOTE: Use a soft faced hammer to make sure bearings are tight against bottom of bore.
35. Install motor drive shaft assembly into housing, using care not to damage seal lips.
ASnap Ring BOil Seal
ouoe049,0001010 1919NOV0118/26
36. Install spacer (G) with notches to bottom of bore and aligned with notches in housing. 37. Install friction plates (F) and plates (E): Begin with one friction plate and align notches in friction plate with notches in gear. Install one plate. Repeat step, alternating friction plates and plates. Keep notches of plates aligned with one another. 38. Apply petroleum jelly to O-rings (C and D). Install O-rings on piston (B) with rounded side out. IMPORTANT: Make sure brake port (A) is clear to allow air to exit as piston is installed.
UN20SEP94
39. Install piston (B) evenly into bore.

ABrake Port BBrake Piston CO-Ring DO-Ring EPlate (4 used) FFriction Plate (5 used) GSpacer
ouoe049,0001010 1919NOV0119/26
TM1931 (09JAN04)
02-0260-14

010904
PN=92
T8319BR
NOTE: To ease installation of piston apply petroleum jelly to outer diameter of piston.
T8319BY
Hydraulic System
40. Install pistons into same bores as they were removed. Make sure pistons move freely. 41. Assemble parts (32) and (33) and align pin (31) with slot in rotor (35). 42. Install rotor (35). 43. Install disk spring (2) so inner diameter contacts the brake piston. 44. Install O-rings (1 and 15).
UN20SEP94 T8319BP
02 0260 15
ouoe049,0001010 1919NOV0120/26
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010904
PN=93
Hydraulic System
45. Remove parts (AC) from alignment port (E) of propel motor cover (D). 46. Move valve plate and servo piston to align pivot plug with port. Install a 6 mm hex key wrench in pivot plug to hold valve plate and link in position. 47. Install a 4.8 mm (3/16 in.) wooden dowel or soft rod (F) through reducing valve port and center of valve plate.
02 0260 16
48. Lift propel motor cover into position over propel motor housing. Align cover to housing and install dowel into bore of center shaft (G). 49. Install and tighten four housing cap screws.
Propel MotorSpecification Propel Motor Cover-to-Motor Housing Cap Screw (270CLC) Torque ......................................................................... 390 Nm (290 lb-ft)
50. Remove dowel (F) and install parts (AC). Tighten plug.
Propel MotorSpecification Brake Pressure Reducing Valve Plug (270CLC)Torque .................................................. 69 Nm (51 lb-ft)
51. Install and tighten plug and O-ring (A).

Propel MotorSpecification Alignment Port Plug (270CLC) Torque ............................................................................. 90 Nm (65 lb-ft)
UN20SEP94
APlug and O-Ring BPressure Reducing Valve CSpring D Propel Motor Cover EAlignment Port FWooden Dowel or Rod GCenter Shaft
ouoe049,0001010 1919NOV0121/26
TM1931 (09JAN04)
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010904
PN=94
T8322BD
T8322BC
UN20SEP94
Hydraulic System
2 3 4
5 7
12 16 13 14 15
6 5 4
02 0260 17
3 2
10 11 8
T143007
1Counterbalance Valve 2Counterbalance Valve Plug (2 used) 3O-Ring (2 used) 4Spring (2 used)
5Spring Seat (2 used) 6Spool 7Propel Motor Cover 8Crossover Relief Valve (2 used)
9Poppet (2 used) 10Spring (2 used) 11Relief Valve (2 used) 12Propel Speed Change Valve
13Propel Speed Change Plug 14O-Ring 15Spring 16Spool
Disassemble and Assemble Propel Motor Cover 200CLC and 230CLC
NOTE: Valves may be removed with propel motor in machine.

Apply a film of clean hydraulic oil to parts before assembly.
Propel Motor CoverSpecification Counterbalance Valve Plug (200CLC and 230CLC) Torque................................................................... 440 Nm (325 lb-ft) Relief Valve (200CLC and 230CLC)Torque ................................................. 310 Nm (230 lb-ft) Propel Speed Change Plug (200CLC and 230CLC) Torque....................................................................... 34 Nm (25 lb-ft)
ouoe049,0001010 1919NOV0122/26
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010904
PN=95
T143007
UN20JUL01
Hydraulic System
02 0260 18
APlug (2 used) BO-Ring (2 used) CCounterbalance Spring (2 used) DSpool Plug (2 used) ECounterbalance Spool FPlug (4 used)
GO-Ring (4 used) HBall Seat (2 used) IBall (2 used) JPlug (2 used) KO-Ring (2 used) LCheck Valve Spring (2 used)
MCheck Valve Poppet (2 used) NRelief Valve (2 used) OPropel Motor Cover PO-Ring (2 used) QPlug (10 used)
RO-Ring (10 used) SPlug TO-Ring UBrake Pressure Reducing Valve Spool VPressure Reducing Spring
Disassemble and Assemble Propel Motor Cover 270CLC
ouoe049,0001010 1919NOV0123/26
TM1931 (09JAN04)
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010904
PN=96
T8322BE
UN26SEP94
Hydraulic System
1. Park Brake Release Shuttle Valve
NOTE: Valve can be removed with propel motor on machine.

UN20SEP94 T8323AB
a. Clean threads of seat (B). Apply cure primer and thread lock and sealer (high strength). b. Install ball (C) and tighten seat (B).
Propel MotorSpecification Ball Seat (270CLC)Torque .................................... 14.5 Nm (128 lb-in.) APlug with O-Ring BBall Seat CBall
02 0260 19
c. Install and tighten plug (A).

Propel MotorSpecification Park Brake Release Shuttle Valve Plug (270CLC)Torque .................................................. 34 Nm (25 lb-ft)
ouoe049,0001010 1919NOV0124/26
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010904
PN=97
Hydraulic System
2. Servo Piston Operating Shuttle Valve

UN20SEP94
a. Clean threads of seat (B). Apply cure primer and thread lock and sealer (high strength). b. Install ball (C) and tighten seat (B).
02 0260 20 Propel MotorSpecification Ball Seat (270CLC)Torque .................................... 14.5 Nm (128 lb-in.) APlug with O-Ring BBall Seat CBall
c. Install and tighten plug (A).

Propel MotorSpecification Servo Piston Operating Shuttle Valve Plug (270CLC)Torque ....................................... 34 Nm (25 lb-ft)

3. Counterbalance Valve (E) a. Apply clean oil to spool. b. Install O-ring and tighten plug.
Propel MotorSpecification Counterbalance Valve Plug (270CLC)Torque ...................................................... 340 Nm (250 lb-ft)
NOTE: Valves can be removed with propel motor on machine.

4. Relief Valves (N) Tighten relief valve.
Propel MotorSpecification Relief Valve (270CLC)Torque.................................. 540 Nm (398 lb-ft)
ouoe049,0001010 1919NOV0125/26
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010904
PN=98
T8323AJ
Hydraulic System NOTE: Valves can be removed with propel motor on machine.
5. Check Valves (M) Install parts and tighten plug.
Propel MotorSpecification Check Valve Plug (270CLC) Torque ......................................................................... 235 Nm (173 lb-ft)

6. Brake Pressure Reducing Valve (U) Install parts and tighten plug.
Propel MotorSpecification Brake Pressure Reducing Valve Plug (270CLC)Torque .................................................. 69 Nm (51 lb-ft)
02 0260 21
ouoe049,0001010 1919NOV0126/26
TM1931 (09JAN04)
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010904
PN=99
Hydraulic System
Propel Motor Start-Up Procedure

IMPORTANT: Propel motor will be damaged if not filled with oil before operating propel function. Procedure must be performed whenever a new propel motor is installed or oil has been drained from the motor. 1. Disconnect drain line (1).
02 0260 22
UN01NOV01
2. Fill motor with hydraulic oil until oil reaches top of drain port.
NOTE: Use a funnel with suitable diameter neck to allow air to escape while filling.
3. Connect drain line (1).
1Propel Motor Drain Line
200CLC and 230CLC Propel Motor Drain Line
270CLC Propel Motor Drain Line
CED,OUOE023,169 1919NOV011/1
Rotary Manifold Repair

Remove and Install Rotary Manifold CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 2. Disconnect upper hydraulic lines.
OUOE049,0000051 1919NOV011/5
TM1931 (09JAN04)
02-0260-22

010904
PN=100
T139271D
UN03MAY01
T146686C
Hydraulic System
3. Remove cap screws (2) and bracket (1). 4. Attach the rotary manifold to a hoist using a lifting strap and two Rotary Manifold Lifting Tool. (Group 9900.) 5. Disconnect lower hydraulic lines.
1Bracket 2Cap Screw (2 used)
UN20JUL01
02 0260 23
OUOE049,0000051 1919NOV012/5

Rotary ManifoldSpecification Rotary ManifoldWeight................................... 27 kg (60 lb) approximate
7. Replace parts as necessary. 8. Install rotary manifold. Tighten four mounting cap screws.
Rotary ManifoldSpecification Manifold-to-Frame Cap Screw Torque ............................................................................. 34 Nm (25 ft-lb)
9. Install stop bracket. Tighten cap screws.

Rotary ManifoldSpecification Stop Bracket-to-Frame Cap ScrewTorque ................................................................ 40 Nm (30 lb-ft)
10. Connect upper and lower hydraulic lines. See Propel System Component Location. (Group 9025-15.)
OUOE049,0000051 1919NOV013/5
TM1931 (09JAN04)
02-0260-23

010904
PN=101
T7685JC
UN27APR92
6. Remove four mounting cap screws. Lower rotary manifold.
T143108B
Hydraulic System
Disassemble and Assemble Rotary Manifold 1. Make alignment marks on spindle (B), housing (G) and cover (K) to aid in assembly. 2. Remove parts (HL). Carefully remove spindle assembly (B) from housing (G). 3. Remove plugs in spindle and clean ports.
02 0260 24
4. Remove parts (CF). 5. Inspect and repair as necessary. 6. Install parts (CF). 7. Install spindle assembly (B) in housing (G), aligning marks made during disassembly. 8. Install parts (HL), aligning marks made during disassembly and tighten cap screws.
Rotary ManifoldSpecification Cover-to-Housing Cap Screw Torque ............................................................................. 49 Nm (36 lb-ft)
9. Install plugs.
APlug BSpindle Assembly COil Seal DO-Ring EBushing FOil Seal Rings (6 used) GHousing HRing ISnap Ring JO-Ring KCover LCap Screw (4 used)
UN17JUN98
OUOE049,0000051 1919NOV014/5
TM1931 (09JAN04)
02-0260-24

010904
PN=102
T115530
Hydraulic System
Rotary Manifold Air Test 1. Install a plug in one port. 2. Apply air pressure using JDG185 Air Test Plug and shop air pressure through the other port in that passage. 3. Listen for air leaks at ports on either side of pressurized port.
T6557JB
UN01NOV88
OUOE049,0000051 1919NOV015/5
02 0260 25
TM1931 (09JAN04)
02-0260-25

010904
PN=103
Hydraulic System
02 0260 26
TM1931 (09JAN04)
02-0260-26

010904
PN=104
Section 04
Engine
Contents
Page
Group 0400Removal and Installation Engine Repair . . . . . . . . . . . . . . . . . . . . . . .04-0400-1 Fuel Injection Pump Repair . . . . . . . . . . . . . .04-0400-4 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-5
04
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04-1

010904
PN=1
Contents
04
TM1931 (09JAN04)
04-2

010904
PN=2
Group 0400
Removal and Installation

Engine Repair
Remove and Install Engine CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to first stop to relieve pressure, then remove. 1. Disconnect battery ground (negative) cable. 2. Drain coolant. Approximate capacity of cooling system is 23.0 L (24.3 qt). See Drain Cooling System. (Operators Manual.) 3. Remove fan guard, radiator shroud, fan blade and spacer. See Fan, Fan Guard, and Fan Shroud Repair. (Group 0510.) 4. Disconnect charge air cooler hoses. 5. Remove upper and lower radiator hoses. 6. Disconnect air intake hose. 7. Remove muffler and muffler bracket.
TS281
UN23AUG88
04 0400 1
NOTE: Label wiring to aid installation.

8. Disconnect engine wiring. See Machine Harness (W2) Component Location. (Group 9015-10.)
NOTE: It is not necessary to discharge the air conditioning system.

9. Disconnect air conditioner compressor bracket from engine. Secure compressor and bracket so it will not interfere with engine removal. 10. Relieve Fuel System Pressure. (CTM170.) 11. Disconnect fuel filter input line, fuel filter overflow tube, and fuel pump overflow tube. 12. Disconnect heater hoses.
TX,04,DH5305 1919NOV011/4
TM1931 (09JAN04)
04-0400-1

010904
PN=107

EngineSpecification Hydraulic Pump and Drive GearboxWeight .......................................... 170 kg (375 lb) approximate
13. Support main hydraulic pump and drive gearbox using DFT1119 Pump Support (A) and a small hoist winch (B). (Group 9900.)
ADFT1119 Pump Support BHoist Winch
04 0400 2
TX,04,DH5305 1919NOV012/4

EngineSpecification EngineWeight ........................................... 954 kg (2100 lb) approximate
IMPORTANT: The recommended method for lifting the engine is using the JDG23 Lifting Sling. The lifting force must be at 90 at the lifting points. 14. Attach JDG23 Lifting Sling (1) to engine as shown. 15. Remove cap screws securing main hydraulic pump and drive gearbox to engine flywheel housing.
1Engine Lifting Sling
TX,04,DH5305 1919NOV013/4
TM1931 (09JAN04)
04-0400-2

010904
PN=108
T143006B
UN20JUL01
T104491
UN17OCT96

5
4 1
5 4 2 4 5
UN19NOV01
3
04 0400 3
4 5
T143012
1Bracket, Right Front 2Bracket, Left Front
3Bracket, Rear (2 used)
4Cap Screw (14 used)
5Washer (14 used)
16. Remove cap screws (4) and washers (5) from engine mounts. 17. Raise engine slightly. Move engine away from hydraulic pump and drive gearbox. Lift and remove engine when disengaged from hydraulic pump drive coupling. 18. Repair or replace parts as necessary. If disassembly is necessary, see Engine Disassembly Sequence. (CTM104.) CAUTION: Heavy component; lift engine using JDG23 Lifting Sling. Lifting force must be 90 to engine lift points.
EngineSpecification EngineWeight .................................... 954 kg (2100 lb) approximate
Tighten cap screws.

EngineSpecification Engine Mount Cap Screw Torque................................................................... 350 Nm (260 lb-ft)
20. Align hydraulic pump and drive gearbox to engine and tighten cap screws.
EngineSpecification Drive Gearbox-to-Flywheel Housing Cap ScrewTorque ................................... 50 Nm (37 lb-ft)
21. Connect engine wiring. See Machine Harness (W2) Component Location Diagram. (Group 9015-10.) 22. Fill radiator and reservoir with coolant. See Cooling System Fill and Deaeration Procedure. (Operators Manual.) 23. Bleed Fuel System. (Operators Manual.)
19. Use JDG23 Lifting Sling to install engine. Install engine mount cap screws (5) and washers (4).
TX,04,DH5305 1919NOV014/4
TM1931 (09JAN04)
04-0400-3

010904
PN=109
T143012
Fuel Injection Pump Repair

Remove and Install Fuel Injection Pump IMPORTANT: Never steam clean or pour cold water on injection pump while pump is running or still warm to prevent pump seizure. For replacement of fuel injection pump, see the following: 200CLC (S.N. 504000), 230CLC and 270CLC See Remove Bosch VP44 Fuel Injection Pump. (CTM170.) 200CLC (S.N. 504001) Perform Remove Injection Pump. (CTM331.)
04 0400 4
TX,04,DH5307 1910NOV031/1
TM1931 (09JAN04)
04-0400-4

010904
PN=110
Starter Repair
Remove and Install Starter IMPORTANT: Always disconnect battery ground (negative) cable before removing starter to prevent short circuits. 1. Disconnect battery ground (negative) cable. 2. Disconnect ground strap and electrical connectors. CAUTION: Heavy component; use a hoist.
StarterSpecification StarterWeight ................................................. 23 kg (50 lb) approximate 1Starter
T144796B
UN15AUG01
3. Remove starter (1). 4. Replace parts as necessary. 5. Install starter (1). 6. Tighten cap screws.
StarterSpecification Starter Mounting Cap Screw Torque ............................................................................. 47 Nm (35 lb-ft)
04 0400 5
7. Connect ground strap and electrical connectors. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015-10.) 8. Connect battery ground (negative) cable.
TX,04,DH5312 1919NOV011/1
TM1931 (09JAN04)
04-0400-5

010904
PN=111
04 0400 6
TM1931 (09JAN04)
04-0400-6

010904
PN=112
Section 05
Engine Auxiliary System

Contents
Page
Group 0510Cooling System Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1 Fan, Fan Guard and Fan Shroud . . . . . . . . .05-0510-1 Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-2 Group 0520Intake System Air Intake System Leakage Test . . . . . . . . . .05-0520-1 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-2 Group 0560External Fuel Supply System Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0560-1 Primary Fuel Filter (Water Separator) . . . . . .05-0560-3 Final Fuel Filter . . . . . . . . . . . . . . . . . . . . . . .05-0560-4
05
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05-1

010904
PN=1
Contents
05
TM1931 (09JAN04)
05-2

010904
PN=2
Group 0510
Cooling System
Radiator Repair
Remove and Install Radiator CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 1. Drain coolant from radiator. Approximate capacity is 28.4 L (30 qt). 2. Remove upper and lower radiator hoses and overflow hose. 3. Remove cap screws (13). CAUTION: Heavy component; use a hoist.
RadiatorSpecification RadiatorWeight .............................................. 39 kg (85 lb) approximate 05 0510 1
4. Attach radiator to hoist and remove. 5. Repair or replace as necessary. 6. Install radiator and tighten cap screws (13). 7. Fill radiator and reservoir with coolant. See Cooling System Fill and Deaeration Procedure. (See Operators Manual.) 8. Start engine and check for leaks.
1Cap Screw (9 used) 2Cap Screw (6 used) 3Cap Screw (4 used)
TX,05,DH5317 1919NOV011/1
Fan, Fan Guard, and Fan Shroud Repair

Remove and Install Fan, Fan Guard, and Fan Shroud
TX,05,DH5318 1919NOV011/2
TM1931 (09JAN04)
05-0510-1

010904
PN=115
T142681
UN02AUG01
TS281
UN23AUG88
Cooling System
CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 1. Remove cap screws (1). Remove fan guard. 2. Remove cap screws (3). Slide fan shroud toward engine. 3. Remove cap screws (2). Remove fan, and fan shroud. 4. Replace parts as necessary. 5. Install fan. Tighten cap screws.
05 0510 2 FanSpecification Engine Fan-to-Pulley Cap ScrewTorque ................................................................ 70 Nm (50 lb-ft)
UN02AUG01
1Cap Screw (4 used) 2Cap Screw (4 used) 3Cap Screw (8 used)
Fan Guard200CLC and 230CLC
Fan Guard270CLC
TX,05,DH5318 1919NOV012/2
Fan Belt Repair

Remove and Install Fan Belt
TX,05,DH5319 1919NOV011/2
TM1931 (09JAN04)
05-0510-2

010904
PN=116
T147134B
UN19NOV01
T142994B
TS281
UN23AUG88
Cooling System
1. Remove fan guard. See Fan, Fan Guard, and Fan Shroud Repair. (See procedure in this group.) 2. Remove air conditioning compressor belt. 3. Place a 15 mm wrench on hex head of cap screw (A) in center of tension adjuster idler. 4. Pull idler away from belt to release belt tension. 5. Remove fan belt. 6. Inspect belt for wear or cracks. Replace as necessary. 7. Install fan belt.
AHex Head of Cap Screw
UN25MAR97
05 0510 3
TX,05,DH5319 1919NOV012/2
TM1931 (09JAN04)
05-0510-3

010904
PN=117
T108219
Cooling System
05 0510 4
TM1931 (09JAN04)
05-0510-4

010904
PN=118
Group 0520
Intake System
Air Intake System Leakage Test
1. Remove air cleaner cover. Remove primary filter element.
UN23FEB89 UN25OCT88 T5906AP
2. Put a large plastic bag inside and over end of element as shown. Install element and cover. 3. Remove fitting for start aid nozzle from intake manifold. 4. Install the JDG51 Inlet Air Adapter (A). 5. Connect air pressure regulator to adapter using hose and fitting. IMPORTANT: Plastic bag could be drawn into the engine causing damage if engine starts. Do not start the engine when turning the engine crankshaft to close valves. 6. Pressurize air intake system to 1421 kPa (0.14 0.21 bar) (23 psi). If intake system cannot be pressurized, turn engine crankshaft slightly to close valves.
Air Intake SystemSpecification Leakage TestPressure .............................. 1421 kPa (0.140.21 bar) (23 psi) AJDG51 Inlet Air Adapter
7. Spray a soap solution over all connections from the air cleaner to turbocharger and intake manifold. Check for leaks. Correct all leaks 8. When installing start aid nozzle, be certain arrow on nozzle is pointing against intake air flow.
TX,05,GG2309 1919NOV011/1
TM1931 (09JAN04)
05-0520-1

010904
PN=119
T6089AR
05 0520 1
Intake System
Air Cleaner Repair
05 0520 2
1Valve 2Air Cleaner 3Indicator 4Clamp (3 used)
5Hose 6Hose 7Cap Screw (4 used)
8Inner Filter Element 9Wing Nut (3 used) 10Outer Filter Element
11Gasket 12Clip 13Cover
Remove and Install Air Cleaner
NOTE: Tighten hose clamps until rubber hose begins to deform.

OUOE027,0000040 1919NOV011/1
TM1931 (09JAN04)
05-0520-2

010904
PN=120
T144782
UN19NOV01
Group 0560
External Fuel Supply System

Fuel Tank Repair
05 0560 1
1Fuel Strainer 2Filler Cap 3Fuel Tank 4Plug 9Bracket
10Cap Screw 11Float (Fuel Level Sender) 12Cap Screw (5 used) 13Gasket 14Lock Washer
15Switch 16Sealing Washer 18Drain Valve 19Fitting 20Plug
22Cap Screw (4 used) 23Lock Washer (4 used) 25Washer (4 used) 26Wiring Connector
TX,05,GG2307 1919NOV011/2
TM1931 (09JAN04)
05-0560-1

010904
PN=121
T105203
UN19NOV96

Remove and Install Fuel Tank 1. Drain fuel from fuel tank. Approximate capacity is 360 L (95 gal). 2. Disconnect wiring connector (26). CAUTION: Heavy component; use a hoist.
Fuel TankSpecification Fuel TankWeight ................................... 91 kg (200 lb) approximate without fuel
6. Install float (fuel level sender) (11) and tighten cap screws (12).
Fuel TankSpecification Float (Fuel Level Sender) and Gasket-to-Fuel Tank Cap ScrewTorque ....................................................... 4.5 Nm (40 lb-in.)
7. Install fuel tank (3) and tighten cap screws (22).

Fuel TankSpecification Frame-to-Fuel Tank Cap ScrewTorque ..................................................... 205 Nm (152 lb-ft)
3. Remove cap screws (22) and remove fuel tank. 4. Repair or replace as necessary.
8. Fill fuel tank with proper fuel. See Diesel Fuel. (Operators Manual.) 9. Bleed Fuel System. (CTM 170.)
5. Apply thread lock and sealer (medium strength) to thread of cap screws (12).
05 0560 2
TX,05,GG2307 1919NOV012/2
TM1931 (09JAN04)
05-0560-2

010904
PN=122
Primary Fuel Filter (Water Separator) Repair

Remove and Install Primary Fuel Filter (Water Separator) 1. Loosen drain valve to drain fuel into a container. Dispose of fuel properly. 2. Loosen clamps (2) and disconnect hoses (34). 3. Remove cap screws (1) and remove primary fuel filter (5). 4. Replace parts as necessary. Disassemble and assemble primary fuel filter as required. See Final Fuel Filter Assembly - Tier 2. (CTM170.) 5. Install primary fuel filter and tighten cap screws.
UN02AUG01
6. Bleed Fuel System. (Operators Manual.)

1Cap Screw, Lock Washer and Washer (2 used) 2Clamp (2 used) 3Primary Filter-to-Fuel Tank 4Primary Filter-to-Final Fuel Filter 5Primary Fuel Filter (Water Separator)
200CLC Shown
TX,05,GG2315 1919NOV011/1
TM1931 (09JAN04)
05-0560-3

010904
PN=123
T142498B
05 0560 3
Final Fuel Filter Repair

Remove and Install Final Fuel Filter 1. Loosen drain valve to drain fuel into a container. Dispose of fuel properly. 2. Disconnect electrical connectors (1 and 7). 3. Disconnect lines (4, 5 and 8). 4. Remove cap screws (2) and remove final fuel filter (6). 5. Replace parts as necessary. Disassemble and assemble final fuel filter as required. See Final Fuel Filter Assembly - Tier 2. (CTM170.) 6. Install final fuel filter (6) and tighten cap screws (2). 7. Connect electrical connectors (1 and 7).
05 0560 4 1Transfer Pump Electrical Connector 2Cap Screw (2 used) 3Transfer Pump 4Final Fuel Filter-to-Injector Pump Line 5Injector Return Port-to-Final Fuel Filter Line 6Final Fuel Filter 7Fuel Pressure Sensor Electrical Connector 8From Primary Fuel Filter Line 9Clamp
UN02AUG01
8. Connect lines (4, 5 and 8). 9. Bleed Fuel System. (Operators Manual.)
TX,05,GG2314 1919NOV011/1
TM1931 (09JAN04)
05-0560-4

010904
PN=124
T142510B
Section 07
Dampener Drive (Flex Coupling)

Contents
Page
Group 0752Elements Dampener Drive (Flex Coupling) . . . . . . . . . .07-0752-1
07
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07-1

010904
PN=1
Contents
07
TM1931 (09JAN04)
07-2

010904
PN=2
Group 0752
Elements
Dampener Drive (Flex Coupling) Repair
Remove and Install Dampener Drive (Flex Coupling) 1. Remove hydraulic pump. See Hydraulic Pump and Drive Gearbox Repair. (Group 3360.)
NOTE: Flex coupling may come off with pump or stay on flywheel.
2. Remove parts (AH). 3. Replace parts as necessary. 4. Install parts (AH). Apply thread lock and sealer (medium strength) to set screws (B) and to cap screws (D and G).
5. Tighten set screws (B).

Dampener Drive (Flex Coupling)Specification Coupling-to-Pump Shaft Set ScrewTorque .............................................................. 108 Nm (80 lb-ft)
6. Tighten cap screws (D and G).

Dampener Drive (Flex Coupling)Specification Insert-to-Flywheel and Coupling Cap ScrewTorque .................................................... 215 Nm (160 lb-ft)
T105285
UN20NOV96
NOTE: Spring pin (F) is for alignment of insert (E) to flywheel.
7. Install hydraulic pump. See Hydraulic Pump and Drive Gearbox Repair. (Group 3360.)
ACoupling BSet Screw (2 used) CFlex Coupling DCap Screw (4 used) EInsert (4 used) FSpring Pin (4 used) GCap Screw (4 used) HInsert (4 used)
07 0752 1
TX,07,DH5336 1919NOV011/1
TM1931 (09JAN04)
07-0752-1

010904
PN=127
Elements
07 0752 2
TM1931 (09JAN04)
07-0752-2

010904
PN=128
Section 17
Frame or Supporting Structure

Contents
Page
Group 1740Frame Installation Welding On Machine . . . . . . . . . . . . . . . . . . .17-1740-1 Welding Repair of Major Structure. . . . . . . . .17-1740-2 Group 1749Chassis Weights Counterweight . . . . . . . . . . . . . . . . . . . . . . . .17-1749-1
17
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17-1

010904
PN=1
Contents
17
TM1931 (09JAN04)
17-2

010904
PN=2
Group 1740
Frame Installation
Welding On Machine
IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery, EPC controller. Disconnect battery ground cable and EPC electrical connectors before welding on the machine. Before welding on the machine, follow the steps listed below to protect the machine electrical system.
TX,16,UU3948 1916OCT001/2
1. Disconnect the battery ground and positive cables.
NOTE: Console cover located behind seat in cab, must be removed to gain access to engine and pump controller connectors.
2. Remove rear console cover. 3. Disconnect electrical connectors (1) from engine and pump controller.
UN20JUL01 T143053B
NOTE: See cab harness (W1) component location diagram for connector information.
1EPC connector (4 used).
17 1740 1
TX,16,UU3948 1916OCT002/2
TM1931 (09JAN04)
17-1740-1

010904
PN=131
Frame Installation
Welding Repair of Major Structure

CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 1. Remove paint before welding or heating. IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to "OFF". Also disconnect the wiring harness connectors to the engine and pump controller. Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter. 2. Use one of the following weld processes: AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process. AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.
Welding Repair of Major StructureSpecification Weld MetalTensile Strength ....................... 482.6 mPa (70,000 psi) Yield Strength ................................................ 413.7 mPa (60,000 psi) Elongation ..................................................................................... 22%
IMPORTANT: Area to be repaired must be preheated to allow better weld penetration. 3. To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38C (100F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177C (350F). To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural assemblies to a minimum of 38C (100F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177C (350F).
Welding Repair of Major StructureSpecification Structural AssembliesPreheat Temperature ................................................................... 38C (100F) Ground Engaging Tools Preheat Temperature.................................................... 177C (350F)
17 1740 2
TX,17,GG2439 1919SEP981/1
TM1931 (09JAN04)
17-1740-2

010904
PN=132
Group 1749
Chassis Weights
Counterweight Repair
Remove and Install Counterweight 1. Park machine on level ground. 2. Remove two plastic caps from top of counterweight (1). CAUTION: Heavy component; use a hoist. The lifting capacity of a lifting eyebolt decreases as the lift angle increases from vertical. A spreader bar should be used to obtain, as close as possible, a vertical lift from eyebolts.
CounterweightSpecification Counterweight (200CLC)Weight ............ 4250 kg (9370 lb) approximate Counterweight (230CLC)Weight ......... 5400 kg (11,900 lb) approximate Counterweight (270CLC)Weight ......... 6100 kg (13,450 lb) approximate
UN20JUL01 UN20JUL01 T143044 UN03SEP02 T143043
NOTE: For 270CLC, use JT05558 Metric Lifting Eyebolt with spreader bar.
3. Connect the counterweight to a hoist (2) using a spreader bar (3). 4. Remove cap screws and washers (4). 5. Remove counterweight. 6. Repair or replace as necessary. 7. Install cap screws and washers (4) and tighten.
CounterweightSpecification Frame-to-Counterweight Cap Screw (200CLC)Torque ......................................... 1150 Nm (830 lb-ft) Frame-to-Counterweight Cap Screw (230CLC and 270CLC) Torque ..................................................................... 1910 Nm (1410 lb-ft)
17 1749 1
1Counterweight 2Hoist 3Spreader Bar 4Cap Screw and Washer (4 used)
OUOE027,000003C 1919NOV011/1
TM1931 (09JAN04)
17-1749-1

010904
PN=133
T143045
Chassis Weights
17 1749 2
TM1931 (09JAN04)
17-1749-2

010904
PN=134
Section 18
Operators Station
Contents
Page
Group 1800Removal and Installation Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Group 1810Operator Enclosure Windowpane Two Piece Molding . . . . . . . . . . . . . . . . . .18-1810-1 One Piece Molding . . . . . . . . . . . . . . . . . .18-1810-2 Sliding Windows . . . . . . . . . . . . . . . . . . . . . .18-1810-3 Windowpanes . . . . . . . . . . . . . . . . . . . . . . . .18-1810-4 Group 1821Seat and Seat Belt Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-1 Group 1830Heating and Air Conditioning Refrigerant Cautions and Proper Handling . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1 Flush and Purge Air Conditioner System. . . .18-1830-3 R134a Refrigerant Oil Information . . . . . . . . .18-1830-6 R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Recover R134a Refrigerant . . . . . . . . . . . . . .18-1830-8 Evacuate R134a System . . . . . . . . . . . . . . . .18-1830-9 Charge R134a System . . . . . . . . . . . . . . . .18-1830-10 Compressor. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Receiver-Dryer . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Air Conditioner and Heater . . . . . . . . . . . . .18-1830-14 Condenser . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-16
18
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010904
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Contents
18
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010904
PN=2
Group 1800

Cab Repair
Remove and Install Cab
NOTE: Seat removal is optional.

1. Disconnect battery ground (-) cable at battery. 2. Remove monitor controller. See Remove and Install Monitor Controller and Display (A5). (Group 9015-20.) 3. Disconnect electrical connectors. 4. Remove fresh air intake cowl. 5. Disconnect windshield washer hose.
SMCLEAN,000000B 1919NOV011/4
18 1800 1
TM1931 (09JAN04)
18-1800-1

010904
PN=137
3 2 1 2
3 2 4 5
3 2
18 1800 2
T143008
1Cap Screw (2 used) 2Washer (9 used)
3Cap Screw (7 used) 4Lock Nut (4 used)
5Washer (4 used)
6Rubber Mount (4 used)

SMCLEAN,000000B 1919NOV012/4
TM1931 (09JAN04)
18-1800-2

010904
PN=138
T143008
UN20JUL01

6. Remove lock nuts (4) securing cab to rubber mounts at all four corners. Discard lock nuts. 7. Remove cap screws (1 and 3).
SMCLEAN,000000B 1919NOV013/4

CabSpecification CabWeight ................................................. 290 kg (640 lb) approximate
NOTE: Move cab forward slightly to clear propel pedals during removal.
9. Remove cab. 10. Repair or replace parts as necessary.
NOTE: Check that all lines and cables are out of the way before installing cab.
11. Install cab. 12. Install cap screws (1 and 3).
CabSpecification Cab-to-Platform Cap Screw Torque ............................................................................. 50 Nm (37 lb-ft)
13. Install washers (5) and new lock nuts (4).

CabSpecification Cab Mount Lock NutTorque .................................... 205 Nm (152 lb-ft)
14. Connect electrical connectors. See Monitor Harness (W3) Component Location and See Cab Harness (W1) Component Location Diagram. (Group 9015-05.) 15. Install monitor controller. See Remove and Install Monitor Controller and Display (A5). (Group 9015-20.)
T106453
UN15JAN97
8. Use lifting straps and connect cab to hoist.
18 1800 3
SMCLEAN,000000B 1919NOV014/4
TM1931 (09JAN04)
18-1800-3

010904
PN=139
18 1800 4
TM1931 (09JAN04)
18-1800-4

010904
PN=140
Group 1810
Operator Enclosure
Windowpane and Two Piece Molding Repair
Remove and Install Windowpane and Two Piece Molding
UN19OCT88
1. Use insert tool to remove locking strip (A) from molding.

ALocking Strip
TX,1800,VV2501 1921SEP981/4
IMPORTANT: Extreme care is required prevent windowpane damage. 2. Carefully push windowpane out from molding.
UN19OCT88
3. Inspect molding for damage; replace if necessary.
TX,1800,VV2501 1921SEP982/4
4. Apply instant gel adhesive in molding (B) frame channel. Install molding. 5. Install windowpane using insertion tool (A) and soap lubricant.
AWindow Pane BWindowpane Insertion Tool
UN19OCT88
T5903AJ
T5903AI
TX,1800,VV2501 1921SEP983/4
6. Use weather strip installation tool (B) to install locking strip (A).
ALocking Strip BWeather Strip Installation Tool
UN19OCT88
TX,1800,VV2501 1921SEP984/4
TM1931 (09JAN04)
18-1810-1

010904
PN=141
T5903AL
T5903AK
18 1810 1
Operator Enclosure
Windowpane and One Piece Molding Repair

Remove and Install Windowpane and One Piece Molding
UN19OCT88
1. Lift inside of molding over cab frame and carefully push windowpane and molding out. 2. Remove molding from windowpane; replace if necessary.
TX,18,VV2502C 1910JAN971/2
3. Install molding on windowpane. Position drain notches (A) at bottom and towards outside of windowpane. 4. Install windowpane and molding. Lift inside of molding over cab frame.
ADrain Notches
UN19OCT88
TX,18,VV2502C 1910JAN972/2
18 1810 2
TM1931 (09JAN04)
18-1810-2

010904
PN=142
T6439XD
T6439XE
Operator Enclosure
Sliding Windows Repair

Remove and Install Sliding Windows 1. Remove molding (3) from inside of window. 2. Use putty knife to cut adhesive (4) between cab flange and window frame (1). IMPORTANT: Work carefully to avoid damaging frame and windowpane. Two technicians are required during window removal; one to push window out of cab, and one to prevent window from falling. 3. Carefully remove window frame from cab. 4. Lift frame slightly at top-center to remove and install windowpanes. 5. Apply instant gel adhesive to cab flange. 6. Install windows and frame with spacers (2) at the bottom. 7. Using water as a lubricant, push window frame tight against cab flange. 8. Install molding (3) around window and cab flange.
1Window Frame 2Bottom Spacer (4 used) 3Molding 4Adhesive
UN30APR01
OUOE047,0000044 1911APR011/1
T140968
18 1810 3
TM1931 (09JAN04)
18-1810-3

010904
PN=143
Operator Enclosure
Windowpanes Repair
Remove and Install Windowpanes The adhesive used to secure windowpanes is a urethane adhesive used on automobile windshields. Urethane adhesive manufactured by Loctite Corporation or equivalent is recommended. DO NOT use any other type of adhesive. It is recommended that an auto glass dealer install windowpanes. IMPORTANT: Windowpanes must include an ultra-violet barrier around edge so adhesive will not deteriorate. Windowpanes ordered through John Deere Parts have this ultra-violet barrier. If windowpane is purchased through glass dealer, the dealer must incorporate an ultra-violet barrier on the glass. 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. DO NOT remove adhesive from window frame or cab. IMPORTANT: Adhesive will not stick to bare metal. 3. If existing adhesive is removed and paint is scraped, paint window frame. Paint must be fully cured before installing windowpane. 4. Trim existing adhesive to form a smooth surface. IMPORTANT: Follow manufacturers instructions for using adhesive. 5. Apply 6 mm (1/4 in.) bead of adhesive over existing adhesive. 6. Position windowpane in cab frame. Use hand pressure to force windowpane down until edges are even with metal frame. 7. Secure windowpane with duct tape until adhesive cures. Allow adhesive to cure for 24 hours before operating machine.
T52,1810,C19 1905JUN981/1
18 1810 4
TM1931 (09JAN04)
18-1810-4

010904
PN=144
Group 1821
Seat and Seat Belt

Seat Belt Repair
18 1821 1
TX,18,GG2447 1914JAN971/2
TM1931 (09JAN04)
18-1821-1

010904
TP48113
UN05AUG96
PN=145
Seat and Seat Belt

0Seat Belt 1Bracket 3Belt 4Belt 5Spacer (Sleeve) 6Spacer (Sleeve) (2 used) 8Cap Screw 11Cap Screw (2 used) 12Spring Washer (4 used)
TX,18,GG2447 1914JAN972/2
18 1821 2
TM1931 (09JAN04)
18-1821-2

010904
PN=146
Group 1830
Heating and Air Conditioning

Refrigerant Cautions and Proper Handling
CAUTION: DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment. DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials. DO NOT heat refrigerant over 52C (125F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment. IMPORTANT: To meet government standards relating to the use of refrigerants,
18 1830 1
R134a is used in the air conditioning system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere. However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the appropriate recovery stations. Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings, components or refrigerant oils. Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling and charging station equipment. Care must be taken to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of system. JT02167A refrigerant test instrument should be used before any testing or repair to system is preformed.
TX,9031,DY5073 1919NOV011/2
TM1931 (09JAN04)
18-1830-1

010904
PN=147

Prism Pro Refrigerant Identification Instrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems.
TX,9031,DY5073 1919NOV012/2
18 1830 2
TM1931 (09JAN04)
18-1830-2

010904
PN=148
Flush and Purge Air Conditioner System

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) b. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. c. Pour flushing solvent into suction port and discharge port. Plug both ports in compressor manifold, using JT02099 and JT03194 Caps.
Flush and Purge Air Conditioner SystemSpecification Flushing Solvent in Suction PortVolume............................................................. 240 mL (8 fl oz) Flushing Solvent in Discharge PortVolume............................................................. 120 mL (4 fl oz)
NOTE: Flushing can be performed on machine.

1. Recover R134a Refrigerant. (See procedure in this group.) Add flushing solvent to system with JT02075 Flusher and JT02098 Flusher Fitting Kit. 2. Remove and discard receiver/dryer. 3. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. 4. Fill flusher tank with solvent and fasten all connections. Dispose of solvent properly.
Flush and Purge Air Conditioner SystemSpecification Flusher TankCapacity ..................................................... 4 L (1 gal)
d. Turn compressor end for end and roll it side to side. e. Remove both plugs from manifold ports and drain solvent from compressor. f. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders. g. Invert compressor. Roll end for end and side to side. Drain thoroughly. h. Repeat previous two steps at least three times.
NOTE: Air pressure must be at least at specification for flushing and purging.
Flush and Purge Air Conditioner SystemSpecification Air PressurePressure ............................. 620 kPa (90 psi) (6.2 bar) minimum for flushing and purging
8. Divide system into two circuits: Condenser circuit, including inlet and outlet hoses. Evaporator circuit, including inlet and outlet hoses. 9. Condenser: IMPORTANT: DO NOT attempt to flush through compressor or receiver/dryer. Flushing through expansion valve is acceptable if refrigerant oil has a normal odor and appearance. a. Flush/Purge Condenser:
5. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve. 6. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. 7. Clean compressor as follows: a. Remove compressor and measure oil drained from both manifold ports.
18 1830 3
TX,18,DU2461 1919NOV011/3
TM1931 (09JAN04)
18-1830-3

010904
PN=149

b. Remove and discard receiver/dryer. c. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. d. Fill flusher tank with solvent and fasten all connections.
If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. See following steps to flush evaporator through expansion valve, if oil appears normal. 11. Flush evaporator: a. Remove evaporator and expansion valve. See Air Conditioner and Heater Repair. (See procedure in this group.) b. Force flushing solvent through evaporator inlet with compressed air.
NOTE: Air pressure must be at least to specification for flushing and purging.
Flush and Purge Air Conditioner SystemSpecification Air PressurePressure ............................. 620 kPa (90 psi) (6.2 bar) minimum for flushing and purging.
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 of receiver/dryer outlet hose using JT03188 adapter. b. Fill flusher tank and fasten all connections.
e. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve. f. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. g. Attach a return hose and aerator nozzle to end of receiver/dryer inlet hose using JT03197 Adapter. Put nozzle in container to collect flushing solvent.
NOTE: Air pressure must be at least to specification for flushing and purging.
Flush and Purge Air Conditioner SystemSpecification Air PressurePressure ............................. 620 kPa (90 psi) (6.2 bar) minimum for flushing and purging.
18 1830 4
NOTE: Purging the condenser circuit takes 1012 minutes to thoroughly remove solvent.
h. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry. 10. See flush evaporator, if evaporator requires flushing.
c. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve. d. Attach a hose and aerator nozzle to compressor inlet line using JT02101 adapter. Put nozzle in a container to collect solvent.
TX,18,DU2461 1919NOV012/3
TM1931 (09JAN04)
18-1830-4

010904
PN=150
Heating and Air Conditioning NOTE: Purging evaporator circuit takes 1215 minutes to thoroughly remove solvent.
13. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard and continue purging until cardboard is dry. 14. Install a new receiver/dryer compatible with R134a refrigerant. Fasten connections and mounting bracket. See Receiver-Dryer Repair. (See procedure in this group.) 15. Add required oil. See R134a Refrigerant Oil Information. (See procedure in this group.) 16. Install compressor and connect refrigerant lines to manifold. 17. Connect clutch coil wire and install drive belt.
TX,18,DU2461 1919NOV013/3
18 1830 5
TM1931 (09JAN04)
18-1830-5

010904
PN=151
R134a Refrigerant Oil Information

CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. IMPORTANT: Do not add any more oil than required or maximum cooling will be reduced. DO NOT leave system or R134a compressor oil containers open. Refrigerant oil easily absorbs moisture. DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils. A new compressor from parts depot contains new oil. The oil level visible through the suction port normally is below the drive shaft. Normal operating oil level of a compressor removed from operation cannot be seen through suction port of compressor. Compressors can be divided into three categories when determining correct oil charge for system. New compressor from parts depot Used compressor removed from operation Compressor internally washed with flushing solvent
18 1830 6 Refrigerant Oil CapacitySpecification OilVolume ............................................................ 210 mL (7.1 fl oz) R134aWeight.............................................. 850 50g (1.9 0.1 lb)
If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl oz per ft ) to determine correct amount of oil to be added. Drain compressor oil into graduated container while rotating compressor shaft and record amount. If oil drained from a compressor removed from operation is very black or amount of oil is less than 6 mL (0.2 fl oz), perform the following and discard oil properly: Determine if R134a leakage was detected, remove component and repair or replace component. Remove and discard receiver/dryer. Flush complete system with TY16134 Air Conditioning Flushing Solvent. If component is serviceable, pour flushing solvent in ports and internally wash out old oil and discard oil properly. Install a new receiver-dryer. See Receiver-Dryer Repair. (See procedure in this group.) Install required amount of TY22025 Refrigerant Oil in compressor. Connect all components, evacuate and charge system. See Evacuate R134a System and Charge R134a System. (See procedures in this group.)
Determining the amount of system oil charge prior to installation of compressor on a machine. When complete system, lines, and components are flushed add correct amount of oil as described.
TX,9031,QQ2365 1919NOV011/1
TM1931 (09JAN04)
18-1830-6

010904
PN=152
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) IMPORTANT: Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling and charging station equipment. CAUTION: Do not remove high pressure relief valve (D). Air conditioning station will discharge rapidly causing possible injury. IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Follow procedures. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) 2. Close both high-side and low-side valves on refrigerant recovery/recycling and charging station (E). 3. Remove cap from low-side charge port. 4. Connect blue hose (C) from refrigerant recovery/recycling and charging station (E) to low-side test port. 5. Remove cap (A) from charge port on high pressure hose and connect red hose (B). 6. Follow the manufacturers instructions when using refrigerant recovery/recycling and charging station.
AHigh Pressure Hose Charge Port Cap BRed Hose CBlue Hose DHigh Pressure Relief Valve ERefrigerant Recovery/Recycling and Charging Station
T8118AG
UN06DEC93
18 1830 7
TX,9031,DU1693 1919NOV011/1
TM1931 (09JAN04)
18-1830-7

010904
PN=153
Recover R134a Refrigerant

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) CAUTION: Do not remove high pressure relief valve. Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Run air conditioning system for three minutes to help in recovery process. Turn air conditioning system off before proceeding with recovery steps. 2. With engine OFF identify refrigerant type using JT02167A Refrigerant Identification Instrument. 3. Connect refrigerant recovery system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (See procedure in this group.) 4. Follow manufacturers instructions when using refrigerant recovery/recycling and charging station.
18 1830 8
TX,9031,DU1694 1919NOV011/1
TM1931 (09JAN04)
18-1830-8

010904
PN=154
Evacuate R134a System

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) Do not remove high pressure relief valve. Air conditioning system will discharge rapidly causing possible injury. 1. Connect refrigerant recovery system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (See procedure in this group.) 2. Open low-side and high-side valves on refrigerant recovery/recycling and charging station. 3. Follow manufacturers instructions and evacuate system. 4. Evacuate system until low-side gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum.
Air Conditioning SystemSpecification Evacuate SystemVacuum ............... 98 kPa (980 mbar) (29 in. Hg)
If above specification vacuum cannot be obtained in 15 minutes, test the system for leaks. See Refrigerant Leak Test. (Group 9031-25.) 5. When vacuum reaches above specification, close low-side and high-side valves. Turn vacuum pump off. 6. If vacuum decreases more than specification in 5 minutes, there is a leak in system.
Air Conditioning SystemSpecification Evacuate SystemVacuum .................. 3.4 kPa (34 mbar) (1 in. Hg)
7. Repair leak. 8. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 9. Close low-side and high-side valves. Stop evacuation. 10. Charge system. See Charge R134a System. (See procedure in this group.)
NOTE: Vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
Air Conditioning SystemSpecification Evacuate SystemVacuum ................ Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level
18 1830 9
TX,1830,DT474 1919NOV011/1
TM1931 (09JAN04)
18-1830-9

010904
PN=155
Charge R134a System

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Identify refrigerant type using JT02167A Refrigerant Identification Instrument. 2. Connect R134a Refrigerant Recovery/Recycling and Charging Station. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (See procedure in this group.) 3. Evacuate system. See Evacuate R134a System. (See procedure in this group.)
Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
Air Conditioning SystemSpecification Evacuate SystemVacuum ................ Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level
4. Follow manufacturers instructions and charge system. 5. Add refrigerant to system .

Air Conditioning SystemSpecification Air Conditioning System RefrigerantRefrigerant Quantity...................................................................... 0.85 kg (1.87 lb)
6. Check air conditioning for proper function. See Diagnose Air Conditioning System Malfunctions. (Group 9031-25.)
NOTE: Before beginning to charge air conditioning system, the following conditions must exist:
18 1830 10
TX,18,DU2481 1919NOV011/1
TM1931 (09JAN04)
18-1830-10

010904
PN=156
Compressor Repair
Remove and Install Compressor 1. Recover refrigerant from the system. See Recover R134a Refrigerant. (See procedure in this group.) 2. Disconnect electrical connector (6) and power lead (5). 3. Remove belt. 4. Remove cap screw, lock washer and washer (2). Disconnect high and low pressure lines (1). 5. Remove cap screws, lock washers and washers (3) and remove compressor (4). 6. Repair or replace parts as necessary. 7. Install compressor (4) and tighten cap screw (3).
CompressorSpecification Pressure Line Cap Screw Torque ........................................................................... 28 Nm (247 lb-in) 1Hi and Low Pressure Lines 2Cap Screw, Lock Washer and Washer 3Cap Screw, Lock Washers and Washers (4 used) 4Compressor 5Power Lead 6Electrical Connector
UN20JUL01 T143114B
8. Install high and low pressure lines (1). 9. Inspect and adjust compressor belt tension. See Inspect Fan Belt. (Operators Manual.) 10. Evacuate and charge the system. See Evacuate R134a System and Charge R134a System. (See procedures in this group.)
18 1830 11
OUOE003,00000E5 1916JUL011/1
TM1931 (09JAN04)
18-1830-11

010904
PN=157
Receiver-Dryer Repair
Remove and Install Receiver-Dryer 1. Recover refrigerant from the system. See Recover R134a Refrigerant. (See procedure in this group.) 2. Disconnect electrical connector (5). 3. Remove cap screw, lock washer, washer (2) and high-pressure input line (3). 4. Remove cap screw, lock washer, washer (4) and high-pressure output line (6). 5. Loosen cap screws (7) and remove receiver-dryer (1) from bracket (8). 6. Repair or replace parts as necessary. 7. Install receiver-dryer (1). 8. Tighten high-pressure output line cap screw (4) and high-pressure input line cap screw (2).
Receiver-DryerSpecification High-Pressure Output and Input Line Cap ScrewTorque .................................................. 5 Nm (44 lb-in)
UN20JUL01
9. Evacuate and charge the system. See Evacuate R134a System and Charge R134a System. (See procedures in this group.)
1Receiver-Dryer 2Cap Screw, Lock Washer and Washer 3High Pressure Input Line 4Cap Screw, Lock Washer and Washer 5Electrical Connector 6High Pressure Output Line 7Cap Screw (2 used) 8Bracket
18 1830 12
OUOE003,00000E6 1925JUL011/1
TM1931 (09JAN04)
18-1830-12

010904
PN=158
T143115B
18 1830 13
TM1931 (09JAN04)
18-1830-13

010904
PN=159
Air Conditioner and Heater Repair
7 4 3 8 9
1 2 11
27
10
18 1830 14
15 20 22 23 24 21 19 18 17 16
UN27AUG01
010904
12
25 26
T145044
13
14
OUOE003,00000E7 1925APR011/2
TM1931 (09JAN04)
18-1830-14

PN=160
T145044
15

1Duct 2Air Conditioner Low Pressure Hose 3Cap Screw (4 used) 4Air Conditioning Controller 5Duct 6Duct 7Cap Screw (2 used) 8Air Conditioner 9Cap Screw (6 used) 10Air Conditioner High Pressure Hose 11Cap Screw 12Bushing 13Hose 14Hose 15Hose Clamp (4 used) 16Nipple 17Gasket 18Hose 19Hose 20Duct 21Cap Screw (2 used) 22Filter 23Clip 24Clip 25Cap Screw (2 used) 26Duct 27Cap Screw (2 used)
Remove and Install Air Conditioner and Heater 1. Drain coolant from radiator. Approximate capacity is 23.0 L (6.1 gal).
3. Remove air conditioner (8). 4. Replace parts as necessary. 5. Install air conditioner.
NOTE: Evaporator and heater core are integral parts of the air conditioner. If evaporator or heater core need replacement, replace entire air conditioner unit.
2. Recover refrigerant from the system. See Recover R134a Refrigerant. (See procedure in this group.)
OUOE003,00000E7 1925APR012/2
18 1830 15
TM1931 (09JAN04)
18-1830-15

010904
PN=161
Condenser Repair
Remove and Install Condenser 1. Recover refrigerant from the system. See Recover R134a Refrigerant. (See procedure in this group.) 2. Remove cap screws (1). Secure receiver-dryer (2) and bracket so it will not interfere with condenser removal.
UN20JUL01
3. Remove cap screw, lock washer, and washer (5) and disconnect high pressure gas input line (4) 4. Remove cap screw, lock washer, and washer (7) and disconnect high pressure liquid output line (6). 5. Remove cap screws, lock washers, washers (8) and condenser (3). 6. Repair or replace condenser as necessary. 7. Install condenser (3). 8. Tighten high pressure liquid output line (6) cap screw (7).
CondenserSpecification Output Line Cap ScrewTorque ................................. 14 Nm (124 lb-in.)
1Cap Screw (2 used) 2Receiver-Dryer 3Condenser 4High Pressure Gas Input Line 5Cap Screw, Lock Washer, Washer 6High Pressure Liquid Output Line 7Cap Screw, Lock Washer, Washer 8Cap Screw (4 used) Lock Washer (4 used) Washer (4 used)
9. Tighten high pressure gas input line (4) cap screw (5).
CondenserSpecification Input Line Cap ScrewTorque .................................... 23 Nm (204 lb-in.)
18 1830 16
OUOE003,00000E8 1919NOV011/1
TM1931 (09JAN04)
18-1830-16

010904
PN=162
T143116B
Section 33
Excavator
Contents
Page Page
Group 3302Buckets Bucket Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-1 Adjust Pivot End Play . . . . . . . . . . . . . . . .33-3302-3 Pin-Up Data . . . . . . . . . . . . . . . . . . . . . . . .33-3302-4 Group 3340Frames Bucket Links . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-1 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-3 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-6 Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses . . . . . . . . . . . . . . .33-3340-11 Bushings and Seals . . . . . . . . . . . . . . . . . .33-3340-14 Group 3360Hydraulic System Hydraulic Oil Tank Pressure Release Procedure . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-1 Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy . . . . . . . . . . . . . . . . .33-3360-2 Hydraulic Pump and Drive Gearbox Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3 Start-Up Procedure . . . . . . . . . . . . . . . . .33-3360-20 Pilot Pump Drive Shaft and Gear . . . . . . . .33-3360-21 Hydraulic Pump Regulator. . . . . . . . . . . . . .33-3360-22 Pilot Pump . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-27 Pilot Pressure Regulating Valve and Filter Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-30 Pilot Shut-Off Valve. . . . . . . . . . . . . . . . . . .33-3360-31 Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-35 Pilot Controller . . . . . . . . . . . . . . . . . . . . . .33-3360-37 Propel Pilot Controller . . . . . . . . . . . . . . . . .33-3360-40 Pilot Signal Manifold . . . . . . . . . . . . . . . . . .33-3360-43 Control Valve . . . . . . . . . . . . . . . . . . . . . . .33-3360-49 Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . .33-3360-66 Restriction Valve Repair . . . . . . . . . . . . . . .33-3360-69 Oil Cooler Bypass Valve . . . . . . . . . . . . . . .33-3360-71 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-74 Remove and Install Boom Cylinder . . . . . . .33-3360-75 Boom Cylinder Disassemble and Assemble 200CLC, 270CLC . . . . . . . . . . . . . . . . . .33-3360-80 Boom Cylinder Disassemble and Assemble 230CLC . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-94 Arm Cylinder Remove and Install . . . . . . . 33-3360-100 TM1931 (09JAN04)
Arm Cylinder Disassemble and Assemble 200CLC, 270CLC . . . . . . . . . . . . . . . . . 33-3360-104 Arm Cylinder Disassemble and Assemble230CLC. . . . . . . . . . . . . . . . 33-3360-118 Bucket Cylinder Remove and Install . . . . . 33-3360-124 Bucket Cylinder Disassemble and Assemble200CLC, 270CLC . . . . . . . . 33-3360-130 Bucket Cylinder Disassemble and Assemble230CLC. . . . . . . . . . . . . . . . 33-3360-144 Hydraulic Cylinder Bleed Procedure . . . . . 33-3360-152
33
33-1

010904
PN=1
Contents
33
TM1931 (09JAN04)
33-2

010904
PN=2
Group 3302
Buckets
Bucket Repair
6 3 3 5 4 3 1 8 2 7
5 4 3
T142450
1 2
1Bushing (4 used) 2Dust Seal (2 used)
3O-Ring (4 used) 4Ring (2 used)
5Pin (2 used) 6Pin
7Pin 8Bucket
Remove and Install Bucket CAUTION: Heavy component; use a hoist.

BucketSpecification Bucket (200CLC)Weight ................... 670 kg (1480 lb) approximate Bucket (230CLC and 270CLC)Weight ................................. 953 kg (2100 lb) approximate
4. Repair or replace as necessary. 5. Align pin bores in bucket with pin bores in arm link to prevent damage to dust seals (2) when pins are installed. 6. Adjust bucket pivot end play. See Adjust Bucket Pivot End Play. (See procedure in this group.) 7. Adjust bucket to arm joint. See Adjusting Bucket to Arm Joint. (Operators Manual.)
33 3302 1
1. Position bucket (8) on level surface. 2. Remove parts (5, 6 and 7). 3. Remove bucket.
TX,33,GG2401 1919NOV011/3
TM1931 (09JAN04)
33-3302-1

010904
PN=165
T142450
UN24JUL01
Buckets
7 6 6
5 9 10
11 12 2 3
13
4 2
33 3302 2
1
UN24JUL01
T142451
TX,33,GG2401 1919NOV012/3
TM1931 (09JAN04)
33-3302-2

010904
PN=166
T142451
Buckets
1Side Cutter (2 used) 2Nut (12 used) 3Washer (12 used) 4Cap Screw (12 used) 5Boss (2 used) 6Shims (as required) 7Cap Screw (6 used) 8Washer (6 used) 9Plate (2 used) 10Boss (2 used) 11Stopper (2 used) 12Boss (2 used)
TX,33,GG2401 1919NOV013/3
Adjust Bucket Pivot End Play

1. Slide O-ring up on boss of bucket. 2. Measure clearance (D) between bushing (B) and arm. Adjust clearance as close to specification.
BucketSpecification Bucket Pivot Bushing-to-Arm Clearance ............................................... As close to but not less than 0.5 mm (0.020 in.)
UN10NOV88 T95788 UN10NOV88 T6879DU UN06DEC88 T95775
NOTE: Alternate buckets may have different adjustment procedures.

3. Remove plate (F). 4. Remove shims (E) as needed to allow bushing to move in to adjust clearance and take up excessive play. 5. Install plate. Tighten cap screws.
BucketSpecification Bucket Pivot Shim-to-Plate Cap ScrewTorque ................................................................ 88 Nm (65 lb-ft)
6. Slide O-ring back into position.

ABucket BBushing CPin DClearance EShim (As Required) FPlate
33 3302 3
TX,33,GG2403 1919NOV011/1
TM1931 (09JAN04)
33-3302-3

010904
PN=167
Buckets
Bucket Pin-Up Data
33 3302 4
TX,33,GG2405 1919NOV011/1
TM1931 (09JAN04)
33-3302-4

010904
PN=168
T142485
1919NOV01
Group 3340
Frames
Bucket Links Repair
8 7 9 6 10 11 4 2 1 5 12 3
4 3 2 5
UN24JUL01
T142977
1Nut (4 used) 2Cap Screw (2 used) 3Thrust Plate (2 used)
4Dust Seal (2 used) 5Bushing (2 used) 6Thrust Plate (4 used)
7Cylinder Pin 8Wooden Block 9Center Link
10Right Side Link 11Left Side Link 12Pin
Remove and Install Bucket Links
arm to hold cylinder up when cylinder pin (7) is removed. 2. Remove parts (15). As cylinder pin (7) is removed, lower links (10 and 11) to ground.
NOTE: Removal of bucket is not necessary for removal of just bucket links.
1. Connect hoist to center link (9) using lifting strap. Put wooden block (8) between bucket cylinder and
T142977
33 3340 1
TX,33,GG2406 1919NOV011/2
TM1931 (09JAN04)
33-3340-1

010904
PN=169
Frames
3. Inspect bushings (2 and 4) and dust seals (1). See Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses. (See procedure in this group.) 4. Replace parts as necessary. 5. Before installing pins, align pin bores to prevent damage to dust seal when pins are installed. 6. Apply multi-purpose grease to all lubrication fittings.
1Dust Seal (6 used) 2Bushing (2 used) 3Lubrication Fitting (2 used) 4Bushing (4 used) 5Shim (As Required) 6Bushing (2 used) 7Spacer
4 4 1 1 2 1
UN19NOV01
2
200CLC and 230CLC
1 5 1
7 6
2 1 1 5 6 3
270CLC
33 3340 2
1 1 5
3
UN19NOV01
TX,33,GG2406 1919NOV012/2
TM1931 (09JAN04)
33-3340-2

010904
PN=170
T147422
T142978
Frames
Arm Repair
Remove and Install Arm 1. Remove bucket. See Bucket Repair. (Group 3302.) 2. Retract arm cylinder. 3. Put floor stand under end of boom so load is on boom, not on arm cylinder. Extend arm cylinder just enough to put end of arm on ground. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 4. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 5. Loosen bucket cylinder hydraulic lines to release any residual pressure. Remove bucket cylinder and linkage only if necessary to repair arm. See Bucket Cylinder Remove and Install. (Group 3360.) 6. Disconnect lines. 7. Remove bucket links and bucket cylinder. See Bucket Links Repair. (See procedure in this group.) See Bucket Cylinder Remove and Install. (Group 3360.)
TX,33,GG2407 1919NOV011/3
33 3340 3
TM1931 (09JAN04)
33-3340-3

010904
PN=171
Frames

ArmSpecification Standard Arm (200CLC)Weight ............... 593 kg (1310 lb) approximate Bucket Cylinder (200CLC) Weight............................................................ 145 kg (320 lb) approximate ArmSpecification Long Arm (230CLC)Weight ..................... 878 kg (1936 Standard Arm (230CLC)Weight ............... 685 kg (1510 Short Arm (230CLC)Weight ....................... 182 kg (400 Bucket Cylinder (230CLC) Weight............................................................ 182 kg (400
lb) approximate lb) approximate lb) approximate lb) approximate
ArmSpecification Arm (270CLC)Weight.................................................. 1500 kg (3306 lb) Bucket Cylinder (270CLC) Weight............................................................ 216 kg (480 lb) approximate
8. Attach hoist to arm.

UN31OCT88
Arm With Bucket Cylinder
TX,33,GG2407 1919NOV012/3
33 3340 4
TM1931 (09JAN04)
33-3340-4

010904
PN=172
T6626JC
Frames
9. Put wooden block between arm cylinder and boom to hold cylinder up when cylinder pin (6) is removed. 10. Remove parts (1-13). 11. Remove arm and lower to floor. 12. Inspect bushings and dust seals. See Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses. (See procedure in this group.) 13. Repair or replace parts as necessary. See Bushings and Seals Repair. (See procedure in this group.) 14. Install thrust plates (4 and 12) equally on each side of arm to get minimal amount of clearance between boom and arm. 15. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 16. Apply multi-purpose grease to all lubrication fittings.
1Nut (2 used) 2Stopper 3Cap Screw 4Thrust Plate (2 used) 5Thrust Plate 6Cylinder Pin 7Cap Screw 8Washer 9Plate 10Block 11Pin 12Thrust Plate (2 used) 13Thrust Plate
UN27SEP01
5 4
13 12
12
10 7 8 9
TX,33,GG2407 1919NOV013/3
T142653
UN24JUL01
11
T142652
33 3340 5
TM1931 (09JAN04)
33-3340-5

010904
PN=173
Frames
Boom Repair
Remove and Install Boom 1. Remove bucket and arm. See Bucket Repair and Arm Repair. (See procedures in this group, and group 3302.) 2. Lower boom to ground. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 3. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.)
TX,33,GG2408 1919NOV011/7
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 4. Loosen hydraulic lines at frame end of boom to release any residual pressure. 5. Disconnect lines. 6. Disconnect wiring harness. 7. Disconnect lubrication lines at rod end of cylinders. 8. Remove arm cylinder only if necessary to repair boom. See Arm Cylinder Remove and Install. (Group 3360.)
UN23AUG88
33 3340 6
TX,33,GG2408 1919NOV012/7
TM1931 (09JAN04)
33-3340-6

010904
PN=174
X9811
Frames

BoomSpecification Boom Cylinder (200CLC) Weight............................................................ 171 kg (377 lb) approximate BoomSpecification Boom Cylinder (230CLC) Weight............................................................ 271 kg (597 lb) approximate BoomSpecification Boom Cylinder (270CLC) Weight............................................................ 247 kg (545 lb) approximate
9. Attach hoist to boom cylinder (F) using lifting strap.

FBoom Cylinder (2 used)
TX,33,GG2408 1919NOV013/7
10. Remove parts (13 and 5). 11. Push boom cylinder-to-boom pin (4) into boom. 12. Lower boom cylinder (6) on floor stand.Repeat procedure for second boom cylinder.
1Nut (4 used) 2Retainer (2 used) 3Cap Screw (2 used) 4Boom Cylinder Rod End-to-Boom Pin 5Thrust Plate (4 used) 6Boom Cylinder (2 used)
TX,33,GG2408 1919NOV014/7
T142979
UN24JUL01
T105828
UN30DEC96
33 3340 7
TM1931 (09JAN04)
33-3340-7

010904
PN=175
Frames
CAUTION: Heavy components; use a hoist.

BoomSpecification Boom (200CLC)Weight .......................... 1230 kg (2712 lb) approximate Arm Cylinder (200CLC)Weight .................. 259 kg (571 lb) approximate BoomSpecification Boom (230CLC)Weight .......................... 1683 kg (3710 lb) approximate Arm Cylinder (230CLC)Weight .................. 286 kg (630 lb) approximate BoomSpecification Boom (270CLC)Weight .......................... 1987 kg (4380 lb) approximate Arm Cylinder (270CLC)Weight .................. 308 kg (680 lb) approximate
13. Attach hoist to boom. Use protective covering to prevent damage to pin if chain is used. Arm end of boom is heavy end with arm cylinder installed. Frame end is heavy end when arm cylinder is removed.
UN31OCT88
TX,33,GG2408 1919NOV015/7
33 3340 8
TM1931 (09JAN04)
33-3340-8

010904
PN=176
T6626JW
Frames
14. Remove parts (13 and 6). 15. Insert bar between plate of boom-to-frame pin (4) and bracket (6). Pull plate out. 16. Remove boom-to-frame pin. Remove washers (5). 17. Remove boom. 18. Inspect bushings and dust seals. See Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses. (See procedure in this group.) 19. Repair or replace parts as necessary. See Bushings and Seals Repair. (See procedure in this group.) 20. Install washers (5) equally on each side of boom to get minimal amount of clearance between boom and frame. 21. Install boom. Tighten boom-to-frame cap screws.
BoomSpecification Boom-to-Frame Cap Screw Torque ......................................................................... 400 Nm (295 lb-ft)
1Cap Screw 2Spacer 3Block 4Boom-to-Frame Pin 5Washer (As Required) 6Washer 7Bracket
22. Connect rod end of boom cylinders. Install thrust plates (5) equally on each side to get minimum amount of clearance between boom and cylinder rod end. 23. Tighten nuts (1) against each other allowing cap screw (3) to be free to turn in hole.
BoomSpecification Boom Cylinder Rod End-to-Boom Pin Retainer NutTorque ........................ 550 Nm (405 lb-ft) (tighten nut against nut)
24. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 25. Connect wiring harness. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015-10). 26. Connect lubrication lines at rod end of cylinders.
T143018
UN24JUL01
33 3340 9
TX,33,GG2408 1919NOV016/7
TM1931 (09JAN04)
33-3340-9

010904
PN=177
Frames
27. Apply multi-purpose grease to all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operators Manual.)
TX,33,GG2408 1919NOV017/7
33 3340 10
TM1931 (09JAN04)
33-3340-10

010904
PN=178
Frames
Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses
ABoom Cylinder Head End-to-Frame Joint BBoom Cylinder Rod End-to-Boom Joint CBoom-to-Frame Joint
DBoom-to-Arm Joint EArm Cylinder Head End-to-Boom Joint FArm Cylinder Rod End-to-Arm Joint
GBucket Cylinder Head End-to-Arm Joint HBucket Cylinder Rod End-to-Side and Center Links Joint
ISide Links-to-Arm Joint JCenter Link-to-Bucket Joint KBucket-to-Arm Joint
Boom (200CLC)Specification Boom Cylinder Head End-to-Frame Joint Pin (200CLC)OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Boom Cylinder Head End-to-Frame Joint Bushing (200CLC)ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Boom Cylinder Head End-to-Frame Joint Boss (200CLC)ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Pin (200CLC)OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Bushing (200CLC)ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Boss (200CLC)ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom-to-Frame Joint Pin (200CLC)OD ......................................... 90.0 mm (3.45 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Boom-to-Frame Joint Bushing (200CLC)ID ........................................... 90.0 mm (3.45 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom-to-Arm Joint Pin (200CLC)OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use
Boom-to-Arm Joint Bushing (200CLC)ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm (200CLC)Specification Arm Cylinder Head End-to-Boom Joint Pin (200CLC)OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Arm Cylinder Head End-to-Boom Joint Bushing (200CLC)ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Arm Cylinder Head End-to-Boom Joint Boss (200CLC)ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Pin (200CLC)OD .......................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Bushing (200CLC)ID .................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Boss (200CLC)ID ......................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket (200CLC)Specification Bucket Cylinder Head End-to-Arm Joint Pin (200CLC)OD ......................................... 71.0 mm (2.80 in.) nominal OD........................................................ 70.0 mm (2.76 in.) limit of use 33 3340 11
CED,TX08227,3206 1919NOV011/4
TM1931 (09JAN04)
33-3340-11

010904
PN=179
T7779AC
UN11JUN92
Frames
Bucket Cylinder Head End-to-Arm Joint Bushing (200CLC)ID ........................................... 71.0 mm (2.80 in.) nominal ID ......................................................... 72.5 mm (2.85 in.) limit of use Bucket Cylinder Head End-to-Arm Joint Boss (200CLC)ID ........................................... 71.0 mm (2.80 in.) nominal ID ......................................................... 72.5 mm (2.85 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint Pin (200CLC)OD .......................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint Bushings (200CLC)ID .................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Side Links-to-Arm Joint Pin (200CLC)OD ......................................... 71.0 mm (2.80 in.) nominal OD........................................................ 70.0 mm (2.76 in.) limit of use Side Links-to-Arm Joint Bushing (200CLC)ID ............................. 71.0 mm (2.80 in.) nominal ID ......................................................... 72.5 mm (2.85 in.) limit of use Center Link-to-Bucket Joint Pin (200CLC)OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Center Link-to-Bucket Joint Bushing (200CLC)ID ............................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket-to-Arm Joint Pin (200CLC)OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Bucket-to-Arm Joint Bushing (200CLC)ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Boom (230CLC)Specification Boom Cylinder Head End-to-Frame Joint Pin (230CLC)OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Boom Cylinder Head End-to-Frame Joint Bushing (230CLC)ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom Cylinder Head End-to-Frame Joint Boss (230CLC)ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Pin (230CLC)OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Bushing (230CLC)ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Boss (230CLC)ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom-to-Frame Joint Pin (230CLC)OD ....................................... 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom-to-Frame Joint Bushing (230CLC)ID ......................................... 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom-to-Arm Joint Pin (230CLC)OD ....................................... 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom-to-Arm Joint Bushing (230CLC)ID ......................................... 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Arm (230CLC)Specification Arm Cylinder Head End-to-Boom Joint Pin (230CLC)OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Arm Cylinder Head End-to-Boom Joint Bushing (230CLC)ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Head End-to-Boom Joint Boss (230CLC)ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Pin (230CLC)OD .......................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Bushing (230CLC)ID .................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Boss (230CLC)ID ......................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Bucket (230CLC)Specification Bucket Cylinder Head End-to-Arm Joint Pin (230CLC)OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Bucket Cylinder Head End-to-Arm Joint Bushing (230CLC)ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use
33 3340 12
CED,TX08227,3206 1919NOV012/4
TM1931 (09JAN04)
33-3340-12

010904
PN=180
Frames
Bucket Cylinder Head End-to-Arm Joint Boss (230CLC)ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint Pin (230CLC)OD .......................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint BushingsID ................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Side Links-to-Arm Joint Pin OD............................................................. 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Side Links-to-Arm Joint BushingID .............................................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Center Link-to-Bucket Joint PinOD .................................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Center Link-to-Bucket Joint BushingID .............................................. 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Bucket-to-Arm Joint PinOD ................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket-to-Arm Joint Bushing ID .............................................................. 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom (270CLC)Specification Boom Cylinder Head End-to-Frame Joint PinOD.................. 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom Cylinder Head End-to-Frame Joint Bushing ID ............................................................ 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom Cylinder Head End-to-Frame Joint BossID................. 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom Cylinder Rod End-to-Boom Joint PinOD................... 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom Cylinder Rod End-to-Boom Joint BushingID............. 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom Cylinder Rod End-to-Boom Joint BossID.................. 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom-to-Frame Joint PinOD............... 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom-to-Frame Joint BushingID ............................................ 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom-to-Arm Joint PinOD .................. 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom-to-Arm Joint BushingID ............ 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Arm (270CLC)Specification Arm Cylinder Head End-to-Boom Joint PinOD..................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Arm Cylinder Head End-to-Boom Joint BushingID............... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Head End-to-Boom Joint BossID.................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Rod End-to-Arm Joint PinOD ........................................... 90.0 mm (3.54 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Arm Cylinder Rod End-to-Arm Joint BushingID ..................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Rod End-to-Arm Joint BossID .......................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Bucket (270CLC)Specification Bucket Cylinder Head End-to-Arm Joint PinOD ....................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Bucket Cylinder Head End-to-Arm Joint BushingID ................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket Cylinder Head End-to-Arm Joint BossID ...................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint PinOD ........................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint BushingsID ................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Side Links-to-Arm Joint Pin OD............................................................. 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Side Links-to-Arm Joint BushingID .............................................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use
33 3340 13
CED,TX08227,3206 1919NOV013/4
TM1931 (09JAN04)
33-3340-13

010904
PN=181
Frames
Center Link-to-Bucket Joint PinOD .................................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Center Link-to-Bucket Joint BushingID .............................................. 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Bucket-to-Arm Joint PinOD ................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket-to-Arm Joint Bushing ID .............................................................. 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use
CED,TX08227,3206 1919NOV014/4
Bushings and Seals Repair

Remove and Install Bushings and Seals IMPORTANT: Only install bushings using press as shown. Bushings will be damaged if installed with driver.
NOTE: Bushing can also be removed by welding three to five weld beads on the inside of bushing. Bushing will shrink enough to permit removal using a hammer.
1. Remove bushings (C) and dust seals using bushing, bearing, and seal driver set. 2. Install bushings with lubrication hole aligned with lubrication passage in pivot. 3. Install bushing to a depth equal to thickness of dust seal (H). 4. Install dust seals with lip toward outside of component.
AHydraulic Ram B1PipeMinimum ID to Clear Bushing OD B2PipeMaximum OD B3PipeLength of Bushing CBushing DDisks EBushing Stop (Disk) FPilot (Disk) GRam Stop (Disk) HThickness of Dust Seal
33 3340 14
CED,OUOE023,2178 1919NOV011/1
TM1931 (09JAN04)
33-3340-14

010904
PN=182
T6641CW
UN31OCT88
T95237
UN01NOV88
Group 3360
Hydraulic System
Hydraulic Oil Tank Pressure Release Procedure
CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by SLOWLY loosening cap (1). 1. Insert 4 mm hex wrench (4) into hole (5) and turn counterclockwise to release locking pin. 2. Slowly turn cap (1) counterclockwise a few degrees to relieve pressure. 3. Remove cap.
1Cap 2Aligning Marks 3Case Assembly 44 mm Hex Key Wrench 5Hole
UN06NOV00
OUOE054,000000F 1907OCT021/1
T135189
33 3360 1
TM1931 (09JAN04)
33-3360-1

010904
PN=183
Hydraulic System
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

SPECIFICATIONS Hydraulic Oil Tank (200CLC) Hydraulic Oil Tank Capacity Hydraulic Oil Tank Filtering Time Hydraulic System Capacity Hydraulic System Filtering Time 130 L (34 gal) approximate 11 minutes approximate 200 L (52.4 gal) approximate 17 minutes approximate Hydraulic Oil Tank (200CLC)Specification Hydraulic Oil TankCapacity.................. 130 L (34 gal) approximate Filtering Time ................................................. 11 minutes approximate Hydraulic Oil Tank (230CLC and 270CLC)Specification Hydraulic Oil TankCapacity.................. 148 L (39 gal) approximate Filtering Time ................................................. 13 minutes approximate
four times.
Hydraulic Oil Tank (230CLC and 270CLC) Hydraulic Oil Tank Capacity Hydraulic Oil Tank Filtering Time Hydraulic System Capacity Hydraulic System Filtering Time 148 L (39 gal) approximate 13 minutes approximate 250 L (66 gal) approximate 22 minutes approximate
NOTE: Filtering time for hydraulic tank is 0.089 minute x number of liters (0.33 minutes x number of gallons).
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 with the smallest capacity circuit then proceed to the next larger capacity circuit. 6. Starting with the smallest capacity circuit, operate each function through a complete cycle. Repeat procedure until the total system capacity has circulated through filter caddy seven times. Each function must go through a minimum of three complete cycles for a thorough cleaning of oil.
Hydraulic Oil Tank (200CLC)Specification Hydraulic SystemCapacity ................ 200 L (52.4 gal) approximate Filtering Time ................................................. 17 minutes approximate Hydraulic Oil Tank (230CLC and 270CLC)Specification Hydraulic SystemCapacity ................... 250 L (66 gal) approximate Filtering Time ................................................. 22 minutes approximate
SERVICE EQUIPMENT AND TOOLS Portable Filter Caddy 3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2 used) Quick Disconnect Fittings Suction Wand 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 caddy suction line to drain port. Add a minimum of 19 L (5 gal) of oil to reservoir. Operate filter caddy and wash out the hydraulic tank.
IMPORTANT: The minimum ID for a connector is 13 mm (1/2 in.) to prevent cavitation of filter caddy pump. 2. Put filter caddy suction and discharge wands into hydraulic tank filler hole so ends are as far apart as possible to obtain a thorough cleaning of oil.
33 3360 2
3. Start the filter caddy. Check to be sure oil is flowing through the filters. Operate filter caddy until all the oil in hydraulic tank has been circulated through the filter a minimum of
NOTE: Filtering time for complete hydraulic system is 0.158 minute x number of liters (0.6 minute x number of gallons). Filtering time for machines with auxiliary hydraulic functions must be increased because system capacity is larger.
7. Stop the engine. Remove the filter caddy. 8. Install new return filter elements.
OUOE027,000001D 1919NOV011/2
TM1931 (09JAN04)
33-3360-2

010904
PN=184
Hydraulic System
9. Check Hydraulic Oil. (Operators Manual.)
OUOE027,000001D 1919NOV012/2
Hydraulic Pump and Drive Gearbox Repair

Remove and Install Hydraulic Pump and Drive Gearbox CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Drain hydraulic oil tank. Approximate capacity is 130 L (34 gal) for 200CLC and 148 L (39 gal) for 230CLC and 270CLC. 3. Drain pump drive gearbox. Approximate oil capacity is 1.0 L (1.1 qt). 4. Remove hood, hood support and covers. 5. Remove muffler and muffler bracket. 6. Disconnect electrical connectors. 7. Disconnect lines. CAUTION: Heavy component; use a hoist.
Hydraulic Pump and Drive GearboxSpecification Hydraulic Pump and Drive GearboxWeight .......................................... 168 kg (370 lb) approximate
8. Install lifting eyebolts to pump. Connect a hoist to eyebolts using lifting straps.
33 3360 3
OUOE027,0000017 1919NOV011/21
TM1931 (09JAN04)
33-3360-3

010904
PN=185
Hydraulic System
9. Remove cap screws (1) and remove pump. 10. Repair or replace as necessary. IMPORTANT: Align dampener drive on drive gearbox with mating part on engine flywheel. 11. Tighten cap screws (1).
Hydraulic Pump and Drive GearboxSpecification Pump Drive Gearbox-to-Flywheel Housing Cap ScrewTorque.......................................... 49 Nm (36 lb-ft)
14. Install split flange and tighten cap screws.

1Cap Screw (6 used) Hydraulic Pump and Drive GearboxSpecification Split Flange 8 mm Cap Screw Torque ............................................................................. 50 Nm (37 lb-ft) Split Flange 10 mm Cap Screw Torque ............................................................................. 90 Nm (67 lb-ft)
15. Apply pipe sealant to pump drive gearbox drain plug threads. IMPORTANT: Hydraulic pump and drive gearbox will be damaged if not filled with oil before starting engine. Start-up procedure must be performed whenever a new pump or gearbox is installed or oil has been drained from the pump, gearbox or hydraulic oil tank. 16. Fill pump housing and pump drive gearbox with oil. See Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.) 17. Check pump regulator adjustments. (Group 9025-25.)
33 3360 4
For minimum flow:
OUOE027,0000017 1919NOV012/21
TM1931 (09JAN04)
33-3360-4

010904
PN=186
T142503
13. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.)
UN20JUL01
12. Connect electrical connectors. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015.)
Hydraulic System
See Hydraulic Pump Regulator Test and AdjustmentMinimum Flow200CLC. (Group 9025-25.) See Hydraulic Pump Regulator Test and AdjustmentMinimum Flow230CLC. (Group 9025-25.) See Hydraulic Pump Regulator Test and AdjustmentMinimum Flow270CLC. (Group 9025-25.) For maximum flow: See Hydraulic Pump Regulator Test and AdjustmentMaximum Flow200CLC. (Group 9025-25.) See Hydraulic Pump Regulator Test and AdjustmentMaximum Flow230CLC. (Group 9025-25.) See Hydraulic Pump Regulator Test and AdjustmentMaximum Flow270CLC. (Group 9025-25.) Disassemble and Assemble Hydraulic Pump and Drive Gearbox
OUOE027,0000017 1919NOV013/21
33 3360 5
TM1931 (09JAN04)
33-3360-5

010904
PN=187
Hydraulic System
10 7 8 9 11 22 23 24
21 19 12 18 17 6 13 5 4 3 2 1 32 15 33 32 31 27 28 36 30 37 28 27 17 16 18 26 25 13 14 16 15 20
23 22 21 20
29
35 56 34
38 55 54 57
33 3360 6
40 46 47 41
45
39 35
44
43
42 49 50 51
48
UN20JUL01
T142373
58
51
OUOE027,0000017 1919NOV014/21
TM1931 (09JAN04)
33-3360-6

010904
PN=188
T142373
53
52
Hydraulic System
1Pump Housing 2Lock Washer (6 used) 3Cap Screw (6 used) 4Spring Pin (4 used) 5O-Ring (10 used) 6O-Ring (2 used) 7Cap Screw (4 used) 8Right Regulator Pump 1 (Front) 9Cap Screw (2 used) 10Cap Screw (2 used) 11Cap Screw (2 used) 12Left Regulator Pump 2 (Rear) 13O-Ring (4 used) 14O-Ring (6 used) 15Bearing Nut (2 used) 16Roller Bearing (2 used) 17Ring (2 used) 18Roller Bearing (2 used) 19Pump 1 (Front) Drive Shaft 20Pin (2 used) 21Center Shaft (2 used) 22Spring (2 used) 23Piston (14 used) 24Cylinder Block (Rotor) (2 used) 25Pump 2 (Rear) Drive Shaft 26Spacer Ring (Pump 2 [Rear] Drive Shaft only) 27O-Ring (2 used) 28Plug (2 used) 29O-Ring 30Special Fitting 31Spring Pin (2 used) 32Oil Seal (2 used) 33Snap Ring (2 used) 34Fill Plug 35Snap Ring (2 used) 36Pump 1 (Front) Driven Gear 37Gasket 38Cap Screw (2 used) 39Pump 2 (Rear) Drive Gear 40Dipstick 41Dipstick Tube 42Gasket 43Drain Plug 44O-Ring 45Cap Screw (2 used) 46Lock Washer (2 used) 47Washer (2 used) 48Pilot Pump 49Snap Ring 50Snap Ring 51Ball Bearing 52Pilot Pump Drive Gear 53Pilot Pump Drive Shaft 54Snap Ring 55Oil Seal 56Pump Drive Gearbox 57Set Screw (2 used) 58Dampener Drive Coupling
OUOE027,0000017 1919NOV015/21
33 3360 7
TM1931 (09JAN04)
33-3360-7

010904
PN=189
Hydraulic System
72 71 70 73 74 71
68 67 62 60 60 61 66 59 60 60 61 82 60 59 81 66 60 63 64 63 69 62 60 62 63 65 63 62 78 77 79 80 76
75
82
UN20JUL01
T142375 33 3360 8
59Dowel Pin 60Snap Ring (12 used) 61Dowel Pin (2 used) 62Lever (4 used) 63Dowel Pin (4 used) 64Pump 1 (Front) Valve Plate
65Pump 2 (Rear) Valve Plate 66Dowel Pin (4 used) 67Backup Ring 68O-Ring 69Spring Pin (2 used) 70Cylinder Head (Cover)
71O-Ring (4 used) 72Cap Screw (8 used) 73Cover (2 used) 74O-Ring (2 used) 75Cap Screw (12 used) 76Set Screw (2 used)
77Servo Piston (2 used) 78Pin (2 used) 79O-Ring (2 used) 80Stop (2 used) 81Cap Screw (8 used) 82Feedback Link (2 used)
OUOE027,0000017 1919NOV016/21
TM1931 (09JAN04)
33-3360-8

010904
PN=190
T142375
Hydraulic System
2. Remove pilot pump (48). 3. Remove cap screws (3) and lock washers (2) to remove pump housing (1) from pump drive gearbox (56).

Hydraulic Pump and Drive GearboxSpecification Hydraulic Pump and Drive GearboxWeight ................................... 168 kg (370 lb) approximate
1. Loosen set screws (57) and remove dampener drive coupling (58).
OUOE027,0000017 1919NOV017/21
33 3360 9
TM1931 (09JAN04)
33-3360-9

010904
PN=191
Hydraulic System
4. To aid in reassembly, make timing marks on drive shafts (A and C), and mark (B) on drive (E) and driven (F) gears. The gears are not interchangeable. Measure amount of backlash between gears.
Hydraulic Pump and Drive GearboxSpecification Pump Drive and Driven Gear Backlash ........................................................ 0.68 mm (0.027 in.) nominal 1.50 mm (0.059 in.) limit of use
UN11DEC96
Remove snap rings (D) and remove gears (E and F). 5. Remove pump regulators (8 and 12). For repair. See Hydraulic Pump Regulator Repair. (See procedure in this group.) CAUTION: Heavy component; use a hoist.
Hydraulic Pump and Drive GearboxSpecification Cylinder HeadWeight ..................................... 30 kg (66 lb) approximate APump 1 (Front) Drive Shaft-to-Driven Gear Timing Mark BDriven Gear-to-Drive Gear Timing Mark CPump 2 (Rear) Drive Shaft-to-Drive Gear Timing Mark DSnap Ring (2 used EDrive Gear FDriven Gear
IMPORTANT: The valve plates (64 and 65) are connected to the feedback linkage and must remain on the cylinder blocks (24). The valve plates and end of cylinder blocks are made with highly machined surfaces and can be damaged. 6. Remove cap screws (75) and carefully remove cylinder head (70). 7. Remove servo pistons (77) only if replacement is necessary. Heat set screw (76) to loosen thread lock and sealer (medium strength) used. Remove set screw using a 6 mm hex key wrench. Remove pin (78).
33 3360 10
OUOE027,0000017 1919NOV018/21
TM1931 (09JAN04)
33-3360-10

010904
PN=192
T105624
Hydraulic System
IMPORTANT: Pump 1 (front) (64) and pump 2 (rear) (65) valve plates are not interchangeable. Take notice of the location and position of ports in plate. The inlet port in valve plate is located towards the center and top of pump housing. 8. Remove pump 1 (front) (64) and pump 2 (rear) (65) valve plates. Protect machined surfaces of plates from damage. 9. Remove special fittings (30) before removing pump 1 (front) (19) and pump 2 (rear) (25) drive shafts. 10. Remove spacer ring (26) for pump 2 (rear) drive shaft (25) from bore. 11. Remove bearing nut (15) using JDG769 Spanner Wrench. 12. Remove roller bearings (16 and 18) from pump 1 (front) (19) and pump 2 (rear) (25) drive shafts using a knife edge puller and a press.
OUOE027,0000017 1919NOV019/21
13. Measure diameter of oil seal contact surfaces (A, B, and D) on pump 1 (front) (E) and pump 2 (rear) (C) drive shafts.
Hydraulic Pump and Drive GearboxSpecification Pump 2 (Rear) Drive Shaft Oil Seal Contact Surface (A)OD .......................... 45 mm (1.77 in.) nominal 44.8 mm (1.76 in.) limit of use Pump 2 (Rear) Drive Shaft Oil Seal Contact Surface (B)OD .......................... 55 mm (2.17 in.) nominal 54.8 mm (2.16 in.) limit of use Pump 1 (Front) Drive Shaft Oil Seal Contact SurfaceOD ................................ 55 mm (2.17 in.) nominal 54.8 mm (2.16 in.) limit of use AOil Seal Contact Surface BOil Seal Contact Surface CPump 2 (Rear) Drive Shaft DOil Seal Contact Surface EPump 1 (Front) Drive Shaft
UN09JAN97
33 3360 11
OUOE027,0000017 1919NOV0110/21
TM1931 (09JAN04)
33-3360-11

010904
PN=193
T105725
Hydraulic System
14. Measure play (H) between piston connecting rod (F) and socket in front and rear drive shafts (G).
Hydraulic Pump and Drive GearboxSpecification Piston-to-Drive Shaft Socket Play ............................................................ 0.058 mm (0.0023 in.) nominal 0.400 mm (0.0157 in.) limit of use
OUOE027,0000017 1919NOV0111/21
15. Measure ID of cylinder block piston bore. Measure OD of piston. Subtract the OD from the ID for clearance.
Hydraulic Pump and Drive GearboxSpecification Cylinder Block Bore-to-Piston Clearance .................................................. 0.043 mm (0.0017 in.) nominal 0.080 mm (0.0032 in.) limit of use
OUOE027,0000017 1919NOV0112/21
TM1931 (09JAN04)
33-3360-12

010904
PN=194
T6557EN
33 3360 12
UN18OCT88
T6557EM
UN18OCT88
T105726
UN09JAN97
FPiston Connecting Rod GRear Drive Shaft HPlay
Hydraulic System
16. Clamp the connecting rod end of a piston in a vise with soft-jaw faces. Measure play between connecting rod and piston.
Hydraulic Pump and Drive GearboxSpecification Piston-to-Connecting RodPlay ............... 0.150 mm (0.0059 in.) nominal 0.400 mm (0.0157 in.) limit of use
OUOE027,0000017 1919NOV0113/21
17. Measure OD (C) of small and large end of servo piston (D). Measure ID (B) of small and large end of bore in cylinder head (A). Subtract the OD from the ID for clearances.
Hydraulic Pump and Drive GearboxSpecification Servo Piston-to-Cylinder Head BoreClearance ....................................... 0.079 mm (0.0033 in.) nominal 0.200 mm (0.0078 in.) limit of use
ACylinder Head BID COD DServo Piston

UN19DEC96
OUOE027,0000017 1919NOV0114/21
T105727
T6557EK
UN18OCT88
33 3360 13
TM1931 (09JAN04)
33-3360-13

010904
PN=195
Hydraulic System
18. Measure OD (C) of servo piston pin (B). Measure ID (D) of bore in valve plate (A). Subtract the OD from the ID for the clearance.
Hydraulic Pump and Drive GearboxSpecification Servo Piston Pin-to-Valve Plate BoreClearance ....................................... 0.051 mm (0.0020 in.) nominal 0.300 mm (0.0118 in.) limit of use
AValve Plate BPiston Pin COD DID
OUOE027,0000017 1919NOV0115/21
33 3360 14
TM1931 (09JAN04)
33-3360-14

010904
PN=196
T105729
UN09JAN97
Hydraulic System
CAUTION: DO NOT heat oil over 182C (360F). Oil fumes or oil can ignite above 193C (380F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 19. Heat roller bearings (6 and 8).
Hydraulic Pump and Drive GearboxSpecification Roller Bearing Heat Temperature ......................................................... 5080C (122176F)
UN12DEC96
20. Apply oil to bearing. Push roller bearing (6) on drive shaft so inner race is tight against shoulder. 21. Install spacer ring (7) and roller bearing (8). 22. Apply oil to threads of bearing nut (9). 23. Tighten bearing nut using JDG769 Spanner Wrench.
Hydraulic Pump and Drive GearboxSpecification Pump Drive Shaft Bearing Nut Rolling Drag Torque .................................. 2.16 0.49 Nm (19 4 lb-in.)
OUOE027,0000017 1919NOV0116/21
24. Install spacer ring (10) into housing bore for pump 2 (rear) drive shaft.
10Spacer Ring
UN11DEC96
T105660
3Pump 2 (Rear) Drive Shaft 4Pump 1 (Front) Drive Shaft 6Roller Bearing 7Spacer Ring 8Roller Bearing 9Bearing Nut
UN12DEC96
T105658
33 3360 15
OUOE027,0000017 1919NOV0117/21
TM1931 (09JAN04)
33-3360-15

010904
PN=197
T105628
Hydraulic System
25. To help installation of drive shafts (3 and 4), heat pump housing using a heat gun such as the JT07010 Two Temperature Heat Gun.
Hydraulic Pump and Drive GearboxSpecification Pump Housing Heat Temperature ......................................................... 5080C (122176F)
26. Apply a film of oil to outer race of bearings. Install the drive shafts. 27. Install and tighten special fittings (15).
Hydraulic Pump and Drive GearboxSpecification Special Plug-to-Pump Housing Special FittingTorque ................................................ 34 Nm (300 lb-in.) 3Drive Shaft 4Drive Shaft 15Special Fitting (2 used)
28. Apply multi-purpose grease to lips of oil seals. Install oil seals with lip (spring side) toward inside of housing. Install snap rings.
OUOE027,0000017 1919NOV0118/21
33 3360 16
TM1931 (09JAN04)
33-3360-16

010904
PN=198
T105626
UN11DEC96
Hydraulic System
29. For original parts, install drive (E) and driven (F) gears on shafts so timing marks (A, B, and C) are aligned. For new parts, install the JDG1054 Aligning Bar on the socket (I and J) end of drive shafts. Install aligning bar so end marked Long Shaft Side is to pump 2 (rear) drive shaft (H). Turn shafts so socket alignment dowels (L and M) engage a socket in drive shafts. The socket for pump 1 (front) drive shaft is slightly below the centerline of socket for pump 2 (rear) drive shaft when shafts are timed correctly. Install cap screws (N) to hold bar in position. 30. From the splined end of shafts, turn shafts to the left to remove any play between socket alignment dowels and sockets. 31. Install gear on pump 2 (rear) drive shaft. Install the snap ring. Install gear on pump 1 (front) drive shaft. As necessary, turn shaft slightly or turn gear to another position so teeth on gears engage. Install snap ring. 32. Apply oil to center shaft (21), pistons (23) and cylinder blocks (24). Use petroleum jelly to hold pin (20) in hole in center shaft. 33. Install cylinder block so pin engages slot in cylinder block. 34. Apply thread lock and sealer (medium strength) to threads of dowel pins (63). Tighten dowel pins into pump 1 (front) (64) and pump 2 (rear) (65) valve plates.
Hydraulic Pump and Drive GearboxSpecification Dowel Pin-to-Pump 1 (Front) and Pump 2 (Rear) Valve Plate Torque ........................................................................... 9.8 Nm (86 lb-in.) 33 3360 17
APump 1 (Front) Drive Shaft-to-Driven Gear Timing Mark BDriven Gear-to-Drive Gear Timing Mark CPump 2 (Rear) Drive Shaft-to-Drive Gear Timing Mark DSnap Ring (2 used) EDrive Gear FDriven Gear GJDG1054 Aligning Bar (Pump Timing Tool) HPump 2 (Rear) Drive Shaft ISocket JSocket KPump 1 (Front) Drive Shaft LSocket Alignment Dowel MSocket Alignment Dowel NM8-1.25 Cap Screw (2 used)
OUOE027,0000017 1919NOV0119/21
TM1931 (09JAN04)
33-3360-17

010904
PN=199
T8323AQ
UN04OCT94
T105624
UN11DEC96
Hydraulic System
IMPORTANT: Pump 1 (front) (64) and pump 2 (rear) (65) valve plates are not interchangeable. The inlet port in valve plate is located toward the center and top of pump housing. 35. 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. 36. Install servo pistons (77) and pins (78). Apply thread lock and sealer (medium strength) to threads of set screw (76). Tighten set screw (76) using a 6 mm hex key wrench.
Hydraulic Pump and Drive GearboxSpecification Servo Piston-to-Pin Set Screw Torque .......................................................................... 34 Nm (300 lb-in.)
Tighten cap screws (72) for stop (80) and cover (73).
Hydraulic Pump and Drive GearboxSpecification Stop and Cover-to-Cylinder Head Cap ScrewTorque .................................................. 19.5 Nm (180 lb-in.)
37. Install cylinder head (70) checking to be sure that pins engage middle hole in valves plates. Tighten cap screws (75).
Hydraulic Pump and Drive GearboxSpecification Cylinder Head-to-Pump Housing Cap ScrewTorque ...................................................... 108 Nm (80 lb-ft)
38. Remove air bleed plugs from pump regulators (8 and 12). Install regulators making sure groove in remote control sleeve and load sleeve engage dowel pin (61) in feedback link (82). Check through hole that groove in sleeves engage dowel pin.
33 3360 18
OUOE027,0000017 1919NOV0120/21
TM1931 (09JAN04)
33-3360-18

010904
PN=200
Hydraulic System
Tighten cap screws.
Hydraulic Pump and Drive GearboxSpecification Regulator-to-Pump Housing Cap ScrewTorque ................................................................ 49 Nm (36 lb-ft)
39. Tighten pump pressure sensors.

Hydraulic Pump and Drive GearboxSpecification Pump Pressure Sensor-to-Pump HousingTorque............................................................. 98 Nm (72 lb-ft)
40. Tighten cap screws (3).

Hydraulic Pump and Drive GearboxSpecification Pump Housing-to-Gearbox Housing Cap ScrewTorque...................................... 147 Nm (109 lb-ft)
41. Apply rigid form-in-place gasket to mounting surface for pilot pump (48). Tighten cap screws (45).
Hydraulic Pump and Drive GearboxSpecification Pilot Pump-to-Gearbox Cap ScrewTorque ................................................................ 49 Nm (36 lb-ft)
42. Apply multi-purpose grease to lips of oil seal (55). Install oil seal with lip (spring side) toward inside of housing. 43. Apply thread lock and sealer (medium strength) to threads of set screws (57) in dampener drive coupling (58). Tighten set screws. For assembly of dampener drive. See Dampener Drive (Flex Coupling) Repair. (Group 0752.)
Hydraulic Pump and Drive GearboxSpecification Dampener Drive Hub-to-Pump 2 (Rear) Drive Shaft Set Screw Torque ........................................................................... 108 Nm (80 lb-ft)
44. Fill pump and pump drive gearbox with oil. See Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)
33 3360 19
OUOE027,0000017 1919NOV0121/21
TM1931 (09JAN04)
33-3360-19

010904
PN=201
Hydraulic System
Hydraulic Pump and Drive Gearbox Start-Up Procedure

IMPORTANT: Hydraulic pump and drive gearbox will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump or gearbox is installed or oil has been drained from the pump, gearbox or hydraulic oil tank. Procedure is to ensure the pumps and gearbox are filled with oil and air is bled from suction side of pumps to prevent cavitation. 1. Remove air bleed plugs (C) from the top of pump regulators to allow housing to fill with oil from the hydraulic oil tank and to let air escape. 2. When pump housing is full of oil, install plugs. 3. As necessary, add oil to hydraulic oil tank until it is between marks on sight glass. See Hydraulic Oil. (Operators Manual). Tighten tank cap. Tighten vent plug. 4. Start engine and run at slow idle. Slowly raise boom to full height and then lower to pressurize hydraulic oil tank. 5. Purge air from the hydraulic system by slowly operating each function through three cycles. Air in pilot circuits are purged automatically.
CAir Bleed Plug (2 used)
UN15JUL96
TX,25,GG2226 1919NOV011/2
33 3360 20
6. Fill pump drive gearbox with oil through filler pipe (B) so level is above H mark on dipstick (A). See Swing Gearbox, Propel Gearbox and Pump Gearbox Oils. (Operators Manual.)
UN15JUL96
ADipstick BFiller Pipe
TX,25,GG2226 1919NOV012/2
TM1931 (09JAN04)
33-3360-20

010904
PN=202
T101493
T101875
Hydraulic System
Pilot Pump Drive Shaft and Gear Repair

Disassemble and Assemble Pilot Pump Drive Shaft and Gear
UN12DEC96
1. Remove snap rings (6 and 7). 2. Remove pilot pump drive shaft (4) and upper ball bearing (5) using a blind-hole puller or an internal puller. Ball bearings are a press fit on drive shaft and in housing. 3. Remove pilot pump drive gear (3) through opening for hydraulic pump.
1Pump Drive Gearbox Case 3Pilot Pump Drive Gear 4Pilot Pump Drive Shaft 5Ball Bearing (2 used) 6Snap Ring 7Snap Ring
OUOE027,0000018 1919NOV011/1
T142290
UN20JUL01
T105657
UN12DEC96
T105640
33 3360 21
TM1931 (09JAN04)
33-3360-21

010904
PN=203
Hydraulic System
Hydraulic Pump Regulator Repair

Remove and Install Hydraulic Pump Regulator
NOTE: Pump 1 (front) and pump 2 (rear) regulators are similar in design. Removal of pump 2 (rear) regulator is shown.
CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.) 3. Disconnect lines. 4. Disconnect electrical connectors.
OUOE027,000001A 1919NOV011/5
33 3360 22
TM1931 (09JAN04)
33-3360-22

010904
PN=204
Hydraulic System
5. Remove cap screws (1) and regulator (2). 6. Repair or replace parts as necessary. 7. Install regulators making sure groove in remote control sleeve and load sleeve engage dowel pin in feedback link. Check through hole that groove in sleeves engage dowel pin. 8. Tighten cap screws (1).
Pump RegulatorSpecification Pump 1 (Front) and Pump 2 (Rear) Regulator-to-Pump Housing Cap ScrewTorque.......................................... 49 Nm (36 lb-ft)
10. Connect lines. See Pilot Signal Manifold-to-Control Valve Component Location. (Group 9025-15.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump installed or oil has been drained from the pump or hydraulic oil tank. 11. Fill pump housing with oil. See Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)
1Cap Screw (8 used) 2Hydraulic Pump Regulator (2 used)
OUOE027,000001A 1919NOV012/5
T142278B
9. Connect electrical connectors. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015-10.)
UN20JUL01
33 3360 23
TM1931 (09JAN04)
33-3360-23

010904
PN=205
Hydraulic System
Pump 2 (Rear) Regulator Shown

1Cap Screw (4 used) 2Nut 3Nut (2 used) 4Minimum Flow Adjusting Screw 5Cover 6Nut (2 used) 7Load Adjusting Cartridge 8O-Ring (3 used) 9Load Adjusting Screw (Stop) 10Regulator Body 11Cap Screw (4 used) 12End Plate 13Flow Adjusting Cartridge 14Maximum Flow Adjusting Screw (Stop) 15Spring (2 used) 16Remote Control Spool 17Remote Control Sleeve 18O-Ring 19Backup Ring 20O-Ring 21Cylinder 22Piston 23Load Piston 24Cylinder 25Load Sleeve 26Load Spool 27Inner Spring
Disassemble and Assemble Hydraulic Pump Regulator
1. Remove the end plate (12) and cover (5) with the adjusting screws and cartridges installed. 2. Repair or replace parts as necessary. 3. Tighten cap screws (1 and 11).
NOTE: Pump 1 (front) and pump 2 (rear) regulators are similar. Pump 2 (rear) regulator is shown,
IMPORTANT: Removal of adjusting screws (4, 9 and 14) and cartridges (7 and 13) from end plate (12) and cover (5) will required the adjustment of pump regulators. Only remove parts from end plate and cover if replacement is necessary.
33 3360 24
Pump RegulatorSpecification Pump 1 (Front) and Pump 2 (Rear) End Plate and Cover-to-Housing Cap Screw Torque................................................................. 19.8 Nm (180 lb-in.)
OUOE027,000001A 1919NOV013/5
TM1931 (09JAN04)
33-3360-24

010904
PN=206
T142272B
UN20JUL01
Hydraulic System
2Load Sleeve 3Load Spool 5Cylinder 6Load Piston 12Load Adjusting Cartridge (Stop) Flow Adjusting Cartridge (Stop)
13Load Adjusting Screw (Stop) 15Spring 16Nut (2 used) 17Nut (2 used) 20Piston 21Cylinder
24Maximum Flow Adjusting Screw (Stop) 27Remote Control Sleeve 28Remote Control Spool 29Minimum Flow Adjusting Screw
34Nut 35End Plate 36Cover 37Cap Screw (8 used) 47Outer Spring 48Inner Spring
4. Tighten cap screws. 5. Tighten air bleed plug.

Pump RegulatorSpecification Pump 1 (Front) and Pump 2 (Rear) Air Bleed Plug-to-HousingTorque ......................................... 78 Nm (58 lb-ft)
For minimum flow: See Hydraulic Pump Regulator Test and AdjustmentsMinimum Flow200CLC. (Group 9025-25.) See Hydraulic Pump Regulator Test and AdjustmentsMinimum Flow230CLC. (Group 9025-25.) See Hydraulic Pump Regulator Test and AdjustmentMinimum Flow270CLC. (Group 9025-25.) For maximum flow: See Hydraulic Pump Regulator Test and AdjustmentsMaximum Flow200CLC. (Group 9025-25.) See Hydraulic Pump Regulator Test and AdjustmentsMaximum Flow230CLC. (Group 9025-25.)
33 3360 25
IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump installed or oil has been drained from the pump or hydraulic oil tank. 6. Fill pump housing with oil. See Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.) 7. Check pump regulator adjustments. (Group 9025-25.)
OUOE027,000001A 1919NOV014/5
TM1931 (09JAN04)
33-3360-25

010904
PN=207
T105706
UN09JAN97
Hydraulic System
See Hydraulic Pump Regulator Test and AdjustmentMaximum Flow270CLC. (Group 9025-25.)
OUOE027,000001A 1919NOV015/5
33 3360 26
TM1931 (09JAN04)
33-3360-26

010904
PN=208
Hydraulic System
Pilot Pump Repair

Remove and Install Pilot Pump CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Drain pump drive gearbox. Approximate oil capacity is 1.0 L (1.1 qt). 3. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.) 4. Disconnect lines. 5. Remove adapter (1). 6. Remove cap screws (2) and pilot pump (3). 7. Repair or replace parts as necessary. 8. Apply Rigid Form-In-Place Gasket to mounting surface for pilot pump. 9. Tighten cap screw (2).
Pilot PumpSpecification Pump-to-Drive Gearbox Cap ScrewTorque ................................................................ 49 Nm (36 lb-ft) 1Adapter 2Cap Screw (2 used) 3Pilot Pump
10. Install adapter (1) and O-ring. 11. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 12. Fill pump drive gearbox so level is above H mark on dipstick. See Change Pump Drive Gearbox Oil. (Operators Manual.)
T142279B
UN20JUL01
33 3360 27
OUOE027,000001B 1919NOV011/4
TM1931 (09JAN04)
33-3360-27

010904
PN=209
Hydraulic System
0Pilot Pump 2Flange 3Oil Seal
5Snap Ring 6Seal (2 used) 9Backup Retainer (2 used)
10Key (2 used) 12O-Ring (2 used) 15Washer (4 used)
16Cap Screw and Washer (4 used)
OUOE027,000001B 1919NOV012/4
TM1931 (09JAN04)
33-3360-28

010904
PN=210
TP47901
UN13MAY96
33 3360 28
Hydraulic System
Disassemble and Assemble Pilot Pump
OUOE027,000001B 1919NOV013/4
IMPORTANT: Be careful not to lose keys (B). 1. Check bushings (D). If inside diameter and surface toward gear are rough or worn, replace pump.
UN13MAY92
2. Check gears (A and C) and housing. If gear teeth, shaft, and inside of housing is rough or worn, replace pump. IMPORTANT: Apply clean hydraulic oil to all parts. Pump failure can result if pump is assembled dry. 3. Apply clean hydraulic oil to all parts. 4. Apply multi-purpose grease to lip of oil seal. Install oil seal with lip (spring side) towards inside of housing. 5. Tighten cap screws.
Pilot PumpSpecification Cover-to-Flange Cap Screw Torque ............................................................................. 41 Nm (31 lb-ft) ADrive Gear BKeys (2 used) CDriven Gear DBushing
6. Check pilot pressure setting. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)
OUOE027,000001B 1919NOV014/4
T7685IX
33 3360 29
TM1931 (09JAN04)
33-3360-29

010904
PN=211
Hydraulic System
Pilot Pressure Regulating Valve and Filter Repair

Remove and Install Pilot Pressure Regulating Valve and Filter CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Disconnect lines.
OUOE027,000001F 1919NOV011/3
3. Remove cap screws (1) and remove pilot pressure regulating valve (2) and pilot filter (3). 4. Repair or replace parts as necessary. 5. Install cap screws (1).
Pilot Pressure Regulating Valve and FilterSpecification Filter Head-to-Support Cap ScrewTorque ................................................................ 49 Nm (36 lb-ft)
6. Replace pilot filter (3) element.

UN20JUL01
Pilot Pressure Regulating Valve and FilterSpecification Pilot Filter Element Housing-to-Filter HeadTorque .................................. 25 Nm (220 lb-in.)
33 3360 30
8. Check pilot pressure setting. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)
1Cap Screw (2 used) 2Pilot Pressure Regulating Valve 3Pilot Filter
OUOE027,000001F 1919NOV012/3
TM1931 (09JAN04)
33-3360-30

010904
PN=212
T143074B
Hydraulic System
Disassemble and Assemble Pilot Pressure Regulating Valve and Filter 1 1. Remove plug (6) with O-ring (5). 2. Remove parts (24). 3. Inspect, clean and replace parts as necessary. 4. Check that poppet (2) slides smoothly in pilot pressure regulating valve housing (1). 5. Tighten plug (6).
Pilot Pressure Regulating Valve and FilterSpecification Plug-to-HousingTorque ................................................ 49 Nm (36 lb-ft)
4 5 6
UN20JUL01
1Pilot Pressure Regulating Valve Housing 2Poppet 3Shim (As required) 4Spring 5O-Ring 6Plug
OUOE027,000001F 1919NOV013/3
Pilot Shut-Off Valve Repair

Remove and Install Pilot Shut-Off Valve 1. Turn upperstructure 90 to tracks. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 2. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 3. Disconnect lines. 4. Disconnect spring.
33 3360 31
OUOE027,000001C 1919NOV011/4
TM1931 (09JAN04)
33-3360-31

010904
PN=213
T143094
Hydraulic System
5. Remove cap screws (1) and remove valve with lever attached. 6. Repair or replace parts as necessary. 7. Install valve. Tighten cap screws.
Pilot Shut-Off ValveSpecification Valve Housing-to-Cab Platform Cap ScrewTorque ........................................................ 49 Nm (36 lb-ft)
8. Connect spring. 9. Connect lines. See Pilot Controllers-to-Pilot Signal Manifold Component LocationExcavator Pattern. (Group 9025-15.)
1Cap Screw (2 used)
OUOE027,000001C 1919NOV012/4
33 3360 32
TM1931 (09JAN04)
33-3360-32

010904
PN=214
T142504
UN20JUL01
Hydraulic System
T143031
UN17JUL01
1Washer 2Backup Ring 3O-Ring 4Body
5Lever Stop Cap Screw 6Retaining Ring 7Washer
8Backup Ring 9O-Ring 10Spool
11Bracket 12Pin 13Cap Screw (3 used)
33 3360 33
Disassemble and Assemble Pilot Shut-Off Valve 1. Remove spring pin and remove lever from valve.
OUOE027,000001C 1919NOV013/4
TM1931 (09JAN04)
33-3360-33

010904
PN=215
Hydraulic System NOTE: Make alignment marks on body (4) and bracket (11) to aid in reassembly.
2. Remove parts (69) and remove spool (10) from body (4). 3. Remove parts (13) from body. 4. Remove cap screws (13) and bracket (11) from spool (10). 7. Position bracket (11) on spool (10). 8. Apply thread lock and seal (medium strength) to threads of cap screws (13) and tighten.
Pilot Shut-Off Valve Specification Bracket-to-Spool Cap Screw Torque..................................................................... 3.9 Nm (2.9 lb-ft)
9. Install parts (13) into body (4). 10. Apply hydraulic oil to spool (10) and install into body (4). 11. Install parts (79) in body (4) and retaining ring (6) to spool (10). 12. Align marks on bracket (11) with body (4). 13. Install lever and spring pin to valve.
NOTE: Remove pin (12) and cap screw (5) only if necessary.
5. Inspect and replace parts as necessary. 6. If cap screw (5) has been removed, apply thread lock and sealer (medium strength) to threads and tighten.
Pilot Shut-Off ValveSpecification Lever Stop Cap ScrewTorque ........................ 29.4 Nm (21.5 lb-ft)
OUOE027,000001C 1919NOV014/4
33 3360 34
TM1931 (09JAN04)
33-3360-34

010904
PN=216
Hydraulic System
Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve Repair
Remove and Install Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Disconnect electrical connector. 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 (8) and spring (7). 6. Tighten cap screws (1).
Solenoid ValveSpecification Solenoid Valve Coil-to-Manifold Cap ScrewsTorque ..................................................... 3 Nm (24 lb-in.) 1Cap Screw (8 used) 2Solenoid Valve Coil (4 used)
UN20JUL01
7. Connect electrical connectors. 8. Check pressure setting of solenoid valves. See Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve Test and Adjustment. (Group 9025-25.)
OUOE027,000001E 1919NOV011/2
T143099B
33 3360 35
TM1931 (09JAN04)
33-3360-35

010904
PN=217
Hydraulic System
1Cap Screw (2 used) 2Proportional Solenoid Valve Coil 3O-Ring 4Lock Nut
5Adjusting Screw 6Spring 7Spring 8O-Ring 9Diaphragm
10Spool 11Washer 12Spring 13O-Ring 14O-Ring
15O-Ring 16Sleeve 17Plate 18Washer
Disassemble and Assemble Proportional Solenoid Valve 1. Remove parts (718).
3. Apply clean oil to sleeve (16), O-rings (13, 14 and 15) and spool (10). After installing spool, push spool against spring to check that spool slides smoothly in sleeve. 4. Install sleeve (16) so ports align with ports in manifold. 5. Install washer (11) and spring (12) on spool and install spool. 6. Install spring (7), O-ring (8) and diaphragm (9).
33 3360 36
NOTE: Only remove the lock nut (4) and adjusting screw (5) if replacement of O-ring (3) is necessary. If disassembled, pressure setting of proportional solenoid valve will need to be adjusted. See Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve Test and Adjustment. (Group 9025-25.)
2. Repair or replace parts as necessary.
OUOE027,000001E 1919NOV012/2
TM1931 (09JAN04)
33-3360-36

010904
PN=218
T143123
UN20JUL01
Hydraulic System
Pilot Controller Repair

Remove and Install Pilot Controller CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Remove covers. 3. Disconnect wiring harness and remove lever. 4. Remove cap screws and remove pilot controller from console. 5. Disconnect lines. 6. Repair or replace parts as necessary. 7. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.)
NOTE: Position cap screw with spring pin, in lower right hole of controller.
8. Install pilot controller and tighten cap screws.
Pilot ControllerSpecification Pilot Controller-to-Console Cap ScrewTorque ............................................................... 10 Nm (7.2 lb-ft)
9. After pilot controller is installed, check operation of all functions to be sure they operate as shown on decal mounted on console.
33 3360 37
OUOE027,0000020 1919NOV011/3
TM1931 (09JAN04)
33-3360-37

010904
PN=219
Hydraulic System
13 12 14 11 15 11 10
7 16 21 5 6 19 3 4 18 2
UN17JUL01
010904
21 20
20
1 17
T143186 33 3360 38
1Spacer (4 used) 2Shim (As required) 3Balance Spring A (2 used) 4Balance Spring B (2 used) 5Return Spring A (2 used) 6Return Spring B (2 used)
7Retaining Ring (4 used) 8Pusher A (2 used) 9Pusher B (2 used) 10Block 11Cap Screw (2 used)
12Cam 13Coupling 14U-Joint 15Oil Seal (4 used) 16Spring Guide (4 used)
17Spool (4 used) 18Housing 19O-Ring 20Dowel Pin (2 used) 21O-Ring (2 used)
OUOE027,0000020 1919NOV012/3
TM1931 (09JAN04)
33-3360-38

PN=220
T143186
Hydraulic System
Disassemble and Assemble Pilot Controller IMPORTANT: The housing (18) and spools (17) are replaced as an assembly because the spools are select fitted to bores in housing. Some parts from ports 1 and 3 are different than parts from ports 2 and 4. Parts for each port must be kept together and installed into the same port from which it was removed. The port numbers are stamped on the housing. Remove U-joint (14) only if necessary. Note port location and quantity of shims (2) when removing. Same number of shims must be used when installing. 1. Remove parts from housing. Remember to keep parts removed from each port together. Identify each group of parts by port numbers stamped on housing. 2. Repair or replace parts as necessary. 3. Install parts. 4. Apply multi-purpose grease to oil seals. 5. Install pushers (8 and 9). Pushers with grooves go into ports 1 and 3. Pushers without grooves go into ports 2 and 4. 6. Tighten cap screw (11).
Pilot ControllerSpecification Block-to-Housing Cap Screw Torque................................................................. 19.6 Nm (14.5 lb-ft)
7. Apply multi-purpose grease to the end of each pushers (8 and 9) and to the joint of U-joint (14). 8. Install cam (12) on U-joint (14). Adjust clearance between pushers (8 and 9) and cam.
Pilot ControllerSpecification Cam-to-PusherClearance...................... 00.20 mm (00.008 in.)
Hold cam (12) and tighten coupling (1).

Pilot ControllerSpecification Coupling-to-Cam and U-Joint Torque.................................................................... 88.2 Nm (65 lb-ft)
NOTE: Install spring guides (16) with protrusion facing up.
OUOE027,0000020 1919NOV013/3
33 3360 39
TM1931 (09JAN04)
33-3360-39

010904
PN=221
Hydraulic System
Propel Pilot Controller Repair

Remove and Install Propel Pilot Controller CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Disconnect lines. 3. Remove cap screws (3) and remove pedals and levers. 4. Remove cap screws (2) and remove propel pilot controller (1). 5. Repair or replace parts as necessary. 6. Tighten cap screws (2).
Propel Pilot ControllerSpecification Controller-to-Cab Platform Cap ScrewTorque ................................................................ 49 Nm (36 lb-ft) 1Propel Pilot Controller 2Cap Screw (2 used) 3Cap Screw (4 used)
7. Tighten cap screws (3).

Propel Pilot ControllerSpecification Propel Pedal-to-Lever Cap ScrewTorque ................................................................ 49 Nm (36 lb-ft)
8. Connect lines. See Propel System Component Location. (Group 9025-15.) 9. After propel pilot controller is installed, check the operation of all functions to be sure they operate correctly.
33 3360 40
OUOE027,0000021 1919NOV011/4
TM1931 (09JAN04)
33-3360-40

010904
PN=222
T143206B
UN20JUL01
Hydraulic System
1 35 34 33 32 31 7 30 6 4 5 3
8 29 27 28 11 10 13 23 26 25 24 20 19 18 21 15
UN17JUL01 T143207
12
14 22
16
17
T143207
1Cap Screw (2 used) 2Cover 3Pin (2 used) 4O-Ring (2 used) 5O-Ring (2 used) 6Dampener (2 used) 7Rubber Seat (2 used) 8Cap Screw (2 used) 9Lock Washer (2 used)
10Holder 11Oil Seal (4 used) 12O-Ring (4 used) 13Bushing (4 used) 14Casing 15O-Ring 16Plug 17Spool (4 used) 18Spring (4 used)
19Spacer (4 used) 20Shim (As required) 21Balance Spring (4 used) 22Spring Guide (4 used) 23Pusher (4 used) 24Spring Pin (2 used) 25Spring Pin (2 used) 26Bracket (2 used) 27Spring Pin (2 used)
28Cap Screw (4 used) 29Lock Washer (4 used) 30Adjusting Bolt (4 used) 31Bushing (4 used) 32Cam (2 used) 33Lock Nut (4 used) 34Spring Pin (2 used) 35Spring Pin (2 used)
33 3360 41
OUOE027,0000021 1919NOV012/4
TM1931 (09JAN04)
33-3360-41

010904
PN=223
Hydraulic System
Disassemble and Assemble Propel Pilot Controller IMPORTANT: The casing (14) and spools (17) are replaced as an assembly because the spools are select fitted to bores in housing. Parts for each port must be kept together and installed into the same port from which it was removed. The port numbers are stamped on the housing. Note port location and quantity of shims (20) when removing. Same number of shims must be used when installing. 1. Remove parts from casing. Remember to keep parts removed from each port together. Identify each group of parts by port numbers stamped on casing. 6. Lock pins (34 and 35) in position by displacing the bore above spring pin using a punch and hammer. 7. Install holder (10) to casing (14) with cap screws (8), lock washers (9) and tighten.
Propel Pilot ControllerSpecification Holder-to-Casing Cap Screw Torque....................................................................... 49 Nm (36 lb-ft)
8. Adjust clearance between cams (32) and pushers (23) .

Propel Pilot ControllerSpecification Cams-to-PusherClearance .................... 00.20 mm (00.008 in.)
9. Tighten lock nut (33).

Propel Pilot ControllerSpecification Cam Adjusting Bolt Lock Nut Torque..................................................................... 9.8 Nm (7.2 lb-ft)
10. Apply multi-purpose grease to O-rings (4 and 5) and install on pin (3). 11. Position rubber seat (7) and dampener (6) on pin (3) with lever facing upward. 12. Install cap screws (28), lock washers (29) and tighten.
Propel Pilot ControllerSpecification Dampener-to-Holder Cap ScrewTorque .......................................................... 7 Nm (5.1 lb-ft)
NOTE: Spring pins (24 and 25) are stepped and can only be removed from one direction. Remove spring pin (27) and bushings (31) only if necessary.
2. Repair or replace parts as necessary. 3. Install spools (17), springs (18), spacers (19), shims (20) and balance springs (21) into casing (14). Use number of shims (20) removed. Install spring guides (22) with stepped end facing down. 4. Apply multi-purpose grease to the end of each pushers (23) and to oil seals (11). IMPORTANT: Note direction of insertion for spring pins (34 and 35). 5. Assemble cam (32) in holder (10) with spring pins (34 and 35), and pin (3). Install spring pins with slits 90 apart.
IMPORTANT: Note direction of insertion for spring pins (24 and 25). Spring pins must be positioned with slits 90 apart. Align brackets with marks made during disassembly. 13. Install brackets (26) and spring pins (24 and 25). 14. Lock pins (24 and 25) in position by displacing the bore above spring pin using a punch and hammer.
33 3360 42
OUOE027,0000021 1919NOV013/4
TM1931 (09JAN04)
33-3360-42

010904
PN=224
Hydraulic System
15. Install cover (2) and cap screws (1) and tighten.
Propel Pilot ControllerSpecification Cover-to-Holder Cap Screw Torque........................................................................ 5 Nm (3.6 lb-ft)
16. Apply multi-purpose grease to spring pin (27).
OUOE027,0000021 1919NOV014/4
Pilot Signal Manifold Repair

Remove and Install Pilot Signal Manifold CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.) 3. Disconnect lines. 4. Disconnect electrical connectors.
OUOE027,0000027 1919NOV011/6
33 3360 43
TM1931 (09JAN04)
33-3360-43

010904
PN=225
Hydraulic System
5. Remove cap screws (3). 6. Repair or replace parts as necessary. 7. Position manifold (1) on bracket (2) and tighten cap screws (3).
Pilot Signal ManifoldSpecification Pilot Signal Manifold-to-Bracket Cap ScrewTorque ........................................................ 50 Nm (37 lb-ft)
8. Connect electrical connectors. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend . (Group 9015.) 9. Install hose and tube adapters and tighten.
Pilot Signal ManifoldSpecification Hose and Tube Adapter-to-Pilot Signal ManifoldTorque .............................................. 39 Nm (347 lb-in.)
1Pilot Signal Manifold 2Bracket 3Cap Screw (4 used)
10. Connect lines. See Pilot Controllers-to-Pilot Signal Manifold Component LocationExcavator Pattern. (Group 9025-15.)
OUOE027,0000027 1919NOV012/6
33 3360 44
TM1931 (09JAN04)
33-3360-44

010904
PN=226
T143184C
UN20JUL01
Hydraulic System
33 3360 45
TM1931 (09JAN04)
33-3360-45

010904
PN=227
Hydraulic System
14 15 16 17 13 19 20 12 11
21
14
22 23 24 6 7 8 9
10
18 19 16 17 3 2 20
5 4
C
25 26 19
A
20
27 16 15 14 17
33 3360 46
28 29
UN17JUL01
010904
19 17 16
T143485
OUOE027,0000027 1919NOV013/6
TM1931 (09JAN04)
33-3360-46

PN=228
T143485
15
Hydraulic System
1Cap Screw (10 used) 2Body 3Gasket 4Body 5Gasket 6Body 7Gasket 8Body 9Gasket 10Body 11Name Plate 12Screw (4 used) 13Plate 14Cap Screw (11 used) 15Plug (7 used) 16O-Ring (7 used) 17Spring (4 used) 18Spring 19Spring Seat (7 used) 20Spool (6 used) 21Plate 22O-Ring 23Valve 24O-Ring 25Spring 26Spool 27Spring 28Spring 29Plate
Disassemble and Assemble Pilot Signal Manifold
OUOE027,0000027 1919NOV014/6
33 3360 47
TM1931 (09JAN04)
33-3360-47

010904
PN=229
Hydraulic System
30
32
31 32 31
30
31 30
33 3360 48
UN17JUL01
C
T143486
30Filter (17 used)
31Shuttle Valve (21 used)
32Spring (4 used)
OUOE027,0000027 1919NOV015/6
TM1931 (09JAN04)
33-3360-48

010904
PN=230
T143486
Hydraulic System
Install hose and tube adapters and tighten.
Pilot Signal ManifoldSpecification Hose and Tube Adapter-to-Pilot Signal ManifoldTorque ....................................... 39 Nm (347 lb-in.)
OUOE027,0000027 1919NOV016/6
Control Valve Repair

Remove and Install Control Valve CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities or 270CLC Drain and Refill Capacities. (Operators Manual.)
TX,33,UU4002 1919NOV011/18
3. Disconnect hydraulic tubes. 4. Disconnect electrical connectors (6). 5. Remove cap screws (2) and washers (3). Place pilot signal manifold (4) with bracket (5) to side. 6. Attach hoist to control valve using lifting strap.
1Control Valve 2Cap Screw (3 used) 3Washer (3 used) 4Pilot Signal Manifold 5Bracket 6Electrical Connector (4 used) 33 3360 49
UN24JUL01
TX,33,UU4002 1919NOV012/18
TM1931 (09JAN04)
33-3360-49

010904
PN=231
T143184B
Hydraulic System

Control ValveSpecification Control ValveWeight .................................. 183 kg (400 lb) approximate
7. Remove cap screws (1) and washers (2). Remove control valve. 8. Replace parts as necessary. 9. Tighten cap screws (1).
Control ValveSpecification Mounting Bracket-to-Control Valve Cap ScrewTorque .......................................... 210 Nm (152 lb-ft)
10. Install pilot signal manifold with bracket. Tighten cap screws.
Control ValveSpecification Pilot Signal Manifold Bracket-to-Control Valve Cap ScrewTorque ............................................................ 137 Nm (101 lb-ft)
3 1
UN02AUG01
T143187
12. Connect electrical connectors. See Cab Harness (W1) Component Location Diagram. (Group 9015-10.) 13. Check Hydraulic Oil. (Operators Manual.) 14. Do Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)
1Cap Screw (4 used) 2Washer (4 used) 3Front Mounting Bracket 4Rear Mounting Bracket
TX,33,UU4002 1919NOV013/18
33 3360 50
TM1931 (09JAN04)
33-3360-50

010904
PN=232
T143187
11. Connect hydraulic tubes. See Main Hydraulic System Component Location. (Group 9025-15.)
Hydraulic System
28 27 26 24 29 30 37 38 23 22 19 18 21 20 39 34 36 32 33
31
H I D C E G F J
35 25 40
16 15
H A G
17 42
44 45 46 47
B A
7 11 6 1 5 4 3 2
T143188
F
13 12 14 66
48 49 50 43 51 53 55 54 56 58
UN19NOV01 T143188
41
52
10 9
67
D
68 69
61 62 63 64 60
57
59
J
Control Valve5-Spool
65
Disassemble and Assemble Control Valve 5-Spool
33 3360 51
TX,33,UU4002 1919NOV014/18
TM1931 (09JAN04)
33-3360-51

010904
PN=233
Hydraulic System
114 111 112 113 110 105 104 106 107 109 108 115 98 102 101 100 99 93 85 84 83 82 81 76 80 86 87 89 91 104 105 79 78 77 74 73 72 71 70 123 75 84 83 82 81 80 86 78 77
T143190 33 3360 52
103
94 88 90
95
96
97
116 92
106
85 88 90 92 87 89 91 119 118 121 120
122
117
79
5-SpoolSide Components
TX,33,UU4002 1919NOV015/18
TM1931 (09JAN04)
33-3360-52

010904
PN=234
T143190
UN19NOV01
Hydraulic System
1Auxiliary Function Flow Combiner Valve 2Cap Screw (2 used) 3Cap 4O-Ring 5Spring Seat 6Spring 7Spool 8Bottom Pilot Cap (5 used) 9Cap Screw (10 used) 10Plug 11O-Ring 12Plug 13O-Ring 14O-Ring (5 used) 15Plug 16O-Ring 17Housing 18O-Ring 19System Relief and Power Boost Valve 20O-Ring 21Plug 22O-Ring 23Plug 24Cap Screw (6 used) 25O-Ring (5 used) 26Top Pilot Cap 27O-Ring 28Plug 29Plug 30O-Ring 31Left Travel Spool 32Auxiliary Spool 33Boom II Spool 34Arm I Spool 35Swing Spool 36Special Cap Screw (5 used) 37Spring Seat (5 used) 38Spring (5 used) 39Spring Seat (5 used) 40Spool 41Arm Reduced Leakage Valve 42Cap Screw (4 used) 43O-Ring 44Plug 45O-Ring 46Piston 47Spring 48Body 49O-Ring 50O-Ring 51Sleeve 52Backup Ring 53O-Ring 54O-Ring 55Backup Ring 56Spool 57Poppet 58Washer 59Spring 60Lift Check and Orifice (Left Propel Power Passage) 61Plug 62Backup Ring 63O-Ring 64Spring 65Poppet 66Arm Out Circuit Relief and Anti-Cavitation Valve 67O-Ring 68O-Ring 69Arm In Circuit Relief and Anti-Cavitation Valve 70Lift Check (Boom II Power Passage) 71Cap Screw (4 used) 72Flange 73O-Ring 74Spring 75Poppet 76Auxiliary Flow Rate Valve 77Plug (2 used) 78O-Ring (2 used) 79Cap Screw (8 used) 80Housing (2 used) 81Spool (2 used) 82Spring (2 used) 83Spring Seat (2 used) 84O-Ring (2 used) 85Plug (2 used) 86O-Ring (2 used) 87Sleeve (2 used) 88Spring (2 used) 89Plug (2 used) 90Spring (2 used) 91Poppet (2 used) 92Poppet (2 used) 93Lift Check (Left Propel Neutral Passage) 94Left Propel Neutral Passage-to-Housing Lift Check Plug 95O-Ring 96Spring 97Poppet 98Auxiliary Flow Combiner Valve Check Valve 99Cap Screw (2 used) 100Flange 101O-Ring 102Spring 103Poppet 104Cap Screw (8 used) 105Cover (2 used) 106O-Ring (2 used) 107Lift Check (Arm I Power Passage) 108Plug 109O-Ring 110Arm I Power Passage-to-Housing Lift Check Cap Screw (4 used) 111Flange 112O-Ring 113Spring 114Poppet 115Housing 116O-Ring (6 used) 117Lift Check (Swing Neutral Passage) 118Cap Screw (4 used) 119Flange 120O-Ring 121Spring 122Poppet 123Arm Priority Flow Rate Valve
1. Remove cap screws (24) and top pilot cap (26). 2. Remove cap screws (9) and bottom pilot caps (8). 3. Spool 5 Spool (3135): IMPORTANT: The spool (3135) are select fitted to bores in housing and are a different design for each function. Spools must be installed into the same bores from which they were removed for proper operation of machine. a. Remove spool (3135).
NOTE: Hold the spool in a vise by the spool end between wooden blocks. The procedures for disassembly and assembly of spool (3135) are the same.
b. Remove parts (3639) c. Inspect control valve spools for wear and damage. d. Replace parts as necessary. e. Assemble parts (3640). Tighten special cap screws (36).
33 3360 53
TX,33,UU4002 1919NOV016/18
TM1931 (09JAN04)
33-3360-53

010904
PN=235
Hydraulic System
Control ValveSpecification Special Cap Screw-to-Control valve SpoolTorque ................................................ 15 Nm (11 lb-ft)
d. Install plug (44) loosely. e. Tighten cap screws (42).

Control ValveSpecification Arm Reduced Leakage Valve Body-to-Housing Cap Screw Torque....................................................................... 62 Nm (46 lb-ft)
NOTE: Apply hydraulic oil to spools before installation.

f. Install spool (3135) into housing (17) while rotating them slowly. g. After installing spool (3135) into housing (17), push them by hand to confirm smoothness. h. Repeat procedure for remaining spool 4. Auxiliary Function Flow Combiner Valve (1): a. Inspect parts (27) for wear and damage. b. Replace parts as necessary. c. Tighten cap screws (2).
Control ValveSpecification Auxiliary Function Flow Combiner Valve-to-Housing Cap ScrewTorque ................................................... 11 Nm (7 lb-ft)
f. Tighten plug (44).

Control ValveSpecification Plug-to-Arm Reduced Leakage ValveTorque ........................................................ 108 Nm (80 lb-ft)
7. Auxiliary Flow Combiner Valve Check Valve (98): a. Remove parts (99103). b. Install flange (100) and tighten cap screws (99).
Control ValveSpecification Auxiliary Flow Combiner Valve Check Valve-to-Housing Cap ScrewTorque ......................................................... 61 Nm (46 lb-ft)
5. Lift Check And Orifice (Left Propel Power Passage) (60): a. Inspect parts (6165) for wear and damage. b. Replace parts as necessary. 6. Arm Reduced Leakage Valve (41): a. Remove cap screws (42) and body (48). b. Replace parts as necessary.
33 3360 54
8. Lift Check (Left Propel Neutral Passage) (93): a. Remove plug (94). b. Remove parts (9597). c. Replace parts as necessary d. Install plug (94) and tighten.
Control ValveSpecification Left Propel Neutral Passage-to-Housing Lift Check PlugTorque ............................................................ 76 Nm (56 lb-ft)
c. Apply petroleum jelly to washer (62) and spring (63) to hold in place. IMPORTANT: Install spool (56) with the hole side towards poppet (57) for proper operation of valve.
9. Lift Check (Arm I Power Passage) (107):
TX,33,UU4002 1919NOV017/18
TM1931 (09JAN04)
33-3360-54

010904
PN=236
Hydraulic System
a. Remove cap screws (110) and flange (111). b. Replace parts as necessary. a. Remove cap screws (79) and housing (80). c. Install flange (111) and tighten cap screws (110). b. Replace parts as necessary.
Control ValveSpecification Arm I Power Passage-to-Housing Lift Check Cap ScrewTorque ................................................. 61 Nm (46 lb-ft)
11. Auxiliary Flow Rate Valve (76) And Arm Priority Flow Rate Valve (123):
c. Install housing (80) and tighten cap screws (79).

Control ValveSpecification Flow Rate Valve Housing-to-Housing Cap ScrewTorque ......................................................... 61 Nm (46 lb-ft)
10. Lift Check (Boom II Power Passage) (70) and Lift Check (Swing Neutral Passage) (117): a. Remove cap screws (71 and 118) and flanges (72 and 119). b. Replace parts as needed. c. Install flanges (72 and 119) and tighten cap screws (71 and 118).
Control ValveSpecification Power Passage-to-Housing Cap ScrewTorque ................................................. 61 Nm (46 lb-ft)
d. Tighten plug (85).

Control ValveSpecification Flow Rate Valve Housing PlugTorque ............................................................ 98 Nm (72 lb-ft)
TX,33,UU4002 1919NOV018/18
33 3360 55
TM1931 (09JAN04)
33-3360-55

010904
PN=237
Hydraulic System
12. System Relief and Power Boost Valve (19)
1 2 3 4 5 6 7 8 9
NOTE: Disassemble valve for cleaning and inspection only. Valve is serviced as an assembly.
a. Tighten nuts (4 and 9).
System Relief ValveSpecification System Relief Valve 27 mm Nut (4)Torque ..................................................................... 64 Nm (47 lb-ft) System Relief Valve 32 mm Nut (9)Torque ..................................................................... 83 Nm (61 lb-ft)
b. Tighten valve cartridge (10).

System Relief ValveSpecification System Relief Valve Cartridge-to-HousingTorque ........................................ 83 Nm (61 lb-ft)
10 11 12 13 15 17
T143388
UN02AUG01
14 c. Check and adjust pressure setting for system relief valve and power boost. See System Relief and Power Boost Valve Test and Adjustment. (Group 9025-25.) 13. Replace parts as necessary. 14. Install top pilot cap (26) and tighten cap screws (24).
Control ValveSpecification Top Pilot Cap-to-Housing Cap ScrewTorque ................................................................ 42 Nm (32 lb-ft)
16
15. Install bottom pilot caps (8) and tighten cap screws (9).
Control ValveSpecification Bottom Pilot Caps-to-Housing Cap ScrewTorque ....................................................... 42 Nm (32 lb-ft)
1First Adjusting Plug 2O-Ring 3Piston 4Nut 5Second Adjusting Plug 6O-Ring 7Pilot Poppet Spring 8Pilot Poppet 9Nut 10Cartridge 11O-Ring 12Pilot Poppet Seat 13Backup Ring 14O-Ring 15Main Poppet Spring 16Main Poppet 17Main Poppet Seat
33 3360 56
TX,33,UU4002 1919NOV019/18
TM1931 (09JAN04)
33-3360-56

010904
PN=238
T143388
Hydraulic System
26
27 34 28 29 35
38 39 40
25
36 37 45 46 48 49 44 47 50 52 53 64 56 54 63 55 65 66 67 68 70 61
30 51 31
24 23
41 42 43
32
E D
33
20
C
22
21 19 9 8 7 6 1 5 4 3 2
T143189
G
59 60
57 58
B
13 18 17 16 14 81 82 83
62 69
71 73
72 74
UN19NOV01 T143189
11 12 10 86 87
15
80
75 77
76 78
84 85
79
D
Control Valve4-Spool
Disassemble and Assemble Control Valve 4-Spool
33 3360 57
TX,33,UU4002 1919NOV0110/18
TM1931 (09JAN04)
33-3360-57

010904
PN=239
Hydraulic System
97 98 99 102 89 96 95 94 91 92 93 90 122 126 125 124 123 127 123 106 128 104 105 103 100 100 101 108 113 112 111 110 114
116
118
117 115 120 121 119 107
127 126 125
124
136 135
134 133 132 131 130 129
137 139 88
T143191 33 3360 58
UN19NOV01
138
4-SpoolSide Components
TX,33,UU4002 1919NOV0111/18
TM1931 (09JAN04)
33-3360-58

010904
PN=240
T143191
Hydraulic System
1Propel Flow Combiner Valve 2Cap Screw (2 used) 3Cap 4O-Ring 5Cap Screw 6Spring Seat 7Spring 8Spring Seat 9Spool 10Cap Screw (8 used) 11O-Ring 12Plug 13Bottom Pilot Cap (4 used) 14Arm Regenerative Valve Check Valve 15Plug 16O-Ring 17Spring 18Poppet 19O-Ring (4 used) 20Housing 21O-Ring 22Plug 23O-Ring 24Bucket Dump Circuit Relief and Anti-Cavitation Valve 25O-Ring (4 used) 26Top Pilot Cap 27Plug 28O-Ring 29Pressure Sensor (Arm Roll-In) 30Cap Screw (6 used) 31O-Ring 32Boom Down Circuit Relief and Anti-Cavitation Valve 33O-Ring 34Right Travel Spool 35Bucket Spool 36Boom I Spool 37Arm II Spool 38Plug 39Backup Ring 40O-Ring 41Sleeve 42Spring 43Poppet 44Special Cap Screw (4 used) 45Spring Seat (3 used) 46Plug 47Spring Seat (4 used) 48Backup Ring 49O-Ring 50Spring Seat 51Spool 52Spring 53Spring 54Spring Seat 55Spring Seat 56Poppet (2 used) 57Spring (2 used) 58O-Ring (2 used) 59Backup Ring (2 used) 60Plug (2 used) 61Boom Reduced Leakage Valve 62O-Ring 63Cap Screw (4 used) 64Plug 65O-Ring 66Piston 67Spring 68Body 69O-Ring 70O-Ring 71Sleeve 72Backup Ring 73O-Ring 74O-Ring 75Backup Ring 76Spool 77Poppet 78Washer 79Spring 80Arm Regenerative Valve 81Spring 82Spacer 83O-Ring 84Backup Ring 85Spool 86Boom Up Circuit Relief and Anti-Cavitation Valve 87Bucket Load Circuit Relief and Anti-Cavitation Valve 88Housing 89Bucket Flow Rate Valve 90Poppet 91Poppet 92Spring 93Plug 94Spring 95Sleeve 96O-Ring 97Plug 98O-Ring 99Spring Seat 100Spring 101Spool 102Housing 103Cap Screw (4 used) 104O-Ring 105Plug 106O-Ring 107Lift Check and Orifice (Arm II Power Passage) 108Poppet 109Spring 110O-Ring 111O-Ring (3 used) 112O-Ring 113Housing 114O-Ring 115Screw 116O-Ring 117Nut 118Nut 119Cap Screw (4 used) 120O-Ring 121Plug 122Lift Check (Boom I Power Passage) 123Poppet 124Spring 125O-Ring 126Flange 127Cap Screw (4 used) 128Lift Check (Arm II Neutral Passage) 129By-Pass Shut-Off Valve 130Spool 131Spring 132O-Ring 133Flange 134Cap Screw (2 used) 135O-Ring 136Plug 137Cap Screw (4 used) 138Flange 139O-Ring
1. Remove cap screws (30) and top pilot cap (26). 2. Remove cap screws (10) and caps (13) from housing (20). 3. Spool 4 Spool (3437):
Spools must be installed into the same bores from which they were removed for proper operation of machine. a. Remove spool (3437).
NOTE: When disassembling spool (35, and 36), heat plugs (38, 46, and 60) to 200300 C (392 482 F) to melt the thread lock and sealer.
IMPORTANT: The spool (3437) are select fitted to bores in housing and are a different design for each function.
NOTE: Hold the spool in a vise by the spool end, using wooden blocks.
b. Remove special cap screw (44) and spools. c. Heat plugs (38, 46, and 60) with heat gun to melt threadlock and sealer and remove plugs.
33 3360 59
TX,33,UU4002 1919NOV0112/18
TM1931 (09JAN04)
33-3360-59

010904
PN=241
Hydraulic System
d. Inspect control valve spools for wear and damage. e. Replace parts as necessary. f. For right travel spool (34) and arm II spool (37), install spool and tighten special cap screw (44).
Control ValveSpecification Special Cap Screw-to-Control Valve SpoolTorque................................................ 15 Nm (11 lb-ft)
c. Inspect valve spools for wear and damage. d. Replace parts as necessary. e. Assemble parts (68) and tighten cap screw (5).
Control ValveSpecification Cap Screw-to-Flow Combiner Valve SpoolTorque.................................................. 11 Nm (7 lb-ft)
g. For bucket and boom I spool (35 and 36): Apply threadlock and sealer (high strength) on plugs (38, 46, and 60). h. Install plugs (38, 46, and 60) onto spool (35 and 36) and tighten.
Control ValveSpecification Plugs-to-Control Valve Spool Torque....................................................................... 15 Nm (11 lb-ft)
f. Install spool (9), cap (3) and tighten cap screws (2).
Control ValveSpecification Cap-to-Housing Cap Screw Torque......................................................................... 10 Nm (7 lb-ft)
5. Arm Regenerative Valve Check Valve (14): a. Replace parts as necessary. b. Install parts (1618) and tighten plug (15).
i. Install special cap screw (44) into spool and tighten.

Control ValveSpecification Special Cap Screw-to-Control Valve SpoolTorque................................................ 15 Nm (11 lb-ft)
Control ValveSpecification Arm Regenerative Valve-to-Housing PlugTorque ............................... 76 Nm (56 lb-ft)
6. Arm Regenerative Valve (80):
NOTE: Apply hydraulic oil to spools before installation.

j. Install spool (3437) into housing (20) while rotating them slowly. IMPORTANT: After installing spool (3437) into housing (20), push them by hand to confirm smoothness. 4. Propel Function Flow Combiner Valve (1): a. Remove cap screws (2) and spool (9). b. Remove parts (58).
NOTE: Do not disassemble spool (85) unless necessary.

a. Inspect valve spool for wear and damage. b. Replace parts as necessary. 7. Boom Reduced Leakage Valve (61): a. Replace parts as necessary. b. Install spool (76), with hole side towards poppet (77).
33 3360 60
TX,33,UU4002 1919NOV0113/18
TM1931 (09JAN04)
33-3360-60

010904
PN=242
Hydraulic System
Apply petroleum jelly to washer (78) and spring (79) to hold them in place. c. Loosely install plug (64). d. Install and tighten cap screws (63).
Control ValveSpecification Boom Reduced Leakage Valve Body-to-Housing Cap Screw Torque....................................................................... 62 Nm (46 lb-ft)
NOTE: Do not remove nuts (117 and 118) and screw (115) from housing (113) unless necessary.
b. Replace parts as necessary. c. Tighten screw (115). d. Tighten 13 mm nut (117) and 4 mm nut (118).
Control ValveSpecification Lift Check and Orifice (Arm II Power Passage) 4 mm Nut Torque........................................................................... 7 Nm (5 lb-ft) Control ValveSpecification Lift Check and Orifice (Arm II Power Passage) 13 mm Nut Torque....................................................................... 13 Nm (10 lb-ft)
e. Tighten plug (64).

Control ValveSpecification Boom Reduced Leakage Valve-to-Body PlugTorque .................................. 108 Nm (80 lb-ft)
8. Bucket Flow Rate Valve (89): a. Remove cap screws (103) and housing (102). b. Replace parts as necessary. c. Install housing (102) and tighten cap screws (103).
Control ValveSpecification Bucket Flow Rate Valve Housing-to-Housing Cap ScrewTorque ......................................................... 61 Nm (46 lb-ft)
e. Install housing (113) and tighten cap screws (119).

Control ValveSpecification Lift Check and Orifice (Arm II Power Passage) Housing-to-Housing Cap ScrewTorque ......................................................... 61 Nm (46 lb-ft)
10. By-Pass Shut-Off Valve (129): a. Remove cap screws (134) and flange (133). b. Replace parts as necessary.
d. Tighten plug (97).

Control ValveSpecification Flow Rate Valve Housing PlugTorque ............................................................ 98 Nm (72 lb-ft)
c. Install flange (133) and tighten cap screws (134).

Control ValveSpecification By-Pass Shut-Off Valve-to-Housing Cap Screw Torque....................................................................... 61 Nm (46 lb-ft) 33 3360 61
9. Lift Check and Orifice (Arm II Power Passage) (107): a. Remove cap screws (119) and housing (113).
TX,33,UU4002 1919NOV0114/18
TM1931 (09JAN04)
33-3360-61

010904
PN=243
Hydraulic System
12. Install top pilot cap (26) and tighten cap screws (30).
Control ValveSpecification Top Pilot Cap-to-Housing Cap ScrewTorque ......................................................... 42 Nm (32 lb-ft)
13. Install bottom pilot caps (13) and tighten cap screws (10).
Control ValveSpecification Bottom Pilot Cap-to-Housing Cap ScrewTorque ................................................ 42 Nm (32 lb-ft)
TX,33,UU4002 1919NOV0115/18
33 3360 62
TM1931 (09JAN04)
33-3360-62

010904
PN=244
Hydraulic System
10 13 21 18 17 22 20 16 15 14 19
9 8
23 7 6 24
25
3 4 26
3 4 4
10 9 11 8 7 12
4 3
10 9 5 8 7 12 3
UN02AUG01 T143217
4
T143217
1 3 2
Disassemble and Assemble 5-Spool and 4-Spool

1 Housing5-Spool 2Cap Screw (6 used) 3Plug (6 used) 4O-Ring (6 used) 5Propel Flow Combiner Valve Check Valve 6Poppet (2 used) 7Spring (3 used) 8O-Ring (3 used) 9Flange (3 used) 10Cap Screw (6 used) 11System Relief Valve Isolation Check Valve 5-Spool 12Poppet 13Right Propel and Bucket Combined Function Check Valve and Orifice 14Poppet 15Spring 16O-Ring 17Flange 18Cap Screw (2 used) 19Poppet 20Spring 21O-Ring 22Plug 23System Relief Valve Isolation Check Valve 4-Spool 24O-Ring (15 used) 25O-Ring (16 used) 26Housing4-Spool
33 3360 63
TX,33,UU4002 1919NOV0116/18
TM1931 (09JAN04)
33-3360-63

010904
PN=245
Hydraulic System
Disassemble and Assemble Control Valve 5-Spool and 4-Spool Sections 1. Right Propel And Bucket Combined Function Check Valve And Orifice (13): a. Remove cap screws (18) and flange (17). b. Remove parts (1922). c. Replace parts as necessary. d. Install and tighten plug (22).
Control ValveSpecification Right Propel and Bucket Combined Function Check Valve and Orifice-to-4-Spool Housing PlugTorque ............................................. 76 Nm (56 lb-ft)
3. Propel Flow Combiner Valve Check Valve (5) and System Relief Valve Isolation Check Valve (11): a. Remove cap screws (10) and flange (9). b. Replace parts as necessary. c. Install flange (9) and tighten cap screws (10).
Control ValveSpecification Propel Flow Combiner Valve Check Valve Cap Screw-to-5-Spool Housing Torque....................................................................... 61 Nm (46 lb-ft) System Relief Valve Isolation Check Valve Cap Screw-to-5-Spool Housing Torque....................................................................... 61 Nm (46 lb-ft)
e. Install flange (17) and tighten cap screws (18).

Control ValveSpecification Right Propel and Bucket Combined Function Check Valve and Orifice Flange-to-4-Spool Housing Cap ScrewTorque ......................................................... 61 Nm (46 lb-ft)

Control ValveSpecification 5-Spool HousingWeight ........................ 75 kg (165 lb) approximate Control ValveSpecification 4-Spool HousingWeight ........................ 74 kg (163 lb) approximate
d. Remove cap screws (2). Separate 5-spool housing (1) from 4-spool housing (26). 2. System Relief Valve Isolation Check Valve 4-Spool (23): a. Remove cap screws (10) and flange (9). b. Replace parts as necessary. c. Install flange (9) and tighten cap screws (10).
Control ValveSpecification System Relief Valve and Isolation Check Valve-to-4-Spool Housing Cap ScrewTorque ......................................................... 61 Nm (46 lb-ft)
e. Remove plugs (3) and O-rings (4) 4. Replace parts as necessary. 5. Combine 5-spool housing (1) and 4-spool housing (26) and tighten cap screws (2).
Control ValveSpecification 5-Spool-to-4-Spool Cap ScrewTorque .................................. 167177 Nm (123130 lb-ft)
33 3360 64
TX,33,UU4002 1919NOV0117/18
TM1931 (09JAN04)
33-3360-64

010904
PN=246
Hydraulic System
ANut BPlug CO-Ring (2 used) DBackup Ring EO-Ring
FO-Ring GBackup Ring HAnti-Cavitation Sleeve IPiston JMain Poppet
KPiston and Main Poppet Spring LCartridge MPilot Poppet NAnti-Cavitation Sleeve Spring
OPilot Poppet Spring PO-Ring QAdjusting Screw
6. Circuit Relief and Anti-Cavitation Valve 5-Spool and 4-Spool
b. Check and adjust pressure setting. See Circuit Relief Valve Test and Adjustment. (Group 9025-25.)
NOTE: Disassemble valves for cleaning and inspection only. Valves are serviced as assemblies.
a. Tighten valve into housing.
Circuit Relief and Anti-Cavitation ValveSpecification Circuit Relief and Anti-Cavitation Valve-to-Control Valve HousingTorque............................................ 83 Nm (61 lb-ft) 33 3360 65
TX,33,UU4002 1919NOV0118/18
TM1931 (09JAN04)
33-3360-65

010904
PN=247
T7996AE
UN04MAY93
Hydraulic System
Hydraulic Oil Tank Repair

Remove and Install Hydraulic Oil Tank CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.) 3. Disconnect lines. 4. Disconnect electrical connector on bottom of tank.
OUOE027,0000022 1919NOV011/4
33 3360 66
TM1931 (09JAN04)
33-3360-66

010904
PN=248
Hydraulic System
5. Remove cap screws (1), lock washers (2) and washers (3). CAUTION: Heavy component; use a hoist.
Hydraulic Oil TankSpecification Hydraulic Oil TankWeight .......................... 150 kg (330 lb) approximate
6. Remove hydraulic oil tank using a hoist and lifting straps. 7. Repair or replace parts as necessary.
3 9. Tighten cap screws (1). 2

Hydraulic Oil TankSpecification Oil Tank-to-Frame Cap Screw Torque ......................................................................... 205 Nm (152 lb-ft)
1
1Cap Screw (4 used) 2Lock Washer (4 used) 3Washer (4 used) 4Hydraulic Oil Tank
Hydraulic Oil TankSpecification T-Bolt Type ClampTorque ......................................... 4.4 Nm (40 lb-in.) Worm Gear Type ClampTorque ............... 5.96.9 Nm (5261 lb-in.)
11. Connect electrical connector on bottom of tank. 12. Fill hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities , 270CLC Drain and Refill Capacities, and Hydraulic Oil. (Operators Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 13. Do Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)
33 3360 67
OUOE027,0000022 1919NOV012/4
TM1931 (09JAN04)
33-3360-67

010904
PN=249
T143359
UN20JUL01
8. Install hydraulic oil tank (4).
Hydraulic System
6 5
7 8
18 9 10 11 12 13 14 15 20 21 19
16 17
22
2 1 23
38 24
37
36 26 26
25
35 34
33 3360 68
33 32 31
T143368
27 30 29 28
OUOE027,0000022 1919NOV013/4
TM1931 (09JAN04)
33-3360-68

010904
PN=250
T143368
UN20JUL01
Hydraulic System
1Suction Strainer 2Nut (3 used) 3Rod 4Cap Screw (4 used) 5Cover 6Cap 7Nut 8Element 9Body 10O-Ring 11Cap Screw (6 used) 12Cover 13O-Ring 14Bracket 15Washer 16Lock Washer 17Cap Screw 18Cap Screw (6 used) 19Cover 20Spring 21O-Ring 22Filter Element 23Hydraulic Oil Tank 24Level Gauge 25Cap Screw (2 used) 26Seal (4 used) 27Gasket 28Sensor 29Plug 30Plug 31Cap Screw (4 used) 32Lock Washer (4 used) 33Washer (4 used) 34Plug 35Elbow 36Adapter (3 used) 37Elbow 38Tee
Disassemble and Assemble Hydraulic Oil Tank 1. Tighten cap screws (11 and 18).
Hydraulic Oil TankSpecification Covers-to-Hydraulic Oil Tank Cap ScrewsTorque ............................................... 49 Nm (36 lb-ft)
Tighten nuts (2).

Hydraulic Oil TankSpecification Suction Strainer Rod Nuts Torque.................................................................... 17 Nm (153 lb-in.)
2. Adjust the length of rod (3) on suction strainer (1).

Hydraulic Oil TankSpecification Suction Strainer RodLength ................................ 683 mm (26.9 in.)
OUOE027,0000022 1919NOV014/4
Restriction Valve Repair

Remove and Install Restriction Valve CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Pull vacuum in hydraulic oil tank using vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (See Operators Manual.)
33 3360 69
OUOE027,0000023 1924OCT011/3
TM1931 (09JAN04)
33-3360-69

010904
PN=251
Hydraulic System
3 2 1
UN02AUG01
T143376 33 3360 70

1Coupling 2Snap Ring 3Restriction Valve 4Hydraulic Oil Tank 5Oil Cooler
3. Repair or replace restriction valve (3) and snap ring (2).
OUOE027,0000023 1924OCT012/3
TM1931 (09JAN04)
33-3360-70

010904
PN=252
T143376
Hydraulic System
4. Tighten nuts on coupling (1).
Restriction ValveSpecification Oil Cooler-to-Hydraulic Oil Tank Return Line Coupling Nut Torque......................................................... 10.312.4 Nm (91110 lb-in.)
IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 6. Do Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)
5. Fill and check Hydraulic Oil level. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (See Operators Manual.)
OUOE027,0000023 1924OCT013/3
Oil Cooler Bypass Valve Repair

Remove and Install Oil Cooler Bypass Valve CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Pull vacuum in hydraulic oil tank using vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.)
OUOE027,0000024 1919NOV011/3
33 3360 71
TM1931 (09JAN04)
33-3360-71

010904
PN=253
Hydraulic System
6 5 1 4 2 3
T143377 33 3360 72

1Control Valve 2Oil Cooler Bypass Valve 3O-Ring 4Cap Screw (2 used) 5Coupling 6Hydraulic Oil Tank
3. Repair or replace oil cooler bypass valve (2).
OUOE027,0000024 1919NOV012/3
TM1931 (09JAN04)
33-3360-72

010904
PN=254
T143377
UN02AUG01
Hydraulic System
4. Tighten nuts on coupling (5).
Oil Cooler Bypass ValveSpecification Control Valve-to-Hydraulic Oil Tank Return Line Coupling NutTorque ............................................... 10.312.4 Nm (91110 lb-in.)
Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 7. Do Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)
5. Tighten cap screw (4).

Oil Cooler Bypass ValveSpecification Split Coupling-to-Control Valve Cap ScrewTorque ................................................. 50 Nm (37 lb-ft)
6. Fill and check Hydraulic Oil level. See 200CLC Drain and Refill Capacities, 230CLC Drain and
OUOE027,0000024 1919NOV013/3
33 3360 73
TM1931 (09JAN04)
33-3360-73

010904
PN=255
Hydraulic System
Oil Cooler Repair

Remove and Install Oil Cooler 1. Remove radiator. See Radiator Repair. (Group 0510.) CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 2. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 3. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.) 4. Disconnect lines. 5. Remove cap screws (1 and 2). CAUTION: Heavy component; use a hoist.
Oil CoolerSpecification Oil CoolerWeight ............................................ 32 kg (70 lb) approximate 1Cap Screw (8 used). 2Cap Screw (4 used).
UN02AUG01
6. Remove oil cooler. 7. Repair or replace parts as necessary. 8. Install radiator. See Radiator Repair. (Group 0510.) 9. Install oil cooler. 10. Tighten cap screws. 11. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 12. Fill and check Hydraulic Oil level. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.)
33 3360 74
OU90U48,0000028 1919NOV011/1
TM1931 (09JAN04)
33-3360-74

010904
PN=256
T142696
Hydraulic System
Remove and Install Boom Cylinder

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 to ground. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 3. Perform Hydraulic Oil Tank Pressure Release Procedure. (Group 3360.) 4. Loosen boom cylinder hydraulic lines at frame end of boom to release any residual pressure. 5. Disconnect lines. 6. Disconnect lubrication line at rod end of cylinder.
UN10JAN97
FR91424,0000002 1904NOV031/6

Specification Boom Cylinder200CLC Weight......................................................................... 171 kg 377 lb Boom Cylinder230CLC Weight......................................................................... 217 kg 480 lb Boom Cylinder270CLC Weight......................................................................... 247 kg 540 lb
approximate approximate approximate approximate approximate approximate

UN30DEC96 T105828
7. Attach hoist to boom cylinder (F) using lifting strap.

FBoom Cylinder
T106031
33 3360 75
FR91424,0000002 1904NOV032/6
TM1931 (09JAN04)
33-3360-75

010904
PN=257
Hydraulic System
8. Remove parts (13, and 5). 9. Push pin (4) into boom. Lower boom cylinder (6) on floor stand.
1Nut (2 used) 2Retainer 3Cap Screw 4Boom Cylinder-to-Boom Pin 5Shim (2 used) 6Boom Cylinder
FR91424,0000002 1904NOV033/6
33 3360 76
TM1931 (09JAN04)
33-3360-76

010904
PN=258
T142979
UN24JUL01
Hydraulic System
10. Disconnect hydraulic lines (7) from head end of boom cylinder (6). 11. Mark location of shims (8) to aid in assembly.
UN02AUG01 T143048
6 9
12. Remove parts (811) and remove boom cylinder (6). 13. Repair or replace parts as necessary. 14. Install shims equally on each side of cylinder head end to get the minimum amount of clearance in joint. 15. Align pin bores so Shims are not damaged as pin (10) is installed. 16. Connect boom cylinder head end to frame. 17. Tighten nuts (11) against each other allowing cap screws (9) to be free to turn in hole.
Specification Boom Cylinder-to-Frame Pin Retainer Nut200CLCTorque........... 271 Nm (tighten nut against nut) 200 lb-ft (tighten nut against nut) Specification Boom Cylinder-to-Frame Pin Retainer Nut230CLC, 270CLCTorque................................... 549 Nm (tighten nut against nut) 405 lb-ft (tighten nut against nut)
7 11
10
11
6Boom Cylinder 7Rod End-to-Boom Section Bottom Port Line Head End-to-Boom Section Top Port Line 8Shim (as required) 9Cap Screw (2 used) 10Boom Cylinder-to-Frame Pin (2 used) 11Nut (4 used)
18. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) Tighten boom cylinder hoses.
Specification Boom Cylinder Hose200CLC Torque .......................................................................................... 175 Nm 130 lb-ft Specification Boom Cylinder Hose230CLC, 270CLCTorque.......................................................................... 206 Nm 152 lb-ft 33 3360 77
FR91424,0000002 1904NOV034/6
TM1931 (09JAN04)
33-3360-77

010904
PN=259
Hydraulic System
IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. 19. Start engine. 20. Slowly extend boom cylinder (6) to align pin bores so shims (5) are not damaged as pin (4) is installed. 21. Install Shims to get the minimum amount of clearance between boom and boom cylinder rod end. 22. Connect boom cylinder rod end to boom. 23. Tighten nuts (1) against each other allowing cap screw (3) to be free to turn in hole.
Specification Boom Cylinder-to-Boom Pin Retainer Nut200CLCTorque........... 271 Nm (tighten nut against nut) 200 lb-ft (tighten nut against nut) Specification Boom Cylinder-to-Boom Pin Retainer Nut230CLC, 270CLCTorque................................... 549 Nm (tighten nut against nut) 405 lb-ft (tighten nut against nut)
24. Connect lubrication line.

Specification Boom Cylinder Pivot Lubrication LineTorque ............................................................................... 29.5 Nm 21.5 lb-ft
25. Lubricate all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease. (Operators Manual.)
33 3360 78
26. Bleed air from cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.)
FR91424,0000002 1904NOV035/6
TM1931 (09JAN04)
33-3360-78

010904
PN=260
Hydraulic System
27. Check hydraulic oil level . See Check Hydraulic Oil Level. (Operators Manual.)
FR91424,0000002 1904NOV036/6
33 3360 79
TM1931 (09JAN04)
33-3360-79

010904
PN=261
Hydraulic System
Boom Cylinder Disassemble and Assemble200CLC, 270CLC
33 3360 80
Boom Cylinder200CLC, 270CLCRight Cylinder Shown

Continued on next page FR91424,0000003 1905NOV031/20
TM1931 (09JAN04)
33-3360-80

010904
PN=262
T190994
UN09MAY03
Hydraulic System
1Cylinder Barrel and Bushings 2Rod and Bushings 3Rod Guide 4Wear Ring 5Snap Ring 6Buffer Ring Seal 7U-Cup Seal 8Back-Up Ring 9Wiper Seal 10O-Ring 11Back-Up Ring 12Cap Screw (12 used) 13Cushion 14Cushion Seal 15Piston 16Cap Seal and O-Ring 17Back-Up Ring (2 used) 18Buffer Seal (2 used) 19Wear Ring (2 used) 20Shim 21Nut 22Set Screw 23Steel Ball 25Seal (2 used) 26Retainer Ring 27Seal (2 used) 28Hydraulic Line 29Hydraulic Line 30O-Ring 31Cap Screw (4 used) 32O-Ring 33Cap Screw (4 used) 34Band 35Clamp 36Cap Screw (2 used) 37Lock Washer (2 used) 38Half Clamp (2 used) 39Cap Screw 40Lock Washer 41Lubrication Fitting
NOTE: Disassemble and assemble procedures are the same for both right and left boom cylinders.
Specification Boom CylinderWeight ...................................... 171 kg approximate 377 lb approximate
1. Fasten head end of cylinder to JT30043 cylinder service stand.
FR91424,0000003 1905NOV032/20
2. Remove line (B). 3. Pull rod out so piston is against rod guide. 4. Connect rod to a hoist using a lifting strap. 5. Remove cap screws (A). 6. Remove rod, rod guide and piston from barrel.
ACap Screw BLine
UN27OCT88 T6557HI
33 3360 81
FR91424,0000003 1905NOV033/20
TM1931 (09JAN04)
33-3360-81

010904
PN=263
Hydraulic System
7. Install rod eye in sliding housing (B) and install housing in the JT30043 cylinder service stand.
BSliding Housing
UN27OCT88
FR91424,0000003 1905NOV034/20
8. Remove the staked material from set screw (A) hole using a small air grinder or a drill and bit. 9. Remove set screw (A) and steel ball (B).
UN27OCT88
ASet Screw BSteel Ball
FR91424,0000003 1905NOV035/20
33 3360 82
TM1931 (09JAN04)
33-3360-82

010904
PN=264
T6585XI
T6557HK
Hydraulic System
IMPORTANT: To avoid damaging the tapped hole for set screw, the cap screw in the JT30043-30 Hex Piston Nut Wrench must be tightened against a side of the nut without the tapped hole. To avoid gouging side of nut, install a piece of steel flat stock between nut and cap screw. 10. Install JT30043-30 Hex Piston Nut Wrench so cap screw is tightened against side of nut (B) without tapped hole. 11. Install a 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) piece of steel flat stock between nut and cap screw. Tighten cap screw. 12. Loosen nut (B).
Specification Boom Cylinder Piston-to-Rod NutTorque ............................................................................... 4780 Nm 3,525 lb-ft
UN22MAY92
BNut
FR91424,0000003 1905NOV036/20
T7768AG
33 3360 83
TM1931 (09JAN04)
33-3360-83

010904
PN=265
Hydraulic System
13. Remove parts (AD and G).
NOTE: Note direction of flat face (E) on cushion and notches (F) in cushion seal and cushion for assembly.
14. Remove parts from rod guide and piston.
UN27OCT88
ANut BShim CPiston DCushion EFlat Face FNotch GCushion Seal

UN16JUL94
FR91424,0000003 1905NOV037/20
33 3360 84
TM1931 (09JAN04)
33-3360-84

010904
PN=266
T8286BL
T6585XK
NOTE: Inspect the piston, inside the rod guide and barrel for wear, scratches and nicks that may cut or damage a seal or wear ring.
Hydraulic System
15. Remove and inspect dust seals (A) and bushings (B) for wear or damage. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. Repair or replace parts as necessary. (Group 3340.)
Boom Cylinder200CLCSpecification Boom Cylinder Head End BushingID.................................................................... 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use Boom Cylinder Rod End BushingID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use Boom Cylinder270CLCSpecification Boom Cylinder Head End BushingID.................................................................. 100.0 mm nominal 3.94 in. nominal ID ............................................................................. 101.5 mm limit of use 4.0 in. limit of use Boom Cylinder Rod End BushingID.................................................................. 100.0 mm nominal 3.94 in. nominal ID ............................................................................. 101.5 mm limit of use 4.0 in. limit of use
UN27OCT88
16. Check for rod curvature on V-blocks using dial indicator.

Specification Boom RodCurvature .................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft
ADust Seal BBushing
17. Inspect rod surface for scratches or wear.

Boom CylinderSpecification Boom Rod Allowable Scratch Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Boom Rod200CLCOD ......................................... 84.97385.00 mm 3.349 3.35 in. Boom Rod270CLCOD ......................................... 94.91095.00 mm 3.736 3.74 in.
T6585XG
UN27OCT88
T6557HR
33 3360 85
FR91424,0000003 1905NOV038/20
TM1931 (09JAN04)
33-3360-85

010904
PN=267
Hydraulic System
33 3360 86
UN09MAY03
Boom Cylinder200CLC, 270CLCRight Cylinder Shown
19.
TM1931 (09JAN04)
33-3360-86

010904
PN=268
T190994
Hydraulic System
Boom Cylinder200CLC, 270CLC

1Cylinder Barrel and Bushings 2Rod and Bushings 3Rod Guide 4Wear Ring 5Snap Ring 6Buffer Ring Seal 7U-Cup Seal 8Back-Up Ring 9Wiper Seal 10O-Ring 11Back-Up Ring 12Cap Screw (12 used) 13Cushion 14Cushion Seal 15Piston 16Cap Seal and O-Ring 17Back-Up Ring (2 used) 18Buffer Seal (2 used) 19Wear Ring (2 used) 20Shim 21Nut 22Set Screw 23Steel Ball 25Seal (2 used) 26Retainer Ring 27Seal (2 used) 28Hydraulic Line 29Hydraulic Line 30O-Ring 31Cap Screw (4 used) 32O-Ring 33Cap Screw (4 used) 34Band 35Clamp 36Cap Screw (2 used) 37Lock Washer (2 used) 38Half Clamp (2 used) 39Cap Screw 40Lock Washer 41Lubrication Fitting
Install boom cylinder barrel and rod bushings to a depth equal to the thickness of seals (25 and 27).
NOTE: Use a cylinder repair kit when assembling a cylinder.

20. Install seals (25 and 27) tight against bushing with seal lip outward.
NOTE: The left and right boom cylinders are the same except for the head (28) and rod (29) end lines, and clamps (34 and 35).
FR91424,0000003 1905NOV0310/20
T106211
UN16JAN97
33 3360 87
TM1931 (09JAN04)
33-3360-87

010904
PN=269
Hydraulic System
21. Push wear ring (C) to bottom of bore using a driver disk and a press. 22. Install the snap ring (B). 23. Install back-up ring (A) and O-ring (D).
ABack-Up Ring BSnap Ring CWear Ring DO-Ring
FR91424,0000003 1905NOV0311/20
33 3360 88
TM1931 (09JAN04)
33-3360-88

010904
PN=270
T6585XN
UN27OCT88
Hydraulic System
24. Install buffer ring seal (I) with notched side towards wear ring (B). 25. Install black buffer ring (D) with notched side (C) towards the wear ring. 26. Install green buffer ring (E). 27. Install U-cup seal (F) with lip towards wear ring (B) using the bending method (K). 28. Install back-up ring (G). 29. Install wiper seal (H) with lip towards outside of cylinder. 30. Install rod guide (J) on the rod.
ASnap Ring BWear Ring CNotched Side DBlack Buffer Ring EGreen Buffer Ring FU-Cup Seal GBack-Up Ring HWiper Seal IBuffer Ring Seal JRod Guide KBending Method Seal Installation
T7963AK
UN01APR93
33 3360 89
FR91424,0000003 1905NOV0312/20
TM1931 (09JAN04)
33-3360-89

010904
PN=271
T7623AF
UN22OCT91
Hydraulic System
31. Install O-ring (C) into the middle groove of piston. 32. Install the buffer seals (D). The buffer seal in groove above helps support the thin section of installer. The buffer seal below keeps the cap seal from going into that groove if pushed too far. 33. Apply clean oil to installer. 34. Push the cap seal (B) down the installer and into the middle groove over the O-ring (C) using the correct size pusher (A).
AJDG901-3 Pusher JDG917 Installer200CLC JDG842-1 Installer270CLC BCap Seal CO-Ring DWear Ring
UN18MAR93
FR91424,0000003 1905NOV0313/20
35. Check the cap seal, seal must fit tight against O-ring and not turn. If seal can be turned, it has been stretched too much and can be damaged during assembly into cylinder barrel. 36. For a cap seal that has been stretched too much, shrink it to its original size using a ring compressor or a plastic tie band and hose clamp. When using a ring compressor, put a piece of shim stock between cap seal and compressor at the joint so it does not damage seal. When using a plastic tie band and hose clamp, grind a taper on one end of tie band. Install tie band with the taper against cap seal. Before tightening the hose clamp, check to be sure tie band is under hose clamp all around piston.
33 3360 90
FR91424,0000003 1905NOV0314/20
TM1931 (09JAN04)
33-3360-90

010904
PN=272
T6396AC
UN27OCT88
T7964AQ
Hydraulic System
37. Install a back-up ring (C) on each side of cap seal. 38. Install the buffer seals (B) and wear rings (A). Turn the seals and rings so the slits are 180 from each other
AWear Ring (2 used) BBuffer Seal (2 used) CBack-Up Ring (2 used)
FR91424,0000003 1905NOV0315/20
39. Install cushion seal (G) so notches (F) are towards the piston and threaded section of rod. 40. Install cushion (D) so wide end of flat face (E) is towards the rod guide and narrow end is towards the piston.
DCushion EFlat Face FNotch GCushion Seal
UN16JUL94
Boom Cylinder Rod
FR91424,0000003 1905NOV0316/20
41. Install piston (C) so flat side is against the cushion (D) 42. Install shim (B).
UN27OCT88
43. Install nut (A).

ANut BShim CPiston DCushion
T8286BL
T6557HV
UN27OCT88
FR91424,0000003 1905NOV0317/20
TM1931 (09JAN04)
33-3360-91

010904
PN=273
T6585XK
33 3360 91
Hydraulic System
IMPORTANT: To avoid damaging the tapped hole for set screw, the cap screw in the JT30043-30 Hex Piston Nut Wrench must be tightened against a side of the nut without the tapped hole. To avoid gouging side of nut, install a piece of steel flat stock between nut and cap screw. 44. Tighten nut using the JT30043-30 Hex Piston Nut Wrench. Install wrench so cap screw is tighten against a side of nut (B) without the tapped hole. Install a 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) piece of steel flat stock between nut and cap screw. Tighten cap screw.
Specification Boom Cylinder Piston-to-Rod NutTorque ............................................................................... 4780 Nm 3525 lb-ft
BNut
FR91424,0000003 1905NOV0318/20
45. Install steel ball (B). 46. Tighten set screw (A).
Specification Boom Cylinder Nut-to-Rod Set ScrewTorque .............................................................................. 57 Nm 42 lb-ft 33 3360 92
FR91424,0000003 1905NOV0319/20
TM1931 (09JAN04)
33-3360-92

010904
PN=274
T6585XI
47. Stake set screw in two places 90 from previous stake marks.
UN27OCT88
T7768AH
UN22MAY92
Hydraulic System
48. Apply clean oil to piston and seals. Attach a hoist to rod using a lifting strap. Carefully install piston, rod and rod guide into barrel. 49. Tighten cap screws (A).
Specification Boom Cylinder Rod Guide-to-Barrel Cap Screw Torque ......................................................................................... 267 Nm 197 lb-ft
UN27OCT88
50. Install the lines (B).

ACap Screw BLines
FR91424,0000003 1905NOV0320/20
T6557HI
33 3360 93
TM1931 (09JAN04)
33-3360-93

010904
PN=275
Hydraulic System
Boom Cylinder Disassemble and Assemble230CLC
11
10
13
14
15
23
20
21 18 22 21 20
4 29 28
44 30 42 25 37 31 36
34
32
1
33 3360 94
33 30 1 40
26 28 29
T196495
Boom Cylinder230CLCRight Cylinder Shown

TM1931 (09JAN04)
33-3360-94

010904
PN=276
T196495
UN26NOV03
Hydraulic System
1Bushings (2 used) 2Rod and Bushings 3Seal 4Rod Guide 5Cap Screw (12 used) 7O-Ring 9Seal 10Ring 11Snap Ring 13Bushing 14Snap Ring 15Cushion Ring 18Piston 20Piston Ring (2 used) 21Wear Ring (2 used) 22Seal Ring 23Packing 25Cap Screw (6 used) 26Hydraulic Line 28Cap Screw (4 used) 29Cap Screw (4 used) 30O-Ring (2 used) 31Hydraulic Line 32Clamp 33Clamp 34Cap Screw (2 used) 36Clamp 37Cap Screw 40Lubrication Fitting 42Washer (6 used) 44Hydraulic Cylinder Barrel
NOTE: Disassemble and assemble procedures are the same for both right and left boom cylinders.
Specification Boom CylinderWeight ...................................... 217 kg approximate 480 lb approximate
FR91424,0000006 1911NOV032/8
ACap Screw BLine
UN27OCT88
FR91424,0000006 1911NOV033/8
T6557HI
33 3360 95
TM1931 (09JAN04)
33-3360-95

010904
PN=277
Hydraulic System
7. Install rod eye in sliding housing (B) and install housing in the JT30043 cylinder service stand. 8. Remove cap screws (25) and washers (42) from piston (18). 9. Remove piston (18), cushion ring (15), rod guide (4) from rod (2). 10. Remove piston rings (20), wear rings (21), seal ring (22), and O-ring (23) from piston (18).
UN27OCT88
11. Remove snap ring (11), seal (3), seal (9), ring (10), snap ring (14), and bushing (13) from rod guide (4). 12. Remove and inspect rod (2) and hydraulic cylinder barrel bushings (1) for wear or damage. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. Repair or replace parts as necessary. (Group 3340.)
Boom Cylinder230CLCSpecification Boom Cylinder Head End BushingID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use Boom Cylinder Rod End BushingID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use
BSliding Housing
FR91424,0000006 1911NOV034/8
33 3360 96
TM1931 (09JAN04)
33-3360-96

010904
PN=278
T6557HK
Hydraulic System
Specification Boom RodCurvature .................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft

Boom CylinderSpecification Boom Rod Allowable Scratch Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Boom Rod230CLCOD ........................................... 89.91090.0 mm 3.536 3.540 in.
FR91424,0000006 1911NOV035/8
T6585XG
UN27OCT88
33 3360 97
TM1931 (09JAN04)
33-3360-97

010904
PN=279
Hydraulic System
11
10
13
14
15
23
20
21 18 22 21 20
4 29 28
44 30 42 25 37 31 36
34
32
1 33
33 3360 98
30
40
26 28 29
T196495
Boom Cylinder230CLCRight Cylinder Shown
16.
TM1931 (09JAN04)
33-3360-98

010904
PN=280
T196495
UN26NOV03
Hydraulic System
Boom Cylinder230CLC
1Bushings (2 used) 2Rod and Bushings 3Seal 4Rod Guide 5Cap Screw (12 used) 7O-Ring 9Seal 10Ring 11Snap Ring 13Bushing 14Snap Ring 15Cushion Ring 18Piston 20Piston Ring (2 used) 21Wear Ring (2 used) 22Seal Ring 23Packing 25Cap Screw (6 used) 26Hydraulic Line 28Cap Screw (4 used) 29Cap Screw (4 used) 30O-Ring (2 used) 31Hydraulic Line 32Clamp 33Clamp 34Cap Screw (2 used) 36Clamp 37Cap Screw 40Lubrication Fitting 42Washer (6 used) 44Hydraulic Cylinder Barrel
Install boom cylinder head end and rod end bushings.
NOTE: The left and right boom cylinders are the same except for the hydraulic lines (26 and 31), and clamps (32 and 33). NOTE: Use a cylinder repair kit when assembling a cylinder.
17. Install bushing (13) to bottom of bore in rod guide (4) using a driver disk and a press. 18. Install the snap ring (14).
Ensure that ring and seals are installed so that slotted side is facing toward cylinder head end (pressure side). 19. Install ring (10), seal (9), seal (3), and snap ring (11). 20. Install O-ring (7). 21. Install packing (23), seal ring (22), wear rings (21), and piston rings (20) on piston (18). 22. Install rod guide assembly on rod (2).
33 3360 99
IMPORTANT: Ring (10), seal (9), and seal (3) must be installed in the correct direction.
FR91424,0000006 1911NOV037/8
TM1931 (09JAN04)
33-3360-99

010904
PN=281
T196497
UN10DEC03
Hydraulic System
IMPORTANT: Cushion ring (15) must be installed in the correct direction. Ensure that cushion ring is installed so that slotted end is facing toward piston (18). 23. Install cushion ring (15) on rod (2). 24. Secure rod assembly on bench and install piston (18) assembly to rod (2). Install cap screws (25) and washers (42).
Specification Piston-to-Rod Cap Screw Torque.................................................................................... 395 Nm 290 lb-ft
25. Apply clean oil to piston and seals. Attach a hoist to rod using a lifting strap. Carefully install piston, rod and rod guide into barrel. 26. Install and tighten cap screws (5).
Specification Boom Cylinder Rod Guide-to-Hydraulic Cylinder Barrel Cap ScrewTorque .................................................. 395 Nm 290 lb-ft
27. Install hydraulic lines (26 and 31).
FR91424,0000006 1911NOV038/8
Arm Cylinder Remove and Install

1. Park machine on firm, level surface.
FR91424,0000004 1911NOV031/6
2. Retract arm and bucket cylinders and lower bucket to ground. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 3. Perform Hydraulic Oil Tank Pressure Release Procedure. (Group 3360.) 4. Loosen arm cylinder hydraulic lines at frame end of boom to release any residual pressure. 5. Disconnect lines.
33 3360 ,100
FR91424,0000004 1911NOV032/6
TM1931 (09JAN04)
33-3360-100

010904
PN=282
T106031
UN10JAN97
Hydraulic System
6. Insert wood block (3 ) between arm cylinder (1) and boom (2). CAUTION: Heavy component; use a hoist.
Specification Arm Cylinder200CLCWeight ............................... 259 kg 570 lb Arm Cylinder230CLCWeight ............................... 285 kg 630 lb Arm Cylinder270CLCWeight ............................... 307 kg 680 lb approximate approximate approximate approximate approximate approximate 1Arm Cylinder 2Boom 3Wood Block
UN02AUG01
7. Attach arm cylinder to hoist using lifting straps.
FR91424,0000004 1911NOV033/6
NOTE: Note location of shims (3) to aid in assembly.

9. Push pin (4) out and remove shims. 10. Disconnect lubrication line.
1Nut (2 used) 2Cap Screw 3Shim (as required) 4Arm Cylinder-to-Arm Pin
FR91424,0000004 1911NOV034/6
T143064
UN02AUG01
T143063
33 3360 ,101
TM1931 (09JAN04)
33-3360-101

010904
PN=283
Hydraulic System
NOTE: Note location of shims (3) to aid in assembly.

12. Push pin (4) out and remove shims. 13. Remove arm cylinder 14. Repair or replace parts as necessary. See Arm Cylinder Disassemble and Assemble200CLC, 270CLCor see Arm Cylinder Disassemble and Assemble230CLC. (Group 3360.) 15. Install shims equally on each side of cylinder to get minimum amount of clearance in joint. There must be some clearance in the joint. 16. Align pin bores so shims are not damaged as pin (4) is installed. 17. Connect lubrication line.
Specification Arm Cylinder Pivot Lubrication LineTorque ............................................................................... 29.5 Nm 21.5 lb-ft 1Nut (2 used) 2Cap Screw 3Shim (as required) 4Arm Cylinder-to-Boom Pin
UN02AUG01
18. Connect arm cylinder head end to boom. 19. Tighten nuts (1) against each other allowing cap screw (2) to be free to turn in hole.
Specification Arm Cylinder-to-Boom Pin Retainer Nut200CLCTorque........... 550 Nm 405 lb-ft Arm Cylinder-to-Boom Pin Retainer Nut230CLC, 270CLCTorque................................... 750 Nm 550 lb-ft
(tighten nut against nut) (tighten nut against nut)
(tighten nut against nut) (tighten nut against nut)
33 3360 ,102
FR91424,0000004 1911NOV035/6
TM1931 (09JAN04)
33-3360-102

010904
PN=284
T143065
Hydraulic System
IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. 20. Slowly extend arm cylinder to align pin bores so shims are not damaged as pin is installed. 21. Connect arm cylinder rod end to arm. 22. Tighten nuts (1) against each other allowing cap screw (2) to be free to turn in hole.
Specification Arm Cylinder-to-Arm Pin Retainer Nut200CLCTorque ......................... 550 Nm 405 lb-ft Arm Cylinder-to-Arm Pin Retainer Nut230CLC, 270CLCTorque .......... 750 Nm 550 lb-ft
(tighten nut against nut) (tighten nut against nut) (tighten nut against nut) (tighten nut against nut)
23. Connect lubrication line.

Specification Arm Cylinder Pivot Lubrication LineTorque ............................................................................... 29.5 Nm 21.5 lb-ft
24. Connect lines. 25. Lubricate all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease. (Operators Manual.) 26. Bleed air from cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 27. Check hydraulic oil level. See Check Hydraulic Oil Level. (Operators Manual.)
33 3360 ,103
FR91424,0000004 1911NOV036/6
TM1931 (09JAN04)
33-3360-103

010904
PN=285
Hydraulic System
Arm Cylinder Disassemble and Assemble200CLC, 270CLC
33 3360 ,104
Arm Cylinder
TM1931 (09JAN04)
33-3360-104

010904
PN=286
T190996
UN09MAY03
Hydraulic System
1Cylinder Barrel and Bushing 2Rod and Bushings 3Rod Guide 4Wear Ring 5Snap Ring 6Buffer Ring Seal 7U-Cup Seal 8Back-Up Ring 9Wiper Seal 10O-Ring 11Back-Up Ring 12Cap Screw (12 used) 13Cushion 14Cushion Seal 15Piston 16Cap Seal and O-Ring 17Back-Up Ring (2 used) 18Buffer Seal (2 used) 19Wear Ring (2 used) 20Shim 21Nut 22Set Screw 23Steel Ball 24Cushion 25Cushion Seal 26Retainer Ring 27Ring 29Seal 30Shoulder Fitting 31Hydraulic Line 32O-Ring 33Cap Screw (8 used) 34Band 35Band 36Cap Screw (2 used) 37Lock Washer (2 used) 38Clamp 39Cap Screw 40Lock Washer 41Lubrication Fitting

Specification Arm Cylinder200CLC Weight .................................................................. 259 kg approximate 571 lb approximate
Arm Cylinder270CLC Weight .................................................................. 307 kg approximate 680 kg approximate
FR91424,0000005 1911NOV032/22
ACap Screw BLine
UN27OCT88
FR91424,0000005 1911NOV033/22
BSliding Housing
UN27OCT88
T6557HI
33 3360 ,105
FR91424,0000005 1911NOV034/22
TM1931 (09JAN04)
33-3360-105

010904
PN=287
T6557HK
Hydraulic System
UN27OCT88
FR91424,0000005 1911NOV035/22
Specification Arm Cylinder Piston-to-Rod Nut 200CLC, 270CLCTorque ..................................................... 10 200 Nm 7,520 lb-ft
UN22MAY92
BNut
33 3360 ,106
FR91424,0000005 1911NOV036/22
TM1931 (09JAN04)
33-3360-106

010904
PN=288
T7768AG
T6585XI
Hydraulic System
13. Remove parts (AD and G).
NOTE: Note direction of flat face (E) on cushion and notches (F) in cushion seal and cushion for assembly.
UN27OCT88
FR91424,0000005 1911NOV037/22
14. Remove ring (A). Push cushion (C) against shoulder. Remove retainer ring (B) and remove cushion.
NOTE: Note direction of flat face on cushion and notches in cushion seal for assembly.
Remove cushion seal (D). 15. Remove parts from rod guide and piston.
Arm Cylinder Rod End Cushion
ARing BRetainer Ring CCushion DCushion Seal
T7778AU
UN10JUN92
T8286BL
UN16JUL94
T6585XK
33 3360 ,107
FR91424,0000005 1911NOV038/22
TM1931 (09JAN04)
33-3360-107

010904
PN=289
Hydraulic System
16. Remove and inspect dust seals (A) and bushing (B) for wear or damage. Replace parts as necessary. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. (Group 3340.)
Arm Cylinder200CLCSpecification Arm Cylinder Head End and Rod End BushingID ............................................................ 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use Arm Cylinder270CLCSpecification Arm Cylinder Head End and Rod End BushingID ............................................................ 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use
UN27OCT88
Specification Arm RodCurvature ....................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft

Arm Cylinder200CLCSpecification Arm Rod Allowable Scratch Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Arm RodOD .............................................................. 94.97395.0 mm 3.7393.740 in. Arm Cylinder270CLCSpecification Arm Rod Allowable Scratch Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Arm RodOD ................................................................. 99.91100 mm 3.9363.940 in. ADust Seal BBushing

33 3360 ,108
FR91424,0000005 1911NOV039/22
TM1931 (09JAN04)
33-3360-108

010904
PN=290
T6585XG
UN27OCT88
T6557HR
Hydraulic System
33 3360 ,109
UN09MAY03
Arm Cylinder
20.
TM1931 (09JAN04)
33-3360-109

010904
PN=291
T190996
Hydraulic System
Arm Cylinder
1Cylinder Barrel and Bushing 2Rod and Bushings 3Rod Guide 4Wear Ring 5Snap Ring 6Buffer Ring Seal 7U-Cup Seal 8Back-Up Ring 9Wiper Seal 10O-Ring 11Back-Up Ring 12Cap Screw (12 used) 13Cushion 14Cushion Seal 15Piston 16Cap Seal and O-Ring 17Back-Up Ring (2 used) 18Buffer Seal (2 used) 19Wear Ring (2 used) 20Shim 21Nut 22Set Screw 23Steel Ball 24Cushion 25Cushion Seal 26Retainer Ring 27Ring 29Seal (4 used) 30Shoulder Fitting 31Hydraulic Line 32O-Ring 33Cap Screw (8 used) 34Band 35Band 36Cap Screw (2 used) 37Lock Washer (2 used) 38Clamp 39Cap Screw 40Lock Washer 41Lubrication Fitting
Install arm cylinder barrel and rod bushings to a depth equal to the thickness of seals (29).
21. Install seals (29) tight against bushing with seal lip outward.
FR91424,0000005 1911NOV0311/22
33 3360 ,110
TM1931 (09JAN04)
33-3360-110

010904
PN=292
T106126
UN16JAN97
Hydraulic System
FR91424,0000005 1911NOV0312/22
T6585XN
UN27OCT88
33 3360 ,111
TM1931 (09JAN04)
33-3360-111

010904
PN=293
Hydraulic System
25. Install buffer ring seal (I) with notched side towards wear ring (B). Install black buffer ring (D) with notched side (C) towards the wear ring. Install green buffer ring (E). 26. Install U-cup seal (F) with lip towards wear ring (B) using the bending method (K). Install back-up ring (G). 27. Install wiper seal (H) with lip towards outside of cylinder. 28. Install rod guide (J) on the rod.
33 3360 ,112
FR91424,0000005 1911NOV0313/22
TM1931 (09JAN04)
33-3360-112

010904
PN=294
T7623AF
UN22OCT91
T7963AK
UN01APR93
Hydraulic System
A JDG901-3 Pusher JDG842-1 Installer200CLC JDG843-1 Installer270CLC BCap Seal CO-Ring DWear Ring
UN18MAR93
FR91424,0000005 1911NOV0314/22
T7964AQ
33 3360 ,113
FR91424,0000005 1911NOV0315/22
TM1931 (09JAN04)
33-3360-113

010904
PN=295
T6396AC
UN27OCT88
Hydraulic System
35. Install a back-up ring (C) on each side of cap seal and O-ring. 36. Install the buffer seals (B) and wear rings (A).
UN27OCT88
Turn the seals and rings so the slits are 180 from each other
FR91424,0000005 1911NOV0316/22
37. Install cushion seals (A and C) so notches (B) are towards the piston and threaded section of rod.
ACushion Seal BNotch CCushion Seal
Arm Cylinder Rod
FR91424,0000005 1911NOV0317/22
33 3360 ,114
TM1931 (09JAN04)
33-3360-114

010904
PN=296
T7778AV
UN10JUN92
T6557HV
Hydraulic System
38. Install cushion (C) so wide end of flat face is towards the end of rod and narrow end is towards the piston. 39. Install retainer ring in groove.
UN10JUN92
40. Pull cushion out against retainer ring. 41. Install ring (A).
ARing BRetainer Ring CCushion DCushion Seal
Arm Cylinder Rod Cushion
FR91424,0000005 1911NOV0318/22
UN27OCT88

ANut BShim CPiston DCushion
FR91424,0000005 1911NOV0319/22
T6585XK
T7778AU
33 3360 ,115
TM1931 (09JAN04)
33-3360-115

010904
PN=297
Hydraulic System
Specification Arm Cylinder Piston-to-Rod Nut Torque ..................................................................................... 10 200 Nm 7,520 lb-ft
BNut
FR91424,0000005 1911NOV0320/22
Specification Arm Cylinder Nut-to-Rod Set ScrewTorque .............................................................................. 57 Nm 42 lb-ft 33 3360 ,116
FR91424,0000005 1911NOV0321/22
TM1931 (09JAN04)
33-3360-116

010904
PN=298
T6585XI
UN27OCT88
T7768AH
UN22MAY92
Hydraulic System
Specification Arm Cylinder Rod Guide-to-Barrel Cap ScrewTorque .................................................................... 365 Nm 270 lb-ft
UN27OCT88
51. Install the lines (B).

ACap Screw BLines
FR91424,0000005 1911NOV0322/22
T6557HI
33 3360 ,117
TM1931 (09JAN04)
33-3360-117

010904
PN=299
Hydraulic System
Arm Cylinder Disassemble and Assemble230CLC

46 2
11
5 10 13 14
30
32
29 40
35
31
4 40 6 39 48 49 53 27
39
15
52
21 51 22 21 52 54 25
36
33 3360 ,118
34 37 34 37
T196496
1 56
Arm Cylinder230CLC
TM1931 (09JAN04)
33-3360-118

010904
PN=300
T196496
UN26NOV03
Hydraulic System
1Bushing (2 used) 2Rod and Bushings 4Rod Guide 5Cap Screw (14 used) 6O-Ring 7Seal 9Seal 10Scraper Ring 11Snap Ring 13Bushing 14Snap Ring 15Cushion Ring 21Piston Ring (2 used) 22Seal Ring 25Cap Screw (6 used) 27Spring 29Hydraulic Line 30Cap Screw (2 used) 31Cap Screw (2 used) 32O-Ring 34Clamp (2 used) 35Clamp 36Clamp 37Cap Screw (4 used) 39Clamp (2 used) 40Cap Screw (4 used) 46Lubrication Fitting 48Stop 49Ball 51Piston 52Ring (2 used) 53Plunger 54Washer (6 used) 56Hydraulic Cylinder Barrel

Specification Arm CylinderWeight ......................................... 285 kg approximate 630 lb approximate
FR91424,0000010 1921NOV032/8
2. Remove line (B). 3. Pull rod out so piston is against rod guide. 4. Connect rod to a hoist using a lifting strap. 5. Remove cap screws (A). IMPORTANT: To avoid damaging sliding surfaces, be sure to pull out rod, rod guide, and piston straight out of cylinder barrel. 6. Remove rod, rod guide and piston from barrel.
ACap Screw BHydraulic Line
UN27OCT88
FR91424,0000010 1921NOV033/8
T6557HI
33 3360 ,119
TM1931 (09JAN04)
33-3360-119

010904
PN=301
Hydraulic System
7. Install rod eye in sliding housing (B) and install housing in the JT30043 cylinder service stand. 8. Remove cap screws (25) and washers (54) from piston (51). 9. Remove piston (51), cushion ring (15), rod guide (4) from rod (2). 10. Remove spring (37), stop (48), ball (49), and plunger (53) from piston (51). 11. Remove piston rings (21), wear rings (52), and seal ring (22) from piston (51).
UN27OCT88
BSliding Housing
Arm Cylinder230CLCSpecification Arm Cylinder Head End BushingID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use Arm Cylinder Rod End Bushing ID .................................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use
33 3360 ,120
FR91424,0000010 1921NOV034/8
TM1931 (09JAN04)
33-3360-120

010904
PN=302
T6557HK
Hydraulic System
Specification Arm RodCurvature ....................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft

Arm CylinderSpecification Arm Rod Allowable Scratch Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Arm Rod230CLCOD.......................................... 104.910105.0 mm 4.126 4.130 in.
FR91424,0000010 1921NOV035/8
T6585XG
UN27OCT88
33 3360 ,121
TM1931 (09JAN04)
33-3360-121

010904
PN=303
Hydraulic System
46 2
11
5 10 13 14
30
32
29 40
35
31
4 40 6 39 48 49 53 27
39
15
52
21 51 22 21 52 54 25
36
33 3360 ,122
34 37 34 37
T196496
1 56
Arm Cylinder230CLC
17.
TM1931 (09JAN04)
33-3360-122

010904
PN=304
T196496
UN26NOV03
Hydraulic System
Arm Cylinder230CLC
1Bushing (2 used) 2Rod and Bushings 4Rod Guide 5Cap Screw (14 used) 6O-Ring 7Seal 9Seal 10Scraper Ring 11Snap Ring 13Bushing 14Snap Ring 15Cushion Ring 21Piston Ring (2 used) 22Seal Ring 25Cap Screw (6 used) 27Spring 29Hydraulic Line 30Cap Screw (2 used) 31Cap Screw (2 used) 32O-Ring 34Clamp (2 used) 35Clamp 36Clamp 37Cap Screw (4 used) 39Clamp (2 used) 40Cap Screw (4 used) 46Lubrication Fitting 48Stop 49Ball 51Piston 52Wear Ring (2 used) 53Plunger 54Washer (6 used) 56Hydraulic Cylinder Barrel
Install arm cylinder head end and rod end bushings.
facing toward cylinder head end (pressure side). 20. Install ring (10), seal (9), seal (7), and snap ring (11). 21. Install O-ring (6). 22. Install seal ring (22), piston rings (21), and wear rings (52) on piston (51). 23. Install plunger (53), ball (49), stop (48), and spring (27).
33 3360 ,123

18. Install bushing (13) to bottom of bore in rod guide (4) using a driver disk and a press. 19. Install the snap ring (14). IMPORTANT: Ring (10), seal (9), and seal (7) must be installed in the correct direction. Ensure that ring and seals are installed so that slotted side is
FR91424,0000010 1921NOV037/8
TM1931 (09JAN04)
33-3360-123

010904
PN=305
T196498
UN09DEC03
Hydraulic System
24. Install rod guide assembly on rod (2). IMPORTANT: Cushion ring (15) must be installed in the correct direction. Ensure that cushion ring is installed so that slotted end is facing toward piston (51). 25. Install cushion ring (15) on rod (2). 26. Secure rod assembly on bench and install piston (51) assembly to rod (2). Install cap screws (25) and washers (54).
Specification Arm Cylinder Rod Guide-to-Hydraulic Cylinder Barrel Cap ScrewTorque .................................................. 395 Nm 290 lb-ft
29. Install hydraulic line (29).
FR91424,0000010 1921NOV038/8
Bucket Cylinder Remove and Install

1. Park machine on firm, level surface. 2. Retract arm cylinder and bucket cylinder (B) and lower bucket to ground. Position end of arm (C) on wood block (D). CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 3. Perform Hydraulic Oil Tank Pressure Release Procedure. (Group 3360.)
33 3360 ,124 BBucket Cylinder CEnd of Arm DWood Block
UN09JAN97
FR91424,0000011 1921NOV031/5
TM1931 (09JAN04)
33-3360-124

010904
PN=306
T106135
T106031
UN10JAN97
Hydraulic System
4. Disconnect lines. 5. Connect center link to hoist using lifting strap. 6. Put wood block (5) between bucket cylinder and arm to hold cylinder up when pin (1) is removed. 7. Remove parts (2 and 6).
8. Push pin (1) out and remove shims (3).

1Side and Center Links-to-Bucket Cylinder Pin 2Cap Screw 3Shim (as required) 4Bucket Cylinder Rod End-to-Bucket Section Top Port Line 5Wood Block 6Nut (2 used) 7Side Link
FR91424,0000011 1921NOV032/5
T143075
NOTE: Mark location of shims (3) to aid in assembly.
UN02AUG01
33 3360 ,125
TM1931 (09JAN04)
33-3360-125

010904
PN=307
Hydraulic System

Bucket CylinderSpecification Bucket Cylinder200CLC Weight......................................................................... 145 kg 320 lb Bucket Cylinder230CLC Weight......................................................................... 182 kg 400 lb Bucket Cylinder270CLC Weight......................................................................... 216 kg 480 lb
approximate approximate approximate approximate approximate approximate
5 6 2 3
UN02AUG01
9. Disconnect bucket cylinder rod end hose (1). 10. Connect bucket cylinder (2) to hoist using lifting strap. 11. Remove parts (3 and 5).
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 Bucket Cylinder Disassemble and Assemble200CLC, 270CLC or see Bucket Cylinder Disassemble and Assemble230CLC. (Group 3360.) 15. Install shims equally on each side of bucket cylinder head end to get minimum amount of clearance in joint. 16. Align pin bores so shims are not damaged as pin is installed. 17. Connect bucket cylinder head end to arm. 18. Tighten nuts (3) against each other allowing cap screw (5) to be free to turn in hole.
Bucket CylinderSpecification Bucket Cylinder-to-Arm Pin Retainer Nut200CLCTorque........... 271 Nm (tighten 200 lb-ft (tighten Bucket Cylinder-to-Arm Pin Retainer Nut230CLC, 270CLCTorque................................... 750 Nm (tighten 550 lb-ft (tighten
1Bucket Cylinder Rod End Hose 2Bucket Cylinder 3Nut (2 used) 4Shim (as required) 5Cap Screw 6Bucket Cylinder-to-Arm Pin
33 3360 ,126
nut against nut) nut against nut)
nut against nut) nut against nut)
FR91424,0000011 1921NOV033/5
TM1931 (09JAN04)
33-3360-126

010904
PN=308
T143076
Hydraulic System
19. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) Tighten bucket cylinder hoses.
Bucket CylinderSpecification Bucket Cylinder Hose 200CLCTorque.......................................................................... 175 Nm 130 lb-ft Bucket Cylinder Hose230CLC, 270CLCTorque.......................................................................... 205 Nm 152 lb-ft
IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. 20. Start engine. 21. Slowly extend bucket cylinder to align pin bores so shims are not damaged as pin is installed. 22. Install shims equally on each side of cylinder rod end and side links to get minimum amount of clearance in joint. 23. Connect bucket cylinder head end to arm. 24. Tighten nuts against each other allowing cap screw to be free to turn in hole.
Bucket CylinderSpecification Bucket Cylinder-to-Pin Retainer NutTorque .......................................... 550 Nm (tighten nut against nut) 405 lb-ft (tighten nut against nut)
25. Lubricate all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operators Manual.) 26. Bleed air from cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.)
33 3360 ,127
FR91424,0000011 1921NOV034/5
TM1931 (09JAN04)
33-3360-127

010904
PN=309
Hydraulic System
27. Check hydraulic oil level. See Check Hydraulic Oil Level. (Operators Manual.)
FR91424,0000011 1921NOV035/5
33 3360 ,128
TM1931 (09JAN04)
33-3360-128

010904
PN=310
Hydraulic System
33 3360 ,129
TM1931 (09JAN04)
33-3360-129

010904
PN=311
Hydraulic System
Bucket Cylinder Disassemble and Assemble200CLC, 270CLC
33 3360 ,130
Bucket Cylinder
TM1931 (09JAN04)
33-3360-130

010904
PN=312
T190997
UN09MAY03
Hydraulic System
1Cylinder Barrel and Bushings 2Rod and Bushings 3Rod Guide 4Wear Ring 5Snap Ring 6Buffer Ring Seal 7U-Cup Seal 8Back-Up Ring 9Wiper Seal 10O-Ring 11Back-Up Ring 12Cap Screw (12 used) 13Cushion 14Piston 15Cap Seal and O-Ring 16Back-Up Ring (2 used) 17Buffer Seal (2 used) 18Wear Ring (2 used) 19Shim 20Nut 21Set Screw 22Steel Ball 23Lubrication Fitting (2 used) 24Seal (2 used) 26Seal (2 used) 27Elbow Fitting 28Hydraulic Line 29O-Ring (2 used) 30Cap Screw (8 used) 31Band 32Band 33Cap Screw (2 used) 34Lock Washer (2 used) 35Clamp 36Cap Screw 37Lock Washer

Specification Bucket Cylinder200CLC Weight .................................................................. 145 kg approximate 320 lb approximate
Bucket Cylinder270CLC Weight .................................................................. 216 kg approximate 480 lb approximate
FR91424,0000012 1921NOV032/20
ACap Screw BLine
UN27OCT88
FR91424,0000012 1921NOV033/20
BSliding Housing
UN27OCT88
T6557HI
33 3360 ,131
FR91424,0000012 1921NOV034/20
TM1931 (09JAN04)
33-3360-131

010904
PN=313
T6557HK
Hydraulic System
UN27OCT88
FR91424,0000012 1921NOV035/20
Specification Bucket Cylinder Piston-to-Rod NutTorque .............................................................................. 6570 Nm 4,850 lb-ft
UN22MAY92
BNut
33 3360 ,132
FR91424,0000012 1921NOV036/20
TM1931 (09JAN04)
33-3360-132

010904
PN=314
T7768AG
T6585XI
Hydraulic System
13. Remove parts (AD). 14. Remove parts from rod guide and piston.
FR91424,0000012 1921NOV037/20
T8286BL
UN16JUL94
T6585XK
UN27OCT88
33 3360 ,133
TM1931 (09JAN04)
33-3360-133

010904
PN=315
Hydraulic System
15. Remove and inspect dust seals (A) and bushing (B) for wear or damage. Replace parts as necessary. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. (Group 3340.)
Bucket Cylinder200CLCSpecification Bucket Cylinder Head End BushingID.................................................................... 71.0 mm nominal 2.80 in. nominal ID ............................................................................... 72.5 mm limit of use 2.85 in. limit of use Bucket Cylinder Rod End BushingID.................................................................... 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use Bucket Cylinder270CLCSpecification Bucket Cylinder Head End BushingID.................................................................... 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use Bucket Cylinder Rod End BushingID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use
UN27OCT88

Specification Bucket RodCurvature................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft
ADust Seal BBushing

Bucket CylinderSpecification Bucket Rod Allowable Scratch Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Bucket Rod200CLCOD .......................................... 79.8180.00 mm 3.1433.150 in. Bucket Rod270CLCOD .......................................... 89.8190.00 mm 3.5333.540 in. 33 3360 ,134
FR91424,0000012 1921NOV038/20
TM1931 (09JAN04)
33-3360-134

010904
PN=316
T6585XG
UN27OCT88
T6557HR
Hydraulic System
33 3360 ,135
UN09MAY03
Bucket Cylinder
19.
TM1931 (09JAN04)
33-3360-135

010904
PN=317
T190996
Hydraulic System
Bucket Cylinder
1Cylinder Barrel and Bushings 2Rod and Bushings 3Rod Guide 4Wear Ring 5Snap Ring 6Buffer Ring Seal 7U-Cup Seal 8Back-Up Ring 9Wiper Seal 10O-Ring 11Back-Up Ring 12Cap Screw (12 used) 13Cushion 14Piston 15Cap Seal and O-Ring 16Back-Up Ring (2 used) 17Buffer Seal (2 used) 18Wear Ring (2 used) 19Shim 20Nut 21Set Screw 22Steel Ball 23Lubrication Fitting (2 used) 24Seal (2 used) 26Seal (2 used) 27Elbow Fitting 28Hydraulic Line 29O-Ring (2 used) 30Cap Screw (8 used) 31Band 32Band 33Cap Screw (2 used) 34Lock Washer (2 used) 35Clamp 36Cap Screw 37Lock Washer
Install cylinder barrel and rod bushing to a depth equal to the thickness of seals (24 and 26).
20. Install seals (24 and 26) tight against bushing with seal lip outward.
FR91424,0000012 1921NOV0310/20
33 3360 ,136
TM1931 (09JAN04)
33-3360-136

010904
PN=318
T106212
UN17JAN97
Hydraulic System
FR91424,0000012 1921NOV0311/20
T6585XN
UN27OCT88
33 3360 ,137
TM1931 (09JAN04)
33-3360-137

010904
PN=319
Hydraulic System
24. Install buffer ring seal (I) with notched side towards wear ring (B). 25. Install black buffer ring (D) with notched side (C) towards the wear ring. 26. Install green buffer ring (E). 27. Install U-cup seal (F) with lip towards wear ring (B) using the bending method (K). 28. Install back-up ring (G). 29. Install wiper seal (H) with lip towards outside of cylinder. 30. Install rod guide (J) on the rod.
33 3360 ,138
FR91424,0000012 1921NOV0312/20
TM1931 (09JAN04)
33-3360-138

010904
PN=320
T7623AF
UN22OCT91
T7963AK
UN01APR93
Hydraulic System
AJDG840-6 Pusher JDG840-4 Installer200CLC JDG842-1 Installer270CLC BCap Seal CO-Ring DWear Ring
UN18MAR93
FR91424,0000012 1921NOV0313/20
T7964AQ
33 3360 ,139
FR91424,0000012 1921NOV0314/20
TM1931 (09JAN04)
33-3360-139

010904
PN=321
T6396AC
UN27OCT88
Hydraulic System
37. Install a back-up ring (C) on each side of cap seal. 38. Install the buffer seals (B) and wear rings (A). Turn the seals and rings so the slits are 180 from each other
FR91424,0000012 1921NOV0315/20
NOTE: For bucket cylinder, no cushion seal is used under the cushion.
39. Install cushion (D) so wide end of flat face (E) is towards the rod guide and narrow end is towards the piston.
DCushion EFlat Face FNotch (not on bucket cylinder) GCushion Seal (not on bucket cylinder)
UN16JUL94
Boom Cylinder Rod Shown
FR91424,0000012 1921NOV0316/20
UN27OCT88

33 3360 ,140 ANut BShim CPiston DCushion
FR91424,0000012 1921NOV0317/20
TM1931 (09JAN04)
33-3360-140

010904
PN=322
T6585XK
T8286BL
T6557HV
UN27OCT88
Hydraulic System
Specification Bucket Cylinder Piston-to-Rod NutTorque .............................................................................. 6570 Nm 4,850 lb-ft
BNut
FR91424,0000012 1921NOV0318/20
Specification Bucket Cylinder Nut-to-Rod Set ScrewTorque .............................................................................. 57 Nm 42 lb-ft
UN27OCT88
T7768AH
UN22MAY92
FR91424,0000012 1921NOV0319/20
TM1931 (09JAN04)
33-3360-141

010904
PN=323
T6585XI
33 3360 ,141
Hydraulic System
Specification Bucket Cylinder Rod Guide-to-Barrel Cap Screw Torque .......................................................................................... 267 Nm 197 lb-ft
UN27OCT88
ACap Screw BLines
FR91424,0000012 1921NOV0320/20
33 3360 ,142
TM1931 (09JAN04)
33-3360-142

010904
PN=324
T6557HI
Hydraulic System
33 3360 ,143
TM1931 (09JAN04)
33-3360-143

010904
PN=325
Hydraulic System
Bucket Cylinder Disassemble and Assemble230CLC
2 42
11
5 10 13 14
6 44 24 15 22 19 4 20 18 21 28 26 41 31 27 1
33 3360 ,144
19
20
46
25 1 35 34 30 32
T196499
Bucket Cylinder230CLC
TM1931 (09JAN04)
33-3360-144

010904
PN=326
T196499
UN26NOV03
Hydraulic System
1Bushings (2 used) 2Rod and Bushings 4Rod Guide 5Cap Screw (12 used) 6O-Ring 7Seal 9Seal 10Ring 11Snap Ring 13Bushing 14Snap Ring 15Cushion Ring 18Piston 19Piston Ring (2 used) 20Wear Ring (2 used) 21Seal Ring 22Packing 24Cap Screw (6 used) 25Hydraulic Line 26Cap Screw (2 used) 27Cap Screw (2 used) 28O-Ring 30Clamp 31Clamp 32Cap Screw (2 used) 34Clamp 35Cap Screw (2 used) 41Lubrication Fitting 42Lubrication Fitting 44Washer (6 used) 46Hydraulic Cylinder Barrel

Specification Bucket CylinderWeight ..................................... 182 kg approximate 400 lb approximate
FR91424,0000013 1921NOV032/9
2. Remove line (B). 3. Pull rod out so piston is against rod guide. 4. Connect rod to a hoist using a lifting strap. 5. Remove cap screws (A). IMPORTANT: To avoid damaging sliding surfaces, be sure to pull out rod, rod guide, and piston straight out of cylinder barrel. 6. Remove rod, rod guide and piston from barrel.
ACap Screw BLine
UN27OCT88
FR91424,0000013 1921NOV033/9
T6557HI
33 3360 ,145
TM1931 (09JAN04)
33-3360-145

010904
PN=327
Hydraulic System
7. Install rod eye in sliding housing (B) and install housing in the JT30043 cylinder service stand. 8. Remove cap screws (24) and washers (44) from piston (18). 9. Remove piston (18), cushion ring (15), rod guide (4) from rod (2). 10. Remove piston rings (19), wear rings (20), seal ring (21), and packing (22) from piston (18).
UN27OCT88
Bucket Cylinder230CLCSpecification Bucket Cylinder Head End BushingID.................................................................... 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use Bucket Cylinder Rod End BushingID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use
BSliding Housing
FR91424,0000013 1921NOV034/9
33 3360 ,146
TM1931 (09JAN04)
33-3360-146

010904
PN=328
T6557HK
Hydraulic System
Specification Bucket RodCurvature................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft

Bucket CylinderSpecification Bucket Rod Allowable Scratch Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Bucket Rod230CLCOD ......................................... 89.91090.0 mm 3.536 3.540 in.
FR91424,0000013 1921NOV035/9
T6585XG
UN27OCT88
33 3360 ,147
TM1931 (09JAN04)
33-3360-147

010904
PN=329
Hydraulic System
2 42
11
5 10 13 14
6 44 24 15 22 19 4 20 18 21 28 26 41 31 27 1 25
33 3360 ,148
19
20
46
1 35 34 30 32
T196499
FR91424,0000013 1921NOV036/9
TM1931 (09JAN04)
33-3360-148

010904
PN=330
T196499
UN26NOV03
Hydraulic System NOTE: Use a cylinder repair kit when assembling a cylinder.
16.
FR91424,0000013 1921NOV037/9
33 3360 ,149
TM1931 (09JAN04)
33-3360-149

010904
PN=331
Hydraulic System
1Bushings (2 used) 2Rod and Bushings 4Rod Guide 5Cap Screw (12 used) 6O-Ring 7Seal 9Seal 10Ring 11Snap Ring 13Bushing 14Snap Ring 15Cushion Ring 18Piston 19Piston Ring (2 used) 20Wear Ring (2 used) 21Seal Ring 22Packing 24Cap Screw (6 used) 25Hydraulic Line 26Cap Screw (2 used) 27Cap Screw (2 used) 28O-Ring 30Clamp 31Clamp 32Cap Screw (2 used) 34Clamp 35Cap Screw (2 used) 41Lubrication Fitting 42Lubrication Fitting 44Washer (6 used) 46Hydraulic Cylinder Barrel
Install bucket cylinder head end and rod end bushings.

17. Install bushing (13) to bottom of bore in rod guide (4) using a driver disk and a press.
33 3360 ,150
installed so that slotted side is facing toward cylinder head end (pressure side). 19. Install ring (10), seal (9), seal (7), and snap ring (11). 20. Install O-ring (6).
18. Install the snap ring (14). IMPORTANT: Ring (10), seal (9), and seal (7) must be installed in the correct direction. Ensure that ring and seals are 21. Install packing (22), seal ring (21), wear rings (20), and piston rings (19) on piston (18). 22. Install rod guide assembly on rod (2).
FR91424,0000013 1921NOV038/9
TM1931 (09JAN04)
33-3360-150

010904
PN=332
T196860
UN10DEC03
Hydraulic System
IMPORTANT: Cushion ring (15) must be installed in the correct direction. Ensure that cushion ring is installed so that slotted end is facing toward piston (18). 23. Install cushion ring (15) on rod (2). 24. Secure rod assembly on bench and install piston (18) assembly to rod (2). Install cap screws (25) and washers (42).
Specification Bucket Cylinder Rod Guide-to-Hydraulic Cylinder Barrel Cap ScrewTorque .................................................. 395 Nm 290 lb-ft
27. Install hydraulic line (25).
FR91424,0000013 1921NOV039/9
33 3360 ,151
TM1931 (09JAN04)
33-3360-151

010904
PN=333
Hydraulic System
Hydraulic Cylinder Bleed Procedure

IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage.
NOTE: Bleed air at initial start-up, whenever major repairs or maintenance (oil change) is done on hydraulic system, or when machine has been in storage for a period of time.
1. Run engine at slow idle. 2. Slowly operate function to move cylinder to the most horizontal position possible. 3. Slowly extend and retract cylinder several times to approximately 100 mm (4 in.) from end of stroke. 4. Operate cylinder several times to full stroke. 5. Check hydraulic oil level. See Check Hydraulic Oil Level. (Operators Manual.)
TX,33,GG2374B 1926NOV031/1
33 3360 ,152
TM1931 (09JAN04)
33-3360-152

010904
PN=334
Section 43
Swing or Pivoting System

Contents
Page
Group 4350Mechanical Drive Elements Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . .43-4350-1 Start-Up Procedure . . . . . . . . . . . . . . . . .43-4350-11 Upperstructure . . . . . . . . . . . . . . . . . . . . . .43-4350-12 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . .43-4350-19 Group 4360Hydraulic System Swing Motor and Park Brake. . . . . . . . . . . . .43-4360-1 Crossover Relief Valve and Make-Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-11 Swing Motor Start-Up Procedure . . . . . . . . . . . . . . . . .43-4360-13 Brake Release Valve270CLC . . . . . . . . .43-4360-13
43
TM1931 (09JAN04)
43-1

010904
PN=1
Contents
43
TM1931 (09JAN04)
43-2

010904
PN=2
Group 4350
Mechanical Drive Elements

Swing Gearbox Repair
Remove and Install Swing Gearbox CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 2. Pull vacuum in hydraulic oil tank using vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.) 3. Disconnect lines.
AGALLARDO,0000039 1919NOV011/14
43 4350 1
TM1931 (09JAN04)
43-4350-1

010904
PN=337
NOTE: Swing motor may be removed by itself or with swing gearbox. To remove swing motor. See Swing Motor and Park Brake Repair. (Group 4360.) Mark swing gearbox housing to machine upperstructure to aid in installation.
4. Install JT01748 Lifting Brackets and connect to hoist.
Swing GearboxSpecification Swing Motor, Brake, and Gearbox200CLCWeight ......................... 230 kg (507 lb) approximate Swing Motor, Brake, and Gearbox230CLCWeight ......................... 275 kg (610 lb) approximate Swing Motor, Brake, and Gearbox270CLCWeight ......................... 355 kg (780 lb) approximate
UN02AUG01

1Cap Screw and Washer (12 used)
5. Remove cap screws and washers (1). 6. Remove swing gearbox. 7. Repair or replace parts as necessary. 8. Apply rigid-form-in place gasket to mating surfaces of swing gearbox housing and upperstructure. 9. Install swing gearbox. 10. Tighten cap screws.
Swing GearboxSpecification Swing Gearbox-to-Upperstructure Cap ScrewTorque .................................................... 500 Nm (370 lb-ft)
11. Connect electrical connector. 12. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 13. If hydraulic oil tank was drained, fill hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.)
43 4350 2
AGALLARDO,0000039 1919NOV012/14
TM1931 (09JAN04)
43-4350-2

010904
PN=338
T143498B

14. Do Swing Gearbox Start-Up Procedure. (See procedure in this group.) See Swing Motor Start-Up Procedure . (Group 4360.)
AGALLARDO,0000039 1919NOV013/14
43 4350 3
TM1931 (09JAN04)
43-4350-3

010904
PN=339
22 1 23
24
2 4 3 5
31 25 21 20 9 19 26 18 27 10
6 7 8
11 12 13
28 29
17 16 15
14
30
43 4350 4
T142044
AGALLARDO,0000039 1919NOV014/14
TM1931 (09JAN04)
43-4350-4

010904
PN=340
T142044
UN14MAY01

1Swing Motor 2First Planet Sun Gear 3Thrust Plate 4Pin (3 used) 5Spring Pin (3 used) 6Needle Bearing (3 used) 7Planetary Gear (3 used) 8Thrust Plate (3 used) 9Pin (3 used) 10Spring Pin (3 used) 11Thrust Plate (6 used) 12Bearing (3 used) 13Planetary Gear (3 used) 14Roller Bearing 15Bearing Nut 16Lock Plate 17Cap Screw (2 used) 18Second Planet Carrier 19Thrust Plate 20Second Planet Sun Gear 21First Planet Carrier 22Cap Screw (8 used) 23Cap Screw (12 used) 24Ring Gear 25Housing 26Oil Seal 27Roller Bearing 28Sleeve 29O-Ring 30Shaft 31Drain Valve
Disassemble and Assemble Swing Gearbox 200CLC and 230CLC 1. Make alignment marks between swing motor (1), ring gears (24), and between ring gear (24) and housing (25) to aid in assembly. CAUTION: Heavy component; use a hoist.
Swing GearboxSpecification Swing Motor200CLC and 230CLCWeight ...................................... 46 kg (100 lb) approximate
5. Remove second planet carrier (18).
NOTE: Second planet sun gear may be removed separately or with carrier.
6. Disassemble first planet carrier (21) assembly. 7. Tap spring pin (5) into pin (4).
NOTE: Procedure for the disassembly of first and second planetary carriers is the same.
8. Remove pin (4), planetary gear (7), needle bearing (6), and thrust plate (8) from first planet carrier (21). 9. Inspect needle bearing for wear.
2. Remove cap screws (22) and swing motor (1) from swing gearbox. 3. Remove first planet carrier (21) from ring gear (24).
10. Remove thrust plate (3) from carrier.
NOTE: First planet sun gear may be removed separately or along with carrier.
Swing GearboxSpecification Ring Gear200CLC and 230CLCWeight ...................................... 23 kg (50 lb) approximate
IMPORTANT: Damaging the surface of pin (4) can cause bearing failure, use care when handling pin. 11. Using wood blocks, clamp pin (4) in vise. Tap spring pin (5) out. 12. Remove cap screws (17) and lock plate (16).
4. Remove cap screws (23) and ring gear (24).
AGALLARDO,0000039 1919NOV015/14
13. Remove bearing nut (15) from shaft (30) using DFT1220 Swing Gearbox Nut Spanner Wrench. (Group 9900.)
15Bearing Nut
UN14MAY01
43 4350 5
AGALLARDO,0000039 1919NOV016/14
TM1931 (09JAN04)
43-4350-5

010904
PN=341
T142064
Mechanical Drive Elements NOTE: Bearing and sleeve are pressed onto shaft.
14. Using press, push upper end of shaft (1) and remove from housing (2). Inner race of roller bearing (27) and sleeve (28) are removed with shaft (30). 15. Remove oil seal (26). 16. Remove outer race from housing by inserting bar through oil passage in housing, and tap it out.
1Shaft 2Housing
UN19NOV01
AGALLARDO,0000039 1919NOV017/14
17. Inspect shaft (1), roller bearing (2), and sleeve (3). 18. If disassembly is necessary, use press to push upper end of shaft to remove roller bearing and sleeve.
UN19NOV01
19. Repair or replace parts as necessary. 20. Apply rigid form-in-place gasket to OD of oil seal (26). 21. Install oil seal so lip (spring side) is toward bottom of bore. Push seal to bottom of bore. 22. Apply thin layer of multi-purpose grease to O-ring (29) and lip of oil seal. 23. Apply hydraulic oil to all internal parts. 24. Apply film of grease on threaded surface of bearing nut (15). Install bearing nut on shaft (30) with stepped side of bearing nut towards roller bearing (14). 25. Tighten bearing nut so splines of lock plate (16) and shaft (30) are aligned. Use DFT1220 Swing Gearbox Nut Spanner Wrench. (Group 9900.)
Swing GearboxSpecification Bearing Nut200CLC and 230CLCTorque......................................................... 490 Nm (360 lb-ft) 1Shaft 2Roller Bearing 3Sleeve
1 2
43 4350 6
AGALLARDO,0000039 1919NOV018/14
TM1931 (09JAN04)
43-4350-6

010904
PN=342
T146899
T146941

26. Install spring pins (5 and 10) with slit towards end of pin. 27. Install thrust plate (19) with oil grooves towards second planet sun gear (20). 28. Install second planet carrier (18) so notch is aligned with lock plate (16). 29. Install second planet sun gear (20) into second planet carrier (18) assembly with small diameter part of second planet sun gear towards up. 30. Install first planet sun gear (2) into first planet carrier (21) assembly with stepped side of sun gear towards down. 31. Apply rigid form-in-place gasket to ring gear (24), housing (25) and swing motor (1) mating surfaces. 32. Apply thread lock and sealer (medium strength) to cap screws (22 and 23). Tighten Cap Screws.
Swing GearboxSpecification Ring Gear-to-Housing Cap Screw200CLC and 230CLC Torque ......................................................................... 206 Nm (152 lb-ft) Swing GearboxSpecification Swing Motor-to-Ring Gear Cap ScrewTorque .................................................................. 88 Nm (65 lb-ft 1Slit
UN22JUN01
AGALLARDO,0000039 1919NOV019/14
T142429
43 4350 7
TM1931 (09JAN04)
43-4350-7

010904
PN=343
13 14 12 11 15
16 19 10 20 21 22 7 9 26 6 8 29 30 5 3 31 4 32 2 29 33 1
43 4350 8
17 18
25
24
23 21
27
28
34
T146719
AGALLARDO,0000039 1919NOV0110/14
TM1931 (09JAN04)
43-4350-8

010904
PN=344
T146719
UN19NOV01

1Shaft 2Sleeve 3Cap Screw (10 used) 4O-Ring 5Oil Seal 6Cover 7Ball Bearing 8Drain Plug 9Pipe 10Housing 11Ball Bearing 12Snap Ring 13Swing Motor 14Cap Screw (12 used) 15First Planet Sun Gear 16Thrust Plate 17Pin (3 used) 18Spring Pin (3 used) 19First Planet Carrier 20Second Planet Sun Gear 21Thrust Plate (6 used) 22Needle Bearing (3 used) 23Planetary Gear (3 used) 24Thrust Plate 25Pin (3 used) 26Spring Pin (3 used) 27Second Planet Carrier 28O-Ring 29Thrust Plate (6 used) 30Bushing (3 used) 31Planetary Gear (3 used) 32Cap Screw (12 used) 33Ring Gear 34O-Ring
Disassemble and Assemble Swing Gearbox 270CLC 1. Make alignment marks between swing motor (13), ring gears (33), and between ring gear (33) and housing (10) to aid in assembly. CAUTION: Heavy component; use a hoist.
Swing GearboxSpecification Swing Motor270CLC Weight ....................................................... 66 kg (150 lb) approximate
5. Remove second planet carrier (27).
NOTE: Second planet sun gear may be removed separately or with carrier.
6. Disassemble first planet carrier (19) assembly . 7. Tap spring pin (18) into pin (17).
NOTE: Procedure for the disassembly of first and second planetary carriers is the same.
8. Remove pin (17), planetary gear (23), needle bearing (22), and thrust plate (21) from first planet carrier (19). 9. Inspect needle bearing for wear. 10. Remove thrust plate (16) from carrier.
2. Remove cap screws (14) and swing motor (13) from swing gearbox. 3. Remove first planet carrier assembly (19) from ring gear (33).
NOTE: First planet sun gear may be removed separately or along with carrier.
Swing GearboxSpecification Ring Gear270CLCWeight .................... 36 kg (80 lb) approximate
IMPORTANT: Damaging the surface of pin (17) can cause bearing failure, use care when handling pin. 11. Using wood blocks, clamp pin (17) in vise. Tap spring pin (18) out. 12. Remove snap ring (12).
4. Remove cap screws (32) and ring gear (33).
AGALLARDO,0000039 1919NOV0111/14
43 4350 9
TM1931 (09JAN04)
43-4350-9

010904
PN=345
Mechanical Drive Elements NOTE: Bearing and sleeve are pressed onto shaft.
13. Using press, push upper end of shaft (1) and remove from housing (2). Ball bearing (7) and sleeve (2) are removed with shaft (1). 14. Secure cover (6) in vise and remove oil seal (5).
1Shaft 2Housing
UN19NOV01
AGALLARDO,0000039 1919NOV0112/14
15. Inspect sleeve (1), ball bearing (2), and shaft (3) for wear. Repair or replace parts as necessary. 16. Use press to push at upper end of shaft and remove ball bearing and sleeve. 17. Apply rigid form-in-place gasket to OD of oil seal (5). 18. Install oil seal so lip (spring side) is toward bottom of bore. Push seal to bottom of bore. 19. Apply thin layer of multi-purpose grease to O-ring (4) and lip of oil seal. 20. Apply hydraulic oil to all internal parts. 1 3
UN19NOV01
1Sleeve 2Ball Bearing 3Shaft
AGALLARDO,0000039 1919NOV0113/14
43 4350 10
TM1931 (09JAN04)
43-4350-10

010904
PN=346
T146889
T146941

21. Install spring pins (18 and 26) with slit towards end of pin. 22. Install thrust plate (24) with oil grooves towards second planet sun gear (20). 23. Install second planet sun gear (20) into second planet carrier (27) assembly with small diameter part of second planet sun gear towards up. 24. Install first planet sun gear (15) into first planet carrier (19) assembly with stepped side of sun gear towards down. 25. Apply rigid form-in-place gasket to ring gear (33), housing (10) and swing motor (13) mating surfaces. 26. Apply thread lock and sealer (medium strength) to cap screws (14 and 32). Tighten cap screws.
Swing GearboxSpecification Ring Gear-to-Housing Cap Screw270CLCTorque ........................................... 400 Nm (300 lb-ft) Swing GearboxSpecification Swing Motor-to-Ring Gear Cap ScrewTorque ................................................................ 88 Nm (65 lb-ft)
UN22JUN01
1Slit
AGALLARDO,0000039 1919NOV0114/14
Swing Gearbox Start-Up Procedure

IMPORTANT: Swing gearbox will be damaged if not filled with oil before operating swing function. Procedure must be performed whenever a new swing gearbox is installed or oil has been drained from the gearbox. 1. Check that drain line plug is installed. 2. Remove fill cap and add oil. See Swing Gearbox, Propel Gearbox and Pump Gearbox Oils. (Operators Manual.) 3. Install fill cap. Check oil level on dipstick.
T142429
43 4350 11
TX,25,GG2228 1919NOV011/1
TM1931 (09JAN04)
43-4350-11

010904
PN=347
Upperstructure Repair
Remove Upperstructure
NOTE: Procedure requires two technicians. The cement floor must be a minimum of 102 mm (4 in.) thick. Area must be large enough so the upperstructure can be turned 180 with the angle between boom and arm at 90100 and the tracks laid out flat on the floor.
1. Clean machine thoroughly.
TX,43,SB524 1919NOV011/10
CAUTION: Keep the angle between boom and arm at 90100 to prevent machine from sliding backwards. 2. Park machine with boom to left side (cab side toward sprocket) of undercarriage. 3. Disconnect tracks and lay out flat on floor to sprocket end of undercarriage. See Track Chain Repair. (Group 0130.)
4. Turn upperstructure and raise right side of machine, using boom down function.
TX,43,SB524 1919NOV012/10
43 4350 12
TM1931 (09JAN04)
43-4350-12

010904
PN=348
T7712AG
NOTE: To make removal of main frame-to-swing bearing cap screws easier after machine is raised into position, loosen the cap screws one turn at this time.
UN24FEB92

5. Put hardwood blocks (B), approximately 254 mm (10 in.) between lower track rollers (A) and track chain (C). 6. Turn upperstructure back to left side so it is 90 to track.
ATrack Rollers BHardwood Blocks CTrack Chain
UN07MAY92
TX,43,SB524 1919NOV013/10

UpperstructureSpecification 200CLC MachineWithout TracksWeight ....................................................... 17 330 kg (38,200 lb) approximate 230CLC MachineWithout TracksWeight ....................................................... 20 329 kg (44,818 lb) approximate 270CLC MachineWithout TracksWeight ....................................................... 22 453 kg (49,500 lb) approximate
7. Put two DFT1089 Barrel Support under counterweight (D). (Group 9900.) To provide enough clearance, use bridge planks (E) and hardwood blocks (F) to raise height of supports and planks to 1.4 m (55 in.). Height is approximate clearance needed to clear bottom of rotary manifold. Do not put blocks under cap screw heads. Keep height below maximum.
UpperstructureSpecification Floor-to-Bottom of Main Frame Height .................................................................... 1.4 m (55 in.) minimum Height ................................................................. 1.45 m (57 in.) maximum
DCounterweight EBridge Plank (As Required) FHardwood Block (As Required) GDFT1089 Barrel Support (4 used)
TX,43,SB524 1919NOV014/10
T7720AS
UN07MAY92
T7720AM
43 4350 13
TM1931 (09JAN04)
43-4350-13

010904
PN=349
ADFT1089 Barrel Support (4 used)
B3.7 m (12 ft) Length of W8 x 28 lb Wide Flange Beam (2 used)
CHardwood Block (Use as Required)
8. Slowly raise left side, using boom down function, until machine is level. 9. Place DFT1089 Barrel Support and 3.7 m (12 ft) length of W8 x 28 lb Wide Flange Beam (B) under main frame at right boom cylinder and right corner of cab. (Group 9900.) For maximum support, barrel supports must be positioned so beam is under main frame and corner of cab as far as possible.
Install hardwood blocks (C) as needed to make up for any unevenness. 10. Lower machine so main frame and corner of cab are on beam. Check that bottom of main frame is 1.4 m (55 in.) off floor and level. Keep height to maximum of 1.45 m (57 in.).
TX,43,SB524 1919NOV015/10
43 4350 14
TM1931 (09JAN04)
43-4350-14

010904
PN=350
T7720AO
UN07MAY92

11. Install 13 mm (1/2 in.) chain around boom cylinder head end boss on frame and rod end boss on boom. Tighten chain just enough to remove slack using chain binder. 12. Disconnect negative battery cables. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 13. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 14. Disconnect lines and fittings from rotary manifold.
TX,43,SB524 1919NOV016/10

UpperstructureSpecification Undercarriage200CLCWeight ......... 5134 kg (11,319 lb) approximate Undercarriage230CLCWeight ......... 5833 kg (12,860 lb) approximate Undercarriage270CLCWeight ......... 8455 kg (18,640 lb) approximate
15. Raise undercarriage into position using two 18-t (20-ton) service jacks. 16. Remove cap screws (B) from swing bearing (A). 17. Slowly lower undercarriage onto track chain. 18. Lift sprocket end of undercarriage so sprocket clears track chain. 19. Pull undercarriage out from under upperstructure. 20. Repair or replace parts as necessary.
ASwing Bearing BCap Screw (31 used)
T105961
UN20DEC96
T7149AJ
UN05OCT89
43 4350 15
TX,43,SB524 1919NOV017/10
TM1931 (09JAN04)
43-4350-15

010904
PN=351

Install Upperstructure CAUTION: Heavy component; use a hoist. 1. Push undercarriage under upperstructure.
UpperstructureSpecification Undercarriage200CLCWeight ......... 4717 kg (10,400 lb) approximate Undercarriage230CLCWeight ......... 5171 kg (11,400 lb) approximate Undercarriage270CLCWeight ......... 7548 kg (16,640 lb) approximate
UN20DEC96
2. Install DFT1144 Guide Pin to help align holes in swing bearing (A) with holes in main frame. (Group 9900.) 3. Raise undercarriage into position using two 18-t (20-ton) service jacks. It may be necessary to turn swing bearing inner race to align teeth on swing motor pinion shaft. 4. Install cap screws (B) and tighten.
UpperstructureSpecification Swing Bearing-to-Upperstructure Cap Screw200CLCTorque ................................... 510 Nm (375 lb-ft) Swing Bearing-to-Upperstructure Cap Screw230CLC and 270CLCTorque......................................................... 640 Nm (470 lb-ft) ASwing Bearing BCap Screw (31 used)
If all cap screws are not accessible, tighten them after machine has been lowered and supports have been removed. 5. Connect fittings and lines to rotary manifold. See Propel System Component Location. (Group 9025-15.) 6. Install stop on rotary manifold. 7. Tighten cap screws.
UpperstructureSpecification Rotary Manifold Stop Cap ScrewTorque ............................................................ 140 Nm (105 lb-ft)
8. Connect negative battery cable.
43 4350 16
TX,43,SB524 1919NOV018/10
TM1931 (09JAN04)
43-4350-16

010904
PN=352
T105961

9. Put hardwood blocks (B) between lower track rollers (A) and track chain (C) on counterweight side.
ATrack Rollers BWooden Blocks CTrack Chain
TX,43,SB524 1919NOV019/10
T7720AM
UN07MAY92
43 4350 17
TM1931 (09JAN04)
43-4350-17

010904
PN=353
ADFT1089 Barrel Support (4 used)
B3.7 m (12 ft) Length of W8 x 28 lb Wide Flange Beam (2 used)
CHardwood Block (use as required)
10. Raise machine just enough to remove hardwood blocks (C), wide flange beam (B), and barrel supports (A). 11. Lower machine so lower track rollers and front idler are on track chain. 12. Remove bridge planks and barrel supports from other side. 13. Turn upperstructure to other side and raise machine just enough to remove hardwood blocks between roller and track chain. 14. Lower machine so lower track rollers and front idler are on track chain.
43 4350 18
15. Tighten any remaining swing bearing-to-main frame cap screws.

UpperstructureSpecification Swing Bearing-to-Upperstructure Cap Screw200CLCTorque .................................... 510 Nm (375 lb-ft) Swing Bearing-to-Upperstructure Cap Screw230CLC and 270CLCTorque .................................................. 640 Nm (470 lb-ft)
16. Install track chains. See Track Chain Repair. (See Group 0130.) 17. Check and Adjust Track Sag. (Operators Manual.)
TX,43,SB524 1919NOV0110/10
TM1931 (09JAN04)
43-4350-18

010904
PN=354
T7720AO
UN07MAY92
Swing Bearing Repair

Remove and Install Swing Bearing 1. Remove upperstructure. See Upperstructure Repair. (See procedure in this group.) CAUTION: Heavy component; use a hoist.
Swing BearingSpecification Swing Bearing200CLCWeight ................ 220 kg (485 lb) approximate Swing Bearing230CLC and 270CLCWeight ........................................... 331 kg (730 lb) approximate
2. Connect swing bearing to hoist using lifting brackets (C) such as JT01748 Lifting Brackets. 3. Remove cap screws and lock washers (D) and remove swing bearing.
UN07MAY92
4. Check and replace swing bearing upper and lower seals if necessary. SeeSwing Bearing Repair. (See procedures in this group.) 5. Replace steel balls and ball supports as necessary. 6. Repair or replace parts as necessary. 7. Clean mating surfaces of swing bearing, upperstructure, and undercarriage.
CJT01748 Lifting Brackets DCap Screw and Lock Washer
TX,43,SB526 1919NOV011/8
T7764AB
43 4350 19
TM1931 (09JAN04)
43-4350-19

010904
PN=355

IMPORTANT: The tooth marked with the letter G or S or equivalent is the starting and stopping point for the hardening process. The tooth and the bearing loading plug must be installed on the right side of the machine so the use of that part of the swing bearing is minimized. 8. Install swing bearing on undercarriage so tooth (A) marked G or S or equivalent and bearing loading plug (B) is to right side of machine. 9. Install cap screws and lock washers and tighten.
Swing BearingSpecification Undercarriage-to-Swing Bearing Cap Screw200CLCTorque ................................... 490 Nm (360 lb-ft) Undercarriage-to-Swing Bearing Cap Screw230CLC and 270CLCTorque......................................................... 640 Nm (470 lb-ft) ATooth BLoading Plug
10. Apply multi-purpose grease to swing bearing teeth and pinion shaft. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operators Manual.) 11. Install upperstructure. See Upperstructure Repair. (See procedure in this group.)
TX,43,SB526 1919NOV012/8
43 4350 20
TM1931 (09JAN04)
43-4350-20

010904
PN=356
T5925AA
UN11APR90
ALubrication Fitting (2 used) BOuter Race CSpacer200CLC & 230CLC (121 used)
Spacer270CLC (90 used) DSteel Ball200CLC & 230CLC (121 used)
Steel Ball270CLC (90 used) ELower Seal
FInner Race GUpper Seal
Disassemble and Assemble Swing Bearing 1. Check swing bearing upper seal (G) and lower seal (E). If damaged, replace. See Swing Bearing Repair. (See procedures in this group.)
TX,43,SB526 1919NOV013/8
T6626JP
UN07NOV88
43 4350 21
TM1931 (09JAN04)
43-4350-21

010904
PN=357

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.
ATack Weld BTaper Pin CLoading Plug
TX,43,SB526 1919NOV014/8
5. Remove steel balls (A) and spacers (B). 6. Turn inner race to remove remaining steel balls and spacers. 7. Lift outer race off inner race. 8. Replace parts as necessary. 9. Install spacers (B) and steel balls (A). Turn inner race as needed to install spacers and steel balls.
ASpacer200CLC & 230CLC (121 used) Spacer270CLC (90 used) BSteel Ball200CLC & 230CLC (121 used) Steel Ball270CLC (90 used)
UN07MAY92
TX,43,SB526 1919NOV015/8
TM1931 (09JAN04)
43-4350-22

010904
PN=358
T7763AB
43 4350 22
UN07MAY92
T6876FK
T6876FI
UN07MAY92

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 through lubrication fittings. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operators Manual.)
ATack Weld BTaper Pin CLoading Plug
UN07MAY92
TX,43,SB526 1919NOV016/8
T6876FI
43 4350 23
TM1931 (09JAN04)
43-4350-23

010904
PN=359

Install Swing Bearing Upper Seal 1. Remove upperstructure. See Upperstructure Repair. (See procedure in this group.)
UN11APR90
2. Remove old seal (A). 3. Scrape old adhesive from seal groove. Thoroughly clean seal groove and new seal using cure primer. 4. Apply instant gel adhesive sparingly to seal groove.
ASeal
5. Install seal with lip against inner bearing race. Start about 76 mm (3 in.) from end of seal using blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal. 6. Before bringing ends of seal together, cut off excess length. 7. Apply instant gel adhesive to both ends of seal. Push ends into seal groove making sure they come together. IMPORTANT: To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using swing function. 8. Install upperstructure. See Upperstructure Repair. (See procedure in this group.) Install Swing Bearing Lower Seal 1. Remove upperstructure. See Upperstructure Repair. (See procedure in this group.)
TX,43,SB526 1919NOV017/8
43 4350 24
TM1931 (09JAN04)
43-4350-24

010904
PN=360
T5925AM
Mechanical Drive Elements NOTE: Part of swing bearing shown cut away to show lower seal in groove.
2. Remove old seal (A).
UN17MAY89
3. Scrape old adhesive from seal groove (B). Thoroughly clean seal groove and new seal using cure primer. 4. Apply instant gel adhesive sparingly to seal groove. 5. Install seal with seal lip against outer race. Start about 76 mm (3 in.) from end of seal using blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal. 6. Before bringing ends of seal together, cut off excess length. 7. Apply adhesive to both ends of seal. Push ends into seal groove making sure they come together. IMPORTANT: To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using swing function. 8. Install upperstructure. See Upperstructure Repair. (See procedure in this group.)
ASeal BSeal Groove
TX,43,SB526 1919NOV018/8
T5936BA
43 4350 25
TM1931 (09JAN04)
43-4350-25

010904
PN=361
43 4350 26
TM1931 (09JAN04)
43-4350-26

010904
PN=362
Group 4360
Hydraulic System
Swing Motor and Park Brake Repair
Remove and Install Swing Motor and Park Brake CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 2. Drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or270CLC Drain and Refill Capacities. (Operators Manual.) 3. Disconnect lines. 4. Disconnect electrical connector (2). CAUTION: Heavy Component; use a hoist.
Swing Motor and Park BrakeSpecification Swing Motor and Park Brake (200CLC and 230CLC Machine)Weight ........................................... 47 kg (104 lb) approximate Swing Motor and Park Brake (270CLC Machine)Weight............................ 66 kg (150 lb) approximate

1Cap Screw (8 used) 2Electrical Connector
5. Remove cap screws (1) and remove swing motor and park brake. 6. Repair or replace parts as necessary. 7. Install swing motor and brake. 8. Tighten cap screws (1).
Swing Motor and Park BrakeSpecification Swing Motor-to-Ring Gear Cap ScrewTorque ................................................................ 88 Nm (65 lb-ft)
9. Connect electrical connector (2). 10. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.)
T143358B
UN20JUL01
43 4360 1
TX,4360,DV1356 1919NOV011/10
TM1931 (09JAN04)
43-4360-1

010904
PN=363
Hydraulic System
11. Fill hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operators Manual.) 12. Do Swing Motor Start-Up Procedure. (See procedure in this group).
TX,4360,DV1356 1919NOV012/10
43 4360 2
TM1931 (09JAN04)
43-4360-2

010904
PN=364
Hydraulic System
43 4360 3
TM1931 (09JAN04)
43-4360-3

010904
PN=365
Hydraulic System
10 10
9 8 6 5 4 1 3 2 15 16 12 17 18 19 13 14 7 11
18 21 28 29 33 31 32 26 27 25 30 24 17 16 15
22 23 20
T142065
TX,4360,DV1356 1919NOV013/10
TM1931 (09JAN04)
43-4360-4

010904
PN=366
T142065
43 4360 4
UN22JUN01
Hydraulic System
1Housing 2Oil Seal 3Bearing 4Shaft 5Trust Plate 6Piston (9 used) 7Plate 8Retainer 9Cylinder Block 10Plate (4 used) 11Friction Plate (3 used) 12Cap Screw (4 used) 13O-Ring (2 used) 14Plug (2 used) 15Plug (2 used) 16O-Ring (2 used) 17Spring (2 used) 18Poppet (2 used) 19Valve Housing 20Crossover Relief Valve (2 used) 21O-Ring 22Bearing 23Valve Plate 24Spring (24 used) 25Brake Piston 26O-Ring 27O-Ring 28O-Ring 29Piston 30Spring 31Ball 32Plug (2 used) 33Snap Ring
Disassemble Swing Motor and Park Brake 200CLC and 230CLC 1. Drain oil. Approximate capacity is 1.5 L (1.6 qt). CAUTION: Heavy Component; use a hoist.
Swing Motor and Park BrakeSpecification Swing Motor and Park Brake (200CLC and 230CLC) Weight .................................................... 46.4 kg (100 lb) approximate
dropped. Hold valve plate during disassembly. 3. Remove valve plate (23) and springs (24). 4. Remove brake piston (25). 5. Remove parts (69) from shaft (4). 6. Remove snap ring (33) and shaft (4). 7. Push out oil seal (2) and remove outer race of bearing (3). 8. Remove inner race of bearing from shaft.
CAUTION: Swing motor valve housing and cover is under spring pressure. Remove cap screws evenly to release spring force. 2. Mark alignment of swing motor housing and valve housing assembly. Loosen cap screws (12). IMPORTANT: Valve plate has a polished surface. Valve plate may remain on valve housing or stay with cylinder block. Valve plate may be damaged if
NOTE: Filter and orifice are mounted inside of piston (29). Unless clogged or deformed, do not disassemble. Do so only when absolutely needed. If internal parts need to be replaced, replace piston as an assembly.
TX,4360,DV1356 1919NOV014/10
43 4360 5
TM1931 (09JAN04)
43-4360-5

010904
PN=367
Hydraulic System
15 14 17 6 12 13 4 7 8 9 10 20 3 2 1 5 25 26 34 29 30 31 32 33 35 41 42 44 45 46 47 48 49
43 4360 6
UN19NOV01
11
16 19
18
23
21 22 24 38
27 28
39 40
36 37
43
T146945
TX,4360,DV1356 1919NOV015/10
TM1931 (09JAN04)
43-4360-6

010904
PN=368
T146945
Hydraulic System
1Bearing 2Snap Ring 3Dowel Pin (2 used) 4O-Ring 5Crossover Relief Valve (2 used) 6Valve Housing 7Poppet (2 used) 8Spring (2 used) 9O-Ring (2 used) 10Drain Plug (2 used) 11Cap Screw (4 used) 12O-Ring (2 used) 13O-Ring (2 used) 14Plate 15Cap Screw (4 used) 16O-Ring (2 used) 17Plug (2 used) 18Valve Plate 19Spring (22 used) 20Brake Piston 21O-Ring 22O-Ring 23Friction Plate (3 used) 24Plate (4 used) 25Snap Ring 26Spacer 27Spring 28Washer 29Cylinder Block 30Pin (12 used) 31Washer 32Ball Bushing 33Retainer 34Piston (9 used) 35Thrust Plate 36Plug 37O-Ring 38Cap Screw (3 used) 39Brake Release Valve 40Housing 41Shaft 42Snap Ring 43Spacer (2 used) 44Bearing 45Snap Ring 46O-Ring 47Oil Seal 48Cover 49Snap Ring
Disassemble Swing Motor and Park Brake 270CLC CAUTION: Heavy Component; use a hoist.
Swing Motor and Park BrakeSpecification Swing Motor and Park Brake (270CLC Machine)Weight ..................... 66 kg (150 lb) approximate
dropped. Hold valve plate during disassembly. 2. Remove valve plate (18) and springs (19). 3. Remove brake piston (20). 4. Remove parts (2934) from shaft (41). 5. Remove snap ring (49) from housing (40) to remove cover (48) and O-ring (46). 6. Install cover (48) in vise and remove oil seal (47). 7. Tap shaft (41) assembly lightly and remove from housing (40). Bearing (44), snap rings (42 and 45), and spacers (43) are removed with shaft. 8. Replace parts as necessary.
CAUTION: Swing motor valve housing and cover is under spring pressure. Remove cap screws evenly to release spring force. 1. Mark alignment of swing motor housing and valve housing assembly. Loosen cap screws (11). IMPORTANT: Valve plate has a polished surface. Valve plate may remain on valve housing or stay with cylinder block. Valve plate may be damaged if
TX,4360,DV1356 1919NOV016/10
43 4360 7
TM1931 (09JAN04)
43-4360-7

010904
PN=369
Hydraulic System
Inspect Swing Motor and Park Brake 1. Measure clearance between outer diameter of piston and inner bore of cylinder.
Swing Motor and Park BrakeSpecification Piston-to-CylinderClearance ........................ 0.027 mm (0.0011 in.) new 0.052 mm (0.0020 in.) maximum used
TX,4360,DV1356 1919NOV017/10
2. Measure clearance between piston and slipper at caulked position.

Swing Motor and Park BrakeSpecification Piston-to-SlipperClearance .................................... 0.0 mm (0.0 in.) new 0.3 mm (0.0118 in.) maximum used
43 4360 8
TX,4360,DV1356 1919NOV018/10
TM1931 (09JAN04)
43-4360-8

010904
T142069
UN22JUN01
T142067
UN22JUN01
PN=370
Hydraulic System
3. Measure thickness of slipper.
Swing Motor and Park BrakeSpecification SlipperThickness .................................................. 5.5 mm (0.22 in.) new 5.3 mm (0.21 in.) minimum
4. Measure thickness of friction plate.

Swing Motor and Park BrakeSpecification Friction PlateThickness ........................................ 2.0 mm (0.08 in.) new 1.8 mm (0.07 in.) minimum
Assemble Swing Motor and Park Brake200CLC and 230CLC 1. Align spline teeth of friction plates (11) with cylinder block (9) and outer tabs of plates (10) with housing (1). 2. Apply petroleum jelly to valve plate (23). 3. Install thrust plate (5) with chamfered edge towards housing (1). 4. Align mating marks on valve housing (19) and housing (1) and tighten cap screws (12).
Swing Motor and Park BrakeSpecification Valve Housing Cap Screw (200CLC and 230CLC)Torque................................. 430 Nm (320 lb-ft)
Slipper Thickness
5. Install poppet (18) and spring (17). Tighten plug (15) with O-ring (16) attached.
Swing Motor and Park BrakeSpecification Poppet Plug (200CLC and 230CLC)Torque ....................................................... 330 Nm (245 lb-ft)
6. Install crossover relief valves (20) into valve housing (19).

Swing Motor and Park BrakeSpecification Crossover Relief ValveTorque ................................. 175 Nm (130 lb-ft)
Friction Plate Thickness
Assemble Swing Motor and Park Brake270CLC 1. Align spline teeth of friction plates (23) with cylinder block and outer tabs of plates (24) with housing (40). 2. Apply petroleum jelly to valve plate (18).
T142073
UN22JUN01
T142072
UN22JUN01
43 4360 9
TX,4360,DV1356 1919NOV019/10
TM1931 (09JAN04)
43-4360-9

010904
PN=371
Hydraulic System
3. Install thrust plate (35) with chamfered edge towards housing (40). 4. Align mating marks on valve housing (6) and housing (40) and tighten cap screws (11).
Swing Motor and Park BrakeSpecification 270CLC Valve Housing Cap ScrewTorque ............................................................ 400 Nm (300 lb-ft)
5. Install poppet (7) and spring (8). Tighten plug (10) with O-ring (9) attached.
Swing Motor and Park BrakeSpecification 270CLC Poppet PlugTorque ................................... 400 Nm (300 lb-ft)
6. Install crossover relief valves (5) into valve housing (6).

Swing Motor and Park BrakeSpecification Crossover Relief ValveTorque ................................. 175 Nm (130 lb-ft)
TX,4360,DV1356 1919NOV0110/10
43 4360 10
TM1931 (09JAN04)
43-4360-10

010904
PN=372
Hydraulic System
Crossover Relief Valve and Make-Up Valve Repair
4 3 1
T139645
1Make-Up Valve
2Make-Up Valve
3Crossover Relief Valve
4Crossover Relief Valve
TX,4360,DV2980 1919NOV011/4
Remove and Install Crossover Relief Valve 1. Tighten crossover relief valve (1).
Crossover Relief and Make-Up ValvesSpecification Crossover Relief ValveTorque ................................. 175 Nm (130 lb-ft)
2. Check crossover relief valve pressure setting. See Swing Motor Crossover Relief Valve Test and Adjustment200CLC and 230CLC or Swing Motor Crossover Relief Valve Test and Adjustment270CLC. (Group 9025-25.)
1Crossover Relief Valve (2 used)
T147132B
UN19NOV01
T139645
UN30APR01
43 4360 11
TX,4360,DV2980 1919NOV012/4
TM1931 (09JAN04)
43-4360-11

010904
PN=373
Hydraulic System
Disassemble and Assemble Crossover Relief Valve Tighten plug (4).
Crossover Relief and Make-Up ValvesSpecification Crossover Relief Valve Plug Torque ........................................................................... 118 Nm (88 lb-ft)
TX,4360,DV2980 1919NOV013/4
Remove and Install Make-Up Valve Tighten make-up valve (1).

Crossover Relief and Make-Up ValvesSpecification 200CLC and 230CLC Make-Up ValveTorque ............................................................. 332 Nm (245 lb-ft) 270CLC Make-Up ValveTorque............................... 400 Nm (300 lb-ft)
TX,4360,DV2980 1919NOV014/4
43 4360 12
TM1931 (09JAN04)
43-4360-12

010904
PN=374
T147132C
1Make-Up Valve (2 used)
UN19NOV01
T142068
UN22JUN01
1Shim 2Piston 3Sleeve 4Plug 5O-Ring 6O-Ring 7O-Ring
Hydraulic System
Swing Motor Start-Up Procedure

IMPORTANT: Swing motor will be damaged if not filled with oil before operating swing function. Start-up procedure must be performed whenever a new swing motor is installed or oil has been drained from the motor. Procedure is to ensure swing motor is filled with oil. 1. Disconnect swing motor hydraulic line (1). 2. Fill motor with Hydraulic Oil through port until oil reaches level of port. (Operators Manual.)
1Hydraulic Line
NOTE: Air must be allowed to escape from the swing motor while filling.
3. Connect hydraulic line (1).
OUOE027,000003D 1919NOV011/1
Brake Release Valve Repair270CLC

Remove and Install Brake Release Valve 1. Disconnect electrical connector (1). 2. Disconnect hydraulic line (3). 3. Remove cap screws (2) and remove brake release valve (4). 4. Repair or replace parts as necessary.
1Electrical Connector 2Cap Screw (3 used) 3Hydraulic Line 4Brake Release Valve
UN19NOV01
OUOE054,0000021 1919NOV011/2
T147133B
T143358D
UN20JUL01
43 4360 13
TM1931 (09JAN04)
43-4360-13

010904
PN=375
Hydraulic System
Disassemble and Assemble Brake Release Valve 2
1O-Ring 2O-Ring 3Poppet 4Spring 5O-Ring 6Spring 7Spool 8Housing 9Bushing 10Filter 11Spacer 12Orifice
5 6
12 11 10 9 7
UN19NOV01
OUOE054,0000021 1919NOV012/2
43 4360 14
TM1931 (09JAN04)
43-4360-14

010904
PN=376
T147146
Section 99
Dealer Fabricated Tools

Contents
Page
99
Group 9900Dealer Fabricated Tools DF1063 Lift Bracket . . . . . . . . . . . . . . . . . . .99-9900-1 ST4920 Track Recoil Spring Disassembly and Assembly Tool . . . . . . . .99-9900-3 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. . .99-9900-7 DFT1110 Spacer. . . . . . . . . . . . . . . . . . . . . .99-9900-8 DFT1130 Adapter . . . . . . . . . . . . . . . . . . . . .99-9900-9 DF1036A Propel Gearbox Nut Wrench . . . .99-9900-10 DF1038 Torque Adapter . . . . . . . . . . . . . . .99-9900-11 DFT1109 Holding Bar . . . . . . . . . . . . . . . . .99-9900-12 Rotary Manifold Lifting Tool. . . . . . . . . . . . .99-9900-13 DFT1089 Barrel Support . . . . . . . . . . . . . . .99-9900-14 DFT1144 Guide Pin . . . . . . . . . . . . . . . . . .99-9900-15 DFT1119 Pump Support . . . . . . . . . . . . . . .99-9900-16 DFT1220 Swing Gearbox Nut Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-18
TM1931 (09JAN04)
99-1

010904
PN=1
Contents
99
TM1931 (09JAN04)
99-2

010904
PN=2
Group 9900

DF1063 Lift Bracket
Tool is the same as used on other machines. Only the lift bracket of the tool is used for this machine with adapter DFT1130. Lift Bracket is used to remove and install propel motor. Material required: 38.1 mm x 76.2 mm x .48 mm (1-1/2 in. x 3 in. x 3/16 in.) 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)
UN20SEP94
99 9900 1
CED,OUTX818,81 1911MAY001/2
TM1931 (09JAN04)
99-9900-1

010904
PN=379
T8318AC
99 9900 2
CED,OUTX818,81 1911MAY002/2
TM1931 (09JAN04)
99-9900-2

010904
PN=380
T7247BW
1925APR90
ST4920 Track Recoil Spring Disassembly and Assembly Tool

NOTE: It is recommended that DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool be used with track recoil spring disassembly and assembly tool. Dimensions given are metric.
Tool is the same as used on other machines except the holder (C). For each track adjuster use the holder with the correct size hole for the nut on that track adjuster. Track Recoil Spring Disassembly and Assembly Tool (compression tool) is used with hydraulic jack to compress recoil 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
ANut (12 used) BStud (4 used) CHolder DEyebolt (2 used) ESupporting Plate FBase Plate GBase (4 used) HCap Screw (4 used) ILock Washer (8 used)
UN24MAR98
99 9900 3
TX,99,SB548 1908JAN971/4
TM1931 (09JAN04)
99-9900-3

010904
PN=381
T6585UY
99 9900 4
TX,99,SB548 1908JAN972/4
TM1931 (09JAN04)
99-9900-4

010904
PN=382
T7029CI
UN06JUL89
99 9900 5
TX,99,SB548 1908JAN973/4
TM1931 (09JAN04)
99-9900-5

010904
PN=383
T7029CH
UN06JUL89
99 9900 6
TX,99,SB548 1908JAN974/4
TM1931 (09JAN04)
99-9900-6

010904
PN=384
T7029CG
UN06JUL89
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

99 9900 7
A3/16 in. 1020 CR Steel Plate B9/16 in. Hole (2 places)
C1/2 in. Nut (2 used)
D1/2 x 2 in. Cap Screw (2 used)
E1/2 x 3 in. Steel Round Stock (2 used)
Track Disassembly and Assembly Guard Tool is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. 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)
TX,99,SB542 1908JAN971/1
TM1931 (09JAN04)
99-9900-7

010904
PN=385
T7162AF
UN17OCT89
DFT1110 Spacer
99 9900 8
Spacer is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. Spacer is installed on the bottom plate so force is applied to spring flange on cylinder and not to the piston. Cut the ends of spacer so they are parallel to each other.
Material Required: 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) Heavy Wall Steel Pipe
TX,99,SB549 1908JAN971/1
TM1931 (09JAN04)
99-9900-8

010904
PN=386
T7708AC
UN23FEB92
DFT1130 Adapter
99 9900 9
AAdapter Plate
BTube
CStop Plate
Adapter is used with DF1063 Lift Bracket to remove and install propel 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)
CED,OUTX818,84 1911MAY001/1
TM1931 (09JAN04)
99-9900-9

010904
PN=387
T8319BN
UN20SEP94
DF1036A Propel Gearbox Nut Wrench

99 9900 10
Propel Gearbox Nut Wrench is used to remove and install the hub-to-housing nut in the propel 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)
TX,99,SB544 1919NOV011/1
TM1931 (09JAN04)
99-9900-10

010904
PN=388
T7681FZ
UN28FEB92
DF1038 Torque Adapter

99 9900 11
Torque Adapter is used to check rolling drag torque on rotor drive shaft. Material required:
17 mm (0.125 in.) hex head driver
CED,OUTX818,83 1911MAY001/1
TM1931 (09JAN04)
99-9900-11

010904
PN=389
T6557CH
UN25OCT95
DFT1109 Holding Bar

99 9900 12
Holding Bar is used with the DF1036A Propel Gearbox Nut Wrench as a guide when loosening the hub-to-housing nut in the propel gearbox.
Material required: 16 mm (5/8 in.) Flat Bar Stock

TX,99,SB550 1923MAY001/1
TM1931 (09JAN04)
99-9900-12

010904
PN=390
T7690AA
UN27FEB92
Rotary Manifold Lifting Tool

Tool is used to remove and install rotary manifold. 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
AThreads 99 9900 13
TX,99,SB546 1908JAN971/1
TM1931 (09JAN04)
99-9900-13

010904
PN=391
T6641DO
UN24OCT88
DFT1089 Barrel Support

99 9900 14
Barrel supports are used to support the upperstructure when removing the undercarriage.
UN09JAN97
CAUTION: Cutting tops off barrels that contained flammable or explosive material can cause serious injury or death. Material required: Clean metal 55 gallon barrels of equal height with lids removed. (Must be 34.535.5 in. height x 24 in. wide.) 1/2 x 4 x 24 in. 1020 CR Plate 1/2 x 4 x 12 in. 1020 CR Plate One empty 3 lb coffee can or equivalent Highway Cement (9 bag mix). Mix extra dry to aid curing time. Insert hook assembly into barrel before cement is set. Hold assembly in position, using a steel plate or wire, until cement begins to cure. Level off cement with top of barrels. Cement must cure for a minimum of ten days. The approximate weight of each barrel support is 545 kg (1200 lb). The approximate support capacity of each barrel support is 385 560 kg (850,000 lb).
A2 x 4 in. Slotted Hole, Recessed B1/2 x 4 x 24 in. 1020 CR Plate C1/2 x 4 x 12 in. 1020 CR Plate D1/4 in. Fillet Weld EOne Empty 3 lb Coffee Can or Equivalent
TX,99,SB551 1908JAN971/1
TM1931 (09JAN04)
99-9900-14

010904
PN=392
T7149AC
DFT1144 Guide Pin

Guide pin is used to align cap screw holes in swing bearing and upperstructure.
UN24OCT88
99 9900 15
Remove threads for a distance (B) and then grind a taper on same end. Materials required: M20-2.5 x 230 mm (9 in.) Threaded Rod
A230 mm (9 in.) B100 mm (4 in.)
TX,99,SB552 1908JAN971/1
TM1931 (09JAN04)
99-9900-15

010904
PN=393
T6641EK
DFT1119 Pump Support

99 9900 16
Pump support is used with a hand hoist to support a pump(s) when an engine is removed. Two end stands are needed. Drill the holes through the square steel tubing so they are 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.) Square Steel Tubing 76.2 x 76.2 x 6.35 mm (3 x 3 x 0.250 in.) Square Steel Tubing 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.) Square Steel 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)
TX,99,SB553 1908JAN971/1
TM1931 (09JAN04)
99-9900-16

010904
PN=394
T7955AA
UN23APR93
99 9900 17
TM1931 (09JAN04)
99-9900-17

010904
PN=395
DFT1220 Swing Gearbox Nut Spanner Wrench

99 9900 18
OUOE047,000000E 1919NOV011/2
TM1931 (09JAN04)
99-9900-18

010904
PN=396
T143704
UN17JUL01

1Weld (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.)
99 9900 19
OUOE047,000000E 1919NOV012/2
TM1931 (09JAN04)
99-9900-19

010904
PN=397
99 9900 20
TM1931 (09JAN04)
99-9900-20

010904
PN=398
Index
Page Page
A
Adjuster, track Disassemble and assemble . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-19 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-2 Air conditioner Compressor, remove and install . . . . . .18-1830-11 Condenser, remove and install . . . . . . .18-1830-16 Receiver-dryer, remove and install . . . .18-1830-12 Remove and install . . . . . . . . . . . . . . . .18-1830-15 Air conditioner and heater Remove and install . . . . . . . . . . . . . . . .18-1830-15 Air conditioner system Flush and purge . . . . . . . . . . . . . . . . . . .18-1830-3 Air conditioning Charge R134a system . . . . . . . . . . . . .18-1830-10 Evacuate R134a system . . . . . . . . . . . . .18-1830-9 Recover R134a refrigerant . . . . . . . . . . .18-1830-8 Refrigerant handling and cautions. . . . . .18-1830-1 R134a refrigerant oil information . . . . . . .18-1830-6 R134a station installation . . . . . . . . . . . .18-1830-7 Air intake system Leakage test . . . . . . . . . . . . . . . . . . . . . .05-0520-1 Air test Rotary manifold. . . . . . . . . . . . . . . . . . .02-0260-25 Arm Remove and install . . . . . . . . . . . . . . . . .33-3340-3 Arm cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Inspect pins and bushings. . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . 33-3360-100 Arm cylinder200CLC, 270CLC Disassemble and assemble . . . . . . . . 33-3360-104 Arm cylinder230CLC Disassemble and assemble . . . . . . . . 33-3360-118 Arm pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Arm regenerative solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-35
Belt, seat Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Bleed procedure Hydraulic cylinder . . . . . . . . . . . . . . . . 33-3360-152 Boom Remove and install . . . . . . . . . . . . . . . . .33-3340-6 Boom cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Inspect pins and bushings. . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . .33-3360-75 Boom cylinder200CLC, 270CLC Disassemble and assemble . . . . . . . . .33-3360-80 Boom cylinder230CLC Disassemble and assemble . . . . . . . . .33-3360-94 Boom pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Boom, arm, and bucket bushings and bosses Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Boom, arm, and bucket pins Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Bucket Adjust pivot end play. . . . . . . . . . . . . . . .33-3302-3 Pin-up data . . . . . . . . . . . . . . . . . . . . . . .33-3302-4 Remove and install . . . . . . . . . . . . . . . . .33-3302-1 Bucket cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Inspect pins and bushings. . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . 33-3360-124 Bucket cylinder200CLC, 270CLC Disassemble and assemble . . . . . . . . 33-3360-130 Bucket cylinder230CLC Dissassemble and assemble. . . . . . . . 33-3360-144 Bucket links Remove and install . . . . . . . . . . . . . . . . .33-3340-1 Bucket pins Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Bushings and seals Remove and install . . . . . . . . . . . . . . . .33-3340-14
Indx 1
C B
Bearing, swing Disassemble and assemble . . . . . . . . .43-4350-21 Lower seal, install . . . . . . . . . . . . . . . . .43-4350-24 Remove and install . . . . . . . . . . . . . . . .43-4350-19 Upper seal, install . . . . . . . . . . . . . . . . .43-4350-24 Belt, fan Remove and install . . . . . . . . . . . . . . . . .05-0510-2 TM1931 (09JAN04) Cab Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Carrier roller, track Disassemble and assemble . . . . . . . . . .01-0130-6 Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1 Remove and install . . . . . . . . . . . . . . . . .01-0130-5 Chain sprocket, track Remove and install . . . . . . . . . . . . . . . .01-0130-14 Chain, track Disassemble and assemble . . . . . . . . .01-0130-12 200CLC, 230CLC & 270CLC Excavator Repair
010904
Index-1
PN=1
Index
Page
Page
Indx 2
Disassemble and assemble to replace broken part . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-13 Remove and install . . . . . . . . . . . . . . . .01-0130-10 Charge R134a system . . . . . . . . . . . . . . .18-1830-10 Cleaner, air Remove and install . . . . . . . . . . . . . . . . .05-0520-2 Cleanup procedure, hydraulic oil Using portable filter caddy. . . . . . . . . . . .33-3360-2 Compressor Remove and install . . . . . . . . . . . . . . . .18-1830-11 Condenser, air conditioner Remove and install . . . . . . . . . . . . . . . .18-1830-16 Control valve Arm priority flow rate valve . . . . . . . . . .33-3360-51 Arm reduced leakage valve. . . . . . . . . .33-3360-51 Arm regenerative valve . . . . . . . . . . . . .33-3360-57 Arm regenerative valve check valve . . .33-3360-57 Auxiliary flow combiner valve check valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Auxiliary flow rate valve . . . . . . . . . . . .33-3360-51 Auxiliary function flow combiner valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Boom reduced leakage valve . . . . . . . .33-3360-57 Bucket flow rate valve . . . . . . . . . . . . . .33-3360-57 Bypass shut-off valve . . . . . . . . . . . . . .33-3360-57 Circuit relief and anti-cavitation valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 Lift check and orifice (arm II power passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-57 Lift check and orifice (left propel power passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Lift check (arm I power passage) . . . . .33-3360-51 Lift check (boom II power passage) . . .33-3360-51 Lift check (left propel neutral passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Lift check (swing neutral passage) . . . .33-3360-51 Propel flow combiner valve check valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 Propel function flow combiner valve . . .33-3360-57 Remove and install . . . . . . . . . . . . . . . .33-3360-49 Right propel and bucket combined function check valve and orifice . . . . . . . . . . .33-3360-64 Spool assemblies (4-spool) . . . . . . . . . .33-3360-57 Spool assemblies (5 spool) . . . . . . . . . .33-3360-51 System relief and power boost valve. . .33-3360-51 System relief valve isolation check valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 4-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-57 5-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Controller, pilot Disassemble and assemble . . . . . . . . .33-3360-39 Remove and install . . . . . . . . . . . . . . . .33-3360-37 TM1931 (09JAN04)
Controller, propel pilot Disassemble and assemble . . . . . . . . .33-3360-42 Remove and install . . . . . . . . . . . . . . . .33-3360-40 Cooler, oil Remove and install . . . . . . . . . . . . . . . .33-3360-74 Counterbalance valve, propel motor Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Counterweight Remove and install . . . . . . . . . . . . . . . . .17-1749-1 Coupling, flex (dampener drive) Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Crossover relief valve Disassemble and assemble . . . . . . . . .43-4360-12 Remove and install . . . . . . . . . . . . . . . .43-4360-11 Crossover relief valve, propel motor Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Cylinder Arm, remove and install . . . . . . . . . . . 33-3360-100 Arm200CLC, 270CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-104 Arm230CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-118 Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Boom, remove and install . . . . . . . . . . .33-3360-75 Boom200CLC, 270CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-80 Boom230CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-94 Bucket, remove and install . . . . . . . . . 33-3360-124 Bucket200CLC, 270CLC, disassemble and asemble. . . . . . . . . . . . . . . . . . . . . . 33-3360-130 Bucket230CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-144 Bushings and seals, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3340-14
D
Dampener drive Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Dealer fabricated tools DFT1087 track recoil spring disassembly and assembly guard tool . . . . . . . . . . . . . .99-9900-7 DFT1089 barrel support . . . . . . . . . . . .99-9900-14 DFT1109 holding bar . . . . . . . . . . . . . .99-9900-12 200CLC, 230CLC & 270CLC Excavator Repair
010904
Index-2
PN=2
Index
Page
Page
DFT1110 spacer . . . . . . . . . . . . . . . . . . .99-9900-8 DFT1114 guide pin . . . . . . . . . . . . . . . .99-9900-15 DFT1119 pump support . . . . . . . . . . . .99-9900-16 DFT1130 adapter . . . . . . . . . . . . . . . . . .99-9900-9 DFT1220 swing gearbox nut spanner wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-18 DF1036A propel gearbox nut wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10 DF1038 torque adapter . . . . . . . . . . . . .99-9900-11 DF1063 lift bracket . . . . . . . . . . . . . . . . .99-9900-1 Rotary manifold lifting tool. . . . . . . . . . .99-9900-13 ST4920 track recoil spring disassembly and assembly tool . . . . . . . . . . . . . . . . . . .99-9900-3 Drive gearbox and hydraulic pump Disassemble and assemble . . . . . . . . . .33-3360-5 Remove and install . . . . . . . . . . . . . . . . .33-3360-3 Drive, dampener (flex coupling) Remove and install . . . . . . . . . . . . . . . . .07-0752-1
Flush air conditioner system . . . . . . . . . . . .18-1830-3 Front idler Disassemble and assemble . . . . . . . . .01-0130-17 Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1 Remove and install . . . . . . . . . . . . . . . .01-0130-16 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-19 Fuel filter, final Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Fuel filter, primary Remove and install . . . . . . . . . . . . . . . . .05-0560-3 Fuel injection pump Remove and install . . . . . . . . . . . . . . . . .04-0400-4 Fuel tank Remove and install . . . . . . . . . . . . . . . . .05-0560-2
Indx 3
G
Gearbox Pump drive, pilot pump drive shaft . . . .33-3360-21 Gearbox, drive and hydraulic pump Disassemble and assemble . . . . . . . . . .33-3360-5 Remove and install . . . . . . . . . . . . . . . . .33-3360-3 Gearbox, propel Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0250-5 Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0250-11 Remove and install . . . . . . . . . . . . . . . . .02-0250-1 Gearbox, swing Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .43-4350-5 Disassemble and assemble270CLC . .43-4350-9 Remove and install . . . . . . . . . . . . . . . . .43-4350-1
E
End play, bucket pivot Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-3 Engine Remove and install . . . . . . . . . . . . . . . . .04-0400-1 Engine air cleaner Remove and install . . . . . . . . . . . . . . . . .05-0520-2 Evacuate R134a system. . . . . . . . . . . . . . .18-1830-9
F
Fan Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Fan belt Remove and install . . . . . . . . . . . . . . . . .05-0510-2 Fan guard Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Fan shroud Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Filter, final fuel Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Filter, pilot Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Filter, primary fuel Remove and install . . . . . . . . . . . . . . . . .05-0560-3 Final fuel filter Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Flex coupling Remove and install . . . . . . . . . . . . . . . . .07-0752-1 TM1931 (09JAN04)
H
Heater Remove and install . . . . . . . . . . . . . . . .18-1830-15 Hydraulic Fittings, 30 cone seat . . . . . . . . . . . . . .00-0003-9 Fittings, 37 flare. . . . . . . . . . . . . . . . . . .00-0003-9 Hydraulic cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Hydraulic fitting Flared connections . . . . . . . . . . . . . . . .00-0003-10 Hydraulic oil Cleanup procedure using portable filter caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-2 Hydraulic oil tank Disassemble and assemble . . . . . . . . .33-3360-69 200CLC, 230CLC & 270CLC Excavator Repair
010904
Index-3
PN=3
Index
Page
Page
Indx 4
Pressure release procedure . . . . . . . . . .33-3360-1 Remove and install . . . . . . . . . . . . . . . .33-3360-66 Hydraulic pump Start-up procedure . . . . . . . . . . . . . . . .33-3360-20 Hydraulic pump and drive gearbox Disassemble and assemble . . . . . . . . . .33-3360-5 Remove and install . . . . . . . . . . . . . . . . .33-3360-3 Hydraulic pump regulator Disassemble and assemble . . . . . . . . .33-3360-24 Remove and install . . . . . . . . . . . . . . . .33-3360-22
Disassemble and assemble270CLC . .02-0260-7 Remove and install200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Remove and install270CLC . . . . . . . . .02-0260-1
O
O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6 Oil Carrier roller, specification. . . . . . . . . . . .01-0130-1 Front idler, specification . . . . . . . . . . . . .01-0130-1 Lines and fittings. . . . . . . . . . . . . . . . . . .00-0003-5 Track roller, specification . . . . . . . . . . . .01-0130-1 Oil cooler Remove and install . . . . . . . . . . . . . . . .33-3360-74 Oil cooler bypass valve Remove and install . . . . . . . . . . . . . . . .33-3360-71 Oil information R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6 Oil leakage test Front idler . . . . . . . . . . . . . . . . . . . . . . .01-0130-19 Track roller . . . . . . . . . . . . . . . . . . . . . . .01-0130-4 Oil lines and fittings . . . . . . . . . . . . . . . . . .00-0003-5 Oil tank, hydraulic Disassemble and assemble . . . . . . . . .33-3360-69 Remove and install . . . . . . . . . . . . . . . .33-3360-66
I
Idler, front Disassemble and assemble . . . . . . . . .01-0130-17 Remove and install . . . . . . . . . . . . . . . .01-0130-16 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-19 Inch torque values . . . . . . . . . . . . . . . . . . .00-0003-1 Injection pump Remove and install . . . . . . . . . . . . . . . . .04-0400-4
L
Leakage test Air intake system . . . . . . . . . . . . . . . . . .05-0520-1 Links, bucket Remove and install . . . . . . . . . . . . . . . . .33-3340-1
P
Pilot controller Disassemble and assemble . . . . . . . . .33-3360-39 Remove and install . . . . . . . . . . . . . . . .33-3360-37 Pilot controller, propel Disassemble and assemble . . . . . . . . .33-3360-42 Remove and install . . . . . . . . . . . . . . . .33-3360-40 Pilot filter Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Pilot filter and pilot pressure regulating valve Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Pilot pressure regulating valve and filter Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Pilot pump Disassemble and assemble . . . . . . . . .33-3360-29 Drive shaft and gear, disassemble . . . .33-3360-21 Remove and install . . . . . . . . . . . . . . . .33-3360-27 Pilot shut-off valve Disassemble and assemble . . . . . . . . .33-3360-33 200CLC, 230CLC & 270CLC Excavator Repair
010904
M
Manifold, pilot signal Disassemble and assemble . . . . . . . . .33-3360-47 Remove and install . . . . . . . . . . . . . . . .33-3360-43 Manifold, rotary Air test . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-25 Disassemble and assemble . . . . . . . . .02-0260-24 Remove and install . . . . . . . . . . . . . . . .02-0260-22 Metal face seals Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Metric torque values . . . . . . . . . . . . . . . . . .00-0003-2 Motor cover, propel Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Motor, propel Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-4 TM1931 (09JAN04)
Index-4
PN=4
Index
Page
Page
Remove and install . . . . . . . . . . . . . . . .33-3360-31 Pilot signal manifold Disassemble and assemble . . . . . . . . .33-3360-47 Remove and install . . . . . . . . . . . . . . . .33-3360-43 Pin-up data Bucket. . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-4 Portable filter caddy Hydraulic oil cleanup procedure . . . . . . .33-3360-2 Power boost solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-35 Pressure release procedure Hydraulic oil tank . . . . . . . . . . . . . . . . . .33-3360-1 Primary fuel filter Remove and install . . . . . . . . . . . . . . . . .05-0560-3 Propel gearbox Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0250-5 Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0250-11 Remove and install . . . . . . . . . . . . . . . . .02-0250-1 Propel motor Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-4 Disassemble and assemble 270CLC . . . . . . . . . . . . . . 02-0260-7, 02-0260-18 Remove and install200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Remove and install270CLC . . . . . . . . .02-0260-1 Start-up procedure . . . . . . . . . . . . . . . .02-0260-22 Propel motor cover Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Propel motor, counterbalance valve Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Propel pilot controller Disassemble and assemble . . . . . . . . .33-3360-42 Remove and install . . . . . . . . . . . . . . . .33-3360-40 Propel speed solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-35 Pump Fuel injection, remove and install . . . . . .04-0400-4 Pump regulator, hydraulic Disassemble and assemble . . . . . . . . .33-3360-24 Remove and install . . . . . . . . . . . . . . . .33-3360-22 Pump, hydraulic and drive gearbox Disassemble and assemble . . . . . . . . . .33-3360-5 Remove and install . . . . . . . . . . . . . . . . .33-3360-3 Start-up procedure . . . . . . . . . . . . . . . .33-3360-20 TM1931 (09JAN04)
Pump, pilot Disassemble and assemble . . . . . . . . .33-3360-29 Remove and install . . . . . . . . . . . . . . . .33-3360-27 Purge air conditioner system . . . . . . . . . . .18-1830-3
R
Radiator Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-12 Recoil spring, track Disassemble and assemble . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-19 Recover R134a refrigerant . . . . . . . . . . . . .18-1830-8 Refrigerant Cautions and proper handling . . . . . . . . .18-1830-1 Recover R134a, air conditioning . . . . . . .18-1830-8 Refrigerant oil information R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Refrigerant recovery/recycling and charging Charging station installation procedure . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Regulator, hydraulic pump Disassemble and assemble . . . . . . . . .33-3360-24 Remove and install . . . . . . . . . . . . . . . .33-3360-22 Relief valve, crossover, propel motor Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Restriction valve Remove and install . . . . . . . . . . . . . . . .33-3360-69 Roller, track Disassemble and assemble . . . . . . . . . .01-0130-3 Oil leakage test . . . . . . . . . . . . . . . . . . . .01-0130-4 Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Rotary manifold Air test . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-25 Disassemble and assemble . . . . . . . . .02-0260-24 Remove and install . . . . . . . . . . . . . . . .02-0260-22 R134a refrigerant recovery . . . . . . . . . . . . .18-1830-8 R134a refrigerant recovery and charging station Installation procedure . . . . . . . . . . . . . . .18-1830-7 R134a system charge. . . . . . . . . . . . . . . .18-1830-10 R134a system evacuate . . . . . . . . . . . . . . .18-1830-9
Indx 5
S
Safety signs . . . . . . . . . . . . . . . . . . . . . . .00-0001-13 200CLC, 230CLC & 270CLC Excavator Repair
010904
Index-5
PN=5
Index
Page
Page
Indx 6
Seals, metal face Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Seat belt Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Shoe, track Remove and install . . . . . . . . . . . . . . . . .01-0130-9 Shut-off valve, pilot Disassemble and assemble . . . . . . . . .33-3360-33 Remove and install . . . . . . . . . . . . . . . .33-3360-31 Signal manifold, pilot Disassemble and assemble . . . . . . . . .33-3360-47 Remove and install . . . . . . . . . . . . . . . .33-3360-43 Sliding window Remove and install . . . . . . . . . . . . . . . . .18-1810-3 Specification Carrier roller oil . . . . . . . . . . . . . . . . . . . .01-0130-1 Front idler oil. . . . . . . . . . . . . . . . . . . . . .01-0130-1 Track roller oil . . . . . . . . . . . . . . . . . . . . .01-0130-1 Spring, track recoil Disassemble and assemble . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-19 Sprocket Remove and install . . . . . . . . . . . . . . . .01-0130-14 Start-up procedure Hydraulic pump . . . . . . . . . . . . . . . . . . .33-3360-20 Propel motor . . . . . . . . . . . . . . . . . . . . .02-0260-22 Swing gearbox . . . . . . . . . . . . . . . . . . .43-4350-11 Swing motor . . . . . . . . . . . . . . . . . . . . .43-4360-13 Starter Remove and install . . . . . . . . . . . . . . . . .04-0400-5 Swing bearing Disassemble and assemble . . . . . . . . .43-4350-21 Lower seal, install . . . . . . . . . . . . . . . . .43-4350-24 Remove and install . . . . . . . . . . . . . . . .43-4350-19 Upper seal, install . . . . . . . . . . . . . . . . .43-4350-24 Swing gearbox Disassemble and assemble200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .43-4350-5 Disassemble and assemble270CLC . .43-4350-9 Remove and install . . . . . . . . . . . . . . . . .43-4350-1 Start-up procedure . . . . . . . . . . . . . . . .43-4350-11 Swing motor Start-up procedure . . . . . . . . . . . . . . . .43-4360-13 Swing motor and park brake Assemble200CLC and 230CLC . . . . . .43-4360-9 Assemble270CLC . . . . . . . . . . . . . . . .43-4360-9 Disassemble200CLC and 230CLC . . .43-4360-5 Disassemble270CLC . . . . . . . . . . . . . .43-4360-7 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-8 Remove and install . . . . . . . . . . . . . . . . .43-4360-1 Swing motor brake release valve Disassemble and assemble . . . . . . . . .43-4360-14 Remove and Install . . . . . . . . . . . . . . . .43-4360-13 TM1931 (09JAN04)
Swing motor make-up valve Remove and install . . . . . . . . . . . . . . . .43-4360-12
T
Tank pressure release procedure . . . . . . . .33-3360-1 Tank, fuel Remove and install . . . . . . . . . . . . . . . . .05-0560-2 Tank, hydraulic oil Disassemble and assemble . . . . . . . . .33-3360-69 Remove and install . . . . . . . . . . . . . . . .33-3360-66 Torque value Flared connections . . . . . . . . . . . . . . . .00-0003-10 Flat face O-ring seal fitting . . . . . . . . . . .00-0003-8 Inch SAE four bolt flange fitting. . . . . . .00-0003-11 Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-3 Metric four bolt flange fitting . . . . . . . . .00-0003-12 O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6 30 cone seat hydraulic fittings . . . . . . . .00-0003-9 37 flare hydraulic fittings . . . . . . . . . . . .00-0003-9 Torque values Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2 Track adjuster Disassemble and assemble . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-19 Track adjuster cylinder Disassemble and assemble . . . . . . . . .01-0130-25 Track carrier roller Disassemble and assemble . . . . . . . . . .01-0130-6 Remove and install . . . . . . . . . . . . . . . . .01-0130-5 Track chain Disassemble and assemble . . . . . . . . .01-0130-12 Disassemble and assemble to replace broken part . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-13 Remove and install . . . . . . . . . . . . . . . .01-0130-10 Track chain sprocket Remove and install . . . . . . . . . . . . . . . .01-0130-14 Track roller Disassemble and assemble . . . . . . . . . .01-0130-3 Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1 Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Test for oil leakage . . . . . . . . . . . . . . . . .01-0130-4 Track shoe Remove and install . . . . . . . . . . . . . . . . .01-0130-9
U
Upperstructure Install . . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-16 200CLC, 230CLC & 270CLC Excavator Repair
010904
Index-6
PN=6
Index
Page
Remove . . . . . . . . . . . . . . . . . . . . . . . .43-4350-12
V
Valve Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Valve, brake release, swing motor Disassemble and assemble . . . . . . . . .43-4360-14 Remove and install . . . . . . . . . . . . . . . .43-4360-13 Valve, control Remove and install . . . . . . . . . . . . . . . .33-3360-49 Valve, counterbalance, propel motor Disassemble and assemble 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Valve, crossover relief Disassemble and assemble . . . . . . . . .43-4360-12 Remove and install . . . . . . . . . . . . . . . .43-4360-11 Valve, make-up, swing motor Remove and install . . . . . . . . . . . . . . . .43-4360-12 Valve, oil cooler bypass Remove and install . . . . . . . . . . . . . . . .33-3360-71 Valve, pilot pressure regulating Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Valve, pilot shut-off Disassemble and assemble . . . . . . . . .33-3360-33 Remove and install . . . . . . . . . . . . . . . .33-3360-31 Valve, restriction Remove and install . . . . . . . . . . . . . . . .33-3360-69
Indx 7
W
Water separator, primary fuel filter Remove and install . . . . . . . . . . . . . . . . .05-0560-3 Welding on machine . . . . . . . . . . . . . . . . . .17-1740-1 Window, sliding Remove and install . . . . . . . . . . . . . . . . .18-1810-3 Windowpane and one piece molding Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Windowpane and two piece molding Remove and install . . . . . . . . . . . . . . . . .18-1810-1 Windowpanes Remove and install . . . . . . . . . . . . . . . . .18-1810-4
TM1931 (09JAN04)
Index-7

010904
PN=7
Index
Indx 8
TM1931 (09JAN04)
Index-8

010904
PN=8

200clc, 230clc, and 270clc Repair Tm1931

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200clc, 230clc, and 270clc Repair Tm1931

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200CLC 230CLC and 270CLC Excavator Repair

TECHNICAL MANUAL 200CLC, 230CLC, and 270CLC Excavator Repair

CTM170 CTM77 SP326

Worldwide Construction And Forestry Division

200CLC, 230CLC & 270CLC Excavator Repair

Technical Information Feedback Form

Ideas, Comments (Please State Page Number):

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

Follow Safety Instructions

Operate Only If Qualified

200CLC, 230CLC & 270CLC Excavator Repair

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding For Special Uses

200CLC, 230CLC & 270CLC Excavator Repair

Stay Clear Of Moving Parts

Avoid High-Pressure Fluids

200CLC, 230CLC & 270CLC Excavator Repair

Beware Of Exhaust Fumes

Prevent Battery Explosions

200CLC, 230CLC & 270CLC Excavator Repair

Handle Chemical Products Safely

Dispose Of Waste Properly

Prepare For Emergencies

200CLC, 230CLC & 270CLC Excavator Repair

Use Steps And Handholds Correctly

Start Only From Operators Seat

Use And Maintain Seat Belt

200CLC, 230CLC & 270CLC Excavator Repair

Prevent Unintended Machine Movement

Avoid Work Site Hazards

200CLC, 230CLC & 270CLC Excavator Repair

Keep Riders Off Machine

Avoid Backover Accidents

200CLC, 230CLC & 270CLC Excavator Repair

Avoid Machine Tip Over

Use Special Care When Lifting Objects

200CLC, 230CLC & 270CLC Excavator Repair

Add And Operate Attachments Safely

Park And Prepare For Service Safely

200CLC, 230CLC & 270CLC Excavator Repair

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

200CLC, 230CLC & 270CLC Excavator Repair

Drive Metal Pins Safely

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

200CLC, 230CLC & 270CLC Excavator Repair

Metric Bolt and Cap Screw Torque Values

200CLC, 230CLC & 270CLC Excavator Repair

Additional Metric Cap Screw Torque Values

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