Professional Documents
Culture Documents
Excavator
Repair
TECHNICAL MANUAL
200D and 200DLC Excavator Repair
TM10079 17MAR09 (ENGLISH)
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.
DX,TMIFC 1929SEP981/1
TM10079 (17MAR09)
PN=2
Introduction
FAX NUMBER:
563-589-5800
OVERALL, how would you rate the quality of this publication? (Check one)
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THANK YOU!
TX,TM,FAX 1903JUL011/1
TM10079 (17MAR09)
PN=3
Introduction
TM10079 (17MAR09)
PN=4
Contents
00
01
02
SECTION 04Engine
Group 0400Removal and Installation
04
05
07
17
SECTION 33Excavator
Group 3302Buckets
Group 3340Frames
Group 3360Hydraulic System
18
33
43
COPYRIGHT 2009
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright 2007, 2008
TM10079 (17MAR09)
PN=1
Contents
00
01
02
04
05
07
17
18
33
43
TM10079 (17MAR09)
ii
PN=2
Contents
99
INDX
TM10079 (17MAR09)
iii
PN=3
Contents
99
INDX
TM10079 (17MAR09)
iv
PN=4
00
Section 00
General Information
Contents
Page
TM10079 (17MAR09)
00-1
PN=1
Contents
00
TM10079 (17MAR09)
00-2
PN=2
Group 01
Safety
00
01
1
T133555
1928AUG00
T133588
TX03679,00016CC 1903JAN071/1
T133556
TX03679,00016F9 1903JAN071/1
TX03679,00016FA 1903JAN071/1
TM10079 (17MAR09)
00-01-1
PN=9
Safety
UN23AUG88
TS206
00
01
2
TX03679,00016D0 1903JAN071/1
AM40430,00000A9 1929JUL081/1
TM10079 (17MAR09)
00-01-2
PN=10
Safety
00
01
3
T133733
UN15SEP00
TX03679,00016CE 1903JAN071/1
Inspect Machine
T6607AQ
UN18OCT88
TX03679,0001734 1903JAN071/1
T133592
UN12SEP01
TX03679,00016D2 1903JAN071/1
TM10079 (17MAR09)
00-01-3
PN=11
Safety
X9811
UN08DEC08
DX,FLUID 1903MAR931/1
T133509
UN20SEP00
UN17MAR06
T133840
00
01
4
TX03679,00016D3 1903NOV081/1
TM10079 (17MAR09)
00-01-4
PN=12
Safety
00
01
5
T133546
UN24AUG00
TX03679,00016D4 1903NOV081/1
T133552
T133554
UN07SEP00
T133553
UN07SEP00
UN14SEP00
Prevent Fires
TX03679,00016F5 1903NOV081/1
TS204
UN23AUG88
TX03679,000174A 1903NOV081/1
TM10079 (17MAR09)
00-01-5
PN=13
Safety
T133580
UN25AUG00
TX03679,00016D7 1903JAN071/1
T133567
UN25AUG00
TX03679,0001733 1903JAN071/1
UN23AUG88
TS291
00
01
6
TX03679,000174B 1903JAN071/1
TM10079 (17MAR09)
00-01-6
PN=14
Safety
00
01
7
T133468
UN30AUG00
TX03679,00016F2 1915MAR071/1
T133715
UN07SEP00
TX03679,0001799 1903JAN071/1
T133716
1914SEP00
TX03679,00016DD 1902DEC081/1
TM10079 (17MAR09)
00-01-7
PN=15
Safety
UN22NOV05
T216779
00
01
8
DW90712,00002C0 1903JAN071/1
TM10079 (17MAR09)
00-01-8
PN=16
Safety
00
01
9
T192984
UN26AUG03
T141904
UN15MAY01
AM40430,0000098 1924JAN071/1
T7273AH
UN08JUN90
TX03679,0001726 1903JAN071/1
TM10079 (17MAR09)
00-01-9
PN=17
Safety
T133548
UN24AUG00
TX03679,00016F3 1903JAN071/1
T133716
UN15SEP00
T133545
UN27SEP00
1914SEP00
T133803
00
01
10
TX03679,00016DF 1903JAN071/1
TM10079 (17MAR09)
00-01-10
PN=18
Safety
00
01
11
T133839
UN27SEP00
TX03679,00016E1 1903JAN071/1
TX03679,00016F0 1912FEB071/1
TM10079 (17MAR09)
00-01-11
PN=19
Safety
T133332
1914DEC01
TS229
UN23AUG88
TX03679,00016E9 1903JAN071/1
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
UN23AUG88
TS281
00
01
12
DX,RCAP 1904JUN901/1
TM10079 (17MAR09)
00-01-12
PN=20
Safety
00
01
13
TS220
UN23AUG88
DX,PAINT 1924JUL021/1
TM10079 (17MAR09)
00-01-13
PN=21
Safety
T133547
UN31AUG00
TX03679,00016D5 1925APR081/1
UN14SEP00
T133738
00
01
14
TX03679,0001745 1903JAN071/1
TM10079 (17MAR09)
00-01-14
PN=22
Group 0003
Torque Values
00
0003
1
TORQ2
UN07SEP99
TopProperty Class and Head Markings; BottomProperty Class and Nut Markings
METRIC BOLT AND CAP SCREW TORQUE VALUESTolerance is 10% unless otherwise specified
Class 4.8
Thread
Size
Lubricateda
Nm (lb-ft)
Dryb
Nm (lb-ft)
Class 10.9
Lubricateda
Nm (lb-ft)
Dryb
Nm (lb-ft)
Class 12.9
Lubricateda
Nm (lb-ft)
Dryb
Nm (lb-ft)
Lubricateda
Nm (lb-ft)
Dryb
Nm (lb-ft)
19.5 (14.5)
M6
4.7 (3.5)
6 (4.4)
9 (6.6)
11.5 (8.5)
13 (9.5)
16.5 (12.2)
15.5 (11.5)
M8
11.5 (8.5)
14.5 (10.7)
22 (16)
28 (20.5)
32 (23.5)
40 (29.5)
37 (27.5)
47 (35)
M10
23 (17)
29 (21)
43 (32)
55 (40)
63 (46)
80 (59)
75 (55)
95 (70)
M12
40 (29.5)
50 (37)
75 (55)
95 (70)
110 (80)
140 (105)
130 (95)
165 (120)
M14
63 (46)
80 (59)
120 (88)
150 (110)
175 (130)
220 (165)
205 (150)
260 (190)
M16
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
M22
265 (195)
330 (245)
510 (375)
650 (480)
725 (535)
920 (680)
850 (625)
1080 (800)
M24
330 (245)
425 (315)
650 (480)
820 (600)
920 (680)
1150 (850)
1080 (800)
1350 (1000)
M27
490 (360)
625 (460)
950 (700)
1200 (885)
1350 (1000)
1700 (1250)
1580 (1160)
2000 (1475)
M30
660 (490)
850 (625)
1290 (950)
1630 (1200)
1850 (1350)
2300 (1700)
2140 (1580)
2700 (2000)
M33
900 (665)
1150 (850)
1750 (1300)
2200 (1625)
2500 (1850)
3150 (2325)
2900 (2150)
3700 (2730)
M36
1150 (850)
1450 (1075)
2250 (1650)
2850 (2100)
3200 (2350)
4050 (3000)
3750 (2770)
4750 (3500)
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
OUT3035,TORQUE2 1922MAR061/1
TM10079 (17MAR09)
00-0003-1
PN=23
Torque Values
UN18OCT88
T6873AA
UN18OCT88
T6873AB
UN18OCT88
T6873AC
00
0003
2
TM10079 (17MAR09)
00-0003-2
04T,90,M170 1929SEP991/2
PN=24
Torque Values
00
0003
3
H-Bolt
Nm
lb-ft
29
21
10
63
12
14
Nm
lb-ft
M-Bolt
Nm
lb-ft
20
15
10
46
45
33
20
15
108
80
88
65
34
25
176
130
137
101
54
40
16
265
195
206
152
78
58
18
392
289
294
217
118
87
20
539
398
392
289
167
125
22
735
542
539
398
216
159
24
931
687
686
506
274
202
27
1372
1012
1029
759
392
289
30
1911
1410
1421
1049
539
398
33
2548
1890
1911
1410
735
542
36
3136
2314
2401
1772
931
687
04T,90,M170 1929SEP992/2
TM10079 (17MAR09)
00-0003-3
PN=25
Torque Values
UN27SEP99
TORQ1A
00
0003
4
TopSAE Grade and Head Markings; BottomSAE Grade and Nut Markings
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUESTolerance is 10% unless otherwise specified
Grade 2a (No Mark)
Lubricated
Nm (lb-ft)
Dry
Nm (lb-ft)
Lubricatedb
Nm (lb-ft)
Dryc
Nm (lb-ft)
Lubricatedb
Nm (lb-ft)
Dryc
Nm (lb-ft)
Grade 8 or 8.2
Lubricatedb
Nm (lb-ft)
Dryc
Nm (lb-ft)
1/4
3.8 (2.8)
4.7 (3.5)
6 (4.4)
7.5 (5.5)
9.5 (7)
12 (9)
13.5 (10)
17 (12.5)
5/16
7.7 (5.7)
9.8 (7.2)
12 (9)
15.5 (11.5)
19.5 (14.5)
25 (18.5)
28 (20.5)
35 (26)
3/8
13.5 (10)
17.5 (13)
22 (16)
27.5 (20)
35 (26)
44 (32.5)
49 (36)
63 (46)
7/16
22 (16)
28 (20.5)
35 (26)
44 (32.5)
56 (41)
70 (52)
80 (59)
100 (74)
1/2
34 (25)
42 (31)
53 (39)
67 (49)
85 (63)
110 (80)
120 (88)
155 (115)
9/16
48 (35.5)
60 (45)
76 (56)
95 (70)
125 (92)
155 (115)
175 (130)
220 (165)
5/8
67 (49)
85 (63)
105 (77)
135 (100)
170 (125)
215 (160)
240 (175)
305 (225)
3/4
120 (88)
150 (110)
190 (140)
240 (175)
300 (220)
380 (280)
425 (315)
540 (400)
7/8
190 (140)
240 (175)
190 (140)
240 (175)
490 (360)
615 (455)
690 (510)
870 (640)
285 (210)
360 (265)
285 (210)
360 (265)
730 (540)
920 (680)
1030 (760)
1300 (960)
1-1/8
400 (300)
510 (375)
400 (300)
510 (375)
910 (670)
1150 (850)
1450 (1075)
1850 (1350)
1-1/4
570 (420)
725 (535)
570 (420)
725 (535)
1280 (945)
1630 (1200)
2050 (1500)
2600 (1920)
1-3/8
750 (550)
950 (700)
750 (550)
950 (700)
1700 (1250)
2140 (1580)
2700 (2000)
3400 (2500)
1-1/2
990 (730)
1250 (930)
990 (730)
1250 (930)
2250 (1650)
2850 (2100)
3600 (2650)
4550 (3350)
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
OUT3035,TORQUE1 1914JAN041/1
TM10079 (17MAR09)
00-0003-4
PN=26
Torque Values
00
0003
5
T6234AC
UN18OCT88
Nm
lb-ft
3/8 - 24 UNF
7/16 - 20 UNF
12
1/2 - 20 UNF
16
12
9/16 - 18 UNF
24
18
3/4 - 16 UNF
46
34
7/8 - 14 UNF
62
46
1-1/16 - 12 UN
102
75
1-3/16 - 12 UN
122
90
1-5/16 - 12 UN
142
105
1-5/8 - 12
190
140
1-7/8 - 12 UN
217
160
T82,BHMA,EL 1929SEP991/1
TM10079 (17MAR09)
00-0003-5
PN=27
Torque Values
T6243AE
00
0003
6
TM10079 (17MAR09)
00-0003-6
04T,90,K66 1929SEP991/2
PN=28
Torque Values
00
0003
7
Angle Fitting
T6520AB
UN18OCT88
Nm
lb-ft
3/8-24 UNF
7/16-20 UNF
12
1/2-20 UNF
16
12
9/16-18 UNF
24
18
3/4-16 UNF
46
34
7/8-14 UNF
62
46
1-1/16-12 UN
102
75
1-3/16-12 UN
122
90
1-5/16-12 UN
142
105
1-5/8-12 UN
190
140
1-7/8-12 UN
217
160
04T,90,K66 1929SEP992/2
TM10079 (17MAR09)
00-0003-7
PN=29
Torque Values
UN17NOV03
T196315
00
0003
8
3Stud End
4Adjustable Fitting
5Hex Nut
6Backup Washer
Nm (lb-ft)
M12 x 1.5
17
39 (29)
M14 x 1.5
19
39 (29)
M16 x 1.5
22
55 (41)
M22 x 1.5
27
75 (55)
M27 x 2
32
110 (81)
M30 x 2
36
141 (104)
M33 x 2
41
165 (122)
M38 x 2
46
165 (122)
M42 x 2
50
275 (203)
TM10079 (17MAR09)
00-0003-8
OUT3035,0000353 1910MAR091/2
PN=30
Torque Values
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD
END NUT WITH INCH THREAD IN ALUMINUM HOUSING
TORQUE VALUESTolerance is 10% unless otherwise
specified
Thread Size
in.
Nm (lb-ft)
1/8
1/4
28 (20)
3/8
39 (29)
1/2
75 (55)
3/4
126 (93)
165 (122)
1-1/8
1-1/4
259 (191)
1-3/8
1-1/2
330 (243)
1-3/4
2. Back the stud end hex nut (5) off as far as possible.
Push backup washer (6) towards the nut to fully
expose the turn down section of stud end. Washer
must fit turned down section and not be too loose
3. Wrap electrical tape over threads to protect O-ring.
Slide O-ring over the tape into turned down section.
Remove tape. Apply hydraulic oil to the threads of
stud end, turned down section, and O-ring.
4. Turn fitting into the boss by hand until face of nut or
backup washer squeezes O-ring into the seat and
contacts face of boss. Loosen an adjustable fitting
no more than one turn for alignment.
Nm (lb-ft)
1/8
7.8 (5.80)
1/4
11.8 (8.70)
3/8
23 (17)
1/2
39 (29)
3/4
55 (41)
86 (64)
1-1/4
126 (93)
1-1/2
157 (116)
204 (150)
OUT3035,0000353 1910MAR092/2
TM10079 (17MAR09)
00-0003-9
PN=31
00
0003
9
Torque Values
UN18OCT88
T6873AE
TORQUE CHART
Straight Thread
Thread
Size
Nm
lb-ft
1/8
15
11
1/4
20
3/8
1/2
3/4
Tapered Thread
Nm
lb-ft
15
45
33
29
21
69
51
49
36
93
69
69
51
176
130
157
116
343
253
1-1/2
196
145
539
398
255
188
588
434
UN18OCT88
T6873AD
00
0003
10
Tapered Thread
04T,90,M171 1928JAN921/1
TM10079 (17MAR09)
00-0003-10
PN=32
Torque Values
00
0003
11
Thread Size
Swivel Nut
Bulkhead Nut
mm
in.
in.
Nm
lb-ft
Nm
lb-ft
6.35
0.250
9/16-18
16
12
12
9
18
9.52
0.375
11/16-16
24
18
24
12.70
0.500
13/16-16
50
37
46
34
15.88
0.625
1-14
69
51
62
46
19.05
0.750
1 3/16-12
102
75
102
75
22.22
0.875
1 3/16-12
102
75
102
75
25.40
1.000
1 7/16-12
142
105
142
105
31.75
1.250
1 11/16-12
190
140
190
140
38.10
1.500
2-12
217
160
217
160
Inch
Inch
Inch
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
04T,90,K67 1902MAR001/1
TM10079 (17MAR09)
00-0003-11
PN=33
Torque Values
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure
Service Recommendations
A
UN12DEC01
G
E
F
H
F
H70406
00
0003
12
EStud End
FTube Nut
GSwivel Nut
HHex Nut
O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000
psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID
Metric Tube
OD
Bulkhead Nut
Thread Size
Hex Size
Torque
Hex Size
Torque
mm
Dash Size
mm (in.)
in.
in.
Nm (lb-ft)
in.
Nm (lb-ft)
-3
4.78 (0.188)
-4
6.35 (0.250)
9/16-18
11/16
24 (18)
13/16
32 (24)
-5
7.92 (0.312)
10
-6
9.53 (0.375)
11/16-16
13/16
37 (27)
42 (31)
12
-8
12.70 (0.500)
13/16-16
15/16
75 (55)
1-1/8
93 (69)
16
-10
15.88 (0.625)
1-14
1-1/8
103 (76)
1-5/16
118 (87)
20
-12
19.05 (0.750)
1-3/16-12
1-3/8
152 (112)
1-1/2
175 (129)
22
-14
22.23 (0.875)
1-3/16-12
152 (112)
175 (129)
25
-16
25.40 (1.000)
1-7/16-12
1-5/8
214 (158)
1-3/4
247 (182)
32
-20
31.75 (1.250)
1-11/16-12
1-7/8
286 (211)
328 (242)
38
-24
38.10 (1.500)
2-12
2-1/4
326 (240)
2-3/8
374 (276)
TM10079 (17MAR09)
00-0003-12
OUT3035,0000420 1914JAN041/2
PN=34
Torque Values
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600
kPa (276 bar) (4000 psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Thread Size
in.
in.
in.
Nm (lb-ft)
3/8-24
5/8
9/16
18 (13)
7/16-20
5/8
5/8
24 (18)
30 (22)
1/2-20
3/4
11/16
9/16-18
3/4
3/4
37 (27)
3/4-16
7/8
15/16
75 (55)
7/8-14
1-1/16
1-1/16
103 (76)
1-1/16-12
1-1/4
1-3/8
177 (131)
1-3/16-12
1-3/8
1-1/2
231 (170)
1-5/16-12
1-1/2
1-5/8
270 (199)
1-5/8-12
1-3/4
1-7/8
286 (211)
1-7/8-12
2-1/8
2-1/8
326 (240)
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
OUT3035,0000420 1914JAN042/2
TM10079 (17MAR09)
00-0003-13
PN=35
00
0003
13
Torque Values
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure
Service Recommendations
1
11
11
11
10
T196337
10
UN18NOV03
10
T196337
00
0003
14
7Swivel Nut
8Stud End
9Hex Nut
10O-Ring
11Identification Groove
O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa
(275.8 bar) (4,000 psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID
Metric Tube
OD
Bulkhead Nut
Thread Size
Hex Size
Torque
Hex Size
Torque
mm
Dash Size
mm (in.)
in.
mm
Nm (lb-ft)
mm
Nm (lb-ft)
-2
3.18 (0.125)
-3
4.78 (0.188)
-4
6.35 (0.250)
9/16-18
17
16 (12)
22
32 (24)
-5
7.92 (0.312)
10
-6
9.53 (0.375)
11/16-16
22
24 (18)
27
42 (31)
12
-8
12.70 (0.500)
13/16-16
24
50 (37)
30
93 (69)
16
-10
15.88 (0.625
1-14
30
69 (51)
36
118 (87)
20
-12
19.05 (0.750)
1-3/16-12
36
102 (75)
41
175 (129)
22
-14
22.23 (0.875)
1-3/16-12
36
102 (75)
41
175 (129)
25
-16
25.40 (1.000)
1-7/16-12
41
142 (105)
46
247 (182)
28
32
-20
31.75 (1.250)
1-11/16-12
50
190 (140)
50
328 (242)
38
-24
38.10 (1.500)
2-12
60
217 (160)
60
374 (276)
50
-32
50.80 (2.000)
TM10079 (17MAR09)
00-0003-14
OUT3035,0000366 1914JAN041/2
PN=36
Torque Values
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27
600 kPa (275.8 bar) (4,000 psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Thread Sizea
Aluminum or Brass
Torque
mm.
mm
mm
Nm (lb-ft)
Nm (lb-ft)
M8 x 1
12
12
8 (6)
5 (4)
M10 x 1
14
14
15 (11)
10 (7)
M12 x 1.5
17
17
25 (18)
17 (12)
M14 x 1.5
19
19
40 (30)
27 (20)
M16 x 1.5
22
22
45 (33)
30 (22)
M18 x 1.5
24
24
50 (37)
33 (25)
M22 x 1.5
27
27
69 (51)
46 (34)
M27 x 2
32
32
100 (74)
67 (49)
M30 x 2
36
36
130 (96)
87 (64)
M33 x 2
41
41
160 (118)
107 (79)
M38 x 2
46
46
176 (130)
117 (87)
M42 x 2
50
50
210 (155)
140 (103)
M48 x 2
55
55
260 (192)
173 (128)
M60 x 2
65
65
315 (232)
210 (155)
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
OUT3035,0000366 1914JAN042/2
TM10079 (17MAR09)
00-0003-15
PN=37
00
0003
15
Torque Values
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service
Recommendations
1
11
11
11
10
T196337
10
UN18NOV03
10
T196337
00
0003
16
7Swivel Nut
8Stud End
9Hex Nut
10O-Ring
11Identification Groove
O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000
psi), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID
Metric Tube
OD
Bulkhead Nut
Thread Size
Hex Size
Torque
Hex Size
Torque
mm
Dash Size
mm (in.)
in.
mm
Nm (lb-ft)
mm
Nm (lb-ft)
-2
3.18 (0.125)
-3
4.78 (0.188)
-4
6.35 (0.250)
9/16-18
17
24 (18)
22
32 (24)
-5
7.92 (0.312)
10
-6
9.53 (0.375)
11/16-16
22
37 (27)
27
42 (31)
12
-8
12.70 (0.500)
13/16-16
24
75 (55)
30
93 (69)
16
-10
15.88 (0.625)
1-14
30
103 (76)
36
118 (87)
20
-12
19.05 (0.750)
1-3/16-12
36
152 (112)
41
175 (129)
22
-14
22.23 (0.875)
1-3/16-12
36
152 (112)
41
175 (129)
25
-16
25.40 (1.000)
1-7/16-12
41
214 (158)
46
247 (182)
28
32
-20
31.75 (1.250)
1-11/16-12
286 (211)
50
328 (242)
38
-24
38.10 (1.500)
2-12
326 (240)
60
374 (276)
TM10079 (17MAR09)
00-0003-16
OUT3035,0000421 1914JAN041/2
PN=38
Torque Values
00
0003
17
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600
KPA (275.8 BAR) (4,000 PSI), TORQUE VALUESTolerance is +15 -20% unless otherwise specified
Thread Sizea
mm.
mm
mm
M8 x 1
12
12
8 (6)
M10 x 1
14
14
15 (11)
M12 x 1.5
17
17
35 (26)
M14 x 1.5
19
19
45 (33)
M16 x 1.5
22
22
55 (41)
M18 x 1.5
24
24
70 (52)
M22 x 1.5
27
27
100 (74)
M27 x 2
32
32
170 (125)
M30 x 2
36
36
215 159)
M33 x 2
41
41
260 (192)
M38 x 2
46
46
320 (236)
M42 x 2
50
50
360 (266)
M48 x 2
55
55
420 (310)
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
OUT3035,0000421 1914JAN042/2
TM10079 (17MAR09)
00-0003-17
PN=39
Torque Values
UN01MAR90
T6890BB
00
0003
18
ASealing Surface
BSplit Flange
CPinched O-Ring
TORQUE CHARTa
Thread
Nm
M6
12
M8
30
22
M10
57
42
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
lb-ft
Tolerance 10%. The torques given are enough for the given
size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
a
04T,90,K175 1929SEP991/1
TM10079 (17MAR09)
00-0003-18
PN=40
Torque Values
00
0003
19
T6890BB
UN01MAR90
ASealing Surface
BSplit Flange
CPinched O-Ring
Nominal
Flange
Size
lb-ft
Cap Screw
Size
Min
Max
Min
Max
1/2
5/16-18
UNC
20
31
15
23
3/4
3/8-16 UNC
28
54
21
40
3/8-16 UNC
37
54
27
40
1-1/4
7/16-14
UNC
47
85
35
63
1-1/2
1/2-13 UNC
62
131
46
97
1/2-13 UNC
73
131
54
97
2-1/2
1/2-13 UNC
107
131
79
97
5/8-11 UNC
158
264
117
195
3-1/2
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
5/8-11 UNC
158
264
117
195
04T,90,K174 1901AUG941/1
TM10079 (17MAR09)
00-0003-19
PN=41
Torque Values
UN01MAR90
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
T6890BB
00
0003
20
ASealing Surface
BSplit Flange
CPinched O-Ring
Nominal
Flange Size
MinMax Torque
in.
in.
Nm (lb-ft)b
1/2
5/16-18 UNC
2031 (1523)
3/4
3/8-16 UNC
3454 (2540)
7/16-14 UNC
5785 (4263)
1-1/4
1/2-13 UNC
85131 (6397)
1-1/2
5/8-11 UNC
159264 (117195)
3/4-10 UNC
271468 (200345)
Minimum torques given are enough for the given size connection
with the recommended working pressure. Torques can be
increased to the maximum shown for each cap screw size if
desired. Increasing cap screw torque beyond the maximum will
result in flange and cap screw bending and connection failures.
OUT3035,0000422 1905MAR091/1
TM10079 (17MAR09)
00-0003-20
PN=42
Section 01
Tracks
Contents
01
Page
TM10079 (17MAR09)
01-1
PN=1
Contents
01
TM10079 (17MAR09)
01-2
PN=2
Group 0130
Track System
Track Roller Remove and Install
1. Swing upperstructure 90 and lower bucket to raise
track off ground. Keep angle between boom and arm
90110 and position round side of bucket on ground.
01
0130
1
OUO6046,0002302 1927JUN081/3
UN28NOV90
T7396DZ
AGrease Fitting
BValve
CBleed Hole
TM10079 (17MAR09)
01-0130-1
OUO6046,0002302 1927JUN082/3
PN=45
Track System
UN25OCT88
Specification
Track RollerWeight ........................................................................ 35 kg
77 lb
T6585TN
01
0130
2
10. Check and adjust track sag. See Check and Adjust
Track Sag. (Operators Manual.)
OUO6046,0002302 1927JUN083/3
TM10079 (17MAR09)
01-0130-2
PN=46
Track System
T8310AH
UN21SEP94
01
0130
3
APlug (2 used)
BBracket (2 used)
CPin (2 used)
DO-Ring (2 used)
GRoller
HAxle
TM10079 (17MAR09)
01-0130-3
OUO6046,0002303 1919APR071/2
PN=47
Track System
11. Wipe finger prints and foreign material off seal ring
face using clean oil and lint-free tissues. Apply a
thin film of oil to each seal ring face.
01
0130
4
Specification
PlugTorque ........................................................................... 30 Nm
22 lb-ft
TM10079 (17MAR09)
OUO6046,0002303 1919APR072/2
01-0130-4
PN=48
Track System
T109691B
OUO6046,0002304 1919APR071/1
TM10079 (17MAR09)
01-0130-5
PN=49
01
0130
5
Track System
UN28NOV90
T7396DZ
OUO6046,0002305 1926JUN081/3
UN07APR06
TX1006136A
01
0130
6
1Track Frame
2Carrier Roller
3Track Chain
4Wood Block
TM10079 (17MAR09)
01-0130-6
OUO6046,0002305 1926JUN082/3
PN=50
Track System
4. Remove cap screws (1) and carrier roller (2).
5. Measure track carrier roller tread diameter. See 200D
and 200DLC Carrier Roller Tread Diameter. (SP326
Undercarriage Appraisal Manual.)
01
0130
7
UN26JAN07
TX1018018A
Specification
Carrier RollerWeight ...................................................................... 21 kg
46 lb
Specification
Carrier Roller-to-Frame Cap
ScrewTorque ............................................................................. 270 Nm
200 lb-ft
11. Check and adjust track sag. See Check and Adjust
Track Sag. (Operators Manual.)
OUO6046,0002305 1926JUN083/3
TM10079 (17MAR09)
01-0130-7
PN=51
Track System
UN24AUG93
T85079
OUO6046,0002306 1905MAR071/4
UN05DEC96
T85080
01
0130
8
TM10079 (17MAR09)
01-0130-8
OUO6046,0002306 1905MAR072/4
PN=52
Track System
3. Clean reusable seals by removing all foreign material
from seal rings, except seal face (A), using a scraper
or a stiff bristled fiber brush.
UN23FEB89
T82840
ASeal Face
TM10079 (17MAR09)
01-0130-9
OUO6046,0002306 1905MAR073/4
PN=53
01
0130
9
Track System
Assemble Metal Face Seals
IMPORTANT: If incorrectly assembled, oil leakage or
damage will occur.
1. Check that the O-ring (A) is not twisted and that it is
installed correctly on seal ring.
2. After installing seal, check that seal ring surface (C) is
parallel with seal mating face (B) by measuring
distances (D) and (E), as shown. If these distances
differ, correct O-ring seating.
UN26JAN07
TX1018110
UN26JAN07
AO-Ring
BMating Face
CRing Surface
DDistance
EDistance
TX1018112
01
0130
10
OUO6046,0002306 1905MAR074/4
TM10079 (17MAR09)
01-0130-10
PN=54
Track System
T6794AM
UN23FEB89
UN23FEB89
Specification
Shoe-to-Link Cap ScrewTorque ............................................... 804 Nm
593 lb-ft
T6352AH
ARounded Edge
BChamfered Edge
OUO6046,0002307 1926JUN081/1
TM10079 (17MAR09)
01-0130-11
PN=55
01
0130
11
Track System
OUO6046,0002308 1927JUN081/4
UN28NOV90
T7396DZ
01
0130
12
TM10079 (17MAR09)
01-0130-12
OUO6046,0002308 1927JUN082/4
PN=56
Track System
NOTE: Master pin (2) and master link are identified by
large dimple (3) and snap ring on master pin.
4. Move track chain so master pin (2) is over front idler or
sprocket.
01
0130
13
UN20JUL01
T143215B
TM10079 (17MAR09)
01-0130-13
OUO6046,0002308 1927JUN083/4
PN=57
Track System
IMPORTANT: Master pin can be installed in only one
direction.
01
0130
14
20. Check and adjust track sag. See Check and Adjust
Track Sag. (Operators Manual.)
OUO6046,0002308 1927JUN084/4
TM10079 (17MAR09)
01-0130-14
PN=58
Track System
01
0130
15
TM10079 (17MAR09)
01-0130-15
PN=59
Track System
T162713
UN15JAN03
01
0130
16
TM10079 (17MAR09)
01-0130-16
OUO6046,0002309 1926JUN081/2
PN=60
Track System
1Track Link (200D, 45 used;
200DLC, 48 used)
2Master Track Link
3Pin (200D, 45 used;
200DLC, 48 used)
5Seal (200D, 90 used;
200DLC, 96 used)
7Master Pin
8Spacer (2 used)
9Snap Ring
10Cap Screw (200D, 184
used; 200DLC, 196 used)
12Nut (200D, 184 used;
200DLC, 196 used)
16Master Bushing
17Track Chain Without
Shoes
01
0130
17
OUO6046,0002309 1926JUN082/2
UN26OCT88
T5821AG
OUO6046,000230A 1905MAR071/4
T5821AH
UN26OCT88
ABushing
TM10079 (17MAR09)
01-0130-17
OUO6046,000230A 1905MAR072/4
PN=61
Track System
4. Burn holes through center of pin stubs (A).
5. Hold a heavy hammer (B) against link while pin stub is
being driven out.
T5821AI
UN26OCT88
APin Stub
BHammer
OUO6046,000230A 1905MAR073/4
UN24MAY89
T5821AJ
01
0130
18
AMaster Pin
BSpacer
CRight Link
DMaster Bushing
ELeft Link
OUO6046,000230A 1905MAR074/4
TM10079 (17MAR09)
01-0130-18
PN=62
Track System
01
0130
19
T143369B
Specification
SprocketWeight (approximate) ...................................................... 46 kg
100 lb
6. Lower machine.
7. Install track chain. See Track Chain Remove and
Install. (Group 0130.)
OUO6046,000230B 1919APR071/1
TM10079 (17MAR09)
01-0130-19
PN=63
Track System
T6876BU
01
0130
20
Specification
Front IdleWeight........................................................................... 119 kg
260 lb
AFront Idler
OUO6046,000230C 1905MAR071/1
TM10079 (17MAR09)
01-0130-20
PN=64
Track System
01
0130
21
G
D
B
E
B
H
F
A
G
E
APin (2 used)
BBushing (2 used)
CIdler
T115165
T115165
UN21APR06
GO-Ring (2 used)
HAxle
IYoke
JCap Screw (4 used)
TM10079 (17MAR09)
01-0130-21
OUO6046,000230D 1919APR071/2
PN=65
Track System
14. Install brackets (E) onto axle (H).
OUO6046,000230D 1919APR072/2
TM10079 (17MAR09)
01-0130-22
PN=66
Track System
01
0130
23
TM10079 (17MAR09)
01-0130-23
OUO6046,000230E 1910APR071/2
PN=67
Track System
3. Slide track adjuster (A) forward, using a pry bar.
CAUTION: Heavy component; use appropriate
lifting device.
UN25OCT88
Specification
Track Adjuster Cylinder and
Recoil SpringWeight .................................................................... 125 kg
280 lb
T6557CX
01
0130
24
ATrack Adjuster
OUO6046,000230E 1910APR072/2
TM10079 (17MAR09)
01-0130-24
PN=68
Track System
01
0130
25
UN25OCT88
T6557DY
Specification
Track Recoil Spring Disassembly
and Assembly ToolWeight ........................................................... 225 kg
496 lb
TM10079 (17MAR09)
01-0130-25
OUO6046,000230F 1905MAR071/5
PN=69
Track System
UN28APR92
ALifting Strap
BTrack Adjuster
CDFT1110 Spacer
T7720AF
01
0130
26
TM10079 (17MAR09)
01-0130-26
OUO6046,000230F 1905MAR072/5
PN=70
Track System
6. Install DFT1087 Track Recoil Spring Disassembly and
Assembly Guard Tool (F). See DFT1087 Track Recoil
Spring Disassembly and Assembly Guard Tool. (Group
9900.)
01
0130
27
7. Install plate top (A) and nuts (B) with smallest opening
to allow access to nut (D).
8. Extend jack ram to provide enough travel to release
spring to the approximate free length.
Specification
Recoil SpringFree Length .......................................................... 606 mm
23.9 in.
UN28APR92
T7720AG
ATop Plate
BNut (8 used)
CValve
DNut
ESpecial Plug
FDFT1087 Track Recoil Spring Disassembly and
Assembly Guard Tool
TM10079 (17MAR09)
01-0130-27
OUO6046,000230F 1905MAR073/5
PN=71
Track System
11. Raise upper half of guard tool (F). Tighten T-handles.
12. Operate jack to compress spring just enough so nut
(D) can be removed.
13. Lower jack ram to release spring force.
14. Repair or replace parts as necessary. See Track
Adjuster Cylinder Disassemble and Assemble. (Group
0130.)
15. Put track adjuster cylinder in assembly tool with
cylinder end on spacer.
16. Install spacer on rod.
17. Install spring using appropriate lifting device and lifting
strap.
UN28APR92
Specification
Recoil SpringWeight ...................................................................... 65 kg
145 lb
T7720AH
01
0130
28
TM10079 (17MAR09)
01-0130-28
OUO6046,000230F 1905MAR074/5
PN=72
Track System
25. Tighten valve.
Specification
Track Adjuster and Recoil Spring
ValveTorque ................................................................................ 88 Nm
65 lb-ft
01
0130
29
OUO6046,000230F 1905MAR075/5
TM10079 (17MAR09)
01-0130-29
PN=73
Track System
TX1004754
UN17MAR06
01
0130
30
1Holder
2Piston Rod
3Dust Seal
4U-Ring
5Cylinder
6Rod
7Spring
8Spacer
9Washer
10Plug
11Nut
12Grease Valve
TM10079 (17MAR09)
01-0130-30
OUO6046,0002310 1905MAR071/2
PN=74
Track System
8. Install spring (7), spacer (8), washer (9), plug (10),
nut (11), and grease valve (12). See Track Adjuster
and Recoil Spring Disassemble and Assemble.
(Group 0130.)
10. Install U-ring (4) and dust seal (3) into cylinder (5).
11. Press holder (1) into piston rod (2).
12. Install piston rod (2) assembly into cylinder (5).
01
0130
31
OUO6046,0002310 1905MAR072/2
TM10079 (17MAR09)
01-0130-31
PN=75
Track System
01
0130
32
TM10079 (17MAR09)
01-0130-32
PN=76
Section 02
02
TM10079 (17MAR09)
02-1
PN=1
Contents
02
TM10079 (17MAR09)
02-2
PN=2
Group 0250
UN21MAR07
TX1020485A
TM10079 (17MAR09)
02-0250-1
OUO6046,0002311 1911APR071/3
PN=79
02
0250
1
T142702B
02
0250
2
TM10079 (17MAR09)
02-0250-2
OUO6046,0002311 1911APR072/3
PN=80
OUO6046,0002311 1911APR073/3
02
0250
3
TM10079 (17MAR09)
02-0250-3
PN=81
TX1000629
UN28NOV05
02
0250
4
TM10079 (17MAR09)
02-0250-4
OUO6046,0002312 1919APR071/7
PN=82
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 (24 used)
Specification
Third Planetary Pinion Carrier
Approximate Weight ................................................................... 40 kg
88 lb
TM10079 (17MAR09)
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)
02-0250-5
OUO6046,0002312 1919APR072/7
PN=83
02
0250
5
TX1018574
02
0250
6
TM10079 (17MAR09)
02-0250-6
OUO6046,0002312 1919APR073/7
PN=84
Specification
Bearing ConeTemperature .................................................... 5070C
122158F
TM10079 (17MAR09)
02-0250-7
OUO6046,0002312 1919APR074/7
PN=85
OUO6046,0002312 1919APR075/7
39
TX1004312
UN14MAR06
10
12
46
TX1004313
TM10079 (17MAR09)
02-0250-8
TX1004313
UN14MAR06
23. Install thrust plates (15) and planetary gears (13) into
third planetary pinion carrier (12).
OUO6046,0002312 1919APR076/7
PN=86
TX1004310
16
TX1004310
UN14MAR06
45
16Pin
45Slit
Specification
Ring Gear-to-Drum Cap Screw
Torque .......................................................................................... 265 Nm
195 lb-ft
OUO6046,0002312 1919APR077/7
TM10079 (17MAR09)
02-0250-9
PN=87
02
0250
9
02
0250
10
TM10079 (17MAR09)
02-0250-10
PN=88
Group 0260
Hydraulic System
02
0260
1
TM10079 (17MAR09)
02-0260-1
PN=89
Hydraulic System
TX1000629
UN28NOV05
02
0260
2
TM10079 (17MAR09)
02-0260-2
FS41334,0000171 1912APR071/7
PN=90
Hydraulic System
0Travel Motor and Gearbox
Assembly
1Travel Motor
2Seal (2 used)
3Tapered Roller Bearing (2
used)
4Drum
5Chain Sprocket
6Cap Screw (18 used)
7Lock Washer (18 used)
9Bearing Nut
10Pin Fastener
11Needle Bearing (6 used)
12Third Planetary Pinion
Carrier
13Planetary Gear (3 used)
15Plate (6 used)
16Pin Fastener (6 used)
17Spring Pin (3 used)
18Third Sun Gear
20Ring Gear
21Cap Screw (24 used)
02
0260
3
TM10079 (17MAR09)
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)
02-0260-3
FS41334,0000171 1912APR072/7
PN=91
Hydraulic System
8. Remove third stage planetary pinion carrier (12).
02
0260
4
TM10079 (17MAR09)
02-0260-4
FS41334,0000171 1912APR073/7
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.)
CAUTION: Heavy component; use an
appropriate lifting device.
Specification
Drum ApproximateWeight .............................................................. 59 kg
130 lb
02
0260
5
UN14FEB07
TX1018574
9Bearing Nut
47DFT1109 Holding Bar
48DFT1036A Travel Gearbox Nut Wrench
TM10079 (17MAR09)
02-0260-5
FS41334,0000171 1912APR074/7
PN=93
Hydraulic System
TM10079 (17MAR09)
02-0260-6
FS41334,0000171 1912APR075/7
PN=94
Hydraulic System
IMPORTANT: Install bearing nut with stepped surface
towards bearing.
21. Apply a thin coat of multi-purpose grease to bearing
nut (9). Tighten bearing nut using tools DFT1109 and
DFT1036A to specification. See DFT1109 Holding Bar
and See DFT1036A Travel Gearbox Nut Wrench.
(Group 9900.)
Specification
Bearing NutTorque.................................................................... 800 Nm
590 lb-ft
02
0260
7
TM10079 (17MAR09)
02-0260-7
FS41334,0000171 1912APR076/7
PN=95
Hydraulic System
25. Install spring pinions with slit (45) toward end of pin
(16).
26. Install third stage planetary pinion carrier (12) and
third stage sun gear (18).
27. Apply PM38627 Rigid Form-in-Place gasket to flange
surface on ring gear (20) and install ring gear.
02
0260
8
TX1004310
Specification
Ring Gear-to-Drum Cap Screw
Torque .......................................................................................... 265 Nm
195 lb-ft
16
TX1004310
UN14MAR06
45
FS41334,0000171 1912APR077/7
TM10079 (17MAR09)
02-0260-8
PN=96
Hydraulic System
02
0260
9
TM10079 (17MAR09)
02-0260-9
PN=97
Hydraulic System
TX1000643
UN01DEC05
02
0260
10
TM10079 (17MAR09)
02-0260-10
FS41334,0000160 1912MAR071/3
PN=98
Hydraulic System
0Hydraulic Motor
0AHousing
1Seal
3Piston
7Shaft
8Snap Ring
9Pin (2 used)
10Roller Bearing
14Piston (9 used)
16Retainer
17Bushing
18Swash Plate
19Spring (6 used)
21Rotor
22Plate (4 used)
23Plate (4 used)
25Piston
26O-Ring
28O-Ring
29Spring
30O-Ring
31O-Ring (2 used)
32Travel Motor Cover
33Needle Bearing
37Dowel Pin (2 used)
39Valve Plate
40Bolt (9 used)
02
0260
11
Specification
Travel Motor HousingWeight .................................................. 50 kg
110 lb
TM10079 (17MAR09)
02-0260-11
FS41334,0000160 1912MAR072/3
PN=99
Hydraulic System
12. Lubricate parts (21, 19, 17, 16, 14, and 18) with
hydraulic oil and install. Ensure that pistons (14) are
installed in their original bores. Install bushing (17)
and retainer (16) as shown.
13. Install parts (29, 28, 25, 26, 22, and 23).
17
02
0260
12
TX1004978
UN23MAR06
16
17Bushing
16Retainer
FS41334,0000160 1912MAR073/3
TM10079 (17MAR09)
02-0260-12
PN=100
Hydraulic System
UN21MAR07
TX1020485A
TM10079 (17MAR09)
02-0260-13
FS41334,000015F 1911APR071/3
PN=101
02
0260
13
Hydraulic System
NOTE: Valves may be removed with travel motor in
machine.
UN07MAR07
12. Fill hydraulic oil tank. See Check Hydraulic Tank Oil
Level. (Operators Manual.)
UN09MAR07
TX1020308
02
0260
14
TX1020307A
TM10079 (17MAR09)
02-0260-14
FS41334,000015F 1911APR072/3
PN=102
Hydraulic System
Specification
Track Frame CoverTorque ......................................................... 50 Nm
37 lb-ft
FS41334,000015F 1911APR073/3
UN21MAR07
TX1020485A
FS41334,000015E 1913APR071/4
UN07MAR07
TX1020327A
TM10079 (17MAR09)
02-0260-15
FS41334,000015E 1913APR072/4
PN=103
02
0260
15
Hydraulic System
TX1020309
UN09MAR07
02
0260
16
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)
TM10079 (17MAR09)
02-0260-16
FS41334,000015E 1913APR073/4
PN=104
Hydraulic System
14. Install cover to track frame.
Specification
Track Frame CoverTorque................................................... 50 Nm
37 lb-ft
FS41334,000015E 1913APR074/4
UN21MAR07
TX1020485A
TM10079 (17MAR09)
02-0260-17
FS41334,000015D 1910APR071/2
PN=105
02
0260
17
Hydraulic System
NOTE: Valves may be removed with travel motor in
machine.
UN07MAR07
UN23MAR07
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.
TX1020910A
02
0260
18
TX1020327A
FS41334,000015D 1910APR072/2
TM10079 (17MAR09)
02-0260-18
PN=106
Hydraulic System
UN21MAR07
TX1020485A
TM10079 (17MAR09)
02-0260-19
FS41334,000015C 1910APR071/2
PN=107
02
0260
19
Hydraulic System
NOTE: Valves may be removed with travel motor in
machine.
UN19MAR07
UN06MAR07
Specification
Fitting PlugTorque ...................................................................... 35 Nm
26 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.
TX1020263A
02
0260
20
TX1019101A
1Line
2Valve Spool
3Spring
4Fitting Plug
FS41334,000015C 1910APR072/2
TM10079 (17MAR09)
02-0260-20
PN=108
Hydraulic System
TX1018694A
UN19MAR07
FS41334,000015B 1912MAR071/1
TM10079 (17MAR09)
02-0260-21
PN=109
02
0260
21
Hydraulic System
02
0260
22
TM10079 (17MAR09)
02-0260-22
PN=110
Section 04
Engine
Contents
Page
04
TM10079 (17MAR09)
04-1
PN=1
Contents
04
TM10079 (17MAR09)
04-2
PN=2
Group 0400
OUO6046,0002329 1919APR071/16
UN23AUG88
TS281
OUO6046,0002329 1919APR072/16
UN21MAR07
TX1020485A
TM10079 (17MAR09)
04-0400-1
OUO6046,0002329 1919APR073/16
PN=113
04
0400
1
TX1021126A
TX1021142A
UN03APR07
1Support
2Air Intake Tube
3Upper Radiator Hose
4Fan Guard
5Intercooler Tube
6Coolant Surge Tank
7Intercooler Tube
8Lower Radiator Hose
TM10079 (17MAR09)
04-0400-2
OUO6046,0002329 1919APR074/16
PN=114
TX1021127A
TX1021128A
UN03APR07
OUO6046,0002329 1919APR075/16
TX1021129A
TX1021130A
UN03APR07
1Hydraulic Hose
2Hydraulic Hose
3Remote Oil Filter Hose
4Remote Oil Filter Hose
5Heater Hose
6Coolant Surge Tank Hose
TM10079 (17MAR09)
04-0400-3
OUO6046,0002329 1919APR076/16
PN=115
04
0400
3
TX1021131A
UN03APR07
OUO6046,0002329 1919APR077/16
TX1020930
UN26MAR07
1Cover
2Shield (3 used)
OUO6046,0002329 1919APR078/16
23. Remove nuts (2) and U-bolts from muffler support (3).
24. Remove muffler (1).
UN23MAR07
1Muffler
2U-bolt Nut (8 used)
3Support
TX1020923A
04
0400
4
TM10079 (17MAR09)
04-0400-4
OUO6046,0002329 1919APR079/16
PN=116
TX1006125A
UN06APR06
1Muffler Bracket
2Cap Screw (4 used)
OUO6046,0002329 1919APR0710/16
04
0400
5
TX1006126A
UN06APR06
1Eyebolts
2Lifting Bracket
OUO6046,0002329 1919APR0711/16
UN06APR06
TX1004022A
TM10079 (17MAR09)
04-0400-5
OUO6046,0002329 1919APR0712/16
PN=117
UN22FEB06
TX1004020A
Specification
Lifting Eye Cap ScrewTorque ................................................... 170 Nm
125 lb-ft
UN22FEB06
TX1004021A
04
0400
6
TM10079 (17MAR09)
04-0400-6
OUO6046,0002329 1919APR0713/16
PN=118
04
0400
7
TM10079 (17MAR09)
04-0400-7
PN=119
TX1022112
UN17APR07
04
0400
8
TM10079 (17MAR09)
04-0400-8
OUO6046,0002329 1919APR0714/16
PN=120
4Isolator (8 used)
5Isolator Cap Screw (4 used)
6Stop (8 used)
33. Remove cap screws (5), washers (7), and nuts (8)
from engine mounts.
34. Raise engine slightly. Move engine away from
pump 1 and 2 and drive gearbox. Lift and remove
engine when disengaged from hydraulic pump
drive coupling.
7Washer (8 used)
8Nut (8 used)
9Washer (8 used)
10Engine Mount-to-Engine
Block Cap Screw (14
used)
Specification
Pump 1 and 2
Housing-to-Flywheel Housing
Cap ScrewTorque ................................................................ 65 Nm
48 lb-ft
Specification
Pump Shield Cap Screws
Torque...................................................................................... 50 Nm
37 lb-ft
Specification
EngineApproximate Weight.................................................. 643 kg
1418 lb
Specification
Engine Isolator Cap Screws
Torque.................................................................................... 392 Nm
289 lb-ft
TM10079 (17MAR09)
04-0400-9
OUO6046,0002329 1919APR0715/16
PN=121
04
0400
9
OUO6046,0002329 1919APR0716/16
TM10079 (17MAR09)
04-0400-10
PN=122
Section 05
TM10079 (17MAR09)
05-1
PN=1
Contents
05
TM10079 (17MAR09)
05-2
PN=2
Group 0510
Cooling System
Radiator Remove and Install
UN23AUG88
TS281
OUO1073,0002115 1918APR071/8
UN23MAR07
TX1020785A
TM10079 (17MAR09)
05-0510-1
OUO1073,0002115 1918APR072/8
PN=125
Cooling System
8. Disconnect fan drive motor hydraulic hose (1) from
hydraulic oil tank. Close all open lines and fittings
using caps and plugs.
UN19APR07
UN22MAR07
TX1022358
TX1020688A
05
0510
2
OUO1073,0002115 1918APR073/8
TX1021410A
1Hydraulic Hose
2Hydraulic Hose
OUO1073,0002115 1918APR074/8
TX1020784A
UN23MAR07
TM10079 (17MAR09)
05-0510-2
OUO1073,0002115 1918APR075/8
PN=126
Cooling System
14. Loosen clamp and disconnect lower radiator hose (1).
15. Remove cap screw (2).
TX1020802A
UN19MAR07
OUO1073,0002115 1918APR076/8
05
0510
3
TM10079 (17MAR09)
05-0510-3
PN=127
Cooling System
UN19MAR07
Specification
RadiatorWeight .............................................................................. 37 kg
82 lb
TX1020803A
19. Ensure all foam seals are in place and install radiator.
Tighten cap screws to specification.
05
0510
4
Specification
Radiator-to-Hydraulic Oil Cooler
Cap ScrewsTorque ..................................................................... 37 Nm
27 lb-ft
Radiator-to-Intercooler Cap
ScrewsTorque ............................................................................. 37 Nm
27 lb-ft
Radiator-to-Frame Lower Cap
ScrewTorque ............................................................................... 55 Nm
41 lb-ft
TM10079 (17MAR09)
05-0510-4
OUO1073,0002115 1918APR077/8
PN=128
Cooling System
27. Fill cooling system. See Cooling System Fill and
Deaeration Procedure. (Operators Manual.)
OUO1073,0002115 1918APR078/8
TX1021429A
1Cap Screws
2Fuel Cooler
OUO1073,0002116 1918APR072/7
UN03APR07
TX1021423A
OUO1073,0002116 1918APR073/7
UN03APR07
TX1021411A
1Hydraulic Hose
TM10079 (17MAR09)
05-0510-5
OUO1073,0002116 1918APR074/7
PN=129
05
0510
5
Cooling System
UN03APR07
Specification
Hydraulic Oil CoolerWeight............................................................ 60 kg
132 lb
TX1021412A
OUO1073,0002116 1918APR075/7
TX1020828A
05
0510
6
TM10079 (17MAR09)
05-0510-6
OUO1073,0002116 1918APR076/7
PN=130
Cooling System
11. Remove washers (3 and 6), nuts (5), cap screws (4),
and mounting bracket (2) from hydraulic oil cooler (1).
4
3
Specification
Hydraulic Oil Cooler-to-Frame
Lower Cap ScrewTorque ............................................................ 55 Nm
41 lb-ft
6
5
TX1021207
UN27MAR07
05
0510
7
18. Fill and check hydraulic oil level. See 200DLC 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.)
OUO1073,0002116 1918APR077/7
TM10079 (17MAR09)
05-0510-7
OUO1073,0002117 1918APR071/8
PN=131
Cooling System
NOTE: It is not necessary to discharge air conditioning
system.
UN23MAR07
TX1020785A
OUO1073,0002117 1918APR072/8
UN19APR07
UN22MAR07
TX1022358
TX1020688A
05
0510
8
TM10079 (17MAR09)
05-0510-8
OUO1073,0002117 1918APR073/8
PN=132
Cooling System
9. Tag and disconnect fan drive motor hydraulic hoses (1
and 2). Close all open lines and fittings using caps and
plugs.
UN03APR07
TX1021410A
1Hydraulic Hose
2Hydraulic Hose
OUO1073,0002117 1918APR074/8
TX1020784A
UN23MAR07
OUO1073,0002117 1918APR075/8
UN23MAR07
TX1020788A
TM10079 (17MAR09)
05-0510-9
OUO1073,0002117 1918APR076/8
PN=133
05
0510
9
Cooling System
UN23MAR07
Specification
IntercoolerWeight ........................................................................... 33 kg
73 lb
TX1020789A
15. Remove cap screws (2), washers, and nuts from each
side of intercooler.
16. Remove intercooler.
1Intercooler
2Cap Screw (8 used)
OUO1073,0002117 1918APR077/8
05
0510
10
TM10079 (17MAR09)
05-0510-10
PN=134
Cooling System
17. Remove cap screws and mounting bracket (1) from
intercooler (2).
UN23MAR07
TX1020790A
Specification
Mounting Bracket-to-Intercooler
Cap ScrewsTorque ..................................................................... 37 Nm
27 lb-ft
1Mounting Bracket
2Intercooler
05
0510
11
Specification
Fan Drive Motor Assembly Cap
ScrewsTorque ............................................................................. 73 Nm
54 lb-ft
OUO1073,0002117 1918APR078/8
TM10079 (17MAR09)
05-0510-11
PN=135
Cooling System
TX1019245A
OUO1073,0002101 1913MAR071/1
UN21MAR07
TX1020485A
05
0510
12
TM10079 (17MAR09)
05-0510-12
OUO1073,000211A 1918APR071/13
PN=136
Cooling System
UN23AUG88
TS281
Specification
Cooling SystemCapacity ............................................................... 26.0 L
6.9 gal
OUO1073,000211A 1918APR072/13
05
0510
13
UN05MAR07
TX1020187A
Specification
Engine HoodWeight ....................................................................... 45 kg
100 lb
TX1018847A
UN20FEB07
TM10079 (17MAR09)
05-0510-13
OUO1073,000211A 1918APR073/13
PN=137
Cooling System
10. Loosen clamps and disconnect upper intercooler tube
(1) and upper radiator hose (3).
UN03APR07
TX1021424A
05
0510
14
OUO1073,000211A 1918APR074/13
UN23MAR07
TX1020785A
19. Remove cap screws (1). Lay condenser (2) aside and
secure in place.
TM10079 (17MAR09)
05-0510-14
OUO1073,000211A 1918APR075/13
PN=138
Cooling System
20. Remove cap screws (2) and condenser mounting
bracket (1).
TX1020786A
UN23MAR07
1Mounting Bracket
2Cap Screws
OUO1073,000211A 1918APR076/13
21. Remove cap screws (1). Lay fuel cooler (2) and
mounting bracket aside and secure in place.
TX1021429A
1Cap Screws
2Fuel Cooler
OUO1073,000211A 1918APR077/13
TX1021411A
UN03APR07
1Hydraulic Hose
TM10079 (17MAR09)
05-0510-15
OUO1073,000211A 1918APR078/13
PN=139
05
0510
15
Cooling System
23. Disconnect fan drive motor hydraulic hose (1) from
hydraulic oil tank. Close all open lines and fittings
using caps and plugs.
UN19APR07
UN22MAR07
TX1022358
TX1020688A
05
0510
16
OUO1073,000211A 1918APR079/13
TX1021410A
1Hydraulic Hose
2Hydraulic Hose
TM10079 (17MAR09)
05-0510-16
OUO1073,000211A 1918APR0710/13
PN=140
Cooling System
UN02APR07
Specification
Cooling PackageApproximate
Weight.............................................................................................. 159 kg
350 lb
TX1021077A
OUO1073,000211A 1918APR0711/13
05
0510
17
TM10079 (17MAR09)
05-0510-17
PN=141
Cooling System
29. Disconnect lower intercooler tube (2) and lower
radiator hose (3).
UN09APR07
TX1021719A
05
0510
18
Specification
Intercooler-to-Frame Lower Cap
ScrewTorque ............................................................................... 55 Nm
41 lb-ft
Radiator-to-Frame Lower Cap
ScrewTorque ............................................................................... 55 Nm
41 lb-ft
Hydraulic Oil Cooler-to-Frame
Lower Cap ScrewTorque ............................................................ 55 Nm
41 lb-ft
TM10079 (17MAR09)
05-0510-18
OUO1073,000211A 1918APR0712/13
PN=142
Cooling System
44. Fill cooling system. See See Cooling System Fill and
Deaeration Procedure. (Operators Manual.)
45. Fill and check hydraulic oil level. See 200DLC 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.
46. Perform pump start-up procedure. See Pump 1 and 2
Start-Up Procedure. (Group 3360.)
OUO1073,000211A 1918APR0713/13
05
0510
19
UN23AUG88
TS281
OUO1073,0002118 1918APR072/9
TX1021405A
UN03APR07
TM10079 (17MAR09)
05-0510-19
OUO1073,0002118 1918APR073/9
PN=143
Cooling System
5. Loosen clamps and remove upper radiator hose.
6. Remove cap screws (2), washers, and fan (1).
UN27MAR07
TX1021215A
Specification
Fan Cap ScrewsTorque .............................................................. 37 Nm
27 lb-ft
1Fan
2Cap Screw (6 used)
Specification
Fan Guard Cap ScrewsTorque .................................................. 37 Nm
27 lb-ft
OUO1073,0002118 1918APR074/9
UN21MAR07
TX1020485A
05
0510
20
TM10079 (17MAR09)
05-0510-20
OUO1073,0002118 1918APR075/9
PN=144
Cooling System
UN23AUG88
TS281
OUO1073,0002118 1918APR076/9
UN05MAR07
TX1020187A
Specification
Engine HoodWeight ....................................................................... 45 kg
100 lb
UN20FEB07
TX1018847A
TM10079 (17MAR09)
05-0510-21
OUO1073,0002118 1918APR077/9
PN=145
05
0510
21
Cooling System
10. Remove fan guard (8) and engine fan.
UN03APR07
TX1021406A
16. Remove cap screws (6) and washers from fan shroud
(5).
IMPORTANT: To prevent damage to fan shroud, use
an additional technician to help guide
shroud past fan drive motor shaft from
below.
17. Lift fan shroud up, tilt toward left-hand side of
machine, and remove.
18. Install fan shroud, washers, and cap screws. Tighten
cap screws to specification.
Specification
Fan Shroud Cap ScrewsTorque ................................................. 37 Nm
27 lb-ft
TM10079 (17MAR09)
05-0510-22
OUO1073,0002118 1918APR078/9
PN=146
Cooling System
24. Install hood.
25. Fill cooling system. See Cooling System Fill and
Deaeration Procedure. (Operators Manual.)
26. Check hydraulic oil level. Fill as necessary. See
200DLC Drain and Refill Capacities. (Operators
Manual.)
OUO1073,0002118 1918APR079/9
UN23AUG88
TS281
OUO1073,0002119 1918APR071/2
UN04APR07
TX1021392A
1Hose
2Hose
3Cap Screw (4 used)
4Coolant Surge Tank
5Hose
OUO1073,0002119 1918APR072/2
TM10079 (17MAR09)
05-0510-23
PN=147
05
0510
23
Cooling System
05
0510
24
TM10079 (17MAR09)
05-0510-24
PN=148
Group 0520
Intake System
05
0520
1
TM10079 (17MAR09)
05-0520-1
PN=149
Intake System
TX1021314
UN04APR07
05
0520
2
TM10079 (17MAR09)
05-0520-2
LD30992,000041E 1905APR071/2
PN=150
Intake System
1Hose Clamp
2Hose
3Hose Clamp
4Air Filter Restriction Switch
5Cap Screw (2 used)
6Washer (2 used)
7Intake Tube
8Washer
9Cap Screw
10Washer (2 used)
11Nut (2 used)
12Cap Screw
13Washer
14Mounting Bracket
15Cap Screw (2 used)
16Washer (2 used)
17Intake Tube
18Tie Band
19Intake Air Temperature
Sensor
20Hose Clamp
21Hose
22Hose Clamp
23Hose Clamp
24Hose
25Hose Clamp
26Cap Screw (4 used)
27Washer (4 used)
28Mounting Bracket
29Washer (4 used)
30Cap Screw (4 used)
31Housing Mounting Clamps
32Air Filter Housing
33Safety Element
34Primary Air Filter Element
35Cover
36Air Cleaner Dust Valve
LD30992,000041E 1905APR072/2
05
0520
3
TM10079 (17MAR09)
05-0520-3
PN=151
Intake System
05
0520
4
TM10079 (17MAR09)
05-0520-4
PN=152
Group 0560
UN30MAR07
TX1021212A
Specification
ToolboxWeight ............................................................................... 33 kg
72 lb
1Cover
2Step
3Handrail
4Toolbox
TM10079 (17MAR09)
05-0560-1
05
0560
1
TJ15698,0000153 1912APR071/3
PN=153
TX1020200A
Specification
Fuel TankWeight .................................. 108 kg approximate without fuel
238 lb approximate without fuel
TX1020197A
05
0560
2
UN07MAR07
Specification
Fuel Tank Mounting Cap
ScrewsTorque ........................................................................... 270 Nm
199 lb-ft
11. Install control valve cover and hydraulic oil tank cover.
1Cap Screws (4 used)
2Fuel Return Hose
3Clamp
4Electrical Connector
TM10079 (17MAR09)
05-0560-2
TJ15698,0000153 1912APR072/3
PN=154
TX1021212A
UN30MAR07
1Cover
2Step
3Handrail
4Toolbox
05
0560
3
TJ15698,0000153 1912APR073/3
UN21MAR07
TX1020481A
TJ15698,0000154 1911APR071/1
TM10079 (17MAR09)
05-0560-3
PN=155
UN21MAR07
TX1020482A
TJ15698,0000155 1911APR071/1
05
0560
4
TM10079 (17MAR09)
05-0560-4
PN=156
Section 07
Group 0752Elements
Dampener Drive (Flex Coupling) Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1
07
TM10079 (17MAR09)
07-1
PN=1
Contents
07
TM10079 (17MAR09)
07-2
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
TX1019969
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)
07
0752
1
FS41334,0000170 1910APR071/3
UN19MAR07
Specification
Flex Coupling-to-Flywheel Cap
ScrewTorque ............................................................................. 137 Nm
101 lb-ft
TX1019893A
TM10079 (17MAR09)
07-0752-1
FS41334,0000170 1910APR072/3
PN=159
Elements
8. Clean face of hydraulic pump housing (1).
UN19MAR07
TX1019891A
Specification
Pump Insert Cap Screws
Torque .......................................................................................... 137 Nm
101 lb-ft
Specification
Hub-to-Pump Shaft Set Screw
Torque .......................................................................................... 108 Nm
80 lb-ft
FS41334,0000170 1910APR073/3
TM10079 (17MAR09)
07-0752-2
PN=160
Section 17
17
TM10079 (17MAR09)
17-1
PN=1
Contents
17
TM10079 (17MAR09)
17-2
PN=2
Group 1740
Frame Installation
Welding On Machine
IMPORTANT: Electrical current traveling from the
welder through the machine electrical
system may damage the machine
electrical system, including battery,
engine control unit (ECU), information
controller (ICF) and main controller
(MCF). Disconnect battery cables and
ECU, ICF and MCF electrical connectors
before welding on the machine.
Before welding on the machine, follow the steps listed
below to protect the machine electrical system.
OUO1073,0002113 1909APR071/4
UN07FEB06
TX1003378A
1Electrical Connectors
2Main Controller (MCF)
OUO1073,0002113 1909APR072/4
TX1003380A
UN01MAR06
TM10079 (17MAR09)
17-1740-1
OUO1073,0002113 1909APR073/4
PN=163
17
1740
1
Frame Installation
TX1021720A
UN09APR07
OUO1073,0002113 1909APR074/4
17
1740
2
TM10079 (17MAR09)
17-1740-2
PN=164
Frame Installation
OUO1073,0002114 1928MAR071/1
TM10079 (17MAR09)
17-1740-3
PN=165
17
1740
3
Frame Installation
17
1740
4
TM10079 (17MAR09)
17-1740-4
PN=166
Group 1749
Chassis Weights
Counterweight Remove and Install
1. Park machine on level ground.
UN20JUL01
T143043
UN03SEP02
Specification
CounterweightWeight ................................................................. 4250 kg
9371 lb
T143044
UN20JUL01
T143045
Specification
Frame-to-Counterweight Cap
ScrewTorque ........................................................................... 1570 Nm
1158 lb-ft
1Plastic Cap (2 used)
2Lifting Device
3Spreader Bar
4Cap Screw and Washer (4 used)
TJ15698,000017D 1902APR071/1
TM10079 (17MAR09)
17-1749-1
PN=167
17
1749
1
Chassis Weights
17
1749
2
TM10079 (17MAR09)
17-1749-2
PN=168
Section 18
Operators Station
Contents
Page
TM10079 (17MAR09)
18-1
18
PN=1
Contents
18
TM10079 (17MAR09)
18-2
PN=2
Group 1800
OUO1073,0002107 1910APR071/12
TX1020388A
UN19MAR07
1Connector
2Connector
3Connector
4Connector
5Ground
OUO1073,0002107 1910APR072/12
18
1800
1
TX1020391
UN16MAR07
1Bracket
2Cap Screw (3 used)
3Cab Frame
4Seat Mount
TM10079 (17MAR09)
18-1800-1
OUO1073,0002107 1910APR073/12
PN=171
UN08MAR07
9. Remove screws (2) and cap screws (3) from rear panel
(4).
10. Pull rear panel forward. Disconnect wiring harness
from lighter and power outlet and remove panel.
TX1020272A
1Cover
2Screws
3Cap Screws
4Panel
OUO1073,0002107 1910APR074/12
11. Remove screws (1), panel (2), and air duct (3).
TX1020347A
UN08MAR07
1Screw
2Panel
3Air Duct
OUO1073,0002107 1910APR075/12
UN08MAR07
1Inlet Duct
2Cap Screw
TX1020275A
18
1800
2
TM10079 (17MAR09)
18-1800-2
OUO1073,0002107 1910APR076/12
PN=172
UN19MAR07
14. Remove cap screw (3), cap screws (5) and bracket
(4).
TX1020387A
15. Disconnect cab wiring harness (2) from left and right
consoles and air conditioning module. See Cab
Harness (W1) Component Location. (Group 9015-10).
16. Remove any clamps or tie bands securing cab
harness to floor or consoles.
TX1020394A
UN19MAR07
1Cap Screw
2Cab Wiring Harness
3Cap Screw
4Bracket
5Cap Screws
OUO1073,0002107 1910APR077/12
UN27MAR07
TX1021236A
1Monitor Controller
2Cup Holder
3Panel
TM10079 (17MAR09)
18-1800-3
OUO1073,0002107 1910APR078/12
PN=173
18
1800
3
TX1020389A
1Ground Wire
2Anchor Bolt
TX1020390A
UN19MAR07
1
2
2
18
1800
4
6
8
18-1800-4
6
7
TM10079 (17MAR09)
UN19MAR07
TX1020393
OUO1073,0002107 1910APR0710/12
PN=174
UN14MAR06
Specification
CabWeight ................................................................................... 330 kg
730 lb
TX1003209A
18
1800
5
TM10079 (17MAR09)
18-1800-5
OUO1073,0002107 1910APR0711/12
PN=175
OUO1073,0002107 1910APR0712/12
18
1800
6
TM10079 (17MAR09)
18-1800-6
PN=176
Group 1810
Operator Enclosure
Sliding Windows Remove and Install
1. Remove molding (3) from inside of window.
2. Use putty knife to cut adhesive (4) between cab flange
and window frame (1).
IMPORTANT: Work carefully to avoid damaging frame
and windowpane. Two technicians are
required during window removal; one to
push window out of cab, and one to
prevent window from falling.
3. Carefully remove window frame from cab.
4. Lift frame slightly at top-center to remove and install
windowpanes.
UN30APR01
T140968
1Window Frame
2Bottom Spacer (4 used)
3Molding
4Adhesive
RO33873,0000A5E 1919MAY081/1
18
1810
1
TM10079 (17MAR09)
18-1810-1
PN=177
Operator Enclosure
RO33873,0000A5F 1903APR071/1
TM10079 (17MAR09)
18-1810-2
PN=178
Operator Enclosure
Windowpanes Dimensions
TX1021276
UN04APR07
18
1810
3
TM10079 (17MAR09)
18-1810-3
OUO1073,0002108 1917APR071/5
PN=179
Operator Enclosure
TX1018573
UN23FEB07
18
1810
4
TM10079 (17MAR09)
18-1810-4
OUO1073,0002108 1917APR072/5
PN=180
Operator Enclosure
TX1021275
UN04APR07
18
1810
5
TM10079 (17MAR09)
18-1810-5
OUO1073,0002108 1917APR073/5
PN=181
Operator Enclosure
TX1018570
UN23FEB07
18
1810
6
TM10079 (17MAR09)
18-1810-6
OUO1073,0002108 1917APR074/5
PN=182
Operator Enclosure
1Black Ceramic Coating
Range
18
1810
7
TM10079 (17MAR09)
18-1810-7
PN=183
Operator Enclosure
18
1810
8
TM10079 (17MAR09)
18-1810-8
PN=184
Group 1821
TX1020303A
UN08MAR07
Specification
SeatWeight.................................................................................... 40 kg
90 lb
TX1020304A
1Cap Screw
2Socket Head Cap Screw
3Cap Screws
4Stop
5Socket Head Cap Screws
10. Install lower seat belt, lock washer and cap screw on
each side of seat. Tighten cap screw to specification.
Specification
Lower Seat Belt Mount Cap
ScrewsTorque ............................................................................. 50 Nm
37 lb-ft
18
1821
1
OUO1073,00020FF 1917APR071/1
TM10079 (17MAR09)
18-1821-1
PN=185
TX1018443A
UN09FEB07
2. Remove cap screw (4) and upper seat belt (3) from
each side of seat.
Specification
Lower Seat Belt Mount Cap
ScrewsTorque ............................................................................. 50 Nm
37 lb-ft
T188988B
UN26MAR03
OUO1073,00020E8 1910APR071/1
18
1821
2
TM10079 (17MAR09)
18-1821-2
PN=186
TX1004008
UN21FEB06
0Seat Assembly
2Cushion Cover
3Support
4Cushion
5Pad
6Frame
7Cable
8Stand
10Spring
11Torsional Damper
12Adjuster
13Lever
14Seat Suspension
15Seat Slide Track Kit
16Handle
17Cover
20Bushing
21Link
24Seat Kit
25Head Restraint
RO33873,0000A6B 1916MAR061/1
TM10079 (17MAR09)
18-1821-3
PN=187
18
1821
3
UN21FEB06
TX1004009
18
1821
4
0Seat Assembly
2Cushion Cover
3Pad
4Cushion
5Pad
6Frame
7Cable
8Handle
9Stand
10Spring
11Seat Slide Track Kit
14Lever Kit
15Bearing Kit
16Compressor
17Lever
18Torsional Damper
19Air Spring Seat Kit
20Valve
21Kit
22Seat Suspension
23Seat Suspension Boot Kit
24Seat Adjustment Cable Kit
25Wiring Lead
26Head Restraint
27Heater
RO33873,0000A6C 1916MAR061/1
TM10079 (17MAR09)
18-1821-4
PN=188
UN08FEB07
TX1018700A
LD30992,00004F1 1928MAR071/3
18
1821
5
TM10079 (17MAR09)
18-1821-5
PN=189
TX1000801
UN15DEC05
18
1821
6
TM10079 (17MAR09)
18-1821-6
LD30992,00004F1 1928MAR072/3
PN=190
3. Remove:
Caps (28)
Screws (4 and 16)
Cap Screws (5, 8, 9, 12, 19, 23, 24, and 27)
Covers (0, 7, 11, 15, 18, 22, and 26)
18Cover
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
LD30992,00004F1 1928MAR073/3
18
1821
7
TM10079 (17MAR09)
18-1821-7
PN=191
18
1821
8
TM10079 (17MAR09)
18-1821-8
PN=192
Group 1830
18
1830
1
TM10079 (17MAR09)
18-1830-1
TX,9031,DY5073 1921JUL061/2
PN=193
TX,9031,DY5073 1921JUL062/2
18
1830
2
TM10079 (17MAR09)
18-1830-2
PN=194
Specification
Flushing Solvent in Suction
PortVolume........................................................................... 240 mL
8 fl oz
Flushing Solvent in Discharge
PortVolume........................................................................... 120 mL
4 fl oz
18
1830
3
TM10079 (17MAR09)
18-1830-3
OUO1073,0002109 1910APR071/3
PN=195
18
1830
4
TM10079 (17MAR09)
18-1830-4
OUO1073,0002109 1910APR072/3
PN=196
OUO1073,0002109 1910APR073/3
18
1830
5
TM10079 (17MAR09)
18-1830-5
PN=197
Specification
OilVolume ............................................................................. 210 mL
7.1 fl oz
R134aWeight................................................................... 850 50 g
1.9 0.1 lb
OUO1073,000210A 1904APR071/1
TM10079 (17MAR09)
18-1830-6
PN=198
UN06DEC93
T8118AG
18
1830
7
OUO1073,000210B 1928MAR071/1
TM10079 (17MAR09)
18-1830-7
PN=199
18
1830
8
OUO1073,000210C 1928MAR071/1
TM10079 (17MAR09)
18-1830-8
PN=200
Specification
Evacuate SystemVacuum ..................................................... 98 kPa
980 kPa
29 in. Hg
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
OUO1073,000210D 1928MAR071/1
TM10079 (17MAR09)
18-1830-9
PN=201
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
Specification
Air Conditioning System
RefrigerantRefrigerant
Quantity.................................................................................... 0.85 kg
1.87 lb
18
1830
10
OUO1073,000210E 1928MAR071/1
TM10079 (17MAR09)
18-1830-10
PN=202
UN03APR07
TX1021309A
OUO1073,000210F 1904APR071/1
TM10079 (17MAR09)
18-1830-11
OUO1073,0002110 1928MAR071/2
PN=203
UN07MAR07
TX1020174A
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)
OUO1073,0002110 1928MAR072/2
TM10079 (17MAR09)
18-1830-12
PN=204
OUO1073,0002111 1910APR071/8
UN08MAR07
4. Remove screws (2) and cap screws (3) from rear panel
(4).
5. Pull rear panel forward. Disconnect wiring harness
from lighter and power outlet and remove panel.
TX1020272A
1Cover
2Screws
3Cap Screws
4Panel
OUO1073,0002111 1910APR072/8
UN08MAR07
TX1020273A
1Air Duct
2Bracket
3Monitor Warning Alarm
4Mounting Bracket
5Cover
TM10079 (17MAR09)
18-1830-13
OUO1073,0002111 1910APR073/8
PN=205
UN08MAR07
TX1020274A
16. Lift cab wiring harness (8). Slide out panel (7) and
remove.
OUO1073,0002111 1910APR074/8
17. Remove cap screws (2) and fresh air inlet duct (1).
UN08MAR07
1Inlet Duct
2Cap Screw
TX1020275A
18
1830
14
TM10079 (17MAR09)
18-1830-14
OUO1073,0002111 1910APR075/8
PN=206
TX1020276A
UN08MAR07
1Screw
2Panel
3Air Duct
4Mounting Bracket
OUO1073,0002111 1910APR076/8
18
1830
15
TM10079 (17MAR09)
18-1830-15
PN=207
UN08MAR07
TX1020277A
18
1830
16
TM10079 (17MAR09)
18-1830-16
OUO1073,0002111 1910APR077/8
PN=208
OUO1073,0002111 1910APR078/8
UN22FEB07
TX1018622A
5. Install receiver-dryer.
6. Tighten high-pressure output line cap screw and high
pressure input line cap screw.
Specification
Receiver-Dryer Input and Output
Line Cap ScrewsTorque ............................................................... 5 Nm
44 lb-in
1Electrical Connector
2High Pressure Liquid Input Line
3Cap Screws
4High Pressure Liquid Output Line
5Cap Screw
6Receiver-Dryer
18
1830
17
OUO1073,0002112 1928MAR071/1
TM10079 (17MAR09)
18-1830-17
PN=209
18
1830
18
TM10079 (17MAR09)
18-1830-18
PN=210
Section 33
Excavator
Contents
Page
Group 3302Buckets
Bucket Remove and Install . . . . . . . . . . . . . .33-3302-1
Bucket Pin-Up Data. . . . . . . . . . . . . . . . . . . .33-3302-2
Group 3340Frames
Bucket Links Remove and Install . . . . . . . . .33-3340-1
Arm Remove and Install . . . . . . . . . . . . . . . .33-3340-2
Boom Remove and Install . . . . . . . . . . . . . . .33-3340-6
Inspect Pins, Bushings and BossesFront
Attachment . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Bushings and Seal Remove and Install . . . .33-3340-14
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. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-45
Solenoid Valve Remove and InstallPower
Dig (SG), Travel Speed (SI), Boom
Mode (SC), and Boom Flow Rate
(SF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-47
TM10079 (17MAR09)
Page
33-1
33
PN=1
Contents
33
TM10079 (17MAR09)
33-2
PN=2
Group 3302
Buckets
Bucket Remove and Install
6
3
3
5
7
4
3
1
UN24JUL01
5
1
T142450
3
T142450
1Bushing (2 used)
2Seal (2 used)
3O-Ring (4 used)
4Ring (2 used)
5Pin (2 used)
6Pin
7Pin
8Bucket
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.)
33
3302
1
TJ15698,0000156 1911APR071/1
TM10079 (17MAR09)
33-3302-1
PN=213
Buckets
2
1
10
16
15
8
7
17
Section A
14
13
12
Section B
TX1003797
TX1003797
UN07MAR06
11
TJ15698,000017C 1915MAR071/2
33
3302
2
TM10079 (17MAR09)
33-3302-2
PN=214
Buckets
IMPORTANT: If the front attachment of a previous
model machine is used, use the
grease intervals for previous model
machine.
Item
1
450 mm
17.7 in.
0 mm
0 in.
604 mm
23.8 in.
580 mm
22.8 in.
476 mm
18.7 in.
1471 mm
57.9 in.
433 mm
17.0 in.
326 mm
12.8 in.
80 mm
3.2 in.
10
475 mm
18.7 in.
11
31 mm
1.2 in.
12
433 mm
17.0 in.
13
307 mm
12.1 in.
14
80 mm
3.2 in.
15
3.7
16
3.7
17
449 mm
17.7 in.
33
3302
3
TJ15698,000017C 1915MAR072/2
TM10079 (17MAR09)
33-3302-3
PN=215
Buckets
33
3302
4
TM10079 (17MAR09)
33-3302-4
PN=216
Group 3340
Frames
Bucket Links Remove and Install
27
27
29
1
1 2 29
24
2
4
24
27
27
18
10
12
13
19
18
24
40
24
5
21 19
11
20
21
T166094
UN13MAR03
20
T166094
Bucket Links
1Bushing (2 used)
2Seal (4 used)
3Bushing (2 used)
4Link
5Link
10Pin
11Pin
12Pin
13Pin
TM10079 (17MAR09)
33-3340-1
24O-Ring (4 used)
27Shim (as required)
29Shim (as required)
40Center Link
TJ15698,0000157 1911APR071/2
PN=217
33
3340
1
Frames
NOTE: It is not necessary to remove bucket to remove
bucket links.
3. Remove pins (10 and 13) and shims (27 and 29).
Tighten nuts (19) against each other. Cap screws
(18) need to be free to turn.
TJ15698,0000157 1911APR072/2
TJ15698,0000158 1911APR071/7
33
3340
2
TM10079 (17MAR09)
33-3340-2
PN=218
Frames
UN21MAR07
TX1020485A
TJ15698,0000158 1911APR072/7
UN08DEC08
X9811
TJ15698,0000158 1911APR073/7
33
3340
3
TM10079 (17MAR09)
33-3340-3
PN=219
Frames
T6626JC
UN31OCT88
TJ15698,0000158 1911APR074/7
1Nut (2 used)
2Pin
3Cap Screw
4Arm
5Arm Cylinder
TX1003794A
33
3340
4
UN19APR06
10. Remove nuts (1), cap screw (3) and pin (2).
TM10079 (17MAR09)
33-3340-4
TJ15698,0000158 1911APR075/7
PN=220
Frames
11. Tag and disconnect hydraulic hoses (3). Close all
open lines and fittings using caps and plugs.
UN15MAR06
TX1003793A
TJ15698,0000158 1911APR076/7
33
3340
5
TM10079 (17MAR09)
33-3340-5
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.
T142652
UN27SEP01
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
10
7
8
T142653
11
UN24JUL01
12
TJ15698,0000158 1911APR077/7
33
3340
6
TM10079 (17MAR09)
33-3340-6
TJ15698,0000159 1911APR071/10
PN=222
Frames
UN21MAR07
TX1020485A
TJ15698,0000159 1911APR072/10
UN08DEC08
X9811
TX1003795A
UN09MAR06
TM10079 (17MAR09)
33-3340-7
TJ15698,0000159 1911APR073/10
PN=223
33
3340
7
Frames
UN30DEC96
T105828
TJ15698,0000159 1911APR074/10
TX1003796A
UN17FEB06
TJ15698,0000159 1911APR075/10
UN24JUL01
T142979
33
3340
8
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)
TM10079 (17MAR09)
33-3340-8
TJ15698,0000159 1911APR076/10
PN=224
Frames
T6626JW
UN31OCT88
TJ15698,0000159 1911APR077/10
TX1020725A
UN21MAR07
1Cover
2Step
TJ15698,0000159 1911APR078/10
33
3340
9
TM10079 (17MAR09)
33-3340-9
PN=225
Frames
13. Remove cap screw (1), washer, and spacer (2).
UN19APR06
TX1003791A
TJ15698,0000159 1911APR079/10
33
3340
10
TM10079 (17MAR09)
33-3340-10
PN=226
Frames
22. Connect rod end of boom cylinders. Install thrust
plates equally on each side to get minimum amount
of clearance between boom and cylinder rod end.
UN17FEB06
TX1003796A
TJ15698,0000159 1911APR0710/10
10
4
9
2
TX1004442
11
TX1004442
1Boom-to-Frame Joint
2Boom Cylinder Head End-to-Frame Joint
3Boom Cylinder Rod End-to-Boom Joint
4Boom-to-Arm Joint
5Arm Cylinder Rod End-to-Arm Joint
6Arm Cylinder Head End-to-Boom Joint
7Bucket Cylinder Head End-to-Arm Joint
8Bucket Cylinder Rod End-to-Side and Bucket
Links Joint
9Side Links-to-Arm Joint
10Bucket Link-to-Bucket Joint
11Bucket-to-Arm Joint
UN06MAR06
33
3340
11
TM10079 (17MAR09)
33-3340-11
TJ15698,000017B 1915MAR071/3
PN=227
Frames
Pins, Bushings, and Bosses
33
3340
12
Item
Standard
Allowable Limit
Remedy
Pin
90 mm
3.54 in.
89.0 mm
3.50 in.
Replace
Bushing
90 mm
3.54 in.
91.5 mm
3.60 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Pin
90 mm
3.54 in.
89.0 mm
3.50 in.
Replace
90 mm
3.54 in.
91.5 mm
3.60 in.
Replace
Boss (Boom)
90 mm
3.54 in.
91.5 mm
3.60 in.
Replace
Pin
90 mm
3.54 in.
89.0 mm
3.50 in.
Replace
Bushing
90 mm
3.54 in.
91.5 mm
3.60 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Boss (Arm)
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
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
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Pin
71 mm
2.80 in.
70.0 mm
2.76 in.
Replace
Boss (Arm)
71 mm
2.80 in.
72.5 mm
2.85 in.
Replace
71 mm
2.80 in.
72.5 mm
2.85 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Bushing
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
TM10079 (17MAR09)
33-3340-12
TJ15698,000017B 1915MAR072/3
PN=228
Frames
Pins, Bushings, and Bosses
10
11
Item
Standard
Allowable Limit
Remedy
Pin
71 mm
2.80 in.
70.0 mm
2.76 in.
Replace
Bushing
71 mm
2.80 in.
72.5 mm
2.85 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Bushing
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
Pin
80 mm
3.15 in.
79.0 mm
3.11 in.
Replace
Bushing
80 mm
3.15 in.
81.5 mm
3.21 in.
Replace
TJ15698,000017B 1915MAR073/3
33
3340
13
TM10079 (17MAR09)
33-3340-13
PN=229
Frames
T6641CW
UN31OCT88
T95237
AHydraulic Ram
B1PipeMinimum ID to Clear Bushing OD
B2PipeMaximum OD
B3PipeLength of Bushing
CBushing
DDisks
EBushing Stop (Disk)
FPilot (Disk)
GRam Stop (Disk)
HThickness of Dust Seal
UN01NOV88
TJ15698,000015A 1912MAR071/1
33
3340
14
TM10079 (17MAR09)
33-3340-14
PN=230
Group 3360
Hydraulic System
Apply Vacuum to Hydraulic Oil Tank
Applying vacuum to hydraulic oil tank eliminates the need
to drain tank prior to servicing of hydraulic system
components.
FS41334,0000165 1912MAR071/3
UN21MAR07
TX1020485A
FS41334,0000165 1912MAR072/3
33
3360
1
TM10079 (17MAR09)
33-3360-1
PN=231
Hydraulic System
TX1003329A
UN06FEB06
TX1000587A
UN17NOV05
FS41334,0000165 1912MAR073/3
33
3360
2
TM10079 (17MAR09)
33-3360-2
PN=232
Hydraulic System
135 L approximate
36 gal approximate
12 minutes approximate
235 L approximate
62 gal approximate
37 minutes approximate
Specification
Hydraulic Oil TankCapacity................................ 135 L approximate
36 gal approximate
Hydraulic Oil TankFiltering
Time ............................................................... 12 minutes approximate
33
3360
3
FS41334,0000166 1910APR071/1
TM10079 (17MAR09)
33-3360-3
PN=233
Hydraulic System
UN21MAR07
TX1020485A
FS41334,000016F 1910APR071/11
TX1021817A
UN11APR07
FS41334,000016F 1910APR072/11
TX1020526A
33
3360
4
TM10079 (17MAR09)
33-3360-4
FS41334,000016F 1910APR073/11
PN=234
Hydraulic System
7. Remove muffler cover (1) and shields (2).
CAUTION: Exhaust parts may be hot. Avoid
burns by waiting until the parts are cool to the
touch before working on them.
8. Support muffler using appropriate lifting device.
9. Loosen exhaust clamp and move onto muffler tube.
TX1020930
UN26MAR07
1Cover
2Shield (3 used)
FS41334,000016F 1910APR074/11
10. Remove nuts (2) and U-bolts from muffler support (3).
11. Remove muffler (1).
UN23MAR07
TX1020923A
13. Tag and disconnect hoses and lines. Close all open
lines and fittings using caps and plugs.
1Muffler
2U-bolt Nut (8 used)
3Support
33
3360
5
TM10079 (17MAR09)
33-3360-5
FS41334,000016F 1910APR075/11
PN=235
Hydraulic System
TX1020397
UN12MAR07
FS41334,000016F 1910APR076/11
33
3360
6
TM10079 (17MAR09)
33-3360-6
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.
UN09MAR07
20. Install muffler support (3), hose bracket (2), and pump
assembly with cap screws (1). Tighten to
specification.
TX1020354
Specification
Pump Drive Gearbox-to-Flywheel
Housing Cap ScrewTorque......................................................... 65 Nm
48 lb-ft
TM10079 (17MAR09)
33-3360-7
FS41334,000016F 1910APR077/11
PN=237
Hydraulic System
25. Install muffler (1) to support using U-bolts and nuts
(2). Hand tighten for next step.
UN23MAR07
TX1020923A
FS41334,000016F 1910APR078/11
UN26MAR07
1Cover
2Shield (3 used)
TX1020930
33
3360
8
TM10079 (17MAR09)
33-3360-8
FS41334,000016F 1910APR079/11
PN=238
Hydraulic System
30. Install engine oil filter assembly (2) using cap screws
(1).
TX1020526A
UN19MAR07
FS41334,000016F 1910APR0710/11
UN11APR07
TX1021817A
33. Fill and check hydraulic oil level. See 200DLC Drain
and Refill Capacities. (Operators Manual.)
34. Fill pump housing and pump drive gearbox with oil.
See Pump 1 and 2 Start-Up Procedure. (Group
3360.)
35. Check pump regulator adjustments.
For minimum flow:
See Pump Regulator Test and Adjustment
Minimum Flow. (Group 9025-25.)
For maximum flow:
33
3360
9
FS41334,000016F 1910APR0711/11
TM10079 (17MAR09)
33-3360-9
PN=239
Hydraulic System
11
21
22
23
20
19
24
12
18
17
16
15
13
13
14
23
22
3
2
21
25
20
18
26
17
32
16
15
33
32
29
31
27
28
27
30
28
35
37
36
34
56
47
35
41
54
57
43
42
48
49
50
51
T142373
58
53
52
51
Continued on next page
TM10079 (17MAR09)
33-3360-10
UN20JUL01
44
T142373
33
3360
10
46
39
55
45
40
38
FS41334,000016E 1918APR071/13
PN=240
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)
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
FS41334,000016E 1918APR072/13
33
3360
11
TM10079 (17MAR09)
33-3360-11
PN=241
Hydraulic System
72
71
73
70
74
71
68
67
75
62
63
60
64
63
60
61
69
62
60
63
78
65
60
59
76
62
66
77
63
60
62
61
66
82
60
60
79
80
59
81
T142375
UN20JUL01
82
T142375
33
3360
12
59Dowel Pin
60Snap Ring (12 used)
61Dowel Pin (2 used)
62Lever (4 used)
63Dowel Pin (4 used)
64Hydraulic Pump 1 Valve
Plate
71O-Ring (4 used)
72Cap Screw (8 used)
73Cover (2 used)
74O-Ring (2 used)
75Cap Screw (12 used)
76Set Screw (2 used)
TM10079 (17MAR09)
33-3360-12
FS41334,000016E 1918APR073/13
PN=242
Hydraulic System
Specification
Hydraulic Pump Housing and
GearboxApproximate Weight ................................................ 168 kg
370 lb
Specification
Pump Housing Assembly
Approximate Weight ................................................................. 105 kg
230 lb
FS41334,000016E 1918APR074/13
33
3360
13
TM10079 (17MAR09)
33-3360-13
PN=243
Hydraulic System
UN07FEB07
TX1018511A
TM10079 (17MAR09)
33-3360-14
FS41334,000016E 1918APR075/13
PN=244
Hydraulic System
Remove set screw. (Use a 6 mm hex key wrench.)
Remove pin (78).
IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)
(65) valve plates are not
interchangeable. Take notice of the
location and position of ports in plate.
The inlet port in valve plate is located
towards the center and top of pump
housing.
11. Remove hydraulic pump 1 (64) and hydraulic pump 2
(65) valve plates. Protect machined surfaces of plates
from damage.
12. Remove special fittings (30) before removing
hydraulic pump 1 (19) and hydraulic pump 2 (25)
drive shafts.
13. Remove hydraulic pump 2 spacer ring (26) from bore.
14. Remove bearing nut (15) using JDG769 Spanner
Wrench.
15. Remove roller bearings (16 and 18) from pump 1 (19)
and pump 2 (25) drive shafts using a knife edge
puller and a press.
16. Clean and inspect parts. Repair or replace parts as
necessary. See Pump 1 and 2 Inspection. (Group
3360.)
17. Assemble hydraulic pump in reverse order, using the
following information.
FS41334,000016E 1918APR076/13
33
3360
15
TM10079 (17MAR09)
33-3360-15
PN=245
Hydraulic System
TX1018493
UN07FEB07
Specification
Roller Bearing Heat
Temperature ................................................................................ 5080C
122176F
UN07FEB07
Specification
Pump Drive Shaft Bearing Nut
Rolling Drag Torque ......................................................... 1.96 0.49 Nm
17 4 lb-in.
TX1018494
15Bearing Nut
16Roller Bearing
17Spacer Ring
18Roller Bearing
19Pump 1 (Front) Drive Shaft
25Pump 2 (Rear) Drive Shaft
FS41334,000016E 1918APR077/13
UN07FEB07
26Spacer Ring
TX1018495A
33
3360
16
TM10079 (17MAR09)
33-3360-16
FS41334,000016E 1918APR078/13
PN=246
Hydraulic System
24. To help installation of drive shafts (19 and 25), heat
pump housing using a heat gun such as the JT07010
Two Temperature Heat Gun.
UN07FEB07
Specification
Hydraulic Pump Housing Heat
Temperature ................................................................................ 5080C
122176F
TX1018496A
19Drive Shaft
25Drive Shaft
30Special Fitting (2 used)
FS41334,000016E 1918APR079/13
33
3360
17
TM10079 (17MAR09)
33-3360-17
PN=247
Hydraulic System
28. Install drive (39) and driven (36) gears using
procedure:
UN07FEB07
TX1018511A
TX1018497
UN07FEB07
33
3360
18
Specification
Dowel Pin-to-Pump 1 (Front) and
Pump 2 (Rear) Valve Plate
Torque ........................................................................................... 9.8 Nm
86 lb-in.
TM10079 (17MAR09)
33-3360-18
FS41334,000016E 1918APR0710/13
PN=248
Hydraulic System
IMPORTANT: Pump 1 (front) (64) and pump 2 (rear)
(65) valve plates are not
interchangeable. The inlet port in valve
plate is located toward the center and
top of pump housing.
32. Install valve plates using procedure:
Apply oil to valve plates.
Install valve plates so inlet port is toward the center
and top of pump housing.
Connect levers (62) for feedback linkage to valve
plates.
33. Install servo pistons (77) and pins (78). If set screw
was removed, install using procedure:
Apply thread lock and sealer (medium strength) to
threads of set screw (76).
Tighten set screw (76) using a 6 mm hex key
wrench.
Specification
Servo Piston-to-Pin Set Screw
Torque ............................................................................................ 34 Nm
25 lb-ft
34. Tighten cap screws (72 and 81) for stop (80) and
cover (73) to specification.
Specification
Stop and Cover-to-Cylinder Head
Cap ScrewTorque .................................................................... 19.5 Nm
180 lb-in.
33
3360
19
TM10079 (17MAR09)
33-3360-19
FS41334,000016E 1918APR0711/13
PN=249
Hydraulic System
Tighten cap screws (75) to specification.
Specification
Cylinder Head-to-Hydraulic Pump
Housing Cap ScrewTorque....................................................... 108 Nm
80 lb-ft
TM10079 (17MAR09)
33-3360-20
FS41334,000016E 1918APR0712/13
PN=250
Hydraulic System
Tighten cap screws (3) to specification.
Specification
Hydraulic Pump
Housing-to-Gearbox Housing Cap
ScrewTorque ............................................................................. 147 Nm
109 lb-ft
44. Fill pump and pump drive gearbox with oil. See Pump
1 and 2 Start-Up Procedure. (Group 3360.)
FS41334,000016E 1918APR0713/13
TM10079 (17MAR09)
33-3360-21
PN=251
Hydraulic System
UN09JAN97
T105725
Specification
Pump 2 (Rear) Drive Shaft Oil
Seal Contact Surface (A)OD ......................................... 45 mm nominal
1.77 in. nominal
44.8 mm limit of use
1.76 in. limit of use
Pump 2 (Rear) Drive Shaft Oil
Seal Contact Surface (B)OD ......................................... 55 mm nominal
2.17 in. nominal
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
FS41334,000016D 1911APR071/6
UN09JAN97
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
T105726
33
3360
22
TM10079 (17MAR09)
33-3360-22
FS41334,000016D 1911APR072/6
PN=252
Hydraulic System
3. Measure ID of cylinder block piston bore. Measure OD
of piston. Subtract the OD from the ID for clearance.
T6557EN
UN18OCT88
T6557EM
UN18OCT88
Specification
Cylinder Block Bore-to-Piston
Clearance ..................................................................... 0.043 mm nominal
0.0017 in. nominal
0.080 mm limit of use
0.0032 in. limit of use
FS41334,000016D 1911APR073/6
T6557EK
UN18OCT88
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
FS41334,000016D 1911APR074/6
33
3360
23
TM10079 (17MAR09)
33-3360-23
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
T105727
UN19DEC96
ACylinder Head
BID
COD
DServo Piston
FS41334,000016D 1911APR075/6
T105729
Specification
Servo Piston Pin-to-Valve Plate
BoreClearance .......................................................... 0.051 mm nominal
0.0020 in. nominal
0.300 mm limit of use
0.0118 in. limit of use
UN09JAN97
AValve Plate
BPiston Pin
COD
DID
33
3360
24
FS41334,000016D 1911APR076/6
TM10079 (17MAR09)
33-3360-24
PN=254
Hydraulic System
TX1020552A
UN19MAR07
UN31AUG01
1. Fill pump drive gearbox with oil through fill plug (2) so
level is above H mark on dipstick (1). See Pump
Gearbox Oil. (Operators Manual.)
T145092
1Dipstick
2Fill Plug
3Air Bleed Plug (2 used)
33
3360
25
FS41334,000016C 1910APR071/1
TM10079 (17MAR09)
33-3360-25
PN=255
Hydraulic System
UN21MAR07
TX1020485A
FS41334,000016B 1910APR071/2
33
3360
26
TM10079 (17MAR09)
33-3360-26
PN=256
Hydraulic System
5. Remove cap screws (1) and regulator (2).
6. Repair or replace parts as necessary.
TX1003224A
UN06FEB06
FS41334,000016B 1910APR072/2
33
3360
27
TM10079 (17MAR09)
33-3360-27
PN=257
Hydraulic System
T142272B
UN16FEB07
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
Specification
Pump 1 (Front) and Pump 2
(Rear) End Plate and
Cover-to-Housing Cap Screw
Torque................................................................................... 19.8 Nm
180 lb-in.
TM10079 (17MAR09)
33-3360-28
FS41334,000016A 1918APR071/2
PN=258
T105706
UN09JAN97
Hydraulic System
2Load Sleeve
3Load Spool
5Cylinder
6Load Piston
12Load Adjusting Cartridge
(Stop)
Flow Adjusting Cartridge
(Stop)
34Nut
35End Plate
36Cover
37Cap Screw (8 used)
47Outer Spring
48Inner Spring
FS41334,000016A 1918APR072/2
TM10079 (17MAR09)
33-3360-29
PN=259
Hydraulic System
UN21MAR07
TX1020485A
FS41334,0000169 1918APR071/3
TX1021817A
UN11APR07
FS41334,0000169 1918APR072/3
33
3360
30
TM10079 (17MAR09)
33-3360-30
PN=260
Hydraulic System
5. Tag and disconnect hoses and lines. Close all open
lines and fittings using caps and plugs.
UN19MAR07
TX1020294A
1Pilot Pump
2Cap Screw (2 used)
3Adapter (2 used)
4Hydraulic Pump Gearbox
FS41334,0000169 1918APR073/3
33
3360
31
TM10079 (17MAR09)
33-3360-31
PN=261
Hydraulic System
TX1000393
UN16NOV05
33
3360
32
TM10079 (17MAR09)
33-3360-32
FS41334,0000168 1910APR071/3
PN=262
Hydraulic System
0Pilot Pump
1Housing
2Flange
3Oil Seal
5Snap Ring
6Seal (2 used)
7End Cover
9Backup Retainer (2 used)
10Key (2 used)
12O-Ring (2 used)
13Driven Gear
14Drive Gear
15Washer (4 used)
16Cap Screw (4 used)
26Bushing
27Bushing
28Pin (4 used)
30Seal Kit
FS41334,0000168 1910APR072/3
T7685IX
FS41334,0000168 1910APR073/3
33
3360
33
TM10079 (17MAR09)
33-3360-33
PN=263
Hydraulic System
T105640
UN12DEC96
T142290
UN20JUL01
T105657
UN12DEC96
FS41334,0000167 1913MAR071/1
33
3360
34
TM10079 (17MAR09)
33-3360-34
PN=264
Hydraulic System
UN21MAR07
TX1020485A
TJ15698,000015B 1911APR071/2
TX1020484A
TJ15698,000015B 1911APR072/2
TM10079 (17MAR09)
33-3360-35
PN=265
Hydraulic System
1
2
4
5
UN07FEB06
TX1003402
TJ15698,000015C 1905APR071/1
UN21MAR07
TX1020485A
33
3360
36
TM10079 (17MAR09)
33-3360-36
TJ15698,000015D 1918APR071/2
PN=266
Hydraulic System
3. Tag and disconnect hoses and lines. Close all open
lines and fittings using caps and plugs.
TX1003406A
UN07FEB06
TX1003407A
UN07FEB06
TJ15698,000015D 1918APR072/2
33
3360
37
TM10079 (17MAR09)
33-3360-37
PN=267
Hydraulic System
TX1000413
UN16NOV05
33
3360
38
TM10079 (17MAR09)
33-3360-38
TJ15698,000015E 1918APR071/2
PN=268
Hydraulic System
1Spring
2Plate
3Housing
4Spool
5Screen
6Solenoid
8Plug (2 used)
9Screw (2 used)
10Screw (2 used)
11O-Ring
12O-Ring (2 used)
13Valve, Pilot Shutoff
Solenoid
Specification
Shutoff Solenoid Valve Housing
PlugTorque ........................................................................... 28 Nm
246 lb-in.
Specification
Solenoid-to-Housing Screws
Torque........................................................................................ 4 Nm
36 lb-in.
TJ15698,000015E 1918APR072/2
UN21MAR07
TX1020485A
TM10079 (17MAR09)
33-3360-39
OUO1073,000211E 1912APR071/2
PN=269
Hydraulic System
3. Loosen clamp and disconnect inlet hose (2).
UN21FEB06
TX1003808A
UN21FEB06
TX1003809A
11. Fill and check hydraulic oil level. See See 200DLC
Drain and Refill Capacities. (Operators Manual.)
1Outlet Hose
2Inlet Hose
3Fan Drive Pump
4Cap Screws (2 used)
OUO1073,000211E 1912APR072/2
OUO1073,000211B 1919APR071/5
33
3360
40
TM10079 (17MAR09)
33-3360-40
PN=270
Hydraulic System
2. Pull a vacuum in hydraulic oil tank using a vacuum
pump. See Apply Vacuum to Hydraulic Oil Tank.
(Group 3360.)
UN19APR07
TX1022358
TX1020688A
UN22MAR07
OUO1073,000211B 1919APR072/5
TX1021410A
1Hydraulic Hose
2Hydraulic Hose
OUO1073,000211B 1919APR073/5
33
3360
41
TX1020784A
UN23MAR07
TM10079 (17MAR09)
33-3360-41
OUO1073,000211B 1919APR074/5
PN=271
Hydraulic System
9. Disconnect hydraulic hoses (4, 6, and 7).
10. Remove lock nut (2) and washer. Discard lock nut.
UN30MAR07
TX1021112A
12. Remove cap screws (3), nuts, washers, and fan drive
motor (5).
13. Replace motor as necessary.
14. Install motor into mounting bracket.
15. Install cap screws, washers, and nuts. Tighten cap
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
20. Install fan and fan shroud. See Fan, Fan Guard, and
Fan Shroud Remove and Install. (Group 0510.)
33
3360
42
OUO1073,000211B 1919APR075/5
TM10079 (17MAR09)
33-3360-42
PN=272
Hydraulic System
UN21MAR07
TX1020485A
OUO1073,000211C 1918APR071/2
33
3360
43
TM10079 (17MAR09)
33-3360-43
PN=273
Hydraulic System
NOTE: Reversing control valve shown, standard valve
similar.
3. Remove storage compartment floor (2) to access fan
drive control valve (1).
4. Remove bottom covers.
TX1021580A
UN16APR07
11. Fill and check hydraulic oil level. See 200DLC Drain
and Refill Capacities. (Operators Manual.)
TX1021582A
UN16APR07
TX1021581A
UN16APR07
33
3360
44
OUO1073,000211C 1918APR072/2
TM10079 (17MAR09)
33-3360-44
PN=274
Hydraulic System
UN21MAR07
TX1020485A
TJ15698,000015F 1911APR071/2
33
3360
45
TM10079 (17MAR09)
33-3360-45
PN=275
Hydraulic System
3. Tag and disconnect electrical connectors.
4. Tag and disconnect hoses and lines.
UN07MAR07
5. Close all open lines, hoses, and fittings using caps and
plugs.
TX1020239A
Specification
Solenoid Valve Manifold Cap
ScrewsTorque ............................................................................. 50 Nm
37 lb-ft
TJ15698,000015F 1911APR072/2
33
3360
46
TM10079 (17MAR09)
33-3360-46
PN=276
Hydraulic System
UN21MAR07
TX1020485A
TJ15698,0000160 1911APR071/2
UN07MAR07
TX1020240A
33
3360
47
TJ15698,0000160 1911APR072/2
TM10079 (17MAR09)
33-3360-47
PN=277
Hydraulic System
UN21MAR07
TX1020485A
TJ15698,0000161 1911APR071/3
33
3360
48
TM10079 (17MAR09)
33-3360-48
PN=278
TX1018524
UN05FEB07
Hydraulic System
1Handle (2 used)
2Tie Band (2 used)
3Nut (4 used)
4Shaft (2 used)
5Boot (2 used)
6Washer (8 used)
7Tie Band (2 used)
TM10079 (17MAR09)
33-3360-49
TJ15698,0000161 1911APR072/3
PN=279
33
3360
49
Hydraulic System
Specification
Pilot Valve-to-Console Cap
ScrewTorque ........................................................................ 20 Nm
177 lb-in.
TJ15698,0000161 1911APR073/3
33
3360
50
TM10079 (17MAR09)
33-3360-50
PN=280
Hydraulic System
33
3360
51
TM10079 (17MAR09)
33-3360-51
PN=281
Hydraulic System
TX1000262
UN16NOV05
33
3360
52
TM10079 (17MAR09)
33-3360-52
TJ15698,0000162 1903APR071/3
PN=282
Hydraulic System
0Housing and Spools
3Shim (4 used)
4Spacer (4 used)
6Balance Spring (2 used)
8Balance Spring (2 used)
10Guide (4 used)
21Plate
22Universal Joint
23Cam
24Coupling
26Plug
27O-Ring
28Snap Ring
33Return Spring (2 used)
34Return Spring (2 used)
35Pilot Valve
Spacer (4)
Spools (0)
Snap Ring (28)
O-Ring (27)
Plug (26)
1. Remove:
Coupling (24)
Cam (23)
Universal Joint (22)
Plate (21)
3. Remove:
TM10079 (17MAR09)
33
3360
53
33-3360-53
TJ15698,0000162 1903APR072/3
PN=283
Hydraulic System
13. Apply TY6341 Multi-Purpose SD Polyurea Grease
to ball at ends of pushers A and pushers B.
14. Apply TY6341 Multi-Purpose SD Polyurea Grease
to joint of universal joint (22) and to inner surface
of sleeve (17) seals.
15. Install O-rings (19) and sleeves (17).
16. Apply LOCTITE 262 Threadlocker (high strength)
to threads of universal joint (22).
IMPORTANT: Align cap screw hole in plate (21)
with cap screw hole in housing (0).
TJ15698,0000162 1903APR073/3
UN21MAR07
TX1020485A
33
3360
54
TM10079 (17MAR09)
33-3360-54
TJ15698,0000163 1911APR071/2
PN=284
Hydraulic System
2. Tag and disconnect hoses underneath of cab.
3. Close all open hoses and fittings using caps and plugs.
UN16FEB06
TX1003510A
TJ15698,0000163 1911APR072/2
33
3360
55
TM10079 (17MAR09)
33-3360-55
PN=285
Hydraulic System
34
33
32
4
5
8
29
27
28
9
11
10
12
13
18
17
25
14
26
24
31
22
23
21
16
15
UN31JAN07
30
TX1018305
20
19
33
3360
56
1Cap Screw (2 used)
2Cover
3Pin (2 used)
4O-Ring (2 used)
5O-Ring (2 used)
6Dampener (2 used)
7Rubber Seat (2 used)
8Cap Screw (2 used)
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)
TM10079 (17MAR09)
33-3360-56
TJ15698,0000164 1905APR071/3
PN=286
Hydraulic System
IMPORTANT: The casing (14) and spools (19) are
replaced as an assembly because
the spools are select fitted to bores
in housing.
Parts for each port must be kept
together and installed into the same
port from which it was removed. The
port numbers are stamped on the
housing.
Note port location and quantity of
shims (22) when removing. Same
number of shims must be used when
installing.
1. Remove parts from casing. Remember to keep
parts removed from each port together. Identify
each group of parts by port numbers stamped on
casing.
NOTE: Spring pins (30 and 31) are stepped and can
only be removed from one direction.
Remove spring pin (27) and bushings (32) only
if necessary.
12. Install brackets (26) and spring pins (30 and 31).
14. Install cover (2) and cap screws (1) and tighten.
Specification
Cover-to-Holder Cap Screw
Torque........................................................................................ 5 Nm
44.3 lb-in.
TM10079 (17MAR09)
33
3360
57
33-3360-57
TJ15698,0000164 1905APR072/3
PN=287
Hydraulic System
16. Install O-ring (18) and plug (17). Tighten plug to
specification.
Specification
PlugTorque ........................................................................... 10 Nm
89 lb-in.
Specification
PlugTorque ........................................................................... 20 Nm
177 lb-in.
TJ15698,0000164 1905APR073/3
UN21MAR07
TX1020485A
TJ15698,0000165 1911APR071/2
33
3360
58
TM10079 (17MAR09)
33-3360-58
PN=288
Hydraulic System
3. Tag and disconnect hoses and lines. Close all open
lines and fittings using caps and plugs.
4. Disconnect electrical connectors.
5. Remove cap screws (3).
6. Repair or replace parts as necessary.
UN20FEB06
TX1003759A
Specification
Pilot Signal Manifold-to-Bracket
Cap ScrewTorque ....................................................................... 50 Nm
37 lb-ft
TJ15698,0000165 1911APR072/2
33
3360
59
TM10079 (17MAR09)
33-3360-59
PN=289
Hydraulic System
14
21
15
10
22
16
17
13
23
19
20
12
24
11
6
18
19
16
4
20
17
3
2
C
B
25
26
19
27
16
15
20
14
17
33
3360
60
28
17
16
T143485
TM10079 (17MAR09)
33-3360-60
15
T143485
19
UN17JUL01
29
TJ15698,0000166 1912MAR071/3
PN=290
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
TJ15698,0000166 1912MAR072/3
33
3360
61
TM10079 (17MAR09)
33-3360-61
PN=291
Hydraulic System
30
32
31
32
31
30
31
30
T143486
UN17JUL01
33
3360
62
T143486
32Spring (4 used)
TJ15698,0000166 1912MAR073/3
TM10079 (17MAR09)
33-3360-62
PN=292
Hydraulic System
UN21MAR07
TX1020485A
OUO6046,0002313 1910APR071/3
UN23MAR07
TX1020604A
OUO6046,0002313 1910APR072/3
33
3360
63
TM10079 (17MAR09)
33-3360-63
PN=293
Hydraulic System
Specification
Mounting Bracket-to-Control
Valve Cap ScrewTorque ........................................................... 270 Nm
200 lb-ft
2
1
TX1003909
1
5
UN20FEB06
33
3360
64
OUO6046,0002313 1910APR073/3
TM10079 (17MAR09)
33-3360-64
PN=294
Hydraulic System
TX1004777
UN26APR06
33
3360
65
TM10079 (17MAR09)
33-3360-65
OUO6046,0002314 1910APR071/8
PN=295
Hydraulic System
TX1004778
UN25APR06
33
3360
66
TM10079 (17MAR09)
33-3360-66
OUO6046,0002314 1910APR072/8
PN=296
Hydraulic System
1Housing
2O-Ring
3Plug
4Poppet
5Spring
6O-Ring (3 used)
7Flange
8Cap Screw (22 Used)
9O-Ring (4 Used)
10Plug (4 Used)
11Poppet
12Spring (2 Used)
13O-Ring (5 Used)
14O-Ring
15Backup Ring
16Plug
17Main Relief and Power
Digging Valve
18O-Ring
19Arm Out Circuit Relief and
Anticavitation Valve (2
Used)
20O-Ring (5 Used)
21O-Ring
22Spring
23Seat
24Poppet
25Backup Ring
26O-Ring
27O-Ring
28Backup Ring
29Sleeve
30Spool
31O-Ring
32Body
33Spring
34Piston
35O-Ring
36Plug
37Poppet
38Spring
39O-Ring
40Spacer
41Left Travel Spool
42Spring Seat (10 Used)
43Spring (5 Used)
44Bolt (5 Used)
45Auxiliary Spool
46Boom 2 Spool
47Arm 1 Spool
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)
TM10079 (17MAR09)
33-3360-67
OUO6046,0002314 1910APR073/8
PN=297
Hydraulic System
f. Tighten cap screws (44) to specification.
Specification
Cap Screw-to-Control Valve
SpoolTorque ......................................................................... 15 Nm
132 lb-in.
Specification
Left Travel Neutral
Passage-to-Housing Lift Check
PlugTorque ........................................................................... 76 Nm
56 lb-ft
Specification
Dig Regenerative
Valve-to-Housing Cap Screw
Torque...................................................................................... 11 Nm
84 lb-in.
TM10079 (17MAR09)
33-3360-68
OUO6046,0002314 1910APR074/8
PN=298
Hydraulic System
8. Lift Check (Boom 2 Power Passage) (121):
Specification
Power Passage-to-Housing
Cap ScrewTorque ................................................................ 61 Nm
46 lb-ft
Specification
Flow Rate Valve Housing
PlugTorque ........................................................................... 98 Nm
72 lb-ft
TM10079 (17MAR09)
33-3360-69
OUO6046,0002314 1910APR075/8
PN=299
Hydraulic System
f. Replace parts as necessary.
Specification
Plug-to-Arm Reduced Leakage
ValveTorque ....................................................................... 108 Nm
80 lb-ft
OUO6046,0002314 1910APR076/8
33
3360
70
TM10079 (17MAR09)
33-3360-70
PN=300
Hydraulic System
12. Main Relief and Power Digging Valve (17)
A
NOTE: Disassemble valve for cleaning and inspection
only. Valve is serviced as an assembly.
B
C
F
17
H
d. Tighten nuts (D and I) to specification.
J
K
P
e. Tighten valve cartridge (J) to specification.
Q
TX1005220
Specification
Main Relief Valve
Cartridge-to-HousingTorque ....................................................... 83 Nm
61 lb-ft
TX1005220
M
N
UN24MAR06
33
3360
71
14. Install bottom pilot caps (98) and tighten cap screws
(52).
TM10079 (17MAR09)
33-3360-71
OUO6046,0002314 1910APR077/8
PN=301
Hydraulic System
Specification
Bottom Pilot Caps-to-Housing
Cap ScrewTorque ...................................................................... 42 Nm
32 lb-ft
OUO6046,0002314 1910APR078/8
33
3360
72
TM10079 (17MAR09)
33-3360-72
PN=302
Hydraulic System
TX1004704
UN16MAR06
33
3360
73
TM10079 (17MAR09)
33-3360-73
OUO6046,0002315 1919APR071/6
PN=303
Hydraulic System
TX1004708
UN16MAR06
33
3360
74
TM10079 (17MAR09)
33-3360-74
OUO6046,0002315 1919APR072/6
PN=304
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
33
3360
75
TM10079 (17MAR09)
33-3360-75
OUO6046,0002315 1919APR073/6
PN=305
Hydraulic System
NOTE: Hold the spool in a vise by the spool end,
using wooden blocks.
Specification
Cap Screw-to-Control Valve
SpoolTorque ......................................................................... 15 Nm
11 lb-ft
Specification
Cap Screw-to-Control Valve
SpoolTorque ......................................................................... 15 Nm
11 lb-ft
33
3360
76
TM10079 (17MAR09)
33-3360-76
OUO6046,0002315 1919APR074/6
PN=306
Hydraulic System
e. Install parts (4, 5458).
Specification
Boom Reduced Leakage Valve
Body-to-Housing Cap Screw
Torque...................................................................................... 62 Nm
46 lb-ft
Specification
Boom Reduced Leakage
Valve-to-Body PlugTorque ................................................. 108 Nm
80 lb-ft
TM10079 (17MAR09)
33-3360-77
OUO6046,0002315 1919APR075/6
PN=307
33
3360
77
Hydraulic System
Specification
Bucket Flow Rate Valve
Housing-to-Housing Cap
ScrewTorque ........................................................................ 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
Boom Reduced Leakage
Valve-to-Housing Cap Screw
Torque...................................................................................... 61 Nm
46 lb-ft
Specification
Bottom Pilot Cap-to-Housing
Cap ScrewTorque ................................................................ 42 Nm
32 lb-ft
OUO6046,0002315 1919APR076/6
33
3360
78
TM10079 (17MAR09)
33-3360-78
PN=308
Hydraulic System
TJ15698,0000180 1911APR071/2
33
3360
79
TM10079 (17MAR09)
33-3360-79
PN=309
Hydraulic System
6. Disconnect connector for oil temperature sensor (4).
7. Remove cap screws (1) and washers (2).
CAUTION: Heavy component; use a hoist.
Specification
Hydraulic Oil TankWeight ....................................... 102 kg approximate
225 lb approximate
Specification
Oil Tank-to-Frame Cap Screw
Torque .......................................................................................... 400 Nm
295 lb-ft
TX1021211
UN30MAR07
3360
80
TJ15698,0000180 1911APR072/2
TM10079 (17MAR09)
33-3360-80
PN=310
Hydraulic System
33
3360
81
TM10079 (17MAR09)
33-3360-81
PN=311
Hydraulic System
TX1020508
UN30MAR07
33
3360
82
TM10079 (17MAR09)
33-3360-82
TJ15698,0000169 1918APR071/2
PN=312
Hydraulic System
1Hydraulic Oil Tank
3O-Ring
4Cap Screw (6 used)
5Spring
6Cover Assembly
6ABracket
6BCover
6CCap Screw
6DWasher
6EWasher
7Filter
7AHousing
7BFilter Element
7CCover
7DNut
7ECap
8Packing
9O-Ring
10Screw (4 used)
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)
Specification
Covers-to-Hydraulic Oil Tank
Cap ScrewsTorque .............................................................. 49 Nm
36 lb-ft
Specification
Suction Strainer Rod Nuts
Torque...................................................................................... 17 Nm
153 lb-in.
TJ15698,0000169 1918APR072/2
UN21MAR07
TX1020485A
TM10079 (17MAR09)
33-3360-83
TJ15698,0000167 1911APR071/3
PN=313
Hydraulic System
TX1020509
UN30MAR07
33
3360
84
TM10079 (17MAR09)
33-3360-84
TJ15698,0000167 1911APR072/3
PN=314
Hydraulic System
1Cap Screw (4 used)
2Flange (2 used)
3Oil Cooler Hose
4Cap Screw
5Washer
6Clamp
7Coupling
8Cap Screw (2 used)
9Washer (2 used)
10Bracket
11Return Line
12O-Ring
13Restriction Valve
14Snap Ring
Specification
Return Line Coupling Cap
ScrewsTorque ...................................................................... 90 Nm
66 lb-ft
TJ15698,0000167 1911APR073/3
UN21MAR07
TX1020485A
TM10079 (17MAR09)
33-3360-85
TJ15698,0000168 1911APR071/2
PN=315
Hydraulic System
6
5
TX1004061
UN09MAR06
1Control Valve
2O-Ring
Specification
Control Valve-to-Hydraulic Oil
Tank Return Line Coupling
NutsTorque........................................................................... 11 Nm
97 lb-in.
33
3360
86
Specification
Return Line Flange-to-Control
Valve Socket Head Cap
ScrewsTorque ...................................................................... 50 Nm
37 lb-ft
TJ15698,0000168 1911APR072/2
TM10079 (17MAR09)
33-3360-86
PN=316
Hydraulic System
UN10JAN97
T106031
OUO6046,0002316 1918APR071/6
UN21MAR07
TX1020485A
OUO6046,0002316 1918APR072/6
33
3360
87
TX1006808
1Boom Cylinder
TM10079 (17MAR09)
33-3360-87
OUO6046,0002316 1918APR073/6
PN=317
Hydraulic System
8. Remove parts (13, and 5).
9. Push pin (4) into boom.
10. Lower boom cylinder (6) on floor stand.
T142979
UN24JUL01
1Nut (2 used)
2Retainer
3Cap Screw
4Boom Cylinder-to-Boom Pin
5Shim (2 used)
6Boom Cylinder
OUO6046,0002316 1918APR074/6
33
3360
88
TM10079 (17MAR09)
33-3360-88
PN=318
Hydraulic System
11. Disconnect hydraulic lines (7) from head end of boom
cylinder (6). Close all open lines and fitting using caps
and plugs.
6
9
10
11
11
T143048
UN02AUG01
6Boom Cylinder
7Hydraulic Lines
8Shim (as required)
9Cap Screw (2 used)
10Boom Cylinder-to-Frame Pin (2 used)
11Nut (4 used)
16. Align pin bores so shims are not damaged as pin (10)
is installed.
17. Connect boom cylinder head end to frame.
18. Tighten nuts (11) against each other allowing cap
screws (9) to be free to turn in hole.
Specification
Boom Cylinder-to-Frame Pin
Retainer NutTorque ........................... 270 Nm (tighten nut against nut)
200 lb-ft (tighten nut against nut)
33
3360
89
TM10079 (17MAR09)
33-3360-89
OUO6046,0002316 1918APR075/6
PN=319
Hydraulic System
IMPORTANT: Trapped air suddenly compressed in a
cylinder is heated and ignites the oil
used for assembly causing cap seal and
ring damage. Start with cylinder rod
retracted and the rod end filled with
clean oil. Connect the cylinder head end
and lines. Operate function to slowly
extend rod. Procedure will eliminate
most of the air and reduce the
possibility of damage.
21. Start engine.
22. Slowly extend boom cylinder (6) to align pin bores so
shims (5) are not damaged as pin (4) is installed.
23. Install shims to get the minimum amount of clearance
between boom and boom cylinder rod end.
24. Connect boom cylinder rod end to boom.
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)
33
3360
90
OUO6046,0002316 1918APR076/6
TM10079 (17MAR09)
33-3360-90
PN=320
Hydraulic System
TX1004546
UN14MAR06
6
5
12
21
13
14 15 14
13 18
UN14MAR06
22
10 11
20
16 17
TX1004547
19
TX1004547
1Rod
2Dust Wiper
3Backup Ring
4U-Ring
5Buffer Ring
6Cap Screw (12 used)
7Cylinder Head
8Bushing
9Snap Ring
10Backup Ring
11O-Ring
12Barrel
33
3360
91
TM10079 (17MAR09)
18Set Screw
19Ball
20Piston Nut
21Cushion Bearing
22Cushion Seal
33-3360-91
OUO6046,0002317 1909APR071/3
PN=321
Hydraulic System
6. Install rod eye in sliding housing and install housing
in JT30043 Cylinder Service Stand.
TM10079 (17MAR09)
33-3360-92
OUO6046,0002317 1909APR072/3
PN=322
Hydraulic System
without tapped hole. Install a piece of steel flat
stock between nut and cap screw. Tighten cap
screw of piston nut wrench. Tighten piston nut (20)
to specification using JT30043 Cylinder Service
Stand.
Specification
Boom Cylinder Piston Nut
Torque.................................................................................. 5600 Nm
4130 lb-ft
OUO6046,0002317 1909APR073/3
T106031
UN10JAN97
TM10079 (17MAR09)
33-3360-93
OUO6046,0002318 1905APR071/6
PN=323
33
3360
93
Hydraulic System
UN21MAR07
TX1020485A
OUO6046,0002318 1905APR072/6
UN02AUG01
T143063
Specification
Arm CylinderWeight .................................................................... 250 kg
550 lb
OUO6046,0002318 1905APR073/6
33
3360
94
TM10079 (17MAR09)
33-3360-94
PN=324
Hydraulic System
8. Remove parts (1 and 2).
NOTE: Note location of shims (3) to aid in assembly.
9. Push pin (4) out and remove shims.
10. Disconnect lubrication line.
T143064
UN02AUG01
1Nut (2 used)
2Cap Screw
3Shim (as required)
4Arm Cylinder-to-Arm Pin
OUO6046,0002318 1905APR074/6
33
3360
95
TM10079 (17MAR09)
33-3360-95
PN=325
Hydraulic System
11. Remove parts (1 and 2).
NOTE: Note location of shims (3) to aid in assembly.
UN02AUG01
T143065
1Nut (2 used)
2Cap Screw
3Shim (as required)
4Arm Cylinder-to-Boom Pin
16. Align pin bores so shims are not damaged as pin (4)
is installed.
17. Connect lubrication line.
Specification
Arm Cylinder Pivot Lubrication
LineTorque .................................................................................. 25 Nm
18 lb-ft
TM10079 (17MAR09)
33-3360-96
OUO6046,0002318 1905APR075/6
PN=326
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)
OUO6046,0002318 1905APR076/6
33
3360
97
TM10079 (17MAR09)
33-3360-97
PN=327
Hydraulic System
TX1004548
UN14MAR06
6
4
18
25
17
18 19 18
17
22
14
UN14MAR06
1Rod
2Dust Wiper
3Backup Ring
4U-Ring
5Buffer Ring
6Cap Screw (12 used)
7Cylinder Head
26 24
10 11
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
Specification
Arm CylinderApproximate
Weight ...................................................................................... 250 kg
550 lb
21Seal Ring
22Set Screw
23Ball
24Piston Nut
25Cushion Bearing
26Cushion Seal
TM10079 (17MAR09)
23 16 15
TX1004549
20 21
TX1004549
13
33-3360-98
OUO6046,000232E 1913MAR091/3
PN=328
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).
TM10079 (17MAR09)
33-3360-99
33
3360
99
OUO6046,000232E 1913MAR092/3
PN=329
Hydraulic System
29. Install assembled cylinder head (7) on rod (1)
using ST8021.
30. Install O-ring (20) and seal ring (21) to piston nut
(24) using ST2978 Installer. Adjust seal ring (21)
using ST2535 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).
37. Install steel ball (23) and set screw (22). Tighten
set screw to specification.
Specification
Set ScrewTorque ................................................................. 57 Nm
42 lb-ft
33
3360
,100
OUO6046,000232E 1913MAR093/3
TM10079 (17MAR09)
33-3360-100
PN=330
Hydraulic System
UN10JAN97
TX1006807
UN21APR06
T106031
1Bucket Cylinder
2End of Arm
3Wood Block
OUO6046,000232F 1909APR071/5
UN21MAR07
TX1020485A
OUO6046,000232F 1909APR072/5
33
3360
,101
TM10079 (17MAR09)
33-3360-101
PN=331
Hydraulic System
4. Disconnect lines. Close all open lines and fittings using
caps and plugs.
UN02AUG01
T143075
OUO6046,000232F 1909APR073/5
33
3360
,102
TM10079 (17MAR09)
33-3360-102
PN=332
Hydraulic System
Specification
Bucket CylinderWeight................................................................ 150 kg
330 lb
5
6
3
UN02AUG01
T143076
33
3360
,103
Specification
Bucket Cylinder HoseTorque .................................................... 175 Nm
130 lb-ft
TM10079 (17MAR09)
33-3360-103
OUO6046,000232F 1909APR074/5
PN=333
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
,104
OUO6046,000232F 1909APR075/5
TM10079 (17MAR09)
33-3360-104
PN=334
Hydraulic System
8 10
11
18
20
TX1004550
15 17 16 15 13
6
7
12
13 14
15
14 13
20
18
UN09MAR06
10 11
16 17
19
TX1004551
13 14
12
14
TX1004550
19
UN09MAR06
TX1004551
1Rod
2Dust Wiper
3Backup Ring
4U-Ring
5Buffer Ring
11O-Ring
12Barrel
13Slide Ring (2 used)
14Wear Ring (2 used)
15Backup Ring (2 used)
16O-Ring
17Seal Ring
18Set Screw
19Ball
20Piston Nut
TM10079 (17MAR09)
33-3360-105
OUO6046,0002330 1905APR071/3
PN=335
33
3360
,105
Hydraulic System
9. Remove set screw (18) and steel ball (19).
28. Install O-ring (16) and seal ring (17) to piston nut
(20) using ST2963 Installer. Adjust seal ring (17)
using ST2207 Adjustment Tool.
29. Install backup rings (15) on each side of seal ring.
33
3360
,106
TM10079 (17MAR09)
33-3360-106
OUO6046,0002330 1905APR072/3
PN=336
Hydraulic System
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.
32. Install ST3245 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.................................................................................. 5150 Nm
3800 lb-ft
OUO6046,0002330 1905APR073/3
33
3360
,107
TM10079 (17MAR09)
33-3360-107
PN=337
Hydraulic System
OUO6046,0002331 1905APR071/1
33
3360
,108
TM10079 (17MAR09)
33-3360-108
PN=338
Section 43
43
TM10079 (17MAR09)
43-1
PN=1
Contents
43
TM10079 (17MAR09)
43-2
PN=2
Group 4350
UN21MAR07
TX1020485A
TJ15698,000016A 1911APR071/3
43
4350
1
TM10079 (17MAR09)
43-4350-1
PN=341
UN02FEB06
TX1003159A
Specification
Swing Motor, Brake, and
GearboxWeight ............................................................................ 218 kg
481 lb
TM10079 (17MAR09)
43-4350-2
TJ15698,000016A 1911APR072/3
PN=342
TJ15698,000016A 1911APR073/3
43
4350
3
TM10079 (17MAR09)
43-4350-3
PN=343
UN09FEB07
TX1018815
43
4350
4
TM10079 (17MAR09)
43-4350-4
TJ15698,000016B 1911APR071/8
PN=344
9Plate
10Cap Screw
11Second Planetary Pinion
Carrier
12Washer
13Pin (2 used)
14Planetary Gear (3 used)
15Needle Bearing (6 used)
16Thrust Plate (3 used)
43
4350
5
TM10079 (17MAR09)
43-4350-5
TJ15698,000016B 1911APR072/8
PN=345
TX1004267
Specification
Housing AssemblyWeight ............................................................ 106 kg
234 lb
8Bearing Nut
TJ15698,000016B 1911APR073/8
TX1004268
1Shaft
6Housing
UN01MAR06
TJ15698,000016B 1911APR074/8
43
4350
6
TM10079 (17MAR09)
43-4350-6
PN=346
20. Insert a round bar into oil passage in housing (6). Tap
and remove outer race of roller bearing (4).
2
TX1004269
TX1004269
UN19APR06
1Shaft
2Sleeve
4Roller Bearing
43
4350
7
TM10079 (17MAR09)
43-4350-7
TJ15698,000016B 1911APR075/8
PN=347
41. Install lock plate (9) to bearing nut (8) with cap
screws (10). Tighten to specification.
Specification
Lock Plate-to-Bearing Nut Cap
ScrewsTorque ............................................................................. 50 Nm
37 lb-ft
42. If lock plate (9) does not engage with splines of shaft
(1), tighten bearing nut until lock plate engages.
43. Assemble planetary gears (14), needle bearings (15),
and thrust plates (16).
44. Position gear assemblies (14, 15, 16) into second
planetary pinion carrier (11).
43
4350
8
TM10079 (17MAR09)
43-4350-8
TJ15698,000016B 1911APR076/8
PN=348
TJ15698,000016B 1911APR077/8
43
4350
9
TM10079 (17MAR09)
43-4350-9
PN=349
48. Align the spline of shaft (1) and install the second
planetary carrier assembly (11).
TX1004270
TX1004270
38
UN19APR06
13
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
TJ15698,000016B 1911APR078/8
TM10079 (17MAR09)
43-4350-10
PN=350
TX1001071A
UN02DEC05
TJ15698,000016C 1911APR071/1
TX1020485A
43
4350
11
TM10079 (17MAR09)
43-4350-11
TJ15698,0000182 1911APR071/4
PN=351
UN17MAR03
Specification
UpperstructureWeight ........................................... 4900 kg approximate
10 805 lb approximate
T188540
UN17MAR03
T188539
TJ15698,0000182 1911APR072/4
T105961
UN20DEC96
ASwing Bearing
BCap Screw (36 used)
Swing Bearing
TJ15698,0000182 1911APR073/4
43
4350
12
TM10079 (17MAR09)
43-4350-12
PN=352
Specification
UpperstructureWeight ........................................... 4900 kg approximate
10 805 lb approximate
UN17MAR03
T188541
TJ15698,0000182 1911APR074/4
TM10079 (17MAR09)
43-4350-13
PN=353
T7764AB
UN07MAY92
TJ15698,000016E 1911APR071/2
43
4350
14
TM10079 (17MAR09)
43-4350-14
PN=354
UN11APR90
T5925AA
Specification
Undercarriage-to-Swing Bearing
Cap ScrewTorque ..................................................................... 490 Nm
361 lb-ft
TJ15698,000016E 1911APR072/2
43
4350
15
TM10079 (17MAR09)
43-4350-15
PN=355
UN25JAN06
TX1000479
43
4350
16
TM10079 (17MAR09)
43-4350-16
TJ15698,000016F 1911APR071/5
PN=356
8Lower Seal
9Upper Seal
TJ15698,000016F 1911APR072/5
T6876FI
UN07MAY92
ATack Weld
BTaper Pin
CLoading Plug
TJ15698,000016F 1911APR073/5
43
4350
17
TM10079 (17MAR09)
43-4350-17
PN=357
T6876FK
9. Install spacers (B) and steel balls (A). Turn inner race
as needed to install spacers and steel balls.
UN07MAY92
T7763AB
UN07MAY92
TJ15698,000016F 1911APR074/5
ATack Weld
BTaper Pin
CLoading Plug
T6876FI
43
4350
18
UN07MAY92
TJ15698,000016F 1911APR075/5
TM10079 (17MAR09)
43-4350-18
PN=358
T5925AM
TJ15698,0000170 1911APR071/1
TJ15698,0000171 1918APR071/2
43
4350
19
TM10079 (17MAR09)
43-4350-19
PN=359
5. Install seal with seal lip against outer race. Start about
76 mm (3 in.) from end of seal using blunt instrument
to force seal into groove. Push seal in direction of
portion already installed to avoid stretching seal.
T5936BA
ASeal
BSeal Groove
TJ15698,0000171 1918APR072/2
43
4350
20
TM10079 (17MAR09)
43-4350-20
PN=360
Group 4360
Hydraulic System
Center Joint Remove and Install
UN21MAR07
TX1020485A
FS41334,0000164 1910APR071/4
UN19MAR07
TX1020553A
1Bracket
2Cap Screw (2 used)
3Hydraulic Line (4 used)
4Small Hydraulic Line (2 used)
FS41334,0000164 1910APR072/4
43
4360
1
TM10079 (17MAR09)
43-4360-1
PN=361
Hydraulic System
7. Attach the center joint to an appropriate lifting device
using a lifting strap. See Center Joint (Rotary Manifold)
Lifting Tool (Group 9900.)
UN27APR92
T7685JC
FS41334,0000164 1910APR073/4
43
4360
2
TM10079 (17MAR09)
43-4360-2
PN=362
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.)
FS41334,0000164 1910APR074/4
43
4360
3
TM10079 (17MAR09)
43-4360-3
PN=363
Hydraulic System
TX1018875
UN12FEB07
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
TM10079 (17MAR09)
43-4360-4
FS41334,0000163 1912MAR071/2
PN=364
Hydraulic System
IMPORTANT: Install dust seal (3) with lip side toward
housing (7).
8. Install dust seal (3) onto spindle (2).
9. Install O-ring (4) and oil seals (6) into housing (7).
IMPORTANT: Install spindle assembly (2) slowly into
housing (7) so oil seals (6) are not
damaged.
10. Lubricate spindle assembly (2) with hydraulic oil and
install into housing (7). Align reference marks made
during disassembly.
IMPORTANT: Install ring (8) with chamfered side
facing spindle assembly (2).
11. Install parts (812), aligning reference marks made
during disassembly.
12. Tighten cap screws (12) to specification.
Specification
Cover-to-Housing Cap Screw
Torque ............................................................................................ 49 Nm
36 lb-ft
FS41334,0000163 1912MAR072/2
T6557JB
UN01NOV88
43
4360
5
FS41334,0000162 1910APR071/1
TM10079 (17MAR09)
43-4360-5
PN=365
Hydraulic System
TX1020485A
UN21MAR07
TJ15698,0000172 1911APR071/3
43
4360
6
TM10079 (17MAR09)
43-4360-6
PN=366
Hydraulic System
3. Tag and disconnect hydraulic lines (2, 3, 4, and 6).
4. Close all open lines and fittings using caps and plugs.
UN19APR06
TX1003156A
TJ15698,0000172 1911APR072/3
43
4360
7
TM10079 (17MAR09)
43-4360-7
PN=367
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 4360.)
TJ15698,0000172 1911APR073/3
43
4360
8
TM10079 (17MAR09)
43-4360-8
PN=368
Hydraulic System
43
4360
9
TM10079 (17MAR09)
43-4360-9
PN=369
Hydraulic System
UN28NOV05
TX1000252
43
4360
10
TM10079 (17MAR09)
43-4360-10
TJ15698,0000173 1912MAR071/2
PN=370
Hydraulic System
0Hydraulic Motor
1Piston (9 used)
5Crossover Relief Valve (2
used)
8Piston
10Shaft
11Cylinder Block
12Retainer
13Plate
14Shoe Plate
15Valve Plate
20Swing Motor Cover
30Housing
35Poppet (2 used)
36Spring (2 used)
40Cap Screw (4 used)
41Roller Bearing
42Roller Bearing
76O-Ring
77O-Ring
78Spring (24 used)
79Friction Plates (3 used)
81Pipe Plug (2 used)
85Seal Kit
87Spring
88Ball
89Packing
43
4360
11
TJ15698,0000173 1912MAR072/2
TM10079 (17MAR09)
43-4360-11
PN=371
Hydraulic System
T142067
UN22JUN01
Specification
Piston-to-CylinderClearance ........................................... 0.027 mm new
0.001 in. new
0.052 mm maximum used
0.0020 in. maximum used
TJ15698,0000174 1912MAR071/4
UN22JUN01
Specification
Piston-to-SlipperClearance ................................................. 0.0 mm new
0.0 in. new
0.3 mm maximum used
0.012 in. maximum used
T142069
43
4360
12
TM10079 (17MAR09)
43-4360-12
TJ15698,0000174 1912MAR072/4
PN=372
Hydraulic System
3. Measure thickness of slipper.
T142072
UN22JUN01
Specification
SlipperThickness ................................................................. 5.5 mm new
0.217 in. new
5.3 mm minimum
0.209 in. minimum
Slipper Thickness
TJ15698,0000174 1912MAR073/4
T142073
UN22JUN01
Specification
Friction PlateThickness ....................................................... 2.0 mm new
0.079 in. new
1.8 mm minimum
0.071 in. minimum
TJ15698,0000174 1912MAR074/4
43
4360
13
TM10079 (17MAR09)
43-4360-13
PN=373
Hydraulic System
UN28NOV05
TX1000252
43
4360
14
TM10079 (17MAR09)
43-4360-14
TJ15698,0000175 1912MAR071/3
PN=374
Hydraulic System
0Hydraulic Motor
1Piston (9 used)
5Crossover Relief Valve (2
used)
8Piston
10Shaft
11Cylinder Block
12Retainer
13Plate
14Shoe Plate
15Valve Plate
20Swing Motor Cover
30Housing
35Poppet (2 used)
36Spring (2 used)
40Cap Screw (4 used)
41Roller Bearing
42Roller Bearing
76O-Ring
77O-Ring
78Spring (24 used)
79Friction Plate (3 used)
81Pipe Plug (2 used)
85Seal Kit
87Spring
88Ball
89Packing
43
4360
15
TM10079 (17MAR09)
43-4360-15
TJ15698,0000175 1912MAR072/3
PN=375
Hydraulic System
22. Install poppets (35) and spring (36). Tighten
make-up check valve plug (44) with O-ring (48)
attached.
Specification
Make-Up Check Valve Plug
Torque.................................................................................... 334 Nm
246 lb-ft
TJ15698,0000175 1912MAR073/3
TX1003231A
UN02FEB06
TJ15698,0000176 1911APR071/1
43
4360
16
TM10079 (17MAR09)
43-4360-16
PN=376
Hydraulic System
Crossover Relief Valve and Make-Up Check Valve Remove and Install
4
1
T139645
UN30APR01
T139645
TJ15698,0000177 1911APR071/3
TX1003161A
TM10079 (17MAR09)
43
4360
17
43-4360-17
TJ15698,0000177 1911APR072/3
PN=377
Hydraulic System
Remove and Install Make-Up Check Valve
1. Remove make-up check valves (1).
UN02FEB06
TX1003232A
TJ15698,0000177 1911APR073/3
UN16FEB06
TX1003721A
TJ15698,0000179 1911APR071/2
43
4360
18
TM10079 (17MAR09)
43-4360-18
PN=378
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.)
TX1003722
UN16FEB06
TJ15698,0000179 1911APR072/2
TJ15698,000017A 1911APR071/1
43
4360
19
TM10079 (17MAR09)
43-4360-19
PN=379
Hydraulic System
43
4360
20
TM10079 (17MAR09)
43-4360-20
PN=380
Section 99
TM10079 (17MAR09)
99-1
PN=1
99
Contents
99
TM10079 (17MAR09)
99-2
PN=2
Group 9900
T8318AC
UN20SEP94
TM10079 (17MAR09)
99-9900-1
TJ15698,0000146 1908MAR071/2
PN=383
T7247BW
1925APR90
99
9900
2
TJ15698,0000146 1908MAR072/2
TM10079 (17MAR09)
99-9900-2
PN=384
UN24MAR98
T6585UY
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
TM10079 (17MAR09)
99-9900-3
TJ15698,0000147 1913APR071/4
PN=385
T7029CI
UN06JUL89
99
9900
4
TM10079 (17MAR09)
99-9900-4
TJ15698,0000147 1913APR072/4
PN=386
T7029CH
UN06JUL89
99
9900
5
TM10079 (17MAR09)
99-9900-5
TJ15698,0000147 1913APR073/4
PN=387
T7029CG
UN06JUL89
99
9900
6
TJ15698,0000147 1913APR074/4
TM10079 (17MAR09)
99-9900-6
PN=388
T7162AF
UN17OCT89
99
9900
7
Material required:
TJ15698,0000148 1913APR071/1
TM10079 (17MAR09)
99-9900-7
PN=389
DFT1110 Spacer
T7708AC
UN23FEB92
99
9900
8
Material Required:
165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) Heavy
Wall Steel Pipe
TJ15698,0000149 1913APR071/1
TM10079 (17MAR09)
99-9900-8
PN=390
DFT1130 Adapter
T8319BN
UN20SEP94
99
9900
9
AAdapter Plate
BTube
CStop Plate
TJ15698,000014A 1908MAR071/1
TM10079 (17MAR09)
99-9900-9
PN=391
T7681FZ
UN28FEB92
99
9900
10
TJ15698,000014B 1913APR071/1
TM10079 (17MAR09)
99-9900-10
PN=392
T6557CH
UN25OCT95
99
9900
11
Material required:
TJ15698,000014C 1913APR071/1
TM10079 (17MAR09)
99-9900-11
PN=393
T7690AA
UN27FEB92
99
9900
12
Material required:
16 mm (5/8 in.) Flat Bar Stock
TJ15698,000014D 1911APR071/1
TM10079 (17MAR09)
99-9900-12
PN=394
T6641DO
UN24OCT88
AThreads
TJ15698,000014E 1913APR071/1
T6641EK
Material Required:
UN24OCT88
TJ15698,000014F 1913APR071/1
TM10079 (17MAR09)
99-9900-13
PN=395
38 mm
(1.5 in.)
13 mm
(0.5 in.)
76 mm
(3 in.)
13 mm
(0.5 in.)
76.2 x 76.2 x 6.35 mm
610 mm
(3 x 3 x 0.250 in.)
(24 in.)
9.5 mm
76 mm
(0.375 in.)
(3 in.)
9.5 mm
(0.375 in.)
11 mm
(0.438 in.)
19 mm
(0.750 in.)
89 mm
(3.5 in.)
102 mm
(4 in.)
63.5 x 63.5 x 6.35 mm
(2.5 x 2.5 x 0.250 in.)
38 mm
(1.5 in.)
76 mm
(3 in.)
114 mm
(4.5 in.)
457 mm
(18 in.)
12 mm
(0.472 in.)
5 Places
11 mm
(0.438 in.)
12 PLACES
38 mm (1.5 in.)
76 mm (3 in.)
152 mm (6 in.)
229 mm (9 in.)
305 mm (12 in.)
380 mm (15 in.)
457 mm (18 in.)
533 mm (21 in.)
610 mm (24 in.)
9.5 mm
(0.375 in.)
1524 mm
(60 in.)
UN11JAN08
9.5 mm
(0.375 in.)
TX1022920
TX1022920
TJ15698,0000150 1930APR071/1
TM10079 (17MAR09)
99-9900-14
PN=396
99
9900
15
TM10079 (17MAR09)
99-9900-15
PN=397
T143704
UN17JUL01
99
9900
16
TM10079 (17MAR09)
99-9900-16
TJ15698,0000151 1908MAR071/2
PN=398
Material required:
99
9900
17
TJ15698,0000151 1908MAR072/2
TM10079 (17MAR09)
99-9900-17
PN=399
99
9900
18
TM10079 (17MAR09)
99-9900-18
PN=400
Index
Page
A
Air cleaner
Remove and install . . . . . . . . . . . . . . . . .05-0520-2
Air conditioner
Condenser, remove and install . . . . . . .18-1830-11
Receiver-dryer, remove and install . . . .18-1830-17
Air conditioner and heater
Remove and install . . . . . . . . . . . . . . . .18-1830-13
Air conditioner system
Flush and purge . . . . . . . . . . . . . . . . . . .18-1830-3
Refrigerant cautions and proper
handling. . . . . . . . . . . . . . . . . . . . . . . .18-1830-1
Air conditioning
Charge R134a system . . . . . . . . . . . . .18-1830-10
Compressor, remove and install . . . . . .18-1830-11
Evacuate R134a system . . . . . . . . . . . . .18-1830-9
Recover R134a refrigerant . . . . . . . . . . .18-1830-8
R134a refrigerant oil information . . . . . . .18-1830-6
R134a station installation . . . . . . . . . . . .18-1830-7
Arm
Remove and install . . . . . . . . . . . . . . . . .33-3340-2
Arm cylinder
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-108
Disassemble and assemble . . . . . . . . .33-3360-98
Inspect pins and bushings. . . . . . . . . . .33-3340-11
Remove and install . . . . . . . . . . . . . . . .33-3360-93
Arm pins and bushings
Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11
Attachments
Adding safely . . . . . . . . . . . . . . . . . . . . . .00-01-11
Operating safely . . . . . . . . . . . . . . . . . . . .00-01-11
Page
C
B
Backover accidents
Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10
Battery explosions
Prevent . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5
Bearing
Swing, disassemble and assemble . . . .43-4350-16
Swing, remove and install . . . . . . . . . . .43-4350-14
Bleed procedure
Hydraulic cylinder . . . . . . . . . . . . . . . . 33-3360-108
Boom
Remove and install . . . . . . . . . . . . . . . . .33-3340-6
Boom cylinder
Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-108
Dissassemble and assemble. . . . . . . . .33-3360-91
Inspect pins and bushings. . . . . . . . . . .33-3340-11
Remove and install . . . . . . . . . . . . . . . .33-3360-87
TM10079 (17MAR09)
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. . . . . . . . . .33-3360-65
Arm regenerative valve . . . . . . . . . . . . .33-3360-73
Index-1
PN=1
Indx
1
Index
Page
Page
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
Index-2
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 . . . . . . . . . . . . . . . .05-0510-12
Fuel filter
Final, remove and install . . . . . . . . . . . . .05-0560-4
Primary, remove and install. . . . . . . . . . .05-0560-3
Fuel tank
Remove and install . . . . . . . . . . . . . . . . .05-0560-1
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 . . . . . . . . . . . . . . . . .05-0510-7
Gearbox, travel
Disassemble and assemble . . . . . . . . . .02-0250-4
Remove and install . . . . . . . . . . . . . . . . .02-0250-1
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 . . . . . . . . . . . . . . . . . 33-3360-108
Hydraulic fitting
Flared connections . . . . . . . . . . . . . . . .00-0003-10
Hydraulic oil
Cleanup procedure using portable filter
caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3
Hydraulic oil cooler
Remove and install . . . . . . . . . . . . . . . . .05-0510-5
Hydraulic oil tank
Apply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1
Disassemble and assemble . . . . . . . . .33-3360-82
Remove and install . . . . . . . . . . . . . . . .33-3360-79
Hydraulic pump
Disassemble and assemble . . . . . . . . .33-3360-10
Inspection . . . . . . . . . . . . . . . . . . . . . . .33-3360-22
TM10079 (17MAR09)
M
Machine inspection. . . . . . . . . . . . . . . . . . . . .00-01-3
Machine modifications
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-2
Machine movement
Unintended . . . . . . . . . . . . . . . . . . . . . . . . .00-01-8
Machine tip over
Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10
Make-up check valve
Disassemble and assemble . . . . . . . . .43-4360-18
Remove and install . . . . . . 02-0260-17, 43-4360-17
Manifold, pilot signal
Remove and install . . . . . . . . . . . . . . . .33-3360-58
Metal face seals
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8
Metal pins. . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-14
Metric bolt and cap screw
Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-1
Motor
Swing, assemble. . . . . . . . . . . . . . . . . .43-4360-14
Swing, disassemble . . . . . . . . . . . . . . .43-4360-10
Swing, inspection . . . . . . . . . . . . . . . . .43-4360-12
Swing, remove and install . . . . . . . . . . . .43-4360-6
Index-3
PN=3
Index
Page
Page
Indx
4
O
O-ring boss fitting in aluminum housingexcavators
Torque value, service
recommendation . . . . . . . . . . . . . . . . .00-0003-8
O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6
O-ring face seal fitting
Inch hex nut and stud end for high pressure torque
values . . . . . . . . . . . . . . . . . . . . . . . .00-0003-12
Metric hex nut and stud end for high pressure
torque values. . . . . . . . . . . . . . . . . . .00-0003-16
Metric hex nut and stud end for standard pressure
torque values. . . . . . . . . . . . . . . . . . .00-0003-14
Oil cooler
Bypass valve, remove and install . . . . .33-3360-85
Oil information
R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6
Operation qualification . . . . . . . . . . . . . . . . . .00-01-1
P
Park brake
Swing, disassemble . . . . . . . . . . . . . . .43-4360-10
Swing, inspection . . . . . . . . . . . . . . . . .43-4360-12
Swing, remove and install . . . . . . . . . . . .43-4360-6
Swing, start-up procedure . . . . . . . . . . .43-4360-16
Park brake and travel motor
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
TM10079 (17MAR09)
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
S
Safety
Operators seat . . . . . . . . . . . . . . . . . . . . . .00-01-7
Index-4
PN=4
Index
Page
Page
TM10079 (17MAR09)
T
Tank, hydraulic oil
Apply vacuum . . . . . . . . . . . . . . . . . . . . .33-3360-1
Tip over
Avoiding . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-10
Torque value
Flared connections . . . . . . . . . . . . . . . .00-0003-10
Flat face O-ring seal fitting . . . . . . . . . .00-0003-11
Inch SAE four bolt flange fitting. . . . . . .00-0003-19
Inch series four bolt flange fitting for high
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20
Metric bolt and cap screw . . . . . . . . . . . .00-0003-1
Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-2
Metric four bolt flange fitting . . . . . . . . .00-0003-18
O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6
O-ring boss fitting in aluminum
housingexcavators. . . . . . . . . . . . . . . .00-0003-8
O-ring face seal fittings with inch hex nut and
stud end for 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
Index-5
PN=5
Indx
5
Index
Page
Page
Track chain
Disassemble and assemble . . . . . . . . .01-0130-16
Remove and install . . . . . . . . . . . . . . . .01-0130-12
Repair . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-17
Track roller . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-5
Disassemble and assemble . . . . . . . . . .01-0130-3
Remove and install . . . . . . . . . . . . . . . . .01-0130-1
Indx
6 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 . . . . . . . . .33-3360-56
Remove and install . . . . . . . . . . . . . . . .33-3360-54
Travel speed selector valve
Remove and install . . . . . . . . . . . . . . . .02-0260-19
Travel speed solenoid valve
Remove and install . . . . . . . . . . . . . . . .33-3360-47
W
Waste disposal . . . . . . . . . . . . . . . . . . . . . . . .00-01-6
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3
Welding precautions . . . . . . . . . . . . . . . . . .17-1740-1
Welding repairs . . . . . . . . . . . . . . . . . . . . . .00-01-14
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 . . . . . . . . . . . . . . . .33-3360-63
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 . . . . . . . . .33-3360-56
TM10079 (17MAR09)
Index-6
PN=6