200clc, 230clc, And 270clc Repair Tm1931

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200CLC 230CLC and 270CLC Excavator Repair

TECHNICAL MANUAL 200CLC, 230CLC, and 270CLC Excavator Repair TM1931 09JAN04 (ENGLISH)

For complete service information also see: 200CLC, 230CLC, and 270CLC Excavator Operation and Tests . . . . . . . . . . . . . . . . . . . POWERTECH 4.5 L & 6.8 L (4045 and 6068) Diesel Engines, Base Engine . . . . . . . . . . . . POWERTECH 4.5 L & 6.8 L (4045 and 6068) Diesel Engines, Level 4 Electronic Fuel Systems with Bosch VP44 Pump . . . . . . . . . Alternators and Starting Motors . . . . . . . . . . Undercarriage Appraisal Manual . . . . . . . . .

TM1930 CTM104

CTM170 CTM77 SP326

Worldwide Construction And Forestry Division LITHO IN U.S.A.

Introduction Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

DX,TMIFC –19–29SEP98–1/1

TM1931 (09JAN04)

200CLC, 230CLC & 270CLC Excavator Repair 010904

PN=2

Introduction

Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements. SEND TO:

John Deere Dubuque Works P.O. Box 538 Attn: Publications Supervisor, Dept. 303 Dubuque, IA 52004-0538

FAX NUMBER:

563-589-5800

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Company Name: Technician Name: Address: Phone: Fax No.: Dealer Acct. No.: THANK YOU!

TX,TM,FAX –19–19JUN00–1/1

TM1931 (09JAN04)


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Introduction

TM1931 (09JAN04)


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Contents 00

SECTION 00—General Information Group 0001—Safety Group 0003—Torque Values SECTION 01—Tracks Group 0130—Track System

01

SECTION 02—Axles and Suspension Systems (Propel) Group 0250—Axle Shaft, Bearings, and Reduction Gears Group 0260—Hydraulic System

02

SECTION 04—Engine Group 0400—Removal and Installation 04

SECTION 05—Engine Auxiliary System Group 0510—Cooling System Group 0520—Intake System Group 0560—External Fuel Supply System SECTION 07—Dampener Drive (Flex Coupling) Group 0752—Elements

05

SECTION 17—Frame or Supporting Structure Group 1740—Frame Installation Group 1749—Chassis Weights

07

SECTION 18—Operator’s Station Group 1800—Removal and Installation Group 1810—Operator Enclosure Group 1821—Seat and Seat Belt Group 1830—Heating and Air Conditioning

17

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

18

SECTION 43—Swing or Pivoting System Group 4350—Mechanical Drive Elements Group 4360—Hydraulic System SECTION 99—Dealer Fabricated Tools Group 9900—Dealer Fabricated Tools

33

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

43

COPYRIGHT  2004 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright  2001

TM1931 (09JAN04)

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Contents 00

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04

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43

TM1931 (09JAN04)

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INDX

TM1931 (09JAN04)

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TM1931 (09JAN04)

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00

Section 00

General Information Contents Page

Group 0001—Safety . . . . . . . . . . . . . . . . . .00-0001-1 Group 0003—Torque Values Unified Inch Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1 Metric Bolt and Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2 Additional Metric Cap Screw Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3 Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-5 Service Recommendations for O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6 Service Recommendations for Flat Face O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-8 Service Recommendations for 37° Flare and 30° Cone Seat Connectors . . . . . . . . .00-0003-9 Service Recommendations For Flared Connections—Straight or Tapered Threads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10 Service Recommendations For Inch Series Four Bolt Flange Fittings. . . . . . . .00-0003-11 Service Recommendations for Metric Series Four Bolt Flange Fitting . . . . . . . .00-0003-12

TM1931 (09JAN04)

00-1


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Contents 00

TM1931 (09JAN04)

00-2


PN=2

Group 0001

Safety 00 0001 1

Recognize Safety Information –UN–28AUG00

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

T133555

Follow the precautions and safe operating practices highlighted by this symbol.

–19–28AUG00

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

T133588

On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

TX03679,00016CC –19–21AUG00–1/1

Follow Safety Instructions –UN–24AUG00

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

T133556

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

TX03679,00016F9 –19–28AUG00–1/1

Operate Only If Qualified Do not operate this machine unless you have read the operator’s manual carefully and you have been qualified by supervised training and instruction. Familiarize yourself with the job site and your surroundings before operating. Try all controls and

machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to your work situation and your work site.

TX03679,00016FA –19–30OCT00–1/1

TM1931 (09JAN04)

00-0001-1


PN=9

Safety

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

–UN–23AUG88

Wear close fitting clothing and safety equipment appropriate to the job.

TS206

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

TX03679,00016D0 –19–30OCT00–1/1

Avoid Unauthorized Machine Modifications Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine.

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

TX03679,00016B7 –19–30OCT00–1/1

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

–UN–15SEP00

Add Cab Guarding For Special Uses

T133733

00 0001 2

FOPS (falling object protective structures) and special screens or guarding should be installed when falling or flying objects may enter or damage the machine. Contact your authorized dealer for information on devices intended to provide protection in special work situations.

TX03679,00016CE –19–30OCT00–1/1

TM1931 (09JAN04)

00-0001-2


PN=10

Safety 00 0001 3

Inspect Machine

T6607AQ

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

–UN–18OCT88

Inspect machine carefully each day by walking around it before starting.

TX03679,0001734 –19–25SEP00–1/1

Stop engine before examining, adjusting or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

T133592

Entanglements in moving parts can cause serious injury.

–UN–12SEP01

Stay Clear Of Moving Parts

TX03679,00016D2 –19–30OCT00–1/1

T133840

If hydraulic fluid penetrates your skin, see a doctor immediately. Injected fluid must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

T133509

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

–UN–20SEP00

This machine uses a high-pressure hydraulic system. Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–31OCT00

Avoid High-Pressure Fluids

TX03679,00016D3 –19–30OCT00–1/1

TM1931 (09JAN04)

00-0001-3


PN=11

Safety

If you must operate in a building, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.

T133546

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

–UN–24AUG00

Beware Of Exhaust Fumes

TX03679,00016D4 –19–14SEP00–1/1

T133552 T133554

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

–UN–07SEP00

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage.

T133553

Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

–UN–07SEP00

Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.

–UN–14SEP00

Prevent Fires

TX03679,00016F5 –19–25SEP00–1/1

Prevent Battery Explosions

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

–UN–23AUG88

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

TS204

00 0001 4

TX03679,000174A –19–14SEP00–1/1

TM1931 (09JAN04)

00-0001-4


PN=12

Safety 00 0001 5

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS). The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely.

T133580

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

–UN–25AUG00

Handle Chemical Products Safely

TX03679,00016D7 –19–14SEP00–1/1

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

T133567

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

–UN–25AUG00

Dispose Of Waste Properly

Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants. If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for more information.

TX03679,0001733 –19–14SEP00–1/1

Prepare For Emergencies Be prepared if an emergency occurs or a fire starts.

TS291

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

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B –19–14SEP00–1/1

TM1931 (09JAN04)

00-0001-5


PN=13

Safety

Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.

T133468

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

–UN–30AUG00

Use Steps And Handholds Correctly

TX03679,00016F2 –19–14SEP00–1/1

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

T133715

Avoid unexpected machine movement. Start engine only while sitting in operator’s seat. Ensure all controls and working tools are in proper position for a parked machine.

–UN–07SEP00

Start Only From Operator’s Seat

TX03679,0001799 –19–02MAY01–1/1

Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.

–19–14SEP00

Use And Maintain Seat Belt

T133716

00 0001 6

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

TX03679,00016DD –19–17OCT00–1/1

TM1931 (09JAN04)

00-0001-6


PN=14

Safety 00 0001 7

Always lower work equipment to the ground and pull pilot control shut-off lever to locked position before standing up or leaving the operator’s seat. Stop engine before exiting.

T133863

Be careful not to accidentally actuate control levers when co-workers are present. Pull pilot control shut-off lever to locked position during work interruptions. Pull pilot control shut-off lever to locked position and stop engine before allowing anyone to approach machine.

–UN–20SEP00

Prevent Unintended Machine Movement

TX03679,0001746 –19–30OCT00–1/1

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

T134986 T133549

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

–UN–27SEP00

Avoid boom or arm contact with overhead obstacles or overhead electrical lines. Never move any part of machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

T133650

Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over.

–UN–24AUG00

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

–UN–31OCT00

Avoid Work Site Hazards

TX03679,0001748 –19–30OCT00–1/1

TM1931 (09JAN04)

00-0001-7


PN=15

Safety

Keep Riders Off Machine

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

T7273AH

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

–UN–08JUN90

Only allow operator on machine.

TX03679,0001726 –19–14SEP00–1/1

Before moving machine, be sure all persons are clear of both travel and swing paths. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair.

–UN–24AUG00

Avoid Backover Accidents

T133548

00 0001 8

Be certain travel alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.

TX03679,00016F3 –19–14SEP00–1/1

TM1931 (09JAN04)

00-0001-8


PN=16

Safety 00 0001 9

Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Extending a heavy load or swinging it over side of undercarriage may cause machine to tip. Ensure solid footing. Use extra care when operating near banks or excavations that may cave-in and cause machine to tip or fall.

T133716 –UN–15SEP00

Be careful on slopes. Use extra care on soft, rocky or frozen ground. Machine may slip sideways in these conditions. When traveling up or down slopes, keep the bucket on uphill side and just above ground level.

T133545

Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps. Properly attach ramps to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel.

–UN–27SEP00

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

T133803

Use seat belt at all times.

–19–14SEP00

Avoid Machine Tip Over

TX03679,00016DF –19–12APR01–1/1

Never lift a load above another person. Keep bystanders clear of all areas where a load might fall if it breaks free. Do not leave the seat when there is a raised load. Do not exceed lift capacity limits posted on machine and in this manual. Extending heavy loads too far or swinging over undercarriage side may cause machine to tip over.

T133839

Never use this machine to lift people.

–UN–27SEP00

Use Special Care When Lifting Objects

Use proper rigging to attach and stabilize loads. Be sure slings or chains have adequate capacity and are in good condition. Use tether lines to guide loads and prearranged hand signals to communicate with co-workers.

TX03679,00016E1 –19–02OCT00–1/1

TM1931 (09JAN04)

00-0001-9


PN=17

Safety

Add And Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability, and may create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. Verify

that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.

TX03679,00016F0 –19–14SEP00–1/1

Park And Prepare For Service Safely

T133332

• Park machine on a level surface and lower equipment to the ground. • Place pilot control shut-off lever in “lock” position. Stop engine and remove key. • Attach a “Do Not Operate” tag in an obvious place in the operator’s station.

–19–14DEC01

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

• Do not support machine with boom, arm, or other hydraulically actuated attachments. • Do not support machine with cinder blocks or wooden pieces that may crumble or crush. • Do not support machine with a single jack or other devices that may slip out of place. Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

–UN–23AUG88

Securely support machine or equipment before working under it.

TS229

00 0001 10

TX03679,00016E9 –19–12APR01–1/1

TM1931 (09JAN04)

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Safety 00 0001 11

Service Cooling System Safely

TS281

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.

–UN–23AUG88

Explosive release of fluids from pressurized cooling system can cause serious burns.

DX,RCAP –19–04JUN90–1/1

Remove paint to at least 76 mm (3 in.) from area to be heated. Wear an approved respirator when sanding or grinding paint. If a solvent or paint stripper is used, wash area with soap and water. Remove solvent or paint stripper containers from work area and allow fumes to disperse at least 15 minutes before welding or heating.

T133546

Hazardous fumes can be generated when paint is heated by welding or using a torch. Dust from sanding or grinding paint can also be hazardous.

–UN–24AUG00

Remove Paint Before Welding or Heating

Work outside or in a well-ventilated area. Dispose of waste, paint and solvents properly.

TX03679,0001732 –19–06SEP00–1/1

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

T133547

NOTE: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors.

–UN–31AUG00

Make Welding Repairs Safely

Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

TX03679,00016D5 –19–02OCT00–1/1

TM1931 (09JAN04)

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PN=19

Safety

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.

–UN–14SEP00

Drive Metal Pins Safely

T133738

00 0001 12

TX03679,0001745 –19–25SEP00–1/1

TM1931 (09JAN04)

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PN=20

Safety 00 0001 13

TX14740,0001D0E –19–09APR01–1/1

TM1931 (09JAN04)

00-0001-13

T141213

–19–17APR01

Safety Signs


PN=21

Safety 00 0001 14

TM1931 (09JAN04)

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PN=22

Group 0003

Torque Values 00 0003 1

TORQ1A

–UN–27SEP99

Unified Inch Bolt and Cap Screw Torque Values

Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings Grade 1 (No Mark) Size 1/4

Grade 2a (No Mark)

Grade 5, 5.1 or 5.2

Grade 8 or 8.2

Lubricatedb N•m(lb-ft)

Dryc N•m(lb-ft)


Dryc N•m(lb-ft)


Dryc N•m(lb-ft)


Dryc N•m(lb-ft)

3.8 (2.8)

4.7 (3.5)

6 (4.4)

7.5 (5.5)

9.5 (7)

12 (9)

13.5 (10)

17 (12.5)

5/16

7.7 (5.7)

9.8 (7.2)

12 (9)

15.5 (11.5)

19.5 (14.5)

25 (18.5)

28 (20.5)

35 (26)

3/8

13.5 (10)

17.5 (13)

22 (16)

27.5 (20)

35 (26)

44 (32.5)

49 (36)

63 (46)

7/16

22 (16)

28 (20.5)

35 (26)

44 (32.5)

56 (41)

70 (52)

80 (59)

100 (74)

1/2

34 (25)

42 (31)

53 (39)

67 (49)

85 (63)

110 (80)

120 (88)

155 (115)

9/16

48 (35.5)

60 (45)

76 (56)

95 (70)

125 (92)

155 (115)

175 (130)

220 (165)

5/8

67 (49)

85 (63)

105 (77)

135 (100)

170 (125)

215 (160)

240 (175)

305 (225)

3/4

120 (88)

150 (110)

190 (140)

240 (175)

300 (220)

380 (280)

425 (315)

540 (400)

7/8

190 (140)

240 (175)

190 (140)

240 (175)

490 (360)

615 (455)

690 (510)

870 (640)

1

285 (210)

360 (265)

285 (210)

360 (265)

730 (540)

920 (680)

1030 (760)

1300 (960)

1-1/8

400 (300)

510 (375)

400 (300)

510 (375)

910 (670)

1150 (850)

1450 (1075)

1850 (1350)

1-1/4

570 (420)

725 (535)

570 (420)

725 (535)

1280 (945)

1630 (1200)

2050 (1500)

2600 (1920)

1-3/8

750 (550)

950 (700)

750 (550)

950 (700)

1700 (1250)

2140 (1580)

2700 (2000)

3400 (2500)

1-1/2

990 (730)

1250 (930)

990 (730)

1250 (930)

2250 (1650)

2850 (2100)

3600 (2650)

4550 (3350)

a

Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length. b

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

c

"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

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

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

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

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

DX,TORQ1 –19–01OCT99–1/1

TM1931 (09JAN04)

00-0003-1


PN=23

Torque Values

–UN–07SEP99

Metric Bolt and Cap Screw Torque Values

TORQ2

00 0003 2

Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings Class 4.8

Class 8.8 or 9.8

Class 10.9

Class 12.9

Lubricateda N•m(lb-ft)

Dryb N•m(lb-ft)


Dryb N•m(lb-ft)


Dryb N•m(lb-ft)


Dryb N•m(lb-ft)

M6

4.7 (3.5)

6 (4.4)

9 (6.6)

11.5 (8.5)

13 (9.5)

16.5 (12.2)

15.5 (11.5)

19.5 (14.5)

M8

11.5 (8.5)

14.5 (10.7)

22 (16)

28 (20.5)

32 (23.5)

40 (29.5)

37 (27.5)

47 (35)

M10

23 (17)

29 (21)

43 (32)

55 (40)

63 (46)

80 (59)

75 (55)

95 (70)

M12

40 (29.5)

50 (37)

75 (55)

95 (70)

110 (80)

140 (105)

130 (95)

165 (120)

M14

63 (46)

80 (59)

120 (88)

150 (110)

175 (130)

220 (165)

205 (150)

260 (190)

Size

M16

100 (74)

125 (92)

190 (140)

240 (175)

275 (200)

350 (255)

320 (235)

400 (300)

M18

135 (100)

170 (125)

265 (195)

330 (245)

375 (275)

475 (350)

440 (325)

560 (410)

M20

190 (140)

245 (180)

375 (275)

475 (350)

530 (390)

675 (500)

625 (460)

790 (580)

M22

265 (195)

330 (245)

510 (375)

650 (480)

725 (535)

920 (680)

850 (625)

1080 (800)

M24

330 (245)

425 (315)

650 (480)

820 (600)

920 (680)

1150 (850)

1080 (800)

1350 (1000)

M27

490 (360)

625 (460)

950 (700)

1200 (885)

1350 (1000)

1700 (1250)

1580 (1160)

2000 (1475)

M30

660 (490)

850 (625)

1290 (950)

1630 (1200)

1850 (1350)

2300 (1700)

2140 (1580)

2700 (2000)

M33

900 (665)

1150 (850)

1750 (1300)

2200 (1625)

2500 (1850)

3150 (2325)

2900 (2150)

3700 (2730)

M36

1150 (850)

1450 (1075)

2250 (1650)

2850 (2100)

3200 (2350)

4050 (3000)

3750 (2770)

4750 (3500)

a

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

b

"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

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

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.

DX,TORQ2 –19–01OCT99–1/1

TM1931 (09JAN04)

00-0003-2


PN=24

Torque Values 00 0003 3 –UN–18OCT88

Additional Metric Cap Screw Torque Values

T6873AA

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

–UN–18OCT88

Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

T6873AB

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

–UN–18OCT88

Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when tightening.

T6873AC

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

Continued on next page

TM1931 (09JAN04)

00-0003-3

04T,90,M170 –19–29SEP99–1/2


PN=25


METRIC CAP SCREW TORQUE VALUESa T-Bolt Nominal Dia 8

H-Bolt

N•m

lb-ft

29

21

N•m

lb-ft

M-Bolt N•m

lb-ft

20

15

10

7

10

63

46

45

33

20

15

12

108

80

88

65

34

25

14

176

130

137

101

54

40

16

265

195

206

152

78

58

18

392

289

294

217

118

87

20

539

398

392

289

167

125

22

735

542

539

398

216

159

24

931

687

686

506

274

202

27

1372

1012

1029

759

392

289

30

1911

1410

1421

1049

539

398

33

2548

1890

1911

1410

735

542

36

3136

2314

2401

1772

931

687

Torque tolerance is ±10%.

a

04T,90,M170 –19–29SEP99–2/2

TM1931 (09JAN04)

00-0003-4


PN=26


X9811

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

–UN–23AUG88

Check Oil Lines And Fittings

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately. Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings.

TX,90,DH1559 –19–01AUG94–1/1

TM1931 (09JAN04)

00-0003-5


PN=27

Torque Values

Service Recommendations for O-Ring Boss Fittings Straight Fitting –UN–18OCT88

1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape.

T6243AE

00 0003 6

3. Tighten fitting to torque value shown on chart.


TM1931 (09JAN04)

00-0003-6

04T,90,K66 –19–29SEP99–1/2


PN=28


Angle Fitting

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

NOTE: Do not allow hoses to twist when tightening fittings.

T6520AB

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

–UN–18OCT88

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

4. Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value. STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size

N•m

lb-ft

3/8-24 UNF

8

6

7/16-20 UNF

12

9

1/2-20 UNF

16

12

9/16-18 UNF

24

18

3/4-16 UNF

46

34

7/8-14 UNF

62

46

1-1/16-12 UN

102

75

1-3/16-12 UN

122

90

1-5/16-12 UN

142

105

1-5/8-12 UN

190

140

1-7/8-12 UN

217

160

NOTE: Torque tolerance is ± 10%.

04T,90,K66 –19–29SEP99–2/2

TM1931 (09JAN04)

00-0003-7


PN=29

Torque Values

Service Recommendations for Flat Face O-Ring Seal Fittings

–UN–18OCT88

1. Inspect the fitting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring. It must be free of damage or defects. 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place.

T6243AD

00 0003 8

4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly. 5. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 6. Tighten fitting or nut to torque value shown on the chart per dash size stamped on the fitting. Do not allow hoses to twist when tightening fittings. FLAT FACE O-RING SEAL FITTING TORQUE Nominal Tube O.D. mm

Dash Size

in.

Thread Size in.

N•m

Swivel Nut

lb-ft

N•m

Bulkhead Nut lb-ft

6.35

0.250

-4

9/16-18

16

12

5.0

3.5

9.52

0.375

-6

11/16-16

24

18

9.0

6.5

12.70

0.500

-8

13/16-16

50

37

17.0

12.5

15.88

0.625

-10

1-14

69

51

17.0

12.5

19.05

0.750

-12

1 3/16-12

102

75

17.0

12.5

22.22

0.875

-14

1 3/16-12

102

75

17.0

12.5

25.40

1.000

-16

1 7/16-12

142

105

17.0

12.5

31.75

1.250

-20

1 11/16-12

190

140

17.0

12.5

38.10

1.500

-24

2-12

217

160

17.0

12.5

NOTE: Torque tolerance is +15 -20%.

04T,90,K67 –19–29SEP99–1/1

TM1931 (09JAN04)

00-0003-8


PN=30


Service Recommendations for 37° Flare and 30° Cone Seat Connectors

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

T6234AC

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

–UN–18OCT88

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

4. Lubricate male threads with hydraulic fluid or petroleum jelly. 5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings. STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size

N•m

lb-ft

8

6

3/8 - 24 UNF 7/16 - 20 UNF

12

9

1/2 - 20 UNF

16

12

9/16 - 18 UNF

24

18

3/4 - 16 UNF

46

34

7/8 - 14 UNF

62

46

1-1/16 - 12 UN

102

75

1-3/16 - 12 UN

122

90

1-5/16 - 12 UN

142

105

1-5/8 - 12

190

140

1-7/8 - 12 UN

217

160

NOTE: Torque tolerance is ± 10%.

T82,BHMA,EL –19–29SEP99–1/1

TM1931 (09JAN04)

00-0003-9


PN=31

Torque Values

Service Recommendations For Flared Connections—Straight or Tapered Threads

–UN–18OCT88

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

T6873AE

2. Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align the tube with the fitting before attempting to start the nut. Straight Thread

4. Lubricate the male threads with hydraulic fluid or petroleum jelly. 5. Index angle fittings and tighten by hand.

TORQUE CHART Straight Thread

b

–UN–18OCT88

6. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings. a

T6873AD

00 0003 10

Tapered Thread

Thread Size

N•m

lb-ft

1/8

15

11

1/4

20

3/8

29

1/2

49

36

93

69

3/4

69

51

176

130

N•m

lb-ft

15

45

33

21

69

51

1

157

116

343

253

1-1/2

196

145

539

398

2

255

188

588

434

Tapered Thread

Torque tolerance is ±10%.

a b

With seat face.

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

04T,90,M171 –19–28JAN92–1/1

TM1931 (09JAN04)

00-0003-10


PN=32


T6890BB

–UN–01MAR90

Service Recommendations For Inch Series Four Bolt Flange Fittings

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

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

D—Single Piece Flange TORQUE CHART N•m

Nominal Flange Size 1/2

lb-ft

Cap Screw Size 5/16-18 UNC

Min

Max

Min

Max

20

31

15

23

3/4

3/8-16 UNC

28

54

21

40

1

3/8-16 UNC

37

54

27

40

1-1/4

7/16-14 UNC

47

85

35

63

1-1/2

1/2-13 UNC

62

131

46

97

2

1/2-13 UNC

73

131

54

97

2-1/2

1/2-13 UNC

107

131

79

97

3

5/8-11 UNC

158

264

117

195

3-1/2

5/8-11 UNC

158

264

117

195

4

5/8-11 UNC

158

264

117

195

5

5/8-11 UNC

158

264

117

195

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.

04T,90,K174 –19–01AUG94–1/1

TM1931 (09JAN04)

00-0003-11


PN=33

Torque Values

–UN–01MAR90

Service Recommendations for Metric Series Four Bolt Flange Fitting

T6890BB

00 0003 12

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

D—Single Piece Flange

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

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component.

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.

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

TORQUE CHARTa

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

Thread

N•m

lb-ft

M6

12

9

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

M12

95

70

M14

157

116

M16

217

160

M18

334

246

M20

421

318

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

b

M8

30

22

M10

57

42

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

b

Metric standard thread.

04T,90,K175 –19–29SEP99–1/1

TM1931 (09JAN04)

00-0003-12


PN=34

Section 01

Tracks Contents

01

Page

Group 0130—Track System Track Roller, Front Idler, and Carrier Roller Oil . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-1 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-1 Track Carrier Roller. . . . . . . . . . . . . . . . . . . .01-0130-5 Metal Face Seals Repair . . . . . . . . . . . . . . . .01-0130-8 Track Shoe . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-9 Track Chain. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-10 Broken Track Chain Part Repair . . . . . . . . .01-0130-13 Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-14 Front Idler . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-16 Track Adjuster and Recoil Spring . . . . . . . .01-0130-19 Track Adjuster Cylinder . . . . . . . . . . . . . . . .01-0130-25

TM1931 (09JAN04)

01-1


PN=1

Contents

01

TM1931 (09JAN04)

01-2


PN=2

Group 0130

Track System Track Roller, Front Idler, and Carrier Roller Oil Use SAE 30 oil meeting API Service GL-5 (MIL-L-2105E). TX,45,DH5142 –19–06NOV01–1/1

Track Roller Repair Remove and Install Track Roller 1. Swing upperstructure 90° and lower bucket to raise track off ground. Keep angle between boom and arm 90—110° and position round side of bucket on ground. CAUTION: Prevent possible injury from unexpected machine movement. Put shop stands under frame to support machine while removing lower track roller. Track Roller—Specification Machine (200CLC)—Weight.................................... 20 298 kg (44,750 lb) approximate Machine (230CLC)—Weight.................................... 23 773 kg (52,410 lb) approximate Machine (270CLC)—Weight.................................... 26 082 kg (57,500 lb) approximate

2. Place shop stands under machine.

OUOE049,0000063 –19–19NOV01–1/6

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

–UN–28NOV90

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

T7396DZ

A—Grease Fitting B—Valve C—Bleed Hole


TM1931 (09JAN04)

01-0130-1

OUOE049,0000063 –19–19NOV01–2/6


PN=37

01 0130 1

Track System

CAUTION: Heavy component; use a hoist.

–UN–25OCT88

4. Attach hoist to track roller (B). Remove cap screws (A) and track roller (B).

T6585TN

01 0130 2

Track Roller—Specification Track Roller (200CLC and 230CLC)—Weight.............................................. 35 kg (77 lb) approximate Track Roller (270CLC)—Weight...................... 54 kg (120 lb) approximate

5. Measure track roller tread diameter. See 200CLC Track Roller Tread Diameter, 230CLC Track Roller Tread Diameter, or 270CLC Track Roller Tread Diameter. (SP326 Undercarriage Appraisal Manual.)

A—Cap Screw (4 used) B—Track Roller

6. Repair or replace parts as necessary. 7. Tighten cap screws. Track Roller—Specification Roller-to-Frame Cap Screw (200CLC and 230CLC)—Torque................................. 460 N•m (340 lb-ft) Roller-to-Frame Cap Screw (270CLC)—Torque ...................................................... 670 N•m (490 lb-ft)

8. If applicable, install rock guard and tighten cap screws. Track Roller—Specification Rock Guard Cap Screw (200CLC and 230CLC)—Torque ................................................ 460 N•m (340 lb-ft) Rock Guard Cap Screw (270CLC)—Torque ...................................................... 670 N•m (490 lb-ft)

9. Check and Adjust Track Sag. (Operator’s Manual.)


TM1931 (09JAN04)

01-0130-2

OUOE049,0000063 –19–19NOV01–3/6


PN=38

Track System

T8310AH

–UN–21SEP94

01 0130 3

A—Plug (2 used) B—Bracket (2 used)

C—Pin (2 used) D—O-Ring (2 used)

E—Metal Face Seal (2 used) F—Bushing (2 used)

G—Roller H—Axle

NOTE: Only remove bushing if replacement is necessary.

Disassemble and Assemble Track Roller 1. Remove plug (A) and drain oil.

7. Remove bushing (F) using a 2 jaw puller and adapters from puller set.

2. Remove pin (C). 3. Remove bracket (B) using a bearing puller attachment and adapters from puller set.

8. Replace parts as necessary. Apply a thin film of oil to bushings (F) and install.

IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face.

IMPORTANT: O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-rings do not slip when roller is turning.

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

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

5. Inspect metal face seals. See Metal Face Seals Repair. (See procedure in this group.) For seals that will be reused, put a piece of cardboard between seal rings to protect seal face.

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

6. Remove axle (H) from roller.


TM1931 (09JAN04)

01-0130-3

OUOE049,0000063 –19–19NOV01–4/6


PN=39

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. 12. Apply a thin layer of NEVER-SEEZ anti-seize lubricant or an equivalent to pin (C). Install pin even with flat surface of bracket.

16. Apply cure primer and pipe sealant to threads of plug. Install and tighten plug. Track Roller—Specification Plug—Torque ......................................................... 20 N•m (177 lb-in.)

13. Install axle to bracket. 14. Apply NEVER-SEEZ anti-seize lubricant or equivalent to pin (C). Install pin even with flat surface of bracket.

NEVER-SEEZ is a trademark of Emhart Chemical Group.

OUOE049,0000063 –19–19NOV01–5/6

Test Track Roller for Oil Leakage 1. Hold the shaft and turn shell several turns to seat metal face seals. –UN–02JUN97

2. Remove the plug. 3. Install parts (A—F). Plug, barbed adapter and connector are from a leak detector kit such as the D05361ST Rubber Stopper/Leak Detector Kit.

T109691B

01 0130 4

15. Fill roller with 260 mL (8.8 oz) of oil.

4. Holding plug so it is not pushed out, slowly pressurize oil cavity using air. Track Roller—Specification Oil Cavity Air Test—Pressure ................ 110 ± 18 kPa (1.1 ± 0.3 bar) (16 ± 4 psi)

5. Close valve and wait for a minimum of 30 seconds. Check for oil leakage. Check gauge to see if air pressure has decreased.

A—Plug, Barbed Adapter and Connector B—JT03001 Tee Fitting 7/16-20 M 37° x 7/16-20 F 37° SW x 7/16-20 M 37° C—Hose (2 used) D—Pressure Gauge E—Snubber (Needle) Valve F—Air Pressure Regulator

6. If there is leakage, disassemble roller and replace parts as necessary. 7. Apply cure primer and pipe sealant to threads. Install plug.

OUOE049,0000063 –19–19NOV01–6/6

TM1931 (09JAN04)

01-0130-4


PN=40

Track System

Track Carrier Roller Repair Remove and Install Track Carrier Roller

–UN–28NOV90


T7396DZ

1. Loosen valve (B) one to two turns to release grease through bleed hole (C). 2. Raise track link, using a jack, enough to permit carrier roller removal.

A—Grease Fitting B—Valve C—Bleed Hole

CAUTION: Prevent accidental lowering of track by securely supporting track before attempting service procedure. 3. Install wooden blocks between track link and frame.

OUOE049,0000064 –19–19NOV01–1/4

4. Remove cap screws (B) and carrier roller (A).

–UN–25OCT88

5. Measure track carrier roller tread diameter. See 200CLC Carrier Roller Tread Diameter, 230CLC Carrier Roller Tread Diameter, or 270CLC Carrier Roller Tread Diameter. (SP326 Undercarriage Appraisal Manual.)

T6557DK

6. Repair or replace parts as necessary. 7. Install carrier roller and tighten cap screws (B). Track Carrier Roller—Specification Roller-to-Frame Cap Screw— Torque ......................................................................... 270 N•m (200 lb-ft)

A—Carrier Roller B—Cap Screw

8. Check and Adjust Track Sag. (Operator’s Manual.)


TM1931 (09JAN04)

01-0130-5

OUOE049,0000064 –19–19NOV01–2/4


PN=41

01 0130 5

Track System

T114725

–UN–30APR98

01 0130 6

A—Plug B—Cover

C—Cap Screw (2 used) D—Thrust Washer

E—Bushing F—Roller

Disassemble and Assemble Track Carrier Roller

G—Metal Face Seal H—Support

2. Remove cap screws (C) through oil plug drain hole.

IMPORTANT: Replace entire roller assembly if bushing (E) and shaft surfaces are damaged. Bushing (E) is no longer serviceable because cover (B) cannot be removed.

3. Remove roller (F) from support (H).

4. Inspect bushing (E) and shaft on support (H).

1. Remove plug (A) and drain oil.


TM1931 (09JAN04)

01-0130-6

OUOE049,0000064 –19–19NOV01–3/4


PN=42

Track System IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face.

A volatile, non-petroleum base solvent or talcum power may be used as a lubricant. 10. Install one half of metal face seal into support (H). 11. Apply a thin coat of oil to the metal faces on each half of the seal.

5. Remove metal face seal (G). 6. Inspect metal face seal. See Metal Face Seals Repair. (See procedure in this group.) For seals that will be reused, put a piece of cardboard between seal rings to protect seal face. 7. Replace parts as necessary. IMPORTANT: O-rings may slip when roller is turning if O-rings and seat surfaces are not clean, dry and oil free. 8. Thoroughly clean the O-rings and seat surfaces in roller, support, and seal bushings using a volatile, non-petroleum base solvent and lint-free tissue. 9. Install O-ring on seal rings.

NOTE: Current carrier roller metal face seals use a tapered fit. There is no longer the “pop” into place fit previously used.

12. Install the other half of metal face seal on the half already in place in support (H). 13. Install roller (F) over shaft on support (H) being sure to keep cap screws (C) in alignment with holes on shaft. 14. Tighten cap screws (C). Track Carrier Roller—Specification Thrust Washer-to-Support Shaft Cap Screw—Torque ................................................. 64 N•m (47 lb-ft)

15. For 200CLC and 230CLC, fill carrier roller with 70 mL (0.018 gal) of clean oil through plug (A) hole. For 270CLC, fill carrier roller with 75 mL (0.020 gal) of oil. 16. Apply cure primer and pipe sealant to threads of plug. Install plug.

OUOE049,0000064 –19–19NOV01–4/4

TM1931 (09JAN04)

01-0130-7


PN=43

01 0130 7

Track System

Metal Face Seals Repair Inspect Metal Face Seals 1. Inspect for the following conditions to determine if seals can be reused: a. The narrow, highly polished sealing area (E) must be in the outer half of seal ring face (D). b. Sealing area must be uniform and concentric with the ID and OD of seal ring (A). c. Sealing area must not be chipped, nicked, or scratched.

T85079

–UN–24AUG93

A—Seal Ring B—Worn Area (Shaded Area) C—Seal Ring Face D—Outer Half of Seal Ring Face E—Sealing Area (Dark Line)

T47,0130,5939HQ –19–19NOV01–1/3

2. Illustration shows examples of worn seal rings (A). I—Sealing area (D) is in inner half of seal ring face (C).

–UN–05DEC96

II—Sealing area (D) not concentric with ID and OD of seal ring. A—Seal Ring B—Worn area (Shaded Area) C—Inner Half of Seal Ring Face D—Sealing Area (Dark Line)

T85080

01 0130 8


TM1931 (09JAN04)

01-0130-8

T47,0130,5939HQ –19–19NOV01–2/3


PN=44

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.

–UN–23FEB89

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

T82840

Apply a thin film of oil to seal ring face. Put face of seal rings together and hold using tape. A—Seal Face

T47,0130,5939HQ –19–19NOV01–3/3

Track Shoe Repair Remove and Install Track Shoe

–UN–23FEB89

1. Measure grouser height. See 200CLC Three Bar Grouser Height, 230CLC Three Bar Grouser Height, or 270CLC Three Bar Grouser Height 800 mm (31.5 in.) Width. (SP326 Undercarriage Appraisal Manual.)

T6794AM

2. Apply a light coat of oil to cap screw threads and install shoe. 3. Install all track shoe nuts with rounded corners (A) against the link and chamfered edges (B) away from the link. Be sure nut is properly positioned in the link so there is full contact between the nut and the link.

–UN–23FEB89

4. Tighten cap screws in pattern shown.

Track Shoe—Specification Shoe-to-Link Cap Screw (20, 22 mm) (230CLC and 270CLC)— Torque Turn ................................................... 298 N•m (220 lb-ft) plus 1/2 (180°) turn

T6352AH

Track Shoe—Specification Shoe-to-Link Cap Screw (18 mm) (200CLC)—Torque Turn.............................. 210 ± 21 N•m (155 ± 16 lb-ft) plus 1/2 (180°) turn

A—Rounded Edge B—Chamfered Edge

TX,01,SB384 –19–19SEP00–1/1

TM1931 (09JAN04)

01-0130-9


PN=45

01 0130 9

Track System

Track Chain Repair Remove and Install Track Chain 1. Swing upperstructure to side. Lower boom to raise track off the ground. Keep the angle between boom and arm at 90—110° with the round side of bucket on the ground. CAUTION: Prevent possible injury from unexpected machine movement. Put blocks or shop stands under machine frame to support machine while measuring track sag. Track Chain—Specification Machine (200CLC)—Weight.................................... 20 298 kg (44,750 lb) approximate Machine (230CLC)—Weight.................................... 23 773 kg (52,410 lb) approximate Machine (270CLC)—Weight.................................... 26 082 kg (57,500 lb) approximate

2. Place blocks or shop stands under the machine to support machine.

OUOE049,0000065 –19–20JUN01–1/5


–UN–28NOV90

3. Loosen valve (B) one to two turns to release grease through bleed hole (C). A—Grease Fitting B—Valve C—Bleed Hole

T7396DZ

01 0130 10


TM1931 (09JAN04)

01-0130-10

OUOE049,0000065 –19–20JUN01–2/5


PN=46

Track System NOTE: The master pin (2) can be identified by the large dimple (3) on the pin’s end. 4. Move track chain so master pin (2) is over front idler or sprocket.

01 0130 11

5. Remove the track shoe on each side of master pin.

–UN–20JUL01

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

T143215B

7. Remove master pin using a 50-Ton Master Pin Pusher Installer. Remove bushings (1). CAUTION: Heavy component; use a hoist. Track Chain—Specification Tracks with 800 mm (32 in.) Shoes (200CLC)—Weight ......................... 1293 kg (2850 lb) approximate Tracks with 800 mm (32 in.) Shoes (230CLC)—Weight ......................... 1395 kg (3075 lb) approximate Tracks with 800 mm (32 in.) Shoes (270CLC)—Weight ......................... 1814 kg (4000 lb) approximate

1—Bushing (2 used) 2—Master Pin 3—Dimple

8. Remove track chain. 9. Measure track chain link, bushing, and pitch. (See SP326 Undercarriage Appraisal Manual.) 10. Replace parts as necessary. 11. Position track chain so section on ground has pin boss on links toward rear of machine. 12. Install end of chain on sprocket and slowly turn sprocket in forward direction to pull chain across top of frame to front idler. 13. Pull ends of chain together. Install bushings and master pin (2) using 50-Ton Master Pin Pusher Installer. 14. Install track shoe. See Track Shoe Repair. (See procedure in this group.) 15. Check and Adjust Track Sag. (Operator’s Manual.)


TM1931 (09JAN04)

01-0130-11

OUOE049,0000065 –19–20JUN01–3/5


PN=47

Track System

T117027

–UN–09SEP98

01 0130 12

A—Track Link (49 used) B—Master Track Link C—Master Pin

D—Snap Ring E—Master Bushing F—Spacer (2 used)

G—Track Link (48 used) H—Seal (96 used) I—Bushing (48 used)

J—Shoe (49 used) K—Pin (48 used)

Disassemble and Assemble Track Chain 1. Measure track components (A—K). See Track Chain. (SP326 Undercarriage Appraisal Manual.)


TM1931 (09JAN04)

01-0130-12

OUOE049,0000065 –19–20JUN01–4/5


PN=48

Track System NOTE: Wear on pins and bushings does not extend over the entire surface. Turning pins and bushing is determined by the amount of wear.

4. Apply grease to the counterbore in track links, the seals, and the ends of bushings. 5. For each joint, fill the clearance between the pin OD and bushing ID with grease.

2. Turn pins (C and K) and bushings (E and I) as required. 3. Clean any dust or rust from the surfaces of track link pin bores and counterbores and the ends of bushings.

01 0130 13

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

OUOE049,0000065 –19–20JUN01–5/5

Broken Track Chain Part Repair Disassemble and Assemble Track Chain to Replace Broken Part –UN–26OCT88

1. Remove track shoes from each side of broken link assembly. See Track Shoe Repair. (See procedure in this group.)

T5821AG

IMPORTANT: When making cuts using cutting torch, be careful not to cut or gouge good parts. A—Cut Locations B—Broken Link

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

OUOE003,0000008 –19–28OCT01–1/4

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

T5821AH

–UN–26OCT88

A—Bushing


TM1931 (09JAN04)

01-0130-13

OUOE003,0000008 –19–28OCT01–2/4


PN=49

Track System 4. Burn holes through center of pin stubs (A). 5. Hold a heavy hammer (B) against the link while pin stub is being driven out.

T5821AI

–UN–26OCT88

A—Pin Stub B—Hammer

OUOE003,0000008 –19–28OCT01–3/4

6. Install links (C and E) on master bushing (D). Check cap screw hole spacing using a track shoe. 7. Instal spacers (B) into counterbore of links. –UN–24MAY89

8. Install link assembly. Install master pins (A). 9. Install track shoes. See Track Shoe Repair. (See procedure in this group.)

T5821AJ

01 0130 14

A—Master Pin B—Spacer C—Right Link D—Master Bushing E—Left Link

OUOE003,0000008 –19–28OCT01–4/4

Sprocket Repair Remove and Install Sprocket


TM1931 (09JAN04)

01-0130-14

OUOE003,0000009 –19–09NOV01–1/2


PN=50

Track System IMPORTANT: Sprocket must be replaced when the tooth tips become excessively rounded, worn, or chipped to prevent excessive wear to chain. If machine is driven in one direction a majority of the time, wear will be on one side of teeth. To extend service life, change sprockets from one side of machine to the other.

01 0130 15

–UN–20JUL01

1. Disconnect track chain. See Track Chain Repair. (See procedure in this group.)

T143369B

2. Lift side of machine so sprocket teeth clear chain. CAUTION: Heavy component; use a hoist. Sprocket—Specification Sprocket (200CLC and 230CLC)—Weight............................................ 46 kg (101 lb) approximate Sprocket (270CLC)—Weight ........................... 70 kg (150 lb) approximate

1—Cap Screw (16 used)

3. Remove cap screws (1) and sprocket. 4. Apply cure primer and thread lock and sealer (high strength) to threads of cap screws (B). 5. Install sprocket and tighten cap screws (1). Sprocket—Specification Sprocket-to-Propel Gearbox Cap Screw—Torque ............................................................ 490 N•m (360 lb-ft)

6. Lower machine. 7. Install track chain. See Track Chain Repair. (See procedure in this group.)

OUOE003,0000009 –19–09NOV01–2/2

TM1931 (09JAN04)

01-0130-15


PN=51

Track System

Front Idler Repair Remove and Install Front Idler

–UN–25OCT88

1. Disconnect track chain. See Track Chain Repair. (See procedure in this group.) 2. Slide front idler (A) forward, using pry bar.

T6876BU

01 0130 16

CAUTION: Heavy component; use a hoist. Front Idler—Specification Front Idler (200CLC and 230CLC)—Weight.......................................... 100 kg (240 lb) approximate Front Idler (270CLC)—Weight....................... 160 kg (350 lb) approximate

A—Front Idler

3. Attach front idler to hoist and remove from frame. 4. Measure front idler wear. See Front Idler Flange Height. (SP326 Undercarriage Appraisal Manual.) 5. Repair or replace idler as necessary. 6. Install front idler. 7. Connect track chain. See Track Chain Repair. (See procedure in this group.)


TM1931 (09JAN04)

01-0130-16

TX,01,SB395 –19–15NOV01–1/4


PN=52

Track System

T8312AA

–UN–21SEP94

01 0130 17

A—Pin (2 used) B—Bushing (2 used) C—Idler

D—Plug (2 used) E—Bracket (Bearing) (2 used) F—Metal Face Seal (2 used)

G—O-Ring (2 used) H—Axle

I—Yoke J—Cap Screw (4 used)

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

Disassemble and Assemble Front Idler 1. Remove cap screws (J) and yoke (I).

NOTE: Remove bushings only if replacement is necessary.

2. Remove drain plug (D) and drain oil. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face. 3. Remove pins (A), brackets (E), O-rings (G) and metal face seals (F).

6. Remove bushing using a 2-jaw puller and adapters from 17-1/2 and 30-ton puller set. 7. Replace parts as necessary. 8. Apply a thin film of oil to bushings (B). Install bushings so flange is tight against shoulder of idler. 9. Install O-rings (G) on axle.

4. Inspect metal face seals. See Metal Face Seals Repair. (See procedure in this group.) Keep seal rings together as a matched set with seal ring faces together to protect surfaces.

10. Apply a thin layer of NEVER-SEEZ anti-seize lubricant or equivalent to end of axle from O-ring to end of axle and to bore in bracket (E).



TM1931 (09JAN04)

01-0130-17

TX,01,SB395 –19–15NOV01–2/4


PN=53

Track System 16. Wipe finger prints and foreign material off seal ring face using clean oil and lint-free tissues. Apply a thin film of oil to each seal face.

11. Install axle into bracket. 12. Apply NEVER-SEEZ anti-seize lubricant or equivalent to pin (A). Install pin. 01 0130 18

IMPORTANT: Metal face seal O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-rings do not slip when idler is turning.

17. For 200CLC and 230CLC, fill front idler with 265 mL (8.96 oz) of oil. For 270CLC, fill front idler with 300 mL (10.14 oz) of oil. 18. Install axle (H) into idler.

13. Thoroughly clean the metal face seal (F) O-rings and seat surfaces in idler, brackets, and seal rings using volatile, non-petroleum base solvent and lint-free tissues.

19. Apply cure primer to threads of drain plug (D).

14. Install metal face seal O-ring on seal rings.

21. Install yoke (I). Tighten cap screws (J).

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

Front Idler—Specification Yoke-to-Bracket Cap Screw— Torque................................................................... 210 N•m (156 lb-ft)

20. Apply thread lock and sealer (medium strength) to threads of plug. Install and tighten plug.

15. Install metal face seals (F) in bracket and idler. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must "pop" down into place so O-ring is tight against seal bore.


TM1931 (09JAN04)


01-0130-18

TX,01,SB395 –19–15NOV01–3/4


PN=54

Track System Test Front Idler for Oil Leakage 1. Turn the shaft several turns to seat metal face seals. 2. Remove the plug (G).

01 0130 19

3. Install parts (A—F) as shown. Plug barbed adapter, and connector are from a leak detector kit such as the D05361ST Rubber Stopper/Leak Detector Kit. 4. Holding plug so it is not pushed out, slowly pressurize oil cavity using air. Front Idler—Specification Oil Cavity Air Test—Pressure ................ 110 ± 28 kPa (1.1 ± 0.3 bar) (16 ± 4 psi)

–UN–13JUN97

5. Close valve and wait for a minimum of 30 seconds to check for oil leakage. Check gauge to see if air pressure has decreased. 6. If there is external leakage, disassemble idler and replace parts as necessary.

T109791B

7. Check oil level in idler. If the oil level is down and there is no external leakage, check for a leak from oil cavity to interior of idler wheel. A—Plug, Adapter and Connector B—Connector 1/8 M NPT x 7/16-20 M 37° C—Hose D—Pressure Gauge E—Snubber (Needle) Valve F—Air Pressure Regulator G—Drain Plug

8. Apply cure primer to threads of plug. 9. Apply thread lock and sealer (medium strength) to threads of plug. Install and tighten plug.

TX,01,SB395 –19–15NOV01–4/4

Track Adjuster and Recoil Spring Repair Remove and Install Track Adjuster and Recoil Spring 1. Remove track chain. See Track Chain Repair. (See procedure in this group.) 2. Remove front idler. See Front Idler Repair. (See procedure in this group.)


TM1931 (09JAN04)

01-0130-19

OUOE003,000000A –19–09NOV01–1/6


PN=55

Track System

–UN–25OCT88 T6557CX

01 0130 20

CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots may result in immediate or eventual failure creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling track adjuster. A compression tool must be used for disassembly and assembly because of the extreme preload on spring.

A—Track Adjuster

3. Slide track adjuster (A) forward, using a pry bar. CAUTION: Heavy component; use a hoist. Track Adjuster and Recoil Spring—Specification Track Adjuster Cylinder and Recoil Spring (200CLC and 230CLC)—Weight.......................................... 129 kg (280 lb) approximate Track Adjuster Cylinder and Recoil Spring (270CLC)—Weight.................. 180 kg (400 lb) approximate

4. Attach track adjuster to hoist and remove from frame. 5. Repair or replace parts as necessary. 6. Install front idler. See Front Idler Repair. (See procedure in this group.) 7. Install track chain. See Track Chain Repair. (See procedure in this group.)


TM1931 (09JAN04)

01-0130-20

OUOE003,000000A –19–09NOV01–2/6


PN=56

Track System Disassemble and Assemble Track Adjuster and Recoil Spring CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots may result in immediate or eventual failure creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling track adjuster.

01 0130 21

A compression tool must be used for disassembly and assembly because of the extreme preload on spring.

–UN–25OCT88


T6557DY

Track Adjuster and Recoil Spring—Specification Track Recoil Spring Disassembly and Assembly Tool—Weight ......................... 225 kg (496 lb) approximate

1. Place an 18-t (20-ton) jack on bottom of ST4920 Track Recoil Spring Disassembly and Assembly Tool (A). Remove nuts (B) and top plate (C). (Group 9900.) A—ST4920 Track Recoil Spring Disassembly and Assembly Tool B—Nut C—Top Plate

NOTE: It is not necessary to remove the recoil spring to replace wear ring and U-ring packing on piston. To replace O-ring in the cylinder, remove recoil spring and rod. 2. Remove nuts (B). Remove top plate (C).


TM1931 (09JAN04)

01-0130-21

OUOE003,000000A –19–09NOV01–3/6


PN=57

Track System


3. Connect track adjuster (B) to a hoist using a lifting strap (A). 4. Put track adjuster in assembly tool with cylinder end on DFT1110 Spacer (C). (Group 9900.) 5. Remove lifting strap.

–UN–28APR92

A—Lifting Strap B—Track Adjuster C—DFT1110 Spacer

T7720AF

01 0130 22

Track Adjuster and Recoil Spring—Specification Track Adjuster Cylinder and Recoil Spring (200CLC and 230CLC)—Weight.......................................... 129 kg (280 lb) approximate Track Adjuster Cylinder and Recoil Spring (270CLC)—Weight.................. 180 kg (400 lb) approximate


TM1931 (09JAN04)

01-0130-22

OUOE003,000000A –19–09NOV01–4/6


PN=58

Track System 6. Install DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool (F). (Group 9900.) 7. Install plate top (A) and nuts (B) with smallest opening to allow access to nut (D).

01 0130 23

8. Extend jack ram to provide enough travel to release spring to the approximate free length. Track Adjuster and Recoil Spring—Specification Recoil Spring (200CLC and 230CLC)—Free Length .......................... 626 mm (24.64 in.) approximate Recoil Spring (270CLC)—Free Length ..................................................... 679 mm (26.73 in.) approximate

9. Tighten nuts (B) so plate is tight against retainer plate. 10. Remove valve (C) and special plug (E).

T7720AG

–UN–28APR92

A—Top Plate B—Nut (8 used) C—Valve D—Nut E—Special Plug F—DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool


TM1931 (09JAN04)

01-0130-23

OUOE003,000000A –19–09NOV01–5/6


PN=59

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. 15. If disassembly of track adjuster cylinder is necessary, seeTrack Adjuster Cylinder Repair. (See procedure in this group.) 16. Put track adjuster cylinder in assembly tool with cylinder end on spacer. 17. Install spacer on rod.

–UN–28APR92

18. Install spring using a hoist and lifting strap. 19. Install retainer plate. 20. Install guard tool.

T7720AH

01 0130 24

21. Install top plate. Install nuts. 22. Raise upper half of guard tool. Tighten T-handles. 23. Operate jack to compress spring to the compressed length. Track Adjuster and Recoil Spring—Specification Recoil Spring (200CLC and 230CLC)—Compressed Length .................................. 521 mm (20.51 in.) Recoil Spring (270CLC)— Compressed Length .................................................... 557 mm (21.92 in.)

A—Top Plate B—Nut (8 used) D—Nut F—DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

24. Install nut (D) so hole is aligned with hole in rod. Install special plug. 25. Tighten valve. Track Adjuster and Recoil Spring—Specification Valve—Torque ................................................................. 88 N•m (65 lb-ft)

OUOE003,000000A –19–09NOV01–6/6

TM1931 (09JAN04)

01-0130-24


PN=60

Track System

Track Adjuster Cylinder Repair Disassemble and Assemble Track Adjuster Cylinder CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots can result in immediate or eventual failure of spring or rod creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling.

01 0130 25

A compression tool must be used for disassembly and assembly because of the extreme preload on spring.

NOTE: It is not necessary to remove the recoil spring to replace wear ring (4) and U-ring packing (5). It is necessary to remove the recoil spring to replace O-ring (8). 1. Remove recoil spring if necessary. See Track Adjuster and Recoil Spring Repair. (See procedure in this group.)


TM1931 (09JAN04)

01-0130-25

TX,01,SB407 –19–25JUN01–1/2


PN=61

Track System 2. If necessary, remove rod (7) from cylinder (9) using a press. 1

2

3. Repair or replace parts as necessary. 3 4. Apply multi-purpose grease to U-ring packing (5), wear ring (4) and O-ring (8). Fill grooves inside flange (2) with grease.

4

5 6

5. Install U-ring packing (5) with lip towards inside of cylinder. 6. Tighten cap screws (1). Track Adjuster Cylinder—Specification Flange-to-Cylinder Cap Screw— Torque ............................................................................. 50 N•m (37 lb-ft)

7 8 9 –UN–20JUL01

1—Cap Screw (3 used) 2—Flange 3—Piston Rod 4—Wear Ring 5—U-Ring 6—Retaining Ring 7—Rod 8—O-Ring 9—Cylinder

T143380

T143380

01 0130 26

TX,01,SB407 –19–25JUN01–2/2

TM1931 (09JAN04)

01-0130-26


PN=62

Section 02

Axles and Suspension Systems (Propel) Contents Page

Group 0250—Axle Shaft, Bearings, and Reduction Gears Propel Gearbox . . . . . . . . . . . . . . . . . . . . . . .02-0250-1

02

Group 0260—Hydraulic System Propel Motor . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Start-Up Procedure . . . . . . . . . . . . . . . . .02-0260-22 Rotary Manifold . . . . . . . . . . . . . . . . . . . . . .02-0260-22

TM1931 (09JAN04)

02-1


PN=1

Contents

02

TM1931 (09JAN04)

02-2


PN=2

Group 0250

Axle Shaft, Bearings, and Reduction Gears Propel Gearbox Repair Remove and Install Propel Gearbox 1. Disconnect track chain. See Track Chain Repair. (Group 0130.) 2. Remove sprocket. See Sprocket Repair. (Group 0130.) CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury.

02 0250 1

3. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 4. Disconnect hydraulic lines.


TM1931 (09JAN04)

02-0250-1

OUOE049,0001000 –19–19NOV01–1/14


PN=65

Axle Shaft, Bearings, and Reduction Gears 5. Attach JDG909 Lifting Bracket to gearbox as shown. CAUTION: Heavy component; use a hoist. Propel Gearbox—Specification Propel Gearbox (200CLC)— Weight............................................................ 310 kg (680 lb) approximate Propel Gearbox (230CLC)— Weight............................................................ 322 kg (710 lb) approximate Propel Gearbox (270CLC)— Weight.......................................................... 480 kg (1060 lb) approximate

–UN–15JUN01

NOTE: Make alignment marks between propel gearbox and undercarriage to aid in installation. 6. Remove cap screws (1). Remove propel gearbox and propel motor.

T142702B

02 0250 2

7. Repair or replace parts as necessary.

NOTE: Align marks made during removal.

200CLC Machine Shown

8. Install gearbox. Tighten cap screws (1).

1—Cap Screw (14 used)—200CLC and 230CLC —Cap Screw (17 used)—270CLC

Propel Gearbox—Specification Gearbox-to-Frame Cap Screw— Torque ......................................................................... 630 N•m (460 lb-ft)

9. Connect lines. See Propel System Component Location. (Group 9025-15.) 10. Fill propel gearbox with oil. See Check Propel Gearbox Oil Level. (Operator’s Manual.) 11. Do Propel Motor Start-Up Procedure. (Group 0260.)


TM1931 (09JAN04)

02-0250-2

OUOE049,0001000 –19–19NOV01–2/14


PN=66

Axle Shaft, Bearings, and Reduction Gears

02 0250 3

TM1931 (09JAN04)

02-0250-3


PN=67


14 15

13 7 02 0250 4

12

6

11

3

16

9

5 4

17

10

3 9 8 2

18

1 20

19

21 22 20 33

23 24 25 26 30

27 26

29

25

32

28

30

T142270

–UN–15JUN01

31

T142270


TM1931 (09JAN04)

02-0250-4

OUOE049,0001000 –19–19NOV01–3/14


PN=68

Axle Shaft, Bearings, and Reduction Gears 1—Third Planet Carrier 2—Third Planet Sun Gear 3—Thrust Plate (6 used) 4—Second Planet Gear (3 used) 5—Needle Bearing (3 used) 6—Pin (3 used) 7—Spring Pin (3 used) 8—Second Planet Carrier

9—Spacer (2 used) 10—Second Planet Sun Gear 11—First Planet Carrier 12—Shaft 13—Ring Gear 14—Thrust Pad 15—Cap Screw (12 used) 16—Cover 17—Cap Screw (24 used)

18—Spring Pin (3 used) 19—Pin (3 used) 20—Thrust Plate (6 used) 21—Needle Bearing (3 used) 22—First Planet Gear (3 used) 23—Spring Pin (3 used) 24—Pin (3 used) 25—Thrust Plate (6 used)

26—Needle Bearing (6 used) 27—Third Planet Gear 28—Propel Motor 29—Metal Face Seal 30—Bearing (2 used) 31—Drum 32—Bearing Nut 33—Dowel Pin

Disassemble and Assemble Propel Gearbox— 200CLC and 230CLC

5. Remove third planet sun gear (2) and third planet carrier (1).

1. Remove cap screws (15) and cover (16). 2. Remove shaft (12) and first planet carrier (11).

NOTE: Disassembly of first, second, and third planet carriers are similar. Repeat procedure as required.

3. Remove second planet sun gear (10) and second planet carrier (8).

6. Remove spring pins, pins, thrust plates, needle bearings, and planetary gears.


02 0250 5

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

Propel Gearbox—Specification Ring Gear (200CLC and 230CLC)—Weight ....................................... 41 kg (90 lb) approximate

4. Install JT01748 Lifting Brackets to ring gear (13). Remove cap screws (17) and ring gear. CAUTION: Heavy component; use a hoist. Propel Gearbox—Specification Third Planet Carrier (200CLC and 230CLC)—Weight................................ 39 kg (85 lb) approximate

OUOE049,0001000 –19–19NOV01–4/14

7. Install spring pins with slit (1) toward end of pin.

–UN–22JUN01

8. Install third planet gear (27) in third planet carrier (1) with marked side towards hole for spring.

T142429

1—Slit


TM1931 (09JAN04)

02-0250-5

OUOE049,0001000 –19–19NOV01–5/14


PN=69

Axle Shaft, Bearings, and Reduction Gears 9. Remove bearing nut (32) from propel motor (28) using DF1036A Propel Gearbox Nut Wrench (35) and DFT1109 Holding Bar (34). Fasten holding bar to ring gear. (Group 9900.) CAUTION: Heavy component; use a hoist.

10. Remove drum (31) using JT01748 Lifting Brackets. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face.

T142380

02 0250 6

–UN–15JUN01

Propel Gearbox—Specification Drum (200CLC and 230CLC)— Weight................................................................ 44 kg (97 lb) approximate

32—Bearing Nut 34—DFT1109 Holding Bar 35— DF1036A Propel Gearbox Nut Wrench

11. Remove metal face seal (29). See Metal Face Seals Repair. (Group 0130.)

NOTE: Further disassembly is not necessary unless bearing replacement is required. Bearing will be destroyed during removal, replace with new bearing. 12. Inspect bearing (30) and race inside housing (31). 13. Replace parts as necessary. CAUTION: DO NOT heat oil over 182°C (260°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 14. Heat inner bearing cone. Install cone tight against shoulder. Propel Gearbox—Specification Bearing Cone (200CLC and 230CLC)—Temperature ....................................... 50—70°C (122—158°F)


TM1931 (09JAN04)

02-0250-6

OUOE049,0001000 –19–19NOV01–6/14


PN=70

Axle Shaft, Bearings, and Reduction Gears IMPORTANT: Metal face seal O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-ring does not slip. 15. Thoroughly clean metal face seal O-rings and seat surfaces in propel motor housing, drum, and seal ring using volatile, non-petroleum base solvent and lint-free tissues.

NOTE: A volatile, non-petroleum base solvent or talcum powder can be used as a lubricant. Solvent must not damage the O-ring or leave an oil residue.

02 0250 7

16. Install O-ring and metal face seal on propel motor housing and drum. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must “pop” down into place so O-ring is tight against seal bore and seal ring is installed squarely. 17. Clean seal ring face. Apply a thin film of clean oil. 18. Apply a thin coat of multi-purpose grease to threads of bearing nut (32). Install bearing nut with machined surface towards bearing. 19. Tighten bearing nut using DF1036A Propel Gearbox Nut Wrench and DFT1109 Holding Bar. Fasten holding bar to ring gear. (Group 9900.) Seat bearings. Propel Gearbox—Specification Bearing Nut (200CLC and 230CLC)—Torque .................................... 790 N•m (580 lb-ft) then tap on drum using a plastic hammer, turn drum 4—5 turns to the right and left to seat the bearings.

20. Repeat steps to ensure bearings are seated.


TM1931 (09JAN04)

02-0250-7

OUOE049,0001000 –19–19NOV01–7/14


PN=71

Axle Shaft, Bearings, and Reduction Gears 21. Ensure center of dowel pin (33) is aligned with center of spline on propel motor shaft. If centers are not aligned tighten bearing nut until dowel pin center aligns with center of the next spline. 22. Install third planet carrier so dowel pin (33) enters hole (35) on third planet carrier.

24. Apply thread lock and sealer (high strength) to cap screws (17). Tighten cap screws.

T142422

Propel Gearbox—Specification Ring Gear-to-Drum Cap Screw (200CLC and 230CLC)—Torque................................. 265 N•m (195 lb-ft)

25. Install second and first planet carriers, sun gears and shaft.

35

–UN–15JUN01

26. Apply rigid from-in-place gasket to flange surface on cover. 27. Apply thread lock and sealer (medium strength) to thread of cap screws (15). Tighten cap screws. Propel Gearbox—Specification Cover-to-Ring Gear Cap Screw (200CLC and 230CLC)—Torque................................... 110 N•m (83 lb-ft)

T142944

02 0250 8

–UN–15JUN01

23. Apply rigid from-in-place gasket to flange surface on ring gear.

28—Propel Motor 32—Bearing Nut 33—Dowel Pin 35—Hole


TM1931 (09JAN04)

02-0250-8

OUOE049,0001000 –19–19NOV01–8/14


PN=72


02 0250 9

TM1931 (09JAN04)

02-0250-9


PN=73


T109286

–UN–25APR97

02 0250 10


TM1931 (09JAN04)

02-0250-10

OUOE049,0001000 –19–19NOV01–9/14


PN=74

Axle Shaft, Bearings, and Reduction Gears 00—Propel Motor 02—Propel Gearbox Housing 03—Seal 05—Drum 06—Sprocket 07—Lock Washer (20 used) 08—Cap Screw (20 used) 09—Roller Bearing (2 used) 10—Nut 11—Lock Plate 12—Cap Screw (2 used) 14—Third Planet Carrier 15—Third Planet Gear (3 used)

17—Thrust Washer (6 used) 18—Pin (3 used) 19—Spring Pin (3 used) 20—Third Planet Sun Gear 21—Needle Bearing (6 used) 23—Ring Gear 25—Cap Screw (24 used) 27—Second Planet Carrier 28—Thrust Washer (2 used) 29—Second Planet Sun Gear (3 used) 30—Needle Bearing (3 used)

31—Thrust Washer (6 used) 32—Pin (3 used) 33—Spring Pin (3 used) 34—Second Planet Sun Gear 35—Thrust Washer 36—First Planet Carrier 37—First Planet Gear (3 used) 38—Needle Bearing (3 used) 39—Thrust Washer (6 used) 40—Pin (3 used) 41—Spring Pin (3 used) 42—Propel Shaft

Disassemble and Assemble Propel Gearbox— 270CLC

44—Cover 45—Pin 46—Roller Bearing 47—Snap Ring 48—Cap Screw and Lock Washer (12 used) 49—Plug (3 used) 51—O-Ring 52—Cap Screw (4 used) 53—Lock Washer (4 used) 55—Name Plate 56—Cap Screw (2 used) 02 0250 11


1. Make alignment marks between cover (44), ring gear (23) and drum (05).

Propel Gearbox—Specification Third Planet Carrier (270CLC)—Weight.................................... 52 kg (120 lb) approximate

2. Remove cap screws and lock washers (48) and cover (44).

6. Remove third planet sun gear (20) and third planet carrier (14).

3. Remove shaft (42) and first planet carrier (36).

NOTE: Disassembly of first, second, and third planet carriers are similar. Repeat procedure as required.

4. Remove second planet sun gear (34) and second planet carrier (27). CAUTION: Heavy component; use a hoist. Propel Gearbox—Specification Ring Gear (270CLC)—Weight .................. 55 kg (120 lb) approximate

7. Remove spring pins, pins, thrust plates, needle bearings, and planetary gears. Clean and inspect parts, replace as necessary. Oil parts with gear oil prior to assembly.

5. Install JT01748 Lifting Brackets to ring gear (23). Remove cap screws (25) and ring gear.

OUOE049,0001000 –19–19NOV01–10/14

IMPORTANT: There is a mark on one side of third planet gear (15). Be sure that this marked side faces the hole for the spring pin. –UN–22JUN01

8. Install spring pins with slit (1) toward end of pin.

T142429

9. Remove cap screws (12) and lock plate (11). 1—Slit


TM1931 (09JAN04)

02-0250-11

OUOE049,0001000 –19–19NOV01–11/14


PN=75

Axle Shaft, Bearings, and Reduction Gears 10. Remove bearing nut (10) using DF1036A Propel Gearbox Nut Wrench (35) and DFT1109 Holding Bar (34). Fasten holding bar to ring gear. (Group 9900.) CAUTION: Heavy component; use a hoist. Propel Gearbox—Specification Drum (270CLC)—Weight ................................ 65 kg (140 lb) approximate

–UN–15JUN01

11. Remove drum (05) using JT01748 Lifting Brackets. IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face.

T142380

02 0250 12

12. Remove metal face seal (03). See Metal Face Seals Repair. (Group 0130.)

NOTE: Further disassembly is not necessary unless bearing replacement is required. Bearing will be destroyed during removal, replace with new bearing. 13. Inspect bearings (09) and races inside housing. 14. Replace parts as necessary. CAUTION: DO NOT heat oil over 182°C (260°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 15. Heat inner bearing cone. Install cone tight against shoulder. Propel Gearbox—Specification Bearing Cone (270CLC)— Temperature ......................................................... 50—70°C (122—158°F)


TM1931 (09JAN04)

02-0250-12

OUOE049,0001000 –19–19NOV01–12/14


PN=76

Axle Shaft, Bearings, and Reduction Gears IMPORTANT: Metal face seal O-rings and seat surfaces for O-rings must be clean, dry, and oil free so O-ring does not slip. 16. Thoroughly clean metal face seal O-rings and seat surfaces in propel motor housing, drum, and seal ring using volatile, non-petroleum base solvent and lint-free tissues.

NOTE: A volatile, non-petroleum base solvent or talcum powder can be used as a lubricant. Solvent must not damage the O-ring or leave an oil residue.

02 0250 13

17. Install O-ring and metal face seal on propel motor housing and drum. Apply equal pressure with fingers at four equally spaced points on seal face. Seal must “pop” down into place so O-ring is tight against seal bore and seal ring is installed squarely. 18. Clean seal ring face. Apply a thin film of clean oil. IMPORTANT: Install bearing nut with stepped surface towards bearing. 19. Apply a thin coat of multi-purpose grease to bearing nut. Tighten bearing nut using DF1036A Propel Gearbox Nut Wrench and DFT1109 Holding Bar. Fasten holding bar to ring gear. (Group 9900.) Propel Gearbox—Specification Bearing Nut (270CLC)—Torque .............. 790 N•m (580 lb-ft) Then tap on drum using a plastic hammer. Then turn drum four-to-five times to the right and left to seat the bearings.

20. To seat bearings, tap on drum using a plastic hammer. Then turn drum three times to the right and left to seat the bearings. Repeat steps to ensure bearings are seated properly.


TM1931 (09JAN04)

02-0250-13

OUOE049,0001000 –19–19NOV01–13/14


PN=77

Axle Shaft, Bearings, and Reduction Gears NOTE: If lock plate (11) will not engage with spline of housing tighten bearing nut until lock plate engages. 21. Install lock plate (11). Apply thread lock and sealer (high strength) to threads of cap screws (12). Tighten cap screws.

02 0250 14

Propel Gearbox—Specification Lock Plate-to-Bearing Nut Cap Screw (270CLC)—Torque ............................................... 88 N•m (65 lb-ft)

22. Apply rigid from-in-place gasket to flange surface on ring gear. Apply thread lock and sealer (high strength) to cap screws (25). Tighten cap screws. Propel Gearbox—Specification Ring Gear-to-Drum Cap Screw (270CLC)—Torque ...................................................... 265 N•m (195 lb-ft)

23. Install second and first planet carriers, sun gears and shaft. 24. Apply rigid from-in-place gasket to flange surface on cover. Apply thread lock and sealer (medium strength) to thread of cap screws (48). Tighten cap screws. Propel Gearbox—Specification Cover-to-Ring Gear Cap Screw (270CLC)—Torque ........................................................ 110 N•m (83 lb-ft)

OUOE049,0001000 –19–19NOV01–14/14

TM1931 (09JAN04)

02-0250-14


PN=78

Group 0260

Hydraulic System Propel Motor Repair Remove and Install Propel Motor—200CLC and 230CLC

NOTE: Propel motor is an integral part of propel gearbox. If removal is required. See Propel Gearbox Repair. (Group 0250.) Remove and Install Propel Motor—270CLC

02 0260 1

CAUTION: Prevent possible injury from unexpected machine movement. Block both tracks when removing propel motors. When propel motors are removed, machine has no brakes and can move. The machine will roll free on a slope or while being towed. 1. Block tracks. 2. Drain oil from propel gearbox. Approximate capacity is 6.0 L (6.5 qt). CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 3. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 4. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 270CLC Drain and Refill Capacities. (Operator’s Manual.)


TM1931 (09JAN04)

02-0260-1

ouoe049,0001010 –19–19NOV01–1/26


PN=79

Hydraulic System 5. Disconnect lines. CAUTION: Heavy component; use a hoist. Propel Motor—Specification Propel Motor Cover (270CLC)— Weight.............................................................. 90 kg (200 lb) approximate

–UN–19NOV01 T147509B

6. Loosen cap screws and lock washers (1). 7. Connect propel motor and park brake to a hoist using lifting straps or chains and DF1063 Lift Bracket and DFT1130 Adapter. (Group 9900.) 8. Remove cap screws (1) and remove propel motor, park brake and remove O-ring. 9. Replace parts as necessary. 10. Install O-ring. Install propel motor and park brake.

–UN–20SEP94

11. Install and tighten cap screws (1). Propel Motor—Specification Propel Motor Cover-to-Propel Gearbox Cap Screw (270CLC)— Torque ......................................................................... 265 N•m (195 lb-ft)

T8318AC

02 0260 2

NOTE: Cap screws (1) used to hold propel motor and park brake to propel gearbox have heads longer than those holding propel motor cover to housing.

12. Connect lines. See Propel System Component Location. (Group 9025-15.)

Right Side Shown 1—Cap Screw and Lock Washer (4 used)

13. Fill propel gearbox with oil. See Check Propel Gearbox Oil Level. (Operator’s Manual.) 14. Do Propel Motor Start-Up Procedure. (See procedure in this group.)


TM1931 (09JAN04)

02-0260-2

ouoe049,0001010 –19–19NOV01–2/26


PN=80

Hydraulic System

7 8 6 5 9 4 2 02 0260 3

6 1 3 17 18

16 15 20

14

19

21

13 12

29

11 29 10 28 27 26

30

25 24

30

23

T142484

–UN–20JUL01

22

T142484

1—Shaft 2—Retaining Ring (2 used) 3—Roller Bearing 4—Oil Seal 5—O-Ring 6—O-Ring (3 used) 7—Brake Release Passage 8—Speed Change Passage (2 used)

9—Housing 10—Pin (2 used) 11—Valve Plate 12—Rotor 13—Spring (6 used) 14—Bushing 15—Retainer 16—Piston (9 used)

17—Swash Plate 18—Pin 19—Plate 20—Ball (2 used) 21—Piston (2 used) 22—Cap Screw (9 used) 23—Propel Motor Cover


TM1931 (09JAN04)

02-0260-3

24—Needle Bearing 25—Disc Spring 26—O-Ring 27—Brake Piston 28—O-Ring 29—Friction Plate (4 used) 30—Plate (4 used)

ouoe049,0001010 –19–19NOV01–3/26


PN=81

Hydraulic System Disassemble and Assemble Propel Motor—200CLC and 230CLC

6. Remove friction plates (29) and plates (30). 7. Inspect parts for wear or damage.

1. If required, remove propel gearbox. See Propel Gearbox Repair. (Group 0250.) CAUTION: Heavy component; use a hoist.

02 0260 4

Propel Motor—Specification Propel Motor (200CLC and 230CLC)—Weight ..................................... 92 kg (203 lb) approximate

Propel Motor—Specification Friction Plate (200CLC and 230CLC)—Height................................ 2.75—2.70 mm (0.108—0.106 in.) Plate (200CLC and 230CLC)— Height.................................................. 1.80—1.75 mm (0.071—0.069 in.)

IMPORTANT: Use care when removing propel motor cover (23), valve plate (11) is easily damaged.

IMPORTANT: Pistons must be installed into the same bores because of wear patterns. Mark location of pistons with respect to bores to aid in assembly.

2. Remove propel motor cover (23), and valve plate (11).

8. Remove parts (12—18).

IMPORTANT: Remove needle bearing (24) only if replacement is necessary. Do not re-use needle bearing as it may have been damaged during removal.

9. Remove parts (1—4) through motor side of housing (9).

3. Remove needle bearing (24) as required.

11. Apply multi-purpose grease to lip of seal (4) and apply rigid form-in-place gasket to outer surface of seal.

4. Remove disc spring (25).

10. Replace parts as necessary.

12. Install parts (1—4) using D01044AA Bushing, Bearing and Seal Driver Set.

Inspect part for wear or damage. Propel Motor—Specification Disc Spring (200CLC and 230CLC)—Height.............................. 7.0—6.9 mm (0.276—0.272 in.)

5. Apply 100—300 kPa (14—43 psi) air pressure to brake release passage (7) to remove brake piston (27).


TM1931 (09JAN04)

02-0260-4

ouoe049,0001010 –19–19NOV01–4/26


PN=82

Hydraulic System 13. Lubricate parts (12—18) with hydraulic oil and install. Insure that pistons (16) are installed in their original bores. Install bushing (14) and retainer (15) as shown. 14. Install parts (25—30). 14

T142996

15. Install needle bearing (24) into propel motor cover (23).

–UN–20JUL01

15

NOTE: Apply petroleum jelly to mating surface of valve plate to adhere it to propel motor cover during assembly.

14—Bushing 15—Retainer

16. Install pins (10) then valve plate (11). 17. Assemble propel motor cover (23) to housing (9). 18. Install cap screws (22) and tighten. Propel Motor—Specification Propel Motor Cover-to-Propel Motor Housing Cap Screw (200CLC and 230CLC)—Torque................................. 300 N•m (225 lb-ft)


TM1931 (09JAN04)

02-0260-5

ouoe049,0001010 –19–19NOV01–5/26


PN=83

02 0260 5

Hydraulic System

18 17 8 02 0260 6

16

6 6

13

5

12 11

4 3

9

15

14

10

2 1 7 7

31 32 33 28 34 30

35 36

29 37 27 19

28

26 38

25

20

21

39 22

23

40

T146684

T146684

42

–UN–01NOV01

24

41 Propel Motor and Park Brake Components—270CLC


TM1931 (09JAN04)

02-0260-6

ouoe049,0001010 –19–19NOV01–6/26


PN=84

Hydraulic System 1—O-Ring 2—Disk Spring 3—Brake Piston 4—O-Ring 5—O-Ring 6—Plate (5 used) 7—Friction Plate (4 used) 8—Spacer 9—Motor Drive Shaft 10—Roller Bearing 11—Spacer

12—Roller Bearing 13—Nut 14—Propel Motor Housing 15—O-Ring 16—Brake Releasing Oil Passage 17—Lip Seal 18—Snap Ring 19—Cap Screw (4 used) 20—Cover 21—O-Ring

Disassemble and Assemble Propel Motor—270CLC IMPORTANT: Valve plate and pistons have machined surfaces. Do not let valve plate and pistons drop. 1. Remove propel motor cover (40) from propel motor housing (14). Make sure valve plate in valve housing is not damaged.

22—Piston Seal 23—Piston Seal 24—Servo Piston 25—Cap Screw (4 used) 26—O-Ring 27—Plug 28—Pivot Plug (2 used) 29—Shoulder Bolt 30—Link 31—Pin 32—Center Shaft

33—Spring 34—Piston (7 used) 35—Rotor 36—Bushing 37—Valve Plate 38—Plate 39—Pin (2 used) 40—Propel Motor Cover 41—Plug 42—O-Ring

5. Apply 100—300 kPa (14—43 psi) air pressure to brake release passage (16) to remove brake piston (3). 6. Remove brake parts (3—8).

NOTE: If parts are not within specification, replace parts. 7. Inspect brake parts for wear or damage.

IMPORTANT: Pistons must be installed into the same bores because of wear pattern.

3. Remove parts (32, 33, and 35).

Propel Motor—Specification Disk Spring (270CLC)—Height......... 7.2—7.6 mm (0.283—0.300 in.) Friction Plate (270CLC)— Thickness ............................................ 3.25—3.30 mm (0.128—0.130 in.) Plate (270CLC)—Thickness ............... 1.75—1.80 mm (0.069—0.071 in.)

NOTE: Remove pin (31) only if necessary.

8. Remove parts (17 and 18).

2. Mark pistons and bores in rotor (35) so pistons are installed into same bores during assembly.

4. Remove pistons (34).

NOTE: Remove piston evenly from bore. Do not scratch or damage piston or bore.


TM1931 (09JAN04)

02-0260-7

ouoe049,0001010 –19–19NOV01–7/26


PN=85

02 0260 7

Hydraulic System 9. Remove nut (B) using JDG911 Spanner Wrench. 10. Use a puller and a press to remove parts (C—E) from shaft (A). A—Motor Drive Shaft B—Nut C—Roller Bearing D—Spacer E—Roller Bearing

T8320AE

–UN–11OCT94

02 0260 8

ouoe049,0001010 –19–19NOV01–8/26

IMPORTANT: Valve plate and slide plate have machined surfaces. Do not let plates drop. 11. Remove parts (A—D).

T8321AF

–UN–20SEP94

A—Cover B—Plug and O-Ring C—Shoulder Bolt D—Valve Plate and Link Assembly


TM1931 (09JAN04)

02-0260-8

ouoe049,0001010 –19–19NOV01–9/26


PN=86

Hydraulic System 12. Disassemble servo piston parts (A—E) if necessary.

T7685IE

–UN–27APR92

A—Plug B—O-Ring C—Spool D—Spring E—Piston Ring (2 used)

ouoe049,0001010 –19–19NOV01–10/26

13. Inspect bushing (B) and replace if necessary. IMPORTANT: Thread lock and sealer (high strength) is used on pivot plugs (A). –UN–20SEP94

NOTE: Remove pivot plugs (A) only if necessary to remove valve plate (C).

T8321AH

14. Replace parts as necessary. A—Pivot Plug B—Bushing C—Valve Plate

ouoe049,0001010 –19–19NOV01–11/26

NOTE: If removed install bushing (B) with chamfered side of bushing facing inside of valve plate (C).

–UN–20SEP94

15. Install bushing (B) using disk drivers, until bushing is even with valve plate (C). 16. If removed, apply thread lock and sealer (high strength) to threads of pivot plugs (A).

T8321AH

IMPORTANT: DO NOT allow thread lock and sealer on smooth portion of pivot plugs. 17. Install valve plate and pivot plugs (A) in link. Tighten pivot plugs.

A—Pivot Plug (2 used) B—Bushing C—Valve Plate

Propel Motor—Specification Pivot Plug (270CLC)—Torque......................................... 49 N•m (36 lb-ft)


TM1931 (09JAN04)

02-0260-9

ouoe049,0001010 –19–19NOV01–12/26


PN=87

02 0260 9

Hydraulic System IMPORTANT: Piston seals are brittle. Use care not to chip, crack or break seals. 18. Assemble servo piston parts (A—E).

T7685IE

–UN–27APR92

A—Plug B—O-Ring C—Spool D—Spring E—Piston Ring (2 used) 02 0260 10

ouoe049,0001010 –19–19NOV01–13/26

19. Apply clean oil to all internal parts. 20. Install parts (D and E). IMPORTANT: Valve plate and slide plate have machined surfaces. Use care not damage or scratch machined surfaces. 21. Apply petroleum jelly to both sides of plate (B). 22. Install parts (A—C). Align link assembly with servo piston.

T8321AG

–UN–20SEP94

A—Valve Plate and Link Assembly B—Plate C—Pin (2 used) D—Servo Piston E—Piston Seal (2 used)


TM1931 (09JAN04)

02-0260-10

ouoe049,0001010 –19–19NOV01–14/26


PN=88

Hydraulic System 23. Install shoulder bolt (C) through link assembly (D) at end of servo piston. Install plug and O-Ring . Tighten shoulder bolt (C) and plug (B). Propel Motor—Specification Shoulder Bolt (270CLC)—Torque ................................... 49 N•m (36 lb-ft)

24. Install O-ring and cover (A). Tighten cover cap screws. Propel Motor—Specification Servo Piston Cover Cap Screw (270CLC)—Torque .......................................................... 88 N•m (65 lb-ft)

02 0260 11

T8321AF

–UN–20SEP94

A—Cover B—Plug and O-Ring C—Shoulder Bolt D—Valve Plate and Link Assembly


TM1931 (09JAN04)

02-0260-11

ouoe049,0001010 –19–19NOV01–15/26


PN=89

Hydraulic System

–UN–23AUG88

CAUTION: DO NOT heat oil over 182°C (360°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. 25. Heat bearing cones (C and E).

TS227

Propel Motor—Specification Bearing Cone (270CLC)— Temperature ......................................................... 50—70°C (122—158°F)

26. Install parts (C—E) on motor drive shaft (A). Install race and spacer with spacer notches towards larger bearing. 27. Apply clean oil to threads of nut (B). Install nut with thin shoulder away from bearing.

–UN–11OCT94

A—Motor Drive Shaft B—Nut C—Roller Bearing D—Spacer E—Roller Bearing

T8320AE

02 0260 12


TM1931 (09JAN04)

02-0260-12

ouoe049,0001010 –19–19NOV01–16/26


PN=90

Hydraulic System

A—Nut

T8320AP

T8320AO

–UN–11OCT94

–UN–26SEP94

02 0260 13

B—DF1038 Torque Adapter

C—JDG911 Spanner Wrench

28. Tighten nut (A) using JDG911 Spanner Wrench (C) until rolling drag torque is to specification.

29. Check rolling drag torque using DF1038 Torque Adapter (B). (Group 9900.)

Propel Motor—Specification Motor Drive Shaft (270CLC)— Rolling Drag Torque .............................. 3.0—4.0 N•m (27—35 lb-in.)

30. Stake nut in one place on the thin shoulder.


TM1931 (09JAN04)

02-0260-13

ouoe049,0001010 –19–19NOV01–17/26


PN=91

Hydraulic System 31. Apply rigid form-in-place gasket to outer diameter of oil seal (B).

–UN–20SEP94

32. Install seal with spring side into bore first. Use a disk driver to push seal to bottom of bore. 33. Apply multi-purpose grease to seal lips.

NOTE: Use a soft faced hammer to make sure bearings are tight against bottom of bore. A—Snap Ring B—Oil Seal

35. Install motor drive shaft assembly into housing, using care not to damage seal lips.

ouoe049,0001010 –19–19NOV01–18/26

36. Install spacer (G) with notches to bottom of bore and aligned with notches in housing. 37. Install friction plates (F) and plates (E): • Begin with one friction plate and align notches in friction plate with notches in gear. • Install one plate. • Repeat step, alternating friction plates and plates. Keep notches of plates aligned with one another.

–UN–20SEP94

38. Apply petroleum jelly to O-rings (C and D). Install O-rings on piston (B) with rounded side out. IMPORTANT: Make sure brake port (A) is clear to allow air to exit as piston is installed.

NOTE: To ease installation of piston apply petroleum jelly to outer diameter of piston.

T8319BR

02 0260 14

T8319BY

34. Install snap ring (A).

39. Install piston (B) evenly into bore. A—Brake Port B—Brake Piston C—O-Ring D—O-Ring E—Plate (4 used) F—Friction Plate (5 used) G—Spacer


TM1931 (09JAN04)

02-0260-14

ouoe049,0001010 –19–19NOV01–19/26


PN=92

Hydraulic System 40. Install pistons into same bores as they were removed. Make sure pistons move freely.

–UN–20SEP94

41. Assemble parts (32) and (33) and align pin (31) with slot in rotor (35). 42. Install rotor (35).

T8319BP

43. Install disk spring (2) so inner diameter contacts the brake piston. 44. Install O-rings (1 and 15).


TM1931 (09JAN04)

02-0260-15

ouoe049,0001010 –19–19NOV01–20/26


PN=93

02 0260 15

Hydraulic System 45. Remove parts (A—C) from alignment port (E) of propel motor cover (D).

–UN–20SEP94

46. Move valve plate and servo piston to align pivot plug with port. Install a 6 mm hex key wrench in pivot plug to hold valve plate and link in position.

48. Lift propel motor cover into position over propel motor housing. Align cover to housing and install dowel into bore of center shaft (G). 49. Install and tighten four housing cap screws. Propel Motor—Specification Propel Motor Cover-to-Motor Housing Cap Screw (270CLC)— Torque ......................................................................... 390 N•m (290 lb-ft)

50. Remove dowel (F) and install parts (A—C). Tighten plug. Propel Motor—Specification Brake Pressure Reducing Valve Plug (270CLC)—Torque .................................................. 69 N•m (51 lb-ft)

51. Install and tighten plug and O-ring (A).

–UN–20SEP94

Propel Motor—Specification Alignment Port Plug (270CLC)— Torque ............................................................................. 90 N•m (65 lb-ft)

A—Plug and O-Ring B—Pressure Reducing Valve C—Spring D— Propel Motor Cover E—Alignment Port F—Wooden Dowel or Rod G—Center Shaft

T8322BD

02 0260 16

T8322BC

47. Install a 4.8 mm (3/16 in.) wooden dowel or soft rod (F) through reducing valve port and center of valve plate.


TM1931 (09JAN04)

02-0260-16

ouoe049,0001010 –19–19NOV01–21/26


PN=94

Hydraulic System

1

2 3 4

5 7

13

02 0260 17

5

16 14

1

6

12 15

4 3 2

–UN–20JUL01

9 10 11

T143007

8 T143007

1—Counterbalance Valve 2—Counterbalance Valve Plug (2 used) 3—O-Ring (2 used) 4—Spring (2 used)

5—Spring Seat (2 used) 6—Spool 7—Propel Motor Cover 8—Crossover Relief Valve (2 used)

Disassemble and Assemble Propel Motor Cover— 200CLC and 230CLC

NOTE: Valves may be removed with propel motor in machine. • Apply a film of clean hydraulic oil to parts before assembly.

9—Poppet (2 used) 10—Spring (2 used) 11—Relief Valve (2 used) 12—Propel Speed Change Valve

Propel Motor Cover—Specification Counterbalance Valve Plug (200CLC and 230CLC)— Torque................................................................... 440 N•m (325 lb-ft) Relief Valve (200CLC and 230CLC)—Torque ................................................. 310 N•m (230 lb-ft) Propel Speed Change Plug (200CLC and 230CLC)— Torque....................................................................... 34 N•m (25 lb-ft)


TM1931 (09JAN04)

13—Propel Speed Change Plug 14—O-Ring 15—Spring 16—Spool

02-0260-17

ouoe049,0001010 –19–19NOV01–22/26


PN=95

Hydraulic System

T8322BE

–UN–26SEP94

02 0260 18

A—Plug (2 used) B—O-Ring (2 used) C—Counterbalance Spring (2 used) D—Spool Plug (2 used) E—Counterbalance Spool F—Plug (4 used)

G—O-Ring (4 used) H—Ball Seat (2 used) I—Ball (2 used) J—Plug (2 used) K—O-Ring (2 used) L—Check Valve Spring (2 used)

M—Check Valve Poppet (2 used) N—Relief Valve (2 used) O—Propel Motor Cover P—O-Ring (2 used) Q—Plug (10 used)

R—O-Ring (10 used) S—Plug T—O-Ring U—Brake Pressure Reducing Valve Spool V—Pressure Reducing Spring

Disassemble and Assemble Propel Motor Cover— 270CLC


TM1931 (09JAN04)

02-0260-18

ouoe049,0001010 –19–19NOV01–23/26


PN=96

Hydraulic System 1. Park Brake Release Shuttle Valve

NOTE: Valve can be removed with propel motor on machine. –UN–20SEP94

a. Clean threads of seat (B). Apply cure primer and thread lock and sealer (high strength).

T8323AB

b. Install ball (C) and tighten seat (B). Propel Motor—Specification Ball Seat (270CLC)—Torque .................................... 14.5 N•m (128 lb-in.) A—Plug with O-Ring B—Ball Seat C—Ball

c. Install and tighten plug (A). Propel Motor—Specification Park Brake Release Shuttle Valve Plug (270CLC)—Torque .................................................. 34 N•m (25 lb-ft)


TM1931 (09JAN04)

02-0260-19

ouoe049,0001010 –19–19NOV01–24/26


PN=97

02 0260 19

Hydraulic System 2. Servo Piston Operating Shuttle Valve

NOTE: Valve can be removed with propel motor on machine. –UN–20SEP94

a. Clean threads of seat (B). Apply cure primer and thread lock and sealer (high strength).

02 0260 20

T8323AJ

b. Install ball (C) and tighten seat (B). Propel Motor—Specification Ball Seat (270CLC)—Torque .................................... 14.5 N•m (128 lb-in.) A—Plug with O-Ring B—Ball Seat C—Ball

c. Install and tighten plug (A). Propel Motor—Specification Servo Piston Operating Shuttle Valve Plug (270CLC)—Torque ....................................... 34 N•m (25 lb-ft)

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

NOTE: Valves can be removed with propel motor on machine. 4. Relief Valves (N) Tighten relief valve. Propel Motor—Specification Relief Valve (270CLC)—Torque.................................. 540 N•m (398 lb-ft)


TM1931 (09JAN04)

02-0260-20

ouoe049,0001010 –19–19NOV01–25/26


PN=98

Hydraulic System NOTE: Valves can be removed with propel motor on machine. 5. Check Valves (M) Install parts and tighten plug. Propel Motor—Specification Check Valve Plug (270CLC)— Torque ......................................................................... 235 N•m (173 lb-ft) 02 0260 21

NOTE: Valve can be removed with propel motor on machine. 6. Brake Pressure Reducing Valve (U) Install parts and tighten plug. Propel Motor—Specification Brake Pressure Reducing Valve Plug (270CLC)—Torque .................................................. 69 N•m (51 lb-ft)

ouoe049,0001010 –19–19NOV01–26/26

TM1931 (09JAN04)

02-0260-21


PN=99

Hydraulic System

Propel Motor Start-Up Procedure IMPORTANT: Propel motor will be damaged if not filled with oil before operating propel function. Procedure must be performed whenever a new propel motor is installed or oil has been drained from the motor. –UN–01NOV01

1. Disconnect drain line (1).

T146686C

2. Fill motor with hydraulic oil until oil reaches top of drain port.

NOTE: Use a funnel with suitable diameter neck to allow air to escape while filling. 200CLC and 230CLC Propel Motor Drain Line

3. Connect drain line (1).

–UN–03MAY01

1—Propel Motor Drain Line

T139271D

02 0260 22

270CLC Propel Motor Drain Line

CED,OUOE023,169 –19–19NOV01–1/1

Rotary Manifold Repair Remove and Install Rotary Manifold CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil from pressurized system can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 2. Disconnect upper hydraulic lines.


TM1931 (09JAN04)

02-0260-22

OUOE049,0000051 –19–19NOV01–1/5


PN=100

Hydraulic System 3. Remove cap screws (2) and bracket (1). 4. Attach the rotary manifold to a hoist using a lifting strap and two Rotary Manifold Lifting Tool. (Group 9900.) 5. Disconnect lower hydraulic lines.

T143108B

–UN–20JUL01

1—Bracket 2—Cap Screw (2 used)

OUOE049,0000051 –19–19NOV01–2/5

CAUTION: Heavy component; use a hoist. Rotary Manifold—Specification Rotary Manifold—Weight................................... 27 kg (60 lb) approximate

–UN–27APR92

6. Remove four mounting cap screws. Lower rotary manifold.

T7685JC

7. Replace parts as necessary. 8. Install rotary manifold. Tighten four mounting cap screws. Rotary Manifold—Specification Manifold-to-Frame Cap Screw— Torque ............................................................................. 34 N•m (25 ft-lb)

9. Install stop bracket. Tighten cap screws. Rotary Manifold—Specification Stop Bracket-to-Frame Cap Screw—Torque ................................................................ 40 N•m (30 lb-ft)

10. Connect upper and lower hydraulic lines. See Propel System Component Location. (Group 9025-15.)


TM1931 (09JAN04)

02-0260-23

OUOE049,0000051 –19–19NOV01–3/5


PN=101

02 0260 23

Hydraulic System Disassemble and Assemble Rotary Manifold 1. Make alignment marks on spindle (B), housing (G) and cover (K) to aid in assembly. 2. Remove parts (H—L). Carefully remove spindle assembly (B) from housing (G). 3. Remove plugs in spindle and clean ports. 4. Remove parts (C—F). 5. Inspect and repair as necessary. 6. Install parts (C—F). 7. Install spindle assembly (B) in housing (G), aligning marks made during disassembly. 8. Install parts (H—L), aligning marks made during disassembly and tighten cap screws. Rotary Manifold—Specification Cover-to-Housing Cap Screw— Torque ............................................................................. 49 N•m (36 lb-ft)

9. Install plugs.

–UN–17JUN98

A—Plug B—Spindle Assembly C—Oil Seal D—O-Ring E—Bushing F—Oil Seal Rings (6 used) G—Housing H—Ring I—Snap Ring J—O-Ring K—Cover L—Cap Screw (4 used)

T115530

02 0260 24


TM1931 (09JAN04)

02-0260-24

OUOE049,0000051 –19–19NOV01–4/5


PN=102

Hydraulic System Rotary Manifold Air Test

2. Apply air pressure using JDG185 Air Test Plug and shop air pressure through the other port in that passage.

T6557JB

3. Listen for air leaks at ports on either side of pressurized port.

–UN–01NOV88

1. Install a plug in one port.

OUOE049,0000051 –19–19NOV01–5/5

TM1931 (09JAN04)

02-0260-25


PN=103

02 0260 25

Hydraulic System

02 0260 26

TM1931 (09JAN04)

02-0260-26


PN=104

Section 04

Engine Contents Page

Group 0400—Removal and Installation Engine Repair . . . . . . . . . . . . . . . . . . . . . . .04-0400-1 Fuel Injection Pump Repair . . . . . . . . . . . . . .04-0400-4 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-5

04

TM1931 (09JAN04)

04-1


PN=1

Contents

04

TM1931 (09JAN04)

04-2


PN=2

Group 0400

Removal and Installation Engine Repair Remove and Install Engine

–UN–23AUG88

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

TS281

Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to first stop to relieve pressure, then remove. 1. Disconnect battery ground (negative) cable. 2. Drain coolant. Approximate capacity of cooling system is 23.0 L (24.3 qt). See Drain Cooling System. (Operator’s Manual.)

04 0400 1

3. Remove fan guard, radiator shroud, fan blade and spacer. See Fan, Fan Guard, and Fan Shroud Repair. (Group 0510.) 4. Disconnect charge air cooler hoses. 5. Remove upper and lower radiator hoses. 6. Disconnect air intake hose. 7. Remove muffler and muffler bracket.

NOTE: Label wiring to aid installation. 8. Disconnect engine wiring. See Machine Harness (W2) Component Location. (Group 9015-10.)

NOTE: It is not necessary to discharge the air conditioning system. 9. Disconnect air conditioner compressor bracket from engine. Secure compressor and bracket so it will not interfere with engine removal. 10. Relieve Fuel System Pressure. (CTM170.) 11. Disconnect fuel filter input line, fuel filter overflow tube, and fuel pump overflow tube. 12. Disconnect heater hoses.


TM1931 (09JAN04)

04-0400-1

TX,04,DH5305 –19–19NOV01–1/4


PN=107

Removal and Installation

CAUTION: Heavy component; use a hoist. Engine—Specification Hydraulic Pump and Drive Gearbox—Weight .......................................... 170 kg (375 lb) approximate

13. Support main hydraulic pump and drive gearbox using DFT1119 Pump Support (A) and a small hoist winch (B). (Group 9900.) A—DFT1119 Pump Support B—Hoist Winch

T104491

–UN–17OCT96

04 0400 2

TX,04,DH5305 –19–19NOV01–2/4

CAUTION: Heavy component; use a hoist. Engine—Specification Engine—Weight ........................................... 954 kg (2100 lb) approximate

IMPORTANT: The recommended method for lifting the engine is using the JDG23 Lifting Sling. The lifting force must be at 90° at the lifting points. 14. Attach JDG23 Lifting Sling (1) to engine as shown. 15. Remove cap screws securing main hydraulic pump and drive gearbox to engine flywheel housing.

T143006B

–UN–20JUL01

1—Engine Lifting Sling


TM1931 (09JAN04)

04-0400-2

TX,04,DH5305 –19–19NOV01–3/4


PN=108


4

5

1

5 4 3

2

04 0400 3

4

–UN–19NOV01

5

4

1—Bracket, Right Front 2—Bracket, Left Front

T143012

5 T143012

3

3—Bracket, Rear (2 used)


16. Remove cap screws (4) and washers (5) from engine mounts.

5—Washer (14 used)

Tighten cap screws.

17. Raise engine slightly. Move engine away from hydraulic pump and drive gearbox. Lift and remove engine when disengaged from hydraulic pump drive coupling. 18. Repair or replace parts as necessary. If disassembly is necessary, see Engine Disassembly Sequence. (CTM104.)

Engine—Specification Engine Mount Cap Screw— Torque................................................................... 350 N•m (260 lb-ft)

20. Align hydraulic pump and drive gearbox to engine and tighten cap screws. Engine—Specification Drive Gearbox-to-Flywheel Housing Cap Screw—Torque ................................... 50 N•m (37 lb-ft)

CAUTION: Heavy component; lift engine using JDG23 Lifting Sling. Lifting force must be 90° to engine lift points. Engine—Specification Engine—Weight .................................... 954 kg (2100 lb) approximate

19. Use JDG23 Lifting Sling to install engine. Install engine mount cap screws (5) and washers (4).

21. Connect engine wiring. See Machine Harness (W2) Component Location Diagram. (Group 9015-10.) 22. Fill radiator and reservoir with coolant. See Cooling System Fill and Deaeration Procedure. (Operator’s Manual.) 23. Bleed Fuel System. (Operator’s Manual.)

TX,04,DH5305 –19–19NOV01–4/4

TM1931 (09JAN04)

04-0400-3


PN=109


Fuel Injection Pump Repair Remove and Install Fuel Injection Pump IMPORTANT: Never steam clean or pour cold water on injection pump while pump is running or still warm to prevent pump seizure. For replacement of fuel injection pump, see the following: • 200CLC (S.N. —504000), 230CLC and 270CLC See Remove Bosch VP44 Fuel Injection Pump. (CTM170.) • 200CLC (S.N. 504001—) Perform Remove Injection Pump. (CTM331.) 04 0400 4 TX,04,DH5307 –19–10NOV03–1/1

TM1931 (09JAN04)

04-0400-4


PN=110


Starter Repair Remove and Install Starter

–UN–15AUG01

IMPORTANT: Always disconnect battery ground (negative) cable before removing starter to prevent short circuits.

T144796B

1. Disconnect battery ground (negative) cable. 2. Disconnect ground strap and electrical connectors. CAUTION: Heavy component; use a hoist.

1—Starter

Starter—Specification Starter—Weight ................................................. 23 kg (50 lb) approximate

04 0400 5

3. Remove starter (1). 4. Replace parts as necessary. 5. Install starter (1). 6. Tighten cap screws. Starter—Specification Starter Mounting Cap Screw— Torque ............................................................................. 47 N•m (35 lb-ft)

7. Connect ground strap and electrical connectors. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015-10.) 8. Connect battery ground (negative) cable.

TX,04,DH5312 –19–19NOV01–1/1

TM1931 (09JAN04)

04-0400-5


PN=111


04 0400 6

TM1931 (09JAN04)

04-0400-6


PN=112

Section 05

Engine Auxiliary System Contents Page

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

TM1931 (09JAN04)

05-1

05


PN=1

Contents

05

TM1931 (09JAN04)

05-2


PN=2

Group 0510

Cooling System Radiator Repair Remove and Install Radiator

–UN–23AUG88


TS281

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 1. Drain coolant from radiator. Approximate capacity is 28.4 L (30 qt). 2. Remove upper and lower radiator hoses and overflow hose. 3. Remove cap screws (1—3).

05 0510 1


–UN–02AUG01

Radiator—Specification Radiator—Weight .............................................. 39 kg (85 lb) approximate

4. Attach radiator to hoist and remove.

T142681

5. Repair or replace as necessary. 6. Install radiator and tighten cap screws (1—3). 7. Fill radiator and reservoir with coolant. See Cooling System Fill and Deaeration Procedure. (See Operator’s Manual.)

1—Cap Screw (9 used) 2—Cap Screw (6 used) 3—Cap Screw (4 used)

8. Start engine and check for leaks.

TX,05,DH5317 –19–19NOV01–1/1

Fan, Fan Guard, and Fan Shroud Repair Remove and Install Fan, Fan Guard, and Fan Shroud


TM1931 (09JAN04)

05-0510-1

TX,05,DH5318 –19–19NOV01–1/2


PN=115

Cooling System


–UN–23AUG88

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.

TS281

1. Remove cap screws (1). Remove fan guard. 2. Remove cap screws (3). Slide fan shroud toward engine. 3. Remove cap screws (2). Remove fan, and fan shroud.

–UN–02AUG01

4. Replace parts as necessary. 5. Install fan. Tighten cap screws.

T142994B

Fan—Specification Engine Fan-to-Pulley Cap Screw—Torque ................................................................ 70 N•m (50 lb-ft)

1—Cap Screw (4 used) 2—Cap Screw (4 used) 3—Cap Screw (8 used)

–UN–19NOV01

Fan Guard—200CLC and 230CLC

T147134B

05 0510 2

Fan Guard—270CLC

TX,05,DH5318 –19–19NOV01–2/2

Fan Belt Repair Remove and Install Fan Belt


TM1931 (09JAN04)

05-0510-2

TX,05,DH5319 –19–19NOV01–1/2


PN=116

Cooling System 1. Remove fan guard. See Fan, Fan Guard, and Fan Shroud Repair. (See procedure in this group.) 2. Remove air conditioning compressor belt. 3. Place a 15 mm wrench on hex head of cap screw (A) in center of tension adjuster idler. 4. Pull idler away from belt to release belt tension. 5. Remove fan belt. 6. Inspect belt for wear or cracks. Replace as necessary. 7. Install fan belt.

T108219

–UN–25MAR97

A—Hex Head of Cap Screw

TX,05,DH5319 –19–19NOV01–2/2

TM1931 (09JAN04)

05-0510-3


PN=117

05 0510 3

Cooling System

05 0510 4

TM1931 (09JAN04)

05-0510-4


PN=118

Group 0520

Intake System Air Intake System Leakage Test 1. Remove air cleaner cover. Remove primary filter element. –UN–23FEB89

2. Put a large plastic bag inside and over end of element as shown. Install element and cover.

T5906AP

3. Remove fitting for start aid nozzle from intake manifold. 4. Install the JDG51 Inlet Air Adapter (A). 5. Connect air pressure regulator to adapter using hose and fitting.

–UN–25OCT88

IMPORTANT: Plastic bag could be drawn into the engine causing damage if engine starts. Do not start the engine when turning the engine crankshaft to close valves.

Air Intake System—Specification Leakage Test—Pressure .............................. 14—21 kPa (0.14—0.21 bar) (2—3 psi)

T6089AR

6. Pressurize air intake system to 14—21 kPa (0.14— 0.21 bar) (2—3 psi). If intake system cannot be pressurized, turn engine crankshaft slightly to close valves. A—JDG51 Inlet Air Adapter

7. Spray a soap solution over all connections from the air cleaner to turbocharger and intake manifold. Check for leaks. Correct all leaks 8. When installing start aid nozzle, be certain arrow on nozzle is pointing against intake air flow.

TX,05,GG2309 –19–19NOV01–1/1

TM1931 (09JAN04)

05-0520-1


PN=119

05 0520 1

Intake System

Air Cleaner Repair

T144782

–UN–19NOV01

05 0520 2

1—Valve 2—Air Cleaner 3—Indicator 4—Clamp (3 used)

5—Hose 6—Hose 7—Cap Screw (4 used)

8—Inner Filter Element 9—Wing Nut (3 used) 10—Outer Filter Element

11—Gasket 12—Clip 13—Cover

Remove and Install Air Cleaner

NOTE: Tighten hose clamps until rubber hose begins to deform. OUOE027,0000040 –19–19NOV01–1/1

TM1931 (09JAN04)

05-0520-2


PN=120

Group 0560

External Fuel Supply System Fuel Tank Repair

T105203

–UN–19NOV96

05 0560 1

1—Fuel Strainer 2—Filler Cap 3—Fuel Tank 4—Plug 9—Bracket

10—Cap Screw 11—Float (Fuel Level Sender) 12—Cap Screw (5 used) 13—Gasket 14—Lock Washer

15—Switch 16—Sealing Washer 18—Drain Valve 19—Fitting 20—Plug


TM1931 (09JAN04)

05-0560-1

22—Cap Screw (4 used) 23—Lock Washer (4 used) 25—Washer (4 used) 26—Wiring Connector

TX,05,GG2307 –19–19NOV01–1/2


PN=121

External Fuel Supply System Remove and Install Fuel Tank

6. Install float (fuel level sender) (11) and tighten cap screws (12).

1. Drain fuel from fuel tank. Approximate capacity is 360 L (95 gal). 2. Disconnect wiring connector (26). CAUTION: Heavy component; use a hoist.

Fuel Tank—Specification Float (Fuel Level Sender) and Gasket-to-Fuel Tank Cap Screw—Torque ....................................................... 4.5 N•m (40 lb-in.)

7. Install fuel tank (3) and tighten cap screws (22).

Fuel Tank—Specification Fuel Tank—Weight ................................... 91 kg (200 lb) approximate without fuel

Fuel Tank—Specification Frame-to-Fuel Tank Cap Screw—Torque ..................................................... 205 N•m (152 lb-ft)

3. Remove cap screws (22) and remove fuel tank.

8. Fill fuel tank with proper fuel. See Diesel Fuel. (Operator’s Manual.)

4. Repair or replace as necessary. 9. Bleed Fuel System. (CTM 170.) 5. Apply thread lock and sealer (medium strength) to thread of cap screws (12).

05 0560 2

TX,05,GG2307 –19–19NOV01–2/2

TM1931 (09JAN04)

05-0560-2


PN=122

External Fuel Supply System

Primary Fuel Filter (Water Separator) Repair Remove and Install Primary Fuel Filter (Water Separator) 1. Loosen drain valve to drain fuel into a container. Dispose of fuel properly. 2. Loosen clamps (2) and disconnect hoses (3—4). 3. Remove cap screws (1) and remove primary fuel filter (5). 4. Replace parts as necessary. Disassemble and assemble primary fuel filter as required. See Final Fuel Filter Assembly - Tier 2. (CTM170.) 5. Install primary fuel filter and tighten cap screws. –UN–02AUG01

6. Bleed Fuel System. (Operator’s Manual.)

T142498B

1—Cap Screw, Lock Washer and Washer (2 used) 2—Clamp (2 used) 3—Primary Filter-to-Fuel Tank 4—Primary Filter-to-Final Fuel Filter 5—Primary Fuel Filter (Water Separator)

200CLC Shown

TX,05,GG2315 –19–19NOV01–1/1

TM1931 (09JAN04)

05-0560-3


PN=123

05 0560 3

External Fuel Supply System

Final Fuel Filter Repair Remove and Install Final Fuel Filter 1. Loosen drain valve to drain fuel into a container. Dispose of fuel properly. 2. Disconnect electrical connectors (1 and 7). –UN–02AUG01

3. Disconnect lines (4, 5 and 8). 4. Remove cap screws (2) and remove final fuel filter (6).

6. Install final fuel filter (6) and tighten cap screws (2). 7. Connect electrical connectors (1 and 7). 05 0560 4

8. Connect lines (4, 5 and 8). 9. Bleed Fuel System. (Operator’s Manual.)

T142510B

5. Replace parts as necessary. Disassemble and assemble final fuel filter as required. See Final Fuel Filter Assembly - Tier 2. (CTM170.) 1—Transfer Pump Electrical Connector 2—Cap Screw (2 used) 3—Transfer Pump 4—Final Fuel Filter-to-Injector Pump Line 5—Injector Return Port-to-Final Fuel Filter Line 6—Final Fuel Filter 7—Fuel Pressure Sensor Electrical Connector 8—From Primary Fuel Filter Line 9—Clamp

TX,05,GG2314 –19–19NOV01–1/1

TM1931 (09JAN04)

05-0560-4


PN=124

Section 07

Dampener Drive (Flex Coupling) Contents Page

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

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Group 0752

Elements Dampener Drive (Flex Coupling) Repair Remove and Install Dampener Drive (Flex Coupling) 1. Remove hydraulic pump. See Hydraulic Pump and Drive Gearbox Repair. (Group 3360.)

NOTE: Flex coupling may come off with pump or stay on flywheel. 2. Remove parts (A—H). 3. Replace parts as necessary. 4. Install parts (A—H). Apply thread lock and sealer (medium strength) to set screws (B) and to cap screws (D and G).

–UN–20NOV96

NOTE: Spring pin (F) is for alignment of insert (E) to flywheel. 5. Tighten set screws (B).

6. Tighten cap screws (D and G). Dampener Drive (Flex Coupling)—Specification Insert-to-Flywheel and Coupling Cap Screw—Torque .................................................... 215 N•m (160 lb-ft)

7. Install hydraulic pump. See Hydraulic Pump and Drive Gearbox Repair. (Group 3360.)

T105285

Dampener Drive (Flex Coupling)—Specification Coupling-to-Pump Shaft Set Screw—Torque .............................................................. 108 N•m (80 lb-ft)

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A—Coupling B—Set Screw (2 used) C—Flex Coupling D—Cap Screw (4 used) E—Insert (4 used) F—Spring Pin (4 used) G—Cap Screw (4 used) H—Insert (4 used)

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Section 17

Frame or Supporting Structure Contents Page

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

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Frame Installation Welding On Machine IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery, EPC controller. Disconnect battery ground cable and EPC electrical connectors before welding on the machine. Before welding on the machine, follow the steps listed below to protect the machine electrical system.

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1. Disconnect the battery ground and positive cables.

3. Disconnect electrical connectors (1) from engine and pump controller.

NOTE: See cab harness (W1) component location diagram for connector information.

T143053B

2. Remove rear console cover.

–UN–20JUL01

NOTE: Console cover located behind seat in cab, must be removed to gain access to engine and pump controller connectors.

1—EPC connector (4 used).

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Frame Installation

Welding Repair of Major Structure CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 1. Remove paint before welding or heating. IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to "OFF". Also disconnect the wiring harness connectors to the engine and pump controller.

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Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter. 2. Use one of the following weld processes:

• AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process. • AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process. Welding Repair of Major Structure—Specification Weld Metal—Tensile Strength ....................... 482.6 mPa (70,000 psi) Yield Strength ................................................ 413.7 mPa (60,000 psi) Elongation ..................................................................................... 22%

IMPORTANT: Area to be repaired must be preheated to allow better weld penetration. 3. To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). Welding Repair of Major Structure—Specification Structural Assemblies—Preheat Temperature ................................................................... 38°C (100°F) Ground Engaging Tools— Preheat Temperature.................................................... 177°C (350°F)

• AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process.

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Group 1749

Chassis Weights Counterweight Repair Remove and Install Counterweight

–UN–20JUL01

1. Park machine on level ground. 2. Remove two plastic caps from top of counterweight (1).

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CAUTION: Heavy component; use a hoist. The lifting capacity of a lifting eyebolt decreases as the lift angle increases from vertical. A spreader bar should be used to obtain, as close as possible, a vertical lift from eyebolts.

–UN–03SEP02

Counterweight—Specification Counterweight (200CLC)—Weight ............ 4250 kg (9370 lb) approximate Counterweight (230CLC)—Weight ......... 5400 kg (11,900 lb) approximate Counterweight (270CLC)—Weight ......... 6100 kg (13,450 lb) approximate

T143044

NOTE: For 270CLC, use JT05558 Metric Lifting Eyebolt with spreader bar. 3. Connect the counterweight to a hoist (2) using a spreader bar (3). 4. Remove cap screws and washers (4). 5. Remove counterweight.

–UN–20JUL01

6. Repair or replace as necessary.

Counterweight—Specification Frame-to-Counterweight Cap Screw (200CLC)—Torque ......................................... 1150 N•m (830 lb-ft) Frame-to-Counterweight Cap Screw (230CLC and 270CLC)— Torque ..................................................................... 1910 N•m (1410 lb-ft)

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7. Install cap screws and washers (4) and tighten.

1—Counterweight 2—Hoist 3—Spreader Bar 4—Cap Screw and Washer (4 used)

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Chassis Weights

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Section 18

Operator’s Station Contents Page

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

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Group 1800

Removal and Installation Cab Repair Remove and Install Cab

NOTE: Seat removal is optional. 1. Disconnect battery ground (-) cable at battery. 2. Remove monitor controller. See Remove and Install Monitor Controller and Display (A5). (Group 9015-20.) 3. Disconnect electrical connectors. 4. Remove fresh air intake cowl. 5. Disconnect windshield washer hose.


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1—Cap Screw (2 used) 2—Washer (9 used)

3—Cap Screw (7 used) 4—Lock Nut (4 used)

5—Washer (4 used) Continued on next page

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Removal and Installation 6. Remove lock nuts (4) securing cab to rubber mounts at all four corners. Discard lock nuts.

7. Remove cap screws (1 and 3).

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8. Use lifting straps and connect cab to hoist.

T106453

NOTE: Move cab forward slightly to clear propel pedals during removal.

–UN–15JAN97

Cab—Specification Cab—Weight ................................................. 290 kg (640 lb) approximate

9. Remove cab. 10. Repair or replace parts as necessary.

NOTE: Check that all lines and cables are out of the way before installing cab. 11. Install cab. 12. Install cap screws (1 and 3). Cab—Specification Cab-to-Platform Cap Screw— Torque ............................................................................. 50 N•m (37 lb-ft)

13. Install washers (5) and new lock nuts (4). Cab—Specification Cab Mount Lock Nut—Torque .................................... 205 N•m (152 lb-ft)

14. Connect electrical connectors. See Monitor Harness (W3) Component Location and See Cab Harness (W1) Component Location Diagram. (Group 9015-05.)

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15. Install monitor controller. See Remove and Install Monitor Controller and Display (A5). (Group 9015-20.)

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Group 1810

Operator Enclosure Windowpane and Two Piece Molding Repair Remove and Install Windowpane and Two Piece Molding –UN–19OCT88

1. Use insert tool to remove locking strip (A) from molding.

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A—Locking Strip

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IMPORTANT: Extreme care is required prevent windowpane damage.

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3. Inspect molding for damage; replace if necessary.

–UN–19OCT88

2. Carefully push windowpane out from molding.

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4. Apply instant gel adhesive in molding (B) frame channel. Install molding.

–UN–19OCT88

5. Install windowpane using insertion tool (A) and soap lubricant.

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A—Window Pane B—Windowpane Insertion Tool

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6. Use weather strip installation tool (B) to install locking strip (A).

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–UN–19OCT88

A—Locking Strip B—Weather Strip Installation Tool

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Operator Enclosure

Windowpane and One Piece Molding Repair

1. Lift inside of molding over cab frame and carefully push windowpane and molding out.

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2. Remove molding from windowpane; replace if necessary.

–UN–19OCT88

Remove and Install Windowpane and One Piece Molding

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3. Install molding on windowpane. Position drain notches (A) at bottom and towards outside of windowpane.

–UN–19OCT88

4. Install windowpane and molding. Lift inside of molding over cab frame.

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A—Drain Notches

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Operator Enclosure

Sliding Windows Repair Remove and Install Sliding Windows 1. Remove molding (3) from inside of window. 2. Use putty knife to cut adhesive (4) between cab flange and window frame (1). IMPORTANT: Work carefully to avoid damaging frame and windowpane. Two technicians are required during window removal; one to push window out of cab, and one to prevent window from falling. 3. Carefully remove window frame from cab.

–UN–30APR01

4. Lift frame slightly at top-center to remove and install windowpanes. 5. Apply instant gel adhesive to cab flange.

T140968

6. Install windows and frame with spacers (2) at the bottom. 7. Using water as a lubricant, push window frame tight against cab flange. 8. Install molding (3) around window and cab flange.

1—Window Frame 2—Bottom Spacer (4 used) 3—Molding 4—Adhesive

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Operator Enclosure

Windowpanes Repair 2. Scrape any broken glass off existing adhesive. DO NOT remove adhesive from window frame or cab.

Remove and Install Windowpanes The adhesive used to secure windowpanes is a urethane adhesive used on automobile windshields. Urethane adhesive manufactured by Loctite Corporation or equivalent is recommended. DO NOT use any other type of adhesive. It is recommended that an auto glass dealer install windowpanes. IMPORTANT: Windowpanes must include an ultra-violet barrier around edge so adhesive will not deteriorate. Windowpanes ordered through John Deere Parts have this ultra-violet barrier. If windowpane is purchased through glass dealer, the dealer must incorporate an ultra-violet barrier on the glass. DO NOT paint border of glass. If auto glass dealer does not install windowpanes, proceed as follows: 1. Remove windowpane frame from cab.

IMPORTANT: Adhesive will not stick to bare metal. 3. If existing adhesive is removed and paint is scraped, paint window frame. Paint must be fully cured before installing windowpane. 4. Trim existing adhesive to form a smooth surface. IMPORTANT: Follow manufacturer’s instructions for using adhesive. 5. Apply 6 mm (1/4 in.) bead of adhesive over existing adhesive. 6. Position windowpane in cab frame. Use hand pressure to force windowpane down until edges are even with metal frame. 7. Secure windowpane with duct tape until adhesive cures. Allow adhesive to cure for 24 hours before operating machine.

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Group 1821

Seat and Seat Belt Seat Belt Repair

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–UN–05AUG96

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Seat and Seat Belt 0—Seat Belt 1—Bracket 3—Belt

4—Belt 5—Spacer (Sleeve)

6—Spacer (Sleeve) (2 used) 8—Cap Screw

11—Cap Screw (2 used) 12—Spring Washer (4 used)

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Group 1830

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

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

Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings, components or refrigerant oils.

DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials.

Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling and charging station equipment. Care must be taken to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of system. JT02167A refrigerant test instrument should be used before any testing or repair to system is preformed.

DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment. IMPORTANT: To meet government standards relating to the use of refrigerants,

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Heating and Air Conditioning Prism Pro Refrigerant Identification Instrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems.

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Heating and Air Conditioning

Flush and Purge Air Conditioner System CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

b. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. c. Pour flushing solvent into suction port and discharge port. Plug both ports in compressor manifold, using JT02099 and JT03194 Caps.

See Refrigerant Cautions and Proper Handling. (See procedure in this group.)

NOTE: Flushing can be performed on machine. 1. Recover R134a Refrigerant. (See procedure in this group.)

Flush and Purge Air Conditioner System—Specification Flushing Solvent in Suction Port—Volume............................................................. 240 mL (8 fl oz) Flushing Solvent in Discharge Port—Volume............................................................. 120 mL (4 fl oz)

Add flushing solvent to system with JT02075 Flusher and JT02098 Flusher Fitting Kit. d. Turn compressor end for end and roll it side to side.

2. Remove and discard receiver/dryer. 3. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. 4. Fill flusher tank with solvent and fasten all connections. Dispose of solvent properly. Flush and Purge Air Conditioner System—Specification Flusher Tank—Capacity ..................................................... 4 L (1 gal)

NOTE: Air pressure must be at least at specification for flushing and purging.

e. Remove both plugs from manifold ports and drain solvent from compressor. f. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders. g. Invert compressor. Roll end for end and side to side. Drain thoroughly. h. Repeat previous two steps at least three times.

Flush and Purge Air Conditioner System—Specification Air Pressure—Pressure ............................. 620 kPa (90 psi) (6.2 bar) minimum for flushing and purging

5. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve. 6. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. 7. Clean compressor as follows: a. Remove compressor and measure oil drained from both manifold ports.

8. Divide system into two circuits: • Condenser circuit, including inlet and outlet hoses. • Evaporator circuit, including inlet and outlet hoses. 9. Condenser: IMPORTANT: DO NOT attempt to flush through compressor or receiver/dryer. Flushing through expansion valve is acceptable if refrigerant oil has a normal odor and appearance. a. Flush/Purge Condenser:


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Heating and Air Conditioning b. Remove and discard receiver/dryer.

If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. See following steps to flush evaporator through expansion valve, if oil appears normal.

c. Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

11. Flush evaporator: d. Fill flusher tank with solvent and fasten all connections. Flush and Purge Air Conditioner System—Specification Flusher Tank—Capacity ..................................................... 4 L (1 gal)

a. Remove evaporator and expansion valve. See Air Conditioner and Heater Repair. (See procedure in this group.) b. Force flushing solvent through evaporator inlet with compressed air.

NOTE: Air pressure must be at least to specification for flushing and purging. Flush and Purge Air Conditioner System—Specification Air Pressure—Pressure ............................. 620 kPa (90 psi) (6.2 bar) minimum for flushing and purging.

c. Purge system until dry. d. Install evaporator and then go to step 13. 12. Flush evaporator through expansion valve: a. Connect flusher outlet hose to connection of receiver/dryer outlet hose using JT03188 adapter.

e. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve.

b. Fill flusher tank and fasten all connections. f. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. g. Attach a return hose and aerator nozzle to end of receiver/dryer inlet hose using JT03197 Adapter. Put nozzle in container to collect flushing solvent.

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NOTE: Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent. h. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry. 10. See flush evaporator, if evaporator requires flushing.

Flush and Purge Air Conditioner System—Specification Flusher Tank—Capacity ..................................................... 4 L (1 gal)

NOTE: Air pressure must be at least to specification for flushing and purging. Flush and Purge Air Conditioner System—Specification Air Pressure—Pressure ............................. 620 kPa (90 psi) (6.2 bar) minimum for flushing and purging.

c. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve. d. Attach a hose and aerator nozzle to compressor inlet line using JT02101 adapter. Put nozzle in a container to collect solvent.


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Heating and Air Conditioning NOTE: Purging evaporator circuit takes 12—15 minutes to thoroughly remove solvent.

bracket. See Receiver-Dryer Repair. (See procedure in this group.)

13. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard and continue purging until cardboard is dry. 14. Install a new receiver/dryer compatible with R134a refrigerant. Fasten connections and mounting

15. Add required oil. See R134a Refrigerant Oil Information. (See procedure in this group.) 16. Install compressor and connect refrigerant lines to manifold. 17. Connect clutch coil wire and install drive belt.

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R134a Refrigerant Oil Information CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. IMPORTANT: Do not add any more oil than required or maximum cooling will be reduced. DO NOT leave system or R134a compressor oil containers open. Refrigerant oil easily absorbs moisture. DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils. A new compressor from parts depot contains new oil. The oil level visible through the suction port normally is below the drive shaft.

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Refrigerant Oil Capacity—Specification Oil—Volume ............................................................ 210 mL (7.1 fl oz) R134a—Weight.............................................. 850 ± 50g (1.9 ± 0.1 lb)

If any section of hose is removed and flushed or replaced, measure length of hose and use formula 3 mL per 30 cm (0.1 fl oz per ft ) to determine correct amount of oil to be added. Drain compressor oil into graduated container while rotating compressor shaft and record amount. If oil drained from a compressor removed from operation is very black or amount of oil is less than 6 mL (0.2 fl oz), perform the following and discard oil properly: ❒ Determine if R134a leakage was detected, remove component and repair or replace component. ❒ Remove and discard receiver/dryer. ❒ Flush complete system with TY16134 Air Conditioning Flushing Solvent. If component is serviceable, pour flushing solvent in ports and internally wash out old oil and discard oil properly.

Normal operating oil level of a compressor removed from operation cannot be seen through suction port of compressor.

Install a new receiver-dryer. See Receiver-Dryer Repair. (See procedure in this group.)

Compressors can be divided into three categories when determining correct oil charge for system.

Install required amount of TY22025 Refrigerant Oil in compressor.

• New compressor from parts depot • Used compressor removed from operation • Compressor internally washed with flushing solvent

Connect all components, evacuate and charge system. See Evacuate R134a System and Charge R134a System. (See procedures in this group.)

Determining the amount of system oil charge prior to installation of compressor on a machine. When complete system, lines, and components are flushed add correct amount of oil as described.

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R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) IMPORTANT: Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling and charging station equipment.

–UN–06DEC93

CAUTION: Do not remove high pressure relief valve (D). Air conditioning station will discharge rapidly causing possible injury.

1. Follow procedures. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) 2. Close both high-side and low-side valves on refrigerant recovery/recycling and charging station (E).

T8118AG

IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. A—High Pressure Hose Charge Port Cap B—Red Hose C—Blue Hose D—High Pressure Relief Valve E—Refrigerant Recovery/Recycling and Charging Station

3. Remove cap from low-side charge port. 4. Connect blue hose (C) from refrigerant recovery/recycling and charging station (E) to low-side test port.

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5. Remove cap (A) from charge port on high pressure hose and connect red hose (B). 6. Follow the manufacturers’ instructions when using refrigerant recovery/recycling and charging station.

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18-1830-7


PN=153


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

18 1830 8 TX,9031,DU1694 –19–19NOV01–1/1

TM1931 (09JAN04)

18-1830-8


PN=154


Evacuate R134a System CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) Do not remove high pressure relief valve. Air conditioning system will discharge rapidly causing possible injury. 1. Connect refrigerant recovery system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (See procedure in this group.)

4. Evacuate system until low-side gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum. Air Conditioning System—Specification Evacuate System—Vacuum ............... 98 kPa (980 mbar) (29 in. Hg)

If above specification vacuum cannot be obtained in 15 minutes, test the system for leaks. See Refrigerant Leak Test. (Group 9031-25.) 5. When vacuum reaches above specification, close low-side and high-side valves. Turn vacuum pump off. 6. If vacuum decreases more than specification in 5 minutes, there is a leak in system.

2. Open low-side and high-side valves on refrigerant recovery/recycling and charging station.

Air Conditioning System—Specification Evacuate System—Vacuum .................. 3.4 kPa (34 mbar) (1 in. Hg)

3. Follow manufacturers’ instructions and evacuate system.

7. Repair leak.

NOTE: Vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level. Air Conditioning System—Specification Evacuate System—Vacuum ................ Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level

8. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 9. Close low-side and high-side valves. Stop evacuation. 10. Charge system. See Charge R134a System. (See procedure in this group.)

18 1830 9 TX,1830,DT474 –19–19NOV01–1/1

TM1931 (09JAN04)

18-1830-9


PN=155


Charge R134a System Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. See Refrigerant Cautions and Proper Handling. (See procedure in this group.) IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Identify refrigerant type using JT02167A Refrigerant Identification Instrument. 2. Connect R134a Refrigerant Recovery/Recycling and Charging Station. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (See procedure in this group.) 3. Evacuate system. See Evacuate R134a System. (See procedure in this group.)

Air Conditioning System—Specification Evacuate System—Vacuum ................ Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level

4. Follow manufacturer’s instructions and charge system. 5. Add refrigerant to system . Air Conditioning System—Specification Air Conditioning System Refrigerant—Refrigerant Quantity...................................................................... 0.85 kg (1.87 lb)

6. Check air conditioning for proper function. See Diagnose Air Conditioning System Malfunctions. (Group 9031-25.)

NOTE: Before beginning to charge air conditioning system, the following conditions must exist:

18 1830 10 TX,18,DU2481 –19–19NOV01–1/1

TM1931 (09JAN04)

18-1830-10


PN=156


Compressor Repair Remove and Install Compressor 1. Recover refrigerant from the system. See Recover R134a Refrigerant. (See procedure in this group.) 2. Disconnect electrical connector (6) and power lead (5).

–UN–20JUL01

3. Remove belt.

T143114B

4. Remove cap screw, lock washer and washer (2). Disconnect high and low pressure lines (1). 5. Remove cap screws, lock washers and washers (3) and remove compressor (4). 6. Repair or replace parts as necessary. 7. Install compressor (4) and tighten cap screw (3). Compressor—Specification Pressure Line Cap Screw— Torque ........................................................................... 28 N•m (247 lb-in)

1—Hi and Low Pressure Lines 2—Cap Screw, Lock Washer and Washer 3—Cap Screw, Lock Washers and Washers (4 used) 4—Compressor 5—Power Lead 6—Electrical Connector

8. Install high and low pressure lines (1). 9. Inspect and adjust compressor belt tension. See Inspect Fan Belt. (Operator’s Manual.) 10. Evacuate and charge the system. See Evacuate R134a System and Charge R134a System. (See procedures in this group.)

18 1830 11 OUOE003,00000E5 –19–16JUL01–1/1

TM1931 (09JAN04)

18-1830-11


PN=157


Receiver-Dryer Repair Remove and Install Receiver-Dryer 1. Recover refrigerant from the system. See Recover R134a Refrigerant. (See procedure in this group.) 2. Disconnect electrical connector (5). 3. Remove cap screw, lock washer, washer (2) and high-pressure input line (3). 4. Remove cap screw, lock washer, washer (4) and high-pressure output line (6). 5. Loosen cap screws (7) and remove receiver-dryer (1) from bracket (8).

–UN–20JUL01

6. Repair or replace parts as necessary. 7. Install receiver-dryer (1).

Receiver-Dryer—Specification High-Pressure Output and Input Line Cap Screw—Torque .................................................. 5 N•m (44 lb-in)

9. Evacuate and charge the system. See Evacuate R134a System and Charge R134a System. (See procedures in this group.)

T143115B

8. Tighten high-pressure output line cap screw (4) and high-pressure input line cap screw (2).

1—Receiver-Dryer 2—Cap Screw, Lock Washer and Washer 3—High Pressure Input Line 4—Cap Screw, Lock Washer and Washer 5—Electrical Connector 6—High Pressure Output Line 7—Cap Screw (2 used) 8—Bracket

18 1830 12 OUOE003,00000E6 –19–25JUL01–1/1

TM1931 (09JAN04)

18-1830-12


PN=158


18 1830 13

TM1931 (09JAN04)

18-1830-13


PN=159


Air Conditioner and Heater Repair

5

6

7 4 3 8 9

1 2

11

27

10

15

18 1830 14

20 22 23

21

12

19

24

18

16

26 15

T145044


TM1931 (09JAN04)

18-1830-14

14

T145044

13

25

–UN–27AUG01

17

OUOE003,00000E7 –19–25APR01–1/2


PN=160

Heating and Air Conditioning 1—Duct 2—Air Conditioner Low Pressure Hose 3—Cap Screw (4 used) 4—Air Conditioning Controller 5—Duct 6—Duct 7—Cap Screw (2 used)

8—Air Conditioner 9—Cap Screw (6 used) 10—Air Conditioner High Pressure Hose 11—Cap Screw 12—Bushing 13—Hose

14—Hose 15—Hose Clamp (4 used) 16—Nipple 17—Gasket 18—Hose 19—Hose 20—Duct

21—Cap Screw (2 used) 22—Filter 23—Clip 24—Clip 25—Cap Screw (2 used) 26—Duct 27—Cap Screw (2 used)

Remove and Install Air Conditioner and Heater

3. Remove air conditioner (8).

1. Drain coolant from radiator. Approximate capacity is 23.0 L (6.1 gal).

4. Replace parts as necessary. 5. Install air conditioner.

NOTE: Evaporator and heater core are integral parts of the air conditioner. If evaporator or heater core need replacement, replace entire air conditioner unit.

6. Evacuate and charge the system. See Evacuate R134a System and Charge R134a System. (See procedures in this group.)

2. Recover refrigerant from the system. See Recover R134a Refrigerant. (See procedure in this group.)

OUOE003,00000E7 –19–25APR01–2/2

18 1830 15

TM1931 (09JAN04)

18-1830-15


PN=161


Condenser Repair Remove and Install Condenser 1. Recover refrigerant from the system. See Recover R134a Refrigerant. (See procedure in this group.) 2. Remove cap screws (1). Secure receiver-dryer (2) and bracket so it will not interfere with condenser removal. –UN–20JUL01

3. Remove cap screw, lock washer, and washer (5) and disconnect high pressure gas input line (4)

5. Remove cap screws, lock washers, washers (8) and condenser (3). 6. Repair or replace condenser as necessary. 7. Install condenser (3). 8. Tighten high pressure liquid output line (6) cap screw (7).

T143116B

4. Remove cap screw, lock washer, and washer (7) and disconnect high pressure liquid output line (6).

1—Cap Screw (2 used) 2—Receiver-Dryer 3—Condenser 4—High Pressure Gas Input Line 5—Cap Screw, Lock Washer, Washer 6—High Pressure Liquid Output Line 7—Cap Screw, Lock Washer, Washer 8—Cap Screw (4 used) Lock Washer (4 used) Washer (4 used)

Condenser—Specification Output Line Cap Screw—Torque ................................. 14 N•m (124 lb-in.)

9. Tighten high pressure gas input line (4) cap screw (5). Condenser—Specification Input Line Cap Screw—Torque .................................... 23 N•m (204 lb-in.)

10. Evacuate and charge the system. See Evacuate R134a System and Charge R134a System. (See procedures in this group.) 18 1830 16 OUOE003,00000E8 –19–19NOV01–1/1

TM1931 (09JAN04)

18-1830-16


PN=162

Section 33

Excavator Contents Page

Page

Group 3302—Buckets Bucket Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-1 Adjust Pivot End Play . . . . . . . . . . . . . . . .33-3302-3 Pin-Up Data . . . . . . . . . . . . . . . . . . . . . . . .33-3302-4

Arm Cylinder Disassemble and Assemble— 200CLC, 270CLC . . . . . . . . . . . . . . . . . 33-3360-104 Arm Cylinder Disassemble and Assemble—230CLC. . . . . . . . . . . . . . . . 33-3360-118 Bucket Cylinder Remove and Install . . . . . 33-3360-124 Bucket Cylinder Disassemble and Assemble—200CLC, 270CLC . . . . . . . . 33-3360-130 Bucket Cylinder Disassemble and Assemble—230CLC. . . . . . . . . . . . . . . . 33-3360-144 Hydraulic Cylinder Bleed Procedure . . . . . 33-3360-152

Group 3340—Frames Bucket Links . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-1 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-3 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-6 Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses . . . . . . . . . . . . . . .33-3340-11 Bushings and Seals . . . . . . . . . . . . . . . . . .33-3340-14 Group 3360—Hydraulic System Hydraulic Oil Tank Pressure Release Procedure . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-1 Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy . . . . . . . . . . . . . . . . .33-3360-2 Hydraulic Pump and Drive Gearbox Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-3 Start-Up Procedure . . . . . . . . . . . . . . . . .33-3360-20 Pilot Pump Drive Shaft and Gear . . . . . . . .33-3360-21 Hydraulic Pump Regulator. . . . . . . . . . . . . .33-3360-22 Pilot Pump . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-27 Pilot Pressure Regulating Valve and Filter Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-30 Pilot Shut-Off Valve. . . . . . . . . . . . . . . . . . .33-3360-31 Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-35 Pilot Controller . . . . . . . . . . . . . . . . . . . . . .33-3360-37 Propel Pilot Controller . . . . . . . . . . . . . . . . .33-3360-40 Pilot Signal Manifold . . . . . . . . . . . . . . . . . .33-3360-43 Control Valve . . . . . . . . . . . . . . . . . . . . . . .33-3360-49 Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . .33-3360-66 Restriction Valve Repair . . . . . . . . . . . . . . .33-3360-69 Oil Cooler Bypass Valve . . . . . . . . . . . . . . .33-3360-71 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-74 Remove and Install Boom Cylinder . . . . . . .33-3360-75 Boom Cylinder Disassemble and Assemble— 200CLC, 270CLC . . . . . . . . . . . . . . . . . .33-3360-80 Boom Cylinder Disassemble and Assemble— 230CLC . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-94 Arm Cylinder Remove and Install . . . . . . . 33-3360-100 TM1931 (09JAN04)

33-1

33


PN=1

Contents

33

TM1931 (09JAN04)

33-2


PN=2

Group 3302

Buckets Bucket Repair

6 3 3 5 7

4 3 2

1 8

–UN–24JUL01

5 1

4

2

T142450

3 T142450

1—Bushing (4 used) 2—Dust Seal (2 used)

3—O-Ring (4 used) 4—Ring (2 used)

5—Pin (2 used) 6—Pin

Remove and Install Bucket

4. Repair or replace as necessary.

CAUTION: Heavy component; use a hoist. Bucket—Specification Bucket (200CLC)—Weight ................... 670 kg (1480 lb) approximate Bucket (230CLC and 270CLC)—Weight ................................. 953 kg (2100 lb) approximate

1. Position bucket (8) on level surface.

7—Pin 8—Bucket

5. Align pin bores in bucket with pin bores in arm link to prevent damage to dust seals (2) when pins are installed. 6. Adjust bucket pivot end play. See Adjust Bucket Pivot End Play. (See procedure in this group.) 7. Adjust bucket to arm joint. See Adjusting Bucket to Arm Joint. (Operator’s Manual.)

2. Remove parts (5, 6 and 7).

33 3302 1

3. Remove bucket.


TM1931 (09JAN04)

33-3302-1

TX,33,GG2401 –19–19NOV01–1/3


PN=165

Buckets

7 6

6

8

5 9 10

11 12 2 3

13

4 2 33 3302 2

3

T142451

–UN–24JUL01

1

T142451


TM1931 (09JAN04)

33-3302-2

TX,33,GG2401 –19–19NOV01–2/3


PN=166

Buckets 1—Side Cutter (2 used) 2—Nut (12 used) 3—Washer (12 used)

4—Cap Screw (12 used) 5—Boss (2 used) 6—Shims (as required)

7—Cap Screw (6 used) 8—Washer (6 used) 9—Plate (2 used)

10—Boss (2 used) 11—Stopper (2 used) 12—Boss (2 used)

TX,33,GG2401 –19–19NOV01–3/3

Adjust Bucket Pivot End Play 1. Slide O-ring up on boss of bucket.

Bucket—Specification Bucket Pivot Bushing-to-Arm— Clearance ............................................... As close to but not less than 0.5 mm (0.020 in.)

T95775

Adjust clearance as close to specification.

–UN–10NOV88

2. Measure clearance (D) between bushing (B) and arm.

NOTE: Alternate buckets may have different adjustment procedures.

5. Install plate. Tighten cap screws. Bucket—Specification Bucket Pivot Shim-to-Plate Cap Screw—Torque ................................................................ 88 N•m (65 lb-ft)

T6879DU

4. Remove shims (E) as needed to allow bushing to move in to adjust clearance and take up excessive play.

–UN–06DEC88

3. Remove plate (F).

6. Slide O-ring back into position.

T95788

–UN–10NOV88

A—Bucket B—Bushing C—Pin D—Clearance E—Shim (As Required) F—Plate

TX,33,GG2403 –19–19NOV01–1/1

TM1931 (09JAN04)

33-3302-3


PN=167

33 3302 3

Buckets

Bucket Pin-Up Data

T142485

–19–19NOV01

33 3302 4

TX,33,GG2405 –19–19NOV01–1/1

TM1931 (09JAN04)

33-3302-4


PN=168

Group 3340

Frames Bucket Links Repair

8 7 9 6 10 12

11

3 4

2

5

1

4 3

1

–UN–24JUL01

2

T142977

5

T142977

1—Nut (4 used) 2—Cap Screw (2 used) 3—Thrust Plate (2 used)

4—Dust Seal (2 used) 5—Bushing (2 used) 6—Thrust Plate (4 used)

7—Cylinder Pin 8—Wooden Block 9—Center Link

Remove and Install Bucket Links

10—Right Side Link 11—Left Side Link 12—Pin

arm to hold cylinder up when cylinder pin (7) is removed.

NOTE: Removal of bucket is not necessary for removal of just bucket links.


1. Connect hoist to center link (9) using lifting strap. Put wooden block (8) between bucket cylinder and

As cylinder pin (7) is removed, lower links (10 and 11) to ground.

33 3340 1


TM1931 (09JAN04)

33-3340-1

TX,33,GG2406 –19–19NOV01–1/2


PN=169

Frames 3. Inspect bushings (2 and 4) and dust seals (1). See Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses. (See procedure in this group.)

1

1

4. Replace parts as necessary. 4

5. Before installing pins, align pin bores to prevent damage to dust seal when pins are installed.

4

1

3

3 2

1

T142978

1—Dust Seal (6 used) 2—Bushing (2 used) 3—Lubrication Fitting (2 used) 4—Bushing (4 used) 5—Shim (As Required) 6—Bushing (2 used) 7—Spacer

3

1

–UN–19NOV01

6. Apply multi-purpose grease to all lubrication fittings.

2 200CLC and 230CLC

1

2

5 1 7 6

1 1 1

5

6 3

5

3

T147422

1

–UN–19NOV01

2

270CLC 33 3340 2

TX,33,GG2406 –19–19NOV01–2/2

TM1931 (09JAN04)

33-3340-2


PN=170

Frames

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


TX,33,GG2407 –19–19NOV01–1/3

33 3340 3

TM1931 (09JAN04)

33-3340-3


PN=171

Frames

CAUTION: Heavy component; use a hoist. Arm—Specification Standard Arm (200CLC)—Weight ............... 593 kg (1310 lb) approximate Bucket Cylinder (200CLC)— Weight............................................................ 145 kg (320 lb) approximate Arm—Specification Long Arm (230CLC)—Weight ..................... 878 kg (1936 Standard Arm (230CLC)—Weight ............... 685 kg (1510 Short Arm (230CLC)—Weight ....................... 182 kg (400 Bucket Cylinder (230CLC)— Weight............................................................ 182 kg (400

lb) approximate lb) approximate lb) approximate lb) approximate

Arm—Specification Arm (270CLC)—Weight.................................................. 1500 kg (3306 lb) Bucket Cylinder (270CLC)— Weight............................................................ 216 kg (480 lb) approximate

T6626JC

–UN–31OCT88

8. Attach hoist to arm.

Arm With Bucket Cylinder


TX,33,GG2407 –19–19NOV01–2/3

33 3340 4

TM1931 (09JAN04)

33-3340-4


PN=172

Frames 9. Put wooden block between arm cylinder and boom to hold cylinder up when cylinder pin (6) is removed.

5

4

4

10. Remove parts (1-13). 11. Remove arm and lower to floor. 12. Inspect bushings and dust seals. See Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses. (See procedure in this group.)

6

3

1

2

13. Repair or replace parts as necessary. See Bushings and Seals Repair. (See procedure in this group.) 14. Install thrust plates (4 and 12) equally on each side of arm to get minimal amount of clearance between boom and arm.

–UN–27SEP01

15. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 16. Apply multi-purpose grease to all lubrication fittings.

T142652

1—Nut (2 used) 2—Stopper 3—Cap Screw 4—Thrust Plate (2 used) 5—Thrust Plate 6—Cylinder Pin 7—Cap Screw 8—Washer 9—Plate 10—Block 11—Pin 12—Thrust Plate (2 used) 13—Thrust Plate

13

12

10 7 8

9

T142653

11

–UN–24JUL01

12

TX,33,GG2407 –19–19NOV01–3/3

33 3340 5

TM1931 (09JAN04)

33-3340-5


PN=173

Frames

Boom Repair Remove and Install Boom 1. Remove bucket and arm. See Bucket Repair and Arm Repair. (See procedures in this group, and group 3302.) 2. Lower boom to ground. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 3. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.)

TX,33,GG2408 –19–19NOV01–1/7

–UN–23AUG88

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 4. Loosen hydraulic lines at frame end of boom to release any residual pressure.

X9811

5. Disconnect lines. 6. Disconnect wiring harness. 7. Disconnect lubrication lines at rod end of cylinders. 8. Remove arm cylinder only if necessary to repair boom. See Arm Cylinder Remove and Install. (Group 3360.)

33 3340 6


TM1931 (09JAN04)

33-3340-6

TX,33,GG2408 –19–19NOV01–2/7


PN=174

Frames

CAUTION: Heavy component; use a hoist. Boom—Specification Boom Cylinder (200CLC)— Weight............................................................ 171 kg (377 lb) approximate

–UN–30DEC96

Boom—Specification Boom Cylinder (230CLC)— Weight............................................................ 271 kg (597 lb) approximate

T105828

Boom—Specification Boom Cylinder (270CLC)— Weight............................................................ 247 kg (545 lb) approximate

9. Attach hoist to boom cylinder (F) using lifting strap. F—Boom Cylinder (2 used)

TX,33,GG2408 –19–19NOV01–3/7

10. Remove parts (1—3 and 5). 11. Push boom cylinder-to-boom pin (4) into boom. 12. Lower boom cylinder (6) on floor stand.Repeat procedure for second boom cylinder.

T142979

–UN–24JUL01

1—Nut (4 used) 2—Retainer (2 used) 3—Cap Screw (2 used) 4—Boom Cylinder Rod End-to-Boom Pin 5—Thrust Plate (4 used) 6—Boom Cylinder (2 used)


TX,33,GG2408 –19–19NOV01–4/7

33 3340 7

TM1931 (09JAN04)

33-3340-7


PN=175

Frames

CAUTION: Heavy components; use a hoist. Boom—Specification Boom (200CLC)—Weight .......................... 1230 kg (2712 lb) approximate Arm Cylinder (200CLC)—Weight .................. 259 kg (571 lb) approximate Boom—Specification Boom (230CLC)—Weight .......................... 1683 kg (3710 lb) approximate Arm Cylinder (230CLC)—Weight .................. 286 kg (630 lb) approximate Boom—Specification Boom (270CLC)—Weight .......................... 1987 kg (4380 lb) approximate Arm Cylinder (270CLC)—Weight .................. 308 kg (680 lb) approximate

13. Attach hoist to boom. Use protective covering to prevent damage to pin if chain is used.

T6626JW

–UN–31OCT88

Arm end of boom is heavy end with arm cylinder installed. Frame end is heavy end when arm cylinder is removed.


TX,33,GG2408 –19–19NOV01–5/7

33 3340 8

TM1931 (09JAN04)

33-3340-8


PN=176

Frames 14. Remove parts (1—3 and 6). 15. Insert bar between plate of boom-to-frame pin (4) and bracket (6). Pull plate out. 16. Remove boom-to-frame pin. Remove washers (5). 17. Remove boom.

–UN–24JUL01

18. Inspect bushings and dust seals. See Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses. (See procedure in this group.)

T143018

19. Repair or replace parts as necessary. See Bushings and Seals Repair. (See procedure in this group.) 20. Install washers (5) equally on each side of boom to get minimal amount of clearance between boom and frame.

1—Cap Screw 2—Spacer 3—Block 4—Boom-to-Frame Pin 5—Washer (As Required) 6—Washer 7—Bracket

21. Install boom. Tighten boom-to-frame cap screws. Boom—Specification Boom-to-Frame Cap Screw— Torque ......................................................................... 400 N•m (295 lb-ft)

22. Connect rod end of boom cylinders. Install thrust plates (5) equally on each side to get minimum amount of clearance between boom and cylinder rod end. 23. Tighten nuts (1) against each other allowing cap screw (3) to be free to turn in hole. Boom—Specification Boom Cylinder Rod End-to-Boom Pin Retainer Nut—Torque ........................ 550 N•m (405 lb-ft) (tighten nut against nut)

24. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 25. Connect wiring harness. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015-10).

33 3340 9

26. Connect lubrication lines at rod end of cylinders.


TM1931 (09JAN04)

33-3340-9

TX,33,GG2408 –19–19NOV01–6/7


PN=177

Frames 27. Apply multi-purpose grease to all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operator’s Manual.) TX,33,GG2408 –19–19NOV01–7/7

33 3340 10

TM1931 (09JAN04)

33-3340-10


PN=178

Frames

T7779AC

–UN–11JUN92

Inspect Boom, Arm, and Bucket Pins, Bushings and Bosses

A—Boom Cylinder Head End-to-Frame Joint B—Boom Cylinder Rod End-to-Boom Joint C—Boom-to-Frame Joint

D—Boom-to-Arm Joint E—Arm Cylinder Head End-to-Boom Joint F—Arm Cylinder Rod End-to-Arm Joint

G—Bucket Cylinder Head End-to-Arm Joint H—Bucket Cylinder Rod End-to-Side and Center Links Joint

Boom (200CLC)—Specification Boom Cylinder Head End-to-Frame Joint Pin (200CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Boom Cylinder Head End-to-Frame Joint Bushing (200CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Boom Cylinder Head End-to-Frame Joint Boss (200CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Pin (200CLC)—OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Bushing (200CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Boss (200CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom-to-Frame Joint Pin (200CLC)—OD ......................................... 90.0 mm (3.45 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Boom-to-Frame Joint Bushing (200CLC)—ID ........................................... 90.0 mm (3.45 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom-to-Arm Joint Pin (200CLC)—OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use

Boom-to-Arm Joint Bushing (200CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm (200CLC)—Specification Arm Cylinder Head End-to-Boom Joint Pin (200CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Arm Cylinder Head End-to-Boom Joint Bushing (200CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Arm Cylinder Head End-to-Boom Joint Boss (200CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Pin (200CLC)—OD .......................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Bushing (200CLC)—ID .................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Boss (200CLC)—ID ......................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket (200CLC)—Specification Bucket Cylinder Head End-to-Arm Joint Pin (200CLC)—OD ......................................... 71.0 mm (2.80 in.) nominal OD........................................................ 70.0 mm (2.76 in.) limit of use


TM1931 (09JAN04)

I—Side Links-to-Arm Joint J—Center Link-to-Bucket Joint K—Bucket-to-Arm Joint

33-3340-11

CED,TX08227,3206 –19–19NOV01–1/4


PN=179

33 3340 11

Frames Bucket Cylinder Head End-to-Arm Joint Bushing (200CLC)—ID ........................................... 71.0 mm (2.80 in.) nominal ID ......................................................... 72.5 mm (2.85 in.) limit of use Bucket Cylinder Head End-to-Arm Joint Boss (200CLC)—ID ........................................... 71.0 mm (2.80 in.) nominal ID ......................................................... 72.5 mm (2.85 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint Pin (200CLC)—OD .......................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint Bushings (200CLC)—ID .................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Side Links-to-Arm Joint Pin (200CLC)—OD ......................................... 71.0 mm (2.80 in.) nominal OD........................................................ 70.0 mm (2.76 in.) limit of use Side Links-to-Arm Joint Bushing (200CLC)—ID ............................. 71.0 mm (2.80 in.) nominal ID ......................................................... 72.5 mm (2.85 in.) limit of use Center Link-to-Bucket Joint Pin (200CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Center Link-to-Bucket Joint Bushing (200CLC)—ID ............................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket-to-Arm Joint Pin (200CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Bucket-to-Arm Joint Bushing (200CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use

33 3340 12

Boom (230CLC)—Specification Boom Cylinder Head End-to-Frame Joint Pin (230CLC)—OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Boom Cylinder Head End-to-Frame Joint Bushing (230CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom Cylinder Head End-to-Frame Joint Boss (230CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Pin (230CLC)—OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use

Boom Cylinder Rod End-to-Boom Joint Bushing (230CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Boss (230CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom-to-Frame Joint Pin (230CLC)—OD ....................................... 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom-to-Frame Joint Bushing (230CLC)—ID ......................................... 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom-to-Arm Joint Pin (230CLC)—OD ....................................... 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom-to-Arm Joint Bushing (230CLC)—ID ......................................... 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Arm (230CLC)—Specification Arm Cylinder Head End-to-Boom Joint Pin (230CLC)—OD ......................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Arm Cylinder Head End-to-Boom Joint Bushing (230CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Head End-to-Boom Joint Boss (230CLC)—ID ........................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Pin (230CLC)—OD .......................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Bushing (230CLC)—ID .................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Boss (230CLC)—ID ......................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Bucket (230CLC)—Specification Bucket Cylinder Head End-to-Arm Joint Pin (230CLC)—OD ......................................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Bucket Cylinder Head End-to-Arm Joint Bushing (230CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use


TM1931 (09JAN04)

33-3340-12

CED,TX08227,3206 –19–19NOV01–2/4


PN=180

Frames Bucket Cylinder Head End-to-Arm Joint Boss (230CLC)—ID ........................................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint Pin (230CLC)—OD .......................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint Bushings—ID ................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Side Links-to-Arm Joint Pin— OD............................................................. 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Side Links-to-Arm Joint Bushing—ID .............................................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Center Link-to-Bucket Joint Pin—OD .................................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Center Link-to-Bucket Joint Bushing—ID .............................................. 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Bucket-to-Arm Joint Pin—OD ................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket-to-Arm Joint Bushing— ID .............................................................. 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Boom (270CLC)—Specification Boom Cylinder Head End-to-Frame Joint Pin—OD.................. 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom Cylinder Head End-to-Frame Joint Bushing— ID ............................................................ 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom Cylinder Head End-to-Frame Joint Boss—ID................. 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Pin—OD................... 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Bushing—ID............. 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom Cylinder Rod End-to-Boom Joint Boss—ID.................. 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom-to-Frame Joint Pin—OD............... 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use

Boom-to-Frame Joint Bushing—ID ............................................ 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Boom-to-Arm Joint Pin—OD .................. 100.0 mm (3.94 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Boom-to-Arm Joint Bushing—ID ............ 100.0 mm (3.94 in.) nominal ID ......................................................... 101.5 mm (4.0 in.) limit of use Arm (270CLC)—Specification Arm Cylinder Head End-to-Boom Joint Pin—OD..................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Arm Cylinder Head End-to-Boom Joint Bushing—ID............... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Head End-to-Boom Joint Boss—ID.................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Pin—OD ........................................... 90.0 mm (3.54 in.) nominal OD........................................................ 99.0 mm (3.90 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Bushing—ID ..................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Arm Cylinder Rod End-to-Arm Joint Boss—ID .......................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Bucket (270CLC)—Specification Bucket Cylinder Head End-to-Arm Joint Pin—OD ....................... 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Bucket Cylinder Head End-to-Arm Joint Bushing—ID ................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket Cylinder Head End-to-Arm Joint Boss—ID ...................... 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint Pin—OD ........................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket Cylinder Rod End-to-Side and Center Links Joint Bushings—ID ................................... 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use Side Links-to-Arm Joint Pin— OD............................................................. 80.0 mm (3.15 in.) nominal OD........................................................ 79.0 mm (3.11 in.) limit of use Side Links-to-Arm Joint Bushing—ID .............................................. 80.0 mm (3.15 in.) nominal ID ......................................................... 81.5 mm (3.21 in.) limit of use


TM1931 (09JAN04)

33-3340-13

CED,TX08227,3206 –19–19NOV01–3/4


PN=181

33 3340 13

Frames Center Link-to-Bucket Joint Pin—OD .................................................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Center Link-to-Bucket Joint Bushing—ID .............................................. 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use

Bucket-to-Arm Joint Pin—OD ................... 90.0 mm (3.54 in.) nominal OD........................................................ 89.0 mm (3.50 in.) limit of use Bucket-to-Arm Joint Bushing— ID .............................................................. 90.0 mm (3.54 in.) nominal ID ......................................................... 91.5 mm (3.60 in.) limit of use

CED,TX08227,3206 –19–19NOV01–4/4

Bushings and Seals Repair Remove and Install Bushings and Seals IMPORTANT: Only install bushings using press as shown. Bushings will be damaged if installed with driver.

NOTE: Bushing can also be removed by welding three to five weld beads on the inside of bushing. Bushing will shrink enough to permit removal using a hammer. 1. Remove bushings (C) and dust seals using bushing, bearing, and seal driver set.

3. Install bushing to a depth equal to thickness of dust seal (H).

–UN–31OCT88

A—Hydraulic Ram B1—Pipe—Minimum ID to Clear Bushing OD B2—Pipe—Maximum OD B3—Pipe—Length of Bushing C—Bushing D—Disks E—Bushing Stop (Disk) F—Pilot (Disk) G—Ram Stop (Disk) H—Thickness of Dust Seal

T6641CW

33 3340 14

T95237

4. Install dust seals with lip toward outside of component.

–UN–01NOV88

2. Install bushings with lubrication hole aligned with lubrication passage in pivot.

CED,OUOE023,2178 –19–19NOV01–1/1

TM1931 (09JAN04)

33-3340-14


PN=182

Group 3360

Hydraulic System Hydraulic Oil Tank Pressure Release Procedure CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. Relieve pressure by SLOWLY loosening cap (1). 1. Insert 4 mm hex wrench (4) into hole (5) and turn counterclockwise to release locking pin.

–UN–06NOV00

2. Slowly turn cap (1) counterclockwise a few degrees to relieve pressure. 3. Remove cap.

T135189

1—Cap 2—Aligning Marks 3—Case Assembly 4—4 mm Hex Key Wrench 5—Hole

OUOE054,000000F –19–07OCT02–1/1

33 3360 1

TM1931 (09JAN04)

33-3360-1


PN=183

Hydraulic System

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy SPECIFICATIONS

four times.

Hydraulic Oil Tank (200CLC) Hydraulic Oil Tank (200CLC)—Specification Hydraulic Oil Tank—Capacity.................. 130 L (34 gal) approximate Filtering Time ................................................. 11 minutes approximate

Hydraulic Oil Tank Capacity

130 L (34 gal) approximate

Hydraulic Oil Tank Filtering Time

11 minutes approximate

Hydraulic System Capacity

200 L (52.4 gal) approximate

Hydraulic System Filtering Time


Hydraulic Oil Tank (230CLC and 270CLC)—Specification Hydraulic Oil Tank—Capacity.................. 148 L (39 gal) approximate Filtering Time ................................................. 13 minutes approximate

Hydraulic Oil Tank (230CLC and 270CLC) Hydraulic Oil Tank Capacity


Hydraulic Oil Tank Filtering Time


Hydraulic System Capacity


Hydraulic System Filtering Time


NOTE: Filtering time for hydraulic tank is 0.089 minute x number of liters (0.33 minutes x number of gallons). 4. Leave filter caddy operating for the next step. 5. Start the engine and run it at fast idle.

SERVICE EQUIPMENT AND TOOLS Portable Filter Caddy 3658 mm (12 ft) x 3/4 in. ID 100R1 Hose with 3/4 M NPT Ends (2 used) Quick Disconnect Fittings Suction Wand

IMPORTANT: For the most effective results, cleaning procedure must start with the smallest capacity circuit then proceed to the next larger capacity circuit.

Discharge Wand

6. Starting with the smallest capacity circuit, operate each function through a complete cycle.

1. Install new return filter elements.

NOTE: For a failure that creates a lot of debris, remove access cover from hydraulic tank. Drain hydraulic tank. Connect filter caddy suction line to drain port. Add a minimum of 19 L (5 gal) of oil to reservoir. Operate filter caddy and wash out the hydraulic tank. IMPORTANT: The minimum ID for a connector is 13 mm (1/2 in.) to prevent cavitation of filter caddy pump. 2. Put filter caddy suction and discharge wands into hydraulic tank filler hole so ends are as far apart as possible to obtain a thorough cleaning of oil. 33 3360 2

3. Start the filter caddy. Check to be sure oil is flowing through the filters. Operate filter caddy until all the oil in hydraulic tank has been circulated through the filter a minimum of

Repeat procedure until the total system capacity has circulated through filter caddy seven times. Each function must go through a minimum of three complete cycles for a thorough cleaning of oil. Hydraulic Oil Tank (200CLC)—Specification Hydraulic System—Capacity ................ 200 L (52.4 gal) approximate Filtering Time ................................................. 17 minutes approximate Hydraulic Oil Tank (230CLC and 270CLC)—Specification Hydraulic System—Capacity ................... 250 L (66 gal) approximate Filtering Time ................................................. 22 minutes approximate

NOTE: Filtering time for complete hydraulic system is 0.158 minute x number of liters (0.6 minute x number of gallons). Filtering time for machines with auxiliary hydraulic functions must be increased because system capacity is larger. 7. Stop the engine. Remove the filter caddy. 8. Install new return filter elements.


TM1931 (09JAN04)

33-3360-2

OUOE027,000001D –19–19NOV01–1/2


PN=184

Hydraulic System 9. Check Hydraulic Oil. (Operator’s Manual.)

OUOE027,000001D –19–19NOV01–2/2

Hydraulic Pump and Drive Gearbox Repair Remove and Install Hydraulic Pump and Drive Gearbox CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Drain hydraulic oil tank. Approximate capacity is 130 L (34 gal) for 200CLC and 148 L (39 gal) for 230CLC and 270CLC. 3. Drain pump drive gearbox. Approximate oil capacity is 1.0 L (1.1 qt). 4. Remove hood, hood support and covers. 5. Remove muffler and muffler bracket. 6. Disconnect electrical connectors. 7. Disconnect lines. CAUTION: Heavy component; use a hoist. Hydraulic Pump and Drive Gearbox—Specification Hydraulic Pump and Drive Gearbox—Weight .......................................... 168 kg (370 lb) approximate

8. Install lifting eyebolts to pump. Connect a hoist to eyebolts using lifting straps. 33 3360 3


TM1931 (09JAN04)

33-3360-3

OUOE027,0000017 –19–19NOV01–1/21


PN=185

Hydraulic System 9. Remove cap screws (1) and remove pump. 10. Repair or replace as necessary. IMPORTANT: Align dampener drive on drive gearbox with mating part on engine flywheel. 11. Tighten cap screws (1). Hydraulic Pump and Drive Gearbox—Specification Pump Drive Gearbox-to-Flywheel Housing Cap Screw—Torque.......................................... 49 N•m (36 lb-ft)

–UN–20JUL01

12. Connect electrical connectors. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015.)

T142503

13. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 14. Install split flange and tighten cap screws. 1—Cap Screw (6 used) Hydraulic Pump and Drive Gearbox—Specification Split Flange 8 mm Cap Screw— Torque ............................................................................. 50 N•m (37 lb-ft) Split Flange 10 mm Cap Screw— Torque ............................................................................. 90 N•m (67 lb-ft)

15. Apply pipe sealant to pump drive gearbox drain plug threads. IMPORTANT: Hydraulic pump and drive gearbox will be damaged if not filled with oil before starting engine. Start-up procedure must be performed whenever a new pump or gearbox is installed or oil has been drained from the pump, gearbox or hydraulic oil tank. 16. Fill pump housing and pump drive gearbox with oil. See Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.) 17. Check pump regulator adjustments. (Group 9025-25.) 33 3360 4

For minimum flow:


TM1931 (09JAN04)

33-3360-4

OUOE027,0000017 –19–19NOV01–2/21


PN=186

Hydraulic System • See Hydraulic Pump Regulator Test and Adjustment—Minimum Flow—200CLC. (Group 9025-25.) • See Hydraulic Pump Regulator Test and Adjustment—Minimum Flow—230CLC. (Group 9025-25.) • See Hydraulic Pump Regulator Test and Adjustment—Minimum Flow—270CLC. (Group 9025-25.) For maximum flow: • See Hydraulic Pump Regulator Test and Adjustment—Maximum Flow—200CLC. (Group 9025-25.) • See Hydraulic Pump Regulator Test and Adjustment—Maximum Flow—230CLC. (Group 9025-25.) • See Hydraulic Pump Regulator Test and Adjustment—Maximum Flow—270CLC. (Group 9025-25.) Disassemble and Assemble Hydraulic Pump and Drive Gearbox


OUOE027,0000017 –19–19NOV01–3/21

33 3360 5

TM1931 (09JAN04)

33-3360-5


PN=187

Hydraulic System

10 7

9

8

11

21

22

23

20

19

24

12 18 17 16

6

15

13

13

5

14

23

4

22

3 2

21

25

20

18

1

26 17

32

16 15

33 32

29

31 27

28

27

30 28

35

37

36

34

56

46 47

39

55

45

40

38 35

41

54 57 44

43

42

48 49 50 51

58

53

52

T142373

T142373

51


TM1931 (09JAN04)

33-3360-6

–UN–20JUL01

33 3360 6

OUOE027,0000017 –19–19NOV01–4/21


PN=188

Hydraulic System 1—Pump Housing 2—Lock Washer (6 used) 3—Cap Screw (6 used) 4—Spring Pin (4 used) 5—O-Ring (10 used) 6—O-Ring (2 used) 7—Cap Screw (4 used) 8—Right Regulator Pump 1 (Front) 9—Cap Screw (2 used) 10—Cap Screw (2 used) 11—Cap Screw (2 used) 12—Left Regulator Pump 2 (Rear) 13—O-Ring (4 used) 14—O-Ring (6 used)

15—Bearing Nut (2 used) 16—Roller Bearing (2 used) 17—Ring (2 used) 18—Roller Bearing (2 used) 19—Pump 1 (Front) Drive Shaft 20—Pin (2 used) 21—Center Shaft (2 used) 22—Spring (2 used) 23—Piston (14 used) 24—Cylinder Block (Rotor) (2 used) 25—Pump 2 (Rear) Drive Shaft 26—Spacer Ring (Pump 2 [Rear] Drive Shaft only) 27—O-Ring (2 used)

28—Plug (2 used) 29—O-Ring 30—Special Fitting 31—Spring Pin (2 used) 32—Oil Seal (2 used) 33—Snap Ring (2 used) 34—Fill Plug 35—Snap Ring (2 used) 36—Pump 1 (Front) Driven Gear 37—Gasket 38—Cap Screw (2 used) 39—Pump 2 (Rear) Drive Gear 40—Dipstick 41—Dipstick Tube 42—Gasket


43—Drain Plug 44—O-Ring 45—Cap Screw (2 used) 46—Lock Washer (2 used) 47—Washer (2 used) 48—Pilot Pump 49—Snap Ring 50—Snap Ring 51—Ball Bearing 52—Pilot Pump Drive Gear 53—Pilot Pump Drive Shaft 54—Snap Ring 55—Oil Seal 56—Pump Drive Gearbox 57—Set Screw (2 used) 58—Dampener Drive Coupling

OUOE027,0000017 –19–19NOV01–5/21

33 3360 7

TM1931 (09JAN04)

33-3360-7


PN=189

Hydraulic System

72 71

73

70

74 71

68 67

75

62 63

60

64 63

60 61

69 62

60

76

62

66

63

59

78

65

60

77 63

60

62

61 66

82

60

60

79 80

59 81

T142375

–UN–20JUL01

82

T142375 33 3360 8

59—Dowel Pin 60—Snap Ring (12 used) 61—Dowel Pin (2 used) 62—Lever (4 used) 63—Dowel Pin (4 used) 64—Pump 1 (Front) Valve Plate

65—Pump 2 (Rear) Valve Plate 66—Dowel Pin (4 used) 67—Backup Ring 68—O-Ring 69—Spring Pin (2 used) 70—Cylinder Head (Cover)

71—O-Ring (4 used) 72—Cap Screw (8 used) 73—Cover (2 used) 74—O-Ring (2 used) 75—Cap Screw (12 used) 76—Set Screw (2 used)


TM1931 (09JAN04)

33-3360-8

77—Servo Piston (2 used) 78—Pin (2 used) 79—O-Ring (2 used) 80—Stop (2 used) 81—Cap Screw (8 used) 82—Feedback Link (2 used)

OUOE027,0000017 –19–19NOV01–6/21


PN=190

Hydraulic System

CAUTION: Heavy component; use a hoist. Hydraulic Pump and Drive Gearbox—Specification Hydraulic Pump and Drive Gearbox—Weight ................................... 168 kg (370 lb) approximate

2. Remove pilot pump (48). 3. Remove cap screws (3) and lock washers (2) to remove pump housing (1) from pump drive gearbox (56).

1. Loosen set screws (57) and remove dampener drive coupling (58).


OUOE027,0000017 –19–19NOV01–7/21

33 3360 9

TM1931 (09JAN04)

33-3360-9


PN=191

Hydraulic System 4. To aid in reassembly, make timing marks on drive shafts (A and C), and mark (B) on drive (E) and driven (F) gears. The gears are not interchangeable.

–UN–11DEC96

Measure amount of backlash between gears.

T105624

Hydraulic Pump and Drive Gearbox—Specification Pump Drive and Driven Gear— Backlash ........................................................ 0.68 mm (0.027 in.) nominal 1.50 mm (0.059 in.) limit of use

Remove snap rings (D) and remove gears (E and F). 5. Remove pump regulators (8 and 12). For repair. See Hydraulic Pump Regulator Repair. (See procedure in this group.)

A—Pump 1 (Front) Drive Shaft-to-Driven Gear Timing Mark B—Driven Gear-to-Drive Gear Timing Mark C—Pump 2 (Rear) Drive Shaft-to-Drive Gear Timing Mark D—Snap Ring (2 used E—Drive Gear F—Driven Gear

CAUTION: Heavy component; use a hoist. Hydraulic Pump and Drive Gearbox—Specification Cylinder Head—Weight ..................................... 30 kg (66 lb) approximate

IMPORTANT: The valve plates (64 and 65) are connected to the feedback linkage and must remain on the cylinder blocks (24). The valve plates and end of cylinder blocks are made with highly machined surfaces and can be damaged. 6. Remove cap screws (75) and carefully remove cylinder head (70). 7. Remove servo pistons (77) only if replacement is necessary. Heat set screw (76) to loosen thread lock and sealer (medium strength) used. Remove set screw using a 6 mm hex key wrench. Remove pin (78).

33 3360 10


TM1931 (09JAN04)

33-3360-10

OUOE027,0000017 –19–19NOV01–8/21


PN=192

Hydraulic System IMPORTANT: Pump 1 (front) (64) and pump 2 (rear) (65) valve plates are not interchangeable. Take notice of the location and position of ports in plate. The inlet port in valve plate is located towards the center and top of pump housing. 8. Remove pump 1 (front) (64) and pump 2 (rear) (65) valve plates. Protect machined surfaces of plates from damage. 9. Remove special fittings (30) before removing pump 1 (front) (19) and pump 2 (rear) (25) drive shafts. 10. Remove spacer ring (26) for pump 2 (rear) drive shaft (25) from bore. 11. Remove bearing nut (15) using JDG769 Spanner Wrench. 12. Remove roller bearings (16 and 18) from pump 1 (front) (19) and pump 2 (rear) (25) drive shafts using a knife edge puller and a press.

OUOE027,0000017 –19–19NOV01–9/21

13. Measure diameter of oil seal contact surfaces (A, B, and D) on pump 1 (front) (E) and pump 2 (rear) (C) drive shafts.

T105725

–UN–09JAN97

Hydraulic Pump and Drive Gearbox—Specification Pump 2 (Rear) Drive Shaft Oil Seal Contact Surface (A)—OD .......................... 45 mm (1.77 in.) nominal 44.8 mm (1.76 in.) limit of use Pump 2 (Rear) Drive Shaft Oil Seal Contact Surface (B)—OD .......................... 55 mm (2.17 in.) nominal 54.8 mm (2.16 in.) limit of use Pump 1 (Front) Drive Shaft Oil Seal Contact Surface—OD ................................ 55 mm (2.17 in.) nominal 54.8 mm (2.16 in.) limit of use A—Oil Seal Contact Surface B—Oil Seal Contact Surface C—Pump 2 (Rear) Drive Shaft D—Oil Seal Contact Surface E—Pump 1 (Front) Drive Shaft


TM1931 (09JAN04)

33-3360-11

OUOE027,0000017 –19–19NOV01–10/21


PN=193

33 3360 11

Hydraulic System 14. Measure play (H) between piston connecting rod (F) and socket in front and rear drive shafts (G). Hydraulic Pump and Drive Gearbox—Specification Piston-to-Drive Shaft Socket— Play ............................................................ 0.058 mm (0.0023 in.) nominal 0.400 mm (0.0157 in.) limit of use

T105726

–UN–09JAN97

F—Piston Connecting Rod G—Rear Drive Shaft H—Play

OUOE027,0000017 –19–19NOV01–11/21

15. Measure ID of cylinder block piston bore. Measure OD of piston. Subtract the OD from the ID for clearance.

–UN–18OCT88

T6557EM

–UN–18OCT88

Hydraulic Pump and Drive Gearbox—Specification Cylinder Block Bore-to-Piston— Clearance .................................................. 0.043 mm (0.0017 in.) nominal 0.080 mm (0.0032 in.) limit of use

T6557EN

33 3360 12


TM1931 (09JAN04)

33-3360-12

OUOE027,0000017 –19–19NOV01–12/21


PN=194

Hydraulic System 16. Clamp the connecting rod end of a piston in a vise with soft-jaw faces. Measure play between connecting rod and piston.

T6557EK

–UN–18OCT88

Hydraulic Pump and Drive Gearbox—Specification Piston-to-Connecting Rod—Play ............... 0.150 mm (0.0059 in.) nominal 0.400 mm (0.0157 in.) limit of use

OUOE027,0000017 –19–19NOV01–13/21

17. Measure OD (C) of small and large end of servo piston (D). Measure ID (B) of small and large end of bore in cylinder head (A). Subtract the OD from the ID for clearances. Hydraulic Pump and Drive Gearbox—Specification Servo Piston-to-Cylinder Head Bore—Clearance ....................................... 0.079 mm (0.0033 in.) nominal 0.200 mm (0.0078 in.) limit of use

T105727

–UN–19DEC96

A—Cylinder Head B—ID C—OD D—Servo Piston


OUOE027,0000017 –19–19NOV01–14/21

33 3360 13

TM1931 (09JAN04)

33-3360-13


PN=195

Hydraulic System 18. Measure OD (C) of servo piston pin (B). Measure ID (D) of bore in valve plate (A). Subtract the OD from the ID for the clearance.

–UN–09JAN97

Hydraulic Pump and Drive Gearbox—Specification Servo Piston Pin-to-Valve Plate Bore—Clearance ....................................... 0.051 mm (0.0020 in.) nominal 0.300 mm (0.0118 in.) limit of use

T105729

A—Valve Plate B—Piston Pin C—OD D—ID


OUOE027,0000017 –19–19NOV01–15/21

33 3360 14

TM1931 (09JAN04)

33-3360-14


PN=196

Hydraulic System

CAUTION: DO NOT heat oil over 182°C (360°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns.

–UN–12DEC96

19. Heat roller bearings (6 and 8).

T105658

Hydraulic Pump and Drive Gearbox—Specification Roller Bearing Heat— Temperature ......................................................... 50—80°C (122—176°F)

20. Apply oil to bearing. Push roller bearing (6) on drive shaft so inner race is tight against shoulder. 21. Install spacer ring (7) and roller bearing (8). 22. Apply oil to threads of bearing nut (9). 23. Tighten bearing nut using JDG769 Spanner Wrench.

–UN–12DEC96

Hydraulic Pump and Drive Gearbox—Specification Pump Drive Shaft Bearing Nut— Rolling Drag Torque .................................. 2.16 ± 0.49 N•m (19 ± 4 lb-in.)

T105660

3—Pump 2 (Rear) Drive Shaft 4—Pump 1 (Front) Drive Shaft 6—Roller Bearing 7—Spacer Ring 8—Roller Bearing 9—Bearing Nut

OUOE027,0000017 –19–19NOV01–16/21

24. Install spacer ring (10) into housing bore for pump 2 (rear) drive shaft.

33 3360 15

T105628

–UN–11DEC96

10—Spacer Ring


TM1931 (09JAN04)

33-3360-15

OUOE027,0000017 –19–19NOV01–17/21


PN=197

Hydraulic System 25. To help installation of drive shafts (3 and 4), heat pump housing using a heat gun such as the JT07010 Two Temperature Heat Gun.

–UN–11DEC96

Hydraulic Pump and Drive Gearbox—Specification Pump Housing Heat— Temperature ......................................................... 50—80°C (122—176°F)

T105626

26. Apply a film of oil to outer race of bearings. Install the drive shafts. 27. Install and tighten special fittings (15). Hydraulic Pump and Drive Gearbox—Specification Special Plug-to-Pump Housing Special Fitting—Torque ................................................ 34 N•m (300 lb-in.)

3—Drive Shaft 4—Drive Shaft 15—Special Fitting (2 used)

28. Apply multi-purpose grease to lips of oil seals. Install oil seals with lip (spring side) toward inside of housing. Install snap rings.


OUOE027,0000017 –19–19NOV01–18/21

33 3360 16

TM1931 (09JAN04)

33-3360-16


PN=198

Hydraulic System 29. For original parts, install drive (E) and driven (F) gears on shafts so timing marks (A, B, and C) are aligned.

–UN–11DEC96

For new parts, install the JDG1054 Aligning Bar on the socket (I and J) end of drive shafts.

T105624

Install aligning bar so end marked “Long Shaft Side” is to pump 2 (rear) drive shaft (H). Turn shafts so socket alignment dowels (L and M) engage a socket in drive shafts. The socket for pump 1 (front) drive shaft is slightly below the centerline of socket for pump 2 (rear) drive shaft when shafts are timed correctly. Install cap screws (N) to hold bar in position.

–UN–04OCT94

30. From the splined end of shafts, turn shafts to the left to remove any play between socket alignment dowels and sockets.

T8323AQ

31. Install gear on pump 2 (rear) drive shaft. Install the snap ring. Install gear on pump 1 (front) drive shaft. As necessary, turn shaft slightly or turn gear to another position so teeth on gears engage. Install snap ring.

A—Pump 1 (Front) Drive Shaft-to-Driven Gear Timing Mark B—Driven Gear-to-Drive Gear Timing Mark C—Pump 2 (Rear) Drive Shaft-to-Drive Gear Timing Mark D—Snap Ring (2 used) E—Drive Gear F—Driven Gear G—JDG1054 Aligning Bar (Pump Timing Tool) H—Pump 2 (Rear) Drive Shaft I—Socket J—Socket K—Pump 1 (Front) Drive Shaft L—Socket Alignment Dowel M—Socket Alignment Dowel N—M8-1.25 Cap Screw (2 used)

32. Apply oil to center shaft (21), pistons (23) and cylinder blocks (24). Use petroleum jelly to hold pin (20) in hole in center shaft. 33. Install cylinder block so pin engages slot in cylinder block. 34. Apply thread lock and sealer (medium strength) to threads of dowel pins (63). Tighten dowel pins into pump 1 (front) (64) and pump 2 (rear) (65) valve plates. Hydraulic Pump and Drive Gearbox—Specification Dowel Pin-to-Pump 1 (Front) and Pump 2 (Rear) Valve Plate— Torque ........................................................................... 9.8 N•m (86 lb-in.)

33 3360 17


TM1931 (09JAN04)

33-3360-17

OUOE027,0000017 –19–19NOV01–19/21


PN=199

Hydraulic System IMPORTANT: Pump 1 (front) (64) and pump 2 (rear) (65) valve plates are not interchangeable. The inlet port in valve plate is located toward the center and top of pump housing. 35. Apply oil to valve plates. Install valve plates so inlet port is toward the center and top of pump housing. Connect levers (62) for feedback linkage to valve plates. 36. Install servo pistons (77) and pins (78). Apply thread lock and sealer (medium strength) to threads of set screw (76). Tighten set screw (76) using a 6 mm hex key wrench. Hydraulic Pump and Drive Gearbox—Specification Servo Piston-to-Pin Set Screw— Torque .......................................................................... 34 N•m (300 lb-in.)

Tighten cap screws (72) for stop (80) and cover (73). Hydraulic Pump and Drive Gearbox—Specification Stop and Cover-to-Cylinder Head Cap Screw—Torque .................................................. 19.5 N•m (180 lb-in.)

37. Install cylinder head (70) checking to be sure that pins engage middle hole in valves plates. Tighten cap screws (75). Hydraulic Pump and Drive Gearbox—Specification Cylinder Head-to-Pump Housing Cap Screw—Torque ...................................................... 108 N•m (80 lb-ft)

38. Remove air bleed plugs from pump regulators (8 and 12).

33 3360 18

Install regulators making sure groove in remote control sleeve and load sleeve engage dowel pin (61) in feedback link (82). Check through hole that groove in sleeves engage dowel pin.


TM1931 (09JAN04)

33-3360-18

OUOE027,0000017 –19–19NOV01–20/21


PN=200

Hydraulic System Tighten cap screws. Hydraulic Pump and Drive Gearbox—Specification Regulator-to-Pump Housing Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

39. Tighten pump pressure sensors. Hydraulic Pump and Drive Gearbox—Specification Pump Pressure Sensor-to-Pump Housing—Torque............................................................. 98 N•m (72 lb-ft)

40. Tighten cap screws (3). Hydraulic Pump and Drive Gearbox—Specification Pump Housing-to-Gearbox Housing Cap Screw—Torque...................................... 147 N•m (109 lb-ft)

41. Apply rigid form-in-place gasket to mounting surface for pilot pump (48). Tighten cap screws (45). Hydraulic Pump and Drive Gearbox—Specification Pilot Pump-to-Gearbox Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

42. Apply multi-purpose grease to lips of oil seal (55). Install oil seal with lip (spring side) toward inside of housing. 43. Apply thread lock and sealer (medium strength) to threads of set screws (57) in dampener drive coupling (58). Tighten set screws. For assembly of dampener drive. See Dampener Drive (Flex Coupling) Repair. (Group 0752.) Hydraulic Pump and Drive Gearbox—Specification Dampener Drive Hub-to-Pump 2 (Rear) Drive Shaft Set Screw— Torque ........................................................................... 108 N•m (80 lb-ft)

44. Fill pump and pump drive gearbox with oil. See Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)

33 3360 19

OUOE027,0000017 –19–19NOV01–21/21

TM1931 (09JAN04)

33-3360-19


PN=201

Hydraulic System

Hydraulic Pump and Drive Gearbox Start-Up Procedure IMPORTANT: Hydraulic pump and drive gearbox will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump or gearbox is installed or oil has been drained from the pump, gearbox or hydraulic oil tank. Procedure is to ensure the pumps and gearbox are filled with oil and air is bled from suction side of pumps to prevent cavitation.

–UN–15JUL96

1. Remove air bleed plugs (C) from the top of pump regulators to allow housing to fill with oil from the hydraulic oil tank and to let air escape. 2. When pump housing is full of oil, install plugs.

4. Start engine and run at slow idle. Slowly raise boom to full height and then lower to pressurize hydraulic oil tank.

T101875

3. As necessary, add oil to hydraulic oil tank until it is between marks on sight glass. See Hydraulic Oil. (Operator’s Manual). Tighten tank cap. Tighten vent plug. C—Air Bleed Plug (2 used)

5. Purge air from the hydraulic system by slowly operating each function through three cycles. Air in pilot circuits are purged automatically.

TX,25,GG2226 –19–19NOV01–1/2

6. Fill pump drive gearbox with oil through filler pipe (B) so level is above “H” mark on dipstick (A). See Swing Gearbox, Propel Gearbox and Pump Gearbox Oils. (Operator’s Manual.) –UN–15JUL96

A—Dipstick B—Filler Pipe

T101493

33 3360 20

TX,25,GG2226 –19–19NOV01–2/2

TM1931 (09JAN04)

33-3360-20


PN=202

Hydraulic System

Pilot Pump Drive Shaft and Gear Repair

2. Remove pilot pump drive shaft (4) and upper ball bearing (5) using a blind-hole puller or an internal puller. Ball bearings are a press fit on drive shaft and in housing.

T105640

1. Remove snap rings (6 and 7).

–UN–12DEC96

Disassemble and Assemble Pilot Pump Drive Shaft and Gear

3. Remove pilot pump drive gear (3) through opening for hydraulic pump.

T142290

–UN–20JUL01

T105657

–UN–12DEC96

1—Pump Drive Gearbox Case 3—Pilot Pump Drive Gear 4—Pilot Pump Drive Shaft 5—Ball Bearing (2 used) 6—Snap Ring 7—Snap Ring

OUOE027,0000018 –19–19NOV01–1/1

33 3360 21

TM1931 (09JAN04)

33-3360-21


PN=203

Hydraulic System

Hydraulic Pump Regulator Repair Remove and Install Hydraulic Pump Regulator

NOTE: Pump 1 (front) and pump 2 (rear) regulators are similar in design. Removal of pump 2 (rear) regulator is shown. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.) 3. Disconnect lines. 4. Disconnect electrical connectors.


OUOE027,000001A –19–19NOV01–1/5

33 3360 22

TM1931 (09JAN04)

33-3360-22


PN=204

Hydraulic System 5. Remove cap screws (1) and regulator (2). 6. Repair or replace parts as necessary. 7. Install regulators making sure groove in remote control sleeve and load sleeve engage dowel pin in feedback link. Check through hole that groove in sleeves engage dowel pin. 8. Tighten cap screws (1).

–UN–20JUL01

Pump Regulator—Specification Pump 1 (Front) and Pump 2 (Rear) Regulator-to-Pump Housing Cap Screw—Torque.......................................... 49 N•m (36 lb-ft)

T142278B

9. Connect electrical connectors. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend. (Group 9015-10.) 10. Connect lines. See Pilot Signal Manifold-to-Control Valve Component Location. (Group 9025-15.)

1—Cap Screw (8 used) 2—Hydraulic Pump Regulator (2 used)

IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump installed or oil has been drained from the pump or hydraulic oil tank. 11. Fill pump housing with oil. See Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)


OUOE027,000001A –19–19NOV01–2/5

33 3360 23

TM1931 (09JAN04)

33-3360-23


PN=205

T142272B

–UN–20JUL01

Hydraulic System

Pump 2 (Rear) Regulator Shown 1—Cap Screw (4 used) 2—Nut 3—Nut (2 used) 4—Minimum Flow Adjusting Screw 5—Cover 6—Nut (2 used) 7—Load Adjusting Cartridge

8—O-Ring (3 used) 9—Load Adjusting Screw (Stop) 10—Regulator Body 11—Cap Screw (4 used) 12—End Plate 13—Flow Adjusting Cartridge 14—Maximum Flow Adjusting Screw (Stop)

15—Spring (2 used) 16—Remote Control Spool 17—Remote Control Sleeve 18—O-Ring 19—Backup Ring 20—O-Ring 21—Cylinder

22—Piston 23—Load Piston 24—Cylinder 25—Load Sleeve 26—Load Spool 27—Inner Spring

Disassemble and Assemble Hydraulic Pump Regulator

1. Remove the end plate (12) and cover (5) with the adjusting screws and cartridges installed.

NOTE: Pump 1 (front) and pump 2 (rear) regulators are similar. Pump 2 (rear) regulator is shown,

2. Repair or replace parts as necessary. 3. Tighten cap screws (1 and 11).

33 3360 24

IMPORTANT: Removal of adjusting screws (4, 9 and 14) and cartridges (7 and 13) from end plate (12) and cover (5) will required the adjustment of pump regulators. Only remove parts from end plate and cover if replacement is necessary.

Pump Regulator—Specification Pump 1 (Front) and Pump 2 (Rear) End Plate and Cover-to-Housing Cap Screw— Torque................................................................. 19.8 N•m (180 lb-in.)


TM1931 (09JAN04)

33-3360-24

OUOE027,000001A –19–19NOV01–3/5


PN=206

T105706

–UN–09JAN97

Hydraulic System

2—Load Sleeve 3—Load Spool 5—Cylinder 6—Load Piston 12—Load Adjusting Cartridge (Stop) —Flow Adjusting Cartridge (Stop)

13—Load Adjusting Screw (Stop) 15—Spring 16—Nut (2 used) 17—Nut (2 used) 20—Piston 21—Cylinder

24—Maximum Flow Adjusting Screw (Stop) 27—Remote Control Sleeve 28—Remote Control Spool 29—Minimum Flow Adjusting Screw

34—Nut 35—End Plate 36—Cover 37—Cap Screw (8 used) 47—Outer Spring 48—Inner Spring

4. Tighten cap screws.

For minimum flow:

5. Tighten air bleed plug.

• See Hydraulic Pump Regulator Test and Adjustments—Minimum Flow—200CLC. (Group 9025-25.) • See Hydraulic Pump Regulator Test and Adjustments—Minimum Flow—230CLC. (Group 9025-25.) • See Hydraulic Pump Regulator Test and Adjustment—Minimum Flow—270CLC. (Group 9025-25.)

Pump Regulator—Specification Pump 1 (Front) and Pump 2 (Rear) Air Bleed Plug-to-Housing—Torque ......................................... 78 N•m (58 lb-ft)

IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting engine. Procedure must be performed whenever a new pump installed or oil has been drained from the pump or hydraulic oil tank. 6. Fill pump housing with oil. See Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.) 7. Check pump regulator adjustments. (Group 9025-25.)

For maximum flow: • See Hydraulic Pump Regulator Test and Adjustments—Maximum Flow—200CLC. (Group 9025-25.) • See Hydraulic Pump Regulator Test and Adjustments—Maximum Flow—230CLC. (Group 9025-25.)


TM1931 (09JAN04)

33-3360-25

OUOE027,000001A –19–19NOV01–4/5


PN=207

33 3360 25

Hydraulic System • See Hydraulic Pump Regulator Test and Adjustment—Maximum Flow—270CLC. (Group 9025-25.)

OUOE027,000001A –19–19NOV01–5/5

33 3360 26

TM1931 (09JAN04)

33-3360-26


PN=208

Hydraulic System

Pilot Pump Repair Remove and Install Pilot Pump CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.)

–UN–20JUL01

2. Drain pump drive gearbox. Approximate oil capacity is 1.0 L (1.1 qt).

T142279B

3. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.) 4. Disconnect lines.

1—Adapter 2—Cap Screw (2 used) 3—Pilot Pump

5. Remove adapter (1). 6. Remove cap screws (2) and pilot pump (3). 7. Repair or replace parts as necessary. 8. Apply Rigid Form-In-Place Gasket to mounting surface for pilot pump. 9. Tighten cap screw (2). Pilot Pump—Specification Pump-to-Drive Gearbox Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

10. Install adapter (1) and O-ring. 11. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 12. Fill pump drive gearbox so level is above “H” mark on dipstick. See Change Pump Drive Gearbox Oil. (Operator’s Manual.)

33 3360 27


TM1931 (09JAN04)

33-3360-27

OUOE027,000001B –19–19NOV01–1/4


PN=209

Hydraulic System

TP47901

–UN–13MAY96

33 3360 28

0—Pilot Pump 2—Flange 3—Oil Seal

5—Snap Ring 6—Seal (2 used) 9—Backup Retainer (2 used)

10—Key (2 used) 12—O-Ring (2 used) 15—Washer (4 used)


TM1931 (09JAN04)

33-3360-28

16—Cap Screw and Washer (4 used)

OUOE027,000001B –19–19NOV01–2/4


PN=210

Hydraulic System Disassemble and Assemble Pilot Pump

OUOE027,000001B –19–19NOV01–3/4

IMPORTANT: Be careful not to lose keys (B). 1. Check bushings (D). If inside diameter and surface toward gear are rough or worn, replace pump. –UN–13MAY92

2. Check gears (A and C) and housing. If gear teeth, shaft, and inside of housing is rough or worn, replace pump.

3. Apply clean hydraulic oil to all parts. 4. Apply multi-purpose grease to lip of oil seal. Install oil seal with lip (spring side) towards inside of housing.

T7685IX

IMPORTANT: Apply clean hydraulic oil to all parts. Pump failure can result if pump is assembled dry. A—Drive Gear B—Keys (2 used) C—Driven Gear D—Bushing

5. Tighten cap screws. Pilot Pump—Specification Cover-to-Flange Cap Screw— Torque ............................................................................. 41 N•m (31 lb-ft)

6. Check pilot pressure setting. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

OUOE027,000001B –19–19NOV01–4/4

33 3360 29

TM1931 (09JAN04)

33-3360-29


PN=211

Hydraulic System

Pilot Pressure Regulating Valve and Filter Repair Remove and Install Pilot Pressure Regulating Valve and Filter CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Disconnect lines.

OUOE027,000001F –19–19NOV01–1/3

3. Remove cap screws (1) and remove pilot pressure regulating valve (2) and pilot filter (3). 4. Repair or replace parts as necessary. 5. Install cap screws (1). Pilot Pressure Regulating Valve and Filter—Specification Filter Head-to-Support Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

6. Replace pilot filter (3) element. –UN–20JUL01

Pilot Pressure Regulating Valve and Filter—Specification Pilot Filter Element Housing-to-Filter Head—Torque .................................. 25 N•m (220 lb-in.)

33 3360 30

T143074B

7. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 8. Check pilot pressure setting. See Pilot Pressure Regulating Valve Test and Adjustment. (Group 9025-25.)

1—Cap Screw (2 used) 2—Pilot Pressure Regulating Valve 3—Pilot Filter


TM1931 (09JAN04)

33-3360-30

OUOE027,000001F –19–19NOV01–2/3


PN=212

Hydraulic System Disassemble and Assemble Pilot Pressure Regulating Valve and Filter 1 1. Remove plug (6) with O-ring (5). 2


3

4 5

3. Inspect, clean and replace parts as necessary.

6 –UN–20JUL01

4. Check that poppet (2) slides smoothly in pilot pressure regulating valve housing (1). 5. Tighten plug (6).

T143094

Pilot Pressure Regulating Valve and Filter—Specification Plug-to-Housing—Torque ................................................ 49 N•m (36 lb-ft)

1—Pilot Pressure Regulating Valve Housing 2—Poppet 3—Shim (As required) 4—Spring 5—O-Ring 6—Plug

OUOE027,000001F –19–19NOV01–3/3

Pilot Shut-Off Valve Repair Remove and Install Pilot Shut-Off Valve 1. Turn upperstructure 90° to tracks. CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 2. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 3. Disconnect lines. 33 3360 31

4. Disconnect spring.


TM1931 (09JAN04)

33-3360-31

OUOE027,000001C –19–19NOV01–1/4


PN=213

Hydraulic System 5. Remove cap screws (1) and remove valve with lever attached.

1

6. Repair or replace parts as necessary. 7. Install valve. Tighten cap screws. Pilot Shut-Off Valve—Specification Valve Housing-to-Cab Platform Cap Screw—Torque ........................................................ 49 N•m (36 lb-ft)

8. Connect spring.

–UN–20JUL01

9. Connect lines. See Pilot Controllers-to-Pilot Signal Manifold Component Location—Excavator Pattern. (Group 9025-15.)

T142504



OUOE027,000001C –19–19NOV01–2/4

33 3360 32

TM1931 (09JAN04)

33-3360-32


PN=214

T143031

–UN–17JUL01

Hydraulic System

1—Washer 2—Backup Ring 3—O-Ring 4—Body

5—Lever Stop Cap Screw 6—Retaining Ring 7—Washer

8—Backup Ring 9—O-Ring 10—Spool

33 3360 33

11—Bracket 12—Pin 13—Cap Screw (3 used)

Disassemble and Assemble Pilot Shut-Off Valve 1. Remove spring pin and remove lever from valve.


TM1931 (09JAN04)

33-3360-33

OUOE027,000001C –19–19NOV01–3/4


PN=215

Hydraulic System NOTE: Make alignment marks on body (4) and bracket (11) to aid in reassembly.

7. Position bracket (11) on spool (10).

2. Remove parts (6—9) and remove spool (10) from body (4).

8. Apply thread lock and seal (medium strength) to threads of cap screws (13) and tighten.

3. Remove parts (1—3) from body.

Pilot Shut-Off Valve —Specification Bracket-to-Spool Cap Screw— Torque..................................................................... 3.9 N•m (2.9 lb-ft)

4. Remove cap screws (13) and bracket (11) from spool (10).

9. Install parts (1—3) into body (4).

NOTE: Remove pin (12) and cap screw (5) only if necessary.

10. Apply hydraulic oil to spool (10) and install into body (4). 11. Install parts (7—9) in body (4) and retaining ring (6) to spool (10).

5. Inspect and replace parts as necessary. 6. If cap screw (5) has been removed, apply thread lock and sealer (medium strength) to threads and tighten.

12. Align marks on bracket (11) with body (4). 13. Install lever and spring pin to valve.

Pilot Shut-Off Valve—Specification Lever Stop Cap Screw—Torque ........................ 29.4 N•m (21.5 lb-ft)

OUOE027,000001C –19–19NOV01–4/4

33 3360 34

TM1931 (09JAN04)

33-3360-34


PN=216

Hydraulic System

Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve Repair Remove and Install Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve

–UN–20JUL01

CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.)

T143099B

2. Disconnect electrical connector. 3. Remove cap screws (1) and remove solenoid valve coil (2). Be careful not to lose spring and O-ring. 1—Cap Screw (8 used) 2—Solenoid Valve Coil (4 used)

4. Keep parts for each individual solenoid valve together. 5. Install solenoid valve coil (2) with O-ring (8) and spring (7). 6. Tighten cap screws (1). Solenoid Valve—Specification Solenoid Valve Coil-to-Manifold Cap Screws—Torque ..................................................... 3 N•m (24 lb-in.)

7. Connect electrical connectors. 8. Check pressure setting of solenoid valves. See Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve Test and Adjustment. (Group 9025-25.)


OUOE027,000001E –19–19NOV01–1/2

33 3360 35

TM1931 (09JAN04)

33-3360-35


PN=217

T143123

–UN–20JUL01

Hydraulic System

1—Cap Screw (2 used) 2—Proportional Solenoid Valve Coil 3—O-Ring 4—Lock Nut

5—Adjusting Screw 6—Spring 7—Spring 8—O-Ring 9—Diaphragm

10—Spool 11—Washer 12—Spring 13—O-Ring 14—O-Ring

Disassemble and Assemble Proportional Solenoid Valve

3. Apply clean oil to sleeve (16), O-rings (13, 14 and 15) and spool (10). After installing spool, push spool against spring to check that spool slides smoothly in sleeve.


33 3360 36

15—O-Ring 16—Sleeve 17—Plate 18—Washer

NOTE: Only remove the lock nut (4) and adjusting screw (5) if replacement of O-ring (3) is necessary. If disassembled, pressure setting of proportional solenoid valve will need to be adjusted. See Power Boost, Propel Speed, Swing Priority, and Arm Regenerative Solenoid Valve Test and Adjustment. (Group 9025-25.)

4. Install sleeve (16) so ports align with ports in manifold. 5. Install washer (11) and spring (12) on spool and install spool. 6. Install spring (7), O-ring (8) and diaphragm (9).


OUOE027,000001E –19–19NOV01–2/2

TM1931 (09JAN04)

33-3360-36


PN=218

Hydraulic System

Pilot Controller Repair Remove and Install Pilot Controller CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Remove covers. 3. Disconnect wiring harness and remove lever. 4. Remove cap screws and remove pilot controller from console. 5. Disconnect lines. 6. Repair or replace parts as necessary. 7. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.)

NOTE: Position cap screw with spring pin, in lower right hole of controller. 8. Install pilot controller and tighten cap screws. Pilot Controller—Specification Pilot Controller-to-Console Cap Screw—Torque ............................................................... 10 N•m (7.2 lb-ft)

9. After pilot controller is installed, check operation of all functions to be sure they operate as shown on decal mounted on console.

33 3360 37


TM1931 (09JAN04)

33-3360-37

OUOE027,0000020 –19–19NOV01–1/3


PN=219

Hydraulic System

13 12 14 11 15 11 10

8

9

7 16 21 5

21

20 20

6 19 3 4

18

1

T143186

17 T143186 33 3360 38

1—Spacer (4 used) 2—Shim (As required) 3—Balance Spring A (2 used) 4—Balance Spring B (2 used) 5—Return Spring A (2 used) 6—Return Spring B (2 used)

7—Retaining Ring (4 used) 8—Pusher A (2 used) 9—Pusher B (2 used) 10—Block 11—Cap Screw (2 used)

12—Cam 13—Coupling 14—U-Joint 15—Oil Seal (4 used) 16—Spring Guide (4 used)


TM1931 (09JAN04)

–UN–17JUL01

2

33-3360-38

17—Spool (4 used) 18—Housing 19—O-Ring 20—Dowel Pin (2 used) 21—O-Ring (2 used)

OUOE027,0000020 –19–19NOV01–2/3


PN=220

Hydraulic System Disassemble and Assemble Pilot Controller

3. Install parts.

IMPORTANT: The housing (18) and spools (17) are replaced as an assembly because the spools are select fitted to bores in housing.

4. Apply multi-purpose grease to oil seals.

Some parts from ports 1 and 3 are different than parts from ports 2 and 4. Parts for each port must be kept together and installed into the same port from which it was removed. The port numbers are stamped on the housing. Remove U-joint (14) only if necessary. Note port location and quantity of shims (2) when removing. Same number of shims must be used when installing.

5. Install pushers (8 and 9). Pushers with grooves go into ports 1 and 3. Pushers without grooves go into ports 2 and 4. 6. Tighten cap screw (11). Pilot Controller—Specification Block-to-Housing Cap Screw— Torque................................................................. 19.6 N•m (14.5 lb-ft)

7. Apply multi-purpose grease to the end of each pushers (8 and 9) and to the joint of U-joint (14). 8. Install cam (12) on U-joint (14). Adjust clearance between pushers (8 and 9) and cam. Pilot Controller—Specification Cam-to-Pusher—Clearance...................... 0—0.20 mm (0—0.008 in.)

Hold cam (12) and tighten coupling (1). 1. Remove parts from housing. Remember to keep parts removed from each port together. Identify each group of parts by port numbers stamped on housing.

Pilot Controller—Specification Coupling-to-Cam and U-Joint— Torque.................................................................... 88.2 N•m (65 lb-ft)


NOTE: Install spring guides (16) with protrusion facing up.

OUOE027,0000020 –19–19NOV01–3/3

33 3360 39

TM1931 (09JAN04)

33-3360-39


PN=221

Hydraulic System

Propel Pilot Controller Repair Remove and Install Propel Pilot Controller CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury.

–UN–20JUL01

1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Disconnect lines.

T143206B

3. Remove cap screws (3) and remove pedals and levers. 4. Remove cap screws (2) and remove propel pilot controller (1). 1—Propel Pilot Controller 2—Cap Screw (2 used) 3—Cap Screw (4 used)

5. Repair or replace parts as necessary. 6. Tighten cap screws (2). Propel Pilot Controller—Specification Controller-to-Cab Platform Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

7. Tighten cap screws (3). Propel Pilot Controller—Specification Propel Pedal-to-Lever Cap Screw—Torque ................................................................ 49 N•m (36 lb-ft)

8. Connect lines. See Propel System Component Location. (Group 9025-15.) 9. After propel pilot controller is installed, check the operation of all functions to be sure they operate correctly.

33 3360 40


TM1931 (09JAN04)

33-3360-40

OUOE027,0000021 –19–19NOV01–1/4


PN=222

Hydraulic System

1 35

2

34 33 32

3

31

6

4 5

7 30

8 29 27

28

9 11 10

12

13 23

14

26

22 25 20

21 15

19

16

18

T143207

17 T143207

1—Cap Screw (2 used) 2—Cover 3—Pin (2 used) 4—O-Ring (2 used) 5—O-Ring (2 used) 6—Dampener (2 used) 7—Rubber Seat (2 used) 8—Cap Screw (2 used) 9—Lock Washer (2 used)

10—Holder 11—Oil Seal (4 used) 12—O-Ring (4 used) 13—Bushing (4 used) 14—Casing 15—O-Ring 16—Plug 17—Spool (4 used) 18—Spring (4 used)

19—Spacer (4 used) 20—Shim (As required) 21—Balance Spring (4 used) 22—Spring Guide (4 used) 23—Pusher (4 used) 24—Spring Pin (2 used) 25—Spring Pin (2 used) 26—Bracket (2 used) 27—Spring Pin (2 used)


TM1931 (09JAN04)

–UN–17JUL01

24

33-3360-41

33 3360 41

28—Cap Screw (4 used) 29—Lock Washer (4 used) 30—Adjusting Bolt (4 used) 31—Bushing (4 used) 32—Cam (2 used) 33—Lock Nut (4 used) 34—Spring Pin (2 used) 35—Spring Pin (2 used)

OUOE027,0000021 –19–19NOV01–2/4


PN=223

Hydraulic System Disassemble and Assemble Propel Pilot Controller IMPORTANT: The casing (14) and spools (17) are replaced as an assembly because the spools are select fitted to bores in housing. Parts for each port must be kept together and installed into the same port from which it was removed. The port numbers are stamped on the housing. Note port location and quantity of shims (20) when removing. Same number of shims must be used when installing. 1. Remove parts from casing. Remember to keep parts removed from each port together. Identify each group of parts by port numbers stamped on casing.

NOTE: Spring pins (24 and 25) are stepped and can only be removed from one direction. Remove spring pin (27) and bushings (31) only if necessary. 2. Repair or replace parts as necessary. 3. Install spools (17), springs (18), spacers (19), shims (20) and balance springs (21) into casing (14).

6. Lock pins (34 and 35) in position by displacing the bore above spring pin using a punch and hammer. 7. Install holder (10) to casing (14) with cap screws (8), lock washers (9) and tighten. Propel Pilot Controller—Specification Holder-to-Casing Cap Screw— Torque....................................................................... 49 N•m (36 lb-ft)

8. Adjust clearance between cams (32) and pushers (23) . Propel Pilot Controller—Specification Cams-to-Pusher—Clearance .................... 0—0.20 mm (0—0.008 in.)

9. Tighten lock nut (33). Propel Pilot Controller—Specification Cam Adjusting Bolt Lock Nut— Torque..................................................................... 9.8 N•m (7.2 lb-ft)

10. Apply multi-purpose grease to O-rings (4 and 5) and install on pin (3). 11. Position rubber seat (7) and dampener (6) on pin (3) with lever facing upward. 12. Install cap screws (28), lock washers (29) and tighten. Propel Pilot Controller—Specification Dampener-to-Holder Cap Screw—Torque .......................................................... 7 N•m (5.1 lb-ft)

IMPORTANT: Note direction of insertion for spring pins (24 and 25).

Use number of shims (20) removed. Install spring guides (22) with stepped end facing down.

Spring pins must be positioned with slits 90° apart.

4. Apply multi-purpose grease to the end of each pushers (23) and to oil seals (11).

33 3360 42

Align brackets with marks made during disassembly.

IMPORTANT: Note direction of insertion for spring pins (34 and 35). 5. Assemble cam (32) in holder (10) with spring pins (34 and 35), and pin (3). Install spring pins with slits 90° apart.

13. Install brackets (26) and spring pins (24 and 25). 14. Lock pins (24 and 25) in position by displacing the bore above spring pin using a punch and hammer.


TM1931 (09JAN04)

33-3360-42

OUOE027,0000021 –19–19NOV01–3/4


PN=224

Hydraulic System 15. Install cover (2) and cap screws (1) and tighten. Propel Pilot Controller—Specification Cover-to-Holder Cap Screw— Torque........................................................................ 5 N•m (3.6 lb-ft)

16. Apply multi-purpose grease to spring pin (27).

OUOE027,0000021 –19–19NOV01–4/4

Pilot Signal Manifold Repair Remove and Install Pilot Signal Manifold CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.) 3. Disconnect lines. 4. Disconnect electrical connectors.


OUOE027,0000027 –19–19NOV01–1/6

33 3360 43

TM1931 (09JAN04)

33-3360-43


PN=225

Hydraulic System 5. Remove cap screws (3). 6. Repair or replace parts as necessary. 7. Position manifold (1) on bracket (2) and tighten cap screws (3).

–UN–20JUL01

Pilot Signal Manifold—Specification Pilot Signal Manifold-to-Bracket Cap Screw—Torque ........................................................ 50 N•m (37 lb-ft)

T143184C

8. Connect electrical connectors. See System Functional Schematic, Component Location, and Wiring Diagram Master Legend . (Group 9015.) 9. Install hose and tube adapters and tighten. Pilot Signal Manifold—Specification Hose and Tube Adapter-to-Pilot Signal Manifold—Torque .............................................. 39 N•m (347 lb-in.)

1—Pilot Signal Manifold 2—Bracket 3—Cap Screw (4 used)

10. Connect lines. See Pilot Controllers-to-Pilot Signal Manifold Component Location—Excavator Pattern. (Group 9025-15.)


OUOE027,0000027 –19–19NOV01–2/6

33 3360 44

TM1931 (09JAN04)

33-3360-44


PN=226

Hydraulic System

33 3360 45

TM1931 (09JAN04)

33-3360-45


PN=227

Hydraulic System

14

14

21 15

10

22

16 17 13

9

23

19 20

12

8

24

11 6

7

5

18 19 16

4 20

17 3 2

1

D

C B

25 26

19 27

A

16 15 20

14 17

33 3360 46

28

17 16 T143485


TM1931 (09JAN04)

33-3360-46

15

T143485

19

–UN–17JUL01

29

OUOE027,0000027 –19–19NOV01–3/6


PN=228

Hydraulic System 1—Cap Screw (10 used) 2—Body 3—Gasket 4—Body 5—Gasket 6—Body 7—Gasket 8—Body

9—Gasket 10—Body 11—Name Plate 12—Screw (4 used) 13—Plate 14—Cap Screw (11 used) 15—Plug (7 used)

16—O-Ring (7 used) 17—Spring (4 used) 18—Spring 19—Spring Seat (7 used) 20—Spool (6 used) 21—Plate 22—O-Ring

23—Valve 24—O-Ring 25—Spring 26—Spool 27—Spring 28—Spring 29—Plate

Disassemble and Assemble Pilot Signal Manifold


OUOE027,0000027 –19–19NOV01–4/6

33 3360 47

TM1931 (09JAN04)

33-3360-47


PN=229

Hydraulic System

30

32

31 32 31

30

A

B

31 30

D

T143486

C

–UN–17JUL01

33 3360 48

T143486

30—Filter (17 used)

31—Shuttle Valve (21 used)

32—Spring (4 used)


TM1931 (09JAN04)

33-3360-48

OUOE027,0000027 –19–19NOV01–5/6


PN=230

Hydraulic System Install hose and tube adapters and tighten. Pilot Signal Manifold—Specification Hose and Tube Adapter-to-Pilot Signal Manifold—Torque ....................................... 39 N•m (347 lb-in.)

OUOE027,0000027 –19–19NOV01–6/6

Control Valve Repair Remove and Install Control Valve CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities or 270CLC Drain and Refill Capacities. (Operator’s Manual.)

TX,33,UU4002 –19–19NOV01–1/18

3. Disconnect hydraulic tubes. 4. Disconnect electrical connectors (6). 5. Remove cap screws (2) and washers (3). Place pilot signal manifold (4) with bracket (5) to side. 6. Attach hoist to control valve using lifting strap.

33 3360 49

T143184B

–UN–24JUL01

1—Control Valve 2—Cap Screw (3 used) 3—Washer (3 used) 4—Pilot Signal Manifold 5—Bracket 6—Electrical Connector (4 used)


TM1931 (09JAN04)

33-3360-49

TX,33,UU4002 –19–19NOV01–2/18


PN=231

Hydraulic System

CAUTION: Heavy component; use a hoist. Control Valve—Specification Control Valve—Weight .................................. 183 kg (400 lb) approximate

7. Remove cap screws (1) and washers (2). Remove control valve. 8. Replace parts as necessary. 9. Tighten cap screws (1).

2

Control Valve—Specification Mounting Bracket-to-Control Valve Cap Screw—Torque .......................................... 210 N•m (152 lb-ft)

10. Install pilot signal manifold with bracket. Tighten cap screws.

3 1

Pilot Signal Manifold Bracket-to-Control Valve Cap Screw—Torque ............................................................ 137 N•m (101 lb-ft)

2 1

T143187

12. Connect electrical connectors. See Cab Harness (W1) Component Location Diagram. (Group 9015-10.)

4

T143187

11. Connect hydraulic tubes. See Main Hydraulic System Component Location. (Group 9025-15.)

–UN–02AUG01

Control Valve—Specification

1—Cap Screw (4 used) 2—Washer (4 used) 3—Front Mounting Bracket 4—Rear Mounting Bracket

13. Check Hydraulic Oil. (Operator’s Manual.) 14. Do Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)


TX,33,UU4002 –19–19NOV01–3/18

33 3360 50

TM1931 (09JAN04)

33-3360-50


PN=232

Hydraulic System 28

31

29

27

36

30

26

32

37

24

33

38 23

39 34

22 19

35

H I D C E G F

20

25 40

J

16

44

H

15

45

42

A

46

G

47

17 13

A

49

12 7

66 9

8

2

52

53

67

55 57

61

D 68

41

B

62 63

69

64

J

T143188

65

C 60

59

54 56 58

T143188

10

4 3

51

43

6 1

50

E

14

11 5

48

F

B

–UN–19NOV01

18 21

Control Valve—5-Spool

33 3360 51

Disassemble and Assemble Control Valve 5-Spool


TM1931 (09JAN04)

33-3360-51

TX,33,UU4002 –19–19NOV01–4/18


PN=233

Hydraulic System

114 111 112 113 110 105

106

107 109

104

108 115 98

103 102 101

100 99 93 85 94

84 83

88

97

90 116

82

92

81 76

95

96

80

86

87

89

91 104

106 105

79 84

78 77

83

75 74

90

123

80

79

120 92

81 70

121

86

87

89

91

119 118

117

–UN–19NOV01

72 71

88

82

73

122

85

78

T143190

77 T143190

5-Spool—Side Components

33 3360 52


TM1931 (09JAN04)

33-3360-52

TX,33,UU4002 –19–19NOV01–5/18


PN=234

Hydraulic System 1—Auxiliary Function Flow Combiner Valve 2—Cap Screw (2 used) 3—Cap 4—O-Ring 5—Spring Seat 6—Spring 7—Spool 8—Bottom Pilot Cap (5 used) 9—Cap Screw (10 used) 10—Plug 11—O-Ring 12—Plug 13—O-Ring 14—O-Ring (5 used) 15—Plug 16—O-Ring 17—Housing 18—O-Ring 19—System Relief and Power Boost Valve 20—O-Ring 21—Plug 22—O-Ring 23—Plug 24—Cap Screw (6 used) 25—O-Ring (5 used) 26—Top Pilot Cap 27—O-Ring 28—Plug 29—Plug 30—O-Ring 31—Left Travel Spool 32—Auxiliary Spool 33—Boom II Spool 34—Arm I Spool

35—Swing Spool 36—Special Cap Screw (5 used) 37—Spring Seat (5 used) 38—Spring (5 used) 39—Spring Seat (5 used) 40—Spool 41—Arm Reduced Leakage Valve 42—Cap Screw (4 used) 43—O-Ring 44—Plug 45—O-Ring 46—Piston 47—Spring 48—Body 49—O-Ring 50—O-Ring 51—Sleeve 52—Backup Ring 53—O-Ring 54—O-Ring 55—Backup Ring 56—Spool 57—Poppet 58—Washer 59—Spring 60—Lift Check and Orifice (Left Propel Power Passage) 61—Plug 62—Backup Ring 63—O-Ring 64—Spring 65—Poppet 66—Arm Out Circuit Relief and Anti-Cavitation Valve

1. Remove cap screws (24) and top pilot cap (26).

67—O-Ring 68—O-Ring 69—Arm In Circuit Relief and Anti-Cavitation Valve 70—Lift Check (Boom II Power Passage) 71—Cap Screw (4 used) 72—Flange 73—O-Ring 74—Spring 75—Poppet 76—Auxiliary Flow Rate Valve 77—Plug (2 used) 78—O-Ring (2 used) 79—Cap Screw (8 used) 80—Housing (2 used) 81—Spool (2 used) 82—Spring (2 used) 83—Spring Seat (2 used) 84—O-Ring (2 used) 85—Plug (2 used) 86—O-Ring (2 used) 87—Sleeve (2 used) 88—Spring (2 used) 89—Plug (2 used) 90—Spring (2 used) 91—Poppet (2 used) 92—Poppet (2 used) 93—Lift Check (Left Propel Neutral Passage) 94—Left Propel Neutral Passage-to-Housing Lift Check Plug 95—O-Ring 96—Spring

97—Poppet 98—Auxiliary Flow Combiner Valve Check Valve 99—Cap Screw (2 used) 100—Flange 101—O-Ring 102—Spring 103—Poppet 104—Cap Screw (8 used) 105—Cover (2 used) 106—O-Ring (2 used) 107—Lift Check (Arm I Power Passage) 108—Plug 109—O-Ring 110—Arm I Power Passage-to-Housing Lift Check Cap Screw (4 used) 111—Flange 112—O-Ring 113—Spring 114—Poppet 115—Housing 116—O-Ring (6 used) 117—Lift Check (Swing Neutral Passage) 118—Cap Screw (4 used) 119—Flange 120—O-Ring 121—Spring 122—Poppet 123—Arm Priority Flow Rate Valve

NOTE: Hold the spool in a vise by the spool end between wooden blocks.

2. Remove cap screws (9) and bottom pilot caps (8).

The procedures for disassembly and assembly of spool (31—35) are the same.

3. Spool —5 Spool (31—35): IMPORTANT: The spool (31—35) are select fitted to bores in housing and are a different design for each function. Spools must be installed into the same bores from which they were removed for proper operation of machine. a. Remove spool (31—35).

b. Remove parts (36—39) c. Inspect control valve spools for wear and damage. d. Replace parts as necessary. e. Assemble parts (36—40). Tighten special cap screws (36).


TM1931 (09JAN04)

33 3360 53

33-3360-53

TX,33,UU4002 –19–19NOV01–6/18


PN=235

Hydraulic System Control Valve—Specification Special Cap Screw-to-Control valve Spool—Torque ................................................ 15 N•m (11 lb-ft)

NOTE: Apply hydraulic oil to spools before installation.

d. Install plug (44) loosely. e. Tighten cap screws (42). Control Valve—Specification Arm Reduced Leakage Valve Body-to-Housing Cap Screw— Torque....................................................................... 62 N•m (46 lb-ft)

f. Install spool (31—35) into housing (17) while rotating them slowly. g. After installing spool (31—35) into housing (17), push them by hand to confirm smoothness.

f. Tighten plug (44). Control Valve—Specification Plug-to-Arm Reduced Leakage Valve—Torque ........................................................ 108 N•m (80 lb-ft)

h. Repeat procedure for remaining spool 4. Auxiliary Function Flow Combiner Valve (1): a. Inspect parts (2—7) for wear and damage.

7. Auxiliary Flow Combiner Valve Check Valve (98):

b. Replace parts as necessary.

a. Remove parts (99—103).

c. Tighten cap screws (2). Control Valve—Specification Auxiliary Function Flow Combiner Valve-to-Housing Cap Screw—Torque ................................................... 11 N•m (7 lb-ft)

5. Lift Check And Orifice (Left Propel Power Passage) (60):

Control Valve—Specification Auxiliary Flow Combiner Valve Check Valve-to-Housing Cap Screw—Torque ......................................................... 61 N•m (46 lb-ft)

8. Lift Check (Left Propel Neutral Passage) (93):

a. Inspect parts (61—65) for wear and damage.

a. Remove plug (94).


b. Remove parts (95—97).

6. Arm Reduced Leakage Valve (41):

c. Replace parts as necessary

a. Remove cap screws (42) and body (48).

d. Install plug (94) and tighten.

b. Replace parts as necessary. 33 3360 54

b. Install flange (100) and tighten cap screws (99).

c. Apply petroleum jelly to washer (62) and spring (63) to hold in place. IMPORTANT: Install spool (56) with the hole side towards poppet (57) for proper operation of valve.

Control Valve—Specification Left Propel Neutral Passage-to-Housing Lift Check Plug—Torque ............................................................ 76 N•m (56 lb-ft)

9. Lift Check (Arm I Power Passage) (107):


TM1931 (09JAN04)

33-3360-54

TX,33,UU4002 –19–19NOV01–7/18


PN=236

Hydraulic System a. Remove cap screws (110) and flange (111).

11. Auxiliary Flow Rate Valve (76) And Arm Priority Flow Rate Valve (123):

b. Replace parts as necessary. a. Remove cap screws (79) and housing (80). c. Install flange (111) and tighten cap screws (110). b. Replace parts as necessary. Control Valve—Specification Arm I Power Passage-to-Housing Lift Check Cap Screw—Torque ................................................. 61 N•m (46 lb-ft)

10. Lift Check (Boom II Power Passage) (70) and Lift Check (Swing Neutral Passage) (117): a. Remove cap screws (71 and 118) and flanges (72 and 119). b. Replace parts as needed. c. Install flanges (72 and 119) and tighten cap screws (71 and 118).

c. Install housing (80) and tighten cap screws (79). Control Valve—Specification Flow Rate Valve Housing-to-Housing Cap Screw—Torque ......................................................... 61 N•m (46 lb-ft)

d. Tighten plug (85). Control Valve—Specification Flow Rate Valve Housing Plug—Torque ............................................................ 98 N•m (72 lb-ft)

Control Valve—Specification Power Passage-to-Housing Cap Screw—Torque ................................................. 61 N•m (46 lb-ft)


TX,33,UU4002 –19–19NOV01–8/18

33 3360 55

TM1931 (09JAN04)

33-3360-55


PN=237

Hydraulic System 12. System Relief and Power Boost Valve (19)

1

NOTE: Disassemble valve for cleaning and inspection only. Valve is serviced as an assembly.

3

2 4

a. Tighten nuts (4 and 9).

5

System Relief Valve—Specification System Relief Valve 27 mm Nut (4)—Torque ..................................................................... 64 N•m (47 lb-ft) System Relief Valve 32 mm Nut (9)—Torque ..................................................................... 83 N•m (61 lb-ft)

6 7 8 9

b. Tighten valve cartridge (10).

10

System Relief Valve—Specification System Relief Valve Cartridge-to-Housing—Torque ........................................ 83 N•m (61 lb-ft)

11 12

16 17 T143388


T143388

c. Check and adjust pressure setting for system relief valve and power boost. See System Relief and Power Boost Valve Test and Adjustment. (Group 9025-25.)

15

–UN–02AUG01

13 14

1—First Adjusting Plug 2—O-Ring 3—Piston 4—Nut 5—Second Adjusting Plug 6—O-Ring 7—Pilot Poppet Spring 8—Pilot Poppet 9—Nut 10—Cartridge 11—O-Ring 12—Pilot Poppet Seat 13—Backup Ring 14—O-Ring 15—Main Poppet Spring 16—Main Poppet 17—Main Poppet Seat

14. Install top pilot cap (26) and tighten cap screws (24). Control Valve—Specification Top Pilot Cap-to-Housing Cap Screw—Torque ................................................................ 42 N•m (32 lb-ft)

15. Install bottom pilot caps (8) and tighten cap screws (9). Control Valve—Specification Bottom Pilot Caps-to-Housing Cap Screw—Torque ....................................................... 42 N•m (32 lb-ft)

33 3360 56


TM1931 (09JAN04)

33-3360-56

TX,33,UU4002 –19–19NOV01–9/18


PN=238

Hydraulic System

27

26

35

34 28 29

25

38

36

39

30

40 24

41

51 31

H

23

G

42

32

F

37

43

E D

44

46

47

48

33

50

49

52

H

C

20

45

53

22

64

G

19

B

68 70

18

13

E

17

5

16 11

14

81

83

12

B

72

75

80

77

84

C

79

74 76 78

T143189

86 87

71

82

15

10

62 69

61

73

85 T143189

67

F

B

6

2

66

60

7

3

55

58

8

4

65

57 59

9

1

56

–UN–19NOV01

21

54 63

D Control Valve—4-Spool

33 3360 57

Disassemble and Assemble Control Valve 4-Spool


TM1931 (09JAN04)

33-3360-57

TX,33,UU4002 –19–19NOV01–10/18


PN=239

Hydraulic System

97 113

98

112

99 102

100

118

114 117

111

115

107

110

101

89

116

108

120

119

96 95 91

92

121

100

103

94 104 105 93

106 127

128

90

125

127

122

126

124

126

123

125 124 123

136 135

134 133 132 131 130

129

137 –UN–19NOV01

139

138

T143191

88 T143191

4-Spool—Side Components

33 3360 58


TM1931 (09JAN04)

33-3360-58

TX,33,UU4002 –19–19NOV01–11/18


PN=240

Hydraulic System 1—Propel Flow Combiner Valve 2—Cap Screw (2 used) 3—Cap 4—O-Ring 5—Cap Screw 6—Spring Seat 7—Spring 8—Spring Seat 9—Spool 10—Cap Screw (8 used) 11—O-Ring 12—Plug 13—Bottom Pilot Cap (4 used) 14—Arm Regenerative Valve Check Valve 15—Plug 16—O-Ring 17—Spring 18—Poppet 19—O-Ring (4 used) 20—Housing 21—O-Ring 22—Plug 23—O-Ring 24—Bucket Dump Circuit Relief and Anti-Cavitation Valve 25—O-Ring (4 used) 26—Top Pilot Cap 27—Plug 28—O-Ring 29—Pressure Sensor (Arm Roll-In) 30—Cap Screw (6 used) 31—O-Ring 32—Boom Down Circuit Relief and Anti-Cavitation Valve

33—O-Ring 34—Right Travel Spool 35—Bucket Spool 36—Boom I Spool 37—Arm II Spool 38—Plug 39—Backup Ring 40—O-Ring 41—Sleeve 42—Spring 43—Poppet 44—Special Cap Screw (4 used) 45—Spring Seat (3 used) 46—Plug 47—Spring Seat (4 used) 48—Backup Ring 49—O-Ring 50—Spring Seat 51—Spool 52—Spring 53—Spring 54—Spring Seat 55—Spring Seat 56—Poppet (2 used) 57—Spring (2 used) 58—O-Ring (2 used) 59—Backup Ring (2 used) 60—Plug (2 used) 61—Boom Reduced Leakage Valve 62—O-Ring 63—Cap Screw (4 used) 64—Plug 65—O-Ring 66—Piston 67—Spring 68—Body

69—O-Ring 70—O-Ring 71—Sleeve 72—Backup Ring 73—O-Ring 74—O-Ring 75—Backup Ring 76—Spool 77—Poppet 78—Washer 79—Spring 80—Arm Regenerative Valve 81—Spring 82—Spacer 83—O-Ring 84—Backup Ring 85—Spool 86—Boom Up Circuit Relief and Anti-Cavitation Valve 87—Bucket Load Circuit Relief and Anti-Cavitation Valve 88—Housing 89—Bucket Flow Rate Valve 90—Poppet 91—Poppet 92—Spring 93—Plug 94—Spring 95—Sleeve 96—O-Ring 97—Plug 98—O-Ring 99—Spring Seat 100—Spring 101—Spool 102—Housing 103—Cap Screw (4 used) 104—O-Ring

1. Remove cap screws (30) and top pilot cap (26).

Spools must be installed into the same bores from which they were removed for proper operation of machine.

2. Remove cap screws (10) and caps (13) from housing (20). 3. Spool —4 Spool (34—37):

105—Plug 106—O-Ring 107—Lift Check and Orifice (Arm II Power Passage) 108—Poppet 109—Spring 110—O-Ring 111—O-Ring (3 used) 112—O-Ring 113—Housing 114—O-Ring 115—Screw 116—O-Ring 117—Nut 118—Nut 119—Cap Screw (4 used) 120—O-Ring 121—Plug 122—Lift Check (Boom I Power Passage) 123—Poppet 124—Spring 125—O-Ring 126—Flange 127—Cap Screw (4 used) 128—Lift Check (Arm II Neutral Passage) 129—By-Pass Shut-Off Valve 130—Spool 131—Spring 132—O-Ring 133—Flange 134—Cap Screw (2 used) 135—O-Ring 136—Plug 137—Cap Screw (4 used) 138—Flange 139—O-Ring

a. Remove spool (34—37).

NOTE: When disassembling spool (35, and 36), heat plugs (38, 46, and 60) to 200—300 °C (392— 482 °F) to melt the thread lock and sealer.

NOTE: Hold the spool in a vise by the spool end, using wooden blocks. b. Remove special cap screw (44) and spools.

IMPORTANT: The spool (34—37) are select fitted to bores in housing and are a different design for each function.

c. Heat plugs (38, 46, and 60) with heat gun to melt threadlock and sealer and remove plugs.


TM1931 (09JAN04)

33 3360 59

33-3360-59

TX,33,UU4002 –19–19NOV01–12/18


PN=241

Hydraulic System c. Inspect valve spools for wear and damage.

d. Inspect control valve spools for wear and damage.

d. Replace parts as necessary. e. Replace parts as necessary. f. For right travel spool (34) and arm II spool (37), install spool and tighten special cap screw (44). Control Valve—Specification Special Cap Screw-to-Control Valve Spool—Torque................................................ 15 N•m (11 lb-ft)

e. Assemble parts (6—8) and tighten cap screw (5). Control Valve—Specification Cap Screw-to-Flow Combiner Valve Spool—Torque.................................................. 11 N•m (7 lb-ft)

f. Install spool (9), cap (3) and tighten cap screws (2).

g. For bucket and boom I spool (35 and 36): Apply threadlock and sealer (high strength) on plugs (38, 46, and 60).

Control Valve—Specification Cap-to-Housing Cap Screw— Torque......................................................................... 10 N•m (7 lb-ft)

h. Install plugs (38, 46, and 60) onto spool (35 and 36) and tighten. Control Valve—Specification Plugs-to-Control Valve Spool— Torque....................................................................... 15 N•m (11 lb-ft)

5. Arm Regenerative Valve Check Valve (14): a. Replace parts as necessary. b. Install parts (16—18) and tighten plug (15). Control Valve—Specification Arm Regenerative Valve-to-Housing Plug—Torque ............................... 76 N•m (56 lb-ft)

i. Install special cap screw (44) into spool and tighten. Control Valve—Specification Special Cap Screw-to-Control Valve Spool—Torque................................................ 15 N•m (11 lb-ft)

6. Arm Regenerative Valve (80):

NOTE: Apply hydraulic oil to spools before installation. j. Install spool (34—37) into housing (20) while rotating them slowly.

NOTE: Do not disassemble spool (85) unless necessary. a. Inspect valve spool for wear and damage. b. Replace parts as necessary.

33 3360 60

IMPORTANT: After installing spool (34—37) into housing (20), push them by hand to confirm smoothness.

7. Boom Reduced Leakage Valve (61): a. Replace parts as necessary.

4. Propel Function Flow Combiner Valve (1): a. Remove cap screws (2) and spool (9).

b. Install spool (76), with hole side towards poppet (77).



TM1931 (09JAN04)

33-3360-60

TX,33,UU4002 –19–19NOV01–13/18


PN=242

Hydraulic System Apply petroleum jelly to washer (78) and spring (79) to hold them in place.

NOTE: Do not remove nuts (117 and 118) and screw (115) from housing (113) unless necessary.

c. Loosely install plug (64).


d. Install and tighten cap screws (63).

c. Tighten screw (115).

Control Valve—Specification Boom Reduced Leakage Valve Body-to-Housing Cap Screw— Torque....................................................................... 62 N•m (46 lb-ft)

e. Tighten plug (64). Control Valve—Specification Boom Reduced Leakage Valve-to-Body Plug—Torque .................................. 108 N•m (80 lb-ft)

d. Tighten 13 mm nut (117) and 4 mm nut (118). Control Valve—Specification Lift Check and Orifice (Arm II Power Passage) 4 mm Nut— Torque........................................................................... 7 N•m (5 lb-ft) Control Valve—Specification Lift Check and Orifice (Arm II Power Passage) 13 mm Nut— Torque....................................................................... 13 N•m (10 lb-ft)

e. Install housing (113) and tighten cap screws (119).

8. Bucket Flow Rate Valve (89): a. Remove cap screws (103) and housing (102). b. Replace parts as necessary.

Control Valve—Specification Lift Check and Orifice (Arm II Power Passage) Housing-to-Housing Cap Screw—Torque ......................................................... 61 N•m (46 lb-ft)

c. Install housing (102) and tighten cap screws (103). Control Valve—Specification Bucket Flow Rate Valve Housing-to-Housing Cap Screw—Torque ......................................................... 61 N•m (46 lb-ft)

10. By-Pass Shut-Off Valve (129): a. Remove cap screws (134) and flange (133). b. Replace parts as necessary. c. Install flange (133) and tighten cap screws (134).

d. Tighten plug (97). Control Valve—Specification Flow Rate Valve Housing Plug—Torque ............................................................ 98 N•m (72 lb-ft)

9. Lift Check and Orifice (Arm II Power Passage) (107):

Control Valve—Specification By-Pass Shut-Off Valve-to-Housing Cap Screw— Torque....................................................................... 61 N•m (46 lb-ft) 33 3360 61


a. Remove cap screws (119) and housing (113).


TM1931 (09JAN04)

33-3360-61

TX,33,UU4002 –19–19NOV01–14/18


PN=243

Hydraulic System 12. Install top pilot cap (26) and tighten cap screws (30).

13. Install bottom pilot caps (13) and tighten cap screws (10).

Control Valve—Specification Top Pilot Cap-to-Housing Cap Screw—Torque ......................................................... 42 N•m (32 lb-ft)

Control Valve—Specification Bottom Pilot Cap-to-Housing Cap Screw—Torque ................................................ 42 N•m (32 lb-ft)


TX,33,UU4002 –19–19NOV01–15/18

33 3360 62

TM1931 (09JAN04)

33-3360-62


PN=244

Hydraulic System

10

23

9 8

13

25 24

7 6

21 17

18

19 22 20

16 15 3

14

4

26

3 4

4

4

10 9

3

8 7

11

12

10 9

8 7

5

12

4

1 3

T143217

T143217

–UN–02AUG01

3

2

Disassemble and Assemble 5-Spool and 4-Spool 1— Housing—5-Spool 2—Cap Screw (6 used) 3—Plug (6 used) 4—O-Ring (6 used) 5—Propel Flow Combiner Valve Check Valve 6—Poppet (2 used) 7—Spring (3 used) 8—O-Ring (3 used)

9—Flange (3 used) 10—Cap Screw (6 used) 11—System Relief Valve Isolation Check Valve— 5-Spool 12—Poppet 13—Right Propel and Bucket Combined Function Check Valve and Orifice

14—Poppet 15—Spring 16—O-Ring 17—Flange 18—Cap Screw (2 used) 19—Poppet 20—Spring 21—O-Ring


TM1931 (09JAN04)

33-3360-63

33 3360 63

22—Plug 23—System Relief Valve Isolation Check Valve— 4-Spool 24—O-Ring (15 used) 25—O-Ring (16 used) 26—Housing—4-Spool

TX,33,UU4002 –19–19NOV01–16/18


PN=245

Hydraulic System Disassemble and Assemble Control Valve 5-Spool and 4-Spool Sections 1. Right Propel And Bucket Combined Function Check Valve And Orifice (13):

3. Propel Flow Combiner Valve Check Valve (5) and System Relief Valve Isolation Check Valve (11): a. Remove cap screws (10) and flange (9).

a. Remove cap screws (18) and flange (17).



c. Install flange (9) and tighten cap screws (10).

c. Replace parts as necessary. d. Install and tighten plug (22). Control Valve—Specification Right Propel and Bucket Combined Function Check Valve and Orifice-to-4-Spool Housing Plug—Torque ............................................. 76 N•m (56 lb-ft)

Control Valve—Specification Propel Flow Combiner Valve Check Valve Cap Screw-to-5-Spool Housing— Torque....................................................................... 61 N•m (46 lb-ft) System Relief Valve Isolation Check Valve Cap Screw-to-5-Spool Housing— Torque....................................................................... 61 N•m (46 lb-ft)


e. Install flange (17) and tighten cap screws (18). Control Valve—Specification Right Propel and Bucket Combined Function Check Valve and Orifice Flange-to-4-Spool Housing Cap Screw—Torque ......................................................... 61 N•m (46 lb-ft)

Control Valve—Specification 5-Spool Housing—Weight ........................ 75 kg (165 lb) approximate Control Valve—Specification 4-Spool Housing—Weight ........................ 74 kg (163 lb) approximate

d. Remove cap screws (2). Separate 5-spool housing (1) from 4-spool housing (26). 2. System Relief Valve Isolation Check Valve— 4-Spool (23):

e. Remove plugs (3) and O-rings (4) 4. Replace parts as necessary.

a. Remove cap screws (10) and flange (9). 5. Combine 5-spool housing (1) and 4-spool housing (26) and tighten cap screws (2).

b. Replace parts as necessary. c. Install flange (9) and tighten cap screws (10).

33 3360 64

Control Valve—Specification System Relief Valve and Isolation Check Valve-to-4-Spool Housing Cap Screw—Torque ......................................................... 61 N•m (46 lb-ft)

Control Valve—Specification 5-Spool-to-4-Spool Cap Screw—Torque .................................. 167—177 N•m (123—130 lb-ft)


TM1931 (09JAN04)

33-3360-64

TX,33,UU4002 –19–19NOV01–17/18


PN=246

T7996AE

–UN–04MAY93

Hydraulic System

A—Nut B—Plug C—O-Ring (2 used) D—Backup Ring E—O-Ring

F—O-Ring G—Backup Ring H—Anti-Cavitation Sleeve I—Piston J—Main Poppet

6. Circuit Relief and Anti-Cavitation Valve 5-Spool and 4-Spool

K—Piston and Main Poppet Spring L—Cartridge M—Pilot Poppet N—Anti-Cavitation Sleeve Spring

O—Pilot Poppet Spring P—O-Ring Q—Adjusting Screw

b. Check and adjust pressure setting. See Circuit Relief Valve Test and Adjustment. (Group 9025-25.)

NOTE: Disassemble valves for cleaning and inspection only. Valves are serviced as assemblies. a. Tighten valve into housing. Circuit Relief and Anti-Cavitation Valve—Specification Circuit Relief and Anti-Cavitation Valve-to-Control Valve Housing—Torque............................................ 83 N•m (61 lb-ft)

33 3360 65

TX,33,UU4002 –19–19NOV01–18/18

TM1931 (09JAN04)

33-3360-65


PN=247

Hydraulic System

Hydraulic Oil Tank Repair Remove and Install Hydraulic Oil Tank CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.) 3. Disconnect lines. 4. Disconnect electrical connector on bottom of tank.


OUOE027,0000022 –19–19NOV01–1/4

33 3360 66

TM1931 (09JAN04)

33-3360-66


PN=248

Hydraulic System 5. Remove cap screws (1), lock washers (2) and washers (3). CAUTION: Heavy component; use a hoist. Hydraulic Oil Tank—Specification Hydraulic Oil Tank—Weight .......................... 150 kg (330 lb) approximate

6. Remove hydraulic oil tank using a hoist and lifting straps.

4

7. Repair or replace parts as necessary. –UN–20JUL01

8. Install hydraulic oil tank (4). 3 9. Tighten cap screws (1).

T143359

2 Hydraulic Oil Tank—Specification Oil Tank-to-Frame Cap Screw— Torque ......................................................................... 205 N•m (152 lb-ft)

1 1—Cap Screw (4 used) 2—Lock Washer (4 used) 3—Washer (4 used) 4—Hydraulic Oil Tank

10. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) Hydraulic Oil Tank—Specification T-Bolt Type Clamp—Torque ......................................... 4.4 N•m (40 lb-in.) Worm Gear Type Clamp—Torque ............... 5.9—6.9 N•m (52—61 lb-in.)

11. Connect electrical connector on bottom of tank. 12. Fill hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities , 270CLC Drain and Refill Capacities, and Hydraulic Oil. (Operator’s Manual.) IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 13. Do Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.) 33 3360 67


TM1931 (09JAN04)

33-3360-67

OUOE027,0000022 –19–19NOV01–2/4


PN=249

Hydraulic System

6

7

5 8 18

4

9 10 19

11 12

20

13 14

21

15 2

16 17

3

22

2 1

23

38 24

37

36 26

26

25

35 34

32 31 T143368

27 30

28

29


TM1931 (09JAN04)

33-3360-68

T143368

33

–UN–20JUL01

33 3360 68

OUOE027,0000022 –19–19NOV01–3/4


PN=250

Hydraulic System 1—Suction Strainer 2—Nut (3 used) 3—Rod 4—Cap Screw (4 used) 5—Cover 6—Cap 7—Nut 8—Element 9—Body 10—O-Ring

11—Cap Screw (6 used) 12—Cover 13—O-Ring 14—Bracket 15—Washer 16—Lock Washer 17—Cap Screw 18—Cap Screw (6 used) 19—Cover 20—Spring

21—O-Ring 22—Filter Element 23—Hydraulic Oil Tank 24—Level Gauge 25—Cap Screw (2 used) 26—Seal (4 used) 27—Gasket 28—Sensor 29—Plug

30—Plug 31—Cap Screw (4 used) 32—Lock Washer (4 used) 33—Washer (4 used) 34—Plug 35—Elbow 36—Adapter (3 used) 37—Elbow 38—Tee

Disassemble and Assemble Hydraulic Oil Tank

Tighten nuts (2).

1. Tighten cap screws (11 and 18).

Hydraulic Oil Tank—Specification Suction Strainer Rod Nuts— Torque.................................................................... 17 N•m (153 lb-in.)

Hydraulic Oil Tank—Specification Covers-to-Hydraulic Oil Tank Cap Screws—Torque ............................................... 49 N•m (36 lb-ft)

2. Adjust the length of rod (3) on suction strainer (1). Hydraulic Oil Tank—Specification Suction Strainer Rod—Length ................................ 683 mm (26.9 in.)

OUOE027,0000022 –19–19NOV01–4/4

Restriction Valve Repair Remove and Install Restriction Valve CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Pull vacuum in hydraulic oil tank using vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (See Operator’s Manual.)

33 3360 69


TM1931 (09JAN04)

33-3360-69

OUOE027,0000023 –19–24OCT01–1/3


PN=251

Hydraulic System

4

3 2

5

T143376

–UN–02AUG01

1

T143376 33 3360 70

200CLC Machine Shown 1—Coupling 2—Snap Ring

3—Restriction Valve

4—Hydraulic Oil Tank

5—Oil Cooler

3. Repair or replace restriction valve (3) and snap ring (2).


TM1931 (09JAN04)

33-3360-70

OUOE027,0000023 –19–24OCT01–2/3


PN=252

Hydraulic System 4. Tighten nuts on coupling (1). Restriction Valve—Specification Oil Cooler-to-Hydraulic Oil Tank Return Line Coupling Nut— Torque......................................................... 10.3—12.4 N•m (91—110 lb-in.)

5. Fill and check Hydraulic Oil level. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (See Operator’s 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. 6. Do Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)

OUOE027,0000023 –19–24OCT01–3/3

Oil Cooler Bypass Valve Repair Remove and Install Oil Cooler Bypass Valve CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.) 2. Pull vacuum in hydraulic oil tank using vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.)


OUOE027,0000024 –19–19NOV01–1/3

33 3360 71

TM1931 (09JAN04)

33-3360-71


PN=253

Hydraulic System

6 5 1 4 3

T143377

–UN–02AUG01

2

T143377 33 3360 72

200CLC Machine Shown 1—Control Valve 2—Oil Cooler Bypass Valve

3—O-Ring 4—Cap Screw (2 used)

5—Coupling

6—Hydraulic Oil Tank

3. Repair or replace oil cooler bypass valve (2).


TM1931 (09JAN04)

33-3360-72

OUOE027,0000024 –19–19NOV01–2/3


PN=254

Hydraulic System 4. Tighten nuts on coupling (5).

Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.)

Oil Cooler Bypass Valve—Specification Control Valve-to-Hydraulic Oil Tank Return Line Coupling Nut—Torque ............................................... 10.3—12.4 N•m (91—110 lb-in.)

5. Tighten cap screw (4). Oil Cooler Bypass Valve—Specification Split Coupling-to-Control Valve Cap Screw—Torque ................................................. 50 N•m (37 lb-ft)

IMPORTANT: Hydraulic pump will be damaged if not filled with oil before starting. Procedure must be performed to fill pump housing whenever oil has been drained from the pump or hydraulic oil tank. 7. Do Hydraulic Pump and Drive Gearbox Start-Up Procedure. (See procedure in this group.)

6. Fill and check Hydraulic Oil level. See 200CLC Drain and Refill Capacities, 230CLC Drain and

OUOE027,0000024 –19–19NOV01–3/3

33 3360 73

TM1931 (09JAN04)

33-3360-73


PN=255

Hydraulic System

Oil Cooler Repair Remove and Install Oil Cooler 1. Remove radiator. See Radiator Repair. (Group 0510.) CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury.

–UN–02AUG01

2. Do Hydraulic Oil Tank Vent Procedure. (See procedure in this group.)

T142696

3. Pull a vacuum in hydraulic oil tank using a vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.) 4. Disconnect lines. 1—Cap Screw (8 used). 2—Cap Screw (4 used).

5. Remove cap screws (1 and 2). CAUTION: Heavy component; use a hoist. Oil Cooler—Specification Oil Cooler—Weight ............................................ 32 kg (70 lb) approximate

6. Remove oil cooler. 7. Repair or replace parts as necessary. 8. Install radiator. See Radiator Repair. (Group 0510.) 9. Install oil cooler. 10. Tighten cap screws. 11. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.)

33 3360 74

12. Fill and check Hydraulic Oil level. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.)

OU90U48,0000028 –19–19NOV01–1/1

TM1931 (09JAN04)

33-3360-74


PN=256

Hydraulic System

Remove and Install Boom Cylinder NOTE: Procedure is the same for both boom cylinders.

–UN–10JAN97

1. Park machine on firm, level surface. 2. Retract arm and bucket cylinders and lower bucket to ground.

T106031

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

FR91424,0000002 –19–04NOV03–1/6


approximate approximate approximate approximate –UN–30DEC96

Specification Boom Cylinder—200CLC— Weight......................................................................... 171 kg 377 lb Boom Cylinder—230CLC— Weight......................................................................... 217 kg 480 lb Boom Cylinder—270CLC— Weight......................................................................... 247 kg 540 lb

approximate approximate

T105828

7. Attach hoist to boom cylinder (F) using lifting strap. F—Boom Cylinder

33 3360 75


TM1931 (09JAN04)

33-3360-75

FR91424,0000002 –19–04NOV03–2/6


PN=257

Hydraulic System 8. Remove parts (1—3, and 5). 9. Push pin (4) into boom. Lower boom cylinder (6) on floor stand.

T142979

–UN–24JUL01

1—Nut (2 used) 2—Retainer 3—Cap Screw 4—Boom Cylinder-to-Boom Pin 5—Shim (2 used) 6—Boom Cylinder


FR91424,0000002 –19–04NOV03–3/6

33 3360 76

TM1931 (09JAN04)

33-3360-76


PN=258

Hydraulic System 10. Disconnect hydraulic lines (7) from head end of boom cylinder (6).

8

8

6 9

12. Remove parts (8—11) and remove boom cylinder (6). 13. Repair or replace parts as necessary. 14. Install shims equally on each side of cylinder head end to get the minimum amount of clearance in joint.

7

10 11

15. Align pin bores so Shims are not damaged as pin (10) is installed.

11

T143048

7

–UN–02AUG01

11. Mark location of shims (8) to aid in assembly.

6—Boom Cylinder 7—Rod End-to-Boom Section Bottom Port Line —Head End-to-Boom Section Top Port Line 8—Shim (as required) 9—Cap Screw (2 used) 10—Boom Cylinder-to-Frame Pin (2 used) 11—Nut (4 used)

16. Connect boom cylinder head end to frame. 17. Tighten nuts (11) against each other allowing cap screws (9) to be free to turn in hole. Specification Boom Cylinder-to-Frame Pin Retainer Nut—200CLC—Torque........... 271 N•m (tighten nut against nut) 200 lb-ft (tighten nut against nut) Specification Boom Cylinder-to-Frame Pin Retainer Nut—230CLC, 270CLC—Torque................................... 549 N•m (tighten nut against nut) 405 lb-ft (tighten nut against nut)

18. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) Tighten boom cylinder hoses. Specification Boom Cylinder Hose—200CLC— Torque .......................................................................................... 175 N•m 130 lb-ft Specification Boom Cylinder Hose—230CLC, 270CLC—Torque.......................................................................... 206 N•m 152 lb-ft 33 3360 77


TM1931 (09JAN04)

33-3360-77

FR91424,0000002 –19–04NOV03–4/6


PN=259

Hydraulic System IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. 19. Start engine. 20. Slowly extend boom cylinder (6) to align pin bores so shims (5) are not damaged as pin (4) is installed. 21. Install Shims to get the minimum amount of clearance between boom and boom cylinder rod end. 22. Connect boom cylinder rod end to boom. 23. Tighten nuts (1) against each other allowing cap screw (3) to be free to turn in hole. Specification Boom Cylinder-to-Boom Pin Retainer Nut—200CLC—Torque........... 271 N•m (tighten nut against nut) 200 lb-ft (tighten nut against nut) Specification Boom Cylinder-to-Boom Pin Retainer Nut—230CLC, 270CLC—Torque................................... 549 N•m (tighten nut against nut) 405 lb-ft (tighten nut against nut)

24. Connect lubrication line. Specification Boom Cylinder Pivot Lubrication Line—Torque ............................................................................... 29.5 N•m 21.5 lb-ft

25. Lubricate all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease. (Operator’s Manual.) 33 3360 78

26. Bleed air from cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.)


TM1931 (09JAN04)

33-3360-78

FR91424,0000002 –19–04NOV03–5/6


PN=260

Hydraulic System 27. Check hydraulic oil level . See Check Hydraulic Oil Level. (Operator’s Manual.)

FR91424,0000002 –19–04NOV03–6/6

33 3360 79

TM1931 (09JAN04)

33-3360-79


PN=261

Hydraulic System

Boom Cylinder Disassemble and Assemble—200CLC, 270CLC

T190994

–UN–09MAY03

33 3360 80

Boom Cylinder—200CLC, 270CLC—Right Cylinder Shown Continued on next page

TM1931 (09JAN04)

33-3360-80

FR91424,0000003 –19–05NOV03–1/20


PN=262

Hydraulic System 1—Cylinder Barrel and Bushings 2—Rod and Bushings 3—Rod Guide 4—Wear Ring 5—Snap Ring 6—Buffer Ring Seal 7—U-Cup Seal 8—Back-Up Ring 9—Wiper Seal 10—O-Ring

11—Back-Up Ring 12—Cap Screw (12 used) 13—Cushion 14—Cushion Seal 15—Piston 16—Cap Seal and O-Ring 17—Back-Up Ring (2 used) 18—Buffer Seal (2 used) 19—Wear Ring (2 used) 20—Shim

NOTE: Disassemble and assemble procedures are the same for both right and left boom cylinders.

21—Nut 22—Set Screw 23—Steel Ball 25—Seal (2 used) 26—Retainer Ring 27—Seal (2 used) 28—Hydraulic Line 29—Hydraulic Line 30—O-Ring 31—Cap Screw (4 used)

32—O-Ring 33—Cap Screw (4 used) 34—Band 35—Clamp 36—Cap Screw (2 used) 37—Lock Washer (2 used) 38—Half Clamp (2 used) 39—Cap Screw 40—Lock Washer 41—Lubrication Fitting

1. Fasten head end of cylinder to JT30043 cylinder service stand.

CAUTION: Heavy component; use a hoist. Specification Boom Cylinder—Weight ...................................... 171 kg approximate 377 lb approximate

FR91424,0000003 –19–05NOV03–2/20

2. Remove line (B). 3. Pull rod out so piston is against rod guide.

–UN–27OCT88

4. Connect rod to a hoist using a lifting strap. 5. Remove cap screws (A).

T6557HI

6. Remove rod, rod guide and piston from barrel. A—Cap Screw B—Line

33 3360 81


TM1931 (09JAN04)

33-3360-81

FR91424,0000003 –19–05NOV03–3/20


PN=263

Hydraulic System 7. Install rod eye in sliding housing (B) and install housing in the JT30043 cylinder service stand.

T6557HK

–UN–27OCT88

B—Sliding Housing

FR91424,0000003 –19–05NOV03–4/20

8. Remove the staked material from set screw (A) hole using a small air grinder or a drill and bit. 9. Remove set screw (A) and steel ball (B).

T6585XI

–UN–27OCT88

A—Set Screw B—Steel Ball


FR91424,0000003 –19–05NOV03–5/20

33 3360 82

TM1931 (09JAN04)

33-3360-82


PN=264

Hydraulic System IMPORTANT: To avoid damaging the tapped hole for set screw, the cap screw in the JT30043-30 Hex Piston Nut Wrench must be tightened against a side of the nut without the tapped hole. To avoid gouging side of nut, install a piece of steel flat stock between nut and cap screw. 10. Install JT30043-30 Hex Piston Nut Wrench so cap screw is tightened against side of nut (B) without tapped hole. 11. Install a 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) piece of steel flat stock between nut and cap screw. Tighten cap screw.

–UN–22MAY92

12. Loosen nut (B).

T7768AG

Specification Boom Cylinder Piston-to-Rod Nut—Torque ............................................................................... 4780 N•m 3,525 lb-ft

B—Nut


FR91424,0000003 –19–05NOV03–6/20

33 3360 83

TM1931 (09JAN04)

33-3360-83


PN=265

Hydraulic System 13. Remove parts (A—D and G).

–UN–27OCT88

NOTE: Note direction of flat face (E) on cushion and notches (F) in cushion seal and cushion for assembly. 14. Remove parts from rod guide and piston.

T6585XK

NOTE: Inspect the piston, inside the rod guide and barrel for wear, scratches and nicks that may cut or damage a seal or wear ring.

T8286BL

–UN–16JUL94

A—Nut B—Shim C—Piston D—Cushion E—Flat Face F—Notch G—Cushion Seal


FR91424,0000003 –19–05NOV03–7/20

33 3360 84

TM1931 (09JAN04)

33-3360-84


PN=266

Hydraulic System 15. Remove and inspect dust seals (A) and bushings (B) for wear or damage. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. Repair or replace parts as necessary. (Group 3340.)

T6557HR

–UN–27OCT88

Boom Cylinder—200CLC—Specification Boom Cylinder Head End Bushing—ID.................................................................... 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use Boom Cylinder Rod End Bushing—ID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use

T6585XG

–UN–27OCT88

Boom Cylinder—270CLC—Specification Boom Cylinder Head End Bushing—ID.................................................................. 100.0 mm nominal 3.94 in. nominal ID ............................................................................. 101.5 mm limit of use 4.0 in. limit of use Boom Cylinder Rod End Bushing—ID.................................................................. 100.0 mm nominal 3.94 in. nominal ID ............................................................................. 101.5 mm limit of use 4.0 in. limit of use

16. Check for rod curvature on V-blocks using dial indicator.

A—Dust Seal B—Bushing

Specification Boom Rod—Curvature .................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft

17. Inspect rod surface for scratches or wear. Boom Cylinder—Specification Boom Rod Allowable Scratch— Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Boom Rod—200CLC—OD ......................................... 84.973—85.00 mm 3.349— 3.35 in. Boom Rod—270CLC—OD ......................................... 94.910—95.00 mm 3.736— 3.74 in. 33 3360 85



TM1931 (09JAN04)

33-3360-85

FR91424,0000003 –19–05NOV03–8/20


PN=267

Hydraulic System

T190994

–UN–09MAY03

33 3360 86

Boom Cylinder—200CLC, 270CLC—Right Cylinder Shown

19. Continued on next page

TM1931 (09JAN04)

33-3360-86

FR91424,0000003 –19–05NOV03–9/20


PN=268

T106211

–UN–16JAN97

Hydraulic System

Boom Cylinder—200CLC, 270CLC 1—Cylinder Barrel and Bushings 2—Rod and Bushings 3—Rod Guide 4—Wear Ring 5—Snap Ring 6—Buffer Ring Seal 7—U-Cup Seal 8—Back-Up Ring 9—Wiper Seal 10—O-Ring


21—Nut 22—Set Screw 23—Steel Ball 25—Seal (2 used) 26—Retainer Ring 27—Seal (2 used) 28—Hydraulic Line 29—Hydraulic Line 30—O-Ring 31—Cap Screw (4 used)

32—O-Ring 33—Cap Screw (4 used) 34—Band 35—Clamp 36—Cap Screw (2 used) 37—Lock Washer (2 used) 38—Half Clamp (2 used) 39—Cap Screw 40—Lock Washer 41—Lubrication Fitting

Install boom cylinder barrel and rod bushings to a depth equal to the thickness of seals (25 and 27).

NOTE: Use a cylinder repair kit when assembling a cylinder.

NOTE: The left and right boom cylinders are the same except for the head (28) and rod (29) end lines, and clamps (34 and 35).

20. Install seals (25 and 27) tight against bushing with seal lip outward.


FR91424,0000003 –19–05NOV03–10/20

33 3360 87

TM1931 (09JAN04)

33-3360-87


PN=269

Hydraulic System 21. Push wear ring (C) to bottom of bore using a driver disk and a press. 22. Install the snap ring (B). 23. Install back-up ring (A) and O-ring (D).

T6585XN

–UN–27OCT88

A—Back-Up Ring B—Snap Ring C—Wear Ring D—O-Ring


FR91424,0000003 –19–05NOV03–11/20

33 3360 88

TM1931 (09JAN04)

33-3360-88


PN=270

Hydraulic System 24. Install buffer ring seal (I) with notched side towards wear ring (B). 25. Install black buffer ring (D) with notched side (C) towards the wear ring. 26. Install green buffer ring (E). 27. Install U-cup seal (F) with lip towards wear ring (B) using the bending method (K). 28. Install back-up ring (G). 29. Install wiper seal (H) with lip towards outside of cylinder. 30. Install rod guide (J) on the rod.

T7963AK

–UN–01APR93

A—Snap Ring B—Wear Ring C—Notched Side D—Black Buffer Ring E—Green Buffer Ring F—U-Cup Seal G—Back-Up Ring H—Wiper Seal I—Buffer Ring Seal J—Rod Guide K—Bending Method Seal Installation

T7623AF

–UN–22OCT91

33 3360 89


TM1931 (09JAN04)

33-3360-89

FR91424,0000003 –19–05NOV03–12/20


PN=271

Hydraulic System 31. Install O-ring (C) into the middle groove of piston. 32. Install the buffer seals (D). The buffer seal in groove above helps support the thin section of installer. The buffer seal below keeps the cap seal from going into that groove if pushed too far. 33. Apply clean oil to installer. 34. Push the cap seal (B) down the installer and into the middle groove over the O-ring (C) using the correct size pusher (A).

T7964AQ

–UN–18MAR93

A—JDG901-3 Pusher —JDG917 Installer—200CLC —JDG842-1 Installer—270CLC B—Cap Seal C—O-Ring D—Wear Ring

FR91424,0000003 –19–05NOV03–13/20

35. Check the cap seal, seal must fit tight against O-ring and not turn. If seal can be turned, it has been stretched too much and can be damaged during assembly into cylinder barrel. 36. For a cap seal that has been stretched too much, shrink it to its original size using a ring compressor or a plastic tie band and hose clamp. When using a ring compressor, put a piece of shim stock between cap seal and compressor at the joint so it does not damage seal.

–UN–27OCT88 T6396AC

33 3360 90

When using a plastic tie band and hose clamp, grind a taper on one end of tie band. Install tie band with the taper against cap seal. Before tightening the hose clamp, check to be sure tie band is under hose clamp all around piston.


TM1931 (09JAN04)

33-3360-90

FR91424,0000003 –19–05NOV03–14/20


PN=272

Hydraulic System 37. Install a back-up ring (C) on each side of cap seal. 38. Install the buffer seals (B) and wear rings (A).

–UN–27OCT88

Turn the seals and rings so the slits are 180° from each other

T6557HV

A—Wear Ring (2 used) B—Buffer Seal (2 used) C—Back-Up Ring (2 used)

FR91424,0000003 –19–05NOV03–15/20

39. Install cushion seal (G) so notches (F) are towards the piston and threaded section of rod.

–UN–16JUL94

40. Install cushion (D) so wide end of flat face (E) is towards the rod guide and narrow end is towards the piston.

T8286BL

D—Cushion E—Flat Face F—Notch G—Cushion Seal

Boom Cylinder Rod

FR91424,0000003 –19–05NOV03–16/20

41. Install piston (C) so flat side is against the cushion (D) 42. Install shim (B). –UN–27OCT88

43. Install nut (A).

T6585XK

A—Nut B—Shim C—Piston D—Cushion


TM1931 (09JAN04)

33-3360-91

FR91424,0000003 –19–05NOV03–17/20


PN=273

33 3360 91

Hydraulic System IMPORTANT: To avoid damaging the tapped hole for set screw, the cap screw in the JT30043-30 Hex Piston Nut Wrench must be tightened against a side of the nut without the tapped hole. To avoid gouging side of nut, install a piece of steel flat stock between nut and cap screw. 44. Tighten nut using the JT30043-30 Hex Piston Nut Wrench. Install wrench so cap screw is tighten against a side of nut (B) without the tapped hole. Install a 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) piece of steel flat stock between nut and cap screw. Tighten cap screw.

–UN–22MAY92

Specification Boom Cylinder Piston-to-Rod Nut—Torque ............................................................................... 4780 N•m 3525 lb-ft

T7768AH

B—Nut

FR91424,0000003 –19–05NOV03–18/20

45. Install steel ball (B). 46. Tighten set screw (A).

47. Stake set screw in two places 90° from previous stake marks.

T6585XI

33 3360 92

–UN–27OCT88

Specification Boom Cylinder Nut-to-Rod Set Screw—Torque .............................................................................. 57 N•m 42 lb-ft



TM1931 (09JAN04)

33-3360-92

FR91424,0000003 –19–05NOV03–19/20


PN=274

Hydraulic System 48. Apply clean oil to piston and seals. Attach a hoist to rod using a lifting strap. Carefully install piston, rod and rod guide into barrel.

50. Install the lines (B).

T6557HI

Specification Boom Cylinder Rod Guide-to-Barrel Cap Screw— Torque ......................................................................................... 267 N•m 197 lb-ft

–UN–27OCT88

49. Tighten cap screws (A).

A—Cap Screw B—Lines

FR91424,0000003 –19–05NOV03–20/20

33 3360 93

TM1931 (09JAN04)

33-3360-93


PN=275

Hydraulic System

Boom Cylinder Disassemble and Assemble—230CLC

2

11

5

7

15

23

20

3

9

10

13

14

21 18 22 21

4

20

29 28 44

34

30 32

42 25 37 36

31

1 33 3360 94

33 1

26 28

T196495

29

40

–UN–26NOV03

30

T196495

Boom Cylinder—230CLC—Right Cylinder Shown Continued on next page

TM1931 (09JAN04)

33-3360-94

FR91424,0000006 –19–11NOV03–1/8


PN=276

Hydraulic System 1—Bushings (2 used) 2—Rod and Bushings 3—Seal 4—Rod Guide 5—Cap Screw (12 used) 7—O-Ring 9—Seal 10—Ring

11—Snap Ring 13—Bushing 14—Snap Ring 15—Cushion Ring 18—Piston 20—Piston Ring (2 used) 21—Wear Ring (2 used) 22—Seal Ring

23—Packing 25—Cap Screw (6 used) 26—Hydraulic Line 28—Cap Screw (4 used) 29—Cap Screw (4 used) 30—O-Ring (2 used) 31—Hydraulic Line 32—Clamp

NOTE: Disassemble and assemble procedures are the same for both right and left boom cylinders.

33—Clamp 34—Cap Screw (2 used) 36—Clamp 37—Cap Screw 40—Lubrication Fitting 42—Washer (6 used) 44—Hydraulic Cylinder Barrel


CAUTION: Heavy component; use a hoist. Specification Boom Cylinder—Weight ...................................... 217 kg approximate 480 lb approximate

FR91424,0000006 –19–11NOV03–2/8


–UN–27OCT88


T6557HI



FR91424,0000006 –19–11NOV03–3/8

33 3360 95

TM1931 (09JAN04)

33-3360-95


PN=277


–UN–27OCT88

8. Remove cap screws (25) and washers (42) from piston (18). 9. Remove piston (18), cushion ring (15), rod guide (4) from rod (2).

T6557HK

10. Remove piston rings (20), wear rings (21), seal ring (22), and O-ring (23) from piston (18).


B—Sliding Housing

11. Remove snap ring (11), seal (3), seal (9), ring (10), snap ring (14), and bushing (13) from rod guide (4). 12. Remove and inspect rod (2) and hydraulic cylinder barrel bushings (1) for wear or damage. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. Repair or replace parts as necessary. (Group 3340.) Boom Cylinder—230CLC—Specification Boom Cylinder Head End Bushing—ID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use Boom Cylinder Rod End Bushing—ID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use


FR91424,0000006 –19–11NOV03–4/8

33 3360 96

TM1931 (09JAN04)

33-3360-96


PN=278

Hydraulic System 13. Check for rod curvature on V-blocks using dial indicator.

–UN–27OCT88

Specification Boom Rod—Curvature .................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft

14. Inspect rod surface for scratches or wear.

T6585XG

Boom Cylinder—Specification Boom Rod Allowable Scratch— Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Boom Rod—230CLC—OD ........................................... 89.910—90.0 mm 3.536— 3.540 in.



FR91424,0000006 –19–11NOV03–5/8

33 3360 97

TM1931 (09JAN04)

33-3360-97


PN=279

Hydraulic System

2

11

5

7

15

23

20

3

9

10

13

14

21 18 22 21

4

20

29 28 44

34

30 32

42 25 37 36

31

1 33 33 3360 98

1

26 28

T196495

29

40

–UN–26NOV03

30

T196495

Boom Cylinder—230CLC—Right Cylinder Shown


TM1931 (09JAN04)

33-3360-98

FR91424,0000006 –19–11NOV03–6/8


PN=280

T196497

–UN–10DEC03

Hydraulic System

Boom Cylinder—230CLC 1—Bushings (2 used) 2—Rod and Bushings 3—Seal 4—Rod Guide 5—Cap Screw (12 used) 7—O-Ring 9—Seal 10—Ring


23—Packing 25—Cap Screw (6 used) 26—Hydraulic Line 28—Cap Screw (4 used) 29—Cap Screw (4 used) 30—O-Ring (2 used) 31—Hydraulic Line 32—Clamp

Ensure that ring and seals are installed so that slotted side is facing toward cylinder head end (pressure side).

Install boom cylinder head end and rod end bushings.

NOTE: The left and right boom cylinders are the same except for the hydraulic lines (26 and 31), and clamps (32 and 33). NOTE: Use a cylinder repair kit when assembling a cylinder.

33—Clamp 34—Cap Screw (2 used) 36—Clamp 37—Cap Screw 40—Lubrication Fitting 42—Washer (6 used) 44—Hydraulic Cylinder Barrel

19. Install ring (10), seal (9), seal (3), and snap ring (11). 33 3360 99

20. Install O-ring (7). 17. Install bushing (13) to bottom of bore in rod guide (4) using a driver disk and a press.

21. Install packing (23), seal ring (22), wear rings (21), and piston rings (20) on piston (18).

18. Install the snap ring (14). 22. Install rod guide assembly on rod (2). IMPORTANT: Ring (10), seal (9), and seal (3) must be installed in the correct direction.


TM1931 (09JAN04)

33-3360-99

FR91424,0000006 –19–11NOV03–7/8


PN=281

Hydraulic System IMPORTANT: Cushion ring (15) must be installed in the correct direction. Ensure that cushion ring is installed so that slotted end is facing toward piston (18).

25. Apply clean oil to piston and seals. Attach a hoist to rod using a lifting strap. Carefully install piston, rod and rod guide into barrel.

23. Install cushion ring (15) on rod (2).

Specification Boom Cylinder Rod Guide-to-Hydraulic Cylinder Barrel Cap Screw—Torque .................................................. 395 N•m 290 lb-ft

24. Secure rod assembly on bench and install piston (18) assembly to rod (2). Install cap screws (25) and washers (42).

26. Install and tighten cap screws (5).

27. Install hydraulic lines (26 and 31). Specification Piston-to-Rod Cap Screw— Torque.................................................................................... 395 N•m 290 lb-ft

FR91424,0000006 –19–11NOV03–8/8

Arm Cylinder Remove and Install 1. Park machine on firm, level surface.

FR91424,0000004 –19–11NOV03–1/6

2. Retract arm and bucket cylinders and lower bucket to ground.

–UN–10JAN97

CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury.

T106031

3. Perform Hydraulic Oil Tank Pressure Release Procedure. (Group 3360.) 4. Loosen arm cylinder hydraulic lines at frame end of boom to release any residual pressure. 5. Disconnect lines. 33 3360 ,100


TM1931 (09JAN04)

33-3360-100

FR91424,0000004 –19–11NOV03–2/6


PN=282

Hydraulic System 6. Insert wood block (3 ) between arm cylinder (1) and boom (2).

approximate approximate approximate approximate approximate approximate

7. Attach arm cylinder to hoist using lifting straps.

T143063

Specification Arm Cylinder—200CLC—Weight ............................... 259 kg 570 lb Arm Cylinder—230CLC—Weight ............................... 285 kg 630 lb Arm Cylinder—270CLC—Weight ............................... 307 kg 680 lb

–UN–02AUG01


1—Arm Cylinder 2—Boom 3—Wood Block

FR91424,0000004 –19–11NOV03–3/6

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

–UN–02AUG01

1—Nut (2 used) 2—Cap Screw 3—Shim (as required) 4—Arm Cylinder-to-Arm Pin


FR91424,0000004 –19–11NOV03–4/6

33 3360 ,101

TM1931 (09JAN04)

33-3360-101


PN=283

Hydraulic System 11. Remove parts (1 and 2).

NOTE: Note location of shims (3) to aid in assembly.

–UN–02AUG01

12. Push pin (4) out and remove shims. 13. Remove arm cylinder

15. Install shims equally on each side of cylinder to get minimum amount of clearance in joint. There must be some clearance in the joint.

T143065

14. Repair or replace parts as necessary. See Arm Cylinder Disassemble and Assemble—200CLC, 270CLCor see Arm Cylinder Disassemble and Assemble—230CLC. (Group 3360.) 1—Nut (2 used) 2—Cap Screw 3—Shim (as required) 4—Arm 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 Line—Torque ............................................................................... 29.5 N•m 21.5 lb-ft

18. Connect arm cylinder head end to boom. 19. Tighten nuts (1) against each other allowing cap screw (2) to be free to turn in hole. Specification Arm Cylinder-to-Boom Pin Retainer Nut—200CLC—Torque........... 550 N•m 405 lb-ft Arm Cylinder-to-Boom Pin Retainer Nut—230CLC, 270CLC—Torque................................... 750 N•m 550 lb-ft

(tighten nut against nut) (tighten nut against nut)

(tighten nut against nut) (tighten nut against nut)

33 3360 ,102


TM1931 (09JAN04)

33-3360-102

FR91424,0000004 –19–11NOV03–5/6


PN=284

Hydraulic System IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. 20. Slowly extend arm cylinder to align pin bores so shims are not damaged as pin is installed. 21. Connect arm cylinder rod end to arm. 22. Tighten nuts (1) against each other allowing cap screw (2) to be free to turn in hole. Specification Arm Cylinder-to-Arm Pin Retainer Nut—200CLC—Torque ......................... 550 N•m 405 lb-ft Arm Cylinder-to-Arm Pin Retainer Nut—230CLC, 270CLC—Torque .......... 750 N•m 550 lb-ft

(tighten nut against nut) (tighten nut against nut) (tighten nut against nut) (tighten nut against nut)

23. Connect lubrication line. Specification Arm Cylinder Pivot Lubrication Line—Torque ............................................................................... 29.5 N•m 21.5 lb-ft

24. Connect lines. 25. Lubricate all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, And Swing Bearing Gear Grease. (Operator’s Manual.) 26. Bleed air from cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.) 27. Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator’s Manual.) 33 3360 ,103

FR91424,0000004 –19–11NOV03–6/6

TM1931 (09JAN04)

33-3360-103


PN=285

Hydraulic System

Arm Cylinder Disassemble and Assemble—200CLC, 270CLC

T190996

–UN–09MAY03

33 3360 ,104

Arm Cylinder Continued on next page

TM1931 (09JAN04)

33-3360-104

FR91424,0000005 –19–11NOV03–1/22


PN=286

Hydraulic System 1—Cylinder Barrel and Bushing 2—Rod and Bushings 3—Rod Guide 4—Wear Ring 5—Snap Ring 6—Buffer Ring Seal 7—U-Cup Seal 8—Back-Up Ring 9—Wiper Seal 10—O-Ring


21—Nut 22—Set Screw 23—Steel Ball 24—Cushion 25—Cushion Seal 26—Retainer Ring 27—Ring 29—Seal 30—Shoulder Fitting 31—Hydraulic Line

CAUTION: Heavy components; use a hoist. Specification Arm Cylinder—200CLC— Weight .................................................................. 259 kg approximate 571 lb approximate

32—O-Ring 33—Cap Screw (8 used) 34—Band 35—Band 36—Cap Screw (2 used) 37—Lock Washer (2 used) 38—Clamp 39—Cap Screw 40—Lock Washer 41—Lubrication Fitting

Arm Cylinder—270CLC— Weight .................................................................. 307 kg approximate 680 kg approximate


FR91424,0000005 –19–11NOV03–2/22


–UN–27OCT88


T6557HI


FR91424,0000005 –19–11NOV03–3/22

7. Install rod eye in sliding housing (B) and install housing in the JT30043 cylinder service stand.

33 3360 ,105

T6557HK

–UN–27OCT88

B—Sliding Housing


TM1931 (09JAN04)

33-3360-105

FR91424,0000005 –19–11NOV03–4/22


PN=287

Hydraulic System 8. Remove the staked material from set screw (A) hole using a small air grinder or a drill and bit. 9. Remove set screw (A) and steel ball (B).

T6585XI

–UN–27OCT88


FR91424,0000005 –19–11NOV03–5/22

IMPORTANT: To avoid damaging the tapped hole for set screw, the cap screw in the JT30043-30 Hex Piston Nut Wrench must be tightened against a side of the nut without the tapped hole. To avoid gouging side of nut, install a piece of steel flat stock between nut and cap screw. 10. Install JT30043-30 Hex Piston Nut Wrench so cap screw is tightened against side of nut (B) without tapped hole. 11. Install a 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) piece of steel flat stock between nut and cap screw. Tighten cap screw.

–UN–22MAY92

12. Loosen nut (B).

T7768AG

Specification Arm Cylinder Piston-to-Rod Nut— 200CLC, 270CLC—Torque ..................................................... 10 200 N•m 7,520 lb-ft

B—Nut

33 3360 ,106


TM1931 (09JAN04)

33-3360-106

FR91424,0000005 –19–11NOV03–6/22


PN=288

Hydraulic System 13. Remove parts (A—D and G).

–UN–27OCT88

NOTE: Note direction of flat face (E) on cushion and notches (F) in cushion seal and cushion for assembly.

T8286BL

–UN–16JUL94

T6585XK


FR91424,0000005 –19–11NOV03–7/22

14. Remove ring (A). Push cushion (C) against shoulder.

–UN–10JUN92

Remove retainer ring (B) and remove cushion.

NOTE: Note direction of flat face on cushion and notches in cushion seal for assembly.

T7778AU

Remove cushion seal (D). 15. Remove parts from rod guide and piston. Arm Cylinder Rod End Cushion


A—Ring B—Retainer Ring C—Cushion D—Cushion Seal


TM1931 (09JAN04)

33-3360-107

33 3360 ,107

FR91424,0000005 –19–11NOV03–8/22


PN=289

Hydraulic System 16. Remove and inspect dust seals (A) and bushing (B) for wear or damage. Replace parts as necessary. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. (Group 3340.)

T6557HR

–UN–27OCT88

Arm Cylinder—200CLC—Specification Arm Cylinder Head End and Rod End Bushing—ID ............................................................ 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use Arm Cylinder—270CLC—Specification Arm Cylinder Head End and Rod End Bushing—ID ............................................................ 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use

–UN–27OCT88


T6585XG

Specification Arm Rod—Curvature ....................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft

18. Inspect rod surface for scratches or wear. Arm Cylinder—200CLC—Specification Arm Rod Allowable Scratch— Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Arm Rod—OD .............................................................. 94.973—95.0 mm 3.739—3.740 in.


Arm Cylinder—270CLC—Specification Arm Rod Allowable Scratch— Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Arm Rod—OD ................................................................. 99.91—100 mm 3.936—3.940 in.

19. Repair or replace parts as necessary. 33 3360 ,108


TM1931 (09JAN04)

33-3360-108

FR91424,0000005 –19–11NOV03–9/22


PN=290

Hydraulic System

T190996

–UN–09MAY03

33 3360 ,109

Arm Cylinder


TM1931 (09JAN04)

33-3360-109

FR91424,0000005 –19–11NOV03–10/22


PN=291

T106126

–UN–16JAN97

Hydraulic System

Arm Cylinder 1—Cylinder Barrel and Bushing 2—Rod and Bushings 3—Rod Guide 4—Wear Ring 5—Snap Ring 6—Buffer Ring Seal 7—U-Cup Seal 8—Back-Up Ring 9—Wiper Seal 10—O-Ring


Install arm cylinder barrel and rod bushings to a depth equal to the thickness of seals (29).

21—Nut 22—Set Screw 23—Steel Ball 24—Cushion 25—Cushion Seal 26—Retainer Ring 27—Ring 29—Seal (4 used) 30—Shoulder Fitting 31—Hydraulic Line

32—O-Ring 33—Cap Screw (8 used) 34—Band 35—Band 36—Cap Screw (2 used) 37—Lock Washer (2 used) 38—Clamp 39—Cap Screw 40—Lock Washer 41—Lubrication Fitting

21. Install seals (29) tight against bushing with seal lip outward.



FR91424,0000005 –19–11NOV03–11/22

33 3360 ,110

TM1931 (09JAN04)

33-3360-110


PN=292


T6585XN

–UN–27OCT88



FR91424,0000005 –19–11NOV03–12/22

33 3360 ,111

TM1931 (09JAN04)

33-3360-111


PN=293

Hydraulic System 25. Install buffer ring seal (I) with notched side towards wear ring (B). Install black buffer ring (D) with notched side (C) towards the wear ring. Install green buffer ring (E). 26. Install U-cup seal (F) with lip towards wear ring (B) using the bending method (K). Install back-up ring (G). 27. Install wiper seal (H) with lip towards outside of cylinder. 28. Install rod guide (J) on the rod.

T7963AK

–UN–01APR93


T7623AF

–UN–22OCT91

33 3360 ,112


TM1931 (09JAN04)

33-3360-112

FR91424,0000005 –19–11NOV03–13/22


PN=294


T7964AQ

–UN–18MAR93

A —JDG901-3 Pusher —JDG842-1 Installer—200CLC —JDG843-1 Installer—270CLC B—Cap Seal C—O-Ring D—Wear Ring

FR91424,0000005 –19–11NOV03–14/22

33. Check the cap seal, seal must fit tight against O-ring and not turn. If seal can be turned, it has been stretched too much and can be damaged during assembly into cylinder barrel. 34. For a cap seal that has been stretched too much, shrink it to its original size using a ring compressor or a plastic tie band and hose clamp. When using a ring compressor, put a piece of shim stock between cap seal and compressor at the joint so it does not damage seal. When using a plastic tie band and hose clamp, grind a taper on one end of tie band. Install tie band with the taper against cap seal. Before tightening the hose clamp, check to be sure tie band is under hose clamp all around piston.

T6396AC

–UN–27OCT88

33 3360 ,113


TM1931 (09JAN04)

33-3360-113

FR91424,0000005 –19–11NOV03–15/22


PN=295

Hydraulic System 35. Install a back-up ring (C) on each side of cap seal and O-ring. 36. Install the buffer seals (B) and wear rings (A). –UN–27OCT88


T6557HV


FR91424,0000005 –19–11NOV03–16/22

37. Install cushion seals (A and C) so notches (B) are towards the piston and threaded section of rod.

T7778AV

–UN–10JUN92

A—Cushion Seal B—Notch C—Cushion Seal

Arm Cylinder Rod


FR91424,0000005 –19–11NOV03–17/22

33 3360 ,114

TM1931 (09JAN04)

33-3360-114


PN=296

Hydraulic System 38. Install cushion (C) so wide end of flat face is towards the end of rod and narrow end is towards the piston. 39. Install retainer ring in groove. –UN–10JUN92

40. Pull cushion out against retainer ring.

T7778AU

41. Install ring (A). A—Ring B—Retainer Ring C—Cushion D—Cushion Seal

Arm Cylinder Rod Cushion

FR91424,0000005 –19–11NOV03–18/22

42. Install piston (C) so flat side is against the cushion (D) 43. Install shim (B). –UN–27OCT88


T6585XK



FR91424,0000005 –19–11NOV03–19/22

33 3360 ,115

TM1931 (09JAN04)

33-3360-115


PN=297


–UN–22MAY92

Specification Arm Cylinder Piston-to-Rod Nut— Torque ..................................................................................... 10 200 N•m 7,520 lb-ft

T7768AH

B—Nut

FR91424,0000005 –19–11NOV03–20/22


48. Stake set screw in two places 90° from previous stake marks.

T6585XI

33 3360 ,116

–UN–27OCT88

Specification Arm Cylinder Nut-to-Rod Set Screw—Torque .............................................................................. 57 N•m 42 lb-ft



TM1931 (09JAN04)

33-3360-116

FR91424,0000005 –19–11NOV03–21/22


PN=298


T6557HI

Specification Arm Cylinder Rod Guide-to-Barrel Cap Screw—Torque .................................................................... 365 N•m 270 lb-ft

–UN–27OCT88


51. Install the lines (B). A—Cap Screw B—Lines

FR91424,0000005 –19–11NOV03–22/22

33 3360 ,117

TM1931 (09JAN04)

33-3360-117


PN=299

Hydraulic System

Arm Cylinder Disassemble and Assemble—230CLC 46 2

11

7

9

5 10 13

30

14

32

29

35

40

31

4 6

40 27

39

15

52

39 48

49

53

21

36 51 22

21

52 54 25

1

34 37 34

56

T196496

37

1

–UN–26NOV03

33 3360 ,118

T196496

Arm Cylinder—230CLC Continued on next page

TM1931 (09JAN04)

33-3360-118

FR91424,0000010 –19–21NOV03–1/8


PN=300

Hydraulic System 1—Bushing (2 used) 2—Rod and Bushings 4—Rod Guide 5—Cap Screw (14 used) 6—O-Ring 7—Seal 9—Seal 10—Scraper Ring 11—Snap Ring

13—Bushing 14—Snap Ring 15—Cushion Ring 21—Piston Ring (2 used) 22—Seal Ring 25—Cap Screw (6 used) 27—Spring 29—Hydraulic Line 30—Cap Screw (2 used)

31—Cap Screw (2 used) 32—O-Ring 34—Clamp (2 used) 35—Clamp 36—Clamp 37—Cap Screw (4 used) 39—Clamp (2 used) 40—Cap Screw (4 used)


46—Lubrication Fitting 48—Stop 49—Ball 51—Piston 52—Ring (2 used) 53—Plunger 54—Washer (6 used) 56—Hydraulic Cylinder Barrel


Specification Arm Cylinder—Weight ......................................... 285 kg approximate 630 lb approximate

FR91424,0000010 –19–21NOV03–2/8


–UN–27OCT88


T6557HI

IMPORTANT: To avoid damaging sliding surfaces, be sure to pull out rod, rod guide, and piston straight out of cylinder barrel. 6. Remove rod, rod guide and piston from barrel. A—Cap Screw B—Hydraulic Line


FR91424,0000010 –19–21NOV03–3/8

33 3360 ,119

TM1931 (09JAN04)

33-3360-119


PN=301


–UN–27OCT88


11. Remove piston rings (21), wear rings (52), and seal ring (22) from piston (51).

T6557HK

10. Remove spring (37), stop (48), ball (49), and plunger (53) from piston (51).

B—Sliding Housing

NOTE: Inspect the piston, inside the rod guide and barrel for wear, scratches and nicks that may cut or damage a seal or wear ring. 12. Remove snap ring (11), seal (3), seal (9), ring (10), snap ring (14), and bushing (13) from rod guide (4). 13. Remove and inspect rod (2) and hydraulic cylinder barrel bushings (1) for wear or damage. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. Repair or replace parts as necessary. (Group 3340.) Arm Cylinder—230CLC—Specification Arm Cylinder Head End Bushing—ID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use Arm Cylinder Rod End Bushing— ID .................................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use

33 3360 ,120


TM1931 (09JAN04)

33-3360-120

FR91424,0000010 –19–21NOV03–4/8


PN=302


–UN–27OCT88

Specification Arm Rod—Curvature ....................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft


T6585XG

Arm Cylinder—Specification Arm Rod Allowable Scratch— Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Arm Rod—230CLC—OD.......................................... 104.910—105.0 mm 4.126— 4.130 in.



FR91424,0000010 –19–21NOV03–5/8

33 3360 ,121

TM1931 (09JAN04)

33-3360-121


PN=303

Hydraulic System

46 2

11

7

9

5 10 13

30

14

32

29

35

40

31

4 6

40 27

39

15

52

39 48

49

53

21

36 51 22

21

52 54 25

1

34 37 34

56

T196496

37

1

–UN–26NOV03

33 3360 ,122

T196496

Arm Cylinder—230CLC


TM1931 (09JAN04)

33-3360-122

FR91424,0000010 –19–21NOV03–6/8


PN=304

T196498

–UN–09DEC03

Hydraulic System

Arm Cylinder—230CLC 1—Bushing (2 used) 2—Rod and Bushings 4—Rod Guide 5—Cap Screw (14 used) 6—O-Ring 7—Seal 9—Seal 10—Scraper Ring 11—Snap Ring

13—Bushing 14—Snap Ring 15—Cushion Ring 21—Piston Ring (2 used) 22—Seal Ring 25—Cap Screw (6 used) 27—Spring 29—Hydraulic Line 30—Cap Screw (2 used)

31—Cap Screw (2 used) 32—O-Ring 34—Clamp (2 used) 35—Clamp 36—Clamp 37—Cap Screw (4 used) 39—Clamp (2 used) 40—Cap Screw (4 used)

Install arm cylinder head end and rod end bushings.

NOTE: Use a cylinder repair kit when assembling a cylinder. 18. Install bushing (13) to bottom of bore in rod guide (4) using a driver disk and a press. 19. Install the snap ring (14).

facing toward cylinder head end (pressure side). 20. Install ring (10), seal (9), seal (7), and snap ring (11). 21. Install O-ring (6). 33 3360 ,123

22. Install seal ring (22), piston rings (21), and wear rings (52) on piston (51).

IMPORTANT: Ring (10), seal (9), and seal (7) must be installed in the correct direction. Ensure that ring and seals are installed so that slotted side is

23. Install plunger (53), ball (49), stop (48), and spring (27).


TM1931 (09JAN04)

46—Lubrication Fitting 48—Stop 49—Ball 51—Piston 52—Wear Ring (2 used) 53—Plunger 54—Washer (6 used) 56—Hydraulic Cylinder Barrel

33-3360-123

FR91424,0000010 –19–21NOV03–7/8


PN=305

Hydraulic System 24. Install rod guide assembly on rod (2). IMPORTANT: Cushion ring (15) must be installed in the correct direction. Ensure that cushion ring is installed so that slotted end is facing toward piston (51). 25. Install cushion ring (15) on rod (2). 26. Secure rod assembly on bench and install piston (51) assembly to rod (2). Install cap screws (25) and washers (54).

27. Apply clean oil to piston and seals. Attach a hoist to rod using a lifting strap. Carefully install piston, rod and rod guide into barrel. 28. Install and tighten cap screws (5). Specification Arm Cylinder Rod Guide-to-Hydraulic Cylinder Barrel Cap Screw—Torque .................................................. 395 N•m 290 lb-ft

29. Install hydraulic line (29).

Specification Piston-to-Rod Cap Screw— Torque.................................................................................... 539 N•m 400 lb-ft

FR91424,0000010 –19–21NOV03–8/8

Bucket Cylinder Remove and Install 1. Park machine on firm, level surface.

–UN–10JAN97

2. Retract arm cylinder and bucket cylinder (B) and lower bucket to ground. Position end of arm (C) on wood block (D).

T106031

CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 3. Perform Hydraulic Oil Tank Pressure Release Procedure. (Group 3360.)

–UN–09JAN97

B—Bucket Cylinder C—End of Arm D—Wood Block

T106135

33 3360 ,124


TM1931 (09JAN04)

33-3360-124

FR91424,0000011 –19–21NOV03–1/5


PN=306

Hydraulic System 4. Disconnect lines. 5. Connect center link to hoist using lifting strap.

–UN–02AUG01

6. Put wood block (5) between bucket cylinder and arm to hold cylinder up when pin (1) is removed. 7. Remove parts (2 and 6).

T143075

NOTE: Mark location of shims (3) to aid in assembly. 8. Push pin (1) out and remove shims (3). 1—Side and Center Links-to-Bucket Cylinder Pin 2—Cap Screw 3—Shim (as required) 4—Bucket Cylinder Rod End-to-Bucket Section Top Port Line 5—Wood Block 6—Nut (2 used) 7—Side Link


FR91424,0000011 –19–21NOV03–2/5

33 3360 ,125

TM1931 (09JAN04)

33-3360-125


PN=307

Hydraulic System


5

approximate approximate approximate approximate

6 3

2

approximate approximate

–UN–02AUG01

Bucket Cylinder—Specification Bucket Cylinder—200CLC— Weight......................................................................... 145 kg 320 lb Bucket Cylinder—230CLC— Weight......................................................................... 182 kg 400 lb Bucket Cylinder—270CLC— Weight......................................................................... 216 kg 480 lb

4

1

9. Disconnect bucket cylinder rod end hose (1).

T143076

10. Connect bucket cylinder (2) to hoist using lifting strap. 11. Remove parts (3 and 5).

NOTE: Mark location of shims (4) to aid in assembly. 12. Push pin (6) out and remove shims (4). 13. Remove bucket cylinder.

1—Bucket Cylinder Rod End Hose 2—Bucket Cylinder 3—Nut (2 used) 4—Shim (as required) 5—Cap Screw 6—Bucket Cylinder-to-Arm Pin

14. Repair or replace parts as necessary. See Bucket Cylinder Disassemble and Assemble—200CLC, 270CLC or see Bucket Cylinder Disassemble and Assemble—230CLC. (Group 3360.) 15. Install shims equally on each side of bucket cylinder head end to get minimum amount of clearance in joint. 16. Align pin bores so shims are not damaged as pin is installed. 17. Connect bucket cylinder head end to arm. 18. Tighten nuts (3) against each other allowing cap screw (5) to be free to turn in hole.

33 3360 ,126

Bucket Cylinder—Specification Bucket Cylinder-to-Arm Pin Retainer Nut—200CLC—Torque........... 271 N•m (tighten 200 lb-ft (tighten Bucket Cylinder-to-Arm Pin Retainer Nut—230CLC, 270CLC—Torque................................... 750 N•m (tighten 550 lb-ft (tighten

nut against nut) nut against nut)

nut against nut) nut against nut)


TM1931 (09JAN04)

33-3360-126

FR91424,0000011 –19–21NOV03–3/5


PN=308

Hydraulic System 19. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) Tighten bucket cylinder hoses. Bucket Cylinder—Specification Bucket Cylinder Hose— 200CLC—Torque.......................................................................... 175 N•m 130 lb-ft Bucket Cylinder Hose—230CLC, 270CLC—Torque.......................................................................... 205 N•m 152 lb-ft

IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage. 20. Start engine. 21. Slowly extend bucket cylinder to align pin bores so shims are not damaged as pin is installed. 22. Install shims equally on each side of cylinder rod end and side links to get minimum amount of clearance in joint. 23. Connect bucket cylinder head end to arm. 24. Tighten nuts against each other allowing cap screw to be free to turn in hole. Bucket Cylinder—Specification Bucket Cylinder-to-Pin Retainer Nut—Torque .......................................... 550 N•m (tighten nut against nut) 405 lb-ft (tighten nut against nut)

25. Lubricate all pivot joints. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operator’s Manual.)

33 3360 ,127

26. Bleed air from cylinder. See Hydraulic Cylinder Bleed Procedure. (Group 3360.)


TM1931 (09JAN04)

33-3360-127

FR91424,0000011 –19–21NOV03–4/5


PN=309

Hydraulic System 27. Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator’s Manual.)

FR91424,0000011 –19–21NOV03–5/5

33 3360 ,128

TM1931 (09JAN04)

33-3360-128


PN=310

Hydraulic System

33 3360 ,129

TM1931 (09JAN04)

33-3360-129


PN=311

Hydraulic System

Bucket Cylinder Disassemble and Assemble—200CLC, 270CLC

T190997

–UN–09MAY03

33 3360 ,130

Bucket Cylinder Continued on next page

TM1931 (09JAN04)

33-3360-130

FR91424,0000012 –19–21NOV03–1/20


PN=312

Hydraulic System 1—Cylinder Barrel and Bushings 2—Rod and Bushings 3—Rod Guide 4—Wear Ring 5—Snap Ring 6—Buffer Ring Seal 7—U-Cup Seal 8—Back-Up Ring 9—Wiper Seal

10—O-Ring 11—Back-Up Ring 12—Cap Screw (12 used) 13—Cushion 14—Piston 15—Cap Seal and O-Ring 16—Back-Up Ring (2 used) 17—Buffer Seal (2 used) 18—Wear Ring (2 used) 19—Shim

20—Nut 21—Set Screw 22—Steel Ball 23—Lubrication Fitting (2 used) 24—Seal (2 used) 26—Seal (2 used) 27—Elbow Fitting 28—Hydraulic Line

CAUTION: Heavy components; use a hoist. Specification Bucket Cylinder—200CLC— Weight .................................................................. 145 kg approximate 320 lb approximate

29—O-Ring (2 used) 30—Cap Screw (8 used) 31—Band 32—Band 33—Cap Screw (2 used) 34—Lock Washer (2 used) 35—Clamp 36—Cap Screw 37—Lock Washer

Bucket Cylinder—270CLC— Weight .................................................................. 216 kg approximate 480 lb approximate


FR91424,0000012 –19–21NOV03–2/20


–UN–27OCT88


T6557HI


FR91424,0000012 –19–21NOV03–3/20

7. Install rod eye in sliding housing (B) and install housing in the JT30043 cylinder service stand.

33 3360 ,131

T6557HK

–UN–27OCT88

B—Sliding Housing


TM1931 (09JAN04)

33-3360-131

FR91424,0000012 –19–21NOV03–4/20


PN=313

Hydraulic System 8. Remove the staked material from set screw (A) hole using a small air grinder or a drill and bit. 9. Remove set screw (A) and steel ball (B).

T6585XI

–UN–27OCT88


FR91424,0000012 –19–21NOV03–5/20

IMPORTANT: To avoid damaging the tapped hole for set screw, the cap screw in the JT30043-30 Hex Piston Nut Wrench must be tightened against a side of the nut without the tapped hole. To avoid gouging side of nut, install a piece of steel flat stock between nut and cap screw. 10. Install JT30043-30 Hex Piston Nut Wrench so cap screw is tightened against side of nut (B) without tapped hole. 11. Install a 38 x 51 x 6.4 mm (1.5 x 2.0 x 0.25 in.) piece of steel flat stock between nut and cap screw. Tighten cap screw.

–UN–22MAY92

12. Loosen nut (B).

T7768AG

Specification Bucket Cylinder Piston-to-Rod Nut—Torque .............................................................................. 6570 N•m 4,850 lb-ft

B—Nut

33 3360 ,132


TM1931 (09JAN04)

33-3360-132

FR91424,0000012 –19–21NOV03–6/20


PN=314

Hydraulic System 13. Remove parts (A—D). 14. Remove parts from rod guide and piston.

–UN–27OCT88


T8286BL

–UN–16JUL94

T6585XK



FR91424,0000012 –19–21NOV03–7/20

33 3360 ,133

TM1931 (09JAN04)

33-3360-133


PN=315

Hydraulic System 15. Remove and inspect dust seals (A) and bushing (B) for wear or damage. Replace parts as necessary. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. (Group 3340.)

T6557HR

–UN–27OCT88

Bucket Cylinder—200CLC—Specification Bucket Cylinder Head End Bushing—ID.................................................................... 71.0 mm nominal 2.80 in. nominal ID ............................................................................... 72.5 mm limit of use 2.85 in. limit of use Bucket Cylinder Rod End Bushing—ID.................................................................... 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use


T6585XG

–UN–27OCT88

Bucket Cylinder—270CLC—Specification Bucket Cylinder Head End Bushing—ID.................................................................... 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use Bucket Cylinder Rod End Bushing—ID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use


Specification Bucket Rod—Curvature................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft

17. Inspect rod surface for scratches or wear. Bucket Cylinder—Specification Bucket Rod Allowable Scratch— Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Bucket Rod—200CLC—OD .......................................... 79.81—80.00 mm 3.143—3.150 in. Bucket Rod—270CLC—OD .......................................... 89.81—90.00 mm 3.533—3.540 in. 33 3360 ,134



TM1931 (09JAN04)

33-3360-134

FR91424,0000012 –19–21NOV03–8/20


PN=316

Hydraulic System

T190996

–UN–09MAY03

33 3360 ,135

Bucket Cylinder


TM1931 (09JAN04)

33-3360-135

FR91424,0000012 –19–21NOV03–9/20


PN=317

T106212

–UN–17JAN97

Hydraulic System

Bucket Cylinder 1—Cylinder Barrel and Bushings 2—Rod and Bushings 3—Rod Guide 4—Wear Ring 5—Snap Ring 6—Buffer Ring Seal 7—U-Cup Seal 8—Back-Up Ring 9—Wiper Seal

10—O-Ring 11—Back-Up Ring 12—Cap Screw (12 used) 13—Cushion 14—Piston 15—Cap Seal and O-Ring 16—Back-Up Ring (2 used) 17—Buffer Seal (2 used) 18—Wear Ring (2 used) 19—Shim

Install cylinder barrel and rod bushing to a depth equal to the thickness of seals (24 and 26).

20—Nut 21—Set Screw 22—Steel Ball 23—Lubrication Fitting (2 used) 24—Seal (2 used) 26—Seal (2 used) 27—Elbow Fitting 28—Hydraulic Line

29—O-Ring (2 used) 30—Cap Screw (8 used) 31—Band 32—Band 33—Cap Screw (2 used) 34—Lock Washer (2 used) 35—Clamp 36—Cap Screw 37—Lock Washer

20. Install seals (24 and 26) tight against bushing with seal lip outward.



FR91424,0000012 –19–21NOV03–10/20

33 3360 ,136

TM1931 (09JAN04)

33-3360-136


PN=318


T6585XN

–UN–27OCT88



FR91424,0000012 –19–21NOV03–11/20

33 3360 ,137

TM1931 (09JAN04)

33-3360-137


PN=319

Hydraulic System 24. Install buffer ring seal (I) with notched side towards wear ring (B). 25. Install black buffer ring (D) with notched side (C) towards the wear ring. 26. Install green buffer ring (E). 27. Install U-cup seal (F) with lip towards wear ring (B) using the bending method (K). 28. Install back-up ring (G). 29. Install wiper seal (H) with lip towards outside of cylinder. 30. Install rod guide (J) on the rod.

T7963AK

–UN–01APR93


T7623AF

–UN–22OCT91

33 3360 ,138


TM1931 (09JAN04)

33-3360-138

FR91424,0000012 –19–21NOV03–12/20


PN=320


T7964AQ

–UN–18MAR93

A—JDG840-6 Pusher —JDG840-4 Installer—200CLC —JDG842-1 Installer—270CLC B—Cap Seal C—O-Ring D—Wear Ring

FR91424,0000012 –19–21NOV03–13/20

35. Check the cap seal, seal must fit tight against O-ring and not turn. If seal can be turned, it has been stretched too much and can be damaged during assembly into cylinder barrel. 36. For a cap seal that has been stretched too much, shrink it to its original size using a ring compressor or a plastic tie band and hose clamp. When using a ring compressor, put a piece of shim stock between cap seal and compressor at the joint so it does not damage seal. When using a plastic tie band and hose clamp, grind a taper on one end of tie band. Install tie band with the taper against cap seal. Before tightening the hose clamp, check to be sure tie band is under hose clamp all around piston.

T6396AC

–UN–27OCT88

33 3360 ,139


TM1931 (09JAN04)

33-3360-139

FR91424,0000012 –19–21NOV03–14/20


PN=321

Hydraulic System 37. Install a back-up ring (C) on each side of cap seal. 38. Install the buffer seals (B) and wear rings (A).

–UN–27OCT88


T6557HV


FR91424,0000012 –19–21NOV03–15/20

NOTE: For bucket cylinder, no cushion seal is used under the cushion.

–UN–16JUL94

39. Install cushion (D) so wide end of flat face (E) is towards the rod guide and narrow end is towards the piston.

T8286BL

D—Cushion E—Flat Face F—Notch (not on bucket cylinder) G—Cushion Seal (not on bucket cylinder)

Boom Cylinder Rod Shown

FR91424,0000012 –19–21NOV03–16/20

40. Install piston (C) so flat side is against the cushion (D) 41. Install shim (B).


T6585XK

33 3360 ,140

–UN–27OCT88



TM1931 (09JAN04)

33-3360-140

FR91424,0000012 –19–21NOV03–17/20


PN=322


–UN–22MAY92

Specification Bucket Cylinder Piston-to-Rod Nut—Torque .............................................................................. 6570 N•m 4,850 lb-ft

T7768AH

B—Nut

FR91424,0000012 –19–21NOV03–18/20


–UN–27OCT88

Specification Bucket Cylinder Nut-to-Rod Set Screw—Torque .............................................................................. 57 N•m 42 lb-ft

T6585XI

46. Stake set screw in two places 90° from previous stake marks. A—Set Screw B—Steel Ball


TM1931 (09JAN04)

33-3360-141

FR91424,0000012 –19–21NOV03–19/20


PN=323

33 3360 ,141


T6557HI

Specification Bucket Cylinder Rod Guide-to-Barrel Cap Screw— Torque .......................................................................................... 267 N•m 197 lb-ft

–UN–27OCT88


A—Cap Screw B—Lines

FR91424,0000012 –19–21NOV03–20/20

33 3360 ,142

TM1931 (09JAN04)

33-3360-142


PN=324

Hydraulic System

33 3360 ,143

TM1931 (09JAN04)

33-3360-143


PN=325

Hydraulic System

Bucket Cylinder Disassemble and Assemble—230CLC

2 42

11

7

9

5 10 13

14

6

19

44 24

15 22

19

4 20 18 21 28

20 46

26 41 31 27 1 25

33 3360 ,144

35

32

34

T196499

30

–UN–26NOV03

1

T196499

Bucket Cylinder—230CLC Continued on next page

TM1931 (09JAN04)

33-3360-144

FR91424,0000013 –19–21NOV03–1/9


PN=326

Hydraulic System 1—Bushings (2 used) 2—Rod and Bushings 4—Rod Guide 5—Cap Screw (12 used) 6—O-Ring 7—Seal 9—Seal 10—Ring


22—Packing 24—Cap Screw (6 used) 25—Hydraulic Line 26—Cap Screw (2 used) 27—Cap Screw (2 used) 28—O-Ring 30—Clamp 31—Clamp


32—Cap Screw (2 used) 34—Clamp 35—Cap Screw (2 used) 41—Lubrication Fitting 42—Lubrication Fitting 44—Washer (6 used) 46—Hydraulic Cylinder Barrel


Specification Bucket Cylinder—Weight ..................................... 182 kg approximate 400 lb approximate

FR91424,0000013 –19–21NOV03–2/9


–UN–27OCT88


T6557HI

IMPORTANT: To avoid damaging sliding surfaces, be sure to pull out rod, rod guide, and piston straight out of cylinder barrel. 6. Remove rod, rod guide and piston from barrel. A—Cap Screw B—Line


FR91424,0000013 –19–21NOV03–3/9

33 3360 ,145

TM1931 (09JAN04)

33-3360-145


PN=327


–UN–27OCT88



T6557HK

10. Remove piston rings (19), wear rings (20), seal ring (21), and packing (22) from piston (18).

B—Sliding Housing

11. Remove snap ring (11), seal (7), seal (9), ring (10), snap ring (14), and bushing (13) from rod guide (4). 12. Remove and inspect rod (2) and hydraulic cylinder barrel bushings (1) for wear or damage. See Boom, Arm, and Bucket Pins, Bushings and Bosses Inspection. Repair or replace parts as necessary. (Group 3340.) Bucket Cylinder—230CLC—Specification Bucket Cylinder Head End Bushing—ID.................................................................... 80.0 mm nominal 3.15 in. nominal ID ............................................................................... 81.5 mm limit of use 3.21 in. limit of use Bucket Cylinder Rod End Bushing—ID.................................................................... 90.0 mm nominal 3.54 in. nominal ID ............................................................................... 91.5 mm limit of use 3.60 in. limit of use


FR91424,0000013 –19–21NOV03–4/9

33 3360 ,146

TM1931 (09JAN04)

33-3360-146


PN=328


–UN–27OCT88

Specification Bucket Rod—Curvature................................................... 0.5 mm per 1 m 0.020 in. per 3.25 ft


T6585XG

Bucket Cylinder—Specification Bucket Rod Allowable Scratch— Depth ........................................................ 0.1 mm (enough to detect by a fingernail) 0.004 in. (enough to detect by a fingernail) Bucket Rod—230CLC—OD ......................................... 89.910—90.0 mm 3.536— 3.540 in.



FR91424,0000013 –19–21NOV03–5/9

33 3360 ,147

TM1931 (09JAN04)

33-3360-147


PN=329

Hydraulic System

2 42

11

7

9

5 10 13

14

6

19

44 24

15 22

19

4 20 18 21 28

20 46

26 41 31 27 1 25

35

32

34

T196499

30

–UN–26NOV03

1

33 3360 ,148

T196499

Bucket Cylinder—230CLC


TM1931 (09JAN04)

33-3360-148

FR91424,0000013 –19–21NOV03–6/9


PN=330

Hydraulic System NOTE: Use a cylinder repair kit when assembling a cylinder.

16.


FR91424,0000013 –19–21NOV03–7/9

33 3360 ,149

TM1931 (09JAN04)

33-3360-149


PN=331

T196860

–UN–10DEC03

Hydraulic System

Bucket Cylinder—230CLC 1—Bushings (2 used) 2—Rod and Bushings 4—Rod Guide 5—Cap Screw (12 used) 6—O-Ring 7—Seal 9—Seal 10—Ring


22—Packing 24—Cap Screw (6 used) 25—Hydraulic Line 26—Cap Screw (2 used) 27—Cap Screw (2 used) 28—O-Ring 30—Clamp 31—Clamp

Install bucket cylinder head end and rod end bushings.

installed so that slotted side is facing toward cylinder head end (pressure side).

NOTE: Use a cylinder repair kit when assembling a cylinder. 17. Install bushing (13) to bottom of bore in rod guide (4) using a driver disk and a press. 33 3360 ,150

32—Cap Screw (2 used) 34—Clamp 35—Cap Screw (2 used) 41—Lubrication Fitting 42—Lubrication Fitting 44—Washer (6 used) 46—Hydraulic Cylinder Barrel

19. Install ring (10), seal (9), seal (7), and snap ring (11). 20. Install O-ring (6).

18. Install the snap ring (14). IMPORTANT: Ring (10), seal (9), and seal (7) must be installed in the correct direction. Ensure that ring and seals are

21. Install packing (22), seal ring (21), wear rings (20), and piston rings (19) on piston (18). 22. Install rod guide assembly on rod (2).


TM1931 (09JAN04)

33-3360-150

FR91424,0000013 –19–21NOV03–8/9


PN=332

Hydraulic System IMPORTANT: Cushion ring (15) must be installed in the correct direction. Ensure that cushion ring is installed so that slotted end is facing toward piston (18).

25. Apply clean oil to piston and seals. Attach a hoist to rod using a lifting strap. Carefully install piston, rod and rod guide into barrel.

23. Install cushion ring (15) on rod (2).

Specification Bucket Cylinder Rod Guide-to-Hydraulic Cylinder Barrel Cap Screw—Torque .................................................. 395 N•m 290 lb-ft

24. Secure rod assembly on bench and install piston (18) assembly to rod (2). Install cap screws (25) and washers (42).

26. Install and tighten cap screws (5).

27. Install hydraulic line (25). Specification Piston-to-Rod Cap Screw— Torque.................................................................................... 395 N•m 290 lb-ft

FR91424,0000013 –19–21NOV03–9/9

33 3360 ,151

TM1931 (09JAN04)

33-3360-151


PN=333

Hydraulic System

Hydraulic Cylinder Bleed Procedure IMPORTANT: Trapped air suddenly compressed in a cylinder is heated and ignites the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retraced and the rod end filled with clean oil. Connect the cylinder head end and lines. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage.

NOTE: Bleed air at initial start-up, whenever major repairs or maintenance (oil change) is done on hydraulic system, or when machine has been in storage for a period of time. 1. Run engine at slow idle. 2. Slowly operate function to move cylinder to the most horizontal position possible. 3. Slowly extend and retract cylinder several times to approximately 100 mm (4 in.) from end of stroke. 4. Operate cylinder several times to full stroke. 5. Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator’s Manual.)

TX,33,GG2374B –19–26NOV03–1/1

33 3360 ,152

TM1931 (09JAN04)

33-3360-152


PN=334

Section 43

Swing or Pivoting System Contents Page

Group 4350—Mechanical Drive Elements Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . .43-4350-1 Start-Up Procedure . . . . . . . . . . . . . . . . .43-4350-11 Upperstructure . . . . . . . . . . . . . . . . . . . . . .43-4350-12 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . .43-4350-19 Group 4360—Hydraulic System Swing Motor and Park Brake. . . . . . . . . . . . .43-4360-1 Crossover Relief Valve and Make-Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-11 Swing Motor Start-Up Procedure . . . . . . . . . . . . . . . . .43-4360-13 Brake Release Valve—270CLC . . . . . . . . .43-4360-13

43

TM1931 (09JAN04)

43-1


PN=1

Contents

43

TM1931 (09JAN04)

43-2


PN=2

Group 4350

Mechanical Drive Elements Swing Gearbox Repair Remove and Install Swing Gearbox CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury. 1. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 2. Pull vacuum in hydraulic oil tank using vacuum pump or drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.) 3. Disconnect lines.


AGALLARDO,0000039 –19–19NOV01–1/14

43 4350 1

TM1931 (09JAN04)

43-4350-1


PN=337

Mechanical Drive Elements


NOTE: Swing motor may be removed by itself or with swing gearbox. To remove swing motor. See Swing Motor and Park Brake Repair. (Group 4360.)

–UN–02AUG01

Mark swing gearbox housing to machine upperstructure to aid in installation. 4. Install JT01748 Lifting Brackets and connect to hoist.

T143498B

Swing Gearbox—Specification Swing Motor, Brake, and Gearbox—200CLC—Weight ......................... 230 kg (507 lb) approximate Swing Motor, Brake, and Gearbox—230CLC—Weight ......................... 275 kg (610 lb) approximate Swing Motor, Brake, and Gearbox—270CLC—Weight ......................... 355 kg (780 lb) approximate

200CLC Machine Shown 1—Cap Screw and Washer (12 used)

5. Remove cap screws and washers (1). 6. Remove swing gearbox. 7. Repair or replace parts as necessary. 8. Apply rigid-form-in place gasket to mating surfaces of swing gearbox housing and upperstructure. 9. Install swing gearbox. 10. Tighten cap screws. Swing Gearbox—Specification Swing Gearbox-to-Upperstructure Cap Screw—Torque .................................................... 500 N•m (370 lb-ft)

11. Connect electrical connector. 12. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.) 13. If hydraulic oil tank was drained, fill hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.)

43 4350 2


TM1931 (09JAN04)

43-4350-2

AGALLARDO,0000039 –19–19NOV01–2/14


PN=338

Mechanical Drive Elements 14. Do Swing Gearbox Start-Up Procedure. (See procedure in this group.) See Swing Motor Start-Up Procedure . (Group 4360.)


AGALLARDO,0000039 –19–19NOV01–3/14

43 4350 3

TM1931 (09JAN04)

43-4350-3


PN=339


22 1 23

24

2 4 3

5

31 25

6 7

21

8 20 9

11

10

12

19 26 18

13

27

17

28

16 29 15

–UN–14MAY01

14

43 4350 4

T142044

30

T142044


TM1931 (09JAN04)

43-4350-4

AGALLARDO,0000039 –19–19NOV01–4/14


PN=340

Mechanical Drive Elements 1—Swing Motor 2—First Planet Sun Gear 3—Thrust Plate 4—Pin (3 used) 5—Spring Pin (3 used) 6—Needle Bearing (3 used) 7—Planetary Gear (3 used) 8—Thrust Plate (3 used)

9—Pin (3 used) 10—Spring Pin (3 used) 11—Thrust Plate (6 used) 12—Bearing (3 used) 13—Planetary Gear (3 used) 14—Roller Bearing 15—Bearing Nut 16—Lock Plate

17—Cap Screw (2 used) 18—Second Planet Carrier 19—Thrust Plate 20—Second Planet Sun Gear 21—First Planet Carrier 22—Cap Screw (8 used) 23—Cap Screw (12 used) 24—Ring Gear

25—Housing 26—Oil Seal 27—Roller Bearing 28—Sleeve 29—O-Ring 30—Shaft 31—Drain Valve

5. Remove second planet carrier (18).

Disassemble and Assemble Swing Gearbox— 200CLC and 230CLC 1. Make alignment marks between swing motor (1), ring gears (24), and between ring gear (24) and housing (25) to aid in assembly. CAUTION: Heavy component; use a hoist. Swing Gearbox—Specification Swing Motor—200CLC and 230CLC—Weight ...................................... 46 kg (100 lb) approximate

2. Remove cap screws (22) and swing motor (1) from swing gearbox.

NOTE: Second planet sun gear may be removed separately or with carrier. 6. Disassemble first planet carrier (21) assembly. 7. Tap spring pin (5) into pin (4).

NOTE: Procedure for the disassembly of first and second planetary carriers is the same. 8. Remove pin (4), planetary gear (7), needle bearing (6), and thrust plate (8) from first planet carrier (21). 9. Inspect needle bearing for wear.

3. Remove first planet carrier (21) from ring gear (24). 10. Remove thrust plate (3) from carrier.

NOTE: First planet sun gear may be removed separately or along with carrier. CAUTION: Heavy component; use a hoist. Swing Gearbox—Specification Ring Gear—200CLC and 230CLC—Weight ...................................... 23 kg (50 lb) approximate

IMPORTANT: Damaging the surface of pin (4) can cause bearing failure, use care when handling pin. 11. Using wood blocks, clamp pin (4) in vise. Tap spring pin (5) out. 12. Remove cap screws (17) and lock plate (16).

4. Remove cap screws (23) and ring gear (24).

AGALLARDO,0000039 –19–19NOV01–5/14

13. Remove bearing nut (15) from shaft (30) using DFT1220 Swing Gearbox Nut Spanner Wrench. (Group 9900.)

T142064

–UN–14MAY01

15—Bearing Nut


TM1931 (09JAN04)

43-4350-5

AGALLARDO,0000039 –19–19NOV01–6/14


PN=341

43 4350 5

Mechanical Drive Elements NOTE: Bearing and sleeve are pressed onto shaft.

–UN–19NOV01

14. Using press, push upper end of shaft (1) and remove from housing (2). Inner race of roller bearing (27) and sleeve (28) are removed with shaft (30). 15. Remove oil seal (26).

T146941

16. Remove outer race from housing by inserting bar through oil passage in housing, and tap it out. 1—Shaft 2—Housing

AGALLARDO,0000039 –19–19NOV01–7/14

17. Inspect shaft (1), roller bearing (2), and sleeve (3). 18. If disassembly is necessary, use press to push upper end of shaft to remove roller bearing and sleeve.

2

21. Install oil seal so lip (spring side) is toward bottom of bore. Push seal to bottom of bore.

3

22. Apply thin layer of multi-purpose grease to O-ring (29) and lip of oil seal.

T146899

20. Apply rigid form-in-place gasket to OD of oil seal (26).

–UN–19NOV01

1


1—Shaft 2—Roller Bearing 3—Sleeve

23. Apply hydraulic oil to all internal parts. 24. Apply film of grease on threaded surface of bearing nut (15). Install bearing nut on shaft (30) with stepped side of bearing nut towards roller bearing (14). 25. Tighten bearing nut so splines of lock plate (16) and shaft (30) are aligned. Use DFT1220 Swing Gearbox Nut Spanner Wrench. (Group 9900.)

43 4350 6

Swing Gearbox—Specification Bearing Nut—200CLC and 230CLC—Torque......................................................... 490 N•m (360 lb-ft)


TM1931 (09JAN04)

43-4350-6

AGALLARDO,0000039 –19–19NOV01–8/14


PN=342

Mechanical Drive Elements 26. Install spring pins (5 and 10) with slit towards end of pin.

–UN–22JUN01

27. Install thrust plate (19) with oil grooves towards second planet sun gear (20). 28. Install second planet carrier (18) so notch is aligned with lock plate (16).

T142429

29. Install second planet sun gear (20) into second planet carrier (18) assembly with small diameter part of second planet sun gear towards up. 1—Slit

30. Install first planet sun gear (2) into first planet carrier (21) assembly with stepped side of sun gear towards down. 31. Apply rigid form-in-place gasket to ring gear (24), housing (25) and swing motor (1) mating surfaces. 32. Apply thread lock and sealer (medium strength) to cap screws (22 and 23). Tighten Cap Screws. Swing Gearbox—Specification Ring Gear-to-Housing Cap Screw—200CLC and 230CLC— Torque ......................................................................... 206 N•m (152 lb-ft) Swing Gearbox—Specification Swing Motor-to-Ring Gear Cap Screw—Torque .................................................................. 88 N•m (65 lb-ft


AGALLARDO,0000039 –19–19NOV01–9/14

43 4350 7

TM1931 (09JAN04)

43-4350-7


PN=343


13 14 12 15

11

16 17

19

18 10 21

20

22 7

25

9

23

24

26 6

21

8

27 29 30

5 3

28

31 4

32

33 1 34

T146719

43 4350 8

T146719


TM1931 (09JAN04)

–UN–19NOV01

2

29

43-4350-8

AGALLARDO,0000039 –19–19NOV01–10/14


PN=344

Mechanical Drive Elements 1—Shaft 2—Sleeve 3—Cap Screw (10 used) 4—O-Ring 5—Oil Seal 6—Cover 7—Ball Bearing 8—Drain Plug 9—Pipe

10—Housing 11—Ball Bearing 12—Snap Ring 13—Swing Motor 14—Cap Screw (12 used) 15—First Planet Sun Gear 16—Thrust Plate 17—Pin (3 used) 18—Spring Pin (3 used)

19—First Planet Carrier 20—Second Planet Sun Gear 21—Thrust Plate (6 used) 22—Needle Bearing (3 used) 23—Planetary Gear (3 used) 24—Thrust Plate 25—Pin (3 used) 26—Spring Pin (3 used)

27—Second Planet Carrier 28—O-Ring 29—Thrust Plate (6 used) 30—Bushing (3 used) 31—Planetary Gear (3 used) 32—Cap Screw (12 used) 33—Ring Gear 34—O-Ring

5. Remove second planet carrier (27).

Disassemble and Assemble Swing Gearbox— 270CLC 1. Make alignment marks between swing motor (13), ring gears (33), and between ring gear (33) and housing (10) to aid in assembly. CAUTION: Heavy component; use a hoist. Swing Gearbox—Specification Swing Motor—270CLC— Weight ....................................................... 66 kg (150 lb) approximate

NOTE: Second planet sun gear may be removed separately or with carrier. 6. Disassemble first planet carrier (19) assembly . 7. Tap spring pin (18) into pin (17).

NOTE: Procedure for the disassembly of first and second planetary carriers is the same. 8. Remove pin (17), planetary gear (23), needle bearing (22), and thrust plate (21) from first planet carrier (19).

2. Remove cap screws (14) and swing motor (13) from swing gearbox. 3. Remove first planet carrier assembly (19) from ring gear (33).

9. Inspect needle bearing for wear. 10. Remove thrust plate (16) from carrier.

NOTE: First planet sun gear may be removed separately or along with carrier. CAUTION: Heavy component; use a hoist.

IMPORTANT: Damaging the surface of pin (17) can cause bearing failure, use care when handling pin.

Swing Gearbox—Specification Ring Gear—270CLC—Weight .................... 36 kg (80 lb) approximate

11. Using wood blocks, clamp pin (17) in vise. Tap spring pin (18) out.

4. Remove cap screws (32) and ring gear (33).

12. Remove snap ring (12).


AGALLARDO,0000039 –19–19NOV01–11/14

43 4350 9

TM1931 (09JAN04)

43-4350-9


PN=345

Mechanical Drive Elements NOTE: Bearing and sleeve are pressed onto shaft.

–UN–19NOV01

13. Using press, push upper end of shaft (1) and remove from housing (2). Ball bearing (7) and sleeve (2) are removed with shaft (1). 14. Secure cover (6) in vise and remove oil seal (5).

T146941

1—Shaft 2—Housing

AGALLARDO,0000039 –19–19NOV01–12/14

15. Inspect sleeve (1), ball bearing (2), and shaft (3) for wear. Repair or replace parts as necessary.

17. Apply rigid form-in-place gasket to OD of oil seal (5). 18. Install oil seal so lip (spring side) is toward bottom of bore. Push seal to bottom of bore.

1

19. Apply thin layer of multi-purpose grease to O-ring (4) and lip of oil seal.

3 –UN–19NOV01

2

T146889

16. Use press to push at upper end of shaft and remove ball bearing and sleeve.

1—Sleeve 2—Ball Bearing 3—Shaft

20. Apply hydraulic oil to all internal parts.


AGALLARDO,0000039 –19–19NOV01–13/14

43 4350 10

TM1931 (09JAN04)

43-4350-10


PN=346

Mechanical Drive Elements 21. Install spring pins (18 and 26) with slit towards end of pin.

–UN–22JUN01

22. Install thrust plate (24) with oil grooves towards second planet sun gear (20).

24. Install first planet sun gear (15) into first planet carrier (19) assembly with stepped side of sun gear towards down.

T142429

23. Install second planet sun gear (20) into second planet carrier (27) assembly with small diameter part of second planet sun gear towards up.

1—Slit

25. Apply rigid form-in-place gasket to ring gear (33), housing (10) and swing motor (13) mating surfaces. 26. Apply thread lock and sealer (medium strength) to cap screws (14 and 32). Tighten cap screws. Swing Gearbox—Specification Ring Gear-to-Housing Cap Screw—270CLC—Torque ........................................... 400 N•m (300 lb-ft) Swing Gearbox—Specification Swing Motor-to-Ring Gear Cap Screw—Torque ................................................................ 88 N•m (65 lb-ft)

AGALLARDO,0000039 –19–19NOV01–14/14

Swing Gearbox Start-Up Procedure IMPORTANT: Swing gearbox will be damaged if not filled with oil before operating swing function. Procedure must be performed whenever a new swing gearbox is installed or oil has been drained from the gearbox. 1. Check that drain line plug is installed. 2. Remove fill cap and add oil. See Swing Gearbox, Propel Gearbox and Pump Gearbox Oils. (Operator’s Manual.)

43 4350 11

3. Install fill cap. Check oil level on dipstick.

TX,25,GG2228 –19–19NOV01–1/1

TM1931 (09JAN04)

43-4350-11


PN=347


Upperstructure Repair Remove Upperstructure

NOTE: Procedure requires two technicians. The cement floor must be a minimum of 102 mm (4 in.) thick. Area must be large enough so the upperstructure can be turned 180° with the angle between boom and arm at 90—100° and the tracks laid out flat on the floor. 1. Clean machine thoroughly.

TX,43,SB524 –19–19NOV01–1/10

CAUTION: Keep the angle between boom and arm at 90—100° to prevent machine from sliding backwards. 2. Park machine with boom to left side (cab side toward sprocket) of undercarriage.

–UN–24FEB92

3. Disconnect tracks and lay out flat on floor to sprocket end of undercarriage. See Track Chain Repair. (Group 0130.)

T7712AG

NOTE: To make removal of main frame-to-swing bearing cap screws easier after machine is raised into position, loosen the cap screws one turn at this time. 4. Turn upperstructure and raise right side of machine, using boom down function.


TX,43,SB524 –19–19NOV01–2/10

43 4350 12

TM1931 (09JAN04)

43-4350-12


PN=348

Mechanical Drive Elements 5. Put hardwood blocks (B), approximately 254 mm (10 in.) between lower track rollers (A) and track chain (C).

–UN–07MAY92

6. Turn upperstructure back to left side so it is 90° to track.

T7720AM

A—Track Rollers B—Hardwood Blocks C—Track Chain

TX,43,SB524 –19–19NOV01–3/10

CAUTION: Heavy component; use a hoist. Upperstructure—Specification 200CLC Machine—Without Tracks—Weight ....................................................... 17 330 kg (38,200 lb) approximate 230CLC Machine—Without Tracks—Weight ....................................................... 20 329 kg (44,818 lb) approximate 270CLC Machine—Without Tracks—Weight ....................................................... 22 453 kg (49,500 lb) approximate

7. Put two DFT1089 Barrel Support under counterweight (D). (Group 9900.)

–UN–07MAY92

To provide enough clearance, use bridge planks (E) and hardwood blocks (F) to raise height of supports and planks to 1.4 m (55 in.). Height is approximate clearance needed to clear bottom of rotary manifold. Do not put blocks under cap screw heads. Keep height below maximum.

T7720AS

Upperstructure—Specification Floor-to-Bottom of Main Frame— Height .................................................................... 1.4 m (55 in.) minimum Height ................................................................. 1.45 m (57 in.) maximum

D—Counterweight E—Bridge Plank (As Required) F—Hardwood Block (As Required) G—DFT1089 Barrel Support (4 used)


TX,43,SB524 –19–19NOV01–4/10

43 4350 13

TM1931 (09JAN04)

43-4350-13


PN=349

T7720AO

–UN–07MAY92


A—DFT1089 Barrel Support (4 used)

B—3.7 m (12 ft) Length of W8 x 28 lb Wide Flange Beam (2 used)

8. Slowly raise left side, using boom down function, until machine is level. 9. Place DFT1089 Barrel Support and 3.7 m (12 ft) length of W8 x 28 lb Wide Flange Beam (B) under main frame at right boom cylinder and right corner of cab. (Group 9900.) For maximum support, barrel supports must be positioned so beam is under main frame and corner of cab as far as possible.

C—Hardwood Block (Use as Required)

Install hardwood blocks (C) as needed to make up for any unevenness. 10. Lower machine so main frame and corner of cab are on beam. Check that bottom of main frame is 1.4 m (55 in.) off floor and level. Keep height to maximum of 1.45 m (57 in.).


TX,43,SB524 –19–19NOV01–5/10

43 4350 14

TM1931 (09JAN04)

43-4350-14


PN=350

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

T7149AJ

–UN–05OCT89

14. Disconnect lines and fittings from rotary manifold.

TX,43,SB524 –19–19NOV01–6/10


–UN–20DEC96

Upperstructure—Specification Undercarriage—200CLC—Weight ......... 5134 kg (11,319 lb) approximate Undercarriage—230CLC—Weight ......... 5833 kg (12,860 lb) approximate Undercarriage—270CLC—Weight ......... 8455 kg (18,640 lb) approximate

T105961

15. Raise undercarriage into position using two 18-t (20-ton) service jacks. 16. Remove cap screws (B) from swing bearing (A). 17. Slowly lower undercarriage onto track chain. A—Swing Bearing B—Cap Screw (31 used)

18. Lift sprocket end of undercarriage so sprocket clears track chain. 19. Pull undercarriage out from under upperstructure. 20. Repair or replace parts as necessary.

43 4350 15


TM1931 (09JAN04)

43-4350-15

TX,43,SB524 –19–19NOV01–7/10


PN=351

Mechanical Drive Elements Install Upperstructure CAUTION: Heavy component; use a hoist.

–UN–20DEC96

1. Push undercarriage under upperstructure.

T105961

Upperstructure—Specification Undercarriage—200CLC—Weight ......... 4717 kg (10,400 lb) approximate Undercarriage—230CLC—Weight ......... 5171 kg (11,400 lb) approximate Undercarriage—270CLC—Weight ......... 7548 kg (16,640 lb) approximate

2. Install DFT1144 Guide Pin to help align holes in swing bearing (A) with holes in main frame. (Group 9900.) A—Swing Bearing B—Cap Screw (31 used)

3. Raise undercarriage into position using two 18-t (20-ton) service jacks. It may be necessary to turn swing bearing inner race to align teeth on swing motor pinion shaft. 4. Install cap screws (B) and tighten. Upperstructure—Specification Swing Bearing-to-Upperstructure Cap Screw—200CLC—Torque ................................... 510 N•m (375 lb-ft) Swing Bearing-to-Upperstructure Cap Screw—230CLC and 270CLC—Torque......................................................... 640 N•m (470 lb-ft)

If all cap screws are not accessible, tighten them after machine has been lowered and supports have been removed. 5. Connect fittings and lines to rotary manifold. See Propel System Component Location. (Group 9025-15.) 6. Install stop on rotary manifold. 7. Tighten cap screws. Upperstructure—Specification Rotary Manifold Stop Cap Screw—Torque ............................................................ 140 N•m (105 lb-ft)

8. Connect negative battery cable.

43 4350 16


TM1931 (09JAN04)

43-4350-16

TX,43,SB524 –19–19NOV01–8/10


PN=352

Mechanical Drive Elements 9. Put hardwood blocks (B) between lower track rollers (A) and track chain (C) on counterweight side.

T7720AM

–UN–07MAY92

A—Track Rollers B—Wooden Blocks C—Track Chain


TX,43,SB524 –19–19NOV01–9/10

43 4350 17

TM1931 (09JAN04)

43-4350-17


PN=353

T7720AO

–UN–07MAY92


A—DFT1089 Barrel Support (4 used)

B—3.7 m (12 ft) Length of W8 x 28 lb Wide Flange Beam (2 used)

10. Raise machine just enough to remove hardwood blocks (C), wide flange beam (B), and barrel supports (A). 11. Lower machine so lower track rollers and front idler are on track chain. 12. Remove bridge planks and barrel supports from other side. 13. Turn upperstructure to other side and raise machine just enough to remove hardwood blocks between roller and track chain. 14. Lower machine so lower track rollers and front idler are on track chain.

C—Hardwood Block (use as required)

15. Tighten any remaining swing bearing-to-main frame cap screws. Upperstructure—Specification Swing Bearing-to-Upperstructure Cap Screw—200CLC—Torque .................................... 510 N•m (375 lb-ft) Swing Bearing-to-Upperstructure Cap Screw—230CLC and 270CLC—Torque .................................................. 640 N•m (470 lb-ft)

16. Install track chains. See Track Chain Repair. (See Group 0130.) 17. Check and Adjust Track Sag. (Operator’s Manual.)

43 4350 18

TX,43,SB524 –19–19NOV01–10/10

TM1931 (09JAN04)

43-4350-18


PN=354


Swing Bearing Repair Remove and Install Swing Bearing 1. Remove upperstructure. See Upperstructure Repair. (See procedure in this group.) CAUTION: Heavy component; use a hoist. Swing Bearing—Specification Swing Bearing—200CLC—Weight ................ 220 kg (485 lb) approximate Swing Bearing—230CLC and 270CLC—Weight ........................................... 331 kg (730 lb) approximate

2. Connect swing bearing to hoist using lifting brackets (C) such as JT01748 Lifting Brackets. 3. Remove cap screws and lock washers (D) and remove swing bearing. –UN–07MAY92

4. Check and replace swing bearing upper and lower seals if necessary. SeeSwing Bearing Repair. (See procedures in this group.)

T7764AB

5. Replace steel balls and ball supports as necessary. 6. Repair or replace parts as necessary. C—JT01748 Lifting Brackets D—Cap Screw and Lock Washer

7. Clean mating surfaces of swing bearing, upperstructure, and undercarriage.


TX,43,SB526 –19–19NOV01–1/8

43 4350 19

TM1931 (09JAN04)

43-4350-19


PN=355


–UN–11APR90

IMPORTANT: The tooth marked with the letter “G” or “S” or equivalent is the starting and stopping point for the hardening process. The tooth and the bearing loading plug must be installed on the right side of the machine so the use of that part of the swing bearing is minimized.

T5925AA

8. Install swing bearing on undercarriage so tooth (A) marked “G” or “S” or equivalent and bearing loading plug (B) is to right side of machine. A—Tooth B—Loading Plug

9. Install cap screws and lock washers and tighten. Swing Bearing—Specification Undercarriage-to-Swing Bearing Cap Screw—200CLC—Torque ................................... 490 N•m (360 lb-ft) Undercarriage-to-Swing Bearing Cap Screw—230CLC and 270CLC—Torque......................................................... 640 N•m (470 lb-ft)

10. Apply multi-purpose grease to swing bearing teeth and pinion shaft. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operator’s Manual.) 11. Install upperstructure. See Upperstructure Repair. (See procedure in this group.)


TX,43,SB526 –19–19NOV01–2/8

43 4350 20

TM1931 (09JAN04)

43-4350-20


PN=356

T6626JP

–UN–07NOV88


A—Lubrication Fitting (2 used) B—Outer Race C—Spacer—200CLC & 230CLC (121 used)

—Spacer—270CLC (90 used) D—Steel Ball—200CLC & 230CLC (121 used)

—Steel Ball—270CLC (90 used) E—Lower Seal

F—Inner Race G—Upper Seal

Disassemble and Assemble Swing Bearing 1. Check swing bearing upper seal (G) and lower seal (E). If damaged, replace. See Swing Bearing Repair. (See procedures in this group.)


TX,43,SB526 –19–19NOV01–3/8

43 4350 21

TM1931 (09JAN04)

43-4350-21


PN=357

Mechanical Drive Elements 2. Grind tack weld (A) off top of taper pin (B). 3. Drive taper pin out from bottom side of bearing. 4. Remove loading plug (C) using an M8-1.25 cap screw.

T6876FI

–UN–07MAY92

A—Tack Weld B—Taper Pin C—Loading Plug

TX,43,SB526 –19–19NOV01–4/8

5. Remove steel balls (A) and spacers (B). 6. Turn inner race to remove remaining steel balls and spacers. 7. Lift outer race off inner race.

–UN–07MAY92

8. Replace parts as necessary. 9. Install spacers (B) and steel balls (A).

T6876FK

Turn inner race as needed to install spacers and steel balls.

–UN–07MAY92

A—Spacer—200CLC & 230CLC (121 used) —Spacer—270CLC (90 used) B—Steel Ball—200CLC & 230CLC (121 used) —Steel Ball—270CLC (90 used)

T7763AB

43 4350 22


TM1931 (09JAN04)

43-4350-22

TX,43,SB526 –19–19NOV01–5/8


PN=358

Mechanical Drive Elements 10. Install loading plug (C). 11. Install taper pin (B) even with top of swing bearing. 12. Tack weld pin (A) to swing bearing.

–UN–07MAY92

13. Add multi-purpose grease to swing bearing through lubrication fittings. See Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease. (Operator’s Manual.)

T6876FI

A—Tack Weld B—Taper Pin C—Loading Plug


TX,43,SB526 –19–19NOV01–6/8

43 4350 23

TM1931 (09JAN04)

43-4350-23


PN=359

Mechanical Drive Elements Install Swing Bearing Upper Seal 1. Remove upperstructure. See Upperstructure Repair. (See procedure in this group.) –UN–11APR90

2. Remove old seal (A). 3. Scrape old adhesive from seal groove.

T5925AM

Thoroughly clean seal groove and new seal using cure primer. 4. Apply instant gel adhesive sparingly to seal groove. A—Seal

5. Install seal with lip against inner bearing race. Start about 76 mm (3 in.) from end of seal using blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal. 6. Before bringing ends of seal together, cut off excess length. 7. Apply instant gel adhesive to both ends of seal. Push ends into seal groove making sure they come together. IMPORTANT: To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using swing function. 8. Install upperstructure. See Upperstructure Repair. (See procedure in this group.) Install Swing Bearing Lower Seal 1. Remove upperstructure. See Upperstructure Repair. (See procedure in this group.)


TX,43,SB526 –19–19NOV01–7/8

43 4350 24

TM1931 (09JAN04)

43-4350-24


PN=360

Mechanical Drive Elements NOTE: Part of swing bearing shown cut away to show lower seal in groove. 2. Remove old seal (A). –UN–17MAY89

3. Scrape old adhesive from seal groove (B).

T5936BA

Thoroughly clean seal groove and new seal using cure primer. 4. Apply instant gel adhesive sparingly to seal groove. 5. Install seal with seal lip against outer race. Start about 76 mm (3 in.) from end of seal using blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching seal.

A—Seal B—Seal Groove

6. Before bringing ends of seal together, cut off excess length. 7. Apply adhesive to both ends of seal. Push ends into seal groove making sure they come together. IMPORTANT: To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using swing function. 8. Install upperstructure. See Upperstructure Repair. (See procedure in this group.)

TX,43,SB526 –19–19NOV01–8/8

43 4350 25

TM1931 (09JAN04)

43-4350-25


PN=361


43 4350 26

TM1931 (09JAN04)

43-4350-26


PN=362

Group 4360

Hydraulic System Swing Motor and Park Brake Repair Remove and Install Swing Motor and Park Brake

–UN–20JUL01

CAUTION: The hydraulic oil tank is pressurized. High pressure release of oil can cause serious burns or penetrating injury.

T143358B

1. Do Hydraulic Oil Tank Vent Procedure. (Group 3360.) 2. Drain hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or270CLC Drain and Refill Capacities. (Operator’s Manual.)

200CLC Machine Shown 1—Cap Screw (8 used) 2—Electrical Connector

3. Disconnect lines. 4. Disconnect electrical connector (2). CAUTION: Heavy Component; use a hoist. Swing Motor and Park Brake—Specification Swing Motor and Park Brake (200CLC and 230CLC Machine)—Weight ........................................... 47 kg (104 lb) approximate Swing Motor and Park Brake (270CLC Machine)—Weight............................ 66 kg (150 lb) approximate

5. Remove cap screws (1) and remove swing motor and park brake. 6. Repair or replace parts as necessary. 7. Install swing motor and brake. 8. Tighten cap screws (1). Swing Motor and Park Brake—Specification Swing Motor-to-Ring Gear Cap Screw—Torque ................................................................ 88 N•m (65 lb-ft)

9. Connect electrical connector (2). 10. Connect lines. See Main Hydraulic System Component Location. (Group 9025-15.)

43 4360 1


TM1931 (09JAN04)

43-4360-1

TX,4360,DV1356 –19–19NOV01–1/10


PN=363

Hydraulic System 11. Fill hydraulic oil tank. See 200CLC Drain and Refill Capacities, 230CLC Drain and Refill Capacities, or 270CLC Drain and Refill Capacities. (Operator’s Manual.) 12. Do Swing Motor Start-Up Procedure. (See procedure in this group).


TX,4360,DV1356 –19–19NOV01–2/10

43 4360 2

TM1931 (09JAN04)

43-4360-2


PN=364

Hydraulic System

43 4360 3

TM1931 (09JAN04)

43-4360-3


PN=365

Hydraulic System

10 10

9 8 6

7 11

5 4 3

1

15

2

16

12 17 18

13

19

14

18 21

17 16

15

28 29 33

22

30

23

31

20

24

32

25 26

T142065

43 4360 4

–UN–22JUN01

27

T142065


TM1931 (09JAN04)

43-4360-4

TX,4360,DV1356 –19–19NOV01–3/10


PN=366

Hydraulic System 1—Housing 2—Oil Seal 3—Bearing 4—Shaft 5—Trust Plate 6—Piston (9 used) 7—Plate 8—Retainer 9—Cylinder Block

10—Plate (4 used) 11—Friction Plate (3 used) 12—Cap Screw (4 used) 13—O-Ring (2 used) 14—Plug (2 used) 15—Plug (2 used) 16—O-Ring (2 used) 17—Spring (2 used) 18—Poppet (2 used)

19—Valve Housing 20—Crossover Relief Valve (2 used) 21—O-Ring 22—Bearing 23—Valve Plate 24—Spring (24 used) 25—Brake Piston

26—O-Ring 27—O-Ring 28—O-Ring 29—Piston 30—Spring 31—Ball 32—Plug (2 used) 33—Snap Ring

dropped. Hold valve plate during disassembly.

Disassemble Swing Motor and Park Brake— 200CLC and 230CLC 1. Drain oil. Approximate capacity is 1.5 L (1.6 qt). CAUTION: Heavy Component; use a hoist. Swing Motor and Park Brake—Specification Swing Motor and Park Brake (200CLC and 230CLC)— Weight .................................................... 46.4 kg (100 lb) approximate

CAUTION: Swing motor valve housing and cover is under spring pressure. Remove cap screws evenly to release spring force. 2. Mark alignment of swing motor housing and valve housing assembly. Loosen cap screws (12). IMPORTANT: Valve plate has a polished surface. Valve plate may remain on valve housing or stay with cylinder block. Valve plate may be damaged if

3. Remove valve plate (23) and springs (24). 4. Remove brake piston (25). 5. Remove parts (6—9) from shaft (4). 6. Remove snap ring (33) and shaft (4). 7. Push out oil seal (2) and remove outer race of bearing (3). 8. Remove inner race of bearing from shaft.

NOTE: Filter and orifice are mounted inside of piston (29). Unless clogged or deformed, do not disassemble. Do so only when absolutely needed. If internal parts need to be replaced, replace piston as an assembly. 9. Replace parts as necessary.


TX,4360,DV1356 –19–19NOV01–4/10

43 4360 5

TM1931 (09JAN04)

43-4360-5


PN=367

Hydraulic System 15

11 14

17 18

16

6 12

19

13 4 23

7 8 9 10

20 3 2

21

1

22

5 24

25 26 27

34

38

28 29 30 31

39

32

40

36 37

33 35 41 42 44 45 46 47

43 4360 6

43

T146945

49

–UN–19NOV01

48

T146945


TM1931 (09JAN04)

43-4360-6

TX,4360,DV1356 –19–19NOV01–5/10


PN=368

Hydraulic System 1—Bearing 2—Snap Ring 3—Dowel Pin (2 used) 4—O-Ring 5—Crossover Relief Valve (2 used) 6—Valve Housing 7—Poppet (2 used) 8—Spring (2 used) 9—O-Ring (2 used) 10—Drain Plug (2 used) 11—Cap Screw (4 used) 12—O-Ring (2 used)

13—O-Ring (2 used) 14—Plate 15—Cap Screw (4 used) 16—O-Ring (2 used) 17—Plug (2 used) 18—Valve Plate 19—Spring (22 used) 20—Brake Piston 21—O-Ring 22—O-Ring 23—Friction Plate (3 used) 24—Plate (4 used) 25—Snap Ring

26—Spacer 27—Spring 28—Washer 29—Cylinder Block 30—Pin (12 used) 31—Washer 32—Ball Bushing 33—Retainer 34—Piston (9 used) 35—Thrust Plate 36—Plug 37—O-Ring

38—Cap Screw (3 used) 39—Brake Release Valve 40—Housing 41—Shaft 42—Snap Ring 43—Spacer (2 used) 44—Bearing 45—Snap Ring 46—O-Ring 47—Oil Seal 48—Cover 49—Snap Ring

dropped. Hold valve plate during disassembly.

Disassemble Swing Motor and Park Brake— 270CLC CAUTION: Heavy Component; use a hoist. Swing Motor and Park Brake—Specification Swing Motor and Park Brake (270CLC Machine)—Weight ..................... 66 kg (150 lb) approximate

CAUTION: Swing motor valve housing and cover is under spring pressure. Remove cap screws evenly to release spring force. 1. Mark alignment of swing motor housing and valve housing assembly. Loosen cap screws (11). IMPORTANT: Valve plate has a polished surface. Valve plate may remain on valve housing or stay with cylinder block. Valve plate may be damaged if

2. Remove valve plate (18) and springs (19). 3. Remove brake piston (20). 4. Remove parts (29—34) from shaft (41). 5. Remove snap ring (49) from housing (40) to remove cover (48) and O-ring (46). 6. Install cover (48) in vise and remove oil seal (47). 7. Tap shaft (41) assembly lightly and remove from housing (40). Bearing (44), snap rings (42 and 45), and spacers (43) are removed with shaft. 8. Replace parts as necessary.


TX,4360,DV1356 –19–19NOV01–6/10

43 4360 7

TM1931 (09JAN04)

43-4360-7


PN=369

Hydraulic System Inspect Swing Motor and Park Brake 1. Measure clearance between outer diameter of piston and inner bore of cylinder.

T142067

–UN–22JUN01

Swing Motor and Park Brake—Specification Piston-to-Cylinder—Clearance ........................ 0.027 mm (0.0011 in.) new 0.052 mm (0.0020 in.) maximum used

TX,4360,DV1356 –19–19NOV01–7/10

2. Measure clearance between piston and slipper at caulked position.

–UN–22JUN01

Swing Motor and Park Brake—Specification Piston-to-Slipper—Clearance .................................... 0.0 mm (0.0 in.) new 0.3 mm (0.0118 in.) maximum used

T142069

43 4360 8


TM1931 (09JAN04)

43-4360-8

TX,4360,DV1356 –19–19NOV01–8/10


PN=370

Hydraulic System 3. Measure thickness of slipper. Swing Motor and Park Brake—Specification Slipper—Thickness .................................................. 5.5 mm (0.22 in.) new 5.3 mm (0.21 in.) minimum

4. Measure thickness of friction plate.

–UN–22JUN01

Swing Motor and Park Brake—Specification Friction Plate—Thickness ........................................ 2.0 mm (0.08 in.) new 1.8 mm (0.07 in.) minimum

Assemble Swing Motor and Park Brake—200CLC and 230CLC

T142072

1. Align spline teeth of friction plates (11) with cylinder block (9) and outer tabs of plates (10) with housing (1). Slipper Thickness

2. Apply petroleum jelly to valve plate (23). 3. Install thrust plate (5) with chamfered edge towards housing (1). 4. Align mating marks on valve housing (19) and housing (1) and tighten cap screws (12).

–UN–22JUN01

Swing Motor and Park Brake—Specification Valve Housing Cap Screw (200CLC and 230CLC)—Torque................................. 430 N•m (320 lb-ft)

5. Install poppet (18) and spring (17). Tighten plug (15) with O-ring (16) attached.

T142073

Swing Motor and Park Brake—Specification Poppet Plug (200CLC and 230CLC)—Torque ....................................................... 330 N•m (245 lb-ft)

Friction Plate Thickness

6. Install crossover relief valves (20) into valve housing (19). Swing Motor and Park Brake—Specification Crossover Relief Valve—Torque ................................. 175 N•m (130 lb-ft)

Assemble Swing Motor and Park Brake—270CLC 1. Align spline teeth of friction plates (23) with cylinder block and outer tabs of plates (24) with housing (40). 2. Apply petroleum jelly to valve plate (18).

43 4360 9


TM1931 (09JAN04)

43-4360-9

TX,4360,DV1356 –19–19NOV01–9/10


PN=371

Hydraulic System 3. Install thrust plate (35) with chamfered edge towards housing (40). 4. Align mating marks on valve housing (6) and housing (40) and tighten cap screws (11). Swing Motor and Park Brake—Specification 270CLC Valve Housing Cap Screw—Torque ............................................................ 400 N•m (300 lb-ft)

5. Install poppet (7) and spring (8). Tighten plug (10) with O-ring (9) attached. Swing Motor and Park Brake—Specification 270CLC Poppet Plug—Torque ................................... 400 N•m (300 lb-ft)

6. Install crossover relief valves (5) into valve housing (6). Swing Motor and Park Brake—Specification Crossover Relief Valve—Torque ................................. 175 N•m (130 lb-ft)

TX,4360,DV1356 –19–19NOV01–10/10

43 4360 10

TM1931 (09JAN04)

43-4360-10


PN=372

Hydraulic System

Crossover Relief Valve and Make-Up Valve Repair

4 1

3

T139645

–UN–30APR01

2

T139645

1—Make-Up Valve

2—Make-Up Valve

3—Crossover Relief Valve

4—Crossover Relief Valve

TX,4360,DV2980 –19–19NOV01–1/4

Remove and Install Crossover Relief Valve 1. Tighten crossover relief valve (1).

–UN–19NOV01

Crossover Relief and Make-Up Valves—Specification Crossover Relief Valve—Torque ................................. 175 N•m (130 lb-ft)

T147132B

2. Check crossover relief valve pressure setting. See Swing Motor Crossover Relief Valve Test and Adjustment—200CLC and 230CLC or Swing Motor Crossover Relief Valve Test and Adjustment—270CLC. (Group 9025-25.) 270CLC Machine Shown

43 4360 11

1—Crossover Relief Valve (2 used)


TM1931 (09JAN04)

43-4360-11

TX,4360,DV2980 –19–19NOV01–2/4


PN=373

Hydraulic System Disassemble and Assemble Crossover Relief Valve Tighten plug (4). Crossover Relief and Make-Up Valves—Specification Crossover Relief Valve Plug— Torque ........................................................................... 118 N•m (88 lb-ft)

T142068

–UN–22JUN01

1—Shim 2—Piston 3—Sleeve 4—Plug 5—O-Ring 6—O-Ring 7—O-Ring

TX,4360,DV2980 –19–19NOV01–3/4

Remove and Install Make-Up Valve Tighten make-up valve (1).

–UN–19NOV01

Crossover Relief and Make-Up Valves—Specification 200CLC and 230CLC Make-Up Valve—Torque ............................................................. 332 N•m (245 lb-ft) 270CLC Make-Up Valve—Torque............................... 400 N•m (300 lb-ft)

T147132C

1—Make-Up Valve (2 used)


TX,4360,DV2980 –19–19NOV01–4/4

43 4360 12

TM1931 (09JAN04)

43-4360-12


PN=374

Hydraulic System

Swing Motor Start-Up Procedure

T143358D

–UN–20JUL01

IMPORTANT: Swing motor will be damaged if not filled with oil before operating swing function. Start-up procedure must be performed whenever a new swing motor is installed or oil has been drained from the motor. Procedure is to ensure swing motor is filled with oil. 1. Disconnect swing motor hydraulic line (1).


2. Fill motor with Hydraulic Oil through port until oil reaches level of port. (Operator’s Manual.)

1—Hydraulic Line

NOTE: Air must be allowed to escape from the swing motor while filling. 3. Connect hydraulic line (1).

OUOE027,000003D –19–19NOV01–1/1

Brake Release Valve Repair—270CLC Remove and Install Brake Release Valve 1. Disconnect electrical connector (1). 2. Disconnect hydraulic line (3).

–UN–19NOV01

3. Remove cap screws (2) and remove brake release valve (4). 4. Repair or replace parts as necessary.

T147133B

1—Electrical Connector 2—Cap Screw (3 used) 3—Hydraulic Line 4—Brake Release Valve


OUOE054,0000021 –19–19NOV01–1/2

43 4360 13

TM1931 (09JAN04)

43-4360-13


PN=375

Hydraulic System Disassemble and Assemble Brake Release Valve 2

4

5 6

12 11

9

7

8

–UN–19NOV01

10

T147146

1—O-Ring 2—O-Ring 3—Poppet 4—Spring 5—O-Ring 6—Spring 7—Spool 8—Housing 9—Bushing 10—Filter 11—Spacer 12—Orifice

1

3

OUOE054,0000021 –19–19NOV01–2/2

43 4360 14

TM1931 (09JAN04)

43-4360-14


PN=376

Section 99

Dealer Fabricated Tools Contents Page

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

TM1931 (09JAN04)

99-1


PN=1

99

Contents

99

TM1931 (09JAN04)

99-2


PN=2

Group 9900

Dealer Fabricated Tools DF1063 Lift Bracket 99 9900 1

Tool is the same as used on other machines. Only the lift bracket of the tool is used for this machine with adapter DFT1130. Lift Bracket is used to remove and install propel motor. Material required:

T8318AC

–UN–20SEP94

• 38.1 mm x 76.2 mm x .48 mm (1-1/2 in. x 3 in. x 3/16 in.) Square Tube • 1.3 mm (1/2 in.) 1020 Steel Plate • 1 mm x 38.1 mm (3/8 in. x 1-1/2 in.) Cap Screw with Nut (4 used)


TM1931 (09JAN04)

99-9900-1

CED,OUTX818,81 –19–11MAY00–1/2


PN=379

Dealer Fabricated Tools

T7247BW

–19–25APR90

99 9900 2

CED,OUTX818,81 –19–11MAY00–2/2

TM1931 (09JAN04)

99-9900-2


PN=380


ST4920 Track Recoil Spring Disassembly and Assembly Tool 99 9900 3

NOTE: It is recommended that DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool be used with track recoil spring disassembly and assembly tool. Dimensions given are metric. Tool is the same as used on other machines except the holder (C). For each track adjuster use the holder with the correct size hole for the nut on that track adjuster. Track Recoil Spring Disassembly and Assembly Tool (compression tool) is used with hydraulic jack to compress recoil spring in track adjuster repair.

–UN–24MAR98

Material required:

T6585UY

• 1020 HR Steel for Holder (C), Supporting Plate (E), Base Plate (F), and Base (G). • “D” Grade (SAE Grade 5) for Eyebolts (D), Nuts (A), and Cap Screws (H). • “F” Grade (SAE Grade 8) for Studs (B). Print Numbers: • • • • • • • • • • •

A—Nut (12 used) B—Stud (4 used) C—Holder D—Eyebolt (2 used) E—Supporting Plate F—Base Plate G—Base (4 used) H—Cap Screw (4 used) I—Lock Washer (8 used)

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


TM1931 (09JAN04)

99-9900-3

TX,99,SB548 –19–08JAN97–1/4


PN=381


T7029CI

–UN–06JUL89

99 9900 4


TM1931 (09JAN04)

99-9900-4

TX,99,SB548 –19–08JAN97–2/4


PN=382


T7029CH

–UN–06JUL89

99 9900 5


TM1931 (09JAN04)

99-9900-5

TX,99,SB548 –19–08JAN97–3/4


PN=383


T7029CG

–UN–06JUL89

99 9900 6

TX,99,SB548 –19–08JAN97–4/4

TM1931 (09JAN04)

99-9900-6


PN=384


DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool

T7162AF

–UN–17OCT89

99 9900 7

A—3/16 in. 1020 CR Steel Plate B—9/16 in. Hole (2 places)

C—1/2 in. Nut (2 used)

D—1/2 x 2 in. Cap Screw (2 used)

Track Disassembly and Assembly Guard Tool is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. Material required:

• • • • •

E—1/2 x 3 in. Steel Round Stock (2 used)

3/16 in. 1020 CR Steel Plate (A) 9/16 in. Hole (2 places) (B) 1/2 in. Nut (2 used) (C) 1/2 x 2 in. Cap Screw (D) (2 used) 1/2 x 3 in. Steel Round Stock (E) (2 used)

TX,99,SB542 –19–08JAN97–1/1

TM1931 (09JAN04)

99-9900-7


PN=385


DFT1110 Spacer

T7708AC

–UN–23FEB92

99 9900 8

Spacer is used with ST4920 Track Recoil Spring Disassembly and Assembly Tool. Spacer is installed on the bottom plate so force is applied to spring flange on cylinder and not to the piston.

Material Required: • 165 x 138 x 138 mm (6.50 x 5.50 x 5.50 in.) Heavy Wall Steel Pipe

Cut the ends of spacer so they are parallel to each other.

TX,99,SB549 –19–08JAN97–1/1

TM1931 (09JAN04)

99-9900-8


PN=386


DFT1130 Adapter

T8319BN

–UN–20SEP94

99 9900 9

A—Adapter Plate

B—Tube

C—Stop Plate

Adapter is used with DF1063 Lift Bracket to remove and install propel motor. Material required:

• 1.3 mm (1/2 in.) 1020 Steel Plate (A) • 38.1 mm x 38.1 mm x .48 mm (1-1/2 in. x 1-1/2 in. x 3/16 in.) Square Tube (B) • .6 mm (1/4 in.) 1020 Steel Plate (C)

CED,OUTX818,84 –19–11MAY00–1/1

TM1931 (09JAN04)

99-9900-9


PN=387


DF1036A Propel Gearbox Nut Wrench

T7681FZ

–UN–28FEB92

99 9900 10

Propel Gearbox Nut Wrench is used to remove and install the hub-to-housing nut in the propel gearbox. Material required:

• • • •

16 mm (5/8 in.) Flat Bar Stock M24 (1 in.) Nut M10-1.5 x 60 mm Cap Screw (2 used) M10-1.5 Nut (2 used)

TX,99,SB544 –19–19NOV01–1/1

TM1931 (09JAN04)

99-9900-10


PN=388


DF1038 Torque Adapter

T6557CH

–UN–25OCT95

99 9900 11

Torque Adapter is used to check rolling drag torque on rotor drive shaft.

• 17 mm (0.125 in.) hex head driver

Material required:

CED,OUTX818,83 –19–11MAY00–1/1

TM1931 (09JAN04)

99-9900-11


PN=389


DFT1109 Holding Bar

T7690AA

–UN–27FEB92

99 9900 12

Holding Bar is used with the DF1036A Propel Gearbox Nut Wrench as a guide when loosening the hub-to-housing nut in the propel gearbox.

Material required: • 16 mm (5/8 in.) Flat Bar Stock TX,99,SB550 –19–23MAY00–1/1

TM1931 (09JAN04)

99-9900-12


PN=390


Rotary Manifold Lifting Tool 99 9900 13

Tool is used to remove and install rotary manifold. Drill and tap disk in fitting cap to M8-1.25 mm threads (A). Material required: • 38H1416 Cap (—12) • M8-1.25 Lifting Eyebolt such as JT05548 Metric Lifting Eyebolt

T6641DO

–UN–24OCT88

A—Threads

TX,99,SB546 –19–08JAN97–1/1

TM1931 (09JAN04)

99-9900-13


PN=391


DFT1089 Barrel Support Barrel supports are used to support the upperstructure when removing the undercarriage. –UN–09JAN97

CAUTION: Cutting tops off barrels that contained flammable or explosive material can cause serious injury or death. Material required: • Clean metal 55 gallon barrels of equal height with lids removed. (Must be 34.5—35.5 in. height x 24 in. wide.) • 1/2 x 4 x 24 in. 1020 CR Plate • 1/2 x 4 x 12 in. 1020 CR Plate • One empty 3 lb coffee can or equivalent • Highway Cement (9 bag mix). Mix extra dry to aid curing time.

T7149AC

99 9900 14

A—2 x 4 in. Slotted Hole, Recessed B—1/2 x 4 x 24 in. 1020 CR Plate C—1/2 x 4 x 12 in. 1020 CR Plate D—1/4 in. Fillet Weld E—One Empty 3 lb Coffee Can or Equivalent

Insert hook assembly into barrel before cement is set. Hold assembly in position, using a steel plate or wire, until cement begins to cure. Level off cement with top of barrels. Cement must cure for a minimum of ten days. The approximate weight of each barrel support is 545 kg (1200 lb). The approximate support capacity of each barrel support is 385 560 kg (850,000 lb).

TX,99,SB551 –19–08JAN97–1/1

TM1931 (09JAN04)

99-9900-14


PN=392


DFT1144 Guide Pin 99 9900 15

Remove threads for a distance (B) and then grind a taper on same end.

T6641EK

Materials required:

–UN–24OCT88

Guide pin is used to align cap screw holes in swing bearing and upperstructure.

• M20-2.5 x 230 mm (9 in.) Threaded Rod A—230 mm (9 in.) B—100 mm (4 in.)

TX,99,SB552 –19–08JAN97–1/1

TM1931 (09JAN04)

99-9900-15


PN=393


DFT1119 Pump Support

T7955AA

–UN–23APR93

99 9900 16

Pump support is used with a hand hoist to support a pump(s) when an engine is removed. Two end stands are needed. Drill the holes through the square steel tubing so they are centered. Material required: • C3 x 5 Steel Channel

• 88.9 x 88.9 x 6.35 mm (3.5 x 3.5 x 0.250 in.) Square Steel Tubing • 76.2 x 76.2 x 6.35 mm (3 x 3 x 0.250 in.) Square Steel Tubing • 63.5 x 63.5 x 6.35 mm (2.5 x 2.5 x 0.250 in.) Square Steel Tubing • 19 mm (3/4 in.) Flat Bar Stock • M10 x 89 mm or 3/8 x 3-1/2 in. D Grade (SAE Grade 5) Cap Screw (2 used) • M10 or 3/8 in. D Grade (SAE Grade 5) Nut (2 used)

TX,99,SB553 –19–08JAN97–1/1

TM1931 (09JAN04)

99-9900-16


PN=394


99 9900 17

TM1931 (09JAN04)

99-9900-17


PN=395


DFT1220 Swing Gearbox Nut Spanner Wrench

T143704

–UN–17JUL01

99 9900 18


TM1931 (09JAN04)

99-9900-18

OUOE047,000000E –19–19NOV01–1/2


PN=396

Dealer Fabricated Tools 1—Weld (4 Places)

• 159.4 x 38.1 x 6.35 mm (6.65 x 1.5 x .25 in.)

Material required:

99 9900 19

• 159.4 x 82.5 mm (6.275 x 3.25 in.) Steel Tubing

OUOE047,000000E –19–19NOV01–2/2

TM1931 (09JAN04)

99-9900-19


PN=397


99 9900 20

TM1931 (09JAN04)

99-9900-20


PN=398

Index Page

A Adjuster, track Disassemble and assemble . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-19 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-2 Air conditioner Compressor, remove and install . . . . . .18-1830-11 Condenser, remove and install . . . . . . .18-1830-16 Receiver-dryer, remove and install . . . .18-1830-12 Remove and install . . . . . . . . . . . . . . . .18-1830-15 Air conditioner and heater Remove and install . . . . . . . . . . . . . . . .18-1830-15 Air conditioner system Flush and purge . . . . . . . . . . . . . . . . . . .18-1830-3 Air conditioning Charge R134a system . . . . . . . . . . . . .18-1830-10 Evacuate R134a system . . . . . . . . . . . . .18-1830-9 Recover R134a refrigerant . . . . . . . . . . .18-1830-8 Refrigerant handling and cautions. . . . . .18-1830-1 R134a refrigerant oil information . . . . . . .18-1830-6 R134a station installation . . . . . . . . . . . .18-1830-7 Air intake system Leakage test . . . . . . . . . . . . . . . . . . . . . .05-0520-1 Air test Rotary manifold. . . . . . . . . . . . . . . . . . .02-0260-25 Arm Remove and install . . . . . . . . . . . . . . . . .33-3340-3 Arm cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Inspect pins and bushings. . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . 33-3360-100 Arm cylinder—200CLC, 270CLC Disassemble and assemble . . . . . . . . 33-3360-104 Arm cylinder—230CLC Disassemble and assemble . . . . . . . . 33-3360-118 Arm pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Arm regenerative solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-35

Page

Belt, seat Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Bleed procedure Hydraulic cylinder . . . . . . . . . . . . . . . . 33-3360-152 Boom Remove and install . . . . . . . . . . . . . . . . .33-3340-6 Boom cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Inspect pins and bushings. . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . .33-3360-75 Boom cylinder—200CLC, 270CLC Disassemble and assemble . . . . . . . . .33-3360-80 Boom cylinder—230CLC Disassemble and assemble . . . . . . . . .33-3360-94 Boom pins and bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Boom, arm, and bucket bushings and bosses Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Boom, arm, and bucket pins Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Bucket Adjust pivot end play. . . . . . . . . . . . . . . .33-3302-3 Pin-up data . . . . . . . . . . . . . . . . . . . . . . .33-3302-4 Remove and install . . . . . . . . . . . . . . . . .33-3302-1 Bucket cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Inspect pins and bushings. . . . . . . . . . .33-3340-11 Remove and install . . . . . . . . . . . . . . . 33-3360-124 Bucket cylinder—200CLC, 270CLC Disassemble and assemble . . . . . . . . 33-3360-130 Bucket cylinder—230CLC Dissassemble and assemble. . . . . . . . 33-3360-144 Bucket links Remove and install . . . . . . . . . . . . . . . . .33-3340-1 Bucket pins Inspect . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-11 Bushings and seals Remove and install . . . . . . . . . . . . . . . .33-3340-14

C B Bearing, swing Disassemble and assemble . . . . . . . . .43-4350-21 Lower seal, install . . . . . . . . . . . . . . . . .43-4350-24 Remove and install . . . . . . . . . . . . . . . .43-4350-19 Upper seal, install . . . . . . . . . . . . . . . . .43-4350-24 Belt, fan Remove and install . . . . . . . . . . . . . . . . .05-0510-2 TM1931 (09JAN04)

Cab Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Carrier roller, track Disassemble and assemble . . . . . . . . . .01-0130-6 Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1 Remove and install . . . . . . . . . . . . . . . . .01-0130-5 Chain sprocket, track Remove and install . . . . . . . . . . . . . . . .01-0130-14 Chain, track Disassemble and assemble . . . . . . . . .01-0130-12

Index-1


PN=1

Indx 1

Index

Indx 2

Page

Page

Disassemble and assemble to replace broken part . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-13 Remove and install . . . . . . . . . . . . . . . .01-0130-10 Charge R134a system . . . . . . . . . . . . . . .18-1830-10 Cleaner, air Remove and install . . . . . . . . . . . . . . . . .05-0520-2 Cleanup procedure, hydraulic oil Using portable filter caddy. . . . . . . . . . . .33-3360-2 Compressor Remove and install . . . . . . . . . . . . . . . .18-1830-11 Condenser, air conditioner Remove and install . . . . . . . . . . . . . . . .18-1830-16 Control valve Arm priority flow rate valve . . . . . . . . . .33-3360-51 Arm reduced leakage valve. . . . . . . . . .33-3360-51 Arm regenerative valve . . . . . . . . . . . . .33-3360-57 Arm regenerative valve check valve . . .33-3360-57 Auxiliary flow combiner valve check valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Auxiliary flow rate valve . . . . . . . . . . . .33-3360-51 Auxiliary function flow combiner valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Boom reduced leakage valve . . . . . . . .33-3360-57 Bucket flow rate valve . . . . . . . . . . . . . .33-3360-57 Bypass shut-off valve . . . . . . . . . . . . . .33-3360-57 Circuit relief and anti-cavitation valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 Lift check and orifice (arm II power passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-57 Lift check and orifice (left propel power passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Lift check (arm I power passage) . . . . .33-3360-51 Lift check (boom II power passage) . . .33-3360-51 Lift check (left propel neutral passage) . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Lift check (swing neutral passage) . . . .33-3360-51 Propel flow combiner valve check valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 Propel function flow combiner valve . . .33-3360-57 Remove and install . . . . . . . . . . . . . . . .33-3360-49 Right propel and bucket combined function check valve and orifice . . . . . . . . . . .33-3360-64 Spool assemblies (4-spool) . . . . . . . . . .33-3360-57 Spool assemblies (5 spool) . . . . . . . . . .33-3360-51 System relief and power boost valve. . .33-3360-51 System relief valve isolation check valve . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-64 4-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-57 5-spool . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-51 Controller, pilot Disassemble and assemble . . . . . . . . .33-3360-39 Remove and install . . . . . . . . . . . . . . . .33-3360-37

Controller, propel pilot Disassemble and assemble . . . . . . . . .33-3360-42 Remove and install . . . . . . . . . . . . . . . .33-3360-40 Cooler, oil Remove and install . . . . . . . . . . . . . . . .33-3360-74 Counterbalance valve, propel motor Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Counterweight Remove and install . . . . . . . . . . . . . . . . .17-1749-1 Coupling, flex (dampener drive) Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Crossover relief valve Disassemble and assemble . . . . . . . . .43-4360-12 Remove and install . . . . . . . . . . . . . . . .43-4360-11 Crossover relief valve, propel motor Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Cylinder Arm, remove and install . . . . . . . . . . . 33-3360-100 Arm—200CLC, 270CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-104 Arm—230CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-118 Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Boom, remove and install . . . . . . . . . . .33-3360-75 Boom—200CLC, 270CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-80 Boom—230CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .33-3360-94 Bucket, remove and install . . . . . . . . . 33-3360-124 Bucket—200CLC, 270CLC, disassemble and asemble. . . . . . . . . . . . . . . . . . . . . . 33-3360-130 Bucket—230CLC, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . 33-3360-144 Bushings and seals, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .33-3340-14

TM1931 (09JAN04)

D Dampener drive Remove and install . . . . . . . . . . . . . . . . .07-0752-1 Dealer fabricated tools DFT1087 track recoil spring disassembly and assembly guard tool . . . . . . . . . . . . . .99-9900-7 DFT1089 barrel support . . . . . . . . . . . .99-9900-14 DFT1109 holding bar . . . . . . . . . . . . . .99-9900-12

Index-2


PN=2

Index

Page

Page

DFT1110 spacer . . . . . . . . . . . . . . . . . . .99-9900-8 DFT1114 guide pin . . . . . . . . . . . . . . . .99-9900-15 DFT1119 pump support . . . . . . . . . . . .99-9900-16 DFT1130 adapter . . . . . . . . . . . . . . . . . .99-9900-9 DFT1220 swing gearbox nut spanner wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-18 DF1036A propel gearbox nut wrench. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10 DF1038 torque adapter . . . . . . . . . . . . .99-9900-11 DF1063 lift bracket . . . . . . . . . . . . . . . . .99-9900-1 Rotary manifold lifting tool. . . . . . . . . . .99-9900-13 ST4920 track recoil spring disassembly and assembly tool . . . . . . . . . . . . . . . . . . .99-9900-3 Drive gearbox and hydraulic pump Disassemble and assemble . . . . . . . . . .33-3360-5 Remove and install . . . . . . . . . . . . . . . . .33-3360-3 Drive, dampener (flex coupling) Remove and install . . . . . . . . . . . . . . . . .07-0752-1

Flush air conditioner system . . . . . . . . . . . .18-1830-3 Front idler Disassemble and assemble . . . . . . . . .01-0130-17 Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1 Remove and install . . . . . . . . . . . . . . . .01-0130-16 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-19 Fuel filter, final Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Fuel filter, primary Remove and install . . . . . . . . . . . . . . . . .05-0560-3 Fuel injection pump Remove and install . . . . . . . . . . . . . . . . .04-0400-4 Fuel tank Remove and install . . . . . . . . . . . . . . . . .05-0560-2

E End play, bucket pivot Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-3 Engine Remove and install . . . . . . . . . . . . . . . . .04-0400-1 Engine air cleaner Remove and install . . . . . . . . . . . . . . . . .05-0520-2 Evacuate R134a system. . . . . . . . . . . . . . .18-1830-9

F Fan Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Fan belt Remove and install . . . . . . . . . . . . . . . . .05-0510-2 Fan guard Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Fan shroud Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Filter, final fuel Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Filter, pilot Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Filter, primary fuel Remove and install . . . . . . . . . . . . . . . . .05-0560-3 Final fuel filter Remove and install . . . . . . . . . . . . . . . . .05-0560-4 Flex coupling Remove and install . . . . . . . . . . . . . . . . .07-0752-1 TM1931 (09JAN04)

G Gearbox Pump drive, pilot pump drive shaft . . . .33-3360-21 Gearbox, drive and hydraulic pump Disassemble and assemble . . . . . . . . . .33-3360-5 Remove and install . . . . . . . . . . . . . . . . .33-3360-3 Gearbox, propel Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0250-5 Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0250-11 Remove and install . . . . . . . . . . . . . . . . .02-0250-1 Gearbox, swing Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .43-4350-5 Disassemble and assemble—270CLC . .43-4350-9 Remove and install . . . . . . . . . . . . . . . . .43-4350-1

H Heater Remove and install . . . . . . . . . . . . . . . .18-1830-15 Hydraulic Fittings, 30° cone seat . . . . . . . . . . . . . .00-0003-9 Fittings, 37° flare. . . . . . . . . . . . . . . . . . .00-0003-9 Hydraulic cylinder Bleed procedure . . . . . . . . . . . . . . . . . 33-3360-152 Hydraulic fitting Flared connections . . . . . . . . . . . . . . . .00-0003-10 Hydraulic oil Cleanup procedure using portable filter caddy . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-2 Hydraulic oil tank Disassemble and assemble . . . . . . . . .33-3360-69

Index-3


PN=3

Indx 3

Index

Indx 4

Page

Page

Pressure release procedure . . . . . . . . . .33-3360-1 Remove and install . . . . . . . . . . . . . . . .33-3360-66 Hydraulic pump Start-up procedure . . . . . . . . . . . . . . . .33-3360-20 Hydraulic pump and drive gearbox Disassemble and assemble . . . . . . . . . .33-3360-5 Remove and install . . . . . . . . . . . . . . . . .33-3360-3 Hydraulic pump regulator Disassemble and assemble . . . . . . . . .33-3360-24 Remove and install . . . . . . . . . . . . . . . .33-3360-22

Disassemble and assemble—270CLC . .02-0260-7 Remove and install—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Remove and install—270CLC . . . . . . . . .02-0260-1

I Idler, front Disassemble and assemble . . . . . . . . .01-0130-17 Remove and install . . . . . . . . . . . . . . . .01-0130-16 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-19 Inch torque values . . . . . . . . . . . . . . . . . . .00-0003-1 Injection pump Remove and install . . . . . . . . . . . . . . . . .04-0400-4

L Leakage test Air intake system . . . . . . . . . . . . . . . . . .05-0520-1 Links, bucket Remove and install . . . . . . . . . . . . . . . . .33-3340-1

M Manifold, pilot signal Disassemble and assemble . . . . . . . . .33-3360-47 Remove and install . . . . . . . . . . . . . . . .33-3360-43 Manifold, rotary Air test . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-25 Disassemble and assemble . . . . . . . . .02-0260-24 Remove and install . . . . . . . . . . . . . . . .02-0260-22 Metal face seals Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Metric torque values . . . . . . . . . . . . . . . . . .00-0003-2 Motor cover, propel Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Motor, propel Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-4 TM1931 (09JAN04)

O O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6 Oil Carrier roller, specification. . . . . . . . . . . .01-0130-1 Front idler, specification . . . . . . . . . . . . .01-0130-1 Lines and fittings. . . . . . . . . . . . . . . . . . .00-0003-5 Track roller, specification . . . . . . . . . . . .01-0130-1 Oil cooler Remove and install . . . . . . . . . . . . . . . .33-3360-74 Oil cooler bypass valve Remove and install . . . . . . . . . . . . . . . .33-3360-71 Oil information R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-6 Oil leakage test Front idler . . . . . . . . . . . . . . . . . . . . . . .01-0130-19 Track roller . . . . . . . . . . . . . . . . . . . . . . .01-0130-4 Oil lines and fittings . . . . . . . . . . . . . . . . . .00-0003-5 Oil tank, hydraulic Disassemble and assemble . . . . . . . . .33-3360-69 Remove and install . . . . . . . . . . . . . . . .33-3360-66

P Pilot controller Disassemble and assemble . . . . . . . . .33-3360-39 Remove and install . . . . . . . . . . . . . . . .33-3360-37 Pilot controller, propel Disassemble and assemble . . . . . . . . .33-3360-42 Remove and install . . . . . . . . . . . . . . . .33-3360-40 Pilot filter Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Pilot filter and pilot pressure regulating valve Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Pilot pressure regulating valve and filter Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Pilot pump Disassemble and assemble . . . . . . . . .33-3360-29 Drive shaft and gear, disassemble . . . .33-3360-21 Remove and install . . . . . . . . . . . . . . . .33-3360-27 Pilot shut-off valve Disassemble and assemble . . . . . . . . .33-3360-33

Index-4


PN=4

Index

Page

Page

Remove and install . . . . . . . . . . . . . . . .33-3360-31 Pilot signal manifold Disassemble and assemble . . . . . . . . .33-3360-47 Remove and install . . . . . . . . . . . . . . . .33-3360-43 Pin-up data Bucket. . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-4 Portable filter caddy Hydraulic oil cleanup procedure . . . . . . .33-3360-2 Power boost solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-35 Pressure release procedure Hydraulic oil tank . . . . . . . . . . . . . . . . . .33-3360-1 Primary fuel filter Remove and install . . . . . . . . . . . . . . . . .05-0560-3 Propel gearbox Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0250-5 Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0250-11 Remove and install . . . . . . . . . . . . . . . . .02-0250-1 Propel motor Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-4 Disassemble and assemble— 270CLC . . . . . . . . . . . . . . 02-0260-7, 02-0260-18 Remove and install—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Remove and install—270CLC . . . . . . . . .02-0260-1 Start-up procedure . . . . . . . . . . . . . . . .02-0260-22 Propel motor cover Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Propel motor, counterbalance valve Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Propel pilot controller Disassemble and assemble . . . . . . . . .33-3360-42 Remove and install . . . . . . . . . . . . . . . .33-3360-40 Propel speed solenoid valve Remove and install . . . . . . . . . . . . . . . .33-3360-35 Pump Fuel injection, remove and install . . . . . .04-0400-4 Pump regulator, hydraulic Disassemble and assemble . . . . . . . . .33-3360-24 Remove and install . . . . . . . . . . . . . . . .33-3360-22 Pump, hydraulic and drive gearbox Disassemble and assemble . . . . . . . . . .33-3360-5 Remove and install . . . . . . . . . . . . . . . . .33-3360-3 Start-up procedure . . . . . . . . . . . . . . . .33-3360-20

Pump, pilot Disassemble and assemble . . . . . . . . .33-3360-29 Remove and install . . . . . . . . . . . . . . . .33-3360-27 Purge air conditioner system . . . . . . . . . . .18-1830-3

TM1931 (09JAN04)

Indx 5

R Radiator Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-12 Recoil spring, track Disassemble and assemble . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-19 Recover R134a refrigerant . . . . . . . . . . . . .18-1830-8 Refrigerant Cautions and proper handling . . . . . . . . .18-1830-1 Recover R134a, air conditioning . . . . . . .18-1830-8 Refrigerant oil information R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Refrigerant recovery/recycling and charging Charging station installation procedure . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Regulator, hydraulic pump Disassemble and assemble . . . . . . . . .33-3360-24 Remove and install . . . . . . . . . . . . . . . .33-3360-22 Relief valve, crossover, propel motor Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-17 Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Restriction valve Remove and install . . . . . . . . . . . . . . . .33-3360-69 Roller, track Disassemble and assemble . . . . . . . . . .01-0130-3 Oil leakage test . . . . . . . . . . . . . . . . . . . .01-0130-4 Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Rotary manifold Air test . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-25 Disassemble and assemble . . . . . . . . .02-0260-24 Remove and install . . . . . . . . . . . . . . . .02-0260-22 R134a refrigerant recovery . . . . . . . . . . . . .18-1830-8 R134a refrigerant recovery and charging station Installation procedure . . . . . . . . . . . . . . .18-1830-7 R134a system charge. . . . . . . . . . . . . . . .18-1830-10 R134a system evacuate . . . . . . . . . . . . . . .18-1830-9

S Safety signs . . . . . . . . . . . . . . . . . . . . . . .00-0001-13

Index-5


PN=5

Index

Indx 6

Page

Page

Seals, metal face Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-8 Seat belt Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Shoe, track Remove and install . . . . . . . . . . . . . . . . .01-0130-9 Shut-off valve, pilot Disassemble and assemble . . . . . . . . .33-3360-33 Remove and install . . . . . . . . . . . . . . . .33-3360-31 Signal manifold, pilot Disassemble and assemble . . . . . . . . .33-3360-47 Remove and install . . . . . . . . . . . . . . . .33-3360-43 Sliding window Remove and install . . . . . . . . . . . . . . . . .18-1810-3 Specification Carrier roller oil . . . . . . . . . . . . . . . . . . . .01-0130-1 Front idler oil. . . . . . . . . . . . . . . . . . . . . .01-0130-1 Track roller oil . . . . . . . . . . . . . . . . . . . . .01-0130-1 Spring, track recoil Disassemble and assemble . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-19 Sprocket Remove and install . . . . . . . . . . . . . . . .01-0130-14 Start-up procedure Hydraulic pump . . . . . . . . . . . . . . . . . . .33-3360-20 Propel motor . . . . . . . . . . . . . . . . . . . . .02-0260-22 Swing gearbox . . . . . . . . . . . . . . . . . . .43-4350-11 Swing motor . . . . . . . . . . . . . . . . . . . . .43-4360-13 Starter Remove and install . . . . . . . . . . . . . . . . .04-0400-5 Swing bearing Disassemble and assemble . . . . . . . . .43-4350-21 Lower seal, install . . . . . . . . . . . . . . . . .43-4350-24 Remove and install . . . . . . . . . . . . . . . .43-4350-19 Upper seal, install . . . . . . . . . . . . . . . . .43-4350-24 Swing gearbox Disassemble and assemble—200CLC and 230CLC . . . . . . . . . . . . . . . . . . . . . . . .43-4350-5 Disassemble and assemble—270CLC . .43-4350-9 Remove and install . . . . . . . . . . . . . . . . .43-4350-1 Start-up procedure . . . . . . . . . . . . . . . .43-4350-11 Swing motor Start-up procedure . . . . . . . . . . . . . . . .43-4360-13 Swing motor and park brake Assemble—200CLC and 230CLC . . . . . .43-4360-9 Assemble—270CLC . . . . . . . . . . . . . . . .43-4360-9 Disassemble—200CLC and 230CLC . . .43-4360-5 Disassemble—270CLC . . . . . . . . . . . . . .43-4360-7 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .43-4360-8 Remove and install . . . . . . . . . . . . . . . . .43-4360-1 Swing motor brake release valve Disassemble and assemble . . . . . . . . .43-4360-14 Remove and Install . . . . . . . . . . . . . . . .43-4360-13

Swing motor make-up valve Remove and install . . . . . . . . . . . . . . . .43-4360-12

TM1931 (09JAN04)

T Tank pressure release procedure . . . . . . . .33-3360-1 Tank, fuel Remove and install . . . . . . . . . . . . . . . . .05-0560-2 Tank, hydraulic oil Disassemble and assemble . . . . . . . . .33-3360-69 Remove and install . . . . . . . . . . . . . . . .33-3360-66 Torque value Flared connections . . . . . . . . . . . . . . . .00-0003-10 Flat face O-ring seal fitting . . . . . . . . . . .00-0003-8 Inch SAE four bolt flange fitting. . . . . . .00-0003-11 Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-3 Metric four bolt flange fitting . . . . . . . . .00-0003-12 O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6 30° cone seat hydraulic fittings . . . . . . . .00-0003-9 37° flare hydraulic fittings . . . . . . . . . . . .00-0003-9 Torque values Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-1 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2 Track adjuster Disassemble and assemble . . . . . . . . .01-0130-21 Remove and install . . . . . . . . . . . . . . . .01-0130-19 Track adjuster cylinder Disassemble and assemble . . . . . . . . .01-0130-25 Track carrier roller Disassemble and assemble . . . . . . . . . .01-0130-6 Remove and install . . . . . . . . . . . . . . . . .01-0130-5 Track chain Disassemble and assemble . . . . . . . . .01-0130-12 Disassemble and assemble to replace broken part . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-13 Remove and install . . . . . . . . . . . . . . . .01-0130-10 Track chain sprocket Remove and install . . . . . . . . . . . . . . . .01-0130-14 Track roller Disassemble and assemble . . . . . . . . . .01-0130-3 Oil specification. . . . . . . . . . . . . . . . . . . .01-0130-1 Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Test for oil leakage . . . . . . . . . . . . . . . . .01-0130-4 Track shoe Remove and install . . . . . . . . . . . . . . . . .01-0130-9

U Upperstructure Install . . . . . . . . . . . . . . . . . . . . . . . . . .43-4350-16

Index-6


PN=6

Index

Page

Remove . . . . . . . . . . . . . . . . . . . . . . . .43-4350-12

V Valve Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Valve, brake release, swing motor Disassemble and assemble . . . . . . . . .43-4360-14 Remove and install . . . . . . . . . . . . . . . .43-4360-13 Valve, control Remove and install . . . . . . . . . . . . . . . .33-3360-49 Valve, counterbalance, propel motor Disassemble and assemble— 270CLC . . . . . . . . . . . . . . . . . . . . . . .02-0260-18 Valve, crossover relief Disassemble and assemble . . . . . . . . .43-4360-12 Remove and install . . . . . . . . . . . . . . . .43-4360-11 Valve, make-up, swing motor Remove and install . . . . . . . . . . . . . . . .43-4360-12 Valve, oil cooler bypass Remove and install . . . . . . . . . . . . . . . .33-3360-71 Valve, pilot pressure regulating Disassemble and assemble . . . . . . . . .33-3360-31 Remove and install . . . . . . . . . . . . . . . .33-3360-30 Valve, pilot shut-off Disassemble and assemble . . . . . . . . .33-3360-33 Remove and install . . . . . . . . . . . . . . . .33-3360-31 Valve, restriction Remove and install . . . . . . . . . . . . . . . .33-3360-69

Indx 7

W Water separator, primary fuel filter Remove and install . . . . . . . . . . . . . . . . .05-0560-3 Welding on machine . . . . . . . . . . . . . . . . . .17-1740-1 Window, sliding Remove and install . . . . . . . . . . . . . . . . .18-1810-3 Windowpane and one piece molding Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Windowpane and two piece molding Remove and install . . . . . . . . . . . . . . . . .18-1810-1 Windowpanes Remove and install . . . . . . . . . . . . . . . . .18-1810-4

TM1931 (09JAN04)

Index-7


PN=7

Index

Indx 8

TM1931 (09JAN04)

Index-8


PN=8

200clc, 230clc, And 270clc Repair Tm1931

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