200D, 20200DLC Repair TM10079

200D and 200DLC
Excavator
Repair
TECHNICAL MANUAL
200D and 200DLC Excavator Repair
TM10079 17MAR09 (ENGLISH)
For complete service information also see:

200D and 200DLC Excavator Operation and
Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM10076
200D and 200DLC Excavator Operators
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OMT226908
POWERTECH 4.5L/6.8L POWERTECH E
6.8L Diesel EnginesBase Engine . . . . . . .
CTM104
POWERTECH E 6.8L Diesel
EnginesLevel 16 Electronic Fuel System
with Denso HPCR . . . . . . . . . . . . . . . . . . . . .
CTM502
Alternators and Starter Motors . . . . . . . . . . .
CTM77
Undercarriage Appraisal Manual . . . . . . . . .
SP326
Super Caddy Oil Cleanup Procedure . . . . . .
CTM310
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
TM10079 (17MAR09)

031709
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.
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John Deere Dubuque Works

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538
FAX NUMBER:
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THANK YOU!
TX,TM,FAX 1903JUL011/1
TM10079 (17MAR09)

031709
PN=3
Introduction
TM10079 (17MAR09)

031709
PN=4
Contents
00
SECTION 00General Information

Group 01Safety
Group 0003Torque Values
SECTION 01Tracks
Group 0130Track System
01
SECTION 02Axles, Differentials and Suspension

Systems
Group 0250Axle Shaft, Bearings, and Reduction
Gears
Group 0260Hydraulic System
02
SECTION 04Engine
Group 0400Removal and Installation
04
SECTION 05Engine Auxiliary System

Group 0510Cooling System
Group 0520Intake System
Group 0560External Fuel Supply System
SECTION 07Dampener Drive (Flex Coupling)
Group 0752Elements
05
SECTION 17Frame or Supporting Structure

Group 1740Frame Installation
Group 1749Chassis Weights
07
SECTION 18Operators Station

Group 1810Operator Enclosure
Group 1821Seat and Seat Belt
Group 1830Heating and Air Conditioning
17
SECTION 33Excavator
Group 3302Buckets
Group 3340Frames
18
SECTION 43Swing or Pivoting System

Group 4350Mechanical Drive Elements
SECTION 99Dealer Fabricated Tools
Group 9900Dealer Fabricated Tools
33
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.
43
COPYRIGHT 2009
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright 2007, 2008
TM10079 (17MAR09)

031709
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01
02
04
05
07
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43
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TM10079 (17MAR09)
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031709
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00
Section 00
General Information
Contents
Page
Group 01Safety . . . . . . . . . . . . . . . . . . . . . .00-01-1

Group 0003Torque Values
Torque Value
Metric Bolt and Cap Screw . . . . . . . . . . . .00-0003-1
Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Torque Value
Unified Inch Bolt and Cap Screw . . . . . . . .00-0003-4
Service Recommendations for 37 Flare
and 30 Cone Seat Connectors . . . . . . . . .00-0003-5
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6
Service Recommendation
O-Ring Boss Fittings In Aluminum
HousingExcavators. . . . . . . . . . . . . . . . .00-0003-8
Service Recommendations For Flared
ConnectionsStraight or Tapered
Threads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10
Service Recommendations For Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0003-11
Service Recommendation
O-Ring Face Seal Fittings with SAE
Inch Hex Nut and Stud End for High
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-12
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for Standard
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-14
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for High
Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-16
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . .00-0003-18
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . .00-0003-19
Inch Series Four Bolt Flange Fitting For
High Pressure Service
Recommendations . . . . . . . . . . . . . . . . . .00-0003-20
TM10079 (17MAR09)
00-1

031709
PN=1
Contents
00
TM10079 (17MAR09)
00-2

031709
PN=2
Group 01
Safety
00
01
1
Recognize Safety Information

UN28AUG00
This is the safety alert symbol. When this symbol is

noticed on the machine or in this manual, be alert for
the potential of personal injury.
T133555
Follow the precautions and safe operating practices

highlighted by this symbol.
1928AUG00
A signal word DANGER, WARNING, or CAUTION is

used with the safety alert symbol. DANGER identifies the
most serious hazards.
T133588
On the 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 1903JAN071/1
Follow Safety Instructions

UN24AUG00
Read the safety messages in this manual and on the

machine. Follow these warnings and instructions carefully.
Review them frequently.
T133556
Be sure all operators of this machine understand every

safety message. Replace operators manual and safety
labels immediately if missing or damaged.
TX03679,00016F9 1903JAN071/1
Operate Only If Qualified

Do not operate this machine unless the operators
manual has been read carefully, and you have been
qualified by supervised training and instruction.
Operator should be familiar with the job site and
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
every work situation and work site.
TX03679,00016FA 1903JAN071/1
TM10079 (17MAR09)
00-01-1

031709
PN=9
Safety
Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
UN23AUG88
Wear close fitting clothing and safety equipment

appropriate to the job.
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.
TS206
00
01
2
TX03679,00016D0 1903JAN071/1
Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John
Deere replacement parts to ensure machine
performance. Never substitute genuine John Deere
parts with alternate parts not intended for the
application as these can create hazardous situations or
hazardous performance. Non-John Deere Parts, or any
damage or failures resulting from their use are not
covered by any John Deere warranty.
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. The
installer of any modification which may affect the
electronic controls of this machine is responsible for
establishing that the modification does not adversely
affect the machine or its performance.
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.
AM40430,00000A9 1929JUL081/1
TM10079 (17MAR09)
00-01-2

031709
PN=10
Safety
00
01
3
T133733
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.
UN15SEP00
Add Cab Guarding for Special Uses
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.
TX03679,00016CE 1903JAN071/1
Inspect Machine
T6607AQ
Keep all guards and shields in good condition and

properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
UN18OCT88
Inspect machine carefully each day by walking around it

before starting.
TX03679,0001734 1903JAN071/1
Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.
T133592
Entanglements in moving parts can cause serious injury.
UN12SEP01
Stay Clear of Moving Parts
TX03679,00016D2 1903JAN071/1
TM10079 (17MAR09)
00-01-3

031709
PN=11
Safety
Avoid High-Pressure Fluids
Search for leaks with a piece of cardboard. Protect hands

and body from high pressure fluids.
X9811
Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
UN08DEC08
Escaping fluid under pressure can penetrate the skin

causing serious injury.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID 1903MAR931/1
Avoid High-Pressure Oils
T133509
If hydraulic oil penetrates your skin, see a doctor

immediately. Injected oil 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.
UN20SEP00
Never search for leaks with your hands. Protect hands.

Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
UN17MAR06
This machine uses a high-pressure hydraulic system.

Escaping oil under pressure can penetrate the skin
causing serious injury.
T133840
00
01
4
TX03679,00016D3 1903NOV081/1
TM10079 (17MAR09)
00-01-4

031709
PN=12
Safety
00
01
5
If you must operate in an enclosed space, 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.
T133546
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
UN24AUG00
Beware of Exhaust Fumes
TX03679,00016D4 1903NOV081/1
T133552
T133554
Keep A Fire Extinguisher Available: Always keep a

multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
UN07SEP00
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.
T133553
Clean Machine Regularly: Keep trash, debris, grease

and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
materials inside a machine compartment.
UN07SEP00
Handle Fuel Safely: Store flammable fluids away from

fire hazards. Never refuel machine while smoking or when
near sparks or flame.
UN14SEP00
Prevent Fires
TX03679,00016F5 1903NOV081/1
Prevent Battery Explosions
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
TS204
Do not charge a frozen battery; it may explode. Warm

battery to 16C (60F).
UN23AUG88
Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.
TX03679,000174A 1903NOV081/1
TM10079 (17MAR09)
00-01-5

031709
PN=13
Safety
If uncertain about safe handling or use of these chemical

products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
T133580
Exposure to hazardous chemicals can cause serious

injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
UN25AUG00
Handle Chemical Products Safely
TX03679,00016D7 1903JAN071/1
Never pour waste onto the ground, down a drain, or into

any water source.
T133567
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.
UN25AUG00
Dispose of Waste Properly
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 1903JAN071/1
Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts.
Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.
UN23AUG88
Keep a first aid kit and fire extinguisher handy.
TS291
00
01
6
TX03679,000174B 1903JAN071/1
TM10079 (17MAR09)
00-01-6

031709
PN=14
Safety
00
01
7
Use extra care when mud, snow, or moisture present

slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
T133468
Prevent falls by facing the machine when getting on and

off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
UN30AUG00
Use Steps and Handholds Correctly
TX03679,00016F2 1915MAR071/1
Never attempt to start engine from the ground. Do not

attempt to start engine by shorting across the starter
solenoid terminals.
T133715
Avoid unexpected machine movement. Start engine only

while sitting in operators seat. Ensure all controls and
working tools are in proper position for a parked machine.
UN07SEP00
Start Only From Operators Seat
TX03679,0001799 1903JAN071/1
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.
T133716
Use seat belt when operating machine. Remember to

fasten seat belt when loading and unloading from trucks
and during other uses.
1914SEP00
Use and Maintain Seat Belt
The complete seat belt assembly should be replaced

every three years, regardless of appearance.
TX03679,00016DD 1902DEC081/1
TM10079 (17MAR09)
00-01-7

031709
PN=15
Safety
Be careful not to accidentally actuate control levers when

co-workers are present. Pull pilot control shutoff lever to
locked position during work interruptions. Pull pilot control
shutoff lever to locked position and stop engine before
allowing anyone to approach machine.
Always lower work equipment to the ground and pull pilot
control shutoff lever to locked position before standing up
or leaving the operators seat. Stop engine before exiting.
UN22NOV05
Prevent Unintended Machine Movement
T216779
00
01
8
DW90712,00002C0 1903JAN071/1
TM10079 (17MAR09)
00-01-8

031709
PN=16
Safety
00
01
9
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.
T192984
Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all
underground utilities before starting work.
UN26AUG03
Avoid Work Site Hazards
Operate only on solid footing with strength sufficient to

support machine. Be especially alert working near
embankments or excavations.
T141904
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.
UN15MAY01
Avoid boom or attachment contact with overhead

obstacles or overhead electrical lines. Never move
machine closer than 3 m (10 ft) plus twice the line
insulator length to overhead wires.
Avoid working under over-hanging embankments or

stockpiles that could collapse under or on machine.
Reduce machine speed when operating with tool on or
near ground when obstacles may be hidden (e.g., during
snow removal or clearing mud, dirt, etc.). At high speeds
hitting obstacles (rocks, uneven concrete or manholes)
can cause a sudden stop. Always wear your seat belt.
AM40430,0000098 1924JAN071/1
Keep Riders Off Machine
Riders may obstruct operators view or impair his ability to

operate machine safely.
T7273AH
Riders are subject to injury. They may fall from machine,

be caught between machine parts, or be struck by foreign
objects.
UN08JUN90
Only allow operator on machine.
TX03679,0001726 1903JAN071/1
TM10079 (17MAR09)
00-01-9

031709
PN=17
Safety
T133548
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.
UN24AUG00
Avoid Backover Accidents
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 1903JAN071/1
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.
T133716
UN15SEP00
Load and unload from trucks or trailers carefully. Be

sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
Avoid trucks with steel beds because tracks slip more
easily on steel.
T133545
Do not jump if the machine tips. You will be unlikely to

jump clear and the machine may crush you.
UN27SEP00
Use seat belt at all times.
1914SEP00
Avoid Machine Tip Over
T133803
00
01
10
TX03679,00016DF 1903JAN071/1
TM10079 (17MAR09)
00-01-10

031709
PN=18
Safety
00
01
11
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.
T133839
Never use this machine to lift people.
UN27SEP00
Use Special Care When Lifting Objects
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 1903JAN071/1
Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting
your authorized dealer. Adding unapproved attachments
may affect machine stability or reliability and may create a
hazard for others near the machine.
Ensure that a qualified person is involved in attachment
installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections
are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all
instructions and warnings. In an area free of bystanders
and obstructions, carefully operate attachment to learn its
characteristics and range of motion.
TX03679,00016F0 1912FEB071/1
TM10079 (17MAR09)
00-01-11

031709
PN=19
Safety
Park and Prepare for Service Safely
T133332
Park machine on a level surface and lower equipment

and attachments to the ground.
Place pilot shutoff lever in lock position. Stop engine
and remove key.
Attach a Do Not Operate tag in an obvious place in
the operators station.
1914DEC01
Warn others of service work. Always park and prepare

your machine for service or repair properly.
Understand service procedures before beginning repairs.

Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TS229
Do not support machine with 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.
UN23AUG88
Securely support machine or attachment before working

under it.
TX03679,00016E9 1903JAN071/1
Service Cooling System Safely
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
UN23AUG88
Explosive release of fluids from pressurized cooling

system can cause serious burns.
TS281
00
01
12
DX,RCAP 1904JUN901/1
TM10079 (17MAR09)
00-01-12

031709
PN=20
Safety
00
01
13
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper 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.
TS220
Remove paint before heating:
UN23AUG88
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT 1924JUL021/1
TM10079 (17MAR09)
00-01-13

031709
PN=21
Safety
Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
T133547
IMPORTANT: Disable electrical power before welding.

Turn off main battery switch or
disconnect positive battery cable.
Separate harness connectors to engine
and vehicle microprocessors.
UN31AUG00
Make Welding Repairs Safely
Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
TX03679,00016D5 1925APR081/1
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
Drive Metal Pins Safely
T133738
00
01
14
TX03679,0001745 1903JAN071/1
TM10079 (17MAR09)
00-01-14

031709
PN=22
Group 0003
Torque Values
00
0003
1
TORQ2
UN07SEP99
Metric Bolt and Cap Screw Torque Values
TopProperty Class and Head Markings; BottomProperty Class and Nut Markings
METRIC BOLT AND CAP SCREW TORQUE VALUESTolerance is 10% unless otherwise specified
Class 4.8
Thread
Size
Lubricateda
Nm (lb-ft)
Class 8.8 or 9.8
Dryb
Nm (lb-ft)
Class 10.9
Lubricateda
Nm (lb-ft)
Dryb
Nm (lb-ft)
Class 12.9
Lubricateda
Nm (lb-ft)
Dryb
Nm (lb-ft)
Lubricateda
Nm (lb-ft)
Dryb
Nm (lb-ft)
19.5 (14.5)
M6
4.7 (3.5)
6 (4.4)
9 (6.6)
11.5 (8.5)
13 (9.5)
16.5 (12.2)
15.5 (11.5)
M8
11.5 (8.5)
14.5 (10.7)
22 (16)
28 (20.5)
32 (23.5)
40 (29.5)
37 (27.5)
47 (35)
M10
23 (17)
29 (21)
43 (32)
55 (40)
63 (46)
80 (59)
75 (55)
95 (70)
M12
40 (29.5)
50 (37)
75 (55)
95 (70)
110 (80)
140 (105)
130 (95)
165 (120)
M14
63 (46)
80 (59)
120 (88)
150 (110)
175 (130)
220 (165)
205 (150)
260 (190)
M16
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
M22
265 (195)
330 (245)
510 (375)
650 (480)
725 (535)
920 (680)
850 (625)
1080 (800)
M24
330 (245)
425 (315)
650 (480)
820 (600)
920 (680)
1150 (850)
1080 (800)
1350 (1000)
M27
490 (360)
625 (460)
950 (700)
1200 (885)
1350 (1000)
1700 (1250)
1580 (1160)
2000 (1475)
M30
660 (490)
850 (625)
1290 (950)
1630 (1200)
1850 (1350)
2300 (1700)
2140 (1580)
2700 (2000)
M33
900 (665)
1150 (850)
1750 (1300)
2200 (1625)
2500 (1850)
3150 (2325)
2900 (2150)
3700 (2730)
M36
1150 (850)
1450 (1075)
2250 (1650)
2850 (2100)
3200 (2350)
4050 (3000)
3750 (2770)
4750 (3500)
"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.
CAUTION: Use only metric tools on metric hardware.

Other tools may not fit properly. Tool may slip and
cause injury.
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.
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.
OUT3035,TORQUE2 1922MAR061/1
TM10079 (17MAR09)
00-0003-1

031709
PN=23
Torque Values
UN18OCT88
Additional Metric Cap Screw Torque Values
T6873AA
CAUTION: Use only metric tools on metric

hardware. Other tools may not fit properly. They
may slip and cause injury.
UN18OCT88
Check tightness of cap screws periodically. Torque values

listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
T6873AB
Fasteners should be replaced with the same or higher

grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
UN18OCT88
Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from
failing when tightening.
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
00
0003
2
Continued on next page
TM10079 (17MAR09)
00-0003-2
04T,90,M170 1929SEP991/2

031709
PN=24
Torque Values
00
0003
3
METRIC CAP SCREW TORQUE VALUESa

T-Bolt
Nominal
Dia
H-Bolt
Nm
lb-ft
29
21
10
63
12
14
Nm
lb-ft
M-Bolt
Nm
lb-ft
20
15
10
46
45
33
20
15
108
80
88
65
34
25
176
130
137
101
54
40
16
265
195
206
152
78
58
18
392
289
294
217
118
87
20
539
398
392
289
167
125
22
735
542
539
398
216
159
24
931
687
686
506
274
202
27
1372
1012
1029
759
392
289
30
1911
1410
1421
1049
539
398
33
2548
1890
1911
1410
735
542
36
3136
2314
2401
1772
931
687
Torque tolerance is 10%.
04T,90,M170 1929SEP992/2
TM10079 (17MAR09)
00-0003-3

031709
PN=25
Torque Values
UN27SEP99
Unified Inch Bolt and Cap Screw Torque Values
TORQ1A
00
0003
4
TopSAE Grade and Head Markings; BottomSAE Grade and Nut Markings
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUESTolerance is 10% unless otherwise specified
Grade 2a (No Mark)
Grade 1 (No Mark)

Thread
Size
Lubricated
Nm (lb-ft)
Dry
Nm (lb-ft)
Lubricatedb
Nm (lb-ft)
Grade 5, 5.1 or 5.2
Dryc
Nm (lb-ft)
Lubricatedb
Nm (lb-ft)
Dryc
Nm (lb-ft)
Grade 8 or 8.2
Lubricatedb
Nm (lb-ft)
Dryc
Nm (lb-ft)
1/4
3.8 (2.8)
4.7 (3.5)
6 (4.4)
7.5 (5.5)
9.5 (7)
12 (9)
13.5 (10)
17 (12.5)
5/16
7.7 (5.7)
9.8 (7.2)
12 (9)
15.5 (11.5)
19.5 (14.5)
25 (18.5)
28 (20.5)
35 (26)
3/8
13.5 (10)
17.5 (13)
22 (16)
27.5 (20)
35 (26)
44 (32.5)
49 (36)
63 (46)
7/16
22 (16)
28 (20.5)
35 (26)
44 (32.5)
56 (41)
70 (52)
80 (59)
100 (74)
1/2
34 (25)
42 (31)
53 (39)
67 (49)
85 (63)
110 (80)
120 (88)
155 (115)
9/16
48 (35.5)
60 (45)
76 (56)
95 (70)
125 (92)
155 (115)
175 (130)
220 (165)
5/8
67 (49)
85 (63)
105 (77)
135 (100)
170 (125)
215 (160)
240 (175)
305 (225)
3/4
120 (88)
150 (110)
190 (140)
240 (175)
300 (220)
380 (280)
425 (315)
540 (400)
7/8
190 (140)
240 (175)
190 (140)
240 (175)
490 (360)
615 (455)
690 (510)
870 (640)
285 (210)
360 (265)
285 (210)
360 (265)
730 (540)
920 (680)
1030 (760)
1300 (960)
1-1/8
400 (300)
510 (375)
400 (300)
510 (375)
910 (670)
1150 (850)
1450 (1075)
1850 (1350)
1-1/4
570 (420)
725 (535)
570 (420)
725 (535)
1280 (945)
1630 (1200)
2050 (1500)
2600 (1920)
1-3/8
750 (550)
950 (700)
750 (550)
950 (700)
1700 (1250)
2140 (1580)
2700 (2000)
3400 (2500)
1-1/2
990 (730)
1250 (930)
990 (730)
1250 (930)
2250 (1650)
2850 (2100)
3600 (2650)
4550 (3350)
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening

procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
Shear bolts are designed to fail under predetermined loads. Always

replace shear bolts with identical grade.
Tighten plastic insert or crimped steel-type lock nuts to approximately

50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher grade. If

higher grade fasteners are used, these should only be tightened to
the strength of the original.
OUT3035,TORQUE1 1914JAN041/1
TM10079 (17MAR09)
00-0003-4

031709
PN=26
Torque Values
00
0003
5
Service Recommendations for 37 Flare and

30 Cone Seat Connectors
3. Align tube with fitting before attempting to start nut.
T6234AC
2. Defects in tube flare cannot be repaired.

Overtightening a defective flared fitting will not stop
leaks.
UN18OCT88
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
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
Nm
lb-ft
3/8 - 24 UNF
7/16 - 20 UNF
12
1/2 - 20 UNF
16
12
9/16 - 18 UNF
24
18
3/4 - 16 UNF
46
34
7/8 - 14 UNF
62
46
1-1/16 - 12 UN
102
75
1-3/16 - 12 UN
122
90
1-5/16 - 12 UN
142
105
1-5/8 - 12
190
140
1-7/8 - 12 UN
217
160
NOTE: Torque tolerance is 10%.
T82,BHMA,EL 1929SEP991/1
TM10079 (17MAR09)
00-0003-5

031709
PN=27
Torque Values
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.
T6243AE
00
0003
6
3. Tighten fitting to torque value shown on chart.
TM10079 (17MAR09)
00-0003-6
04T,90,K66 1929SEP991/2

031709
PN=28
Torque Values
00
0003
7
Angle Fitting
3. Turn fitting head-end counterclockwise to proper index

(maximum of one turn).
NOTE: Do not allow hoses to twist when tightening
fittings.
T6520AB
2. Turn fitting into threaded boss until back-up washer

contacts face of boss.
UN18OCT88
1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.
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
Nm
lb-ft
3/8-24 UNF
7/16-20 UNF
12
1/2-20 UNF
16
12
9/16-18 UNF
24
18
3/4-16 UNF
46
34
7/8-14 UNF
62
46
1-1/16-12 UN
102
75
1-3/16-12 UN
122
90
1-5/16-12 UN
142
105
1-5/8-12 UN
190
140
1-7/8-12 UN
217
160
NOTE: Torque tolerance is 10%.
04T,90,K66 1929SEP992/2
TM10079 (17MAR09)
00-0003-7

031709
PN=29
Torque Values
UN17NOV03
O-Ring Boss Fittings In Aluminum Housing Service RecommendationsExcavators
T196315
00
0003
8
O-Ring Boss Straight and Adjustable Fittings

1Straight Fitting
2O-Ring
3Stud End
4Adjustable Fitting
5Hex Nut
6Backup Washer
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD

END NUT WITH METRIC THREAD IN ALUMINUM HOUSING
TORQUE VALUESTolerance is 10% unless otherwise
specified
Thread Size
mm
Hex Nut Size

mm
Nm (lb-ft)
M12 x 1.5
17
39 (29)
M14 x 1.5
19
39 (29)
M16 x 1.5
22
55 (41)
M22 x 1.5
27
75 (55)
M27 x 2
32
110 (81)
M30 x 2
36
141 (104)
M33 x 2
41
165 (122)
M38 x 2
46
165 (122)
M42 x 2
50
275 (203)
TM10079 (17MAR09)
00-0003-8
OUT3035,0000353 1910MAR091/2

031709
PN=30
Torque Values
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD
END NUT WITH INCH THREAD IN ALUMINUM HOUSING
TORQUE VALUESTolerance is 10% unless otherwise
specified
Thread Size
in.
Nm (lb-ft)
1/8
1/4
28 (20)
3/8
39 (29)
1/2
75 (55)
3/4
126 (93)
165 (122)
1-1/8
1-1/4
259 (191)
1-3/8
1-1/2
330 (243)
1-3/4
2. Back the stud end hex nut (5) off as far as possible.
Push backup washer (6) towards the nut to fully
expose the turn down section of stud end. Washer
must fit turned down section and not be too loose
3. Wrap electrical tape over threads to protect O-ring.
Slide O-ring over the tape into turned down section.
Remove tape. Apply hydraulic oil to the threads of
stud end, turned down section, and O-ring.
4. Turn fitting into the boss by hand until face of nut or
backup washer squeezes O-ring into the seat and
contacts face of boss. Loosen an adjustable fitting
no more than one turn for alignment.
O-RING BOSS PLUG STUD END WITH INCH THREAD IN

ALUMINUM HOUSING TORQUE VALUESTolerance is 10%
unless otherwise specified
Thread Size
in.
1. Inspect fitting and O-ring boss sealing surfaces and

the O-ring. They must be free of dirt, scratches,
nicks, or burrs. O-ring must be free of dirt, cuts,
cracks, swelling or flatten condition.
5. Tighten straight fitting or hex nut to the torque value

given. Hold body of adjustable fitting using a
second wrench when tightening hex nut.
Nm (lb-ft)
1/8
7.8 (5.80)
1/4
11.8 (8.70)
3/8
23 (17)
1/2
39 (29)
3/4
55 (41)
86 (64)
1-1/4
126 (93)
1-1/2
157 (116)
204 (150)
OUT3035,0000353 1910MAR092/2
TM10079 (17MAR09)
00-0003-9

031709
PN=31
00
0003
9
Torque Values
Service Recommendations For Flared

ConnectionsStraight or Tapered Threads
UN18OCT88
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
T6873AE
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
4. Lubricate the male threads with hydraulic fluid or

petroleum jelly.
5. Index angle fittings and tighten by hand.
TORQUE CHART
Straight Thread
Thread
Size
Nm
lb-ft
1/8
15
11
1/4
20
3/8
1/2
3/4
Tapered Thread
Nm
lb-ft
15
45
33
29
21
69
51
49
36
93
69
69
51
176
130
157
116
343
253
1-1/2
196
145
539
398
255
188
588
434
Torque tolerance is 10%.
With seat face.
UN18OCT88
6. Tighten fitting or nut to torque value shown on the

fittings.
T6873AD
00
0003
10
Tapered Thread
NOTE: If female thread is cast iron (control valves, brake

valves motors, etc.), torque must be reduced
approximately 10%.
04T,90,M171 1928JAN921/1
TM10079 (17MAR09)
00-0003-10

031709
PN=32
Torque Values
00
0003
11
Service Recommendations For Flat Face O-Ring Seal Fittings

1. Inspect the fitting sealing surfaces and O-ring. They
must be free of dirt or defects.
fittings, use backup wrench on straight hose

couplings.
2. Lubricate O-rings and install into grove using

petroleum jelly to hold in place.
IMPORTANT: Tighten fittings to 150% of listed

torque value if indexing is necessary
or if fitting is attached to an
actuating devise.
3. Index angle fittings and tighten by hand pressing

joint together to insure O-ring remains in place.
Tighten fittings to 50% of listed

torque value if used in aluminum
housing.
4. Tighten fitting or nut to torque value shown on the

FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D.
Thread Size
Swivel Nut
Bulkhead Nut
mm
in.
in.
Nm
lb-ft
Nm
lb-ft
6.35
0.250
9/16-18
16
12
12
9
18
9.52
0.375
11/16-16
24
18
24
12.70
0.500
13/16-16
50
37
46
34
15.88
0.625
1-14
69
51
62
46
19.05
0.750
1 3/16-12
102
75
102
75
22.22
0.875
1 3/16-12
102
75
102
75
25.40
1.000
1 7/16-12
142
105
142
105
31.75
1.250
1 11/16-12
190
140
190
140
38.10
1.500
2-12
217
160
217
160
*Torque tolerance is +15 -20% unless otherwise specified.

Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size
Straight Hex Size
Locknut Hex Size
Inch
Inch
Inch
Straight Fitting or Locknut Toque

Nm
lb-ft
3/8-24
5/8
9/16
12
7/16-20
5/8
5/8
21
15
1/2-20
3/4
11/16
26
19
9/16-18
3/4
3/4
34
25
3/4-16
7/8
15/16
73
55
7/8-14
1 1/16
1 1/16
104
76
1 1/16-12
1 1/4
1 3/8
176
130
1 3/16-12
1 3/8
1 1/2
230
170
1 5/16-12
1 1/2
1 5/8
285
210
*Torque tolerance is +15 -20% unless otherwise specified.
04T,90,K67 1902MAR001/1
TM10079 (17MAR09)
00-0003-11

031709
PN=33
Torque Values
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure
Service Recommendations
A
UN12DEC01
G
E
F
H
F
H70406
00
0003
12
A90 Swivel Elbow and Tube

Nut
B90 Adjustable Stud Elbow
CStud Straight and Tube Nut

DBulkhead Union and Nut
EStud End
FTube Nut
GSwivel Nut
HHex Nut
O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000
psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID
Metric Tube
OD
Inch Tube OD or Hose ID
O-Ring Face Seal Hose or Tube Swivel Nut
Bulkhead Nut
Thread Size
Hex Size
Torque
Hex Size
Torque
mm
Dash Size
mm (in.)
in.
in.
Nm (lb-ft)
in.
Nm (lb-ft)
-3
4.78 (0.188)
-4
6.35 (0.250)
9/16-18
11/16
24 (18)
13/16
32 (24)
-5
7.92 (0.312)
10
-6
9.53 (0.375)
11/16-16
13/16
37 (27)
42 (31)
12
-8
12.70 (0.500)
13/16-16
15/16
75 (55)
1-1/8
93 (69)
16
-10
15.88 (0.625)
1-14
1-1/8
103 (76)
1-5/16
118 (87)
20
-12
19.05 (0.750)
1-3/16-12
1-3/8
152 (112)
1-1/2
175 (129)
22
-14
22.23 (0.875)
1-3/16-12
152 (112)
175 (129)
25
-16
25.40 (1.000)
1-7/16-12
1-5/8
214 (158)
1-3/4
247 (182)
32
-20
31.75 (1.250)
1-11/16-12
1-7/8
286 (211)
328 (242)
38
-24
38.10 (1.500)
2-12
2-1/4
326 (240)
2-3/8
374 (276)
TM10079 (17MAR09)
00-0003-12
OUT3035,0000420 1914JAN041/2

031709
PN=34
Torque Values
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600
kPa (276 bar) (4000 psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Thread Size
Straight Hex Sizea
Adjustable Nut Hex Size
Steel or Gray Iron Torque
in.
in.
in.
Nm (lb-ft)
3/8-24
5/8
9/16
18 (13)
7/16-20
5/8
5/8
24 (18)
30 (22)
1/2-20
3/4
11/16
9/16-18
3/4
3/4
37 (27)
3/4-16
7/8
15/16
75 (55)
7/8-14
1-1/16
1-1/16
103 (76)
1-1/16-12
1-1/4
1-3/8
177 (131)
1-3/16-12
1-3/8
1-1/2
231 (170)
1-5/16-12
1-1/2
1-5/8
270 (199)
1-5/8-12
1-3/4
1-7/8
286 (211)
1-7/8-12
2-1/8
2-1/8
326 (240)
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
1. Inspect fitting and connector sealing surfaces and

the O-rings. They must be free of dirt, scratches,
nicks, and burrs. O-ring must be free of dirt, cuts,
2. Back the stud end hex nut off as far as possible.
Push backup washer towards the nut to fully
expose the turn down section. Washer must fit
turned down section and not be too loose
3. Lubricate O-rings using a thin film of clean hydraulic
oil or as needed, petroleum jelly to hold O-ring in
place.
Install O-ring into groove making sure it is seated at
the bottom. Excess petroleum jelly will prevent
seating of O-ring and cause it to pop out.
To protect an O-ring from threads, wrap electrical

tape over the threads. Slide O-ring over the tape
into the turned down section. Remove the tape.
washer squeezes the O-ring into the seat and
contacts face of boss. Loosen adjustable fittings no
more than one turn for alignment.
Hold connections together while tightening nut to
ensure O-ring remains in place.
5. Tighten fitting or nut to torque value shown. Use a
second wrench to hold the fitting in position or to
keep hose from twisting while tightening nut.
OUT3035,0000420 1914JAN042/2
TM10079 (17MAR09)
00-0003-13

031709
PN=35
00
0003
13
Torque Values
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure
Service Recommendations
1
11
11
11
10
T196337
10
190 Swivel Elbow

290 Adjustable Stud Elbow
3Stud Straight
UN18NOV03
10
4Bulkhead Union and Nut

5External Hex Stud End Plug
6Tube Nut
T196337
00
0003
14
7Swivel Nut
8Stud End
9Hex Nut
10O-Ring
11Identification Groove
O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa
(275.8 bar) (4,000 psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Metric Tube
OD
Bulkhead Nut
Thread Size
Hex Size
Torque
Hex Size
Torque
mm
Dash Size
mm (in.)
in.
mm
Nm (lb-ft)
mm
Nm (lb-ft)
-2
3.18 (0.125)
-3
4.78 (0.188)
-4
6.35 (0.250)
9/16-18
17
16 (12)
22
32 (24)
-5
7.92 (0.312)
10
-6
9.53 (0.375)
11/16-16
22
24 (18)
27
42 (31)
12
-8
12.70 (0.500)
13/16-16
24
50 (37)
30
93 (69)
16
-10
15.88 (0.625
1-14
30
69 (51)
36
118 (87)
20
-12
19.05 (0.750)
1-3/16-12
36
102 (75)
41
175 (129)
22
-14
22.23 (0.875)
1-3/16-12
36
102 (75)
41
175 (129)
25
-16
25.40 (1.000)
1-7/16-12
41
142 (105)
46
247 (182)
28
32
-20
31.75 (1.250)
1-11/16-12
50
190 (140)
50
328 (242)
38
-24
38.10 (1.500)
2-12
60
217 (160)
60
374 (276)
50
-32
50.80 (2.000)
TM10079 (17MAR09)
00-0003-14
OUT3035,0000366 1914JAN041/2

031709
PN=36
Torque Values
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27
600 kPa (275.8 bar) (4,000 psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Thread Sizea
Straight Hex Sizeb
Adjustable Nut Hex

Size
Aluminum or Brass
Torque
mm.
mm
mm
Nm (lb-ft)
Nm (lb-ft)
M8 x 1
12
12
8 (6)
5 (4)
M10 x 1
14
14
15 (11)
10 (7)
M12 x 1.5
17
17
25 (18)
17 (12)
M14 x 1.5
19
19
40 (30)
27 (20)
M16 x 1.5
22
22
45 (33)
30 (22)
M18 x 1.5
24
24
50 (37)
33 (25)
M22 x 1.5
27
27
69 (51)
46 (34)
M27 x 2
32
32
100 (74)
67 (49)
M30 x 2
36
36
130 (96)
87 (64)
M33 x 2
41
41
160 (118)
107 (79)
M38 x 2
46
46
176 (130)
117 (87)
M42 x 2
50
50
210 (155)
140 (103)
M48 x 2
55
55
260 (192)
173 (128)
M60 x 2
65
65
315 (232)
210 (155)
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.

place.

OUT3035,0000366 1914JAN042/2
TM10079 (17MAR09)
00-0003-15

031709
PN=37
00
0003
15
Torque Values
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service
Recommendations
1
11
11
11
10
T196337
10
190 Swivel Elbow

290 Adjustable Stud Elbow
3Stud Straight
UN18NOV03
10
4Bulkhead Union and Nut

5External Hex Stud End Plug
6Tube Nut
T196337
00
0003
16
7Swivel Nut
8Stud End
9Hex Nut
10O-Ring
11Identification Groove
O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000
psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Metric Tube
OD
Bulkhead Nut
Thread Size
Hex Size
Torque
Hex Size
Torque
mm
Dash Size
mm (in.)
in.
mm
Nm (lb-ft)
mm
Nm (lb-ft)
-2
3.18 (0.125)
-3
4.78 (0.188)
-4
6.35 (0.250)
9/16-18
17
24 (18)
22
32 (24)
-5
7.92 (0.312)
10
-6
9.53 (0.375)
11/16-16
22
37 (27)
27
42 (31)
12
-8
12.70 (0.500)
13/16-16
24
75 (55)
30
93 (69)
16
-10
15.88 (0.625)
1-14
30
103 (76)
36
118 (87)
20
-12
19.05 (0.750)
1-3/16-12
36
152 (112)
41
175 (129)
22
-14
22.23 (0.875)
1-3/16-12
36
152 (112)
41
175 (129)
25
-16
25.40 (1.000)
1-7/16-12
41
214 (158)
46
247 (182)
28
32
-20
31.75 (1.250)
1-11/16-12
286 (211)
50
328 (242)
38
-24
38.10 (1.500)
2-12
326 (240)
60
374 (276)
TM10079 (17MAR09)
00-0003-16
OUT3035,0000421 1914JAN041/2

031709
PN=38
Torque Values
00
0003
17
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600
KPA (275.8 BAR) (4,000 PSI), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Thread Sizea
Straight Hex Sizeb
Adjustable Nut Hex Size

Nm (lb-ft)
mm.
mm
mm
M8 x 1
12
12
8 (6)
M10 x 1
14
14
15 (11)
M12 x 1.5
17
17
35 (26)
M14 x 1.5
19
19
45 (33)
M16 x 1.5
22
22
55 (41)
M18 x 1.5
24
24
70 (52)
M22 x 1.5
27
27
100 (74)
M27 x 2
32
32
170 (125)
M30 x 2
36
36
215 159)
M33 x 2
41
41
260 (192)
M38 x 2
46
46
320 (236)
M42 x 2
50
50
360 (266)
M48 x 2
55
55
420 (310)
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.

place.

OUT3035,0000421 1914JAN042/2
TM10079 (17MAR09)
00-0003-17

031709
PN=39
Torque Values
UN01MAR90
Service Recommendations for Metric Series Four Bolt Flange Fitting
T6890BB
00
0003
18
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange
then tighten the diagonally opposite cap screw.

Tighten two remaining cap screws. Tighten all cap
screws as specified in the chart below.
1. Clean sealing surfaces (A). Inspect. Scratches

cause leaks. Roughness causes seal wear.
Out-of-flat causes seal extrusion. If defects cannot
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
2. Install the correct O-ring (and backup washer if

required) into groove using petroleum jelly to hold it
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B)

halves. Make sure split is centrally located and
perpendicular to the port. Hand tighten cap screws
to hold parts in place. Do not pinch O-ring (C).
Thread
Nm
M6
12
M8
30
22
M10
57
42
4. Single piece flange (D): Place hydraulic line in

center of flange and install four cap screws. Flange
must be centrally located on port. Hand tighten cap
screws to hold flange in place. Do not pinch O-ring.
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
5. After components are properly positioned and cap

screws are hand tightened, tighten one cap screw,
lb-ft
Tolerance 10%. The torques given are enough for the given
size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
a
Metric standard thread.
04T,90,K175 1929SEP991/1
TM10079 (17MAR09)
00-0003-18

031709
PN=40
Torque Values
00
0003
19
T6890BB
UN01MAR90
Service Recommendations For Inch Series Four Bolt Flange Fittings
ASealing Surface
BSplit Flange
CPinched O-Ring
1. Clean sealing surfaces (A). Inspect. Scratches

cause leaks. Roughness causes seal wear.
Out-of-flat causes seal extrusion. If defects cannot
be polished out, replace component.
2. Install O-ring (and backup washer if required) into
groove using petroleum jelly to hold it in place.
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.

TORQUE CHART
Nm
Nominal
Flange
Size
lb-ft
Cap Screw
Size
Min
Max
Min
Max
1/2
5/16-18
UNC
20
31
15
23
3/4
3/8-16 UNC
28
54
21
40
3/8-16 UNC
37
54
27
40
1-1/4
7/16-14
UNC
47
85
35
63
1-1/2
1/2-13 UNC
62
131
46
97
1/2-13 UNC
73
131
54
97
2-1/2
1/2-13 UNC
107
131
79
97
5/8-11 UNC
158
264
117
195
3-1/2
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
04T,90,K174 1901AUG941/1
TM10079 (17MAR09)
00-0003-19

031709
PN=41
Torque Values
UN01MAR90
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
T6890BB
00
0003
20
ASealing Surface
BSplit Flange
CPinched O-Ring
1. Clean sealing surfaces (A). Inspect. Scratches,

nicks, and burrs cause leaks. Roughness causes
O-ring wear. Out-of-flat causes O-ring extrusion. If
imperfection cannot be polished out, replace
component.
2. Install the O-ring (and backup ring, if used) into
groove. Use petroleum jelly to hold it in place.
4. Tighten one cap screw and then the diagonally

opposite cap screw. Tighten the two remaining cap
screws. Tighten cap screws within the specified
torque values.
INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa
(414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES
Tolerance is 10% unless otherwise specified
IMPORTANT: DO NOT use air wrenches. DO NOT

tighten one cap screw fully before
tightening the others. DO NOT over
tighten.
perpendicular to port. Hand tighten cap screws to
hold flange halves and line in place. Do not pinch
O-ring (C).
Single piece flange (D): Make sure flange is
centrally located on port and line is centered in
flange. Install the cap screws. Hand tighten cap
screws to hold flange and line in place. Do not
pinch O-ring.
Nominal
Flange Size
Cap Screw Sizea
MinMax Torque
in.
in.
Nm (lb-ft)b
1/2
5/16-18 UNC
2031 (1523)
3/4
3/8-16 UNC
3454 (2540)
7/16-14 UNC
5785 (4263)
1-1/4
1/2-13 UNC
85131 (6397)
1-1/2
5/8-11 UNC
159264 (117195)
3/4-10 UNC
271468 (200345)
JDM A17D, SAE Grade 5 or better cap screws with plated

hardware.
Lock washers are permissible but not recommended.
b
Minimum torques given are enough for the given size connection
with the recommended working pressure. Torques can be
increased to the maximum shown for each cap screw size if
desired. Increasing cap screw torque beyond the maximum will
result in flange and cap screw bending and connection failures.
OUT3035,0000422 1905MAR091/1
TM10079 (17MAR09)
00-0003-20

031709
PN=42
Section 01
Tracks
Contents
01
Page
Group 0130Track System

Track Roller Remove and Install . . . . . . . . . .01-0130-1
Track Roller Disassemble and Assemble . . .01-0130-3
Track Roller Pressure Test . . . . . . . . . . . . . .01-0130-5
Track Carrier Roller Remove and Install . . . .01-0130-6
Metal Face Seals Repair . . . . . . . . . . . . . . . .01-0130-8
Track Shoe Remove and Install . . . . . . . . .01-0130-11
Track Chain Remove and Install . . . . . . . . .01-0130-12
Track Chain Disassemble and Assemble . .01-0130-16
Track Chain Repair . . . . . . . . . . . . . . . . . . .01-0130-17
Sprocket Remove and Install. . . . . . . . . . . .01-0130-19
Front Idler Remove and Install . . . . . . . . . .01-0130-20
Front Idler Disassemble and Assemble . . . .01-0130-21
Track Adjuster and Recoil Spring Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .01-0130-23
Track Adjuster and Recoil Spring
Disassemble and Assemble. . . . . . . . . . .01-0130-25
Track Adjuster Cylinder Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-30
TM10079 (17MAR09)
01-1

031709
PN=1
Contents
01
TM10079 (17MAR09)
01-2

031709
PN=2
Group 0130
Track System
Track Roller Remove and Install
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.
01
0130
1
CAUTION: Prevent possible injury from

unexpected machine movement. Position shop
stands under frame to support machine while
removing lower track roller.
2. Put shop stands under machine.
Specification
200D ExcavatorWeight
(approximate).............................................................................. 22 000 kg
49 000 lb
Specification
200DLC ExcavatorWeight
(approximate).............................................................................. 23 000 kg
50 000 lb
OUO6046,0002302 1927JUN081/3
CAUTION: Prevent possible injury from high

pressure grease. Do not remove grease fitting
(A) from valve (B).
UN28NOV90
3. Loosen valve (B) one to two turns to release grease

through bleed hole (C).
T7396DZ
AGrease Fitting
BValve
CBleed Hole
TM10079 (17MAR09)
01-0130-1
OUO6046,0002302 1927JUN082/3

031709
PN=45
Track System
CAUTION: Heavy component; use appropriate

lifting device.
UN25OCT88
Specification
Track RollerWeight ........................................................................ 35 kg
77 lb
4. Attach appropriate lifting device to track roller (B).

Remove cap screws (A) and track roller (B).
T6585TN
01
0130
2
5. Measure track roller tread diameter. See 200D and

200DLC Track Roller Tread Diameter. (SP326
Undercarriage Appraisal Manual.)
6. Repair or replace parts as necessary. See Track Roller
Disassemble and Assemble. (Group 0130.)
ACap Screw (4 used)

BTrack Roller
7. Install track roller and tighten cap screws to

specification.
Specification
Roller-to-Frame Cap Screw
Torque .......................................................................................... 460 Nm
340 lb-ft
8. If equipped, install track roller guard and tighten cap

screws to specification.
Specification
Track Roller Guard Cap Screw
Torque .......................................................................................... 460 Nm
340 lb-ft
9. Tighten valve on track adjuster to specification.

Specification
Track Adjuster ValveTorque ....................................................... 88 Nm
65 lb-ft
10. Check and adjust track sag. See Check and Adjust
Track Sag. (Operators Manual.)
OUO6046,0002302 1927JUN083/3
TM10079 (17MAR09)
01-0130-2

031709
PN=46
Track System
Track Roller Disassemble and Assemble
T8310AH
UN21SEP94
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
7. Remove bushings (F) using a 2-jaw puller and

adapters from puller set.
1. Remove plug (A) and drain oil.

2. Remove pin (C).
8. Replace parts as necessary.

3. Remove bracket (B) using a bearing puller
attachment and adapters from puller set.
Apply a thin film of oil to bushings (F) and install.
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. (Group 0130.)
6. Remove axle (H) from roller.
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.
NOTE: Only remove bushings if replacement is

necessary.
TM10079 (17MAR09)
01-0130-3
OUO6046,0002303 1919APR071/2

031709
PN=47
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
12. Install axle (H) to bracket (B).
16. Fill roller to specification.

Specification
Lower Track RollerCapacity ................................................. 260 mL
8.8 oz
17. Apply PM37509 Cure Primer and PM37398 Pipe

Sealant to threads of plug. Install and tighten plug.
13. Install roller (G) onto axle (H).

14. Install opposite side bracket (B) on roller
assembly.
Specification
PlugTorque ........................................................................... 30 Nm
22 lb-ft
15. Apply TY24811NEVER-SEEZ anti-seize lubricant

or equivalent to pins (C). Install pins (C) even with
flat surface of brackets (B).
NEVER-SEEZ is a trademark of Bostik Findley, Inc.
TM10079 (17MAR09)
OUO6046,0002303 1919APR072/2
01-0130-4

031709
PN=48
Track System
Track Roller Pressure Test

1. Hold shaft and turn shell of roller several turns to seat
metal face seals.
UN02JUN97
2. Remove the drain plug.
T109691B
NOTE: Plug, barbed adapter, and connector (A) are from

leak detector kit D05361ST.
3. Install parts (AF).
4. Tighten plug. Slowly pressurize oil cavity to test
pressure specification.
Specification
Track Roller Oil CavityPressure ....................................... 110 28 kPa
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
ENeedle Valve
FAir Pressure Regulator
5. Close valve. Wait for 30 seconds. Check for oil leaks

or pressure decrease.
6. If leakage, disassemble roller and replace parts as
necessary. See Track Roller Disassemble and
Assemble. (Group 0130.)
7. Apply PM37509 Cure Primer and PM37398 Pipe
Sealant to threads of plug. Install and tighten plug to
specification.
Specification
PlugTorque.................................................................................. 30 Nm
22 lb-ft
OUO6046,0002304 1919APR071/1
TM10079 (17MAR09)
01-0130-5

031709
PN=49
01
0130
5
Track System
Track Carrier Roller Remove and Install
UN28NOV90
T7396DZ

AGrease Fitting
BValve
CBleed Hole
OUO6046,0002305 1926JUN081/3
2. Raise track chain (3), using a jack, enough to permit

carrier roller (2) removal.
UN07APR06
CAUTION: Prevent accidental lowering of track

by securely supporting track before attempting
service procedure.
3. Install wooden block (4) between track chain (3) and
track frame (1).
TX1006136A
01
0130
6

(A) from valve (B).
1Track Frame
2Carrier Roller
3Track Chain
4Wood Block
TM10079 (17MAR09)
01-0130-6
OUO6046,0002305 1926JUN082/3

031709
PN=50
Track System
4. Remove cap screws (1) and carrier roller (2).
5. Measure track carrier roller tread diameter. See 200D
and 200DLC Carrier Roller Tread Diameter. (SP326
01
0130
7
UN26JAN07
IMPORTANT: Carrier roller replaced as assembly

only.
6. Replace carrier roller as necessary.
TX1018018A
Specification
Carrier RollerWeight ...................................................................... 21 kg
46 lb
7. Install carrier roller and cap screws (1).

8. Tighten carrier roller cap screws (1) to specification.
1Cap Screw (4 used)

2Carrier Roller
Specification
Carrier Roller-to-Frame Cap
ScrewTorque ............................................................................. 270 Nm
200 lb-ft
9. Remove wooden blocks and jack.

10. Tighten valve on track adjuster to specification.
Specification
65 lb-ft
OUO6046,0002305 1926JUN083/3
TM10079 (17MAR09)
01-0130-7

031709
PN=51
Track System
Metal Face Seals Repair

Inspect Metal Face Seals
IMPORTANT: If seals are to be reused, keep seal
rings together as a matched set with
seal ring faces together. Insert a piece
of cardboard to protect surfaces.
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).
UN24AUG93
b. Sealing area must be uniform and concentric with

the ID and OD of seal ring (A).
T85079
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)
OUO6046,0002306 1905MAR071/4
2. Illustration shows examples of worn seal rings (A).

ISealing area (D) is in inner half of seal ring face (C).
UN05DEC96
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)
T85080
01
0130
8
TM10079 (17MAR09)
01-0130-8
OUO6046,0002306 1905MAR072/4

031709
PN=52
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.
UN23FEB89
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.
T82840
ASeal Face
TM10079 (17MAR09)
01-0130-9
OUO6046,0002306 1905MAR073/4

031709
PN=53
01
0130
9
Track System
Assemble Metal Face Seals
IMPORTANT: If incorrectly assembled, oil leakage or
damage will occur.
1. Check that the O-ring (A) is not twisted and that it is
installed correctly on seal ring.
2. After installing seal, check that seal ring surface (C) is
parallel with seal mating face (B) by measuring
distances (D) and (E), as shown. If these distances
differ, correct O-ring seating.
UN26JAN07
TX1018110
UN26JAN07
AO-Ring
BMating Face
CRing Surface
DDistance
EDistance
TX1018112
01
0130
10
OUO6046,0002306 1905MAR074/4
TM10079 (17MAR09)
01-0130-10

031709
PN=54
Track System
Track Shoe Remove and Install
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.
T6794AM
2. Apply a light coat of oil to cap screw threads and install

shoe.
UN23FEB89
1. Measure grouser height. See 200D and 200DLC Three

Bar Grouser Height. (SP326 Undercarriage Appraisal
Manual.)
4. Tighten cap screws in pattern shown.
UN23FEB89
Specification
Shoe-to-Link Cap ScrewTorque ............................................... 804 Nm
593 lb-ft
T6352AH
ARounded Edge
BChamfered Edge
OUO6046,0002307 1926JUN081/1
TM10079 (17MAR09)
01-0130-11

031709
PN=55
01
0130
11
Track System
Track Chain Remove and Install

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.
2. Place blocks or shop stands under the machine to
support machine.
Specification
200D ExcavatorWeight
(approximate).............................................................................. 22 000 kg
49 000 lb
Specification
200DLC ExcavatorWeight
(approximate).............................................................................. 23 000 kg
50 000 lb
OUO6046,0002308 1927JUN081/4

(A) from valve (B).
UN28NOV90

AGrease Fitting
BValve
CBleed Hole
T7396DZ
01
0130
12
TM10079 (17MAR09)
01-0130-12
OUO6046,0002308 1927JUN082/4

031709
PN=56
Track System
NOTE: Master pin (2) and master link are identified by
large dimple (3) and snap ring on master pin.
4. Move track chain so master pin (2) is over front idler or
sprocket.
01
0130
13
5. Remove track shoe on each side of master pin. See

Track Shoe Remove and Install. (Group 0130.)
UN20JUL01
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.
T143215B
7. Remove snap ring.

IMPORTANT: Master pin can be removed in only one
direction.
1Bushing (2 used)
2Master Pin
3Dimple
8. Remove master pin using a 50-Ton Master Pin Pusher

Installer.
9. If chain was disconnected at idler, slowly operate travel
lever in reverse direction to remove chain from top of
track frame.
lifting device.
Specification
TracksWeight ............................................................................. 1260 kg
2780 lb
10. Remove track chain.

11. Measure track chain link, bushing, and pitch. (See
SP326 Undercarriage Appraisal Manual.)
13. Position track chain so section on ground has pin
boss on links toward rear of machine.
14. Install end of chain on sprocket and slowly turn
sprocket in forward direction to pull chain across top
of frame to front idler.
15. Remove stand and lower machine.
TM10079 (17MAR09)
01-0130-13
OUO6046,0002308 1927JUN083/4

031709
PN=57
Track System
IMPORTANT: Master pin can be installed in only one
direction.
01
0130
14
16. Pull ends of chain together. Install master pin using

50-Ton Master Pin Pusher Installer.
IMPORTANT: Replace snap ring with new one.
17. Install snap ring.
18. Install track shoe. See Track Shoe Remove and
Install. (Group 0130.)
19. Tighten valve in track adjuster to specification.
Specification
65 lb-ft
OUO6046,0002308 1927JUN084/4
TM10079 (17MAR09)
01-0130-14

031709
PN=58
Track System
01
0130
15
TM10079 (17MAR09)
01-0130-15

031709
PN=59
Track System
Track Chain Disassemble and Assemble
T162713
UN15JAN03
01
0130
16
TM10079 (17MAR09)
01-0130-16
OUO6046,0002309 1926JUN081/2

031709
PN=60
Track System
1Track Link (200D, 45 used;
200DLC, 48 used)
2Master Track Link
3Pin (200D, 45 used;
200DLC, 48 used)
5Seal (200D, 90 used;
200DLC, 96 used)
7Master Pin
8Spacer (2 used)
9Snap Ring
10Cap Screw (200D, 184
used; 200DLC, 196 used)
12Nut (200D, 184 used;
200DLC, 196 used)
13Shoe (200D, 46 used;

200DLC, 49 used)
14Track Link (200D, 45 used;
200DLC, 48 used)
15Bushing (200D, 45 used;
200DLC, 48 used)
1. Measure track components (117). See 200D and

200DLC Standard Bushing Outer Diameter. (SP326
2. Turn pins (3 and 7) and bushings (15 and 16) as
required.
16Master Bushing
17Track Chain Without
Shoes
01
0130
17
4. Apply grease to counterbore in track links, the

seals, and ends of bushings.
5. For each joint, fill clearance between pin OD and
bushing ID with grease.
6. Install seal (5) so tapered side is toward bushing.
3. Clean any dust or rust from surfaces of track link

pin bores, counterbores, and ends of bushings.
OUO6046,0002309 1926JUN082/2
Track Chain Repair
UN26OCT88
1. Remove track shoes from each side of broken link

assembly. See Track Shoe Remove and Install. (Group
0130.)
T5821AG
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
OUO6046,000230A 1905MAR071/4
3. Grind ends of bushing (A) even with links to make it

into a master bushing.
T5821AH
UN26OCT88
ABushing
TM10079 (17MAR09)
01-0130-17
OUO6046,000230A 1905MAR072/4

031709
PN=61
Track System
4. Burn holes through center of pin stubs (A).
5. Hold a heavy hammer (B) against link while pin stub is
being driven out.
T5821AI
UN26OCT88
APin Stub
BHammer
OUO6046,000230A 1905MAR073/4
6. Install links (C and E) on master bushing (D). Check

cap screw hole spacing using a track shoe.
8. Install link assembly. Install master pins (A).

9. Install track shoes. See Track Shoe Remove and
UN24MAY89
7. Instal spacers (B) into counterbore of links.
T5821AJ
01
0130
18
AMaster Pin
BSpacer
CRight Link
DMaster Bushing
ELeft Link
OUO6046,000230A 1905MAR074/4
TM10079 (17MAR09)
01-0130-18

031709
PN=62
Track System
Sprocket Remove and Install

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.
UN20JUL01
01
0130
19
T143369B
1. Disconnect track chain. See Track Chain Remove and

2. Lift side of machine so sprocket teeth clear chain.
lifting device.
1Cap Screw (18 used)
Specification
SprocketWeight (approximate) ...................................................... 46 kg
100 lb
3. Remove cap screws (1) and sprocket.

4. Apply PM37509 Cure Primer and PM37421 Thread
Lock and Sealer (High Strength) to threads of cap
screws (B).
5. Install sprocket and tighten cap screws (1).
Specification
Sprocket-to-Travel Gearbox Cap
ScrewTorque ............................................................................. 500 Nm
369 lb-ft
6. Lower machine.
7. Install track chain. See Track Chain Remove and
OUO6046,000230B 1919APR071/1
TM10079 (17MAR09)
01-0130-19

031709
PN=63
Track System
Front Idler Remove and Install

1. Disconnect track chain. See See Track Chain Remove
and Install. (Group 0130.)
UN25OCT88
2. Slide front idler (A) forward, using pry bar.

lifting device.
T6876BU
01
0130
20
Specification
Front IdleWeight........................................................................... 119 kg
260 lb
AFront Idler
3. Attach appropriate lifting device to front idler 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. See Front Idler
6. Install front idler.
7. Connect track chain. See Track Chain Remove and
OUO6046,000230C 1905MAR071/1
TM10079 (17MAR09)
01-0130-20

031709
PN=64
Track System
Front Idler Disassemble and Assemble

A
F
01
0130
21
G
D
B
E
B
H
F
A
G
E
APin (2 used)
BBushing (2 used)
CIdler
DDrain Plug (2 used)

EBracket (2 used)
FMetal Face Seal (2 used)
1. Remove cap screws (J) and yoke (I).
T115165
T115165
UN21APR06
GO-Ring (2 used)
HAxle
IYoke
JCap Screw (4 used)
a matched set with seal ring faces together to

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

IMPORTANT: Metal face seals (F) 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.
IMPORTANT: Put matching marks on brackets (E)
and axle (H).
3. Remove pins (A), brackets (E), O-rings (G) and
metal face seals (F).
5. Remove axle (H). Inspect axle (H) and bushings (B)

for scoring or excessive wear.
NOTE: Remove bushings (B) only if replacement is
necessary.
6. Remove bushing (B) using a 2-jaw puller and
adapters from 17-1/2 and 30-ton puller set.
7. Apply a thin film of oil to new bushings (B). Install
bushings (B) so flange is tight against shoulder of
idler (C).
4. Inspect metal face seals (F). See Metal Face Seals

Repair. (Group 0130.) Keep seal rings together as
TM10079 (17MAR09)
01-0130-21
OUO6046,000230D 1919APR071/2

031709
PN=65
Track System
14. Install brackets (E) onto axle (H).
8. Apply a thin layer of anti-seize lubricant or

equivalent to end of axle (H) and to bore in
brackets (E).
01
0130
22
15. Apply anti-seize lubricant or equivalent to pins (A).

Install pins.
IMPORTANT: Seat surfaces for O-rings must be

clean, dry, and oil free so O-rings do
not slip when idler is turning.
9. Thoroughly clean seat surfaces in idler (C),
brackets (E), and seal rings using volatile,
non-petroleum base solvent and lint-free tissues.
NOTE: A volatile, non-petroleum base solvent or
talcum powder may be used as a lubricant.
10. Install metal face seal (F) in bracket (E). 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.
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 face.
NOTE: Repeat steps 12 and 13 for installing opposite
side metal face seal (F) and bracket (E) in
idler.
12. Install axle (H) into idler.
16. Add oil through plug holes on bearing brackets (E)

to specification.
Specification
Front Idler OilCapacity ......................................................... 265 mL
8.96 oz
17. Apply PM37509 Cure Primer to threads of drain

plug (D).
18. Apply PM37418 Thread Lock and Sealer (Medium
Strength) to threads of plug.
19. Install and tighten plug (D) to specification.
Specification
Front Idler PlugTorque ......................................................... 30 Nm
22 lb-ft
20. Install yoke (I). Tighten cap screws (J) to

specification.
Specification
Yoke-to-Bracket Cap Screw
Torque.................................................................................... 206 Nm
150 lb-ft
13. Install O-rings (G) on axle.
OUO6046,000230D 1919APR072/2
TM10079 (17MAR09)
01-0130-22

031709
PN=66
Track System
Track Adjuster and Recoil Spring Remove

and Install
1. Remove track chain. See Track Chain Remove and
01
0130
23
2. Remove front idler. See Front Idler Remove and Install.

(Group 0130.)
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.
TM10079 (17MAR09)
01-0130-23
OUO6046,000230E 1910APR071/2

031709
PN=67
Track System
3. Slide track adjuster (A) forward, using a pry bar.
lifting device.
UN25OCT88
Specification
Track Adjuster Cylinder and
Recoil SpringWeight .................................................................... 125 kg
280 lb
T6557CX
01
0130
24
4. Attach appropriate lifting device to track adjuster and

remove from frame.
5. Repair or replace parts as necessary. See Track
Adjuster and Recoil Spring Disassemble and
Assemble. (Group 0130.)
ATrack Adjuster
6. Install front idler. See Front Idler Remove and Install.

(Group 0130.)
7. Install track chain. See Track Chain Remove and
OUO6046,000230E 1910APR072/2
TM10079 (17MAR09)
01-0130-24

031709
PN=68
Track System

Disassemble and Assemble
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
handling, transporting, or disassembling track
adjuster.
01
0130
25

UN25OCT88

lifting device.
T6557DY
Specification
Track Recoil Spring Disassembly
and Assembly ToolWeight ........................................................... 225 kg
496 lb
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). See ST4920 Track
Recoil Spring Disassembly and Assembly Tool. (Group
9900.)
AST4920 Track Recoil Spring Disassembly and

Assembly Tool
BNut
CTop Plate
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).
TM10079 (17MAR09)
01-0130-25
OUO6046,000230F 1905MAR071/5

031709
PN=69
Track System

lifting device.
Specification
Track Adjuster Cylinder and
Recoil SpringWeight .................................................................... 125 kg
280 lb
3. Connect appropriate lifting device to track adjuster (B)

using a lifting strap (A).
4. Put track adjuster in assembly tool with cylinder end on
DFT1110 Spacer (C). See DFT1110 Spacer. (Group
9900.)
5. Remove lifting strap.
UN28APR92
ALifting Strap
BTrack Adjuster
CDFT1110 Spacer
T7720AF
01
0130
26
TM10079 (17MAR09)
01-0130-26
OUO6046,000230F 1905MAR072/5

031709
PN=70
Track System
6. Install DFT1087 Track Recoil Spring Disassembly and
Assembly Guard Tool (F). See DFT1087 Track Recoil
Spring Disassembly and Assembly Guard Tool. (Group
9900.)
01
0130
27
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.
Specification
Recoil SpringFree Length .......................................................... 606 mm
23.9 in.
9. Tighten nuts (B) so top plate (A) is tight against

retainer plate.
UN28APR92
10. Remove valve (C) and special plug (E).
T7720AG
ATop Plate
BNut (8 used)
CValve
DNut
ESpecial Plug
FDFT1087 Track Recoil Spring Disassembly and
Assembly Guard Tool
TM10079 (17MAR09)
01-0130-27
OUO6046,000230F 1905MAR073/5

031709
PN=71
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.
13. Lower jack ram to release spring force.
14. Repair or replace parts as necessary. See Track
Adjuster Cylinder Disassemble and Assemble. (Group
0130.)
15. Put track adjuster cylinder in assembly tool with
cylinder end on spacer.
16. Install spacer on rod.
17. Install spring using appropriate lifting device and lifting
strap.
UN28APR92
Specification
Recoil SpringWeight ...................................................................... 65 kg
145 lb
18. Install retainer plate.
T7720AH
01
0130
28
19. Install guard tool.

20. Install top plate. Install nuts.
ATop Plate
BNut (8 used)
DNut
FDFT1087 Track Recoil Spring Disassembly and
Assembly Guard Tool
21. Raise upper half of guard tool. Tighten T-handles.

22. Operate jack to compress spring to the compressed
length.
Specification
Recoil SpringCompressed
Length ............................................................................................ 490 mm
19.3 in.
23. Install nut (D) so hole is aligned with hole in rod.

Install special plug.
24. Tighten special plug to specification.
Specification
Special PlugTorque..................................................................... 15 Nm
133 lb-in.
TM10079 (17MAR09)
01-0130-28
OUO6046,000230F 1905MAR074/5

031709
PN=72
Track System
25. Tighten valve.
Specification
ValveTorque ................................................................................ 88 Nm
65 lb-ft
01
0130
29
OUO6046,000230F 1905MAR075/5
TM10079 (17MAR09)
01-0130-29

031709
PN=73
Track System
Track Adjuster Cylinder Disassemble and Assemble
TX1004754
UN17MAR06
01
0130
30
1Holder
2Piston Rod
3Dust Seal
4U-Ring
5Cylinder
6Rod
7Spring
8Spacer
9Washer
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
handling, transporting, or disassembling.
NOTE: It is not necessary to remove the recoil spring
to replace dust seal (3) and U-ring packing (4).
It is necessary to remove the recoil spring to
replace rod (6).
10Plug
11Nut
12Grease Valve
2. Remove holder (1) from piston rod (2) using a

press.
IMPORTANT: Do not damage dust seal (3) and
U-ring (4).
3. Remove dust seal (3) and U-ring (4) from cylinder
(5).
4. Remove recoil spring if necessary. See Track
Adjuster and Recoil Spring Remove and Install.
(Group 0130.)
5. Remove rod (6) from cylinder (5).
6. Repair or replace parts as necessary.
7. Install rod (6) into cylinder (5).
1. Remove piston rod (2) from cylinder (5).
TM10079 (17MAR09)
01-0130-30
OUO6046,0002310 1905MAR071/2

031709
PN=74
Track System
8. Install spring (7), spacer (8), washer (9), plug (10),
nut (11), and grease valve (12). See Track Adjuster
and Recoil Spring Disassemble and Assemble.
(Group 0130.)
10. Install U-ring (4) and dust seal (3) into cylinder (5).
11. Press holder (1) into piston rod (2).
12. Install piston rod (2) assembly into cylinder (5).
01
0130
31
9. Apply grease to inner surfaces of U-ring (4) and

dust seal (3)
NOTE: Install U-ring (4) with lip towards inside of
cylinder (5).
OUO6046,0002310 1905MAR072/2
TM10079 (17MAR09)
01-0130-31

031709
PN=75
Track System
01
0130
32
TM10079 (17MAR09)
01-0130-32

031709
PN=76
Section 02
Axles, Differentials and Suspension Systems

Contents
Page
Group 0250Axle Shaft, Bearings, and Reduction

Gears
Travel Gearbox Remove and Install . . . . . . .02-0250-1
Travel Gearbox Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-4
02

Travel Motor and Park Brake Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-2
Travel Motor and Park Brake Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . .02-0260-10
Counterbalance Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-13
Crossover Relief Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-15
Make-Up Check Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-17
Travel Speed Selector Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-19
Travel Motor and Park Brake Start-Up
Procedure . . . . . . . . . . . . . . . . . . . . . . . .02-0260-21
TM10079 (17MAR09)
02-1

031709
PN=1
Contents
02
TM10079 (17MAR09)
02-2

031709
PN=2
Group 0250
Axle Shaft, Bearings, and Reduction Gears

Travel Gearbox Remove and Install
UN21MAR07
1. Disconnect track chain. See Track Chain Repair.

(Group 0130.)
2. Remove sprocket. See Sprocket Remove and Install.
(Group 0130.)
TX1020485A
CAUTION: High pressure release of oil from

pressurized system can cause serious burns or
penetrating injury. Relieve pressure by pushing
pressure release button (1).
1Pressure Release Button
2Hydraulic Oil Tank Cover
3. Push pressure release button (1).

4. Remove cover from track frame.
5. Drain oil from travel gearbox. The approximate
capacity of travel gearbox is 6.8 L (1.8 gal).
6. Drain oil from hydraulic oil tank or pull vacuum in
hydraulic oil tank using vacuum pump. See Apply
Vacuum to Hydraulic Oil Tank. (Group 3360.) The
approximate capacity of hydraulic oil tank is 135 L (36
gal).
7. Tag and disconnect lines. Close all open lines and
fittings using caps and plugs.
TM10079 (17MAR09)
02-0250-1
OUO6046,0002311 1911APR071/3

031709
PN=79
02
0250
1

lifting device.
8. Attach JDG909 Lifting Bracket to gearbox as shown.
Specification
Travel Gearbox and Motor
AssemblyApproximate Weight ..................................................... 310 kg
685 lb
NOTE: Make alignment marks between travel gearbox

and undercarriage to aid in installation.
UN15JUN01
9. Remove cap screws (1). Remove travel gearbox and

motor assembly.
10. Repair or replace parts as necessary. See Travel
Gearbox Disassemble and Assemble. (Group 0250.)
T142702B
02
0250
2
NOTE: Align marks made during removal.

11. Install travel gearbox and motor assembly. Tighten

cap screws (1).
Specification
Travel Gearbox-to-Frame Cap
ScrewTorque ............................................................................. 630 Nm
465 lb-ft
12. Connect lines. See Travel Hydraulic System Line

Connection. (Group 9025-15.)
13. Fill travel gearbox with oil. See Check Travel Gearbox
Oil Level. (Operators Manual.)
14. Do Travel Motor and Park Brake Start-Up Procedure.
(Group 0260.)
15. Install cover. Tighten cap screws to specification.
Specification
Travel Gearbox Cover Cap
ScrewsTorque ............................................................................. 50 Nm
(37 lb-ft)
16. Install sprocket. See Sprocket Remove and Install.

(Group 0130.)
17. Connect track chain. See Track Chain Remove and
TM10079 (17MAR09)
02-0250-2
OUO6046,0002311 1911APR072/3

031709
PN=80

OUO6046,0002311 1911APR073/3
02
0250
3
TM10079 (17MAR09)
02-0250-3

031709
PN=81
Travel Gearbox Disassemble and Assemble
TX1000629
UN28NOV05
02
0250
4
TM10079 (17MAR09)
02-0250-4
OUO6046,0002312 1919APR071/7

031709
PN=82

0Hydraulic Motor and
Gearbox Assembly
1Hydraulic Motor
2Seal (2 used)
3Tapered Roller Bearing (2
used)
4Drum
5Chain Sprocket
7Lock Washer (18 used)
9Bearing Nut
10Pin Fastener
11Needle Bearing (6 used)
12Third Planetary Pinion
Carrier
13Planetary Gear (3 used)
15Plate (6 used)
16Pin Fastener (3 used)
17Spring Pin (3 used)
18Third Sun Gear
20Ring Gear
1. Remove cap screws (43) and cover (41).

2. Remove shaft (39) and first planetary pinion carrier
(32).
23Second Planetary Pinion

Carrier
24Washer
27Plate (6 used)
30Second Sun Gear
32First Planetary Pinion
Carrier
4. Install JT01748 Lifting Brackets to ring gear (20).

Remove cap screws (21) and ring gear from drum
(4).
CAUTION: Heavy component; use
appropriate lifting device.
3. Remove second sun gear (30) and second

planetary pinion carrier (23) from ring gear (20).
Specification
Third Planetary Pinion Carrier
Approximate Weight ................................................................... 40 kg
88 lb

Specification
Ring GearApproximate
Weight ......................................................................................... 64 kg
140 lb
5. Remove third sun gear (13) and third planetary

pinion carrier (12).
TM10079 (17MAR09)
33Spacer
36Plate (6 used)
37Spacer (3 used)
39Shaft
41Cover
42Pin
44Fitting Plug (3 used)
02-0250-5
OUO6046,0002312 1919APR072/7

031709
PN=83
02
0250
5

6. Remove bearing nut (9) from travel motor (1) using
DFT1109 Holding Bar (47) and DFT1036A Travel
Gearbox Nut Wrench (48). See DFT1109 Holding Bar.
See DFT1036A Travel Gearbox Nut Wrench. (Group
9900.)
lifting device.
Specification
DrumApproximate Weight .............................................................. 59 kg
130 lb
UN14FEB07
7. Remove drum (4) using JT01748 Lifting Brackets.

NOTE: Disassembly of first, second, and third planetary
pinion carriers are similar. Repeat procedure as
required.
TX1018574
02
0250
6
8. Remove spring pins, pins, thrust plates, needle

bearings, and planetary gears.
9Bearing Nut
47DFT1109 Holding Bar
48DF1036A Travel Gearbox Nut Wrench
Clean and inspect parts, replace as necessary. Oil

parts with gear oil prior to assembly.
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.
9. Remove metal face seal (2). See Metal Face Seals
NOTE: Further disassembly is not necessary unless
bearing replacement is required. Bearing will be
destroyed during removal, replace with new
bearing.
11. Inspect bearing (3) and race inside drum (4).
TM10079 (17MAR09)
02-0250-6
OUO6046,0002312 1919APR073/7

031709
PN=84
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.
12. Heat inner bearing cone. Install cone tight against
shoulder.
02
0250
7
Specification
Bearing ConeTemperature .................................................... 5070C
122158F
13. Install drum (4).

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.
14. Thoroughly clean metal face seal O-rings and seat
surfaces in travel motor ring gear, 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.
15. Install O-ring and metal face seal on travel motor ring
gear 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.
16. Clean seal ring face. Apply a thin film of clean oil.
17. Install drum (4) onto hydraulic motor (1).
18. Apply a thin coat of multi-purpose grease to threads
of bearing nut (9). Install bearing nut with machined
surface towards bearing.
19. Tighten bearing nut (9) using DFT1109 Holding Bar
and DFT1036A Travel Gearbox Nut Wrench. See
DFT1109 Holding Bar. See DFT1036A Travel
Gearbox Nut Wrench. (Group 9900.) Seat bearings.
TM10079 (17MAR09)
02-0250-7
OUO6046,0002312 1919APR074/7

031709
PN=85

Specification
Bearing NutTorque.................................................................... 800 Nm
590 lb-ft
20. To seat bearings, tap on drum using a plastic

hammer. Then turn drum four-to- five times to the
right and left to seat the bearings.
Repeat steps to ensure bearings are seated properly.
02
0250
8
OUO6046,0002312 1919APR075/7
21. Ensure center of dowel pin (10) is aligned with center

of spline on travel motor (39). If centers are not
aligned tighten bearing nut (9) until dowel pin center
aligns with center of the next spline.
NOTE: Assembly of first, second, and third planetary

pinion carrier assemblies is similar. Repeat
procedure as required.
39
TX1004312
22. Install needle bearings (11) into planetary gears (13).

TX1004312
IMPORTANT: There is an identification groove on one

side of third planetary gears (16). Be
sure that this marked side faces the
hole for the spring pin.
UN14MAR06
10
12
46
24. Install pins (16).

9Bearing Nut
10Dowel Pin
12Third Planetary Pinion Carrier
39Travel Motor
46Hole
TX1004313
TM10079 (17MAR09)
02-0250-8
TX1004313
UN14MAR06
23. Install thrust plates (15) and planetary gears (13) into
third planetary pinion carrier (12).
OUO6046,0002312 1919APR076/7

031709
PN=86

25. Install spring pins (17) with slit (45) toward end of
pins (16).
26. Assemble second and first planetary pinion carrier
assemblies.
27. Install third planetary pinion carrier so dowel pin (10)
enters hole (46) on third planetary pinion carrier (12).
28. Apply PM38656 Rigid Form-in-Place gasket to flange
surface on ring gear.
TX1004310
16
TX1004310
UN14MAR06
45
29. Install ring gear (20) onto drum (4).

30. Apply PM37421 Thread Lock and Sealer (high
strength) to cap screws (21). Install and tighten cap
screws.
16Pin
45Slit
Specification
Ring Gear-to-Drum Cap Screw
Torque .......................................................................................... 265 Nm
195 lb-ft
31. Install second and first planetary pinion carriers, sun

gears, and shaft.
32. Apply PM38656 Form-in-Place gasket to flange
surface on cover (41).
33. Install cover on ring gear (20).
34. Apply PM37418 Thread Lock and Sealer (medium
strength) to thread of cap screws (43). Install and
tighten cap screws.
Specification
Cover-to-Ring Gear Cap Screw
Torque .......................................................................................... 110 Nm
83 lb-ft
OUO6046,0002312 1919APR077/7
TM10079 (17MAR09)
02-0250-9

031709
PN=87
02
0250
9
02
0250
10
TM10079 (17MAR09)
02-0250-10

031709
PN=88
Group 0260
Hydraulic System
02
0260
1
TM10079 (17MAR09)
02-0260-1

031709
PN=89
Hydraulic System
Travel Motor and Park Brake Remove and Install
TX1000629
UN28NOV05
02
0260
2
TM10079 (17MAR09)
02-0260-2
FS41334,0000171 1912APR071/7

031709
PN=90
Hydraulic System
0Travel Motor and Gearbox
Assembly
1Travel Motor
2Seal (2 used)
3Tapered Roller Bearing (2
used)
4Drum
5Chain Sprocket
9Bearing Nut
10Pin Fastener
12Third Planetary Pinion
Carrier
15Plate (6 used)
18Third Sun Gear
20Ring Gear
IMPORTANT: Travel motor housing will be

damaged if removal is attempted
while travel gearbox is on machine.
Travel motor housing is an integral
part of travel gearbox and retained in
place by bearing nut (9).
This procedure is written to show
removal and installation of the travel
gearbox from the travel motor. This
is the recommended repair
procedure for performing major
repairs to travel motor or park brake.
NOTE: Travel motor and park brake internal
components can be replaced with care while
motor is on machine.
1. Remove travel motor and gearbox assembly from
machine. See Travel Gearbox Remove and Install.
(Group 0250.)

Carrier
24Washer
27Plate (6 used)
30Second Sun Gear
Gear
02
0260
3
2. Position travel motor and gearbox assembly

securely in a vertical position with the motor valve
plate end down.
Specification
Travel Motor and Gearbox
Weight ....................................................................................... 310 kg
685 lb
3. Make alignment marks between cover (41), ring

gear (20), and drum (4).
4. Remove cap screws (43) and cover (41).
5. Remove shaft (39) and first stage planetary pinion
carrier (32) from ring gear (20).
6. Remove second stage sun gear (30), second stage
planetary pinion carrier (23), and third stage sun
gear (18) from ring gear (20).
CAUTION: Heavy component; use an

IMPORTANT: Weight of travel motor and gearbox
assembly can damage motor valve
plate. Block travel motor and
gearbox assembly so that the motor
cover does not carry full weight of
travel motor and gearbox assembly.
7. Install JT01748 lifting brackets to ring gear (20).

Remove cap screws (21) and ring gear (20) from
drum (4).
Specification
Ring Gear Approximate
Weight ......................................................................................... 64 kg
140 lb
TM10079 (17MAR09)
33Spacer
36Plate (6 used)
37Spacer (3 used)
39Shaft
41Cover
42Pin
02-0260-3
FS41334,0000171 1912APR072/7

031709
PN=91
Hydraulic System
8. Remove third stage planetary pinion carrier (12).

Specification
Third Stage Planetary Pinion
Carrier ApproximateWeight ..................................................... 40 kg
88 lb
02
0260
4
TM10079 (17MAR09)
02-0260-4
FS41334,0000171 1912APR073/7

031709
PN=92
Hydraulic System
9. Remove bearing nut (9) using holding bar (47) and
travel gearbox nut wrench (48). See DFT1109 Holding
Bar and See DFT1036A Travel Gearbox Nut Wrench.
(Group 9900.)
Specification
Drum ApproximateWeight .............................................................. 59 kg
130 lb
02
0260
5
UN14FEB07
10. Remove drum (4) from travel motor housing using

JT01748 lifting brackets.
TX1018574
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 surface.
11. Remove metal face seal (2). See Metal Face Seals
9Bearing Nut
47DFT1109 Holding Bar
48DFT1036A Travel Gearbox Nut Wrench
12. Repair or replace parts as necessary. See Travel

Motor and Park Brake Disassemble and Assemble.
(Group 0260.)
13. Clean and oil parts with gear oil prior to assembly.
NOTE: Further disassembly is not necessary unless
bearing replacement is required. Bearing will be
destroyed during removal, replace with a new
bearing.
14. Inspect bearings (3) and races inside housing.
TM10079 (17MAR09)
02-0260-5
FS41334,0000171 1912APR074/7

031709
PN=93
Hydraulic System
CAUTION: DO NOT heat oil over 182 C (260 F).

Oil fumes or oil can ignite above 193C (380 F).
Use thermometer to measure. Do Not allow a
flame or heating element to come in contact
with the oil. Heat in a well ventilated area. Plan
a safe handling procedure to avoid burns.
Specification
Bearing ConeTemperature .................................................... 5070 C
122158 F
02
0260
6
16. Heat inner bearing cone. Install cone tight against

shoulder.
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.
17. Thoroughly clean metal face seal O-rings and seat
surfaces in travel motor housing, drum, and seal ring.
Use volatile, non-petroleum based solvent and
lint-free tissues.
NOTE: A volatile, non-petroleum based solvent or talcum
powder can be used as a lubricant. Solvent must
not damage the O-ring or leave an oil residue.
18. Install O-ring and metal face seal on travel motor
housing and drum. Apply equal pressure with fingers
at four, equally spaced points on seal face.
Seal most pop down into place so O-ring is tight
against seal bore and seal ring is installed squarely.
19. Clean ring seal face. Apply a thin film of clean oil.
20. Install drum (4) onto travel motor. Make sure that
roller bearings are fully installed by checking to see
that clearance between motor and drum is equal.
TM10079 (17MAR09)
02-0260-6
FS41334,0000171 1912APR075/7

031709
PN=94
Hydraulic System
IMPORTANT: Install bearing nut with stepped surface
towards bearing.
21. Apply a thin coat of multi-purpose grease to bearing
nut (9). Tighten bearing nut using tools DFT1109 and
DFT1036A to specification. See DFT1109 Holding Bar
and See DFT1036A Travel Gearbox Nut Wrench.
(Group 9900.)
Specification
590 lb-ft
02
0260
7
22. To seat bearings, tap around face of drum with a

plastic hammer. Then, rotate drum 4 to 5 times in
each direction. Retighten to specification.
NOTE: If dowel pin does not engage with spline of
housing, tighten bearing nut (9) until dowel pin
center aligns with center of next spline.
23. Ensure center of dowel pin (10) is aligned with center
of spline on travel motor. If centers are not aligned,
tighten bearing nut (9) until dowel pin center aligns
with center of next spline.
24. Install planetary gears (13) in third stage planetary
pinion carrier (12), if removed.
TM10079 (17MAR09)
02-0260-7
FS41334,0000171 1912APR076/7

031709
PN=95
Hydraulic System
25. Install spring pinions with slit (45) toward end of pin
(16).
26. Install third stage planetary pinion carrier (12) and
third stage sun gear (18).
27. Apply PM38627 Rigid Form-in-Place gasket to flange
surface on ring gear (20) and install ring gear.
02
0260
8
28. Apply PM37421 Thread Lock and Sealer (high

strength) to cap screws (21). Tighten to specification.
TX1004310
Specification
Ring Gear-to-Drum Cap Screw
Torque .......................................................................................... 265 Nm
195 lb-ft
16
TX1004310
UN14MAR06
45
Spring Pin Installation

16Pin
45Slit
29. Install second stage planetary pinion carrier (23),

washer (24), sun gear (30), first stage planetary
pinion carrier (32), washer (33), and shaft (39).
30. Apply PM38656 Rigid Form-in-Place to flange surface
of ring gear cover (41).
31. Apply PM37418 Thread Lock and Sealer (medium
strength) to threads of cap screws (43). Tighten to
specification.
Specification
Cover-to-Ring Gear Cap Screw
Torque .......................................................................................... 110 Nm
83 lb-ft
32. Install travel motor and gearbox assembly. See Travel

Gearbox Remove and Install. (Group 0250.)
FS41334,0000171 1912APR077/7
TM10079 (17MAR09)
02-0260-8

031709
PN=96
Hydraulic System
02
0260
9
TM10079 (17MAR09)
02-0260-9

031709
PN=97
Hydraulic System
Travel Motor and Park Brake Disassemble and Assemble
TX1000643
UN01DEC05
02
0260
10
TM10079 (17MAR09)
02-0260-10
FS41334,0000160 1912MAR071/3

031709
PN=98
Hydraulic System
0Hydraulic Motor
0AHousing
1Seal
3Piston
7Shaft
8Snap Ring
9Pin (2 used)
10Roller Bearing
14Piston (9 used)
16Retainer
17Bushing
18Swash Plate
19Spring (6 used)
21Rotor
22Plate (4 used)
23Plate (4 used)
25Piston
26O-Ring
28O-Ring
29Spring
30O-Ring
31O-Ring (2 used)
32Travel Motor Cover
33Needle Bearing
37Dowel Pin (2 used)
39Valve Plate
40Bolt (9 used)
PlateHeight .............................................................. 1.801.75 mm

0.0710.069 in.

Specification
Travel MotorApproximate
Weight ......................................................................................... 91 kg
200 lb
IMPORTANT: Use care when removing travel

motor cover (32), valve plate is
easily damaged.
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.
02
0260
11
7. Remove parts (21, 19, 17, 16, and 14).
1. Remove travel motor cover (32), and plate (39).
8. Remove parts (7, 10, 8, and 1) through motor side

of housing (0A).
IMPORTANT: Remove needle bearing (33) only if

replacement is necessary. Do not
reuse needle bearing as it may have
been damaged during removal.
2. Remove needle bearing (33) as required.
Specification
Travel Motor HousingWeight .................................................. 50 kg
110 lb
3. Remove disc spring (29). Inspect part for wear or

damage.
Specification
Disc SpringHeight ....................................................... 7.06.9 mm
0.2760.272 in.
4. Apply 100300 kPa (1443 psi) air pressure to

brake release passage to remove brake piston (25).

10. Apply multi-purpose grease to lip of seal (1) and

apply PM38627 Rigid Form-in-Place Gasket to
outer surface of seal.
11. Install parts (7, 10, 8, and 1) using D01044AA
Bushing, Bearing and Seal Driver Set.
5. Remove friction plates (22) and plates (23).

6. Inspect parts for wear or damage.
Specification
Friction PlateHeight ................................................. 2.752.70 mm
0.1080.106 in.
TM10079 (17MAR09)
02-0260-11
FS41334,0000160 1912MAR072/3

031709
PN=99
Hydraulic System
12. Lubricate parts (21, 19, 17, 16, 14, and 18) with
hydraulic oil and install. Ensure that pistons (14) are
installed in their original bores. Install bushing (17)
and retainer (16) as shown.
13. Install parts (29, 28, 25, 26, 22, and 23).
17
02
0260
12
NOTE: Apply petroleum jelly to mating surface of valve

plate to adhere it to travel motor cover during
assembly.
15. Install pins (37) then valve plate (39).
TX1004978
14. Install needle bearing (33) into travel motor cover

(32).
UN23MAR06
16
17Bushing
16Retainer
16. Assemble travel motor cover to housing (0A).

17. Install cap screws (40) and tighten.
Specification
Travel Motor Cover-to-Travel
Motor Housing Cap Screw
Torque .......................................................................................... 300 Nm
220 lb-ft
FS41334,0000160 1912MAR073/3
TM10079 (17MAR09)
02-0260-12

031709
PN=100
Hydraulic System
Counterbalance Valve Remove and Install
UN21MAR07

pressure relief button (1).
TX1020485A
1. Push pressure relief button (1).

gal).
1Pressure Relief Button

3. Disconnect battery ground (negative) cable.

TM10079 (17MAR09)
02-0260-13
FS41334,000015F 1911APR071/3

031709
PN=101
02
0260
13
Hydraulic System
NOTE: Valves may be removed with travel motor in
machine.
UN07MAR07
5. Remove counterbalance valve plugs (5) from travel

motor cover (1).
7. Remove valve spool (6) from travel motor using a

magnet.
8. Repair or replace parts as needed. Apply a film of
clean hydraulic oil to parts before assembly.
9. Install valve spool (6) halfway into cover (1).
10. Instal spools (2), Springs (3), and plugs (5) on each
side of valve spool (6). Tighten by hand.
11. Tighten counterbalance valve plug (5) on each side to
specification.
Specification
Counterbalance Valve Plug
Torque .......................................................................................... 450 Nm
332 lb-ft
12. Fill hydraulic oil tank. See Check Hydraulic Tank Oil
Level. (Operators Manual.)
UN09MAR07
IMPORTANT: Hydraulic pump will be damaged if not

filled with oil before starting engine.
Procedure must be performed whenever
a new pump is installed or oil has been
drained from the pump or hydraulic oil
tank.
TX1020308
02
0260
14
TX1020307A
6. Remove spring (3) and spool (2) from travel motor

using a magnet.
13. Fill pump housing with oil. See Pump 1 and 2

Start-Up Procedure. (Group 3360.)
1Travel Motor Cover

2Spool (2 used)
3Spring (2 used)
4O-Ring (2 used)
5Plug (2 used)
6Valve Spool
14. Connect battery ground (negative) cable.

15. Perform travel motor start-up procedure. See Travel
Motor and Park Brake Start-Up Procedure. (Group
0260.)
16. Install cover to track frame and torque to
specification.
TM10079 (17MAR09)
02-0260-14
FS41334,000015F 1911APR072/3

031709
PN=102
Hydraulic System
Specification
Track Frame CoverTorque ......................................................... 50 Nm
37 lb-ft
FS41334,000015F 1911APR073/3
Crossover Relief Valve Remove and Install
UN21MAR07

TX1020485A

gal).


FS41334,000015E 1913APR071/4

machine.
UN07MAR07
5. Remove crossover relief valves (10) from travel motor

cover (1).
TX1020327A
Crossover relief valves retain make-up check valve and

spring. For correct reinstallation; See Make-Up Check
Valve Remove and Install. (Group 0260.)
1Travel Motor Cover
2Plug (2 used)
TM10079 (17MAR09)
02-0260-15
FS41334,000015E 1913APR072/4

031709
PN=103
02
0260
15
Hydraulic System
TX1020309
UN09MAR07
02
0260
16
1Travel Motor Cover

2Sleeve (2 used)
3O-Ring (2 used)
4Back-Up Ring (4 used)
5Valve (2 used)
6Guide (2 used)
7Spring (2 used)
8Piston (2 used)
9Back-Up Ring (4 used)
10Plug (2 used)
IMPORTANT: Disassembly of crossover relief

valve will alter the set pressure.
Adjust after repairs are made.
11O-Ring (2 used)
12Packing (2 used)
13Shim (2 used)
IMPORTANT: Hydraulic pump will be damaged if

not filled with oil before starting
engine. Procedure must be
performed whenever a new pump is
installed or oil has been drained
from the pump or hydraulic oil tank.
6. Disassemble crossover relief valves.


8. Assemble crossover relief valves.

9. Install relief valves (10) and tighten to specification.
Specification
Relief ValveTorque............................................................. 450 Nm
332 lb-ft
13. Perform travel motor start-up procedure. See

Travel Motor and Park Brake Start-Up Procedure.
(Group 0260.)
10. Fill hydraulic oil tank. See Check Hydraulic Tank

TM10079 (17MAR09)
02-0260-16
FS41334,000015E 1913APR073/4

031709
PN=104
Hydraulic System
14. Install cover to track frame.
Specification
Track Frame CoverTorque................................................... 50 Nm
37 lb-ft
15. Perform crossover relief valve test and adjustment.

See Travel Motor Crossover Relief Valve Test and
Adjustment. (9025-25.)
FS41334,000015E 1913APR074/4
Make-Up Check Valve Remove and Install
UN21MAR07

TX1020485A

gal).


TM10079 (17MAR09)
02-0260-17
FS41334,000015D 1910APR071/2

031709
PN=105
02
0260
17
Hydraulic System
machine.
UN07MAR07
5. Remove relief valves (2) from travel motor cover (1).

6. Remove springs (3) and check valves (4) from travel
motor using a magnet.
8. Install Springs (3) to check valves (4). Install check

valves into travel motor cover (1).
9. Install relief valves (2) and tighten to specification.
UN23MAR07
Specification
Relief ValveTorque ................................................................... 450 Nm
332 lb-ft
tank.
TX1020910A
02
0260
18
TX1020327A

1Travel Motor Cover

2Relief Valve (2 used)
3Spring (2 used)
4Check Valve (2 used)

0260.)
Specification
37 lb-ft
FS41334,000015D 1910APR072/2
TM10079 (17MAR09)
02-0260-18

031709
PN=106
Hydraulic System
Travel Speed Selector Valve Remove and

Install
UN21MAR07

TX1020485A

gal).


TM10079 (17MAR09)
02-0260-19
FS41334,000015C 1910APR071/2

031709
PN=107
02
0260
19
Hydraulic System
machine.
UN19MAR07
5. Remove fitting plug (4) from travel motor cover.

6. Remove compression spring (3) and valve spool (2)
from travel motor cover using a magnet.
8. Install valve spool (2) into cover with shoulder facing

spring.
9. Install spring (3) and fitting plug (4). Tighten to
specification.
UN06MAR07
Specification
Fitting PlugTorque ...................................................................... 35 Nm
26 lb-ft
tank.
TX1020263A
02
0260
20
TX1019101A

1Line
2Valve Spool
3Spring
4Fitting Plug

0260.)
Specification
37 lb-ft
15. Perform travel speed solenoid valve test and adjust.

See Travel Speed Solenoid Valve Test and Adjust.
(Group 9025-25.)
FS41334,000015C 1910APR072/2
TM10079 (17MAR09)
02-0260-20

031709
PN=108
Hydraulic System
Travel Motor and Park Brake Start-Up

Procedure
TX1018694A
UN19MAR07
IMPORTANT: Travel motor will be damaged if not

filled with oil before operating travel
function. Procedure must be performed
whenever a new travel motor is
installed or oil has been drained from
the motor.
1. Disconnect drain line (1).
2. Fill motor with hydraulic oil until oil reaches top of drain
port.
1Travel Motor Drain Line
NOTE: Use a funnel with suitable diameter neck to allow

air to escape while filling.
3. Connect drain line (1).
FS41334,000015B 1912MAR071/1
TM10079 (17MAR09)
02-0260-21

031709
PN=109
02
0260
21
Hydraulic System
02
0260
22
TM10079 (17MAR09)
02-0260-22

031709
PN=110
Section 04
Engine
Contents
Page

Engine Remove and Install . . . . . . . . . . . . . .04-0400-1
04
TM10079 (17MAR09)
04-1

031709
PN=1
Contents
04
TM10079 (17MAR09)
04-2

031709
PN=2
Group 0400
Removal and Installation

Engine Remove and Install
OUO6046,0002329 1919APR071/16
CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns.
UN23AUG88
Shut off engine. Remove filler cap when cool to

touch. Slowly loosen filler cap to first stop to
relieve pressure, then remove.
TS281
2. Drain coolant from radiator. Approximate capacity is 26

L (6.9 gal).
OUO6046,0002329 1919APR072/16
UN21MAR07

TX1020485A
4. Pull a vacuum in hydraulic oil tank using a vacuum

pump, or drain tank. See Apply Vacuum to Hydraulic
Oil Tank. (Group 3360.)
5. Close fuel supply valve on bottom of fuel tank.
TM10079 (17MAR09)
04-0400-1
OUO6046,0002329 1919APR073/16

031709
PN=113
04
0400
1

6. Remove support (1).
7. Remove coolant surge tank (6). See Coolant Surge
Tank Remove and Install. (Group 0510.)
8. Remove intercooler tubes (5 and 7).
9. Remove upper radiator hose (3) and lower radiator
hose (8).
UN03APR07
10. Remove fan guard (4).

11. Remove air intake tube (2).
TX1021126A
12. Disconnect engine wiring. Label wiring to aid

installation. See Engine Harness (W4) Component
04
Location, and See Machine Harness (W2) Component
0400
Location. (Group 9015-10.)
2
TX1021142A
UN03APR07
1Support
2Air Intake Tube
3Upper Radiator Hose
4Fan Guard
5Intercooler Tube
6Coolant Surge Tank
7Intercooler Tube
8Lower Radiator Hose
TM10079 (17MAR09)
04-0400-2
OUO6046,0002329 1919APR074/16

031709
PN=114

13. Disconnect fuel hoses (1, 2, 4, and 5).
14. Disconnect heater hose (3).
UN03APR07
NOTE: It is not necessary to discharge the air

conditioning system.
TX1021127A
15. Disconnect air conditioner compressor from engine

mounting bracket. Fasten compressor so it will not
interfere with engine removal. See Compressor
Remove and Install. (Group 1830.)
TX1021128A
UN03APR07
1Fuel Hose (Outlet to Final Fuel Filter)

2Fuel Hose (Inlet from Pre-Filter)
3Heater Hose
4Fuel Hose (Return)
5Fuel Hose (Supply)
OUO6046,0002329 1919APR075/16
16. Disconnect hydraulic hoses (1 and 2) from fan drive

pump. Close all open lines and fittings using caps and
plugs.
UN03APR07
17. Disconnect heater hose (5) and coolant surge tank

hose (6).
TX1021129A
18. Disconnect oil hose (3 and 4) to remote oil filter.

Close all open lines and fittings using caps and plugs.
TX1021130A
UN03APR07
1Hydraulic Hose
2Hydraulic Hose
3Remote Oil Filter Hose
4Remote Oil Filter Hose
5Heater Hose
6Coolant Surge Tank Hose
TM10079 (17MAR09)
04-0400-3
OUO6046,0002329 1919APR076/16

031709
PN=115
04
0400
3

19. Remove fuel filter assembly (1) and oil filter assembly
(2) and set aside.
TX1021131A
UN03APR07
1Fuel Filter Assembly

2Oil Filter Assembly
OUO6046,0002329 1919APR077/16
20. Remove cover (1) and shields (2).

CAUTION: Exhaust parts may be hot. Avoid
burns by waiting until the parts are cool to the
touch before working on them.
21. Support muffler using appropriate lifting device.
22. Loosen exhaust clamp and move onto muffler tube.
TX1020930
UN26MAR07
1Cover
2Shield (3 used)
OUO6046,0002329 1919APR078/16
23. Remove nuts (2) and U-bolts from muffler support (3).
24. Remove muffler (1).
UN23MAR07
1Muffler
2U-bolt Nut (8 used)
3Support
TX1020923A
04
0400
4
TM10079 (17MAR09)
04-0400-4
OUO6046,0002329 1919APR079/16

031709
PN=116

25. Support pump 1 and 2. Remove cap screws (2) and
muffler bracket (1). Reinstall cap screws.
TX1006125A
UN06APR06
1Muffler Bracket
2Cap Screw (4 used)
OUO6046,0002329 1919APR0710/16
26. Install JT05550 Lifting Eyebolts (1) and JDG19 Lifting

Bracket (2) in housing of pump 1 and 2.
04
0400
5
TX1006126A
UN06APR06
1Eyebolts
2Lifting Bracket
OUO6046,0002329 1919APR0711/16

lifting device.
27. Install DFT1119 Pump Support (1) on machine as
shown. See DFT1119 Pump Support. (Group 9900.)
Specification
Pump 1 and 2Weight .................................................................. 164 kg
362 lb
UN06APR06
28. Attach pump support to machine using C-clamps to

prevent movement.
TX1004022A
29. Support pump 1 and 2 using DFT1119 Pump Support

(1) and a lever block (2). Attach lever block to
eyebolts and lifting bracket installed in pump housing
using suitable lifting sling.
1DFT1119 Pump Support
2Lever Block
TM10079 (17MAR09)
04-0400-5
OUO6046,0002329 1919APR0712/16

031709
PN=117
UN22FEB06
30. Install JD244 Lifting Eye (1) at location shown using

Grade 10.9 M12 x 40 cap screw. Install JD244 Lifting
Eye (2) at location shown using Grade 10.9 M12 x 35
cap screw. Tighten cap screws to specification.
TX1004020A
Specification
Lifting Eye Cap ScrewTorque ................................................... 170 Nm
125 lb-ft

lifting device.
Specification
EngineApproximate Weight ........................................................ 643 kg
1418 lb
UN22FEB06
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.
31. Attach JDG23 Lifting Sling to engine.
TX1004021A
04
0400
6
32. Remove cap screws securing pump 1 and 2 and drive

gearbox to engine flywheel housing.
1JD244-1 Lifting Eye
2JD244-2 Lifting Eye
TM10079 (17MAR09)
04-0400-6
OUO6046,0002329 1919APR0713/16

031709
PN=118
04
0400
7
TM10079 (17MAR09)
04-0400-7

031709
PN=119
TX1022112
UN17APR07
04
0400
8
TM10079 (17MAR09)
04-0400-8
OUO6046,0002329 1919APR0714/16

031709
PN=120

1Engine Mount (Fan End)
2Engine Mount (Fan End)
3Engine Mount (Flywheel
End)(2 used)
4Isolator (8 used)
5Isolator Cap Screw (4 used)
6Stop (8 used)
33. Remove cap screws (5), washers (7), and nuts (8)
from engine mounts.
34. Raise engine slightly. Move engine away from
pump 1 and 2 and drive gearbox. Lift and remove
engine when disengaged from hydraulic pump
drive coupling.
7Washer (8 used)
8Nut (8 used)
9Washer (8 used)
10Engine Mount-to-Engine
Block Cap Screw (14
used)
Specification
Pump 1 and 2
Housing-to-Flywheel Housing
Cap ScrewTorque ................................................................ 65 Nm
48 lb-ft
39. Remove lifting sling and lifting eyes from engine.

40. Remove lifting bracket, lifting eyebolt, and pump
support from pump 1 and 2.
35. Repair or replace parts as necessary. If

disassembly is necessary, See Engine
Disassembly Sequence. (CTM104.)
41. Install shields surrounding pump 1 and 2. Tighten

shield hardware to specification.
36. If removed, install engine mounts (1, 2, and 3),

cap screws (10), and washers (9). Tighten cap
Specification
Engine Mount Cap Screw
Torque.................................................................................... 108 Nm
80 lb-ft
Specification
Pump Shield Cap Screws
Torque...................................................................................... 50 Nm
37 lb-ft
42. Install nuts, U-bolts, and muffler.

43. Connect heater hoses.
CAUTION: Heavy component; lift engine

using JDG23 Lifting Sling. Lifting force must
be 90 to engine lift points.
44. Connect inlet and outlet hydraulic hoses to fan

drive pump.
Specification
EngineApproximate Weight.................................................. 643 kg
1418 lb
45. Connect oil lines to remote oil filter.
37. Use JDG23 Lifting Sling to install engine. Install

cap screws (5) washers (7), and nuts (8). Tighten
cap screws.
47. Connect fuel lines to fuel injection pump.
Specification
Engine Isolator Cap Screws
Torque.................................................................................... 392 Nm
289 lb-ft
49. Install air conditioning compressor and mounting

bracket to engine.
38. Align hydraulic pump and drive gearbox to engine.

Install cap screws and muffler bracket. Tighten
cap screws to specification.
46. Connect fuel lines to fuel transfer pump.
48. Open fuel supply valve on bottom of fuel tank.
50. Connect engine wiring. See Engine Harness (W4)

Component Location and See Machine Harness
(W2) Component Location. (Group 9015-10.)
TM10079 (17MAR09)
04-0400-9
OUO6046,0002329 1919APR0715/16

031709
PN=121
04
0400
9

51. Install air intake mounting bracket at front of
engine.
57. Fill and check hydraulic oil level. See 200DLC

Drain and Refill Capacities. (Operators Manual.)
52. Connect air intake tubes.

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.
53. Connect upper and lower radiator hoses.

54. Install intercooler tubes.
55. Install top covers over control valve and muffler.
Tighten cap screws to specification.
Specification
Cover Cap ScrewsTorque.................................................... 50 Nm
37 lb-ft
04
0400
10
56. Fill cooling system. See Cooling System Fill and

Deaeration Procedure. (See Operators Manual.)
58. If hydraulic oil tank was drained, perform pump

start-up procedure. See Pump 1 and 2 Start-Up
Procedure. (Group 3360.)
59. Bleed fuel system. See Bleed Fuel System.
(Operators Manual.)
OUO6046,0002329 1919APR0716/16
TM10079 (17MAR09)
04-0400-10

031709
PN=122
Section 05
Engine Auxiliary System

Contents
Page
Group 0510Cooling System

Radiator Remove and Install . . . . . . . . . . . . .05-0510-1
Hydraulic Oil Cooler Remove and Install . . . .05-0510-5
Intercooler Remove and Install . . . . . . . . . . .05-0510-7
Fuel Cooler Remove and Install . . . . . . . . .05-0510-12
Cooling Package Remove and Install . . . . .05-0510-12
Fan, Fan Guard, and Fan Shroud Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .05-0510-19
Coolant Surge Tank Remove and Install . . .05-0510-23
Group 0520Intake System
Air Cleaner Remove and Install. . . . . . . . . . .05-0520-2
05
Group 0560External Fuel Supply System

Fuel Tank Remove and Install. . . . . . . . . . . .05-0560-1
Primary Fuel Filter (Water Separator)
Remove and Install . . . . . . . . . . . . . . . . . .05-0560-3
Final Fuel Filter Remove and Install . . . . . . .05-0560-4
TM10079 (17MAR09)
05-1

031709
PN=1
Contents
05
TM10079 (17MAR09)
05-2

031709
PN=2
Group 0510
Cooling System
Radiator Remove and Install
UN23AUG88
CAUTION: Prevent possible injury from hot

spraying water. DO NOT remove surge tank cap
unless engine is cool. Then remove cap slowly.
1. Remove surge tank filler cap to relieve pressure.
TS281
2. Open drain valve and drain coolant into suitable

container.
Specification
Cooling SystemCapacity ............................................................... 26.0 L
6.9 gal
3. Remove batteries. See Battery Remove and Install.

(Group 9015-20).
4. Remove fan and fan shroud. See Fan, Fan Guard, and
Fan Shroud Remove and Install. (Group 0510.)
05
0510
1
OUO1073,0002115 1918APR071/8
NOTE: It is not necessary to discharge air conditioning

system.
UN23MAR07
5. Disconnect wiring harness connector (3) from

receiver-dryer.
TX1020785A
6. Remove any clamps attaching air conditioning lines to

frame or panels.
IMPORTANT: Use caution when repositioning
condenser to avoid damaging
condenser fins.
1Cap Screw (4 used)
2Condenser
3Connector
7. Remove cap screws (1). Lay condenser (2) aside and

secure in place.
TM10079 (17MAR09)
05-0510-1
OUO1073,0002115 1918APR072/8

031709
PN=125
Cooling System
8. Disconnect fan drive motor hydraulic hose (1) from
hydraulic oil tank. Close all open lines and fittings
using caps and plugs.
UN19APR07
9. Remove cap screw (2) and hose clamp.

10. Route hydraulic hose back to fan drive motor.
UN22MAR07
TX1022358
1Hydraulic Hose (to Fan Drive Motor)

2Cap Screw
TX1020688A
05
0510
2
OUO1073,0002115 1918APR073/8
11. Tag and disconnect fan drive motor hydraulic hoses

(1 and 2). Close all open lines and fittings using caps
and plugs.
UN03APR07
12. Route hoses through opening in side of frame.
TX1021410A
1Hydraulic Hose
2Hydraulic Hose
OUO1073,0002115 1918APR074/8
13. Support fan drive motor assembly (2). Remove cap

screws (1) and fan drive motor assembly (2).
TX1020784A
UN23MAR07
1Cap Screw (4 used)

2Fan Drive Motor Assembly
TM10079 (17MAR09)
05-0510-2
OUO1073,0002115 1918APR075/8

031709
PN=126
Cooling System
14. Loosen clamp and disconnect lower radiator hose (1).
15. Remove cap screw (2).
TX1020802A
UN19MAR07
1Lower Radiator Hose

2Cap Screw
OUO1073,0002115 1918APR076/8
05
0510
3
TM10079 (17MAR09)
05-0510-3

031709
PN=127
Cooling System
CAUTION: Heavy component; use a hoist.
UN19MAR07
Specification
RadiatorWeight .............................................................................. 37 kg
82 lb
16. Attach suitable lifting device to radiator (1).
TX1020803A
17. Remove cap screws (2), washers, and nuts attaching

radiator to intercooler and hydraulic oil cooler.
18. Remove radiator.
1Radiator
19. Ensure all foam seals are in place and install radiator.
05
0510
4
Specification
Radiator-to-Hydraulic Oil Cooler
Cap ScrewsTorque ..................................................................... 37 Nm
27 lb-ft
Radiator-to-Intercooler Cap
ScrewsTorque ............................................................................. 37 Nm
27 lb-ft
Radiator-to-Frame Lower Cap
ScrewTorque ............................................................................... 55 Nm
41 lb-ft
20. Connect lower radiator hose.

21. Install fan drive motor assembly. Tighten cap screws
to specification.
Specification
Fan Drive Motor Assembly Cap
ScrewsTorque ............................................................................. 73 Nm
54 lb-ft
22. Connect fan drive motor hydraulic hoses.

23. Install condenser assembly.
24. Connect wiring harness connector to receiver-dryer.
25. Install fan and fan shroud. See Fan, Fan Guard, and
26. Install batteries. See Battery Remove and Install.
(Group 9015-20).
TM10079 (17MAR09)
05-0510-4
OUO1073,0002115 1918APR077/8

031709
PN=128
Cooling System
Deaeration Procedure. (Operators Manual.)
OUO1073,0002115 1918APR078/8
Hydraulic Oil Cooler Remove and Install

1. Remove radiator. See Radiator Remove and Install.
(Group 0510.)
OUO1073,0002116 1918APR071/7
IMPORTANT: Use caution when repositioning fuel

cooler to avoid damaging fuel cooler
fins.
UN05APR07
2. Remove cap screws (1). Lay fuel cooler (2) and

mounting bracket aside and secure in place.
TX1021429A
1Cap Screws
2Fuel Cooler
OUO1073,0002116 1918APR072/7
3. Disconnect upper hydraulic hose (3) from hydraulic oil

cooler (1).
UN03APR07
4. Remove cap screws and upper mounting bracket (2).
TX1021423A
1Hydraulic Oil Cooler

2Upper Mounting Bracket
3Hydraulic Hose
OUO1073,0002116 1918APR073/7
5. Drain hydraulic oil tank. Approximate oil capacity is 136

L (36 gal).
UN03APR07
6. Disconnect lower oil cooler hydraulic hose (1). Apply

caps and plugs to close all openings.
TX1021411A
1Hydraulic Hose
TM10079 (17MAR09)
05-0510-5
OUO1073,0002116 1918APR074/7

031709
PN=129
05
0510
5
Cooling System
UN03APR07
Specification
Hydraulic Oil CoolerWeight............................................................ 60 kg
132 lb
7. Attach suitable lifting device to hydraulic oil cooler.
TX1021412A
8. Remove cap screws (1) and (2).

1Hydraulic Oil Cooler-to-Frame Lower Cap Screw
2Mounting Bracket-to-Frame Cap Screws
OUO1073,0002116 1918APR075/7
9. Move hydraulic oil cooler (1) toward rear of machine

until hydraulic fitting in lower port clears access hole in
side panel.
UN23MAR07
10. Remove hydraulic oil cooler.

TX1020828A
05
0510
6
TM10079 (17MAR09)
05-0510-6
OUO1073,0002116 1918APR076/7

031709
PN=130
Cooling System
11. Remove washers (3 and 6), nuts (5), cap screws (4),
and mounting bracket (2) from hydraulic oil cooler (1).
4
3
Specification
Hydraulic Oil Cooler-to-Frame
Lower Cap ScrewTorque ............................................................ 55 Nm
41 lb-ft
6
5
14. Connect upper and lower hydraulic hoses.
TX1021207
13. Install hydraulic oil cooler. Tighten cap screw to

specification.
UN27MAR07
12. Install mounting bracket onto new hydraulic oil cooler.

2Mounting Bracket
3Washer (8 used)
4Cap Screw (8 used)
5Nut (8 used)
6Washer (8 used)
15. Install fuel cooler and mounting bracket.

16. Install upper mounting bracket and cap screws.
17. Install radiator. See Radiator Remove and Install.
(Group 0510.)
05
0510
7
18. Fill and check hydraulic oil level. See 200DLC Drain
and Refill Capacities. (Operators Manual.)
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.
19. Perform pump start-up procedure. See Pump 1 and 2
OUO1073,0002116 1918APR077/7
Intercooler Remove and Install

(Group 9015-20).
TM10079 (17MAR09)
05-0510-7
OUO1073,0002117 1918APR071/8

031709
PN=131
Cooling System
system.
UN23MAR07

receiver-dryer.
TX1020785A

frame or panels.
condenser fins.
1Cap Screw (4 used)
2Condenser
3Connector

secure in place.
OUO1073,0002117 1918APR072/8

UN19APR07

UN22MAR07
TX1022358

2Cap Screw
TX1020688A
05
0510
8
TM10079 (17MAR09)
05-0510-8
OUO1073,0002117 1918APR073/8

031709
PN=132
Cooling System
9. Tag and disconnect fan drive motor hydraulic hoses (1
and 2). Close all open lines and fittings using caps and
plugs.
UN03APR07
TX1021410A
1Hydraulic Hose
2Hydraulic Hose
OUO1073,0002117 1918APR074/8

TX1020784A
UN23MAR07
1Cap Screw (4 used)

OUO1073,0002117 1918APR075/8
12. Remove cap screws (1) and (2) from bottom of

intercooler.
UN23MAR07
13. Loosen clamps and disconnect lower intercooler tube

(3).
TX1020788A
1Mounting Bracket-to-Frame Cap Screws

2Intercooler-to-Frame Lower Cap Screw
3Lower Intercooler Tube
TM10079 (17MAR09)
05-0510-9
OUO1073,0002117 1918APR076/8

031709
PN=133
05
0510
9
Cooling System
UN23MAR07
Specification
IntercoolerWeight ........................................................................... 33 kg
73 lb
14. Attach suitable lifting device to intercooler (1).
TX1020789A
15. Remove cap screws (2), washers, and nuts from each
side of intercooler.
16. Remove intercooler.
1Intercooler
2Cap Screw (8 used)
OUO1073,0002117 1918APR077/8
05
0510
10
TM10079 (17MAR09)
05-0510-10

031709
PN=134
Cooling System
17. Remove cap screws and mounting bracket (1) from
intercooler (2).
UN23MAR07
18. Install mounting bracket onto new intercooler. Tighten

TX1020790A
Specification
Mounting Bracket-to-Intercooler
27 lb-ft
19. Ensure all foam seals are in place and install

intercooler. Tighten cap screws to specification.
Specification
Intercooler-to-Radiator Cap
ScrewsTorque ............................................................................. 37 Nm
27 lb-ft
Intercooler-to-Frame Lower Cap
ScrewTorque ............................................................................... 55 Nm
41 lb-ft
1Mounting Bracket
2Intercooler

to specification.
05
0510
11
Specification
Fan Drive Motor Assembly Cap
ScrewsTorque ............................................................................. 73 Nm
54 lb-ft
21. Connect fan drive motor hydraulic hoses.

22. Install condenser assembly.
(Group 9015-20).
OUO1073,0002117 1918APR078/8
TM10079 (17MAR09)
05-0510-11

031709
PN=135
Cooling System
Fuel Cooler Remove and Install

1. Tag and disconnect fuel hoses (1 and 4).
UN15FEB07
2. Remove cap screws (3) and fuel cooler (2).

3. Repair or replace as necessary.
TX1019245A
4. Install cooler and connect hoses.

5. Install air filter assembly.
1Fuel Return Hose
2Fuel Cooler
3Cap Screws (4 used)
4Fuel Supply Hose
OUO1073,0002101 1913MAR071/1
Cooling Package Remove and Install
UN21MAR07

penetrating injury. The hydraulic tank is
pressurized. Relieve pressure by pushing
TX1020485A
05
0510
12

TM10079 (17MAR09)
05-0510-12
OUO1073,000211A 1918APR071/13

031709
PN=136
Cooling System

UN23AUG88

3. Open drain valve and drain coolant into suitable
container.
TS281
Specification
Cooling SystemCapacity ............................................................... 26.0 L
6.9 gal

(Group 9015-20).
5. Remove access panels on bottom of machine.
OUO1073,000211A 1918APR072/13
05
0510
13
6. Raise engine hood.
UN05MAR07
7. Remove retaining pin and disconnect hood support rod

(1).
TX1020187A
Specification
Engine HoodWeight ....................................................................... 45 kg
100 lb
8. Attach appropriate lifting device to hood.

9. Remove cap screws (2) and hood (3).
TX1018847A
UN20FEB07
1Hood Support Rod

2Cap Screws
3Hood
TM10079 (17MAR09)
05-0510-13
OUO1073,000211A 1918APR073/13

031709
PN=137
Cooling System
10. Loosen clamps and disconnect upper intercooler tube
(1) and upper radiator hose (3).
UN03APR07
11. Remove turbocharger inlet tube (2).

12. Loosen clamps and disconnect coolant hose (4) from
radiator.
TX1021424A
13. Remove clamps attaching coolant hose (5) to fan

guard.
14. Drain hydraulic oil tank. Approximate oil capacity is
136 L (36 gal).
1Upper Intercooler Tube
2Turbocharger Inlet Tube
4Coolant Hose
5Coolant Hose
6Hydraulic Hose
7Hydraulic Hose
8Upper Mounting Bracket
15. Disconnect hydraulic hoses (6 and 7) to hydraulic oil

cooler. Apply caps and plugs to close all openings.
16. Remove cap screws and upper mounting bracket (8).
05
0510
14
OUO1073,000211A 1918APR074/13

system.
UN23MAR07

receiver-dryer.
TX1020785A

frame or panels.
condenser fins.
1Cap Screw (4 used)
2Condenser
3Connector
secure in place.
TM10079 (17MAR09)
05-0510-14
OUO1073,000211A 1918APR075/13

031709
PN=138
Cooling System
20. Remove cap screws (2) and condenser mounting
bracket (1).
TX1020786A
UN23MAR07
1Mounting Bracket
2Cap Screws
OUO1073,000211A 1918APR076/13
IMPORTANT: Use caution when repositioning fuel

cooler to avoid damaging fuel cooler
fins.
UN05APR07
21. Remove cap screws (1). Lay fuel cooler (2) and
mounting bracket aside and secure in place.
TX1021429A
1Cap Screws
2Fuel Cooler
OUO1073,000211A 1918APR077/13
22. Disconnect lower oil cooler hydraulic hose (1). Apply

caps and plugs to close all openings.
TX1021411A
UN03APR07
1Hydraulic Hose
TM10079 (17MAR09)
05-0510-15
OUO1073,000211A 1918APR078/13

031709
PN=139
05
0510
15
Cooling System
UN19APR07

UN22MAR07
TX1022358

2Cap Screw
TX1020688A
05
0510
16
OUO1073,000211A 1918APR079/13
26. Tag and disconnect fan drive motor hydraulic hoses

(1 and 2). Close all open lines and fittings using caps
and plugs.
UN03APR07
TX1021410A
1Hydraulic Hose
2Hydraulic Hose
TM10079 (17MAR09)
05-0510-16
OUO1073,000211A 1918APR0710/13

031709
PN=140
Cooling System
UN02APR07
Specification
Cooling PackageApproximate
Weight.............................................................................................. 159 kg
350 lb
TX1021077A
IMPORTANT: Do not use lifting eyes on individual

cooling package components
(intercooler, radiator, and hydraulic oil
cooler) to lift entire cooling package.
28. Attach suitable lifting device to cooling package (1).
1Cooling Package
OUO1073,000211A 1918APR0711/13
05
0510
17
TM10079 (17MAR09)
05-0510-17

031709
PN=141
Cooling System
29. Disconnect lower intercooler tube (2) and lower
radiator hose (3).
UN09APR07
30. Remove cap screws (46) from cooling package

components.
TX1021719A
IMPORTANT: Ensure lower hydraulic oil cooler fitting

is clear of panels and covers when
lifting cooling package.
31. Remove cap screws (1) and cooling package.
32. Replace components as necessary.
1Cap Screws
2Intercooler Tube
3Radiator Hose
4Cap Screw
5Cap Screw
6Cap Screw
33. Install cooling package. Tighten cap screws (46) to

specification.
05
0510
18
Specification
Intercooler-to-Frame Lower Cap
ScrewTorque ............................................................................... 55 Nm
41 lb-ft
Radiator-to-Frame Lower Cap
ScrewTorque ............................................................................... 55 Nm
41 lb-ft
Hydraulic Oil Cooler-to-Frame
Lower Cap ScrewTorque ............................................................ 55 Nm
41 lb-ft
34. Connect upper and lower intercooler tubes.

35. Connect upper and lower radiator hoses.
36. Connect upper and lower hydraulic oil cooler hoses.
37. Route and connect fan drive motor hydraulic hoses.
38. Install air conditioning condenser and fuel cooler.
40. Install cooling package upper mounting bracket and
cap screws.
41. Install covers.
42. Install hood.
(Group 9015-20).
TM10079 (17MAR09)
05-0510-18
OUO1073,000211A 1918APR0712/13

031709
PN=142
Cooling System
44. Fill cooling system. See See Cooling System Fill and
46. Perform pump start-up procedure. See Pump 1 and 2
OUO1073,000211A 1918APR0713/13
05
0510
19
Fan, Fan Guard, and Fan Shroud Remove

and Install
Remove and Install Fan and Fan Guard
OUO1073,0002118 1918APR071/9

UN23AUG88
TS281
2. Drain coolant until level is below upper radiator hose.
OUO1073,0002118 1918APR072/9
3. Remove cap screws (2) and fan guard (3).

4. Loosen clamps and remove upper radiator hose (1).
TX1021405A
UN03APR07

2Cap Screw (4 used)
3Fan Guard
TM10079 (17MAR09)
05-0510-19
OUO1073,0002118 1918APR073/9

031709
PN=143
Cooling System
5. Loosen clamps and remove upper radiator hose.
6. Remove cap screws (2), washers, and fan (1).
UN27MAR07
7. Install fan, washers, and cap screws. Tighten cap

TX1021215A
Specification
Fan Cap ScrewsTorque .............................................................. 37 Nm
27 lb-ft
8. Install upper radiator hose.

9. Install fan guard and cap screws. Tighten cap screws
to specification.
1Fan
2Cap Screw (6 used)
Specification
Fan Guard Cap ScrewsTorque .................................................. 37 Nm
27 lb-ft

Remove and Install Fan Shroud
OUO1073,0002118 1918APR074/9
UN21MAR07

TX1020485A
05
0510
20

TM10079 (17MAR09)
05-0510-20
OUO1073,0002118 1918APR075/9

031709
PN=144
Cooling System

UN23AUG88
TS281
3. Drain coolant until level is below upper radiator hose.
OUO1073,0002118 1918APR076/9
4. Raise engine hood.
UN05MAR07
5. Remove retaining pin and disconnect hood support rod

(1).
TX1020187A
Specification
Engine HoodWeight ....................................................................... 45 kg
100 lb
6. Attach appropriate lifting device to hood.

7. Remove cap screws (2) and hood (3).
8. Remove fan and fan guard.
UN20FEB07
9. Remove access covers on bottom of machine.
TX1018847A
1Hood Support Rod

2Cap Screws
3Hood
TM10079 (17MAR09)
05-0510-21
OUO1073,0002118 1918APR077/9

031709
PN=145
05
0510
21
Cooling System
10. Remove fan guard (8) and engine fan.
UN03APR07
11. Loosen clamps and remove upper intercooler tube

(1).
12. Remove turbocharger inlet tube (2).
TX1021406A
13. Loosen clamps and disconnect upper radiator hose

(3) and coolant hose (4).
pump. See Apply Vacuum to Hydraulic Oil Tank.
(Group 3360.)
1Upper Intercooler Tube
2Turbocharger Inlet Tube
4Coolant Hose
5Fan Shroud
6Cap Screw (8 used)
7Hydraulic Hose
8Fan Guard
15. Disconnect hydraulic hose (7). Close all open lines

and fittings using caps and plugs.
NOTE: Lower shroud cap screws can be accessed by
removing access panel on bottom of
upperstructure.
05
0510
22
16. Remove cap screws (6) and washers from fan shroud
(5).
IMPORTANT: To prevent damage to fan shroud, use
an additional technician to help guide
shroud past fan drive motor shaft from
below.
17. Lift fan shroud up, tilt toward left-hand side of
machine, and remove.
18. Install fan shroud, washers, and cap screws. Tighten
Specification
Fan Shroud Cap ScrewsTorque ................................................. 37 Nm
27 lb-ft
19. Connect hydraulic oil cooler hose.

20. Install upper intercooler cooler tube.
21. Install turbocharger inlet tube.
22. Install fan and fan guard.
23. Connect upper radiator hose and coolant hose.
TM10079 (17MAR09)
05-0510-22
OUO1073,0002118 1918APR078/9

031709
PN=146
Cooling System
24. Install hood.
26. Check hydraulic oil level. Fill as necessary. See
200DLC Drain and Refill Capacities. (Operators
Manual.)
OUO1073,0002118 1918APR079/9
Coolant Surge Tank Remove and Install
UN23AUG88

TS281
OUO1073,0002119 1918APR071/2
2. Drain coolant until level is below surge tank.
UN04APR07
3. Loosen hose clamps and disconnect hoses (1, 2, and

5).
4. Remove cap screws (3) and coolant surge tank (4).
TX1021392A
5. Remove coolant surge tank. Replace as necessary.

6. Install coolant surge tank and cap screws.
7. Connect hoses and tighten clamps.
1Hose
2Hose
3Cap Screw (4 used)
4Coolant Surge Tank
5Hose
OUO1073,0002119 1918APR072/2
TM10079 (17MAR09)
05-0510-23

031709
PN=147
05
0510
23
Cooling System
05
0510
24
TM10079 (17MAR09)
05-0510-24

031709
PN=148
Group 0520
Intake System
05
0520
1
TM10079 (17MAR09)
05-0520-1

031709
PN=149
Intake System
Air Cleaner Remove and Install
TX1021314
UN04APR07
05
0520
2
TM10079 (17MAR09)
05-0520-2
LD30992,000041E 1905APR071/2

031709
PN=150
Intake System
1Hose Clamp
2Hose
3Hose Clamp
4Air Filter Restriction Switch
5Cap Screw (2 used)
6Washer (2 used)
7Intake Tube
8Washer
9Cap Screw
10Washer (2 used)
11Nut (2 used)
12Cap Screw
13Washer
14Mounting Bracket
16Washer (2 used)
17Intake Tube
18Tie Band
19Intake Air Temperature
Sensor
20Hose Clamp
21Hose
22Hose Clamp
23Hose Clamp
24Hose
25Hose Clamp
27Washer (4 used)
28Mounting Bracket
29Washer (4 used)
31Housing Mounting Clamps
32Air Filter Housing
33Safety Element
34Primary Air Filter Element
35Cover
36Air Cleaner Dust Valve
LD30992,000041E 1905APR072/2
05
0520
3
TM10079 (17MAR09)
05-0520-3

031709
PN=151
Intake System
05
0520
4
TM10079 (17MAR09)
05-0520-4

031709
PN=152
Group 0560
External Fuel Supply System

Fuel Tank Remove and Install
1. Drain fuel from tank. Approximate capacity is 400 L
(105.7 gal).
NOTE: Two cap screws for cover (1) are located in
toolbox (4).
UN30MAR07
2. Disconnect and remove wiring harness from inside of

toolbox.
3. Remove step (2), cover (1), handrail (3), and toolbox
(4).
TX1021212A
Specification
ToolboxWeight ............................................................................... 33 kg
72 lb
4. Remove control valve cover and hydraulic oil tank

cover.
1Cover
2Step
3Handrail
4Toolbox
TM10079 (17MAR09)
05-0560-1
05
0560
1
TJ15698,0000153 1912APR071/3

031709
PN=153

5. Disconnect electrical connector (4) and return hose (2).
6. Disconnect fuel supply hose from bottom of tank.
UN07MAR07

7. Remove cap screws (1) and fuel tank.
TX1020200A
Specification
Fuel TankWeight .................................. 108 kg approximate without fuel
238 lb approximate without fuel

9. Install fuel tank and tighten mounting cap screws to
specification.
10. Connect fuel supply hose, return hose, and electrical

connector.
TX1020197A
05
0560
2
UN07MAR07
Specification
Fuel Tank Mounting Cap
ScrewsTorque ........................................................................... 270 Nm
199 lb-ft
11. Install control valve cover and hydraulic oil tank cover.
2Fuel Return Hose
3Clamp
4Electrical Connector
TM10079 (17MAR09)
05-0560-2
TJ15698,0000153 1912APR072/3

031709
PN=154

12. Install handrail (3), toolbox (4), cover (1), and step
(2).
13. Fill tank with fuel.
14. Bleed fuel system. See Bleed Fuel System.
(Operators Manual.)
TX1021212A
UN30MAR07
1Cover
2Step
3Handrail
4Toolbox
05
0560
3
TJ15698,0000153 1912APR073/3
Primary Fuel Filter (Water Separator) Remove

and Install
UN21MAR07
1. Loosen drain valve on bottom of filter and drain fuel

into a container.
2. Disconnect electrical connector (2) from bottom of filter.
TX1020481A
3. Tag and disconnect fuel hoses (3).

4. Remove cap screws (1) and primary fuel filter
assembly.
5. Install primary fuel filter assembly and tighten cap
screws.
1Cap Screw (2 used)

3Fuel Hose (2 used)
6. Connect fuel hoses and electrical connector.

7. Bleed fuel system. See Bleed Fuel System. (Operators
Manual.)
TJ15698,0000154 1911APR071/1
TM10079 (17MAR09)
05-0560-3

031709
PN=155
Final Fuel Filter Remove and Install
UN21MAR07
1. Loosen drain valve on bottom of filter and drain fuel

into a container.
2. Disconnect electrical connector (2).
TX1020482A
3. Tag and disconnect fuel hoses (3).

4. Remove cap screws (1) and final fuel filter assembly.
5. Install final fuel filter assembly and tighten cap screws.
6. Connect fuel hoses and electrical connector.
7. Bleed fuel system. See Bleed Fuel System. (Operators
Manual.)
1Cap Screw (2 used)

3Fuel Hose (2 used)
TJ15698,0000155 1911APR071/1
05
0560
4
TM10079 (17MAR09)
05-0560-4

031709
PN=156
Section 07
Dampener Drive (Flex Coupling)

Contents
Page
Group 0752Elements
Dampener Drive (Flex Coupling) Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1
07
TM10079 (17MAR09)
07-1

031709
PN=1
Contents
07
TM10079 (17MAR09)
07-2

031709
PN=2
Group 0752
Elements
Dampener Drive (Flex Coupling) Remove and
Install
1. Remove engine or hydraulic pump. See Engine
Remove and Install. (Group 0400.) or See Pump 1 and
2 Remove and Install. (Group 3360.)
NOTE: Flex coupling may come off with pump or stay on
engine flywheel.
2. Remove parts (18).
UN02MAR07
3. Inspect and replace parts as necessary.
TX1019969
IMPORTANT: Do not use steel hammer to install

guide pins (2). Use only rubber or
plastic mallet.
4. If guide pins in engine flywheel are damaged, remove
and replace pins. Use new pins and install into
flywheel using a plastic or rubber mallet.
1Hub
2Set Screw (2 used)
3Flex Coupling
4Cap Screw (4 used)
5Insert (4 used)
6Guide Pins (4 used)
7Cap Screw (4 used)
8Insert (4 used)
5. Install each insert so index hole is aligned with guide

pin, installed in previous step.
07
0752
1
FS41334,0000170 1910APR071/3

Strength) to cap screws (3). Tighten to specification.
UN19MAR07
Specification
Flex Coupling-to-Flywheel Cap
ScrewTorque ............................................................................. 137 Nm
101 lb-ft
TX1019893A
7. Install flex coupling (4) onto flywheel inserts (2) as

shown.
1Engine Flywheel
2Insert (4 used)
3Cap Screw (4 used)
4Flex Coupling
TM10079 (17MAR09)
07-0752-1
FS41334,0000170 1910APR072/3

031709
PN=159
Elements
8. Clean face of hydraulic pump housing (1).
UN19MAR07

Strength) to threads of cap screws (4).
10. Install inserts (2) onto hub (5) using cap screws (4)
and tighten to specification.
CAUTION: Install hub assembly so face is flush

with end of pump shaft. It cannot rub or hit
pump housing or shaft oil seal when rotated.
11. Install hub (5) onto splines of pump shaft (6). Position
hub so face is flush with pump shaft end. Space
between hub and pump housing is approximately 2
mm (0.08 in.).
TX1019891A
Specification
Pump Insert Cap Screws
Torque .......................................................................................... 137 Nm
101 lb-ft
1Hydraulic Pump Housing

2Insert (4 used)
3Set Screw (2 used)
4Cap Screw (4 used)
5Hub
6Pump Shaft

Strength) to set screws (3).
13. Tighten set screws (3) to specification.
07
0752
2
Specification
Hub-to-Pump Shaft Set Screw
Torque .......................................................................................... 108 Nm
80 lb-ft
14. Install engine or hydraulic pump. See Engine Remove

and Install. (Group 0400.) or See Pump 1 and 2
FS41334,0000170 1910APR073/3
TM10079 (17MAR09)
07-0752-2

031709
PN=160
Section 17
Frame or Supporting Structure

Contents
Page
Group 1740Frame Installation

Welding On Machine . . . . . . . . . . . . . . . . . . .17-1740-1
Welding Repair of Major Structure. . . . . . . . .17-1740-3
Group 1749Chassis Weights
Counterweight Remove and Install . . . . . . . .17-1749-1
17
TM10079 (17MAR09)
17-1

031709
PN=1
Contents
17
TM10079 (17MAR09)
17-2

031709
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,
engine control unit (ECU), information
controller (ICF) and main controller
(MCF). Disconnect battery cables and
ECU, ICF and MCF electrical connectors
before welding on the machine.
Before welding on the machine, follow the steps listed
below to protect the machine electrical system.
OUO1073,0002113 1909APR071/4
1. Disconnect battery ground and positive cables.
UN07FEB06
2. Remove rear console cover behind seat. See Rear

Cover Remove and Install. (9015-20.)
3. Disconnect electrical connectors (1) from MCF (2). See
Cab Harness (W1) Component Location(9015-10.)
TX1003378A
1Electrical Connectors
2Main Controller (MCF)
OUO1073,0002113 1909APR072/4
4. Disconnect electrical connectors (1) from ICF (2). See

Cab Harness (W1) Component Location. (9015-10.)
TX1003380A
UN01MAR06
1Electrical Connector (2 used)

2Information Controller (ICF)
TM10079 (17MAR09)
17-1740-1
OUO1073,0002113 1909APR073/4

031709
PN=163
17
1740
1
Frame Installation
6. Disconnect electrical connectors (2) from engine

control unit (ECU) (1). See Engine Interface Harness
(W5) Component Location. (9015-10.)
TX1021720A
1Engine Control Unit (ECU)

2Electrical Connectors
UN09APR07
NOTE: Engine Control Unit (ECU) is located in the engine

compartment.
OUO1073,0002113 1909APR074/4
17
1740
2
TM10079 (17MAR09)
17-1740-2

031709
PN=164
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 and
positive cables. Also disconnect the
wiring harness connectors to the
main controller (MCF), information
controller (ICF) and engine control
unit (ECU). See Welding on Machine.
(Group 1740.)
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.
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)
2. Use one of the following weld processes:

AWS-E-7018 covered electrode with shielded
metal arc welding (SMAW) process.
OUO1073,0002114 1928MAR071/1
TM10079 (17MAR09)
17-1740-3

031709
PN=165
17
1740
3
Frame Installation
17
1740
4
TM10079 (17MAR09)
17-1740-4

031709
PN=166
Group 1749
Chassis Weights
Counterweight Remove and Install
1. Park machine on level ground.
UN20JUL01
2. Remove two plastic caps (1) from top of counterweight.
T143043

lifting device.
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.
UN03SEP02
Specification
CounterweightWeight ................................................................. 4250 kg
9371 lb
T143044
3. Connect counterweight to an appropriate lifting device

(2) using a spreader bar (3).
4. Remove cap screws and washers (4).
5. Remove counterweight.
UN20JUL01
7. Install counterweight onto machine using appropriate

lifting device.
8. Install cap screws and washers (4). Tighten to
specification.
T143045
Specification
Frame-to-Counterweight Cap
ScrewTorque ........................................................................... 1570 Nm
1158 lb-ft
1Plastic Cap (2 used)
2Lifting Device
3Spreader Bar
4Cap Screw and Washer (4 used)
TJ15698,000017D 1902APR071/1
TM10079 (17MAR09)
17-1749-1

031709
PN=167
17
1749
1
Chassis Weights
17
1749
2
TM10079 (17MAR09)
17-1749-2

031709
PN=168
Section 18
Operators Station
Contents
Page

Cab Remove and Install . . . . . . . . . . . . . . . .18-1800-1
Group 1810Operator Enclosure
Sliding Windows Remove and Install. . . . . . .18-1810-1
Windowpanes Remove and Install . . . . . . . .18-1810-2
Windowpanes Dimensions . . . . . . . . . . . . . .18-1810-3
Group 1821Seat and Seat Belt
Seat Remove and Install . . . . . . . . . . . . . . . .18-1821-1
Seat Belt Remove and Install . . . . . . . . . . . .18-1821-2
Mechanical Suspension Seat Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-3
Air Suspension Seat Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-4
Left and Right Console Covers Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-5
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 Remove and Install . . . . . . . . .18-1830-11
Condenser Remove and Install . . . . . . . . . .18-1830-11
Heater and Air Conditioner Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13
Receiver-Dryer Remove and Install . . . . . . .18-1830-17
TM10079 (17MAR09)
18-1
18

031709
PN=1
Contents
18
TM10079 (17MAR09)
18-2

031709
PN=2
Group 1800

Cab Remove and Install
1. Disconnect battery ground (-) cable.
2. Remove panels to access rear of cab.
OUO1073,0002107 1910APR071/12
3. Disconnect cab wiring harness connectors (14).

4. Disconnect ground wires (5) from frame.
5. Remove seat. See Seat Remove and Install. (Group
1821.)
6. Remove cab floor mat.
TX1020388A
UN19MAR07
1Connector
2Connector
3Connector
4Connector
5Ground
OUO1073,0002107 1910APR072/12
7. Remove cap screws (2) and bracket (1) from cab

frame (3) and seat mount (4).
18
1800
1
TX1020391
UN16MAR07
1Bracket
2Cap Screw (3 used)
3Cab Frame
4Seat Mount
TM10079 (17MAR09)
18-1800-1
OUO1073,0002107 1910APR073/12

031709
PN=171

8. Remove cover (1) from rear panel.
UN08MAR07
9. Remove screws (2) and cap screws (3) from rear panel
(4).
10. Pull rear panel forward. Disconnect wiring harness
from lighter and power outlet and remove panel.
TX1020272A
1Cover
2Screws
3Cap Screws
4Panel
OUO1073,0002107 1910APR074/12
11. Remove screws (1), panel (2), and air duct (3).
TX1020347A
UN08MAR07
1Screw
2Panel
3Air Duct
OUO1073,0002107 1910APR075/12
UN08MAR07
1Inlet Duct
2Cap Screw
TX1020275A
18
1800
2
12. Remove cap screws (2), mounting bracket, and fresh

air inlet duct (1).
TM10079 (17MAR09)
18-1800-2
OUO1073,0002107 1910APR076/12

031709
PN=172

13. Remove cap screw (1) behind 12 volt power
converter.
UN19MAR07
14. Remove cap screw (3), cap screws (5) and bracket
(4).
TX1020387A
15. Disconnect cab wiring harness (2) from left and right
consoles and air conditioning module. See Cab
Harness (W1) Component Location. (Group 9015-10).
16. Remove any clamps or tie bands securing cab
harness to floor or consoles.
TX1020394A
UN19MAR07
1Cap Screw
2Cab Wiring Harness
3Cap Screw
4Bracket
5Cap Screws
OUO1073,0002107 1910APR077/12
17. Remove monitor controller (1). See Monitor Controller

Remove and Install. (Group 9015-20.)
UN27MAR07
18. Remove cup holder (2) and panel (3).
TX1021236A
1Monitor Controller
2Cup Holder
3Panel
TM10079 (17MAR09)
18-1800-3
OUO1073,0002107 1910APR078/12

031709
PN=173
18
1800
3

19. Remove access covers from bottom of cab.
20. Remove anchor bolts (1), spacers, and washers.
UN19MAR07
21. Remove cap screw and disconnect ground (1) from

frame.
TX1020389A
1Ground Wire
2Anchor Bolt
TX1020390A
UN19MAR07
Rear Anchor Bolt
Front Anchor Bolt

OUO1073,0002107 1910APR079/12
1
2
2
18
1800
4
1Lock Nut (4 used)

2Washer (4 used)
3Socket Head Cap Screw (4 used)
4Washer (4 used)
5Cap Screw (6 used)
6Washer (6 used)
7Socket Head Cap Screw
8Washer
6
8
18-1800-4
6
7
TM10079 (17MAR09)
UN19MAR07
TX1020393
22. Remove socket head cap screws (3 and 7), cap

screws (5), and isolator lock nuts (1) to separate cab
frame from floor. Discard lock nuts.
OUO1073,0002107 1910APR0710/12

031709
PN=174

lifting device.
UN14MAR06
Specification
CabWeight ................................................................................... 330 kg
730 lb
TX1003209A
23. Use lifting straps and connect appropriate lifting

device to lifting brackets (1) on roof of cab.
IMPORTANT: Before lifting cab, ensure all wiring
harness connectors and ducts have
been disconnected.
1Lifting Brackets
24. Remove cab.

IMPORTANT: Ensure all wiring harnesses and other
components are out of the way before
installing cab.
26. Install cab. Tighten cab mounting hardware to
specification.
Specification
Cab-to-Floor Socket Head Cap
ScrewsTorque ............................................................................. 50 Nm
37 lb-ft
Specification
Cab-to-Floor Cap Screws
Torque ............................................................................................ 50 Nm
37 lb-ft
Specification
Cab Isolator Lock NutsTorque .................................................. 210 Nm
155 lb-ft
Specification
Cab Anchor BoltsTorque .......................................................... 550 Nm
406 lb-ft
18
1800
5
27. Install access covers on bottom of cab. Tighten cap

Specification
Cab Access Cover Cap Screws
Torque ............................................................................................ 50 Nm
37 lb-ft
TM10079 (17MAR09)
18-1800-5
OUO1073,0002107 1910APR0711/12

031709
PN=175

28. Connect cab wiring harness connectors. See Cab
Harness (W1) Component Location. (Group 9015-10).
29. Connect ducts to heater and air conditioning module.
30. Install monitor controller. See Monitor Controller
Remove and Install. (Group 9015-20.)
31. Install seat. See Seat Remove and Install. (Group
1821.)
32. Install panels behind cab.
OUO1073,0002107 1910APR0712/12
18
1800
6
TM10079 (17MAR09)
18-1800-6

031709
PN=176
Group 1810
Operator Enclosure
Sliding Windows Remove and Install
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.
UN30APR01
5. Apply PM37532 Black Weatherstrip Adhesive to cab

flange.
T140968
6. Install windows and frame with spacers (2) at the

bottom.
7. Using water as 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
RO33873,0000A5E 1919MAY081/1
18
1810
1
TM10079 (17MAR09)
18-1810-1

031709
PN=177
Operator Enclosure
Windowpanes Remove and Install

The adhesive used to secure windowpanes is a urethane
adhesive used on automobile windshields. Urethane
adhesive manufactured by Henkel 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
ultraviolet barrier around edge to
prevent adhesive deterioration.
Windowpanes ordered through John
Deere Parts include ultraviolet barrier. If
windowpane is purchased through
glass dealer, the dealer must
incorporate ultraviolet 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 bond to bare metal.
3. If existing adhesive is removed and paint is scraped,
paint window frame. Paint must fully cure before
installing windowpane.
4. Trim existing adhesive to form a smooth surface.
IMPORTANT: Follow manufacturers instructions for
using adhesive.
18
1810
2
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.
RO33873,0000A5F 1903APR071/1
TM10079 (17MAR09)
18-1810-2

031709
PN=178
Operator Enclosure
Windowpanes Dimensions
TX1021276
UN04APR07
18
1810
3
Cab Door Glass

TM10079 (17MAR09)
18-1810-3
OUO1073,0002108 1917APR071/5

031709
PN=179
Operator Enclosure
TX1018573
UN23FEB07
18
1810
4
Cab Right-Hand Glass
TM10079 (17MAR09)
18-1810-4
OUO1073,0002108 1917APR072/5

031709
PN=180
Operator Enclosure
TX1021275
UN04APR07
18
1810
5
Cab Rear and Left-Hand Rear Glass
TM10079 (17MAR09)
18-1810-5
OUO1073,0002108 1917APR073/5

031709
PN=181
Operator Enclosure
TX1018570
UN23FEB07
18
1810
6
Cab Front Glass
TM10079 (17MAR09)
18-1810-6
OUO1073,0002108 1917APR074/5

031709
PN=182
Operator Enclosure
1Black Ceramic Coating
Range
2Black Ceramic Coating

Surface
NOTE: Dimensions shown are in millimeters.

OUO1073,0002108 1917APR075/5
18
1810
7
TM10079 (17MAR09)
18-1810-7

031709
PN=183
Operator Enclosure
18
1810
8
TM10079 (17MAR09)
18-1810-8

031709
PN=184
Group 1821
Seat and Seat Belt

Seat Remove and Install
1. Slide seat forward.
UN08MAR07
2. Remove cap screws (1), lock washers, and lower seat

belts from each side of seat.
TX1020303A
3. Remove socket head cap screws (2) from rear of seat.

4. Slide seat rearward.
5. Remove socket head cap screws (5) from front of seat.
UN08MAR07
Specification
SeatWeight.................................................................................... 40 kg
90 lb
TX1020304A
6. Remove seat through front window using lifting strap

and hoist.
8. Install seat.
9. Tighten seat mounting hardware to specification.
Specification
Seat Mount Socket Head Cap
ScrewsTorque ............................................................................. 20 Nm
177 lb-in.
1Cap Screw
2Socket Head Cap Screw
3Cap Screws
4Stop
5Socket Head Cap Screws
10. Install lower seat belt, lock washer and cap screw on
each side of seat. Tighten cap screw to specification.
Specification
Lower Seat Belt Mount Cap
ScrewsTorque ............................................................................. 50 Nm
37 lb-ft
18
1821
1
OUO1073,00020FF 1917APR071/1
TM10079 (17MAR09)
18-1821-1

031709
PN=185
Seat and Seat Belt
Seat Belt Remove and Install

1. Slide seat forward. Remove cap screw (2), lock washer
and lower seat belt (1) from each side of seat.

4. Install seat belts and cap screws (4).
5. Install lower seat belt to lower mount on each side of
seat using cap screw (4), lock washer and cap screw.
Tighten cap screw to specification.
TX1018443A
UN09FEB07
2. Remove cap screw (4) and upper seat belt (3) from
each side of seat.
Specification
Lower Seat Belt Mount Cap
ScrewsTorque ............................................................................. 50 Nm
37 lb-ft
T188988B
UN26MAR03
1Lower Seat Belt

2Cap Screw
3Upper Seat Belt
4Cap Screw
OUO1073,00020E8 1910APR071/1
18
1821
2
TM10079 (17MAR09)
18-1821-2

031709
PN=186
Seat and Seat Belt
TX1004008
UN21FEB06
Mechanical Suspension Seat Disassemble and Assemble
0Seat Assembly
2Cushion Cover
3Support
4Cushion
5Pad
6Frame
7Cable
8Stand
10Spring
11Torsional Damper
12Adjuster
13Lever
14Seat Suspension
15Seat Slide Track Kit
16Handle
17Cover
20Bushing
21Link
24Seat Kit
25Head Restraint
RO33873,0000A6B 1916MAR061/1
TM10079 (17MAR09)
18-1821-3

031709
PN=187
18
1821
3
Seat and Seat Belt
UN21FEB06
Air Suspension Seat Disassemble and Assemble
TX1004009
18
1821
4
0Seat Assembly
2Cushion Cover
3Pad
4Cushion
5Pad
6Frame
7Cable
8Handle
9Stand
10Spring
11Seat Slide Track Kit
14Lever Kit
15Bearing Kit
16Compressor
17Lever
18Torsional Damper
19Air Spring Seat Kit
20Valve
21Kit
22Seat Suspension
23Seat Suspension Boot Kit
24Seat Adjustment Cable Kit
25Wiring Lead
26Head Restraint
27Heater
RO33873,0000A6C 1916MAR061/1
TM10079 (17MAR09)
18-1821-4

031709
PN=188
Seat and Seat Belt
Left and Right Console Covers Remove and

Install
UN08FEB07
1. Remove pilot control shutoff lever (1).

2. Remove cap screws (2) from pilot control boot.
TX1018700A
1Pilot Control Shutoff Lever

2Cap Screws and Washers (8 used)
LD30992,00004F1 1928MAR071/3
18
1821
5
TM10079 (17MAR09)
18-1821-5

031709
PN=189
Seat and Seat Belt
TX1000801
UN15DEC05
18
1821
6
TM10079 (17MAR09)
18-1821-6
LD30992,00004F1 1928MAR072/3

031709
PN=190
Seat and Seat Belt

0Cover
4Screw (4 used)
5Cap Screw, Washer, and
Lock Washer
7Cover
Lock Washer (2 used)

Lock Washer
11Cover
Lock Washer
15Cover
16Screw (4 used)
3. Remove:
Caps (28)
Screws (4 and 16)
Cap Screws (5, 8, 9, 12, 19, 23, 24, and 27)
Covers (0, 7, 11, 15, 18, 22, and 26)
18Cover
22Cover
Lock Washer
26Cover
28Cap (2 used)
30Label
31Label

5. Install covers, cap screws, screws, and caps.
6. Install pilot control shutoff lever and pilot control
boot cap screws.
LD30992,00004F1 1928MAR073/3
18
1821
7
TM10079 (17MAR09)
18-1821-7

031709
PN=191
Seat and Seat Belt
18
1821
8
TM10079 (17MAR09)
18-1821-8

031709
PN=192
Group 1830
Heating and Air Conditioning

Refrigerant Cautions and Proper Handling
R134a is used in the air conditioning
system. Because it does not contain
chlorine, R134a is not detrimental to
the ozone in the atmosphere.
However, it is illegal to discharge
any refrigerant into the atmosphere.
It must be recovered using the
appropriate recovery stations.
CAUTION: DO NOT allow liquid refrigerant to

contact eyes or skin. Liquid refrigerant will
freeze eyes or skin on contact. Wear
goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO
NOT rub the area. Splash large amounts of
COOL water on affected area. Go to a
physician or hospital immediately for
treatment.
Use correct refrigerant recovery,

recycling and charging stations.
Never mix refrigerants, hoses,
fittings, components or refrigerant
oils.
DO NOT allow refrigerant to contact open

flames or very hot surfaces such as electric
welding arc, electric heating element and
lighted smoking materials.
Use only John Deere approved

R134a refrigerant products. Mixing of
products not compatible will cause
system damage and contaminate
recovery, recycling and charging
station equipment. Care must be
taken to identify and use equipment,
refrigerant oil and refrigerant
designed only for R134a refrigerant
systems. Refrigerant should be
tested for type and purity before
recovery, recycling or charging of
system. JT02167A refrigerant test
instrument should be used before
any testing or repair to system is
preformed.
DO NOT heat refrigerant over 52C (125F) in

a closed container. Heated refrigerant will
develop high pressure which can burst the
container.
Keep refrigerant containers away from heat
sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container
with your bare hands. Skin may freeze to
container. Wear gloves.
If skin freezes to container, pour COOL
water over container to free the skin. Go to a
physician or hospital immediately for
treatment.
IMPORTANT: To meet government standards
relating to the use of refrigerants,
18
1830
1
TM10079 (17MAR09)
18-1830-1
TX,9031,DY5073 1921JUL061/2

031709
PN=193

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 1921JUL062/2
18
1830
2
TM10079 (17MAR09)
18-1830-2

031709
PN=194
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. (Group 1830.)
a. Remove compressor and measure oil drained

from both manifold ports.
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.
NOTE: Flushing can be performed on machine.

1. Recover refrigerant from system. See Recover
R134a Refrigerant. (Group 1830.)
Specification
Flushing Solvent in Suction
PortVolume........................................................................... 240 mL
8 fl oz
Flushing Solvent in Discharge
PortVolume........................................................................... 120 mL
4 fl oz
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.
d. Turn compressor end for end and roll it side to

side.
4. Fill flusher tank with solvent and fasten all

connections. Dispose of solvent properly.
Specification
Flusher TankCapacity ................................................................. 4 L
1 gal
NOTE: Air pressure must be at least at specification

for flushing and purging.
Specification
Air PressureMinimum
Pressure........................................................ 620 kPa for flushing and
purging
90 psi for flushing and purging
6.2 bar for flushing and purging
e. Remove both plugs from manifold ports and

drain solvent from compressor.
f. Connect battery power to compressor clutch coil.
Rotate pulley at least five revolutions to move
solvent out of cylinders.
g. Invert compressor. Roll end for end and side to
side. Drain thoroughly.
h. Repeat previous two steps at least three times.
8. Divide system into two circuits:
5. Connect 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.
18
1830
3
Condenser circuit, including inlet and outlet

hoses.
Evaporator circuit, including inlet and outlet
hoses.
9. Condenser:
7. Clean compressor as follows:
TM10079 (17MAR09)
18-1830-3
OUO1073,0002109 1910APR071/3

031709
PN=195

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:
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 piece of
cardboard; continue purging until cardboard is
dry.
b. Remove and discard receiver/dryer.

c. Connect flusher outlet hose to inlet end of
compressor discharge line using JT02102
Adapter.
10. See flush evaporator, if evaporator requires

flushing.
d. Fill flusher tank with solvent and fasten all

connections.
Specification
1 gal
NOTE: Air pressure must be at least to specification

Specification
Air PressureMinimum
Pressure........................................................ 620 kPa for flushing and
purging.
90 psi for flushing and purging.
6.2 bar for flushing and
purging.
e. Connect supply line of moisture-free compressed

air or dry nitrogen to flusher air valve.
18
1830
4
Put nozzle in container to collect flushing

solvent.
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 return hose and aerator nozzle to end of
receiver/dryer inlet hose using JT03197 Adapter.
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
Heater and Air Conditioner Remove and Install.
(Group 1830.)
b. Force flushing solvent through evaporator inlet
with compressed air.
c. Purge system until dry.
d. Install evaporator and then go to step 13.
12. Flush evaporator through expansion valve:
a. Connect flusher outlet hose to connection of
receiver/dryer outlet hose using JT03188
adapter.
b. Fill flusher tank and fasten all connections.
Specification
1 gal
TM10079 (17MAR09)
18-1830-4
OUO1073,0002109 1910APR072/3

031709
PN=196

NOTE: Air pressure must be at least to specification
Specification
Air PressureMinimum
Pressure........................................................ 620 kpa for flushing and
purging.
90 psi for flushing and purging.
6.2 bar for flushing and
purging.
c. Connect supply line of moisture-free

compressed air or dry nitrogen to flusher air
valve.
d. Attach hose and aerator nozzle to compressor
inlet line using JT02101 adapter. Put nozzle in
container to collect solvent.
13. Disconnect hose from aeration nozzle to check

circuit for solvent. Hold hose close to piece of
cardboard and continue purging until cardboard is
dry.
14. Install new receiver/dryer compatible with R134a
refrigerant. Fasten connections and mounting
bracket. See Receiver-Dryer Remove and Install.
(Group 1830.)
15. Add required oil. See R134a Refrigerant Oil
Information. (Group 1830.)
16. Install compressor and connect refrigerant lines to
manifold.
17. Connect clutch coil wire and install drive belt.
NOTE: Purging evaporator circuit takes 1215

minutes to thoroughly remove solvent.
OUO1073,0002109 1910APR073/3
18
1830
5
TM10079 (17MAR09)
18-1830-5

031709
PN=197
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.
New compressor from parts depot contains new oil. Oil
level visible through suction port normally is below
drive shaft.
Normal operating oil level of 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.
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 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 new receiver-dryer. See Receiver-Dryer Remove
Install required amount of TY22025 Refrigerant Oil in
compressor.
New compressor from parts depot

Used compressor removed from operation
Compressor internally washed with flushing solvent
18
1830
6
Specification
OilVolume ............................................................................. 210 mL
7.1 fl oz
R134aWeight................................................................... 850 50 g
1.9 0.1 lb
Connect all components. Evacuate and charge system.

See Evacuate R134a System and See Charge R134a
System. (Group 1830.)
Determine amount of system oil charge prior to

installation of compressor on machine.
When complete system, lines, and components are
flushed add correct amount of oil as described.
OUO1073,000210A 1904APR071/1
TM10079 (17MAR09)
18-1830-6

031709
PN=198
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.
(Group 1830.)
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.
UN06DEC93
CAUTION: Do not remove high pressure relief

valve (D). Air conditioning station will discharge
rapidly causing possible injury.
1. Follow procedures. See Refrigerant Cautions and

Proper Handling. (Group 1830.)
2. Close both high-side and low-side valves on refrigerant
recovery/recycling and charging station (E).
T8118AG
IMPORTANT: Use only John Deere approved

refrigerant recovery/recycling and
charging stations. DO NOT mix
refrigerant, hoses, fittings, components
or refrigerant oils.
AHigh Pressure Hose Charge Port Cap
BRed Hose
CBlue Hose
DHigh Pressure Relief Valve
ERefrigerant Recovery/Recycling and Charging
Station
3. Remove cap from low-side charge port.

4. Connect blue hose (C) from refrigerant
recovery/recycling and charging station (E) to low-side
test port.
18
1830
7
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.
OUO1073,000210B 1928MAR071/1
TM10079 (17MAR09)
18-1830-7

031709
PN=199
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.
(Group 1830.)
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. (Group 1830.)
4. Follow manufacturers instructions when using
refrigerant recovery/recycling and charging station.
18
1830
8
OUO1073,000210C 1928MAR071/1
TM10079 (17MAR09)
18-1830-8

031709
PN=200
Evacuate R134a System

4. Evacuate system until low-side gauge registers 98

kPa (980 mbar) (29 in. Hg) vacuum.

Specification
Evacuate SystemVacuum ..................................................... 98 kPa
980 kPa
29 in. Hg
Do not remove high pressure relief valve. Air

conditioning system will discharge rapidly
causing possible injury.
If above specification vacuum cannot be obtained in 15

minutes, test the system for leaks. See Refrigerant
Leak Test. (Group 9031-25.)
1. Connect refrigerant recovery system. See R134a

Refrigerant Recovery/Recycling and Charging
Station Installation Procedure. (Group 1830.)
5. When vacuum reaches above specification, close

low-side and high-side valves. Turn vacuum pump
off.
2. Open low-side and high-side valves on refrigerant

recovery/recycling and charging station.
6. If vacuum decreases more than specification in 5

minutes, there is a leak in system.
3. Follow manufacturers instructions and evacuate

system.
Specification
Evacuate SystemVacuum .................................................... 3.4 kPa
34 mbar
1 in. Hg
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.
Specification
Evacuate SystemVacuum ................ Subtract 3.4 kPa from 98 kPa
for each 300 m elevation above
sea level
Subtract 34 mbar from 980
mbar for each 300 m elevation
above seal level
Subtract 1 in. Hg from 29 in.
Hg for each 1000 ft elevation
above sea level
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.
(Group 1830.)
18
1830
9
OUO1073,000210D 1928MAR071/1
TM10079 (17MAR09)
18-1830-9

031709
PN=201
Charge R134a System

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.

IMPORTANT: Use only John Deere approved

refrigerant recovery/recycling and
charging stations. DO NOT mix
refrigerant, hoses, fittings,
components or refrigerant oils.
Specification
Evacuate SystemVacuum ................ Subtract 3.4 kPa from 98 kPa
for each 300 m elevation above
sea level
Subtract 34 mbar from 980
mbar for each 300 m elevation
above seal level
Subtract 1 in. Hg from 29 in.
Hg for each 1000 ft elevation
above sea level
1. Identify refrigerant type using JT02167A Refrigerant

Identification Instrument.
4. Follow manufacturers instructions and charge

system.
2. Connect R134a Refrigerant Recovery/Recycling

and Charging Station. See R134a Refrigerant
Recovery/Recycling and Charging Station
Installation Procedure. (Group 1830.)
5. Add refrigerant to system.

3. Evacuate system. See Evacuate R134a System.

(Group 1830.)
NOTE: Before beginning to charge air conditioning
system, the following conditions must exist:
Engine STOPPED, the pump must be capable
of pulling at least 28.6 in. Hg vacuum (sea
Specification
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 9031-15.)
18
1830
10
OUO1073,000210E 1928MAR071/1
TM10079 (17MAR09)
18-1830-10

031709
PN=202
Compressor Remove and Install
UN03APR07
1. Recover refrigerant from system. See See Recover

R134a Refrigerant. (Group 1830.)
2. Remove compressor drive belt (6).
TX1021309A
3. Disconnect wiring harness connector.

4. Remove cap screws (3) and disconnect low pressure
line (4) and high pressure line (2). Close all open lines
1Compressor
2High Pressure Line
3Cap Screws
4Low Pressure Line
5Cap Screw (4 used)
6Belt
5. Remove cap screws (5) and compressor (1).

6. Install compressor. Tighten cap screws to specification.
Specification
Air Conditioning Compressor Cap
ScrewTorque ............................................................................... 30 Nm
22 lb-ft
7. Connect harness connector.

8. Connect high and low pressure lines. Install and
tighten cap screws (1).
Specification
Pressure Line Cap Screw
Torque ............................................................................................ 28 Nm
21 lb-ft
9. Install compressor belt. Inspect and adjust compressor

belt tension. See See Check and Adjust A/C Belt.
(Operators Manual.)
10. Evacuate and charge system. See Evacuate R134a
System and See Charge R134a System. (Group
1830.)
18
1830
11
OUO1073,000210F 1904APR071/1
Condenser Remove and Install

1. Recover refrigerant from system. See Recover R134a
Refrigerant. (Group 1830.)
TM10079 (17MAR09)
18-1830-11
OUO1073,0002110 1928MAR071/2

031709
PN=203

3. Remove cap screws and disconnect high pressure
liquid input line (2) and high pressure liquid output line
(5) from receiver-dryer (6).
4. Loosen cap screw (7) and remove receiver-dryer (6)
from bracket.
UN07MAR07
5. Remove cap screw and disconnect high pressure gas

input line (4) from condenser (1).
6. Remove cap screws (9) and condenser (1).
TX1020174A
7. Remove cap screws and receiver-dryer mounting

bracket (8) from condenser.
8. Install condenser.
9. Connect high pressure gas input line (4) to condenser.
Tighten cap screw to specification.
Specification
High Pressure Gas Input Line
Cap ScrewTorque ....................................................................... 23 Nm
17 lb-ft
1Condenser
2High Pressure Liquid Input Line
4High Pressure Gas Input Line
5High Pressure Gas Output Line
6Receiver-Dryer
7Cap Screw
8Bracket
10. Install receiver-dryer.

11. Connect high-pressure output line and high pressure
input line cap screw to receiver-dryer. Tighten cap
Specification
Receiver-Dryer Input and Output
Line Cap ScrewsTorque ............................................................... 5 Nm
44 lb-in.
12. Install air filter assembly.

18
1830
12

1830.)
OUO1073,0002110 1928MAR072/2
TM10079 (17MAR09)
18-1830-12

031709
PN=204
Heater and Air Conditioner Remove and

Install
1821.)
OUO1073,0002111 1910APR071/8
3. Remove cover (1) from rear panel.
UN08MAR07
4. Remove screws (2) and cap screws (3) from rear panel
(4).
5. Pull rear panel forward. Disconnect wiring harness
from lighter and power outlet and remove panel.
TX1020272A
1Cover
2Screws
3Cap Screws
4Panel
OUO1073,0002111 1910APR072/8
6. Remove screws and air duct (1).

18
1830
13
7. Remove screws and bracket (2).

8. Remove monitor warning alarm (3) from mounting
bracket (4).
9. Remove screws and mounting bracket (4).
UN08MAR07
10. Remove cover (5).
TX1020273A
1Air Duct
2Bracket
3Monitor Warning Alarm
4Mounting Bracket
5Cover
TM10079 (17MAR09)
18-1830-13
OUO1073,0002111 1910APR073/8

031709
PN=205

11. Remove screws attaching relay block (2) to panel (7).
NOTE: Panel (7) may be removed with power converter
and information controller installed on panel.
12. Disconnect 12 volt power converter (3) and
information controller (ICF) (6) from cab wiring
harness.
UN08MAR07
13. Remove clamps and hold-downs attaching cab wiring

harness (8) to panel (7).
14. Remove cap screws (1 and 5).
TX1020274A
15. Disconnect cab wiring harness (8) from and right

console, security alarm, and ground locations on
panel (7). See Cab Harness (W1) Component
Location . (Group 9015-10.)
1Cap Screws
2Relay Block
312 Volt Power Converter
4Cap Screw
5Cap Screws
6Information Controller (ICF)
7Panel
8Cab Wiring Harness
16. Lift cab wiring harness (8). Slide out panel (7) and
remove.
OUO1073,0002111 1910APR074/8
17. Remove cap screws (2) and fresh air inlet duct (1).
UN08MAR07
1Inlet Duct
2Cap Screw
TX1020275A
18
1830
14
TM10079 (17MAR09)
18-1830-14
OUO1073,0002111 1910APR075/8

031709
PN=206

18. Remove screws (1), panel (2), and air duct (3).
19. Remove cap screws and mounting bracket (4).
TX1020276A
UN08MAR07
1Screw
2Panel
3Air Duct
4Mounting Bracket
OUO1073,0002111 1910APR076/8
18
1830
15
TM10079 (17MAR09)
18-1830-15

031709
PN=207

20. Clamp off engine coolant hoses (3). Disconnect
engine coolant hoses from air conditioner (1). Plug
engine coolant lines to minimize coolant loss.
21. Remove air conditioner refrigerant lines (4) from air
conditioner (1).
22. Disconnect wiring harness from air conditioner (1).
UN08MAR07
23. Remove screws (7) and air duct (5).

24. Remove cap screws (6). Separate air conditioner (1)
from air duct (2) and remove.
TX1020277A

26. Install air conditioner and cap screws.
27. Connect wiring harness.
1Air Conditioner
2Air Duct
3Engine Coolant Hoses
4Air Conditioner Refrigerant Lines
5Air Duct
6Cap Screw (6 used)
7Screws
28. Connect air ducts.

29. Connect engine coolant hoses and refrigerant lines.
30. Install mounting bracket, rear panel, and air duct.
31. Install fresh air inlet duct.
32. Install rear panel and cap screws.
33. Connect cab wiring harness.See Cab Harness (W1)
Component Location . (Group 9015-10.)
34. Attach wiring harness to panel using clamps and
hold-downs.
18
1830
16
35. Install air duct, mounting brackets, and monitor

warning alarm.
36. Connect wiring harness to lighter and power outlet
and install rear panel.
37. Install seat. See Seat Remove and Install (Group
1821.)
1830.)
TM10079 (17MAR09)
18-1830-16
OUO1073,0002111 1910APR077/8

031709
PN=208

39. Check engine coolant level. Add coolant as
necessary. See Cooling System Fill and Deaeration
Procedure. (Operators Manual.)
OUO1073,0002111 1910APR078/8
Receiver-Dryer Remove and Install

UN22FEB07
3. Remove cap screws (3) and disconnect high pressure

liquid input line (2) and high pressure liquid output line
(4).
4. Loosen cap screw (5) and remove receiver-dryer (6)
from bracket.
TX1018622A
5. Install receiver-dryer.
6. Tighten high-pressure output line cap screw and high
pressure input line cap screw.
Specification
Receiver-Dryer Input and Output
Line Cap ScrewsTorque ............................................................... 5 Nm
44 lb-in
7. Connect electrical connector.
2High Pressure Liquid Input Line
3Cap Screws
4High Pressure Liquid Output Line
5Cap Screw
6Receiver-Dryer

System and See Charge R134a System. (Group 1830.)
18
1830
17
OUO1073,0002112 1928MAR071/1
TM10079 (17MAR09)
18-1830-17

031709
PN=209
18
1830
18
TM10079 (17MAR09)
18-1830-18

031709
PN=210
Section 33
Excavator
Contents
Page
Group 3302Buckets
Bucket Remove and Install . . . . . . . . . . . . . .33-3302-1
Bucket Pin-Up Data. . . . . . . . . . . . . . . . . . . .33-3302-2
Group 3340Frames
Bucket Links Remove and Install . . . . . . . . .33-3340-1
Arm Remove and Install . . . . . . . . . . . . . . . .33-3340-2
Boom Remove and Install . . . . . . . . . . . . . . .33-3340-6
Inspect Pins, Bushings and BossesFront
Attachment . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Bushings and Seal Remove and Install . . . .33-3340-14
Apply Vacuum to Hydraulic Oil Tank . . . . . . .33-3360-1
Hydraulic Oil Cleanup Procedure Using
Portable Filter Caddy . . . . . . . . . . . . . . . . .33-3360-3
Pump 1 and 2 Remove and Install . . . . . . . .33-3360-4
Pump 1 and 2 Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-10
Pump 1 and 2 Inspection . . . . . . . . . . . . . .33-3360-22
Pump 1 and 2 Start-Up Procedure . . . . . . .33-3360-25
Pump 1 and 2 Regulator Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-26
Pump 1 and 2 Regulator Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-28
Pilot Pump Remove and Install . . . . . . . . . .33-3360-30
Pilot Pump Disassemble and Assemble . . .33-3360-32
Pilot Pump Drive Shaft Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-34
Pilot Pressure Regulating Valve and Filter
Remove and Install . . . . . . . . . . . . . . . . .33-3360-35
Disassemble and Assemble. . . . . . . . . . .33-3360-36
Pilot Shutoff Solenoid Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-36
Pilot Shutoff Solenoid Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-38
Fan Drive Pump Remove and Install. . . . . .33-3360-39
Fan Drive Motor Remove and Install . . . . . .33-3360-40
Fan Drive Control Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-43
Solenoid Valve Manifold Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-45
Solenoid Valve Remove and InstallPower
Dig (SG), Travel Speed (SI), Boom
Mode (SC), and Boom Flow Rate
(SF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-47
TM10079 (17MAR09)
Page
Pilot Valve (Left and Right) Remove and

Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-48
Pilot Valve (Left and Right) Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-52
Travel Pilot Valve Remove and Install . . . . .33-3360-54
Travel Pilot Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-56
Pilot Signal Manifold Remove and Install. . .33-3360-58
Pilot Signal Manifold Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-60
Control Valve Remove and Install . . . . . . . .33-3360-63
Control Valve (5-Spool) Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-65
Control Valve (4-Spool) Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-73
Hydraulic Oil Tank Remove and Install . . . .33-3360-79
Hydraulic Oil Tank Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-82
Restriction Valve Remove and Install . . . . .33-3360-83
Hydraulic Oil Cooler Bypass Valve Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .33-3360-85
Boom Cylinder Remove and Install . . . . . . .33-3360-87
Boom Cylinder Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-91
Arm Cylinder Remove and Install . . . . . . . .33-3360-93
Arm Cylinder Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-98
Bucket Cylinder Remove and Install . . . . . 33-3360-101
Bucket Cylinder Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-105
Hydraulic Cylinder Bleed Procedure . . . . . 33-3360-108
33-1
33

031709
PN=1
Contents
33
TM10079 (17MAR09)
33-2

031709
PN=2
Group 3302
Buckets
Bucket Remove and Install
6
3
3
5
7
4
3
1
UN24JUL01
5
1
T142450
3
T142450
1Bushing (2 used)
2Seal (2 used)
3O-Ring (4 used)
4Ring (2 used)
5Pin (2 used)
6Pin

Specification
BucketWeight ................................................. 1018 kg approximate
2245 lb approximate
1. Position bucket (8) on level surface.
7Pin
8Bucket
3. Remove bucket.
5. Align pin bores and install pins (6 and 7).
6. Adjust bucket to arm joint. See Adjusting Bucket to
Arm Joint. (Operators Manual.)
2. Remove parts (5, 6, and 7).
33
3302
1
TJ15698,0000156 1911APR071/1
TM10079 (17MAR09)
33-3302-1

031709
PN=213
Buckets
Bucket Pin-Up Data
2
1
10
16
15
8
7
17
Section A
14
13
12
Section B
TX1003797
TX1003797
UN07MAR06
11
TJ15698,000017C 1915MAR071/2
33
3302
2
TM10079 (17MAR09)
33-3302-2

031709
PN=214
Buckets
IMPORTANT: If the front attachment of a previous
model machine is used, use the
grease intervals for previous model
machine.
Item
1
450 mm
17.7 in.
0 mm
0 in.
604 mm
23.8 in.
580 mm
22.8 in.
476 mm
18.7 in.
1471 mm
57.9 in.
433 mm
17.0 in.
326 mm
12.8 in.
80 mm
3.2 in.
10
475 mm
18.7 in.
11
31 mm
1.2 in.
12
433 mm
17.0 in.
13
307 mm
12.1 in.
14
80 mm
3.2 in.
15
3.7
16
3.7
17
449 mm
17.7 in.
33
3302
3
TJ15698,000017C 1915MAR072/2
TM10079 (17MAR09)
33-3302-3

031709
PN=215
Buckets
33
3302
4
TM10079 (17MAR09)
33-3302-4

031709
PN=216
Group 3340
Frames
Bucket Links Remove and Install
27
27
29
1
1 2 29
24
2
4
24
27
27
18
10
12
13
19
18
24
40
24
5
21 19
11
20
21
T166094
UN13MAR03
20
T166094
Bucket Links
1Bushing (2 used)
2Seal (4 used)
3Bushing (2 used)
4Link
5Link
10Pin
11Pin
12Pin
13Pin

19Nut (4 used)
20Retainer (2 used)
21Pin (2 used)
TM10079 (17MAR09)
33-3340-1
24O-Ring (4 used)
27Shim (as required)
29Shim (as required)
40Center Link
TJ15698,0000157 1911APR071/2

031709
PN=217
33
3340
1
Frames
NOTE: It is not necessary to remove bucket to remove
bucket links.

8. Install center link (40) and pin (12).
1. Connect center link (40) to a hoist using a lifting

strap. Put a wood block between bucket cylinder
and arm to hold cylinder up when cylinder pin (10)
is removed.
2. Remove cap screws (18) and nuts (19).
NOTE: Mark location of shims (27 and 29) to aid in
assembly.
9. Install pin (21) and retainer (20).

10. Install shims (27 and 29) equally on each side of
joint to get a minimal amount of clearance in the
joint. There must be some clearance in the joint.
11. Align pin bores and install pins (10 and 13).
12. Install cap screws (18) and nuts (19).
3. Remove pins (10 and 13) and shims (27 and 29).
Tighten nuts (19) against each other. Cap screws
(18) need to be free to turn.
4. Remove retainer (20) and pin (21).

5. Remove pin (12) and center link (40).
6. Inspect bushings and seals. See Inspect Pins,
Bushings, and BossesFront Attachment. (Group
3340.) See Bushings and Seal Remove and Install.
(Group 3340.)
13. Apply multi-purpose grease to pivot joints. See

Track Adjuster, Working Tool Pivot, Swing
Bearing, and Swing Bearing Gear Grease.
(Operators Manual.)
TJ15698,0000157 1911APR072/2
Arm Remove and Install

1. Remove bucket. See Bucket Remove and Install.
(Group 3302.)
2. Retract arm cylinder.
3. Put floor stand under end of boom, so load is on
boom, not on arm cylinder. Extend arm cylinder just
enough to put end of arm on ground.
TJ15698,0000158 1911APR071/7
33
3340
2
TM10079 (17MAR09)
33-3340-2

031709
PN=218
Frames
UN21MAR07

TX1020485A

TJ15698,0000158 1911APR072/7
UN08DEC08
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
5. Loosen bucket cylinder hydraulic hoses to release any
residual pressure.
X9811
NOTE: Remove bucket cylinder and linkage only if

necessary to repair arm.
7. Remove bucket links and bucket cylinder. See Bucket
Links Remove and Install (Group 3340.) See Bucket
Cylinder Remove and Install. (Group 3360.)
TJ15698,0000158 1911APR073/7
33
3340
3
TM10079 (17MAR09)
33-3340-3

031709
PN=219
Frames

lifting device. Weight of boom, arm and bucket
assembly and components will vary depending
on machine configuration.
Specification
Boom, Arm and Bucket
AssemblyApproximate Weight ................................................... 3450 kg
7610 lb
Bucket CylinderWeight................................................................. 150 kg
330 lb
Arm CylinderWeight ..................................................................... 250 kg
550 lb
T6626JC
UN31OCT88
8. Attach appropriate lifting device to arm.
Arm With Bucket Cylinder
TJ15698,0000158 1911APR074/7
9. Put wooden block between arm cylinder (5) and boom

to hold cylinder up when cylinder pin (2) is removed.
1Nut (2 used)
2Pin
3Cap Screw
4Arm
5Arm Cylinder
TX1003794A
33
3340
4
UN19APR06
10. Remove nuts (1), cap screw (3) and pin (2).
TM10079 (17MAR09)
33-3340-4
TJ15698,0000158 1911APR075/7

031709
PN=220
Frames
11. Tag and disconnect hydraulic hoses (3). Close all
open lines and fittings using caps and plugs.
UN15MAR06
12. Remove cap screw (1) and boom-to-arm pin (2).

13. Remove arm and lower to floor.
TX1003793A
14. Inspect bushings and dust seals. See Inspect Pins,

Bushings and BossesFront Attachment. (Group
3340.)
15. Repair or replace parts as necessary. See Bushings
and Seal Remove and Install. (Group 3340.)
1Cap Screw
2Pin
3Hydraulic Hose
TJ15698,0000158 1911APR076/7
33
3340
5
TM10079 (17MAR09)
33-3340-5

031709
PN=221
Frames
16. Install thrust plates (4 and 12) equally on each side of
arm to get minimal amount of clearance between
boom and arm.
17. Install boom-to-arm pin (11), block (10), plate (9),

washer (8) and cap screw (7).
18. Connect arm cylinder by inserting cylinder pin (6), cap
screw (3) and nuts (1).
19. Connect hoses. See Hydraulic System Line

Connections. (Group 9025-15.)
20. Apply multi-purpose grease to all lubrication fittings.

21. Install bucket. See Bucket Remove and Install.
(Group 3302.)
T142652
UN27SEP01
1Nut (2 used)
2Stopper
3Cap Screw
4Thrust Plate (2 used)
5Thrust Plate
6Cylinder Pin
7Cap Screw
8Washer
9Plate
10Block
11Pin
13Thrust Plate
13
12
10
7
8
T142653
11
UN24JUL01
12
TJ15698,0000158 1911APR077/7
33
3340
6
Boom Remove and Install

1. Remove bucket and arm. See Bucket Remove and
Install. (Group 3302.) See Arm Remove and Install.
(Group 3340.)
2. Lower boom to ground.
3. Disconnect wiring harness.
TM10079 (17MAR09)
33-3340-6
TJ15698,0000159 1911APR071/10

031709
PN=222
Frames
UN21MAR07

TX1020485A

TJ15698,0000159 1911APR072/10
UN08DEC08
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
X9811
5. Slowly loosen hydraulic hoses (1) to relieve any

residual pressure; then disconnect hoses. Close all
6. Remove arm cylinder only if necessary to repair boom.
See Arm Cylinder Remove and Install. (Group 3360.)
TX1003795A
UN09MAR06
1Hydraulic Hoses (4 used)
TM10079 (17MAR09)
33-3340-7
TJ15698,0000159 1911APR073/10

031709
PN=223
33
3340
7
Frames

lifting device.
Specification
Boom CylinderWeight .................................................................. 180 kg
397 lb
UN30DEC96
7. Attach appropriate lifting device to boom cylinder (F)

using lifting strap.
T105828
FBoom Cylinder (2 used)
TJ15698,0000159 1911APR074/10
8. Disconnect lubrication hoses (2), nuts, cap screws (1),

and retainers (3).
TX1003796A
UN17FEB06
1Cap Screw (2 used)

2Lubrication Hoses (2 used)
3Retainer (2 used)
TJ15698,0000159 1911APR075/10
9. Push boom cylinder-to-boom pin (4) into boom.

10. Lower boom cylinder (6) onto floor stand. Repeat
procedure for second boom cylinder.
UN24JUL01
T142979
33
3340
8
1Nut (4 used)
2Retainer (2 used)
3Cap Screw (2 used)
4Boom Cylinder Rod End-to-Boom Pin
6Boom Cylinder (2 used)
TM10079 (17MAR09)
33-3340-8
TJ15698,0000159 1911APR076/10

031709
PN=224
Frames

lifting device. Weight of boom, arm, and bucket
assembly and components will vary depending
on machine configuration.
Specification
Boom, Arm and Bucket
AssemblyApproximate Weight ................................................... 3450 kg
7610 lb
Bucket CylinderWeight................................................................. 150 kg
330 lb
Arm CylinderWeight ..................................................................... 250 kg
550 lb
11. Attach appropriate lifting device to boom. Use

protective covering to prevent damage to pin if chain
is used.
T6626JW
UN31OCT88
IMPORTANT: Arm end of boom is heavy end with arm

cylinder installed. Frame end is heavy
end when arm cylinder is removed.
TJ15698,0000159 1911APR077/10
12. Remove step (2) and cover (1).
TX1020725A
UN21MAR07
1Cover
2Step
TJ15698,0000159 1911APR078/10
33
3340
9
TM10079 (17MAR09)
33-3340-9

031709
PN=225
Frames
13. Remove cap screw (1), washer, and spacer (2).
UN19APR06
14. Insert bar between plate of boom-to-frame pin (3) and

bracket. Pull plate out.
15. Remove boom-to-frame pin (3). Remove washers.
TX1003791A
16. Remove boom.

17. Inspect bushings and dust seals. See Inspect Pins,
Bushings and BossesFront Attachment. (Group
3340.)
1Cap Screw
2Spacer
3Boom-to-Frame Pin
18. Repair or replace parts as necessary. See Bushings

and Seal Remove and Install. (Group 3340.)
19. Install washers equally on each side of boom to get
minimal amount of clearance between boom and
frame.
20. Install boom. Tighten boom-to-frame cap screw (1).
Specification
Boom-to-Frame Cap Screw
Torque .......................................................................................... 392 Nm
290 lb-ft
21. Install cover and step.
TJ15698,0000159 1911APR079/10
33
3340
10
TM10079 (17MAR09)
33-3340-10

031709
PN=226
Frames
22. Connect rod end of boom cylinders. Install thrust
plates equally on each side to get minimum amount
of clearance between boom and cylinder rod end.
UN17FEB06
23. Install retainers (3) and cap screws (1).
TX1003796A
24. Tighten nuts against each other allowing cap screw

(1) to be free to turn in hole.
Specification
Boom Cylinder Rod End-to-Boom
Pin Retainer NutTorque ..................... 550 Nm (tighten nut against nut)
405 lb-ft (tighten nut against nut)
1Cap Screw (2 used)
2Lubrication Lines (2 used)
3Retainer (2 used)
25. Connect lubrication hoses (2).

26. Connect hydraulic hoses. See Hydraulic System Line
27. Apply multi-purpose grease to all pivot joints. See
Track Adjuster, Working Tool Pivot, Swing Bearing,
and Swing Bearing Gear Grease. (Operators
Manual.)
TJ15698,0000159 1911APR0710/10
10
4
9
2
TX1004442
11
TX1004442
1Boom-to-Frame Joint
2Boom Cylinder Head End-to-Frame Joint
3Boom Cylinder Rod End-to-Boom Joint
4Boom-to-Arm Joint
5Arm Cylinder Rod End-to-Arm Joint
6Arm Cylinder Head End-to-Boom Joint
7Bucket Cylinder Head End-to-Arm Joint
8Bucket Cylinder Rod End-to-Side and Bucket
Links Joint
9Side Links-to-Arm Joint
10Bucket Link-to-Bucket Joint
11Bucket-to-Arm Joint
UN06MAR06
Inspect Pins, Bushings and BossesFront

Attachment
33
3340
11
TM10079 (17MAR09)
33-3340-11
TJ15698,000017B 1915MAR071/3

031709
PN=227
Frames
Pins, Bushings, and Bosses
33
3340
12
Item
Standard
Allowable Limit
Remedy
Pin
90 mm
3.54 in.
89.0 mm
3.50 in.
Replace
Bushing
90 mm
3.54 in.
91.5 mm
3.60 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Boss (Main Frame)
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Bushing (Boom Cylinder)
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Pin
90 mm
3.54 in.
89.0 mm
3.50 in.
Replace
Bushing (Boom Cylinder)
90 mm
3.54 in.
91.5 mm
3.60 in.
Replace
Boss (Boom)
90 mm
3.54 in.
91.5 mm
3.60 in.
Replace
Pin
90 mm
3.54 in.
89.0 mm
3.50 in.
Replace
Bushing
90 mm
3.54 in.
91.5 mm
3.60 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Boss (Arm)
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Bushing (Arm Cylinder)
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Boss (Boom)
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Bushing (Arm Cylinder)
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Pin
71 mm
2.80 in.
70.0 mm
2.76 in.
Replace
Boss (Arm)
71 mm
2.80 in.
72.5 mm
2.85 in.
Replace
Bushing (Bucket Cylinder)
71 mm
2.80 in.
72.5 mm
2.85 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Bushing
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Bushing (Bucket Cylinder)
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
TM10079 (17MAR09)
33-3340-12
TJ15698,000017B 1915MAR072/3

031709
PN=228
Frames
Pins, Bushings, and Bosses
10
11
Item
Standard
Allowable Limit
Remedy
Pin
71 mm
2.80 in.
70.0 mm
2.76 in.
Replace
Bushing
71 mm
2.80 in.
72.5 mm
2.85 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Bushing
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Bushing
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
TJ15698,000017B 1915MAR073/3
33
3340
13
TM10079 (17MAR09)
33-3340-13

031709
PN=229
Frames
Bushings and Seal Remove and Install

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.
4. Install dust seals with lip toward outside of component.
T6641CW
UN31OCT88
T95237
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
UN01NOV88
3. Install bushing to a depth equal to thickness of dust

seal (H).
TJ15698,000015A 1912MAR071/1
33
3340
14
TM10079 (17MAR09)
33-3340-14

031709
PN=230
Group 3360
Hydraulic System
Apply Vacuum to Hydraulic Oil Tank
Applying vacuum to hydraulic oil tank eliminates the need
to drain tank prior to servicing of hydraulic system
components.
FS41334,0000165 1912MAR071/3
UN21MAR07

TX1020485A

FS41334,0000165 1912MAR072/3
33
3360
1
TM10079 (17MAR09)
33-3360-1

031709
PN=231
Hydraulic System
3. Assemble fittings and hydraulic oil tank adapter from

D15032NU Vacuum Pump Kit, and JT07085A Vacuum
Pump Set. Install in hydraulic tank opening as shown.
Refer to pump instructions for operating information.
TX1003329A
UN06FEB06
TX1000587A
UN17NOV05
2. Use 5 mm hex wrench to remove cap screws (3) and

cover.
FS41334,0000165 1912MAR073/3
33
3360
2
TM10079 (17MAR09)
33-3360-2

031709
PN=232
Hydraulic System
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

SPECIFICATIONS
Hydraulic Oil Tank Capacity
135 L approximate
36 gal approximate
Hydraulic Oil Tank Filtering

Time
12 minutes approximate
Hydraulic System Capacity
235 L approximate
62 gal approximate
Hydraulic System Filtering Time
37 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.
SERVICE EQUIPMENT AND TOOLS

JDG1724A Super Caddy
JT05679 Hose 3.7 m (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M
NPT Ends (2 used)
JTO5751A Suction Wand
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.
JTO5750A Discharge Wand
1. Install new return filter elements.

NOTE: For a failure that creates a lot of debris,
remove access cover from hydraulic tank.
Drain hydraulic tank. Connect filter 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.
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
four times.
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.
Specification
Hydraulic SystemCapacity ................................. 235 L approximate
62 gal approximate
Hydraulic SystemFiltering
Time ............................................................... 37 minutes approximate
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.
9. Check hydraulic oil level. See Check Hydraulic
Tank Oil Level. (Operators Manual.)
Specification
Hydraulic Oil TankCapacity................................ 135 L approximate
36 gal approximate
Hydraulic Oil TankFiltering
Time ............................................................... 12 minutes approximate
33
3360
3
FS41334,0000166 1910APR071/1
TM10079 (17MAR09)
33-3360-3

031709
PN=233
Hydraulic System
Pump 1 and 2 Remove and Install
UN21MAR07

TX1020485A

2. Drain hydraulic oil tank. Approximate capacity is 135 L
(36 gal).
3. Drain pump drive gearbox. Approximate oil capacity is

1.0 L (1.1 qt).
4. Remove hydraulic compartment cover and rear engine
cover.
FS41334,000016F 1910APR071/11
5. Remove cap screws (1) and set fuel filters (2 and 3)

aside. Protect against damage to hoses and filters.
TX1021817A
UN11APR07
1Cap Screw (4 used)

2Final Fuel Filter
3Primary Fuel Filter
FS41334,000016F 1910APR072/11
6. Remove cap screws (1) and set engine oil filter

assembly (2) aside. Protect against damage to hoses
and filter.
UN19MAR07
1Cap Screw (2 used)

TX1020526A
33
3360
4
TM10079 (17MAR09)
33-3360-4
FS41334,000016F 1910APR073/11

031709
PN=234
Hydraulic System
7. Remove muffler cover (1) and shields (2).
CAUTION: Exhaust parts may be hot. Avoid
burns by waiting until the parts are cool to the
touch before working on them.
8. Support muffler using appropriate lifting device.
9. Loosen exhaust clamp and move onto muffler tube.
TX1020930
UN26MAR07
1Cover
2Shield (3 used)
FS41334,000016F 1910APR074/11
10. Remove nuts (2) and U-bolts from muffler support (3).
11. Remove muffler (1).
UN23MAR07
12. Disconnect electrical connectors.
TX1020923A
13. Tag and disconnect hoses and lines. Close all open
lines and fittings using caps and plugs.
1Muffler
2U-bolt Nut (8 used)
3Support
33
3360
5
TM10079 (17MAR09)
33-3360-5
FS41334,000016F 1910APR075/11

031709
PN=235
Hydraulic System

Specification
Hydraulic Pump and Drive
GearboxApproximate Weight ....................................................... 168 kg
370 lb
TX1020397
UN12MAR07
14. Install JT05550 Lifting Eyebolt and JDG19 Lifting

Bracket to pump (1). Connect an appropriate lifting
device to eyebolt and lifting bracket using lifting
straps.
1Lift Point (3 used)
FS41334,000016F 1910APR076/11
33
3360
6
TM10079 (17MAR09)
33-3360-6

031709
PN=236
Hydraulic System
15. Remove cap screws (4), muffler support (3), and hose
bracket (2) from hydraulic pump gearbox (1).
16. Pull pump assembly (1) away from flywheel housing
to disengage damper drive (flex coupler).
17. Remove hydraulic pump and drive gearbox from
machine.
IMPORTANT: Align flex coupler on drive gearbox with
mating part on engine flywheel.
19. Align damper drive and install pump assembly to
flywheel housing.
UN09MAR07
20. Install muffler support (3), hose bracket (2), and pump
assembly with cap screws (1). Tighten to
specification.
TX1020354
Specification
Pump Drive Gearbox-to-Flywheel
Housing Cap ScrewTorque......................................................... 65 Nm
48 lb-ft
21. Connect lines. See Pump 1, Pump 2, and Pilot Pump

Line Identification. (Group 9025-15.)
1Hydraulic Pump Drive Gearbox

2Support
3Bracket
4Cap Screw (8 used)
22. Connect electrical connectors. See Pump Harness

23. Install split flange and tighten cap screws.
Specification
Split Flange 8 mm Cap Screw
Torque ............................................................................................ 50 Nm
37 lb-ft
Split Flange 10 mm Cap Screw
Torque ............................................................................................ 90 Nm
67 lb-ft
24. Apply pipe sealant to pump drive gearbox pipe plug

threads, if removed.
33
3360
7
TM10079 (17MAR09)
33-3360-7
FS41334,000016F 1910APR077/11

031709
PN=237
Hydraulic System
25. Install muffler (1) to support using U-bolts and nuts
(2). Hand tighten for next step.
UN23MAR07
NOTE: Clamp torque is 8.5 Nm (75 lb-in.) with maximum

torque of 20 Nm (177 lb-in.)
26. Install exhaust clamp and tighten.
TX1020923A
27. Tighten muffler U-bolt nuts to specification.

Specification
Muffler U-Bolt NutTorque ............................................................ 50 Nm
37 lb-ft
1Muffler
2U-Bolt Nut (8 used)
3Support
FS41334,000016F 1910APR078/11
28. Install muffler shields (2) and cover (1).

29. Route muffler water drain down through shield.
UN26MAR07
1Cover
2Shield (3 used)
TX1020930
33
3360
8
TM10079 (17MAR09)
33-3360-8
FS41334,000016F 1910APR079/11

031709
PN=238
Hydraulic System
30. Install engine oil filter assembly (2) using cap screws
(1).
TX1020526A
UN19MAR07
1Cap Screw (2 used)

FS41334,000016F 1910APR0710/11
31. Install fuel filters (2 and 3) using cap screws (1).
UN11APR07
32. Install hydraulic compartment cover and rear engine

cover.
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.
TX1021817A
1Cap Screw (4 used)

2Final Fuel Filter
34. Fill pump housing and pump drive gearbox with oil.
See Pump 1 and 2 Start-Up Procedure. (Group
3360.)
35. Check pump regulator adjustments.
For minimum flow:
See Pump Regulator Test and Adjustment
Minimum Flow. (Group 9025-25.)
For maximum flow:
33
3360
9
See Pump Regulator Test and Adjustment

Maximum Flow. (Group 9025-25.)
FS41334,000016F 1910APR0711/11
TM10079 (17MAR09)
33-3360-9

031709
PN=239
Hydraulic System
Pump 1 and 2 Disassemble and Assemble

10
7
11
21
22
23
20
19
24
12
18
17
16
15
13
13
14
23
22
3
2
21
25
20
18
26
17
32
16
15
33
32
29
31
27
28
27
30
28
35
37
36
34
56
47
35
41
54
57
43
42
48
49
50
51
T142373
58
53
52
51
TM10079 (17MAR09)
33-3360-10
UN20JUL01
44
T142373
33
3360
10
46
39
55
45
40
38
FS41334,000016E 1918APR071/13

031709
PN=240
Hydraulic System
1Pump Housing
3Cap Screw (6 used)
5O-Ring (10 used)
6O-Ring (2 used)
7Cap Screw (4 used)
8Hydraulic Pump 1 (Front)
Regulator
9Cap Screw (2 used)
12Hydraulic Pump 2 (Rear)
Regulator
13O-Ring (4 used)
14O-Ring (6 used)
15Bearing Nut (2 used)
16Roller Bearing (2 used)

17Ring (2 used)
18Roller Bearing (2 used)
19Hydraulic Pump 1 (Front)
Drive Shaft
20Pin (2 used)
21Center Shaft (2 used)
22Spring (2 used)
23Piston (14 used)
24Cylinder Block (Rotor)
(2 used)
25Hydraulic Pump 2 (Rear)
Drive Shaft
26Hydraulic Pump 2 Spacer
Ring
27O-Ring (2 used)
28Plug (2 used)
29O-Ring
30Special Fitting
32Oil Seal (2 used)
33Snap Ring (2 used)
34Fill Plug
36Hydraulic Pump 1 Driven
Gear
37Gasket
39Hydraulic Pump 2 Drive
Gear
40Dipstick
41Dipstick Tube
42Gasket
43Drain Plug
44O-Ring
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
FS41334,000016E 1918APR072/13
33
3360
11
TM10079 (17MAR09)
33-3360-11

031709
PN=241
Hydraulic System
72
71
73
70
74
71
68
67
75
62
63
60
64
63
60
61
69
62
60
63
78
65
60
59
76
62
66
77
63
60
62
61
66
82
60
60
79
80
59
81
T142375
UN20JUL01
82
T142375
33
3360
12
59Dowel Pin
62Lever (4 used)
64Hydraulic Pump 1 Valve
Plate
65Hydraulic Pump 2 Valve

Plate
67Back-Up Ring
68O-Ring
70Cylinder Head (Cover)
71O-Ring (4 used)
73Cover (2 used)
74O-Ring (2 used)
76Set Screw (2 used)
77Servo Piston (2 used)

78Pin (2 used)
79O-Ring (2 used)
80Stop (2 used)
82Feedback Link (2 used)
1. Remove plug (43) from pump gearbox. Drain gear

oil. Approximate oil capacity is 1.0 L (1.1 qt).
TM10079 (17MAR09)
33-3360-12
FS41334,000016E 1918APR073/13

031709
PN=242
Hydraulic System


Specification
Hydraulic Pump Housing and
GearboxApproximate Weight ................................................ 168 kg
370 lb
Specification
Pump Housing Assembly
Approximate Weight ................................................................. 105 kg
230 lb
2. Loosen set screws (57) and remove dampener

drive coupling (58).
4. Remove cap screws (3) and lock washers (2) to

remove pump housing (1) from pump drive gearbox
(56).
3. Remove pilot pump (48). See Pilot Pump Remove

FS41334,000016E 1918APR074/13
33
3360
13
TM10079 (17MAR09)
33-3360-13

031709
PN=243
Hydraulic System
UN07FEB07
NOTE: The gears are not interchangeable. To aid in

reassembly, make timing marks on drive shafts at
(84) and (85), and mark (83) on drive gear (39)
and driven gear (36).
5. Make timing marks on pump gears to aid in
reassembly.
TX1018511A
6. Measure amount of backlash between gears, using

specification, to determine limit of use.
Specification
Pump Drive and Driven Gear
Backlash ........................................................ 0.68 mm (0.027 in.) nominal
1.50 mm (0.059 in.) limit of use

36Driven Gear
39Drive Gear
83Driven Gear-to-Drive Gear Timing Mark
84Pump 2 (Rear) Drive Shaft-to-Drive Gear
Timing Mark
85Pump 1 (Front) Drive Shaft-to-Driven Gear
Timing Mark
7. Remove snap rings (35) and remove gears (36 and

39).
8. Remove pump regulators (8 and 12). Repair or replace
as necessary. See Pump 1 and 2 Regulator
Specification
Cylinder HeadApproximate
Weight................................................................................................ 30 kg
66 lb
IMPORTANT: Valve plates (64 and 65) are connected

to the feedback linkage and must
remain on the cylinder blocks (24).
Valve plates and end of cylinder blocks
have highly machined surfaces and can
be damaged.
9. Remove cap screws (75) and carefully remove cylinder
head (70).
10. Remove servo pistons (77) only if replacement is
necessary.
33
3360
14
Disassemble servo piston using following procedure:

Heat set screw (76) to loosen thread lock and
sealer. (Medium strength thread lock used.)
TM10079 (17MAR09)
33-3360-14
FS41334,000016E 1918APR075/13

031709
PN=244
Hydraulic System
Remove set screw. (Use a 6 mm hex key wrench.)
Remove pin (78).
IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)
(65) valve plates are 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.
11. Remove hydraulic pump 1 (64) and hydraulic pump 2
(65) valve plates. Protect machined surfaces of plates
from damage.
12. Remove special fittings (30) before removing
hydraulic pump 1 (19) and hydraulic pump 2 (25)
drive shafts.
13. Remove hydraulic pump 2 spacer ring (26) from bore.
14. Remove bearing nut (15) using JDG769 Spanner
Wrench.
15. Remove roller bearings (16 and 18) from pump 1 (19)
and pump 2 (25) drive shafts using a knife edge
puller and a press.
16. Clean and inspect parts. Repair or replace parts as
necessary. See Pump 1 and 2 Inspection. (Group
3360.)
17. Assemble hydraulic pump in reverse order, using the
following information.
FS41334,000016E 1918APR076/13
33
3360
15
TM10079 (17MAR09)
33-3360-15

031709
PN=245
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.
18. Heat roller bearings (16 and 18).
TX1018493
UN07FEB07
Specification
Roller Bearing Heat
Temperature ................................................................................ 5080C
122176F
19. Apply oil to bearing. Push roller bearing (18) on drive

shaft so inner race is tight against shoulder.
20. Install spacer ring (17) and roller bearing (16).
21. Apply oil to threads of bearing nut (15).
22. Tighten bearing nut using JDG769 Spanner Wrench.
UN07FEB07
Specification
Pump Drive Shaft Bearing Nut
Rolling Drag Torque ......................................................... 1.96 0.49 Nm
17 4 lb-in.
TX1018494
15Bearing Nut
16Roller Bearing
17Spacer Ring
18Roller Bearing
19Pump 1 (Front) Drive Shaft
25Pump 2 (Rear) Drive Shaft
FS41334,000016E 1918APR077/13
23. Install hydraulic pump 2 spacer ring (26) into housing

bore.
UN07FEB07
26Spacer Ring
TX1018495A
33
3360
16
TM10079 (17MAR09)
33-3360-16
FS41334,000016E 1918APR078/13

031709
PN=246
Hydraulic System
24. To help installation of drive shafts (19 and 25), heat
pump housing using a heat gun such as the JT07010
Two Temperature Heat Gun.
UN07FEB07
Specification
Hydraulic Pump Housing Heat
Temperature ................................................................................ 5080C
122176F
TX1018496A
25. Apply a film of oil to outer race of bearings. Install the

drive shafts.
NOTE: Allow housing to cool to the touch, to safely
handle after drive shaft installation.
19Drive Shaft
25Drive Shaft
30Special Fitting (2 used)
26. Install and tighten special fittings (30).

Specification
Special Plug-to-Hydraulic Pump
Housing Special FittingTorque.................................................... 34 Nm
25 lb-ft
27. Apply multi-purpose grease to lips of oil seals (32).

Install oil seals with lip (spring side) toward inside of
housing. Install snap rings (33).
FS41334,000016E 1918APR079/13
33
3360
17
TM10079 (17MAR09)
33-3360-17

031709
PN=247
Hydraulic System
28. Install drive (39) and driven (36) gears using
procedure:
UN07FEB07
For original parts;
TX1018511A
Install drive (39) and driven (36) gears on shafts so

timing marks (83, 84, and 85) are aligned. Install
snap rings (35).
For new parts;
TX1018497
UN07FEB07
Install the JDG1054 Aligning Bar on the socket (87

and 88) end of drive shafts.
Install aligning bar so end marked Long Shaft
Side is to pump 2 (rear) drive shaft (25). Turn
shafts so socket alignment dowels (89 and 90)
engage a socket in drive shafts. The socket for
pump 1 (front) drive shaft is slightly below the
center-line of socket for pump 2 (rear) drive shaft
when shafts are timed correctly.
Install cap screws (91) to hold bar in position.
From the spline end of shafts, turn shafts to the left
to remove any play between socket alignment
dowels and sockets.
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.
29. Apply oil to center shaft (21), pistons (23), and
cylinder blocks (24). Use petroleum jelly to hold pin
(20) in hole in center shaft.
19Pump 1 (Front) Drive Shaft

25Pump 2 (Rear) Drive Shaft
36Driven Gear
39Drive Gear
83Driven Gear-to-Drive Gear Timing Mark
84Pump 2 (Rear) Drive Shaft-to-Drive Gear
Timing Mark
85Pump 1 (Front) Drive Shaft-to-Driven Gear
Timing Mark
86JDG1054 Aligning Bar (Pump Timing Tool)
87Socket
88Socket
89Socket Alignment Dowel
90Socket Alignment Dowel
91M8-1.25 Cap Screw (2 used)
30. Install cylinder block so pin engages slot in cylinder

block.
31. 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.
33
3360
18
Specification
Dowel Pin-to-Pump 1 (Front) and
Pump 2 (Rear) Valve Plate
Torque ........................................................................................... 9.8 Nm
86 lb-in.
TM10079 (17MAR09)
33-3360-18
FS41334,000016E 1918APR0710/13

031709
PN=248
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.
32. Install valve plates using procedure:
Apply oil to valve plates.
Install valve plates so inlet port is toward the center
and top of pump housing.
Connect levers (62) for feedback linkage to valve
plates.
33. Install servo pistons (77) and pins (78). If set screw
was removed, install using procedure:
Apply thread lock and sealer (medium strength) to
threads of set screw (76).
Tighten set screw (76) using a 6 mm hex key
wrench.
Specification
Servo Piston-to-Pin Set Screw
Torque ............................................................................................ 34 Nm
25 lb-ft
34. Tighten cap screws (72 and 81) for stop (80) and
cover (73) to specification.
Specification
Stop and Cover-to-Cylinder Head
Cap ScrewTorque .................................................................... 19.5 Nm
180 lb-in.

35. Install cylinder head (70) checking to be sure that
pins engage middle hole in valves plates.
Specification
Cylinder HeadApproximate
Weight................................................................................................ 30 kg
66 lb
33
3360
19
TM10079 (17MAR09)
33-3360-19
FS41334,000016E 1918APR0711/13

031709
PN=249
Hydraulic System
Tighten cap screws (75) to specification.
Specification
Cylinder Head-to-Hydraulic Pump
Housing Cap ScrewTorque....................................................... 108 Nm
80 lb-ft
36. Install regulators:

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.
Reinstall air bleed plugs to avoid contamination to
hydraulic pump during installation.
Specification
Regulator-to-Hydraulic Pump
37 lb-ft
37. Install and tighten pump pressure sensors to

specification.
Specification
Pump Pressure
Sensor-to-Hydraulic Pump
HousingTorque............................................................................ 98 Nm
72 lb-ft
38. Install parts (49-53). See Pilot Pump Drive Shaft

Specification
Hydraulic Pump Housing
AssemblyApproximate Weight ..................................................... 105 kg
230 lb
39. Install pump housing assembly (1) to gearbox (56).

33
3360
20
TM10079 (17MAR09)
33-3360-20
FS41334,000016E 1918APR0712/13

031709
PN=250
Hydraulic System
Specification
Hydraulic Pump
Housing-to-Gearbox Housing Cap
ScrewTorque ............................................................................. 147 Nm
109 lb-ft
40. Apply rigid form-in-place gasket to mounting surface

for pilot pump (48).
Specification
Pilot Pump-to-Gearbox Cap
ScrewTorque ............................................................................... 50 Nm
37 lb-ft
41. Apply multi-purpose grease to lips of oil seal (55).

Install oil seal with lip (spring side) toward inside of
housing.
CAUTION: Install damper drive coupling hub so
face is flush with end of pump shaft. It cannot
rub or hit gearbox housing or shaft oil seal
when rotated.
42. Install damper drive coupling (58) onto splines of
pump shaft (25). Position so hub face is flush with
pump shaft end. Space between coupling and
gearbox housing (56) is approximately 2 mm (0.08
in.).
43. Apply thread lock and sealer (medium strength) to
threads of set screws (57).
Tighten set screws (57) to specification. For assembly
of dampener drive: See Dampener Drive (Flex
Coupling) Remove and Install. (Group 0752.)
Specification
Dampener Drive Hub-to-Pump 2
(Rear) Drive Shaft Set Screw
Torque .......................................................................................... 108 Nm
80 lb-ft
33
3360
21
44. Fill pump and pump drive gearbox with oil. See Pump
1 and 2 Start-Up Procedure. (Group 3360.)
FS41334,000016E 1918APR0713/13
TM10079 (17MAR09)
33-3360-21

031709
PN=251
Hydraulic System
Pump 1 and 2 Inspection
UN09JAN97
1. Measure diameter of oil seal contact surfaces (A, B,

and D) on pump 1 (front) (E) and pump 2 (rear) (C)
drive shafts.
T105725
Specification
Pump 2 (Rear) Drive Shaft Oil
Seal Contact Surface (A)OD ......................................... 45 mm nominal
1.77 in. nominal
44.8 mm limit of use
1.76 in. limit of use
Pump 2 (Rear) Drive Shaft Oil
Seal Contact Surface (B)OD ......................................... 55 mm nominal
2.17 in. nominal
Pump 1 (Front) Drive Shaft Oil
Seal Contact SurfaceOD ............................................... 55 mm nominal
2.17 in. nominal
AOil Seal Contact Surface

BOil Seal Contact Surface
CPump 2 (Rear) Drive Shaft
DOil Seal Contact Surface
EPump 1 (Front) Drive Shaft
FS41334,000016D 1911APR071/6
2. Measure play (H) between piston connecting rod (F)

and socket in front and rear drive shafts (G).
UN09JAN97
Specification
Piston-to-Drive Shaft Socket
Play ............................................................................... 0.058 mm nominal
0.0023 in. nominal
T105726
FPiston Connecting Rod

GRear Drive Shaft
HPlay
33
3360
22
TM10079 (17MAR09)
33-3360-22
FS41334,000016D 1911APR072/6

031709
PN=252
Hydraulic System
3. Measure ID of cylinder block piston bore. Measure OD
of piston. Subtract the OD from the ID for clearance.
T6557EN
UN18OCT88
T6557EM
UN18OCT88
Specification
Cylinder Block Bore-to-Piston
Clearance ..................................................................... 0.043 mm nominal
0.0017 in. nominal
FS41334,000016D 1911APR073/6
4. Clamp the connecting rod end of a piston in a vise with

soft-jaw faces. Measure play between connecting rod
and piston.
T6557EK
UN18OCT88
Specification
Piston-to-Connecting RodPlay .................................. 0.150 mm nominal
0.0059 in. nominal
FS41334,000016D 1911APR074/6
33
3360
23
TM10079 (17MAR09)
33-3360-23

031709
PN=253
Hydraulic System
5. 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.
Specification
Servo Piston-to-Cylinder Head
BoreClearance .......................................................... 0.079 mm nominal
0.0033 in. nominal
T105727
UN19DEC96
ACylinder Head
BID
COD
DServo Piston
FS41334,000016D 1911APR075/6
T105729
Specification
Servo Piston Pin-to-Valve Plate
BoreClearance .......................................................... 0.051 mm nominal
0.0020 in. nominal
UN09JAN97
6. 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.
AValve Plate
BPiston Pin
COD
DID
33
3360
24
FS41334,000016D 1911APR076/6
TM10079 (17MAR09)
33-3360-24

031709
PN=254
Hydraulic System
Pump 1 and 2 Start-Up Procedure
TX1020552A
UN19MAR07

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.
UN31AUG01
1. Fill pump drive gearbox with oil through fill plug (2) so
level is above H mark on dipstick (1). See Pump
Gearbox Oil. (Operators Manual.)
T145092
2. Remove air bleed plugs (3) from the top of pump

regulators to allow housing to fill with oil from the
hydraulic oil tank and to let air escape.
3. When pump housing is full of oil, install plugs.
4. As necessary, add oil to hydraulic oil tank until it is
between marks on sight glass. See Hydraulic Oil.
(Operators Manual.) Tighten tank cap. Tighten vent
plug.
1Dipstick
2Fill Plug
3Air Bleed Plug (2 used)
5. Start engine and run at slow idle. Slowly raise boom to

full height and then lower to pressurize hydraulic oil
tank.
6. Purge air from the hydraulic system by slowly
operating each function through three cycles. Air in
pilot circuits are purged automatically.
33
3360
25
FS41334,000016C 1910APR071/1
TM10079 (17MAR09)
33-3360-25

031709
PN=255
Hydraulic System
Pump 1 and 2 Regulator Remove and Install
UN21MAR07
NOTE: Pump 1 (front) and pump 2 (rear) regulators are

similar in design. Removal of pump 2 (rear)
regulator is shown.
TX1020485A


pump or drain hydraulic oil tank. See Apply Vacuum to
Hydraulic Oil Tank. (Group 3360.) Hydraulic oil tank
capacity is approximately 135 L (36 gal).
FS41334,000016B 1910APR071/2
33
3360
26
TM10079 (17MAR09)
33-3360-26

031709
PN=256
Hydraulic System
5. Remove cap screws (1) and regulator (2).
TX1003224A
UN06FEB06
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) to specification.
Specification
Pump 1 (Front) and Pump 2
(Rear) Regulator-to-Pump
36 lb-ft
1Cap Screw (8 used)

2Hydraulic Pump Regulator (2 used)

10. Connect electrical connectors. See Pump Harness
a new pump installed or oil has been
tank.
FS41334,000016B 1910APR072/2
33
3360
27
TM10079 (17MAR09)
33-3360-27

031709
PN=257
Hydraulic System
T142272B
UN16FEB07
Pump 1 and 2 Regulator Disassemble and Assemble
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
12End Plate
13Flow Adjusting Cartridge
14Maximum Flow Adjusting
Screw (Stop)
NOTE: Pump 1 (front) and pump 2 (rear) regulators

are similar. Pump 2 (rear) regulator is shown.
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

3. Tighten cap screws (1 and 11).
IMPORTANT: Removal of adjusting screws (4, 9

and 14) and cartridges (7 and 13)
33
from end plate (12) and cover (5) will
3360
require the adjustment of pump
28
regulators. Only remove parts from
end plate and cover if replacement is
necessary.
Specification
(Rear) End Plate and
Cover-to-Housing Cap Screw
Torque................................................................................... 19.8 Nm
180 lb-in.
1. Remove end plate (12) and cover (5) with adjusting

screws and cartridges installed.
TM10079 (17MAR09)
33-3360-28
FS41334,000016A 1918APR071/2

031709
PN=258
T105706
UN09JAN97
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
4. Tighten cap screws.
24Maximum Flow Adjusting

Screw (Stop)
27Remote Control Sleeve
28Remote Control Spool
29Minimum Flow Adjusting
Screw
34Nut
35End Plate
36Cover
47Outer Spring
48Inner Spring

5. Tighten air bleed plug.

7. Check pump regulator adjustments.
Specification
(Rear) Air Bleed
Plug-to-HousingTorque ........................................................ 78 Nm
58 lb-ft

not filled with oil before starting
engine. Procedure must be
performed whenever a new pump is
installed or oil has been drained
from the pump or hydraulic oil tank.
For minimum flow:

See Pump Regulator Test and Adjustments
Minimum Flow. (Group 9025-25.)
For maximum flow:
See Pump Regulator Test and Adjustments
Maximum Flow. (Group 9025-25.)
33
3360
29
FS41334,000016A 1918APR072/2
TM10079 (17MAR09)
33-3360-29

031709
PN=259
Hydraulic System
Pilot Pump Remove and Install
UN21MAR07

TX1020485A

2. Drain pump drive gearbox. Approximate oil capacity is
1.0 L (1.1 qt).
Hydraulic Oil Tank. (Group 3360.) See 200DLC Drain

FS41334,0000169 1918APR071/3
4. Remove cap screws (1) and set fuel filters (2 and 3)

aside. Protect against damage to hoses and filters.
TX1021817A
UN11APR07
1Cap Screw (4 used)

2Final Fuel Filter
FS41334,0000169 1918APR072/3
33
3360
30
TM10079 (17MAR09)
33-3360-30

031709
PN=260
Hydraulic System
UN19MAR07
6. Remove adapters (3).

7. Remove cap screws (2) and pilot pump (1) from
gearbox.
TX1020294A
8. Repair or replace parts as necessary. See Pilot Pump

9. Apply T43514 Rigid Form-In-Place Gasket to mounting
surface for pilot pump.
Specification
Pilot Pump-to-Pump Drive
Gearbox Cap ScrewTorque ........................................................ 50 Nm
37 lb-ft
1Pilot Pump
2Cap Screw (2 used)
3Adapter (2 used)
4Hydraulic Pump Gearbox
11. Install adapters (3) and O-rings.

13. Install fuel filters.
14. Fill pump drive gearbox so level is above H mark on
dipstick. See Change Pump Drive Gearbox Oil.
(Operators Manual.)
FS41334,0000169 1918APR073/3
33
3360
31
TM10079 (17MAR09)
33-3360-31

031709
PN=261
Hydraulic System
Pilot Pump Disassemble and Assemble
TX1000393
UN16NOV05
33
3360
32
TM10079 (17MAR09)
33-3360-32
FS41334,0000168 1910APR071/3

031709
PN=262
Hydraulic System
0Pilot Pump
1Housing
2Flange
3Oil Seal
5Snap Ring
6Seal (2 used)
7End Cover
9Backup Retainer (2 used)
10Key (2 used)
12O-Ring (2 used)
13Driven Gear
14Drive Gear
15Washer (4 used)
26Bushing
27Bushing
28Pin (4 used)
30Seal Kit
FS41334,0000168 1910APR072/3
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.
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.
T7685IX
IMPORTANT: Apply clean hydraulic oil to all parts.

Pump failure can result if pump is
assembled dry.
ADrive Gear
BKeys (2 used)
CDriven Gear
DBushing

Specification
Cover-to-Flange Cap Screw
Torque ............................................................................................ 41 Nm
30 lb-ft
6. Check pilot pressure setting. See See Pilot Pressure

Regulating Valve Test and Adjustment. (Group
9025-25.)
FS41334,0000168 1910APR073/3
33
3360
33
TM10079 (17MAR09)
33-3360-33

031709
PN=263
Hydraulic System
Pilot Pump Drive Shaft Remove and Install
3. Remove pilot pump drive gear (3) through opening for

hydraulic pump.
T105640
2. Remove pilot pump drive shaft (4) and outer ball

bearing (5) using a blind-hole puller or an internal
puller. Ball bearings are a press fit on drive shaft and
in housing.
UN12DEC96
1. Remove snap rings (6 and 7).
4. Repair or replace as needed.

5. Assemble in reverse order.
T142290
UN20JUL01
T105657
UN12DEC96
1Pump Drive Gearbox Case

3Pilot Pump Drive Gear
4Pilot Pump Drive Shaft
5Ball Bearing (2 used)
6Snap Ring
7Snap Ring
FS41334,0000167 1913MAR071/1
33
3360
34
TM10079 (17MAR09)
33-3360-34

031709
PN=264
Hydraulic System

Remove and Install
UN21MAR07

TX1020485A

TJ15698,000015B 1911APR071/2
2. Tag and disconnect hoses.

3. Close all open hoses and fittings using caps and plugs.
UN21MAR07
4. Remove cap screws (2) and remove pilot pressure

regulating valve (1) and filter (3).
TX1020484A

6. Install cap screws (2).
Specification
Filter Head-to-Support Cap
ScrewTorque ............................................................................... 50 Nm
37 lb-ft
1Pilot Pressure Regulating Valve

2Cap Screw (2 used)
3Filter
7. Replace pilot filter element (3).

Specification
Pilot Filter Element
Housing-to-Filter HeadTorque ................................................... 25 Nm
220 lb-in.
33
3360
35
8. Connect hoses. See Hydraulic System Line

9. Check pilot pressure setting. See Pilot Pressure
Regulating Valve Test and Adjustment. (Group
9025-25.)
TJ15698,000015B 1911APR072/2
TM10079 (17MAR09)
33-3360-35

031709
PN=265
Hydraulic System

Disassemble and Assemble
1
2
1. Remove plug (6) with O-ring (5).
4
5
2. Remove parts (24).
UN07FEB06
3. Inspect, clean and replace parts as necessary.
TX1003402
4. Check that poppet (2) slides smoothly in pilot pressure

regulating valve housing.
5. Tighten plug (6).
Specification
Plug-to-housingTorque................................................................ 50 Nm
37 lb-ft
1Pilot Pressure Regulating Valve Housing

2Poppet
3Shim (as required)
4Spring
5O-Ring
6Plug
TJ15698,000015C 1905APR071/1
Pilot Shutoff Solenoid Valve Remove and

Install
UN21MAR07
1. Turn upperstructure 90 to tracks.
TX1020485A

33
3360
36

TM10079 (17MAR09)
33-3360-36
TJ15698,000015D 1918APR071/2

031709
PN=266
Hydraulic System

7. Install valve. Tighten cap screws.
Specification
Pilot Shutoff Valve
Housing-to-Cab Platform Cap
ScrewTorque .............................................................................. 50 Nm
37 lb-ft
8. Connect lines. See Pilot Shutoff Solenoid Valve

Operation. (Group 9025-05.)
TX1003406A
1Cap Screw (2 used)

2Connector
UN07FEB06
5. Remove cap screws (1) and valve.
TX1003407A
UN07FEB06
4. Disconnect solenoid connector (2).
TJ15698,000015D 1918APR072/2
33
3360
37
TM10079 (17MAR09)
33-3360-37

031709
PN=267
Hydraulic System
Pilot Shutoff Solenoid Valve Disassemble and Assemble
TX1000413
UN16NOV05
33
3360
38
TM10079 (17MAR09)
33-3360-38
TJ15698,000015E 1918APR071/2

031709
PN=268
Hydraulic System
1Spring
2Plate
3Housing
4Spool
5Screen
6Solenoid
8Plug (2 used)
9Screw (2 used)
10Screw (2 used)
11O-Ring
12O-Ring (2 used)
13Valve, Pilot Shutoff
Solenoid
Specification
Shutoff Solenoid Valve Housing
PlugTorque ........................................................................... 28 Nm
246 lb-in.
1. Clamp housing (3) in a vise.

2. Scribe a line on housing (3) and solenoid (6).
3. Remove screws (9), solenoid (6), and O-ring (11).
8. Install screen (5).
4. Remove plug (8), O-ring (12), spring (1), and spool

(4), from housing.
9. Install O-ring (11) to solenoid (6).
5. Remove screen (5).
10. Align scribe marks and install solenoid (6) to

housing (3), using screws (9). Tighten screws to
specification.
6. Clean and inspect all parts. Replace worn or

damaged parts as necessary. Use new O-rings
when assembling.
7. Install spool (4), spring (1), plug (8), and O-ring
(12). Tighten plug to specification.
Specification
Solenoid-to-Housing Screws
Torque........................................................................................ 4 Nm
36 lb-in.
TJ15698,000015E 1918APR072/2
Fan Drive Pump Remove and Install
UN21MAR07

TX1020485A

pump, or drain tank. See See Apply Vacuum to
Hydraulic Oil Tank. (Group 3360.) Approximate oil
capacity is 135 L (36 gal).

33
3360
39
TM10079 (17MAR09)
33-3360-39
OUO1073,000211E 1912APR071/2

031709
PN=269
Hydraulic System
3. Loosen clamp and disconnect inlet hose (2).
UN21FEB06
4. Disconnect outlet hose (1). Install caps and plugs.

Close all open lines and fitting using caps and plugs.
5. Remove cap screws (4), washers, pump (3), and
gasket.
TX1003808A
6. If installing new pump, remove fittings and top cap

screw from existing pump and install onto new pump
using new O-rings on fittings.
7. Install pump and new gasket.
UN21FEB06
9. Connect inlet and outlet hoses.

10. Tighten fittings and clamp.
TX1003809A
11. Fill and check hydraulic oil level. See See 200DLC
Drain and Refill Capacities. (Operators Manual.)
1Outlet Hose
2Inlet Hose
3Fan Drive Pump
OUO1073,000211E 1912APR072/2
Fan Drive Motor Remove and Install

OUO1073,000211B 1919APR071/5
33
3360
40
TM10079 (17MAR09)
33-3360-40

031709
PN=270
Hydraulic System
(Group 3360.)
UN19APR07

TX1022358

TX1020688A
UN22MAR07

2Cap Screw
OUO1073,000211B 1919APR072/5
6. Tag and disconnect fan drive motor hydraulic hoses (1

and 2). Close all open lines and fittings using caps and
plugs.
UN03APR07
TX1021410A
1Hydraulic Hose
2Hydraulic Hose
OUO1073,000211B 1919APR073/5

33
3360
41
TX1020784A
UN23MAR07
1Cap Screw (4 used)

TM10079 (17MAR09)
33-3360-41
OUO1073,000211B 1919APR074/5

031709
PN=271
Hydraulic System
9. Disconnect hydraulic hoses (4, 6, and 7).
10. Remove lock nut (2) and washer. Discard lock nut.
UN30MAR07
11. Remove hub (1) from motor shaft using suitable

puller.
TX1021112A
12. Remove cap screws (3), nuts, washers, and fan drive
motor (5).
13. Replace motor as necessary.
14. Install motor into mounting bracket.
15. Install cap screws, washers, and nuts. Tighten cap
Specification
Fan Drive Motor-to-Mounting
Bracket Cap ScrewsTorque ........................................................ 73 Nm
54 lb-ft
1Hub
2Lock Nut
3Cap Screws
4Hydraulic Hose
5Fan Drive Motor
6Hydraulic Hose
7Hydraulic Hose
16. Install hub on fan shaft.

17. Install washer and new lock nut onto fan shaft.
Tighten lock nut to specification.
Specification
Fan Motor Shaft Lock Nut
Torque ............................................................................................ 50 Nm
37 lb-ft
18. Connect hydraulic hoses

to specification.
Specification
Fan Drive Motor
Assembly-to-Cooling Package
54 lb-ft
33
3360
42
OUO1073,000211B 1919APR075/5
TM10079 (17MAR09)
33-3360-42

031709
PN=272
Hydraulic System
Fan Drive Control Valve Remove and Install
UN21MAR07

TX1020485A

(Group 3360.)

OUO1073,000211C 1918APR071/2
33
3360
43
TM10079 (17MAR09)
33-3360-43

031709
PN=273
Hydraulic System
NOTE: Reversing control valve shown, standard valve
similar.
3. Remove storage compartment floor (2) to access fan
drive control valve (1).
4. Remove bottom covers.
7. Remove cap screws and fan drive control valve (1).

8. Install valve and cap screws.
TX1021580A
6. Disconnect wiring harness connector from valve

solenoids.
UN16APR07
5. Tag and disconnect hydraulic hose (3 and 4). Apply

caps and plugs to close all opening.
9. Connect hydraulic hoses. See Fan Drive System

Component Location. (Group 9025-15.)
TX1021582A
UN16APR07
TX1021581A
1Fan Drive Control Valve

2Floor
3Hydraulic Hoses
4Hydraulic Hoses
UN16APR07
10. Connect wiring harness connectors.
33
3360
44
OUO1073,000211C 1918APR072/2
TM10079 (17MAR09)
33-3360-44

031709
PN=274
Hydraulic System
Solenoid Valve Manifold Remove and Install
UN21MAR07

TX1020485A


TJ15698,000015F 1911APR071/2
33
3360
45
TM10079 (17MAR09)
33-3360-45

031709
PN=275
Hydraulic System
3. Tag and disconnect electrical connectors.
4. Tag and disconnect hoses and lines.
UN07MAR07
5. Close all open lines, hoses, and fittings using caps and
plugs.
TX1020239A
6. Remove cap screws (2) and solenoid valve manifold

(1).
8. Install manifold and tighten cap screws to specification.
1Solenoid Valve Manifold
Specification
Solenoid Valve Manifold Cap
ScrewsTorque ............................................................................. 50 Nm
37 lb-ft
9. Connect hoses and lines.

10. Connect electrical connectors.
11. Fill hydraulic oil tank. Approximate oil capacity is 135
L (36 gal).
12. Perform pump 1 and 2 start-up procedure. See Pump
1 and 2 Start-Up Procedure. (Group 3360.)
TJ15698,000015F 1911APR072/2
33
3360
46
TM10079 (17MAR09)
33-3360-46

031709
PN=276
Hydraulic System
UN21MAR07
Solenoid Valve Remove and InstallPower

Dig (SG), Travel Speed (SI), Boom Mode
(SC), and Boom Flow Rate (SF)
TX1020485A

TJ15698,0000160 1911APR071/2
UN07MAR07
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.
TX1020240A
5. Install solenoid valve coil (2) with O-ring and spring.

6. Tighten cap screws (1).
Specification
Solenoid Valve Coil-to-Manifold
Cap ScrewsTorque ....................................................................... 6 Nm
53 lb-in.
1Cap Screw (8 used)

2Solenoid Valve Coil (4 used)
3Electrical Connector (4 used)
7. Connect electrical connectors (3).

8. Check pressure setting of solenoid valves. See Power
Digging Solenoid Valve Test and Adjustment. See
Travel Speed Solenoid Valve Test and Adjustment.
See Arm Regenerative Solenoid Valve Test and
Adjustment. See Dig Regenerative Solenoid Valve Test
and Adjustment. (Group 9025-25.)
33
3360
47
TJ15698,0000160 1911APR072/2
TM10079 (17MAR09)
33-3360-47

031709
PN=277
Hydraulic System
Pilot Valve (Left and Right) Remove and

Install
UN21MAR07

TX1020485A

1821.)
3. Remove console covers. See Left and Right Console

Covers Remove and Install. (Group 1821.)
TJ15698,0000161 1911APR071/3
33
3360
48
TM10079 (17MAR09)
33-3360-48

031709
PN=278
TX1018524
UN05FEB07
Hydraulic System
1Handle (2 used)
2Tie Band (2 used)
3Nut (4 used)
4Shaft (2 used)
5Boot (2 used)
6Washer (8 used)
7Tie Band (2 used)
8Cap Screw and Washer (6

used)
4. Disconnect wiring harness and remove handles (1).

Handles are threaded onto shaft (4).
5. Remove cap screws (8 and 10) and remove pilot
valves (12) from console.
6. Tag and disconnect hoses. Close all open hoses
8. Connect hoses. See Pilot Control Valve-to-Signal

Manifold Component LocationExcavator Pattern.
(Group 9025-15.)
NOTE: Position cap screw (10) with spring pin (9), in
lower left hole of left pilot valve, and lower
right hole of right pilot valve.
9. Install pilot valves (12) and tighten cap screws (8
and 10).
TM10079 (17MAR09)

11Washer (2 used)
12Pilot Valve (2 used)
33-3360-49
TJ15698,0000161 1911APR072/3

031709
PN=279
33
3360
49
Hydraulic System
Specification
Pilot Valve-to-Console Cap
ScrewTorque ........................................................................ 20 Nm
177 lb-in.
10. After pilot valve is installed, check operation of all

functions. See Control Lever Pattern Operation.
(Operators Manual.)
11. Install console covers. See Left and Right Console

Covers Remove and Install. (Group 1821.)
12. Install seat. See Seat Remove and Install. (Group
1821.)
TJ15698,0000161 1911APR073/3
33
3360
50
TM10079 (17MAR09)
33-3360-50

031709
PN=280
Hydraulic System
33
3360
51
TM10079 (17MAR09)
33-3360-51

031709
PN=281
Hydraulic System
Pilot Valve (Left and Right) Disassemble and Assemble
TX1000262
UN16NOV05
33
3360
52
TM10079 (17MAR09)
33-3360-52
TJ15698,0000162 1903APR071/3

031709
PN=282
Hydraulic System
0Housing and Spools
3Shim (4 used)
4Spacer (4 used)
6Balance Spring (2 used)
10Guide (4 used)

14Pusher B (2 used)
15Pusher A (2 used)
17Sleeve (4 used)
19O-Ring (4 used)
21Plate
22Universal Joint
23Cam
24Coupling
26Plug
IMPORTANT: The housing and spools (0) 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 universal joint (22) only if
necessary.
Note port location and quantity of
shims (3) when removing. Same
number of shims must be used when
installing.
27O-Ring
28Snap Ring
33Return Spring (2 used)
34Return Spring (2 used)
35Pilot Valve
Spacer (4)
Spools (0)
Snap Ring (28)
O-Ring (27)
Plug (26)

5. Install O-ring (27) onto plug (26).
6. Install plug (26) and snap ring (28).
IMPORTANT: Components are select fit to bores.
Install components in the same bore
that they were removed from.
7. Install spools (0).
IMPORTANT: Ports 1 and 3 use short balance
springs. Ports 2 and 4 use long
balance springs.
1. Remove:
8. Install spacers (4), shims (3), and balance springs

(6 and 8).
Coupling (24)
Cam (23)
Universal Joint (22)
Plate (21)
IMPORTANT: Ports 1 and 3 use short return

springs. Ports 2 and 4 use long
return springs.
NOTE: Sleeves (17) cannot be disassembled. Do not

attempt to remove oil seal from sleeve.
9. Install return springs (33 and 34).
2. Remove sleeves (17).
10. Install guides (10) with protrusion facing upward.
3. Remove:
11. Install snap rings (11).
Pusher (14 and 15)

Snap Ring (11)
Guide (10)
Spring (6 and 8)
Spring (33 and 34)
Shim (3)
IMPORTANT: Ports 1 and 3 use pushers with 1

outer groove. Ports 2 and 4 use
pushers with 2 outer grooves.
12. Install pushers A (15) and pushers B (14).
TM10079 (17MAR09)
33
3360
53
33-3360-53
TJ15698,0000162 1903APR072/3

031709
PN=283
Hydraulic System
13. Apply TY6341 Multi-Purpose SD Polyurea Grease
to ball at ends of pushers A and pushers B.
14. Apply TY6341 Multi-Purpose SD Polyurea Grease
to joint of universal joint (22) and to inner surface
of sleeve (17) seals.
15. Install O-rings (19) and sleeves (17).
16. Apply LOCTITE 262 Threadlocker (high strength)
to threads of universal joint (22).
IMPORTANT: Align cap screw hole in plate (21)
with cap screw hole in housing (0).
18. Install cam (23) on universal joint (22). Adjust

clearance between pushers A (15) and pushers B
(14) and cam.
Specification
Cam-to-Pusher A and Pusher
BClearance................................................................... 00.20 mm
00.008 in.
19. Hold cam (23) and tighten coupling (24).

Specification
Coupling-to-Cam and Universal
JointTorque .......................................................................... 69 Nm
51 lb-ft
17. Install plate (21) and universal joint (22). Tighten

universal joint.
Specification
Universal JointTorque ....................................................... 24.5 Nm
217 lb-in.
LOCTITE is a trademark of Henkel Corporation
TJ15698,0000162 1903APR073/3
Travel Pilot Valve Remove and Install
UN21MAR07

TX1020485A

33
3360
54
TM10079 (17MAR09)
33-3360-54
TJ15698,0000163 1911APR071/2

031709
PN=284
Hydraulic System
2. Tag and disconnect hoses underneath of cab.
3. Close all open hoses and fittings using caps and plugs.
UN16FEB06
4. Remove cap screws (1) and remove pedals and levers.
TX1003510A
5. Remove cap screws (2) and remove travel pilot valve

(3).
Specification
Valve-to-Cab Platform Cap
ScrewTorque ............................................................................... 50 Nm
37 lb-ft
1Cap Screw (4 used)

2Cap Screw (2 used)
3Travel Pilot Valve

Specification
Travel Pedal-to-Lever Cap
ScrewTorque ............................................................................... 50 Nm
37 lb-ft
9. Connect hoses. See Travel Hydraulic System Line

10. After travel pilot valve is installed, check the operation
of all functions to be sure they operate correctly.
TJ15698,0000163 1911APR072/2
33
3360
55
TM10079 (17MAR09)
33-3360-55

031709
PN=285
Hydraulic System
Travel Pilot Valve Disassemble and Assemble

1
35
34
33
32
4
5
8
29
27
28
9
11
10
12
13
18
17
25
14
26
24
31
22
23
21
16
15
UN31JAN07
30
TX1018305
20
19
33
3360
56
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)
10Holder
11Oil Seal (4 used)
12O-Ring (4 used)
13Bushing (4 used)
14Casing
15O-Ring
16Plug
17Plug
18O-Ring
19Spool (4 used)
20Spring (4 used)
21Spacer (4 used)
22Shim (As required)
24Spring Guide (4 used)
25Pusher (4 used)
26Bracket (2 used)
TM10079 (17MAR09)
33-3360-56

32Bushing (4 used)
33Cam (2 used)
TJ15698,0000164 1905APR071/3

031709
PN=286
Hydraulic System
IMPORTANT: The casing (14) and spools (19) 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 (22) 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.
NOTE: Spring pins (30 and 31) are stepped and can
only be removed from one direction.
Remove spring pin (27) and bushings (32) only
if necessary.
7. Lock pins (34 and 35) in position by displacing the

bore above spring pin using a punch and hammer.
8. Install holder (10) to casing (14) with cap screws
(8), lock washers (9) and tighten.
Specification
Holder-to-Casing Cap Screw
Torque...................................................................................... 50 Nm
37 lb-ft
9. Apply multi-purpose grease to O-rings (4 and 5)

and install on pin (3).
10. Position rubber seat (7) and dampener (6) on pin
(3) with lever facing upward.
11. Install cap screws (28), lock washers (29) and
tighten.
Specification
Dampener-to-Holder Cap
ScrewTorque .......................................................................... 7 Nm
62 lb-in.
IMPORTANT: Note direction of insertion for spring

pins (30 and 31).
Spring pins must be positioned with
slits 90 apart.

NOTE: Use same number of shims (22) as were
removed.
Align brackets with marks made

during disassembly.
3. Install spools (19), springs (20), spacers (21), shims

(22) and balance springs (23) into casing (14).
12. Install brackets (26) and spring pins (30 and 31).
4. Install spring guides (24) with stepped end facing

down.
13. Lock pins (30 and 31) in position by displacing the

bore above spring pin using a punch and hammer.
5. Apply multi-purpose grease to the end of each

pusher (25) and to oil seals (11).
14. Install cover (2) and cap screws (1) and tighten.
IMPORTANT: Note direction of insertion for spring

pins (34 and 35).
6. Assemble cam (33) in holder (10) with spring pins
(34 and 35), and pin (3). Install spring pins with slits
90 apart.
Specification
Cover-to-Holder Cap Screw
Torque........................................................................................ 5 Nm
44.3 lb-in.
TM10079 (17MAR09)
33
3360
57
15. Apply multi-purpose grease to spring pin (27).
33-3360-57
TJ15698,0000164 1905APR072/3

031709
PN=287
Hydraulic System
16. Install O-ring (18) and plug (17). Tighten plug to
specification.
17. Install O-ring (15) and plug (16). Tighten plug to

specification.
Specification
PlugTorque ........................................................................... 10 Nm
89 lb-in.
Specification
PlugTorque ........................................................................... 20 Nm
177 lb-in.
TJ15698,0000164 1905APR073/3
Pilot Signal Manifold Remove and Install
UN21MAR07

TX1020485A


TJ15698,0000165 1911APR071/2
33
3360
58
TM10079 (17MAR09)
33-3360-58

031709
PN=288
Hydraulic System
5. Remove cap screws (3).
UN20FEB06
7. Position manifold (1) on bracket (2) and tighten cap

screws (3).
8. Connect electrical connectors. See System Functional

Schematic, Component Location, and Wiring Diagram
Master Legend. (Group 9015-10.)
9. Connect hoses and lines. See Pilot Controllers-to-Pilot
Signal Manifold Component LocationExcavator
Pattern. See Pilot Signal Manifold-to-Control Valve Line
TX1003759A
Specification
Pilot Signal Manifold-to-Bracket
Cap ScrewTorque ....................................................................... 50 Nm
37 lb-ft
1Pilot Signal Manifold

2Bracket
3Cap Screw (4 used)

L (36 gal).
TJ15698,0000165 1911APR072/2
33
3360
59
TM10079 (17MAR09)
33-3360-59

031709
PN=289
Hydraulic System
Pilot Signal Manifold Disassemble and Assemble

14
14
21
15
10
22
16
17
13
23
19
20
12
24
11
6
18
19
16
4
20
17
3
2
C
B
25
26
19
27
16
15
20
14
17
33
3360
60
28
17
16
T143485
TM10079 (17MAR09)
33-3360-60
15
T143485
19
UN17JUL01
29
TJ15698,0000166 1912MAR071/3

031709
PN=290
Hydraulic System
2Body
3Gasket
4Body
5Gasket
6Body
7Gasket
8Body
9Gasket
10Body
11Name Plate
12Screw (4 used)
13Plate
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
TJ15698,0000166 1912MAR072/3
33
3360
61
TM10079 (17MAR09)
33-3360-61

031709
PN=291
Hydraulic System
30
32
31
32
31
30
31
30
T143486
UN17JUL01
33
3360
62
T143486
30Filter (17 used)
31Shuttle Valve (21 used)
32Spring (4 used)
TJ15698,0000166 1912MAR073/3
TM10079 (17MAR09)
33-3360-62

031709
PN=292
Hydraulic System
Control Valve Remove and Install
UN21MAR07

TX1020485A

pump, or drain tank. See Apply Vacuum to Hydraulic
Oil Tank. (Group 3360.) See 200DLC Drain and Refill
Capacities. (Operators Manual.)

OUO6046,0002313 1910APR071/3
3. Tag and disconnect hydraulic lines and hoses. Close

all open lines and fittings using caps and plugs.
UN23MAR07

5. Remove cap screws (1) and washers. Place pilot
signal manifold (2) with bracket to side.
TX1020604A
6. Attach an appropriate lifting device to control valve

using lifting straps.
1Cap Screws
2Pilot Signal Manifold
OUO6046,0002313 1910APR072/3
33
3360
63
TM10079 (17MAR09)
33-3360-63

031709
PN=293
Hydraulic System

Specification
Control ValveApproximate
Weight.............................................................................................. 216 kg
475 lb
7. Remove cap screws (1), washers (2), and spacers (3).

Remove control valve.
9. Install in reverse order.

2
Specification
Mounting Bracket-to-Control
Valve Cap ScrewTorque ........................................................... 270 Nm
200 lb-ft
11. Install pilot signal manifold with bracket. Tighten cap

3
Specification
Pilot Signal Manifold
Bracket-to-Control Valve Cap
ScrewTorque ............................................................................. 140 Nm
103 lb-ft
12. Connect hydraulic hoses and lines. See Hydraulic

System Line Connections. (Group 9025-15.)
2
1
TX1003909
1
5
UN20FEB06
1Cap Screw (4 used)

2Washer (4 used)
3Spacer (4 used)
4Front Mounting Bracket
5Rear Mounting Bracket
13. Connect electrical connectors.

14. Check hydraulic oil. See Check Hydraulic Tank Oil
15. Do Pump 1 and 2 Start-Up Procedure. (Group 3360.)
33
3360
64
OUO6046,0002313 1910APR073/3
TM10079 (17MAR09)
33-3360-64

031709
PN=294
Hydraulic System
Control Valve (5-Spool) Disassemble and Assemble
TX1004777
UN26APR06
33
3360
65
Control Valve End Caps 5-Spool Side

TM10079 (17MAR09)
33-3360-65
OUO6046,0002314 1910APR071/8

031709
PN=295
Hydraulic System
TX1004778
UN25APR06
33
3360
66
TM10079 (17MAR09)
33-3360-66
OUO6046,0002314 1910APR072/8

031709
PN=296
Hydraulic System
1Housing
2O-Ring
3Plug
4Poppet
5Spring
6O-Ring (3 used)
7Flange
8Cap Screw (22 Used)
9O-Ring (4 Used)
10Plug (4 Used)
11Poppet
12Spring (2 Used)
13O-Ring (5 Used)
14O-Ring
15Backup Ring
16Plug
17Main Relief and Power
Digging Valve
18O-Ring
19Arm Out Circuit Relief and
Anticavitation Valve (2
Used)
20O-Ring (5 Used)
21O-Ring
22Spring
23Seat
24Poppet
25Backup Ring
26O-Ring
27O-Ring
28Backup Ring
29Sleeve
30Spool
31O-Ring
32Body
33Spring
34Piston
35O-Ring
36Plug
37Poppet
38Spring
39O-Ring
40Spacer
41Left Travel Spool
42Spring Seat (10 Used)
43Spring (5 Used)
44Bolt (5 Used)
45Auxiliary Spool
46Boom 2 Spool
47Arm 1 Spool
49Spring
50Swing Spool
51O-Ring (10 Used)
53O-Ring
54Plug
55Cap
56Plug (2 Used)
57O-Ring (2 Used)
59Arm 1 Flow Rate Spool
60Spring
62O-Ring (2 Used)
63Plug (2 Used)
64Sleeve (2 Used)
65Spring (2 Used)
66Plug
67Spring
1. Remove cap screws (52) and bottom pilot caps

(98).
68Poppet
69Poppet
70Plug
71O-Ring
72Flange
73Spring
74Poppet
75Flange (2 Used)
76Poppet (2 Used)
77Auxiliary Flow Rate Spool
78Spring
79Plug
80Spring
81Poppet
82Poppet
83Poppet
84Cover (2 Used)
85O-Ring (2 Used)
86Poppet
87Plug
88O-Ring
89Spring
90Poppet
91Socket Bolt (4 Used)
92Cap (2 Used)
94Spring
95Auxiliary Flow Combiner
Spool
96Spring
97Dig Regenerative Spool
98Cap (4 Used)
99Arm In Circuit Relief and
Anticavitation Valve
100O-Ring
104Body
Check Valve
106Main Relief Valve
Isolation Check Valve
107Arm Reduced Leakage
Valve
108Left Travel Spool
109Auxiliary Spool
110Boom II Spool
111Arm I Spool
112Swing Spool
113Check Valve
114Auxiliary Flow Rate
Control Valve
Valve Check Valve
116Lift Check (Left Travel
Power Passage Check
Valve)
117Dig Regenerative Check
Valve
Valve
119Dig Regenerative Valve
120Arm Reduced Leakage
Valve
121Lift Check (Boom 2
Power Passage)
122Arm 1 Flow Rate Control
Valve
123Lift Check (Swing Neutral
Passage)
NOTE: Hold spool in a vise by the spool end between

wooden blocks.
2. Remove cap screws (52) and top pilot cap (55).
a. Remove spools (108112).
3. Spool5 Spool (108112):
b. Disassemble control valve spools.
IMPORTANT: The spool (108112) 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.
c. Inspect control valve spools for wear and

damage.
d. Replace parts as necessary.
e. Assemble in reverse order.
33
3360
67
TM10079 (17MAR09)
33-3360-67
OUO6046,0002314 1910APR073/8

031709
PN=297
Hydraulic System
f. Tighten cap screws (44) to specification.
e. Install plug (10) and tighten to specification.
Specification
Cap Screw-to-Control Valve
SpoolTorque ......................................................................... 15 Nm
132 lb-in.
NOTE: Apply clean hydraulic oil to spools before

installation.
Specification
Left Travel Neutral
Passage-to-Housing Lift Check
PlugTorque ........................................................................... 76 Nm
56 lb-ft
6. Auxiliary Flow Combiner Valve Check Valve

(115):
g. Install spools (108112) into housing (1) while

rotating them slowly.
h. After installing spools into housing, push them
by hand to confirm smoothness.
a. Remove parts (8, 7, 6, 5 and 83).

b. Inspect parts for wear and damage.
c. Assemble in reverse order.
4. Dig Regenerative Valve (119):

a. Remove cap screws (91) and parts (92, 6, 93,
96 and 97).
d. Install flange (7) and tighten cap screws (8) to

specification.
Specification
Auxiliary Flow Combiner Valve
Check Valve-to-Housing Cap
ScrewTorque ........................................................................ 61 Nm
46 lb-ft

c. Replace parts as necessary.
d. Assemble in reverse order.
e. Tighten cap screws (91) to specification.
7. Arm Reduced Leakage Valve (120):
Specification
Dig Regenerative
Valve-to-Housing Cap Screw
Torque...................................................................................... 11 Nm
84 lb-in.
a. Remove cap screws (8) and flange (72).

b. Remove spring (73) and poppet (74).
c. Inspect parts for wear and damage.
5. Lift Check (Left Travel Neutral Passage) (116):

a. Remove plug (10) O-ring (9), spring (38) and
poppet (86).
33
3360
68

c. Replace parts as necessary
f. Install flange (72) and tighten cap screws (8).

Specification
Arm Reduced Leakage
Torque...................................................................................... 61 Nm
46 lb-ft
TM10079 (17MAR09)
33-3360-68
OUO6046,0002314 1910APR074/8

031709
PN=298
Hydraulic System
8. Lift Check (Boom 2 Power Passage) (121):
b. Loosen plugs (56 and 63) from bodies (104).
a. Remove cap screws (8) and flanges (75).
c. Remove O-rings (20 and 13).
b. Remove O-ring (13), spring (12) and poppet

(76).
d. Remove plugs (63), spring seats (61), springs

(60 and 78) and spools (59 and 77).
e. Remove plugs (56).
f. Remove sleeves (64), springs (65), plugs (66

and 79), springs (67 and 80) and poppets (68,
69, 81, and 82) from housing (1).

f. Install flanges (75) and tighten cap screws (8) to
specification.
g. Inspect parts for wear and damage.

h. Replace parts as necessary.
Specification
Power Passage-to-Housing
46 lb-ft
i. Assemble in reverse order.

j. Install housing (104) and tighten cap screws
(58) to specification.
Specification
Flow Rate Valve
Housing-to-Housing Cap
ScrewTorque ........................................................................ 61 Nm
46 lb-ft
9. Lift Check (Swing Neutral Passage) (123):

a. Remove cap screws (8) and flanges (75).
b. Remove O-ring (13), spring (12) and poppet
(76).
k. Tighten plug (63) to specification.
Specification
Flow Rate Valve Housing
PlugTorque ........................................................................... 98 Nm
72 lb-ft

f. Install flanges (75) and tighten cap screws (8) to
specification.
11. Arm Reduced Leakage Valve (107):

Specification
Neutral Passage-to-Housing
46 lb-ft
a. Remove plug (36).

b. Remove cap screws (8) and body (32).
33
3360
69
c. Remove parts (3335).

10. Auxiliary Flow Rate Control Valve (114) and
Arm I Flow Rate Control Valve (122):
a. Remove cap screws (58) and housing (104).
d. Remove parts (2231).

e. Inspects parts for wear and damage.
TM10079 (17MAR09)
33-3360-69
OUO6046,0002314 1910APR075/8

031709
PN=299
Hydraulic System
f. Replace parts as necessary.
k. Tighten plug (36) to specification.
g. Assemble in reverse order.

h. Apply petroleum jelly to valve seat (23) and
spring (22) to hold in place.
Specification
Plug-to-Arm Reduced Leakage
ValveTorque ....................................................................... 108 Nm
80 lb-ft
IMPORTANT: Install spool (30) with the hole side

towards poppet (24) to ensure
proper operation of valve.
i. Install plug (36) loosely.
j. Tighten cap screws (8) to specification.
Specification
Arm Reduced Leakage Valve
Body-to-Housing Cap Screw
Torque...................................................................................... 62 Nm
46 lb-ft
OUO6046,0002314 1910APR076/8
33
3360
70
TM10079 (17MAR09)
33-3360-70

031709
PN=300
Hydraulic System
12. Main Relief and Power Digging Valve (17)
A
NOTE: Disassemble valve for cleaning and inspection
only. Valve is serviced as an assembly.
B
C
a. Disassemble parts (AQ).
c. If any part of valve is damaged, replace valve as

an assembly.
F
17
H
d. Tighten nuts (D and I) to specification.
Main Relief ValveSpecification

Main Relief Valve 27 mm Nut
(D)Torque .................................................................................... 64 Nm
47 lb-ft
Main Relief Valve 32 mm Nut
(I)Torque ..................................................................................... 83 Nm
61 lb-ft
J
K
P
e. Tighten valve cartridge (J) to specification.
Q
TX1005220
Specification
Main Relief Valve
Cartridge-to-HousingTorque ....................................................... 83 Nm
61 lb-ft
TX1005220
M
N
UN24MAR06
AFirst Adjusting Plug

BO-Ring
CPiston
DNut
ESecond Adjusting Plug
FO-Ring
GPilot Poppet Spring
HPilot Poppet
INut
JCartridge
KO-Ring
LPilot Poppet Seat
MBackup Ring
NO-Ring
OMain Poppet Spring
PMain Poppet
QMain Poppet Seat
f. Check and adjust pressure setting for system relief

valve and power boost. See Main Relief and Power
Digging Valve Test and Adjustment. (Group
9025-25.)
13. Install top pilot cap (55) and tighten cap screws (52)
to specification.
Specification
Top Pilot Cap-to-Housing Cap
ScrewTorque ............................................................................... 42 Nm
32 lb-ft
33
3360
71
14. Install bottom pilot caps (98) and tighten cap screws
(52).
TM10079 (17MAR09)
33-3360-71
OUO6046,0002314 1910APR077/8

031709
PN=301
Hydraulic System
Specification
Bottom Pilot Caps-to-Housing
Cap ScrewTorque ...................................................................... 42 Nm
32 lb-ft
OUO6046,0002314 1910APR078/8
33
3360
72
TM10079 (17MAR09)
33-3360-72

031709
PN=302
Hydraulic System
Control Valve (4-Spool) Disassemble and Assemble
TX1004704
UN16MAR06
33
3360
73
4-Spool Control Valve

TM10079 (17MAR09)
33-3360-73
OUO6046,0002315 1919APR071/6

031709
PN=303
Hydraulic System
TX1004708
UN16MAR06
33
3360
74
Control Valve End Caps (4-Spool Side)
TM10079 (17MAR09)
33-3360-74
OUO6046,0002315 1919APR072/6

031709
PN=304
Hydraulic System
1Housing
2Poppet
3Spring (2 used)
4O-Ring (3 used)
5Flange
7O-Ring (3 used)
8Plug (3 used)
9O-Ring (5 used)
10Plug (3 used)
11Poppet
12Spring
13O-Ring (3 used)
14O-Ring
15Poppet
16Flange
17Main Relief Valve Isolation
Check Valve
18Right Travel and Bucket
Combined Function Check
Valve
19O-Ring (2 used)
20Circuit Relief and
used)
21Spring
22Washer
23Poppet
24Backup Ring
25O-Ring
26O-Ring
27Arm Regenerative Circuit
Check Valve
28Backup Ring
29Sleeve
30Spool
31O-Ring
32Body
33Spring
34Piston
35O-Ring
36Plug
37Right Travel Spool
39Spring (4 used)
40Body
42Plug
43Backup Ring (2 used)
44O-Ring
45Spring
46Poppet
47Bucket Spool
48Plug
49Poppet
50Boom 1 Spool
51Arm 2 Spool
53Spring
54Arm Regenerative Spool
55O-Ring
56Backup Ring
57Arm Regenerative Spool
58Spring
59O-Ring (8 Used)
60O-Ring
61Plug
62Top Pilot Cap
64Bottom Pilot Cap
65O-Ring
66Plug
67Cap (3 Used)
69Cap
70Cap Screw
1. Remove cap screws (63), top pilot cap (62) and

O-rings (59) from housing (1).
2. Remove cap screws (63) and bottom pilot caps (67)
from housing (1).
72Spring
73Travel Flow Combiner
Spool
74Circuit Relief and
Used)
75Poppet
76Spring
77O-Ring (5 Used)
78O-Ring (2 Used)
79O-Ring
80Manual Boom Lower
Screw
81O-Ring
82Plug
83Poppet
84Poppet
85Spring
86Plug
87Spring (3 Used)
88Sleeve
89Plug
90O-Ring
91Body
92Bucket Flow Rate Spool
93Spring
94Spring Seat
95O-Ring
96Plug
98Poppet
99Poppet
100Spring
101Plug
102O-Ring
103Cap
105By-Pass Shut-Off Spool
106Spring
107Flange
108Poppet
109Poppet
110Spring
111Plug
112Poppet
113Spring
114Plug (3 Used)
115O-Ring (3 Used)
117Spring
119Plug (3 Used)
120O-Ring (3 Used)
121Spring
123Body
125Spring
126O-Ring
127Plug
128Boom Reduced Leakage
Valve
129By-Pass Shut-Off Valve
130Right Travel Spool
131Bucket Spool
132Boom 1 Spool
133Arm 2 Spool
134Arm Regenerative Valve
135Travel Flow Combiner
Valve
136Boom Reduced Leakage
Valve
137Bucket Flow Rate
Control Valve
138Arm 2 Flow Rate Control
Valve
IMPORTANT: The spools (130133) are select fit

to bores in housing and are a
different design for each function.
Spools must be installed into same
bores from which they were removed
for proper operation of machine.
3. Spool4 Spool (130133):

a. Remove spools (130133).
NOTE: When disassembling spools (131, and 132),
heat plugs (46, 48, and 49) to 200300 C
(392482 F) to melt thread lock and sealer.
33
3360
75
TM10079 (17MAR09)
33-3360-75
OUO6046,0002315 1919APR073/6

031709
PN=305
Hydraulic System
NOTE: Hold the spool in a vise by the spool end,
using wooden blocks.
j. Install spools (130133) into housing (1) while

rotating them slowly.
b. Remove cap screws (41) and spools.

c. Heat plugs (46, 48, and 49) with heat gun to
melt thread lock and sealer and remove plugs.
IMPORTANT: After installing spool (130133) into

housing (1), push them by hand to
confirm smoothness.
4. Travel Flow Combiner Valve (135):
d. Inspect parts for wear and damage.

a. Remove cap screws (68) and cap (69).
e. Replace parts as necessary.
b. Remove parts (4,7072).
f. For right travel spool (130) and arm 2 spool
(133); install and tighten cap screws (41) to
specification.

Specification
SpoolTorque ......................................................................... 15 Nm
11 lb-ft
g. For bucket and boom 1 spool (131 and 132):

f. Tighten cap screw (70) to specification.
Specification
Cap Screw-to-Flow Combiner
Valve SpoolTorque............................................................... 11 Nm
7 lb-ft
Apply thread lock and sealer (high strength) to

plugs (46, 48, and 49).
h. Install plugs (46, 48, and 49) onto spool (131
and 132) and tighten to specification.
Specification
Plugs-to-Control Valve Spool
Torque...................................................................................... 15 Nm
11 lb-ft
i. Install cap screw (41) into spool and tighten to

specification.
g. Install spool (73), cap (69) and tighten cap

screws (68) to specification.
Specification
Cap-to-Housing Cap Screw
Torque...................................................................................... 10 Nm
7 lb-ft
5. Arm Regenerative Valve (134):

a. Remove parts (4, 5458).
Specification
SpoolTorque ......................................................................... 15 Nm
11 lb-ft
33
3360
76

c. Replace parts as necessary.
NOTE: Apply hydraulic oil to spools before installation.
TM10079 (17MAR09)
33-3360-76
OUO6046,0002315 1919APR074/6

031709
PN=306
Hydraulic System
e. Install parts (4, 5458).
g. Apply petroleum jelly to washer (22) and spring

(21) to hold them in place.
6. Arm 2 Flow Rate Control Valve (138):

a. Remove cap screws (97) and body (123).
h. Install spool (30), with hole side towards poppet

(23).
b. Remove O-rings (77, 13) and poppet (15).
i. Install parts (3335).
c. Remove plugs (114), spring seats (116), springs

(117, 121, 125) and spools (118, 122, 124).
j. Loosely install plug (36).

k. Install and tighten cap screws (6) to
specification.
d. Remove plugs (119) and (127).

e. Remove spring (113) and poppet (112).
f. Remove springs (87) and poppets (98, 108).
Remove plugs (101, 111), springs (100, 110) and
poppets (99, 109) from poppets (98, 108).
Specification
Boom Reduced Leakage Valve
Torque...................................................................................... 62 Nm
46 lb-ft
g. Inspect parts for wear and damage.

l. Tighten plug (36) to specification.
h. Replace parts as necessary.
i. Install in reverse order and loosely install plugs.
j. Install body (123) to housing (1) using cap
screws (97). Tighten to specification.
Specification
Arm 2 Flow Rate Control Valve
Torque...................................................................................... 61 Nm
45 lb-ft
Specification
Boom Reduced Leakage
Valve-to-Body PlugTorque ................................................. 108 Nm
80 lb-ft
8. Bucket Flow Rate Valve (137):

a. Remove cap screws (97), housing (91), and
O-ring (13).
b. Remove parts (89, 90, 9296)).
7. Boom Reduced Leakage Valve (128):
c. Remove (8388) from housing (1).
a. Remove plug (36).
d. Inspect parts for wear and damage.
b. Remove parts (3335).
e. Replace parts as necessary.
c. Remove cap screws (6) and body (32).
f. Assemble in reverse order.
d. Remove parts (2131).
g. Install housing (91) and tighten cap screws (97)

to specification.
e. Inspect parts for wear and damage.

f. Replace parts as necessary.
TM10079 (17MAR09)
33-3360-77
OUO6046,0002315 1919APR075/6

031709
PN=307
33
3360
77
Hydraulic System
Specification
Bucket Flow Rate Valve
Housing-to-Housing Cap
ScrewTorque ........................................................................ 61 Nm
46 lb-ft
10. By-Pass Shut-Off Valve (129):

a. Remove cap screws (6), flange (107) and
O-ring (4) from housing (1).
b. Remove spring (106) and spool (105).
h. Tighten plug (96) to specification.

Specification
Flow Rate Valve Housing
PlugTorque ........................................................................... 98 Nm
72 lb-ft

e. Install O-ring (4) and parts (105107); then
tighten cap screws (6) to specification.
Specification
By-Pass Shut-Off
Torque...................................................................................... 61 Nm
46 lb-ft
9. Boom Reduced Leakage Valve (136):

a. Remove cap screws (6), housing (40), and
O-rings (13).
b. Remove parts (7578).
11. Install top pilot cap (62) and tighten cap screws
(63) to specification.
Specification
Top Pilot Cap-to-Housing Cap
ScrewTorque ........................................................................ 42 Nm
32 lb-ft
f. Install housing (40) and tighten cap screws (6) to

specification.
12. Install bottom pilot caps (64 and 67) and tighten
cap screws (63) to specification.
Specification
Boom Reduced Leakage
Torque...................................................................................... 61 Nm
46 lb-ft
Specification
Bottom Pilot Cap-to-Housing
32 lb-ft
OUO6046,0002315 1919APR076/6
33
3360
78
TM10079 (17MAR09)
33-3360-78

031709
PN=308
Hydraulic System
Hydraulic Oil Tank Remove and Install

CAUTION: The hydraulic oil tank is pressurized.
High pressure release of oil can cause serious
burns or penetrating injury.
2. Drain hydraulic oil tank. Approximate oil capacity is 135
L (36 gal).
3. Remove control valve cover and hydraulic oil tank
covers.
4. Disconnect return and supply lines.
5. Close all open lines and fittings using caps and plugs.
TJ15698,0000180 1911APR071/2
33
3360
79
TM10079 (17MAR09)
33-3360-79

031709
PN=309
Hydraulic System
6. Disconnect connector for oil temperature sensor (4).
7. Remove cap screws (1) and washers (2).
Specification
Hydraulic Oil TankWeight ....................................... 102 kg approximate
225 lb approximate
8. Remove hydraulic oil tank using a hoist and lifting

straps.
10. Install hydraulic oil tank.
Specification
Oil Tank-to-Frame Cap Screw
Torque .......................................................................................... 400 Nm
295 lb-ft
12. Connect lines. See Hydraulic System Line

TX1021211
UN30MAR07
1Cap Screw (4 used)

2Washer (4 used)
3Gasket
4Oil Temperature Sensor
13. Install covers.

14. Connect oil temperature sensor connector.
L (36 gal).
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 Pump 1 and 2 Start-Up Procedure. (Group
33
3360.)
3360
80
TJ15698,0000180 1911APR072/2
TM10079 (17MAR09)
33-3360-80

031709
PN=310
Hydraulic System
33
3360
81
TM10079 (17MAR09)
33-3360-81

031709
PN=311
Hydraulic System
Hydraulic Oil Tank Disassemble and Assemble
TX1020508
UN30MAR07
33
3360
82
TM10079 (17MAR09)
33-3360-82
TJ15698,0000169 1918APR071/2

031709
PN=312
Hydraulic System
1Hydraulic Oil Tank
3O-Ring
4Cap Screw (6 used)
5Spring
6Cover Assembly
6ABracket
6BCover
6CCap Screw
6DWasher
6EWasher
7Filter
7AHousing
7BFilter Element
7CCover
7DNut
7ECap
8Packing
9O-Ring
10Screw (4 used)
12Sight Glass
12ACap Screws
13Washers
14Hydraulic Oil Temperature
Sensor
15Gasket
16Suction Strainer and Rod
16ARod
16BSuction Strainer
17Plug and O-Ring (4 used)
18Plug and O-Ring
20Adapter Fitting and
O-Ring (3 used)
21Elbow Fitting and O-Ring

22Filter Element
30Filter Element
30ASealing Ring
30BValve
30CO-Ring
30DFilter Element
32Cover
35Washer (4 used)
1. Tighten cap screws (4 and 11).
3. Tighten nuts on suction strainer rod.
Specification
Covers-to-Hydraulic Oil Tank
Cap ScrewsTorque .............................................................. 49 Nm
36 lb-ft
Specification
Suction Strainer Rod Nuts
Torque...................................................................................... 17 Nm
153 lb-in.
2. Adjust the length of rod on suction strainer (16).

Specification
Suction Strainer Rod (Top of
Rod-to-Bottom of Strainer)
Length .................................................................................... 869 mm
34.2 in.
TJ15698,0000169 1918APR072/2
Restriction Valve Remove and Install
UN21MAR07

TX1020485A

pump or drain tank. See Apply Vacuum to Hydraulic
Oil Tank. (Group 3360.) Approximate oil capacity is
135 L (36 gal).

33
3360
83
TM10079 (17MAR09)
33-3360-83
TJ15698,0000167 1911APR071/3

031709
PN=313
Hydraulic System
TX1020509
UN30MAR07
33
3360
84
TM10079 (17MAR09)
33-3360-84
TJ15698,0000167 1911APR072/3

031709
PN=314
Hydraulic System
1Cap Screw (4 used)
2Flange (2 used)
3Oil Cooler Hose
4Cap Screw
5Washer
6Clamp
7Coupling
8Cap Screw (2 used)
9Washer (2 used)
10Bracket
11Return Line
3. Remove clamp (6).
12O-Ring
13Restriction Valve
14Snap Ring
9. Fill hydraulic oil tank. Approximate oil capacity is

135 L (36 gal).
4. Disconnect hose (3) from line (11).

5. Remove snap ring (14) and restriction valve (13).
7. Install restriction valve (13) and snap ring (14).
8. Connect hose (3) to line (11).

hydraulic oil tank.
10. Perform pump 1 and 2 start-up procedure. See
Pump 1 and 2 Start-Up Procedure. (Group 3360.)
Specification
Return Line Coupling Cap
ScrewsTorque ...................................................................... 90 Nm
66 lb-ft
TJ15698,0000167 1911APR073/3
Hydraulic Oil Cooler Bypass Valve Remove

and Install
UN21MAR07

TX1020485A

pump or drain tank. See Apply Vacuum to Hydraulic
Oil Tank. (Group 3360.) Approximate oil capacity is
135 L (36 gal).

33
3360
85
TM10079 (17MAR09)
33-3360-85
TJ15698,0000168 1911APR071/2

031709
PN=315
Hydraulic System
6
5
TX1004061
UN09MAR06
1Control Valve
2O-Ring
3Oil Cooler Bypass Valve

4Socket Head Cap Screws
5Hydraulic Return Line

6Coupling
7Hydraulic Oil Tank
3. Loosen cap screws and nuts on coupling (6).
9. Tighten nuts on coupling.
4. Remove socket head cap screws (4) and hydraulic

return line (5).
Specification
Control Valve-to-Hydraulic Oil
Tank Return Line Coupling
NutsTorque........................................................................... 11 Nm
97 lb-in.
5. Remove oil cooler bypass valve (3) and O-ring (2)

from control valve (1). Repair or replace as
necessary.
10. Fill hydraulic oil tank. Approximate oil capacity is

135 L (36 gal).
6. Install oil cooler bypass valve (3) and O-ring (2).

hydraulic oil tank.
7. Install hydraulic line (5).

8. Install socket head cap screws (4). Tighten to
specification.
33
3360
86
Specification
Return Line Flange-to-Control
Valve Socket Head Cap
ScrewsTorque ...................................................................... 50 Nm
37 lb-ft
11. Perform pump 1 and 2 start-up procedure. See

Pump 1 and 2 Start-Up Procedure. (Group 3360.)
TJ15698,0000168 1911APR072/2
TM10079 (17MAR09)
33-3360-86

031709
PN=316
Hydraulic System
Boom Cylinder Remove and Install

NOTE: Procedure is the same for both boom cylinders.
UN10JAN97
1. Park machine on firm, level surface.
T106031
2. Retract arm and bucket cylinders and lower bucket to

ground.
OUO6046,0002316 1918APR071/6
UN21MAR07

TX1020485A
4. Loosen boom cylinder hydraulic lines at frame end of

boom to release any residual pressure.
5. Disconnect lines. Close all open lines and fittings using
caps and plugs.
6. Disconnect lubrication line at rod end of cylinder.
OUO6046,0002316 1918APR072/6

lifting device.
Specification
Boom CylinderWeight .................................................................. 170 kg
375 lb
7. Attach appropriate lifting device to boom cylinder (1)

using lifting strap.
UN21APR06
33
3360
87
TX1006808
1Boom Cylinder
TM10079 (17MAR09)
33-3360-87
OUO6046,0002316 1918APR073/6

031709
PN=317
Hydraulic System
8. Remove parts (13, and 5).
9. Push pin (4) into boom.
10. Lower boom cylinder (6) on floor stand.
T142979
UN24JUL01
1Nut (2 used)
2Retainer
3Cap Screw
4Boom Cylinder-to-Boom Pin
5Shim (2 used)
6Boom Cylinder
OUO6046,0002316 1918APR074/6
33
3360
88
TM10079 (17MAR09)
33-3360-88

031709
PN=318
Hydraulic System
11. Disconnect hydraulic lines (7) from head end of boom
cylinder (6). Close all open lines and fitting using caps
and plugs.
6
9
13. Remove parts (811) and remove boom cylinder (6).

7
10
11
15. Install shims equally on each side of cylinder head

end to get the minimum amount of clearance in joint.
11
T143048
UN02AUG01
12. Mark location of shims (8) to aid in assembly.
6Boom Cylinder
7Hydraulic Lines
8Shim (as required)
9Cap Screw (2 used)
10Boom Cylinder-to-Frame Pin (2 used)
11Nut (4 used)
16. Align pin bores so shims are not damaged as pin (10)
is installed.
17. Connect boom cylinder head end to frame.
18. Tighten nuts (11) against each other allowing cap
screws (9) to be free to turn in hole.
Specification
Boom Cylinder-to-Frame Pin
Retainer NutTorque ........................... 270 Nm (tighten nut against nut)

20. Tighten boom cylinder hoses.
Specification
Boom Cylinder Hose Fitting
36mmTorque ............................................................................. 175 Nm
130 lb-ft
Specification
Boom Cylinder Hose Fitting
41mmTorque ............................................................................. 205 Nm
150 lb-ft
33
3360
89
TM10079 (17MAR09)
33-3360-89
OUO6046,0002316 1918APR075/6

031709
PN=319
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
retracted 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.
21. Start engine.
22. Slowly extend boom cylinder (6) to align pin bores so
shims (5) are not damaged as pin (4) is installed.
23. Install shims to get the minimum amount of clearance
between boom and boom cylinder rod end.
24. Connect boom cylinder rod end to boom.
screw (3) to be free to turn in hole.
Specification
Boom Cylinder-to-Frame Pin
26. Connect lubrication line.

Specification
Boom Cylinder Pivot Lubrication
LineTorque .................................................................................. 25 Nm
18 lb-ft
27. Lubricate all pivot joints. See Track Adjuster, Working

Tool Pivot, Swing Bearing, and Swing Bearing Gear
Grease. (Operators Manual.)
28. Bleed air from cylinder. See Hydraulic Cylinder Bleed
33
3360
90
29. Check hydraulic oil level. See Check Hydraulic Tank

OUO6046,0002316 1918APR076/6
TM10079 (17MAR09)
33-3360-90

031709
PN=320
Hydraulic System
TX1004546
UN14MAR06
Boom Cylinder Disassemble and Assemble
6
5
12
21
13
14 15 14
13 18
UN14MAR06
22
10 11
20
16 17
TX1004547
19
TX1004547
1Rod
2Dust Wiper
3Backup Ring
4U-Ring
5Buffer Ring
7Cylinder Head
8Bushing
9Snap Ring
10Backup Ring
11O-Ring
12Barrel
13Slide Ring (2 used)

14Wear Ring (2 used)
16O-Ring
17Seal Ring
2. Pull rod out so piston nut is against cylinder head.

Specification
Boom CylinderApproximate
Weight ....................................................................................... 170 kg
375 lb
1. Fasten head end of cylinder to JT30043 Cylinder

Service Stand.
33
3360
91
3. Connect rod to appropriate lifting device using a

lifting strap.
4. Remove cap screws (6) from cylinder head (7).
5. Remove rod, cylinder head and piston nut from
barrel (12).
TM10079 (17MAR09)
18Set Screw
19Ball
20Piston Nut
21Cushion Bearing
22Cushion Seal
33-3360-91
OUO6046,0002317 1909APR071/3

031709
PN=321
Hydraulic System
6. Install rod eye in sliding housing and install housing
in JT30043 Cylinder Service Stand.
IMPORTANT: Note direction of dust wiper (2) and

U-ring (4) for installation.
7. Make an alignment mark on piston nut (20) and rod

(1).
16. Remove components (25) and (911) from

cylinder head (7).
8. Remove staked material from set screw (18) hole

using a small air grinder or a drill and bit.
17. Remove bushing (8) using ST8020.
9. Remove set screw (18) and steel ball (19).

IMPORTANT: To avoid damaging tapped hole for
set screw, cap screw in ST3244 Hex
Piston Nut Wrench must be
tightened against a side of nut
without tapped hole.
To avoid gouging side of nut, install
a piece of steel flat stock between
nut and cap screw.
10. Install ST3244 Hex Piston Nut Wrench so cap
screw is tightened against side of piston nut (20)
11. Install a piece of steel flat stock between piston
nut and cap screw. Tighten cap screw of piston
nut wrench.
12. Remove piston nut (20) using JT30043 Cylinder
Service Stand.
Specification
Boom Cylinder Piston Nut
Torque.................................................................................. 5600 Nm
4130 lb-ft
IMPORTANT: Note direction of oil groove in

cushion bearing (21) and notch in
cushion seal (22) for installation.
13. Remove cushion bearing (21) and cushion seal
(22) from rod (1).
33
3360
92
14. Remove components (1317) from piston nut

(20).
18. Inspect dust seals and bushings in rod (1) and

barrel (12) for wear or damage. Repair or replace
parts as necessary. See Inspect Pins, Bushings
and BossesFront Attachment. (Group 3340.)
19. 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

21. Install bushing (8) into cylinder head (7) using
ST8020. Press to bottom of bore.
22. Install snap ring (9).
23. Install backup ring (10) and O-ring (11).
24. Install buffer ring (5).
25. Install U-ring (4) with lip towards bushing (8).
26. Install backup ring (3).
27. Install dust wiper (2) using ST8020 with lip
towards outside of cylinder.
28. Install assembled cylinder head (7) on rod (1)
using ST8020.
29. Install O-ring (16) and seal ring (17) to piston nut
(20) using ST2964 Installer. Adjust seal ring (17)
using ST2208 Adjustment Tool.
30. Install backup rings (15) on each side of seal ring.
15. Remove cylinder head (7) from rod (1).
TM10079 (17MAR09)
33-3360-92
OUO6046,0002317 1909APR072/3

031709
PN=322
Hydraulic System
without tapped hole. Install a piece of steel flat
stock between nut and cap screw. Tighten cap
screw of piston nut wrench. Tighten piston nut (20)
to specification using JT30043 Cylinder Service
Stand.
31. Install wear rings (14) and slide rings (13) to

piston nut (20).
IMPORTANT: Install cushion seal (22) so that
notch is towards piston.
Specification
Boom Cylinder Piston Nut
Torque.................................................................................. 5600 Nm
4130 lb-ft
32. Install cushion seal (22).

cushion bearing (21) during
installation.
36. Install steel ball (19) and set screw (18).
33. Install cushion bearing (21).

34. Align marks made during disassembly and install
piston nut (20).
nut and cap screw.
37. Stake set screw (18) in two places 90 from

previous stake marks.
38. Apply clean oil to piston nut and seals. Attach
appropriate lifting device to rod using a lifting
strap. Carefully install piston nut, rod and cylinder
head into barrel.
39. Install cylinder head cap screws (6). Tighten to
specification.
Specification
Boom Cylinder Head-to-Barrel
Cap ScrewTorque .............................................................. 267 Nm
197 lb-ft

OUO6046,0002317 1909APR073/3
Arm Cylinder Remove and Install

T106031
UN10JAN97
2. Retract arm and bucket cylinders and lower bucket to

ground.
TM10079 (17MAR09)
33-3360-93
OUO6046,0002318 1905APR071/6

031709
PN=323
33
3360
93
Hydraulic System
UN21MAR07

TX1020485A
4. Loosen arm cylinder hydraulic lines at frame end of

boom to release any residual pressure.
caps and plugs.
OUO6046,0002318 1905APR072/6
6. Insert wood block (3) between arm cylinder (1) and

boom (2).
UN02AUG01

lifting device.
T143063
Specification
Arm CylinderWeight .................................................................... 250 kg
550 lb
7. Attach arm cylinder to appropriate lifting device using

lifting straps.
1Arm Cylinder
2Boom
3Wood Block
OUO6046,0002318 1905APR073/6
33
3360
94
TM10079 (17MAR09)
33-3360-94

031709
PN=324
Hydraulic System
8. Remove parts (1 and 2).
NOTE: Note location of shims (3) to aid in assembly.
9. Push pin (4) out and remove shims.
10. Disconnect lubrication line.
T143064
UN02AUG01
1Nut (2 used)
2Cap Screw
3Shim (as required)
4Arm Cylinder-to-Arm Pin
OUO6046,0002318 1905APR074/6
33
3360
95
TM10079 (17MAR09)
33-3360-95

031709
PN=325
Hydraulic System
NOTE: Note location of shims (3) to aid in assembly.
UN02AUG01
12. Push pin (4) out and remove shims.

13. Remove arm cylinder
T143065

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.
1Nut (2 used)
2Cap Screw
3Shim (as required)
4Arm Cylinder-to-Boom Pin
16. Align pin bores so shims are not damaged as pin (4)
is installed.
Specification
Arm Cylinder Pivot Lubrication
LineTorque .................................................................................. 25 Nm
18 lb-ft
18. Connect arm cylinder head end to boom.

Specification
Arm Cylinder-to-Boom Pin

33
3360
96
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.
TM10079 (17MAR09)
33-3360-96
OUO6046,0002318 1905APR075/6

031709
PN=326
Hydraulic System
Specification
Arm Cylinder-to-Arm Pin Retainer
NutTorque .......................................... 550 Nm (tighten nut against nut)

Specification
Arm Cylinder Pivot Lubrication
LineTorque .................................................................................. 25 Nm
18 lb-ft
24. Tighten arm cylinder hoses.

Specification
Arm Cylinder Hose Fitting
36mmTorque ............................................................................. 175 Nm
130 lb-ft
Specification
Arm Cylinder Hose Fitting
41mmTorque ............................................................................. 205 Nm
150 lb-ft

OUO6046,0002318 1905APR076/6
33
3360
97
TM10079 (17MAR09)
33-3360-97

031709
PN=327
Hydraulic System
TX1004548
UN14MAR06
Arm Cylinder Disassemble and Assemble
6
4
18
25
17
18 19 18
17
22
14
UN14MAR06
1Rod
2Dust Wiper
3Backup Ring
4U-Ring
5Buffer Ring
7Cylinder Head
26 24
10 11
8Bushing
9Snap Ring
10Backup Ring
11O-Ring
12Barrel
13Stopper (2 used)
14Cushion Bearing
15Cushion Seal
16Snap Ring
20O-Ring
Specification
Arm CylinderApproximate
Weight ...................................................................................... 250 kg
550 lb

Service Stand.
21Seal Ring
22Set Screw
23Ball
24Piston Nut
25Cushion Bearing
26Cushion Seal

lifting strap.
barrel (12).
TM10079 (17MAR09)
23 16 15
TX1004549

33
3360
98
20 21
TX1004549
13
33-3360-98
OUO6046,000232E 1913MAR091/3

031709
PN=328
Hydraulic System
6. Remove stopper (13), cushion bearing (14), cushion
seal (15), and snap ring (16).
14. Remove cushion bearing (25) and cushion seal

(26) from rod (1).
(24).

(1).
nut and cap screw.
12. Install a piece of steel flat stock between nut and
cap screw. Tighten cap screw of piston nut
wrench.
Service Stand.
Specification
Arm Cylinder Piston Nut
Torque.................................................................................. 8860 Nm
6535 lb-ft


cylinder head (7).
indicator.
Specification
Arm Cylinder RodCurvature ................................... 0.5 mm per 1 m
0.020 in. per 3.25 ft

TM10079 (17MAR09)
33-3360-99
33
3360
99
OUO6046,000232E 1913MAR092/3

031709
PN=329
Hydraulic System
using ST8021.
32. Install slide rings (17) and wear rings (18) to
piston nut (24).

Stand.
Specification
Arm Cylinder Piston Nut
Torque.................................................................................. 8860 Nm
6535 lb-ft
37. Install steel ball (23) and set screw (22). Tighten
set screw to specification.
Specification
Set ScrewTorque ................................................................. 57 Nm
42 lb-ft


33. Install cushion seal (26).


installation.
39. Install snap ring (16) and cushion seal (15).

34. Install cushion bearing (25).
piston nut (24).
nut and cap screw.

installation.
40. Install cushion bearing (14) and stopper (13).
head into barrel.
specification.
Specification
Arm Cylinder Head-to-Barrel
270 lb-ft
33
3360
,100
OUO6046,000232E 1913MAR093/3
TM10079 (17MAR09)
33-3360-100

031709
PN=330
Hydraulic System
Bucket Cylinder Remove and Install

UN10JAN97
2. Retract arm cylinder and bucket cylinder (1) and lower

bucket to ground. Position end of arm (2) on wood
block (3).
TX1006807
UN21APR06
T106031
1Bucket Cylinder
2End of Arm
3Wood Block
OUO6046,000232F 1909APR071/5
UN21MAR07

TX1020485A

OUO6046,000232F 1909APR072/5
33
3360
,101
TM10079 (17MAR09)
33-3360-101

031709
PN=331
Hydraulic System
caps and plugs.
UN02AUG01
5. Connect center link to appropriate lifting device using

lifting strap.
6. Put wood block (5) between bucket cylinder and arm to
hold cylinder up when pin (1) is removed.
T143075

NOTE: Mark location of shims (3) to aid in assembly.
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
OUO6046,000232F 1909APR073/5
33
3360
,102
TM10079 (17MAR09)
33-3360-102

031709
PN=332
Hydraulic System

lifting device.
Specification
Bucket CylinderWeight................................................................ 150 kg
330 lb
9. Disconnect bucket cylinder rod end hose (1).
5
6
3
UN02AUG01
10. Connect bucket cylinder (2) to appropriate lifting

device using lifting strap.
1
T143076
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 Assemble. (Group 3360.)
1Bucket Cylinder Rod End Hose

2Bucket Cylinder
3Nut (2 used)
4Shim (as required)
5Cap Screw
6Bucket Cylinder-to-Arm Pin
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.
Specification
Bucket Cylinder-to-Arm Pin

20. Tighten bucket cylinder hoses.
33
3360
,103
Specification
Bucket Cylinder HoseTorque .................................................... 175 Nm
130 lb-ft
TM10079 (17MAR09)
33-3360-103
OUO6046,000232F 1909APR074/5

031709
PN=333
Hydraulic System
21. Start engine.
22. Slowly extend bucket cylinder to align pin bores so
shims are not damaged as pin is installed.
23. Install shims equally on each side of cylinder rod end
and side links to get minimum amount of clearance in
joint.
24. Connect bucket cylinder head end to arm.
25. Tighten nuts against each other allowing cap screw to
be free to turn in hole.
Specification
Bucket Cylinder-to-Pin Retainer
NutTorque .......................................... 550 Nm (tighten nut against nut)

33
3360
,104
OUO6046,000232F 1909APR075/5
TM10079 (17MAR09)
33-3360-104

031709
PN=334
Hydraulic System
Bucket Cylinder Disassemble and Assemble

7
8 10
11
18
20
TX1004550
15 17 16 15 13
6
7
12
13 14
15
14 13
20
18
UN09MAR06
10 11
16 17
19
TX1004551
13 14
12
14
TX1004550
19
UN09MAR06
TX1004551
1Rod
2Dust Wiper
3Backup Ring
4U-Ring
5Buffer Ring

7Cylinder Head
8Bushing
9Snap Ring
10Backup Ring
11O-Ring
12Barrel
16O-Ring
17Seal Ring
18Set Screw
19Ball
20Piston Nut

Specification
Bucket CylinderApproximate
Weight ...................................................................................... 150 kg
330 lb

barrel (12).

Service Stand.

(1).


lifting strap.
TM10079 (17MAR09)
33-3360-105
OUO6046,0002330 1905APR071/3

031709
PN=335
33
3360
,105
Hydraulic System


nut and cap screw.
11. Install a piece of steel flat stock between nut and
cap screw. Tighten cap screw of piston nut
wrench.
Service Stand.
Specification
Bucket Cylinder Piston Nut
Torque.................................................................................. 5150 Nm
3800 lb-ft

(20).

indicator.
Specification
Bucket Cylinder Rod
Curvature ................................................................... 0.5 mm per 1 m
0.020 in. per 3.25 ft

using ST8019.

cylinder head (7).
30. Install slide rings (13) and wear rings (14) to

piston nut (20).


piston nut (20).
33
3360
,106
TM10079 (17MAR09)
33-3360-106
OUO6046,0002330 1905APR072/3

031709
PN=336
Hydraulic System
nut and cap screw.
Stand.
33. Install steel ball (19) and set screw (18).

head into barrel.
specification.
Specification
Bucket Cylinder Head-to-Barrel
197 lb-ft
Specification
Bucket Cylinder Piston Nut
Torque.................................................................................. 5150 Nm
3800 lb-ft
OUO6046,0002330 1905APR073/3
33
3360
,107
TM10079 (17MAR09)
33-3360-107

031709
PN=337
Hydraulic System
Hydraulic Cylinder Bleed Procedure

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.
OUO6046,0002331 1905APR071/1
33
3360
,108
TM10079 (17MAR09)
33-3360-108

031709
PN=338
Section 43
Swing or Pivoting System

Contents
Page
Group 4350Mechanical Drive Elements

Swing Gearbox Remove and Install . . . . . . .43-4350-1
Swing Gearbox Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-4
Swing Gearbox Start-Up Procedure . . . . . .43-4350-11
Upperstructure Remove And Install . . . . . . .43-4350-11
Swing Bearing Remove and Install . . . . . . .43-4350-14
Swing Bearing Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .43-4350-16
Swing Bearing Upper Seal Install . . . . . . . .43-4350-19
Swing Bearing Lower Seal Install . . . . . . . .43-4350-19
Center Joint Remove and Install . . . . . . . . . .43-4360-1
Center Joint Disassemble and Assemble . . .43-4360-4
Center Joint Air Test . . . . . . . . . . . . . . . . . . .43-4360-5
Swing Motor and Park Brake Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-6
Swing Motor and Park Brake
Disassemble . . . . . . . . . . . . . . . . . . . . . .43-4360-10
Swing Motor and Park Brake Inspection . . .43-4360-12
Swing Motor and Park Brake Assemble . . .43-4360-14
Swing Motor and Park Brake Start-Up
Procedure . . . . . . . . . . . . . . . . . . . . . . . .43-4360-16
Crossover Relief Valve and Make-Up
Check Valve Remove and Install . . . . . . .43-4360-17
Make-Up Check Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .43-4360-18
Swing Park Brake Release Valve Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .43-4360-19
43
TM10079 (17MAR09)
43-1

031709
PN=1
Contents
43
TM10079 (17MAR09)
43-2

031709
PN=2
Group 4350
Mechanical Drive Elements

Swing Gearbox Remove and Install
UN21MAR07

TX1020485A

2. Pull vacuum in hydraulic oil tank using vacuum pump
or drain hydraulic oil tank. See Apply Vacuum to
Hydraulic Oil Tank. (Group 3360.) The approximate
capacity of hydraulic oil tank is 135 L (36 gal).

3. Tag and disconnect lines from swing motor. Close all

TJ15698,000016A 1911APR071/3
43
4350
1
TM10079 (17MAR09)
43-4350-1

031709
PN=341

lifting device.
UN02FEB06
NOTE: Swing motor may be removed by itself or with

swing gearbox. See Swing Motor and Park Brake
TX1003159A
Mark swing gearbox housing to machine

upperstructure to aid in installation.
4. Install JT01748 Lifting Brackets and connect to
1Cap Screw and Washer (14 used)
Specification
Swing Motor, Brake, and
GearboxWeight ............................................................................ 218 kg
481 lb

6. Remove cap screws and washers (1).
7. Remove swing gearbox and motor.
8. Repair or replace parts as necessary. See Swing
Gearbox Disassemble and Assemble. (Group 4350.)
9. Apply PM38656 Thread Lock and Sealer (High
Strength) to mating surfaces of swing gearbox housing
and upperstructure.
10. Install swing gearbox and motor.
Specification
Swing Gearbox-to-Upperstructure
Cap ScrewTorque ..................................................................... 500 Nm
369 lb-ft
12. Connect electrical connector (2).

14. See Swing Gearbox Start-Up Procedure. (Group
4350.) See Swing Motor and Park Brake Start-Up
43
4350
2
TM10079 (17MAR09)
43-4350-2
TJ15698,000016A 1911APR072/3

031709
PN=342

15. If hydraulic oil tank was drained, fill hydraulic oil tank.
The approximate capacity of hydraulic oil tank is 135
L (36 gal).
TJ15698,000016A 1911APR073/3
43
4350
3
TM10079 (17MAR09)
43-4350-3

031709
PN=343
UN09FEB07
Swing Gearbox Disassemble and Assemble
TX1018815
43
4350
4
TM10079 (17MAR09)
43-4350-4
TJ15698,000016B 1911APR071/8

031709
PN=344

0Swing Gearbox
1Shaft
2Sleeve
3O-Ring
4Roller Bearing
5Seal
6Housing
7Roller Bearing
8Bearing Nut
9Plate
10Cap Screw
Carrier
12Washer
13Pin (2 used)
1. Make alignment marks between swing motor, ring

gear housing (20) and housing (6) to aid in
assembly.
2. Remove swing motor. See Swing Motor and Park
Brake Remove and Install. (Group 4360.)

18Second Stage Sun Gear
20Ring Gear Housing
Carrier
24Thrust Plate
25Pin (3 used)

30Snap Ring
31First Stage Sun Gear
33Line
36Fitting Plug
6. Disassemble first planetary pinion carrier (23)

assembly.
IMPORTANT: Hole for spring pin (29) located on
first planetary pinion carrier (23) is
not a through hole.
7. Tap spring pin (29) into pin (25) until it reaches the
center of pin (25).

Specification
Swing MotorWeight ................................................................. 48 kg
105 lb
3. Remove first planetary pinion carrier assembly

(23-29) from ring gear housing (20).
8. Remove pin (25), planetary gear (26), needle

bearing (27), and thrust plate (28) from first planet
pinion carrier (23).
9. Inspect needle bearing (27) for wear.
10. Remove thrust plate (24) from carrier.
NOTE: First stage sun gear (31) may be removed

separately or along with carrier.
IMPORTANT: Damaging the surface of pin (25) can

cause bearing failure, use care when
handling pin.

Specification
Ring GearWeight..................................................................... 23 kg
50 lb
4. Remove cap screws (21) and ring gear housing

(20).
11. Using wood blocks, clamp pin (25) in vise. Tap

spring pin (29) out of pin.
12. Disassemble second planetary pinion carrier (11)
assembly as in Steps 7-11.
13. Remove cap screws (10) and lock plate (9) from
bearing nut (8).
5. Remove second planetary pinion carrier assembly

(11-18).
NOTE: Second stage sun gear (18) may be removed
separately or with carrier.
43
4350
5
TM10079 (17MAR09)
43-4350-5
TJ15698,000016B 1911APR072/8

031709
PN=345

14. Remove bearing nut (8) from shaft (1) using DFT1220
Swing Gearbox Nut Spanner Wrench. See DFT1220
Swing Gearbox Nut Spanner Wrench. (Group 9900.)
8
UN01MAR06

lifting device.
TX1004267
Specification
Housing AssemblyWeight ............................................................ 106 kg
234 lb
15. Install eyebolts into bolt hole on housing (6). Use

appropriate lifting device and position housing
assembly (6) onto press.
8Bearing Nut
TJ15698,000016B 1911APR073/8
NOTE: Bearing and sleeve are pressed onto shaft.

16. Using press, push upper end of shaft (1) and remove
from housing (6). Inner race of roller bearing (4) and
sleeve (2) are removed with shaft (1).
TX1004268
1Shaft
6Housing
UN01MAR06
TJ15698,000016B 1911APR074/8
43
4350
6
TM10079 (17MAR09)
43-4350-6

031709
PN=346

17. Inspect shaft (1), roller bearing (4), and sleeve (2).
18. If disassembly is necessary, use press and knife edge
bearing puller to push upper end of shaft (1) and
remove inner race of roller bearing (4) and sleeve (2).
20. Insert a round bar into oil passage in housing (6). Tap
and remove outer race of roller bearing (4).
2
TX1004269
21. Remove oil seal (5) from housing (6).
TX1004269
19. Remove O-ring (3) from sleeve (2).
UN19APR06
1Shaft
2Sleeve
4Roller Bearing
NOTE: Oil seal (5) can not be reused.

22. Remove outer race of roller bearing (7) from housing
(6) using brass drift and hammer.
24. Install O-ring (3) in sleeve (2).
25. Install sleeve (2) and inner race of roller bearing (4) to
shaft (1) using press and a piece of pipe.
26. Install outer race of roller bearing (4) into housing (6).
Strength) to OD of oil seal (5).
28. Install oil seal (5) so lip (spring side) is toward bottom
of bore. Push seal to bottom of bore.
29. Apply grease to ID of oil seal (5).
30. Apply grease to outer surface of sleeve (2) on shaft
(1).
lifting device.
Specification
Housing AssemblyWeight .............................................................. 65 kg
143 lb
31. Install eyebolts into bolt holes in housing (6).

32. Using appropriate lifting device, slowly lift housing (6)
assembly onto shaft (1).
43
4350
7
TM10079 (17MAR09)
43-4350-7
TJ15698,000016B 1911APR075/8

031709
PN=347

IMPORTANT: Align carefully so as not to damage oil
seal (5) lip.
33. Install inner race of roller bearing (7) onto shaft (1).
34. Tap inner race of roller bearing (7) until upper end of
inner race reaches two threads for bearing nut (8) on
shaft (1).
35. Hand tighten bearing nut (8) to shaft (1) to retain
shaft assembly.
36. Install eyebolts into ring gear housing (20) and lift
onto housing (6).
37. Remove bearing nut (8) from shaft (1).
38. Press on inner race of roller bearing (7).
39. Apply film of grease on threaded surface of bearing
nut (8). Install bearing nut (8) on shaft (1) with
stepped side of bearing nut (8) towards roller bearing
(7).
40. Tighten bearing nut (8) to specification. Use DFT1220
Swing Gearbox Nut Spanner Wrench. See DFT1220
Swing Gearbox Nut Spanner Wrench. (Group 9900.)
Specification
360 lb-ft
41. Install lock plate (9) to bearing nut (8) with cap
screws (10). Tighten to specification.
Specification
Lock Plate-to-Bearing Nut Cap
ScrewsTorque ............................................................................. 50 Nm
37 lb-ft
42. If lock plate (9) does not engage with splines of shaft
(1), tighten bearing nut until lock plate engages.
43. Assemble planetary gears (14), needle bearings (15),
and thrust plates (16).
44. Position gear assemblies (14, 15, 16) into second
planetary pinion carrier (11).
43
4350
8
TM10079 (17MAR09)
43-4350-8
TJ15698,000016B 1911APR076/8

031709
PN=348

45. Align holes in pins (13) and planetary carrier (11).
TJ15698,000016B 1911APR077/8
43
4350
9
TM10079 (17MAR09)
43-4350-9

031709
PN=349

46. Install spring pins (17) with slit (38) of spring pins
towards end of pins (13).
NOTE: Procedure for assembly of first and second
planetary pinion carrier assemblies is identical.
48. Align the spline of shaft (1) and install the second
planetary carrier assembly (11).
TX1004270
49. Install thrust plate (12) with oil grooves towards

second planet pinion carrier (11).
TX1004270
38
47. Assemble first planetary pinion carrier (23) assembly

following Step 43 through 46.
UN19APR06
13
13Pin (2 used)
38Slit
50. Install second stage sun gear (18) into second

planetary pinion carrier (11) assembly with smaller
diameter of second stage sun gear upward.
Strength) to ring gear housing (20) mounting surface
of housing (6).
52. Align mating marks and install ring gear housing (20)
to housing (6).
Strength) to cap screws (21). Tighten cap screws (21)
to specification.
Specification
Ring Gear Housing-to-Housing
155 lb-ft
54. Align spline of second stage sun gear (18) and install
first planetary pinion carrier (23) assembly.
55. Install first stage sun gear (31) into first planetary
pinion carrier (23) assembly with stepped side of sun
gear down.
56. Install swing motor. See Swing Motor and Park Brake
43
4350
10
TJ15698,000016B 1911APR078/8
TM10079 (17MAR09)
43-4350-10

031709
PN=350
Swing Gearbox Start-Up Procedure
TX1001071A
UN02DEC05
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 (2) and add oil. See Swing Gearbox
and Travel Gearbox Oils. (Operators Manual.)
1Dipstick
2Fill Cap
3. Install fill cap. Check oil level on dipstick (1).
TJ15698,000016C 1911APR071/1
Upperstructure Remove And Install

1. Clean machine thoroughly.
UN21MAR07
2. Disconnect negative battery cables.
TX1020485A


4. Drain hydraulic oil tank. Approximate capacity is 135 L

(36 gal).
5. Remove cab. See Cab Remove and Install. (Group
1800.)
6. Remove counterweight. See Counterweight Remove
7. Remove boom. See Boom Remove and Install. (Group
3340.)
8. Disconnect center joint hydraulic hoses and remove
stop. See Center Joint Remove and Install. (Group
4360.)
43
4350
11
TM10079 (17MAR09)
43-4350-11
TJ15698,0000182 1911APR071/4

031709
PN=351
UN17MAR03
Specification
UpperstructureWeight ........................................... 4900 kg approximate
10 805 lb approximate
9. Attach chains to counterweight support beams and

boom bracket.
T188540
UN17MAR03
T188539
IMPORTANT: Make sure chains do not touch engine.
TJ15698,0000182 1911APR072/4
10. Put matching marks on the upperstructure and outer

race of the swing bearing to aid in installation. Loosen
and remove cap screws (B).
T105961
UN20DEC96
ASwing Bearing
BCap Screw (36 used)
Swing Bearing
TJ15698,0000182 1911APR073/4
43
4350
12
TM10079 (17MAR09)
43-4350-12

031709
PN=352

11. Lift upperstructure from undercarriage using hoist.
Specification
UpperstructureWeight ........................................... 4900 kg approximate
10 805 lb approximate
UN17MAR03
13. Install upperstructure to undercarriage.
T188541
14. Align mark on the outer race of swing bearing with

mark on upperstructure. Install DFT1144 Guide Pins
to help align holes in swing bearing with holes in
upperstructure. See DFT1144 Guide Pin. (Group
9900.)
15. Install cap screws (B).
16. Remove chains from upperstructure and tighten cap
screws (B).
Specification
Swing Bearing-to-Upperstructure
Cap ScrewsTorque ................................................................... 510 Nm
380 lb-ft
17. Connect center joint hydraulic hoses and install stop.

See Center Joint Remove and Install. (Group 4360.)
18. Install boom. See Boom Remove and Install. (Group
3340.)
19. Install counterweight. See Counterweight Remove
20. Install cab. See Cab Remove and Install. (Group
1800.)
Start-up procedure must be performed
whenever a new pump is installed or oil
has been drained from the pump or
hydraulic oil tank.
43
4350
13
TJ15698,0000182 1911APR074/4
TM10079 (17MAR09)
43-4350-13

031709
PN=353
Swing Bearing Remove and Install

1. Remove upperstructure. See Upperstructure Remove
lifting device.
Specification
Swing BearingWeight................................................................... 226 kg
500 lb
2. Connect swing bearing to appropriate lifting device

using lifting brackets (C) such as JT01748 Lifting
Brackets.
3. Remove cap screws and lock washers (D) and remove
swing bearing.
T7764AB
UN07MAY92
4. Check and replace swing bearing upper and lower

seals if necessary. See Swing Bearing Upper Seal
Install. (Group 4350.) See Swing Bearing Lower Seal
5. Replace steel balls and ball supports as necessary.
CJT01748 Lifting Brackets
DCap Screw and Lock Washer
7. Clean mating surfaces of swing bearing,

upperstructure, and undercarriage.
TJ15698,000016E 1911APR071/2
43
4350
14
TM10079 (17MAR09)
43-4350-14

031709
PN=354
UN11APR90
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.
9. Install cap screws and lock washers and tighten.
T5925AA
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.
ATooth
BLoading Plug
Specification
Undercarriage-to-Swing Bearing
361 lb-ft
10. Apply multi-purpose grease to swing bearing teeth

and pinion shaft. See Track Adjuster, Working Tool
Pivot, Swing Bearing, and Swing Bearing Gear
11. Install upperstructure. See Upperstructure Remove
TJ15698,000016E 1911APR072/2
43
4350
15
TM10079 (17MAR09)
43-4350-15

031709
PN=355
UN25JAN06
Swing Bearing Disassemble and Assemble
TX1000479
43
4350
16
TM10079 (17MAR09)
43-4350-16
TJ15698,000016F 1911APR071/5

031709
PN=356

0Outer Race
1Inner Race
2Steel Ball (111 used)

5Lubrication Fitting (2 used)
8Lower Seal
9Upper Seal
1. Check swing bearing upper seal (9) and lower seal

(8). If damaged, replace. See Swing Bearing Upper
10Spacer (111 used)

11Swing Bearing
Seal Install. (Group 4350.) See Swing Bearing

Lower Seal Install. (Group 4350.)
TJ15698,000016F 1911APR072/5
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.
T6876FI
UN07MAY92
ATack Weld
BTaper Pin
CLoading Plug
TJ15698,000016F 1911APR073/5
43
4350
17
TM10079 (17MAR09)
43-4350-17

031709
PN=357

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.
T6876FK
9. Install spacers (B) and steel balls (A). Turn inner race
as needed to install spacers and steel balls.
UN07MAY92
T7763AB
UN07MAY92
ASpacer (111 used)

BSteel Ball (111 used)
TJ15698,000016F 1911APR074/5
10. Install loading plug (C).

11. Install taper pin (B) even with top of swing bearing.
12. Tack weld pin (A) to swing bearing.
ATack Weld
BTaper Pin
CLoading Plug
T6876FI
43
4350
18
UN07MAY92
13. Add multi-purpose grease to swing bearing through

lubrication fittings. See Track Adjuster, Working Tool
Pivot, Swing Bearing, and Swing Bearing Gear
TJ15698,000016F 1911APR075/5
TM10079 (17MAR09)
43-4350-18

031709
PN=358
Swing Bearing Upper Seal Install

UN11APR90
2. Remove old seal (A).
T5925AM
3. Scrape old adhesive from seal groove. Thoroughly

clean seal groove and new seal using PM37509 Cure
Primer.
4. Apply PM37391 Gel Super Glue 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 PM37391 Gel Super Glue 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 Remove and
TJ15698,0000170 1911APR071/1
Swing Bearing Lower Seal Install

TJ15698,0000171 1918APR071/2
43
4350
19
TM10079 (17MAR09)
43-4350-19

031709
PN=359

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 PM37509 Cure
Primer.
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.
T5936BA
4. Apply PM37391 Gel Super Glue sparingly to seal

groove.
ASeal
BSeal Groove
6. Before bringing ends of seal together, cut off excess

length.
7. Apply PM37391 Gel Super Glue 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 Remove and
TJ15698,0000171 1918APR072/2
43
4350
20
TM10079 (17MAR09)
43-4350-20

031709
PN=360
Group 4360
Hydraulic System
Center Joint Remove and Install
UN21MAR07

TX1020485A

3. Apply vacuum to hydraulic tank or drain hydraulic tank.
See Apply Vacuum to Hydraulic Oil Tank. (Group
3360). The approximate capacity of hydraulic oil tank is
135 L (36 gal).

FS41334,0000164 1910APR071/4
4. Tag and disconnect upper hydraulic lines (3). Close all

UN19MAR07
5. Remove cap screws (2) and bracket (1).

6. Disconnect small hydraulic lines (4). Close all open
TX1020553A
1Bracket
2Cap Screw (2 used)
3Hydraulic Line (4 used)
4Small Hydraulic Line (2 used)
FS41334,0000164 1910APR072/4
43
4360
1
TM10079 (17MAR09)
43-4360-1

031709
PN=361
Hydraulic System
7. Attach the center joint to an appropriate lifting device
using a lifting strap. See Center Joint (Rotary Manifold)
Lifting Tool (Group 9900.)
UN27APR92
8. Tag and disconnect lower hydraulic lines. Close all

T7685JC

lifting device.
Specification
Center JointWeight ........................................................................ 27 kg
60 lb
9. Remove four cap screws and lower center joint.

10. Replace parts as necessary. See Center Joint
11. Install center joint. Tighten four cap screws to
specifications.
Specification
Center Joint-to-Frame Cap
ScrewTorque ............................................................................... 90 Nm
66 lb-ft
12. Install stop bracket. Tighten cap screws.

Specification
Stop Bracket-to-Frame Cap
ScrewTorque ............................................................................. 140 Nm
103 lb-ft
13. Connect upper and lower hydraulic lines.

FS41334,0000164 1910APR073/4
43
4360
2
TM10079 (17MAR09)
43-4360-2

031709
PN=362
Hydraulic System
FS41334,0000164 1910APR074/4
43
4360
3
TM10079 (17MAR09)
43-4360-3

031709
PN=363
Hydraulic System
Center Joint Disassemble and Assemble

lifting device.
Specification
Center JointWeight ........................................................................ 27 kg
60 lb
1. Make alignment marks on spindle assembly (2),

housing (7) and cover (11) to aid in assembly.
2. Remove cover (11), snap ring (9), and ring (8).
3. Install puller to housing (7) using cap screws (12).
Carefully remove spindle assembly (2) from housing
(7).
4. Remove plug (1) from spindle assembly and clean
port.
NOTE: Bushing (5) can be removed using built-up weld at
4 places on its inner diameter, then quenching
bushing to shrink. Cover seal surfaces to protect
from weld spatter.
5. Remove dust seal (3), bushing (5), and oil seals (6).
6. Inspect and repair or replace parts as necessary.
7. Install bushing (5) into housing (7) using a press.
Lubricate bushing with grease or molybdenum
disulfide.
TX1018875
UN12FEB07
1Plug (Ball)
2Spindle
3Dust Seal
4O-Ring
5Bushing
6Oil Seal (6 used)
7Housing
8Ring
9Snap Ring
10O-Ring
11Cover
43
4360
4
TM10079 (17MAR09)
43-4360-4
FS41334,0000163 1912MAR071/2

031709
PN=364
Hydraulic System
IMPORTANT: Install dust seal (3) with lip side toward
housing (7).
8. Install dust seal (3) onto spindle (2).
9. Install O-ring (4) and oil seals (6) into housing (7).
IMPORTANT: Install spindle assembly (2) slowly into
housing (7) so oil seals (6) are not
damaged.
10. Lubricate spindle assembly (2) with hydraulic oil and
install into housing (7). Align reference marks made
during disassembly.
IMPORTANT: Install ring (8) with chamfered side
facing spindle assembly (2).
11. Install parts (812), aligning reference marks made
during disassembly.
Specification
Cover-to-Housing Cap Screw
Torque ............................................................................................ 49 Nm
36 lb-ft
13. Install plug (1).
FS41334,0000163 1912MAR072/2
Center Joint Air Test
2. Apply shop air pressure, using JDG185 Air Test Plug,

to the other port in that passage.
T6557JB
3. Listen for air leaks at other ports on either side of

center joint.
UN01NOV88
1. Install a plug in one port of a selected passage.
4. Repeat test for other passages.

5. Repair or replace if leaks are found. See Center Joint
43
4360
5
FS41334,0000162 1910APR071/1
TM10079 (17MAR09)
43-4360-5

031709
PN=365
Hydraulic System
Swing Motor and Park Brake Remove and

Install
TX1020485A
UN21MAR07

2. Apply vacuum to hydraulic tank or drain hydraulic tank.
See Apply Vacuum to Hydraulic Tank. (Group 3360).
The approximate capacity of hydraulic oil tank is 135 L
(36 gal).

TJ15698,0000172 1911APR071/3
43
4360
6
TM10079 (17MAR09)
43-4360-6

031709
PN=366
Hydraulic System
3. Tag and disconnect hydraulic lines (2, 3, 4, and 6).
4. Close all open lines and fittings using caps and plugs.
UN19APR06
TX1003156A

lifting device.
Specification
Weight................................................................................................ 48 kg
105 lb
2Hydraulic Line
3Main Hydraulic Line
4Hydraulic Line
5Cap Screw (8 used)
6Swing Dampener Valve Hydraulic Lines
6. Remove cap screws (5) to remove swing motor and

park brake.
7. Repair or replace parts as necessary. See Swing
Motor and Park Brake Disassemble. (Group 4360.)
8. Install swing motor and park brake.
Specification
Swing Motor-to-Ring Gear Cap
ScrewTorque ............................................................................... 90 Nm
67 lb-ft
10. Connect electrical connector (1).

12. See Swing Motor and Park Brake Start-Up Procedure.
(Group 4360.)
13. Check oil level in hydraulic oil tank. See Check
Hydraulic Tank Oil Level. (Operators Manual). Add oil
if necessary. See Hydraulic Oil. (Operators Manual).
TJ15698,0000172 1911APR072/3
43
4360
7
TM10079 (17MAR09)
43-4360-7

031709
PN=367
Hydraulic System
Procedure (Group 4360.)
TJ15698,0000172 1911APR073/3
43
4360
8
TM10079 (17MAR09)
43-4360-8

031709
PN=368
Hydraulic System
43
4360
9
TM10079 (17MAR09)
43-4360-9

031709
PN=369
Hydraulic System
UN28NOV05
Swing Motor and Park Brake Disassemble
TX1000252
43
4360
10
TM10079 (17MAR09)
43-4360-10
TJ15698,0000173 1912MAR071/2

031709
PN=370
Hydraulic System
0Hydraulic Motor
1Piston (9 used)
5Crossover Relief Valve (2
used)
8Piston
10Shaft
11Cylinder Block
12Retainer
13Plate
14Shoe Plate
15Valve Plate
20Swing Motor Cover
30Housing
35Poppet (2 used)
36Spring (2 used)
41Roller Bearing
42Roller Bearing

44Make-Up Check Valve
Plug (2 used)
45O-Ring
47O-Ring (2 used)
48O-Ring (2 used)
49Seal
70Brake Piston
73Plates (4 used)
IMPORTANT: Do not disassemble crossover relief

valve (5).
76O-Ring
77O-Ring
78Spring (24 used)
79Friction Plates (3 used)
81Pipe Plug (2 used)
85Seal Kit
87Spring
88Ball
89Packing
6. Remove O-ring (45).

7. Remove springs (78).
1. Remove crossover relief valves (5) from swing

motor cover (20).
8. Remove brake piston (70).
2. Remove make-up check valve plugs (44).
9. Remove O-rings (76, 77) from housing (30).
3. Remove springs (36) and poppets (35).
10. Remove parts (1, 13 and 12) from shaft (10).

11. Remove plates (73) and friction plates (79).

Specification
Weight ......................................................................................... 48 kg
105 lb
CAUTION: Swing motor housing and swing

motor cover is under spring pressure.
Remove cap screws evenly to release spring
force.
4. Mark alignment of swing motor housing (30) and
swing motor cover (20) assembly. Loosen cap
screws (40).
IMPORTANT: Do not remove roller bearing (42)
unless necessary.
IMPORTANT: Valve plate (15) has a polished
surface. Valve plate may remain on
swing motor cover (20) or stay with
cylinder block (11). Valve plate may
be damaged if dropped. Hold valve
plate during disassembly.
5. Remove valve plate (15) from cylinder block (11).
IMPORTANT: Do not damage sliding surface of

shoe plate (14).
12. Remove shoe plate (14).
13. Remove shaft (10) from housing (30) using a
plastic hammer.
14. Push out oil seal (49) and remove outer race of
roller bearing (41) from housing (30).
15. Remove inner race of roller bearing (41) from
shaft (10) using a press.
NOTE: Filter and orifice are mounted inside of piston
(8). Unless clogged or deformed, do not
disassemble. Do so only when absolutely
needed. If internal parts need to be replaced,
replace piston (8) as an assembly.
16. Remove swing park brake release valve piston (8),
packing (89), spring (87), and ball (88).
NOTE: Use seal kit (85) to replace seals and O-rings.
43
4360
11
TJ15698,0000173 1912MAR072/2
TM10079 (17MAR09)
43-4360-11

031709
PN=371
Hydraulic System
Swing Motor and Park Brake Inspection

1. Measure clearance between outer diameter of piston
and inner bore of cylinder.
T142067
UN22JUN01
Specification
Piston-to-CylinderClearance ........................................... 0.027 mm new
0.001 in. new
0.052 mm maximum used
0.0020 in. maximum used
TJ15698,0000174 1912MAR071/4
2. Measure clearance between piston and slipper.
UN22JUN01
Specification
Piston-to-SlipperClearance ................................................. 0.0 mm new
0.0 in. new
0.3 mm maximum used
0.012 in. maximum used
T142069
43
4360
12
TM10079 (17MAR09)
43-4360-12
TJ15698,0000174 1912MAR072/4

031709
PN=372
Hydraulic System
3. Measure thickness of slipper.
T142072
UN22JUN01
Specification
SlipperThickness ................................................................. 5.5 mm new
0.217 in. new
5.3 mm minimum
0.209 in. minimum
Slipper Thickness
TJ15698,0000174 1912MAR073/4
4. Measure thickness of friction plate.
T142073
UN22JUN01
Specification
Friction PlateThickness ....................................................... 2.0 mm new
0.079 in. new
1.8 mm minimum
0.071 in. minimum
Friction Plate Thickness
TJ15698,0000174 1912MAR074/4
43
4360
13
TM10079 (17MAR09)
43-4360-13

031709
PN=373
Hydraulic System
UN28NOV05
Swing Motor and Park Brake Assemble
TX1000252
43
4360
14

TM10079 (17MAR09)
43-4360-14
TJ15698,0000175 1912MAR071/3

031709
PN=374
Hydraulic System
0Hydraulic Motor
1Piston (9 used)
5Crossover Relief Valve (2
used)
8Piston
10Shaft
11Cylinder Block
12Retainer
13Plate
14Shoe Plate
15Valve Plate
20Swing Motor Cover
30Housing
35Poppet (2 used)
36Spring (2 used)
41Roller Bearing
42Roller Bearing

Plug (2 used)
45O-Ring
47O-Ring (2 used)
48O-Ring (2 used)
49Seal
70Brake Piston
73Plate (4 used)
76O-Ring
77O-Ring
78Spring (24 used)
79Friction Plate (3 used)
81Pipe Plug (2 used)
85Seal Kit
87Spring
88Ball
89Packing
spline teeth side of friction plates

(79).
1. Install ball (88), spring (87), packing (89), and

piston (8) into housing (30).
IMPORTANT: Install inner race of roller bearing
(41) with flange facing step side of
shaft (10).
IMPORTANT: Align each notch when installing.

12. Alternately install plates (73) and friction plates
(79) to housing (30).
2. Install inner race of roller bearing (41) onto shaft

(10) using a press.
13. Install O-rings (76, 77) to housing (30).
3. Install oil seal (49) to housing (30).
14. Align mating marks and install brake piston (70).
4. Install outer race of roller bearing (41) to housing

(30).
15. Install springs (78) to brake piston (70).

NOTE: Do step 15 only if bearing (42) was removed.
IMPORTANT: Wind tape onto spline end of shaft

(10) to prevent damage to oil seal
(49).
16. Install roller bearing (42) into swing motor cover

(20) using plastic hammer.
5. Install shaft (10) into housing (30).
17. Install O-ring (45) to swing motor cover (20).
6. Install shoe plate (14) to housing (30) with

chamfered surface toward housing.
18. Install valve plate (15) to swing motor cover (20)

with notch in port facing toward cylinder block
(11).
7. Align notches on plate (13) and retainer (12). Install

pistons (1).
8. Install retainer (12) and plate (13) to pistons (1) with
notches facing shoe plate (14).
9. Apply hydraulic oil into piston holes in cylinder block
(11).
10. Insert piston (1) assembly into cylinder block (11).
11. Install cylinder block (11) assembly to shaft (10).
IMPORTANT: There are four notches on outer side
of plates (73) and four notches on
19. Apply grease to valve plate (15) to help retain to

swing motor cover (20).
20. Apply grease to roller bearing (42) ID to ease
shaft (10) installation.
21. Align mating marks on swing motor cover (20) and
housing (30). Install cap screws (40) and tighten to
specification.
Specification
Swing Motor Cover-to-Housing
318 lb-ft
43
4360
15
TM10079 (17MAR09)
43-4360-15
TJ15698,0000175 1912MAR072/3

031709
PN=375
Hydraulic System
22. Install poppets (35) and spring (36). Tighten
make-up check valve plug (44) with O-ring (48)
attached.
Specification
Make-Up Check Valve Plug
Torque.................................................................................... 334 Nm
246 lb-ft
23. Install crossover relief valves (5) into swing motor

cover (20).
Specification
Crossover Relief Valve
Torque.................................................................................... 177 Nm
131 lb-ft
TJ15698,0000175 1912MAR073/3
Swing Motor and Park Brake Start-Up

Procedure
TX1003231A
UN02FEB06
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.
NOTE: Procedure is to ensure swing motor is filled with
oil.
1Hydraulic Line
1. Disconnect swing motor hydraulic line (1).

2. Fill motor through port until oil reaches level of port.
See Hydraulic Oil. (Operators Manual.)
NOTE: Air must be allowed to escape from the swing
motor while filling.
3. Connect hydraulic line (1).
TJ15698,0000176 1911APR071/1
43
4360
16
TM10079 (17MAR09)
43-4360-16

031709
PN=376
Hydraulic System
Crossover Relief Valve and Make-Up Check Valve Remove and Install
4
1
T139645
UN30APR01
T139645
3Crossover Relief Valve
4Crossover Relief Valve
TJ15698,0000177 1911APR071/3
Remove and Install Crossover Relief Valve

1. Remove crossover relief valves (1).
UN02FEB06
2. Replace crossover relief valves (1) as necessary.
TX1003161A
3. Install crossover relief valves (1). Tighten to

specification.
Specification
Crossover Relief ValveTorque .................................................. 177 Nm
130 lb-ft
4. Check crossover relief valve pressure setting. See

Swing Motor Crossover Relief Valve Test and
Adjustment. (Group 9025-25.)
TM10079 (17MAR09)
43
4360
17
1Crossover Relief Valve (2 used)
43-4360-17
TJ15698,0000177 1911APR072/3

031709
PN=377
Hydraulic System
Remove and Install Make-Up Check Valve
1. Remove make-up check valves (1).
UN02FEB06
2. Repair or replace parts as necessary. See Make-Up

Check Valve Disassemble and Assemble. (Group
4360.)
TX1003232A
3. Install make-up check valves (1). Tighten to

specification.
Specification
Make-Up Check ValveTorque................................................... 334 Nm
245 lb-ft
1Make-Up Check Valve (2 used)
TJ15698,0000177 1911APR073/3
Make-Up Check Valve Disassemble and

Assemble
UN16FEB06
1. Remove make-up check valves (1). See Crossover

Relief Valve and Make-Up Check Valve Remove and
TX1003721A
1Make-Up Check Valve (2 used)
TJ15698,0000179 1911APR071/2
43
4360
18
TM10079 (17MAR09)
43-4360-18

031709
PN=378
Hydraulic System
2. Examine O-rings (2), springs (3), and poppets (4) for
wear and damage.
4. Install O-rings (2), springs (3), poppets (4), and
make-up check valve plugs (1).
5. Tighten make-up check valve plugs (1) to specification.
See Crossover Relief Valve and Make-Up Check Valve
TX1003722
UN16FEB06
1Make-Up Check Valve Plug (2 used)

2O-Ring (2 used)
3Spring (2 used)
4Poppet (2 used)
5Cap Screw (4 used)
6Swing Motor Top Plate
7O-Ring
TJ15698,0000179 1911APR072/2
Swing Park Brake Release Valve Remove

and Install
NOTE: Swing park brake release valve is internally
located in swing motor. See Swing Motor and
Park Brake Disassemble. See Swing Motor and
Park Brake Assemble. (Group 4360.)
TJ15698,000017A 1911APR071/1
43
4360
19
TM10079 (17MAR09)
43-4360-19

031709
PN=379
Hydraulic System
43
4360
20
TM10079 (17MAR09)
43-4360-20

031709
PN=380
Section 99
Dealer Fabricated Tools

Contents
Page
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
DFT1036A Travel Gearbox Nut Wrench . . .99-9900-10
DF1038 Torque Adapter . . . . . . . . . . . . . . .99-9900-11
DFT1109 Holding Bar . . . . . . . . . . . . . . . . .99-9900-12
Center Joint (Rotary Manifold) Lifting
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-13
DFT1144 Guide Pin . . . . . . . . . . . . . . . . . .99-9900-13
DFT1119 Pump Support . . . . . . . . . . . . . . .99-9900-14
DFT1220 Swing Gearbox Nut Spanner
Wrench . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-16
TM10079 (17MAR09)
99-1

031709
PN=1
99
Contents
99
TM10079 (17MAR09)
99-2

031709
PN=2
Group 9900

DF1063 Lift Bracket
99
9900
1
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 travel motor.
Material required:
T8318AC
UN20SEP94
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)
TM10079 (17MAR09)
99-9900-1
TJ15698,0000146 1908MAR071/2

031709
PN=383
T7247BW
1925APR90
99
9900
2
TJ15698,0000146 1908MAR072/2
TM10079 (17MAR09)
99-9900-2

031709
PN=384
ST4920 Track Recoil Spring Disassembly and

Assembly Tool
99
9900
3
NOTE: It is recommended that DFT1087 Track Recoil

Spring Disassembly and Assembly Guard Tool be
used with track recoil spring disassembly and
assembly tool. See DFT1087 Track Recoil Spring
Disassembly and Assembly Guard Tool. (Group
9900.)
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.
UN24MAR98
Track Recoil Spring Disassembly and Assembly Tool

(compression tool) is used with hydraulic jack to compress
recoil spring in track adjuster repair.
Material required:
T6585UY
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).
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)
Print Numbers:
A-ST4050 Nut
B-ST4045 Bolt
C-ST4035 Holder (Plate)
D-ST4047 Eyebolt
E-ST4040 Supporting Base
F-ST4042 Base Plate
G-ST4041 Base
H-ST4046 Cap Screw
I-ST4049 Lock Washer
TM10079 (17MAR09)
99-9900-3
TJ15698,0000147 1913APR071/4

031709
PN=385
T7029CI
UN06JUL89
99
9900
4
TM10079 (17MAR09)
99-9900-4
TJ15698,0000147 1913APR072/4

031709
PN=386
T7029CH
UN06JUL89
99
9900
5
TM10079 (17MAR09)
99-9900-5
TJ15698,0000147 1913APR073/4

031709
PN=387
T7029CG
UN06JUL89
99
9900
6
TJ15698,0000147 1913APR074/4
TM10079 (17MAR09)
99-9900-6

031709
PN=388
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
T7162AF
UN17OCT89
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)
Track Disassembly and Assembly Guard Tool is used

with ST4920 Track Recoil Spring Disassembly and
Assembly Tool. See ST4920 Track Recoil Spring
Disassembly and Assembly Tool. (Group 9900.)
E1/2 x 3 in. Steel Round

Stock (2 used)
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)
Material required:
TJ15698,0000148 1913APR071/1
TM10079 (17MAR09)
99-9900-7

031709
PN=389
DFT1110 Spacer
T7708AC
UN23FEB92
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. See ST4920 Track
Recoil Spring Disassembly and Assembly Tool. (Group
9900.)
Material Required:
165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) Heavy
Wall Steel Pipe
Cut the ends of spacer so they are parallel to each

other.
TJ15698,0000149 1913APR071/1
TM10079 (17MAR09)
99-9900-8

031709
PN=390
DFT1130 Adapter
T8319BN
UN20SEP94
99
9900
9
AAdapter Plate
BTube
CStop Plate
Adapter is used with DF1063 Lift Bracket to remove

and install travel motor.
Material required:
1.3 mm (1/2 in.) 1020 Steel Plate (A)

38.1 mm x 38.1 mm x .48 mm (1-1/2 in. x 1-1/2 in. x
3/16 in.) Square Tube (B)
.6 mm (1/4 in.) 1020 Steel Plate (C)
TJ15698,000014A 1908MAR071/1
TM10079 (17MAR09)
99-9900-9

031709
PN=391
DFT1036A Travel Gearbox Nut Wrench
T7681FZ
UN28FEB92
99
9900
10
Travel Gearbox Nut Wrench is used to remove and

install the hub-to-housing nut in the travel gearbox.
Material required:
16 mm (5/8 in.) Flat Bar Stock

M24 (1 in.) Nut
M10-1.5 x 60 mm Cap Screw (2 used)
M10-1.5 Nut (2 used)
TJ15698,000014B 1913APR071/1
TM10079 (17MAR09)
99-9900-10

031709
PN=392
DF1038 Torque Adapter
T6557CH
UN25OCT95
99
9900
11
Torque Adapter is used to check rolling drag torque on

rotor drive shaft.
17 mm (0.125 in.) hex head driver
Material required:
TJ15698,000014C 1913APR071/1
TM10079 (17MAR09)
99-9900-11

031709
PN=393
DFT1109 Holding Bar
T7690AA
UN27FEB92
99
9900
12
Holding Bar is used with the as a guide when

loosening the hub-to-housing nut in the travel gearbox.
See DF1036A Travel Gearbox Nut Wrench. (Group
9900.)
Material required:
TJ15698,000014D 1911APR071/1
TM10079 (17MAR09)
99-9900-12

031709
PN=394
Center Joint (Rotary Manifold) Lifting Tool

99
9900
13
Tool is used to remove and install center joint.

Drill and tap disk in fitting cap to M8-1.25 mm threads (A).
Material required:
38H1416 Cap (12)
M8-1.25 Lifting Eyebolt such as JT05548 Metric Lifting
Eyebolt
T6641DO
UN24OCT88
AThreads
TJ15698,000014E 1913APR071/1
DFT1144 Guide Pin
Remove threads for a distance (B) and then grind a taper

on same end.
T6641EK
Material Required:
UN24OCT88
Guide pin is used to align cap screw holes in swing

bearing and upperstructure.
M20-2.5 x 230 mm (9 in.) Threaded Rod

A230 mm (9 in.)
B100 mm (4 in.)
TJ15698,000014F 1913APR071/1
TM10079 (17MAR09)
99-9900-13

031709
PN=395
DFT1119 Pump Support

99
9900
14
38 mm
(1.5 in.)
13 mm
(0.5 in.)
76 mm
(3 in.)
13 mm
(0.5 in.)
76.2 x 76.2 x 6.35 mm
610 mm
(3 x 3 x 0.250 in.)
(24 in.)
9.5 mm
76 mm
(0.375 in.)
(3 in.)
9.5 mm
(0.375 in.)
11 mm
(0.438 in.)
19 mm
(0.750 in.)
89 mm
(3.5 in.)
102 mm
(4 in.)
63.5 x 63.5 x 6.35 mm
(2.5 x 2.5 x 0.250 in.)
38 mm
(1.5 in.)
76 mm
(3 in.)
114 mm
(4.5 in.)
457 mm
(18 in.)
12 mm
(0.472 in.)
5 Places
11 mm
(0.438 in.)
12 PLACES
38 mm (1.5 in.)
76 mm (3 in.)
152 mm (6 in.)
229 mm (9 in.)
305 mm (12 in.)
380 mm (15 in.)
457 mm (18 in.)
533 mm (21 in.)
610 mm (24 in.)
9.5 mm
(0.375 in.)
1524 mm
(60 in.)
104.8 mm (4.125 in.)

165 mm (6.5 in.)
376 mm (14.8 in.)
UN11JAN08
9.5 mm
(0.375 in.)
88.9 x 88.9 x 6.35 mm

(3.5 x 3.5 x 0.250 in.)
TX1022920
335 mm (13.2 in.)
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
TX1022920
233 mm (9.2 in.)
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
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)
TJ15698,0000150 1930APR071/1
TM10079 (17MAR09)
99-9900-14

031709
PN=396
99
9900
15
TM10079 (17MAR09)
99-9900-15

031709
PN=397
DFT1220 Swing Gearbox Nut Spanner Wrench
T143704
UN17JUL01
99
9900
16
TM10079 (17MAR09)
99-9900-16
TJ15698,0000151 1908MAR071/2

031709
PN=398

1Weld (4 Places)
159.4 x 38.1 x 6.35 mm (6.65 x 1.5 x .25 in.)
Material required:
99
9900
17
159.4 x 82.5 mm (6.275 x 3.25 in.) Steel Tubing
TJ15698,0000151 1908MAR072/2
TM10079 (17MAR09)
99-9900-17

031709
PN=399
99
9900
18
TM10079 (17MAR09)
99-9900-18

031709
PN=400
Index
Page
A
Air cleaner
Remove and install . . . . . . . . . . . . . . . . .05-0520-2
Air conditioner
Condenser, remove and install . . . . . . .18-1830-11
Receiver-dryer, remove and install . . . .18-1830-17
Air conditioner and heater
Remove and install . . . . . . . . . . . . . . . .18-1830-13
Air conditioner system
Flush and purge . . . . . . . . . . . . . . . . . . .18-1830-3
Refrigerant cautions and proper
handling. . . . . . . . . . . . . . . . . . . . . . . .18-1830-1
Air conditioning
Charge R134a system . . . . . . . . . . . . .18-1830-10
Compressor, remove and install . . . . . .18-1830-11
Evacuate R134a system . . . . . . . . . . . . .18-1830-9
Recover R134a refrigerant . . . . . . . . . . .18-1830-8
R134a refrigerant oil information . . . . . . .18-1830-6
R134a station installation . . . . . . . . . . . .18-1830-7
Arm
Arm cylinder
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-108
Disassemble and assemble . . . . . . . . .33-3360-98
Inspect pins and bushings. . . . . . . . . . .33-3340-11
Arm pins and bushings
Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Attachments
Adding safely . . . . . . . . . . . . . . . . . . . . . .00-01-11
Operating safely . . . . . . . . . . . . . . . . . . . .00-01-11
Page
Boom flow rate solenoid valve

Boom mode solenoid valve
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
Brake
Swing park, inspection . . . . . . . . . . . . .43-4360-12
Swing park, remove and install . . . . . . . .43-4360-6
Brake, park and travel motor
Bucket
Bucket cylinder
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-108
Disassemble and assemble . . . . . . . . 33-3360-105
Remove and install . . . . . . . . . . . . . . . 33-3360-101
Bucket links
Bucket pins
Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Bushings
C
B
Backover accidents
Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10
Battery explosions
Prevent . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5
Bearing
Swing, disassemble and assemble . . . .43-4350-16
Swing, remove and install . . . . . . . . . . .43-4350-14
Bleed procedure
Hydraulic cylinder . . . . . . . . . . . . . . . . 33-3360-108
Boom
Boom cylinder
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-108
Dissassemble and assemble. . . . . . . . .33-3360-91
TM10079 (17MAR09)
Cab
Cab guarding . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3
Center joint
Air test . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-5
Disassemble and assemble . . . . . . . . . .43-4360-4
Check valve, make-up
Chemical products
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-6
Condenser, air conditioner
Console covers
Control valve
Arm reduced leakage valve. . . . . . . . . .33-3360-65
Arm regenerative valve . . . . . . . . . . . . .33-3360-73
Index-1

031709
PN=1
Indx
1
Index
Page
Auxiliary flow combiner valve check

valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-65
Auxiliary flow rate valve . . . . . . . . . . . .33-3360-65
Auxiliary function flow combiner
valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-65
Boom reduced leakage valve . . . . . . . .33-3360-73
Indx
Bucket flow rate valve . . . . . . . . . . . . . .33-3360-73
2
Bypass shut-off valve . . . . . . . . . . . . . .33-3360-73
Lift check and orifice (left travel power
passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-65
Lift check (arm I power passage) . . . . .33-3360-65
Lift check (boom II power passage) . . .33-3360-65
Lift check (left travel neutral
passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-65
Lift check (swing neutral passage) . . . .33-3360-65
Spool assemblies (4-spool) . . . . . . . . . .33-3360-73
Spool assemblies (5 spool) . . . . . . . . . .33-3360-65
System relief and power boost valve. . .33-3360-65
Travel function flow combiner valve . . .33-3360-73
4-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-73
5-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-65
Cooling package
Cooling system
Fan drive motor, remove and install . . .33-3360-40
Fan drive pump, remove and install . . .33-3360-39
Fan guard, remove and install. . . . . . . .05-0510-19
Fan shroud, remove and install . . . . . . .05-0510-19
Fan, remove and install. . . . . . . . . . . . .05-0510-19
Radiator, remove and install . . . . . . . . . .05-0510-1
Surge tank, remove and install . . . . . . .05-0510-23
Counterbalance valve, travel motor
Counterweight
Coupling, flex
Crossover relief valve
Crossover relief valve, travel motor
Cylinder
Arm, disassemble and assemble. . . . . .33-3360-98
Arm, remove and install . . . . . . . . . . . .33-3360-93
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-108
Boom, disassemble and assemble . . . .33-3360-91
Boom, remove and install . . . . . . . . . . .33-3360-87
Bucket, disassemble and asemble . . . 33-3360-105
Bucket, remove and install . . . . . . . . . 33-3360-101
TM10079 (17MAR09)
Page
D
Dampener drive
Dealer fabricated tools
Center joint lifting tool . . . . . . . . . . . . . .99-9900-13
DFT1036A travel gearbox nut
wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10
DFT1087 track recoil spring disassembly and
assembly guard tool . . . . . . . . . . . . . .99-9900-7
DFT1109 holding bar . . . . . . . . . . . . . .99-9900-12
DFT1110 spacer . . . . . . . . . . . . . . . . . . .99-9900-8
DFT1119 pump support . . . . . . . . . . . .99-9900-14
DFT1130 adapter . . . . . . . . . . . . . . . . . .99-9900-9
DFT1144 guide pin . . . . . . . . . . . . . . . .99-9900-13
DFT1220 swing gearbox nut spanner
wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-16
DF1038 torque adapter . . . . . . . . . . . . .99-9900-11
DF1063 lift bracket . . . . . . . . . . . . . . . . .99-9900-1
ST4920 track recoil spring disassembly and
assembly tool . . . . . . . . . . . . . . . . . . .99-9900-3
Drive gearbox
Start-up procedure . . . . . . . . . . . . . . . .33-3360-25
Drive shaft, pilot pump
Driving metal pins. . . . . . . . . . . . . . . . . . . . .00-01-14
E
Emergency preparation . . . . . . . . . . . . . . . . .00-01-6
Engine
Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . .00-01-5
Explosion
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5
F
Fan
Fan drive control valve
Fan drive motor
Fan drive pump
Fan guard
Fan shroud
Index-2

031709
PN=2
Index
Page
Page
Filter, pilot
Fire prevention . . . . . . . . . . . . . . . . . . . . . . . .00-01-5
Flex coupling
Front idler
Fuel cooler
Fuel filter
Final, remove and install . . . . . . . . . . . . .05-0560-4
Primary, remove and install. . . . . . . . . . .05-0560-3
Fuel tank

Hydraulic pump regulator
Indx
3
I
Inch bolt and cap screw
Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-4
Inch series four bolt flange fitting
Service recommendation, torque value for high
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20
Inspect machine . . . . . . . . . . . . . . . . . . . . . . .00-01-3
Inspection
Hydraulic pump . . . . . . . . . . . . . . . . . . .33-3360-22
Intercooler
Gearbox, travel
Lifting objects
Special care . . . . . . . . . . . . . . . . . . . . . . .00-01-11
H
Handhold use . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7
Hazards
Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-9
Heater and air conditioner
High-pressure oils
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-4
Hydraulic
Fittings, 30° cone seat. . . . . . . . . . .00-0003-5
Fittings, 37° flare . . . . . . . . . . . . . . .00-0003-5
Hydraulic cylinder
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-108
Hydraulic fitting
Flared connections . . . . . . . . . . . . . . . .00-0003-10
Hydraulic oil
Cleanup procedure using portable filter
caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3
Hydraulic oil cooler
Hydraulic oil tank
Apply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1
Hydraulic pump
Inspection . . . . . . . . . . . . . . . . . . . . . . .33-3360-22
TM10079 (17MAR09)
M
Machine inspection. . . . . . . . . . . . . . . . . . . . .00-01-3
Machine modifications
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-2
Machine movement
Unintended . . . . . . . . . . . . . . . . . . . . . . . . .00-01-8
Machine tip over
Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10
Make-up check valve
Remove and install . . . . . . 02-0260-17, 43-4360-17
Manifold, pilot signal
Metal face seals
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8
Metal pins. . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-14
Metric bolt and cap screw
Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-1
Motor
Swing, assemble. . . . . . . . . . . . . . . . . .43-4360-14
Swing, disassemble . . . . . . . . . . . . . . .43-4360-10
Swing, inspection . . . . . . . . . . . . . . . . .43-4360-12
Swing, remove and install . . . . . . . . . . . .43-4360-6
Index-3

031709
PN=3
Index
Page
Page
Motor, travel and park brake

Moving parts
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3
Pilot signal manifold

Pilot valve, travel
Portable filter caddy
Hydraulic oil cleanup procedure . . . . . . .33-3360-3
Power dig solenoid valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . .01-0130-5
Protective equipment . . . . . . . . . . . . . . . . . . .00-01-2
Pump regulator, hydraulic
Pump, hydraulic
Pump, pilot
Indx
4
O
O-ring boss fitting in aluminum housingexcavators
Torque value, service
recommendation . . . . . . . . . . . . . . . . .00-0003-8
O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6
O-ring face seal fitting
Inch hex nut and stud end for high pressure torque
values . . . . . . . . . . . . . . . . . . . . . . . .00-0003-12
Metric hex nut and stud end for high pressure
torque values. . . . . . . . . . . . . . . . . . .00-0003-16
Metric hex nut and stud end for standard pressure
torque values. . . . . . . . . . . . . . . . . . .00-0003-14
Oil cooler
Bypass valve, remove and install . . . . .33-3360-85
Oil information
R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6
Operation qualification . . . . . . . . . . . . . . . . . .00-01-1
P
Park brake
Swing, disassemble . . . . . . . . . . . . . . .43-4360-10
Swing, inspection . . . . . . . . . . . . . . . . .43-4360-12
Swing, remove and install . . . . . . . . . . . .43-4360-6
Swing, start-up procedure . . . . . . . . . . .43-4360-16
Park brake and travel motor
Pilot control shut-off lever . . . . . . . . . . . . . . . .00-01-8
Pilot filter
Pilot filter and pilot pressure regulating valve
Pilot pressure regulating valve and filter
Pilot pump
Drive shaft, remove and install . . . . . . .33-3360-34
Pilot shutoff solenoid valve
TM10079 (17MAR09)
R
Radiator
Receiver-dryer
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
Relief valve, crossover, travel motor
Riding machine. . . . . . . . . . . . . . . . . . . . . . . .00-01-9
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
S
Safety
Operators seat . . . . . . . . . . . . . . . . . . . . . .00-01-7
Index-4

031709
PN=4
Index
Page
Page
Safety equipment . . . . . . . . . . . . . . . . . . . . . .00-01-2

Safety information
Recognizing . . . . . . . . . . . . . . . . . . . . . . . .00-01-1
Safety instructions . . . . . . . . . . . . . . . . . . . . .00-01-1
Safety symbols . . . . . . . . . . . . . . . . . . . . . . . .00-01-1
Seal,
Swing bearing lower, install. . . . . . . . . .43-4350-19
Swing bearing upper, install . . . . . . . . .43-4350-19
Seals
Seals, metal face
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8
Seat
Air suspension, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-4
Mechanical suspension, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-3
Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7
Service recommendation
Inch series four bolt flange fitting for high
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20
O-ring boss fitting in aluminum
housingexcavators. . . . . . . . . . . . . . . .00-0003-8
O-ring face seal fittings with inch hex nut and
stud end for high pressure. . . . . . . . .00-0003-12
O-ring face seal fittings with metric hex nut and
stud end for standard pressure . . . . .00-0003-14
Servicing machine safely . . . . . . . . . . . . . . .00-01-12
Shutoff solenoid valve, pilot
Sliding window
Solenoid valve
Boom flow rate, remove and install . . . .33-3360-47
Boom mode, remove and install . . . . . .33-3360-47
Power dig, remove and install . . . . . . . .33-3360-47
Travel speed, remove and install . . . . .33-3360-47
Sprocket
Start-up procedure
Drive gearbox . . . . . . . . . . . . . . . . . . . .33-3360-25
Hydraulic pump . . . . . . . . . . . . . . . . . . .33-3360-25
Travel motor and park brake . . . . . . . . .02-0260-21
Steps use . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7
Surge tank
Swing bearing
Lower seal install . . . . . . . . . . . . . . . . .43-4350-19

Upper seal, install . . . . . . . . . . . . . . . . .43-4350-19
Swing gearbox
Swing motor
Assemble . . . . . . . . . . . . . . . . . . . . . . .43-4360-14
Disassemble . . . . . . . . . . . . . . . . . . . . .43-4360-10
Inspection . . . . . . . . . . . . . . . . . . . . . . .43-4360-12
Swing park brake release valve
TM10079 (17MAR09)
T
Tank, hydraulic oil
Apply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1
Tip over
Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10
Torque value
Flared connections . . . . . . . . . . . . . . . .00-0003-10
Flat face O-ring seal fitting . . . . . . . . . .00-0003-11
Inch SAE four bolt flange fitting. . . . . . .00-0003-19
Inch series four bolt flange fitting for high
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20
Metric bolt and cap screw . . . . . . . . . . . .00-0003-1
Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-2
Metric four bolt flange fitting . . . . . . . . .00-0003-18
O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6
O-ring boss fitting in aluminum
housingexcavators. . . . . . . . . . . . . . . .00-0003-8
O-ring face seal fittings with inch hex nut and
stud end for standard pressure . . . . .00-0003-14
Unified inch bolt and cap screw . . . . . . .00-0003-4
30° cone seat hydraulic fittings . . . .00-0003-5
37° flare hydraulic fittings . . . . . . . .00-0003-5
Track adjuster
Recoil spring, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .01-0130-25
Recoil spring, remove and install . . . . .01-0130-23
Track adjuster cylinder
Track carrier roller
Index-5

031709
PN=5
Indx
5
Index
Page
Page
Track chain
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-17
Track roller . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-5
Indx
6 Track shoe
Travel gearbox
Travel motor and park brake
Travel motor, counterbalance valve
Travel pilot valve
Travel speed selector valve
Travel speed solenoid valve

Valve, travel speed selector
W
Waste disposal . . . . . . . . . . . . . . . . . . . . . . . .00-01-6
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3
Welding precautions . . . . . . . . . . . . . . . . . .17-1740-1
Welding repairs . . . . . . . . . . . . . . . . . . . . . .00-01-14
Window, sliding
Windowpanes
Dimensions . . . . . . . . . . . . . . . . . . . . . . .18-1810-3
Work site hazards
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-9
U
Upperstructure
V
Valve
Crossover relief, remove and install . . .43-4360-17
Make-up check, disassemble . . . . . . . .43-4360-18
Make-up check, remove and install . . . .43-4360-17
Pilot pressure regulating, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-36
Swing park brake release, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .43-4360-19
Valve, control
Valve, pilot pressure regulating
Valve, pilot shutoff solenoid
Valve, travel pilot
TM10079 (17MAR09)
Index-6

031709
PN=6

200D, 20200DLC Repair TM10079

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200D, 20200DLC Repair TM10079

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200D and 200DLC

For complete service information also see:

Information is organized in groups for the various

200D and 200DLC Excavator Repair

Technical Information Feedback Form

John Deere Dubuque Works

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200D and 200DLC Excavator Repair

200D and 200DLC Excavator Repair

SECTION 00General Information

SECTION 02Axles, Differentials and Suspension

SECTION 05Engine Auxiliary System

SECTION 17Frame or Supporting Structure

SECTION 18Operators Station

SECTION 43Swing or Pivoting System

All information, illustrations and specifications in this manual are based on

200D and 200DLC Excavator Repair

200D and 200DLC Excavator Repair

200D and 200DLC Excavator Repair

200D and 200DLC Excavator Repair

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

200D and 200DLC Excavator Repair

200D and 200DLC Excavator Repair

Recognize Safety Information

This is the safety alert symbol. When this symbol is

Follow the precautions and safe operating practices

A signal word DANGER, WARNING, or CAUTION is

On the machine, DANGER signs are red in color,

Follow Safety Instructions

Read the safety messages in this manual and on the

Be sure all operators of this machine understand every

Operate Only If Qualified

machine functions with the machine in an open area

200D and 200DLC Excavator Repair

Wear Protective Equipment

Wear close fitting clothing and safety equipment

Avoid Unauthorized Machine Modifications

machine stability or reliability, and may create a hazard

200D and 200DLC Excavator Repair

Special work situations or machine attachments may

Add Cab Guarding for Special Uses

FOPS (falling object protective structures) and special

Keep all guards and shields in good condition and

Inspect machine carefully each day by walking around it

Stop engine before examining, adjusting or maintaining

Entanglements in moving parts can cause serious injury.

Stay Clear of Moving Parts

200D and 200DLC Excavator Repair

Avoid High-Pressure Fluids

Search for leaks with a piece of cardboard. Protect hands

Avoid the hazard by relieving pressure before

Escaping fluid under pressure can penetrate the skin

If an accident occurs, see a doctor immediately. Any fluid

Avoid High-Pressure Oils

If hydraulic oil penetrates your skin, see a doctor

Never search for leaks with your hands. Protect hands.

This machine uses a high-pressure hydraulic system.

200D and 200DLC Excavator Repair

If you must operate in an enclosed space, provide

Prevent asphyxiation. Engine exhaust fumes can cause

Beware of Exhaust Fumes

Keep A Fire Extinguisher Available: Always keep a

Maintain Hoses and Wiring: Replace hydraulic hoses