160D Repair

160DLC Excavator Repair
TECHNICAL MANUAL 160DLC Excavator Repair

TM10091 11JAN08 (ENGLISH)
For complete service information also see: 160DLC Excavator Operation and Tests . . . TM10088 160DLC Excavator Operators Manual . . . . . OMT226911 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
TM10091 (11JAN08)

011108
PN=2
Introduction
Technical Information Feedback Form

We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements.
SEND TO: John Deere Dubuque Works P.O. Box 538 Attn: Publications Supervisor, Dept. 303 Dubuque, IA 52004-0538 563-589-5800
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TX,TM,FAX 1903JUL011/1
TM10091 (11JAN08)

011108
PN=3
Introduction
TM10091 (11JAN08)

011108
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Contents
00
SECTION 00General Information Group 01Safety Group 0003Torque Values

SECTION 01Tracks Group 0130Track System
SECTION 02Axles, Differentials and Suspension Systems Group 0250Axle Shaft, Bearings, and Reduction Gears Group 0260Hydraulic System
01
02
SECTION 04Engine Group 0400Removal and Installation
SECTION 05Engine Auxiliary System Group 0510Cooling System Group 0520Intake System Group 0560External Fuel Supply System
04
SECTION 07Dampener Drive (Flex Coupling) Group 0752Elements
05
SECTION 17Frame or Supporting Structure Group 1740Frame Installation Group 1749Chassis Weights
07
SECTION 18Operators Station Group 1800Removal and Installation Group 1810Operator Enclosure Group 1821Seat and Seat Belt Group 1830Heating and Air Conditioning
17
SECTION 33Excavator Group 3302Buckets Group 3340Frames Group 3360Hydraulic System
18
SECTION 43Swing or Pivoting System Group 4350Mechanical Drive Elements Group 4360Hydraulic System
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.
COPYRIGHT 2008 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright 2007
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TM10091 (11JAN08)

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04
05
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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 Service Recommendation Inch Series Four Bolt Flange For High Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-20
TM10091 (11JAN08)
00-1

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Contents
00
TM10091 (11JAN08)
00-2

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Group 01
Safety
Recognize Safety Information
UN28AUG00
00 01 1
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. Follow the precautions and safe operating practices highlighted by this symbol. A signal word DANGER, WARNING, or CAUTION is used with the safety alert symbol. DANGER identifies the most serious hazards. On 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. 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 1908JAN081/1
TM10091 (11JAN08)
00-01-1

011108
PN=9
T133556
T133588
1928AUG00
T133555
Safety
00 01 2
Wear Protective Equipment

Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
TX03679,00016D0 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 1917JUL071/1
TM10091 (11JAN08)
00-01-2

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PN=10
TS206
UN23AUG88
Safety
Add Cab Guarding for Special Uses

Special work situations or machine attachments may create an environment with falling or flying objects. Working near an overhead bank, doing demolition work, using a hydraulic hammer, or working in a wooded area, for example, may require added guarding to protect the operator. FOPS (falling object protective structures) and special screens or guarding should be installed when falling or flying objects may enter or damage the machine. Contact your authorized dealer for information on devices intended to provide protection in special work situations.
UN15SEP00
00 01 3
TX03679,00016CE 1903JAN071/1
Inspect Machine
Inspect machine carefully each day by walking around it before starting.
UN18OCT88
Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.
TX03679,0001734 1903JAN071/1
Stay Clear of Moving Parts

Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.
UN12SEP01
TX03679,00016D2 1903JAN071/1
TM10091 (11JAN08)
00-01-3

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PN=11
T133592
T6607AQ
T133733
Safety
00 01 4
Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury.
UN23AUG88
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury 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

This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury. Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system. 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.
UN17MAR06
TX03679,00016D3 1901OCT071/1
TM10091 (11JAN08)
00-01-4

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PN=12
T133840
UN20SEP00
T133509
X9811
Safety
Beware of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.
00 01 5
TX03679,00016D4 1903JAN071/1
Prevent Fires
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines and electrical wiring. Never store oily rags or flammable materials inside a machine compartment. Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage. Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly.
UN14SEP00
TX03679,00016F5 1908MAR071/1
Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16C (60F).
TX03679,000174A 1903JAN071/1
TM10091 (11JAN08)
00-01-5

011108
PN=13
TS204
UN23AUG88
T133554
UN07SEP00
T133553
UN07SEP00
T133552
T133546
UN24AUG00
Safety
00 01 6
Handle Chemical Products Safely

UN25AUG00
Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous. If uncertain about safe handling or use of these chemical products, contact your authorized John Deere 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.
TX03679,00016D7 1908JAN081/1
Dispose of Waste Properly

UN25AUG00
Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly. Never pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants. If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for more information.
TX03679,0001733 1903JAN071/1
Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts. Keep a first aid kit and fire extinguisher handy.
UN23AUG88
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
TX03679,000174B 1903JAN071/1
TM10091 (11JAN08)
00-01-6

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PN=14
TS291
T133567
T133580
Safety
Use Steps and Handholds Correctly

UN30AUG00
00 01 7
Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds. Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.
TX03679,00016F2 1925JAN071/1
Start Only From Operators Seat

Avoid unexpected machine movement. Start engine only while sitting in operators seat. Ensure all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.
UN07SEP00
TX03679,0001799 1903JAN071/1
Use and Maintain Seat Belt

1914SEP00
Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly. The complete seat belt assembly should be replaced every three years, regardless of appearance.
TX03679,00016DD 1910JAN071/1
TM10091 (11JAN08)
00-01-7

011108
PN=15
T133716
T133715
T133468
Safety
00 01 8
Prevent Unintended Machine Movement

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.
DW90712,00002BF 1926OCT061/1
TM10091 (11JAN08)
00-01-8

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PN=16
T216779
UN22NOV05
Safety
Avoid Work Site Hazards

Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before you dig. Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or arm contact with overhead obstacles or overhead electrical lines. Never move any part of machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires. Keep bystanders clear at all times. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Operate only on solid footing with strength sufficient to support machine. When working close to an excavation, position travel motors away from the hole. 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.
00 01 9
TX03679,0001748 1913DEC071/1
Keep Riders Off Machine

Only allow operator on machine. Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operators view or impair his ability to operate machine safely.
TX03679,0001726 1903JAN071/1
TM10091 (11JAN08)
00-01-9

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PN=17
T7273AH
UN08JUN90
T133549
UN24AUG00
T133650
UN27SEP00
T134986
UN31OCT00
Safety
00 01 10
Avoid Backover Accidents

Before moving machine, be sure all persons are clear of both travel and swing paths. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain travel alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.
TX03679,00016F3 1903JAN071/1
Avoid Machine Tip Over

1914SEP00
Use seat belt at all times. Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you. Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel. Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these conditions. When traveling up or down slopes, keep the bucket on uphill side and just above ground level. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy load or swinging it over side of undercarriage may cause machine to tip. Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or fall.
TX03679,00016DF 1903JAN071/1
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00-01-10

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PN=18
T133803
UN27SEP00
T133545
UN15SEP00
T133716
T133548
UN24AUG00
Safety
Use Special Care When Lifting Objects

UN27SEP00
00 01 11
Never use this machine to lift people. Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free. Do not leave the seat when there is a raised load. Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or swinging over undercarriage side may cause machine to tip over. Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good condition. Use tether lines to guide loads and prearranged hand signals to communicate with coworkers.
TX03679,00016E1 1924SEP071/1
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
TM10091 (11JAN08)
00-01-11

011108
PN=19
T133839
Safety
00 01 12
Park and Prepare for Service Safely

Warn others of service work. Always park and prepare your machine for service or repair properly. Park machine on a level surface and lower equipment 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. Securely support machine or attachment before working under it. Do not support machine with boom, arm, or other hydraulically actuated attachments. Do not support machine with cinder blocks or wooden pieces that may crumble or crush. Do not support machine with a single jack or other devices that may slip out of place. Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.
1914DEC01
TX03679,00016E9 1903JAN071/1
Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
DX,RCAP 1904JUN901/1
TM10091 (11JAN08)
00-01-12

011108
PN=20
TS281
UN23AUG88
TS229
UN23AUG88
T133332
Safety
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating: 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. 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.
UN23AUG88
00 01 13
DX,PAINT 1924JUL021/1
TM10091 (11JAN08)
00-01-13

011108
PN=21
TS220
Safety
00 01 14
Make Welding Repairs Safely

IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors. Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.
UN31AUG00
TX03679,00016D5 1912SEP071/1
Drive Metal Pins Safely

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.
UN14SEP00
TX03679,0001745 1917JUL071/1
TM10091 (11JAN08)
00-01-14

011108
PN=22
T133738
T133547
Group 0003
Torque Values
Metric Bolt and Cap Screw Torque Values
00 0003 1
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
M6
Class 8.8 or 9.8

Lubricateda Nm (lb-ft)
9 (6.6)
Class 10.9
13 (9.5)
Class 12.9
15.5 (11.5)
4.7 (3.5)
Dryb Nm (lb-ft)
6 (4.4)
Dryb Nm (lb-ft)
11.5 (8.5)
Dryb Nm (lb-ft)
16.5 (12.2)
Dryb Nm (lb-ft)
19.5 (14.5)
M8
11.5 (8.5)
14.5 (10.7)
22 (16)
28 (20.5)
32 (23.5)
40 (29.5)
37 (27.5)
47 (35)
M10
23 (17)
29 (21)
43 (32)
55 (40)
63 (46)
80 (59)
75 (55)
95 (70)
M12
40 (29.5)
50 (37)
75 (55)
95 (70)
110 (80)
140 (105)
130 (95)
165 (120)
M14
63 (46)
80 (59)
120 (88)
150 (110)
175 (130)
220 (165)
205 (150)
260 (190)
M16
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
M22
265 (195)
330 (245)
510 (375)
650 (480)
725 (535)
920 (680)
850 (625)
1080 (800)
M24
330 (245)
425 (315)
650 (480)
820 (600)
920 (680)
1150 (850)
1080 (800)
1350 (1000)
M27
490 (360)
625 (460)
950 (700)
1200 (885)
1350 (1000)
1700 (1250)
1580 (1160)
2000 (1475)
M30
660 (490)
850 (625)
1290 (950)
1630 (1200)
1850 (1350)
2300 (1700)
2140 (1580)
2700 (2000)
M33
900 (665)
1150 (850)
1750 (1300)
2200 (1625)
2500 (1850)
3150 (2325)
2900 (2150)
3700 (2730)
M36
a
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.
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.
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.
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
TM10091 (11JAN08)
00-0003-1

011108
PN=23
TORQ2
UN07SEP99
Torque Values
00 0003 2
Additional Metric Cap Screw Torque Values

CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when tightening. Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.
UN18OCT88
Continued on next page
04T,90,M170 1929SEP991/2
TM10091 (11JAN08)
00-0003-2

011108
PN=24
T6873AC
UN18OCT88
T6873AB
UN18OCT88
T6873AA
Torque Values
METRIC CAP SCREW TORQUE VALUESa
T-Bolt
Nominal Dia
8
Nm lb-ft
H-Bolt
Nm lb-ft
M-Bolt
Nm lb-ft
00 0003 3
29
21
20
15
10
10
63
46
45
33
20
15
12
108
80
88
65
34
25
14
176
130
137
101
54
40
16
265
195
206
152
78
58
18
392
289
294
217
118
87
20
539
398
392
289
167
125
22
735
542
539
398
216
159
24
931
687
686
506
274
202
27
1372
1012
1029
759
392
289
30
1911
1410
1421
1049
539
398
33
2548
1890
1911
1410
735
542
36
a
3136
2314
2401
1772
931
687
Torque tolerance is 10%.
04T,90,M170 1929SEP992/2
TM10091 (11JAN08)
00-0003-3

011108
PN=25
Torque Values
00 0003 4
Unified Inch Bolt and Cap Screw Torque Values
TopSAE Grade and Head Markings; BottomSAE Grade and Nut Markings
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUESTolerance is 10% unless otherwise specified
Grade 1 (No Mark)
Thread Size
1/4
Grade 2a (No Mark)

c
Grade 5, 5.1 or 5.2

Lubricatedb Nm (lb-ft)
9.5 (7)
Grade 8 or 8.2
13.5 (10)
Lubricated Nm (lb-ft)
3.8 (2.8)
Dry Nm (lb-ft)
4.7 (3.5)
6 (4.4)
Dryc Nm (lb-ft)
7.5 (5.5)
Dryc Nm (lb-ft)
12 (9)
Dryc Nm (lb-ft)
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
a
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. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.
Make sure fastener threads are clean and 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,TORQUE1 1914JAN041/1
TM10091 (11JAN08)
00-0003-4

011108
PN=26
TORQ1A
UN27SEP99
Torque Values
Service Recommendations for 37 Flare and 30 Cone Seat Connectors

1. Inspect flare and flare seat. They must be free of dirt or obvious defects. 2. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align tube with fitting before attempting to start nut. 4. Lubricate male threads with hydraulic fluid or petroleum jelly. 5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size
3/8 - 24 UNF
7/16 - 20 UNF
UN18OCT88
00 0003 5
Nm
8
12
lb-ft
6
9
1/2 - 20 UNF
16
12
9/16 - 18 UNF
24
18
3/4 - 16 UNF
46
34
7/8 - 14 UNF
62
46
1-1/16 - 12 UN
102
75
1-3/16 - 12 UN
122
90
1-5/16 - 12 UN
142
105
1-5/8 - 12
190
140
1-7/8 - 12 UN
217
160
NOTE: Torque tolerance is 10%.
T82,BHMA,EL 1929SEP991/1
TM10091 (11JAN08)
00-0003-5

011108
PN=27
T6234AC
Torque Values
00 0003 6
Service Recommendations for O-Ring Boss Fittings

Straight Fitting
UN18OCT88
1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart.
04T,90,K66 1929SEP991/2
TM10091 (11JAN08)
00-0003-6

011108
PN=28
T6243AE
Torque Values
Angle Fitting 1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.
UN18OCT88
00 0003 7
2. Turn fitting into threaded boss until back-up washer contacts face of boss. 3. Turn fitting head-end counterclockwise to proper index (maximum of one turn). NOTE: Do not allow hoses to twist when tightening fittings. 4. Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size
3/8-24 UNF
7/16-20 UNF
Nm
8
12
lb-ft
6
9
1/2-20 UNF
16
12
9/16-18 UNF
24
18
3/4-16 UNF
46
34
7/8-14 UNF
62
46
1-1/16-12 UN
102
75
1-3/16-12 UN
122
90
1-5/16-12 UN
142
105
1-5/8-12 UN
190
140
1-7/8-12 UN
217
160
NOTE: Torque tolerance is 10%.
04T,90,K66 1929SEP992/2
TM10091 (11JAN08)
00-0003-7

011108
PN=29
T6520AB
Torque Values
00 0003 8
O-Ring Boss Fittings In Aluminum Housing Service RecommendationsExcavators
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)
OUT3035,0000353 1914JAN041/2
TM10091 (11JAN08)
00-0003-8

011108
PN=30
T196315
UN17NOV03
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.
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. 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. 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.
00 0003 9
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
O-RING BOSS PLUG STUD END WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUESTolerance is 10% unless otherwise specified
Thread Size in.
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 1914JAN042/2
TM10091 (11JAN08)
00-0003-9

011108
PN=31
Torque Values
00 0003 10
Service Recommendations For Flared ConnectionsStraight or Tapered Threads

1. Inspect flare and flare seat. They must be free of dirt or obvious defects. 2. Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align the tube with the fitting before attempting to start the nut.
Straight Thread
UN18OCT88
4. Lubricate the male threads with hydraulic fluid or petroleum jelly. 5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings.
TORQUE CHART
Straight Thread
Thread Size
1/8
Nm
b
Tapered Thread
Nm lb-ft
lb-ft
Tapered Thread
15
11
1/4
20
15
45
33
3/8
29
21
69
51
1/2
49
36
93
69
3/4
69
51
176
130
157
116
343
253
1-1/2
196
145
539
398
2
a
255
188
588
434
Torque tolerance is 10%.
With seat face.
NOTE: If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced approximately 10%.
04T,90,M171 1928JAN921/1
TM10091 (11JAN08)
00-0003-10

011108
PN=32
T6873AD
UN18OCT88
T6873AE
Torque Values
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. 2. Lubricate O-rings and install into grove using petroleum jelly to hold in place. 3. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 4. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings. IMPORTANT: Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating devise. Tighten fittings to 50% of listed torque value if used in aluminum housing.
00 0003 11
FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D.
mm
6.35
Thread Size
in.
9/16-18
Swivel Nut
Nm
16
Bulkhead Nut
lb-ft
12
in.
0.250
Nm
12
lb-ft
9
9.52
0.375
11/16-16
24
18
24
18
12.70
0.500
13/16-16
50
37
46
34
15.88
0.625
1-14
69
51
62
46
19.05
0.750
1 3/16-12
102
75
102
75
22.22
0.875
1 3/16-12
102
75
102
75
25.40
1.000
1 7/16-12
142
105
142
105
31.75
1.250
1 11/16-12
190
140
190
140
38.10
1.500
2-12
217
160
217
160
*Torque tolerance is +15 -20% unless otherwise specified.
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size
Straight Hex Size
Locknut Hex Size
Straight Fitting or Locknut Toque
Inch
Inch
Inch
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
TM10091 (11JAN08)
00-0003-11

011108
PN=33
Torque Values
00 0003 12
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations
A
F
E
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
O-Ring Face Seal Hose or Tube Swivel Nut
Bulkhead Nut
Metric Tube OD
Inch Tube OD or Hose ID
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)
OUT3035,0000420 1914JAN041/2
TM10091 (11JAN08)
00-0003-12

011108
PN=34
H70406
UN12DEC01
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
in.
00 0003 13
Straight Hex Sizea

in.
Adjustable Nut Hex Size

in.
Steel or Gray Iron Torque

Nm (lb-ft)
3/8-24
5/8
9/16
18 (13)
7/16-20
5/8
5/8
24 (18)
1/2-20
3/4
11/16
30 (22)
9/16-18
3/4
3/4
37 (27)
3/4-16
7/8
15/16
75 (55)
7/8-14
1-1/16
1-1/16
103 (76)
1-1/16-12
1-1/4
1-3/8
177 (131)
1-3/16-12
1-3/8
1-1/2
231 (170)
1-5/16-12
1-1/2
1-5/8
270 (199)
1-5/8-12
1-3/4
1-7/8
286 (211)
1-7/8-12
a
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, cracks, swelling or flatten condition. 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. 4. Turn fitting into the boss by hand until face of nut or 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
TM10091 (11JAN08)
00-0003-13

011108
PN=35
Torque Values
00 0003 14
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations
1
2
10
11
9
8
11
6
10
5
11
6
10
T196337
190 Swivel Elbow 290 Adjustable Stud Elbow 3Stud Straight
8
4Bulkhead Union and Nut 5External Hex Stud End Plug 6Tube Nut 7Swivel Nut 8Stud End 9Hex Nut
8
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
mm
4
5
6
8
10
12
16
20
22
25
28
32
38
50

Thread Size
in.
9/16-18
11/16-16
13/16-16
1-14
1-3/16-12
1-3/16-12
1-7/16-12
1-11/16-12
2-12
Bulkhead Nut
Hex Size
mm
22
27
30
36
41
41
46
50
60

Dash Size
-2
-3
-4
-5
-6
-8
-10
-12
-14
-16
-20
-24
-32
Hex Size
mm
17
22
24
30
36
36
41
50
60
Torque
Nm (lb-ft)
16 (12)
24 (18)
50 (37)
69 (51)
102 (75)
102 (75)
142 (105)
190 (140)
217 (160)
Torque
Nm (lb-ft)
32 (24)
42 (31)
93 (69)
118 (87)
175 (129)
175 (129)
247 (182)
328 (242)
374 (276)
mm (in.)
3.18 (0.125)
4.78 (0.188)
6.35 (0.250)
7.92 (0.312)
9.53 (0.375)
12.70 (0.500)
15.88 (0.625
19.05 (0.750)
22.23 (0.875)
25.40 (1.000)
31.75 (1.250)
38.10 (1.500)
50.80 (2.000)
OUT3035,0000366 1914JAN041/2
TM10091 (11JAN08)
00-0003-14

011108
PN=36
T196337
UN18NOV03
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
mm.
00 0003 15
Straight Hex Sizeb

mm

mm

Nm (lb-ft)
Aluminum or Brass Torque

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
a
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.
OUT3035,0000366 1914JAN042/2
TM10091 (11JAN08)
00-0003-15

011108
PN=37
Torque Values
00 0003 16
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations
1
2
10
11
9
8
11
6
10
5
11
6
10
T196337
190 Swivel Elbow 290 Adjustable Stud Elbow 3Stud Straight
8
4Bulkhead Union and Nut 5External Hex Stud End Plug 6Tube Nut 7Swivel Nut 8Stud End 9Hex Nut
8
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
mm
4
5
6
8
10
12
16
20
22
25
28
32
38

Thread Size
in.
9/16-18
11/16-16
13/16-16
1-14
1-3/16-12
1-3/16-12
1-7/16-12
1-11/16-12
2-12
Bulkhead Nut
Hex Size
mm
22
27
30
36
41
41
46
50
60

Dash Size
-2
-3
-4
-5
-6
-8
-10
-12
-14
-16
-20
-24
Hex Size
mm
17
22
24
30
36
36
41
Torque
Nm (lb-ft)
24 (18)
37 (27)
75 (55)
103 (76)
152 (112)
152 (112)
214 (158)
286 (211)
326 (240)
Torque
Nm (lb-ft)
32 (24)
42 (31)
93 (69)
118 (87)
175 (129)
175 (129)
247 (182)
328 (242)
374 (276)
mm (in.)
3.18 (0.125)
4.78 (0.188)
6.35 (0.250)
7.92 (0.312)
9.53 (0.375)
12.70 (0.500)
15.88 (0.625)
19.05 (0.750)
22.23 (0.875)
25.40 (1.000)
31.75 (1.250)
38.10 (1.500)
OUT3035,0000421 1914JAN041/2
TM10091 (11JAN08)
00-0003-16

011108
PN=38
T196337
UN18NOV03
Torque Values
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
mm.
00 0003 17
Straight Hex Sizeb

mm

mm

Nm (lb-ft)
M8 x 1
12
12
8 (6)
M10 x 1
14
14
15 (11)
M12 x 1.5
17
17
35 (26)
M14 x 1.5
19
19
45 (33)
M16 x 1.5
22
22
55 (41)
M18 x 1.5
24
24
70 (52)
M22 x 1.5
27
27
100 (74)
M27 x 2
32
32
170 (125)
M30 x 2
36
36
215 159)
M33 x 2
41
41
260 (192)
M38 x 2
46
46
320 (236)
M42 x 2
50
50
360 (266)
M48 x 2
a
55
55
420 (310)
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
OUT3035,0000421 1914JAN042/2
TM10091 (11JAN08)
00-0003-17

011108
PN=39
Torque Values
00 0003 18
Service Recommendations for Metric Series Four Bolt Flange Fitting
ASealing Surface
BSplit Flange
CPinched O-Ring
DSingle Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw,
a
then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
TORQUE CHARTa
Thread
M6
M8
b
Nm
12
30
lb-ft
9
22
M10
57
42
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
Tolerance 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures.
b
Metric standard thread.
04T,90,K175 1929SEP991/1
TM10091 (11JAN08)
00-0003-18

011108
PN=40
T6890BB
UN01MAR90
Torque Values
Service Recommendations For Inch Series Four Bolt Flange Fittings
00 0003 19
ASealing Surface
BSplit Flange
CPinched O-Ring

TORQUE CHART
Nm lb-ft
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
Nominal Flange Size

1/2
Cap Screw Size

Min Max Min Max
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
04T,90,K174 1901AUG941/1
TM10091 (11JAN08)
00-0003-19

011108
PN=41
T6890BB
UN01MAR90
Torque Values
00 0003 20
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
ASealing Surface
BSplit Flange
CPinched O-Ring
INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa (414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES Tolerance is 10% unless otherwise specified
Nominal Flange Size Cap Screw Sizea MinMax Torque
2. Install the O-ring (and backup ring, if used) into groove. Use petroleum jelly to hold it in place. IMPORTANT: DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold 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. 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.
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)
2
a
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.
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.
OUT3035,0000422 1914JAN041/1
TM10091 (11JAN08)
00-0003-20

011108
PN=42
T6890BB
UN01MAR90
Section 01
Tracks
Contents
Page
01
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 . . . . . . . . .01-0130-11 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
TM10091 (11JAN08)
01-1

011108
PN=1
Contents
01
TM10091 (11JAN08)
01-2

011108
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.
CAUTION: Prevent possible injury from unexpected machine movement. Position shop stands under frame to support machine while removing lower track roller.
Specification MachineWeight (Approximate)................................................ 18 151 kg 39 980 lb
01 0130 1
2. Put shop stands under machine.
OUO6046,00022F1 1903APR071/3
CAUTION: Prevent possible injury from high pressure grease. Do not remove grease fitting (A) from valve (B). 3. Loosen valve (B) one to two turns to release grease through bleed hole (C).
AGrease Fitting BValve CBleed Hole
OUO6046,00022F1 1903APR072/3
TM10091 (11JAN08)
01-0130-1

011108
PN=45
T7396DZ
UN28NOV90
Track System
CAUTION: Heavy component; use appropriate lifting device.

Specification Track RollerWeight ........................................................................ 35 kg 77 lb
4. Attach appropriate lifting device to track roller (B). Remove cap screws (A) and track roller (B). 5. Measure track roller tread diameter. See 160DLC Track Roller Tread Diameter. (SP326 Undercarriage Appraisal Manual.) 6. Repair or replace parts as necessary. See Track Roller Disassemble and Assemble. (Group 0130.) 7. Install track roller and tighten cap screws to specification.
Specification Roller-to-Frame Cap Screw Torque .......................................................................................... 460 Nm 340 lb-ft
ACap Screw (4 used) BTrack Roller
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.)
OUO6046,00022F1 1903APR073/3
TM10091 (11JAN08)
01-0130-2

011108
PN=46
T6585TN
UN25OCT88
01 0130 2
Track System
Track Roller Disassemble and Assemble
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
1. Remove plug (A) and drain oil. 2. Remove pin (C).
7. Remove bushings (F) using a 2-jaw puller and adapters from puller set. 8. Replace parts as necessary.
3. Remove bracket (B) using a bearing puller attachment and adapters from puller set. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face. 4. Remove metal face seal (E) from roller and bracket. Keep seal rings together as a matched set with seal ring faces together to protect surfaces. 5. Inspect metal face seals. See Metal Face Seals Repair. (Group 0130.) 6. Remove axle (H) from roller. NOTE: Only remove bushings if replacement is necessary.
Apply a thin film of oil to bushings (F) and install. IMPORTANT: O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-rings do not slip when roller is turning. 9. Thoroughly clean O-rings and seat surfaces in brackets (B) and in seal rings using volatile, non-petroleum base solvent and lint-free tissues. 10. Install seals (E) in brackets (B) and in roller (G). Apply equal pressure with fingers at four equally spaced points on seal face. Seal must pop down into place so O-ring is tight against seal bore. A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant.
OUO6046,00022F2 1919APR071/2
TM10091 (11JAN08)
01-0130-3

011108
PN=47
T8310AH
UN21SEP94
Track System
11. Wipe finger prints and foreign material off seal ring face using clean oil and lint-free tissues. Apply a thin film of oil to each seal ring face.
01 0130 4
16. Fill roller to specification.

Specification Lower Track RollerCapacity ................................................. 260 mL 8.8 oz
12. Install axle (H) to bracket (B). 13. Install roller (G) onto axle (H). 14. Install opposite side bracket (B) on roller assembly. 15. Apply TY24811NEVER-SEEZ anti-seize lubricant or equivalent to pins (C). Install pins (C) even with flat surface of brackets (B).
17. Apply PM37509 Cure Primer and PM37398 Pipe Sealant to threads of plug. Install and tighten plug.
Specification PlugTorque ........................................................................... 30 Nm 22 lb-ft
NEVER-SEEZ is a trademark of Bostik Findley, Inc.
OUO6046,00022F2 1919APR072/2
TM10091 (11JAN08)
01-0130-4

011108
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. 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
01 0130 5
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
OUO6046,00022F3 1919APR071/1
TM10091 (11JAN08)
01-0130-5

011108
PN=49
T109691B
Track System
Track Carrier Roller Remove and Install

CAUTION: Prevent possible injury from high pressure grease. Do not remove grease fitting (A) from valve (B). 1. Loosen valve (B) one to two turns to release grease through bleed hole (C).
UN28NOV90
01 0130 6
OUO6046,00022F4 1905MAR071/3
2. Raise track chain (3), using a jack, enough to permit carrier roller (2) removal.
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).
1Track Frame 2Carrier Roller 3Track Chain 4Wood Block
OUO6046,00022F4 1905MAR072/3
TM10091 (11JAN08)
01-0130-6

011108
PN=50
TX1006136A
UN07APR06
T7396DZ
Track System
4. Remove cap screws (1) and carrier roller (2). 5. Measure track carrier roller tread diameter. See 160DLC Carrier Roller Tread Diameter. (SP326 Undercarriage Appraisal Manual.) IMPORTANT: Carrier roller replaced as assembly only. 6. Replace carrier roller as necessary.
Specification Carrier RollerWeight ...................................................................... 21 kg 46 lb
UN26JAN07
01 0130 7
7. Install carrier roller and cap screws (1). 8. Tighten carrier roller cap screws (1) to specification.
Specification Carrier Roller-to-Frame Cap ScrewTorque ............................................................................. 270 Nm 200 lb-ft 1Cap Screw (4 used) 2Carrier Roller
9. Remove wooden blocks and jack. 10. Tighten valve on track adjuster to specification.
OUO6046,00022F4 1905MAR073/3
TM10091 (11JAN08)
01-0130-7

011108
PN=51
TX1018018A
Track System
Metal Face Seals Repair

Inspect Metal Face Seals
01 0130 8
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). b. Sealing area must be uniform and concentric with the ID and OD of seal ring (A). c. Sealing area must not be chipped, nicked, or scratched.
ASeal Ring BWorn Area (Shaded Area) CSeal Ring Face DOuter Half of Seal Ring Face ESealing Area (Dark Line)
UN24AUG93
OUO6046,00022F5 1905MAR071/4
2. Illustration shows examples of worn seal rings (A). ISealing area (D) is in inner half of seal ring face (C). IISealing area (D) not concentric with ID and OD of seal ring.
ASeal Ring BWorn area (Shaded Area) CInner Half of Seal Ring Face DSealing Area (Dark Line)
OUO6046,00022F5 1905MAR072/4
TM10091 (11JAN08)
01-0130-8

011108
T85080
UN05DEC96
PN=52
T85079
Track System
3. Clean reusable seals by removing all foreign material from seal rings, except seal face (A), using a scraper or a stiff bristled fiber brush. 4. Wash seal rings and O-rings using a volatile, non-petroleum base solvent to remove all oil. Thoroughly dry parts using a lint-free tissue.
ASeal Face
OUO6046,00022F5 1905MAR073/4
TM10091 (11JAN08)
01-0130-9

011108
PN=53
T82840
UN23FEB89
01 0130 9
Track System
Assemble Metal Face Seals IMPORTANT: If incorrectly assembled, oil leakage or damage will occur.
01 0130 10
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.
AO-Ring BMating Face CRing Surface DDistance EDistance
OUO6046,00022F5 1905MAR074/4
TM10091 (11JAN08)
01-0130-10

011108
PN=54
TX1018112
UN26JAN07
TX1018110
UN26JAN07
Track System
Track Shoe Remove and Install

1. Measure grouser height. See 160DLC Three Bar Grouser Height. (SP326 Undercarriage Appraisal Manual.) 2. Apply a light coat of oil to cap screw threads and install shoe. 3. Install all track shoe nuts with rounded corners (A) against the link and chamfered edges (B) away from the link. Be sure nut is properly positioned in the link so there is full contact between the nut and the link. 4. Tighten cap screws in pattern shown.
Specification Shoe-to-Link Cap ScrewTorque ............................................... 804 Nm 593 lb-ft
UN23FEB89 UN23FEB89
01 0130 11
ARounded Edge BChamfered Edge
OUO6046,00022F6 1905MAR071/1
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.
Specification MachineWeight ....................................................................... 18 151 kg 39 980 lb
2. Place blocks or shop stands under the machine to support machine.
OUO6046,00022F7 1903APR071/4
TM10091 (11JAN08)
01-0130-11

011108
PN=55
T6352AH
T6794AM
Track System
CAUTION: Prevent possible injury from high pressure grease. Do not remove grease fitting (A) from valve (B).
01 0130 12
OUO6046,00022F7 1903APR072/4
TM10091 (11JAN08)
01-0130-12

011108
PN=56
T7396DZ
UN28NOV90
3. Loosen valve (B) one to two turns to release grease through bleed hole (C).
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. 5. Remove track shoe on each side of master pin. See Track Shoe Remove and Install. (Group 0130.) 6. If removing chain at idler, put wooden blocks in front of idler and under chain so chain does not fall when master pin is removed. 7. Remove snap ring. IMPORTANT: Master pin can be removed in only one direction. 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.
Specification TracksWeight ............................................................................. 1180 kg 2602 lb
01 0130 13
1Bushing (2 used) 2Master Pin 3Dimple
10. Remove track chain. 11. Measure track chain link, bushing, and pitch. (See SP326 Undercarriage Appraisal Manual.) 12. Replace parts as necessary. 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.
OUO6046,00022F7 1903APR073/4
TM10091 (11JAN08)
01-0130-13

011108
PN=57
T143215B
UN20JUL01
Track System
IMPORTANT: Master pin can be installed in only one direction. 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.
01 0130 14
OUO6046,00022F7 1903APR074/4
TM10091 (11JAN08)
01-0130-14

011108
PN=58
Track System
01 0130 15
TM10091 (11JAN08)
01-0130-15

011108
PN=59
Track System
Track Chain Disassemble and Assemble
01 0130 16
OUO6046,00022F8 1903APR071/2
TM10091 (11JAN08)
01-0130-16

011108
PN=60
T162713
UN15JAN03
Track System
1Track Link (42 used) 2Master Track Link 3Pin (42 used) 5Seal (84 used) 7Master Pin 8Spacer (2 used) 9Snap Ring 10Cap Screw (172 used) 12Nut (172 used) 13Shoe (43 used) 14Track Link (42 used) 15Bushing (42 used) 16Master Bushing 17Track Chain Without Shoes
1. Measure track components (117). See 160DLC Standard Bushing Outer Diameter. (SP326 Undercarriage Appraisal Manual.) 2. Turn pins (3 and 7) and bushings (15 and 16) as required. 3. Clean any dust or rust from surfaces of track link pin bores, counterbores, and ends of bushings.
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.
01 0130 17
OUO6046,00022F8 1903APR072/2
Track Chain Repair

1. Remove track shoes from each side of broken link assembly. See Track Shoe Remove and Install. (Group 0130.) 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
UN26OCT88
OUO6046,00022F9 1905MAR071/4
3. Grind ends of bushing (A) even with links to make it into a master bushing.
ABushing
UN26OCT88
OUO6046,00022F9 1905MAR072/4
TM10091 (11JAN08)
01-0130-17

011108
PN=61
T5821AH
T5821AG
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.
UN26OCT88
01 0130 18
APin Stub BHammer
OUO6046,00022F9 1905MAR073/4
6. Install links (C and E) on master bushing (D). Check cap screw hole spacing using a track shoe. 7. Instal spacers (B) into counterbore of links.
UN24MAY89
8. Install link assembly. Install master pins (A). 9. Install track shoes. See Track Shoe Remove and Install. (Group 0130.)
AMaster Pin BSpacer CRight Link DMaster Bushing ELeft Link
OUO6046,00022F9 1905MAR074/4
TM10091 (11JAN08)
01-0130-18

011108
PN=62
T5821AJ
T5821AI
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. 1. Disconnect track chain. See Track Chain Remove and Install. (Group 0130.) 2. Lift side of machine so sprocket teeth clear chain.
Specification SprocketWeight (approximate) ...................................................... 46 kg 100 lb
UN01FEB02
01 0130 19
1Cap Screw (16 used)
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 Install. (Group 0130.)
OUO6046,00022FA 1919APR071/1
TM10091 (11JAN08)
01-0130-19

011108
PN=63
T145912B
Track System
Front Idler Remove and Install

1. Disconnect track chain. See See Track Chain Remove and Install. (Group 0130.)
UN25OCT88
01 0130 20
2. Slide front idler (A) forward, using pry bar.

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 Disassemble and Assemble. (Group 0130.) 6. Install front idler. 7. Connect track chain. See Track Chain Remove and Install. (Group 0130.)
OUO6046,00022FB 1905MAR071/1
TM10091 (11JAN08)
01-0130-20

011108
PN=64
T6876BU
Track System
Front Idler Disassemble and Assemble

A
F
C
B
G
D
01 0130 21
E
B
A
G
E
D
T115165
APin (2 used) BBushing (2 used) CIdler
DDrain Plug (2 used) EBracket (2 used) FMetal Face Seal (2 used)
GO-Ring (2 used) HAxle
IYoke JCap Screw (4 used)
1. Remove cap screws (J) and yoke (I). 2. Remove drain plug (D) and drain oil. IMPORTANT: Metal face seals (F) can be reused 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). 4. Inspect metal face seals (F). See Metal Face Seals Repair. (Group 0130.) Keep seal rings together as
a matched set with seal ring faces together to protect surfaces. 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).
OUO6046,00022FC 1919APR071/2
TM10091 (11JAN08)
01-0130-21

011108
PN=65
T115165
UN21APR06
Track System
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
14. Install brackets (E) onto axle (H). 15. Apply anti-seize lubricant or equivalent to pins (A). Install pins. 16. Add oil through plug holes on bearing brackets (E) to specification.
Specification Front Idler OilCapacity ......................................................... 265 mL 8.96 oz
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. 13. Install O-rings (G) on axle.
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
OUO6046,00022FC 1919APR072/2
TM10091 (11JAN08)
01-0130-22

011108
PN=66
Track System
Track Adjuster and Recoil Spring Remove and Install

1. Remove track chain. See Track Chain Remove and Install. (Group 0130.) 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.
01 0130 23
OUO6046,00022FD 1910APR071/2
TM10091 (11JAN08)
01-0130-23

011108
PN=67
Track System
3. Slide track adjuster (A) forward, using a pry bar.
UN25OCT88
01 0130 24
Specification Track Adjuster Cylinder and Recoil SpringWeight .................................................................... 125 kg 280 lb
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.) 6. Install front idler. See Front Idler Remove and Install. (Group 0130.) 7. Install track chain. See Track Chain Remove and Install. (Group 0130.)
ATrack Adjuster
OUO6046,00022FD 1910APR072/2
TM10091 (11JAN08)
01-0130-24

011108
PN=68
T6557CX
Track System
Track Adjuster and Recoil Spring 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 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.
Specification Track Recoil Spring Disassembly and Assembly ToolWeight ........................................................... 225 kg 496 lb
01 0130 25
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.) NOTE: It is not necessary to remove the recoil spring to replace wear ring and U-ring packing on piston. To replace O-ring in the cylinder, remove recoil spring and rod. 2. Remove nuts (B). Remove top plate (C).
AST4920 Track Recoil Spring Disassembly and Assembly Tool BNut CTop Plate
OUO6046,00022FE 1905MAR071/5
TM10091 (11JAN08)
01-0130-25

011108
PN=69
T6557DY
UN25OCT88
Track System

Specification Track Adjuster Cylinder and Recoil SpringWeight .................................................................... 125 kg 280 lb
01 0130 26
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.
ALifting Strap BTrack Adjuster CDFT1110 Spacer
UN28APR92
OUO6046,00022FE 1905MAR072/5
TM10091 (11JAN08)
01-0130-26

011108
PN=70
T7720AF
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.) 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.
01 0130 27
9. Tighten nuts (B) so top plate (A) is tight against retainer plate. 10. Remove valve (C) and special plug (E).
ATop Plate BNut (8 used) CValve DNut ESpecial Plug FDFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
UN28APR92
OUO6046,00022FE 1905MAR073/5
TM10091 (11JAN08)
01-0130-27

011108
PN=71
T7720AG
Track System
11. Raise upper half of guard tool (F). Tighten T-handles. 12. Operate jack to compress spring just enough so nut (D) can be removed.
01 0130 28
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.
Specification Recoil SpringWeight ...................................................................... 65 kg 145 lb
18. Install retainer plate. 19. Install guard tool. 20. Install top plate. Install nuts. 21. Raise upper half of guard tool. Tighten T-handles. 22. Operate jack to compress spring to the compressed length.
Specification Recoil SpringCompressed Length ............................................................................................ 490 mm 19.3 in. ATop Plate BNut (8 used) DNut FDFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool
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.
OUO6046,00022FE 1905MAR074/5
TM10091 (11JAN08)
01-0130-28

011108
PN=72
T7720AH
UN28APR92
Track System
25. Tighten valve.
Specification Track Adjuster and Recoil Spring ValveTorque ................................................................................ 88 Nm 65 lb-ft
01 0130 29
OUO6046,00022FE 1905MAR075/5
TM10091 (11JAN08)
01-0130-29

011108
PN=73
Track System
Track Adjuster Cylinder Disassemble and Assemble
01 0130 30
1Holder 2Piston Rod 3Dust Seal
4U-Ring 5Cylinder 6Rod
7Spring 8Spacer 9Washer
10Plug 11Nut 12Grease Valve
CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots can result in immediate or eventual failure of spring or rod creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling. A compression tool must be used for disassembly and assembly because of the extreme preload on spring. 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). 1. Remove piston rod (2) from cylinder (5).
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).
OUO6046,00022FF 1905MAR071/2
TM10091 (11JAN08)
01-0130-30

011108
TX1004754
UN17MAR06
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.) 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). 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
OUO6046,00022FF 1905MAR072/2
TM10091 (11JAN08)
01-0130-31

011108
PN=75
Track System
01 0130 32
TM10091 (11JAN08)
01-0130-32

011108
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
Group 0260Hydraulic System 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 Change Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-19 Travel Motor and Park Brake Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . .02-0260-21
02
TM10091 (11JAN08)
02-1

011108
PN=1
Contents
02
TM10091 (11JAN08)
02-2

011108
PN=2
Group 0250
Axle Shaft, Bearings, and Reduction Gears

Travel Gearbox Remove and Install
1. Disconnect track chain. See Track Chain Repair. (Group 0130.) 2. Remove sprocket. See Sprocket Remove and Install. (Group 0130.)
CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 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 120.4 L (31.8 gal). 7. Tag and disconnect lines. Close all open lines and fittings using caps and plugs.
1Pressure Release Button 2Hydraulic Oil Tank Cover
UN07MAR07 TX1020196A
02 0250 1
OUO6046,0002300 1916APR071/3
TM10091 (11JAN08)
02-0250-1

011108
PN=79
CAUTION: Heavy component; use appropriate lifting device. 8. Attach JDG909 Lifting Bracket to gearbox as shown.
Specification Travel Gearbox and Motor AssemblyApproximate Weight ..................................................... 325 kg 717 lb
02 0250 2
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.) 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
1Cap Screw (14 used)
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 ........................................................................... 140 Nm 103 lb-ft
16. Install sprocket. See Sprocket Remove and Install. (Group 0130.) 17. Connect track chain. See Track Chain Remove and Install. (Group 0130.)
OUO6046,0002300 1916APR072/3
TM10091 (11JAN08)
02-0250-2

011108
PN=80
T142702B

OUO6046,0002300 1916APR073/3
02 0250 3
TM10091 (11JAN08)
02-0250-3

011108
PN=81
Travel Gearbox Disassemble and Assemble
02 0250 4
OUO6046,0002301 1919APR071/7
TM10091 (11JAN08)
02-0250-4

011108
PN=82
TX1021556
UN03APR07

0Hydraulic Motor and Gearbox Assembly 1Hydraulic Motor 2Seal (2 used) 3Tapered Roller Bearing (2 used) 4Drum 5Chain Sprocket 6Cap Screw (16 used) 7Lock Washer (16 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 21Cap Screw (20 used) 23Second Planetary Pinion Carrier 24Washer 25Planetary Gear (3 used) 26Needle Bearing (3 used) 27Plate (6 used) 28Pin Fastener (3 used) 29Pin Fastener (3 used) 30Second Sun Gear 32First Planetary Pinion Carrier 33Spacer 34Planetary Gear (3 used) 35Needle Bearing (3 used) 36Plate (6 used) 37Spacer (3 used) 38Spring Pin (3 used) 39Shaft 41Cover 42Pin 43Cap Screw (16 used) 44Fitting Plug (3 used) O-Ring
1. Remove cap screws (43) and cover (41). 2. Remove shaft (39) and first planetary pinion carrier (32). 3. Remove second sun gear (30) and second planetary pinion carrier (23) from ring gear (20).
Specification Ring GearApproximate Weight ......................................................................................... 40 kg 88 lb
4. Install JT01748 Lifting Brackets to ring gear (20). Remove cap screws (21) and ring gear from drum (4).
Specification Third Planetary Pinion Carrier Approximate Weight ................................................................... 40 kg 88 lb
02 0250 5
5. Remove third sun gear (13) and third planetary pinion carrier (12).
OUO6046,0002301 1919APR072/7
TM10091 (11JAN08)
02-0250-5

011108
PN=83

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.)
02 0250 6
Specification DrumApproximate Weight .............................................................. 54 kg 120 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. 8. Remove spring pins, pins, thrust plates, needle bearings, and planetary gears. Clean and inspect parts, replace as necessary. Oil parts with gear oil prior to assembly. 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 Repair. (Group 0130.) 10. Replace parts as necessary. 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).
9Bearing Nut 47DFT1109 Holding Bar 48DF1036A Travel Gearbox Nut Wrench
OUO6046,0002301 1919APR073/7
TM10091 (11JAN08)
02-0250-6

011108
PN=84
TX1018574
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.
Specification Bearing ConeTemperature .................................................... 5070C 122158F
02 0250 7
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.
OUO6046,0002301 1919APR074/7
TM10091 (11JAN08)
02-0250-7

011108
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
OUO6046,0002301 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. 22. Install needle bearings (11) into planetary gears (13). 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. 23. Install thrust plates (15) and planetary gears (13) into third planetary pinion carrier (12). 24. Install pins (16).
9Bearing Nut 10Dowel Pin 12Third Planetary Pinion Carrier 39Travel Motor 46Hole
10
39
TX1004312
12
46
TX1004313
OUO6046,0002301 1919APR076/7
TM10091 (11JAN08)
02-0250-8

011108
PN=86
TX1004313
UN14MAR06
TX1004312
UN14MAR06

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. 29. Install ring gear (20) onto drum (4). 30. Install and tighten cap screws (21).
Specification Ring Gear-to-Drum Cap Screw Torque .......................................................................................... 270 Nm 199 lb-ft 16Pin 45Slit
45
UN14MAR06
TX1004310
16
TX1004310
011108
02 0250 9
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
OUO6046,0002301 1919APR077/7
TM10091 (11JAN08)
02-0250-9

PN=87
02 0250 10
TM10091 (11JAN08)
02-0250-10

011108
PN=88
Group 0260
Hydraulic System
02 0260 1
TM10091 (11JAN08)
02-0260-1

011108
PN=89
Hydraulic System
Travel Motor and Park Brake Remove and Install
02 0260 2
FS41334,0000172 1910APR071/7
TM10091 (11JAN08)
02-0260-2

011108
PN=90
TX1000629
UN28NOV05
Hydraulic System
0Travel Motor and Gearbox Assembly 1Travel Motor 2Seal (2 used) 3Tapered Roller Bearing (2 used) 4Drum 5Chain Sprocket 6Cap Screw (20 used) 7Lock Washer (20 used) 9Bearing Nut 10Pin Fastener 11Needle Bearing (6 used) 12Third Planetary Pinion Carrier 13Planetary Gear (3 used) 15Plate (6 used) 16Pin Fastener (6 used) 17Spring Pin (3 used) 18Third Sun Gear 20Ring Gear 21Cap Screw (28 used) 23Second Planetary Pinion Carrier 24Washer 25Planetary Gear (3 used) 26Needle Bearing (3 used) 27Plate (6 used) 28Pin Fastener (3 used) 29Pin Fastener (3 used) 30Second Sun Gear 32First Planetary Pinion Gear 33Spacer 34Planetary Gear (3 used) 35Needle Bearing (3 used) 36Plate (6 used) 37Spacer (3 used) 38Spring Pin (3 used) 39Shaft 41Cover 42Pin 43Cap Screw (12 used) 44Fitting Plug (3 used)
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.)
CAUTION: Heavy component; use an appropriate lifting device. 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.
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
02 0260 3
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 appropriate lifting device. 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
FS41334,0000172 1910APR072/7
TM10091 (11JAN08)
02-0260-3

011108
PN=91
Hydraulic System
8. Remove third stage planetary pinion carrier (12).
CAUTION: Heavy component; use an appropriate lifting device.

Specification Third Stage Planetary Pinion Carrier ApproximateWeight ..................................................... 40 kg 88 lb
02 0260 4
FS41334,0000172 1910APR073/7
TM10091 (11JAN08)
02-0260-4

011108
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
11. Remove metal face seal (2). See Metal Face Seals Repair. (Group 0130.) 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. 15. Replace parts as necessary.
9Bearing Nut 47DFT1109 Holding Bar 48DFT1036A Travel Gearbox Nut Wrench
FS41334,0000172 1910APR074/7
TM10091 (11JAN08)
02-0260-5

011108
PN=93
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.
UN14FEB07
10. Remove drum (4) from travel motor housing using JT01748 lifting brackets.
02 0260 5
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.
FS41334,0000172 1910APR075/7
TM10091 (11JAN08)
02-0260-6

011108
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.)
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.
FS41334,0000172 1910APR076/7
TM10091 (11JAN08)
02-0260-7

011108
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. 28. Apply PM37421 Thread Lock and Sealer (high strength) to cap screws (21). Tighten to specification.
Specification Ring Gear-to-Drum Cap Screw Torque .......................................................................................... 265 Nm 195 lb-ft
45
UN14MAR06
02 0260 8
TX1004310
16
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.)
FS41334,0000172 1910APR077/7
TM10091 (11JAN08)
02-0260-8

011108
PN=96
TX1004310
Hydraulic System
02 0260 9
TM10091 (11JAN08)
02-0260-9

011108
PN=97
Hydraulic System
Travel Motor and Park Brake Disassemble and Assemble
02 0260 10
FS41334,0000152 1908MAR071/3
TM10091 (11JAN08)
02-0260-10

011108
PN=98
TX1000643
UN01DEC05
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)

Specification Travel MotorApproximate Weight ......................................................................................... 91 kg 200 lb
PlateHeight .............................................................. 1.801.75 mm 0.0710.069 in.
IMPORTANT: Pistons must be installed into the same bores because of wear patterns. Mark location of pistons with respect to bores to aid in assembly. 7. Remove parts (21, 19, 17, 16, and 14). 8. Remove parts (7, 10, 8, and 1) through motor side of housing (0A). 9. Replace parts as necessary.
Specification Travel Motor HousingWeight .................................................. 50 kg 110 lb
02 0260 11
IMPORTANT: Use care when removing travel motor cover (32), valve plate is easily damaged. 1. Remove travel motor cover (32), and plate (39). 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. 3. Remove disc spring (29). Inspect part for wear or damage.
Specification Disc SpringHeight ....................................................... 7.06.9 mm 0.2760.272 in.
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.
4. Apply 100300 kPa (1443 psi) air pressure to brake release passage to remove brake piston (25). 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.
FS41334,0000152 1908MAR072/3
TM10091 (11JAN08)
02-0260-11

011108
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 14. Install needle bearing (33) into travel motor cover (32).
02 0260 12
16
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). 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
17Bushing 16Retainer
FS41334,0000152 1908MAR073/3
TM10091 (11JAN08)
02-0260-12

011108
PN=100
TX1004978
UN23MAR06
Hydraulic System
Counterbalance Valve Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure relief button (1). 1. Push pressure relief button (1). 2. 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 120.4 L (31.8 gal). 3. Disconnect battery ground (negative) cable. 4. Remove cover from track frame.
TX1020196A
UN07MAR07
02 0260 13
1Pressure Relief Button 2Hydraulic Oil Tank Cover
FS41334,0000151 1913APR071/3
TM10091 (11JAN08)
02-0260-13

011108
PN=101
Hydraulic System
NOTE: Valves may be removed with travel motor in machine. 5. Remove counterbalance valve plugs (5) from travel motor cover (1). 6. Remove spring (3) and spool (2) from travel motor using a magnet. 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
02 0260 14
12. Fill hydraulic oil tank. See Check Hydraulic Tank Oil Level. (Operators Manual.) 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. 13. Fill pump housing with oil. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 14. Connect battery ground (negative) cable. 15. Perform travel motor start-up procedure. See Travel Motor and Park Brake Start-Up Procedure. (Group 3360.) 16. Install cover to track frame and torque to specification.
1Travel Motor Cover 2Spool (2 used) 3Spring (2 used) 4O-Ring (2 used) 5Plug (2 used) 6Valve Spool
TX1020308
UN09MAR07
FS41334,0000151 1913APR072/3
TM10091 (11JAN08)
02-0260-14

011108
PN=102
TX1020307A
UN07MAR07
Hydraulic System
Specification Track Frame CoverTorque ......................................................... 50 Nm 37 lb-ft
FS41334,0000151 1913APR073/3
Crossover Relief Valve Remove and Install

02 0260 15
FS41334,0000159 1913APR071/4
NOTE: Valves may be removed with travel motor in machine. 5. Remove crossover relief valves (10) from travel motor cover (1). 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)
FS41334,0000159 1913APR072/4
TM10091 (11JAN08)
02-0260-15

011108
PN=103
TX1020327A
UN07MAR07
TX1020196A
UN07MAR07
Hydraulic System
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)
11O-Ring (2 used) 12Packing (2 used) 13Shim (2 used)
IMPORTANT: Disassembly of crossover relief valve will alter the set pressure. Adjust after repairs are made. 6. Disassemble crossover relief valves. 7. Repair or replace parts as needed. Apply a film of clean hydraulic oil to parts before assembly. 8. Assemble crossover relief valves.
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. 11. Fill pump housing with oil. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 12. Connect battery ground (negative) cable.
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 Oil Level. (Operators Manual.)
FS41334,0000159 1913APR073/4
TM10091 (11JAN08)
02-0260-16

011108
PN=104
TX1020309
UN09MAR07
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.)
FS41334,0000159 1913APR074/4
02 0260 17
Make-Up Check Valve Remove and Install

FS41334,0000158 1913APR071/2
TM10091 (11JAN08)
02-0260-17

011108
PN=105
TX1020196A
UN07MAR07
Hydraulic System
NOTE: Valves may be removed with travel motor in machine. 5. Remove relief valves (2) from travel motor cover (1). 6. Remove springs (3) and check valves (4) from travel motor using a magnet. 7. Repair or replace parts as needed. Apply a film of clean hydraulic oil to parts before assembly.
02 0260 18
UN07MAR07
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.
Specification Relief ValveTorque ................................................................... 450 Nm 332 lb-ft
10. Fill hydraulic oil tank. See Check Hydraulic Tank Oil Level. (Operators Manual.) 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. 11. Fill pump housing with oil. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 12. Connect battery ground (negative) cable. 13. Perform travel motor start-up procedure. See Travel Motor and Park Brake Start-Up Procedure. (Group 0260.) 14. Install cover to track frame.
1Travel Motor Cover 2Relief Valve (2 used) 3Spring (2 used) 4Check Valve (2 used)
FS41334,0000158 1913APR072/2
TM10091 (11JAN08)
02-0260-18

011108
PN=106
TX1020910A
UN23MAR07
TX1020327A
Hydraulic System
Travel Speed Change Valve Remove and Install

TX1020196A
UN07MAR07
02 0260 19
FS41334,0000157 1913APR071/2
TM10091 (11JAN08)
02-0260-19

011108
PN=107
Hydraulic System
NOTE: Valves may be removed with travel motor in machine. 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. 7. Repair or replace parts as needed. Apply a film of clean hydraulic oil to parts before assembly.
02 0260 20
UN19MAR07
8. Install valve spool (2) into cover with shoulder facing spring. 9. Install spring (3) and fitting plug (4). Tighten to specification.
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. 11. Fill pump housing with oil. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 12. Connect battery ground (negative) cable. 13. Perform travel motor start-up procedure. See Travel Motor and Park Brake Start-Up Procedure. (Group 0260.) 14. Install cover to track frame.
1Line 2Valve Spool 3Spring 4Fitting Plug
15. Perform travel speed solenoid valve test and adjust. Travel Speed Solenoid Valve Test and Adjustment. (Group 9025-25.)
FS41334,0000157 1913APR072/2
TM10091 (11JAN08)
02-0260-20

011108
PN=108
TX1020263A
10. Fill hydraulic oil tank. See Check Hydraulic Tank Oil Level. (Operators Manual.)
UN06MAR07
Specification Fitting PlugTorque ...................................................................... 35 Nm 26 lb-ft
TX1019101A
Hydraulic System
Travel Motor and Park Brake Start-Up Procedure

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. NOTE: Use a funnel with suitable diameter neck to allow air to escape while filling. 3. Connect drain line (1).
1Travel Motor Drain Line
TX1018694A
UN19MAR07
02 0260 21
FS41334,0000150 1908MAR071/1
TM10091 (11JAN08)
02-0260-21

011108
PN=109
Hydraulic System
02 0260 22
TM10091 (11JAN08)
02-0260-22

011108
PN=110
Section 04
Engine
Contents
Page
Group 0400Removal and Installation Engine Remove and Install . . . . . . . . . . . . . .04-0400-1
04
TM10091 (11JAN08)
04-1

011108
PN=1
Contents
04
TM10091 (11JAN08)
04-2

011108
PN=2
Group 0400
Removal and Installation

Engine Remove and Install
1. Disconnect battery ground (negative) cable.
TJ15698,0000181 1911APR071/18
CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to first stop to relieve pressure, then remove. 2. Drain coolant from radiator. Approximate capacity is 19 L (5 gal).
UN23AUG88
TJ15698,0000181 1911APR072/18
CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 3. Push pressure release button (1). 4. Pull a vacuum in hydraulic oil tank using a vacuum pump, or drain tank. Approximate oil capacity is 120.4 L (31.8 gal). See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) 5. Close fuel supply valve on bottom of fuel tank. 6. Remove engine cover, muffler cover, and control valve cover.
UN07MAR07
TJ15698,0000181 1911APR073/18
TM10091 (11JAN08)
04-0400-1

011108
PN=113
TX1020196A
TS281
04 0400 1

7. Remove coolant surge tank (3). See Coolant Surge Tank Remove and Install. (Group 0510.) 8. Remove upper intercooler tube (1), upper radiator hose (2), and lower radiator hose.
1Upper Intercooler Tube 2Upper Radiator Hose 3Coolant Surge Tank
UN29MAR07
04 0400 2
TJ15698,0000181 1911APR074/18
9. Remove cap screws (1) and set fuel filters (2 and 3) aside.
1Cap Screw (4 used) 2Final Fuel Filter 3Primary Fuel Filter
TJ15698,0000181 1911APR075/18
10. Remove water drain (3), cap screws (2), and muffler shield (1).
1Shield 2Cap Screws (6 used) 3Water Drain
TJ15698,0000181 1911APR076/18
TM10091 (11JAN08)
04-0400-2

011108
PN=114
TX1020874A
UN22MAR07
TX1020192A
UN05APR07
TX1021007A
CAUTION: Exhaust parts may be hot. Avoid burns by waiting until the parts are cool to the touch before working on them.
11. Disconnect exhaust pipe from turbocharger. 12. Support pump 1 and 2. Remove cap screws (2) and bracket (3) with muffler (1). Reinstall cap screws.
1Muffler 2Cap Screw (4 used) 3Bracket
04 0400 3
TJ15698,0000181 1911APR077/18
13. Remove air intake tube (5) and bracket (4). 14. Disconnect electrical connectors (2) and remove engine control unit (1). 15. Disconnect electrical connector and wires from alternator (7). 16. Disconnect fan drive pump supply hose (6) and line from pump and engine mount. 17. Close all open hoses and fittings using caps and plugs. 18. Remove cover (3).
1Engine Control Unit 2Electrical Connector (2 used) 3Cover 4Bracket 5Air Intake Tube 6Fan Drive Pump Supply Hose 7Alternator
TJ15698,0000181 1911APR078/18
TM10091 (11JAN08)
04-0400-3

011108
PN=115
TX1021000A
UN29MAR07

19. Disconnect connectors (1).
1Electrical Connector (2 used)
UN29MAR07
TJ15698,0000181 1911APR079/18
04 0400 4
NOTE: It is not necessary to discharge the air conditioning system. 20. Disconnect air conditioner compressor mounting bracket (1) from engine. Fasten compressor and bracket so it will not interfere with engine removal. 21. Disconnect fuel hoses (2) and close all open fittings and hoses using caps and plugs. 22. Remove lower intercooler tube (3).
1Compressor Mounting Bracket 2Fuel Hose (2 used) 3Lower Intercooler Tube
TJ15698,0000181 1911APR0710/18
23. Tag and disconnect fuel hoses (2). Close all open fittings and hoses using caps and plugs. 24. Disconnect wires from starter (1).
1Starter 2Fuel Hose (2 used)
UN29MAR07
TJ15698,0000181 1911APR0711/18
TM10091 (11JAN08)
04-0400-4

011108
PN=116
TX1021005A
TX1021001A
UN29MAR07
TX1021004A

25. Tag and disconnect heater hoses (2), hose (1), and oil filter hoses (3). 26. Close all open hoses and fittings using caps and plugs.
1Fan Drive Pump Outlet Hose 2Heater Hose (2 used) 3Engine Oil Filter Hose (2 used)
TJ15698,0000181 1911APR0712/18
27. Install JT05550 Lifting Eyebolt (1) and JDG19 Lifting Bracket (2) in housing of pump 1 and 2.
1Eyebolt (2 used) 2Lifting Bracket
TX1021006A
UN29MAR07
04 0400 5
UN02APR07
TJ15698,0000181 1911APR0713/18
CAUTION: Heavy component; use appropriate lifting device. 28. Install DFT1119 Pump Support (1) on machine as shown. See DFT1119 Pump Support. (Group 9900.)
Specification Pump 1 and 2Weight .................................................................. 190 kg 419 lb
29. Attach pump support to machine using C-clamps to prevent movement. 30. 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
UN29MAR07
TJ15698,0000181 1911APR0714/18
TM10091 (11JAN08)
04-0400-5

011108
PN=117
TX1021141A
TX1021205A

31. Install lifting eyes (2) and lifting sling (1).
Specification EngineApproximate Weight ........................................................ 491 kg 1083 lb
UN29MAR07
33. Remove cap screws securing pump 1 and 2 and drive gearbox to engine flywheel housing.
1Lifting Sling 2Lifting Eye (2 used)
04 0400 6
TJ15698,0000181 1911APR0715/18
TM10091 (11JAN08)
04-0400-6

011108
PN=118
TX1021109A

34. Remove cap screws (1) and nuts (2). 35. 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. 36. Repair or replace parts as necessary.
Specification EngineApproximate Weight ........................................................ 491 kg 1083 lb
Counterweight Side
37. Align hydraulic pump and drive gearbox to engine and install engine. Install cap screws (1), washers, and nuts (2). Tighten cap screws and nuts to specification.
Specification Engine Mount Cap Screw Torque .......................................................................................... 110 Nm 81 lb-ft Specification Engine Isolator NutTorque ........................................................ 400 Nm 295 lb-ft
UN29MAR07
TX1021106A
UN29MAR07
04 0400 7
Swing Gearbox Side
38. Install pump housing cap screws. Tighten cap screws to specification.
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. Connect engine oil filter hoses. 41. Connect heater hoses. 42. Connect hoses to fan drive pump. See Fan Drive Pump Remove and Install. (Group 3360.) 43. Connect fuel hoses to fuel transfer pump. 44. Install cover.
Bottom Side 1Cap Screw (14 used) 2Nut (4 used)
TJ15698,0000181 1911APR0716/18
TM10091 (11JAN08)
04-0400-7

011108
PN=119
TX1021108A
UN29MAR07
TX1021107A

45. Install engine control unit and connect harness connectors. 46. Connect starter and alternator wires. 47. Install air conditioning compressor and mounting bracket to engine. 48. Install compressor belt. Inspect and adjust compressor belt tension. See Check and Adjust A/C Belt. (Operators Manual.) 49. Connect fuel hoses to fuel injection pump. 50. Install muffler and bracket. Tighten muffler bracket cap screws to specification.
Specification Pump 1 and 2 Housing-to-Flywheel Housing Cap ScrewTorque ............................................................................... 65 Nm 48 lb-ft
04 0400 8
51. Remove lifting bracket, lifting eyebolt, and pump support from pump 1 and 2. 52. Install covers surrounding muffler. 53. Connect air intake tube. 54. Connect upper and lower radiator hoses. See Radiator Remove and Install. (Group 0510.) 55. Install intercooler tubes. See Intercooler Remove and Install. (Group 0510.) 56. Install fuel filters. 57. Install top covers over control valve and muffler. 58. Open fuel supply valve on bottom of fuel tank. 59. Fill engine with clean engine oil. See Diesel Engine Oil. (Operators Manual.) 60. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operators Manual.)
TJ15698,0000181 1911APR0717/18
TM10091 (11JAN08)
04-0400-8

011108
PN=120

61. Fill and check hydraulic oil level. Approximate oil capacity is 120.4 L (31.8 gal). IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 62. If hydraulic oil tank was drained, perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 63. Bleed fuel system. See Bleed Fuel System. (Operators Manual.)
04 0400 9
TJ15698,0000181 1911APR0718/18
TM10091 (11JAN08)
04-0400-9

011108
PN=121
04 0400 10
TM10091 (11JAN08)
04-0400-10

011108
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 . . . .05-0510-4 Intercooler Remove and Install . . . . . . . . . . .05-0510-6 Fuel Cooler Remove and Install . . . . . . . . .05-0510-11 Cooling Package Remove and Install . . . . .05-0510-11 Fan, Fan Guard, and Fan Shroud Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .05-0510-19 Coolant Surge Tank Remove and Install . . .05-0510-24
Group 0520Intake System Air Cleaner Remove and Install. . . . . . . . . . .05-0520-1
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
TM10091 (11JAN08)
05-1

011108
PN=1
Contents
05
TM10091 (11JAN08)
05-2

011108
PN=2
Group 0510
Cooling System
Radiator Remove and Install
1. Remove batteries. See Battery Remove and Install. (Group 9015-20).
LD30992,0000598 1918APR071/7
CAUTION: Prevent possible injury from hot spraying water. DO NOT remove surge tank cap unless engine is cool. Then remove cap slowly. 2. Remove surge tank filler cap to relieve pressure. 3. Open drain valve and drain coolant into suitable container.
Specification Cooling SystemCapacity ............................................................... 19.0 L 5.0 gal
UN23AUG88 TS281
4. Remove coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.) 5. Remove fan and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.)
05 0510 1
LD30992,0000598 1918APR072/7
NOTE: It is not necessary to discharge air conditioning system. 6. Disconnect wiring harness connector (3) from receiver-dryer. 7. Remove any clamps attaching air conditioning lines to frame or panels. IMPORTANT: Use caution when repositioning condenser to avoid damaging condenser fins. 8. Remove cap screws (1). Lay condenser (2) aside and secure in place.
1Cap Screw (4 used) 2Condenser 3Connector
LD30992,0000598 1918APR073/7
TM10091 (11JAN08)
05-0510-1

011108
PN=125
TX1020785A
UN23MAR07
Cooling System
9. Support fan drive motor assembly (2). Remove cap screws (1) and fan drive motor assembly (2).
1Cap Screw (4 used) 2Fan Drive Motor Assembly
LD30992,0000598 1918APR074/7
10. Loosen clamp and disconnect lower radiator hose (1). 11. Remove cap screw (2).
UN19MAR07
1Lower Radiator Hose 2Cap Screw
LD30992,0000598 1918APR075/7
TM10091 (11JAN08)
05-0510-2

011108
PN=126
TX1020802A
05 0510 2
TX1020784A
UN23MAR07
Cooling System
CAUTION: Heavy component; use a hoist.

Specification RadiatorWeight .............................................................................. 27 kg 60 lb
12. Attach suitable lifting device to radiator (1). 13. Remove cap screws (2), washers, and nuts attaching radiator to intercooler and hydraulic oil cooler. 14. Remove radiator. Repair or replace as necessary. 15. Ensure all foam seals are in place and install radiator. Tighten cap screws to specification.
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
1Radiator 2Cap Screw (16 used)
TX1020803A
UN19MAR07
05 0510 3
16. Connect lower radiator hose. 17. Install fan drive motor assembly. Tighten cap screws to specification.
Specification Fan Drive Motor Assembly Cap ScrewsTorque ............................................................................. 73 Nm 54 lb-ft
18. Install condenser assembly. 19. Connect wiring harness connector to receiver-dryer. 20. Install fan and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.) 21. Install coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.) 22. Install batteries. See Battery Remove and Install. (Group 9015-20).
LD30992,0000598 1918APR076/7
TM10091 (11JAN08)
05-0510-3

011108
PN=127
Cooling System
23. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operators Manual.)
LD30992,0000598 1918APR077/7
Hydraulic Oil Cooler Remove and Install

1. Remove radiator. See Radiator Remove and Install. (Group 0510.)
LD30992,0000599 1918APR071/6
2. Remove cap screw (1) from upper mounting bracket. IMPORTANT: Use caution when repositioning fuel cooler to avoid damaging fuel cooler fins.
05 0510 4
3. Remove cap screws (2). Lay fuel cooler (3) and mounting bracket aside and secure in place.
1Cap Screw 2Cap Screws 3Fuel Cooler
LD30992,0000599 1918APR072/6
4. Drain hydraulic oil tank. Approximate oil capacity is 120.4 L (31.8 gal). 5. Remove cap screws from cover (2) to gain further access to fitting on lower oil cooler hydraulic hose (1). 6. Disconnect lower oil cooler hydraulic hose (1). Apply caps and plugs to close all openings.
1Hydraulic Hose 2Cover
LD30992,0000599 1918APR073/6
TM10091 (11JAN08)
05-0510-4

011108
PN=128
TX1020827A
UN23MAR07
TX1020824A
UN23MAR07
Cooling System

Specification Hydraulic Oil CoolerWeight............................................................ 42 kg 92 lb
7. Attach suitable lifting device to hydraulic oil cooler. 8. Remove cap screws (1) and (2).
1Hydraulic Oil Cooler-to-Frame Lower Cap Screw 2Mounting Bracket-to-Frame Cap Screws
LD30992,0000599 1918APR074/6
TX1020826A
UN23MAR07
9. Move hydraulic oil cooler (1) toward rear of machine until hydraulic fitting in lower port clears access hole in side panel.
UN23MAR07
05 0510 5
10. Remove hydraulic oil cooler.

1Hydraulic Oil Cooler
LD30992,0000599 1918APR075/6
TM10091 (11JAN08)
05-0510-5

011108
PN=129
TX1020828A
Cooling System
11. Remove washers (3 and 6), nuts (5), cap screws (4), and mounting bracket (2) from hydraulic oil cooler (1). 12. Install mounting bracket onto new hydraulic oil cooler.
UN27MAR07
011108
13. Install hydraulic oil cooler. Tighten cap screw to specification.

Specification Hydraulic Oil Cooler-to-Frame Lower Cap ScrewTorque ............................................................ 55 Nm 41 lb-ft
14. Connect lower hydraulic hose. 15. Install fuel cooler and mounting bracket. 16. Install upper mounting bracket cap screw. 17. Install radiator. See Radiator Remove and Install. (Group 0510.)
05 0510 6
1Hydraulic Oil Cooler 2Mounting Bracket 3Washer (8 used) 4Cap Screw (8 used) 5Nut (8 used) 6Washer (8 used)
18. Fill and check hydraulic oil level. See 160DLC Drain and Refill Capacities. (Operators Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 19. Perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
LD30992,0000599 1918APR076/6
Intercooler Remove and Install

1. Remove batteries. See Battery Remove and Install. (Group 9015-20). 2. Remove coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.) 3. Remove fan and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.)
LD30992,000059A 1910APR071/9
TM10091 (11JAN08)
05-0510-6

PN=130
TX1021207
Cooling System
LD30992,000059A 1910APR072/9
TX1020785A
UN23MAR07
7. Remove cap screws (2) and condenser mounting bracket (1).

1Mounting Bracket 2Cap Screws
05 0510 7
LD30992,000059A 1910APR073/9
8. Remove cap screw (1) from upper mounting upper mounting bracket.
1Cap Screw
UN23MAR07
LD30992,000059A 1910APR074/9
TM10091 (11JAN08)
05-0510-7

011108
PN=131
TX1020787A
TX1020786A
UN23MAR07
Cooling System
LD30992,000059A 1910APR075/9
10. Remove cap screws (1) and (2) from bottom of intercooler. 11. Loosen clamps and disconnect lower intercooler tube (3).
05 0510 8
1Mounting Bracket-to-Frame Cap Screws 2Intercooler-to-Frame Lower Cap Screw 3Lower Intercooler Tube
LD30992,000059A 1910APR076/9

Specification IntercoolerWeight ........................................................................... 27 kg 60 lb
12. Attach suitable lifting device to intercooler (1). 13. Remove cap screws (2), washers, and nuts from each side of intercooler. 14. Remove intercooler.
1Intercooler 2Cap Screw (8 used)
LD30992,000059A 1910APR077/9
TM10091 (11JAN08)
05-0510-8

011108
PN=132
TX1020789A
UN23MAR07
TX1020788A
UN23MAR07
TX1020784A
UN23MAR07
Cooling System
15. Remove cap screws and mounting bracket (1) from intercooler (2). 16. Install mounting bracket onto new intercooler. Tighten cap screws to specification.
Specification Mounting Bracket-to-Intercooler Cap ScrewsTorque ..................................................................... 37 Nm 27 lb-ft
1Mounting Bracket 2Intercooler
LD30992,000059A 1910APR078/9
TX1020790A
UN23MAR07
05 0510 9
TM10091 (11JAN08)
05-0510-9

011108
PN=133
Cooling System
IMPORTANT: Ensure wiring harness (1) is secured behind foam and mounting bracket before fully lower intercooler.
UN23MAR07
17. 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 1Wiring Harness
18. Install upper mounting bracket cap screw. 19. Install fan drive motor assembly. Tighten cap screws to specification.
Specification Fan Drive Motor Assembly Cap ScrewsTorque ............................................................................. 73 Nm 54 lb-ft
05 0510 10
20. Install condenser assembly. 21. Connect wiring harness connector to receiver-dryer. 22. Install fan and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.) 23. Install coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.) 24. Install batteries. See Battery Remove and Install. (Group 9015-20).
LD30992,000059A 1910APR079/9
TM10091 (11JAN08)
05-0510-10

011108
PN=134
TX1020791A
Cooling System
Fuel Cooler Remove and Install

1. Tag and disconnect fuel hoses (1 and 4). 2. Remove cap screws (3) and fuel cooler (2). 3. Repair or replace as necessary. 4. Install cooler and connect hoses. 5. Install air filter assembly.
1Fuel Return Hose 2Fuel Cooler 3Cap Screws (4 used) 4Fuel Supply Hose
UN15FEB07
OUO1073,0002101 1913MAR071/1
TX1019245A
Cooling Package Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1).
05 0510 11
LD30992,000059C 1918APR071/16
TM10091 (11JAN08)
05-0510-11

011108
PN=135
TX1020196A
UN07MAR07
Cooling System
CAUTION: Prevent possible injury from hot spraying water. DO NOT remove surge tank cap unless engine is cool. Then remove cap slowly. 2. Remove surge tank filler cap to relieve pressure. 3. Open drain valve and drain coolant into suitable container.
Specification Cooling SystemCapacity ............................................................... 19.0 L 5.0 gal
UN23AUG88
4. Remove batteries. See Battery Remove and Install. (Group 9015-20). 5. Remove coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.) 6. Remove access panels on bottom of machine.
05 0510 12
LD30992,000059C 1918APR072/16
7. Raise engine hood. 8. Remove retaining pin and disconnect hood support rod (1).
Specification Engine HoodWeight ....................................................................... 36 kg 80 lb
UN03APR07
9. Attach appropriate lifting device to hood. 10. Remove cap screws (2) and hood (3).
1Hood Support Rod 2Cap Screws 3Hood
LD30992,000059C 1918APR073/16
TM10091 (11JAN08)
05-0510-12

011108
PN=136
TX1021549A
UN03APR07
TX1021548A
TS281
Cooling System
11. Loosen clamps and disconnect upper intercooler tube (1) and upper radiator hose (2). 12. Drain hydraulic oil tank. Approximate oil capacity is 120.4 L (31.8 gal). 13. Disconnect hydraulic hoses (3 and 4) to hydraulic oil cooler. Apply caps and plugs to close all openings. 14. Remove covers (5 and 6).
1Intercooler Tube 2Radiator Hose 3Hydraulic Hose 4Hydraulic Hose 5Cover 6Cover
LD30992,000059C 1918APR074/16
TX1021073A
UN02APR07
05 0510 13
LD30992,000059C 1918APR075/16
18. Remove cap screws (2) and condenser mounting bracket (1).
1Mounting Bracket 2Cap Screws
LD30992,000059C 1918APR076/16
TM10091 (11JAN08)
05-0510-13

011108
PN=137
TX1020786A
UN23MAR07
TX1020785A
UN23MAR07
Cooling System
19. Remove cap screw (1) from upper mounting bracket.
1Cap Screw
UN23MAR07
LD30992,000059C 1918APR077/16
20. Remove cap screw (1) from upper mounting bracket. IMPORTANT: Use caution when repositioning fuel cooler to avoid damaging fuel cooler fins.
05 0510 14
21. Remove cap screws (2). Lay fuel cooler (3) and mounting bracket aside and secure in place.
1Cap Screw 2Cap Screws 3Fuel Cooler
LD30992,000059C 1918APR078/16
TM10091 (11JAN08)
05-0510-14

011108
PN=138
TX1021622A
UN05APR07
TX1020787A
Cooling System
22. Remove cap screws attaching air filter assembly (1) to panel (3). Secure air filter to side panel behind rear of cab.
UN02APR07
23. Disconnect wiring harness connectors from fan drive control valve (2). NOTE: Hydraulic hoses do not need to be disconnected from fan control valve. 24. Remove cap screws attaching fan control valve (2) to panel (3). Lay fan control valve on floor panel. 25. Disconnect hose from cold weather starting aid (4). 26. Disconnect wiring harness connector from cold weather starting aid. 27. Remove any clamps attaching wiring harness to panel (3). 28. Remove mounting cap screws from panel. Lift panel (3) and remove.
1Air Filter Assembly 2Fan Drive Control Valve 3Panel 4Cold Weather Starting Aid
TX1021074A
05 0510 15
LD30992,000059C 1918APR079/16
29. Remove cap screws (1) and disconnect lower oil cooler hydraulic hose (2). Apply caps and plugs to close all openings.
UN02APR07
1Cap Screw (4 used) 2Hydraulic Hose
LD30992,000059C 1918APR0710/16
30. Remove cap screws (1) and cover.

1Cap Screws
UN07MAR07
LD30992,000059C 1918APR0711/16
TM10091 (11JAN08)
05-0510-15

011108
PN=139
TX1020211A
TX1021075A
Cooling System
31. Disconnect fan drive motor hydraulic hose (1) from hydraulic oil tank. Apply caps and plugs to close all openings.
UN22MAR07
32. Remove cap screw (2) and hose clamp. 33. Route hydraulic hose back through opening in side of fan shroud.
1Hydraulic Hose (to Fan Drive Motor) 2Cap Screw
LD30992,000059C 1918APR0712/16
34. Tag and disconnect hydraulic hoses (1 and 2). Apply caps and plugs to close all openings. 35. Route hoses through opening in side of fan shroud.
1Hydraulic Hose 2Hydraulic Hose
UN22MAR07
LD30992,000059C 1918APR0713/16
TM10091 (11JAN08)
05-0510-16

011108
PN=140
TX1020690A
TX1020688A
05 0510 16
UN22MAR07
TX1020687A
Cooling System

Specification Cooling PackageApproximate Weight.............................................................................................. 126 kg 278 lb
36. Attach suitable lifting device to cooling package (1).

1Cooling Package
LD30992,000059C 1918APR0714/16
TX1021077A
IMPORTANT: Do not use lifting eyes on individual cooling package components (intercooler, radiator, and hydraulic oil cooler) to lift entire cooling package.
UN02APR07
05 0510 17
TM10091 (11JAN08)
05-0510-17

011108
PN=141
Cooling System
37. Disconnect lower intercooler tube (2) and lower radiator hose (6). 38. Remove cap screws (35) from cooling package components. 39. Remove cap screws (1) and cooling package. 40. Replace components as necessary. 41. Install cooling package. Tighten cap screws (35) to specification.
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 1Cap Screws 2Intercooler Tube 3Cap Screw 4Cap Screw 5Cap Screw 6Radiator Hose
05 0510 18
42. Connect upper and lower intercooler tubes. 43. Connect upper and lower radiator hoses. 44. Connect upper and lower hydraulic oil cooler hoses. 45. Install panel, air filter assembly, fan drive control valve, and cold weather starting aid. 46. Route and connect fan drive motor hydraulic hoses. 47. Connect wiring harness connectors to cold weather starting aid. 48. Connect cold weather starting aid hose. 49. Connect wiring harness connectors to fan drive control valve. 50. Install air conditioning condenser and fuel cooler. 51. Connect wiring harness connector to receiver-dryer. 52. Install cooling package upper mounting bracket cap screws.
LD30992,000059C 1918APR0715/16
TM10091 (11JAN08)
05-0510-18

011108
PN=142
TX1021076A
UN02APR07
Cooling System
53. Install covers. 54. Install hood. 55. Install batteries. See Battery Remove and Install. (Group 9015-20). 56. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operators Manual.) 57. Fill and check hydraulic oil level. See 160DLC Drain and Refill Capacities. (Operators Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 58. Perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
05 0510 19
LD30992,000059C 1918APR0716/16
Fan, Fan Guard, and Fan Shroud Remove and Install

Remove and Install Fan and Fan Guard 1. Remove coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.)
OUO1073,0002103 1910APR071/9
2. Remove cap screws (1) and fan guard (2).

1Cap Screw (4 used) 2Fan Guard
UN22MAR07
OUO1073,0002103 1910APR072/9
TM10091 (11JAN08)
05-0510-19

011108
PN=143
TX1020695A
Cooling System
3. Loosen clamps and remove upper radiator hose. 4. Remove cap screws (2), washers, and fan (1).
UN27MAR07
5. Install fan, washers, and cap screws. Tighten cap screws to specification.
Specification Fan Cap ScrewsTorque .............................................................. 37 Nm 27 lb-ft
6. Install upper radiator hose. 7. Install fan guard and cap screws. Tighten cap screws to specification.
Specification Fan Guard Cap ScrewsTorque .................................................. 37 Nm 27 lb-ft 1Fan 2Cap Screw (6 used)
8. Install coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.)
05 0510 20
Remove and Install Fan Shroud
OUO1073,0002103 1910APR073/9
1. Push pressure release button (1).

OUO1073,0002103 1910APR074/9
TM10091 (11JAN08)
05-0510-20

011108
PN=144
TX1020196A
UN07MAR07
CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button (1).
TX1021215A
Cooling System
2. Raise engine hood. 3. Remove retaining pin and disconnect hood support rod (1).
Specification Engine HoodWeight ....................................................................... 36 kg 80 lb
UN03APR07 UN03APR07 TX1021548A
4. Attach appropriate lifting device to hood. 5. Remove cap screws (2) and hood (3). 6. Remove fan and fan guard. 7. Remove access covers on bottom of machine. 8. Pull a vacuum in hydraulic oil tank using a vacuum pump. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)
1Hood Support Rod 2Cap Screws 3Hood
OUO1073,0002103 1910APR075/9
9. Remove cap screws (1) and cover.

1Cap Screws
UN07MAR07
OUO1073,0002103 1910APR076/9
TM10091 (11JAN08)
05-0510-21

011108
PN=145
TX1020211A
TX1021549A
05 0510 21
Cooling System
10. Disconnect fan drive motor hydraulic hose (1) from hydraulic oil tank. Apply caps and plugs to close all openings.
UN22MAR07
11. Remove cap screw (2) and hose clamp. 12. Route hydraulic hose back through opening in side of fan shroud.
1Hydraulic Hose (to Fan Drive Motor) 2Cap Screw
OUO1073,0002103 1910APR077/9
13. Tag and disconnect fan drive motor hydraulic hoses (1 and 2). Apply caps and plugs to close all openings. 14. Route hoses through opening in side of fan shroud.
1Hydraulic Hose 2Hydraulic Hose
UN22MAR07
OUO1073,0002103 1910APR078/9
TM10091 (11JAN08)
05-0510-22

011108
PN=146
TX1020690A
TX1020688A
05 0510 22
UN22MAR07
TX1020687A
Cooling System
15. Loosen clamps and remove upper intercooler tube (6). 16. Disconnect hydraulic oil cooler hoses (3 and 4). Apply caps and plugs to close all openings. NOTE: Lower shroud cap screws can be accessed by removing access panel on bottom of upperstructure.
UN27MAR07
17. Remove cap screws (1) and washers from fan shroud (2). IMPORTANT: To prevent damage to fan shroud, use an additional technician to help guide shroud past fan drive motor shaft (5) from below. 18. Lift fan shroud up, tilt toward left-hand side of machine, and remove. 19. Install fan shroud, washers, and cap screws. Tighten cap screws to specification.
Specification Fan Shroud Cap ScrewsTorque ................................................. 37 Nm 27 lb-ft
1Cap Screw (8 used) 2Fan Shroud 3Hydraulic Hose 4Hydraulic Hose 5Fan Drive Motor Shaft 6Upper Intercooler Tube
TX1020691A
05 0510 23
20. Connect hydraulic oil cooler hoses. 21. Install upper intercooler cooler tube. 22. Route hydraulic hoses back through opening in fan shroud and connect. 23. Install access covers. 24. Install fan and fan guard. 25. Install upper radiator hose. 26. Install hood. 27. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operators Manual.) 28. Check hydraulic oil level. Fill as necessary. See 160DLC Drain and Refill Capacities. (Operators Manual.)
OUO1073,0002103 1910APR079/9
TM10091 (11JAN08)
05-0510-23

011108
PN=147
Cooling System
Coolant Surge Tank Remove and Install

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.
UN23AUG88
OUO1073,0002102 1918APR071/2
2. Drain coolant until level is below surge tank. 3. Loosen hose clamps and disconnect hoses (1, 2, and 3). 4. Remove cap screws (4) from coolant surge tank (5). Reposition coolant surge tank to access lower hose 05 (5). 5. Loosen hose clamp and disconnect lower hose (6). 6. Remove coolant surge tank. Replace as necessary. 7. Install coolant surge tank and cap screws. 8. Connect hoses and tighten clamps. 9. Fill cooling system. See Cooling System Fill and Deaeration Procedure. (Operators Manual.)
1Hose (to Engine) 2Hose 3Hose (to Radiator) 4Cap Screw (4 used) 5Hose 6Coolant Surge Tank
UN22MAR07
OUO1073,0002102 1918APR072/2
TM10091 (11JAN08)
05-0510-24

011108
PN=148
TX1020677A
0510 24
TS281
Group 0520
Intake System
Air Cleaner Remove and Install
05 0520 1
1Cap Screw (4 used) 2Washer (4 used) 3Brackets 4Air Filter Restriction Switch 5Intake Tube 6Mounting Bracket 7Hose Clamp
8Hose 9Hose Clamp 10Mounting Bracket 11Washer (3 used) 12Cap Screw (3 used) 13Cap Screw (4 used) 14Washer (4 used)
15Intake Air Temperature Sensor 16Hose Clamp 17Hose 18Hose Clamp 19Cap Screw 20Screen
21Nut 22Air Cleaner Dust Valve 23Air Filter Housing 24Safety Element 25Primary Air Cleaner Element
LD30992,00005A0 1904APR071/1
TM10091 (11JAN08)
05-0520-1

011108
PN=149
TX1021229
UN04APR07
Intake System
05 0520 2
TM10091 (11JAN08)
05-0520-2

011108
PN=150
Group 0560
External Fuel Supply System

Fuel Tank Remove and Install
1. Drain fuel from tank. Approximate capacity is 320 L (85 gal). NOTE: Two cap screws for panel (1) are located in toolbox (4).
CAUTION: Heavy component; use a hoist. 2. Disconnect and remove wiring harness from inside of toolbox. 3. Remove step (2), cover (1), handrail (3), and toolbox (4).
Specification ToolboxWeight ............................................................................... 33 kg 72 lb
UN07MAR07
1Cover 2Step 3Handrail 4Toolbox
TX1020209A
05 0560 1
TJ15698,000012F 1911APR071/4
4. Remove cap screws (1) and bracket (2). 5. Remove control valve cover.
UN07MAR07
1Cap Screw (3 used) 2Panel Latch Bracket
TJ15698,000012F 1911APR072/4
TM10091 (11JAN08)
05-0560-1

011108
PN=151
TX1020212A

6. Disconnect electrical connector (4) and return hose (2). 7. Disconnect fuel supply hose from bottom of tank.
UN07MAR07
CAUTION: Heavy component; use a hoist. 8. Remove cap screws (1) and fuel tank.
Specification Fuel TankWeight .................................... 97 kg approximate without fuel 214 lb approximate without fuel
9. Repair or replace as necessary. 10. Install fuel tank and tighten mounting cap screws to specification.
UN07MAR07
Specification Fuel Tank Mounting Cap ScrewsTorque ........................................................................... 270 Nm 199 lb-ft
12. Install control valve cover and side panel latch bracket.
1Cap Screws (4 used) 2Fuel Return Hose 3Clamp 4Electrical Connector
TJ15698,000012F 1911APR073/4
TM10091 (11JAN08)
05-0560-2

011108
PN=152
TX1020197A
05 0560 2
11. Connect fuel supply hose, return hose, and electrical connector.
TX1020200A

13. Install handrail (3), toolbox (4), cover (1), and step (2). 14. Fill tank with fuel. 15. Bleed fuel system. See Bleed Fuel System. (Operators Manual.)
05 0560 3
TJ15698,000012F 1911APR074/4
Primary Fuel Filter (Water Separator) Remove and Install

1. Loosen drain valve on bottom of filter and drain fuel into a container. 2. Disconnect electrical connector from bottom of filter. 3. Tag and disconnect fuel hoses (2). 4. Remove cap screws (1) and primary fuel filter assembly. 5. Install primary 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) 2Fuel Hose
TJ15698,000012D 1911APR071/1
TM10091 (11JAN08)
05-0560-3

011108
PN=153
TX1020198A
UN07MAR07
Final Fuel Filter Remove and Install

1. Loosen drain valve on bottom of filter and drain fuel into a container. 2. Disconnect electrical connector (3). 3. Tag and disconnect fuel hoses (2). 4. Remove cap screws (1) and final fuel filter assembly. 5. Install final fuel filter assembly and tighten cap screws. 6. Connect fuel hoses and electrical connector. 7. Bleed fuel system. See Bleed Fuel System. (Operators Manual.)
1Cap Screw (2 used) 2Fuel Hose 3Electrical Connector
UN07MAR07
TJ15698,000012E 1911APR071/1
05 0560 4
TM10091 (11JAN08)
05-0560-4

011108
PN=154
TX1020210A
Section 07
Dampener Drive (Flex Coupling)

Contents
Page
Group 0752Elements Dampener Drive (Flex Coupling) Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1
07
TM10091 (11JAN08)
07-1

011108
PN=1
Contents
07
TM10091 (11JAN08)
07-2

011108
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. 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. 5. Install each insert so index hole is aligned with guide pin, installed in previous step.
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)
TX1019969
07 0752 1
FS41334,0000145 1910APR071/3
6. Apply PM37418 Thread Lock and Sealer (Medium Strength) to cap screws (3). Tighten to specification.
Specification Flex Coupling-to-Flywheel Cap ScrewTorque ............................................................................. 137 Nm 101 lb-ft
1Engine Flywheel 2Insert (4 used) 3Cap Screw (4 used) 4Flex Coupling
FS41334,0000145 1910APR072/3
TM10091 (11JAN08)
07-0752-1

011108
PN=157
TX1019893A
7. Install flex coupling (4) onto flywheel inserts (2) as shown.
UN19MAR07
Elements
8. Clean face of hydraulic pump housing (1). 9. Apply PM37418 Thread Lock and Sealer (Medium Strength) to threads of cap screws (4). 10. Install inserts (2) onto hub (5) using cap screws (4) and tighten to specification.
Specification Pump Insert Cap Screws Torque .......................................................................................... 137 Nm 101 lb-ft
UN19MAR07
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.). 12. Apply PM37418 Thread Lock and Sealer (Medium 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
1Hydraulic Pump Housing 2Insert (4 used) 3Set Screw (2 used) 4Cap Screw (4 used) 5Hub 6Pump Shaft
14. Install engine or hydraulic pump. See Engine Remove and Install. (Group 0400.) or See Pump 1 and 2 Remove and Install. (Group 3360.)
FS41334,0000145 1910APR073/3
TM10091 (11JAN08)
07-0752-2

011108
PN=158
TX1019891A
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
TM10091 (11JAN08)
17-1

011108
PN=1
Contents
17
TM10091 (11JAN08)
17-2

011108
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.
OUO1073,0002105 1909APR071/4
1. Disconnect battery ground and positive cables. 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.)
1Electrical Connectors 2Main Controller (MCF)
UN07FEB06 TX1003378A
OUO1073,0002105 1909APR072/4
17 1740 1
4. Disconnect electrical connectors (1) from ICF (2). See Cab Harness (W1) Component Location. (9015-10.)
1Electrical Connector (2 used) 2Information Controller (ICF)
OUO1073,0002105 1909APR073/4
TM10091 (11JAN08)
17-1740-1

011108
PN=161
TX1003380A
UN01MAR06
Frame Installation
NOTE: Engine Control Unit (ECU) is located in the engine compartment. 6. Disconnect electrical connectors (2) from engine control unit (ECU) (1). See Engine Interface Harness (W5) Component Location. (9015-10.)
1Engine Control Unit (ECU) 2Electrical Connectors
OUO1073,0002105 1909APR074/4
17 1740 2
TM10091 (11JAN08)
17-1740-2

011108
PN=162
TX1021721A
UN10APR07
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. 2. Use one of the following weld processes: AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process. AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.
Welding Repair of Major StructureSpecification Weld MetalTensile Strength ....................... 482.6 mPa (70,000 psi) Yield Strength ................................................ 413.7 mPa (60,000 psi) Elongation ..................................................................................... 22%
IMPORTANT: Area to be repaired must be preheated to allow better weld penetration. 3. To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38C (100F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177C (350F). To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural assemblies to a minimum of 38C (100F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177C (350F).
Welding Repair of Major StructureSpecification Structural AssembliesPreheat Temperature ................................................................... 38C (100F) Ground Engaging Tools Preheat Temperature.................................................... 177C (350F)
17 1740 3
OUO1073,0002106 1928MAR071/1
TM10091 (11JAN08)
17-1740-3

011108
PN=163
Frame Installation
17 1740 4
TM10091 (11JAN08)
17-1740-4

011108
PN=164
Group 1749
Chassis Weights
Counterweight Remove and Install
1. Park machine on level ground. 2. Remove two plastic caps (1) from top of counterweight.
CAUTION: Heavy component; use appropriate 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.
Specification CounterweightWeight ................................................................. 3310 kg 7299 lb
UN20JUL01 UN20JUL01 T143044 UN03SEP02 T143043
3. Connect counterweight to an appropriate lifting device (2) using a spreader bar (3). 4. Remove cap screws and washers (4). 5. Remove counterweight. 6. Repair or replace as necessary. 7. Install counterweight onto machine using appropriate lifting device. 8. Install cap screws and washers (4). Tighten to specification.
Specification Frame-to-Counterweight Cap ScrewTorque ........................................................................... 1150 Nm 830 lb-ft
17 1749 1
1Plastic Cap (2 used) 2Lifting Device 3Spreader Bar 4Cap Screw and Washer (4 used)
TJ15698,0000144 1929MAR071/1
TM10091 (11JAN08)
17-1749-1

011108
PN=165
T143045
Chassis Weights
17 1749 2
TM10091 (11JAN08)
17-1749-2

011108
PN=166
Section 18
Operators Station
Contents
Page
Group 1800Removal and Installation 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
18
TM10091 (11JAN08)
18-1

011108
PN=1
Contents
18
TM10091 (11JAN08)
18-2

011108
PN=2
Group 1800

Cab Remove and Install
1. Disconnect battery ground (-) cable.
OUO1073,0002100 1903APR071/17
2. Remove door (1).

1Door
UN16MAR07
OUO1073,0002100 1903APR072/17
3. Remove cover (1).

1Cover
UN16MAR07
OUO1073,0002100 1903APR073/17
4. Loosen hose clamp (1).

1Hose Clamp
UN16MAR07
TX1020458A
TX1020462A
18 1800 1
OUO1073,0002100 1903APR074/17
TM10091 (11JAN08)
18-1800-1

011108
PN=169
TX1020459A

5. Disconnect hose (3) from windshield washer reservoir (2). 6. Disconnect wiring harness from windshield washer reservoir (2). 7. Lift windshield washer reservoir (2) off of mounting bracket and remove. 8. Remove cap screws attaching diagnostic connector (4) to air filter assembly mounting bracket. Lay connector aside. 9. Remove cap screws (5) and air filter assembly (1). Close air tube openings.
1Air Filter Assembly 2Windshield Washer Reservoir 3Hose 4Diagnostic Connector 5Cap Screw (4 used)
OUO1073,0002100 1903APR075/17
NOTE: Lower mounting hardware for panel (1) can be accessed by removing access panels on bottom of machine.
UN16MAR07
10. Remove panels (1 and 2) to access rear of cab.

1Panel 2Panel
OUO1073,0002100 1903APR076/17
11. Disconnect cab wiring harness connectors (14).

18 1800 2
12. Disconnect ground wires (5) from frame. 13. Remove seat. See Seat Remove and Install. (Group 1821.) 14. Remove cab floor mat.
1Connector 2Connector 3Connector 4Connector 5Ground
OUO1073,0002100 1903APR077/17
TM10091 (11JAN08)
18-1800-2

011108
PN=170
TX1020388A
UN19MAR07
TX1020461A
TX1020460A
UN16MAR07

15. Remove cap screws (2) and bracket (1) from cab frame (3) and seat mount (4).
1Bracket 2Cap Screw (3 used) 3Cab Frame 4Seat Mount
OUO1073,0002100 1903APR078/17
16. Remove cover (1) from rear panel. 17. Remove screws (2) and cap screws (3) from rear panel (4). 18. Pull rear panel forward. Disconnect wiring harness from lighter and power outlet and remove panel.
1Cover 2Screws 3Cap Screws 4Panel
UN08MAR07
OUO1073,0002100 1903APR079/17
19. Remove screws (1), panel (2), and air duct (3).
1Screw 2Panel 3Air Duct
TX1020272A
TX1020391
UN16MAR07
18 1800 3
UN08MAR07
OUO1073,0002100 1903APR0710/17
TM10091 (11JAN08)
18-1800-3

011108
PN=171
TX1020347A

20. Remove cap screws (2), mounting bracket, and fresh air inlet duct (1).
1Inlet Duct 2Cap Screw
OUO1073,0002100 1903APR0711/17
21. Remove cap screw (1) behind 12 volt power converter. 22. Remove cap screw (3), cap screws (5) and bracket (4). 23. Disconnect cab wiring harness (2) from left and right consoles and air conditioning module. See Cab Harness (W1) Component Location . (Group 9015-10). 24. Remove any clamps or tie bands securing cab harness to floor or consoles.
1Cap Screw 2Cab Wiring Harness 3Cap Screw 4Bracket 5Cap Screws
18 1800 4
OUO1073,0002100 1903APR0712/17
25. Remove monitor controller (1). See Monitor Controller Remove and Install. (Group 9015-20.) 26. Remove cup holder (2) and panel (3).
1Monitor Controller 2Cup Holder 3Panel
UN27MAR07
OUO1073,0002100 1903APR0713/17
TM10091 (11JAN08)
18-1800-4

011108
PN=172
TX1021236A
TX1020394A
UN19MAR07
TX1020387A
UN19MAR07
TX1020275A
UN08MAR07

27. Remove access covers from bottom of cab. 28. Remove anchor bolts (1), spacers, and washers.
UN19MAR07
29. Remove cap screw and disconnect ground (1) from frame.
1Ground Wire 2Anchor Bolt
Rear Anchor Bolt
Front Anchor Bolt

OUO1073,0002100 1903APR0714/17
30. 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.
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
3
4
7
5
4
UN19MAR07
011108
6
3
4
5
6
TX1020390A
UN19MAR07
TX1020389A
OUO1073,0002100 1903APR0715/17
TM10091 (11JAN08)
18-1800-5

PN=173
TX1020393
18 1800 5

Specification CabWeight ................................................................................... 380 kg 838 lb
IMPORTANT: Before lifting cab, ensure all wiring harness connectors and ducts have been disconnected.
1Lifting Brackets
32. Remove cab. 33. Repair or replace parts as necessary. IMPORTANT: Ensure all wiring harnesses and other components are out of the way before installing cab. 34. 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 6
35. Install access covers on bottom of cab. Tighten cap screws to specification.
Specification Cab Access Cover Cap Screws Torque ............................................................................................ 50 Nm 37 lb-ft
OUO1073,0002100 1903APR0716/17
TM10091 (11JAN08)
18-1800-6

011108
PN=174
TX1003209A
31. Use lifting straps and connect appropriate lifting device to lifting brackets (1) on roof of cab.
UN14MAR06

36. Connect cab wiring harness connectors. See Cab Harness (W1) Component Location . (Group 9015-10). 37. Connect ducts to heater and air conditioning module. 38. Install monitor controller. See Monitor Controller Remove and Install. (Group 9015-20.) 39. Install seat. See Seat Remove and Install. (Group 1821.) 40. Install panels behind cab. 41. Install air filter assembly. 42. Install windshield washer reservoir and connect hose. 43. Install diagnostic connector to air filter assembly mounting bracket. 44. Install door.
OUO1073,0002100 1903APR0717/17
18 1800 7
TM10091 (11JAN08)
18-1800-7

011108
PN=175
18 1800 8
TM10091 (11JAN08)
18-1800-8

011108
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. 5. Apply PM37391 Instant Gel Adhesive to cab flange. 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
UN30APR01
RO33873,0000A5E 1903APR071/1
T140968
18 1810 1
TM10091 (11JAN08)
18-1810-1

011108
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
TM10091 (11JAN08)
18-1810-2

011108
PN=178
Operator Enclosure
Windowpanes Dimensions
18 1810 3
Cab Door Glass

OUO1073,0002108 1917APR071/5
TM10091 (11JAN08)
18-1810-3

011108
PN=179
TX1021276
UN04APR07
Operator Enclosure
18 1810 4
Cab Right-Hand Glass
OUO1073,0002108 1917APR072/5
TM10091 (11JAN08)
18-1810-4

011108
PN=180
TX1018573
UN23FEB07
Operator Enclosure
18 1810 5
Cab Rear and Left-Hand Rear Glass
OUO1073,0002108 1917APR073/5
TM10091 (11JAN08)
18-1810-5

011108
PN=181
TX1021275
UN04APR07
Operator Enclosure
18 1810 6
Cab Front Glass
OUO1073,0002108 1917APR074/5
TM10091 (11JAN08)
18-1810-6

011108
PN=182
TX1018570
UN23FEB07
Operator Enclosure
1Black Ceramic Coating Range 2Black Ceramic Coating Surface
NOTE: Dimensions shown are in millimeters.

OUO1073,0002108 1917APR075/5
18 1810 7
TM10091 (11JAN08)
18-1810-7

011108
PN=183
Operator Enclosure
18 1810 8
TM10091 (11JAN08)
18-1810-8

011108
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. 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.
Specification SeatWeight.................................................................................... 40 kg 90 lb
6. Remove seat through front window using lifting strap and hoist. 7. Repair or replace parts as necessary. 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
TX1020304A
UN08MAR07
TX1020303A
18 1821 1
OUO1073,00020FF 1917APR071/1
TM10091 (11JAN08)
18-1821-1

011108
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. 2. Remove cap screw (4) and upper seat belt (3) from each side of seat. 3. Repair or replace parts as necessary. 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.
Specification Lower Seat Belt Mount Cap ScrewsTorque ............................................................................. 50 Nm 37 lb-ft
UN09FEB07
1Lower Seat Belt 2Cap Screw 3Upper Seat Belt 4Cap Screw
OUO1073,00020E8 1910APR071/1
18 1821 2
TM10091 (11JAN08)
18-1821-2

011108
PN=186
T188988B
UN26MAR03
TX1018443A
Seat and Seat Belt
Mechanical Suspension Seat Disassemble and Assemble
UN21FEB06
18 1821 3
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
TM10091 (11JAN08)
18-1821-3

011108
PN=187
TX1004008
Seat and Seat Belt
Air Suspension Seat Disassemble and Assemble
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
TM10091 (11JAN08)
18-1821-4

011108
PN=188
TX1004009
UN21FEB06
Seat and Seat Belt
Left and Right Console Covers Remove and Install

1. Remove pilot control shutoff lever (1). 2. Remove cap screws (2) from pilot control boot.
1Pilot Control Shutoff Lever 2Cap Screws and Washers (8 used)
UN08FEB07
LD30992,00004F1 1928MAR071/3
TX1018700A
18 1821 5
TM10091 (11JAN08)
18-1821-5

011108
PN=189
Seat and Seat Belt
18 1821 6
LD30992,00004F1 1928MAR072/3
TM10091 (11JAN08)
18-1821-6

011108
PN=190
TX1000801
UN15DEC05
Seat and Seat Belt

0Cover 4Screw (4 used) 5Cap Screw, Washer, and Lock Washer 7Cover 8Cap Screw, Washer, and Lock Washer (2 used) 9Cap Screw, Washer, and Lock Washer 11Cover 12Cap Screw, Washer, and Lock Washer 15Cover 16Screw (4 used) 18Cover 19Cap Screw, Washer, and Lock Washer (3 used) 22Cover 23Cap Screw, Washer, and Lock Washer (2 used) 24Cap Screw, Washer, and Lock Washer 26Cover 27Cap Screw, Washer, and Lock Washer (4 used) 28Cap (2 used) 30Label 31Label
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)
4. Repair or replace parts as necessary. 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
TM10091 (11JAN08)
18-1821-7

011108
PN=191
Seat and Seat Belt
18 1821 8
TM10091 (11JAN08)
18-1821-8

011108
PN=192
Group 1830
Heating and Air Conditioning

Refrigerant Cautions and Proper Handling
CAUTION: DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment. DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials. DO NOT heat refrigerant over 52C (125F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment. IMPORTANT: To meet government standards relating to the use of refrigerants,
18 1830 1
R134a is used in the air conditioning system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere. However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the appropriate recovery stations. Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings, components or refrigerant oils. Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling and charging station equipment. Care must be taken to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of system. JT02167A refrigerant test instrument should be used before any testing or repair to system is preformed.
TX,9031,DY5073 1921JUL061/2
TM10091 (11JAN08)
18-1830-1

011108
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
TM10091 (11JAN08)
18-1830-2

011108
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.) NOTE: Flushing can be performed on machine. 1. Recover refrigerant from system. See Recover R134a Refrigerant. (Group 1830.) Add flushing solvent to system with JT02075 Flusher and JT02098 Flusher Fitting Kit. 2. Remove and discard receiver/dryer. 3. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. 4. Fill flusher tank with solvent and fasten all connections. Dispose of solvent properly.
Specification Flusher TankCapacity ................................................................. 4 L 1 gal
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.
Specification Flushing Solvent in Suction PortVolume........................................................................... 240 mL 8 fl oz Flushing Solvent in Discharge PortVolume........................................................................... 120 mL 4 fl oz
d. Turn compressor end for end and roll it side to side. e. Remove both plugs from manifold ports and drain solvent from compressor. f. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders. g. Invert compressor. Roll end for end and side to side. Drain thoroughly. h. Repeat previous two steps at least three times. 8. Divide system into two circuits:
18 1830 3
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
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. 7. Clean compressor as follows:
Condenser circuit, including inlet and outlet hoses. Evaporator circuit, including inlet and outlet hoses. 9. Condenser:
OUO1073,00020F4 1910APR071/3
TM10091 (11JAN08)
18-1830-3

011108
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: b. Remove and discard receiver/dryer. c. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. d. Fill flusher tank with solvent and fasten all connections.
Put nozzle in container to collect flushing solvent. 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. 10. See flush evaporator, if evaporator requires flushing. 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.
NOTE: Air pressure must be at least to 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. Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve. f. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. g. Attach return hose and aerator nozzle to end of receiver/dryer inlet hose using JT03197 Adapter.
18 1830 4
OUO1073,00020F4 1910APR072/3
TM10091 (11JAN08)
18-1830-4

011108
PN=196

NOTE: Air pressure must be at least to 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.
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.
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. NOTE: Purging evaporator circuit takes 1215 minutes to thoroughly remove solvent.
OUO1073,00020F4 1910APR073/3
18 1830 5
TM10091 (11JAN08)
18-1830-5

011108
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. New compressor from parts depot Used compressor removed from operation Compressor internally washed with flushing solvent
18 1830 6
Specification OilVolume ............................................................................. 180 mL 6.09 fl oz R134aWeight................................................................... 950 50 g 2.09 0.1 lb
If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl oz per ft ) to determine correct amount of oil to be added. Drain compressor oil into graduated container while rotating compressor shaft and record amount. If oil drained from 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 and Install. (Group 1830.) Install required amount of TY22025 Refrigerant Oil in compressor. 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.
OUO1073,00020F5 1904APR071/1
TM10091 (11JAN08)
18-1830-6

011108
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.
CAUTION: Do not remove high pressure relief valve (D). Air conditioning station will discharge rapidly causing possible injury. IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Follow procedures. See Refrigerant Cautions and Proper Handling. (Group 1830.) 2. Close both high-side and low-side valves on refrigerant recovery/recycling and charging station (E). 3. Remove cap from low-side charge port. 4. Connect blue hose (C) from refrigerant recovery/recycling and charging station (E) to low-side test port. 5. Remove cap (A) from charge port on high pressure hose and connect red hose (B). 6. Follow the manufacturers instructions when using refrigerant recovery/recycling and charging station.
AHigh Pressure Hose Charge Port Cap BRed Hose CBlue Hose DHigh Pressure Relief Valve ERefrigerant Recovery/Recycling and Charging Station
T8118AG
UN06DEC93
18 1830 7
OUO1073,00020F6 1905MAR071/1
TM10091 (11JAN08)
18-1830-7

011108
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
OUO1073,00020F7 1905MAR071/1
TM10091 (11JAN08)
18-1830-8

011108
PN=200
Evacuate R134a System

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (Group 1830.) Do not remove high pressure relief valve. Air conditioning system will discharge rapidly causing possible injury. 1. Connect refrigerant recovery system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (Group 1830.) 2. Open low-side and high-side valves on refrigerant recovery/recycling and charging station. 3. Follow manufacturers instructions and evacuate system. NOTE: Vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
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
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
If above specification vacuum cannot be obtained in 15 minutes, test the system for leaks. See Refrigerant Leak Test. (Group 9031-25.) 5. When vacuum reaches above specification, close low-side and high-side valves. Turn vacuum pump off. 6. If vacuum decreases more than specification in 5 minutes, there is a leak in system.
Specification Evacuate SystemVacuum .................................................... 3.4 kPa 34 mbar 1 in. Hg
7. Repair leak. 8. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 9. Close low-side and high-side valves. Stop evacuation. 10. Charge system. See Charge R134a System. (Group 1830.)
18 1830 9
OUO1073,00020F8 1905MAR071/1
TM10091 (11JAN08)
18-1830-9

011108
PN=201
Charge R134a System

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (Group 1830.) IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Identify refrigerant type using JT02167A Refrigerant Identification Instrument. 2. Connect R134a Refrigerant Recovery/Recycling and Charging Station. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (Group 1830.) 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 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.
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
4. Follow manufacturers instructions and charge system. 5. Add refrigerant to system.

Specification Air Conditioning System RefrigerantRefrigerant Quantity...................................................................................... .95 kg 2.09 lb
6. Check air conditioning for proper function. See Diagnose Air Conditioning System Malfunctions. (Group 9031-15.)
18 1830 10
OUO1073,00020F9 1927MAR071/1
TM10091 (11JAN08)
18-1830-10

011108
PN=202
Compressor Remove and Install

1. Recover refrigerant from system. See See Recover R134a Refrigerant. (Group 1830.) 2. Remove compressor drive belt (7). 3. Disconnect wiring harness connector (4). 4. Remove cap screws (1) and disconnect low pressure line (2) and high pressure line (3). Close all open lines and fittings using caps and plugs. 5. Remove cap screws (5) and compressor (6). 6. Install compressor. Tighten cap screws to specification.
Specification Air Conditioning Compressor Cap ScrewTorque ............................................................................... 30 Nm 22 lb-ft 1Cap Screws 2Low Pressure Line 3High Pressure Line 4Connector 5Cap Screw (4 used) 6Compressor 7Belt
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
OUO1073,00020FA 1903APR071/1
Condenser Remove and Install

1. Recover refrigerant from system. See Recover R134a Refrigerant. (Group 1830.)
OUO1073,00020FB 1927MAR071/2
TM10091 (11JAN08)
18-1830-11

011108
PN=203

2. Disconnect electrical connector (3). 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. 5. Remove cap screw and disconnect high pressure gas input line (4) from condenser (1). 6. Remove cap screws (9) and condenser (1). 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 3Electrical Connector 4High Pressure Gas Input Line 5High Pressure Gas Output Line 6Receiver-Dryer 7Cap Screw 8Bracket 9Cap Screws (4 used)
10. Install receiver-dryer. 11. Connect high-pressure output line and high pressure input line cap screw to receiver-dryer. Tighten cap screws to specification.
Specification Receiver-Dryer Input and Output Line Cap ScrewsTorque ............................................................... 5 Nm 44 lb-in.
12. Install air filter assembly.

18 1830 12
13. Evacuate and charge system. See Evacuate R134a System and See Charge R134a System. (Group 1830.)
OUO1073,00020FB 1927MAR072/2
TM10091 (11JAN08)
18-1830-12

011108
PN=204
TX1020174A
UN07MAR07
Heater and Air Conditioner Remove and Install

1. Recover refrigerant from system. See Recover R134a Refrigerant. (Group 1830.) 2. Remove seat. See Seat Remove and Install. (Group 1821.)
OUO1073,00020FE 1913APR071/8
3. Remove cover (1) from rear panel. 4. Remove screws (2) and cap screws (3) from rear panel (4). 5. Pull rear panel forward. Disconnect wiring harness from lighter and power outlet and remove panel.
1Cover 2Screws 3Cap Screws 4Panel
UN08MAR07
OUO1073,00020FE 1913APR072/8
6. Remove screws and air duct (1). 7. Remove screws and bracket (2). 8. Remove monitor warning alarm (3) from mounting bracket (4). 9. Remove screws and mounting bracket (4). 10. Remove cover (5).
1Air Duct 2Bracket 3Monitor Warning Alarm 4Mounting Bracket 5Cover
UN08MAR07
TX1020272A
18 1830 13
OUO1073,00020FE 1913APR073/8
TM10091 (11JAN08)
18-1830-13

011108
PN=205
TX1020273A

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. 13. Remove clamps and hold-downs attaching cab wiring harness (8) to panel (7). 14. Remove cap screws (1 and 5). 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.) 16. Lift cab wiring harness (8). Slide out panel (7) and remove.
1Cap Screws 2Relay Block 312 Volt Power Converter 4Cap Screw 5Cap Screws 6Information Controller (ICF) 7Panel 8Cab Wiring Harness
OUO1073,00020FE 1913APR074/8
17. Remove cap screws (2) and fresh air inlet duct (1).
18 1830 14
1Inlet Duct 2Cap Screw
UN08MAR07
OUO1073,00020FE 1913APR075/8
TM10091 (11JAN08)
18-1830-14

011108
PN=206
TX1020275A
TX1020274A
UN08MAR07

18. Remove screws (1), panel (2), and air duct (3). 19. Remove cap screws and mounting bracket (4).
UN08MAR07
1Screw 2Panel 3Air Duct 4Mounting Bracket
OUO1073,00020FE 1913APR076/8
TX1020276A
18 1830 15
TM10091 (11JAN08)
18-1830-15

011108
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). 23. Remove screws (7) and air duct (5). 24. Remove cap screws (6). Separate air conditioner (1) from air duct (2) and remove. 25. Repair or replace parts as necessary. 26. Install air conditioner and cap screws. 27. Connect wiring harness. 28. Connect air ducts. 29. Connect engine coolant hoses and refrigerant lines. 30. Install mounting bracket, rear panel, and air duct. 31. Install fresh air inlet duct. 32. Install rear panel and cap screws. 33. Connect cab wiring harness. See Cab Harness (W1) Component Location . (Group 9015-10.) 34. Attach wiring harness to panel using clamps and hold-downs. 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.) 38. Evacuate and charge system. See Evacuate R134a System and See Charge R134a System. (Group 1830.)
1Air Conditioner 2Air Duct 3Engine Coolant Hoses 4Air Conditioner Refrigerant Lines 5Air Duct 6Cap Screw (6 used) 7Screws
UN08MAR07
18 1830 16
OUO1073,00020FE 1913APR077/8
TM10091 (11JAN08)
18-1830-16

011108
PN=208
TX1020277A

39. Check engine coolant level. Add coolant as necessary. See Cooling System Fill and Deaeration Procedure. (Operators Manual.)
OUO1073,00020FE 1913APR078/8
Receiver-Dryer Remove and Install

1. Recover refrigerant from system. See Recover R134a Refrigerant. (Group 1830.) 2. Disconnect electrical connector (1). 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. 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 1Electrical Connector 2High Pressure Liquid Input Line 3Cap Screws 4High Pressure Liquid Output Line 5Cap Screw 6Receiver-Dryer
7. Connect electrical connector. 8. Evacuate and charge system. See Evacuate R134a System and See Charge R134a System. (Group 1830.)
18 1830 17
OUO1073,00020FC 1905MAR071/1
TM10091 (11JAN08)
18-1830-17

011108
PN=209
18 1830 18
TM10091 (11JAN08)
18-1830-18

011108
PN=210
Section 33
Excavator
Contents
Page 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 . . . . . . . . . . . . . . . .33-3340-3 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
Group 3360Hydraulic System 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 Pilot Pressure Regulating Valve and Filter 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. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-44 Solenoid Valve Remove and InstallPower Dig (SG), Travel Speed (SI), Boom Mode (SC), and Boom Flow Rate (SF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-46
TM10091 (11JAN08)
Pilot Valve (Left and Right) Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-47 Pilot Valve (Left and Right) Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-50 Travel Pilot Valve Remove and Install . . . . .33-3360-52 Travel Pilot Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-54 Pilot Signal Manifold Remove and Install. . .33-3360-56 Pilot Signal Manifold Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-58 Control Valve Remove and Install . . . . . . . .33-3360-61 Control Valve (5-Spool) Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63 Control Valve (4-Spool) Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-71 Hydraulic Oil Tank Remove and Install . . . .33-3360-76 Hydraulic Oil Tank Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-80 Restriction Valve Remove and Install . . . . .33-3360-81 Hydraulic Oil Cooler Bypass Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .33-3360-83 Boom Cylinder Remove and Install . . . . . . .33-3360-85 Boom Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-89 Arm Cylinder Remove and Install . . . . . . . .33-3360-91 Arm Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-96 Bucket Cylinder Remove and Install . . . . . .33-3360-99 Bucket Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . 33-3360-103 Hydraulic Cylinder Bleed Procedure . . . . . 33-3360-106
33
33-1

011108
PN=1
Contents
33
TM10091 (11JAN08)
33-2

011108
PN=2
Group 3302
Buckets
Bucket Remove and Install
6
3
3
5
4
7
3
1
8
1
2
3
T142450
1Bushing (2 used) 2Seal (2 used)
3O-Ring (4 used) 4Ring (2 used)
5Pin (2 used) 6Pin
7Pin 8Bucket

Specification BucketWeight ................................................. 1018 kg approximate 2245 lb approximate
3. Remove bucket. 4. Repair or replace parts as necessary. 5. Align pin bores and install pins (6 and 7). 6. Adjust bucket to arm joint. See Adjusting Bucket to Arm Joint. (Operators Manual.)
1. Position bucket (8) on level surface. 2. Remove parts (4, 5, 6, and 7).
T142450
UN24JUL01
33 3302 1
TJ15698,0000128 1911APR071/1
TM10091 (11JAN08)
33-3302-1

011108
PN=213
Buckets
Bucket Pin-Up Data
4
3
10
15
16
11
9 8 7 17 Section A
14 13 12
TX1003797
Section B
TJ15698,0000183 1929MAR071/2
33 3302 2
TM10091 (11JAN08)
33-3302-2

011108
PN=214
TX1003797
UN07MAR06
Buckets
IMPORTANT: If the front attachment of a previous model machine is used, use the grease intervals for previous model machine.
Item
1
2
370 mm 14.6 in.

10 mm 0.4 in.
540 mm 21.2 in.
520 mm 20.4 in.
400 mm 15.7 in.
1430 mm 56.3 in.
433 mm 17 in.
326 mm 12.8 in.
80 mm 3.2 in.
10
400 mm 15.7 in.
11
31 mm 1.2 in.
12
433 mm 17 in.
13
307 mm 12.1 in.
14
80 mm 3.1 in.
15
16
17
449 mm 17.7 in.
33 3302 3
TJ15698,0000183 1929MAR072/2
TM10091 (11JAN08)
33-3302-3

011108
PN=215
Buckets
33 3302 4
TM10091 (11JAN08)
33-3302-4

011108
PN=216
Group 3340
Frames
Bucket Links Remove and Install
1Nut (4 used) 2Cap Screw (2 used) 3Thrust Plate (2 used) 4Dust Seal (2 used) 5Bushing (2 used)
6Thrust Plate (4 used) 7Bucket Cylinder Rod End-to-Side and Center Links Pin 8Wood Block
9Center Link (2 used) 10Right Side Link 11Left Side Link 12Side Links-to-Arm Pin 13Bucket-to-Center Links Pin
14O-Ring (2 used) 15Pin 16Ring
NOTE: Removal of bucket is not necessary for removal of bucket links. 1. Connect hoist to center links (9) using lifting strap. Put wood block (8) between bucket cylinder and arm to hold cylinder up when cylinder pin (7) is removed. 2. Remove parts (15).
As cylinder pin (7) is removed, lower links (10 and 11) to ground. 3. Remove ring (16) and pin (15). 4. Remove pins (12 and 13) and remove side and center links.
33 3340 1
TJ15698,0000129 1913APR071/2
TM10091 (11JAN08)
33-3340-1

011108
PN=217
TX1020202
UN04APR07
Frames
1Dust Seal (6 used) 2Bushing (4 used)
3Center Link 4Lubrication Fitting (2 used)
5Dust Seal (2 used) 6Bushing (2 used)
7Spacer
5. Inspect bushings (2 and 6) and dust seals (1 and 5). See Inspect Pins, Bushings and BossesFront Attachment. (Group 3340.) 6. Replace parts as necessary. 7. Before installing pins, align pin bores to prevent damage to dust seal when pins are installed.
8. Tighten nuts against each other allowing cap screws to be free to turn in hole. 9. Apply multi-purpose grease to all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease. (Operators Manual.)
33 3340 2
TJ15698,0000129 1913APR072/2
TM10091 (11JAN08)
33-3340-2

011108
PN=218
TX1020201
UN07MAR07
Frames
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.
TJ15698,000012A 1911APR071/7

TJ15698,000012A 1911APR072/7
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 5. Loosen bucket cylinder hydraulic hoses to release any residual pressure. 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.)
UN23AUG88
TX1020196A
UN07MAR07
33 3340 3
TJ15698,000012A 1911APR073/7
TM10091 (11JAN08)
33-3340-3

011108
PN=219
X9811
Frames
CAUTION: Heavy component; use appropriate lifting device. Weight of boom, arm and bucket assembly and components will vary depending on machine configuration.
Specification Boom, Arm and Bucket AssemblyApproximate Weight ................................................... 2900 kg 6395 lb Bucket CylinderWeight................................................................. 120 kg 265 lb Arm CylinderWeight ..................................................................... 205 kg 452 lb
8. Attach appropriate lifting device to arm.
Arm With Bucket Cylinder
TJ15698,000012A 1911APR074/7
9. Put wooden block between arm cylinder (5) and boom to hold cylinder up when cylinder pin (2) is removed. 10. Remove nuts (1), cap screw (3) and pin (2).
1Nut (2 used) 2Pin 3Cap Screw 4Arm 5Arm Cylinder
UN19APR06
TJ15698,000012A 1911APR075/7
TM10091 (11JAN08)
33-3340-4

011108
PN=220
TX1003794A
33 3340 4
T6626JC
UN31OCT88
Frames
11. Tag and disconnect hydraulic hoses (3). Close all open lines and fittings using caps and plugs. 12. Remove cap screw (1) and boom-to-arm pin (2). 13. Remove arm and lower to floor. 14. Inspect bushings and dust seals. See Inspect Pins, Bushings and 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
UN15MAR06
TJ15698,000012A 1911APR076/7
TX1003793A
33 3340 5
TM10091 (11JAN08)
33-3340-5

011108
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.)
1Nut (2 used) 2Stopper 3Cap Screw 4Thrust Plate (2 used) 5Thrust Plate 6Cylinder Pin 7Cap Screw 8Washer 9Plate 10Block 11Pin 12Thrust Plate (2 used) 13Thrust Plate
13
12
12
10
7
TJ15698,000012A 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.
TJ15698,000012C 1911APR071/10
TM10091 (11JAN08)
33-3340-6

011108
PN=222
T142653
UN24JUL01
11
T142652
UN27SEP01
Frames

TJ15698,000012C 1911APR072/10
CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 5. Slowly loosen hydraulic hoses (1) to relieve any residual pressure; then disconnect hoses. Close all open lines and fittings using caps and plugs. 6. Remove arm cylinder only if necessary to repair boom. See Arm Cylinder Remove and Install. (Group 3360.)
1Hydraulic Hoses (4 used)
UN23AUG88 TX1003795A UN09MAR06 X9811
TX1020196A
UN07MAR07
33 3340 7
TJ15698,000012C 1911APR073/10
TM10091 (11JAN08)
33-3340-7

011108
PN=223
Frames

Specification Boom CylinderWeight .................................................................. 155 kg 342 lb
FBoom Cylinder (2 used)
TJ15698,000012C 1911APR074/10
8. Disconnect lubrication hoses (2), nuts, cap screws (1), and retainers (3).
1Cap Screw (2 used) 2Lubrication Hoses (2 used) 3Retainer (2 used)
TJ15698,000012C 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.
1Nut (4 used) 2Retainer (2 used) 3Cap Screw (2 used) 4Boom Cylinder Rod End-to-Boom Pin 5Thrust Plate (4 used) 6Boom Cylinder (2 used)
UN24JUL01
33 3340 8
TJ15698,000012C 1911APR076/10
TM10091 (11JAN08)
33-3340-8

011108
PN=224
T142979
TX1003796A
UN17FEB06
T105828
UN30DEC96
7. Attach appropriate lifting device to boom cylinder (F) using lifting strap.
Frames
CAUTION: Heavy component; use appropriate lifting device. Weight of boom, arm, and bucket assembly and components will vary depending on machine configuration.
Specification Boom, Arm and Bucket AssemblyApproximate Weight ................................................... 2900 kg 6395 lb Bucket CylinderWeight................................................................. 120 kg 265 lb Arm CylinderWeight ..................................................................... 205 kg 452 lb
11. Attach appropriate lifting device to boom. Use protective covering to prevent damage to pin if chain is used. IMPORTANT: Arm end of boom is heavy end with arm cylinder installed. Frame end is heavy end when arm cylinder is removed.
TJ15698,000012C 1911APR077/10
CAUTION: Heavy component; use a hoist. NOTE: Two cap screws for cover (1) are located in toolbox (4). 12. Remove step (2), cover (1), and toolbox (4).
Specification ToolboxWeight ............................................................................... 33 kg 72 lb
UN07MAR07
Disconnect and remove wiring harness from inside of toolbox.

T6626JW
UN31OCT88
TJ15698,000012C 1911APR078/10
TM10091 (11JAN08)
33-3340-9

011108
PN=225
TX1020209A
33 3340 9
Frames
13. Remove cap screw (1), washer, and spacer (2). 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. 16. Remove boom. 17. Inspect bushings and dust seals. See Inspect Pins, Bushings and BossesFront Attachment. (Group 3340.) 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 1Cap Screw 2Spacer 3Boom-to-Frame Pin
UN19APR06
21. Install toolbox, cover, and step.
TJ15698,000012C 1911APR079/10
33 3340 10
TM10091 (11JAN08)
33-3340-10

011108
PN=226
TX1003791A
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. 23. Install retainers (3) and cap screws (1). 24. Tighten nuts against each other allowing cap screw (1) to be free to turn in hole.
Specification Boom Cylinder Rod End-to-Boom Pin Retainer NutTorque ..................... 550 Nm (tighten nut against nut) 405 lb-ft (tighten nut against nut)
UN17FEB06
25. Connect lubrication hoses (2). 26. Connect hydraulic hoses. See Hydraulic System Line Connections. (Group 9025-15.) 27. Apply multi-purpose grease to all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operators Manual.)
1Cap Screw (2 used) 2Lubrication Lines (2 used) 3Retainer (2 used)
TJ15698,000012C 1911APR0710/10
Inspect Pins, Bushings and BossesFront Attachment

1
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
6
3
7
8
10
UN06MAR06 TX1004442
11
TX1004442
TX1003796A
33 3340 11
TJ15698,0000184 1929MAR071/3
TM10091 (11JAN08)
33-3340-11

011108
PN=227
Frames
Pins, Bushings, and Bosses
Item
1 Pin
Boss (Main Frame)
Standard
80 mm 3.15 in.
80 mm 3.15 in.
Allowable Limit
79.0 mm 3.11 in.
81.5 mm 3.21 in.
Remedy
Replace
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
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
80 mm 3.15 in.
79.0 mm 3.11 in.
Replace
Bushing (Boom Cylinder)
80 mm 3.15 in.
81.5 mm 3.21 in.
Replace
Boss (Boom)
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)
80 mm 3.15 in.
81.5 mm 3.21 in.
Replace
Pin
71 mm 2.80 in.
70.0 mm 2.77 in.
Replace
Boss (Arm)
71 mm 2.80 in.
72.5 mm 2.85 in.
Replace
Bushing (Arm Cylinder)
71 mm 2.80 in.
72.5 mm 2.85 in.
Replace
Pin
71 mm 2.80 in.
70.0 mm 2.77 in.
Replace
Boss (Boom)
71 mm 2.80 in.
72.5 mm 2.85 in.
Replace
Bushing (Arm Cylinder)
71 mm 2.80 in.
72.5 mm 2.85 in.
Replace
Pin
65 mm 2.56 in.
64.0 mm 2.52 in.
Replace
Boss (Arm)
65 mm 2.56 in.
66.5 mm 2.62 in.
Replace
Bushing (Bucket Cylinder)

33 3340 12
65 mm 2.56 in.
66.5 mm 2.62 in.
Replace
Pin
71 mm 2.80 in.
70.0 mm 2.77 in.
Replace
TJ15698,0000184 1929MAR072/3
TM10091 (11JAN08)
33-3340-12

011108
PN=228
Frames
Pins, Bushings, and Bosses
Item
Boss (Link B)
Bushing (Link A)
Bushing (Bucket Cylinder)
9 Pin
Standard
71 mm 2.80 in.
71 mm 2.80 in.
71 mm 2.80 in.
71 mm 2.80 in.
Allowable Limit
72.5 mm 2.85 in.
72.5 mm 2.85 in.
72.5 mm 2.85 in.
70.0 mm 2.76 in.
Remedy
Replace
Replace
Replace
Replace
Boss (Arm)
71 mm 2.80 in.
72.5 mm 2.85 in.
Replace
Bushing (Arm)
71 mm 2.80 in.
72.5 mm 2.85 in.
Replace
10
Pin
80 mm 3.15 in.
79.0 mm 3.11 in.
Replace
Boss (Bucket)
80 mm 3.15 in.
79.0 mm 3.11 in.
Replace
Bushing (Link A)
80 mm 3.15 in.
81.5 mm 3.21 in.
Replace
11
Pin
80 mm 3.15 in.
79.0 mm 3.11 in.
Replace
Boss (Arm)
80 mm 3.15 in.
79.0 mm 3.11 in.
Replace
Bushing (Arm)
80 mm 3.15 in.
81.5 mm 3.21 in.
Replace
TJ15698,0000184 1929MAR073/3
33 3340 13
TM10091 (11JAN08)
33-3340-13

011108
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. 3. Install bushing to a depth equal to thickness of dust seal (H).
UN01NOV88
4. Install dust seals with lip toward outside of component.

AHydraulic Ram B1PipeMinimum ID to Clear Bushing OD B2PipeMaximum OD B3PipeLength of Bushing CBushing DDisks EBushing Stop (Disk) FPilot (Disk) GRam Stop (Disk) HThickness of Dust Seal
TJ15698,000012B 1905MAR071/1
33 3340 14
TM10091 (11JAN08)
33-3340-14

011108
PN=230
T6641CW
UN31OCT88
T95237
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.
FS41334,000014E 1905MAR071/3

FS41334,000014E 1905MAR072/3
TX1020196A
UN07MAR07
33 3360 1
TM10091 (11JAN08)
33-3360-1

011108
PN=231
Hydraulic System
2. Use 5 mm hex wrench to remove cap screws (3) and cover. 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.
3Cap Screws (4 used)
FS41334,000014E 1905MAR073/3
33 3360 2
TM10091 (11JAN08)
33-3360-2

011108
PN=232
TX1003329A
UN06FEB06
TX1000587A
UN17NOV05
Hydraulic System
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

SPECIFICATIONS
Hydraulic Oil Tank Capacity
Hydraulic Oil Tank Filtering Time
120 L approximate 31.8 gal approximate

11 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.
Hydraulic System Capacity
220 L approximate 58 gal approximate
5. Start the engine and run it at fast idle. IMPORTANT: For the most effective results, cleaning procedure must start with the smallest capacity circuit then proceed to the next larger capacity circuit. 6. Starting with the smallest capacity circuit, operate each function through a complete cycle. Repeat procedure until the total system capacity has circulated through filter caddy seven times. Each function must go through a minimum of three complete cycles for a thorough cleaning of oil.
Specification Hydraulic SystemCapacity ................................. 220 L approximate 58 gal approximate Hydraulic SystemFiltering Time ............................................................... 35 minutes approximate
Hydraulic System Filtering Time
35 minutes approximate
SERVICE EQUIPMENT AND TOOLS
JDG1724A Super Caddy
JT05679 Hose 3.7 m (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2 used)
JTO5751A Suction Wand
JTO5750A Discharge Wand
1. Install new return filter elements. NOTE: For a failure that creates a lot of debris, remove access cover from hydraulic tank. Drain hydraulic tank. Connect filter 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.
Specification Hydraulic Oil TankCapacity................................ 120 L approximate 31.8 gal approximate Hydraulic Oil TankFiltering Time ............................................................... 11 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.)
33 3360 3
FS41334,000014D 1910APR071/1
TM10091 (11JAN08)
33-3360-3

011108
PN=233
Hydraulic System
Pump 1 and 2 Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Drain hydraulic oil tank. Approximate capacity is 120.4 L (31.8 gal). 3. Drain pump drive gearbox. Approximate oil capacity is 0.9 L (1.0 qt). 4. Remove hydraulic compartment cover and muffler cover.
FS41334,000014C 1913APR071/13
5. Remove cap screws (1) and set fuel filters (2 and 3) aside. Protect against damage to hoses and filters.
1Cap Screws (4 used) 2Final Fuel Filter 3Primary Fuel Filter
FS41334,000014C 1913APR072/13
33 3360 4
6. Remove cap screws (2) and set engine oil filter assembly (1) aside. Protect against damage to hoses and filter.
UN19MAR07
1Oil Filter Assembly 2Cap Screw (2 used)
FS41334,000014C 1913APR073/13
TM10091 (11JAN08)
33-3360-4

011108
PN=234
TX1020366A
TX1020192A
UN05APR07
TX1020196A
UN07MAR07
Hydraulic System
7. Remove cap screws (2), water drain (3), and muffler shield (1).
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.
1Shield 2Cap Screws (6 used) 3Water Drain
FS41334,000014C 1913APR074/13
9. Loosen clamp (1) and move onto muffler tube (2).

1Clamp 2Tube 3Muffler
FS41334,000014C 1913APR075/13
10. Remove nuts (2) and U-bolts from muffler support (3). 11. Remove muffler (1).
UN23MAR07
12. Disconnect electrical connectors. 13. Disconnect lines.

1Muffler 2U-Bolt Nut (8 used) 3Support
TX1020749A
UN19MAR07
TX1020874A
UN22MAR07
FS41334,000014C 1913APR076/13
TM10091 (11JAN08)
33-3360-5

011108
PN=235
TX1020923A
33 3360 5
Hydraulic System

Specification Hydraulic Pump and Drive GearboxApproximate Weight ....................................................... 168 kg 370 lb
1Lift Point (3 used)
FS41334,000014C 1913APR077/13
33 3360 6
TM10091 (11JAN08)
33-3360-6

011108
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.
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. 18. Repair or replace as necessary. IMPORTANT: Align flex coupler on drive gearbox with mating part on engine flywheel. 19. Align damper drive and install pump assembly to flywheel housing. 20. Install muffler support (3), hose bracket (2), and pump assembly with cap screws (1). Tighten to specification.
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.) 22. Connect electrical connectors. See Pump Harness (W8) Component Location. (Group 9015-10.) 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
1Hydraulic Pump Drive Gearbox 2Bracket 3Support 4Cap Screw (8 used)
24. Apply pipe sealant to pump drive gearbox pipe plug threads, if removed.
33 3360 7
FS41334,000014C 1913APR078/13
TM10091 (11JAN08)
33-3360-7

011108
PN=237
TX1020354
UN09MAR07
Hydraulic System
25. Install muffler (1) to support using U-bolts and nuts (2). Hand tighten for next step.
1Muffler 2U-Bolt Nut (8 used) 3Support
FS41334,000014C 1913APR079/13
NOTE: Clamp torque is 8.5 Nm (75 lb-in.) with maximum torque of 20 Nm (177 lb-in.). 26. Install clamp (1) and tighten. 27. Tighten muffler U-bolt nuts to specification.
Specification Muffler U-Bolt NutTorque ............................................................ 50 Nm 37 lb-ft
UN19MAR07
1Clamp 2Tube 3Muffler
FS41334,000014C 1913APR0710/13
28. Install muffler shield (1) using cap screws (2). 29. Install and route water drain (3) down through muffler shield.
1Shield 2Cap Screw (6 used) 3Water Drain
UN22MAR07
FS41334,000014C 1913APR0711/13
TM10091 (11JAN08)
33-3360-8

011108
PN=238
TX1020874A
33 3360 8
TX1020749A
TX1020923A
UN23MAR07
Hydraulic System
30. Install engine oil filter (1) assembly using cap screws (2).
1Engine Oil Filter 2Cap Screw (2 used)
FS41334,000014C 1913APR0712/13
31. Install fuel filters (2 and 3) using cap screws (1). 32. Install muffler cover and hydraulic compartment cover.
UN05APR07
33. Fill and check hydraulic oil level. See 160DLC Drain and Refill Capacities. (Operators Manual.) 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. 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: See Pump Regulator Test and Adjustment Maximum Flow. (Group 9025-25.)
TX1020192A
TX1020366A
UN19MAR07
33 3360 9
FS41334,000014C 1913APR0713/13
TM10091 (11JAN08)
33-3360-9

011108
PN=239
Hydraulic System
Pump 1 and 2 Disassemble and Assemble

10
11
21
19
12
22
23
20
24
18
17
6
16
13
5
15
13
14
23
3
2
1
32
15
17
18
25
21
22
20
26
16
33
32
31
27
28
30
28
27
29
37
35
36
56
34
38
55
33 3360 10
40
46
45
39
47
35
54
41
57
44
43
42
49
48
50
51
T142373
58
51
FS41334,000015A 1913APR071/13
TM10091 (11JAN08)
33-3360-10

011108
PN=240
T142373
53
52
UN20JUL01
Hydraulic System
1Pump Housing 2Lock Washer (6 used) 3Cap Screw (6 used) 4Spring Pin (4 used) 5O-Ring (10 used) 6O-Ring (2 used) 7Cap Screw (4 used) 8Hydraulic Pump 1 (Front) Regulator 9Cap Screw (2 used) 10Cap Screw (2 used) 11Cap 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 31Spring Pin (2 used) 32Oil Seal (2 used) 33Snap Ring (2 used) 34Fill Plug 35Snap Ring (2 used) 36Hydraulic Pump 1 Driven Gear 37Gasket 38Cap Screw (2 used) 39Hydraulic Pump 2 Drive Gear 40Dipstick 41Dipstick Tube 42Gasket 43Drain Plug 44O-Ring 45Cap Screw (2 used) 46Lock Washer (2 used) 47Washer (2 used) 48Pilot Pump 49Snap Ring 50Snap Ring 51Ball Bearing 52Pilot Pump Drive Gear 53Pilot Pump Drive Shaft 54Snap Ring 55Oil Seal 56Pump Drive Gearbox 57Set Screw (2 used) 58Dampener Drive Coupling
FS41334,000015A 1913APR072/13
33 3360 11
TM10091 (11JAN08)
33-3360-11

011108
PN=241
Hydraulic System
72
71
70
73
74
68
67
71
75
62
60
63
64
63
69
60
61
66
62
60
62
63
65
78
76
59
60
60
77
63
61
62
79
80
81
82
60
59
66
60
82
UN20JUL01
T142375
33 3360 12
59Dowel Pin 60Snap Ring (12 used) 61Dowel Pin (2 used) 62Lever (4 used) 63Dowel Pin (4 used) 64Hydraulic Pump 1 Valve Plate
65Hydraulic Pump 2 Valve Plate 66Dowel Pin (4 used) 67Back-Up Ring 68O-Ring 69Spring Pin (2 used) 70Cylinder Head (Cover)
71O-Ring (4 used) 72Cap Screw (8 used) 73Cover (2 used) 74O-Ring (2 used) 75Cap Screw (12 used) 76Set Screw (2 used)
77Servo Piston (2 used) 78Pin (2 used) 79O-Ring (2 used) 80Stop (2 used) 81Cap Screw (8 used) 82Feedback Link (2 used)
1. Remove plug (43) from pump gearbox. Drain gear oil. Approximate oil capacity is 0.9 L (1.0 qt).
FS41334,000015A 1913APR073/13
TM10091 (11JAN08)
33-3360-12

011108
PN=242
T142375
Hydraulic System
Specification Pump Housing Assembly Approximate Weight ................................................................. 105 kg 230 lb

Specification Hydraulic Pump Housing and GearboxApproximate Weight ................................................ 168 kg 370 lb
4. Remove cap screws (3) and lock washers (2) to remove pump housing (1) from pump drive gearbox (56). 5. Remove parts (49-53). For removal of pilot pump drive shaft: See Pilot Pump Drive Shaft Remove and Install. (Group 3360.)
2. Loosen set screws (57) and remove dampener drive coupling (58). 3. Remove pilot pump (48). For repair: See Pilot Pump Disassemble and Assemble. (Group 3360.)
FS41334,000015A 1913APR074/13
33 3360 13
TM10091 (11JAN08)
33-3360-13

011108
PN=243
Hydraulic System
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). 6. Make timing marks on pump gears to aid in reassembly. 7. 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
UN07FEB07
8. Remove snap rings (35) and remove gears (36 and 39). 9. Remove pump regulators (8 and 12). For repair: See Pump 1 and 2 Regulator Disassemble and Assemble. (Group 3360.)
Specification Cylinder HeadApproximate Weight................................................................................................ 30 kg 66 lb
35Snap Ring (2 used) 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
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. 10. Remove cap screws (75) and carefully remove cylinder head (70). 11. 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.)
FS41334,000015A 1913APR075/13
TM10091 (11JAN08)
33-3360-14

011108
PN=244
TX1018511A
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. 12. Remove hydraulic pump 1 (64) and hydraulic pump 2 (65) valve plates. Protect machined surfaces of plates from damage. 13. Remove special fittings (30) before removing hydraulic pump 1 (19) and hydraulic pump 2 (25) drive shafts. 14. Remove hydraulic pump 2 spacer ring (26) from bore. 15. Remove bearing nut (15) using JDG769 Spanner Wrench. 16. Remove roller bearings (16 and 18) from pump 1 (19) and pump 2 (25) drive shafts using a knife edge puller and a press. 17. Clean and inspect parts. Repair or replace parts as necessary. See Pump 1 and 2 Inspection. (Group 3360.) 18. Assemble hydraulic pump in reverse order, using the following information.
FS41334,000015A 1913APR076/13
33 3360 15
TM10091 (11JAN08)
33-3360-15

011108
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. 19. Heat roller bearings (16 and 18).
UN07FEB07
Specification Roller Bearing Heat Temperature ................................................................................ 5080C 122176F
20. Apply oil to bearing. Push roller bearing (18) on drive shaft so inner race is tight against shoulder. 21. Install spacer ring (17) and roller bearing (16). 22. Apply oil to threads of bearing nut (15). 23. Tighten bearing nut using JDG769 Spanner Wrench.
Specification Pump Drive Shaft Bearing Nut Rolling Drag Torque ......................................................... 1.96 0.49 Nm 17 4 lb-in.
FS41334,000015A 1913APR077/13
33 3360 16
24. Install hydraulic pump 2 spacer ring (26) into housing bore.
26Spacer Ring
UN07FEB07
FS41334,000015A 1913APR078/13
TM10091 (11JAN08)
33-3360-16

011108
TX1018495A
PN=246
TX1018494
15Bearing Nut 16Roller Bearing 17Spacer Ring 18Roller Bearing 19Pump 1 (Front) Drive Shaft 25Pump 2 (Rear) Drive Shaft
UN07FEB07
TX1018493
Hydraulic System
25. 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
NOTE: Allow housing to cool to the touch, to safely handle after drive shaft installation. 27. Install and tighten special fittings (30).
Specification Special Plug-to-Hydraulic Pump Housing Special FittingTorque.................................................... 34 Nm 25 lb-ft
19Drive Shaft 25Drive Shaft 30Special Fitting (2 used)
28. 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).
FS41334,000015A 1913APR079/13
TX1018496A
26. Apply a film of oil to outer race of bearings. Install the drive shafts.
33 3360 17
TM10091 (11JAN08)
33-3360-17

011108
PN=247
Hydraulic System
29. Install drive (39) and driven (36) gears using procedure: For original parts; 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; 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. 30. Apply oil to center shaft (21), pistons (23), and cylinder blocks (24). Use petroleum jelly to hold pin (20) in hole in center shaft. 31. Install cylinder block so pin engages slot in cylinder block. 32. 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.
Specification Dowel Pin-to-Pump 1 (Front) and Pump 2 (Rear) Valve Plate Torque ........................................................................................... 9.8 Nm 86 lb-in. 19Pump 1 (Front) Drive Shaft 25Pump 2 (Rear) Drive Shaft 35Snap Ring (2 used) 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)
UN07FEB07
33 3360 18
FS41334,000015A 1913APR0710/13
TM10091 (11JAN08)
33-3360-18

011108
PN=248
TX1018497
UN07FEB07
TX1018511A
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. 33. Install valve plates using procedure: Apply oil to valve plates. Install valve plates so inlet port is toward the center and top of pump housing. Connect levers (62) for feedback linkage to valve plates. 34. Install servo pistons (77) and pins (78). If set 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
35. 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.
CAUTION: Heavy component; user an appropriate lifting device. 36. 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
FS41334,000015A 1913APR0711/13
TM10091 (11JAN08)
33-3360-19

011108
PN=249
Hydraulic System
Tighten cap screws (75) to specification.
Specification Cylinder Head-to-Hydraulic Pump Housing Cap ScrewTorque....................................................... 108 Nm 80 lb-ft
37. 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. Tighten cap screws to specification.
Specification Regulator-to-Hydraulic Pump Housing Cap ScrewTorque......................................................... 49 Nm 36 lb-ft
38. Install and tighten pump pressure sensors to specification.

Specification Pump Pressure Sensor-to-Hydraulic Pump HousingTorque............................................................................ 98 Nm 72 lb-ft
39. Install parts (49-53). For installation of pilot pump drive shaft: See Pilot Pump Drive Shaft Remove and Install. (Group 3360.)
Specification Hydraulic Pump Housing AssemblyApproximate Weight ..................................................... 105 kg 230 lb
33 3360 20
40. Install pump housing assembly (1) to gearbox (56).
FS41334,000015A 1913APR0712/13
TM10091 (11JAN08)
33-3360-20

011108
PN=250
Hydraulic System
Tighten cap screws (3) to specification.
Specification Hydraulic Pump Housing-to-Gearbox Housing Cap ScrewTorque ............................................................................. 147 Nm 109 lb-ft
41. Apply rigid form-in-place gasket to mounting surface for pilot pump (48). Tighten cap screws (45) to specification.
Specification Pilot Pump-to-Gearbox Cap ScrewTorque ............................................................................... 49 Nm 36 lb-ft
42. Apply multi-purpose grease to lips of oil seal (55). Install oil seal with lip (spring side) toward inside of housing.
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. 43. 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.). 44. 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
45. Fill pump and pump drive gearbox with oil. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
33 3360 21
FS41334,000015A 1913APR0713/13
TM10091 (11JAN08)
33-3360-21

011108
PN=251
Hydraulic System
Pump 1 and 2 Inspection

1. Measure diameter of oil seal contact surfaces (A, B, and D) on pump 1 (front) (E) and pump 2 (rear) (C) drive shafts.
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 54.8 mm limit of use 2.16 in. limit of use Pump 1 (Front) Drive Shaft Oil Seal Contact SurfaceOD ............................................... 55 mm nominal 2.17 in. nominal 54.8 mm limit of use 2.16 in. limit of use
UN09JAN97
AOil Seal Contact Surface BOil Seal Contact Surface CPump 2 (Rear) Drive Shaft DOil Seal Contact Surface EPump 1 (Front) Drive Shaft
FS41334,000014A 1911APR071/6
2. Measure play (H) between piston connecting rod (F) and socket in front and rear drive shafts (G).
Specification Piston-to-Drive Shaft Socket Play ............................................................................... 0.058 mm nominal 0.0023 in. nominal 0.400 mm limit of use 0.0157 in. limit of use
UN09JAN97
FPiston Connecting Rod GRear Drive Shaft HPlay
33 3360 22
FS41334,000014A 1911APR072/6
TM10091 (11JAN08)
33-3360-22

011108
PN=252
T105726
T105725
Hydraulic System
3. Measure ID of cylinder block piston bore. Measure OD of piston. Subtract the OD from the ID for clearance.
Specification Cylinder Block Bore-to-Piston Clearance ..................................................................... 0.043 mm nominal 0.0017 in. nominal 0.080 mm limit of use 0.0032 in. limit of use
FS41334,000014A 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.
Specification Piston-to-Connecting RodPlay .................................. 0.150 mm nominal 0.0059 in. nominal 0.400 mm limit of use 0.0157 in. limit of use
FS41334,000014A 1911APR074/6
T6557EK
UN18OCT88
T6557EN
UN18OCT88
T6557EM
UN18OCT88
33 3360 23
TM10091 (11JAN08)
33-3360-23

011108
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 0.200 mm limit of use 0.0078 in. limit of use
FS41334,000014A 1911APR075/6
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.
Specification Servo Piston Pin-to-Valve Plate BoreClearance .......................................................... 0.051 mm nominal 0.0020 in. nominal 0.300 mm limit of use 0.0118 in. limit of use
AValve Plate BPiston Pin COD DID
33 3360 24
FS41334,000014A 1911APR076/6
TM10091 (11JAN08)
33-3360-24

011108
PN=254
T105729
UN09JAN97
T105727
UN19DEC96
ACylinder Head BID COD DServo Piston
Hydraulic System
Pump 1 and 2 Start-Up Procedure

IMPORTANT: Hydraulic pump and drive gearbox will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump or gearbox is installed or oil has been drained from the pump, gearbox or hydraulic oil tank. Procedure is to ensure the pumps and gearbox are filled with oil and air is bled from suction side of pumps to prevent cavitation. 1. 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.) 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.
UN19MAR07 UN31AUG01
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.
1Dipstick 2Fill Plug 3Air Bleed Plug (2 used)
TX1020374A
T145092
TX1020193A
UN06MAR07
33 3360 25
FS41334,0000149 1910APR071/1
TM10091 (11JAN08)
33-3360-25

011108
PN=255
Hydraulic System
Pump 1 and 2 Regulator Remove and Install

NOTE: Pump 1 (front) and pump 2 (rear) regulators are similar in design. Removal of pump 2 (rear) regulator is shown.
CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) Hydraulic oil tank capacity is approximately 120.4 L (31.8 gal). 3. Disconnect lines. 4. Disconnect electrical connectors.
FS41334,0000148 1913APR071/2
33 3360 26
TM10091 (11JAN08)
33-3360-26

011108
PN=256
TX1020196A
UN07MAR07
Hydraulic System
5. Remove cap screws (1) and regulator (2). 6. Repair or replace parts as necessary.
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 Housing Cap ScrewTorque......................................................... 49 Nm 36 lb-ft
1Cap Screw (8 used) 2Hydraulic Pump Regulator (2 used)
9. Connect lines. See Pump 1, Pump 2, and Pilot Pump Line Identification. (Group 9025-15.) 10. Connect electrical connectors. See Pump Harness (W8) Component Location. (Group 9015-10.) 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. 11. Fill pump housing with oil. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
FS41334,0000148 1913APR072/2
TX1003224A
33 3360 27
TM10091 (11JAN08)
33-3360-27

011108
PN=257
Hydraulic System
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 11Cap Screw (4 used) 12End Plate 13Flow Adjusting Cartridge 14Maximum Flow Adjusting Screw (Stop) 15Spring (2 used) 16Remote Control Spool 17Remote Control Sleeve 18O-Ring 19Backup Ring 20O-Ring 21Cylinder 22Piston 23Load Piston 24Cylinder 25Load Sleeve 26Load Spool 27Inner Spring
NOTE: Pump 1 (front) and pump 2 (rear) regulators are similar. Pump 2 (rear) regulator is shown. IMPORTANT: Removal of adjusting screws (4, 9 and 14) and cartridges (7 and 13) 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. 1. Remove end plate (12) and cover (5) with adjusting screws and cartridges installed.
2. Repair or replace parts as necessary. 3. Tighten cap screws (1 and 11).

Specification Pump 1 (Front) and Pump 2 (Rear) End Plate and Cover-to-Housing Cap Screw Torque................................................................................... 19.8 Nm 180 lb-in.
FS41334,0000147 1910APR071/2
TM10091 (11JAN08)
33-3360-28

011108
PN=258
T142272B
UN16FEB07
Hydraulic System
2Load Sleeve 3Load Spool 5Cylinder 6Load Piston 12Load Adjusting Cartridge (Stop) Flow Adjusting Cartridge (Stop)
13Load Adjusting Screw (Stop) 15Spring 16Nut (2 used) 17Nut (2 used) 20Piston 21Cylinder
24Maximum Flow Adjusting Screw (Stop) 27Remote Control Sleeve 28Remote Control Spool 29Minimum Flow Adjusting Screw
34Nut 35End Plate 36Cover 37Cap Screw (8 used) 47Outer Spring 48Inner Spring
4. Tighten cap screws. 5. Tighten air bleed plug.
6. Fill pump housing with oil. See Pump 1 and 2 Start-Up Procedure. (Group 3360.) 7. Check pump regulator adjustments.
Specification Pump 1 (Front) and Pump 2 (Rear) Air Bleed Plug-to-HousingTorque ........................................................ 78 Nm 58 lb-ft
For minimum flow: See Pump Regulator Test and Adjustment Minimum Flow. (Group 9025-25.) For maximum flow: See Pump Regulator Test and Adjustment Maximum Flow. (Group 9025-25.)
33 3360 29
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.
FS41334,0000147 1910APR072/2
TM10091 (11JAN08)
33-3360-29

011108
PN=259
T105706
UN09JAN97
Hydraulic System
Pilot Pump Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Drain pump drive gearbox. Approximate oil capacity is 0.9 L (1.0 qt). 3. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) and See 160DLC Drain and Refill Capacities. (Operators Manual.)
FS41334,0000146 1910APR071/3
4. Remove cap screws (1) and set fuel filters (2 and 3) aside. Protect against damage to hoses and filters.
FS41334,0000146 1910APR072/3
33 3360 30
TM10091 (11JAN08)
33-3360-30

011108
PN=260
TX1020192A
UN05APR07
TX1020196A
UN07MAR07
Hydraulic System
5. Tag and disconnect lines and hoses. Close all open lines and fittings using caps and plugs. 6. Remove adapters (3). 7. Remove cap screws (2) and pilot pump (1) from gearbox (4). 8. Repair or replace parts as necessary. 9. Apply T43514 Rigid Form-In-Place Gasket to mounting surface for pilot pump. 10. Tighten cap screws (2) to specification.
Specification Pilot Pump-to-Pump Drive Gearbox Cap ScrewTorque ........................................................ 49 Nm 36 lb-ft 1Pilot Pump 2Cap Screw (2 used) 3Adapter (2 used) 4Pump Drive Gearbox
UN19MAR07
11. Install adapters (3) and O-ring. 12. Connect lines. See Pump 1, Pump 2, and Pilot Pump Line Identification. (Group 9025-15.) 13. Fill pump drive gearbox so level is above H mark on dipstick. See Change Pump Drive Gearbox Oil. (Operators Manual.)
FS41334,0000146 1910APR073/3
TX1020294A
33 3360 31
TM10091 (11JAN08)
33-3360-31

011108
PN=261
Hydraulic System
Pilot Pump Disassemble and Assemble
33 3360 32
TJ15698,0000113 1911APR071/3
TM10091 (11JAN08)
33-3360-32

011108
PN=262
TX1000393
UN16NOV05
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) 16Cap Screw (4 used) 26Bushing 27Bushing 28Pin (4 used) 30Seal Kit
TJ15698,0000113 1911APR072/3
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. IMPORTANT: Apply clean hydraulic oil to all parts. Pump failure can result if pump is assembled dry. 3. Apply clean hydraulic oil to all parts. 4. Apply multi-purpose grease to lip of oil seal. Install oil seal with lip (spring side) towards inside of housing. 5. Tighten cap screws.
Specification Cover-to-Flange Cap Screw Torque ............................................................................................ 41 Nm 30 lb-ft ADrive Gear BKeys (2 used) CDriven Gear DBushing
6. Check pilot pressure setting. See See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)
TJ15698,0000113 1911APR073/3
T7685IX
33 3360 33
TM10091 (11JAN08)
33-3360-33

011108
PN=263
Hydraulic System
Pilot Pump Drive Shaft Remove and Install

1. Remove snap rings (6 and 7). 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. 3. Remove pilot pump drive gear (3) through opening for hydraulic pump. 4. Repair or replace as needed. 5. Assemble in reverse order.
1Pump Drive Gearbox Case 3Pilot Pump Drive Gear 4Pilot Pump Drive Shaft 5Ball Bearing (2 used) 6Snap Ring 7Snap Ring
FS41334,000014F 1902MAR071/1
33 3360 34
TM10091 (11JAN08)
33-3360-34

011108
PN=264
T142290
UN20JUL01
T105657
UN12DEC96
T105640
UN12DEC96
Hydraulic System
Pilot Pressure Regulating Valve and Filter Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1).
TJ15698,0000138 1911APR071/2
2. Tag and disconnect hoses (1). 3. Close all open hoses and fittings using caps and plugs.
UN07MAR07
4. Remove cap screws (4) and remove pilot pressure regulating valve (2) and filter (3). 5. Repair or replace as necessary. 6. Install cap screws (4).
Specification Filter Head-to-Support Cap ScrewTorque ............................................................................... 49 Nm 36 lb-ft
7. Replace pilot filter element (3).

Specification Pilot Filter Element Housing-to-Filter HeadTorque ................................................... 25 Nm 220 lb-in.
1Hydraulic Hose 2Pilot Pressure Regulating Valve 3Filter 4Cap Screw (2 used)
TX1020241A
TX1020196A
UN07MAR07
8. Connect hoses. See Hydraulic System Line Connections. (Group 9025-15.) 9. Check pilot pressure setting. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)
33 3360 35
TJ15698,0000138 1911APR072/2
TM10091 (11JAN08)
33-3360-35

011108
PN=265
Hydraulic System
Pilot Pressure Regulating Valve and Filter Disassemble and Assemble

1. Remove plug (6) with O-ring (5). 2. Remove parts (24). 3. Inspect, clean and replace parts as necessary. 4. Check that poppet (2) slides smoothly in pilot pressure regulating valve housing. 5. Tighten plug (6).
Specification Plug-to-housingTorque................................................................ 49 Nm 36 lb-ft
1
2
3
4
5
6
UN07FEB06
1Pilot Pressure Regulating Valve Housing 2Poppet 3Shim (as required) 4Spring 5O-Ring 6Plug
TJ15698,0000139 1906MAR071/1
Pilot Shutoff Solenoid Valve Remove and Install

1. Turn upperstructure 90 to tracks.
TJ15698,0000130 1918APR071/3
33 3360 36
UN07MAR07
TJ15698,0000130 1918APR072/3
TM10091 (11JAN08)
33-3360-36

011108
PN=266
TX1020196A
TX1003402
Hydraulic System
3. Tag and disconnect hoses and lines. Close all open lines and fittings using caps and plugs. 4. Disconnect solenoid connector (2). 5. Remove cap screws (1) and valve. 6. Repair or replace parts as necessary. 7. Install valve. Tighten cap screws.
Specification Pilot Shutoff Valve Housing-to-Cab Platform Cap ScrewTorque ............................................................................... 49 Nm 36 lb-ft
UN07FEB06
1Cap Screw (2 used) 2Connector
TJ15698,0000130 1918APR073/3
TX1003406A
UN07FEB06
8. Connect lines. See Pilot Shutoff Solenoid Valve Operation. (Group 9025-05.)
TX1003407A
33 3360 37
TM10091 (11JAN08)
33-3360-37

011108
PN=267
Hydraulic System
Pilot Shutoff Solenoid Valve Disassemble and Assemble
33 3360 38
TJ15698,0000114 1918APR071/2
TM10091 (11JAN08)
33-3360-38

011108
PN=268
TX1000413
UN16NOV05
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
1. Clamp housing (3) in a vise. 2. Scribe a line on housing (3) and solenoid (6). 3. Remove screws (9), solenoid (6), and O-ring (11). 4. Remove plug (8), O-ring (12), spring (1), and spool (4), from housing. 5. Remove screen (5). 6. Clean and inspect all parts. Replace worn 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 Shutoff Solenoid Valve Housing PlugTorque ........................................................................... 28 Nm 246 lb-in.
8. Install screen (5). 9. Install O-ring (11) to solenoid (6). 10. Align scribe marks and install solenoid (6) to housing (3), using screws (9). Tighten screws to specification.
Specification Solenoid-to-Housing Screws Torque........................................................................................ 4 Nm 36 lb-in.
TJ15698,0000114 1918APR072/2
Fan Drive Pump Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Pull a vacuum in hydraulic oil tank using a vacuum pump, or drain tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) Approximate capacity of hydraulic oil tank it 120.4 L (31.8 gal).
TX1020196A
UN07MAR07
33 3360 39
OUO6046,0002328 1910APR071/2
TM10091 (11JAN08)
33-3360-39

011108
PN=269
Hydraulic System
3. Disconnect cold weather starting aid line (1). 4. Loosen clamp and disconnect inlet hose (2).
UN23MAR07
5. Disconnect outlet hose (3). Close all open lines and fittings using caps and plugs. 6. Remove cap screws (4), washers, pump (3), and gasket. 7. If installing new pump, remove fittings and top cap screw from existing pump and install onto new pump using new O-rings on fittings. 8. Install pump and new gasket. 9. Tighten cap screws. 10. Connect inlet and outlet hoses. 11. Tighten fittings and clamp. 12. Fill and check hydraulic oil level. See 160DLC Drain and Refill Capacities. (Operators Manual.)
1Cold Weather Starting Aid Line 2Inlet Hose 3Outlet Hose 4Cap Screws (2 used)
OUO6046,0002328 1910APR072/2
Fan Drive Motor Remove and Install

1. Remove coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.) 2. Remove fan and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.)
33 3360 40
OUO6046,0002327 1904APR071/3
TM10091 (11JAN08)
33-3360-40

011108
PN=270
TX1020829A
UN23MAR07
TX1020830A
Hydraulic System
OUO6046,0002327 1904APR072/3
TX1020784A
UN23MAR07
33 3360 41
TM10091 (11JAN08)
33-3360-41

011108
PN=271
Hydraulic System
4. Disconnect hydraulic hoses (4, 6, and 7). 5. Remove lock nut (2) and washer. Discard lock nut.
UN30MAR07
6. Remove hub (1) from motor shaft using suitable puller. 7. Remove cap screws (3), nuts, washers, and fan drive motor (5). 8. Replace motor as necessary. 9. Install motor into mounting bracket. 10. Install cap screws, washers, and nuts. Tighten cap screws to specification.
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
11. Install hub on fan shaft. 12. 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
13. Connect hydraulic hoses. 14. Install fan drive motor assembly. Tighten cap screws to specification.
Specification Fan Drive Motor Assembly-to-Cooling Package Cap ScrewsTorque ..................................................................... 73 Nm 54 lb-ft
15. Install fan and fan shroud. See Fan, Fan Guard, and Fan Shroud Remove and Install. (Group 0510.)
33 3360 42
16. Install coolant surge tank. See Coolant Surge Tank Remove and Install. (Group 0510.)
OUO6046,0002327 1904APR073/3
TM10091 (11JAN08)
33-3360-42

011108
PN=272
TX1021112A
Hydraulic System
Fan Drive Control Valve Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Pull a vacuum in hydraulic oil tank using a vacuum pump. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.)
OUO1073,0002104 1918APR071/2
NOTE: Reversing control valve shown, standard valve similar. 3. Disconnect wiring harness connectors (1). 4. Tag and disconnect hydraulic hoses. Close all open lines and fittings using caps and plugs. 5. Remove cap screws (2) and fan drive control valve (3).
UN27MAR07
6. Install valve and cap screws. 7. Connect hydraulic hoses. See Fan Drive System Component Location. (Group 9025-15.) 8. Connect wiring harness connectors. 9. Fill and check hydraulic oil level. See 160DLC Drain and Refill Capacities. (Operators Manual.)
1Connectors 2Cap Screw (2 used) 3Fan Drive Control Valve
TX1021223A
TX1020196A
UN07MAR07
33 3360 43
OUO1073,0002104 1918APR072/2
TM10091 (11JAN08)
33-3360-43

011108
PN=273
Hydraulic System
Solenoid Valve Manifold Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) Approximate oil capacity is 120.4 L (31.8 gal).
TJ15698,0000131 1911APR071/2
33 3360 44
TM10091 (11JAN08)
33-3360-44

011108
PN=274
TX1020196A
UN07MAR07
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. 6. Remove cap screws (2) and solenoid valve manifold (1). 7. Repair or replace as necessary. 8. Install manifold and tighten cap screws to specification.
Specification Solenoid Valve Manifold Cap ScrewsTorque ............................................................................. 50 Nm 37 lb-ft 1Solenoid Valve Manifold 2Cap Screws (2 used)
9. Connect hoses and lines. 10. Connect electrical connectors. 11. Fill hydraulic oil tank. Approximate oil capacity is 120.4 L (31.8 gal). IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 12. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
TJ15698,0000131 1911APR072/2
TX1020239A
33 3360 45
TM10091 (11JAN08)
33-3360-45

011108
PN=275
Hydraulic System
Solenoid Valve Remove and InstallPower Dig (SG), Travel Speed (SI), Boom Mode (SC), and Boom Flow Rate (SF)
UN07MAR07
TJ15698,0000132 1911APR071/2
2. Disconnect electrical connector (3). 3. Remove cap screws (1) and remove solenoid valve coil (2). Be careful not to lose spring and O-ring. 4. Keep parts for each individual solenoid valve together. 5. Install solenoid valve coil (2) with O-ring and spring. 6. Tighten cap screws (1).
Specification Solenoid Valve Coil-to-Manifold Cap ScrewsTorque ....................................................................... 6 Nm 53 lb-in.
UN07MAR07
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 33 3360 and Adjustment. (Group 9025-25.)
46
TJ15698,0000132 1911APR072/2
TM10091 (11JAN08)
33-3360-46

011108
PN=276
TX1020240A
TX1020196A
Hydraulic System
Pilot Valve (Left and Right) Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Remove seat. See Seat Remove and Install. (Group 1821.) 3. Remove console covers. See Left and Right Console Covers Remove and Install. (Group 1821.)
TJ15698,0000133 1911APR071/3
TX1020196A
UN07MAR07
33 3360 47
TM10091 (11JAN08)
33-3360-47

011108
PN=277
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) 9Spring Pin (2 used)
10Cap Screw (2 used) 11Washer (2 used) 12Pilot Valve (2 used)
4. Disconnect wiring harness and remove handles (1). Handles are threaded onto shaft (4).
33 3360 48
8. Connect hoses. See Pilot Control Valve-to-Pilot 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).
5. Remove cap screws (8 and 10) and remove pilot valves (12) from console. 6. Tag and disconnect hoses. Close all open hoses and fittings using caps and plugs. 7. Repair or replace parts as necessary.
TJ15698,0000133 1911APR072/3
TM10091 (11JAN08)
33-3360-48

011108
PN=278
TX1018524
UN05FEB07
Hydraulic System
Specification Pilot Valve-to-Console Cap ScrewTorque ........................................................................ 20 Nm 177 lb-in.
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.)
10. After pilot valve is installed, check operation of all functions. See Control Lever Pattern Operation. (Operators Manual.)
TJ15698,0000133 1911APR073/3
33 3360 49
TM10091 (11JAN08)
33-3360-49

011108
PN=279
Hydraulic System
Pilot Valve (Left and Right) Disassemble and Assemble
33 3360 50
TJ15698,0000116 1903APR071/3
TM10091 (11JAN08)
33-3360-50

011108
PN=280
TX1000262
UN16NOV05
Hydraulic System
0Housing and Spools 3Shim (4 used) 4Spacer (4 used) 6Balance Spring (2 used) 8Balance Spring (2 used) 10Guide (4 used) 11Snap Ring (4 used) 14Pusher B (2 used) 15Pusher A (2 used) 17Sleeve (4 used) 19O-Ring (4 used) 21Plate 22Universal Joint 23Cam 24Coupling 26Plug 27O-Ring 28Snap Ring 33Return Spring (2 used) 34Return Spring (2 used) 35Pilot Valve
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. 1. Remove: Coupling (24) Cam (23) Universal Joint (22) Plate (21)
Spacer (4) Spools (0) Snap Ring (28) O-Ring (27) Plug (26)
4. Repair or replace parts as necessary. 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. 8. Install spacers (4), shims (3), and balance springs (6 and 8). IMPORTANT: Ports 1 and 3 use short return springs. Ports 2 and 4 use long return springs. 9. Install return springs (33 and 34). 10. Install guides (10) with protrusion facing upward. 11. Install snap rings (11). IMPORTANT: Ports 1 and 3 use pushers with 1 outer groove. Ports 2 and 4 use pushers with 2 outer grooves. 12. Install pushers A (15) and pushers B (14).
NOTE: Sleeves (17) cannot be disassembled. Do not attempt to remove oil seal from sleeve. 2. Remove sleeves (17). 3. Remove: Pusher (14 and 15) Snap Ring (11) Guide (10) Spring (6 and 8) Spring (33 and 34) Shim (3)
33 3360 51
TJ15698,0000116 1903APR072/3
TM10091 (11JAN08)
33-3360-51

011108
PN=281
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). 17. Install plate (21) and universal joint (22). Tighten universal joint.
Specification Universal JointTorque ....................................................... 24.5 Nm 217 lb-in.
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
LOCTITE is a trademark of Henkel Corporation
TJ15698,0000116 1903APR073/3
Travel Pilot Valve Remove and Install

33 3360 52
TJ15698,0000134 1911APR071/2
TM10091 (11JAN08)
33-3360-52

011108
PN=282
TX1020196A
UN07MAR07
Hydraulic System
2. Tag and disconnect hoses underneath of cab. 3. Close all open hoses and fittings using caps and plugs. 4. Remove cap screws (1) and remove pedals and levers. 5. Remove cap screws (2) and remove travel pilot valve (3). 6. Repair or replace parts as necessary. 7. Tighten cap screws (2).
Specification Valve-to-Cab Platform Cap ScrewTorque ............................................................................... 50 Nm 37 lb-ft 1Cap Screw (4 used) 2Cap Screw (2 used) 3Travel Pilot Valve
UN16FEB06
8. Tighten cap screws (1).

Specification Travel Pedal-to-Lever Cap ScrewTorque ............................................................................... 50 Nm 37 lb-ft
9. Connect hoses. See Travel Hydraulic System Line Connection. (Group 9025-15.) 10. After travel pilot valve is installed, check the operation of all functions to be sure they operate correctly.
TJ15698,0000134 1911APR072/2
TX1003510A
33 3360 53
TM10091 (11JAN08)
33-3360-53

011108
PN=283
Hydraulic System
Travel Pilot Valve Disassemble and Assemble

1
35
34
33
3
6
7
32
4
5
8
29
27
28
9
11
10
12
13
18
25
26
31
30
17
14
24
22
21
20
23
16
15
UN31JAN07
19
33 3360 54
1Cap Screw (2 used) 2Cover 3Pin (2 used) 4O-Ring (2 used) 5O-Ring (2 used) 6Dampener (2 used) 7Rubber Seat (2 used) 8Cap Screw (2 used) 9Lock Washer (2 used)
10Holder 11Oil Seal (4 used) 12O-Ring (4 used) 13Bushing (4 used) 14Casing 15O-Ring 16Plug 17Plug 18O-Ring
19Spool (4 used) 20Spring (4 used) 21Spacer (4 used) 22Shim (As required) 23Balance Spring (4 used) 24Spring Guide (4 used) 25Pusher (4 used) 26Bracket (2 used) 27Spring Pin (2 used)
28Cap Screw (4 used) 29Lock Washer (4 used) 30Spring Pin (2 used) 31Spring Pin (2 used) 32Bushing (4 used) 33Cam (2 used) 34Spring Pin (2 used) 35Spring Pin (2 used)
TJ15698,0000117 1916FEB071/3
TM10091 (11JAN08)
33-3360-54

011108
PN=284
TX1018305
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. 2. Repair or replace parts as necessary. NOTE: Use same number of shims (22) as were removed. 3. Install spools (19), springs (20), spacers (21), shims (22) and balance springs (23) into casing (14). 4. Install spring guides (24) with stepped end facing down. 5. Apply multi-purpose grease to the end of each pusher (25) and to oil seals (11). 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. 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...................................................................................... 49 Nm 36 lb-ft
9. Apply multi-purpose grease to O-rings (4 and 5) and install on pin (3). 10. Position rubber seat (7) and dampener (6) on pin (3) with lever facing upward. 11. Install cap screws (28), lock washers (29) 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. Align brackets with marks made during disassembly. 12. Install brackets (26) and spring pins (30 and 31). 13. Lock pins (30 and 31) in position by displacing the bore above spring pin using a punch and hammer. 14. Install cover (2) and cap screws (1) and tighten.
Specification Cover-to-Holder Cap Screw Torque........................................................................................ 5 Nm 44.3 lb-in.
15. Apply multi-purpose grease to spring pin (27).
33 3360 55
TJ15698,0000117 1916FEB072/3
TM10091 (11JAN08)
33-3360-55

011108
PN=285
Hydraulic System
16. Install O-ring (18) and plug (17). Tighten plug to specification.
Specification PlugTorque ........................................................................... 10 Nm 89 lb-in.
17. Install O-ring (15) and plug (16). Tighten plug to specification.
Specification PlugTorque ........................................................................... 20 Nm 177 lb-in.
TJ15698,0000117 1916FEB073/3
Pilot Signal Manifold Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) Approximate oil capacity is 120.4 L (31.8 gal).
TJ15698,0000135 1911APR071/2
33 3360 56
TM10091 (11JAN08)
33-3360-56

011108
PN=286
TX1020196A
UN07MAR07
Hydraulic System
3. Tag and disconnect hoses and lines. 4. Close all open lines, hoses, and fittings using caps and plugs. 5. Disconnect electrical connectors. 6. Remove cap screws (3). 7. Repair or replace parts as necessary. 8. Position manifold (1) on bracket (2) and tighten cap screws (3).
Specification Pilot Signal Manifold-to-Bracket Cap ScrewTorque ....................................................................... 50 Nm 37 lb-ft 1Pilot Signal Manifold 2Bracket 3Cap Screw (4 used)
UN02APR07
9. Connect electrical connectors. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015-10.) 10. Connect hoses and lines. See Pilot Controllers-to-Pilot Signal Manifold Component LocationExcavator Pattern. See Pilot Signal Manifold-to-Control Valve Line Connection. (Group 9025-15.) 11. Fill hydraulic oil tank. Approximate oil capacity is 120.4 L (31.8 gal).
TJ15698,0000135 1911APR072/2
TX1021445A
33 3360 57
TM10091 (11JAN08)
33-3360-57

011108
PN=287
Hydraulic System
Pilot Signal Manifold Disassemble and Assemble

14
15
21
14
16
22
17
10
9
8
13
19
23
20
12
11
24
6
18
19
16
4
20
17
3
2
C
25
B
26
19
A
20
27
16
15
14
33 3360 58
17
28
29
UN17JUL01
011108
19
17
16
T143485
TJ15698,0000118 1916FEB071/3
TM10091 (11JAN08)
33-3360-58

PN=288
T143485
15
Hydraulic System
1Cap Screw (10 used) 2Body 3Gasket 4Body 5Gasket 6Body 7Gasket 8Body 9Gasket 10Body 11Name Plate 12Screw (4 used) 13Plate 14Cap Screw (11 used) 15Plug (7 used) 16O-Ring (7 used) 17Spring (4 used) 18Spring 19Spring Seat (7 used) 20Spool (6 used) 21Plate 22O-Ring 23Valve 24O-Ring 25Spring 26Spool 27Spring 28Spring 29Plate
TJ15698,0000118 1916FEB072/3
33 3360 59
TM10091 (11JAN08)
33-3360-59

011108
PN=289
Hydraulic System
30
32
31
32
31
30
31
30
33 3360 60
UN17JUL01
C
T143486
30Filter (17 used)
31Shuttle Valve (21 used)
32Spring (4 used)
TJ15698,0000118 1916FEB073/3
TM10091 (11JAN08)
33-3360-60

011108
PN=290
T143486
Hydraulic System
Control Valve Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Pull a vacuum in hydraulic oil tank using a vacuum pump, or drain tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) See 160DLC Drain and Refill Capacities. (Operators Manual.)
OUO6046,000231D 1910APR071/3
3. Tag and disconnect hydraulic lines and hoses. Close all open lines and fittings using caps and plugs. 4. Disconnect electrical connectors. 5. Remove cap screws (1) and washers. Place pilot signal manifold (2) with bracket to side. 6. Attach an appropriate lifting device to control valve using lifting straps.
1Cap Screws 2Pilot Signal Manifold
UN23MAR07
OUO6046,000231D 1910APR072/3
TX1020604A
TX1020196A
UN07MAR07
33 3360 61
TM10091 (11JAN08)
33-3360-61

011108
PN=291
Hydraulic System

Specification Control ValveApproximate Weight.............................................................................................. 220 kg 485 lb
7. Remove cap screws (1), washers (2), and spacers (3). Remove control valve. 8. Replace parts as necessary. 9. Install in reverse order. 10. Tighten cap screws (1) to specification.
Specification Mounting Bracket-to-Control Valve Cap ScrewTorque ........................................................... 270 Nm 200 lb-ft
11. Install pilot signal manifold with bracket. Tighten cap screws to specification.
3
Specification Pilot Signal Manifold Bracket-to-Control Valve Cap ScrewTorque ............................................................................. 140 Nm 103 lb-ft
1
1Cap Screw (4 used) 2Washer (4 used) 3Spacer (4 used) 4Front Mounting Bracket 5Rear Mounting Bracket
12. Connect hydraulic hoses and lines. See Hydraulic System Line Connections. (Group 9025-15.) 13. Connect electrical connectors. 14. Check hydraulic tank oil level. See Check Hydraulic Tank Oil Level. (Operators Manual.) 15. Do Pump 1 and 2 Start-Up Procedure. (Group 3360.)
33 3360 62
OUO6046,000231D 1910APR073/3
TM10091 (11JAN08)
33-3360-62

011108
PN=292
TX1003909
UN20FEB06
Hydraulic System
Control Valve (5-Spool) Disassemble and Assemble
33 3360 63
Control Valve End Caps 5-Spool Side

OUO6046,000231E 1916APR071/8
TM10091 (11JAN08)
33-3360-63

011108
PN=293
TX1004777
UN26APR06
Hydraulic System
33 3360 64
UN25APR06
OUO6046,000231E 1916APR072/8
TM10091 (11JAN08)
33-3360-64

011108
PN=294
TX1004778
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 48Spring Seat (2 Used) 49Spring 50Swing Spool 51O-Ring (10 Used) 52Cap Screw (16 Used) 53O-Ring 54Plug 55Cap 56Plug (2 Used) 57O-Ring (2 Used) 58Cap Screw (8 Used) 59Arm 1 Flow Rate Spool 60Spring 61Spring Seat (2 Used) 62O-Ring (2 Used) 63Plug (2 Used) 64Sleeve (2 Used) 65Spring (2 Used) 66Plug 67Spring 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) 93Spring Seat (2 Used) 94Spring 95Auxiliary Flow Combiner Spool 96Spring 97Dig Regenerative Spool 98Cap (4 Used) 99Arm In Circuit Relief and Anticavitation Valve 100O-Ring 104Body 105Auxiliary Flow Combiner 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 115Auxiliary Flow Combiner Valve Check Valve 116Lift Check (Left Travel Power Passage Check Valve) 117Dig Regenerative Check Valve 118Auxiliary Flow Combiner 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)
1. Remove cap screws (52) and bottom pilot caps (98). 2. Remove cap screws (52) and top pilot cap (55). 3. Spool5 Spool (108112): 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.
NOTE: Hold spool in a vise by the spool end between wooden blocks. a. Remove spools (108112). b. Disassemble control valve spools. c. Inspect control valve spools for wear and damage. d. Replace parts as necessary. e. Assemble in reverse order.
33 3360 65
OUO6046,000231E 1916APR073/8
TM10091 (11JAN08)
33-3360-65

011108
PN=295
Hydraulic System
f. Tighten cap screws (44) to specification.
Specification Cap Screw-to-Control Valve SpoolTorque ......................................................................... 15 Nm 132 lb-in.
e. Install plug (10) and tighten to specification.

Specification Left Travel Neutral Passage-to-Housing Lift Check PlugTorque ........................................................................... 76 Nm 56 lb-ft
NOTE: Apply clean hydraulic oil to spools before installation. g. Install spools (108112) into housing (1) while rotating them slowly. h. After installing spools into housing, push them by hand to confirm smoothness. 4. Dig Regenerative Valve (119): a. Remove cap screws (91) and parts (92, 6, 93, 96 and 97). b. Inspect parts for wear and damage. c. Replace parts as necessary. d. Assemble in reverse order. e. Tighten cap screws (91) to specification.
Specification Dig Regenerative Valve-to-Housing Cap Screw Torque...................................................................................... 11 Nm 84 lb-in.
6. Auxiliary Flow Combiner Valve Check Valve (115): a. Remove parts (8, 7, 6, 5 and 83). b. Inspect parts for wear and damage. c. Assemble in reverse order. 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
7. Arm Reduced Leakage Valve (120): a. Remove cap screws (8) and flange (72). b. Remove spring (73) and poppet (74). c. Inspect parts for wear and damage. d. Replace parts as necessary.
5. Lift Check (Left Travel Neutral Passage) (116): e. Assemble in reverse order. a. Remove plug (10) O-ring (9), spring (38) and poppet (86).
33 3360 66
f. Install flange (72) and tighten cap screws (8).

Specification Arm Reduced Leakage Valve-to-Housing Cap Screw Torque...................................................................................... 61 Nm 46 lb-ft
b. Inspect parts for wear and damage. c. Replace parts as necessary d. Assemble in reverse order.
OUO6046,000231E 1916APR074/8
TM10091 (11JAN08)
33-3360-66

011108
PN=296
Hydraulic System
8. Lift Check (Boom 2 Power Passage) (121): a. Remove cap screws (8) and flanges (75). b. Remove O-ring (13), spring (12) and poppet (76). c. Inspect parts for wear and damage. d. Replace parts as necessary. e. Assemble in reverse order. f. Install flanges (75) and tighten cap screws (8) to specification.
Specification Power Passage-to-Housing Cap ScrewTorque ................................................................ 61 Nm 46 lb-ft
b. Loosen plugs (56 and 63) from bodies (104). c. Remove O-rings (20 and 13). d. Remove plugs (63), spring seats (61), springs (60 and 78) and spools (59 and 77). e. Remove plugs (56). f. Remove sleeves (64), springs (65), plugs (66 and 79), springs (67 and 80) and poppets (68, 69, 81, and 82) from housing (1). g. Inspect parts for wear and damage. h. Replace parts as necessary. i. Assemble in reverse order. j. Install housing (104) and tighten cap screws (58) to specification.
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). c. Inspect parts for wear and damage. d. Replace parts as necessary. e. Assemble in reverse order. f. Install flanges (75) and tighten cap screws (8) to specification.
k. Tighten plug (63) to specification.

Specification Flow Rate Valve Housing PlugTorque ........................................................................... 98 Nm 72 lb-ft
11. Arm Reduced Leakage Valve (107):

Specification Neutral Passage-to-Housing Cap ScrewTorque ................................................................ 61 Nm 46 lb-ft
a. Remove plug (36). b. Remove cap screws (8) and body (32). c. Remove parts (3335).
33 3360 67
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.
OUO6046,000231E 1916APR075/8
TM10091 (11JAN08)
33-3360-67

011108
PN=297
Hydraulic System
f. Replace parts as necessary. g. Assemble in reverse order. h. Apply petroleum jelly to valve seat (23) and spring (22) to hold in place. 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
k. Tighten plug (36) to specification.

Specification Plug-to-Arm Reduced Leakage ValveTorque ....................................................................... 108 Nm 80 lb-ft
OUO6046,000231E 1916APR076/8
33 3360 68
TM10091 (11JAN08)
33-3360-68

011108
PN=298
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. a. Disassemble parts (AQ). b. Inspect parts for wear and damage. c. If any part of valve is damaged, replace valve as an assembly. 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
E
F
17
J
K
N
O
Q
TX1005220
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
Specification Main Relief Valve Cartridge-to-HousingTorque ....................................................... 83 Nm 61 lb-ft
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
TX1005220
e. Tighten valve cartridge (J) to specification.
UN24MAR06
14. Install bottom pilot caps (98) and tighten cap screws (52).
33 3360 69
OUO6046,000231E 1916APR077/8
TM10091 (11JAN08)
33-3360-69

011108
PN=299
Hydraulic System
Specification Bottom Pilot Caps-to-Housing Cap ScrewTorque ...................................................................... 42 Nm 32 lb-ft
OUO6046,000231E 1916APR078/8
33 3360 70
TM10091 (11JAN08)
33-3360-70

011108
PN=300
Hydraulic System
Control Valve (4-Spool) Disassemble and Assemble
33 3360 71
4-Spool Control Valve

OUO6046,000231F 1919APR071/6
TM10091 (11JAN08)
33-3360-71

011108
PN=301
TX1004704
UN16MAR06
Hydraulic System
Control Valve End Caps (4-Spool Side)
OUO6046,000231F 1919APR072/6
TM10091 (11JAN08)
33-3360-72

011108
PN=302
TX1004708
UN16MAR06
33 3360 72
Hydraulic System
1Housing 2Poppet 3Spring (2 used) 4O-Ring (3 used) 5Flange 6Cap Screw (13 used) 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 Anticavitation Valve (2 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 38Spring Seat (8 used) 39Spring (4 used) 40Body 41Cap Screw (4 used) 42Plug 43Backup Ring (2 used) 44O-Ring 45Spring 46Poppet 47Bucket Spool 48Plug 49Poppet 50Boom 1 Spool 51Arm 2 Spool 52Spring Seat (2 used) 53Spring 54Arm Regenerative Spool 55O-Ring 56Backup Ring 57Arm Regenerative Spool 58Spring 59O-Ring (8 Used) 60O-Ring 61Plug 62Top Pilot Cap 63Cap Screw (14 Used) 64Bottom Pilot Cap 65O-Ring 66Plug 67Cap (3 Used) 68Cap Screw (2 Used) 69Cap 70Cap Screw 71Spring Seat (2 Used) 72Spring 73Travel Flow Combiner Spool 74Circuit Relief and Anticavitation Valve (2 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 97Cap Screw (12 Used) 98Poppet 99Poppet 100Spring 101Plug 102O-Ring 103Cap 104Cap Screw (4 Used) 105By-Pass Shut-Off Spool 106Spring 107Flange 108Poppet 109Poppet 110Spring 111Plug 112Poppet 113Spring 114Plug (3 Used) 115O-Ring (3 Used) 116Spring Seat (3 Used) 117Spring 118Arm 2 Flow Rate Spool 119Plug (3 Used) 120O-Ring (3 Used) 121Spring 122Arm 2 Flow Rate Spool 123Body 124Arm 2 Flow Rate Spool 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
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). 3. Spool4 Spool (130133):
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. 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 73
OUO6046,000231F 1919APR073/6
TM10091 (11JAN08)
33-3360-73

011108
PN=303
Hydraulic System
NOTE: Hold the spool in a vise by the spool end, using wooden blocks. b. Remove cap screws (41) and spools. c. Heat plugs (46, 48, and 49) with heat gun to melt thread lock and sealer and remove plugs. 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 Cap Screw-to-Control Valve SpoolTorque ......................................................................... 15 Nm 11 lb-ft
j. Install spools (130133) into housing (1) while rotating them slowly. IMPORTANT: After installing spool (130133) into housing (1), push them by hand to confirm smoothness. 4. Travel Flow Combiner Valve (135):
c. Inspect parts for wear and damage. d. Replace parts as necessary. e. Assemble in reverse order. f. Tighten cap screw (70) to specification.
Specification Cap Screw-to-Flow Combiner Valve SpoolTorque............................................................... 11 Nm 7 lb-ft
g. For bucket and boom 1 spool (131 and 132): 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
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
i. Install cap screw (41) into spool and tighten to specification.

Specification Cap Screw-to-Control Valve SpoolTorque ......................................................................... 15 Nm 11 lb-ft
5. Arm Regenerative Valve (134): a. Remove parts (4, 5458). b. Inspect parts for wear and damage. c. Replace parts as necessary. d. Assemble in reverse order.
33 3360 74
NOTE: Apply hydraulic oil to spools before installation.
OUO6046,000231F 1919APR074/6
TM10091 (11JAN08)
33-3360-74

011108
PN=304
Hydraulic System
e. Install parts (4, 5458). 6. Arm 2 Flow Rate Control Valve (138): a. Remove cap screws (97) and body (123). b. Remove O-rings (77, 13) and poppet (15). c. Remove plugs (114), spring seats (116), springs (117, 121, 125) and spools (118, 122, 124). d. Remove plugs (119) and (127). e. Remove spring (113) and poppet (112). f. Remove springs (87) and poppets (98, 108). Remove plugs (101, 111), springs (100, 110) and poppets (99, 109) from poppets (98, 108). 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 Body-to-Housing Cap Screw Torque...................................................................................... 61 Nm 45 lb-ft Specification Boom Reduced Leakage Valve-to-Body PlugTorque ................................................. 108 Nm 80 lb-ft
g. Apply petroleum jelly to washer (22) and spring (21) to hold them in place. h. Install spool (30), with hole side towards poppet (23). i. Install parts (3335). j. Loosely install plug (36). k. Install and tighten cap screws (6) to specification.
Specification Boom Reduced Leakage Valve Body-to-Housing Cap Screw Torque...................................................................................... 62 Nm 46 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): a. Remove plug (36). b. Remove parts (3335). c. Remove cap screws (6) and body (32). d. Remove parts (2131). e. Inspect parts for wear and damage. f. Replace parts as necessary.
c. Remove (8388) from housing (1). d. Inspect parts for wear and damage. e. Replace parts as necessary. f. Assemble in reverse order. g. Install housing (91) and tighten cap screws (97) to specification.
33 3360 75
OUO6046,000231F 1919APR075/6
TM10091 (11JAN08)
33-3360-75

011108
PN=305
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
c. Inspect parts for wear and damage. d. Replace parts as necessary. e. Install O-ring (4) and parts (105107); then tighten cap screws (6) to specification.
Specification By-Pass Shut-Off Valve-to-Housing Cap Screw 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). c. Inspect parts for wear and damage. d. Replace parts as necessary. e. Assemble in reverse order. f. Install housing (40) and tighten cap screws (6) to specification.
Specification Boom Reduced Leakage Valve-to-Housing Cap Screw Torque...................................................................................... 61 Nm 46 lb-ft
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
12. Install bottom pilot caps (64 and 67) and tighten cap screws (63) to specification.
Specification Bottom Pilot Cap-to-Housing Cap ScrewTorque ................................................................ 42 Nm 32 lb-ft
OUO6046,000231F 1919APR076/6
33 3360 76
Hydraulic Oil Tank Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1).
TJ15698,000013A 1911APR071/5
TM10091 (11JAN08)
33-3360-76

011108
PN=306
TX1020196A
UN07MAR07
Hydraulic System
2. Remove covers (1 and 2). 3. Drain hydraulic oil tank. Approximate capacity is 120.4 L (31.8 gal).
1Engine Cover 2Control Valve Cover
TJ15698,000013A 1911APR072/5
4. Tag and disconnect hoses (3) and lines (2). 5. Close all open lines and fittings using caps and plugs.
UN07MAR07
6. Remove cap screw (1).

1Cap Screw 2Return Line (2 used) 3Hydraulic Hose (4 used)
TJ15698,000013A 1911APR073/5
TX1020242A
TX1020325A
UN09MAR07
33 3360 77
TM10091 (11JAN08)
33-3360-77

011108
PN=307
Hydraulic System
7. Remove bracket (2). 8. Disconnect electrical connector (6). 9. Remove bottom cover and disconnect pump supply hose. 10. Tag and disconnect hoses (7). 11. Close all open hoses and fittings using caps and plugs.
UN07MAR07
12. Remove clamps (4) and filter housings (1 and 3) from tank and support. 13. Remove cap screws (5).
Specification Hydraulic Oil TankWeight ....................................... 102 kg approximate 225 lb approximate
14. Remove hydraulic oil tank using a hoist and lifting straps. 15. Remove tank components. See Hydraulic Oil Tank Disassemble and Assemble. (Group 3360.) 16. Repair or replace parts as necessary. 17. Install tank components. See Hydraulic Oil Tank Disassemble and Assemble. (Group 3360.) 18. Install hydraulic oil tank. 19. Tighten tank mounting cap screws to specification.
Specification Hydraulic Oil Tank-to-Frame Cap ScrewTorque ............................................................................. 400 Nm 295 lb-ft
1Engine Oil Filter Housing 2Panel Latch Bracket 3Pilot Pressure Regulating Valve and Filter Housing 4Clamps (4 used) 5Cap Screws (4 used) 6Electrical Connector 7Hydraulic Hose
33 3360 78
TJ15698,000013A 1911APR074/5
TM10091 (11JAN08)
33-3360-78

011108
PN=308
TX1020243A
Hydraulic System
20. Connect return lines and hoses. 21. Connect electrical connector (6). 22. Install filter housings (1 and 3), hoses (7), clamps (4), and bracket (2). 23. Install covers. 24. Fill hydraulic oil tank. Approximate capacity is 120.4 L (31.8 gal). IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 25. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
1Engine Oil Filter Housing 2Panel Latch Bracket 3Pilot Pressure Regulating Valve and Filter Housing 4Clamps (4 used) 5Cap Screws (4 used) 6Electrical Connector 7Hydraulic Hose
UN07MAR07
TJ15698,000013A 1911APR075/5
TX1020243A
33 3360 79
TM10091 (11JAN08)
33-3360-79

011108
PN=309
Hydraulic System
Hydraulic Oil Tank Disassemble and Assemble
33 3360 80
TJ15698,0000137 1930MAR071/2
TM10091 (11JAN08)
33-3360-80

011108
PN=310
TX1020244
UN07MAR07
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) 11Cap Screw (6 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 23Cover 31Washer (4 used ) 32Cap Screw (4 used) 33Filter Element 33ASealing Ring 33BValve 33CO-Ring 33DFilter Element
1. Tighten cap screws (4 and 11).

Specification Covers-to-Hydraulic Oil Tank Cap ScrewsTorque .............................................................. 49 Nm 36 lb-ft
3. Tighten nuts on suction strainer rod.

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
TJ15698,0000137 1930MAR072/2
Restriction Valve Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) Approximate oil capacity is 120.4 L (31.8 gal).
TX1020196A
UN07MAR07
33 3360 81
TJ15698,0000143 1911APR071/3
TM10091 (11JAN08)
33-3360-81

011108
PN=311
Hydraulic System
TJ15698,0000143 1911APR072/3
TM10091 (11JAN08)
33-3360-82

011108
PN=312
TX1020324
UN09MAR07
33 3360 82
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 12O-Ring 13Restriction Valve 14Snap Ring
3. Remove clamp (6). 4. Disconnect hose (3) from line (11). 5. Remove snap ring (14) and restriction valve (13). 6. Repair or replace parts as necessary. 7. Install restriction valve (13) and snap ring (14). 8. Connect hose (3) to line (11).
Specification Hydraulic Oil Tank Return Line Coupling Cap ScrewTorque ................................................. 90 Nm 66 lb-ft
9. Fill hydraulic oil tank. Approximate oil capacity is 120.4 L (31.8 gal). IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 10. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
TJ15698,0000143 1911APR073/3
Hydraulic Oil Cooler Bypass Valve Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain tank. See Apply Vacuum to Hydraulic Oil Tank. (Group 3360.) Approximate oil capacity is 120.4 L (31.8 gal).
TX1020196A
UN07MAR07
33 3360 83
TJ15698,0000136 1911APR071/2
TM10091 (11JAN08)
33-3360-83

011108
PN=313
Hydraulic System
6
5
3
1
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). 4. Remove socket head cap screws (4) and hydraulic return line (5). 5. Remove oil cooler bypass valve (3) and O-ring (2) from control valve (1). Repair or replace as necessary. 6. Install oil cooler bypass valve (3) and O-ring (2). 7. Install hydraulic line (5). 8. Install socket head cap screws (4). Tighten to specification.
Specification Return Line Flange-to-Control Valve Socket Head Cap ScrewsTorque ...................................................................... 50 Nm 37 lb-ft
9. Tighten nuts on coupling.

Specification Control Valve-to-Hydraulic Oil Tank Return Line Coupling NutsTorque........................................................................... 11 Nm 97 lb-in.
10. Fill hydraulic oil tank. Approximate oil capacity is 120.4 L (31.8 gal). IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 11. Perform pump 1 and 2 start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
33 3360 84
TJ15698,0000136 1911APR072/2
TM10091 (11JAN08)
33-3360-84

011108
PN=314
TX1004061
Hydraulic System
Boom Cylinder Remove and Install

NOTE: Procedure is the same for both boom cylinders. 1. Park machine on firm, level surface. 2. Retract arm and bucket cylinders and lower bucket to ground.
UN10JAN97
OUO6046,0002320 1918APR071/6
CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 3. Push pressure release button (1). 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.
UN07MAR07
OUO6046,0002320 1918APR072/6

Specification Boom CylinderWeight .................................................................. 155 kg 342 lb
7. Attach appropriate lifting device to boom cylinder (1) using lifting strap.
1Boom Cylinder
UN21APR06
TX1020196A
T106031
33 3360 85
OUO6046,0002320 1918APR073/6
TM10091 (11JAN08)
33-3360-85

011108
PN=315
TX1006808
Hydraulic System
8. Remove parts (13, and 5). 9. Push pin (4) into boom. 10. Lower boom cylinder (6) on floor stand.
1Nut (2 used) 2Retainer 3Cap Screw 4Boom Cylinder-to-Boom Pin 5Shim (2 used) 6Boom Cylinder
OUO6046,0002320 1918APR074/6
33 3360 86
TM10091 (11JAN08)
33-3360-86

011108
PN=316
T142979
UN24JUL01
Hydraulic System
11. Disconnect hydraulic lines (7) from head end of boom cylinder (6). Close all open lines and fitting using caps and plugs. 12. Mark location of shims (8) to aid in assembly. 13. Remove parts (811) and remove boom cylinder (6). 14. Repair or replace parts as necessary. 15. Install shims equally on each side of cylinder head end to get the minimum amount of clearance in joint. 16. Align pin bores so shims are not damaged as pin (10) is installed. 17. Connect boom cylinder head end to frame. 18. Tighten nuts (11) against each other allowing cap screws (9) to be free to turn in hole.
Specification Boom Cylinder-to-Frame Pin Retainer NutTorque ........................... 270 Nm (tighten nut against nut) 200 lb-ft (tighten nut against nut)
UN02AUG01 T143048
10
11
11
6Boom Cylinder 7Hydraulic Lines 8Shim (as required) 9Cap Screw (2 used) 10Boom Cylinder-to-Frame Pin (2 used) 11Nut (4 used)
19. Connect lines. See Hydraulic System Line Connections. (Group 9025-15.) 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 87
OUO6046,0002320 1918APR075/6
TM10091 (11JAN08)
33-3360-87

011108
PN=317
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. 25. Tighten nuts (1) against each other allowing cap screw (3) to be free to turn in hole.
Specification Boom Cylinder-to-Frame Pin Retainer NutTorque ........................... 550 Nm (tighten nut against nut) 405 lb-ft (tighten nut against nut)
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 Procedure. (Group 3360.) 29. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operators Manual.)
33 3360 88
OUO6046,0002320 1918APR076/6
TM10091 (11JAN08)
33-3360-88

011108
PN=318
Hydraulic System
Boom Cylinder Disassemble and Assemble
7
12
10 11
20
16 17
19
TX1004547
1Rod 2Dust Wiper 3Backup Ring 4U-Ring 5Buffer Ring 6Cap Screw (12 used) 7Cylinder Head 8Bushing 9Snap Ring 10Backup Ring 11O-Ring 12Barrel 13Slide Ring (2 used) 14Wear Ring (2 used) 15Backup Ring (2 used) 16O-Ring 17Seal Ring 18Set Screw 19Ball 20Piston Nut 21Cushion Bearing 22Cushion Seal

Specification Boom CylinderApproximate Weight ....................................................................................... 155 kg 342 lb
2. Pull rod out so piston nut is against cylinder head. 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).
33 3360 89
1. Fasten head end of cylinder to JT30043 Cylinder Service Stand.
OUO6046,0002321 1905APR071/3
TM10091 (11JAN08)
33-3360-89

011108
PN=319
TX1004547
22
UN14MAR06
21
13
14 15 14
13
18
TX1004546
UN14MAR06
Hydraulic System
6. Install rod eye in sliding housing and install housing in JT30043 Cylinder Service Stand. 7. Make an alignment mark on piston nut (20) and rod (1). 8. Remove staked material from set screw (18) hole using a small air grinder or a drill and bit. 9. Remove set screw (18) and steel ball (19). IMPORTANT: To avoid damaging tapped hole for set screw, cap screw in ST3243 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 ST3243 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (20) without tapped hole. 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.................................................................................. 4000 Nm 2950 lb-ft
IMPORTANT: Note direction of dust wiper (2) and U-ring (4) for installation. 16. Remove components (25) and (911) from cylinder head (7). 17. Remove bushing (8) using ST8019. 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
20. Repair or replace parts as necessary. 21. Install bushing (8) into cylinder head (7) using ST8019. Press to bottom of bore. 22. Install snap ring (9). 23. Install backup ring (10) and O-ring (11). 24. Install buffer ring (5). 25. Install U-ring (4) with lip towards bushing (8). 26. Install backup ring (3). 27. Install dust wiper (2) using ST8019 with lip towards outside of cylinder. 28. Install assembled cylinder head (7) on rod (1) using ST8019. 29. Install O-ring (16) and seal ring (17) to piston nut (20) using ST2962 Installer. Adjust seal ring (17) using ST2205 Adjustment Tool. 30. Install backup rings (15) on each side of seal ring.
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 90
14. Remove components (1317) from piston nut (20). 15. Remove cylinder head (7) from rod (1).
OUO6046,0002321 1905APR072/3
TM10091 (11JAN08)
33-3360-90

011108
PN=320
Hydraulic System
31. Install wear rings (14) and slide rings (13) to piston nut (20). IMPORTANT: Install cushion seal (22) so that notch is towards piston. 32. Install cushion seal (22). IMPORTANT: Note direction of oil groove in cushion bearing (21) during installation. 33. Install cushion bearing (21). 34. Align marks made during disassembly and install piston nut (20). IMPORTANT: To avoid damaging tapped hole for set screw, cap screw in ST3243 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. 35. Install ST3243 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (20) 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.
Specification Boom Cylinder Piston Nut Torque.................................................................................. 4000 Nm 2950 lb-ft
36. Install steel ball (19) and set screw (18). 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
OUO6046,0002321 1905APR073/3
Arm Cylinder Remove and Install

1. Park machine on firm, level surface. 2. Retract arm and bucket cylinders and lower bucket to ground.
UN10JAN97
33 3360 91
OUO6046,0002322 1905APR071/6
TM10091 (11JAN08)
33-3360-91

011108
PN=321
T106031
Hydraulic System
CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by pushing pressure release button (1). 3. Push pressure release button (1). 4. Loosen arm 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.
UN07MAR07
OUO6046,0002322 1905APR072/6
6. Insert wood block (3) between arm cylinder (1) and boom (2).
Specification Arm CylinderWeight .................................................................... 205 kg 452 lb
UN02AUG01
7. Attach arm cylinder to appropriate lifting device using lifting straps.

1Arm Cylinder 2Boom 3Wood Block
OUO6046,0002322 1905APR073/6
33 3360 92
TM10091 (11JAN08)
33-3360-92

011108
PN=322
T143063
TX1020196A
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.
1Nut (2 used) 2Cap Screw 3Shim (as required) 4Arm Cylinder-to-Arm Pin
OUO6046,0002322 1905APR074/6
T143064
UN02AUG01
33 3360 93
TM10091 (11JAN08)
33-3360-93

011108
PN=323
Hydraulic System
11. Remove parts (1 and 2). NOTE: Note location of shims (3) to aid in assembly. 12. Push pin (4) out and remove shims. 13. Remove arm cylinder 14. Repair or replace parts as necessary. 15. Install shims equally on each side of cylinder to get minimum amount of clearance in joint. There must be some clearance in the joint. 16. Align pin bores so shims are not damaged as pin (4) is installed. 17. Connect lubrication line.
Specification Arm Cylinder Pivot Lubrication LineTorque .................................................................................. 25 Nm 18 lb-ft
UN02AUG01
1Nut (2 used) 2Cap Screw 3Shim (as required) 4Arm Cylinder-to-Boom Pin
18. Connect arm cylinder head end to boom. 19. Tighten nuts (1) against each other allowing cap screw (2) to be free to turn in hole.
Specification Arm Cylinder-to-Boom Pin Retainer NutTorque ........................... 550 Nm (tighten nut against nut) 405 lb-ft (tighten nut against nut)
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.
33 3360 94
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.
OUO6046,0002322 1905APR075/6
TM10091 (11JAN08)
33-3360-94

011108
PN=324
T143065
Hydraulic System
22. Tighten nuts (1) against each other allowing cap screw (2) to be free to turn in hole.
Specification Arm Cylinder-to-Arm Pin Retainer NutTorque .......................................... 550 Nm (tighten nut against nut) 405 lb-ft (tighten nut against nut)
23. Connect lubrication line.

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
OUO6046,0002322 1905APR076/6
33 3360 95
TM10091 (11JAN08)
33-3360-95

011108
PN=325
Hydraulic System
Arm Cylinder Disassemble and Assemble
7
18
13
10 11
26 24
20 21
23 16 15 TX1004549
1Rod 2Dust Wiper 3Backup Ring 4U-Ring 5Buffer Ring 6Cap Screw (12 used) 7Cylinder Head
8Bushing 9Snap Ring 10Backup Ring 11O-Ring 12Barrel 13Stopper (2 used) 14Cushion Bearing
15Cushion Seal 16Snap Ring 17Slide Ring (2 used) 18Wear Ring (2 used) 19Backup Ring (2 used) 20O-Ring
21Seal Ring 22Set Screw 23Ball 24Piston Nut 25Cushion Bearing 26Cushion Seal

33 3360 96
Specification Arm CylinderApproximate Weight ...................................................................................... 205 kg 452 lb
2. Pull rod out so piston nut is against cylinder head. 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).
1. Fasten head end of cylinder to JT30043 Cylinder Service Stand.
OUO6046,000232A 1909APR071/3
TM10091 (11JAN08)
33-3360-96

011108
PN=326
TX1004549
UN14MAR06
25
17
18 19 18
17
22
14
TX1004548
UN14MAR06
Hydraulic System
IMPORTANT: Note direction of oil groove in cushion bearing (14) and notch in cushion seal (15) for installation. 6. Remove stopper (13), cushion bearing (14), cushion seal (15), and snap ring (16). 7. Install rod eye in sliding housing and install housing in JT30043 Cylinder Service Stand. 8. Make an alignment mark on piston nut (24) and rod (1). 9. Remove staked material from set screw (22) hole using a small air grinder or a drill and bit. 10. Remove set screw (22) and steel ball (23). IMPORTANT: To avoid damaging tapped hole for set screw, cap screw in ST3245 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. 11. Install ST3245 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (24) without tapped hole. 12. Install a piece of steel flat stock between nut and cap screw. Tighten cap screw of piston nut wrench. 13. Remove piston nut (24) using JT30043 Cylinder Service Stand.
Specification Arm Cylinder Piston Nut Torque.................................................................................. 5150 Nm 3799 lb-ft
14. Remove cushion bearing (25) and cushion seal (26) from rod (1). 15. Remove components (1721) from piston nut (24). 16. Remove cylinder head (7) from rod (1). IMPORTANT: Note direction of dust wiper (2) and U-ring (4) for installation. 17. Remove components (25) and (911) from cylinder head (7). 18. Remove bushing (8) using ST8024. 19. 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.) 20. Check for rod curvature on V-blocks using dial indicator.
Specification Arm Cylinder RodCurvature ................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft
21. Repair or replace parts as necessary. 22. Install bushing (8) into cylinder head (7) using ST8024. Press to bottom of bore. 23. Install snap ring (9). 24. Install backup ring (10) and O-ring (11). 25. Install buffer ring (5). 26. Install U-ring (4) with lip towards bushing (8). 27. Install backup ring (3). 28. Install dust wiper (2) using ST8024 with lip towards outside of cylinder.
33 3360 97
IMPORTANT: Note direction of oil groove in cushion bearing (25) and notch in cushion seal (26) for installation.
OUO6046,000232A 1909APR072/3
TM10091 (11JAN08)
33-3360-97

011108
PN=327
Hydraulic System
29. Install assembled cylinder head (7) on rod (1) using ST8024. 30. Install O-ring (20) and seal ring (21) to piston nut (24) using ST2964 Installer. Adjust seal ring (21) using ST2208 Adjustment Tool. 31. Install backup rings (19) on each side of seal ring. 32. Install slide rings (17) and wear rings (18) to piston nut (24). IMPORTANT: Install cushion seal (26) so that notch is towards piston. 33. Install cushion seal (26). IMPORTANT: Note direction of oil groove in cushion bearing (25) during installation. 34. Install cushion bearing (25). 35. Align marks made during disassembly and install piston nut (24). IMPORTANT: To avoid damaging tapped hole for set screw, cap screw in ST3245 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. 36. Install ST3245 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (24) 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 (24) to specification using JT30043 Cylinder Service Stand.
Specification Arm Cylinder Piston Nut Torque.................................................................................. 5150 Nm 3799 lb-ft
37. Install steel ball (23) and set screw (22). 38. Stake set screw (22) in two places 90 from previous stake marks. IMPORTANT: Install cushion seal (15) so that notch is towards piston. 39. Install snap ring (16) and cushion seal (15). IMPORTANT: Note direction of oil groove in cushion bearing (14) during installation. 40. Install cushion bearing (14) and stopper (13). 41. 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. 42. Install cylinder head cap screws (6). Tighten to specification.
Specification Arm Cylinder Head-to-Barrel Cap ScrewTorque .............................................................. 267 Nm 197 lb-ft
33 3360 98
OUO6046,000232A 1909APR073/3
TM10091 (11JAN08)
33-3360-98

011108
PN=328
Hydraulic System
Bucket Cylinder Remove and Install

1. Park machine on firm, level surface. 2. Retract arm cylinder and bucket cylinder (1) and lower bucket to ground. Position end of arm (2) on wood block (3).
1Bucket Cylinder 2End of Arm 3Wood Block
OUO6046,000232B 1909APR071/5
UN07MAR07
OUO6046,000232B 1909APR072/5
TX1020196A
TX1006807
UN21APR06
T106031
UN10JAN97
33 3360 99
TM10091 (11JAN08)
33-3360-99

011108
PN=329
Hydraulic System
4. Disconnect lines. Close all open lines and fittings using caps and plugs. 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. 7. Remove parts (2 and 6). 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
UN02AUG01
OUO6046,000232B 1909APR073/5
33 3360 ,100
TM10091 (11JAN08)
33-3360-100

011108
PN=330
T143075
Hydraulic System

Specification Bucket CylinderWeight................................................................ 120 kg 265 lb
9. Disconnect bucket cylinder rod end hose (1). 10. Connect bucket cylinder (2) to appropriate lifting device using lifting strap. 11. Remove parts (3 and 5). NOTE: Mark location of shims (4) to aid in assembly. 12. Push pin (6) out and remove shims (4). 13. Remove bucket cylinder. 14. Repair or replace parts as necessary. See Bucket Cylinder Disassemble and Assemble. (Group 3360.) 15. Install shims equally on each side of bucket cylinder head end to get minimum amount of clearance in joint. 16. Align pin bores so shims are not damaged as pin is installed. 17. Connect bucket cylinder head end to arm. 18. Tighten nuts (3) against each other allowing cap screw (5) to be free to turn in hole.
Specification Bucket Cylinder-to-Arm Pin Retainer NutTorque ........................... 270 Nm (tighten nut against nut) 200 lb-ft (tighten nut against nut)
3
UN02AUG01 T143076
1Bucket Cylinder Rod End Hose 2Bucket Cylinder 3Nut (2 used) 4Shim (as required) 5Cap Screw 6Bucket Cylinder-to-Arm Pin
19. Connect lines. See Hydraulic System Line Connections. (Group 9025-15.) 20. Tighten bucket cylinder hoses.
Specification Bucket Cylinder HoseTorque .................................................... 175 Nm 130 lb-ft
33 3360 ,101
OUO6046,000232B 1909APR074/5
TM10091 (11JAN08)
33-3360-101

011108
PN=331
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 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) 405 lb-ft (tighten nut against nut)
33 3360 ,102
OUO6046,000232B 1909APR075/5
TM10091 (11JAN08)
33-3360-102

011108
PN=332
Hydraulic System
Bucket Cylinder Disassemble and Assemble

1
7
8 10
11
9
6
12
UN09MAR06
18
19
14
13 14
20
15 17 16 15 13
6
TX1004550
12
10 11
TX1004551
1Rod 2Dust Wiper 3Backup Ring 4U-Ring 5Buffer Ring 6Cap Screw (12 used) 7Cylinder Head 8Bushing 9Snap Ring 10Backup Ring 11O-Ring 12Barrel 13Slide Ring (2 used) 14Wear Ring (2 used) 15Backup Ring (2 used) 16O-Ring 17Seal Ring 18Set Screw 19Ball 20Piston Nut

Specification Bucket CylinderApproximate Weight ...................................................................................... 120 kg 265 lb
4. Remove cap screws (6) from cylinder head (7). 5. Remove rod, cylinder head and piston nut from barrel (12). 6. Install rod eye in sliding housing and install housing in JT30043 Cylinder Service Stand. 7. Make an alignment mark on piston nut (20) and rod (1). 8. Remove staked material from set screw (18) hole using a small air grinder or a drill and bit.
TX1004551
16 17
19
UN09MAR06
13 14
15
14 13
20
18
TX1004550
1. Fasten head end of cylinder to JT30043 Cylinder Service Stand. 2. Pull rod out so piston nut is against cylinder head. 3. Connect rod to appropriate lifting device using a lifting strap.
33 3360 ,103
OUO6046,000232C 1909APR071/3
TM10091 (11JAN08)
33-3360-103

011108
PN=333
Hydraulic System
9. Remove set screw (18) and steel ball (19). IMPORTANT: To avoid damaging tapped hole for set screw, cap screw in ST3242 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 ST3242 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (20) without tapped hole. 11. Install a piece of steel flat stock between nut and cap screw. Tighten cap screw of piston nut wrench. 12. Remove piston nut (20) using JT30043 Cylinder Service Stand.
Specification Bucket Cylinder Piston Nut Torque.................................................................................. 4280 Nm 3157 lb-ft
parts as necessary. See Inspect Pins, Bushings and BossesFront Attachment. (Group 3340.) 18. Check for rod curvature on V-blocks using dial indicator.
Specification Bucket Cylinder Rod Curvature ................................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft
19. Repair or replace parts as necessary. 20. Install bushing (8) into cylinder head (7) using ST8018. Press to bottom of bore. 21. Install snap ring (9). 22. Install backup ring (10) and O-ring (11). 23. Install buffer ring (5). 24. Install U-ring (4) with lip towards bushing (8). 25. Install backup ring (3). 26. Install dust wiper (2) using ST8018 with lip towards outside of cylinder. 27. Install assembled cylinder head (7) on rod (1) using ST8018. 28. Install O-ring (16) and seal ring (17) to piston nut (20) using ST2977 Installer. Adjust seal ring (17) using ST2332 Adjustment Tool. 29. Install backup rings (15) on each side of seal ring. 30. Install slide rings (13) and wear rings (14) to piston nut (20). 31. Align marks made during disassembly and install piston nut (20).
13. Remove components (1317) from piston nut (20). 14. Remove cylinder head (7) from rod (1). IMPORTANT: Note direction of dust wiper (2) and U-ring (4) for installation. 15. Remove components (25) and (911) from cylinder head (7). 16. Remove bushing (8) using ST8018. 17. Inspect dust seals and bushings in rod (1) and barrel (12) for wear or damage. Repair or replace
33 3360 ,104
OUO6046,000232C 1909APR072/3
TM10091 (11JAN08)
33-3360-104

011108
PN=334
Hydraulic System
IMPORTANT: To avoid damaging tapped hole for set screw, cap screw in ST3242 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. 32. Install ST3242 Hex Piston Nut Wrench so cap screw is tightened against side of piston nut (20) 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.
Specification Bucket Cylinder Piston Nut Torque.................................................................................. 4280 Nm 3157 lb-ft
33. Install steel ball (19) and set screw (18). 34. Stake set screw (18) in two places 90 from previous stake marks. 35. 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. 36. Install cylinder head cap screws (6). Tighten to specification.
Specification Bucket Cylinder Head-to-Barrel Cap ScrewTorque .............................................................. 267 Nm 197 lb-ft
OUO6046,000232C 1909APR073/3
33 3360 ,105
TM10091 (11JAN08)
33-3360-105

011108
PN=335
Hydraulic System
Hydraulic Cylinder Bleed Procedure

IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod 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. NOTE: Bleed air at initial start-up, whenever major repairs or maintenance (oil change) is done on hydraulic system, or when machine has been in storage for a period of time. 1. Run engine at slow idle. 2. Slowly operate function to move cylinder to the most horizontal position possible. 3. Slowly extend and retract cylinder several times to approximately 100 mm (4 in.) from end of stroke. 4. Operate cylinder several times to full stroke. 5. Check hydraulic oil level. See Check Hydraulic Tank Oil Level. (Operators Manual.)
OUO6046,000232D 1905APR071/1
33 3360 ,106
TM10091 (11JAN08)
33-3360-106

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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 . . . . . . . .43-4350-20
Group 4360Hydraulic System 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
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43-1

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Contents
43
TM10091 (11JAN08)
43-2

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Group 4350
Mechanical Drive Elements

Swing Gearbox Remove and Install
CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 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 120.4 L (31.8 gal).
TJ15698,000013B 1911APR071/3
TX1020196A
UN07MAR07
43 4350 1
TM10091 (11JAN08)
43-4350-1

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PN=339

3. Tag and disconnect lines from swing motor. Close all open lines and fittings using caps and plugs.
CAUTION: Heavy component; use appropriate lifting device. NOTE: Swing motor may be removed by itself or with swing gearbox. See Swing Motor and Park Brake Remove and Install. (Group 4360.) Mark swing gearbox housing to machine upperstructure to aid in installation. 4. Install JT01748 Lifting Brackets and connect to appropriate lifting device.
Specification Swing Motor, Brake, and GearboxWeight ............................................................................ 218 kg 481 lb
1Cap Screw and Washer (14 used) 2Electrical Connector
5. Disconnect electrical connector (2). 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. 11. Tighten cap screws.
Specification Swing Gearbox-to-Upperstructure Cap ScrewTorque ..................................................................... 500 Nm 369 lb-ft
12. Connect electrical connector (2). 13. Connect lines. See Hydraulic System Line Connections. (Group 9025-15.)
43 4350 2
TJ15698,000013B 1911APR072/3
TM10091 (11JAN08)
43-4350-2

011108
PN=340
TX1003159A
UN02FEB06

14. See Swing Gearbox Start-Up Procedure. (Group 4350.) See Swing Motor and Park Brake Start-Up Procedure. (Group 4360.) 15. If hydraulic oil tank was drained, fill hydraulic oil tank. Approximate oil capacity is 120.4 L (31.8 gal). IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 16. If hydraulic oil tank was drained, perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
TJ15698,000013B 1911APR073/3
43 4350 3
TM10091 (11JAN08)
43-4350-3

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Swing Gearbox Disassemble and Assemble
43 4350 4
TJ15698,0000119 1911APR071/8
TM10091 (11JAN08)
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TX1018815
UN09FEB07

0Swing Gearbox 1Shaft 2Sleeve 3O-Ring 4Roller Bearing 5Seal 6Housing 7Roller Bearing 8Bearing Nut 9Plate 10Cap Screw 11Second Planetary Pinion Carrier 12Washer 13Pin (2 used) 14Planetary Gear (3 used) 15Needle Bearing (6 used) 16Thrust Plate (3 used) 17Spring Pin (3 used) 18Second Stage Sun Gear 20Ring Gear Housing 21Cap Screw (12 used) 23First Planetary Pinion Carrier 24Thrust Plate 25Pin (3 used) 26Planetary Gear (3 used) 27Needle Bearing (3 used) 28Thrust Plate (3 used) 29Spring Pin (3 used) 30Snap Ring 31First Stage Sun Gear 33Line 34Fitting Plug (2 used) 36Fitting Plug
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.)
Specification Swing MotorWeight ................................................................. 48 kg 105 lb
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). 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.
3. Remove first planetary pinion carrier assembly (23-29) from ring gear housing (20). NOTE: First stage sun gear (31) may be removed separately or along with carrier.
Specification Ring GearWeight..................................................................... 23 kg 50 lb
IMPORTANT: Damaging the surface of pin (25) can cause bearing failure, use care when handling pin. 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).
4. Remove cap screws (21) and ring gear housing (20). 5. Remove second planetary pinion carrier assembly (11-18). NOTE: Second stage sun gear (18) may be removed separately or with carrier.
43 4350 5
TJ15698,0000119 1911APR072/8
TM10091 (11JAN08)
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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

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
TJ15698,0000119 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).
1Shaft 6Housing
1
6
UN01MAR06
TJ15698,0000119 1911APR074/8
43 4350 6
TM10091 (11JAN08)
43-4350-6

011108
PN=344
TX1004268
TX1004267

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). 19. Remove O-ring (3) from sleeve (2). 20. Insert a round bar into oil passage in housing (6). Tap and remove outer race of roller bearing (4). 21. Remove oil seal (5) from housing (6). NOTE: Oil seal (5) can not be reused. 22. Remove outer race of roller bearing (7) from housing (6) using brass drift and hammer. 23. Repair or replace parts as necessary. 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). 27. Apply PM38656 Thread Lock and Sealer (High 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). 4
2
1
UN19APR06 TX1004269
TX1004269
1Shaft 2Sleeve 4Roller Bearing

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
TJ15698,0000119 1911APR075/8
TM10091 (11JAN08)
43-4350-7

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PN=345

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.)
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
TJ15698,0000119 1911APR076/8
TM10091 (11JAN08)
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45. Align holes in pins (13) and planetary carrier (11).
TJ15698,0000119 1911APR077/8
43 4350 9
TM10091 (11JAN08)
43-4350-9

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PN=347

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. 47. Assemble first planetary pinion carrier (23) assembly following Step 43 through 46. 48. Align the spline of shaft (1) and install the second planetary carrier assembly (11). 49. Install thrust plate (12) with oil grooves towards second planet pinion carrier (11). 50. Install second stage sun gear (18) into second planetary pinion carrier (11) assembly with smaller diameter of second stage sun gear upward. 51. Apply PM38656 Thread Lock and Sealer (High Strength) to ring gear housing (20) mounting surface of housing (6). 52. Align mating marks and install ring gear housing (20) to housing (6). 53. Apply PM37418 Thread Lock and Sealer (Medium Strength) to cap screws (21). Tighten cap screws (21) to specification.
Specification Ring Gear Housing-to-Housing Cap ScrewTorque ..................................................................... 210 Nm 155 lb-ft
13
TX1004270
13Pin (2 used) 38Slit
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 Remove and Install. (Group 4360.)
43 4350 10
TJ15698,0000119 1911APR078/8
TM10091 (11JAN08)
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TX1004270
UN19APR06
38
Swing Gearbox Start-Up Procedure

IMPORTANT: Swing gearbox will be damaged if not filled with oil before operating swing function. Procedure must be performed whenever a new swing gearbox is installed or oil has been drained from the gearbox. 1. Check that drain line plug is installed. 2. Remove fill cap (2) and add oil. See Swing Gearbox and Travel Gearbox Oils. (Operators Manual.) 3. Install fill cap. Check oil level on dipstick (1).
1Dipstick 2Fill Cap
TJ15698,000013C 1911APR071/1
Upperstructure Remove And Install

1. Clean machine thoroughly.
UN07MAR07
2. Disconnect negative battery cables.

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button (1). 3. Push pressure release button (1). 4. Drain hydraulic oil tank. Approximate capacity is 120.4 L (31.8 gal). 5. Remove cab. See Cab Remove and Install. (Group 1800.) 6. Remove counterweight. See Counterweight Remove and Install. (Group 1749.) 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.)
TX1020196A
TX1001071A
UN02DEC05
43 4350 11
TJ15698,000017F 1911APR071/4
TM10091 (11JAN08)
43-4350-11

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PN=349

Specification UpperstructureWeight ........................................... 4500 kg approximate 9923 lb approximate
9. Attach chains to counterweight support beams and boom bracket. IMPORTANT: Make sure chains do not touch engine.
TJ15698,000017F 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).
ASwing Bearing BCap Screw (36 used)
Swing Bearing
TJ15698,000017F 1911APR073/4
43 4350 12
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T105961
UN20DEC96
T188540
UN17MAR03
T188539
UN17MAR03

11. Lift upperstructure from undercarriage using hoist. 12. Repair or replace parts as necessary.
Specification UpperstructureWeight ........................................... 4500 kg approximate 9923 lb approximate
UN17MAR03 T188541
13. Install upperstructure to undercarriage. 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 and Install. (Group 1749.) 20. Install cab. See Cab Remove and Install. (Group 1800.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting engine. Start-up procedure must be performed whenever a new pump is installed or oil has been drained from the pump or hydraulic oil tank. 21. Fill pump housing with oil. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
43 4350 13
TJ15698,000017F 1911APR074/4
TM10091 (11JAN08)
43-4350-13

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Swing Bearing Remove and Install

1. Remove upperstructure. See Upperstructure Remove and Install. (Group 4350.)
Specification Swing BearingWeight................................................................... 210 kg 463 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. 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 Install. (Group 4350.) 5. Replace steel balls and ball supports as necessary. 6. Repair or replace parts as necessary. 7. Clean mating surfaces of swing bearing, upperstructure, and undercarriage.
CJT01748 Lifting Brackets DCap Screw and Lock Washer
TJ15698,0000125 1911APR071/2
43 4350 14
TM10091 (11JAN08)
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T7764AB
UN07MAY92

IMPORTANT: The tooth marked with the letter G or S or equivalent is the starting and stopping point for the hardening process. The tooth and the bearing loading plug must be installed on the right side of the machine so the use of that part of the swing bearing is minimized. 8. Install swing bearing on undercarriage so tooth (A) marked G or S or equivalent and bearing loading plug (B) is to right side of machine. 9. Install cap screws and lock washers and tighten.
Specification Undercarriage-to-Swing Bearing Cap ScrewTorque ..................................................................... 510 Nm 376 lb-ft ATooth BLoading Plug
10. Apply multi-purpose grease to swing bearing teeth and pinion shaft. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operators Manual.) 11. Install upperstructure. See Upperstructure Remove and Install. (Group 4350.)
TJ15698,0000125 1911APR072/2
T5925AA
UN11APR90
43 4350 15
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Swing Bearing Disassemble and Assemble
43 4350 16
TJ15698,000011A 1911APR071/5
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TX1000479
UN25JAN06

0Outer Race 1Inner Race 2Steel Ball (121 used) 5Lubrication Fitting (2 used) 8Lower Seal 9Upper Seal 10Spacer (121 used) 11Swing Bearing
1. Check swing bearing upper seal (9) and lower seal (8). If damaged, replace. See Swing Bearing Upper
Seal Install. (Group 4350.) See Swing Bearing Lower Seal Install. (Group 4350.)
TJ15698,000011A 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.
ATack Weld BTaper Pin CLoading Plug
TJ15698,000011A 1911APR073/5
T6876FI
UN07MAY92
43 4350 17
TM10091 (11JAN08)
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PN=355

5. Remove steel balls (A) and spacers (B). 6. Turn inner race to remove remaining steel balls and spacers. 7. Lift outer race off inner race. 8. Replace parts as necessary. 9. Install spacers (B) and steel balls (A). Turn inner race as needed to install spacers and steel balls.
ASpacer (121 used) BSteel Ball (121 used)
UN07MAY92
TJ15698,000011A 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. 13. Add multi-purpose grease to swing bearing through lubrication fittings. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operators Manual.)
ATack Weld BTaper Pin CLoading Plug
UN07MAY92
TJ15698,000011A 1911APR075/5
TM10091 (11JAN08)
43-4350-18

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T6876FI
43 4350 18
T7763AB
UN07MAY92
T6876FK
Swing Bearing Upper Seal Install

UN11APR90
2. Remove old seal (A). 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 Install. (Group 4350.)
TJ15698,0000123 1911APR071/1
T5925AM
43 4350 19
TM10091 (11JAN08)
43-4350-19

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Swing Bearing Lower Seal Install

UN17MAY89
NOTE: Part of swing bearing shown cut away to show lower seal in groove. 2. Remove old seal (A). 3. Scrape old adhesive from seal groove (B). Thoroughly clean seal groove and new seal using PM37509 Cure Primer. 4. Apply PM37391 Gel Super Glue sparingly to seal groove. 5. Install seal with seal lip against outer race. Start about 76 mm (3 in.) from end of seal using blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal. 6. Before bringing ends of seal together, cut off excess length. 7. Apply 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 Install. (Group 4350.)
ASeal BSeal Groove
TJ15698,0000124 1918APR071/1
43 4350 20
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T5936BA
Group 4360
Hydraulic System
Center Joint Remove and Install
CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Disconnect battery ground (negative) cable. 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 120.4 L (31.8 gal).
FS41334,0000144 1913APR071/4
4. Tag and disconnect upper hydraulic lines (3). Close all open lines and fittings using caps and plugs. 5. Remove cap screws (2) and bracket (1). 6. Disconnect small hydraulic lines (4). Close all open lines and fittings using caps and plugs.
1Bracket 2Cap Screw (2 used) 3Hydraulic Line (4 used) 4Small Hydraulic Line (2 used)
UN19MAR07
FS41334,0000144 1913APR072/4
TX1020553A
TX1020196A
UN07MAR07
43 4360 1
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Hydraulic System
7. Attach the center joint to an appropriate lifting device using a lifting strap. See Center Joint (Rotary Manifold) Lifting Tool (2 used). See (Group 9900.) 8. Tag and disconnect lower hydraulic lines. Close all open lines and fittings using caps and plugs.
Specification Center JointWeight ........................................................................ 27 kg 60 lb
9. Remove four cap screws and lower center joint. 10. Replace parts as necessary. See Center Joint Disassemble and Assemble. (Group 4360.) 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. 14. Fill and check hydraulic oil level. See 160DLC Drain and Refill Capacities. (Operators Manual.) 15. Connect battery ground (negative) cable.
FS41334,0000144 1913APR073/4
43 4360 2
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T7685JC
UN27APR92
Hydraulic System
IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 16. If hydraulic oil tank was drained, perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
FS41334,0000144 1913APR074/4
43 4360 3
TM10091 (11JAN08)
43-4360-3

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PN=361
Hydraulic System
Center Joint Disassemble and Assemble

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.
1Plug (Ball) 2Spindle 3Dust Seal 4O-Ring 5Bushing 6Oil Seal (6 used) 7Housing 8Ring 9Snap Ring 10O-Ring 11Cover 12Cap Screw (4 used)
43 4360 4
FS41334,0000143 1902MAR071/2
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PN=362
TX1018875
UN12FEB07
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. 12. Tighten cap screws (12) to specification.
Specification Cover-to-Housing Cap Screw Torque ............................................................................................ 49 Nm 36 lb-ft
13. Install plug (1).
FS41334,0000143 1902MAR072/2
Center Joint Air Test

1. Install a plug in one port of a selected passage. 2. Apply shop air pressure, using JDG185 Air Test Plug, to the other port in that passage. 3. Listen for air leaks at other ports on either side of center joint. 4. Repeat test for other passages. 5. Repair or replace if leaks are found. See Center Joint Disassemble and Assemble. (Group 4360.)
T6557JB
UN01NOV88
43 4360 5
FS41334,0000142 1902MAR071/1
TM10091 (11JAN08)
43-4360-5

011108
PN=363
Hydraulic System
Swing Motor and Park Brake Remove and Install

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. The hydraulic tank is pressurized. Relieve pressure by pushing pressure release button (1). 1. Push pressure release button (1). 2. Apply vacuum to hydraulic tank or drain hydraulic tank. See Apply Vacuum to Hydraulic Tank. (Group 3360). The approximate capacity of hydraulic oil tank is 120.4 L (31.8 gal).
TJ15698,000013D 1911APR071/3
43 4360 6
TM10091 (11JAN08)
43-4360-6

011108
PN=364
TX1020196A
UN07MAR07
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
5. Disconnect electrical connector (1).

Specification Swing Motor and Park Brake Weight................................................................................................ 48 kg 105 lb
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. 9. Tighten cap screws (5).
Specification Swing Motor-to-Ring Gear Cap ScrewTorque ............................................................................... 90 Nm 67 lb-ft
1Electrical Connector 2Hydraulic Line 3Main Hydraulic Line 4Hydraulic Line 5Cap Screw (8 used) 6Swing Dampener Valve Hydraulic Lines
10. Connect electrical connector (1). 11. Connect lines. See Hydraulic System Line Connections. (Group 9025-15.) 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).
TJ15698,000013D 1911APR072/3
TX1003156A
43 4360 7
TM10091 (11JAN08)
43-4360-7

011108
PN=365
Hydraulic System
IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 14. If hydraulic oil tank was drained, perform pump start-up procedure. See Pump 1 and 2 Start-Up Procedure. (Group 3360.)
TJ15698,000013D 1911APR073/3
43 4360 8
TM10091 (11JAN08)
43-4360-8

011108
PN=366
Hydraulic System
43 4360 9
TM10091 (11JAN08)
43-4360-9

011108
PN=367
Hydraulic System
Swing Motor and Park Brake Disassemble
43 4360 10
TJ15698,000011B 1916FEB071/2
TM10091 (11JAN08)
43-4360-10

011108
PN=368
TX1000252
UN28NOV05
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) 40Cap Screw (4 used) 41Roller Bearing 42Roller Bearing 43Fitting Plug (2 used) 44Make-Up Check Valve Plug (2 used) 45O-Ring 47O-Ring (2 used) 48O-Ring (2 used) 49Seal 70Brake Piston 73Plates (4 used) 76O-Ring 77O-Ring 78Spring (24 used) 79Friction Plates (3 used) 81Pipe Plug (2 used) 85Seal Kit 87Spring 88Ball 89Packing
IMPORTANT: Do not disassemble crossover relief valve (5). 1. Remove crossover relief valves (5) from swing motor cover (20). 2. Remove make-up check valve plugs (44). 3. Remove springs (36) and poppets (35).
Specification Swing Motor and Park Brake Weight ......................................................................................... 48 kg 105 lb
6. Remove O-ring (45). 7. Remove springs (78). 8. Remove brake piston (70). 9. Remove O-rings (76, 77) from housing (30). 10. Remove parts (1, 13 and 12) from shaft (10). 11. Remove plates (73) and friction plates (79). IMPORTANT: Do not damage sliding surface 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. 17. Replace parts as necessary.
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).
43 4360 11
TJ15698,000011B 1916FEB072/2
TM10091 (11JAN08)
43-4360-11

011108
PN=369
Hydraulic System
Swing Motor and Park Brake Inspection

1. Measure clearance between outer diameter of piston and inner bore of cylinder.
Specification Piston-to-CylinderClearance ........................................... 0.027 mm new 0.001 in. new 0.052 mm maximum used 0.0020 in. maximum used
TJ15698,000011C 1929MAR071/4
2. Measure clearance between piston and slipper.

Specification Piston-to-SlipperClearance ................................................. 0.0 mm new 0.0 in. new 0.3 mm maximum used 0.0117 in. maximum used
43 4360 12
TJ15698,000011C 1929MAR072/4
TM10091 (11JAN08)
43-4360-12

011108
T142069
UN22JUN01
T142067
UN22JUN01
PN=370
Hydraulic System
3. Measure thickness of slipper.
Specification SlipperThickness ................................................................. 5.5 mm new 0.214 in. new 5.3 mm minimum 0.207 in. minimum
Slipper Thickness
TJ15698,000011C 1929MAR073/4
4. Measure thickness of friction plate.

Specification Friction PlateThickness ....................................................... 2.0 mm new 0.078 in. new 1.8 mm minimum 0.070 in. minimum
Friction Plate Thickness
TJ15698,000011C 1929MAR074/4
T142073
UN22JUN01
T142072
UN22JUN01
43 4360 13
TM10091 (11JAN08)
43-4360-13

011108
PN=371
Hydraulic System
Swing Motor and Park Brake Assemble
43 4360 14
Swing Motor and Park Brake

TJ15698,000011D 1916FEB071/3
TM10091 (11JAN08)
43-4360-14

011108
PN=372
TX1000252
UN28NOV05
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) 40Cap Screw (4 used) 41Roller Bearing 42Roller Bearing 43Fitting Plug (2 used) 44Make-Up Check Valve 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
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). 2. Install inner race of roller bearing (41) onto shaft (10) using a press. 3. Install oil seal (49) to housing (30). 4. Install outer race of roller bearing (41) to housing (30). IMPORTANT: Wind tape onto spline end of shaft (10) to prevent damage to oil seal (49). 5. Install shaft (10) into housing (30). 6. Install shoe plate (14) to housing (30) with chamfered surface toward housing. 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
spline teeth side of friction plates (79). IMPORTANT: Align each notch when installing. 12. Alternately install plates (73) and friction plates (79) to housing (30). 13. Install O-rings (76, 77) to housing (30). 14. Align mating marks and install brake piston (70). 15. Install springs (78) to brake piston (70). NOTE: Do step 15 only if bearing (42) was removed. 16. Install roller bearing (42) into swing motor cover (20) using plastic hammer. 17. Install O-ring (45) to swing motor cover (20). 18. Install valve plate (15) to swing motor cover (20) with notch in port facing toward cylinder block (11). 19. Apply grease to valve plate (15) to help retain 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 Cap ScrewTorque .............................................................. 431 Nm 318 lb-ft
43 4360 15
TJ15698,000011D 1916FEB072/3
TM10091 (11JAN08)
43-4360-15

011108
PN=373
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
TJ15698,000011D 1916FEB073/3
Swing Motor and Park Brake Start-Up Procedure

IMPORTANT: Swing motor will be damaged if not filled with oil before operating swing function. Start-up procedure must be performed whenever a new swing motor is installed or oil has been drained from the motor. NOTE: Procedure is to ensure swing motor is filled with oil. 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).
1Hydraulic Line
TJ15698,000013E 1911APR071/1
43 4360 16
TM10091 (11JAN08)
43-4360-16

011108
PN=374
TX1003231A
UN02FEB06
Hydraulic System
Crossover Relief Valve and Make-Up Check Valve Remove and Install
4
3
1
T139645
1Make-Up Check Valve
2Make-Up Check Valve
3Crossover Relief Valve
4Crossover Relief Valve
TJ15698,000013F 1911APR071/3
Remove and Install Crossover Relief Valve 1. Remove crossover relief valves (1). 2. Replace crossover relief valves (1) as necessary. 3. Install crossover relief valves (1). Tighten 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.)
T139645
UN30APR01
1Crossover Relief Valve (2 used)
43 4360 17
TJ15698,000013F 1911APR072/3
TM10091 (11JAN08)
43-4360-17

011108
PN=375
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.) 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)
TJ15698,000013F 1911APR073/3
Make-Up Check Valve Disassemble and Assemble

1. Remove make-up check valves (1). See Crossover Relief Valve and Make-Up Check Valve Remove and Install. (Group 4360.)
1Make-Up Check Valve (2 used)
TJ15698,0000140 1911APR071/2
43 4360 18
TM10091 (11JAN08)
43-4360-18

011108
PN=376
TX1003721A
UN16FEB06
TX1003232A
Hydraulic System
2. Examine O-rings (2), springs (3), and poppets (4) for wear and damage. 3. Replace parts as necessary. 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 Remove and Install. (Group 4360.)
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
UN16FEB06
TJ15698,0000140 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.)
TJ15698,0000120 1911APR071/1
TX1003722
43 4360 19
TM10091 (11JAN08)
43-4360-19

011108
PN=377
Hydraulic System
43 4360 20
TM10091 (11JAN08)
43-4360-20

011108
PN=378
Section 99
Dealer Fabricated Tools

Contents
Page
99
Group 9900Dealer Fabricated Tools DF1063 Lift Bracket . . . . . . . . . . . . . . . . . . .99-9900-1 ST4920 Track Recoil Spring Disassembly and Assembly Tool . . . . . . . . . . . . . . . . . .99-9900-3 DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool. . .99-9900-7 DFT1110 Spacer. . . . . . . . . . . . . . . . . . . . . .99-9900-8 DFT1130 Adapter . . . . . . . . . . . . . . . . . . . . .99-9900-9 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
TM10091 (11JAN08)
99-1

011108
PN=1
Contents
99
TM10091 (11JAN08)
99-2

011108
PN=2
Group 9900

DF1063 Lift Bracket
Tool is the same as used on other machines. Only the lift bracket of the tool is used for this machine with adapter DFT1130. Lift Bracket is used to remove and install travel motor. Material required: 38.1 mm x 76.2 mm x .48 mm (1-1/2 in. x 3 in. x 3/16 in.) Square Tube 1.3 mm (1/2 in.) 1020 Steel Plate 1 mm x 38.1 mm (3/8 in. x 1-1/2 in.) Cap Screw with Nut (4 used)
UN20SEP94
99 9900 1
TJ15698,0000106 1916FEB071/2
TM10091 (11JAN08)
99-9900-1

011108
PN=381
T8318AC
99 9900 2
TJ15698,0000106 1916FEB072/2
TM10091 (11JAN08)
99-9900-2

011108
PN=382
T7247BW
1925APR90
ST4920 Track Recoil Spring Disassembly and Assembly Tool

NOTE: It is recommended that DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool be used with track recoil spring disassembly and assembly tool. 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. Track Recoil Spring Disassembly and Assembly Tool (compression tool) is used with hydraulic jack to compress recoil spring in track adjuster repair. Material required: 1020 HR Steel for Holder (C), Supporting Plate (E), Base Plate (F), and Base (G). D Grade (SAE Grade 5) for Eyebolts (D), Nuts (A), and Cap Screws (H). F Grade (SAE Grade 8) for Studs (B). Print Numbers: A-ST4050 Nut B-ST4045 Bolt C-ST4035 Holder (Plate) C-ST4036 Holder (Plate) C-ST4037 Holder (Plate) D-ST4047 Eyebolt E-ST4040 Supporting Base F-ST4042 Base Plate G-ST4041 Base H-ST4046 Cap Screw I-ST4049 Lock Washer
ANut (12 used) BStud (4 used) CHolder DEyebolt (2 used) ESupporting Plate FBase Plate GBase (4 used) HCap Screw (4 used) ILock Washer (8 used)
UN24MAR98
99 9900 3
TJ15698,0000107 1913APR071/4
TM10091 (11JAN08)
99-9900-3

011108
PN=383
T6585UY
99 9900 4
TJ15698,0000107 1913APR072/4
TM10091 (11JAN08)
99-9900-4

011108
PN=384
T7029CI
UN06JUL89
99 9900 5
TJ15698,0000107 1913APR073/4
TM10091 (11JAN08)
99-9900-5

011108
PN=385
T7029CH
UN06JUL89
99 9900 6
TJ15698,0000107 1913APR074/4
TM10091 (11JAN08)
99-9900-6

011108
PN=386
T7029CG
UN06JUL89
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

99 9900 7
A3/16 in. 1020 CR Steel Plate B9/16 in. Hole (2 places)
C1/2 in. Nut (2 used)
D1/2 x 2 in. Cap Screw (2 used)
E1/2 x 3 in. Steel Round Stock (2 used)
Track Disassembly and Assembly Guard Tool is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. See ST4920 Track Recoil Spring Disassembly and Assembly Tool. (Group 9900.) Material required:
3/16 in. 1020 CR Steel Plate (A) 9/16 in. Hole (2 places) (B) 1/2 in. Nut (2 used) (C) 1/2 x 2 in. Cap Screw (D) (2 used) 1/2 x 3 in. Steel Round Stock (E) (2 used)
TJ15698,0000108 1913APR071/1
TM10091 (11JAN08)
99-9900-7

011108
PN=387
T7162AF
UN17OCT89
DFT1110 Spacer
99 9900 8
Spacer is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. Spacer is installed on the bottom plate so force is applied to spring flange on cylinder and not to the piston. See ST4920 Track Recoil Spring Disassembly and Assembly Tool. (Group 9900.) Cut the ends of spacer so they are parallel to each other.
Material Required: 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) Heavy Wall Steel Pipe
TJ15698,0000109 1913APR071/1
TM10091 (11JAN08)
99-9900-8

011108
PN=388
T7708AC
UN23FEB92
DFT1130 Adapter
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)
TJ15698,000010A 1916FEB071/1
TM10091 (11JAN08)
99-9900-9

011108
PN=389
T8319BN
UN20SEP94
DFT1036A Travel Gearbox Nut Wrench

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)
TJ15698,000010B 1913APR071/1
TM10091 (11JAN08)
99-9900-10

011108
PN=390
T7681FZ
UN28FEB92
DF1038 Torque Adapter

99 9900 11
Torque Adapter is used to check rolling drag torque on rotor drive shaft. Material required:
17 mm (0.125 in.) hex head driver
TJ15698,000010C 1913APR071/1
TM10091 (11JAN08)
99-9900-11

011108
PN=391
T6557CH
UN25OCT95
DFT1109 Holding Bar

99 9900 12
Holding Bar is used with the DF1036A Travel Gearbox Nut Wrench as a guide when loosening the hub-to-housing nut in the travel gearbox. See DF1036A Travel Gearbox Nut Wrench. (Group 9900.)
Material required: 16 mm (5/8 in.) Flat Bar Stock
TJ15698,000010D 1911APR071/1
TM10091 (11JAN08)
99-9900-12

011108
PN=392
T7690AA
UN27FEB92
Center Joint (Rotary Manifold) Lifting Tool

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
AThreads
99 9900 13
TJ15698,000010E 1913APR071/1
DFT1144 Guide Pin

Guide pin is used to align cap screw holes in swing bearing and upperstructure.
UN24OCT88
Remove threads for a distance (B) and then grind a taper on same end. Material Required: M20-2.5 x 230 mm (9 in.) Threaded Rod
A230 mm (9 in.) B100 mm (4 in.)
TJ15698,000010F 1913APR071/1
TM10091 (11JAN08)
99-9900-13

011108
PN=393
T6641EK
T6641DO
UN24OCT88
DFT1119 Pump Support

99 9900 14
38 mm (1.5 in.) 13 mm (0.5 in.) 13 mm (0.5 in.) 76 mm (3 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.)
88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 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.)
11 mm (0.438 in.) 12 PLACES
38 mm (1.5 in.) 76 mm (3 in.) 114 mm (4.5 in.) 9.5 mm (0.375 in.)
9.5 mm (0.375 in.) 12 mm (0.472 in.) 5 Places
457 mm (18 in.)
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.)
1524 mm (60 in.)
UN11JAN08
104.8 mm (4.125 in.) 165 mm (6.5 in.) 376 mm (14.8 in.)
TX1022920
335 mm (13.2 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 19 mm (3/4 in.) Flat Bar Stock M10 x 89 mm or 3/8 x 3-1/2 in. D Grade (SAE Grade 5) Cap Screw (2 used) M10 or 3/8 in. D Grade (SAE Grade 5) Nut (2 used)
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
TJ15698,0000110 1930APR071/1
TM10091 (11JAN08)
99-9900-14

011108
PN=394
TX1022920
233 mm (9.2 in.)
99 9900 15
TM10091 (11JAN08)
99-9900-15

011108
PN=395
DFT1220 Swing Gearbox Nut Spanner Wrench

99 9900 16
TJ15698,0000111 1916FEB071/2
TM10091 (11JAN08)
99-9900-16

011108
PN=396
T143704
UN17JUL01

1Weld (4 Places)
Material required: 159.4 x 82.5 mm (6.275 x 3.25 in.) Steel Tubing
159.4 x 38.1 x 6.35 mm (6.65 x 1.5 x .25 in.)
99 9900 17
TJ15698,0000111 1916FEB072/2
TM10091 (11JAN08)
99-9900-17

011108
PN=397
99 9900 18
TM10091 (11JAN08)
99-9900-18

011108
PN=398
Index
Page Page
A
Air cleaner Remove and install . . . . . . . . . . . . . . . . .05-0520-1 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 Remove and install . . . . . . . . . . . . . . . . .33-3340-3 Arm cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-106 Disassemble and assemble . . . . . . . . .33-3360-96 Inspect pins and bushings. . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . .33-3360-91 Arm pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Attachments Adding safely . . . . . . . . . . . . . . . . . . . . . .00-01-11 Operating safely . . . . . . . . . . . . . . . . . . . .00-01-11
Boom flow rate solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-46 Boom mode solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-46 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 Disassemble and assemble . . . . . . . . .02-0260-10 Remove and install . . . . . . . . . . . . . . . . .02-0260-2 Bucket Remove and install . . . . . . . . . . . . . . . . .33-3302-1 Bucket cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-106 Disassemble and assemble . . . . . . . . 33-3360-103 Inspect pins and bushings. . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . .33-3360-99 Bucket links Remove and install . . . . . . . . . . . . . . . . .33-3340-1 Bucket pins Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Bushings Remove and install . . . . . . . . . . . . . . . .33-3340-14
Indx 1
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 . . . . . . . . . . . . . . . . 33-3360-106 Boom Remove and install . . . . . . . . . . . . . . . . .33-3340-6 Boom cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-106 Dissassemble and assemble. . . . . . . . .33-3360-89 Inspect pins and bushings. . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . .33-3360-85
TM10091 (11JAN08)
Cab Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Cab guarding . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3 Center joint Air test . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-5 Disassemble and assemble . . . . . . . . . .43-4360-4 Remove and install . . . . . . . . . . . . . . . . .43-4360-1 Check valve, make-up Remove and install . . . . . . . . . . . . . . . .02-0260-17 Chemical products Handling . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-6 Condenser, air conditioner Remove and install . . . . . . . . . . . . . . . .18-1830-11 Console covers Remove and install . . . . . . . . . . . . . . . . .18-1821-5 Control valve Arm reduced leakage valve. . . . . . . . . .33-3360-63 Arm regenerative valve . . . . . . . . . . . . .33-3360-71
011108
Index-1
PN=1
Index
Page
Page
Indx 2
Auxiliary flow combiner valve check valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63 Auxiliary flow rate valve . . . . . . . . . . . .33-3360-63 Auxiliary function flow combiner valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63 Boom reduced leakage valve . . . . . . . .33-3360-71 Bucket flow rate valve . . . . . . . . . . . . . .33-3360-71 Bypass shut-off valve . . . . . . . . . . . . . .33-3360-71 Lift check and orifice (left travel power passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-63 Lift check (arm I power passage) . . . . .33-3360-63 Lift check (boom II power passage) . . .33-3360-63 Lift check (left travel neutral passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-63 Lift check (swing neutral passage) . . . .33-3360-63 Remove and install . . . . . . . . . . . . . . . .33-3360-61 Spool assemblies (4-spool) . . . . . . . . . .33-3360-71 Spool assemblies (5 spool) . . . . . . . . . .33-3360-63 System relief and power boost valve. . .33-3360-63 Travel function flow combiner valve . . .33-3360-71 4-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-71 5-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-63 Cooling package Remove and install . . . . . . . . . . . . . . . .05-0510-11 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 . . . . . . .05-0510-24 Counterbalance valve, travel motor Remove and install . . . . . . . . . . . . . . . .02-0260-13 Counterweight Remove and install . . . . . . . . . . . . . . . . .17-1749-1 Coupling, flex Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Crossover relief valve Remove and install . . . . . . . . . . . . . . . .43-4360-17 Crossover relief valve, travel motor Remove and install . . . . . . . . . . . . . . . .02-0260-15 Cylinder Arm, disassemble and assemble. . . . . .33-3360-96 Arm, remove and install . . . . . . . . . . . .33-3360-91 Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-106 Boom, disassemble and assemble . . . .33-3360-89 Boom, remove and install . . . . . . . . . . .33-3360-85 Bucket, disassemble and asemble . . . 33-3360-103 Bucket, remove and install . . . . . . . . . .33-3360-99
D
Dampener drive Remove and install . . . . . . . . . . . . . . . . .07-0752-1 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 Remove and install . . . . . . . . . . . . . . . .33-3360-34 Driving metal pins. . . . . . . . . . . . . . . . . . . . .00-01-14
E
Emergency preparation . . . . . . . . . . . . . . . . .00-01-6 Engine Remove and install . . . . . . . . . . . . . . . . .04-0400-1 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . .00-01-5 Explosion Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5
F
Fan Remove and install . . . . . . . . . . . . . . . .05-0510-19 Fan drive control valve Remove and install . . . . . . . . . . . . . . . .33-3360-43 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
TM10091 (11JAN08)
Index-2

011108
PN=2
Index
Page
Page
Filter, pilot Remove and install . . . . . . . . . . . . . . . .33-3360-35 Fire prevention . . . . . . . . . . . . . . . . . . . . . . . .00-01-5 Flex coupling Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Front idler Disassemble and assemble . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-20 Fuel cooler Remove and install . . . . . . . . . . . . . . . .05-0510-11 Fuel filter Final, remove and install . . . . . . . . . . . . .05-0560-4 Primary, remove and install. . . . . . . . . . .05-0560-3 Fuel tank Remove and install . . . . . . . . . . . . . . . . .05-0560-1
Remove and install . . . . . . . . . . . . . . . . .33-3360-4 Start-up procedure . . . . . . . . . . . . . . . .33-3360-25 Hydraulic pump regulator Disassemble and assemble . . . . . . . . .33-3360-28 Remove and install . . . . . . . . . . . . . . . .33-3360-26
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 Remove and install . . . . . . . . . . . . . . . . .05-0510-6
G
Gearbox, travel Disassemble and assemble . . . . . . . . . .02-0250-4 Remove and install . . . . . . . . . . . . . . . . .02-0250-1
L
Lifting objects Special care . . . . . . . . . . . . . . . . . . . . . . .00-01-11
H
Handhold use . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7 Hazards Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-9 Heater and air conditioner Remove and install . . . . . . . . . . . . . . . .18-1830-13 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 . . . . . . . . . . . . . . . . . 33-3360-106 Hydraulic fitting Flared connections . . . . . . . . . . . . . . . .00-0003-10 Hydraulic oil Cleanup procedure using portable filter caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3 Hydraulic oil cooler Remove and install . . . . . . . . . . . . . . . . .05-0510-4 Hydraulic oil tank Apply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1 Disassemble and assemble . . . . . . . . .33-3360-80 Remove and install . . . . . . . . . . . . . . . .33-3360-76 Hydraulic pump Disassemble and assemble . . . . . . . . .33-3360-10 Inspection . . . . . . . . . . . . . . . . . . . . . . .33-3360-22
TM10091 (11JAN08)
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 Disassemble and assemble . . . . . . . . .43-4360-18 Remove and install . . . . . . 02-0260-17, 43-4360-17 Manifold, pilot signal Remove and install . . . . . . . . . . . . . . . .33-3360-56 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
011108
Index-3
PN=3
Index
Page
Page
Motor, travel and park brake Disassemble and assemble . . . . . . . . .02-0260-10 Remove and install . . . . . . . . . . . . . . . . .02-0260-2 Moving parts Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3
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 . . . . .33-3360-83 Oil information R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6 Operation qualification . . . . . . . . . . . . . . . . . .00-01-1
Pilot signal manifold Remove and install . . . . . . . . . . . . . . . .33-3360-56 Pilot valve, travel Disassemble and assemble . . . . . . . . .33-3360-54 Remove and install . . . . . . . . . . . . . . . .33-3360-52 Portable filter caddy Hydraulic oil cleanup procedure . . . . . . .33-3360-3 Power dig solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-46 Pressure test . . . . . . . . . . . . . . . . . . . . . . .01-0130-5 Protective equipment . . . . . . . . . . . . . . . . . . .00-01-2 Pump regulator, hydraulic Disassemble and assemble . . . . . . . . .33-3360-28 Remove and install . . . . . . . . . . . . . . . .33-3360-26 Pump, hydraulic Disassemble and assemble . . . . . . . . .33-3360-10 Remove and install . . . . . . . . . . . . . . . . .33-3360-4 Pump, pilot Disassemble and assemble . . . . . . . . .33-3360-32 Remove and install . . . . . . . . . . . . . . . .33-3360-30
R
Radiator Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-17 Refrigerant Cautions and proper handling . . . . . . . . .18-1830-1 Recover R134a, air conditioning . . . . . . .18-1830-8 Refrigerant oil information R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Refrigerant recovery/recycling and charging Charging station installation procedure . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Regulator, hydraulic pump Disassemble and assemble . . . . . . . . .33-3360-28 Remove and install . . . . . . . . . . . . . . . .33-3360-26 Relief valve, crossover, travel motor Remove and install . . . . . . . . . . . . . . . .02-0260-15 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
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 Disassemble and assemble . . . . . . . . .02-0260-10 Remove and install . . . . . . . . . . . . . . . . .02-0260-2 Pilot control shut-off lever . . . . . . . . . . . . . . . .00-01-8 Pilot filter Remove and install . . . . . . . . . . . . . . . .33-3360-35 Pilot filter and pilot pressure regulating valve Remove and install . . . . . . . . . . . . . . . .33-3360-35 Pilot pressure regulating valve and filter Remove and install . . . . . . . . . . . . . . . .33-3360-35 Pilot pump Disassemble and assemble . . . . . . . . .33-3360-32 Drive shaft, remove and install . . . . . . .33-3360-34 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Pilot shutoff solenoid valve Disassemble and assemble . . . . . . . . .33-3360-38 Remove and install . . . . . . . . . . . . . . . .33-3360-36
S
Safety Operators seat . . . . . . . . . . . . . . . . . . . . . .00-01-7
TM10091 (11JAN08)
Index-4

011108
PN=4
Index
Page
Page
Welding repairs . . . . . . . . . . . . . . . . . . . . .00-01-14 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. . . . . . . . . .43-4350-20 Swing bearing upper, install . . . . . . . . .43-4350-19 Seals Remove and install . . . . . . . . . . . . . . . .33-3340-14 Seals, metal face Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Seat Air suspension, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-4 Mechanical suspension, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . .18-1821-3 Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-7 Remove and install . . . . . . . . . . . . . . . . .18-1821-2 Service recommendation Inch series four bolt flange fitting for high pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20 O-ring boss fitting in aluminum housing excavators . . . . . . . . . . . . . . . . . . . . . .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 high pressure. . . . . . . . .00-0003-16 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 Remove and install . . . . . . . . . . . . . . . .33-3360-36 Sliding window Remove and install . . . . . . . . . . . . . . . . .18-1810-1 Solenoid valve Boom flow rate, remove and install . . . .33-3360-46 Boom mode, remove and install . . . . . .33-3360-46 Power dig, remove and install . . . . . . . .33-3360-46 Travel speed, remove and install . . . . .33-3360-46 Sprocket Remove and install . . . . . . . . . . . . . . . .01-0130-19 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 Remove and install . . . . . . . . . . . . . . . .05-0510-24 Swing bearing Disassemble and assemble . . . . . . . . .43-4350-16
Lower seal install . . . . . . . . . . . . . . . . .43-4350-20 Remove and install . . . . . . . . . . . . . . . .43-4350-14 Upper seal, install . . . . . . . . . . . . . . . . .43-4350-19 Swing gearbox Disassemble and assemble . . . . . . . . . .43-4350-4 Remove and install . . . . . . . . . . . . . . . . .43-4350-1 Start-up procedure . . . . . . . . . . . . . . . .43-4350-11 Swing motor Assemble . . . . . . . . . . . . . . . . . . . . . . .43-4360-14 Disassemble . . . . . . . . . . . . . . . . . . . . .43-4360-10 Inspection . . . . . . . . . . . . . . . . . . . . . . .43-4360-12 Remove and install . . . . . . . . . . . . . . . . .43-4360-6 Start-up procedure . . . . . . . . . . . . . . . .43-4360-16 Swing park brake release valve Remove and install . . . . . . . . . . . . . . . .43-4360-19
Indx 5
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 housing excavators . . . . . . . . . . . . . . . . . . . . . .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 high pressure. . . . . . . . .00-0003-16 O-ring face seal fittings with metric 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 Disassemble and assemble . . . . . . . . .01-0130-30 Track carrier roller Remove and install . . . . . . . . . . . . . . . . .01-0130-6
TM10091 (11JAN08)
Index-5

011108
PN=5
Index
Page
Page
Indx 6
Track chain Disassemble and assemble . . . . . . . . .01-0130-16 Remove and install . . . . . . . . . . . . . . . .01-0130-11 Repair . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-17 Track roller . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-5 Disassemble and assemble . . . . . . . . . .01-0130-3 Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Track shoe Remove and install . . . . . . . . . . . . . . . .01-0130-11 Travel gearbox Disassemble and assemble . . . . . . . . . .02-0250-4 Remove and install . . . . . . . . . . . . . . . . .02-0250-1 Travel motor and park brake Disassemble and assemble . . . . . . . . .02-0260-10 Remove and install . . . . . . . . . . . . . . . . .02-0260-2 Start-up procedure . . . . . . . . . . . . . . . .02-0260-21 Travel motor, counterbalance valve Remove and install . . . . . . . . . . . . . . . .02-0260-13 Travel pilot valve Disassemble and assemble . . . . . . . . .33-3360-54 Remove and install . . . . . . . . . . . . . . . .33-3360-52 Travel speed change valve Remove and install . . . . . . . . . . . . . . . .02-0260-19 Travel speed solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-46
Remove and install . . . . . . . . . . . . . . . .33-3360-52 Valve, travel speed change Remove and install . . . . . . . . . . . . . . . .02-0260-19
W
Waste disposal . . . . . . . . . . . . . . . . . . . . . . . .00-01-6 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Welding precautions . . . . . . . . . . . . . . . . . .17-1740-1 Window, sliding Remove and install . . . . . . . . . . . . . . . . .18-1810-1 Windowpanes Dimensions . . . . . . . . . . . . . . . . . . . . . . .18-1810-3 Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Work site hazards Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-9
U
Upperstructure Remove and install . . . . . . . . . . . . . . . .43-4350-11
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 Remove and install . . . . . . . . . . . . . . . .33-3360-61 Valve, pilot pressure regulating Remove and install . . . . . . . . . . . . . . . .33-3360-35 Valve, pilot shutoff solenoid Disassemble and assemble . . . . . . . . .33-3360-38 Remove and install . . . . . . . . . . . . . . . .33-3360-36 Valve, travel pilot Disassemble and assemble . . . . . . . . .33-3360-54
TM10091 (11JAN08)
Index-6

011108
PN=6

160D Repair

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160DLC Excavator Repair

TECHNICAL MANUAL 160DLC Excavator Repair

Worldwide Construction And Forestry Division

160DLC Excavator Repair

Technical Information Feedback Form

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160DLC Excavator Repair

160DLC Excavator Repair

SECTION 00General Information Group 01Safety Group 0003Torque Values

SECTION 04Engine Group 0400Removal and Installation

SECTION 07Dampener Drive (Flex Coupling) Group 0752Elements

SECTION 33Excavator Group 3302Buckets Group 3340Frames Group 3360Hydraulic System

SECTION 99Dealer Fabricated Tools Group 9900Dealer Fabricated Tools

160DLC Excavator Repair

160DLC Excavator Repair

160DLC Excavator Repair

160DLC Excavator Repair

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

160DLC Excavator Repair

160DLC Excavator Repair

Follow Safety Instructions

Operate Only If Qualified

160DLC Excavator Repair

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

160DLC Excavator Repair

Add Cab Guarding for Special Uses

Stay Clear of Moving Parts

160DLC Excavator Repair

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

160DLC Excavator Repair

Beware of Exhaust Fumes

Prevent Battery Explosions

160DLC Excavator Repair

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

160DLC Excavator Repair

Use Steps and Handholds Correctly

Start Only From Operators Seat

Use and Maintain Seat Belt

160DLC Excavator Repair

Prevent Unintended Machine Movement

160DLC Excavator Repair

Avoid Work Site Hazards

Keep Riders Off Machine

160DLC Excavator Repair

Avoid Backover Accidents

Avoid Machine Tip Over

160DLC Excavator Repair

Use Special Care When Lifting Objects

Add and Operate Attachments Safely

160DLC Excavator Repair

Park and Prepare for Service Safely

Service Cooling System Safely

160DLC Excavator Repair

Remove Paint Before Welding or Heating

160DLC Excavator Repair

Make Welding Repairs Safely

Drive Metal Pins Safely

160DLC Excavator Repair

Class 8.8 or 9.8